New MR All PDF

Part no.
: 550066261
Revision:
0 (01/2014)
Technical information for Yale service

centres
This manual is intended solely for the specialized technicians of

the Yale service network
D849.....
MR14 MR16N
MR16 MR16HD
MR20 MR20HD
MR25
INTRODUCTION
SERVICE
IMPORTANT
The Service Manuals are updated regularly, but may not contain the most recent product design modifications. The updated technical information is in any case available from your nearest authorised Yale
dealer. The Service Manuals provide the guidelines for correct maintenance and are designed for use by
appropriately trained technicians. Incorrect maintenance or non-compliance with the instructions contained
in this manual could cause damage to property or injury and even death to people.
We therefore recommend that you read this manual carefully and keep it in a good condition so it is always
decipherable and complete.
This manual does not replace the use and maintenance manual, it is a supplement to it.
Product support group
SERVICE
INTRODUCTION
GUIDE TO USING THE MANUAL
SECTIONS
This handbook is composed of the following sections:
Section 1:
Section 2:
Section 3:
Section 4:
Section 5:
Section 6:
Section 7:
Section 8:
Section 9:
Section 10:
Section 11:
Presentation
Installation and settings
Diagnostics and measurements
Electrical system
Hydraulic system
Truck base mechanics
Mast assembly mechanics
Small fork mast mechanics
Reduction gear
Braking system
Standard maintenance
Use the sections index with the numbered black bands to go quickly to the desired section.
SYMBOLS
Signals a danger that can cause accidents to people or damage to the machine.
Signals danger due to high temperatures.
Signals important notes or information to take into particular consideration.
Signals disposal/recycling of harmful substances under the protection of current legislation.
INSTALLATION PROCEDURES
For the installation procedures, carry out the reverse procedure to disassembly, observing any notes and
information given for the truck to function properly.
INTRODUCTION
SERVICE
GENERAL SAFETY RULES

PERSONAL SAFETY

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

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

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

If lifting unbalanced loads it is advised as a precaution to downrate the load capacities of the lifting elements:
Slings with 2 booms, consider them as corresponding to 1 boom.
Slings with 3 and 4 booms, consider them as corresponding to 2 booms.
Tips for maintenance
Periodically examine the belts, ropes and suspension elements according to current legislation to define
their state of service.
Change them in the following cases:
When the components show: deformation, cracks, hollows, cuts or abrasions.
When the wear of the components exceeds 10% of the original dimensions.
When the sling shows signs of overloading.
SERVICE
INTRODUCTION
Belt capacity table
Colour
Working load
capacity (kg)
purple
green
yellow
grey
red
brown
blue
1000
2000
3000
4000
5000
6000
8000
2000
4000
6000
8000
10000
12000
16000
1400
2800
4200
5600
7000
8400
11200
800
1600
2400
3200
4000
4800
6400
orange
10000
12000
20000
24000
14000
16800
8000
9600
15000
20000
25000
30000
30000
40000
50000
60000
21000
28000
35000
42000
12000
16000
20000
24000
1.4
0.8
orange
orange
orange
orange
orange
Coefficient
Rope capacity table
Working load
capacity (kg)
Coefficient
Colour
Track
(mm)
black
purple
black
green
yellow
grey
red
brown
blue
orange
35
50
50
60
75
120
150
180
240
300
500
1000
1500
2000
3000
4000
5000
6000
8000
10000
1000
2000
3000
4000
6000
8000
10000
12000
16000
20000
700
1400
2100
2800
4200
5600
7000
8400
11200
14000
400
800
1200
1600
2400
3200
4000
4800
6400
8000
1.4
0.8
SERVICE
INTRODUCTION
Suspension element capacity table
Colour
Working load
capacity (kg)
Coefficient
purple
green
yellow
grey
red
1000
2000
3000
4000
5000
1400
2800
3800
5600
6600
2100
4200
6300
8400
9800
2100
4200
6300
8400
10500
1.4
2.1
2.1
Working load capacity: the working load capacity is calculated with an angle at the
centre of 90
SERVICE
INTRODUCTION
TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS

Before disassembling the various parts
and nuts and bolts, read the following
carefully.
To make the threaded matings secure, LOCTITE 270 is
used for tightening the screws.
If it is not possible to unscrew the bolts because this
product has been used, avoid applying extensions to
the tools, instead slightly heat the area (at most 50C)
so as to eliminate the LOCTITE 270 effect.
In the cases described, reapply LOCTITE 270 during
installation in a moderate quantity (30% of the mating
surface).
The torque setting used for tightening the threaded
couplings is extremely important to make the coupling
secure and the machine safe.
The tables on this page give the classes of bolts normally
used with the relevant torque settings.
TORQUE SETTING Nm
Nominal
diameter
Class 8
Class 10
M3
5.2
M4
9.15
M5
12.14
14.8
M6
17.2
20.9
M8
31.8
38.1
M10
50.5
60.3
M12
74.2
88.5
M14
101.2
120.8
M16
138.2
164.9
M18
176.6
203.5
M20
225.4
259.7
M22
278.8
321.2
M24
324.8
374.2
M27
422.3
486.5
M30
516.1
594.7
TORQUE SETTING Nm
Pre-load N
Class 8.8
Class 10.9
M4
0.7
2400
1.92
1.44
3.07
2.3
4.17
3.13
M5
0.8
3880
3.88
2.91
6.2
4.65
8.43
6.33
M6
10
5490
6.58
4.94
10.5
7.9
14.3
10.8
M8
1.25
13
9990
16
12
25.6
19.2
34.8
26.1
M8
13
10700
17.1
12.8
27.4
20.5
37.3
27.9
M10
1.5
16
15825
31.7
23.8
51
38
69
52
M10
1.25
16
16700
33.4
25.1
53
40.1
73
55
M12
1.75
18
10
23025
55
41.4
88
66
120
90
M12
1.25
18
10
25150
60
45.3
96
72
130
98
M14
21
12
31400
88
66
140
105
190
145
M14
1.5
21
12
34125
96
72
155
115
210
155
M16
24
14
42850
135
105
220
165
300
225
M16
1.5
24
14
45600
145
110
235
175
320
240
M20
2.5
30
17
66875
270
200
430
320
580
435
M20
1.5
30
17
74250
295
225
475
355
650
485
= with lubricant
Class 5.8
SERVICE
INTRODUCTION
CORRECT METHOD FOR APPLYING FEMALE FITTINGS

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

Torque setting Nm
Outside
diameter
Nominal torque
min / max
of the pipe
UNF
thread
REVOLVING FEMALE jic 37

Torque setting Nm
Size
Nominal torque
min / max
M 12x1.5
20
15 -25
7/16-20
-4
15
9 - 21
M 14x1.5
38
30 - 45
1/2-20
-5
20
13 - 27
45
38 - 52
9/16-18
-6
30
18 - 42
3/4-16
-8
50
30 - 70
7/8-14
-10
69
44 - 94
1.1/16-12
-12
98
63 - 133
1.3/16-12
-14
118
73 - 163
1.5/16-12
-16
140
90 - 190
1.5/8-12
-20
210
135 - 285
M 16x1.5
M 18x1.5
M 20x1.5
M 22x1.5
8
10
10
12
12
14
15
51
43 - 85
58
50 - 65
74
60 - 88
M 24x1.5
16
74
60 - 88
1.7/8-12
-24
290
200 - 380
M 26x1.5
18
105
85 - 125
2.1/2-12
-32
450
300 - 600
135
115 - 155
166
140 - 192
30
240
210 - 270
35
290
255 - 325
330
280 - 380
M 30x2
M 36x2
M 42x2
M 45x2
M 52x2
UNF
thread
G1/4
20
22
25
28
38
42
REMOVING FEMALE BSP

Torque setting Nm
UNF
thread
REVOLVING FEMALE ORFS

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

Inspection of pipes and fittings
When even just one of the following conditions arises the pipe must immediately be disconnected and
replaced:
a shift of the connector on the pipe;

the presence of damage, cuts or abrasions on the surface layer;
hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
the presence of cracks, damage or bad corrosion on the connector;
the presence of leaks along the pipe or at the connector;
the presence of permanent creases, compression, flattening or twists in the pipe;
the presence of blisters, softening, wear of the external coat.
Pre-installation inspection
Before installing a flexible hose it is necessary to inspect the pipes carefully. First check that the type, size,
reference code and length are correct, then check there is no debris, blockages, bubbles, peeling of the
outer layer or any other visible defects.
Installation
Avoid twisting the pipe, which could cause it to burst under pressure.
There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assembled pipe decreases considerably when below the minimum radius of curvature.
The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly
greater length than the requirement in order to compensate for these changes.
10
SERVICE
INTRODUCTION
SECTION CONTENTS
Presentation
Installation and settings
Diagnostics and measurements
Electrical system
Hydraulic system
Truck base mechanics
6
7
Small fork mast mechanics
6
8
Reduction gear
7
9
Braking system
10
8
11
7
11
INTRODUCTION
12
SERVICE
SERVICE
PRESENTATION
Presentation
TRUCK PRESENTATION 2
VIEWS OF THE TRUCK 3
TRUCK AND LOAD IDENTIFICATION DATA 4
TRUCK IDENTIFICATION DATA PLATE 4
RESIDUAL LOAD PLATE 4
MAST SERIAL NUMBER PUNCHING and location of documentation 5
GENERAL SPECIFICATIONS 6
BATTERIES TABLE 10
PRESENTATION
SERVICE
TRUCK PRESENTATION
The new range of retractable trucks consists of 7 models with nominal load capacities from 1400 kg to
2500 kg.
Electrical system
All the motors benefit from the use of three phase AC alternate current technology: traction motor, steering
motor and pump motor.
The high battery efficiency is ensured by the regenerative inversion and release braking.
The electronic controls VCM, ACE2 Traction, ACE2 Pump and EPS ACW communicate via a CAN-Bus
system (Controller Area Network Bus). There are two separate CAN-Bus lines to improve the efficiency,
reliability and independence of the modules.
Hydraulic system
The 14 kW pump motor provides excellent performance thanks to the technology with proportional solenoid valves for the carriage out/return, lifting/lowering, fork tilting and side shifting operations with smooth
movements of the actuators.
Mast
The masts comprise three stages: external, middle and internal.
The rigidity and stability characteristics of the masts allow the forks to reach maximum heights of between
5 and 12 metres depending on the model.
The lifting cylinders are single-acting plungers.
SERVICE
PRESENTATION
VIEWS OF THE TRUCK
PRESENTATION
SERVICE
TRUCK AND LOAD IDENTIFICATION DATA

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

driver's cab
Manufacturer's name
Model
Serial number
Weight without battery
Year of manufacture
Max. battery weight

Min. battery weight
Battery voltage
Nominal load capacity
Persons on board
RESIDUAL LOAD PLATE
The load plate is located on the roof assembly

The load plate bears the following data:
Model
Liftable load values up to varying heights up to the maximum load with different distances from the
load centre of gravity of the forks.
Always refer to the load plate to be sure to lift an admissible load to an appropriate
height.
4
SERVICE
PRESENTATION
MAST SERIAL NUMBER PUNCHING and location of documentation
xxxxxxxx
The mast serial number is stamped on the

mast itself.
The truck documentation is stored in the document holder behind the backrest of the seat.
PRESENTATION
GENERAL SPECIFICATIONS
SERVICE
SERVICE
PRESENTATION
1.2
1.3
1.4
1.5
1.6
1.8
1.9
2.1
2.3
2.4
2.5
3.1
3.2
3.3
3.5
3.7
4.1
4.2
4.3
4.4
4.5
4.7
4.8
4.10
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.28
4.31
4.32
4.34.1
4.34.2
4.35
4.37
4.42
OTHER
DATA
MOTOR UNITS
PERFORMANCE
DIMENSIONS
WHEELS &
TYRES
WEIGHTS CHARACTERISTICS
manufacturers type designation
motor unit: battery, diesel, LPG, petrol, electric
driving: manual, on ground, standing, seated
load capacity/rated load
Q (t)
load centre of gravity
c (mm)
load distance from load wheel axle - forks
x (mm)
wheelbase (WB)
y (mm)
weight with no load (including battery)
kg
load on axle with no load (front/rear) (5)
kg
kg
load on axle with forks out with load (front/rear)
kg
load on axle with forks retracted with load (front/rear)
tyres: full rubber, polyurethane, vulkollan (front/rear)
front wheel size
(mm x mm)
rear wheel size
(mm x mm)
wheel quantity (x = traction) (front/rear)
rear track width
b 11 (mm)
/ ()
mast tilt / forks forward/backward
h1 (mm)
height of closed mast
h2 (mm)
free lift
lifting height
h3 (mm)
h4 (mm)
height, mast extended (1)
h6 (mm)
height of protective roof assembly (cab) (2)
h7 (mm)
seat height
h8 (mm)
armrest height
total length
l1 (mm)
length to face of forks
l2 (mm)
b1/b2 (mm)
overall width (3)
fork dimensions DIN ISO 2331
s/e/l (mm)
fork carriage ISO 2328, class/type A,B
b3 (mm)
fork carriage width
b5 (mm)
outer fork width (min/max) (8)
b4 (mm)
distance between the clamps of the load wheels
I4 (mm)
retractable travel
m1 (mm)
ground clearance under mast with load
ground clearance at wheelbase centre
m2 (mm)
working aisle for pallet length 1000 x 1200 crosswise
Ast (mm)
Ast (mm)
working aisle for pallet length 800 x 1200 lengthwise
turning radius
Wa (mm)
I7 (mm)
length between the wheel arms
mm
wheelbase height (from ground to footboard)
wheelbase height (between the steps between the footboard and the
mm
4.43
ground)
5.1 traction speed with/without load (7)
km/h
km/h
5.1.1 traction speed with/without load reverse drive (7)
5.2
lift speed with/without load (7)
m/s
5.3
5.4
5.7
5.8
5.9
5.10
6.1
6.2
6.3
6.4
6.5
6.6
8.1
10.1
10.2
10.7
lowering speed with/without load

Retractable carriage speed
grade ability with/without load
maximum gradeability with/without load
acceleration time, laden/unladen
service brake
traction motor, power S2 60 minutes
lifting motor, power S3 15%
battery in compliance with DIN 43531/35/36 A,B,C, no
battery rated voltage/capacity at 5 hours
battery weight (4)
consumption per VDI cycle
type of drive control
working pressure for additional attachments
volume of oil for additional attachments
noise level at the operating station
m/s
m/s
%
%
s
kW
kW
V/Ah
kg
kWh/h
bar
l/min
dB(A)
MR14
MR16
MR16N
electric (battery)
seated
1.4
1.6
1.6
600
600
600
258
308
202
1400
1450
1450
3495
3546
3498
2055/1440 2103/1443 1955/1543
885/4010 810/4336
757/4341
1711/3184 1779/3367 1514/3584
vulkollan/vulkollan
343 x 140 343 x 140 343 x 140
285 x 100 285 x 100 285 x 100
1x/2
1x/2
1x/2
1155
1155
1025
2/4
2/4
2/4
2195
2195
2195
1648
1648
1648
5000
5000
5000
5563
5563
5563
2175
2175
2175
1082
1082
1082
308
308
308
2523
2523
2629
1373
1373
1479
1265
1265
1125
40/80/1150 40/120/1150 40/120/1150
2A
2A
2A
700
700
700
220/640
260/680
260/680
900
900
795
441
491
385
75
75
75
75
75
75
2825
2834
2898
2895
2896
2976
1671
1718
1700
1795
1845
1845
550
550
550
371
371
371
11/11(14/14) 11/11(14/14) 11/11(14/14)

11/11(14/14) 11/11(14/14) 11/11(14/14)
0,37 / 0,63 0,32 / 0,63 0,32 / 0,63
(0,47 / 0,73) (0,42 / 0,73) (0,42 / 0,73)
0.55
0.55
0.55
0,15 / 0,15 0,15 / 0,15 0.15 / 0.15
12 / 15
11 / 15
11 / 15
12 / 15
12 / 15
12 / 15
-/-/-/Electrical
6,4
6,4
6,4
14
14
14
C
C
B
48/700 (6)
48/700 (6)
48/700 (6)
1119
1119
1119
-/-/-/AC
180
180
180
20
20
20
<69.7
<69.7
<69.7
SERVICE
PRESENTATION
1.2
1.3
1.4
1.5
1.6
1.8
1.9
2.1
2.3
2.4
2.5
3.1
3.2
3.3
3.5
3.7
4.1
4.2
4.3
4.4
4.5
4.7
4.8
4.10
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.28
4.31
4.32
4.34.1
4.34.2
4.35
4.37
4.42
DIMENSIONS
WHEELS &
TYRES
OTHER
DATA
MOTOR UNITS
PERFORMANCE
4.43
5.1
5.1.1
5.2
5.3
5.4
5.7
5.8
5.9
5.10
6.1
6.2
6.3
6.4
6.5
6.6
8.1
10.1
10.2
10.7

Q (t)
c (mm)
x (mm)
wheelbase (WB)
y (mm)
kg
kg
kg
kg
front wheel size
(mm x mm)
rear wheel size
(mm x mm)
rear track width
b 11 (mm)
/ ()
h1 (mm)
h2 (mm)
free lift
lifting height
h3 (mm)
h4 (mm)
h6 (mm)
h7 (mm)
seat height
h8 (mm)
armrest height
total length
l1 (mm)
l2 (mm)
overall width (3)
b1/b2 (mm)
s/e/l (mm)
b3 (mm)
fork carriage width
b5 (mm)
b4 (mm)
I4 (mm)
retractable travel
m1 (mm)
m2 (mm)
Ast (mm)
Ast (mm)
turning radius
Wa (mm)
I7 (mm)
mm
mm
ground)
traction speed with/without load (7)
km/h
km/h
traction speed with/without load reverse drive (7)
m/s
m/s
m/s
%
%
s
service brake
kW
kW
V/Ah
battery weight (4)
kg
kWh/h
bar
l/min
dB(A)
MR20
MR25
electric (battery)
seated
2.0
2.5
600
600
358
431
1500
1650
3801
4230
2296/1504 2565/1665
770/5030
876/5855
1971/3829 2306/4424
vulkollan/vulkollan
343 x 140 343 x 140
285 x 100 285 x 140
1x/2
1x/2
1155
1195
2/4
2/4
2195
2195
1582
1582
4650
4650
5263
5263
2175
2175
1082
1082
308
308
2523
2600
1373
1450
1265
1345
40/120/1150 45/120/1150
2A
2A
700
700
260/680
260/680
900
900
541
614
65
65
65
65
2846
2938
2900
2978
1767
1911
1895
2045
550
550
371
371
14 / 14
14 / 14
14 / 14
14 / 14
0.37 / 0.64 0.30 / 0.64
0.55 / 0.50 0.55 / 0.50
0,15 / 0,15 0.15 / 0.15
10 / 15
8 / 14
12 / 15
12 / 15
-/-/Electrical
6,4
6,4
14
14
C
C
48/700 (6)
48/840 (6)
1119
1306
-/-/AC
180
180
20
20
<69.7
<69.7
SERVICE
PRESENTATION
1.2
1.3
1.4
1.5
1.6
1.8
1.9
2.1
2.3
2.4
2.5
3.1
3.2
3.3
3.5
3.7
4.1
4.2
4.3
4.4
4.5
4.7
4.8
4.10
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.28
4.31
4.32
4.34.1
4.34.2
4.35
4.37
4.42
DIMENSIONS
WHEELS &
TYRES
OTHER
DATA
MOTOR UNITS
PERFORMANCE
4.43
5.1
5.1.1
5.2
5.3
5.4
5.7
5.8
5.9
5.10
6.1
6.2
6.3
6.4
6.5
6.6
8.1
10.1
10.2
10.7

Q (t)
c (mm)
x (mm)
wheelbase (WB)
y (mm)
kg
kg
kg
kg
front wheel size
(mm x mm)
rear wheel size
(mm x mm)
rear track width
b 11 (mm)
/ ()
h1 (mm)
h2 (mm)
free lift
lifting height
h3 (mm)
h4 (mm)
h6 (mm)
h7 (mm)
seat height
h8 (mm)
armrest height
total length
l1 (mm)
l2 (mm)
overall width (3)
b1/b2 (mm)
s/e/l (mm)
b3 (mm)
fork carriage width
b5 (mm)
b4 (mm)
I4 (mm)
retractable travel
m1 (mm)
m2 (mm)
Ast (mm)
Ast (mm)
turning radius
Wa (mm)
I7 (mm)
mm
mm
ground)
traction speed with/without load (7)
km/h
km/h
traction speed with/without load reverse drive (7)
m/s
m/s
m/s
%
%
s
service brake
kW
kW
V/Ah
battery weight (4)
kg
kWh/h
bar
l/min
dB(A)
MR16HD
MR20HD
electric (battery)
seated
1.6
2.0
600
600
308
281
1450
1500
4224
4617
2428/1796 2577/2040
979/4845
985/5632
2104/3720 2149/4468
vulkollan/vulkollan
343 x 140 343 x 140
285 x 100 285 x 140
1x/2
1x/2
1155
1195
2/4
2/4
3227
3227
2680
2614
7900
7750
8463
8363
2175
2175
1082
1082
308
308
2523
2600
1373
1450
1265
1345
40/120/1150 45/120/1150
2A
2A
700
700
260/680
260/680
900
900
491
464
65
65
65
65
2834
2903
2896
2970
1718
1767
1845
1895
550
550
371
371
14 / 14
14 / 14
14 / 14
14 / 14
0,42 / 0,73 0,37 / 0,68
0.55
0.55
0,15 / 0,15 0.15 / 0.15
10 / 14
8 / 13
12 / 15
12 / 15
-/-/Electrical
6,4
6,4
14
14
C
C
48/700 (6)
48/840 (6)
1119
1306
-/-/AC
180
180
20
20
<69.7
<69.7
SERVICE
PRESENTATION
NOTES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
with load grille h4 + 508 mm (all models except for 2 ton and 2.5 ton), h4 + 443 mm (2 ton and 2.5 ton models only)
with flashing light h6 + 120 mm; with protective grille h6 + 20 mm; with protective screen h6 + 30 mm
with load wheel side cover: 1289 mm (all models except for Narrow, 2.5 ton, HD 2.0 ton versions), 1153 mm (Narrow model only), 1373
mm (2.5 ton, HD 2.0 ton models only)
This value can vary by 5%
Forks retracted
see batteries table
the values in
parentheses are optional
the side shift travel is 75 mm on all models. It is reduced to 25 mm for the Narrow model
BATTERIES TABLE
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5
10

wheelbase (WB)
load on axle with forks retracted with load (front/
rear)
total length
retractable travel
turning radius
battery in compliance with DIN 43531/35/36 A,B,C,
no
battery weight (4)

wheelbase (WB)
rear)
total length
retractable travel
turning radius
no
battery weight (4)
x (mm)
y (mm)
kg
kg
kg
402
1400
3112
1977/1135
682/3830
330
1400
3309
2025/1285
792/3917
MR14
402
1400
3112
1977/1135
682/3830
330
1400
3320
2032/1289
800/3921
258
1400
3541
2084/1457
914/4027
kg
1778/2735
1753/2956
1778/2735
1760/2960
1741/3201
l1 (mm)
l2 (mm)
I4 (mm)
2379
1229
585
2451
1301
513
2379
1229
585
2451
1301
513
2523
1373
441
Ast (mm)
2718
2771
2718
2771
2826
Ast (mm)
2764
2829
2764
2829
2895
Wa (mm)
1671
1671
1671
1671
1671
C "Super"
C "Super"
C "Super"
V/Ah
kg
48/420
750
48/560
939
48/465
750
48/620
950
48/775
1165
x (mm)
y (mm)
kg
kg
kg
452
1450
3162
2018/1144
601/4162
380
1450
3360
2069/1291
714/4246
MR16
452
1450
3162
2018/1144
601/4162
380
1450
3371
2077/1294
721/4250
308
1450
3592
2133/1459
839/4352
kg
1853/2909
1825/3135
1853/2909
1832/3139
1809/3383
l1 (mm)
l2 (mm)
I4 (mm)
2379
1229
635
2451
1301
563
2379
1229
635
2451
1301
563
2523
1373
491
Ast (mm)
2731
2781
2731
2781
2834
Ast (mm)
2767
2830
2767
2830
2896
Wa (mm)
1718
1718
1718
1718
1718
C "Super"
C "Super"
C "Super"
48/420
750
48/560
939
48/465
750
48/620
950
48/775
1165
V/Ah
kg
SERVICE
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5
PRESENTATION

wheelbase (WB)
rear)
total length
retractable travel
turning radius
no
battery weight (4)
x (mm)
y (mm)
kg
kg
kg
382
1450
3111
1922/1189
569/4142
292
1450
3309
1947/1362
672/4237
MR16N
382
1450
3115
1924/1191
572/4143
292
1450
3317
1952/1365
677/4240
202
1450
3514
1965/1549
766/4347
kg
1680/3032
1606/3303
1682/3033
1611/3306
1524/3590
l1 (mm)
l2 (mm)
I4 (mm)
2449
1299
565
2539
1389
475
2449
1299
565
2539
1389
475
2629
1479
385
Ast (mm)
2762
2828
2762
2828
2899
Ast (mm)
2811
2893
2811
2893
2976
Wa (mm)
1700
1700
1700
1700
1700
B "Super"
B "Super"
B "Super"
48/420
746
48/560
937
48/465
750
48/620
945
48/775
1135
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

wheelbase (WB)
total length
retractable travel
turning radius
battery weight (4)
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

wheelbase (WB)
total length
retractable travel
turning radius
battery weight (4)
V/Ah
kg
x (mm)
y (mm)
kg
kg
kg
kg
l1 (mm)
l2 (mm)
I4 (mm)
Ast (mm)
Ast (mm)
Wa (mm)
V/Ah
kg
x (mm)
y (mm)
kg
kg
kg
kg
l1 (mm)
l2 (mm)
I4 (mm)
Ast (mm)
Ast (mm)
Wa (mm)
V/Ah
kg
MR20
430
430
358
1500
1500
1500
3615
3626
3847
2261/1354 2268/1358 2326/1520
671/4943
679/4947
801/5046
2032/3583 2039/3586 2002/3845
2451
2451
2523
1301
1301
1373
613
613
541
2795
2795
2846
2835
2835
2900
1767
1767
1767
C
C "Super" C "Super"
48/560
48/620
48/775
939
950
1165
MR25
503
503
431
1650
1650
1650
4038
4084
4292
2520/1518 2552/1532 2606/1686
773/5765
804/5780
917/5875
2371/4167 2402/4182 2348/4444
2528
2528
2600
1378
1378
1450
686
686
614
2890
2890
2938
2915
2915
2978
1911
1911
1911
C
C "Super" C "Super"
48/700
48/775
48/930
1119
1165
1368
11
SERVICE
PRESENTATION
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

wheelbase (WB)
total length
retractable travel
turning radius
battery weight (4)
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

wheelbase (WB)
total length
retractable travel
turning radius
battery weight (4)
x (mm)
y (mm)
kg
kg
kg
kg
l1 (mm)
l2 (mm)
I4 (mm)
Ast (mm)
Ast (mm)
Wa (mm)
V/Ah
kg
x (mm)
y (mm)
kg
kg
kg
kg
l1 (mm)
l2 (mm)
I4 (mm)
Ast (mm)
Ast (mm)
Wa (mm)
V/Ah
kg
MR16HD
308
308
308
1450
1450
1450
4038
4049
4270
2417/1621 2424/1625 2457/1813
883/4755
891/4758 1009/4861
2172/3466 2180/3469 2134/3736
2523
2523
2523
1373
1373
1373
491
491
491
2834
2834
2834
2896
2896
2896
1718
1718
1718
C
C "Super" C "Super"
48/560
48/620
48/775
939
950
1165
MR20HD
353
353
281
1500
1500
1500
4425
4471
4679
2567/1858 2597/1874 2616/2063
891/5534
921/5550 1024/5655
2235/4189 2266/4205 2189/4490
2528
2528
2600
1378
1378
1450
536
536
464
2850
2850
2903
2904
2904
2970
1767
1767
1767
C
C "Super" C "Super"
48/700
48/775
48/930
1119
1165
1368
NOTES
(4)
(5)
This value can vary by 5%

Forks retracted
The weights from point 2.1 to 2.5 are calculated with the mast lowered and standard forks
All values are nominal and may be subject to tolerances. The values may vary with alternative configurations.
12
SERVICE
INSTALLATION AND SETTINGS
Installation and
settings
BEFORE INSTALLATION 2
WEIGHT TABLES 2
TRUCK ASSEMBLY 6
LIST OF MATERIALS RECEIVED FROM THE DEALER 6
UNLOADING OFF THE TRUCK AND FITTING THE MAST TO THE TRUCK BASE 8
TOPPING UP THE OIL RESERVOIR 10
INSTALLATION OF THE BATTERY 11
ASSEMBLY OF MOVING FORKS 14
CONTRASTING ROLLER ASSEMBLY 15
List of the SETTINGS AND ADJUSTMENTS to be carried out 16
SETTING THE ACE2 TRACTION AND THE ACE2 PUMP MODULE BATTERY VOLTAGES 16
CHECK THE CONDITIONS OF USE OF THE TRUCK 18
CHECK THE MOVEMENT OF THE CONTRASTING AISLE ROLLERS 18
Enabling and programming of the LEVEL pre-selector. 19
ENABLING AND PROGRAMMING MIDDLE FORK LIFTING BLOCKS 19
ENABLING AND PROGRAMMING OF THE PASSWORD 19
SERVICE
BEFORE INSTALLATION
Depending on the size of the mast and the kind of transportation (container, truck, etc.), the carriage may
be shipped:
complete in vertical position (option A)
with the mast assembly separate from the truck base (option B).
In the second instance one must check in advance that one is equipped with all the tools necessary to bring
it to the vertical position and fit the column (hire forklift truck, bridge crane, belts, etc.). These machines
are tested for all their functions and the mast assemblies are then dismantled, tying the fork carrier plate to
the base of the column so that it does not run along the inner mast; caps are also put on all the hydraulic
connectors to prevent oil leaking out during transport. When the unit arrives, the column must have been
fitted and testing performed for all the functions.
Before delivering to the client it is very important to check the suitability of the place where the carriage is
to be installed.
WEIGHT TABLES
COMPLETE FORKLIFT TRUCK
Model
Height of mast
assembly when
closed
(h1)
Height of mast
assembly when
open
(h3)
Weight of
truck base
Weight of
retractable
carriage
Total weight
(excluding
battery)
mm
mm
kg
kg
kg
MR14
(1)
2195
5000
1125
222
2435
MR16H
(2)
2195
5000
1136
222
2485
MR16N
(3)
2195
5000
1095
210
2432
MR20
(4)
2195
4650
1324
242
2740
MR25
(5)
2195
4650
1547
242
2978
MR16HD (6)
3227
8050
1327
245
3134
MR20HD (7)
3227
7900
1487
245
3335
battery 420DinC, forks 80x40x1150

(3)
battery 420DinB, forks 120x40x1150
(4)
(5)
(6)
(7)
(1)
(2)
SERVICE
BATTERIES
Weight (kg)
Type
48/420
48/560
48/700
48/840
min.
max.
DIN C
735
810
DIN B
736
811
DIN C
922
1016
DIN B
925
1018
DIN C
1099
1211
DIN B
1104
1216
DIN C
1282
1413
FORK CARRIAGE
Models
Weight
(kg)
MR14 MR16H MR16N

MR20 MR16HD
115.6
MR25 MR20HD
121.6
FORKS
Dimensions
Weight
mm
kg
80x40x1150
82.3
80x40x1200
84.8
120x35x800
84.3
120x35x1000
97.4
120x35x1150
107.3
120x35x1200
110.5
120x40x800
95.4
120x40x1000
110.3
120x40x1150
121.6
120x40x1200
125.3
120x40x1500
147.8
120x40x1800
170.2
120x45x800
106.4
120x45x1000
123.3
120x45x1150
135.9
120x45x1200
140.1
120x45x1500
165.4
120x45x1800
190.7
3
SERVICE
MAST ASSEMBLIES
Model
MR16N
MR14
MR16
MR20
MR25
Total auxiliary lift

(mm)
Free Lift
(mm)
Height, mast
lowered
(mm)
Extended
dimensions
(mm)
Weight
(kg)
h3
h2
h1
h4
5000
1648
2195
5563
911
5250
1734
2281
5813
936
5500
1820
2367
6063
961
5750
1906
2453
6313
986
6000
1992
2539
6563
1010
6250
2078
2625
6813
1035
6500
2164
2711
7063
1060
6750
2250
2797
7313
1090
7000
2336
2883
7563
1115
7250
2422
2969
7813
1140
7500
2508
3055
8063
1164
7750
2594
3141
8313
1220
8000
2680
3227
8563
1244
8250
2766
3313
8813
1269
8500
2852
3399
9063
1299
8750
2938
3485
9313
1324
9000
3024
3571
9563
1349
9250
3110
3657
9813
1376
9500
3196
3743
10063
1400
9750
3282
3829
10313
1425
10000
3368
3915
10563
1454
10250
3454
4001
10813
1478
10500
3540
4087
11063
1503
4650
1582
2195
5263
958
4900
1668
2281
5513
985
5150
1754
2367
5763
1012
5400
1840
2453
6013
1038
5650
1926
2539
6263
1065
5900
2012
2625
6513
1092
6150
2098
2711
6763
1118
6400
2184
2797
7013
1150
6650
2270
2883
7263
1177
6900
2356
2969
7513
1204
7150
2442
3055
7763
1230
7400
2528
3141
8013
1288
7650
2614
3227
8263
1314
7900
2700
3313
8513
1341
8150
2786
3399
8763
1373
SERVICE
Model
MR20HD
MR16HD

(mm)
Free Lift
(mm)
Height, mast
lowered
(mm)
Extended
dimensions
(mm)
h3
h2
h1
h4
7900
2614
3227
8513
1372
8150
2700
3313
8763
1401
8400
2786
3399
9013
1435
8650
2872
3485
9263
1464
8900
2958
3571
9513
1523
9150
3044
3657
9763
1552
9400
3130
3743
10013
1581
9650
3216
3829
10263
1609
9900
3302
3915
10513
1638
10150
3388
4001
10763
1671
10400
3474
4087
11013
1699
10650
3560
4173
11263
1728
10900
3646
4259
11513
1757
11150
3732
4345
11763
1786
Weight
(kg)
11400
3818
4431
12013
1814
11650
3904
4517
12263
1843
11900
3990
4603
12513
1872
12150
4076
4689
12763
1901
12400
4162
4775
13013
1929
12650
4248
4861
13263
1958
8050
2680
3227
8613
1346
8300
2766
3313
8863
1374
8550
2852
3399
9113
1408
8800
2938
3485
9363
1436
9050
3024
3571
9613
1495
9300
3110
3657
9863
1524
9550
3196
3743
10113
1552
9800
3282
3829
10363
1580
10050
3368
3915
10613
1612
10300
3454
4001
10863
1641
10550
3540
4087
11113
1669
10800
3626
4173
11363
1698
11050
3712
4259
11613
1726
11300
3798
4345
11863
1755
11550
3884
4431
12113
1783
SERVICE
TRUCK ASSEMBLY
LIST OF MATERIALS RECEIVED FROM THE DEALER
CARRIAGE SOLD WITHOUT BATTERY
The materials received from the dealer may vary according to whether or not optional accessories are
included.
Ref.
Description
Truck base and mast assembled (option A)

Truck base and mast separate (option B)
Contrast rollers (optional)
Battery runner rollers
Forks
Hydraulic fluid canister
Batter catch plate
SERVICE
CARRIAGE SOLD WITH BATTERY
5
7
The materials received from the dealer may vary according to whether or not optional accessories are
included.
Ref.
Description
Truck base and mast assembled (option A)

Truck base and mast separate (option B)
Contrast rollers (optional)
Battery runner rollers
Forks
Hydraulic fluid canister
Batter catch plate
Battery
SERVICE

UNLOADING OFF THE TRUCK AND FITTING THE MAST TO THE TRUCK BASE
Equipment and tools
fork lift truck

load capacity
2500 kg
crane truck or
bridge crane
load capacity
2500 kg
open ended spanner

19 mm
torque wrench
lifting sling
load capacity
2500 kg
ladder
Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Phase 1
TRUCK BATTERY - FORK LIFT TRUCK LOAD CAPACITY 2500kg
Connect the battery to the truck base, switch on the forklift and transfer it to a place equipped with a crane
truck or bridge crane. Using the lift truck, fork the pallet on which the mast assembly is secured, raise it
and carry it to the same place as the truck base.
Phase 2
BRIDGE CRANE - LIFT BELT
Remove the packing of the mast assembly.
Slip the lifting belt beneath the upper crossbars of the mast assembly by making a noose and hook the
other end to the bridge crane hook (fig.1).
Start lifting slowly with the bridge crane and raise the mast assembly, separating it from the pallet. Take
the mast assembly into the vertical
position.
Fig. 1
8
SERVICE
Phase 3
OPEN ENDED SPANNER 19 mm
Using the open ended spanner, unscrew and remove the screws securing
both side blocks of the mast assembly (ref.A fig.2). Remove the blocks
(ref.B fig.2).
Using the bridge crane, slowly lift the mast assembly and rest it vertically
on the truck base in the special housings (ref.C fig.2). Keeping the belt
taut, position both side blocks and, using a torque wrench, tighten the
fixing screws (ref.A fig.2) to a torque of 88 to 97 Nm.
Fig. 2
Phase 4
BRIDGE CRANE - LADDER - LIFT BELT
Set the ladder next to the mast assembly and climb up.
Insert the lift belt beneath the upper crossbar of the middle section of
the mast assembly by making a noose and hook the ends to the bridge
crane hook (fig.3). Climb down the ladder, raise the bridge crane to
reveal the seats of the screws securing the mast assembly to the truck
base (fig.4).
Phase 5
TORQUE WRENCH - BRIDGE CRANE - LIFT BELT
Using the torque wrench, tighten the bolts securing the mast assembly
to the truck base (ref.D fig.4) to a torque of 300 to 330 Nm.
Using the bridge crane, lower the mast assembly to the ground.
Climb up the ladder and remove the belt from the mast assembly.
Fig. 3
Phase 6
Remove the cover to access the hydraulic control valve (fig.5).
Connect the hydraulic pipes from the control valve on the truck base to
the one on the mast assembly (fig.6).
Fig. 4
Fig. 5
Fig. 6
9
SERVICE

TOPPING UP THE OIL RESERVOIR
Fig. 1
Before topping up the oil in the hydraulic oil reservoir make sure that the
forks are fully lowered.
Equipment and tools
funnel
oil resistant gloves
T handle hex key

5 mm
Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the carriage to a safe place, away from areas of
transit of other vehicles and all pedestrians. Turn the
keyswitch to OFF and disconnect the battery.
Fig. 2
Phase 1
T-HANDLE HEX KEY 5 mm
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.A fig.1).
Completely open the cover (fig.2).
Fig. 3
Phase 3
To facilitate the filling of the tank unscrew the breather valve (ref.B fig.3),
so that the air can come out when topping up.
Phase 3
FUNNEL
Unscrew the reservoir cap (ref.C fig.3), place the funnel in the filler hole
and top up the oil level.
Be sure not to fill the reservoir too much by checking the level via the
marks on the reservoir (fig.4).
Screw the breather valve and the reservoir cap back on.
10
Fig. 4
SERVICE
INSTALLATION OF THE BATTERY

WITH VERTICAL REMOVAL
Equipment and tools
bridge crane
load capacity
2000 kg
spreader bar
Fig. 1
open ended
spanner
10 mm
Procedure
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians.
Fig. 2
Fig. 3
BRIDGE CRANE - SPREADER BAR
Pull up the lever in front of the throttle pedal board next to the seat (fig.1)
so as to free the battery housing. Make the battery housing come fully
out (fig.2).
Using the open ended spanner, unscrew and remove the screws fastening
the battery cover (where applicable) (ref.A fig.3). Remove the cover.
Attach the spreader bar to the bridge crane.
Attach the spreader bar to the battery, lift it using the bridge crane and
position it over the battery housing.
Lower the battery very carefully into the carriage compartment (fig.4).
Unhook the spreader bar from the battery.
Connect the cables to the battery.
Switch on the truck and, using the controls in the cab, retract the retractable carriage completely so that the battery hooks onto the locking
system.
A
Fig. 4
11
SERVICE
WITH LATERAL REMOVAL

Equipment and tools
bridge crane
load capacity
2000 kg
spreader bar
rollerway
Procedure
Fig. 1
Fig. 2

A
BRIDGE CRANE - SPREADER BAR - ROLLERWAY
Pull up the lever in front of the throttle pedal board next to the seat (fig.1)
so as to free the battery housing. Make the battery housing come fully
out (fig.2). Remove the battery catch (ref.A fig.2).
Position the rollerway alongside the battery housing and adjust the height
so that the top of the rollerway is aligned with the bottom of the battery
compartment.
Attach the spreader bar to the bridge crane.
Attach the spreader bar to the battery; lift it using the bridge crane and
place it on the rollerway.
Unhook the spreader bar from the battery. Push the battery into its housing (fig.3). Position the battery catch.
Connect the cables to the battery.
Switch on the truck and, using the controls in the cab, retract the retractable carriage completely so that the battery hooks onto the locking
system.
12
Fig. 3
SERVICE
CONNECTION OF CABLES TO BATTERY

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

Connection of the cable to the
negative terminal
Tag coloured RED
Connect lead to positive
terminal
Negative terminal
coloured BLUE
Positive terminal
coloured RED
13
SERVICE
ASSEMBLY OF MOVING FORKS
Procedure
Phase 1
Using the controls in the cab, lift the fork carriage to facilitate fork assembly operations.
Turn the keyswitch to OFF and disconnect the battery.
Phase 2
Insert the fork in and let it slide along the fork carrier plate (fig.1) until the
fastening pin slots into the notch (fig.2).
14
Fig. 1
Fig. 2
SERVICE
CONTRASTING ROLLER ASSEMBLY

Equipment and tools
open ended spanner

19 mm
Procedure
transit of other vehicles and all pedestrians.
Fig. 1
Phase 1
Retrieve the contrast roller and its parts, apply the spacers (ref.A,B
fig.2).
Phase 2
FIXED GAUGE 19 mm SPANNER
Position the roller complete with spacers in its section and fix it with the
two screws to the truck base (ref.C fig.2).
A
B
Fig. 2
15
SERVICE
List of the SETTINGS AND ADJUSTMENTS to be carried out

After assembling all the machine's components as described in the previous pages, the following operations
must be carried out in the sequence given:

Setting the battery voltage

Checking the conditions of use of the truck
Checking the contrast roller movement along the aisle
Enabling and programming level pre-selection
Enabling and programming middle fork lifting blocks
Enabling and programming operator passwords
SETTING THE ACE2 TRACTION AND THE ACE2 PUMP MODULE BATTERY VOLTAGES
If a battery that is not provided by the factory is installed on the truck, the battery voltage on the VCM
module must be set.
To carry out this regulation, it is good practice to proceed with an additional charging period for the battery
used on the carriage in order that it may provide the maximum voltage.
Equipment and tools
programmer
tester
T handle hex key

5 mm
large Philips
screw driver
Procedure
Remove the rubber mat at the operator's feet inside the cab. Using the T-handle hex key, unscrew and
remove the screws securing the cover of the electronic controls. Unscrew and remove the screw locking
the bonnet (ref.A fig.1), remove the electronic controls cover and open the bonnet (fig.2).
Using a crosshead screwdriver, unscrew the panel fixing screw to access the VCM control (ref.B fig.3).
With the engine turned off connect the programmer
Turn on the machine (ON switch) and select the following parameter:
VCM module / config menu adjustment / adjust battery
Using the tester, measure the exact voltage of the battery on the VCM control between the negative power
connection (-Batt) on one of the two traction or pump inverters and the positive measured on pin 28 of
connector A of the VCM module (fig.4). The parameter "adjust battery" must be set with the value of
this tension.
Turn the machine off (switch key OFF) and disconnect the programmer.
Turn the machine back on (ON switch).
16
SERVICE
Fig. 1
Fig. 3
Fig. 2
24
13
1
35
23
12
A
Fig. 4
17
SERVICE
CHECK THE CONDITIONS OF USE OF THE TRUCK

In order to ensure the safety personnel and materials, before proceeding with the operations described below, it is important to assess the following:
The type of load to be moved
The general conditions of the warehouse, aisles and flooring
Having carried out these assessments verify whether the conditions given are compatible with the performance levels set:

maximum traction speed

traction acceleration
reduction of traction speed
maximum fork lifting/lowering speed
braking
If necessary, reduce truck performance by using the programmer to customise the truck configuration parameter (see "TRUCK FUNCTIONS"section "ELECTRICAL SYSTEM").
In order not to jeopardize the safety of the truck, the only way in which the truck configuration parameters may be modified is by reducing the factory-set values.
Parameter values that exceed the factory-set values are not permitted.
CHECK THE MOVEMENT OF THE CONTRASTING AISLE ROLLERS

Make sure that the truck can enter the aisle easily and that the contrasting rollers are correctly adjusted
(maximum tolerance 5 mmon one side fig.1).
If necessary remove or add shims.
Check the roller movement along the entire length of the aisle.
max 5 mm
b6
18
Fig. 1
SERVICE
Enabling and programming of the LEVEL pre-selector.

