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Technical Information for
YALE Service Centres
Part No 524159096
This manual is addressed exclusively to the specialised

technicians of the Yale service network
C849...........
MR14
MR14H
MR16
MR16H
MR16N
MR20
MR2OH
MR20W
MR25
AC..
SERVICE
CONTENTS
Section: CONTENTS
GENERAL SAFETY PRESCRIPTIONS

NEVER DO ANY CLEANING, LUBRICATING OR SERVICING WITH THE BATTERY CONNECTED.
DO NOT WEAR RINGS, WATCHES, JEWELLERY, LOOSE CLOTHING SUCH AS SCARVES,
UNBUTTONED OR UNZIPPED JACKETS OR SHIRTS THAT COULD GET CAUGHT UP IN MOVING PARTS. WE RECOMMEND INSTEAD THAT THE OPERATOR WEAR APPROVED SAFETY
CAPS CLOTHING: HARD HAT, NON-SLIP FOOTWEAR, GLOVES, SAFETY GLASSES.
DO NOT USE PETROL, DIESEL FUEL OR OTHER FLAMMABLE LIQUIDS AS DETERGENTS:
USE INSTEAD NON-FLAMMABLE, NON-TOXIC COMMERCIAL SOLVENTS.
DO NOT SMOKE, USE NAKED FLAMES OR CAUSE ANY SPARKS NEARBY WHEN HANDLING
EASILY FLAMMABLE MATERIALS.
When working on the truck outside the workshop, park on a level surface, if possible, and chock the
wheels. If working on a gradient is unavoidable, chock the wheels to prevent the truck moving and
transfer it to a level area as soon as it is safe to do so.
Disconnect the batteries and label all the controls to warn of the work in progress. Immobilize the
machine and all equipment that has to be lifted.
When towing, use solely the prescribed towing points and make sure the pins and/or bolts are firmly
secured before starting to pull. Lift and handle all heavy parts with lifting equipment of suitable capacity. Use the lifting eyes provided. Beware of persons in the vicinity of the load to lift.
Do not get chains or steel ropes tangled up.
Do not use damaged chains or kinked ropes for lifting or pulling. Always wear safety gloves when
handling ropes or chains.
Handle all parts carefully, do not put your hands or fingers between one part and another.
Wear approved safety clothing such as safety goggles, gloves and footwear.
The area where maintenance work is performed must be kept clean and dry. Clean up any spilt
water or oil immediately.
Do not pile up greasy or oily rags: they constitute a serious fire risk. Always store these materials in
a closed metal container.
Do not carry out any servicing on the machine with persons at the controls, unless they are qualified
operators helping in the work to be done.
When using compressed air to clean parts, protect your eyes with goggles that have side shields.
Welding
When welding, always wear the prescribed safety gear: welding goggles, helmet, overalls, gloves
and footwear. Dark goggles should also be worn by anyone working in the vicinity of the welding
operation. Never look at the welding arc without appropriate eye protection.
Batteries
When using batteries, remember that the both ends of cables must be connected to the terminals as
prescribed: (+) to (+) and (-) to (-).
Take care not short the terminals.
The gas given off during battery recharging is highly flammable. When recharging, leave the battery
compartment open for better ventilation and remove the caps.
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Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
NEVER CAUSE SPARKS OR ALLOW ANY NAKED FLAMES NEAR THE BATTERY!
Do not check the battery charge level by placing metal objects across the terminals.
Before carrying any operations, check the electrical system for short-circuits.
Always disconnect the batteries before working on the electrical system.
For battery chargers and similar equipment, use only auxiliary power supplies with an efficient earth
connection in order to avoid the risk of electric shock.
Hydraulic system
Pressurised fluid escaping through a tiny hole may be virtually invisible although projected with sufficient
force to penetrate the skin; when checking for possible leaks, always use a piece of card or wood.
Never use your hands.
Always use the appropriate instruments when checking system pressure.
NOTE: THIS MANUAL IS NOT INTENDED AS A SUBSTITUTE FOR THE USE AND MAINTENANCE
MANUAL BUT AS A SUPPLEMENT TO IT
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
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CONTENTS
Section: CONTENTS
SERVICE
CONTENTS
Section: CONTENTS
Section:
1.0
2.0
1.0
2.0
3.0
4.0
5.0
5.1
5.2
6.0
6.3
7.0
8.0
8.1
8.2
8.3
8.4
8.5
9.0
9.1
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
10.0
10.1
10.2
10.3
10.4
10.5
10.6
10.8
10.9
11.0
11.3
11.4
11.5
11.6
11.8
12.0
13.0
13.1
ELECTRICAL SYSTEM
INTRODUCTION TO THE TRUCK ............................................................................................................... 10

INSTALLING THE TRUCK .......................................................................................................................... 11
KEY TO ELECTRICAL DIAGRAMS ............................................................................................................ 14
KEY TO LOCATION OF ELECTRICAL COMPONENTS .............................................................................. 16
TABLE OF FUNCTION INPUTS .................................................................................................................. 18
PARAMETER TABLES .............................................................................................................................. 20
PROCEDURE FOR ACCESSING THE CALIBRATION FUNCTION FOR THE VARIOUS
MODULES ................................................................................................................................................. 24
MODULE SEARCH PROCEDURE ............................................................................................................. 25
AC2 TRACTION INVERTER BATTERY VOLTAGE SETTING ...................................................................... 26
TRACTION START SEQUENCE ................................................................................................................. 27
HYDRAULIC FUNCTIONS START SEQUENCE ......................................................................................... 28
SPEED CUTBACK ..................................................................................................................................... 29
MODULES REPLACEMENT PROCEDURE ............................................................................................... 30
REPLACING MODULES 2 OR 5 - AC2 TRACTION INVERTER ................................................................. 30
REPLACING MODULE 1 - I/O CAN ........................................................................................................... 32
REPLACING MODULE 16 - SICOS (DISPLAY) .......................................................................................... 33
REPLACING MODULE 9 - MHYRIO ........................................................................................................... 34
REPLACING MODULE 6 - EPS-AC .......................................................................................................... 34
SICOS (DISPLAY) ...................................................................................................................................... 36
GENERAL DESCRIPTION OF CONTROL COMPONENTS AND INSTRUMENTS ....................................... 36
BATTERY CHARGE STATUS INDICATOR .................................................................................................. 37
SPEED CUTBACK INDICATOR .................................................................................................................. 37
TRAVEL DIRECTION AND WHEEL ROTATION INDICATOR ....................................................................... 38
SELECTED HYDRAULIC FUNCTION INDICATOR ...................................................................................... 38
TRACTION OPERATING MODE INDICATOR .............................................................................................. 39
HOUR METER ACTIVE INDICATOR ........................................................................................................... 39
TRUCK SPEED, TRUCK HOUR METER, FORKS HEIGHT, MODULE ALARM INDICATOR ....................... 40
PARKING BRAKE SELECTOR BUTTON ................................................................................................... 41
AUXILIARY HYDRAULIC FUNCTION SELECTOR BUTTON ....................................................................... 41
DRIVE PERMISSIVE FUNCTION SELECTOR BUTTON ............................................................................. 42
DISPLAY MENUS ...................................................................................................................................... 42
MAIN MENU 1 ........................................................................................................................................... 42
TESTER MENU ......................................................................................................................................... 43
ALARMS MENU ........................................................................................................................................ 43
PROGRAM OFFSET ................................................................................................................................. 44
INSERT PASSWORD ................................................................................................................................ 44
MAIN MENU 2 ........................................................................................................................................... 44
PROGRAM PASSWORD ........................................................................................................................... 46
READ USERS MENU ............................................................................................................................... 47
PRE-HEIGHT SELECTOR .......................................................................................................................... 48
OPERATION WITHOUT REACH CARRIAGE IN SEQUENCE ..................................................................... 49
OPERATION WITH REACH CARRIAGE IN SEQUENCE ........................................................................... 50
ADJUSTING THE PRE-HEIGHT SELECTOR .............................................................................................. 51
PROGRAMMING IN SELF-TEACH MODE ................................................................................................. 51
USING THE PRE-HEIGHT SELECTOR ...................................................................................................... 53
ALARMS .................................................................................................................................................... 54
DIAGNOSTICS ........................................................................................................................................... 55
TROUBLESHOOTING GUIDE .................................................................................................................... 55
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Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
ADDITIONAL FUNCTIONS
OPTION SHEET No. 1 - Setting of the steering for a turn of 360 and 90...........................................................4
OPTION SHEET No. 2 - DC_DC converter installation.........................................................................................6
OPTION SHEET No. 3 - Flashing rotating light installation...................................................................................8
OPTION SHEET No. 4 - Working light installation.............................................................................................10
OPTION SHEET No. 5 - Reverse motion audible alarm installation......................................................................12
OPTION SHEET No. 6 - Height preselector installation .....................................................................................14
OPTION SHEET No. 7 - Installation and enabling of the 5. function ....................................................................16
OPTION SHEET No. 8 - Deceleration of the HE mast lifting limit switches........................................................19
OPTION SHEET No. 9 - Electric block of the lowering forks with 1200mm pallet....................................................21
OPTION SHEET No. 10 - Warmed seat installation ..........................................................................................23
OPTION SHEET No. 11 - Cab for -30 refrigerating room ...................................................................................27
OPTION SHEET No. 12 - Seat belt installation...................................................................................................35
Section:
HYDRAULIC SYSTEM
1.01 KEY TO HYDRAULIC SYSTEM SYMBOLS ................................................................................................ 2

HYDRAULIC DIAGRAMS ........................................................................................................................... 2a
1.02 CORRECT ASSEMBLY METHOD FOR FEMALE UNIONS ......................................................................... 3
1.03 HYDRAULIC UNIT COMPONENTS ............................................................................................................. 4
1.04 TABLE OF HYDRAULIC UNIT COMPONENTS ........................................................................................... 5
1.05 BASIC TRUCK HYDRAULIC SYSTEM ........................................................................................................ 6
1.06 TABLE OF BASIC TRUCK HYDRAULIC SYSTEM COMPONENTS ............................................................ 6
1.07 MAST HYDRAULIC SYSTEM ..................................................................................................................... 7
1.08 TABLE OF MAST HYDRAULIC SYSTEM COMPONENTS .......................................................................... 7
1.09 SINGLE-ACTING LATERAL LIFT CYLINDER ............................................................................................... 8
1.10 TABLE OF SINGLE-ACTING LATERAL LIFT CYLINDER COMPONENTS .................................................. 8
1.11 SINGLE-ACTING CENTRAL LIFT CYLINDER .............................................................................................. 9
1.12 TABLE OF SINGLE-ACTING CENTRAL LIFT CYLINDER COMPONENTS................................................... 9
1.13 SINGLE-ACTING LIFT CYLINDERS WITH HYDRAULIC CUSHIONING AT DOWN
AND UP STROKE LIMITS .......................................................................................................................... 10
1.14 PLUNGER TYPE LATERAL LIFT CYLINDER ............................................................................................. 11
1.15 TABLE OF PLUNGER TYPE LATERAL LIFT CYLINDER COMPONENTS .................................................. 11
1.16 PLUNGER TYPE CENTRAL LIFT CYLINDER ............................................................................................ 12
1.17 TABLE OF PLUNGER TYPE CENTRAL LIFT CYLINDER COMPONENTS ................................................. 12
1.18 PLUNGER TYPE LIFT CYLINDERS ........................................................................................................... 13
1.19 REACH CARRIAGE CYLINDER ................................................................................................................. 14
1.20 TABLE OF REACH CARRIAGE CYLINDER COMPONENTS ..................................................................... 14
1.21 FORKS TILT CYLINDER............................................................................................................................. 15
1.22 TABLE OF FORKS TILT CYLINDER COMPONENTS ................................................................................. 15
1.23 FORKS SIDESHIFTER CYLINDER ............................................................................................................ 16
1.24 TABLE OF FORKS SIDESHIFTER CYLINDER COMPONENTS ................................................................. 16
2.00 REMOVING THE LATERAL LIFT CYLINDERS FROM THE MAST ............................................................. 17
2.01 REPLACEMENT OF THE LATERAL SINGLE-ACTING CYLINDER SEALS ................................................ 19
2.02 REMOVING THE CENTRAL LIFT CYLINDERS FROM THE MAST ............................................................ 20
2.03 REPLACEMENT OF THE SINGLE-ACTING CENTRAL LIFT CYLINDER SEALS ........................................ 22
2.04 REPLACEMENT OF THE LATERAL PLUNGER CYLINDER SEALS .......................................................... 23
2.05 REPLACEMENT OF THE CENTRAL PLUNGER CYLINDER SEALS ......................................................... 25
UPDATE
Date: Mar. 2002
Part No.: 524159096
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CONTENTS
Section:
Section: CONTENTS
SERVICE
CONTENTS
Section: CONTENTS
2.06
2.07
2.08
2.09
2.10
2.11
REMOVING THE FORKS TILT CYLINDER ................................................................................................. 27

REPLACING THE SEALS .......................................................................................................................... 29
REPLACEMENT OF THE SIDESHIFTER CYLINDER SEALS .................................................................... 30
REMOVING THE REACH CYLINDER ........................................................................................................ 31
REPLACEMENT OF THE REACH CYLINDER SEALS .............................................................................. 32
REPLACEMENT OF HYDRAULIC HOSES OF THE TILT CYLINDER AND SIDESHIFTER
CYLINDER ................................................................................................................................................. 33
2.12 REMOVING THE CENTRAL CYLINDER HYDRAULIC SUPPLY HOSE ...................................................... 34
Section:
1.00
1.01
1.02
1.03
1.04
1.05
1.06
2.00
2.01
2.02
2.03
2.04
2.05
2.06
2.07
2.08
2.09
2.10
MAST TYPES ............................................................................................................................................. 3

SIDESHIFTER COMPONENTS ................................................................................................................... 3
TABLE OF SIDESHIFTER COMPONENTS ................................................................................................. 3
BETA MAST ................................................................................................................................................ 4
HE 140L MAST ........................................................................................................................................... 5
HE 140 MAST ............................................................................................................................................. 6
HE 140R MAST .......................................................................................................................................... 7
PROCEDURE FOR REMOVING THE MAST .............................................................................................. 8
DIAGRAM WITH MAST ASSEMBLY DIRECTIONS .................................................................................... 10
MAST INCLINATION TABLE ....................................................................................................................... 11
FORK ARM CARRIAGE REMOVAL PROCEDURE .................................................................................... 12
BEARING REPLACEMENT PROCEDURE ................................................................................................ 14
GREASING THE BEARING ....................................................................................................................... 15
PROCEDURE FOR REPLACING THE MAST BEARINGS ......................................................................... 16
LIFTING CHAIN .......................................................................................................................................... 17
CHAIN MEASUREMENT ........................................................................................................................... 18
REPLACING THE CENTRAL LIFT CHAIN (FREE LIFT) .............................................................................. 19
REPLACING THE LATERAL LIFT CHAINS ................................................................................................. 20
Section:
1.00
1.01
1.02
1.03
2.00
2.01
2.02
2.02
3.00
3.01
3.01
3.02
4.00
4.01
4.02
4.03
MASTS
MECHANICS
TABLE OF SCREW TIGHTENING TORQUES ............................................................................................. 2

DRIVE WHEEL REPLACEMENT PROCEDURE ......................................................................................... 3
LOAD WHEELS REPLACEMENT PROCEDURE (MODELS R1.4-R1.6-R1.6N) .......................................... 4
LOAD WHEELS REPLACEMENT PROCEDURE (MODELS R1.6 OPT.-R2.0-R2.0H-R2.0W-R2.5) ............. 5
FORKS SIDESHIFTER SLIDING SHOES REPLACEMENT PROCEDURE ................................................. 7
BATTERY BLOCK FUNCTION .................................................................................................................... 9
BATTERY BLOCK REMOVAL PROCEDURE ............................................................................................. 10
REPLACING THE LATCH AND SPRING .................................................................................................... 11
TRACTION MOTOR REPLACEMENT PROCEDURE ................................................................................. 12
TRACTION MOTOR COMPONENTS .......................................................................................................... 13
TABLE OF TRACTION MOTOR COMPONENTS ........................................................................................ 13
REPLACING THE ENCODER BEARING .................................................................................................... 14
PUMP MOTOR REMOVAL PROCEDURE ................................................................................................. 16
REPLACING THE PUMP CONNECTING FLANGE OIL SEAL .................................................................... 17
PUMP MOTOR COMPONENTS ................................................................................................................ 18
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Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
STEERING GEARED MOTOR REMOVAL PROCEDURE .......................................................................... 20

STEERING MOTOR COMPONENTS ......................................................................................................... 21
STEERING UNIT ........................................................... ...................................................................... 23
STEERING UNIT LINKAGE COMPONENTS .............................................................................................. 24
TABLE OF STEERING UNIT LINKAGE COMPONENTS ............................................................................. 25
REPLACING THE STEERING UNIT GAS SPRING ..................................................................................... 26
ADJUSTING STEERING HANDWHEEL ROTATION RESISTANCE ............................................................. 27
DISASSEMBLING THE HANDWHEEL - DISPLAY UNIT ............................................................................ 28
Section:
1.00
1.01
1.02
1.03
2.00
2.01
2.02
REACH CARRIAGE
REACH CARRIAGES UTILISED .................................................................................................................

REACH CARRIAGE COMPONENTS ..........................................................................................................
TABLE OF REACH CARRIAGE - TRUCK COMBINATIONS ........................................................................
TABLE OF REACH CARRIAGE COMPONENTS .........................................................................................
REACH CARRIAGE DISASSEMBLY PROCEDURE ...................................................................................
BEARING REPLACEMENT ........................................................................................................................
REPLACING THE REACH CARRIAGE GUIDE SHOES ..............................................................................
Section:
1.00
1.01
2.00
2.01
2.02
1.00
1.01
1.02
1.03
1.04
1.05
1.06
2.00
2.01
3.00
3.01
3.02
REDUCTION GEAR
REDUCTION GEAR COMPONENTS ..........................................................................................................

TABLE OF REDUCTION GEAR COMPONENTS .........................................................................................
REDUCTION GEAR REMOVAL PROCEDURE ...........................................................................................
REPLACING THE MOTOR SHAFT OIL SEAL ............................................................................................
REPLACING THE DRIVE WHEEL AXLE OIL SEAL ....................................................................................
Section:
2
2
3
4
5
6
6
2
2
3
5
6
BRAKING SYSTEM
ELECTROMAGNETIC BRAKE COMPONENTS .......................................................................................... 2

TABLE OF ELECTROMAGNETIC BRAKE COMPONENTS ........................................................................ 2
LOAD WHEEL BRAKING SYSTEM COMPONENTS .................................................................................. 3
TABLE OF BRAKING SYSTEM COMPONENTS ....................................................................................... 3
LOAD WHEELS BRAKE COMPONENTS ................................................................................................... 4
TABLE OF LOAD WHEELS BRAKE COMPONENTS ................................................................................. 4
BRAKING SYSTEM .................................................................................................................................... 5
REMOVAL AND ADJUSTMENT OF THE ELECTROMAGNETIC BRAKE ..................................................... 6
ADJUSTING AND PUTTING INTO SERVICE THE ELECTROMAGNETIC BRAKE ....................................... 7
REMOVING THE BRAKE MASTER CYLINDER .......................................................................................... 8
REPLACING THE LOAD WHEEL BRAKES ................................................................................................ 9
BLEEDING AIR FROM THE BRAKE CIRCUIT ............................................................................................ 11
UPDATE
Date: Mar. 2002
Part No.: 524159096
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CONTENTS
5.00
5.01
5.02
6.00
6.01
6.02
6.03
6.04
6.05
Section: CONTENTS
SERVICE
Section: ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
NOTES:
Page: 8
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
ELECTRICAL SYSTEM
INTRODUCTION
INSTALLING
THE TRUCK
D INTRODUCTION TO THE TRUCK ......................................................... 8
D INSTALLING THE TRUCK .................................................................... 9
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 9
SERVICE
ELECTRICAL SYSTEM
1.0 INTRODUCTION TO THE TRUCK

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

PUNCH MARKING
Fig. 4
TRUCK SERIAL NUMBER

DATAPLATE
Page: 10
Fig. 2
Part No.: 524159096
Fig. 1
Date: Mar. 2002
UPDATE
SERVICE
2.0 INSTALLING THE TRUCK

MODEL ALL MODELS
Trucks are delivered after testing and checking of all the factory parameters. Certain truck models are
delivered with the mast removed because the overall height exceeds the maximum permissible height for
transportation purposes.
All functions of the trucks are tested, after which the mast is removed and the fork arm carriage is secured
to its base in such a way that it does not tend to slide along the internal mast section. All hydraulic
connections are suitably plugged to prevent the egress of oil during transportation.
When the truck arrives at its destination the mast must be installed and all the various functions must be
tested.
To refit the mast, use a crane of suitable height or an overhead crane and a lifting sling of suitable capacity
to lift the mast from the ground and install it on the basic truck (see figure below)
There is a bag secured to the mast containing the fixing screws and shims to be inserted behind the mast
base to impart the required inclination in accordance with the height. For directions on mast installation and
positioning of the shims, refer to the section masts, heading 2.01-2.02 page 10-11.
Set the battery voltage (Adjust Battery) on AC2 Traction inverter and AC2 Pump inverter (see procedure
on pag. 26)
Fig. 5
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 11
ELECTRICAL SYSTEM
SERVICE
ELECTRICAL SYSTEM
NOTES:
Page: 12
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
ELECTRICAL SYSTEM
ELECTRICAL
SYSTEM
D KEY TO ELECTRICAL DIAGRAMS ...................................................14
D KEY TO POSITION OF ELECTRICAL COMPONENTS ........................16
D FUNCTION INPUTS TABLE ................................................................ 18
D PARAMETER TABLES....................................................................... 20
D ACCESS PROCEDURE FOR CALIBRATION OF THE VARIOUS M ... 24
D TRACTION START SEQUENCE ......................................................... 27
D SPEED CUTBACK ............................................................................. 29
D MODULES REPLACEMENT PROCEDURE ....................................... 30
D SICOS DISPLAY ................................................................................ 36
D DISPLAY MENUS .............................................................................. 42
D PRE-HEIGHT SELECTOR .................................................................. 48
D ALARMS ............................................................................................ 54
D DIAGNOSTICS ................................................................................... 55
D TROUBLESHOOTING GUIDE ............................................................ 55
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 13
SERVICE
ELECTRICAL SYSTEM
1.0 KEY TO ELECTRICAL DIAGRAMS

MODEL ALL MODELS
D i a g ra m
S y m b o l R e f.
SW 1
SW 2
SW 3
SW 4
SW 5
SW 6
SW 7
SW 8
SW 9
S W 10
S W 11
S W 12
S W 13
S W 14
S W 15
S W 16
S W 17
S W 18
S W 19
S W 20
S W 21
S W 22
S W 23
S W 24
S W 25
S W 26
FU1
FU2
FU3
FU4
FU5
FU6
FU7
EM B
ENC. M T R
EN C . M S
EN C . M P
EN C . H .I
EV I
EV 2
EV 3
EV 4
EV 5
EV 6
EV 7
EV 8
OPT. 1
OPT. 2
H1
H2
H3
H4
M1
M2
L O A D C EL L
M TR
MP
MS
POT. 1
S
S .S .
T. M TR
T. M P
T. M S
J 1 (2 a x i x )
J 2 (2 a x i x )
J1
J2
J3
J4
Page: 14
D ia g r a m
P a g e R e f.
1/7
1/7
2/7
2/7
3/7
3/7
3/7
3/7
3/7
3/7
3/7
4/7
4/7
4/7
4/7
4/7
4/7
5/7
5/7
5/7
4/7
5/7
5/7
4/7
4c /7
4c /7
1/7
1/7
1/7
1/7
2/7
2/7
2/7
2/7
2/7
2/7
3/7
3/7
3/7
3/7
3/7
3/7
3/7
3/7
3/7
3/7
3/7
3/7
4/7
4/7
4/7
3/7
2/7
3/7
3/7
1/7
1/7
1/7
4/7
1/7
2/7
2/7
3/7
2/7
4 -4 c / 7
4 -4 c / 7
4 a -4 d /7
4 a -4 d /7
4 a -4 d /7
4 a -4 d /7
D e sc ri p ti o n o f C o m p o n e n t
E m e rg e n c y p u s h b u t t o n
K e y s w it c h
O p e ra t o r p re s e n c e in d u c t ive s e n s o r
S t e e r w h e e l c e n t re d in d u c t ive s e n s o r
S p e e d re d u c t io n a n d h e ig h t in d ic a t o r z e ro in d u c t ive s e n s o r
S p e e d re d u c t io n in h e ig h t in d u c t ive s e n s o r
In d u c t ive s e n s o r - R e a c h c a rria g e fo rw a rd s t o p - R e a c h c a rria g e re tra c t d e c e le ra t io n
In d u c t ive s e n s o r - R e a c h c a rria g e re tra c tio n s to p - R e a c h c a rria g e fo rw a rd d e c e le ra t io n
F o rk s lo w e rin g d e c e le ra t io n in d u c t ive s e n s o r
F o rk s lo w e rin g in t e rlo c k in d u c t ive s e n s o r
L o a d p re s e n c e o n fo rk s in d u c t ive s e n s o r
F o rw a rd t ra ve l c o m m a n d o n p e d a l in d u c tive s e n s o r
R e ve rs e t ra ve l c o m m a n d o n p e d a l in d u c tive s e n s o r
F o rw a rd /re ve rs e t ra ve l S t a rt in d u c t ive s e n s o r
P e d a l b ra k e c o n tro l in d u c t ive b ra k in g s e n s o r
B a t te ry o u t o f p o s it io n in d u c tive s e n s o r
O p e ra t o r p re s e n c e m ic ro s w itc h lo c a t e d u n d e r s e a t (o p tio n a l)
Tra c t io n p e rm is s ive p u s h b u t t o n w it h b a t t e ry o u t
P a rk in g p e rm is s ive p u s h b u tt o n
L o w s p e e d t ra ve l p e rm is s ive b u t t o n a n d p e rfo rm a n c e c h a n g e (S L O W - S TD - H A R D H o rn b u t to n
F ifth h y d ra u lic c irc u it c o n t ro l p u s h b u t to n
A u t o m a t ic s c a le s c o n tro l p u s h b u t to n
W o rk lig h t s p o w e r O N p u s h b u t t o n
F o rw a rd t ra ve l s e le c t o r b u t to n o n d a s h b o a rd
R e ve rs e t ra ve l s e le c t o r b u t to n o n d a s h b o a rd
A C 2 t ra c t io n c o n tro lle r 3 0 0 A p o w e r fu s e
A C 2 p u m p c o n t ro lle r 3 0 0 A p o w e r fu s e
E P S A C c o n t ro lle r 3 2 A p o w e r fu s e
A u x ilia ry lin e 1 0 A fu s e
A u x ilia ry lin e 6 A fu s e
E le c t ro m a g n e t ic b ra k e
Tra c t io n m o t o r e n c o d e r
S t e e rin g m o t o r e n c o d e r
P um p m otor enc oder
H e ig h t in d ic a tio n e n c o d e r
P ro p o rt io n a l lo w e rin g s o le n o id va lve
P ro p o rt io n a l lift in g s o le n o id va lve
R e a c h c a rria g e re t ra c t io n p ro p o rt io n a l s o le n o id va lve
R e a c h c a rria g e e x t e n s io n p ro p o rt io n a l s o le n o id va lve
Tilt B a c k s o le n o id va lve
Tilt F W D s o le n o id va lve
F o rk s rig h t -h a n d s id e s h ift s o le n o id va lve
F o rk s le ft -h a n d s id e s h ift s o le n o id va lve
O p tio n s s o le n o id va lve w irin g c o n n e c t o r
O p tio n s s o le n o id va lve w irin g c o n n e c t o r
H o rn
R e ve rs e t ra ve l w a rn in g s o u n d e r
W o rk lig h t s
Tru c k in m o t io n fla s h in g w a rn in g b e a c o n
M o t o r c o m p a rt m e n t c o o lin g fa n
M o t o r c o m p a rt m e n t c o o lin g fa n
L o a d c e ll fo r d e te c t in g w e ig h t o f lo a d o n fo rk s
A C t ra c t io n m o t o r
A C pum p m otor
A C s t e e rin g m o t o r
Tra c t io n s p e e d va ria t io n p o t e n t io m e t e r
B a t te ry to m a c h in e e le c t ric a l s y s te m c o n n e c t o r p lu g
S t e e rin g s te p p e r m o to r
Tra c t io n m o t o r t e m p e ra t u re p ro b e
P u m p m o t o r te m p e ra t u re p ro b e
S t e e rin g m o t o r t e m p e ra tu re p ro b e
F o rk s lift/ lo w e r c o n t ro l a n d re a c h c a rria g e e x t e n d /re t ra c t c o n t ro l jo y s tic k
F o rk s B a c k / F w d t ilt a n d rig h t / le ft s id e s h ift c o n t ro l jo y s t ic k
F o rk s lift/ lo w e r c o n t ro l jo y s tic k
R e a c h c a rria g e e x t e n d / re t ra c t c o n t ro l jo y s tic k
F o rk s b a c k /fw d t ilt c o n t ro l jo y s t ic k
F o rk s rig h t /le ft s id e s h ift c o n t ro l jo y s t ic k
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Sezione: ELECTRICAL SYSTEM
FUNCTIONAL ELECTRICAL DIAGRAM 1/7

MOTORS AND CONTROLLERS CONNECTION
CONTROL CIRCUITS POWER SUPPLY
AGGIORNAMENTO
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14a
SERVICE
Fuse after
keyswitch
Solenoid valves power

supply fuse
Auxiliary services
power supply fuse

AC TRACTION MODULE CONNECTION
EPS AC MODULE CONNECTION
Reference to diagram number at top right

4a -4d,/7 joysticks R1 power supply positive. (Resistor for cold store version)
DC-DC CONVERTER FOR 12/24V

POWER SUPPLY (OPTIONAL
24V ALLINSERZIONE - 19V DI ALIMENTAZIONE

24V ON THE START UP - 19V TO KEEP EMB OPEN
1B - 2B PONTE CONFIGURAZIONE INVERTER

PRESENTE = POMPA / NON PRESENTE = TRAZIONE
1B - 2B INVERTER JUMPER CONFIGURATION
CLOSED = PUMP / OPEN = TRACTION
AGGIORNAMENTO
1501469-2
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14b
SERVICE

AC PUMP MODULE CONNECTION
MHYRIO MODULE CONNECTION
3
1
1B - 2B PONTE CONFIGURAZIONE INVERTER

PRESENTE = POMPA / NON PRESENTE = TRAZIONE
1B - 2B INVERTER JUMPER CONFIGURATION
CLOSED = PUMP / OPEN = TRACTION
24V ALLINSERZIONE - 19V DI ALIMENTAZIONE

24V ON THE START UP - 19V TO KEEP EMB OPEN
SE SW5 NON E PRESENTE PONTICELLARE 15A CON 12A

IF SW5 IS NOT MOUNTED JUMPER 15A WITH 12A
1501469-3
AGGIORNAMENTO
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14c
SERVICE

CAN I/O MODULE CONNECTION
2-JOYSTICK HYDRAULIC CONTROL
FWD/REV TRAVEL CONTROL ON PEDALS
POT. J1
Function
Lift
Low
Forw. Carr.
Rev. Carr.
Range
2,6V - 4,5V
2,4V - 0.5V
2,4V - 0,5V
2,6V - 4.5V
POT. J2
Function
Tilt Up
Tilt Down
Side Shift rh.
Side Shift sh
Ra nge
2,6V - 4,5V
2,4V - 0.5V
2,6V - 4,5V
2,4V - 0.5V
SW13
SW12
DUAL FUNCTION PEDAL WITH DIRECTIONAL

CONTROL FORW/REV
AND TWO JOYSTICKS HYDRAULIC CONTROL
NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS

NOT PRESENT WHEN THE TRAVEL DIRECTION CONTROL
ON THE PEDALS IS UTILIZED
AGGIORNAMENTO
0 1
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14d
SERVICE

FUNCTIONAL ELECTRICAL DIAGRAM 4a/7
POT. J1
POT. J2
Function
Lift
Low
Forw. Carr.
Rev. Carr.
Range
2,6V - 4,5V
2,4V - 0.5V
2,4V - 0,5V
2,6V - 4.5V
POT. J3
POT. J4
Function
Tilt Up
Tilt Down
Side Shift rh.
Side Shift sh
Ra nge
2,6V - 4,5V
2,4V - 0.5V
2,6V - 4,5V
2,4V - 0.5V
SW13
SW12

CONTROL FORW/REV
AND FOUR JOYSTICKS HYDRAULIC CONTROL

NOT PRESENT WHEN THE TRAVEL DIRECTION CONTROL
ON THE PEDALS IS UTILIZED
AGGIORNAMENTO
0 1
R1
RESITOR FOR COLD STORE VERSION
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14e
SERVICE

FUNCTIONAL ELECTRICAL DIAGRAM 4b/7
SINGLE JOYSTICK HYDRAULIC CONTROL
SW13
SW12
CON PEDALIERA DOPPIA IN FUNZIONE, IL COMANDO SUL JOYSTICK E DISATTIVATO

WITH DUAL FUNCTION PEDAL, THE SPEED CONTROL IS DISABILITY
CONTROL FORW/REV
AND ONLY ONE JOYSTICKS HYDRAULIC CONTROL
NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A

IS NOT PRESENT WHEN THE TRAVEL DIRECTION
CONTROL ON THE PEDALS IS UTILIZED
AGGIORNAMENTO
0 1
5 6 Data: Mar. 2002
Part No: 524159096
Pag.
14f
SERVICE

FUNCTIONAL ELECTRICAL DIAGRAM 4c/7
FWD/REV TRAVEL CONTROL
ON INSTRUMENT PANEL
POT. J1
Function
Lift
Low
Forw. Carr.
Rev. Carr.
Range
2,6V - 4,5V
2,4V - 0.5V
2,4V - 0,5V
2,6V - 4.5V
POT. J2
SW26
FORWARD BACKWARD WITH SWITCH

AND TWO JOYSTICKS FOR IDRAULIC CONTROL
Function
Tilt Up
Tilt Down
Side Shift rh.
Side Shift sh
Range
2,6V - 4,5V
2,4V - 0.5V
2,6V - 4,5V
2,4V - 0.5V
SW25

PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE
INSTRUMENT PANEL IS UTILIZED
AGGIORNAMENTO
0 1
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14g
SERVICE

FUNCTIONAL ELECTRICAL DIAGRAM 4d/7
TRAVEL CONTROL ON INSTRUMENT PANEL
POT. J1
POT. J2
Function
Lift
Low
Forw. Carr.
Rev. Carr.
Range
2,6V - 4,5V
2,4V - 0.5V
2,4V - 0,5V
2,6V - 4.5V
POT. J3
POT. J4
SW26
FORWARD BACKWARD WITH SWITCH

AND FOUR JOYSTICKS FOR IDRAULIC CONTROL
0 1
Ra nge
2,6V - 4,5V
2,4V - 0.5V
2,6V - 4,5V
2,4V - 0.5V
SW25

PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE
INSTRUMENT PANEL IS UTILIZED
AGGIORNAMENTO
Function
Tilt Up
Tilt Down
Side Shift rh.
Side Shift sh
R1 RESITOR FOR COLD STORE VERSION
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14h
SERVICE

FUNCTIONAL ELECTRICAL DIAGRAM 4e/7
TRAVEL CONTROL ON JOYSTICK
SW25
SW26
FORWARD BACKWARD AND HYDRAULIC

CONTROL WITH ONLY JOYSTICK
NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS PRESENT

WHEN THE ITT JOYSTICK IS UTILIZED WITH INTEGRAL TRAVEL
CONTROL
AGGIORNAMENTO
0 1
5 6 Data: Mar. 2002
Part No: 524159096
Pag.
14i
SERVICE

SICOS MODULE CONNECTIONS
1501469 - 10
AGGIORNAMENTO
5 6 Data: Mar. 2002
Part No: 524159096
Pag.
14l
SERVICE

CAN BUS MODULES CONNECTION
1501469 - 11
AGGIORNAMENTO
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14m
SERVICE

CONNECTION DIAGRAM
POWER CABLES
1501486
AGGIORNAMENTO
5 6 Data: Mar. 2002
Part No: 524159096
Pag.
14n
SERVICE
INPUT / OUTPUT CONNECTORS

MODULES AC2 T, AC2 P
Input / output connectors module AC2 POMPA
Input / output connectors module AC2 TRAZIONE
AGGIORNAMENTO
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14o
SERVICE

MODULES EPS AC, MHYRIO
Input / output connectors module EPS AC
Input / output connectors module MHYRIO
AGGIORNAMENTO
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14p
SERVICE

MODULES CAN I/O, SICOS
(display)
Input / output connectors module CAN I/O
Input / output connectors module SICOS
AGGIORNAMENTO
5 6 Data: Mar. 2002
Part No: 524159096
Pag. 14q
SERVICE
ELECTRICAL SYSTEM
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 15
SERVICE
ELECTRICAL SYSTEM
2.0 KEY TO POSITION OF ELECTRICAL COMPONENTS

MODEL ALL MODELS
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Diagram
Diagram
Symbol Ref. Page Ref.
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
MTR
MP
MS
SW3
Pot 1
SW14
SW12
SW13
SW15
H1
SW16
SW4
SW8
SW7
M1
S.S.
EPS AC Logic
SW25
SW26
SW21
AC2 Traction
Logic
AC2 Pump
Logic
CAN I/O
Mhyrio
Sicos
M2
Enc Height Ind
SW5
SW1
SW2
FU7
FU6
FU5
FU4
J1 (2axix)
J2 (2axix)
J1
J2
J3
J4
41
J ITT
21
22
42
43
44
45
Page: 16
1/7
1/7
1/7
2/7
4/7
4/7
4/7
4/7
4/7
4/7
4/7
2/7
3/7
3/7
2/7
2/7
2/7
4c/7
4c/7
4/7
Description of Component
AC traction motor - 6.4 kW 70 Hz
AC pump motor - 11 kW 8 Hz
AC steering motor - 0.4 kW 95 Hz
Operator presence inductive sensor
Acceleration traction potentiometer
Forward/reverse travel start inductive sensor
Forward travel selection inductive sensor on pedal
Reverse travel selection inductive sensor on pedal
Brake pedal control braking inductive sensor
Horn
Battery out of position inductive sensor
Steer wheel centred inductive sensor
Inductive sensor - reach carriage forward deceleration and retraction stop
Inductive sensor - reach carriage retraction deceleration and forward stop
Motor compartment cooling fan
Steering stepper motor
AC steering motor control module
Forward travel selection switch on dashboard
Reverse travel selection switch on dashboard
Horn button
2/7
AC traction motor control module
3/7
AC pump motor control module
4/7
3/7
5/7
3/7
3/7
3/7
1/7
1/7
2/7
2/7
2/7
1/7
4-4c/7
4-4c/7
4a-4d/7
4a-4d/7
4a-4d/7
4a-4d/7
CAN I/O control module

Mhyrio control module for valves bank management
Sicos (display) control module for alarms and test information
Panels cooling fan
Height indication encoder
Height encoder, speed reduction inductive zero sensor
Emergency circuit breaker
Keyswitch
Auxiliary line fuse
Auxiliary line fuse
Auxiliary line fuse
Auxiliary line fuse
Joystick - forks Up/Down control, reach carriage extend/retract
Joystick - forks tilt back/fwd control and forks left/right sideshift control
Joystick - forks lift/lower
Joystick - reach carriage forward/back control
Joystick - forks tilt Fwd/Back control
Joystick - forks left/right sideshift control
Multifunction Joystick. Displace lever up and down for lift and lower, displace right
4b-4e/7
and left for reach carriage movements
Travel forward / reverse control pushbutton
Forks tilt Fwd / Back control pushbutton
Forks right and left sideshift control pushbutton
Horn button
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
MOTORS COMPARTMENT ELECTRICAL COMPONENTS WITH

FORWARD/REVERSE TRAVEL PUSHBUTTONS ON PEDALS
MODEL ALL MODELS
16
15
2
3
17
1
4
5
6
8
7
12
11
13
14
6
10
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 16a
SERVICE

MOTORS COMPARTMENT ELECTRICAL COMPONENTS
FORWARD/REVERSE TRAVEL CONTROL WITH DIRECTION
CHANGE CONTROL ON INSTRUMENT PANEL
MODEL ALL MODELS
16
15
2
3
17
19
18
20
12
11
13
14
6
10
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 16b
SERVICE
ELECTRICAL COMPONENTS AND

POSITION OF CONTROL MODULES
MODEL ALL MODELS
25
43
44
30
30
29
42
30
37
35
36
45
28
29
38
39
29
40
41
19
27
18
19
20
18
20
23
22
21
30
26
32
24
31
33
34
29
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 16c
SERVICE
POSITIONING OF DECELERATION
SENSORS ON REACH CARRIAGE
MODEL ALL MODELS
140-150mm
1
2
3
1
2
3
4
STANDARD AND PLUS REACH CARRIAGE WITH
SENSOR POSITIONING ACCORDING TO
BASIC TRUCK BATTERY SIZE
BASIC TRUCK WITH THREE

