Combilift AME Forklift Truck Operator's Manual PDF

Dear Customer,
You have chosen the Aisle-Master articulated VNA (very narrow aisle)
fork lift truck. Thank you for showing your faith in the Aisle-Master
product. You now own a machine designed and manufactured in Ireland
by our team of experienced engineers using the most up to date design
techniques and technology with the sole aim of producing a machine
that is safe, reliable and efficient and the right tool for your material
handling needs. This is what makes the Aisle-Master one of the leading
products in the material handling industry.
In order to familiarise yourself with your truck in a quick comprehensive

manner please read this manual attentively. In addition to the
information regarding operation, this manual also contains important
maintenance checks and instructions for ensuring the continuous
reliable operation of your truck. Should you have any questions or
problems relating to your truck, please contact your Aisle-Master partner
who will be happy to respond to your questions, suggestions and/or
comments. We at Aisle-Master are confident that you will be wholly
satisfied with your Aisle-Master VNA truck.
https://www.besttruckmanuals.com/
Table of Contents
Page
Safety ...........................................................................................................S-1
The Meaning of Safety Statements ...............................................................S-2
Forklift Safety Statements .............................................................................S-2
Location of Decals ........................................................................................S-3
Safe Operation..............................................................................................S-4
Battery Charging ...........................................................................................S-4
Operating in Hazardous Areas......................................................................S-4
Introduction .................................................................................................1-1
Vehicle Description .......................................................................................1-2
Terminology Used in Manual ........................................................................1-2
Illustrations Used in Manual ..........................................................................1-2
Questions and Comments ............................................................................1-2
Component Identification ..............................................................................1-3
Information Plates .........................................................................................1-4
Serial Number ...............................................................................................1-5
Model Description .........................................................................................1-6
Before You Begin ........................................................................................2-1

Operator Training ..........................................................................................2-2
Operator Safety ............................................................................................2-2
Understanding Stability .................................................................................2-2
Knowing the Rated Capacity.........................................................................2-5
Understanding Workplace Conditions ...........................................................2-9
Operating Your Forklift...............................................................................3-1

Operator’s Daily Checks ...............................................................................3-2
Controls and Indicators .................................................................................3-2
Operating Instructions – Basic Procedures ...................................................3-6
Operating Instructions – Handling a Load .....................................................3-10
Transporting an Aisle-Master Forklift ............................................................3-20
Aisle-Master Operator’s & Service Manual ii

Table of Contents
Page
Inspection and Maintenance ......................................................................4-1
Initial Service at 100 Hours ...........................................................................4-2
Inspection and Maintenance .........................................................................4-3
Inspection and Maintenance Responsibilities ...............................................4-4
Inspection and Maintenance Practices .........................................................4-4
Operator Daily/Preoperational Inspection .....................................................4-7
Routine Maintenance (Maintenance Chart) ..................................................4-8
Fork Maintenance .........................................................................................4-9
Mast Maintenance ........................................................................................4-10
Brake Maintenance .......................................................................................4-14
Hydraulic Oil .................................................................................................4-17
Hydraulic System Maintenance ....................................................................4-17
Steering Support Oil (If Applicable) ...............................................................4-19
Drive Transmission Oil ..................................................................................4-20
Battery Maintenance .....................................................................................4-21
Greasing .......................................................................................................4-24
Steering Chain Maintenance (If Applicable) ..................................................4-27
Putting a Truck in Storage ............................................................................4-28
Final Decommissioning .................................................................................4-28
Schematic Circuit Diagrams ......................................................................5-1

Standard Electric Circuit Diagram .................................................................5-2
Pre-Height Selector Electric Circuit Diagram ................................................5-7
Hydraulic Circuit Diagram – Standard & Low Nose ......................................5-12
Hydraulic Circuit Diagram – Narrow Front (Chain Steering) .........................5-13
Fuse Box & Relays .......................................................................................5-14
Appendix A (Checklists).............................................................................A-1
Operator’s Daily Checklist.............................................................................A-2
Initial 100 Hour Service Checklist .................................................................A-3
500 Hour Service Interval Checklist ..............................................................A-4
Installation Checklist .....................................................................................A-5
Appendix B (FAQs) .....................................................................................B-1

Calibrating the Load Monitor .........................................................................B-2
Adjusting the Pressure Switch ......................................................................B-4
Fitting a Mast ................................................................................................B-6
Battery Removal ...........................................................................................B-7
Appendix C (Controller Diagnostics & Troubleshooting) .......................C-1

Traction Motor Controller Diagnostics ...........................................................C-2
Pump Motor Controller Diagnostics ..............................................................C-12
Appendix D (Warranty Registration) .........................................................D-1
Aisle-Master Operator’s & Service Manual iii

General Information
Preface Intended Use

This manual describes how to operate, maintain
and repair the Aisle-Master truck safely and Warning
efficiently. It is essential that this manual remain Unintended use can endanger the
with the machine at all times. It is essential that the lives of operating personnel or other
operator and all persons involved in work with the persons in the vicinity of the truck.
truck read this manual before attempting to operate Unintended use can cause
or service the truck. extensive damage to the truck
and/or to property or materials
Follow all local laws and regulations with regard to being handled.
the operation of lift trucks where they apply at the
place of use. Operation of the truck by
Follow all instructions, prohibitive or otherwise,
inexperienced users or in an
found in this manual. They are there to protect the unintended manner can result in
lives of the operator and others working in the hazards that can lead to personal risk
vicinity of the truck. and subsequent harm to the operator
and persons in the operating area of
Always perform the Daily/Pre-shift Inspection as the truck.
indicated in this manual according to the checklist
located in appendix A and follow the guidelines on The intended use is described in this
service intervals. Ensure that the truck is in good manual. Do not make any changes to
mechanical condition at all times. Report any fault the truck and use only Aisle-Master
and have it corrected immediately otherwise even approved attachments.
minor faults may result in major failures and
dangerous operating conditions.
About This Manual

The descriptions and illustrations contained in this
manual are not in any way binding. Aisle-Master
must reserve the right to make changes without
prior notice in the interest of enhancement of the
product.
Some trucks may be customised to suit the needs

of individual customers. Therefore these trucks may
deviate slightly from the descriptions contained
within this manual.
Every effort has been made to ensure that the

information contained herein is accurate at the time
of writing. However it cannot be guaranteed that all
of the statements in this manual are completely
correct.
Aisle-Master Operator’s & Service Manual iv

Safety
Safety
Aisle-Master Ltd. has made every effort to provide you with the safest
forklift trucks on the market. This section describes the proper
procedures for safely operating and maintaining your lift truck.
After you review this section you will understand the meaning of the
following safety symbols and safety statements:
• Safety Alert Symbol
• Danger
• Warning
• Caution
• Note
Aisle-Master Operator’s & Service Manual S-5

Safety
The Meaning of Safety Aisle-Master Forklift

Statements Safety Statements
You will find various types of safety information on The safety statements contained in this
the following pages and on the machine signs manual relate to the operation and
(decals) attached to the vehicle. This section maintenance of Aisle-Master forklift
explains their meaning. trucks.
Note:
This is the Safety Alert Symbol. It is used to Make sure you read and understand
alert the reader to potential hazards. the information contained in this
manual and on the machine signs
(decals) before you attempt to operate
or maintain this vehicle.
Danger
Danger indicates a hazardous situation
which if not avoided will result in serious The location of each machine sign on the
injury or death. Aisle-Master forklift is illustrated in image
1 on the next page and a representation
of each machine sign is shown in image
Warning 2 on page S-4.
Warning indicates a hazardous situation
which if not avoided could result in serious Make sure you check each machine sign
injury or death. before you operate your Aisle-Master
forklift and replace any that are no longer
legible, missing or damaged.
Caution
Caution indicates an unsafe practice which
if not avoided could result in serious injury
or property damage.
Note:
Used without the safety symbol indicates a
situation that if not avoided could result in
damage to the equipment or property.

Safety
Location of Decals
NOTE: Number 10 is located
behind the side panel.
15
14
9
2
12
10 6 3 13
12
3
1 11
8
7
3 4
1 5
6
14
13
1 12
Note: See next page for number reference.

Safety
Decals
9
2
3 10
11
4
1 12
13
5
15
6
14

Safety
Safe Operation Battery Charging

 Aisle-Master Ltd will not assume any liability Charging installations must be sited in
for injuries or damage arising from or caused designated areas that are well ventilated and
by the removal of any safety devices from properly equipped. Batteries contain sulphuric
their vehicles. acid and generate explosive gasses when
 Fully trained, qualified and authorised drivers being charged. They must be charged in
must only operate this forklift truck. designated, well ventilated areas by trained
 Ensure that the truck is suitable for the area and authorised personnel only.
in which it is to be operated.
 Before raising or lowering forks, give clear When checking electrolyte levels do not use a
indication of your intentions to other people cigarette lighter, matches or anything else that
and ask them to stand clear. may cause ignition for illumination.
 Do not allow anyone to walk or stand
beneath elevated forks. When transporting and charging batteries the
 Do not exceed the rated load capacity of the operator should wear protective clothing and
truck. In no circumstances should goggles and take particular care not to spill or
counterweights be added to increase come into contact with electrolyte (battery
capacity. acid).
 If the mast mechanism malfunctions or
becomes stuck in a raised position, operate Fire fighting equipment and a supply of clean
the mast control lever to eliminate any slack fresh water must be readily available in the
in the chains. DO NOT go under the elevated charging area at all times in case of accidents.
parts of the truck to attempt to carry out
repairs. In the event of an accident flush acid away
from the eyes and/or skin using plain water
and seek medical attention immediately.
General
If battery acid is spilled on the floor, clean up
These forklift trucks are designed for use in promptly using a neutraliser such as baking
ambient temperatures ranging from -16°C soda.
(+3.2°F) to +45°C (+113°F) if the correct
hydraulic oils and greases are used. For Warning
operation outside these temperatures, please
Batteries produce flammable gases that
consult the manufacturer as special
may form an explosive mix. Keep all
modifications and lubricants may be required.
arcs, sparks, and flames and lighted
tobacco away from the batteries.
Standard trucks must not be operated in
flammable areas, corrosive atmospheres, or in
areas containing a high degree of dust
contamination. Only trucks specifically designed Operating In
or modified to operate in these conditions can
enter such areas. Hazardous Areas
The safe maximum load capacity of the truck with No spark proofing is fitted to the truck as
relation to the load centre and fork heights, which standard; consequently it MUST NOT be
MUST NOT BE EXCEEDED, is stated on the used in flammable or explosive areas. For
capacity plate.
further details contact the manufacturer.
The truck must be operated strictly in accordance
with the operating instructions provided in this The truck MUST NOT be used in corrosive
manual in conjunction with the safety regulations atmospheres or in areas containing a high
of the country in which the forklift truck is being degree of dust contamination.
operated.

SECTION 1
Introduction
It is the responsibility of employers to assess their fork truck
operations, and introduce safe working procedures to reduce or
limit the risk as far as possible. Safety procedures include operator-
training, procedures for the control of pedestrians and traffic and
the implementation of proper maintenance procedures.
Safe and efficient forklift operation requires operators to be skilled

and alert. Operators must be familiar with the vehicle, understand
its capabilities, and follow the operating procedures and safety
instructions recommended in this manual. According to rules
issued by OSHA (occupational health and safety authority), or the
relevant local Health and Safety Authority in the country where the
machine will operate, employers must make training available to
ensure that operators are competent to safely operate the type of
forklift that they will be using in the workplace.
Safe and efficient operation also depends on correct maintenance

of the vehicle. An Operator’s Daily Checklist, which outlines checks
that must be performed each time the vehicle is put into operation,
is located in Appendix A. The checklist is part of a complete
preventive Maintenance Schedule. Make certain that the vehicle is
correctly maintained and is in good mechanical condition at all
times. Report any failure immediately for correction. Otherwise,
even minor failures or damage may result in major failures, or
create unsafe operating conditions.
Note:
This manual is not designed for purposes of extensive
maintenance work. Such work must be performed by
approved professionals.
Aisle-Master Operator’s & Service Manual 1-1

Introduction
Vehicle Description
1
The Aisle-Master is a narrow aisle type lift truck.
The principle of this type of truck is that the
weight of the load, which is carried on the forks
in front of the load wheels, is offset by the
combined weight of the heavy truck chassis.
Aisle-Master forklifts are available in capacities 2

up to 2500Kg (5500lbs.). The front end of the
truck can be over-articulated. This permits the
vehicle to act as a conventional forklift as well
as a very narrow aisle forklift.
Terminology Used in
Manual 1
Whenever front and rear, right and left are

mentioned throughout this manual, it is
assumed that you are standing behind the Questions and Comments
vehicle looking toward the forks.
If you have any questions or comments
about this manual, or any procedure or
description within it please contact:
Illustrations Used in Manual
This manual makes use of many illustrations to Aisle-Master Ltd,
help you locate components on your forklift and Gallinagh,
to follow the procedures outlined. Co. Monaghan,
Ireland.
You will note that each illustration has an Tel: +353 47 80400
identifying numeral 1 in one of the corners and
Fax +353 47 80402
each item in the illustration that is referenced in the
Email: info@aisle-master.com
text is identified with a number 1
In the text, illustration references appear in bold

square brackets [1], and the item numbers are
in standard brackets (item 1). Let’s look at an
example:
The accelerator pedal (item 1) [1], is located on

the floor to the right of the steering wheel
towards the outside of the truck.
The brake pedal (item 2) [1], is located on the
floor to the right of the steering wheel towards
the inside of the truck.

Introduction
Component Identification
The following illustrations show the location of
components on the Aisle-Master.
Forks (item 1) [2]

Mast (item 2) [2]
Front Wheels (item 3) [2]
Back Wheels (item 4) [2]
Overhead Guard (item 5) [2]
Mast Serial Number (Item 6) [2]
6
5
1
4 3

Introduction
Information Plates The illustration below shows where this

information will appear on your Aisle-
The serial plate (item 1) [3] and the capacity Master forklift. The identification (serial)
plate (item 2) [3] show the rated capacity, serial plate may be located on the opposite side
number, and other vehicle characteristics. to that marked.

Introduction
Serial Number
The serial number of the forklift (item 1)
[5] is located on the serial plate.
The serial number consists of 5 numerical digits
Aisle-Master Serial Number e.g.
23456
4 1
Caution
The serial number is also stamped on the
left side of the frame (item 1) [4]. Raise
the seat to access the serial number
stamp. You must compare the serial
number listed on the identification plate
with the serial number on the frame of the
truck before operating the truck. Contact
Aisle-Master if these numbers do not
match.
1
AA WW MMM
23456
5
4

Introduction
Model Description
General
The operation of the Aisle-Master is as follows. A battery supplies power for the traction motor, the
hydraulic pump motor and the control panel and instruments. The motors are controlled by an
electronic control system.
Forward or reverse travel is controlled by a direction control lever mounted to the right of the
driver. An accelerator pedal controls travel speed.
The truck is equipped with a combined battery discharge indicator and hour meter.
A brake pedal applies the hydraulic service brakes at the rear wheels. The parking brake is
applied by a lever situated to the right of the driver.
Key Switch
The key switch (item 2) [6] has 2 positions "OFF" and "ON". Insert the key and turn clockwise to
the "ON" position.
"Power On" Indication

When the key switch (item 2) [6] is turned to the "ON" position the electronic display unit will
illuminate, indicating that the truck is ready for operation.
Battery Plug
The battery plug (item 2) [7], is wired to the battery. When connected to the truck plug (item 1) [7],
it enables power to flow to the trucks electrics. The battery plug is also used to connect the battery
to the charger for recharging.
Truck Plug
The truck plug (item 1) [7] is situated at the rear of the truck and is connected to the trucks
electrical system. Lift the rear bonnet to gain access to the truck plug.
Battery State of Charge

An LCD gauge (item 1) [8] shows the battery's State of Charge. With a fully charged battery all the
bars are displayed. As the battery becomes discharged, the bars turn off progressively, in
proportion to the residual charge of the battery. When only the last two bars are displayed the red
battery light symbol (item 2) [8], will illuminate and only the drive and steering will be operational.
Hour meter
A liquid crystal display is fitted in the centre of the display unit that shows the number of hours
worked.
Hour Glass Symbol

This symbol flashes when the hour meter is working.