To enable and program the height pre-selector see "LEVEL PRE-SELECTOR" section "ELECTRICAL
SYSTEM".
ENABLING AND PROGRAMMING MIDDLE FORK LIFTING BLOCKS
To enable and program the middle cab lifting blocks see "FORK LIFTING/LOWERING BLOCKS" section
"ELECTRICAL SYSTEM".
ENABLING AND PROGRAMMING OF THE PASSWORD
To enable and program the operator passwords see "MAIN MENU 2 / PROGRAMMING ACCESS CODE
WITH COMBINED OPERATOR CODE READING" section "ELECTRICAL SYSTEM".
19
20
SERVICE
SERVICE
DIAGNOSTICS AND MEASUREMENTS
Diagnostics and
measurements
DESCRIPTION MODULE CONNECTORS 2
ACE2 TRACTION MODULE 2
ACE2 PUMP MODULE 3
eps acw MODULE 4
MASTER CONTROL CARD PREMIUM MODULE 5
TESTER MENU 7
ACE2 PUMP MODULE 7
EPS ACW MODULE 7
Vcm MODULE 8
BREAKDOWN SEARCH 12
WARNING MEMORIZATION 12
ACe2 PUMP AND TRACTION MODULE DIAGNOSIS SYSTEM 13
ACE2 PUMP AND TRACTION MODULE ALARMS 13
PUMP AND TRACTION ACE2 MODULE ALARM ANALYSIS AND TROUBLESHOOTING 22
DIAGNOSIS SYSTEM FOR Vcm MODULE 33
Vcm - MASTER MODULE ALARM ANALYSIS AND TROUBLESHOOTING 33
Vcm - SLAVE MODULE ALARM ANALYSIS AND TROUBLESHOOTING 38
EPS ACW MODULE DIAGNOSIS SYSTEM 42
eps acw MODULE ALARM ANALYSIS AND TROUBLESHOOTING 42
DESCRIPTION MODULE CONNECTORS

ACE2 TRACTION MODULE
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
+ 48V logic power supply

+ 5V auxiliary power supply for Hall effect sensors
Input of accelerator sensor output 1
drive selector (analogue forward/reverse) (digital forward)
reverse drive selector
Input of service brake sensor output 2
Input CH A motor encoder
+ 12V power supply for motor encoder
Horn negative
Input of service brake sensor output 1
CAN communication line 2
Input of accelerator sensor output 1
Input CH B motor encoder
- Batt auxiliary power supply for Hall effect sensors and encoder
Traction main contactor negative
+ 48V power supply for main contactor, electromagnetic brake, horn
Electromagnetic brake negative
Man on board sensor output 1
Engine temperature sensor input
- Batt engine temperature sensor
SERVICE
SERVICE
ACE2 PUMP MODULE
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23

+ 5V auxiliary power supply for Hall effect sensors
Not used
Not used
Not used
Not used
Input CH A motor encoder
+ 12V power supply for motor encoder
Flasher negative
Not used
Not used
Input CH B motor encoder
- Batt auxiliary power supply for Hall effect sensors and encoder
Pump main contactor negative
+ 48V power supply for main contactor, flasher, fan
Fan negative
Not used
Engine temperature sensor input
- Batt engine temperature sensor

eps acw MODULE
A1
A2
A3
Power supply positive
A4
A5
A6
Power supply negative
A7
A8
A9
Fan positive (+48V)
A10
Fan negative
A11 Sensor with driving wheel at 90
A12 Sensor with driving wheel at 0 straight
A13
Auxiliary power supply negative
A14
Not used
A15
A16 Stepper motor DL line power supply negative
A17 Stepper motor QL line input
A18
Auxiliary power supply positive
A19 Stepper motor QL line power supply negative
A20 Stepper motor DL line input
A21
Auxiliary power supply positive
A22
A23
SERVICE
SERVICE
MASTER CONTROL CARD PREMIUM MODULE
A1
+ 48V output power supply
A2
Negative of proportional valve for carriage forward (PWM) Current controlled
A3
Negative of proportional valve for carriage backward (PWM) Current controlled
A4
Negative of diverter valve for Tilt or Side Shift (PWM) Current controlled
A5
Negative of diverter valve for 5th way (PWM) Current controlled
A6
Negative of electromagnet for battery block release (PWM) Current controlled
A7
Negative of reverse drive buzzer (PWM) Current controlled
A8 Seat microswitch
A9
Man on board sensor output 2
A10
Traction speed reduction button
A11
A12
A13
+ 48V auxiliary power supply
A14
A15
A16
A17
A18 Sensor 1 battery out Normally open
A19 Sensor 2 battery out Normally closed
A20 Seat belt microswitch
A21 Steering mode selection button 180- 360
A22
- Batt auxiliary power supply
A23
Carriage position potentiometer input
A24
Negative of lowering proportional valve (PWM) Current controlled
A25
Negative of lifting proportional valve (PWM) Current controlled
A26
Negative of proportional valve right hydraulic function (PWM) Current controlled
A27
Negative of proportional valve left hydraulic function (PWM) Current controlled
5

A28
A29
A30
A31
A32
A33
A34
A35

- Batt logic power supply
not used
not used
B1 Side shift position sensor

B2
not used
B3
Tilt position inclinometer input
B4
Encoder reset sensor input
B5 not used
B6
Pressure transducer sensor input
B7
+ 48V output power supply
B8
B9
Main lifting cylinder position potentiometer transducer input
B10
Main lifting cylinder position potentiometer transducer input
B11
Load cell input
B12
not used
B13 Weighing button
B14
Lifting by-pass button
B15
Negative of pallet recognition laser (PWM) Current controlled
B16
B17
Free lifting cylinder position potentiometer transducer input
B18
Free lifting cylinder position potentiometer transducer input
B19
B20
B21
Pallet presence sensor
B22
not used
B23
Negative of load wheel brakes (PWM 4A) Current controlled
SERVICE
SERVICE
TESTER MENU
The main input and output signals can be measured in real time using the TESTER function of the programmer. The programmer acts as a multimeter capable of reading voltage, current and temperature.
Certain of these menu parameters refer to functions whose status is received via Can bus, others refer to
functions directly connected to the analog/digital inputs of the module. The following list shows the relative
measurements:
MAIN TESTER MENU
PARAMETER
BATTERY VOLTAGE
measurement unit
Volt
Battery voltage measured on the key input
ACE2 PUMP MODULE

MAIN TESTER MENU
PARAMETER
BATTERY VOLTAGE
measurement unit
Volt
EPS ACW MODULE

MAIN TESTER MENU
PARAMETER
BATTERY VOLTAGE
measurement unit
Volt
SERVICE

Vcm MODULE
MAIN TESTER MENU
PARAMETER
measurement unit
WORKING HOURS
Hours
Indicates the truck's working hours according to the setting of the HOUR COUNTER option
FORK HEIGHT
mm
Indicates the fork height off the ground in real time if the HEIGHT INDICATOR option is activated
BATTERY VOLTAGE
Value of the voltage to 1 decimal place. Level of battery voltage measured at key-switch on
BATTERY CHARGE
Percentage value. Provides the battery's residual charge as a percentage of the level of the complete charge
STEER ANGLE
degrees
Value in degrees. Indicates the current steering angle

RTC HOUR
hours
Hour of the Real Time Clock

RTC MINUTES
minutes
Minutes of the Real Time Clock

LIFT/LOW POT.
Percentage value. Level of the LIFT/LOWER control

REACH POT.
Percentage value. Level of the REACH control

TILT POT.
Percentage value. Level of the TILT control

SIDE SHIFT POT.
Percentage value. Level of the SHIFT control

AUTOC.SSHIFT SW.
ON/OFF. Level of the self-centring side shift button

AUTOC.TILT SW.
ON/OFF. Level of the self-centring side shift button
5 WAY SWITCH
ON/OFF. Level of the hydraulic 5th way button
JOY. HORN SW
ON/OFF. Level of the horn button
8
SERVICE
PARAMETER
measurement unit
PALLET SWITCH
ON/OFF. Level of the Pallet button
SEATBELT SWITCH
ON/OFF. Level of the seat belt button
SEAT SWITCH
ON/OFF. Level of the Seat button
BATTERY OUT SW1
ON/OFF. Level of the Battery 1 disconnected sensor
BATTERY OUT SW2
ON/OFF. Level of the Battery 2 disconnected sensor
SSHIFT POS. SW
ON/OFF. Level of the side shift position sensor

TILT POS. SW
ON/OFF. Level of the tilt position sensor

REACH AN I SENSOR
mV
Value in volts. Level of the analog input A23 (truck potentiometer position)
OUTPUT GROUP #1
Value %. Percentage of the maximum current applied on output unit #1 (EVP1 and EVP2 lifting/lowering)
OUTPUT GROUP #2
Value %. Percentage of the maximum current applied on output unit #2 (EVP3 and EVP4 retractable carriage
backward / forward)
OUTPUT GROUP #3
Value %. Percentage of the maximum current applied on output unit #3 (EVP5 and EVP6 tilt down/left side shift tilt up/right side shift)
OUTPUT GROUP #4
Value %. Percentage of the maximum current applied on output unit #4 (EVP7 and EVP8 tilt / side shift valve sensor - 5th way valve sensor)
NEVP9 OUTPUT
Value %. Percentage of the maximum current applied on EVP9 (wheel brakes charge)
NEV3 OUTPUT
Value %. Percentage of battery voltage applied on EV3 (Laser)

NEV2 OUTPUT
Value %. Percentage of battery voltage applied on EV2 (Back-up alarm)
PARAMETER
NEV1 OUTPUT
SERVICE
measurement unit
%
Value %. Percentage of battery voltage applied on EV1 (not used)

RESET ENCODER #1
ON/OFF. Encoder reset sensor level
ENCODER #1
pulses
Number of pulses ready by encoder 1

ENCODER #2
pulses
Number of pulses ready by encoder 2

RPM PUMP
Value in Hz. Pump motor speed
DIGITAL INPUT #1
ON/OFF. A8 digital input level
DIGITAL INPUT #2
DIGITAL INPUT #3
DIGITAL INPUT #4
DIGITAL INPUT #5
DIGITAL INPUT #6
DIGITAL INPUT #7
DIGITAL INPUT #8
ON/OFF. B13 digital input level
DIGITAL INPUT #9
DIG. INPUT #10
DIG. INPUT #11
10
Hz
SERVICE
PARAMETER
ANALOG INPUT #1
measurement unit
mV
Value in volts. Level of the analog input A23 (truck potentiometer position)
ANALOG INPUT #2
mV
Value in volts. Level of the analog input A35 (not used)

ANALOG INPUT #3
mV
Value in volts. Level of the analog input B1 (side shift position)

ANALOG INPUT #4
mV
Value in volts. Level of the analog input B2 (not used)

ANALOG INPUT #5
mV
Value in volts. Level of the analog input B3 (tilt position)

ANALOG INPUT #6
mV
Value in volts. Level of the analog input B4 (encoder reset)

ANALOG INPUT #7
mV

ANALOG INPUT #8
mV
Value in volts. Level of the analog input B6 (transducer pressure)

ANALOG INPUT #9
mV
Value in volts. Level of the analog input B11 (load cell)

ANALOG INPUT #10
mV
11
SERVICE
BREAKDOWN SEARCH
WARNING MEMORIZATION
Enter the MAIN MENU 1 /alarms on the display to visualize the last 20 warnings memorized and the information relative to the total number of hours worked by the module, the number of times the warning has
been activated and the number that identifies the module.
MODULE 2: ACE2 Traction
MODULE 5: ACE2 Pump
12
MODULE 6: EPS ACW

MODULE 1: VCM
SERVICE
ACe2 PUMP AND TRACTION MODULE DIAGNOSIS SYSTEM

ACE2 PUMP AND TRACTION MODULE ALARMS
programmer
message
WATCHDOG
EEPROM KO
LOGIC FAILURE #3
LOGIC FAILURE #2
message
sicos
CALL
SERVICE
description
effect
state of the truck
MC open, EB activated, Start up

The Watchdog signal is
traction/pump station- Stand-by
not in the correct state.
ary.
During traction
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Error
detected
in The control device
EEPROM or in EEPROM works using the default Continuous
management.
parameters.
Re-start procedure:
None.
CALL
SERVICE
Hardware protection cir- MC not closed, EB accuit failure due to high tivated, traction/pump Start up
current.
stationary.
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
MC open, EB activated, Switch-on (imMotor phase voltage feedtraction/pump station- mediately after the
back circuit failure.
ary.
MC closes)
Re-start procedure:
LOGIC FAILURE #1
Vmn low
Vmn HIGH
CONTACTOR
CLOSED
CALL
SERVICE
a condition of undervolt- MC not closed, EB ac- Start up

age/overvoltage has been tivated, traction/pump Stand-by
detected.
stationary.
During traction
Re-start procedure:
CALL
SERVICE
MC open, EB activated,
Motor output voltage low Start up
traction/pump stationer than expected.
During traction
ary.
Re-start procedure:
CALL
SERVICE
MC not closed, EB acMotor output voltage high Start up

tivated, traction/pump
er than expected.
Stand-by
stationary.
Re-start procedure:
CALL
SERVICE
The LC contact is locked
MC not closed (the

control has not been
activated), EB activat- Start up
ed, traction/pump stationary.
Re-start procedure:
13
programmer
message
CONTACTOR
OPEN
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
Switch-on (imThe MC coil has been ac- MC open, EB activated, mediately after the
tivated, but the MC fails to traction/pump station- MC closes)
close.
ary.
Stand-by
During traction
Re-start procedure:
STBY I HIGH
CALL
SERVICE
In stand-by conditions (no

current applied to the mo- MC not closed, EB actor), current feedback is tivated, traction/pump Start up
outside the permissible stationary.
stand-by limits.
Re-start procedure:
CAPACITOR
CHARGE
TH. PROTECTION
CALL
SERVICE
The voltage of the power MC not closed, EB accapacitors fails to in- tivated, traction/pump Start up
crease.
stationary.
Re-start procedure:
CALL
SERVICE
The control device has

reached the thermal reduction temperature of
85C when the current is
IMAX.
The traction control device reduces the maximum current linearly Continuous
from IMAX (85C) to 0A
(105C).
Re-start procedure:
None.
MOTOR
TEMPERAT.
CALL
SERVICE
The motor temperature

sensor is open (if dig- The maximum current
ital) or has exceeded the is halved and the speed Continuous
150C threshold (if ana- is reduced.
logue).
Re-start procedure:
None.
CALL
SERVICE
BATTERY LOW
DRIVER SHORTED
The battery is <= 10%

when
the
BATTERY
CHECK parameter is set
to >0
Re-start procedure:
Recharge the battery.
CALL
SERVICE
The MC driver has shorted and therefore is not

capable of opening the
contactor.
Re-start procedure:
14
The maximum current

Start up
is halved and the speed
Stand-by
is reduced (if CHECK
During traction
OPTION=1).
MC open (the control

Start up
has been released),
Stand-by
EB activated, traction/
During traction
pump stationary.
SERVICE
programmer
message
CONTACTOR
DRIVER
VACC NOT OK
message
sicos
CALL
SERVICE
description
effect
state of the truck
MC open (the control

The MC coil driver is dam- has been released), Stand-by
aged (it can't close).
EB activated, traction/ During traction
pump stationary.
Re-start procedure:
CALL
SERVICE
The
value
of
the
accelerator/lifting
potentiometer is greater
Start up
The traction/pump mothan
the
minimum
Stand-by
tor is stationary.
recorded
value
and
During traction
the
direction/activation
switches are off.
Re-start procedure:
INCORRECT
START
FORW + BACK
ENCODER ERROR
VDC OFF
SHORTED
WRONG SLAVE
VER.
VDC LINK OVERV.
CALL
SERVICE
Incorrect
quences.
starting
se- The traction/pump mo- Start up

tor is stationary.
Stand-by
Re-start procedure:
CALL
SERVICE
Drive requests active

in both directions at the Traction is stationary.
same time.
Start up
Stand-by
During traction
Re-start procedure:
Make a traction request.
CALL
SERVICE
Problem in reading the
traction/pump station- During traction
encoder.
ary.
Re-start procedure:
CALL
SERVICE
When switching on, the MC open, EB activated,

VDC-off logic signal is traction/pump station- Start up
low.
ary.
Re-start procedure:
CALL
SERVICE
The software versions for MC open, EB activated,

the Slave and Master are traction/pump station- Start up
not the same.
ary.
Re-start procedure:
CALL
SERVICE
A condition of overvoltage
Stand-by
traction/pump stationhas been detected.
During traction
ary.
Re-start procedure:
Make a valve or traction or hydraulic request.
15
programmer
message
TILLER MISMATCH
message
sicos
CALL
SERVICE
description
effect
The Master C and Slave

C do not have the same
Traction is stationary.
value for the tiller input
from the VCM.
SERVICE
state of the truck
Start up
Stand-by
During traction
Re-start procedure:
BRAKE RUN OUT
STOP RQ. FROM

EPS
INIT VMN HIGH
CALL
SERVICE
The brakes potentiometer No effect. The warning

input is at the maximum is shown on the con- Continuous
value with no HB request. sole only.
Re-start procedure:
CALL
SERVICE
EPS sends a request to

Traction is stationary.
stop the motor.
Start up
Stand-by
During traction
Re-start procedure:
CALL
SERVICE
The motor phase voltage

is higher than expected,
traction/pump station- Start up
before activating the
ary.
bridge.
Re-start procedure:
INIT VMN LOW
CALL
SERVICE
The motor phase voltage

is lower than expected,
before activating the
ary.
bridge.
Re-start procedure:
EEPROM KO
PARAM RESTORE
CALL
SERVICE
it is impossible to
recover the data from the No effect.
memory.
Start up
Re-start procedure:
CALL
SERVICE
Partial/complete
parameter reset has been
No effect.
performed since the last
shutdown.
Start up
Re-start procedure:
WRONG RAM
MEM.
16
CALL
SERVICE
The program checks the

content of the main RAM
traction/pump station- Continuous
registers and finds a dirty
ary.
value.
Re-start procedure:
SERVICE
programmer
message
STALL ROTOR
message
sicos
CALL
SERVICE
description
The traction
blocked.
rotor
effect
state of the truck
Start up
is The traction/pump is
Stand-by
stationary.
During traction
Re-start procedure:
WAITING SLAVE
HARDWARE
FAULT
POT. ACCEL MISM
CALL
SERVICE
No activation message
from the Slave.
ary.
Re-start procedure:
CALL
SERVICE
The drivers fail to switch MC not closed, EB acoff with the Watchdog sig- tivated, traction/pump Start up
nal in an alarm state.
stationary.
Re-start procedure:
CALL
SERVICE
There is a discrepancy
Start up
between Master and The traction/pump is
Stand-by
Slave on the accelerator stationary.
During traction
signal.
Re-start procedure:
POT. BRAKE MISM
SENS MOT TEMP

KO
PEV NOT OK
CALL
SERVICE
There is a discrepancy be Start up

The traction/pump is
tween Master and Slave
Stand-by
stationary.
on the brake signal.
During traction
Re-start procedure:
CALL
SERVICE
The motor heat sensor The maximum current

output is outside the lim- is halved and the speed Continuous
its.
is reduced.
Re-start procedure:
None.
CALL
SERVICE
The PEV connector (A17)

MC closed, EB acti- Start up
is not connected to the
vated, traction/pump, Stand-by
battery or the voltage is
valves stationary.
During traction
different.
Re-start procedure:
Make a traction or hydraulic or valve request.
VKEY OFF
SHORTED
CALL
SERVICE
MC not closed, EB acWhen switching on, the

tivated, traction/pump Start up
Key-off logic signal is low.
stationary.
Re-start procedure:
17
programmer
message
FLASH
CHECKSUM
MC COIL SHOR.
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
MC not closed, EB acThe program check is not

OK.
stationary.
Re-start procedure:
CALL
SERVICE
Switch-on (imMC open, EB activated, mediately after the

Short-circuit on the MC
traction/pump station- MC closes)
coil.
Stand-by
ary.
During traction
Re-start procedure:
WAITING FOR
NODE
VACC OUT RANGE
CALL
SERVICE
No activation signals ar- MC open, EB activated, Start up

rive from the other system traction/pump station- Stand-by
units.
ary.
During traction
Re-start procedure:
CALL
SERVICE
The accelerator input is

outside the Vacc_min
Start up
to Vacc_max range that The traction/pump mo Stand-by
has been acquired with tor is stationary.
During traction
the PROGRAMM VACC
function.
Re-start procedure:
TILLER OPEN
OUTPUT
MISMATCH
WD SYNCRO
NO SLAVE
ENABLE
18
CALL
SERVICE
The truck is on stand-by

with the tiller switch off for LC opens.
longer than 30 seconds.
Stand-by
Re-start procedure:
CALL
SERVICE
There is a discrepancy be- MC not closed, EB ac Stand-by

tween Master and Slave tivated, traction/pump
During traction
on the motor control.
stationary.
Re-start procedure:
CALL
SERVICE
The Slave C has not re- MC open, EB activated, Start up

ceived the Watchdog sig- traction/pump station- Stand-by
nal from the Master C.
ary.
During traction
Re-start procedure:
CALL
SERVICE
No activation message
traction/pump station- During traction
from the Slave.
ary.
Re-start procedure:
SERVICE
programmer
message
DIR SEL OUT
RANG
POWER MOS
SHORT
COIL SHOR. EB
message
sicos
CALL
SERVICE
description
effect
state of the truck
Start up
The selected direction sig- Traction/pump station Stand-by
nal is outside the limits.
ary.
During traction
Re-start procedure:
CALL
SERVICE
MC not closed, EB acShort-circuit on the power

MOSFETs.
stationary.
Re-start procedure:
CALL
SERVICE
Switch-on (imMC open, EB activated, mediately after the

Short-circuit on the EB
traction/pump station- MC closes)
coil.
Stand-by
ary.
During traction
Re-start procedure:
Current Gain
CALL
SERVICE
The maximum current

gain
parameters
are
the default values. This The control device
Start up
means that the maximum works, but with a low
Stand-by
current adjustment proce- maximum current.
dure has not yet been carried out.
Re-start procedure:
None.
Analog input
CALL
SERVICE
The analogue channel traction/pump station- Start up
reading is not up-to-date. ary.
During traction
Re-start procedure:
CALL
SERVICE
TILLER ERROR
Tiller failure.
The main remote-con Start up

trol switch, open power
Stand-by
bridge, electromagnetic
During traction
brake activated.
Re-start procedure:
Re-synchronisation of the system:
release all requests (traction and hydraulic)
make a traction or hydraulic request or both.
19
programmer
message
EVP DRIVER OPEN
M/S PAR CHK

MISM
INPUT MISMATCH
PARAM
TRANSFER
SP MISMATCH
Throttle prog.
Iq mismatched
Aux Driv. Open
20
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
The EVP coil driver is

MC closed, EB activatopen and is not able to
EVP on
ed, EVP stationary.
close.
Re-start procedure:
Make an EVP request.
CALL
SERVICE
The checksum test be- MC open, EB activated,

tween Master and Slave traction/pump station- Start up
has not been passed.
ary.
Re-start procedure:
CALL
SERVICE
The Slave C has differ- MC open, EB activated, Start up

ent values to the inputs traction/pump station- Stand-by
from the Master C.
ary.
During traction
Re-start procedure:
CALL
SERVICE
The Master cannot trans- MC open, EB activated,

fer the parameters to the traction/pump station- Start up
Slave.
ary.
Re-start procedure:
CALL
SERVICE
The Slave C has detect- MC open, EB activated, Start up

ed an incorrect set point traction/pump station- Stand-by
of the Master C.
ary.
During traction
Re-start procedure:
CALL
SERVICE
One of the potentiometers

Start up
Traction/pump stationhas not been programmed
Stand-by
ary.
correctly.
During traction
Re-start procedure:
CALL
SERVICE
The error between the lq

set point and the estimat- Traction stationary.
ed lq is outside the limits.
During traction
Re-start procedure:
CALL
SERVICE
The AUX coil driver has MC open, EB activated,

Stand-by
failed (it cannot operate traction/pump station During traction
the brake).
ary.
Re-start procedure:
SERVICE
programmer
message
DATA
ACQUISITION
message
sicos
CALL
SERVICE
description
effect
The maximum current

adjustment procedure is
in progress (NOTE: This
Traction stationary.
procedure must be performed by the Zapi testing
department only).
state of the truck
Stand-by
Re-start procedure:
NO CAN MSG.
CHECK UP
NEEDED
THERMIC SENS.
KO
Wrong set bat.
CALL
SERVICE

Communication error with
the supervisor.
ary.
During traction
Re-start procedure:
CALL
SERVICE
Start up
it is time to carry out Traction is reduced or
Stand-by
maintenance work.
stationary.
During traction
Re-start procedure:
Switch the key back on, after performing maintenance.
CALL
SERVICE
The control device heat The maximum current

sensor output is outside is halved and the speed Continuous
the limits.
is reduced.
Re-start procedure:
None.
CALL
SERVICE
The absolute difference

between the voltage of
MC not closed, EB acthe key and the nomitivated, traction/pump Start up
nal voltage of the battery
stationary.
is greater than 20% of
Vbatt nom.
Re-start procedure:
Wrong zero
Field orient. KO
aux driv.shrt.
CALL
SERVICE
The motor phase voltage MC not closed, EB acfeedback is outside the tivated, traction/pump Start up
permissible limits.
stationary.
Re-start procedure:
CALL
SERVICE
The error between the ld MC not closed, EB acset point and the estimat- tivated, traction/pump During traction
ed ld is outside the limits. stationary.
Re-start procedure:
CALL
SERVICE
The EB/AUX driver has

shorted and therefore is
not capable of opening
ary.
During traction
the contactor.
Re-start procedure:
21
SERVICE
PUMP AND TRACTION ACE2 MODULE ALARM ANALYSIS AND TROUBLESHOOTING

ALARM
breakdown search
Watchdog
This alarm could be caused by a malfunctioning of the
Cause:
canbus shutting off Master-Slave communication.
This is a safety test. it is a self-diagnosis test within the
logic between the Master and Slave micro-controllers.
Eeprom ko
Try to carry out a CLEAR EEPROM operation (see the

console manual). Turn off then on again with the key to
Cause:
verify the result. If the alarm persists, the control device
This alarm is due to a HW or SW defect in the integrated
needs replacing. If the alarm disappears, the paramnon-volatile memory that supports the parameters of the
eters previously reset will be replaced by the default
control device. This alarm does not inhibit machine operaparameters.
tion, but the truck will work with the default values.
Logic failure #3
This type of failure is not connected to external compoCause:

nents, so when it manifests itself the ACE logic board
A hardware problem pertaining to the logic card as a pro- needs replacing.
tection against high current values (overload).
Logic failure #2

nents, so when it manifests itself the ACE2 logic board
The fault pertains to the hardware section of the logic card needs replacing.
that manages the retroaction of the phase voltage.
Logic failure #1
Cause:
This alarm appears when the control device detects over
or under voltage conditions. The overvoltage threshold is
45V, the undervoltage threshold is 9V on the 24V control
device. On the 48V control device, the overvoltage threshold is 65V and the undervoltage threshold is 11V.
22
Finding the trouble appearing on start up or in standby,

it is very likely in these cases that the fault is due to undervoltage, so it is advisable to check:
Diminishing pulsations of the key input signal (beneath the undervoltage threshold) due to external
loads, such as switching on DC/DC converters,
switching on relays or contactors, energizing/deenergizing solenoids.
Check the connection of the electrical cables to the
battery terminal, positive and negative, to MC and to
the control device +Batt and Batt, which must be
tightened to a torque of between 13Nm and 15Nm.
If no voltage transient is detected on the power supply line and the alarm is present every time the key
is switched on, then the fault probably lies with the
hardware of the control device and so the logic board
needs replacing.
Finding the trouble appearing during motor operation, in
this case there could be undervoltage or overvoltage.
If the alarm appears during acceleration while in traction or operation of the hydraulic functions, it is most
likely due to undervoltage; check the battery charge
and the connection of the electrical cables.
If the alarm appears during brake release, it is most
likely due to overvoltage; check the contact of the line
contactor and the connection of the electrical cables
of the battery.
SERVICE
ALARM
breakdown search
Vmn low
If the problem appears on start up (LC doesn't close at

all), check:
The internal motor connections (ohm continuity)
Cause 1:
The motor power cable connections
Test on start-up. Before switching on the LC, the software Motor loss to the truck frame
checks the power bridge: it turns on the top side power If the motor connections are OK, the problem lies
MOSFETs alternately and waits until the phase voltage
within the control device, so replace it.
rises up to the value of the capacitor in parallel. If the
voltage of the phases is under 66% of the voltage of the If the alarm takes place while the motor is operating,
check:
capacitor in parallel, this alarm appears.
The motor connections
Cause 2:
If the coil-winding/cables of the motor phases show
losses towards the truck's bodywork
Motor operating test. When the motor is operating, the

That the LC power contact closes correctly, with a
power bridge is ON and the motor voltage feedback is
good contact
tested; if it is below the controlled value (considering a

If no trouble is found with the motors, the problem
range of values), an error status appears.
lies within the control device, so replace it.
Vmn high
Cause 1:
Before switching on the LC, the software checks the power
bridge: it turns on the bottom side power MOSFETs alternately and waits until the phase voltage decreases down
to -BATT. If the voltage of the phases is under 10% of the
nominal voltage of the battery, this alarm appears.
Cause 2:
This alarm may appear even once the start-up diagnosis
has been passed and therefore the LC has closed. In
this situation, the phase voltage should be less than 1/2
Vbatt. Should it exceed this value, an error status would
appear.
If the problem appears on start up (LC doesn't close at

all), check:
If the motor connections are OK, the problem lies
If the problem appears after having closed the LC (LC
closes and then opens again), check:
The motor connections
If the coil-winding/cables of the motor phases show
losses towards the truck's bodywork
If no trouble is found with the motors, the problem
lies within the control device, so replace it.
Contactor closed
Cause:
Before activating the MC coil, the control device verifies
Please check the LC power contacts and replace it if
whether the contactor is blocked. The control device acnecessary.
tivates the bridge for a few tens of milliseconds, trying to
discharge the bank of capacitors If the capacitor voltage
fails to decrease by 20% of the key voltage, an alarm is
generated.
Contactor open
It could be a problem with the contacts in the MC not

working (not inserted), try replacing the MC.
Cause:
If the MC contactors work properly, the problem lies
The main contactor coil has been activated by the control
device, but the contactor fails to close.
Stby I high
This type of error is not connected to external comCause:

ponents, so when it manifests itself the control device
The current transducer or the current feedback circuit has needs replacing.
a fault in the control device.
23
ALARM
SERVICE
breakdown search
Capacitor charge
The charging capacitor diagram is shown below:
Cause:
When the key is turned on, the inverter tries to charge
the power capacitors through a series of PTC and the
power resistance and it checks whether the capacitors
have charged within a short time frame. If the measured
capacitor voltage is less than 20% of the nominal voltage
of the battery, an alarm is signalled; the main contactor is
not closed.
There is an external load in parallel with the bank

of capacitors that disperses the current from the
pre-charging circuit of the capacitors of the control
device, thereby preventing the central contacts from
charging. Check if a lamp bulb or a dc/dc converter
or an auxiliary load is positioned in parallel with the
bank of capacitors.
The charge resistance or PTC is open; add a power
resistance over the electrical terminals of the line
contactor; if the alarm disappears, it means that the
internal charge resistance of the control device is
damaged.
The charging circuit is faulty inside the control device.
There is a problem in the electrical section of the
control device.
Th. protection
it is necessary to increase the cooling of the control

device. In the case of a finned heat dissipation device,
to achieve adequate cooling, these factors are important:
the flow [m3/h] and temperature [C] of the cooling air. In
Cause:
the case of a heat dissipation device with the base plate
This alarm appears when the base plate temperature is of the control device installed on the truck's bodywork, the
above 85C. Afterwards, the maximum current decreases thickness of the bodywork and the flatness and roughin proportion to the increase in temperature from 85C to ness of its surface are important. If, when the alarm is
105C. At 105 the current is limited to 0 Amps.
signalled, the control device is cold, the possible causes
could be failure of the thermal sensor or of the logic card.
In this case the control device needs to be replaced.
Motor temperat.
Check the heat sensor inside the motor (look for MOTOR TEMPERATURE in the TESTER menu); check the
Cause:
value in ohms of the sensor and the sensor cabling. If
This warning appears when the temperature sensor is the sensor is OK, boost the motor cooling. If the warning
open (if digital) or it has exceeded the 150C threshold is present when the motor is cold, then the problem is
(if analog).
located inside the control device.
Battery low
Take the charged battery. If it doesn't work, measure the

Cause:
battery voltage with a voltmeter and compare it to the value
It appears when the battery charge is less than or equal to in the BATTERY VOLTAGE parameter. If they are differ10% of the total charge and the BATTERY CHECK adjust- ent, adjust the value of the ADJUST BATTERY function.
ment is not 0 (refer to SET OPTION menu).
Driver shorted
Cause:
The driver of the main contactor coil has shorted.
24
Check if there is a short circuit or a low pull-down

impedance between NMC (CNA#16) and BATT.
The driver circuit is damaged in the logic board, which
must be replaced.
SERVICE
ALARM
troubleshooting
Contactor driver
This kind of failure is not connected to external compoCause:
nents; replace the ACE2 logic board.
The MC coil driver is not capable of carrying the load. The
device or its pilot circuit is damaged.
Vacc not ok
Cause:
The test has been performed with the key activated and
immediately after both drive requests have been deactivated. This alarm appears if the ACCELERATOR reading
in the TESTER menu is 1.0V over the min. PROGRAM
VACC acquisition when the throttle is released.
Incorrect start
Cause:
It is a warning for an incorrect start sequence.
Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the
alarm persists, check the mechanical calibration and
the operation of the potentiometer. If the alarm is not
deactivated, the fault is in the ACE logic board, therefore
proceed with replacement.
The possible causes of this alarm are (see the TESTER
items to make troubleshooting easier):
Active drive request with key activated
Active man on board sensor with key activated.
Check the wiring. Check the microswitches. It could also
be an issue of an incorrect error sequence performed by
the operator. a fault in the logic board is another possibility; therefore, after checking all the above conditions and
finding nothing, replace the ACE logic board.
Forw+back
Check the wiring of the inputs of the Fwd and Rev drive
requests (see the TESTER items to make troubleshooting easier). Check for any faults with the microswitches.
Cause:
a fault in the logic board is another possibility. Therefore,
This alarm appears when both the (Fwd and Bwd) motion after checking that the drive request switches work
requests are active at the same time.
properly and the wiring is correct, the ACE-2 logic board
needs replacing.
Encoder error
Cause:
This fault is signalled under the following conditions: the
frequency supplied to the motor is greater than 40 Hz and
the encoder's feedback signal shows leaps of more than
40 Hz in just a few tens of mSec. This behaviour is linked
to an encoder malfunction.
Check both the electrical and mechanical operation

of the encoder and check for any constriction of the
cables.
Verify the encoder's mechanical installation, checking whether the encoder slides inside its housing,
producing an alarm condition.
E ven an electromagnetic sound on the sensor
bearing could cause this alarm. In these cases, try
replacing the encoder.
If the problem persists even after replacing the encoder, the fault lies with the control device.
25
ALARM
SERVICE
troubleshooting
Vdc off shorted
it is very likely that the fault is due to overvoltage, therefore you should check:
The connection of the electrical cables to the battery
terminal, positive and negative, to MC and to the control device +Batt and Batt, which must be tightened
Cause:
to a torque of between 13Nm and 15Nm.
This fault is displayed when the control device detects
If no voltage transient is detected on the line +B and
a low logic level of the VDC-off signal during start-up
the alarm is present every time the key is switched
diagnosis.
on, then the fault probably lies with the hardware
of the control device and so the logic board needs
replacing.
Wrong slave ver.

Cause:
Check the two software versions.
The software versions for the Slave and Master are not
the same.
Vdc link overv.
Finding the trouble appearing on start up or in standby:

Check the connection of the electrical cables to the
battery terminal, positive and negative, to LC and to
the control device +Batt and Batt, which must be
Cause:
This fault is displayed when the control device detects a If no voltage transient is detected on the power
line and the alarm is present every time the key is
condition of overvoltage. The overvoltage threshold is 65V
switched on, then the fault probably lies with the
on the 48V control device. On the 116V control device, the
undervoltage threshold is 30V.
needs replacing.
Finding the trouble appearing during motor operation:
If the alarm appears during brake release, check the
contact of the line contactor and the connection of the
electrical cables of the battery.
Tiller mismatch
Check the wiring of the Tiller input (use the TESTER

items to make troubleshooting easier). a fault in the logic
Cause:
is another possibility. Therefore, after checking that the
The Master and Slave have a different value to the Tiller Tiller switch works properly and the wiring is correct, the
signal from the VCM unit.
ACE-2 logic board needs replacing.
Brake run out
Check the mechanical calibration and the operation of

the brake potentiometer. If the alarm remains, the fault
Cause:
lies with the ACE logic board, proceed with replaceThe CPOTBRAKE input read by the microcontroller is at
ment.
the maximum value with no handbrake request.
Stop rq. from eps

Cause:
The EPS sends a signal causing the motor to stop.
26
Check the EPS.
SERVICE
ALARM
Init vmn high
Cause:
Before switching on the LC, the software checks the voltage of the power bridge without activating it. The software
expects the voltage to have a stationary state value. If
this value is too high, this alarm appears.
troubleshooting
Check:
The internal motor connections
Motor loss to the truck frame
within the control device.
Init vmn low
Check:
Cause:
Before switching on the LC, the software checks the volt Motor loss to the truck frame
age of the power bridge without activating it. The software
expects the voltage to have a stationary state value. If
within the control device.
this value is too low, this alarm appears.
Eeprom ko
Cause:
The control device cannot access the memory.
This kind of failure is not connected to external components; replace the ACE2 logic board.
Param restore
If CLEAR EEPROM has been run before last switching

on the key, this warning only means that the EEPROM
has been completely reset. A drive request or a hydraulic
Cause:
request cancels the alarm. If this alarm appears when
This warning appears when the control device has reset the key is activated without CLEAR EEPROM being
to its default values.
requested by the operator, then the problem could be
located inside the control device.
Wrong ram mem

Cause:
Try switching the key off and back on again. If the alarm
The algorithm implemented to check the main RAM reg- still remains, replace the ACE2 logic board.
isters finds incorrect content: the register is dirty. This
alarm inhibits machine operations.
Stall rotor
Check that the indications of FREQUENCY and ENCause:

CODER in the tester menu are the same and are not
The traction rotor is blocked or the encoder signal is not zero during a traction request.
received correctly by the control device.
Waiting slave
Cause:
still remains, replace the ACE2 logic board.
When switching on, there is no activation message from
Slave C to Master C.
Hardware fault

nents, so when it manifests itself the ACE logic board
The software versions for the Slave and Master are dif- needs replacing.
ferent.
27
ALARM
SERVICE
troubleshooting
Pot accel mism
Check the potentiometers. a fault in the logic board is

another possibility. Therefore, after checking that the
Cause:
potentiometer works properly and the wiring is correct,
The Master and Slave do not have the same value on the
the ACE-2 logic board needs replacing.
accelerator signal from one of the two potentiometers.
Pot brake mism
Check the potentiometers. a fault in the logic board is

another possibility. Therefore, after checking that the
Cause:
potentiometer works properly and the wiring is correct,
The Master and Slave do not have the same value on the
the ACE-2 logic board needs replacing.
brake signal from one of the two potentiometers.
Sens mot temp ko

Cause:
The motor heat sensor output is outside the limits.
Check the ohm value of the sensor and the wire harness assembly of the sensor. If the sensor is OK, then
the problem is in the ACE logic board, proceed with
replacement.
Pev not ok
Cause:
The PEV connector (CNA#17) is not connected to the Check the connector A17.
battery or the voltage is different. The traction is stationary if AUXOUT is used for electrical braking and PEV is
indispensable (AUX OUT FUNCTION = PRESENT).
Vkey off shorted
it is very likely that the fault is due to undervoltage,

therefore you should check:
Diminishing pulsations of the key input signal (beneath the undervoltage threshold) due to external
loads, such as switching on DC/DC converters,
switching on relays or contactors, energizing / deenergizing solenoids.

