Part No.

: 550066261 Revision: 3 (05/2022)

Technical information for Yale service

centres

This manual is intended solely for the specialized technicians of

the Yale service network

MR14 MR16N
MR16 MR16HD
D849
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

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SERVICE INTRODUCTION

GUIDE TO USING THE MANUAL

SECTIONS
This handbook is composed of the following sections:
Section 1: Presentation
Section 2: Installation and settings
Section 3: Diagnostics and measurements
Section 4: Electrical system
Section 5: Hydraulic system
Section 6: Truck base mechanics
Section 7: Mast assembly mechanics
Section 8: Small fork mast mechanics
Section 9: Reduction gear
Section 10: Braking system
Section 11: Routine maintenance

Use the sections index with the numbered black bands to go quickly to the desired section.

SYMBOLS

Signals a danger that can cause injury 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.

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 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.

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 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 across 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.

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 INTRODUCTION SERVICE

Belt capacity table

45°
Colour

purple 1000 2000 1400 800

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

Rope capacity table

45°
Width
Colour
(mm)

black 35 500 1000 700 400

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

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SERVICE INTRODUCTION

Suspension element capacity table

Colour

purple 1000 1400 2100 2100

green 2000 2800 4200 4200
Working load
yellow 3000 3800 6300 6300
capacity (kg)
grey 4000 5600 8400 8400
red 5000 6600 9800 10500
Coefficient 1 1.4 2.1 2.1

Working load capacity: the working load capacity is calculated with an angle at the
centre of 90°

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 INTRODUCTION SERVICE

TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS

Before disassembling the various parts
and nuts and bolts, read the following Nominal TORQUE SETTING Nm
carefully. diameter
Class 8 Class 10
A threadlocking compound is applied to bolts before M3 4 5.2
tightening to prevent loosening.
M4 7 9.15
If it is not possible to unscrew the bolts because this
M5 12.14 14.8
product has been used, avoid applying extensions to
the tools, instead slightly heat the area (max. 50°C) so M6 17.2 20.9
as to eliminate the effect of the threadlocker. M8 31.8 38.1
In these cases, reapply a moderate amount of M 10 50.5 60.3
threadlocking compound on reassembly (covering 30% M 12 74.2 88.5
of the mating surface). M 14 101.2 120.8
The torque setting used for tightening the threaded M 16 138.2 164.9
couplings is extremely important to make the coupling
M 18 176.6 203.5
secure and the machine safe.
M 20 225.4 259.7
M 22 278.8 321.2
The tables on this page give the classes of bolts normally
used with the relevant torque settings. M 24 324.8 374.2
M 27 422.3 486.5
M 30 516.1 594.7

TORQUE SETTING Nm
Pre-load N Class 5.8 Class 8.8 Class 10.9

mm mm mm mm

M4 0.7 7 3 2400 1.92 1.44 3.07 2.3 4.17 3.13

M5 0.8 8 4 3880 3.88 2.91 6.2 4.65 8.43 6.33
M6 1 10 5 5490 6.58 4.94 10.5 7.9 14.3 10.8
M8 1.25 13 6 9990 16 12 25.6 19.2 34.8 26.1
M8 1 13 6 10700 17.1 12.8 27.4 20.5 37.3 27.9
M 10 1.5 16 8 15825 31.7 23.8 51 38 69 52
M 10 1.25 16 8 16700 33.4 25.1 53 40.1 73 55
M 12 1.75 18 10 23025 55 41.4 88 66 120 90
M 12 1.25 18 10 25150 60 45.3 96 72 130 98
M 14 2 21 12 31400 88 66 140 105 190 145
M 14 1.5 21 12 34125 96 72 155 115 210 155
M 16 2 24 14 42850 135 105 220 165 300 225
M 16 1.5 24 14 45600 145 110 235 175 320 240
M 20 2.5 30 17 66875 270 200 430 320 580 435
M 20 1.5 30 17 74250 295 225 475 355 650 485

= with lubricant

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 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

METRIC REVOLVING FEMALE REVOLVING FEMALE jic 37°

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

REMOVING FEMALE BSP REVOLVING FEMALE ORFS

Torque setting Nm Torque setting Nm
UNF UNF
Size
thread Nominal torque max thread Nominal torque max.

G1/4 20 15 - 25 9/16-18 -4 14 16
G3/8 34 27 - 41 11/16-16 -6 24 27
G1/2 60 42 - 76 13/16-16 -8 43 47
G5/8 69 44 - 94 1-14 -10 60 68
G3/4 115 95 - 135 1.3/16-12 -12 90 95
G1 140 115 - 165 1.3/16-12 -14 90 95
G1.1/4 210 140 - 280 1.7/16-12 -16 125 135
G1.1/2 290 215 - 365 1.11/16-12 -20 170 190
G2 400 300 - 500 2-12 -24 200 225
2-1/2-20 -32 460 490

The values given in the tables refer to galvanized steel fittings. Fittings of other materials
have other values.

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 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 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.

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.

Special wrench for hydraulic couplings:

Code:
582031404 (C8 - C10)
582031405 (C12)
582031406 (C16)

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SERVICE INTRODUCTION

SECTION CONTENTS

Presentation 1
Installation and settings 2
Diagnostics and measurements 3
Electrical system 4
Hydraulic system 5
Truck base mechanics 6
Mast assembly mechanics 6
7
Small fork mast mechanics 6
8
Reduction unit 7
9
Braking system 10
8
Standard maintenance 11
7

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 INTRODUCTION SERVICE

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 SERVICE PRESENTATION

PRESENTATION
TRUCK PRESENTATION������������������������������������������������������������������������������������������������������������������������������������������� 2
VIEWS OF THE TRUCK��������������������������������������������������������������������������������������������������������������������������������������������� 3
TRUCK IDENTIFICATION DATA AND LOAD CAPACITIES�������������������������������������������������������������������������������������� 6
TRUCK IDENTIFICATION DATA PLATE��������������������������������������������������������������������������������������������������������������������� 6
RESIDUAL LOAD PLATE�������������������������������������������������������������������������������������������������������������������������������������������� 7
TRUCK SERIAL NUMBER������������������������������������������������������������������������������������������������������������������������������������������ 8
MAST SERIAL NUMBER AND LOCATION OF DOCUMENTATION��������������������������������������������������������������������������� 8
GENERAL SPECIFICATIONS������������������������������������������������������������������������������������������������������������������������������������ 9
BATTERIES TABLE��������������������������������������������������������������������������������������������������������������������������������������������������� 57

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 PRESENTATION SERVICE

TRUCK PRESENTATION
The new range of reach trucks consists of 7 models with rated load capacities ranging from 1400 kg to
2500 kg, available in standard and cold store versions:
MR14
MR16
MR16N
MR20
MR25
MR16HD
MR20HD
The models MR16, MR20 and MR16HD are also available in wide and extra wide versions.

Electrical system
All the motors benefit from the use of three phase AC alternate current technology: drive motor, steering
motor and pump motor.
Superior battery efficiency is ensured by the regenerative braking system, which charges the battery on
release of the drive control and on changing drive direction.
The electronic controllers 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 use of proportional solenoid valve
technology for the carriage out/return, lifting/lowering, fork tilting and side shifting operations and the smooth
operation of the actuators.

Mast
The mast may be comprised of three stages: outer, middle and inner, or four stages: outer, two middle and
inner.
The rigidity and stability 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.

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SERVICE PRESENTATION

VIEWS OF THE TRUCK

3
 PRESENTATION SERVICE

VIEWS OF THE TRUCK MY 2019

4
SERVICE PRESENTATION

VIEWS OF THE TRUCK MY 2021

5
 PRESENTATION SERVICE

TRUCK IDENTIFICATION AND LOAD CAPACITY DATA

TRUCK IDENTIFICATION DATA PLATE

The truck identification data plate is located inside the

operator 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

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SERVICE PRESENTATION

RESIDUAL LOAD PLATE

The load plate is affixed to the overhead guard

and bears the following data:
• Model
• Load values liftable 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.

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 PRESENTATION SERVICE

TRUCK SERIAL NUMBER

The truck serial number is punched on the

truck chassis

MAST SERIAL NUMBER PUNCHING AND LOCATION OF DOCUMENTATION

xxxxxxxx

The truck documentation is stored in the

The mast serial number is stamped on the document holder behind the seat backrest.
mast itself.

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 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR14 - MR16 - MR16N standard version

GENERAL SPECIFICATIONS TABLE NOTES (10)

(11)
For models MR20 - MR25 and with 4-stage mast: “x” - 108 mm.
For AST with 4-stage mast, refer to the "14-16 4-stage mast tables" and "20-25 4-stage mast tables".
(1) With seat loaded h4 + 508 mm. (MR14 - MR16 - MR16N - MR16HD), + 443 mm (MR20 - MR25 (12) For height complete with wire mesh/Lexan screen h6 + 18 mm.
- MR20HD). (13) For model MR16N with worklights of truck w 900mm: b1 +113 mm.
(2) With flashing beacon h6+120 mm. (14) For worklights on truck w 1100 mm: b1 +313mm for model MR16N; b1 +173 mm for models MR14 - MR16 -
(3) With load wheel side covers: 1289 mm (MR14 - MR16 - MR20 - MR16HD), 1153 mm (MR16N), MR20 - MR16HD; b1 +93 mm for models MR25 and MR20HD.
1373 mm (MR25 - MR20HD). (15) With PAL lateral line h6 +135 mm with dual front worklights h6 + 220 mm
(4) These values may vary by +/- 5%. (16) For model MR14 with h3 <= 5500mm: 420Ah battery and Transparent Operator Shield (Lexan)/ Wire Mesh
(5) Forks retracted. Screen: l2 + 72 mm, x - 72 mm, AST 4.34.1 = 2770 mm, AST 4.34.2 = 2829 mm
(6) Refer to the batteries table. (17) For model MR16 with h3 <= 5500 mm: battery 420Ah and Transparent Operator Shield (Lexan)/ Wire Mesh
(7) The values in parentheses are optional. Screen: l2 + 72 mm, x - 72 mm, AST 4.34.1 = 2781 mm, AST 4.34.2 = 2830 mm
(8) Side shift travel is ± 75 mm on all trucks: Reduced to ± 25 mm for model MR16N. (18) Maximum gradeability based on motor thermal capacity, available torque and brake requirements.
(9) For models MR14 - MR16 and with 4-stage mast: “x” -53 mm. (19) 4kW drive motor available for Russian market.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

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 PRESENTATION SERVICE
GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR14 MR16 MR16N

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol MR14 electricMR16
(battery) MR16N
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.4 1.6 1.6
1.6 load centre distance c (mm) 600 600 600
1.8 load distance from load wheel axle - forks (9-10-16-17) x (mm) 258 308 202
1.9 wheelbase (WB) y (mm) 1400 1450 1450
2.1 unladen weight kg 3495 3546 3498
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2055/1440 2103/1443 1955/1543
2.4 load on axle with forks out with load (front/rear) kg 885/4010 810/4336 757/4341
2.5 load on axle with forks retracted with load (front/rear) kg 1711/3184 1779/3367 1514/3584
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140 343 x 140 343 x 140
TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100 285 x 100 285 x 100
3.5 wheel quantity (x = drive) (front/rear) 1x/2 1x/2 1x/2
3.7 rear track width b 11 (mm) 1155 1155 1025
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4 2/4
4.2 height with mast retracted h1 (mm) 2195 2195 2195
4.3 free lift h2 (mm) 1648 1648 1648
4.4 lifting h3 (mm) 5000 5000 5000
4.5 height, mast extended (1) h4 (mm) 5563 5563 5563
4.7 height of overhead guard (cab) (2-12-15) h6 (mm) 2175 2175 2175
4.8 seat height relative to SIP h7 (mm) 1082 1082 1082
4.10 armrest height h8 (mm) 308 308 308
4.19 total length l1 (mm) 2523 2523 2629
4.20 length to face of forks (16-17) l2 (mm) 1373 1373 1479
4.21 total length (3-13-14) b1/b2 (mm) 1265 1265 1125
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/80/1150 40/120/1150 40/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A 2A
4.24 fork carriage width b3 (mm) 700 700 700
4.25 distance between fork arms (MIN/MAX) (8) b5 (mm) 220/640 260/680 260/680
4.26 distance between the load wheel arms b4 (mm) 900 900 795
4.28 retractable travel b4 (mm) 441 491 385
4.31 ground clearance under mast with load m1 (mm) 75 75 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 75 75 65
4.34.1working aisle for pallet length 1000 x 1200 crosswise (11-16-17) AST (mm) 2826 2834 2899
4.34.2working aisle for pallet length 800 x 1200 lengthwise (11-16-17) AST (mm) 2895 2896 2976
4.35 turning radius Wa (mm) 1671 1718 1700
4.37 length between the wheel arms b7 (mm) 1795 1845 1845
4.42 wheelbase height (from ground to footboard) mm 550 550 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371 371 371
and the ground)
5.1 drive speed with/without load (7) km/h 11/11(14/14) 11/11(14/14) 11/11(14/14)
5.1.1 drive speed with/without load reverse drive (7) km/h 11/11(14/14) 11/11(14/14) 11/11(14/14)
0,37 / 0,63 0,32 / 0,63 0,32 / 0,63
PERFORMANCE

5.2 lift speed with/without load (7) m/s

(0,47 / 0,73) (0,42 / 0,73) (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55 0.55 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17 0.17 / 0.17 0.17 / 0.17
5.7 gradeability with/without load (7-18) % 7/10 (15/20) 7/10 (14/20) 7/10 (14/20)
5.8 maximum gradeability with/without load (7-18) % 15/20 (15/20) 14/20 (14/20) 14/20 (14/20)
3.3/3.3 3.4/3.4 3.4/3.4
5.9 acceleration time, with/without load(7) s
(2.6/2.6) (2.7/2.7) (2.7/2.7)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes (7) kW 5.4 (9.6) (19) 5.4 (9.6) (19) 5.4 (9.6) (19)
MOTOR UNITS

6.2 lifting motor, power S3 15% (7) kW 9.9 (14) 9.9 (14) 9.9 (14)
6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C B
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 (6) 48/700 (6) 48/700 (6)
6.5 battery weight (4) kg 1119 1119 1119
6.6 Energy consumption according to DIN EN 16796 kWh/h 3.8 4.0 4.0
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180 180 180
10.2 volume of oil for additional attachments l/min 20 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7 <69.7

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 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR20 - MR25 standard version

GENERAL SPECIFICATIONS TABLE NOTES (10)

(11)
For models MR20 - MR25 and with 4-stage mast: “x” - 108 mm.
For AST with 4-stage mast, refer to the "14-16 4-stage mast tables" and "20-25 4-stage mast tables".
(12) For height complete with wire mesh/Lexan screen h6 + 18 mm.
(1) With seat loaded h4 + 508 mm. (MR14 - MR16 - MR16N - MR16HD), + 443 mm (MR20 -
(13) For model MR16N with worklights of truck w 900mm: b1 +113 mm.
MR25 - MR20HD).
(14) For worklights on truck w 1100 mm: b1 +313mm for model MR16N; b1 +173 mm for models MR14 -
(2) With flashing beacon h6+120 mm.
MR16 - MR20 - MR16HD; b1 +93 mm for models MR25 and MR20HD.
(3) With load wheel side covers: 1289 mm (MR14 - MR16 - MR20 - MR16HD), 1153 mm
(15) With PAL lateral line h6 +135 mm with dual front worklights h6 + 220 mm
(MR16N), 1373 mm (MR25 - MR20HD).
(16) For model MR14 with h3 <= 5500mm: 420Ah battery and Transparent Operator Shield (Lexan)/ Wire
(4) These values may vary by +/- 5%.
Mesh Screen: l2 + 72 mm, x - 72 mm, AST 4.34.1 = 2770 mm, AST 4.34.2 = 2829 mm
(5) Forks retracted.
(17) For model MR16 with h3 <= 5500 mm: battery 420Ah and Transparent Operator Shield (Lexan)/ Wire
(6) Refer to the batteries table.
Mesh Screen: l2 + 72 mm, x - 72 mm, AST 4.34.1 = 2781 mm, AST 4.34.2 = 2830 mm
(7) The values in parentheses are optional.
(18) Maximum gradeability based on motor thermal capacity, available torque and brake requirements.
(8) Side shift travel is ± 75 mm on all trucks: Reduced to ± 25 mm for model MR16N.
(9) For models MR14 - MR16 with 4-stage mast: “x” -53 mm. (19) 4kW drive motor available for Russian market.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

11
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS

1.1 Manufacturer Yale

CHARACTERISTICS

1.2 Identification code MR20 MR25

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 2.0 2.5
1.6 load centre distance c (mm) 600 600
1.8 load distance from load wheel axle - forks (9-10-16-17) x (mm) 343 416
1.9 wheelbase (WB) y (mm) 1500 1650
2.1 unladen weight kg 3801 4230
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2296/1504 2565/1665

2.4 load on axle with forks out with load (front/rear) kg 770/5030 876/5855
2.5 load on axle with forks retracted with load (front/rear) kg 1971/3829 2306/4424
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140 343 x 140
TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100 285 x 140
3.5 wheel quantity (x = drive) (front/rear) 1x/2 1x/2
3.7 rear track width b11 (mm) 1155 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4
4.2 height with mast retracted h1 (mm) 2195 2195
4.3 free lift h2 (mm) 1582 1582
4.4 lifting h3 (mm) 4650 4650
4.5 height, mast extended (1) h4 (mm) 5263 5263
4.7 height of overhead guard (cab) (2-12-15) h6 (mm) 2175 2175
4.8 seat height relative to SIP h7 (mm) 1082 1082
4.10 armrest height h8 (mm) 308 308
4.19 total length l1 (mm) 2538 2615
4.20 length to face of forks (16-17) l2 (mm) 1388 1465
DIMENSIONS

4.21 total length (3-13-14) b1/b2 (mm) 1265 1345

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150 45/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A
4.24 fork carriage width b3 (mm) 700 700
4.25 distance between fork arms (MIN/MAX) (8) b5 (mm) 260/680 260/680
4.26 distance between the load wheel arms b4 (mm) 900 900
4.28 retractable travel b4 (mm) 541 641
4.31 ground clearance under mast with load m1 (mm) 65 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (11-16-17) AST (mm) 2857 2949
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (11-16-17) AST (mm) 2913 2992
4.35 turning radius Wa (mm) 1767 1911
4.37 length between the wheel arms b7 (mm) 1895 2045
4.42 wheelbase height (from ground to footboard) mm 550 550
wheelbase height (between intermediate steps between the footboard and the
4.43 mm 371 371
ground)
5.1 drive speed with/without load (7) km/h 11/11(14/14) 11/11(14/14)
5.1.1 drive speed with/without load reverse drive (7) km/h 11/11(14/14) 11/11(14/14)
PERFORMANCE

5.2 lift speed with/without load (7) m/s 0.37 / 0.64 0.30 / 0.64
5.3 lowering speed with/without load m/s 0.55 / 0.50 0.55 / 0.50
5.4 Retractable carriage speed m/s 0.17 / 0.17 0.17 / 0.17
5.7 gradeability with/without load (7-18) % 12/20 10/18
5.8 maximum gradeability with/without load (7-18) % 12/20 10/18
5.9 acceleration time, with/without load(7) s 2.6/2.5 2.7/2.6
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes (7) kW 9.6 9.6
MOTOR UNITS

6.2 lifting motor, power S3 15% (7) kW 14 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 (6) 48/840 (6)
6.5 battery weight (4) kg 1119 1306
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.6 5.2
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180 180

10.2 volume of oil for additional attachments l/min 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7

12
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16HD - MR20HD standard version

GENERAL SPECIFICATIONS TABLE NOTES (10)

(11)
For models MR20 - MR25 and with 4-stage mast: “x” - 108 mm.
For AST with 4-stage mast, refer to the "14-16 4-stage mast tables" and "20-25 4-stage mast tables".
(12) For height complete with wire mesh/Lexan screen h6 + 18 mm.
(1) With seat loaded h4 + 508 mm. (MR14 - MR16 - MR16N - MR16HD), + 443 mm (MR20 -
(13) For model MR16N with worklights of truck w 900mm: b1 +113 mm.
MR25 - MR20HD).
(14) For worklights on truck w 1100 mm: b1 +313mm for model MR16N; b1 +173 mm for models MR14 -
(2) With flashing beacon h6+120 mm.
MR16 - MR20 - MR16HD; b1 +93 mm for models MR25 and MR20HD.
(3) With load wheel side covers: 1289 mm (MR14 - MR16 - MR20 - MR16HD), 1153 mm
(15) With PAL lateral line h6 +135 mm with dual front worklights h6 + 220 mm
(MR16N), 1373 mm (MR25 - MR20HD).
(16) For model MR14 with h3 <= 5500mm: 420Ah battery and Transparent Operator Shield (Lexan)/ Wire
(4) These values may vary by +/- 5%.
Mesh Screen: l2 + 72 mm, x - 72 mm, AST 4.34.1 = 2770 mm, AST 4.34.2 = 2829 mm
(5) Forks retracted.
(17) For model MR16 with h3 <= 5500 mm: battery 420Ah and Transparent Operator Shield (Lexan)/ Wire
(6) Refer to the batteries table.
Mesh Screen: l2 + 72 mm, x - 72 mm, AST 4.34.1 = 2781 mm, AST 4.34.2 = 2830 mm
(7) The values in parentheses are optional.
(18) Maximum gradeability based on motor thermal capacity, available torque and brake requirements.
(8) Side shift travel is ± 75 mm on all trucks: Reduced to ± 25 mm for model MR16N.
(9) For models MR14 - MR16 with 4-stage mast: “x” -53 mm. (19) 4kW drive motor available for Russian market.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

13
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16HD MR20HD

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6 2.0
1.6 load centre distance c (mm) 600 600
1.8 load distance from load wheel axle - forks (9-10-16-17) x (mm) 293 266
1.9 wheelbase (WB) y (mm) 1450 1500
2.1 unladen weight kg 4224 4617
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2428/1796 2577/2040

2.4 load on axle with forks out with load (front/rear) kg 979/4845 985/5632
2.5 load on axle with forks retracted with load (front/rear) kg 2104/3720 2149/4468
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140 343 x 140
TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100 285 x 100
3.5 wheel quantity (x = drive) (front/rear) 1x/2 1x/2
3.7 rear track width b 11 (mm) 1155 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4
4.2 height with mast retracted h1 (mm) 3227 3227
4.3 free lift h2 (mm) 2680 2614
4.4 lifting h3 (mm) 7900 7750
4.5 height, mast extended (1) h4 (mm) 8463 8363
4.7 height of overhead guard (cab) (2-12-15) h6 (mm) 2175 2175
4.8 seat height relative to SIP h7 (mm) 1082 1082
4.10 armrest height h8 (mm) 308 308
4.19 total length l1 (mm) 2538 2615
4.20 length to face of forks (16-17) l2 (mm) 1388 1465
4.21 total length (3-13-14) b1/b2 (mm) 1265 1345
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150 40/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A
4.24 fork carriage width b3 (mm) 700 700
4.25 distance between fork arms (MIN/MAX) (8) b5 (mm) 260/680 260/680
4.26 distance between the load wheel arms b4 (mm) 900 900
4.28 retractable travel b4 (mm) 491 464
4.31 ground clearance under mast with load m1 (mm) 65 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (11-16-17) AST (mm) 2845 2915
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (11-16-17) AST (mm) 2909 2984
4.35 turning radius Wa (mm) 1718 1767
4.37 length between the wheel arms b7 (mm) 1845 1895
4.42 wheelbase height (from ground to footboard) mm 550 550
wheelbase height (between intermediate steps between the footboard and the
4.43 mm 371 371
ground)
5.1 drive speed with/without load (7) km/h 11/11(14/14) 11/11(14/14)
5.1.1 drive speed with/without load reverse drive (7) km/h 11/11(14/14) 11/11(14/14)
PERFORMANCE

5.2 lift speed with/without load (7) m/s 0.42 / 0.73 0.37 / 0.68
5.3 lowering speed with/without load m/s 0.55 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17 0.17 / 0.17
5.7 gradeability with/without load (7-18) % 12/18 11/16
5.8 maximum gradeability with/without load (7-18) % 12/18 11/16
5.9 acceleration time, with/without load(7) s 2.6/2.5 2.7/2.6
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes (7) kW 9.6 9.6
MOTOR UNITS

6.2 lifting motor, power S3 15% (7) kW 14 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 (6) 48/840 (6)
6.5 battery weight (4) kg 1119 1306
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.2 4.8
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180 180

10.2 volume of oil for additional attachments l/min 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7

14
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR25 - MR20HD Model Year 2021

GENERAL SPECIFICATIONS TABLE NOTES (10)

(11)
For models MR20 - MR25 and with 4-stage mast: “x” - 108 mm.
For AST with 4-stage mast, refer to the "14-16 4-stage mast tables" and "20-25 4-stage mast tables".
(12) For height complete with wire mesh/Lexan screen h6 + 18 mm.
(1) With seat loaded h4 + 508 mm. (MR14 - MR16 - MR16N - MR16HD), + 443 mm (MR20 -
(13) For model MR16N with worklights of truck w 900mm: b1 +113 mm.
MR25 - MR20HD).
(14) For worklights on truck w 1100 mm: b1 +313mm for model MR16N; b1 +173 mm for models MR14 -
(2) With flashing beacon h6+120 mm.
MR16 - MR20 - MR16HD; b1 +93 mm for models MR25 and MR20HD.
(3) With load wheel side covers: 1289 mm (MR14 - MR16 - MR20 - MR16HD), 1153 mm
(15) With PAL lateral line h6 +135 mm with dual front worklights h6 + 220 mm
(MR16N), 1373 mm (MR25 - MR20HD).
(16) For model MR14 with h3 <= 5500mm: 420Ah battery and Transparent Operator Shield (Lexan)/ Wire
(4) These values may vary by +/- 5%.
Mesh Screen: l2 + 72 mm, x - 72 mm, AST 4.34.1 = 2770 mm, AST 4.34.2 = 2829 mm
(5) Forks retracted.
(17) For model MR16 with h3 <= 5500 mm: battery 420Ah and Transparent Operator Shield (Lexan)/ Wire
(6) Refer to the batteries table.
Mesh Screen: l2 + 72 mm, x - 72 mm, AST 4.34.1 = 2781 mm, AST 4.34.2 = 2830 mm
(7) The values in parentheses are optional.
(18) Maximum gradeability based on motor thermal capacity, available torque and brake requirements.
(8) Side shift travel is ± 75 mm on all trucks: Reduced to ± 25 mm for model MR16N.
(9) For models MR14 - MR16 with 4-stage mast: “x” -53 mm. (19) 4kW drive motor available for Russian market.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

15
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR25 MR20HD

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6 2.0
1.6 load centre distance c (mm) 600 600
1.8 load distance from load wheel axle - forks (9-10-16-17) x (mm) 416 315
1.9 wheelbase (WB) y (mm) 1650 1550
2.1 unladen weight kg 4230 4617
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2565/1665 2577/2040

2.4 load on axle with forks out with load (front/rear) kg 876/5855 985/5632
2.5 load on axle with forks retracted with load (front/rear) kg 2306/4424 2149/4468
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140 343 x 140
TYRES

3.3 rear wheel size Ø (mm x mm) 350 x 140 350 x 110
3.5 wheel quantity (x = drive) (front/rear) 1x/2 1x/2
3.7 rear track width b 11 (mm) 1183 1153
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4
4.2 height with mast retracted h1 (mm) 2195 3227
4.3 free lift h2 (mm) 1582 2614
4.4 lifting h3 (mm) 4650 7750
4.5 height, mast extended (1) h4 (mm) 5263 8363
4.7 height of overhead guard (cab) (2-12-15) h6 (mm) 2175 2175
4.8 seat height relative to SIP h7 (mm) 1082 1082
4.10 armrest height h8 (mm) 373 373
4.19 total length l1 (mm) 2615 2615
4.20 length to face of forks (16-17) l2 (mm) 1465 1465
4.21 total length (3-13-14) b1/b2 (mm) 1345 1273
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 45/120/1150 40/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A
4.24 fork carriage width b3 (mm) 700 700
4.25 distance between fork arms (MIN/MAX) (8) b5 (mm) 260/680 260/680
4.26 distance between the load wheel arms b4 (mm) 900 900
4.28 retractable travel b4 (mm) 646 496
4.31 ground clearance under mast with load m1 (mm) 65 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (11-16-17) AST (mm) 2949 2926
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (11-16-17) AST (mm) 2992 2986
4.35 turning radius Wa (mm) 1911 1815
4.37 length between the wheel arms b7 (mm) 2078 1978
4.42 wheelbase height (from ground to footboard) mm 550 550
wheelbase height (between intermediate steps between the footboard and the
4.43 mm 371 371
ground)
5.1 drive speed with/without load (7) km/h 11/11(14/14) 11/11(14/14)
5.1.1 drive speed with/without load reverse drive (7) km/h 11/11(14/14) 11/11(14/14)
PERFORMANCE

5.2 lift speed with/without load (7) m/s 0.30 / 0.64 0.37 / 0.68
5.3 lowering speed with/without load m/s 0.55 / 0.50 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17 0.17 / 0.17
5.7 gradeability with/without load (7-18) % 10/18 11/16
5.8 maximum gradeability with/without load (7-18) % 10/18 11/16
5.9 acceleration time, with/without load(7) s 2.7/2.6 2.7/2.6
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes (7) kW 9.6 9.6
MOTOR UNITS

6.2 lifting motor, power S3 15% (7) kW 14 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/840 (6) 48/840 (6)
6.5 battery weight (4) kg 1306 1306
6.6 Energy consumption according to DIN EN 16796 kWh/h 5.2 4.8
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180 180

10.2 volume of oil for additional attachments l/min 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7

16
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR14 version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

17
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR14

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.4
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 330
1.9 wheelbase (WB) y (mm) 1400
2.1 unladen weight (6) kg 3362 3362 3560 3571
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2164/1198 2164/1198 2231/1329 2238/1333
2.4 load on axle with forks out with load (front/rear) kg 932/3830 932/3830 998/3961 1006/3965
2.5 load on axle with forks retracted with load (front/rear) kg 1893/2869 1893/2869 1959/3000 1966/3004
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2605
4.20 length to face of forks (8) l2 (mm) 1455
4.21 total width b1/b2 (mm) 1265
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/80/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 220/640
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 513
4.31 ground clearance under mast with load m1 (mm) 75
4.32 ground clearance under the centre of the wheelbase m2 (mm) 75
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 2895
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 2955
4.35 turning radius Wa (mm) 1787
4.37 length between the wheel arms b7 (mm) 1949
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the
4.43 mm 371
footboard and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.37/0.63 (0.47/0.73)

5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (15/20)
5.8 maximum gradeability laden/unladen % 15/20 (15/20)
5.9 acceleration time, with/without load s 3.3/3.3 (2.6/2.6)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (9.6)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/420 48/465 48/560 (2) 48/620 (2)
6.5 battery weight (1) kg 750 939 950
6.6 Energy consumption according to DIN EN 16796 kWh/h 3.8
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180 180

10.2 volume of oil for additional attachments l/min 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7

18
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR14 version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

19
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR14

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.4
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 258
1.9 wheelbase (WB) y (mm) 1400
2.1 unladen weight (6) kg 3745 3791
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2261/1484 2209/1501

2.4 load on axle with forks out with load (front/rear) kg 1091/4054 1120/4071
2.5 load on axle with forks retracted with load (front/rear) kg 1917/3228 1947/3245
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2677
4.20 length to face of forks (8) l2 (mm) 1527
4.21 total width b1/b2 (mm) 1265
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/80/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 220/640
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 441
4.31 ground clearance under mast with load m1 (mm) 75
4.32 ground clearance under the centre of the wheelbase m2 (mm) 75
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 2950
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 3021
4.35 turning radius Wa (mm) 1787
4.37 length between the wheel arms b7 (mm) 1949
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard and the
4.43 mm 371
ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.37/0.63 (0.47/0.73)

5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (15/20)
5.8 maximum gradeability laden/unladen % 15/20 (15/20)
5.9 acceleration time, with/without load s 3.3/3.3 (2.6/2.6)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (9.6)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C “Super”
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 (3) 48/775 (3)
6.5 battery weight (1) kg 1119 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 3.8
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180 180

10.2 volume of oil for additional attachments l/min 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7

20
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16 version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

21
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 380
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight (6) kg 3412 3412 3610 3621
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2206/1206 2206/1206 2273/1337 2281/1340
2.4 load on axle with forks out with load (front/rear) kg 851/4162 851/4162 918/4292 925/4296
2.5 load on axle with forks retracted with load (front/rear) kg 1962/3051 1962/3051 2029/3181 2036/3185
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2605
4.20 length to face of forks (8) l2 (mm) 1455
4.21 total width b1/b2 (mm) 1265
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 563
4.31 ground clearance under mast with load m1 (mm) 75
4.32 ground clearance under the centre of the wheelbase m2 (mm) 75
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 2905
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 2956
4.35 turning radius Wa (mm) 1834
4.37 length between the wheel arms b7 (mm) 1999
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0,32 / 0,63 (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (14/20)
5.8 maximum gradeability laden/unladen % 14/20 (14/20)
5.9 acceleration time, with/without load s 3.4/3.4 (2.7/2.7)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (9.6)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C “Super” C C “Super”
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/420 48/465 48/560 (2) 48/620 (2)
6.5 battery weight (1) kg 750 939 950
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.0
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

22
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16 version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%.
(8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg).
cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
All weights (2.1 to 2.5) are with lowered masts and standard forks.
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

23
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 308
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight (6) kg 3796 3842
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2307/1489 2337/1505

2.4 load on axle with forks out with load (front/rear) kg 1014/4382 1043/4398
2.5 load on axle with forks retracted with load (front/rear) kg 1983/3413 2013/3429
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2677
4.20 length to face of forks (8) l2 (mm) 1527
4.21 total width b1/b2 (mm) 1265
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 491
4.31 ground clearance under mast with load m1 (mm) 75
4.32 ground clearance under the centre of the wheelbase m2 (mm) 75
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 2959
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 3022
4.35 turning radius Wa (mm) 1834
4.37 length between the wheel arms b7 (mm) 1999
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0,32 / 0,63 (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (14/20)
5.8 maximum gradeability laden/unladen % 14/20 (14/20)
5.9 acceleration time, with/without load s 3.4/3.4 (2.7/2.7)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (9.6)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C “Super”
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 (3) 48/775 (3)
6.5 battery weight (1) kg 1119 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.0
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

24
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16N version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

25
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16N

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 292
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight (6) kg 3351 3351 3549 3557
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2162/1189 2162/1189 2147/1402 2152/1405
2.4 load on axle with forks out with load (front/rear) kg 809/4142 809/4142 872/4277 877/4280
2.5 load on axle with forks retracted with load (front/rear) kg 1920/3032 1920/3032 1806/3343 1811/3346
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1025
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2693
4.20 length to face of forks (8) l2 (mm) 1543
4.21 total width b1/b2 (mm) 1125
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 795
4.28 retractable travel b4 (mm) 475
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 2936
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 3002
4.35 turning radius Wa (mm) 1800
4.37 length between the wheel arms b7 (mm) 1999
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the
4.43 mm 371
footboard and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0,32 / 0,63 (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (14/20)
5.8 maximum gradeability laden/unladen % 14/20 (14/20)
5.9 acceleration time, with/without load s 3.4/3.4 (2.7/2.7)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (9.6)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no B B “Super” B B “Super”
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/420 48/465 48/560 48/620
6.5 battery weight (1) kg 746 937 945
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.0
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

26
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16N version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

27
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16N

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 202
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight (6) kg 3738 3754
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2155/1583 2165/1589

2.4 load on axle with forks out with load (front/rear) kg 957/4381 966/4387
2.5 load on axle with forks retracted with load (front/rear) kg 1714/3624 1724/3630
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1025
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2783
4.20 length to face of forks (8) l2 (mm) 1633
4.21 total width b1/b2 (mm) 1125
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 795
4.28 retractable travel b4 (mm) 385
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 3007
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 3085
4.35 turning radius Wa (mm) 1800
4.37 length between the wheel arms b7 (mm) 1999
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the
4.43 mm 371
footboard and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0,32 / 0,63 (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (14/20)
5.8 maximum gradeability laden/unladen % 14/20 (14/20)
5.9 acceleration time, with/without load s 3.4/3.4 (2.7/2.7)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (+9.6)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no B B “Super”
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 48/775
6.5 battery weight (1) kg 1119 1135
kWh/h no. of
6.6 Energy consumption according to DIN EN 16796 cycles
4.0
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

28
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR20 version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

29
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR20

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 2.0
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 415 415 343 343
1.9 wheelbase (WB) y (mm) 1500
2.1 unladen weight (6) kg 3865 3876 4050 4096
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2460/1405 2467/1409 2495/1555 2525/1571
2.4 load on axle with forks out with load (front/rear) kg 870/4994 878/4998 969/5081 1000/5097
2.5 load on axle with forks retracted with load (front/rear) kg 2231/3634 2238/3637 2170/3880 2201/3896
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1582
4.4 lifting h3 (mm) 4650
4.5 height with mast extended h4 (mm) 5263
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2605 2605 2677 2677
4.20 length to face of forks (8) l2 (mm) 1470 1470 1542 1542
4.21 total width b1/b2 (mm) 1265
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 613 613 541 541
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 2922 2922 2974 2974
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 2965 2965 3030 3030
4.35 turning radius Wa (mm) 1884
4.37 length between the wheel arms b7 (mm) 2049
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.37 / 0.64

5.3 lowering speed with/without load m/s 0.55 / 0.50
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 12/20
5.8 maximum gradeability laden/unladen % 12/20
5.9 acceleration time, with/without load s 2.6/2.5
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/560 (2) 48/620 (2) 48/700 (3) 48/775 (3)
6.5 battery weight (1) kg 939 950 1119 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.6
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

30
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR25 version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

31
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS

1.1 Manufacturer Yale

CHARACTERISTICS

1.2 Identification code MR25

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 2.5
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 488 488 416 416
1.9 wheelbase (WB) y (mm) 1650
2.1 unladen weight (6) kg 4288 4334 4480 4542
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2709/1579 2741/1593 2754/1726 2795/1747
2.4 load on axle with forks out with load (front/rear) kg 962/5862 993/5841 1065/5916 1106/5936
2.5 load on axle with forks retracted with load (front/rear) kg 2560/4228 2591/4243 2495/4485 2537/4505
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 140

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b11 (mm) 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1582
4.4 lifting h3 (mm) 4650
4.5 height with mast extended h4 (mm) 5263
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2682 2682 2754 2754
4.20 length to face of forks (8) l2 (mm) 1547 1547 1619 1619
4.21 total width b1/b2 (mm) 1345
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 45/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 686 686 614 614
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 3018 3018 3066 3066
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 3046 3046 3109 3109
4.35 turning radius Wa (mm) 2029
4.37 length between the wheel arms b7 (mm) 2231
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.30 / 0.64

5.3 lowering speed with/without load m/s 0.55 / 0.50
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 10/18
5.8 maximum gradeability laden/unladen % 10/18
5.9 acceleration time, with/without load s 2.7/2.6
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 (3) 48/775 (3) 48/840 48/930
6.5 battery weight (1) kg 1119 1165 1306 1368
6.6 Energy consumption according to DIN EN 16796 kWh/h 5.2
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

32
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR25 version with cold store cab - MODEL YEAR 2021

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

33
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS

1.1 Manufacturer Yale

CHARACTERISTICS

1.2 Identification code MR25

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 2.5
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 488 488 416 416
1.9 wheelbase (WB) y (mm) 1650
2.1 unladen weight (6) kg 4288 4334 4480 4542
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2709/1579 2741/1593 2754/1726 2795/1747
2.4 load on axle with forks out with load (front/rear) kg 962/5862 993/5841 1065/5916 1106/5936
2.5 load on axle with forks retracted with load (front/rear) kg 2560/4228 2591/4243 2495/4485 2537/4505
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 140

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b11 (mm) 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1582
4.4 lifting h3 (mm) 4650
4.5 height with mast extended h4 (mm) 5263
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2682 2682 2754 2754
4.20 length to face of forks (8) l2 (mm) 1547 1547 1619 1619
4.21 total width b1/b2 (mm) 1345
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 45/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 718 718 646 646
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 3018 3018 3066 3066
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 3046 3046 3109 3109
4.35 turning radius Wa (mm) 2029
4.37 length between the wheel arms b7 (mm) 2263
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.30 / 0.64

5.3 lowering speed with/without load m/s 0.55 / 0.50
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 10/18
5.8 maximum gradeability laden/unladen % 10/18
5.9 acceleration time, with/without load s 2.7/2.6
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 (3) 48/775 (3) 48/840 48/930
6.5 battery weight (1) kg 1119 1165 1306 1368
6.6 Energy consumption according to DIN EN 16796 kWh/h 5.2
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

34
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16HD version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

35
 PRESENTATION SERVICE
GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16HD

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 248 248 248 248
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight (6) kg 4288 4299 4474 4520
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2561/1727 2568/1731 2626/1848 2655/1865
2.4 load on axle with forks out with load (front/rear) kg 978/4910 986/4913 1177/4897 1207/4913
2.5 load on axle with forks retracted with load (front/rear) kg 2267/3621 2275/3624 2302/3772 2332/3788
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
Ø (mm x
WHEELS &

3.2 front wheel size mm)

343 x 140
TYRES

Ø (mm x
3.3 rear wheel size mm)
285 x 100
3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 3227
4.3 free lift h2 (mm) 2680
4.4 lifting h3 (mm) 7900
4.5 height with mast extended h4 (mm) 8463
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2722 2722 2722 2722
4.20 length to face of forks (8) l2 (mm) 1587 1587 1587 1587
4.21 total width b1/b2 (mm) 1265
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 446 446 446 446
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 2996
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 3067
4.35 turning radius Wa (mm) 1834
4.37 length between the wheel arms b7 (mm) 1999
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.42 / 0.73

5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 12/18
5.8 maximum gradeability laden/unladen % 12/18
5.9 acceleration time, with/without load s 2.6/2.5
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/560 (2) 48/620 (2) 48/700 (3) 48/775 (3)
6.5 battery weight (1) kg 939 950 1119 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.2
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

36
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR20HD version with cold store cab

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

37
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR20HD

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 2.0
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 293 293 266 266
1.9 wheelbase (WB) y (mm) 1500
2.1 unladen weight (6) kg 4675 4721 4867 4929
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2704/1971 2734/1987 2768/2099 2807/2122
2.4 load on axle with forks out with load (front/rear) kg 968/5707 998/5723 1176/5691 1215/5714
2.5 load on axle with forks retracted with load (front/rear) kg 2312/4362 2343/4378 2340/4527 2380/4549
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 3227
4.3 free lift h2 (mm) 2614
4.4 lifting h3 (mm) 7750
4.5 height with mast extended h4 (mm) 8363
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2727 2727 2754 2754
4.20 length to face of forks (8) l2 (mm) 1592 1592 1619 1619
4.21 total width b1/b2 (mm) 1345
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 491 491 464 464
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 3011 3011 3032 3032
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 3075 3075 3100 3100
4.35 turning radius Wa (mm) 1884
4.37 length between the wheel arms b7 (mm) 2039
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.37 / 0.68

5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 11/16
5.8 maximum gradeability laden/unladen % 11/16
5.9 acceleration time, with/without load s 2.7/2.6
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 (3) 48/775 (3) 48/840 48/930
6.5 battery weight (1) kg 1119 1165 1306 1368
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.8
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

38
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR20HD version with cold store cab - MODEL YEAR 2021

GENERAL SPECIFICATIONS TABLE NOTES (7) Narrow Cold Store cab with GLASS screens / Narrow Cold Store cab with
POLYCARBONATE screens: 60 kg less.
(1) These values may vary by +/- 5%. (8) For models MR20 and MR25 with h3 = 4650 mm, 560Ah battery and Cold Store
(2) Available with 48V/450Ah lithium battery (895 kg). cab: l2 +7 2 mm, x -72 mm, AST 4.34.1 = 2857 mm, AST 4.34.2 =2913 mm.
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) With mesh OHG + 45 mm; with mast worklights + 125 mm; with front worklights All weights (2.1 to 2.5) are with lowered masts and standard forks.
+145 mm; with beacon (red line) on standard/narrow + 65 mm; with beacon (red
line) on DriveIN 185 mm; with signal light +65 mm.
(5) Forks retracted.
(6) Standard Cold Store cab with GLASS screens / Standard Cold Store cab with
POLYCARBONATE screens: 58 kg less.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

39
 PRESENTATION SERVICE
GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR20HD

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 2.0
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks (8) x (mm) 343 343 316 316
1.9 wheelbase (WB) y (mm) 1550
2.1 unladen weight (6) kg 4675 4721 4867 4929
WEIGHTS

2.3 load on axle with no load (front/rear) (5) kg 2704/1971 2734/1987 2768/2099 2807/2122
2.4 load on axle with forks out with load (front/rear) kg 968/5707 998/5723 1176/5691 1215/5714
2.5 load on axle with forks retracted with load (front/rear) kg 2312/4362 2343/4378 2340/4527 2380/4549
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 3227
4.3 free lift h2 (mm) 2614
4.4 lifting h3 (mm) 7750
4.5 height with mast extended h4 (mm) 8363
4.7 height of overhead guard (cab) (4) h6 (mm) 2245
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2727 2727 2754 2754
4.20 length to face of forks (8) l2 (mm) 1592 1592 1619 1619
4.21 total width b1/b2 (mm) 1345
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 700
4.25 distance between fork arms (MIN/MAX) b5 (mm) 260/680
4.26 distance between the load wheel arms b4 (mm) 900
4.28 retractable travel b4 (mm) 491 491 464 464
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (8) AST (mm) 3024 3024 3044 3044
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (8) AST (mm) 3080 3080 3104 3104
4.35 turning radius Wa (mm) 1934
4.37 length between the wheel arms b7 (mm) 2132
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.37 / 0.68

5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 11/16
5.8 maximum gradeability laden/unladen % 11/16
5.9 acceleration time, with/without load s 2.7/2.6
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/700 (3) 48/775 (3) 48/840 48/930
6.5 battery weight (1) kg 1119 1165 1306 1368
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.8
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

40
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16 wide version

GENERAL SPECIFICATIONS TABLE NOTES All weights (2.1 to 2.5) are with lowered masts and standard forks.
(1) These values may vary by +/- 5%.
(2) Available with 48V/450Ah lithium battery (895 kg).
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) Forks retracted.
(5) With load wheel side covers: 1489 mm (Wide), 1689 mm (Extra Wide).
(6) Side shift travel is +/-75 mm on all trucks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

41
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks x (mm) 452 380 308 452
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight kg 3214 3409 3571 3214
WEIGHTS

2.3 load on axle with no load (front/rear) (4) kg 2062/1172 2096/1313 2093/1478 2062/1172
2.4 load on axle with forks out with load (front/rear) kg 592/4242 690/4319 728/4444 592/4242
2.5 load on axle with forks retracted with load (front/rear) kg 1862/2973 1816/3193 1710/3462 1862/2973
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) h6 (mm) 2175
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2379 2451 2523 2379
4.20 length to face of forks l2 (mm) 1229 1301 1373 1229
4.21 overall width (5) b1/b2 (mm) 1465
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 900
4.25 distance between fork arms (MIN/MAX) (6) b5 (mm) 260/884
4.26 distance between the load wheel arms b4 (mm) 1095
4.28 retractable travel b4 (mm) 635 563 491 635
4.31 ground clearance under mast with load m1 (mm) 75
4.32 ground clearance under the centre of the wheelbase m2 (mm) 75
4.34.1 working aisle for pallet length 1000 x 1200 crosswise AST (mm) 2731 2781 2834 2731
4.34.2 working aisle for pallet length 800 x 1200 lengthwise AST (mm) 2766 2830 2896 2766
4.35 turning radius Wa (mm) 1720
4.37 length between the wheel arms b7 (mm) 1845
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0,32 / 0,63 (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (14/20)
5.8 maximum gradeability laden/unladen % 14/20 (14/20)
5.9 acceleration time, with/without load s 3.4/3.4 (2.7/2.7)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (9.6)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C C C “Super”
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/420 48/560 (2) 48/700 (3) 48/465
6.5 battery weight (1) kg 750 939 1119 750
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.0
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

42
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16 wide version

GENERAL SPECIFICATIONS TABLE NOTES All weights (2.1 to 2.5) are with lowered masts and standard forks.
(1) These values may vary by +/- 5%.
(2) Available with 48V/450Ah lithium battery (895 kg).
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) Forks retracted.
(5) With load wheel side covers: 1489 mm (Wide), 1689 mm (Extra Wide).
(6) Side shift travel is +/-75 mm on all trucks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

43
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks x (mm) 380 308
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight kg 3409 3571
WEIGHTS

2.3 load on axle with no load (front/rear) (4) kg 2096/1313 2093/1478

2.4 load on axle with forks out with load (front/rear) kg 690/4319 728/4444
2.5 load on axle with forks retracted with load (front/rear) kg 1816/3193 1710/3462
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) h6 (mm) 2175
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2451 2523
4.20 length to face of forks l2 (mm) 1301 1373
4.21 overall width (5) b1/b2 (mm) 1465
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 900
4.25 distance between fork arms (MIN/MAX) (6) b5 (mm) 260/884
4.26 distance between the load wheel arms b4 (mm) 1095
4.28 retractable travel b4 (mm) 563 491
4.31 ground clearance under mast with load m1 (mm) 75
4.32 ground clearance under the centre of the wheelbase m2 (mm) 75
4.34.1 working aisle for pallet length 1000 x 1200 crosswise AST (mm) 2781 2834
4.34.2 working aisle for pallet length 800 x 1200 lengthwise AST (mm) 2830 2896
4.35 turning radius Wa (mm) 1720
4.37 length between the wheel arms b7 (mm) 1845
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0,32 / 0,63 (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (14/20)
5.8 maximum gradeability laden/unladen % 14/20 (14/20)
5.9 acceleration time, with/without load s 3.4/3.4 (2.7/2.7)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (9.6)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C "Super" C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/620 (2) 48/775 (3)
6.5 battery weight (1) kg 950 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.0
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

44
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16 extra wide version

GENERAL SPECIFICATIONS TABLE NOTES All weights (2.1 to 2.5) are with lowered masts and standard forks.
(1) These values may vary by +/- 5%.
(2) Available with 48V/450Ah lithium battery (895 kg).
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) Forks retracted.
(5) With load wheel side covers: 1489 mm (Wide), 1689 mm (Extra Wide).
(6) Side shift travel is +/-75 mm on all trucks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

45
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks x (mm) 452 380 308 452
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight kg 3331 3506 3661 3331
WEIGHTS

2.3 load on axle with no load (front/rear) (4) kg 2127/1204 2158/1348 2138/1523 2127/1204
2.4 load on axle with forks out with load (front/rear) kg 630/4301 728/4378 740/4522 630/4301
2.5 load on axle with forks retracted with load (front/rear) kg 1920/3011 1872/3234 1738/3523 1920/3011
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) h6 (mm) 2175
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2379 2451 2523 2379
4.20 length to face of forks l2 (mm) 1229 1301 1373 1229
4.21 overall width (5) b1/b2 (mm) 1665
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 1100
4.25 distance between fork arms (MIN/MAX) (6) b5 (mm) 260/1078
4.26 distance between the load wheel arms b4 (mm) 1295
4.28 retractable travel b4 (mm) 635 563 491 635
4.31 ground clearance under mast with load m1 (mm) 75
4.32 ground clearance under the centre of the wheelbase m2 (mm) 75
4.34.1 working aisle for pallet length 1000 x 1200 crosswise AST (mm) 2780 2830 2883 2780
4.34.2 working aisle for pallet length 800 x 1200 lengthwise AST (mm) 2815 2879 2945 2815
4.35 turning radius Wa (mm) 1767
4.37 length between the wheel arms b7 (mm) 1845
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0,32 / 0,63 (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (14/20)
5.8 maximum gradeability laden/unladen % 14/20 (14/20)
5.9 acceleration time, with/without load s 3.4/3.4 (2.7/2.7)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (9.6)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C C C “Super”
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/420 48/560 (2) 48/700 (3) 48/465
6.5 battery weight (1) kg 750 939 1119 750
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.0
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

46
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16 extra wide version

GENERAL SPECIFICATIONS TABLE NOTES All weights (2.1 to 2.5) are with lowered masts and standard forks.
(1) These values may vary by +/- 5%.
(2) Available with 48V/450Ah lithium battery (895 kg).
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) Forks retracted.
(5) With load wheel side covers: 1489 mm (Wide), 1689 mm (Extra Wide).
(6) Side shift travel is +/-75 mm on all trucks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

47
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks x (mm) 380 308
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight kg 3506 3661
WEIGHTS

2.3 load on axle with no load (front/rear) (4) kg 2158/1348 2138/1523

2.4 load on axle with forks out with load (front/rear) kg 728/4378 740/4522
2.5 load on axle with forks retracted with load (front/rear) kg 1872/3234 1738/3523
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1648
4.4 lifting h3 (mm) 5000
4.5 height with mast extended h4 (mm) 5563
4.7 height of overhead guard (cab) h6 (mm) 2175
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2451 2523
4.20 length to face of forks l2 (mm) 1301 1373
4.21 overall width (5) b1/b2 (mm) 1665
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 1100
4.25 distance between fork arms (MIN/MAX) (6) b5 (mm) 260/1078
4.26 distance between the load wheel arms b4 (mm) 1295
4.28 retractable travel b4 (mm) 563 491
4.31 ground clearance under mast with load m1 (mm) 75
4.32 ground clearance under the centre of the wheelbase m2 (mm) 75
4.34.1 working aisle for pallet length 1000 x 1200 crosswise AST (mm) 2830 2883
4.34.2 working aisle for pallet length 800 x 1200 lengthwise AST (mm) 2879 2945
4.35 turning radius Wa (mm) 1767
4.37 length between the wheel arms b7 (mm) 1845
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0,32 / 0,63 (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 7/10 (14/20)
5.8 maximum gradeability laden/unladen % 14/20 (14/20)
5.9 acceleration time, with/without load s 3.4/3.4 (2.7/2.7)
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 5.4 (9.6) (19)
MOTOR UNITS

6.2 lift motor, power S3 15% kW 9.9 (14)

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C "Super" C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/620 (2) 48/775 (3)
6.5 battery weight (1) kg 950 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.0
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

48
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR20 wide version

GENERAL SPECIFICATIONS TABLE NOTES All weights (2.1 to 2.5) are with lowered masts and standard forks.
(1) These values may vary by +/- 5%.
(2) Available with 48V/450Ah lithium battery (895 kg).
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) Forks retracted.
(5) With load wheel side covers: 1489 mm (Wide), 1689 mm (Extra Wide).
(6) Side shift travel is +/-75 mm on all trucks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

49
 PRESENTATION SERVICE
GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR20

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 2.0
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks x (mm) 415 343 415 343
1.9 wheelbase (WB) y (mm) 1500
2.1 unladen weight kg 3715 3878 3715 3878
WEIGHTS

2.3 load on axle with no load (front/rear) (4) kg 2329/1386 2327/1551 2329/1386 2327/1551
2.4 load on axle with forks out with load (front/rear) kg 672/5043 707/5171 672/5043 707/5171
2.5 load on axle with forks retracted with load (front/rear) kg 2054/3661 1927/3951 2054/3661 1927/3951
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1582
4.4 lifting h3 (mm) 4650
4.5 height with mast extended h4 (mm) 5263
4.7 height of overhead guard (cab) h6 (mm) 2175
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2451 2523 2451 2523
4.20 length to face of forks l2 (mm) 1316 1388 1316 1388
4.21 overall width (5) b1/b2 (mm) 1465
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 900
4.25 distance between fork arms (MIN/MAX) (6) b5 (mm) 260/884
4.26 distance between the load wheel arms b4 (mm) 1095
4.28 retractable travel b4 (mm) 613 541 613 541
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise AST (mm) 2806 2858 2806 2858
4.34.2 working aisle for pallet length 800 x 1200 lengthwise AST (mm) 2849 2914 2849 2914
4.35 turning radius Wa (mm) 1768
4.37 length between the wheel arms b7 (mm) 1895
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.37 / 0.64

5.3 lowering speed with/without load m/s 0.55 / 0.50
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 12/20
5.8 maximum gradeability laden/unladen % 12/20
5.9 acceleration time, with/without load s 2.6/2.5
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C C "Super" C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/560 (2) 48/700 (3) 48/620 (2) 48/775 (3)
6.5 battery weight (1) kg 939 1119 950 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.6
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

50
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR20 extra wide version

GENERAL SPECIFICATIONS TABLE NOTES All weights (2.1 to 2.5) are with lowered masts and standard forks.
(1) These values may vary by +/- 5%.
(2) Available with 48V/450Ah lithium battery (895 kg).
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) Forks retracted.
(5) With load wheel side covers: 1489 mm (Wide), 1689 mm (Extra Wide).
(6) Side shift travel is +/-75 mm on all trucks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

51
 PRESENTATION SERVICE

GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR20

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 2.0
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks x (mm) 415 343 415 343
1.9 wheelbase (WB) y (mm) 1500
2.1 unladen weight kg 4041 4195 4041 4195
WEIGHTS

2.3 load on axle with no load (front/rear) (4) kg 2573/1468 2553/1643 2573/1468 2553/1643
2.4 load on axle with forks out with load (front/rear) kg 890/5152 895/5300 890/5152 895/5300
2.5 load on axle with forks retracted with load (front/rear) kg 2293/3748 2134/4062 2293/3748 2134/4062
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
WHEELS &

3.2 front wheel size Ø (mm x mm) 343 x 140

TYRES

3.3 rear wheel size Ø (mm x mm) 285 x 100

3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 2195
4.3 free lift h2 (mm) 1582
4.4 lifting h3 (mm) 4650
4.5 height with mast extended h4 (mm) 5263
4.7 height of overhead guard (cab) h6 (mm) 2175
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2451 2523 2451 2523
4.20 length to face of forks l2 (mm) 1316 1388 1316 1388
4.21 overall width (5) b1/b2 (mm) 1665
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 1100
4.25 distance between fork arms (MIN/MAX) (6) b5 (mm) 260/1078
4.26 distance between the load wheel arms b4 (mm) 1295
4.28 retractable travel b4 (mm) 613 541 613 541
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise AST (mm) 2850 2902 2850 2902
4.34.2 working aisle for pallet length 800 x 1200 lengthwise AST (mm) 2893 2958 2893 2958
4.35 turning radius Wa (mm) 1812
4.37 length between the wheel arms b7 (mm) 1895
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.37 / 0.64

5.3 lowering speed with/without load m/s 0.55 / 0.50
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 12/20
5.8 maximum gradeability laden/unladen % 12/20
5.9 acceleration time, with/without load s 2.6/2.5
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C C "Super" C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/560 (2) 48/700 (3) 48/620 (2) 48/775 (3)
6.5 battery weight (1) kg 939 1119 950 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.6
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

52
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16HD wide version

GENERAL SPECIFICATIONS TABLE NOTES All weights (2.1 to 2.5) are with lowered masts and standard forks.
(1) These values may vary by +/- 5%.
(2) Available with 48V/450Ah lithium battery (895 kg).
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) Forks retracted.
(5) With load wheel side covers: 1489 mm (Wide), 1689 mm (Extra Wide).
(6) Side shift travel is +/-75 mm on all trucks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

53
 PRESENTATION SERVICE
GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16HD

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks x (mm) 308 293 308 293
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight kg 4141 4304 4141 4304
WEIGHTS

2.3 load on axle with no load (front/rear) (4) kg 2502/1639 2468/1836 2502/1639 2468/1836
2.4 load on axle with forks out with load (front/rear) kg 1172/4568 929/4974 1172/4568 929/4974
2.5 load on axle with forks retracted with load (front/rear) kg 2215/3525 2077/3826 2215/3525 2077/3826
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
Ø (mm x
WHEELS &

3.2 front wheel size mm)

343 x 140
TYRES

Ø (mm x
3.3 rear wheel size mm)
285 x 100
3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 3227
4.3 free lift h2 (mm) 2680
4.4 lifting h3 (mm) 7900
4.5 height with mast extended h4 (mm) 8463
4.7 height of overhead guard (cab) h6 (mm) 2175
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2523 2523 2523 2523
4.20 length to face of forks l2 (mm) 1373 1388 1373 1388
4.21 overall width (5) b1/b2 (mm) 1465
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 900
4.25 distance between fork arms (MIN/MAX) (6) b5 (mm) 260/884
4.26 distance between the load wheel arms b4 (mm) 1095
4.28 retractable travel b4 (mm) 491 491 491 491
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise AST (mm) 2834 2845 2834 2845
4.34.2 working aisle for pallet length 800 x 1200 lengthwise AST (mm) 2896 2909 2896 2909
4.35 turning radius Wa (mm) 1720
4.37 length between the wheel arms b7 (mm) 1845
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.42 / 0.73

5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 12/18
5.8 maximum gradeability laden/unladen % 12/18
5.9 acceleration time, with/without load s 2.6/2.5
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C C "Super" C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/560 (2) 48/700 (3) 48/620 (2) 48/775 (3)
6.5 battery weight (1) kg 939 1119 950 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.2
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

54
 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
MR16HD extra wide version

GENERAL SPECIFICATIONS TABLE NOTES All weights (2.1 to 2.5) are with lowered masts and standard forks.

(1) These values may vary by +/- 5%.