Introduction
Isolator Switch
This is used as a master isolator to disconnect the battery in the event of an emergency. In the
unlikely event of an electrical failure that causes the vehicle to go out of control, push this button
(item 3) [6], to immobilise the vehicle.
Parking Brake Lever

Pull this lever (item 1) [6], upwards to apply the parking brake. Press in the button on the end of
the lever and lower the lever to release the parking brake.
2 1
2
1
6 7
2 1

SECTION 2
Before You Begin
This section of your Aisle-Master Forklift Operator’s & Service
Manual discusses the following concepts that must be
thoroughly understood before you can operate an Aisle-Master
forklift:
Operator Training – Discusses the operator training required

by Health and Safety Authorities, and its implications for
operators of forklifts.
Operator Safety – Reviews the safety guidelines operators

need to be aware of before they operate an Aisle-Master forklift.
Understanding Stability – In this section you will learn about

the stability triangle and how to use it to help prevent your Aisle-
Master forklift from tipping over.
Knowing the Rated Capacity – The meaning of rated capacity

and how it relates to how high you lift the load, the load centre,
and attachments used are detailed using several examples.
Understanding Workplace Conditions – This section makes

you aware of hazards in the workplace that you must
understand to avoid accidents. You need to stay aware of
changing conditions in your workplace such as potholes,
overhead obstructions, and pedestrian traffic that may change
on a daily basis. You also need to understand how to load and
unload transport vehicles.

Before You Begin
Warning Understanding Stability

Read the Operator’s Manual and
machine signs (decals) before using the
forklift. Failure to do so can cause Warning
serious injury or death. Never load the truck beyond its rated
capacity. Loading beyond rated
capacity can cause the axle(s) to
break, the truck to tip over, the load
Operator Training to fall and/or serious injury or death.
See identification and capacity plates
for capacity ratings and load centre
Warning information.
Every forklift operator must be trained in
accordance to the rules provided by the
relevant local Health and Safety Warning
Authority (HSA). Never allow anyone to stand beneath
Employers must ensure that each or pass under the lifting mechanism.
powered industrial truck operator is The load could fall causing serious
competent to operate a powered injury or death.
industrial truck safely, as demonstrated
by the successful completion of the
relevant training as specified by the Warning
relevant local authority. Operating a Make sure that the load is centred
powered industrial truck without the and the forks are fully engaged.
proper training can cause serious injury Failure to do so can cause the load to
or death. fall, or the truck to tip over, resulting
in serious injury or death.
Operator Safety
Before commencing use of the Aisle-Master
forklift operators must become familiar with its
capabilities and thoroughly read and understand
the material contained in this Operator’s Manual
along with the meanings of the various machine
signs (decals) found on the truck.
Whether you are a new operator or have used

forklifts for many years, read through the
following guidelines. They provide step-by-
step instructions to help you operate your
Aisle-Master forklift in a safe and efficient
manner.

Before You Begin
Basic Principles • You drive with the load raised.
• The load is not distributed properly (always
The concepts concerning stability are actually keep the heavier items near the face of the
quite simple. As the angle between the forks and forks).
the body of the truck approaches 90 to the right • You drive across a slope.
[1] or left [2], the truck is in its least stable • You drive on a slope with the load facing
position. downhill
• A battery is used that weighs less than the
Unlike an automobile, which has four points of battery that was originally supplied with the
suspension, Aisle-Master forklift trucks operate truck.
on a three-point suspension. When the forks are
turned nearly 90 to the right, two of the The same holds true when the forks are turned
suspension points are on the rear axle (item 1) almost 90to the left. The suspension points are
[1] and (item 2) [1]. The third suspension point is (item 1) [2], (item 2) [2], and (item 3) [2]. The
the centre point of the front axle (item 3) [1]. The fulcrum is between (item 1) [2] and (item 3) [2].
centre of gravity i.e. the point at which the truck’s The centre of gravity is at (item 4) [2] when the
weight may be considered to act, is located as forks are turned nearly 90 to the left, the truck is
shown (item 4) [1] when: not carrying a load, and the truck is at rest. If the
centre of gravity shifts (item 6) [2] so it falls
• The forks are turned nearly 90 to the right outside of the stability triangle, the truck will tip
• No load is placed on the forks around the fulcrum.
• The truck is at rest.
Note:
In this position, the fulcrum, or axis around which The illustration on the following page
the truck will tip, is between suspension point conveys a greater understanding stability.
(item 2) [1] and (item 3) [1]. Some trucks have a wider wheel base to
improve stability.
If you try to pick up a load that is too heavy, the
truck may tip around the fulcrum. Let’s see why. 1
Imagine a triangle (item 5) [1] is drawn between
the three suspension points (item 1) [1], (item2)
3
[1], and (item 3) [1]. This triangle is commonly
called the stability triangle. The centre of gravity
is not a fixed point, it will shift for various reasons 4
that we will explore in a moment. The crucial
thing to remember is, as long as the centre of
gravity of the truck remains within the border of 6
5
the stability triangle, the truck will not tip.
2
If the centre of gravity shifts (item 6) [1] so it falls
outside of the border of the stability triangle, the 1
truck will tip around the fulcrum.
The centre of gravity will shift if:

1
• The load exceeds the rated capacity listed on 5
6
the serial plate.
• The load exceeds the load centre dimensions
listed on the serial plate.
• The forks are not fully placed into the pallet, 4
called “tip loading”.
• You take a corner too fast (with the truck unloaded 3
or loaded).
2 2

Before You Begin

Before You Begin
Knowing the Rated Before you begin to operate your Aisle-Master

forklift, you need to know some basic
Capacity principles of how it works. This includes
! knowing how much weight it can carry and
how to properly carry a load to maintain
Warning stability.
Never load the truck above its rated
capacity. Loading above the rated One of the most important facts you need to
capacity can cause axles to break, the know about your forklift is its rated capacity
truck to tip over, the load to fall and/or (how much weight it can safely lift). This
serious injury or death. See serial and weight is listed as the rated capacity on the
capacity plates for rated capacity and serial plate. The rated capacity varies for each
load centre information. load depending on:
Before you begin to operate your Aisle-Master • Where the horizontal and vertical load
forklift, you need to know some basic principles centres are.
of how it works. This includes knowing how • The height you plan to lift the load
much weight it can carry and how to properly • Attachments used.
carry a load to maintain stability.

Before You Begin
Serial Plate Capacity Plate

The following list explains each item that appears Actual Capacity (item 7) [3], the actual
on the serial plate and capacity plate shown in [3] capacity is stated with the forks at various
in the Introduction and below. fork heights. As you lift the load higher, the
rated capacity of the forklift decreases.
Model (item 1) [3], the model number of your
Aisle-Master forklift appears here. Height (item 8) [3], this is the fork height
stated in both millimetres and inches. It is the
Serial No. (item 2) [3], the serial number of distance between the ground and the top
your forklift appears here. vertical face of the forks where the load sits.
Rated Capacity (item 3) [3], this is the Weight (item 9) [3], the load capacity of the
capacity in kilograms (kg) or pounds (lbs) that forklift at various fork heights stated in
the fork truck will lift. kilograms and pounds.
Load Centre (item 4) [3], this is the distance Horizontal Load Centre (item 10) [3], the
from the front face of the forks to the centre horizontal load centre is equal to one-half the
of gravity of the load. width of the rated load when the weight is
evenly distributed.
Un-laden Weight (item 5) [3], this is the
weight of the forklift with no load on the forks. Vertical Load Centre (item 11) [3], the
vertical load centre is equal to one half the
Manufactured Date (item 6) [3], the date on height of the rated load when the weight is
which the fork truck was manufactured. evenly distributed.
1 10
2
7
3
8
4
5
6
11
9
3

Before You Begin
Load Centre Always make sure the load is flush against

the front vertical face of the forks (item 3) [4],
(or the load backrest if fitted) and that loads
Warning that are unbalanced horizontally are loaded
Make sure the actual horizontal and with the heaviest end of the load nearest to
vertical load centres do not exceed the the truck.
maximum load centres stated on the data
plate. Failure to do this can cause the The vertical load centre (item 4) [4], is equal to
forklift to tip over causing serious injury or one-half the height of the load when the weight
death. is evenly distributed. For example, a load that
is 122 cm (48 in) high has a vertical load
centre of 61 cm (24 in).
You need to consider two types of load centres.
The horizontal load centre (item 1) [4], is equal
Always make sure that loads that are
to one-half the depth of the load when the
unbalanced vertically are loaded with the
weight is evenly distributed. For example, a
heaviest end of the load nearest to the
load that is 122 cm (48 in) long has a horizontal
horizontal face of the forks (item 5) [4].
load centre of 61 cm (24 in). The further the
load centre is from the fulcrum (item 2) [4], the
less stable the forklift.
3 4
2 5
4

Before You Begin
Maximum Fork Height Attachments to the forks may affect the load
centre. When the factory, dealer, or distributor
Warning installs attachments approved by, Aisle-
Master Ltd. an additional identification plate
The load capacity of your forklift
should be attached to the truck. The new plate
decreases the higher you raise the forks.
identifies the type of attachment, the changes
Refer to the rated capacity at various
in the load centres, and the rated capacity.
heights listed on the capacity plate. Failure
to heed these guidelines can cause your
forklift to tip over causing serious injury or
death. Determining the Weight of the
Load
The maximum fork height (item 1) [5], is the In addition to the rated capacity you must
highest position your Aisle-Master forklift can lift determine the weight of the load before you
a load. This is measured from the floor to the attempt to lift it with your Aisle-Master forklift:
forks when they are raised in their highest posit-
ion. The higher the forks are raised, the less • Weight is listed on pallet wrapper
stable the Aisle-Master forklift becomes. • Weight is listed on Bill of Lading
• Weight is determined by multiplying the weight
of each small container/bag by the number of
Tilting Considerations small containers/bags on a pallet. Each small
The amount of forward and rearward tilt you container should be marked with its weight.
should use is governed by the application. • Ask your supervisor when in doubt.
When you travel with the truck loaded tilt the mast
back and keep the load low. This will help
stabilize loads with an uneven weight distribution. 5
When you load at high elevations, tilt the load
back far enough to seat it against the front vertical
faces of the forks or the load back rest (if fitted).
When you unload at high elevations, make sure

you only use enough tilt to place the load onto the
rack or stack.
Attachments
Warning 1
Never modify your Aisle-Master forklift in
any manner. Only options and
attachments approved by Aisle-Master Ltd.
may be installed on the truck. Other
modifications will void the warranty and
can cause serious injury or death.

Before You Begin
Understanding Workplace Dock Boards (Bridge Plates)

Conditions Dock boards are designed and maintained so
! that one end contacts the dock (or loading
platform) and the other end contacts the
Warning transport vehicle. When you load or unload the
Workplace situations are constantly transport vehicle, the dock board must be
changing. Check your area before locked in place to prevent it from rocking or
beginning work for the day. If in doubt, sliding. Dock boards must have a high friction
check with your supervisor. Failure to surface designed to reduce the possibility of
observe new workplace conditions can people or trucks slipping.
lead to serious injury or death.
Special rules should be followed if you’re
In addition to stability, you need to be aware of workplace uses dock boards on loading docks:
special situations in your workplace to avoid
forklift accidents. Even if you work in the same • Never exceed the carrying capacity marked
area each day, there could be changes that affect on portable or powered dock boards.
your safety, such as:
• Portable dock boards must be secured in
• Contractors doing maintenance position, using anchors or other devices that
• Wet areas prevent slipping.
• Overhead repair work
Be on the lookout for anything that might present

a hazard. Other situations that could present Trailers and Rail Cars
special operating conditions include:
1. Before you load or unload a trailer, or rail
• Potholes car, make sure it does not move
• Pedestrian traffic unintentionally:
• Very narrow aisle ways
• Overhead obstructions • Set the brakes
• Poor lighting making it hard to see hazards • Chock the wheels
• Wet, oily, or rough terrain
• Other equipment or vehicles operated in the 2. In addition to setting the brakes and
area chocking the wheels, if a semi-trailer is not
coupled to a tractor, make sure that all four
Note: corners are supported to prevent upending
Standard Aisle-Master trucks are not or corner dipping.
equipped to operate in cold stores,
flammable or explosive areas, corrosive 3. Maintain a safe distance from the edge of
atmospheres or areas containing a high ramps, platforms, or other similar
degree of dirt contamination. working surfaces.
Remember: Do not block the following items with 4. Never attempt to move a trailer with the
your Aisle-Master forklift or the materials you are Aisle-Master.
moving:
• Electrical panels
• Fire exits
• Emergency stop buttons
• Aisle ways
• Fire extinguishers/hoses

Before You Begin
Warning Devices
Sound the horn at an intersection. Stop and look
for other vehicles and/or pedestrians and proceed
with caution.
Your Aisle-Master forklift may have the following

warning devices installed. Make sure they are in
working order before you start work:
• An amber overhead strobe warning light

• Flashing backup light
• Rear safety light package
• Reversing/Backup alarm (bleeping or talking)
• Park brake warning alarm
• Convex rear view mirror
Power Lines
Warning
Contact between the truck and live
electrical wires may result in serious
injury or death.
Keep all parts of the truck at a sufficient distance

from electrical lines (see table below).
If contact with a live electric source occurs:
 Do not leave the loader until the electricity

has been disconnected and a qualified
technician directs the operator to leave the
machine.
 If possible, drive the loader away from the
danger area.
 Warn any people around the loader not to get
any closer and not to touch the machine.
 Arrange to have the power turned off.
Nominal voltage Clearance distance

Up to 1000 V 1 m (1.1 yd)
Over 1 kV up to 110 kV 3 m (3.3 yd)
Unknown nominal voltage 5 m (5.5 yd)

SECTION 3
Operating Your Aisle-Master
Forklift
This section of your Aisle-Master Forklift Operator’s & Service Manual
discusses the following concepts that must be thoroughly understood
to operate an Aisle-Master forklift:
Operator’s Daily Checklist – Inspecting your Aisle-Master forklift

before you begin work is a mandatory requirement. The procedure for
performing this inspection is explained.
Controls and Indicators – The location of each control and indicator

is illustrated as well as its operation.
Operating Instructions – Basic Procedures – Basic procedures

such as getting on and off the Aisle-Master forklift, driving position,
starting and travelling, turning, stopping, and parking are discussed.
Operating Instructions – Handling a Load – This section describes

the proper procedures for loading and unloading your Aisle-Master
forklift, travelling with a load, what to do in case of a tip over and going
up and down an incline.
Using Lifting Equipment to Move an Aisle-Master Forklift to

Another Location – This section describes the proper procedure for
lifting and moving Aisle-Master trucks.

Operating Your Aisle-Master Forklift
Warning Controls and Indicators

Please ensure you have read the
‘Before You Begin’ section in this This section explains how each of the controls
manual. It contains crucial information function and the purpose of each indicator on
on topics such as stability and rated your forklift and identifies their location with an
capacity that you need to be familiar illustration.
with before you operate your Aisle-
Master forklift. Failure to follow the
information provided in the ‘Before You Accelerator Pedal
Begin’ section can lead to serious The accelerator pedal (item 1) [1], is located
injury or death. on the floor and is closest to the right hand
side of the truck.
!
Warning Operation - Pressing the accelerator pedal
According to legislation employers down starts the truck moving in the direction
must make training available to ensure you selected, see discussion of the “Direction
that you are competent to safely Lever” on page 3-4. The closer you press the
operate the type of forklift that you will accelerator pedal to the floor the faster the
be using in the workplace. More truck moves.
information on operator training
requirements is included in the ‘Before
You Begin’ section of this manual. Brake Pedal
Failure to receive proper operator The brake pedal (item 2) [1], is located on the
training can cause serious injury or floor to the left of the accelerator pedal.
death.
Operation – Pressing the brake pedal down
applies the service brake.
Operator’s Daily Checks

!
Note: 1
Daily inspection is a legal requirement.
Report any defect immediately to your
supervisor!
You are responsible for the daily inspection

of your forklift. The daily checklist sheet is
located in Appendix A in the back of this
manual. Before starting a shift: 2
• Inspect the truck and fill out a copy of the
checklist
• Return the checklist to your supervisor
• Report defects to your supervisor
Note:
See Section 4 - Operator’s Daily Checks
1
Note that your Aisle-Master forklift also has a

parking brake. For more information see
page 3-4.