Check
the connection of the electrical cables to the
Cause:
battery
terminal, positive and negative, to MC and
This fault is displayed when the control device detects a low
to
the
control
device +Batt and Batt, which must be
logic level of the Key-off signal during start-up diagnosis.
If no voltage transient is detected on the power supply line and the alarm is present every time the key
is switched on, then the fault probably lies with the
needs replacing.
"Flash checksum"
The problem is in the flash memory of the microcontroller that could be damaged or in the program saved in
Cause:
it that could be corrupted. Try reprogramming the logic,
After switching on the key, the software checks the integrity
if the alarm is still signalled, then the problem is in the
of the program saved in the flash memory. If the outcome
microcontroller. Replace the ACE logic board.
of the test is negative, this alarm is generated.
MC coil shor.
The most likely cause of this error code is in the wire

harness assembly or in the load coil. Therefore, the
Cause:
first step is to check the connections between the
This alarm occurs when there is a short circuit in the MC
outputs of the control device and the loads.
coils connected to the output CNA#16. Once the overload If no faults/problems are found on the outside, the
has been removed the alarm automatically disappears,
trouble lies in the control device that must therefore
releasing and therefore re-enabling a drive request.
be replaced.
28
SERVICE
ALARM
troubleshooting
Waiting for node

Cause:
Check the communication channel.
The control device is waiting for the activation signal from
one of the system's units but this signal fails to arrive.
Vacc out range

Cause:
The CPOT input read by the microcontroller is not within
the Vacc_min to Vacc_max range, programmed via the
PROGRAMM VACC function.
Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the alarm
persists, check the mechanical calibration and the operation of the potentiometer. If the alarm remains, the fault
is in the ACE logic board, proceed with replacement.
Tiller open
Cause:
The warning disappears with the next drive request.
This warning appears when the tiller is released, after a set
stand-by time (30 seconds) the main contactor opens.
Output mismatch
Cause:
This is a fault inside the control device, it is necessary
This is a safety test. The Slave C checks the command to proceed with replacement.
output data of the motor of the Master C and finds a
discrepancy.
Wd syncro
This is a fault inside the control device, it is necessary
Cause:
to proceed with replacement.
The Watchdog signal is not received by the Slave's microcontroller.
No slave enable
Cause:
still remains, replace the ACE2 logic board.
There is no activation message from the Slave C to the
Master C while the control device is in operation.
Dir sel out rang

Check the connections of the switch and measure the
Cause:
signal with a tester.
The signal from the drive request switch is outside the
limits.
Power mos short

Cause:
Before switching on the MC, the software checks the power This kind of failure is not connected to external compobridge: it turns on the bottom and top side power MOSFETs nents; replace the control device.
alternately and waits until the phase voltage decreases
toward -BATT (increase up to +Batt). If the phase voltage
does not follow the commands, this alarm appears.
29
ALARM
SERVICE
troubleshooting
Coil shor. eb.

harness assembly or in the load coil. Therefore, the
Cause:
first step is to check the connections between the
This alarm appears when there is a short circuit in the
outputs of the control device and the loads.
EB/AUX coils connected to the output CNA#18. Once the If no faults/problems are found on the outside, the
overload has been removed the alarm automatically disaptrouble lies in the control device that must therefore
pears, releasing and then re-enabling a drive request.
be replaced.
Current gain
Request the assistance of a Zapi technician to carry out
Cause:
the correct adjustment procedure for the current gain
The maximum current gain parameters contain default
parameters.
values, which means that the maximum current adjustment
procedure has not yet been performed.
Analog input
Cause:
This alarm appears when the A/D conversion of the analog
If the problem persists, the ACE logic board needs
inputs gives a frozen value, on all the converted signals,
replacing.
for longer than 400msec. The aim of this diagnosis is to
find a fault in the A//D converter or a problem in the stream
of codes that omits resetting the conversion of the analog
signal.
Tiller error
Using a voltmeter check the voltage between the two

PIN's If the state of one of the inputs is correct, it could
Cause:
be a problem internal to the module. Replace the modIncongruence between PIN signals (XA2-1) and (XA2ule.
15).
Evp driver open

Cause:
The EVP driver is not capable of carrying the load.

must be replaced.
M/S par chk mism

Cause:
Try resetting and saving the list of parameters.
When switching on, there is a discrepancy between Master
and Slave in the checksum parameter.
Input mismatch
This is a fault inside the control device, proceed with
Cause:
replacement.
The Slave C has different values to the inputs from the
Master C.
Param transfer
Cause:
replacement.
The Master cannot transfer the list of parameters to the
Slave.
30
SERVICE
ALARM
troubleshooting
Sp mismatch
Cause:
replacement.
This is a safety test. The Master C has detected an incorrect set point of the Slave C.
Throttle prog.
Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the
alarm persists, check the mechanical calibration and
Cause:
the operation of the potentiometer. If the alarm is not
One of the potentiometers has not been programmed
deactivated, the fault is in the ACE logic board, therefore
correctly.
Iq mismatched
Cause:
the correct adjustment of the motor parameters.
The error between the lq set point and the estimated lq is
outside the limits.
Aux driv.open
nents; replace the ACE2 logic board.
The EB/AUX coil driver is not capable of carrying the load.
The device or its pilot circuit is damaged.
Data acquisition
Cause:
Acquisition of current gains.
The alarm ends when the acquisition is completed.
No can msg.
nents, so when it persists the ACE logic board needs
This fault is signalled when there is no communication with
replacing.
the supervisor uC.
Check up needed
Cause:
it is sufficient to take the CHECK UP DONE option onto
It is only a warning reminding you to call scheduled main- level ON after maintenance has been performed.
tenance.
Thermic sensor ko
nents; replace the control device.
The control device heat sensor output is outside the limits.
Wrong set bat.
Check that the value of the SET-BATTERY parameter

of the control device corresponds to the nominal voltage of the battery.
Cause:
Verify that the TESTER MENU / BATTERY VOLTAGE
On start up, the control device checks the battery voltparameter has the same value as the battery voltage
age and ensures that it is within a specific range of the
measured using a voltmeter. If it does not match, run
nominal value.
the ADJUST BATTERY function.
Replace the battery.
31
ALARM
SERVICE
troubleshooting
Wrong zero
It is recommended to check:
Cause:
On start up, the high resolution VMN feedback does not Motor loss to the truck frame
come within the range of permissible values around 2.5V. If the motor connections are OK, the problem lies
The circuit is damaged in the control device.
Field orient ko
Cause:
the correct adjustment of the motor parameters.
The error between the ld set point and the estimated ld is
outside the limits.
Aux driv. shrt.
Check if there is a short circuit or a low pull-down

impedance between NEB/NAUX (CNA#18) and
Cause:
BATT.
The driver of the coil of the electromechanical brake / The driver circuit is damaged in the logic board, which
auxiliary solenoid valve has shorted.
must be replaced.
32
SERVICE
DIAGNOSIS SYSTEM FOR Vcm MODULE

Vcm - MASTER MODULE ALARM ANALYSIS AND TROUBLESHOOTING
ALARM
Out port pull-up
Cause:
This alarm pertains to the hardware configuration.
Pump inc. start
Cause:
This signal is displayed for an incorrect start sequence.
troubleshooting
The problem is on the logic board, which must be replaced.
The probable causes of this alarm (use the TESTER
items to make troubleshooting easier) can be an active
pump request when switching on the key or a pump
request when there is not an active seat input. Check
the wire harness assemblies. Check the microswitches.
The cause could also be an error in the sequence performed by the operator or a fault in the logic; if all the
above conditions have been checked and nothing has
been found, replace the control device.
No can msg.
First of all, check the wire harness assemblies. If they
Cause:
are correct, the problem is on the logic board, which
Problem on the CAN-BUS line. The error is reported if the
must then be replaced.
VCM control device does not receive any message from
the CAN-BUS line.
M/S par chk mism

Cause:
The parameters are saved in both the Master and Slave Try saving the parameters again.
EEPROM. These two non-volatile memories must contain If the trouble still remains when the key switch is reacthe same parameter values and must be periodically com- tivated, replace the board.
pared. This alarm is generated if any differences are found.
This alarm does not prevent the machine from working,
but the default parameters are used.
Param transfer
Cause:
Try saving the parameters again.
The parameters are saved in both the Master and Slave If the trouble still remains when the key switch is reacEEPROM. These two non-volatile memories must contain tivated, replace the board.
the same values for each parameter and the values must
be periodically compared. If the Master cannot transfer the
parameters to the Slave, an alarm is generated.
Reset encoder
The cause of this alarm (use the TESTER items to

make troubleshooting easier) is due to the fact that the
encoder reset input is not active.
First of all, lower the forks until the encoder reset input
Cause:
is active.
VCM waits for the encoder reset input to be active before If the trouble remains, check the wire harness assemenabling any hydraulic function (only the lowering function blies and check that the microswitches work correctly.
is permitted).
it is possible that there is also a fault in the logic; if all
the above conditions have been checked and nothing
has been found, replace the control device.
33
ALARM
SERVICE
troubleshooting
Analog input
This is a fault inside the microcontroller, replace the
Cause:
board.
Problem in the analog-digital module of the microcontroller.
All the functions are stopped.
Watchdog
Cause:
This is an internal error, the module needs replacing.
A software watchdog is programmed for each microcontroller. Its function is to check that the software is working
properly. All the functions are stopped.
Reset encoder ko
The cause of this alarm (use the TESTER items to make

troubleshooting easier) depends on the fact that the encoder reset input is active in an incorrect fork position.
If the trouble remains, check the wire harness assemCause:
blies and the operation of the microswitches. it is also
VCM displays the active encoder reset input in a different
possible that there is a fault in the logic; if all the above
position to the expected one.
conditions have been checked and nothing has been
found, replace the control device.
Logic failure #1
Depends on the cause of the alarm:

There has been a real drop in voltage. The alarm
should simply disappear upon switching the key off
and back on again. The cause of the undervoltage is
Cause:
to be determined according to the conditions in which
This alarm signals that a condition of undervoltage has
it occurs. For example: a truck function that requires
been detected upon inserting the key. All the functions
a high voltage can reduce the battery voltage.
are stopped.
Fault in the circuit detecting undervoltage conditions.
The board must be replaced.
Battery out
The cause of this alarm (use the TESTER items to make

troubleshooting easier) depends on the fact that the
inputs of the disconnected battery are not active.
First of all, insert the battery into the correct position in
the truck's bodywork.
Cause:
If the trouble remains, check the wire harness assemVCM waits to see that the inputs of the disconnected bat- blies and check that the microswitches work correctly
tery are active before enabling any functions.
according to the settings of the parameters. it is also
Waiting for node

Cause:
The control device receives a message from the CAN The COMBI module cannot be activated, but it has to wait
indicating that another control device in the network has until the other module exits from the error condition.
failed; consequently the VCM control device cannot be
operated but has to WAIT for the other control device to
exit from its error condition.
34
SERVICE
ALARM
troubleshooting
Valve enable
Check whether there is an alarm on the supervisor uC.

Cause:
If there are no alarms, the fault is in the hardware and
It occurs when uC Master tries to activate an output but the board needs replacing.
the supervisor uC does not enable it.
Tiller mismatch
The cause of this alarm (use the TESTER items to

make troubleshooting easier) derives from a different
reading of the condition of the "dead man" switch by
VCM and traction.
Cause:
If the trouble remains, check the wire harness assemMisalignment between VCM and traction for the dead blies and the operation of the microswitches. it is also
man input.
Battery low
Cause:
It occurs when the battery charge level is less than or equal
to 10% of the total charge and the BATTERY CHECK setting is not 0 (refer to SET OPTION menu).
Recharge the battery. If it doesn't work, measure the

battery voltage with a voltmeter and compare it to the
value of the BATTERY VOLTAGE parameter. If the
values are different, adjust the value of the ADJUST
BATTERY function.
Wrong ram mem.

Cause:
Try switching the key off and then on; if the alarm still
The algorithm included to check the main RAM registers remains, replace the logic board.
has found incorrect content: the register is dirty. This
alarm prevents the machine's functions.
Eeprom ko
Cause:
A fault in the area of memory containing the parameters or
problems existing during the operations of reading/writing
to this memory. This alarm does not prevent the machine
from working, but the default parameters are used.
If the fault persists after the key has been reactivated,

replace the module. If the fault disappears, the previously saved parameters will be replaced by the default
parameters.
Controller mism.
Cause:
Replace the control device.
Incorrect customer ID code in the protected area of the
memory where this parameter is saved.
Param restore
If CLEAR EEPROM mode was active before last switching on the key, this message indicates that the EEPROM
has been correctly deleted. The alarm disappears on
Cause:
making a drive or pump request. If this alarm occurs
This message appears when the control device has reset when switching on the key without CLEAR EEPROM
to its default values.
being requested by the operator, there could be a problem in the control device.
Sdo trac
Cause:
HM communication trouble between VCM and traction.
Check the communication between the two control devices, if the communication is correct then replace the
board.
35
ALARM
SERVICE
troubleshooting
Encoder locked #1
Check whether ENCODER1 in the tester menu is other

than zero during a lifting request. Verify the wire harness
assembly and the operation of the sensor. it is also
Cause:
The encoder is blocked or the encoder signals are not
Encoder locked #2
Check whether ENCODER2 in the tester menu is other

than zero during a lifting request. Verify the wire harness
Cause:
The encoder is blocked or the encoder signals are not
Hm mismatch
Cause:
Check the settings of the hour meter parameters.
Inconsistency between VCM and traction for the hour
meter.
Lift/low lever
Cause:
Check the mini-lever.
The mini-lever in relation to the lifting/lowering lever is in
an alarm status.
Pump in alarm
Cause:
Alarm on the pump control device.
Wrong slave ver.

Cause:
Incorrect software release on the supervisor uC.
Check the alarm on the pump control device.
Install the correct software release on the supervisor

uC.
No can msg. 14
Cause:
No CAN message from the pump control device.
Check the pump control device.
No can msg. A
Cause:
No CAN message from the mini-lever.
Interlock fork
Check whether Reach pot is acquired correctly. If it is

not, then it must be acquired. Verify the wire harness
Cause:
VCM is not able to run the interlock function.
Carriage lever
Cause:
The mini-lever in relation to the retractable carriage lever
is in an alarm status.
36
SERVICE
ALARM
troubleshooting
Tilt lever
Cause:
The mini-lever in relation to the tilt lever is in an alarm
status.
Side shift lever

Cause:
The mini-lever in relation to the side shift lever is in an
alarm status.
Wrong config
Cause:
Incorrect communication between VCM and traction.
No config master
Cause:
Incorrect configuration file in Master uC.
No config backup
Cause:
Incorrect configuration file in the supervisor uC.
Check the configuration of the parameters for this function. Download the configuration file again.
Pcf timeout
Check the configuration of the parameters for this funcCause:
tion. Download the configuration file again.
Time expired when checking the configuration file between
VCM and traction.
Waiting pcf
Cause:
Wait for the update to be completed.
Waiting to check the configuration file between VCM and
traction.
Preselector
Check which function generates the alarm condition.

Verify the wire harness assemblies and the operation of
Cause:
the sensor. it is also possible that there is a fault in the
VCM is not able to run the height pre-selection function logic; if all the above conditions have been checked and
correctly.
nothing has been found, replace the control device.
37
SERVICE
Vcm - SLAVE MODULE ALARM ANALYSIS AND TROUBLESHOOTING

ALARM
Drv. shrt A
Cause:
The driver of one the first eight outputs has shorted.
Drv. open A
Cause:
VCM is not able to enable one of the first eight outputs.
troubleshooting
Check if there is a short circuit or low impedance
between one of the outputs and BATT.
This kind of failure is not connected to external components; replace the logic board.
Watchdog master
Cause:
This is an internal error, the module needs replacing.
A hardware watchdog enables synchronising the microcontrollers. All the functions are blocked.
No can msg.
First of all, check the wire harness assemblies. If they
Cause:
are correct, the problem lies with the logic board, which
There is a problem connected with the CAN-BUS line. The
must be replaced.
error is reported if the supervisor uCr does not receive any
messages from the CAN-BUS line.
Pev drv. short.

Cause:
The top driver of the PEVP1 output has shorted.
Check if there is a short circuit or low impedance

between pin A13 and +BATT.
must be replaced.
Pev drv. open

nents; replace the logic board.
VCM is not able to enable the top driver of the PEVP1
output.
Coil open A
It is recommended to check the wire harness assembly to see whether the coil is connected to the correct
Cause:
pin and whether the connection is broken.
This fault occurs when no load is connected between one If, in spite of connecting the coil to the correct pin or
of the outputs NEVP1, NEVP2.NEVP8 and the positive
replacing it, the alarm remains, the problem is in the
pole.
logic board, which must then be replaced.
Valve mism. out

Cause:
Alarm of the SLAVE currently disabled. Set point calculated
by the SLAVE different to the set point of the MASTER.
Watchdog
Cause:
This is an internal error, the module needs to be
There is watchdog software in each microcontroller. Its replaced.
function is to check that the software is working properly.
All the functions are blocked.
38
SERVICE
ALARM
Out port pull-up
Cause:
This alarm pertains to the hardware configuration.
troubleshooting
The problem is on the logic board, which must be replaced.
Analog input
This is a fault inside the microcontroller, replace the
Cause:
board.
There is a problem in the "from analog to digital" module
of the microcontroller. All the functions are blocked.
Logic failure #1
Depends on the cause that generated the alarm:

In the case of a real drop in voltage, the alarm will
disappear by simply turning the key off and then back
on. The cause of the undervoltage is to be determined
Cause:
according to the conditions in which it occurs. For
This alarm signals that a condition of undervoltage has
example: a truck function that requires a high voltage
occurred upon inserting the key. All the functions are
can reduce the battery voltage.
blocked.
Fault in the circuit detecting undervoltage conditions.
The board must be replaced.
No can msg. 14
Cause:
No CAN message from the pump control device.
Check the pump control device.
No can msg. A
Cause:
No CAN message from the mini-lever.
In. mism. D
Compare the values read by Master and Slave with the

Cause:
panel's tester menu.
Incorrect match on the digital input between Master and Contact Zapi technical support.
Slave.
In. mism. A/E
Compare the values read by Master and Slave with the

Cause:
panel's tester menu.
Incorrect match on the analog inputs or on the inputs of Contact Zapi technical support.
the encoder between Master and Slave.
Wrong ram mem.

Cause:
Try turning the key off and back on; if the alarm still
The algorithm implemented to check the main RAM reg- remains, replace the logic board.
isters finds incorrect content: the register is dirty. This
alarm inhibits the operation of the machine.
Eeprom ko
Cause:
A fault in the area of memory containing the parameters
or problems during the operations of reading/writing to
this memory. This alarm does not inhibit the machine from
working, but the default parameters are used.
If the fault persists after the key has been reactivated,

replace the module. If the fault disappears, the previously saved parameters will be replaced by the default
parameters.
39
ALARM
SERVICE
troubleshooting
Controller mism.
Cause:
Replace the control device.
Incorrect customer ID code in the protected area of the
memory where this parameter has been saved.
Param restore
If CLEAR EEPROM mode was active before last switching on the key, this message indicates that the EEPROM
has been correctly deleted. The alarm disappears on
Cause:
making a drive or pump request. If this alarm appears
This message appears when the control device has reset when switching on the key without CLEAR EEPROM beto its default values.
ing requested by the operator, there could be a problem
in the control device.
Drv. shrt B
Check for a short circuit or low impedance between

one of the outputs and BATT.
Cause:
The driver of one the outputs NEVP9, NEV1,..NEV3 has
shorted.
Dvr. open B
nents; replace the logic board.
VCM is not able to enable one of the outputs NEVP9,
NEV1,..NEV3.
Coil open B
It is recommended to check the wire harness assembly to see whether the coil is connected to the correct
pin and there are no breaks.
Cause:
If, in spite of connecting the coil to the correct pin
This fault occurs when no load is connected between one
or replacing it, the alarm remains, the problem is in
of the outputs NEVP1, NEVP2.NEVP8 and the positive
the logic board of the control device, which must be
pole.
replaced.
Out 1/2 coil sh.

harness assembly or in the load coil. Therefore, first
Cause:
of all check the connections between the outputs of
This alarm occurs when there is a short circuit of the coil
the control device and the loads.
of EVP1 or EVP2. Once the overload has been removed
If no problems are found on the outside, the trouble
the alarm automatically disappears, releasing and then
lies with the control device that must be replaced.
re-enabling a drive request.
Out 3/4 coil sh.

Cause:
40
SERVICE
ALARM
troubleshooting
Out 5/6 coil sh.

Cause:
Out 7/8 coil sh.

Cause:
Laser coil sh.

Cause:
of EV1. Once the overload has been removed the alarm
automatically disappears, releasing and then re-enabling
a drive request.
Bat out coil sh.

Cause:
a drive request.
Load brk coil sh

Cause:
is in the control device that must be replaced.
a drive request.
Alarm coil sh.

Cause:
is in the control device that must be replaced.
a drive request.
41
SERVICE
EPS ACW MODULE DIAGNOSIS SYSTEM

eps acw MODULE ALARM ANALYSIS AND TROUBLESHOOTING
ALARM
breakdown search
Watchdog
Cause:
MuC and SuC communicate via a Can Bus local commu- If this alarm is repeated, the problem lies with the control
nication system. Communication between them requires device.
bit stuffing (the bit stuffing must be reversed for each new
frame). If the bit stuffing remains frozen for longer than
100msec, this alarm is generated.
Eeprom ko
Cause:
Each microcontroller has its own EEPROM with two lists
Run Clear Eeprom. If the problem persists, replace the
of parameters (to have a local backup). Each list has its
control device.
own checksum. When both checksums are wrong, this
alarm is generated. If one list of parameters has an incorrect checksum, it will be settled by using the second list
(backup with correct checksum).
Logic failure #4
Cause:
This alarm occurs with the steering system at rest if the it is necessary to replace the control device.
amplifier on the connected voltage Vu-Vw is in the range
of +/- 250mV around Vuw_zero for 96msec (sampling time
8msec for 12 consecutive samples).
Logic failure #3
Cause:
This alarm occurs with the steering system at rest if the it is necessary to replace the control device.
amplifier on the connected voltage Vu-Vw is in the range
of +/- 250mV around Vuw_zero for 96msec (sampling time
8msec for 12 consecutive samples).
Vmn not ok
Cause:
This alarm occurs with the key enabled if at least one voltage amplifier on the connected voltage Vv-Vu and Vu-Vw If the alarm is repeated, the control device needs reis in the range of +/- 300mV around 2.4Vdc for 50msec placing.
(sampling time 10msec for 5 consecutive samples). (Permissible outputs at rest from 2.1V to 2.7V). On completing
the diagnosis, the offset value of the voltage amplifiers
(Vvu_zero and Vuw_zero) will be acquired.
42
SERVICE
ALARM
troubleshooting
Main cont. open

This is not a problem related to Eps. When this warning
Cause:
is generated, it means that the contactor is open (or not
This warning is active when the steering system control
yet closed).
device receives the information that the current contactor
is open via CAN BUS.
Stby I high
Cause:
This alarm occurs in two ways:
With the key enabled, if at least one current amplifier
on the U and W phase is in the range of +/- 300mV
around 2.5Vdc for 50msec (sampling time 10msec
for 5 consecutive samples). (Permissible outputs of If the alarm is repeated, the control device needs recurrent amplifiers with key enabled are from 2.2V to placing.
2.8V). On completing the diagnosis, the offset value
of the current amplifiers (IU_zero and IW_zero) will be
acquired.
With the steering system at rest, if at least one current amplifier on the U and W phase is in the range
of +/- 150mV around IU_zero or IW_zero for 96msec
(sampling time 8msec for 12 consecutive samples).
Capacitor charge
Some cases:
If this alarm occurs only in the control device of the
steering system, check the continuity of the cables
at CNA#3-4-5 from the battery and from Eps.
If the cables at CNA #3-4-5 are OK, measure the
voltage CNA#3-4-5 and B within 3 sec of enabling
the key. Only if the measured voltage is greater than
14Vdc (and on a short duration on STATUS#5 it is
Cause:
instead lower) replace the control device.
This alarm occurs with the key enabled, if the DC Bus
If the voltage measured between CNA#3-4-5 and B
(capacitors in parallel) fails to reach a minimum value of
is close to 0 there are two possibilities:
14Vdc within 3.2secs. STATUS #5 gives the value in real
- Short circuit on DC rail and B in Eps (discontime of the battery connection (+B) on a short duration.
nect CNA#3-4-5 and measure the voltage in the
DC bus of the traction control device (+B to B):
replace Eps if the voltage of the DC bus of the
traction device is greater than 14Vdc.
- Short circuit on DC rail and B on another unit in
the truck.
High temperature
Cause:
This alarm occurs when the temperature in the MOSFET
cases is:
Improve the cooling system of the control device. Other greater than 80C for longer than 3.84secs @ MAXI- wise, it is necessary to replace the control device.
MUM CURRENT=70A
O
greater than 90C for longer than 3.84secs @ MAXIMUM CURRENT=50A.
43
ALARM
SERVICE
troubleshooting
Motor temperat.
Cause:
This alarm occurs only when DIAG MOTOR TEMP is
Check whether the heat sensor in the motor is working
ON and the heat sensor at the motor input measures a
correctly. If it is, improve the motor cooling system.
temperature greater than 120C. It also occurs when the
motor resistance has been acquired with a temperature
in the motor greater than 120C (also with DIAG MOTOR
TEMP ON).
High current
Cause:
If the alarm is repeated, the control device needs reThis alarm occurs with the key enabled, if the the circuit
placing.
is always active in order to limit the maximum current via
hardware (it may be due to a fault with the current amplifier).
Power failure #3
If the alarm is repeated, check that the battery is connected to the control device. Otherwise, the problem
Cause:
can be a fault in the three-phase bridge or in the motor
Current in phase W of the motor less than 5.4Arms for
connection to the terminal W.
100msec even if controlled at more than 28% Imax.
Power failure #2
Cause:
Current in phase V of the motor less than 5.4Arms at
connection to the terminal V.
Power failure #1
Cause:
Current in phase U of the motor less than 5.4Arms at
connection to the terminal U.
Bad steer 0-set

Cause:
Switch off the key.
This warning appears when the hardware setting 0-POS
TEACHING has been activated (and the key switched
back on).
Steer sensor KO
Cause:
This alarm occurs when the steering potentiometer (XA1-8 Replace the potentiometer.
XA1-9) varies with a peak broader than 1 Volt in 16 msec.
This alarm is used to identify a discontinuity in the control
potentiometer voltages.
Steer hazard
Cause:
Turn the steering wheel in the opposite direction.
This warning occurs when the steered wheel reaches the
maximum angle.
44
SERVICE
ALARM
troubleshooting
Selfcheck #2
Cause:
This warning appears when SELFCHECKING routine #2
is in progress and the outcome of the check has not yet
been determined. This self-checking routine monitors the
encoder and the current in the motor when it is operated to Turn the key back on to clear the warning SELFCHECK
move at a fixed speed of 25Hz. It is recommended to run #2.
SELFCHECK #2 with the steered wheel raised. The aim of
this self-test is to check the operation of the encoder and
mechanical components (transmission, sensor bearings,
gears, pinion). Once the collected data have been processed and there is an unexpected outcome, this warning
message turns into an alarm message.
Selfcheck #1
Cause:
This warning appears when SELFCHECKING routine #1
is in progress and the outcome of the check has not yet
been determined. This self-checking routine measures the
Turn the key back on to clear the warning SELFCHECK
resistances of the motor between phases V and W (Rvw)
#1.
and between phases W and U (Rwu) with a multimeter,
using a fixed current of 14.7Adc. The aim of this self-test is
to check the operation of the motor and the power bridge
of the three phases. Once the collected data have been
processed and there is an unexpected outcome, this warning message turns into an alarm message.
Can bus warn
The problem could concern the cables of the Can Bus

Cause:
or the Can Bus transceiver inside the traction, the Eps
If a node fails to receive the Can Bus message of the or another unit on the truck. To identify the root of the
traction (Can ID 0x388 for MuC and 0x389 for SuC) for problem, a Can Bus is required.
longer than 200msec, this alarm will appear.
45
ALARM
SERVICE
troubleshooting
SP mismatch YY
Cause:
Depending on the command, MuC and SuC calculate
the set point of the steering motor speed independently
of each other. SuC is concerned that the values it is calculating in real time match the values calculated by MuC.
This alarm is generated when there is no such match. SuC
specifies the condition that led to a discrepancy with a hex
code (see YY pair above).
Incorrect conditions between MuC and SuC may be:
If the alarm is repeated, the problem lies with the control
With no limitation on the closed loop maximum angle, device.
there is a discrepancy on the point of setting the steering motor speed greater than 10Hz. YY = 01h.
With a limitation on the closed loop maximum angle,
there is a discrepancy due to the fact that MuC has
detected the limitation of the maximum angle and SuC
has not detected it (or vice versa). YY = 02h.
With a closed loop due to resetting at rest, there is a
discrepancy due to the fact that MuC has detected the
condition for resetting at rest and SuC has not detected
it (or vice versa). YY = 04h.
Out mismatch YY
Cause:
MuC and SuC read the commands and calculate the set
point of the steering motor independently of each other.
Then MuC activates the motor; SuC checks, in real time,
that the operation on the motor conforms to the value of
the set point of the steering motor. This alarm is generated
if the above does not occur. SuC specifies the condition
leading to a discrepancy with a hex code (see YY pair
above).
Incorrect conditions between MuC and SuC may be:
The present and controlled steering motor speeds (set
point) have a greater movement than 10Hz and with
opposite signs. YY = 03h.
The present and controlled steering motor speeds (set
device.
point) have the same sign, one movement greater
than 10Hz, but the present speed is 50% less than
the controlled speed. YY = 05h.
At least one of the above discrepancies occurs. The
present and controlled pair currents (set point) have a
greater movement than 3Aac and with opposite sign
YY = 0Bh when the first discrepancy mentioned above
occurs; 0Dh when the second discrepancy mentioned
above occurs.
At least one discrepancy between point 1 and 2 occurs.
The present and controlled pair currents have the same
sign, one movement greater than 3Aac, but the present
pair current is 50% less than the controlled pair current.
YY = 13h when condition 1 occurs; 15h when condition
2 occurs.
46
SERVICE
ALARM
troubleshooting
W.D. syncro
Cause:
Every 32 measurements of the input values (analog and
digital) (e.g. every 4msec) MuC generates a falling edge
on an input of the SuC used as Request Interrupt. This IR Reactivate the key. If the alarm is repeated, the probworks as a synchronizing mechanism for SuC allowing it to lem is in the control device. It could also be a problem
start the first of the 32 measurements of the input values. related to ESD.
When MuC has completed the second A/D conversion
(second of the 32 AD conversions in autoscan mode), it
triggers the Synchro input at a higher level. SuC generates
this alarm when no falling edge is detected on the Synchro
input for more than 90 msec.
Wrong slave ver

Download the same software release (same number)
Cause:
on both microcontrollers.
This alarm is generated by MuC if the Software releases on
MuC and SuC do not match (different releases).
Wrong ram memory

Cause:
The process (running the code) does not pass through
one (at least) of the main steps of the stream of codes
for a time longer than 80msec (e.g. function for reading
inputs, functions to calculate the set point values for
the steering motor, function to supervise the state of
the steering system, ISRs to operate the motor control
device).
device.
O
Deterministic Finite Automaton (DFA) is characterised
by state transitions. As a protective measure, every
transition state is controlled by assigning two variables
(state label and its complement). These two variables
identify the new state (redundancy on the label). This
redundancy has been designed to prevent a failure in
the RAM leading to an incorrect destination status for
DFAs. If the two state labels are inconsistent or not
complementary, this alarm is generated.
Param restore
Cause:
Reactivate the key.
This alarm is a confirmation that a Clear Eeprom parameter
has been run correctly.
Can bus ko m/s

Cause:
If the alarm is repeated, the problem lies with the steerMuC and SuC communicate via a local Can Bus coming system control device.
munication system (integrated). If a node receives no
response from another node for any longer than 100msec,
this alarm is generated.
47
ALARM
SERVICE
troubleshooting
Stepper motor mism

Cause:
This alarm appears in two ways:
Channels D and Q of the stepper motor are processed
in two ways: A/D conversion and alignment encoder
interface. When the A/D conversion gives a fast movement (breadth of line D or Q greater than the crest 4.6V)
and the alignment encoder gives a slow movement
(less than 2 pulses in 80msec: e.g. 25Hz) for more than
200msec.
O
If the crest value of a channel of the stepper motor
(DL or QL) is less than 0.61V while the crest value of
the second channel is greater than 2V for more than
120msec (it detects a short circuit between one channel
of the stepper motor and GND).
Check that there is no short circuit between CNA#20 or

CNA#17 and GND. Check that the stepper motor is type
approved. If it is, replace the stepper motor and check the
wire harness assembly. If the problem persists, replace
the control device.
Motor locked
Cause:
Too much torque required for steering or trouble with the
This alarm occurs if the current in the motor remains
encoder (run selfcheck #2).
greater than 90% Imax for more than 1 sec, when the traction speed is greater than 15% (the delay time becomes 5
sec, when the traction speed is less than 5%).
M/S par chk mism
Check which are the different parameters between

Cause:
MuC and SuC and update (write) the parameters that
MuC compares its own checksum for the list of parameters do not match. To identify the problem easily run Clear
with the checksum of the list of parameters in SuC. If there Eeprom.
are any discrepancies, MuC generates this alarm.
Fb jerk
Cause:
This alarm occurs if the position of the steered wheel measured with the encoder has a step (discontinuity) greater
than 21 degrees (turn 244/4096) in 16msec and the step
does not return to having a smaller gap for 13 consecutive
sample measurements (total 208msec).
Interference or defect of the encoder or encoder cables.

One possibility is that the correct phase movement of
90 degrees between CHA and CHB in the encoder has
been lost.
Current gain
Cause:
This alarm occurs when the gains of the current amplifiers Contact Zapi technical support or replace the control.
(ADJUSTMENT #03 and ADJUSTMENT #04) are set on
default values (Imax has not yet been adjusted).
48
SERVICE
ALARM
troubleshooting
Position error
Cause:
This alarm occurs due to an error in the feedback sensor
redundancy test. Here we have one encoder and one (two)
toggle switch. This alarm occurs if the sector count (toggle
switch configuration) and the encoder count do not match.
The sector is equipped with a FEEDBACK SECTOR reader
in the tester menu; the encoder count device is equipped
If the alarm occurs when installing a new control device,
with STEER ANGLE reading in the tester menu.
make sure that AUX FUNCTION 11 corresponds to the
layout of the toggle switches and that PULSE IN 180
If there are two toggle switches:
DEG. has been set correctly. If the alarm occurs after the
set-up
has been performed properly, search for a fault
FEEDBACK
STEER ANGLE
on
a
toggle
switch or on the encoder. Troubleshooting
SECTOR
[degrees]
consists
in
comparing
the STEER ANGLE and FEEDpermitted
BACK SECTOR when an alarm occurs. In the event of
an alarm, it is expected that these values will not observe
from -15 to +15
1 or 4
the permitted matches given in the tables alongside. The
from +15 to +75
1
problem could concern a sensor (check PROX SWITCH
from +75 to +105
1 or 2
1 and PROX SWITCH 2) or the encoder (check STEER
from +105 to +165
2
ANGLE and FEEDBACK SECTOR).
from +165 to -165
2 or 3
from -165 to -105
A list of possible fault modes is given below:

A switch changes its level even though it has not
from -105 to -75
3 or 4
been engaged by the iron plate (cam) on the steered
from -75 to -15
4
wheel.
If the encoder is composed of a bearing with a senIf there is only one toggle switch:
sor, a ring of the sensor bearing has slippage (the
sensor bearing has two rings: one is connected to
FEEDBACK
STEER ANGLE
the rotor shaft, the other to the motor chassis). Check
SECTOR
[degrees]
that these two rings are each firmly joined to their
permitted
structure with no slippage.
from +15 to +165
1
Fault in the encoder with low resolution (such as a
from -165 to -15
4
loose magnet or a fault with the Hall sensor).
The STEER ANGLE has slipped it could also occur
When the FEEDBACK SECTOR and STEER ANGLE do
when the truck is stationary) due to interference on
not match, there is a POSITION ERROR alarm in less
the encoder channels.
than 100msec.
NOTE: The permitted STEER ANGLE thresholds for each
FEEDBACK SECTOR given in the above tables refer to an
ideal situation with STEER 0-POS DEG set to 0 degrees
(no offset between SW1 and null angle) and a cam of length
180 degrees. The actual thresholds concerning the offset
SW1 and the length of the cam are shown in real time in
the FEEDBACK SECTOR message.
49
ALARM
SERVICE
troubleshooting
Slave alarm XX
Cause:
When SuC generates an alarm, the power supply is cut off
and the steering motor can no longer be activated. MuC
then generates this warning. On the Zapi panel, MuC
specifies the LSByte of the alarm code of SuC on position
XX. For example:
device.
1.
LOGIC FAILURE #4: SLAVE ALARM 10
2.
OUTPUT MISMATCH: SLAVE ALARM D0
3.
INPUT MISMATCH: SLAVE ALARM FA
4. SP MISMATCH: SLAVE ALARM CF
Waiting master
Cause:
If the warning is repeated, the problem lies with the
With the key activated, SuC waits for MuC to send a ready
control device.
to steer frame on the local CAN Bus communication system. If the message fails to arrive for longer than 4sec,
this warning will appear.
Eps not aligned

Cause:
This warning occurs with the key enabled in three different ways:
No activation on the straight switch (SW1 on CNA#12)
Selfchecking STATUS #2 helps find the origin of the
for longer than 3 sec.
problem.
O
No activation on the straight switch (SW1 on CNA#12)
for a 180 MDU rotation.
O
The encoder is not able to return to the position of 0
(straight) after SW1 has been activated.
Logic supply err

Reactivate the key. If the error is repeated, the problem
Cause:
lies with the control device.
This alarm appears if the 13.5V logic power voltage that actuates the three phase power bridge is less than 11Vdc.
50
SERVICE
ALARM
troubleshooting
Fb sensor locked
Cause:
It is closed loop monitoring. This alarm occurs if the current
speed (freq_enci measured with the main encoder) does
not follow the controlled speed (set point) (freq_req deriving
from pre-processing the outputs of the stepper motor) for
longer than 500msec and the traction speed is greater than
15% (at the lowest traction speed, the delay time increases
up to 2.5sec, when the traction speed is less than 5%).
This alarm occurs if the misalignment between the current
speed and the controlled speed remains greater than 30%
of the controlled speed and greater than 5Hz above the
delay time of 500msec (variable depending on the speed
of the truck). Monitoring is suspended for 400ms whenever
the error sign (freq_req_freq_enc.) changes from positive
to negative or vice versa.
This alarm may be due to:

At least one encoder channel is broken
Too much friction in the transmission
A fault in the control device
A fault in the motor (e.g. a blocked encoder or a
broken phase of the motor).
Q line sensor ko
Cause:
This alarm occurs when the average voltage on the stepper motor alignment line (connection CNA#17) is not zero:
the voltage on each stepper motor line is a sinusoid with
zero average voltage.
Check the continuity of the stepper motor connections.

In particular the resistance between CNA#17 and the
negative pole of the battery (with the stepper motor at
rest) should be very low (around 30 Ohms).
D line sensor ko
Cause:
This alarm occurs when the average voltage on the stepper motor direct line (connection CNA#20) is not zero: the
voltage on each stepper motor line is a sinusoid with zero
average voltage.
Check the continuity of the stepper motor connections.