(2) Available with 48V/450Ah lithium battery (895 kg).
(3) Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium
battery (1091 kg).
(4) Forks retracted.
(5) With load wheel side covers: 1489 mm (Wide), 1689 mm (Extra Wide).
(6) Side shift travel is +/-75 mm on all trucks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

55
 PRESENTATION SERVICE
GENERAL SPECIFICATIONS
1.1 Manufacturer Yale
CHARACTERISTICS

1.2 Identification code MR16HD

1.3 Propulsion unit: electrical (battery or mains), diesel, LPG, petrol electric (battery)
1.4 driving position: manual, on ground, standing, seated seated
1.5 relative load/capacity Q (t) 1.6
1.6 load centre distance c (mm) 600
1.8 load distance from load wheel axle - forks x (mm) 308 293 308 293
1.9 wheelbase (WB) y (mm) 1450
2.1 unladen weight kg 4404 4559 4404 4559
WEIGHTS

2.3 load on axle with no load (front/rear) (4) kg 2696/1708 2640/1918 2696/1708 2640/1918
2.4 load on axle with forks out with load (front/rear) kg 1345/4659 1068/5090 1345/4659 1068/5090
2.5 load on axle with forks retracted with load (front/rear) kg 2404/3600 2234/3924 2404/3600 2234/3924
3.1 tyres: polyurethane, Topthane, NDIIThane (front/rear) NDIIThane/NDIIThane
Ø (mm x
WHEELS &

3.2 front wheel size mm)

343 x 140
TYRES

Ø (mm x
3.3 rear wheel size mm)
285 x 100
3.5 wheel quantity (x = drive) (front/rear) 1x/2
3.7 rear track width b 11 (mm) 1155
4.1 mast tilt / forks forward/backward α/β (°) 2/4
4.2 height with mast retracted h1 (mm) 3227
4.3 free lift h2 (mm) 2680
4.4 lifting h3 (mm) 7900
4.5 height with mast extended h4 (mm) 8463
4.7 height of overhead guard (cab) h6 (mm) 2175
4.8 seat height relative to SIP h7 (mm) 1082
4.10 armrest height h8 (mm) 308
4.19 total length l1 (mm) 2523 2523 2523 2523
4.20 length to face of forks l2 (mm) 1373 1388 1373 1388
4.21 overall width (5) b1/b2 (mm) 1665
DIMENSIONS

4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150

4.23 fork carriage ISO 2328, class/type A,B 2A
4.24 fork carriage width b3 (mm) 1100
4.25 distance between fork arms (MIN/MAX) (6) b5 (mm) 260/1078
4.26 distance between the load wheel arms b4 (mm) 1295
4.28 retractable travel b4 (mm) 491 491 491 491
4.31 ground clearance under mast with load m1 (mm) 65
4.32 ground clearance under the centre of the wheelbase m2 (mm) 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise AST (mm) 2883 2894 2883 2894
4.34.2 working aisle for pallet length 800 x 1200 lengthwise AST (mm) 2945 2958 2945 2958
4.35 turning radius Wa (mm) 1767
4.37 length between the wheel arms b7 (mm) 1845
4.42 wheelbase height (from ground to footboard) mm 550
wheelbase height (between intermediate steps between the footboard
4.43 mm 371
and the ground)
5.1 drive speed with/without load km/h 11/11(14/14)
5.1.1 drive speed with/without load reverse drive km/h 11/11(14/14)
PERFORMANCE

5.2 lifting speed with/without load m/s 0.42 / 0.73

5.3 lowering speed with/without load m/s 0.55
5.4 Retractable carriage speed m/s 0.17 / 0.17
5.7 gradeability laden/unladen % 12/18
5.8 maximum gradeability laden/unladen % 12/18
5.9 acceleration time, with/without load s 2.6/2.5
5.10 service brake Electrical
6.1 drive motor, power S2 60 minutes kW 9.6
MOTOR UNITS

6.2 lift motor, power S3 15% kW 14

6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C C "Super" C "Super"
6.4 battery voltage/nominal capacity K5 (V)/(Ah) 48/560 (2) 48/700 (3) 48/620 (2) 48/775 (3)
6.5 battery weight (1) kg 939 1119 950 1165
6.6 Energy consumption according to DIN EN 16796 kWh/h 4.2
8.1 drive type AC-Controller
OTHER
DATA

10.1 working pressure for additional attachments bar 180

10.2 volume of oil for additional attachments l/min 20
10.7 noise level at the operating station dB(A) <69.7

56
 SERVICE PRESENTATION

BATTERIES TABLE
1.2 identification code MR14
1.8 load distance from load wheel axle - forks x (mm) 402 330 402 330 258 258
1.9 wheelbase (WB) y (mm) 1400 1400 1400 1400 1400 1400
2.1 unladen weight (including battery) kg 3112 3309 3112 3320 3495 3541
2.3 load on axle with no load (front/rear) (4) kg 1977/1135 2025/1285 1977/1135 2032/1289 2055/1440 2084/1457
2.4 load on axle with forks out with load (front/rear) kg 682/3830 792/3917 682/3830 800/3921 885/4010 914/4027
2.5 load on axle with forks retracted with load (front/rear) kg 1778/2735 1753/2956 1778/2735 1760/2960 1711/3184 1741/3201
4.19 total length l1 (mm) 2379 2451 2379 2451 2523 2523
4.20 length to face of forks l2 (mm) 1229 1301 1229 1301 1373 1373
4.28 retractable travel b4 (mm) 585 513 585 513 441 441
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (5) AST (mm) 2718 2771 2718 2771 2828 2826
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (5) AST (mm) 2764 2829 2764 2829 2895 2895
4.35 turning radius Wa (mm) 1671 1671 1671 1671 1671 1671
6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C C "Super" C "Super" C C "Super"
6.4 battery rated voltage/capacity at 5 hours (V)/(Ah) 48/420 48/560 (2) 48/465 48/620 (2) 48/700 (3) 48/775 (3)
6.5 battery weight (1) kg 750 939 750 950 1119 1165

1.2 identification code MR16

1.8 load distance from load wheel axle - forks x (mm) 452 380 452 380 308 308
1.9 wheelbase (WB) y (mm) 1450 1450 1450 1450 1450 1450
2.1 unladen weight (including battery) kg 3162 3360 3162 3371 3546 3592
2.3 load on axle with no load (front/rear) (4) kg 2018/1144 2069/1291 2018/1144 2077/1294 2103/1443 2133/1459
2.4 load on axle with forks out with load (front/rear) kg 601/4162 714/4246 601/4162 721/4250 810/4336 839/4352
2.5 load on axle with forks retracted with load (front/rear) kg 1853/2909 1825/3135 1853/2909 1832/3139 1779/3367 1809/3383
4.19 total length l1 (mm) 2379 2451 2379 2451 2523 2523
4.20 length to face of forks l2 (mm) 1229 1301 1229 1301 1373 1373
4.28 retractable travel b4 (mm) 635 563 635 563 491 491
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (5) AST (mm) 2731 2781 2731 2781 2834 2834
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (5) AST (mm) 2767 2830 2767 2830 2896 2896
4.35 turning radius Wa (mm) 1718 1718 1718 1718 1718 1718
6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C C "Super" C "Super" C C "Super"
6.4 battery rated voltage/capacity at 5 hours (V)/(Ah) 48/420 48/560 (2) 48/465 48/620 (2) 48/700 (3) 48/775 (3)
6.5 battery weight (1)
kg 750 939 750 950 1119 1165

1.2 identification code MR16N

1.8 load distance from load wheel axle - forks x (mm) 382 292 382 292 202 202
1.9 wheelbase (WB) y (mm) 1450 1450 1450 1450 1450 1450
2.1 unladen weight (including battery) kg 3111 3309 3115 3317 3498 3514
2.3 load on axle with no load (front/rear) (4) kg 1922/1189 1947/1362 1924/1191 1952/1365 1955/1543 1965/1549
2.4 load on axle with forks out with load (front/rear) kg 569/4142 672/4237 572/4143 677/4240 757/4341 766/4347
2.5 load on axle with forks retracted with load (front/rear) kg 1680/3032 1606/3303 1682/3033 1611/3306 1514/3584 1524/3590
4.19 total length l1 (mm) 2449 2539 2449 2539 2629 2629
4.20 length to face of forks l2 (mm) 1299 1389 1299 1389 1479 1479
4.28 retractable travel b4 (mm) 565 475 565 475 385 385
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (5) AST (mm) 2762 2828 2762 2828 2898 2899
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (5) AST (mm) 2811 2893 2811 2893 2976 2976
4.35 turning radius Wa (mm) 1700 1700 1700 1700 1700 1700
6.3 battery conforms to DIN 43531/35/36 A,B,C, no B B B "Super" B "Super" B B "Super"
6.4 battery rated voltage/capacity at 5 hours (V)/(Ah) 48/420 48/560 48/465 48/620 48/700 48/775
6.5 battery weight (1) kg 746 937 750 945 1119 1135

(1)
These values may vary by ± 5%.
(2)
Available with 48V/450Ah lithium battery (895 kg).
(3)
Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium battery (1091 kg).
(4)
Forks retracted.
(5)
For AST with 4-stage mast, refer to “4-stage mast 14-16 table” and “4-stage mast 20-25 table”.
All weights (2.1 to 2.5) are with lowered masts and standard forks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

57
 PRESENTATION SERVICE

1.2 identification code MR20

1.8 load distance from load wheel axle - forks x (mm) 415 415 343 343
1.9 wheelbase (WB) y (mm) 1500 1500 1500 1500
2.1 unladen weight (including battery) kg 3615 3626 3801 3847
2.3 load on axle with no load (front/rear) (4) kg 2261/1354 2268/1358 2296/1504 2326/1520
2.4 load on axle with forks out with load (front/rear) kg 671/4943 679/4947 770/5030 801/5046
2.5 load on axle with forks retracted with load (front/rear) kg 2032/3583 2039/3586 1971/3829 2002/3845
4.19 total length l1 (mm) 2451 2451 2523 2523
4.20 length to face of forks l2 (mm) 1316 1316 1388 1388
4.28 retractable travel b4 (mm) 613 613 541 541
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (5) AST (mm) 2805 2805 2857 2857
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (5) AST (mm) 2848 2848 2913 2912
4.35 turning radius Wa (mm) 1767 1767 1767 1767
6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery rated voltage/capacity at 5 hours (V)/(Ah) 48/560 (2) 48/620 (2) 48/700 (3) 48/775 (3)
6.5 battery weight (1)
kg 939 950 1119 1165

1.2 identification code MR25

1.8 load distance from load wheel axle - forks x (mm) 488 488 416 416
1.9 wheelbase (WB) y (mm) 1650 1650 1650 1650
2.1 unladen weight (including battery) kg 4038 4084 4230 4292
2.3 load on axle with no load (front/rear) (4) kg 2520/1518 2552/1532 2565/1665 2606/1686
2.4 load on axle with forks out with load (front/rear) kg 773/5765 804/5780 876/5855 917/5875
2.5 load on axle with forks retracted with load (front/rear) kg 2371/4167 2402/4182 2306/4424 2348/4444
4.19 total length l1 (mm) 2528 2528 2600 2600
4.20 length to face of forks l2 (mm) 1393 1393 1465 1465
4.28 retractable travel b4 (mm) 686 686 614 614
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (5) AST (mm) 2900 2900 2949 2948
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (5) AST (mm) 2927 2927 2991 2991
4.35 turning radius Wa (mm) 1911 1911 1911 1911
6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery rated voltage/capacity at 5 hours (V)/(Ah) 48/700 (3) 48/775 (3) 48/840 48/930
6.5 battery weight (1)
kg 1119 1165 1306 1368

1.2 identification code MR16HD

1.8 load distance from load wheel axle - forks x (mm) 308 308 293 293
1.9 wheelbase (WB) y (mm) 1450 1450 1450 1450
2.1 unladen weight (including battery) kg 4038 4049 4224 4270
2.3 load on axle with no load (front/rear) (4) kg 2417/1621 2424/1625 2428/1796 2457/1813
2.4 load on axle with forks out with load (front/rear) kg 883/4755 891/4758 979/4845 1009/4861
2.5 load on axle with forks retracted with load (front/rear) kg 2172/3466 2180/3469 2104/3720 2134/3736
4.19 total length l1 (mm) 2523 2523 2523 2523
4.20 length to face of forks l2 (mm) 1373 1373 1388 1388
4.28 retractable travel b4 (mm) 491 491 491 491
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (5) AST (mm) 2834 2834 2845 2845
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (5) AST (mm) 2896 2896 2909 2909
4.35 turning radius Wa (mm) 1718 1718 1718 1718
6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery rated voltage/capacity at 5 hours (V)/(Ah) 48/560 (2) 48/620 (2) 48/700 (3) 48/775 (3)
6.5 battery weight (1) kg 939 950 1119 1165

(1)
These values may vary by ± 5%.
(2)
Available with 48V/450Ah lithium battery (895 kg).
(3)
Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium battery (1091 kg).
(4)
Forks retracted.
(5)
For AST with 4-stage mast, refer to “4-stage mast 14-16 table” and “4-stage mast 20-25 table”.
All weights (2.1 to 2.5) are with lowered masts and standard forks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

58
 SERVICE PRESENTATION

1.2 identification code MR20HD

1.8 load distance from load wheel axle - forks x (mm) 338 338 266 266
1.9 wheelbase (WB) y (mm) 1500 1500 1500 1500
2.1 unladen weight (including battery) kg 4425 4471 4617 4679
2.3 load on axle with no load (front/rear) (4) kg 2567/1858 2597/1874 2577/2040 2616/2063
2.4 load on axle with forks out with load (front/rear) kg 891/5534 921/5550 985/5632 1024/5655
2.5 load on axle with forks retracted with load (front/rear) kg 2235/4189 2266/4205 2149/4468 2189/4490
4.19 total length l1 (mm) 2528 2528 2600 2600
4.20 length to face of forks l2 (mm) 1393 1393 1465 1465
4.28 retractable travel b4 (mm) 536 536 464 464
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (5) AST (mm) 2860 2860 2915 2915
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (5) AST (mm) 2917 2917 2983 2983
4.35 turning radius Wa (mm) 1767 1767 1767 1767
6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery rated voltage/capacity at 5 hours (V)/(Ah) 48/700 (3) 48/775 (3) 48/840 48/930
6.5 battery weight (1)
kg 1119 1165 1306 1368

1.2 identification code MR25 (model year 2021)

1.8 load distance from load wheel axle - forks x (mm) 488 488 416 416
1.9 wheelbase (WB) y (mm) 1650 1650 1650 1650
2.1 unladen weight (including battery) kg 4038 4084 4230 4292
2.3 load on axle with no load (front/rear) (4) kg 2520/1518 2552/1532 2565/1665 2606/1686
2.4 load on axle with forks out with load (front/rear) kg 773/5765 804/5780 876/5855 917/5875
2.5 load on axle with forks retracted with load (front/rear) kg 2371/4167 2402/4182 2306/4424 2348/4444
4.19 total length l1 (mm) 2528 2528 2600 2600
4.20 length to face of forks l2 (mm) 1393 1393 1465 1465
4.28 retractable travel b4 (mm) 718 718 646 646
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (5) AST (mm) 2900 2900 2949 2948
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (5) AST (mm) 2927 2927 2991 2991
4.35 turning radius Wa (mm) 1911 1911 1911 1911
6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery rated voltage/capacity at 5 hours (V)/(Ah) 48/700 (3) 48/775 (3) 48/840 48/930
6.5 battery weight (1)
kg 1119 1165 1306 1368

1.2 identification code MR20HD (model year 2021)

1.8 load distance from load wheel axle - forks x (mm) 387 387 315 315
1.9 wheelbase (WB) y (mm) 1550 1550 1550 1550
2.1 unladen weight (including battery) kg 4425 4471 4617 4679
2.3 load on axle with no load (front/rear) (4) kg 2567/1858 2597/1874 2577/2040 2616/2063
2.4 load on axle with forks out with load (front/rear) kg 891/5534 921/5550 985/5632 1024/5655
2.5 load on axle with forks retracted with load (front/rear) kg 2235/4189 2266/4205 2149/4468 2189/4490
4.19 total length l1 (mm) 2528 2528 2600 2600
4.20 length to face of forks l2 (mm) 1393 1393 1465 1465
4.28 retractable travel b4 (mm) 536 536 464 464
4.34.1 working aisle for pallet length 1000 x 1200 crosswise (5) AST (mm) 2872 2872 2926 2926
4.34.2 working aisle for pallet length 800 x 1200 lengthwise (5) AST (mm) 2921 2921 2986 2986
4.35 turning radius Wa (mm) 1815 1815 1815 1815
6.3 battery conforms to DIN 43531/35/36 A,B,C, no C C "Super" C C "Super"
6.4 battery rated voltage/capacity at 5 hours (V)/(Ah) 48/700 (3) 48/775 (3) 48/840 48/930
6.5 battery weight (1) kg 1119 1165 1306 1368

(1)
These values may vary by ± 5%.
(2)
Available with 48V/450Ah lithium battery (895 kg).
(3)
Available with 48V/450Ah lithium battery (1067/1068 kg); 48V/600Ah lithium battery (1091 kg).
(4)
Forks retracted.
(5)
For AST with 4-stage mast, refer to “4-stage mast 14-16 table” and “4-stage mast 20-25 table”.
All weights (2.1 to 2.5) are with lowered masts and standard forks.

All values are nominal and subject to tolerances; for further information, contact the manufacturer. Yale products are subject to change without notice. The lift
trucks illustrated may include optional components. The values may vary with alternative configurations.

59
 PRESENTATION SERVICE

60
 SERVICE INSTALLATION AND SETTINGS

INSTALLATION AND
SETTINGS
BEFORE INSTALLATION................................................................................................................................2
WEIGHTS TABLE...........................................................................................................................................................3
TRUCK BASE.....................................................................................................................................................................3
OPTIONAL COMPONENTS..........................................................................................................................................................3
RETRACTABLE CARRIAGE.............................................................................................................................................4
CAB - OVERHEAD GUARD (OHG)...........................................................................................................................4
48V BATTERIES...........................................................................................................................................5
FORKS........................................................................................................................................6
ATTACHMENT...............................................................................................................................7
MAST...............................................................................................................................................8
MACHINE ASSEMBLY...................................................................................................................................15
LIST OF MATERIALS RECEIVED FROM THE DEALER.....................................................................................................15
UNLOADING OFF THE TRUCK AND FITTING THE MAST TO THE TRUCK BASE...........................................17
OIL TOP UP IN THE TANK.....................................................................................................................................19
BATTERY INSTALLATION - REMOVAL.............................................................................................................................20
ASSEMBLY OF THE FEM FORKS.............................................................................................................23
LOAD RACK ASSEMBLY...................................................................................................................................24
CONTRAST ROLLER ASSEMBLY...................................................................................................................25
LIST AND DESCRIPTION OF ADJUSTMENTS AND SETTINGS TO BE CARRIED OUT........................................26
SETTING THE ACE2 TRACTION AND THE ACE2 PUMP MODULE BATTERY VOLTAGES.......................26
CHECKING THE CONDITIONS OF USE OF THE TRUCK................................................................................28
CHECKING THE MOVEMENT OF THE CONTRAST ROLLERS ALONG THE AISLE...........................................28
ENABLING AND PROGRAMMING OF LEVEL PRE-SELECTOR.................................................................29
ENABLING AND PROGRAMMING INTERMEDIATE FORK LIFTING BLOCKS...................................29
ENABLING AND PROGRAMMING OF PASSWORD.................................................................................29

1
 INSTALLATION AND SETTINGS 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 disassembled, 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.

Before lifting, make sure that the chains are correctly positioned in the pulleys and
tensioned

2
 SERVICE INSTALLATION AND SETTINGS

WEIGHT TABLES

TRUCK BASE

Weight of
Load Weight of
Width optional Overall weight
Model capacity Frame carriage
components
B2 kg kg kg kg
MR14 1265 1400 R14 1059 20 1079

MR16 1265 1600 R16 1070 20 1090

MR16 1465 1600 R16W 1103 20 1123

MR16 1665 1600 R16XW 1148 20 1168

MR16N 1125 1600 R16N 1029 20 1049

MR16HD 1265 1600 R16HD 1261 20 1281

MR16HD 1465 1600 R16HDW 1294 20 1314

MR16HD 1665 1600 R16HDXW 1339 20 1359

MR20 1265 2000 R20 1258 20 1278

MR20 1465 2000 R20W 1291 20 1311

MR20 1665 2000 R20XW 1336 20 1356

MR20HD 1345 2000 R20HD 1421 20 1441

MR25 1345 2500 R25 1481 20 1501

The weights indicated above include: oil in the tank (28 lt equal to 23 Kg), seat (24 Kg), control,
steering, pedal, lever, any optional components.
The following is not included: operator, retractable carriage, forks, attachment, battery, load, cab,
guard (66 Kg), battery stand.

OPTIONAL COMPONENTS

Weight
Optional component
kg
Side rollers 20

Load wheel side cover 15

Multifunctional bracket 5

Prem Seat 4

Camera on mast 3

Work lights 2

Flashing 1

3
 INSTALLATION AND SETTINGS SERVICE

RETRACTABLE CARRIAGE

Larghezza Portata Carro Peso carro retrattile

Modello
retrattile
B2 Kg Kg
MR14 1265 1400 Standard 14-16 242

MR16 1265 1600 Standard 14-16 242

MR16 1465 1600 Wide 316

MR16 1665 1600 XWide 341

MR16N 1125 1600 Narrow 226

MR16HD 1265 1600 HD16-HD20 296

MR16HD 1465 1600 Wide 384

MR16HD 1665 1600 XWide 411

MR20 1265 2000 Standard 20-25 297

MR20 1465 2000 Wide 384

MR20 1665 2000 XWide 411

MR20HD 1345 2000 HD16-HD20 296

MR25 1345 2500 Standard 20-25 297

The weights indicated above include: retractable carriage valve block, tilt cylinder and carriage,
chains and pipes of the retractable carriage, rollers.
The battery stand is not included.

CAB - OVERHEAD GUARD (OHG)

Weight
Operator compartment
kg
Standard 66
Overhead guard Drive-in 65
High visibility 60

Cold store 180

Cab
Weather-resistant protection 160

4
SERVICE INSTALLATION AND SETTINGS

48V BATTERY

Battery Battery
Amps Weight (Kg) Battery
Compartment Standard Stand
mm Ah Nominal Minimum Maximum kg kg
1223x283x784 420 DIN C 750 713 788 22 283

1223x283x784 465 DIN C 750 713 788 22 283

1223x355x784 560 DIN C 939 892 986 30 355

1223x355x784 620 DIN C 950 903 998 30 355

1223x355x784 450 Li-Ion 895 892 980 30 355

1223x427x784 700 DIN C 1119 1063 1175 36 427

1223x427x784 775 DIN C 1165 1107 1223 36 427

1223x427x784 450 Li-Ion 1067 1063 1150 36 427

1223x427x784 600 Li-Ion 1091 1063 1150 36 427

1223x499x784 840 DIN C 1306 1241 1371 41 499

1223x499x784 930 DIN C 1368 1300 1436 41 499

1035x263x784 280 DIN B 541 514 568 19 263

1035x263x784 310 DIN B 543 517 568 19 263

1035x263x784 300 Li-Ion 519 517 571 19 263

1035x353x784 420 DIN B 746 709 783 28 353

1035x353x784 465 DIN B 750 713 788 28 353

1035x443x784 560 DIN B 937 890 984 35 443

1035x443x784 620 DIN B 945 898 992 35 443

1035x533x784 700 DIN B 1119 1063 1175 41 533

1035x533x784 775 DIN B 1135 1078 1192 41 533

The weights indicated above include: battery case, lead battery cells, lithium battery cells, ballast,
battery stand, battery cover.
The weights do not include: side extraction (24 Kg), optional side extraction "Wide” (44 Kg), optional
side extraction “Extra Wide” (52 Kg).

5
 INSTALLATION AND SETTINGS SERVICE

FORKS

Dimensions Weight
Fork Type
mm kg
FEM 2A 800x80x40 65

FEM 2A 900x80x40 70

FEM 2A 1000x80x40 75

FEM 2A 1150x80x40 82

FEM 2A 1200x80x40 85

FEM 2A 1400x80x40 95

FEM 2A 800x120x35 84

FEM 2A 1000x120x35 97

FEM 2A 1150x120x35 107

FEM 2A 1200x120x35 111

FEM 2A 800x120x40 95

FEM 2A 1000x120x40 110

FEM 2A 1150x120x40 122

FEM 2A 1200x120x40 125

FEM 2A 1500x120x40 148

FEM 2A 1800x120x40 170

FEM 2A 800x120x45 106

FEM 2A 1000x120x45 123

FEM 2A 1150x120x45 136

FEM 2A 1200x120x45 140

FEM 2A 1500x120x45 165

FEM 2A 1800x120x45 191

Size
Weight
Fork Type Extendable forks
mm kg
Telescopic 1200x130x57 850/250 161

Telescopic 1400x130x57 1050/250 182

6
SERVICE INSTALLATION AND SETTINGS

ATTACHMENT

Size Weight
Attachment
mm kg
Fork positioner 800 800-755/315 53

Fork positioner 940 940-895/315 63

Fork positioner 1150 1150-1105/315 78

7
 INSTALLATION AND SETTINGS SERVICE

MAST

Mast details - 3 stage FFL (1400 Kg - 1600 Kg)

Height, Height,
Lift
Free lift lowered extended Weight (2) (3)
Model height
mast mast
h3 h2 h1 h 4 (1)
mm mm mm mm kg
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
MR16N 7000 2336 2883 7563 1115
7250 2422 2969 7813 1140
7500 2508 3055 8063 1164
MR14 7750 2594 3141 8313 1220
MR16 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 3753 10063 1407
9750 3282 3839 10313 1431
10000 3368 3925 10563 1460
10250 3454 4011 10813 1485
10500 3540 4097 11063 1509
10750 3626 4183 11313 1534
(1)
With load support plate (h=1000 mm) h4 + 508 mm; with load support plate (h=1500 mm) h4 + 1008 mm;
(2)
All weights include: mast structure (profiles, cylinders, chain, pulley) + carriage + oil. THEY DO NOT INCLUDE: forks, accessories
(3)
With load support plate 700 mm and height 1000 mm: weight +13 Kg; with load support plate width 700 mm and height 1500: weight +21 Kg mm.

All values in the tables are nominal and subject to tolerances. For more information, ple-
ase contact the manufacturer.
Yale products can be changed without notice.
The trucks illustrated may be equipped with optional equipment. The values may vary
depending on the different configurations.

8
 SERVICE INSTALLATION AND SETTINGS

Mast details - 3 stage FFL (2000 Kg - 2500 Kg)

Height, Height,
Lift
Free lift lowered extended Weight (2) (3)
Model height
mast mast
h3 h2 h1 h 4 (1)
mm mm mm mm kg
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
MR20 7400 2528 3141 8013 1288
MR25 7650 2614 3227 8263 1314
7900 2700 3313 8513 1341
8150 2786 3399 8763 1373
8400 2873 3485 9013 1402
8650 2959 3571 9263 1431
8900 3045 3657 9513 1461
9150 3131 3753 9763 1490
9400 3217 3839 10013 1520
9650 3303 3925 10263 1549
9900 3389 4011 10513 1579
10150 3475 4097 10763 1608
10400 3561 4183 11013 1638

(1)
With load support plate (h=1000 mm) h4 + 443 mm; with load support plate (h=1500 mm) h4 + 943 mm;
(2)
All weights include: mast structure (profiles, cylinders, chain, pulley) + oil. THEY DO NOT INCLUDE: forks, accessories
(3)
With load support plate 700 mm and height 1000 mm: weight +13 Kg; with load support plate width 700 mm and height 1500: weight +21 Kg mm.

All values in the tables are nominal and subject to tolerances. For more information, ple-
ase contact the manufacturer.
Yale products can be changed without notice.
The trucks illustrated may be equipped with optional equipment. The values may vary
according to the different configurations.

9
 INSTALLATION AND SETTINGS SERVICE

Mast details- HD 3 stage FFL (1600 Kg)

Height, Height,
Lift
Free lift lowered extended Weight (2) (3)
Model height
mast mast
h3 h2 h1 h 4 (1)
mm mm mm mm kg
7900 2680 3227 8463 1376
8150 2766 3313 8713 1404
8400 2852 3399 8963 1438
8650 2938 3485 9213 1467
8900 3024 3571 9463 1495
9150 3110 3657 9713 1523
9400 3196 3753 9963 1558
MR16HD 9650 3282 3839 10213 1586
9900 3368 3925 10463 1649
10150 3454 4011 10713 1677
10400 3540 4097 10963 1706
10650 3626 4183 11213 1734
10900 3712 4269 11463 1763
11150 3798 4355 11713 1791
11400 3884 4441 11963 1819
(1)
With load support plate (h=1000 mm) h4 + 508 mm; with load support plate (h=1500 mm) h4 + 1008 mm;
(2)
All weights include: mast structure (profiles, cylinders, chain, pulley) + oil. THEY DO NOT INCLUDE: forks, accessories
(3)
With load support plate width 700 mm and height 1000 mm: weight +13 Kg; with load support plate width 700 mm and height 1500: weight
+21 Kg.

All values in the tables are nominal and subject to tolerances. For more information, ple-
ase contact the manufacturer.
Yale products can be changed without notice.
The trucks illustrated may be equipped with optional equipment. The values may vary
according to the different configurations.

10
 SERVICE INSTALLATION AND SETTINGS

Mast details- HD 3 stage FFL (2000 Kg)

Height, Height,
Lift
Free lift lowered extended Weight (2) (3)
Model height
mast mast
h3 h2 h1 h 4 (1)
mm mm mm mm kg
7750 2614 3227 8363 1402
8000 2700 3313 8613 1431
8250 2786 3399 8863 1465
8500 2872 3485 9113 1494
8750 2958 3571 9363 1523
9000 3044 3657 9613 1552
9250 3130 3753 9863 1587
9500 3216 3839 10113 1615
9750 3302 3925 10363 1678
10000 3388 4011 10613 1707
MR20HD 10250 3474 4097 10863 1736
10500 3560 4183 11113 1765
10750 3646 4269 11363 1793
11000 3732 4355 11613 1822
11250 3818 4441 11863 1851
11500 3904 4527 12113 1880
11750 3990 4613 12363 1908
12000 4076 4699 12613 1937
12250 4162 4785 12863 1966
12500 4248 4871 13113 1995
12750 4334 4957 13373 2024
13000 4420 5043 13613 2051

MR20HD 13250 4506 5129 13863 2080

MY2021 13500 4592 5215 14113 2109
ONLY 13750 4678 5301 14363 2138
14000 4764 5387 14613 2167

(1)
With load support plate (h=1000 mm) h4 + 443 mm; with load support plate (h=1500 mm) h4 + 943 mm;
(2)
All weights include: mast structure (profiles, cylinders, chain, pulley) + oil. THEY DO NOT INCLUDE: forks, accessories
(3)
With load support plate 700 mm and height 1000 mm: weight +13 Kg; with load support plate width 700 mm and height 1500: weight +21 Kg mm.

All values in the tables are nominal and subject to tolerances. For more information, ple-
ase contact the manufacturer.
Yale products can be changed without notice.
The trucks illustrated may be equipped with optional equipment. The values may vary
according to the different configurations.

11
 INSTALLATION AND SETTINGS SERVICE

Mast details - 4 stage FFL (1400 Kg - 1600 Kg)

Height, Height,
Lift
Free lift lowered extended Weight (2) (3)
Model height
mast mast
h3 h2 h1 h 4 (1)
mm mm mm mm kg
6650 1700 2280 7230 1014
7050 1800 2380 7630 1046
7450 1900 2480 8030 1078
7850 2000 2580 8430 1110
MR16N
8050 2050 2630 8630 1126
MR14 8300 2150 2730 8880 1158
MR16 8500 2200 2780 9080 1207
8700 2250 2830 9280 1223
9150 2400 2980 9730 1271
9400 2500 3080 9980 1303
9850 2650 3230 10430 1351
10050 2700 3280 10630 1367

(1)
With load support plate (h=1000 mm) h4 + 508 mm; with load support plate (h=1500 mm) h4 + 1008 mm;
(2)
All weights include: mast structure (profiles, cylinders, chain, pulley) + carriage + oil. THEY DO NOT INCLUDE: forks, accessories
(3)
With load support plate 700 mm and height 1000 mm: weight +13 Kg; with load support plate width 700 mm and height 1500: weight +21 Kg mm.

All values in the tables are nominal and subject to tolerances. For more information, ple-
ase contact the manufacturer.
Yale products can be changed without notice.
The trucks illustrated may be equipped with optional equipment. The values may vary
depending on the different configurations.

12
 SERVICE INSTALLATION AND SETTINGS

Mast details - 4 stage FFL (2000 Kg - 2500 Kg)

Height, Height,
Lift
Free lift lowered extended Weight (2) (3)
Model height
mast mast
h3 h2 h1 h 4 (1)
mm mm mm mm kg
7050 1800 2380 7630 1295
7450 1900 2480 8030 1335
MR20 7850 2000 2580 8430 1375
MR25 8050 2050 2630 8630 1395
8300 2150 2730 8880 1435
8500 2200 2780 9080 1490

(1)
With load support plate (h=1000 mm) h4 + 508 mm; with load support plate (h=1500 mm) h4 + 1008 mm;
(2)
All weights include: mast structure (profiles, cylinders, chain, pulley) + oil. THEY DO NOT INCLUDE: forks, accessories
(3)
With load support plate 700 mm and height 1000 mm: weight +13 Kg; with load support plate width 700 mm and height 1500: weight +21 Kg
mm.

All values in the tables are nominal and subject to tolerances. For more information, ple-
ase contact the manufacturer.
Yale products can be changed without notice.
The trucks illustrated may be equipped with optional equipment. The values may vary
depending on the different configurations.

13
 INSTALLATION AND SETTINGS SERVICE

Mast details- HD 4 stage FFL (2000 Kg)

Height, Height,
Lift
Free lift lowered extended Weight (2) (3)
Model height
mast mast
h3 h2 h1 h 4 (1)
mm mm mm mm kg
7050 1800 2380 7630 1295
7450 1900 2480 8030 1335
7850 2000 2580 8430 1375
8050 2050 2630 8630 1395
8300 2150 2730 8880 1435
8500 2200 2780 9080 1490
8700 2250 2830 9280 1510
9150 2400 2980 9730 1570
MR20HD
9400 2500 3080 9980 1610
9850 2650 3230 10430 1670
10050 2700 3280 10630 1690
10300 2800 3380 10880 1730
10500 2850 3430 11080 1750
10750 2950 3530 11330 1790
11000 3050 3630 11580 1830
11400 3150 3730 11980 1870

(1)
With load support plate (h=1000 mm) h4 + 508 mm; with load support plate (h=1500 mm) h4 + 1008 mm;
(2)
All weights include: mast structure (profiles, cylinders, chain, pulley) + oil. THEY DO NOT INCLUDE: forks, accessories
(3)
With load support plate 700 mm and height 1000 mm: weight +13 Kg; with load support plate width 700 mm and height 1500: weight +21 Kg
mm.

All values in the tables are nominal and subject to tolerances. For more information, ple-
ase contact the manufacturer.
Yale products can be changed without notice.
The trucks illustrated may be equipped with optional equipment. The values may vary
depending on the different configurations.

14
 SERVICE INSTALLATION AND SETTINGS

MACHINE ASSEMBLY
LIST OF MATERIALS RECEIVED FROM THE DEALER
CARRIAGE SOLD WITHOUT BATTERY

4
6 5

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)

1
Truck base and mast separate (option B)
2 Contrast rollers (optional)
3 Battery movement rollers (only with side battery extraction)
4 Forks
5 Hydraulic fluid canister
6 Battery stop plate (only with side battery extraction)

15
 INSTALLATION AND SETTINGS SERVICE

CARRIAGE SOLD WITH BATTERY

5
4
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)

1
Truck base and mast separate (option B)
2 Contrast rollers (optional)
3 Battery movement rollers (only with side battery extraction)
4 Forks
5 Hydraulic fluid canister
6 Battery stop plate (only with side battery extraction)
7 Battery

16
 SERVICE INSTALLATION AND SETTINGS

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

fork lift truck crane truck or 19 mm open en- lifting sling

load capacity bridge crane ded spanner torque spanner load capacity step ladder
2500 kg load capacity 2500 kg
2500 kg

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
Phase 3
19 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws securing Fig. 2
both side blocks of the mast assembly (ref.A fig.2). Remove the blocks
A
(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 B
taut, position both side blocks and, using a torque spanner, tighten the
fixing screws (ref.A fig.2) to a torque of 88 to 97 Nm.

17
 INSTALLATION AND SETTINGS SERVICE

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 SPANNER - BRIDGE CRANE - LIFT BELT
Using the torque spanner, tighten the bolts securing the mast assembly Fig. 3
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.

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).

D
Fig. 4 D

Fig. 5

Fig. 6

18
SERVICE INSTALLATION AND SETTINGS

TOPPING UP THE OIL RESERVOIR

Before topping up the oil in the hydraulic tank, perform at least one
complete fork raising and lowering cycle.

Equipment and tools

A
hexagonal "T" Fig. 1
funnel oil resistant gloves section spanner
5 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from the areas of
transit of other vehicles and all pedestrians. Turn the key
switch to OFF and disconnect the battery.

Fig. 2

Phase 1
Fig. 3
5 mm T HANDLE HEX KEY B
Lower forks to lowest position. Use the T-handle hex key to unscrew and
remove the motor cover screw (ref.A fig.1).
C
Completely open the cover (fig.2).

Phase 2
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 Fig. 4
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.

19
 INSTALLATION AND SETTINGS SERVICE

BATTERY INSTALLATION - REMOVAL

WITH VERTICAL REMOVAL
Equipment and tools

Fig. 1
bridge crane open ended
load capacity spreader bar spanner
2000 kg 10 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.

HOIST - SPREADER BAR Fig. 2

Pull up the lever located next to the seat (fig.1) in order to free the
battery housing. Using an auxiliary battery, make the battery housing
exit completely (fig.2). Fig. 3
Using the open ended spanner, unscrew and remove the screws fastening
the battery cover (where applicable) (ref.A fig.3). Remove the cover.
Connect the spreader bar to the hoist and to the battery to install in
correspondence of the points marked with the specific symbol.
Make sure that the hoist is set at a right angle to the battery.
Lift the battery and place it perpendicularly above its housing (fig.4).
Lower the battery carefully until it is placed in its compartment. A
The battery must always be located with the terminals
turned to the operator side.
Unhook the spreader bar from the battery. Fig. 4
Connect the new battery to the truck electrical system through the relative
socket
Turn on the truck and use the relative command to fully retract the
extendable carriage to fix and block the stand surface with the new battery.

If replacing the battery, please note that it is permitted to

release the battery only with the truck stopped and the
retractable carriage fully retracted.
The battery socket and the truck connector must be
separated only when the carriage is switched off

20
 SERVICE INSTALLATION AND SETTINGS

WITH LATERAL REMOVAL

Equipment and tools

hoist 2000 kg spreader bar extraction carriage

Procedure Fig. 1
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit Fig. 2
of other vehicles and all pedestrians.

BRIDGE CRANE - SPREADER BAR - EXTRACTION CARRIAGE

Pull up the lever located next to the seat (fig.1) in order to free the
battery housing. Using an auxiliary battery, make the battery housing
exit completely (fig.2).
Remove the fixing element (ref.A fig.2) from the battery stand surface.
Position the battery extraction carriage such that it is aligned with the A
truck, adjusting the height by means of the relative nuts.
The maximum distance between the battery extraction car-
riage and the truck must not exceed 150 mm; a tolerance
of ±30 mm is permitted. If these distances are not complied
with, the battery could fall during the installation and ex-
traction operations.
Connect the spreader bar to the hoist and to the battery to install in
correspondence of the points marked with the specific symbol.
Make sure that the hoist is set at a right angle to the battery.
Fig. 3
Lift the battery and position it at a right-angle to the extraction carriage.
Lower the battery carefully until it is placed on the extraction carriage.

The battery must always be located with the terminals turned to the operator side.
Unhook the spreader bar from the battery. Push the battery into its housing (fig.3). Refit the side fastening
element (ref.A fig.2). Connect the new battery to the truck electrical system through the relative socket
Turn on the truck and use the relative command to fully retract the extendable carriage to fix and block the
stand surface with the new battery

If replacing the battery, please note that it is permitted to release the battery only with the
truck stopped and the retractable carriage fully retracted.
The battery socket and the truck connector must be separated only when the carriage is
switched off

21
 INSTALLATION AND SETTINGS SERVICE

CONNECTION OF CABLES TO BATTERY

The battery poles are marked with the colour red or the + symbol to identify the positive pole, and with
the colour blue or the symbol to identify the negative pole.
The battery connector cables are in turn marked with a stripe in red for the connection to the positive pole
and a stripe in blue for the connection to the negative pole.

After connecting the cables to the battery terminals, apply Vaseline to protect against
corrosion.

_ 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

22
 SERVICE INSTALLATION AND SETTINGS

ASSEMBLY OF THE FEM FORKS

bridge crane 2 lift belts

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.

Phase 1
Using the controls in the cab, lift the fork carriage to facilitate fork as-
sembly operations.

Turn the keyswitch to OFF and disconnect the battery.

In order to be fastened, the fork cannot be supported in

a stable manner. It is possible to rotate the vertical part.

Phase 2
BRIDGE CRANE - LIFT BELTS
Support the fork with the straps in the inclined position and the tip facing
upward (fig.1). Turn the lever to raise the fork lock pin
(ref.A fig.2).

Fig. 1
Phase 3
Fasten the fork to the FEM profile in a central position, placing it on the
lower profile. Use the opening in the lower profile to fasten the fork at the
bottom, moving it to the right or left.
Turn the lever in the opposite direction to lock the fork (ref.A fig.2).
A

Fig. 2

23
 INSTALLATION AND SETTINGS SERVICE

LOAD RACK ASSEMBLY

If the truck was dispatched with the load rack disassembled, during assembly keep it parallel to the
upright, adjusted so as to keep the greatest distance possible from the upright itself (from the profile).

20 mm socket
bridge crane 1 lift belt
spanner

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit Fig. 1
of other vehicles and all pedestrians.

Phase 1
BRIDGE CRANE - LIFT BELT
Support the load rack with the lifting strap (fig.1).

Turn the keyswitch to OFF and disconnect the battery.

Phase 2 Fig. 2
20 MM HEX SOCKET SPANNER
Carefully place the load rack parallel to the mast and fasten it to the fork
mast using the 4 fastening screws located to the side (ref.A fig.2). A

24
 SERVICE INSTALLATION AND SETTINGS

CONTRASTING ROLLER ASSEMBLY

Equipment and tools

open ended span- ratchet with

ner extension bar
19 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing. Fig. 1
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.
Turn the keyswitch to OFF and disconnect the battery.

Phase 1
Retrieve the contrast roller and its parts, apply the spacers (ref.A,B fig.2).

Phase 2
19 mm open ended spanner - RATCHET WITH EXTENSION
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 C Fig. 2

25
 INSTALLATION AND SETTINGS SERVICE

LIST AND DESCRIPTION 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:
• Battery voltage setting
• Check the conditions of use of the truck
• Checking the movement of the contrast rollers along the aisle
• Enabling and programming of the level pre-selector
• Enabling and programming intermediate fork lifting blocks
• Enabling and programming of 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

5 mm T-handle large Philips

programmer tester
hex key screw driver

Procedure

Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open the bonnet (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 (ref.B fig.1) and remove it.
Using a crosshead screwdriver, unscrew the panel fixing screw to access the VCM control (ref.C fig.3).
With the engine turned off connect the programmer.
Turn the machine on(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).

26
SERVICE INSTALLATION AND SETTINGS

Fig. 1 Fig. 2 Fig. 3

Fig. 4

27
 INSTALLATION AND SETTINGS SERVICE

CHECK THE CONDITIONS OF USE OF THE TRUCK

In order to ensure the safety personnel and materials, before proceeding with the opera-
tions described below, it is important to assess the following:
• the type of load to be moved
• The general conditions of the warehouse, the aisles and the flooring
Based on these checks, evaluate whether the conditions given are compatible with the set per-
formance levels:

• 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 pa-
rameters (see "TRUCK FUNCTIONS“ section “ELECTRICAL SYSTEM”).

The parameter adjustment can be changed based on the application and conditions of use.
If they are not compatible with the set truck performance , a reduction is recommended.

CHECKING THE MOVEMENT OF THE CONTRAST ROLLERS ALONG THE AISLE

Make sure that the truck can enter the aisle easily and that the contrasting rollers are correctly adjusted
(maximum tolerance 5 mm on one side - fig.1).
If necessary remove or add shims.
Check the roller movement along the entire length of the aisle.

Fig. 1

28
SERVICE INSTALLATION AND SETTINGS

ENABLING AND PROGRAMMING OF THE LEVEL PRE-SELECTOR

To enable and program the height pre-selector, refer to the "Level pre-selector”paragraph in the section
"ELECTRICAL SYSTEM".

ENABLING AND PROGRAMMING INTERMEDIATE FORK LIFTING BLOCKS

To enable and program the fork lifting blocks refer to the "Fork lifting/lowering blocks" paragraph in the
section "ELECTRICAL SYSTEM".

ENABLING AND PROGRAMMING OF THE PASSWORD

To enable and program the operator passwords, refer to the "Main menu 2 / programming access code
with combined operator code reading" in the section "ELECTRICAL SYSTEM".

29
 INSTALLATION AND SETTINGS SERVICE

30
 SERVICE DIAGNOSTICS AND MEASUREMENTS

DIAGNOSTICS AND
MEASUREMENTS

KEY TO CONTROLLER CONNECTORS........................................................................................................................2

ACE2 DRIVE CONTROLLER........................................................................................................................2
ACE2 PUMP CONTROLLER......................................................................................................................................3
EPS ACW CONTROLLER..................................................................................................................................4
VCM CONTROLLER........................................................................................................................................................5
TESTER MENU............................................................................................................................................................7
ACE2 DRIVE CONTROLLER......................................................................................................................................7
ACE2 PUMP CONTROLLER.......................................................................................................................................10
EPS ACW CONTROLLER..............................................................................................................................................12
VCM CONTROLLER....................................................................................................................................................14
TROUBLESHOOTING.............................................................................................................................................18
DIAGNOSIS SYSTEM FOR ACE2 DRIVE CONTROLLER.....................................................................................18
DIAGNOSIS SYSTEM FOR ACE2 PUMP CONTROLLER..............................................................................................28
DIAGNOSIS SYSTEM FOR EPS ACW CONTROLLER .................................................................................................38
DIAGNOSIS SYSTEM FOR VCM CONTROLLER .........................................................................................................47
DISPLAY WARNINGS................................................................................................................61
ELECTRICAL COMPONENT MEASUREMENTS...................................................................................................63
SOLENOID VALVE COILS.......................................................................................................................................63
ELECTROMAGNETIC BRAKE COILS....................................................................................................................64
MOTORS.....................................................................................................................................................................64

1
 DIAGNOSTICS AND MEASUREMENTS SERVICE

KEY TO CONTROLLER CONNECTORS

ACE2 DRIVE CONTROLLER

A1 + 48V logic power

A2 + 5V auxiliary power supply for Hall effect sensors
A3 Input for throttle sensor output 2
A4 Drive selector (with mini levers)
Forward drive selector (with joystick option)
A5 Non used (with mini levers - premium)
Input redundancy drive selector (with mini levers - Model Year)
Reverse drive selector (with joystick option)
A6 Input for service brake sensor output 1
A7 Input A for motor encoder
A8 + 12V power for motor encoder
A9 Horn relay coil negative
A10 Input for service brake sensor output 2
A11 Can Low 2
A12 Can High 2
A13 Input for throttle sensor output 1
A14 Input B for motor encoder
A15 Motor encoder negative
A16 Drive main contactor negative that powers auxiliary K5 relays
A17 + 48V power for main contactor that powers auxiliary K5 relays electromagnetic brake, horn
A18: Electromagnetic brake negative
A19 Operator presence sensor
A20 Can Low 1
A21 Can High 1
A22 +5V power for motor temperature sensor
A23 Motor temperature sensor negative

2
SERVICE DIAGNOSTICS AND MEASUREMENTS

ACE2 PUMP CONTROLLER

A1 + 48V logic power

A2 + 5V auxiliary power
* if both the Drive and Pump controllers are 350A, it is connected to A3 (analog input 1) and A10
(analog input 3)
A3 Analog Input 1
A4 Not used
A5 Not used
A6 Not used
A7 Input A for pump motor encoder
A8 + 12V power for pump motor encoder
A9 Flashing light negative
A10 Analog Input 3
A11 Can Low 2
A12 Can High 2
A13 Not used
A14 Input B for pump motor encoder
A15 Pump motor encoder negative
A16 Pump main contactor negative
A17 + 48V power for main pump contactor and flashing light
A18 Not used
A19 Not used
A20 Can Low 1
A21 Can High 1
A22 + 5V motor temperature sensor
A23 Motor temperature sensor negative

3
 DIAGNOSTICS AND MEASUREMENTS SERVICE

EPS ACW CONTROL

A1 Can High 2
A2 Can Low 2
A3 Power supply positive
A4 Power supply positive
A5 Power supply positive
A6 Power supply negative
A7 Power supply negative
A8 Power supply negative
A9 Fan positive (+48V)
A10 Fan negative
A11 Sensor with drive wheel at 90°
A12 Sensor with drive wheel straight ahead at 0°
A13 Power supply negative for wheel position sensors
A14 Not used
A15 + 48V logic power
A16 Negative for stepper motor DL line power
A17 Stepper motor QL line input
A18 + 13.5V Power supply positive for wheel position sensors
A19 Negative for stepper motor QL line power
A20 Stepper motor DL line input
A21 +5 V Not used
A22 Can Low 1
A23 Can High 1

4
SERVICE DIAGNOSTICS AND MEASUREMENTS

VCM CONTROLLER

B A

A1 +48V power
A2 Negative for carriage back proportional valve
A3 Negative for carriage forward proportional valve
A4 Negative for mast tilt, side shift
A5 Input valve 5th way
Power supply for worklights on forks
A6 Negative for blue light relay
A7 Negative for moving vehicle warning buzzer
A8 Seat microswitch
A9 Operator presence sensor
A10 Input from speed reduction button
A11 Can Low 1
A12 Can High 1
A13 + 48V auxiliary power output 1
A14 + 48V auxiliary power output 2
A15 + 48V auxiliary power output 3
A16 + 48V auxiliary power output 4
A17 + 48V auxiliary power output 5
A18 Sensor 1 battery out NO
A19 Sensor 2 battery out NC
A20 Seat belt microswitch
A21 180°/360° steering mode selector button
A22 Negative for carriage position potentiometer, mast raising encoder, free lift encoder, tilt angle and
load cell
A23 Input for carriage position potentiometer
A24 Negative for lowering proportional solenoid valve
A25 Negative for raising proportional solenoid valve

5
 DIAGNOSTICS AND MEASUREMENTS SERVICE

A26 Negative for left hydraulic function proportional solenoid valve

A27 Negative for right hydraulic function proportional solenoid valve
A28 + 48V logic power
A29 - Batt. logic power
A30 Can Low 2
A31 Can High 2
A32 Not used
A33 + 12V auxiliary power
A34 + 5V power for carriage position potentiometer, free lift and mast encoder
A35 Not used

B1 Side shift position sensor

B2 Not used
B3 Mast tilt sensor input
B4 Encoder reset sensor input
B5 Not used
B6 Not used
B7 + 48V logic power
B8 + 48V power for load wheel brakes
B9 Mast raising encoder output 2A
B10 Mast raising encoder output 2B
B11 Load cell input
B12 Not used
B13 Weighing button
B14 Fork raise by-pass button
B15 Power supply negative for Laser
B16 + 5V auxiliary power (not used)
B17 Free lift encoder output 1A
B18 Free lift encoder output 1B
B19 Not used
B20 Not used
B21 Pallet presence sensor
B22 +48V power input
B23 Negative for load wheel brakes

6
 SERVICE DIAGNOSTICS AND MEASUREMENTS

TESTER MENU
The main input and output signals can be measured in real time using the TESTER function of the pro-
grammer. The programmer acts as a multimeter capable of reading voltage, current and temperature.
Some 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.

ACE2 DRIVE CONTROLLER

TESTER MAIN MENU

PARAMETER measurement unit

KEY VOLTAGE V
Battery voltage level measured at startup.

VDC LINK VOLTAGE V

Battery voltage level measured at power condensers.

MOTOR VOLTAGE %
The voltage supplied to the motor by the controller is expressed as a percentage of the maximum voltage (which
depends on the battery voltage).

FREQUENCY Hz
Estimated frequency applied to the motor controller and to the AC drive motor.

ENCODER Hz
Real speed detected by the AC drive motor encoder.

SPEED VALUE km/h

Value in km/h that represents the setpoint speed

SLIP VALUE Hz
Speed difference between the rotation field and the motor rotor, expressed in the same unit as the frequency.

CURRENT RMS A
RMS current applied to the AC drive motor.

ID FILTERED RMS A
Magnetizing RMS current.

IQ FILTERED RMS A
Torque RMS current.

IQ IMAX LIMIT A
Limit RMS of torque current according to set parameters.

MOT. POWER WATT W

Instantaneous power supplied by the AC drive motor.

7
 DIAGNOSTICS AND MEASUREMENTS SERVICE

PARAMETER measurement unit

FLUX WB/1000 Wb

Flux to the stator.

MOTION TORQUE Nm
Torque to the motor.

BATTERY CHARGE %
Battery charge percentage level.

TEMPERATURE °C

Controller temperature measured on the heatsink.

MOTOR TEMPERAT. °C
Traction motor temperature.

MAN PRESENCE
Operator presence switch digital input level.

A4 FW/REV AD IN V
Fwd/rev drive analog sensor level

FORWARD SWITCH
ON/OFF. Reverse drive request digital input level

DIG INPUT A-4

ON/OFF. Level of digital input A-4.

BACKWARD SWITCH
ON/OFF. Level of reverse digital input BW.

DIG INPUT A-5

ON/OFF. Level of digital input A-5.

POT1 ACCEL. A-13 V

Level of analog input A-13.

POT1 BRAKE A-6 V

Level of analog input A-6.

POT2 ACCEL. A-3 V

Level of analog input A-3.

POT2 BRAKE A-10 V

Level of analog input A-10.

8
SERVICE DIAGNOSTICS AND MEASUREMENTS

PARAMETER measurement unit

OUTPUT EV1

ON/OFF. This parameter provides feedback from the valve EV1.

MAIN CONT. VOLT. %

Percentage of battery voltage applied on output A-16.

ELEC.BRAKE VOLT. %
Percentage of battery voltage applied on output A-18.

MC CURRENT mA

Current flow on main contactor coil

EB CURRENT mA
Current flow on electromagnetic brake coil

STEER ANGLE degrees

Value of the steering angle in degrees.

9
 DIAGNOSTICS AND MEASUREMENTS SERVICE

ACE2 PUMP CONTROLLER

PARAMETER measurement unit

KEY VOLTAGE V
Battery voltage level measured at startup.

VDC LINK VOLTAGE V

Battery voltage level measured at power condensers.

MOTOR VOLTAGE %
The voltage supplied to the motor by the controller is expressed as a percentage of the maximum voltage (which
depends on the battery voltage).

FREQUENCY Hz
Estimated frequency applied by the motor controller and by the pump motor.

ENCODER Hz
Actual speed detected by the pump motor encoder.

SLIP VALUE Hz
Speed difference between the rotation field and the motor rotor, expressed in the same unit as the frequency.

CURRENT RMS A
RMS current applied to the pump motor

ID FILTERED RMS A
Magnetizing RMS current.

IQ FILTERED RMS A
Torque RMS current.

IQ IMAX LIMIT A
Limit RMS of torque current according to set parameters.

MOT. POWER WATT W

Instantaneous power supplied by the pump motor

FLUX WB/1000 Wb
Flux to the stator

MOTION TORQUE Nm
Torque to the motor.

TEMPERATURE °C
Temperature of the inverter measured on the heat sink.

MOTOR TEMPERAT. °C
Pump motor temperature.

10
SERVICE DIAGNOSTICS AND MEASUREMENTS

PARAMETER measurement unit

MAN PRESENCE

Operator presence switch digital input level.

DIG INPUT A-4

ON/OFF. Level of digital input A-4.

DIG INPUT A-5

ON/OFF. Level of digital input A-5.

OUTPUT EV1
ON/OFF. This parameter provides feedback from the valve EV1.

MAIN CONT. VOLT. %

Percentage of battery voltage applied to pump contactor.

ELEC. BRAKE VOLT. %

Percentage of battery voltage applied to electromagnetic brake.

MC CURRENT mA
Current on main contactor coil

EB CURRENT mA
Current on electromagnetic brake coil

11
 DIAGNOSTICS AND MEASUREMENTS SERVICE

EPS ACW CONTROL

PARAMETER measurement unit

STEPPER MOTOR V
2-digit decimal value. Measurement of steering motor speed in the range 0 - 5Vdc.

FEEDBACK SECTOR
Feedback signal indicating the actual position of the wheel relative to the straight-ahead position FEEDBACK
SECTOR=1 wheel positioned at a STEER ANGLE between 0° and 180° FEEDBACK SECTOR=4 wheel positio-
ned at a STEER ANGLE STEER ANGLE between -180° and 0°

DISPLAY ANGLE degrees

Indicates the angle of the steered wheel in degrees with sign (+/-) sent over the CAN Bus. It is equal to the STE-
ER ANGLE but with the sign (+/-) defined by the WHEEL DIRECTION parameter. Changing the WHEEL DIREC-
TION parameter will invert the sign sent over the CAN Bus (and received by the console).

STEER ANGLE degrees

Indicates angle of the steered wheel in degrees with the sign measured relative to the straight-ahead position.

ENC COUNTING A
Encoder count relative to the actual straight-ahead position

ENC SPEED Hz
Motor speed measured by the encoder mounted on the motor shaft.

FREQUENCY Hz
Frequency applied to the steering motor.

MOTOR VOLTAGE %
The voltage supplied to the motor by the controller expressed as a percentage of the maximum voltage

MOTOR CURRENT A
Motor current value

IQ RMS A
Torque RMS current

ID RMS A
The current directed to the motor

TEMPERATURE °C
Controller temperature measured on the heatsink

MOTOR TEMPERAT. °C

Temperature of the steering motor measured by the sensor located inside the motor.

PROX SWITCH 1
Indicates in real time the status of the "wheel centered" sensor switch

PROX SWITCH 2
Indicates in real time the status of the "wheel at 90°" sensor switch.
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SERVICE DIAGNOSTICS AND MEASUREMENTS

PARAMETER measurement unit

PROX SWITCH 2
Indicates in real time the status of the "wheel at 90°" sensor switch.

CW LIMIT LEVEL

Activated when the upper limit set by the parameters '1st and 2nd angle gain' is reached.

ACW LIMIT LEVEL

Activated when the lower limit set by the parameters '1st and 2nd angle gain' is reached.

TRUCK MOVING

1 when drive is activated

I OUT 1 mA

Fan current pin XA4-10

MOT POWER WATT W

Real time measurement of the power supplied to the motor.

STATUS #5 V

Selfcheck of the insulation between the phases of the motor and the battery

STATUS #2 Hz

Selfcheck of encoder and transmission

STATUS #1 A

Selfcheck of motor and power drivers

TRUCK SPEED %

Traction speed as percentage of MAX SPEED TRAC

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

VCM CONTROLLER

TESTER MAIN MENU

PARAMETER measurement unit

WORKING HOURS Hours

Indicates the number of truck operating hours in accordance with 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 V
Voltage value to 1 decimal place. Battery voltage measured on Pin A1

BATTERY CHARGE %
Percentage value. Indicates the residual battery charge as a percentage of the full charge value.

STEER ANGLE degrees

Value in degrees. Indicates the actual 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 command

REACH POT. %
Percentage value. Level of the REACH command

TILT POT. %
Percentage value. Level of the TILT command

SIDE SHIFT POT. %

Percentage value. Level of the SIDE SHIFT command

AUTOC.SSHIFT SW. %
ON/OFF Level of the forks side shift self-centering button

AUTOC.TILT SW. %
ON/OFF Level of forks tilt self-centering button

5 WAY SWITCH
ON/OFF. Level of the hydraulic 5th way button

JOY. HORN SW
ON/OFF. Level of the horn button

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SERVICE DIAGNOSTICS AND MEASUREMENTS

PARAMETER measurement unit

PALLET SWITCH

ON/OFF Pallet presence sensor input

SEATBELT SWITCH
Seatbelt sensor input

SEAT SWITCH
ON/OFF Seat sensor input

BATTERY OUT SW1

ON/OFF Battery out sensor 1 input (N.O.)

BATTERY OUT SW2

ON/OFF Battery out sensor 2 input (N.C.)

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 analog input A23 (carriage position sensor)

OUTPUT GROUP #1 %
Value %. Percentage of maximum current applied to output unit #1 (EVP1/EVP2)

OUTPUT GROUP #2 %
Value %. Percentage of maximum current applied to output unit #2 (EVP3/EVP4)

OUTPUT GROUP #3 %
Value %. Percentage of maximum current applied to output unit #3 (EVP5/EVP6)

OUTPUT GROUP #4 %
Value %. Percentage of maximum current applied to output unit #4 (EVP7/EVP8)

NEVP9 OUTPUT %
Value %. Percentage of maximum current applied ton EVP9 (load wheel brakes)

NEV3 OUTPUT %
Value %. Percentage of battery voltage applied to EV3 (Laser)

NEV2 OUTPUT %
Value %. Percentage of battery voltage applied to EV2 (Back up alarm)

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

PARAMETER measurement unit

NEV1 OUTPUT %
Value %. Percentage of battery voltage applied to EV1 (option)

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 Hz
Value in Hz. Pump motor speed

DIGITAL INPUT #1
ON/OFF. Level of digital input pin A8.

DIGITAL INPUT #2
ON/OFF. Level of digital input pin A9.

DIGITAL INPUT #3
ON/OFF. Level of digital input pin A10.

DIGITAL INPUT #4
ON/OFF. Level of digital input pin A18.

DIGITAL INPUT #5
ON/OFF. Level of digital input pin A19.

DIGITAL INPUT #6
ON/OFF. Level of digital input pin A20.

DIGITAL INPUT #7
ON/OFF. Level of digital input pin A21.

DIGITAL INPUT #8
ON/OFF. Level of digital input pin B13.

DIGITAL INPUT #9
ON/OFF. Level of digital input pin B14.

DIG. INPUT #10

ON/OFF. Level of digital input pin B21.

DIG. INPUT #11

ON/OFF. Level of digital input pin B22.

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SERVICE DIAGNOSTICS AND MEASUREMENTS

PARAMETER measurement unit

ANALOG INPUT #1 mV

Value in volts. Level of the analog input pin A23 (truck potentiometer position)

ANALOG INPUT #2 mV
Value in volts. Level of the analog input pin A35 (not used)

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

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

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

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

ANALOG INPUT #7 mV
Value in volts. Level of the analog input pin B5 (not used)

ANALOG INPUT #8 mV
Value in volts. Level of the analog input pin B6 (not used)

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

ANALOG INPUT #10 mV

Value in volts. Level of the analog input pin B12 (not used)

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

TROUBLESHOOTING
The diagnosis system is divided into two main groups:

BLOCKING ALARMS
When a blocking alarm occurs, the current to all controls is interrupted by the main contactor and the elec-
tromagnetic brake is released (it is activated during braking).

Blocking alarms are caused by:

• faults in the controls, if due to breakage in the power and/or auxiliary connections.
• faults in the motors due to electrical problems.
• faults due to components directly and/or indirectly connected to safety functions.

WARNING ALARMS
Warning alarms are due to the following factors:
• incorrect starting sequences by the operator.
• conditions that require a reduction of performance (for example high temperature, ...)

ALARMS LOG DISPLAY

Enter MAIN MENU 1 / alarms on the display to view the last 32 alarms logged and other information com-
prising the total operating hours of the module, the number of times the alarm has been activated and the
identification number of the alarm and the module.

MODULE 2: ACE2 Traction master MODULE 34: ACE2 Traction Slave

MODULE 5: ACE2 Pump master MODULE 37: ACE2 Pump Slave
MODULE 6: EPS ACW Master MODULE 38: EPS ACW Slave
MODULE 1: VCM Master MODULE 33: VCM Slave

Given below are explanations of the various alarms and preliminary indications
for troubleshooting. Refer to the wiring diagrams in the section “ELECTRICAL
SYSTEM”

DIAGNOSIS SYSTEM FOR ACE2 DRIVE CONTROLLER

The diagnostics system operates via CAN BUS communication.
Due to the dual microcontroller controls, the nodes for identifying each individual controller are:

Microcontroller Node
Master 2
Slave 34

The alarms are shown on the display in the format xxx-yy, where xxx is the alarm code and yy is the
node. For example 79A02 is the Incorrect Start alarm on the Master microcontroller

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SERVICE DIAGNOSTICS AND MEASUREMENTS

ACE2 DRIVE CONTROLLER - MASTER NODE 2

Alarm Code MDI Troubleshooting

WATCHDOG 8
Cause:
The system is provided with a self-diagnosis
This is an internal fault in the controller. Replace the controller
circuit. A microchip tests the self-diagnosis
circuit to verify its correct operation. If the result
is negative, this alarm appears

LOGIC FAILURE #3 17
Cause: This type of fault is not connected to external components, so when it
A hardware problem in the control circuit occurs the controller must be replaced.
as a protection against high current values
(overload).

LOGIC FAILURE #2 18
Cause: This type of fault is not connected to external components, so when it
A fault in the hardware section of the control that occurs the controller must be replaced.
controls the retroaction of the phase voltage.

LOGIC FAILURE #1 19 • If the alarm appears on start up or in standby, it is

very likely that the problem is due to undervoltage.
Cause: In this case the following checks are recommended:
This alarm appears when the controller detects decreasing pulses of the Key Input signal (beneath the undervoltage
an overvoltage or undervoltage. The overvoltage level) due to an external load, such as the start up of a DC/DC
limit is 65V, the undervoltage limit is 11V. converter, start up of a relay or of a contactor, charging/discharging
of coils.
• If no change in the voltage is detected on the power supply
line and the alarm is present every time the key switch is
turned to ON, then the fault is probably in the controller
hardware. In this case, the controller must be replaced.
If the fault appears while the truck is moving, then it could be due to
undervoltage or overvoltage.
• If the alarm appears during acceleration while in traction, it is most
likely due to undervoltage; check the battery charge state and the
power connections.
• If the alarm appears when the brake is released, it is probably
due to overvoltage; check the contactor contacts and the power
connections.

VMN LOW 30 If the problem appears on start up (the contactor fails to close), check:
Cause 1: startup testing: • the internal motor connections (ohmic continuity);
Before closing the contactor, the software • the motor power connections;
checks the power section: it powers on the If the motor connections are correct, then the problem could be located
Mosfets on the high side alternately and waits in the control, which therefore should be replaced.
for the phase voltage to rise to the capacitor If the alarm takes place while the motor is operating, check:
values. If the voltage is less than 66% of the • the motor connections;
capacitor voltage, this alarm appears. • if the windings/cables of the motor phases are leaking towards the
Cause 2: test during operation truck chassis;
When the motor is operating, the power bridge • the power contact of the contactor is closing correctly
is ON and the motor power supply voltage is If no problems are found with the motors, then the fault lies in the
monitored; if it is below the set value, an error
controller, which therefore must be replaced.
condition is generated.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

VMN HIGH 31
If the problem appears on start up (the contactor fails to close), check:
Cause 1: • the internal motor connections (ohmic continuity);
Before closing the contactor, the software
• the motor power connections;
checks the power section: it powers on the
If the motor connections are correct, then the problem could be located
Mosfets on the low side alternately and waits for
the phase voltage to fall to -BATT. If the voltage in the control, which therefore should be replaced.
is more than 10% of the nominal battery voltage, If the problem appears after closing the contactor (the contactor closes
this alarm appears. and then re-opens immediately), check:
Cause 2: • the motor connections;
This alarm can also appear when the startup • if the windings/cables of the motor phases are leaking towards the
diagnosis is exceeded and the contactor closes. truck chassis;
In this condition, the phase voltage should be If no problems are found with the motors, then the fault lies in the
lower than 1/2 Vbatt. controller, which therefore must be replaced.
If the voltage is higher, this alarm appears.

CONTACTOR CLOSED 37
Cause:
Before activating the contactor coil, the controller
checks whether the contactor is stuck. The • Check the contacts of the contactor. If the alarm persists, replace
controller activates the power section for a few the controller.
milliseconds to try to discharge the contactor
capacitors. If the voltage of the capacitors does
not decrease the key switch voltage by 20%,
this alarm appears.

CONTACTOR OPEN 38
• Check the contacts of the contactor and, if necessary, replace the
Cause: contactor.
The main contactor coil is activated by the If the contacts of the contactor function correctly, the problem lies within the
control, but the contactor contacts do not close. control, which should be replaced.

