Part no.

: 4138678 Revision: 4 (07/2021)

Technical information for Hyster service

centres

This manual is intended solely for the specialized technicians of

the Hyster service network

P1.6 - P1.8
A418.....
P2.0 - P2.2
 INTRODUCTION SERVICE

IMPORTANT
The Service Manuals are updated regularly, but may not contain the most recent product design modifica-
tions. The updated technical information is in any case available from your nearest authorised Hyster®
dealer. The Service Manuals provide guidelines for maintenance and are designed for the use of suitably
trained technicians. Incorrect maintenance or a failure to adhere to the instructions in this manual could
result in damage to the product or other objects, personal injury or even death.
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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 INTRODUCTION SERVICE

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: Mechanical system
Section 7: Reduction gear
Section 8: Braking system
Section 9: 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, unbut-
toned 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.
• Keep sparks, naked flames and cigarettes away from flammable materials such as the gas produced
by 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 pos-
sible 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 are assisting 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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 INTRODUCTION SERVICE

• 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.
• When necessary to check the system pressure, use appropriate instruments.

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE

• Keep a record of all the suspension elements used, stating the characteristics of the suspension ele-
ments 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 crane
and 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

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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 INTRODUCTION SERVICE

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 carefully. Nominal TORQUE SETTINGS Nm
diameter
Apply a threadlocking compound to the threads Class 8 Class 10
of screws to prevent them working loose. M3 4 5.2
If it is not possible to unscrew the bolts because this M4 7 9.15
product has been used, avoid applying extensions to
M5 12.14 14.8
the tools, instead slightly heat the area (max. 50°C) so
as to eliminate the effect of the threadlocker. M6 17.2 20.9

In these cases, reapply a moderate amount of M8 31.8 38.1

threadlocking compound on reassembly (covering 30% M10 50.5 60.3
of the mating surface). M12 74.2 88.5
The torque setting used for tightening the threaded M14 101.2 120.8
couplings is extremely important to make the coupling M16 138.2 164.9
secure and the machine safe.
M18 176.6 203.5
The tables on this page give the classes of bolts normally
M20 225.4 259.7
used with the relevant torque settings.
M22 278.8 321.2
M24 324.8 374.2
M27 422.3 486.5
M30 516.1 594.7

TORQUE SETTING Nm
Pre-load N Class 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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 INTRODUCTION SERVICE

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 SWIVEL FEMALE SWIVEL 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

BSP SWIVEL FEMALE ORFS SWIVEL FEMALE

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.

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 INTRODUCTION SERVICE

SECTION CONTENTS

Presentation 1
Installation and settings 2
Diagnostics and measurements 3
Electrical system 4
Hydraulic system 5
Truck base mechanics 6
Reduction gear 6
7
Braking system 6
8
Standard maintenance 7
9

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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...................................................................................4
TRUCK IDENTIFICATION DATA PLATE.............................................................................................4
M A S T S E R I A L N U M B E R S TA M P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D O C U M E N TAT I O N P O S I T I O N ..............................................................................................5
GENERAL SPECIFICATIONS.................................................................................................................6
BATTERY TABLES...............................................................................................................................................10

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 PRESENTATION SERVICE

TRUCK PRESENTATION
The new range of pedestrian tiller operated pallet trucks has a nominal load capacity of from 1600 kg to
2200 kg.
These trucks are electric vehicles on which a battery provides sufficient current for driving and lifting. The
battery is in the compartment on the fork frame and is raised/lowered together with the movement of the
forks. The battery compartment also acts as a load rack and helps keep the load blocked.
The tiller is used to select the various functions, among which steering, selecting the drive mode, braking,
directing the truck and controlling the speed, lifting and lowering of the forks.

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SERVICE PRESENTATION

VIEWS OF THE TRUCK

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 PRESENTATION SERVICE

TRACTOR AND LOAD IDENTIFICATION DATA

TRUCK IDENTIFICATION DATA PLATE

The truck identification data plate is located in the battery

compartment.

• Manufacturer's name • Max. battery weight

• Model • Min. battery weight
• Serial number • Battery voltage
• Weight without battery • Nominal load capacity
• Year of manufacture • Persons on board

TRUCK SERIAL NUMBER

The truck serial number is stamped on top of

the frame.

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SERVICE PRESENTATION

DOCUMENTATION POSITION

The truck documentation is located in the

battery compartment.

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 PRESENTATION SERVICE

GENERAL SPECIFICATIONS

P1.6 - P1.8

1 - Running
2 - Braking

(1)
These values can vary by +/- 5%.
(2)
See “Battery tables”.
(3)
Batteries available: 150Ah, 210Ah and 50Ah. 56Ah, 100Ah, 112Ah, 168Ah Li-on
(4)
Batteries available: 150Ah, 210Ah, 250Ah, 315Ah and 50Ah. 56Ah, 100Ah, 112Ah, 168Ah Li-on
(5)
Batteries available: 210Ah, 250Ah, 315Ah

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 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
1.0 Manufacturer (abbreviation) Hyster Hyster
CHARACTERISTICS

1.2 Manufacturer's type designation P1.6 P1.8

1.3 Drive: electric (battery or mains), diesel, petrol, fuel gas Battery Battery

1.4 Operator type: Hand, pedestrian, standing, seated, orderpicker Pedestrian Pedestrian

1.5 Rated capacity / rated load Q (t) 1.6 1.8

1.6 Distance from load centre of gravity (2)

c (mm) 600 600

1.8 Distanced of load from centre of drive axle to the fork(2) x (mm) 955 955

1.9 Wheelbase (2)

y (mm) 1368 1368

2.1 Service weight (1) (2) kg 545 545

WEIGHTS

2.2 Load on axle, with front/rear load (2)

kg 841 / 1304 893 / 1452

2.3 Load on axle, without front/rear load (2) kg 425 / 120 425 / 120

3.1 3.1 Tyres: polyurethane, topthane, NDII-Thane, front/rear polyurethane polyurethane

3.2 Front tyre size ø (mmxmm) 250 x 75 250 x 75

WHEELS AND
CHASSIS

3.3 Rear tyre size ø (mmxmm) 85 x 110 85 x 110

3.4 Additional wheels (dimensions) ø (mmxmm) 100 x 40 100 x 40

3.5 Wheels, number front/rear (x = non-driven wheels) 1x + 2/2 1x + 2/2

3.6 Tread, front b10 (mm) 461 461

3.7 Tread, rear b11 (mm) 390 390

4.4 Lifting h3 (mm) 130 130

4.9 Height of tiller in drive position (min/max) h14 (mm) 744 / 1221 744 / 1221

4.15 Height, lowered h13 (mm) 85 85

4.19 Overall length (pedestrian) (2) l1 (mm) 1734 1734

4.20 Length to face of forks (pedestrian) (2) l2 (mm) 578 578

DIMENSIONS

4.21 Overall width b1/b2 (mm) 712 712

4.22 Fork size (2)

s / e / l (mm) 64 / 172 / 1156 64 / 172 / 1156

4.25 Outside Fork Width b5 (mm) 560 560

4.32 Ground clearance, centre of wheelbase m2 (mm) 21 21

4.33 Dimensions of load b12 × l6 crossways b12 × l6 (mm) - -

4.34.1 Aisle width for pallets 1000mm x 1200mm crossways (pedestrian) (2)
Ast (mm) 2337 2337

4.34.2 Aisle width for pallets 800 mm x 1200mm wide lengthways (pedestrian) (2)
Ast (mm) 2204 2204

4.35 Turning radius (pedestrian) (2) Wa (mm) 1535 1535

5.1 Travel speed with/without load km/h 6/6 6/6

PERFORMANCE

5.1.1 Travel speed, laden/unladen, reverse km/h 6/6 6/6

5.2 Lifting speed with/without load m/s 0.04 / 0.05 0.04 / 0.05

5.3 Lowering speed with/without load m/s 0.09 / 0.04 0.09 / 0.04

5.7 Gradeability with/without load % 5.5 / 15 5 / 15

5.8 Gradeability with/without load % 10 / 20 9 / 20

5.10 Service brake electromagnetic electromagnetic

6.1 Drive Motor, S2 60 minute rating kW 1.25 1.25

6.2 Lift motor S3 15% rating kW 1.2 1.2

ELECTRICAL
MOTORS

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no (1)

B B

6.4 Battery voltage/nominal capacity (2) V/Ah 24 / 250 (3) 24 / 250 (3)

6.5 Battery weight (2) (1) kg 212 212

kWh/h at number
6.6 Energy consumption per VDI cycle 0.384 0.384
of cycles
DRIVE

8.1 Type of drive unit CA control unit CA control unit

Upd.
data

10.7 Sound pressure level at driver's position dB (A) < 70 < 70

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 PRESENTATION SERVICE

GENERAL SPECIFICATIONS

P2.0 - P2.2

1 - Running
2 - Braking

(1)
These values can vary by +/- 5%.
(2)
See “Battery tables”.
(3)
Batteries available: 150Ah, 210Ah and 50Ah. 56Ah, 100Ah, 112Ah, 168Ah Li-on
(4)
Batteries available: 150Ah, 210Ah, 250Ah, 315Ah and 50Ah. 56Ah, 100Ah, 112Ah, 168Ah Li-on
(5)
Batteries available: 210Ah, 250Ah, 315Ah

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 SERVICE PRESENTATION

GENERAL SPECIFICATIONS
1.0 Manufacturer (abbreviation) Hyster Hyster

1.2 Manufacturer's type designation P 2.0 P 2.2

CHARACTERISTICS

1.3 Drive: electric (battery or mains), diesel, petrol, fuel gas Battery Battery

1.4 Operator type: Hand, pedestrian, standing, seated, orderpicker Pedestrian Pedestrian

1.5 Rated capacity / rated load Q (t) 2.0 2.2

1.6 Distance from load centre of gravity (2)

c (mm) 600 600

1.8 Distanced of load from centre of drive axle to the fork (2)
x (mm) 955 955

1.9 Wheelbase (2) y (mm) 1440 1440

2.1 Service weight (1) (2) kg 632 632

WEIGHTS

2.2 Load on axle, with front/rear load (2) kg 983 / 1649 1032 / 1800

2.3 Load on axle, without front/rear load (2) kg 489 / 143 489/ 143

3.1 3.1 Tyres: polyurethane, topthane, NDII-Thane, front/rear polyurethane polyurethane

3.2 Front tyre size ø (mmxmm) 250 x 75 250 x 75

WHEELS AND
CHASSIS

3.3 Rear tyre size ø (mmxmm) 85 x 110 85 x 110

3.4 Additional wheels (dimensions) ø (mmxmm) 100 x 40 100 x 40

3.5 Wheels, number front/rear (x = non-driven wheels) 1x + 2/2 1x + 2/2

3.6 Tread, front b10 (mm) 461 461

3.7 Tread, rear b11 (mm) 390 390

4.4 Lifting h3 (mm) 130 130

4.9 Height of tiller in drive position (min/max) h14 (mm) 744 / 1221 744 / 1221

4.15 Height, lowered h13 (mm) 85 85

4.19 Overall length (pedestrian) (2)

l1 (mm) 1806 1806

4.20 Length to face of forks (pedestrian) (2) l2 (mm) 650 650

DIMENSIONS

4.21 Overall width b1/b2 (mm) 712 712

4.22 Fork size (2) s / e / l (mm) 64 / 172 / 1156 64 / 172 / 1156

4.25 Outside Fork Width b5 (mm) 560 560

4.32 Ground clearance, centre of wheelbase m2 (mm) 21 21

4.33 Dimensions of load b12 × l6 crossways b12 × l6 (mm) - -

4.34.1 Aisle width for pallets 1000mm x 1200mm crossways (pedestrian) (2) Ast (mm) 2409 2409

4.34.2 Aisle width for pallets 800 mm x 1200mm wide lengthways (pedestrian) (2)
Ast (mm) 2276 2276

4.35 Turning radius (pedestrian) (2)

Wa (mm) 1607 1607

5.1 Travel speed with/without load km/h 6/6 6/6

PERFORMANCE

5.1.1 Travel speed, laden/unladen, reverse km/h 6/6 6/6

5.2 Lifting speed with/without load m/s 0.04 / 0.05 0.04 / 0.05

5.3 Lowering speed with/without load m/s 0.09 / 0.04 0.09 / 0.04

5.7 Gradeability with/without load % 4.5 / 15 4 / 15

5.8 Gradeability with/without load % 8 / 20 7.5 / 20

5.10 Service brake electromagnetic electromagnetic

6.1 Drive Motor, S2 60 minute rating kW 1.25 1.25

6.2 Lift motor S3 15% rating kW 1.2 1.2

ELECTRICAL
MOTORS

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no (1)

B B

6.4 Battery voltage/nominal capacity (2)

V/Ah 24 / 375 (4)
24 / 375 (4)

6.5 Battery weight (2) (1)

kg 288 288

kWh/h at number
6.6 Energy consumption per VDI cycle 0.384 0.384
of cycles
DRIVE

8.1 Type of drive unit CA control unit CA control unit

Upd.
data

10.7 Sound pressure level at driver's position dB (A) < 70 < 70

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 PRESENTATION SERVICE

BATTERY TABLES

Battery compartment 375/315 Ah

(b5 = 520mm - 580mm - 670mm)
1.6 Load centre distance c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 1084 1290 1440 1684 1884

2.1 Weight in service (1) kg 612 623 632 646 657

kg (front) 809 944 983 1106 1166

2.2 Load on axle, with front/rear load (2)
kg (rear) 1803 1679 1649 1540 1491

kg (front) 441 471 489 513 529

2.3 Load on axle, without front/rear load
kg (rear) 171 152 143 133 128

4.19 Overall length (pedestrian) l1 (mm) 1450 1656 1806 2050 2250

4.20 Length to face of forks (pedestrian) l2 (mm) 650 650 650 650 650

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2173 2288 2409 2683 2972

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2173 2219 2276 2451 2698

4.35 Turning radius (pedestrian) W(a) (mm) 1251 1457 1607 1851 2051

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no B

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 375 - 315

6.5 Battery weight (1) kg 288

(1)
These values can vary by +/- 5%.
(2)
Axle loading with LOAD = 2000 kg
(3)
Li-on batteries

All values are

​​ nominal and subject to tolerances. For further information, please contact the
manufacturer.
Hyster products are subject to change without notice.
Lift trucks illustrated may feature optional equipment.
The values may
​​ vary depending on the configurations.

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 SERVICE PRESENTATION

Battery compartment 250/210 Ah

(b5 = 520mm - 560mm - 670mm)
1.6 Load centre distance( c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 1012 1218 1368 1612 1812

2.1 Weight in service (1) kg 525 536 545 559 570

kg (front) 776 910 945 1066 1123

2.2 Load on axle, with front/rear load (2)
kg (rear) 1749 1626 1600 1493 1447

kg (front) 382 409 425 447 461

2.3 Load on axle, without front/rear load
kg (rear) 143 127 120 112 109

4.19 Overall length (pedestrian) l1 (mm) 1378 1584 1734 1978 2178

4.20 Length to face of forks (pedestrian) l2 (mm) 578 578 578 578 578

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2101 2216 2337 2611 2900

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2101 2147 2204 2379 2626

4.35 Turning radius (pedestrian) W(a) (mm) 1179 1385 1535 1779 1979

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no B

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 250 - 210

6.5 Battery weight (1)

kg 212

Battery compartment 250/210 Ah

(b5 = 520mm - 560mm - 670mm)
1.6 Load centre distance( c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 1012 1218 1368 1612 1812

2.1 Weight in service (1) kg 499 (5) 510 (5) 519 (5) 533 (5) 544 (5)

kg (front) 768 771 774 909 945

2.2 Load on axle, with front/rear load (2)
kg (rear) 1731 1739 1745 1624 1599

kg (front) 363 371 378 407 424

2.3 Load on axle, without front/rear load
kg (rear) 136 139 141 126 120

4.19 Overall length (pedestrian) l1 (mm) 1378 1584 1734 1978 2178

4.20 Length to face of forks (pedestrian) l2 (mm) 578 578 578 578 578

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2101 2216 2337 2611 2900

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2101 2147 2204 2379 2626

4.35 Turning radius (pedestrian) W(a) (mm) 1179 1385 1535 1779 1979

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no B

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 250 (4)

6.5 Battery weight (1) kg 180

(1)
These values can vary by +/- 5%.
(2)
Axle loading with LOAD = 2000 kg.
(3)
Li-on batteries
(4)
Version with polypropylene body shell
(5)
Including 6 kg ballast

All values are

​​ nominal and subject to tolerances. For further information, please contact the
manufacturer.
Hyster products are subject to change without notice.
Lift trucks illustrated may feature optional equipment.
The values may
​​ vary depending on the configurations.

11
 PRESENTATION SERVICE

Battery compartment 150 Ah

(b5 = 520mm - 560mm - 670mm)
1.6 Load centre distance( c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 950 1156 1306 1550 1750

2.1 Weight in service (1) kg 499 460 469 483 494

kg (front) 748 881 912 1032 1086

2.2 Load on axle, with front/rear load (2)
kg (rear) 1701 1579 1557 1451 1408

kg (front) 328 352 367 387 400

2.3 Load on axle, without front/rear load
kg (rear) 121 108 102 96 94

4.19 Overall length (pedestrian) l1 (mm) 1316 1522 1672 1916 2116

4.20 Length to face of forks (pedestrian) l2 (mm) 516 516 516 516 516

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2039 2154 2275 2549 2838

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2039 2085 2142 2317 2564

4.35 Turning radius (pedestrian) W(a) (mm) 1117 1323 1473 1717 1917

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no no

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 150

6.5 Battery weight (1)

kg 144

Battery compartment 150 Ah

(b5 = 520mm - 560mm - 670mm)
1.6 Load centre distance( c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 950 1156 1306 1550 1750

2.1 Weight in service (1) kg 430 441 450 464 475

kg (front) 729 862 893 1013 1067

2.2 Load on axle, with front/rear load (2)
kg (rear) 1701 1579 1557 1451 1408

kg (front) 314 337 352 371 384

2.3 Load on axle, without front/rear load
kg (rear) 116 104 98 93 91

4.19 Overall length (pedestrian) l1 (mm) 1316 1522 1672 1916 2116

4.20 Length to face of forks (pedestrian) l2 (mm) 516 516 516 516 516

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2039 2154 2275 2549 2838

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2039 2085 2142 2317 2564

4.35 Turning radius (pedestrian) W(a) (mm) 1117 1323 1473 1717 1917

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no no

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 150 (4)

6.5 Battery weight (1) kg 125

(1)
These values can vary by +/- 5%.
(2)
Axle loading with LOAD = 2000 kg.
(3)
Li-on batteries
(4)
Version with polypropylene body shell
(5)
Including 6 kg ballast

All values are

​​ nominal and subject to tolerances. For further information, please contact the
manufacturer.
Hyster products are subject to change without notice.
Lift trucks illustrated may feature optional equipment.
The values may
​​ vary depending on the configurations.

12
 SERVICE PRESENTATION

Battery compartment 150 Ah

(b5 = 520mm - 560mm - 670mm)
1.6 Load centre distance( c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 950 1156 1306 1550 1750

2.1 Weight in service (1) kg 345 356 365 379 390

kg (front) 650 790 826 953 1013

2.2 Load on axle, with front/rear load (2)
kg (rear) 1695 1566 1539 1426 1377

kg (front) 238 365 282 307 324

2.3 Load on axle, without front/rear load
kg (rear) 107 91 83 72 66

4.19 Overall length (pedestrian) l1 (mm) 1316 1522 1672 1916 2116

4.20 Length to face of forks (pedestrian) l2 (mm) 516 516 516 516 516

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2039 2154 2275 2549 2838

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2039 2085 2142 2317 2564

4.35 Turning radius (pedestrian) W(a) (mm) 1117 1323 1473 1717 1917

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no no

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 56 (2)

6.5 Battery weight (1) kg 40

Battery compartment 150 Ah

(b5 = 520mm - 560mm - 670mm)
1.6 Load centre distance( c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 950 1156 1306 1550 1750

2.1 Weight in service (1) kg 358 369 378 392 403

kg (front) 660 800 836 964 1024

2.2 Load on axle, with front/rear load (2)
kg (rear) 1698 1569 1542 1428 1379

kg (front) 247 275 293 317 335

2.3 Load on axle, without front/rear load
kg (rear) 111 94 85 75 68

4.19 Overall length (pedestrian) l1 (mm) 1316 1522 1672 1916 2116

4.20 Length to face of forks (pedestrian) l2 (mm) 516 516 516 516 516

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2039 2154 2275 2549 2838

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2039 2085 2142 2317 2564

4.35 Turning radius (pedestrian) W(a) (mm) 1117 1323 1473 1717 1917

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no no

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 112 (2)

6.5 Battery weight (1) kg 53

(1)
These values can vary by +/- 5%.
(2)
Axle loading with LOAD = 2000 kg.
(3)
Li-on batteries
(4)
Version with polypropylene body shell
(5)
Including 6 kg ballast

All values are

​​ nominal and subject to tolerances. For further information, please contact the
manufacturer.
Hyster products are subject to change without notice.
Lift trucks illustrated may feature optional equipment.
The values may
​​ vary depending on the configurations.

13
 PRESENTATION SERVICE

Battery compartment 150 Ah

(b5 = 520mm - 560mm - 670mm)
1.6 Load centre distance( c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 950 1156 1306 1550 1750

2.1 Weight in service (1) kg 371 382 391 405 416

kg (front) 669 810 847 975 1035

2.2 Load on axle, with front/rear load (2)
kg (rear) 1702 1572 1544 1430 1381

kg (front) 256 285 303 328 346

2.3 Load on axle, without front/rear load
kg (rear) 115 97 88 77 70

4.19 Overall length (pedestrian) l1 (mm) 1316 1522 1672 1916 2116

4.20 Length to face of forks (pedestrian) l2 (mm) 516 516 516 516 516

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2039 2154 2275 2549 2838

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2039 2085 2142 2317 2564

4.35 Turning radius (pedestrian) W(a) (mm) 1117 1323 1473 1717 1917

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no no

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 168 (2)

6.5 Battery weight (1) kg 66

Battery compartment 150 Ah

(b5 = 520mm - 560mm - 670mm)
1.6 Load centre distance( c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 950 1156 1306 1550 1750

2.1 Weight in service (1) kg 349 360 369 383 394

kg (front) 651 791 827 955 1015

2.2 Load on axle, with front/rear load (2)
kg (rear) 1698 1569 1542 1428 1379

kg (front) 238 266 284 308 326

2.3 Load on axle, without front/rear load
kg (rear) 111 94 85 75 68

4.19 Overall length (pedestrian) l1 (mm) 1316 1522 1672 1916 2116

4.20 Length to face of forks (pedestrian) l2 (mm) 516 516 516 516 516

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2039 2154 2275 2549 2838

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2039 2085 2142 2317 2564

4.35 Turning radius (pedestrian) W(a) (mm) 1117 1323 1473 1717 1917

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no no

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 50 (2)

6.5 Battery weight (1) kg 44

(1)
These values can vary by +/- 5%.
(2)
Axle loading with LOAD = 2000 kg.
(3)
Li-on batteries
(4)
Version with polypropylene body shell
(5)
Including 6 kg ballast

All values are

​​ nominal and subject to tolerances. For further information, please contact the
manufacturer.
Hyster products are subject to change without notice.
Lift trucks illustrated may feature optional equipment.
The values may
​​ vary depending on the configurations.