In particular the resistance between CNA#20 and the
negative pole of the battery (with the stepper motor at
rest) should be very low (around 30 Ohms).
Param transfer
Cause:
Master uC and Slave uC have their own list of parameters
(with their own local backup). Parameter modification is Try changing a parameter again. If the problem persists,
controlled by MuC only. MuC writes its own parameters replace the control device.
and instructs SuC to do the same for its own list of parameters. Running the writing parameter on SuC is password
protected. This alarm is generated by the MuC should SuC
refuse to run the writing command.
Data acquisition
Cause:
This alarm occurs when adjusting the maximum current Reactivate the key.
(set in the factory) and when a procedure is run for acquiring the motor resistance. Acquiring motor resistance has
not yet been implemented.
51
ALARM
SERVICE
breakdown search
Can bus ko
The problem may consist in an incorrect Can Bus conCause:

nection or depend on the traction control device being
If on both MuC and SuC there are no Can Bus messages switched off or not fitted. To identify the root of the
pertaining to traction (Can ID 0x388 for MuC and 0x389 for problem, a Can Bus analyser is required.
SuC) for longer than 200msec, this alarm is generated.
Input mismatch YY
Cause:
MuC and SuC read the values of the inputs independently of each other. SuC is concerned that the values it is
reading match, in real time, the values MuC is reading. If
this does not occur, this alarm is generated. SuC specifies
which input is responsible for the discrepancy with a hex
code (see YY pair above).
The faulty inputs between MuC and SuC may be:
Discrepancy on straight or 90 switch (SW1 on CNA#12
device.
and SW2 on CNA#11). YY = 83h.
Discrepancy in the quadrant of the MDU in a turn of
360 (SW1 vs. SW2 vs. AUX FUNCTION #11 setting).
YY=08h.
Discrepancy in the speed of the stepper motor greater
than max_stepper_motor_speed/5 (CNA#20 and
CNA#17).YY=04h.
Discrepancy in the encoder count greater than 10
counts (one count of 2296 corresponds to an MDU at
180) (CNG#1 and CNG#3). YY=20h.
Init vmn not ok
Try and disconnect the motor terminals from the control

device, reactivate the key and read STATUS #5. If the
long duration value (e.g. 1st value) is in the range between 8 and 13.5Vdc, the problem is a dispersion (loss of
Cause:
After activating the key with the three-phase bridge disa- motor isolation). Otherwise, replace the control device.
bled, the DC bus voltage should reach 14Vdc in 3.2sec
(CAPACITOR CHARGE alarm, if this does not occur). At
the same time the steering control device monitors the voltage common to the motor terminals (see STATUS #5 1st
value) and generates this alarm after the 3.2sec. and:
The common voltage is less than 7Vdc (bottom MOSFET shorted B).
O
The common voltage is blocked at DC Bus (top MOSFET shorted +B). (it is considered blocked if it is in a
range of +/- 1Vdc around the DC Bus). STATUS #5 in
the TESTER menu gives the value in real time of this
common voltage on long duration.
52
SERVICE
ALARM
troubleshooting
Analog
Cause:
With the key activated, the A/D converter is on and
should complete an initial conversion of the analog
inputs within 16msec. If this does not occur, this alarm Reactivate the key. If the problem persists, replace the
control device.
is generated.
Under conditions of stationary status, the main signals
(currents of the motor and sensor in the wheel of the
steering system) require a new A/D conversion every
250usec. Should no conversion successfully conclude
within 1.25msec, this alarm will be generated (e.g. after
5 consecutive failed conversions).
53
54
SERVICE
SERVICE
ELECTRICAL SYSTEM
Electrical system
ELECTRICAL WIRING DIAGRAMS 4
CONTROLS 6
IDENTIFICATION OF ARMREST, PEDAL UNIT AND MAIN PANEL CONTROLS 6
STANDARD DISPLAY 8
KEYPAD AND SYMBOLS DISPLAYED 8
DISPLAY BRIGHTNESS CONTROL 9
SOFTWARE 9
ICONS ASSOCIATED WITH THE GRAPHIC SCREENS 9
FUNCTIONAL GRAPHIC SCREENS 13
DESCRIPTION OF THE OPTIONAL GRAPHIC SCREENS 27
DESCRIPTION OF THE MENU SCREENS 39
MAIN MENU 1 39
MAIN MENU 1 / TESTER 39
MAIN MENU 1 / SET CLOCK 41
MAIN MENU 1 / SOFTWARE VERSION. 41
MAIN MENU 1 / ALARMS. 42
MAIN MENU 1 / PARAMETER SETTING. 43
MAIN MENU 2 45
MAIN MENU 2 \ CLEAR ALARMS 46
MAIN MENU 2 \ MEASURING SYSTEM 46
main menu 2 \ FORKS SETUP 47
main menu 2 \ PARAMETER ACQUISITION 48
main menu 2 \ PROGRAMMING ACCESS CODE WITH COMBINED OPERATOR CODE READING 48
main menu 2 \ read user code 51
main menu 2 \ clear access code 51
TRUCK FUNCTIONS 52
FORWARD/REVERSE TRACTION 52
SPEED REDUCTION 54
BRAKING 57
STEERING 58
STEERING 60
FORK LIFTING/LOWERING 61
ACCELERATION / DECELERATION RAMPS 63
LIMIT STOP SLOWDOWN lifting / LOWERING 63
1
ELECTRICAL SYSTEM
SERVICE
FORK LIFTING/LOWERING BLOCKS (WITH FORK HEIGHT ENCODER) 64

HYDRAULIC FUNCTIONS 65
RETRACTABLE CARRIAGE ACCELERATION / DECELERATION RAMPS 66
CARRIAGE OUT / RETURN LIMIT STOP SLOWDOWN 67
AUXILIARY FUNCTIONS ACCELERATION / DECELERATION RAMPS 67
FORK SELF-CENTRING 67
CONFIGURATION PARAMETER ACCESS PROCEDURE 68
MENU SEARCH PROCEDURE and parameter modification 68
STANDARD CONFIGURATION OF MODULE PARAMETERS 73
VCM MODULE 73
ACE2 PUMP MODULE 76
EPS ACW MODULE 76
DESCRIPTION OF MODULE PARAMETERS 77
VCM MODULE 1 77
ACE2 PUMP MODULE 88
EPS ACW MODULE 88
MODULES: INTRODUCTION 90
POSITIONING OF THE "PC TOOL" CONNECTORS 90
INVERTER ACE2 MODULE 91
EPS ACW MODULE 92
VCM MODULE 93
REPLACEMENT OF MODULES: INSTRUCTIONS 94
REPLACING THE "ACE2 INVERTER" MODULE 94
REPLACEMENT OF THE EPS ACW MODULE 96
VCM MODULE REPLACEMENT 98
REMOVAL OF ELECTRICAL COMPONENTS 100
REPLACEMENT OF ENCODER 100
ENCODER RESET SENSOR REPLACEMENT 102
LOAD CELL REPLACEMENT 103
REPLACEMENT OF THE HORN 104
REPLACEMENT OF THE CONTACTORS 105
FUSE REPLACEMENT 106
REPLACEMENT OF THE MOTOR COMPARTMENT COOLING FAN 108
REPLACEMENT OF ARMREST AND MAIN PANEL CONTROLS: 110
SIDE SHIFT POSITION SENSOR REPLACEMENT 117
PALLET PRESENCE SENSOR REPLACEMENT 118
TILT POSITION SENSOR REPLACEMENT 119
90 WHEEL SENSOR AND STEERED WHEEL SENSOR REPLACEMENT 120
BATTERY OUT SENSOR REPLACEMENT 121
2
SERVICE
ELECTRICAL SYSTEM
OPERATOR PRESENCE PEDAL REPLACEMENT 122

ACCELERATOR AND BRAKE PEDALS REPLACEMENT 123
SERVICE
ELECTRICAL SYSTEM
ELECTRICAL WIRING DIAGRAMS

COMPONENTS
Ref.
Ref.
Description
A1
Standard display
M1
Traction motor
A2
Type of drive control
M2
Pump motor
A3
Pump control
M3
Steering motor
A4
Steering control
M4
Stepper motor
A5
Master card control
P1
Horn
A6
Mast connector card
P2
Flashing
A7
Multi-lever board
P5
Fan
A8
Premium display
P6
Fan
A9
Relay-fuse board
P7
Reversing buzzer
A10
Multi-function joystick board
P8
Work light
A11
Cab heater control
P9
Work light
A12
Multi-function joystick
P10
Work light
B1
Traction motor encoder
Q1
Lowering proportional solenoid valve
B2
Traction motor heat sensor
Q2
Lifting proportional solenoid valve
B3
Pump motor encoder
Q3
Carriage in proportional solenoid valve
B4
Pump motor heat sensor
Q4
Carriage out proportional solenoid valve
B5
Steering motor encoder
Q5
Left hydraulic function proportional solenoid valve
B6
Steer motor heat sensor
Q6
Right hydraulic function proportional solenoid valve
B7
Centred wheel sensor
Q7
Tilt-shift diverter solenoid valve
B8
90 steered wheel sensor
Q8
Hydraulic 5th way diverter solenoid valve
B9
Battery out sensor
R1
Varistor
B10
Tilt position sensor
R2
Electromagnetic brake
B11
Mast lifting encoder
R3
Accelerator pedal sensor
B12
Side shift position sensor
R4
Brake pedal sensor
B13
Pallet presence sensor
R5
Carriage position potentiometer
B14
Encoder reset sensor
R8
Right load wheel electromagnetic brake
B15
Free lift encoder
R9
Left load wheel electromagnetic brake
B16
Temperature sensor
R10
Load cell
C1
Battery
R11
Laser
C2
Electrolyte capacitor 100 F 50V
S1
Key switch
F1
Fuse for emergency push-button and contactors (10A)
S2
Emergency button
F2
Contactor fuse (10A)
S3
Operator presence switch
F3
Key relay fuse (2A)
S4
Drive direction switch
F4
Drive power fuse
S5
Seat belt microswitch
F5
Pump power fuse
S6
Work lights switch
F6
Steering power fuse
S7
Steering mode 180/360
K1
Drive contactor coil
S8
Traction speed reduction
K2
Pump contactor coil
S9
Weighing device button
K3
Key relay
S10
Lift by-pass button
K4
Horn relay
S12
Lifting-lowering potentiometer lever
K5
Auxiliary relay
S13
Carriage out-in potentiometer lever
K6
Auxiliary relay +5/+12V
S14
Tilt potentiometer lever
K7
Work lights relay
S15
Side shift potentiometer lever
K8
Work light relay
S16
Automatic tilt centring button
K9
Diode (1A)
S17
Automatic side shift centring button
K10
Diode (1A)
S18
Hydraulic 5th way button
K11
Diode (1A)
S19
Horn button
K12
Diode (1A)
S20
K13
Diode (1A)
S21
Work light switch
K14
Diode (1A)
S22
Seat microswitch (optional)
K15
Diode (1A)
T1
DC/DC 48V/24V converter
K16
Optional relay
T2
DC/DC 48V/12V converter
K17
Diode (1A)
Description
Motor assembly
SERVICE
ELECTRICAL SYSTEM
4a
SERVICE
ELECTRICAL SYSTEM
4b
SERVICE
ELECTRICAL SYSTEM
4c
SERVICE
ELECTRICAL SYSTEM
4d
SERVICE
ELECTRICAL SYSTEM
NOTES
(2) as a reference use the colour X of the
individual wire (or the number printed on it,
if the wire is black)
(3) standard for the Heavy-duty version, optional for the other versions
4e
SERVICE
ELECTRICAL SYSTEM
4f
SERVICE
ELECTRICAL SYSTEM
4g
SERVICE
ELECTRICAL SYSTEM
NOTES
(2) as a reference use the colour
X of the individual wire (or the number printed on it, if the wire is black)
4h
SERVICE
ELECTRICAL SYSTEM
4i
SERVICE
ELECTRICAL SYSTEM
NOTES
individual wire (or the number printed
on it, if the wire is black)
(4) if B15 is not mounted, use B14 for drive
speed reduction and Free Lift/Main Lift
lifting
4j
SERVICE
ELECTRICAL SYSTEM
4k
SERVICE
ELECTRICAL SYSTEM
NOTES
(1) connected on the multi-lever version only
(2) as a reference use the colour X of the individual wire (or the number printed on it, if the
wire is black)
4l
SERVICE

ELECTRICAL SYSTEM
application diagram - MULTI-FUNCTION JOYSTICK (optional)
NOTES
(2) as a reference use the colour X of the individual wire (or the number printed on it, if the
wire is black)
4m
SERVICE
ELECTRICAL SYSTEM
4n
SERVICE
ELECTRICAL SYSTEM
application diagram - PREMIUM DISPLAY (optional)
(see also page (a) for the connections)
application diagram - COLD STORE STANDARD DISPLAY (optional)

(see also page (a) for the connections)
NOTE (2)
application diagram - DC/DC CONVERTER (optional)

(see also page (h) for the connections)
DC/DC DOUBLE CONVERTER (OPTIONAL)

individual wire (or the number printed on it,
if the wire is black)
(see also page (b) for the connections)
NOTES
application diagram - COLD STORE CAB (optional)
4o
SERVICE
ELECTRICAL SYSTEM
SERVICE
ELECTRICAL SYSTEM
CONTROLS
IDENTIFICATION OF ARMREST, PEDAL UNIT AND MAIN PANEL CONTROLS
3
7
10
11
8
1
12
13
13
14
18
23
17
14
15
22
18
24
16
17
15
21
20
19
16
SERVICE
ELECTRICAL SYSTEM
26
25
Ref.
Description
27
Wiring diagram ref.
Keyswitch
S1
Small steering wheel
Standard or premium display
Speed reduction button
S8
Weighing button
S9
180/360 steering mode button
S7
Auxiliary function button
Auxiliary function button
Work lights switch
S6
10
Work lights switch
S21
11
Auxiliary function switch
12
PC tool connection port compartment
13
Emergency button
S2
14
Horn button
S19
15
S4
16
Automatic tilt centring button
S16
17
Automatic side shift centring button
S15
A1 - A8
X40-X41
18
Hydraulic 5th way button
S18
19
Fork lifting/lowering mini-lever
S12
20
Carriage in/out mini-lever
S13
21
Forks up/down tilt mini-lever
S14
22
Forks right/left shift mini-lever
S15
23
Joystick
A12
24
Fork tilt/shift lever
25
Operator presence pedal
S3
26
Brake pedal
R4
27
Accelerator pedal
R3
7
SERVICE
ELECTRICAL SYSTEM
STANDARD DISPLAY
KEYPAD AND SYMBOLS DISPLAYED
Ref.
Description
Numerical keys from 0 to 9
Forward or upward scroll key
Backward or downward scroll key
Ignition switch with or without key
OUT function key
ENTER function key
SERVICE
ELECTRICAL SYSTEM
DISPLAY BRIGHTNESS CONTROL

a) Disconnect the emergency button with the key switch in position 1
b) Reset the emergency button with the numerical button 0 pressed
c) When the display lights up, use the two scroll buttons to change the brightness
d) Once you reach the desired brightness, press the "ENTER" function key to save it
SOFTWARE
The software is loaded by the supplier.
The software release is indicated on the label on the component.
When switching on, the display has to send an SDO to the VMC identification controller that will respond
with another SDO for confirmation. When the key switch is turned off the display must warn the VMC
150ms before cutting off the +12V supplying the key relay.
ICONS ASSOCIATED WITH THE GRAPHIC SCREENS

The icons used in the various functions shown on the display are illustrated below.
ICON
DESCRIPTION
Battery charge level indicator.
The system continuously monitors the battery charge
indicated by the number of solid segments.
5 segments = from 100% to 76%
1 segment = from 20% to 0
Segments 5-4-3 shown steady. Segments 2-1 shown
blinking. The battery charge status data will be sent
to the display via Can bus with PDO.
Parking brake indicator.
The data reaches the display via Can bus with
PDO.
SERVICE
ELECTRICAL SYSTEM
ICON
DESCRIPTION
Remaining battery life indicator.
Indicates the remaining hours and minutes of battery
life. The data will be sent to the display via Can bus
with PDO.
24:00
Daily clock, indicates the hours and minutes.

PDO
0001 h
Worked hours indicator.

SDO.
10.50 km/h
Traction speed indicator.

PDO.
10.50 m
Indicator of fork height off the ground.

PDO.
0150 kg
Weighing Indicator.
SDO.
Reduced speed indicator.
PDO.
Maximum speed indicator.
PDO.
Seat belt indicator.
Appears when the seat belt is not fastened. The data
reaches the display via Can bus with PDO.
Lifting limit stop indicator.
This icon is displayed on reaching the lifting limit. The
data reaches the display via Can bus with PDO.
Fork tilt up indicator.
This icon is displayed during the fork "tilt up" function. The data reaches the display via Can bus
with PDO.
Fork tilt down indicator.
This icon is displayed during the fork "tilt down"
function.
PDO.
Fork right side shift indicator.
This icon is displayed during the fork "right side shift"
function.
PDO.
Fork left side shift indicator.
This icon is displayed during the fork "left side shift"
function.
PDO.
10
SERVICE
ELECTRICAL SYSTEM
ICON
DESCRIPTION
Fork side shift self-centring indicator.
This icon is displayed during the fork "side shift selfcentring" function. Icon blinking while moving, steady
once centred. Optional. The data comes via Can
bus with PDO.
Fork tilt self-levelling indicator.
This icon is displayed during the fork "tilt 0 selflevelling" function. Icon blinking while moving, steady
once centred. Optional. The data reaches the display
via Can bus with PDO.
Indicator for hydraulic 5th way option active.
This icon is displayed when the hydraulic 5th way
option is activated. The data reaches the display via
Can bus with PDO.
IN/OUT hydraulic 5th way function indicator.
This icon is displayed blinking (at a frequency of 2
Hz) when the hydraulic 5th way function is active in
the two work modes. The data reaches the display
via Can bus with PDO.
Forks lowering interlock indicator.
This icon is displayed during the fork lowering function when the fork lowering lock trips. Optional. The
Carriage return interlock indicator.
This icon is displayed during the request for carriage
return with the interlock option active. Optional. The
Battery out-of-place indicator.
This icon is displayed when the battery is no longer
locked in its correct position. The data reaches the
display via Can bus with PDO.
Alarm indicator.
This icon is displayed in the event of a hardware or
software failure on the electrical system and is associated with a numerical code that identifies the type
of alarm and control involved.
Password prompt indicator.
This icon appears if a password is required for access.
11
SERVICE
ELECTRICAL SYSTEM
ICON
DESCRIPTION
Incorrect password entry indicator.
This icon appears if the access password entry is
incorrect.
Steer wheel 360 position indicator.

This icon is always displayed. The data reaches the
Steer wheel 360 position indicator showing forward gear engaged.

This icon, with the arrow indicating the direction of
travel, is displayed after making the selection and
throughout the duration of the function. The direction
indication follows the position of the steer wheel. The
Steer wheel 360 position indicator showing reverse gear engaged.
Steer wheel 180 position indicator.
This icon is always displayed. The data reaches the
Steer wheel 180 position indicator showing forward gear engaged.

Steer wheel 180 position indicator showing reverse gear engaged.
12
SERVICE
ELECTRICAL SYSTEM
FUNCTIONAL GRAPHIC SCREENS

The graphic screens for each single function are shown below in sequence.
SCREEN DISPLAYED ON SWITCHING ON THE KEY SWITCH
Steering 360
Steering 180
Remaining battery life indicator

Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Worked hours indicator displayed for 5 seconds
SCREEN DISPLAYED 5 SECONDS AFTER SWITCHING ON THE KEY SWITCH

Steering 360
Steering 180

Clock
Speed indicator, expressed in km/h or mph
13
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH FORWARD DRIVE SELECTED
Steering 360
Steering 180

Clock
Forward drive indicator following the steering wheel position indicator
SCREEN DISPLAYED WITH REVERSE DRIVE SELECTED

Steering 360
Steering 180

Clock
Reverse drive indicator following the steering wheel position indicator
14
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH FORK LIFTING ON AND DRIVE OFF

Steering 360
Steering 180

Clock
Fork lifting indicator
SCREEN DISPLAYED WITH FORK LOWERING ON AND DRIVE OFF

Steering 360
Steering 180

Clock
Fork lowering indicator
15
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH CARRIAGE OUT ON AND DRIVE OFF
Steering 360
Steering 180

Clock
Carriage out indicator
SCREEN DISPLAYED WITH CARRIAGE RETURN ON AND DRIVE OFF

Steering 360

Clock
Carriage return indicator
16
Steering 180
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH FORK TILT UP ON AND DRIVE OFF

Steering 360
Steering 180

Clock
Fork tilt up indicator
SCREEN DISPLAYED WITH FORK TILT DOWN ON AND DRIVE OFF

Steering 360
Steering 180

Clock
Fork tilt down indicator
17
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH FORK SIDE SHIFT TO RIGHT ON AND DRIVE OFF
Steering 360
Steering 180

Clock
Fork side shift to right indicator
SCREEN DISPLAYED WITH FORK SIDE SHIFT TO LEFT ON AND DRIVE OFF
Steering 360

Clock
Fork side shift to left indicator
18
Steering 180
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH BATTERY OUT-OF-PLACE

Steering 360
Steering 180

Clock
Forward drive indicator
Battery out-of-place indicator
Fork lifting block indicator
206-01 alarm indicator (Battery out)
SCREEN DISPLAYED WITH BATTERY REMOVAL ON AND DRIVE OFF

Steering 360
Steering 180

Clock
Carriage out indicator
19
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH BATTERY RETURN INTO PLACE ON AND DRIVE OFF
Steering 360

Clock
20
Steering 180
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF

Steering 360
Steering 180

Clock
Tilt up indicator
The screen shown above is an example of combined hydraulic functions.
Possible combinations
Forks up
carriage out
tilt up
Forks up
carriage out
tilt down
Forks up
carriage out
right side shift
Forks up
carriage out
left side shift
Forks up
carriage return
tilt up
Forks up
carriage return
tilt down
Forks up
carriage return
right side shift
Forks up
carriage return
left side shift
Forks lowering
carriage out
tilt up
Forks lowering
carriage out
tilt down
Forks lowering
carriage out
right side shift
Forks lowering
carriage out
left side shift
Forks lowering
carriage return
tilt up
Forks lowering
carriage return
tilt down
Forks lowering
carriage return
right side shift
Forks lowering
carriage return
left side shift
21
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON
Steering 360
Steering 180

Clock
Carriage forward indicator
Tilt up indicator
The screen shown above is an example of combined hydraulic functions with the drive on.
22
Forks up
carriage out
tilt up
for forward/reverse drive
Forks up
carriage out
tilt down
Forks up
carriage out
right side shift
Forks up
carriage out
left side shift
Forks up
carriage return
tilt up
Forks up
carriage return
tilt down
Forks up
carriage return
right side shift
Forks up
carriage return
left side shift
Forks lowering
carriage out
tilt up
Forks lowering
carriage out
tilt down
Forks lowering
carriage out
right side shift
Forks lowering
carriage out
left side shift
Forks lowering
carriage return
tilt up
Forks lowering
carriage return
tilt down
Forks lowering
carriage return
right side shift
Forks lowering
carriage return
left side shift
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION ON

Steering 360
Steering 180

Clock
Energy Saving indicator
SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION, DRIVE AND HYDRAULICS ON

Steering 360
Steering 180

Clock
Energy Saving indicator
23
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH WARNING SIGNALLING
This screen is displayed after an incorrect sequence performed by the operator.
Steering 360
Steering 180

Clock
Warning indicator
Indication of the problem
The incorrect sequences are:
24
INC. START TRACTION
INC. START REACH OUT
INC. START LIFT
INC. START SHIFT RIGHT
INC. START LOW
INC. START SHIFT LEFT
INC. START TILT UP
INC. START 5TH WAY IN
INC. START TILT DOWN
INC. START 5TH WAY OUT
INC. START REACH IN
GET HOME
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH ALARM SIGNALLING

Steering 360
Steering 180

Clock
Alarm indicator
Alarm code number indicator
NOTE: 249 = code number of type of alarm.
6 = identification of the control on which the alarm occurred.
SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE OFF.
Steering 360
Steering 180

Clock
Lifting limit stop indicator
25
SERVICE
ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE ON.
Steering 360

Clock
Lifting limit stop indicator
26
Steering 180
SERVICE
ELECTRICAL SYSTEM
DESCRIPTION OF THE OPTIONAL GRAPHIC SCREENS

The graphic screens for each single optional function are shown below in sequence.
OPERATOR SEAT BELT OPTIONAL SCREEN

Clock
Seat belt not fastened indicator
When the direction of travel is selected, the above screen will appear if the seat belt is not fastened.
The indicator showing that the seat belt is not fastened blinks at a frequency of 1.5 Hz.
FORK TILT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE OFF.

Steering 360
Steering 180

Clock
Fork tilt self-centring indicator
During the self-centring phase the icon will blink alternately with showing the tilt movement (tilt up/tilt down). If
there is a request for self-centring and the forks are already in the correct position the icon is on steady.
27
SERVICE
ELECTRICAL SYSTEM
FORK TILT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE ON.
Steering 360
Steering 180

Clock
Fork tilt self-centring indicator
During the self-centring phase the icon will blink alternately with showing the tilt movement (tilt up/tilt down). If
there is a request for self-centring and the forks are already in the correct position the icon is on steady.
FORK SIDE SHIFT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE OFF.

Steering 360
Steering 180

Clock
Fork side shift self-centring indicator
During the self-centring phase the icon will blink alternately with showing the side shift movement (side shift
right/side shift left). If there is a request for self-centring and the forks are already in the correct position
the icon is on steady.
28
SERVICE
ELECTRICAL SYSTEM
FORK SIDE SHIFT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE ON.

Steering 360
Steering 180

Clock
Fork side shift self-centring indicator
During the self-centring phase the icon will blink alternately with showing the side shift movement (side shift
right/side shift left). If there is a request for self-centring and the forks are already in the correct position
the icon is on steady.
OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE OFF

Steering 360
Steering 180

Clock
Hydraulic 5th way indicator
29
SERVICE
ELECTRICAL SYSTEM
OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE ON
Steering 360
Steering 180

Clock
Hydraulic 5th way indicator
OPTIONAL SCREEN FOR INPUT HYDRAULIC 5TH WAY WITH DRIVE OFF
Steering 360

Clock
Input hydraulic 5th way indicator
30
Steering 180
SERVICE
ELECTRICAL SYSTEM
OPTIONAL SCREEN FOR OUTPUT HYDRAULIC 5TH WAY WITH DRIVE OFF
Steering 360
Steering 180

Clock
Output hydraulic 5th way indicator
OPTIONAL SCREEN FOR INPUT HYDRAULIC 5TH WAY WITH DRIVE ON

Steering 360
Steering 180

Clock
Input hydraulic 5th way indicator
31
SERVICE
ELECTRICAL SYSTEM
OPTIONAL SCREEN FOR OUTPUT HYDRAULIC 5TH WAY WITH DRIVE ON
Steering 360

Clock
Output hydraulic 5th way indicator
32
Steering 180
SERVICE
ELECTRICAL SYSTEM
OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF

Steering 360
Steering 180

Clock
Tilt self-centring indicator
The screen shown above is an example of combined hydraulic functions with the drive on.
Forks up
Forks up
Forks up
Forks up
Forks lowering
Forks lowering
Forks lowering
carriage out
carriage out
carriage return
carriage return
carriage out
carriage out
carriage return
tilt self-centring
side shift self-centring
tilt self-centring
tilt self-centring
tilt self-centring
Forks lowering
carriage return
33
SERVICE
ELECTRICAL SYSTEM
OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON
Steering 360
Steering 180

Clock
Tilt self-centring indicator
The screen shown above is an example of combined hydraulic functions with the drive off.
34
Forks up
Forks up
Forks up
Forks up
Forks lowering
Forks lowering
Forks lowering
carriage out
carriage out
carriage return
carriage return
carriage out
carriage out
carriage return
tilt self-centring
tilt self-centring
tilt self-centring
tilt self-centring

Forks lowering
carriage return
SERVICE
ELECTRICAL SYSTEM
OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE OFF

Steering 360
Steering 180

Clock
Fork lifting/lowering indicator
Digital height display measured in metres or feet
OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE ON

Steering 360
Steering 180

Clock
Fork lifting/lowering indicator
Digital height display in metres or feet off the ground
During the forks up or down function with drive on, the measured fork height must always be displayed.
When the machine is stopped, the fork height off the ground is displayed. When the machine is running
only in drive mode, the speed indicator is displayed.
35
SERVICE
ELECTRICAL SYSTEM
OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE AND HYDRAULICS OFF
Steering 360
Steering 180

Clock
Load weighing indicator in kg or lb
During the load weighing function with drive on, the weight must appear for 5 seconds and then the drive
speed will be displayed.
OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE ON AND HYDRAULICS OFF

Steering 360
Steering 180

Clock
Forward drive engaged indicator
Load weighing indicator in kg or lb
During the load weighing function with drive on, the weight must appear for 5 seconds and then the drive
speed will be displayed.
36
SERVICE
ELECTRICAL SYSTEM
FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF

Steering 360
Steering 180

Clock
Forks lowering interlock indicator
The forks lowering indicator blinks at a frequency of 1.5 Hz.
FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON

Steering 360
Steering 180

Clock
Forks lowering interlock indicator
The forks lowering indicator blinks at a frequency of 1.5 Hz.
37
SERVICE
ELECTRICAL SYSTEM
CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF

Steering 360
Steering 180

Clock
Carriage return interlock indicator
The carriage return indicator blinks at a frequency of 1.5 Hz.
CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON

Steering 360

Clock
Carriage return interlock indicator
The carriage return indicator blinks at a frequency of 1.5 Hz.
38
Steering 180
SERVICE
ELECTRICAL SYSTEM
DESCRIPTION OF THE MENU SCREENS

The graphic screens for each menu are shown below in sequence.
MAIN MENU 1
Pressing the "ENTER" function key takes you from the main screen to MAIN MENU 1 as shown above.
To access the different sub-menus, you need to move the arrow by pressing the "SCROLL" keys and, once
you have made your selection, press ENTER.
MAIN MENU 1 / TESTER

The TESTER function allows you to check the operation of the truck.
Once in the TESTER sub-menu, the TESTER 1 screen will appear, as shown below. Using the SCROLL
keys you can change the screens of the TESTER sub-menu (from TESTER 1 to TESTER 5)
TESTER 1
TRACTION
CURRENT
VOLTAGE
FREQUENCY
TEMPERATURE
MOTOR TEMP
HOURS
= 0000 A
= 000%
= 000 Hz
= 000 C
= 000 C
= 0000 h
TESTER1 enables checking the signals sent by the traction controller.

The display via an SDO will request these data from the traction controller that will respond with an SDO
via Can Bus.
TESTER 2
PUMP
CURRENT
VOLTAGE
FREQUENCY
TEMPERATURE
MOTOR TEMP
HOURS
= 0000 A
= 000%
= 000 Hz
= 000 C
=000 C
= 0000 h
TESTER 2 enables checking the signals sent by the pump controller.

The display via an SDO will request these data from the pump controller that will respond with an SDO
via Can Bus.
39
ELECTRICAL SYSTEM
SERVICE
TESTER 3
STEERING
CURRENT
VOLTAGE
FREQUENCY
TEMPERATURE
MOTOR TEMP
HOURS
= 0000 A
= 000%
= 000 Hz
= 000 C
= 000 C
= 0000 h
TESTER 3 enables checking the signals sent by the steering system controller.
The display via an SDO will request these data from the steering system controller that will respond with
an SDO via Can Bus.
TESTER 4 enables checking the status of the digital inputs.

Empty square = OFF
Solid square = ON
The display via an SDO will request these data from the VMC controller that will respond with an SDO
via Can Bus.
TESTER 5 enables checking the status of the analogue inputs.

via Can Bus.
By pressing the "OUT" function key, you can exit the screen at any time.
40
SERVICE
ELECTRICAL SYSTEM
MAIN MENU 1 / SET CLOCK

The SET CLOCK function allows you to set the current time.
Once you enter the sub-menu, the hours will flash. Use the numerical keys to set the correct time, then
confirm with "ENTER". The minutes will now blink. Use the numerical keys to set the minutes and confirm
with "ENTER". After this operation you exit the screen automatically.
The display via SDO will send these data to the VMC controller that will respond with an SDO as confirmation. The VMC will have an RTC device with Backup
MAIN MENU 1 / SOFTWARE VERSION.

The SOFTWARE VERSION function allows you to check the versions of the software used.
via Can Bus.
41
ELECTRICAL SYSTEM
SERVICE
MAIN MENU 1 / ALARMS.

These four screens are used for saving and displaying up to 32 different alarms that have occurred while
using the machine. They display:

The code number of the type of alarm.
The time when the alarm occurred.
The number of times it has occurred.
Identifier of the control on which the alarm occurred.
Once in the ALARMS sub-menu, the screen will appear with the first 10 alarms. Using the "SCROLL"
keys, you can change the screens to be able to view all 32 alarms, when there are that many, otherwise
the pages are automatically reduced to display only the alarms present.
via Can Bus.
By pressing the function key OUT (see page 13), you can exit the screen at any time.
42
SERVICE
ELECTRICAL SYSTEM
MAIN MENU 1 / PARAMETER SETTING.

On these screens, the operator can modify the machine's drive performance, with the ability to lock it with
a password.
Once in the PARAMETER SETTING sub-menu, the screen shown below will appear.
With the "SCROLL" keys you can select the parameter you want to change:
1) TRACTION SPEED from 1.00 km/h to 14.00 km/h
2) ACCELERATION from 1 to 5

1: +1 sec (lower performing)

2: +0.5 sec
3: standard setting
4: -0.3 sec
5: -0.5 sec (higher performing)
3) INVERSION BRAKING from 1 to 5

1: +0.5 sec (lower performing)

2: +0.2 sec
3: standard setting
4: -0.3 sec
4) RELEASE BRAKING from 1 to 5


2: +0.2 sec
3: standard setting
4: -0.3 sec
To change the 4 above parameters, proceed as follows:
a) Position the cursor, using the "SCROLL" keys, on the parameter to be changed
b) Press the "ENTER" key.
c) The value of the parameter will blink and you can now change the value with the "NUMERICAL" keys.
d) Press the "ENTER" key to confirm.
43
ELECTRICAL SYSTEM
SERVICE
5) ENERGY SAVING from OFF to ON. If set ON, the machine traction and lifting performance will be
reduced to save battery power consumption. This function will be indicated by the ECO icon.
To modify this parameter, proceed as follows:
a) Position the cursor, using the "SCROLL" keys, on the parameter to be changed.
c) The word OFF will blink and you can now change it to ON using the "SCROLL" keys.
d) Press the "ENTER" key to confirm.
6) LOCK PARAM. from OFF to ON. If set ON, you will be prompted for a password to lock the set
parameters.
To modify this parameter, proceed as follows:
e) Position the cursor, using the "SCROLL" keys, on the parameter to be changed.
f) Press the "ENTER" key.
g) A window will open where you can enter the 4 digits of the PIN that you can set as a password.
Enter the 4-digit password using the "NUMERICAL" keys and press "ENTER" to confirm.
The modified parameters will now be locked and you are taken back to the PARAMETER
SETTING screen and the LOCK PARAM value will be ON. Now, all the parameters are
locked.
If the user attempts to modify the parameters with the lock on, the screen for entering the password will
reappear.
On restarting the machine the screen for entering the password shown below will be displayed.
If you enter the wrong password, the screen shown below will appear for 5 seconds, after which the password prompt screen will return.
With the SUPERVISOR PASSWORD (default 5555) or the ENGINEERING PASSWORD (1959)
it is always possible to unlock the parameters.
The display via an SDO will send these data to the VMC controller that will respond with an
SDO via Can Bus.
44
SERVICE
ELECTRICAL SYSTEM
MAIN MENU 2
The MAIN MENU 2 function allows you to access the functions that only technical support can modify.
Once in the MAIN MENU 2 sub-menu, the following screen will appear.
Enter the 4-digit password using the "NUMERICAL" keys and press "ENTER" to confirm. If you enter the
wrong password, the screen shown below will appear for 5 seconds, after which the password prompt
screen will return.
When the password is correct, the following screen will be displayed.
With the SUPERVISOR PASSWORD (default 5555) or the ENGINEERING PASSWORD (1959)
it is always possible to access MAIN MENU 2.
To access the different sub-menus, you need to move the arrow by pressing the "SCROLL" keys
and, once you have made your selection, press ENTER.
45
ELECTRICAL SYSTEM
SERVICE
MAIN MENU 2 \ CLEAR ALARMS

The CLEAR ALARMS function allows you to delete the alarms in the ALARMS menu
When this screen appears, pressing the direction buttons scrolls through the two possible options of YES
and NO.
Pressing the ENTER button with YES displayed clears the saved alarms and takes you back to the MAIN
MENU 2 screen. Pressing the ENTER button with NO displayed exits without clearing the alarms and
takes you back to the MAIN MENU 2 screen.
With the "OUT" button you exit without clearing the alarms.
MAIN MENU 2 \ MEASURING SYSTEM

The MEAS. SYSTEM TYPE function allows you to convert the following units of measurement simultaneously, as follows:
km/h into mph
m into ft

kg into lb
When this screen appears, by using the scroll buttons you can select the available systems of measurement (INTERNATIONAL SYSTEM/IMPERIAL SYSTEM) and, once selected, on pressing the ENTER
button the units of measurement are converted by the display's software and you are taken back to the
MAIN MENU 2 screen. The metric system is present by default on Can Bus.
46
SERVICE
ELECTRICAL SYSTEM
main menu 2 \ FORKS SETUP

The FORKS SETUP function allows you to change the two fork adjustment values. The first one, FORKS
OFFSET , is the minimum height of the forks off the ground. The second one, FORKS UP LIMIT, allows
you to limit lifting the forks up to the set height.
When this screen appears, on pressing the ENTER button the selected value, for example FORKS OFFSET, will blink. Type in the new offset value in metres, using the NUMERICAL buttons.
Press the "ENTER" key to confirm. The modified value will be displayed steady
The same procedure for changing the value applies to the second value, FORKS UP LIMIT, which can
be selected with the direction buttons.
The display via an SDO will send these data to the VMC controller that will respond with an SDO via
Can Bus.
47
ELECTRICAL SYSTEM
SERVICE
main menu 2 \ PARAMETER ACQUISITION
On this screen you can acquire the electrical values of carriage all in, carriage all out, minimum load cell
value (with no load on the forks) and maximum load cell value (nominal load on the forks).
With the scroll keys you can select the value you want to acquire. To access carriage all out/in acquisition,
proceed as follows:
a) Position the cursor, using the scroll keys, onto the value to be acquired: REACH FULL FWD /
REACH FULL BACK.
b) Press the "ENTER" key and the selected value will start flashing.
c) Move the carriage forwards/backwards until the desired position is reached..
d) Press the "ENTER" key to save the modified value.
e) Press the "OUT" button to exit.
To access acquisition of the load cell minimum and maximum values, proceed as follows:
a) Position the cursor, using the scroll keys, onto the value to be acquired: MIN WEIGHT CELL/MAX
WEIGHT CELL.
b) Press the "ENTER" key and the selected value will start flashing.
c) Raise the forks off the ground by approximately 50mm.
d) Press the "ENTER" key to save the modified value.
e) Press the "OUT" button to exit.
main menu 2 \ PROGRAMMING ACCESS CODE WITH COMBINED OPERATOR CODE READING
This function is optional, therefore the display needs to be enabled via PDO to make it operative on the
truck. The PROG. PIN CODE ACCESS function allows you to create an access code for operator or
supervisor use and to define the driver profile for each access code. Up to a total of 104 codes can be
programmed. If this function is enabled, when switching on the key switch the display will prompt you for
the access code.
With the correct access code, the +12V output of the key relay is enabled, the screen will be displayed
and the operator will be enabled to use the machine. If the truck is not operated for any longer than 10
minutes (message sent by Can Bus via SDO), the display will disable the +12V output of the key relay
and switch off. To be able to restart, simply press any button and the display will prompt you for the access
code again.
The screens and the descriptions for the programming are illustrated below.
48
SERVICE
ELECTRICAL SYSTEM
ACCESS CODE PROGRAMMING SCREEN
To enter the codes, you need to move the arrow by pressing the "SCROLL" keys and, once you have selected
the row, press ENTER. The cursor will now be positioned on the digit of the code to enter that will start
flashing. Type in the four-digit code with the "NUMERIC" keys and confirm with ENTER. The cursor will
automatically move onto "U" that will start flashing. Using the SCROLL buttons you can go from U (user)
to S (supervisor) and pressing ENTER confirms the selection. Lastly, the cursor will move onto "NA"
that will start flashing. Using the SCROLL buttons you can go from NA (not available) to A (available),
pressing ENTER confirms the selection. If NA is confirmed, the cursor will move onto the next row,
whereas confirming A will show the screen to be able to match the driver profile with the access code.
With the "SCROLL" keys you can select the parameter you want to change:
1) TRACTION SPEED from 1.00 km/h to 14.00 km/h
2) ACCELERATION from 1 to 5

1: +1 sec (lower performing)

2: +0.5 sec
3: standard setting
4: -0.3 sec
3) INVERSION BRAKING from 1 to 5


2: +0.2 sec
3: standard setting
4: -0.3 sec
49
ELECTRICAL SYSTEM
SERVICE
4) RELEASE BRAKING from 1 to 5


2: +0.2 sec
3: standard setting
4: -0.3 sec
To change the 4 above parameters, proceed as follows:

a) Position the cursor, using the "SCROLL" keys, on the parameter to be changed
c) The value of the parameter will blink and you can now change the value with the "NUMERICAL" keys.
d) Press the "ENTER" key to confirm and return to the PROG. PIN CODE ACCESS screen
with the cursor positioned on the next row.
This procedure applies to all 104 access codes.
ACCESS CODE PROMPT SCREEN
Enter the 4-digit password using the "NUMERICAL" keys and press "ENTER" to confirm. If you enter the
wrong password, the screen shown below will appear for 5 seconds, after which the password prompt
screen will return.
50
SERVICE
ELECTRICAL SYSTEM
main menu 2 \ read user code

The READ USER CODE function enables displaying the last 24 USER codes that have used the machine, saving the start and end of work times.
Use the truck operating hours to calculate the start and end of work.
To be able to view the remaining USER CODES on the other pages, use the SCROLL buttons
main menu 2 \ clear access code

The CLEAR PIN CODE ACCESS function allows you to delete the access codes, user code reading and
profile settings in the PRG. PIN CODE ACCESS menu.
When this screen appears, pressing the direction buttons scrolls through the two possible options of NO
and YES. On confirming with the ENTER button, the saved codes are deleted and you are automatically
taken back to the MAIN MENU 2 screen.
51
SERVICE
ELECTRICAL SYSTEM
TRUCK FUNCTIONS
FORWARD/REVERSE TRACTION
CONTROLS
Brake pedal
Dead man pedal
Forward/reverse gear selection

button
Accelerator pedal
To perform forward traction press the gear selection button upwards and press the accelerator while
keeping the dead man pedal depressed.
To perform reverse traction press the gear selection button downwards and press the accelerator
while keeping the dead man pedal depressed.
The driving speed is adjusted by the potentiometer on the accelerator pedal both going forwards
and backwards.
Devices involved
Keyswitch
ON
Emergency switch
ON
Forward/reverse gear selection button
enabled
Dead man pedal
ON
Seat microswitch*
ON
Seat belts fastened sensor*
ON
Accelerator pedal
* where applicable
52
status
forward/reverse traction
Symbol on diagram
SERVICE
ELECTRICAL SYSTEM
CONFIGURATION PARAMETERS
cutback speed
cutback speed 2
pedal brk range
Config menu
set options
load brake
battery check
seatbelt
seat switch
seat sw.combi
ACE2 TRACTION
i min braking
i max braking
Config menu
adjustment
acceler. delay
release braking
tiller braking
invers. braking
decel. braking
pedal braking
speed limit brk.
curve speed 1
curve speed 2
max speed forw
max speed back
max speed limit
EPS
VMC
Main menu
parameter change
speed lim vs trac
For the adjustment values of each individual parameter, see the paragraph "standard
configuration of module parameters".
For a description of each individual parameter see "DESCRIPTION OF MODULE PARAMETERS".
The maximum traction speed and acceleration can be set via the programmer.
Maximum forward and backward traction speed setting
ACE2 TRACTION / main menu parameter change / max speed forw
ACE2 TRACTION / main menu parameter change / max speed back
Setting the acceleration
AC2 TRACTION / main menu parameter change / acceler. delay
53
ELECTRICAL SYSTEM
SERVICE
SPEED REDUCTION
There are two levels of speed reduction available on the machine.

cutback speed
first reduction in traction speed (7 km/h).