BASIC TRUCK WITH THREE
STANDARD AND PLUS REACH CARRIAGE

WITH FOUR SENSOR HOLDER SLOTS
2
BASIC TRUCK WITH TWO
SENSOR READING CAMS
NARROW REACH CARRIAGE

WITH TWO SENSOR HOLDER SLOTS
POSITIONS OF SENSORS WITH REFERENCE TO BASIC TRUCK AND BATTERY DIMENSIONS

MR14 MR14H MR16 MR16H MR16N MR20 MR20H MR20W MR25
Slot Ref.
Battery Dimensions
"A"
"A"
"A"
"A"
"A"
"A"
"A"
"A"
"A"
Read distance between the two sensors 140-150mm
Din C 420A (1220x280x784)
127
109
39
1
Din C 560A (1220x352x784)
127
109
39
39
51
2
Din C 700A (1220x424x784)
127
109
39
39
51
51
22
23
3
Din C 840A (1220x496x784)
51
51
22
23
4
1
2
Din B 420A (1032x350x784)

Din B 560A (1032x440x784)
UPDATE
39
39
Date: Mar. 2002
Part No.: 524159096
Page 16d
SERVICE
ELECTRICAL SYSTEM
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 17
SERVICE
ELECTRICAL SYSTEM
3.0 TABLE OF FUNCTION INPUTS

MODEL ALL MODELS
The tables show all the sensors and microswitches that are activated in accordance with the requested
functions.
Key
Input =
Description of Functions =
List of sensor inputs in the modules with specification of pins and

access connector.
Description of the function to be executed
Enabled function =
Description of the requested enabled function
Control =
Controller involved
Pin =
Pin corresponding to signal output
Status =
State of the sensor at the time of the function request
SW4 - SW23 =
Sensors activated on the basis of the requested function
NOTES:
Page: 18
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Sezione: IMPIANTO ELETTRICO

INPUT TABLE OF THE
FUNCTIONS (Sheet 1/3)
Inputs
TRACTION MAX SPEED
FORWARD SPEED
AC2-TR
ELECTROMAGNETIC BRAKE
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
FORWARD SPEED
AC2-TR
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
FORWARD SPEED
AC2-TR
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
FORWARD SPEED
AC2-TR
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
FORWARD SPEED
AC2-TR
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
FORWARD SPEED
AC2-TR
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
FORWARD SPEED
AC2-TR
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
FORWARD SPEED
AC2-TR
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
l
l
l
l
l
l
SW1
J1/J1
J1/J2
J3
J4
SW21
AUTOMATIC
WEIGHT BUTTON
SW3
SICOS
15/A
OPTIONAL 1-2
IDR.VALVE
BUTTON
l
l
SW17
SICOS
3/A
PARKING
BUTTON
SW16
SICOS
2/A
SLOW SPEED
BUTTON
SW15
SICOS
6/A
BATTERY OUT
BUTTON
SW14
PEDAL MODE
l
l
CLACSON
BUTTON
ENABLE
SIDE SHIFT
ENABLE TILT
ENABLE
CARRIAGE
l
l
ENABLE
LIFT/LOW
EMERGENCY
SW12/25 SW13/26
DEAD MAN
SW11
SEAT SWITC
(OPTIONAL)
l
l
SW10
BATTERY OUT
ON
SW9
BRAKE
ENABLE
SW8
CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS
1/C
4/C
13/A
8/A
1/A
4/G
1/G
2/G
9/A
14/A
5/G
6/G
1/B
4/B
BACKWARD
SW7
FORWARD
SW4
LOAD
PRESENCE
SW3
ON
INTERLOCK
LOW FORKS
SW6
STATU
S
REDUCTION
SPEED LOW
SW5
CARRIAGE
CUT OUT FORW.
FOR.
STOP
CARRIAGE
REV. SLOW D.
CARRIAGE
CUT OUT
REVERSE
FOR.
SLOW D.
CARRIAGE
REV. STOP
REDUCTION
SPEED LIFT
PIN
REDUCTION
SPEED AND
RESET ENCODER
FUNCTION OPERATED CONTROL
STEER
POSITION
FUNCTION DESCRIPTION
DEAD MAN
= INPUT ACTIVITY
PUMP MODE
AC2-TR EPS-AC AC2-PU MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO CAN-I/O
4/F
12/B
2/B
12/A
1/A
2/A
3/A
5/A
7/A
8/A
3/G
SW18
SW20
SW19
SW22
SW23
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
DUAL FUNCTION PEDAL

WITH DIRECTIONAL CONTROL FW/ BACKW
TRACTION MAX SPEED
9/F
ON
DUAL FUNCTION PEDAL

TRACTION MAX SPEED
9/F
ON
ON
FORWARD/BACKWARD
WITH SWITCH
TRACTION MAX SPEED
9/F
ON
ON
FORWARD/BACKWARD
WITH SWITCH
TRACTION REDUCTION SPEED
9/F
ON
ON
WITH SLOW DOWN BUTTON ACTIVITY

DUAL FUNCTION PEDAL
9/F
ON
ON

DUAL FUNCTION PEDAL
9/F
ON
ON

FORWARD/BACKWARD
WITH SWITCH
9/F
ON
ON

FORWARD/BACKWARD
WITH SWITCH
9/F
ON
ON
l
l
l
l
l
l
l
l
WITH FORKS OVER FREE LIFT

DUAL FUNCTION PEDAL
9/F
ON
ON

DUAL FUNCTION PEDAL
9/F
ON
ON

FORWARD/BACKWARD
WITH SWITCH
9/F
ON
ON

FORWARD/BACKWARD
WITH SWITCH
TRACTION SPEED REDUCTION
9/F
l
l
l
l
l
l
ON
l
l
ON
ON
ON
WITH CARRIAGE ALL OUT

DUAL FUNCTION PEDAL
9/F
ON
ON

DUAL FUNCTION PEDAL
9/F
ON
ON

FORWARD/BACKWARD
WITH SWITCH
9/F
ON

FORWARD/BACKWARD
WITH SWITCH
9/F
AGGIORNAMENTO
0 1
5 6 Data: Marzo 2002 Part No: 524159096
Pag. 18a
SERVICE

INPUT TABLE OF THE
Inputs
FORWARD SPEED
AC2-TR
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
FORWARD SPEED
AC2-TR
AC2-TR
BACKWARD SPEED
AC2-TR
AC2-TR
FORWARD SPEED
AC2-TR
J1/J1
J1/J2
J3
J4
SW21
PEDAL MODE
ENABLE
BACKWARD
FORWARD
SW1
AUTOMATIC
WEIGHT BUTTON
SW3
OPTIONAL 1-2
IDR.VALVE
BUTTON
SW17
PARKING
BUTTON
l
l
SW16
SLOW SPEED
BUTTON
SW15
BATTERY OUT
BUTTON
CLACSON
BUTTON
ENABLE
SIDE SHIFT
l
l
ENABLE TILT
ENABLE
CARRIAGE
ENABLE
LIFT/LOW
EMERGENCY
l
l
DEAD MAN
SW11 SW12/25 SW13/26 SW14
SEAT SWITC
(OPTIONAL)
SW10
BATTERY OUT
SW9
BRAKE
SW8
LOAD
PRESENCE
ON
SW7
INTERLOCK
LOW FORKS
SW6
REDUCTION
SPEED LOW
ON
SW5
REV. SLOW D.
CARRIAGE
CUT OUT
FOR.
SLOW D.
REVERSE
CARRIAGE
REV.
STOP
SW4
CARRIAGE
SW3
CUT
OUT
FORW.
FOR.
STOP
CARRIAGE
STATUS
REDUCTION
SPEED LIFT
PIN
REDUCTION
SPEED AND
RESET ENCODER
FUNCTION OPERATED CONTROL
STEER
POSITION
FUNCTION DESCRIPTION
DEAD MAN
= INPUT ACTIVITY
PUMP MODE
AC2-TR EPS-AC AC2-PU MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS
4/F
12/B
2/B
12/A
1/A
2/A
3/A
5/A
7/A
8/A
3/G
4/G
1/G
2/G
9/A
14/A
5/G
6/G
1/B
4/B
1/C
4/C
13/A
8/A
1/A
6/A
2/A
3/A
15/A
SW18
SW20
SW19
SW22
SW23
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
WITH BATTERY OUT

DUAL FUNCTION PEDAL
9/F
ON
WITH BATTERY OUT

DUAL FUNCTION PEDAL
9/F
ON
ON
WITH BATTERY OUT

FORWARD/BACKWARD
WITH SWITCH
9/F
ON
ON
WITH BATTERY OUT

FORWARD/BACKWARD
WITH SWITCH
PARKING BRAKE ACTIVITY
9/F
ON
OFF
l
l
DUAL FUNCTION PEDAL

OR SWITCH
PARKING BRAKE ACTIVITY
AC2-TR
BACKWARD SPEED
AC2-TR
9/F
OFF
l
l
OFF
OFF
DUAL FUNCTION PEDAL

OR SWITCH
STRIGHT WELL
LIFT FORKS MAX SPEED
LIFT FORKS REDUCTION SPEED
LOWER FORKS MAX SPEED
LOWER FORKS REDUCTION SPEED
CARRIAGE FORWARD MAX SPEED
CARRIAGE FORWARD REDUCTION SPEED
CARRIAGE FORWARD STOP
CARRIAGE REVERSE MAX SPEED
CARRIAGE REVERSE REDUCTION SPEED
CARRIAGE REVERSE STOP
TILT UP
TILT DOWN
SIDE SHIFT RIGHT
SIDE SHIFT LEFT
OPTIONAL 1
AC2-TR
ELECTIRC STEERING
EPS-AC
AC2-PU
MHYRIO
AC2-PU
MHYRIO
MHYRIO
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
MOTOR PUMP
EV2
MOTOR PUMP
EV2
EV1
EV1
MOTOR PUMP
EV4
MOTOR PUMP
EV4
MOTOR PUMP
EV4
MOTOR PUMP
EV3
MOTOR PUMP
EV3
MOTOR PUMP
EV3
MOTOR PUMP
EV5
MOTOR PUMP
EV6
MOTOR PUMP
EV7
MOTOR PUMP
EV8
MOTOR PUMP
OPT.1
9/F
ON
ON
7/G
ON
l
l
l
ON
7/G
8/G
8/G
ON
ON
ON
l
l
ON
5/G
ON
ON
5/G
ON
OFF
5/G
OFF
ON
6/G
ON
ON
ON
OFF
6/G
OFF
ON
4/G
ON
ON
ON
ON
2/G
ON
ON
1/G
ON
ON
3/F
ON
AGGIORNAMENTO
0 1
Pag. 18b
SERVICE

INPUT TABLE OF THE
Inputs
LOWERANDCARRIAGEREVERSEMAXSPEED
LOWERANDCARRIAGEREVERSE REDUCTION
SPEED
LOWERANDCARRIAGEREVERSESTOP
LOWERANDSIDESHIFTRIGHT
LOWERANDSIDESHIFTLEFT
LOWERWITHCARRIAGEALLREVERSE
ANDINTERLOKFORKSDEVICEACTIVITY
CARRIAGEREVERSEWITHFORKSALLDOWN
ANDINTERLOKFORKSDEVICEACTIVITY
AUTOMATICWEIGHTLOAD
CLACSON
EV8-EV1
EV1
MHYRIO
MOTORPUMP
AC2-PU
MHYRIO
AC2-PU
MHYRIO
MOTORPUMP
EV2-EV4-EV1
MOTORPUMP
EV2-EV4-EV1
MOTORPUMP
EV2-EV4-EV1
MOTORPUMP
EV2-EV3-EV1
MOTORPUMP
EV2-EV3-EV1
MOTORPUMP
EV2-EV3-EV1
MOTORPUMP
EV7-EV1
MOTORPUMP
EV3
MOTORPUMP
EV2
H2
BACKUPALARMDUALFUNCTIONPEDAL
REVERSESPEED
WITHDIRECTIONALCONTROLFW/BACKW
H3
BACKUPALARMFORWARDBACWARD
WITHSWITH
FLSHINGBEACON
REVERSESPEED
H3
H1
CANI/O
AC2-TR
CANI/O
AC2-TR
CANI/O
AC2-PU
l
l
AUTOMATIC
WEIGHT BUTTON
OPTIONAL 1-2 IDR

.VALVE BUTTON
SW21
PARKING
BUTTON
J4
SLOW SPEED
BUTTON
J3
SW11 SW12/25 SW13/26 SW14
BATTERY OUT
BUTTON
J1/J2
ENABLE
J1/J1
BACKWARD
SW1
SW10
FORWARD
SW3
SW9
LOAD
PRESENCE
SW17
INTERLOCK
LOW FORKS
SW16
REDUCTION
SPEED LOW
SW15
SW8
PEDAL MODE
CARRIAGE
CUT OUT
FORW.
FOR.
STOP
CARRIAGE
REV. SLOW D.
CARRIAGE
CUT OUT
FOR.
SLOW D.
REVERSE
CARRIAGE
REV.
STOP
REDUCTION
SPEED LIFT
CLACSON
BUTTON
LOWERANDCARRIGAFORWARDSTOP
EV2-EV3
ENABLE SIDE
SHIFT
LOWERANDCARRIAGEFORWARDREDUCTION
SPEED
EV2-EV3
MOTORPUMP
ENABLE TILT
LOWERANDCARRIAGEFORWARDMAXSPEED
EV2-EV3
MOTORPUMP
ENABLE
CARRIAGE
LIFTANDCARRIAGEREVERSESTOP
EV2-EV4
MOTORPUMP
SW7
ENABLE
LIFT/LOW
LIFTANDCARRIAGEREVERSEREDUCTION
SPEED
EV2-EV4
MOTORPUMP
SW6
EMERGENCY
LIFTANDCARRIAGEREVERSEMAXSPEED
EV2-EV4
MOTORPUMP
SW5
DEAD MAN
LIFTANDCARRIAGEFORWARDSTOP
MOTORPUMP
SW4
SEAT SWITC
(OPTIONAL)
LIFTANDCARRIAGEFORWARDREDUCTION
SPEED
OPT.2
STATUS SW3
BATTERY OUT
LIFTANDCARRIAGEFORWARDMAXSPEED
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
AC2-PU
MHYRIO
MOTORPUMP
PIN
BRAKE
OPTIONAL 2
FUNCTIONOPERATED CONTROL
REDUCTION
SPEED AND
RESET ENCODER
FUNCTIONDESCRIPTION
PUMP MODE
DEAD MAN
= INPUTACTIVITY
STEER
POSITION
AC2-TR EPS-AC AC2-PU MHYRIOMHYRIOMHYRIOMHYRIOMHYRIOMHYRIOMHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS
1/C
4/C
13/A
8/A
1/A
6/A
2/A
3/A
15/A
4/F
12/B 2/B
12/A
1/A
2/A
3/A
5/A
7/A
8/A
3/G
4/G
1/G
2/G
9/A
14/A
5/G
6/G
1/B
4/B
SW18 SW20 SW19 SW22 SW23
ON
2/F
ON
ON
7/G-5/G
ON
ON
7/G-5/G
ON
OFF
7/G-5/G
OFF
ON
7/G-6/G
ON
ON
7/G-6/G
ON
OFF
7/G-6/G
OFF
ON
7/G-5/G-8/G
ON
ON
7/G-5/G-8/G
ON
OFF
7/G-5/G-8/G
OFF
ON
7/G-6/G-8/G
ON
ON
7/G-6/G-8/G
ON
OFF
7/G-6/G-8/G
OFF
ON
2/G-8/G
ON
1/G-8/G
ON
8/G
OFF
l
l
OFF
6/G
OFF
ON
7/G
ON
8/G
ON
ON
7/G
ON
ON
7/G
8/F
ON
ON
l
l
OR
OR
AGGIORNAMENTO
0 1
l
OR
OR
OR
OR
Pag. 18c
SERVICE
ELECTRICAL SYSTEM
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 19
SERVICE
4.0 PARAMETERS TABLE

MODULE 2 AC2 TRACTION
The values of certain levels programmed in the PARAMETER CHANGE main menu are displayed in
different ways depending on how the PERFORMANCE TYPE parameter in the config. menu SET
OPTIONS is set on the SICOS display module.
PERFORMANCE TYPE can be set in four different modes by means of the console (see following
on the display (see description):
numbers) or directly by means of the button
0) SLOW = Cutback speed 1 activation
1) SOFT = Reduction of parameters ACCELERATION DELAY, RELEASE BRAKING,
INVERSION BRAKING and MAX SPEED by one level.
2) STDN = Parameters programmed from the console
3) HARD = Increase of parameters ACCELERATION DELAY, RELEASE BRAKING,
INVERSION BRAKING and MAX SPEED by one level.
NOTE: In order to change the value of the parameters in the PARAMETER CHANGE of the AC2
traction inverter you must have the parameter PERFORMANCE TYPE of the SICOS 2 (the display
must indicate the letters STDN).
Page: 20
SET OPTIONS
ADJUST
RUNNING
ON
ON
Brake
Digital
HOUR COUNTER
BATTERY CHECK
STOP ON RAMP
AUX OUTPUT
PEDAL BRAKING
SET BATTERY TYPE
ADJUST BATTERY
ADJUSTMENT # 1
ADJUSTMENT # 2
PARAMETER CHANGE
CONFIG MENU'
MODULE (DISPLAY) PARAMETERS AC2 TRACTION
MAIN MENU'
ELECTRICAL SYSTEM
ACCELER. DELAY
RELEASE BRAKING
INVERS. BRAKING
PEDAL BRAKING
MAX SPEED FORW .
MAX SPEED BACK
CURVE CUTBACK
STEER DEAD ANGLE
FREQUENCY CREEP
MAXIMUN CURRENT
AUXILIARY TIME
Part No.: 524159096
KEYON
OFF
OFF
Analog
48V
51,6V
LEVEL 3
LEVEL 5
1
7
8
9
105 Hz
105 Hz
44%
6%
1,20 Hz
7
1.5
Date: Mar. 2002
Max
Max
Max
Max
Min 95Hz Min 95Hz -
= 9
= 9
= 9
= 9
Mx 114Hz
Mx 114Hz
Max = 9
Min 0sec - Max 5sec
UPDATE
SERVICE
ELECTRICAL SYSTEM
4.1 PARAMETER TABLES

MODULE 5 AC2 PUMP
SET OPTIONS
ADJUST
HO UR CO UNTE R
RUNNING
S E T B A TTE RY TY P E
KE YON
48V
A DJUS T B A TTE RY
PARAMETER CHANGE
MAIN MENU'
CONFIG MENU'
M O DULE (DIS P L AY) P ARAM ET ERS AC2 P UM P
51,6V
M A XIM UN CURRE NT
M ax 9

MODULO 6 EPS-AC
UPDATE
SET OPTIONS
HOUR COUNTE R
ADJUST
SET
SET
SET
SET
PARAMETER CHANGE
MAIN MENU'
CONFIG MENU'
M ODULE (DIS P LA Y ) P A RA M E TE RS E P S -A C S TE E RING
S P E E D LIM IT
A UX FUNCTION 3
7
5
M ax = 9
M ax = 9
S E NS IB ILITY
M ax = 9
5
5
2
2
40%
M ax = 9
M ax = 9
M ax = 9
M ax = 9
M in 0% M ax 70%
RUNNING
A UTO IM P UT A CTIV E
RA NGE 360
1
ON
OFF
5.000V
2,5V
7,2V
10.0V
S TE E R 0-P OS .
M IN. E NCODE R
M A X E NCODE R
180 E NCODE R
A UX FUNCTION 2
CRE E P S P E E D
COM P E NS A TION
A UXILIA RY TIM E
A NTIROLLB A CK
K E Y ON
Date: Mar. 2002
Part No.: 524159096
Page: 21
SERVICE

MHYRIO MODULE 9
#
#
#
#
#
#
#
#
2
2
2
2
1
1
1
1
ADJUST
SET OPTIONS
OP TION
OP TION
OP TION
OP TION
OP TION
OP TION
OP TION
OP TION
48V
E V 2 TY P E
E V 1 TY P E
E V 3 TY P E
E V 4 TY P E
E V 5TY P E
E V 6 TY P E
E V 7 TY P E
E V 8 TY P E
S E T B A TTE RY TY P E
Not available
Not available
PARAMETER CHANGE
MAIN MENU'
CONFIG MENU'
M ODULE (DIS P LAY) P ARAM ETERS M HYRIO
Not available
Not available
4.4 SICOS MODULE 16

PARAMETERS TABLE
Page: 22
SET OPTIONS
PARAMETER CHANGE ADJUST
CONFIG MENU
S ICOS M ODULE (DIS P LA Y ) P A RA M E TE RS
MAIN MENU
ELECTRICAL SYSTEM
P E RFORM A NCE TY P E
HOUR COUNTE R
E NCODE R TY P E
LOA D S E NS OR
P RE -HE IGHT S E LE CTOR
P A S S W ORD
A UX FUNCTION 1
OP TIONA L 1-2 HY D
A UTOM A TIC W E IGHT
0
RUNNING
0
ON
ON
ON
ON
ON
ON
K E Y ON
1
OFF
OFF
OFF
OFF
OFF
OFF
E NCODE R A DJUS TM E NT
127
M in 1 M ax 255
Not available
Part No.: 524159096
Not available
Date: Mar. 2002
UPDATE
SERVICE
4.4.1
Section: ELECTRIC SYSTEM
MODULE 16 SICOS PARAMETER TABLE
SET OPTIONS
MODULE 16 "SICOS"
PARAMETER
PERFORMANCE TYPE
HOUR COUNTER
ENCODER TYPE
AUX INPUT 1
PRE-HEIGHT SELECTOR
PASSWORD
AUX FUNCTION
OPTIONAL 1-2 HYD
AUTOMATIC WEIGHT
ENCODER ADJUSTMENT
ADJ 2000 KG POIN
ADJ 1500 KG POIN
ADJ 1000 KG POIN
ADJ 0 KG POIN
PARAMETER CHANGE
MAIN MENU
ADJUST
CONFIG MENU
Not available
ELECTRIC
This table does not substitute the previous one, but it is an integral part of it.
The update refers to the weighing function enabling
The update begins from the serial number of Module 16 SICOS P/N 300206213
PARAMETERS
LEVEL
0
1-2-3
RUNNING
KEY ON
0
1
0
1-2
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
127
Min. 1 Max 255
2000 Kg value to be stored
Not available
UPDATES TO BE INSERTED IN THE SERVICE MANUAL MR1.4/2.5

SECTION "ELECTRIC SYSTEM"
Release
Update description
1
4.4.1 New Module 16 "SICOS" parameter table
4.5.1 New Modul 1 "CAN I/O" parameter table
2
UPDATE
0 1
2 3
Page
22
23
5 6 Date: March 2004 Comp. No.:524159096 Page: 22a
SERVICE
ELECTRIC
Page: 22b Comp. No.:524159096 Date: March 2004 0
3 4
5 6
UPDATE
SERVICE
ELECTRICAL SYSTEM

CAN I/O MODULE 1
SET OPTIONS
0
RUNNING
ON
ON
ON
ON
ON
ON
ON
1
KEYON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
THROTTLE 0 ZONE
0%
Max 17%
THROTTLE X ZONE
THROTTLE Y ZONE
45%
Min 18% Max 100%
47%
Min 4% Max 100%
CUTBACK SPEED 1
CUTBACK SPEED 2
1 ST SPEED COARSE
2 ST SPEED COARSE
3 ST SPEED COARSE
4 ST SPEED COARSE
5 ST SPEED COARSE
PUMP CREEP # 1
PUMP CREEP # 2-3
PUMP CREEP # 4
PUMP CREEP # 5
LIFT SPEDD CTB
LOW SPEED CTB
SPEED 2 CUTBACK
PUMP ACC. # 1
PUMP ACC. # 2-3
PUMP ACC. # 4-5
PUMP DEC DELAY
PU DEC DEL # 2-3
ADJUST # 2
PRE-H. LIFT CTB
PRE-H. LOW CTB
OPTION 03
OPTION 04
OPTION 05
OPTION 06
3
3
9
6
7
6
6%
0
0
0
0
8
8
3
0
3
2
1
5
4
5
5
5
5
5
5
ADJUST
MAIN MENU'
UPDATE
CHECK UP TYPE
HOUR COUNTER
BATTERY CHECK
CHECK UP DONE
SEAT SWITC
SINGLE FUNCTION
AUX FUNCTION 1
AUX FUNCTION 2
AUX FUNCTION 3
PARAMETER CHANGE
CONFIG MENU'
MODULE (DISPLAY) PARAMETERS CAN I/O
Date: Mar. 2002
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
Max
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
Part No.: 524159096
Page: 23
SERVICE
MODULE CAN I/O PARAMETER TABLE
SET OPTIONS
MODULE 1 "CAN I/O" PARAMETERS

LEVEL
PARAMETER
CHECK UP TYPE
HOUR COUNTER
BATTERY CHECK
CHECK UP DONE
SEAT SWITCH
SINGLE FUNCTION
AUX FUNCTION 1
AUX FUNCTION 2
AUX FUNCTION 3
SPEED LIMIT
PARAMETER CHANGE
ADJUSTMENT
CONFIG MENU
This table does not substitute the previous one, but it an integral part of it.
The updates concern the possibility of disabling the reduction speed function with the carriage completely
extended.
The update begins from the serial number of Module 1 CAN I/O P/N 300208628
MAIN MENU
ELECTRIC
4.5.1
Not available
CUTBACK SPEED 1
CUTBACK SPEED 2
1ST SPEED COARSE
2ND SPEED COARSE
3RD SPEED COARSE
4TH SPEED COARSE
5TH SPEED COARSE
PUMP CREEP # 1
PUMP CREEP # 2-3
PUMP CREEP # 4
PUMP CREEP # 5
LIFT SPEED CTB
LOW SPEED CTB
SPEED 2 COT BACK
PUMP ACC # 1
PUMP ACC # 2-3
PUMP ACC # 4-5
PUMP DEC DELAY
PUMP DEC # 2-3
ADJUST # 1
PRE-H. LIFT CTB
PRE-H. LOW CTB
OPTION 03
OPTION 04
OPTION 05
OPTION 06
3
3
9
6
7
6
6
0
0
0
0
8
8
3
0
3
2
1
5
4
3
3
5
7
5
5
Page: 23a Comp. No.:524159096 Date: March 2004 0
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
Min = 0 Max = 9
3 4
5 6
UPDATE
SERVICE
ELECTRIC
UPDATE
0 1
2 3
5 6 Date: March 2004 Comp. No.:524159096 Page: 23b
SERVICE
ELECTRICAL SYSTEM
5.0 ACCESS PROCEDURE FOR CALIBRATION OF THE VARIOUS MODULES

MODEL ALL MODELS
MODULES CAN BUS

CONNECTION DIAGRAM
Fig. 6
Each module (controller) is identified by a number. Thanks to the CAN BUS connection you can access
programming of each module by means of the SET MODEL MENU, using the console to connect to any
module by typing the relevant address.
When a module assumes alarm status it inhibits all the other module by means of a signal transmitted
on the CAN BUS. The display shows a description of the alarm and an indication of the module concerned.
The most accessible module on the reach truck for connection of the programming console is the EPS
which is accommodated behind the seat. To access this module simply move the seat forward and
remove the EPS connector cover working through the opening in the truck body panel (Ref. A Fig. 9); now
insert the console connector. For the access procedure to find the module required, refer to the sequence
of operations described on the next page.
NOTE: Before connecting the console
to the module, set the keyswitch
to OFF.
Fig. 8
Fig. 7
Page: 24
Part No.: 524159096
Date: Mar. 2002
Fig. 9
5
UPDATE
SERVICE
ELECTRICAL SYSTEM
5.1 MODULE SEARCH PROCEDURE

MODEL ALL MODELS
CONFIG. MENU / SET MODEL
EPS-AC
NA 0.15
48V 300 A
0000
DISPLAY
1)
Initial display
2)
Press ROLLUP+SETUP simultaneously
3)
The heading of the SET MODEL menu is displayed
4)
Press ENTER
5)
A number is displayed corresponding to the connected

module
6)
Use SET UP or SET DOWN to select a different

connected module
7)
The newly selected module is displayed
8)
Press OUT to quit the selection procedure
9)
A prompt asking you to confirm the change is displayed
KEYPAD
CONFIG MENU
SET MODEL
CONNECTED TO
1
CONNECTED TO
5
ARE YOU SURE?

YES=ENTER NO=OUT
10) Press ENTER to confirm or OUT to cancel the change

11) The heading of the SET MODEL menu is displayed
CONFIG MENU
SET MODEL
12) Press ROLL DOWN, ENTER, and SET DOWN

simultaneously
13) The display will show the screen relative to the
selected module from which you can view/edit all the
associated menus
AC2P 2B NA 0.21
48V
300 A 0000
Fig. 10
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Date: Mar. 2002
Part No.: 524159096
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SERVICE
ELECTRICAL SYSTEM
5.2 AC2 TRACTION INVERTER BATTERY VOLTAGE SETTING

MODEL ALL MODELS
Before handing over the truck to the end customer, it is indispensable to set the battery voltage on the AC2
Traction inverter and on the AC2 Pump inverter.
Before making these settings it is advisable to execute a supplementary charge of the truck battery to
ensure that it is able to deliver the maximum voltage.
With the truck switched off connect the programming console to the EPS-AC module (see procedure
on page 17) and execute the procedure for selection of the AC2 Traction inverter module 2 (see
procedure on page 18); now select MAIN - MENU - ADJUSTMENT and select the ADJUST
BATTERY parameter.
Use a tester to check the exact battery voltage on the AC2 Traction inverter between -Batt. (negative
power connection to the inverter) and the positive as present on pin 1 of connector F keyswitch input (Fig.
11); this value must be entered in the ADJUST BATTERY parameter.
Select AC2 Pump inverter module 5 and set the same value in the ADJUST BATTERY parameter
of the main menu ADJUSTMENT. Switch off the keyswitch and then power on again to store the new
settings.
If when the truck is switched on with the battery fully charged the display should indicate a battery charge
of 90%, increase the value of the ADJUSTMENTS # 1 parameter in the CONFIG MENU.
This setting is indispensable to obtain the correct battery charge reading on the display.
AC2 TRACTION INVERTER
Fig. 11
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Part No.: 524159096
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SERVICE
6.0 TRACTION START SEQUENCE

MODEL ALL MODELS
When you board the truck, before starting observe the sequence described
below.
6.1 TRUCK WITH TRAVEL DIRECTION REVERSAL PEDAL

CONTROL
1) Set the keyswitch to ON and activate the main circuit breaker.
2) Press the deadman button (SW3 Fig. 15).
3) Select forward or reverse travel buy pressing the relevant button
(SW12 or SW13 Fig. 15).
4) Press the accelerator.
NOTE: If this sequence is not executed, the alarm INCORRECT START
will appear on the display.
If you release the deadman control the truck hydraulic functions will
remain enabled for 1 minute. At the end of the function the
INCORRECT START alarm will be shown on the display.
Fig. 12
SW13
SW12
SW3
6.2 TRUCK WITH TRAVEL DIRECTION REVERSAL CONTROL

ON THE INSTRUMENT PANEL
Fig. 15

3) Select forward or reverse travel by pressing the relevant button
(SW25 or SW26 Fig. 19-21).
4) Press the accelerator.
NOTE : If this sequence of operations is not observed the INCORRECT
START alarm will appear on the display.
If the deadman control is released the truck hydraulic functions will
remain enabled for 1 minute. At the end of the function the
INCORRECT START alarm will appear on the display.
SW26
Fig. 13
SW25
SW3
Fig. 20
Fig. 21
SW26
Fig. 19
Fig. 14
SW25
Fig. 17
Fig. 18
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Date: Mar. 2002
Fig. 16
Part No.: 524159096
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ELECTRICAL SYSTEM
SERVICE
ELECTRICAL SYSTEM
6.3 HYDRAULIC FUNCTIONS START SEQUENCE

MODEL ALL MODELS
For the hydraulic functions perform the following sequence:
3) Select the required hydraulic function (depending on the group of joysticks installed on the truck
(Fig. 24)
NOTE: If you release the deadman control the hydraulic functions will remain enabled for 1 minute, after
which the INCORRECT START alarm will be shown on the display.
1 JOYSTICK
4 JOYSTICKS
2 JOYSTICKS
Fig. 24
SW3
Fig. 22
Fig. 23
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Part No.: 524159096
Date: Mar. 2002
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SERVICE
This heading describes all the speed cutback options available on the truck.
7.1 BATTERY TROLLEY OUT OF POSITION (BATTERY EXTRACTED

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

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

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

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

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

In these circumstances with the reach carriage fully extended the truck travels with a speed reduction
corresponding to 50% of the maximum available current.
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Date: Mar. 2002
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ELECTRICAL SYSTEM
7.0 SPEED CUTBACK
SERVICE
The following headings contain a description of the procedure for replacing each individual module in such
a way that at the end of the operation the truck operates in exactly the same way as with the original
modules.
Note: Ensure you perform this procedure without skipping any of the steps in the sequence.
Incorrect operations could damage the new module.
Before replacing any of the modules check the table of settings relative to the module as shown in the
manual and compare them with the parameters stored on the module in the PARAMETER CHANGE and
SET OPTIONS submenus. The values could be different depending on the options enabled.
At the end of the replacement operation always check that the new module is programmed in exactly the
same way as the original module.
8.1 REPLACING MODULES 2 OR 5 - TRACTION OR PUMP INVERTER AC2

Before starting the replacement procedure save the controller settings on the console by means of the
SAVE PARAMETERS submenu present in the MAIN MENU (for more details refer to the AC MOTORS
MODULAR CONTROL SYSTEM manual).
1) Switch off the keyswitch an press the emergency pushbutton.
2) Disconnect the battery.
3) Only when the battery is disconnected: connect a resistor of between 33 and 100 Ohm 50W across
the inverter positive B+ and negative B-. Wait for approximately 8 seconds while for the controller
internal capacitors to discharge and then disconnect the resistor.
Note: To avoid short-circuits ensure that the resistor is insulated.
If it is impractical to use an external resistor to discharge the capacitors you must wait at least 90
seconds before disconnecting any of the power cables.
60 Ohm 50W
RESISTOR
ELECTRICAL SYSTEM
8.0 MODULES REPLACEMENT PROCEDURE
1234
1234
1234
1234
1234
1234
1234
1234
Fig. 26
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Part No.: 524159096
Date: Mar. 2002
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SERVICE
4) Disconnect the power cables, ensuring that they are still marked in relation to the corresponding
connectors; if the cables are not marked, mark them before disconnecting.
5) Disconnect auxiliary connectors C,D,F. In the case of the PUMP inverter, remember to disconnect the
jumper on connector B to apply it to the new controller. Without this jumper the system is unable to
operate. This jumper is not present on the TRACTION inverter.
BATTERY CABLES
TRACTION MOTOR
POWER CABLES
D2
A2
B2 C2
F2
E2
Fig. 27
BATTERY CABLES
PUMP MOTOR
POWER CABLES
D5
A5
B5 C5
F5
E5
Fig. 28
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Date: Mar. 2002
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ELECTRICAL SYSTEM
SERVICE
ELECTRICAL SYSTEM
6)
Unscrew the screws that secure the controller to the truck and remove the inverter.
7)
Install the new module fitting the screws, connectors and cables in accordance with a reverse
sequence of operations with respect to the removal procedure. Remember that connector B of the
PUMP inverter must be equipped with a jumper.
8)
Connect the console to the inverter
9)
After having checked the correct connection of the cables, connect the battery, reset the emergency
switch and set the keyswitch to ON.
10) By means of the RESTORE PARAMETERS submenu in the MAIN MENU, download to the controller
the module settings previously saved to the console by means of the SAVE PARAMETERS
procedure.
11) With the assistance of the table in the manual check that all the PARAMETER CHANGE and SET
OPTIONS submenu settings correspond.
12) Test all the truck functions.
8.2 REPLACING MODULE 1 - CAN I/O

Note: the CAN I/O module is identical in terms of size, shape, and connector positions, to the MHYRIO
module. Therefore, when replacing this module pay special attention to the identification label on the
outer case.
The truck duty hours are stored on the CAN I/O and SICOS (display) modules. If it should become
necessary to renew the CAN I/O module you must first execute a procedure that makes it possible to
transfer the duty hours value stored in the display to the new CAN I/O module.
1) With the keyswitch set to OFF connect the console to the SICOS module (display). Set the keyswitch
to ON.
2) In the CONFIG MENU>SET OPTIONS submenu set the AUX FUNCTION 1>parameter to OFF.
This allows the CAN I/O module to set up to receive the truck duty hour data stored on the DISPLAY.
Before starting the replacement procedure remember to save the controller settings to the console by
means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to
the AC MOTORS MODULAR CONTROL SYSTEM manual).
3) Switch off the keyswitch and press the emergency pushbutton.
4) Disconnect the battery.
5) Disconnect all the connectors after checking that their positions are clearly identified.
6) Unscrew the screws that secure the module to the truck and remove the module.
7) Install the new module, fitting the screws and connectors by following the removal steps in reverse
order.
8) After having checked that the connectors are correctly inserted, connect the console to the CAN I/O
module by means of the adapter that you removed from the faulty module and then inserted on the
relative connector of the new CAN I/O module.
9) Connect the battery, reset the emergency pushbutton and set the keyswitch to ON.
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Part No.: 524159096
Date: Mar. 2002
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SERVICE
10) With the console, via the RESTORE PARAMETERS submenu present in the MAIN MENU upload
to the controller the settings of the module previously saved on the console by means of the SAVE
PARAMETERS procedure.
11) Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE
and SET OPTIONS submenus correspond, including any option settings.
8.3 REPLACING SICOS MODULE 16 (display)

The truck duty hours are stored on the SICOS module and CAN I/O bus. If you need to replace the
SICOS module you must perform a procedure that makes it possible to transfer the duty hours memorized
on the CAN I/O to the SICOS.
1)
With the keyswitch set to OFF connect the console to the SICOS module. Set the keyswitch to ON.
2)
In CONFIG MENU>SET OPTIONS set the parameter AUX FUNCTION 1>to OFF.
In this manner the SICOS module sets up to accept the truck operating hours stored on the CAN I/
O bus.
3)
Switch off the keyswitch and press the emergency pushbutton.
4)
Disconnect the battery.
5)
Disconnect all the connectors after checking that their positions are clearly identified.
6)
Unscrew the screws that secure the module to the truck and remove the module.
7)
Install the new module, fitting the screws and connectors by following the removal steps in reverse
order.
8)
After having checked that the connectors are correctly inserted, connect the console to the SICOS
relative connector of the new SICOS module.
9)
Connect the battery, reset the emergency pushbutton and set the keyswitch to ON.
10) Using the console, by means of the RESTORE PARAMETERS submenu located in the MAIN
MENU, download to the controller the settings of the original module saved on the console by means
of the SAVE PARAMETERS procedure.
11) With the assistance of the table in the manual check that all the adjustments relative to the
PARAMETER CHANGE and SET OPTIONS submenus correspond, including possible changes
relative to the option settings.
Note: If the options PASSWORD or PRE-HEIGHT SELECTOR were enabled on the previous
display, these functions must be completely reset by means of the new display (see relative
heading).
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Date: Mar. 2002
Part No.: 524159096
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ELECTRICAL SYSTEM
SERVICE
ELECTRICAL SYSTEM
8.4 REPLACING MODULE 9 - MHYRIO

1)
Set the keyswitch to OFF and press the emergency pushbutton.
2)
3)
4)
Unscrew the screws that secure the controller to the truck and remove the module.
5)
order.
6)
After having checked that the connectors are correctly inserted, connect the console to the MHYRIO
relative connector of the new MHYRIO module.
7)
Connect the battery, activate the emergency switch and set the keyswitch to ON.
8)
With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU,
download to the controller the module settings previously saved to the console by means of the SAVE
9)
Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE
8.5 REPLACING MODULE 6 - EPS-AC

1)
Set the keyswitch to OFF and press the emergency pushbutton.
2)
3)
4)
Unscrew the screws that secure the controller to the truck and remove the module.
5)
order.
6)
After having checked that the connectors are correctly inserted, connect the console to the EPS-AC
relative connector of the new EPS-AC module.
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Part No.: 524159096
Date: Mar. 2002
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SERVICE
7)
Connect the battery, activate the emergency switch and set the keyswitch to ON.
8)
With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU,
download to the controller the module settings previously saved to the console by means of theSAVE
9)
Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE
10) Perform the most appropriate EPS-AC setup procedure depending whether or not the 360 steering
or +90 -90 steering option is enabled (see EPS-AC manual).
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
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ELECTRICAL SYSTEM
SERVICE
ELECTRICAL SYSTEM
9.0 SICOS (DISPLAY)