14
 SERVICE PRESENTATION

Battery compartment 150 Ah

(b5 = 520mm - 560mm - 670mm)
1.6 Load centre distance( c (mm) 400 500 600 700 800

1.8 Distance of load from centre of drive axle to fork x (mm) 599 805 955 1199 1399

1.9 Wheelbase y (mm) 950 1156 1306 1550 1750

2.1 Weight in service (1) kg 410 421 430 444 455

kg (front) 694 838 875 1005 1066

2.2 Load on axle, with front/rear load (2)
kg (rear) 1716 1583 1555 1439 1389

kg (front) 281 312 332 359 377

2.3 Load on axle, without front/rear load
kg (rear) 129 109 98 85 78

4.19 Overall length (pedestrian) l1 (mm) 1316 1522 1672 1916 2116

4.20 Length to face of forks (pedestrian) l2 (mm) 516 516 516 516 516

4.22 Fork length l (mm) 800 1006 1156 1400 1600

4.34.1 Aisle width for pallets 1000mm x 1200mm wide (pedestrian) Ast (mm) 2039 2154 2275 2549 2838

4.34.2 Aisle width for pallets 800 mm x 1200mm wide (pedestrian) Ast (mm) 2039 2085 2142 2317 2564

4.35 Turning radius (pedestrian) W(a) (mm) 1117 1323 1473 1717 1917

6.3 Battery in compliance with DIN 43531/365/36 A, B, C, no no

6.4 Battery voltage/capacity at 5 hours rate (3) V / Ah 24 / 100 (2)

6.5 Battery weight (1) kg 105

(1)
These values can vary by +/- 5%.
(2)
Axle loading with LOAD = 2000 kg.
(3)
Li-on batteries
(4)
Version with polypropylene body shell
(5)
Including 6 kg ballast

All values are

​​ nominal and subject to tolerances. For further information, please contact the
manufacturer.
Hyster products are subject to change without notice.
Lift trucks illustrated may feature optional equipment.
The values ​​may vary depending on the configurations.

15
 PRESENTATION SERVICE

16
 SERVICE INSTALLATION AND SETTINGS

INSTALLATION AND
SETTINGS
BEFORE INSTALLATION.........................................................................................................................................2
WEIGHTS TA B L E ....................................................................................2
MACHINE A S S E M B LY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L I S T O F M AT E R I A L S R E C E I V E D F R O M T H E D E A L E R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
UNLOADING THE TRUCK......................................................................4
TOPPING UP THE OIL RESERVOIR.................................................5
B AT T E RY I N S TA L L AT I O N.........................................................6
WITH SIDE EXTRACTION.....................................................................7
B AT T E R Y CABLE CONNECTION...............................................................8
LIST AND DESCRIPTION OF ADJUSTMENTS AND SETTINGS TO BE CARRIED OUT..............9
CHECKING THE CONDITIONS OF USE OF THE TRUCK.....................................................................9

1
 INSTALLATION AND SETTINGS SERVICE

BEFORE INSTALLATION
Make sure in advance that all the tools required to unload the truck are available (bridge crane, lift truck,
lifting slings, etc.). Before delivering to the client it is very important to check the suitability of the place
where the carriage is to be installed.

WEIGHT TABLE
Weight (exclud- Battery voltage/ Battery
Fork length Overall weight
Model ing battery) capacity weight
mm kg V/Ah kg kg
800 x 520
305 24 / 150 144 449
800 x 560
313 24 / 210-250 212 525
800 x 670
1006 x 520
316 24 / 150 144 460
1006 x 560
324 24 / 210-250 212 536
1006 x 670
1156 x 520
325 24 / 150 144 469
P1.6 1156 x 560
333 24 / 210-250 212 545
1156 x 670
1400 x 520
339 24 / 150 144 483
1400 x 560
347 24 / 210-250 212 559
1400 x 670
1600 x 520
350 24 / 150 144 494
1600 x 560
358 24 / 210-250 212 570
1600 x 670
800 x 520
305 24 / 150 144 449
800 x 560
313 24 / 210-250 212 525
800 x 670
1006 x 520
316 24 / 150 144 460
1006 x 560
324 24 / 210-250 212 536
1006 x 670
1156 x 520
325 24 / 150 144 469
P1.8 1156 x 560
333 24 / 210-250 212 545
1156 x 670
1400 x 520
339 24 / 150 144 483
1400 x 560
347 24 / 210-250 212 559
1400 x 670
1600 x 520
350 24 / 150 144 494
1600 x 560
358 24 / 210-250 212 570
1600 x 670
800 x 520 314 24 / 150 144 458
800 x 560 322 24 / 210-250 212 534
800 x 670 333 24 / 310-375 288 621
1006 x 520 325 24 / 150 144 469
1006 x 560 333 24 / 210-250 212 545
1006 x 670 344 24 / 310-375 288 632
1156 x 520 334 24 / 150 144 478
P2.0 1156 x 560 342 24 / 210-250 212 554
1156 x 670 353 24 / 310-375 288 641
1400 x 520 348 24 / 150 144 492
1400 x 560 356 24 / 210-250 212 568
1400 x 670 367 24 / 310-375 288 655
1600 x 520 359 24 / 150 144 503
1600 x 560 367 24 / 210-250 212 579
1600 x 670 378 24 / 310-375 288 666
800 x 520
322 24 / 210-250 212 534
800 x 560
333 24 / 310-375 288 621
800 x 670
1006 x 520
333 24 / 210-250 212 545
1006 x 560
344 24 / 310-375 288 632
1006 x 670
1156 x 520
342 24 / 210-250 212 554
P2.2 1156 x 560
353 24 / 310-375 288 641
1156 x 670
1400 x 520
356 24 / 210-250 212 568
1400 x 560
367 24 / 310-375 288 655
1400 x 670
1600 x 520
367 24 / 210-250 212 579
1600 x 560
378 24 / 310-375 288 666
1600 x 670

2
SERVICE INSTALLATION AND SETTINGS

MACHINE ASSEMBLY
LIST OF MATERIALS RECEIVED FROM THE DEALER

The materials received from the dealer may vary according to whether or not optional accessories are
included.

Ref. Description

1 Truck
2 Battery connection plug extension lead (with lateral removal)
3 External battery charger (optional)
4 Battery
5 Top up bottle for battery electrolyte
6 Rollerway for side battery removal (optional)

3
 INSTALLATION AND SETTINGS SERVICE

UNLOADING THE TRUCK

Equipment and tools

fork lift truck bridge crane 2 lifting slings

load capacity load capacity load capacity
1000 kg 1000 kg 1000 kg

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.

Phase 1
FORK LIFT TRUCK
Pick up the pallet using the lift truck, raise it and carry it to a safe place,
away from the transit areas of other vehicles and pedestrians.

Phase 2
BRIDGE CRANE - 2 LIFTING SLINGS
Remove the packaging.
Attach the two lifting slings to the lifting attachments on the truck base
(fig.1).
Fig. 1

Ensure that the bridge crane is positioned vertically above

the truck to be lifted.

Attach the lifting slings to the bridge crane, lift the truck off the pallet and
slowly lower it to the ground.

4
 SERVICE INSTALLATION AND SETTINGS

TOPPING UP THE OIL RESERVOIR

If required top up the oil in the hydraulic oil reservoir. Before proceeding, make sure that the forks are fully
lowered.

Equipment and tools

socket wrench
funnel oil resistant gloves
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 pede-
strians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

Phase 1
13 mm SOCKET WRENCH
B
Use the T-handle socket wrench to unscrew and
remove the motor cover fixing nuts (ref.A fig.1).
Remove the motor cover by pressing your hands
first on the left and then on the right-hand side to
release the locking clips (ref.B fig.1). A

Phase 2
OIL RESISTANT GLOVES - FUNNEL
Unscrew the reservoir cap (ref.C fig.2), place the funnel in the filler hole Fig. 2
and top up the oil level.
Take the oil level in the tank to between the MIN and MAX values (ref.D
fig.2).
At the end of the operation screw the tank cap back on.

5
 INSTALLATION AND SETTINGS SERVICE

INSTALLATION OF THE BATTERY

Equipment and tools

6 mm T
bridge crane load
spreader bar handle hex
capacity 1600 kg
key

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.

Phase 1
T-HANDLE HEX KEY SIZE 6 mm Fig. 2
Raise the cover of the battery compartment.
Using the T-handle hex key, unscrew the battery bracket fixing screw
(ref.A fig.1) and remove the battery bracket.

Phase 2
BRIDGE CRANE - SPREADER BAR
Hook the spreader bar to the bridge crane.
Attach the spreader bar to the battery, lift the battery using the bridge
crane and position it over the battery compartment.
Lower the battery very carefully into the carriage compartment (fig.2).
Unhook the spreader bar from the battery.

Phase 3
T-HANDLE HEX KEY SIZE 6 mm
Fit the battery catch back in place. Using the T-handle hex key, screw in
the battery bracket fixing screw.

6
 SERVICE INSTALLATION AND SETTINGS

WITH SIDE EXTRACTION

Equipment and tools

bridge crane load

spreader bar rollerway
capacity 1600 kg

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
ROLLERWAY - OPEN-ENDED WRENCH
Open the upper cover of the battery compartment.
Position the rollerway for side battery extraction next to the truck, by the
opening to the battery compartment.
Using the open-ended wrench, loosen the locknuts and adjust the height
of the rollerway for side extraction by turning the adjuster screws (ref. A A
and B fig. 1). Fig. 1 B
Phase 2
BRIDGE CRANE - SPREADER BAR
Using a tackle and spreader bar, carefully position the battery on the
rollerway.
Unhook the spreader bar and push the battery into the battery com-
partment (fig. 2).
Push the battery removal handle down and to the right to lock the battery
in place.

Phase 3
Connect the battery socket with the plug.
Fig. 2

CLOSED POSITION OPEN POSITION

A A

Fig. 3

7
 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 pole -
colour BLUE

Positive pole - colour

_
RED

8
 SERVICE INSTALLATION AND SETTINGS

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:
• Check the conditions of use of the truck

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
Having carried out these assessments verify whether the conditions given are compatible with the perfor-
mance levels set:

• maximum traction speed

• traction acceleration
• reduction of traction speed
• maximum fork lifting/lowering speed
• braking
If necessary, reduce truck performance by using the programmer to customize the truck configuration pa-
rameters (see "TRUCK FUNCTIONS“ section “ELECTRICAL SYSTEM”).

In order not to jeopardize the carriage's safety, the configuration parameter customisation
can only be carried out by exclusively reducing factory values.
Parameter values that exceed the factory-set values are not permitted.

9
 INSTALLATION AND SETTINGS SERVICE

10
 DIAGNOSTICS AND MEASUREMENTS SERVICE

DIAGNOSTICS AND
MEASUREMENTS
DESCRIPTION OF MODULE CONNECTORS........................................................................................................................2
COMBI MODULE....................................................................................................................................................................2
MENU................................................................................................................................................................................................4
MONITOR MENU..........................................................................................................................................................................4
DTC CODE................................................................................................................................................................14
LED FLASHES.........................................................................................................................................................14
COMBI CONTROLLER ALARMS - NODE 30...................................................................................................................16
TILLER BOARD ALARMS - NODE 60................................................................................................................................25
ELECTRICAL COMPONENT MEASUREMENTS..............................................................................................................27
SOLENOID VALVE COILS...........................................................................................................................................................27
ELECTROMAGNETIC BRAKE COILS...........................................................................................................................27
MOTORS.........................................................................................................................................................28

1
 DIAGNOSTICS AND MEASUREMENTS SERVICE

KEY TO CONTROLLER CONNECTORS

COMBI MODULE

1 - +24V logic power supply from key switch

2 – Optional buzzer negative
3 – Lowering solenoid coil negative
4 – Pump contactor coil negative
5 – Electromagnetic brake coil negative
6 – Main contactor coil negative
7 - Encoder power supply negative
8 - Motor temperature sensor input
9 – Drive interlock input
10 – Not used
11 - Optional steering sensor input

2
 DIAGNOSTICS AND MEASUREMENTS SERVICE

12 – Not used
13 – +24V coil power supply output
14 – Lifting block optional sensor input
15 – Not used
16 – Accelerator potentiometer input
17 – Accelerator potentiometer input
18 – Not used
19 – Not used
20 – Horn negative
21 – Can bypass termination pin 34
22 – Belly Switch digital input
23 – Can High
24 – Not used
25 – 12V BDI output
26 – 5V output
27 – Not used
28 – Serial line transmission
29 – Serial line reception
30 – Not used
31 – Encoder phase A input
32 – Encoder phase B input
33 – Not used
34 – Can bypass termination pin 21
35 – Can Low

3
 DIAGNOSTICS AND MEASUREMENTS SERVICE

MENU
The main input and output signals can be measured in real time using the MONITOR function of the
programmer. 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.

MONITOR MENU

MONITOR MAIN MENU  System Controller Information

PARAMETER
TRUCK SERIES
Not used

MODEL
Controller model number

CONTROLLER SERIAL Nu
Controller serial number

CONTROLLER MFG DATE

Date of manufacture of the controller. The first two digits indicate the year, the last three digits indicate the day.

HARDWARE VERSION
Hardware version

OS VERSION
Latest version of the operating system installed

BUILD NUMBER
First version of the operating system installed

START MANAGER VERSION

Version of the Start Manager installed on the controller

PARAM BLOCK VERSION

Version of the Parameter Block installed on the controller

VCL APP VERSION

Version of the programming language software installed

VEHICLE SERIAL NUMBER

Not used

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

MONITOR MAIN MENU  Software Enabled Features

This submenu shows the activation status of the truck options (refer to “DESCRIPTION OF MODULE
PARAMETERS”, Electrical System section).
PARAMETER
BUZZER OPTION

CHARGER PRESENT

BEVERAGE TRUCK ENABLING

STEER REDUCTION OPTION

ADVANCES TURTLE OPTION

TURTLE ACTIVATION A

LIFT FUNCTION 0-NORM

PERFORMANCE MODE

MONITOR MAIN MENU  Charger Messages

PARAMETER
CHARGER STATE OF CHARGE
Shows the battery charger status

CHARGER ERROR CODES

Shows the battery charger status

CHARGER EVENTS
Shows the battery charger status

CHARGER HOURMETER
Shows the battery charger status

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

MONITOR MAIN MENU  Throttle Inputs

PARAMETER
RAW CAN THROTTLE
Numeric status level of traction control butterfly rotation

MAPPED CAN THROTTLE

Percentage status level of traction control butterfly rotation

RAW REDUNDANT THROTTLE

Not used

MAPPED REDUNDANT THROTTLE

Not used

MONITOR MAIN MENU  Tiller Switch Inputs

PARAMETER
NEUTRAL SWITCH
Traction control butterfly level: ON if in rest position

EMER REV SWITCH

Emergency reverse button selection

SNAIL SWITCH
"Snail" mode button selection

HORN SWITCH
Horn button selection

FORK LIFT SWITCH

Slow fork lifting button selection

FORK LOWER SWITCH

Slow fork lowering button selection

MAST LIFT SWITCH

Slow fork lifting button selection

MAST LOWER SWITCH

Forks lowering button selection

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

MONITOR MAIN MENU  Maintenance Timers

PARAMETER
TOTAL HOURS LEFT
Number of key-on operating hours remaining before servicing

TRACTION HOURS LEFT

Number of traction hours remaining before servicing

PUMP HOURS LEFT

Number of hydraulic pump operating hours remaining before servicing

MONITOR MAIN MENU  Inputs

PARAMETER
THROTTLE COMMAND
Angular displacement of the traction control butterfly

MAPPED THROTTLE
Angular displacement of the traction control butterfly evaluated after mapping

THROTTLE POT
Not used

BRAKE COMMAND
Not used

MAPPED BRAKE
Not used

POT2 RAW
Not used

MAPPED HYD THROTTLE

Not used

PUMP THROTTLE
Not used

PD THROTTLE
Not used

STEER POT
Not used

STEER ANGLE (DEG)

Not used

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

INTERLOCK
Tiller status level: ON during activation

EMER REV
Emergency direction reversal level: ON during direction reversal

ANALOG 1
Not used

ANALOG 2
Thermal sensor voltage sensor measured on input A8

SWITCH 1
Not used

SWITCH 2
Not used

SWITCH 3
Status level of the tiller measured on input A9

SWITCH 4
Not used

SWITCH 5
Optional steering sensor status level

SWITCH 6
Not used

SWITCH 7
Belly switch status level measured on input A22

SWITCH 8
Not used

DRIVER 1 INPUT
See the parameter main menu monitor / Outputs / Driver 1 PWM

DRIVER 2 INPUT
See the parameter main menu monitor / Outputs / Driver 2 PWM

DRIVER 3 INPUT
See the parameter main menu monitor / Outputs / Driver 3 PWM

DRIVER 4 INPUT
See the parameter main menu monitor / Outputs / Driver 4 PWM

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

PD INPUT
See the parameter main menu monitor / Outputs / PD PWM

DIGOUT6 INPUT
See the parameter main menu monitor / Outputs / Digital Out 6

DIGOUT7 INPUT
See the parameter main menu monitor / Outputs / Digital Out 7

SWITCH 16
Status level of the optional lifting block sensor on input A14

MONITOR MAIN MENU  Outputs

PARAMETER
ANALOG OUT
Not used

DIGITAL OUT 6
Not used

DIGITAL OUT 7
Status level of the horn control signal on output A20

DRIVER 1 PWM
Percentage level of main contactor coil control on output A6

DRIVER 2 PWM
Percentage level of electromagnetic brake control on output A5

DRIVER 3 PWM
Percentage level of hydraulic pump contactor coil control on output A4

DRIVER 4 PWM
Percentage level of forks down solenoid valve control on output A3

PD PWM
Percentage level of optional buzzer control on output A2

PUMP PWM
Percentage level of control on output A4

PD CURRENT
Current measured on output A2

PUMP CURRENT
Current measured on output A4

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

5 VOLTS
Voltage measured on output A26

12 VOLTS
Voltage measured on output A25

EXT SUPPLY CURRENT

Current measured on outputs A25 - A26

POT LOW
Not used

MONITOR MAIN MENU  Battery

PARAMETER
BDI
Battery charge level percentage

CAPACITOR VOLTAGE
Voltage at internal capacitor bank, measured at terminal B+ of the controller

KEY SWITCH VOLTAGE

Key switch voltage measured at input A1

INSULATION RESISTANCE
Not used

MONITOR MAIN MENU  Motor

PARAMETER
MOTOR RPM
Motor speed

TEMPERATURE
Motor temperature read by thermal sensor

MOTORSPEED A
Rpm of phase A of the motor encoder

MOTORSPEED B
Rpm of phase B of the motor encoder

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

MONITOR MAIN MENU  Controller

PARAMETER
CURRENT (RMS)
Controller current draw

MODULATION DEPTH
Voltage percentage applied to the motor

FREQUENCY
Rotation frequency applied to the motor

TEMPERATURE
Controller internal temperature

MAIN STATE
Main contactor status:
0 = open
1 = precharge
2 = soldering check
3 = closing delay
4 = check missing
5 = closed (with Main Enable parameter > ON)
6 = delay
7 = arc check
8 = opening delay
9 = error
10 = closed (with Main Enable parameter > OFF)

REGEN
ON during all phases of current regeneration

VCL ERROR MODULE

Software runtime error (code 68); information on the cause/s of the error are saved in the parameters VCL Error
Module and VCL Error.

VCL ERROR
Software runtime error (code 68); information on the cause/s of the error are saved in the parameters VCL Error
Module and VCL Error.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

MONITOR MAIN MENU  Cutbacks

PARAMETER
MOTOR TEMP CUTBACK
Percentage of cutback during motor temperature reduction stage

CONTROLLER TEMP CUTBACK

Percentage of cutback during controller temperature reduction stage

UNDERVOLTAGE CUTBACK
Percentage of cutback during under-voltage reduction stage

OVERVOLTAGE CUTBACK
Percentage of cutback during over-voltage reduction stage

MONITOR MAIN MENU  Vehicle

PARAMETER
VEHICLE SPEED
Speed of the truck

VEHICLE ODOMETER
Distance travelled in forward drive

VEHICLE ACCELERATION
Acceleration of the truck

TIME TO SPEED 1
Time required to reach 0 km/h from a speed value pre-defined in the software

TIME TO SPEED 2
Time required to reach 0 km/h from a speed value pre-defined in the software

TIME BETWEEN SPEEDS

Time taken to get from Speed ​1 to Speed ​​2

TIME TO DIST 1
Time taken to cover a pre-defined distance in the software

TIME TO DIST 2
Time taken to cover a pre-defined distance in the software

TIME TO DIST 3
Time taken to cover a pre-defined distance in the software

BRAKING DISTANCE CAPTURE

Distance travelled during all phases of the braking action

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

DISTANCE SINCE STOP

Total distance travelled by the truck, calculated as the sum of distances travelled in both directions. This value is
reset to zero each time the truck is stopped.

DISTANCE FINE
Net distance travelled by the truck calculated as the sum of the distances travelled in the direction the operator is
facing (positive value) and in the opposite direction (negative value).

MONITOR MAIN MENU  CAN Status

PARAMETER
CAN NODE ID
Displays the Can node of the controller

CONTROLLER TEMP CUTBACK

Displays the Can NMT status
0= initialization
4=stopped
5= operational
127=pre-operation

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

DTC CODE
The status codes inform the operator of any malfunctioning and incorrect use of the truck.
The status codes are numeric codes that indicate failure or malfunctioning. If, during operation, the truck
is used incorrectly or there is a fault, the key symbol will flash and the status code number will appear
on the LCD screen. If the numeric status code appears, the truck must be checked and repaired by an
authorized technician.
The causes of each status code are detailed in this manual. This manual also provides detailed
troubleshooting procedures for the following systems or nodes:
NODE 30: TRACTION CONTROLLER
NODE 60: TILLER CARD
NODE 12: BATTERY CHARGER
The error codes are composed of 5 digits: the first two digits indicate the affected node, the last three
indicate the number of the alarm.
Examples:
30001 – Lift Coil = Alarm Coil3 Open/Short on Combi controller
60058 – Snail = Snail redundant fault alarm on tiller board
12044 – Charger = Charger Fault alarm on optional battery charger

LED FLASHES
The module is equipped with a two-colour status LED (red and yellow) which, in the event of a fault, will
flash the corresponding error code. The red LED flashes once to indicate that the system is about to signal
first digit of the error code, then the yellow LED will emit the number of flashes corresponding to this first
digit. The red LED now flashes twice to indicate that the system is about to signal second digit of the error
code, then the yellow LED will emit the number of flashes corresponding to this second digit.

DTC CODE MDI TXT DTC TXT LED FLASHES

30001 LiftCoil Coil3 Open/short 33
30003 Lwr Coil Coil4 Open/short 34
Coil 1 open/short
30033 MainCoil 31
Main open/short
Coil2 open/short 32
30035 Brake Embrake Open/short 32
embrake failed to set 92
30037 AlrmCoil Coil7 Open/short 27
PD Open/short 35
30039 AlrmCoil
Coil6 Open/Short 26
Thumb Sw Throttle Wiper high 41
30052
Start Up Analog HPD fault 67
30060 Mtr Curr Controller overcurrent 12
30061 Mtr Open motor open 37
Encoder fault 36
30062 Encoder
Encoder LOS 93
30067 MainCont Main contactor welded 38
30068 MainCont Main contactor DNC 39
30069 PreCharg Precharge failed 14
OverHeat Motor temp hot cutback 28
30080
MtTmpSns Motor temp sensor do not display 29
30082 OverHeat overtemp cutback 22
30083 OverHeat Severe overtemp 16

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

DTC CODE MDI TXT DTC TXT LED FLASHES

Severe Undervoltage 17
30086 Low Batt Undervoltage Cutback 23
Severe Undervoltage Shutdown
Overvoltage 18
30087 OverVolt
Overvoltage Cutback 24
external supply out of range
30090 12&5Vout
5v supply failure 25
Current sensor fault 13
30099 CTRLLR
OS general 71
CAN Startup failure 51
30106 CAN Comm
PDO Timeout
HPD Sequencing fault 47
30201 Startup interlock fault 58
EMR HPD 47
30227 Stalled Stall detected 73
30231 Maintremnd Maintenance reminder
EEPROM Failure 46
30232 Software
VCL runtime error 68
Parameter change fault 49
30247 Parametr
motor characterization fault 87
30248 Low Temp Severe undertemp 15
EMR cutback shutdown
60050 EmerRev
Parity belly fault 59
60058 Snail Snail redundant fault 63
60099 CtrlCard Rema tiller fault 53
60210 EmerRev BB sequencing fault 61
60211 Start Up KSI Interlock SRO 62
12044 Charger Charger fault 54
12113 Charger Charger CAN fault 55
NA NA Supervisor fault 77

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

COMBI CONTROLLER ALARMS - Node 30

ALARM troubleshooting
DTC CODE MDI TXT • Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
30001 LiftCoil CAUSE A
Description: • Disconnect connectors TS11 and TS12 from the contactor coil and switch on
the truck.
The Combi controller has detected a • Measure the voltage between the connector TS11 and B(-). If the voltage is not
problem on the pump contactor coil. 24 ± 2.5 Vdc, check wire 239.
Possible causes: • Disconnect connector CPS01 from the Combi controller and measure resistance
between pin 4 and the connector TS11. If the resistance is > 1 ohm, check wire
A. Short circuit or open circuit in the W028.
coil wire harness • Measure the voltage between the connector TS12 and B(+) holding down the fork
B. Short circuit or open circuit in the lifting button. If the voltage is not 24 ± 2.5 Vdc, proceed with cause C.
coil windings CAUSE B
C. Combi controller faulty • Measure the resistance between the two contacts of the contactor coil; if the
resistance is not equal to 55 ± 5.25 ohms, replace the pump contactor.
CAUSE C
• If no trouble is found, replace the controller.