This trips when the height of the forks off the ground exceeds the free lift
(h2) or when the retractable carriage is fully out (the speed starts decreasing
when the carriage is over 100 mm out and falls in line with the movement of
the retractable carriage).
cutback speed 2
second reduction in traction speed (4 km/h).

This trips when the height of the forks off the ground exceeds 9 metres (applicable only with the fork encoder option).
Setting of the speed reduction levels

VMC / config menu adjustment / cutback speed
VMC / config menu adjustment / cutback speed 2
DECELERATION WITH STEERING TRACTION WHEEL
This function reduces the maximum traction speed in proportion to the increase in the steering angle. The
dead zone within which deceleration does not trigger is between 0 and 5.
Above 5 there is an initial slowdown (10 km/h) that remains steady if the steering angle is between 5
and 20. Above 20 a second deceleration triggers that increases as the steering angle increases. This
deceleration reaches a maximum of 6.5 km/h with the wheel turned 90.
maximum speed
with steering angle between 0 and 5 (nonsettable dead zone):

maximum speed
with steering angle between 5 and 20: settable deceleration with

the parameter curve
speed 1
Setting deceleration with steering wheel between 5 and 20

ACE2 TRACTION / menu parameter change / curve speed 1
Setting maximum deceleration with steering wheel 90
ACE2 TRACTION / menu parameter change / curve speed 2
54
with steering angle between 20 and 90: deceleration in proportion

to the steering angle
that can be set with the
parameter curve speed
2
SERVICE
ELECTRICAL SYSTEM
SPEED REDUCTIONS AND TRACTION BLOCK WITH CHECK UP NEEDED WARNING

When the programmed maintenance control is enabled, if it is not performed, depending on the parameter
values it is possible that the truck may first be subject to a reduction in speed and then to a traction block.
One can set what actions will occur to the truck via the programmer.
Setting the action that follows a maintenance warning.
VMC / main menu adjustment / check up type

0: no alarm

1: the alarm appears after 300 hours

2: the alarm appears after 300 hours and a reduction in speed takes
place after 340 hours

3: the alarm appears after 300 hours, a speed reduction takes place
after 340 hours and the traction is blocked after 380 hours
Once the programmed maintenance is performed, to reset the "check up needed" warming, one must set
the parameter:
Reset the hourmeter of the maintenance hours
VMC / main menu adjustment / check up done
ON
SPEED REDUCTIONS AND BRAKING

When the truck speed is reduced this causes a gradual deceleration of the truck through a braking process
that can be set by the programmer.
Setting the deceleration slope for speed reduction
ACE2 TRACTION / menu parameter change / speed limit brk
DECELERATION WITH LOW BATTERY

When the level of the battery charge drops below 20% the traction speed is reduced to 24% of the maximum
speed. To restore initial operating conditions of the traction motor the battery must be recharged.
When the charge reaches 40% the low battery indicator is reset and the maximum current is restored on
the traction motor.
It is possible to set the behaviour of the truck with a flat battery.
Setting truck behaviour with a flat battery
VMC / config menu set options / battery check
0: no action
1: the BATTERY LOW alarm appears, the speed
is reduced to 24% of the maximum speed, the
maximum current on the motor is reduced by 50%
2: the BATTERY LOW alarm appears, no other
action
3: the BATTERY LOW alarm appears, the speed
is reduced to 24% of the maximum speed, fork lifting block is enabled
55
ELECTRICAL SYSTEM
SERVICE
TRACTION BLOCKS
Traction is disabled if the seated operator microswitch (optional) and the fastened seat belt sensor (optional) are not active and if you fail to observe the sequence of operator seated seat belt fastened.
it is possible to enable/disable the seated operator microswitch, the fastened seat belt sensor and the
correct sequence check via the programmer.
Enabling/disabling seat microswitch
VMC / config menu set options / seat switch
Enabling/disabling seat belts fastened sensor
VMC / config menu set options / seatbelt
Enabling/disabling correct sequence check
VMC / config menu set options / seat sw.combi
56
SERVICE
ELECTRICAL SYSTEM
BRAKING
The truck is equipped with four braking systems:

Release braking.
Braking on direction reversal.
Emergency braking.
Parking brake
Tall machines are fitted with electromagnetic brakes on the load wheels that can be operated with the brake
pedal for safer braking.
Truck braking will be performed in different ways according to which of the above systems is implemented. For
further information on the braking systems see "BRAKING SYSTEMS" BRAKING SYSTEM section.
BRAKING SYSTEMS
WHEN APPLIED
Release braking
Traction control accelerator pedal release
Partial release braking
Traction control accelerator pedal partial release
Braking on direction reversal
Inversion of the direction of travel using the gear selection button

Through operation of the emergency button
Emergency braking
Dead man pedal release

an alarm has been generated that requires traction to be halted immediately
Parking brake
The machine is stationary and no traction control is activated
Pedal brake
Brake pedal pressure
It is possible to set the deceleration ramp of the various braking methods using the programmer.
Setting the deceleration ramp for release braking
ACE2 TRACTION / menu parameter change / release braking
Setting the partial release braking deceleration ramp
ACE2 TRACTION / menu parameter change / decel. braking
Setting the deceleration ramp for direction reversal braking
ACE2 TRACTION / menu parameter change / invers. braking
Setting the deceleration ramp for emergency braking
ACE2 TRACTION / menu parameter change / tiller braking
Setting the deceleration ramp for pedal braking
ACE2 TRACTION / menu parameter change / pedal braking
57
ELECTRICAL SYSTEM
SERVICE
STEERING
CONTROLS
To steer to the right or to the left rotate the steering handwheel in the corresponding direction.
Devices involved
Keyswitch
ON
Emergency switch
ON
Steering centring sensor

58
status
Traction wheel autocentring sequence performed

rotation right/left
Symbol on diagram
SERVICE
ELECTRICAL SYSTEM
EPS
ACE2
TRACTION
Main menu
Config menu
Config menu
parameter change special adjustment hardware settings
Config menu
set options
Config menu
adjustment
curve speed 1
curve speed 2
-
speed limit
sensitivity
sensitive vs trc
speed lim vs trc
debug output
autoteaching
aux output #1
aux output #2
set steer 0-pos
The truck is equipped with a multi-turn steering system with a "stepper motor".
When switching on the key switch (S1), by means of the steering centring sensor (B7), the software autocentres the traction wheel.
59
ELECTRICAL SYSTEM
SERVICE
STEERING
When a steering angle of 5 is exceeded the maximum traction speed is reduced.
STEERING SYSTEM CONFIGURATION
The steering motor rotation speed is inversely proportional to the traction speed, as the speed increases
the steering unit reaches the steering angle at an increasing speed.
It is possible to set the steering sensitivity reduction by reducing the steering speed at a given traction
speed for slow or fast steers.
Setting the steering motor speed reduction as the traction speed increases for slow rotation of the steering
handwheel
EPS ACW / menu parameter change / sensitive vs trc
Setting the steering motor speed reduction to the maximum traction speed for fast rotation of the steering
handwheel
EPS ACW / menu parameter change / speed lim vs trc
It is possible to set the speed of rotation of the steering motor according to the speed of rotation of the
handwheel (fast rotation and sensitivity with slow rotation)
Setting decrease in steering motor speed while reaching the position controlled by the steering system
EPS ACW / main menu parameter change / speed limit
Setting steering sensitivity
EPS ACW / main menu parameter change / sensitivity
60
SERVICE
ELECTRICAL SYSTEM
FORK LIFTING/LOWERING
CONTROLS
Standard
Joystick
Standard Version: to raise the forks, pull up the fork lifting/lowering lever, and to lower the forks,
push down the fork lifting/lowering lever.
Joystick Version: to raise the forks, pull the joystick backward, and to lower the forks, push the
joystick forward.
Devices involved
status
Keyswitch
ON
Emergency switch
ON
Abbreviation
Lever backward/forward
Fork lifting/lowering request
Joystick backward/forward
61
SERVICE
ELECTRICAL SYSTEM
Main menu
parameter change
VMC
accel delay lift

decel delay lift
max lft sp limit
max low sp limit
i min evp1
evp1 opn delay 1
evp1 opn delay 2
evp1 cls delay 1
evp1 cls delay 2
evp2 open delay
evp2 close delay
Config menu
adjustment
mlm deadband
mlm deadband end
joy. deadband
joy. deadb. end
offset fork
lift limit blk m
lift limit blk cm
ctb rng lift lmt
ctb spd lift lmt
low soft rng sp
lower soft speed
lft range ffl ml
lft slow ffl ml
low range ffl ml
low slow ffl ml
lft blk1 hght m
lft blk1 hght cm
lft blk2 hght m
lft blk2 hght cm
height p lft ctb
height p lft ctb r
height p low ctb
height p low ctb r
offset pick
offset place
Config menu
set options
height indicator
slow spd ffl ml
lift limit stop
lower soft stop
1 lift block
2 lift block
interlock forks
interl. frk ovrd
battery check
enc. lock test
height selector
The maximum fork lifting and lowering speed can be set with the programmer.
Setting the maximum fork lifting speed.
VMC / main menu parameter change / max lft sp limit
Setting the maximum fork lowering speed
VMC / main menu parameter change / max low sp limit
62
SERVICE
ELECTRICAL SYSTEM
ACCELERATION / DECELERATION RAMPS

On operating the lifting lever, the forks begin to rise with an acceleration ramp that can be set via the programmer.
Setting the fork lift acceleration ramp
VMC / main menu parameter change / accel delay lift
On releasing the lifting lever, the forks begin to stop with a deceleration ramp that can be set via the programmer.
Setting the lever release deceleration ramp
VMC / main menu parameter change / decel delay lift
LIMIT STOP SLOWDOWN lifting / LOWERING

We need to distinguish between two cases:
There is no fork height encoder
There is a fork height encoder (optional)
If there is no fork height encoder, the forks undergo no deceleration before reaching the maximum height
in the lifting phase nor the limit stop in the lowering phase.
WITH FORK HEIGHT ENCODER (OPTIONAL)

In the phase of lifting and lowering, the forks start slowing down in the transition between the free lift limit
stop and main lifting.
With the programmer it is possible to set the speed of deceleration and the distance off the ground where
the forks start slowing down.
Setting lifting speed
VMC / config menu adjustment / lft slow ffl ml
Setting deceleration distance when lifting
VMC / config menu adjustment / lft range ffl ml
Setting lowering speed
VMC / config menu adjustment / low slow ffl ml
Setting deceleration distance when lowering
VMC / config menu adjustment / low range ffl ml
These parameters are only considered by the software if the VMC / config menu set options
/ height indicator and slow spd ffl ml parameters are set to PRESENT
63
ELECTRICAL SYSTEM
SERVICE
The forks start slowing down before reaching the maximum lifting height.
With the programmer it is possible to set the reduction in lifting speed and the distance where the forks
start slowing down.
Setting reduction in lifting speed
VMC / config menu adjustment / ctb spd lift lmt
Setting deceleration distance
VMC / config menu adjustment / ctb rng lift lmt
The maximum fork height is indicated in the VMC / config menu adjustment / lift limit blk
m and lift limit blk cm parameters according to the formula (lift limit blk m)x100 + (lift
limit blk cm).
The forks start slowing down before reaching the lowering limit stop.
With the programmer it is possible to set the speed of deceleration and the distance off the ground where
the forks start slowing down.
Setting deceleration speed
VMC / config menu adjustment / lower soft speed
Setting deceleration distance
VMC / config menu adjustment / low soft rng sp
FORK LIFTING/LOWERING BLOCKS (WITH FORK HEIGHT ENCODER)

There are two lifting blocks that can be set with the programmer.
Setting the maximum fork height of the first block
VMC / config menu adjustment / lft blk 1 hght m
VMC / config menu adjustment / lft blk 1 hght cm
Setting the maximum fork height of the second block
VMC / config menu adjustment / lft blk 2 hght m
VMC / config menu adjustment / lft blk 2 hght cm
The height is calculated according to the formula (lft blk 1 hght m)x100 + (lft blk 1 hght
cm).
64
SERVICE
ELECTRICAL SYSTEM
HYDRAULIC FUNCTIONS
CONTROLS
Standard
Joystick
Standard Version: to perform one of the hydraulic functions, pull/push the corresponding lever.
Joystick Version: to perform the carriage out function, move the joystick to the right, and to close
the carriage, move the joystick to the left. For the fork tilt function, move the mini-joystick up/down,
and for the fork side shift function, move the mini-joystick to the right/left.
Devices involved
status
Keyswitch
ON
Emergency switch
ON
Abbreviation
Lever backward/forward
Hydraulic request
Joystick right/left
Mini-joystick up/down - right/
left
65
SERVICE
ELECTRICAL SYSTEM
VMC
Main menu
parameter change
acc. delay reach
dec. delay reach
reach fw max spd
reach rv max spd
accel delay aux
decel delay aux
opt hyd max spd
evp3 open delay
evp3 close delay
evp4 open delay
evp4 close delay
evp5 open delay
evp5 close delay
evp6 open delay
evp6 close delay
Config menu
adjustment
mlm deadband
mlm deadband end
joy. deadband
joy. deadb. end
reach full fwd
reach full back
reach rng ctb ff
reach rng ctb fb
reach ctb speed
reach ctb speedm
Config menu
set options
autoc. sideshift
autoc. tilt
5th way hydraul.
extended multif.
RETRACTABLE CARRIAGE ACCELERATION / DECELERATION RAMPS

On operating the carriage out/return lever, the carriage begins to move with an acceleration ramp that can
be set via the programmer.
Setting the carriage out/return acceleration ramp
VMC / main menu parameter change / acc. delay reach
On releasing the carriage out/return lever, the carriage begins to stop with a deceleration ramp that can be
set via the programmer.
VMC / main menu parameter change / dec. delay reach
The maximum carriage out and return speed can be set with the programmer.
Setting the maximum carriage out speed
VMC / main menu parameter change / reach fw max spd
Setting the maximum carriage return speed
VMC / main menu parameter change / reach rv max spd
66
SERVICE
ELECTRICAL SYSTEM
CARRIAGE OUT / RETURN LIMIT STOP SLOWDOWN

In the out and return phase the carriage starts slowing down before reaching the limit stop.
With the programmer it is possible to set the speed of the carriage and the distance where it starts slowing
down.
Setting the carriage out/return speed
VMC / config menu adjustment / reach ctb speed
Setting out deceleration distance
VMC / config menu adjustment / reach rng ctb ff
Setting return deceleration distance
VMC / config menu adjustment / reach rng ctb fb
AUXILIARY FUNCTIONS ACCELERATION / DECELERATION RAMPS

On operating the lever of an auxiliary function (fork tilting or side shifting), the forks begin to move with an
acceleration ramp that can be set via the programmer.
Setting the auxiliary function acceleration ramp
VMC / main menu parameter change / accel delay aux
On releasing the lever of an auxiliary function (fork tilting or side shifting), the forks begin to stop with a
deceleration ramp that can be set via the programmer.
VMC / main menu parameter change / decel delay aux
FORK SELF-CENTRING
On pressing the button for the desired self-centring (side shifting, tilting), the forks begin to carry out the
desired self-centring procedure.
With the programmer it is possible to enable/disable these options.
Enabling fork side shift self-centring
VMC / config menu set options / autoc. sideshift
Enabling fork tilt self-centring
VMC / config menu set options / autoc. tilt
67
ELECTRICAL SYSTEM
SERVICE
CONFIGURATION PARAMETER ACCESS PROCEDURE

Thanks to the CAN BUS connection the module parameters can be configured by connecting the console
to the connector in the control panel and accessing the relative menu.
Before connecting the console to the module, turn the keyswitch to OFF.
Each module is identified by a number. Thanks to the CAN BUS connection it is possible to configure the
parameters of the various modules by connecting the console and then searching for the relevant module
via the SET MODEL menu.
Before using the console to select the number of the module to configure, make sure that
the model type option of the control to which it is connected is on 0.
MODULE
MODULE NUMBER
MODEL TYPE
VMC
ACE2 TRACTION
ACE2 PUMP
EPS ACW
MENU SEARCH PROCEDURE and parameter modification
EPSWSM 1Q
24V
50A
NA4.98
00000
Opening heading
Press the Roll h and Set h buttons simultaneously
*CONFIG. MENU*
SET MODEL
The SET MODEL menu heading appears. If another

menu is displayed, press the Roll h or Roll i
buttons until the SET MODEL menu appears.
Press Enter
68
SERVICE
ELECTRICAL SYSTEM
CONNECTED TO
6
The number corresponding to the module you are

connected to appears
Press the Set h or Set i buttons to edit the

selection of the module you wish to connect to
CONNECTED TO
2
The new selected module appears
Press the Roll h button to check the model

type
MODEL TYPE
1
The model type appears
Press the Set h or Set i buttons to scroll

through the model type to value 0.
MODEL TYPE
0
The model type of the selected module appears
Press the key "Out" to exit the selection.
ARE YOU SURE?

YES=ENTER
NO=OUT
The modification confirmation request appears
Press the Enter button to confirm. If one doesn't

want to confirm the choice press the "Out"key.
69
ELECTRICAL SYSTEM
*CONFIG. MENU*
SET MODEL
SERVICE
Having pressed the enter key the heading of the

SET MODEL menu appears.
Simultaneously press Roll i, Out and Set i
CONNECTED TO
ACE2 TRACTION
NA----
ACE2 TRACTION
NA-.--
1V
1A
0h
The display shows the connection to the selected

module for a moment
The selected module screen appears; here you can

configure the different parameters
Press the Roll h and Set h buttons simultaneously
*CONFIG. MENU*
SET MODEL
The SET MODEL menu heading appears.
Press the Roll h or Roll i button until the desired menu appears.
*CONFIG. MENU*
SET OPTION
The SET OPTION menu heading appears.
Press Enter
70
SERVICE
ELECTRICAL SYSTEM
HOUR COUNTER
RUNNING
The heading of the first parameter with its current

value appears. To scroll through the parameters
press Roll h or Roll i
Press the Set h or Set i buttons to modify the

value.
HOUR COUNTER
KEY ON
The new value appears.
ARE YOU SURE?

YES=ENTER NO=OUT

*CONFIG. MENU*
SET OPTION
After having pressed the enter key the heading of

the SET OPTION menu reappears.
Press the "Out" key to return to the opening heading
EPSWSM 1Q
24V
50A
NA4.98
00000
Opening heading
71
ELECTRICAL SYSTEM
EPSWSM 1Q
24V
50A
NA4.98
00000
SERVICE
Opening heading
Press the "Enter"key to enter the main menu
*MAIN MENU*
PARAMETER CHANGE
The PARAMETER CHANGE menu heading appears. If another menu is displayed, press the
Roll h or Roll i buttons until the PARAMETER
CHANGE menu appears.
Press Enter
ACCELER. DELAY
LEVEL = 2.6
The heading of the first parameter with its current

value appears. To scroll through the parameters
press Roll h or Roll i
Press the Set h or Set i buttons to modify the
value.
ACCELER. DELAY
LEVEL = 3.0
The new value appears.
ARE YOU SURE?

YES=ENTER NO=OUT

72
SERVICE
ELECTRICAL SYSTEM
STANDARD CONFIGURATION OF MODULE PARAMETERS

It is advisable to retain the factory settings seeing as they have been designed to achieve
the best compromise between performance and part wear and tear. It is however possible
to customise the performance to suit the customer's requirements, the characteristics of
the warehouse and the materials to be moved, but no parameters must be changed if this
jeopardises the safety of the truck.
VCM MODULE
VCM / main menu parameter change /
VCM / config menu special adjustment /
VCM / config menu hardware setting /
VCM / config menu set options /
VCM / config menu adjustment /
MAIN MENU PARAMETER CHANGE
PARAMETER
level
PARAMETER
level
ACCEL DELAY LIFT
0.7
EVP5 OPEN DELAY
0.5
DECEL DELAY LIFT
0.5
EVP5 CLOSE DELAY
0.5
MAX LOW SP LIMIT
0.55 m/s
EVP6 OPEN DELAY
0.5
ACC. DELAY REACH
0.5
EVP6 CLOSE DELAY
0.5
DEC. DELAY REACH
0.5
REACH FW MAX SPD
35 Hz
REACH RV MAX SPD
22 Hz
ACCEL DELAY AUX
0.1
PARAMETER
level
DECEL DELAY AUX
0.1
PRESENT
OPT HYD MAX SPD
25 Hz
PREMIUM DISPLAY
I MIN EVP1
20%
I MIN BRAKING
25.1%
I MAX BRAKING
100%
EVP1 OPN DELAY 1
0.1
EVP1 OPN DELAY 2
0.6
EVP1 CLS DELAY 1
0.3
EVP1 CLS DELAY 2
0.6
EVP2 OPEN DELAY
0.8
EVP2 CLOSE DELAY
0.7
EVP3 OPEN DELAY
EVP3 CLOSE DELAY
EVP4 OPEN DELAY
EVP4 CLOSE DELAY
CONFIG MENU Special Adjustment
CONFIG MENU Hardware Setting

PARAMETER
level
SET CONFIGURAT
73
ELECTRICAL SYSTEM
CONFIG MENU Set Option
74
SERVICE
CONFIG MENU Adjustment
PARAMETER
level
PARAMETER
level
HOUR COUNTER
RUNNING
MLM DEADBAND
0%
BACKUP ALRM MODE
LEVEL = 0
MLM DEADBAND END
0%
HEIGHT INDICATOR
ABSENT
JOY. DEADBAND
19%
SLOW SPD FFL ML
ABSENT
JOY. DEADB. END
18%
LIFT LIMIT STOP
ABSENT
OFFSET FORK
350
LOWER SOFT STOP
ABSENT
LIFT LIMIT BLK M
AUTOC.SIDESHIFT
ABSENT
LFT LIMIT BLK CM
95
AUTOC.TILT
ABSENT
CTB RNG LIFT LMT
500
WEIGHT
ABSENT
CTB SPD LIFT LMT
0.20 m/s
LASER
ABSENT
LOW SOFT RNG SP
550
LOAD BRAKE
ABSENT
LOWER SOFT SPEED
0.08 m/s
5TH WAY HYDRAUL.
ABSENT
LFT RANGE FFL ML
500
PIN ACCESS CODE
ABSENT
LFT SLOW FFL ML
0.40 m/s
SEATBELT
ABSENT
LOW RANGE FFL ML
250
SEAT SWITCH
ABSENT
LOW SLOW FFL ML
0.32 m/s
SEAT SW.COMBI
ABSENT
CUTBACK SPEED
7.0 km/h
1 LIFT BLOCK
ABSENT
CUTBACK SPEED 2
4.0 km/h
2 LIFT BLOCK
ABSENT
LFT BLK1 HGHT M
INTERLOCK FORKS
ABSENT
LFT BLK1 HGHT CM
INTERL. FRK OVRD
ABSENT
LFT BLK2 HGHT M
BATTERY CHECK
LEVEL = 3
LFT BLK2 HGHT CM
50
TRANSFER HOURS
LEVEL = 0
REACH FULL FWD
3.7 V
EXTENDED MULTIF.
ABSENT
REACH FULL BACK
0.5 V
ENC. LOCK TEST
PRESENT
REACH RNG CTB FF
10.2%
HEIGHT SELECTOR
ABSENT
REACH RNG CTB FB
20%
PALLET SENSOR
ABSENT
REACH CTB SPEED
14.9%
NEV1
ABSENT
REACH CTB SPEEDM
50.2%
CHECK UP DONE
ABSENT
MAX WGT CELL
4.4 V
CHECK UP TYPE
NONE
MIN WGT CELL
0.0 V
PEDAL BRK RANGE
50.2%
ADJUST BATTERY
49.58 V
BAT. MIN ADJ.
LEVEL = 2
BAT. MAX ADJ.
LEVEL = 1
WATCH HOURS
WATCH MINUTES
SERVICE
ELECTRICAL SYSTEM
CONFIG MENU Adjustment

PARAMETER
level
WATCH MINUTES
HEIGHT P LFT CTB
0.07
HEIGHT P LFT CTB R
350
HEIGHT P LOW CTB
0.08
HEIGHT P LOW CTB R
350
OFFSET PICK
100
OFFSET PLACE
100

ACE2 TRACTION / main menu parameter change /
ACE2 TRACTION / config menu set options /
config menu set options

PARAMETER
level
PARAMETER
level
ACCELER. DELAY
2.6
HOUR COUNTER
RUNNING
RELEASE BRAKING
2.2
M.C. FUNCTION
ON
TILLER BRAKING
2.2
AUX OUT FUNCT.1
PRESENT
INVERS. BRAKING
1.9
AUX OUT FUNCT.2
PRESENT
DECEL. BRAKING
PULSE DIR INPUT
OPTION #1
PEDAL BRAKING
0.3
SPEED LIMIT BRK.
2.8
CURVE SPEED 1
10.0 km/h
CURVE SPEED 2
6.5 km/h
MAX SPEED FORW
5.0 km/h
MAX SPEED BACK
5.0 km/h
MAX SPEED LIMIT
5.0 km/h
ACCEL DISPLAY
2.6
MAX SPEED DISP
5.0 km/h
REL BRK DISPLAY
2.2
INV BRK DISPLAY
1.9
75
ELECTRICAL SYSTEM
SERVICE
ACE2 PUMP MODULE

ACE2 PUMP / config menu set option /
config menu set option
PARAMETER
level
M.C. FUNCTION
ON
AUX OUT FUNCT.1
ABSENT
AUX OUT FUNCT.2
ABSENT
EPS ACW MODULE

EPS ACW / main menu parameter change /
EPS ACW / config menu special adjustment /
EPS ACW / config menu hardware setting /
EPS ACW / config menu set option /
EPS ACW / config menu adjustments /
main menu parameter change
config menu adjustments
PARAMETER
level
PARAMETER
level
SPEED LIMIT
LEVEL = 6
SET STEER 0-POS.
2500 mV
SENSITIVITY
LEVEL = 3
SENSITIVE VS TRC
40%
SPEED LIM VS TRC
50%
config menu special adjustment

PARAMETER
level
DEBUG OUTPUT
15
config menu hardware setting

PARAMETER
level
AUTOTEACHING
OFF
76
PARAMETER
level
AUX OUTPUT #1
ABSENT
AUX OUTPUT #2
ABSENT
SERVICE
ELECTRICAL SYSTEM
DESCRIPTION OF MODULE PARAMETERS

VCM MODULE 1
VCM / main menu parameter change /
VCM / config menu special adjustment /
VCM / config menu hardware setting /
VCM / config menu set options /
VCM/ config menu adjustment /

PARAMETER
level = 0
level = 9
ACCEL DELAY LIFT

Seconds. Determines the acceleration ramp during a lifting function. This parameter sets the time needed to
accelerate the pump motor from 0Hz to 100Hz
DECEL DELAY LIFT
Seconds. Determines the deceleration ramp when the lifting control has been lowered or not completely released.
This parameter sets the time needed to decelerate the pump motor from 100Hz to 0Hz
MAX LFT SP LIMIT
Defines the maximum lifting speed in m/s
MAX LOW SP LIMIT
Defines the maximum lowering speed in m/s
ACC. DELAY REACH
Seconds. Determines the acceleration ramp during a retractable function. This parameter sets the time needed to
accelerate the pump motor from 0Hz to 100Hz
DEC. DELAY REACH
Seconds. Controls the deceleration ramp when the retractable control has been lowered or not completely released.
This parameter sets the time needed to decelerate the pump motor from 100Hz to 0Hz
REACH FW MAX SPD
Defines the maximum speed of the pump motor during a retractable carriage out function
REACH RV MAX SPD
Defines the maximum speed of the pump motor during a retractable carriage in function
ACCEL DELAY AUX
Seconds. Determines the acceleration ramp during an auxiliary function (tilting or side shifting). This parameter sets
the time needed to accelerate the pump motor from 0Hz to 100Hz
DECEL DELAY AUX
Seconds. Controls the deceleration ramp when the auxiliary function control (tilting or side shifting) has been
lowered. This parameter sets the time needed to decelerate the pump motor from 100Hz to 0Hz
77
SERVICE
ELECTRICAL SYSTEM

PARAMETER
level = 0
level = 9
OPT HYD MAX SPD

Defines the maximum speed of the pump motor during the optional hydraulic 5th function
I MIN EVP1
From 0 to 100. This parameter determines the minimum current applied on EVP1 when the position of the control
is at the minimum (lowering)
I MIN BRAKING
From 0 to 100. This parameter determines the maximum current applied to the load wheel brakes when the position
of the control is at the minimum
I MAX BRAKING
From 0 to 100. This parameter determines the maximum current applied to the load wheel brakes when the position
of the control is at the maximum
EVP1 OPN DELAY 1
Seconds. Determines the acceleration ramp on EVP1.
EVP1 OPN DELAY 2
EVP1 CLS DELAY 1
Seconds. Determines the deceleration ramp on EVP1.
EVP1 CLS DELAY 2
EVP2 OPEN DELAY
EVP2 CLOSE DELAY
EVP3 OPEN DELAY
EVP3 CLOSE DELAY
78
SERVICE
ELECTRICAL SYSTEM

PARAMETER
level = 0
level = 9
level = 0
level = 9
level = 0
level = 9
EVP4 OPEN DELAY

EVP4 CLOSE DELAY
EVP5 OPEN DELAY
EVP5 CLOSE DELAY
EVP6 OPEN DELAY
EVP6 CLOSE DELAY

LEVEL 4
PREMIUM DISPLAY
This must be set to PRESENT if the optional premium display is installed

LEVEL 4
SET CONFIGURAT
1: with the NO CFG MASTER alarm it copies the EEPROM of the traction device to VCM
2: with the WRONG CONFIG alarm it copies from VCM to the traction device
3: with the WRONG CONFIG alarm it copies from the traction device to VCM
79
SERVICE
ELECTRICAL SYSTEM
CONFIG MENU set options

PARAMETER
level
KEY ON: record of truck start up
HOUR COUNTER
RUNNING: record of an active traction request
Select the hourmeter mode

BACKUP ALRM MODE
LEVEL 0: Backup alarm disabled- LEVEL 1: the backup alarm is activated when the truck moves in reverse driveLEVEL2: the backup alarm is activated when the truck moves in forward drive LEVEL3: Backup alarm activated
when the truck moves in either forward or reverse drive
HEIGHT INDICATOR
This parameter enables the fork height indicator. When set to ON, the height encoder is managed by the VCM and
the fork height is shown on the display
SLOW SPD FFL ML
If set to PRESENT with HEIGHT INDICATOR, the lifting and lowering speed is automatically decreased in the
transition from FREE LIFT to MAIN LIFT
LIFT LIMIT STOP
If set to PRESENT with HEIGHT INDICATOR it enables blocking lifting at the maximum height
LOWER SOFT STOP
If set to PRESENT with HEIGHT INDICATOR the lowering speed is decreased before reaching the ground
AUTOC.SIDESHIFT
This parameter enables the side-shift self-centring option
AUTOC.TILT
This parameter enables the tilt self-centring option
WEIGHT
This parameter enables the weighing option
LASER
If set to PRESENT with HEIGHT INDICATOR the Laser is automatically activated on the FREE LIFT zone
LOAD BRAKE
This parameter enables the brakes of the load wheel
5TH WAY HYDRAUL.
This parameter enables the hydraulic 5th function
PIN ACCESS CODE
If set to PRESENT, a password will be required to enable the truck functions
80
SERVICE
ELECTRICAL SYSTEM

LEVEL 4
level = 0
level = 9
SEATBELT
This parameter enables the seat belt presence switch
SEAT SWITCH
This parameter enables the seat presence switch
SEAT SW.COMBI
This parameter enables the sequence of the seat switch and then the seat belt switch
1 LIFT BLOCK
If set to PRESENT with HEIGHT INDICATOR it enables the first intermediate block
2 LIFT BLOCK
If set to PRESENT with HEIGHT INDICATOR and option 1 LIFT BLOCK it enables the second intermediate block
INTERLOCK FORKS
If set to PRESENT with HEIGHT INDICATOR it enables stopping fork lowering at a height of 600mm
INTERL. FRK OVRD
If set to PRESENT it is possible to by-pass the fork interlock with the override button
BATTERY CHECK
The battery charge level is checked:
0: no action
1: the BATTERY LOW alarm appears, the speed is reduced to 24% of the maximum speed, the maximum
current on the motor is reduced by 50%
2: the BATTERY LOW alarm appears, no other action
3: the BATTERY LOW alarm appears, the speed is reduced to 24% of the maximum speed, fork lifting
block is enabled
TRANSFER HOURS
LEVEL 1= if there is any discrepancy between the traction hour meter and VCM, an alarm is signalled and the value
on the traction is saved in the VCM
LEVEL 2= if there is any discrepancy between the traction hour meter and VCM, an alarm is signalled and the value
in the VCM is saved in the traction
EXTENDED MULTIF.
If set to PRESENT, three combined functions are permitted
ENC. LOCK TEST
Enables the diagnosis of encoder locked for encoder 1 and encoder 2. If the encoder is locked, an alarm is
generated and the pump stops
81
SERVICE
ELECTRICAL SYSTEM

LEVEL 4
level = 0
level = 9
NEV1
Enables output No.1 of the voltage that controls the battery block relay
ON =programmed maintenance
performed
CHECK UP DONE
OFF = programmed maintenance

not performed
Maintenance programme performed when enabled. When set to ON at the end of the maintenance it resets the
maintenance hourmeter and the CHECK UP NEEDED warning
0: disabled
1: alarm after 300 hours
2: like 1 plus speed reduction after
340 hours
3: like 2 plus truck block after 380
hours
CHECK UP TYPE
Enables/disables the programmed maintenance mode and warning . At the end of maintenance set the parameter
VMC / config menu set options / check up done ON
HEIGHT SELECTOR
If set to PRESENT with HEIGHT INDICATOR the operator can control up to 40 levels for picking up and positioning
the load
PALLET SENSOR
When set to PRESENT with the height pre-selector, pallet presence is checked
config menu adjustment

LEVEL 4
level = 0
level = 9
MLM DEADBAND
Determines an unused band in the set point value of the mini-lever in the zero position
MLM DEADBAND END
Determines an unused band in the set point value of the mini-lever in the final position
JOY. DEADBAND
Determines an unused band in the set point value of the joystick in the zero position
JOY. DEADB. END
Determines an unused band in the set point value of the joystick in the final position
OFFSET FORK
This parameter defines the height of the forks off the ground when the encoder reset sensor is OFF just after the
cam
82
SERVICE
ELECTRICAL SYSTEM

LEVEL 4
level = 0
level = 9
LIFT LIMIT BLK M

This parameter defines the maximum height of the forks off the ground in metres, where the lifting block is applied.
The limit is defined by the formula LIFT LIMIT BLK M + LIFT LIMIT BLK CM
LFT LIMIT BLK CM
This parameter defines the centimetres to add to LIFT LIMIT BLK M to define the maximum height of the forks off
the ground, where the lifting block is applied
CTB RNG LIFT LMT
Defines the distance from the LIFT LIMIT BLOCK height where the speed starts to be reduced
CTB SPD LIFT LMT
Defines the lifting speed reduction before the LIFT LIMIT BLOCK
LOW SOFT RNG SP
Defines the height off the ground where the lowering speed is set to LOW SOFT SPEED, if the LOW SOFT STOP
and HEIGHT INDICATOR options are activated
LOWER SOFT SPEED
Defines the lowering speed, when the LOW SPEED SOFT option is activated
LFT RANGE FFL ML
Defines the height of the forks off the ground, within which the lifting speed is reduced to LFT SLOW FFL ML in
the transition from FREE LIFT to MAIN LIFT, when the SLOW SPD FFL ML and HEIGHT INDICATOR options are
activated.
LFT SLOW FFL ML
Defines the lifting speed, when SLOW SPD FFL ML is activated
LOW RANGE FFL ML
Defines the height of the forks off the ground, within which the lowering speed is reduced to LOW SLOW FFL ML
in the transition from MAIN LIFT to FREE LIFT, when the SLOW SPD FFL ML and HEIGHT INDICATOR options
are activated.
LOW SLOW FFL ML
Defines the lowering speed in LOW RANGE FFL ML, when SLOW SPD FFL ML is activated
CUTBACK SPEED
Defines the first traction speed reduction.
CUTBACK SPEED 2
Defines the second traction speed reduction.
LFT BLK1 HGHT M
This parameter defines the maximum height of the forks off the ground in metres, where the lifting block 1 is applied.
The limit is defined by the formula LIFT BLK1 M + LIFT BLK1 CM
83
SERVICE
ELECTRICAL SYSTEM

LEVEL 4
level = 0
level = 9
LFT BLK1 HGHT CM

This parameter defines the centimetres to add to LIFT BLK1 M to determine the height of the forks off the ground,
where the lifting block 1 is applied
LFT BLK2 HGHT M
This parameter defines the maximum height of the forks off the ground in metres, where the lifting block 2 is applied.
The limit is defined by the formula LIFT BLK2 M + LIFT BLK2 CM
LFT BLK2 HGHT CM
This parameter defines the centimetres to add to LIFT BLK2 M to determine the height of the forks off the ground,
where the lifting block 2 is applied
REACH FULL FWD
Value of the position sensor when the retractable carriage is in the fully out position
REACH FULL BACK
Value of the position sensor when the retractable carriage is in the fully in position
REACH RNG CTB FF
Defines the distance from the fully out position where REACH CTB SPEED is applied
REACH RNG CTB FB
Defines the distance from the fully in position where REACH CTB SPEED is applied
REACH CTB SPEED
Defines the retractable speed when speed reduction is applied
REACH CTB SPEEDM
Defines the retractable speed when speed reduction is applied during a combined function
MAX WGT CELL
Defines the maximum weight with the nominal load on the forks
MIN WGT CELL
Defines the maximum weight without the nominal load on the forks (0kg)
PEDAL BRK RANGE
Defines the value of the brake potentiometer at which VCM starts up to control the load wheel brakes
ADJUST BATTERY
Correct adjustment of the battery voltage measured by the control device
BAT. MIN ADJ.
Adjusts the lower level of the battery discharge table. It is used to calibrate the discharge algorithm with the
battery of the application.
84
SERVICE
ELECTRICAL SYSTEM

LEVEL 4
level = 0
level = 9
BAT. MAX ADJ.

