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Part no.

: 550066261

Revision:

0 (01/2014)

Technical information for Yale service


centres

This manual is intended solely for the specialized technicians of


the Yale service network

D849.....

MR14 MR16N
MR16 MR16HD
MR20 MR20HD
MR25

INTRODUCTION

SERVICE

IMPORTANT
The Service Manuals are updated regularly, but may not contain the most recent product design modifications. The updated technical information is in any case available from your nearest authorised Yale
dealer. The Service Manuals provide the guidelines for correct maintenance and are designed for use by
appropriately trained technicians. Incorrect maintenance or non-compliance with the instructions contained
in this manual could cause damage to property or injury and even death to people.
We therefore recommend that you read this manual carefully and keep it in a good condition so it is always
decipherable and complete.
This manual does not replace the use and maintenance manual, it is a supplement to it.

Product support group

SERVICE

INTRODUCTION

GUIDE TO USING THE MANUAL

SECTIONS
This handbook is composed of the following sections:
Section 1:
Section 2:
Section 3:
Section 4:
Section 5:
Section 6:
Section 7:
Section 8:
Section 9:
Section 10:
Section 11:

Presentation
Installation and settings
Diagnostics and measurements
Electrical system
Hydraulic system
Truck base mechanics
Mast assembly mechanics
Small fork mast mechanics
Reduction gear
Braking system
Standard maintenance

Use the sections index with the numbered black bands to go quickly to the desired section.
SYMBOLS
Signals a danger that can cause accidents to people or damage to the machine.

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

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

INSTALLATION PROCEDURES
For the installation procedures, carry out the reverse procedure to disassembly, observing any notes and
information given for the truck to function properly.

INTRODUCTION

SERVICE

GENERAL SAFETY RULES


PERSONAL SAFETY

Always wear the personal protective equipment in situations requiring it.

Pay particular attention to the risk of getting crushed due to moving parts, oscillations, material not
properly secured when performing lifting operations or moving loads.

Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbuttoned jackets or tops with open zippers that can get caught up in moving parts.

Never do any cleaning, lubrication or maintenance work with the battery connected.

Using compressed air to clean the parts, protect yourself with goggles that have side protection. The
maximum air pressure must not exceed 1 bar.

SAFETY AT THE WORKPLACE


Make sure that all the work tools are perfectly efficient and ready for use. Keep the work surfaces clean
and clear of debris that can come into contact with parts of the machine and cause damage.

Make sure you keep sparks, naked lights and cigarettes away from fuels or flammable materials such
as the gas of the batteries and fuels.

Make sure that the work area is ventilated, well illuminated, dry and clean. Remove any puddles of
water or oil stains.

Make sure that the equipment, devices or lifting machinery used is able to sustain the load in a stable
manner.

Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable
and non-toxic trade solvents.

When working outside the garage, move the machine preferably onto the level and block it. If working
on a slope is inevitable, block the machine beforehand and move it onto a level area as soon as possible with a certain margin of safety.

Disconnect the batteries and label all the controls to signal that work is in progress. Block the machine
and every attachment that has to be raised.

Never perform any servicing on the machine with persons at the controls, unless they are accredited
operators and help with the operation to be performed.

When towing use solely the prescribed coupling points and check that the pins and/or bolts are firmly
secured before pulling. Lift and handle all the heavy parts with lifting equipment of adequate capacity.
Use the lifting eyebolts intended for this purpose. Make sure no one is near the load to be lifted.

Avoid twisting chains or metal ropes.

Do not trust bent or damaged chains or ropes: do not use them for lifting or pulling. Always wear the
safety gloves to handle them.

Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away
into a closed metal container.

Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.
Special companies can be employed to dispose of or recycle industrial oils according to the laws in
force in individual countries.

When welding is necessary, you must use appropriate safety protection: dark goggles, hard hat, overalls,
gloves, safety footwear. Dark goggles must be worn also by those who are not doing the work if they
remain nearby during the welding.

SERVICE

INTRODUCTION

Before using the batteries, make sure that both ends of the cables are connected to the terminals as
prescribed: (+) with (+) and (-) with (-).

Do not short-circuit the terminals.

The gas released when charging is highly flammable. When charging, leave the battery compartment
uncovered for more effective ventilation and take off the plugs.

Never check the battery charge with "jumpers" obtained by putting metal items on the terminals.

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

Always disconnect the battery before working on the electrical system.

For battery chargers and similar equipment, use solely auxiliary power sources with an effective ground
connection to avoid any electric shocks.

Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate
under the skin; in such cases, having to make a check, use a card or a piece of wood.

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

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE


Keep a record of all the suspension elements used, stating the characteristics of the suspension elements and the data given on the identification plate .

Never leave belts, cords or suspension elements in use whose identification plate has been lost.

Always use belts, ropes or suspension elements of suitable dimensions. Concerning the suspension
elements, take into consideration the lifting angle and any unbalancing of the load.

The bells on the suspension elements must be sized in proportion to the hook of the overhead travelling
crane and anyhow must be free to move easily.

Always rest the load in the race of the hook.

Never load the tip of the hook.

When lifting, avoid sudden operations that can jerk on the ropes and belts.

Never do any lifting with the ropes and belts twisted.

Knots are not permissible. Always protect the ropes and belts when they come into contact with sharp
edges.

When moving with no load, to prevent impact and accidental hooking, hang the hooks in the bells and
close the safety ones.

Using suspension elements under conditions of unbalanced load


If lifting unbalanced loads it is advised as a precaution to downrate the load capacities of the lifting elements:
Slings with 2 booms, consider them as corresponding to 1 boom.
Slings with 3 and 4 booms, consider them as corresponding to 2 booms.
Tips for maintenance
Periodically examine the belts, ropes and suspension elements according to current legislation to define
their state of service.
Change them in the following cases:
When the components show: deformation, cracks, hollows, cuts or abrasions.
When the wear of the components exceeds 10% of the original dimensions.
When the sling shows signs of overloading.

SERVICE

INTRODUCTION
Belt capacity table

Colour

Working load
capacity (kg)

purple
green
yellow
grey
red
brown
blue

1000
2000
3000
4000
5000
6000
8000

2000
4000
6000
8000
10000
12000
16000

1400
2800
4200
5600
7000
8400
11200

800
1600
2400
3200
4000
4800
6400

orange

10000
12000

20000
24000

14000
16800

8000
9600

15000
20000
25000
30000

30000
40000
50000
60000

21000
28000
35000
42000

12000
16000
20000
24000

1.4

0.8

orange
orange
orange
orange
orange

Coefficient

Rope capacity table

Working load
capacity (kg)

Coefficient

Colour

Track
(mm)

black
purple
black
green
yellow
grey
red
brown
blue
orange

35
50
50
60
75
120
150
180
240
300

500
1000
1500
2000
3000
4000
5000
6000
8000
10000

1000
2000
3000
4000
6000
8000
10000
12000
16000
20000

700
1400
2100
2800
4200
5600
7000
8400
11200
14000

400
800
1200
1600
2400
3200
4000
4800
6400
8000

1.4

0.8

SERVICE

INTRODUCTION

Suspension element capacity table

Colour

Working load
capacity (kg)
Coefficient

purple
green
yellow
grey
red

1000
2000
3000
4000
5000

1400
2800
3800
5600
6600

2100
4200
6300
8400
9800

2100
4200
6300
8400
10500

1.4

2.1

2.1

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

SERVICE

INTRODUCTION

TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS


Before disassembling the various parts
and nuts and bolts, read the following
carefully.
To make the threaded matings secure, LOCTITE 270 is
used for tightening the screws.
If it is not possible to unscrew the bolts because this
product has been used, avoid applying extensions to
the tools, instead slightly heat the area (at most 50C)
so as to eliminate the LOCTITE 270 effect.
In the cases described, reapply LOCTITE 270 during
installation in a moderate quantity (30% of the mating
surface).
The torque setting used for tightening the threaded
couplings is extremely important to make the coupling
secure and the machine safe.
The tables on this page give the classes of bolts normally
used with the relevant torque settings.

TORQUE SETTING Nm

Nominal
diameter

Class 8

Class 10

M3

5.2

M4

9.15

M5

12.14

14.8

M6

17.2

20.9

M8

31.8

38.1

M10

50.5

60.3

M12

74.2

88.5

M14

101.2

120.8

M16

138.2

164.9

M18

176.6

203.5

M20

225.4

259.7

M22

278.8

321.2

M24

324.8

374.2

M27

422.3

486.5

M30

516.1

594.7

TORQUE SETTING Nm
Pre-load N

Class 8.8

Class 10.9

M4

0.7

2400

1.92

1.44

3.07

2.3

4.17

3.13

M5

0.8

3880

3.88

2.91

6.2

4.65

8.43

6.33

M6

10

5490

6.58

4.94

10.5

7.9

14.3

10.8

M8

1.25

13

9990

16

12

25.6

19.2

34.8

26.1

M8

13

10700

17.1

12.8

27.4

20.5

37.3

27.9

M10

1.5

16

15825

31.7

23.8

51

38

69

52

M10

1.25

16

16700

33.4

25.1

53

40.1

73

55

M12

1.75

18

10

23025

55

41.4

88

66

120

90

M12

1.25

18

10

25150

60

45.3

96

72

130

98

M14

21

12

31400

88

66

140

105

190

145

M14

1.5

21

12

34125

96

72

155

115

210

155

M16

24

14

42850

135

105

220

165

300

225

M16

1.5

24

14

45600

145

110

235

175

320

240

M20

2.5

30

17

66875

270

200

430

320

580

435

M20

1.5

30

17

74250

295

225

475

355

650

485

= with lubricant

Class 5.8

SERVICE

INTRODUCTION

CORRECT METHOD FOR APPLYING FEMALE FITTINGS


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

UNF
thread

METRIC REVOLVING FEMALE


Torque setting Nm
Outside
diameter
Nominal torque
min / max
of the pipe

UNF
thread

REVOLVING FEMALE jic 37


Torque setting Nm
Size

Nominal torque

min / max

M 12x1.5

20

15 -25

7/16-20

-4

15

9 - 21

M 14x1.5

38

30 - 45

1/2-20

-5

20

13 - 27

45

38 - 52

9/16-18

-6

30

18 - 42

3/4-16

-8

50

30 - 70

7/8-14

-10

69

44 - 94

1.1/16-12

-12

98

63 - 133

1.3/16-12

-14

118

73 - 163

1.5/16-12

-16

140

90 - 190

1.5/8-12

-20

210

135 - 285

M 16x1.5
M 18x1.5
M 20x1.5
M 22x1.5

8
10
10
12
12
14
15

51

43 - 85

58

50 - 65

74

60 - 88

M 24x1.5

16

74

60 - 88

1.7/8-12

-24

290

200 - 380

M 26x1.5

18

105

85 - 125

2.1/2-12

-32

450

300 - 600

135

115 - 155

166

140 - 192

30

240

210 - 270

35

290

255 - 325

330

280 - 380

M 30x2
M 36x2
M 42x2
M 45x2
M 52x2

UNF
thread
G1/4

20
22
25
28

38
42

REMOVING FEMALE BSP


Torque setting Nm

UNF
thread

REVOLVING FEMALE ORFS


Torque setting Nm
Size

Nominal torque

max.

Nominal torque

max

20

15 - 25

9/16-18

-4

14

16

-6

24

27
47

G3/8

34

27 - 41

11/16-16

G1/2

60

42 - 76

13/16-16

-8

43

G5/8

69

44 - 94

1-14

-10

60

68

G3/4

115

95 - 135

1.3/16-12

-12

90

95

G1

140

115 - 165

1.3/16-12

-14

90

95

G1.1/4

210

140 - 280

1.7/16-12

-16

125

135

G1.1/2

290

215 - 365

1.11/16-12

-20

170

190

G2

400

300 - 500

2-12

-24

200

225

2-1/2-20

-32

460

490

The values given in the tables refer to galvanized steel fittings. Fittings of other materials
have other values.
9

INTRODUCTION

SERVICE

INSTRUCTIONS FOR INSTALLING FLEXIBLE HOSES AND FITTINGS


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

a shift of the connector on the pipe;


the presence of damage, cuts or abrasions on the surface layer;
hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
the presence of cracks, damage or bad corrosion on the connector;
the presence of leaks along the pipe or at the connector;
the presence of permanent creases, compression, flattening or twists in the pipe;
the presence of blisters, softening, wear of the external coat.

Pre-installation inspection
Before installing a flexible hose it is necessary to inspect the pipes carefully. First check that the type, size,
reference code and length are correct, then check there is no debris, blockages, bubbles, peeling of the
outer layer or any other visible defects.
Installation
Avoid twisting the pipe, which could cause it to burst under pressure.
There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assembled pipe decreases considerably when below the minimum radius of curvature.
The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly
greater length than the requirement in order to compensate for these changes.

10

SERVICE

INTRODUCTION

SECTION CONTENTS

Presentation

Installation and settings

Diagnostics and measurements

Electrical system

Hydraulic system

Truck base mechanics

Mast assembly mechanics

6
7

Small fork mast mechanics

6
8

Reduction gear

7
9

Braking system

10
8

Standard maintenance

11
7

11

INTRODUCTION

12

SERVICE

SERVICE

PRESENTATION

Presentation
TRUCK PRESENTATION 2
VIEWS OF THE TRUCK 3
TRUCK AND LOAD IDENTIFICATION DATA 4
TRUCK IDENTIFICATION DATA PLATE 4
RESIDUAL LOAD PLATE  4
MAST SERIAL NUMBER PUNCHING and location of documentation 5
GENERAL SPECIFICATIONS 6
BATTERIES TABLE 10

PRESENTATION

SERVICE

TRUCK PRESENTATION
The new range of retractable trucks consists of 7 models with nominal load capacities from 1400 kg to
2500 kg.
Electrical system
All the motors benefit from the use of three phase AC alternate current technology: traction motor, steering
motor and pump motor.
The high battery efficiency is ensured by the regenerative inversion and release braking.
The electronic controls VCM, ACE2 Traction, ACE2 Pump and EPS ACW communicate via a CAN-Bus
system (Controller Area Network Bus). There are two separate CAN-Bus lines to improve the efficiency,
reliability and independence of the modules.
Hydraulic system
The 14 kW pump motor provides excellent performance thanks to the technology with proportional solenoid valves for the carriage out/return, lifting/lowering, fork tilting and side shifting operations with smooth
movements of the actuators.
Mast
The masts comprise three stages: external, middle and internal.
The rigidity and stability characteristics of the masts allow the forks to reach maximum heights of between
5 and 12 metres depending on the model.
The lifting cylinders are single-acting plungers.

SERVICE

PRESENTATION

VIEWS OF THE TRUCK

PRESENTATION

SERVICE

TRUCK AND LOAD IDENTIFICATION DATA


TRUCK IDENTIFICATION DATA PLATE

The truck identification data plate is located inside the


driver's cab

Manufacturer's name
Model
Serial number
Weight without battery
Year of manufacture

Max. battery weight


Min. battery weight
Battery voltage
Nominal load capacity
Persons on board

RESIDUAL LOAD PLATE

The load plate is located on the roof assembly


The load plate bears the following data:

Model
Liftable load values up to varying heights up to the maximum load with different distances from the
load centre of gravity of the forks.

Always refer to the load plate to be sure to lift an admissible load to an appropriate
height.
4

SERVICE

PRESENTATION

MAST SERIAL NUMBER PUNCHING and location of documentation

xxxxxxxx

The mast serial number is stamped on the


mast itself.

The truck documentation is stored in the document holder behind the backrest of the seat.

PRESENTATION

GENERAL SPECIFICATIONS

SERVICE

SERVICE

PRESENTATION

1.2
1.3
1.4
1.5
1.6
1.8
1.9
2.1
2.3
2.4
2.5
3.1
3.2
3.3
3.5
3.7
4.1
4.2
4.3
4.4
4.5
4.7
4.8
4.10
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.28
4.31
4.32
4.34.1
4.34.2
4.35
4.37
4.42

OTHER
DATA

MOTOR UNITS

PERFORMANCE

DIMENSIONS

WHEELS &
TYRES

WEIGHTS CHARACTERISTICS

GENERAL SPECIFICATIONS
manufacturers type designation
motor unit: battery, diesel, LPG, petrol, electric
driving: manual, on ground, standing, seated
load capacity/rated load
Q (t)
load centre of gravity
c (mm)
load distance from load wheel axle - forks
x (mm)
wheelbase (WB)
y (mm)
weight with no load (including battery)
kg
load on axle with no load (front/rear) (5)
kg
kg
load on axle with forks out with load (front/rear)
kg
load on axle with forks retracted with load (front/rear)
tyres: full rubber, polyurethane, vulkollan (front/rear)
front wheel size
(mm x mm)
rear wheel size
(mm x mm)
wheel quantity (x = traction) (front/rear)
rear track width
b 11 (mm)
/ ()
mast tilt / forks forward/backward
h1 (mm)
height of closed mast
h2 (mm)
free lift
lifting height
h3 (mm)
h4 (mm)
height, mast extended (1)
h6 (mm)
height of protective roof assembly (cab) (2)
h7 (mm)
seat height
h8 (mm)
armrest height
total length
l1 (mm)
length to face of forks
l2 (mm)
b1/b2 (mm)
overall width (3)
fork dimensions DIN ISO 2331
s/e/l (mm)
fork carriage ISO 2328, class/type A,B
b3 (mm)
fork carriage width
b5 (mm)
outer fork width (min/max) (8)
b4 (mm)
distance between the clamps of the load wheels
I4 (mm)
retractable travel
m1 (mm)
ground clearance under mast with load
ground clearance at wheelbase centre
m2 (mm)
working aisle for pallet length 1000 x 1200 crosswise
Ast (mm)
Ast (mm)
working aisle for pallet length 800 x 1200 lengthwise
turning radius
Wa (mm)
I7 (mm)
length between the wheel arms
mm
wheelbase height (from ground to footboard)
wheelbase height (between the steps between the footboard and the
mm
4.43
ground)
5.1 traction speed with/without load (7)
km/h
km/h
5.1.1 traction speed with/without load reverse drive (7)
5.2

lift speed with/without load (7)

m/s

5.3
5.4
5.7
5.8
5.9
5.10
6.1
6.2
6.3
6.4
6.5
6.6
8.1
10.1
10.2
10.7

lowering speed with/without load


Retractable carriage speed
grade ability with/without load
maximum gradeability with/without load
acceleration time, laden/unladen
service brake
traction motor, power S2 60 minutes
lifting motor, power S3 15%
battery in compliance with DIN 43531/35/36 A,B,C, no
battery rated voltage/capacity at 5 hours
battery weight (4)
consumption per VDI cycle
type of drive control
working pressure for additional attachments
volume of oil for additional attachments
noise level at the operating station

m/s
m/s
%
%
s
kW
kW
V/Ah
kg
kWh/h
bar
l/min
dB(A)