STBY I HIGH 53
Cause: I This type of fault is not connected to external components. When it appears
The current transducer (Hall effect sensor) or the controller must be replaced.
the power supply circuit inside the controller is
damaged.

CAPACITOR CHARGE 60
Cause:
To better understand the meaning of this alarm,
see the following diagram:
• There is an external load parallel to the capacitors, which reduces the
control's pre-charge circuit current, preventing its charging. Check if a
lamp or a dc/dc converter or an auxiliary load is connected.
• The charge resistor is open; add a power resistor on the contactor
terminals; if the alarm disappears it means that the charge resistor inside
the controller is damaged. Replace the controller.
• The charging circuit in the controller is faulty. Replace the controller.
When the key is set to ON, the inverter tries to • There's a problem in the power section of the controller. Replace the
load the capacitor through a power resistance controller.
and checks if the capacitor has charged within
a certain time frame. If the capacitor voltage is
less than 20% of the nominal battery voltage,
an alarm is generated; the main contactor is not
closed.

TH.PROTECTION 62
Cause:
This alarm appears if the temperature • Check the temperature of the controller.
measured on the controller heat sink is above If the alarm appears when the module is cold, there could be a fault in
85°C. When this temperature is reached, the the temperature sensor or in the logic card. In this case, the controller
current is reduced proportionally to the increase must be replaced.
in temperature down to the value of 0 Amps
corresponding to 105°C.

20
SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

MOTOR TEMPERAT. 65
• Check the temperature sensor in the motor;
Cause: • Check the ohm value of the sensor and the wiring.
This alarm appears when the temperature If the sensor does not have problems, improve motor ventilation.
sensor is open or the motor temperature If the alarm is present when the motor is cold, the problem is in the controller.
exceeds 150°C.

BATTERY LOW 66 • Charge the battery.

• If the alarm is still present, measure the battery voltage with a voltmeter
Cause: and compare it with the value of the VOLTAGE BATTERY parameter. If
This alarm appears when the battery charge is the values do not match, adjust the value of ADJUST BATTERY function
lower than or equal to 10% of the full charge. connected to the pin of the right connector making sure they are not
interrupted.
If the alarm persists, the problem lies in the control, which must be replaced.

DRIVER SHORTED 74
• Check for a short circuit or low pull-down impedance between pin
Cause: A16 and -BATT.
The driver of the main contactor coil is shorting. • The driver circuit is damaged internally and must be replaced.

CONTACTOR DRIVER 75
Cause: This type of fault is not related to external components; replace the
The contactor coil driver is not capable of piloting controller.
the load. This same device or the piloting circuit
is damaged.

VACC NOT OK 78
Cause:
The test is performed on startup and • Check the mechanical calibration of the potentiometer and that it
immediately after both drive requests have been functions correctly.
deactivated. This alarm occurs if the value of the • If the alarm persists, the problem lies in the controller, which must be
accelerator, read in the TESTER menu, is 1.0 V replaced.
greater than the minimum value required, when
the accelerator is in neutral position.

INCORRECT START TRACT 79 The possible cause of this alarm are:

• An active drive request on startup;
Cause: • operator present sensor activated at startup.
It is an incorrect start sequence alarm. Check the wiring. Check the microswitches.
The alarm could also be caused by an error in the sequence of operations
performed the operator or by a fault in the controller.
If, after checking the above, no faults are found, replace the controller.

FORW + BACK 80
• Check the inputs of the forward and reverse drive requests.
Cause: • Check the microswitches.
This alarm occurs when both drive requests If, after checking the above, no faults are found, replace the controller.
(forward and reverse) are active simultaneously.

ENCODER ERROR 82 • Check the wiring and the electrical and mechanical functionality of the
encoder.
Cause: • Check installation of the encoder; if the encoder slides inside its housing,
This alarm appears when a malfunction of the it could cause an alarm.
encoder is detected. • The alarm could also be caused by electromagnetic disturbance; in
these cases, replace the encoder.
If the problem persists after the replacement of the encoder, the fault lies in
the controller, which therefore must be replaced.

INCORRECT START PEDAL 199

• Check the wiring of the operator presence signal input.
Cause: • Check the microswitches.
This alarm appears when the operator presence If no problems are found with the drive request switches and the wiring is
signal is active on startup. OK, replace the controller.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

WRONG SLAVE VER. 200
Cause:
This alarm occurs when the software versions • Check the two software versions.
of the master and slave microcontroller are not
the same.

VDC LINK OVERV. 202 • Check the connections of the power cables to the battery. to the contactor
and to +Batt and -Batt of the control; the connections should be tightened
Cause: to a torque of 13Nm to 15Nm.
This alarm appears when the controller detects If no voltage is detected on the power supply line and the alarm is present
an overvoltage. The threshold at which the each time the truck is powered on, the fault probably lies in the hardware of
alarm occurs is 65V. the controller, which therefore must be replaced.

TILLER MISMATCH 203

Cause: • Check the wiring of the operator presence pedal.
The master microcontroller and the slave If no problems are found in the pedal microswitch and the wiring, the
microcontroller have a different value to the controller must be replaced.
operator present signal sent from the VCM unit.

BRAKE RUN OUT 204

Cause: This type of fault is not related to external components; replace the
The contactor coil driver is not capable of piloting controller.
the load. This same device of the piloting circuit
is damaged.

STOP RQ.FROM EPS 205

Cause: Check the EPS controller.
The EPS controller sends a signal that stops the
motor.

INIT VMN HIGH 206

Cause: • Check the connections inside the motor.
Before closing the contactor, the software • Check the motor power cable connections.
checks the voltage of the power bridge without • Check that there is no leakage towards the truck chassis.
activating it. The software expects that the If the motor connections are OK, the problem is in the controller, which must
voltage has a steady value. This alarm appears be replaced.
if the voltage is too high.

INIT VMN LOW 207

Cause: • Check the connections inside the motor.
Before closing the contactor, the software • Check the motor power cable connections.
checks the voltage of the power bridge without • Check that there is no leakage towards the truck chassis.
activating it. The software expects that the If the motor connections are OK, the problem is in the controller, which must
voltage has a steady value. This alarm appears be replaced.
if the voltage value is too low.

EEPROM KO 208
Cause: • Try to carry out a reset of the EEPROM (clear eeprom) using the
This alarm is caused by a fault in hardware of programming console.
software of the non-volatile memory that the • Turn the truck off and on again to check the result.
supports the parameters of the controller. This If the alarm persists, replace the controller.
alarm does not block operation of the truck, If the alarm disappears, the parameters previously recorded will be replaced
which will operate with the default parameter by default parameters.
settings.

22
SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

PARAM RESTORE 209 • If an EEPROM reset has been run (clear eeprom) before the last ignition,
this warning means that the EEPROM has been correctly reset. The
Cause: alarm is cancelled by a drive request or a hydraulic function.
This alarm appears when the default settings of • If this alarm appears on switching on the truck without an EEPROM
the controller are restored. reset being requested by the operator, there could be a problem in the
controller, which should be replaced.

WRONG RAM MEM. 210

Cause:
This alarm appears when the algorithm • Switch the truck off and then back on.
implemented to check the main RAM registers If the alarm persists, replace the controller.
detects incorrect content: the register is dirty.
This alarm inhibits operation of the truck.

STALL ROTOR 211

• Check that the FREQUENCY and ENCODER signs on the TESTER
Cause: menu are the same and are not zero during the drive request.
The drive rotor is jammed or the controller is not To reset the system, carry out the startup procedure again.
receiving the encoder signal correctly.

WAITING SLAVE 212

Cause: • Switch the truck off and then back on.
This alarm appears when no activation message If the alarm persists, replace the controller.
is sent from the slave microcontroller to the
master microcontroller at startup.

HARDWARE FAULT 213

Cause: • This type of fault is not connected to external components, so when it
The software versions of the master occurs the controller must be replaced.
microcontroller and the slave microcontroller
are different.

POT ACCEL MISM. 214

Cause: • Check the potentiometers.
The master and slave microcontrollers do not If no problems related to the potentiometers are found, the controller must
have the same value on receipt of an accelerator be replaced.
signal from one of the two potentiometers.

POT BRAKE MISM. 215

Cause: • Check the potentiometers.
The master and slave microcontrollers do not If no problems related to the potentiometers are found, the controller must
have the same value on receipt of a brake signal be replaced.
from one of the two potentiometers.

SENS MOT TEMP KO 218

• Check the ohmic value of the sensor and its wiring.
Cause: If no faults are found in the sensor or in the wiring, the fault lies in the
The output of the drive motor temperature controller, which therefore must be replaced.
sensor is not a permitted value.

PEV NOT OK 219

Cause:
This alarm appears when the PAUX input (pin • Check pin A17.
A17) is not connected to +battery or if the
voltage is different.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

VKEY OFF SHORTED 220 It is highly probable that the alarm is due to overvoltage. We advise to:
• check the descending pulses of the key switch input signal (below the
Cause: undervoltage threshold) caused by external loads, such as startup of DC/
This alarm appears when the controller detects DC converters, contactor relays or enabling/disabling of solenoids.
a low level Key-Off signal during diagnosis • check the connections of the power cables to the battery. to the main
during startup diagnosis. contactor and to +Batt and -Batt of the controller; the connections should
be tightened to a torque between 13Nm and 15Nm.
If no transient voltage is detected on the +B line and the alarm is present
each time the truck is started, the fault probably lies in the hardware of the
controller, which therefore must be replaced.

MC COIL SHOR. 223

• Check the connections between the outputs of the controller and the
Cause: loads.
This alarm appears when there is a short circuit If no connection problems are found, the fault lies in the controller, which
of the contactor coils connected to output A16. therefore must be replaced.

WAITING FOR NODE 224

Cause:
This alarm appears when the controller is Check the Can Bus and resistance of the Can line (60 ohms).
waiting for an enabling signal from another unit
is system

VACC OUT RANGE 226

Cause: • Check the mechanical calibration of the potentiometer and check
The CPOT input read by the microcontroller is that it functions correctly.
not within the range “Vacc_min - Vacc_max” If the alarm persists, the problem lies in the controller, which must be
programmed via the function “PROGRAM replaced.
VACC”

TILLER OPEN 228

Cause:
This message appears when, with the key
switch ON and the operator presence pedal in The alarm disappears when the operator presence pedal is pressed again.
rest state (i.e. not pressed), the preset stand-by
period (30 seconds) elapses without a traction
or lifting request being received; the main
contactor opens.

OUTPUT MISMATCH 229

Cause:
The slave microcontroller verifies the motor This is an internal fault of the controller, which must be replaced.
output data of the master microcontroller and
detects a mismatch.

WD SYNCHRO 230
• Switch the truck off and then back on.
Cause: • Check for electrostatic charges.
Delay in communication between the Master If there are no external causes, replace the controller.
microcontroller and Slave micro controller.

NO SLAVE ENABLE 231

Cause: • Switch the truck off and then back on.
No enabling message sent from the slave If the alarm persists, replace the controller.
microcontroller to the master microcontroller
while the controller is in operation.

DIR SEL OUT RANG 232

Cause: • Check the connections of the switch and measure the signal level using
The signal from the drive request switch is a tester.
outside the permitted range.

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SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

POWER MOS SHORT 233
Cause:
Before closing the contactor, the software This kind of failure is not related to external components; replace the
checks the power section: it turns on the Mosfets module.
alternately and waits for the phase voltage to fall
to -BATT. If the phase voltage does not respond
to the commands, this alarm appears.

COIL SHOR. EB 235

• Check the connections between the outputs of the controller and the
Cause: loads.
This alarm appears when there is a short circuit • If no connection problems are found, the fault lies in the control, which
of the electromagnetic brake coil connected to therefore must be replaced.
output A2-18.

CURRENT GAIN 236

Cause:
This alarm occurs when the gains of the • Run Clear Eeprom.
current amplifiers (ADJUSTMENT #03 and If the problem persists, replace the controller.
ADJUSTMENT #04) are set to their default
values (Imax has not yet been adjusted).

ANALOG INPUT 237

Cause:
The analogue/digital conversion has returned a
negative value on all the signals converted for If the problem occurs consistently, the controller must be replaced.
more than 400 msec. The aim of this diagnosis
is to find a fault in the A//D converter or a
problem in the code that omits the updating of
the conversion of the analogue signal.

CONTROLLER MISM. 239

• Make a drive request; if the alarm does not reset, try switching the truck
Cause: off and then on again to clear the Eeprom.
This alarm appears when the software in not If the alarm persists, replace the controller.
compatible with the hardware of the controller.

M/S PAR CHK MISM 241

Cause: • Check the parameters and update the parameters that do not coincide.
This alarm occurs when, at startup, there is • To identify the problem easily, run Clear Eeprom. Doing this will reset
a mismatch between the master “checksum” all parameters to their default values.
parameter and the slave “checksum” parameter.

PARAM TRANSFER 242

Cause:
This alarm occurs when the master This is an internal fault of the control, which therefore must be replaced.
microcontroller is unable to transfer the list of
parameters to the slave microcontroller.

THROTTLE PROG. 243 • Acquire the maximum and minimum value of the potentiometer via the
PROGRAM VACC function.
Cause: Check the mechanical calibration of the potentiometer and check that it
This alarm occurs when one of the functions correctly.
potentiometers has not been programmed If the alarm persists, the problem lies in the controller, which must be
correctly. replaced.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

IQ MISMATCHED 245
Cause:
This alarm appears when the error between the Contact Hyster-Yale assistance.
lq set point and the estimated Iq value is outside
the permitted range.

AUX DRIV.OPEN 246

Cause: • Check the connections.
The driver of the auxiliaries coil is not capable of If the problem persists, replace the controller.
piloting the load.

DATA ACQUISITION 247

Cause:
This alarm appears during acquisition of the The alarm disappears once the acquisition has been completed.
current gains.

NO CAN MSG. 248 • Check the Can bus wiring and the resistance of the Can line (60 ohm).
• If the other modules in the CAN bus network display error messages that
Cause: clearly indicate the DRIVE controller is not detected on the CAN bus, the
This alarm appears when there is no CAN fault is probably in the controller itself.
communication. • If the other controllers in the CAN bus network display the error message
CANBUS KO, this indicates a malfunction of the CAN bus network. Try
disconnecting the individual controllers until the CAN bus starts to work
again.

THERMIC SENS. NOT OK 250

Cause: This type of fault is not connected to external components; replace the
This alarm appears if temperature sensor signal controller.
of the electronic controller is outside the range
of permissible values.

WRONG SET BAT. 251 • Check that the value of the “SET BATTERY” parameter corresponds to
the nominal battery voltage.
Cause: • Check that the“TESTER MENU / BATTERY VOLTAGE” parameter
On startup, the controller measures the battery indicates the same value as the battery voltage measured with a
voltage and checks that it lies within a specific voltmeter. If values do not match, use the function “ADJUST BATTERY”.
range around the nominal value. • Replace the battery.

WRONG ZERO 252

Cause:
The voltage during the amplifier output • Check the motor connections and for current leakage to ground.
initialisation stage (used to measure the drive If no external causes are found, replace the controller.
motor voltage) is greater than 3 volts or lower
than 2 volts

FIELD ORIENT. NOT OK 253

Cause:
The error between the ld set point of the drive Contact Hyster-Yale assistance.
motor and the estimated ld is outside the
permitted range.

AUX DRIV.SHRT. 254

• Check if there is a short circuit or low impedance between the auxiliaries
Cause: negative and -BATT.
The driver of the coil of the auxiliary solenoid • The driver circuit is damaged; the controller must be replaced.
valve is shorting.

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SERVICE DIAGNOSTICS AND MEASUREMENTS

ACE2 DRIVE CONTROLLER - SLAVE NODE 34

The alarms of the Slave Node have the same descriptions and troubleshooting procedures as the Master
Node, with the exception of those listed below

Alarm Code MDI Troubleshooting

WD SYNCHRO 230
Cause:
The slave microcontroller does not receive the • Try switching the truck off and then back on again.
watchdog signal. If the error persists, the fault lies in the control, which must be replaced.

INPUT MISMATCH 241

Cause:
The inputs of the slave microcontroller differ to • Try switching the truck off and then back on again.
the inputs of the master microcontroller. If the error persists, the fault lies in the control, which must be replaced.

SP MISMATCH 242
Cause:
The master microcontroller has detected • Try switching the truck off and then back on again.
incorrect set points on the slave microcontroller. If the error persists, the fault lies in the control, which must be replaced.

27
 DIAGNOSTICS AND MEASUREMENTS SERVICE

DIAGNOSIS SYSTEM FOR ACE2 PUMP CONTROL

The diagnostics system operates via CAN BUS communication.
Due to the dual microcontroller controls, the nodes for identifying each individual controller are:

Microcontroller Node
Master 5
Slave 37

The alarms are shown on the display in the format xxx-yy, where xxx is the alarm code and yy is the
node.
For example 79A05 is the Incorrect Start alarm on the Master microcontroller

ACE2 PUMP CONTROL - MASTER NODE 5

Alarm Code MDI Troubleshooting

WATCHDOG 8
Cause:
The system is provided with a self-diagnosis
This is an internal fault in the controller. Replace the controller
circuit. A microchip tests the self-diagnosis
circuit to verify its correct operation. If the result
is negative, this alarm appears

LOGIC FAILURE #3 17
Cause: This type of fault is not connected to external components, so when it
A hardware problem in the control circuit occurs the controller must be replaced.
as a protection against high current values
(overload).

LOGIC FAILURE #2 18
Cause: This type of fault is not connected to external components, so when it
A fault in the hardware section of the controller occurs the controller must be replaced.
that controls the retroaction of the phase
voltage.

LOGIC FAILURE #1 19 • If the alarm appears on start up or in standby, it is

very likely that the problem is due to undervoltage.
Cause: In this case the following checks are recommended:
This alarm appears when the controller detects decreasing pulses of the Key switch input signal (below the
an overvoltage or undervoltage. The overvoltage undervoltage level) due to an external load, such as the startup
limit is 65V, the undervoltage limit is 11V. of a DC/DC converter, startup of a relay or a contactor, charging/
discharging of coils.
• If no change in the voltage is detected on the power supply
line and the alarm is present every time the key switch is
turned to ON, then the fault is probably in the controller
hardware. In this case, the controller must be replaced.
If the fault appears while the truck is moving, then it could be due to
undervoltage or overvoltage.
• If the alarm appears during acceleration while in traction, it is most
likely due to undervoltage; check the battery charge state and the
power connections.
• If the alarm appears when the brake is released, it is probably
due to overvoltage; check the contactor contacts and the power
connections.

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SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

VMN LOW 30 If the problem appears on start up (the contactor fails to close), check:
• the internal motor connections (ohmic continuity);
Cause: • the motor power connections;
This alarm appears when the controller detects If the motor connections are correct, then the problem could be located
an overvoltage or undervoltage. The overvoltage in the control, which therefore should be replaced.
limit is 65V, the undervoltage limit is 11V. If the alarm takes place while the motor is operating, check:
• the motor connections;
• if the windings/cables of the motor phases are leaking towards the
truck chassis;
• the power contact of the contactor is closing correctly
If no problems are found with the motors, then the fault lies in the
controller, which therefore must be replaced.

PUMP VMN HIGH 31

If the fault appears at startup (the contactor does not close at all),
Cause 1: check:
Before closing the contactor, the software • the internal motor connections (ohmic continuity);
checks the power section: it powers on the • the motor power connections;
Mosfets on the low side alternately and waits for • If the motor connections are correct, then the problem could be
the phase voltage to fall to -BATT. If the voltage located in the control, which therefore should be replaced.
is more than 10% of the nominal battery voltage, If the problem appears after closing the contactor (the contactor closes
this alarm appears. and then re-opens immediately), check:
Cause 2: • the motor connections;
This alarm can also appear when the startup • if the windings/cables of the motor phases are leaking towards the
diagnosis is exceeded and the contactor closes. truck chassis;
In this condition, the phase voltage should be If no problems are found with the motors, then the fault lies in the
lower than 1/2 Vbatt. controller, which therefore must be replaced.
If the voltage is higher, this alarm appears.

CONTACTOR CLOSED 37
Cause:
Before activating the contactor coil, the controller
checks whether the contactor is stuck. The • Check the contacts of the contactor. If the alarm persists, replace
controller activates the power section for a few the controller.
milliseconds to try to discharge the contactor
capacitors. If the voltage of the capacitors does
not decrease the key switch voltage by 20%,
this alarm appears.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

CONTACTOR OPEN 38
• Check the contacts of the contactor and, if necessary, replace the
Cause: contactor.
The main contactor coil is activated by the If the contacts of the contactor function correctly, the problem lies within the
control, but the contactor contacts do not close. control, which should be replaced.

STBY I HIGH 53
Cause: I This type of fault is not connected to external components. When it appears
The current transducer (Hall effect sensor) or the controller must be replaced.
the power supply circuit inside the controller is
damaged.

CAPACITOR CHARGE 60
Cause:
To better understand the meaning of this alarm,
see the following diagram:
• There is an external load parallel to the capacitors, which reduces the
control's pre-charge circuit current, preventing its charging. Check if a
lamp or a dc/dc converter or an auxiliary load is connected.
• The charge resistor is open; add a power resistor on the contactor
terminals; if the alarm disappears it means that the charge resistor inside
the controller is damaged. Replace the controller.
• The charging circuit in the controller is faulty. Replace the controller.
When the key is set to ON, the inverter tries to • There's a problem in the power section of the controller. Replace the
load the capacitor through a power resistance controller.
and checks if the capacitor has charged within
a certain time frame. If the capacitor voltage is
less than 20% of the nominal battery voltage,
an alarm is generated; the main contactor is not
closed.

TH.PROTECTION 62
Cause:
This alarm appears if the temperature • Check the temperature of the controller.
measured on the controller heat sink is above • If the alarm appears when the module is cold, there could be a
85°C. When this temperature is reached, the fault in the temperature sensor or in the logic card. In this case, the
current is reduced proportionally to the increase controller must be replaced.
in temperature down to the value of 0 Amps
corresponding to 105°C.

MOTOR TEMPERAT. 65
• Check the temperature sensor in the motor;
Cause: • Check the ohm value of the sensor and the wiring. If the sensor does not
This alarm appears when the temperature sen- have problems, improve motor ventilation. If the alarm is present when
sor is open or the motor temperature exceeds the motor is cold, the problem is located in the module.
150°C.

30
SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

DRIVER SHORTED 74
• Check for a short circuit or low pull-down impedance between pin
Cause: A16 and -BATT.
The driver of the main contactor coil is shorting. • The driver circuit is damaged internally and must be replaced.

CONTACTOR DRIVER 75
Cause: This type of fault is not related to external components; replace the
The contactor coil driver is not capable of piloting controller.
the load. This same device or the piloting circuit
is damaged.

ENCODER ERROR 82 • Check both the electrical and mechanical functionality of the encoder
and the wiring.
Cause: • Check the encoder is installed correctly; if the encoder rotates in its hous-
This alarm appears when a malfunction of the ing, it will cause the alarm.
encoder is detected. • The alarm can also be caused by electromagnetic disturbance. In these
cases, replace the encoder.
If the problem persists after the replacement of the encoder, the fault lies in
the control, which therefore must be replaced.

WRONG SLAVE VER. 201

Cause:
This alarm occurs when the software versions • Check the two software versions.
of the master and slave microcontroller are not
the same.

VDC LINK OVERV. 202 • Check the connections of the power cables to the battery. to the contactor
and to +Batt and -Batt of the control; the connections should be tightened
Cause: to a torque of 13Nm to 15Nm.
This alarm appears when the controller detects • If no voltage is detected on the power supply line and the alarm is present
an overvoltage. The threshold at which the each time the truck is powered on, the fault probably lies in the hardware
alarm occurs is 65V. of the controller. Replace the controller.

BRAKE RUN OUT 204

Cause: This type of fault is not related to external components; replace the
The contactor coil driver is not capable of piloting controller.
the load. This same device or the piloting circuit
is damaged.

INIT VMN HIGH. 206

Cause: • Check the connections inside the motor.
Before closing the contactor, the software • Check the motor power cable connections.
checks the voltage of the power bridge without • Check that there is no leakage towards the truck chassis.
activating it. The software expects that the If the motor connections are OK, the problem is in the controller, which must
voltage has a steady value. This alarm appears be replaced.
if the voltage is too high.

INIT VMN LOW 207

Cause: • Check the connections inside the motor.
Before closing the contactor, the software • Check the motor power cable connections.
checks the voltage of the power bridge without • Check that there is no leakage towards the truck chassis.
activating it. The software expects that the If the motor connections are OK, the problem is in the controller, which must
voltage has a steady value. This alarm appears be replaced.
if the voltage value is too low.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

EEPROM KO 208
• Try to carry out a reset of the EEPROM (clear eeprom) using the
Cause: programming console.
Before closing the contactor, the software • Turn the truck off and on again to check the result.
checks the voltage of the power bridge without • If the alarm persists, replace the controller.
activating it. The software expects that the • If the alarm disappears, the parameters previously recorded will be
voltage has a steady value. This alarm appears replaced by default parameters.
if the voltage is too high.

PARAM RESTORE 209 • If an EEPROM reset has been run (clear eeprom) before the last ignition,
this warning means that the EEPROM has been correctly reset. The
Cause: alarm is cancelled by a drive request or a hydraulic function.
This alarm appears when the default settings of • If this alarm appears when switching on the key switch without an
the controller are restored. EEPROM reset having been requested by the operator, there could be a
problem in the controller.

WRONG RAM MEM. 210

Cause:
This message appears when the algorithm • Switch the truck off and then back on.
implemented to check the main RAM registers If the alarm persists, replace the controller.
detects incorrect content: the register is dirty.
This alarm inhibits operation of the truck.

STALL ROTOR 211 • Check that the FREQUENCY and ENCODER signs on the TESTER
Cause: menu are the same and are different from zero during the traction
The drive rotor is jammed or the controller is not request.
receiving the encoder signal correctly. • To reset the system, carry out the startup procedure again.

WAITING SLAVE 212

Cause: • Switch the truck off and then back on.
This alarm appears when no activation message If the alarm persists, replace the controller.
is sent from the slave microcontroller to the
master microcontroller at startup.

HARDWARE FAULT 213

Cause: • This type of fault is not connected to external components, so when it
The versions of the software on master and occurs the controller must be replaced.
slave microcontrollers are different.

SENS MOT TEMP KO 218

• Check the ohmic value of the sensor and its wiring.
Cause: • If no faults were found in the sensor or in the wiring, the fault is in the
The output of the pump motor temperature controller, which must be replaced.
sensor has assumed an impermissible value.

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SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

PEV NOT OK 219
Cause:
This alarm appears when the input on pin XA3- • Check the voltage on pin XA3-17.
17 is not connected to +battery or if the voltage
is different.

VKEY OFF SHORTED 220 It is highly probable that the alarm is due to overvoltage. We advise to:
• check the descending pulses of the key switch input signal (below the
Cause: undervoltage threshold) caused by external loads, such as startup of DC/
This alarm appears when the controller detects DC converters, contactor relays or enabling/disabling of solenoids.
a low level Key-Off signal during diagnosis • check the connections of the power cables to the battery. to the main
during startup diagnosis. contactor and to +Batt and -Batt of the controller; the connections should
be tightened to a torque between 13Nm and 15Nm.
If no transient voltage is detected on the +B line and the alarm is present
each time the truck is started, the fault probably lies in the hardware of the
controller, which therefore must be replaced.

MC COIL SHOR. 223

• Check the connections between the outputs of the controller and the
Cause: loads.
This alarm appears when there is a short circuit If no connection problems are found, the fault lies in the control, which
of the contactor coils connected to output XA3- therefore must be replaced.
16.

WAITING FOR NODE 224

Cause:
This alarm appears when the controller is Check the Can Bus and resistance of the Can line (60 ohms).
waiting for an enabling signal from another unit
in the system.

TILLER OPEN 228

Cause:
This message appears when, with the key
switch ON and the operator presence pedal in The alarm disappears when the operator presence pedal is pressed again.
rest state (i.e. not pressed), the preset stand-by
period (30 seconds) elapses without a traction
or lifting request being received; the main
contactor opens.

OUTPUT MISMATCH 229

Cause:
The slave microcontroller verifies the motor • This is an internal fault of the controller, which must be replaced.
output data of the master microcontroller and
detects a mismatch.

WD SYNCHRO 230
• Switch the truck off and then back on.
Cause: • Check for electrostatic charges.
Delay in communication between Master If there are no external causes, replace the controller.
microcontroller and Slave microcontroller.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

NO SLAVE ENABLE 231
Cause: • Switch the truck off and then back on.
No enabling message sent from the slave If the alarm persists, replace the controller.
microcontroller to the master microcontroller
while the controller is in operation.

POWER MOS SHORT 233

Cause:
Before closing the contactor, the software
checks the power section: it powers on the This type of fault is not connected to external components; replace the
Mosfets alternatively and waits until the phase controller.
voltage drops to -BATT. If the phase voltage
does not respond to the commands, this alarm
appears.

COIL SHOR. EB 235

Cause: • Check for short circuits in the auxiliary circuits.
This alarm appears in the event of an overload If no problems are found, replace the controller.
or short circuit to the auxiliary circuits connected
to the pins XA3-9 and/or XA3-18.

CURRENT GAIN 236

Cause:
This alarm occurs when the gains of the • Run Clear Eeprom.
current amplifiers (ADJUSTMENT #03 and If the problem persists, replace the controller.
ADJUSTMENT #04) are set to their default
values (Imax has not yet been adjusted).

ANALOG INPUT 237

Cause:
The analogue/digital conversion has returned a
negative value on all the signals converted for If the problem constantly reoccurs, replace the controller.
more than 400 msec. The aim of this diagnosis
is to find a fault in the A//D converter or a
problem in the code that omits the updating of
the conversion of the analogue signal.

CONTROLLER MISM. 239

• Raise/lower the forks and if the alarm is not reset, try turning the truck off
Cause: and then on again to clear the Eeprom.
This alarm appears when the software in not If the alarm persists, replace the controller.
compatible with the hardware of the controller.

M/S PAR CHK MISM 241

Cause: • Check the parameters and update the parameters that do not coincide.
This alarm occurs when, at startup, there is • To identify the problem easily, run Clear Eeprom. Doing this will reset
a mismatch between the master “checksum” all parameters to their default values.
parameter and the slave “checksum” parameter.

34
SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

PARAM TRANSFER 242
Cause:
This alarm occurs when the master This is an internal fault of the controller, which must be replaced.
microcontroller is unable to transfer the list of
parameters to the slave microcontroller.

IQ MISMATCHED 245
Cause:
This alarm appears when the error between the Contact Hyster-Yale assistance.
set point of the Iq and the estimated Iq value is
outside the permitted range.

AUX DRIV.OPEN 246

Cause: Check the connections.
The driver of the auxiliaries coil is not capable of If the alarm persists, replace the controller.
piloting the load.

DATA ACQUISITION 247

Cause:
This alarm appears during acquisition of the The alarm disappears once the acquisition has been completed.
current gains.

NO CAN MSG. 248 • Check the Can bus wiring and the resistance of the Can line (60 ohm).
• If the other modules in the CAN bus network display error messages that
Cause: clearly indicate the PUMP controller is not detected on the CAN bus, the
This alarm appears when there is no CAN fault is probably in the controller itself.
communication. • If the other controllers in the CAN bus network display the error message
CANBUS KO, this indicates a malfunction of the CAN bus network. Try
disconnecting the individual controllers until the CAN bus starts to work
again.

THERMIC SENS. NOT OK 250

Cause: This kind of failure is not related to external components; replace the
This alarm appears if temperature sensor signal module.
of the electronic controller is outside the range
of permissible values.

WRONG SET BAT. 251 • Check that the value of the “SET BATTERY” parameter corresponds to
the nominal battery voltage.
Cause: • Check that the“TESTER MENU / BATTERY VOLTAGE” parameter
On startup the module measures the battery indicates the same value as the battery voltage measured with a
voltage and checks that it lies within a specific voltmeter. If values do not match, use the function “ADJUST BATTERY”.
range around the nominal value. • Replace the battery.

35
 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

WRONG ZERO 252
Cause:
The voltage during the amplifier output • Check the motor connections and for current leakage to ground.
initialisation stage (used to measure the drive If no external causes are found, replace the controller.
motor voltage) is greater than 3 volts or lower
than 2 volts

FIELD ORIENT. NOT OK 253

Cause:
The error between the ld set point of the drive Contact Hyster-Yale assistance.
motor and the estimated ld is outside the
permitted range.

AUX DRIV.SHRT. 254

• Check if there is a short circuit or low impedance between the auxiliaries
Cause: negative and -BATT.
The driver of the coil of the auxiliary solenoid The driver circuit is damaged; replace the module.
valve is shorting.

36
SERVICE DIAGNOSTICS AND MEASUREMENTS

ACE2 PUMP CONTROL - SLAVE NODE 37

The alarms of the Slave Node have the same descriptions and troubleshooting procedures as the Master
Node, with the exception of those listed below

Alarm Code MDI Troubleshooting

WD SYNCHRO 230
Cause:
The slave microcontroller does not receive the • Switch the truck off and then back on.
watchdog signal. • If the error persists, replace the control.

INPUT MISMATCH 241

Cause:
• Try switching the truck off and then back on again.
The inputs of the slave microcontroller differ to
• If the error persists, the fault lies in the control, which must be re-
the inputs of the master microcontroller.
placed.

SP MISMATCH 242
Cause:
• Try switching the truck off and then back on again.
The master microcontroller has detected
• If the error persists, the fault lies in the control, which must be re-
incorrect set points on the slave microcontroller.
placed.

37
 DIAGNOSTICS AND MEASUREMENTS SERVICE

DIAGNOSIS SYSTEM FOR EPS ACW CONTROL

The diagnostics system operates via CAN BUS communication.
Due to the dual microcontroller controls, the nodes for identifying each individual controller are:

Microcontroller Node
Master 6
Slave 38

The alarms are shown on the display in the format xxx-yy, where xxx is the alarm code and yy is the
node.
For example 79A05 is the Incorrect Start alarm on the Master microcontroller

EPS ACW CONTROLLER - MASTER NODE 6

Alarm Code MDI Troubleshooting
WATCHDOG 8
Cause:
The system is provided with a self-diagnosis This is an internal fault in the controller. Replace the controller.
circuit. A microchip tests the self-diagnosis
circuit to verify its correct operation. If the result
is negative, this alarm appears

EEPROM KO 13
Cause:
Each microcontroller has its own Eeprom with
two parameter lists (to provide a local backup
copy). Each list has its own checksum. When both Perform a 'Clear EEprom' procedure. If the problem persists, replace
checksums give errors, this alarm is generated. the controller.
In the event that only one of the parameter lists
gives a checksum error, this list will corrected
using the second list (backup copy with correct
checksum).

LOGIC FAILURE #4 16
Cause: Check the power connections between the controller and the steering
This alarm occurs if, when the steering is at motor.
rest, the difference between the actual W phase • If the alarm persists, replace the controller.
voltage and the U phase voltage is greater than
250mV.

LOGIC FAILURE #3 17
Cause: Check the power connections between the controller and the steering
This alarm occurs if, when the steering is at rest, motor.
the difference between the actual V phase voltage • If the alarm persists, replace the controller.
and the U phase voltage is greater than 250mV.

VMN NOT OK 32
Cause:
This alarm check that, with the steering system
at rest, if at least one voltage amplifier on the
connected voltage Vv-Vu and Vu-Vw is in the
range of 2.4Vdc +/- 300mV for 50msec (sam- If the alarm persists, replace the controller.
pling time 10msec for 5 consecutive samples).
(Permitted outputs at rest: 2.1V to 2.7V). Once
diagnosis has been completed, the offset value of
the voltage amplifiers (Vvu_zero and Vuw_zero)
will be acquired.

38
SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

MAIN CONT. OPEN 48
Cause:
This alarm is activated when the steering Check that the line contactor is closed.
controller receives, via the CAN bus, the
information that the power line contactor is open.

STBY I HIGH 53
Cause:
This alarm occurs in two different situations:
• With the key switch enabled, if at least one of
the current amplifiers on the phases U and W
is not within the range of 2.5Vdc +/- 300mV
for 50msec (sampling time 10msec for 5
consecutive samples). (With the key switch
enabled, permitted current amplifier outputs If the alarm persists, the controller must be replaced.
are from 2.2V to 2.8V). Once diagnosis has
been completed, the offset value of the cur-
rent amplifiers (IU_zero and IW_zero) will be
acquired.
• With the key switch enabled, if at least one
of the current amplifiers on the phases U
and W is not within the range of IU_zero or
IW_zero+/- 150mV for 96msec (sampling time
8msec for 12 consecutive samples).

CAPACITOR CHARGE 60 • If this alarm is generated only on the steering controller, check the
continuity of the wires between +Batt and pins XA4-2 XA4-3 XA4-
Cause: 4 of the EPS.
This alarm occurs with key switch enabled, if the • If there is nor problem with the wiring, measure the voltage
DC Bus (capacitors in parallel) does not reach the between pins pin XA4-4 and -B within 3 sec. of key on:
minimum value of 14Vdc within 3.2 sec. if the voltage exceeds 14V before 3sec, replace the controller; if the
voltage is around zero, there are 2 possibilities, an internal short circuit
of the EPS (disconnect XA4-3 XA4-4 XA4-5 and measure the voltage
in the DC bus of the drive controller between +B and –B and replace
the EPS if it is greater than 14Vdc; if instead the voltage is still around
zero, the problem is located in another controller.

HIGH TEMPERATURE 61
Cause: Improve the cooling system of the controller. Otherwise, replace the
This alarm occurs when the internal temperature controller.
of the controller exceeds 80°C.

MOTOR TEMPERAT. 65
Cause: Check that the temperature sensor in the motor is functioning correctly.
This alarm is triggered when the temperature If so, improve the motor cooling system.
measured by the internal sensor of the motor
exceeds 120°C.

HIGH CURRENT 70
Cause:
This alarm occurs when, with the key switch If the alarm persists, the controller must be replaced.
enabled, the hardware current limiting circuit is
always activated (this may be due to a fault in
the current amplifier).

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

POWER FAILURE #3 71 • If the alarm persists, check that the connections of the W phase
power wire of the EPS are securely tightened and that the battery
Cause: is connected to +B.
This alarm appears when the current of the W • Check fuse F6
phase of the motor falls below 5.4 Amps for • Check that motor supply phases are isolated from each other and
100msecs. even when driven at more than 28% from the chassis
Imax. • Otherwise, the problem could be a fault in the 3-phase bridge, it is
therefore necessary to replace the controller
POWER FAILURE #2 72 • If the alarm persists, check that the connections of the V phase wire of
the EPS are securely tightened and that the battery is connected to +B
Cause: • Check fuse F6
This alarm appears when the current of the V • Check that motor supply phases are isolated from each other and
phase of the motor falls below 5.4 Amps for from the chassis
100msecs. even when driven at more than 28% • Otherwise, the problem could be a fault in the 3-phase bridge, it is
Imax. therefore necessary to replace the controller

POWER FAILURE #1 73 • If the alarm persists, check that the connections of the U phase wire of
the EPS are securely tightened and that the battery is connected to +B
Cause: • Check fuse F6
This alarm appears when the current of the U • Check that motor supply phases are isolated from each other and
phase of the motor falls below 5.4 Amps for from the chassis
100msecs. even when driven at more than 28% • Otherwise, the problem could be a fault in the 3-phase bridge, it is
Imax. therefore necessary to replace the controller

SPEED SENSOR KO 84
Cause:
This alarm is generated if there is a short circuit Check for a short circuit between pins XA4-17 and XA4-20
between the two channels QL and DL of the
stepper motor

STEER HAZARD 85
Cause: Turn the steering wheel in the opposite direction.
This alarm occurs when the wheel is steered to
the maximum angle.

ACQ ABORTED 202

• Check that encoder 1 is read correctly by the controller:
Cause: EPS/Tester menu/Enc Counting.
This alarm occurs when there is an error in the If the values are read correctly and the alarm persists, replace the
encode acquisition. controller.

ENC PULSES ACQ 203

Cause:
The EPS is acquiring the number of encoder Wait for the procedure to be completed.
pulses per complete revolution.

CAN BUS WARN 206

Cause: Check the Can Bus line, connections and resistance of the Can line
This alarm occurs when the a node does not (60 ohm).
receive the CAN bus drive message for more
than 200msec.

W.D. SYNCHRO 209

Cause: Reactivate the key switch. If the alarm persists, the problem is in the
The comparison between the Master and Slave controller. It could also be a problem with ESD (electrostatic discharge).
self-diagnosis has not given a positive result.

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SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

WRONG SLAVE VER. 210
Cause: Download the same software versions (with the same number) on both
This alarm is generated by the master microcontroller microcontrollers.
if the software versions of the master and slave do
not match (different versions).

WRONG RAM MEM. 212

Cause: If the alarm persists, there is an internal problem in the controller, which
• This alarm occurs when there is an error data must be replaced.
written to the RAM.

PARAM RESTORE 213

Cause:
This message confirms that the 'Clear Eeprom' Switch off the truck, wait a few seconds then restart the truck.
procedure has been performed correctly.

CAN BUS KO M/S 215

Cause:
The master and slave microcontrollers communi- Switch the truck off and then on again; if the alarm persists, the problem
cate via a local CAN Bus communication system lies in the steering controller.
(integrated in the control). If a node does not
receive any response from another node for more
than 100msec, this alarm is generated.

STEPPER MOT MISM 219

Cause: Check the wiring and look for a short circuit between pins XA4-17 and
This alarm appears if there is a mismatch XA4-20 or to GND. If everything is OK, replace the stepper motor. If the
between the signals coming from the two problem persists, replace the controller.
channels (D&Q) of the stepper motor.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

MOTOR LOCKED 220
Cause:
This alarm occurs when the motor current • Check that motor rotates easily and is not mechanically obstructed.
remains greater than 90% Imax for more then 1 If the motor is OK, check the motor encoder or the connections between
sec, when the drive speed is greater than 15% the encoder and the EPS.
(the delay time changes to 5 sec. when the drive
speed is less than 5%).

M/S PAR CHK MISM 221

Cause: • Check the parameters and update the parameters that do not coincide.
This alarm occurs when, at startup, there is • To identify the problem easily, run Clear Eeprom. Doing this will reset
a mismatch between the master “checksum” all parameters to their default values.
parameter and the slave “checksum” parameter.

FB JERK 223
Cause: • Check the continuity of the encoder connection.
This alarm occurs if the position of the steered • Check for interference on the encoder signals
wheel measured by the encoder changes with a • Encoder fault
step greater than 21° in 16msec.

CURRENT GAIN 225

Cause:
This alarm occurs when the gains of the Switch the truck off and then on again; if the alarm persists, replace
current amplifiers (ADJUSTMENT #03 and the controller.
ADJUSTMENT #04)are set to the default values
(Imax has not yet been set).

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SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

POSITION ERROR 228
Cause:
This alarm is caused by a mismatch between
the signal of the steering motor encoder and the
signals of the two feedback sensors (0° pin XA4-
12 and 90° pin XA4-11). The correspondence
between the FEEDBACK SECTOR and STEER
ANGLE parameters in the tester menu is
indicated in the following table

Permitted
STEER ANGLE
FEEDBACK
[degrees]
SECTOR
from -15 to +15 1° or 4°
from +15 to +75 1° • Check the correspondence between the parameters and values given
from +75 to +105 1° or 2° in the table here; if the parameters do not match, the problem could
be caused by a sensor (check PROX SWITCH 1 and PROX SWITCH
from +105 to 2° 2) or the encoder (check STEER ANGLE and FEEDBACK SECTOR).
+165 • Check that the encoder and the feedback sensors are connected
from +165 to 2° or 3° correctly and functioning correctly; the status of the feedback sensors
-165 should change during steering according to whether or not they read
the cam.
from -165 to -105 3°
from -105 to -75 3° or 4°
from -75 to -15 4°

When the FEEDBACK SECTOR and STEER AN-

GLE do not match the above values, a POSITION
ERROR alarm is generated in less than 100msec.

NOTE: The permitted STEER ANGLE thresholds

for each FEEDBACK SECTOR given in the abo-
ve table 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 that concern the
SW1 offset and the length of the cam are shown
in real time in the FEEDBACK SECTOR.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

SLAVE ALARM 237
Cause: Connecting with the Can Console, the message will be follo-
When the slave microcontroller generates an wed by two characters identifying which Slave alarm is present.
alarm, the electrical power supply is interrupted If the alarm persists, the problem is related to the controller.
and the steering motor cannot be activated. The
master microcontroller generates this warning.

EPS NOT ALIGNED 238

Cause:
This alarm can appear at startup:
- if no signals are received from switch SW 1 • Check the connections and correct operation of position sensor B7.
of the position sensor B7 ( 0° pin XA4-12 ) with • Check the connections and correct operation of the encoder.
steered wheel position at 0° or 180°
- if the encoder is not able to return to the
position of 0° (straight-ahead) after SW1 has
been activated.

KEYOFF 240
Cause: Switch the truck off and then on again; if the alarm persists, replace
This alarm appears if the pilot power of three- the module.
phase bridge , inside the control, is less than
11Vdc.

FB SENSOR LOCKED 241 This alarm may be caused by:

Cause:
This alarm appears if the speed of the steering • a fault in at least one channel of the encoder;
motor measured by the encoder does not corre- • Excessive friction in the transmission;
spond to the commanded speed (defined by the • a fault in the controller;
outputs of the stepper motor) • a fault in the motor (e.g. encoder jammed or broken phase wire).

Q LINE SENSOR KO 242

Cause:
This alarm occurs when the average voltage Check the continuity of the stepper motor connections. In particular, the
on the quadrature line of the stepper motor resistance between CNA#17 and the negative battery terminal (with the
(connection CNA#17) is not zero: the voltage on stepper motor at rest) should be very low (around 30 Ohms).
each line of the stepper motor is a sine wave with
average voltage equal to zero.

D LINE SENSOR KO 243

Cause:
This alarm occurs when the average voltage on Check the continuity of the stepper motor connections. In particular, the
the Direct line of the stepper motor (connection resistance between CNA#20 and the negative battery terminal (with the
CNA#20) is not zero: the voltage on each line of stepper motor at rest) should be very low (around 30 Ohms).
the stepper motor is a sine wave with average
voltage equal to zero.

PARAM TRANSFER 244

Cause:
The master microcontroller and the slave
microcontroller each have their own parameter
list (with their own local backup copy). Parameter
editing is controlled by the master microcontroller • Try again to change a parameter and save.
only. The master microcontroller writes its • If the problem persists, run the Clear Eeprom procedure.
own parameters and commands the slave If the problem persists, replace the controller.
microcontroller to do the same for its own list of
parameters. Execution of the parameter write
command in the microcontroller is password
protected. This alarm is generated by the master
microcontroller if the slave microcontroller refuses
to execute the write command

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SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

DATA ACQUISITION 245 The alarm disappears on termination of the acquisition procedure and
Cause: once the truck has been switched on again.
This alarm occurs during the maximum current to perform.
setting procedure (factory set) and when a If the alarm appears during use of the truck, run the
procedure for the acquisition of the motor Clear Eeprom procedure.
resistance is launched. If the alarm persists, replace the controller.

CAN BUS KO 247

Cause:
• Check the CAN bus wiring and connections.
This alarm occurs if the Master microcontroller
and the Slave microcontroller do not receive • Check that Drive controller is functioning correctly.
CAN messages from the traction for a time period
of more than 200msec.

CAN BUS KO 247

Cause:
• Check the CAN bus wiring and connections.
This alarm occurs if the Master microcontroller
and the Slave microcontroller do not receive • Check that Drive controller is functioning correctly.
CAN messages from the traction for a time period
of more than 200msec.

INIT VMN NOT OK 251 Try disconnecting the terminals of the motor from the controller, turn the
key switch back to on and read STATUS #5. If the 1st value is in the
Cause: range 8 to 13.5 Vdc, the problem is leakage (loss of motor insulation).
After activating the key with the three-phase If not, replace the controller.
bridge disabled, the DC bus voltage should
reach 14Vdc in 3.2sec (CAPACITOR CHARGE
alarm, if this does not occur). At the same time,
the steering controller monitors the common
voltage at the motor terminals (see STATUS #5
1° value) and generates this alarm after 3.2sec
have elapsed, if:
• The common voltage is less than 7Vdc (lower
Mosfet shorting to –B).
OR
• The common voltage is locked to the DC
Bus (upper mosfet shorting to +B). (IT IS
considered locked if in a range of +/- 1Vdc
around the DC Bus). STATUS #5 in the
TESTER menu provides the real time value
of this common voltage over a long duration.

ANALOG 253
Cause: Switch the truck off and then back on. If the alarm persists, replace the
This alarm appears when a problem arises in the controller.
controller's analog-digital converter.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

EPS ACV CONTROLLER - SLAVE NODE 38

The alarms of the Slave Node have the same descriptions and troubleshooting procedures as the Master
Node, with the exception of those listed below

Alarm Code MDI Troubleshooting

SP MISMATCH 207
Cause:
According to the command, the master and slave
microcontrollers calculate independently from Switch the truck off and then on again; if the alarm persists, the problem
each other the set point of the steering motor lies in the controller, which must be replaced.
speed. The slave microcontroller checks that the
values it reads correspond, in real time, to the
values calculated by the master microcontroller.
If not, this alarm is generated.

OUT MISMATCH 208

Cause:
The master and slave microcontrollers read the
values of the outputs independently from each Switch the truck off and then on again; if the alarm persists, the problem
other. The slave microcontroller checks that the lies in the controller, which must be replaced.
values it reads correspond, in real time, to the
values that the master microcontroller is reading.
If this is not the case, this alarm is generated.

WAITING MASTER 237

Cause:
On startup the Master microcontroller sends an Switch the truck off and then on again; if the alarm persists, the problem
enabling signal to the Slave microcontroller over lies in the controller, which must be replaced.
the internal CAN bus. If this signal is absent for
a time period exceeding 4 sec., this message
appears

INPUT MISMATCH 250

Cause:
The master and slave microcontrollers read the
values of the inputs independently from each Switch the truck off and then on again; if the alarm persists, the problem
other. The slave microcontroller checks that the lies in the controller, which must be replaced.
values it reads correspond, in real time, to the
values that the master microcontroller is reading.
If this is not the case, this alarm is generated.

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 SERVICE DIAGNOSTICS AND MEASUREMENTS

DIAGNOSIS SYSTEM FOR VCM CONTROL

The diagnostics system operates via CAN bus communication.
Due to the dual microcontroller controls, the nodes for identifying each individual controller are:

Microcontroller Node
Master 1
Slave 33

The alarms are shown on the display in the format xxx-yy, where xxx is the alarm code and yy is the
node.

VCM CONTROL - MASTER NODE 1

Alarm Code MDI Troubleshooting
WATCHDOG 8
Cause:
The system is provided with a self-diagnosis
This is an internal fault of the controller, which must be replaced.
circuit. A microchip tests the self-diagnosis
circuit to verify its correct operation. If the result
is negative , this alarm appears

LOGIC FAILURE #1 19
Cause: • Switch the truck off using the emergency button and then switch it
This alarm signals that an undervoltage condition back on again.
has been detected when the key switch is acti- • If the alarm persists, replace the controller.
vated. All functions are suspended.

CHARGING 196
With the MIDAC lithium battery option • If the battery is not actually recharging, check that the cap of the
Cause: charging socket connector is not open.
The connector of the battery charger is con- • If the cap is closed, it could be a problem in the internal circuit of the
nected to the battery lithium battery.

CAN BUS KO BMS 197 Check the Can bus wiring and the resistance of the Can line (60
ohm).
With the MIDAC lithium battery option • If the other modules in the CAN bus network display error messages
Cause: that clearly indicate the VCM controller is not detected on the CAN
It appears if the module fails to receive any bus, the fault is probably in the controller itself.
Can messages from the Battery Management • If even the other modules of the can bus network present the same
System (BMS). error message CANBUS KO, it means that the entire can bus
network is not working. We suggest to try disconnecting the individual
modules until the Can bus functionality is restored. It is advisable to
start disconnecting from one end of the can bus network.

BMS TRUCK INHIBIT 198

With the MIDAC lithium battery option • Check the battery's state of charge and, if necessary, charge it. This
Cause: alarm is generated 15 seconds after activation of the WARNING
This alarm is used when LITHIUM batteries INHIBIT or following receipt of a drive/pump/steering request when
are installed; it indicates that the battery has the battery charging connector cap is open or the battery is con-
detected an anomaly and consequently the nected to the battery charger.
contactor must be opened to disconnect the
truck power.

OVERLOAD 199
• Check that the weight load on the forks does not exceed the rated
Cause: load capacity indicated on the identification data plate. If so, remove
The load is greater than the capacity of the truck. the excess load.
• If the alarm persists, check that the load cells are functioning properly
and that the parameters are set properly.
• If the alarm persists, replace the controller.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

WRONG PARAMETER 200
Cause:
This alarm appears when an error is detected in
• Check the parameters.
the configuration parameters.

WRONG SLAVE VER. 201

Cause:
This alarm appears when the slave microcontroller
• Install the correct version of the software.
has an incorrect software version.

HM MISMATCH 202
Cause:
This alarm appears when there is a mismatch
• Check the settings of the hour meter parameters.
between the VCM controller and the drive
controller relative to the hour meter.

TILLER MISMATCH 203

This alarm is caused when the status of the operator presence switch
Cause: is read differently by the VCM controller and the drive controller.
This alarm appears when there is a mismatch • If the anomaly persists, check the wiring and the operation of the
between the VCM controller and the drive con- microswitches.
troller relative to the operator presence input. • If all the above conditions have been checked and no faults are found,
replace the controller.

BATTERY LOW 204 • Charge the battery.

Cause: • If the alarm is still present, measure the battery voltage with a
• with the parameter HYG LI-ION BATT = OFF, voltmeter and compare it with the value of the VOLTAGE BATTERY
it appears when the battery charge level is parameter.
below 20%. • If the values do not match, adjust the value of ADJUST BATTERY
• with the parameter HYG LI-ION BATT = ON function connected to the pin of the right connector making sure they
it appears when the battery charge level falls are not interrupted.
below 2% and the BMS activates performance If the alarm persists, the problem lies in the controller, which
reduction. must be replaced.

RESET ENCODER 205

• Lower the forks until the reset input of the encoder is activated. If he
Cause:
problem persists, check the wiring and check that the microswitches
The VCM waits for activation of the encoder reset
function correctly.
input (pins A5-B4) before enabling any hydraulic
If all the above conditions are checked but no faults are found, replace
functions (only the fork lowering function is
the controller.
enabled).

BATTERY OUT 206

• Insert the battery in the correct position in the truck frame.
Cause: • If the anomaly persists,check the wiring and check that the
This alarm appears when the switches of the microswitches function correctly in accordance with the parameter
sensor B9 detect that the battery is out of position settings.
( pin XA5-A18 = 0 pin XA5-A19 = +VB ) • IF all the above conditions have been checked but no fault is found,
replace the controller.

EEPROM KO 208
Switch the truck off using the emergency button and then switch it
Cause:
back on again.
This alarm appears when a fault occurs in the
If the alarm disappears, the previously programmed parameters will be
area of memory where the parameters are stored
replaced by the default parameters.
or if problems occur during the reading/writing of
If the alarm persists, replace the controller.
this memory.

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SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

PARAM RESTORE 209 • If CLEAR EEPROM mode was active before last switching on the
key switch, this message indicates that the EEPROM has been
Cause:
correctly deleted.
This signal appears when the controller has
• The alarm disappears when a drive or pump request is made.
restored the default values.
• If this alarm appears when switching on the key switch without a
CLEAR EEPROM being requested by the operator, there could be
a problem in the controller.

WRONG RAM MEM. 210

Cause:
• Switch the truck off using the emergency button and then switch it
This alarm appears when the algorithm entered
back on again.
to check the main registries of the RAM detects
• If the alarm persists, replace the controller.
incorrect content: the registry is "dirty".

PUMP INC. START 211 The probable cause of this alarm is an incorrect sequence of operations
carried out by the operator.
Cause: • an active pump request on start up;
This signal is displayed in the event of an incor- • pump request with seat switch not activated.
rect starting sequence. If the sequence of operations is correct, check the wiring and that the
microswitches are functioning correctly.
If all the above are checked but no faults are found, replace the con-
troller.

ENCODER LOCKED 1 213 • Check whether ENCODER1 in the tester menu is other than zero
during a lifting request.
Cause:
• Verify the wire harness assembly and the operation of the sensor.
The encoder is jammed or the encoder signals
If all the above conditions are checked but no faults are found, replace
are not being received correctly by the controller.
the controller.

ENCODER LOCKED 2 214 • Check whether ENCODER2 in the tester menu is other than zero
during a lifting request.
Cause:
• Verify the wire harness assembly and the operation of the sensor.
The encoder is jammed or the encoder signals
If all the above conditions are checked but no faults are found, replace
are not being received correctly by the controller.
the controller.

OUT PORT PULL-UP 215

Cause:
This is an internal fault of the controller, which must be replaced.
This alarm is related to the hardware configuration.

ANALOG INPUT 217

Cause:
This alarm appears when a problem arises in the This is an internal fault of the controller, which must be replaced.
controller's analog-digital converter.

RESET ENCODER KO 218 • Lower the forks until the encoder reset input is actiated.
Cause: • If the trouble remains, check the wire harness assemblies and check
VCM waits for the encoder reset input to be active that the microswitches work correctly.
before enabling any hydraulic function (only the If all the above conditions have been checked and no faults are found,
lowering function is permitted). replace the controller.

VALVE ENABLE 219

Cause:
This alarm appears when the master • Check if the alarm is also present on the slave microcontroller.
microcontroller attempts to activate an output • If there are no active alarms, replace the controller.
but the slave microcontroller does not activate
the enable signal.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

LIFT/LOW LEVER 222
Cause:
Check the mini-lever and the associated wiring.
This alarm concerns the mini-lever for raising/
lowering the forks

NO CAN MSG. SLAVE VCM 223

Cause:
• Switch the truck off using the emergency button and then switch it
Timeout on CAN BUS slave of the VCM (local
back on again.
CAN BUS).
If the alarm persists, replace the VCM.

WAITING FOR NODE 224

Cause:
This alarm appears when the controller is waiting
Check the Can Bus and resistance of the Can line (60 ohms).
for an enabling signal from another unit is system

CONTROLLER MISM. 225

Cause: • Switch the truck off using the emergency button and then switch it
This alarm appears when the software in not back on again. If the alarm persists, replace the controller.
compatible with the controller hardware.

PUMP IN ALARM 226

Cause:
This alarm indicates that the pump is in alarm Check the alarm on the pump controller.
condition.

NO CAN MSG. PUMP 227

Cause: • Check the connections on the pump controller.
This alarm appears when no CAN messages are • Check that the pump controller is communicating via the CAN Bus.
received from the pump controller.

NO CAN MSG. JOYSTICK 228

Cause: • Check the CAN connections on the joystick/mini-levers.
This alarm appears when no CAN message is • Check that the joystick/mini-levers are communicating via the CAN
received from the joystick or mini-levers. bus.

SDO TRAC. 229

Cause:
This alarm appears when an HM communication • Check the communication between the drive controller and the VCM
problem occurs between the VCM controller and controller.
the drive controller. • If the communication is OK, replace the controller.

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SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

INTERLOCK FORK 230 • Check that the truck position potentiometer signal has been acquired
correctly, if not proceed with acquisition.
Cause:
• Check the wiring and the operation of the sensor.
The VCM controller is not able to perform the
If all the above conditions have been checked and no faults are found,
interlock function.
replace the controller.

CARRIAGE LEVER 231

Cause:
This alarm is related to the mini-lever used to
• Check the carriage forward/back lever and the relative wiring.
move the carriage forward and back.

TILT LEVER 232

Cause:
This alarm concerns the fork tilt control mini-lever.
• Check the fork tilt control lever and the associated wiring.

SIDE SHIFT LEVER 233

Cause:
This alarm concerns the fork side-shift mini-lever. • Check the fork side shift lever and the related wiring.

WAITING PCF 234

Cause:
This alarm appears when the controller is waiting
• Wait for the operation to end
to verify the configuration file between the VCM
controller and the drive controller.

WRONG CONFIG 235

Cause: • Check the configuration file.
This alarm appears when there is a difference • Download the configuration file again.
between the configuration files (CDF) of the VCM
controller and the drive controller.

NO CONFIG BACKUP 236

Cause: • Check the configuration file.
This alarm appears when there is an incorrect • Download the configuration file again.
configuration file in the slave microcontroller.

NO CONFIG MASTER 237

Cause: • Check the configuration file.
This alarm appears when there is an incorrect • Download the configuration file again.
configuration file in the master microcontroller.

PCF TIMEOUT 238

Cause:
This alarm appears when the time limit has • Check the configuration file.
expired for cross-checking the configuration • Download the configuration file again.
file between the VCM controller and the drive
controller.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

REACH SENS OUT R 239
Cause: • Check that the sensor is functioning correctly.
This alarm appears when the analog carriage • Check the wiring.
position sensor is out of the permitted range.

REACH ACQ. SENS 240 • Repeat the acquisition.

Cause: • If the alarm persists:
This alarm appears when the maximum value • Check that the sensor is functioning correctly.
acquired by the analog carriage position sensor • Check the wiring;
is lower than the minimum value. • Replace the sensor.

M/S PAR CHK MISM 241

Cause: • Check the parameters and update the parameters that do not coincide.
This alarm occurs when, at startup, there is • To identify the problem easily, run Clear Eeprom. Doing this will reset
a mismatch between the master “checksum” all parameters to their default values.
parameter and the slave “checksum” parameter.

PARAM TRANSFER 242

Cause:
This alarm occurs when the master This is an internal fault of the control, which therefore must be replaced.
microcontroller is unable to transfer the list of
parameters to the slave microcontroller.

PRESELECTOR 243
• Check which function generates the alarm condition.
Cause: • Verify the wire harness assemblies and the operation of the sensor.
The VCM controller is not able to perform the If all the above conditions have been checked and no faults are found,
height pre-selection function correctly. replace the controller.

CHECK UP 244
Cause: At the end of the maintenance set the parameter VCM / Set Option /
This message appears when it is necessary to Check up done = ON.
carry out programmed maintenance.

SEAT 245 • Check the seat and the operator presence pedal.
• Use the console to check that the sensors are being read correctly
Cause: by the VCM controller.
his alarm appears when the operator presence • Check the wiring.
pedal is pressed without an operator on the seat. If all the above conditions are checked but no faults are found, replace
the controller.

NO CAN MSG. TRACTION 246

Cause: • Check the connections on the drive controller.
This alarm appears when no CAN messages are • Check that the drive controller is communicating via the CAN Bus.
received from the drive controller.

NO CAN MSG. EPS 247

Cause: • Check the connections on the EPS controller.
This alarm appears when no CAN messages are • Check that the EPS controller is communicating via the CAN Bus.
received from the EPS controller.

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SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

NO CAN MSG. DISPLAY 248
Cause: • Check the display connections.
This alarm appears when no CAN message is • Check that the display communicates via the CAN Bus.
received from the display.

CAN BUS DISPLAY 249

Cause: • Check that the display is connected correctly, in particular, the CAN
This alarm appears when the key switch relay bus connections (pins 3 and 4).
controlled by the display is open. If the connection is correct, it could an internal fault of the display.

CAN TILLER 250

Cause:
The Can Tiller is connected to the CAN bus. The Using only during testing; if it appears during operation, check connec-
VCM controller executes the hydraulic command tions on connctor X40.
sent from the Can Tiller. Any other command that
arrives from the Joystick or the MLM is ignored.

TROLLEY BLOCKED 251

• Check that the carriage sensor is receiving power and functions
Cause: correctly.
This alarm appears when the signal from the • Check the wiring.
carriage sensor does not move when the carriage • If the problem persists, replace the controller.
is moved forward or back.

BMS MISMATCH 252

With the Midac lithium battery option
Cause: Enable the parameter HYG LI-ION BATT
This alarm is generated if the parameter HYG
LI-IONBATT is set to OFF, but messages are
received from the BMS.

BMS SHUTDOWN 253

With the Midac lithium battery option
Cause: Check the charge level and the CAN connection to the battery.
The BMS disables the battery's internal
contactor.

WARNING INHIBIT 254

• Recharge the battery.
With the Midac lithium battery option • Close the charging connector cap of the battery.
Cause: If the alarm persists without any apparent reason, the cause could be
Battery charge level (SOC)<= 0 %. Charging a problem in the internal circuit of the lithium battery.
connector cap open.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

VCM CONTROL - SLAVE NODE 33

The alarms of the Slave Node have the same descriptions and troubleshooting procedures as the Master
Node, with the exception of those listed below

Alarm Code MDI Troubleshooting

CHARGING 184
Cause: • If the battery is not actually recharging, check that the cap of the
With the MIDAC lithium battery option charging socket connector is not open.
Cause: • If the cap is closed, it could be a problem in the internal circuit of the
The connector of the battery charger is con- lithium battery.
nected to the battery

DRV. SHRT. EVP1 (LOWER) 185 The most likely cause of this error code is a fault in the wiring or in the
solenoid valve coil.
Cause: • Check for short circuit or low impedance of the coil connected to pins
The driver of the solenoid valve EVP1 (Q1) is XA5-13 and XA5-24.
shorting. • If low impedance is measured between the pins, with the connector
disconnected, the driver circuit is damaged and the controller must
be replaced.