9.1 GENERAL DESCRIPTION OF CONTROL COMPONENTS AND INSTRUMENTS
The following section contains a description of the controls indicated on the display, the position of the
controls, and their method of use.
1
17
100
50
20
14
16
S
OP
F
T
13
Kmh
12
11
15
00 01
10
9
Fig. 29
9.2 TABLE OF DISPLAY SYMBOLS WITH DESCRIPTIONS

Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Page: 36
Description
Auxiliary hydraulic function (5th function) selector button
Traction permissive selection button with battery out
Parking brake function selector button
Traction mode selector button
LCD screen
Numerical keypad for altimeter / pre-height selector settings (when installed)
ENTER' key to use during reading of the various display menus
UP and DOWN keys to use during reading of the display menus
Out key to use during reading of the display menus
Indicator for truck speed, hour meter, forks height, alarms on module
Travel direction and drive wheel rotation indicator
Hour meter running indicator
Parking brake indicator
Battery charge status indicator
Selected hydraulic function indicator
Speed cutback indicator
Selected traction functional mode indicator
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Provides a proportional reading of battery charge status. The AC2 traction inverter reads the battery voltage
and transmits the information to the display. Battery charge status is shown on the display by means of
ten lines, each of which corresponds to 10%. When the battery charge falls to 30%, the corresponding
three lines start flashing. At this point it is advisable to charge the battery. When battery charge reaches
20%, Traction inverter AC2 transmits a message to the display to give a 20% charge reading, and another
message to the AC2 pump controller instructing it to inhibit the lift function, leaving only the reach carriage
operational. Furthermore, the available traction current is reduced by 50% (this precaution serves to allow
the truck to proceed to the charging station) (Fig. 30).
NOTE: The battery charge indicator can operate correctly only if the ADJUST BATTERY procedure has
been performed correctly prior to delivery of the truck (see the section of the manual regarding the
electrical system).
100
Battery
charge
indicator
50
20
S
O
F
T
Kmh
00 01
Fig. 30
9.4 SPEED CUTBACK INDICATOR

This indicator is activated when SLOW traction mode is selected (Fig. 31) pressing the button with
, (the display presents the same symbol). Or when the following speed reduction
the symbol
speed states are tripped:
- Reach carriage extended (50% current supplied to traction motor, not adjustable).
- Forks height above free lift height (SW5 mast sensor connected to MHYRIO unit; speed cutback
intensity is adjustable by means of CUTBACK SPEED 2 in CAN I/O).
Speed
cutback
selector
button
100
50
Speed
cutback
indicator
20
S
O
F
T
P
Kmh
00 01
Fig. 31
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Date: Mar. 2002
Part No.: 524159096
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ELECTRICAL SYSTEM
9.3 BATTERY CHARGE STATUS INDICATOR
SERVICE
ELECTRICAL SYSTEM
9.5 TRAVEL DIRECTION AND DRIVE WHEEL ROTATION INDICATOR

This indicator performs the following three functions: indication of truck forward travel direction, reverse
travel direction and drive wheel rotation (in 45 steps).
The drive wheel angular position and truck travel direction are shown by the arrow positioned inside the
truck logo.
When the truck is in use the arrow illuminates in accordance with the forward/reverse travel selector when
the operator presses the accelerator pedal. The arrow shows the travel direction of the truck with respect
to the seated operator; the right hand arrow illuminates when the truck proceeds in reverse, while the left
hand arrow indicates that the truck is travelling forward (Fig. 32)
100
50
20
S
O
F
T
Kmh
00 01
Travel direction
and drive wheel
rotation
indicator
Fig. 32
9.6 SELECTED HYDRAULIC FUNCTION INDICATOR

An arrow on the display indicates the type of hydraulic movement being performed: reach carriage extend/
retract, lift/lower, tilt back/forward (Fig. 33).
100
50
20
Page: 38
S
OP
F
T
Part No.: 524159096
Kmh
Selected
hydraulic
function
indicator
Fig. 33
00 01
Date: Mar. 2002
UPDATE
SERVICE
Indicates the traction mode selected by means of the relevant pushbutton

; this function allows
the operator to personalize truck traction functions without requiring the intervention of a skilled
technician.
There are four different preset levels that are shown on the display:
SLOW / STND / SOFT / HARD
SLOW - Maximum speed settable by means of the console connected to the CAN I/O module,
edit the CUTBACK SPEED 1 parameter.
STND - The acceleration, release braking, and top speed parameters
programmed in the AC2 Traction Inverter module are applied.
SOFT - The acceleration, release braking, and top speed functions are executed at a level below
the levels programmed in the AC2 Traction Inverter module 2.
HARD - The acceleration, braking, release braking, and top speed functions are executed at
a level above the levels programmed in AC2 Traction Inverter module 2 (Fig. 34).
100
50
20
S
O
F
T
Kmh
00 01
Selected traction
mode indicator
Fig. 34
9.8 HOUR METER RUNNING INDICATOR

Flashes during execution of any of the truck functions, thereby indicating that the hour meter is running
(Fig. 35).
100
50
20
S
O
F
T
Kmh
00 01
Hour meter
running
indicator
UPDATE
Date: Mar. 2002
Fig. 35
Part No.: 524159096
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ELECTRICAL SYSTEM
9.7 SELECTED TRACTION OPERATING MODE INDICATOR
SERVICE
ELECTRICAL SYSTEM
9.9 INDICATOR FOR TRUCK SPEED, TRUCK HOUR METER, FORKS HEIGHT,
MODULE ALARM
HOUR METER / SPEEDOMETER
For two seconds after the truck is switched on this meter indicates the total truck duty hours, reading the
value stored on the CAN I/O module; the indication is subsequently replaced by a display of the truck speed.
To display the truck duty hours without turning off the keyswitch press the ENTER key to access the main
menu and then the OUT key to exit. This action will generate a two-second display of truck duty hours.
NOTE:When the SICOS or CAN I/O module is replaced the truck duty hours can be retained (see
below).
PROCEDURE FOR RETAINING DUTY HOURS WHEN RENEWING THE CAN I/O MODULE
Before renewing the CAN I/O module use the console to check that AUX FUNCTION 1 in SICOS is set to
OFF, and then change the CAN I/O module by following the directions on page 30. When the truck is
switched on the RESET HOUR METER alarm is displayed. After 1 minute the alarm message will be
cleared and the duty hours memorized in SICOS will be transferred to the CAN I/O module and shown on
the display.
PROCEDURE FOR RETAINING DUTY HOURS WHEN RENEWING THE SICOS MODULE
Change the SICOS module in accordance with the directions on page 31. When the truck is switched on
the RESET HOUR METER alarm will be displayed; at this point you have one minute to connect the console
to the SICOS module and change AUX FUNCTION 1 from OFF to ON. This done, the RESET HOUR
METER alarm will be cleared and the duty hours memorized on the CAN I/O module will be shown on the
display. We recommend resetting AUX FUNCTION 1 in SICOS from ON to OFF (default value) when the
operation is terminated.
SPEED/MODULE ALARM
If an alarm is generated, the relevant name and the module on which the alarm is present will be shown
in place of the truck speed display. To perform additional diagnostics the programming console must be
connected to the faulty module.
SPEED/FORKS HEIGHT INDICATION
When a forks height indicator is installed with the relative correctly calibrated encoder, the height of the
forks is displayed in place of the truck speed (Fig. 36).
100
50
20
S
O
F
T
Fig. 36
Page: 40
Part No.: 524159096
Kmh
00 01
Indicator of truck speed,

hour meter, module alarm
forks height
Date: Mar. 2002
UPDATE
SERVICE
The parking brake must be applied by pressing the relevant button with the P symbol; at this point
the display will shown the letter P and all drive functions are inhibited, although the trucks hydraulic
functions remain active. When the button is pressed again the parking brake is released and truck
drive functions are re-enabled (Fig. 37).
ATTENTION The parking brake selector can be activated only when the keyswitch is set
to 1 (ON). Do not use the parking brake as a service brake during normal operation of the truck.
Parking brake
selector button
100
Parking brake
indicator
50
20
S
O
F
T
P
Kmh
00 01
Fig. 37
9.11 AUXILIARY HYDRAULIC FUNCTION SELECTION BUTTON (5th FUNCTION)

Enables an auxiliary hydraulic function (5th function). The function must be set initially with the programming
console connected to the SICOS module, selecting CONFIG MENU - SET OPTIONS, and subsequently
selecting the parameter OPTIONAL 1-2 HYDRAUL VALVE ON/OFF.
When level OFF is selected the pushbutton has no effect.
When level ON is selected the function is shown in place of the forks down indicator by means of an icon
representing a hydraulic gripper (Fig. 38).
Auxiliary
hydraulic
function
selection button
(5th function)
+
100
50
20
S
O
F
T
P
Kmh
00 01
Fig. 38
UPDATE
Date: Mar. 2002
The fork logo

changes and
is replaced
with a
hydraulic
gripper icon
Part No.: 524159096
Page: 41
ELECTRICAL SYSTEM
9.10 PARKING BRAKE SELECTOR BUTTON PARKING BRAKE INDICATOR
SERVICE
ELECTRICAL SYSTEM
9.12 TRACTION PERMISSIVE WITH BATTERY OUT FUNCTION SELECTOR BUTTON

This button serves to allow limited truck traction mobility in order to facilitate a battery change.
When, during loading and unloading of a battery to and from the battery change rollerway, it becomes
necessary to move the truck slightly backwards or forwards, the truck safety systems prevent the normal
travel controls from being used. In these circumstances, to move the truck the operator, seated at the
controls, must press the relevant permissive button and then press the accelerator pedal.
The resulting travel speed corresponds to 50% of the current available at Vmax. This value cannot be
adjusted by means of the console (Fig. 39).
ATTENTION This control must not be used during normal working procedures. Pressing
this button at any speed would result in intensive deceleration.
Traction with
battery out
permissive
function
selector button
+
100
50
20
S
O
F
T
Kmh
00 01
Fig. 39
10.0 DISPLAY MENU

10.1 MAIN MENU 1
Press the ENTER key to access the main menu 1 (Fig. 40). Pressing the ENTER key from a given position
of the cursor arrow opens the page relative to the selected option.
The MAIN MENU 1 submenus are described in the following headings.
main menu 1
TESTER SLAVES
ALARMS
PROGRAM OFFSET
INSERT PASWORD
Fig. 40
Page: 42
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
When you enter the TESTER menu you will be presented with the most important information relative to
the traction motor inverter and pump motor inverter status and the operating hours of the various modules
(Fig. 41). To go from tester screen 1 to tester screen 2 and then tester screen 3, press the DOWN ARROW
KEY (Fig. 41).
tester 1
CURRENT TRACTION
VOLTAGE TRACTION
FREQUENCY TRAC.
TEMPERATURE TR.
=
=
=
=
004 AMP.
009 %
000 HERZ
025 GRADI
tester 2
CURRENT PUMP
VOLTAGE PUMP
FREQUENCY PUMP
TEMPERATURE PU.
=
=
=
=
004 AMP.
009 %
000 HERZ
026 GRADI
tester 3
TR.HOUR COUNTER
PU. HOUR COUNTER
EPS HOUR COUNTER
EV HOUR COUNTER
=
=
=
=
00011
00006
00003
00129
Fig. 41
10.3 ALARMS MENU

When you open the ALARMS menu you will be presented with the last 5 alarms stored with the information
regarding the module concerned, the number of times the alarm has occurred, the temperature, and the
time of the alarm (Fig. 42). Press OUT to display the message CLEAR ALARMS, at this point press OUT
to leave the alarms in the memory, or press ENTER to erase them.
ALARMS
1)BATTERY OUT
2)HEIGHT ENC. ERROR
3)CAN BUS KO
4)BATTERY OUT
5)NULL
HOURS
NUM
NTC
0001
0003
0003
0003
01
04
01
01
17
29
29
27
MOD
1
1
2
1
Fig. 42
UPDATE
Date: Mar. 2002
Part No.: 524159096
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ELECTRICAL SYSTEM
10.2 TESTER MENU
SERVICE
ELECTRICAL SYSTEM
10.4 PROGRAM OFFSET

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

This submenu serves to input the password that provides access to use of the truck when this option is
programmed (see PROGRAM PASSWORD heading). If the option is not set, selecting this function will
automatically return you to the main menu.
10.6 MAIN MENU 2

In addition to MAIN MENU 1, there is a second menu designated MAIN MENU 2. This menu is concealed
from the operator and can be accessed by holding down the OUT key while setting the keyswitch to ON.
In this case MAIN MENU 1 will appear and MAIN MENU 2 can be accessed by means of the down arrow
key.
main menu 1
ENTER
TESTER SLAVES
ALARMS
PROGRAM OFFSET
INSERT PASWORD
main menu 2
DOWN
ARROW
PROGRAM BLOCK
PROGRAM PASSWORD
READ USERS
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Part No.: 524159096
Date: Mar. 2002
Fig. 44
0
UPDATE
SERVICE
By pressing the ENTER key with the cursor arrow positioned on a given option, you will automatically
open the page relative to the option in question.
The MAIN MENU 2 submenus are described in the following headings (Fig. 44).
10.7 PROGRAM BLOCK

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

3. Select the PROGRAM OFFSET menu with the down arrow / up arrow and check that the programmed
free lift value is correct.
4. Press the OUT key on the display twice in succession to return to the MAIN DISPLAY.
5. Lift the forks until you reach the desired height.
6. Press ENTER on the display to enter MAIN MENU 1.
7. Enter MAIN MENU 2 by pressing the DOWN ARROW key.
8. Press the ENTER key on the display to enter the PROGRAM BLOCK function.
autoteaching
HEIGHT VALUE = 04814
ENCODER VALUE = 05900
Fig. 46
9. Press the ENTER key on the display to save the value shown on the display; the message MEMO will
appear to confirm that the value has been effectively saved.
8. KEY OFF then KEY ON to save all settings (Fig. 45 - 46).
UPDATE
Date: Mar. 2002
Part No.: 524159096
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ELECTRICAL SYSTEM
SERVICE
ELECTRICAL SYSTEM
10.8 PASSWORD PROGRAM

The password program serves to set up to 5 passwords to allow the truck to be used by 5 different
operators.
To store the 5 passwords in this menu enable the PASSWORD function as described in the following
procedure.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Connect the programming console to the SICOS (module 16), see AC Motors Modular Control
System service manual (Programming Section).
KEY ON
With the console enter the SICOS CONFIG MENU/SET OPTIONS submenu.
Select the PASSWORD menu and set to ON to configure SICOS (Display) at the password function
press OUT and then ENTER on the console to save the setting.
KEY OFF, you can now disconnect the console from the SICOS module.
KEY ON pressing the OUT key.
Press ENTER on the display to enter MAIN MENU 1.
Enter MAIN MENU 2 using the DOWN ARROW key
Select PASSWORD PROGRAM with the UP ARROW key and then press ENTER on the display to
enter the program.
set password
PASS1 = 1986
PASS2 = 0000
PASS3 = 0000
PASS4 = 0000
PASS5 = 0000
Fig. 47
10. Select the password to be set using the DOWN ARROW and UP ARROW keys.
11. Press ENTER and set the password with the numerical keypad.
12. Press ENTER; the message MEMO will be displayed to confirm that the data have been saved. The
same procedure applies to all five passwords.
13. KEY OFF then KEY ON to save all your changes (Fig. 47).
From this time on in order to use the truck functions it is necessary to enter one of the preset passwords.
With the PASSWORD function enabled, when the truck is powered on the message ALARM ON MOD
16 PASSWORD NEEDED is displayed (Fig. 48).
100
50
20
S
O
F
T
ALARM ON MOD 16
PASSWORD NEEDED
Fig. 48
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Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
1. Press ENTER to enter MAIN MENU 1 of the main display.

2. Select INSERT PASSWORD with the DOWN ARROW and open the function by pressing ENTER
INSERT YOUR
PASSWORD !
1986
Fig. 49
3. Type the password on the numerical keypad.
4. Press ENTER to return to the main display; the truck functions will have been enabled (Fig. 49).
10.9 MENU READ USERS

By entering the READ USERS menu of MAIN MENU 2 It is possiple to visualize the work hours at the end
of each shift of each operator.
users logbook
USERS = 1986
HOURS = 0006
Fig. 50
NOTE:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 47
ELECTRICAL SYSTEM
To input the access password:
SERVICE
ELECTRICAL SYSTEM
11.0 PRE-HEIGHT SELECTOR

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

The pre-height selector gives the operator the opportunity to perform picking and put-away cycles on
shelves on 21 programmable levels (00-20) in a semi-automatic manner.
The various heights to perform these operations on various levels of shelving are programmed on the
display beforehand.
The programming procedures are described in the following headings.
When the pre-height selector function is selected, the operator must indicate whether he intends to
perform a put away (load) cycle or a picking (unload) cycle.
If the forks load sensor (load cell) is installed, the display provides an indication of forks with or without load
and the consequent put away or picking cycle is executed.
If the load indicator is not present, the put-away (load) or picking (unload) selection is performed manually
by the operator by means of the up arrow/down arrow keys shown on the display; the pre-height selector
informs the operator with regard to the hydraulic functions necessary to complete the mission. These
functions can be either lifting or lowering depending on the position of the forks at the time of the level
request.
Lifting hydraulic deceleration and stroke end cushioning are performed automatically.
There are two types of possible programming.
1) Consider automatic movements of the reach carriage.
2) Do not consider automatic movements of the reach carriage.
Both types of programming are illustrated below.
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Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
A) UNLOAD SEQUENCE - EXAMPLE STARTING FROM GROUND

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

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

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

5. Lowering - LOAD OFFSET value defined with the console in CANIO
PARAMETER CHANGE - OPTION 05 (see USING THE PRE-HEIGHT
SELECTOR)
4. Reach carriage extension.
3. Lifting end.
2. Deceleration phase - value defined with the console in CAN I/O PARAMETER CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see
USING THE PRE-HEIGHT SELECTOR
1. Lifting (sequence start) - height programmed on display plus DEPOSIT

OFFSET value (OPTION 5), see USING THE PRE-HEIGHT SELECTOR
heading
At point 5 this symbol is presented
on the display to indicate that a
lowering movement is required to
reach the selected level.
At point 1 this symbol is presented
on the display to indicate that a lift
movement is required to reach the
selected level.
PALLET
Fig. 53
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Date: Mar. 2002
Part No.: 524159096
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ELECTRICAL SYSTEM
11.3 OPERATION WITHOUT REACH CARRIAGE IN SEQUENCE
SERVICE
ELECTRICAL SYSTEM
11.4 OPERATION WITH REACH CARRIAGE IN SEQUENCE

C) UNLOAD SEQUENCE - EXAMPLE STARTING FROM GROUND
5. Lifting - UNLOADING OFFSET value defined with console in CANI/O PARAMETER CHANGE - OPTION 06 (see USING THE PRE-HEIGHT
SELECTOR)
6. Reach carriage retract (sequence end)
PALLET
3. Lifting end - height programmed by means of the display (see point 1).
4.Reach
carriage
extension.
2. Deceleration phase - value defined with console in CAN I/O - PARAMETER

CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see USING THE PREHEIGHT SELECTOR
1. Lifting (sequence start) - height programmed on display.
At point 6 this symbol is presented on the
display to indicate that the reach carriage
must be retracted.
At point 4 this symbol is presented on
the display to indicate that the reach
carriage must be extended.
At points 1 and 5 this symbol is
presented on the display to indicate that
a lift movement is required to reach the
selected level.
Fig. 54
D) LOAD SEQUENCE - EXAMPLE STARTING FROM GROUND

5. Lowering - LOAD OFFSET value defined with the console in CANIO
PARAMETER CHANGE - OPTION 05 (see USING THE PRE-HEIGHT
SELECTOR)
4. Reach carriage extension.
3. Lifting end.
6. Reach
carriage
retract
(sequence
end)
2. Deceleration phase - value defined with the console in CAN I/O PARAMETER CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see
USING THE PRE-HEIGHT SELECTOR
1. Lifting (sequence start) - height programmed on display plus DEPOSIT
OFFSET value (OPTION 5), see USING THE PRE-HEIGHT SELECTOR
heading
carriage must be retracted.
the display to indicate that a lowering
selected level.
carriage must be extended.
the display to indicate that a lift
selected level.
Fig. 55
PALLET
Page: 50
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Before programming the various values relative to the required heights remember to enable the pre-heights
selector function (trucks configured with the necessary components).
The enable procedure is as follows:
A) PRE-HEIGHT SELECTOR FUNCTION ENABLE WITHOUT REACH CARRIAGE IN SEQUENCE
1. Connect the programming console to the SICOS module 16, see AC Motors Modular Control System
service manual (Programming Section).
2. KEY ON.
3. With the console enter the CONFIG MENU/SET OPTIONS submenu.
4. Select the PRE-HEIGHT SELECTOR parameter and set to ON to configure SICOS (Display) at the
PRE-HEIGHT SELECTOR function; this done, press ENTER to save your settings.
5. KEY OFF to save all data; now the console can be disconnected from the SICOS module.
B) PRE-HEIGHT SELECTOR FUNCTION ENABLE WITH REACH CARRIAGE IN SEQUENCE
1. Connect the programming console to the CAN I/O module 1, see AC Motors Modular Control System
2. KEY ON.
3. With the console enter the CONFIG MENU/SET OPTIONS submenu.
4. Select the AUX FUNCTION 2 parameter and set to ON to configure CAN I/O at the PRE-HEIGHT
SELECTOR function; this done, press ENTER to save your settings.
5. KEY OFF to save all data; now the console can be disconnected from the CAN I/O module.
After having enabled the function there are two methods to program the pre-height selector, one
AUTOTEACHING (recommended) and the other in manual mode.
Before performing the programming procedure (in both AUTOTEACHING and manual mode) you will need
to check that the PROGRAM OFFSET value has been set correctly (see heading PROGRAM OFFSET
in MAIN MENU1, DISPLAY MENU).
11.6 PROGRAMMING IN AUTOTEACHING MODE (RECOMMENDED METHOD)

1. KEY ON, the MAIN DISPLAY appears (Fig. 56).
100
50
20
S
T
N
D
Mm
5025
Fig. 56
2. Lift the forks to the required height (the lowest programmable level must be higher than the value of
(PROGRAM OFFSET).
3. Type the number of the level to be programmed (e.g. 03) on the display numerical keypad.
The pre-height selector working screen is displayed (Fig. 57).
PRE-HEIGHT SEL
LEVEL NUMBER = 03
LOAD
PROGRAM = ENTER
UPDATE
Date: Mar. 2002
Fig. 57
Part No.: 524159096
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ELECTRICAL SYSTEM
11.5 PRE-HEIGHT SELECTOR ADJUSTMENT
SERVICE
ELECTRICAL SYSTEM
4. Press ENTER to enter the pre-height selector programming screen.

Autoteaching
LEVEL NUMBER = 03
Fig. 58
5. Press ENTER again to save the value acquired in AUTOTEACHING (value shown under the heading
ENCODER VALUE).
6. Press OUT to return to the pre-height selector working screen and the press OUT again to return to the
MAIN DISPLAY.
7. Programming of additional levels in AUTOTEACHING must always start from the MAIN DISPLAY with
manual lifting.
8. KEY OFF to save all your data (Fig. 58).
11.7 MANUAL PROGRAMMING FROM THE DISPLAY

1. KEY ON, the MAIN DISPLAY appears (Fig. 59).
+
100
50
20
S
O
F
T
Kmh
00 01
Fig. 59
2. Type the number of the level you wish to program (e.g. 03) with the display numerical keypad. The preheight selector working screen is displayed (Fig. 60).
PRE-HEIGHT SEL
LEVEL NUMBER = 03
HIEGHT VALUE = 00000
LOAD
PROGRAM = ENTER
Fig. 60
3. Press ENTER to enter the pre-height selector programming screen (Fig. 61).
Autoteaching
LEVEL NUMBER = 03
Fig. 61
4. Specify the desired height in millimetres using the numerical keypad next to the item HEIGHT VALUE
and then strike ENTER to save the value; use the UP ARROW and DOWN ARROW keys to move on
to programming of further levels. Press OUT OUT to return to the main display.
5. KEY OFF to save all your data.
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Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
From the main menu select the required level (e.g. 03) using the display numerical keypad.
If the forks load sensor is not installed, the pre-height selector working screen is displayed in LOAD mode
by default; if, however, the forks are empty and you intend execute an UNLOAD cycle, press the UP
ARROW or DOWN ARROW to set UNLOAD.
Function requested to follow the
programmed sequence
Screen heading
Selected level
PRE-HEIGHT SEL
LEVEL NUMBER = 03
LOAD
PROGRAM = ENTER
Level preset
height
Current forks
height
To go to the level
programming screen
UP ARROW
DOWN ARROW
Sequence to execute
LOAD/UNLOAD
Fig. 62
IMPORTANT: If the forks load sensor is not installed, the LOAD/UNLOAD sequence must be set correctly
before starting the sequence, otherwise there is a risk of damaging the shelving and/or the material stored
on the shelves.
ATTENTION: If the pre-height selector is set with the reach carriage movement option included, lift (or
lower) the forks with the reach carriage retracted, extend the carriage, pick up the load, and then retract
the carriage (sequence end).
The pre-height selector working display (above) shows, with the forks symbol, the inputs required to
complete each phase of the selected sequence; the operator must activate the appropriate joystick in
relation to the requested function and maintain the function enabled until it stops automatically on the preset
value. At this point the operator will be prompted for the next input required, and so forth until the end of the
sequence.
To modify (when necessary) the deceleration phase at the end of the lift/lower movement in such a way
as to reach the selected level compensating for inertia and ensuring that the forks stop at the programmed
height:
Connect the console to the CAN I/O module
1. Connect the programming console to the CAN I/O module, see AC Motors Modular Control System
2. KEY ON
3. With the console enter the MAIN MENU/PARAMETER CHANGE submenu
4. Select the parameter OPTION 03 to modify deceleration during upward movement (default value is 5)
Select the parameter OPTION 04 to modify deceleration during downward movement (default value 5)
Increase the value to increase the deceleration distance.
5. Press OUT and then ENTER on the console to save the new setting.
6. KEY OFF to save all your changes; you can now disconnect the console.
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Date: Mar. 2002
Part No.: 524159096
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ELECTRICAL SYSTEM
11.8 USING THE PRE-HEIGHT SELECTOR
SERVICE
ELECTRICAL SYSTEM
For reasons of headroom available above the load and the shelving, it may prove necessary to adjust the
lifting distance to lift the pallet from the shelf or the lowering distance to deposit the pallet on the shelf(LOAD
OFFSET and UNLOAD OFFSET) see operating examples in the headings OPERATION WITHOUT
REACH TRUCK and OPERATION WITH REACH TRUCK IN SEQUENCE.
To edit these values:
1. Connect the programming console to the CAN IOO module, see AC Motors Modular Control System
2. KEY ON
3. With the console enter the MAIN MENU/PARAMETER CHANGE submenu
4. Select the OPTION 05 parameter to modify the LOAD OFFSET (default value is 5)
Select parameter OPTION 06 to edit the UNLOAD OFFSET (default value 5)
Increasing the value of OPTION 05 corresponds to an increase in the loading stroke
Increasing the value of OPTION 06 corresponds to an increase in the unloading stroke
5. Press ENTER, followed by OUT and then ENTER again on the console to save the modified value.
6. KEY OFF to save all data; at this point the programming console can be disconnected from the SICOS
module.
12.0 ALARMS
All the alarms are shown on the display together with an indication of the module on which the fault has
occurred.
Connect the console to the most accessible module (Module 6 EPS-AC) and perform the procedure
indicated on page 23 in order to address the required module.
Every 200msec messages arrive from the MHYRIO, CAN I/O, PUMP,
TRACTION and EPS modules as they confirm their connected status.
CAN BUS KO:
If within this interval one of the modules should fail to transmit the message
to the DISPLAY, an alarm status results:
CAN BUS KO MHYRIO: the mhyrio module has not transmitted its message
CAN BUS KO CAN I/O: the can i/o module has not transmitted its message
CAN BUS KO PUMP: the pump module has not transmitted its message
CAN BUS KO TRACTION: the traction module has not transmitted its
message
CAN BUS KO EPS: the eps module has not transmitted its message
-Connect to the specified module to identify the alarm condition.
NO CAN MESAGE:
If no message reaches the display via the CAN BUS, the display
assumes alarm status.
Possible causes:
- Interrupted communication due to a missing connection - Restore the
connection.
- Faulty display - Renew the SICOS module 16
NOTE: CAN BUS alarms on the display assume priority with respect to all other alarms.
12.1 ALARMS CONCERNING THE DISPLAY

PASSWORD NEEDED
This alarm is generated when the truck access Passwords are

requested.
- Enter the access Password
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Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
EEPROM KO:
This alarm appears in the presence of a fault in the memory area in which
the setup parameters are stored; the EEPROM KO alarm inhibits operation
of the truck.
Set the keyswitch to OFF and then to ON again; if the alarm is cleared note
that the parameters stored previously have been erased and replaced by the
factory default parameters.
If the alarm persists - Renew the controller.
ENCODER RESET:
This alarm is generated when the truck is equipped with pre-height selector
and zero sensor.
When the keyswitch is set to ON the forks are above the zero level
Possible causes:
- Zero sensor faulty - Renew sensor
- Sensor not reading - Reduce the sensor gap for more positive reading
This alarm appears when the display hour meter count and the CAN I/O
count are different.
The differences are eliminated after 1 minute with the transfer of the hours
value from the display to the CAN I/O module.
Refer to the procedure for transferring the hours value from the display
module to the CAN I/O module and vice versa - page 38.
RESET HOUR METER:
13.0
DIAGNOSTICS
13.1 TROUBLESHOOTING GUIDE

The tables shown below are provided to complete the diagnostics section of the modules manual entitled
AC Motors Modular Control System.
For more rapid troubleshooting we recommend consulting both manuals.
NOTE:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 55
ELECTRICAL SYSTEM
Page: 56
Part No.: 524159096
Date: Mar. 2002
#NA ME?
Keysw itch
CA N-BUS
SW2
SW3
T.MTR
Traction motor
thermal ov erload
cutout
Operator presence
sensor
EMB
ENEC-MTR
Electromagnetic
brake
Permis sive f rom

electric steering
Traction motor
encoder f eedback
COM PONENT
SYM BOL
ON
DIAGRAM
1F
1C-4C
4F
6F, 12F
3F, 9F
3F, 9F
11F, 5F
3D, 5D
3D, 5D
3D, 5D
2D
1D
CONNECT.
the truck travels w ithout alarms until it
exceeds a speed of 2 km/h. A t this
point the traction f unction is inhibited
and the alarm is tripped
TRUCK REACTION
open
open
open c ircuit
s ensor output in short c ircuit

(+V bat f ixed)
s ensor output interrupted
open c ircuit
c oil or w ires short-circuited
c oil or w ires in open circuit
inputs open, negativ e

permis sive signal transmitted
by EPS-A C is missing
Check enc oder connections and

renew enc oder if neces sary
02 ENCODER ERROR
check pow er f uses and pow er

connection
TROUBLESHOOTING GUIDE
(AC2 TRACTION MODULE 2)
02 V MN LOW
alarm activ e if tripped at start-up. No

alarm if tripped during traction
check keys w itc h and relative

connections
check CA N-BUSS lines connections.

Renew the module if necess ary
16 NO CA N MESSA GE; 01 CA N BUS

KO EPS or 01 CA N BUS KO TR in the
c ase of intermittent connections
01 CA N BUS KO TR immediately; 05
CA N BUS KO later,
renew operator presenc e sensor (lef thand pedal)
renew operator presenc e sensor (lef thand pedal)
check thermal c utout connec tions and

general condition. A naly ze reasons
f or motor temperature rise
02 INCORRECT STA RT
02 INCORRECT STA RT only af ter

having pressed the acc elerator
02 MOTOR TEMPERA TURE
02 COIL SHORTED, if this f ault occurs

check elec tromagnetic brake
during trac tion; 02 INCORRECT STA RT
connection or renew the brake
if the f ault trips during s tartup
renew elec tromagnetic brake
06 MA IN CONT. OPEN, if occ urs

f ault to be f ound on elec tric s teering
during trac tion; 02 INCORRECT STA RT
sy stem. Check alarms on EPS-A C
during startup


ACTIONS REQUIRED
None
02 ENCODER ERROR
ALARM
no f unction. A larm activ e
f unctions blocked. A larm ac tive
f unctions blocked. A larm ac tive only

af ter having pressed the ac celerator
pedal
f unctions blocked. A larm ac tive w hen
keysw itch is s et to ON
alarm activ e
f unctions blocked and alarm activ e
no active alarms. Brake engaged. The

motor tends to run w ith braking applied
traction inhibited and alarm active
encoder phases A and B are the truck travels at reduced speed No

s horting
alarm displayed
the truck travels w ithout alarms until it
exceeds a speed of 2 km/h. A t this
the encoder phases are at point the traction f unction is inhibited
B
and the alarm is tripped
one of the w ires is not

c onnected
FAULT TYPE
AC2-TRACTION (MODULE 2)
ELECTRICAL SYSTEM
SERVICE
UPDATE
UPDATE
Date: Mar. 2002
#NAME?
Keysw itch
SW2
T.MS
Steering motor
thermal cutout
CAN-BUS
STEPPER
MOTOR
SW4
ECN-MS
Stepping motor
(steering
transducer)
Wheel centred
sensor
Steering motor
encoder feedback
COMPONENT
SYMBOL
ON
DIAGRAM
open
open
open circuit
3A, 4A,
13A, 14A
channels A/B open
common open
sensor output short-circuited
sensor output open circuit
open circuit
11B
TRUCK REACTION
16 NO CAN MESSAGE
06 MOTORE TEMPERATURE
06 D LINE SENSOR KO
06 NOT ALIGNED
06 MOTOR LOCKED
ALARM
check connection and general

condition of thermal cutout. Analyze
reasons for motor temperature rise
check CAN-BUS lines connection. If
necessary renew the module
check stepper motor connections.

Renew if necessary
check w heel centred sensor and

relative connections. Renew if
necessary
Check encoder connections and

renew encoder if necessary
ACTIONS REQUESTED
no function. Alarm active
Part No.: 524159096
Page: 57
ELECTRICAL SYSTEM
(EPS-AC TRACTION MODULE 6)
01 CAN BUS KO EPS starting to steer;

check keysw itch and relative
16 CAN BUS KO EPS at keysw itch
connections
pow er-on
alarm active if tripped at pow er up. No
check pow er fuse and pow er
06 POWER FAILURE #2
alarm if tripped during traction
connections
functions inhibited. Alarm active
traction speed reduction and alarm

active
the drive w heel steers clockw ise for 5

seconds and then the alarm trips and
the truck travels at reduced speed
Brief steering turn f ollow ed by

functions inhibit w ith alarm active
Brief steering turn f ollow ed by
B- open
encoder phases A and B are Brief steering turn f ollow ed by
short-circuited
+5V open
FAULT TYPE
11A, 7A
3B, 9B
4B
12B
16A, 17A
8A
6A
CONNECT.
EPS-AC (MODULE 6):
SERVICE
Page: 58
Part No.: 524159096
Date: Mar. 2002
#NAME?
Keyswitch
SW2
1F
1C-4C
CAN-BUS
open
open
open circuit
open
open
encoder phases are at -B
5D
6F, 12F
encoder phases A and B are

short-circuited
one of the wires is not

connected
FAULT TYPE
3D
1B, 2B
T.MP
ENC-MP
2D
1D
SYMBOL ON
CONNECT.
DIAGRAM
Pump inverter
configuration jumper
Thermal cutout
Pump motor encoder

feedback
COMPONENT
alarm active
alarm active
the pump rotates slowly without alarms

until the rotation speed increases. At this
point the functions are inhibited and the
alarm is tripped
TRUCK REACTION
AC2-PUMP (MODULE 5)
check for presence of jumper on

connector B.
check connection and general condition

of thermal cutout. Analyze reasons for
motor temperature rise
check encoder connections and renew

encoder if necessary
ACTIONS REQUIRED
05 VMN LOW
16 CAN BUS KO PU
(AC2 PUMP MODULE 5)
check power fuse and power connection
check keyswitch and relative connections
16 NO CAN MESSAGE; if connection is

intermittent or open during operation: 01 check CAN-BUS lines connection. If
CAN BUS KO EPS& 01 CAN BUS KO necessary, renew the module
TR
16 CAN BUS KO PU
05 MOTOR TEMPERATURE
05 ENCODER ERROR
ALARM
ELECTRICAL SYSTEM
SERVICE
UPDATE
UPDATE
Date: Mar. 2002
Reac h c arriage
bac k limit s ens or
Reac h c arriage
f orw ard limit s ens or
Lif ting s peed

reduc tion s ens or
Height
indic ator/trac tion
s peed c utbac k af ter
Height indic ator

enc oder
COM PONENT
SW8
SW7
SW6
SW5
ECN-HEIGHT
IND
SYM BOL
ON
DIAGRAM
3A
2A
1A
12A
4D, 2D
CUTBA CK SPEED 2 ac tiv e. If open at
the time of pow er-on, alarm ac tiv e
the v alue of the height indic ator

remains f ix ed on the dis play
T RUCK REACTION
s ens or output
s ens or output
s ens or output
s ens or output
in s hort c irc uit
lif ting s peed reduc tion not ac tiv e
lif ting s peed reduc tion alw ay s ac tiv e

No c arriage retrac ted s top if output
opens w hile f unc tion is ac tiv e; no
c arriage f orw ard f unc tion if already
c ompletely at retrac ted s troke limit.
interrupted
Res etting the key s w itc h it is pos s ible
to ac tiv ate the c arriage f orw ard
mov ement w ith reduc ed pump s peed
until the oppos ite s troke limits w itc h
trips
c arriage retrac ted s troke limit not
s hort-c irc uited f unc tioning; c arriage ex tended s peed
reduc tion not f unc tioning
No c arriage f orw ard s top if output
opens w hile f unc tion is ac tiv e; no
c arriage retrac ted f unc tion if already
c ompletely at f orw ard s troke limit.
interrupted
Res etting the key s w itc h it is pos s ible
to ac tiv ate the c arriage bac k
mov ement w ith reduc ed pump s peed
until the oppos ite s troke limits w itc h
trips
c arriage f orw ard s troke limit not
s hort-c irc uited f unc tioning; c arriage retrac ted s peed
reduc tion not f unc tioning
s ens or output interrupted
output in s hort c irc uit (alw ay s No alarm. The v alue of the height
at +V bat)
indic ator remains f ix ed on the dis play
output not ac tiv ated
enc oder phas es A and B are

s hort-c irc uiting
one of the w ires is not

c onnec ted
3D
1D
FAULT TYPE
CONNECT .
M HYRIO (M ODULE 9) - (1)
none
none
none
none
none
16 RESET ENCODER
none
ALARM
Part No.: 524159096
Page: 59
ELECTRICAL SYSTEM
(MHYRIO MODULE 9)
renew f aulty s ens or
renew f aulty s ens or
renew s ens or
none
f irs t c hec k c orrec t adjus tment of

induc tiv e s ens or. Renew if nec es s ary
c hec k the enc oder c onnec tions and

replac e if nec es s ary
ACTIONS REQUIRED
SERVICE
Page: 60
Part No.: 524159096
CAN-BUS
4B, 1B
2B
Keysw itch
SW2
6B
TRUCK REACTION
MHYRIO (MODULO 9) - (2)
open circuit
open
open
none
none
ALARM
no f unction. Alarm active
no f unction. Alarm active
b) 09
check keysw itch and relative

connections
check connection
In the case of FF VA LVES identif y the

short-circuiting coil and renew ; in the
case of DRIV ER SHORTED, renew the
module
check coil of solenoid valve 8 and

renew if necessary
renew f aulty sensor
ACTIONS REQUIRED
Date: Mar. 2002
(MHYRIO MODULE 9)
01 CAN BUS KO EPS at pow er on; 16

check CA N-BUS lines connection. If
NO CAN MESSAGE if tripped during
necessary, renew the module
operation
16 CAN BUS KO V ALVE
09 DRIV ER OPEN, also 16 RESET

ENCODER on start
a) soneoid valve coils shorted:

hydraulic f unctions disabled and alarm
a) 09 FF VA LV ES
active; b) coil control driver shorted:
DRIV ER SHORTED
hydraulic f unctions inhibited and alarm
active
low ering speed reeduction not

low ering speed reduction alw ays
renew short-circuiting sensor
enabled
solenoid valve coil open
no f unction. No active alarm
circuit
FAULT TYPE
sensor output interrupted
3B-8G;11G6G;16G5G;15GShorted
2G;12G1G;13G4G;9G-3G
10G-7G;
5A
CONNECT.
Coils pow er supply