ALARM troubleshooting
DTC CODE MDI TXT •
Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
30003 LwrCoil CAUSE A
Description: • Disconnect the connector CRS05 from the down valve coil located on the hydraulic
pump and switch on the truck.
The Combi controller has detected • Measure the voltage between connector CRS05 pin 1 and B(-), if the voltage is
a problem on the fork down valve. not equal to 24 ± 2.5 Vdc, check wire W239-D.
Possible causes: • Disconnect the connector CPS01 from the Combi controller and measure the
resistance between CRS05 pin 2 and CPS01 pin 3; and if the resistance is > 1
A. Short circuit or open circuit in the ohm, check the wire W801.
coil wire harness • Measure the voltage between the connector CRS05 pin 2 and B(+) holding down
B. Short circuit or open circuit in the the fork lifting button. If the voltage is not 24 ± 2.5 Vdc, proceed with cause C.
coil windings CAUSE B
C. Combi controller faulty • Measure the resistance between the two contacts of the valve coil; if the resistance
is not equal to 19 ± 2.0 ohms, replace the down valve coil.
CAUSE C
• If no trouble is found, replace the controller.

ALARM troubleshooting
DTC CODE MDI TXT
• Carry out a visual inspection of all the connectors paired with the error code.
30033 MainCoil Restart the truck and check whether the error code is still present.
Description: CAUSE A
The Combi controller has detected • With the key switch set to ON, disconnect the connector TS07 from the coil and
contactor TS07 and B(-); if the voltage 24 ± 2.5 Vdc, check wire W239-B.
a problem in the main contactor coil.
• With the key switch set to OFF, disconnect the connector CPS01 from the Combi
Possible causes: controller and the connector TS08 (negative) of the contactor coil. Measure the
resistance between the connector TS08 and CPS01 pin 6; if the resistance > 1
A. Short circuit or open circuit in the Ohm, check wire 075.
coil wire harness
CAUSE B
B. Short circuit or open circuit in the • With the key OFF, measure the resistance between the contacts of the main con-
coil windings tactor coil; if the resistance is not equal to 30 ± 3 ohms, replace the main contactor.
C. Combi controller faulty CAUSE C
• If no trouble is found, replace the Combi controller.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
DTC CODE MDI TXT
• Carry out a visual inspection of all the connectors paired with the error code.
30035 Brake Restart the truck and check whether the error code is still present.
CAUSE A
Description:
• With the key in the ON position, disconnect the connector CPS01 from the Combi
The Combi controller has detected controller and measure the voltage between pin 1 of the connector CPS01 and
a problem in the electromagnetic B (-). Note the value of the voltage, reconnect the connector CPS01, switch
brake coil. the truck off and back on again. Disconnect the connector CRP04-A from the
electromagnetic brake and measure the voltage between pin 1 of the connector
Possible causes: CRP04-A and B (-). If the two voltages measured are not equal, check wire 239.
A. Short circuit or open circuit in the CAUSE B
coil wire harness • Measure the resistance between pin 1 and pin 2 of connector CRP04-A; if the
resistance is not equal to 23 ± 2.3 ohms, replace the brake coil.
B. Short circuit or open circuit in the CAUSE C
coil windings
• If no trouble is found, replace the Combi controller.
C. Combi controller faulty

ALARM troubleshooting
DTC CODE MDI TXT • Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
30037 AlrmCoil CAUSE A
Description: • With the key in the ON position, disconnect the connector TS09 and measure
the voltage between TS09 and B(-). If the voltage is not equal to 24 ± 2.5 Vdc,
The Combi controller has detected
check wire 239.
an issue with the electronic horn.
• Disconnect the connector CPS01 from the Combi controller. Measure the resistance
Possible causes: between pin 20 of the connector CPS01 and connector TS09. If the resistance is > 1 ohm,
A. Short circuit or open circuit in the check wire 045.
horn wiring harness. CAUSE B
B. Internal fault in the horn. • With the key in the ON position and holding down the horn button, measure the con-
tinuity between the connector TS09 and B(-); if there is continuity, replace the horn.
C. Combi controller faulty
CAUSE C
• If no trouble is found, replace the controller.

ALARM troubleshooting
DTC CODE MDI TXT
• Carry out a visual inspection of all the connectors paired with the error
30039 MainCoil code. Restart the truck and check whether the error code is still present.
CAUSE A
Description: • With the key in the ON position, disconnect the connector CPS13 from
The Combi controller has detected the optional buzzer and measure the voltage between pin 1 and B (-). If
the voltage is not equal to 24 ± 2.5 Vdc, check wire 010.
an issue with the optional buzzer. • Disconnect the connector CPS01 from the Combi controller. Measure the
resistance between pin 2 of the connector CPS01 and pin 2 of connector
Possible causes: CPS13. If the resistance is > 1 ohm, check wire 728.
A. Short circuit or open circuit in the CAUSE B
optional buzzer wiring harness. • With the key in the ON position and the optional buzzer working, measure
the continuity between pin 2 of the connector CPS13 and B(-); if there is
B. Internal fault in the optional buzzer. continuity, replace the optional buzzer.
C. Combi controller faulty CAUSE C
• If no problem is found, replace the Combi controller.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
DTC CODE MDI TXT
30052 Thumb Sw,
Start Up •
Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
Description: CAUSE A
Voltage on pin 16 of the Combi Con- • Perform the correct ignition and start-up procedure.
troller too high. CAUSE B
Possible causes: • Check for a short circuit on pin 16 of the connector CPS01.
A. Incorrect start-up sequence. CAUSE C
• If no trouble is found, replace the Combi controller.
B. Short circuit on pin 16 of the con-
nector CPS01.
C. Internal fault in the Combi controller

ALARM troubleshooting
DTC CODE MDI TXT • Check the condition of the battery and its state of charge.
• Carry out a visual inspection of all the connectors paired with the error code.
30060 Mtr Curr Restart the truck and check whether the error code is still present.
Description: CAUSE A
The Combi controller has detected • Check the three phases are correctly tightened on the traction motor and Combi
controller.
overcurrent on one of the phases of
• Check the wire harness continuity.
the traction motor.
CAUSE B
Possible causes: • Check whether there is continuity between phases U and V of the traction motor.
A. External short circuit on connec- If there is not, then replace the traction motor.
tions of phases U, V or W to the • Check whether there is continuity between phases U and W of the traction motor.
motor If there is not, then replace the traction motor.
• Check whether there is continuity between phases W and V of the traction motor.
B. Internal fault in the motor If there is not, then replace the traction motor.
C. Combi controller faulty CAUSE C
• If no trouble is found, replace the Combi controller

ALARM troubleshooting
DTC CODE MDI TXT •
Check the condition of the battery and its state of charge.
•
Carry out a visual inspection of all the connectors paired with the error code.
30061 Mtr Open Restart the truck and check whether the error code is still present.
Description: CAUSE A
The Combi controller has detected • Check the three phases are correctly tightened on the traction motor and Combi
controller.
an open circuit on one of the phases
• Check the wire harness continuity.
of the motor.
CAUSE B
Possible causes: • Check whether there is continuity between phases U and V of the traction motor.
A. Open circuit on connections of If there is not, then replace the traction motor.
phases U, V or W to the motor • Check whether there is continuity between phases U and W of the traction motor.
If there is not, then replace the traction motor.
B. Internal fault in the motor
• Check whether there is continuity between phases W and V of the traction motor.
C. Combi controller faulty If there is not, then replace the traction motor.
CAUSE C
• If no trouble is found, replace the Combi controller.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
DTC CODE MDI TXT •Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
30062 Encoder CAUSE A
Description: • Disconnect the connector CPS03 of the traction motor encoder and measure the
voltage between pin 1 and B(-). If the voltage is not equal to 5 ± 0.5 Vdc, check
The Combi controller has detected wire 250.
a problem with the encoder of the • Measure the voltage between pin 1 and pin 4 of encoder connector CPS03; if the
traction motor. voltage is not equal to 5 ± 0.5 Vdc, check the continuity of wire 102.
• Disconnect the connector CPS01 from the Combi controller and measure the re-
Possible causes: sistance between pin 32 of the connector CPS01 and pin 3 of connector CPS03.
A. Short circuit or open circuit in the If the resistance is > 1 ohm, check wire 578.
motor encoder wiring harness • Measure the resistance between pin 31 of the connector CPS01 and pin 2 of
B. Internal problem in the encoder. connector CPS03; if the resistance is > 1 ohm, check wire 577.
CAUSE B
C. Combi controller faulty
• With the battery connected and the traction motor running, compare
the Motor>MotorSpeed A and Motor>MotorSpeedB parameters with the
Controller>Frequency parameter to check the state of the encoder.
CAUSE C
• If no trouble is found, replace the Combi controller

ALARM troubleshooting
DTC CODE MDI TXT
• Carry out a visual inspection of all the connectors paired with the error code.
30067 MainCont Restart the truck and check whether the error code is still present.
Description: CAUSE A
• With the key switch in the ON position, disconnect the connector TS07 from the
The Combi controller has detected main contactor coil and measure the voltage between TS07 and B(-); if the voltage
that the main contactor is jammed is not 24 ± 2.5 Vdc, check wire 239.
closed or its contacts are soldered. • Disconnect the connector CPS01 from the Combi controller and the connector
TS08 from the main contactor coil. Measure the continuity between TS08 and pin
Possible causes: 6 of the controller CPS01. If there is no continuity, check wire 075.
A. Short circuit or open circuit in the CAUSE B
main contactor coil wiring harness. • With the key in the OFF position, measure the voltage B(+) and B(-) on the Combi
B. Main contactor contacts soldered. controller, if the voltage is 24 ± 2.5 Vdc, replace the main contactor.
C. Combi controller faulty CAUSE C
• If no trouble is found, replace the controller.

ALARM troubleshooting
DTC CODE MDI TXT
30068 MainCont • Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
Description: CAUSE A
The controller has detected that the • With the key switch in the ON position, disconnect the connector TS07 from the
main contactor is not closed or is main contactor coil and measure the voltage between TS07 and B(-); if the voltage
jammed open. is not 24 ± 2.5 Vdc, check wire 239.
• Disconnect the connector CPS01 from the Combi controller and the connector
Possible causes: TS08 from the main contactor coil. Measure the continuity between TS08 and pin
A. Short circuit or open circuit in the 6 of the controller CPS01. If there is no continuity, check wire 075.
main contactor coil wiring harness. CAUSE B
• With the tiller in its working position, measure the voltage between terminals B(+)
B. Contactor contacts blocked. and B(-) on the Combi controller. Press the Snail button while measuring the volta-
C. Combi controller faulty ge. If no voltage is measured between B(+) and B(-), replace the main contactor.
CAUSE C
• If no trouble is found, replace the controller.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
DTC CODE MDI TXT
•
Carry out a visual inspection of all the connectors paired with the error code.
30069 PreCharge Restart the truck and check whether the error code is still present.
CAUSE A
Description: • Repair or replace the connector or the wire harness paired with the error code.
The Combi controller has detected CAUSE B
an error in charging the capacitor • Disconnect the battery and discharge the capacitor. Reconnect the battery, if
bank. the alarm is still present, check the capacitor voltage and battery voltage on the
Monitor menu. If the voltage of the capacitor and battery are equal, check the
Possible causes: battery charge status.
A- Problem with the Combi controller • If the voltage of the capacitor and battery are not equal, measure the voltage
connections between the terminal of the traction controller B(+) and B(-); if the pre-charge vol-
tage is identical to the battery voltage, check for external charges or short circuits.
B- Combi controller faulty

ALARM troubleshooting
DTC CODE MDI TXT
• Carry out a visual inspection of all the connectors paired with the error code.
30080 OverHeat, Restart the truck and check whether the error code is still present.
MtTempSns CAUSE A
Description: • Repair or replace the connector or the wire harness paired with the error code.
• Reduce truck use and allow the controller to cool for at least 15 minutes. The
The motor temperature has reached
system restarts on reaching temperatures below 115°C for the traction motor
or exceeded the threshold tempe- and 85°C for the traction controller. If the error does not reoccur, we suggest you
rature reread the information on truck use and load capacity.
• If the alarm persists, disconnect the connectors CPS01 and CPS02. Measure the
Possible causes:
resistance between pin 8 of CPS01 and pin 1 of CPS02. If the resistance is > 1
A. Short circuit or open circuit in the ohm, check the continuity of wire 367.
traction motor temperature sensor • Measure the resistance between pin 2 of the connector CPS02 and terminal B(-) on
wiring harness. the Combi controller. If the resistance is > 1 ohm, check the continuity of wire 101.
B. Combi controller faulty CAUSE B
• If no trouble is found, replace the controller.

ALARM troubleshooting
DTC CODE MDI TXT
30082 OverHeat •
Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
Description:
CAUSE A
: The Combi controller is operating in • Return the temperature to below the maximum limit of 85°C, release all the tiller
high temperature conditions (above controls, remove all loads from the truck, switch off the truck, wait a few minutes,
85°C) then switch it on again. Check the load handled and reduce truck use. See whether
the error code reappears.
Possible causes: CAUSE B
A. Truck overloaded. • Check that the module is installed correctly.
B. Combi controller incorrectly in- CAUSE C
stalled. • If no trouble is found, replace the controller.
C. Combi controller faulty

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
DTC CODE MDI TXT
•
Carry out a visual inspection of all the connectors paired with the error code.
30083 OverHeat Restart the truck and check whether the error code is still present.
CAUSE A
Description:
• Return the temperature to below the maximum limit of 95°C, release all the tiller
The Combi controller is operating controls, remove all loads from the truck, switch off the truck, wait a few minutes,
in too high temperature conditions then switch it on again. Check the load handled and reduce truck use. See whether
(above 95°C) the error code reappears.
CAUSE B
Possible causes:
• Check that the module is installed correctly.
A. Truck overloaded. CAUSE C
B. Combi controller incorrectly in- • If no trouble is found, replace the controller.
stalled.
C. Combi controller faulty

ALARM troubleshooting
DTC CODE MDI TXT
30086 Low Batt
• Carry out a visual inspection of all the connectors paired with the error code.
Description: Restart the truck and check whether the error code is still present.
CAUSE A
The Combi controller has detected
a low voltage condition on the bank • Repair or replace the connector or the wire harness paired with the error code
of capacitors • Measure the voltage between B(-) and B(+); if the voltage is not equal to 25 ± 0.5
Vdc, charge the battery.
Possible causes: CAUSE B
A. Low battery charge, battery resi- • Measure the voltage between terminal B(+) and B(-) of the Combi controller, if the
stance too high. pre-charge voltage is not equal to the battery voltage, check the cable B(+). Check
the cable continuity, check the tightening of the connector on the controller. Check
B. Error in the Combi controller wire the state of the fuses FU1 and FU2. Check the main contactor works properly.
harness. CAUSE C
C. Combi controller faulty • If no trouble is found, replace the controller.

ALARM troubleshooting
DTC CODE MDI TXT
• Carry out a visual inspection of all the connectors paired with the error code.
30087 OverVolt Restart the truck and check whether the error code is still present.
Description: CAUSE A
The Combi controller has detected • Repair or replace the connector or the wire harness paired with the error code
a high voltage condition on the bank • Measure the voltage between terminals B(-) and B(+) of the Combi controller; if
the voltage is higher than 26Vdc, check that the battery voltage is 24V and that
of capacitors
it is correctly connected to the truck.
Possible causes: CAUSE B
A. Voltage on the Combi controller • Measure the voltage between terminal B(+) and B(-) of the Combi controller, if
terminals too high. the pre-charge voltage is not equal to the battery voltage, check the cable B(+).
Check the cable continuity, check the tightening of the connector on the controller.
B. Error in the Combi controller wire Check the state of the fuses FU1 and FU2.
harness. CAUSE C
C. Combi controller faulty • If no trouble is found, replace the Combi controller.

21
 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
DTC CODE MDI TXT •Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
30090 12&5Volt CAUSE A
Description: • With the key in the ON position, disconnect the connector CRS07 from the MDI
display: switch the truck off and on. If the alarm is no longer present continue
The traction controller has detected with Cause B.
a fault in the 5/12 Volt output power • With the key in the ON position, disconnect the connector CPS03 from the trac-
supply. tion motor encoder: switch the truck off and on. If the alarm is no longer present
continue with Cause C.
Possible causes: • If the alarm persists, measure the supply voltages of the encoder and MDI on the
A. Fault in the wiring harnesses Combi controller referring to the wiring diagram.
B. Fault in the MDI display CAUSE B
C. Fault in the traction motor encoder • If the fault disappears on disconnecting the MDI display and reappears on recon-
necting it, replace the MDI display module.
D. Combi controller faulty CAUSE C
• If the fault disappears on disconnecting the traction motor encoder and reappears
on reconnecting it, replace the encoder sensor.
CAUSE D
• If no trouble is found, replace the Combi controller.

ALARM troubleshooting
DTC CODE MDI TXT
30099 CTRLLR
• Carry out a visual inspection of all the connectors paired with the error code.
Description: Restart the truck and check whether the error code is still present.
The Combi controller has detected CAUSE A
an issue with the values of the trac- • Check the wire harnesses of the traction motor phases: check for a short-circuit
tion motor currents. or low impedance on the phases U, V and W.
• Check the motor parameters are correct.
Possible causes: CAUSE B
A. Current leakage from phases U, • If no fault is found in the wiring or the parameters but the alarm persists, then the
V or W to the truck chassis (short problem lies in the module.
circuit of motor stator)
B. Combi controller faulty.

ALARM troubleshooting
DTC CODE MDI TXT
30106 CAN Comm
Description:
The tiller board fails to communi-
cate with the Combi controller via • Carry out a visual inspection of all the connectors paired with the error code.
CANbus. Restart the truck and check whether the error code is still present.
Possible causes: • Check the wiring harness between the Combi controller (pin 23 and pin 35) and
the tiller board (CRS 18 connector pin 4 and pin 3).
A. CANbus communication error – no • Check that the connectors are clean.
reception of the message via CAN
B. Error in the tiller board wiring har-
ness – short circuit or open circuit
on pins 23 and 35 of the Combi
controller.

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
DTC CODE MDI TXT
30201 Startup •
Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
Description:
CAUSE A
Incorrect start-up and firing sequen- • Follow the correct start up sequence
ce.
CAUSE B
Possible causes: • Check the tiller wiring and the electrical panel wiring
A. Incorrect start up sequence • Check condition of pushbutton connectors, clean if necessary.
B. Wiring or connectors or pushbut- • Check that all the tiller controls have been released.
tons damaged

ALARM troubleshooting
DTC CODE MDI TXT
• Make sure there is nothing obstructing the transmission and the wheels.
30227 Stalled • Carry out a visual inspection of all the connectors paired with the fault code. Restart
Description: the truck and check whether the error code is still present.
• Make sure the electromagnetic brake is raised when a request is made for traction
The Combi controller has detected and that it lets the motor turn freely.
the traction motor is stalled.
•
Possible causes: CAUSE A
A. Encoder wiring harness damaged • Check the encoder connections: check the continuity of wires 250, 577, 578 and
102. Check the condition of the connector CPS03.
B. Motor encoder damaged
CAUSE B
C. Traction motor faulty • With the battery connected and the traction motor running, compare
D. Combi controller faulty the Motor>MotorSpeed A and Motor>MotorSpeedB parameters with the
Controller>Frequency parameter to check the state of the encoder.
CAUSE C
• Check continuity of the 3 traction motor phases. If two phases do not have con-
tinuity, replace the traction motor.
CAUSE D
• If no trouble is found, replace the Combi controller.

ALARM troubleshooting
DTC CODE MDI TXT
30231 Maintremnd
Description:
Warning that you need to perform • Perform regular maintenance.
regular maintenance. • Reset the regular maintenance counters.

Possible causes:
A. Time interval until regular mainte-
nance is due.

23
 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
DTC CODE MDI TXT
30232 Software
Description: • If this error occurs after editing parameters or installing new software, restore
The Combi controller has detected a conditions existing prior to the error.
problem with the controller software • Download and install the correct software; use the standard parameter configu-
or parameter settings. ration.
• Switch the truck off and then back on.
Possible causes:
• If no fault is found and the alarm persists, then the problem lies in the module
A. Incorrect installation of new softwa-
re
B- Incorrect changes to the configu-
ration of the parameters

ALARM troubleshooting
DTC CODE MDI TXT
30247 Parameter
Description:
The Combi controller has detected • Switch the truck off and on: check whether the error is still present.
a fault in the configuration of the • Restore the original configuration of the parameters.
parameters
Possible causes:
A. Incorrect configuration of the pa-
rameters

ALARM troubleshooting
DTC CODE MDI TXT
30248 Low Temp
Description:
CAUSE A
The Combi controller is operating in • Bring the
the temperature
temperature to toabove
abovethethelower
lowerlimit
limitofof
-30°C,
valuerelease
-30°C, all
release
tiller controls,
all tiller
low temperature conditions (below turn off and
controls, turnrestart
off and
therestart
truck.the truck.
-30°C). CAUSE B
Possible causes: • If no fault is found and the alarm persists, then the problem lies in the module.

A. Operating temperature too low

B. Fault with the temperature sensor
in the controller

24
 DIAGNOSTICS AND MEASUREMENTS SERVICE

TILLER BOARD ALARMS - Node 60

ALARM troubleshooting
DTC CODE MDI TXT
60050 EmerRev
Description:
The tiller board has detected an
incorrect start-up sequence or a • Release all the tiller controls
problem with the belly switch. • Check that the Belly button is released
• Switch the truck off and on: check whether the problem is still present.
Possible causes:
A. Incorrect start-up sequence
B- After an emergency reversing
manoeuvre, some of the inputs
may not have returned to neutral
position.

ALARM troubleshooting
DTC CODE MDI TXT
60058 Snail
Description: • Carry out a visual inspection of all the connectors paired with the error code.
The tiller board sends the Snail but- Restart the truck and check whether the error code is still present.
ton signal via Can but the signal is CAUSE A
not present on pin 7 of connector X1 • Check the continuity of the wire from pin 7 of connector X1.
of the tiller board. CAUSE B
• Check for 24 V on pin 7 of connector X1 when the Snail button is active.
Possible causes:
A. Fault in the wiring harness of the
signal on pin 7 of connector X1.
B. Tiller board faulty

ALARM troubleshooting
DTC CODE MDI TXT
60099 CtrlCard • Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
Description: • Check that all the tiller controls are released.
Issue with the tiller board • Switch the truck off and on and check whether the problem is still present.
Possible causes:
A. Tiller board faulty

ALARM troubleshooting
DTC CODE MDI TXT
60210 EmerRev
CAUSE A
Description:
• Release all the tiller controls. Do not activate the Belly button with the tiller in the
The tiller board has detected the rest position.
Belly button is active with the tiller in CAUSE B
the rest position. • Check the operation of the Belly button.
Possible causes:
A- Incorrect start-up sequence
B- Belly switch shorted.