There are two braking systems on the Steering Wheel
Aisle-Master: The steering wheel (item 2) [3], is equipped
with a steering knob (item 3) [3], which
1. For precise speed control and braking should be held firmly with your left hand at all
during normal operation of the truck, use times.
the electronic braking system. To stop the
truck release the accelerator pedal and
the truck will come to a controlled stop.
2
2. For more rapid braking use the service

brakes on the rear axle. Depress the 4
brake pedal to bring the truck to a stop.
3
1
5
1
2 3
The steering column tilt angle is adjustable:

Key Switch
The key switch (item 1) [3], is located on 1. Turn the Locking Lever (item 1) [2] Anti-
the right side of the steering column. It is a Clockwise to loosen.
two position (ON, OFF) switch. Turn the
key clockwise to set the switch to the ON 2. Adjust the angle of the steering column to
position. All controls are inactive when the the desired position.
key switch is in the OFF position. Turn the
key fully counter clockwise to the OFF 3. Turn the locking lever clockwise to
position. tighten.

Dash Display Parking Brake
The Dash Display (item 4) [3] is mounted The parking brake lever (item 5) [3], is
behind the steering wheel. It displays a located to the right hand side of the driver.
record of operating time in hours and also
incorporates various warning lights and Operation – Pull the parking brake lever
indicators, see below for a detailed layout of upwards to apply the brake. Push the button
the display. on the end of the lever and lower it to
release the brake.
If the operator vacates the seat while the

parking brake is released a warning buzzer
will sound.
Warning
Never leave the operators enclosure
without applying the park brake.
A. Hour Meter – Displays the total number of
hours the truck has been operated for to
date.
B. Battery Charge Meter – Displays the level

of charge remaining in the battery.
C. Low Battery Indicator – When the level of

charge remaining in the battery falls below
20% the low battery indicator will be
displayed. Only the drive and steering will
operate normally at this point. The working
speed of the hydraulic functions will be Direction Lever
dramatically reduced. The direction lever (item 1) [4], is located in
the middle left of the control pod. It has 3
D. Park Brake Indicator – This indicator will positions Forward (F), Neutral (N) and
be displayed when the park brake is Reverse (R).
applied.
2 3 4
E. Pump Motor Temperature Indicator – If
the pump motor overheats the pump motor
temperature indicator will be displayed. If
this indicator is displayed the truck should
1 5
be parked immediately as described on
page 3-9 and the cause of the elevated
temperature investigated.
Caution
Allow sufficient time for the motor to
cool before investigating the cause
of the elevated temperature.
F. Pump Motor Brush Wear Indicator –

When the pump motor brush wear indicator 4
is displayed the brushes in the pump motor
must be replaced at the earliest Operation - Push the lever forward so the
convenience. truck moves forward, or pull it backwards so
the truck moves in reverse.

Lift Lever Seat Adjustments
The lift lever (item 2) [4], is located at the
front of the control pod. It is the long lever Horizontal Adjustment
nearest the operator. The standard seat can be positioned as the
Operation - Pull the lever back to lift the operator requires by releasing the seat slide
forks; push it forward to lower the forks. lever (item 1) [6] and moving the seat
forward or back.
Tilt Lever
The second lever (item 3) [4], from the Weight Adjustment
operator at the front of the control pod The weight adjustment is controlled by
controls the tilt function. moving the weight adjustment lever (item 2)
[6] to increase or decrease the firmness of
Operation - Pull the lever back for the seat base suspension. There are 5
backward tilt; push it forward for forward tilt. weight settings from 50-120 kg (110-265lbs).
Side Shift Lever Angle Adjustment

The third lever (item 4) [4], from the The seat angle can be adjusted by releasing
operator at the front of the control pod the seat tilt lever (item 3) [6] and tilting the
controls the side shift function. seat forward or back. There are 2 seat tilt
positions.
Operation - Pull the lever back to shift to
the right; push it forward to shift to the left.
Backrest Adjustment
The angle of backrest can be adjusted by
Horn releasing the backrest tilt lever (item 4) [6],
The horn button (item 5) [4], is located in and tilting the backrest forward or back.
the middle right of the armrest. There are three backrest tilt settings.
Operation – Press and hold the button to
sound the horn.
Battery Isolator Switch

The battery isolator switch (item 1) [5] is
located on the seat panel to the right hand
side of the seat. It is used to disconnect
power from the battery in the event of an 4
emergency. Turn the switch to ‘OFF’ by
pressing it down until it clicks into the
closed position. The truck will not power-up 1
unless the switch is returned to the ‘ON’
position by pulling the switch up.
2 3
6 5
1
Seat Switch
The seat switch (item 5) [6], detects when
the operator is in the seat and sends a signal
to the electric drive system controllers. The
truck will not operate unless the operator in
sat on the seat.

Operating Instructions – Getting On and Off the Aisle-

Master Forklift
Basic Procedures
! • Always maintain a three-point contact when
you get on and off the Aisle-Master forklift.
Warning
Check all systems before operating this • Use the step (item 1) [7], and handrail (item 2)
vehicle. Report unsafe conditions and [7], provided for this purpose.
correct them before operating the
vehicle. Do not operate the vehicle • Enter and exit the forklift from the left hand
unless trained and authorised to do so. side under normal circumstances. Only enter
Failure to follow these guidelines can or exit from the right hand side in the case of
result in serious injury or death. emergencies.
!
Warning
Every forklift operator must be trained in
accordance with the rules provided by
the relevant health and safety authority 2
in the location where the truck is
operating. Employers must ensure that
each powered industrial truck operator is
competent to operate a powered
industrial truck safely, as demonstrated
by the successful completion of training
and evaluation as specified by the
relevant Health and Safety authority.
Operating a powered industrial truck
without the proper training can cause
serious injury or death. It is also against
the law in many locations.
Warning
Look in the direction you intend to travel
before you begin to drive the forklift.
Failure to look in the direction you are
travelling can cause serious injury or
death.
Before you operate your forklift, get used to

the controls and indicators and practice
going forward, backward, turning, stopping
and parking without a load on the truck. After 1
you become familiar with the truck’s
operation, learn how to load and unload it.

Driving Position Starting and Travelling
!
Note:
Warning Make sure all accessories (lights, etc.) are
Only operate the vehicle from the off before continuing.
operator’s seat with the seat belt
fastened. Do not place any part of your 1. Make sure your right foot is not on the
body outside the vehicle. Do not carry accelerator pedal.
passengers. Failure to follow these
guidelines can result in serious injury or 2. Set the direction lever (item 1) [9], to
death. neutral.
Only use the right foot to operate both
the accelerator and brake pedals. 3. Turn the key switch (item 3) [10] clockwise
!
to the ON position.
Refer to Figure [8] for proper seating
position.
4. Use the lift lever (item 2) [9], to raise the
forks 102 to 152 mm (4 to 6 in) off the
1. Adjust the seat for comfortable operation
ground and the tilt lever (item 3) [9], to tilt
of the Aisle-Master forklift controls. You
the mast back. This is the recommended
must be correctly seated with all body
travelling position.
parts inside the cab. Use your right foot
(item 1) [8], on both the accelerator and
brake pedals and keep your left foot (item 2 3
2) [8], on the floor of the cab at all times.
2. Fasten your seatbelt.
! 1
1
9
5. Release the Parking brake (item 1) [10]
and hold the steering knob (item 2) [10]
firmly with your left hand.
6. Note the position of the front wheels. The

truck will move in the direction the front
wheels are pointed.
2 7. Make sure the way is clear and select the

8 direction of travel with the direction lever
(item 1) [9].
Warning
Remain in your seat with the seat belt 8. When travelling in reverse look in that
fastened while the truck is moving. Your direction. A convex rear view mirror is fitted
seatbelt will help you remain inside the to assist with visibility and alert the operator
cab should the truck tip over. Never jump to potential hazards.
from the truck if it begins to tip. In most
cases the truck will land on you causing 9. Gently press the accelerator pedal (item 1)
serious injury or death. [11], with your right foot until the truck
begins to move. Increase pressure on the
accelerator pedal to increase truck speed.

Turning
Warning
A lateral tip-over can occur if your
truck is improperly operated. Slow
down before turning! Failure to slow
down can cause serious injury or
death.
When you reach an intersection:
2 3  Slow down. Even if the forklift is not

carrying a load it can tip-over if you turn at
high speed.
 Sound the horn as you reach an

1 intersection to warn pedestrians and other
equipment operators you are approaching
the intersection.
 Always follow the rules of the road and

yield to other equipment operators and
pedestrians as required.
Stopping
10
Warning
When you stop, stay inside the cab
until the truck comes to a complete
stop. Failure to stay inside the cab
can result in serious injury or death.
1 !
Warning
Do not apply brakes abruptly. If you
stop abruptly the load may dislodge
from the forks causing serious injury
or death.
!
2 To slow down, release the accelerator.
11
To perform an emergency stop release the
accelerator pedal and press hard on the brake
pedal (item 2) [11] with your right foot.

Changing Direction When you park your Aisle-Master forklift
always:
Release the accelerator pedal. Gently apply
pressure to the brake pedal to bring the truck 1. Apply the parking brake.
to a halt.
2. Tilt the mast forward.
Select change of direction by using the 3. Lower the forks to the ground.
direction lever, release the brake and
gradually increase pressure on the 4. Turn the key switch to the ‘OFF’ position.
accelerator pedal until the truck is travelling
at the desired speed. 5. Remove the key.
Note:
Make sure all accessories are off (lights,
Stopping Distance etc.) before you turn the key switch to the
Stopping distances change with the incline ‘Off’ position.
and quality of the road surface.
If the operator vacates the seat while the
To make sure you come to a safe stop: parking brake is released a warning buzzer
will sound.
 Reduce speed
 Reduce load size Warning
 Allow adequate distance between the Never leave the operators enclosure
truck and any other vehicle, object or without applying the park brake.
person.
Parking
!
Warning
Before you exit the vehicle, place
controls in neutral and apply the parking
brake.
If the truck is to be left unattended, fully
lower the mast, turn the key to the ‘Off’
position and remove the key.
Failure to properly exit and park your
forklift can cause serious injury or death.
Before you park the vehicle make sure:
 The parked truck will not cause an

obstruction or safety hazard.
 The parked truck is clear of fire exits, fire
equipment, and stairways.
 The truck is not left unattended on an
incline.
If the truck cannot be driven and it must be

left parked on an incline, securely chock the
wheels and remove the key.

Operating Instructions – The Load Moment indicator (optional)
Handling a Load  The Load Moment indicator (when fitted) is a

visual and audible device intended to
continuously monitor the longitudinal Load
Warning Moment effect of the fork load on the machine by
Look in the direction you will travel before measuring the load on a suitable vehicle part.
you begin to drive the forklift.  The load sensor is mounted on the mast carrier
and the Load Indicator Display is mounted inside
Make sure forks are set so the spacing the roll cage, in the middle of the front cross
between them is equal to one-half the member, within the driver’s view. The display has
opening between the end stringers on the a vertical arrangement of five lights (three green,
pallet. one amber and one red) the lights progressively
illuminate or go out to indicate the percentage of
Make sure you insert forks fully into the the rated capacity being carried by the forks.
pallet. Do not “tip load”.  The actual rated capacities are those referred to
Read and understand the information in the on the capacity plate located on the front of the
Before You Begin section of this manual machine to the right hand side of the driver
console when seated on the machine seat.
before you operate an Aisle-Master forklift.
 When the machine ignition is turned to ‘On’ (and
Do not handle unstable or loosely stacked the machine is not carrying any load) the load
loads. indicator display will show only the green “power
on” light. The first display light will illuminate
Use caution when you handle long, high or
when the load reaches approximated 45% of the
deep loads. rated capacity. Each successive light is
Do not allow anyone to stand beneath or equivalent to approximately 15% of rated
pass under the mast. capacity.
 When the display has reached 100% (all green
Never use the forklift to elevate anyone lights plus the amber light flashing) the vehicle is
without the use of an approved man up carrying its maximum rated capacity. The red
cage. light plus the audible alarm represents 110% of
Be aware of rear end swing when turning. the rated capacity and greater, there is no further
visual or audible change from there on to the “tip
Never carry passengers on the truck. up condition”.
Obey site rules and take particular care
when there are pedestrians who should be Warning
given priority.
If the alarm sounds and/or the red light
Use banks men if operating in congested or illuminates, the driver should act
busy areas. immediately to minimise the instability,
Never load your Aisle-Master forklift beyond by stopping driving, lowering the load
its rated capacity. Rated capacity is stated and tilting the mast back. Failure to do
on the truck’s identification plate. Loading so could result in serious injury or
the truck beyond its rated capacity can death.
cause axle(s) to break, the truck to tip over
and the load to fall.  Please note this device is only an indication that
a dangerous operation may be taking place it
Make sure the load centre of the load does does NOT prevent the operator from tipping the
not exceed the load centre rating stated on machine over; therefore the weights, lift height
the truck’s capacity plate. and load centre as stated on the capacity plate
If the mast continues to rise after the lift should never be exceed.
 Operators should check the Load Moment
lever is released, turn the key switch to the
Indicator is functioning correctly prior to use at
‘Off’ position immediately. the beginning of each shift. The unit is tested by
Failure to follow these guidelines can cause pressing the “TEST” button. This will cause all
serious injury or death. See the serial and lights to flash on and the audible warning to
capacity plates for rated capacity and load sound. The “TEST” button can also be pressed at
centre information. any time during operation. If in doubt park the
machine and contact your supervisor.

Setting the Forks

3. Move the forks until the spacing between
them is equal to one-half the opening
Before operating the Aisle-Master forklift make
between the end stringers on the pallet.
sure the spacing between the forks (item 1) [12],
Make sure the forks are seated in a
is properly set:
carriage notch and equidistant from the
ends of the carriage (item 4) [12].
1. Measure the opening between the end
stringers on the pallet (item 2) [12].
4. Press the fork locks down to ensure
locking.
2. Lift the fork locks (item 3) [12], up.
2
12

3 1
Retrieving a Load
The following steps outline the proper
procedure to be followed when retrieving a
load.
The black arrows indicate the direction to 4

turn the steering wheel and the grey arrows
indicate the truck drive and mast
carrier/fork directions.
1. Drive straight down the middle of the

2
aisle (item 1) [13] and slow down when
approaching the load (item 2) [13].
2. For narrow aisles bear to the side of 13

the aisle that is opposite to the load
(item 3) [13]. Maintain a distance of
approximately 150mm (6 inches)
between the side of the truck and the
side of the aisle. For wider aisles stay
in the centre of the aisle
3. Centre the forks using the side shift.
Warning
If the forks or load jam or catch during
a stacking operation, do not attempt to
free them by reaching through the
mast. Failure to follow this guideline
4. Drive forward until the centres of the

front wheels are aligned with the centre 1
of the pallet/load to be lifted (item 4) 14
[13], stop the truck and put the direction
lever into neutral.
5. Lift the forks to the required height and

use the tilt to level the forks.
6. Turn the steering wheel/forks towards

the load to be lifted (anticlockwise for
LHS). Stop turning when the fork
nearest to the load (item 1) [14] is
approximately 100mm (4 inches) from
the face of the rack/stack.
7. Set the direction lever to reverse. Slowly

reverse the truck and simultaneously
turn the steering wheel/forks towards
the load (anticlockwise for LHS) until the
forks are aligned central to the sides of
the load/pallet to be lifted [15]. 15

Note:
When turning the steering with the truck
stopped do not apply the foot brake or
the park brake.
8. Set the direction lever to forward. Drive

the truck forward towards the load and
simultaneously turn the steering
wheel/forks (clockwise for LHS) so that
the forks stay aligned parallel and
central to the sides of the load/pallet to
be lifted [16]. Use the side shift to centre
the forks with the load if necessary.
9. Lift the load just enough to clear the

rack/floor, otherwise it may catch on the
rack above. 16
S
turn the steering wheel/forks
(anticlockwise for LHS) so that the
load/pallet stays aligned parallel and
central to the sides of adjacent
loads/pallets [17]. Use the side shift to
centre the load with the adjacent pallets
if necessary.
Note:
If there is not enough clearance to
remove the load/pallet drive forward and
1
try the removal process again. To get
more clearance, don’t start turning the
forks until you have backed out 200 to
400mm (8 to 16 in.) 17
11. When the front right hand corner of the

load (item 1) [17] clears the racking,
stop reversing and turn the steering
wheel (clockwise for LHS) to align the
sides of the load/pallet with the sides of
the aisle.
12. Lower the forks until they are 100 to

150mm (4 to 6 in.) off the ground and
slowly drive the truck forward while
using the steering to straighten the truck
in the centre of the aisle. Drive to the
next location observing the safety rules
previously stated.
18

In Case the Aisle-Master 3. Brace your feet [21].
Forklift Tips Over
The following conditions can cause an Aisle-
Master forklift to tip over:
 Tip Loading (forks not inserted fully into

pallet)
 A load that is too heavy
 A load with a load centre exceeding that
stated on the capacity plate
 Taking a corner too fast
 Driving with the load elevated 4. Don’t jump out of the cabin [22].
 A load that is not distributed properly
(keep the load centre nearest the load
backrest / fork carriage)
 Driving across a slope
 Driving on a slope with the load facing
downhill.
 Using a battery that weighs less than the
original battery supplied with the truck.
Warning
Failure to follow these guidelines can
result in serious injury or death. Turning
If you sense your forklift is going to tip
over, follow these instructions:
1. Lean away from the direction the truck is

tipping [19].
Warning
A lateral tip-over can occur if your truck
is improperly operated [23]. Slow down
before turning! Failure to slow down can
cause serious injury or death.
2. Hold on to the steering wheel [20]. Follow these rules when turning with a load to
help prevent the truck from tipping:
 Slow down. Your Aisle-Master forklift can
tip over if you turn at high speed.
 Sound the horn as you reach an
intersection to warn pedestrians and other
equipment operators you are
approaching.
 Always follow the rules of the road and
yield to other equipment operators and
pedestrians as required.