+Batt
Solenodi valves
connection inputs
Solenoid valves *8
Low ering speed
COM PONENT
SYM BOL
ON
DIAGRAM
SW9
ELECTRICAL SYSTEM
SERVICE
UPDATE
UPDATE
Date: Mar. 2002
SW17
SW21
SW3
Horn sw itch
Operator presence
POT1
Traction
Seat sensor
SW16
SW15
SW14
SW13
Battery out sensor
Brake pedal sensor
Start sensor
Reverse travel
Forw ard travel
COM PONENT
SYM BOL
ON
DIAGRAM
SW12
13A
5G
14A
no traction, alarm activated

traction normal operation
not operational
alarm as soon as f unction is selected
alarm at keysw itch pow er-on
sensor output short-circuit

open
no traction, alarm activated
pedal braking not f unctioning

no traction
only reach carriage f unction available.
Reduced speed traction possible w ith
"battery out" button
same f unctions as w hen battery is in
position
alarm at keysw itch pow er-on, af ter 1
alarm active
no f orw ard travel

at time of reverse travel enable,
f unctions are inhibited and alarm is
tripped
no reverse travel
at time of f orw ard travel enable,
f unctions are inhibited and alarm is
tripped
no traction. A larm w hen almost at
accelerator stroke limit
TRUCK REACTION
sensor outupt interrupted
negative open
central open
5A
7A
positive open

closed circuit
open circuit
FAULT TYPE
4A
9A
2G
1G
4G
3G
CONNECT.
CANIO (MODULE 1) - (1)
none
none
01 INCORRECT START
01 INCORRECT START
Part No.: 524159096
check seat sensor and renew if

necessary
none
none
check operator presence sensor (lef t-
perf orm PROGRA M V ACC procedure
renew battery out sensor
renew brake pedal sensor
renew start sensor
renew f orw ard travel sensor
renew f orw ard travel sensor
ACTIONS REQUIRED
Page: 61
ELECTRICAL SYSTEM
(CAN I/O MODULE 1)
01 V ACC NOT OK, pedal dow n 01

PEDAL WIRE KO
01 V ACC NOT OK
none
01 BATTERY OUT
none
01 INCORRECT START
01 V ACC NOT OK
01 FORW & REV
none
01 FORW & REV
none
ALARM
SERVICE
Page: 62
Part No.: 524159096
Date: Mar. 2002
Tilt bac k/f orw ards

enable s w itc h
Tilt Potentiometer
J2
J2/POT1
J1
J1/POT2
Reac h c arriage
potentiometre
Reac h c arriage
f w d/bac k enable
J1
J1/POT1
SW 1
Lif t/low er enable

s w itc h
Lif t/low er
potentiometer
Emergenc y c irc uit

breaker
C OM PONENT
SYM BOL
ON
DIA GRA M
1C
6C
2C
3C
4B
4
ac tiv e alarm
alarm at key s w itc h pow er-on
c los ed c irc uit
alarm pres ent at key s w itc h pow er-on

and f unc tions ac tiv ation
open c irc uit
negativ e open
c entral open
pos itiv e open
if the alarm is generated at the time of

key s w itc h pow er-on: f unc tion
unav ailable. For alarm during
operations tilt mov ement bac kw ards ,
or return to neutral f rom f orw ard
(dow n) pos ition.
f unc tion not av ailable, no alarm
alarm ac tiv e
c los ed c irc uit
alarm pres ent at key s w itc h pow er-on

and f unc tions ac tiv ation
immediate alarm at pow er-on, all

hy draulic f unc tions inhibited.
f unc tion av ailable - no alarm
open c irc uit
negativ e open
c entral open
5B
6B
pos itiv e open
3B
alarm ac tiv e
c los ed c irc uit
alarm ac tiv e if c ontac ts are opened

f ollow ing pow er-on.
if the alarm appears at the time of
pow er-on: f unc tion bloc ked. If this
alarm trips during operations , only
low ering mov ements are allow ed.
f unc tion not av ailable, no alarm
f unc tion not av ailable, alarm pres ent
T RUC K REA C T ION
open c irc uit
c entral open
negativ e open
2B
6B
1B
pos itiv e open
open c irc uit
FA UL T T YPE
3B
6G
C ONNEC T .
CANIO (M O DULE 1) - (2)
01 INCORRECT STA RT
01 POT #3 NOT OK
01 POT #1 NOT OK
01 POT #1 NOT OK
01 INCORRECT STA RT
01 POT #2 NOT OK
01 POT #1 NOT OK
01 POT #1 NOT OK
01 INCORRECT STA RT
01 POT #1 NOT OK
01 POT #1 NOT OK
01 POT #1 NOT OK
05 LOGIC FA ILURE #2, 01

EMERGENCY
A L A RM
(CAN I/O MODULE 1)
none
c hec k potentiometer c onnec tions and

renew the joy s tic k if nec es s ary .
none

renew joy s tic k if nec es s ary .
none

renew the joy s tic k if nec es s ary .
c hec k emergenc y c irc uit breaker

c ontac ts and c irc uit breaker.
A C T IONS REQUIRED
ELECTRICAL SYSTEM
SERVICE
UPDATE
UPDATE
Date: Mar. 2002
J7
J7
J7
Joystic k pow er
supply positive
A ll sw itches except
f orw ard/reverse
and horn
J7
E3-A 1
B-
J2
J2/POT2
Joystic k pow er
supply negative
CAN joys tick :

Connec tion
betw een Joy stick
and CA N I/O
BUS connec tion

w ith SICOS module
Keysw itch
Battery negative
Rh/lh sideshif t
enable sw itc h
Sideshif t
potentiometer
COM PONENT
SYM BOL
ON
DIAGRAM
1D
4D
2D, 3D
to CA NIO
1F, 2F
9F
18A , 14G,
10F
4C
6C
5C
3C
CONNECT.
open or closed c ircuit
open circuit
open circuit
01 INCORRECT STA RT
01 CA N BUS KO JOY
no alarm at pow er-on, alarm present

af ter s hort interv al or w ith f unctions
activation
alarm active
16 NO CA N MESSA GE
01 CA N BUS KO JOY
16 NO CA N MESSA GE
16 CA N BUS KO IO
16 CA N BUS KO IO
Part No.: 524159096
none
check +12v, connections, joystick and

CA N I/O; renew if nec essary.
check pow er supply negative,

connections and CA N I/O; renew if
neces sary .
Chec k connections, joystic k and CA N

I/O; renew joystick if necessary .
check battery negativ e, connec tions

and CA N I/O; renew if nec essary
Chec k key sw itc h, connections and
CA N I/O; renew if nec essary
Chec k connection betw een CA N I/O
and SICOS and renew modules if
neces sary .
none
check potentiometer c onnections and

renew joys tick if nec essary.
ACTIONS REQUIRED
Page: 63
ELECTRICAL SYSTEM
(CAN I/O MODULE 1)
16 CA N BUS KO EPS, 16 NO CA N
MESSA GE
01 INCORRECT STA RT
01 POT #4 NOT OK
01 POT #1 NOT OK
01 POT #1 NOT OK
ALARM
immediate alarm at key sw itch pow eron; all hydraulic operations inhibited
No alarm at keys w itch pow er-on,

alarm present and no f unction at
activation of f irst action.
alarm at key sw itch pow er-on
c losed circ uit
open circuit
open circuit
open circuit
alarm af ter slight delay
alarm present at keys w itch pow er-on
c losed circ uit
open circuit
alarm active
alarm present at keys w itch pow er on

and f unctions ac tivation
f unction not available, no alarm.
if the alarm is present at pow er-on:

f unction not available. If the alarm is
tripped during operations s ideshif t to
TRUCK REACTION
open circuit
negative open
c entral open
positiv e open
FAULT TYPE
CANIO (MODULE 1) - (3)
SERVICE
Page: 64
Part No.: 524159096
Date: Mar. 2002
Bus connection
w ith CAN I/O
module
Keysw itch
E4-A1
C4
SW23
Automatic capacity
detector
Battery negative
SW22
SW20
Low speed travel

sw itch
Optional Valves
SW19
Holding or parking
sw itch
Traction permissive
COM PONENT
SYM BOL
ON
DIAGRAM
SW18
1F, 2F
9F
10F, 18A
15A
3A
6A
2A
1A
CONNECT.
open circuit
open circuit
16 NO CAN MSG,
01 INCORRECT START, also "TON"

display
02 HANDBRAKE
ALARM
Check battery negative and SICOS

module (renew module if necessary).
Check the keysw itch, connections
w ith the SICOS module, and the SICOS
module itself (renew the sw itch or
SICOS if necessary)
Check connections w ith CAN I/O:
Check SICOS and CAN I/O and renew
if necessary.
Check sw itch and connections; renew

sw itch if necessary.

Check sw itch and connections w ith

SICOS and renew sw itch if

ACTIONS REQUIRED
(SICOS MODULE 1)
Display and f unctions unavailable if

open at pow er-on; all f unctions
available if circuit opens w hen truck is
already operating.
All f unctions available w ith truck in
16 CAN KO EPS, then 16 NO CAN
operation, f or other possibilities no
MSG,
f unctions available.
no f unctions permitted.
alarm at keysw itch pow er-on, no

hydraulic f unctions permitted.
closed circuit
open circuit
f unction request not f ulf illed, no alarm.
same as w hen open, but translation

not executed.
closed circuit
open circuit
f unction request not f ulf illed, no alarm
closed circuit
open circuit
Parking brake active, alarm present at

traction request.
closed circuit
open circuit
f unction request not f ulf illed; no alarm
no movement even though sw itch is

activated
closed circuit
open circuit
no movement even though sw itch is
TRUCK REACTION
open circuit
FAULT TYPE
SICOS - Display (MODULO 16)
ELECTRICAL SYSTEM
SERVICE
UPDATE
SERVICE
ELECTRICAL SYSTEM
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 65
SERVICE
ELECTRICAL SYSTEM
14
WIRING HARNESS CONNECTION DIAGRAM
The following diagrams are to be used in the event of replacement of wiring harnesses or auxiliary cables
between connectors and modules.
Each diagram carries indications of connectors and the relative cable insulation colours.
NOTES:
Page: 66
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE

VEDI
Pag. 66e
VEDI
Pag. 66f
VEDI
Pag. 66i
VEDI
Pag. 66g
WIRING DIAGRAM
AUXILIARI CABLES
VEDI
Pag. 66C
VEDI
Pag. 66b
VEDI
Pag. 66f
VEDI
Pag. 66c
VEDI
Pag. 66g
VEDI
Pag. 66g
VEDI
Pag. 66i
VEDI
Pag. 66h
VEDI
Pag. 66e
VEDI
Pag. 66i
VEDI
Pag. 66d
AGGIORNAMENTO
0 1
Pag. 66a
SERVICE

WIRING CONNECTIONS
MODULE AC2 TRAZIONE
MODULE AC2 POMPA
WIRING CONNECTIONS MODULE AC2 TRAZIONE
WIRING CONNECTIONS MODULE AC2 POMPA
AGGIORNAMENTO
0 1
Pag. 66b
SERVICE
WIRING CONNECTIONS
MODULE EPS - AC,
MODULO CA I/O
WIRING CONNECTIONS MODULE CAN I/O
WIRING CONNECTIONS MODULE EPS - AC
AGGIORNAMENTO
0 1
Pag. 66c
SERVICE

WIRING CONNECTIONS
MODULE MHYRIO, ELETTROVALVES,
SENSORS
COLLEGAMENTO FILI MODULO MHYRIO
AGGIORNAMENTO
0 1
Pag. 66d
SERVICE

WIRING CONNECTIONS
MODULE SICOS, JOYSTICK ITT
WIRING CONNECTIONS MODULE SICOS
AGGIORNAMENTO
0 1
WIRING CONNECTIONS JOYSTICK ITT
Pag. 66e
SERVICE

WIRING CONNECTIONS
GROUP 2 JOYSTICKS
GROUP 4 JOYSTICKS
WIRING CONNECTIONS 2 JOYSTICKS
WIRING CONNECTIONS 4 JOYSTICKS
AGGIORNAMENTO
0 1
Pag. 66f
SERVICE

WIRING CONNECTIONS
INVERSORE MARCIA, HORN BUTTON,
EMERGENCY SWITCH, KEYSWITCH,
PANEL FAN
TRACTION INVERTER
HORN BUTTON
EMERGENCY SWITCH
KEY SWITCH
AGGIORNAMENTO
0 1
PANEL FAN
Pag. 66g
SERVICE
WIRING CONNECTIONS
SENSORS, POTENTIOMETER
COLLEGAMENTO FILI SENSORI
AGGIORNAMENTO
0 1
Pag. 66h
SERVICE

WIRING CONNECTIONS
ENCODER, THERMAL SENSORS,
SENSORS,
WORK LIGHTS, FLASHING BEACON
ENCODER AND MOTOR THERNMAL SENSOR WIRING CONNECTIONS
WORK LIGHTS AND FLASHING BEACON WIRING CONNECTIONS

AGGIORNAMENTO
0 1
Pag. 66i
SERVICE
Section: ADDITIONAL FUNCTIONS
ADDITIONAL
FUNCTIONS
! OPTION SHEET No. 1 Setting of the steering for a turn of 360 and 90............................4
! OPTION SHEET No. 2 DC_DC converter installation.............................................................6
! OPTION SHEET No. 3 -
Flashing rotating light installation........................................................8
! OPTION SHEET No. 4 Working light installation....................................................................10
! OPTION SHEET No. 5 Reverse motion audible alarm installation.......................................12
! OPTION SHEET No. 6 -
Height preselector installation .........................................................14
! OPTION SHEET No. 7 !

!
!
!
!
!
!
!
REVISION
Installation and enabling of the 5. function ......................................16

OPTION SHEET No. 8 Deceleration of the HE mast lifting limit switches..........................19
OPTION SHEET No. 9 Electric block of the lowering forks with 1200mm pallet...................21
OPTION SHEET No. 10 Warmed seat installation .................................................................23
OPTION SHEET No. 11 Cab for -30 refrigerating room ........................................................27
OPTION SHEET No. 12 Seat belt installation.........................................................................35
UPDATE
OPTION SHEET No. 1 Intermediate lifting lock sensor
Function release by means of the push button on the display.........37
UPDATE
OPTION SHEET No. 2 Enabling of the weighing function.....................................................42
UPDATE
OPTION SHEET No. 3 removal of the speed reduction function with the carriage
completely extended.........................................................................43
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 1
SERVICE
NOTES:
Page: 2 Comp. No.: 524159096 Date: Mar. 2002 0 1
2 3
5 6
REVISION
SERVICE
ADDITIONAL FUNCTIONS
According to the different functions, which can be applied on this model, it might be necessary
to install further components and above all change some settings on various modules in order
to obtain the desired function.
This section aims at guiding the technician through the installation and through the settings,
which are necessary for the new function.
Every function sheet consists of 3 parts:
NECESSARY ADDITIONAL COMPONENTS
INSTALLATION NOTES
MODULE CONFIGURATION
The section CONFIG MENU indicates the adjustments, which must be carried out on each
model in order to obtain the desired function.
The table containing such data is described below.
Progressive No.
Accessories
Module
MAIN MENU CONFIG MENU
Parameters
Setting
Parameter to be modified
Setting to be modified
Module configuration
submenu access menu
Machine parameter access menu
Module on which you must act
Devices to be used
Progressive number
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 3
SERVICE
OPTION SHEET No. 1
a)
STEERING SETTING FOR 360 MOVEMENTS
PROCEDURE TO CONNECT THE EPS - AC MODULE TO SET THE STEERING

FOR THE 360 MOVEMENT ON PAGE 4a
Pict. 1
b)
STEERING SETTING FOR 90 MOVEMENTS
PROCEDURE TO CONNECT THE EPS - AC MODULE TO SET THE STEERING

FOR THE 90 MOVEMENT ON PAGE 4b
Pict. 2
2 3
5 6
REVISION
SERVICE
OPTION SHEET No. 1/A

EPS-AC
CONTROL
360 STEERING GUIDE

X

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

Sequence
No.
Accessories
Module
MAIN MENU CONFIG MENU
Parameters
Description of the operations to be performed
Setting
W hen the machine is off, connect the console to the EPS Module. Place the
key switch in position ON and check that the automatic wheel reaches the
central position
SET OPTIONS
RANGE 360
ON
SET OPTIONS
LIMIT DEVICE
OFF
EPS - AC
4
ADJUSTMENT
Key switch on OFF and then on ON. Check that the wheel reaches
automatically the central position. If the wheel is not centered consider the
following point
Remove the stop of the steering wheel at 90 and perform the steering at 360
Increase the value displayed in order to adjust the centering of the wheel
clockwise (+5mV). Decrease the value displayed in order to adjust the
SET STEER 0-POS Va lue displa ye d 5V
centering of the wheel antickwise (-5mv). Key switch OFF then ON. Check
that at the starting the automatic wheel reaches the central position
Rotate the steering clockwise till 180 position is reached
ADJUSTMENT
SET 180 ENC
REVISION
If the SET 180 ENC parameter does not correspond to 10V, position on the
parameter, press ENTER. From the centered position of the wheel, steer the
wheel clockwise until 10V appears, press OUT then ENTER
Va lue displa ye d
10V
0 1
5 6
Date: March 2002
Comp.No.: 524159096
Page 4a
SERVICE
OPTION SHEET No. 1/B

EPS-AC
CONTROL
90 STEERING GUIDE
X

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

S eq u en ce
No.
Access o ries
Mo d u le
M AIN ME N U C ON F IG ME N U
P ara m eters
W hen the m ac hine is off, c onnec t the c ons ole to the E P S M odule. P lac e the
k ey s witc h in pos ition ON and c hec k that the autom atic wheel reac hes the
c entral pos ition
S ET O P TIONS
ADJUS T M ENT
EP S - AC
D e scrip tio n o f th e o p e ratio n s to b e p erfo rm ed
S ettin g
S ET O P TIONS
RANGE 360
K ey s witc h on OF F then on O N. Chec k that the wheel reac hes autom atic ally
the c entral pos ition. If the wheel is not c entered, c ons ider the following point
O FF
Inc reas e the value dis play ed to adjus t the c entering of the wheel c loc k wis e
(+ 5m V ). Dec reas e the value dis play ed to adjus t the c entering of the wheel
S ET S T EER 0-P O S V a lu e d isp la ye d 5V
antic loc k wis e (-5m v). K ey s witc h OF F then O N. A nd c hec k that at the
s tarting the autom atic wheel reac hes the c entral pos ition
L IM IT DEV ICE
ON
K ey s witc h on OF F then on O N. Chec k that the wheel reac hes autom atic ally
the c entral pos ition
ADJUS T M ENT
S ET M AX ENC
V a lu e disp la ye d
7,2V
ADJUS T M ENT
S ET M IN ENC
V a lu e disp la ye d
2,6V
S ET O P TIONS
L IM IT DEV ICE
ON
REVISION
0 1
Rotate the s teering c loc k wis e in order to reac h the 90 pos ition 90 (value
dis play ed 7,2V ). S ave the s et value by pres s ing E NTE R then O UT and s till
E NTE R, then plac ee the k ey s witc h in pos ition O FF then on ON and c hec k
that at the s tarting the autom atic wheel reac hes the c entral pos ition
Rotate the s teering antic loc k wis e untill the 90 pos ition is reac hed (value
dis play ed 2,6V ). S ave the s et value by pres s ing E NTE R then O UT and s till
E NTE R, then plac e the k ey s witc h in pos ition O FF then on O N and c hec k
that at the s tarting the autom atic wheel reac hes the c entral pos ition
S et on O N. K ey s witc h on OF F to s ave the param eters
5 6
Date: March 2002
Comp.No.: 524159096
Page 4b
SERVICE
NOTES:
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 5
SERVICE
OPTION SHEET NO. 2

DC-DC CONVERTER INSTALLATION AND CONNECTION
- DC_DC CONVERTER KIT
-NONE
INSTALLATION NOTES
NECESSARY STANDARD TOOLS
Slotted
screwdriver
Medium Phillips
screwdriver
13mm
Spanner
5mm Allen
wrench
The DC-DC converter is supplied with a kit including connection sheaths and fastening screws and is assembled
behind the seat next to EPS_AC 6 module.
For the assembly it is necessary to open the engine compartment bonnet by means of a 5mm Allen wrench
and fix, by means the Allen wrench itself, the converter to the holes already provided. Open the system
compartment bonnet by means of the Phillips screwdriver, connect a cable terminal to the B-Batt of the
Pump AC2 module by means of the 13 mm spanner, connect the other cable terminal to the B+ 48V of the
FU7 fuse by means of the slotted screwdriver as shown in the drawing below. The sheath with the connector
is linked to the converter output; the converter is used for the auxiliary system connections.
NOTE: Before starting the assembly and the connection put the key switch in position OFF and
disconnect the battery.
Pict. 5
Connector to join the
auxiliary systems
B+ 48V Connection
to the Aux FU7 fuse
B- Batt Connection to
the Pump AC2 module
2 3
5 6
REVISION
SERVICE
DC-DC CONVERTER
WIRING DIAGRAM
DC-DC CONVERTER
CONNECTION
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 7
SERVICE
OPTION SHEET No. 3

FLASHING ROTATING LIGHT CONNECTION AND INSTALLATION
- FLASHING ROTATING LIGHT KIT
-NONE
INSTALLATION NOTES
Medium Phillips
screwdriver
5mm Allen
wrench
The flashing rotating light is provided with a kit complete with connection sheath and fastening screws
and is assembled on the roof in the outer corner over the support column (as shown in the picture).
For the assembly it is necessary to open the bonnet under the steering wheel and the system compartment
bonnet by means of the Phillips screwdriver. The assembly point is provided with two M6 holes to fasten
the flashing rotating light and with a 30 hole for the cable. Insert the wire in the hole and make it pass
through the roof interspace by following the direction indicated by the arrow, then join the connector end
cable and drag it completely up to the Inverter Pump AC2 5 Module and insert the connector in the
connector No. 26. Connect the other end of the cable to the flashing rotating light and fix it to the roof by
means of the 5mm Allen wrench.
Connector already provided
and connected to Pin 2/F 8/F of the PUMP AC2
module
30 hole for
the cable
passage
FLASHING ROTATING
LIGHT
Cable passage
interspace
Pict. 6
Pict. 7
2 3
5 6
REVISION
SERVICE
WIRING DIAGRAM FOR THE

FLASHING ROTATING LIGHT
CONNECTION
FLASHING
ROTATING LIGHT
CONNECTION
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 9
SERVICE
OPTION SHEET No.4

WORKING LIGHT INSTALLATION AND CONNECTION
- WORKING LIGHT KIT
MODULE CONFIGURACONFIGURAZIONE MODULI

-NONE
INSTALLATION NOTES
Medium Phillips
screwdriver
5mm
Allen wrench
The working lights are provided with a kit complete with connection sheath, selector for the starting and
fastening screws.They are assembled on the outer part of the roof facing the mast (as shown in the
picture).
For the assembly open the bonnet under the steering wheel and the system compartment bonnet by
means of the Phillips screwdriver. The assembly point is provided with four M6 holes, two for each light,
and two 30 holes for the cable passage (as shown in picture 8). Insert the wire in the holes and make
it pass through the roof interspace by following the direction indicated by the arrow. Then join the cables
and drag them completely up to the connector No. 24 (already provided), insert the starting selector
sheath, fix the selector on the dashboard and join the two connectors. Connect the other ends of the
cables to the lights and fix them to the roof by means of the 5mm Allen wrench.
disconnect the battery
cable passage
interspace
30 holes provided for
the sheath passage
Connector already provided

and connected: Pin 1/24 to
B- Batt, 2/24 to FU4 B+ Batt
48V fuse
Pict. 8
Pict. 9
Pict. 10
2 3
5 6
REVISION
SERVICE
WORKING LIGHT
CONNECTION
REVISION
0 1
2 3
WIRING DIAGRAM
FOR THE WORKING
LIGHT CONNECTION
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 11
SERVICE
OPTION SHEET No. 5

INSTALLATION AND CONNECTION OF THE REVERSE MOTION AUDIBLE
ALARM
- AUDIBLE ALARM KIT
INSTALLATION NOTES
Medium Phillips
screwdriver
5mm
Allen wrench
The buzzer is provided with a kit complete with a connection sheath and is assembled under the board
on a slotted bracket near the klaxon (as shown in picture 11).
For the assembly it is necessary to open the engine compartment bonnet and the board by means of the
5mm Allen wrench, remove the system compartment bonnet by means of
the Phillips screwdriver. Loosen the buzzer ring nut, insert the buzzer itself
in the proper slot and tighten the ring nut to fasten the buzzer to the bracket.
Bring the sheath connector into the system compartment by making it follow
the way of the sensors and join it to the connector No.28.
NOTE: Before starting the assembly and the connection, place the key
switch in position OFF and disconnect the battery.
Pict. 12
Buzzer
application
Connector joint to Pin

16/G - 7/G of the CAN
I/O module
Pict. 11
2 3
5 6
REVISION
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
CAN I/O
Se que nce
Acce ssorie sModule
No.
SET OPTIONS
AUX
FUNCTION 3
MENU CONFIG. CONSOLE

CONSOLE
PARAMETER
Audible alarm enabled with reverse movement

Audible alarm enabled with forward movement
OFF
W hen the machine is off, connect the console

to the CAN I/O module, key switch ON.
De scription of the ope ra tions to be

pe rform e d
ON
SETTING
ADJUSTMENT TO ENABLE THE AUDIBLE ALARM W HEN THE TRUCK IS RUNNING
CAN I/O MODULE CONFIGURATION TABLE
SERVICE
WIRING DIAGRAM FOR THE
REVERSE MOTION AUDIBLE
ALARM CONNECTION
REVERSE
MOTION
AUDIBLE ALARM
CONNECTION
Page: 13
SERVICE
OPTION SHEET No. 6

ENABLING OF THE HEIGHT PRESELECTOR FUNCTION
THERE ARE TWO TYPES OF CONFIGURATION
a) RETRACTABLE CARRIAGE INCLUDED IN THE AUTOMATIC DRAWING/STORING SEQUENCE
b) RETRACTABLE CARRIAGE EXCLUDED IN THE AUTOMATIC DRAWING/STORING SEQUENCE
- HEIGHT PRESELECTOR KIT
SW5 =
LIFTING SPEED REDUCTION
SENSOR
NYLON THREAD FOR

THE ENCODER
OPERATION
ENCODER RESET.
INDUCTIVE
ENCODER
SHEATH
CONNECTORS JOINT
TO THE MHYRIO
MODULE
Pict. 13
CONNECTION OF THE INDUCTIVE ENCODER AND SPEED REDUCTION SENSOR ON MHYRIO 6

MODULE
MHYRIO
6 MODULE
Pict. 14
CONNECTOR A
FOR THE ENCODER
RESET SENSOR
CONNECTION
CONNECTOR D FOR
THE ENCODER
CONNECTION
2 3
5 6
REVISION
SERVICE

PROCEDURE TO INSTALL THE HEIGHT PRESELECTOR COMPONENTS
HEIGHT PRESELECTOR
COMPONENT TABLE
Ref.
1
2
3
4
5
6
7
8
9
Component description
Height measurement encoder
Fork lifting deceleration sensor
Sensor support bracket
Encoder locking bolts
Nylon thread for the encoder rotation
Spring coupling upper ring
Tightening spring
Insertion for the thread connection
Threads coupling lower ring
Tapeline
Drill
Pict. 16
Pliers for faston
8,5
10mm spanner
drill
INSTALLATION PROCEDURE
Before starting the working, make sure to wear suitable safety clothing.
Drive the truck in a safety area far from the passage of pedestrians or other vehicles,
move forward the retractable carriage, lower the forks till they touch the ground, put the
switch in position OFF, disconnect the battery.
ROTATION DIRECTION
OF THE THREAD ON
THE PULLEY
Screw tap
Ladder
1) 10mm SPANNER, LADDER WITH PLATFORM - Position the ladder on the right side of
the column and assemble the ENCODER on the proper bracket (Pict. 17).
2) DRILL COMPLETE WITH 5mm DRILL , TAP WRENCH COMPLETE WITH M6 SCREW
TAP, LADDER WITH PLATFORM , 10mm SPANNER - Draw the holes (as shown in the
picture enclosed) of the sensor support bracket of the fixed mast (Ref. 3 Pict. 17), carry out
the holes and thread. Draw the holes (as shown in the picture enclosed) of the bracket with
ring on the lower part of the intermediate mast upper crosspiece (Ref. 6 Pict. 16), carry out
the holes and thread. Fasten the bracket complete sensor and the bracket with ring by
means of the spanner.
2
+ 50mm
estention
3) PLIERS FOR FASTON - Take the nylon rope and form a ring (Ref. 8 Pict. 16) and by means
of the pliers tighten the crimp in order to fix it; hook the spring to the ring fixed on the mast
crosspiece, hook the ring of the nylon rope to the spting lower hook (Pict. 19). By means of
the nylon rope make a complete revolution on the encoder pulley observing the direction of
revolution (as shown in pict. 19) by letting the other end of the rope fall down.
2
1
4) Move the ladder far from the truck, connect the battery and put the key switch in position
ON. Lift the forks till the lower crosspiece of the intermediate mast reaches 1m height
from the floo; position the beam under the mast (Pict. 20), lower the forks and lean the
mast on the beam, put the key switch in position OFF and disconnect the battery.
WARNING: The beam has a safety function and so it must be positioned well.
Pict. 19
Pict. 17
6) PLIERS FOR FASTON - Make the nylon rope end go through the ring and tighten it by
pulling it until the spring is stretched of about 50mm (Pict. 19); using the nylon rope form
a ring and tighten the crimp in order to fix (Ref. 8 Pict. 4), cut the exceeded rope.
7) Fasten the onnection cable to the right mast cylinder by moving the connector upwards;
connect the cable lower ends to the MHYRIO module (see diagram on page 10), join the
encoder and sensor connectors. Connect the battery, put the key switch in position ON,
lift the forks and remove the beam, lower the forks till they touch the ground and program
the preselector referring to the table enclosed and the Service manual on page 51 of the
electric section.
Pict. 15
5) DRILL COMPLETE WITH 5mm DRILL, TAP WRENCH COMPLETE WITH M6 SCREW
TAP, 10mm SPANNER- Draw the holes (as shown in the picture enclosed) of the bracket
with ring on the upper part of the intermediate mast lower crosspiece (Pict. 18-20), draw
the holes and thread. Fix the bracket by means of the bracket.
9
Pict. 18
Bracket
locked by ring
Support
beam
REVISION
Pict. 20
0 1
5 6
Date: March 2002
Comp. No.: 524159096
Page 14a
SERVICE
WIRING DIAGRAM TO CONNECT

- INDUCTIVE ENCODER
- DECELERATION SENSOR
(UPWARD MOVEMENT)
AND ENCODER RESET
INDUCTIVE
ENCODER
MHYRIO
6 MODULE
Sw5
INDUCTIVE
ENCODER
INDUTTIVO
ENCODER
REVISION
0 1
5 6
Date: March 2002
Comp. No.: 524159096
Page 14b
SERVICE
OPTION SHEET No. 6/C
EPS-AC
ENABLING OF THE HEIGHT PRESELECTOR FUNCTION WITHOUT RETRACTABLE CARRIAGE

-CONSOLE CONNECTION NOTES
To carry out this operation the console must be linked to the SICOS 16 module in order to enable the preselector function.
All the height setting operations are carried out by means of the SICOS (Display) module keyboard.
To enable the SICOS 16 module to the preselector function, the console can be connected (when the machine is off) to the EPS-AC 6 module by
means of the access hole located behind the seat; by means of the CAN BUS connection the SICOS 16 module can be entered. To search the
module, refer to the SERVICE MANUAL (electric section)on page 24-25
CONSOLE CONNECTION
CONNECTOR
Pict. 21
NOTE: This table does not substitute the procedure described on the Manual Service; it is an indication of a function quick configuration

HEIGHT PRESELECTOR ENABLING WITHOUT RETRACTABLE CARRIAGE IN SEQUENCE
Sequence
No.
Accessories
Module
CONSOLE
MAIN MENU
CONFIG MENU SELECTION MAIN MENU 1 MAIN MENU 2 SELECTION

CONSOLE
KEY DISPLAY
DISPLAY
DISPLAY
KEY DISPLAY
CONSOLE
PARAMETER
DISPLAY
PARAMETER
SELECTION
KEY DISPLAY
Setting
When the machine is off connect the console to the SICOS

(Display) 16 module. Put the key switch in position ON
1
2
16 - SICOS
(Diaplay)
SET OPTIONS
ENCODER TYPE
SET OPTIONS
PRE-HEIGHT
SELECTOR
Enter
Enter
16 - SICOS
(Diaplay)
MAIN MENU 1
Set 1 to enable the SICIS to read the encoder

ON
DOWN arrow
UP arrow
PROGRAM
OFFSET
Enter
MEMO
LEVEL SETTING - SEQUENCE TO BE REPEATED FOR EVERY LEVEL
7
8
Enter
Enter
OUT
OUT
Set ON to link Sicos to the HEIGHT PRESELECTOR

function, press OUT, then ENTER to store. Put the key
switch in position OFF to save. Remove the console. Put the
key switch in position ON
Lift the forks up to the level after whch the withdrawing of the
mast begins. Measure the fork height from the ground. Set
the value using the numeric keyboard on the display.
Put the key switch in position OFF then in position ON to
save the value.
Lift the forks till the desired height is reached (the
programmed level must be higher than the "PROGRAM
OFFSET" value). Type the No. Of the desired level (i.e. 03)
To enter the "AUTOTEACHING" selector program
To save the value acquired
To restore the preselector working screen and to restore the
main DISLAY
DELTA ADJUSTMENT TO DRAW AND STORE THE PALLET ON THE SHELF

10
CAN I/O
11
PRAMETER
CHANGE
PRAMETER
CHANGE
To modify the store stroke delta (default value 5). Increasing

the value, the store stroke is increased.
To modify the drawing stroke delta (default value 5)
Increasing the value the drawing stroke is increased.
OPTION 5
OPTION 6
REVISION
0 1
5 6
Date: March 2002
Comp. No.: 524159096
Page 14c
SERVICE
OPTION SHEET No. 6/D
EPS-AC
ENABLING OF THE HEIGHT PRESELECTOR FUNCTION WITH RETRACTABLE CARRIAGE IN SEQUENCE
-CONSOLE CONNECTION NOTES
To carry out this operation the console must be linked to the SICOS 16 module in order to enable the preselector function. All the height setting operations are
carried out by means of the SICOS (Display) module key board.
To enable the SICOS 16 module to the preselector function, the console can be connected (when the machine is off) to the EPS-AC module by means of the
access hole located behind the seat; By means of the CAN BUS connection the SICOS 16 module can be entered. to search the module, refer to the SERVICE
MANUAL (electric section) on page 24-25
CONSOLE CONNECTION
CONNECTOR
NOTE: This table does not substitute the procedure described on the Service Manual; it is an indication of a function quick configuration
Pict. 22
TABLE CONFIGURATION MODULE

ENABLING OF THE HEIGHT PRESELECTOR WITH RETRACTABLE CARRIAGE IN SEQUENCE
Sequence
No.
Accessories
Module
CONSOLE
MAIN MENU
CONSOLE
CONFIG MENU
SELECTION
KEY DISPLAY
DISPLAY
DISPLAY
SELECTION
MAIN MENU 1 MAIN MENU 2 KEY DISPLAY
CONSOLE
PARAMETER
DISPLAY
PARAMETER
SELECTION
KEY DISPLAY
Setting
When the machine is off connect the console to the SICOS

(Display) 16 module. Put the key switch in position ON
1
2
3
16 - SICOS
(Diaplay)
SET OPTIONS
ENCODER TYPE
SET OPTIONS
PRE-HEIGHT
SELECTOR
ON
SET OPTIONS
AUX FUNCTION
2
ON
Enter
Enter
16 - SICOS
(Diaplay)
MAIN MENU 1
Set 1 to enable the SICOS to read the encoder
DOWN arrow UP
arrow
PROGRAM
OFFSET
Enter
MEMO
LEVEL SETTING - SEQUENCE TO BE REPEATED FOR EVERY MODEL
8
9
Enter
Enter
10
OUT
OUT
Set ON to link Sicos to the HEIGHT PRESELECTOR

function, press OUT, then ENTER to store
Set ON to link Sicos to operate with retractable carriage,
press OUT, then ENTER to store. Put the key switch in
position OFF to save. Remove the console. Put the key
switch in position ON
Lift the forks up to the level after which the withdrawing of the
mast begins. Measure the fork height from the ground. Set
the value using the numeric keyboard on the display.
Put the key switch in position OFF then ON to save the
value.
Lift the forks till the desired height is reached (the program
level must be higher than "PROGRAM OFFSET" value).
Type the No. Of the desired level (i.e. 03)
To enter the "AUTOTEACHING" selector program
To save the value acquired
To restore the preselector working screen and to restore the
main DISPLAY
DELTA ADJUSTING TO DRAW AND STORE THE PALLET ON THE SHELF

11
CAN I/O
12
PARAMETER
CHANGE
PARAMETER
CHANGE
To modify the store stroke delta (delta value 5) Increasing

the value, the store stroke is increased.
To modify the drawing stroke delta (default value 5).
Increasing the value, the drawing stroke value is increased.
OPTION 5
OPTION 6
REVISION
0 1
5 6
Date: March 2002
Comp. No.: 524159096
Page 14d
SERVICE
NOTES:
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 15
SERVICE
OPTION SHEET No. 7

ENABLING OF THE 5. HYDRAULIC FUNCTION
- 5. HYDRAULIC FUNCTION KIT
PUSHBUTTON TO BE PRESSED
TO ENABLE THE 5. FUNCTION
S Y M B O L
APPEARING IN
THE DISPLAY
WINDOW
+
100
50
20
S
T
N
D
Pict. 23
5. FUNCTION
CONNECTOR F
PIPE FITTING TO CONNECT THE
FOR THE SOLENOID
HOSE REEL SUPPLY PIPE
V
A
L
V
E
CONNECTION
SOLENOID VALVE IN
ADDITION TO THE
HYDRAULIC UNIT
Pict. 24
2 3
5 6
REVISION
SERVICE
INSTALLATION NOTES
Before ordering the assembly kit, refer to the hose reel/ H3 mast height and assembled
battery pairing table (Page 12a).
13-17-18-19mm
SPANNER
SMALL
SLOTTED
SCREWDRIVER
M10 SCREW
TAP
6mm ALLEN
WRENCH
ELECTRIC
DRILL
SCRIBE
4 and
8,5
STEEL DRILL
SQUARE
TAPELINE
LADDER
WITH TAP WRENCH
PROCEDURE
Before starting any work always wear suitable safety clothings.
Drive the truck to a safety area, far from the passage of pedestrians and other vehicles, move
forward the retractable carriage. lower the forks until they touch the ground, put the key switch
in position OFF, disconnect the battery.
1) LADDER WITH PLATFORM, SCRIBE SQUARE, TAPELINE - Place the ladder on the left side of
the truck connected with the mast, climb the ladder with the tools and the drawing in order to mark
the position of the holes to fix the hose reel support bracket.
NOTE:
In case of HE mast the holes must be carried out on the crosspiece as shown in picture 26 on
page 18a
In case of BETA mast the holes must be carried out aside the mast as shown in picture 27 on
page 18a
2) ELECTRIC DRILL, 4 e 8,5 STEEL DRILL, M10 SCREW TAP COMPLETE WITH TAP WRENCH,
17mm SPANNER - carry out the holes marked earlier by means of the 4 small drill and then by
means of the 8,5 large drill and the thread using the M10 screw tap. Fasten the bracket to the
column by means of the spanner and then fix the hose reel
complete with hoses on the bracket.
3) No. 2 13mm SPANNER - Loosen the valve (Ref. A Pict. 30) to
discharge the pressure inside the valve unit, tighten the valve.
By means of the same spanner, unscrew the threaded bar stop
nuts keeping the valve unit joint (Ref. B-B1 Pict. 30). Take out
the threaded bars and replace them with the longer ones
contained in the kit, add the new solenoid valve with the proper
O-Rings (Ref. C Fig. 30) and tighten, paying attention that the
O-Rings do not move from their seat. Carry out the solenoid
valve electric connection referring to the wiring diagram enclosed
on page 18b.
REVISION
0 1
2 3
A
C
B
B1
E
D
Pict. 30
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 17
SERVICE
4) 17-18-19mm SPANNER - Screw the pipe fittings of an end of the hoses twined to the hose reel pipe
fittings and bring the other end of the hoses to the hydraulic unit and bind them to the hoses located
on the mast by means of clamps and screw the the pipe fittings to the 5. function solenoid valve
5) SCRIBE, TAPELINE, SQUARE - Connect the battery, enable the emergency pushbutton and put the
key switch in position ON. Enable the lifting and move the upper part of the fork holder plate to the
height of 1m. Mark the position of the holes (see the drawing enclosed) on the fork holder plate
shoulder (Ref. 9 Pict. 20 on page 18a) by means of the tools in order to apply the support bracket of
the revolving joint.
6) ELECTRIC DRILL, 4 e 8,5mm STEEL DRILL, M10 SCREW TAP - carry out the holes on the points
marked earlier with the 4mm small drill and then with the 8,5mm large drill, thread the holes by
means of the M10 screw tap.
7) 17mm SPANNER, 6mm ALLEN WRENCH - Fix the bracket to the fork holder plate shoulder by means
of the spanner (Ref. 9 Pict. 20 on page 18a) and fasten the revolving joint to the bracket by means of
the Allen wrench (Ref. 7 Pict. 20 on page 18a).
8) 18-19mm SPANNER - Act the lifting and align the revolving joint with the lower hose reel base.
Keeping the hoses completely rolled load the spring by turning the hose reel clockwise three times
and connect the hose pipe fittings to the revolving joint pipe fittings. Carry out a complete lifting and
lowering movement and make sure that the hose reel twined hose is always tightened.
9) Connect the console to the SICOS 16 module and carry out the procedure to enable the 5. function
referring to the table on page 18b and to the Service Manual on page 41 of the electric section.
2 3
5 6
REVISION
SERVICE
COMPONENTS TO ASSEMBLE THE