25
 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
DTC CODE MDI TXT
60211 Start Up •
Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
Description:
CAUSE A
The tiller board has detected an error • Perform the correct truck start-up procedure. Do not switch on the truck with the
in the truck start-up phase. tiller in the operating position.
Possible causes: CAUSE B
• Check the state of the tiller sensor.
A. Switching on the truck with the tiller
in the operating position
B. Tiller sensor short circuited

ALARM troubleshooting
SUPERVISOR FAULT
No.of flashes 77
Description:
• Carry out a visual inspection of all the connectors paired with the error code.
The controller has detected a lack Restart the truck and check whether the error code is still present.
of correspondence in the redundant • Check with the tester the correct voltages at the inputs of the switches of the
readings of the Master and Slave controller.
microprocessors. • Test for and eliminate any remove the stray and leakage voltages.
Possible causes:
A. Internal fault of the controller
B. Voltages at the inputs outside limits

26
 DIAGNOSTICS AND MEASUREMENTS SERVICE

If the truck is equipped with MIDAC lithium battery, the following alarms may appear:

CODE
ALARM Cause effect
MDI
This alarm is generated
Traction is reduced in accordance with the
CHARGE if the parameter HYG LI-ION
NA parameter BMS RED. SPEED and the
BRYT BATT is set to ON, but the BMS activates
pump lifting function is inhibited.
limited performance mode
This alarm is generated
CAN BUS KO BMS NOK if the parameter HYG LI-ION After 15 seconds, traction and pump
BMS 30108 BATT is set to ON, but no are stopped.
communication is received from the BMS
The battery has detected an anomaly
and consequently the need to open the
contactor to power off the truck.
This alarm is generated 15 seconds after
BMS TRUCK BMS TI
activation of the WARNING INHIBIT or Traction and pump stopped
INHIBIT 30109
following a traction/pump/steering request
is received when the battery charging
connector cap is open or the battery is
connected to the battery charger (1).

Battery charge level (SoC)<= 0 %

After 15 seconds, traction and pump
BMS ALARM NA Charging connector cap open(1)
are stopped.

BMS
The BMS disables the battery's internal
SHUTDOWN NA Traction and pump stopped
contactor
(only fault log)

This alarm is generated

BMS
BMS if the parameter HYG LI-ION
MSM Traction and pump stopped
MISMATCH BATT is set to OFF, but messages are re-
30107
ceived from the BMS
The connector of the battery charger is
connected to the battery.
CHARGE
NA Battery charge socket cap open with truck Traction and pump stopped
STATUS
stationary and no requests from operator
(1)
.

27
 DIAGNOSTICS AND MEASUREMENTS SERVICE

ELECTRICAL COMPONENT MEASUREMENTS

SOLENOID VALVE COILS

Ref. Solenoid valve Value measured (Ohm)

1 Q1 27

ELECTROMAGNETIC BRAKE COILS

Drive wheel electroma-

gnetic brake

Coil Value measured (Ohm)

Electromagnetic
24
brake

28
 DIAGNOSTICS AND MEASUREMENTS SERVICE

MOTORS
To measure the motor insulation resistance, disconnect the phase wires (U, V, W). Connect one of the te-
ster probes to the U phase and the other probe to the bodywork. The resistance reading ( ) on the tester
should be infinity ( ). If not, the motor is not insulated and the module connected to the motor in question
will diagnose the alarm "capacitor charge".
Repeat the operation with the other two phases (V, W).

29
 ELECTRICAL SYSTEM SERVICE

ELECTRICAL SYSTEM
WIRING DIAGRAMS.........................................................................3
ELECTRICAL COMPONENTS..................................................................7
K E Y T O E L E C T R I C A L C O M P O N E N T S .............................................................................7
TILLER BOARD.....................................................................................................9
C O N T R O L S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
K E Y TO T I L L E R C O N T R O L S A N D M A I N PA N E L.................................................................11
DISPLAY (BATTERY CHARGE STATUS INDICATOR)....................................................................13
O P T I O N A L K E Y PA D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7
INSTRUCTIONS FOR USE OF THE NEW KEYPAD APPLICATION..................................................20
T R U C K F U N C T I O N S ......................................................................................................24
F O RWA R D/R E V E R S E T R A C T I O N...........................................................................................24
A C T U AT I O N C O N T R O L S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4
C O N F I G U R AT I O N PA R A M E T E R S .....................................................................................25
S P E E D A N D A C C E L E R AT I O N .....................................................................25
SPEED REDUCTION AND TRACTION LOCKOUT.............................................................................25
MODE SELECTION...........................................................................................................................25
B R A K I N G....................................................................................................................26
EMERGENCY REVERSE MANOEUVRE....................................................................26
SNAIL FUNCTION............................................................................27
CONTROLS....................................................................................28
A C T U AT I O N C O N T R O L S..........................................................................................................28
SPEED REDUCTION OPTION.......................................................................................................................28
SPEED REDUCTION WITH STEERED DRIVE WHEEL............................................................................28
FORKS RAISING/LOWERING....................................................................29
C O N F I G U R AT I O N PA R A M E T E R S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9
L I F T I N G L O C K O U T W I T H L O W B A T T E R Y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0
T I M E D L I F T I N G L O C K O U T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0
D E C E L E R AT I O N A P P R O A C H I N G F O R K R A I S I N G / L O W E R I N G L I M I T S . . . . . . . . . . . . . . . . . . 3 0
LIFTING WITH INTELLIGENT LIFT OPTION.............................................................................................30
A L A R M D I S P L AY P R O C E D U R E............................................................................................31
STANDARD MODULE CONFIGURATION PARAMETERS............................................................................31
DESCRIPTION OF MODULE PARAMETERS....................................................................................................................35
MODULO: INTRODUCTION.......................................................................................................................................42
REPLACEMENT OF THE MODULE........................................................................44
I N S TA L L AT I O N O F E L E C T R I C A L C O M P O N E N T S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 8
REPLACEMENT OF THE MAIN EMERGENCY SWITCH.........................................48
R E P L A C E M E N T O F T H E D I S P L AY......................................................................................49
REPLACEMENT OF THE KEYSWITCH...........................................................................................................50
REPLACEMENT OF THE HORN...............................................................................................................51
FUSE REPLACEMENT..........................................................................................................................................52
REPLACEMENT OF THE TILLER BOARD..........................................................................................................................53
REPLACEMENT OF THE TILLER BUTTONS.......................................................................................................................54
REPLACEMENT OF THE TILLER CONTROL SPRINGS.....................................................................................55
REMOVAL OF THE BATTERY CHARGER..............................................................................................................63

1
 ELECTRICAL SYSTEM SERVICE

2
SERVICE ELECTRICAL SYSTEM

(sheet 1/4)
SERVICE ELECTRICAL SYSTEM

(sheet 2/4)
SERVICE ELECTRICAL SYSTEM

(sheet 3/4)
SERVICE ELECTRICAL SYSTEM

(sheet 4/4)
 ELECTRICAL SYSTEM SERVICE

ELECTRICAL COMPONENTS
IDENTIFICATION OF ELECTRICAL COMPONENTS

Ref. Description

1 Battery charge level indicator (display)

2 Power fuse - 175 A
3 Key switch
4 Electronic control
5 Electromagnetic brake
6 Traction motor
7 Pump motor
8 Pump contactor
9 Horn
10 Battery charger socket (optional)
11 Battery charger (optional)

7
 ELECTRICAL SYSTEM SERVICE

9 1 2

10

8
3

4
5

11

8
 ELECTRICAL SYSTEM SERVICE

TILLER BOARD

Ref. Description

1 Rapid reverse microswitch

2 Enabling microswitch for slow travel with tiller vertical
3 Tiller control cable connection connector
4 Connector not used
5 Connector not used
6 Lifting ON/OFF button connector
7 Lowering ON/OFF button connector
8 Lifting ON/OFF button connector
9 Lowering ON/OFF button connector
10 Connector not used
11 Connector not used
12 Connector not used
13 Connector not used
14 Horn microswitch

9
 ELECTRICAL SYSTEM SERVICE

14
13

12

11

10

4 3

10
 ELECTRICAL SYSTEM SERVICE

CONTROLS
KEY TO TILLER CONTROLS AND MAIN PANEL

4 5 5 4

2
3

11
 ELECTRICAL SYSTEM SERVICE

9
10

Ref. Description

1 Rapid reverse button

2 Horn button
3 Forward/reverse traction control throttle
4 Fork lowering button
5 Fork lifting button
6 Slow travel enabling button with tiller in rest position
7 Emergency button
8 MDI
9 Key switch
10 Keypad (optional)

12
 ELECTRICAL SYSTEM SERVICE

DISPLAY (BATTERY CHARGE STATUS INDICATOR) before July 2018

Refer to the Parts Manual for the correct break serial number

2 3 4

Ref. Description

1 Total worked hours and alarms indicator

2 Green LED - hour meter ON
3 Yellow LED - battery low
4 Red LED - alarm and maintenance indicator

When starting the truck (key-on) the MDI performs a number of tests, and each element will illuminate
for one second. On completion of the tests, the display will show the total truck operating hours for a few
seconds, followed by the battery charge status. The green operating LED will illuminate.

13
 ELECTRICAL SYSTEM SERVICE

When the tiller is lowered or a traction command is given, the total number of traction hours are displayed
for a few seconds.

When a lifting or lowering command is given, the total operating hours of the truck pump appear on the
display for a few seconds.

BATTERY CHARGE STATUS INDICATOR

The battery charge status is indicated on the display.
When the battery charge state reaches 20% the fork lifting is inhibited.
The "battery low" indicator LED illuminates.
To reset the low battery charge indicator, recharge the battery. When
the charge level reaches 75%% the "battery low" indicator it resets and
fork lifting is enabled.

ALARMS AND MAINTENANCE INDICATOR

The MDI provides an indication of the truck alarm status. When an alarm
signal is generated, the red LED will start flashing.
The display shows the error code that generated the alarm identified
by a number (see “DIAGNOSTICS” section).

On reaching the number of hours of operation after which maintenance

is required, the red LED lights up. After carrying out the necessary
maintenance, reset the parameters MAIN MENU PROGRAM / display
functions / maintenance timers / reset total maintenance - reset trac-
tion maintenance - reset pump maintenance (see “DESCRIPTION OF
MODULE PARAMETERS”).

14
 ELECTRICAL SYSTEM SERVICE

DISPLAY (BATTERY CHARGE STATUS INDICATOR) after July 2018

Refer to the Parts Manual for the correct break serial number

2 3 4

Ref. Description

1 Total worked hours and alarms indicator

The green LED illuminates to indicate that the MDI is powered up and the
2
truck is switched on
The yellow LED illuminates to indicate that the battery charge is low.
3 The yellow LED flashes to signal a "Warning" or that a particular function is
active
The red LED illuminates to indicate that the truck requires servicing.
4
The red LED flashes to indicate the presence of an alarm.

15
 ELECTRICAL SYSTEM SERVICE

The display backlight can be turned on or off by setting the service parameter “MDI Backlight Enable”
accordingly.

The connection is only possible via PC and PCST software.

If the COMBI controller is replaced, when the truck is powered on, the number of saved in the two components
(COMBI and MDI) are automatically compared.
If the number of hours in the new COMBI controller are less than 100 and the hours saved in the MDI are
greater than 100, the display will show the message “HM COPY” and hour meters for the truck, traction
and pump will be copied from the MDI to the new controller.
Do not switch off the controller if the message HM COPY is shown on the display.

When the truck is powered on, the MDI will display the following information in sequence:

TOTAL TRUCK HOURS TRACTION HOURS PUMP HOURS

HOURS BEFORE NEXT SCHEDULED

SERVICE TRACTION MODE

ALARMS AND MAINTENANCE INDICATOR

The MDI provides an indication of the truck alarm status. When an alarm
is generated, the red LED starts to flash and the message "DTC" appears
on the first line of the display, with the alarm code and wrench symbol on
the second line.

16
 ELECTRICAL SYSTEM SERVICE

OPTIONAL KEYPAD after July 2018

Refer to the Service Bulletin FF145R01 and the Parts Manual for the correct break serial number

The new keypad has two operating modes:

• Supervisor Mode
• User Mode
When the emergency button is pressed, the keypad is activated: the RED and GREEN LEDs flash once.
When the RED LED is illuminated, it is possible to enter the password. All passwords must consist of 5
characters; up to 99 different access codes can be entered.

SUPERVISOR MODE

SUPERVISOR LOGIN
• Enter the supervisor password (the default password is 01982).
• Characters entered by mistake can be deleted by pressing “O”.
• Press “I” to confirm the password.
• When the RED and GREEN LEDs flash 3 times, this indicates that the password has been accepted,
while an incorrect password is signalled by a single flash of the RED LED.
• Both LEDS (red and green) are extinguished
• To exit supervisor mode, press “O” for at least 2 seconds.

SUPERVISOR MENU INDEX

When you log in as a supervisor and the password is accepted, use the numerical keypad to access the
following menus:
MENU 1: add user
MENU 2: edit supervisor password
MENU 3: edit user password
MENU 4: block/unblock user
MENU 5: reset factory values
MENU 6: auto power off function

MENU 1: add user

• Press “1” to access the menu. The RED LED will flash once. Both LEDs (RED and GREEN) are
extinguished.
• Enter a new user password (5 characters) and press “I”. If the RED and GREEN LEDs flash once, this
indicates that the operation was successful. The keypad automatically returns to the supervisor menu
index. If the RED LED flashes once, this means that there was an error in the procedure or that the
password entered has already been used.

MENU 2: edit supervisor password

• Press “2” to access the menu. The RED LED flashes twice. Both LEDs (RED and GREEN) are
extinguished.
• Enter a new supervisor password and press “I”. If the RED and GREEN LEDs flash once, this indicates
that the operation was successful. The keypad automatically returns to the supervisor menu index. If
the RED LED flashes once, this means that there was an error in the procedure or that the password
entered has already been used.

17
 ELECTRICAL SYSTEM SERVICE

MENU 3: edit user password

• Press “3” to access the menu. The RED LED flashes three times. The flashes of the LEDs indicate the
user ID: the flashes of the red LED indicate the tens, while the flashes of the green LED indicate the
units. For example, 2 flashes of the red LED and 3 flashes of the green LED indicate user #23. Press
“2” to scroll up and “8” to scroll down through the list of user IDs.
• Press “I” to select the user ID for which you wish to edit the password. The RED and GREEN LEDs
are extinguished. Enter a new user password and then press “I”. The GREEN LED will flash once. If
the RED LED flashes once, this means that there was an error in the procedure or that the password
entered has already been used.
• Enter a new user password and then press “I”. If the RED and GREEN LEDs flash once, this indicates
that the operation was successful. The keypad automatically returns to the supervisor menu index.

MENU 4: block/unblock user

• Press “4” to access the menu. The RED LED flashes four times. The flashes of the LEDs indicate the
user ID: the flashes of the red LED indicate the tens, while the flashes of the green LED indicate the
units. For example, 2 flashes of the red LED and 3 flashes of the green LED indicate user #23. Press
“2” to scroll up and “8” to scroll down through the list of user IDs.
• Press “I” to select the user ID for which you wish to edit the password. The selected user ID will be
blocked and the RED LED will flash twice. The keypad automatically returns to the supervisor menu index.
• Press “2” to scroll up and “8” to scroll down through the list of user IDs, then press “I” to select the user
ID you wish to unblock. The selected user ID will be unblocked and the GREEN LED will flash twice.
The keypad automatically returns to the supervisor menu index.

MENU 5: reset factory values

• Press “5” to access the menu. The RED LED flashes five times.
• Press “5” for at least 2 seconds. If the RED and GREEN LEDs flash once, this means that all the
passwords have been deleted. This operation deletes all the passwords saved in memory, except for
user password (55555) and supervisor password (01982) which will remain available. The keypad
automatically returns to the supervisor menu index.

MENU 6: auto power off function

You can choose between three different time intervals for the auto power off function.
• Press “6” to access the menu. The RED LED flashes six times.
• Press 0 to disable the auto power off function. If the RED and GREEN LEDs flash once, this indicates
that the operation was successful. The keypad automatically returns to the supervisor menu index.
• Press 1 to enable auto power off after 5 minutes. If the RED and GREEN LEDs flash once, this indicates
that the operation was successful. The keypad automatically returns to the supervisor menu index.
• Press 2 to enable auto power off after 10 minutes. If the RED and GREEN LEDs flash once, this indicates
that the operation was successful. The keypad automatically returns to the supervisor menu index.
• Press 3 to enable auto power off after 20 minutes. If the RED and GREEN LEDs flash once, this indicates
that the operation was successful. The keypad automatically returns to the supervisor menu index.

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 ELECTRICAL SYSTEM SERVICE

USER MODE

USER LOGIN
• Enter one of the passwords activated previously in the supervisor menu (default password 55555).
• Characters entered by mistake can be deleted by pressing “O”.
• Press the "I" key.
• The GREEN LED illuminated steadily to conform that the password was entered successfully.
• The truck is activated.
• If the RED LED flashes once, this means that the password entered was not valid. If the user presses
“I” before entering all 5 characters, the RED LED will flash once and the characters entered will be
deleted. The RED LED illuminates steadily to confirm that a new password is to be entered.

USER LOGOUT
There are 3 options available:
• Press the "O" button for at least 2 seconds. The truck stops. The RED LED illuminates steadily to confirm
that a new password is to be entered.
• Switch off the emergency button
• Leave the truck inactive for a time period greater than that set in menu 6.

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INSTRUCTIONS FOR USE OF THE NEW KEYPAD APPLICATION

The new keypad application for PC can be downloaded from Hypass Online, in the “software”section of the
truck. To install the application, follow the instructions in the section “DOWNLOAD AND INSTALLATION
OF THE APPLICATION”. You can find all the necessary instructions for use in the section “USE OF THE
APPLICATION” In particular, the section “UPDATING KEYPAD SOFTWARE” contains the instructions for
updating the software of the device.

DOWNLOAD AND INSTALLATION OF THE APPLICATION

Select the serial number of the truck on Hypass Online, then select the section “software” and lastly “New
Keypad 4663266 software.zip”.

Use a suitable application to extract the files from the archive *.zip; the zip archive contains the files
“ECS_Manager_0_4.exe” and “KEYPAD_MAIN_1_4.s19”.

The download includes:

• ECS_Manager_0_4.exe: PC application for connection of the keypad to a PC
• KEYPAD_MAIN_1_4.s19: new software for the keypad V1.4; this version enables use of the truck function
"auto power off".

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 ELECTRICAL SYSTEM SERVICE

UPDATING KEYPAD SOFTWARE

Updating of the keypad software is dependent on the original version of the software
installed; updating is only possible if the original version is V1.3 or later. To check which
version of the software is installed, look which appears under “Firmware Release” in the
box on HYG ECS Manager

To update the keypad software, open the application “HYG ECS Manager” and click on “Upgrade Firmware”
(at the bottom right). A dialogue box opens asking you to confirm the update and the download will start
(see figure below).

Once you have confirmed you intention to update the keypad software, a search window opens; select the
file “KEYPAD_MAIN_1_4.s19” previously extracted from the archive “New Keypad 4663266 software.zip”.

The application will show the progress of the software update process.

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 ELECTRICAL SYSTEM SERVICE

USE OF THE APPLICATION

1. Connection to the keypad:

• Connect the computer to the truck using an the IFAK cable.

NOTE: to ensure that the PC is connected correctly to the keypad, the truck must be switched
off with the emergency button disarmed.
• Switch on the truck, releasing the emergency button; do not enter the access code on the keypad.
• Open the application and click on “LOAD FROM ECS” to acquire the data relative to the keypad. If
the data acquisition procedure is completed successfully, the window shown below will be displayed;
otherwise the application will display the message “TRANSFER DATA FAIL”; in this case, check the
cable connections and repeat the operations from step 1.

2. Add or edit access codes:

• To add or edit the access codes, click on “CLICK TO ADD”: the window below will be displayed. Enter
the code and click on “Save”. The “Lock Status” window allows you to temporarily block access with
that particular code.

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 ELECTRICAL SYSTEM SERVICE

• Once all the codes have been entered, click on “SAVE TO ECS” to transfer the codes to the keypad.

3. Transfer of access codes from one device to another.

• After having connected the device from which the codes are to be copied, enter the “File” menu and
select “Save”.
• Connect to the truck the computer to which the list of codes is to be copied, switch on the truck (see
instructions in point 1) and re-launch the application. Click on “File” at the top left and then on “Load”;
in the search window that appears, select the previously saved document.
• Press the button “SAVE TO ECS” to complete the code copying procedure.

4. Auto power off.

• In this window you can set the number of minutes after which the truck will switch off automatically.
• The setting “OFF” disables the auto power off function.

5. Key mode.

• ON: the truck can be switched on simply by pressing the green button (no need to enter the code).
• OFF: to switch on the truck, it is necessary to enter one of the access codes.

6. Supervisor Password

• Set a password with supervisor access rights (refer to page 20 in this section)

7. Default factory settings

• This function allows deletion of all the users saved except for the user code 55555 and supervisor code
01982.

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 ELECTRICAL SYSTEM SERVICE

TRUCK FUNCTIONS
FORWARD/REVERSE TRACTION
ACTUATION CONTROLS

To activate traction, turn the butterfly control in the desired direction.

The drive direction is acquired via two hall effect sensors, one for forward travel and the other for
reverse travel.

Actuators involved Status

Key switch ON
Emergency switch ON
Tilted tiller sensor ON*
Forward/reverse traction control throttle forward/reverse rotation

* OFF if the “snail” button is pressed

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CONFIGURATION PARAMETERS

main menu program

Snail speed TM1 Speed Red3 (Steer)
Max Decel TM1 Max Speed

MODULE
Max Speed TM2 Walk Accel
Max Accel TM2 Max Decel
Max Decel TM2 Neutral Braking
Neutral Braking TM2 Max Braking
Max Braking TM2

For the settings of each individual parameter, see the paragraph “CONFIGURATION OF
STANDARD MODULE PARAMETERS”.
For a description of each individual parameter, see the paragraph “DESCRIPTION OF
MODULE PARAMETERS”.

SPEED AND ACCELERATION

The maximum traction speed and acceleration in operating Mode 1 and operating Mode 2 can be set in
the programmer.
Maximum forward/reverse traction speed setting
main menu program / traction / mode 1 / max speed
Setting acceleration
main menu program / traction / mode 1 / walk accel
The same settings can be applied for the operating Mode 2 by accessing the following menu:
main menu program / traction / mode 2
SPEED REDUCTION AND TRACTION LOCKOUT
When the traction motor reaches a temperature of 115°C, the current supplied
to the motor is limited, leading to a reduction in performance and hence truck speed. If the temperature
reaches 140°C, the motor lockout is tripped.

MODE SELECTION:
There are 3 selectable traction modes:
1- Mode 1: Used to save battery power, with limited performance..
2- Mode 2: average performance.
3- Mode 3 (default): maximum performance, cannot be edited via the programmer.
Procedure for selecting traction mode:
• The tiller must be in the rest position, the brake on and the key switch off (OFF).
• Press and hold the horn button while switching on the truck (key switch ON).
• When the horn sounds, release the button on the tiller.
• Select the preferred mode using the fork lifting/lowering buttons.
• The horn emits a sound according to the selected mode, one sound for mode 1, two for mode 2 and
three for mode 3.
• Lower the tiller to confirm the selected mode that will be saved by the truck.

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 ELECTRICAL SYSTEM SERVICE

BRAKING
The truck is equipped with four braking systems:
• Release braking.
• Braking on direction reversal.
• Emergency braking.
• Parking brake.
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 COME INTO OPERATION?

Release braking Release of the butterfly traction control

Braking on direction reversal Inversion of the direction of travel using the butterfly control

Through operation of the emergency button

Emergency braking Deactivation of the tiller sensor

An alarm has been generated that requires traction to be halted im-

mediately.

Parking brake The machine is stationary and no traction control is activated

With the programmer it is possible to set the deceleration ramps for release braking, emergency braking
and direction reversal braking.

Setting the deceleration ramp for release braking

main menu program / traction / normal mode / neutral braking
Setting the deceleration ramp for emergency braking
main menu program / traction / normal mode / max braking
Setting the deceleration ramp for direction reversal braking
main menu program / traction / normal mode / max decel

EMERGENCY REVERSE MANOEUVRE

The emergency reverse manoeuvre is a safety function
in the event that the operator, when driving forwards (di-
rection of the traction wheel), hits an object. In this event,
pressing the reverse button causes the truck to immedia-
tely reverse, thereby preventing the operator from being
crushed.
The emergency reverse procedure is activated with the emergency reverse
truck in forward drive, the tiller in the driving position (tiller function activation
sensor active) and the "BELLY SWITCH" button pressed. button

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 ELECTRICAL SYSTEM SERVICE

SNAIL FUNCTION
The "snail" function enables traction even when the tiller is in the rest position (tiller sensor not active). This
allows the operator to drive the truck even when there is not enough room to lower the tiller. The "snail"
function is activated by pressing the button on the tiller head. Once the "snail" button is pressed, the traction
request is performed by the butterfly control potentiometer.
The snail speed can be set via the programmer:
main menu program / traction / Snail Speed TM1

tiller sensor butterfly control potentiometer (accelerator)

snail function activa-

tion button

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 ELECTRICAL SYSTEM SERVICE

STEERING WHEEL
ACTUATION CONTROLS

To steer to the right or to the left rotate the steering tiller in the corresponding direction.