Adjusts the upper level of the battery discharge table. It is used to calibrate the discharge algorithm with the battery
of the application.
WATCH HOURS
Used to set the hour of the Real Time Clock
WATCH MINUTES
Used to set the minutes of the Real Time Clock
HEIGHT P LFT CTB
In PRESELECTOR mode, it defines the final lifting speed when the desired height is reached
HEIGHT P LFT CTB R
In PRESELECTOR mode, it defines the distance from the final height where HEGHT P LFT CTB is applied
HEIGHT P LOW CTB
In PRESELECTOR mode, it defines the final lowering when the desired height is reached
HEIGHT P LOW CTB R
In PRESELECTOR mode, it defines the distance from the final height where HEGHT P LOW CTB is applied
OFFSET PICK
In PRESELECTOR mode, it defines the offset to add to the desired final height during a pick-up operation
OFFSET PLACE
In PRESELECTOR mode, it defines the offset to add to the desired final height during a placement operation
85
ELECTRICAL SYSTEM
SERVICE

ACE2 TRACTION / main menu parameter change /
ACE2 TRACTION / config menu set options /
PARAMETER
level
ACCELER. DELAY
traction acceleration slope
RELEASE BRAKING
Release braking deceleration ramp
TILLER BRAKING
Deceleration ramp for emergency braking
INVERS. BRAKING
Direction reversal braking deceleration ramp
DECEL. BRAKING
Deceleration ramp with mini-lever released but not completely (partial release braking)
PEDAL BRAKING
Pedal braking deceleration ramp
SPEED LIMIT BRK.
Deceleration ramp when a speed limit is active
CURVE SPEED 1
Maximum traction speed when there is a speed reduction with the wheel turned more than between 5 and 20
CURVE SPEED 2
Maximum traction speed with wheel turned 90
MAX SPEED FORW
Maximum forward traction speed
MAX SPEED BACK
Maximum backward traction speed
MAX SPEED LIMIT
Maximum settable speed
86
SERVICE
ELECTRICAL SYSTEM

PARAMETER
level
ACCEL. DISPLAY
Maximum traction acceleration ramp that can be set with the display
MAX SPEED DISP
Maximum speed that can be set with the display
REL BRK DISPLAY
Maximum release braking deceleration ramp that can be set with the display
INV BRK DISPLAY
Maximum reverse braking deceleration ramp that can be set with the display
CONFIG MENU SET OPTIONS

PARAMETER
level
KEY ON: record of truck start up
HOUR COUNTER
RUNNING: record of an active request
Select the hourmeter mode

M.C. FUNCTION
OFF: no main contactor
ON: main contactor present
OPTION#1: traction + pump only 1 main contactor
OPTION#2: Traction + Pump 2 main contactors
AUX OUT FUNCT.1
When PRESENT is set the electromechanical brake is controlled after a traction request if all the relevant diagnosis
is passed.
If ABSENT is set, no diagnosis is performed and the brake is not closed after a traction request
AUX OUT FUNCT.2
When PRESENT is set the auxiliary coil is controlled after a traction request if all the relevant diagnosis is passed.
If ABSENT is set, no diagnosis is performed and the coil is not closed after a traction request
PULSE DIR INPUT
This parameter decides where there is the input for the forward/reverse traction request.
OPTION#1: the analogue input is on the mini-lever
OPTION#2: the digital inputs are on the joystick
OPTION#3: the two-state input is on the mini-lever
87
ELECTRICAL SYSTEM
SERVICE
ACE2 PUMP MODULE

ACE2 PUMP / config menu set options /
PARAMETER
level
M.C. FUNCTION
See M.C.FUNCTION traction
AUX OUT FUNCT.1
See AUX. OUT FUNCT.1 traction
AUX OUT FUNCT.2
See AUX. OUT FUNCT.2 traction
EPS ACW MODULE

EPS ACW / main menu parameter change /
EPS ACW / config menu special adjustment /
EPS ACW / config menu hardware setting /
EPS ACW / config menu set option /
EPS ACW / config menu adjustments /
MAIN MENU parameter change

PARAMETER
level
SPEED LIMIT
Determines the ratio between the handwheel rotation speed and the steering motor rotation speed, but only if
the handwheel is turned quickly. As the value of this parameter increases, the steering motor rotation speed is
increased
SENSITIVITY
Determines the ratio between the handwheel rotation speed and the steering motor rotation speed, but only if
the handwheel is turned slowly. As the value of this parameter increases, the steering motor rotation speed is
increased
SENSITIVE VS TRC
Reduction in steering sensitivity at the maximum traction speed due to slow rotation of the handwheel
SPEED LIM VS TRC
Reduction in steering sensitivity at the maximum traction speed due to fast rotation of the handwheel
88
SERVICE
ELECTRICAL SYSTEM

PARAMETER
level
DEBUG OUTPUT
This parameter is used to temporarily modify the truck configuration or inhibit some diagnoses to aid
troubleshooting.
Remember to take the value of this parameter back to level 15 after finishing with troubleshooting.
auto-acquisition of the stepper motor offset in open cycle applications. It automatically returns to
Level 0:
level 15 after acquisition
Level 1:
manual setting wheel 180
Level 2-10:
reserved
Level 11:
disables the FB SENS LOCKED and MOTOR LOCKED alarms until this parameter is next
modified
Level 12-13:
not used
Level 14:
disables the FB SENS LOCKED and MOTOR LOCKED alarms. It automatically returns to level
15 after switching the truck back on
Level 15:
standard value, no special function active

PARAMETER
level
AUTOTEACHING
This parameter set to ON runs the auto-acquisition procedure. Switching the truck off and back on again starts the
acquisition procedure. During this process the display shows the warning ENC PULSES ACQ. If the readings taken
are not consistent, they will not be saved and the display will show the message ACQ.ABORTED #1 or #2.

PARAMETER
level
AUX OUTPUT #1
Enables/disables the auxiliary function on pin 10
AUX OUTPUT #2
Enables/disables the auxiliary function on pin 14
config menu adjustments

PARAMETER
level
SET STEER 0-POS.

Determines the position of the steer wheel after self-centring.
89
ELECTRICAL SYSTEM
SERVICE
MODULES: INTRODUCTION
The module electronic system for AC motor control is composed of:
ACE2 INVERTER - traction module for managing the AC traction motor
ACE2 INVERTER - pump module for managing the AC pump motor
EPS ACW module for managing the AC steering motor
VCM module with graphic display for managing the various truck functions
The modules are connected and communicate through the CANBUS network, which allows access to truck
diagnostics or programming via PC.
The connector (X40 or X41) for the cable kit interface connection ("PC TOOL") is connected to the modules
and can be accessed from the control panel.
The modules are equipped with flash memory, which enables the software to be updated by connecting a
PC to the CANBUS network (Can flash).
POSITIONING OF THE "PC TOOL" CONNECTORS
PC interface cable kit

code 580039670
90
pc tool connector
SERVICE
ELECTRICAL SYSTEM
INVERTER ACE2 MODULE

Technical specifications:
Inverter for three-phase asynchronous AC motors
Regenerative braking functions
Digital control via microcontroller
Voltage: ........................................................................................24V - 36V - 48V - 80V - 96V
Maximum current (48V-350A):......................................................350A (RMS) for 3
Maximum current (48V-400A):......................................................400A (RMS) for 3
Current evaluation 1 hour (48V-350A)...........................................170A (RMS)
Current evaluation 1 hour (48V-400A)...........................................200A (RMS)
Operating frequency:.....................................................................8 kHz
Outside working temperature limits...............................................-30C to 40C
Maximum inverter temperature (at maximum power):...................75
- BATT
+ BATT
91
ELECTRICAL SYSTEM
SERVICE
EPS ACW MODULE

The module is integrated in the steering motor.
Technical specifications:
Digital control by two microprocessors; both microprocessors connected via CAN Bus
Encoder interface
Interface for stepper motor
Analog input for thermal sensor
Operating frequency:.....................................................................8kHz with PWM aligned in the centre
Maximum inverter temperature:....................................................80C
Protection:.....................................................................................IP65
+ BATT
- BATT
92
SERVICE
ELECTRICAL SYSTEM
VCM MODULE
Functions:
BDI
Hour meter
Alarms
Performance
Height gauge
Technical specifications (standard version)
Voltage: ........................................................................................36-48V
Digital inputs (n):..........................................................................7
Analog inputs (n):.........................................................................2
Outputs supplied at 12V (no.)........................................................1
Outputs supplied at 5V (no.)..........................................................1
Protection......................................................................................IP65
Technical specifications (premium version):
Voltage: ........................................................................................36-48V
Digital inputs (n):..........................................................................11
Analog inputs (n):.........................................................................10
Outputs supplied at 12V (no.)........................................................1
Outputs supplied at 5V (no.)..........................................................2
Protection......................................................................................IP65
93
SERVICE
ELECTRICAL SYSTEM
REPLACEMENT OF MODULES: INSTRUCTIONS

The hours of operation of the truck are memorised on the VCM module and on the "ACE2
TRACTION" module. After replacing the ACE2 TRACTION module, it is necessary to
acquire the operating hours by loading them from the VCM module.
REPLACING THE "ACE2 INVERTER" MODULE
Equipment and tools
T handle hex key

5 mm
resistance 33 to
100 50W insulated
large flat blade

screwdriver
22 mm socket
wrench with
ratchet
13 mm
Procedure
Fig. 1

Phase 1
5 mm T-handle hex key
Fig. 2
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet, remove the electronic controls
cover and open the bonnet (fig.1).
Phase 2
RESISTOR
Using the screwdriver, remove the caps protecting the contacts.
Connect a resistor that can have a value of between 33 and 100 Ohm 50W between the positive (B+) and
negative (B-) of the module (fig.2).
Wait approximately 10 seconds for the internal capacitors to discharge and then disconnect the resistor.
To avoid short circuits, it is important that the resistor is isolated.
If it is not possible to use an external resistor to run down the capacitors, it will be necessary to wait at least
90 seconds before disconnecting the power cables.
94
SERVICE
ELECTRICAL SYSTEM
Phase 3
socket wrench with ratchet size 13 mm - MEDIUM FLAT
BLADE SCREWDRIVER
Using the socket wrench and ratchet unscrew and remove the screws
fastening the electric cables, fuse, copper connecting bars and power
cables. Unscrew and remove the nut fastening the fuse too.
Mark the electric cables and the copper bars for reassembly and disconnect them. Disconnect the connector.
B
A
Fig. 3
Phase 4
5 mm FLEXIBLE T-HANDLE HEX KEY
Unscrew the four screws fastening the module to the panel (ref.A fig.3).
Extract the module and remove it.
Recover the fuse (ref.B fig.3) and proceed with the replacement.
CONFIGURATION
ADAPTER - PROGRAMMER OR CONSOLE
Connect the adaptor to the PC TOOL" connector.
Connect the USB connector of the interface cable to the USB port on the PC.
Connect the battery and switch on the truck (starter key to ON). Start the PC Tool programme.
Create a new configuration and copy the factory configuration or a customised configuration.
SETTING THE BATTERY VOLTAGE

Carry out the procedure for setting the battery voltage. See SETTING THE BATTERY VOLTAGE section
INSTALLATION AND SETTINGS.
ACQUISITION OF OPERATING HOURS acE2 traction module

The hours of operation of the truck are memorised on the VCM module and on the "ACE2 TRACTION"
module.
On ignition the system assesses the hours recorded on both modules. If the difference is greater than 20
hours the hm mismatch alarm appears and all the truck functions are disabled. After 2 minutes the higher
value is saved on both modules and all the truck functions are restored.
95
SERVICE
ELECTRICAL SYSTEM
REPLACEMENT OF THE EPS ACW MODULE
Equipment and tools
Fig. 1
T handle hex key medium cross5-6 mm

head screwdriver
resistance 33 to open-ended spanner

100 50W insu8 mm
lated
Procedure

Phase 1
(ref.A fig.1).
Phase 2
RESISTOR
Connect a resistor that can have a value of between 33 and 100 Ohm
50W between the positive (B+) and negative (B-) of the module (fig.3).
Wait approximately 10 seconds for the internal capacitors to discharge
and then disconnect the resistor.
To avoid short circuits, it is important that the resistor is
isolated.
If it is not possible to use an external resistor to run down the capacitors,
it will be necessary to wait at least 90 seconds before disconnecting the
power cables.
96
Fig. 2
Fig. 3
SERVICE
ELECTRICAL SYSTEM
Phase 3
8 mm open ended spanner
Using the open ended spanner, unscrew and remove the screws fastening the electrical cables and fuse. Disconnect the connector.
Fig. 4
Phase 4
MEDIUM CROSSHEAD SCREWDRIVER - 6 mm T-HANDLE HEX
KEY
With the screwdriver, unscrew and remove the screws fastening the upper
cover of the electrical box (ref.B fig.4). Remove the cover.
Unscrew and remove the three fastening screws of the motor phase
terminals (ref.C fig.5).
Unscrew and remove the fastening screws of the EPS module (ref.D
fig.6). Remove the module and proceed with replacement.
Fig. 5
C
CONFIGURATION
Connect the USB connector of the interface cable to the USB port on
the PC.
Connect the battery and switch on the truck (starter key to ON). Start the
PC Tool programme.
Fig. 6
97
SERVICE
ELECTRICAL SYSTEM
VCM MODULE REPLACEMENT
Equipment and tools
Fig. 1
T handle hex key medium cross4-5 mm

head screwdriver
Procedure

Phase 1
5 mm T-HANDLE HEX KEY - MEDIUM CROSSHEAD SCREWDRIVER
(ref.A fig.1).
Using a crosshead screwdriver, unscrew the panel fixing screw to access
the VCM control (ref.B fig.3).
Fig. 2
Phase 2
Disconnect the module connector.
Using the T-handle hex key, unscrew the screws securing the module
to the carriage (ref.C fig.4). Remove the module and proceed with replacement.
CONFIGURATION
Connect the USB connector of the interface cable to the USB port on
the PC.
Connect the battery and switch on the truck (starter key to ON). Start the
PC Tool programme.
98
Fig. 3
SERVICE
ELECTRICAL SYSTEM
SETTING THE BATTERY VOLTAGE

Carry out the procedure for setting the battery voltage. See SETTING
THE BATTERY VOLTAGE section INSTALLATION AND SETTINGS.
ACQUISITION OF VCM module OPERATING HOURS
Fig. 4
The hours of operation of the truck are memorised on the VCM module
and on the "ACE2 TRACTION" module.
On ignition the system assesses the hours recorded on both modules. If
the difference is greater than 20 hours the hm mismatch alarm appears
and all the truck functions are disabled. After 2 minutes the higher value
is saved on both modules and all the truck functions are restored.
99
SERVICE
ELECTRICAL SYSTEM
REMOVAL OF ELECTRICAL COMPONENTS

REPLACEMENT OF ENCODER
Equipment and tools
ladder
safety harness
open-ended
spanner
7-8 mm
2 x 10 mm
socket wrench
7 mm
ratchet
Procedure
Fig. 1
Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Remove the hydraulic control valve cover to facilitate the disassembly
procedure (fig.2).
REMOVING THE FREE LIFT ENCODER

Phase 2
7 mm OPEN ENDED SPANNER - 7 mm SOCKET WRENCH - RATCHET
- 8 mm open ended spanner
Using the 7 mm spanner, lock the nut securing the encoder wire (ref.A
fig.5). Using the socket wrench and the ratchet, unscrew and remove
the screw securing the encoder wire (ref.B fig.5).
With the 8 mm open ended spanner, unscrew and remove the screws
securing the encoder (ref.C fig.3). Remove the encoder and proceed
with replacement.
100
Fig. 2
SERVICE
ELECTRICAL SYSTEM
REMOVING THE MAIN LIFT ENCODER

Phase 2
ladder - safety harness - 7 mm OPEN ENDED SPANNER - No.2 x 10 mm open ended spanners
Using the 7 mm spanner, lock the nut securing the encoder wire (ref.D fig.8). Using the socket wrench and
the ratchet, unscrew and remove the screw securing the encoder wire (ref.E fig.8).
Climb up the ladder with the tools and secure the safety harness to the cab.
Using one 10 mm open ended spanner lock the nut securing the encoder (ref.F fig.6), while with the other
open ended spanner unscrew and remove the screw fastening the encoder (ref.G fig.6). Remove the encoder and proceed with replacement.
Fig. 3
Fig. 4
A
B
Fig. 5
Fig. 6
Fig. 7
Fig. 8
101
ELECTRICAL SYSTEM
SERVICE
ENCODER RESET SENSOR REPLACEMENT

Equipment and tools
open ended
spanner
2 x 28 mm
Procedure
Fig. 1

Phase 1
out (fig.1).
Phase 2
2 x 28 mm OPEN ENDED SPANNERS
Loosen the ring nuts fastening the sensor to the support plate (fig.3).
Disconnect the connector, unscrew the sensor and proceed with replacement.
Fig. 2
Fig. 3
102
SERVICE
ELECTRICAL SYSTEM
LOAD CELL REPLACEMENT

Equipment and tools
Fig. 1
wooden beam
taper end pliers
Procedure
of other vehicles and pedestrians. Lower the forks to the
ground.
Phase 1
out (fig.1).
Phase 2
WOODEN BLOCK
Raise the forks just enough to be able to pass the wooden block underneath.
Place the wooden block under the forks (fig.2). Lower the forks to rest
on the block and continue until the end stroke of the cylinder.
Fig. 2
Position the key switch to OFF and disconnect the battery.

Phase 3
TAPE END PLIERS
Using the taper end pliers remove the cotter pins and the hinge pins securing the load cell to the chain and to the fork mast (ref.A fig.3). Disconnect
the connector, remove the load cell and proceed with replacement.
Fig. 3
ASSEMBLY
Do not reuse the chain anchoring safety pins, use new
cotter pins, ensuring they are the correct size.
103
SERVICE
ELECTRICAL SYSTEM
REPLACEMENT OF THE HORN
Equipment and tools
T handle hex key

5 mm
open ended
spanner
13 mm
Allen key
6 mm
Procedure
Fig. 1
Fig. 2
A
Phase 1
the electronic controls. Unscrew and remove the screw locking the bonnet,
remove the electronic controls cover and open the bonnet (fig.1).
Phase 2
FIXED 13 mm SPANNER - 6 mm ALLEN KEY
Using the open ended spanner, counterhold the nut (ref.A fig.2), and
with the bent Allen key unscrew and remove the screw securing the horn
(ref.B fig.2).
Disconnect the connectors, remove the horn and proceed with replacement.
INSTALLATION
Before connecting them again, make sure the Faston connectors are suitably tight. If not, tighten the connectors
with Faston pliers.
104
SERVICE
ELECTRICAL SYSTEM
REPLACEMENT OF THE CONTACTORS

Equipment and tools
T handle hex key

4-5 mm
open ended
spanner
13 mm
medium flat blade

screwdriver
Procedure
Fig. 1

Phase 1
Phase 2
MEDIUM FLAT BLADE SCREWDRIVER - 13 mm OPEN ENDED SPANNER
Using the open ended spanner unscrew and remove the nuts fastening
the electrical cables and copper bar to the contactor (ref.A fig.2).
Disconnect the cables and connectors, noting down their position to make
assembly easier.
A
Fig. 2
Fig. 3
Phase 3
Using the T handle hex key, unscrew and remove the screws securing
the contactor (ref.B fig.3).
Remove the contactor and proceed with replacement.
105
SERVICE
ELECTRICAL SYSTEM
FUSE REPLACEMENT

2A fuse key relay (F3)

10A fuse emergency push-button and contactors (F1)
10A fuse contactors (F2)
power fuse traction controller (F4)
power fuse pump controller (F5)
power fuse steering controller (F6)
Equipment and tools
medium/large
medium flat blade
T handle hex key
crosshead screwscrewdrivers
5 mm
driver
22 mm socket
wrench with
ratchet
13 mm
open-ended
spanner
8 mm
Procedure
transit of other vehicles and all pedestrians. Set the key
switch to OFF and disconnect the battery.
Fig. 1
A
A
FUSES F1,F2,F3
Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.A fig.1).
Remove the panel.
Phase 2
Remove the desired fuse from the control board (fig.2) and proceed with
replacement.
106
Fig. 2
SERVICE
ELECTRICAL SYSTEM
POWER FUSE F6
Fig. 3
Phase 1
(ref.B fig.3).
Phase 2
Using the open ended spanner, unscrew and remove the nuts fastening
the fuse (ref.C fig.5). Remove the fuse and proceed with replacement.
POWER FUSES F4,F5

Phase 1
Fig. 4
Fig. 5
Phase 2
socket wrench with ratchet size 13 mm - MEDIUM FLAT
BLADE SCREWDRIVER
Using the socket wrench and the ratchet, unscrew and remove the
screws securing the fuse (ref.D fig.6). Remove the fuse and proceed
with replacement.
Fig. 6
107
SERVICE
ELECTRICAL SYSTEM
REPLACEMENT OF THE MOTOR COMPARTMENT COOLING FAN
Equipment and tools
Fig. 1
medium/large
T handle hex key
T handle hex key
crosshead screw4 mm
5 mm
driver
22 mm socket
wrench with
ratchet
13 mm
Procedure
MOTOR COMPARTMENT FAN

Fig. 2
Phase 1
(ref.A fig.1).
Fig. 3
Phase 2
Using the flexible T-handle hex key, unscrew and remove the screws
securing the fan bracket (ref.B fig.4).
Remove the bracket together with the fan, disconnect the connector and
Fig. 4
108
SERVICE
ELECTRICAL SYSTEM
ADDITIONAL TRACTION MOTOR FAN
Fig. 5
Phase 2
Using the flexible T-handle hex key, unscrew and remove the screws
securing the fan bracket (ref.C fig.6).
Remove the bracket together with the fan, disconnect the connector and
Fig. 6
109
SERVICE
ELECTRICAL SYSTEM
REPLACEMENT OF ARMREST AND MAIN PANEL CONTROLS:

keyswitch
buttons
main emergency switch
steering handwheel stepper motor
joystick
mini-levers
display
Equipment and tools

Fig. 1
hexagonal "T"
section spanner
1.5-3 mm
hex bit socket

10-13 mm
medium/large
small/medium flat
crosshead screwblade screwdriver
driver
ratchet
open-ended
spanner
7-10-13-14 mm
Torx key
C spanner
Procedure
KEY SWITCH (version with premium display)

Phase 1
Remove the panel.
110
Fig. 2
Fig. 3
SERVICE
ELECTRICAL SYSTEM
Phase 2
Remove the key switch.
Unscrew the nut (ref. B fig.2), remove the switch block from the console
(fig.3).
Disconnect the wiring connectors and proceed with the replacement.
Fig. 4
INSTALLATION
Before connecting them again, make sure the Faston connectors are suitably tight. If not, tighten the connectors
with Faston pliers.
Fig. 5
DASHBOARD PUSH-BUTTONS
D
Phase 1
Remove the panel.
Fig. 6
Phase 2
LARGE CROSSHEAD SCREWDRIVER - 10 mm open ended spanner
Use the screwdriver and the open ended spanner to unscrew and remove
the screws fastening the dashboard (ref.C-D fig.4-5).
Turn over dashboard.
Phase 3
Use the screwdriver and the open ended spanner to unscrew and remove
the screws fastening the dashboard (ref.C-D fig.4-5).
Fig. 7
Phase 4
For the round buttons, use the open ended spanner to loosen the ring
nut locking the button (ref.E fig.6). Unscrew and remove the button,
disconnect the connectors and proceed with replacement.
For the rectangular buttons, press the tabs at the sides of the buttons
(fig.8). Extract the button, disconnect the connectors and proceed with
replacement.
Fig. 8
111
SERVICE
ELECTRICAL SYSTEM
ARMREST BUTTONS
Fig. 9
Phase 1
Using the controls in the cab, move the retractable carriage fully against
the battery.
Pull up the lever in front of the throttle pedal board next to the bonnet so
as to free the battery.
out together with the battery.

Fig. 10
the armrest from the battery compartment (ref.F fig.10).
Remove the armrest and turn it over.
Phase 2
MEDIUM PHILIPS SCREWDRIVER
Using the screwdriver, unscrew and remove the screws fastening the
lower cover of the armrest (ref.G fig.11).
Remove the cover.
Phase 3
Use the screwdriver to unscrew and remove the fastening screws of the
electronic board (ref.H fig.11).
Remove the cover.
Phase 4
For the round buttons of the auxiliary functions, use the open ended
spanner to loosen the ring nut locking the button (ref.E fig.6). Unscrew
and remove the button, disconnect the connectors and proceed with
replacement.
For the horn and direction of travel buttons, press the tabs at the sides
of the buttons (fig.12). Extract the button, disconnect the connectors and
112
Fig. 11
Fig. 12
SERVICE
ELECTRICAL SYSTEM
MAIN EMERGENCY SWITCH
Fig. 13
Phase 1
the battery.
out together with the battery.
Fig. 14
the armrest from the battery compartment (ref.I fig.14).
Remove the armrest and turn it over.
Phase 2
Using the screwdriver, unscrew and remove the screws fastening the
lower cover of the armrest (ref.J fig.15).
Remove the cover.
Phase 3
C SPANNER FOR SELF-LOCKING RING NUTS - SMALL FLAT BLADE
SCREWDRIVER
Using the C spanner, unscrew and remove the self-locking ring nut of
the emergency button (ref.K fig.16). Using the small screwdriver, free
the tabs of the push-button (fig.16), remove the button, disconnect the
connectors and proceed with replacement.
Fig. 15
Fig. 16
113
SERVICE
ELECTRICAL SYSTEM
STEERING HANDWHEEL STEPPER MOTOR
Fig. 17
Phase 1
panel located under the control panel (ref.L fig.17).
Remove the panel.
Phase 2
small flat blade screwdriver - 13 mm hex socket wrench
- ratchet
Using the flat blade screwdriver, remove the cover located over the
handwheel (ref.M fig.18).
Using the socket wrench and the ratchet, unscrew and remove the screw
securing the handwheel to the assembly (ref.N fig.18). Remove the
handwheel.
l
l
Fig. 18
M
N
Phase 3
Use the screwdriver to unscrew and remove the screws of the covers of
the steering handwheel assembly (fig.19).
Remove the two covers.
If there is any difficulty in unscrewing the upper screws

under the control panel, remove the dashboard.
Phase 4
7 mm open ended spanner - 1.5-3 mm T-HANDLE HEX KEY
Using the 1.5 mm T-handle hex key unscrew and remove the grub screw
(ref.O fig.20).
Using the open ended spanner hold the nut firm (ref.P fig.20), with the
T-handle hex key unscrew and remove the screw fastening the stepper
motor to the bearing block (ref.Q fig.20).
Remove the motor and proceed with replacement.
Fig. 19
Fig. 20
114
SERVICE
ELECTRICAL SYSTEM
JOYSTICK
Phase 1
SMALL FLAT BLADE SCREWDRIVER - 10 mm HEX SOCKET
WRENCH - ratchet
Using the small screwdriver, remove the cover under the joystick (ref.R
fig.21).
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the joystick to the armrest (ref.S fig.21). Remove the joystick
and proceed with replacement or disassembly.
MINI-LEVERS
Fig. 21
Fig. 22
Phase 1
TORX KEY
Using the Torx key, unscrew and remove the screws fastening the minilever (ref.T fig.22).
Remove the mini-lever and proceed with replacement.
STANDARD DISPLAY
Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER - medium flat
blade screwdriver
Remove the panel.
Disconnect the connector from the display. Using the flat blade screwdriver, prise on the lower tab of the display (fig.23), put outwards and
remove.
Fig. 23
115
SERVICE
ELECTRICAL SYSTEM
PREMIUM DISPLAY
Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER - 10 mm HEX SOCKET
WRENCH - RATCHET
Remove the panel.
Disconnect the connector from the display. Using the socket wrench and
ratchet, unscrew and remove the lock nut on the rear of the display (ref.U
Fig.24). Remove the display outwards.
116
Fig. 24
SERVICE
ELECTRICAL SYSTEM
SIDE SHIFT POSITION SENSOR REPLACEMENT

Equipment and tools
open ended
spanner
2 x 28 mm
Procedure
Fig.1
Phase 1
Unscrew the ring nuts fastening the sensor to the support plate (ref.A
fig.2).
Disconnect the connector, unscrew the sensor and proceed with replacement.
Fig.2
117
SERVICE
ELECTRICAL SYSTEM
PALLET PRESENCE SENSOR REPLACEMENT
Equipment and tools
Fig.1
external circlip
pliers
Allen key
2-3 mm
Procedure
A
A
Phase 1
SMALL EXTERNAL CIRCLIP PLIERS
Use the pliers to remove the two circlips securing the pin of the plate with
the cam (ref.A fig.2). Remove the pin and the plate.
Phase 2
2-3 mm ALLEN WRENCH
Using the 2 mm Allen wrench, unscrew the grub screw securing the sensor (ref.B fig.3). Using the 3 mm Allen wrench, unscrew and remove the
screws securing the sensor bracket (ref.C fig.3).
Unscrew the sensor, disconnect the connector and extract it inside the
liner. Proceed with replacement
118
Fig.2
C
Fig.3
SERVICE
ELECTRICAL SYSTEM
TILT POSITION SENSOR REPLACEMENT

Equipment and tools
Fig.1
open-ended
spanner
8 mm
2 x 28 mm
Procedure
Phase 1
8 mm OPEN ENDED SPANNER
Using the open ended spanner loosen the screws securing the bracket
of the sensor (ref.A fig.2).
Disconnect the connector, remove the bracket together with the sensor
Fig.2
Phase 2
Loosen the ring nuts fastening the sensor to the support plate (ref.B
fig.3).
Unscrew the old sensor and fit the new one.
Fig.3
119
SERVICE
ELECTRICAL SYSTEM
90 WHEEL SENSOR AND STEERED WHEEL SENSOR REPLACEMENT
Equipment and tools
Fig. 1
T handle hex key

5 mm
open-ended
spanner
16 mm
Procedure
Phase 1
T-handle hex key, unscrew and remove the screws securing the cover
of the electronic controls. Unscrew and remove the screw locking the
bonnet (ref.A fig.1), remove the electronic controls cover and open the
bonnet (fig.2).
Fig. 2
Fig. 3
Phase 2
With the open ended spanner, unscrew the ring nut securing the sensor
to the supporting plate (ref.B fig.4).
Disconnect the connector, unscrew the sensor from the supporting plate
and proceed with replacement.
Fig. 4
120
SERVICE
ELECTRICAL SYSTEM
BATTERY OUT SENSOR REPLACEMENT

Equipment and tools
T handle hex key

5 mm
open-ended
spanner
16 mm
Procedure
Fig. 1
Fig. 2
Phase 1
Fig. 3
Phase 2
10mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the nut securing
the sensor bracket (ref.A fig.3).
Disconnect the connector, remove the bracket together with the sensor
Phase 3
Loosen the ring nuts fastening the sensor to the support plate (ref.B
fig.4).
Unscrew the old sensor and fit the new one.
Fig. 4
121
SERVICE
ELECTRICAL SYSTEM
OPERATOR PRESENCE PEDAL REPLACEMENT
Equipment and tools
T handle hex key

5 mm
open ended
spanner
7 mm
Procedure
Phase 1
Phase 2
Using the open ended spanner, unscrew and remove the screws fastening the operator presence pedal (ref.A fig.2).
Remove the pedal and proceed with replacement.
122
Fig. 1
Fig. 2
SERVICE
ELECTRICAL SYSTEM
ACCELERATOR AND BRAKE PEDALS REPLACEMENT

Equipment and tools
T handle hex key

5 mm
open ended
spanner
13 mm
Procedure
Fig. 1
Fig. 2
Phase 1
Phase 2
13 mm OPEN ENDED SPANNER - 5 mm T-HANDLE HEX KEY
Using the open ended spanner, counterhold the nuts (ref.A fig.2), and
with the T-handle hex key unscrew and remove the screws securing the
pedal (ref.B fig.2).
Remove the pedal and proceed with replacement.
123
ELECTRICAL SYSTEM
124
SERVICE
SERVICE
HYDRAULIC SYSTEM
Hydraulic system
HYDRAULIC FUNCTIONS 3
HYDRAULIC DIAGRAMS 4
symbols 4
MAIN HYDRAULIC DIAGRAM 5
HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS 8
SOLENOID VALVE OPERATION CHART 8
HYDRAULIC FORK LIFTING DIAGRAM 9
HYDRAULIC FORK LOWERING DIAGRAM 10
HYDRAULIC RETRACTABLE CARRIAGE OUT DIAGRAM 11
HYDRAULIC RETRACTABLE CARRIAGE IN DIAGRAM 12
HYDRAULIC FORK UPWARD TILTING DIAGRAM 13
HYDRAULIC FORK DOWNWARD TILTING DIAGRAM 14
HYDRAULIC FORK LEFT SIDE SHIFT DIAGRAM 15
HYDRAULIC FORK RIGHT SIDE SHIFT DIAGRAM 16
HYDRAULIC EMERGENCY LOWERING DIAGRAM 17
HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE 18
HYDRAULIC COMPONENTS 20
HYDRAULIC COMPONENT IDENTIFICATION 20
DISTRIBUTOR COMPONENT IDENTIFICATION 22
DISTRIBUTOR DISMANTLING 23
gasket replacement 23
REMOVAL OF THE PRESSURE RELIEF VALVE 25
CALIBRATION OF THE PRESSURE RELIEF VALVE 26
CARTRIDGE SOLENOID VALVES 27
IDENTIFICATION of SOLENOID VALVE CARTRIDGE COMPONENTS 27
SOLENOID VALVE DISMANTLING 28
CYLINDERS 29
SINGLE ACTING CYLINDER 29
IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS 30
IDENTIFICATION OF THE SIDE LIFT CYLINDER COMPONENTS 31
IDENTIFICATION OF THE RETRACTABLE CARRIAGE CYLINDER COMPONENTS 32
IDENTIFICATION OF THE FORK TILT CYLINDER COMPONENTS 33
IDENTIFICATION OF THE FORK SIDE SHIFT CYLINDER COMPONENTS 34
CENTRAL LIFT CYLINDER DISMANTLING 35
DISMANTLING OF LATERAL LIFT CYLINDER 37
LIFTING CYLINDER: AIR BLEEDING 39
REMOVAL OF THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER 40
HYDRAULIC SYSTEM
SERVICE
REMOVAL OF THE FORK TILT CYLINDER 42

CYLINDER DISMANTLING 44
lift pump 46
KEY TO LIFT PUMP COMPONENTS 46
LIFT PUMP DISMANTLING 48
REPLACEMENT OF THE PUMP 50
HYDRAULIC PIPES 51
PIPE PLACEMENT FOR HYDRAULIC CIRCUIT 51
RENEWAL OF THE MIDDLE LIFT CYLINDER FEED PIPE 52
RENEWAL OF THE FORK HYDRAULIC FUNCTIONS SUPPLY PIPES 54
SERVICE
HYDRAULIC SYSTEM
HYDRAULIC FUNCTIONS

Fork Lifting
Fork Lowering
Fork right side shift
Fork left side shift
Fork tilt up
Fork tilt down
Retractable carriage out
Retractable carriage in
HYDRAULIC SYSTEM
SERVICE
HYDRAULIC DIAGRAMS
symbols
ELECTRIC MOTOR
LINE CONNECTION
RESERVOIR
PUMP
SINGLE ACTING
CYLINDER
DUAL ACTION PUMP
DOUBLE ACTING
CYLINDER
HYDRAULIC MOTOR
PRESSURE RELIEF
VALVE
FILTER
DIVERTER VALVE
FILTER CLOGGING
INDICATOR
TWO-POSITION VALVE
MANUAL COCK
ONE-WAY VALVE
CHECK VALVE
THREE-POSITION
VALVE
SERVICE
HYDRAULIC SYSTEM
MAIN HYDRAULIC DIAGRAM
HYDRAULIC SYSTEM
BACK: VERSION WITH 5TH WAY
SERVICE
SERVICE
HYDRAULIC SYSTEM
BACK: VERSION WITHOUT 5TH WAY
SERVICE
HYDRAULIC SYSTEM
HYDRAULIC DIAGRAMS FOR VARIOUS

FUNCTIONS

Fork Lifting
Fork Lowering
Fork tilt up
Fork tilt down
Emergency mast lowering
The hydraulic control valve in the motor compartment
is equipped with a screw to open the emergency lowering valve. Unscrew the valve gradually by no more
than two turns so that the mast is lowered slowly. Once
the forks have been lowered, close the valve.
Oil drain through the pressure relief valve
Emergency
lowering valve
relief valve
SOLENOID VALVE OPERATION CHART
Function
Fork Lifting
Pump
Q1
Q2
Q3
Q4
Q5
Q6
+
+
Fork Lowering
Fork tilt up
Fork tilt down
Oil drain through the pressure relief

valve
= pump in operation
P
+
= solenoid valve coil energised
SERVICE
HYDRAULIC SYSTEM
HYDRAULIC FORK LIFTING DIAGRAM
Oil delivery
Oil return
HYDRAULIC SYSTEM
SERVICE
HYDRAULIC FORK LOWERING DIAGRAM
Oil delivery
Oil return
10
SERVICE
HYDRAULIC SYSTEM
HYDRAULIC RETRACTABLE CARRIAGE OUT DIAGRAM
Oil delivery
Oil return
11
HYDRAULIC SYSTEM
HYDRAULIC RETRACTABLE CARRIAGE IN DIAGRAM
Oil delivery
Oil return
12
SERVICE
SERVICE
HYDRAULIC SYSTEM
HYDRAULIC FORK UPWARD TILTING DIAGRAM

Oil delivery
Oil return
13
HYDRAULIC SYSTEM
SERVICE
HYDRAULIC FORK DOWNWARD TILTING DIAGRAM

Oil delivery
Oil return
14
SERVICE
HYDRAULIC SYSTEM
HYDRAULIC FORK LEFT SIDE SHIFT DIAGRAM

Oil delivery
Oil return
15
HYDRAULIC SYSTEM
SERVICE
HYDRAULIC FORK RIGHT SIDE SHIFT DIAGRAM

Oil delivery
Oil return
16
SERVICE
HYDRAULIC SYSTEM
HYDRAULIC EMERGENCY LOWERING DIAGRAM
17
HYDRAULIC SYSTEM
SERVICE
HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE
Pressure relief or pressure limiting valves are used in hydraulic systems to maintain the pressures permitted by the system and to protect and safeguard the system against sudden pressure surges that could
seriously damage the components.
The pressure relief valve may intervene in the following cases:

18
Pressure control not suitable for the truck load capacity.

Attempt to lift a load in excess of the truck's load capacity
Faulty or stuck valve
SERVICE
HYDRAULIC SYSTEM
19
HYDRAULIC SYSTEM
HYDRAULIC COMPONENTS
HYDRAULIC COMPONENT IDENTIFICATION
Ref.
20
Description
Distributor
Lift pump
Tank
Filter
Retractable carriage cylinder
Fork lift cylinder
Mast lift cylinders
Fork side shift cylinder
Fork tilt cylinders
SERVICE
SERVICE
HYDRAULIC SYSTEM
6
8
4
21
SERVICE
HYDRAULIC SYSTEM
DISTRIBUTOR COMPONENT IDENTIFICATION
10
4
5
Ref.
22
Description
Solenoid valve
Solenoid valve
Solenoid valve
Solenoid valve
Solenoid valve
Solenoid valve
Fork pressure relief valve
Side shift/tilt pressure relief valve
Retractable carriage pressure relief valve
10
Emergency lowering valve
SERVICE
HYDRAULIC SYSTEM
DISTRIBUTOR DISMANTLING

gasket replacement
The gaskets must be replaced when an oil leak is identified or when the truck is used in a cold store.
Equipment and tools
Fig. 1
open ended
spanner
13mm
Schfer wrenches
for connectors
Procedure
ground..
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.
Phase 1
Make the retractable carriage come fully out (fig.1).
Fig. 2

Phase 2
SHFER WRENCHES FOR CONNECTORS - OIL RESISTANT
GLOVES
Wear the oil resistant gloves.
Label the hydraulic pipes in order to reassemble them correctly.
Unscrew the hydraulic pipe connectors with the Shfer wrenches
(fig.3).
Disconnect the solenoid valve supply connectors.
Fig. 3
23
SERVICE
HYDRAULIC SYSTEM
Phase 3
Using the open ended spanner, unscrew and remove the screws fastening the control valve at the bottom of the truck (ref.A fig.5).
Remove the control valve assembly.
Remove the O-rings from the seat, carefully clean the parts and install
the new gasket set.
Fig. 4
A
Fig. 5
24
SERVICE
HYDRAULIC SYSTEM
REMOVAL OF THE PRESSURE RELIEF VALVE

Malfunction of the pressure relief valve can be caused by the presence of dirt or weakening of the internal
spring.
In the first case thorough cleaning is required, in the second case the valve needs to be replaced.
Equipment and tools
Fig. 1
large flat blade

screwdriver
oil protecting
gloves
socket wrench
22 mm
ratchet
Procedure
ground.
Phase 1
Make the retractable carriage come fully out (fig.1).
Phase 2
RATCHET - 22 mm SOCKET WRENCH - OIL PROTECTING LOVES
Put the oil proof gloves on.
Use the spanner to unscrew and remove the valve assembly (ref.A fig.3)
and proceed with the replacement.
Fig. 2
Fig. 3
INSTALLATION
On installation, tighten the valve with a torque wrench to
10 to 12 Nm.
25
HYDRAULIC SYSTEM
SERVICE
CALIBRATION OF THE PRESSURE RELIEF VALVE

The pressure relief valve must be calibrated following replacement.
Equipment and tools
open ended
spanner
10 mm
Procedure
Phase 1
Connect the battery and switch on the truck (starter key to ON).
Place on the forks a load equivalent to the truck's load capacity, as indicated on the truck's dataplate. Wear
the oil resistant gloves.
Phase 2
10mm OPEN ENDED SPANNER
Loosen the lock nut with the spanner (ref.A fig.2).
Using the open ended spanner loosen the adjusting screw (ref.B fig.2) turning it counter-clockwise until,
while pressing the fork lifting button, the pressure decreases and the oil drains back to tank (the lifting action ceases). At this point, turn the adjuster screw in the opposite direction (clockwise) to the point where
the forks start to lift again.
Release the lifting button and tighten the screw by a further 1/4 turn.
Carry out a few trial lifts and lowering manoeuvres with the load on the forks, checking that the pressure
setting is sufficient to cope with the pressure surge during the initial lifting stage.
If this is not the case, tighten the screw by a further 1/4 turn.
Use the spanner to tighten the lock nut (ref.A fig.2), to lock the adjusting screw in position.
B
26
Fig. 2
SERVICE
HYDRAULIC SYSTEM
CARTRIDGE SOLENOID VALVES

The distributor solenoid valves are of the screw on cartridge type.
This kind of valve is comprised of a chassis with a hexagon nut attached to the chassis, a threaded part,
a range of static seal gaskets; inside a mobile element allows communication between the various holes.
IDENTIFICATION of SOLENOID VALVE CARTRIDGE COMPONENTS
1
2
Ref.
Description
Coil
Valve body
27
SERVICE
HYDRAULIC SYSTEM
SOLENOID VALVE DISMANTLING
Fig. 1
Equipment and tools
fixed gauge spanner