5. HYDRAULIC FUNCTION
HOSE REEL WITH SUPPORT FOR THE A 709 (HE) MAST

Pict. 26
HOSE REEL WITH SUPPORT FOR THE A 708 (BETA) MAST

Pict. 27
10
7
Pict. 25
1032 X 784 X 350

1032 X 784 X 440
420 Ah
560 Ah
FROM 4500 TO 6700

FROM 4500 TO 6700
COMPONENTS FOR THE 5. HYDRAULIC FUNCTION APPLICATION

Re f
Com pone nt de scription
1
Hose reel for "HE" 340mm & 400mm mast
2
Hose reel support bracket for the "HE" mast
3
Bolts to fasten the hose reel to the bracket
4
Hose reel for "BETA" 340mm & 400mm mast
5
Hose reel support bracket for "BETA" mast
6
Bolts to fasten the hose reel to the bracket
7
Rotating joint to connect the hoses
8
Rotating joint support bracket
9
Bolts to fasten the bracket to the fork holder plate
10
Solenoid valve to be added for the 5. Function
11
threaded bars to connect the solenoid valve
12
Hydraulic hose kit (supplied according to the column height)
Pict. 28
TABLE OF COUPLING HOSE REEL H3 MAST

TYPE OF MAST
A708 & A709
A709
HOSE REEL DIAMETER
340m m
400m m
H3
H3
TYPE OF BATTERY
DIN "C" 1220 X 784 X 280 420 Ah FROM 4500 TO 6700 FROM 6700 TO
DIN "B"
DIN "B"
11 Pict. 29
NOTES
9800
9800
9800
9800
FROM 6700 TO 8700

FROM 6700 TO 8700
Only for the

NARROW truck
REVISION
0 1
5 6
Date: Marzo 2002
Comp. No.: 524159096
Page 18a
SERVICE
-SOLENOID VALVE CONNECTION DIAGRAM

-MODULE CONFIGURATION TABLE
MODULO 6
MHYRIO
5. FUNCTION
5. FUNCTION
Se que nce
No.
Acce ssorie s
Module
CONSOLE
MAIN MENU
CONSOLE
SELECTION
CONFIG MENU
KEY
CONSOLE
PARAMETER
Se tting
De scription of the ope ra tion to

be pe rform e d
W hen the machine is off connect
the console to the 16 SICOS
(Display) module. Place the key
switch in position ON
1
16 - SICOS
(Diaplay)
SET OPTIONS
REVISION
OPTIONAL 1-2
HYDRAUL
VALVE ON/OFF
0 1
5 6
OFF
Select OFF, key switch OFF then

ON to save. By pressing the key the
5. Function is enabled and on the
display the fork symbol is replaced
by the hydraulic jaws symbol
Date: Marzo 2002
Comp. No.: 524159096
Page 18b
SERVICE
OPTION SHEET No. 8

DECELERATION OF THE SIDE CYLINDERS AND OF THE CENTRAL
CYLINDER OF THE HE MASTS (LAST 50mm - UPWARD MOVEMENT)
DECELERATION SENSOR OF
THE SIDE CYLINDERS
THE CENTRAL CYLINDER
READING CAM OF
THE SIDE CYLINDER
SENSOR
REVISION
0 1
Pict. 31
2 3
READING CAM OF
THE CENTRAL
CYLINDER SENSOR
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 19
SERVICE
OPERATING PROCEDURE OF THE DECELERATION KIT (UPWARD

MOVEMENT)
-DECELERATION KIT (UPWARD MOVEMENT)
-NONE
OPERATING NOTES
The kit is applied on the great elevation HE masts where some hole rod plunger cylinders without any
internal deceleration device are assembled. This equipment is applied to avoid any metallic flapping at
the end of every end of stroke of the central cylinder and of the side cylinders.
POSITIONING OF THE DEVICES
1) The deceleration sensor of the free lifting (central cylinder) is fastened on a plate (already provided
with threaded holes) and welded on the outer side of the fixed mast (Ref. 1-2 Pict. 40 on page 20b). The
reading cam is welded on the rear side between the fork holder plate and the mast shoulder (Ref. 3 Pict.
39 on page 20b).
2) The side cylinder deceleration sensor is fixed on a plate welded on a metallic collar, fastened on the
upper end of the right cylinder (Ref. 1-2 Pict. 34 on page 20a). The reading cam is welded on the internal
withdrawing device base (Ref. 3 Pict. 33 on page 20a) bent as shown in pict. 36-37 on page 20a).
3) The connection is obtained by means of sheath with two connector to join the two sensors which
becomes a sole connector. It joins on connector A Pin 1-16-19 of the MHYRIO 6 module. See the
connection diagram enclosed on page 20c.
OPERATION
When the lifting is carried out and the free lifting cam is connected with the sensor , the pump motor
reduces the number of revolutions decelerating the stroke in the last 50 mm. Once the stroke is over the
pump motor increases the number of revolutions carrying out the lifting with the maximum speed until
the second cam is connected with the second sensor causing the decreasing of the pump motor revolution
number and decelerating the side cylinder stroke in the last 50mm.
2 3
5 6
REVISION
SERVICE

POSITION OF THE READING SENSOR ON
THE RIGHT LIFTING CYLINDER
COM P ONENTS FOR THE DECELERATION OF THE S IDE

CYLINDER END OF S TROKE
Re f.
S ens or s upport with fas tening c ollar on the c y linder
1
Induc tive s ens or
2
S ens or reading c am
3
Connec tion s heath
4
APPLICATION OF THE SENSOR AND CAM TO

DECELERATE THE SIDE CYLINDERS OF THE
HE MAST (LAST 50mm - UPWARD
MOVEMENT)
CAM WELDING ON THE A

708 BETA MAST
CAM WELDING ON A 709

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

THE INTERMEDIATE MAST
Pict. 37
Pict. 36
Pict. 33
Pict. 35
Pict. 32
REVISION
0 1
5 6
Date: March 2002
Part No: 524159096
Page 20a
SERVICE
APPLICATION OF THE SENSOR AND CAM TO

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

CAM ON THE REAR SIDE OF
THE FORK HOLDER PLATE
3
Pict. 39
Pict. 38
REVISION
0 1
5 6
Date: March 2002
Part No: 524159096
Page 20b
SERVICE
WIRING DIAGRAM FOR THE DECELERATION

SENSOR CONNECTION OF THE CENTRAL
CYLINDER AND THE SIDE CYLINDERS (LAST 50mm
- UPWARD MOVEMENT)
OPTION SHEATH No. 8/C

THE CENTRAL CYLINDER
(LAST
50mmUPWARD
MOVEMENT
CON. 16/B
CON. 16/A
CON. 16
1/A
16/A
THE SIDE CYLINDERS (LAST
50mm
UPWARD
MOVEMENT)
19/A
CON. 16/C
Page
Page
MHYRIO
6 MODULE
5. Function
REVISION
0 1
5 6
Date: March 2002
Part No: 524159096
Page 20c
SERVICE
APPLICATION OF THE PHOTOCELL FOR THE

DECELERATION IN THE LAST 50 mm
(UPWARD MOVEMENT) OF THE HE AND
BETA MAST SIDE CYLINDERS
OPERATING PROCEDURE OF THE DECELERATION KIT

(UPWARD MOVEMENT) WITH PHOTOCELL
The kit is applied on the great elevation HE masts where some hole rod
plunger cylinders without any internal deceleration device are assembled. This
equipment is applied to avoid any metallic flapping at the end of every forward
movement of the central cylinder and of the side cylinders.
POSITION OF THE PHOTOCELL
1) The deceleration photocell of the side cylinders is fixed on a plate. The Plate
is fixed on the front part connecting to the fixed mast (Ref. A Pict. 2-3)
2) The rear reflector is welded on the internal withdrawing device base (Hin. B
Pict. 4)
3) The electric connection is obtained by means of a sheath complete with
connectors. A connector is joint to the photocell connector, the other one is
joint to the sensor and the third one to the connector 16, which is connected to
connector A on the Pin 1-16-19 of MHYRIO modul 6. See the connection
diagram (page 20c)
OPERATION
When the lifting is carried out and the free lifting cam is connected with the first
reading sensor.
The pump motor reduces the number of revolutions decelerating the stroke in
the last 50mm. Once the stroke is over the pump motor increases the number
of revolutions carrying out the lifting with the maximum speed until the rear
reflector is connected with the photocell causing the decreasing of the pump
motor revolution number and decelerating the side cylinder stroke in the last
50mm.
NOTE: In case the photocell is assembled on operating machines, it is
advisable to carry out some tests in order to determine the right position, before
fixing the photocell and sticking the rear reflector.
Ref.
1
2
3
4
Component Description
Reading Photocell
Photocell Support
Photocell Fixing Plate (welded)
Photocell Reading Reflective Strip
A
A
1
2
3
Fig. 1
REVISION
Fig. 4
Fig. 3
Fig. 2
0 1
5 6
Date: March 2002
Part No: 524159096
Page 20d
SERVICE
OPTION SHEET No. 9

FORK LOCK WITH 1200mm PALLET (DOWNWARD MOVEMENT)
sensor
Reading
cam
Pict. 41
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 21
SERVICE
OPERATING PROCEDURE OF THE BLOCK WITH 1200mm PALLET

(DOWNWARD MOVEMENT)
-FORK LOCK KIT (DOWNWARD MOVEMENT)
OPERATION NOTES
The kit is applied on the machines using the pallet from the 1200mm side. This equipment is applied to
avoid that during the lowering phase with retractable carriage completely retracted, the pallet flaps against
the truck wheelbase.
NOTE: This option allows lowering the forks till they touch the ground only when the sideshift carriage is
completely extended. In some narrow aisles it will be impossible to draw or store the pallet placed on the
ground.
POSITION OF THE DEVICES.
1) The block sensor is fastened on a plate welded on the left shoulder of the retractable carriage under
the mast support (Ref. 1-2 Pict. 43 on page 22a for the Standard machine, Ref. 1-2 PICT. 45 on PAGE
22a for the Narrow machine), and it is connected electrically to connector 19 on MHYRIO Pin 7-1720 CN A 6 Module. See the wiring diagram on page 22b.
2) The reading cam is welded on the mast side fork holder plate shoulder (Ref. 3 Pict. 44 on page 22a for
Standard machine, Ref. 3 Pict. 46 on page 22a for Narrow machine)
OPERATION
When the pallet resting on the forks is lowered and the retractable carriage is completely retracted the
cam reaches the sensor and locks the lowering. This prevents the pallet from flapping against the
wheelbase. To place the pallet on the ground it is necessary to extend the retractable carriage.
CAN I/O MODULE CONFIGURATION TABLE

To enable the machine to work with the pallet forked on the 1200mm side it is necessary to perform the
procedure described below by setting the AUX FUNCTION 1 in position ON.
ADJUSTMENT TO ENABLE THE MACHINE TO THE 1200m m PALLET DRAW ING
Se que nce
Acce ssorie s Module
No.
MENU CONFIG.
CONSOL
CONSOLE
PARAMETER
De scription of the ope ra tion to

be pe rform e d
SETTING
W hen the machine is off, connect

the console to the CAN I/O
module, key switch ON.
CAN I/O
SET OPTIONS
AUX
FUNCTION 1
To enable the machine to draw

pallet on the 1200mm side and to
prevent the pallet from leaning on
the wheelbase with retractable
carriage retracted.
ON
2 3
5 6
REVISION
SERVICE
APPLICATION OF THE SENSOR AND CAM

FOR THE FORK LOWERING LOCK WITH
1200mm PALLET
COM P ONENTS TO AP P LY THE FORK

LOW ERING BLOCK W ITH 1200m m P ALLET
Re f
P late to be welded for the s ens or s upport
1
Induc tive s ens or
2
S ens or reading c am
3
Connec tion s heath
4
1
2
1
Pict. 43
Pict. 45
SENSOR POSITION OF THE STANDARD
RETRACTABLE CARRIAGE.
SENSOR POSITION ON THE

NARROW RETRACTABLE
CARRIAGE
READING CAM POSITION FOR THE

STANDARD MACHINE
READING CAM POSITION FOR

NARROW MACHINE
Pict. 42
Pict. 44
REVISION
Pict. 46
0 1
5 6
Date: March 2002
Comp. No.: 524159096
Page 22a
SERVICE
REVISION
0 1
5 6
Date: March 2002
Comp. No.: 524159096
SERVICE
OPTION SHEET No. 10

WARMED SEAT
CONNECTOR TO
JOIN
THE
RESISTANCE
Fig. 47
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 23
SERVICE
PROCEDURE TO INSTALL THE WARMED SEAT KIT

- WARMED SEAT KIT
-NONE
INSTALLATION NOTES
Medium Phillips
screwdriver
5mm
Allen wrench
The warmed seat is equipped with a kit complete with connection sheaths.
For the assembly it is necessary to open the motor compartment bonnet by means of an Allen wrench,
take out the standard seat and assemble the warmed seat on the same guides.
Open the system compartment bonnet by means of the Phillips screwdriver and disconnect the engine
compartment cooling fan connection from connector L. Join the sheath male connector to the system
connector L, the famale connector L to the cooling fan and the sheath connector G to the seat
connector. See the picture below.
NOTE: Before starting the assembly and the connection, put the key switch in position OFF and
disconnect the battery
SHEATH MALE CONNECTOR

L MUST BE CONNECTED TO
THE SYSTEM CONNECTOR
L
CONNECTOR
L JOINT TO
THE SYSTEM
SHEATH FEMALE
CONNECTOR G
MUST BE JOINT TO
THE SEAT
WARMED SEAT
SHEATH
SHEATH FEMALE
CONNECTOR L
MUST
BE
CONNECTED TO
THE FAN
Pict. 48
2 3
5 6
REVISION
SERVICE
WIRING DIAGRAM TO
CONNECT
THE
WARMED SEAT
STARTING
INTERNAL
THERMOSTAT
WARMED SEAT
RESISTANCE
CONNECTION FOR
THE
REFRIGERATING
ROOM
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 25
SERVICE
NOTES:
2 3
5 6
REVISION
SERVICE
OPTION SHEET No. 11

- 30 REFRIGERATING ROOM
Pict. 49
INTERCOM FOR
THE EXTERNAL
COMMUNICATION
FIXED INSIDE THE
ROOF COLUMN
Pict. 50
ELECTRIC DEVICE AND
PROGRAMMING CONSOLE
CASE
Pict. 51
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 27
SERVICE
ELECTRIC COMPONENTS OF THE REFRIGERATING ROOM

22
23
25
24
Pict. 52
7
10 11 12 13 14 15 16
6
3
17 18 19 20 21
2
9
Pict. 53
2 3
5 6
REVISION
SERVICE
ELECTRIC COMPONENT POSITION

The electric components shown in the previous page are described in the table below.
Re f.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Card
Resistance container to heat the cab
Fan to heat the cab
Main remote control switch
Resistance remote control switch to heat the secondary devices
Resistance remote control switch to heat the primary devices
Primary resistances
Cab heating resistance thermal switch
Connector connection
Fuse 3A to protect the control card
Fuse 3A to protect the starting key
Fuse 3A to protect the fan
Fuse 10A to protect the cab heating resistance ( 1 )
Fuse 10A to protect the cab heating resistance (1a)
Fuse 10A to protect the cab heating resistance (2)
Fuse 10A to protect the cab heating resistance (2a)
Fuse 7,5A to protect the windscreen defroster resistance
Fuse 3A to protect the upper roof glass defroster resistance
Fuse 5A to protect the driver's side front glass defroster resistance
Fuse 1A to protect the side door glass defroster resistance
Fuse 5A to protect the central door glass defroster resistance
Console to program the temperatures and the intercom audio
Upper air recirculation louver
Lower air recirculation louver
Control panel closing door
NOTE: All the Yale codes of the components are contained in the spare part catalogue
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 29
SERVICE

-NONE
-NONE
OPERATION NOTES
ELECTRIC SYSTEM OPERATION DESCRIPTION
CAB CONSOLE
CAB
TEMPERATURE
ADJUSTMENT
LED
HEATER
TIME ADJUSTMENT
OF THE GLASS
RESISTANCE
LED
20
ON
15
ON
10
INTERCOM
VOLUME
ADJUSTMENT
LED
GLASS HEATER
00
INTERCOM
ON
TALK
MINUTES
RESISTANCE
STARTING
TIME
By using the console you can adjust:
1)
The inner temperature of the cab by acting on the HEATER keys.
2)
The glass resistance operating time to allow the refrigeration room inlet and outlet defrosting by
acting on the GLASS HEATER keys.
3)
Variation of the volume of the intercom for the external audio connection by acting on the
INTERCOM keys.
The procedures of the adjustments are described in the following pages.
2 3
5 6
REVISION
SERVICE
1)
HEATER CAB HEATING
LED
HEATER
LED
GLASS HEATER
20
ON
00
ON
15
MINUTES
10
ON
LED
INTERCOM
ON
TALK
KEY ON - By pressing this key the resistance starting remote control switch to heat the cab
is enabled and disabled.
GREEN LED - If it is on, it indicates that the resistance starting remote control switch is
enabled.
20
15
10
TEMPERATURE INDICATOR - It indicates the set or the real temperature (from 10C to
20C with level of 1C). The indication of the set temperature occurs immediately when the
key ON is enabled and not when the machine is started. The real temperature is displayed
by pressing the arrows
and
at the same time. If the temperature is lower than the
minimum scale temperature, the first LED of the indicator flashes. If the temperature is higher
than the maximum scale temperature the whole indicator scale flashes.
UP and DOWN ARROWS - To vary the set temperature press one of the two keys for a
second at least, till the desired temperature is reached. To display the real temperature press
both keys at the same time.
The two cab heating elements are inserted at the same time till the set temperature is reached
(1 or 2 degrees earlier), afterwards, the resistances 2 and 2A are automatically disabled and
the heating operates with a heating element only: resistances 1 e 1A.
After the manual disabling of the function, the fan remains enabled for about 5 minutes. The
last set temperature stored when the machine is turnd off.
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 31
SERVICE
2)
ENABLING TIME ADJUSTMENT OF THE GLASS HEATER GLASS

DEFROSTING RESISTANCES
LED
HEATER
LED
20
ON
15
10
ON
ON
LED
GLASS HEATER
00
INTERCOM
ON
TALK
MINUTES
KEY ON - By pressing this key the glass resistance automatic starting remote controlswitch
is enabled and disabled.
NOTE: a) The glass heater starting and the cab heating starting must not be performed at the
same time.
b) The glass resistences must be enabled 5 minutes before going in or out the
refrigerating room.
GREEN LED - If it is on, it indicates that the glass heating resistance remote control switch is
enabled.
00
MINUTE INDICATOR DISPLAY - It indicates the real time during which the heater is operating
(the minute scan) and the initial set time displayed when the machine is started. the time
MINUTI selection can occur between 1 and 15 minutes. When the machine is stopped, the last set
datum is stored.
UP AND DOWN ARROW - To vary the heating time press one of the tow key for at least
second until the desired value is reached. To display the set time press both keys at the same
time.
2 3
5 6
REVISION
SERVICE
3)
INTERCOM EXTERNAL COMMUNICATION AUDIO VOLUME

ADJUSTMENT
LED
HEATER
LED
GLASS HEATER
20
ON
00
ON
15
MINUTES
10
ON
LED
INTERCOM
ON
TALK
KEY ON - By pressing the key, the audio reception from the inside to the outside of the cab
is enabled.
GREEN LED - If it is on, it indicates that the audio function is enabled.
TALK
KEY TALK - By keeping this key pressed the transmission of the audio from the inside to
the outside of the cab is enabled, by releasing the key the audio transmission stops.
+
VOLUME INDICATION - It indicates the 10 different levels of volume intensity coming from
the outside and displayed any time the intercom is started. Once the machine is off the last set
set value is stored.
UP and DOWN ARROW - To vary the volume intensity from the outside to the inside, press
one of the two keys for till the desired volume is reached.
ADJUSTMENT OF THE VOLUME FROM THE INSIDE TO THE OUTSIDE - it can be adjusted
by means of a trimmer located inside the cab on the intercommunication system/loudspeaker
unit.
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 33
SERVICE
POSITION OF THE COMPONENTS ON THE REFRIGERATING ROOM CAB PANEL
RES - 1 - 1A
RES - 2 - 2A
THERMAL
DEVICE
FAN
J4
J2
J3
CONNECTOR TO JOIN THE HEATER
J1
F1
F2
F5
F3
F6
F4
F7
F11
F8
F12
F9
F13
F10
J5
J6
T1
T2
T3
CONNECTOR TO JOIN THE HEATER
2 3
BATT
BATT
5 6
REVISION
SERVICE
Section: ELECTRIC INSTALLATION

WIRING DIAGRAM TO CONNECT THE CABLES
OF THE REFRIGERATING ROOM CAB
MOD. ALL THE MODELS
CONTROL ELECTRONIC CARD

J1
J4
J2
TERMICA
T2
F11
F14
F13
RES-1
1 2
RED
RED
BLEU
VIOLET
VIOLET
BLEU
BROWN
ORANGE
BLEU
RED
T1
J5
J3
1
GRUPPO ALTOPARLANTE
SULLA PORTA
SCREENED CABLE 8 POLES
T3
OUT
MC
+
-
+ BATT
DEFROSTER
RES-2
FAN
J6
BLACK
BLACK
MIC.
SCREENED CABLE
& POLES
W IRING DIAGRAM
T1
T2
T3
F5
F3
F4
F1
RES-2
400 H
RES-1
400 H
RES-1A
400 H
Dia gra m
re f.
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
T1
T2
T3
RES-1-1A
RES-2-2A
V
MIC
+Ba tt
-Ba tt
F6
F7
F8
F9
F10
RED
RED
RED
F2
RES-2A
400 H
- BATT
HEATER
CONNECTOR
DOOR DEFROSTER
RESISTANCES
REVISION
0 1
2 3
De scription of the function

Fuse to protect the RES-2
Fuse to protect the RES-2A
Fuse to protect the RES-1
Fuse to protect the RES-1A
Not used
Fuse to protect the central door defroster resistance
Fuse to protect the side door defroster resistance
Fuse to protect the driver front glass defroster resistance
Fuse to protect the roof upper glass defroster resistance
Fuse to protect the windscreen glass defroster resistance
Fuse to protect the fan of the air recirculation in the cab
Fuse to protect the control card output cable
Fuse to protect the control card input cable
RES-1 e 1A remote control switch
RES-2 e 2A remote control switch
Door defroster remote control switch
400 H cab heating resistances
400 H cab heating resistances
fan of warm air recirculation in the cab
Microphone to communicate with the outside
Battery positive connection cable
Battery negative connection cable
5 6 Date: March 2002 Comp. No.: 524195096
Fuse va lue
10A
10A
10A
10A
5A
1A
5A
3A
7,5A
3A
3A
3A
Page 34a
SERVICE
OPTION SHEET No. 12

SEAT BELT
-SEAT BELT KIT
-NONE
INSTALLATION NOTES
ELECTRIC
DRILL
8,5mm STEEL
DRILL
TAPELINE
SCRIBE
5-6mm ALLEN
WRENCH
13mm
SPANNER
SQUARE
PROCEDURE
Before starting working, make sure to wear suitable safety clothing.
Drive the carriage in a safety area far from pedestrian and other vehicle passage, move forward
the retractable carriage, lower the forks, put the key switch in position OFF, disconnect the battery.
1) 5mm ALLEN WRENCH, TAPELINE, SCRIBE, SQUARE - By means of the Allen wrench open the
engine compartment bonnet and remove the seat by taking it out from the guides (Pict. 54 on page
29a). By means of the tapeline, the scribe and the square mark the holes to fix the seat belt support
bracket on the bonnet observing the measures shown in picture 56 for the NARROW truck and in
picture 57 for the STANDARD truck ON PAGE 29A).
2) ELECTRIC DRILL, STEEL DRILL, 6mm ALLEN WRENCH, 13mm SPANNER - Assemble the drill and
carry out the holes in the marked points; by using the two wrenches assemble the bracket complete
with seat belt as shown in picture 58 on page 36a.
REVISION
0 1
2 3
5 6 Date: Mar. 2002 Comp. No.: 524159096
Page: 35
SERVICE
NOTES:
2 3
5 6
REVISION
SERVICE
Section: ADDITIONAL FUNCTIONSI
OPTION SHEET No. 12a
SCHEMA DI MONTAGGIO
CINTURA DI SICUREZZA
COMPLESSIVO CINTURA
MONTATO
Pict. 58
Pict. 55
N 2 Fori 8,5
No. 2 8,5
holes
HOLE TO APPLY THE NARROW TRUCK SEAT
HOLE TO APPLY THE STANDARD
BELT
TRUCK SEAT BELT
Pict. 56
Pict. 57
Pict. 54
REVISION
0 1
5 6
Date: March 2002
Comp. No.: 524159096
Page 36a
SERVICE
OPTION SHEET: UPDATE No. 1

-INTERMEDIATE LIFTING LOCK SENSOR (SW11)
-FUNCTION RELEASE BY MEANS OF THE PUSH BUTTON ON THE
DISPLAY (SW18)
Picture 01
UPDATES TO BE INSERTED IN THE SERVICE MANUAL
MR1.4/2.5 SECTION "ADDITIONAL FUNCTIONS" Page 36
Release
1
2
3
UPDATE
0 1
Update description
Description of the lifting lock sensor assembly and SICOS
module configuration
Description of the weighing function programming
Description of the speed reduction removal speed with
carriage completely extended
2 3
5 6 Date: March 2004 Comp. No.:524159096 Page: 37
SERVICE
OPERATING PROCEDURE OF THE LIFTING LOCK KIT

!

- LIFTING BLOCK KIT
OPERATION NOTE
The kit is generally installed on machines, which are not provided with encoder or height preselector. The
equipment is used for programming an intermediate lifting lock, in case some hindrances prevents the
operator from working with the mast completely withdrawn.
POSITION OF THE EQUIPMENT
The sensor is fixed on a collar, which is generally fastened on the right lifting cylinder of the column
(Picture 04-05). The sensor is turned to the internal mast (Picture 05-06) . It is connected to connector
20, which is already provided on module 9 MHYRIO Pin 8-17-20 CN A.
The sensor reading cam correspond to the internal mast profile (Ref. B Picture 06) whereas the final end
is the base of the mast itself (Ref. A Picture 06).
HOW IT OPERATES
When performing the lifting, the internal mast base reaches
the sensor and stops the lifting to the established position. To
disable the lock, press push button BATTERY OUT located
on the display panel (Picture 02) and, in the same time, pull
the lifting lever (Joystick) to take the forks to the maximum
height.
PUSH BUTTONS LOCATED ON THE DISPLAY AND

USED FOR ENABLING THE INTERMEDIATE
LIFTING REALESE
Picture 02
CONFIGURATION TO MODULE 16 SICOS TABLE

To enable the lifting lock function, follow the procedure below by setting AUX INPUT 1 to 2 of the SET
OPTION configuration menu.
ADJUSTMENT TO ENABLE THE LIFTING LOCK

MENU
CONSOLE
Sequence
SETTING
Accessorie s Module CONFIGURATI
PARAMETER
No.
ON CONSOLE
Description of the operations

to be follow ed
W hen the machine is off, connect
the console to the module 6
"EPS" control and enter module
16 "SICOS", then start the
machine, (key switch "ON")
SICOS
SET OPTIONS
AUX INPUT 1
Page: 38 Comp. No.:524159096 Date:March 2004 0 1
To enable an intermediate lifting

block with realese by means of
key "BATTERY OUT" on the
display keyboard
3 4
5 6
UPDATE
SERVICE
INSTALLATION OF THE LIFTING LOCK SENSOR (SW11)
Picture 04
LIFTING LOCK SENSOR KIT
SENSOR SUPPORTING UNIT
Picture 05 FIXED ON THE CYLINDER
Picture 03
UPDATE
0 1
2 3
SENSOR
READING
PROFILE
(B)
Picture 06
(A)
SENSOR
READING FINAL
POINT
INTERMADIATE
MAST
SERVICE
"
INSTALLATION NOTE
5-6mm
ALLEN WRENCH
PROCEDURE
No. 2 13mm
OPEN ENDED
SPANNER
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage
of pedestrians,extend the retractable carriage
1) 5mm ALLEN WRENCH - Unscrew the bolts fastening the valve unit on the carriage, remove the
bonnet to reach module 9 MHYRIO. To lock, lift the forks, until the desired height is reached. Disable
the key switch, disconnect the battery.
2) No. 2 13mm OPEN ENDED SPANNER - Assemble the various components of the sensor kit. Fix the
collar complete with sensor to the lifting cylinder (Picture 05) by means of the spanner and position it
near the end of the intermediate mast (Picture 06 arrow A). Connect the sensor to Module 9
MHYRIO (see diagram on page 41), bind the cable to the cylinder by means of a clamp. Connect
the battery, set the key to ON, lower the forks and enable the sensor by performing the configuration
procedure of Module 16 SICOS (see table on page 2).
3 4
5 6
UPDATE
SERVICE
SW11 LOCK SENSOR CONNECTING DIAGRAM
UPDATE
0 1
2 3
SERVICE

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

1) Connect the console (see table) and perform
procedure 1 and 2. Press push button SW23
provided with the balance symbol (Picture 07)
located on the display. The system starts the
weighing.
2) Pull the lifting lever (Joystick), the forks lift only
few seconds by keeping constant speed. It is
now possible to detect the weight value. This
value is shown on the display about 4/5
seconds then it disappears and appears
automatically the weighing function.
PUSH BUTTON (SW23)TO SELECT THE

WEIGHING FUNCTION
Picture 07
b) WEIGHT WITH LOADS ON THE FORKS

3) Carry out table procedure 3. Put the nominal load on the forks. Take the forks with the load up to
1000mm, press push button SW23 provided with the balance symbol (Picture 07). Carry out procedure 2 to detect the weight.
TABLE OF CONFIGURATION TO MODULE 16 SICOS

To enable automatic weighing function, follow the procedure below
WEIGHING FUNCTION ENABLING
Sequence
Accessories Module
No.
Config Menu
Parameters
SICOS
SET OPTIONS
ADJUSTMENTS
ADJUSTMENTS
AUTOMATIC
WIEGHT
Settings
Description of the operations to be

performed
When the machine is off, connect the

console to the Module 6 "EPS-AC" and
enter Module 16 "SICOS". Start the
machine (set key switch to "ON")
Press "ENTER" to save the data, press
ON
"OUT" to quit
(See description 1 and 2 ).Press
ADJ 0 KG
"ENTER" and store the weight without
POINT
load
(See description 3 and 2). Press
ADJ 1000 KG
"ENTER" to store the sample weight.
POINT
Press "OUT" to quit.
3 4
5 6
UPDATE
SERVICE

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

PROCEDURE TO REMOVE SPEED REDUCTION FUNCTION WITH WITHDRAWN CARRIAGE
Sequence
Accessories Module
No.
Config Menu
Parameters
Settings
SICOS
UPDATE
SET OPTIONS
0 1
2 3
SPEED LIMIT
OFF
Description of the operations to be

performed
When the machine is off, connect the
console to Module 6 "EPS-AC" and
enter Module 1 "CAN-I/O". Start the
machine (set the key switch to "ON")
Press "ENTER" to save the data,
press "OUT" to quit
SERVICE
3 4
5 6
UPDATE
SERVICE
Section: HYDRAULIC SYSTEM
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
UPDATE
HYDRAULIC SYSTEM
HYDRAULIC
SYSTEM
KEY TO HYDRAULIC SYSTEM SYMBOLS ............................................................ 2
ELECTRICAL DIAGRAMS ..................................................................................... 2a
CORRECT ASSEMBLY METHOD FOR FEMALE UNIONS ..................................... 3
HYDRAULIC UNIT COMPONENTS ......................................................................... 4
BASIC TRUCK HYDRAULIC SYSTEM .................................................................... 6
BETA TYPE MAST HYDRAULIC SYSTEM ............................................................. 7
SINGLE ACTING LATERAL LIFT CYLINDER ........................................................... 8
SELF-BRAKING DURING LOWERING .................................................................... 8
SINGLE ACTING CENTRAL LIFT CYLINDER .......................................................... 9
SELF BRAKING DURING LIFTING AND LOWERING .............................................. 9
SINGLE ACTING LIFT CYLINDERS WITH STROKE END HYDRAULIC
CUSHIONING IN LIFTING AND LOWERING DIRECTIONS .................................... 10
LATERAL PLUNGER TYPE LIFT CYLINDER ........................................................ 11
CENTRAL PLUNGER TYPE LIFT CYLINDER ....................................................... 12
PLUNGER TYPE LIFT CYLINDERS ...................................................................... 13
REACH TRUCK REACH CYLINDER ..................................................................... 14
FORKS TILT CYLINDER........................................................................................ 15
FORKS SIDESHIFT CYLINDER ............................................................................ 16
DISASSEMBLING LATERAL LIFT CYLINDERS FROM MAST .............................. 17
REPLACING SINGLE ACTING LATERAL CYLINDER SEALS ............................... 19
DISASSEMBLING CENTRAL LIFT CYLINDERS FROM MAST ............................. 20
REPLACING SINGLE ACTING CENTRAL CYLINDER SEALS .............................. 22
REPLACING THE LATERAL PLUNGER CYLINDER SEALS ................................. 23
REPLACING THE CENTRAL PLUNGER CYLINDER SEALS ................................ 25
DISASSEMBLING THE FORKS TILT CYLINDER .................................................. 27
REPLACING THE SEALS ..................................................................................... 29
REPLACING THE FORKS SIDESHIFT CYLINDER SEALS ................................... 30
DISASSEMBLING THE REACH TRUCK CYLINDER ............................................. 31
REPLACING THE FORKS REACH CYLINDER SEALS ........................................ 32
REPLACING THE OIL SUPPLY HOSES TO THE TILT CYLINDER
AND SIDESHIFT CYLINDER ................................................................................. 33
DISASSEMBLING THE CENTRAL CYLINDER OIL SUPPLY LINE ........................ 34
Date: Mar. 2002
Part No.: 524159096
Page: 1
SERVICE

1.01 KEY TO HYDRAULIC SYSTEM SYMBOLS
MODEL ALL MODELS
HYDRAULIC SYSTEM
Here we give the symbols used in the diagrams in this section with their meanings.
TWO-POSITION SOLENOID
VALVE
THREE-POSITION
SOLENOID VALVE
FILTER
CHECK VALVE
DOUBLE-ACTING
CYLINDER
PROPORTIONAL VALVE
SINGLE-ACTING CYLINDER
PUMP
HYDRAULIC MOTOR
TANK
Page: 2
LINE CONNECTION
ELECTRIC MOTOR
PRESSURE RELIEF VALVE
FLOW CONTROL VALVE
MANUAL VALVE
BY-PASS VALVE
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE

HYDRAULIC FUNCTIONAL DIAGRAM
MODEL ALL MODELS
Ev2
Ev4
Ev6
Ev8
Ev1
Ev4
Ev6
Ev8
Ev1
Ev5
Ev3
Ev2
Ev3
Ev5
Ev7
Ev7
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2a
SERVICE
THE INPUT MODULE IS HMT TYPE FOR LIFT TRUCKS,

DESIGNED TO RESTRICT INTERNAL LEAKAGE DURING
DOWNWARD MOVEMENT TO 3 CM3 PER MINUTEAT FULL LOAD.
3
8
A
LIFTING AND LOWERING

CONTROL VALVES BANK
MODEL ALL MODELS
LIFTING VALVE
A
9
P
1
H
C
(1) PROPORTIONAL VALVE

This is a cartridge type valve
When it is activated it opens completely and
the oil flow is proportional to the pump motor
rpm.
It provides proportional operation exclusively
for simultaneous movements (fork lift/reach
carriage extension)
Min. opening 250mA
Max. opening 650mA
(3)PRESSURE RELIEF VALVE

Composed of adjuster screw (A), spring
(C), spool (D) and poppet (E).
The function of this valve is to regulate
pressure in the hydraulic circuit. The relief
valve is calibrated at between 200 and
220 bar depending on the rated capacity
of the truck
D
C
(6) CHECK VALVE

Composed of plug (A), spring (C), plunger
(D)
The function of the check valve is to prevent
oil from returning to tank through the valve
and pump when the joystick is in the rest
position
7
4
INPUT MODULE
Ev3
Ev 6
Ev 4
(4) REGULATOR SPOOL

Composed of spool (A), precalibrated spring (B) and adjuster
screw (D).
The function of the regulator spool
is to control oil flow during
lowering movements.
Screw: adjustment for maximum
speed (16.8 mm opening)
(2) PILOT VALVE

Composed of magnet (A) and
pilot valve (B) screwed into the
block. The pilot valve serves to
drive the regulator spool
Ev2
Ev1
(7) EMERGENCY LOWERING VALVE

Composed of screw (A), sector (B), and
spool (C).
This valve is used to lower the forks without
electrical command signals
Ev5
Ev8
Ev7
LOWERING VALVES BANK
2
4
(5) PRESSURE
COMPENSATOR
Composed of spool (A) and
spring (B).
The pressure compensator
serves to assure constant speed
of hydraulic movements in
loaded or unloaded conditions
16.8mm
6
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2b
SERVICE

REACH CARRIAGE AND FORKS "UP"
TILT "BACK" / "FORWARD"
CONTROL VALVES BANK
MODEL ALL MODELS
OVERCENTRE VALVE INSTALLED ON THE TILT CYLINDERS
SOLENOID VALVE
100 bar
FORKS TILT MOVEMENT
200 bar
VALVE PILOT TRANSMISSION

RATIO 1-8
12 bar
If a load on the forks generates

pressure of 100 bar, the pilot
pressure required in point P will
be: 200 - 100
= 12
8
PRESSURE COMPENSATOR
(REACH CARRIAGE 10 BAR)
FORKS TILT VALVES BANK
Ev4
Ev6
Ev8
Ev1
After valve EV5 or EV6 opens oil

flows through the overcentre valve
located on the tilt cylinders, which
operates on the tilt "forward" stroke
Closed centre solenoid valve on

return line to prevent hydraulic
accumulator effects resulting from
the large amount of oil contained in
the truck's hydraulic lines.
EV5 fork tilt "back" control
EV6 fork tilt "forward" control
In the event of tilt problems, with the

load tending to descend when no
command is present, renew the
overcentre valve - do not attempt
to clean
INPUT MODULE
REACH
CARRIAGEVALVES BANK
Proportional 4-way closed centre

solenoid valve
carriage retract control valve EV3
carriage extend control valve EV4
Ev2
235mm
Ev3
Ev5
Ev7
1) EV3 carriage retraction

antishock valve EV3
calibrated at 60 bar.
2) EV4 carriage extension
antishock valve calibrated at
80 bar.
Removing the plug reveals
a spring that exerts
pressure on a check ball; in
the event of malfunctions
remove the parts and clean
the seat
A and B proportional spools for

maximum opening adjusted to a
distance between stroke limits of
235 mm
Solenoid valves proportional

opening
min. 390 mA - max 900 mA
UPDATE
3) Pressure compensator.
The pressure compensator performs a
dual function in forks lifting and reach
carriage extension movement. This
component provides pressure
compensation that eliminates
performance differences in loaded and
unloaded conditions
lifting 200 bar
.
Example
carriage 50 bar
3) TRANSLATION MOVEMENT
BLOCKED.
The compensator closes and the oil is
dumped to tank through the pressure
relief valve. Remove the valve, unscrew
the plug, clean the internal parts
thoroughly and then refit
Date: Mar. 2002
Part No.: 524159096
Page 2c
SERVICE