Actuators involved status

Key switch ON
Emergency switch ON
Tilted tiller sensor ON
Tiller rotation right/left rotation

SPEED REDUCTION OPTION (optional sensor)

Speed reduction according to the steering angle is optional.

It is activated via the Steer Reduction Option and is managed via the Speed Red 3 (Steer) parameter and
occurs with a steering angle greater than 15°.

SPEED REDUCTION WITH TRACTION WHEEL STEERED

This optional function reduces the maximum traction speed on exceeding a steering angle of 15°.
Above this value speed limitation trips and this can be set via the programmer. This feature is only available
if the Steer Reduction Option is active.

Setting speed reduction for steering angles over 15°

main menu program / Trucks options / Steer Reduction Option / 1
main menu program / traction / speed reduction / speed red3 (Steer)

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 ELECTRICAL SYSTEM SERVICE

FORK LIFTING/LOWERING
ACTUATION CONTROLS

D C A B

To lift the forks, press the on/off button “A” or “C”.

To lower the forks, press the on/off button "B" or “D”.

Actuators involved status

Key switch ON
Emergency switch ON
ON/OFF button for lifting/
Fork lifting/lowering
lowering activated
Tilted tiller sensor ON*

* OFF to lower the forks, or raise them if the “snail” button is pressed

CONFIGURATION PARAMETERS

main menu program

803 Lockout Enable
Quick Lift Window
Quick Lift Re-Enable Time
MODULE

Initial Lift Interval

Full Lift Interval
Lift run time
BDI Warning Enable
Lift Delay Time Valve 1-2
Lowering Delay Time Valve 1-2

For the settings of each single parameter, see the paragraph "STANDARD CONFIGURA-
TION OF MODULE PARAMETERS". For a description of each single parameter, see the
paragraph "DESCRIPTION OF MODULE PARAMETERS".

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 ELECTRICAL SYSTEM SERVICE

LIFTING LOCKOUT WITH LOW BATTERY

When the level of the battery charge drops below 20% fork lifting is inhibited. To restore
initial operating conditions the battery must be recharged.
When the battery charge reaches 75% the "battery low" indicator is reset and normal fork operation is
restored.
Lifting lockout due to low battery may be disabled via the programmer.
Enabling/disabling lifting lockout with battery low (with optional MDI)
main menu program / display functions / bdi warning enable > off: disabled, on: enabled

The level of battery charge at which the "battery low" condition is activated can be modified using the pro-
grammer.

Battery low level

main menu program / display functions / warning bdi

TIMED LIFTING LOCKOUT

On pressing a "lift" button, the forks start to rise and continue to rise for the maximum time that can be set
using the programmer.

Setting the maximum fork lift run time.

main menu program / hydraulic functions / lift run time

Once this time period has elapsed, to continue lifting, you must first press a "lower" button
and then press the "lift" button again.

END POINT SLOWDOWN LIFTING/LOWERING FORKS

When lifting, the forks rise to their maximum height without slowing down, the motion stopping when the
cylinder reaches its mechanical end-of-stroke position.
During lowering, the forks reach their lowest position without slowing down, the motion
stopping at the mechanical travel limit.
When there is the optional sensor, the lifting limit stop will be managed by the sensor.

LIFTING WITH INTELLIGENT LIFT™ OPTION

The forklifts can be equipped with the optional INTELLIGENT LIFT™. On trucks equipped with this function,
you can enable and disable the option by simultaneously pressing the lifting and lowering buttons on the
left or right sides. To activate the function, select the lifting and lowering functions simultaneously. Activation
of the horn confirms that the function is active. To deactivate the function, select the lifting and lowering
functions simultaneously. Double activation of the horn confirms that the function is no longer active. To
start lifting, briefly press the lift button. The truck then lifts up to a programmed height. Verify that there are
no obstacles in the vicinity of the truck and load. Lifting will stop when you start driving forwards. The lifting
function can be interrupted by pressing the lowering button.

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 ELECTRICAL SYSTEM SERVICE

STANDARD CONFIGURATION OF MODULE PARAMETERS

It is always advisable to keep the factory settings as designed in order to have the best
compromise between performance and components 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.
MAIN MENU PROGRAM
MAIN MENU PROGRAM 
MAIN MENU PROGRAM  Truck Options
MAIN MENU PROGRAM  Emergency Reverse
MAIN MENU PROGRAM  Hydraulic Functions
MAIN MENU PROGRAM  Traction
MAIN MENU PROGRAM  Traction  Speed Reduction
MAIN MENU PROGRAM  Traction  Mode 1
MAIN MENU PROGRAM  Traction  Mode 2
MAIN MENU PROGRAM  Display Functions
MAIN MENU PROGRAM  Display Functions  Maintenance Timers
MAIN MENU PROGRAM  Display Functions  Hour Meter Preset
MAIN MENU PROGRAM  Motor  Typical Max Speed
MAIN MENU PROGRAM  Battery

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 ELECTRICAL SYSTEM SERVICE

MAIN MENU PROGRAM

PARAMETER PARAMETER PARAMETER

level
MENU LEV.2 MENU LEV.3 MENU LEV.4
INTERLOCK TIMEOUT 120 sec.
BUZZER DEAD BAND 70 rpm
TRUCK OPTIONS BUZZER OPTION 1
CHARGER PRESENT 0
BEVERAGE TRUCK ENABLE 0
STEER REDUCTION OPTION 1
ADVANCED TURTLE OPTION 0
TURTLE ACTIVATION ALARM 0
LIFT FUNCTION 0-NORMAL,
3
1-QUICK, 2-AUTO, 3-EU STD

BDI PARTIAL RESET ENABLE 0

BDI CALCULATION TYPE 0
TOE GUARD SYSTEM ENABLE 0
HYG LI-ION BATTERY 0
EMERGENCY REVERSE EM TYPE 1
EM TIME LIMIT 10 sec.
EM BEEP ENABLE 1
TOE GUARD CREEP SPEED 200 rpm
TOE GUARD TIME LIMIT 5 sec.
HYDRAULIC FUNCTIONS 803 LOCKOUT ENABLE 0
QUICK LIFT WINDOW 0.5 sec
QUICK LIFT RE-ENABLE TIME 0.4 sec
INITIAL LIFT INTERVAL 0.6 sec
FULL LIFT INTERVAL 2 sec
LIFT RUN TIME 4.3 sec
LIFT DELAY TIME VALVE 1-2 0.3 sec
LOWERING DELAY TIME VALVE
0.3 sec
1-2

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 ELECTRICAL SYSTEM SERVICE

MAIN MENU PROGRAM

PARAMETER OR PARAMETER OR PARAMETER

level
MENU LEV.2 MENU LEV.3 MENU LEV.4
TRACTION SNAIL SPEED TM 1 931 rpm
MAX DECEL TM1 1 sec.
MAX SPEED TM2 2780 rpm
MAX ACCEL TM2 1.5 sec.
MAX DECEL TM2 1 sec.
NEUTRAL BRAKING TM2 1 sec.
MAX BRAKING TM2 0.4 sec.
SPEED REDUCTION SPEED RED 3 (STEER) 70%
MODE 1 MAX SPEED 2300 rpm
MAX ACCEL 2.5 sec.
WALK ACCEL 2.4 sec.
MAX DECEL 1.4 sec.
NEUTRAL BRAKING 2 sec.
MAX BRAKING 0.4 sec.
MODE 2 MAX SPEED 2900 rpm
MAX ACCEL 2 sec.
WALK ACCEL 2 sec.
MAX DECEL 1 sec.
NEUTRAL BRAKING 1.6 sec.
MAX BRAKING 0.4 sec.
DISPLAY FUNCTIONS BDI WARNING ENABLE 1
BDI WARNING 20%
BDI PARTIAL RESET DELTA 20%
BDI UPDATE MINIMUM CURRENT 10A
BDI UPDATE MAXIMUM CURRENT 120A
BDI UPDATE CONDITIONS 0
LIFT UNDERVOLTAGE 0%
MDI BACKLIGHT ENABLE 1

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 ELECTRICAL SYSTEM SERVICE

MAIN MENU PROGRAM

PARAMETER OR PARAMETER OR PARAMETER

level
MENU LEV.2 MENU LEV.3 MENU LEV.4
DISPLAY FUNCTIONS MAINTENANCE TIMERS TOTAL MAINTENANCE ENABLE 1
TRACTION MAINTENANCE ENABLE 1
PUMP MAINTENANCE ENABLE 1
MAINTENANCE INTERVAL 1000 h
RESET TOTAL MAINTENANCE 0
RESET TRACTION MAINTENANCE 0
RESET PUMP MAINTENANCE 0
HOUR METER PRESET 10S OF HOURS 0
REMAINING HRS IN MINS 0
PRESET TOTAL HOURMETER 0
PRESET TRACTION HOURMETER 0
PRESET PUMP HOURMETER 0
MOTOR TYPICAL MAX SPEED 3550
BATTERY NOMINAL VOLTAGE 24V
USER OVERVOLTAGE 125%
USER UNDERVOLTAGE 70%
RESET VOLTS PER CELL 2.080V
FULL VOLTS PER CELL 2.040V
EMPTY VOLTS PER CELL 1.745V
DISCHARGE TIME 150 min
BDI RESET PERCENT 75%

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 ELECTRICAL SYSTEM SERVICE

MODULE PARAMETER DESCRIPTION

MAIN MENU PROGRAM

PARAMETER min max

INTERLOCK TIMEOUT 0 sec 120 sec
Maximum time period the truck may remain with the tiller in the operating position without any command being
given.

BUZZER DEAD BAND 0 rpm 1000 rpm

This parameter lets you set the RPM threshold beyond which the optional alarm is activated.
NOTE: the buzzer sounds only for RPM higher than or equal to this value.

MAIN MENU PROGRAM  Truck Options

PARAMETER min max

BUZZER OPTION 0 3
This parameter lets you set the Buzzer mode:
0-Buzzer off
1-Buzzer on when driving in reverse
2-Buzzer on when driving in both directions of travel
3-Buzzer on when driving forwards

CHARGER PRESENT 0 1
This parameter enables the CANopen battery charger.

BEVERAGE TRUCK ENABLE 0 1

This optional parameter lets you set the Beverage option (not used on the EMEA version).

STEER REDUCTION OPTION 0 1

This optional parameter allows you to enable speed reduction when cornering, providing the sensor is installed.

ADVANCED TURTLE OPTION 0 1

This optional parameter lets you enable the truck for driving at reduced speed, with the tiller in the working
position.

TURTLE ACTIVATION ALARM 0 1

This parameter lets you set the alarm indicating whether the Advance Turtle option is enabled or disabled.

LIFT FUNCTION 0-NORMAL, 1-QUICK, 2-AUTO, 3-EU STD 0 3

This parameter lets you set the lifting performance level: 0-Normal, 1-Quick, etc..

BDI PARTIAL RESET ENABLE 0 1

Always set this parameter to 0. This parameter enables reset of the BDI following partial charging of the battery.
Function not provided.

BDI CALCULATION TYPE 0 2

This parameter is only used with HYG Li-Ion Battery=0 and defines the BDI calculation mode.
0 = Lead acid batteries - 1 = BMZ li-ion batteries - 2 = BDI disabled because BMS installed (aftermarket EMEA).

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 ELECTRICAL SYSTEM SERVICE

PARAMETER min max

TOE GUARD SYSTEM ENABLE 0 1
SPED Option

HYG LI-ION BATTERY 0 2

This parameter enables use of lithium ion batteries.

MAIN MENU PROGRAM  Emergency Reverse

PARAMETER min max
EM TYPE 0 1
This parameter lets you set emergency stopping:
0- the truck is stopped immediately
1- the truck is stopped after a delay according to the level of the EM Time Limit parameter.

EM TIME LIMIT 0 30 sec.

This parameter lets you define for how long the truck is to be driven in reverse on pressing the BB switch

EM BEEP ENABLE 0 1
This parameter lets you enable the buzzer, when the emergency reversing switch is pressed.

TOE GUARD CREEP SPEED 0 1000 rpm

SPED Option

TOE GUARD TIME LIMIT 0 30 sec.

SPED Option

MAIN MENU PROGRAM  Hydraulic Functions

PARAMETER min max
803 LOCKOUT ENABLE 0 1
Enables/disables lifting when the battery is low (only used on US version – on the EMEA version it should be kept
OFF).

QUICK LIFT WINDOW 0 15 sec.

This optional parameter defines the minimum length of time that the lifting button must remain pressed before the
Quick Lift is activated.

QUICK LIFT RE-ENABLE TIME 0 15 sec.

This optional parameter defines the minimum fork lowering time before you can again perform lifting in Quick Lift
mode.

INITIAL LIFT INTERVAL 0 10 sec.

This optional parameter lets you set the time for which the truck performs lifting in Quick Lift mode. The time must
be sufficient for lifting the load.

FULL LIFT INTERVAL 0 10 sec.

This optional parameter lets you set the time for which the truck will perform lifting in Quick Lift mode while traction
is active.

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 ELECTRICAL SYSTEM SERVICE

LIFT RUN TIME 0 10 sec.

Defines the maximum time for which continuous fork lifting is enabled.

LIFT DELAY TIME VALVE 1-2 0 5 sec.

This parameter defines the maximum time beyond which the valve closes after the pump has stopped having raised
the forks.

LOWERING DELAY TIME VALVE 1-2 0 5 sec.

This parameter defines the maximum time beyond which the valve closes after the pump has stopped having low-
ered the forks.

MAIN MENU PROGRAM  Traction

PARAMETER min max

SNAIL SPEED TM1 0 2000 rpm
This parameter allows you to set the traction speed obtained with the snail button pressed.

MAX DECEL TM1 0 3500 rpm

Braking time required when the traction butterfly control is inverted in mode 1.

MAX SPEED TM2 0 3500 rpm

This parameter lets you define the maximum number of revolutions per minute of the motor under full acceleration
when the truck is moving in Advance Turtle mode.

MAX ACCEL TM2 0.1 5 sec.

This parameter sets the time taken to go from 0 to Max Speed TM2 when the truck is moving in Advanced Turtle
mode. Higher values correspond to a slower response.

MAX DECEL TM2 0.1 5 sec.

Braking time required when the traction control throttle is inverted in Advanced Turtle mode.

NEUTRAL BRAKING TM2 0.1 5 sec.

Braking time required on releasing the traction control throttle in Advanced Turtle mode.

MAX BRAKING TM2 0.1 sec 5 sec.

Braking time required on releasing the tiller in Advanced Turtle mode.

MAIN MENU PROGRAM  Traction  Speed Reduction

PARAMETER min max
SPEED RED 3 (STEER) 0% 100%
This parameter defines the speed reduction (expressed as a percentage) for a steering angle greater than 15°
(feature active only with the Steer Reduction Option).

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 ELECTRICAL SYSTEM SERVICE

MAIN MENU PROGRAM  Traction  Mode1

PARAMETER min max

MAX SPEED 0 rpm 3550 rpm
This parameter defines the maximum number of revolutions per minute of the motor under full acceleration. RPM
= desired V * 936 Example: rpm. = 2.5MPH * 963 = 2340 rpm

MAX ACCEL 0.1 sec. 5 sec.

Parameter not used on the EMEA version.

WALK ACCEL 0.1 sec. 5 sec.

Time required to accelerate from 0% to 100% of the speed with the traction control throttle fully rotated.

MAX DECEL 0.1 sec. 2 sec.

Braking time required when the traction control throttle is inverted.

NEUTRAL BRAKING 0.1 sec. 3 sec.

Braking time required on releasing the traction control throttle.

MAX BRAKING 0.1 sec. 2 sec.

Braking time required on releasing the tiller.

MAIN MENU PROGRAM  Traction  Mode2

PARAMETER min max

MAX SPEED 0 rpm 3550 rpm
This parameter defines the maximum number of revolutions under full acceleration. RPM = desired speed *963.
Example RPM = 2.5 MPH *963 = 2340 rpm

MAX ACCEL 0.1 sec. 5 sec.

Parameter not used on the EMEA version.

WALK ACCEL 0.1 sec. 5 sec.

Time required to accelerate from 0% to 100% of the speed with the traction control throttle fully rotated.

MAX DECEL 0.1 sec. 2 sec.

Braking time required when the traction control throttle is inverted.

NEUTRAL BRAKING 0.1 sec. 3 sec.

Braking time required on releasing the traction control throttle.

MAX BRAKING 0.1 sec. 2 sec.

Braking time required on releasing the tiller.

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 ELECTRICAL SYSTEM SERVICE

MAIN MENU PROGRAM  Display Functions

PARAMETER min max
BDI WARNING ENABLE 0 1
Enables/disables fork lifting lockout and traction speed reduction to 900 rpm when the battery charge percentage
falls to the level defined by the Warning BDI parameter

BDI WARNING 0% 100%

Defines the battery charge percentage on reaching which the truck will block the lifting function and reduce the
traction speed.

BDI PARTIAL RESET DELTA 0A 200A

With BDI partial reset enable set to 0, this parameter is not used.

BDI UPDATE MINIMUM CURRENT 0A 200A

Do not change

BDI UPDATE MAXIMUM CURRENT 0A 200A

Do not change

BDI UPDATE CONDITIONS 0 2

Do not change

LIFT UNDERVOLTAGE 0% 100%

Leave this parameter set to 0 so that it is disabled.

MAIN MENU PROGRAM  Display Functions  Maintenance Timers

PARAMETER min max
TOTAL MAINTENANCE ENABLE 0 1
enables/disables signalling maintenance is necessary when the number
of hours of machine key-on operation reaches the preset maximum value.
0: signalling disabled
1: signalling enabled

TRACTION MAINTENANCE ENABLE 0 1

enables/disables signalling maintenance is necessary when the number
of hours of machine traction operation reaches the preset maximum value.
0: signalling disabled
1: signalling enabled

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 ELECTRICAL SYSTEM SERVICE

PARAMETER min max

PUMP MAINTENANCE ENABLE 0 1
If the optional MDI is present, it enables/disables signalling maintenance is necessary when the number of operating
hours of the machine's hydraulic pump reaches the preset maximum value.
0: signalling disabled
1: signalling enabled

MAINTENANCE INTERVAL 10 hours 20,000 hours

Number of truck operating hours after which maintenance is required.

RESET TOTAL MAINTENANCE 0 1

When set to 1, the remaining key-on operating hours before the next maintenance interval expires are reset to the
value indicated by the parameter MENU PROGRAM / Hours Meter Functions / Maintenance Interval.
After setting to 1 after carrying out maintenance, switch the truck off and then on again.
0: maintenance not carried out
1: maintenance carried out

RESET TRACTION MAINTENANCE 0 1

When set to 1, the remaining traction operating hours before the next maintenance interval expires are reset to the
value indicated by the parameter MENU PROGRAM / Hours Meter Functions / Maintenance Interval.
After setting to 1 after carrying out maintenance, switch the truck off and then on again.
0: maintenance not carried out
1: maintenance carried out

RESET PUMP MAINTENANCE 0 1

When set to 1, the remaining pump operating hours before the next maintenance interval expires are reset to the
value indicated by the parameter MENU PROGRAM / Hours Meter Functions / Maintenance Interval.
After setting to ON following maintenance, switch the truck off and then on again.
0: maintenance not carried out
1: maintenance carried out

MAIN MENU PROGRAM  Display Functions  Hour Meter Preset

PARAMETER min max
10S OF HOURS 0 20,000
Value used to preset the operating hours count. Each unit corresponds to 10 hours (e.g. the value 23 corresponds
to 230 hours).

REMAINING HRS IN MINS 0 600

Value used to preset the operating hour meter, expressed in minutes (the value 360 corresponds to 6 hours).

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 ELECTRICAL SYSTEM SERVICE

MAIN MENU PROGRAM  Hour Meter Preset

PARAMETER min max

PRESET TRACTION HOURMETER 0 1
When set to 1, the number of truck traction hours is preset to the value defined in the parameters MENU PROGRAM
/ Hour Meter Functions / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of Hours” * 10)
+ (“Remaining HRs in Mins” / 60)
0: presetting not performed
1: presetting performed

PRESET TOTAL HOURMETER 0 1

When set to 1, the number of truck key-on hours is preset to the value defined in the parameters MENU PROGRAM
/ Hour Meter Functions / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of Hours” * 10)
+ (“Remaining HRs in Mins” / 60)
0: presetting not performed
1: presetting performed

PRESET PUMP HOURMETER 0 1

When set to 1, the number of truck pump operation hours is preset to the value defined in the parameters MENU
PROGRAM / Hour Meter Functions / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of
Hours” * 10) + (“Remaining HRs in Mins” / 60)
0: presetting not performed
1: presetting performed

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 ELECTRICAL SYSTEM SERVICE

MODULE: INTRODUCTION
The module has been designed to perform all the electrical functions normally present on the truck:
• control of the 1.2 kW AC motor
• control of the 1 kW - 1.4 kW hydraulic pump
• driver for the proportional solenoid valve
• CanBus interface
• interface with the tiller Can Bus
• alarms
• performances

Technical specifications:
Inverter for asynchronous three phase AC motors and chopper for DC pump motors
Regenerative braking functions
Digital control via microcontroller
Voltage:.........................................................................................24V
Inverter maximum current (24V):...................................................180A (RMS) for 2’
PWM operating frequency.............................................................10 kHz
Maximum encoder frequency........................................................10 kHz
Maximum control output frequency...............................................300 Hz
Outside temperature limits............................................................-40°C to 50°C

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 ELECTRICAL SYSTEM SERVICE

The module is connected and communicates through the CANBUS network, which allows access to truck
diagnostics or programming via PC or laptop.
The connector (X30) for the cable kit interface connection ("PC TOOL") is connected to the module and
can be accessed by removing the of the motor compartment.
The module is equipped with a flash memory, which enables the software to be updated by connecting a
PC to the CANBUS network (Can flash).

POSITIONING OF THE "PC TOOL" CONNECTOR

connettore pc

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 ELECTRICAL SYSTEM SERVICE

MODULE REPLACEMENT: INSTRUCTIONS

Equipment and tools

B
open ended resistor
wrench 100 Ohm 25w
10 mm isolated

socket wrench Fig. 1

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. Turn the keyswitch to OFF and disconnect the battery.

Phase 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove the motor cover fixing
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1).

Phase 2
RESISTANCE 100 Ohm 25 W
Connect a resistance between the positive (B+) and negative (B-) of the
module (fig.2).
Wait approximately 10 seconds for the internal capacitors to lose their
charge and then disconnect the resistance.

Fig. 2
To avoid short circuits, it is important that the resistance
is insulated.

If it is not possible to have an external resistance to run down the capacitors, it will be necessary to wait at
least 90 seconds before disconnecting the power cables.

44
 ELECTRICAL SYSTEM SERVICE

Phase 3
10 mm OPEN ENDED WRENCH
Using the open ended wrench, unscrew and remove the power cable retaining screws.
Disconnect the module wiring connector.
Mark the power cables for reassembling and then disconnect them.

Phase 4
10 mm T-HANDLE SOCKET WRENCH
Using the T-handle hex socket wrench unscrew and remove the nuts securing the module and remove the
washers.
Remove the module including the heat sink and proceed with replacement.

CONFIGURATION
ADAPTER - PROGRAMMER
Connect the adapter to the “PC CONSOLE" connector.
Connect the USB connector of the interface cable to the USB port on the PC.
Connect the battery and switch on the truck (starter key to ON). Start the PC Console program.

ACQUISITION OF OPERATING HOURS

THE truck operating hours are saved in the display memory..
After replacing the controller, on switching on the truck make a note of the operating hours shown on the
display (value H: e.g. 138.9). Perform the operation H / 10. The result will be in the format XX.YY (e.g. 13.89).