Transporting a Load
Follow these guidelines when you transport a
load:
 Do not speed.
 Use the horn to warn others of danger.
 Make sure the load is seated firmly
against the load backrest / vertical front
face of the fork.
 Tilt the mast back.
 Lower the load so the forks are 100 to
150mm (4 to 6 in.) off of the ground. 24
 Be alert to overhead obstructions such
as low doorways, racking, and pipes.  If vision is obscured, arrange for a “spotter” to
Make sure you know the raised and guide you.
lowered heights of the mast.
 If you are not carrying a load, travel with the
 Make sure the load is not wider than the
forks facing uphill when you are going up an
width of the gangways or aisles,
incline and with the forks facing downhill when
especially if you are backing a bulky load
you are travelling down an incline [25].
down an incline.
Travelling On Inclines
!
Warning
Use extra caution when operating on
slopes. Travel slowly and do not turn.
When carrying a load always travel with
the forks facing uphill whether driving
up or down the slope.
result in serious injury or death.
When you travel up or down an incline,

follow these guidelines:
 Always drive straight on inclines.
 Make sure the gradient does not exceed

15% (8.5°).
Warning
When carrying a load always travel with
the forks facing uphill whether travelling
up or down an incline. That means you
must back down an incline when you 25
are carrying a load [24].

Warning
Never travel across a slope [26]. This
can cause the truck to tip-over laterally
and can result in serious injury or death.
26
Note:
Use the brake pedal to keep the truck
speed under control when travelling
down an incline.
Raise the forks as necessary to prevent the

forks or load from hitting the ground and
getting damaged as the road surface
changes gradient going up or down an
incline [27]. Lower the forks to 100 to
150mm (4 to 6 in.) off the ground when clear
of the change in gradient.
27

Unloading Your Forklift
3 1
The following steps outline the proper
procedure to be followed when unloading the
truck.
The black arrows indicate the direction to
turn the steering wheel and the grey arrows
indicate the truck drive and mast 4
carrier/fork directions.
1. Drive straight down the middle of the

aisle (item 1) [28] and slow down when
approaching the location where the load
2
is to be placed (item 2) [28].
2. For narrow aisles bear to the side of

the aisle that is opposite to the 28
space/stack (item 3) [28]. Maintain a
distance of approximately 150mm (6
inches) between the side of the truck
and the side of the aisle. For wider
aisles stay in the centre of the aisle.
3. Centre the forks using the side shift.
Warning
If the forks or load jam or catch during
a stacking operation, do not attempt to
free them by reaching through the
mast. Failure to follow this guideline
4. Drive forward until the centres of the

front wheels are aligned with the centre 1
of the space/stack where the load is to
be placed (item 4) [28] stop the truck 29
and set the direction lever to neutral.
5. Lift the load to the required height and

use the tilt to level the forks.
6. Turn the steering wheel/forks towards

the space/stack (anticlockwise for LHS).
Stop turning when the near front corner
of the load (item 1) [29] is approximately
100mm (4 inches) from the face of the
rack/stack.

turn the steering wheel/load towards the
space (anticlockwise for LHS) until the
near front corner of the load clears the
racking [30]. Stop and set the direction 30
lever to neutral.

8. Continue turning the steering wheel/load

towards the space (anticlockwise for
LHS) until the load is centred with the
space [31].
Note:
When turning the steering with the truck
stopped do not apply the foot brake or
the park brake.
31
9. Set the direction lever to forward. Drive

the truck forward towards the
space/stack and simultaneously turn the
steering wheel/load (clockwise for LHS)
so that the load stays aligned parallel
and central to the sides of the
space/stack [32]. Use the side shift to
centre the load if necessary.
10. Position the load in the space or over

the stack [32], set the direction lever to
neutral and lower the load until it sits
firmly on the rack/stack. Continue to
lower the forks until they are clear of the
bottom of the load (item 1) [33].
32
Warning
When lowering the forks clear of the
bottom of the load (item 1) [33], make 1
sure to not lower them too far. If the
forks are lowered too far the mast, rack,
or other containers on the stack could
get damaged. This could result in
serious injury or death.
11. Use the tilt to level the forks if required.
33

turn the steering wheel/forks
(anticlockwise for LHS) so that the forks
stay aligned parallel and central to the
sides of load/pallet [34]. Use the side
shift to centre the forks with the
load/pallet if necessary.
Warning 1
Do not attempt to withdraw the forks
until they have been lowered clear of the 34
bottom of the load. Failure to follow this
guideline can cause the load to fall off
the rack/stack causing serious injury or
death.
13. When the front of the forks (item 1) [34]

clear the rack/stack, stop reversing and
turn the forks away from the rack/stack
(clockwise for LHS) [35].
35
14. Lower the forks until they are 100 to

150mm (4 to 6 in.) off the ground. Set
the direction lever to forward and slowly
drive the truck forward while using the
steering to straighten the truck in the
centre of the aisle [36]. Drive to the next
location observing the safety rules
previously stated.
36

Transporting an Aisle- Tying-Down

Master Forklift Failure to securely tie down the truck when
transporting can allow it to shift. This can lead
to instability in the behaviour of the transport
Lifting with a Hoist vehicle or the truck being lost from the vehicle.
Use wheel chocks to prevent the truck from
Warning rolling. Only use the front tie down point (item
Failure to use lifting equipment of 1) [38] and rear tie down points (items 2) [38]
adequate capacity to lift and move your to tie down the truck in order to avoid
forklift can cause lifting equipment failure, damaging other parts of the truck. Use ratchet
which can lead to serious injury or death. straps that are sufficiently rated to restrain the
mass of the truck.
If you use lifting equipment to move the Aisle-
Master forklift to another location make sure Warning
the equipment has adequate size and
capacity to lift the truck. Confirm that the lifting Failure to tie down the truck securely
devices are in serviceable condition according with adequate equipment during
to their ratings. transit can allow the truck to break
loose which may result in serious
If you need to use a hoist to lift your Aisle- injury or death.
Master forklift:
1. Pass a suitable strap (item 1) [37], under

the truck just behind the rear wheels.
Ensure the strap is directly under the flat
area.
2. Pass another suitable strap (item 2) [37],

under the cross braces of all sections at the
top of the mast.
2
1 1
2 38
37

SECTION 4
Inspection and Maintenance
discusses the following concepts that must be thoroughly understood
before you inspect or perform maintenance on a forklift:
Initial 100 Hour Service - Describes the maintenance tasks that

must be performed after the first 100 hours of operating.
Inspection and Maintenance – Describes the tasks involved in

performing forklift inspections and preventive maintenance.
Inspection and Maintenance Responsibilities – Details the

inspection responsibilities for forklift operators and service facilities
authorised by Aisle-Master Ltd. to perform preventive maintenance.
Inspection and Maintenance Practices – Describes the precautions

and steps you should take when you perform inspection or preventive
maintenance tasks on Aisle-Master forklifts.
Operator Maintenance – Describes the tasks that must be

performed at the beginning of each shift before the truck can be used.
Routine Maintenance – Describes the routine maintenance tasks

that should be carried out regularly on your Aisle-Master forklift.
Fork Maintenance – Describes how inspection tasks should be

carried out on the forks of the Aisle-Master forklift.
Mast Maintenance – Describes the maintenance tasks that should

be carried out on the mast on your Aisle-Master forklift.
Brake Maintenance – Describes the maintenance tasks that should

be carried out on the brakes on your Aisle-Master forklift.
Hydraulic Maintenance – Describes the maintenance tasks that

should be carried out regularly on the hydraulic system and
components on your Aisle-Master forklift.
Transmission Maintenance – Describes the maintenance tasks that

should be performed on the transmission on your Aisle-Master forklift.
Battery Maintenance – Describes the maintenance tasks that should

be carried out regularly on the battery in your Aisle-Master forklift.
Greasing – Describes the procedure that should be followed when

greasing components on your Aisle-Master forklift.
Putting a Truck in Storage – Describes how to store a truck.
Final Decommissioning – Describes how to dispose of a truck.

Initial Service at 100 Hours

An initial service is required after the first 100 hours of operation to ensure that the truck is in
optimum working condition. The initial 100 hour service is conducted as follows:
 Check battery electrolyte levels.
 Check all electrical connections/terminals.
 Check emergency stop button.
 Check all bolts and fittings are tight.
 Torque wheel nuts
 Front Wheel Nuts (305N/m)

 Rear Wheel Nuts (176N/m)
 Grease all points (See grease point chart on Page 4-24).
 Check mast chains - lubricate and adjust if required.
 Check mast channels – lubricate if required.
 Check for leaks - hydraulic oil, brake fluid, battery electrolyte.
 Check hydraulic oil level.
 Change transmission oil (front axle).
 Check load monitor is working correctly (if fitted).
 Check brake fluid level.
 Adjust handbrake if required.
 Check tyres for cracks and debris.
 Change steering support oil (if applicable).
 Check steering chains and lubricate (if applicable).
 Check steering.
Note: Lubricate all grease points weekly (See Grease Point Chart Page 4-24)
Note: An initial service checklist is located in Appendix A at the back of this

manual.

Inspection and Maintenance Warning

Before conducting a maintenance
General procedure ensure the battery is
This section contains a MAINTENANCE disconnected, and the mast and
SCHEDULE and the instructions for maintenance forks are fully lowered.
and inspection.
Inspection Program
Industrial trucks are thoroughly examined, tested
and lubricated before leaving the factory; however, The inspection program designed by Aisle-
regular maintenance and lubrication are necessary Master Ltd. periodically checks the integrity
to ensure smooth running and long life. of Aisle-Master forklift systems such as:
The recommended maintenance periods are for  Checking performance of operator
trucks operating in normal, clean conditions. For functions such as lift, tilt, side shift,
abnormal temperatures, dust contamination areas attachment, and traction systems
or moist conditions, etc., more frequent  Checking for leaks
maintenance will be required.  Checking fluid levels
 Making sure components are securely
The maintenance work covered in this manual is attached
divided into sections:  Checking the tyres
1. Checks and adjustments (where no special Except for the Operator’s Daily Checks,
skills are required) that may be performed by these tasks are usually performed by a
the operator. service and maintenance facility that is
2. Repairs and adjustments that must be done by approved by Aisle-Master Ltd.
trained service people.
To make sure these and other systems are
Warning checked periodically, Aisle-Master Ltd. has
developed a system of checklists. A blank
Do not operate a lift truck that is in need of copy of each checklist can be found in
repair. Report the need for repair Appendix A. These checklists include:
immediately. If repair is necessary, put a
"DO NOT OPERATE" label in the operator's  Operator’s Daily Checklist
area. Remove the key from the key switch.  Initial service at 100 Hours
 Every 500 Hour Service Checklist
 Installation Checklist / Pre-delivery
Inspection (PDI)
Warning
Never perform any maintenance or service
procedures unless specifically indicated in Maintenance Program
this manual or requested by your
supervisor. All other service and In addition to the inspection program, Aisle-
maintenance on your Aisle-Master forklift Master Ltd. has set up a preventive
must be provided by a facility authorised by Maintenance program. Preventive
Aisle-Master Ltd. to perform these services. maintenance procedures include:
Failure to follow these guidelines can cause
serious injury or death.  Changing transmission oil
 Cleaning hydraulic reservoir suction
screens
 Changing hydraulic oil and filters
 Lubricating mechanical systems

Preventive maintenance tasks are usually Regular Service intervals in normal use are:
performed by a service and maintenance facility
that is approved by Aisle-Master Ltd. Operators  500 hours of operation or 3 months
may be asked to assist in some routine (whichever comes first)
maintenance procedures. Never perform any of  2000 hours of operation or 12 months
these maintenance procedures unless directed (whichever comes first)
by your supervisor.
Typically an authorised service and
maintenance facility performs preventive
Inspection and maintenance procedures. At times operators
may be requested to assist in performing
Maintenance routine maintenance, such as doing routine
Responsibilities lubrication. If requested to do so, make sure
you read and understand the guidelines
discussed in the “Inspection and Maintenance
500 and 2000 Hour Service Practices for Aisle-Master Forklift Operators,”
section on the following page of this manual.
During these inspections technicians from an
authorised service and maintenance facility will
inspect all mechanical and electrical systems and Inspection and
perform preventive maintenance operations
designated by Aisle-Master Ltd. Maintenance Practices
This section explains the general precautions
and warnings that must be observed during
Installation Inspection inspection and maintenance procedures. In
addition, the duties of the operator and service
When your Aisle-Master forklift is installed, the and maintenance technician are explained.
authorised service facility is required to complete Finally, these specific procedures are
an Installation Checklist. The installation report explained:
initiates the warranty for the vehicle.
 Preparing for Inspection or Maintenance
Routine Maintenance Schedule  Performance Testing
 Completing Performance Testing
The Routine Maintenance Schedule is located on
Page 4-8. Note that each task should be Warning
performed at the time interval or number of
Wipe up any spills immediately to prevent
operation hours indicated, whichever comes first.
serious injury or death from slipping, fire,
explosion, or contact with hazardous
Warning materials.
Never perform any maintenance or service
procedures unless specifically indicated in Warning
this manual or requested by your supervisor.
All other service and maintenance on your To help avoid fire hazards:
forklift must be provided by a facility • Have fire protection equipment present
authorised by Aisle-Master Ltd. to perform in the work area.
these services. Failure to follow these • Do not use an open flame to check fluid
guidelines can cause serious injury or death. level, leaking oil, or electrolyte.
• Do not use fuel or flammable cleaning
fluids to clean parts.

cause serious injury or death.

Warning Inspection and Maintenance

Batteries produce flammable and explosive Practices for Authorised Facilities
gases. Keep arcs, sparks, flames, and lighted ONLY
tobacco away to prevent an explosion. Keep
the area well ventilated. Failure to follow these  Follow the procedures outlined in this
guidelines can cause serious injury or death. manual.
Warning  Inspect and maintain wheel hubs and

Failure to use lifting equipment of adequate protective devices.
capacity to lift and move your forklift can
cause lifting equipment failure, which can lead  Only use replacement parts, including
to serious injury or death. tyres that are equal to, or exceed, the
quality of the parts supplied by the
! original equipment manufacturer. Install
Inspection and Maintenance parts, including tyres, according to
Practices for Aisle-Master Forklift procedures established by Aisle-Master
Ltd.
Operators
 When you remove tyres, follow industry
These guidelines will help prevent downtime for safety practices.
your Aisle-Master forklift and maintain it in a safe
operating condition:
 Perform the tasks listed on the Operator’s Preparing for Inspection or

Daily Checklist even if you are taking Maintenance
responsibility of the truck from another
operator. You are responsible for the Inspect the truck in an area that has sufficient
condition of the forklift on your shift. Work clearance to check all operating functions.
together as a team with your co-workers,
supervisor, and authorised service facility to Lower forks to the ground and tilt mast forward.
keep the truck in peak operating condition.
Accidents happen when you assume  If you will not be operating the truck to
another operator has checked out the check operator functions, disconnect the
forklift. battery and chock the wheels.
 Keep your truck clean to minimise fire  If you need to hoist the truck, make sure
hazards and facilitate detection of loose or the hoisting equipment has adequate size
defective parts. and capacity to move the equipment. See
‘lifting with a hoist’ on page 3-20.
If you are asked or required to perform basic
lift truck maintenance, make special note of
the following:
 Before you perform service or maintenance

on an Aisle-Master forklift, read and
understand the Aisle-Master Forklift
operator’s and service manual, and machine
safety signs.