MR14

MR16
MR16N
electric (battery)
seated
1.4
1.6
1.6
600
600
600
258
308
202
1400
1450
1450
3495
3546
3498
2055/1440 2103/1443 1955/1543
885/4010 810/4336
757/4341
1711/3184 1779/3367 1514/3584
vulkollan/vulkollan
343 x 140 343 x 140 343 x 140
285 x 100 285 x 100 285 x 100
1x/2
1x/2
1x/2
1155
1155
1025
2/4
2/4
2/4
2195
2195
2195
1648
1648
1648
5000
5000
5000
5563
5563
5563
2175
2175
2175
1082
1082
1082
308
308
308
2523
2523
2629
1373
1373
1479
1265
1265
1125
40/80/1150 40/120/1150 40/120/1150
2A
2A
2A
700
700
700
220/640
260/680
260/680
900
900
795
441
491
385
75
75
75
75
75
75
2825
2834
2898
2895
2896
2976
1671
1718
1700
1795
1845
1845
550
550
550
371

371

371

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


11/11(14/14) 11/11(14/14) 11/11(14/14)
0,37 / 0,63 0,32 / 0,63 0,32 / 0,63
(0,47 / 0,73) (0,42 / 0,73) (0,42 / 0,73)
0.55
0.55
0.55
0,15 / 0,15 0,15 / 0,15 0.15 / 0.15
12 / 15
11 / 15
11 / 15
12 / 15
12 / 15
12 / 15
-/-/-/Electrical
6,4
6,4
6,4
14
14
14
C
C
B
48/700 (6)
48/700 (6)
48/700 (6)
1119
1119
1119
-/-/-/AC
180
180
180
20
20
20
<69.7
<69.7
<69.7

SERVICE

PRESENTATION

1.2
1.3
1.4
1.5
1.6
1.8
1.9
2.1
2.3
2.4
2.5
3.1
3.2
3.3
3.5
3.7
4.1
4.2
4.3
4.4
4.5
4.7
4.8
4.10
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.28
4.31
4.32
4.34.1
4.34.2
4.35
4.37
4.42

DIMENSIONS

WHEELS &
TYRES

WEIGHTS CHARACTERISTICS

GENERAL SPECIFICATIONS

OTHER
DATA

MOTOR UNITS

PERFORMANCE

4.43

5.1
5.1.1
5.2
5.3
5.4
5.7
5.8
5.9
5.10
6.1
6.2
6.3
6.4
6.5
6.6
8.1
10.1
10.2
10.7

manufacturers type designation


motor unit: battery, diesel, LPG, petrol, electric
driving: manual, on ground, standing, seated
load capacity/rated load
Q (t)
load centre of gravity
c (mm)
load distance from load wheel axle - forks
x (mm)
wheelbase (WB)
y (mm)
weight with no load (including battery)
kg
load on axle with no load (front/rear) (5)
kg
kg
load on axle with forks out with load (front/rear)
kg
load on axle with forks retracted with load (front/rear)
tyres: full rubber, polyurethane, vulkollan (front/rear)
front wheel size
(mm x mm)
rear wheel size
(mm x mm)
wheel quantity (x = traction) (front/rear)
rear track width
b 11 (mm)
/ ()
mast tilt / forks forward/backward
h1 (mm)
height of closed mast
h2 (mm)
free lift
lifting height
h3 (mm)
h4 (mm)
height, mast extended (1)
h6 (mm)
height of protective roof assembly (cab) (2)
h7 (mm)
seat height
h8 (mm)
armrest height
total length
l1 (mm)
length to face of forks
l2 (mm)
overall width (3)
b1/b2 (mm)
fork dimensions DIN ISO 2331
s/e/l (mm)
fork carriage ISO 2328, class/type A,B
b3 (mm)
fork carriage width
outer fork width (min/max) (8)
b5 (mm)
b4 (mm)
distance between the clamps of the load wheels
I4 (mm)
retractable travel
m1 (mm)
ground clearance under mast with load
ground clearance at wheelbase centre
m2 (mm)
working aisle for pallet length 1000 x 1200 crosswise
Ast (mm)
Ast (mm)
working aisle for pallet length 800 x 1200 lengthwise
turning radius
Wa (mm)
I7 (mm)
length between the wheel arms
mm
wheelbase height (from ground to footboard)
wheelbase height (between the steps between the footboard and the
mm
ground)
traction speed with/without load (7)
km/h
km/h
traction speed with/without load reverse drive (7)
lift speed with/without load (7)
m/s
lowering speed with/without load
m/s
m/s
Retractable carriage speed
%
grade ability with/without load
maximum gradeability with/without load
%
s
acceleration time, laden/unladen
service brake
traction motor, power S2 60 minutes
kW
lifting motor, power S3 15%
kW
battery in compliance with DIN 43531/35/36 A,B,C, no
battery rated voltage/capacity at 5 hours
V/Ah
battery weight (4)
kg
kWh/h
consumption per VDI cycle
type of drive control
working pressure for additional attachments
bar
volume of oil for additional attachments
l/min
noise level at the operating station
dB(A)

MR20
MR25
electric (battery)
seated
2.0
2.5
600
600
358
431
1500
1650
3801
4230
2296/1504 2565/1665
770/5030
876/5855
1971/3829 2306/4424
vulkollan/vulkollan
343 x 140 343 x 140
285 x 100 285 x 140
1x/2
1x/2
1155
1195
2/4
2/4
2195
2195
1582
1582
4650
4650
5263
5263
2175
2175
1082
1082
308
308
2523
2600
1373
1450
1265
1345
40/120/1150 45/120/1150
2A
2A
700
700
260/680
260/680
900
900
541
614
65
65
65
65
2846
2938
2900
2978
1767
1911
1895
2045
550
550

371

371

14 / 14
14 / 14
14 / 14
14 / 14
0.37 / 0.64 0.30 / 0.64
0.55 / 0.50 0.55 / 0.50
0,15 / 0,15 0.15 / 0.15
10 / 15
8 / 14
12 / 15
12 / 15
-/-/Electrical
6,4
6,4
14
14
C
C
48/700 (6)
48/840 (6)
1119
1306
-/-/AC
180
180
20
20
<69.7
<69.7

SERVICE

PRESENTATION

1.2
1.3
1.4
1.5
1.6
1.8
1.9
2.1
2.3
2.4
2.5
3.1
3.2
3.3
3.5
3.7
4.1
4.2
4.3
4.4
4.5
4.7
4.8
4.10
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.28
4.31
4.32
4.34.1
4.34.2
4.35
4.37
4.42

DIMENSIONS

WHEELS &
TYRES

WEIGHTS CHARACTERISTICS

GENERAL SPECIFICATIONS

OTHER
DATA

MOTOR UNITS

PERFORMANCE

4.43
5.1
5.1.1
5.2
5.3
5.4
5.7
5.8
5.9
5.10
6.1
6.2
6.3
6.4
6.5
6.6
8.1
10.1
10.2
10.7

manufacturers type designation


motor unit: battery, diesel, LPG, petrol, electric
driving: manual, on ground, standing, seated
load capacity/rated load
Q (t)
load centre of gravity
c (mm)
load distance from load wheel axle - forks
x (mm)
wheelbase (WB)
y (mm)
weight with no load (including battery)
kg
load on axle with no load (front/rear) (5)
kg
kg
load on axle with forks out with load (front/rear)
kg
load on axle with forks retracted with load (front/rear)
tyres: full rubber, polyurethane, vulkollan (front/rear)
front wheel size
(mm x mm)
rear wheel size
(mm x mm)
wheel quantity (x = traction) (front/rear)
rear track width
b 11 (mm)
/ ()
mast tilt / forks forward/backward
h1 (mm)
height of closed mast
h2 (mm)
free lift
lifting height
h3 (mm)
h4 (mm)
height, mast extended (1)
h6 (mm)
height of protective roof assembly (cab) (2)
h7 (mm)
seat height
h8 (mm)
armrest height
total length
l1 (mm)
length to face of forks
l2 (mm)
overall width (3)
b1/b2 (mm)
fork dimensions DIN ISO 2331
s/e/l (mm)
fork carriage ISO 2328, class/type A,B
b3 (mm)
fork carriage width
outer fork width (min/max) (8)
b5 (mm)
b4 (mm)
distance between the clamps of the load wheels
I4 (mm)
retractable travel
m1 (mm)
ground clearance under mast with load
ground clearance at wheelbase centre
m2 (mm)
working aisle for pallet length 1000 x 1200 crosswise
Ast (mm)
Ast (mm)
working aisle for pallet length 800 x 1200 lengthwise
turning radius
Wa (mm)
I7 (mm)
length between the wheel arms
mm
wheelbase height (from ground to footboard)
wheelbase height (between the steps between the footboard and the
mm
ground)
traction speed with/without load (7)
km/h
km/h
traction speed with/without load reverse drive (7)
lift speed with/without load (7)
m/s
lowering speed with/without load
m/s
m/s
Retractable carriage speed
%
grade ability with/without load
maximum gradeability with/without load
%
s
acceleration time, laden/unladen
service brake
traction motor, power S2 60 minutes
kW
lifting motor, power S3 15%
kW
battery in compliance with DIN 43531/35/36 A,B,C, no
battery rated voltage/capacity at 5 hours
V/Ah
battery weight (4)
kg
kWh/h
consumption per VDI cycle
type of drive control
working pressure for additional attachments
bar
volume of oil for additional attachments
l/min
noise level at the operating station
dB(A)

MR16HD
MR20HD
electric (battery)
seated
1.6
2.0
600
600
308
281
1450
1500
4224
4617
2428/1796 2577/2040
979/4845
985/5632
2104/3720 2149/4468
vulkollan/vulkollan
343 x 140 343 x 140
285 x 100 285 x 140
1x/2
1x/2
1155
1195
2/4
2/4
3227
3227
2680
2614
7900
7750
8463
8363
2175
2175
1082
1082
308
308
2523
2600
1373
1450
1265
1345
40/120/1150 45/120/1150
2A
2A
700
700
260/680
260/680
900
900
491
464
65
65
65
65
2834
2903
2896
2970
1718
1767
1845
1895
550
550

371

371

14 / 14
14 / 14
14 / 14
14 / 14
0,42 / 0,73 0,37 / 0,68
0.55
0.55
0,15 / 0,15 0.15 / 0.15
10 / 14
8 / 13
12 / 15
12 / 15
-/-/Electrical
6,4
6,4
14
14
C
C
48/700 (6)
48/840 (6)
1119
1306
-/-/AC
180
180
20
20
<69.7
<69.7

SERVICE

PRESENTATION
NOTES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

with load grille h4 + 508 mm (all models except for 2 ton and 2.5 ton), h4 + 443 mm (2 ton and 2.5 ton models only)
with flashing light h6 + 120 mm; with protective grille h6 + 20 mm; with protective screen h6 + 30 mm
with load wheel side cover: 1289 mm (all models except for Narrow, 2.5 ton, HD 2.0 ton versions), 1153 mm (Narrow model only), 1373
mm (2.5 ton, HD 2.0 ton models only)
This value can vary by 5%
Forks retracted
see batteries table
the values in
parentheses are optional
the side shift travel is 75 mm on all models. It is reduced to 25 mm for the Narrow model

BATTERIES TABLE
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

10

manufacturers type designation


load distance from load wheel axle - forks
wheelbase (WB)
weight with no load (including battery)
load on axle with no load (front/rear) (5)
load on axle with forks out with load (front/rear)
load on axle with forks retracted with load (front/
rear)
total length
length to face of forks
retractable travel
working aisle for pallet length 1000 x 1200 crosswise
working aisle for pallet length 800 x 1200 lengthwise
turning radius
battery in compliance with DIN 43531/35/36 A,B,C,
no
battery rated voltage/capacity at 5 hours
battery weight (4)

manufacturers type designation


load distance from load wheel axle - forks
wheelbase (WB)
weight with no load (including battery)
load on axle with no load (front/rear) (5)
load on axle with forks out with load (front/rear)
load on axle with forks retracted with load (front/
rear)
total length
length to face of forks
retractable travel
working aisle for pallet length 1000 x 1200 crosswise
working aisle for pallet length 800 x 1200 lengthwise
turning radius
battery in compliance with DIN 43531/35/36 A,B,C,
no
battery rated voltage/capacity at 5 hours
battery weight (4)

x (mm)
y (mm)
kg
kg
kg

402
1400
3112
1977/1135
682/3830

330
1400
3309
2025/1285
792/3917

MR14
402
1400
3112
1977/1135
682/3830

330
1400
3320
2032/1289
800/3921

258
1400
3541
2084/1457
914/4027

kg

1778/2735

1753/2956

1778/2735

1760/2960

1741/3201

l1 (mm)
l2 (mm)
I4 (mm)

2379
1229
585

2451
1301
513

2379
1229
585

2451
1301
513

2523
1373
441

Ast (mm)

2718

2771

2718

2771

2826

Ast (mm)

2764

2829

2764

2829

2895

Wa (mm)

1671

1671

1671

1671

1671

C "Super"

C "Super"

C "Super"

V/Ah
kg

48/420
750

48/560
939

48/465
750

48/620
950

48/775
1165

x (mm)
y (mm)
kg
kg
kg

452
1450
3162
2018/1144
601/4162

380
1450
3360
2069/1291
714/4246

MR16
452
1450
3162
2018/1144
601/4162

380
1450
3371
2077/1294
721/4250

308
1450
3592
2133/1459
839/4352

kg

1853/2909

1825/3135

1853/2909

1832/3139

1809/3383

l1 (mm)
l2 (mm)
I4 (mm)

2379
1229
635

2451
1301
563

2379
1229
635

2451
1301
563

2523
1373
491

Ast (mm)

2731

2781

2731

2781

2834

Ast (mm)

2767

2830

2767

2830

2896

Wa (mm)

1718

1718

1718

1718

1718

C "Super"

C "Super"

C "Super"

48/420
750

48/560
939

48/465
750

48/620
950

48/775
1165

V/Ah
kg

SERVICE
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

PRESENTATION

manufacturers type designation


load distance from load wheel axle - forks
wheelbase (WB)
weight with no load (including battery)
load on axle with no load (front/rear) (5)
load on axle with forks out with load (front/rear)
load on axle with forks retracted with load (front/
rear)
total length
length to face of forks
retractable travel
working aisle for pallet length 1000 x 1200 crosswise
working aisle for pallet length 800 x 1200 lengthwise
turning radius
battery in compliance with DIN 43531/35/36 A,B,C,
no
battery rated voltage/capacity at 5 hours
battery weight (4)

x (mm)
y (mm)
kg
kg
kg

382
1450
3111
1922/1189
569/4142

292
1450
3309
1947/1362
672/4237

MR16N
382
1450
3115
1924/1191
572/4143

292
1450
3317
1952/1365
677/4240

202
1450
3514
1965/1549
766/4347

kg

1680/3032

1606/3303

1682/3033

1611/3306

1524/3590

l1 (mm)
l2 (mm)
I4 (mm)

2449
1299
565

2539
1389
475

2449
1299
565

2539
1389
475

2629
1479
385

Ast (mm)

2762

2828

2762

2828

2899

Ast (mm)

2811

2893

2811

2893

2976

Wa (mm)

1700

1700

1700

1700

1700

B "Super"

B "Super"

B "Super"

48/420
746

48/560
937

48/465
750

48/620
945

48/775
1135

1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

manufacturers type designation


load distance from load wheel axle - forks
wheelbase (WB)
weight with no load (including battery)
load on axle with no load (front/rear) (5)
load on axle with forks out with load (front/rear)
load on axle with forks retracted with load (front/rear)
total length
length to face of forks
retractable travel
working aisle for pallet length 1000 x 1200 crosswise
working aisle for pallet length 800 x 1200 lengthwise
turning radius
battery in compliance with DIN 43531/35/36 A,B,C, no
battery rated voltage/capacity at 5 hours
battery weight (4)

1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

manufacturers type designation


load distance from load wheel axle - forks
wheelbase (WB)
weight with no load (including battery)
load on axle with no load (front/rear) (5)
load on axle with forks out with load (front/rear)
load on axle with forks retracted with load (front/rear)
total length
length to face of forks
retractable travel
working aisle for pallet length 1000 x 1200 crosswise
working aisle for pallet length 800 x 1200 lengthwise
turning radius
battery in compliance with DIN 43531/35/36 A,B,C, no
battery rated voltage/capacity at 5 hours
battery weight (4)

V/Ah
kg

x (mm)
y (mm)
kg
kg
kg
kg
l1 (mm)
l2 (mm)
I4 (mm)
Ast (mm)
Ast (mm)
Wa (mm)
V/Ah
kg

x (mm)
y (mm)
kg
kg
kg
kg
l1 (mm)
l2 (mm)
I4 (mm)
Ast (mm)
Ast (mm)
Wa (mm)
V/Ah
kg

MR20
430
430
358
1500
1500
1500
3615
3626
3847
2261/1354 2268/1358 2326/1520
671/4943
679/4947
801/5046
2032/3583 2039/3586 2002/3845
2451
2451
2523
1301
1301
1373
613
613
541
2795
2795
2846
2835
2835
2900
1767
1767
1767
C
C "Super" C "Super"
48/560
48/620
48/775
939
950
1165

MR25
503
503
431
1650
1650
1650
4038
4084
4292
2520/1518 2552/1532 2606/1686
773/5765
804/5780
917/5875
2371/4167 2402/4182 2348/4444
2528
2528
2600
1378
1378
1450
686
686
614
2890
2890
2938
2915
2915
2978
1911
1911
1911
C
C "Super" C "Super"
48/700
48/775
48/930
1119
1165
1368

11

SERVICE

PRESENTATION
1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

manufacturers type designation


load distance from load wheel axle - forks
wheelbase (WB)
weight with no load (including battery)
load on axle with no load (front/rear) (5)
load on axle with forks out with load (front/rear)
load on axle with forks retracted with load (front/rear)
total length
length to face of forks
retractable travel
working aisle for pallet length 1000 x 1200 crosswise
working aisle for pallet length 800 x 1200 lengthwise
turning radius
battery in compliance with DIN 43531/35/36 A,B,C, no
battery rated voltage/capacity at 5 hours
battery weight (4)

1.2
1.8
1.9
2.1
2.3
2.4
2.5
4.19
4.20
4.28
4.34.1
4.34.2
4.35
6.3
6.4
6.5

manufacturers type designation


load distance from load wheel axle - forks
wheelbase (WB)
weight with no load (including battery)
load on axle with no load (front/rear) (5)
load on axle with forks out with load (front/rear)
load on axle with forks retracted with load (front/rear)
total length
length to face of forks
retractable travel
working aisle for pallet length 1000 x 1200 crosswise
working aisle for pallet length 800 x 1200 lengthwise
turning radius
battery in compliance with DIN 43531/35/36 A,B,C, no
battery rated voltage/capacity at 5 hours
battery weight (4)

x (mm)
y (mm)
kg
kg
kg
kg
l1 (mm)
l2 (mm)
I4 (mm)
Ast (mm)
Ast (mm)
Wa (mm)
V/Ah
kg

x (mm)
y (mm)
kg
kg
kg
kg
l1 (mm)
l2 (mm)
I4 (mm)
Ast (mm)
Ast (mm)
Wa (mm)
V/Ah
kg

MR16HD
308
308
308
1450
1450
1450
4038
4049
4270
2417/1621 2424/1625 2457/1813
883/4755
891/4758 1009/4861
2172/3466 2180/3469 2134/3736
2523
2523
2523
1373
1373
1373
491
491
491
2834
2834
2834
2896
2896
2896
1718
1718
1718
C
C "Super" C "Super"
48/560
48/620
48/775
939
950
1165

MR20HD
353
353
281
1500
1500
1500
4425
4471
4679
2567/1858 2597/1874 2616/2063
891/5534
921/5550 1024/5655
2235/4189 2266/4205 2189/4490
2528
2528
2600
1378
1378
1450
536
536
464
2850
2850
2903
2904
2904
2970
1767
1767
1767
C
C "Super" C "Super"
48/700
48/775
48/930
1119
1165
1368

NOTES
(4)
(5)

This value can vary by 5%


Forks retracted

The weights from point 2.1 to 2.5 are calculated with the mast lowered and standard forks

All values are nominal and may be subject to tolerances. The values may vary with alternative configurations.