HYDRAULIC CIRCUIT STATUS
IN FORKS LIFTING PHASE
Ev2
Ev4
Ev6
Ev8
Ev1
Ev7
Ev5
Ev3
OIL DELIVERY
OIL RETURN
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2d
SERVICE

IN FORKS LOWERING PHASE
Ev2
Ev4
Ev6
Ev8
Ev1
Ev5
Ev3
Ev7
OIL DELIVERY
OIL RETURN
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2e
SERVICE

IN REACH CARRIAGE EXTENSION PHASE
Ev2
Ev4
Ev6
Ev8
Ev1
Ev5
Ev3
Ev7
OIL DELIVERY
OIL RETURN
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2f
SERVICE

IN REACH CARRIAGE RETRACTION PHASE
ITT JOYSTICK HYDRAULIC CONTROL
Ev2
Ev4
Ev6
Ev8
Ev1
Ev5
Ev3
Ev7
OIL DELIVERY
OIL RETURN
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2g
SERVICE

IN FORKS UPWARD TILT PHASE
Ev2
Ev4
Ev6
Ev8
Ev1
Ev5
Ev3
Ev7
OIL DELIVERY
OIL RETURN
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2h
SERVICE

IN FORKS FORWARD TILT PHASE
Ev2
Ev4
Ev6
Ev8
Ev1
Ev5
Ev3
Ev7
OIL DELIVERY
OIL RETURN
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2i
SERVICE

IN FORKS SIDESHIFT TO LEFT
Ev2
Ev4
Ev6
Ev8
Ev1
Ev5
Ev3
Ev7
OIL DELIVERY
OIL RETURN
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2l
SERVICE

IN FORKS SIDESHIFT TO RIGHT
Ev2
Ev4
Ev6
Ev8
Ev1
Ev5
Ev3
Ev7
OIL DELIVERY
OIL RETURN
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page 2m
SERVICE
1.02 CORRECT ASSEMBLY METHOD FOR FEMALE UNIONS

To ensure an oil-tight connection between the female unions and adapters shown in this manual, observe
the following procedure, which differs from that used for flexible hoses.
HYDRAULIC SYSTEM
FEMALE UNIONS WITHOUT SEALS (METAL TO METAL COUPLING)

Snug the nut by hand and then tighten with a wrench by no more than 1/4 turn.
FEMALE UNIONS WITH O-RING SEAL
12
Snug the nut by hand and then use a wrench to tighten by no more than a further 1/2 turn.
In all cases, ensure that the line is correctly aligned before tightening the adapter nut.
Note:
The values supplied in the tables are typical for the recommended assembly method in
the case of galvanized unions. Unions made of different materials call for the use of
alternative values.
TORQUE VALUES
TORQUE VALUES
TORQUE VALUES
ORFS
METRIC FEMALE UNION

METRIC
THREAD
M12x1,5
M14x1,5
M16x1,5
M18x1,5
M20x1,5
M22x1,5
M24x1,5
M26x1,5
M30x2
M36x2
M42x2
M45x2
M52x2
Nm
Nm
OUTSIDE
6
8
8
10
10
12
12
14
15
16
18
20
22
25
28
30
35
38
42
NOMINAL
MIN./MAX
20
38
15-25
30-45
45
38-52
51
43-58
58
50-65
74
60-88
74
105
60-88
85-125
135
115-155
166
140-192
240
290
210-270
255-325
330
280-380
UNF THREAD
SIZE
9/16-18
11/16-16
13/16-16
1-14
1.3/16-12
1.3/16-12
1.7/16-12
1.11/16-12
2-12
-4
-6
-8
-10
-12
-14
-16
-20
-24
MIN
MAX
14
24
43
60
90
90
125
170
200
16
27
47
68
95
95
135
190
225
Table 2
Table 1
TORQUE VALUES
TORQUE VALUES
JIC 37 FEMALE UNION
FEMALE UNION BSP

Nm
UNF THREAD
SIZE
7/16-20
1/2-20
9/16-18
3/4-16
7/8-14
1.1/16-12
1.3/16-12
1.5/16-12
1.5/8-12
1.7/8-12
2.1/2-12
-4
-5
-6
-8
-10
-12
-14
-16
-20
-24
-32
Nm
NOMINAL
MIN./MAX
BSPP THREAD
15
20
30
50
69
98
118
140
210
290
450
9-21
13-27
18-42
30-70
44-94
63-133
73-163
90-190
135-285
200-380
300-600
G1/4
G3/8
G1/2
G5/8
G3/4
G1
G1.1/4
G1.1/2
G2
NOMINAL
MIN./MAX
20
34
60
69
115
140
210
290
400
15-25
27-41
42-76
44-94
95-135
115-165
140-280
215-365
300-500
Table 3
UPDATE
Date: Mar. 2002
Table 4
Part No.: 524159096
Page: 3
SERVICE

1.03 HYDRAULIC UNIT COMPONENTS
13
15
10
EV6
EV8
EV5
EV7
60 bar
200/220
bar
16
8
EV4
EV1
HYDRAULIC SYSTEM
11
17
1
14
80 bar
12
38
5
EV3
EV2
11
32
32
33
24
34
35
25
36
27
26
29
30
Fig. 1
28
23
Ev2
Ev4
Ev6
Ev8
Ev1
2
21
13
18
22
19
Ev7
Ev5
Ev3
31
20
Fig. 2
37
37
Page: 4
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
1.04 TABLE OF HYDRAULIC UNIT COMPONENTS

MODEL ALL MODELS
The hydraulic unit components illustrated on the previous page are described in the following table.
Ref.
Ref. Diagram
Re f.
1
2
3
4
5
6
7
8
9
10
11
Re f. Dia gra m
EV1
EV2
EV3
EV4
EV5
EV6
EV7
EV8
Compone nt de scription
Oil inlet module
Hydraulic pressure regulator valve (set at between 200 and 220 bar)
Mast lowering proportional solenoid valve
Mast lifting proportional solenoid valve
Reach carriage cylinder "retract" proportional solenoid valve
Reach carriage "extend" proportional solenoid valve
Tilt cylinder "back" solenoid valve
Tilt cylinder "forward" solenoid valve
Forks sideshifter cylinder "Lh" movement solenoid valve
Forks sideshifter cylinder "Rh" movement solenoid valve
Adjustment of proportional spools for maximum opening of the reach carriage valve
Lowering movement oil flow regulator spool adjusted with maximum capacity at
51 l. and at 155 bar (screw adjusted for maximum speed 16.8 mm opening).
Valve for emergency lowering when no electrical controls are available
Connection union for oil delivery hose arriving from pump
Connection union for lift cylinders delivery hose
Connection union for oil return line to tank
Pressure gauge connection union for system pressure testing
Pump motor
Lift pump
Return oil filer
Valve bank hydraulic supply line (lift pump to valves bank)
Oil return line (valves bank to tank)
Lift cylinders supply line (valves bank to cylinders) 3/8"
Reach carriage cylinder supply lines (valves bank to cylinder) 1/4"
Tilt cylinders supply lines (valves bank to cylinders) 1/4"
Forks sideshifter cylinders hydraulic supply lines (valves bank, cylinders)
Valve controlling oil flow to forks sideshifter cylinders
Tilt cylinders pressure relief valve
Reach cylinder anti-shock valve located internally to the valves bank
Valve controlling oil flow of cylinders during lowering
Pressure compensation valve for simultaneous activation of lift function and reach
Mast lifting lateral cylinders
Mast lifting central cylinder
Extend/Retract reach carriage cylinder
Forks "back/forward" tilt cylinders
Forks right/left sideshift cylinder
Oil tank
Pressure compensator valve for mast descent
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Component reference in exploded view

Reference to symbol in functional diagram
Function of component
P
H
R
M
LB
DW
DW
NOTE: All Yale Part Numbers are given in the parts catalogue.
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 5
HYDRAULIC SYSTEM
Key:
SERVICE

1.05 BASIC TRUCK HYDRAULIC SYSTEM
MODEL ALL MODELS
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM COMPONENTS
10
9
11
13
14
12
1
4
Fig. 3
1.06 TABLE OF BASIC TRUCK HYDRAULIC SYSTEM COMPONENTS

Ref.
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Lift pump l. 11 - MR20 - MR25
Lift pump l. 16 - MR14 - MR14H - MR16 - MR16H - MR20H - MR20W
Solenoid valves bank
Reach carriage cylinder
Oil suction line (tank/pump)
Oil pressure line (pump/valves bank)
Oil return line (valves bank/tank)
Cylinders delivery diverter block
Connection line between valves bank and cylinders delivery diverter block
Return oil filter
Oil filter housing
Oil tank
Pump suction line union
Pump pressure line union
11 KW pump unit
Page: 6
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
1.07 MAST HYDRAULIC SYSTEM

MODEL ALL MODELS
HYDRAULIC SYSTEM COMPONENTS
5
HYDRAULIC SYSTEM
1
6
9
8
12
4
10 11
4
1
2
Fig. 4
1060175
1.08 TABLE OF MAST HYDRAULIC SYSTEM COMPONENTS

Ref.
1
2
3
4
5
6
7
8
9
10
11
12
Connection hose to central cylinder
Connection hose to lateral cylinders
Twin connection hoses to forks sideshifter cylinder
Twin connection hoses to tilt cylinder
Pulleys unit for hoses on mast
Pulleys unit for hoses on central cylinder
Single-acting central lift cylinder with upward stroke cushioning
Single-acting Rh lateral lift cylinder with downward stroke cushioning
Single-acting Lh lateral lift cylinder with downward stroke cushioning
Bracket for twin hoses and central cylinder
Bracket for twin hoses
Hose connecting bracket
UPDATE
5 6 Date: Mar. 2002
Part No.: 524159096
Page: 7
SERVICE

1.09 SINGLE ACTING LATERAL LIFT CYLINDER
WITH SELF-BRAKING DURING LOWERING
MODEL BETA - HE140L - HE140
HYDRAULIC SYSTEM
CYLINDER COMPONENTS
7
9
Fig. 5
1.10 TABLE OF LATERAL SINGLE ACTING CYLINDER COMPONENTS

Ref.
1
2
3
4
5
6
7
8
9
Complete cylinder
Cylinder barrel
Cylinder rod
Gasket bushing
Set of seals for gasket bushing
LB hose break safety valve (prevents oil flow in the event of a hose break)
Seals holder piston and lowering cushioning valve
Set of cylinder piston seals
Cushioning valve
Page: 8
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
1.11 CENTRAL SINGLE ACTING LIFT CYLINDER

WITH SELF-BRAKING DURING LIFTING
MODEL BETA - HE140L - HE140
HYDRAULIC SYSTEM
CYLINDER COMPONENTS
1
2
7
6
9
Fig. 6
1.12 TABLE OF SINGLE ACTING CENTRAL CYLINDER COMPONENTS

Ref.
1
2
3
4
5
6
7
8
9
Complete cylinder
Cylinder barrel
Cylinder rod
Gasket bushing
LB hose break safety valve (prevents oil flow in the event of a burst supply hose)
Sealks holder piston and lift stroke cushioning valve
Set of seals for cylinder piston
Cushioning valve
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 9
SERVICE

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

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

STROKE
The cylinder rod features a hollow core (Ref. G Fig. 8) which is terminated with
a seals holder piston (Ref. F) complete with valve (Ref. E Fig. 8); the rod also
features two oilways for forced oil flow (Ref. C-D Fig. 8).
Fig. 7
central
lift cylinder
Before starting the lifting movement pour 150 cc of oil inside the cylinder barrel
through the plug (Ref. A Fig. 8).
During the lift stroke, when the piston (Ref. F Fig. 8) reaches its stroke limit it
causes the oil previously poured into the barrel to be compressed against the
bush (Ref. B) thus causing a pressure rise that causes the oil to enter the
hollow core in the piston rod by way of the hole (Ref. C) thus compressing the
air in the hollow core (Ref. G) and resulting in the slowing of upward movement
during the final 40 mm of the stroke.
During the lowering stroke the thrust exerted by the rod decreases as the air
pressure in the core decreases, thus causing the 150 cc of oil to flow out of the
rod core into the cylinder barrel.
The function of the valve (Ref. E Fig. 8) is that of maintaining constant pressure
in the rod cavity at the time of ingress of the oil compressed the bushing.
The valve is calibrated in order to witstand the compression of 150cc of oil.
Any excess oil unloaded to the conventional circuit through the valve.
If no deceleration occur over the final 4-5 mm of stroke this indicates that the
valve has ceased functioning and must therefore be replaced.
G
OIL LEVEL
D
C
Through prolonged use and with constant pressure changes inside the
cylinder, the oil in the barrel tends to return to the normal hydraulic circuit due
to infiltration past the piston seals. To counter this problem, 150 cc of oil must
be poured into the cylinder barrel through the plug (Ref. A) every 500-600 duty
hours.
Page: 10
Part No.: 524159096
Date: Mar. 2002
E
F
4
Fig. 8
5
UPDATE
SERVICE
1.14 LATERAL PLUNGER TYPE LIFT CYLINDER

MODEL HE140 - HE140R
CYLINDER COMPONENTS
10
11
HYDRAULIC SYSTEM
10
4
5
3
3
1
2
8
7
6
9
7
1511146_1
Fig. 9
1.15 TABLE OF LATERAL PLUNGER TYPE LIFT CYLINDER COMPONENTS

Ref.
1
2
3
4
5
6
7
8
9
10
11
Complete cylinder
Cylinder barrel
Hollow rod
Gasket bushing
LB hose break safety valve (prevents oil flow in the event of a hose burst)
Hollow rod lower plug
Rod guide bush
Valve for oil flow to rod cavity
Rod air bleed plug
Hollow rod upper plug
Table 10
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 11
SERVICE

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

Ref.
1
2
3
4
5
6
7
8
Complete cylinder
Cylinder barrel
Cylinder rod
Gasket bushing
LB hose break safety valve (prevents oil flow in the event of a hose burst)
Rod guide bush
Cylinder air bleed plug
Page: 12
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
1.18 PLUNGER TYPE LIFT CYLINDERS

LATERAL CYLINDER
The lateral plunger cylinders with hollow rod are utilised on high lift masts. In
these cylinders, unlike single acting cylinders, both the barrel and the rod are
filled with oil before starting the lift stroke.
This solution is adopted to increase the strength of the cylinders at maximum
elevation, and to make it possible to use compactly sized barrels and rods.
HYDRAULIC SYSTEM
LATERAL PLUNGER TYPE CYLINDER WITH HOLLOW ROD
OPERATION
When the cylinder is assembled in the test phase the air must be bled out by
opening the bleed screws (A - B Fig. 11).
Before supplying oil to the cylinder it is essential to loosen the two bleed
screws on the rod (A Fig. 11) and the barrel (B Fig. 11).
When oil is supplied to the cylinder the first cavity to be filled is the rod; continue
to pump in oil until only oil and no air escapes through the bleed screw (A
Fig.11); this indicates that the rod is full of oil and empty of air and so the bleed
screw must be tightened.
In the second stage the cylinder barrel is filled; continue to pump in oil until only
oil and no air escapes through the bleed screw (B Fig. 11); this indicates that
the barrel is full of oil and empty of air and so the bleed screw must be
tightened.
1511146_1
Fig. 11
CENTRAL CYLINDER
The oil pressure formed inside the rod and in the barrel increases the strength
of the cylinder assembly and reduces the flexibility of the parts at full
extension.
CENTRAL PLUNGER TYPE CYLINDER
This type of cylinder differs from the lateral type because it does not have a
hollow rod. The operating characteristics and the air bleed procedure through
the bleed screw (A Fig. 12) are identical to those of the lateral cylinder.
1512290_1
Fig.
12
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 13
SERVICE

1.19 REACH CARRIAGE CYLINDER
MODEL ALL MODELS
HYDRAULIC SYSTEM
CYLINDER COMPONENTS
9
8
5
Fig. 13
1.20 TABLE OF REACH CARRIAGE CYLINDER COMPONENTS

Ref.
1
2
3
4
5
6
7
8
9
Complete cylinder
Cylinder barrel
Cylinder rod
Gasket bushing
Set of cylinder seals
Set of bushing seals
Rod eye
Grease nipple
Page: 14
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
1.21 FORKS TILT CYLINDER

MODEL ALL MODELS
10
7
8
6
3
4
5
Fig. 14
1.22 TABLE OF FORKS TILT CYLINDER COMPONENTS

Ref.
1
2
3
4
5
6
7
8
9
10
Complete cylinders block
Cylinder rod
Rod piston
Gasket bushing
Bushing retaining circlip
Piston seal
Piston O-ring
Set of bushing external seals
Set of bushing internal seals
Piston to rod fixing screw
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 15
HYDRAULIC SYSTEM
CYLINDER COMPONENTS
SERVICE

1.23 SIDESHIFT CYLINDER
MODEL ALL MODELS
HYDRAULIC SYSTEM
CYLINDER COMPONENTS
1
5
3
4
6
2
Fig. 15
1.24 TABLE OF FORKS SIDESHIFT CYLINDER COMPONENTS

Ref.
1
2
3
4
5
6
Piston cylinder incorporated in fork arm carriage
Cylinder rod
Rod guide bush
Rod guide bush circlip
Seal
Wiper seal
Page: 16
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
To replace the seals of the single acting lateral cylinders the complete cylinders must first be removed from
the mast. The operations described below are also applicable to the removal of lateral plunger type
cylinders for integral renewal.
To perform these procedures it is important to work in a place with sufficient headroom for the truck with
the mast at its full extension and equipped with an overhead crane; it is also necessary to have access
to suitable equipment for the recovery of the cylinder.
SPECIAL TOOLS REQUIRED
Long lifting sling with a capacity of 2000 kg

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

4 mm ALLEN
WRENCH
OVERHEAD CRANE
A
MEDIUM EXTERNAL
CIRCLIP PLIERS
13-22-24 mm
HEX WRENCH
PROCEDURE
Fig. 17
Before starting work, make sure you are wearing

suitable safety clothing.
Park the truck in a safe place away from moving
vehicles and pedestrians. Bring the reach carriage
to its fully forward position.
1) LADDER WITH PLATFORM - CIRCLIP PLIERS 13 mm HEX WRENCH - Place the ladder on the side of
the mast in order to access one of the cylinders, and
ascend with the necessary tools.
Use the circlip pliers to remove the circlip from the end
of the cylinder (Ref. A Fig. 17).
Use the hex wrench to unscrew and remove the cylinder
mounting bracket fixing screws (Ref. B Fig.18); this
done, descend the ladder and remove it from the work
area.
Fig. 18
Fig. 19
Fig. 16
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 17
HYDRAULIC SYSTEM
2.00 REMOVING THE LATERAL LIFT CYLINDERS FROM THE MAST

MODEL ALL MODELS
SERVICE
HYDRAULIC SYSTEM
2) 22-24 mm HEX WRENCH - HYDRAULIC PLUGS - The hydraulic

hoses must be detached from inside the reach carriage. Use the
24 mm hex wrench to unscrew the hydraulic supply hose union on
the cylinder to be removed (Ref. C Fig. 19).
With the 22 mm wrench fit the male plug to the hose union (Ref. D
Fig. 20) and the female plug to the cylinder union (Ref. E Fig. 20).
3) SHORT LIFTING SLING - OVERHEAD CRANE - Attach the short
lifting string to the top of the inner mast section and attach the to
ends of the sling to the overhead crane (Fig.16). Start lifting with the
only cylinder still connected and simultaneously lift with the overhead
crane; continue the lift stroke to maximum height and allow the sling
to take the strain.
The same operation must be used to remove the second cylinder.
Fig. 20
4) LONG LIFTING SLING - 4 mm ALLEN WRENCH - LIFT TRUCK

- Attach the sling to the mid point of the cylinder (Ref. F Fig. 16),
attach the sling to the lift truck and take the strain.
Use the wrench to unscrew the cylinder fixing grub screw (Ref. G
Fig. 20), lift the cylinder and extract it from the lower seat; now lower
the cylinder and angle it towards the outside so that it can be
extracted from the upper cross member. Bring the cylinder to a
horizontal position and place it on a workbench.
Now either fit a new cylinder or strip the original unit and renew the
seals.
F
Fig. 21
NOTES:
Page: 18
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.01 REPLACING LATERAL SINGLE-ACTING CYLINDER SEALS

MODEL MR14 - MR16
Tube clamp 6080

Oil collection container
HYDRAULIC SYSTEM
C-SPANNER
60 80
MEDIUM SLOTTED
SCREWDRIVER
PROCEDURE
Before starting work, make sure you are wearing suitable safety
clothing.
1) TUBE CLAMP - OIL COLLECTION CONTAINER - C-SPANNER Position the cylinder in the clamp and tighten carefully to avoid
distorting the barrel, position the container under the cylinder bush.
Use the wrench to completely unscrew the seal holder bush (Ref. H
Fig. 22), remove the bush from the rod and withdraw the rod from the
barrel; place the bush on a clean workbench and fit new seals.
2) SMALL SCREWDRIVER - Use the screwdriver to remove the seals
from the bush and from the rod piston; carefully clean and oil the seal
seats to facilitate refitting. Now fit the new seals.
To reassemble, perform the disassembly steps in reverse order.
Fig. 22
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 19
SERVICE

2.02 REMOVING THE CENTRAL LIFT CYLINDER FROM THE MAST
MODEL ALL MODELS
HYDRAULIC SYSTEM
To renew the single acting central cylinder seals the cylinders must be first removed from the mast. The
operations described below also apply to the removal of central plunger type cylinders for complete
replacement purposes.
Long sling with lifting capacity of 2000 kg
Parcher type male-female 3/4 plugs for hydraulic hoses
Wooden beam 100x100x800
13-22-24 mm
HEX WRENCH
PROCEDURE
4 mm
ALLEN WRENCH
clothing.
Park the truck in a safe place away from moving vehicles and
pedestrians. Bring the reach carriage to its fully forward position.
L
Fig. 26
Fig. 25
N
M
Fig. 27
Fig. 24
Fig. 23
Page: 20
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
1) WOODEN BEAM - Raise the forks until the fork arm carriage is high enough to clear the beam on the
floor (Fig. 23). Position the beam and then lower the forks until the fork arm carriage is supported on
the beam. Continue to lower the forks until the cylinder is completely closed.
2) 13 mm HEX WRENCH - Use the hex wrench to unscrew and remove the fixing screw from the fork
shaped plate of the pulleys assembly (Ref. L Fig. 25), remove the plate and lift the pulleys assembly
complete with hoses and chain, withdrawing it from the cylinder. Use the same wrench to unscrew and
remove the cylinder mounting bracket fixing screws (Ref. I Fig. 24): now remove the bracket.
3) 22-24 mm HEX WRENCH - 4 mm ALLEN WRENCH - Use the 24 mm hex wrench to unscrew the
cylinder oil supply hose union (Ref. N Fig. 24); now use the 22 mm wrench to fit the male plug to the
hose union and the female plug to the cylinder union. Use the Allen wrench to unscrew the cylinder
securing grub screw (Ref. M Fig. 27).
4) LIFTING SLING - OVERHEAD CRANE - Attach one end of the sling to the cylinder in the vicinity of the
bush; attach the other end to the overhead crane hook. Take the strain with the sling and then continue
to lift in order to extract the cylinder from the top of the fork arm carriage; this done, use the crane to
transfer the cylinder to a workbench. Now either fit a new cylinder or strip the original unit and renew the
seals.
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 21
HYDRAULIC SYSTEM
Warning: The beam is of fundamental importance to safety for the entire duration of the
work and must therefore be in a stable and secure position before proceeding.
SERVICE

2.03 REPLACING THE SINGLE ACTING CENTRAL CYLINDER SEALS
MODEL MR14 - MR14H - MR16 - MR16H - MR16N
HYDRAULIC SYSTEM
Tube clamp 60 80
Container for collecting oil
C-SPANNER
60 80
MEDIUM SLOTTED
SCREWDRIVER
PROCEDURE
clothing.
1) TUBE CLAMP, OIL COLLECTION CONTAINER, C-SPANNER - Place

the cylinder in the clamp and tighten with care to avoid distortion of the
cylinder barrel, place the container beneath the cylinder bush. Use the
wrench to completely unscrew the seals holder bush (Ref. O Fig. 28),
withdraw the bush from the rod and the rod from the cylinder barrel;
place the assembly on a clean workbench and renew the seals.
2) SMALL SCREWDRIVER - Use the screwdriver to remove the seals
from the bush and the rod piston, clean the seal seats thoroughly and
oil them to facilitate insertion of the new seals. Now fit the new seals.
Fig. 28
Page: 22
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.04 REPLACING THE LATERAL PLUNGER CYLINDER SEALS

MODEL MR16H Optional - MR20 - MR20H - MR20W - MR25
Wooden chock 100x100x800

Ladder with platform
HYDRAULIC SYSTEM
MEDIUM EXTERNAL
CIRCLIP PLIERS
MEDIUM SLOTTED
SCREWDRIVER
C-SPANNER
100 110
CHAIN TYPE
OIL FILTER WRENCH
PROCEDURE
Before starting work, make sure you are wearing suitable safety clothing.
Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach
carriage to its fully forward position.
Q
Fig. 31
Fig. 29
UPDATE
Date: Mar. 2002
Fig. 30
Part No.: 524159096
Page: 23
SERVICE
HYDRAULIC SYSTEM
1) CIRCLIP PLIERS - LADDER WITH PLATFORM Place the ladder on the side of the mast in order to
access one of the cylinders, and use the circlip pliers
to remove the circlip from the cylinder rod (Ref. Q
Fig. 31).
2) WOODEN BLOCK - Raise the forks until the block can
be inserted under the central mast profile as shown
(Fig. 32). Position the beam and then lower the forks
until the mast rests on the beam and the cylinder whose
circlip has been removed has closed with the rod
completely inside the barrel.
Fig. 32
3) C-SPANNER - CHAIN TYPE OIL FILTER WRENCH - SMALL CROSSHEAD SCREWDRIVER - Two
persons are required in order to unscrew the ringnut.
Fit the filter wrench at the mid point of the cylinder barrel (Ref. P Fig. 29) in such a way that it tightens
in the reverse direction with respect to the direction in which the bush must be unscrewed.
Use the C-spanner to unscrew the ring completely and then withdraw it from the cylinder rod. Now renew
the seals.
4) SMALL SLOTTED SCREWDRIVER - Remove the seals from the bush, clean and oil the seats. Renew
the seals.
Repeat the same procedure for the cylinder on the other side of the mast.
NOTES:
Page: 24
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.05 REPLACING THE CENTRAL PLUNGER CYLINDER SEALS

MODEL MR16H Optional - MR20 - MR20H - MR20W - MR25
HYDRAULIC SYSTEM
13 mm
HEX WRENCH
MEDIUM SLOTTED
SCREWDRIVER
C-SPANNER
100 110
PROCEDURE
R
Fig. 35
Fig. 35b
Fig. 34
Fig. 33
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 25
SERVICE
1) WOODEN BEAM - Raise the forks to the height necessary to clear the beam as shown (Fig. 33).
Position the beam under the fork arm carriage, lower the forks until the carriage is resting on the beam.
Continue to lower the forks until the cylinder has retracted completely, causing the hoses and chain to
become slack.
HYDRAULIC SYSTEM
Warning: The wooden block is of fundamental importance to safety for the entire duration
of the work and must therefore be in a stable and secure position before proceeding.
2) 13 mm HEX WRENCH - Unscrew and remove the fixing screw of the pulleys assy. mounting plate
(Ref. R Fig. 35), withdraw the mounting plate from the cylinder and lift the complete pulleys assy away
from the cylinder.
3) C-SPANNER - Completely unscrew the bush from the cylinder, withdraw it from the rod and place it on
a workbench.
4) SMALL SLOTTED SCREWDRIVER - Remove the seals from the bush, clean and oil the seal seats
to facilitate fitting of the new seals; renew the seals.
NOTES:
Page: 26
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.06 REMOVING THE FORKS TILT CYLINDER

MODEL ALL MODELS
Wooden block 100x100x200
HYDRAULIC SYSTEM
LARGE SLOTTED
SCREWDRIVER
19 mm SOCKET WRENCH
WITH RATCHET
17-19 mm
HEX WRENCH
5-10 mm
ALLEN WRENCH
PROCEDURE
carriage to its fully forward position and lift the forks to a position one metre above the ground.
1) Disassemble the fork arm carriage (refer to mechanics section heading 2.01 page 9).
Fig. 37
T
S
Fig. 38
UPDATE
Date: Mar. 2002
Fig. 36
Part No.: 524159096
Page: 27
SERVICE
HYDRAULIC SYSTEM

2) 19 mm SOCKET WRENCH WITH RATCHET - WOODEN
BLOCK - Activate the tilt control lever in the up direction until
the tilt cylinders are at their fully extended position.
Use the wrench to unscrew and remove the nuts responsible
for securing the cylinder rods to the plate (Ref. T Fig. 38),
and wedge the block between the oscillating plate and the
mast (Ref. S Fig. 36). Activate the tilt control lever in the
down direction and cause the rods to retract into the
cylinders (Fig. 40). Set the keyswitch to OFF and disconnect
the battery.
Fig. 39
U
Warning: The wooden block is of fundamental

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

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

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

order.
Fig. 42
NOTES:
Page: 28
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.07 REPLACING THE TILT CYLINDER SEALS

MODEL ALL MODELS
MEDIUM INTERNAL
CIRCLIP PLIERS
HYDRAULIC SYSTEM
MEDIUM SLOTTED
SCREWDRIVER
PROCEDURE
1) CIRCLIP PLIERS - After having disassembled

the cylinder place it on a workbench and use the
relative pliers to remove the circlip (Ref. A Fig. 43);
now extract the rod complete with bush.
2) SMALL SCREWDRIVER - Remove the bush

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

in reverse order.
UPDATE
Date: Mar. 2002
Part No.: 524159096
Fig. 44
Page: 29
SERVICE

2.08 REPLACING THE SIDESHIFT CYLINDER SEALS
MODEL ALL MODELS
HYDRAULIC SYSTEM
MEDIUM INTERNAL
CIRCLIP PLIERS
MEDIUM SLOTTED
SCREWDRIVER
PROCEDURE
carriage to its fully forward position and lift the forks to a position one metre above the ground. Set
the keyswitch to OFF and disconnect the battery.
1) Remove the fork arm carriage (see mechanics
section heading 2.01 page 9).
I
H
2) CIRCLIP PLIERS - SMALL SCREWDRIVER Extract the piston from its seat; use the small
screwdriver to remove the wiper seal (Ref. F
Fig. 45-46) and use the circlip pliers to remove
the circlip (Ref. G Fig. 47).
Extract the rod guide bush (Ref. H Fig. 45) and
then remove the seal (Ref. I Fig. 45).
Before fitting the new seals clean the parts
carefully and oil the seats to facilitate
replacement. Now fit the new seals.
To reassemble, perform the disassembly steps
in reverse order.
Fig. 45
I
F
G
H
Fig. 46
Page: 30
Part No.: 524159096
Date: Mar. 2002
Fig. 47
0
UPDATE
SERVICE
2.09 REMOVING THE REACH CYLINDER

MODEL ALL MODELS
13-19 mm
HEX WRENCH
PROCEDURE
5 mm
ALLEN WRENCH
carriage to its fully forward position and lift the forks to a position one metre above the ground.
1) 5 mm ALLEN WRENCH - Unscrew and remove the fixing screws of the valves assembly protective
guard on the reach carriage; remove the guard.
2) 13-19 mm HEX WRENCH - Use the 13 mm hex wrench to unscrew and remove the screw responsible
for securing the cylinder to the reach carriage (Ref. N Fig. 50). Lift the cylinder and withdraw from the
rod.
Operate the cylinder control lever and cause the rod to retract; then set the keyswitch to OFF and
Use the 19 mm wrench to unscrew the unions of the cylinder hydraulic hoses (Ref. L Fig. 51) and detach
the relative hoses.
Use the 13 mm wrench to unscrew the second cylinder fixing screw (Ref. M Fig. 49) then raise and
withdraw from the rod. Recover the cylinder by extracting it from the mast direction.
L
L
Fig. 51
Fig. 50
Fig. 49
Fig. 48
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 31
HYDRAULIC SYSTEM
SERVICE

2.10 REPLACING THE REACH CYLINDER SEALS
MODEL ALL MODELS
HYDRAULIC SYSTEM
C-SPANNER
5
MEDIUM SLOTTED
SCREWDRIVER
PROCEDURE
1) C-SPANNER - SMALL SCREWDRIVER - When the cylinder has been removed, place it on a
workbench equipped with a vice. Lock the cylinder in the vice taking care not to deform the barrel. Use
the c-spanner to unscrew and remove the ringnut (Ref. O Fig. 52), extract the rod complete with seals
holder piston. Use the screwdriver to remove the seals from the bush and the rod piston. Before fitting
the new seals clean the parts and oil the seats to facilitate installation; now fit the new seals.
Fig. 52
Page: 32
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.11 REPLACING THE TILT AND SIDESHIFT CYLINDERS OIL SUPPLY HOSES
AND THE CENTRAL CYLINDER SUPPLY HOSE
MODEL ALL MODELS
The procedure for disassembling the tilt, sideshift, and central cylinders oil supply hoses are identical,
because the hoses follow the same path and run on different pulleys.
HYDRAULIC SYSTEM

Ladder with platform
13-16-18-22 mm
HEX WRENCH
5-6 mm
ALLEN WRENCH
22 mm
HEX WRENCH
PROCEDURE
P
Fig. 55
Q
Fig. 56
S
Fig. 53
UPDATE
Date: Mar. 2002
Fig. 57
Part No.: 524159096
Fig. 54
Page: 33
SERVICE
1) WOODEN BEAM - Raise the forks until the fork arm carriage is high enough to clear the beam on the
floor (Fig. 53). Position the beam and then lower the forks until the fork arm carriage is supported on
the beam. Continue to lower the forks until the chain and hoses become slack. Set the keyswitch to
OFF and disconnect the battery.
HYDRAULIC SYSTEM
2) 10-13 mm HEX WRENCH - 5 mm ALLEN WRENCH - Use the 13 mm wrench to unscrew and
remove the hoses anti-shear bracket fixing bolts (Ref. U Fig. 60) and remove the bracket.
Use the 10 mm hex wrench and 5 mm Allen wrench to unscrew and remove the bolts from the hose
restraining block (Ref. S Fig. 57). Use the Allen wrench to unscrew and remove the hose restraint fixing
bolts (Ref. X Fig. 61). After this sequence of operations all the hoses will be loose along their entire
length.
3) 13 mm HEX WRENCH - 6 mm ALLEN WRENCH - LADDER WITH PLATFORM - Use the Allen wrench
to unscrew and remove the fixing bolts of the upper hose carrier bracket (Ref. T Fig. 59). Remove the
bracket with the hoses.
To access the lower ones place the ladder alongside the mast next to the hydraulic lines and then climb
the ladder and use the 13 mm wrench to unscrew and remove the bracket fixing bolts (Ref. P Fig. 55).
Remove the bracket and shift the upper hydraulic lines support.
4) 18 mm HEX WRENCH - Unscrew the twin hose unions (Ref. R Fig. 56) and unions (Ref. Y-Z
Fig. 61). Remove the pipelines and fit replacements.
2.12 REMOVING THE CENTRAL

CYLINDER OIL SUPPLY LINE
Fig. 59
1) 22 mm HEX WRENCH - Unscrew the hose

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

steps in reverse order.
Fig. 60
X
Fig. 61
Fig. 58
Page: 34
Part No.: 524159096
Date: Mar. 2002
Y
3
UPDATE
SERVICE
HYDRAULIC SYSTEM
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 35
SERVICE
HYDRAULIC SYSTEM
NOTES:
Page: 36
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MASTS
UPDATE
TYPE OF MASTS ....................................................................... 3
MAST REMOVAL PROCEDURE ................................................ 8
DRAWING WITH MAST ASSEMBLY NOTES ........................... 10
MAST TILT ANGLES TABLE ..................................................... 11
FORK ARM CARRIAGE REMOVAL PROCEDURE ................... 12
BEARINGS REPLACEMENT PROCEDURE ............................. 14
GREASING OF BEARING ........................................................ 15
MAST BEARINGS REPLACEMENT PROCEDURE .................. 16
LIFT CHAIN ............................................................................... 17
REPLACING THE CENTRAL LIFT CHAIN (FREE LIFT) ............. 19
REPLACING THE LATERAL LIFT CHAINS ................................ 20
Date: Mar. 2002
Part No.: 524159096
MASTS
MASTS
Page: 1
SERVICE
Section: MASTS
MASTS
NOTES:
Page: 2
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MASTS
TABLE OF MAST - TRUCK COMBINATIONS
COMPOSITION OF TRUCK AND MAST IN RELATION TO CAPACITY AND LIFT HEIGHT

Mast
Geared Geared Driver
Driver
Load
Load
Load
Load
Mast
Mast
Mast
Truck Front Rear Wheelbase
Maximun
Motor
Motor
Wheel
Wheel
Wheel Wheel Wheel Wheel
Model
Channel Channel Channel Channel
Type Forks tilt
Y
Height
MDU 150 MDU 170 305x140 342x140 250x100 285x100 350x100 350x127
Beta
HE140 HE140L HE140R
MR14 4500/6700
x
1
2 / 4
1435
x
x
x
MR14H 7000/8700
x
2
2 / 4
1450
x
x
x
MR16 4500/6700
x
3
2 / 4
1485
x
x
x
MR16H 7000/9200
x
3
2 / 4
1485
x
x
x
MR20 4500/6300
x
4
2 / 4
1550
x
x
x
MR20H 6700/8000
x
4
2 / 4
1550
x
x
x
MR20H 8500/11400
x
4
2 / 4
1550
x
x
x
MR25 4500/8000
x
5
2 / 4
1650
x
x
x
MR25 8500/11400
x
5
2 / 4
1650
x
x
x
MR16N 4500/6700
x
6
2 / 4
1435
x
x
x
MR16N 7000/8700
x
6
2 / 4
1435
x
x
x
MR20W 4500/8000
x
7
2 / 4
1580
x
x
x
MR20W 8500/11400
x
7
2 / 4
1580
x
x
x
BETA MAST
HE 140 - 140L MAST
UPDATE
Load
wheel
Bracke
No
No
Option
Option
Std
Std
Std
Std
Std
No
No
Std
Std
HE 140 R MAST
Date: Mar. 2002
Part No.: 524159096
Page 2a
SERVICE
Section: MASTS
POSITION OF PUNCH MARKING SHOWNIG
DIAMETER OF BEARINGS UTILIZED ON
MAST MODELS HE 140L - HE 140 - HE 140R
CENTRAL
EXTERNAL
BEARING 2
BEARING 1
BEARING 3
TOURELLE COMPLETE
INTERNAL
BEARING 4
DETAIL W
DETAIL X
DETAIL Z
DETAIL Y
BEARING 2 INFO
MARKING
BEARING 1 INFO
MARKING
BEARINGS 4 & 6
INFO MARKING
MARQUAGE INFO
GALET 3 ET 5
MARQUAGE INFO
GALET 8
MARQUAGE INFO
GALET 7
INTERNAL MAST
SECTION
GALET 5
INFO MARKING (LETTER A, B OR C)
ON OUTER SIDE OF BEARING 1 MAST
CHANNEL
DETAIL X
FOR BEARING 2 APPLY

SYMMETRICAL MARKING ON
OTHER SIDE OF CHANNEL
GALET 6
EXTERNAL MAST
SECTION
GALET 7
GALET 8
ON OUTER SIDE OF BEARING 7
MAST CHANNEL

TOP LETTER: BEARING 3
BOTTOM LETTER: BEARING 5
DETAIL Z
DETAIL Y
FOR BEARINGS 4 & 6 APPLY
SYMMETRICAL MARKING ON OTHER
SIDE OF CHANNEL
CENTRAL MAST
SECTION
FOR BEARINGS 4 & 6 APPLY

SYMMETRICAL MARKING ON OTHER
SIDE OF CHANNEL
UPDATE
NOTE:
- PUNCH THE LETTER ON BOTH SIDES OF THE
CHANNEL
- USE PUNCHES WITH 12 MM LETTER HEIGHT
- MARK LETTERS ON ALL A709 MODELS:
HE140L
HE140
HE140R
Date: Mar. 2002
DETAIL W
FINAL RESULT AFTER
MARKING
INFO
LETTER
Part No.: 524159096
BEARING
DIAMETER
Page 2b
SERVICE
Section: MASTS
1.00 MAST TYPES

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

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

Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Sideshifter carriage
Tilt plate incorporating sideshifter cylinder
Forks sideshifter plate
Tilt cylinders assy.
Forks sideshifter cylinder rod
Sideshifter movement upper shoe
Sideshifter movement lower shoe
Forks sideshifter plate mechanical stop
Forks sideshifter rod guide bush
Forks tilt cylinder rod
Forks tilt cylinder assy. mechanical stop
Valve controlling oil flow to tilt cylinder
Kit of seals for tilt cylinder
Tilt cylinder bush retaining circlip
Tilt cylinder rod guide bush
Forks sideshifter cylinder seals kit
Forks sideshifter cylinder rod guide retaining circlip
Mast channel bearings
Table 1
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 3
SERVICE
Section: MASTS
1.03 BETA MAST