DRV. SHRT. EVP2 (LIFT) 186 The most likely cause of this error code is a fault in the wiring or in the
solenoid valve coil.
Cause: • Check for short circuit or low impedance of the coil connected to pins
The driver of the solenoid valve EVP2 (Q2) is XA5-13 and XA5-25.
shorting. • If low impedance is measured between the pins, with the connector
disconnected, the driver circuit is damaged and the controller must
be replaced.

DRV. SHRT. EVP3 (REVERSE 187 The most likely cause of this error code is a fault in the wiring or in the
TROLLEY) solenoid valve coil.
• Check for short circuit or low impedance of the coil connected to pins
Cause: XA5-14 and XA5-2.
The driver of the solenoid valve EVP3 (Q3) is • If low impedance is measured between the pins, with the connector
shorting. disconnected, the driver circuit is damaged and the controller must
be replaced.

DRV. SHRT. EVP4 (FORWARD 188 The most likely cause of this error code is a fault in the wiring or in the
TROLLEY) solenoid valve coil.
• Check for short circuit or low impedance of the coil connected to pins
Cause: XA5-14 and XA5-3.
The driver of the solenoid valve EVP4 (Q4) is • If low impedance is measured between the pins, with the connector
shorting. disconnected, the driver circuit is damaged and the controller must
be replaced.

DRV. SHRT. EVP5 (LEFT AUX VALVE) 189 The most likely cause of this error code is a fault in the wiring or in the
solenoid valve coil.
Cause: • Check for short circuit or low impedance of the coil connected to pins
The driver of the solenoid valve EVP5 (Q5) is XA5-15 and XA5-26.
shorting. • If low impedance is measured between the pins, with the connector
disconnected, the driver circuit is damaged and the controller must
be replaced.

DRV. SHRT. EVP6 (RIGHT AUX VALVE) 190 The most likely cause of this error code is a fault in the wiring or in the
solenoid valve coil.
Cause: • Check for short circuit or low impedance of the coil connected to pins
The driver of the solenoid valve EVP6 (Q6) is XA5-15 and XA5-27.
shorting. • If low impedance is measured between the pins, with the connector
disconnected, the driver circuit is damaged and the controller must
be replaced.

DRV. SHRT. EVP7 191 The most likely cause of this error code is a fault in the wiring or in the
(TILT /SIDE SHIFT SELECT VALVE) solenoid valve coil.
• Check for short circuit or low impedance of the coil connected to pins
Cause: XA5-16 and XA5-4.
The driver of the solenoid valve EVP7 (Q7) is • If low impedance is measured between the pins, with the connector
shorting. disconnected, the driver circuit is damaged and the controller must
be replaced.

54
SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

DRV. SHRT. EVP8 (5° WAY SELECT 192 The most likely cause of this error code is a fault in the wiring or in the
VALVE) solenoid valve coil.
Cause: • Check for short circuit or low impedance of the coil connected to pins
The driver of the solenoid valve EVP8 (Q8) is XA5-16 and XA5-5.
shorting. • If low impedance is measured between the pins, with the connector
disconnected, the driver circuit is damaged and the controller must
be replaced.

DRV. OPEN EVP1 (LOWER) 193 • Check the continuity and connections between solenoid valve EVP1
Cause: (Q1) and pins XA5-13 and XA5-24.
This alarm appears when the VCM controller • Check the ohmic value of the solenoid valve coil (see table at the end
cannot enable the proportional solenoid valve of this section).
EVP1 (Q1) for lowering the forks. • If no external problems are found, the problem lies in the controller,
which must be replaced.

DRV. OPEN EVP2 (LIFT) 194 • Check the continuity and connections between solenoid valve EVP2
(Q2) and pins XA5-13 and XA5-25.
Cause: • Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller of this section).
cannot enable the proportional solenoid valve • If no external problems are found, the problem lies in the controller,
EVP2 (Q2) for raising the forks. which must be replaced.

DRV. OPEN EVP3 (REVERSE 195 • Check the continuity and connections between solenoid valve EVP3
TROLLEY) (Q3) and pins XA5-14 and XA5-2.
Cause: • Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller of this section).
cannot enable the proportional solenoid valve • If no external problems are found, the problem lies in the controller,
EVP3 (Q3) for moving the carriage back. which must be replaced.

DRV. OPEN EVP4 (FORWARD 196 • Check the continuity and connections between solenoid valve EVP4
TROLLEY) (Q4) and pins XA5-14 and XA5-3.
Cause: • Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller of this section).
cannot enable the proportional solenoid valve • If no external problems are found, the problem lies in the controller,
EVP4 (Q4) for moving the carriage forward. which must be replaced.

DRV. OPEN EVP5 (LEFT AUX VALVE) 197 • Check the continuity and connections between solenoid valve EVP5
(Q5) and pins XA5-15 and XA5-26.
Cause: • Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller of this section).
cannot enable the proportional solenoid valve • If no external problems are found, the problem lies in the controller,
EVP5 (Q5) for shifting the carriage to the left. which must be replaced.

DRV. OPEN EVP6 (RIGHT AUX VALVE) 198 • Check the continuity and connections between solenoid valve EVP6
(Q6) and pins XA5-15 and XA5-27.
Cause: • Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller of this section).
cannot enable the proportional solenoid valve • If no external problems are found, the problem lies in the controller,
EVP6 (Q6) for shifting the carriage to the right. which must be replaced.

OUT1/2 COIL SH.(LIFT/LOWER) 199

Cause: The most probable cause of this error code is a fault in the wiring or
This alarm occurs when there is a short circuit of in the load coil.
the coil of the proportional solenoid valve EVP1 • Check the connections between the outputs of the controller and
(Q1) or EVP2 (Q2). Once the overload condition the loads.
has been eliminated, the alarm disappears, • If no external problems are found, the problem lies in the control,
automatically releasing and subsequently re- which must be replaced.
enabling a drive request.

55
 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

OUT3/4 COIL SH. ( REV/FW TROLLEY) 200
Cause: The most probable cause of this error code is a fault in the wiring or
This alarm occurs when there is a short circuit of in the load coil.
the coil of the proportional solenoid valve EVP3 • Check the connections between the outputs of the controller and
(Q3) or EVP4 (Q4). Once the overload condition the loads.
has been eliminated, the alarm disappears, • If no external problems are found, the problem lies in the control,
automatically releasing and subsequently re- which must be replaced.
enabling a drive request.

OUT5/6 COIL SH. (LEFT/RIGHT AUX 201

VALVE)
The most probable cause of this error code is a fault in the wiring or
Cause: in the load coil.
This alarm occurs when there is a short circuit of • Check the connections between the outputs of the controller and
the coil of the proportional solenoid valve EVP5 the loads.
(Q5) or EVP6 (Q6). Once the overload condition • If no external problems are found, the problem lies in the control,
has been eliminated, the alarm disappears, which must be replaced.
automatically releasing and subsequently re-
enabling a drive request.

OUT7/8 COIL SH. (TILT/SIDESHIFT - 5° 202

WAY SELECT VALVE)
The most probable cause of this error code is a fault in the wiring or
Cause: in the load coil.
This alarm occurs when there is a short circuit of • Check the connections between the outputs of the controller and
the coil of the proportional solenoid valve EVP7 the loads.
(Q7) or EVP8 (Q8). Once the overload condition • If no external problems are found, the problem lies in the control,
has been eliminated, the alarm disappears, which must be replaced.
automatically releasing and subsequently re-
enabling a drive request.

LASER COIL SH. 203 The most likely cause of this error code is a fault in the wiring or leakage
to the truck chassis.
Cause: • Check the connections between the outputs of the controller and the
This alarm occurs when there is a short circuit or laser, physically disconnecting the laser from the truck chassis.
low impedance of the connection of the optional If no external problems are found, the problem lies in the controller,
laser (XB5-15). which must be replaced.

BLUE SPOT COIL SH 204 The most likely cause of this error code is a fault in the wiring or leakage
to the truck chassis.
Cause: • Check the connections between the outputs of the controller and the
This alarm occurs when there is a short circuit or blue spot, physically disconnecting the blue spot from the truck chassis.
low impedance at the connection of the optional If no external problems are found, the problem lies in the controller,
blue spot (XA5-6). which must be replaced.

LOAD BRK COIL SH 205 The most likely cause of this error code is a fault in the wiring or in the coil.
• Check the connections between the outputs of the controller and the
Cause:
loads (XB5-8 and XB5-23).
This alarm occurs when there is a short circuit of
If no external problems are found, the problem lies in the controller,
the coils of the load wheel brakes.
which must be replaced.

ALARM COIL SH. 206 The most likely cause of this error code is a fault in the wiring or leakage
to the truck chassis.
Cause: • Check the connections between the outputs of the controller and the
This alarm appears when there is a short circuit or truck in motion warning buzzer, physically disconnecting the buzzer
low impedance at the connection of the optional from the truck chassis.
truck in motion warning connected between pins If no external problems are found, the problem lies in the controller,
X5A-7 and X5A-17. which must be replaced.

56
SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

WATCH DOG MASTER 207
Cause:
This is an internal problem of the controller; switch the truck off using
In the controller there is a self-diagnosis circuit
the emergency button and then switch it back on again.
for synchronisation of the microcontrollers; if this
If the problem persists, replace the controller.
malfunctions, this alarm appears.

PEV DRV. OPEN 211

Cause:
• Switch the truck off using the emergency button and then switch it
This alarm appears when the VCM controller
back on again.
cannot enable the +48 V power supply.
• If the alarm persists, replace the controller.

PEV DRV. SHORT. 212

Cause:
• Check if there is a short circuit or low impedance between pin A13
This alarm when the driver of the +48V power
and +BATT, with the truck switched off.
of the proportional solenoid valves PEVP1 is
• The driver circuit is damaged; the controller must be replaced.
shorting to +Batt

VALVE MISM. OUT 213

Cause:
This alarm appears when there is a mismatch
This an internal fault; replace the controller.
between the valve output set points of the Master
and Slave microcontrollers.

DRV. OPEN BRAKE 214

Cause:
This alarm appears when the VCM controller Check the wiring and connections of the coils. If the problem persists,
is not bale to power the coil of the load wheel replace the controller.
brakes.

IN. MISM. D 218

Cause: • Switch the truck off using the emergency button and then switch it
This alarm appears when there is a mismatch back on again.
between the readings of the Master and Slave • If the alarm persists, replace the controller.
for the same digital input.

IN. MISM. A/E 219

Cause: • Switch the truck off using the emergency button and then switch it
This alarm appears when there is a mismatch back on again.
between the readings of the Master and Slave • If the alarm persists, replace the controller.
with regard to the same analog/encoder input.

DRV. OPEN EV1 220 • Check continuity and connections between pin XA5-6 and relay board
Cause: XA9C-8 and between relay board XA9C-4 and the Blue Spot;
This alarm appears when the VCM controller • Check relay K18 is functioning correctly.
cannot pilot the solenoid valve EV1 (BLUE SPOT If anomalies are not found, the problem could be in the controller, which
LIGHT). must be replaced.

DRV. OPEN EV2 (BACK UP ALARM) 221

Cause: • Check the continuity and connection of the Back-up alarm on pins
This alarm appears when the VCM controller XA5-7 and XA5-1.
cannot pilot the solenoid valve EV2. If no anomalies are found, the problem could be in the controller, which
must be replaced.

57
 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

DRV. OPEN EV3 (LASER) 222
Cause: • Check the continuity and connection of the Laser on pins XB5-15.
This alarm appears when the VCM controller If no anomalies are found, the problem could be in the controller, which
cannot pilot the solenoid valve EV3. must be replaced.

NO CAN MSG. TRACTION 223

Cause: • Check the connections on the driver controller.
This alarm appears when no CAN messages are • Check that the drive controller is communicating via the CAN Bus.
received from the drive controller.

NO CAN MSG. MASTER VCM 224

Cause: • It is internal problem in the controller; switch the truck off using the
This alarm appears when no CAN message is emergency button and then switch it back on again.
received from the VCM master microcontroller. • If the problem persists, replace the controller.

BMS TRUCK INHIBIT 226

Cause:
With the MIDAC lithium battery option Check the battery's state of charge and, if necessary, charge it. This
Cause: alarm is generated 15 seconds after activation of the WARNING
This alarm is used when LITHIUM batteries INHIBIT or following receipt of a drive/pump/steering request when the
are installed; it indicates that the battery has battery charging connector cap is open or the battery is connected to
detected an anomaly and consequently the the battery charger.
contactor must be opened to disconnect the
truck power.

DRV. OPEN EVP7 229 • Check the continuity and connections between solenoid valve EVP7
(TILT SIDE SHIFT SELECT VALVE) (Q7) and pins XA5-16 and XA5-4.
Cause: • Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller of this section).
cannot pilot the solenoid valve EVP7 (Q7). If no external problems are found, the problem lies in the controller,
which must be replaced.

DRV. OPEN EVP8 230 • Check the continuity and connections between solenoid valve EVP8
(5° WAY SELECT VALVE) (Q8) and pins XA5-16 and XA5-5.
Cause: • Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller of this section).
cannot pilot the solenoid valve EVP8 (Q8). If no external problems are found, the problem lies in the controller,
which must be replaced.

DRV. SHRT. EV1 235

The most likely cause of this error code is a fault in the wiring or leakage
Cause: to the truck chassis.
This alarm appears when the output driver of the • Check the connections between the outputs of the controller and the
solenoid valve EV1 is shorting. blue spot, physically disconnecting the blue spot from the truck chassis.
If no external problems are found, the problem lies in the controller,
which must be replaced.

DRV. SHRT. EV2 (BACK UP ALARM) 236 The most likely cause of this error code is a fault in the wiring or leakage
to the truck chassis.
Cause:
• Check the connections between the outputs of the controller and the
This alarm appears when the output driver of
truck in motion warning buzzer, physically disconnecting the buzzer
the solenoid valve EV2 (truck in motion buzzer)
from the truck chassis.
is shorting.
If no external problems are found, the problem lies in the controller,
which must be replaced.

DRV SHRT BRAKE 237 The most likely cause of this error code is a fault in the wiring or in the coil.
• Check the connections between the outputs of the controller and the
Cause:
loads (XB5-8 and XB5-23).
This alarm occurs when there is a short circuit of
If no external problems are found, the problem lies in the controller,
the coils of the load wheel brakes.
which must be replaced.

58
SERVICE DIAGNOSTICS AND MEASUREMENTS

Alarm Code MDI Troubleshooting

DRV SHRT EV3 (LASER). 238 The most likely cause of this error code is a fault in the wiring or leakage
to the truck chassis.
Cause: • Check the connections between the outputs of the controller and the
This alarm occurs when there is a short circuit or laser, physically disconnecting the laser from the truck chassis.
low impedance of the connection of the optional If no external problems are found, the problem lies in the controller,
laser (XB5-15). which must be replaced.

COIL OPEN EV1 239 • Check continuity and connections between pin XA5-6 and relay board
Cause: XA9C-8 and between relay board XA9C-4 and the Blue Spot;
This alarm appears when the VCM controller • Check relay K18 is functioning correctly.
cannot pilot the solenoid valve EV1 (BLUE SPOT If anomalies are not found, the problem could be in the controller, which
LIGHT). must be replaced.

COIL OPEN EV2 (BACK UP ALARM) 240

• Check the continuity and connection of the Back-up alarm on pins
Cause:
XA5-7 and XA5-1.
This alarm appears when the VCM controller
If no anomalies are found, the problem could be in the controller, which
cannot pilot the solenoid valve EV2.
must be replaced.

COIL OPEN BRAKE 241

Cause:
This alarm appears when the VCM controller Check the wiring and connections of the coils. If the problem persists,
is not bale to power the coil of the load wheel replace the controller.
brakes.

COIL OPEN EV3 (LASER) 242

Cause: • Check the continuity and connection of the Laser on pins XB5-15.
This alarm appears when the VCM controller If no anomalies are found, the problem could be in the controller, which
cannot pilot the solenoid valve EV3. must be replaced.

CAN BUS KO BMS 243

Cause:
This alarm is generated if the parameter
After 15 seconds, drive and pump motors are stopped.
HYG LI-IONBATT is set to ON, but no
communication is received from the BMS

COIL OPEN EVP1 (LOWER) 244

• Check the continuity and connections between solenoid valve EVP1
Cause: (Q1) and pins XA5-13 and XA5-24.
This alarm appears when the VCM controller • Check the ohmic value of the solenoid valve coil (see table at the end
cannot enable the proportional solenoid valve of this section).
EVP1 (Q1) for raising the forks. If no external problems are found, the problem lies in the controller,
which must be replaced.

COIL OPEN EVP2 (LIFT) 245 • Check the continuity and connections between solenoid valve EVP2
(Q2) and pins XA5-13 and XA5-25.
Cause:
• Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller
of this section).
cannot enable the proportional solenoid valve
If no external problems are found, the problem lies in the controller,
EVP2 (Q2) for raising the forks.
which must be replaced.

COIL OPEN EVP3 246

• Check the continuity and connections between solenoid valve EVP3
(REVERSE TROLLEY) (Q3) and pins XA5-14 and XA5-2.
Cause: • Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller of this section).
cannot enable the proportional solenoid valve If no external problems are found, the problem lies in the controller,
EVP3 (Q3) for moving the carriage back. which must be replaced.

59
 DIAGNOSTICS AND MEASUREMENTS SERVICE

Alarm Code MDI Troubleshooting

COIL OPEN EVP4 247
• Check the continuity and connections between solenoid valve EVP4
(FORWARD TROLLEY) (Q4) and pins XA5-14 and XA5-3.
Cause: • Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller of this section).
cannot enable the proportional solenoid valve • If no external problems are found, the problem lies in the controller,
EVP4 (Q4) for moving the carriage forward. which must be replaced.

COIL OPEN EVP5 (LEFT AUX VALVE) 248

• Check the continuity and connections between solenoid valve EVP5
Cause: (Q5) and pins XA5-15 and XA5-26.
This alarm appears when the VCM controller • Check the ohmic value of the solenoid valve coil (see table at the end
cannot enable the proportional solenoid valve of this section).
EVP5 (Q5) for shifting the carriage to the left. • If no external problems are found, the problem lies in the controller,
which must be replaced.

COIL OPEN EVP6 (RIGHT AUX VALVE) 249

• Check the continuity and connections between solenoid valve EVP6
Cause: (Q6) and pins XA5-15 and XA5-27.
This alarm appears when the VCM controller • Check the ohmic value of the solenoid valve coil (see table at the end
cannot enable the proportional solenoid valve of this section).
EVP6 (Q6) for shifting the carriage to the right. If no external problems are found, the problem lies in the controller,
which must be replaced.

COIL OPEN EVP7 250

(TILT/SIDE SHIFT SELECT VALVE) • Check the continuity and connections between solenoid valve EVP7
(Q7) and pins XA5-16 and XA5-4.
Cause:
• Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller
of this section).
cannot pilot the solenoid valve EVP7 (Q7).
If no external problems are found, the problem lies in the controller,
which must be replaced.

COIL OPEN EVP8 251

(5° WAY SELECT VALVE) • Check the continuity and connections between solenoid valve EVP8
(Q8) and pins XA5-16 and XA5-5.
Cause:
• Check the ohmic value of the solenoid valve coil (see table at the end
This alarm appears when the VCM controller
of this section).
cannot pilot the solenoid valve EVP8 (Q8).
If no external problems are found, the problem lies in the controller,
which must be replaced.

BMS MISMATCH 252

With the Midac lithium battery option
Cause:
Enable the parameter HYG LI-ION BATT
This alarm is generated if the parameter HYG LI-ION
BATT is set to OFF, but messages are received
from the BMS

BMS SHUTDOWN 253

With the Midac lithium battery option
Cause:
Check the charge level and the CAN connection to the battery.
The BMS disables the battery's internal
contactor.

WARNING INHIBIT 254

With the Midac lithium battery option • Recharge the battery.
Cause: • Close the charging connector cap of the battery.
Battery charge level (SOC)<= 0 %. Charging If the alarm persists without any apparent reason, the cause could be
connector cap open. a problem in the internal circuit of the lithium battery.

60
SERVICE DIAGNOSTICS AND MEASUREMENTS

DISPLAY WARNINGS
The following error messages may appear on the display:

Indication Troubleshooting
INC. START TRACTION
Cause:
Carry out the correct sequence to start drive.
This message appears when the drive start sequence
is performed incorrectly.

INC. START LIFT

Cause:
Carry out the correct sequence to start lifting.
This message appears when the lifting start sequence
is performed incorrectly.

INC. START LOW

Cause:
Carry out the correct sequence to start lowering.
This message appears when the lowering start
sequence is performed incorrectly.

INC. START TILT UP

Cause:
Carry out the correct sequence to start upward tilt.
This message appears when the upward tilt start
sequence is performed incorrectly.

INC. START TILT DOWN

Cause:
Carry out the correct sequence to start downward tilt.
This message appears when the downward tilt start
sequence is performed incorrectly.

INC. START REACH IN

Cause:
Carry out the correct sequence to start carriage return.
This message appears when the carriage return start
sequence is performed incorrectly.

INC. START REACH OUT

Cause:
Carry out the correct sequence to start carriage extension.
This message appears when the carriage extension
start sequence is performed incorrectly.

INC. START SHIFT RIGHT

Cause:
Carry out the correct sequence to start fork side shift to the right.
This message appears when the fork right shift start
sequence is performed incorrectly.

INC. START SHIFT LEFT

Cause:
Carry out the correct sequence to start fork side shift to the left.
This message appears when the fork left shift start
sequence is performed incorrectly.

INC. START 5TH WAY IN

Cause:
Carry out the correct sequence to start the 5th function IN.
This message appears when the 5th function IN start
sequence is performed incorrectly.

61
 DIAGNOSTICS AND MEASUREMENTS SERVICE

Indication Troubleshooting
INC. START 5TH WAY OUT
Cause:
Carry out the correct sequence to start the 5th function OUT.
This message appears when the 5th function OUT
start sequence is performed incorrectly.

GET HOME Turn the truck off using the emergency button and then restart it; if the alarm persists,
connect the diagnostic instrument and check whether the alarm is active on each controller.
Cause: It is also possible to scroll through the alarms log on the display.
This message generally appears in the presence of In case of doubt, consider:
an alarm and allows the truck to continue operating • deleting the alarms log
but with reduced performance. • continue using the lift truck as long GET HOME mode is activated
• check the fault recorded in the alarms log and proceed accordingly following the
indications in the troubleshooting guide provided in the previous pages.

SEAT SWITCH
Cause:
Check that the seat microswitch is connected and functioning correctly.
This message appears when the operator is seated
correctly or the position sensor is faulty.

62
 SERVICE DIAGNOSTICS AND MEASUREMENTS

ELECTRICAL COMPONENT MEASUREMENTS

SOLENOID VALVE COILS

MAIN HYDRAULIC UNIT

Q1

Q5

Q3

Q2

Q6

Q4

FORK CARRIAGE HYDRAULIC UNIT

Q8

Solenoid valve Value measured (Ohm)

Q7
Q1 24.6
Q2 24.6
Q3 24.6
Q4 24.6
Q5 24.6
Q6 24.6
Q7 22
Q8 (optional) 22

63
 DIAGNOSTICS AND MEASUREMENTS SERVICE

ELECTROMAGNETIC BRAKE COILS

Coil Value measured (Ohm)

Drive motor brake 15

Load wheel
24
brakes

MOTORS
To measure the motor insulation resistance, disconnect the phase wires (U, V, W). Connect one of the
tester probes to the U phase and the other probe to the bodywork in an unpainted zone. The resistance
reading ( W) on the tester should be infinity (~). Otherwise, the motor is not insulated and must be replaced
immediately.
Repeat the operation with the other two phases (V, W).

64
 SERVICE ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
WIRING DIAGRAMS...................................................................................................................................................4
CONTROLS.................................................................................................................................................................33
KEY TO MAIN PANEL, ARMREST AND PEDAL UNIT CONTROLS......................................33
STANDARD DISPLAY.......................................................................................................................................35
KEYPAD AND SYMBOLS DISPLAYED.............................................................................................................................35
DISPLAY BRIGHTNESS CONTROL.....................................................................................................................36
SOFTWARE.................................................................................................................................................................36
ICONS ASSOCIATED WITH THE GRAPHIC SCREENS..................................................................................36
FUNCTIONAL GRAPHIC SCREENS.........................................................................................................41
DESCRIPTION OF OPTIONAL GRAPHIC SCREENS........................................................................55
DESCRIPTION OF THE MENU SCREENS...................................................................................65
MAIN MENU 1..............................................................................................................................................65
MAIN MENU 1 / TESTER..........................................................................................................................65
MAIN MENU 1 / CLOCK SETTING.......................................................................................67
MAIN MENU 1 / SOFTWARE VERSION..................................................................................................67
MAIN MENU 1 / ALARMS....................................................................................................................68
MAIN MENU 1 / PARAMETER SETTINGS.......................................................................................69
MAIN MENU 2..................................................................................................................................................71
MAIN MENU 2 \ CANCELLING ALARMS...........................................................................................72
MAIN MENU 2 \ MEASUREMENT SYSTEM.............................................................................................72
MAIN MENU 2 \ FORKS SETUP..............................................................................................................73
MAIN MENU 2 \ PARAMETER ACQUISITION..............................................................................74
MAIN MENU 2 \ PROGRAMMING THE ACCESS CODE COMBINED WITH OPERATOR CODE READING.......74
MAIN MENU 2 \ READ USER CODE............................................................................................................77
MAIN MENU 2 \ CLEAR ACCESS CODE............................................................................................................77
PREMIUM DISPLAY............................................................................................................................78
SOFTWARE............................................................................................................................................................79
ICONS ASSOCIATED WITH THE GRAPHIC SCREENS......................................................................79
FUNCTIONAL GRAPHIC SCREENS.....................................................................................................85
OPTIONAL GRAPHIC SCREENS.............................................................................................99
HEIGHT PRE-SELECTOR........................................................................................................................115
DESCRIPTION OF THE MENU SCREENS................................................................................124
D I S P L AY S O F T WA R E U P D AT E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 1
TRUCK FUNCTIONS...........................................................................................................153

1
 ELECTRICAL SYSTEM SERVICE

FORWARD/REVERSE DRIVE.....................................................................................................................................153
SPEED REDUCTIONS..............................................................................................................155
BRAKING..........................................................................................................................................158
STEERING............................................................................................................................159
STEER WHEEL................................................................................................................................................161
FORK LIFTING/LOWERING.................................................................................................162
ACCELERATION / DECELERATION RAMPS................................................................................164
L I F T I N G / L O W E R I N G T R AV E L L I M I T D E C E L E R AT I O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 4
FORK LIFTING/LOWERING INTERLOCKS (WITH FORK HEIGHT ENCODER)......................................165
HYDRAULIC FUNCTIONS..................................................................................................................166
RETRACTABLE CARRIAGE ACCELERATION / DECELERATION RAMPS..............................................167
CARRIAGE FORWARD/BACK TRAVEL LIMIT DECELERATION................................................................168
AUXILIARY FUNCTION ACCELERATION / DECELERATION RAMPS..........................................168
FORK AUTO CENTERING..........................................................................................................168
FORK TILT AUTO CENTERING SYSTEM..............................................................................................169
C O N F I G U R AT I O N PA R A M E T E R A C C E S S P R O C E D U R E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 0
MENU SEARCH PROCEDURE AND PARAMETER MODIFICATION.........................................................................170
GUIDE TO INSTALLATION OF CAN PC CONSOLE ON PCST................................................................175
CDF FILE LOADING PROCEDURE.................................................................................................181
CONFIGURATION OF STANDARD CONTROLLER PARAMETERS...............................................................183
VCM CONTROLLER.......................................................................................................................................183
ACE2 DRIVE CONTROLLER............................................................................................................186
ACE2 PUMP CONTROLLER............................................................................................................................186
EPS ACW CONTROLLER.............................................................................................................................187
DESCRIPTION OF CONTROLLER PARAMETERS.........................................................................................188
VCM CONTROLLER..........................................................................................................................................188
ACE2 DRIVE CONTROLLER........................................................................................................................199
ACE2 PUMP CONTROLLER....................................................................................................................201
EPS ACW CONTROLLER................................................................................................................................201
CONTROLLERS: INTRODUCTION....................................................................................................................203
POSITIONS OF THE PC TOOL CONNECTORS........................................................................203
ACE2 INVERTER CONTROLLER....................................................................................................204
EPS ACW CONTROLLER...........................................................................................................................205
VCM CONTROLLER.........................................................................................................................206
CONTROLLER REPLACEMENT: INSTRUCTIONS..............................................................................................207
REPLACEMENT OF THE ACE2 INVERTER CONTROLLER....................................................................................207
REPLACEMENT OF THE EPS ACW CONTROLLER............................................................................................209
REPLACEMENT OF THE VCM CONTROLLER......................................................................................211
REMOVAL OF ELECTRICAL COMPONENTS......................................................................................................213
REPLACMENT OF THE ENCODER............................................................................................................................213
REPLACEMENT OF THE ENCODER RESET SENSOR..............................................................................................215

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 SERVICE ELECTRICAL SYSTEM

REPLACEMENT OF THE LOAD CELL .................................................................................................................216

REPLACEMENT OF THE HORN.......................................................................................................217
REPLACMENT OF THE CONTACTORS.........................................................................................................218
FUSE REPLACEMENT..............................................................................................................................219
REPLACEMENT OF THE MOTOR COMPARTMENT COOLING FAN............................................................221
REPLACEMENT OF THE MAIN PANEL AND ARMREST CONTROLS ...................................................................223
REPLACEMENT OF THE SIDE SHIFT POSITION SENSOR.......................................................................................230
REPLACEMENT OF THE PALLET PRESENCE SENSOR.....................................................................................231
REPLACEMENT OF THE TILT POSITION SENSOR..................................................................................232
REPLACEMENT OF THE INCLINOMETER...........................................................................................................233
REPLACEMENT OF THE STEER WHEEL AND 90° WHEEL POSITION SENSOR...................................................234
REPLACMENT OF THE BATTERY OUT SENSOR..................................................................................................235
REPLACEMENT OF THE OPERATOR PRESENCE PEDAL.......................................................................................236
REPLACEMENT OF THE ACCELERATOR AND BRAKE PEDALS..................................................................237

3
 ELECTRICAL SYSTEM SERVICE

WIRING DIAGRAMS
COMPONENTS
Ref. Description Ref. Description
A1 Standard display K8 Work light relay
A2 Drive controller K9 Diode (1A)
A3 Pump controller K10 Diode (1A)
A4 Steering controller K11 Diode (1A)
A5 Master card controller K12 Diode (1A)
A6 Mast connector card K13 Diode (1A)
A7 Multi-lever board K14 Diode (1A)
A8 PREMIUM DISPLAY K15 Diode (1A)
A9 Relay-fuse board K16 Truck lights relay
A10 Multi-function joystick board K17 Diode (1A)
A11 Cab heater control K18 Blue light point relay
A12 Multi-function joystick K19 Diode (1A)
A101 Telemetry Module K60 Buzzer (Telemetry system)
A110 Antenna M Motor assembly
A120 Card Reader M1 Drive motor
A130 Display (Telemetry system) M2 Pump motor
B1 Drive motor encoder M3 Steering motor
B2 Traction motor heat sensor M4 Stepper motor
B3 Pump motor encoder P1 Horn
B4 Pump motor heat sensor P2 Flashing light
B5 Steering motor encoder P5 Fan
B6 Steer motor heat sensor P6 Fan
B7 Centred wheel sensor P7 Reversing buzzer
B8 90° steered wheel sensor P8 Work light
B9 Battery out sensor P9 Work light
B11 Mast lifting encoder P10 Work light
B12 Side shift position sensor P11 Truck light
B13 Pallet presence sensor P12 Truck light
B14 Encoder reset/speed reduction sensor P13 Blue/red light point
B15 Free lift encoder P14 Blue/red light point
B16 Temperature sensor P15 Blue/red light point
C1 Battery P16 Red light line
C2 Electrolyte capacitor 100 μF 50V P17 Red light line
Fuse for emergency push-button and contactors P18 Fan
F1
(10A) P60 Relè (Telemetry system)
F2 Contactor fuse (10A) Q1 Lowering proportional solenoid valve
F3 Key relay fuse (2A) Q2 Lifting proportional solenoid valve
F4 Drive power fuse Q3 Carriage back proportional solenoid valve
F5 Pump power fuse Q4 Carriage forward proportional solenoid valve
F6 Steering power fuse Downward tilt/left side shift proportional solenoid val-
Q5
K1 Drive contactor coil ve
K2 Pump contactor coil Q6 Upward tilt/right side shift proportional solenoid valve
K3 Key relay Q7 Tilt-shift diverter solenoid valve
K4 Horn relay Q8 Auxiliary functions solenoid diverter valve
K5 Auxiliary relay
K6 Auxiliary relay +5/+12V
K7 Work lights relay

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SERVICE ELECTRICAL SYSTEM

Ref. Description
R1 Varistor
R2 Electromagnetic brake
R3 Accelerator pedal sensor
R4 Brake pedal sensor
R5 Carriage position potentiometer
R6 Tilt position inclinometer
R8 Right load wheel electromagnetic brake
R9 Left load wheel electromagnetic brake
R10 Load cell
R11 Laser
S1 Key switch
S2 Emergency button
S3 Operator presence switch
S4 Drive direction switch
S5 Seat belt microswitch
S6 Work lights switch
S7 Steering mode 180°/360°
S8 Drive speed reduction
S9 Weighing device button
S10 Lift by-pass button
S12 Lifting-lowering potentiometer lever
S13 Carriage forward-back potentiometer lever
S14 Tilt potentiometer lever
S15 Side shift potentiometer lever
S16 Tilt automatic centering button
S17 Side shift automatic centering button
S18 Hydraulic 5th way button
S19 Horn button
S20 Drive direction switch
S21 Work light switch
S22 Seat microswitch (optional)
S23 Truck lights switch
T1 DC/DC 48V/24V converter
T2 DC/DC 48V/12V converter

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NOTE 5: This connection is only used on RT with 350Ah / 350Ah drive

pump controller

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

NOTE 3: Standard for HD versions, optional for other versions

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

NOTE 4: If B15 is not installed, use B14 for drive speed reduction and
Free Lift/Main Lift for lifting

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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NOTE 1: Connected only in multilever versions

NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

NOTE 4: If B15 is not installed, use B14 for drive speed reduction and
Free Lift/Main Lift for lifting

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

NOTE 5: If B15 is not installed, use B21 as descent forks interlock

sensor

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APPLICATIVE DIAGRAM FOR TELEMETRY SYSTEM

ACCESS LEVEL 1 (OPT.)

NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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NOTE 1: mmq means mm2

NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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APPLICATIVE DIAGRAM FOR MY2021 VAM TELEMETRY SYSTEM

ACCESS LEVEL 1 (OPT.)

NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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APPLICATIVE DIAGRAM FOR MY2021 VAM TELEMETRY SYSTEM

ACCESS LEVEL 2 (OPT.)

NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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APPLICATIVE DIAGRAM FOR MY2021 VAM TELEMETRY SYSTEM

ACCESS LEVEL 3 (OPT.)

NOTE 2: As a reference, use the colour of the single wire (or the number
printed on it, if the wire is black)

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WIRING DIAGRAMS FOR COLD STORE CABS

 ELECTRICAL SYSTEM SERVICE

Two heaters have been added for use in cold stores. Their function is to prevent the tem-
perature inside the motors compartment from falling below 0°C. The control panel heater
under the footplate is equipped with a cover that protects the electrical components from
condensation.

Ref. Description

1 Temperature sensor
2 Heater assembly with fan
3 Fan
4 Heater Assembly
5 Temperature sensor

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SERVICE ELECTRICAL SYSTEM

CONTROLS
KEY TO MAIN PANEL CONTROLS, ARMREST AND PEDAL UNIT

4
5
6 9

7
10

11

1
12

13 13

14

18 17
23 15
14
22

21 15
24 18
20
17
16 16
19

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 ELECTRICAL SYSTEM SERVICE

27
25 26

Ref. Description Wiring diagram ref.

1 Key switch S1
2 Steering wheel -
3 Standard or premium display A1 - A8
4 Speed limitation button S8
5 Weighing button S9
6 180°/360° steering mode selector switch S7
7 Auxiliary function button
8 Auxiliary function button
9 Work lights switch S6
10 Work lights switch S21
11 Auxiliary function switch
12 Diagnostic connector access cover
13 Emergency button S2
14 Horn button S19
15 Drive direction switch S4
16 Tilt automatic centering button S16
17 Side shift automatic centering button S17
18 Hydraulic 5th way button S18
19 Fork lifting/lowering mini-lever S12
20 Carriage forward/back mini-lever S13
21 Fork up/down tilt mini-lever S14
22 Fork right/left side shift mini-lever S15
23 Joystick A12
24 Fork tilt/side shift lever S14 / S15
25 Operator presence pedal S3
26 Brake pedal R4
27 Accelerator pedal R3

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SERVICE ELECTRICAL SYSTEM

STANDARD DISPLAY
KEYPAD AND SYMBOLS DISPLAYED

1 1
5 6

3 2

Ref. Description

1 Numerical keys from 0 to 9

2 Forward or upward scroll key
3 Backward or downward scroll key
4 Ignition switch with or without key
5 OUT function key
6 ENTER function key

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 ELECTRICAL SYSTEM SERVICE

DISPLAY BRIGHTNESS CONTROL

a) Press 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 VCM identification controller that will respond
with another “SDO” for confirmation. When the key switch is turned off the display must warn the VCM
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%
4 segments = from 75% to 50%
3 segments = from 49% to 35%
2 segments = from 34% to 21%
1 segment = from 20% to 0
Segments 5, 4, 3 indicated with a fixed light.
Segments 2 and 1 are flashing.
To ensure correct operation of the battery discharge
indicator, before recharging, discharge the battery by at
least 40%. Do not attempt to charge it if the segments 4
and 5 are lit.

Parking brake indicator.

Indicates that the parking brake has been applied.

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SERVICE ELECTRICAL SYSTEM

ICON DESCRIPTION

Remaining battery life indicator.

Indicates the hour and minutes of remaining battery life.

24:00 Daily clock, indicates the hours and minutes.

Indicates the hours and minutes.
Worked hours indicator.
0001 h Counts the hours of truck driving and of operating the
hydraulic functions.

10.50 km/h Drive speed indicator (expressed in Km/h or Mph).

Indicates the speed, in both forward and reverse drive.

Forks height indicator

10.50 m Indicates the height of the forks above ground level.
Weighing Indicator.
Indicates the weight of the load. During the load
0150 kg weighing operation with drive engaged, the weight
should be displayed for 5 seconds after which the
travel speed reappears.
Speed limitation function indicator.
Indicates that the speed limitation function is activated
(slow speed).
Maximum speed indicator.
Indicates that the maximum drive speed function is acti-
vated.

Seat belt indicator.

Indicates that the seat belt is not fastened.

Energy saving mode indicator.

This icon appears when the ENERGY SAVING function is
activated, by switching it ON.
Signalling indicator light.
This icon is displayed together with an indication
if the operator performs an incorrect control sequence.
Hour meter.
This icon is displayed together with an indication
of the worked hours.

Fork lifting function indicator.

This icon appears when the fork lifting function is activated.

Fork lowering function indicator.

This icon appears when the fork lowering function is ac-
tivated.

Retractable fork support plate extension indicator.

This icon appears when the fork
retractable carriage back function is activated.

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 ELECTRICAL SYSTEM SERVICE

ICON DESCRIPTION

Retractable fork support plate extension indicator.

This icon appears when the fork
retractable carriage back function is activated.

Lifting travel limit indicator

This icon is displayed on reaching the lifting
limit.

Upward tilt function indicator.

This icon appears when the fork upward tilt or inclination
function is activated.

Downward tilt function indicator.

This icon appears when the fork downward tilt or inclination
function is activated.

Fork side shift to right function indicator.

This icon appears when the fork side shift to right function
is activated.

Fork side shift to left function indicator.

This icon appears when the fork side shift to left function
is activated.

Fork side shift auto centering indicator

This icon appears when the fork
side shift automatic centering function is activated.
When the centering function is in operation, the icon flashes
to show the side shift movement (right side shift/left side
shift). If auto centering is requested when the forks are
already in the correct position, the icon is illuminated with
a steady light.
Fork tilt auto levelling indicator
This icon appears when automatic fork levelling at 0° tilt
is activated.
When the centering function is in operation, the icon flashes
to show the tilt movement (tilt up/down). If auto centering is
requested when the forks are already in the correct position,
the icon is illuminated with a steady light.

5th hydraulic function indicator

This icon appears when the 5th hydraulic function
is activated.

5th hydraulic function inlet and outlet indicator

This icon appears with the 5th hydraulic function is
activated in the two operating modes.

Fork lowering interlock indicator

This icon appears when the interlock is tripped during fork
lowering.

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SERVICE ELECTRICAL SYSTEM

ICON DESCRIPTION

Fork carriage back interlock

This icon appears when a request to recall the fork carriage
is made when the interlock is activated.

Battery out-of-place indicator.

This icon, combined with error code 206-01, appears when
the battery is not properly secured in its seat.

Alarm indicator.
This icon is displayed in the event of a malfunction of
the physical components or the software of the electrical
system and is associated with a numeric code that identifies
the type of alarm and the control or function affected.
249 = example numeric code indicating the alarm type.
6 = example of identification number indicating the control
or function concerned.
Password prompt indicator.
This icon appears if a password is required for access.

Incorrect password indicator

This icon appears if an incorrect access password is
entered.

Steering wheel 360° indicator

This icon is always displayed when the steering wheel 360°
setting position is selected.

Steering wheel 360° setting indicator with forward drive

engagement signal.
This icon, displayed together with the drive direction
indicator arrow, appears after the forward drive has been
selected and remains displayed the entire time the function
is active. The direction indication follows the position of the
steering wheel.
Steering wheel 360° setting indicator with reverse drive
engagement signal.
This icon, displayed together with the drive direction
indicator arrow, appears after the reverse drive has been
selected and remains displayed the entire time the function
is active. The direction indication follows the position of the
steering wheel.
Steering wheel 180° indicator.
This icon is always displayed when the steering wheel 180°
setting position is selected.

39
 ELECTRICAL SYSTEM SERVICE

ICON DESCRIPTION

Steer wheel 180° setting indicator with forward drive

engagement signal.
This icon, displayed together with the drive direction
indicator arrow, appears after the forward drive has been
selected and remains displayed the entire time the function
is active. The direction indication follows the position of the
steering wheel.

Steer wheel 180° setting indicator with reverse drive

engagement signal.
This icon, displayed together with the drive direction
indicator arrow, appears after the reverse drive has been
selected and remains displayed the entire time the function
is active. The direction indication follows the position of the
steering wheel.

40
 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
• Drive performance indicator (tortoise or hare)
• Steer 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°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Reverse drive indicator following the steer wheel position indicator
• Speed indicator, expressed in km/h or mph

41
 ELECTRICAL SYSTEM SERVICE

SCREEN DISPLAYED WITH FORWARD DRIVE SELECTED

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator following the steering wheel position indicator
• Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH REVERSE DRIVE SELECTED

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Reverse drive indicator following the steer wheel position indicator
• Speed indicator, expressed in km/h or mph

42
 SERVICE ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH FORK LIFTING ON AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Fork lifting indicator
• Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH FORK LOWERING ON AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Fork lowering indicator
• Speed indicator, expressed in km/h or mph

43
 ELECTRICAL SYSTEM SERVICE

SCREEN DISPLAYED WITH CARRIAGE FORWARD ACTIVATED AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Carriage forward indicator
• Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH CARRIAGE BACK ACTIVATED AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Carriage return indicator
• Speed indicator, expressed in km/h or mph

44
 SERVICE ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH FORK TILT UP ACTIVATED AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Fork tilt up indicator
• Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH FORK TILT DOWN ACTIVATED AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Fork tilt down indicator
• Speed indicator, expressed in km/h or mph

45
 ELECTRICAL SYSTEM SERVICE

SCREEN DISPLAYED WITH FORK RIGHT SIDE SHIFT ACTIVATED AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Fork side shift to right indicator
• Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH FORK LEFT SIDE SHIFT ACTIVATED AND DRIVE OFF.

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Fork side shift to left indicator
• Speed indicator, expressed in km/h or mph

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 SERVICE ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH BATTERY OUT-OF-PLACE

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• 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°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Carriage forward indicator
• Battery out-of-place indicator
• Fork lifting block indicator
• 206-01 alarm indicator (Battery out)

47
 ELECTRICAL SYSTEM SERVICE

SCREEN DISPLAYED WITH BATTERY RETURN INTO PLACE ON AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Carriage return indicator
• Battery out-of-place indicator
• Fork lifting block indicator
• 206-01 alarm indicator (Battery out)

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 SERVICE ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Fork lifting indicator
• Carriage return indicator
• Speed indicator, expressed in km/h or mph

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
Fork Lowering carriage out tilt up
Fork Lowering carriage out tilt down
Fork Lowering carriage out right side shift
Fork Lowering carriage out left side shift
Fork Lowering carriage return tilt up
Fork Lowering carriage return tilt down
Fork Lowering carriage return right side shift
Fork Lowering carriage return left side shift

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 ELECTRICAL SYSTEM SERVICE

SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator
• Fork lifting indicator
• Carriage forward indicator
• Speed indicator, expressed in km/h or mph

The screen shown above is an example of combined hydraulic functions with the drive on.

Possible combinations

Forks up carriage out tilt up for forward/reverse drive

Forks up carriage out tilt down for forward/reverse drive
Forks up carriage out right side shift for forward/reverse drive
Forks up carriage out left side shift for forward/reverse drive
Forks up carriage return tilt up for forward/reverse drive
Forks up carriage return tilt down for forward/reverse drive
Forks up carriage return right side shift for forward/reverse drive
Forks up carriage return left side shift for forward/reverse drive
Fork Lowering carriage out tilt up for forward/reverse drive
Fork Lowering carriage out tilt down for forward/reverse drive
Fork Lowering carriage out right side shift for forward/reverse drive
Fork Lowering carriage out left side shift for forward/reverse drive
Fork Lowering carriage return tilt up for forward/reverse drive
Fork Lowering carriage return tilt down for forward/reverse drive
Fork Lowering carriage return right side shift for forward/reverse drive
Fork Lowering carriage return left side shift for forward/reverse drive

50
SERVICE ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION ON

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Energy Saving indicator
• Steer wheel position indicator
• Parking brake indicator
• Speed indicator, expressed in km/h or mph
If ON, this function limits the truck's drive and lifting performance to save battery charge.
This function will be indicated by the “ECO” icon. To set this parameter to ON, see the
paragraph MAIN MENU 1/ PARAMETER SETTINGS in this section.

SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION, DRIVE AND HYDRAULICS ON

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Energy Saving indicator
• Steer wheel position indicator
• Forward drive indicator
• Fork lifting indicator
• Speed indicator, expressed in km/h or mph

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 ELECTRICAL SYSTEM SERVICE

SCREEN DISPLAYED WITH WARNING SIGNALLING

This screen is displayed after an incorrect sequence performed by the operator.

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Warning indicator
• Indication of the problem

The incorrect sequences are:

• INC. START TRACTION (Incorrect start of traction)

• INC. START LIFT (Incorrect start of lifting)
• INC. START LOW (Incorrect start of lowering)
• INC. START TILT UP (Incorrect start of upward tilt)
• INC. START TILT DOWN (Incorrect start of downward tilt)
• INC. START REACH IN (Incorrect start of retractable carriage return
• INC. START REACH OUT (Incorrect start of retractable carriage extension)
• INC. START SHIFT RIGHT (Incorrect start of fork side shift to right)
• INC. START SHIFT LEFT (Incorrect start of fork side shift to left)
• INC. START 5 VIA IN (Incorrect start 5th function inlet)
• INC. START 5 VIA OUT (Incorrect start 5th function outlet)
• GET HOME
• RESET ENCODER
• BATTERY LOW (Low battery charge level)
• OVERLOAD (Load lifted exceeds rated capacity)
• CHECK UP (Scheduled maintenance required)
• SEAT SWITCH (Incorrect position on seat or position sensor faulty)

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SCREEN DISPLAYED WITH ALARM SIGNALLING.

STEERING 360° STEERING 180°

GET HOME GET HOME

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Alarm indicator
• GET HOME indicator

SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE OFF.

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Lifting travel limit indicator
• Speed indicator, expressed in km/h or mph

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SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE ON.

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator
• Lifting travel limit indicator
• Speed indicator, expressed in km/h or mph

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DESCRIPTION OF THE OPTIONAL GRAPHIC SCREENS

The graphic screens for each single optional function are shown below in sequence.

OPERATOR SEAT BELT OPTIONAL SCREEN.

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Seat belt not fastened indicator
• Speed indicator, expressed in km/h or mph
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 AUTO CENTERING OPTIONAL SCREEN WITH DRIVE OFF.

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Fork tilt auto centering indicator
• Speed indicator, expressed in km/h or mph
When the centering function is in operation, the icon flashes to show the fork tilt move-
ment (tilt up/down). If there is a request for auto centering and the forks are already in the
correct position the icon is steadily illuminated.
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FORK TILT AUTO CENTERING OPTIONAL SCREEN WITH DRIVE ON.

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator
• Fork tilt auto centering indicator
• Speed indicator, expressed in km/h or mph

When the centering function is in operation, the icon flashes to show the fork tilt movement
(tilt up/down). If there is a request for auto centering and the forks are already in the correct
position the icon is steadily illuminated.

FORK SIDE SHIFT AUTO CENTERING OPTIONAL SCREEN WITH DRIVE OFF.

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Fork side shift auto centering indicator
• Speed indicator, expressed in km/h or mph

When the centering function is in operation, the icon flashes to show the side shift
movement (right side shift/left side shift). If there is a request for auto centering and the
forks are already in the correct position the icon is steadily illuminated.

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FORK SIDE SHIFT AUTO CENTERING OPTIONAL SCREEN WITH DRIVE ON.

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator
• Fork side shift auto centering indicator
• Speed indicator, expressed in km/h or mph

When the centering function is in operation, the icon flashes to show the side shift movement
(right side shift/left side shift). If there is a request for auto centering and the forks are already in
the correct position the icon is steadily illuminated.

OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Hydraulic 5th way indicator
• Speed indicator, expressed in km/h or mph

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OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE ON

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator
• Hydraulic 5th way indicator
• Speed indicator, expressed in km/h or mph

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SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Parking brake indicator
• Fork lifting indicator
• Carriage forward indicator
• Tilt auto centering indicator
• Speed indicator, expressed in km/h or mph

The screen shown above is an example of combined hydraulic functions with the drive off.

Possible combinations

Forks up carriage out tilt auto centering

Forks up carriage out side shift auto centering
Forks up carriage return tilt auto centering
Forks up carriage return side shift auto centering
Fork Lowering carriage out tilt auto centering
Fork Lowering carriage out side shift auto centering
Fork Lowering carriage return tilt auto centering
Fork Lowering carriage return side shift auto centering

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OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator
• Fork lifting indicator
• Carriage forward indicator
• Tilt auto centering indicator
• Speed indicator, expressed in km/h or mph

The screen shown above is an example of combined hydraulic functions with the drive on.

Possible combinations

Forks up carriage out tilt auto centering for forward/reverse drive

Forks up carriage out side shift auto centering for forward/reverse drive
Forks up carriage return tilt auto centering for forward/reverse drive
Forks up carriage return side shift auto centering for forward/reverse drive
Fork Lowering carriage out tilt auto centering for forward/reverse drive
Fork Lowering carriage out side shift auto centering for forward/reverse drive
Fork Lowering carriage return tilt auto centering for forward/reverse drive
Fork Lowering carriage return side shift auto centering for forward/reverse drive

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OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Fork lifting/lowering indicator
• Fork height display measured in metres or feet

OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE ON

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator
• Fork lifting/lowering indicator
• Fork height expressed in metres or feet from ground level

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.

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OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE AND HYDRAULICS OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position 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.

OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE ON AND HYDRAULICS OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• 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.

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FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Forks lowering interlock indicator
• Speed indicator, expressed in km/h or mph

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°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator
• Forks lowering interlock indicator
• Speed indicator, expressed in km/h or mph

The forks lowering indicator blinks at a frequency of 1.5 Hz.

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CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Parking brake indicator
• Steer wheel position indicator
• Carriage return interlock indicator
• Speed indicator, expressed in km/h or mph

The carriage return indicator blinks at a frequency of 1.5 Hz.

CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON

STEERING 360° STEERING 180°

• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Drive performance indicator (tortoise or hare)
• Steer wheel position indicator
• Forward drive indicator
• Carriage return interlock indicator
• Speed indicator, expressed in km/h or mph

The carriage return indicator blinks at a frequency of 1.5 Hz.

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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 is used to check the operating conditions of the truck.
Once the TESTER sub-menu is accessed, the TESTER appears, as shown below.
The scroll keys can be used to switch between the screens of TESTER sub-menu (from the
TESTER 1 screen to the TESTER 5 screen.

The TESTER 1 allows you to check the signals sent by the traction control unit.

The TESTER 2 allows you to check the signals sent by the pump control unit.

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The TESTER 3 allows you to check the signals sent by the steering wheel control unit.

= ON
= OFF

The TESTER 4 screen allows you to check the status of the digital inputs.

The TESTER 5 screen allows you to check the status of the analogue inputs.

By pressing the "OUT" function key, you can exit the screen at any time.

Input correspondence tables

DIGITAL INPUT ANALOG INPUT
D01 SEAT SENSOR A01 POT. TRUCK POSITION
D02 OPERATOR PRESENCE PEDAL A02 Not used
D03 SPEED REDUCTION BUTTON A03 SIDE SHIFT CENTRE SENSOR
D04 BATTERY SENSOR - OUT 1 A04 Not used
D05 BATTERY SENSOR - OUT 2 A05 TILT CENTRE SENSOR
D06 SEAT BELTS FASTENED SENSOR A06 ENCODER RESET SENSOR
D07 180°/360° STEERING BUTTON A07 Not used
D08 WEIGHING DEVICE BUTTON A08 Not used
D09 LIFT BY-PASS BUTTON A09 LOAD CELLS
D10 PALLET PRESENCE SENSOR A10 Not used
D11 RELAY K3 A11 Not used
D12 ENCODER RESET SENSOR A12 Not used
D13 Not used
D14 Not used
D15 Not used
D16 Not used

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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 VCM controller that will respond with an “SDO” as con-
firmation. The VCM will have an RTC device with Backup.

By pressing the "OUT" function key, you can exit the screen at any time.

MAIN MENU 1 / SOFTWARE VERSION.

The "SOFTWARE VERSION" function allows you to check the versions of the software used.

The display via an “SDO” will request these data from the VCM controller that will respond with an “SDO”
via “Can Bus”.

By pressing the "OUT" function key, you can exit the screen at any time.

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MAIN MENU 1 / ALARMS.

These four screens are used to save and display up to 32 different alarm conditions that are checked while
the truck is used.
They present:
• Alarm type code number
• Truck operating hours the when alarm was tripped (first time)
• Number of times the alarm has occurred.
• The identifier of the command or control on which the alarm occurred

Once the ALARMS sub-menu is accessed, the screen with the first 10 alarms will appear. The scroll keys
can be used to switch between the screens to view all 32 alarms, if this number is present. If there are
fewer alarms, the respective display screens are automatically reduced.
The display via an “SDO” will request these data from the VCM controller that will respond with an “SDO”
via “Can Bus”.

By pressing the "OUT" function key, you can exit the screen at any time.

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MAIN MENU 1 / PARAMETER SETTING.

The operator can use these screens to change the drive performance settings for the truck, and also
protect them with a password (see LOCK PARAMETERS.
After accessing the PARAMETER SETTINGS sub-menu, the following screen is displayed.

You can use the scroll keys to select the parameter you want to change:
1. TRACTION SPEED from 1.00 km/h to 11.00 km/h
2. ACCELERATION on a scale of 1 to 5.

Changes in terms of
Setting scale
performance
1 + 1 sec

2 + 0.5 sec.

3 Standard setting

4 - 0.3 sec.

5 - 0.5 sec.

3. INVERSION BRAKING on a scale of 1 to 5.

Changes in terms of
Setting scale
performance
1 + 0.5 sec.

2 + 0.2 sec.

3 Standard setting

4 - 0.2 sec.

5 - 0.5 sec.

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4. RELEASE BRAKING on a scale of 1 to 5.

Changes in terms of
Setting scale
performance
1 + 0.5 sec

2 + 0.2 sec.

3 Standard setting

4 - 0.2 sec.

5 - 0.5 sec.

To change the 4 parameters indicated above, proceed as follows:

1. Use the scroll keys to position the cursor (shown dash) on the parameter to modify.
2. Press ENTER.
3. The parameter value will start to flash indicating that it can be changed using the numerical keys.
4. Press ENTER to confirm.

5. ENERGY SAVING from OFF to ON.

If ON, this function limits the truck's traction and lifting performance to save battery charge. To modify
this parameter from OFF to ON or vice versa, proceed as follows:
1. Use the scroll keys to position the cursor (shown dash) on the parameter to modify.
2. Press ENTER.
3. The OFF or ON indicator will start to flash, which can be changed using the scroll keys, activating or
deactivating the function.
4. Press ENTER to confirm.

6. LOCK PARAM. from OFF to ON.

If this function is ON, the user is requested to enter an access password to change the individual parame-
ters.
To modify this parameter from OFF to ON or vice versa, proceed as follows:
1. Use the scroll keys to position the cursor (shown dash) on the parameter to modify.
2. Press ENTER.
3. Enter the 4-digit password using the numerical keys.
4. Press ENTER to confirm.

The LOCK PARAM. value will be changed now and the parameters will be locked if changing from OFF
to ON or unlocked if changing from ON to OFF. The PARAMETER SETTINGS screen is then auto-
matically displayed.

If an incorrect password is entered, the incorrect password screen will appear for 5 seconds
and then the screen that requests password entry will appear again.

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MAIN MENU 2

The MAIN MENU 2 function can only be accessed by qualified technicians authorised by the truck
manufacturer.
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) it is possible to access the “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.

By pressing the "OUT" function key, you can exit the screen at any time.

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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 key with YES displayed clears the saved alarms and takes you back to the MAIN
MENU 2 screen. Pressing the ENTER key with NO displayed exits without clearing the alarms and takes
you back to the MAIN MENU 2 screen.
With the OUT key 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 key 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”.

By pressing the "OUT" function key, you can exit the screen at any time.

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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 OF-
FSET”, 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”.

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MAIN MENU 2 \ PARAMETER ACQUISITION

On this screen you can acquire the electrical values of carriage fully forward, carriage fully back, 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.

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ACCESS CODE PROGRAMMING SCREEN

To enter the codes, move the arrow using 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.

You can use the scroll keys to select the parameter you want to change:
1. TRACTION SPEED from 1.00 km/h to 11.00 km/h
2. ACCELERATION on a scale of 1 to 5.

Changes in terms of
Setting scale
performance
1 + 1 sec
2 + 0.5 sec.
3 Standard setting
4 - 0.3 sec.
5 - 0.5 sec.

3. INVERSION BRAKING on a scale of 1 to 5.

Changes in terms of
Setting scale
performance
1 + 0.5 sec.
2 + 0.2 sec.
3 Standard setting
4 - 0.2 sec.
5 - 0.5 sec.

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4. RELEASE BRAKING on a scale of 1 to 5.

Changes in terms of
Setting scale
performance
1 + 0.5 sec
2 + 0.2 sec.
3 Standard setting
4 - 0.2 sec.
5 - 0.5 sec.

To change the 4 parameters indicated above, proceed as follows:

1. Use the scroll keys to position the cursor on the parameter to be modified.
2. Press ENTER.
3. The parameter value will start to flash, thereby indicating that it can be changed using the numerical
keys.
4. Press ENTER to confirm and return to the initial screen.
By pressing the "OUT" function key, you can exit the screen at any time.
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.

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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” keys

By pressing the "OUT" function key, you can exit the screen at any time.

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 thePRG. 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 key, the saved codes are deleted and you are automatically taken
back to the MAIN MENU 2 screen.

By pressing the "OUT" function key, you can exit the screen at any time.

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PREMIUM DISPLAY

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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 VCM identification controller that will respond
with another “SDO” for confirmation. When the key switch is turned off the display must warn the VCM
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 colour and fill level of the battery
symbol.
• From 100% to 40% = green
• From 40% to 20% = yellow
• From 20% to 0% = red

The battery displays 10 different charge levels, in

10% steps.

Parking brake indicator.

Indicates that the parking brake has been applied.

Battery residual autonomy indicator.Indicates the

remaining hours and minutes of battery autonomy.

Time and date

Indicates the hours, minutes and the date.

Worked hours indicator.

Counts the hours of truck driving and hydraulic
function operation.

Drive speed indicator (expressed in km/h or mph).

Indicates the speed in both forward and reverse drive.

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ICON DESCRIPTION

Fork height indicator

Indicates the height of the forks above ground level.

Weight indicator
Indicates the weight of the load. During the load wei-
ghing function with drive activated/deactivated, the
weight indication should appear for 5 seconds and
then return to the previous screen (if the altimeter
option is on it will return to the fork height display).
With drive activated, the drive speed indicator is
always shown.
Speed limitation indicator.
Indicates that the speed limitation function is activa-
ted (slow speed).

Maximum speed indicator

Indicates that the maximum drive speed function is
activated.

Seat belt indicator

Indicates that the seat belt is not fastened.

Energy saving mode indicator

This icon appears when the ENERGY SAVING fun-
ction is activated, by switching it ON.

Signalling indicator light

This icon is displayed along with a indication if the
operator performs an incorrect command sequence.

Fork lifting indicator

This icon appears when the fork lifting function is
activated.
If the forks are lifted when drive is activated, both
the measured fork height and the travel speed will
be displayed.
Fork lowering indicator
If the forks are lowered when drive is activated, both
the measured fork height and the travel speed will
be displayed.

Retractable fork carriage out indicator.

This icon appears when the fork carriage out function
is activated.

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ICON DESCRIPTION

Retractable fork carriage return indicator

This icon appears when the fork carriage return
function is activated.

Lifting travel limit indicator

This icon is displayed on reaching the lifting
of the lifting chains

Fork tilt up indicator

This icon is displayed in the event of a malfunction
of the physical components or the software of the
electrical system and is associated with a numeric
code that identifies the type of alarm and the control
or function affected
Fork tilt down indicator
This icon appears when the fork downward tilt or
inclination function is activated.

Fork right side shift indicator

This icon appears when the fork side shift to right
function is activated.

Fork left side shift indicator

This icon appears when the fork side shift to left
function is activated.

Side shift auto centering indicator

This icon appears when the fork side shift auto
centering function is activated.
When the centering function is in operation, the icon
flashes to show the side shift movement (right side
shift/left side shift). If auto centering is requested
when the forks are already in the correct position,
the icon is illuminated with a steady light.
Fork tilt auto levelling indicator
This icon appears when automatic fork levelling at
0° tilt is activated.
When the centering function is in operation, the icon
flashes to show the tilt movement (tilt up/down).
If auto centering is requested when the forks are
already in the correct position, the icon is illuminated
with a steady light.

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ICON DESCRIPTION

5th hydraulic function indicator

This icon appears when the 5th hydraulic function
is activated.

5th hydraulic function inlet/outlet indicator

This icon appears with the 5th hydraulic function is
activated in the two operating modes.

Fork lowering interlock indicator

This icon appears when the interlock is tripped during
fork lowering.

Fork carriage return interlock indicator.

This icon appears when a request to recall the fork
carriage is made when the interlock is activated.

Battery out-of-place indicator.

This icon, combined with error code 206-01, appears
when the battery is not properly secured in its seat.

Alarm indicator
This icon is displayed in the event of a malfunction
of the physical components or the software of the
electrical system and is associated with a numeric
code that identifies the type of alarm and the control
or function affected.
213 = example of code number of type of alarm.
01 = example of identification of the control on which
the alarm occurred.
Password prompt indicator
This icon appears if an access password is required.

Incorrect password indicator

This icon appears if an incorrect access password
is entered

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ICON DESCRIPTION

OFF button
Used to switch off the truck (available only in
association with the access via PIN option)

Steer wheel position indicator

This icon is always displayed.

Indication of steer wheel position with forward

drive engaged
This icon, displayed together with the drive direction
indicator arrow, appears after forward drive has been
selected and remains displayed for the entire time this
function is activated. The direction indication follows
the position of the steer wheel.

Indication of steer wheel position with reverse

drive engaged
This icon, displayed together with the drive direction
indicator arrow, appears after forward drive has been
selected and remains displayed for the entire time this
function is activated. The direction indication follows
the position of the steer wheel.

Menu button
This icon gives access to the "user menu" screen.

Height pre-selector button

Provides access to the height pre-selector functions.

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If the on/off switch is turned off and on rapidly, it is possible that an alarm code may be
generated that causes the truck to enter fault mode, thereby disabling its functions.
Truck operation can be easily reset using the EMERGENCY SWITCH to cancel the alarm
code. After switching the truck off, it is advisable to wait at least five seconds before
switching the truck on again. Resetting the truck through the ignition switch only will not
stop the failure mode.