29 mm
Procedure
ground.
Fig. 2
Phase 1
out (fig.1).
Fig. 3
B
Phase 2
OIL RESISTANT GLOVES - 29 mm OPEN ENDED SPANNER
Disconnect the solenoid valve supply connector.
Unscrew the coil retaining nut (ref.A fig.3). Withdraw the coil.
Using the open ended spanner, unscrew the nut securing the valve body
to the control unit (ref.B fig.3). Proceed with replacement
On refitting the valve body, tighten the retaining nut to a
torque of 29 Nm.
28
SERVICE
HYDRAULIC SYSTEM
CYLINDERS
SINGLE ACTING CYLINDER
Single acting cylinders receive and discharge the oil through a single pipe and the pressurised oil acts
on just one side of the piston (single acting pushing cylinders) or on the flat face of the rod in the case of
plunger type cylinders.
Single-acting plunger type cylinders
In this type of cylinder the piston is replaced by the flat end face of the piston rod or plunger; these cylinders
are usually mounted vertically or in other positions in which the force of gravity returns the plunger to the
rest position. Usually the diameter of the lower end of the rod is increased by a few millimetres in order to
avoid it slipping out at the end of it's upstroke; this gives rise to a hydraulic damping effect during the last
stages of the stroke which helps the slowing of the rod and avoids recoil on the upper end cap. Static seals
located in the end cap prevent oil leaking outside the cylinder.
To replace these seals it is necessary to unscrew the seal carrier bush.
Single acting cylinder with hollow rods differ in that before the lifting stroke begins the rod is also filled with
oil. This solution is used on particularly tall truck masts to increase the resistance of the cylinders at the
maximum height and make it possible to use smaller cylinder barrels and rods.
Static seals and dynamic seals
Dynamic seals, installed on the piston, prevent oil from leaking between the chambers of the cylinder barrel, while the static seals, located at the joint between two parts (seal carrier bush - barrel) or between the
sliding parts (rod barrel), prevent oil leaking from the inside to the outside of the cylinder.
29
SERVICE
HYDRAULIC SYSTEM
IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS
The cylinder is of the single-acting plunger type.
1
2
3
4
5
Ref.
1
Description
Bushing
2
3
4
Gaskets
5
6
Piston rod
Seal
Piston
9
10
11
Gaskets
7
8
9
10
11
12
13
Valve
14
Barrel
15
Parachute valve
12
13
14
15
30
SERVICE
HYDRAULIC SYSTEM
IDENTIFICATION OF THE SIDE LIFT CYLINDER COMPONENTS

The cylinder is of the single-acting plunger type.
After replacing the cylinder, bleed the air through the bleed valve.
2
3
4
Ref.
Description
Seal
Bushing
3
4
Gaskets
Barrel
Piston rod
Parachute valve
31
SERVICE
HYDRAULIC SYSTEM
IDENTIFICATION OF THE RETRACTABLE CARRIAGE CYLINDER COMPONENTS
Ref.
Description
Grease nipple
Barrel
Piston rod
Grease nipple
5
6
7
Gaskets
8
9
10
Nut
11
Piston
12
Bushing
13
Ring
14
Bearing
4
5
6
7
8
9
10
11
12
32
13
14
SERVICE
HYDRAULIC SYSTEM
IDENTIFICATION OF THE FORK TILT CYLINDER COMPONENTS
3
1
5
7
2
4
6
8
Ref.
Description
Barrel
Bushing
3
4
5
Gaskets
6
7
8
Rod and piston
Elastic ring
33
SERVICE
HYDRAULIC SYSTEM
IDENTIFICATION OF THE FORK SIDE SHIFT CYLINDER COMPONENTS
2
3
4
6
5
Ref.
1
Description
Barrel
2
3
Gaskets
34
Piston rod
Seal
SERVICE
HYDRAULIC SYSTEM
CENTRAL LIFT CYLINDER DISMANTLING

Equipment and tools
hoist
load capacity
1000kg
lifting sling
load capacity
1000kg
ratchet
hex bit socket

13 mm
taper end pliers
Shfer wrench for

connectors
wooden block
open-ended spanner
28 mm
Procedure
ground.
Phase 1
WOODEN BLOCK
out.
Phase 2
TAPER END PLIERS - SHFER WRENCH FOR CONNECTORS
Using the taper end pliers remove the cotter pin and the chain hinge pin
at the top (ref.A fig.2). Rest the chain on the forks.
Using the Shfer wrench, detach the hydraulic pipes on the control valve of
the fork carriage. Disconnect the electric cables from the fork carriage.
Fig. 1
Fig. 2
35
SERVICE
HYDRAULIC SYSTEM
Phase 3
Raise the cylinder using the controls in the cab until the fork carriage is
fully extracted from below.
Set the fork carriage in a safe place.
Fig. 3
Phase 4
Lower the forks until you can see the screw fastening the cylinder at the
bottom in the inner mast (fig.3).
Using the open ended spanner, unscrew and remove the screw fastening
the cylinder (ref.B fig.4).
Lower the cylinder down to the ground to its limit stop.
Using the Shfer wrench, remove the connector of the hydraulic pipe
connected to the cylinder (ref.C fig.5).
Phase 5
HOIST - LIFT BELT - HEXAGONAL 13mm SOCKET WRENCH - RATCHET
Harness the cylinder with the lift belt.
Set the hoist at right-angles on the belt, hook the belt to the hoist and lift
to make it taut.
Using the socket wrench and ratchet, unscrew the screws of the cylinder
block and remove it (ref.D fig.6).
With the aid of the hoist, remove the cylinder, place it on a clean work
bench and proceed with replacement.
Fig. 4
Fig. 6
Fig. 5
36
SERVICE
HYDRAULIC SYSTEM
DISMANTLING OF LATERAL LIFT CYLINDER

Equipment and tools
Fig. 1
hoist
load capacity
2000 kg
lifting sling
load capacity
2000 kg
medium external
circlip pliers
2 open ended
spanners
15 mm
Shfer wrench for

connectors
ladder
Allen key
6 mm
Procedure
Move the truck to a safe place of a sufficient height for the
fully raised column, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground.
Fig. 2

Phase 1
out and raise the forks until you can see the top of the side cylinder rod
(fig.1).
Phase 2
MEDIUM EXTERNAL CIRCLIP PLIERS - ladder - 2 OPEN ENDED
SPANNERS SIZE 15 mm
Set the ladder next to the column. Climb up and use the pliers to remove
the circlip securing the cylinder (ref.A fig.2).
Using the open ended spanners, unscrew and remove the screws fastening the cylinder locking bracket (ref.B fig.3). Remove the bracket.
Using the cab controls, lower the forks completely down to the ground.
Fig. 3
37
SERVICE
HYDRAULIC SYSTEM
Phase 3
OIL RESISTANT GLOVES - SHFER WRENCH FOR CONNECTORS
Using the Shfer wrench, detach the hydraulic pipe at the base of the
cylinder (ref.C fig.5).
Phase 3
BRIDGE CRANE - LIFT BELT
Hook the lifting belt at the top of the inner mast and hook both ends of
the belt to the bridge crane (fig.6).
Start lifting with just the cylinder connected and at the same time raise
the bridge crane up to the maximum height and keep the belt taut.
Phase 3
LIFT BELT - LIFT - 6 mm ALLEN WRENCH - TRESTLES
Harness the cylinder with the lift belt, hook it onto the lift and take up the
slack.
Using the Allen wrench, unscrew and remove the screw securing the
cylinder (ref.D fig.5). Lift the cylinder upwards until the bottom comes
away from the seat by the mast bottom, lower bending it outwards and
make it come out from the front of the truck. Set it horizontally and place
it on the two trestles and proceed with dismantling or replacement.
After installation, bleed the air from the cylinder (see

LIFTING CYLINDER: AIR BLEEDING).
38
Fig. 4
D
Fig. 5
SERVICE
HYDRAULIC SYSTEM
LIFTING CYLINDER: AIR BLEEDING

Equipment and tools
open ended spanner

13 mm
Procedure
Phase 1
OIL RESISTANT GLOVES - 13 mm OPEN ENDED SPANNER - LADDER
Wear the oil resistant gloves. Set the ladder next to the column and climb
up.
Using the spanner, unscrew the air bleed screw by two turns (ref.B
fig.1).
Connect the battery and turn the starter key to ON.
Fig. 1
A
B
Phase 2
Using the controls in the cab, raise the forks with no load by approximately
300mm, stop and wait for approximately 10 seconds, repeat this process
until all the air has come out of the bleed valve (fig.1).
Take the forks to full height, stop and tighten the screw (ref.B fig.1).
Wipe the cylinder with a clean cloth.
39
SERVICE
HYDRAULIC SYSTEM
REMOVAL OF THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER
Equipment and tools
Fig. 1
T handle hex key

Shfer wrench for
3 - 5 mm
connectors
hex socket
wrench
24 mm
ratchet
open-ended spanner
8 - 24 mm
extension
Procedure
Fig. 2
Phase 1
out (fig.1).
Fig. 3
Phase 2
40
SERVICE
HYDRAULIC SYSTEM
Phase 3
3 mm T-HANDLE HEX KEY - 8-24 mm OPEN ENDED SPANNER
Using the 8mm open ended spanner and the T-handle hex key, unscrew
and remove the screw fastening the potentiometer to the cylinder (ref.A
fig.4).
Using the 24mm open ended spanner unscrew and remove the bolt fastening the cylinder to the retractable carriage (ref.B fig.4).
Phase 4
24 mm HEX SOCKET WRENCH - RATCHET - EXTENSION
Using the open ended spanner, through the electronic controls compartment, unscrew and remove the bolt fastening the cylinder to the retractable carriage (ref.C fig.5).
Raise the cylinder rod to extract it from the pin.
Using the controls in the cab, make the rod come fully into the cylinder.
B
A
Fig. 4
Phase 5
Using the Shfer wrench, detach the connectors of the hydraulic pipes
on the cylinder (ref.D fig.6).
Raise the cylinder to extract it from the pin.
Remove the cylinder, place it on a clean work bench and proceed with
dismantling or replacement.
C
Fig. 5
Fig. 6
41
SERVICE
HYDRAULIC SYSTEM
REMOVAL OF THE FORK TILT CYLINDER
Equipment and tools
T handle hex key

6 mm
Allen key
10 mm
tackle
load capacity
1000 kg
2 lifting slings
load capacity
1000 kg
Procedure
medium flat blade

screwdriver
Fig. 1

A
Phase 1
Remove the forks.
out and raise the forks by approximately one metre.

Phase 2
10 mm Allen wrench
Using the Allen wrench, unscrew and remove the screws securing the
anti-turnover block (ref.A fig.1). Remove the block.
Phase 3
HOIST - 2 LIFTING SLINGS
Harness the movable frame with the lift belts. Hook the lift belts onto the
hoist.
Turning the movable frame, raise it with the hoist and extract it from the
fixed frame (fig.2).
42
Fig. 2
SERVICE
HYDRAULIC SYSTEM
Phase 4
MEDIUM FLAT BLADE SCREWDRIVER - 14 mm OPEN ENDED SPANNER - 6 mm T-HANDLE HEX KEY
Using the medium flat blade screwdriver, lever on and remove the lower
sliding block (ref.B fig.3).
Using the open ended spanner, unscrew and remove the hydraulic pipes
from the connectors (ref.C fig.4).
Using the T-handle hex key, unscrew and remove the screws securing
the flange (ref.D fig.3) and remove it.
Extract the cylinder from its seat and dismantle or replace.
Fig. 3
B
Fig. 4
43
SERVICE
HYDRAULIC SYSTEM
CYLINDER DISMANTLING

gasket replacement
replacing the parachute valve
Equipment and tools
workbench
vice
oil protecting
gloves
fixed gauge spanner
small flat blade

screwdrivers
oil syringe
brush
C spanner
Procedure
Phase 1
Carry out the removal procedure for the relevant cylinder (see paragraphs
above).
Phase 2
WORK BENCH WITH VICE - OIL RESISTANT GLOVES - C SPANNER
- oil pan
Lock the cylinder in the vice, placing a rubber guard between the jaws and
the cylinder and tighten carefully in order not to deform the pipe. Place the
underneath the bush of the cylinder. Apply the C spanner at the notches
on the seal carrier bush. Unscrew the bushing from the cylinder (ref.A
fig.1) extract it from the shaft and place it on the workbench. Remove
the rod from the cylinder (fig.1).
44
oil pan
round nose pliers
SERVICE
HYDRAULIC SYSTEM
REPLACING THE GASKET

Phase 3
SMALL FLAT HEAD SCREWDRIVER - BRUSH
Using the screwdriver, remove the internal seals and the seals external
to the bush and proceed with replacement.
Fig. 1
Fitting the seals is a delicate stage in the lift cylinder assembly procedure. Most maintenance operations are to
be ascribed to gasket leakage. Do not damage the parts
during assembly.
Clean the seal carrier bush and lubricate the seal contact
faces in the bush and the seals themselves with clean
hydraulic oil before installation.
DISMANTLING OF THE PARACHUTE VALVE (LIFT CYLINDERS)

Malfunction of the parachute valve can be caused by dirt causing the
spool to stick.
Clean carefully.
Phase 4
OIL RESISTANT GLOVES - ROUND NOSE PLIERS - OPEN ENDED
SPANNER
Use the open ended spanner to unscrew and remove the connector
from the cylinder (ref.B fig.2). Use the pliers to remove the valve from
its seat (ref.C fig.2). Proceed with the cleaning and elimination of any
dirt residue.
Replace if broken.
INSTALLATION
Fig. 2
The bush should be tightened during assembly to:

353-380 Nm (middle lift cylinder)
358 Nm (side lift cylinders)
Lubricate all the inner parts of the cylinder with clean hydraulic oil. Use new gaskets.
45
HYDRAULIC SYSTEM
lift pump
KEY TO LIFT PUMP COMPONENTS
Ref.
1
Cover
Gear wheel
Seal
Upper flange
5
6
46
Description
Gaskets
Upper bearing
Stator
Rotor
10
Lower bearing
11
O-ring
12
Lower flange
13
Heat sensor
SERVICE
SERVICE
HYDRAULIC SYSTEM
1
2
13
5
6
7
10
11
12
47
SERVICE
HYDRAULIC SYSTEM
LIFT PUMP DISMANTLING
Equipment and tools
workbench
hex socket
wrench
15
ratchet
extension
open ended spanShfer wrench for T handle hex key

ner
connectors
5 mm
17 mm
hoist
load capacity
1000 kg
lift belt
load capacity
1000 kg
eyebolt
Procedure
Fig. 1

ground. Turn the keyswitch to OFF and disconnect the
battery.
Before starting work, drain the oil reservoir.
Phase 1
5 mm T-HANDLE HEX KEY
(ref.A fig.1).
48
Fig. 2
SERVICE
HYDRAULIC SYSTEM
Phase 2
Using the fixed spanner, unscrew the nuts fastening the pump motor power cables.
Take note of the position of the cables. Remove the cables and disconnect the connectors.
Phase 3
15 mm SOCKET WRENCH - RATCHET - EXTENSION - Shfer WRENCH FOR CONNECTORS - OIL
RESISTANT GLOVES
Using the Shfer wrench, disconnect the connector of the hydraulic pipe connected to the pump block
(ref.B fig.3). Use the open ended spanner to unscrew the fastening screw of the elastic strip that fastens
the inlet pipe (ref.C fig.3).
Using the socket wrench, ratchet and extension, unscrew the two nuts securing the pump hydraulic block
(ref.D fig.3), loosen the nut (ref.E fig.3).
Phase 4
HOIST - LIFT BELT - EYEBOLT
Screw the eyebolt onto the pump. Insert the lift belt into the eyebolt and hook it onto the hoist.
Very carefully take up the slack in the belt with the hoist, remove the pump carrier plate from the slot (ref.F
fig.3) and slowly start raising the assembly.
Place it on a work bench or on a pallet and proceed with dismantling.
C
D
F
49
SERVICE
HYDRAULIC SYSTEM
REPLACEMENT OF THE PUMP
Equipment and tools
hex socket
wrench
17 mm
ratchet
Procedure
ground. Turn the keyswitch to OFF and disconnect the
battery.
Fig. 1
Phase 1
Carry out the procedure to remove the lift pump (see "REMOVAL OF
THE LIFT PUMP").
Phase 2
17mm SOCKET WRENCH - RATCHET
Using the socket wrench and the ratchet, unscrew and remove both
screws securing the pump to the flange (ref.A fig.1).
Remove the pump and proceed with the replacement.
INSTALLATION
During the assembly stage tighten the nuts that fasten the
pump to the flange with a torque wrench set at 45 Nm.
50
SERVICE
HYDRAULIC SYSTEM
HYDRAULIC PIPES
PIPE PLACEMENT FOR HYDRAULIC CIRCUIT
51
SERVICE
HYDRAULIC SYSTEM
RENEWAL OF THE MIDDLE LIFT CYLINDER FEED PIPE
Equipment and tools
Fig. 1
hexagonal socket
wrench
17 mm
ratchet
Procedure
ground.
Phase 1
out (fig.1).
Phase 2
WOODEN BEAM
Raise the forks by approximately one metre using the controls in the
cab.
Position the wooden beam beneath the fork carriage (ref.A fig.3).
Lower the forks and rest them on the beam, continue the descent until
the fork lift cylinder hydraulic power feed pipe becomes loose.
52
Fig. 2
Fig. 3
SERVICE
HYDRAULIC SYSTEM
Phase 3
Shfer WRENCH FOR CONNECTORS - OIL RESISTANT GLOVES
Using the Shfer wrench, disconnect the connector of the hydraulic pipe
connected to the middle lift cylinder (ref.B fig.4).
connected to the hydraulic block (ref.C fig.5).
Extract the pipe from the hose sheave and fit the new one
Fig. 4
C
Fig. 5
53
SERVICE
HYDRAULIC SYSTEM
RENEWAL OF THE FORK HYDRAULIC FUNCTIONS SUPPLY PIPES
Equipment and tools
Fig. 1
hexagonal socket
wrench
17 mm
ratchet
Procedure
ground.
Phase 1
out (fig.1).
Fig. 2
Phase 2
Using the open ended spanner, unscrew and remove the screws fastening the pipe clamps (ref.A fig.3).
Phase 3
WOODEN BEAM
Raise the forks by approximately one metre using the controls in the
cab.
Position the wooden beam beneath the fork carriage (ref.B fig.4).
Lower the forks and rest them on the beam, continue the descent until
the fork hydraulic functions supply pipe becomes loose.
54
Fig. 2
SERVICE
HYDRAULIC SYSTEM
Fig. 4
Set the key switch to OFF and disconnect the battery.
Phase 4
Shfer WRENCH FOR CONNECTORS - OIL RESISTANT GLOVES
connected to the hydraulic block on the fork carriage (ref.C fig.5).
connected to the hydraulic block (ref.D fig.5).
Extract the pipe from the hose sheave and fit the new one
Fig. 5
55
HYDRAULIC SYSTEM
56
SERVICE
SERVICE
TRUCK BASE MECHANICS

WHEELS & TYRES 2
IDENTIFICATION OF TRACTION WHEEL COMPONENTS 2
REMOVAL OF THE DRIVE WHEEL 3
KEY TO LOAD WHEEL COMPONENTS 5
REMOVING THE LOAD WHEEL 6
BATTERY BLOCK 8
RENEWAL OF THE BATTERY BLOCK 8
MOTORS 10
KEY TO TRACTION MOTOR COMPONENTS 10
REMOVAL OF THE TRACTION MOTOR 11
REPLACEMENT OF TRACTION MOTOR BEARINGS 13
KEY TO STEERING MOTOR COMPONENTS 15
STEERING MOTOR DISASSEMBLY 16
STEERING MOTOR DISMANTLING 17
STEERING SYSTEM ASSEMBLY 19
KEY TO STEERING SYSTEM ASSEMBLY COMPONENTS 19
RENEWAL OF STEERING SYSTEM ASSEMBLY BEARING 20
retractable carriage 21
KEY TO RETRACTABLE CARRIAGE COMPONENTS 21
REMOVAL OF THE RETRACTABLE CARRIAGE 22
RENEWAL OF BEARINGS AND RETRACTABLE CARRIAGE PINS 24
REMOVING THE RETRACTABLE CARRIAGE POTENTIOMETER 25
WHEELS & TYRES

IDENTIFICATION OF TRACTION WHEEL COMPONENTS
Ref.
Description
Vulkollan ring complete with hub
Drive wheel flanged retaining nut
SERVICE
SERVICE
REMOVAL OF THE DRIVE WHEEL

Equipment and tools
hydraulic jack
wooden block
T handle hex key

5 mm
hex socket
wrench
12 mm
ratchet with
extension bar
M6 screw
2 x 70 mm
Procedure
Fig. 1

ground, turn the keyswitch to OFF and disconnect the
battery.
Phase 1
bonnet (fig.2).
Phase 2
HYDRAULIC JACK - WOODEN BLOCK
Position the hydraulic jack beside the drive wheel and lift until the wooden
block can pass beneath.
Position the wooden block to the side of the truck, lower the jack to rest
the truck on the block and take up the slack on the jack (fig.3).
Fig. 2
Phase 3
2 M6 SCREWS 70 mm LONG
Insert the screws into the holes above the electromagnetic brake (fig.4),
screw them in to reach the lower disk and then tighten by a further turn
The purpose of this procedure is to disconnect the electromagnetic brake so as to free the wheel.
Fig. 3
3
SERVICE

Phase 4
12 mm SOCKET WRENCH - RATCHET - EXTENSION
Turn the wheel by hand so as to set it parallel to the truck. Using the socket
wrench, ratchet and extension, unscrew and remove the nuts securing
the drive wheel to the reduction unit (ref.B fig.5).
Raise with the hydraulic jack until the wheel passes under the truck (fig.6).
Proceed with replacement
Fig. 4
INSTALLATION
The traction wheel retaining nuts must be tightened using
a torque wrench to a torque of 130 Nm.
Unscrew and remove the two screws used to disconnect
the electromagnetic brake.
Fig. 6
Fig. 5
SERVICE
KEY TO LOAD WHEEL COMPONENTS
4
5
7
8
9
10
11
12
13
Ref.
Description
Electromagnetic brake
Brake disk
Springs
Bush
Screws fastening to the truck base
Wheel
Brake regulator
Wheel-brake fixing screw
bearing
10
Elastic ring
11
Spacer
12
Ring
13
Self-locking ring nut
SERVICE

REMOVING THE LOAD WHEEL
Equipment and tools
hydraulic jack
wooden block
socket wrench for

self-locking ring
nut
ratchet
internal circlip
pliers
T handle hex key

6 mm
Procedure
battery.
Fig. 1
Phase 1
Position the hydraulic jack beside the load wheel and lift until the wooden
stock can pass beneath.
Set the wooden block under the clamp, lower the jack to rest the truck
on the block and take up the slack on the jack (fig.1).
Phase 2
SOCKET WRENCH FOR SELF-LOCKING RING NUT - RATCHET
Using the socket wrench for the self-locking ring nut and the ratchet,
unscrew and remove the ring nut (ref.A fig.2), remove the toothed
washer.
Extract the wheel from the hub and dismantle or replace.
a
Fig. 2
Fig. 3
REMOVAL OF THE WHEEL BEARING
Phase 3
LARGE INTERNAL CIRCLIP PLIERS
Use the internal circlip pliers to remove the circlip securing the bearing
(ref.B fig.3). Remove the bearing (ref.C fig.3) and proceed with the
replacement.
SERVICE
REMOVAL OF THE BRAKE DISK

Phase 4
HEXAGONAL 6 mm "T" SECTION SPANNER
Using the T-handle hex key, remove the screws securing the brake disk to
the wheel together with the bush and spring (ref.D fig.4). When removing
the disk, pay attention to the springs (ref.E fig.4).
Fig. 4
INSTALLATION
The screws securing the brake disk must be tightened using a torque wrench to a torque of 25 Nm. Apply Loctite
270.
SERVICE
BATTERY BLOCK
RENEWAL OF THE BATTERY BLOCK
Equipment and tools
hex socket
wrench
15 mm
ratchet
open-ended span- hexagonal "T"

ner
section spanner
10 - 13 mm
5 - 6 mm
Procedure
Fig. 1

ground.
Phase 1
the battery.
out.

Phase 2
bonnet (fig.2).
Fig. 2
Fig. 3
B
C
SERVICE
Phase 3
Using the open ended spanner, unscrew and remove the screws fastening the bracket inside the motor compartment (ref.B fig.3). Remove the
bracket (ref.C fig.3).
Fig. 4
Phase 4
15 mm HEXAGONAL SOCKET WRENCH - RATCHET
Using the hex socket wrench and the ratchet, unscrew and remove the
screws securing the battery block (ref.D fig.4). Remove the battery block
and proceed with replacement or disassembly.
BLOCK DISMANTLING
Phase 5
6 mm T-HANDLE HEX KEY - 13 mm OPEN ENDED SPANNER
Using the open ended spanner, loosen the nut (ref.E fig.5) and, using
the T-handle hex key, unscrew and remove the screw (ref.F fig.5). Extract the pin including the spring and proceed with replacement of the
components.
Fig. 5
F
E
SERVICE
MOTORS
KEY TO TRACTION MOTOR COMPONENTS
1
2
3
10
11
12
13
14
15
16
17
18
Ref.
10
Description
Ref.
Description
upper flange fastening screws
11
Stator
Upper flange
12
Lower flange
Circlip
13
Bush
Circlip
14
Seal
O-ring
15
Lower bearing
Upper bearing
16
Elastic ring
Elastic ring
17
Circlip
Gear wheel
18
O-ring
Rotor
10
Sensor
SERVICE
REMOVAL OF THE TRACTION MOTOR

Equipment and tools
tackle
load capacity
1000 kg
lift belt
load capacity
1000 kg
open ended spanT handle hex key

ner
5-6 mm
13 mm
eyebolt
Procedure
Fig. 1

Phase 1
bonnet (fig.2).
Phase 2
Carry out the electromagnetic brake removal procedure (see "REMOVAL
OF THE ELECTROMAGNETIC BRAKE" in the "BRAKING SYSTEM"
section).
Phase 3
Unscrew the traction motor power cable fastening nuts. Note the position of the cables prior to removing them. Disconnect the sensor cable
connector.
Phase 4
Using the T-handle hex key, unscrew and remove the 6 screws fastening
the traction motor to the reduction unit (ref.B fig.3).
Fig. 2
Fig. 3
11
SERVICE

Phase 5
HOIST - LIFT BELT - EYEBOLT
Screw the eyebolt onto the rotor shaft. Insert the lift belt into the eyebolt
and hook it onto the hoist.
Very carefully start slowly lifting the motor (fig.4).
Place it on a work bench or on a pallet and proceed with dismantling.
INSTALLATION
Before installing the motor on the reduction unit, lubricate
the drive shaft with a thin, even layer of special grease:
SHELL GADUS S2 OGH 0/00.
During the coupling stage, carefully rotate the wheel shaft
to help the motor shaft engage with the pinion.
12
Fig. 4
SERVICE
REPLACEMENT OF TRACTION MOTOR BEARINGS

Equipment and tools
Fig. 1
A
T handle hex key
5 mm
medium
adjustable pliers
plastic hammer
bush
internal circlip
pliers
external circlip
pliers
Procedure

Phase 1
MEDIUM ADJUSTABLE PLIERS - EXTERNAL CIRCLIP PLIERS
Using the adjustable pliers, extract the key securing the brake guide
(ref.A fig.1).
Use the external circlip pliers to remove the circlip securing the flange to
the shaft (ref.B fig.1).
Phase 2
Using the T-handle hex key, unscrew and remove the screws fastening the
upper flange to the lower flange (ref.C fig.2). Recover both flanges.
Fig. 2
13
SERVICE

Phase 3
INTERNAL CIRCLIP PLIERS
Use the circlip pliers to remove the circlip securing the upper bearing to
the flange (ref.D fig.3).
Recover the bearing and proceed with replacement.
Fig. 3
Phase 4
INTERNAL CIRCLIP PLIERS - EXTERNAL CIRCLIP PLIERS - MEDIUM
ADJUSTABLE PLIERS
Remove the pinion from the shaft. Using the adjustable pliers, extract
the pinion coupling key. Use the circlip pliers to remove the two circlips
securing the lower bearing and the bush to the shaft (ref.E-F fig.4).
INSTALLATION
During the assembly stage replace all the gaskets with new
gaskets.
Assemble the new bearings using a plastic hammer and
a bushing.
14
F
E
Fig. 4
SERVICE
KEY TO STEERING MOTOR COMPONENTS
6
1
7
8
9
2
10
11
3
12
13
14
15
Ref.
Description
Ref.
Description
upper flange fastening screws
11
Upper bearing
Sensor
12
Elastic ring
Upper flange
13
Rotor
Stator
14
Lower bearing
Lower flange
15
Ring
Elastic ring
Ring
Elastic ring
Magnet
10
Circlip
15
SERVICE

STEERING MOTOR DISASSEMBLY
Equipment and tools
open ended spanT handle hex key

ner
5 mm
13 mm
Procedure
Fig. 1

Phase 1
bonnet (fig.2).
Phase 2
Disconnect the connector. Using the socket wrench, unscrew and remove
the three screws fastening the steering motor to the plate (ref.B fig.3).
Remove the steering motor without damaging the gear wheel and proceed
with dismantling or replacement.
Fig. 2
Fig. 3
B
16
SERVICE
STEERING MOTOR DISMANTLING

Equipment and tools
Fig. 1
A
hexagonal "T"
section spanner
3-4-5-6 mm
medium crosshead screwdriver
plastic hammer
bush
internal circlip
pliers
external circlip
pliers
Fig. 2
B
Procedure
C
REMOVAL OF THE ELECTRICAL BOX
Phase 1
MEDIUM CROSSHEAD SCREWDRIVER - 6 mm T-HANDLE HEX
KEY
With the screwdriver, unscrew and remove the screws fastening the upper
cover of the electrical box (ref.A fig.1). Remove the cover.
Unscrew and remove the three fastening screws of the motor phase
terminals (ref.B fig.2).
Unscrew and remove the screws that fasten the side cover (ref.C fig.3).
Remove the cover together with the printed circuit board. Disconnect the
internal connector.
Using the T-handle hex key, unscrew the screws fastening the box to
the motor flange.
Fig. 3
17
SERVICE

BEARING REMOVAL
Phase 2
4-5-6 mm T-HANDLE HEX KEY
Using the 5 mm T-handle hex key unscrew and remove the pinion fixing
screw (ref.D fig.4). Remove the washer (ref.E fig.4) and take out the
pinion (ref.F fig.4).
Using the 6 mm T-handle hex key, unscrew and remove the screws securing the triangular bracket (ref.G fig.4). Remove the bracket.
Using the 4 mm T-handle hex key, unscrew and remove the screws securing the steering box (ref.H fig.4). Remove the box.
Phase 3
3-4 mm T-HANDLE HEX KEY - EXTERNAL CIRCLIP PLIERS - INTERNAL CIRCLIP PLIERS
Using the 3 mm T-handle hex key, unscrew and remove the screws securing the motor cover (ref.I fig.5). Remove the cover.
Use the external circlip pliers to remove the circlip securing the flange
to the crankshaft.
Using the 4 mm T-handle hex key, unscrew and remove the screws
joining the upper flange to the lower flange (ref.J fig.5). Recover both
flanges.
Use the circlip pliers to remove the circlip securing the upper bearing to
the flange.
INSTALLATION
During the assembly stage replace all the gaskets with new
gaskets.
Assemble the new bearings using a plastic hammer and
a bushing.
18
Fig. 4
E
F
G
Fig. 5
I
J
SERVICE
STEERING SYSTEM ASSEMBLY

KEY TO STEERING SYSTEM ASSEMBLY COMPONENTS
12
3
4
5
6
13
8
9
14
10
11
Ref.
Description
Ref.
Description
11
Stepper motor
Driving
12
Bearing
Adjuster plate
13
Spring
Block
14
Bearing
Pin
Spring
Pushrod
Elastic ring
Ball bearing
10
Shaft
19
SERVICE

RENEWAL OF STEERING SYSTEM ASSEMBLY BEARING
Equipment and tools
small flat blade

screwdriver
internal circlip
pliers
hex socket
wrench
7-13 mm
ratchet
Procedure
Phase 1
To recover the block together with the bearing, see REPLACING THE
ARMREST AND MAIN PANEL CONTROLS: STEERING WHEEL STEPPER MOTOR in the ELECTRICAL SYSTEM section.
Phase
internal circlip pliers
Use the internal circlip pliers to remove the circlip securing the bearing
(ref.A fig.1). Remove the bearing and proceed with the replacement.
20
Fig. 1
SERVICE
retractable carriage
KEY TO RETRACTABLE CARRIAGE COMPONENTS
3
4
7
Ref.
Description
Cover for access to the hydraulic control valve
Circlip
Bearing
Pin
bearing
Adjuster roller
Self-locking ring nut
Buffer
Adjusting screw
21
SERVICE

REMOVAL OF THE RETRACTABLE CARRIAGE
Equipment and tools
B
bridge crane
load capacity
2000 kg
2 lifting slings
load capacity
2000 kg
hex socket
wrench
10 mm
ratchet and
extension
Fig. 1
Fig. 2
hexagonal "T" open-ended spanShfer wrench for
section spanner
ner
connectors
3-14 mm
8-24 mm
Procedure
Phase 1
Carry out the mast removal procedure (see REMOVAL OF THE BEARINGS in the MAST MECHANICS section).
Phase 2
Using the Shfer wrench, detach the connectors of the hydraulic pipes
on the hydraulic control valve.
Disconnect the connectors from the solenoid valves.
22
C
Fig. 3
Fig. 4
SERVICE
Phase 3
3 mm T-HANDLE HEX KEY - 8-24 mm OPEN ENDED SPANNER
Using the 8mm open ended spanner and the T-handle hex key, unscrew
and remove the screw fastening the potentiometer to the cylinder (ref.A
fig.1).
Using the 24mm open ended spanner unscrew and remove the bolt fastening the cylinder to the retractable carriage (ref.B fig.1).
Raise the cylinder to extract it from the pin.
Fig. 5
Phase 4
10 mm socket wrench - extension - ratchet
Using the socket wrench, extension and ratchet, unscrew and remove
the screws securing the carriage of the plate on which is secured the
pipe carrier chain (ref.C fig.3).
Phase 5
Using the T-handle hex key, unscrew and remove the limit stop screws
of the retractable carriage (ref.D fig.4).
Phase 6
BRIDGE CRANE - 2 LIFTING SLINGS
Harness the retractable carriage with the lift belts on the two crossbars
(fig.5). Hook the lift belts onto the bridge crane. Take up the slack on the
belts and extract the retractable carriage horizontally, place it on a pallet
and proceed with dismantling.
INSTALLATION
The limit stop screws must be tightened using a torque
wrench with a tightening torque of 300 - 330 Nm.
23
SERVICE

RENEWAL OF BEARINGS AND RETRACTABLE CARRIAGE PINS
Equipment and tools
external circlip
pliers
open ended
spanner
24 mm
socket wrench for

self-locking ring
nut
ratchet
driving tool
10 mm
hammer
Procedure
Phase 1
Carry out the retractable carriage removal procedure (see REMOVAL
OF THE RETRACTABLE CARRIAGE).
A
Fig. 1
Phase 2
external circlip pliers
Use the circlip pliers to remove the circlip securing the bearing block (ref.A
fig.1). Remove the bearing and proceed with the replacement.
Phase 3
24 mm OPEN ENDED SPANNER - SOCKET WRENCH FOR SELFLOCKING RING NUT - RATCHET. CLAMP GUDGEON - HAMMER
Using the open ended spanner, unscrew the nut securing the roller adjusting screw (ref.B fig.2). Unscrew and remove the screw (ref.C fig.2).
Using the hammer and the clamp gudgeon extract the roller (ref.D
Fig.2).
Using the socket wrench for self-locking ring nuts, unscrew and remove
the ring nut (ref.E fig.2).
Using the hammer and clamp gudgeon extract the pin from the carriage
(ref.F fig.2).
INSTALLATION
Coat the new bearings with a layer of special lubricating
grease RETINAX HDX2 for standard applications or
AERO SHELL GREASE 6 for applications in a cold
store.
24
C
B
Fig. 2
SERVICE
REMOVING THE RETRACTABLE CARRIAGE POTENTIOMETER

Equipment and tools
Fig. 1
T-handle hex key

3 mm
open-ended spanner
8 mm
Procedure
Phase 1
out (fig.1).
Fig. 2
Phase 2
3 mm T-HANDLE HEX KEY - 8 mm OPEN ENDED SPANNER
Using the T-handle hex key, unscrew and remove the screw securing the
potentiometer to the cylinder (ref.A fig.3).
Using the open ended spanner, unscrew and remove the nut securing
the potentiometer to the carriage (ref.B fig.3).
Disconnect the connector and proceed with replacement.
Fig.3
25
26
SERVICE
SERVICE
MAST ASSEMBLY MECHANICS
Mast assembly
mechanics
MAST CHARACTERISTICS 2
MAST ELEVATION 4
3 STAGE MAST 8
IDENTIFICATION OF THE 3 STAGE MAST ASSEMBLY COMPONENTS 8
BEARING REPLACEMENT 9
REPLACEMENT OF CHAINS AND CHAIN TENSIONER 14
RENEWAL OF THE MIDDLE SECTION CHAIN SHEAVES 17
RENEWAL OF THE MIDDLE CYLINDER CHAIN SHEAVE 19
SERVICE
MAST CHARACTERISTICS
The masts used have three stages.
These masts have machined channels so as to reduce the distance between the channel chamber and
the rollers. The channels are machined with special machinery to permit smooth movement of the mast
assembly, less oscillation, less friction, low wear, and less noise.
Wider rollers permit handling heavier loads. Hassle-free setting of the correct axis of the bearings without
having to remove the roller entirely.
SERVICE
MAST ELEVATION
SERVICE
SERVICE
Model
MR16N
MR14
MR16
MR20
MR25

(mm)
Free Lift
(mm)
Height, mast
lowered
(mm)
Extended
dimensions
(mm)
h3
h2
h1
h4
5000
1648
2195
5563
911
5250
1734
2281
5813
936
5500
1820
2367
6063
961
5750
1906
2453
6313
986
6000
1992
2539
6563
1010
6250
2078
2625
6813
1035
6500
2164
2711
7063
1060
6750
2250
2797
7313
1090
7000
2336
2883
7563
1115
7250
2422
2969
7813
1140
7500
2508
3055
8063
1164
7750
2594
3141
8313
1220
8000
2680
3227
8563
1244
8250
2766
3313
8813
1269
8500
2852
3399
9063
1299
8750
2938
3485
9313
1324
9000
3024
3571
9563
1349
9250
3110
3657
9813
1376
9500
3196
3743
10063
1400
9750
3282
3829
10313
1425
10000
3368
3915
10563
1454
10250
3454
4001
10813
1478
10500
3540
4087
11063
1503
4650
1582
2195
5263
958
4900
1668
2281
5513
985
5150
1754
2367
5763
1012
5400
1840
2453
6013
1038
5650
1926
2539
6263
1065
5900
2012
2625
6513
1092
6150
2098
2711
6763
1118
6400
2184
2797
7013
1150
6650
2270
2883
7263
1177
6900
2356
2969
7513
1204
7150
2442
3055
7763
1230
7400
2528
3141
8013
1288
7650
2614
3227
8263
1314
7900
2700
3313
8513
1341
8150
2786
3399
8763
1373
Weight
(kg)
Model
MR20HD
MR16HD
SERVICE

(mm)
Free Lift
(mm)
Height, mast
lowered
(mm)
Extended
dimensions
(mm)
h3
h2
h1
h4
7900
2614
3227
8513
1372
8150
2700
3313
8763
1401
8400
2786
3399
9013
1435
8650
2872
3485
9263
1464
8900
2958
3571
9513
1523
9150
3044
3657
9763
1552
9400
3130
3743
10013
1581
9650
3216
3829
10263
1609
9900
3302
3915
10513
1638
10150
3388
4001
10763
1671
10400
3474
4087
11013
1699
10650
3560
4173
11263
1728
10900
3646
4259
11513
1757
11150
3732
4345
11763
1786
Weight
(kg)
11400
3818
4431
12013
1814
11650
3904
4517
12263
1843
11900
3990
4603
12513
1872
12150
4076
4689
12763
1901
12400
4162
4775
13013
1929
12650
4248
4861
13263
1958
8050
2680
3227
8613
1346
8300
2766
3313
8863
1374
8550
2852
3399
9113
1408
8800
2938
3485
9363
1436
9050
3024
3571
9613
1495
9300
3110
3657
9863
1524
9550
3196
3743
10113
1552
9800
3282
3829
10363
1580
10050
3368
3915
10613
1612
10300
3454
4001
10863
1641
10550
3540
4087
11113
1669
10800
3626
4173
11363
1698
11050
3712
4259
11613
1726
11300
3798
4345
11863
1755
11550
3884
4431
12113
1783
SERVICE
3 STAGE MAST
IDENTIFICATION OF THE 3 STAGE MAST ASSEMBLY COMPONENTS
Ref.
Description
Outer upright
Intermediate upright
Inner upright
Roller
Chain tensioner
Buffer
Hose sheave
Side lift cylinder
Middle lift cylinder
10
Hydraulic pipe
SERVICE
SERVICE
4
6
5
7
8
10
5
6
7
4
5
4
8a
SERVICE
BEARING REPLACEMENT
3 STAGE MAST
To allow bearing replacement the mast assembly must be removed from the truck base.
Equipment and tools
bridge crane
load capacity
3000 kg
ladder
safety harness
n. 3 iron trestles
wooden block
Shfer wrench for

connectors
lifting sling
load capacity
3000 kg
Allen key
6 - 2.5 mm
24 mm socket
wrench
ratchet
plastic hammer
taper end pliers
open ended spanmedium elastic

ner
ring opening pliers
size 19 - 2x24 2x15 mm
Procedure
Move the truck to a safe place, away from the transit areas of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.
The hydraulic fluid gets very hot during system operation and can cause burns. It is
advisable to wear gloves that are resistant to oil and high temperatures.
SERVICE

MAST ASSEMBLY REMOVAL
Phase 1
out.
Phase 2
WOODEN BLOCK
Place the wooden block under the forks (fig.1). Lower the clamps to rest
on the blocks and continue until the end stroke of the cylinder.
Fig. 1
Fig. 2
Phase 3
at the top (ref.A fig.2). Rest the chain on the forks.
Using the Shfer wrench, detach the hydraulic pipes on the control valve of
the fork carriage. Disconnect the electric cables from the fork carriage.
Phase 4
Raise the cylinder using the controls in the cab until the fork carriage is
fully extracted from below.
Set the fork carriage in a safe place. Fully retract the cylinder.
Phase 5
BRIDGE CRANE - LADDER - SAFETY HARNESS - LIFT BELT
Climb up the ladder with the tools and secure the safety harness to the
cab.
Insert the lift belt beneath the upper crossbar of the middle section of the
mast assembly by making a noose and hook the ends to the bridge crane
hook (fig.4). Climb down the ladder, raise the bridge crane to reveal the
screws securing the mast assembly to the truck base.
Fig. 3
Fig. 4
10
SERVICE
Phase 6
24 mm SOCKET WRENCH - RATCHET - BRIDGE CRANE - LIFT
BELT
securing the mast assembly to the truck base (ref.B fig.5).
Using the bridge crane, lower the mast assembly to the ground.
Climb the ladder again.
Slip the lift belt beneath the upper crossbars of the mast assembly by
making a noose and hook the ends to the bridge crane hook (fig.6). Lift
the bridge crane and take up the slack in the belt.
Fig. 5
Phase 7
SHFER WRENCH FOR CONNECTORS
Using the Shfer wrench, detach the hydraulic pipes on the control valve
of the mast assembly (ref.C fig.7).
Phase 8
Using the open ended spanner, unscrew and remove the screws securing
both side blocks of the mast assembly (ref.D fig.8). Remove the blocks
(ref.E fig.8).
Using the bridge crane slowly lift the mast assembly and separate it from
the truck base. Position the mast assembly on two iron trestles and rest
it on the ground on wooden beams (fig.9).
Fig. 6
Fig. 7
Fig. 8
Fig. 9
11
SERVICE
Fig. 10
J
H
REMOVAL OF CHAINS AND CYLINDERS

Phase 9
TAPER END PLIERS - 2 OPEN ENDED SPANNERS SIZE 24 mm
Using the taper end pliers remove the cotter pin on the chain tensioner (ref.F fig.10) and the one on the
pin (ref.G fig.10).
Using the open ended spanners, unscrew and remove the nuts fastening the chain tensioner to the mast
assembly (ref.H fig.10). Remove the pin and extract the chain from the hose sheave. Perform the same
procedure on the opposite side of the mast assembly.
Phase 10
MEDIUM EXTERNAL CIRCLIP PLIERS - 2 OPEN ENDED SPANNERS SIZE 15 mm - SHFER WRENCH
FOR CONNECTORS - ALLEN WRENCH SIZE 6 mm
Use the pliers to remove the circlip securing the cylinder (ref.I fig.10).
Using the open ended spanners, unscrew and remove the screws fastening the cylinder locking bracket
(ref.J fig.10). Remove the bracket.
Using the Shfer wrench, detach the hydraulic pipe at the base of the cylinder (ref.K fig.10).
Using the Allen wrench, unscrew and remove the screw securing the cylinder (ref.L fig.10).
Remove the cylinder and carry out the same procedure on the other cylinder.
12
SERVICE
BEARING REMOVAL
Fig. 11
Phase 11
Shift the inner upright in such a way as to get a view of the bearings.
Phase 12
2.5 mm ALLEN WRENCH - PLASTIC HAMMER
bearing to the mast assembly (ref.M fig.11). With the aid of the hammer,
remove the bearing and proceed with the replacement.
INSTALLATION
Fig. 12
The new bearings do not need to be greased.