The BETA mast is installed on truck models MR 14 - MR 16 - with maximum elevation of 6700 mm. (see
table 1 page 2a).
SPECIFICATIONS:
The external stage is built of C profiles and anchored to the reach carriage by means of two pins welded
to each side of the mast, to be fastened to the reach carriage supports.
The lower part of the mast is secured to the reach carriage by means of three screws
MASTS
The intermediate and internal stages are constructed of J section profiles. Reciprocal movement of the
two sections is assured by interposed bearings.
The fork arm carriage runs inside the internal mast section. The carriage incorporates the mast tilt cylinder
and forks sideshift cylinder.
The mast is equipped with a total of 8 taper roller bearings 91 mm (Fig. 2).
The roller journals are welded in an inclined position to allow them to run on the internal
corner of the profile.
Specially designed shims of various dimensions are utilized to reduce play between the
mast stages.
The fork arm carriage is equipped with 4 81mm taper roller bearings.
The journals of the upper rollers are welded in an inclined position with the angle in the
opposite direction with respect to the lower roller journals in order to eliminate front and side
play.
Fig. 2
The lateral lift cylinders are of the Single acting self-braking type, with cushioning activated on the
downward stroke (for more information consult the hydraulic section of the manual).
The central cylinder is of the Single acting self-braking type with cushioning activated at the top of the
upward stroke (for more information consult the hydraulic section of the manual).
The lift chains are prime quality Fleyer series AL and BL type, wherein Fleyer denotes a traction type
chain.
MAST VIEWED
FROM
FORKS SIDE
MAST VIEWED
FROM ABOVE
MAST VIEWED
FROM
CYLINDERS SIDE
VIEW OF BEARING
POSITIONS IN MAST CHANNEL
Fig. 3
Page: 4
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MASTS
1.04 MAST HE 140L

Mast model HE 140L is installed on trucks with lift heights from 4500 mm to 8000 mm according to the
rated load capacity of the truck (see table 1 page 2a).
SPECIFICATIONS:
The external, intermediate, and internal stages are constructed of HE section channels. Anchorage to
the reach carriage is identical to that of the Beta mast, thus ensuring that the masts are fully
interchangeable on the same reach carriage.
1
The mast complete with fork arm carriage is equipped with a total of 12 Combined roller
bearings 101 mm (Fig. 4).
2
The bearings are composed of an outer roller that runs in a plane parallel to the mast channel
and a lateral roller that runs on the internal profile; this combination, with the aid of suitable
shims, has made it possible to minimize play between lateral and front mast sections.
Fig. 4
The lateral lift cylinders are of the Single acting self-braking type with cushioning activated on the
downward stroke (for more information consult the hydraulic section of this manual).
The central cylinder is of the Single acting self-braking type with cushioning activated at the top of the
upward stroke (for more information consult the hydraulic section of the manual).
chain.
MAST VIEWED
FROM
FORKS SIDE
MAST VIEWED
FROM ABOVE
MAST VIEWED
FROM
CYLINDERS SIDE
UPDATE
VIEW OF BEARING
POSITIONS IN MAST CHANNEL
Date: Mar. 2002
Part No.: 524159096
Fig. 5
Page: 5
MASTS
The fork arm carriage runs within the internal mast stage and it incorporates the mast tilt
cylinder and forks sideshift cylinder.
SERVICE
Section: MASTS
1.05 MAST HE 140

Mast model HE 140 is installed on trucks with lift heights from 6700 mm to 9200 mm according to the rated
load capacity of the truck (see table 1 page 2a).
SPECIFICATIONS:
The specifications of this mast are analogous the data quoted for type HE 140L.
The principal difference lies in the use of different types of lateral lift cylinders.
MASTS
The lateral lift cylinders are Plunger type with hollow rod (for more information consult the hydraulic
section of this manual).
The central cylinder is Single acting self-braking type with cushioning activated at the top of the upward
stroke (for more information consult the hydraulic section of the manual).
chain.
VIEW OF MAST
FROM FORKS SIDE
VIEW OF MAST
FROM ABOVE
VIEW OF MAST
FROM
CYLINDERS SIDE
VIEW OF BEARING
POSITIONS IN THE MAST CHANNEL
Fig. 6
Page: 6
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MASTS
1.06 MAST TYPE HE 140R

Mast model HE 140R is installed on trucks with lift heights up to 11400 mm (see table 1 page 2a).
SPECIFICATIONS:
The specifications of the mast profile and bearings are identical to those quoted for mast model HE 140L.
The lateral lift cylinders are Plunger with hollow rod type (for more information consult the hydraulic
section of this manual).
The central lift cylinder is of the Plunger type (for more information consult the hydraulic section of this
manual).
chain.
VIEW OF MAST FROM

FORKS SIDE
VIEW OF MAST
FROM ABOVE
VIEW OF MAST
FROM CYLINDERS SIDE
VIEW OF BEARING POSITIONS

IN MAST CHANNEL
Fig. 7
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 7
MASTS
To enable the mast to reach high elevations a series of reinforcements have been applied to the external
stage and the intermediate stage. This mast also utilizes different lift cylinders.
SERVICE
Section: MASTS
2.00 MAST REMOVAL PROCEDURE

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

Sling with max. load capacity of 3000 kg
Overhead crane with lifting capacity of 4000 kg max.
MASTS
6-8 mm
ALLEN WRENCH
17-19-24 mm
HEX WRENCH
24 mm SOCKET WRENCH
WITH RATCHET
OVERHEAD CRANE
Fig. 12
F
H
C
Fig. 8
Page: 8
Part No.: 524159096
Fig. 10
Fig. 9
Fig. 11
Fig. 14
Date: Mar. 2002
Fig. 15
Fig. 13
3
UPDATE
SERVICE
Section: MASTS
PROCEDURE
carriage to its forward position.
2) SLING - OVERHEAD CRANE - Attach one end of the sling to the top cross beam of the external mast
stage (Fig. 8). Attach the other end of the sling to the crane hook and then allow the crane to take the
strain.
3) WOODEN BEAM - Lift the forks beyond the free lift thus exposing the screws that fasten the mast to
the reach carriage (Fig. 9) and then continue to lift until the beam can be inserted under the intermediate
section; place the beam under the section (Ref. H Fig. 9) then lower the forks until they are supported
on the beam. Now set the keyswitch to OFF and disconnect the battery.
Warning: the beam fills an important safety function for the entire duration of the work and
must therefore be positioned where it is perfectly stable and safe.
4) 24 mm SOCKET WRENCH - Unscrew and remove the three screws that secure the mast to the reach
carriage (Ref. A Fig. 9). Connect the battery and set the keyswitch to ON. Lift the mast by
10 centimeters and remove the wooden beam. Now lower the mast until it is completely closed and then
set the keyswitch to OFF and disconnect the battery. Use the same wrench to unscrew and remove
the mast stop screws on the reach carriage (Ref. C Fig. 11). Remove the upper stops.
5) 17-19-24 mm HEX WRENCHES - Use the 17 mm wrench to unscrew the unions of the twin hydraulic
lines supplying the tilt cylinder and sideshift cylinder (Ref. D Fig. 12).
With the 24 mm hex wrench unscrew the central cylinder hydraulic hose union (Ref. E Fig. 12).
With the same wrench unscrew the union of the lateral cylinders hydraulic supply line (Ref. B Fig. 13).
6) Lift the mast ensuring that the mast base, supported on the reach carriage, does not foul the
solenoid valve pipelines and that the lateral profiles transit past the mast stabilizer mechanical
stops (Fig.14-15).
Now lower the mast to the ground and proceed with repair work or fit new bearings.
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 9
MASTS
1) SLING - CRANE - 6-8 mm ALLEN WRENCH - Lift the forks until they are positioned at one metre above
the ground, then use the 7 mm. Allen wrench to unscrew and remove the fixing screws of the load
restraint grille (Ref. G Fig. 10). Remove the grille from the fork arm carriage.
Using the 8 mm Allen wrench unscrew and remove the forks mechanical locking screw (Ref. F Fig. 10).
Move the forks one at a time towards the centre of the carriage and remove them with the aid of the
overhead crane and the sling.
SERVICE
Section: MASTS
2.01 DIAGRAM WITH DESCRIPTION OF MAST ASSEMBLY STEPS
Notes on installing or removing the mast with indications of the shims to be inserted to provide the correct
inclination in relation to height and screw torquing directions for mast installation.
MASTS
TORQUE TO 300 Nm / ASSEMBLE

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

WITH LOCTITE 243 / 4 SCREWS
SHIMS TO ADD OR REMOVE
TO ADJUST THE MAST
INCLINATION ANGLE
CHAIN/CARRIAGE
VIEWED FROM BELOW
NOTA:
FARE
ATTENZIONE AD INSERIRE
NOTE:
LA COLONNA
PIASTRA
DI
ENSURE NELLA
THE MAST
IS CORRECTLY
FERMO DEL CARRO RETRATTILE
INSERTED IN THE REACH CARRIAGE

RETAINER PLATE
Fig. 15a
Page: 10
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MASTS
2.02 TABLE OF MAST INCLINATION ANGLES

The following table gives the inclination measurements for the various mast types and the ground to
stabilizer shoe distance in relation to the height and model.
QUOTA
MASTS
QUOTA B
h1
STABILIZER SHOE - GROUND

DISTANCE
Fig. 15b
MAST INCLINATION
MAST INCLINATION
A708 BETA
Reference H3 Reference H1
mm
mm
4500
5000
5400
6000
6300
6500
6700
7000
7500
8000
8500
8700
9000
9300
9500
10000
10500
11400
2075
2275
2376
2575
2675
2775
2825
2925
3175
3325
3525
3725
3825
3925
3975
4275
4425
4725
A709 HE 140 A709 HE 140L A709 HE 140R

Horizontal
distance
reference
H1 mm
9
9
10
10
11
11
12
12
13
13
14
14
15
15
Horizontal
distance
reference
H1 mm
11
11
12
12
13
13
14
Horizontal
distance
reference
H1 mm
9
9
10
10
11
11
12
12
13
13
14
14
15
15
QUOTA "A"
UPDATE
Date: Mar. 2002
Horizontal
distance
reference
H1 mm
13
14
14
15
15
16
16
17
17
Stabilizer shoe
Adjustment
Shoe to Ground
Clearence mm
30
30
30
30
30
30
30
30
30
30
20
20
20
20
20
10
10
10
QUOTA "B"
Part No.: 524159096
Page: 11
SERVICE
Section: MASTS
2.03 FORK ARM CARRIAGE REMOVAL PROCEDURE

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

Overhead crane with lifting capacity of 2000 kg max.
MASTS
5-6-8 mm ALLEN
WRENCH
17-19 mm HEX
WRENCH
OVERHEAD CRANE
Fig. 20
REGULAR
Fig. 17
L
M
N
Fig. 16
Page: 12
Part No.: 524159096
Fig. 18
Date: Mar. 2002
Fig. 19
2
UPDATE
SERVICE
Section: MASTS
PROCEDURE
2) SLING - OVERHEAD CRANE - Attach one end of the sling to the fork arm carriage (Fig. 16) and attach
the other end to the crane hook; now allow the crane to take the strain. Continue to lift until the lift chain
and tilt/sideshift cylinder hydraulic hoses have become slack.
3) 5 mm ALLEN WRENCH - REGULAR PLIERS - 17 mm HEX WRENCH - Use the 5 mm Allen wrench
to unscrew and remove the hose carrier block (Ref. I Fig. 18), use the hex wrench to unscrew the
hydraulic hose unions (Ref. L Fig.19).
Use the pliers to remove the circlip from the chain pin (Ref. N Fig. 18). Remove the chain fixing pin
(Ref. M Fig. 18).
Lower the fork arm carriage to the ground and then remove the lifting sling.
4) Attach one end of the sling to the mast internal section cross beam (Fig. 16) and attach the other end
to the crane hook and then take the strain with the crane. Lift the mast section until the fork arm carriage
is free of its location. Place the fork arm carriage on a workbench and proceed to repair the carriage
or replace the bearings.
To reassemble, perform the disassembly steps in reverse order
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 13
MASTS
1) 6-8 mm ALLEN WRENCH - Lift the forks until they are one metre above the ground. Use the 6 mm
wrench to unscrew and remove the load restraint grille fixing screws (Ref. G Fig. 20). Remove the load
restraint grille from the fork arm carriage.
With the 8 mm wrench unscrew and remove the forks mechanical fastening screw (Ref. F Fig. 20).
Move the forks towards the centre of the carriage one at a time and then use the crane and sling to
remove them.
SERVICE
Section: MASTS
MASTS
2.04 BEARING REPLACEMENT PROCEDURE

MODELS HE 140 - HE 140L - HE 140R
The combined bearings are available in three different sizes characterized
by the following outside diameters 101.5 - 101.9 - 102.3 (Ref. N
Fig. 21). When the mast is assembled the bearings are first tested by
running them inside the channels so that the bearing that offers the
smallest frontal play can be utilized (Fig. 22). Shims are also utilized to
insert on the journal at the rear of the bearing in order to eliminate lateral
play (Fig. 22). Once the mast has been assembled, the measurement of
the rollers is punched onto each profile in the form of a letter that identifies
the diameter utilized.
For more information regarding the position of the punch marking (see
Page 2b).
The bearings must be renewed every 6000/7000 duty hours.
The lifetime of the bearings depends basically on the conditions and work
cycles, the working environment, and the grease lubrication frequency.
Failure to observe correct maintenance practices can result in excessive
play on the mast profiles both in the frontal and axial directions, or even
seizure of the internal rollers due to inadequate lubrication. In this situation
it becomes necessary to renew the rollers before the normal end of their
working life. Alternatively, it is possible to measure both the axial and frontal
clearance of the rollers in the mast channels caused by cold deformation
and, if the tolerance values surpass the values shown in (Fig. 22) it is
advisable to renew the bearings.
If at the time of refitting it should be noted that the original size bearing
presents clearances that are outside the requested tolerance, this bearing
must be substituted for the bearing of the next diameter up and punch mark
the letter indicating the size of the new bearing (see position on page 2b).
The roller is supplier as a spare part complete with a contrast roller but
without the weld-on journal.
The procedures for removing and refitting bearings on the mast and on the
fork arm carriage are identical.
Fig. 21
0,5
0,5
Fig. 22
Mast channel

3 mm ALLEN
WRENCH
PROCEDURE
clothing.
1) 3 mm ALLEN WRENCH - Unscrew the four fixing screws securing the
welded journal bearing (Ref. O Fig. 24), remove the plate and bearing
complete with contrast roller and fit a new replacement part.
Fig. 23
Fork arm carriage
Page: 14
Part No.: 524159096
Date: Mar. 2002
Fig. 25
0
Fig. 24
2
UPDATE
SERVICE
Section: MASTS
2.05 GREASING THE BEARING

The bearing lubrication frequency depends on several factors such as the environment in which lifting is
performed and the type of work that the truck is called to carry out.
Dusty and corrosive environments, with high or excessively low temperatures and constant use of the
truck over multiple shifts will make it necessary to increase the frequency of maintenance.
For normal use of the truck in low dust environments with temperatures within average values the required
greasing frequency is once every 300/400 duty hours.
Recommended lubricants:
Standard bearing grease
= Mobil Grease 532
Low temperature bearing grease = Texaco Regal AFB2
Mast lubricant
= Molykotez Graphitized Grease
MASTS

Grease gun

GREASE NIPPLE
3 mm
ALLEN WRENCH
PROCEDURE
1) 3 mm ALLEN WRENCH, GREASE GUN, GREASE NIPPLE - Using the Allen wrench unscrew and
remove the grub screw currently plugging the bore (Ref. P Fig. 29) fit a 6 mm diameter grease nipple
(Ref. Q Fig. 26) and proceed to inject grease. Repeat the same procedure for all four mast bearings.
This procedure must be repeated every 300/400 duty hours.
With the same frequency it is good practice to lubricate the bearing tracks by brushing them with grease
as shown (Fig. 30).
Fig. 29
Fig. 27
Fig. 30
Q
Fig. 28
Fig. 26
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 15
SERVICE
Section: MASTS
2.06 MAST BEARINGS REPLACEMENT PROCEDURE

MODEL BETA
The roller utilised in conjunction with the BETA mast is composed of a ball bearing inside a steel shell
with radiused outer edge.
The bearing is fitted over a welded journal inclined with respect to the mast channel in such a way that the
rounded part of the bearing runs on the internal corner of the channel (Ref. S Fig. 31).
To minimise lateral and frontal play shims, in the required number and thicknesses, are installed on the
journal behind the bearing (Ref. T Fig. 31).
MASTS
The bearings must be renewed every 6000/7000 duty hours.

The bearings, not equipped with grease nipples, are sealed and
prelubricated with long life grease.
The roller must be renewed when play is detected between shell and
internal bearing, or when the dimensional tolerance of the convex section
of the roller becomes too great and the roller ceases to run truly in the
corner of the mast channel (Ref. S Fig. 31).
In both cases it will be necessary to remove the mast from the truck.
Fig. 31

R
Fig. 32
MEDIUM CIRCLIP
PLIERS
PROCEDURE
Fig. 33
1) CIRCLIP PLIERS - Remove the bearing retaining circlip from the journal
(Ref. R Fig. 32) and remove the shims. Remove the bearing and fit a
replacement part.
If you notice that the new bearing presents excessive play in the mast
channel, insert one of the previously removed shim washers under the
circlip.
To ensure the maximum freedom of movement of the bearings, use a brush
to apply a coating of grease to the mast channel as shown (Fig. 34). This
operation should be performed every 400 500 duty hours using Molykotez
Graphitized Grease.
Page: 16
Part No.: 524159096
Date: Mar. 2002
Fig. 34
UPDATE
SERVICE
Section: MASTS
2.07 LIFT CHAIN

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

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

N 10 Links
Maximum Stretch
Referred to Sample
Length
158,75
254
158,75
254
158,75
254
158,75
254
162
259
162
259
162
259
162
259
Table 3
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 17
SERVICE
Section: MASTS
2.08 MEASURING THE CHAIN

If chains are found to display an insignificant degree of stretching (less than
2%), this fact alone cannot be construed as indicating that the chains are
in perfect condition.
On the contrary, chains may display signs of stress-related distortion; for
this reason it is good practice to carefully inspect the chain over its entire
length.
G
F
MASTS
CHECKING CHAIN LINKS

C
Prepare for the inspection by cleaning the chain with paraffin or a paraffinbased solvent.
The chains may be inspected without removing them from the mast.
Inspect the chain and associated components (Fig. 36-37):
E
Fig. 36
A)
B)
C)
D)
E)
F)
G)
H)
I)
Wear of the journal

Condition of the journal (possible damage)
Cracked links
Wear of the link edges
Wear of the link bores
Excess play between the links
Rust
Out of round of the chain tensioner bore
Wear of the chain pivot pin
H
If the chains and/or associated parts display one or more of the foregoing
defects, they must be replaced.
I
Fig. 37
NOTES:
Page: 18
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MASTS
2.09 REPLACING THE CENTRAL LIFT CHAIN (FREE LIFT)


REGULAR PLIERS
13 mm
HEX WRENCH
PROCEDURE
1) WOODEN BEAM - Raise the forks until the beam can be inserted under them; position the beam under
the forks (Fig. 38); lower the forks until they are resting on the beam and then continue to lower until the
chain and hydraulic hoses become slack. Set the keyswitch to OFF and disconnect the battery.
2) 13 mm HEX WRENCH - Unscrew and remove the anti-derailment bracket fixing screws (Ref. L Fig. 41).
Remove the bracket.
3) REGULAR PLIERS - Remove the split pins and chain pivot pins, (Ref. M-N
Fig. 40-41), remove the chain, and fit a replacement.
L
Fig. 41
N
Fig. 38
UPDATE
Fig. 40
Date: Mar. 2002
Fig. 39
Part No.: 524159096
Page: 19
MASTS
SERVICE
Section: MASTS
2.10 REPLACING THE LATERAL LIFT CHAINS


PROCEDURE
REGULAR PLIERS
MASTS
Fig. 35
Fig. 36
P
Fig. 34
Fig. 37
Fig. 38
Page: 20
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MASTS
1) WOODEN BEAM - Lift the forks beyond the free lift until the beam can be inserted under
the internal section (Fig. 34).
Insert the beam and lower the forks until the internal section is resting on the beam; continue to
lower the forks until the chains become slack.
Set the keyswitch to OFF and disconnect the battery.
2) REGULAR PLIERS - Remove the split pins and chain pivot pins at the base of the
internal section (Ref. P Fig. 37-38) and then disengage the chain from the terminal connection.
Remove the split pins and the chain pivot pins from the chain tensioners (Ref. O Fig. 35). Recover the
chains and fit replacements.
MASTS
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 21
SERVICE
Section: MASTS
MASTS
NOTES:
Page: 22
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MECHANICS
UPDATE
TABLE OF SCREW TIGHTENING TORQUES ................................ 2
DRIVE WHEEL REPLACEMENT PROCEDURE ............................ 3
LOAD WHEELS REPLACEMENT PROCEDURE .......................... 4
FORK SIDESHIFTER SHOES REPLACEMENT PROCEDURE ..... 7
FUNCTION OF THE BATTERY RESTRAINT ................................... 9
BATTERY RESTRAINT REMOVAL PROCEDURE ....................... 10
REPLACING THE LATCH AND SPRING ...................................... 11
REPLACING THE TRACTION MOTOR ......................................... 12
TRACTION MOTOR COMPONENTS ............................................ 13
ENCODER BEARING REPLACEMENT ....................................... 14
REMOVAL OF THE PUMP MOTOR ............................................. 16
PUMP MOTOR COMPONENTS .................................................. 18
REPLACING THE ENCODER BEARING ...................................... 19
STEERING GEARED MOTOR REMOVAL PROCEDURE ............ 20
STEERING MOTOR COMPONENTS ........................................... 21
ENCODER BEARING REPLACEMENT ....................................... 22
STEERING UNIT .......................................................................... 23
Date: Mar. 2002
Part No.: 524159096
MECHANICS
MECHANICS
MECHANICS
Page: 1
SERVICE
Section: MECHANICS
1.00 TABLE OF SCREW TIGHTENING TORQUES

NOTE: before disassembling and reassembling parts of the truck and fasteners, read the
following information carefully.
LOCTITE 270 is used to lock threaded fasteners and ensure that they will not work loose during operation.
A certain amount of resistance may be encountered when undoing bolts, etc. Should they prove impossible
to unfasten using normal tools, do not use extensions (the head of the bolt might shear off), but instead,
heat the area slightly so as to eliminate the effects of the Loctite (max 50 C).
In the cases described above, apply a moderate amount of Loctite when refitting (generally speaking, 30%
of the mating surface should be coated)
The tightening torque applied to threaded fasteners is of maximum importance for the safety of the joint
itself and therefore for the safety of the machine.
MECHANICS
The following table indicates the classes of nuts and bolts normally used on the machine with the relative
tightening torques.
NOM SIZE
TENSILLE
STRESS
PITCH
PROPERTY CLASS 5.8

CLAMP
TORQUE (N.m
PROPERTY CLASS 8.8

CLAMP
PROPERTY CLASS 10.9
TORQUE (N.m)
CLAMP
TORQUE (N.m)
AREA
LOAD
DRY
LUBEET
LOAD
DRY
LUBED
LOAD
DRY
LUBED
As (mm)
W (N)
K=0.20
K=0.15
W (N)
K=0.20
K=0.15
W (N)
K=0.20
K=0.15
M4 x 0,5
M5 x 0,8
M6 x 1
8,78
14,20
20,10
2 400
3 880
5 490
1,92
3,88
6,58
1,44
2,91
4,94
3 830
6 200
8 770
3,07
6,20
10,50
M8 x 1,25
M8 x 1
M10 x 1,5
M10 x 1,25
36,60 9 990
39,20 10 700
58,00 15 825
61,20 16 700
16,00
17,10
31,70
33,40
12,00
12,80
23,80
25,10
15 975
17 100
25 325
25 725
25,60
27,40
51,00
53,00
19,20
20,50
38,00
40,10
21 750
23 275
34 450
36 350
36 800 88,00 66,00

40 200 96,00 72,00
50 200 140,00 105,00
54 550 155,00 115,00
50 075
54 700
68 300
74 250
M12 x 1,75
M12 x 1,25
M14 x 2
M14 x 1,5
84,30
92,10
115,00
125,00
23 025
25 150
31 400
34 125
55,00
60,00
88,00
96,00
41,40
45,30
66,00
72,00
M16 x 2
M16 x 1,5
M20 x 2,5
M20 x 1,5
157,00
167,00
245,00
272,00
42 850
45 600
66 875
74 250
135,00
145,00
270,00
295,00
105,00
110,00
200,00
225,00
68 525
72 900
106 950
118 750
2,30 5 220
4,65 8 430
7,90 11 950
220,00
235,00
430,00
475,00
165,00
175,00
320,00
355,00
93 250
99 200
145 550
161 550
4,17
8,43
14,30
3,13
6,33
10,80
34,80
37,30
69,00
73,00
26,10
27,90
52,00
55,00
120,00 90,00
130,00 98,00
190,00 145,00
210,00 155,00
300,00
320,00
580,00
650,00
225,00
240,00
435,00
485,00
Table 1
NOTE: The truck is assembled using screws and bolts of PROPERTY CLASS 8.8 - LUBED.
Page: 2
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MECHANICS
1.01 DRIVE WHEEL REPLACEMENT PROCEDURE

MODEL ALL MODELS
N 2 wooden blocks 150x150x200
5-10 mm
ALLEN WRENCH
19 mm SOCKET
WRENCH
WITH RATCHET
MECHANICS
HYDRAULIC JACK
carriage to its forward position, lower the forks to the ground, set the keyswitch to OFF and
1) HYDRAULIC JACK - WOODEN BLOCKS - Set the jack in the centre of the truck in correspondence
with the drive wheel, and raise the truck until the blocks can be inserted. Position the blocks as shown
(Fig. 2) and lower the jack until the truck is resting on the blocks. Remove the jack.
2) 5-10 mm ALLEN WRENCH - Use the 5 mm Allen wrench to open the motor compartment door, then
use the 10 mm Allen wrench to remove the wheel protection plate (Ref. A Fig. 1).
3) 19 mm SOCKET WRENCH WITH RATCHET - Unscrew and remove the wheel fixing screws (Ref. B
Fig. 2). Remove the drive wheel and fit a replacement.
Fig. 1
UPDATE
B
5
Date: Mar. 2002
Fig. 2
Part No.: 524159096
Page: 3
MECHANICS
PROCEDURE
SERVICE
Section: MECHANICS
1.02 LOAD WHEELS REPLACEMENT PROCEDURE

MODEL MR14 - MR16 - MR16N
2 wooden blocks 150x150x200
MECHANICS
3 mm ALLEN
WRENCH
HYDRAULIC JACK
1 kg HAMMER
Fig. 3
20x200 DRIFT
PROCEDURE
Fig. 4
clothing.
Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the
forks to the ground, set the keyswitch to OFF and disconnect the
battery.
C
1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack alongside the

load wheel and raise the truck until the block can be inserted.
Position the block alongside the jack (Fig. 4) and lower the jack so that
the truck is resting on the block. Repeat the same procedure for the
opposite side wheel.
Fig. 5
2) 3 mm ALLEN WRENCH - HAMMER - DRIFT - Using the 3 mm Allen

wrench unscrew and remove the wheel spindle fixing screws (Ref. C
Fig. 5)
Use the hammer and drift to drive out the wheel spindle (Ref. D Fig. 3) as
shown (Fig. 6). Remove the wheel and proceed to change the entire
wheel or the bearings only.
Recover the shims interposed between the bearings and the load wheel
channels because they must be refitted together with the new wheel.
Fig. 6
Fig. 7
Page: 4
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MECHANICS
1.03 LOAD WHEELS REPLACEMENT PROCEDURE

MODEL MR16 Optional - MR20 - MR20H - MR20W - MR25

HYDRAULIC JACK
MECHANICS
5-8 mm ALLEN
WRENCH
Fig. 8
25x200 DRIFT
1 kg HAMMER
MECHANICS
7-14 mm HEX
WRENCH
Fig. 9
COMPASS WRENCH
WITH 5 mm PINS
C-SPANNER FOR
RINGNUTS 40
PROCEDURE
clothing.
Fig. 10
Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the
forks to the ground, set the keyswitch to OFF and disconnect the
battery.
1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack at the side of
the load wheel and raise the truck until the block can be inserted.
Place the block alongside the jack and lower the jack so that the truck is
resting on the block.
Repeat the same procedure for the opposite side wheel.
2) 14 mm HEX WRENCH - Empty and remove the brake fluid line union nut
with thru hole (Ref. E Fig. 9) and collect the brake fluid, ensuring that it
does not come into contact with the brake unit.
Fig. 11
3) 5 mm ALLEN WRENCH - Unscrew and remove the five screws that

secure the brake unit to the truck body (Ref. F Fig. 11) thereby freeing the
wheel.
4) COMPASS WRENCH - 8 mm ALLEN WRENCH - Position the compass
wrench pins in the holes in the spindle (Ref. G Fig. 10). Using the Allen
wrench, unscrew and remove the spindle fixing screw (Ref. H Fig. 11).
UPDATE
Date: Mar. 2002
Part No.: 524159096
Fig. 12
Page: 5
SERVICE
Section: MECHANICS
5) HAMMER - DRIFT - Use the hammer and drift to drive out the wheel
spindle from the inside of the straddle channel towards the outside
(Ref. I Fig. 12). Remove the wheel and place it on a workbench.
6) C-SPANNER - Unscrew and remove the ring responsible for fixing the
brake unit to the wheel (Ref. L Fig. 13).
Remove the brake unit and proceed to change the wheel and the
bearings (Fig. 14).
L
NOTE: it is advisable to order and replace the wheel complete with

hub; this ensures that the new wheel will be perfectly
centred.
Fig. 13

7) 7 mm HEX WRENCH - Bleed the brake circuit of air (see procedure in
the braking system section, heading 6.02 Page 13).
MECHANICS
Fig. 14
NOTES:
Page: 6
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MECHANICS
2.00 FORKS SIDESHIFT SHOES REPLACEMENT PROCEDURE

MODEL ALL MODELS
MECHANICS
Due to constant use of the sideshift facility, the shideshift shoes tend to wear with the result of excess
friction during sliding movements or, in extreme cases, jamming of the mechanism. The lifetime of the
shoes depends basically on the working conditions and cycles, the working environment, and the
frequency of use of the sideshift.
For normal use in a low dust environment with average temperatures and greasing carried out every 300/
400 duty hours, the shoes should be renewed on average every 4000/5000 duty hours.
The replacement procedure is described below.
Lifting sling with terminal rings and max load capacity of 2000 kg
8-12 mm ALLEN
WRENCH
MECHANICS
OVERHEAD CRANE MAX. LOAD

CAPACITY 2000 kg
PROCEDURE
Fig. 15
Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its
forward position, raise the forks until they are one metre from the ground, set the keyswitch to OFF and
1) 8 mm ALLEN WRENCH - SLING - OVERHEAD CRANE Unscrew the forks fixing screw located at the centre of the
fork arm carriage (Ref. M Fig. 16).
Shift the forks towards the centre of the carriage one at a time
to the position of the lower forks latch.
Attach the two ends of the sling to the fork (one end
next to the fork tip and the other near
the fork heel (Fig. 15). Attach the mid-section of the sling to
the crane hook and then lift the fork, detaching it from the fork
arm carriage.
UPDATE
Date: Mar. 2002
Part No.: 524159096
Fig. 16
Fig. 17
Page: 7
SERVICE
Section: MECHANICS
2) 12 mm ALLEN WRENCH - SLING - OVERHEAD CRANE Attach the ends of the sling to the top bar of the fork arm
carriage (Fig. 18). Attach the mid section of the sling to the
crane hook and allow the crane to take the strain.
Using the Allen wrench unscrew and remove the fixing
screws of the sideshift blocks (Ref. N Fig. 17) and remove the
blocks.
Move the base of the carriage outwards and lift
until it is possible to remove the sideshift and thus expose the
sliding shoes (Ref. O - P Fig. 19); at this point, remove the
shoes
and fit replacement parts.
After replacing the shoes apply a generous amount of grease
to the sliding surface. It is good practice to grease the parts
every 300 400 duty hours
Fig. 18
MECHANICS

order.
Fig. 19
NOTES:
Page: 8
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MECHANICS
2.01 FUNCTION OF THE BATTERY RESTRAINT

MODEL ALL MODELS
SITUATION
OF BRACKET
DURING BATTERY
EXTRACTION
- Battery extraction
Bring the reach carriage to the position in which it is completely
located against the battery.
Use your shoe heel to press pedal (Ref. A Fig. 22) located
opposite the accelerator pedal alongside the motor hood, and
then lift the pin (Ref. C Fig. 23).
At this point spring (D) forces the bracket to the left, thus moving hook (B) out of the centre of pin (C) and simultaneously
engaging hook (E) with reach carriage pin (F).
Now move the reach carriage towards the load wheels, causing the battery to be drawn out of is compartment in the truck
body (Fig. 20).
- Reinserting the battery
Once the battery has been charged, move the reach carriage
back towards the battery compartment. When it reaches its
stroke limit the bevel of hook (B) slides over pin (C) causing
the bracket to move to the right and, thanks to the force exerted by spring (D) it engages with the pin, thus locking the
battery in the truck body battery compartment (Fig. 21).
MECHANICS
DESCRIPTION OF HOW THE MECHANISM WORKS

E
F
D
B
Fig. 20
C
Fig. 23
- Battery in working position

As can be seen (Fig. 21) hook (B) of the bracket is engaged
with pin (C) and, assisted by the force exerted by spring (D), it
maintains the bracket locked to the hook thus enabling the truck
to be operated with the battery completely restrained in its
position.
Due to the sliding friction of the bracket hooks when the
locate with the pins, it is advisable to keep all the parts
properly greased to facilitate engagement and
disengagement movements.
F
D
B
SITUATION OF
BRACKET DURING
BATTERY LOCKING
Fig. 22
UPDATE
Fig. 21
5
Date: Mar. 2002
Part No.: 524159096
Page: 9
MECHANICS
The battery restraint performs the important job of keeping the

battery secured when the truck is in operation, while also
allowing the extraction of the battery compartment for charging purposes. The bracket complete with hooks is anchored
below the battery enclosure, hook E engages with pin F during
extraction, while hook B engages with pin C in the locked, work
position.
SERVICE
Section: MECHANICS
2.02 BATTERY RESTRAINT REPLACEMENT PROCEDURE

MODEL ALL MODELS
13-32 mm
HEX WRENCH
REGULAR PLIERS
5 mm ALLEN
WRENCH
MEDIUM EXTERNAL
CIRCLIP PLIERS
PROCEDURE
MECHANICS
carriage to its forward position, lower the forks, set the keyswitch to OFF and disconnect the
battery.
1) 5 mm ALLEN WRENCH - Open the motor compartment door and remove the platform.
2) 13 mm HEX WRENCH - Extract the battery towards
the load wheels. Use the wrench to unscrew and
remove the restraint assy. fixing screws (Ref. Q Fig. 26).
Remove the assy. and fit a complete replacement or
strip down the original assy to replace the worn parts.
3) 13 mm HEX WRENCH - REGULAR PLIERS - Use the
wrench to loosen the locking nut (Ref. R Fig. 27)
Use the pliers to disengage the pin restraining clips
(Ref. S Fig. 27) and then remove the pin (Ref. T Fig. 28)
taking care to recover the bush (Ref. V Fig. 28).
Manually keep the pin pressed upwards (Fig. 28) and
unscrew the latch and nut. Withdraw the pin complete
with spring (Fig. 29) and fit replacement parts.
Fig. 24
To reassemble, perform the disassembly steps in

order.
T
reverse
V
Fig. 25
R
Q
Fig. 27
Page: 10
Fig. 28
Part No.: 524159096
Date: Mar. 2002
Fig. 29
0
Fig. 26
2
UPDATE
SERVICE
Section: MECHANICS
4) CIRCLIP PLIERS - 5 mm ALLEN WRENCH Move

the reach carriage towards the load wheels.
To access the bracket you will need to lie on the
ground and, using a worklight to illuminate the area,
proceed with removal.
Use the Allen wrench to unscrew and remove the
spring fixing screws (Ref. W Fig. 30-31) and then
remove the spring.
Use the pliers to remove the circlip (Ref. Z Fig. 3031), remove the latch from the pivot pin and fit a
replacement.
reverse order.
Fig. 30
MECHANICS
NOTES:
UPDATE
Fig. 31
Date: Mar. 2002
MECHANICS
LATCH AND SPRING REPLACEMENT
Part No.: 524159096
Page: 11
SERVICE
Section: MECHANICS
3.00 TRACTION MOTOR REPLACEMENT PROCEDURE

MODEL ALL MODELS
Lifting sling with hook
12
12
12
12
12
MECHANICS
5 mm ALLEN
WRENCH
OVERHEAD CRANE
13-17 mm 8 mm
HEX WRENCH
8 mm EYEBOLT
CAPACITY 100 KG
PROCEDURE
carriage to its forward position, lower the forks, set the keyswitch to OFF and disconnect the
battery.
1) 5 mm ALLEN WRENCH - Open the battery compartment door
and remove the platform.
2) 13 - 17 mm HEX WRENCH - Use the 17 mm wrench to unscrew
the power cable terminals on the motor and detach the cables.
Use the 13 mm wrench to unscrew and remove the four screws
that secure the motor to the gear unit (Ref. Y Fig. 32).
3) EYEBOLT - SLING - OVERHEAD CRANE - Screw the eyebolt
into the rotor shaft through the electromagnetic brake unit (Fig. 32).
Attach the sling hook to the eyebolt and attach the other end of the
sling to the crane hook.
Carefully lift the motor clear of the gear unit in order to fit a
replacement or to strip down the original motor.
Fig. 32
Page: 12
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MECHANICS
3.01 TRACTION MOTOR COMPONENTS

MODEL ALL MODELS
7
2
10
13
MECHANICS
4
11
12
MECHANICS
Fig. 33
TABLE OF TRACTION MOTOR COMPONENTS
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
Rotor
Stator
Casing
Upper motor flange
Lower motor flange
Tie rod 8
Terminal block
Encoder bearing
Encoder connector
Motor thermal cutout connector
Dust seal
Circlip
Wiring between terminal block and stator
Table 2
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 13
SERVICE
Section: MECHANICS
3.02 REPLACING THE ENCODER BEARING

MODEL ALL MODELS
Once the motor has been removed from the truck it can be stripped down to access the various parts.
13-17 mm
HEX WRENCH
MEDIUM EXTERNAL
CIRCLIP PLIERS
5 mm ALLEN
WRENCH
BEARING PULLER
MECHANICS
PROCEDURE
clothing.
1) 5 mm ALLEN WRENCH - 17 mm HEX WRENCH - Place the motor
in a vice and clamp the casing carefully. Use the hex wrench to
unscrew and remove the motor power cable terminal nuts (Ref. A
Fig. 35).
Use the Allen wrench to unscrew and remove the screws securing the
terminal block to the motor (Ref. B Fig. 35). Remove the terminal
block.
Fig. 34
2) 13 mm HEX WRENCH - Unscrew and remove the fixing nuts of the

flange connecting tie bars (Ref. C Fig. 37) and remove the four bars
(Ref. D Fig. 37) thereby freeing the flanges.
Withdraw the rotor complete with upper flange (Fig. 38).
3) 5 mm ALLEN WRENCH - Remove the casing from the vice and, in its
place, insert the rotor after fitting the vice jaws with aluminium cheeks
to prevent marring of the rotor. Clamp the rotor carefully.
Use the wrench to unscrew and remove the fixing screws of the
bearing retaining flange (Ref. E Fig. 39). Remove the flange from the
rotor (Fig. 40).
Fig. 35
Page: 14
Fig. 39
Part No.: 524159096
Fig. 37
Fig. 38
Date: Mar. 2002
Fig. 36
UPDATE
SERVICE
Section: MECHANICS
4) CIRCLIP PLIERS - PULLER - Use the pliers to remove the bearing

circlip (Ref. F Fig. 41). Fit the puller to the bearing (Fig. 42) and
withdraw the bearing from the rotor shaft (Fig. 43); fit a new bearing
(Fig. 44).
MECHANICS
Fig. 40
Fig. 41
MECHANICS
Fig. 43
Fig. 44
Fig. 42
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 15
SERVICE
Section: MECHANICS
4.00 PUMP MOTOR REMOVAL PROCEDURE