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FUNCTIONAL GRAPHIC SCREENS

The graphic screens for each single function are shown below in sequence.

SCREEN DISPLAYED ON SWITCHING ON THE KEY SWITCH.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Worked hours indicator
• Menu access button

SCREEN DISPLAYED ON SWITCHING ON WITH OPERATOR ACCESS BY CODE.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Worked hours indicator
• Menu access button
• OFF button

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SCREEN DISPLAYED WITH FORWARD DRIVE SELECTED.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Forward drive indicator following the steering wheel position indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

SCREEN DISPLAYED WITH REVERSE DRIVE SELECTED.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Reverse drive indicator following the steering wheel position indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

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SCREEN DISPLAYED WITH FORK LIFTING ON AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork lifting indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

SCREEN DISPLAYED WITH FORK LOWERING ON AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork lowering indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

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SCREEN DISPLAYED WITH CARRIAGE OUT ON AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Carriage forward indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

SCREEN DISPLAYED WITH CARRIAGE RETURN ON AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Carriage forward indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

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SCREEN DISPLAYED WITH FORK TILT UP ON AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork tilt up indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

SCREEN DISPLAYED WITH FORK TILT DOWN ON AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork tilt down indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

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SCREEN DISPLAYED WITH FORK SIDE SHIFT TO RIGHT ON AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Right side shift indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

SCREEN DISPLAYED WITH FORK LEFT SIDE SHIFT ACTIVATED AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Left side shift indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

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SCREEN DISPLAYED WITH BATTERY OUT-OF-PLACE.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Battery out-of-place indicator
• 206-01 alarm indicator (Battery out)
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

SCREEN DISPLAYED WITH BATTERY REMOVAL ACTIVATED AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Carriage forward indicator
• Battery out-of-place indicator
• 206-01 alarm indicator (Battery out)
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

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SCREEN DISPLAYED WITH BATTERY RETURN ACTIVATED AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Carriage return indicator
• Battery out-of-place indicator
• 206-01 alarm indicator (Battery out)
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

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SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork lifting indicator
• Carriage return indicator
• Tilt up indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

The screen displayed above is an example of combined hydraulic functions.

The possible combinations are:

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
Fork Lowering carriage out tilt up
Fork Lowering carriage out tilt down
Fork Lowering carriage out right side shift
Fork Lowering carriage out left side shift
Fork Lowering carriage return tilt up
Fork Lowering carriage return tilt down
Fork Lowering carriage return right side shift
Fork Lowering carriage return left side shift

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SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Traction performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Forward drive indicator
• Fork lifting indicator
• Carriage forward indicator
• Tilt up indicator
• Speed indicator, expressed in km/h or mph
• Worked hours indicator
• Menu access button

The screen displayed above is an example of combined hydraulic functions with the drive on.
The possible combinations are:

Possible combinations

Forks up carriage out tilt up for forward/reverse drive

Forks up carriage out tilt down for forward/reverse drive
Forks up carriage out right side shift for forward/reverse drive
Forks up carriage out left side shift for forward/reverse drive
Forks up carriage return tilt up for forward/reverse drive
Forks up carriage return tilt down for forward/reverse drive
Forks up carriage return right side shift for forward/reverse drive
Forks up carriage return left side shift for forward/reverse drive
Fork Lowering carriage out tilt up for forward/reverse drive
Fork Lowering carriage out tilt down for forward/reverse drive
Fork Lowering carriage out right side shift for forward/reverse drive
Fork Lowering carriage out left side shift for forward/reverse drive
Fork Lowering carriage return tilt up for forward/reverse drive
Fork Lowering carriage return tilt down for forward/reverse drive
Fork Lowering carriage return right side shift for forward/reverse drive
Fork Lowering carriage return left side shift for forward/reverse drive

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SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION ACTIVATED.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Traction performance indicator (tortoise or hare)
• Energy Saving indicator
• Steering mode indicator (180° or 360°)
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION, DRIVE AND HYDRAULICS ACTIVATED.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Energy Saving indicator
• Steering mode indicator (180° or 360°)
• Steer wheel position indicator
• Forward drive indicator
• Fork lifting indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

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SCREEN DISPLAYED WITH WARNING SIGNALLING.

This screen is displayed after an incorrect sequence performed by the operator.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Steer wheel position indicator
• Warning indicator
• Indication of the problem
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

NOTE: The incorrect sequences and anomaly warnings are:

• INC. START TRACTION (Incorrect start of traction)

• INC. START LIFT (Incorrect start of lifting)
• INC. START LOW (Incorrect start of lowering)
• INC. START TILT UP (Incorrect start of upward tilt)
• INC. START TILT DOWN (Incorrect start of downward tilt)
• INC. START REACH IN (Incorrect start of retractable carriage return
• INC. START REACH OUT (Incorrect start of retractable carriage extension)
• INC. START SHIFT RIGHT (Incorrect start of fork side shift to right)
• INC. START SHIFT LEFT (Incorrect start of fork side shift to left)
• INC. START 5 VIA IN (Incorrect start 5th function inlet)
• INC. START 5 VIA OUT (Incorrect start 5th function outlet)
• GET HOME
• RESET ENCODER
• BATTERY LOW (Low battery charge level)
• OVERLOAD (Load lifted exceeds rated capacity)
• CHECK UP (Scheduled maintenance required)
• SEAT SWITCH (Incorrect position on seat or position sensor faulty)

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SCREEN DISPLAYED WITH ALARM SIGNALLING.

This screen is displayed after a hardware or software failure on the electrical system.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Alarm indicator
• Alarm numeric code indication
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

NOTE: 213 = alarm type code.

01 = identification of the control on which the alarm occurred.

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SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Lifting travel limit indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

SCREEN DISPLAYED WITH FORK LIFTING TRAVEL LIMIT INDICATOR WITH DRIVE ON.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Forward drive indicator
• Lifting travel limit indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

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OPTIONAL GRAPHIC SCREENS

The graphic screens for each single optional function are shown below in sequence.

OPERATOR SEAT BELT OPTIONAL SCREEN.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Seat belt not fastened indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

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.

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FORK TILT AUTO CENTERING OPTIONAL SCREEN WITH DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork tilt auto centering indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

When the centering function is in operation, the icon flashes to show the fork tilt movement (tilt
up/down). If there is a request for auto centering and the forks are already in the correct position
the icon is steadily illuminated.

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FORK TILT AUTO CENTERING OPTIONAL SCREEN WITH DRIVE ON.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork tilt auto centering indicator
• Forward drive indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

When the centering function is in operation, the icon flashes to show the fork tilt movement (tilt
up/down). If there is a request for auto centering and the forks are already in the correct position
the icon is steadily illuminated.

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FORK SIDE SHIFT AUTO CENTERING OPTIONAL SCREEN WITH DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork side shift auto centering indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

When the centering function is in operation, the icon flashes to show the side shift movement
(right side shift/left side shift). If there is a request for auto centering and the forks are already in
the correct position the icon is steadily illuminated.

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FORK SIDE SHIFT AUTO CENTERING OPTIONAL SCREEN WITH DRIVE ON.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork side shift auto centering indicator
• Forward drive indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

When the centering function is in operation, the icon flashes to show the side shift movement
(right side shift/left side shift). If there is a request for auto centering and the forks are already in
the correct position the icon is steadily illuminated.

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OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Hydraulic 5th way activated indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE ON

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Hydraulic 5th way activated indicator
• Forward drive indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

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OPTIONAL SCREEN FOR INPUT HYDRAULIC 5TH WAY WITH DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Hydraulic 5th way activated indicator
• Hydraulic 5th way inlet indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

OPTIONAL SCREEN FOR OUTPUT HYDRAULIC 5TH WAY WITH DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Hydraulic 5th way activated indicator
• Hydraulic 5th way outlet indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

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OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY INLET WITH DRIVE ON.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Hydraulic 5th way activated indicator
• Hydraulic 5th way inlet indicator
• Forward drive indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY OUTLET WITH DRIVE ON.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Hydraulic 5th way activated indicator
• Hydraulic 5th way outlet indicator
• Forward drive indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

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OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork lifting indicator
• Carriage forward indicator
• Tilt auto centering indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

This shown above is an example of combined hydraulic functions with the drive off.

The possible combinations are:

Possible combinations

Fork up carriage forward tilt auto centering

Fork up carriage forward side shift auto centering
Fork up carriage back tilt auto centering
Fork up carriage back side shift auto centering
Fork lowering carriage forward tilt auto centering
Fork lowering carriage forward side shift auto centering
Fork lowering carriage back tilt auto centering
Fork lowering carriage back side shift auto centering

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OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork lifting indicator
• Carriage forward indicator
• Tilt auto centering indicator
• Forward drive indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

This shown above is an example of combined hydraulic functions with the drive off.

The possible combinations are:

Possible combinations

carriage
Fork up tilt auto centering for forward/reverse drive
forward
carriage
Fork up side shift auto centering for forward/reverse drive
forward
Fork up carriage back tilt auto centering for forward/reverse drive
Fork up carriage back side shift auto centering for forward/reverse drive
carriage
Fork lowering tilt auto centering for forward/reverse drive
forward
carriage
Fork lowering side shift auto centering for forward/reverse drive
forward
Fork lowering carriage back tilt auto centering for forward/reverse drive
Fork lowering carriage back side shift auto centering for forward/reverse drive

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OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Fork lifting/lowering indicator
• Speed indicator, expressed in km/h or mph
• Fork height display measured in metres or feet
• Hours worked indicator
• Menu access button

OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE ON.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Forward drive indicator
• Fork lifting/lowering indicator
• Speed indicator, expressed in km/h or mph
• Fork height expressed in metres or feet from ground level
• Hours worked indicator
• Menu access button

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.

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OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE AND HYDRAULICS OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Speed indicator, expressed in km/h or mph
• Load weighing indicator in kg or lb
• Hours worked indicator
• Menu access button

During the load weighing function with drive off, the weight must appear for 5 seconds and then
it must disappear. If the altimeter option is active the forks height will be displayed again.

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OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE ON AND HYDRAULICS OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Forward drive engaged indicator
• Speed indicator, expressed in km/h or mph
• Load weighing indicator in kg or lb
• Hours worked indicator
• Menu access button

During the load weighing function with drive on, the weight must appear for 5 seconds and then
the drive speed will be displayed.

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FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Forks lowering interlock indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

The forks lowering indicator blinks at a frequency of 1.5 Hz

FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Forward drive indicator
• Forks lowering interlock indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

The forks lowering indicator blinks at a frequency of 1.5 Hz.

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CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF.

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Parking brake indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Carriage return interlock indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

The carriage return indicator blinks at a frequency of 1.5 Hz.

CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON

• Remaining battery life indicator

• Battery charge level indicator
• Clock, date
• Drive performance indicator (tortoise or hare)
• Steering mode indicator (180° or 360°)
• Forward drive indicator
• Carriage return interlock indicator
• Speed indicator, expressed in km/h or mph
• Hours worked indicator
• Menu access button

The carriage return indicator blinks at a frequency of 1.5 Hz.

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OPTIONAL SCREEN WITH ACTIVE ACCESS CODE PIN.

When the truck is turned on with active pin code, the following user recognition screen will appear:

Enter the 4-digit password using the numerical keypad and press "OK" 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.

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HEIGHT PRE-SELECTOR
PRE-SELECTOR OPTIONAL SCREEN.
The main screen with the pre-selector option on appears as follows.

• Remaining battery life indicator

• Battery charge level indicator
• Date/time indicator
• Hours worked indicator
• Drive performance indicator (tortoise or hare)
• Steering mode indicator
• Speed indicator, expressed in km/h or mph
• Fork height indicator
• Pre-selector options button

To activate the pre-selection functions, press the “HEIGHT PRESELECTOR” button.

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PRE-SELECTOR SHELF SELECTION SCREEN WITHOUT PALLET SENSOR OPTION

The following screen appears to permit selecting the shelf:

To select the area, press one of the area selection buttons on the bar at the top of the screen (on entering
the menu, the selected area by default is “AREA A”). For each of the 4 areas there are 10 levels, for a total
of 40 settable levels.
To select the desired shelf, press the buttons to the side of the chosen area.
In particular:
• If you have a load on the forks and you want to put the pallet on the shelf, you should select the
following button next to the chosen level:

• If you do not have a load on the forks and you want to take the pallet from the shelf, you should select
the following button next to the chosen level:

PRE-SELECTOR SHELF SELECTION SCREEN WITH PALLET SENSOR OPTION, WITH NO LOAD ON
THE FORKS
When the pallet sensor function is combined with the pre-selector function, pallets are automatically
detected on the forks.
If the pallet sensor does not detect a pallet on the forks, it means that the truck is ready for picking and the
pre-selector screen will only allow pick up from the shelf:

To select the area, press one of the area selection buttons on the bar at the top of the screen (on entering
the menu, the selected area by default is “AREA A”).

To activate picking up, press the button next to the chosen level.

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PRE-SELECTOR SHELF SELECTION SCREEN WITH PALLET SENSOR OPTION, WITH LOAD ON
THE FORKS
When the pallet sensor function is combined with the pre-selector function, pallets are automatically
detected on the forks.
If the pallet sensor detects a pallet on the forks, it means that the truck must place the load on the shelf
and the pre-selector screen will only allow putting down the load:

To select the area, press one of the area selection buttons on the bar at the top of the screen (on entering
the menu, the selected area by default is “AREA A”).

To activate picking up, press the button next to the chosen level.

SCREEN FOR PICKING UP LOAD WITH SELECTED LEVEL ABOVE FORK HEIGHT
After selecting the shelf for picking up, you go back to the main screen:

A box is displayed in the middle of the screen containing information on the selected shelf and at the
bottom in the middle there is the height to reach for picking up. The icon indicating the control to carry out
(fork lifting, in this case) will blink in the middle of the screen.
You can exit the selected level at any time by pressing the “EXIT” button on the screen.

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After operating the forks up control and reaching the set height, the icon will stop blinking and the following
screen will appear:

On releasing the up control you can fork the load on the shelf and the icon for the request to operate the
forks up control will activate. Now, on operating the up lever the forks will rise 100 mm to allow picking up
the pallet (see picture below).

On completing this operation the system will go back into manual mode and the main screen will return as
follows:

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SCREEN FOR PUTTING DOWN LOAD WITH SELECTED LEVEL ABOVE FORK HEIGHT
After selecting the shelf for putting down, you go back to the main screen:

A box appears in the middle of the screen providing information on the selected shelf and at the bottom in
the middle there is the height to reach for putting down. The icon indicating the operation to carry out (fork
lifting, in this case) will blink in the middle of the screen at a frequency of 1.5 Hz. You can exit the selected
level at any time by pressing the “EXIT” button on the screen.

After operating the forks up control and reaching the set height, the icon will stop blinking and the following
screen will appear:

On releasing the up control you can position the forks to release the load on the shelf and the icon for
the request to operate the forks down control will activate. Now, on operating the down lever the forks will
lower 100 mm to allow putting down the pallet.

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On completing this operation the system will go back into manual mode and the main screen will return as
follows:

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SCREEN FOR PICKING UP LOAD WITH SELECTED LEVEL BELOW FORK HEIGHT
After selecting the shelf for picking up, you go back to the main screen:

A box appears in the middle of the screen providing information on the selected shelf and at the bottom in
the middle there is the height to reach for picking up. The icon indicating the control to carry out (fork lowe-
ring, in this case) will blink in the middle of the screen at a frequency of 1.5 Hz. You can exit the selected
level at any time by pressing the “EXIT” button on the screen.
After operating the down control and reaching the set height, the icon will stop blinking and the following
screen will appear:

On releasing the down control you can fork the load on the shelf and the icon for the request to operate
the forks up control will activate. Now, on operating the up lever the forks will rise 100 mm to allow picking
up the pallet.

On completing this operation the system will go back into manual mode and the main screen will return as
follows:

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SCREEN FOR PUTTING DOWN LOAD WITH SELECTED LEVEL BELOW FORK HEIGHT
After selecting the shelf for putting down, you go back to the main screen:

A box appears in the middle of the screen providing information on the selected shelf and at the bottom in
the middle there is the height to reach for putting down. The icon indicating the control to carry out (fork
lowering, in this case) will blink in the middle of the screen at a frequency of 1.5 Hz. You can exit the se-
lected level at any time by pressing the “EXIT” button on the screen.
After operating the forks down control and reaching the set height, the icon will stop blinking and the fol-
lowing screen will appear:

On releasing the down control you can position the forks to release the load on the shelf and the icon for
the request to operate the forks down control will activate. Now, on operating the down lever the forks will
lower 100 mm to allow putting down the pallet.

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On completing this operation the system will go back into manual mode and the main screen will return
as follows:

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DESCRIPTION OF THE MENU SCREENS

The graphic screens for each menu are shown below in sequence.

DESCRIPTION OF THE USER MENU SCREEN.

From the main screen press the “MENU” button to access the “USER MENU” shown above.
To access the different sub-menus, it is necessary to press the desired sub-menu on the screen in the
rectangle around the function.
To go back to the main menu, press “EXIT”.

DESCRIPTION OF THE DIAGNOSTICS SCREEN.

From the menu screen press the “DIAGNOSTICS” button to access the “DIAGNOSTICS” submenu
shown above.
To access the different diagnostic sub-menus, you need to press the desired sub-menu on the screen in
the rectangle around the function.
To return to the “USER MENU” screen, press “EXIT”.

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Description of the "TESTER" screens

The "DIAGNOSTICS" function allows you to check the operation of the truck.
Once in the "DIAGNOSTICS" sub-menu, pressing “TRACTION”, the screen shown in the figure will appe-
ar. IT is possible to return to the “DIAGNOSTICS” submenu pressing the “EXIT” button.

The “TRACTION” menu 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”.

The “PUMP” menu 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”.

The “PUMP” submenu is displayed pressing the “PUMP” button on the "DIAGNOSTICS" submenu.
It is possible to return to the “DIAGNOSTICS” submenu pressing the “EXIT” button.

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The “STEERING” menu enables checking the signals sent by the steering controller.
The display via an “SDO” will request these data from the steering system controller that will respond with
an “SDO” via “Can Bus”.

The “STEERING” submenu is displayed by pressing “STEERING” in the "DIAGNOSTICS" submenu.

It is possible to return to the “DIAGNOSTICS” submenu pressing the “EXIT” button.

The “DIGITAL INPUTS MONITOR” allows you to check the status of the digital inputs.
Grey box with a 0 = INPUT OFF
Grey box with a 1 = INPUT ON
The display via an “SDO” will request these data from the VCM controller that will respond with an “SDO”
via “Can Bus”.

The “DIGITAL INPUTS MONITOR” submenu is displayed pressing the “DIGITAL INPUTS MONITOR”
button on the "DIAGNOSTICS" submenu.
It is possible to return to the “DIAGNOSTICS” submenu pressing the “EXIT” button.

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The “ANALOG INPUTS MONITOR” allows you to check the status of the analogue inputs.
The display via an “SDO” will request these data from the VCM controller that will respond with an “SDO”
via “Can Bus”.

The “ANALOG INPUTS MONITOR” submenu is displayed pressing the “ANALOG INPUTS MONITOR”
button in the "DIAGNOSTICS" submenu.
IT is possible to return to the “DIAGNOSTICS” submenu pressing the “EXIT” button.

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DESCRIPTION OF THE CLOCK AND DATE SETTING SCREEN

The “SET CLOCK & DATE” function allows you to set the current time and date.

On accessing this submenu, the hours digits will start to flash. Use the numerical keys to set the correct
time and confirm with "OK". The minutes digits will then start flashing. Use the numerical keys to set the
minutes and confirm with "OK". You are now automatically taken to the next screen for setting the date.

The day will blink. Use the numerical keys to set the day and confirm with "OK". The month will now blink.
Use the numerical keys to set the month and confirm with "OK". The year will now blink. Use the numerical
keys to set the year and confirm with "OK". On completion of the operation, the screen will close automa-
tically.

By pressing the “EXIT” button you can go back to the “USER MENU” screen at any time, but
losing the set data.

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DESCRIPTION OF THE SOFTWARE VERSION SCREEN.

The "SOFTWARE VERSION" function allows you to check the versions of the software used.

NOTE: It is possible to return to the "USER MENU" by pressing the "EXIT" button at any time.

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DESCRIPTION OF THE ALARMS SCREENS.

These screens are used for saving and displaying up to 32 different alarms that have occurred while using
the machine. The screen contains:

• Alarm type code number;

• time when the alarm occurred;
• the number of times the alarm has occurred;
• the identification of the controller on which the alarm occurred.
•
On accessing the ALARMS submenu, a screen contianing the first 8 alarms will appear. Using the scroll
keys (Up and Down), you can change the screens to be able to view all 32 alarms when they are present.

By pressing the "EXIT" function key, you can exit the screen at any time.

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DESCRIPTION OF THE PARAMETERS SETTING SCREEN.

In these screens the operator can change the truck performance parameters, and, if required, enable pas-
sword protection of these settings.

On accessing the “PARAMETER SETTING” sub-menu, the screen shown below will appear.

By pressing in the parameters area shown in blue, you can select the parameter you want to change:
1. TRACTION SPEED from 1.00 km/h to 14.00 km/h T
o change the above parameter, proceed as follows:
a) Press in the blue area that contains the current value of the parameter, this screen will appear.

b) Enter a new value for the parameter from the digital numerical keypad.

c) Press the "OK" button to confirm. On confirming, the "Parameter Setting" screen will re-appear.

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2. ACCELERATION o n a scale from 1 to 5.

Scale of settings Changes in performance

1 +1 Sec.
2 +0.5 Sec.
3 Standard Setting
4 -0.5 Sec.
5 -1 Sec.

3. INVERSION BRAKING on a scale from 1 to 5.

Scale of settings Changes in performance

1 +0.5 Sec.
2 +0.2 Sec.
3 Standard Setting
4 -0.2 Sec.
5 -0.5 Sec.

4. RELEASE BRAKING on a scale from 1 to 5.

Scale of settings Changes in performance

1 +0.5 Sec.
2 +0.2 Sec.
3 Standard Setting
4 -0.2 Sec.
5 -0.5 Sec.

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To change the settings of the above parameters 2, 3 and 4, proceed as follows:

The following screen will appear:

a) Press in the blue area that contains the current value of the parameter, this screen will appear:

b) Select the desired value within the scale of permissible values for the parameter. The system will
automatically return to display of the “PARAMETERS SETTING” screen.

c) The parameter is changed.

5. ENERGY SAVING
If ON, this function limits the truck's drive and lifting performance to save battery charge. This function
will be indicated by the “ECO” icon.

To change this parameter from OFF to ON or vice versa, proceed as follows:

a) Press in the blue area on the current value of the parameter.

b) Tap to change the parameter status (if it was “OFF” it will become “ON” and vice versa).

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6. LOCK PARAM.
When set to “ON”, it is not possible to change the parameters. To change this parameter from "OFF"
to "ON" or vice versa, proceed as follows.

a) Press in the blue area that contains the current value of the parameter. Tap to change the parame-
ter status (if it was “OFF” it will become “ON” and vice versa).

b) Enter the 4-digit password using the numerical keypad and press "OK" to confirm. The LOCK
PARAMETERS setting will change, and the parameters will be locked if changed from
“OFF” to “ON” or unlocked if changed from “ON” to “OFF”.
The system automatically returns to display of the “PARAMETERS SETTING” screen.

If the user attempts to modify the parameters with the lock on, the screen for entering the
password will reappear.

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DESCRIPTION OF THE SERVICE MENU SCREEN.

Access only permitted to qualified technicians authorised by the manufacturer of the lift truck.

Enter the 4-digit password using the numerical keypad and press "OK" 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.

With the “SUPERVISOR PASSWORD” (default 5555) it is possible to access the “SERVICE
MENU”.
By pressing the "EXIT" button, you can exit the screen at any time.

When the password is correct, the following screen will be displayed.

By pressing the "EXIT" button, you can exit the screen and return to the user menu at any time.

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DESCRIPTION OF THE ALARMS CLEARING SCREEN.

The “CLEAR ALARMS” function allows you to delete the alarms in the “ALARMS” menu

When this screen appears, the two possible options of “YES” and “NO” appear.
Pressing the “YES” button clears the saved alarms and displays the “SERVICE MENU" screen again.
Pressing the “NO” button exits without clearing the alarms and displays the “SERVICE MENU" screen
again.
With the "EXIT" button you exit without clearing the alarms.

DESCRIPTION OF THE UNIT OF MEASURE SETTING SCREEN.

The "UNIT OF MEASURE” function allows you to convert the following units of measurement simultaneously,
as follows:
• km/h to mph (miles per hour)
• m to ft (feet)
• kg to lb (pounds)

From the service menu you can select the measurement systems available ("METRIC"/"ANGLO-
AMERICAN"), simply by pressing the blue box that displays the current value. After changing the current
value, the units of measure are converted by the display software. The metric system is present by default
on “Can Bus”.

By pressing the "EXIT" function key, you can exit the screen at any time and go back to the
"USER MENU" screen.

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DESCRIPTION OF THE HEIGHT SETTING SCREEN.

The “HEIGHT SETUP” function allows you to change the two fork adjustment values.
The first one, “RESET HEIGHT”, is the Reset value set for the height indicator.
The second one, “END STOP”, allows you to limit lifting the forks up to the set height.
The third one, “LIFT STOP 1”, allows you to set the first forks lifting interlocking to at the height set.
The fourth one, “LIFT STOP 2”, allows you to set the first forks lifting interlocking to at the height set.

In this screen, to change a parameter, press on one of the blue boxes that shows the current value of the
parameter.

Now the screen shows the following display:

Enter the desired parameter using the numerical keypad and then press "OK" to confirm. The "HEIGHT
SETUP" menu and the changed value is updated to the value entered.
The same procedure for changing the value applies to the second value “END STOP”, to the third value
“LIFT STOP 1” and to the fourth value “LIFT STOP 2”.
The display via an “SDO” will send these data to the VMC controller that will respond with an “SDO” via
“Can Bus”.

By pressing the "EXIT" function key, you can exit the screen at any time and return to the “HEIGHT
SETUP” screen.

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DESCRIPTION OF THE PARAMETERS ACQUISITION SCREEN.

On this screen you can acquire the electrical values of carriage fully forward, carriage fully back, minimum
load cell value (with no load on the forks) and maximum load cell value (nominal load on the forks).
The first one, “REACH FULL FWD”, is the analogue value with carriage fully out.
The second one, “REACH FULL BACK”, is the analogue value with carriage fully in.
The third "MIN LOAD CELL" is the analogue value acquired of the load cell signal, with no weight on the
forks.
The four 'MAX LOAD CELL" is the analogue value acquired of the load cell signal, with the maximum no-
minal weight on the forks provided for the truck.

To access to the acquisition of the minimum and maximum values of the carriage, press on one of the blue
boxes that display the current value of the parameter (for example "REACH FULL FWD").
The following screen will appear:

To acquire the carriage forward value, proceed in this way:

a) Operate the carriage reach control mini-lever/joystick to move the carriage to the desired maximum
permissible forward position.

b) Press the "CONFIRM" button on the screen to acquire the value.

Press the “ABORT” button to cancel the acquisition without storing the changed value.
Press the “EXIT” button to exit the screen without storing the value.

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To proceed with the acquisition of the carriage back value, press on one of the blue boxes that display the
current value of the parameter in the "ACQUIRE PARAMETERS" menu and proceed as follows:
a) Operate the carriage reach control mini-lever/joystick to move the carriage to the desired maximum
permissible back position.

b) Press the "CONFIRM" button on the screen to acquire the value.

NOTE: Press the “ABORT” button to cancel the acquisition without storing the changed value.

NOTE: Press the “EXIT” button to exit the screen without storing the value.

To access the acquisition of the minimum and maximum values of the load cell, press on one of the blue
boxes that display the current value of the parameter (for example "MIN LOAD CELL").
The following screen will appear:

Proceed as follows:
a) To acquire the value of the empty load cell, bring the forks to half height of the free lift.

b) Now press the "CONFIRM" button to acquire the value in volts of the load cell that will correspond to
0 kg on the forks.

Press the “ABORT” button to cancel the acquisition without storing the changed value.
Press the “EXIT” button to exit the screen without storing the value.

To access the acquisition of the maximum value of the load cell, press on one of the blue boxes that di-
splays the current value of the parameter in the "MAX LOAD CELL” menu and proceed as follows:
a) Place on the forks the maximum nominal load specified for the carriage, raise the forks from the
ground with the nominal load.

b) Press the “CONFIRM” button on the screen to acquire the value in Volts relative to the weight.

Press the “ABORT” button to cancel the acquisition without storing the changed value.
Press the “EXIT” button to exit the screen without storing the value.

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DESCRIPTION OF THE OPERAOR ACCESS SCREEN.

This function is optional, therefore the display needs to be enabled via “PDO” to make it operative on the
truck. Once you select "OPERATOR ACCESS" in the "SERVICE MENU" the "OPERATOR ACCESS"
submenu is displayed:

Description of the options:

• “NEW”: to create a new operator enabled to use the truck.
• “MODIFY”: to modify an existing operator code.
• “DELETE”: to delete an existing operator code.
• • “VIEW ALL”: to display all existing operator codes.
• “DELETE ALL”: to delete the entire operator database.

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DESCRIPTION OF THE NEW ACCESS CODE PROGRAMMING SCREEN.

Press the “NEW” button to create a new user; the following screen is displayed:

To enter the "PIN CODE" press in the blue area that displays the value. The following screen appears:

After entering the code with the digital numeric keypad press the "OK" button to return to the "NEW" menu.
Select the type of profile "USER/ADMIN" by simply pressing the blue box on the "ACCESS MODE" field.
With "USER" profile it is not possible to change the parameters in the "PARAMETERS SETTING" menu,
while with "ADMIN" you can do it.
If you want to set an operator profile for the pin code entered press the "SET PROFILE" button in the
"NEW" menu to enable the submenu shown below:

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To modify the driving profile, select in the blue box the parameter to be changed. The parameters can be
changed within the following ranges:

1) TRACTION SPEED from 1.00 km/h to 14.00 km/h

2) ACCELERATION on a scale from 1 to 5.
3) INV. BRAKING on a scale from 1 to 5.
4) REL. BRAKING on a scale from 1 to 5.

To modify the “TRACTION SPEED” parameter, proceed as follows:

a) Press in the blue area that contains the current value of the parameter, the following screen will ap-
pear:

b) Use the digital numerical keypad to enter a new value for the parameter.

c) Press "OK" to confirm.

By pressing the "EXIT" function key, you can exit the screen at any time, without storing the va-
lue.

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To change the "ACCELERATION", "INVERSE BRAKING" and "RELEASE BRAKING" parameters the
procedure is the same for all three parameters.
Considering the parameter "ACCELERATION" as an example:
a) Press in the blue area that contains the current value of the parameter, this screen will appear:

b) Select the desired value within the scale of permissible values for the parameter; the system will then
automatically return to display of the "NEW" menu.

c) The parameter is changed.

By pressing the "EXIT" function key, you can exit the screen at any time and the following screen is displa-
yed:

Press the “YES” button to save the pin code created, press the “NO” button to exit without saving, press
the “EXIT” button to return to the “NEW” screen.

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DESCRIPTION OF THE OPERATOR DATA MODIFICATION SCREEN

Pressing the "MODIFY" button, you can create a new user, and the following screen is displayed:

Enter the Pin to be changed (for example 3333) and then press the "OK" button. At this point the "NEW"
screen related to the code to be modified is displayed:

To change the code the procedure is exactly as in the "NEW" menu.

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DESCRIPTION OF THE OPERATOR CODE DELETE SCREEN.

Press the "DELETE" button on the "OPERATOR ACCESS" menu to access the following screen:

Enter the 4-digit operator code using the digital numeric keypad and press "OK" to confirm the code to be
deleted. At this point the "OPERATOR ACCESS" menu is automatically displayed again and the operator
code cancellation can be checked by the "VIEW ALL" menu.

DESCRIPTION OF OPERATOR CODE READING SCREEN.

The "VIEW ALL" function allows you view the last 100 "USER/ADMIN" codes of who used the machine.
Using the two arrows (page Up and page Down) it is possible to scroll through the pages.

By pressing the "EXIT" function key, you can exit the screen at any time.

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DESCRIPTION OF THE ACCESS PIN CODES CLEARING SCREEN.

The “CLEAR ALL CODES” function allows you to clear the access codes, the operator code reading and
profile settings in the “VIEW ALL” menu.

Pressing the “YES” button clears the saved operator profiles and displays the “OPERATOR ACCESS"
screen again. Pressing the “NO” button exits without cancelling the operator codes and returns to display
of the “OPERATOR ACCESS" screen.

By pressing the "EXIT" function key, you can exit the screen at any time and return to the “OPE-
RATOR ACCESS” screen.

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DESCRIPTION OF THE PRE-SELECTOR CONFIGURATION SCREEN

To configure the pre-selector press "HEIGHT PRESELECTOR" button on the "SERVICE MENU".

This displays the height pre-selector configuration screen as follows:

The two sub-menus are:

• "SET HEIGHTS" allows you to set the height of the different levels and areas.
• "CLEAR ALL HEIGHTS" allows you to delete all the previously entered pre-selector configuration data.

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DESCRIPTION OF THE PRE-SELECTOR - SET HEIGHTS CONFIGURATION SCREEN

If the “SET HEIGHTS” menu is selected the following screen appears:

To select the area to be configured, press one of the area selection buttons on the bar at the top of the
screen (by default after going into the menu the selected area is “AREA A”). For each of the 4 areas to be
configured there are 10 levels, for a total of 40 settable levels.

The options for each level are 2:

• With the "EDIT" button, you can set the height manually; a window is displayed with the numeric
keypad used to input the height.

Once inserted the desired height to confirm press the "OK" button.

It is possible to return to the "SET HEIGHTS" submenu by pressing the "EXIT" button at any time.

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• With the "AUTO" button, the height of the selected level is set semi-automatically. Once you press the
button, the screen looks like this:

The height flashes at a frequency of 1.5 Hz and turns yellow, thereby indicating that its is possible to select
the level height by raising/lowering the forks.
Once positioned the forks as desired, press the "SAVE" button to save the height. It is possible to return to
the "SET HEIGHTS" submenu pressing the "ABORT" button at any time.

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DESCRIPTION OF PRESELECTOR CONFIGURATION SCREEN - CLEAR ALL HEIGHTS

By pressing the "CLEAR ALL HEIGHTS" button in the "SET HEIGHTS" menu, the following screen
appears:

By selecting the "YES" button all set levels are deleted..

Instead press the "NO" or "EXIT" buttons to return to the "HEIGHT PRESELECTOR" submenu.

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DISPLAY SOFTWARE UPDATE.

Procedure for updating the display software.
1. Download the required files to a USB memory stick
2. Turn on the carriage
3. Pull the the USB cable from the connectors cover (see photo below) and insert the stick into the
connector.

4. If the display has a different software version to that of the USB memory stick, the following screen is
displayed:

5. Press "YES" if you want to apply the update to "NO" or "EXIT" to end the operation without executing
the software.
6. Once you click on "YES" the display updates and reboots.
7. Check in the USER menu under "SOFTWARE VERSION", that the software version was changed.

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If the display has a the same software version as the USB memory stick, the following screen is displayed:

By pressing the "EXIT" function key, you can exit the screen at any time and return to the main screen.

Pressing “OK” displays the following screen

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TRUCK FUNCTIONS
FORWARD/REVERSE DRIVE
ACTUATION CONTROLS

Forward/reverse
drive selection
button

Brake pedal
Accelerator
pedal

Operator presence
detection pedal

Forward/reverse
drive selection
button

To activate forward drive, press the drive selection button upwards and press the accelerator while
keeping the operator presence pedal pressed.
To activate reverse drive, press the drive selection button downwards and press the accelerator
while keeping the operator presence pedal depressed.
The driving speed is adjusted by the potentiometer on the accelerator pedal both going forwards
and backwards.

Actuators involved status Symbol on diagram

Key switch ON S1
Emergency switch ON S2
Forward/reverse drive selection button enabled S4
Operator presence detection pedal ON S3
Seat microswitch* ON S22
Seat belts fastened sensor* ON S5
Accelerator pedal forward/reverse drive R3

* where applicable

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CONFIGURATION PARAMETERS

Parameter change Adjustment Set options

i min braking cutback speed load brake

i max braking cutback speed 2 battery check
VCM

cutback speed 3 seatbelt

pedal brk range seat switch
seat sw.combi
acceler. delay
release braking
tiller braking
ACE2 TRACTION

invers. braking
decel. braking
pedal braking
- -
speed limit brk.
curve speed 1
curve speed 2
max speed forw
max speed back
spd 2ped recover
EPS

speed lim vs trac - -

For the adjustment values of each individual parameter, see the paragraph "STANDARD
CONFIGURATION OF CONTROLLER PARAMETERS".
For a description of each individual parameter, see the paragraph "DESCRIPTION OF
CONTROLLER PARAMETERS".

The maximum drive speed and acceleration are settable through 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

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SPEED REDUCTION
There are two settable levels of speed reduction available on the machine:
cutback speed first reduction in drive speed (7 km/h).
Intervenes when the height of the forks above ground exceeds the free lift height (h2).

cutback speed 2 second reduction in drive speed (4 km/h).

Intervenes when the height of the forks above ground exceeds 9 metres (applicable only with the fork encoder
option).

cutback speed 3 third reduction in drive speed (7 km/h).

Intervenes when the retractable fork carriage is fully forward (the speed starts reducing when the carriage
is extended forward over
100 mm and decreases in line with the forward movement of the carriage)

• Setting of the speed reduction levels

VCM / config menu adjustment / cutback speed
VCM / config menu adjustment / cutback speed 2
VCM / config menu adjustment / cutback speed 3

The truck is also equipped with a speed reduction button located on the control panel that, when pres-
sed, reduces the the drive speed to 7 km/h.

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 with steering angle with steering angle
between 0° and 5° (non- between 5° and 20°: between 20° and 90°:
settable dead zone): settable deceleration deceleration in proportion
maximum speed with the parameter to the steering angle
“curve speed 1” that can be set with the
parameter “curve speed
2”

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

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SPEED REDUCTIONS AND TRACTION BLOCK WITH “CHECK UP NEEDED” WARNING

When the programmed maintenance control is enabled, if maintenance is not carried out, depending on
the parameter values, it is possible that the truck may first be subject to a reduction in speed and then to
a drive interlock. Various truck operating parameters can be set via the programmer.
Setting the action that follows a maintenance warning
VCM / 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
VCM / 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
VCM / 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 ma-
ximum 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

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TRACTION BLOCKS
Traction is disabled if the seated operator microswitch (optional) and the fastened seat belt sensor (optio-
nal) 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
VCM / config menu set options / seat switch
Enabling/disabling seat belts fastened sensor
VCM / config menu set options / seatbelt
Enabling/disabling correct sequence check
VCM / config menu set options / seat sw.combi

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BRAKING
The truck is equipped with four braking systems:

• Service braking
• Braking on direction reversal
• Emergency braking
• Release braking

Truck braking will be performed in different ways according to which one of the above systems is implemented.
For further information on the braking systems see BRAKING SYSTEMS BRAKING SYSTEM section.

BRAKING SYSTEM WHEN DOES IT OPERATE?

Service braking The service brakes are applied when the brake pedal is pressed.

Electric braking of the drive motor; controls the deceleration ramp when
Braking on direction reversal
the drive direction is inverted.
Emergency braking occurs when an alarm is triggered that requires an
Emergency braking immediate arrest of truck drive or when one of the emergency buttons
on the truck is pressed.
Electric braking of the traction motor controls the deceleration ramp
Release braking
when the accelerator pedal is released.

Parking brake The machine is stationary and no drive control is activated

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

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STEERING WHEEL
ACTUATION CONTROLS

To steer to the right or to the left rotate the steering wheel in the corresponding direction.

Actuators involved status Symbol on diagram

Key switch ON S1
Emergency switch ON S2
Traction wheel auto-
Steering centering sensor centering sequence B7
performed
Steering wheel right/left rotation S20

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CONFIGURATION PARAMETERS

Special Hardware
Parameter change Set options
adjustment settings
curve speed 1
TRACTION

curve speed 2
ACE2

speed limit debug output autoteaching aux output #1

sensitivity top max speed aux output #2
EPS

sensitivy vs trc 0-pos teaching

speed lim vs trc

For the adjustment values of each individual parameter, see the paragraph "STANDARD
CONFIGURATION OF CONTROLLER PARAMETERS".
For a description of each individual parameter, see the paragraph "DESCRIPTION OF
CONTROLLER PARAMETERS".

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 centering sensor B7, the software auto-
centres the traction wheel.

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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

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FORK LIFTING/LOWERING
ACTUATION CONTROLS

Standard control lever Joystick (optional)

Version with lever (standard): to lift the forks, back the fork lifting/lowering lever back, to lower
the forks, push the fork lifting/lowering lever forward.

Joystick version (optional): to lift the forks, pull the joystick back; to lower the forks push the
joystick forward.

Actuators involved status Abbreviation

Key switch ON S1
Emergency switch ON S2
Lever backward/forward S12
Fork lifting/lowering request Joystick backward/
S12
forward

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CONFIGURATION PARAMETERS

Parameter change Adjustment Set options

accel delay lift mlm deadband height indicator

decel delay lift mlm deadband end slow spd ffl ml
max lft sp limit joy. deadband lift limit stop
lift min spd joy. deadb. end
max low sp limit offset fork lower soft stop
i min evp1 lift limit blk m 1 lift block
i middle evp1 lift limit blk cm 2 lift block
i min evp2 ctb rng lift lmt interlock forks
evp1 opn delay 1 ctb spd lift lmt interl. frk ovrd
evp1 opn delay 2 low soft rng sp battery check
evp1 cls delay 1 lower soft speed enc. lock test
evp1 cls delay 2 lft range ffl ml height selector
evp2 open delay lft slow ffl ml
VCM

evp2 close delay low range ffl ml

low slow ffl ml
lft blk1 hght m
lft blk1 hght cm
lft blk2 hght m
lft blk2 hght cm
interl hgt blk f
height p lft ctb
height p lft ctb r
height p low ctb
height p low ctb r
offset pick
offset place

For the adjustment values of each individual parameter, see the paragraph "STANDARD
CONFIGURATION OF CONTROLLER PARAMETERS".
For a description of each individual parameter, see the paragraph "DESCRIPTION OF
CONTROLLER PARAMETERS".

The maximum fork lifting and lowering speed can be set with the programmer.
Setting the maximum fork lifting speed
VCM / main menu parameter change / max lft sp limit
Setting for minimum pump speed during fork lifting
VCM / main menu parameter change / lift min spd
Setting the maximum fork lowering speed
VCM / main menu parameter change / max low sp limit

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ACCELERATION/DECELERATION RAMPS
On operating the lifting lever, the forks begin to rise with an acceleration ramp that can be set via the pro-
grammer.
Setting the fork lift acceleration ramp
VCM / 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 pro-
grammer.
Setting the lever release deceleration ramp
VCM / main menu parameter change / decel delay lift

LIMIT STOP SLOWDOWN LIFTING / LOWERING

We need to distinguish between two cases:
• Fork height encoder not installed
• fork height encoder installed (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.
During lifting and lowering, the forks start slowing down in the transition between the free lift travel limit
and main lifting.
The speeds can be with in the following parameters:
Setting lifting speed
VCM / config menu adjustment / lft slow ffl ml
Setting lowering speed
VCM / config menu adjustment / low slow ffl ml

WITH FORK HEIGHT ENCODER (OPTIONAL)

During lifting and lowering, the forks start slowing down in the transition between the free lift travel limit
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
VCM / config menu adjustment / lft slow ffl ml
Setting deceleration distance when lifting
VCM / config menu adjustment / lft range ffl ml
Setting lowering speed
VCM / config menu adjustment / low slow ffl ml
Setting deceleration distance when lowering
VCM / 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

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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
VCM / config menu adjustment / ctb spd lift lmt
Setting deceleration distance
VCM / 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
VCM / config menu adjustment / lower soft speed
Setting deceleration distance
VCM / config menu adjustment / low soft rng sp

FORK LIFTING/LOWERING INTERLOCKS (WITH FORK HEIGHT ENCODER)

Setting the maximum fork height of the first block
VCM / config menu adjustment / lft blk 1 hght m
VCM / config menu adjustment / lft blk 1 hght cm
Setting the maximum fork height of the second block
VCM / config menu adjustment / lft blk 2 hght m
VCM / config menu adjustment / lft blk 2 hght cm
Setting the fork lowering interlock height
VCM / config menu adjustment / interl hgt blk f

The height is calculated according to the formula (lft blk 1 hght m)x100 + (lft blk 1 hght cm).

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HYDRAULIC FUNCTIONS
ACTUATION CONTROLS

Standard control lever Joystick (optional)

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.

Actuators involved status Abbreviation

Key switch ON S1
Emergency switch ON S2
Lever backward/forward S13
Retractable carriage back
Joystick right/left S13
Lever backward/forward S14
Fork tilt
Mini-joystick up/down S14
Lever backward/forward S15
Fork side shift
Mini-joystick right/left S15

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CONFIGURATION PARAMETERS

Parameter change Adjustment Set options

acc. delay reach mlm deadband autoc. sideshift

dec. delay reach mlm deadband end autoc. tilt
reach fw max spd joy. deadband 5th way hydraul.
reach rv max spd joy. deadb. end extended multif.
accel delay aux reach full fwd
decel delay aux reach full back
opt hyd max spd reach rng ctb ff
VCM

evp3 open delay reach rng ctb fb

evp3 close delay reach ctb speed
evp4 open delay reach ctb speedm
evp4 close delay
evp5 open delay
evp5 close delay
evp6 open delay
evp6 close delay

For the adjustment values of each individual parameter, see the paragraph "STANDARD
CONFIGURATION OF CONTROLLER PARAMETERS".
For a description of each individual parameter, see the paragraph "DESCRIPTION OF
CONTROLLER PARAMETERS".

RETRACTABLE CARRIAGE ACCELERATION / DECELERATION RAMPS

On operating the carriage forward/back lever, the carriage begins to move with an acceleration ramp that
can be set via the programmer.

Setting the carriage forward/back acceleration ramp

VCM / main menu parameter change / acc. delay reach

On releasing the carriage forward/back lever, the carriage begins to stop with a deceleration ramp that can
be set via the programmer.
Setting the lever release deceleration ramp
VCM / main menu parameter change / dec. delay reach

The maximum carriage forward and back speed can be set with the programmer.
Setting the maximum carriage forward speed
VCM / main menu parameter change / reach fw max spd

Setting the maximum carriage back speed

VCM / main menu parameter change / reach rv max spd

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CARRIAGE FORWARD / BACK TRAVEL LIMIT DECELERATION

When moving forward and back, the carriage start to slow down before it reaches the travel limit.
With the programmer it is possible to set the speed of the carriage and the distance where it starts slowing
down.
Setting the carriage forward/back speed
VCM / config menu adjustment / reach ctb speed

Setting forward deceleration distance

VCM / config menu adjustment / reach rng ctb ff

Setting back deceleration distance

VCM / config menu adjustment / reach rng ctb fb

AUXILIARY FUNCTIONS ACCELERATION / DECELERATION RAMPS

On operating the lever of an auxiliary function (fork tilt or side shift), the forks begin to move with an acce-
leration ramp that can be set via the programmer.
Setting the auxiliary function acceleration ramp
VCM / main menu parameter change / accel delay aux

On releasing the lever of an auxiliary function (fork tilt or side shift), the forks begin to stop with a decele-
ration ramp that can be set via the programmer.
Setting the lever release deceleration ramp
VCM / main menu parameter change / decel delay aux

FORKS AUTO CENTERING

On pressing the button for the desired auto centering (side shifting, tilting), the forks begin to carry out the
desired auto centering procedure.
With the programmer it is possible to enable/disable these options.
Enabling fork side shift auto centering
VCM / config menu set options / autoc. sideshift
Enabling fork tilt auto centering
VMC / config menu set options / autoc. tilt

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FORK TILT AUTO CENTERING SYSTEM

The tilt auto centering system provides a tilt angle precision of 0.1°thanks to the integrated inclinometer.
If the auto centering function fails to return the forks to the horizontal position, it will be necessary to carry
out the sensor calibration procedure to acquire the following parameter settings, which can be accessed
in the menu VCM/menu adjustment:

Tilt Full Down

Press the operator presence pedal and tilt the forks downwards.
With the forks tilted fully downwards, click on the “Acquire” icon of the “Tilt Full Down” parameter on the
PC Service Tool.

Tilt Full Up
Press the operator presence pedal and tilt the forks upwards.
With the forks tilted fully upwards, click on the “Acquire” icon of the “Tilt Full Up” parameter on the PC
Service Tool.

Tilt Horizontal
Press the operator presence pedal and tilt the fork carriage up /down until the forks are horizontal and then
click on the "Acquire" icon of the “Tilt Horizontal” parameter on the PC Service Tool.
To improve the precision of the tilt auto centering system, rest the forks on the shelving and acquire the tilt
“Tilt Horizontal” value.

Tilt Horizontal is the reference parameter for the tilt auto centering position. An incorrect
setting of this parameter would cause a positioning error during activation of the Auto Tilt
function.

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CONFIGURATION PARAMETER ACCESS PROCEDURE

Thanks to the CAN BUS connection, the controller parameters can be configured by connecting the console
to the connector in the control panel or PCSTool (via IFAk cable) via connector X40, selecting the 250KBps
connection speed and accessing the relative menu.

Before connecting the console to the controller, position the key switch on “OFF”.

Each controller is identified by a number. Thanks to the CAN BUS connection it is possible to configure
the parameters of the various controllers by connecting the console and then searching for the relevant
controller in the “SET MODEL” menu.

Before using the console to select the number of the controller to configure, make sure
that the “model type” option of the controller to which it is connected is set to 0.

Controller CONTROLLER NUMBER MODEL TYPE

VCM 1 0
ACE2 TRACTION 2 0
ACE2 PUMP 5 0
EPS ACW 6 0

MENU SEARCH PROCEDURE AND PARAMETER MODIFICATION

Opening heading

Press “Roll h” and “Set h” at the same time

The SET MODEL menu heading appears. If another

menu is displayed, press the “Roll h” or “Roll i”
key until the SET MODEL menu appears.

Press “Enter”

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The number corresponding to the controller you are

connected to appears

Press “Set h” or “Set i” to change the selected

controller to which you want to connect

The new selected controller appears

Press the “Roll h” key to check the “model type”

The model type appears

Press “Set h” or “Set i” to scroll through the “mo-

del types” to value 0.

The model type of the selected controller appears

Press the "Out" key to exit the selection

The modification confirmation request appears

Press “Enter” to confirm. To exit without confirming

the selection, press "Out".

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Having pressed the enter key the heading of the

SET MODEL menu appears

Press “Roll i”, “Out” and “Set i” at the same time

The display briefly shows the connection to the

selected controller

The selected controller screen appears, allowing

configuration of the various parameters

Press “Roll h” and “Set h” at the same time

The SET MODEL menu heading appears.

Press the “Roll h” or “Roll i” key until the desired

menu appears.

The SET OPTION menu heading appears.

Press “Enter”

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SERVICE ELECTRICAL SYSTEM

The heading of the first parameter with its current

value appears. To scroll through the parameters
press the “Roll h” or “Roll i” key

Press “Set h” or “Set i” to edit the value.

The new value appears.

Press the "Out" key to exit the selection

The modification confirmation request appears

Press “Enter” to confirm. To exit without confirming

the selection, press "Out".

After having pressed the enter key the heading of

the SET OPTION menu reappears.

Press the "Out" key to return to the opening heading

Opening heading

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Opening heading

Press the "Enter"key to enter the main menu

The PARAMETER CHANGE menu heading appe-

ars. If another menu is displayed, press the “Roll
h” or “Roll i” key until the PARAMETER CHANGE
menu appears.

Press “Enter”

The heading of the first parameter with its current

value appears. To scroll through the parameters
press the “Roll h” or “Roll i” key

Press “Set h” or “Set i” to edit the value.

The new value appears.

Press the "Out" key to exit the selection

The modification confirmation request appears

Press “Enter” to confirm. To exit without confirming

the selection, press "Out".

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 SERVICE ELECTRICAL SYSTEM

GUIDE FOR INSTALLATION OF CAN PC CONSOLE ON PCST

To allow connection of PCST to the truck, it is essential that the CAN PC Console is correctly configured
in the PCST.
The CAN PC Console can be downloaded from the "Software Resources" section (in Vehicle Operating
Software - NON Serial Number Specific section).

Once downloaded, the zip file must be extracted to any location (or a specific location) on the computer.
To configure the CAN PC Console in the PCST, use the following procedure:

1. Open the folder where you have saved the file extracted by .zip file.

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2. Run the installer file by double clicking on it

3. Windows will probably give you a warning, press "Continue" or “Run”

4. Select the language:

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 SERVICE ELECTRICAL SYSTEM

5. The following window will appear: click “Next”.

6.NOTE: If Windows XP is installed on the computer in any languages except English, you will
have to create the folder “Program Files” under C:\ (i.e.: C:\Program files\), this is the installation
pathway for Can PC Console.

7. Accept the license agreement and click “Next”. Click again on “Next” to agree with the specified folder.

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8. Confirm installation by pressing “Install”

9. Installation will begin:

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SERVICE ELECTRICAL SYSTEM

10. The following message will appear on completion of installation is finished, click on “Finish”:

11. To connect to the truck, proceed as follows:

• Open PCST 4.7

• Enter username and password
• File > Connect
• Select D849 unit code
• To open the Can PC Console click here

If the arrow does not appear, please, read again point 6

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• The Can PC Console will open as in the following screen:

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 SERVICE ELECTRICAL SYSTEM

CDF FILE LOADING PROCEDURE

The configuration file (CDF) is present in the drive controller and in the VCM controller. It will be necessary
to reload the CDF file in the following cases:
1. Replacement of both controllers.

2. CDF file damaged on both controllers.

3. Purchase of aftermarket kits or modifications that require updating of the CDF.
In these cases, after purchasing a kit or following modification, a new CDF file, updated to the latest
version, shall be automatically generated and released. Consequently, in order to ensure the configuration
file is loaded correctly, all the controllers on the machine will have to be updated with the latest version.

It is important to note that the configuration file available online cannot be uploaded if the truck's controllers
have been updated from the original versions and the first digit after the point of the new software version
differs from that of the version originally installed (for example, a CDF created for version 2.30 can be
installed on truck with software version 2.33, but not 2.40.

To avoid the issue described in point 2, carry out the procedure to copy the CDF file on
the controllers (see
the SET CONFIGURAT parameter in this section of the manual)

Requirements for file installation:

• Windows XP 32-64 bit, Windows 7 32-64 bit, Windows 10 32-64 bit, not tested for Windows 8.

Installation:
• Create a folder on your C: drive called C:\cdf_program
• Create a folder on your C: drive called C:\temp_cdf
• Extract the files from the .zip file in the folder C:\cdf_program
• The folder C:\cdf_program should contain two files:
1. ZAPI.EXE
2. cdf_upload_tool.exe

Use:

• Copy the CDF file, previously downloaded

from the AxcessOnline website, in the folder
C:\temp_cdf.
• Connect the IFAK cable to the connector of
the truck (X40).
• Run the file C:\cdf_program\cdf_upload_tool.
exe.
• Enter the serial number of the truck into the
• window and press "Enter" (Fig.1). Å
Fig. 1

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• The program looks for the CDF file in the

folder C:\temp_cdf (DXXXT01406P_01.txt in
this example).
If the file is found correctly, the CHK button is
enabled.
• Press the CHK button to continue (Fig.2).

Fig. 2

• The program checks the syntax of the CDF file

and the CAN communication.
Each error is reported and the update execution
is stopped (see error list).
Correct the problem or exit.
Å
• If all checks are successful, the GO button is
enabled (Fig.3)
• Press the GO button to start loading the CDF
file.

Fig. 3

Error
Description Corrective action
code
0 OK No action is required

1 Parameters not correct Contact the Service

Check that the file was saved in the folder C.\temp_cdf. If it is

2 CDF file not found
not present ask for assistance by the Service

3 CheckSum Error The CDF file may be corrupt, report the problem to the Service

4 Wrong IFAK configuration Check the configuration of the IFAK and tray again

5 Wrong CANbus configuration Check the CANbus connection and switch on the truck.
CAN Master communication setting
6 Check the CANbus connection and switch on the truck.
error
7-8-9 CDF file loading error Report the problem to the Service

100 Serial number not matching The CDF file refers to another truck, loading is forbidden
Software running on the truck is not
200 Check the software version on the truck, contact the Service
valid for the CDF file
211 Parameters not found Contact the Service

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STANDARD CONFIGURATION OF CONTROLLER PARAMETERS

It is always advisable to keep the factory settings as designed in order to have the best
compromise between performance and component wear. It is however possible to cu-
stomise 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 CONTROLLER
VCM / main menuparameter change /
VCM / config menu special adjustment /
VCM / config menu hardware setting /
VCM / config menu set options /
VCM / config menu adjustment /

PARAMETER CHANGE MENU PARAMETER CHANGE MENU

PARAMETER level PARAMETER level

ACCEL DELAY LIFT 0.9 sec. EVP4 CLOSE DELAY 1 sec.
DECEL DELAY LIFT 0.5 sec. EVP5 OPEN DELAY 0.5 sec.
MAX LFT SP LIMIT 0.70 m/s EVP5 CLOSE DELAY 0.5 sec.
LIFT MIN SPD 3 Hz EVP6 OPEN DELAY 0.5 sec.
MAX LOW SP LIMIT 0.55 m/s EVP6 CLOSE DELAY 0.5 sec.
ACC. DELAY REACH 0.5 sec.
DEC. DELAY REACH 0.5 sec.
HARDWARE SETTING MENU
REACH FW MAX SPD 38 Hz
PARAMETER level
REACH RV MAX SPD 24 Hz
SET CONFIGURAT 0
ACCEL DELAY AUX 0.1 sec.
DECEL DELAY AUX 0.1 sec.
OPT HYD MAX SPD 25 Hz
I MIN EVP1 20%
I MIDDLE EVP1 22.70%
I MIN EVP2 20%
I MIN BRAKING 25.1%
I MAX BRAKING 100%
EVP1 OPN DELAY 1 0.1 sec.
EVP1 OPN DELAY 2 0.6 sec.
EVP1 CLS DELAY 1 0.3 sec.
EVP1 CLS DELAY 2 0.6 sec.
EVP2 OPEN DELAY 0.8 sec.
EVP2 CLOSE DELAY 0.7 sec.
EVP3 OPEN DELAY 0.8 sec.
EVP3 CLOSE DELAY 1 sec.
EVP4 OPEN DELAY 0.9 sec.

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SET OPTIONS menu SET OPTION menu

PARAMETER level PARAMETER level

HOUR COUNTER RUNNING BA FORWARD ABSENT
BACKUP ALRM MODE ABSENT BA LFT TRL TL SS ABSENT
HEIGHT INDICATOR ABSENT BA LOW TRL TL SS ABSENT
SLOW SPD FFL ML ABSENT BA CONTINUOUS ABSENT
LIFT LIMIT STOP ABSENT FLASHING BEACON ABSENT
LOWER SOFT STOP ABSENT FB REVERSE ABSENT
AUTOC.SIDESHIFT ABSENT FB FORWARD ABSENT
AUTOC.TILT ABSENT FB LFT TRL TL SS ABSENT
AUTOC.TILT CONF OPTION#1 FB LOW TRL TL SS ABSENT
WEIGHT ABSENT FB CONTINUOUS ABSENT
LASER ABSENT SPOT LIGHT LEVEL = 0
LOAD BRAKE ABSENT HYG LI-ION BATT. ABSENT
5TH WAY HYDRAUL. ABSENT BMS RED.SPEED 5.6 km/h
PIN ACCESS CODE ABSENT
SEATBELT ABSENT
SEAT SWITCH ABSENT
SEAT SW.COMBI ABSENT
1 LIFT BLOCK ABSENT
2 LIFT BLOCK ABSENT
INTERLOCK FORKS ABSENT
INTERL. FRK OVRD NONE
BATTERY CHECK LEVEL = 3
TRANSFER HOURS LEVEL = 0
EXTENDED MULTIF. ABSENT
ENC. LOCK TEST PRESENT
HEIGHT SELECTOR ABSENT
PALLET SENSOR ABSENT
NEV1 ABSENT
CHECK UP DONE ABSENT
CHECK UP TYPE NONE
OVERLOAD TEST PRESENT
QUADRUPLEX ABSENT
5TH WAY HYD SAFE ABSENT
BACKUP ALRM PULSE PRESENT
MAST DEFL REDUCT ABSENT
BA REVERSE ABSENT

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ADJUSTMENT menu ADJUSTMENT menu

PARAMETER level PARAMETER level

MLM DEADBAND 3% WATCH YEAR 0
MLM DEADBAND END 0% WATCH MONTH 0
JOY. DEADBAND 17% WATCH DATE 0
JOY. DEADB. END 24% WATCH HOURS 0
OFFSET FORK 350 mm WATCH MINUTES 0
LIFT LIMIT BLK M 4m HEIGHT P LFT CTB 0.07 m/s
LFT LIMIT BLK CM 95 cm HEIGHT P LFT CTB R 350 mm
CTB RNG LIFT LMT 500 mm HEIGHT P LOW CTB 0.08 m/s
CTB SPD LIFT LMT 0.20 m/s HEIGHT P LOW CTB R 350 mm
LOW SOFT RNG SP 550 mm OFFSET PICK 100 mm
LOWER SOFT SPEED 0.08 m/s OFFSET PLACE 100 mm
LFT RANGE FFL ML 500 mm EXCHANGE VLV ON 800
LFT SLOW FFL ML 0.40 m/s TILT FULL DOWN 1.9 V
LOW RANGE FFL ML 250 mm TILT HORIZONTAL 2.1 V
LOW SLOW FFL ML 0.32 m/s TILT FULL UP 2.9 V
CUTBACK SPEED 7.0 km/h
CUTBACK SPEED 2 4.0 km/h
LFT BLK1 HGHT M 3m
LFT BLK1 HGHT CM 0 cm
LFT BLK2 HGHT M 3m
LFT BLK2 HGHT CM 50 cm
INTERL HGT BLK F 600 mm
REACH FULL FWD 3.7 V
REACH FULL BACK 0.5 V
REACH RNG CTB FF 11.4%
REACH RNG CTB FB 19.6%
REACH CTB SPEED 14.9%
REACH CTB SPEEDM 50.2%
CUTBACK SPEED 3 7.0 km/h
MAX WGT CELL 4.4 V
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 0h

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ACE2 TRACTION CONTROLLER

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

PARAMETER CHANGE MENU SET OPTIONS MENU

PARAMETER level PARAMETER level

ACCELER. DELAY 2.6 sec. HOUR COUNTER RUNNING

RELEASE BRAKING 2.2 sec. AUX OUT FUNCT.1 PRESENT

TILLER BRAKING 2.2 sec. AUX OUT FUNCT.2 PRESENT

INVERS. BRAKING 1.9 sec. PULSE DIR INPUT OPTION #1

DECEL. BRAKING 3 sec.

PEDAL BRAKING 0.3 sec.
SPEED LIMIT BRK. 2.8 sec.
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
SPD 2PED RECOVER 0.2 km/h
ACCEL DISPLAY 2.6 sec.
MAX SPEED DISP 5.0 km/h
REL BRK DISPLAY 2.2 sec.
INV BRK DISPLAY 1.9 sec.

ACE2 PUMP CONTROLLER

ACE2 PUMP / config menu set option /

SET OPTIONS MENU

PARAMETER level
AUX OUT FUNCT.1 ABSENT
AUX OUT FUNCT.2 ABSENT

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EPS ACW CONTROLLER

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 /

PARAMETER CHANGE MENU SET OPTIONS MENU

PARAMETER level PARAMETER level

SPEED LIMIT LEVEL = 6 AUX OUTPUT #1 ABSENT
SENSITIVITY LEVEL = 3 AUX OUTPUT #2 ABSENT
SENSITIVE VS TRC 40%
SPEED LIM VS TRC 50% HARDWARE SETTING MENU

PARAMETER level
SPECIAL ADJUSTMENT MENU TOP MAX SPEED 58 Hz
PARAMETER level AUTOTEACHING OFF

DEBUG OUTPUT 15 0-POS TEACHING OFF

REV STEEL WHEEL OFF

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DESCRIPTION OF CONTROLLER PARAMETERS

VCM CONTROLLER 1
VCM / main menuparameter change /
VCM / config menu special adjustment /
VCM / config menu hardware setting /
VCM / config menu set options /
VCM/ config menu adjustment /

PARAMETER CHANGE MENU

PARAMETER level = 0 level = 9

ACCEL DELAY LIFT
Determines the acceleration ramp, in seconds, during lifting function. This parameter sets the time needed to
accelerate the pump motor from 0Hz to 100Hz

DECEL DELAY LIFT

Determines the deceleration ramp in seconds 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

LIFT MIN SPD

Defines the maximum speed of the pump motor during the lifting function.