12

SERVICE

INSTALLATION AND SETTINGS

Installation and
settings
BEFORE INSTALLATION 2
WEIGHT TABLES 2
TRUCK ASSEMBLY 6
LIST OF MATERIALS RECEIVED FROM THE DEALER 6
UNLOADING OFF THE TRUCK AND FITTING THE MAST TO THE TRUCK BASE 8
TOPPING UP THE OIL RESERVOIR 10
INSTALLATION OF THE BATTERY 11
ASSEMBLY OF MOVING FORKS 14
CONTRASTING ROLLER ASSEMBLY 15
List of the SETTINGS AND ADJUSTMENTS to be carried out 16
SETTING THE ACE2 TRACTION AND THE ACE2 PUMP MODULE BATTERY VOLTAGES 16
CHECK THE CONDITIONS OF USE OF THE TRUCK 18
CHECK THE MOVEMENT OF THE CONTRASTING AISLE ROLLERS 18
Enabling and programming of the LEVEL pre-selector. 19
ENABLING AND PROGRAMMING MIDDLE FORK LIFTING BLOCKS  19
ENABLING AND PROGRAMMING OF THE PASSWORD 19

SERVICE

INSTALLATION AND SETTINGS

BEFORE INSTALLATION
Depending on the size of the mast and the kind of transportation (container, truck, etc.), the carriage may
be shipped:
complete in vertical position (option A)
with the mast assembly separate from the truck base (option B).
In the second instance one must check in advance that one is equipped with all the tools necessary to bring
it to the vertical position and fit the column (hire forklift truck, bridge crane, belts, etc.). These machines
are tested for all their functions and the mast assemblies are then dismantled, tying the fork carrier plate to
the base of the column so that it does not run along the inner mast; caps are also put on all the hydraulic
connectors to prevent oil leaking out during transport. When the unit arrives, the column must have been
fitted and testing performed for all the functions.
Before delivering to the client it is very important to check the suitability of the place where the carriage is
to be installed.
WEIGHT TABLES
COMPLETE FORKLIFT TRUCK

Model

Height of mast
assembly when
closed
(h1)

Height of mast
assembly when
open
(h3)

Weight of
truck base

Weight of
retractable
carriage

Total weight
(excluding
battery)

mm

mm

kg

kg

kg

MR14

(1)

2195

5000

1125

222

2435

MR16H

(2)

2195

5000

1136

222

2485

MR16N

(3)

2195

5000

1095

210

2432

MR20

(4)

2195

4650

1324

242

2740

MR25

(5)

2195

4650

1547

242

2978

MR16HD (6)

3227

8050

1327

245

3134

MR20HD (7)

3227

7900

1487

245

3335

battery 420DinC, forks 80x40x1150


battery 420DinC, forks 120x40x1150
(3)
battery 420DinB, forks 120x40x1150
(4)
battery 560DinC, forks 120x40x1150
(5)
battery 700DinC, forks 120x45x1150
(6)
battery 560DinC, forks 120x40x1150
(7)
battery 700DinC, forks 120x45x1150
(1)
(2)

SERVICE

INSTALLATION AND SETTINGS

BATTERIES
Weight (kg)

Type
48/420
48/560
48/700
48/840

min.

max.

DIN C

735

810

DIN B

736

811

DIN C

922

1016

DIN B

925

1018

DIN C

1099

1211

DIN B

1104

1216

DIN C

1282

1413

FORK CARRIAGE
Models

Weight
(kg)

MR14 MR16H MR16N


MR20 MR16HD

115.6

MR25 MR20HD

121.6

FORKS
Dimensions

Weight

mm

kg

80x40x1150

82.3

80x40x1200

84.8

120x35x800

84.3

120x35x1000

97.4

120x35x1150

107.3

120x35x1200

110.5

120x40x800

95.4

120x40x1000

110.3

120x40x1150

121.6

120x40x1200

125.3

120x40x1500

147.8

120x40x1800

170.2

120x45x800

106.4

120x45x1000

123.3

120x45x1150

135.9

120x45x1200

140.1

120x45x1500

165.4

120x45x1800

190.7
3

INSTALLATION AND SETTINGS

SERVICE

MAST ASSEMBLIES

Model

MR16N
MR14
MR16

MR20
MR25

Total auxiliary lift


(mm)

Free Lift
(mm)

Height, mast
lowered
(mm)

Extended
dimensions
(mm)

Weight
(kg)

h3

h2

h1

h4

5000

1648

2195

5563

911

5250

1734

2281

5813

936

5500

1820

2367

6063

961

5750

1906

2453

6313

986

6000

1992

2539

6563

1010

6250

2078

2625

6813

1035

6500

2164

2711

7063

1060

6750

2250

2797

7313

1090

7000

2336

2883

7563

1115

7250

2422

2969

7813

1140

7500

2508

3055

8063

1164

7750

2594

3141

8313

1220

8000

2680

3227

8563

1244

8250

2766

3313

8813

1269

8500

2852

3399

9063

1299

8750

2938

3485

9313

1324

9000

3024

3571

9563

1349

9250

3110

3657

9813

1376

9500

3196

3743

10063

1400

9750

3282

3829

10313

1425

10000

3368

3915

10563

1454

10250

3454

4001

10813

1478

10500

3540

4087

11063

1503

4650

1582

2195

5263

958

4900

1668

2281

5513

985

5150

1754

2367

5763

1012

5400

1840

2453

6013

1038

5650

1926

2539

6263

1065

5900

2012

2625

6513

1092

6150

2098

2711

6763

1118

6400

2184

2797

7013

1150

6650

2270

2883

7263

1177

6900

2356

2969

7513

1204

7150

2442

3055

7763

1230

7400

2528

3141

8013

1288

7650

2614

3227

8263

1314

7900

2700

3313

8513

1341

8150

2786

3399

8763

1373

SERVICE

Model

MR20HD

MR16HD

INSTALLATION AND SETTINGS

Total auxiliary lift


(mm)

Free Lift
(mm)

Height, mast
lowered
(mm)

Extended
dimensions
(mm)

h3

h2

h1

h4

7900

2614

3227

8513

1372

8150

2700

3313

8763

1401

8400

2786

3399

9013

1435

8650

2872

3485

9263

1464

8900

2958

3571

9513

1523

9150

3044

3657

9763

1552

9400

3130

3743

10013

1581

9650

3216

3829

10263

1609

9900

3302

3915

10513

1638

10150

3388

4001

10763

1671

10400

3474

4087

11013

1699

10650

3560

4173

11263

1728

10900

3646

4259

11513

1757

11150

3732

4345

11763

1786

Weight
(kg)

11400

3818

4431

12013

1814

11650

3904

4517

12263

1843

11900

3990

4603

12513

1872

12150

4076

4689

12763

1901

12400

4162

4775

13013

1929

12650

4248

4861

13263

1958

8050

2680

3227

8613

1346

8300

2766

3313

8863

1374

8550

2852

3399

9113

1408

8800

2938

3485

9363

1436

9050

3024

3571

9613

1495

9300

3110

3657

9863

1524

9550

3196

3743

10113

1552

9800

3282

3829

10363

1580

10050

3368

3915

10613

1612

10300

3454

4001

10863

1641

10550

3540

4087

11113

1669

10800

3626

4173

11363

1698

11050

3712

4259

11613

1726

11300

3798

4345

11863

1755

11550

3884

4431

12113

1783

SERVICE

INSTALLATION AND SETTINGS

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

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

Description

Truck base and mast assembled (option A)


Truck base and mast separate (option B)

Contrast rollers (optional)

Battery runner rollers

Forks

Hydraulic fluid canister

Batter catch plate

SERVICE

INSTALLATION AND SETTINGS

CARRIAGE SOLD WITH BATTERY

5
7

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

Description

Truck base and mast assembled (option A)


Truck base and mast separate (option B)

Contrast rollers (optional)

Battery runner rollers

Forks

Hydraulic fluid canister

Batter catch plate

Battery

SERVICE

INSTALLATION AND SETTINGS


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

fork lift truck


load capacity
2500 kg

crane truck or
bridge crane
load capacity
2500 kg

open ended spanner


19 mm

torque wrench

lifting sling
load capacity
2500 kg

ladder

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

Phase 1
TRUCK BATTERY - FORK LIFT TRUCK LOAD CAPACITY 2500kg
Connect the battery to the truck base, switch on the forklift and transfer it to a place equipped with a crane
truck or bridge crane. Using the lift truck, fork the pallet on which the mast assembly is secured, raise it
and carry it to the same place as the truck base.
Phase 2
BRIDGE CRANE - LIFT BELT
Remove the packing of the mast assembly.
Slip the lifting belt beneath the upper crossbars of the mast assembly by making a noose and hook the
other end to the bridge crane hook (fig.1).
Start lifting slowly with the bridge crane and raise the mast assembly, separating it from the pallet. Take
the mast assembly into the vertical
position.

Fig. 1
8

SERVICE

INSTALLATION AND SETTINGS

Phase 3
OPEN ENDED SPANNER 19 mm
Using the open ended spanner, unscrew and remove the screws securing
both side blocks of the mast assembly (ref.A fig.2). Remove the blocks
(ref.B fig.2).
Using the bridge crane, slowly lift the mast assembly and rest it vertically
on the truck base in the special housings (ref.C fig.2). Keeping the belt
taut, position both side blocks and, using a torque wrench, tighten the
fixing screws (ref.A fig.2) to a torque of 88 to 97 Nm.

Fig. 2

Phase 4
BRIDGE CRANE - LADDER - LIFT BELT
Set the ladder next to the mast assembly and climb up.
Insert the lift belt beneath the upper crossbar of the middle section of
the mast assembly by making a noose and hook the ends to the bridge
crane hook (fig.3). Climb down the ladder, raise the bridge crane to
reveal the seats of the screws securing the mast assembly to the truck
base (fig.4).
Phase 5
TORQUE WRENCH - BRIDGE CRANE - LIFT BELT
Using the torque wrench, tighten the bolts securing the mast assembly
to the truck base (ref.D fig.4) to a torque of 300 to 330 Nm.
Using the bridge crane, lower the mast assembly to the ground.
Climb up the ladder and remove the belt from the mast assembly.

Fig. 3

Phase 6
Remove the cover to access the hydraulic control valve (fig.5).
Connect the hydraulic pipes from the control valve on the truck base to
the one on the mast assembly (fig.6).

Fig. 4

Fig. 5

Fig. 6
9

SERVICE

INSTALLATION AND SETTINGS


TOPPING UP THE OIL RESERVOIR

Fig. 1

Before topping up the oil in the hydraulic oil reservoir make sure that the
forks are fully lowered.
Equipment and tools

funnel

oil resistant gloves

T handle hex key


5 mm

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

Phase 1
T-HANDLE HEX KEY 5 mm
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.A fig.1).
Completely open the cover (fig.2).

Fig. 3

Phase 3
To facilitate the filling of the tank unscrew the breather valve (ref.B fig.3),
so that the air can come out when topping up.
Phase 3
FUNNEL
Unscrew the reservoir cap (ref.C fig.3), place the funnel in the filler hole
and top up the oil level.
Be sure not to fill the reservoir too much by checking the level via the
marks on the reservoir (fig.4).
Screw the breather valve and the reservoir cap back on.

10

Fig. 4

SERVICE

INSTALLATION AND SETTINGS

INSTALLATION OF THE BATTERY


WITH VERTICAL REMOVAL
Equipment and tools

bridge crane
load capacity
2000 kg

spreader bar

Fig. 1

open ended
spanner
10 mm

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

Fig. 2
Fig. 3
BRIDGE CRANE - SPREADER BAR
Pull up the lever in front of the throttle pedal board next to the seat (fig.1)
so as to free the battery housing. Make the battery housing come fully
out (fig.2).
Using the open ended spanner, unscrew and remove the screws fastening
the battery cover (where applicable) (ref.A fig.3). Remove the cover.
Attach the spreader bar to the bridge crane.
Attach the spreader bar to the battery, lift it using the bridge crane and
position it over the battery housing.
Lower the battery very carefully into the carriage compartment (fig.4).
Unhook the spreader bar from the battery.
Connect the cables to the battery.
Switch on the truck and, using the controls in the cab, retract the retractable carriage completely so that the battery hooks onto the locking
system.

A
Fig. 4

11

INSTALLATION AND SETTINGS

SERVICE

WITH LATERAL REMOVAL


Equipment and tools

bridge crane
load capacity
2000 kg

spreader bar

rollerway

Procedure

Fig. 1

Fig. 2

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians.

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

12

Fig. 3

SERVICE

INSTALLATION AND SETTINGS

CONNECTION OF CABLES TO BATTERY


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

_
+

Tag coloured BLUE


Connection of the cable to the
negative terminal
Tag coloured RED
Connect lead to positive
terminal

Negative terminal
coloured BLUE
Positive terminal
coloured RED

13

INSTALLATION AND SETTINGS

SERVICE

ASSEMBLY OF MOVING FORKS

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

Phase 1
Using the controls in the cab, lift the fork carriage to facilitate fork assembly operations.

Turn the keyswitch to OFF and disconnect the battery.

Phase 2
Insert the fork in and let it slide along the fork carrier plate (fig.1) until the
fastening pin slots into the notch (fig.2).

14

Fig. 1

Fig. 2

SERVICE

INSTALLATION AND SETTINGS

CONTRASTING ROLLER ASSEMBLY


Equipment and tools

open ended spanner


19 mm

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

Fig. 1

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

Phase 2
FIXED GAUGE 19 mm SPANNER
Position the roller complete with spacers in its section and fix it with the
two screws to the truck base (ref.C fig.2).

A
B

Fig. 2

15

INSTALLATION AND SETTINGS

SERVICE

List of the SETTINGS AND ADJUSTMENTS to be carried out


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





Setting the battery voltage


Checking the conditions of use of the truck
Checking the contrast roller movement along the aisle
Enabling and programming level pre-selection
Enabling and programming middle fork lifting blocks
Enabling and programming operator passwords

SETTING THE ACE2 TRACTION AND THE ACE2 PUMP MODULE BATTERY VOLTAGES
If a battery that is not provided by the factory is installed on the truck, the battery voltage on the VCM
module must be set.
To carry out this regulation, it is good practice to proceed with an additional charging period for the battery
used on the carriage in order that it may provide the maximum voltage.
Equipment and tools

programmer

tester

T handle hex key


5 mm

large Philips
screw driver

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

16

SERVICE

INSTALLATION AND SETTINGS

Fig. 1

Fig. 3

Fig. 2

24
13
1

35
23
12

A
Fig. 4

17

INSTALLATION AND SETTINGS

SERVICE

CHECK THE CONDITIONS OF USE OF THE TRUCK


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




maximum traction speed


traction acceleration
reduction of traction speed
maximum fork lifting/lowering speed
braking

If necessary, reduce truck performance by using the programmer to customise the truck configuration parameter (see "TRUCK FUNCTIONS"section "ELECTRICAL SYSTEM").

In order not to jeopardize the safety of the truck, the only way in which the truck configuration parameters may be modified is by reducing the factory-set values.
Parameter values that exceed the factory-set values are not permitted.

CHECK THE MOVEMENT OF THE CONTRASTING AISLE ROLLERS


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

max 5 mm

b6

18

Fig. 1

SERVICE

INSTALLATION AND SETTINGS

Enabling and programming of the LEVEL pre-selector.


To enable and program the height pre-selector see "LEVEL PRE-SELECTOR" section "ELECTRICAL
SYSTEM".
ENABLING AND PROGRAMMING MIDDLE FORK LIFTING BLOCKS
To enable and program the middle cab lifting blocks see "FORK LIFTING/LOWERING BLOCKS" section
"ELECTRICAL SYSTEM".
ENABLING AND PROGRAMMING OF THE PASSWORD
To enable and program the operator passwords see "MAIN MENU 2 / PROGRAMMING ACCESS CODE
WITH COMBINED OPERATOR CODE READING" section "ELECTRICAL SYSTEM".