Performance Testing 4. Turn the key switch, (item 1) [2], to the ‘ON’
position.
Note:
Make sure all accessories (lights, etc.) are off 5. Set the direction lever (item 1) [1], to the
before continuing. forward position.
1. Make sure you are in the operator’s seat. 6. Check functions described on the Operator’s
Daily Checklist (Page A-2) or every 500 hour
2. Make sure your right foot is on the floor of checklist (Page A-4).
the operator’s cab.
3. Set the direction lever (item 1) [1], to the Completing Performance Testing
neutral (centre) position.
Note:
Make sure all accessories are off (lights,
1 etc.) before you turn the key switch to the
‘Off’ position.
1. Apply the parking brake (item 2) [2].
2. Tilt the mast forward.
3. Lower the forks to the ground.
4. Turn the key switch to the ‘OFF’ position.

1
5. Remove the key.
Before you leave the truck make sure that:
• The parked truck will not cause an

obstruction or safety hazard.
• The forklift is clear of fire exits, fire

equipment, and stairways.
• The truck is not left unattended on an incline.
1 If the truck cannot be driven and you must

leave it parked on an incline, securely chock the
wheels and remove the key.

 Hydraulics - Inspect the hydraulic hoses for
Operator Maintenance kinks, routing and wear. Check all seals and
couplings for damage and leaks.
 Mast - Inspect the mast channels, chains
Daily/Pre-operation Inspection and bearings for excessive wear, damage,
deformation and cracks. Check the mast
Note: chains for missing links or pins. Check
In many countries, it is a legal requirement to chains are of equal tension and well
perform the daily/preoperational inspection lubricated.
and to keep a record of the inspections.  Fork carriage – Check for excessive wear,
Report any defect(s) immediately. Contact damage, deformation and cracks.
your local authorities in order to find out  Overhead Guard - Check for damage or
what regulations are in place regarding daily cracks. Ensure it is fixed securely.
inspections of industrial equipment of this
 Hydraulic Tank – Check for damage or
nature.
leaks. Check the hydraulic oil level.
 Battery - Check the battery connections are
 Employers must ensure that the daily checks
secure. Check the cells for damage and
are performed and that records are kept.
leaks. Check the electrolyte level. Check
 Operators must perform the checks and report leads for loose or bare wires.
any defects to their supervisor.
 Serial and Capacity plates – Check they
 Never operate a truck that has not been are present and securely attached and
checked or that has failed on any of the check the rated capacity.
checks.
 Seat Belt - Look for cuts in the belt. Check
 If a truck becomes unsafe during a shift, stop the retractor and retainer are functioning.
operating the truck and report the problem
 Drive and Braking – Drive the truck in
immediately.
forward and reverse and test the service and
park brakes.
The daily inspection must be carried out at the
 Steering - Check in both directions whilst
start of the working day before the machine
stationary and on the move. Look for
commences operation. Alternatively if a multi shift
excessive freedom or stiffness.
system is being operated the checks should be
carried out at the beginning of each shift.  Seat – Check it is anchored securely and
that runners and sliders operate freely.
The details of the inspection should be recorded Check for objects under the seat that may
on a copy of the daily checklist (appendix A interfere with the seat switch.
page A2) and a record of these inspections should  Hydraulic controls – ensure smooth
be kept on file within the company records. operation of all controls to their full extent of
travel.
The following checks must be performed in  Horn, Lights, Reverse Bleeper & Beacon
accordance with daily/preoperational – Test and check for normal operation.
inspection:  Dash display – Check the hour meter is
working and all warning lights are
 Overall condition – Check the condition of extinguished.
protective covers. Look for missing or loose  Rear View Mirror – Check it is present,
nuts and bolts. Look around and under the truck clean and in good condition.
for leaking hydraulic oil, battery electrolyte or  Load Monitor (if fitted) – Check it is
brake fluid operating normally.
 Wheels & Tyres – Check wheels for damage  Electrical Connections/Terminals – Check
and that wheel nuts are present and tight. they are securely connected and
Check tyres for cuts and foreign objects. undamaged.
 Forks - Inspect the forks for excessive wear,  Motors – inspect the pump and drive motors
cracks, fractures, deformation. Ensure they are for any unusual sounds or smells
equally spaced and locating pins are engaged
 Load Backrest (if fitted) – Check for
deformation or cracks. Ensure it is fixed
securely.

Inspecting Specially Equipped Aisle- The forklift trucks are built with quality
components; the use of inferior spare parts can
Master Forklift Trucks result in inadequate safety and poor reliability.
The following information is provided for Only use genuine approved parts.
authorised service facilities ONLY.
Maintenance Chart
Forklift trucks that were designed to meet special
applications should be inspected and tested to The following tasks must be performed at the
make sure they meet original design criteria intervals indicated in order to keep the truck in
described by the specific (local) agency. optimum working condition.
Service Interval
Information Plate and Safety (Hrs)
Item
Warnings 500 2000
Check All Electrical Connections/Terminals ●
Warning Visually Inspect The Brake Shoes & Drum ●
Make sure that the identification plate and Inspect the Brake Cylinder & Adjuster ●
safety warnings (decals) located on the truck Check All Nuts And Bolts Are Present & Secure ●
are legible and that the information provided Check Drive Transmission Oil Level ●
matches the characteristics of the truck.
Change Drive Transmission Oil ●
Failure to follow this guideline can result in
serious injury or death. Change Steering Support Oil ●
Check Motor Mounts & Mounting Bolts ●
The following information is provided for Check Pump Operation & Mounting Bolts ●
Check Cooling Fan ●
Contact Aisle-Master Ltd. if any accessories that Check Hydraulic Oil Level ●
modify the capacity and truck operation are Change Hydraulic Oil ●
planned. After the factory reviews your request, Change Hydraulic Return Filter Cartridge ●
new identification tags will be issued to update the
rated capacity and other operation characteristics. Change Hydraulic In-Tank Strainer Filter ●
Replace Mast Carrier Bearing Auto Lubricators (If
Applicable) ●
Routine Maintenance Grease Slew Ring Bearing (If Applicable) ●

Check Park Brake & Adjust Park Brake Cables ●
Routine maintenance may be carried out by the Check Mast Mounting Points ●
users / operators, but only if the correct facilities Check Load Monitor Operation ●
and replacement parts, e.g. filters are used. Check Mast Bearings ●
The service intervals are given in both operating

Check Lubricate & Adjust Mast Chains ●
hours (recorded on the lift truck hour meter) and in Check & Lubricate Steering Chains (If Applicable) ●
calendar time. Grease Mast Channels ●
Check Service Brake Master Cylinder Fluid Level ●
Service the machine at the interval that occurs
first. These intervals are based on normal Torque Front Wheel Nuts – 305Nm (225ft-lb) ●
operation of 8 hours per day. The time intervals Torque Rear Wheel Nuts – 176Nm (130ft-lb) ●
must be decreased from the recommendations in Check Hydraulic Hoses for Wear and Leaks ●
the maintenance schedule for the following
500 hours or 3 months (Whichever Occurs First)
reasons:
2000 hours or 12 months (Whichever Occurs First)
 If the lift truck is used more than 8 hours per
day. Top up Battery Electrolyte Level Weekly.
 If the lift truck must work in harsh operating Grease all Points Marked on the Grease Point
Chart weekly (see page 4-24).
environments.
Grease the steering pinion every 250 hours.

Fork Maintenance Fork Angle:
Check the angle between the front vertical face
Warning of each fork and the load face of each shank. If
Never operate your Aisle-Master forklift if you the deviation exceeds 3° from the original
suspect the forks are damaged. Report any specification withdraw the fork from service.
fork damage to your supervisor immediately.
Failure to follow this recommendation can Difference in Height between Fork Tips:
cause serious injury or death. Check the difference in height between tips of
the forks with the forks mounted on the fork
The following information is provided for carriage. If the difference in tip heights exceeds
authorised service facilities ONLY. 3% of the length of the blade, the forks should
be removed from service.
Check the forks, and associated components, as
required by the various checklists located in Positioning Lock:
Appendix A. The following discussion provides Check the positioning lock on each fork to
detailed procedures necessary to perform a make sure it functions properly. If any problems
complete fork inspection. are noted, repair or replace the fork.
!
Wear:
Warning Two different areas of the fork and fork
If you find any defect in the forks or mounting attachment should be checked for wear.
components, take the Aisle-Master forklift out
of service until the fork is repaired or replaced. Fork Blade and Shank – Check each fork blade
Failure to follow this guideline can cause the and shank for wear, pay special attention to the
load to fall resulting in serious injury or death. area surrounding the heel of the fork. If the
thickness is reduced to 90% of the original
Rated Capacity and Load Centre: thickness, remove the fork from service.
The rated capacity of each fork must be at least
half of the rated capacity stated on the Fork Hooks – Check the support face of the top
identification plate. The load centre of each fork hook and the retaining faces of both hooks for
must match the load centre stated on the data wear, crushing, and other local deformations. If
plate. If the values do not match, replace the fork any of these deficiencies cause excessive
with one that has the correct characteristics. clearance between the fork and the fork
carriage, remove the fork from service.
Cracks:
Visually examine the forks for surface cracks. Pay Fork Marking:
special attention to: If the fork marking is not clearly legible, the fork
manufacturer, or their representative should
 Fork heel remark it.
 Welds that attach mounting components to the
fork blank
Repairing Forks
Forks with surface cracks should not be returned If you suspect that a fork needs to be repaired
to service or replaced, return it to the manufacturer or
other expert of equal competence who shall
Straightness of Blade and Shank: decide if it may be repaired or if it must be
Check the straightness of the upper face of each replaced with a new fork. Never try to repair
blade and the front face of each shank. If the surface cracks or wear by welding the fork. If
deviation from straightness exceeds 0.5% of the you need to reset a fork, make sure it is
length of the blade and/or the height of the shank, subjected to an appropriate heat-treatment
respectively withdraw the fork from service. before it is returned to service.

Load Testing Forks Worn Surfaces on Outer Plates/Pin Heads:

Check alignment and adjust as necessary
A fork that has undergone repairs - other than If wear is excessive replace chains
repair or replacement of the positioning lock or
marking - must be load tested before it is returned
to service. The test load must correspond to 2.5
times the rated capacity marked on the fork.
Tight Joints:
Mast Maintenance Dirt – clean and lubricate
Corrosion or damage – replace chains
The following information is provided for
Perform checks on the mast as required by the

operator’s daily checklist and maintenance as
Cracked Side Plates:
required by the initial 100 hour service checklist
Replace both strands of chain
and 500 hour service checklist for Aisle-Master
Eliminate high load condition or dynamic
Forklifts located in Appendix A. Guidelines are
overloading
provided in the following paragraphs.
Warning
Never work on the mast with a load on the Abnormal Protruding or Turned Pins:
forks or attachment in the raised position Replace chains and improve lubrication.
without supports or while anyone is near the
lift truck control handles.
Chain Maintenance
Regular inspection and lubrication of the chains will Fractured Plates:
vastly increase their service life and reduce Replace chains and correct cause of overload
downtime. When you perform chain maintenance,
make sure you follow the guidelines in ‘Chain
Inspection’, ‘Measuring Chain Stretch’, ‘Chain
Lubrication’ and ‘Chain Adjustment’.
Arc like Cracked Plates:
Replace chains and correct from hostile
environment
Chain Inspection
Inspect the chains as required by the inspection
and maintenance charts. Check for the following:
Enlarged Holes:
Worn Contours: Replace chains and correct cause of overload
Normal wear - replace when 5% worn
Abnormal wear – check alignment and adjust
Corrosion Pitting:
Replace chains and protect from hostile
environment
Worn, broken or misaligned chain anchors:

Replace or adjust as required.

Measuring Chain Stretch It is recommended that the lubricant used on

the chains has the following properties:
Leaf chain failure is usually a result of gradual
elongation as the chain wears. Measure the chain  Satisfactory corrosion protection and
elongation with a chain wear gauge that displays lubrication
the elongation of the chain as a percentage value.  Ability to penetrate through / under water
Follow the chain wear gauge instructions.  Continuously viscous after application
 Good adhesion properties
Chains should ideally be cleaned and measured  Layer thickness and protective film able
in situ while placed under load. It is acceptable for to withstand later aggression (rain / hail
the chain to be tensioned by the weight of the etc.)
carriage and forks.
The following lubricants (available in an
When checking for chain wear it is vital that the aerosol can) are recommended:
section that passes over the pulley is measured
as this section experiences the most wear during Fuchs anticorit bw366
normal operation. Molykote mkl-n
Kluber structovis bhd 75s
Warning
If a chain has reached a level of 2% elongation, Where chains are encased in dirt and dust
a safe time limit must be set for the chains to the lubricant will be prevented from flowing to
be replaced. If a chain has reached 3% the vital load bearing contact areas of the
elongation, it must be taken out of service chain between the link plates and pins.
immediately.
It is essential that leaf chains should be
To check the free lift chains, raise the carriage 1ft removed of all dirt and debris prior to
(30 cm) off the ground to put tension on the chains. lubrication.
To check the main lift chains, raise the mast Recommended jet equipment cleaning
until the inner upright starts to extend putting method for leaf chain:
tension on the chains.
The following method is recommended
when the use of jet cleaning equipment
cannot be avoided in leaf chain and
Chain Lubrication forklift chain maintenance:
Caution 1. Cleaning - Clean the leaf chain using

The chains must be kept lubricated at all steam or hot water only. Absolutely no
times. additives should be used.
2. Compressed Air - Immediately after
Running the chain dry can substantially shorten its cleaning the leaf chain, all water should
life. Oil must be reapplied on a regular basis to be removed both from the surface and
ensure the chains maximum life is achieved. from inside the chain joints using high
pressure compressed air. The
The frequency of this operation is at the discretion articulating links of the chain should be
of the user and essentially depends upon the moved several times during this process.
working conditions and the workplace. 3. Re-lubricating – Make sure that
the chain is slack and then spray with a
Ensure that the chain is slack during the preservative and lubricant. Articulate
lubrication process so that the lubricant can the chain several times so that the
flow between the chain link plates and pins. lubricant penetrates the chain joints.

Chain Adjustment Fork Chain Adjustment

The chains connecting the fork carriage to the
Chain elongation due to stretch (see ‘Measuring inner mast stage must be adjusted so that the
Chain Stretch’ on the previous page) can be bottom faces of the forks are approximately
compensated for by adjusting the chain anchors 6mm of the ground with the truck parked on a
(item 1) [3], [4]. The chain anchors are located on smooth level surface and the mast unloaded
the fork carriage and also on the mast stages. and tilted forward fully.
To set the clearance between the upper stops

on the fork carriage and the inner stage of the
mast, remove the forks and raise the fork
1 carriage fully. Adjust the chain anchors so that
there is a clearance of approximately 1mm
between the stops. When the forks and a load
are present the clearance will increase to a
desirable value of approximately 5mm.
3
1
1 2
4
5
Mast Chain Adjustment
Chain Tension Adjustment
The chains connecting the mast stages must be The chains on the mast must be adjusted so
adjusted in such a way as that the vertical mast that each chain acting as one of a pair is
channels are approximately flush with each other under equal tension to the opposite chain in
at the bottom and not in contact with the bottom the pair for proper load distribution and mast
plate when the mast is unloaded and fully lowered. operation.
To adjust a mast stage, tighten or loosen the To check and set the chain tension:
adjusting nut on one of the chain anchors to 1. With the mast unloaded raise the sections to
achieve the desired dimension. Adjust the put the chains under tension.
opposite chain of the pair to achieve equal tension 2. Press the centre of a strand of chain with a
in the chains. suitable rod and then press at the same place
on the opposite chain of the pair.
Raise the mast fully and check that a clearance of 3. Each chain in a pair should have equal “give”.
at least 1mm exists between the end of run stops 4. If the tension is not equal, tighten the bolt on
(item 1) [5], (item 2) [5] on each of the mast the anchor of the slack chain.
stages. 5. Test the tension again. Tighten the bolt until
the tension is equal.
Note:
Never place hands inside the mast to
check chain tension.