MAX LOW SP LIMIT

Defines the maximum lowering speed in m/s

ACC. DELAY REACH

Determines the acceleration ramp in seconds during a reach function. This parameter sets the time needed to
accelerate the pump motor from 0Hz to 100Hz

DEC. DELAY REACH

Controls the deceleration ramp in seconds when the reach 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 reach forward function

REACH RV MAX SPD

Defines the maximum speed of the pump motor during a reach back function

ACCEL DELAY AUX

Determines the acceleration ramp in seconds during an auxiliary function (tilt or side shift). This parameter sets the
time needed to accelerate the pump motor from 0Hz to 100Hz

DECEL DELAY AUX

Controls the deceleration ramp when the auxiliary function control (tilt or side shift) has been lowered. This parameter
sets the time needed to decelerate the pump motor from 100Hz to 0Hz

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PARAMETER CHANGE MENU

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
This parameter determines the minimum current applied on EVP1 when the lowering control is in the minimum
position.

I MIDDLE EVP1
This parameter determines the minimum current applied on EVP1 when the lowering control is in the middle position.

I MIN EVP2
This parameter determines the minimum current applied on EVP2 when the lifting control is in the minimum position.

I MIN BRAKING
From 0 to 100. This parameter determines the maximum current applied to the load wheel brakes when the control
is in the minimum position

I MAX BRAKING
From 0 to 100. This parameter determines the maximum current applied to the load wheel brakes when the control
is in the maximum position

EVP1 OPN DELAY 1

Determines the acceleration ramp, in seconds, on EVP1. The parameter sets the time necessary to increase the
current from MIN EVP1 to MIDDLE EVP1.

EVP1 OPN DELAY 2

Determines the acceleration ramp, in seconds, on EVP1. The parameter sets the time necessary to increase the
current from MIDDLE EVP1 to MAX EVP1.

EVP1 CLS DELAY 1

Determines the deceleration ramp, in seconds, on EVP1. The parameter sets the time necessary to reduce the
current from MIDDLE EVP1 to MIN EVP1.

EVP1 CLS DELAY 2

Determines the deceleration ramp, in seconds, on EVP1. The parameter sets the time necessary to reduce the
current from MAX EVP1 to MIDDLE EVP1.

EVP2 OPEN DELAY

Determines the acceleration ramp, in seconds, on EVP2. The parameter sets the time necessary to increase the
current from MIN EVP2 to MIDDLE EVP2.

EVP2 CLOSE DELAY

Determines the deceleration ramp, in seconds, on EVP2. The parameter sets the time necessary to reduce the
current from MIDDLE EVP2 to MIN EVP2.

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MAIN MENU PARAMETER CHANGE

PARAMETER level = 0 level = 9

EVP3 OPEN DELAY
Determines the acceleration ramp, in seconds, on EVP3. The parameter sets the time necessary to increase the
current from MIN EVP3 to MAX EVP3.

EVP3 OPEN DELAY

Determines the deceleration ramp, in seconds, on EVP3. The parameter sets the time necessary to reduce the
current from MIDDLE EVP3 to MIN EVP3.

EVP4 OPEN DELAY

Determines the acceleration ramp, in seconds, on EVP4. The parameter sets the time necessary to increase the
current from MIN EVP4 to MAX EVP4.

EVP4 CLOSE DELAY

Determines the deceleration ramp, in seconds, on EVP4. The parameter sets the time necessary to reduce the
current from MAX EVP4 to MIN EVP4.

EVP5 OPEN DELAY

Determines the acceleration ramp, in seconds, on EVP5. The parameter sets the time necessary to increase the
current from MIN EVP5 to MAX EVP5.

EVP5 CLOSE DELAY

Determines the deceleration ramp, in seconds, on EVP5. The parameter sets the time necessary to reduce the
current from MIDDLE EVP5 to MIN EVP5.

EVP6 OPEN DELAY

Determines the acceleration ramp, in seconds, on EVP6. The parameter sets the time necessary to increase the
current from MIN EVP6 to MAX EVP6.

EVP6 CLOSE DELAY

Determines the deceleration ramp, in seconds, on EVP6. The parameter sets the time necessary to reduce the
current from MIDDLE EVP6 to MIN EVP6.

HARDWARE SETTING MENU

PARAMETER level = 0 level = 9

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

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SET OPTIONS menu

PARAMETER level
KEY ON: record of truck start up
HOUR COUNTER RUNNING: record of an active trac-
tion 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
drive- LEVEL2: the backup alarm is activated when the truck moves in forward drive LEVEL3: The backup alarm is
activated in both forward and 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 auto centering option

AUTOC.TILT
This parameter enables the tilt auto centering option

AUTOC.TILT CONF
Option #1 enables the tilt auto centering option via inductive sensor. Option#2 enables the tilt auto centering option
via inclinometer

WEIGHT
This parameter enables the weighing option

LASER
If set to PRESENT with HEIGHT INDICATOR, the Laser is automatically activated in 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

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SET OPTIONS menu

PARAMETER level = 0 level = 9

PIN ACCESS CODE
If set to PRESENT, a password will be required to enable the truck functions

SEATBELT
This parameter enables the seat belt presence switch

SEAT SWITCH
This parameter enables the operator 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 0= if there is any discrepancy between the transfer hours meter and the VCM, an alarm is signalled and
after 2 minutes the highest value is saved on both controllers. LEVEL 1= 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
LEVEL 2= 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

EXTENDED MULTIF.
If set to PRESENT, three combined functions are permitted

ENC. LOCK TEST

Enables the “encoder locked” diagnosis for encoder 1 and encoder 2. If the encoder is locked, an alarm is generated
and the pump stops.

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SET OPTIONS menu

PARAMETER 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
CHECK UP TYPE
340 hours
3: like 2 plus truck block after 380
hours
Enables/disables the programmed maintenance mode and warning. At the end of maintenance set the VCM / config
menu set options / check up done ON parameter

HEIGHT SELECTOR
If set to PRESENT with HEIGHT INDICATOR, the operator can program up to 40 levels for picking and placing the
load

PALLET SENSOR
When set to PRESENT with the height pre-selector, pallet presence is checked

OVERLOAD TEST
Enables a load cell test when the weight of the load exceeds the nominal weight by 150 kg or more.

QUADRUPLEX
This parameter is present when a 4-stage mast is installed

5TH WAY HYD SAFE

If this parameter is set to "PRESENT", the 5th way selection button must always be held pressed in order to enable
operation of the 5th hydraulic way.

BACKUP ALRM PULSE

If set to “ABSENT”, this parameter changes the sound of the backup alarm buzzer to a continuous sound.

MAST DEFL REDUCT

If set to “PRESENT”, this parameter stops the functions carriage forward and reverse drive when the pallet is picked.

BA REVERSE
Back alarm buzzer activated, when the truck moves in reverse (fork side)

BA FORWARD
The backup alarm buzzer is activated when the truck moves forward (operator side).

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SET OPTIONS menu

PARAMETER level = 0 level = 9

BA LFT TRL TL SS
The backup alarm buzzer is activated during fork lifting, carriage movement, tilt and side shift.

BA LOW TRL TL SS
The backup alarm buzzer is activated during fork lowering, carriage movement, tilt and side shift.

BA CONTINUOUS
The backup alarm buzzer is activated upon switching the truck on.

FLASHING BEACON
This parameter enables the flashing beacon

FB REVERSE
The flashing beacon is activated when the truck moves in reverse (fork side).

FB FORWARD
The flashing beacon is activated when the truck moves forward (operator side)

FB LFT TRL TL SS
The flashing beacon is activated during fork lifting, carriage movement, tilt and side shift.

FB LOW TRL TL SS
The flashing beacon is activated during fork lowering, carriage movement, tilt and side shift.

FB CONTINUOUS
The flashing beacon is activated upon switching the truck on.

SPOT LIGHT
LEVEL = 0 Spot light deactivated - LEVEL 1: Spot light activated when the truck travels in reverse (fork side) -
LEVEL2: Spot light activated when the truck travels forward

HYG LI-ION BATT.

If set to “ABSENT”, the truck is equipped with a lead battery. If set to “PRESENT”, the truck is equipped with a
lithium ion battery

BMS RED.SPEED
This parameter is only used when the truck is equipped with a lithium ion battery. Activates speed reduction when
the BMS system generates an alarm.

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ADJUSTMENT MENU

PARAMETER 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

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

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 ELECTRICAL SYSTEM SERVICE

CONFIG MENU ADJUSTMENT

PARAMETER level = 0 level = 9

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

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

INTERL HGT BLK F

Defines the height (in cm) from ground level at which the fork lowering function will stop when the INTERLOCK
FORKS and HEIGHT INDICATOR options are activated.

REACH FULL FWD

Value of the position sensor when the retractable carriage is in the fully forward position

REACH FULL BACK

Value of the position sensor when the retractable carriage is in the fully back 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

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CONFIG MENU ADJUSTMENT

PARAMETER level = 0 level = 9

REACH CTB SPEED
Defines the retractable carriage speed when speed reduction is applied

REACH CTB SPEEDM

Defines the retractable carriage speed when speed reduction is applied during a combined function

CUTBACK SPEED 3
Defines the drive speed when TRACTION CUTBACK 3 is applied with the retractable carriage forward.

MAX WGT CELL

Defines the maximum weight with the nominal load on the forks

MIN WGT CELL

Defines the minimum 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.

BAT. MAX ADJ.

Adjusts the upper level of the battery discharge table.

WATCH YEAR
Used to set the year on the clock in real time

WATCH MONTH
Used to set the month on the clock in real time

WATCH HOURS
Used to set the hour on the clock in real time

WATCH MINUTES
Used to set the minutes on the clock in real time

HEIGHT P LFT CTB

In PRESELECTOR mode, it defines the final lifting speed when the desired height is reached

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CONFIG MENU ADJUSTMENT

PARAMETER level = 0 level = 9

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

EXCHANGE VLV ON
Defines the delay of the fork tilt/side shift valve

TILT FULL DOWN

Defines the value of the inclinometer when the forks are tilted fully downwards

TILT HORIZONTAL
Defines the value of the inclinometer when the forks are horizontal

TILT FULL UP
Defines the value of the inclinometer when the forks are tilted fully upwards

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ACE2 TRACTION CONTROLLER

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

PARAMETER CHANGE MENU

PARAMETER level
ACCELER. DELAY
Traction acceleration ramp

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

SPD 2PED RECOVER

It is used only for double pedals and determines the the speed below which both accelerator pedals must be
released to restart drive, in the event that both pedals are pressed simultaneously during drive.

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 ELECTRICAL SYSTEM SERVICE

PARAMETER CHANGE MENU

PARAMETER level
ACCEL. DISPLAY
Maximum drive 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

SET OPTIONS MENU

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

AUX OUT FUNCT.1

When set to PRESENT, the electromechanical brake is activated after a drive request if all the relevant diagnostic
checks are passed.
If set to ABSENT, no diagnostic checks are performed and the brake is not activated after a drive request

AUX OUT FUNCT.2

When set to PRESENT, the auxiliary coil is activated after a drive request if all the relevant diagnostic checks are
passed.
If set to ABSENT, no diagnostic checks are performed and the coil is not activated after a drive 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

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ACE2 PUMP CONTROLLER

ACE2 PUMP / config menu set options /

SET OPTIONS menu

PARAMETER level
AUX OUT FUNCT.1
When set to PRESENT, the electromechanical brake is activated after a pump request if all the relevant diagnostic
checks are passed.
If set to ABSENT, no diagnostic checks are performed and the brake is not activated after a pump request

AUX OUT FUNCT.2

When set to PRESENT, the auxiliary coil is activated after a pump request if all the relevant diagnostic checks are
passed.
If set to ABSENT, no diagnostic checks are performed and the coil is not activated after a pump request

EPS ACW CONTROLLER

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 /

PARAMETER CHANGE menu

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

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SPECIAL ADJUSTMENT MENU

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.
Level 0: auto-acquisition of the stepper motor offset in open cycle applications. It automatically returns to
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

REV STEER WHEEL

Inverts the direction of rotation of the steering motor, with respect to the direction in which the stepper motor is
rotated.

HARDWARE SETTING MENU

PARAMETER level
AUTOTEACHING
When this parameter is set to ON, the autoteaching procedure to acquire encoder pulses is performed.

0-POS TEACHING
Determines the position of the steer wheel after auto centering.

TOP MAX SPEED

Maximum steering motor speed

SET OPTIONS MENU

PARAMETER level
AUX OUTPUT #1
Enables/disables the auxiliary function on pin 10

AUX OUTPUT #2
Enables/disables the auxiliary function on pin 14

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CONTROLLERS: INTRODUCTION
The modular electronic system for AC motor control is comprised of:
• “ACE2 INVERTER - drive” controller for management of the AC drive motor
• “ACE2 INVERTER - pump” controller for management of the AC pump motor
• “EPS ACW” controller for management of the AC steering motor
• “VCM” controller with graphic display for management of the various truck functions
The controllers 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 control-
lers and can be accessed from the control panel.
The controllers 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

cod.580039670
pc tool connector

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 ELECTRICAL SYSTEM SERVICE

“INVERTER ACE2” CONTROLLER

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’
1 hour current evaluation (48V-350A)...........................................170A (RMS)
1 hour current evaluation (48V-400A)...........................................200A (RMS)
Operating frequency......................................................................8 kHz
Outside working temperature limits...............................................-30°C to 40°C
Maximum inverter temperature (at maximum power):...................75°

- BATT + BATT

U V W

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 SERVICE ELECTRICAL SYSTEM

EPS ACW CONTROLLER

The controller 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
Analogue input for thermal sensor
Operating frequency:.....................................................................8kHz with PWM aligned in the centre
Maximum inverter temperature:....................................................80°C
Protection:.....................................................................................IP65

U V W

+ BATT

- BATT

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 ELECTRICAL SYSTEM SERVICE

VCM CONTROLLER
Functions:
BDI
Hour meter
Alarms
Performance
Height gauge

Technical specifications (standard version)

Voltage:.........................................................................................36-48V
Digital inputs (qty):.........................................................................7
Analogue inputs (qty):...................................................................2
12V outputs (qty)...........................................................................1
5V outputs (qty).............................................................................1
Protection rating:...........................................................................IP65
Outside working temperature limits...............................................-40°C to 50°C

Technical specifications (premium version):

Voltage:.........................................................................................36-48V
Digital inputs (qty):.........................................................................11
Analogue inputs (qty):...................................................................10
12V outputs (qty)...........................................................................1
5V outputs (qty).............................................................................2
Protection rating:...........................................................................IP65
Outside working temperature limits...............................................-40°C to 50°C

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 SERVICE ELECTRICAL SYSTEM

CONTROLLER REPLACEMENT: INSTRUCTIONS

The hours of operation of the truck are memorised on the VCM controller and on the
ACE2 TRACTION controller. After replacement of the ACE2 TRACTION controller, it will
be necessary to acquire the operating hours by uploading them from the VCM controller.

REPLACEMENT OF THE "ACE2 INVERTER" CONTROLLER

Tools

resistance 33 to socket wrench

T-handle hex key large flat
100Ω 50W insu- with ratchet
5 mm blade screw driver
lated 13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing. B
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch A
to OFF and disconnect the battery.
Fig. 1

Phase 1
5 mm “T” HANDLE HEX KEY
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (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 controllers (ref.B fig1) and remove it.

Phase 2
RESISTOR Fig. 2
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 controller (fig.3).
Wait approximately 10 seconds for the internal capacitors to lose their
charge and then disconnect the resistance.

To avoid short circuits, it is important that the resistance is insu-

lated.

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 discon-
necting the power cables.
Fig. 3

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 ELECTRICAL SYSTEM SERVICE

Phase 3
13 MM SOCKET WRENCH WITH RATCHET - MEDIUM FLAT BLADE
SCREWDRIVER
Using the screwdriver, remove the caps protecting the contacts.
Using the socket wrench and ratchet unscrew and remove the screws D
fastening the electric cables, fuse, copper connecting bars and power
cables. Unscrew and remove also the nut fastening the fuse.
Mark the electric cables and the copper bars for reassembly and discon-
nect them. Disconnect the connector. C
Fig. 4
Phase 4
5 mm FLEXIBLE T-HANDLE HEX KEY
Unscrew the four screws securing the controller to the panel (ref.C fig.4).
Extract the controller and remove it.
Recover the fuse (ref.D fig.4) 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 (keyswitch to ON). Start the PC Tool programme.
If the NO CONFIG alarm is present, connect to the VCM and copy the configuration file to the new con-
troller: VMC ( node 1) / hardware setting / SET CONFIGURATION → level 1.
If the WRONG CONFIG alarm is present, connect to the VCM and copy the configuration file to the new
controller:
VMC ( node 1) / hardware setting / SET CONFIGURATION → level 2.

BATTERY VOLTAGE SETTING

Carry out the procedure for setting the battery voltage. See “SETTING THE BATTERY VOLTAGE” section
“INSTALLATION AND SETTINGS”.

ACQUISITION OF OPERATING HOURS “ACE2 TRACTION” CONTROLLER

The hours of operation of the truck are memorised on the VCM controller and on the ACE2 TRACTION
controller.
On startup, the system checks the hours recorded on both controllers. 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 controllers and all truck functions are restored.

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 SERVICE ELECTRICAL SYSTEM

REPLACEMENT OF THE “EPS ACW” CONTROLLER

Tools

medium resistor 33 to open ended span-

T-handle hex key
crosshead 100Ω 50W insu- ner
5-6 mm
screwdriver lated 8 mm

Fig. 1
Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

Phase 1
5 mm T-HANDLE HEX KEY
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.A fig.1).
Completely open the cover (fig.2).

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 controller (fig.3). Fig. 2
Wait approximately 10 seconds for the internal capacitors to lose their
charge and then disconnect the resistance. Fig. 3

To avoid short circuits, it is important that the resistance

is insulated.

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.

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 ELECTRICAL SYSTEM SERVICE

Phase 3
Fig. 4
8 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws fastening B
the electrical cables and fuse. Disconnect the connector.

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 retaining screws of the EPS controller (ref.D
fig.6). Remove the controller and proceed with replacement. Fig. 5

Fig. 6

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 SERVICE ELECTRICAL SYSTEM

REPLACEMENT OF THE VCM CONTROLLER

Tools

medium
T-handle hex key
crosshead
4-5 mm
screwdriver

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit Fig. 1
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

Phase 1
5 MM T-HANDLE HEX KEY - MEDIUM CROSSHEAD SCREWDRI-
VER
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.A fig.1).
Completely open the cover (fig.2). Using a crosshead screwdriver,
unscrew the panel fixing screw to access the VCM control (ref.B fig.3).

Phase 2
4 mm T-HANDLE HEX KEY
Disconnect the controller connector.Using the T-handle hex key, unscrew
the screws securing the controller to the truck (ref.C fig.4). Remove the
controller and proceed with replacement.

Fig. 2
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 (keyswitch to ON). Start the B
PC Tool programme.
If the NO CONFIG alarm is present, connect to the VCM and copy the
configuration file to the new controller:
VMC ( node 1) / hardware setting / SET CONFIGURATION → level 1.
If the WRONG CONFIG alarm is present, connect to the VCM and copy
the configuration file to the new controller
Fig. 3
VMC ( node 1) / hardware setting / SET CONFIGURATION → level 3.

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 ELECTRICAL SYSTEM SERVICE

BATTERY VOLTAGE SETTING

Fig. 4
Carry out the procedure for setting the battery voltage. See “SETTING
THE BATTERY VOLTAGE” section “INSTALLATION AND SETTINGS”.

ACQUISITION OF “VCM” CONTROLLER OPERATING HOURS C

The hours of operation of the truck are memorised on the VCM controller
and on the ACE2 TRACTION controller.
On startup, the system checks the hours recorded on both controllers. 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 controllers and all truck functions are restored.

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 SERVICE ELECTRICAL SYSTEM

DISMANTLING THE ELECTRICAL COMPONENTS

REPLACEMENT OF ENCODER
Tools

step ladder open ended socket wrench

safety harness ratchet
spanner 7 mm
7-8 mm
2 x 10 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
forward (fig.1). Fig. 1
Unscrew the screws to remove the plates and access the control valve
(fig.2).

Turn the keyswitch to OFF and disconnect the battery.

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.

Fig. 2

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REMOVING THE MAIN LIFT ENCODER

Phase 2
ladder - safety harness - 7 MM OPEN ENDED SPANNER - 2x 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

C
A
B

Fig. 5

Fig. 6
E
D
F G

Fig. 7 Fig. 8

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ENCODER RESET SENSOR REPLACEMENT

Tools

open ended
spanner
2 x 28 mm

Procedure
Fig. 1
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
forward (fig.1).

Turn the keyswitch to OFF and disconnect the battery.

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 repla-
cement.

Fig. 2

Fig. 3

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 ELECTRICAL SYSTEM SERVICE

LOAD CELL REPLACEMENT

Tools

wooden beam long nose pliers

Procedure Fig. 1
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
forward (fig.1).

Phase 2
WOODEN BLOCK
Raise the forks just enough to be able to pass the wooden block under-
neath.
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.

Turn the keyswitch to OFF and disconnect the battery.

Phase 3 Fig. 2
LONG NOSE PLIERS
Using the taper end pliers remove the cotter pins and the hinge pins se-
curing the load cell to the chain and to the fork mast (ref.A fig.3). Discon-
nect the connector, remove the load cell and proceed with replacement.

INSTALLATION
A
Do not reuse the chain anchoring safety pins, use new cotter pins,
ensuring they are the correct size.

Fig. 3

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 SERVICE ELECTRICAL SYSTEM

REPLACEMENT OF THE HORN

Tools

open ended
T-handle hex key Allen key
spanner
5 mm 6 mm
13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit B
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery. A

Fig. 1

Phase 1
5 mm “T” HANDLE HEX KEY
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (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 controllers (ref.B fig1) and remove it.

Phase 2
Fig. 2
FIXED 13 mm SPANNER - 6 mm ALLEN KEY
Using the open ended spanner, Fig. 3
counterhold the nut (ref.C fig.3), C
and with the Allen key, unscrew and
remove the screw securing the horn C
(ref.D fig.3).
Disconnect the connectors, remove
D
the horn and proceed with the
replacement.
D

INSTALLATION

Before reconnecting them, check that the faston clamps are properly secure. If not, tighten the
connectors with Faston pliers.

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 ELECTRICAL SYSTEM SERVICE

REPLACEMENT OF THE CONTACTORS

Tools

open ended
T-handle hex key medium flat blade
4-5 mm
spanner
screwdriver
B
13 mm
A
Procedure
Fig. 1
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

Phase 1 Fig. 2
5 mm “T” HANDLE HEX KEY
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (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 controllers (ref.B fig.1) and remove it.

Phase 2
MEDIUM FLAT BLADE SCREWDRIVER - 13 mm OPEN ENDED
SPANNER
C
Using the screwdriver, remove the caps protecting the contacts.
Using the open ended spanner, unscrew and remove the nuts securing
the electrical cables and copper bar to the contactor (ref.C fig.3). Fig. 3
Disconnect the cables and connectors, noting down their position to make
assembly easier.

Phase 3 D
4 mm T-handle hex key
Using the T-handle hex key, unscrew and remove the screws securing
the contactor (ref.D fig.4).
Remove the contactor and proceed with replacement.
Fig. 4

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 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)

Tools

medium/lar- socket wrench open ended

medium flat blade T-handle hex key
ge crosshead with ratchet spanner
screwdrivers 5 mm
screwdriver 13 mm 8 mm

Procedure
Before starting work, ensure that you are wearing suitable
Fig. 1
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

A
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.
Fig. 2

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 ELECTRICAL SYSTEM SERVICE

POWER FUSE F6

Phase 1
5 mm T-HANDLE HEX KEY
Unscrew and remove the screw locking the motor compartment cover
(ref.B fig.3) and open the cover (fig.4). Remove the rubber mat at the
operator's feet inside the cab. Using the T-handle hex key, unscrew and C
remove the screws securing the cover of the electronic controllers (ref.C
fig.3) and remove it.
B

Phase 2 Fig. 3
8 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the retaining nuts
of the fuse (ref.D fig.5). Remove the fuse and proceed with replacement.

POWER FUSES F4,F5

Phase 1
5 mm “T” HANDLE HEX KEY
Remove the rubber mat at the operator's feet inside the cab. Using the Fig. 4
T-handle hex key, unscrew and remove the screws securing the cover
of the electronic controls. Unscrew and remove the screw locking the Fig. 5
bonnet, remove the electronic controls cover and open the bonnet (fig.5).

Phase 2 D
13 MM SOCKET WRENCH WITH RATCHET - MEDIUM FLAT BLADE
SCREWDRIVER
Using the screwdriver, remove the caps protecting the contacts.
Using the socket wrench and the ratchet, unscrew and remove the
retaining screws of the fuse (ref.E fig.6). Remove the fuse and proceed
with replacement.

Fig. 6

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SERVICE ELECTRICAL SYSTEM

REPLACEMENT OF THE MOTOR COMPARTMENT COOLING FAN

Tools

Fig. 1

T-handle hex medium/lar- socket wrench

key ge crosshead T-handle hex key with ratchet
5 mm screwdriver 4 mm 13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

MOTOR COMPARTMENT FAN

Phase 1
5 mm T-HANDLE HEX KEY Fig. 2
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 2
4 mm FLEXIBLE T-HANDLE HEX KEY
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
proceed with replacement.

Fig. 4

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 ELECTRICAL SYSTEM SERVICE

ADDITIONAL TRACTION MOTOR FAN

Fig. 5
Phase 2
3 mm FLEXIBLE T-HANDLE HEX KEY
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
proceed with replacement.

Fig. 6

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 SERVICE ELECTRICAL SYSTEM

REPLACEMENT OF THE MAIN PANEL AND ARMREST CONTROLS:

• key switch
• buttons
• main emergency switch
• steering handwheel stepper motor
• joystick
• mini-levers
• display

Tools

medium/lar-
T-handle hex key small/medium flat
ge crosshead Torx key
1.5-3 mm blade screwdriver
screwdriver
Fig. 1

A
hex socket open ended
wrench ratchet spanner C wrench
A A
10-13 mm 7-10-13-14 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing. B
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

Fig. 2

KEY SWITCH (version with premium display) Fig. 3

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.

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 ELECTRICAL SYSTEM SERVICE

Phase 2
Fig. 4
Remove the key switch.
C
Unscrew the RING nut (ref. B fig.2), remove the switch block from the
console (fig.3).
Disconnect the connectors and proceed with replacement.

INSTALLATION

Before reconnecting them, check that the faston clamps

are properly secure. If not, tighten the connectors with
Faston pliers.
Fig. 5

DASHBOARD PUSH-BUTTONS

D
Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER
Fig. 6
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.A fig.1).
Remove the panel.

E
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
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). Fig. 7

Phase 4 Fig. 8
14 mm OPEN ENDED SPANNER
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.

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 SERVICE ELECTRICAL SYSTEM

ARMREST BUTTONS
Fig. 9

Phase 1
13 mm OPEN ENDED SPANNER
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.
Using the controls in the cab, make the retractable carriage come fully
fowrad together with the battery.

Turn the keyswitch to OFF and disconnect the battery.

Using the open ended spanner, unscrew and remove the

armrest retaining nuts from the battery compartment (ref.F fig.10). Fig. 10
Remove the armrest and overturn it.

Phase 2
MEDIUM CROSSHEAD SCREWDRIVER F
Using the screwdriver, unscrew and remove the screws fastening the
lower cover of the armrest (ref.G fig.11).
Remove the cover.

Phase 3
Fig. 11
MEDIUM CROSSHEAD SCREWDRIVER
Use the screwdriver to unscrew and remove the fastening screws of the
electronic board (ref.H fig.11).
Remove the cover.
G H
Phase 4
14 mm OPEN ENDED SPANNER
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
proceed with replacement.
Fig. 12

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 ELECTRICAL SYSTEM SERVICE

MAIN EMERGENCY SWITCH

Fig. 13

Phase 1
13 mm OPEN ENDED SPANNER
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.
Using the controls in the cab, make the retractable carriage come fully
fowrad together with the battery.

Turn the key switch to OFF and disconnect the battery.

Fig. 14
Using the open ended spanner unscrew and remove the nuts fastening
the armrest from the battery compartment (ref.I fig.14).
Remove the armrest and overturn it.

I
Phase 2
MEDIUM CROSSHEAD SCREWDRIVER
Using the screwdriver, unscrew and remove the screws fastening the
lower cover of the armrest (ref.J fig.15).
Remove the cover.
Fig. 15

Phase 3
C SPANNER FOR SELF-LOCKING RING NUTS - SMALL FLAT J
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. 16
K

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SERVICE ELECTRICAL SYSTEM

STEERING HANDWHEEL STEPPER MOTOR

Fig. 17

Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER
Using the screwdrivers, unscrew and remove the screws fastening the
L
panel located under the control panel (ref.L fig.17).
Remove the panel. L L

Phase 2
small flat blade screwdriver - 13 MM HEX SOCKET WRENCH -
RATCHET Fig. 18
Using the flat blade screwdriver, remove the cover located over the
M
handwheel (ref.M fig.18). N
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.

Phase 3
MEDIUM CROSSHEAD SCREWDRIVER
Use the screwdriver to unscrew and remove the screws of the covers of
the steering handwheel assembly (fig.19 ref. O).
Remove the two covers.

O
If there is any difficulty in unscrewing the upper screws O O O
under the control panel, remove the dashboard.

Phase 4
7 MM open ended spanner - 1.5-3 MM T-HANDLE HEX KEY O O O
Using the 1.5 mm T-handle, hex key unscrew and remove the grub screw Fig. 19
(ref.P fig.20).
Using the open ended spanner, counterhold the nut (ref.Q fig.20), and
with the T-handle hex key, unscrew and remove the screw securing the Fig. 20
stepper motor to the bearing block (ref.R fig.20).
Q
Remove the motor and proceed with replacement. P

227
 ELECTRICAL SYSTEM SERVICE

COMPLETE JOYSTICK
Fig. 21
U
Phase 1 T
SMALL FLAT BLADE SCREWDRIVER - 10 MM HEX SOCKET
WRENCH - RATCHET
Using the small screwdriver, remove the cover under the joystick (ref.S
fig.21).
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the joystick to the armrest (ref.T fig.21). Remove the joystick
and proceed with replacement or disassembly. S

In event of malfunction of the bi-directional button only

(ref.U fig.22), disassemble the joystick and proceed with
replacement of the button and the relative card only.

MINI-LEVERS Fig. 22 V

Phase 1
TORX KEY
Using the Torx key, unscrew and remove the screws fastening the mini-
lever (ref.V fig.22).
Remove the mini-lever and proceed with replacement.

STANDARD DISPLAY

Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER - MEDIUM FLAT
BLADE SCREWDRIVER
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.L fig.17).
Remove the panel.
Disconnect the connector from the display. Using the flat blade screwdri-
ver, prise on the lower tab of the display (fig.23), put outwards and remove.

Fig. 23

228
 SERVICE ELECTRICAL SYSTEM

PREMIUM DISPLAY
Fig. 24

Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER - 10 MM HEX
SOCKET WRENCH - RATCHET
Using the screwdrivers, unscrew and remove the screws fastening the Z
panel located under the control panel (ref.L fig.17).
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.Z
Fig.24). Remove the display outwards.

INSTALLATION

On installation, tighten the nut (ref. Z fig.24) to a torque

of 8Nm

229
 ELECTRICAL SYSTEM SERVICE

SIDE SHIFT POSITION SENSOR REPLACEMENT

Equipment and tools

open ended
spanner
2 x 28 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

Phase 1 Fig.1
2 x 28 mm OPEN ENDED SPANNERS
Unscrew the ring nuts fastening the sensor to the support plate (ref.A
fig.2).
Disconnect the connector, unscrew the sensor and proceed with repla-
cement.
A

Fig.2

230
 SERVICE ELECTRICAL SYSTEM

PALLET PRESENCE SENSOR REPLACEMENT

Equipment and tools

Fig.1

internal circlip Allen key

pliers 2-3 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

A
Phase 1
SMALL EXTERNAL CIRCLIP PLIERS
Use the pliers to remove the two circlips securing the pin of the plate with Fig.2
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. C
B
C
Fig.3

231
 ELECTRICAL SYSTEM SERVICE

TILT POSITION SENSOR REPLACEMENT

Equipment and tools

Fig.1

open ended
spanner
8 mm
2 x 28 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery. A

Phase 1
8 mm OPEN ENDED SPANNER
Using the open ended spanner loosen the screws securing the bracket Fig.2
of the sensor (ref.A fig.2).
Disconnect the connector, remove the bracket together with the sensor

B
Phase 2
2 x 28 mm OPEN ENDED SPANNERS
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

232
 SERVICE ELECTRICAL SYSTEM

REPLACEMENT OF THE INCLINOMETER

Equipment and tools

TILT POSITION SENSOR REPLACEMENT

Equipment and tools

open ended
spanner
8 mm
2 x 28 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch Fig.1
to OFF and disconnect the battery.

Phase 1
8 mm OPEN ENDED SPANNER
Disconnect the connector (ref.A fig.1). Remove the ties (ref.B fig.1)
and unscrew the retaining screws (ref.C fig.1). Recover the inclinometer
and proceed with replacement.

Fig.2
A

B
B

233
 ELECTRICAL SYSTEM SERVICE

90° WHEEL SENSOR AND STEERED WHEEL SENSOR REPLACEMENT

Equipment and tools

open ended
T-handle hex key
spanner
5 mm
16 mm
B

Procedure Fig. 1

Before starting work, ensure that you are wearing suitable

protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

Phase 1
5 mm “T” HANDLE HEX KEY Fig. 2
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (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 controllers (ref.B fig1) and remove it.

Phase 2
16 mm OPEN ENDED SPANNER
With the open ended spanner, unscrew the ring nut securing the sensor
to the supporting plate (ref.C fig.4).
Disconnect the connector, unscrew the sensor from the supporting plate
and proceed with replacement. Fig. 3

Fig. 4

234
 SERVICE ELECTRICAL SYSTEM

BATTERY OUT SENSOR REPLACEMENT

Equipment and tools

open ended
T-handle hex key
5 mm
spanner B
16 mm

Fig. 1

Procedure
Fig. 2
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

Phase 1 Fig. 2
5 mm “T” HANDLE HEX KEY
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
Fig. 3
the bonnet (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 controllers (ref.B fig.1) and remove it.

Phase 2
A
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

Fig. 4

Phase 3
2 x 28 mm OPEN ENDED SPANNERS
Loosen the ring nuts fastening the sensor to the support plate (ref.B fig.4).
Unscrew the old sensor and fit the new one. B

235
 ELECTRICAL SYSTEM SERVICE

OPERATOR PRESENCE PEDAL REPLACEMENT

Equipment and tools

open ended
T-handle hex key
spanner
5 mm
7 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

A
Phase 1
Fig. 1
5 mm “T” HANDLE HEX KEY
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (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 controllers (ref.B fig.1) and remove it.

Phase 2
7 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws securing
the operator presence pedal (ref.C fig.3). Fig. 2
Remove the pedal and proceed with replacement.
Fig. 3

236
 SERVICE ELECTRICAL SYSTEM

ACCELERATOR AND BRAKE PEDALS REPLACEMENT

Equipment and tools

open ended
T-handle hex key
spanner
5 mm
13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the key switch
to OFF and disconnect the battery.

B
Phase 1
A
5 mm “T” HANDLE HEX KEY
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
Fig. 1
the bonnet (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 controllers (ref.B fig.1) and remove it.

Phase 2
13 mm OPEN ENDED SPANNER - 5 MM T-HANDLE HEX KEY
Using the open ended spanner, counterhold the nuts (ref.C fig.3), and
with the T-handle hex key unscrew and remove the screws securing the
pedal (ref.D fig.3).
Remove the pedal and proceed with replacement. Fig. 1

Fig. 2

237
 ELECTRICAL SYSTEM SERVICE

238
 SERVICE HYDRAULIC SYSTEM

HYDRAULIC SYSTEM
HYDRAULIC FUNCTIONS.....................................................................................................................3
HYDRAULIC DIAGRAMS............................................................................................................................4
SYMBOLS..........................................................................................................................................4
MAIN HYDRAULIC DIAGRAM.....................................................................................................5
OPTIONAL FUNCTIONS HYDRAULIC DIAGRAM....................................................................................6
HYDRAULIC DIAGRAMS BY FUNCTION...................................................................................................7
S O L E N O I D VA LV E O P E R AT I O N TA B L E.....................................................................................8
FORKS LIFTING HYDRAULIC DIAGRAM.......................................................................................9
FORKS LOWERING HYDRAULIC DIAGRAM.................................................................................10
CARRIAGE OUT HYDRAULIC DIAGRAM ...........................................................................................11
CARRIAGE IN HYDRAULIC DIAGRAM .........................................................................................12
FORKS UPWARD TILT HYDRAULIC DIAGRAM...............................................................................13
FORKS DOWNWARD TILT HYDRAULIC DIAGRAM........................................................................14
FORKS LEFT SIDE SHIFT HYDRAULIC DIAGRAM............................................................................15
FORKS RIGHT SIDE SHIFT HYDRAULIC DIAGRAM.......................................................................16
EMERGENCY LOWERING HYDRAULIC DIAGRAM..................................................................................17
HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE......18
HYDRAULIC SYSTEM COMPONENTS..............................................................................................................20
KEY TO HYDRAULIC COMPONENTS........................................................................................................21
KEY TO HYDRAULIC UNIT COMPONENTS.......................................................................................22
REMOVAL AND REPLACEMENT OF MAIN HYDRAULIC UNIT......................................................23
REMOVAL OF HYDRAULIC UNIT ON FORK CARRIAGE............................................................25
ADJUSTMENT OF THE FLOW LIMITING VALVE.........................................................................26
REMOVAL OF THE PRESSURE RELIEF VALVE........................................................................29
CALIBRATION OF THE PRESSURE RELIEF VALVE .............................................................................30
CARTRIDGE SOLENOID VALVES....................................................................................................31
KEY TO COMPONENTS OF CARTRIDGE SOLENOID VALVES.........................................................31
REPLACEMENT OF THE FORKS RAISE AND LOWER SOLENOID VALVE............................................32
CYLINDERS...........................................................................................................................................34
SINGLE ACTING CYLINDERS.......................................................................................................34
IDENTIFICATION TO THE CENTRAL LIFT CYLINDER COMPONENTS.........................................................35
IDENTIFICATION TO THE LATERAL LIFT CYLINDER COMPONENTS......................................................37
IDENTIFICATION TO THE RETRACTABLE CARRIAGE CYLINDER COMPONENTS...........................................40
IDENTIFICATION TO THE FORKS TILT CYLINDER COMPONENTS......................................................41
IDENTIFICATION TO THE FORKS SIDE SHIFT CYLINDER COMPONENTS.........................................................43
IDENTIFICATION TO THE POSITIONER CYLINDER COMPONENTS.........................................................45

1
 HYDRAULIC SYSTEM SERVICE

DISMANTLING OF THE CENTRAL LIFT CYLINDER......................................................................46

REMOVAL OF THE LATERAL LIFT CYLINDERS..........................................................................48
CYLINDERS BRAKDOWN (LATERAL- CENTRAL)..........................................................................50
LIFT CYLINDER: AIR BLEEDING....................................................................................................52
REMOVAL OF THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER.......................................................53
BREAKDOWN THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER..........................................56
REMOVAL OF THE FORK TILTING CYLINDER...........................................................................58
FORK TILTING CYLINDER BREAKDOWN........................................................................................59
LIFT PUMP MOTOR.....................................................................................................................................61
KEY TO LIFT PUMP MOTOR COMPONENTS..................................................................................................61
REMOVAL OF THE LIFT PUMP ASSEMBLY....................................................................................65
REPLACEMENT OF THE PUMP..................................................................................................................67
HYDRAULIC PIPES.................................................................................................................................68
PIPE PLACEMENT FOR HYDRAULIC CIRCUIT.................................................................................68
RENEWAL OF THE CENTRAL LIFT CYLINDER SUPPLY HOSE.........................................................69
RENEWAL OF THE FORK HYDRAULIC FUNCTIONS SUPPLY PIPES......................................71

2
 SERVICE HYDRAULIC SYSTEM

HYDRAULIC FUNCTIONS
• Forks lifting
• Forks lowering
• Forks right side shift
• Forks left side shift
• Forks tilt up
• Forks tilt down
• Retractable carriage out
• Retractable carriage in

3
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC DIAGRAMS
SYMBOLS

LINE CONNECTION
ELECTRIC MOTOR

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

THREE-POSITION
VALVE
ONE-WAY VALVE

CHECK VALVE

4
SERVICE HYDRAULIC SYSTEM

GENERAL HYDRAULIC DIAGRAM

MAIN HYDRAULIC UNIT

FORK CARRIAGE HYDRAULIC

UNIT

EVP4 EVP3
 HYDRAULIC SYSTEM SERVICE

OPTIONAL FUNCTIONS HYDRAULIC DIAGRAM

FORK CARRIAGE HYDRAULIC

UNIT

6
 SERVICE HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS BY FUNCTION

EVP3
• Forks lifting
• Forks lowering EVP4
• Retractable carriage out
• Retractable carriage in
• Fork left side shift EVP5
• Fork right side shift
• Tilt up EVP6
• Tilt down
• Back/closed auxiliary function
• Forward/open auxiliary function EVP1

• Emergency mast lowering EVP2

The hydraulic control valve in the motor compartment
is equipped with a screw to open the emergency low- Emergency pressure relief
ering valve. Unscrew the valve gradually by no more lowering valve valve
than two turns so that the mast is lowered slowly. Once
the forks have been lowered, close the valve.
MAIN HYDRAULIC UNIT
• Oil release through the pressure relief valve

EVP8

EVP7

HYDRAULIC UNIT ON FORK CARRIAGE

7
 HYDRAULIC SYSTEM SERVICE

SOLENOID VALVE OPERATION CHART

EVP1 EVP2 EVP3 EVP4 EVP5 EVP6 EVP7 EVP8

Function Pump
Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8

Forks lifting P +
Forks lowering +
Carriage in P +
Carriage out P +
Forks left side shift P + +
Forks right side shift P + +
Tilt upwards P +
Tilt downwards P +
Enabling back/closed
auxiliary function P + +
Enabling forward/open
auxiliary function P + +
Oil drain through the pressure
relief valve P - - - - - - - -

P = pump in operation
+ = solenoid valve coil energised

8
SERVICE HYDRAULIC SYSTEM

FORKS RAISING HYDRAULIC DIAGRAM

Oil delivery
Oil return

9
 HYDRAULIC SYSTEM SERVICE

FORKS LOWERING HYDRAULIC DIAGRAM

Oil delivery
Oil return

10
SERVICE HYDRAULIC SYSTEM

CARRIAGE IN HYDRAULIC DIAGRAM

Oil delivery
Oil return

EVP4 EVP3

11
 HYDRAULIC SYSTEM SERVICE

CARRIAGE OUT HYDRAULIC DIAGRAM

Oil delivery
Oil return

EVP4 EVP3

12
SERVICE HYDRAULIC SYSTEM

FORKS UPWARD TILT HYDRAULIC DIAGRAM

Oil delivery
Oil return

EVP4 EVP3

13
 HYDRAULIC SYSTEM SERVICE

FORKS DOWNWARD TILT HYDRAULIC DIAGRAM

Oil delivery
Oil return

EVP4 EVP3

14
SERVICE HYDRAULIC SYSTEM

FORKS LEFT SIDE SHIFT HYDRAULIC DIAGRAM

Oil delivery
Oil return

EVP4 EVP3

15
 HYDRAULIC SYSTEM SERVICE

FORKS RIGHT SIDE SHIFT HYDRAULIC DIAGRAM.

Oil delivery
Oil return

EVP4 EVP3

16
SERVICE HYDRAULIC SYSTEM

EMERGENCY LOWERING HYDRAULIC 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 limit the system pressures to the permitted
values and to protect the system against sudden pressure surges that could seriously damage components.
The pressure relief valve may intervene in the following cases:
• Pressure control setting not suitable for the truck load capacity
• Attempt to lift a load in excess of the truck's load capacity
• Faulty or stuck valve

DV1 general pressure relief valve protecting the lifting, side shift line and is activated if one of the valves
described below fails to operate.
• DV2 pressure relief valve protecting the carriage out line.
• DV3 pressure relief valve protecting the forks tilt line.

18
SERVICE HYDRAULIC SYSTEM

19
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC COMPONENTS

20
SERVICE HYDRAULIC SYSTEM

KEY TO HYDRAULIC COMPONENTS

Ref. Description

1 Directional control valve

2 Lift pump
3 Reservoir
4 Filter
5 Retractable carriage cylinder
6 Fork lift cylinder
7 Mast lift cylinders
8 Fork side shift cylinder
9 Fork tilt cylinders

21
 HYDRAULIC SYSTEM SERVICE

KEY TO HYDRAULIC UNIT COMPONENTS

6
MAIN HYDRAULIC UNIT

FORK CARRIAGE
4 HYDRAULIC UNIT
3
10

2
1
11

Ref. Description

1 Emergency mast lowering valve

2 Pressure relief valve
3 Forks lowering solenoid valve EVP1 (Q1)
4 Lowering rate control
5 Downward tilt/left side shift solenoid valve EVP5 (Q5)
6 Carriage IN solenoid valve EVP3 (Q3)
7 Carriage OUT solenoid valve EVP4 (Q4)
8 Upward tilt/right side shift solenoid valve EVP6 (Q6)
9 Forks lifting solenoid valve EVP2 (Q2)
10 Auxiliary functions solenoid diverter valve EVP8 (Q8)
11 Side shift/tilt solenoid diverter valve EVP7 (Q7)

22
 SERVICE HYDRAULIC SYSTEM

REMOVAL AND REPLACEMENT OF THE MAIN HYDRAULIC UNIT

Tools

open ended
wrench for
wrench oil resistant gloves
hydraulic fittings
13mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Fig. 1
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
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Unscrew the screws to remove the plates and access the control valve
(fig.2).

Turn the keyswitch to OFF and disconnect the battery.

Fig. 2
Phase 2
WRENCH FOR HYDRAULIC FITTINGS - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Label the hydraulic hoses in order to refit them correctly.
Detach the hydraulic hoses using the wrench for hydraulic fittings (fig.3).
Disconnect the solenoid valve power supply connectors.

Fig. 3

23
 HYDRAULIC SYSTEM SERVICE

Phase 3
13 mm OPEN ENDED WRENCH
Using the open ended wrench, unscrew and remove the screws fastening
the control valve at the bottom of the truck (ref.A fig.4).
Remove the control valve assembly.
Remove the O-rings from their seats, carefully clean the parts and install
the new seal set.

The seals must be replaced in the case of oil leaks.

Fig. 4

After fitting the hydraulic unit, it will be necessary to

adjust the valve controlling the maximum forks lowering
rate as described in he paragraph "ADJUSTMENT OF THE
FLOW LIMITING VALVE" in this section. A

In the event of problems with the valves EVP3, EVP4,

EVP5, EVP6, it will be necessary to replace the complete
hydraulic unit as described in this procedure.

24
 SERVICE HYDRAULIC SYSTEM

REMOVAL OF THE HYDRAULIC UNIT ON THE FORK CARRIAGE

Tools

wrench for
2 wooden blocks Allen key
hydraulic fittings

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all
pedestrians.
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.

Fig. 1

Phase 1
WOODEN BLOCK
Using the controls in the cab, make the retractable carriage come fully
out. Lift the forks and position the blocks below the carriage in corre-
spondence with the forks. Operate the forks lowering control to rest the
carriage on the blocks.

Phase 2
WRENCH FOR HYDRAULIC FITTINGS
Use the wrench for hydraulic fittings to disconnect the hydraulic hoses
from the fork carriage (ref.A fig.2).
Disconnect the electric cables from the fork carriage.

A
Phase 3
ALLEN KEY
Using the Allen key, remove the 3 screws (ref.B fig.2) securing the
hydraulic unit to the fork carriage. Remove the hydraulic unit and proceed Fig. 2
with replacement.

25
 HYDRAULIC SYSTEM SERVICE

ADJUSTMENT OF THE FLOW LIMITING VALVE

Each time the hydraulic unit is replaced, it will be necessary to adjust the valve controlling the maximum
forks lowering rate.

Tools

wrench for
2 wooden blocks Allen key stopwatch
hydraulic fittings

Procedure
Fig. 1
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.
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
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Unscrew the screws to remove the plates and access the control valve
(fig.2).

Phase 2
Remove the plastic cap (ref.A fig.3) from the flow limiting valve. Use a
felt tip pen to mark the original positions of the valve, the screw (ref.B
fig.3) and the locknut (ref.C fig.3)

Fig. 2
Phase 3
10 MM HEX WRENCH - T-HANDLE HEX KEY
While restraining the screw (ref.B fig.3) with the T-handle hex key,
unscrew the locknut (ref.C fig.3) using the 10 mm hex wrench.
Check that the mark made previously on the
screw (ref.B fig.3)is aligned with the mark on
outer part of the valve. If not, turn the screw to C A
bring the two marks into alignment. B

Fig. 3

26
 SERVICE HYDRAULIC SYSTEM

Phase 3
Turn the screw (ref.B fig.3) counter clockwise as indicated in the table below.

Previous (and included) Subsequent

Truck S/N: D849T03105N Truck S/N: D849T03105N
Angle of Angle of
Screw turns Screw turns
Model rotation Model rotation
(ref.B fig.3) (ref.B fig.3)
(ref.B fig.3) (ref.B fig.3)
1.4 - - 1.4 1/4 90°
1.6 - 16N - - 1.6 - 16N 1/4 90°
1.6HD 1/4 90° 1.6HD 1/4 90°
2.0HD 3/4 270° 2.0HD 3/4 270°
2.0 1+1/4 1 turn + 90° 2.0 1+1/4 1 turn + 90°
2.5 1+1/4 1 turn + 90° 2.5 1+1/4 1 turn + 90°

Phase 4
With the T-handle hex key, restrain the screw (ref.B fig.3) and re-tighten the locknut (ref.C fig.3) using the
10 mm hex wrench; then replace the plastic cap (ref.A fig.3) on the flow limiting valve.

After adjusting the flow limiting valve, check the maximum fork lowering rate.

Checking the maximum fork lowering speed

Phase 5
STOPWATCH
With a stopwatch measure the actual lowering speed by placing on the
truck forks the nominal load and measuring the time taken for the forks
to descend (operating the lowering control lever to the maximum) in the
600mm grey area indicated in fig.4.
The descent time in the 600mm grey area must match the values given
in the table below:

Acceptable range Acceptable range

3 Stage Mast 4 Stage Mast
Model
Nominal Nominal Nominal Nominal Nominal Nominal
time time time time time time
(s) (s) (s) (s) (s) (s)
Fig. 4
1.4 1.07 1.13 1.05 1.25 1.58 1.05
1.6 - 16N 1.07 1.13 1.05 1.25 1.58 1.05
1.6HD 1.13 1.18 1.07
2.0HD 1.13 1.18 1.07 1.13 1.43 0.95
2.0 1.13 1.18 1.07 1.13 1.43 0.95
2.5 1.13 1.18 1.07 1.13 1.43 0.95

If the maximum lowering speed is outside the permitted range indicated in the table
above, the flow limiting valve must be recalibrated using the procedure described in
“ADJUSTMENT OF THE FLOW LIMITING VALVE" in this section.

27
 HYDRAULIC SYSTEM SERVICE

If the descent time is too long, turn the screw (ref B fig.3) counter-clockwise in 45° steps.
If the descent time is too short, turn the screw (ref B fig.3) clockwise in 45° steps.
In either case, do not turn the screw (ref B fig.3) more than 90° clockwise or counter-
clockwise from the value indicated in phase 3 of this procedure.
If adjustment is not possible, please the Warehouse product support group using the
Contact Management system.

28
 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.

Tools

Fig. 1

large flat blade socket wrench

oil resistant gloves ratchet
screwdriver 22 mm

Procedure
Before starting work, ensure that you are wearing suit-
able protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Unscrew the screws to remove the plates and access the control valve
(fig.2). Fig. 2

Fig. 3
A
Phase 2
RATCHET - 22 mm SOCKET WRENCH - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Use the wrench to unscrew and remove the valve assembly (ref.A fig.3)
and proceed with the replacement.

INSTALLATION
During assembly, tighten the valve with a torque wrench
to 10-12 Nm.

29
 HYDRAULIC SYSTEM SERVICE

PRESSURE RELIEF VALVE CALIBRATION

The pressure relief valve must be calibrated following replacement.

Tools

open ended
oil resistant gloves wrench
10 mm

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.

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
10 mm OPEN ENDED WRENCH
Loosen the lock nut with the open ended wrench (ref.A fig.1).
Using the open ended wrench, loosen the adjusting screw (ref.B fig.1) turning it counter-clockwise until,
while pressing the fork lifting button, the pressure decreases and the oil drains back to tank (the lifting ac-
tion ceases). At this point change the direction of the rotation of the adjusting screw (clockwise) and tighten
it until the forks resume their lifting action.
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 wrench to tighten the lock nut (ref.A fig.1), to lock the adjusting screw in position.

B A
Fig. 1

30
 SERVICE HYDRAULIC SYSTEM

CARTRIDGE SOLENOID VALVES

The solenoid valves of the directional control valve are of the screw-in 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 seals; inside a mobile element allows communication between the various holes.

KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS

Ref. Description

1 Coil
2 Valve body

SOLENOID REPLACEMENT
- Clean the outside of the block to prevent contamination from entering the chamber while replacing the
valve.
- Disconnect the power supply to the solenoid valve.
- Remove the cap and unscrew the plastic nut (ref.A), remove the solenoid (ref.B), taking care not to lose
the O-ring.

Fit the new solenoid, tightening the plastic nut (5-7Nm) and refit the cap. Connect the
solenoid valve power supply connector.

Lift and lower the forks to the maximum height repeatedly (at least 3 times) to allow the
circuit to fill up again with oil

31
 HYDRAULIC SYSTEM SERVICE

REPLACEMENT OF THE FORKS RAISING AND LOWERING SOLENOID VALVES

Tools

open ended
oil resistant gloves wrench
29 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing. Fig. 1
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Unscrew the screws to remove the plates and access the control valve
(fig.2).

Turn the keyswitch to OFF and disconnect the battery.

Phase 2 Fig. 2
OIL RESISTANT GLOVES - 30 mm OPEN ENDED WRENCH
To prevent the oil from leaking from the valve chamber during replace-
ment, unscrew the filter cap on the tank (ref. A fig.3). A
Clean the outside of the valve block to prevent contamination while re-
placing the valve

Fig. 3

32
 SERVICE HYDRAULIC SYSTEM

Phase 3
Fig. 4
30 mm OPEN ENDED WRENCH C
Disconnect the solenoid valve supply connector.
Remove the solenoid cap and unscrew the plastic nut (ref.d fig.4),
remove the solenoid (ref.C fig.4), taking care not to lose the O-ring. D
Use the open ended wrench to unscrew the valve (ref.D fig.5); oil
could leak out during this phase.
Proceed with replacement.
B
INSTALLATION

On installation, tighten the new valve to a torque of 40Nm

(it is advisable to apply grease to the thread of the valve).
Refit the solenoid by tightening the plastic nut to a torque
of 5-7Nm.

Close the filter plug on the tank.

After replacement, lift and lower the forks to the maximum height
repeatedly (at least 3 times) to allow the circuit to fill up
again with oil.

33
 HYDRAULIC SYSTEM SERVICE

CYLINDERS
SINGLE ACTING CYLINDERS
SINGLE acting cylinders receive and discharge the oil through a single pipe and the pressurised oil acts
on just one side of the piston (push type single acting cylinders) or on the flat face on the rod side in the
case of pull type cylinders.
Single-acting pull 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 bottom of the shaft is increased by a few millimetres in order to
avoid it slipping out at the top of it's upstroke; this gives rise to a hydraulic damping effect during the last
stages of its stroke which helps the slowing of the shaft and avoids recoils on the upper cylinder head.
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 cylinders 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 bar-
rel, 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.

34
 SERVICE HYDRAULIC SYSTEM

IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS

3 STAGE MAST
The cylinder is of the single-acting plunger type.

3
4

6
Ref. Description

1 Bushing
2
3
Seals
4
5 7
6 Rod 8
7
8 9
Seals
9
10
10
11 Valve 11
12 Spacer
13 Barrel
14 Hose break valve
12

13

14

35
 HYDRAULIC SYSTEM SERVICE

IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS

4 STAGE MAST
The cylinder is of the single-acting plunger type.

1
2
3
4
5
6

Ref. Description

1 Bushing
2
3
4 Seals
5
6
7 Rod
8 Barrel
7 8

36
SERVICE HYDRAULIC SYSTEM

IDENTIFICATION OF THE SIDE LIFT CYLINDER COMPONENTS

3 STAGE MAST
The cylinder is of the single-acting plunger type.
After cylinder replacement, the air must be vented through the bleed valve.

Ref. Description

1 Seal 6
2 Bushing
3
Seals
4
5
5 Rod
6 Barrel
7 Hose break valve

37
 HYDRAULIC SYSTEM SERVICE

IDENTIFICATION OF THE SIDE LIFT CYLINDER COMPONENTS

4 STAGE MAST
The cylinder is of the single-acting plunger type.
After cylinder replacement, the air must be vented through the bleed valve.

1 3
4
5
6

8
9
10
11
14

7
2

12

13

38
SERVICE HYDRAULIC SYSTEM

Ref. Description

1 Bushing
2 Barrel
3
4
Seals
5
6
7 Rod
8
9
Seals
10
11
12 Rod
13 Barrel
14 Bushing

39
 HYDRAULIC SYSTEM SERVICE

IDENTIFICATION OF THE RETRACTABLE CARRIAGE CYLINDER COMPONENTS

13
12

11 14
9 10

1 5 8
6
7
2
4

Ref. Description

1 Circlip
2 Bearing
3 Grease nipple
4 Barrel
5 Nut
6 Piston
7
8
9 Seals
10
11
12 Bushing
13 Rod
14 Grease nipple

40
SERVICE HYDRAULIC SYSTEM

IDENTIFICATION OF THE FORK TILTING CYLINDER COMPONENTS

3 STAGE MAST

1
5

7 2

Ref. Description

1 Barrel
2 Bushing
3
4
5 Seals
6
7
8 Rod and piston

41
 HYDRAULIC SYSTEM SERVICE

IDENTIFICATION OF THE FORK TILTING CYLINDER COMPONENTS

4 STAGE MAST

1
4 3 2

6 5
7

Ref. Description

1 Bushing
2
3
4 Seals
5
6
7 Rod and piston
8 Barrel

42
SERVICE HYDRAULIC SYSTEM

IDENTIFICATION TO THE FORK SIDE SHIFT CYLINDER COMPONENTS

3 STAGE MAST

3
4
6

Ref. Description

1 Barrel
2
3 Seals
4
5 Rod
6 Seal

43
 HYDRAULIC SYSTEM SERVICE

IDENTIFICATION TO THE FORK SIDE SHIFT CYLINDER COMPONENTS

4 STAGE MAST

1
2 6
3
4
5

Ref. Description

1 Ring
2 Seal
3 Bush
4 Circlip
5 Terminal ring
6 Rod

44
SERVICE HYDRAULIC SYSTEM

IDENTIFICATION TO THE CYLINDER POSITIONER COMPONENTS (OPTIONAL)

3 5 7
9
11

1
2 4 6
8

10

Ref. Description

1 Barrel
2
3 Seal
4
5 Bush
6 Scraper
7
Seal
8
9 Rod
10 O ring
11 Spacer

45
 HYDRAULIC SYSTEM SERVICE

DISMANTLING THE CENTRAL LIFT CYLINDER

Tools

hoist lifting sling open ended

wrench for
load capacity load capacity long nose pliers wooden block wrench
hydraulic fittings
1000kg 1000kg 28 mm

hex socket
ratchet wrench
13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
WOODEN BLOCK Fig. 1
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 under-
neath. Fig. 2
Place the wooden block under the forks (fig.1). Lower the forks to rest
on the block and continue until the end stroke of the cylinder.

Phase 2
LONG-NOSE PLIERS - WRENCH FOR HYDRAULIC FITTINGS A
Using the long nose pliers, remove the cotter pins (ref.A fig.2) and the
hinge pin (ref.B fig.2) at the top of the chain. Rest the chain on the forks.
Using the hydraulic fittings wrench, disconnect the hydraulic hoses on
the fork carriage control valve. Disconnect the electric cables from the
fork carriage.
B

46
 SERVICE HYDRAULIC SYSTEM

Phase 3
Fig. 3
Raise the mast using the controls in the cab until the fork carriage is
fully withdrawn from below in order to access the cylinder’s hydraulic
connection.
Set the fork carriage in a safe place.

Phase 4
28 mm open ended wrench
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 wrench, unscrew and remove the screw securing
the cylinder (ref.B fig.3).
Lower the cylinder down to the ground to its limit stop.
Using the wrench for hydraulic fittings, remove the hydraulic hose from
the cylinder (ref.C fig.4).

Phase 5
HOIST - LIFTING SLING B
Harness the cylinder with the lift belt.
Position the hoist perpendicularly above the sling, attach the sling to the
hoist and raise to take up the slack.

Phase 6
13 mm HEX SOCKET WRENCH - RATCHET
Using the socket wrench and ratchet, unscrew the screws of the cylinder
block and remove it (ref.D fig.5).
With the aid of the hoist, remove the cylinder, place it on a clean work
bench and proceed with replacement.

INSTALLATION

To refit, reverse the removal procedure.

Fig. 4
C

Fig. 5

47
 HYDRAULIC SYSTEM SERVICE

REMOVAL OF THE LATERAL LIFT CYLINDERS

Tools

hoist lifting sling 2 open ended

medium external
load capacity load capacity wrenches
circlip pliers
2000 kg 2000 kg 15 mm

Fig. 1

wrench for Allen key

oil resistant gloves step ladder
hydraulic fittings 6 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
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.
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.
A

Phase 1
Using the controls in the cab, make the retractable carriage come fully 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 - 2x 15 mm OPEN
ENDED WRENCHES
Position the ladder next to the mast. Climb up and use the pliers to remove
the circlip securing the cylinder (ref.A fig.1).
Using the open ended wrenches, unscrew and remove the screws fasten-
ing the cylinder locking bracket (ref.B fig.2). Remove the bracket. B
Using the cab controls, lower the forks completely down to the ground.

Fig. 2

48
 SERVICE HYDRAULIC SYSTEM

Phase 3
OIL RESISTANT GLOVES - WRENCH FOR HYDRAULIC FITTINGS
Wear the oil resistant gloves.
Remove the plates to access the hydraulic control valve (fig.3).
Using the wrench for hydraulic fittings, disconnect the hydraulic hose at
the base of the cylinder (ref.C fig.4).

Phase 4
BRIDGE CRANE - LIFT BELT
Attach the lifting sling to the top of the inner mast section and attach both Fig. 3
ends of the sling to the bridge crane.
Start lifting with just the cylinder connected and at the same time raise Fig. 4
the bridge crane up to the maximum height and keep the belt taut. C

Phase 5
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 D
cylinder (ref.D fig.4). 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 the assembly perform the cylinder air bleeding

procedure (see “CYLINDERS: AIR BLEEDING choke”).

INSTALLATION

To refit, reverse the removal procedure.

49
 HYDRAULIC SYSTEM SERVICE

CYLINDER BREAKDOWN (SIDES - CENTRAL)

• seal replacement
• hose break valve replacement

Tools

open ended
workbench vice oil resistant gloves oil pan round nose pliers
wrench

small flat blade

oil syringe brush C wrench
screwdriver

Procedure

Before starting work, ensure that you are wearing suitable Fig. 1
protective clothing.

Phase 1
Carry out the removal procedure for the relevant cylinder (see paragraphs
above).

Phase 2
WORK BENCH WITH VICE - OIL RESISTANT GLOVES - C WRENCH
- 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 wrench at the notches
on the seal carrier bush. Unscrew the bushing from the cylinder (ref.A
fig.1) extract it from the rod and place it on the workbench. Remove the
rod from the cylinder (fig.1).

50
 SERVICE HYDRAULIC SYSTEM

SEAL REPLACEMENT
Fig. 2
Phase 3
SMALL FLAT HEAD SCREWDRIVER - BRUSH
Using the screwdriver, remove the seals inside the bush proceed with
replacement (fig.2). Remove the seals outside the bush from the rod and
proceed with replacement (fig.3).

The fitting of the sealing seals is a delicate stage of the lift

cylinder assembly procedure. Most maintenance opera-
tions can be ascribed to leaking seals. 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.

Fig. 3

REMOVAL OF THE HOSE BREAK VALVE

(LIFT CYLINDERS)
Malfunction of the hose break valve can be caused by dirt causing the
spool to stick.
Clean carefully.

Phase 4
OIL RESISTANT GLOVES - ROUND NOSE PLIERS - OPEN ENDED
WRENCH
Use the open ended wrench to unscrew and remove the connector from
the cylinder (ref.B fig.4). Use the pliers to remove the valve from its seat
(ref.C fig.4). Proceed with the cleaning to remove any dirt residue.
Replace if broken.

INSTALLATION
The bush should be tightened during assembly to:
353-380 Nm (middle lift cylinder)
358 Nm (side lift cylinders)
C
B
Lubricate all the inner parts of the cylinder with clean hy-
draulic oil. Use new seals.