19

INSTALLATION AND SETTINGS

20

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

Diagnostics and
measurements
DESCRIPTION MODULE CONNECTORS 2
ACE2 TRACTION MODULE 2
ACE2 PUMP MODULE 3
eps acw MODULE 4
MASTER CONTROL CARD PREMIUM MODULE 5
TESTER MENU 7
ACE2 TRACTION MODULE 7
ACE2 PUMP MODULE 7
EPS ACW MODULE 7
Vcm MODULE 8
BREAKDOWN SEARCH 12
WARNING MEMORIZATION 12
ACe2 PUMP AND TRACTION MODULE DIAGNOSIS SYSTEM 13
ACE2 PUMP AND TRACTION MODULE ALARMS 13
PUMP AND TRACTION ACE2 MODULE ALARM ANALYSIS AND TROUBLESHOOTING 22
DIAGNOSIS SYSTEM FOR Vcm MODULE  33
Vcm - MASTER MODULE ALARM ANALYSIS AND TROUBLESHOOTING 33
Vcm - SLAVE MODULE ALARM ANALYSIS AND TROUBLESHOOTING 38
EPS ACW MODULE DIAGNOSIS SYSTEM 42
eps acw MODULE ALARM ANALYSIS AND TROUBLESHOOTING 42

DIAGNOSTICS AND MEASUREMENTS

DESCRIPTION MODULE CONNECTORS


ACE2 TRACTION MODULE

A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23

+ 48V logic power supply


+ 5V auxiliary power supply for Hall effect sensors
Input of accelerator sensor output 1
drive selector (analogue forward/reverse) (digital forward)
reverse drive selector
Input of service brake sensor output 2
Input CH A motor encoder
+ 12V power supply for motor encoder
Horn negative
Input of service brake sensor output 1
CAN communication line 2
CAN communication line 2
Input of accelerator sensor output 1
Input CH B motor encoder
- Batt auxiliary power supply for Hall effect sensors and encoder
Traction main contactor negative
+ 48V power supply for main contactor, electromagnetic brake, horn
Electromagnetic brake negative
Man on board sensor output 1
CAN communication line 1
CAN communication line 1
Engine temperature sensor input
- Batt engine temperature sensor

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ACE2 PUMP MODULE

A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23

+ 48V logic power supply


+ 5V auxiliary power supply for Hall effect sensors
Not used
Not used
Not used
Not used
Input CH A motor encoder
+ 12V power supply for motor encoder
Flasher negative
Not used
CAN communication line 2
CAN communication line 2
Not used
Input CH B motor encoder
- Batt auxiliary power supply for Hall effect sensors and encoder
Pump main contactor negative
+ 48V power supply for main contactor, flasher, fan
Fan negative
Not used
CAN communication line 1
CAN communication line 1
Engine temperature sensor input
- Batt engine temperature sensor

DIAGNOSTICS AND MEASUREMENTS


eps acw MODULE

A1
CAN communication line 2
A2
CAN communication line 2
A3
Power supply positive
A4
Power supply positive
A5
Power supply positive
A6
Power supply negative
A7
Power supply negative
A8
Power supply negative
A9
Fan positive (+48V)
A10
Fan negative
A11 Sensor with driving wheel at 90
A12 Sensor with driving wheel at 0 straight
A13
Auxiliary power supply negative
A14
Not used
A15
+ 48V logic power supply
A16 Stepper motor DL line power supply negative
A17 Stepper motor QL line input
A18
Auxiliary power supply positive
A19 Stepper motor QL line power supply negative
A20 Stepper motor DL line input
A21
Auxiliary power supply positive
A22
CAN communication line 1
A23
CAN communication line 1

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

MASTER CONTROL CARD PREMIUM MODULE

A1
+ 48V output power supply
A2
Negative of proportional valve for carriage forward (PWM) Current controlled
A3
Negative of proportional valve for carriage backward (PWM) Current controlled
A4
Negative of diverter valve for Tilt or Side Shift (PWM) Current controlled
A5
Negative of diverter valve for 5th way (PWM) Current controlled
A6
Negative of electromagnet for battery block release (PWM) Current controlled
A7
Negative of reverse drive buzzer (PWM) Current controlled
A8 Seat microswitch
A9
Man on board sensor output 2
A10
Traction speed reduction button
A11
CAN communication line 1
A12
CAN communication line 1
A13
+ 48V auxiliary power supply
A14
+ 48V auxiliary power supply
A15
+ 48V auxiliary power supply
A16
+ 48V auxiliary power supply
A17
+ 48V auxiliary power supply
A18 Sensor 1 battery out Normally open
A19 Sensor 2 battery out Normally closed
A20 Seat belt microswitch
A21 Steering mode selection button 180- 360
A22
- Batt auxiliary power supply
A23
Carriage position potentiometer input
A24
Negative of lowering proportional valve (PWM) Current controlled
A25
Negative of lifting proportional valve (PWM) Current controlled
A26
Negative of proportional valve right hydraulic function (PWM) Current controlled
A27
Negative of proportional valve left hydraulic function (PWM) Current controlled
5

DIAGNOSTICS AND MEASUREMENTS


A28
A29
A30
A31
A32
A33
A34
A35

+ 48V logic power supply


- Batt logic power supply
CAN communication line 2
CAN communication line 2
not used
+ 12V auxiliary power supply
+ 5V auxiliary power supply
not used

B1 Side shift position sensor


B2
not used
B3
Tilt position inclinometer input
B4
Encoder reset sensor input
B5 not used
B6
Pressure transducer sensor input
B7
+ 48V output power supply
B8
+ 48V auxiliary power supply
B9
Main lifting cylinder position potentiometer transducer input
B10
Main lifting cylinder position potentiometer transducer input
B11
Load cell input
B12
not used
B13 Weighing button
B14
Lifting by-pass button
B15
Negative of pallet recognition laser (PWM) Current controlled
B16
+ 5V auxiliary power supply
B17
Free lifting cylinder position potentiometer transducer input
B18
Free lifting cylinder position potentiometer transducer input
B19
- Batt auxiliary power supply
B20
- Batt auxiliary power supply
B21
Pallet presence sensor
B22
not used
B23
Negative of load wheel brakes (PWM 4A) Current controlled

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

TESTER MENU
The main input and output signals can be measured in real time using the TESTER function of the programmer. The programmer acts as a multimeter capable of reading voltage, current and temperature.
Certain of these menu parameters refer to functions whose status is received via Can bus, others refer to
functions directly connected to the analog/digital inputs of the module. The following list shows the relative
measurements:
ACE2 TRACTION MODULE
MAIN TESTER MENU
PARAMETER
BATTERY VOLTAGE

measurement unit
Volt

Battery voltage measured on the key input

ACE2 PUMP MODULE


MAIN TESTER MENU
PARAMETER
BATTERY VOLTAGE

measurement unit
Volt

Battery voltage measured on the key input

EPS ACW MODULE


MAIN TESTER MENU
PARAMETER
BATTERY VOLTAGE

measurement unit
Volt

Battery voltage measured on the key input

SERVICE

DIAGNOSTICS AND MEASUREMENTS


Vcm MODULE
MAIN TESTER MENU
PARAMETER

measurement unit

WORKING HOURS

Hours

Indicates the truck's working hours according to the setting of the HOUR COUNTER option
FORK HEIGHT

mm

Indicates the fork height off the ground in real time if the HEIGHT INDICATOR option is activated
BATTERY VOLTAGE

Value of the voltage to 1 decimal place. Level of battery voltage measured at key-switch on
BATTERY CHARGE

Percentage value. Provides the battery's residual charge as a percentage of the level of the complete charge
STEER ANGLE

degrees

Value in degrees. Indicates the current steering angle


RTC HOUR

hours

Hour of the Real Time Clock


RTC MINUTES

minutes

Minutes of the Real Time Clock


LIFT/LOW POT.

Percentage value. Level of the LIFT/LOWER control


REACH POT.

Percentage value. Level of the REACH control


TILT POT.

Percentage value. Level of the TILT control


SIDE SHIFT POT.

Percentage value. Level of the SHIFT control


AUTOC.SSHIFT SW.

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


AUTOC.TILT SW.
ON/OFF. Level of the self-centring side shift button
5 WAY SWITCH
ON/OFF. Level of the hydraulic 5th way button
JOY. HORN SW
ON/OFF. Level of the horn button
8

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER

measurement unit

PALLET SWITCH
ON/OFF. Level of the Pallet button
SEATBELT SWITCH
ON/OFF. Level of the seat belt button
SEAT SWITCH
ON/OFF. Level of the Seat button
BATTERY OUT SW1
ON/OFF. Level of the Battery 1 disconnected sensor
BATTERY OUT SW2
ON/OFF. Level of the Battery 2 disconnected sensor
SSHIFT POS. SW

ON/OFF. Level of the side shift position sensor


TILT POS. SW

ON/OFF. Level of the tilt position sensor


REACH AN I SENSOR

mV

Value in volts. Level of the analog input A23 (truck potentiometer position)
OUTPUT GROUP #1

Value %. Percentage of the maximum current applied on output unit #1 (EVP1 and EVP2 lifting/lowering)
OUTPUT GROUP #2

Value %. Percentage of the maximum current applied on output unit #2 (EVP3 and EVP4 retractable carriage
backward / forward)
OUTPUT GROUP #3

Value %. Percentage of the maximum current applied on output unit #3 (EVP5 and EVP6 tilt down/left side shift tilt up/right side shift)
OUTPUT GROUP #4

Value %. Percentage of the maximum current applied on output unit #4 (EVP7 and EVP8 tilt / side shift valve sensor - 5th way valve sensor)
NEVP9 OUTPUT

Value %. Percentage of the maximum current applied on EVP9 (wheel brakes charge)
NEV3 OUTPUT

Value %. Percentage of battery voltage applied on EV3 (Laser)


NEV2 OUTPUT

Value %. Percentage of battery voltage applied on EV2 (Back-up alarm)

DIAGNOSTICS AND MEASUREMENTS

PARAMETER
NEV1 OUTPUT

SERVICE
measurement unit
%

Value %. Percentage of battery voltage applied on EV1 (not used)


RESET ENCODER #1
ON/OFF. Encoder reset sensor level
ENCODER #1

pulses

Number of pulses ready by encoder 1


ENCODER #2

pulses

Number of pulses ready by encoder 2


RPM PUMP
Value in Hz. Pump motor speed
DIGITAL INPUT #1
ON/OFF. A8 digital input level
DIGITAL INPUT #2
ON/OFF. A9 digital input level
DIGITAL INPUT #3
ON/OFF. A10 digital input level
DIGITAL INPUT #4
ON/OFF. A18 digital input level
DIGITAL INPUT #5
ON/OFF. A19 digital input level
DIGITAL INPUT #6
ON/OFF. A20 digital input level
DIGITAL INPUT #7
ON/OFF. A21 digital input level
DIGITAL INPUT #8
ON/OFF. B13 digital input level
DIGITAL INPUT #9
ON/OFF. B14 digital input level
DIG. INPUT #10
ON/OFF. B21 digital input level
DIG. INPUT #11
ON/OFF. B22 digital input level

10

Hz

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER
ANALOG INPUT #1

measurement unit
mV

Value in volts. Level of the analog input A23 (truck potentiometer position)
ANALOG INPUT #2

mV

Value in volts. Level of the analog input A35 (not used)


ANALOG INPUT #3

mV

Value in volts. Level of the analog input B1 (side shift position)


ANALOG INPUT #4

mV

Value in volts. Level of the analog input B2 (not used)


ANALOG INPUT #5

mV

Value in volts. Level of the analog input B3 (tilt position)


ANALOG INPUT #6

mV

Value in volts. Level of the analog input B4 (encoder reset)


ANALOG INPUT #7

mV

Value in volts. Level of the analog input B5 (not used)


ANALOG INPUT #8

mV

Value in volts. Level of the analog input B6 (transducer pressure)


ANALOG INPUT #9

mV

Value in volts. Level of the analog input B11 (load cell)


ANALOG INPUT #10

mV

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

11

DIAGNOSTICS AND MEASUREMENTS

SERVICE

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

12

MODULE 6: EPS ACW


MODULE 1: VCM

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ACe2 PUMP AND TRACTION MODULE DIAGNOSIS SYSTEM


ACE2 PUMP AND TRACTION MODULE ALARMS
programmer
message

WATCHDOG

EEPROM KO

LOGIC FAILURE #3

LOGIC FAILURE #2

message
sicos
CALL
SERVICE

description

effect

state of the truck

MC open, EB activated, Start up


The Watchdog signal is
traction/pump station- Stand-by
not in the correct state.
ary.
During traction

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

Error
detected
in The control device
EEPROM or in EEPROM works using the default Continuous
management.
parameters.

Re-start procedure:
None.
CALL
SERVICE

Hardware protection cir- MC not closed, EB accuit failure due to high tivated, traction/pump Start up
current.
stationary.

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

MC open, EB activated, Switch-on (imMotor phase voltage feedtraction/pump station- mediately after the
back circuit failure.
ary.
MC closes)

Re-start procedure:
Make a traction or hydraulic request.

LOGIC FAILURE #1

Vmn low

Vmn HIGH

CONTACTOR
CLOSED

CALL
SERVICE

a condition of undervolt- MC not closed, EB ac- Start up


age/overvoltage has been tivated, traction/pump Stand-by
detected.
stationary.
During traction

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

MC open, EB activated,
Motor output voltage low Start up
traction/pump stationer than expected.
During traction
ary.

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

MC not closed, EB acMotor output voltage high Start up


tivated, traction/pump
er than expected.
Stand-by
stationary.

Re-start procedure:
Make a traction or hydraulic request.

CALL
SERVICE

The LC contact is locked

MC not closed (the


control has not been
activated), EB activat- Start up
ed, traction/pump stationary.

Re-start procedure:
Make a traction or hydraulic request.
13

DIAGNOSTICS AND MEASUREMENTS

programmer
message

CONTACTOR
OPEN

message
sicos
CALL
SERVICE

description

effect

SERVICE
state of the truck

Switch-on (imThe MC coil has been ac- MC open, EB activated, mediately after the
tivated, but the MC fails to traction/pump station- MC closes)
close.
ary.
Stand-by
During traction

Re-start procedure:
Make a traction or hydraulic request.

STBY I HIGH

CALL
SERVICE

In stand-by conditions (no


current applied to the mo- MC not closed, EB actor), current feedback is tivated, traction/pump Start up
outside the permissible stationary.
stand-by limits.

Re-start procedure:
Make a traction or hydraulic request.

CAPACITOR
CHARGE

TH. PROTECTION

CALL
SERVICE

The voltage of the power MC not closed, EB accapacitors fails to in- tivated, traction/pump Start up
crease.
stationary.

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

The control device has


reached the thermal reduction temperature of
85C when the current is
IMAX.

The traction control device reduces the maximum current linearly Continuous
from IMAX (85C) to 0A
(105C).

Re-start procedure:
None.

MOTOR
TEMPERAT.

CALL
SERVICE

The motor temperature


sensor is open (if dig- The maximum current
ital) or has exceeded the is halved and the speed Continuous
150C threshold (if ana- is reduced.
logue).

Re-start procedure:
None.
CALL
SERVICE
BATTERY LOW

DRIVER SHORTED

The battery is <= 10%


when
the
BATTERY
CHECK parameter is set
to >0

Re-start procedure:
Recharge the battery.
Re-start up of the key.
CALL
SERVICE

The MC driver has shorted and therefore is not


capable of opening the
contactor.

Re-start procedure:
Make a traction or hydraulic request.

14

The maximum current


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

MC open (the control


Start up
has been released),
Stand-by
EB activated, traction/
During traction
pump stationary.

SERVICE
programmer
message

CONTACTOR
DRIVER

VACC NOT OK

DIAGNOSTICS AND MEASUREMENTS

message
sicos
CALL
SERVICE

description

effect

state of the truck

MC open (the control


The MC coil driver is dam- has been released), Stand-by
aged (it can't close).
EB activated, traction/ During traction
pump stationary.

Re-start procedure:
Make a traction or hydraulic request.

CALL
SERVICE

The
value
of
the
accelerator/lifting
potentiometer is greater
Start up
The traction/pump mothan
the
minimum
Stand-by
tor is stationary.
recorded
value
and
During traction
the
direction/activation
switches are off.

Re-start procedure:
Make a traction or hydraulic request.
INCORRECT
START

FORW + BACK

ENCODER ERROR

VDC OFF
SHORTED

WRONG SLAVE
VER.

VDC LINK OVERV.

CALL
SERVICE

Incorrect
quences.

starting

se- The traction/pump mo- Start up


tor is stationary.
Stand-by

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

Drive requests active


in both directions at the Traction is stationary.
same time.

Start up
Stand-by
During traction

Re-start procedure:
Make a traction request.
CALL
SERVICE

MC open, EB activated,
Problem in reading the
traction/pump station- During traction
encoder.
ary.

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

When switching on, the MC open, EB activated,


VDC-off logic signal is traction/pump station- Start up
low.
ary.

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

The software versions for MC open, EB activated,


the Slave and Master are traction/pump station- Start up
not the same.
ary.

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

MC open, EB activated,
A condition of overvoltage
Stand-by
traction/pump stationhas been detected.
During traction
ary.

Re-start procedure:
Make a valve or traction or hydraulic request.

15

DIAGNOSTICS AND MEASUREMENTS

programmer
message

TILLER MISMATCH

message
sicos
CALL
SERVICE

description

effect

The Master C and Slave


C do not have the same
Traction is stationary.
value for the tiller input
from the VCM.

SERVICE
state of the truck
Start up
Stand-by
During traction

Re-start procedure:
Make a traction request.

BRAKE RUN OUT

STOP RQ. FROM


EPS

INIT VMN HIGH

CALL
SERVICE

The brakes potentiometer No effect. The warning


input is at the maximum is shown on the con- Continuous
value with no HB request. sole only.

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

EPS sends a request to


Traction is stationary.
stop the motor.

Start up
Stand-by
During traction

Re-start procedure:
Make a traction request.
CALL
SERVICE

The motor phase voltage


MC open, EB activated,
is higher than expected,
traction/pump station- Start up
before activating the
ary.
bridge.

Re-start procedure:
Re-start up of the key.

INIT VMN LOW

CALL
SERVICE

The motor phase voltage


MC open, EB activated,
is lower than expected,
traction/pump station- Start up
before activating the
ary.
bridge.

Re-start procedure:
Re-start up of the key.

EEPROM KO

PARAM RESTORE

CALL
SERVICE

it is impossible to
recover the data from the No effect.
memory.

Start up

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

Partial/complete
parameter reset has been
No effect.
performed since the last
shutdown.

Start up

Re-start procedure:
Make a traction or hydraulic request.

WRONG RAM
MEM.

16

CALL
SERVICE

The program checks the


MC open, EB activated,
content of the main RAM
traction/pump station- Continuous
registers and finds a dirty
ary.
value.

Re-start procedure:
Re-start up of the key.

SERVICE
programmer
message

STALL ROTOR

DIAGNOSTICS AND MEASUREMENTS

message
sicos
CALL
SERVICE

description
The traction
blocked.

rotor

effect

state of the truck

Start up
is The traction/pump is
Stand-by
stationary.
During traction

Re-start procedure:
Re-start up of the key.

WAITING SLAVE

HARDWARE
FAULT

POT. ACCEL MISM

CALL
SERVICE

MC open, EB activated,
No activation message
traction/pump station- Start up
from the Slave.
ary.

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

The drivers fail to switch MC not closed, EB acoff with the Watchdog sig- tivated, traction/pump Start up
nal in an alarm state.
stationary.

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

There is a discrepancy
Start up
between Master and The traction/pump is
Stand-by
Slave on the accelerator stationary.
During traction
signal.

Re-start procedure:
Re-start up of the key.

POT. BRAKE MISM

SENS MOT TEMP


KO

PEV NOT OK

CALL
SERVICE

There is a discrepancy be Start up


The traction/pump is
tween Master and Slave
Stand-by
stationary.
on the brake signal.
During traction

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

The motor heat sensor The maximum current


output is outside the lim- is halved and the speed Continuous
its.
is reduced.

Re-start procedure:
None.
CALL
SERVICE

The PEV connector (A17)


MC closed, EB acti- Start up
is not connected to the
vated, traction/pump, Stand-by
battery or the voltage is
valves stationary.
During traction
different.