Procedure for pre July 2018 display

With the truck switched off (keyswitch OFF), connect the programmer.
Switch on the truck (keyswitch ON) and select the parameter main menu program / display functions / hour
meter preset / 10s of hours.
Set the parameter to the value XX (e.g.13).
Select the parameter main menu program / display functions / hour meter preset / remaining hrs in mins.
Set the parameter to the value YY·6 (e.g.89·6=534).
Select the parameter main menu program / display functions / hour meter preset / preset total hourmeters.
Set the parameter to “ON”.
Switch off the truck (Keyswitch OFF) and switch it back on again ( Keyswitch ON).
At this point the module will make the necessary modifications to the monitor menu parameters regarding
maintenance hours and will reset the parameter preset total hourmeters to “OFF“.

New display procedure

Refer to the paragraph “NEW DISPLAY” in this section of the manual.

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 ELECTRICAL SYSTEM SERVICE

DISMANTLING THE ELECTRICAL COMPONENTS

REPLACEMENT OF THE GENERAL EMERGENCY SWITCH
Equipment and tools

B
socket wrench medium crosshe-
13 mm ad screwdriver

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 pe-
destrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the
battery.

Phase 1
SOCKET WRENCH SIZE 13 mm Fig. 2
Use the socket wrench to unscrew and remove the motor cover fixing
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1). D

Phase 2
13 mm T-HANDLE SOCKET WRENCH - PHILLIPS SCREWDRIVER
Mark the wires and remove all the faston connectors from the switch.
Using the T-handle socket wrench take out the screw securing the bracket
to the switch (ref.C fig.2).
Using the screwdriver, remove the two fixing screws of the emergency C
main switch (ref.D fig.2) and make the replacement.

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 DISPLAY

Equipment and tools

B
socket wrench
13 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.

D
Phase 1
SOCKET WRENCH SIZE 13 mm
E
Use the socket wrench to unscrew and remove the motor cover fixing
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1).

Phase 2
Disconnect the wiring connector (ref.E fig.2).
Loosen the nuts securing the retaining bracket (ref.C fig.2). Remove the
bracket (ref.D fig.2).
Remove the display and proceed with replacement.
Fig. 2

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 ELECTRICAL SYSTEM SERVICE

REPLACEMENT OF THE KEY SWITCH

Equipment and tools

socket wrench
10 - 13 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.
Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Phase 1
SOCKET WRENCH SIZE 13 mm Fig. 2
Use the socket wrench to unscrew and remove the motor cover fixing B
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1).

Phase 2
Remove the ignition key (fig.2).
Unscrew the RING nut (ref. B fig.2), remove the switch block from the
console (fig.3).
Disconnect the connectors and proceed with replacement. Fig. 3

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 HORN

Equipment and tools

socket wrench
10 - 13 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 pede-
strians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 2
Phase 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove the motor cover fixing
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1). C

Phase 2
10 MM SOCKET WRENCH
Using the socket wrench, unscrew and remove the horn fastening
nut(ref.C fig.2). Disconnect the connectors, remove the horn and proceed
with the replacement.

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

FUSE REPLACEMENT
• 4A fuse (F3)
• 175A power fuse (F2)

Equipment and tools

B
socket wrench
13 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 keyswitch
to OFF and disconnect the battery.

D
C
Phase 1
13 MM SOCKET WRENCH
Use the socket wrench to unscrew and remove the motor cover fixing
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1).

Phase 2
13 MM SOCKET WRENCH
Remove the fuse (ref.C fig.2) from its seat and proceed with the repla-
cement.
Using the T-handle socket wrench remove the nuts that fasten the power
fuse (ref.D fig.2), remove the fuse and proceed with the replacement.
Fig. 2

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 ELECTRICAL SYSTEM SERVICE

TILLER BOARD REPLACEMENT

Equipment and tools

T-handle hex key

small flat blade
wrench
screwdriver
2.5 - 4 mm
A B
Fig. 1 C
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.
D
Fig. 2

Phase 1 EF G
4 MM T-HANDLE HEX KEY H
Unscrew the nuts holding the upper frame housing in place (ref. A,B,C
fig.1).

Phase 2
Lift the upper casing and detach it from the lower casing (fig.2). Discon-
nect the connector connecting the serial cable (ref. D fig.2) and place
the cover on a clean work bench.
Fig. 3

Phase 3
2.5 MM T-HANDLE HEX KEY
Loosen the screw holding one of the two throttle valves (ref. E fig.3) and
retrieve the washer (ref. F fig.3). Remove the throttle from the pin (ref.G
fig.3). Remove the other throttle complete with the guide pin (ref.H fig.3).

Phase 4
SMALL FLAT BLADE SCREWDRIVER K
Unscrew the tiller board latch fastening screw (ref. I fig.4). Remove the
latch (ref. J fig.4) and the card from its seat (ref. K fig.4), disconnect the
connectors of the various micro commands.
Proceed with replacement.
J
Fig. 4 I

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 ELECTRICAL SYSTEM SERVICE

REPLACEMENT OF TILLER BUTTONS

Equipment and tools

A B
Fig. 1 C
T-handle hex key
small flat blade
wrench
screwdriver
4 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 D
of other vehicles and all pedestrians. Lower the forks to
the ground, turn the keyswitch to OFF and disconnect Fig. 2
the battery.

Fig. 3

Phase 1
4 MM T-HANDLE HEX KEY
Unscrew the nuts holding the upper frame housing in place (ref. A,B,C
fig.1).

Phase 2
Lift the frame of the upper housing and remove it from the lower frame
housing (fig.2). Disconnect the connector connecting the serial cable
(ref. D fig.2) and place the cover on a clean work bench.

Phase 3
SMALL FLAT BLADE SCREWDRIVER
Using the screwdriver, prise open the clips (fig.4) and push the button Fig. 4
out of its seat (fig.4,5).
Proceed with replacement.

Fig. 5

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 ELECTRICAL SYSTEM SERVICE

REPLACEMENT OF THE TILLER CONTROL SPRINGS

Equipment and tools

T-handle hex key

small flat blade
wrench
screwdriver
2.5 - 4 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.

Phase 1
4 MM T-HANDLE HEX KEY
Unscrew the nuts holding the upper frame housing in place (ref. A,B,C
fig.1).
A B
Fig. 1 C

Phase 2
Lift the frame of the upper housing and remove it from the lower frame
housing (fig.2). Disconnect the connector connecting the serial cable
(ref. D fig.2) and place the cover on a clean work bench.

D
Fig. 2
Phase 3
2.5 MM T-HANDLE HEX KEY
Loosen the screw holding one of the two throttle valves (ref. E fig.3) and
Fig. 3
retrieve the washer (ref. F fig.3). Remove the throttle from the pin (ref.G EF G
fig.3). Remove the other throttle complete with the guide pin (ref.H fig.3).
H

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 ELECTRICAL SYSTEM SERVICE

BUTTERFLY CONTROL SPRING

Fig. 4
Phase 4
SMALL FLAT BLADE SCREWDRIVER J
With the screwdriver, prise out the butterfly guide bush (ref.I fig.4) and
remove it. In the same way, prise up the butterfly control spring(ref.J
fig.4) and remove it.
Proceed with replacement.
I

BELLY AND HORN BUTTON SPRINGS

Fig. 5
Phase 4
SMALL FLAT BLADE SCREWDRIVER
With the screwdriver, apply leverage under the belly switch near the lo-
cking pin (fig.5). Remove the switch (ref.K fig.6) and recover the spring
(ref.L fig.6).
In the same way apply leverage under the horn button at the lug(fig.5).
Remove the button (ref.M fig.6) and recover the spring (ref.N fig.6).
Proceed with replacement.

Fig. 6

K
L
N

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 ELECTRICAL SYSTEM SERVICE

REPLACEMENT OF THE TILLER ENABLES SENSOR

Equipment and tools

B
T-handle hex key
socket wrench
wrench
13 mm
4 mm

open ended Fig. 1

wrench
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. Lower the forks to
the ground, turn the keyswitch to OFF and disconnect
the battery.

Phase 1
13 MM SOCKET WRENCH
Use the socket wrench to unscrew and remove the motor cover fixing Fig. 2
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1).
D

Phase 2
4 MM T-HANDLE HEX KEY
Disconnect the sensor connector located alongside the traction motor
(ref.C fig.2).
Using the T-handle hex key, unscrew and remove the two screws securing
the upper cover to the tiller base (ref.D fig.2). Remove the cover. C

55
 ELECTRICAL SYSTEM SERVICE

Phase 3
Fig. 3
28 MM OPEN ENDED WRENCH
Lower the tiller. While keeping the tiller completely lowered, use the
D
wrench to unscrew the sensor retaining nut (ref.E fig.3).
Take the sensor out of its housing, remove the wire and proceed with
the replacement.

The optimal sensor sensitivity distance from the cam is

4 mm.

56
 ELECTRICAL SYSTEM SERVICE

REPLACEMENT OF OPTIONAL STEERING SENSOR

Equipment and tools

B
open ended
socket wrench
wrench
13 mm
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. Lower the forks to
the ground, turn the keyswitch to OFF and disconnect
the battery.

Phase 1
13 MM SOCKET WRENCH
Use the socket wrench to unscrew and remove the motor cover fixing
nuts (ref.A fig.1). Fig. 2
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1).

Phase 2
28 MM OPEN ENDED WRENCH
Disconnect the sensor connector located behind the traction motor (ref.C
fig.2).
Using the wrench, loosen the sensor retaining nut (ref.E fig.3).
Take the sensor out of its housing, remove the wire and proceed with D C
the replacement.

The optimal sensor sensitivity distance from the cam is

4 mm.

57
 ELECTRICAL SYSTEM SERVICE

INSTALLATION OF THE NEW TILLER CABLE

A new tiller cable was introduced on trucks from serial number

A418T06887T onwards. Installation of the new cable entails modification
of the fixing points on the truck and the addition of a protective cover for the
parking brake. To update a truck with serial number before A418T06887T,
it will be necessary to purchase the relative kit complete with tiller cable,
brake cover and retaining straps; if the truck has been recently updated,
it will be sufficient to replace the tiller cable.

INSTALLATION

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.
Fig. 1
B

Phase 1
Remove the obsolete tiller cable and install the brake cover (ref. A fig. 1).
C
A
Phase 2
Feed the tiller cable through the tiller and the hole in the base. The
previously installed cover will protect the cable from rubbing against the
top of the brake.

Phase 3
Use strap B (ref. B fig. 1) to fasten the new tiller cable and the sensor
cable to the tiller. Fully tighten the strap to permanently fasten the cables
near the reference mark (670mm).
Fig. 3
Use the strap C (ref. C fig.1) to secure the cable in the correct position
(see figure).

Do not fully tighten strap C so as to allow the cable to

move during use of the tiller

Phase 4
Connect the cable to the main wiring loom of the truck and to the tiller
board; use a normal strap to fasten the cable to the main wiring loom,
positioning it near the reference mark (1115 mm).

58
 ELECTRICAL SYSTEM SERVICE

ON-BOARD BATTERY CHARGER (OPTIONAL)

Trucks can be equipped with an on-board battery charger in the motor
compartment (ref.A fig.1) and the relative charger socket (AC port) with
status LED on the control panel (ref. B fig.1).that allows recharging of the B
battery and monitoring of the battery charger without having to remove
the motor compartment cover.
The LEDs on the AC port and the sequence in which they illuminate
indicate the status of the battery charger during the charging cycle and/
or any error codes present (fig. 2).
A

Fig. 1
LED Colour

1 RED AC power supply

2 RED Interruption

3 RED Battery reading

Flashing when performing checks,

4 YELLOW
steady when charging.

5 GREEN Upload
Fig. 2

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 ELECTRICAL SYSTEM SERVICE

ERROR MODE
When an alarm related to the battery charger is present, the combined statuses of the five LEDs (figure 2)
identifies the type of alarm. Refer to the following table for fault diagnosis.

CONDITION LED 1 LED 2 LED 3 LED 4 LED 5

Battery Over Voltage Off Off Off Off Flashing

Battery temperature Low Off Off Off Flashing Flashing

Battery Temperature High Off Off Flashing Off Off

Battery Pack Unbalanced - V Off Off Flashing Flashing Flashing

Battery Pack Unbalanced - A Off Flashing Off Off Off

Battery is 100% Discharged Off Flashing Off Off Flashing

Batt Beyond Over Discharged Off Flashing Off Flashing Off

Battery Emergency Under-Voltage Off Flashing Off Flashing Flashing

Batt Temperature Sensor Open Off Flashing Flashing Flashing Flashing

Batt Temperature Sensor Shorted Flashing Off Off Off Off

Batt Over-Temperature Flashing Off Off Off Flashing

Battery Testing Error Flashing Off Off Flashing Flashing

Battery Testing Error - Sulphate Flashing Off Flashing Off Off

Battery Testing Error - Discharged Flashing Off Flashing Off Flashing

Bulk Charge Safety Time Error Flashing Flashing Off Off Flashing

Absorption Safety Time Error Flashing Flashing Off Flashing Off

Excessive Safety Time Error 1 Off Off Off Off Flashing

Mode Selected Not Valid - Empty 1 Off Off Off Flashing Off

Product Not Operational 1 Off Off Off Flashing Flashing

Lockout (Inhibit) Enable Defective 1 Off Off Flashing Off Off

Lockout (Inhibit) Disable Defective 1 Off Off Flashing Off Off

Internal Over Temperature 1 Flashing Off Off Off Flashing

1
LEDs flashing rapidly.

If any one of the LEDs flashes with the repetitive sequence of “three fast flashes, off, three
fast flashes”, this means that the charging cycle was ended prematurely. An anomalous
charge condition was detected and as a result, the charging was interrupted.

60
 ELECTRICAL SYSTEM SERVICE

Battery Over Voltage

The battery charger output DC cable might be connected to a battery that has a higher voltage than that
of the battery charger.

Battery Temperature Low/High: If an external thermistor is connected, the battery charger detects the
attempt to use the battery at a temperature outside of the recommended range. Before restarting charging,
it is recommended to defrost the battery if the temperature is too low or to stop charging and allow the
battery to heat up if the temperature is too high.

Battery Pack Unbalanced - V: caused by an unbalance in the battery pack or the excessive sulphation
of the battery plate while charging with a constant current. Example: some batteries have a higher state
of charge than others; in these cases it may be necessary to replace the batteries. It is recommended to
always refer to the battery maintenance manual.

Battery Pack Unbalanced - A: caused by an unbalance in the battery pack while charging with constant
voltage. Check the batteries using a tester and check if any of the batteries is “hotter” to the touch that the
others part of the pack. If this occurs, it may be due to a short circuit of one or more of the battery cells
or the stratification of the electrolyte (overcharge due to an incorrect setting); in these cases it may be
necessary to replace the batteries. It is recommended to always refer to the battery maintenance manual.

Batt Is 100% discharged: considering a reference value of 1.75Vdc/cell, this error occurs when the cell
voltage drops below the reference value (example: 21Vdc for 24V batteries). Connect the battery charger
to an AC power supply and start charging.

Batt Emergency Under-Voltage: considering a reference value of 1.31Vdc/cell, the battery may have
been subjected to a prolonged condition of over-discharge (example: 15.75Vdc for 24V batteries); in this
case the battery may be irreparably damaged. Use a voltmeter and check if the battery voltage is well
lower than a 100% discharge. Remove all loads from the battery, including the battery charger and allow
the battery to reach 1.31V/cell. Reconnect only the battery charger to the battery and recharge.

Batt Beyond Over Discharged: considering a reference value of 1Vdc/ cell, the battery may have been
subjected to a prolonged condition of over-discharge (example: 12Vdc for 24V batteries); in this case
the battery may be irreparably damaged and may have a shorter lifespan than expected. Charging was
turned off completely to prevent extending the decay process. Use a voltmeter and check if the battery
voltage is considerably lower than a 100% discharge. Remove all loads from the battery, including the
battery charger and allow the battery to return to above 1Vdc/cell. Reconnect only the battery charger to
the battery and recharge.

Batt Temperature Sensor Open / Shorted: This error occurs if the battery has a temperature sensor and
the relative cable is open or short circuited. It is recommended to check the cause and resolve the fault.

Batt Over-Temperature: This error occurs when the battery charging process is interrupted because the
maximum permitted temperature was reached. Check if the cells were damaged and perform a load test
for each battery.

61
 ELECTRICAL SYSTEM SERVICE

Battery Storage Error: If the batteries are stored for too long, they may be depleted. Immediately connect
the battery charger to an AC power supply and start charging. The error disappears.

Battery Testing Error - sulphate/discharged: this error occurs during the pre-qualification test phase and
is generated only by one of the two following conditions:
Sulphatisation: considerably sulphatised battery plates prevent the charging flow to increase the minimum
value. Disconnect and reconnect the AC power supply to the battery charger to restart the phase. If also
the second attempt fails, perform a load for each battery and replace the faulty batteries.
Discharged: A very discharged battery does not charge up to 1.75Vdc per cell (for example 21Vdc for
24V batteries) in a period of time between 4 and 8 hours. Check for loads that prevent the battery from
increasing the charge and/or check that there are no defective batteries that are not able to be charged.

Bulk Charge Safety Time Error: This occurs during the maximum charge phase, when the safety timer
associated with it disconnects and the battery voltage is not able to increase above 2.17V/cell. The possi-
ble causes include: use of a battery load that draws energy from the battery itself while the battery charger
is trying to charge the battery, old or unbalanced battery cells, etc.

Absorption Charge Safety Time Error: This occurs during the absorption phase, when the safety timer
associated with it disconnects and the battery voltage is brought below 2.17V/cell. The possible causes
include: use of a battery load that draws energy from the battery while the battery charger is trying to
charge it.

Excessive Charge Time Error: This occurs when the charge takes too much time and the battery volta-
ge. does not increase above 2.17V/cell. Possible causes: a load that draws energy from the battery while
the battery charger is trying to charge it, old or unbalanced battery cells, etc.

Mode Selected Empty: The charge algorithm selected, set using the switches is empty or do not have a
setting that is valid for battery charging - reset the switches and insert a valid value.

Lockout (Inhibit) Enable Defective: this error occurs if an equipment lockout cable is installed and
presumably active, but is not – Check the wiring; if the wiring is correct, the internal inhibition switch may
be overloaded. Contact technical support.

Lockout (Inhibit) Disable Defective: This error occurs if an equipment lockout cable is installed and
presumably active, but is not – Check the wiring; if the wiring is correct, the internal inhibition switch may
be overloaded. Contact the technical support

Internal Over Temperature: The battery charger turns off due to internal over-temperature – check the
operation of the fan and remove the lockouts, if present. Also remove anything obstructing the air flow in
the immediate vicinity of the product.

A.C. Convenience Port Accessory

If the system has an “AC port”, the led display corresponds to the led display of the battery charger with
a single exception:
If a LED flashes from the central led to the external led in a repetitive manner, this means that the port has
a communication problem. Check the wiring.

62
 ELECTRICAL SYSTEM SERVICE

REMOVAL OF THE BATTERY CHARGER

Equipment and tools

open ended
wrench
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 pe-
destrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the
battery.

Phase 1
13 MM OPEN ENDED WRENCH
Use the socket wrench to unscrew and remove the motor cover fixing
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1). E
Fig. 1 C D
Phase 2
Loosen the nut and disconnect the battery charger connector (ref. C
fig. 1)

Phase 3
Trace the two wires (ref. D and E fig. 1) from the battery charger and G
disconnect them from respectively the main wiring (connector CPP1)
and from the connector of the AC port wiring.
H
Phase 4
13 mm OPEN ENDED WRENCH
Remove the retaining strap and disconnect the power supply plug (ref.
F fig.2).located under the battery charger. Using the 13mm wrench,
remove the flanged nuts (ref. G and H fig.2) and proceed with removal F
and replacement of the battery charger.

Fig. 2

63
 ELECTRICAL SYSTEM SERVICE

64
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC SYSTEM
HYDRAULIC FUNCTIONS........................................................................................................................................2
FORK LIFTING AND LOWERING.............................................................................................................................2
HYDRAULIC CIRCUIT SUPPLY................................................................................................................................3
PRESSURE REGULATING VALVES........................................................................................................................3
DIRECTIONAL VALVES.............................................................................................................................................3
HYDRAULIC DIAGRAMS..........................................................................................................................................4
SYMBOLS....................................................................................................................................................................4
MAIN HYDRAULIC DIAGRAM...................................................................................................................................5
HYDRAULIC DIAGRAMS BY FUNCTION...............................................................................................................6
HYDRAULIC DIAGRAM FOR FORK LIFTING.........................................................................................................7
HYDRAULIC DIAGRAM FOR FORK LOWERING...................................................................................................8
HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE........................9
HYDRAULIC COMPONENTS.................................................................................................................................10
REMOVAL OF THE PRESSURE RELIEF VALVE..................................................................................................10
CALIBRATION OF THE PRESSURE RELIEF VALVE...........................................................................................12
CHANGING THE OIL FILTER..................................................................................................................................13
CARTRIDGE SOLENOID VALVES.........................................................................................................................14
KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS..................................................................................14
REMOVAL OF THE SOLENOID VALVE..................................................................................................................15
CYLINDERS...............................................................................................................................................................17
SINGLE ACTING CYLINDERS..................................................................................................................................17
LIFTING CYLINDER.................................................................................................................................................17
IDENTIFICATION OF THE LIFTING CYLINDER COMPONENTS............................................................................18
REMOVAL OF THE LIFTING CYLINDER...............................................................................................................19
REPLACEMENT OF THE LIFTING CYLINDER SEALS........................................................................................21
LIFT PUMP.................................................................................................................................................................23
KEY TO LIFT PUMP COMPONENTS.......................................................................................................................23
REMOVAL OF THE LIFT PUMP................................................................................................................................24
REPLACEMENT OF THE PUMP..............................................................................................................................26
REPLACEMENT OF THE CYLINDER SUPPLY PIPE............................................................................................27

1
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC FUNCTIONS
• Forks lifting
• Forks lowering

FORK LIFTING/LOWERING
The fork lifting speed is determined by the rpm at which the pump motor transmits drive to the pump drive
shaft.
In the lowering stage, a check valve prevents the flow of oil through the pump and the oil returns to tank
through the flow control valve.

2
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC CIRCUIT POWER SUPPLY

Fixed displacement pumps
With fixed displacement pumps, the oil flow is constant, providing the
rotation speed of the motor shaft remains unchanged.
A reduction in the shaft rpm will reduce the pump capacity: if the rpm are
reduced so is the flow rate and vice versa; the pressure, providing the
load is unchanged, remains constant.

PRESSURE REGULATING VALVES

Pressure limiting valves
The "pressure limiting" or "pressure relief" valves are mainly used to
guarantee that the maximum permissible system pressure is not exceed
in the system and to protect the pump from damaging pressure levels
that exceed its structural characteristics.
The use of pressure limiting devices is not restricted to the functions
described above, but they are commonly used in many devices where it
is crucial to prevent pressure build ups. An example are anti-shock and
anti-knock valves.
As long as the circuit is not subjected to excess pressure conditions, the
pressure limiting device remains in the closed position: the force exerted by the pressurised oil is lower than
that exerted by the opposing spring. With the piston at its end-of-stroke or if an anomalous situation arises
which generates forces in excess of the set level (for example with a load in excess of the load capacity),
the over-pressured oil overcomes the force of the spring and flows towards the oil outlet.

DIRECTIONAL CONTROL VALVES

One-way valves and check valves
The function of "one-way" or "non-return" valves is to allow the oil to flow in one direction only, while pre-
venting the flow in the opposite direction.
They are essentially comprised of a fixed part connected to the end of the pipe; in the appropriate inner
housing runs the moving element which might be a bearing or a conical plug.
Check valves instead have an opposing spring. In the direction of free flow, the oil pressure must exceed
the force exerted by the spring.