Greasing Mast Channels Mast Bearings

The bearings on the mast do not require
All roller surfaces must be greased periodically periodic greasing.
where the fork carriage and mast section roller
bearings run [6]. The frequency of this operation is Check for cracks or flat areas on the surface
at the discretion of the user and essentially of the bearings and also check for restrictions
depends upon the working conditions and the to rolling. Replace if any of these are detected
workplace. and try to eliminate the cause(s) of the failure.
Perform checks on the mast channel lubrication as Principle Causes of Bearing Failure
required by the initial 100 hour service checklist
and 500 hour service checklist for Aisle-Master Shocks
Forklifts located in Appendix A. Violent frontal collisions during loading can
cause bearings to fail.
A lubrication interval of about 500 hours can be The external surface will show cracks (item 1)
taken as a typical value, under normal working [7] that cut the surface parallel to the rolling
conditions. For this purpose use graphite grease, axis.
avoid spray greases.
1
Large Load Centre

Another possible cause of breakage is the
mounting of special equipment to handle
loads with a very large load centre e.g.
carpets, even if their weight is lower than the
rated capacity.
This condition creates oscillations that cause
6 the detachment of the external hardened
surface of the bearing. In this case
circumferential cracks (item 1) [8] will appear
and will run completely around the roller.

Visually inspect the brake cylinder (item 3) [9]
Brake Maintenance for excessive wear, damage or leaks. Use only
The following information is provided for a spirit to clean the cylinder. Never use mineral
authorised service facilities ONLY. oil containing cleaning agents. The cylinder
may not be repaired. If necessary replace the
complete cylinder.
Caution
Before commencing maintenance and Visually inspect the automatic adjuster
repair work on the brakes, the vehicle assembly (item 4) [9] for damage. Apply a
must be secured to prevent it from rolling little heat resistant grease to the threads of the
off. adjusting bolts (item 5) [9]. Use only
compressed air to clean the adjuster. Do not
Before commencing work on the brake, dismantle individual components. The adjuster
ensure that the brake cannot be operated may not be repaired. If necessary replace the
unintentionally. complete unit.
3
Brake Inspection
1
The thickness of the lining (item 1) [9] on the
brake shoes (item 2) [9] should be visually
inspected at every 500 hour service interval.
To inspect the thickness of the brake linings jack

up the truck and remove the wheels and brake
drums. Remove all dirt and corrosion from the
brake drum and linings.
The brake shoes must be replaced if:

2
1. The thickness of the brake lining has worn
down to 2mm or less at the thinnest point.
4 5
9
2. The brake surface is glazed.
3. The brake lining is damaged or cracked. Brake Servicing

Removing the Drum
4. The brake shoes are excessively worn
damaged or deformed. 1. Jack the truck up with a suitable jack.
2. Place supports under the truck that are
5. The brake operation is insufficient. capable of safely supporting the weight of
the truck.
3. Release the parking brake and remove the
Caution wheels.
Replace all brake shoes on both sides of 4. Take the brake drum off by removing the
the truck to avoid unequal braking. two M8 countersunk hex head bolts from the
Replace only complete shoes. holes they are in and inserting two M8x30
hex head bolts into the two open holes.
Visually inspect the brake drums for excessive Tighten both bolts evenly to push the drum
wear and grooves on the internal brake surface off normal to the hub.
and for cracks on all surfaces. Replace if 5. With the drum removed perform the checks
necessary (replace both drums to avoid unequal described under brake inspection.
breaking).

Changing the Brake Shoes
2 10
1. Unhook the tension and compression springs 3
from the brake shoes using spring pliers and
compressors.
2. Remove the old brake shoes.
3. Reset the adjuster assembly. See ‘automatic
adjuster setting’ below.
4. Fit the new brake shoes.
5. Fit new tension and compression springs to the 1
brake shoes.
Caution 11
Replace all brake shoes on both sides of
the truck to avoid unequal braking.
Replace only complete shoes.
Automatic Adjuster Setting

The automatic adjusters must be set when:
 They are replaced, removed or remounted.

 New brake shoes and or drums are fitted.
 Any repair work is done where the basic setting 5. Adjust the park brake cables in such a way
of the adjusting bolts (item 1) [10] is altered. that the brake diameter is not altered. To
access the cable adjuster the battery must
be removed (see appendix B page B-6 at
the back of this manual).
To set the automatic adjusters:
Note:
1. Apply a little heat resistant grease to the
The cables must not be pre-tensioned
threads of the adjusting bolts (item 1) [10].
otherwise the adjuster may not function
2. Carefully move the adjusting lever (item 2) [10]
correctly.
away from the adjusting wheel (item 3) [10]
and turn the adjusting wheel – using suitable
6. Mount the drum (see ‘refitting the drum’ on
tools - in the direction indicated by the grey
the following page) and fit the wheels.
arrow in [10] to screw the adjusting bolt back
7. Only if the automatic adjuster has been
into the assembly.
renewed, removed or remounted loosen the
3. Ensure the distance between the bottom of the
hex bolt that fastens the adjuster and
notch in the adjusting bolt and the outer face of
actuate the brakes several times to centre
the adjusting wheel ‘x’ [11] is equal on both
the brake shoes/adjuster in the drum.
sides.
Torque the hex bolt to 90Nm.
4. Stop screwing the bolts into the adjuster when
8. Lightly apply the handbrake and check that
the distance between the notches in the
both the rear wheels are equally difficult to
adjusting screws is equal to 79mm. See [11].
turn. If one wheel is easier to turn, correct
the imbalance at the park brake cable
Note: adjuster.
Precise setting of the automatic adjuster is of 9. Lower the truck to the ground and perform
critical importance for the function of the approximately 10 stops from the trucks
adjuster. maximum speed. The automatic adjuster is
now set.

Refitting the Drum Bleeding the Brakes

1. Ensure the park brake is disengaged. Bleeding the brakes should only ever be
2. Line up the two countersunk holes in the drum necessary if a part of the hydraulic brake
with the two M8 threaded holes in the wheel system has leaked or has been replaced.
hub and slide the drum onto the hub over the Repair any leaks in the system before
wheel studs. bleeding.
3. Screw the two M8x20 countersunk hex bolts -
that were taken out when removing the drum - Caution
back into the hub. Before commencing any work on the
brakes the truck must be secured to
Caution prevent it from rolling off.
Brake parts are safety critical. Use only
original spare parts. Bleeding the brakes requires two people.
Aisle-Master accepts no responsibility
for the use of non-original spare parts. Before the brakes can be bled the battery must
be removed from the truck (see appendix B
page B-6 at the back of this manual).
Brake Fluid
The Aisle-Master truck is supplied with Dot 4 To bleed the brakes:
(SAE J 1704/ISO 4925 – class 4) brake fluid.
1. Park the truck on level ground.
To check the brake fluid level: 2. Secure the truck to prevent it from rolling off
and remove the battery.
1. Park the truck on a level surface and apply the 3. Connect a length of clear tubing to the
park brake. bleed adapter (item 1) [13] on one of the
2. Remove the floor inspection panel (item 1) [12] rear wheel hubs (item 2) [13] and run to a
3. Check that the fluid in the brake master clear container to collect the escaping fluid.
cylinder reservoir (item 2) [12] is between the 4. Pump the brake pedal to compress the air
max and min level marks. in the system then hold pressure on it.
4. Top up if necessary with Dot 4 (SAE J 5. Unscrew the bleed adapter (item 1) [13] to
1704/ISO 4925 – class 4) brake fluid and check let out fluid and air; then tighten the adapter
for leaks in the system. after the pedal has landed (to prevent air
being sucked back in on the upstroke).
Repeat the process (typically 5-10 times for
each wheel).
6. Refill the master cylinder reservoir (item 2)
[12] frequently; if it is emptied the entire
process must be restarted.
7. Repeat steps 3-6 for the opposite hub
8. The cap on the reservoir must be left loose
so that the fluid may be drawn, but should
be in place so that fluid does not squirt out
1 on the return stroke.
9. A block may be placed under the pedal so
2 that it does not bottom out during this
procedure, as the master cylinder seals
could be damaged.
10. Top the reservoir up to the maximum mark
after the brakes have been effectively bled.
12

Note:
1 Before adding hydraulic oil, ensure that
all cylinders are retracted and fill to the
maximum mark on the dipstick.
2
Checking Hydraulic Oil Level
 Park the truck on a level surface.
 Lower the forks fully, tilt the mast forward
fully and retract all cylinders on any
attachments.
 Loosen the hydraulic oil filler cap to release
pressure from the tank before checking the
level on the dipstick.
13
 Remove the dipstick and wipe clean with a
Hydraulic Oil lint free cloth.
 Insert the dipstick fully into the tank and
Clean ISO grade hydraulic oils with improved remove again.
viscosity / temperature characteristics must be  Check that the oil level is between the
used in the Aisle-Master lift truck. Oil must also minimum and maximum marks.
have the correct temperature range for the  If necessary top up to the maximum mark.
ambient temperature in which the machine is  Replace the dipstick and tighten the filler
being operated. If the operating temperature is cap.
outside the standard range, the standard oil
should be replaced with the correct grade.
The correct grade of oil for the relevant Hydraulic System

operating temperature range can be
determined using the following table:
Maintenance
HYDRAULIC OIL CHART The following information is provided for
FLUID OPERATING
-11°C to 66°C -4°C to 74°C 4°C to 89°C
TEMPERATURE 12°F to 150°F 24°F to 166°F 39°F to 193°C
RANGE
RECOMMENDED Maintain the hydraulic system, and
FLUIDS associated components, as required by the
Castrol Hyspin AWH various checklists and the Routine
BP Bartran HV Maintenance Schedule for Aisle-Master
ISO GRADE
ISO GRADE
ISO GRADE
Mobil Univis N Forklifts located in Appendix A. Guidelines

32
46
68
Mobil DTE 10 Excel for hydraulic system maintenance are

Shell Tellus Oil T
provided in the following paragraphs.
Chevron Rando HDZ
Maxol Multivis Caution

Do not allow hydraulic fluid level to drop
Note: significantly or allow the reservoir to
Use of hydraulic oil that does not meet the run dry. This will induce air into the
required grade or temperature range may cause system and cause damage to hydraulic
poor operation, reduced efficiency and/or system components.
damage to hydraulic components.
Note: Cylinders and Valves: Check for leaks,

The machine is supplied with ISO 46 hydraulic damage and excessive wear. Ensure they are
fluid when leaving the factory. Please check if securely mounted.
this is suitable for the ambient temperature in
which the machine is to be operated.

Hoses: Check for cracks, hardening, or other Changing Hydraulic Oil
signs of wear. Reroute any usable hoses that are
kinked, severely bent, or rest against wearing or To drain the oil from the hydraulic tank:
hot parts. Look for leaks, especially at couplings
and fittings. 1. Park the truck on level ground.
2. Retract all hydraulic cylinders i.e. lower
Hydraulic Fluid: Check fluid level and look for air the forks, tilt the mast forward etc.
bubbles. Check the filters. 3. Place a suitable size receptacle directly
underneath the drain screw (item 2)
Other Hydraulic System Components: [14], to prevent any oil spillage.
Visually check other hydraulic system 4. Remove the drain screw by turning anti-
components for signs of leaks damage or wear. clockwise to drain the system.
Ensure they are securely mounted 5. Allow time for the tank to drain
completely
Warning
 Allow the truck time to cool to a safe Once completed fill the system to the
working temperature before commencing appropriate level with Hydraulic oil of the same
any service work on the hydraulic grade as that, which was in the tank.
system.
 Relieve residual pressure from the

hydraulic system before commencing
any service work on the system. Lower
the forks until they are resting on the
ground. With the truck off, actuate all of
the controls several times in both 1
directions and open the steering
cartridge valves.
 Never use the hands or any other body

part to check for fluid leaks. Use a piece
of solid material. Remember to wear
safety glasses.
Leaking fluid under high pressure can

penetrate body tissue resulting in infection
or death.
If fluid is injected into the eyes or skin, seek
treatment immediately from a doctor
familiar with this type of injury 2
14
Checking Side Shift for Leaks
To check side shift circuit: Hydraulic Tank Capacity
1. Side shift completely to the left and hold 40 litres (42 quarts) of oil are required to
the control handle in this position for 5 bring the oil level to the centre of the oil
seconds. Check for external leaks at the level marker on the dipstick (item 1) [14].
cylinder, fittings and hoses.
2. Side shift completely to the right and hold

the control handle in this position for 5
seconds. Check for external leaks at the
cylinder, fittings and hoses.

Hydraulic Filters In-Tank Strainer Filter:

The In-Tank Strainer Filter (item 2) [15],
There are 2 separate hydraulic filters in the located inside the tank must be replaced at
hydraulic system that must be replaced at certain intervals of every 2000 hours (or 12 months
intervals. These filters are: depending on which occurs first). The
strainer filter can only be accessed when the
1. The Return Filter (item 1) [15] hydraulic tank has been drained.
2. The In-Tank Strainer Filter (item 2) [15]
To replace the In-Tank Strainer Filter:
The locations of these filters are shown below. 1. Remove the floor plate to access the top
of the hydraulic tank.
2. Drain the hydraulic oil tank by removing
3 the bung on the bottom right hand
corner of the tank.
3. Remove the access panel (item 3) [15]
1 from the top of the tank.
4. Insert your hand into the tank and
remove the filter by rotating it anti-
clockwise.
5. Fit the new strainer filter. Only use a
genuine Combilift component.
6. Replace the access panel remembering
to correctly fit the access panel O-ring
seal.
2 Steering Support Oil

1. Place a suitable size receptacle directly
15 underneath the drain screw (item 2)
[16], to prevent any oil spillage.
Return Filter: 2. Remove the fill screw (item 1) [16] and
The return filter element - located inside the drain screw (item 2) [16] by turning anti-
return filter housing (item 1) [15] on the top of the clockwise to drain the system.
hydraulic tank - must be replaced at intervals of 3. Allow time for the support to drain
every 500 hours (or 3 months depending on completely.
which occurs first). 4. Replace the drain screw and refill the
support with the specified quantity of the
To replace the Return Filter element: recommended oil through the drain
1. Remove the floor plate to access the top of screw.
the hydraulic tank.
2. Loosen the lid on the filter housing by Grade: API-GL4 Gear Oil 80W/90
turning it anticlockwise. Steering Support Oil Volume: 0.5L (0.53 qt)
3. Remove the lid to gain access to the filter
element.
4. Remove the retaining spring from the top
of the filter element 1
5. Remove the old filter element and replace
with the new filter element. Only use a
genuine Combilift component.
6. Fit the retaining spring to the top of the
new filter element and refit the housing lid.
2
7. Tighten the lid onto the filter housing by
turning it clockwise.
16
Drive Transmission Oil Drive Transmission Oil

(Standard) (Narrow)
Note: Note
It is essential that the machine is parked on The two sides of the narrow front axle are
level ground to ensure accurate oil level lubricated separately.
checking and changing.
Thoroughly clean the area around the oil Checking Oil Level
plugs on the axle to prevent any dirt or
contamination from entering the axle. 1. At the axle casing remove fill/level plugs
(item 1) [18]. Oil should be level with the
Checking Oil Level bottom of the fill/level hole.
1. At the axle casing remove fill/level plug (item 1) 2. If necessary, top up with recommended oil
[17]. Oil should be level with the bottom of the (see below). Clean and refit fill/level plugs
fill/level hole. (item 1) [18].
2. If necessary, top up with recommended oil (see

below). Clean and refit fill/level plug (item 1)
[17].
18 2
Changing Oil
17 2 1
1. Remove the fill/level plugs (item 1) [18]
and drain plugs (item 2) [18] from the axle
Changing Oil casing. Allow time for the oil to drain out
into a suitable container. Oil should be
1. Remove the fill/level plug (item 1) [17] and warm when draining.
drain plug (item 2) [17] from the axle casing.
Allow time for the oil to drain out into a suitable 2. Thoroughly clean and refit the drain plugs
container. Oil should be warm when draining. (item 2) [18]. Torque to 25 Nm (18 ft-lb).
2. Thoroughly clean and refit the drain plug (item 3. Fill the axle with the specified quantity of
2) [17]. oil (see below) through the fill/level plugs
(item 1) [18]. Torque to 25 Nm (18 ft-lb).
3. Fill the axle with the specified quantity of oil
(see below) through the fill/level plug (item 1) 4. Thoroughly clean and refit the fill/level
[17]. plugs (item 1) [18].
4. Thoroughly clean and refit the fill/level plug Transmission Oil: API GL-4
(item 1) [17]. Capacity: 1.2 L (1.27 qt) LH Side
0.5 L (0.53 qt) RH Side
Transmission Oil: API GL-4 Note:
Capacity: 1.8 L (1.9 qt) Do not pour fluids into the ground, down a
drain or into a stream, pond or lake.
Observe relevant environmental protection
regulations when disposing of oil.