Re-start procedure:
Make a traction or hydraulic or valve request.

VKEY OFF
SHORTED

CALL
SERVICE

MC not closed, EB acWhen switching on, the


tivated, traction/pump Start up
Key-off logic signal is low.
stationary.

Re-start procedure:
Re-start up of the key.

17

DIAGNOSTICS AND MEASUREMENTS

programmer
message
FLASH
CHECKSUM

MC COIL SHOR.

message
sicos
CALL
SERVICE

description

effect

SERVICE
state of the truck

MC not closed, EB acThe program check is not


tivated, traction/pump Start up
OK.
stationary.

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

Switch-on (imMC open, EB activated, mediately after the


Short-circuit on the MC
traction/pump station- MC closes)
coil.
Stand-by
ary.
During traction

Re-start procedure:
Make a traction or hydraulic request.

WAITING FOR
NODE

VACC OUT RANGE

CALL
SERVICE

No activation signals ar- MC open, EB activated, Start up


rive from the other system traction/pump station- Stand-by
units.
ary.
During traction

Re-start procedure:
Re-start up of the key.

CALL
SERVICE

The accelerator input is


outside the Vacc_min
Start up
to Vacc_max range that The traction/pump mo Stand-by
has been acquired with tor is stationary.
During traction
the PROGRAMM VACC
function.

Re-start procedure:
Make a traction or hydraulic request.

TILLER OPEN

OUTPUT
MISMATCH

WD SYNCRO

NO SLAVE
ENABLE

18

CALL
SERVICE

The truck is on stand-by


with the tiller switch off for LC opens.
longer than 30 seconds.

Stand-by

Re-start procedure:
Make a traction or hydraulic or valve request.
CALL
SERVICE

There is a discrepancy be- MC not closed, EB ac Stand-by


tween Master and Slave tivated, traction/pump
During traction
on the motor control.
stationary.

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

The Slave C has not re- MC open, EB activated, Start up


ceived the Watchdog sig- traction/pump station- Stand-by
nal from the Master C.
ary.
During traction

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

MC open, EB activated,
No activation message
traction/pump station- During traction
from the Slave.
ary.

Re-start procedure:
Re-start up of the key.

SERVICE
programmer
message
DIR SEL OUT
RANG

POWER MOS
SHORT

COIL SHOR. EB

DIAGNOSTICS AND MEASUREMENTS

message
sicos
CALL
SERVICE

description

effect

state of the truck

Start up
The selected direction sig- Traction/pump station Stand-by
nal is outside the limits.
ary.
During traction

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

MC not closed, EB acShort-circuit on the power


tivated, traction/pump Start up
MOSFETs.
stationary.

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

Switch-on (imMC open, EB activated, mediately after the


Short-circuit on the EB
traction/pump station- MC closes)
coil.
Stand-by
ary.
During traction

Re-start procedure:
Make a traction or hydraulic request.

Current Gain

CALL
SERVICE

The maximum current


gain
parameters
are
the default values. This The control device
Start up
means that the maximum works, but with a low
Stand-by
current adjustment proce- maximum current.
dure has not yet been carried out.

Re-start procedure:
None.

Analog input

CALL
SERVICE

MC open, EB activated,
The analogue channel traction/pump station- Start up
reading is not up-to-date. ary.
During traction

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
TILLER ERROR

Tiller failure.

The main remote-con Start up


trol switch, open power
Stand-by
bridge, electromagnetic
During traction
brake activated.

Re-start procedure:
Re-synchronisation of the system:
release all requests (traction and hydraulic)
make a traction or hydraulic request or both.

19

DIAGNOSTICS AND MEASUREMENTS

programmer
message

EVP DRIVER OPEN

M/S PAR CHK


MISM

INPUT MISMATCH

PARAM
TRANSFER

SP MISMATCH

Throttle prog.

Iq mismatched

Aux Driv. Open

20

message
sicos
CALL
SERVICE

description

effect

SERVICE
state of the truck

The EVP coil driver is


MC closed, EB activatopen and is not able to
EVP on
ed, EVP stationary.
close.

Re-start procedure:
Make an EVP request.
CALL
SERVICE

The checksum test be- MC open, EB activated,


tween Master and Slave traction/pump station- Start up
has not been passed.
ary.

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

The Slave C has differ- MC open, EB activated, Start up


ent values to the inputs traction/pump station- Stand-by
from the Master C.
ary.
During traction

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

The Master cannot trans- MC open, EB activated,


fer the parameters to the traction/pump station- Start up
Slave.
ary.

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

The Slave C has detect- MC open, EB activated, Start up


ed an incorrect set point traction/pump station- Stand-by
of the Master C.
ary.
During traction

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

One of the potentiometers


Start up
Traction/pump stationhas not been programmed
Stand-by
ary.
correctly.
During traction

Re-start procedure:
Re-start up of the key.
CALL
SERVICE

The error between the lq


set point and the estimat- Traction stationary.
ed lq is outside the limits.

During traction

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

The AUX coil driver has MC open, EB activated,


Stand-by
failed (it cannot operate traction/pump station During traction
the brake).
ary.

Re-start procedure:
Make a traction or hydraulic request.

SERVICE
programmer
message

DATA
ACQUISITION

DIAGNOSTICS AND MEASUREMENTS

message
sicos

CALL
SERVICE

description

effect

The maximum current


adjustment procedure is
in progress (NOTE: This
Traction stationary.
procedure must be performed by the Zapi testing
department only).

state of the truck

Stand-by

Re-start procedure:
Make a traction request.

NO CAN MSG.

CHECK UP
NEEDED

THERMIC SENS.
KO

Wrong set bat.

CALL
SERVICE

MC open, EB activated, Start up


Communication error with
traction/pump station- Stand-by
the supervisor.
ary.
During traction

Re-start procedure:
Make a traction or hydraulic or valve request.
CALL
SERVICE

Start up
it is time to carry out Traction is reduced or
Stand-by
maintenance work.
stationary.
During traction

Re-start procedure:
Switch the key back on, after performing maintenance.
CALL
SERVICE

The control device heat The maximum current


sensor output is outside is halved and the speed Continuous
the limits.
is reduced.

Re-start procedure:
None.

CALL
SERVICE

The absolute difference


between the voltage of
MC not closed, EB acthe key and the nomitivated, traction/pump Start up
nal voltage of the battery
stationary.
is greater than 20% of
Vbatt nom.

Re-start procedure:
Make a traction or hydraulic request.

Wrong zero

Field orient. KO

aux driv.shrt.

CALL
SERVICE

The motor phase voltage MC not closed, EB acfeedback is outside the tivated, traction/pump Start up
permissible limits.
stationary.

Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE

The error between the ld MC not closed, EB acset point and the estimat- tivated, traction/pump During traction
ed ld is outside the limits. stationary.

Re-start procedure:
Make a traction or hydraulic or valve request.
CALL
SERVICE

The EB/AUX driver has


MC open, EB activated, Start up
shorted and therefore is
traction/pump station- Stand-by
not capable of opening
ary.
During traction
the contactor.

Re-start procedure:
Make a traction or hydraulic request.

21

DIAGNOSTICS AND MEASUREMENTS

SERVICE

PUMP AND TRACTION ACE2 MODULE ALARM ANALYSIS AND TROUBLESHOOTING


ALARM

breakdown search

Watchdog
This alarm could be caused by a malfunctioning of the
Cause:
canbus shutting off Master-Slave communication.
This is a safety test. it is a self-diagnosis test within the
logic between the Master and Slave micro-controllers.

Eeprom ko

Try to carry out a CLEAR EEPROM operation (see the


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

Logic failure #3

This type of failure is not connected to external compoCause:


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

Logic failure #2

This type of failure is not connected to external compoCause:


nents, so when it manifests itself the ACE2 logic board
The fault pertains to the hardware section of the logic card needs replacing.
that manages the retroaction of the phase voltage.

Logic failure #1

Cause:
This alarm appears when the control device detects over
or under voltage conditions. The overvoltage threshold is
45V, the undervoltage threshold is 9V on the 24V control
device. On the 48V control device, the overvoltage threshold is 65V and the undervoltage threshold is 11V.

22

Finding the trouble appearing on start up or in standby,


it is very likely in these cases that the fault is due to undervoltage, so it is advisable to check:
Diminishing pulsations of the key input signal (beneath the undervoltage threshold) due to external
loads, such as switching on DC/DC converters,
switching on relays or contactors, energizing/deenergizing solenoids.
Check the connection of the electrical cables to the
battery terminal, positive and negative, to MC and to
the control device +Batt and Batt, which must be
tightened to a torque of between 13Nm and 15Nm.
If no voltage transient is detected on the power supply line and the alarm is present every time the key
is switched on, then the fault probably lies with the
hardware of the control device and so the logic board
needs replacing.
Finding the trouble appearing during motor operation, in
this case there could be undervoltage or overvoltage.
If the alarm appears during acceleration while in traction or operation of the hydraulic functions, it is most
likely due to undervoltage; check the battery charge
and the connection of the electrical cables.
If the alarm appears during brake release, it is most
likely due to overvoltage; check the contact of the line
contactor and the connection of the electrical cables
of the battery.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

breakdown search

Vmn low

If the problem appears on start up (LC doesn't close at


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


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


If no trouble is found with the motors, the problem
range of values), an error status appears.
lies within the control device, so replace it.

Vmn high
Cause 1:
Before switching on the LC, the software checks the power
bridge: it turns on the bottom side power MOSFETs alternately and waits until the phase voltage decreases down
to -BATT. If the voltage of the phases is under 10% of the
nominal voltage of the battery, this alarm appears.
Cause 2:
This alarm may appear even once the start-up diagnosis
has been passed and therefore the LC has closed. In
this situation, the phase voltage should be less than 1/2
Vbatt. Should it exceed this value, an error status would
appear.

If the problem appears on start up (LC doesn't close at


all), check:
The internal motor connections (ohm continuity)
The motor power cable connections
If the motor connections are OK, the problem lies
within the control device, so replace it.
If the problem appears after having closed the LC (LC
closes and then opens again), check:
The motor connections
If the coil-winding/cables of the motor phases show
losses towards the truck's bodywork
If no trouble is found with the motors, the problem
lies within the control device, so replace it.

Contactor closed
Cause:
Before activating the MC coil, the control device verifies
Please check the LC power contacts and replace it if
whether the contactor is blocked. The control device acnecessary.
tivates the bridge for a few tens of milliseconds, trying to
discharge the bank of capacitors If the capacitor voltage
fails to decrease by 20% of the key voltage, an alarm is
generated.

Contactor open

It could be a problem with the contacts in the MC not


working (not inserted), try replacing the MC.
Cause:
If the MC contactors work properly, the problem lies
The main contactor coil has been activated by the control
within the control device, so replace it.
device, but the contactor fails to close.

Stby I high

This type of error is not connected to external comCause:


ponents, so when it manifests itself the control device
The current transducer or the current feedback circuit has needs replacing.
a fault in the control device.

23

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

breakdown search

Capacitor charge
The charging capacitor diagram is shown below:

Cause:
When the key is turned on, the inverter tries to charge
the power capacitors through a series of PTC and the
power resistance and it checks whether the capacitors
have charged within a short time frame. If the measured
capacitor voltage is less than 20% of the nominal voltage
of the battery, an alarm is signalled; the main contactor is
not closed.

There is an external load in parallel with the bank


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

Th. protection

it is necessary to increase the cooling of the control


device. In the case of a finned heat dissipation device,
to achieve adequate cooling, these factors are important:
the flow [m3/h] and temperature [C] of the cooling air. In
Cause:
the case of a heat dissipation device with the base plate
This alarm appears when the base plate temperature is of the control device installed on the truck's bodywork, the
above 85C. Afterwards, the maximum current decreases thickness of the bodywork and the flatness and roughin proportion to the increase in temperature from 85C to ness of its surface are important. If, when the alarm is
105C. At 105 the current is limited to 0 Amps.
signalled, the control device is cold, the possible causes
could be failure of the thermal sensor or of the logic card.
In this case the control device needs to be replaced.

Motor temperat.

Check the heat sensor inside the motor (look for MOTOR TEMPERATURE in the TESTER menu); check the
Cause:
value in ohms of the sensor and the sensor cabling. If
This warning appears when the temperature sensor is the sensor is OK, boost the motor cooling. If the warning
open (if digital) or it has exceeded the 150C threshold is present when the motor is cold, then the problem is
(if analog).
located inside the control device.

Battery low

Take the charged battery. If it doesn't work, measure the


Cause:
battery voltage with a voltmeter and compare it to the value
It appears when the battery charge is less than or equal to in the BATTERY VOLTAGE parameter. If they are differ10% of the total charge and the BATTERY CHECK adjust- ent, adjust the value of the ADJUST BATTERY function.
ment is not 0 (refer to SET OPTION menu).

Driver shorted
Cause:
The driver of the main contactor coil has shorted.

24

Check if there is a short circuit or a low pull-down


impedance between NMC (CNA#16) and BATT.
The driver circuit is damaged in the logic board, which
must be replaced.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Contactor driver
This kind of failure is not connected to external compoCause:
nents; replace the ACE2 logic board.
The MC coil driver is not capable of carrying the load. The
device or its pilot circuit is damaged.

Vacc not ok
Cause:
The test has been performed with the key activated and
immediately after both drive requests have been deactivated. This alarm appears if the ACCELERATOR reading
in the TESTER menu is 1.0V over the min. PROGRAM
VACC acquisition when the throttle is released.

Incorrect start

Cause:
It is a warning for an incorrect start sequence.

Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the
alarm persists, check the mechanical calibration and
the operation of the potentiometer. If the alarm is not
deactivated, the fault is in the ACE logic board, therefore
proceed with replacement.
The possible causes of this alarm are (see the TESTER
items to make troubleshooting easier):
Active drive request with key activated
Active man on board sensor with key activated.
Check the wiring. Check the microswitches. It could also
be an issue of an incorrect error sequence performed by
the operator. a fault in the logic board is another possibility; therefore, after checking all the above conditions and
finding nothing, replace the ACE logic board.

Forw+back

Check the wiring of the inputs of the Fwd and Rev drive
requests (see the TESTER items to make troubleshooting easier). Check for any faults with the microswitches.
Cause:
a fault in the logic board is another possibility. Therefore,
This alarm appears when both the (Fwd and Bwd) motion after checking that the drive request switches work
requests are active at the same time.
properly and the wiring is correct, the ACE-2 logic board
needs replacing.

Encoder error
Cause:
This fault is signalled under the following conditions: the
frequency supplied to the motor is greater than 40 Hz and
the encoder's feedback signal shows leaps of more than
40 Hz in just a few tens of mSec. This behaviour is linked
to an encoder malfunction.

Check both the electrical and mechanical operation


of the encoder and check for any constriction of the
cables.
Verify the encoder's mechanical installation, checking whether the encoder slides inside its housing,
producing an alarm condition.
E ven an electromagnetic sound on the sensor
bearing could cause this alarm. In these cases, try
replacing the encoder.
If the problem persists even after replacing the encoder, the fault lies with the control device.

25

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Vdc off shorted

it is very likely that the fault is due to overvoltage, therefore you should check:
The connection of the electrical cables to the battery
terminal, positive and negative, to MC and to the control device +Batt and Batt, which must be tightened
Cause:
to a torque of between 13Nm and 15Nm.
This fault is displayed when the control device detects
If no voltage transient is detected on the line +B and
a low logic level of the VDC-off signal during start-up
the alarm is present every time the key is switched
diagnosis.
on, then the fault probably lies with the hardware
of the control device and so the logic board needs
replacing.

Wrong slave ver.


Cause:
Check the two software versions.
The software versions for the Slave and Master are not
the same.

Vdc link overv.

Finding the trouble appearing on start up or in standby:


Check the connection of the electrical cables to the
battery terminal, positive and negative, to LC and to
the control device +Batt and Batt, which must be
Cause:
tightened to a torque of between 13Nm and 15Nm.
This fault is displayed when the control device detects a If no voltage transient is detected on the power
line and the alarm is present every time the key is
condition of overvoltage. The overvoltage threshold is 65V
switched on, then the fault probably lies with the
on the 48V control device. On the 116V control device, the
hardware of the control device and so the logic board
undervoltage threshold is 30V.
needs replacing.
Finding the trouble appearing during motor operation:
If the alarm appears during brake release, check the
contact of the line contactor and the connection of the
electrical cables of the battery.

Tiller mismatch

Check the wiring of the Tiller input (use the TESTER


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

Brake run out

Check the mechanical calibration and the operation of


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

Stop rq. from eps


Cause:
The EPS sends a signal causing the motor to stop.

26

Check the EPS.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM
Init vmn high
Cause:
Before switching on the LC, the software checks the voltage of the power bridge without activating it. The software
expects the voltage to have a stationary state value. If
this value is too high, this alarm appears.

troubleshooting
Check:
The internal motor connections
The motor power cable connections
Motor loss to the truck frame
If the motor connections are OK, the problem lies
within the control device.

Init vmn low

Check:
The internal motor connections (ohm continuity)
Cause:
The motor power cable connections
Before switching on the LC, the software checks the volt Motor loss to the truck frame
age of the power bridge without activating it. The software
If the motor connections are OK, the problem lies
expects the voltage to have a stationary state value. If
within the control device.
this value is too low, this alarm appears.

Eeprom ko
Cause:
The control device cannot access the memory.

This kind of failure is not connected to external components; replace the ACE2 logic board.

Param restore

If CLEAR EEPROM has been run before last switching


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

Wrong ram mem


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

Stall rotor

Check that the indications of FREQUENCY and ENCause:


CODER in the tester menu are the same and are not
The traction rotor is blocked or the encoder signal is not zero during a traction request.
received correctly by the control device.

Waiting slave
Try switching the key off and back on again. If the alarm
Cause:
still remains, replace the ACE2 logic board.
When switching on, there is no activation message from
Slave C to Master C.

Hardware fault

This type of failure is not connected to external compoCause:


nents, so when it manifests itself the ACE logic board
The software versions for the Slave and Master are dif- needs replacing.
ferent.

27

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Pot accel mism

Check the potentiometers. a fault in the logic board is


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

Pot brake mism

Check the potentiometers. a fault in the logic board is


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

Sens mot temp ko


Cause:
The motor heat sensor output is outside the limits.

Check the ohm value of the sensor and the wire harness assembly of the sensor. If the sensor is OK, then
the problem is in the ACE logic board, proceed with
replacement.

Pev not ok
Cause:
The PEV connector (CNA#17) is not connected to the Check the connector A17.
battery or the voltage is different. The traction is stationary if AUXOUT is used for electrical braking and PEV is
indispensable (AUX OUT FUNCTION = PRESENT).