3
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC DIAGRAMS
SYMBOLS

TWO POSITION SOLENOID THREE POSITION

VALVE SOLENOID VALVE

ONE-WAY VALVE
FILTER

DOUBLE ACTING
CYLINDER PROPORTIONAL VALVE

SINGLE ACTING CYLINDER PUMP

TANK HYDRAULIC MOTOR

LINE CONNECTION ELECTRIC MOTOR

PRESSURE RELIEF VALVE FLOW VALVE

MANUAL COCK BY-PASS VALVE

4
 HYDRAULIC SYSTEM SERVICE

OVERALL HYDRAULIC DIAGRAM

5
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC DIAGRAMS BY FUNCTION

• Forks lifting
• Forks lowering

SOLENOID VALVE OPERATION CHART

Function Pump EV1

Forks lifting P -
Forks lowering +
pressure
P = pump in operation relief valve in
+ = solenoid valve coil energised the tank

6
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC DIAGRAM FOR FORK LIFTING

7
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC DIAGRAM FOR FORK LOWERING

8
 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 main-
tain the pressures permitted by the system and to protect and safeguard
the system against sudden pressure surges that could seriously damage the components.
The pressure relief valve may intervene in the following cases:
• 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

9
 HYDRAULIC SYSTEM SERVICE

HYDRAULIC COMPONENTS
REMOVAL OF THE PRESSURE RELIEF VALVE
Equipment and tools

open ended
socket wrench oil resistant Torx key
spanner
13 mm gloves T30
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 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
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and
remove the motor cover fixing nuts
(ref.A fig.1).
Remove the motor cover by pressing
your hands first on the left and then on B
the right-hand side to trip the locking
clips (ref.B fig.1).

Fig. 1
Phase 2
Carry out the procedure to remove the lift pump (see "REMOVAL OF THE LIFT PUMP").

10
 HYDRAULIC SYSTEM SERVICE

Phase 3
T30 TORX KEY - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Unscrew the tank fastening screws using the torx key (ref.C fig.2). Re-
move the tank.

Fig. 2

Fig. 3
Phase 4
12 mm OPEN ENDED SPANNER
Use the spanner to unscrew and remove the valve assembly (ref.D fig.3)
and proceed with the replacement.

INSTALLATION
Install the valve and tighten with a torque wrench to 15 Nm.

After replacement, before reassembling the tank, regulate the valve

(see "REGULATING THE PRESSURE RELIEF VALVE")

11
 HYDRAULIC SYSTEM SERVICE

PRESSURE RELIEF VALVE CALIBRATION

The pressure relief valve must be calibrated following replacement.

Equipment and tools

10mm open
ended spanner small wrench

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.

The valve pressure setting is approx. 35/40 bar for each screw turn.

Phase 1
FIXED 10 mm SPANNER - A SMALL FLAT HEAD SCREWDRIVER Fig. 1
Loosen the valve fastening bolt using the open ended spanner (ref.A
fig.1).
With a screwdriver completely unscrew the valve adjusting screw (fig.1)
and then screw it back in by 4½ turns. Use the spanner to tighten the
A
lock nut (ref.A fig.1), to lock the adjusting screw in position.

Screw

Phase 2
Re-install the pump on the truck, connect the battery and switch on the
truck (keyswitch ON).
Place on the forks a load equivalent to the truck's load capacity, as indi-
cated on the truck's dataplate.
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.
Otherwise, adjust once more by turning the screw another ½ turn.

12
 HYDRAULIC SYSTEM SERVICE

CHANGE OIL FILTER

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.

Phase 1
Unscrew the filter (ref.A fig.1) from the oil suction hose (ref.B fig.1) and proceed with the replacement.

Fig. 1

13
 HYDRAULIC SYSTEM SERVICE

CARTRIDGE SOLENOID VALVES

The solenoid valves of the directional control valve are of the screw-in cartridge type.
This type of valve is comprised of a body with a fixed hex nut, a threaded part, a set of static seals; inside
a moving element allows communication between the various chambers.

KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS

2 1

Ref. Description

1 Coil
2 Valve body

14
 HYDRAULIC SYSTEM SERVICE

REMOVAL OF THE SOLENOID VALVE

Equipment and tools

open ended span-

small Phillips socket wrench
oil resistant gloves ner
screwdriver 13 mm
19-24 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 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
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and B
remove the motor cover fixing nuts
(ref.A fig.1).
Remove the motor cover by pressing
your hands first on the left and then on
the right-hand side to trip the locking
clips (ref.B fig.1). A

Fig. 1

Phase 2
SMALL PHILIPS SCREWDRIVER
Unscrew the retaining screws and disconnect the connector of the power
supply to the solenoid valve coil (fig.2).

Fig. 2

15
 HYDRAULIC SYSTEM SERVICE

Phase 3
OIL RESISTANT GLOVES - 19-24 mm OPEN ENDED SPANNER
D C
With the 19 mm spanner, unscrew the nut securing the coil (ref.C fig.3).
Withdraw the coil.
Using the 24 mm spanner, unscrew the nut securing the valve body to
the hydraulic unit (ref.D fig.3. Proceed with replacement.

Fig. 3

INSTALLATION
On refitting the valve body, tighten the retaining nut to a
torque of 35 Nm. Tighten the coil retaining nut to a torque
of 6 Nm.

16
 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.

LIFTING CYLINDER

Rod diameter Height H3

Type of cylinder
mm mm

Type “A” single-acting plunger

50 130
cylinder with solid rod

H3

17
 HYDRAULIC SYSTEM SERVICE

KEY TO LIFTING CYLINDER COMPONENTS

The cylinder is of the single-acting plunger type.
After cylinder replacement, the air must be vented through the bleed valve.
The static seals can be replaced with the cylinder installed in the truck.

1
2

10
5

9
6
7

11
7

Ref. Description Ref. Description

1 Spacers 7 O-ring
2 Locking key 8 Barrel
3 Rod and piston 9 Sealing gasket
4 Oil scraper seal 10 Gasket case bush
5 Sealing gasket 11 Bottom
6 Gasket housing bushing

18
 HYDRAULIC SYSTEM SERVICE

REMOVAL OF THE LIFTING CYLINDER

Equipment and tools

socket wrench hexagonal "T" open ended span-

socket wrench
with flexible section spanner ner
13 mm
handle 5 mm 18 mm
13 mm

oil resistant gloves "Parker" cap 2 wooden blocks

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. 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
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove the motor cover fixing nuts (ref.A fig.1).
Remove the motor cover by pressing
your hands first on the left and then on
the right-hand side to trip the locking
clips (ref.B fig.1).

Phase 2
B
2 WOODEN BLOCKS
Raise the forks to the maximum height.
Place the wooden blocks under the
forks and lower them until they rest
on them. A

Fig. 1

19
 HYDRAULIC SYSTEM SERVICE

Fig. 2
Turn the keyswitch to OFF and disconnect the battery.

Phase 3
5 mm T HANDLE HEX KEY C
Open the cover of the battery compartment. From the battery com-
partment, with the T-handle hex key, unscrew and remove the screw
securing the upper cover of the cylinder (ref.C fig.2). Remove the upper
cover of the cylinder by sliding it out upwards.

Phase 4
13 mm SOCKET WITH FLEXIBLE HANDLE
Fig. 3
With the swivel socket wrench loosen the three nuts of the cylinder's
central cover (ref.D fig.3). Raise the cover upwards to remove it.

D
Connect the battery and turn the keyswitch to ON.

Phase 5
OIL RESISTANT GLOVES - 18 mm OPEN ENDED SPANNER - "PAR-
KER" SERVICE PLUG
Wear the oil resistant gloves.
Fig. 4
Remove the cylinder locking key (ref.E fig.4) and press the forks down
button, use your hand to push the stem down to its limit stop. Switch off
the truck. E
Using the spanner, unscrew the hydraulic hose union (ref.F fig.4).
Fit the service plug to the hydraulic hose.
Withdraw the cylinder from its housing, place it on a clean workbench
with a vice and proceed with disassembly or replacement.

INSTALLATION

Before tightening the hydraulic connection fittings, con-

sult the reference table, (see "CORRECT METHOD FOR F
APPLYING FEMALE FITTINGS”, "FOREWORD" section).

20
 HYDRAULIC SYSTEM SERVICE

REPLACEMENT OF THE LIFTING CYLINDER SEALS

Equipment and tools

small flat blade

oil resistant gloves C spanner chain pipe wrench
screwdriver

work bench vice brush

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. 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
Carry out the lifting cylinder removal procedure (see “REMOVAL OF THE LIFTING CYLINDER”).

REPLACEMENT OF THE UPPER SEALS

Fig. 1
Phase 2
WORK BENCH - VICE - OIL RESISTANT GLOVES - C SPANNER - A
CHAIN WRENCH
Wear the oil resistant gloves.
Secure the cylinder in the vice, interposing a rubber protection between
the vice jaws and the cylinder barrel.
Apply the C spanner to one of the notches on the seal carrier bush (ref.A
fig.1) and apply the pipe wrench to the cylinder barrel (ref.B fig.1). Un-
screw the bush from the cylinder and slide it off the rod (fig.1).

21
 HYDRAULIC SYSTEM SERVICE

Phase 3
SMALL FLAT BLADE SCREWDRIVER
Using the screwdriver, remove the external O-rings (ref.C fig.2) and the C
seals inside the bush (ref.D fig.2) and proceed with replacement.

REPLACEMENT OF THE LOWER SEALS D

Fig. 2
Phase 4
SMALL FLAT BLADE SCREWDRIVER
Remove the stem from the cylinder, remove the bottom (ref.E fig.3) and
remove the seal carrier bush (ref.F fig.3).

E
Fig. 3
Phase 5
With the small flat blade screwdriver, remove the seals and proceed with
replacement (ref.G fig.4). G

G
Fig. 4
INSTALLATION

The fitting of the seals is a delicate stage of the lift cylin-

der assembly procedure. Most maintenance operations
can be ascribed to leaking seals.

Clean the seal carrier bush and lubricate the seal contact
faces in the bush and the seals themselves with clean
hydraulic oil before installation.

The seal carrier bush should be tightened to a torque of

275 Nm.

22
 HYDRAULIC SYSTEM SERVICE

LIFT PUMP
IDENTIFICATION OF THE LIFT PUMP COMPONENTS

5
4
3
2

9
6

Ref. Description

1 Pump motor
2 Solenoid valve coil
3 Solenoid valve body
4 Pump support
5 Check valve
6 Oil inlet pipe
7 Filter
8 Pressure relief valve
10
9 O-ring
10 Tank

23
 HYDRAULIC SYSTEM SERVICE

LIFT PUMP DISMANTLING

Equipment and tools

open ended span-

small Phillips socket wrench
oil resistantgloves ner
screwdriver 13 mm
10-13-19 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 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
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove the motor cover fixing nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then on the right-hand side to trip the
locking clips (ref.B fig.1).

Fig. 1

24
 HYDRAULIC SYSTEM SERVICE

Phase 2
Fig. 2
10-13 mm open ended spanner C
Using the open ended spanner, unscrew the nuts fastening the pump
motor power cables (ref.C fig.2).
Take note of the position of the cables. Extract the cables.

Phase 3
SMALL PHILIPS SCREWDRIVER Fig. 3
Unscrew the retaining screws and disconnect the power supply connector
of the solenoid valve coil (ref.D fig.3).

D
Phase 4
OIL RESISTANT GLOVES - 19 mm open ended spanner
Wear the gloves.
Using the spanner, unscrew the connection fitting of the hydraulic pipe
(ref.E fig.3). E

Fig. 4

Phase 5
Remove the battery (reverse the procedure described in “BATTERY
INSTALLATION, “INSTALLATION AND SETTINGS” section)
F

Phase 6
13 mm OPEN ENDED SPANNER
Support the pump assembly with one hand and using the spanner unscrew
and remove the fixing screws located inside the battery compartment
(ref.F fig.4).
Recover the pump and proceed with replacement or disassembly.
F

25
 HYDRAULIC SYSTEM SERVICE

REPLACEMENT OF THE PUMP

Equipment and tools

T handle hex key Torx key oil resistant

5 mm T30 gloves

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
Carry out the procedure to remove the lift pump (see "REMOVAL OF
THE LIFT PUMP").
Fig. 2

Phase 2
T30 TORX KEY - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Unscrew the tank fastening screws using the torx key (ref.A fig.1). Re-
move the tank.

Phase 3
5 mm T HANDLE HEX WRENCH
Use the hexagonal T-handle spanner to unscrew and remove the bolts
fastening the pump chassis to the flange (ref.B fig.2), remove the pump
and proceed with the replacement.

B
INSTALLATION

During the assembly stage tighten the nuts that fasten the
pump to the flange with a torque wrench set at 29 Nm. Use
a torque wrench set at 29 Nm

26
 HYDRAULIC SYSTEM SERVICE

REPLACEMENT OF THE CYLINDER SUPPLY PIPE

Equipment and tools

open ended span-

T handle hex key
ner "Parker" caps oil resistant gloves
5-6 mm
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 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.

Phase 1
SOCKET WRENCH SIZE 13 mm
Use the T-handle socket wrench to unscrew and remove the motor cover
fixing nuts. A
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips.

Phase 2
OIL RESISTANT GLOVES - 19 mm OPEN ENDED SPANNER - "PAR-
KER" PLUGS
Wear the oil resistant gloves.
Using the spanner unscrew the couplings of the hydraulic pipe (ref.A
fig.1).
Fig. 1
Apply the caps to the fittings. Recover the hydraulic pipe and proceed
with replacement.

27
 HYDRAULIC SYSTEM SERVICE

28
 MECHANICS SERVICE

MECHANICS
DRIVE WHEEL....................................................................................................................................................2
KEY TO DRIVE WHEEL COMPONENTS.................................................................................................2
REMOVING THE DRIVE WHEEL................................................................................................................................3
CASTOR WHEELS ASSEMBLY................................................................................................................................4
KEY TO CASTOR WHEELS ASSEMBLY COMPONENTS....................................................................4
REMOVING THE CASTOR WHEELS ASSEMBLY.....................................................................................................6
ADJUSTMENT OF THE WHEEL HEIGHT.........................................................................................................................8
LOAD WHEELS..................................................................................................................................................10
KEY TO LOAD WHEEL COMPONENTS.....................................................................................10
REPLACING THE LOAD WHEELS.....................................................................................................................11
REPLACING THE LOAD WHEELS ASSEMBLY.....................................................................................................12
LINKAGE..............................................................................................................................................................13
KEY TO LINKAGE ASSEMBLY COMPONENTS................................................................................13
REMOVING THE LINKAGE ASSEMBLY..................................................................................................................14
LINKAGE ASSEMBLY GREASING POINTS..............................................................................................17
TILLER......................................................................................................................................................................18
KEY TO TILLER COMPONENTS.........................................................................................................18
DISASSEMBLY OF THE TILLER....................................................................................................................................20
TILLER SPRING REPLACEMENT...........................................................................................................................22
TRACTION MOTOR.................................................................................................................................................24
KEY TO MOTOR COMPONENTS............................................................................................................24
REMOVING THE TRACTION MOTOR........................................................................................................................25

1
 MECHANICS SERVICE

DRIVE WHEEL
KEY TO DRIVE WHEEL COMPONENTS

1 2

Ref. Description

1 Drive wheel
2 Drive wheel retaining nut

2
 MECHANICS SERVICE

REMOVAL OF THE DRIVE WHEEL

Equipment and tools

2x wooden socket wrench socket wrench ratchet with

hydraulic jack
blocks 13 mm 18 mm extension bar

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. Raise the forks to the maximum height, turn the keyswitch to OFF and disconnect
the battery.

Fig. 1

B
Phase 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and
remove the motor cover fixing nuts A
(ref.A fig.1).
Remove the motor cover by pressing your hands
first on the left and then on the right-hand side to
trip the locking clips (ref.B fig.1).

Phase 2 Fig. 2
HYDRAULIC JACK - 2 WOODEN BLOCKS
Position the hydraulic jack on the right-hand side of the truck body and
raise the truck sufficiently to insert the wooden block underneath. Lower
the jack so that the truck rests on the wooden block. Repeat the operation
on the left-hand side of the truck body (fig.2).

Phase 3
18 mm SOCKET WRENCH - RATCHET - EXTENSION - TORQUE
WRENCH
Unscrew and remove the 5 nuts securing the drive wheel to the axle shaft
and remove the wheel (ref.C fig.2).

INSTALLATION

The drive wheel retaining nuts must be tightened using a torque

wrench to a torque of 100 Nm.
C

3
 MECHANICS SERVICE

PIVOTING WHEEL ASSEMBLY

KEY TO PIVOTING WHEEL ASSEMBLY COMPONENTS

15 2

16
17 3

19

14
13
17 4
16 11
15 18

10

12
6
9

11
7
8
13
14

4
 MECHANICS SERVICE

Ref. Description

1 Cap
2 Circlip
3 Upper plate
4 Pivot assembly rotation bearing
5 Circlip
6 Yoke
7 Nut
8 Screw
9 Rubber bush
10 Wheel lower yoke
11 Spring pin
12 Axle
13 Adjustable segment
14 Flanged screw
15 Dust cover
16 Spacer
17 Wheel bearing
18 Wheel
19 Bush

5
 MECHANICS SERVICE

REMOVAL OF THE PIVOT WHEEL ASSEMBLY

Equipment and tools

hydraulic jack 2x wooden 8 mm T-handle open ended socket wrench small flat blade
ratchet
blocks swivel hex key spanner 13-15-19 mm screwdriver
wrench 13 -19 mm

Fig. 1

hammer slide hammer B

small external socket wrench
circlip pliers 13 mm

A
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. Raise the clamps to the maximum height,
turn the keyswitch to OFF and disconnect the battery.
Fig. 2

Phase 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove the motor cover fixing
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1).

Phase 2
HYDRAULIC JACK - 2 WOODEN BLOCKS
Fig. 3
Position the hydraulic jack on the right-hand side of the truck body and
C
raise the truck sufficiently to insert the wooden block underneath. Lower
the jack so that the truck rests on the wooden block. Repeat the operation
on the left-hand side of the truck body (fig.2).

Phase 3
15 mm SOCKET WRENCH - RATCHET
Using the socket wrench and ratchet, unscrew and remove the four bolts,
along with their nuts and washers, securing the castor wheel assembly
to the truck body (ref.C fig.3).
Remove the wheel assembly and proceed with its replacement or disas-
sembly.

6
 MECHANICS SERVICE

DISMANTLING OF CASTOR WHEEL

Phase 4
13 mm SOCKET WRENCH - RATCHET - 13 mm OPEN ENDED SPAN-
NER - DRIVING TOOL - HAMMER
Using the open ended spanner, lock one of the two screws fastening
the castor wheel pin, while with the socket wrench and ratchet unscrew
and remove the other screw (ref.F fig.4). Using the hammer and the pin E
punch, extract the wheel pin (ref.E fig.4), remove the adjuster segment
(ref.D fig.4) and extract the wheel from its seat.
Proceed with replacement. D F

DISASSEMBLY OF THE CASTOR WHEEL Fig. 4

Phase 5
Fig. 5
SMALL FLAT BLADE SCREWDRIVER G
Using the small flat blade screwdriver, extract the dust cap (ref.G fig.5), H
remove the spacers (ref.H fig.5), bearings (ref.I fig.5) and bush (ref.L
fig.5).
Proceed with replacement. I
L
I
REMOVAL OF THE BUFFERS
H
Phase 6
19 mm SOCKET WRENCH - RATCHET - 19 mm open ended spanner G
Counterhold the self-locking nut (ref.M fig.6) with the open ended span-
ner, while unscrewing and removing the screws of the yoke (ref.N fig.6)
using the socket wrench and the ratchet. Remove the buffers (ref.O fig.6). N
Proceed with replacement.

REMOVAL OF THE UNIT ROTATION BEARING O

Phase 7
Fig. 6 M
MEDIUM PLIERS FOR OPENING CIRCLIPS - LARGE PLIERS FOR
CLOSING CIRCLIPS - SMALL FLAT BLADE SCREWDRIVER Fig. 7
P
Using the screwdriver, remove the plug (ref.P fig.7). Using the medium
external circlip pliers, remove the ring fastening the upper plate to the Q
yoke (ref.Q Fig.7), extract the plate together with the bearing. Using the
large pliers for closing circlips, remove the locking ring (ref.S fig.7) and
remove the bearing (ref.R fig.7).
Proceed with replacement. R
S
INSTALLATION

The nut (ref.C fig.3) securing the castor wheel must be

tightened using a torque wrench to a torque of 38 Nm.

7
 MECHANICS SERVICE

ADJUSTMENT OF THE WHEEL HEIGHT

The pivot wheel assembly is equipped with a system for adjusting the height of the wheels, to be done when:
• the drive wheel is worn out and slips when driving
• one of the two pivot wheels is much more worn than the other one
• both pivot wheels are worn out and the weight of the truck rests solely on the drive wheel
Wear on the wheels must be checked on a perfectly flat floor.

Equipment and tools

2x wooden open ended socket wrench

hydraulic jack ratchet
blocks spanner 13 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 pede-
strians. Raise the clamps to the maximum height, turn the keyswitch to OFF and discon-
nect the battery.

Phase 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove Fig. 1
the motor cover fixing nuts (ref.A fig.1).
Remove the motor cover by pressing your hands
first on the left and then on the right-hand side to B
trip the locking clips (ref.B fig.1).

8
 MECHANICS SERVICE

Phase 2
Fig. 2
HYDRAULIC JACK - 2 WOODEN BLOCKS
Position the hydraulic jack on the right-hand side of the truck body and
raise the truck sufficiently to insert the wooden block underneath. Lower
the jack so that the truck rests on the wooden block. Repeat the operation
on the left-hand side of the truck body (fig.2).

Phase 3
13 mm SOCKET WRENCH - RATCHET - 13 MM OPEN ENDED SPAN-
NER
Using the open ended spanner, lock one of the two screws fastening the
castor wheel pin, while with the socket wrench and ratchet loosen the
other screw (ref.A fig.3). Loosen the two screws until the adjuster ring
nuts (ref.B fig.3) can be sufficiently extracted so as to be able to adjust
the desired height using the reference spring pins (ref.C fig.3).
Screw the fixing screws back on and carry out the same operation on A A
the other wheel. Fig. 3

C B

9
 MECHANICS SERVICE

LOAD WHEELS
KEY TO LOAD WHEEL COMPONENTS

4
5

9
8
10
11

8 9

Ref. Description

1 Shaft fastening screw

2 Shaft
3 Spring pin
4 Tie-rod pivot pin
5 Bush
6 Spring pin
7 Load wheel pin
8 Dust cover
9 Bearing
10 Load wheel
11 Spacer

10
 MECHANICS SERVICE

REPLACEMENT OF THE LOAD WHEELS

Equipment and tools

2x wooden
hammer slide hammer pin punch small flat blade cartridge grease
blocks
Ø 15 mm Ø 4 mm screwdriver gun
150 x 150 x 500
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. Raise the forks to the maximum height, press the down button to discharge the
pressure from the hydraulic system, set the keyswitch to OFF and disconnect the battery.

Phase 1 Fig. 1
2 WOODEN BLOCKS
Position the wooden blocks under the forks (fig.1). Lower the forks so
that they rest on the wooden blocks and continue lowering until the load
wheels are raised off the ground by about 2 cm.

Turn the key switch to OFF and disconnect the battery.

Phase 2
HAMMER - PIN PUNCH - DRIVING TOOL
Using the hammer and the pin punch, drive out the spring pin securing
the pivot pin (ref.A fig.2). Drive out the pivot pin (ref.B fig.2) using the B
driving tool and the hammer, then take the load wheel out of its seat and
proceed with dismantling or replacement.

Phase 3
SMALL FLAT BLADE SCREWDRIVER A
Fig. 2
Using the small flat blade screwdriver, prise off the dust cap (ref.C fig.3),
recover the bearings (ref.D fig.4) and the spacer (ref.E fig.4). Lastly
remove any remains of lubricant from the load wheel and then
proceed with replacement.
E
INSTALLATION D
C
Following installation of new load wheels, grease the bea- C
rings using a grease gun.
D
Fig. 3

11
 MECHANICS SERVICE

REPLACEMENT OF THE LOAD WHEEL ASSEMBLY

Equipment and tools

2x wooden
slide hammer socket wrench pin punch
hammer blocks ratchet
Ø 15 mm 13 mm Ø 4 mm
150 x 150 x 500
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. Raise the forks to the maximum height.