Battery Maintenance
Battery Charging
Correct operation of the battery charger is 1
important. Follow the instructions of the charger
manufacturer.
Never permit the battery to discharge below the 2

minimum value given by the battery manufacturer.
Generally 80% discharge.
3
Never charge a battery at a rate that will raise the
electrolyte temperature above the recommended
level. 19
Recharge the battery daily except when only Note:
lightly discharged. Never use a battery that weighs more or
less than the original battery supplied with
Do not leave the battery in a discharged state. the truck. The combined weight of the
battery and the truck must be equal to the
Supplementary/Opportunity charging of standard unladen weight quoted on the serial plate.
batteries is not recommended as it shortens the
overall life of the battery.
Safety Precautions
Recommended Charging Procedure Warning
 Park the truck in a designated battery Keep all flames and lit tobacco away
charging area. from the battery during or soon after
 Open the Rear Battery Cover (item 1) [19]. charging as the gases evolved can form
And leave open during charging to allow an explosive mixture.
evolved gases to disperse.
 Disconnect the battery plug (item 3) [19]
from the truck plug (item 2) [19].
 Check the charger cable for damage such Warning
as frayed leads or broken connectors. Never do anything that could cause an
 Check that the charger is switched on and electric spark on or near the battery.
the ammeter is working.
 If the cable is free from damage attach the
charger plug to the battery plug (item 3)
[19]. Warning
 Charging will start automatically.
 When the battery is fully charged, it should Never lay tools or any other objects
be left connected to the charger until capable of conducting electricity on top
required. of the battery.
 The charger must be paused by pressing
the pause button before disconnecting the
charger cable from the battery plug.
 Reconnect the battery plug to the truck plug. Warning
Isolate electrical connections before
working on the battery. Use only
insulated tools.

Warning Caution
Wear suitable protective clothing and eye Never connect the battery charger plug
protection when working on the battery. to the plug of the lift truck. You can
damage the traction control circuit.
Warning Caution
Batteries must only be charged in Ensure that the charger voltage is the
designated charging areas. When charging correct voltage for the battery.
batteries, keep the vent plugs closed.
The battery charging area must have
adequate ventilation to allow the evolved
gases to disperse. Keep the battery cover Warning
open during charging. Ensure to pause the charger before
disconnecting the battery.
Warning
Ensure the electrical circuit is safe before Warning
making a connection to the battery Check bolted connections on the
battery for tightness and ensure they
are clean.
Warning
The acid in the battery electrolyte will cause
burns or irritation if it comes into contact Warning
with the skin or eyes.
Ensure the insulating shrouds on the
If acid is spilled on the floor, neutralise as
cell connectors are in position.
quickly as possible, using an alkali such as
soda ash, sodium bicarbonate or dilute
ammonia.
If acid is spilled on clothing, wash as soon Note
as possible. A smear of petroleum jelly applied to
If acid comes into contact with skin, wash clean terminals will offer protection
off immediately with plenty of clean water. against acid corrosion.
If acid splashes into the eye, immediately
flood the eye with copious quantities of
water; then obtain medical attention at Warning
once. Protective clothing and goggles should
be worn and particular care taken not to
come into contact with or spill
Caution electrolyte when checking its level.
Keep the battery clean and dry, and
Add nothing to the cells but distilled, terminals free from corrosion. Check
deionised or approved water and do this that the ventilation holes in battery caps
often enough to keep the visible are clear. Temperature must not exceed
components just covered (electrolyte 43° C (110° F) during charging.
visible). Top up electrolyte with the battery
in its fully charged state.

Care of Battery out of Service

If a battery is to be taken out of service for a time,
or if a new battery cannot be put into service
immediately, it should be given a charge and
stored in a cool dry place. Disconnect detachable
connectors.
Every month, give a charge and check electrolyte

levels.
If a truck is used at irregular intervals, the battery

should be given a charge every month and the
battery disconnected from the truck during idle
periods. Charge and check the electrolyte levels
before returning to service.
Disposal of Batteries
Careless disposal of a battery
can harm the environment and
can be dangerous to persons.
Always dispose of batteries to

an authorised dealer.
Do not attempt to open or dismantle a battery or

cell.

Greasing
Weekly Grease Point Chart
7 5 3 1
6 4 2
20
7 5 3 1
6 4 2
1. Back of RH Tilt Cylinder 2. Back of LH Tilt Cylinder 3. Front of RH Tilt Cylinder 4. Front of LH Tilt Cylinder
5. Right Hand Mast Pivot 6. Left Hand Mast Pivot 7. Side Shift Top 8. Side Shift Bottom
Note:
(Item 8) [20] grease points are underneath the bottom side shift bar.
Lubricate all points weekly using EP2 grease.
Also Lubricate all grease points on the mast, and attachments where fitted.

Steering Slew Ring Grease Points (500 Hr Interval)
Does not apply to narrow front trucks with chain steering.
There are 2 grease points on the front steering slew ring that must be greased every 500 hours.
The following procedure describes how to grease the steering grease points.
 Park in a suitable area ensuring that you have enough room to turn the mast to 90°.
 Turn the steering wheel left or right until the mast is turned to at least 90° as shown.
 Remove the bottom nose cone (item 1) [21].
 Apply EP2 grease (Mobilux NLGI 2 is Recommended) lightly through the grease nipples
(items 2) [21].
 Replace the bottom nose cone (item 1) [21].
1
21
Narrow Front Mast Carrier Bearing Automatic Lubricators (If Fitted)

A small number of narrow front trucks with chain steering are fitted with 2 automatic lubricators.
The lubricators are fitted inside the front nose panel. They should be set to 12 which means they
will dispense grease over a 12 month period. The lubricator must then be replaced. See the
accompanying spare parts manual for part numbers when ordering.

Steering Pinion Greasing (250 Hr Interval)
Does not apply to narrow front trucks with chain steering.
The steering pinion (item 1) [22] must be greased every 250 hours. The following procedure
describes how to grease the steering pinion.
 Park in a suitable area with the mast pointing straight forward.

 The steering pinion (item 1) [22] can only be accessed from underneath the truck.
 Apply EP2 grease (Pyroplex Black NLGI 2 is Recommended) between the pinion teeth.
22

Steering Chain Maintenance It is recommended that the lubricant used on

the chains has the following properties:
(If Applicable)
 Satisfactory corrosion protection and
The following information is provided for lubrication
authorised service facilities ONLY.  Ability to penetrate through / under
water
Perform maintenance on the steering chains as  Continuously viscous after application
required by the initial 100 hour service checklist  Good adhesion properties
and 500 hour service checklist. Guidelines are  Layer thickness and protective film able
provided in the following paragraphs. to withstand later aggression (rain / hail
etc.)
Chain Maintenance
The following lubricants (available in an
Regular inspection and lubrication of the chains aerosol can) are recommended:
will increase their service life and reduce
downtime. When you perform chain maintenance, Fuchs anticorit bw366
make sure you follow the guidelines in ‘Chain Molykote mkl-n
Inspection’ and ‘Chain Lubrication’. Kluber structovis bhd 75s
Chain Inspection
23
To locate the steering chains (item 1) [23] remove
the front nose cover (item 2) [23].
The following checks should be performed:
See ‘Chain Inspection’ on page 5-19
Chain Lubrication
Caution 2 1
The chains must be kept lubricated at all
times.
Running the chain dry can substantially shorten its

life. Oil must be reapplied on a regular basis to
ensure the chains maximum life is achieved.
The frequency of this operation is at the discretion

of the user and essentially depends upon the
working conditions and the workplace.
Ensure that the chain is slack during the

lubrication process so that the lubricant can
flow between the chain link plates and pins.

Putting a Truck in Storage Final Decommissioning

To prevent problems, the lift truck must be correctly Drain all fluids into suitable containers and
serviced and maintained during storage. dispose of in accordance with the relevant
local environmental protection regulations.
Components that need extra care during storage
are electric motors, hydraulic components and Note:
electric truck batteries. Do not pour fluids into the ground, down
a drain or into a stream, pond or lake.
Electric trucks can best be protected by being Observe relevant environmental
operated for a short period of time each month. protection regulations when disposing of
oil and electrolyte.
Before putting any truck in storage, you must
choose an area which is clean, dry and free from Dismantle and recycle the individual
dust or fumes in the air that can harm the lift truck. components separately.
Electric drive motors must be operated to keep Note:

them free of rust and dirt caused by condensation Local regulations governing the correct
over periods when the truck is not used. Operate recycling and disposal of waste must be
the truck for at least five minutes. observed.
Before operating, perform the daily/pre-operation

inspection. Take care of any problems
immediately. Also, check the fluid level in the
hydraulic tank and brake master cylinder.
Electric trucks must not have batteries installed

during storage. A fully charged battery must be
available to operate a lift truck.
Warning
Do not use a battery charger as a power
source for any reason.
All hydraulic cylinders should be put through a

complete operation cycle several times each
month. This will help keep the seals active and
coat the interior walls with oil. Fully extend and
retract each cylinder.
To protect the cylinder rods, park your truck with

the mast lowered and tilted fully forward (cylinders
fully retracted)
When parked with the power off, operate each

control handle to release hydraulic pressure.
Masts should be stored fully lowered
Coat any exposed area of the cylinder rods with

fresh high grade S.A.E. 30 or 40 engine oil.
Put chocks at the front and rear of a drive tyre
when parked. Do not use the hand brake.

SECTION 5
Schematic Circuit Diagrams
This section contains detailed electrical and hydraulic circuit diagrams and
information that can be used to assist with repairs.
 Standard Electric Circuit Diagram
 Pre-height Selector Electric Circuit Diagram
 Hydraulic Circuit Diagram – Standard & Low Nose
 Hydraulic Circuit Diagram – Narrow Front (Chain Steering)
 Fuse Box and Relays

Standard Electric Circuit Diagram





Pre-Height Selector Electric Circuit Diagram





Hydraulic Circuit Diagram – Standard & Low Nose

Hydraulic Circuit Diagram – Narrow Front

Fuse Box & Relays The following table shows the part of the
electric circuit related to each of the fuses in
Fuse Box the fuse box:
On standard trucks the fuse box (item 1) [1] Fuse Circuit Rating
is located on the steering column. 1 Seat Switch 7.5A
2 Reversing Bleeper 7.5A
On low nose and narrow front trucks the 3 Auxiliary Hydraulic Function 7.5A
fuse box is located behind the right hand 4 Auxiliary Supplies x 2 7.5A
side panel (item 1) [2]. Pre-Height Selector
5 7.5A
(Optional)
6 Spare
Work Lights, Dash Lights,
7 20A
Work Light Switch
8 Spare
9 Horn 7.5A
10 Cooling Fan 7.5A
11 Beacon 7.5A
2
Relays
1
On standard trucks the relays are located
inside the steering column cover (item 2)
[1], the steering column cover must be
removed to access the relays.
1
On low nose and narrow front trucks the
relays are located behind the right hand
side panel (item 1) [2]. The steering column
cover must be removed to access the relays.
The following table shows the part of the

electric circuit related to each of the relays:
Relay Circuit Rating

A Seat Switch 12v 20/40A
B Seat Switch 12v 20/40A
C Lift Cut-Out (Optional Pre- 12v 20/40A
Height Selector Trucks Only)
1 22 Work Lights 12v 20/40A

2 32 Auxiliary 12v 20/40A
Fuse Box Layout

Appendix A (Checklists)
includes the following checklists and maintenance schedules:
 Operator’s Daily Checklist

 Initial service at 100 Hours Checklist
 Every 500 Hour Inspection Checklist
 Installation Checklist
Aisle-Master Operator’s & Service Manual A-1

Aisle-Master
Operator's Daily Checklist
Daily pre-shift inspection requirement. It is important that these inspections are documented
Date Inspector Record Fluid Added:

Truck No. Model No. Hydraulic Oil
Location Serial No.
Shift Drive Hour
SAFETY & OPERATION CHECKS

Have a qualified mechanic correct all problems. O.K. (X) Needs Maintenance
Overall Condition – Protective Covers, Missing Or Loose Nuts & Bolts
Leaks - Hydraulic Oil, Brake Fluid, Battery Electrolyte
Tyres – Cuts, Foreign Objects.
Wheels – Damage, Wheel Nuts Present & Secure (Not Hand Tight)
Forks – Excessive Wear, Cracks, Fractures, Deformation, Equal Spacing, Locating
Pins Engaged
Load Backrest (If Fitted) – Deformation, Cracks, Securely Mounted
Hydraulic Hoses – Wear, Damage, Leaks, Kinks, Routing
Mast Bearings, Chains, Channels, Stops – Wear, Damage Deformation, Cracks
Mast Chains – Equal Tension, Lubricated
Fork Carriage – Excessive Wear, Damage, Deformation, Cracks
Overhead Guard – Damage, Cracks, Securely Mounted
Safety Warnings - Attached
Hydraulic Tank – Damage, Leaks, Oil Level
Battery – Connections Secure, Cell Damage, Leaks, Electrolyte Levels, Leads
Operators Compartment Capacity Plate Attached - Information Matches
Model, Serial Number Attachments
Seat Belt, Buckle and Retractor – Cuts In Belt, Functioning Smoothly
Seat – Anchored Securely, Runners Operating Freely, No Objects Underneath
Electrical Connections/Terminals – Securely Connected, Undamaged
Motors - Unusual Noises, Smells
Accelerator - Functioning Smoothly In Forward & Reverse
Park Brake & Service Brake – Functioning
Steering Operation - Functioning Smoothly In Both Directions, Excessive
Freedom/Stiffness
Drive Control - Forward/Reverse - Functioning Smoothly
Hydraulic Controls – Forward/Back Smooth Operation Through Full Travel
Horn, Lights, Reversing Bleeper & Flashing Beacon – Functioning Normally
Rear View Mirror – Securely Attached, Clean, In Good Condition
Dash Display Module/Hour Meter - Functioning
Warning Lights – Functioning/Extinguished
Load Monitor (If Fitted) – Functioning Normally

Aisle-Master
Initial Service at 100 Hour Checklist
To be performed after first 100 hours of truck operation in addition to the required pre-shift daily inspection.

Location Serial No.
Shift Drive Hour
FIRST 100 HOUR SERVICE

SAFETY & OPERATIONAL CHECKS O.K. (X) Needs Maintenance
Check Battery Electrolyte Levels
Adjust handbrake if Required
Check Hydraulic Oil Level
Change Transmission Oil (Front Axle)
Grease All Points.
Check all Electrical Connections/Terminals
Check all Bolts and Fittings are Tight.
Check Mast Chains - Lubricate and Adjust
Check Mast Channels – Lubricate if required
Tyres - Check for Cracks & Debris
Wheel Nuts - Torque to (Front - 305Nm), (Rear - 176 Nm)
Check steering operation
Load Monitor – Functioning correctly
Check Brake Fluid level
Check Drive Axle for Gear Oil
Check Emergency Stop button
Change steering support oil (If applicable)
Check & Lubricate steering chains (If applicable)

Aisle-Master
Every 500 Hour Service Checklist
To be performed after every 500 hours of truck operation in addition to the required pre-shift daily inspection.

Location Serial No.
Shift Drive Hour
EVERY 500 HOUR SERVICE
SAFETY & OPERATIONAL CHECKS O.K. (X) Comments

Tyres – Cuts, Foreign Objects
Wheels – Damage, Wheel Nuts Present - Torque to (Front - 305Nm), (Rear - 176 Nm)
Forks – Excessive Wear, Cracks, Fractures, Deformation, Equal Spacing, Locating
Pins Engaged
Load Backrest (If Fitted) – Deformation, Cracks, Securely Mounted
Hydraulic Hoses - Check for Wear, Damage Leaks, Kinks, Routing
Mast Bearings, Chains, Channels, Stops – Wear, Damage Deformation, Cracks
Mast Chains – Equal Tension, Lubricated
Fork Carriage – Excessive Wear, Damage, Deformation, Cracks
Grease Mast Channels
Check Torque on pump mounting bolts
Check All Connections for Proper Torque
Check Brake Fluid Level
Check Hydraulic Tank – Damage, Leaks, Oil Level
Check Transmission Oil Level
Check All Electrical Connections/Terminals
Model, Serial No. And Attachments
Seat Belt, Buckle and Retractor – Cuts In Belt, Functioning Smoothly
Seat – Anchored Securely, Runners Operating Freely, No Objects Underneath
Motors - Unusual Noises, Smells
Accelerator - Functioning Smoothly In Forward & Reverse
Park Brake & Service Brake – Functioning
Steering Operation - Functioning Smoothly In Both Directions, Excessive
Freedom/Stiffness
Hydraulic Controls – Forward/Back Smooth Operation Through Full Travel
Horn, Lights, Reversing Bleeper & Flashing Beacon – Functioning Normally
Dash Display Module/Hour Meter - Functioning
Warning Lights – Functioning/Extinguished
Slew Ring - Functions Smoothly, Wear
Emergency Stop Button - Functioning
Load Monitor (If Fitted) – Functioning Normally

Aisle-Master
Installation Checklist
QUALITY CONTROL SHEET Remit Copy to Aisle-Master Ltd.