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

Lifting sling with hook
12
12
12
12
12
12
5 mm ALLEN
WRENCH
OVERHEAD CRANE
17-19-22-24 mm
HEX WRENCH
MEDIUM SLOTTED
SCREWDRIVER
8 mm EYEBOLT
LOAD CAPACITY
100 kg
MECHANICS
PROCEDURE
1) 5 mm ALLEN WRENCH - Open the hatch to access the motor
compartment.
2) OIL COLLECTION CONTAINER - At the base of the tank next to the
pump suction hose there is a 8 mm vertically disposed oil tube that
functions as an oil level gauge. This line also serves to empty the oil
tank.
Detach the line from the upper restraint and insert it into the 30 litre oil
collection drum, allowing the oil tank to empty completely.
3) SLOTTED SCREWDRIVER - 17-22 mm HEX WRENCH - Once the
tank is empty, use the screwdriver to loosen the steel clamp securing
the suction hose (Ref. I Fig. 46) and detach the hose from the pump.
Using the 22 mm hex wrench unscrew the pump pressure line union
(Ref. H Fig. 46).
Using the 17 mm hex wrench unscrew the motor cable terminal nuts and
detach the cables from the terminals.
Fig. 45
4) 17 mm HEX WRENCH - EYEBOLT - SLING - OVERHEAD CRANE Screw the eyebolt into the pump rotor shaft (Fig. 45) and attach one end
of the sling to the eyebolt and the other to the crane hook. Take the strain
with the crane and then use the wrench to unscrew and remove the pump
support fixing nuts (Ref. G Fig. 46); now lift the pump and transfer it to a
workbench.
I
G
Page: 16
Part No.: 524159096
Date: Mar. 2002
Fig. 46
6
UPDATE
SERVICE
Section: MECHANICS
5) 17-19 mm HEX WRENCH - Use the 17 mm wrench to unscrew

and remove the two screws responsible for fixing the pump casing
to the motor (Ref. M Fig. 47), detach the pump casing.
Use the 19 mm wrench to unscrew and remove the four screws
responsible for fixing the support to the motor (Ref. L Fig. 47) and
remove the support. Now fit a completely new unit or strip down the
original motor.
4.01 REPLACING THE PUMP CONNECTION FLANGE

OIL SEAL
Fig. 47
Remove the pump motor (see heading 4.00 Page 16).
MECHANICS
1) 17 mm HEX WRENCH - MEDIUM CROSSHEAD SCREWDRIVER

- Use the wrench to unscrew the screws that fix the pump to the
flange (Ref. M Fig. 47) and remove the pump body.
Use the screwdriver to remove the flange oil seal (Ref. N Fig. 48)
and fit a replacement seal.
N
Fig. 48
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
MECHANICS
Page: 17
SERVICE
Section: MECHANICS
4.02 PUMP MOTOR COMPONENTS

MODEL ALL MODELS
10
7
2
14
8
11
12
13
MECHANICS
1
Fig. 49
PUMP MOTOR COMPONENTS TABLE
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Rotor
Stator
Casing
Lower pump body flange
Upper flange
Flange connecting tie rod
Terminal block
Encoder bearing
Encoder connector
Lower flange oil seal
Lower flange bearing
Lower flange bearing circlip
Wiring between terminal block and stator
Table 3
Page: 18
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MECHANICS

MODEL ALL MODELS
Once the complete pump motor has been removed strip it down in order to access the various parts.
NOTE: The encoder bearing can be removed also without first removing the motor from the
truck.
MECHANICS
13-17 mm
HEX WRENCH
Fig. 50
BEARING
PULLER TOOL
PROCEDURE
Before starting work, make sure you are wearing suitable
safety clothing.
1) 17 mm HEX WRENCH - 5 mm ALLEN WRENCH - Place the
motor in a vice and carefully clamp the casing. Use the hex
wrench to unscrew and remove the power cable terminal nuts
(Ref. S Fig. 51). Use the Allen wrench to unscrew and remove the
screws fixing the terminal block to the motor (Ref. Q Fig. 51) and
remove the terminal block.
S
Q
Fig. 51
2) 13 mm HEX WRENCH - Unscrew and remove the flange

connection tie bar nuts (Ref. R Fig. 51). Remove the flange to gain
access to the encoder bearing (Fig. 52-53).
3) PULLER - Fit the puller to the bearing and withdraw the encoder/
bearing from the rotor (Fig. 54-55) and proceed to fit a replacement.
Fig. 52
Fig. 55
UPDATE
Fig. 54
3
Date: Mar. 2002
Part No.: 524159096
Fig. 53
Page: 19
MECHANICS
5 mm
ALLEN WRENCH
SERVICE
Section: MECHANICS
5.00 STEERING GEARED MOTOR REMOVAL PROCEDURE

MODEL ALL MODELS
5 mm
ALLEN WRENCH
10-13 mm
HEX WRENCH
PROCEDURE
MECHANICS
1) 5 mm ALLEN WRENCH - Open the motor compartment hatch. Use the same wrench to unscrew and
remove the pinion fixing screw (Ref. O Fig. 57) and extract the pinion.
2) 10-13 mm HEX WRENCH - Use the 10 mm wrench to unscrew and remove the motor power cable
terminal nuts.
Use the 13 mm wrench to unscrew the four screws that secure the geared motor to the gear unit flange
(Ref. P Fig. 57), extract the geared motor and either fit a replacement part or strip down the original part
on a workbench.
Fig. 56
Page: 20
Part No.: 524159096
Date: Mar. 2002
O
0
Fig. 57
5
UPDATE
SERVICE
5.01
Section: MECHANICS
STEERING MOTOR COMPONENTS

MODEL ALL MODELS
11
10
MECHANICS
5
6
MECHANICS
Fig. 58
TABLE FO STEERING MOTOR COMPONENTS
Ref.
1
2
3
4
5
6
7
8
9
10
11
Rotor
Stator
Casing
Lower flange
Upper flange
Lower flange oil seal
Lower flange bearing
Upper flange encoder bearing
Terminal block
Encoder connector
Table 4
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 21
SERVICE
Section: MECHANICS

MODEL ALL MODELS
Once the motor has been removed from the truck it can be stripped
down to access the various parts.
Fig. 59
4-5 mm
ALLEN WRENCH
BEARING PULLER
MECHANICS
PROCEDURE
Fig. 60

safety clothing.
1) 5 mm ALLEN WRENCH - Place the motor in a vice and carefully
clamp the jaws. Using the wrench unscrew and remove the
screws that fix the gear unit to the motor (Ref. T Fig. 60). Remove
the gear unit paying attention to the shims and gears, which should
not be moved from their locations.
2) 4 mm ALLEN WRENCH - PULLER - Unscrew and remove the
upper and lower motor flange fixing screws (Ref. U-V Fig. 62-63).
Remove the upper flange.
Fit the puller to the lower flange for connection to the gear unit
(Fig. 64), detach the flange from the motor bearing and extract the
rotor from the stator (Fig. 65).
Remove the motor casing from the vice and insert the rotor in its
place, ensuring you first fit aluminium cheeks to the vice jaws to
prevent marring. Clamp the vice carefully (Fig. 66).
Fit the puller to the bearing/encoder and remove it from the rotor
shaft. Now fit a new bearing.
Page: 22
Fig. 66
Part No.: 524159096
Fig. 61
Fig. 63
Fig. 64
Fig. 65
Date: Mar. 2002
Fig. 62
UPDATE
SERVICE
Section: MECHANICS
6.00 STEERING UNIT

MODEL ALL MODELS
The steering unit is designed so that it can be adjusted to suit the preferences of the operator by means
of a gas spring and series of linkages.
Activating lever no. 2 (Fig. 69) provides two adjustment functions: extending or shortening the reach of the
steering unit and up/down rotation of the panel.
Lever no. 2 operates an eccentric pin that serves to unlock rotary movement of the steering handwheel
unit and display, while simultaneously loosening the conical plug in the tube so that steering handwheel
reach can be adjusted and the handwheel rotated until the operator finds the most comfortable position.
MECHANICS
Activating lever no. 1 (Fig. 68), which is located on the instrument panel next to the hydraulic joysticks,
causes a valve to be operated in the gas spring by means of a wire cable and sheath system, thus allowing
the steering unit to be positioned at the most comfortable height for the operator.
MECHANICS
The following pages present the components that make up the steering unit, with details of the disassembly
steps required for repair or replacement.
Fig. 68
LEVER
ROTATION
G
IN
EN G
H
T
IN
NG TEN
LE
R
O
SH
LEVER
REACH ADJUSTMENT
TUBE
Fig. 67
UPDATE
Date: Mar. 2002
VALVE CONTROLLED
BY LEVER 1
Part No.: 524159096
GAS
SPRING
Fig. 69
Page: 23
SERVICE
Section: MECHANICS
6.01 STEERING UNIT LINKAGE COMPONENTS

MODEL ALL MODELS
5
36
33
34
35
40
32
38
STEERING UNIT ASSEMBLY DRAWING
30
26
25
31
24
28
MECHANICS
41
39
29
23
44
43
2
22
STEERING UNIT SECTIONAL VIEW
HANDWHEEL BEARING ENCODER SECTIONAL VIEW
14
20
37
42
27
2
13
19
13
14
17
21
15
16
12
7
STEERING LINKAGES ASSEMBLY DRAWING
11
9
18
10
10
2
STEERING LINKAGES SECTIONAL VIEW
RETURN GAS SPRING
Fig. 70
Page: 24
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MECHANICS
6.02 TABLE OF STEERING LINKAGE COMPONENTS

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

UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 25
SERVICE
Section: MECHANICS
6.03 REPLACING THE STEERING UNIT GAS SPRING

MODEL ALL MODELS
The gas spring fills an important function in moving the steering unit to the position that the operator
considers to be most comfortable. Therefore, when the spring no longer provides sufficient force, it must
be renewed.
13 mm
HEX WRENCH
MEDIUM EXTERNAL
CIRCLIP PLIERS
REGULAR PLIERS
MEDIUM
CROSSHEAD
SCREWDRIVER
PROCEDURE
MECHANICS
B
Fig. 72
C
A
D
D
Fig. 73
E
F
F
Fig. 71
Page: 26
Part No.: 524159096
Date: Mar. 2002
Fig. 75
0
Fig. 74
2
UPDATE
SERVICE
Section: MECHANICS
1) MEDIUM CROSSHEAD SCREWDRIVER, REGULAR PLIERS - Using the screwdriver, unscrew and
remove the fixing screws of the hood under the steering handwheel unit (Ref. A Fig. 71) and remove
the hood. Use the pliers to remove the pin securing the steel cable of the lever that operates the gas
spring valve (Ref. C fig. 73).
2) CIRCLIP PLIERS, 13 mm HEX WRENCH - Remove the circlips that couple the gas spring to the bracket
(Ref. D Fig. 73) and extract the gas spring and place it on a workbench. Use the hex wrench to loosen
the locking nut (Ref. E Fig. 74) and unscrew the lever (Ref. F Fig. 74-75); remove the lever and then
screw it to the new gas spring. Now fit the new gas spring in place of the original part.
6.04 ADJUSTING STEERING HANDWHEEL TORQUE

MODEL ALL MODELS
If the handwheel turns too easily, the turning torque can be increased to suit the expectations of the
operator. Beneath the handwheel there are two Teflon pins that exert frictional force on the handwheel;
by increasing the pressure of the relative thrust spring by adding shims it is possible to increase the effort
required to turn the handwheel.
5 mm ALLEN
WRENCH
SMALL SLOTTED
SCREWDRIVER
PROCEDURE
safety clothing.
Fig. 76
Park the truck in a safe place away from moving vehicles

and pedestrians. Bring the reach carriage to its forward
position, lower the forks to the ground, set the keyswitch to
1) 5 mm ALLEN WRENCH, SLOTTED SCREWDRIVER - Use the
screwdriver to remove the handwheel central cover cap (Ref. G
Fig. 76). Using the Allen wrench, unscrew and remove the
handwheel locking screw (Ref. H Fig. 77). Remove the handwheel
from the shaft. Remove the Teflon pin (Ref. L Fig. 77), remove
the spring (Ref. M Fig. 77) and add shimming washers until
obtaining the required stiffness of handwheel rotation.
H
L
M
N
L
M

order.
Fig. 77
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 27
MECHANICS
MECHANICS
SERVICE
Section: MECHANICS
6.05 DISMANTLING THE HANDWHEEL - DISPLAY ASSEMBLY

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

safety clothing.
Park the truck in a safe place away from moving vehicles
and pedestrians. Bring the reach carriage to its forward
position, lower the forks to the ground, set the keyswitch to
1) Remove the handwheel (see heading N 5.04 page 27)

T
2) CROSSHEAD SCREWDRIVER - Detach the steering tube

protective bellows from the hood side and the display side
(Ref. W Fig. 80). Using the screwdriver, unscrew and remove the
fixing screws of the upper hood and lower truck body side hood
(Fig. 71); remove the hoods to gain access to the spring and
display electrical connectors. Using the same screwdriver,
unscrew and remove the fixing screws of the display upper and
lower covers (Ref. O Fig. 78) and remove the covers to expose
the complete display. Unscrew and remove the display fixing
screws (Ref. P Fig. 78); disconnect the electrical connector, and
remove the display. Disconnect the power cable connector from
the electrical system side under the hood.
Fig. 79
Fig. 80
Page: 28
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: MECHANICS
3) 6 mm ALLEN WRENCH - Loosen the guide screw of the sliding tube (Ref. R Fig. 79), loosen the
eccentric pin lever (Ref. Q Fig. 79) to unlock the linkage system, and then extract the assembly from
the supporting tube (Ref. S Fig. 79) and place it on a workbench (Fig. 81).
5) REGULAR PLIERS - Unscrew the threaded bar from the pin (Ref. U
Fig. 83), and extract the eccentric pin from its seat as shown in
(Fig. 84).
Fig. 81
MECHANICS
6) CIRCLIP PLIERS - Remove the circlip (Ref. V Fig. 85), extract the
spring (Ref. J Fig. 85) and disassemble the eccentric pin as shown
in (Fig. 85); carry out the necessary replacement or repair operations.

Z
Fig. 82
V
J
U
UPDATE
Fig. 83
Fig. 84
Fig. 85
Date: Mar. 2002
Part No.: 524159096
MECHANICS
4) 13 mm HEX WRENCH - Unscrew and remove the locknut of the

conical tube guide bar (Ref. Z Fig. 79-82), withdraw the short conical
tube and the long conical tube as shown in (Fig. 82).
Page: 29
SERVICE
Section: MECHANICS
MECHANICS
NOTES:
Page: 30
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: REACH CARRIAGE
REACH
CARRIAGE
REACH CARRIAGES UTILIZED ............................................... 2
REACH CARRIAGE REMOVAL PROCEDURE ........................ 5
REACH CARRIAGE
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 1
SERVICE
1.00 REACH CARRIAGES UTILIZED

MODEL ALL MODELS
1.01 REACH CARRIAGE COMPONENTS
12
4
STANDARD TRUCK
13
16
14
10
7
15
11
2
9
REACH CARRIAGE
Fig. 1
NARROW TRUCK
12
4
8
13
3
8
16
10
14
7
15
11
2
9
Page: 2
Part No.: 524159096
Date: Mar. 2002
Fig. 2
UPDATE
SERVICE
PLUS WIDE TRUCK
12
4
13
8
3
16
10
14
7
15
11
2
1
9
5
Fig. 3
1.02 TABLE OF REACH CARRIAGE - TRUCK COMBINATIONS

REACH CARRIAGE - TRUCK COMBINATIONS
Reach Carriage
Combination with Truck
MR14 - MR14H
MR16 - MR16H
Standard
MR20 - MR20H
MR25
MR16N
Narrow
MR20W
Plus
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 3
REACH CARRIAGE
SERVICE
1.03 TABLE OF REACH CARRIAGE COMPONENTS

MODEL ALL MODELS
The components shown are described in the following table
Key:
REACH CARRIAGE
Ref.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Component reference
LIST OF REACH CARRIAGE COMPONENTS

Reach carriage
Sliding carriage guide blocks
Upper Lh mast channel fixing support
Upper Rh mast channel fixing support
Carriage guide shoe
Carriage guide shoe shim washer
Carriage rollers
Battery return buffers
Carriage rollers grease nipples
Carriage equipment cover plate
Carriage guide fixing screws
Upper mast supports fixing screws
Spring washers for support screws
Equipment cover plate fixing screws
Rollers to carriage fixing screws
Battery extraction attachment pin
NOTE: All Yale Part Numbers are given in the spare parts catalogue.
NOTES:
Page: 4
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.00 REACH CARRIAGE REMOVAL PROCEDURE

MODEL ALL MODELS
The reach carriage is equipped with four roller bearings and two U guides mounted to the left-hand side
of the truck next to the cylinder.
The bearings run on case hardened plates secured to the inside of the load wheel support straddles. The
guides run in a case hardened plate secured to the left-hand straddle to avoid possible sideways play during
forward and backward carriage movements.
Movement must be uniform and frictionless. Therefore, when either the bearings or shoes must be
replaced, it is essential to slide the reach carriage out of the truck.
The procedure is described below.
Lifting sling with three hooks, max. capacity 1000 kg
HEX WRENCH
13-19-24 mm
MEDIUM SLOTTED
SCREWDRIVER
OVERHEAD
CRANE
C Fig. 8
Fig. 7
Fig. 9
B
Fig. 6
A
Fig. 5
Fig. 4
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 5
REACH CARRIAGE
ALLEN WRENCH
3-5 mm
SERVICE

PROCEDURE
1) Remove the mast (see masts section heading 2.01 page 10)
2) 13 mm HEX WRENCH - 5 mm ALLEN WRENCH - With the Allen wrench unscrew and remove the
two reach carriage travel limit stops (Ref. A Fig. 5);
use the hex wrench to unscrew and remove the
cylinder fixing screw (Ref. B Fig. 6), lift the cylinder
and remove it from its pivot pin.
REACH CARRIAGE
3) HEX WRENCH 19-24 mm - Use the 19 mm

wrench to loosen the guide shoe fixing screws
(Ref. C Fig. 7-8).
Using the 24 mm wrench unscrew the solenoid
valve bank hydraulic line unions (Ref. D Fig. 9) and
disconnect the Mhyrio board electrical connector.
4) SLING - OVERHEAD CRANE - Attach the sling to
the reach carriage in such a way that it can be
withdrawn horizontally (Fig.10).
Attach the other end of the sling to the bridge crane
and allow it to take the strain.
Extract the reach carriage outwards and then
renew the bearings and sliding shoes.
2.01 BEARING REPLACEMENT

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

SHOES
6) MEDIUM SLOTTED SCREWDRIVER - Using the
screwdriver press the shoe pin through the
assembly hole in the guide (Ref. F Fig.11).
Remove the shoe and fit a replacement part.
E

reverse order.
F
Fig. 11
Page: 6
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
REACH CARRIAGE
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 7
SERVICE
REACH CARRIAGE
NOTES:
Page: 8
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: REDUCTION GEAR
REDUCTION
GEAR
a REDUCTION GEAR COMPONENTS ...................................... 2
a REDUCTION GEAR REMOVAL PROCEDURE ...................... 3
a REPLACING THE MOTOR SHAFT OIL SEAL ...................... 5
REDUCTION GEAR
a REPLACING THE DRIVE WHEEL AXLE SHAFT OIL SEAL ... 6
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 1
SERVICE
1.00 REDUCTION GEAR COMPONENTS

MODEL ALL MODELS
8
5
5
8
7
3
REDUCTION GEAR
Fig. 1
1.01 TABLE OF REDUCTION GEAR COMPONENTS

Ref.
1
2
3
4
5
6
7
8
9
MDU 150
MDU 170
Complete reduction gear
Upper flange
Drive wheel
Drive motor shaft oil seal
Drive wheel axle shaft oil seal
Wheel stud
Motor shaft
Steering gear wheel
Oil filler plug
Oil Kg 2,00 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel
Page: 2
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.00 REDUCTION GEAR REMOVAL PROCEDURE

MODEL ALL MODELS
There are two different models of reduction gear utilized, identifiable by means of a code:
- MDU 150 installed on models MR14 - MR14H - MR16 - MR16N
- MDU 170 installed on models MR16H - MR20 - MR20H - MR20W - MR25
The technical specifications of the two units are similar and the units are interchangeable.
The removal and installation procedure is therefore identical for both units.
500 mm lever with flat bladed end

2 Wooden blocks 150x150x200
Sling with two hooks
12
12
12
12
12
EYEBOLT
HEX WRENCH
10-13-17-24 mm
ALLEN WRENCH
5-6 mm
OVERHEAD
CRANE
HYDRAULIC
JACK
PROCEDURE
1) 5-6 mm ALLEN WRENCH - Use the 6 mm Allen wrench to open the motor compartment hood, and use
the 5 mm Allen wrench to remove the floor panel.
2) HYDRAULIC JACK - Place the jack alongside the drive
wheel and lift the truck until the blocks can be inserted
under it.
Place the blocks at the sides (Fig. 2) and lower the jack
so that the truck is supported on the blocks. Remove the
jack.
3) Remove the steering motor (see mechanical section
heading 5.00, page 20).
Fig. 2
4) Remove the drive motor (see mechanical section

heading 3.00 page 12).
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 3
REDUCTION GEAR
SERVICE

5) Remove the drive wheel (see mechanical section heading
1.01 page 3).
6) LIFTING SLING - EYEBOLTS - Screw the eyebolts into two
opposite side drive motor fixing holes, (Fig. 4).
Attach the lifting sling hooks to the two eyebolts (Fig. 4) and the
other end of the sling to the overhead crane hook.
Take the strain with the sling.
7) TWO 24 mm HEX WRENCHES - LEVER - Unscrew the nuts of

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

Fig. 4
REDUCTION GEAR
NOTES:
Page: 4
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.01 REPLACING THE MOTOR SHAFT OIL SEAL

MODEL ALL MODELS
The motor shaft oil seal is located in the reduction gear upper flange and cannot be removed without first
removing the drive motor.
HEX WRENCH
13-17 mm
ALLEN WRENCH
5 mm
MEDIUM SLOTTED
SCREWDRIVER
PROCEDURE
1) Remove the drive motor (see heading mechanical section heading 3.00 page 12).
2) SLOTTED SCREWDRIVER - Use the screwdriver to prise the oil seal (Ref. C Fig. 5), remove the oil
seal and fit a replacement.
REDUCTION GEAR
Fig. 6
Fig. 5
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 5
SERVICE
2.02 REPLACING THE DRIVE WHEEL AXLE SHAFT OIL SEAL

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

Loctite sealing compound for gaskets
2 wooden blocks 150x150x200
ALLEN WRENCH
5-10 mm
DRIFT 30x200
SOCKET WRENCH
13-19 mm WITH
RATCHET
HYDRAULIC
JACK
MEDIUM-WEIGHT
STEEL HAMMER
MEDIUM SLOTTED
SCREWDRIVER
RUBBER
MALLET
REDUCTION GEAR
C-SPANNER FOR
60 RINGNUTS
HEX WRENCH
13 mm
SMALL CHISEL
Fig. 7
G
E
Fig. 10
Page: 6
Part No.: 524159096
Date: Mar. 2002
Fig. 8
Fig. 9
0
UPDATE
SERVICE
PROCEDURE
clothing.
pedestrians. Bring the reach carriage to its forward position, lower
the forks to the ground, set the keyswitch to OFF and disconnect
the battery.
1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack in the centre of
the carriage alongside the drive wheel, and lift the truck until the wooden
blocks can be inserted. Place the blocks alongside the jack and then lower
the jack until the truck body is resting on the blocks. Now remove the jack.
2) ALLEN WRENCH 5-10 mm - Use the 5 mm wrench to open the motor
compartment hood. With the 10 mm Allen wrench remove the guard in
correspondence with the drive wheel.
Fig. 11
3) Remove the drive wheel (see mechanical section heading 1.01

page 2).
4) 10 mm ALLEN WRENCH - OIL COLLECTION CONTAINER - Position the
container under the reduction gear drain plug (Ref. D Fig. 9), using the Allen
wrench unscrew and remove the plug and allow the oil to drain out of the
reduction gear.
Fig. 12
5) 13 mm SOCKET WRENCH WITH RATCHET - Unscrew and remove the

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

seal and bearing (Ref. H Fig. 11). Extract the oil seal from its seat and fit
a replacement part.
MDU 150
MDU 170
UPDATE
Fig. 14
Date: Mar. 2002
Part No.: 524159096
Page: 7
REDUCTION GEAR
6) CHISEL - MEDIUM-WEIGHT STEEL HAMMER - Using the hammer and

chisel raise the clenched lip of the locking ring in the axle shaft seat (Ref. F
Fig. 7) so that the locking ring can be unscrewed.
SERVICE
REDUCTION GEAR
NOTES:
Page: 8
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
Section: BRAKING SYSTEM
BRAKING
SYSTEM
ELECTROMAGNETIC BRAKE COMPONENTS ................................... 2
LOAD WHEEL BRAKING SYSTEM COMPONENTS ........................... 3
LOAD WHEEL BRAKE COMPONENTS .............................................. 4
BRAKING SYSTEM ............................................................................. 5
REMOVING AND ADJUSTING THE ELECTROMAGNETIC BRAKE ..... 6
ADJUSTING THE ELECTROMAGNETIC BRAKE AND PUTTING

IT INTO SERVICE ................................................................................ 7
REMOVING THE BRAKE MASTER CYLINDER ................................... 8
REPLACING THE LOAD WHEEL BRAKES ......................................... 9
BLEEDING AIR THE BRAKES CIRCUIT ............................................ 11
BRAKING SYSTEM
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 1
SERVICE
1.00 ELECTROMAGNETIC BRAKE COMPONENTS

MODEL ALL MODELS
55
2
6
Fig. 1a
1.01 TABLE OF ELECTROMAGNETIC BRAKE COMPONENTS
BRAKING SYSTEM
Ref.
1
2
3
4
5
6
Complete electromagnetic brake
Electromagnet coil
Brake disc
Brake disc guide pinion
Fixing screws
Brake disc adjuster nut
Page: 2
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
1.02 LOAD WHEEL BRAKING SYSTEM COMPONENTS

MODEL MR16 OPTIONAL - MR20 - MR20H - MR20W - MR25
14
10
13
15
11
12
4
6
3
7
2
5
1
Fig. 1b
1.03 TABLE OF BRAKING SYSTEM COMPONENTS

Brake master cylinder
Master cylinder plunger rod
Brake cylinder pipelines distributor connection
Master cylinder supply line union
Brake pedal sensor
Master cylinder fixing screws
Brake fluid reservoir
Rh brake line branch connection
Rh wheel brake unit
Lh wheel brake unit
Line connecting master cylinder to Rh brake unit
Line connecting master cylinder to Lh brake unit
Line connecting brake fluid reservoir to master cylinder
Brake unit pipeline union
Brake pedal
BRAKING SYSTEM
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 3
SERVICE
1.04 LOAD WHEEL BRAKE COMPONENTS

MODEL MR16 OPTIONAL - MR20 - MR20H - MR20W - MR25
8
14
4
2
7
10
13
6
19
11
11 9
12
G
17
15
16
18
Fig. 1c
1.05 TABLE OF LOAD WHEEL BRAKE COMPONENTS
BRAKING SYSTEM
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Load wheel
Brake unit complete
Brake shoes
Brake shoe support spring
Brake shoe tension spring
Brake/wheel pivot pin
Brake unit pin assembly flange
Brake cylinder
Taper roller bearings
Dust seal
Bearing shield rings
Serrated lock washer
Locking ring
Brake block holder plate
Wheel pivot pin
Pin restraining washer
Wheel spindle fixing screw
Screws securing brake unit to straddle arm
Screws for securing spindle and brake unit
Page: 4
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
1.06 BRAKING SYSTEM

MODEL ALL MODELS
The reach trucks are fitted with four braking systems:
A)
B)
C)
D)
Release braking.
Service or reverse travel braking.
Emergency braking.
Parking braking.
A) RELEASE BRAKING
Activates a deceleration ramp when the travel control is released.
Release braking is activated by releasing the travel pedal when the truck is travelling in either direction.
This action results in regenerative braking, the intensity of which is proportional to the current value entered
using the programming console (RELEASE BRAKING parameter): level 9 corresponds to maximum
intensity. Since release braking and service braking are separate functions, release braking intensity can
be customized on the basis of the customers preferences.
B) SERVICE BRAKING
Service braking involves application of a deceleration ramp when the travel direction signal is inverted.
Service braking, which as also known as reverse current braking, consists of reversing the current
delivered to the drive motor thereby changing the travel direction when the truck is moving.
When the motor current is inverted the truck starts to decelerate at an intensity that is proportional to the
current value entered with the programming console (INVERSION BRAKING parameter): level 9
corresponds to maximum intensity.
Braking current must be regulated in such a way that the truck stops in a distance that is no less than its
length.
C) EMERGENCY BRAKING
Emergency braking consists of a regenerative braking action that is activated when the brake pedal is
pressed.
This action is combined with regenerative braking associated with the release of the accelerator pedal,
thereby causing the truck to stop in a shorter distance. Once the truck is stationary the electromagnetic
brake is applied.
Braking intensity is proportional to the current value entered with the programming console (PEDAL
BRAKING parameter).
Simply pressing the accelerator pedal will cause the electromagnetic brake to be released.
All truck models are equipped with this type of brake function.
Truck models MR16 OPTIONAL, MR20, MR20H, MR20W, MR25, which are heavier vehicles, are
additionally equipped, on the load wheels, with brake units that are activated by means of a brake master
cylinder connected to the brake pedal.
The load wheel brakes are activated after regenerative braking has been applied, by increasing the
pressure exerted on the brake pedal.
D) PARKING BRAKE
The parking brake function is provided by the electromagnetic brake mounted on the drive motor.
The electromagnetic brake is applied in two situations:
A) If the operator releases the deadman button when the truck is stationary. In this case power is
disconnected from the electromagnetic brake coil causing the brake to be applied.
B) If a button marked with the brake symbol on the instrument panel is pressed when the truck is on a grade.
In this case power is disconnected from the electromagnetic brake coil causing the brake to be applied
and inhibiting drive; hydraulic functions, however, remain operational.
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 5
BRAKING SYSTEM
Applies a deceleration ramp when the travel control is released and the brake pedal switch contacts are
closed.
SERVICE
2.00 REMOVING AND ADJUSTING THE ELECTROMAGNETIC BRAKE

MODEL ALL MODELS
Having described the trucks brake system, this section illustrates the procedures for removing the various
units in the system so that they can be renewed or so that their subassemblies can be renewed.
Due to rubbing friction during braking, the brake disk is subject to wear. Once the depth of wear exceeds
4 mm the disc must be renewed.
The removal and adjustment procedure is described below.
6 mm
ALLEN WRENCH
13 mm
HEX WRENCH
FEELER GAUGE
CIRCLIP PLIERS
PROCEDURE
1) 6 mm ALLEN WRENCH - 13 mm HEX WRENCH - Use the Allen wrench to open the motor
compartment hood.
Using the 13 mm hex wrench loosen the three locking nuts (Ref. A Fig. 2).
Now use the Allen wrench to unscrew and remove the three electromagnetic brake fixing screws
(Ref. B Fig. 2) and detach the brake from the motor.
2) CIRCLIP PLIERS - Withdraw the brake disk from the guide pinion; use the circlip pliers to remove the
circlip from the motor shaft and extract the brake disk guide pinion.
BRAKING SYSTEM
NOTE: When you fit a new brake disk it is essential to renew

also the pinion.
B
Fig. 2
Page: 6
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
2.01 ADJUSTING THE ELECTROMAGNETIC BRAKE AND PUTTING IT INTO SERVICE

MODEL ALL MODELS
- After refitting the brake assembly, before operating the truck you must adjust the brake disk.
- To obtain good braking action, the distance between the brake disk and the electromagnet plate (Ref. S
Fig. 3) should be no more than 0.4 mm. You will therefore need a feeler gauge of this size.
- With the three nuts (Ref. R) loosened off, insert the
feeler gauge next to one of the bolts and then tighten
bolt (Ref. V) with the 6 mm Allen wrench.
Adjust the plate so that the feeler gauge can be with
drawn with slight friction. Repeat the same operation
on all three bolts (Ref. V).
Tighten nuts (Ref. R).
- Adjusting braking distance: start the truck and travel at
maximum speed.
Remove your foot from the deadman button. The truck
must brake in a distance that is no less than and no
greater than its own length. To optimize the braking
distance turn adjuster nut (Ref. G): turn clockwise to
reduce braking distance and counter-clockwise to
increase it.
Fig. 3
BRAKING SYSTEM
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 7
SERVICE
3.00 REMOVING THE BRAKE MASTER CYLINDER

MODEL MR16 optional - MR20 - MR20H - MR20W - MR25
The brake unit master cylinder is a hydraulic system and it is subject to wear of the seals and internal parts.
In the case of worn internal parts, a new master cylinder must be fitted in order to restore efficient braking
action.
5-6 mm
ALLEN WRENCH
13-17-19-22 mm
HEX WRENCH
PROCEDURE
1) 5-6 mm ALLEN WRENCH - Use the 6 mm Allen wrench to unscrew the motor compartment hood fixing
screws to gain access to the brake system. With the 5 mm Allen wrench unscrew and remove the floor
panel fixing screws (Ref. F Fig. 5); remove the floor panel.
C
2) 17 mm HEX WRENCH - Unscrew the brake master cylinder supply

line union (Ref. C Fig. 4); detach the brake cylinder pipeline and use
self-locking pliers to clamp the line to prevent the brake fluid from
draining out and emptying the reservoir.
BRAKING SYSTEM
3) 22 mm HEX WRENCH - Unscrew the union of the load wheel brake

unit supply pipelines (Ref. D Fig. 4) and detach the union from the
master cylinder.
Fig. 4
4) 13 mm HEX WRENCH - Unscrew the two screws responsible

for fixing the master cylinder to the support (Ref. E Fig. 4),
recovery the defective master cylinder and fit a replacement
unit.
order.
For information on how to bleed the brake circuit of air,
refer to the procedure on page 11.
Page: 8
Part No.: 524159096
Date: Mar. 2002
Fig. 5
3
UPDATE
SERVICE
3.01 REPLACING THE LOAD WHEEL BRAKES

MODEL MR16 OPTIONAL - MR20 -MR20H - MR20W - MR25
5-8 mm
ALLEN WRENCH
7-10-14 mm
HEX WRENCH
500 g HAMMER
REGULAR PLIERS
HYDRAULIC JACK
C-SPANNER FOR 60
RINGNUTS
DRIFT 25x200 mm
COMPASS SPANNER
WITH 5 PINS
PROCEDURE
clothing
pedestrians. Bring the reach carriage to its forward position, lower
the forks to the ground, set the keyswitch to OFF and
Fig. 6
BRAKING SYSTEM
1) Remove the load wheel (see mechanical section heading 1.02

page 4).
2) C-SPANNER - Unscrew the ring that fastens the brake unit boss to the
wheel (Ref. G Fig. 7) and withdraw the kit from the wheel hub as
shown (Fig. 6).
Now strip down the brake unit in order to renew individual parts or
renew the entire unit.
UPDATE
Date: Mar. 2002
Fig. 7
Part No.: 524159096
Page: 9
SERVICE

3) 5 mm ALLEN WRENCH - To renew the complete brake unit you must first
remove the bearings (Ref. H Fig. 8) and then use the wrench to unscrew
the screws responsible for fastening the spindle to the brake unit (Ref. M
Fig. 9). Extract the spindle and renew the brake unit.

Using the same procedure described in point 3 it is also possible to replace
exclusively the spindle.
Fig. 8
4) 10 mm HEX WRENCH - To renew the brake cylinder (Ref. L Fig. 8)

unscrew the screws that secure the cylinder to the shoe carrier plate
(Ref. M Fig. 9), remove the cylinder and fit a replacement.

5) REGULAR PLIERS - To replace the brake shoes, remove the retaining
springs using the pliers, remove the shoes, and then fit replacement parts.
Fig. 9
BRAKING SYSTEM
NOTES:
Page: 10
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
3.02 BLEEDING AIR FROM THE BRAKE CIRCUIT

MODEL MR16 Optional - MR20 - MR20H - MR20W - MR25
After changing the brake units, the brake cylinder, the load wheel or the master cylinder it is essential to
bleed air from the brake fluid circuit.
To bleed the brakes efficiently it is advisable to prepare two stands of approximately 300 400 mm in height,
each equipped with a container for collecting drained oil. Fit one end of a 6 mm tube to the brake unit
bleed union and insert the other end in the collection container (Ref. N Fig. 10).
2 stands (Fig.12)
Rubber tube, inside 6 - length 200 mm
2 litres of brake fluid
7-8 mm
HEX WRENCH
Fig. 10
1) Remove the dust cap from the bleed screw located behind the
brake unit (Fig. 10).
2) 7-8 mm HEX WRENCH - STAND - CONTAINER - Place the
stand complete with container and tube next to the wheel and
fit the tube to the bleed union. Using the wrench loosen the
bleed union by rotating it through 3/4 of a turn (Ref. N Fig. 10);
repeat the same procedure on the opposite side wheel and
then pour brake fluid into the two containers until the bleed
screw connecting tube is completely submerged.
Fig. 11
UPDATE
Date: Mar. 2002
BRAKING SYSTEM
3) Fill the master cylinder reservoir with brake fluid (Ref. O

Fig. 11) to start the flow of brake fluid to the collection containers.
Slowly depress the brake pedal and release it ten times in
succession (Ref. P Fig.11) after which do not press the pedal
for approximately five minutes, allowing the brake fluid to flow
into the container under the pressure accumulated in the
circuit.
The brake fluid reservoir is higher than the collection containers
positioned next to the load wheels, therefore the fluid in the
master cylinder will be transferred into the containers via the
master cylinder, forcing all the air out of the circuit in the
process. Ensure that the reservoir is kept permanently full of
oil.
Repeat the sequence of brake pedal cycles at five minute
intervalsuntil all the air has been expelled from the circuit.
Now use the wrench to tighten the bleed union screws.
Fig. 12
Part No.: 524159096
Page: 11
SERVICE
4) Fit the cap to the brake fluid reservoir and remove the collection containers; depress the brake pedal
4 or 5 times to pressurize the circuit, until you meet solid resistance when attempting to depress the
pedal, indicating that the master cylinder has no internal leakage. Now re-close the various panels and
hoods on the truck.
Test the brake circuit with the truck in motion. If you detect a spongy feel when pressing the brake pedal,
this indicates that there is still air in the circuit so the air bleeding operation described above must be
repeated.
BRAKING SYSTEM
NOTES:
Page: 12
Part No.: 524159096
Date: Mar. 2002
UPDATE
SERVICE
BRAKING SYSTEM
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524159096
Page: 13
SERVICE
BRAKING SYSTEM
Part N 524159096
Page: 14
Part No.: 524159096
Date: Mar. 2002
4 65
UPDATE

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Technical Information for

YALE Service Centres

This manual is addressed exclusively to the specialised

GENERAL SAFETY PRESCRIPTIONS

Part No.: 524159096

Date: Mar. 2002

Date: Mar. 2002

Part No.: 524159096

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

Part No.: 524159096

Date: Mar. 2002

1.01 KEY TO HYDRAULIC SYSTEM SYMBOLS ................................................................................................ 2

Date: Mar. 2002

Part No.: 524159096

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

MAST TYPES ............................................................................................................................................. 3

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

Part No.: 524159096

Date: Mar. 2002

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

REACH CARRIAGES UTILISED .................................................................................................................

REDUCTION GEAR COMPONENTS ..........................................................................................................

ELECTROMAGNETIC BRAKE COMPONENTS .......................................................................................... 2

Date: Mar. 2002

Part No.: 524159096

Section: ELECTRICAL SYSTEM

Part No.: 524159096

Date: Mar. 2002

Section: ELECTRICAL SYSTEM

Date: Mar. 2002

Part No.: 524159096

Section: ELECTRICAL SYSTEM

1.0 INTRODUCTION TO THE TRUCK

MAST SERIAL NUMBER

TRUCK SERIAL NUMBER

Part No.: 524159096

Date: Mar. 2002

2.0 INSTALLING THE TRUCK

Date: Mar. 2002

Part No.: 524159096

Section: ELECTRICAL SYSTEM

Section: ELECTRICAL SYSTEM

Part No.: 524159096

Date: Mar. 2002

Section: ELECTRICAL SYSTEM

Date: Mar. 2002

Part No.: 524159096

Section: ELECTRICAL SYSTEM

1.0 KEY TO ELECTRICAL DIAGRAMS

Part No.: 524159096

Date: Mar. 2002

Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 1/7

5 6 Data: Mar. 2002

Part No: 524159096

Sezione: ELECTRICAL SYSTEM

Solenoid valves power

FUNCTIONAL ELECTRICAL DIAGRAM 2/7

Reference to diagram number at top right

DC-DC CONVERTER FOR 12/24V

24V ALLINSERZIONE - 19V DI ALIMENTAZIONE

1B - 2B PONTE CONFIGURAZIONE INVERTER