Fig. 1
Phase 1
2 WOODEN BLOCKS
Position the wooden blocks under the forks (fig.1). Lower the forks so
that they rest on the wooden blocks and continue lowering until the load
wheels are raised off the ground by about 2 cm.

Turn the key switch to OFF and disconnect the battery.

Phase 2
13MM SOCKET WRENCH - RATCHET
Using the socket wrench and ratchet, unscrew the screw (ref.A fig.2).
Drive out the pivot pin using the driving tool and the hammer (ref.B fig.2).
B
A
Fig. 2
Phase 3
HAMMER - PIN PUNCH - DRIVING TOOL
Using the hammer and the pin punch, drive out the spring pin securing C
the pivot pin (ref.C fig.3). Extract the pivot (ref.D fig.3) using the clamp
gudgeon and the hammer. Withdraw the load wheel assembly from its
housing.
D
Proceed with replacement.

Fig. 3

12
 MECHANICS SERVICE

LINKAGE
KEY TO LINKAGE ASSEMBLY COMPONENTS

1 13

2 3 12

14

12
4
4 10

9
5 7 8 11

1
4

Ref. Description

1 Screw fixing traction assembly frame pivot pin

2 Traction assembly frame pivot pin
3 Grease nipple
4 Bush
5 Rocker arm
6 Front forks frame pivot pin
7 Linkage assembly pivot pin
8 Screw fixing linkage to wheel assembly
9 Rear forks frame pivot pin
10 Spring pin
11 Wheels assembly pivot pin
12 Bush
13 Wheel
14 Grease nipple

13
 MECHANICS SERVICE

REMOVAL OF THE LINKAGE ASSEMBLY

Equipment and tools

hoist pin punch slide hammer socket wrench

socket wrench hammer
load capacity spreader bar Ø 4 mm Ø 15 mm 13 mm
13 mm
2000 kg

ratchet extension bar

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 key switch to OFF and disconnect
the battery.

When performing maintenance work that requires removing the rocker arm, it is essential
for the main frame and the forks frame to be properly supported so they cannot lower or
swing when there is no connection.
The battery is very heavy. It is recommended to be careful when handling it or working
near it to avoid any damage to persons or property.

Do not place hands, arms, feet and/or legs between the battery and a solid object. Make
sure that the capacity of the lifting device and of the spreader bar is greater than the
weight of the battery, which is normally stamped on its body. The spreader bar must not
be made of metal or must be provided with insulating belts.

Phase 1 Fig. 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove
the motor cover fixing nuts (ref.A fig.1). B
Remove the motor cover by pressing your hands
first on the left and then on the right-hand side
to trip the locking clips (ref.B fig.1).
A

14
 MECHANICS SERVICE

Phase 2
Fig. 2
BRIDGE CRANE - SPREADER BAR
Put wooden blocks on both sides of the truck near to the battery com-
partment and under both forks.
Raise the cover of the battery compartment
Hook the spreader bar to the bridge crane. Position the bridge crane
above the battery compartment.
Attach the spreader bar to the battery; carefully lift the battery clear of
the battery compartment with the bridge crane (fig.2).
Gently lower the battery to the ground and detach the spreader bar.

Disconnect all the hydraulic and electrical connections

before removing the linkage assembly.

Phase 3
T-HANDLE SOCKET WRENCH - PIN PUNCH -
HAMMER - RATCHET - EXTENSION BAR - 13MM D
SOCKET WRENCH
Unscrew the fastener securing the pivot pin joining D
the bracket and linkage (ref.C fig.2), insert the pin Fig. 2
punch into the hole (ref.D fig.2) and, with the aid of the
hammer, extract the pin.
Repeat this operation on the opposite side and
free the linkage assembly from the frame (fig.3).

Fig. 3

Phase 4
13mm SOCKET WRENCH - PUNCH PIN - HAMMER
Unscrew the fasteners securing the pivot pins of the rear linkage (ref.E F
fig.4) and, with the aid of the pin punch and hammer, extract the pin
(ref.F fig.4).

E Fig. 4

15
 MECHANICS SERVICE

Phase 5
T-HANDLE SOCKET WRENCH - PIN PUNCH - HAMMER
U s i n g t h e T- h a n d l e k e y w r e n c h , u n s c r e w t h e f a -
stener securing the linkage pivot pin to the wheel
assembly (ref.G fig.5) and, with the aid of the pin punch and hammer,
extract the pin (ref.H fig.5). Repeat this operation on the other side too.
H
G
Fig. 5

I
Phase 6
HAMMER - PIN PUNCH - DRIVING TOOL
Using the hammer and the pin punch, drive out the spring pin securing L
the pivot pin (ref.I fig.6). Drive out the pivot pin (ref.L fig.6) using the
driving tool and the hammer. Withdraw the load wheel assembly from
its housing. After repeating the operation on the other side too, you can
separate the linkage from the cover and make the replacement (Fig.7).

Fig. 6

Fig. 7

16
 MECHANICS SERVICE

LINKAGE ASSEMBLY GREASING POINTS

Set the truck on wooden blocks

to access the grease fittings.

Grease gun

17
 MECHANICS SERVICE

TILLER
KEY TO TILLER COMPONENTS

1
20

6
3 4

5 7

4 8

11

14 9
13
12
15
18 10

17

19

16

18
 MECHANICS SERVICE

Ref. Description
1 Tiller head assembly
2 Screw
3 Nut
4 Cover
5 Nut
6 Ball pivot pin
7 Spring
8 Fastening clamp
9 Tiller sensor
10 Bushing
11 Cover
12 Screw
13 Washer
14 Tiller handle pivot pin
15 Screw
16 Grommet
17 Nut
18 Screw
19 Tiller covering bracket
20 Washer

19
 MECHANICS SERVICE

DISASSEMBLY OF THE TILLER

Equipment and tools

open ended slide hammer

hammer ratchet socket wrench 5 mm T-handle
spanner Ø 15 mm
13 mm hex key
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, turn the keyswitch to OFF and disconnect
the battery.

Phase 1
Fig. 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove the
motor cover fixing nuts (ref.A fig.1). B
Remove the motor cover by pressing your hands first
on the left and then on the right-hand side to trip the
locking clips (ref.B fig.1). A

Phase 2
Fig. 2
T-HANDLE HEX KEY WRENCH
Disconnect the tiller wire (ref. C fig. 2) then, using a T-handle
hex key, unscrew the four screws fastening the tiller to the
transmission unit and remove the screws with their washers
(ref.D fig.3). Put the tiller on a work bench and disassemble it

Fig. 3 C

20
 MECHANICS SERVICE

The tiller spring contains pressurized gas and lubricating

hydraulic oil.

Phase 3
FIXED 13 mm SPANNER - 5mm HEXAGONAL "T"" SECTION SPANNER
Using one of the spanners, restrain the self-locking nut securing the tiller Fig. 4
spring (ref.F fig.4) and unscrew and remove the spring retaining bolt with
the other spanner (ref.E fig.4). Recover the self-locking nut.

F
E
Phase 4
HAMMER - CLAMP GUDGEON
Unscrew the bolt (ref.G fig.5) and remove the pivot pin (ref.H fig.5) using
the pin punch and the hammer.
Fig. 5
Remove the tiller assembly and proceed with its disassembly or
replacement.
G

21
 MECHANICS SERVICE

REPLACEMENT OF THE TILLER SPRING

Equipment and tools

open ended T-handle hex key

ratchet socket wrench
spanner wrench
13 mm
13 mm 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 the ground, turn the keyswitch to OFF and disconnect
the battery.

Phase 1
Fig. 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove
the motor cover fixing nuts (ref.A fig.1).
Remove the motor cover by pressing your hands
B
first on the left and then on the right-hand side to
trip the locking clips (ref.B fig.1).

Phase 2
Fig. 2
Remove the plastic caps to access the tiller spring (ref. C fig. 2) and
then release the spring pressure.

The tiller spring contains pressurized gas and

lubricating hydraulic oil.

22
 MECHANICS SERVICE

Phase 3
Fig. 3
2 x 13 mm OPEN ENDED SPANNERS
Disconnect the tiller wiring connector.
Using one of the spanners, restrain the self-locking nut securing the tiller
spring (ref.E fig.3) and unscrew and remove the spring retaining bolt with
the other spanner (ref.D fig.3). Recover the self-locking nut.

E
D

Phase 4
Fig. 4
HEXAGONAL 5 mm "T" SECTION SPANNER - 13mm SOCKET
WRENCH - RATCHET
Remove the plastic cap (ref.F fig.6), then unscrew and remove the I
fixing screw of the upper part of the spring (ref.G fig.6).
Withdraw the spring from the tiller and proceed with replacement. F

G F

23
 MECHANICS SERVICE

TRACTION MOTOR
KEY TO TRACTION MOTOR COMPONENTS

Ref. Description
Screws fastening the motor to the reduction
1
unit
2 Motor body
3 Speed sensor

24
 MECHANICS SERVICE

REMOVAL OF THE TRACTION MOTOR

Equipment and tools

2 open ended brush socket wrench

spanners T handle hex key
13 mm
10 mm 6 mm

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Turn the key switch to OFF and disconnect the battery.

Fig. 1

B
Phase 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove
the motor cover fixing nuts (ref.A fig.1). A
Remove the motor cover by pressing your hands
first on the left and then on the right-hand side to
trip the locking clips (ref.B fig.1).

Phase 2 Fig. 2
T-HANDLE HEX KEY WRENCH
Disconnect the tiller wire harnesses then, using a
T-handle hex key, unscrew the four screws fastening
the tiller to the transmission unit and remove the
screws with their washers (ref.C fig.2), then remove
the bracket together with the tiller.
C

Phase 3
Carry out the electromagnetic brake removal procedure (see "REMOVAL
OF THE ELECTROMAGNETIC BRAKE" in the "BRAKING SYSTEM"
section).

25
 MECHANICS SERVICE

Phase 4
Fig. 3
2 x 10 mm OPEN ENDED SPANNERS
Using the two spanners, unscrew the nuts securing the traction motor
power supply cables (ref.D fig.3). Note the position of the cables prior
to removing them. Disconnect all the wiring connectors.

Phase 5 Fig. 4
Unscrew and remove the four screws and their washers (ref.E fig.4)
fastening the traction motor to the gearbox.

Phase 5
Lift the motor until the shaft is completely removed from the reduction unit. Remove it from the truck body
and proceed with replacement or disassembly.

INSTALLATION
Before installing the motor on the reduction unit, lubricate the drive shaft with a thin, even
layer of grease.
During the coupling stage, carefully rotate the wheel shaft to help the motor shaft engage
with the pinion.
The screws securing the reduction unit to the chassis must be tightened using a torque
wrench to a torque of 24 Nm.

26
 MECHANICS SERVICE

27
 REDUCTION UNIT SERVICE

REDUCTION UNIT
KEY TO REDUCTION UNIT COMPONENTS.....................................................................................................................2
REMOVAL OF THE REDUCTION UNIT.............................................................................................................................3
CHANGE REDUCTION GEAR BEARING............................................................................................................................5

1
 REDUCTION UNIT SERVICE

KEY TO REDUCTION UNIT COMPONENTS

type gearbox supplier code

TYP.

part number CODE

C.P.N.

production date DATE NR serial number

Ref. Description

1 Reduction unit
2 Reduction unit bearing
Screws fastening the bearing to the reduction
3
gear
4 Reduction gear identification plate

2
 REDUCTION UNIT SERVICE

REMOVAL OF THE REDUCTION UNIT

Equipment and tools

lifting rope 2x wooden socket wrench extension bar

bridge crane spreader bar hydraulic jack blocks 13-21 mm

hammer slide hammer ratchet

Ø 15 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 key switch to OFF and disconnect
the battery.

Phase 1
Carry out the drive wheel removal procedure (see “REMOVAL OF THE DRIVE WHEEL” in the
“MECHANICS” section.

Phase 2
Carry out the tiller removal procedure (see “REMOVAL OF THE TILLER” in the “MECHANICS” section).

Phase 3
Carry out the lift cylinder dismantling procedure (see “LIFT CYLINDER DISMANTLING” in the "HYDRAULIC
SYSTEM" section).

Phase 4
Carry out the traction motor removal procedure (see “REMOVAL OF THE TRACTION MOTOR” in the
“MECHANICS” section).

3
 REDUCTION UNIT SERVICE

Phase 5
Fig. 1
BRIDGE CRANE - SPREADER BAR
Make sure you have put wooden blocks on both sides of the truck near
to the battery compartment and under both forks.
Raise the cover of the battery compartment
Hook the spacer bar to the bridge crane. Position the bridge crane above
the battery compartment.
Attach the spreader bar to the battery; carefully lift the battery clear of
the battery compartment with the bridge crane (fig.1).
Gently lower the battery to the ground and detach the spreader bar.

Phase 6
13MM HEX WRENCH - PIN PUNCH - HAMMER A
Unscrew the fastener securing the pin joining the bracket and linkage
(ref.A fig.2), insert the pin punch into the hole (ref.B fig.2) and, with the
aid of the hammer, extract the pin.
Repeat this operation on the opposite side and free
the linkage assembly from the frame.
B

B Fig. 2

Phase 7
21MM SOCKET WRENCH
Unscrew the 4 fasteners securing the drive assembly bracket to the frame
(ref.C fig.3), then remove it together with the reduction gear.
Remove the reduction unit (fig.4), place it on a clean workbench and
proceed with replacement or disassembly.

C Fig. 3

Fig. 4

INSTALLATION

The screws securing the drive assembly bracket to the

chassis must be tightened using a torque wrench to a
torque of 225 Nm.

4
 REDUCTION UNIT SERVICE

CHANGE REDUCTION GEAR BEARING

Equipment and tools

6 mm hex socket
vice oil resistant gloves
wrench

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.

Phase 1
OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Carry out the reduction unit removal procedure (see “REMOVAL OF THE REDUCTION UNIT”).

Phase 2
VICE - MEDIUM FLAT BLADE SCREWDRIVER
Position the reduction unit in the vice and clamp firmly.

B Fig. 1
Phase 3
SOCKET WRENCH
Unscrew the 8 screws (ref.A fig.1) securing the bearing (ref.B fig.1) to
the reduction gear, then remove the bearing and make the change.

5
 REDUCTION UNIT SERVICE

6
 BRAKING SYSTEM SERVICE

BRAKING SYSTEM
KEY TO THE COMPONENTS OF THE ELECTROMAGNETIC BRAKE.............................................2
OPERATION.....................................................................................................................................3
BRAKING SYSTEMS..............................................................................................................................3
R E M O VA L O F T H E E L E C T R O M A G N E T I C B R A K E..................................................................4

1
 BRAKING SYSTEM SERVICE

KEY TO THE COMPONENTS OF THE ELECTROMAGNETIC BRAKE

Ref. Description

1 Dust cover
2 Brake
3 Fixing screws

2
 BRAKING SYSTEM SERVICE

OPERATION
The electromagnetic brake mounted on the traction motor is a spring-operated brake.
When the electromagnet is powered, it attracts the brake plate and releases the friction disc, allowing the
latter to rotate freely.
When the power supply to the electromagnet is cut, the springs push the brake plate down onto the friction
disc, thus applying the brake.

BRAKING SYSTEMS drive control release

There are 4 braking systems used:

• Release braking
• Braking on direction reversal
• Emergency braking
• Parking brake

A) Release braking
Release braking is performed by the drive motor and controls the
deceleration ramp when the drive control is released.

direction reversal
B) Braking on direction reversal
Controls the deceleration ramp when the travel direction 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 in a distance
that is at least not less than the length of the truck itself.

C) Emergency braking
Emergency braking occurs when an alarm is triggered that requires an
immediate arrest of truck traction or when the tiller sensor is deactivated
(tiller in rest position or fully lowered).
The braking action is performed by the electromagnetic brake mounted on the traction motor.

D) Parking brake
The "parking brake" action is performed by the electromagnetic brake and is applied when the truck is
stationary and the tiller is in the rest position.

3
 BRAKING SYSTEM SERVICE

REMOVAL OF THE ELECTROMAGNETIC BRAKE

Equipment and tools

open ended span-

socket wrench 5 mm T-handle
ner scissors
size 13mm hex key
15 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 pe-
destrians. Lower the forks to the ground, turn the key switch to OFF and disconnect the
battery. Lock the wheels to prevent sudden movements.

Phase 1 Fig. 1

SOCKET WRENCH SIZE 13 mm

Use the socket wrench to unscrew and remove
the motor cover fixing screws (ref.A fig.1). B
Remove the motor cover by pressing your han-
ds first on the left and then on the right-hand
side to trip the locking clips (ref.B fig.1)
A

Fig. 2
Phase 2
5 MM T-HANDLE HEX KEY
Disconnect the tiller wire harnesses then, using a T-handle hex key,
unscrew the four screws fastening the tiller to the transmission unit and
remove the screws with their washers (ref.C fig.2), then remove the
bracket together with the tiller.

4
 BRAKING SYSTEM SERVICE

Phase 3
Fig. 3
Discharge the capacitor of the control device by connecting a 25W - 100 D
ohm resistor to connectors B+ and B- (ref.D fig.3) and disconnect the
wire harnesses of the control handle and the proximity sensor of the tiller
boom located on top of the drive motor.

Phase 4 E Fig. 4

OPEN ENDED SPANNER - T-HANDLE HEX KEY SIZE 5 mm

Remove the dust cap (ref.E fig.4)
Disconnect the brake wire harness connector then, using the T-handle
hex key, unscrew and remove the three cap screws (ref.F fig.4) securing
the brake assembly to the motor and remove the brake (fig.5). F

Fig. 5

5
 BRAKING SYSTEM SERVICE

6
 ROUTINE MAINTENANCE SERVICE

ROUTINE MAINTENANCE
OILS AND LUBRICANTS.........................................................................................................4
CLEANING PRODUCTS...........................................................................................................................4
SCHEDULED MAINTENANCE......................................................................................................5

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 can get caught up in moving parts.
• Never do any cleaning, lubrication or maintenance work with the battery connected.
• Never perform any servicing on the machine with persons at the controls, unless they are accredited
operators and help with the operation to be performed.
• Using compressed air to clean the parts, protect yourself with goggles that have side protection. The
maximum air pressure must not exceed 1 bar.
• Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable
and non-toxic trade solvents.
• Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away
into a closed metal container.
• The capacitors in the transistor control unit can keep an electric charge even after disconnecting the
battery. To avoid electric shocks and personal injury, discharge the capacitors before inspecting or
repairing any component in the electric compartment. Wear safety glasses. Make sure the battery has
been disconnected.
• Do not file or lubricate the contacts of the contactors. This could cause the contacts to stick and, as a
result, loss of control and damage to property or injury to people.
• Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.
Special companies can be employed to dispose of or recycle industrial oils according to the laws in
force in individual countries.
• Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate
under the skin; in such cases, having to make a check, use a card or a piece of wood.
• Protect the hydraulic system from dirt or contaminants getting inside when checking the fluid level of
changing the filter.
• Never operate the pump without an adequate quantity of fluid in the hydraulic system. Operation with
low levels of hydraulic fluid will damage the hydraulic pump.
• Do not place any tools on the battery. Metal items on the battery can generate accidental 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, you would risk damaging the battery casing. Check that
the battery compartment is clean and dry. When the battery is in service, the aeration plugs must all be
installed. If the aeration plugs are not installed, electrolyte can come out, corroding the battery casing
and compartment.

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 ROUTINE MAINTENANCE SERVICE

• The acid in the electrolyte can cause injury. If the electrolyte gets spilled it should be cleaned up with
water. Neutralize the acid with a solution of sodium bicarbonate (soda). Areas of the skin that come
into contact with the acid must be rinsed with water immediately. Acid splashed into the eyes must be
washed away with water constantly for at least 10 minutes, then call a doctor.
• The batteries belong to the counterweight system of the lift truck. When installing a battery that is
too small, the lift truck might not have enough weight for the nominal load. When replacing a battery,
see the truck identification data plate to check that the battery has the rated capacity and correct
dimensions. See “TRUCK AND LOAD CAPACITY IDENTIFICATION DATA” in the “PRESENTATION”
section for the exact battery specifications for the lift truck at issue.
• Do not work under a raised 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.

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 ROUTINE MAINTENANCE SERVICE

OILS AND LUBRICANTS

Application Std Cold Type

store

HYDRAULIC OIL  SHELL TELLUS S2 VX 46

 SHELL AEROSHELL FLUID 41

SHELL SPIRAX S2

OIL
 A 80W-90
S3 AX 80W-90
for lubrication
REDUCTION UNIT SHELL SPIRAX S2
 S5 ATE 75W-90
S6 AXME 75W-90

GREASE
for lubrication of
 SHELL ALBIDA GREASE EP2

PIVOT PINS, TIE-RODS AND

LEVERS  AEROSHELL GREASE 6

Insulation
Pure Vaseline
BATTERY TERMINALS

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 THE MAST PROFILES AND FORK MAST

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.

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 ROUTINE MAINTENANCE SERVICE

SCHEDULED MAINTENANCE
 = check and maintenance
 = operator check Maintenance intervals
x = replacement
every every every
Operation description 8 hours 1000 hours 3000 hours
1 day 12 months 36 months

Check the tightening of the nuts and bolts 

FRAME

Check welded joints 

General cleaning 

Check the dynamic braking action  

BRAKING SYSTEM

Check the braking action on drive reversal  

Check the normal braking action  
Check the emergency braking action  
Check the wear on brake linings (4)

General cleaning 

Check for leaks  

HYDRAULIC SYSTEM

Check hydraulic functions  

Check the oil level in the tank 
General cleaning 
Check the condition of the flexible hoses (5)

Change the oil in the tank x
Change the oil filter x

Check for oil leaks  

REDUCTION

Check noise of reduction unit 

UNIT

Change oil in the reduction unit (7)

General cleaning 
FORKS

Check condition of forks  

General cleaning 

Check the condition and wear of the driving wheel (4)  

WHEELS & TYRES

Check the condition and wear of the loading wheels (4)  

Check the castor wheels for signs of wear (4)
 
Check the bearings of the castor wheels for wear(4)  
Check the bearings of the load wheel and castor wheels for wear (4)

Check the tightness of the traction wheel nuts 
Check the tightness of the castor wheel nuts 
RODS
TIE-

Check condition of linkages 

Check tiller condition and operation 

TILLER

Check efficiency of the gas spring 

GREASING

Greasing of the MDU Gears

POINTS


Greasing pins, tie rods and levers 

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 ROUTINE MAINTENANCE SERVICE

 = check and maintenance

 = operator check Maintenance intervals
x = replacement
every every every
Operation description 8 hours 1000 hours 3000 hours
1 day 12 months 36 months
Check motor insulation 
Check wire connections 
MOTORS

Check condition of retaining nuts 

Check bearing noise 
General cleaning 
Check operation of belly switch 
CONTROLS

Check operation of horn button 


Check operation of snail button
Check the condition of the battery connection plug/socket 
ELECTRONIC

Check electrical connections 

SYSTEM

Check condition of electrical cables 

Check operation of sensors 
General cleaning 
Check battery charge levels  
Check for liquid leaks  
BATTERY

Check electrolyte specific gravity 

Check battery insulation 
Check electrolyte level (7) 
General cleaning 
Check labels and decals 

To carry out these checks and maintenance operations, refer to the instructions provided in “Maintenance proce-
(1)

dures”.
(2)
To carry out these checks and maintenance operations, contact the Hyster service centre:
(3)
To carry out these replacement operations, contact the Hyster service centre.
(4)
Replace if necessary
(5)
Proceed with replacement in the following cases:
• a shift of the connection on the pipe;
• presence of damage, cuts or superficial abrasions;
• hardening or stiffening of pipes, presence of burnt or cracked areas due to exposure to heat;
• presence of cracks, damages or strong corrosion on the coupling joint;
• presence of leaks along the pipe or at the coupling joint;
• the presence of permanent creases, compression, flattening or twists in the pipe;
• presence of blisters, softening or wear of the external coat.
(6)
Top up when the electrolyte level falls 5 - 10 mm (0.19 - 0.39 in.) below the splash guard.
(7)
Does not need to be changed, oil has a very long service life.

Trucks working in cold stores must be lubricated every 500 hours, or even more frequently in the
case of particularly intensive use

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Code: 4138678 Revision: 4 (07/2021)