Vkey off shorted

it is very likely that the fault is due to undervoltage,


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

Check
the connection of the electrical cables to the
Cause:
battery
terminal, positive and negative, to MC and
This fault is displayed when the control device detects a low
to
the
control
device +Batt and Batt, which must be
logic level of the Key-off signal during start-up diagnosis.
tightened to a torque of between 13Nm and 15Nm.
If no voltage transient is detected on the power supply line and the alarm is present every time the key
is switched on, then the fault probably lies with the
hardware of the control device and so the logic board
needs replacing.

"Flash checksum"

The problem is in the flash memory of the microcontroller that could be damaged or in the program saved in
Cause:
it that could be corrupted. Try reprogramming the logic,
After switching on the key, the software checks the integrity
if the alarm is still signalled, then the problem is in the
of the program saved in the flash memory. If the outcome
microcontroller. Replace the ACE logic board.
of the test is negative, this alarm is generated.

MC coil shor.

The most likely cause of this error code is in the wire


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

28

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Waiting for node


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

Vacc out range


Cause:
The CPOT input read by the microcontroller is not within
the Vacc_min to Vacc_max range, programmed via the
PROGRAMM VACC function.

Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the alarm
persists, check the mechanical calibration and the operation of the potentiometer. If the alarm remains, the fault
is in the ACE logic board, proceed with replacement.

Tiller open
Cause:
The warning disappears with the next drive request.
This warning appears when the tiller is released, after a set
stand-by time (30 seconds) the main contactor opens.

Output mismatch
Cause:
This is a fault inside the control device, it is necessary
This is a safety test. The Slave C checks the command to proceed with replacement.
output data of the motor of the Master C and finds a
discrepancy.

Wd syncro
This is a fault inside the control device, it is necessary
Cause:
to proceed with replacement.
The Watchdog signal is not received by the Slave's microcontroller.

No slave enable
Try switching the key off and back on again. If the alarm
Cause:
still remains, replace the ACE2 logic board.
There is no activation message from the Slave C to the
Master C while the control device is in operation.

Dir sel out rang


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

Power mos short


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

29

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Coil shor. eb.

The most likely cause of this error code is in the wire


harness assembly or in the load coil. Therefore, the
Cause:
first step is to check the connections between the
This alarm appears when there is a short circuit in the
outputs of the control device and the loads.
EB/AUX coils connected to the output CNA#18. Once the If no faults/problems are found on the outside, the
overload has been removed the alarm automatically disaptrouble lies in the control device that must therefore
pears, releasing and then re-enabling a drive request.
be replaced.

Current gain
Request the assistance of a Zapi technician to carry out
Cause:
the correct adjustment procedure for the current gain
The maximum current gain parameters contain default
parameters.
values, which means that the maximum current adjustment
procedure has not yet been performed.

Analog input
Cause:
This alarm appears when the A/D conversion of the analog
If the problem persists, the ACE logic board needs
inputs gives a frozen value, on all the converted signals,
replacing.
for longer than 400msec. The aim of this diagnosis is to
find a fault in the A//D converter or a problem in the stream
of codes that omits resetting the conversion of the analog
signal.

Tiller error

Using a voltmeter check the voltage between the two


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

Evp driver open


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

The driver circuit is damaged in the logic board, which


must be replaced.

M/S par chk mism


Cause:
Try resetting and saving the list of parameters.
When switching on, there is a discrepancy between Master
and Slave in the checksum parameter.

Input mismatch
This is a fault inside the control device, proceed with
Cause:
replacement.
The Slave C has different values to the inputs from the
Master C.

Param transfer
This is a fault inside the control device, proceed with
Cause:
replacement.
The Master cannot transfer the list of parameters to the
Slave.

30

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Sp mismatch
This is a fault inside the control device, proceed with
Cause:
replacement.
This is a safety test. The Master C has detected an incorrect set point of the Slave C.

Throttle prog.

Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the
alarm persists, check the mechanical calibration and
Cause:
the operation of the potentiometer. If the alarm is not
One of the potentiometers has not been programmed
deactivated, the fault is in the ACE logic board, therefore
correctly.
proceed with replacement.

Iq mismatched
Request the assistance of a Zapi technician to carry out
Cause:
the correct adjustment of the motor parameters.
The error between the lq set point and the estimated lq is
outside the limits.

Aux driv.open
This kind of failure is not connected to external compoCause:
nents; replace the ACE2 logic board.
The EB/AUX coil driver is not capable of carrying the load.
The device or its pilot circuit is damaged.

Data acquisition
Cause:
Acquisition of current gains.

The alarm ends when the acquisition is completed.

No can msg.
This type of failure is not connected to external compoCause:
nents, so when it persists the ACE logic board needs
This fault is signalled when there is no communication with
replacing.
the supervisor uC.

Check up needed
Cause:
it is sufficient to take the CHECK UP DONE option onto
It is only a warning reminding you to call scheduled main- level ON after maintenance has been performed.
tenance.

Thermic sensor ko
This kind of failure is not connected to external compoCause:
nents; replace the control device.
The control device heat sensor output is outside the limits.

Wrong set bat.

Check that the value of the SET-BATTERY parameter


of the control device corresponds to the nominal voltage of the battery.
Cause:
Verify that the TESTER MENU / BATTERY VOLTAGE
On start up, the control device checks the battery voltparameter has the same value as the battery voltage
age and ensures that it is within a specific range of the
measured using a voltmeter. If it does not match, run
nominal value.
the ADJUST BATTERY function.
Replace the battery.

31

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Wrong zero

It is recommended to check:
The internal motor connections (ohm continuity)
Cause:
The motor power cable connections
On start up, the high resolution VMN feedback does not Motor loss to the truck frame
come within the range of permissible values around 2.5V. If the motor connections are OK, the problem lies
The circuit is damaged in the control device.
within the control device, so replace it.

Field orient ko
Request the assistance of a Zapi technician to carry out
Cause:
the correct adjustment of the motor parameters.
The error between the ld set point and the estimated ld is
outside the limits.

Aux driv. shrt.

Check if there is a short circuit or a low pull-down


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

32

SERVICE

DIAGNOSTICS AND MEASUREMENTS

DIAGNOSIS SYSTEM FOR Vcm MODULE


Vcm - MASTER MODULE ALARM ANALYSIS AND TROUBLESHOOTING
ALARM
Out port pull-up
Cause:
This alarm pertains to the hardware configuration.

Pump inc. start

Cause:
This signal is displayed for an incorrect start sequence.

troubleshooting
The problem is on the logic board, which must be replaced.
The probable causes of this alarm (use the TESTER
items to make troubleshooting easier) can be an active
pump request when switching on the key or a pump
request when there is not an active seat input. Check
the wire harness assemblies. Check the microswitches.
The cause could also be an error in the sequence performed by the operator or a fault in the logic; if all the
above conditions have been checked and nothing has
been found, replace the control device.

No can msg.
First of all, check the wire harness assemblies. If they
Cause:
are correct, the problem is on the logic board, which
Problem on the CAN-BUS line. The error is reported if the
must then be replaced.
VCM control device does not receive any message from
the CAN-BUS line.

M/S par chk mism


Cause:
The parameters are saved in both the Master and Slave Try saving the parameters again.
EEPROM. These two non-volatile memories must contain If the trouble still remains when the key switch is reacthe same parameter values and must be periodically com- tivated, replace the board.
pared. This alarm is generated if any differences are found.
This alarm does not prevent the machine from working,
but the default parameters are used.

Param transfer
Cause:
Try saving the parameters again.
The parameters are saved in both the Master and Slave If the trouble still remains when the key switch is reacEEPROM. These two non-volatile memories must contain tivated, replace the board.
the same values for each parameter and the values must
be periodically compared. If the Master cannot transfer the
parameters to the Slave, an alarm is generated.

Reset encoder

The cause of this alarm (use the TESTER items to


make troubleshooting easier) is due to the fact that the
encoder reset input is not active.
First of all, lower the forks until the encoder reset input
Cause:
is active.
VCM waits for the encoder reset input to be active before If the trouble remains, check the wire harness assemenabling any hydraulic function (only the lowering function blies and check that the microswitches work correctly.
is permitted).
it is possible that there is also a fault in the logic; if all
the above conditions have been checked and nothing
has been found, replace the control device.

33

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Analog input
This is a fault inside the microcontroller, replace the
Cause:
board.
Problem in the analog-digital module of the microcontroller.
All the functions are stopped.

Watchdog
Cause:
This is an internal error, the module needs replacing.
A software watchdog is programmed for each microcontroller. Its function is to check that the software is working
properly. All the functions are stopped.

Reset encoder ko

The cause of this alarm (use the TESTER items to make


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

Logic failure #1

Depends on the cause of the alarm:


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

Battery out

The cause of this alarm (use the TESTER items to make


troubleshooting easier) depends on the fact that the
inputs of the disconnected battery are not active.
First of all, insert the battery into the correct position in
the truck's bodywork.
Cause:
If the trouble remains, check the wire harness assemVCM waits to see that the inputs of the disconnected bat- blies and check that the microswitches work correctly
tery are active before enabling any functions.
according to the settings of the parameters. it is also
possible that there is a fault in the logic; if all the above
conditions have been checked and nothing has been
found, replace the control device.

Waiting for node


Cause:
The control device receives a message from the CAN The COMBI module cannot be activated, but it has to wait
indicating that another control device in the network has until the other module exits from the error condition.
failed; consequently the VCM control device cannot be
operated but has to WAIT for the other control device to
exit from its error condition.

34

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Valve enable

Check whether there is an alarm on the supervisor uC.


Cause:
If there are no alarms, the fault is in the hardware and
It occurs when uC Master tries to activate an output but the board needs replacing.
the supervisor uC does not enable it.

Tiller mismatch

The cause of this alarm (use the TESTER items to


make troubleshooting easier) derives from a different
reading of the condition of the "dead man" switch by
VCM and traction.
Cause:
If the trouble remains, check the wire harness assemMisalignment between VCM and traction for the dead blies and the operation of the microswitches. it is also
man input.
possible that there is a fault in the logic; if all the above
conditions have been checked and nothing has been
found, replace the control device.

Battery low
Cause:
It occurs when the battery charge level is less than or equal
to 10% of the total charge and the BATTERY CHECK setting is not 0 (refer to SET OPTION menu).

Recharge the battery. If it doesn't work, measure the


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

Wrong ram mem.


Cause:
Try switching the key off and then on; if the alarm still
The algorithm included to check the main RAM registers remains, replace the logic board.
has found incorrect content: the register is dirty. This
alarm prevents the machine's functions.

Eeprom ko
Cause:
A fault in the area of memory containing the parameters or
problems existing during the operations of reading/writing
to this memory. This alarm does not prevent the machine
from working, but the default parameters are used.

If the fault persists after the key has been reactivated,


replace the module. If the fault disappears, the previously saved parameters will be replaced by the default
parameters.

Controller mism.
Cause:
Replace the control device.
Incorrect customer ID code in the protected area of the
memory where this parameter is saved.

Param restore

If CLEAR EEPROM mode was active before last switching on the key, this message indicates that the EEPROM
has been correctly deleted. The alarm disappears on
Cause:
making a drive or pump request. If this alarm occurs
This message appears when the control device has reset when switching on the key without CLEAR EEPROM
to its default values.
being requested by the operator, there could be a problem in the control device.

Sdo trac
Cause:
HM communication trouble between VCM and traction.

Check the communication between the two control devices, if the communication is correct then replace the
board.

35

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Encoder locked #1

Check whether ENCODER1 in the tester menu is other


than zero during a lifting request. Verify the wire harness
assembly and the operation of the sensor. it is also
Cause:
possible that there is a fault in the logic; if all the above
The encoder is blocked or the encoder signals are not
conditions have been checked and nothing has been
received correctly by the control device.
found, replace the control device.

Encoder locked #2

Check whether ENCODER2 in the tester menu is other


than zero during a lifting request. Verify the wire harness
assembly and the operation of the sensor. it is also
Cause:
possible that there is a fault in the logic; if all the above
The encoder is blocked or the encoder signals are not
conditions have been checked and nothing has been
received correctly by the control device.
found, replace the control device.

Hm mismatch
Cause:
Check the settings of the hour meter parameters.
Inconsistency between VCM and traction for the hour
meter.

Lift/low lever
Cause:
Check the mini-lever.
The mini-lever in relation to the lifting/lowering lever is in
an alarm status.

Pump in alarm
Cause:
Alarm on the pump control device.

Wrong slave ver.


Cause:
Incorrect software release on the supervisor uC.

Check the alarm on the pump control device.

Install the correct software release on the supervisor


uC.

No can msg. 14
Cause:
No CAN message from the pump control device.

Check the pump control device.

No can msg. A
Cause:
No CAN message from the mini-lever.

Check the mini-lever.

Interlock fork

Check whether Reach pot is acquired correctly. If it is


not, then it must be acquired. Verify the wire harness
assembly and the operation of the sensor. it is also
possible that there is a fault in the logic; if all the above
conditions have been checked and nothing has been
found, replace the control device.

Cause:
VCM is not able to run the interlock function.

Carriage lever
Cause:
Check the mini-lever.
The mini-lever in relation to the retractable carriage lever
is in an alarm status.

36

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Tilt lever
Cause:
Check the mini-lever.
The mini-lever in relation to the tilt lever is in an alarm
status.

Side shift lever


Cause:
Check the mini-lever.
The mini-lever in relation to the side shift lever is in an
alarm status.

Wrong config
Cause:
Incorrect communication between VCM and traction.

No config master
Cause:
Incorrect configuration file in Master uC.

No config backup
Cause:
Incorrect configuration file in the supervisor uC.

Check the configuration of the parameters for this function. Download the configuration file again.

Check the configuration of the parameters for this function. Download the configuration file again.

Check the configuration of the parameters for this function. Download the configuration file again.

Pcf timeout
Check the configuration of the parameters for this funcCause:
tion. Download the configuration file again.
Time expired when checking the configuration file between
VCM and traction.

Waiting pcf
Cause:
Wait for the update to be completed.
Waiting to check the configuration file between VCM and
traction.

Preselector

Check which function generates the alarm condition.


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

37

DIAGNOSTICS AND MEASUREMENTS

SERVICE

Vcm - SLAVE MODULE ALARM ANALYSIS AND TROUBLESHOOTING


ALARM
Drv. shrt A
Cause:
The driver of one the first eight outputs has shorted.

Drv. open A
Cause:
VCM is not able to enable one of the first eight outputs.

troubleshooting
Check if there is a short circuit or low impedance
between one of the outputs and BATT.
The driver circuit is damaged in the logic board, which
must then be replaced.
This kind of failure is not connected to external components; replace the logic board.

Watchdog master
Cause:
This is an internal error, the module needs replacing.
A hardware watchdog enables synchronising the microcontrollers. All the functions are blocked.

No can msg.
First of all, check the wire harness assemblies. If they
Cause:
are correct, the problem lies with the logic board, which
There is a problem connected with the CAN-BUS line. The
must be replaced.
error is reported if the supervisor uCr does not receive any
messages from the CAN-BUS line.

Pev drv. short.


Cause:
The top driver of the PEVP1 output has shorted.

Check if there is a short circuit or low impedance


between pin A13 and +BATT.
The driver circuit is damaged in the logic board, which
must be replaced.

Pev drv. open


This kind of failure is not connected to external compoCause:
nents; replace the logic board.
VCM is not able to enable the top driver of the PEVP1
output.

Coil open A

It is recommended to check the wire harness assembly to see whether the coil is connected to the correct
Cause:
pin and whether the connection is broken.
This fault occurs when no load is connected between one If, in spite of connecting the coil to the correct pin or
of the outputs NEVP1, NEVP2.NEVP8 and the positive
replacing it, the alarm remains, the problem is in the
pole.
logic board, which must then be replaced.

Valve mism. out


Cause:
Alarm of the SLAVE currently disabled. Set point calculated
by the SLAVE different to the set point of the MASTER.

Watchdog
Cause:
This is an internal error, the module needs to be
There is watchdog software in each microcontroller. Its replaced.
function is to check that the software is working properly.
All the functions are blocked.

38

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM
Out port pull-up
Cause:
This alarm pertains to the hardware configuration.

troubleshooting
The problem is on the logic board, which must be replaced.

Analog input
This is a fault inside the microcontroller, replace the
Cause:
board.
There is a problem in the "from analog to digital" module
of the microcontroller. All the functions are blocked.

Logic failure #1

Depends on the cause that generated the alarm:


In the case of a real drop in voltage, the alarm will
disappear by simply turning the key off and then back
on. The cause of the undervoltage is to be determined
Cause:
according to the conditions in which it occurs. For
This alarm signals that a condition of undervoltage has
example: a truck function that requires a high voltage
occurred upon inserting the key. All the functions are
can reduce the battery voltage.
blocked.
Fault in the circuit detecting undervoltage conditions.
The board must be replaced.

No can msg. 14
Cause:
No CAN message from the pump control device.

Check the pump control device.

No can msg. A
Cause:
No CAN message from the mini-lever.

Check the mini-lever.

In. mism. D

Compare the values read by Master and Slave with the


Cause:
panel's tester menu.
Incorrect match on the digital input between Master and Contact Zapi technical support.
Slave.

In. mism. A/E

Compare the values read by Master and Slave with the


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

Wrong ram mem.


Cause:
Try turning the key off and back on; if the alarm still
The algorithm implemented to check the main RAM reg- remains, replace the logic board.
isters finds incorrect content: the register is dirty. This
alarm inhibits the operation of the machine.

Eeprom ko
Cause:
A fault in the area of memory containing the parameters
or problems during the operations of reading/writing to
this memory. This alarm does not inhibit the machine from
working, but the default parameters are used.

If the fault persists after the key has been reactivated,


replace the module. If the fault disappears, the previously saved parameters will be replaced by the default
parameters.

39

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Controller mism.
Cause:
Replace the control device.
Incorrect customer ID code in the protected area of the
memory where this parameter has been saved.

Param restore

If CLEAR EEPROM mode was active before last switching on the key, this message indicates that the EEPROM
has been correctly deleted. The alarm disappears on
Cause:
making a drive or pump request. If this alarm appears
This message appears when the control device has reset when switching on the key without CLEAR EEPROM beto its default values.
ing requested by the operator, there could be a problem
in the control device.

Drv. shrt B

Check for a short circuit or low impedance between


one of the outputs and BATT.
Cause:
The driver circuit is damaged in the logic board, which
The driver of one the outputs NEVP9, NEV1,..NEV3 has
must then be replaced.
shorted.

Dvr. open B
This kind of failure is not connected to external compoCause:
nents; replace the logic board.
VCM is not able to enable one of the outputs NEVP9,
NEV1,..NEV3.

Coil open B

It is recommended to check the wire harness assembly to see whether the coil is connected to the correct
pin and there are no breaks.
Cause:
If, in spite of connecting the coil to the correct pin
This fault occurs when no load is connected between one
or replacing it, the alarm remains, the problem is in
of the outputs NEVP1, NEVP2.NEVP8 and the positive
the logic board of the control device, which must be
pole.
replaced.