When fitting the new bearings, use a plastic hammer and
a pipe as wide as the black part of the bearing (fig.12).
Position the pipe on the black part of the bearing and hammer until you hear the metal of the mast channel.
During the assembly stage, tighten the nuts securing the
mast assembly to the truck base with a torque wrench to
300-330 Nm.
During the assembly stage, tighten the screws fastening
both side blocks of the mast assembly (ref.D fig.8) with a
torque wrench set at 88-97 Nm.
13
SERVICE

REPLACEMENT OF CHAINS AND CHAIN TENSIONER
3 STAGE MAST
Never just replace the worn part of a chain. Replace the entire chain. Similarly, never
replace just one chain of a couple, always replace both.
Equipment and tools
Fig. 1
bridge crane
load capacity
1200 kg
lifting sling
load capacity
1200 kg
wooden beam
ladder
safety harness
open-ended spanner
2x24 mm
taper end pliers
Fig. 2
Procedure
ground.
Phase 1
out (fig.1).
Fig. 3
14
SERVICE
MAST ASSEMBLY CHAIN TENSIONER AND CHAIN

Phase 2
WOODEN BEAM
Raise the forks by approximately two metres using the controls in the
cab.
Place the wooden beam beneath the inner mast channel (ref.A fig.2).
Lower the forks until they rest on the beam, continue the descent until
the chains are loose.
Fig. 4
Fig. 5
Phase 3
cab.
Insert the lift belt beneath the upper crossbar of the inner upright of the
hook (fig.3). Climb down the ladder, raise the bridge crane and take up
the slack in the belt.
Phase 4
Using the taper end pliers remove the cotter pin on the chain tensioner
on the inner upright of the mast assembly (ref.B fig.6).
Using the open ended spanners, unscrew and remove the nuts fastening
the chain tensioner (ref.C fig.6). Extract the chain tensioner upwards.
Using the taper end pliers remove the cotter pin and the hinge pin securing the chain to the chain tensioner (ref.D fig.6).
Phase 5
Using the taper end pliers remove the cotter pin on the chain tensioner
at the top on the outer upright of the mast assembly (ref.E fig.4).
the chain tensioner (ref.F fig.4). Extract the chain tensioner upwards,
retrieve the chain by sliding it on the hose sheave and proceed with the
replacement.
Fig. 6
B
15
SERVICE

FORK CHAIN TENSIONER AND CHAIN
Phase 2
WOODEN BLOCK

Fig. 7
Phase 3
at the top (ref.G fig.8). Rest the chain on the forks.
the chain tensioner (ref.H fig.9). Extract the chain tensioner upwards.
at the bottom (ref.I fig.10).
Retrieve the chain and proceed with the replacement.
Fig. 8
ASSEMBLY
Fig. 9
Do not reuse the chain anchoring safety pins, use new

cotter pins, ensuring they are the correct size.
Fig. 10
16
SERVICE
RENEWAL OF THE MIDDLE SECTION CHAIN SHEAVES

3 STAGE MAST
Equipment and tools
Fig. 1
bridge crane
load capacity
1200 kg
lifting sling
load capacity
1200 kg
external circlip
pliers
wooden beam
ladder
safety harness
Fig. 2
Procedure
ground.
Phase 1
out (fig.1).
Phase 2
WOODEN BEAM
Raise the forks by approximately two metres using the controls in the
cab.
Place the wooden beam beneath the inner mast channel (ref.A fig.2).
Lower the forks until they rest on the beam, continue the descent until
the chains are loose.
Fig. 3
17
SERVICE
Fig. 4
Turn the ignition key to OFF and disconnect the battery.
Phase 3
cab.
Insert the lift belt beneath the upper crossbar of the inner upright of the
hook (fig.3). Climb down the ladder, raise the bridge crane and take up
the slack in the belt.
Phase 4
MEDIUM SIZE ELASTIC RING OPENING PLIERS
Use the pliers to remove the circlip securing the sheave (ref.B fig.4).
Remove the hose sheave and proceed with the replacement.
18
SERVICE
RENEWAL OF THE MIDDLE CYLINDER CHAIN SHEAVE

3 STAGE MAST
Equipment and tools
Fig. 1
A
fixed gauge spanT handle hex key
ner
6 mm
18 mm
hammer
clamp gudgeon
Procedure
ground.
Phase 1
Carry out the fork chain dismantling procedure (see "CHAIN AND CHAIN
TENSIONER REPLACEMENT").
Phase 2
Using the open ended spanner, unscrew and remove the screws fastening
the two hose sheaves at the sides of the chain sheave (ref.A fig.1).
Remove the two sheaves.
Phase 3
6 mm "T" HANDLE HEX KEY - HAMMER - CLAMP GUDGEON 30
mm
Using the T-handle hex key, unscrew and remove the sheave pin retaining screw (ref.B fig.2).
Using the hammer and clamp gudgeon extract the pin, remove the sheave
and proceed with replacement.
Fig. 2
19
20
SERVICE
SERVICE
SMALL FORK MAST MECHANICS
Small fork mast

mechanics
FORK CARRIAGE 2
KEY TO FORK CARRIAGE COMPONENTS 2
REMOVAL OF THE FORK CARRIAGE 3
REMOVAL OF THE SLIDING BLOCKS 4
BEARING REPLACEMENT 6
SERVICE
FORK CARRIAGE
KEY TO FORK CARRIAGE COMPONENTS
10
8
3
11
12
6
5
Ref.
Description
Ref.
Description
Forks
Bearing
Hydraulic block
Side shift cylinder
Fixed frame
Upper sliding block
Movable frame
10
Anti-overturning system block
Flange
11
Movable frame sliding blocks
Tilt cylinder
12
Lower sliding block
SERVICE
REMOVAL OF THE FORK CARRIAGE

Equipment and tools
Shfer wrench for

connectors
wooden block
taper end pliers
Procedure
Fig. 1
Fig. 2

A
Phase 1
out. Remove the cover to access the hydraulic control valve (fig.3).
Phase 2
WOODEN BLOCK
Using the controls in the cab, make the retractable carriage come fully out.
Raise the forks just enough to be able to pass the wooden block underneath. Place the wooden block under the forks (fig.1). Lower the clamps
to rest on the blocks and continue until the end stroke of the cylinder.
Phase 3
at the top (ref.A fig.2). Rest the chain on the forks. Using the Shfer
wrench, detach the hydraulic pipes on the control valve of the fork carriage. Disconnect the electric cables from the fork carriage.
Fig. 3
Phase 4
Raise the cylinder using the controls in the cab until the fork carriage is fully extracted from below. Set the
fork carriage in a safe place and proceed with dismantling.
SERVICE

REMOVAL OF THE SLIDING BLOCKS
The sliding blocks must be replaced in the event of wear, that is if their thickness is:
upper sliding blocks: less than 4.5mm
movable sliding blocks: less than 3mm
Equipment and tools
Allen key
10 mm
tackle
load capacity
1000 kg
2 lifting slings
load capacity
1000 kg
flat head screwdriver
Procedure
hammer
pin punch
Fig. 1

A
Phase 1
Remove the forks.
out and raise the forks by approximately one metre.

Phase 2
10 mm Allen wrench
anti-turnover block (ref.A fig.1). Remove the block.
Phase 3
HOIST - 2 LIFTING SLINGS
Harness the movable frame with the lift belts. Hook the lift belts onto the
hoist.
Turning the movable frame, raise it with the hoist and extract it from the
fixed frame (fig.2).
4
Fig. 2
SERVICE
REMOVAL OF THE LOWER SLIDING BLOCK
Fig. 3
Phase 4
MEDIUM FLAT BLADE SCREWDRIVER
Using the medium flat blade screwdriver, lever between the sliding block
and the fixed frame. Remove the lower sliding block (ref.B fig.3) and
REMOVAL OF THE UPPER SLIDING BLOCKS

Phase 4
MEDIUM FLAT BLADE SCREWDRIVER
Using the flat blade screwdriver, prise out the upper sliding block (ref.C
fig.4). Proceed with replacement
Fig. 4
REMOVAL OF THE MOVABLE FRAME SLIDING BLOCKS

Phase 4
MEDIUM FLAT BLADE SCREWDRIVER - hammer - pin punch
With the flat head screwdriver unscrew the screws fastening the sliding
block (ref.D fig.5). Using the hammer and pin punch, strike the pins (ref.E
fig.5), remove the sliding block and proceed with replacement.
Fig. 5
SERVICE

BEARING REPLACEMENT
Equipment and tools
T-handle hex key

2.5 mm
plastic hammer
Procedure
Phase 1
Carry out the fork carriage removal procedure (see REMOVAL OF THE
FORK CARRIAGE).
Phase 2
2.5 mm T-HANDLE HEX KEY - PLASTIC HAMMER
bearing to the mast assembly (ref.A fig.1). With the aid of the hammer,
remove the bearing and proceed with the replacement.
Fig. 1
SERVICE
REDUCTION GEAR
Reduction gear
KEY TO REDUCTION UNIT COMPONENTS 2
REMOVAL OF THE REDUCTION UNIT 4
REPLACEMENT OF TRACTION MOTOR DRIVE SHAFT RADIAL O-RING 6
REPLACEMENT OF WHEEL SHAFT RADIAL O-RING 7
CHANGING THE REDCUTION UNIT OIL 9
SERVICE
REDUCTION GEAR
KEY TO REDUCTION UNIT COMPONENTS
1
2
41
3
4
5
6
7
8
10
11
13
12
15
14
17
16
18
19
22
23
20
21
42
32
40
39
38
37 36 35 34 33
24 25 26 27 28 29 30 31
type gearbox
serial number
TYPE
42
PARTS LIST N
gearbox model
CUSTOMER CODE N
SERIAL-N
TOTAL RATIO
gearbox transmission
SERVICE
Ref.
REDUCTION GEAR
Description
Ref.
Description
Revolving ring bearing
22
Spring pin
Cap screws
23
Reduction unit housing
Steering pinion
24
Elastic dowel
Steering ring
25
Crown wheel
Washer
26
Circlip
Hex nut
27
Taper roller bearing
Helical gear
28
Spacer
29
O-ring
Radial seal ring
30
Reduction unit housing cover
10
Spacers
31
Cap screw
11
Elastic ring
32
Seal rings
12
Ball bearing
33
Oil drain plug
13
34
Oil filler plug
14
Crown wheel coupling pinion
35
15
Bevel pinion
36
Spacer
16
Hex nut
37
Radial seal ring
17
Screw cap
38
Wheel shaft
18
Seal ring
39
Wheel pin
19
Ball bearing
40
Wheel shaft guard
20
Cover
41
Gearbox type punching
21
Cap screw
42
Data plate
SERVICE
REDUCTION GEAR
REMOVAL OF THE REDUCTION UNIT

Equipment and tools
open ended spanner

10 mm
tackle
load capacity
1000 kg
2 lifting slings
load capacity
1000 kg
socket wrench
16 mm
Procedure
ratchet
torque wrench
Fig. 1
A
B
Phase 1
Perform the traction wheel dismantling procedure (see DISMANTLING
THE TRACTION WHEEL in the BASE TRUCK MECHANICS section).
Phase 2
Perform the traction motor dismantling procedure (see DISMANTLING
THE TRACTION MOTOR in the BASE TRUCK MECHANICS section).
Phase 3
Perform the steering motor dismantling procedure (see DISMANTLING
THE STEERING MOTOR in the BASE TRUCK MECHANICS section).
Fig. 2
Phase 4
Empty the reducer of all oil (see REPLACEMENT OF REDUCER
OIL).
Phase 5
Using the open ended spanner, unscrew and remove the screws fastening the bracket inside the motor compartment (ref.A fig.1). Remove the
bracket (ref.B fig.1).
Fig. 3
SERVICE
REDUCTION GEAR
Phase 6
16 mm SOCKET WRENCH - RATCHET
Disconnect the connector of the centring sensor.
securing the plate to the frame (ref.C fig.2).
Phase 7
HOIST - 2 LIFT BELTS - 16 mm SOCKET WRENCH - RATCHET
Secure the reduction unit plate with the two lift belts. Attach the belts to
the hoist (fig.3).
Using the hoist, slowly lift the plate together with the reduction unit and
rest it on a work surface.
securing the reduction unit to the plate (ref.D fig.4). Remove the plate
and proceed with dismantling the reduction unit.
Fig. 4
INSTALLATION
The screws securing the reduction unit to the plate must
be tightened using a torque wrench to a torque of 88 Nm.
REDUCTION GEAR
SERVICE
REPLACEMENT OF TRACTION MOTOR DRIVE SHAFT RADIAL O-RING

Equipment and tools
small flat blade

screwdriver
brush
Procedure
Phase 1
Perform the traction motor dismantling procedure (see DISMANTLING
THE TRACTION MOTOR in the BASE TRUCK MECHANICS section).
Phase 2
SMALL FLAT BLADE SCREWDRIVER
Using the screwdrivers extract the radial o-ring from it's seat (fig.1) and
proceed with its replacement.
INSTALLATION
In the assembly stage apply a uniform layer of "SHELL
ALVANIA R3" grease over the o-ring radial gasket.
Fig. 1
SERVICE
REDUCTION GEAR
REPLACEMENT OF WHEEL SHAFT RADIAL O-RING

Equipment and tools
workbench
puller
seelant
Loctite 574
hex socket
wrench
8 mm
clamp gudgeon
hammer
small flat blade

screwdriver
brush
ratchet
medium elastic
ring opening pliers
Procedure
Phase 1
Carry out the reduction unit removal procedure (see REMOVAL OF THE
REDUCTION UNIT).
Phase 2
HEXAGONAL 8 mm "T" SECTION SPANNER - RATCHET
Unscrew and remove the screws fastening the reducer box casing (ref.A
fig.1).
Remove the cover (fig.1).
Fig. 1
Phase 3
EXTRACTOR - MEDIUM SIZE ELASTIC RING OPENING PLIERS
Using the extractor remove the conical roller bearing (ref.B fig.2) from
the wheel drive shaft.
Use the elastic ring pliers to remove the elastic ring holding the wheel
drive shaft bearing (ref.C fig.2).
Fig. 2
SERVICE
REDUCTION GEAR
Phase 4
CLAMP GUDGEON - HAMMER
Position the clamp gudgeon against the wheel drive shaft (fig.3) and use
the hammer to expel the shaft out the other side (ref.D fig.4). Retrieve
the wheel shaft protection (ref.E fig.4).
Phase 5
Remove the bevel gear ring (ref.F fig.5).
Retrieve the spacers (ref.H fig.5) and the conical roller bearing (ref.H
fig.5).
Fig. 3
Phase 6
SMALL FLAT HEAD SCREWDRIVER
Using the screwdrivers extract the radial o-ring gasket from it's seat (ref.I
fig.6) and proceed with its replacement.
D E
INSTALLATION
In the assembly stage apply a uniform layer of "SHELL
ALVANIA R3" grease over the o-ring radial gasket.
Fig. 4
During the assembly stage apply "LOCTITE 574" seelant

to the reducer casing cover.
HS
G
Fig. 5
Fig. 6
8
SERVICE
REDUCTION GEAR
CHANGING THE REDCUTION UNIT OIL

Equipment and tools
oil pan
hex socket
wrench
6-12 mm
extension
torque wrench
T handle hex key

5 mm
ratchet
Procedure
battery.
Fig. 1
Use caution as the oil in the reduction unit will be hot

after use of the truck. It is advisable to wear gloves that
Do not dispose of used oil in the ground or by pouring it
down the drain. Contact a waste disposal company specialised in the disposal and recycling of industrial oils.
Phase 1
(ref.A fig.1).
Fig. 2
SERVICE
REDUCTION GEAR
Phase 2
OIL PROTECTIVE GLOVES - OIL RECOVERY SUMP
Clean the area around the oil filler and drain plugs thoroughly. Place a
suitably sized oil pan beneath the drain plug.
Phase 3
OIL PROTECTION GLOVES - HEXAGONAL 6 mm SOCKET WRENCH
- RATCHET - EXTENSION - TORQUE WRENCH - OIL SYRINGE
Using the hexagonal socket wrench, the ratchet and the extension
unscrew the oil filler plug (ref.C fig.3), remove the cap and the gasket.
Using the same tools unscrew the oil drainage cap (ref.D fig.3), remove
the cap and gasket. Empty the oil sump completely.
Clean the drain plug thoroughly from accumulated impurities that may
have collected during reducer operation and screw back on together with
a new gasket.
D
Fig. 3
The tightening of the oil drain cap must be done using a

torque wrench with a torque tightening power of 22 Nm.
Model
reduction unit
Oil type
Quantity
GK20
Standard and Cold Store
~2.2 litres
GK25
FUCHS
TITAN CYTRAC HSY SAE 75W-90
~3.3 litres
To top up use a pressure aspiration syringe (fig.4), that will easily enable
the gearbox to be topped up with oil.
The correct level and quantity of oil is achieved when the oil surface
reaches the lower lip of the oil filler neck or at worst when the oil pours
out of the oil filler neck.
L
OI
The oil filler plug must be tightened using a torque wrench

to a torque of 22 Nm.
Fig. 4
10
SERVICE
BRAKING SYSTEM
Braking system
KEY TO THE TRACTION MOTOR ELECTROMAGNETIC BRAKE COMPONENTS 2
KEY TO THE LOAD WHEEL ELECTROMAGNETIC BRAKE COMPONENTS 3
OPERATION 4
BRAKING systems 4
REMOVAL OF THE BRAKES 5
REMOVAL OF THE DRIVE WHEEL ELECTROMAGNETIC BRAKE 5
REMOVAL OF THE LOAD WHEEL ELECTROMAGNETIC BRAKE 7
SERVICE
BRAKING SYSTEM
KEY TO THE TRACTION MOTOR ELECTROMAGNETIC BRAKE COMPONENTS
2
3
4
5
Ref.
Description
Retaining screw
Electromagnet
Brake plate
Circlip
Pinion
Friction disc
Dust cover
Disc
SERVICE
BRAKING SYSTEM
KEY TO THE LOAD WHEEL ELECTROMAGNETIC BRAKE COMPONENTS
1
3
Ref.
Description
Electromagnet with brake liner
Brake disk
Spring
Bush
Brake regulator
BRAKING SYSTEM
SERVICE
OPERATION
BRAKE FITTED ON THE TRACTION MOTOR
The electromagnetic brake mounted on the traction motor is only a parking brake and it is a spring-operated
brake.
When the electromagnet is powered, it attracts the brake plate and releases the friction disc, allowing the
latter to rotate freely.
When the power supply to the electromagnet is cut, the springs push the brake plate down onto the friction
disc, thus applying the brake.
BRAKE FITTED ON THE LOAD WHEELS
Tall machines are fitted with electromagnetic brakes on the load wheels for safer braking.
The electromagnet is secured on the base of the wheel pin while the brake disk is secured to the wheel
with screws, the brake regulator and the springs.
Braking is activated by pressing on the brake pedal in the cab, the electromagnet attracts the brake disk
against the brake liner creating friction between these two parts.
BRAKING systems
There are 4 braking systems used:

Release braking
Braking on direction reversal
Emergency braking
Parking brake
A) Release braking
Controls the deceleration ramp when the drive control is released.
B) Braking on direction reversal
Controls the deceleration ramp when the travel direction is inverted.
Braking on direction reversal", also know as counter current braking, consists of reversing the current
supplied to the motor, thus changing the direction of travel when the truck is in motion.
The braking current must be adjusted so that the truck stops in a distance that is at least not less than the
length of the truck itself.
C) Emergency braking
Emergency braking occurs when the dead man's pedal is released or an alarm is triggered that requires an
immediate arrest of truck traction or when one of the emergency buttons on the truck is pressed.
The braking action is performed by the electromagnetic brake mounted on the traction motor and by the
load wheels (when fitted).
D) Parking brake
The "parking brake" action is performed by the electromagnetic brake and is applied when the truck is
stationary and the dead man's pedal is released.
SERVICE
BRAKING SYSTEM
REMOVAL OF THE BRAKES

REMOVAL OF THE DRIVE WHEEL ELECTROMAGNETIC BRAKE
Equipment and tools
Fig. 1
T handle hex key

5 mm
external circlip
pliers
large flat blade

screwdriver
puller
Procedure
ground, turn the key switch to OFF and disconnect the
battery.
When replacing the rotor, the pinion must also be replaced.

Fig. 2
Phase 1
(ref.A fig.1).
Fig. 3
Phase 2
Remove the dust cover.
Using the T handle hex key, unscrew the three screws securing the electromagnetic brake to the traction motor (ref.B fig.3).
Disconnect the connector from the brake and withdraw it from the tab.
Remove the electromagnetic brake from the motor.
SERVICE
BRAKING SYSTEM
Phase 3
EXTERNAL CIRCLIP PLIERS - PULLER
Slide out rotor (ref.D fig.4) from the pinion.
Using the circlip pliers, remove the circlip from the drive shaft (ref.E fig.4).
Using the extractor remove the pinion (ref.F fig.4).
INSTALLATION
After mounting the electromagnetic brake does not require
adjustment.
Fig. 4
SERVICE
BRAKING SYSTEM
REMOVAL OF THE LOAD WHEEL ELECTROMAGNETIC BRAKE

Equipment and tools
hydraulic jack
wooden block
socket wrench for

self-locking ring
nut
ratchet
T handle hex key

6 mm
Procedure
battery.
Phase 1
Position the hydraulic jack beside the load wheel and lift until the wooden
stock can pass beneath.
Set the wooden block under the clamp, lower the jack to rest the truck
on the block and take up the slack on the jack (fig.1).
Fig. 1
Phase 2
SOCKET WRENCH FOR SELF-LOCKING RING NUT - RATCHET
Using the socket wrench for the self-locking ring nut and the ratchet,
unscrew and remove the ring nut (ref.A fig.2), remove the toothed
washer.
Extract the wheel from the hub and dismantle or replace.
Phase 3
Using the T-handle hex key, remove the screws securing the brake disk to
the wheel together with the bush and spring (ref.b fig.3). When removing
the disk, pay attention to the springs (ref.C fig.3).
a
Fig. 2
Fig. 3
SERVICE
BRAKING SYSTEM
Phase 4
8 mm T HANDLE HEX KEY
Using the T-handle hex key, remove the screws fastening the electromagnetic brake at the base of the wheel pin (ref.D fig.4). Disconnect the
connector and remove the brake.
INSTALLATION
The screws securing the brake disk to the wheel must be
tightened using a torque wrench to a torque of 25 Nm. Apply Loctite 270.
Fig. 4
SERVICE
STANDARD MAINTENANCE
OILS AND LUBRICANTS 4
CLEANING PRODUCTS 4
SCHEDULED MAINTENANCE 5
MAINTENANCE PROCEDURES 8
frame, cab, roof assembly 8
SERVICE
WARNINGS

If maintenance operations are carried out immediately after the truck is stopped, some components of
the motor and of the hydraulic system could be hot. Always wear the personal protective equipment in
situations requiring it.
Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbuttoned jackets or tops with open zippers that can get caught up in moving parts.
Never do any cleaning, lubrication or maintenance work with the battery connected.
Never perform any servicing on the machine with persons at the controls, unless they are accredited
operators and help with the operation to be performed.
Using compressed air to clean the parts, protect yourself with goggles that have side protection. The
maximum air pressure must not exceed 1 bar.
Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable
and non-toxic trade solvents.
Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away
into a closed metal container.
The capacitors in the transistor control unit can keep an electric charge even after disconnecting the
battery. To avoid electric shocks and personal injury, discharge the capacitors before inspecting or
repairing any component in the electric compartment. Wear safety glasses. Make sure the battery has
been disconnected.
Do not file or lubricate the contacts of the contactors. This could cause the contacts to stick and, as a
result, loss of control and damage to property or injury to people.
Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.
Special companies can be employed to dispose of or recycle industrial oils according to the laws in
force in individual countries.
Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate
under the skin; in such cases, having to make a check, use a card or a piece of wood.
Protect the hydraulic system from dirt or contaminants getting inside when checking the fluid level of
changing the filter.
Never operate the pump without an adequate quantity of fluid in the hydraulic system. Operation with
low levels of hydraulic fluid will damage the hydraulic pump.
Do not place any tools on the battery. Metal items on the battery can generate accidental shortcircuiting and possibly damage or injury.
The batteries generate explosive gases. Keep the vents clean. Keep sparks and flames well away
from the battery compartment. Pay attention not to create any sparks when disconnecting the battery
cables. Disconnect the battery during maintenance work.
Always use a spreader bar and slings to raise the battery vertically with the specific eyelets. Do not
use chains or slings without a spreader bar, you would risk damaging the battery casing. Check that
the battery compartment is clean and dry. When the battery is in service, the aeration plugs must all be
installed. If the aeration plugs are not installed, electrolyte can come out, corroding the battery casing
and compartment.
The acid in the electrolyte can cause injury. If the electrolyte gets spilled it should be cleaned up with
water. Neutralize the acid with a solution of sodium bicarbonate (soda). Areas of the skin that come
into contact with the acid must be rinsed with water immediately. Acid splashed into the eyes must be
washed away with water constantly for at least 10 minutes, then call a doctor.
SERVICE
The batteries belong to the counterweight system of the lift truck. When installing a battery that is too
small, the lift truck might not have enough weight for the nominal load. When replacing a battery, see
the truck identification data plate to check that the battery has the rated capacity and correct dimensions. See TRUCK AND LOAD CAPACITY IDENTIFICATION DATA in the PRESENTATION section for the exact battery specifications for the lift truck at issue.
Do not work under a raised carriage. Lower the carriage or use a safety chain to prevent the carriage
from lowering during maintenance work on the mast and on the lifting chains.
Never repair damaged forks using heat or welding. The forks are made of steel that is hardened with
special procedures. Replace damaged forks.
Before servicing the hydraulic system you must eliminate any residual pressure inside it.
Close the valves at the end of the maintenance work.
The maintenance and repair procedures must be carried out only by specialist service technicians with
the relevant authorizations and appropriate training. Repairs carried out incorrectly can create hazardous work conditions for the operator.
Do not utilize a truck if it requires repairs. Affix a DO NOT USE label on the steering wheel. Remove
the key and disconnect the battery.
SERVICE
OILS AND LUBRICANTS

Application
OIL for lubrication of the
HYDRAULIC CIRCUIT
Std
Cold
store
Trademark
Type
Shell
TELLUS S2 V 46
Shell
AEROSHELL FLUID 41
OIL for lubrication of the

REDUCTION UNIT
Fuchs
TITAN CYTRAC HSY

SAE 75W-90
GREASE for lubrication of

REDUCTION UNIT OUTER GEAR
(STEERING CROWN WHEEL AND PINION)
Shell
GADUS S2 OGH 0/00
Klber
KlberOIL 4UH 1-150N
Lubrication
VG 150
OIL for lubrication of

LIFTING CHAINS

MAST BEARINGS SLIDING GUIDES
RETRACTABLE CARRIAGE BEARINGS SLIDING
GUIDES
BATTERY TRAY SLIDING BLOCKS
SIDE SHIFT GUIDES
SIDE SHIFT SLIDING BLOCKS
RETRACTABLE CARRIAGE CYLINDER JOINT
BEARINGS
Insulation of BATTERY TERMINALS
Rexnord Kette
REXOIL VG 150
Klber
Lubrication
KlberOIL 4UH 1-68N

VG 68
Klber
GRAFLOSCON C-SG - 0
Lubrication
ULTRA
Shell
GADUS S2 V100 2
Shell
AEROSHELL GREASE 6
Pure Vaseline
CLEANING PRODUCTS
Casing and plastic cover cleaning - Cleaning of painted truck parts
For general cleaning of the truck, use only dry air, damp rags or degreasing detergents.
Do not use water jets, vapours, solvents or flammable products that may damage the
truck or that can be dangerous for the operator.
Motor and electronic system cleaning
For general cleaning purposes use dry air at low pressure and a clean dry brush.
Do not use wet rags, water jets, vapour, solvents or flammable products that may damage
the truck or that may be dangerous for the operator.
Cleaning MAST AND RETRACTABLE CARRIAGE BEARINGS SLIDING GUIDES
Use degreasing solvents.
Do not use water jets, vapour, solvents or flammable products that may damage the small
mast or be harmful to the operator.
SERVICE
SCHEDULED MAINTENANCE
= checks and maintenance to be performed by the operator or the person assigned to truck maintenance
(refer to the instructions given in the MAINTENANCE section of the operator's manual)
= checks and maintenance operations that should only be performed by a technician authorised by the truck manufacturer
(refer to the instructions given under the following headings in this section)
x = replacement of parts that should only be performed by a skilled technician authorised by the truck manufacturer
(refer to the instructions given in the sections of this manual)
Maintenance intervals
every
8 hours
1 day
every
every
every
1000 hours 3000 hours 5000 hours
1 year
2 years
3 years
Check the screws and bolts
Check the integrity of the cab and frame fixing supports
Check the conditions of the guides for sliding the retractable

carriage
Clean the guides for sliding the retractable carriage
Check the height of the outriggers off the ground
(1)
BRAKING SYSTEM
Visually check the main welds
MOTORS
HYDRAULIC SYSTEM
FRAME, CAB, OVERHEAD GUARD
Operation description
Dynamic braking action check
Reverse braking action check
Normal braking action check
Emergency braking action check
Electromagnetic parking brake and coil efficiency check

Load wheels brake liner wear check
REDUCTION
UNIT
(2)
Oil leak check
Valve operation check
Tank oil level check
Check the condition and tension of the hoses(3)
Tank oil change
Renew oil filter cartridge
Renew plug with air cleaner
Motor insulation check
Cable connection check
Fixing nut condition check
Bearing noise check
General cleaning
Oil leak check
Check oil level
Change oil in reduction unit(4)

General cleaning
Check reduction unit outer gear teeth wear (steering crown

wheel and pinion)
Check condition and wear of drive wheel(2)

WHEELS & TYRES
Electromagnetic parking brake liner wear check(2)
Check drive wheel fixing nuts
Check condition and wear of load wheels(2)

Check load wheel fixing nuts
Check conditions of load wheel bearings(2)
Check condition and wear of steering side rollers
(2)
Check steering side rollers fixing nuts

Check condition of steering side rollers bearings
(2)
SERVICE
every
8 hours
1 day
Check the screws and bolts
Check conditions of bearings of retractable carriage and

mast(2)
Check the fork support device screws
Check play of side shift outrigger sliding blocks
GREASING POINTS
RETRACTABLE CARRIAGE,
MAST, FORKS
fork support
device
Adjust retractable carriage side rollers

Check chain tensioner conditions(2)
Check lifting chain link and pin wear
(2)
Check lift chains stretch
Check conditions of chain pulleys, tubes and cables
Clean mast bearings sliding guides
Check conditions of mast bearings sliding guides
Check fork condition
Check wear of side shift upper and lower sliding blocks(2)
Check conditions of fork support device bearings
(2)
Grease reduction unit outer gear (steering crown wheel and

pinion)
Grease battery tray sliding blocks
Grease retractable carriage cylinder joint bearings
Grease retractable carriage bearings sliding guides
Grease mast bearings sliding guides
Lubricate lifting chains
Grease side shift guides
CONTROLS,
INSTRUMENTS
CAB
ELECTRICAL
SYSTEM
Check the seat conditions and operation
Check seat belt conditions and operation
Check machine functions with actuating controls and

instrumentation
Battery plug/socket integrity check
Check conditions of electrical power connections
Check conditions of electronic controllers auxiliary

connections
Electrical wiring check
Sensor operation check
General cleaning of electrical panel
Battery charge check
Cable connection check

BATTERY
Check side shift and tilt cylinder rods and check steering
bushes(2)
Grease side shift sliding blocks
every
every
every
1 year
2 years
3 years
Liquid leaks check
Electrolyte density check
Electrolyte level check
(5)
Battery insulation check
General cleaning
SERVICE
SAFETY DECALS
every
8 hours
1 day
every
every
every
1 year
2 years
3 years
Check safety labels and decals
Clean safety labels and decals
(1)
check also when replacing the drive wheel
(2)
replace if necessary
replace in the following situations:

a shift of the connection on the pipe;
the presence of damage, cuts or abrasions on the superficial layer;
hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
the presence of cracks, damages or strong corrosion on the connection;
the presence of leaks along the pipe or at the coupling joint;
the presence of permanent creases, compression, flattening or twists in the pipe;
the presence of blisters, softening, wear of the external coat.
(3)
(4)
change recommended after 7500 hours or 5 years
(5)
fill up whenever the electrolyte levels falls to 5-10 mm (0.19-0.39 in) from the splash guard
Trucks working in cold stores must be lubricated every 500 hours, or even more frequently in the case of particularly intensive use.
SERVICE
MAINTENANCE PROCEDURES
frame, cab, roof assembly
CHECK HEIGHT OF OUTRIGGERS OFF GROUND
Equipment and tools
Fig. 1
caliper
open-ended spanner
46 mm
Procedure
Phase 1
CALIPER
Check that the two outriggers have not been damaged and have not
come loose.
Use the caliper to measure the height of the outriggers off the ground
(fig.2).
The correct value of X is given in the following table:
Model
X = 27 mm
X = 20 mm
X = 10 mm
1.4-1.6 ton
5000 < h3 < 8200 8200 < h3 < 9400
h3 > 9400
1.6 ton Narrow
5000 < h3 < 7100 7100 < h3 < 8200
h3 > 8200
2.0-2.5 ton
4650< h3 < 7500
h3 > 7500
1.6 ton HD
h3 > 8200
h3 > 8200
2.0 ton HD
h3 > 8200
h3 > 8200
A
X 2 mm
B
floor
Fig. 2
h3 = lift height (see MAST MECHANICS section).
Phase 2
Loosen the outrigger locking nut with the open ended spanner (ref.A fig.2). Unscrew or screw in the outrigger (ref.B fig.2) to reach the desired height. Tighten the locking nut.
8
SERVICE
CHECK CHAINS
Equipment and tools
caliper
Replace the chains if they have stretched beyond 3% of their length or if the links, hinge pins or chain
tensioner are worn to such an extent that replacement is indispensable
Measure the extension with a callipers (fig.1) on many sections 10 steps apart taken in the more stressed
sections.
A) Pin wear
B) Pin damage
C) Link damage
D) Link edge wear
E) Wear and ovalization of the links
F) Too much play between the links
G) Oxidization check
H) Wear and ovalization of the chain tensioner
I) Wear of the chain hinge gudgeon
c
h
b
G
Fig. 1
f
e
Fig. 2
Fig. 3
If chains are not excessively worn and stretched, replace them every 3 years (5000 hours) under normal
working conditions. Replace chains every 2 years (3000 hours) when the truck is used in cold rooms or
in corrosive environments.
SERVICE
CHECK FORKS
Equipment and tools
rule
There must be no cracks in the structure of the forks and particularly at welded joins (ref.A fig.1). If any
cracks are visible, replace the fork. Do not attempt any repairs by welding;
Measure the thickness of the heel (ref.B fig.1). If the thickness of the heel is less than 90% of the thickness
of the vertical bracket (ref.C fig.1) replace the fork.
The fork tips must be aligned to within 3% of the length of the fork at the time of installation on the carrier
plate (ref.D fig.1). Do not attempt to correct the alignment of the forks by altering the angle of the bend or
the connection between the carrier plate and the forks. Certain improvements can be obtained by shifting
the forks from one side of the carrier plate to the other, or by selecting other forks of corresponding length
from the equipment store.
In cases where there is a permanent deflection between the vertical bracket (ref.E fig.1) and the blade
(ref.F fig.1), the maximum acceptable angle is 93 degrees. If the angle (ref.G fig.1) exceeds 93, the fork
must be replaced.
C
A
E
G
Fig. 1
10
SERVICE
11
Code: 550066261
Revision: 0 (01/2014)

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Part no.

Technical information for Yale service

This manual is intended solely for the specialized technicians of

Product support group

GUIDE TO USING THE MANUAL

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

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

GENERAL SAFETY RULES

Always wear the personal protective equipment in situations requiring it.

SAFETY AT THE WORKPLACE

Avoid twisting chains or metal ropes.

Do not short-circuit the terminals.

Before taking any action, check that no elements are shorted.

Always disconnect the battery before working on the electrical system.

Having to check the system pressure, use the specific instruments.

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE

Always rest the load in the race of the hook.

Never load the tip of the hook.

Never do any lifting with the ropes and belts twisted.

Using suspension elements under conditions of unbalanced load

Rope capacity table

Suspension element capacity table

TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS

CORRECT METHOD FOR APPLYING FEMALE FITTINGS

METRIC REVOLVING FEMALE

REVOLVING FEMALE jic 37

REMOVING FEMALE BSP

REVOLVING FEMALE ORFS

INSTRUCTIONS FOR INSTALLING FLEXIBLE HOSES AND FITTINGS

a shift of the connector on the pipe;

Installation and settings

Diagnostics and measurements

Truck base mechanics

Mast assembly mechanics

Small fork mast mechanics

VIEWS OF THE TRUCK

TRUCK AND LOAD IDENTIFICATION DATA

The truck identification data plate is located inside the

Max. battery weight

RESIDUAL LOAD PLATE

The load plate is located on the roof assembly

MAST SERIAL NUMBER PUNCHING and location of documentation

The mast serial number is stamped on the

lift speed with/without load (7)

lowering speed with/without load

11/11(14/14) 11/11(14/14) 11/11(14/14)

manufacturers type designation

manufacturers type designation

manufacturers type designation

manufacturers type designation

manufacturers type designation

manufacturers type designation

manufacturers type designation

manufacturers type designation

manufacturers type designation

This value can vary by 5%

INSTALLATION AND SETTINGS

INSTALLATION AND SETTINGS

battery 420DinC, forks 80x40x1150

INSTALLATION AND SETTINGS

MR14 MR16H MR16N