Fig. 4

51
 HYDRAULIC SYSTEM SERVICE

LIFT CYLINDER: AIR BLEEDING

Tools

open ended
oil resistant gloves wrench
13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the keyswitch
to OFF and disconnect the battery.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
OIL RESISTANT GLOVES - 13 mm OPEN ENDED WRENCH - LADDER
Wear the oil resistant gloves. Set the ladder next to the column and climb Fig. 1
up.
Using the wrench, unscrew the air bleed screw by two turns (ref.B fig.1).

Connect the battery and turn the starter key to ON.

A

Phase 2
13 mm OPEN ENDED WRENCH
B
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.

52
 SERVICE HYDRAULIC SYSTEM

REMOVAL OF THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER

Tools

open ended
T handle hex key wrench for
oil resistant gloves wrench
3 - 5 mm hydraulic fittings
8 - 24 mm

Fig. 1

hex socket
wrench ratchet extension bar
24 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit of
other vehicles and all pedestrians.
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
Using the controls in the cab, make the retractable carriage come fully Fig. 2
out (fig.1).
Unscrew the screws to remove the plates and access the control valve
(fig.2).

Phase 2
5 MM T-HANDLE HEX KEY
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.3).
Fig. 3

53
 HYDRAULIC SYSTEM SERVICE

Phase 3a
3 MM T-HANDLE HEX KEY - 8-24 MM OPEN ENDED WRENCH
Using the 8mm open ended wrench and the T-handle hex key, unscrew B
and remove the screw fastening the potentiometer to the cylinder (ref.A
fig.4).
Using the 24mm open ended wrench, unscrew and remove the bolt se- A
curing the cylinder to the retractable carriage (ref.B fig.4).

Phase 4a Fig. 4
24 MM HEX SOCKET WRENCH - RATCHET - EXTENSION
Using the open ended wrench, through the electronic controls compart-
ment, unscrew and remove the bolt fastening the cylinder to the retract-
able 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.

Phase 5a Fig. 5
OIL RESISTANT GLOVES - WRENCH FOR HYDRAULIC FITTINGS
Wear the oil resistant gloves.
Using the wrench for hydraulic fittings, disconnect the hydraulic hose
fittings 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
INSTALLATION

To refit, reverse the removal procedure.

D
Fig. 6

54
 SERVICE HYDRAULIC SYSTEM

Phase 3b
3 - 5 MM T HANDLE HEX KEY - 8 MM OPEN ENDED WRENCH A
Using the 8 mm open ended wrench and the T-handle hex key, unscrew
and remove the screw fastening the potentiometer to the cylinder (ref.A B
fig.3).
Using the 5 mm hex key, unscrew and remove the screw securing the C
cylinder pivot pin to the retractable carriage(ref.B fig.3). Remove the pin
(ref.C fig.3). Fig. 3

Phase 4b
5 MM "T" HANDLE HEX KEY
Insert the T handle key though the motor compartment, unscrew and re-
move the screw that blocks the cylinder stop to the carriage base (ref.D
fig.4). Remove the pin (ref.E fig.4) and move the cylinder rod to be able Fig. 4
to remove it from its seat.
Using the controls in the cab, make the rod come fully into the cylinder.
D

Phase 5b
OIL RESISTANT GLOVES - WRENCH FOR HYDRAULIC FITTINGS
Wear the oil resistant gloves.
Using the wrench or hydraulic fittings, disconnect the hydraulic hoses
from the cylinder (ref.F fig.6).
Remove the cylinder from its seat, place it on a clean work bench and
F
proceed with dismantling or replacement.

INSTALLATION

To refit, reverse the removal procedure.

F
Fig. 6

55
 HYDRAULIC SYSTEM SERVICE

BREAKDOWN OF THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER

Tools

workbench oil resistant C reservoir

vice circlip pliers
gloves wrench oil collection pan

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.
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
Carry out the retractable carriage side shift cylinder disassembly proce-
dure
(see the previous paragraphs).

Fig. 1
BEARING REPLACEMENT A

B
Phase 2
SMALL FLAT HEAD SCREWDRIVER
Using the screwdriver, remove the ring (ref.A fig.1) that holds the
bearing in its seat, recover the bearing (ref.B fig.1) and proceed
with replacement.

56
 SERVICE HYDRAULIC SYSTEM

Fig. 2
D
C
E

F E

SEAL REPLACEMENT

Phase 3
WORK BENCH WITH VICE - OIL RESISTANT GLOVES - C WRENCH - OIL PAN
Secure the cylinder in the vice, interposing a rubber protection between the vice jaws and cylinder and
tighten carefully.
Place the underneath the bush of the cylinder. Apply the C wrench at the notches on the bush. Unscrew
the bush from the cylinder (ref.C fig.2), slide it off the rod (ref.D fig.2).

Using the screwdriver, recover the seals (ref.E fig.2) and the piston (ref.F fig.2), then replace the seal kit
or the piston.

Fitting the seals is a delicate stage in the cylinder assembly procedure. Most maintenance
operations can be ascribed to leaking seals. 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.

57
 HYDRAULIC SYSTEM SERVICE

REMOVAL OF THE FORK TILTING CYLINDER

Tools

hoist 2 lift belts

T handle hex key Allen key medium flat blade
load capacity load capacity
6 mm 10 mm screwdriver
1000 kg 1000 kg

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all pede-
strians.
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
Using the controls in the cab, fully extend the retractable carriage and raise the forks by approximately one
metre. Remove the forks.
Fig. 1

Turn the keyswitch to OFF and disconnect the battery.

Phase 2
Perform the mobile frame removal procedure (see “REMOVAL OF D
THE MOBILE FRAME” described in the section "FORK CARRIAGE
MECHANICS").
Disconnect the hydraulic hoses.

Before working on the cylinder, release the pressure from

B
the carriage circuit.

Phase 3
MEDIUM FLAT BLADE SCREWDRIVER - 14 MM OPEN ENDED
WRENCH - 6 MM T-HANDLE HEX KEY
Using the medium flat blade screwdriver, lever on and remove the lower
sliding block (ref.B fig.1).
Using the open ended wrench, unscrew and remove the hydraulic hoses
from the fittings (ref.C fig.2). C Fig. 2
Using the T-handle hex key, unscrew and remove the screws securing
the flange (ref.D fig.1) and remove it.
Extract the cylinder from its seat and dismantle or replace.

INSTALLATION

To refit, reverse the removal procedure.

58
 SERVICE HYDRAULIC SYSTEM

FORK TILTING CYLINDER BREAKDOWN

Tools

workbench oil resistant C reservoir

vice circlip pliers
gloves wrench oil collection pan

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.
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
Carry out the disassembly procedure for the fork tilting cylinder (see the
previous paragraphs).

SEAL REPLACEMENT
Phase 2
WORK BENCH WITH VICE - OIL RESISTANT GLOVES - C WRENCH
- OIL PAN
Secure the cylinder in the vice, interposing a rubber protection between
the vice jaws and cylinder and tighten carefully.
Place the underneath the bush of the cylinder. Apply the C wrench at the
notches on the bush. Unscrew the bush from the cylinder (ref.C fig.1),
slide off the rod (ref.D fig.1).

Using the screwdriver, recover the seals (ref.AND fig.1) and the piston
(ref.D fig.1), then proceed with replacement of the seals kit or the piston.

59
 HYDRAULIC SYSTEM SERVICE

Fig. 1

3 STAGE
MAST
E

E
D
C

4 STAGE
MAST

Fitting the seals is a delicate stage in the cylinder assembly procedure. Most maintenance
operations can be ascribed to leaking seals. 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.

60
SERVICE HYDRAULIC SYSTEM

LIFT PUMP MOTOR

KEY TO LIFT PUMP MOTOR COMPONENTS
9.9 KW POWER
FOR MODELS MR14 AND MR16 ONLY

13

12

11

10

8
7 6

14

3
2

61
 HYDRAULIC SYSTEM SERVICE

Ref. Description

1 Final cover
2 Washer
3 Bearing
4 Stator
5 Rotor
6 Toothed wheel sensor
7 Circlip
8 End unit
9 Bearing
10 O-ring
11 Upper protection
12 Pump fixing screws
13 Sensor (speed)
14 Pump motor heat sensor

62
SERVICE HYDRAULIC SYSTEM

KEY TO LIFT PUMP MOTOR COMPONENTS

14 KW POWER
FOR MODELS MR14 AND MR16 ONLY

2
3 13

5
6
7

14

10

11

12

63
 HYDRAULIC SYSTEM SERVICE

Ref. Description

1 Cover
2 Gear wheel
3 Seal
4 Upper flange
5
Seals
6
7 Upper bearing
8 Stator
9 Rotor
10 Lower bearing
11 O-ring
12 Lower flange
13 Sensor (speed)
14 Pump motor heat sensor

64
SERVICE HYDRAULIC SYSTEM

REMOVAL OF THE LIFT PUMP ASSEMBLY

Equipment and tools

hex socket hoist lifting sling

workbench wrench ratchet extension bar load capacity load capacity
15 mm 1000 kg 1000 kg

open ended
wrench for T handle hex key
wrench oil resistant gloves eyebolt
hydraulic fittings 5 mm
17 mm

Procedure
Fig. 1
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground. Turn the keyswitch to OFF and disconnect
the battery.
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.

Before starting work, drain the oil reservoir.

Phase 1
5 mm T-HANDLE HEX KEY
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. 2

65
 HYDRAULIC SYSTEM SERVICE

Phase 2
17 mm open ended wrench
Using the open ended wrench, unscrew the nuts fastening the pump motor power cables.
Take note of the position of the cables. Slide the cables out and disconnect the connectors.

Phase 3
15 MM SOCKET WRENCH - RATCHET - EXTENSION - WRENCH FOR HYDRAULIC FITTINGS - OIL
RESISTANT GLOVES
Wear the oil resistant gloves.
Using the wrench for hydraulic fittings, disconnect the hydraulic hose from the pump block (ref.B fig.3).
Use the open ended wrench to unscrew the fastening screw of the hose clip securing the suction hose
(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.

66
SERVICE HYDRAULIC SYSTEM

REPLACEMENT OF THE PUMP

Equipment and tools

hex socket
wrench ratchet
17 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing. Fig. 1
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground. Turn the keyswitch to OFF and disconnect
the battery.

Phase 1
Carry out the lift pump removal procedure (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. A

INSTALLATION

During the assembly stage tighten the nuts that fasten the
pump to the flange with a torque wrench set at 45 Nm.

67
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC PIPES
PIPE PLACEMENT FOR HYDRAULIC CIRCUIT

68
 SERVICE HYDRAULIC SYSTEM

RENEWAL OF THE CENTRAL LIFT CYLINDER SUPPLY PIPE

Equipment and tools

wooden beam wrench for

oil resistant gloves
hydraulic fittings

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Fig. 1

Phase 1
Using the controls in the cab, make the retractable carriage come fully
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.2).
Lower the forks and rest them on the beam, continue lowering until the
fork lift cylinder hydraulic power feed pipe becomes slack. Fig. 2

Turn the keyswitch to OFF and disconnect the battery.

69
 HYDRAULIC SYSTEM SERVICE

Phase 3
WRENCH FOR HYDRAULIC FITTINGS - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Using the wrench for hydraulic fittings, disconnect the hydraulic hose
from the central lift cylinder (ref.B fig.3) and the hydraulic hose from the
hydraulic unit (ref.C fig.4).
Extract the hose from the sheave and proceed with replacement.

B
Fig. 3

Fig. 4

70
 SERVICE HYDRAULIC SYSTEM

RENEWAL OF THE FORK HYDRAULIC FUNCTIONS SUPPLY PIPES

Equipment and tools

10 mm
open ended wooden beam wrench for
oil resistant gloves
wrench hydraulic fittings

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Fig. 1

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
A

Phase 2
10 mm OPEN ENDED WRENCH
Using the open ended wrench, unscrew and remove the screws fastening
the pipe clamps (ref.A fig.2).
Fig. 2

Fig. 4

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.3).
Lower the forks and rest them on the beam, continue lowering until the
fork hydraulic functions supply hose becomes slack.
B

71
 HYDRAULIC SYSTEM SERVICE

Turn the keyswitch to OFF and disconnect the battery.

Phase 4
WRENCH FOR HYDRAULIC FITTINGS - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
D C
Using the wrench for hydraulic fittings, disconnect the hydraulic hose
from the hydraulic unit on the fork carriage (ref.C fig.4).
Using the wrench for hydraulic fittings, disconnect the hydraulic hose
from the hydraulic unit (ref.D fig.4).
Fig. 4
Extract the hose from the sheave and proceed with replacement.

72
 SERVICE TRUCK BASE MECHANICS

TRUCK BASE MECHANICS

WHEELS.........................................................................................................................................................................2
KEY TO DRIVE WHEEL COMPONENTS...............................................................................................2
REMOVAL OF THE DRIVE WHEEL....................................................................................................3
KEY TO LOAD WHEEL ASSEMBLY COMPONENTS...............................................................................5
KEY TO LOAD WHEEL COMPONENTS...........................................................6
R E M O VA L O F T H E L O A D W H E E L S.........................................................................................7
K E Y TO C O M P O N E N T S O F T H E O P T I O N A L L O A D W H E E L C O V E R....................................9
REMOVAL OF THE LOAD WHEEL COVER...........................................................................................10
B AT T E RY B L O C K....................................................................................................................11
REPLACEMENT OF THE BATTERY BLOCK.........................................................................................11
M O TO R S...............................................................................................................................13
K E Y T O D R I V E M O T O R C O M P O N E N T S , 6.4 K W.............................................................13
K E Y T O D R I V E M O T O R C O M P O N E N T S , 5.4 - 9.6 K W ..................................................14
REMOVAL OF THE DRIVE MOTOR..............................................................................................15
REPLACEMENT OF DRIVE MOTOR BEARINGS.........................................................................17
K E Y T O S T E E R I N G M O T O R C O M P O N E N T S ...................................................................19
REMOVAL OF THE DRIVE MOTOR...........................................................................................................20
DISASSEMBLY OF THE STEERING MOTOR.............................................................................................21
STEERING ASSEMBLY.....................................................................................................................23
K E Y T O S T E E R I N G A S S E M B LY C O M P O N E N T S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3
REPLACEMENT OF THE STEERING ASSEMBLY BEARING...............................................................24
RETRACTABLE CARRIAGE..........................................................................................................25
K E Y TO R E T R A C TA B L E C A R R I A G E C O M P O N E N T S............................................................25
REMOVAL OF THE RETRACTABLE CARRIAGE.....................................................................................................28
REPLACEMENT OF RETRACTABLE CARRIAGE BEARINGS AND PINS.................................................................30
REMOVAL OF THE RETRACTABLE CARRIAGE POTENTIOMETER.................................................................31
O P T I O N A L L AT E R A L G U I D E R O L L E R S...............................................................................32
KEY TO COMPONENTS OF THE LATERAL GUIDE ROLLERS......................................................32
REPLACEMENT OF THE LATERAL GUIDE ROLLERS.................................................................................34
O V E R H E A D G U A R D .........................................................................................................35
KEY TO OVERHEAD GUARD COMPONENTS...............................................35
R E M O VA L O F T H E O V E R H E A D G U A R D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9

1
 TRUCK BASE MECHANICS SERVICE

WHEELS & TYRES

KEY TO DRIVE WHEEL COMPONENTS

Ref. Description

1 Drive wheel
2 Washer
3 Drive wheel flanged retaining nut

2
 SERVICE TRUCK BASE MECHANICS

REMOVAL OF THE DRIVE WHEEL

Equipment and tools

hex socket
T-handle hex key ratchet with M5/M6 screw
hydraulic jack wooden block wrench
5 mm extension bar 2 x 70 mm
12 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground, turn the keyswitch to OFF and disconnect
the battery.
B

Phase 1 Fig. 1
5 mm T-HANDLE HEX KEY
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (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 (ref.B fig.1) and remove it.

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
2x M6 or M5 SCREWS, LENGTH 70 mm
Insert the two M6x60 screws in the holes (ref. C fig.1) or insert the two
M5x60 in the holes (ref.D fig.1) above the electro-magnetic brake (fig.4),
screw them in until they touch the lower disc, then screw them in one
further turn.

The purpose of this procedure is to release the

electromagnetic brake so as to free the wheel.
Fig. 3

3
 TRUCK BASE MECHANICS SERVICE

Phase 4 Fig. 4
12 mm SOCKET WRENCH - RATCHET - EXTENSION C
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.D fig.5).
Raise with the hydraulic jack until the wheel passes under the truck (fig.6).
Proceed with replacement.
D

INSTALLATION

To refit, reverse the removal procedure.

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.

B Fig. 5

Fig. 6

4
SERVICE TRUCK BASE MECHANICS

KEY TO LOAD WHEEL ASSEMBLY COMPONENTS

2 5
1
6
3

4 10

12

11
9

Ref. Description

1 Load wheel brake connector*

2 Screw*
3 Clip*
4 Brake assembly*
5 Retaining screws*
6 Load wheel
7 Wheel retaining screws
8 Spacer
9 Lock washer
10 Lock nut
11 Cap
12 Screws*

* Only present if the load wheel brake is installed

5
 TRUCK BASE MECHANICS SERVICE

KEY TO LOAD WHEEL COMPONENTS

2
3

Ref. Description

1 Washer
2 Bearing
3 Circlip
4 Wheel

6
 SERVICE TRUCK BASE MECHANICS

REMOVAL OF THE LOAD WHEELS

Equipment and tools

socket wrench for internal circlip T-handle hex key

hydraulic jack wooden block ratchet
self-locking ring pliers 6 mm
nut

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground, turn the keyswitch to OFF and disconnect
the battery.

Phase 1
HYDRAULIC JACK - WOODEN BLOCK
Position the hydraulic jack beside the load wheel and lift until the wooden
stock can pass beneath. Fig. 1
Set the wooden block below 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, un-
screw and remove the ring nut (ref.A fig.2), remove the toothed washer
(ref.B fig.3). A
Extract the wheel from the hub and dismantle or replace.
B Fig. 2

Fig. 3
REPLACEMENT OF THW WHEEL BEARING

Phase 3 C
LARGE INTERNAL CIRCLIP PLIERS
Use the internal circlip pliers to remove the circlip securing the bearing
(ref.C fig.3). Remove the bearing (ref.D fig.3) and proceed with the
replacement.
D

7
 TRUCK BASE MECHANICS SERVICE

REMOVAL OF THE BRAKE DISK

F Fig. 4
Phase 4
6 mm T-HANDLE HEX KEY E
Using the T-handle hex key, remove the screws securing the brake disk to
the wheel together with the bush and spring (ref.E fig.4). When removing
the disk, take care to lose the springs (ref.F fig.4).

INSTALLATION

The screws securing the brake disk must be tightened using

a torque wrench to a torque of 25 Nm. Apply threadlocker

8
SERVICE TRUCK BASE MECHANICS

KEY TO COMPONENTS OF THE OPTIONAL LOAD WHEEL COVER

3 4

Ref. Description

1 Cover
2 Screw
3 Washer
4 Nut

9
 TRUCK BASE MECHANICS SERVICE

REMOVAL OF THE LOAD WHEEL COVERS

Equipment and tools

6mm open ended

5mm allen key
spanner

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground, turn the keyswitch to OFF and disconnect
the battery.

Phase 1
OPEN ENDED SPANNER - ALLEN KEY B
C
Using the Allen key, unscrew the two cover retaining screws (rif.A fig.1).
With the open ended spanner, counterhold the nut (ref. B fig.1) and
unscrew the screw (ref.C fig.1) with the Allen key, then remove the cover
(ref.D fig.1). A

D A Fig. 1

10
 SERVICE TRUCK BASE MECHANICS

BATTERY LOCK
RENEWAL OF THE BATTERY BLOCK
Equipment and tools

hex socket open ended span-

T-handle hex key
wrench ratchet ner
5 - 6 mm
15 mm 10 - 13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground.

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.
Using the controls in the cab, make the retractable carriage come fully out.

Turn the keyswitch to OFF and disconnect the battery. A

Fig. 1

Phase 2
5 mm T-HANDLE HEX KEY
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (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 (ref.B fig.1) and remove it.

Fig. 2

11
 TRUCK BASE MECHANICS SERVICE

Phase 3
Fig. 3
10 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws securing
the bracket inside the motor compartment (ref.C fig.3). Remove the
bracket (ref.D fig.3). C

Phase 4 D
15 MM HEXAGONAL SOCKET WRENCH - RATCHET
Using the hex socket wrench and the ratchet, unscrew and remove the
screws securing the battery block (ref.E fig.4). Remove the battery block
Fig. 4
and proceed with replacement or disassembly.

DISASSEMBLY OF THE BATTERY BLOCK

Phase 5
6 MM T-HANDLE HEX KEY - 13 MM OPEN ENDED SPANNER Fig. 5
Using the open ended spanner, loosen the nut (ref.F fig.5) and, using the
T-handle hex key, unscrew and remove the screw (ref.G fig.5). Extract the
pin including the spring and proceed with replacement of the components.

12
SERVICE TRUCK BASE MECHANICS

MOTORS
KEY TO DRIVE MOTOR COMPONENTS
6.4 KW

3
4
5
6
7
8

10

11

12
13
14
15
16
17
18

Ref. Description Ref. Description

1 Upper flange retaining screws 10 Speed Sensor
2 Upper flange 11 Stator
3 Circlip 12 Lower flange
4 Circlip 13 Bush
5 O-ring 14 Seal
6 Upper bearing 15 Lower bearing
7 Circlip 16 Circlip
8 Gear wheel 17 Circlip
9 Rotor 18 O-ring

13
 TRUCK BASE MECHANICS SERVICE

KEY TO DRIVE MOTOR COMPONENTS

5.4 - 9.6 KW

21
20
8 22
23

7 19
5 18
1 3
17

12 13 16
10 11 14 15
2
4 9
6

Ref. Description Ref. Description

1 Wrench 13 Ball bearing

2 Circlip 14 O Ring
3 Circlip 15 Final cover
4 Ball bearing 16 Screw
5 Seal 17 Circlip
6 O-ring 18 Key
7 Bushing 19 Circlip
8 Ring Nut 20 Sensor
9 Stator 21 Clip
10 Rotor 22 Terminal board
11 Gear wheel 23 Sensor
12 Circlip

14
 SERVICE TRUCK BASE MECHANICS

REMOVAL OF THE DRIVE MOTOR

Equipment and tools

hoist lifting sling open ended span-

T-handle hex key
load capacity load capacity ner eyebolt
5-6 mm
1000 kg 1000 kg 13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.

Phase 1
5 mm T-HANDLE HEX KEY B
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (fig.2). Remove the rubber mat at the operator's feet inside A
the cab. Using the T-handle hex key, unscrew and remove the screws
securing the cover of the electronic controls (ref.B fig.1) and remove it.
Fig. 1

Phase 2
Carry out the electromagnetic brake removal procedure (see "REMOVAL
OF THE ELECTROMAGNETIC BRAKE" in the "BRAKING SYSTEM"
section).

Phase 3
13 mm OPEN ENDED WRENCH
Unscrew the traction motor power cable fastening nuts. Note the posi-
tion of the cables prior to removing them. Disconnect the sensor cable
connector. Fig. 2

Fig. 3
Phase 4
6 mm T-HANDLE HEX KEY
Using the T-handle hex key, unscrew and remove the 6 screws fastening
the drive motor to the reduction unit (ref.C fig.3).
C

15
 TRUCK BASE MECHANICS SERVICE

Phase 5
HOIST - LIFTING SLING - 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: Fig. 4
"SHELL GADUS S2 OGH 0/00”.

During the coupling stage, carefully rotate the wheel shaft

to help the motor shaft engage with the pinion.

16
 SERVICE TRUCK BASE MECHANICS

REPLACEMENT OF TRACTION MOTOR BEARINGS

Equipment and tools

T-handle hex key medium internal circlip external circlip

5 mm adjustable pliers pliers pliers

Fig. 1
B

plastic mallet bush C spanner

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.

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
6 mm T-HANDLE HEX KEY
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

17
 TRUCK BASE MECHANICS SERVICE

Phase 3
Fig. 3
INTERNAL CIRCLIP PLIERS
Use the circlip pliers to remove the circlip securing the upper bearing to
the flange (ref.D fig.3). D
Recover the bearing and proceed with replacement.

Phase 4
C SPANNER - INTERNAL CIRCLIP PLIERS - EXTERNAL CIRCLIP
PLIERS - MEDIUM ADJUSTABLE PLIERS
Using the open ended spanner, remove the nut (ref.E fig.4) securing
the reduction unit drive pinion. Using the puller, remove the reduction
unit coupling pinion (ref.F fig.4). Using the adjustable pliers, pull out the
pinion retaining key (ref.G fig.5). Use the circlip pliers to remove the two
circlips securing the lower bearing and the bush to the shaft (ref.H-I fig.5).
Remove the bearing (ref.L fig.5) and proceed with the replacement.
E
F
INSTALLATION

During the assembly stage replace all the gaskets with

new gaskets.
Assemble the new bearings using the plastic hammer and
the bush.
Tighten the nut (ref.E fig.4) to a torque of 55Nm

Fig. 4

Fig. 5
H
I

18
SERVICE TRUCK BASE MECHANICS

KEY TO STEERING MOTOR COMPONENTS

3
4

14

13 15
8 10

6
12
11
9
7

Ref. Description Ref. Description

1 Upper flange retaining screws 11 Upper bearing
2 Sensor 12 Circlip
3 Upper flange 13 Rotor
4 Stator 14 Lower bearing
5 Lower flange 15 Ring
6 Circlip
7 Ring
8 Circlip
9 Magnet
10 Circlip

19
 TRUCK BASE MECHANICS SERVICE

STEERING MOTOR DISASSEMBLY

Equipment and tools

open ended
T-handle hex key
spanner
5 mm
13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.

A
Phase 1
5 mm T-HANDLE HEX KEY Fig. 1
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (fig.2).

Phase 2
13 mm OPEN ENDED WRENCH
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

20
SERVICE TRUCK BASE MECHANICS

STEERING MOTOR DISMANTLING

Equipment and tools

T-handle hex key medium cross- internal circlip external circlip

3-4-5-6 mm head screwdriver pliers pliers

Fig. 1
plastic mallet bush
A

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.

Fig. 2

REMOVAL OF THE ELECTRICAL BOX

B

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. C
Using the T-handle hex key, unscrew the screws fastening the box to
the motor flange.

Fig. 3

21
 TRUCK BASE MECHANICS SERVICE

BEARING REMOVAL
Fig. 4
D
Phase 2
4-5-6 mm T-HANDLE HEX KEY E
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). F
Using the 6 mm T-handle hex key, unscrew and remove the screws
securing the triangular bracket (ref.G fig.4). Remove the bracket. G
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 H
3-4 mm T-HANDLE HEX KEY - EXTERNAL CIRCLIP PLIERS - INTER-
NAL 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. Fig. 5
Use the circlip pliers to remove the circlip securing the upper bearing to
the flange.
Recover the bearing and proceed with replacement. I
J

INSTALLATION

During the assembly stage replace all the gaskets with

new gaskets.
Assemble the new bearings using the plastic hammer and
the bush.

22
SERVICE TRUCK BASE MECHANICS

STEERING SYSTEM ASSEMBLY

KEY TO STEERING SYSTEM ASSEMBLY COMPONENTS

1
12 2

5
6
7
8

10

11

Ref. Description Ref. Description

1 Small steering wheel 7 Pushrod
2 Driving 8 Circlip
3 Adjuster plate 9 Bearing
4 Block 10 Shaft
5 Pin 11 Stepper motor
6 Spring 12 Bearing

23
 TRUCK BASE MECHANICS SERVICE

RENEWAL OF STEERING SYSTEM ASSEMBLY BEARING

Equipment and tools

internal circlip
pliers

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing. Fig. 1
A

Phase 1
To recover the block complete with bearing see the paragraph
“REPLACEMENT OF MAIN PANEL AND ARMREST CONTROLS:
STEERING HANDHEEL STEPPER MOTOR” in the section “ELECTRICAL
SYSTEM”.

Phase 2
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.

24
SERVICE TRUCK BASE MECHANICS

RETRACTABLE CARRIAGE
KEY TO RETRACTABLE CARRIAGE COMPONENTS

1
14
2
15
12
13 3
16

4
11
9
10 5
19
8
7 6

18

17
22

20

21

Ref. Description Ref. Description

1 Screw 12 Retainer
2 Block 13 Buffer
3 Retractable carriage 14 Plate
4 Bearing 15 Screw
5 Circlip 16 Pin
6 Side Roller 17 Spacer
7 Screw 18 Pin
8 Potentiometer 19 Shaft block
9 Nut 20 Left plate
10 Pin 21 Plate retaining screw
11 Bearing 22 Right plate

25
 TRUCK BASE MECHANICS SERVICE

KEY TO RETRACTABLE CARRIAGE COMPONENTS

MR16N MODEL

1 1
14
14 15 2
15 2

13 13
12
3
12 10 16
16 3

4
11 9
9 5 4
11 19
8 19
10 56
7
8
7 6 18
18

17
17
22
22

2020

21
21

Ref. Description Ref. Description

1 Screw 12 Retainer
2 Block 13 Buffer
3 Retractable carriage 14 Plate
4 Bearing 15 Screw
5 Circlip 16 Pin
6 Side Roller 17 Spacer
7 Screw 18 Pin
8 Potentiometer 19 Shaft block
9 Nut 20 Left plate
10 Pin 21 Plate retaining screw
11 Bearing 22 Right plate

26
SERVICE TRUCK BASE MECHANICS

KEY TO RETRACTABLE CARRIAGE COMPONENTS

FOR WIDE AND EXTRAWIDE MODELS ONLY

1
14
2
15
12
3
16
13

11
10 9 4
7
8
5
19
6

18

17

22

20

Ref. Description Ref. Description

1 Screw 12 Retainer
2 Block 13 Buffer
3 Retractable carriage 14 Plate
4 Bearing 15 Screw
5 Circlip 16 Pin
6 Side Roller 17 Spacer
7 Screw 18 Pin
8 Potentiometer 19 Shaft block
9 Nut 20 Left plate
10 Pin 21 Plate retaining screw
11 Bearing 22 Right plate

27
 TRUCK BASE MECHANICS SERVICE

REMOVAL OF THE RETRACTABLE CARRIAGE

Equipment and tools

bridge crane 2 lifting slings hex socket open ended span-

ratchet and T-handle hex key
load capacity load capacity wrench ner
extension 3-14 mm
2000 kg 2000 kg 10 mm 8-24 mm

wrench for
oil resistant gloves
hydraulic fittings

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all pede-
strians.
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
Carry out the mast removal procedure (see “REMOVAL OF THE MAST ASSEMBLY” in the “MAST ME-
CHANICS” section).

Phase 2
OIL RESISTANT GLOVES - WRENCH FOR HYDRAULIC FITTINGS
Wear the oil resistant gloves.
Using the wrench for hydraulic fittings, disconnect the hydraulic hose fittings on the control valve.
Disconnect the connectors from the solenoid valves.

According to the type of pin installed, carry out one of the following "Phase
3" procedures.

Phase 3
B
3 MM T-HANDLE HEX KEY - 8-24 MM OPEN ENDED WRENCH
Using the 8mm open ended wrench and the T-handle hex key, unscrew
and remove the screw fastening the potentiometer to the cylinder (ref.A A
fig.1).
Using the 24mm open ended spanner unscrew and remove the bolt fa-
stening the cylinder to the retractable carriage (ref.B fig.1).
Raise the cylinder to extract it from the pin.
Fig. 1

28
 SERVICE TRUCK BASE MECHANICS

Phase 3b
3 - 5 MM T HANDLE HEX KEY - 8 MM OPEN ENDED WRENCH A
Using the 8 mm open ended wrench and the T-handle hex key, unscrew
and remove the screw fastening the potentiometer to the cylinder (ref.A B
fig.2).
Using the 5 mm hex key, unscrew and remove the screw securing the C
cylinder pivot pin to the retractable carriage (ref.B fig.2). Remove the
pin (ref.C fig.2). Fig. 2

Phase 4
Fig. 3
10 MM SOCKET WRENCH - EXTENSION - RATCHET
Using the socket wrench, extension and ratchet, unscrew and remove
the screws securing to the carriage the plate to which the hose chain
(ref.C fig.3) is fixed.

Phase 5
14 mm T-HANDLE HEX KEY
Using the T-handle hex key, unscrew and remove the stop screws of the
retractable carriage (ref.E 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.
D
INSTALLATION

The stop screws (ref.E fig.4) must be tightened using a

torque wrench with a tightening torque of 300 - 330 Nm.

Fig.5 Fig. 4

29
 TRUCK BASE MECHANICS SERVICE

RENEWAL OF BEARINGS AND RETRACTABLE CARRIAGE PINS

Equipment and tools

open ended
external circlip socket wrench for driving tool
spanner ratchet hammer
pliers self-locking ring Ø 10 mm
24 mm
nut

adjustable pin
C spanner
wrench

Procedure

Before starting work, ensure that you are wearing suitable

protective clothing.

Phase 1
Carry out the retractable carriage removal procedure (see “REMOVAL
OF THE RETRACTABLE CARRIAGE”).

A
Phase 2 Fig. 1
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. D
F
Phase 3
24 mm OPEN ENDED SPANNER - SOCKET WRENCH FOR SELF-
LOCKING 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). C
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 B E
the ring nut (ref.E fig.2). Fig. 2
Using the hammer and clamp gudgeon extract the pin from the carriage
(ref.F fig.2).

30
 SERVICE TRUCK BASE MECHANICS

INSTALLATION
Coat the new bearings with a layer of special lubricating grease “SHELL GADUS S2 V100
2” for standard applications or “AERO SHELL GREASE 6” for cold store applications.

After having replaced the bearings and repositioned the carriage in the guide rails of the truck base, the
bearings must be adjusted.

ADJUSTMENT OF RETRACTABLE CARRIAGE SIDE ROLLERS

Phase 1 Fig. 3
Retract the carriage up to the bumpers. Position the carriage fully to the
right (as viewed from the forks end) and check that the roller is in contact
with the arm of the truck base (fig.3).
At the opposite side, using the open ended spanner, loosen the nut,
and turn the screw to bring the roller into contact with the surface of the
channel arm of the truck base (fig.4). In this position, unscrew the screws
by a 1/2 turn, then tighten the locknuts (ref. G and H fig.5) Repeat the
above procedure on the rear bearing (operator side).

Fig. 5 Fig. 4

ADJUSTMENT OF THE ECCENTRIC BEARINGS

Move the carriage to the forward position. Mast Fig. 6

side
The eccentric bearings must be adjusted to bring them into contact with Battery
the frame profile as follows: side
Operator side eccentric bearing: rotated into contact with the lower side
of the profile.
Forks side eccentric bearing (if present): rotated into contact with the
upper side of the profile.

Procedure
Turn the eccentric pin to bring the bearing into contact with the base. I
Taking care to maintain contact with the base, using the holes in the
eccentric pin and the adjustable pin wrench, tighten the M40x1.5 locknut
(ref.I fig.7) using the C spanner.

Fig. 7

31
 TRUCK BASE MECHANICS SERVICE

REMOVING THE RETRACTABLE CARRIAGE POTENTIOMETER

Equipment and tools

open ended
T-handle hex key
spanner
3 mm
8 mm

Procedure
Fig. 1

Before starting work, ensure that you are wearing suitable

protective clothing.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Unscrew the screws to remove the plates and access the control valve
(fig.2).

Turn the keyswitch to OFF and disconnect the battery.

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 Fig. 2
the potentiometer to the carriage (ref.B fig.3).
Disconnect the connector and proceed with replacement.

B A

Fig. 2
Fig. 3

32
SERVICE TRUCK BASE MECHANICS

OPTIONAL LATERAL GUIDE ROLLERS

KEY TO COMPONENTS OF THE LATERAL GUIDE ROLLERS

2
3

6
8 7

Ref. Description
1 Spacers
2 Lateral guide rollers
3 Lateral guide roller support screw
4 Guide roller
5 Circlip
6 Bearing
7 Washer
8 Screw

33
 TRUCK BASE MECHANICS SERVICE

KEY TO COMPONENTS OF THE LATERAL GUIDE ROLLERS

FOR B6 = 1340 MM ONLY

2
3

1
5

6
7

Ref. Description
1 Spacers
2 Lateral guide rollers
3 Lateral guide roller support screw
4 Bearing
5 Lateral guide roller
6 Washer
7 Screw

34
 SERVICE TRUCK BASE MECHANICS

REPLACEMENT OF THE LATERAL GUIDE ROLLERS

open ended
external circlip
spanner
pliers

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.

Phase 1
OPEN ENDED SPANNER
With the open ended spanner, unscrew the retaining screw (ref.A fig.1)
of the lateral guide roller support, recover the washer (ref.B fig.1) and
B
support (ref.C fig.1).

C
B A
Fig. 1
Phase 2
OPEN ENDED SPANNER - CIRCLIP PLIERS
Using the open ended spanner, unscrew and remove the screw (ref.D
fig.2) securing the roller to the support.. Next remove the bearing (ref.E
fig.2) and, using the circlip pliers, remove the circlip (ref.F fig.2), recover
the roller (ref.G fig.2) and upper bearing (ref.H fig.2), then proceed with H
replacement of the parts. G
F
E
Fig. 2 D

35
 TRUCK BASE MECHANICS SERVICE

OVERHEAD GUARD
KEY TO OVERHEAD GUARD COMPONENTS

6
3

9 8
4

Ref. Description
1 Overhead guard frame retaining nuts
2 Overhead guard frame retaining screws
3 Overhead guard frame
4 Cover
5 Head Rest
6 Handle retaining screw
7 Handle
8 Overhead guard frame retaining screws
9 Overhead guard retaining bolt

36
SERVICE TRUCK BASE MECHANICS

KEY TO OVERHEAD GUARD COMPONENTS

DRIVE-IN MODELS 1400/1450 ONLY

7
6

9 5
8
4

Ref. Description
1 Overhead guard frame retaining nuts
2 Overhead guard frame retaining screws
3 Overhead guard frame
4 Cover
5 Head Rest
6 Handle retaining screw
7 Handle
8 Overhead guard frame retaining screws
9 Overhead guard retaining bolt

37
 TRUCK BASE MECHANICS SERVICE

KEY TO OVERHEAD GUARD COMPONENTS

DRIVE-IN 1700 MODELS ONLY

6
5

8 3
9

Ref. Description
1 Overhead guard frame retaining nuts
2 Overhead guard frame retaining screws
3 Overhead guard frame
4 Cover
5 Head Rest
6 Handle retaining screw
7 Handle
8 Overhead guard frame retaining screws
9 Overhead guard retaining bolt

38
SERVICE TRUCK BASE MECHANICS

KEY TO OVERHEAD GUARD COMPONENTS - HIGH VISIBILITY VERSION (OPTIONAL)

11

10

5 3
8
9

Ref. Description
1 Overhead guard frame retaining nuts
2 Overhead guard frame retaining screws
3 Overhead guard frame
4 Cover
5 Head Rest
6 Handle retaining screw
7 Handle
8 Overhead guard frame retaining screws
9 Overhead guard retaining bolt
10 Seal
11 Glass

39
 TRUCK BASE MECHANICS SERVICE

REMOVAL OF THE OVERHEAD GUARD

Equipment and tools

open ended span- cross-head

T-handle hex key
ner screwdriver
3 mm
8 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing. A

Fig. 1

Phase 1
5 mm T-HANDLE HEX KEY
Unscrew and remove the screw locking the bonnet (ref.A fig.1) and open
the bonnet (fig.2).

Phase 2
CROSS-HEAD SCREWDRIVER
With the cross-head screwdriver, unscrew and remove the retaining Fig. 2
screws (ref.B fig.3) of the cover of the overhead guard support frame.

Phase 3 B
OPEN ENDED SPANNER
With the open ended spanner, unscrew and remove the screws (ref.C
fig.4) that secure the support frame of the overhead guard to the chassis.

Fig. 3

Fig. 4

40
 SERVICE TRUCK BASE MECHANICS

Phase 4
CROSS-HEAD SCREWDRIVER
With the cross-head screwdriver, unscrew and remove the retaining screw
(ref.D fig.5) d of the dashboard cover.

Fig. 5

Phase 5
OPEN ENDED SPANNER
With the open ended spanner, unscrews the nuts (ref.E fig.5) securing
the overhead guard frame to the chassis.
Remove the upper dashboard, remove the screws (ref.F fig.6) and
proceed with removal of the overhead guard. E
E
E
Fig. 6

Fig. 6

REMOVAL OF THE GLASS HIGH VISIBILITY OVERHARD GUARD

(OPTIONAL) Fig. 7
If it is necessary to remove the glass of the high-visibility overhead guard,
gently push the glass upwards; remove the glass (ref.G fig.7) and the
seal (ref.H fig.7) and proceed with replacement. G

41
 TRUCK BASE MECHANICS SERVICE

42
 SERVICE MAST MECHANICS

MAST MECHANICS

MAST CHARACTERISTICS............................................................................................................................2
3 STAGE FFL MAST..............................................................................................................................4
KEY TO COMPONENTS OF OUTER SECTION.......................................................................................4
K E Y TO I N T E R M E D I AT E S E C T I O N.........................................................................................5
KEY TO INTERMEDIATE SECTION...........................................................................................................6
4 STAGE FFL MAST........................................................................................................................................7
KEY TO COMPONENTS OF OUTER SECTION - 4 STAGE 14-16 MASTS ONLY..........................7
KEY TO COMPONENTS OF 1ST INTERMEDIATE SECTION - 4 STAGE 14-16 MASTS ONLY.......8
KEY TO COMPONENTS OF 2ND INTERMEDIATE SECTION - 4 STAGE 14-16 MASTS ONLY....9
K E Y T O C O M P O N E N T S O F I N N E R S E C T I O N - 4 S TA G E 1 4 - 1 6 M A S T S O N LY. . . . . . . 1 0
K E Y TO C O M P O N E N T S O F O U T E R S E C T I O N - 4 S TA G E 20-25-20 H D M A S T S O N LY.......11
K E Y T O C O M P O N E N T S O F 1 S T I N T E R M E D I AT E S E C T I O N - 4 S TA G E 20-25-
2 0 H D M A S T S O N LY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2
K E Y T O C O M P O N E N T S O F 2 N D I N T E R M E D I AT E S E C T I O N - 4 S TA G E 20-25-
20 H D M A S T S O N LY..........................................................................................................13
K E Y T O C O M P O N E N T S O F I N N E R S E C T I O N - 4 S TA G E 20-25-20 H D M A S T S O N LY.......14
REMOVAL OF THE COMPLETE MAST ASSEMBLY.....................................................................................15
REMOVAL OF CHAINS AND LIFTING CYLINDERS..............................................................................17
R E P L A C E M E N T O F B E A R I N G S............................................................................................19
REPLACEMENT OF THE CHAINS AND CHAIN TENSIONER............................................................20
R E P L A C E M E N T O F T H E I N T E R M E D I AT E S E C T I O N C H A I N S H E AV E S.............................23
R E P L A C E M E N T O F T H E C E N T R A L C Y L I N D E R C H A I N S H E AV E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 5

1
 MAST MECHANICS SERVICE

MAST CHARACTERISTICS
Trucks may be equipped with 3 or 4 stage masts
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. The correct axis of the bearings can be set without having to
remove the roller entirely.

3 STAGE MAST

2
SERVICE MAST MECHANICS

4 STAGE MAST

3
 MAST MECHANICS SERVICE

3 STAGE FFL MAST

KEY TO COMPONENTS OF OUTER SECTION

6 7 9
5 10

4
8 11
3 12

Ref. Description Ref. Description

1 Outer section 7 Screw
2 Screw 8 Roller
3 Nut 9 Spacer
4 Washer 10 Dowel
5 Screw 11 Bearing
6 Buffer 12 Hose guide

4
SERVICE MAST MECHANICS

KEY TO COMPONENTS OF INTERMEDIATE SECTION

4
5

3 6

Ref. Description
1 Intermediate section
2 Bearing
3 Dowel
4 Spacer
5 Roller
6 Screw

5
 MAST MECHANICS SERVICE

KEY TO COMPONENTS OF INNER SECTION

2
4
5

3 6

Ref. Description
1 Inner section
2 Bearing
3 Dowel
4 Spacer
5 Roller
6 Screw

6
SERVICE MAST MECHANICS

4 STAGE FFL MAST

KEY TO COMPONENTS OF OUTER SECTION
FOR 4 STAGE 14-16 MASTS ONLY
4
2
5
3
6
7

10
8
1

18

17 10

11
16
15 14
13
12

Ref. Description Ref. Description

1 Screw 10 Pipe
2 Nut 11 Cylinder supply pipe
3 Screw 12 Valve
4 Bearing 13 Connector
5 Circlip 14 Connector
6 Buffer 15 Adapter
7 Chain 16 Cap
8 Chain tensioner 17 Screw
9 Outer section 18 Seals kit

7
 MAST MECHANICS SERVICE

KEY TO COMPONENTS OF 1ST INTERMEDIATE SECTION

FOR 4 STAGE 14-16 MASTS ONLY

6 8
2 7

3
4
5

10

11

12

Ref. Description Ref. Description

1 Nut 7 Pulley
2 Screw 8 Chain
3 Bearing 9 Chain tensioner
4 Circlip 10 Chain tensioner retaining nut
5 Buffer 11 1st intermediate section
6 Circlip 12 Sliding pads

8
SERVICE MAST MECHANICS

KEY TO COMPONENTS OF 2ND INTERMEDIATE SECTION

FOR 4 STAGE 14-16 MASTS ONLY
3 5

1 7
2
4
6
8

10

11
13

12 15 16
17
18
14

Ref. Description Ref. Description

1 Pulley 10 Chain
2 Circlip 11 Chain tensioner
3 Bracket 12 Nut
4 Pin 13 Screw and washer
5 Pulley 14 Nut
6 Bracket 15 Screw
7 Screw 16 Bearing
8 Screw 17 Circlip
9 2nd intermediate section 18 Buffer

9
 MAST MECHANICS SERVICE

KEY TO COMPONENTS OF INNER SECTION

FOR 4 STAGE 14-16 MASTS ONLY

6
7

10 12
8
13
14
9
11

Ref. Description Ref. Description

1 Chain 8 Screw and washer
2 Chain tensioner 9 Screw and washer
3 Nut 10 Nut
4 Inner section 11 Screw
5 Chain 12 Bearing
6 Chain tensioner 13 Circlip
7 Nut 14 Buffer

10
SERVICE MAST MECHANICS

KEY TO COMPONENTS OF OUTER SECTION

FOR 4 STAGE 20 - 25 - 20HD MASTS ONLY

4
2
5
3
6

7
1

18

17
16

10
11
15 14
13
12

Ref. Description Ref. Description

1 Screw 10 Pipe
2 Nut 11 Cylinder supply pipe
3 Screw 12 Valve
4 Bearing 13 Connector
5 Bush 14 Connector
6 Chain 15 Screw
7 Chain tensioner 16 Cap
8 Outer section 17 Adapter
9 Cylinder assembly 18 Seals kit

11
 MAST MECHANICS SERVICE

KEY TO COMPONENTS OF 1ST INTERMEDIATE SECTION

FOR 4 STAGE 20 - 25 - 20HD MASTS ONLY

7
5
6
2 8

3 4

10

11 13
14

12

Ref. Description Ref. Description

1 Nut 8 Chain tensioner
2 Screw 9 Chain tensioner retaining nut
3 Bearing 10 1st intermediate section
4 Bush 11 Nut
5 Circlip 12 Screw
6 Pulley 13 Bearing
7 Chain 14 Bush

12
SERVICE MAST MECHANICS

KEY TO COMPONENTS OF 2ND INTERMEDIATE SECTION

FOR 4 STAGE 20 - 25 - 20HD MASTS ONLY

3
5
1 7
2
4
6

10

11

12 14
15

13 16

Ref. Description Ref. Description

1 Pulley 9 2nd intermediate section
2 Circlip 10 Chain
3 Bracket 11 Chain tensioner
4 Pin 12 Nut
5 Pulley 13 Nut
6 Bracket 14 Screw
7 Screw 15 Bearing
8 Screw 16 Bush

13
 MAST MECHANICS SERVICE

KEY TO COMPONENTS OF INNER SECTION

FOR 4 STAGE 20 - 25 - 20HD MASTS ONLY

14
2

10
12
8
13
9 11

Ref. Description Ref. Description

1 Chain 8 Nut
2 Chain tensioner 9 Screw and washer
3 Nut 10 Nut
4 Nut 11 Screw
5 Chain 12 Bearing
6 Chain tensioner 13 Bush
7 Screw and washer 14 Inner section

14
SERVICE MAST MECHANICS

REMOVAL OF COMPLETE MAST ASSEMBLY

Tools

bridge crane lifting sling

load capacity load capacity 4 steel stands 2 wooden blocks oil resistant gloves wrench for
3000 kg 3000 kg hydraulic fittings

19 mm open en-
24 mm socket
step ladder long nose pliers ded spanner
wrench

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all pe-
destrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the
battery.
The hydraulic fluid gets very hot during system operation and can cause burns. It is
advisable to wear gloves that are resistant to oil and high temperatures.

Phase 1
Using the controls in the cab, fully extend the retractable carriage.
Raise the forks sufficiently to insert the blocks beneath them. Lower the
forks so that rest on the blocks (fig.1) and continue lowering for the full
cylinder stroke.

Fig. 1
Phase 2
Fig. 2
LONG NOSE PLIERS - WRENCH FOR HYDRAULIC FITTINGS
Using the long nose pliers, remove the cotter pins (ref.A fig.2) and the
hinge pin (ref.B fig.2) at the top of the chain. Rest the chain on the forks.
Using the hydraulic fittings wrench, disconnect the hydraulic hoses on
the fork carriage control valve. Disconnect the electric cables from the
fork carriage. AB

15
 MAST MECHANICS SERVICE

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. Fully retract the cylinder.

Turn the keyswitch to OFF and disconnect the battery.

4 STAGE 3 STAGE
MAST MAST Fig. 3
Phase 4
LADDER - BRIDGE CRANE - LIFTING
SLING
Climb the ladder.
Loop the lifting sling under the upper crossbars
of the mast assembly (except the outer sec-
tion crossbar) and attach the ends to the brid-
ge crane hook (fig.3). Climb down the ladder,
raise the bridge crane to reveal the screws
securing the mast assembly to the truck base.

Phase 5
24 MM SOCKET WRENCH - RATCHET - BRIDGE CRANE - LIFTING
SLING
Raise the bridge crane and take up the slack in the sling.
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the mast assembly to the truck base (ref.C fig.4).

Fig. 4 C

Phase 6
Using the bridge crane, lower the mast assembly to the ground. Climb the ladder again. Loop the lifting
sling under all the upper crossbars of the mast 4 STAGE 3 STAGE
Fig. 5
MAST MAST
assembly and attach the ends to the bridge
crane hook. Lift the bridge crane and take up
the slack in the sling.

16
 SERVICE MAST MECHANICS

Phase 7
WRENCH FOR HYDRAULIC FITTINGS
Using the hydraulic fittings wrench, disconnect the hydraulic hoses on D
the control valve of the mast assembly (ref.D fig.6).

Phase 8
Fig. 6
19 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws securing
both side blocks of the mast assembly (ref.E fig.7). Remove the blocks E
(ref.F fig.7).
Using the bridge crane slowly lift the mast assembly and separate it from
the truck base. Position the mast assembly on two steel stands and rest F
it on the ground on wooden beams.

INSTALLATION
On installation, tighten the nuts (ref.C fig.4) securing the
mast assembly to the truck base with a torque wrench to Fig. 7
300-330 Nm.

On installation, tighten the screws fastening both side

blocks of the mast assembly (ref.E fig.6) with a torque
wrench to 88-97 Nm.

17
 MAST MECHANICS SERVICE

REMOVAL OF CHAINS AND LIFTING CYLINDERS

Tools

2x 24 mm open 2x 15 mm open
wrench for internal circlip
long nose pliers ended spanners ended spanners 6 mm Allen key
hydraulic fittings pliers

Procedure
Before starting work, ensure that you are wearing suitable protective clothing. Move the
truck to a safe place, away from areas of transit of other vehicles and all pedestrians.
Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

The hydraulic fluid gets very hot during system operation and can cause burns. Wear oil
resistant gloves capable of withstanding high temperatures.

Phase 1
Carry out the “REMOVAL OF COMPLETE MAST ASSEMBLY“ procedure described in this section.

Phase 2
LONG NOSE PLIERS - 2X 24 MM OPEN ENDED SPANNERS
Using the long nose pliers remove the cotter pins on the chain tensioner (ref.A fig.1) and on the pivot pin
(ref.B fig.1).
Using the open ended spanners, unscrew and remove the nuts fastening the chain tensioner to the mast
assembly (ref.C fig.1). Remove the pin and extract the chain from the hose sheave. Perform the same
procedure on the opposite side of the mast assembly.

Phase 3
MEDIUM EXTERNAL CIRCLIP PLIERS - 2x 15 MM OPEN ENDED SPANNERS - WRENCH FOR HYDRAU-
LIC FITTINGS - 6MM ALLEN KEY
Use the pliers to remove the circlip securing the cylinder (ref.D fig.1). Using the open ended spanners,
unscrew and remove the screws fastening the cylinder retaining bracket (ref.E fig.1).
Using the wrench for hydraulic fittings, disconnect the hydraulic hose at the base of the cylinder (ref.F fig.1).
Using the Allen key, unscrew and remove the screw securing the cylinder (ref.G fig.1). Remove the cylinder
and carry out the same procedure on the other cylinder.

18
SERVICE MAST MECHANICS

D
A
B

E G
F
Fig. 1

INSTALLATION

Installation is the reverse of removal procedure.

19
 MAST MECHANICS SERVICE

REPLACEMENT OF THE BEARINGS

Tools

2.5mm Allen key rubber mallet

Procedure
Before starting work, ensure that you are wearing suitable protective clothing. Move the
truck to a safe place, away from areas of transit of other vehicles and all pedestrians.
Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

The hydraulic fluid gets very hot during system operation and can cause burns. Wear oil
resistant gloves capable of withstanding high temperatures.

Fig. 1

Phase 1
Carry out the “REMOVAL OF COMPLETE MAST ASSEMBLY“ procedure
described in this section.

Phase 2
Carry out the procedure to remove the chains and lifting cylinders de-
scribed in this section.
A
Phase 3
Slide out the inner section so as to expose the bearings.
Fig. 2
Phase 4
2.5 MM ALLEN WRENCH - PLASTIC MALLET
Using the Allen wrench, unscrew and remove the screws securing the bea-
ring to the mast assembly (ref.A fig.1). With the aid of the hammer, remove
the bearing and proceed with the replacement.

INSTALLATION

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.2). Position the pipe on the black part of the bearing and hammer until
you hear the metal of the mast channel.

20
SERVICE MAST MECHANICS

REPLACEMENT OF THE CHAINS AND CHAIN TENSIONER

Always replace the entire chain, not just the worn part. On trucks equipped with a pair of
chains, both lift chains must be replaced together.

Tools

bridge crane lifting sling

load capacity load capacity wooden beam long nose pliers
1200 kg 1200 kg

open ended span-

step ladder safety harness ner
2x24 mm

Procedure
Fig. 1
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Fig. 2

MAST ASSEMBLY CHAIN TENSIONER AND CHAIN

Phase 2
WOODEN BEAM
Using the controls in the cab, raise the forks approximately 2 metres
from the ground.
Place the wooden beam beneath the inner mast channel (ref.A fig.2). A
Lower the forks until they rest on the beam, continue the descent until
the chains are loose.

21
 MAST MECHANICS SERVICE

Turn the keyswitch to OFF and disconnect the battery.

Phase 3
BRIDGE CRANE - LADDER - SAFETY HARNESS - LIFTING SLING
Climb up the ladder with the tools and secure the safety harness to the
cab.
Loop the lifting sling under the upper crossbars of the mast assembly and
attach the ends to the bridge crane hook (fig.3). Climb down the ladder,
raise the bridge crane and take up the slack in the belt.

Fig. 3
Phase 4
LONG NOSE PLIERS - 2X 24 MM OPEN Fig. 4
ENDED SPANNERS
Using the long nose pliers, remove the cotter
pin on the chain tensioner on the inner section E
of the mast assembly (ref.B fig.4).
Using the open ended spanners, unscrew
and remove the nuts fastening the chain
tensioner (ref.C fig.4). Extract the chain
tensioner upwards.
Using the long nose pliers, remove the cotter
F
pin and the hinge pin securing the chain to
the chain tensioner (ref.D fig.4).

Phase 5
LONG NOSE PLIERS - 2X 24 MM OPEN EN- D
DED SPANNERS
Using the long nose pliers, remove the cotter
pin on the chain tensioner at the top of the outer
section of the mast assembly (ref.E fig.4).
Using the open ended spanners, unscrew and
remove the nuts fastening the chain tensio- C
ner (ref.F fig.4). Extract the chain tensioner
upwards, retrieve the chain by sliding it on the
hose sheave and proceed with the replacement. B

22
 SERVICE MAST MECHANICS

FORK CHAIN TENSIONER AND CHAIN

Phase 2
WOODEN BLOCK
Raise the forks just enough to be able to position the wooden block
underneath. Lower the forks so that they rest on the block. Continue
lowering for the full cylinder stroke.

Turn the keyswitch to OFF and disconnect the battery.

Fig. 5

Phase 3
LONG NOSE PLIERS Fig. 6
Using the long nose pliers, remove the cotter pin and the top chain hinge
pin (ref.G-H fig.6). Rest the chain on the forks.

Phase 4 G
2X 24 MM OPEN ENDED SPANNERS - LONG NOSE PLIERS
Using the open ended spanners, unscrew and remove the nuts securing
the chain tensioner (ref.I fig.7). Extract the chain tensioner upwards.
Using the long nose pliers, remove the cotter pin and the bottom chain
hinge pin (ref.L fig.8).
Retrieve the chain and proceed with the replacement.
H

Fig. 7

INSTALLATION

Do not reuse the chain anchoring safety pins, use new

cotter pins, ensuring they are the correct size.

Fig. 8

23
 MAST MECHANICS SERVICE

RENEWAL OF THE MIDDLE SECTION CHAIN SHEAVES

Tools

bridge crane lifting sling

load capacity load capacity step ladder
1600 kg 1600 kg

internal circlip
wooden beam safety harness
pliers

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to Fig. 1
the ground.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).

Phase 2
WOODEN BEAM
Fig. 2
Using the controls in the cab, raise the forks approximately 2 metres
from the ground.
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.

Turn the keyswitch to OFF and disconnect the battery.

A

24
 SERVICE MAST MECHANICS

Phase 3
Fig. 3
Climb the ladder.
Loop the lifting sling under the upper crossbars of the mast assembly and
attach the ends to the bridge crane hook (fig.3). Climb down the ladder
and raise the bridge crane to take up the slack in the sling.

Phase 4
MEDIUM EXTERNAL CIRCLIP PLIERS
Use the pliers to remove the circlip securing the sheave (ref.B fig.4).
Remove the hose sheave and proceed with the replacement.

Fig. 4

25
 MAST MECHANICS SERVICE

RENEWAL OF THE MIDDLE CYLINDER CHAIN SHEAVE

Tools

open ended span- T-handle hex

ner wrench hammer driving tool
18 mm 6 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing. Fig. 1
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
A
the ground.

Phase 1
Carry out the fork chain removal procedure (see "REPLACEMENT OF
THE CHAINS AND CHAIN TENSIONER").

Phase 2
18 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws faste-
ning 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 WRENCH - HAMMER - PARALLEL PUNCH Ø30
mm
Using the T-handle hex wrench, unscrew and remove the sheave pin
retaining screw (ref.B fig.2).
Using the hammer and parallel punch, drive out the pin, remove the
sheave and proceed with replacement.
B

Fig. 2

26
 SERVICE FORK MAST MECHANICS

FORK MAST MECHANICS

FORK CARRIAGE......................................................................................................................................................2
KEY TO FORK CARRIAGE UNIT COMPONENTS..................................................................................................2
FORK REPLACEMENT...........................................................................................................................................7
DISASSEMBLY OF THE FORK CARRIAGE............................................................................................................8
DISASSEMBLY OF THE MOBILE FRAME...............................................................................................................9
R E P L A C E M E N T O F T H E S L I D I N G S K I D S ........................................................................11
D I S A S S E M B LY O F T H E R I G H T/L E F T S H I F T C Y L I N D E R....................................................13
REPLACEMENT OF THE BEARINGS....................................................................................................................15
E X T E N D A B L E F O R K S .......................................................................................................16
K E Y T O E X T E N D A B L E F O R K C O M P O N E N T S .................................................................16
REPLACEMENT OF HYDRAULIC PIPES..........................................................................................................17
D I S A S S E M B LY O F T H E VA LV E L O C K ...............................................................................18
DISASSEMBLY OF THE CHOCKS........................................................................................................19
REPLACEMENT OF THE SKIDS.......................................................................................................20
DISASSEMBLY OF THE CYLINDERS................................................................................................21
REPLACEMENT OF THE GASKETS.......................................................................................................22
POSITIONER.......................................................................................................23
KEY TO POSITIONER COMPONENTS..................................................................23
REPLACEMENT OF HYDRAULIC PIPES......................................................................................24
R E M O VA L O F T H E P O S I T I O N E R........................................................................................25
REPLACEMENT OF THE SKIDS.......................................................................................................27
D I S A S S E M B LY O F T H E S H I F T C Y L I N D E R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 8
DISASSEMBLY OF THE GUIDE PIPE AND FORK SUPPORTS.......................................................29
DISASSEMBLY OF THE FORK POSITIONING CYLINDERS.............................................................33
REPLACEMENT OF THE FORK POSITIONING CYLINDER GASKETS....................................34

1
 FORK MAST MECHANICS SERVICE

FORK CARRIAGE
KEY TO FORK CARRIAGE UNIT COMPONENTS

1 2
3

13
5
6 7 14
8 10
9 11
15
12
16

17
18
27

28
19

20
21

24

25 22
23
26

2
SERVICE FORK MAST MECHANICS

Ref. Description Ref. Description

1 Cap head screw 15 Selector
2 Loading roll 16 Valve assembly
3 Spacers 17 Fittings
Screws fastening the hydraulic block to the
4 Bearing 18
carriage frame
5 Seals kit 19 Tilt cylinder
6 Scraper 20 Pipes and couplings
7 Side shift cylinder 21 Anti-turnover block
8 Gaskets 22 Metal plate fastening screws
9 Lateral upper translation skid 23 Bronze skids
10 Carriage frame 24 Flange
11 Hydraulic pipe and coupling 25 Lower sliding block
12 Hydraulic hose and couplings 26 Movable frame sliding blocks
13 Hydraulic block screws 27 Integral
14 Block 28 Grease nipple

3
 FORK MAST MECHANICS SERVICE

FORK CARRIAGE
KEY TO FORK CARRIAGE UNIT COMPONENTS
MODELS WITH ADDITIONAL HYDRAULIC FUNCTION

10
1 11
2 3
6
4 5 7
8
12

13
14
2

23

15
16
17

20

21 18
22 19

Ref. Description Ref. Description

1 Seals kit 13 Fittings
Screws fastening the hydraulic block to the
2 Scraper 14
carriage frame
3 Side shift cylinder 15 Tilt cylinder
4 Gaskets 16 Pipes and couplings
5 Lateral upper translation skid 17 Anti-overturning system block
6 Carriage frame 18 Metal plate fastening screws
7 Hydraulic pipe and coupling 19 Metal Plate
8 Hydraulic hose and couplings 20 Flange
9 Hydraulic block screws 21 Lower sliding block
10 Block 22 Movable frame sliding blocks
11 Selector 23 Integral
12 Valve assembly 24 Grease nipple

4
SERVICE FORK MAST MECHANICS

FORK CARRIAGE
KEY TO FORK CARRIAGE UNIT COMPONENTS
ONLY FOR MODELS 4 STAGE FFL - MAST 14-16

12

14
13
11
1
15

10
9

8
6 7
5
3 4
16
2

Ref. Description Ref. Description

1 Frame 9 Side shift cylinder
2 Pin 10 Anti-overturning system block
3 Plate 11 Integral
4 Tilt cylinder 12 Grease nipple
5 Plate 13 Lateral upper translation skid
6 Screw 14 Grease nipple
7 Tilt frame 15 Valve assembly
8 Lower sliding block 16 Seals kit

5
 FORK MAST MECHANICS SERVICE

FORK CARRIAGE
KEY TO FORK CARRIAGE UNIT COMPONENTS
ONLY FOR MODELS 4 STAGE FFL - MAST 20-25

14 13
12
10
1

11
15

8
6

4 5 7

2 3

16

Ref. Description Ref. Description

1 Frame 9 Grease nipple
2 Tilt cylinder 10 Integral
3 Plate 11 Circlip
4 Screw 12 Lateral upper translation skid
5 Tilt frame 13 Grease nipple
6 Lower sliding block 14 Plate
7 Side shift cylinder 15 Valve assembly
8 Anti-overturning system block 16 Seals kit

6
 SERVICE FORK MAST MECHANICS

FORK REPLACEMENT
Equipment and tools

2x lifting
bridge crane
belts

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.

Fig. 2
A
Phase 1
Use the controls in the cab to lift the fork carriage to facilitate fork disas-
sembly.

Turn the keyswitch to OFF and disconnect the battery.