Out 1/2 coil sh.

The most likely cause of this error code is in the wire


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

Out 3/4 coil sh.

The most likely cause of this error code is in the wire


harness assembly or in the load coil. Therefore, first
Cause:
of all check the connections between the outputs of
This alarm occurs when there is a short circuit of the coil
the control device and the loads.
of EVP3 or EVP4. Once the overload has been removed
If no problems are found on the outside, the trouble
the alarm automatically disappears, releasing and then
lies with the control device that must be replaced.
re-enabling a drive request.

40

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Out 5/6 coil sh.

The most likely cause of this error code is in the wire


harness assembly or in the load coil. Therefore, first
Cause:
of all check the connections between the outputs of
This alarm occurs when there is a short circuit of the coil
the control device and the loads.
of EVP5 or EVP6. Once the overload has been removed
If no problems are found on the outside, the trouble
the alarm automatically disappears, releasing and then
lies with the control device that must be replaced.
re-enabling a drive request.

Out 7/8 coil sh.

The most likely cause of this error code is in the wire


harness assembly or in the load coil. Therefore, first
Cause:
of all check the connections between the outputs of
This alarm occurs when there is a short circuit of the coil
the control device and the loads.
of EVP7 or EVP8. Once the overload has been removed
If no problems are found on the outside, the trouble
the alarm automatically disappears, releasing and then
lies with the control device that must be replaced.
re-enabling a drive request.

Laser coil sh.

The most likely cause of this error code is in the wire


harness assembly or in the load coil. Therefore, first
Cause:
of all check the connections between the outputs of
This alarm occurs when there is a short circuit of the coil
the control device and the loads.
of EV1. Once the overload has been removed the alarm
If no problems are found on the outside, the trouble
automatically disappears, releasing and then re-enabling
lies with the control device that must be replaced.
a drive request.

Bat out coil sh.

The most likely cause of this error code is in the wire


harness assembly or in the load coil. Therefore, first
Cause:
of all check the connections between the outputs of
This alarm occurs when there is a short circuit of the coil
the control device and the loads.
of EV2. Once the overload has been removed the alarm
If no problems are found on the outside, the trouble
automatically disappears, releasing and then re-enabling
lies with the control device that must be replaced.
a drive request.

Load brk coil sh

The most likely cause of this error code is in the wire


harness assembly or in the load coil. Therefore, first
Cause:
of all check the connections between the outputs of
This alarm occurs when there is a short circuit of the coil
the control device and the loads.
of EV9. Once the overload has been removed the alarm
If no problems are found on the outside, the trouble
automatically disappears, releasing and then re-enabling
is in the control device that must be replaced.
a drive request.

Alarm coil sh.

The most likely cause of this error code is in the wire


harness assembly or in the load coil. Therefore, first
Cause:
of all check the connections between the outputs of
This alarm occurs when there is a short circuit of the coil
the control device and the loads.
of EV3. Once the overload has been removed the alarm
If no problems are found on the outside, the trouble
automatically disappears, releasing and then re-enabling
is in the control device that must be replaced.
a drive request.

41

DIAGNOSTICS AND MEASUREMENTS

SERVICE

EPS ACW MODULE DIAGNOSIS SYSTEM


eps acw MODULE ALARM ANALYSIS AND TROUBLESHOOTING
ALARM

breakdown search

Watchdog
Cause:
MuC and SuC communicate via a Can Bus local commu- If this alarm is repeated, the problem lies with the control
nication system. Communication between them requires device.
bit stuffing (the bit stuffing must be reversed for each new
frame). If the bit stuffing remains frozen for longer than
100msec, this alarm is generated.

Eeprom ko
Cause:
Each microcontroller has its own EEPROM with two lists
Run Clear Eeprom. If the problem persists, replace the
of parameters (to have a local backup). Each list has its
control device.
own checksum. When both checksums are wrong, this
alarm is generated. If one list of parameters has an incorrect checksum, it will be settled by using the second list
(backup with correct checksum).

Logic failure #4
Cause:
This alarm occurs with the steering system at rest if the it is necessary to replace the control device.
amplifier on the connected voltage Vu-Vw is in the range
of +/- 250mV around Vuw_zero for 96msec (sampling time
8msec for 12 consecutive samples).

Logic failure #3
Cause:
This alarm occurs with the steering system at rest if the it is necessary to replace the control device.
amplifier on the connected voltage Vu-Vw is in the range
of +/- 250mV around Vuw_zero for 96msec (sampling time
8msec for 12 consecutive samples).

Vmn not ok
Cause:
This alarm occurs with the key enabled if at least one voltage amplifier on the connected voltage Vv-Vu and Vu-Vw If the alarm is repeated, the control device needs reis in the range of +/- 300mV around 2.4Vdc for 50msec placing.
(sampling time 10msec for 5 consecutive samples). (Permissible outputs at rest from 2.1V to 2.7V). On completing
the diagnosis, the offset value of the voltage amplifiers
(Vvu_zero and Vuw_zero) will be acquired.

42

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Main cont. open


This is not a problem related to Eps. When this warning
Cause:
is generated, it means that the contactor is open (or not
This warning is active when the steering system control
yet closed).
device receives the information that the current contactor
is open via CAN BUS.

Stby I high
Cause:
This alarm occurs in two ways:
With the key enabled, if at least one current amplifier
on the U and W phase is in the range of +/- 300mV
around 2.5Vdc for 50msec (sampling time 10msec
for 5 consecutive samples). (Permissible outputs of If the alarm is repeated, the control device needs recurrent amplifiers with key enabled are from 2.2V to placing.
2.8V). On completing the diagnosis, the offset value
of the current amplifiers (IU_zero and IW_zero) will be
acquired.
With the steering system at rest, if at least one current amplifier on the U and W phase is in the range
of +/- 150mV around IU_zero or IW_zero for 96msec
(sampling time 8msec for 12 consecutive samples).

Capacitor charge

Some cases:
If this alarm occurs only in the control device of the
steering system, check the continuity of the cables
at CNA#3-4-5 from the battery and from Eps.
If the cables at CNA #3-4-5 are OK, measure the
voltage CNA#3-4-5 and B within 3 sec of enabling
the key. Only if the measured voltage is greater than
14Vdc (and on a short duration on STATUS#5 it is
Cause:
instead lower) replace the control device.
This alarm occurs with the key enabled, if the DC Bus
If the voltage measured between CNA#3-4-5 and B
(capacitors in parallel) fails to reach a minimum value of
is close to 0 there are two possibilities:
14Vdc within 3.2secs. STATUS #5 gives the value in real
- Short circuit on DC rail and B in Eps (discontime of the battery connection (+B) on a short duration.
nect CNA#3-4-5 and measure the voltage in the
DC bus of the traction control device (+B to B):
replace Eps if the voltage of the DC bus of the
traction device is greater than 14Vdc.
- Short circuit on DC rail and B on another unit in
the truck.

High temperature
Cause:
This alarm occurs when the temperature in the MOSFET
cases is:
Improve the cooling system of the control device. Other greater than 80C for longer than 3.84secs @ MAXI- wise, it is necessary to replace the control device.
MUM CURRENT=70A
O
greater than 90C for longer than 3.84secs @ MAXIMUM CURRENT=50A.

43

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Motor temperat.
Cause:
This alarm occurs only when DIAG MOTOR TEMP is
Check whether the heat sensor in the motor is working
ON and the heat sensor at the motor input measures a
correctly. If it is, improve the motor cooling system.
temperature greater than 120C. It also occurs when the
motor resistance has been acquired with a temperature
in the motor greater than 120C (also with DIAG MOTOR
TEMP ON).

High current
Cause:
If the alarm is repeated, the control device needs reThis alarm occurs with the key enabled, if the the circuit
placing.
is always active in order to limit the maximum current via
hardware (it may be due to a fault with the current amplifier).

Power failure #3

If the alarm is repeated, check that the battery is connected to the control device. Otherwise, the problem
Cause:
can be a fault in the three-phase bridge or in the motor
Current in phase W of the motor less than 5.4Arms for
connection to the terminal W.
100msec even if controlled at more than 28% Imax.

Power failure #2

If the alarm is repeated, check that the battery is connected to the control device. Otherwise, the problem
Cause:
can be a fault in the three-phase bridge or in the motor
Current in phase V of the motor less than 5.4Arms at
connection to the terminal V.
100msec even if controlled at more than 28% Imax.

Power failure #1

If the alarm is repeated, check that the battery is connected to the control device. Otherwise, the problem
Cause:
can be a fault in the three-phase bridge or in the motor
Current in phase U of the motor less than 5.4Arms at
connection to the terminal U.
100msec even if controlled at more than 28% Imax.

Bad steer 0-set


Cause:
Switch off the key.
This warning appears when the hardware setting 0-POS
TEACHING has been activated (and the key switched
back on).

Steer sensor KO
Cause:
This alarm occurs when the steering potentiometer (XA1-8 Replace the potentiometer.
XA1-9) varies with a peak broader than 1 Volt in 16 msec.
This alarm is used to identify a discontinuity in the control
potentiometer voltages.

Steer hazard
Cause:
Turn the steering wheel in the opposite direction.
This warning occurs when the steered wheel reaches the
maximum angle.

44

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Selfcheck #2
Cause:
This warning appears when SELFCHECKING routine #2
is in progress and the outcome of the check has not yet
been determined. This self-checking routine monitors the
encoder and the current in the motor when it is operated to Turn the key back on to clear the warning SELFCHECK
move at a fixed speed of 25Hz. It is recommended to run #2.
SELFCHECK #2 with the steered wheel raised. The aim of
this self-test is to check the operation of the encoder and
mechanical components (transmission, sensor bearings,
gears, pinion). Once the collected data have been processed and there is an unexpected outcome, this warning
message turns into an alarm message.

Selfcheck #1
Cause:
This warning appears when SELFCHECKING routine #1
is in progress and the outcome of the check has not yet
been determined. This self-checking routine measures the
Turn the key back on to clear the warning SELFCHECK
resistances of the motor between phases V and W (Rvw)
#1.
and between phases W and U (Rwu) with a multimeter,
using a fixed current of 14.7Adc. The aim of this self-test is
to check the operation of the motor and the power bridge
of the three phases. Once the collected data have been
processed and there is an unexpected outcome, this warning message turns into an alarm message.

Can bus warn

The problem could concern the cables of the Can Bus


Cause:
or the Can Bus transceiver inside the traction, the Eps
If a node fails to receive the Can Bus message of the or another unit on the truck. To identify the root of the
traction (Can ID 0x388 for MuC and 0x389 for SuC) for problem, a Can Bus is required.
longer than 200msec, this alarm will appear.

45

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

SP mismatch YY
Cause:
Depending on the command, MuC and SuC calculate
the set point of the steering motor speed independently
of each other. SuC is concerned that the values it is calculating in real time match the values calculated by MuC.
This alarm is generated when there is no such match. SuC
specifies the condition that led to a discrepancy with a hex
code (see YY pair above).
Incorrect conditions between MuC and SuC may be:
If the alarm is repeated, the problem lies with the control
With no limitation on the closed loop maximum angle, device.
there is a discrepancy on the point of setting the steering motor speed greater than 10Hz. YY = 01h.
With a limitation on the closed loop maximum angle,
there is a discrepancy due to the fact that MuC has
detected the limitation of the maximum angle and SuC
has not detected it (or vice versa). YY = 02h.
With a closed loop due to resetting at rest, there is a
discrepancy due to the fact that MuC has detected the
condition for resetting at rest and SuC has not detected
it (or vice versa). YY = 04h.

Out mismatch YY
Cause:
MuC and SuC read the commands and calculate the set
point of the steering motor independently of each other.
Then MuC activates the motor; SuC checks, in real time,
that the operation on the motor conforms to the value of
the set point of the steering motor. This alarm is generated
if the above does not occur. SuC specifies the condition
leading to a discrepancy with a hex code (see YY pair
above).
Incorrect conditions between MuC and SuC may be:
The present and controlled steering motor speeds (set
point) have a greater movement than 10Hz and with
opposite signs. YY = 03h.
If the alarm is repeated, the problem lies with the control
The present and controlled steering motor speeds (set
device.
point) have the same sign, one movement greater
than 10Hz, but the present speed is 50% less than
the controlled speed. YY = 05h.
At least one of the above discrepancies occurs. The
present and controlled pair currents (set point) have a
greater movement than 3Aac and with opposite sign
YY = 0Bh when the first discrepancy mentioned above
occurs; 0Dh when the second discrepancy mentioned
above occurs.
At least one discrepancy between point 1 and 2 occurs.
The present and controlled pair currents have the same
sign, one movement greater than 3Aac, but the present
pair current is 50% less than the controlled pair current.
YY = 13h when condition 1 occurs; 15h when condition
2 occurs.

46

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

W.D. syncro
Cause:
Every 32 measurements of the input values (analog and
digital) (e.g. every 4msec) MuC generates a falling edge
on an input of the SuC used as Request Interrupt. This IR Reactivate the key. If the alarm is repeated, the probworks as a synchronizing mechanism for SuC allowing it to lem is in the control device. It could also be a problem
start the first of the 32 measurements of the input values. related to ESD.
When MuC has completed the second A/D conversion
(second of the 32 AD conversions in autoscan mode), it
triggers the Synchro input at a higher level. SuC generates
this alarm when no falling edge is detected on the Synchro
input for more than 90 msec.

Wrong slave ver


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

Wrong ram memory


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

Param restore
Cause:
Reactivate the key.
This alarm is a confirmation that a Clear Eeprom parameter
has been run correctly.

Can bus ko m/s


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

47

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Stepper motor mism


Cause:
This alarm appears in two ways:
Channels D and Q of the stepper motor are processed
in two ways: A/D conversion and alignment encoder
interface. When the A/D conversion gives a fast movement (breadth of line D or Q greater than the crest 4.6V)
and the alignment encoder gives a slow movement
(less than 2 pulses in 80msec: e.g. 25Hz) for more than
200msec.
O
If the crest value of a channel of the stepper motor
(DL or QL) is less than 0.61V while the crest value of
the second channel is greater than 2V for more than
120msec (it detects a short circuit between one channel
of the stepper motor and GND).

Check that there is no short circuit between CNA#20 or


CNA#17 and GND. Check that the stepper motor is type
approved. If it is, replace the stepper motor and check the
wire harness assembly. If the problem persists, replace
the control device.

Motor locked
Cause:
Too much torque required for steering or trouble with the
This alarm occurs if the current in the motor remains
encoder (run selfcheck #2).
greater than 90% Imax for more than 1 sec, when the traction speed is greater than 15% (the delay time becomes 5
sec, when the traction speed is less than 5%).

M/S par chk mism

Check which are the different parameters between


Cause:
MuC and SuC and update (write) the parameters that
MuC compares its own checksum for the list of parameters do not match. To identify the problem easily run Clear
with the checksum of the list of parameters in SuC. If there Eeprom.
are any discrepancies, MuC generates this alarm.

Fb jerk
Cause:
This alarm occurs if the position of the steered wheel measured with the encoder has a step (discontinuity) greater
than 21 degrees (turn 244/4096) in 16msec and the step
does not return to having a smaller gap for 13 consecutive
sample measurements (total 208msec).

Interference or defect of the encoder or encoder cables.


One possibility is that the correct phase movement of
90 degrees between CHA and CHB in the encoder has
been lost.

Current gain
Cause:
This alarm occurs when the gains of the current amplifiers Contact Zapi technical support or replace the control.
(ADJUSTMENT #03 and ADJUSTMENT #04) are set on
default values (Imax has not yet been adjusted).

48

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Position error
Cause:
This alarm occurs due to an error in the feedback sensor
redundancy test. Here we have one encoder and one (two)
toggle switch. This alarm occurs if the sector count (toggle
switch configuration) and the encoder count do not match.
The sector is equipped with a FEEDBACK SECTOR reader
in the tester menu; the encoder count device is equipped
If the alarm occurs when installing a new control device,
with STEER ANGLE reading in the tester menu.
make sure that AUX FUNCTION 11 corresponds to the
layout of the toggle switches and that PULSE IN 180
If there are two toggle switches:
DEG. has been set correctly. If the alarm occurs after the
set-up
has been performed properly, search for a fault
FEEDBACK
STEER ANGLE
on
a
toggle
switch or on the encoder. Troubleshooting
SECTOR
[degrees]
consists
in
comparing
the STEER ANGLE and FEEDpermitted
BACK SECTOR when an alarm occurs. In the event of
an alarm, it is expected that these values will not observe
from -15 to +15
1 or 4
the permitted matches given in the tables alongside. The
from +15 to +75
1
problem could concern a sensor (check PROX SWITCH
from +75 to +105
1 or 2
1 and PROX SWITCH 2) or the encoder (check STEER
from +105 to +165
2
ANGLE and FEEDBACK SECTOR).
from +165 to -165

2 or 3

from -165 to -105

A list of possible fault modes is given below:


A switch changes its level even though it has not
from -105 to -75
3 or 4
been engaged by the iron plate (cam) on the steered
from -75 to -15
4
wheel.
If the encoder is composed of a bearing with a senIf there is only one toggle switch:
sor, a ring of the sensor bearing has slippage (the
sensor bearing has two rings: one is connected to
FEEDBACK
STEER ANGLE
the rotor shaft, the other to the motor chassis). Check
SECTOR
[degrees]
that these two rings are each firmly joined to their
permitted
structure with no slippage.
from +15 to +165
1
Fault in the encoder with low resolution (such as a
from -165 to -15
4
loose magnet or a fault with the Hall sensor).
The STEER ANGLE has slipped it could also occur
When the FEEDBACK SECTOR and STEER ANGLE do
when the truck is stationary) due to interference on
not match, there is a POSITION ERROR alarm in less
the encoder channels.
than 100msec.
NOTE: The permitted STEER ANGLE thresholds for each
FEEDBACK SECTOR given in the above tables refer to an
ideal situation with STEER 0-POS DEG set to 0 degrees
(no offset between SW1 and null angle) and a cam of length
180 degrees. The actual thresholds concerning the offset
SW1 and the length of the cam are shown in real time in
the FEEDBACK SECTOR message.

49

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

Slave alarm XX
Cause:
When SuC generates an alarm, the power supply is cut off
and the steering motor can no longer be activated. MuC
then generates this warning. On the Zapi panel, MuC
specifies the LSByte of the alarm code of SuC on position
If the alarm is repeated, the problem lies with the control
XX. For example:
device.
1.
LOGIC FAILURE #4: SLAVE ALARM 10
2.

OUTPUT MISMATCH: SLAVE ALARM D0

3.

INPUT MISMATCH: SLAVE ALARM FA

4. SP MISMATCH: SLAVE ALARM CF

Waiting master
Cause:
If the warning is repeated, the problem lies with the
With the key activated, SuC waits for MuC to send a ready
control device.
to steer frame on the local CAN Bus communication system. If the message fails to arrive for longer than 4sec,
this warning will appear.