Location Serial No.
Shift Drive Hour
SAFETY & OPERATION CHECKS

Have a qualified mechanic correct all problems. O.K. (X) Needs Maintenance
Tyres – Cuts, Foreign Objects
Wheels – Damage, Wheel Nuts Present - Torque (Front - 305Nm), (Rear - 176 Nm)
Forks – Excessive Wear, Cracks, Fractures, Deformation, Equal
Spacing, Locating Pins Engaged
Load backrest extension - Attached
Hydraulic Hoses - Check for Wear, Damage Leaks, Kinks, Routing
Finger Guards - Attached
Overhead Guard - Attached
Safety Warning Decals - Attached (Refer to Page S-3 of this Manual)
Brake Fluid Level
Hydraulic Fluid Level
Model, Serial No. And Attachments
Seat Belt, Buckle and Retractor - Functioning Smoothly
Controls (Turn Power On) Investigate Unusual Noises Immediately
Accelerator - Functioning Smoothly
Hand Brake - Functioning
Steering operation - Functioning Smoothly
Tilt Controls - Forward and Back - Functioning Smoothly
Lift and Lowering Control - Functioning Smoothly
Attachment Controls - Operational
Check Emergency Stop Button - Functioning
Horn - Functioning
Lights - Functioning
Gauges: Hour Meter – Functioning
Warning light - Functioning
Load Monitor - Functioning
Reverse Warning Bleeper - Functioning
Check Drive Axle for Gear Oil

Appendix B (FAQs)
describes how to perform the tasks related to the following frequently asked
questions:
 How to calibrate the load monitor?

 How to adjust the pressure switch?
 How to fit a mast?
 How to remove the battery?
Aisle-Master Operator’s & Service Manual B-1

FAQs
Calibrating the Load Monitor
Calibration of the Load Monitor requires the setting up of two reference points, 0% and 100%.
A magnetic “key” is required to initiate the set up procedure. This must be held in position on
the front panel, just above the TEST button.
PROCEDURE:
1. Place the vehicle in the 0% calibration position, i.e. vehicle level, park brake on, steering
straight ahead, forks lowered but not resting on the ground, and no load on the forks.
2. Leave the ignition turned on as normal.
3. Press and hold the TEST button. The display will show all LEDs flashing and the sounder on.
Keep holding the TEST button and place the magnet in position on the front panel at the top
right hand corner of the test switch. The correct position is indicated when the sounder stops
and all the LEDs stay on, fully lit. KEEP HOLDING THE TEST BUTTON AND MAGNET IN
PLACE for a period until the display changes again to show the red LED only lit. This indicates
that the system is now in calibration mode, and waiting for the first reference point. Release
the button and remove the calibration magnet. (If the button or key is released too early the
display will revert back to normal operation.) Short intermittent beeps will then be emitted to
indicate the system is waiting for an input.
4. Check that the vehicle is still positioned correctly for the 0% reference, and press the TEST
button ONCE. The system will give a single, short beep indicating that the 0% point is set. The
display will change to show one red LED and one amber LED (and continuing intermittent
beeps), indicating that the system is ready and waiting for the 100% reference. (NOTE - if a
long beep is emitted from the sounder during calibration, this indicates a fault condition - see
below).
5. With the vehicle level, and the park brake on, pick up the calibrated 100% load and LIFT to a
height of 1 metre (39 inches).
6. When in position press the TEST button ONCE to set the 100% reference. The display will
again give a single beep to confirm that it is set.
7. The display should now change back to normal operation, and show 100%, i.e. all green and
amber LEDs lit and flashing.
8. System calibration has now been completed. No further action is required.
NOTES:
1. The system allows five minutes for each part of the calibration procedure to be completed.
During these times the system will emit a short beep every five seconds to remind the operator
that it is in calibration mode.
2. If a part of the calibration procedure is not completed within the five minutes allowed the
system will automatically revert to normal operation with the previous calibration settings.
3. If the ignition is switched off during calibration the system will automatically revert to the
previous calibration settings.

FAQs
Adjusting the Pressure Switch
The pressure switch is located on the pressure supply line into the valve chest. The switch is
set before the truck leaves the factory so that the pump motor runs at a low speed when only
the steering is required but will then run at a higher speed when any of the fork functions are
used e.g. the lift, tilt, side shift etc.
It can be the case that after a certain ‘run in’ period the pressure switch needs to be adjusted
to keep the pump motor running at the correct speeds for the steering and fork functions. The
following procedure describes how the pressure switch should be adjusted.
1. Pull the seat latch and raise the seat panel (item 1) [1].
2. Remove the right hand side cover panel (item 2) [1] taking care not to damage the wire (item
3) [1] going to the horn button and directional switch.
3. Remove the rubber boot (item 1) [2] from the pressure switch (item 2) [2].
3
1
1 2

FAQs
4. Adjust the screw in the pressure switch using a flat head screwdriver (item 1) [3].
5. If the truck will not go in to high speed, i.e. the hydraulic functions are operating slowly turn the
screw anticlockwise. Test by using the lift function with no load on forks. Keep turning the
screw anticlockwise until the lift speed changes to high speed.
6. If the truck is always running in high speed turn the screw clockwise until it goes to low speed
or steering speed, this will be noticeable when steering the truck. Keep turning the screw
clockwise and turning the steering until the steering goes into low speed.

FAQs
Fitting a Mast 5
Note: Make sure to apply a little thread locking
fluid to the threads on each of the bolts used to
fasten the mast and associated parts.
2
1. Remove the upper mast bearing blocks (item 4) [1]
and bearings (item 3) [1] from the mast carrier. Lift
4
the mast above the lower mast bearing blocks
(items 1) [1]. Suitable lifting equipment with
sufficient lifting capacity to lift a mast weighing up to
2300kg must be used. Pass a suitable strap around
all of the upper cross members on the mast (items
2) [1].
2. Fit the bearings (items 3) [1] and shims (if 3

applicable) to the mast. Line up the bearings on the
mast with the lower mast bearing blocks on the 1
truck (items 1) [1] as shown opposite and lower the
mast until the bearings are seated on the blocks.
3. Remove the tilt cylinder fasteners (item 2) [2] from

the bosses (item 6) [1] on the bottom of the mast.
4. Fit the upper mast bearing blocks (item 4) [1] to the

6
lower mast bearing blocks and fasten using the
bolts and washers (items 5) [1] provided.
Note: Torque the M12 socket cap (plated) bolts to

100 Nm (74 ft lb).
1
5. Fit the tilt cylinders (item 1) [2] - which are attached
to the truck - onto the bosses (item 6) [1] on the
bottom of the mast and fasten using the tilt cylinder
fasteners (item 2) [2]. 4
Note: Torque the M10 hex head bolts to 50 Nm (37
ft lb).
6. Connect the hydraulic lines (item 3) [2] and camera

plug (if applicable). Ensure the hydraulic fittings are 2
tight.
3
7. Fit the forks to the fork carriage and ensure that the
fork pins are engaged in one of the notches in the
1
upper fork bar (item 4) [2].
Note: On trucks with hydraulic fork positioners the

top fork bar will not be notched. The fork
positioner cylinders will need to be attached to the
2
bosses on the back of the forks.
Note: When testing the lift function ensure
8. When the mast has been fitted test each function all hoses are travelling freely around the
i.e. the lift, tilt, side-shift etc. Check that the camera hose rollers and are not at risk of incurring
and monitor are operating correctly (if applicable). damage from the moving mast sections.
Make any necessary adjustments.
FAQs
Battery Removal
The truck uses a 48v DC battery, with various
Amp-Hour capacities to suit the truck's duty cycle.
Always consult the truck's technical specification
before attempting to fit or connect a battery
voltage to the truck's electrical system. It is also
important to check the charger specification to 1
ensure that it is compatible with the battery before
charging. Read the charger handbook before 2
connecting.
3
Note: Battery chargers should only be
installed by a qualified electrician.
To unlatch the battery for removal:
 Open the rear bonnet (item 1) [5].
 Disconnect the battery plug (item 2) [5] from 6

the truck plug (item 3) [5].
Note: There are two different battery
 Release the latches (items 4) [5] on the left systems available for the electric Aisle-
and right hand sides of the battery by rotating Master truck.
them as indicated.
 Release the seat panel latch (item 1) [6] and

lift the seat panel (item 2) [6].
 Rotate the front battery latch bracket (item 3) A B

[6] clockwise as indicated.
4
1 1
3
2 7
1.
4 In the case of battery system A fork pockets

2 (item 1) [7] are incorporated in the battery
platform. To remove the battery from the
truck the battery platform must also be
removed.
5
In the case of battery system B fork pockets
(item 1) [7] are incorporated in the battery
therefore the battery can be removed
without the need to remove the battery
platform.

FAQs
To remove the battery from a truck fitted with Note:
battery system A using another forklift truck: If a pallet truck it used to remove the
battery it cannot be placed on the ground.
 Follow the instructions on the previous page to Battery box stands (item 1) [9] are
unlatch the battery for removal. available for placing batteries on when not
in service.
 Set the forks on a forklift truck the appropriate
distance apart and insert the forks into the fork
pockets (item 1) [8] in the platform under the
battery.
9
1
8 To remove the battery from a truck fitted
with battery system B using another forklift
truck:
 Raise the battery by approximately 20mm and
back it out clear of the chassis.  Follow the instructions on the previous
page to unlatch the battery for removal.
 Ensure the sides of the battery remain parallel
to the sides of the truck until clear.  Set the forks on a forklift truck the
appropriate distance apart and insert the
 Set the battery and platform down in a safe forks into the fork pockets (item 1) [10] in
designated location such as a battery charging the battery.
bay.
To remove the battery from a truck fitted with

battery system A using a pallet truck:
 Follow the instructions on the previous page to 1

unlatch the battery for removal.
 Centre the pallet truck with the battery and

push the pallet truck in underneath the battery 10
platform.
 Raise the battery by approximately 20mm and  Raise the battery by approximately 20mm
back it out clear of the chassis. and back it out clear of the chassis.
 Ensure the sides of the battery remain parallel  Ensure the sides of the battery remain
to the sides of the truck until clear. parallel to the sides of the truck until clear.
 Set the battery and platform down in a safe  Set the battery down in a safe designated
designated location such as a battery charging location such as a battery charging bay.
bay.
Note: The battery platform remains in the
truck with this system.

Diagnostics
Appendix C (Diagnostics)
This section of your Aisle-Master Forklift Operator’s & Service
Manual describes how to diagnose and remedy faults on the
trucks electrical controllers.
 Traction Motor Controller

 Pump Motor Controller
Aisle-Master Operator’s & Service Manual C-1

Diagnostics
Traction Motor Controller

Diagnostics

Diagnostics

Diagnostics

Diagnostics

Diagnostics

Diagnostics

Diagnostics

Diagnostics

Diagnostics

Diagnostics
Pump Motor Controller

Diagnostics

Diagnostics

Warranty Registration
Appendix D
(Warranty Registration)
The warranty registration form can be filled and submitted online
at:
www.combilift.com/warranty
Please complete the warranty registration online within 30 days of

receipt of the truck.
Alternatively the warranty registration form on the following page

can be used.
Aisle-Master Operator’s & Service Manual D-1

WARRANTY REGISTRATION FORM
Please complete the form below and return this to us within 30 days of delivery to Customer.
Form can be submitted online @ www.combilift.com/warranty
DEALER DETAILS: (Supplier)
Dealer Name: ___________________________________Tel: _________________________
First Name: ________________________ Last Name: ______________________________
E-mail: ____________________________ Position/Role: ____________________________
Street: ____________________________ Address Line 2: __________________________
City: ______________________________ Zip/Postal Code: __________________________
County/State:_______________________ Country: ________________________________
MACHINE DETAILS
MODEL: ___________________ SERIAL NO.
Delivery / installation date: _ _ / _ _ _ / _ _ _ _
CUSTOMER DETAILS (please state address where truck is located)
Customer Business Name: ________________________ Tel: _________________________
First Name: ________________________ Last Name: ______________________________
E-mail: ____________________________ Position/Role: ____________________________
Street: ____________________________ Address Line 2: __________________________
City: ______________________________ Zip/Postal Code: __________________________
County/State:_______________________ Country: ________________________________
I have received my Aisle-Master forklift and read the Operators Manual and am satisfied with both.
*Customer’s Signature: ________________________________ Date: _____________________
WHEN COMPLETED PLEASE RETURN TO:
BY POST TO: Combilift, Gallinagh, Monaghan, County Monaghan, Ireland.
BY EMAIL TO: warranty@combilift.com
Failure to complete Warranty Registration Form may impact the Warranty Claim Process.

Combilift AME Forklift Truck Operator&#39;s Manual PDF

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Combilift AME Forklift Truck Operator&#39;s Manual PDF

Uploaded by

Copyright:

Available Formats

Dear Customer,

In order to familiarise yourself with your truck in a quick comprehensive

Before You Begin ........................................................................................2-1

Operating Your Forklift...............................................................................3-1

Aisle-Master Operator’s & Service Manual ii

Schematic Circuit Diagrams ......................................................................5-1

Appendix B (FAQs) .....................................................................................B-1

Appendix C (Controller Diagnostics & Troubleshooting) .......................C-1

Appendix D (Warranty Registration) .........................................................D-1

Aisle-Master Operator’s & Service Manual iii

Preface Intended Use

About This Manual

Some trucks may be customised to suit the needs

Every effort has been made to ensure that the

Aisle-Master Operator’s & Service Manual iv

• Safety Alert Symbol

Aisle-Master Operator’s & Service Manual S-5

The Meaning of Safety Aisle-Master Forklift

Aisle-Master Operator’s & Service Manual S-6

Note: See next page for number reference.

Aisle-Master Operator’s & Service Manual S-7

Aisle-Master Operator’s & Service Manual S-4

Safe Operation Battery Charging

Aisle-Master Operator’s & Service Manual S-5

Safe and efficient forklift operation requires operators to be skilled

Safe and efficient operation also depends on correct maintenance

Aisle-Master Operator’s & Service Manual 1-1

Aisle-Master forklifts are available in capacities 2

Whenever front and rear, right and left are

In the text, illustration references appear in bold

The accelerator pedal (item 1) [1], is located on

Aisle-Master Operator’s & Service Manual 1-2

Forks (item 1) [2]

Aisle-Master Operator’s & Service Manual 1-3

Information Plates The illustration below shows where this

Aisle-Master Operator’s & Service Manual 1-4

The serial number consists of 5 numerical digits

Aisle-Master Serial Number e.g.

Aisle-Master Operator’s & Service Manual 1-5

"Power On" Indication

Battery State of Charge

Hour Glass Symbol

Aisle-Master Operator’s & Service Manual 1-6

Parking Brake Lever

Aisle-Master Operator’s & Service Manual 1-7

Operator Training – Discusses the operator training required

Operator Safety – Reviews the safety guidelines operators

Understanding Stability – In this section you will learn about

Knowing the Rated Capacity – The meaning of rated capacity

Understanding Workplace Conditions – This section makes

Aisle-Master Operator’s & Service Manual 2-1

Warning Understanding Stability

Whether you are a new operator or have used

Aisle-Master Operator’s & Service Manual 2-2

The centre of gravity will shift if:

Aisle-Master Operator’s & Service Manual 2-3

Aisle-Master Operator’s & Service Manual 2-4

Knowing the Rated Before you begin to operate your Aisle-Master

Aisle-Master Operator’s & Service Manual 2-5

Serial Plate Capacity Plate

Aisle-Master Operator’s & Service Manual 2-6

Load Centre Always make sure the load is flush against

Aisle-Master Operator’s & Service Manual 2-7

When you unload at high elevations, make sure

Combilift AME Forklift Truck Operator's Manual PDF

Combilift AME Forklift Truck Operator's Manual PDF