Phase 2
BRIDGE CRANE - LIFT BELTS
Support the fork with the straps in the inclined position and the tip facing
upward (fig.1).

Phase 3
Turn the lever to lift the fork locking pin (ref.A fig.2).
Move the fork centrally and release it from the lower profile
in correspondence of the relative opening (ref.B
fig.3). Move the fork to the right or left to detach it
completely, then proceed with its replacement.

Fig. 3

7
 FORK MAST MECHANICS SERVICE

DISASSEMBLY OF THE FORK CARRIAGE

Equipment and tools

spanner for
hydraulic 2 wooden blocks long nose pliers
couplings

Procedure
Before starting work, ensure that you are wearing suitable protec-
tive clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.
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.

Fig. 1
Phase 1
WOODEN BLOCK
Using the controls in the cab, make the retractable carriage come fully Fig. 1 Fig. 2
out. Lift the forks and position the blocks below the carriage in correspon-
dence of the forks. Actuate the lowering command to the end stroke of
the cylinder, resting the carriage on the blocks.
A
Phase 2
Perform the procedure for disassembling the forks described in the pa-
ragraph “FORK REPLACEMENT”

Phase 3
B
LONG-NOSE PLIERS - SPANNER FOR HYDRAULIC COUPLINGS
Use the long-nose pliers to remove the split pins (ref.A fig.2) and the
hinge pin (ref.B fig.2). Remove the pin from the chain tensioner.
Use the spanner for hydraulic couplings to disconnect the hydraulic pipes
from the fork carriage (ref.C fig.3).
Disconnect the electric cables from the fork carriage.
C
Phase 4
Slowly 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

Fig. 3

8
 SERVICE FORK MAST MECHANICS

DISASSEMBLY OF THE MOBILE FRAME

Equipment and tools

hoist 2 lift belts

load capacity load capacity 10 mm Allen key
1000 kg 1000 kg

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.
Fig. 1
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
Using the controls in the cab, make the retractable carriage come fully
out and raise the forks approximately one metre (fig.1).

Phase 2
Carry out the fork removal procedure (see “FORK REPLACEMENT” in
this section). Fig. 2

Turn the keyswitch to OFF and disconnect the battery.

Before disassembling the mobile frame, release the pres-

sure from the carriage circuit.

Phase 3
HOIST - 2 LIFT BELTS - ALLEN KEY
Harness the movable frame with the lift belts. Hook the lift belts onto the
hoist.
Using the Allen key, unscrew and remove the screws securing the anti-
turnover block (ref.A fig.1). Remove the block.

9
 FORK MAST MECHANICS SERVICE

Phase 4
Fig. 3
Turn the lower part of the mobile frame forward. Lift in order to detach it
from the fixed frame (fig.3).

After this phase, it is prohibited to repressurise the hydraulic circuit.

The cylinder stems could exit the guides.

ADJUSTING THE LOWER HOOK

With the hook fastening screws loosened (ref.B fig.4):

a) Insert a 0.3 mm shim between the skids and the rear part
of the carriage (fig.5)
b) Reposition the skid, pushing it upward to eliminate
excess play, tighten the screws with the correct torque
(136Nm) and remove the spacer
c) Lubricate the carriage in the points shown in the figure
(ref.C fig.4 and fig.6)

Fig. 4 Fig. 5 Fig. 6 C

10
 SERVICE FORK MAST MECHANICS

REPLACEMENT OF SLIDING SKIDS

Equipment and tools

Allen key flat head screwdri-

hammer pin punch
10 mm ver

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all pede-
strians.
The hydraulic fluid gets very hot during system operation and can cause burns. It is advi-
sable to wear gloves that are resistant to oil and high temperatures.

Phase 1
Using the controls in the cab, make the retractable carriage come fully out and raise the forks by approxi-
mately one metre.

Turn the keyswitch to OFF and disconnect the battery.

Phase 2
Perform the procedure to remove the forks and the mobile frame (see the procedures in this section).

Phase 3
MEDIUM FLAT BLADE SCREWDRIVER Fig. 1
Using the medium flat blade screwdriver, lever between the sliding block
and the fixed frame. Remove the lower sliding block (ref.A fig.1) and
proceed with replacement.

11
 FORK MAST MECHANICS SERVICE

Phase 4
Fig. 2
MEDIUM FLAT BLADE SCREWDRIVER B
Using the flat blade screwdriver, prise out the upper sliding block (ref.B
fig.2). Proceed with replacement.

Due to improper use of the truck, the side translation

skids of the carriage could exit their seat causing wear or
premature breakage.
A kit is available for this purpose that can be installed
only on trucks with a standard back (refer to the technical
bulletin IE002 (E)).

Phase 5
MEDIUM FLAT BLADE SCREWDRIVER - HAMMER - PIN PUNCH
Fig. 3
With the flat head screwdriver unscrew the screws fastening the sliding
block of the mobile frame (ref.C fig.3). Using the hammer and pin punch,
strike the pins (ref.D fig.3), remove the sliding block and proceed with
replacement. C

Replace the upper and lower skids if they are less than 4.5
mm thick.
Replace the mobile frame skids if they are less than 3 mm D
thick.

After replacing the skids, it is recommended to:

• Make sure there is no interference between the skid and the mast.
• Check that the screw tightening torque (ref.E fig.4) is 136 Nm.
• Check that skid play is 0.3mm. If necessary correct the skid play, loosen the screws (ref.E fig.4), insert
a 0.3mm spacer between the skids and the rear part of the carriage (fig.5). Reposition the skid, tighten
the screws with the correct torque and remove the spacer.
• Lubricate the carriage in the points shown in the figure (ref.F fig.4-6).

Fig. 4 Fig. 5 F Fig. 6

12
SERVICE FORK MAST MECHANICS

DISASSEMBLY OF THE RIGHT/LEFT SIDE SHIFT CYLINDER

Equipment and tools

oil resistant gloves oil pan Pliers circlip pliers

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.
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
Using the controls in the cab, make the retractable carriage come fully
out and raise the forks approximately one metre (fig.1).
Remove the forks.

Turn the keyswitch to OFF and disconnect the battery. Fig. 1

Phase 2
Perform the mobile frame disassembly procedure (see “REMOVAL OF
THE MOBILE FRAME” in this section).
Disconnect the hydraulic pipes.

Before working on the cylinder, release the pressure from

the carriage circuit.

13
 FORK MAST MECHANICS SERVICE

Phase 3
OIL RESISTANT GLOVES - OIL PAN - RAG - PLIERS - SMALL FLAT
HEAD SCREWDRIVER - CIRCLIP PLIERS
Wear the oil resistant gloves.
Place the oil pan below the cylinder.
Use a rag and pliers to remove the rod (ref.B fig.3).
Use the small screwdriver to remove the scraper (ref.A fig.3).
Then remove the hydraulic sealing gaskets (ref.C fig.3).

Replace the components that require replacement.

Replace the gaskets in a clean environment without dust

and following the assembly direction.

When replacement is complete, perform some empty mo-

vements to check the hydraulic seal.

B
A

14
 SERVICE FORK MAST MECHANICS

REPLACEMENT OF THE BEARINGS

Equipment and tools

T handle hex key

rubber mallet
2.5 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.

Phase 1 Fig. 1
Carry out the fork carriage disassembly procedure described in this
section.

Phase 2
2.5 MM T-HANDLE HEX KEY - PLASTIC HAMMER
Using the T-handle hex key, unscrew and remove the screws securing
the bearing to the mast (ref.A fig.1). With the aid of the hammer, remove
the bearing and proceed with the replacement.
A

15
 FORK MAST MECHANICS SERVICE

EXTENDABLE FORKS
KEY TO EXTENDABLE FORK COMPONENTS

1 2 3
4 5
16
6

7
8
9

10

14 11
15 12

13

Pos. Description Pos. Description

1 Chrome-plated stems 9 Upper hooks
2 Stem scraper 10 Feeding channels
3 Sliding skids 11 Lower hooks
4 Pressure checking pressure gauge faste- 12 Fork heel
ning 13 Cylinder seat
5 Fork extension power supply inputs 14 Cylinder stem fastening
6 Hydraulic system 15 Chock base in wear-resistant material
7 Valve guard 16 Fork block lever
8 Valve block

16
SERVICE FORK MAST MECHANICS

REPLACEMENT OF HYDRAULIC PIPES

Tools

open ended span-

ner
17-19 mm

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all pede-
strians. Turn the keyswitch to OFF and disconnect the battery.

Before disconnecting/connecting the pipes release the pressure from the truck circuit.

Oil may exit the pipes. It is recommended to position a container to collect the fluids.
EXTENDABLE FORK HYDRAULIC PIPES

Phase 1
17MM and 19MM OPEN-ENDED SPANNER C
Use the open-ended spanners to unscrew
the hydraulic couplings (ref.A fig.1) for the
extendable fork pipes.
Recover the pipes and proceed with
replacement.
A
HYDRAULIC CONNECTION PIPES BETWEEN A
THE EXTENDABLE FORKS AND THE FORK
CARRIAGE

Phase 2
17MM and 19MM OPEN-ENDED SPANNER
Use the 19mm open ended spanner to unscrew
the nuts of the couplings that connect the
hydraulic pipes to the hydraulic block on the Fig. 1 B
fork carriage(ref.B fig.1).
Use the 17mm and 19mm open-ended spanners to unscrew the coupling nuts that connect the hydraulic
pipes to the extendable forks (ref.C fig.1).
Then recover the hydraulic pipes and proceed with replacement if necessary.

17
 FORK MAST MECHANICS SERVICE

DISASSEMBLY OF THE BATTERY LOCK

Tools

open ended span-

5-6 mm Allen key ner
17-19 mm

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all pede-
strians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1
Use a 6mm Allen key to remove the screws (ref.A fig.1) fixing the
coupling and pipe guards

B
Before disconnecting/connecting the pipes release the
pressure from the truck circuit. A

Oil may exit the pipes. It is recommended to position a

container to collect the fluids. C

Fig. 1
Phase 2
17mm and 19 mm OPEN-ENDED SPANNER D
Use the 17mm open-ended spanner to block the fixed coupling (ref.C
fig.1) and use the 19mm open-ended spanner to loosen the fixing nut
(ref. B fig.1), in order to remove the connection pipes.

Phase 3
5mm ALLEN KEY
Using a 5mm Allen key, remove the screws fixing the valve (ref.D
fig.2), then remove the valve.

Fig. 2

18
 SERVICE FORK MAST MECHANICS

DISASSEMBLY OF THE CHOCKS

Tools

Pin punch parallel punch

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all pede-
strians.

Phase 1
With the forks in the closed position, extend them 10 mm Fig. 1

Turn the keyswitch to OFF and disconnect the battery.

Phase 2
Using the pin punch and the parallel punch, remove the retainer pin from
the cylinder stem (ref.A fig.1), located on the tip of the fork, exercising A
a robust action from the bottom upwards.
Remove and/or replace the chocks

19
 FORK MAST MECHANICS SERVICE

REPLACEMENT OF THE SKIDS

Tools

Pin punch parallel punch

Procedure

Before starting work, ensure that you are wearing suitable

protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.

Fig. 1
Phase 1
With the forks in the closed position, extend them 10 mm.

Turn the keyswitch to OFF and disconnect the battery.

A
Phase 2
Using the pin punch and the parallel punch, remove the retainer pin from
the cylinder stem (ref.A fig.1), located on the tip of the fork, exercising
a robust action from the bottom upwards.
Remove and/or replace the chocks. Fig.2

Phase 3 B
Check the condition of the sliding skids (ref.B fig.2).
In the case of breakage, permanent deformation or
B
if the thickness is < 3mm, replace them.

20
SERVICE FORK MAST MECHANICS

DISASSEMBLY OF THE CYLINDERS

Tools

Pin punch parallel punch 5 mm Allen key

Procedure

Before starting work, ensure that you are wearing suitable

protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians.

Before disconnecting/connecting the pipes release the

pressure from the truck circuit.

Oil may exit the pipes. It is recommended to position a

container to collect the fluids.

Procedure

Phase 1
With the forks in the closed position, extend them 10 mm

Turn the keyswitch to OFF and disconnect the battery.

Phase 2
Remove the chocks, as described in the paragraph “DISASSEMBLY OF
THE CHOCKS” in this section.
A

Phase 3
5MM ALLEN KEY
Using a 5mm Allen key, unscrew the screws (ref.A fig.1) that fasten the
cylinder cap (ref.B fig.1).
B C Fig. 1
Phase 4
Slowly remove the cylinder stem (ref.C fig.1) from the fork, previously
positioning a container to collect the oil.

21
 FORK MAST MECHANICS SERVICE

GASKET REPLACEMENT

Tools

Pin punch parallel punch 5 mm Allen key

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all pede-
strians. Turn the keyswitch to OFF and disconnect the battery.

Before disconnecting/connecting the pipes release the pressure from the truck circuit.

Oil may exit the pipes. It is recommended to position a container to collect the fluids.

Phase 1
Carry out the procedure to disassemble the cylinders, as described in the previous paragraph.

Phase 2
Access the gaskets, check their condition and replace them if worn or broken (fig.1).

Fig. 1

When replacing the gaskets, respect the direction of assembly and work in an area
protected against dust

To restore the previously described disassembled parts, carry out the procedures described
above in reverse order.

22
SERVICE FORK MAST MECHANICS

POSITIONER
KEY TO POSITIONER COMPONENTS

4
5

3 6
7

2
8
1

11
12

13

10

Pos. Description Pos. Description

1 Lower hooks 8 Upper sliding profile of the fork carrier plate
2 Frame 9 Fork support control linear actuator
3 Hydraulic system 10 Fork support guide pipe
4 Power supply input for fork positioning 11 Fork support
5 Frame lifting hook 12 Fork striker plate screws
6 Side movement power supply inputs 13 Fork fixing block
7 Translation control linear actuator

23
 FORK MAST MECHANICS SERVICE

REPLACEMENT OF HYDRAULIC PIPES

Tools

open ended span-

ner
17-19 mm

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe area, away from the passage of other vehicles and pedestrian
traffic. Position the ignition switch to OFF and disconnect the battery.

Before disconnecting/connecting the pipes release the pressure from the truck circuit.

Oil may exit the pipes. It is recommended to position a container to collect the fluids.

HYDRAULIC CONNECTION PIPES BETWEEN THE A

POSITIONER AND THE FORK CARRIAGE

Phase 1
17MM and 19MM OPEN-ENDED SPANNER
Use the 19mm open ended spanner to unscrew the nuts
of the couplings that connect the hydraulic pipes to the
hydraulic block on the fork carriage(ref.B fig.1).
Use the 17mm and 19mm open-ended spanners to
unscrew the coupling nuts that connect the hydraulic pipes
to the positioner (ref.A fig.1).
Then recover the hydraulic pipes and proceed with
replacement if necessary.

Fig. 1 B

24
 SERVICE FORK MAST MECHANICS

REMOVAL OF THE POSITIONER

Tools

10 -24 -27 mm
Pin punch parallel punch 10 mm Allen key combination bridge crane lift
spanner belts

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all
pedestrians.

Prior to every operation, turn off the fork lift truck and release the pressure from the
hydraulic circuit by actuating the positioner levers multiple times in both directions with
the truck turned off.
Make sure that for the entire period of maintenance no one turns the ignition key or
actuates the control levers in the truck.

DISASSEMBLY OF THE FORKS

Phase 1
10MM ALLEN KEY - 17MM COMBINATION SPANNER
If the positioner has standard side panels, use the 10mm Allen key to
unscrew the two screws (ref.A fig.1) that fasten the fork to the support,
them remove the fork laterally (fig.2).
In the case of a positioner with dedicated side panels, use a 17mm open
ended spanner to unscrew and remove the screws (ref. B fig.3) of the A
retainer (ref. C fig. 3) that blocks the fork, then extract it (fig.4).

To refit the forks, perform the procedure in reverse order. Fig. 1

Tighten the screws with a tightening torque of 84Nm.

C
B

Fig. 2 Fig. 3 Fig. 4

25
 FORK MAST MECHANICS SERVICE

REMOVAL OF THE LOWER HOOKS

Phase 2
24MM AND 17MM COMBINATION SPANNER
Remove the split pins (ref.D fig.5) that block the shift cylinder on the mobile frame.
Use the 24mm and 27mm combination spanners to unscrew and remove the nuts (ref.E fig.5) and the
screws (ref.F fig.5) that fasten the lower hooks. Then remove the hooks.

F F
D F F
D

E E E Fig. 5

Phase 3
Remove the mobile frame from the truck FEM plate using a lifting system with a minimum load capacity of
400Kg (fig.6).

Fig. 6

26
SERVICE FORK MAST MECHANICS

REPLACEMENT OF THE SKIDS

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all
pedestrians.

Prior to every operation, turn off the fork lift truck and release the pressure from the
hydraulic circuit by actuating the positioner levers multiple times in both directions with
the truck turned off.
Make sure that for the entire period of maintenance no one turns the ignition key or
actuates the control levers in the truck.

Phase 1
Perform the procedure for positioner disassembly and removal, as described in the paragraph “REMOVAL
OF THE POSITIONER”.

Phase 2
Remove the upper skids (ref.A fig.1) and replace them with new skids, making sure that they engage
correctly in their seat in the mobile frame (fig.1) then lubricate them with the specific grease.

Phase 3
Remove the lower skids (ref.B fig.1), performing the indicated movement; then fit the new skids and
lubricate with the specific lubricant.

Fig. 1

27
 FORK MAST MECHANICS SERVICE

DISASSEMBLY OF THE SHIFT CYLINDER

ONLY FOR VERSIONS WITH SEPARATE SHIFT
Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all
pedestrians.

Prior to every operation, turn off the fork lift truck and release the pressure from the
hydraulic circuit by actuating the positioner levers multiple times in both directions with
the truck turned off.
Make sure that for the entire period of maintenance no one turns the ignition key or
actuates the control levers in the truck.

Phase 1
Perform the procedure for positioner disassembly and removal, as described in the paragraph “REMOVAL
OF THE POSITIONER”.
Fig. 1

Phase 2
Disassemble the pipes and remove the cylinder from the fixed support
(fig.1).

Phase 3
Block the box and use an adjustable spanner to rotate the cap until it has A C Fig. 2
completely exited the retaining ring (ref.A fig.2). Remove the retaining
ring (ref.B fig.2). Remove the cap (ref.C fig.2).
B

INSTALLATION
To reassemble the cylinder, perform the operations in reverse order

When replacing the gaskets, respect the correct assembly direction

28
 SERVICE FORK MAST MECHANICS

DISASSEMBLY OF THE GUIDE PIPE AND FORK SUPPORTS

FOR POSITIONERS WITH STANDARD SIDE PANELS AND DEDICATED SIDE PANELS
Tools

19mm combina- 13mm socket

tion spanner spanner
Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all
pedestrians.

Phase 1
Remove the forks as described in the paragraph “REMOVAL OF THE POSITIONER”.

Phase 2 Fig. 1
Move the fork supports into the minimum opening position (cylinders B
retracted).
Then turn off the fork lift truck and release the pressure from the hydraulic
circuit by actuating the positioner levers multiple times in both directions with
the truck turned off. Make sure that for the entire period of maintenance no B
one turns the ignition key or actuates the control levers in the truck.
A
Phase 3
19MM COMBINATION SPANNER
Fig. 2
Using a 19mm combination spanner, block the fork support pin and
loosen and remove the nuts (ref.A fig.1) fixing the cylinder stem ball
joints (ref.B fig.1). Release the cylinder stem ball joints (ref.B fig.1) C D E
from the fork support pins.

Phase 4
13MM SOCKET SPANNER
Use the socket and recover the screw (ref.C fig.2) and the safety washer
(ref.D fig.2) then remove the guide pipe retainer (ref.E fig.2).
For reassembly, replace the safety washer (ref.D fig.2) and tighten the
screw (ref.C fig.2) to torque of 25 Nm, applying threadlocker.
Fig. 3
Phase 5
Move the fork supports laterally, to approx. 10 mm from the side panel
(fig. 3).

To move the supports, turn the guide pipe in its seat.

29
 FORK MAST MECHANICS SERVICE

Phase 6
Turn the guide pipe approx. 90° and remove it from its seat with the fork Fig. 4
supports (fig.4).
If necessary, remove a cylinder and proceed as described in the
paragraph “DISASSEMBLY OF THE SHIFT CYLINDER”.
Then extract the fork supports from the guide pipe, pulling them out.
To refit the guide pipe and the fork supports, perform the previous
operations in reverse order.

30
 SERVICE FORK MAST MECHANICS

DISASSEMBLY OF THE GUIDE PIPE AND FORK SUPPORTS

ONLY FOR POSITIONERS WITH STANDARD SIDE PANELS
Tools

19mm combina- 13mm socket

tion spanner spanner

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all
pedestrians.
Fig. 1

Phase 1 B
Remove the forks as described in the paragraph “REMOVAL OF THE
POSITIONER”. A

Phase 2
Move the fork supports into the minimum opening position (cylinders retracted). Fig. 2
Then turn off the fork lift truck and release the pressure from the hydraulic C
circuit by actuating the positioner levers multiple times in both directions with D
the truck turned off. Make sure that for the entire period of maintenance no E
one turns the ignition key or actuates the control levers in the truck.

Phase 3
19MM - 22MM COMBINATION SPANNER
Use a 22mm combination spanner (fig.C fig.2) to keep the fork support
stationary and a 19mm combination spanner (ref.D fig.2) to loosen the
pin (ref.E fig.2). Then remove the pin. Fig. 3

The pins are locked with threadlocker. It may be necessary F G H

to preheat them prior to their removal.
For reassembly, tighten them with a torque of 84 Nm,
applying threadlocker.

Phase 4
13MM SOCKET SPANNER
Use the socket and recover the screw (ref.F fig.3) and the safety washer
(ref.G fig.3) then remove the guide pipe retainer (ref.H fig.3).
For reassembly, replace the safety washer (ref.G fig.3) and tighten the
Fig. 4
screw (ref.F fig.3) to torque of 25 Nm, applying threadlocker.

Phase 5
Extract the fork supports, sliding them out from the hole in the right side
panel (fig. 4).

To move the supports, turn the guide pipe in its seat.

31
 FORK MAST MECHANICS SERVICE

Phase 6
Fig. 5
Turn the guide pipe approx. 90° and remove it from its seat with the fork
supports (fig.5).
If necessary, remove a cylinder and proceed as described in the
paragraph “DISASSEMBLY OF THE SHIFT CYLINDER”.
Then extract the fork supports from the guide pipe, pulling them out.
To refit the guide pipe and the fork supports, perform the previous
operations in reverse order.

32
 SERVICE FORK MAST MECHANICS

DISASSEMBLY OF THE FORK POSITIONING CYLINDERS

Tools

17-19mm
combination
spanner

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all
pedestrians.

Phase 1
Remove the forks, as described in the paragraph “REMOVAL OF THE POSITIONER” in this section.

Phase 2
Move the fork supports into the minimum opening position (cylinders retracted).
Then turn off the fork lift truck and release the pressure from the hydraulic circuit by actuating the positioner levers
multiple times in both directions with the truck turned off. Make sure that for the entire period of maintenance no
one turns the ignition key or actuates the control levers in the truck.

Phase 3
19MM COMBINATION SPANNER
Using a 19mm combination spanner, block the fork support pin and loosen and remove the nuts (ref.A
fig.1) fixing the cylinder stem ball joints. Release the cylinder stem ball joints from the fork support pins.

Phase 4
17MM COMBINATION SPANNER
Use a 17mm combination wrench to detach the cylinder flexible and rigid pipes cylinders from the fork
support pins.
Fig. 1
Phase 5
Remove the split pins
fixing the cylinder base
plate (ref.B fig.1) and
extract the pins (ref. C
fig.1) fixing the cylinder
base plate. Remove the
cylinders. A

To r e a s s e m b l e t h e
cylinders, perform the
previous operations in
reverse order.
C

33
 FORK MAST MECHANICS SERVICE

REPLACEMENT OF THE FORK POSITIONING CYLINDER GASKETS

Tools

17-19mm Compass
combination spanner
spanner

Procedure

Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all
pedestrians.

Phase 1
Perform the fork positioning cylinder disassembly procedure.

Phase 2
Remove the gaskets, following the sequence indicated in the figure below. To reassemble them, perform
the sequence in the reverse order.

1 2 3 5 6 7
4
1 3 6 7
2 4 5

34
 SERVICE REDUCTION UNIT

REDUCTION UNIT
KEY TO REDUCTION UNIT COMPONENTS..........................................................................................................2
REMOVAL OF THE REDUCTION UNIT...................................................................................................................4
REPLACEMENT OF TRACTION MOTOR DRIVE SHAFT RADIAL O-RING........................................................6
REDUCTION UNIT DISMANTLING..........................................................................................................................7
CHANGE OIL IN REDUCTION UNIT........................................................................................................................9

1
 REDUCTION UNIT SERVICE

KEY TO REDUCTION UNIT COMPONENTS

31 34
35
32

30

16
33 18 17
1
23
2 24 19
29 25
28 27 20
21
3 22

4
26
15
5
14
7 6 8

12 13
11
10

gearbox type serial number

TYPE SERIAL-N°

34
PARTS LIST N° TOTAL RATIO

gearbox model CUSTOMER CODE N° gearbox transmission

2
SERVICE REDUCTION UNIT

Ref. Description Ref. Description

1 Vent valve 19 O Ring

2 Cap 20 Spacer
3 Pinion 21 Bearing
4 Housing 22 Check valve
5 Seal 23 Hex head screw
6 Wheel shaft 24 Cover
7 Protection 25 Gear
8 Seal ring 26 Cap
9 Cap 27 Spacer
10 Bearing 28 Bearing
11 Bush 29 Nut
12 Spacer 30 Ring gear
13 Bevel gear kit 31 Screw
14 Bearing 32 Sealing bearing
15 Spacer 33 Splined screw
16 Cap screw 34 Data plate
17 Spring pin 35 Gearbox type punching
18 Cover

3
 REDUCTION UNIT SERVICE

REMOVAL OF THE REDUCTION UNIT

Equipment and tools

open ended span- hoist 2 lifting slings

socket wrench
ner load capacity load capacity ratchet torque wrench
16 mm
10 mm 1000 kg 1000 kg

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.

Phase 1
Perform the traction wheel dismantling procedure described in the paragraph “Dismantling the traction
wheel” in the “BASE TRUCK MECHANICS” section.

Phase 2
Perform the traction motor dismantling procedure described in the paragraph “Dismantling the traction
wheel” in the “BASE TRUCK MECHANICS” section.

Phase 3
Perform the steering motor dismantling procedure described in the paragraph “Dismantling the traction
wheel” in the “BASE TRUCK MECHANICS” section.

Phase 4 Fig. 1
Empty the oil from the reduction unit, as described in the paragraph
“CHANGE OIL IN REDUCTION UNIT” in this section. A

Phase 5
10 mm OPEN ENDED SPANNER B
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. 2

C
Phase 6
16 mm SOCKET WRENCH - RATCHET
Disconnect the center and 90° sensor connectors.
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the plate to the frame (ref.C fig.2).

4
 SERVICE REDUCTION UNIT

Phase 7
HOIST - 2 LIFT BELTS - 16 mm SOCKET WRENCH - RATCHET Fig. 3
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.
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the reduction unit to the plate (ref.D fig.4). Remove the plate
and proceed with dismantling the reduction unit.

INSTALLATION

The screws securing the reduction unit to the plate must

be tightened using a torque wrench to a torque of 88 Nm.
D

Fig. 4

5
 REDUCTION UNIT SERVICE

REPLACEMENT OF TRACTION MOTOR DRIVE SHAFT RADIAL O-RING

Equipment and tools

small flat blade

brush
screwdriver

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.

Phase 1 Fig. 1
Perform the traction motor dismantling procedure described in the
paragraph “Dismantling the traction wheel” in the “BASE TRUCK
MECHANICS” section.

Phase 2
SMALL FLAT BLADE SCREWDRIVER
Using the screwdriver, 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.

6
SERVICE REDUCTION UNIT

DISASSEMBLY OF THE REDUCTION UNIT

Equipment and tools

hex socket
workbench vice wrench soft head hammer 5mm T handle
(rubber or plastic) hex key
8 - 24 mm

Procedure

Before starting work, ensure that you are wearing suitable

protective clothing.

GASKET REPLACEMENT

Phase 1
Carry out the reduction unit disassembly procedure described in this Fig. 1
section.

Phase 2
8 mm HEX SOCKET SPANNER B
Unscrew and remove the 8 screws (ref.A fig.1) fastening the reduction
unit box cover.
Remove the cover (ref.B fig.1), recover the gasket (ref.C fig.1) and then
replace it. A

INSTALLATION

The screws securing the reduction unit box cover must be C

tightened using a torque spanner to a tightening torque of
46 Nm.

7
 REDUCTION UNIT SERVICE

REPLACEMENT OF THE BEARING AND RING GEAR

A
Phase 3
VICE - 24MM SOCKET SPANNER - 5 MM T HANDLE HEX KEY - SOFT C
HEAD HAMMER (RUBBER OR PLASTIC)
Place the reduction unit securely in a vice. Use the hex spanner to
B
remove the 12 screws (ref.A fig.2) that fasten the reduction unit body.
Use a soft head hammer (rubber or plastic) to strike the lower part of
the ring gear, remove the bearing (ref.B fig.2) and the ring gear (ref.C
fig.2) and proceed with replacement.

INSTALLATION

The screws securing the reduction unit body must be

tightened using a torque wrench to a torque of 34 Nm.

Fig. 2

8
SERVICE REDUCTION UNIT

CHANGE OIL IN REDUCTION UNIT

Equipment and tools

hex socket
oil resistant gloves oil pan wrench ratchet
6-12 mm

T handle hex key

extension bar torque wrench oil syringe
5 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to Fig. 1
the ground, turn the keyswitch to OFF and disconnect
the battery.
Use caution as the oil in the reduction unit will be hot
after use of the truck. It is advisable to wear gloves that
are resistant to oil and high temperatures.
Do not dispose of used oil in the ground or by pouring
it down the drain. Contact a company specialised in the
disposal or recycling of industrial oils.

Phase 1
5 mm T HANDLE HEX KEY
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. 2

9
 REDUCTION UNIT SERVICE

Phase 2
OIL RESISTANT GLOVES - OIL PAN
Clean the area around the oil filler and drain plugs thoroughly. Place a
suitably sized oil pan with a capacity of at least 3.5 litres beneath the
drain plug.
C
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. Drain all the oil into the pan.
D
Clean the drain plug thoroughly from accumulated impurities that may
have collected during reducer operation and screw back on together with
a new gasket. Fig. 3

The tightening of the oil drain cap must be done using a

torque wrench with a torque tightening power of 22 Nm.

Reduction unit
Oil type Quantity
model

Standard and Cold Store

GK25 ~3.3 litres
SHELL SPIRAX S3 AM 80W-90

For filling, use a syringe (fig.4), which will permit filling the reduction
unit case faster and with less dispersion. The correct level of lubricant is
reached when the oil reaches the lower edge of the filler hole or, at most,
flows out of the hole.

The tightening of the oil filler cap must be done using a

torque wrench with a torque tightening power of 22 Nm.
Fig. 4

10
 SERVICE BRAKING SYSTEM

BRAKING SYSTEM
KEY TO THE TRACTION MOTOR ELECTROMAGNETIC BRAKE COMPONENTS ............................................2
KEY TO LOAD WHEEL ELECTROMAGNETIC BRAKE COMPONENTS ..............................................................4
OPERATION ...............................................................................................................................................................6
BRAKING SYSTEMS .................................................................................................................................................6
REMOVAL OF THE BRAKES ...................................................................................................................................7
REMOVAL OF THE DRIVE WHEEL ELECTROMAGNETIC BRAKE .....................................................................7
REMOVAL OF THE LOAD WHEEL ELECTROMAGNETIC BRAKE .........................................................................9

1
 BRAKING SYSTEM SERVICE

KEY TO TRACTION BRAKE COMPONENTS

1
6
1

7
3

Ref. Description

1 Retaining screw
2 Two-way connector (electromagnetic brake coil power supply)
3 Hub
4 Rotor
5 Brake disc
6 Cap
7 Dust seal ring

2
SERVICE BRAKING SYSTEM

KEY TO TRACTION BRAKE COMPONENTS

4
5

Ref. Description

1 Cap
2 Hub
3 Retaining screw
4 Dust seal ring
5 Two-way connector (electromagnetic brake coil power supply)

3
 BRAKING SYSTEM SERVICE

KEY TO LOAD WHEEL BRAKE COMPONENTS

1 3

2
4

5
6

Ref. Description

1 Two-way connector (electromagnetic brake coil power supply)

2 Magnetic Brake
3 Armature
4 Spring
5 Regulator
6 Self Lubricating bushing

4
 SERVICE BRAKING SYSTEM

OPERATION
BRAKE FITTED ON THE TRACTION MOTOR
The electromagnetic brake is fit on the traction motor. This is a spring brake applied on a single disc with
two friction surfaces and is electromagnetically released.
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.
The release of the traction brake is controlled by the traction control based on the conditions of the truck
(accelerator pedal status, brake pedal status, operator presence button, parking brake, etc.).
If the truck has an electrical fault, the parking brake can be released manually following the procedure
indicated below:
Unscrew the screw (ref. A fig.1) to open the engine compartment cover.
To release the brake, insert two M6x60 screws in the holes (ref. B fig.1) or insert two M5x60 screws in the
holes (ref.C fig.1)

Fig. 1

BRAKE FITTED ON THE LOAD WHEELS

The load wheel brakes are optional for models with load capacity of 1400 Kg and 1600 Kg, whereas they
are installed standard in all models with higher load capacities to make braking safer.
Trucks with the “drive performance option with a maximum speed of 14 Km/h are equipped with brakes
on the load wheels.
The MY2019 truck version does not include installed brakes on the load wheel for trucks with a maximum
speed of 11 Km/h (only as an optional); they are supplied standard for trucks with a maximum speed of up
to 14 Km/h. They are fit directly on the load wheel and are spring brakes activated by an electromechanical
command from the VCM control; the braking intensity is proportional to the pressure on the brake pedal.
The brakes fit on the load wheels do not require adjustment

5
 BRAKING SYSTEM SERVICE

BRAKING SYSTEMS
There are 4 braking systems used:

• Service braking
• Braking on direction reversal
• Emergency braking
• Release braking
•
Service braking
Service braking activates when the brake pedal is pressed. It involves the electric braking system of the
traction motor and the electromagnetic brakes on the load wheels (if present).

Braking on direction reversal

Electric braking of the traction motor controls the deceleration ramp when the gear request is inverted.
“Braking on direction reversal", also know as reverse-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 within a distance that is at least not less than the length of the
truck itself.

Emergency braking
Emergency braking occurs when 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.

Release braking
Electric braking of the traction motor controls the deceleration ramp when the accelerator pedal is released.

There is also a parking brake; an electromagnetic brake located on the traction motor, it activates when
the truck has stopped. It is released by pressing the accelerator pedal when the operator presence pedal
is already pressed.

6
 SERVICE BRAKING SYSTEM

REMOVAL OF THE BRAKES

REMOVAL OF THE DRIVE WHEEL BRAKE

Equipment and tools

T-handle hex
internal circlip
wrench large flat blade
pliers puller
5 mm screwdriver

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground, turn the keyswitch to OFF and disconnect
the battery.

When replacing the rotor, the pinion must also be replaced.

Phase 1
5 mm T HANDLE HEX KEY
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.A fig.1).
Completely open the cover (fig.2).

Phase 2
5 mm T HANDLE HEX KEY Fig. 2
Remove the dust seal ring.
Using the T handle hex key, unscrew Fig. 3a Fig. 3b
the three screws securing the electro-
B
magnetic brake to the traction motor
(ref.B fig.3a - 3b).
Disconnect the connector from the
brake and withdraw it from the tab.
Remove the electromagnetic brake
from the motor.

7
 BRAKING SYSTEM SERVICE

Phase 3
INTERNAL CIRCLIP PLIERS - E
PULLER F E
F
Slide out rotor (ref.D fig.4a) from the
pinion. D
Using the circlip pliers, remove the
circlip from the drive shaft (ref.E fig.4a
and 4b). Using the puller, remove the
pinion (ref.F fig.4a and 4b).

INSTALLATION
Proceed in the reverse order to assem-
ble the brake. Fig. 4a Fig. 4b

The screws securing the brake must be tightened using a torque wrench to a torque of
23 Nm.
After mounting the electromagnetic brake does not require adjustment.

8
 SERVICE BRAKING SYSTEM

REMOVAL OF THE LOAD WHEEL ELECTROMAGNETIC BRAKE

Equipment and tools

T-handle hex
hydraulic jack wooden block socket wrench for ratchet wrench
self-locking ring 6 mm
nut

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground, turn the keyswitch to OFF and disconnect
the battery.

Phase 1 Fig. 1
HYDRAULIC JACK - WOODEN BLOCK
Position the hydraulic jack beside the load wheel and lift until the wooden
stock can pass beneath.
Set the wooden block below 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, un- A
screw and remove the ring nut (ref.A fig.2), remove the toothed washer.
Extract the wheel from the hub and dismantle or replace. Fig. 2

Phase 3 C Fig. 3
6 mm T HANDLE HEX KEY
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 B
the disk, pay attention to the springs (ref.C fig.3).

9
 BRAKING SYSTEM SERVICE

Phase 4
8 mm T HANDLE HEX KEY
Using the T-handle hex key, remove the screws fastening the electroma-
gnetic brake at the base of the wheel pin (ref.D fig.4). Disconnect the
connector and remove the brake.
D

INSTALLATION Fig. 4
Proceed in the reverse order to assemble the brake.

The screws securing the brake disk to the wheel must be

tightened using a torque wrench to a torque of 25 Nm.
Apply threadlocker

10
 SERVICE ROUTINE MAINTENANCE

ROUTINE MAINTENANCE
OILS AND LUBRICANTS...............................................................................................................4
OIL QUANTITIES..........................................................................................................................................4
CLEANING PRODUCTS..........................................................................................................5
SCHEDULED MAINTENANCE........................................................................................................6
MAINTENANCE PROCEDURES...............................................................................................10
CHECK THE HEIGHT OF OUTRIGGERS OFF GROUND.............................................................................10
CHECK THE SCREWS AND BOLTS......................................................................................................................11
CHECK THE CHAINS.....................................................................................................................................16
CHECK THE FORKS..................................................................................................................................18
CHECK THE WEAR OF ELECTROMAGNETIC BRAKES....................................................................................19
CHECK THE TANK OIL LEVEL..................................................................................................19
CHECK THE EXTENDABLE FORKS.........................................................................................................................21
DAILY CHECKS.....................................................................................................................21
ROUTINE MAINTENANCE.........................................................................................................22
CHECK FORK POSITIONER...................................................................................................23
D A I LY C H E C K S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3
PERIODIC MAINTENANCE........................................................................................................24

1
 ROUTINE MAINTENANCE SERVICE

WARNINGS
• If maintenance operations are carried out immediately after the truck is stopped, some components of
the motor and of the hydraulic system could be hot. Always wear the personal protective equipment in
situations requiring it.
• Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbuttoned
jackets or tops with open zippers that could 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 when checking the fluid level or 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. Contact between metal items and the battery could generate
accidental short-circuiting 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 to avoid 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, causing the corrosion of 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 abundant water for at least 10 minutes, then call a doctor.

2
 SERVICE ROUTINE MAINTENANCE

• 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 the battery,
consult the truck identification 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 fork carriage. Lower the fork carriage or use a safety chain to prevent the
fork carriage from dropping during maintenance work on the mast and 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 circuit pressure.
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.

3
 ROUTINE MAINTENANCE SERVICE

OILS AND LUBRICANTS

Application Standard Cold stores

OIL for lubrication of the Shell SHELL

HYDRAULIC CIRCUIT TELLUS S2 VX 46 AEROSHELL FLUID 41
KLÜBER LUBRICATION
OIL for lubrication of KLÜBEROIL 4UH 1-150N VG 150
KLÜBER LUBRICATION
LIFTING CHAINS KLÜBEROIL 4UH 1-68N VG 68
REXNORD KETTE REXOIL VG
150
SHELL
Lubrication OIL for REDUCTION UNITS
SPIRAX S3 AM 80W-90

GREASE for lubrication of

SHELL
REDUCTION UNIT OUTER GEAR
GADUS S2 OGH 0/00
(STEERING CROWN WHEEL AND PINION)
GREASE for lubrication of
MAST BEARINGS SLIDING
KLÜBER LUBRICATION
GUIDES
GRAFLOSCON C-SG - 0 ULTRA
DOOR CLOSING DEVICE (CAB FOR APPLICATION
IN COLD ROOM)
GREASE for lubrication of the
RETRACTABLE FORK CARRIER PLATE BEARINGS
SLIDING GUIDES
SHELL Shell
BATTERY TRAY SLIDING BLOCKS
GADUS S2 V100 2 AEROSHELL GREASE 6
SIDE SHIFT CARRIAGE
RETRACTABLE FORK C ARRIERPLATE CYLINDER
COUPLING BEARINGS

BATTERY TERMINALS insulation Pure Vaseline

OIL QUANTITIES

3 STAGE MAST
Truck /
5000 5250 5500 5750 6000 6250 6500 6750 7000 7250 7500 7750 8000 8250 8500 8750 9000 9250 9500 9750 10000 10250 10500
h3 (mm)
14-16 28 lt 28 lt 28 lt 28 lt 28 lt 28 lt 28 lt 28 lt 28 lt 28 lt 28 lt 28 lt 30 lt 30 lt 30 lt 30 lt 34 lt 34 lt 34 lt 34 lt 34 lt 34 lt 34 lt

16N 20 lt 20 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt 24 lt

Truck /
4650 4900 5150 5400 5650 5900 6150 6400 6650 6900 7150 7400 7650 7900 8150
h3 (mm)
20-25 28 lt 30 lt 30 lt 30 lt 30 lt 30 lt 30 lt 30 lt 30 lt 36 lt 36 lt 36 lt 36 lt 36 lt 36 lt

Truck /
7900 8150 8400 8650 8900 9150 9400 9650 9900 10150 10400 10650 10900 11150 11400
h3 (mm)
16HD 30 lt 30 lt 30 lt 30 lt 36 lt 36 lt 36 lt 36 lt 36 lt 36 lt 36 lt 38 lt 38 lt 38 lt 38 lt

Truck /
7750 8000 8250 8500 8750 9000 9250 9500 9750 10000 10250 10500 10750 11000 11250 11500 11750 12000 12250 12500 12750
h3 (mm)
20HD 30 lt 36 lt 36 lt 36 lt 36 lt 36 lt 36 lt 36 lt 36 lt 36 lt 38 lt 38 lt 38 lt 38 lt 38 lt 38 lt 38 lt 38 lt 38 lt 38 lt 38 lt

4 STAGE MAST
Truck /
6650 7050 7450 7850 8050 8300 8500 8700 9150 9400 9850 10050 10300 10500 10750 11000 11400
h3 (mm)
14-16 22 lt 22 lt 22 lt 25 lt 25 lt 25 lt 25 lt 25 lt 25 lt 25 lt 25 lt 30 lt

16N 22 lt 22 lt 22 lt 25 lt 25 lt 25 lt 25 lt 25 lt

20HD 30 lt 30 lt 30 lt 30 lt 30 lt 30 lt 30 lt 30 lt 32 lt 32 lt 32 lt

20-25 25 lt 30 lt 30 lt 30 lt 30 lt

After delivering oil in the hydraulic system circuit, it must be topped up

4
SERVICE ROUTINE MAINTENANCE

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, steam, solvents or flammable products as they could damage the
truck or be hazardous 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 damp cloths, water jets, steam, solvents or flammable products as they could
damage the truck or be hazardous for the operator.

CLEANING MAST AND RETRACTABLE CARRIAGE BEARINGS SLIDING GUIDES

Use degreasing solvents.
Do not use water jets, steam, solvents or flammable products as they could damage the
fork mast or be hazardous for the operator.

If checks, maintenance or cleaning operations are carried out immediately after the truck
is stopped, some components of the motor or of the hydraulic system could be hot.
It is recommended to wear safety footwear, gloves, and suitable clothing.

If traffic is obstructed because of a truck breakdown, move the truck as indicated

in paragraph “Removal in the event of lift truck breakdown” in the “Operating
instructions” chapter of the operator manual.

SCHEDULED MAINTENANCE TABLE KEY

■ = Checks and maintenance to be performed by the operator or the person assigned to truck
maintenance. To carry out these checks and maintenance operations, refer to the instructions
provided in the “Maintenance procedures” paragraph of the operator manual.
● = Checks and maintenance operations that must only be performed by a technician authorised
by the truck manufacturer. To carry out these checks and maintenance operations, contact the
HYG service centre.
X = Replacement of parts that should only be performed by a skilled technician authorised by
the truck manufacturer. To carry out these checks and maintenance operations, contact the HYG
service centre.

5
 ROUTINE MAINTENANCE SERVICE

SCHEDULED MAINTENANCE

Maintenance intervals
Every Every Every Every
8 hours 1000 hours 3000 hours 5000 hours
1 day 1 year 2 years 3 years
Check the screws and bolts 
OVERHEAD

Visually check the main welds 

FRAME,

GUARD

Check the integrity of the frame fastening supports 

Check the height of the outriggers off the ground(1) 
General cleaning 
Normal braking operation check  
Dynamic braking operation check
BRAKING SYSTEM

 
Check counter current braking operation  
Emergency braking operation check  
Electromagnetic parking brake and coil efficiency check 
Electromagnetic parking brake liner wear check (2)

Load wheels brake liner wear check (2)

General cleaning 
Oil leak check  
HYDRAULIC SYSTEM

Valve operation check  

Check the tank oil level 
Check the condition and tension of the hoses(3) 
Tank oil change x
Renew oil filter cartridge x
Renew plug with air cleaner x
General cleaning 
Motor insulation check 
Cable connection check
MOTORS


Fixing nut condition check 
Bearing noise check 
General cleaning 
Oil leak check  
Check the oil level
REDUCTION UNIT


Change oil in reduction unit (4)

Check reduction unit outer gear teeth wear (steering crown


wheel and pinion)
Reduction unit noise check 
Frame-MDU fastening plate screws check 
General cleaning 
Check condition and wear of drive wheel(2)  
Check condition and wear of load wheels (2))
WHEELS & TYRES

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

6
SERVICE ROUTINE MAINTENANCE

Maintenance intervals

Operation description Every Every Every Every

8 hours 1000 hours 3000 hours 5000 hours
1 day 1 year 2 years 3 years
Adjust retractable carriage side rollers 
Check conditions of bearings of retractable carriage and
RETRACTABLE CARRIAGE,


mast(2)
Check the screws and bolts 
MAST, FORKS

Check chain tensioner conditions(2) 

Check lift chains stretch 
Check lifting chain link and pin wear(2) 
Check conditions of chain pulleys, tubes and cables 
Clean mast bearings sliding guides 
Check conditions of mast bearings sliding guides 
Check fork condition  
Check the fork support device screws 
MAST FORK

Check play of side shift outrigger sliding blocks 

SUPPORT
3 STAGE

DEVICE

Check side shift and tilt cylinder rods and check the steering

bushes(2)
Check wear of side shift upper and lower sliding blocks(2) 
Check conditions of fork support device bearings (2)

Check the screws that fasten the hooks and the tilt cylinders 
MAST FORK
SUPPORT
4 STAGE

DEVICE

Check the integrity of the tilt cylinders 

Check the wear of the sliding blocks 

Check the condition of the fork support bearings 

Lifting chain lubrication 
GREASING POINTS

Grease the reduction unit outer gear (steering crown wheel


and pinion)
Grease the battery tray sliding blocks 
Grease the retractable carriage cylinder joint bearings 
Grease the retractable carriage bearings sliding guides 
Grease the mast bearings sliding guides 
Grease side shift 
Check the seat conditions and operation  
Check the seat belt conditions and operation  
Check the integrity of the cab fastening supports 
Check the operation of the emergency exit levers (cab for

application in cold rooms)
CABIN

Check the adjustment of the door closing device (cab for

application in cold rooms) (5)
Check the conditions of the door hinge bearings (cab for
application in cold room) (2) (5)
Replacement of the heater filter (cab for application in cold
room) (5)
INSTRUMENTATIONI
CHECKS

Check the machine functions using the controls and

 
instrumentation

7
 ROUTINE MAINTENANCE SERVICE

Maintenance intervals

Operation description Every Every Every Every

8 hours 1000 hours 3000 hours 5000 hours
1 day 1 year 2 years 3 years
Battery plug/socket integrity check  
ELECTRONICS

Electrical connection check 

Check the conditions of the auxiliary connections of the

electronic control devices
Check the conditions of the electrical wiring 
Sensor operation check 
General cleaning of electrical panel 
Check the battery charge level  
Check the connection conditions 
BATTERY

Check liquid leaks  

Check electrolyte density 
Check the electrolyte level 
Battery insulation check 
General cleaning 
Clean and grease the sliding blocks and the sliding surface

of the sliding element
EXTENDABLE FORKS

Check the play between the forks and the sliding element  
Check the condition of the cylinders(6)  
Check for hydraulic system liquid leaks (6)
 
Check the conditions of the cylinder rod and the socket 
Check the planarity of the sliding element surface 
Check the synchronism of the fork movement 
Check for deformations or breakage in the structure and

welds of the sliding elements.
Check that the fixing nuts that tighten the descent hooks are
 
well tightened (6)
Check for any damage to the pipes and fittings of the
hydraulic system and check that they are tightened correctly  
(6)

Check the tightening of the fork locking screws (6)  

Check the play between the descent bar of the truck and the
FORK POSITIONER

 
descent hooks of the fork positioner (6)
Grease the fork support guide pipe 
Grease the upper and lower sliding blocks 
Grease the descent bar of the trunk in the area of the fork

positioning sliding blocks
Check the conditions of the hydraulic actuators 
Check the conditions of the fork support guide pipe and the

surface trim
Check the upper and lower sliding block tightening 
Check the sliding support bearings (2) 
Replace the upper and lower sliding blocks 
Replace the fixing nuts for tightening the descent hooks 
Check the conditions of the plates and visible warning decals 
DECALS
PLATES

General cleaning of the plates and visible warning decals 

AND

Check the conditions of the plates and warning decals 

General cleaning of the plates and warning decals 

8
 SERVICE ROUTINE MAINTENANCE

(1)
Check also when replacing the drive wheel
(2)
Replace if necessary
(3)
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 hose, 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 hose or at the connection fitting;
• the presence of permanent creases, compression, flattening or twists in the pipe;
• the presence of blisters, softening, wear of the external coat.
(4)
change recommended after 7500 hours or 5 years. This operation must be performed only by a technician
authorised by the truck manufacturer.
(5)
Replacement is recommended after 500 hours. This operation must be performed only by a technician authorised
by the truck manufacturer.
(6)
Visual inspection

Trucks working in cold stores must be lubricated every 500 hours, or even more frequently
in the case of particularly intensive use.

9
 ROUTINE MAINTENANCE SERVICE

MAINTENANCE PROCEDURES
CHECK HEIGHT OF OUTRIGGERS OFF GROUND
Equipment and tools

Fig. 1

open ended span-

calliper metre ner
46 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the keyswitch
to OFF and disconnect the battery.

Phase 1
Check that the two outriggers have not been damaged and have not
come loose.
Measure the height of the outriggers off the ground (fig.2).
A
The correct value of X is given in the following table:

Model X = 27 mm X = 20 mm X = 10 mm
X ± 2 mm B
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 floor

2.0-2.5 ton 4650< h3 < 7500 h3 > 7500 - Fig. 2

1.6 ton HD - h3 < 8200 h3 > 8200

2.0 ton HD - h3 < 8200 h3 > 8200

h3 = lift height (see MAST MECHANICS section).

Phase 2
46 mm open ended spanner
Loosen the outrigger locking nut with the open ended spanner (ref.A fig.2). Unscrew or screw in the ou-
trigger (ref.B fig.2) to reach the desired height. Tighten the locking nut.

10
 SERVICE ROUTINE MAINTENANCE

CHECK THE SCREWS AND BOLTS

Equipment and tools

Torque open ended span- hexagonal "T"

wrench ners section spanners

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and all pede-
strians. Turn the keyswitch to OFF and disconnect the battery.

TORQUE WRENCH - OPEN ENDED SPANNER

Check the wear of the screws and bolts of the truck and check that they are sufficiently tight according to
the following table:

Tightening
Screw or nut Tolerance Ref. figure
(Nm)
Screws fastening the mast to the retractable carriage 300÷330 - fig.2

Screws fastening the bracket to the mast block 88÷97 - fig.3

Limit stop screws of the retractable carriage 300÷330 - fig.4

Screws fastening the left boom of the safety roof to the chassis 55 + 0÷10% fig.7

Screws fastening the right boom of the safety roof to the chassis 55 + 0÷10% fig.9

Screws fastening the chassis to the cab 220 + 0÷10% fig.12-13

Ferrules fastening the load wheels 150÷170 - fig.14

Screws fastening the drive wheel 140 - fig.15

Screw fastening the MDU assy plate to the chassis 88 - fig.16

Screws fastening the traction motor to the reduction unit 34 fig.16

Screws fastening the reduction unit to the MDU assy 88 fig.16

Screws fastening the steering motor to the MDU assy plate 88 fig.17

11
 ROUTINE MAINTENANCE SERVICE

Fig. 1

bridge crane lifting sling

load capacity load capacity step ladder safety harness
3000 kg 3000 kg

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.1). Climb down the ladder, raise the bridge crane to
reveal the screws securing the mast assembly to the truck base (fig.2).

Fig. 2

Fig. 3
19 mm OPEN ENDED SPANNER
Using the torque wrench, check the tightening of the screws securing
both side blocks of the mast assembly (fig.3).

12
SERVICE ROUTINE MAINTENANCE

14 mm T HANDLE HEX KEY

Fig. 4
Using the torque wrench check the tightening of the limit stop screws of
the retractable carriage (fig.4).

Fig. 5
5 mm T HANDLE HEX KEY
Using the T-handle hex key, unscrew and remove the screw locking the
bonnet (ref.B fig.5) and open the bonnet (fig.6).

15 mm OPEN ENDED SPANNER

Using the torque wrench, check the tightening of the screws fastening
the left boom of the safety roof to the chassis (fig.7).

Fig. 7 Fig. 6

13
 ROUTINE MAINTENANCE SERVICE

Fig. 8

medium/lar-
ge crosshead B
screwdriver
B B
MEDIUM/LARGE CROSSHEAD SCREWDRIVER
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.B fig.8).
Remove the panel.

15 mm OPEN ENDED SPANNER

Using the torque wrench, check the tightening of the screws fastening
the right boom of the safety roof to the chassis (fig.9).

Fig. 9

5 mm T HANDLE HEX KEY

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.10), remove the electronic controls cover and open the
bonnet (fig.11).

24 MM OPEN ENDED SPANNER - 24 mm HEX SOCKET WRENCH

Using the torque wrench check the tightening of the screws fastening the
cab to the chassis (fig.12-13).

Fig. 10

Behind the electronic controls panel Behind the oil reservoir of the hydraulic system

Fig. 13 Fig. 12 Fig. 11

14
 SERVICE ROUTINE MAINTENANCE

SOCKET WRENCH FOR SELF-LOCKING FERRULES

Using the torque wrench check the tightening of the ferrules fastening
the load wheels(fig.14).

Fig. 14

5 mm T HANDLE HEX KEY

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.10), remove the electronic controls cover and open the
bonnet (fig.11).

12 mm SOCKET WRENCH - RATCHET - EXTENSION

Using the torque wrench check the tightening of the screws fastening the
drive wheel (ref. B fig.15).

Fig. 15 B

Fig. 16
5 mm T HANDLE HEX KEY
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.10), remove the electronic controls cover and open the
bonnet (fig.11).

13-16 mm HEX SOCKET WRENCH

Using the torque wrench, check the tightening of the screws fastening the
MDU as(ref.A fig.16), of the traction motor to the reduction unit (ref.B
fig.16), of the reduction unit to the plate (ref.C fig.16), of the steering
motor to the plate (fig.17).

Fig. 17

15
 ROUTINE MAINTENANCE SERVICE

CHECK CHAINS
Equipment and tools

calliper

CHAIN GREASING
The element that permits extending the life of the chain is lubrication. Therefore periodic lubrication must
be carried out using a brush or spray can with suitable oil. The frequency with which this operation should
be performed depends considerably on the type of work and the environmental conditions, and is on
average after 1000 hours of work.

CHAIN STRETCH
The chains tend to stretch out with use. This stretching can be recovered using the chain tensioner. The
maximum recovery possible of a stretched chain is equal to max. 2%; once this value is exceeded the
chain must be replaced.

CHAIN MEASUREMENT
Measure the extension with a calliper (fig.1) on many sections 10 pitches apart taken in the more stressed
sections. This check must be performed after approx. every 1000 hours of operation. The measurement of
the 10 pitches is shown in the table below with reference to the respective chain.

1 pitch “P” 10 pitches “10P”

Maximum permitted stretching

Length of pitch “P” Length of sample “10 P” +2% in reference to the sample
Chain length “10 P”
mm in mm in mm in

14-16-20-25 Main Lift 19.05 0.75 190.5 7.5 194.31 7.65

14-16 Free Lift 19.05 0.75 190.5 7.5 194.31 7.65

20-25 Free Lift 25.4 1 254 10 259.08 10.2

If it is checked that the chains had insignificant stretching, less than 2%, this does not mean that they
remained intact without any faults.
On the contrary, there may be deformations caused by stress; therefore it is a good idea to make a careful
check along the entire chain, checking the state of wear of the links, the hinge pins, the chain tensioner
and the chain tensioner pin.

16
SERVICE ROUTINE MAINTENANCE

CHECK OF THE LINKS, PINS AND CHAIN TENSIONER

Before performing the check, clean the chain as necessary, using paraffin or a paraffin derivative.
The chain can be examined in position.
Examine the chain and the associated components (figure to the side):

A) Pin wear
B) Pin damage C
C) Link damage
D) Link edge wear A
E) Wear and ovalisation of the links
F) Too much play between the links B
G) Oxidisation check
H) Wear and ovalisation of the chain tensioner G E
I) Wear of the chain hinge gudgeon
F Fig. 2
D
If chains are not excessively worn and the stretching is tolerable,
replace them every 3 years (5000 hours of operation) under normal
working conditions. Replace chains every 2 years (3000 hours
of operation) when the truck is used in cold rooms or in corrosive
environments.

H
I

17
 ROUTINE MAINTENANCE SERVICE

CHECK FORKS
Equipment and tools

metre

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 then 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.

Fig. 1

18
 SERVICE ROUTINE MAINTENANCE

CHECK WEAR ON ELECTROMAGNETIC BRAKE LINERS

See "REMOVAL OF THE BRAKE" in the "BRAKING SYSTEM" section.

CHECK THE TANK OIL LEVEL

Before topping up the oil in the hydraulic oil reservoir make sure that the forks are fully lowered.

Equipment and tools

hexagonal "T"
funnel oil resistant gloves section spanner
5 mm

Procedure
Fig. 1
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Turn the keyswitch
to OFF and disconnect the battery.

Phase 1
5 mm T HANDLE HEX KEY
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. 2

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 ROUTINE MAINTENANCE SERVICE

Phase 2
Check the oil level via the marks on the reservoir (fig.3). Fig. 3
If it is necessary to fill up oil, unscrew the reservoir cap (ref.C fig.4), un-
screw the breather valve (ref.B fig.4), place the funnel into the filler hole
and top up using the oil suggested in the table "OILS AND LUBRICANTS"
at the beginning of this section.
Screw the breather valve and the reservoir cap back on.

Fig. 4

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 SERVICE ROUTINE MAINTENANCE

CHECK THE EXTENDABLE FORKS

DAILY CHECKS
At the start of every work shift, the following is recommended:

• Check that the sliding element fastening pins are in the correct position;
• Check that the hooks are positioned and fastened correctly;
• Check that the upper hook pins of the forks engage the notches of the truck fork carrier plate;
• Check for any leaks from the cylinders and/or from the hydraulic circuit;
• Check the cleaning and lubrication of the sliding element sliding areas.

4 5

3 Fig. 1

Pos. Description
1 Sliding element fastening pin
2 Sliding element sliding area
3 Bottom hook
4 Pin and hook lever
5 Top hook

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 ROUTINE MAINTENANCE SERVICE

PERIODIC MAINTENANCE

After 1000 hours of work, the following is recommended:

• Cleaning and greasing the sliding blocks and sliding surfaces of the sliding elements (ref. A fig.2).
• The check of the play between the fork and the sliding element (ref. B fig. 3); when the play is very
reduced (< 0.5mm), insert shims below the sliding blocks to increase the play to 1- 1.2 mm). To insert
the shims, refer to the relative diagram (fig.4) and the paragraph “SLIDING BLOCK REPLACEMENT”
in the section “SMALL FORK MAST MECHANICS”.
• The check of the cylinder seal; any oil leaks involve the replacement of the gaskets and any worn parts.
• The check of the hydraulic system with particular attention for the pipes and fitting that protrude above
the forks (ref.C fig.1).
• The check of the plates and the safety decals (ref.D fig.1).

Fig. 2 Fig. 3
D C
H E B

SLIDING BLOCK SHIMMING VALVE A0 CONNECTION LOAD

Fig. 4 Fig. 6
CAPACITY 2 TON
G
F

Fig. 5

Remove the sliding elements, using a punch extract the stop pin from the cylinder stem (ref.H fig.2) located
on the tip of the fork, then proceed as follows:

• Check the thickness of the sliding blocks (ref.E fig.2). If the sliding block thickness is < 3mm, the sliding
blocks must be replaced.
• The check of the cap and stem of the cylinder (ref. F fig. 6), which must be replaced if worm or dented.
• The check of the straightness and proper condition of the surface and the sliding element (ref.G fig.6).
In the case of significant deformation or wear, restore or replace the parts.
• Check of the synchronisation of fork movement: move the cylinder stem to its limit stop and disconnect the
A0 connection of the valve (fig.5) to check for oil leaks and possibly replace the piston gaskets (for forks
with load capacity 2ton). For higher load capacities, directly check the condition of the piston gaskets; if
there is no synchronism and no leaks in the piston gaskets, replace the flow divider.
• The search for deformations or breakage in the structure and welds of the sliding elements.

Before disconnecting/connecting the pipes, release the pressure from the truck circuit.
If using the equipment in dusty, humid or corrosive environments, it is recommended to
reduce the hours for the required maintenance intervals by half.
The recommended lubricant is: SHELL ALVANIA GREASE R2 for interiors and ESSO
NUTO 32 for exteriors.

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 SERVICE ROUTINE MAINTENANCE

FORK POSITIONER CHECK

DAILY CHECKS
At the start of every work shift, the following is recommended:

• Check that the nuts fixing the cylinder stem head are tightened and that the pins and split pins fixing the
base plate are positioned correctly;
• Check that the fork locking screws are tightened;
• Check that the fork support sliding bush screws are tightened;
• Check that the guide pipe locking screw is tightened;
• Check that there are no leaks from the fork support movement cylinders;
• Check the cleaning and greasing of the fork support guide pipe;
• Check that the central tooth of the upper sliding block guide engages the central notch of the truck’s
fork carrier plate;
• Check that there are no leaks from the translation cylinder;
• Check that the sliding blocks and lower hooks are correctly positioned and well fixed.

1
2

Pos. Description
1 Side shift cylinder
2 Cylinder stem head fixing
nut
3 Cylinder base plate fixing
pin and split pin
4 Guide pipe
5 Guide pipe locking screw
3
6 Fork support sliding bush
screw
7 Fork locking screws

5
4

6 7 Fig. 1

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 ROUTINE MAINTENANCE SERVICE

PERIODIC MAINTENANCE

Every 1000 hours of operation:

• Check that the locking screws (ref.A fig.2) of the lower hooks are well tightened;
• Check if the hydraulic system pipes or fittings are damaged and check that the fittings are well tightened.
• Check that the fork locking screws are well tightened. Check the play between the lower bar of the truck
and the lower hooks of the positioner. In case of excessive play, adjust the hooks and tighten the screws
again (fig.3).
• Grease the guide pipe of the fork supports (ref.E fig.2) (or apply the spray lubricant);
• Grease the upper (ref.B fig.2) and lower sliding blocks (ref.C fig.2).
• Apply grease on the lower bar of the truck in the positioner sliding block area.
• Check the condition of the hydraulic actuators (ref.D fig.2);
• Check that there are no leaks from the cap;
• Check the condition of the chrome-plated stem surface.
• Check the condition of the guide pipe of the fork supports (ref.E fig.2).
• Check the thickness of the upper sliding blocks; if the thickness is < 4mm, replace them.
• Check the thickness of the lower sliding blocks; if the thickness is < 5mm, replace them
• Check and if necessary replace the support sliding bushes(ref.F fig.4), if Ø<29,5mm.
• Replace the upper and lower sliding blocks.
• Replace the self-locking nuts for tightening the lower hooks.

For the assembly instructions, refer to the section “SMALL FORK MAST MECHANICS”

B E B
D

C Fig. 3
D
C
A
A Fig. 2 Fig. 4
F

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SERVICE ROUTINE MAINTENANCE

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Code: 550066261 Revision: 3 (05/2022)