Eps not aligned


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

Logic supply err


Reactivate the key. If the error is repeated, the problem
Cause:
lies with the control device.
This alarm appears if the 13.5V logic power voltage that actuates the three phase power bridge is less than 11Vdc.

50

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Fb sensor locked
Cause:
It is closed loop monitoring. This alarm occurs if the current
speed (freq_enci measured with the main encoder) does
not follow the controlled speed (set point) (freq_req deriving
from pre-processing the outputs of the stepper motor) for
longer than 500msec and the traction speed is greater than
15% (at the lowest traction speed, the delay time increases
up to 2.5sec, when the traction speed is less than 5%).
This alarm occurs if the misalignment between the current
speed and the controlled speed remains greater than 30%
of the controlled speed and greater than 5Hz above the
delay time of 500msec (variable depending on the speed
of the truck). Monitoring is suspended for 400ms whenever
the error sign (freq_req_freq_enc.) changes from positive
to negative or vice versa.

This alarm may be due to:


At least one encoder channel is broken
Too much friction in the transmission
A fault in the control device
A fault in the motor (e.g. a blocked encoder or a
broken phase of the motor).

Q line sensor ko
Cause:
This alarm occurs when the average voltage on the stepper motor alignment line (connection CNA#17) is not zero:
the voltage on each stepper motor line is a sinusoid with
zero average voltage.

Check the continuity of the stepper motor connections.


In particular the resistance between CNA#17 and the
negative pole of the battery (with the stepper motor at
rest) should be very low (around 30 Ohms).

D line sensor ko
Cause:
This alarm occurs when the average voltage on the stepper motor direct line (connection CNA#20) is not zero: the
voltage on each stepper motor line is a sinusoid with zero
average voltage.

Check the continuity of the stepper motor connections.


In particular the resistance between CNA#20 and the
negative pole of the battery (with the stepper motor at
rest) should be very low (around 30 Ohms).

Param transfer
Cause:
Master uC and Slave uC have their own list of parameters
(with their own local backup). Parameter modification is Try changing a parameter again. If the problem persists,
controlled by MuC only. MuC writes its own parameters replace the control device.
and instructs SuC to do the same for its own list of parameters. Running the writing parameter on SuC is password
protected. This alarm is generated by the MuC should SuC
refuse to run the writing command.

Data acquisition
Cause:
This alarm occurs when adjusting the maximum current Reactivate the key.
(set in the factory) and when a procedure is run for acquiring the motor resistance. Acquiring motor resistance has
not yet been implemented.

51

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

breakdown search

Can bus ko

The problem may consist in an incorrect Can Bus conCause:


nection or depend on the traction control device being
If on both MuC and SuC there are no Can Bus messages switched off or not fitted. To identify the root of the
pertaining to traction (Can ID 0x388 for MuC and 0x389 for problem, a Can Bus analyser is required.
SuC) for longer than 200msec, this alarm is generated.

Input mismatch YY
Cause:
MuC and SuC read the values of the inputs independently of each other. SuC is concerned that the values it is
reading match, in real time, the values MuC is reading. If
this does not occur, this alarm is generated. SuC specifies
which input is responsible for the discrepancy with a hex
code (see YY pair above).
The faulty inputs between MuC and SuC may be:
If the alarm is repeated, the problem lies with the control
Discrepancy on straight or 90 switch (SW1 on CNA#12
device.
and SW2 on CNA#11). YY = 83h.
Discrepancy in the quadrant of the MDU in a turn of
360 (SW1 vs. SW2 vs. AUX FUNCTION #11 setting).
YY=08h.
Discrepancy in the speed of the stepper motor greater
than max_stepper_motor_speed/5 (CNA#20 and
CNA#17).YY=04h.
Discrepancy in the encoder count greater than 10
counts (one count of 2296 corresponds to an MDU at
180) (CNG#1 and CNG#3). YY=20h.

Init vmn not ok

Try and disconnect the motor terminals from the control


device, reactivate the key and read STATUS #5. If the
long duration value (e.g. 1st value) is in the range between 8 and 13.5Vdc, the problem is a dispersion (loss of
Cause:
After activating the key with the three-phase bridge disa- motor isolation). Otherwise, replace the control device.
bled, the DC bus voltage should reach 14Vdc in 3.2sec
(CAPACITOR CHARGE alarm, if this does not occur). At
the same time the steering control device monitors the voltage common to the motor terminals (see STATUS #5 1st
value) and generates this alarm after the 3.2sec. and:
The common voltage is less than 7Vdc (bottom MOSFET shorted B).
O
The common voltage is blocked at DC Bus (top MOSFET shorted +B). (it is considered blocked if it is in a
range of +/- 1Vdc around the DC Bus). STATUS #5 in
the TESTER menu gives the value in real time of this
common voltage on long duration.

52

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

Analog
Cause:
This alarm occurs in two ways:
With the key activated, the A/D converter is on and
should complete an initial conversion of the analog
inputs within 16msec. If this does not occur, this alarm Reactivate the key. If the problem persists, replace the
control device.
is generated.
Under conditions of stationary status, the main signals
(currents of the motor and sensor in the wheel of the
steering system) require a new A/D conversion every
250usec. Should no conversion successfully conclude
within 1.25msec, this alarm will be generated (e.g. after
5 consecutive failed conversions).

53

DIAGNOSTICS AND MEASUREMENTS

54

SERVICE

SERVICE

ELECTRICAL SYSTEM

Electrical system
ELECTRICAL WIRING DIAGRAMS  4
CONTROLS  6
IDENTIFICATION OF ARMREST, PEDAL UNIT AND MAIN PANEL CONTROLS  6
STANDARD DISPLAY 8
KEYPAD AND SYMBOLS DISPLAYED  8
DISPLAY BRIGHTNESS CONTROL 9
SOFTWARE 9
ICONS ASSOCIATED WITH THE GRAPHIC SCREENS 9
FUNCTIONAL GRAPHIC SCREENS 13
DESCRIPTION OF THE OPTIONAL GRAPHIC SCREENS 27
DESCRIPTION OF THE MENU SCREENS 39
MAIN MENU 1 39
MAIN MENU 1 / TESTER 39
MAIN MENU 1 / SET CLOCK 41
MAIN MENU 1 / SOFTWARE VERSION. 41
MAIN MENU 1 / ALARMS. 42
MAIN MENU 1 / PARAMETER SETTING. 43
MAIN MENU 2 45
MAIN MENU 2 \ CLEAR ALARMS 46
MAIN MENU 2 \ MEASURING SYSTEM 46
main menu 2 \ FORKS SETUP 47
main menu 2 \ PARAMETER ACQUISITION 48
main menu 2 \ PROGRAMMING ACCESS CODE WITH COMBINED OPERATOR CODE READING 48
main menu 2 \ read user code 51
main menu 2 \ clear access code 51
TRUCK FUNCTIONS 52
FORWARD/REVERSE TRACTION 52
SPEED REDUCTION  54
BRAKING 57
STEERING 58
STEERING 60
FORK LIFTING/LOWERING 61
ACCELERATION / DECELERATION RAMPS 63
LIMIT STOP SLOWDOWN lifting / LOWERING  63
1

ELECTRICAL SYSTEM

SERVICE

FORK LIFTING/LOWERING BLOCKS (WITH FORK HEIGHT ENCODER) 64


HYDRAULIC FUNCTIONS 65
RETRACTABLE CARRIAGE ACCELERATION / DECELERATION RAMPS 66
CARRIAGE OUT / RETURN LIMIT STOP SLOWDOWN 67
AUXILIARY FUNCTIONS ACCELERATION / DECELERATION RAMPS 67
FORK SELF-CENTRING 67
CONFIGURATION PARAMETER ACCESS PROCEDURE 68
MENU SEARCH PROCEDURE and parameter modification 68
STANDARD CONFIGURATION OF MODULE PARAMETERS 73
VCM MODULE 73
ACE2 TRACTION MODULE 75
ACE2 PUMP MODULE 76
EPS ACW MODULE  76
DESCRIPTION OF MODULE PARAMETERS 77
VCM MODULE 1 77
ACE2 TRACTION MODULE 86
ACE2 PUMP MODULE 88
EPS ACW MODULE 88
MODULES: INTRODUCTION 90
POSITIONING OF THE "PC TOOL" CONNECTORS 90
INVERTER ACE2 MODULE 91
EPS ACW MODULE 92
VCM MODULE  93
REPLACEMENT OF MODULES: INSTRUCTIONS 94
REPLACING THE "ACE2 INVERTER" MODULE 94
REPLACEMENT OF THE EPS ACW MODULE 96
VCM MODULE REPLACEMENT 98
REMOVAL OF ELECTRICAL COMPONENTS 100
REPLACEMENT OF ENCODER 100
ENCODER RESET SENSOR REPLACEMENT  102
LOAD CELL REPLACEMENT  103
REPLACEMENT OF THE HORN 104
REPLACEMENT OF THE CONTACTORS  105
FUSE REPLACEMENT 106
REPLACEMENT OF THE MOTOR COMPARTMENT COOLING FAN 108
REPLACEMENT OF ARMREST AND MAIN PANEL CONTROLS: 110
SIDE SHIFT POSITION SENSOR REPLACEMENT 117
PALLET PRESENCE SENSOR REPLACEMENT 118
TILT POSITION SENSOR REPLACEMENT 119
90 WHEEL SENSOR AND STEERED WHEEL SENSOR REPLACEMENT 120
BATTERY OUT SENSOR REPLACEMENT 121
2

SERVICE

ELECTRICAL SYSTEM

OPERATOR PRESENCE PEDAL REPLACEMENT 122


ACCELERATOR AND BRAKE PEDALS REPLACEMENT 123

SERVICE

ELECTRICAL SYSTEM

ELECTRICAL WIRING DIAGRAMS


COMPONENTS
Ref.

Ref.

Description

A1

Standard display

M1

Traction motor

A2

Type of drive control

M2

Pump motor

A3

Pump control

M3

Steering motor

A4

Steering control

M4

Stepper motor

A5

Master card control

P1

Horn

A6

Mast connector card

P2

Flashing

A7

Multi-lever board

P5

Fan

A8

Premium display

P6

Fan

A9

Relay-fuse board

P7

Reversing buzzer

A10

Multi-function joystick board

P8

Work light

A11

Cab heater control

P9

Work light

A12

Multi-function joystick

P10

Work light

B1

Traction motor encoder

Q1

Lowering proportional solenoid valve

B2

Traction motor heat sensor

Q2

Lifting proportional solenoid valve

B3

Pump motor encoder

Q3

Carriage in proportional solenoid valve

B4

Pump motor heat sensor

Q4

Carriage out proportional solenoid valve

B5

Steering motor encoder

Q5

Left hydraulic function proportional solenoid valve

B6

Steer motor heat sensor

Q6

Right hydraulic function proportional solenoid valve

B7

Centred wheel sensor

Q7

Tilt-shift diverter solenoid valve

B8

90 steered wheel sensor

Q8

Hydraulic 5th way diverter solenoid valve

B9

Battery out sensor

R1

Varistor

B10

Tilt position sensor

R2

Electromagnetic brake

B11

Mast lifting encoder

R3

Accelerator pedal sensor

B12

Side shift position sensor

R4

Brake pedal sensor

B13

Pallet presence sensor

R5

Carriage position potentiometer

B14

Encoder reset sensor

R8

Right load wheel electromagnetic brake

B15

Free lift encoder

R9

Left load wheel electromagnetic brake

B16

Temperature sensor

R10

Load cell

C1

Battery

R11

Laser

C2

Electrolyte capacitor 100 F 50V

S1

Key switch

F1

Fuse for emergency push-button and contactors (10A)

S2

Emergency button

F2

Contactor fuse (10A)

S3

Operator presence switch

F3

Key relay fuse (2A)

S4

Drive direction switch

F4

Drive power fuse

S5

Seat belt microswitch

F5

Pump power fuse

S6

Work lights switch

F6

Steering power fuse

S7

Steering mode 180/360

K1

Drive contactor coil

S8

Traction speed reduction

K2

Pump contactor coil

S9

Weighing device button

K3

Key relay

S10

Lift by-pass button

K4

Horn relay

S12

Lifting-lowering potentiometer lever

K5

Auxiliary relay

S13

Carriage out-in potentiometer lever

K6

Auxiliary relay +5/+12V

S14

Tilt potentiometer lever

K7

Work lights relay

S15

Side shift potentiometer lever

K8

Work light relay

S16

Automatic tilt centring button

K9

Diode (1A)

S17

Automatic side shift centring button

K10

Diode (1A)

S18

Hydraulic 5th way button

K11

Diode (1A)

S19

Horn button

K12

Diode (1A)

S20

Drive direction switch

K13

Diode (1A)

S21

Work light switch

K14

Diode (1A)

S22

Seat microswitch (optional)

K15

Diode (1A)

T1

DC/DC 48V/24V converter

K16

Optional relay

T2

DC/DC 48V/12V converter

K17

Diode (1A)

Description

Motor assembly

SERVICE

ELECTRICAL SYSTEM

4a

SERVICE

ELECTRICAL SYSTEM

4b

SERVICE

ELECTRICAL SYSTEM

4c

SERVICE

ELECTRICAL SYSTEM

4d

SERVICE

ELECTRICAL SYSTEM

NOTES
(2) as a reference use the colour X of the
individual wire (or the number printed on it,
if the wire is black)
(3) standard for the Heavy-duty version, optional for the other versions

4e

SERVICE

ELECTRICAL SYSTEM

4f

SERVICE

ELECTRICAL SYSTEM

4g

SERVICE

ELECTRICAL SYSTEM

NOTES
(2) as a reference use the colour

X of the individual wire (or the number printed on it, if the wire is black)

4h

SERVICE

ELECTRICAL SYSTEM

4i

SERVICE

ELECTRICAL SYSTEM

NOTES
(2) as a reference use the colour X of the
individual wire (or the number printed
on it, if the wire is black)
(4) if B15 is not mounted, use B14 for drive
speed reduction and Free Lift/Main Lift
lifting

4j

SERVICE

ELECTRICAL SYSTEM

4k

SERVICE

ELECTRICAL SYSTEM

NOTES
(1) connected on the multi-lever version only
(2) as a reference use the colour X of the individual wire (or the number printed on it, if the
wire is black)

4l

SERVICE

ELECTRICAL SYSTEM
application diagram - MULTI-FUNCTION JOYSTICK (optional)

NOTES
(2) as a reference use the colour X of the individual wire (or the number printed on it, if the
wire is black)

4m

SERVICE

ELECTRICAL SYSTEM

4n

SERVICE

ELECTRICAL SYSTEM
application diagram - PREMIUM DISPLAY (optional)
(see also page (a) for the connections)

application diagram - COLD STORE STANDARD DISPLAY (optional)


(see also page (a) for the connections)

NOTE (2)

application diagram - DC/DC CONVERTER (optional)


(see also page (h) for the connections)

DC/DC DOUBLE CONVERTER (OPTIONAL)

(2) as a reference use the colour X of the


individual wire (or the number printed on it,
if the wire is black)

(see also page (b) for the connections)

NOTES

application diagram - COLD STORE CAB (optional)

4o

SERVICE

ELECTRICAL SYSTEM

SERVICE

ELECTRICAL SYSTEM

CONTROLS
IDENTIFICATION OF ARMREST, PEDAL UNIT AND MAIN PANEL CONTROLS

3
7

10
11

8
1
12

13

13

14
18
23

17

14

15
22

18

24
16

17

15

21
20
19

16

SERVICE

ELECTRICAL SYSTEM

26

25

Ref.

Description

27

Wiring diagram ref.

Keyswitch

S1

Small steering wheel

Standard or premium display

Speed reduction button

S8

Weighing button

S9

180/360 steering mode button

S7

Auxiliary function button

Auxiliary function button

Work lights switch

S6

10

Work lights switch

S21

11

Auxiliary function switch

12

PC tool connection port compartment

13

Emergency button

S2

14

Horn button

S19

15

Drive direction switch

S4

16

Automatic tilt centring button

S16

17

Automatic side shift centring button

S15

A1 - A8

X40-X41

18

Hydraulic 5th way button

S18

19

Fork lifting/lowering mini-lever

S12

20

Carriage in/out mini-lever

S13

21

Forks up/down tilt mini-lever

S14

22

Forks right/left shift mini-lever

S15

23

Joystick

A12

24

Fork tilt/shift lever

25

Operator presence pedal

S3

26

Brake pedal

R4

27

Accelerator pedal

R3
7

SERVICE

ELECTRICAL SYSTEM

STANDARD DISPLAY
KEYPAD AND SYMBOLS DISPLAYED

Ref.

Description

Numerical keys from 0 to 9

Forward or upward scroll key

Backward or downward scroll key

Ignition switch with or without key

OUT function key

ENTER function key

SERVICE

ELECTRICAL SYSTEM

DISPLAY BRIGHTNESS CONTROL


a) Disconnect the emergency button with the key switch in position 1
b) Reset the emergency button with the numerical button 0 pressed
c) When the display lights up, use the two scroll buttons to change the brightness
d) Once you reach the desired brightness, press the "ENTER" function key to save it

SOFTWARE
The software is loaded by the supplier.
The software release is indicated on the label on the component.
When switching on, the display has to send an SDO to the VMC identification controller that will respond
with another SDO for confirmation. When the key switch is turned off the display must warn the VMC
150ms before cutting off the +12V supplying the key relay.

ICONS ASSOCIATED WITH THE GRAPHIC SCREENS


The icons used in the various functions shown on the display are illustrated below.

ICON

DESCRIPTION
Battery charge level indicator.
The system continuously monitors the battery charge
indicated by the number of solid segments.
5 segments = from 100% to 76%
4 segments = from 75% to 50%
3 segments = from 49% to 35%
2 segments = from 34% to 21%
1 segment = from 20% to 0
Segments 5-4-3 shown steady. Segments 2-1 shown
blinking. The battery charge status data will be sent
to the display via Can bus with PDO.
Parking brake indicator.
The data reaches the display via Can bus with
PDO.

SERVICE

ELECTRICAL SYSTEM

ICON

DESCRIPTION
Remaining battery life indicator.
Indicates the remaining hours and minutes of battery
life. The data will be sent to the display via Can bus
with PDO.

24:00

Daily clock, indicates the hours and minutes.


The data reaches the display via Can bus with
PDO

0001 h

Worked hours indicator.


The data reaches the display via Can bus with
SDO.

10.50 km/h

Traction speed indicator.


The data reaches the display via Can bus with
PDO.

10.50 m

Indicator of fork height off the ground.


The data reaches the display via Can bus with
PDO.

0150 kg

Weighing Indicator.
The data reaches the display via Can bus with
SDO.
Reduced speed indicator.
The data reaches the display via Can bus with
PDO.
Maximum speed indicator.
The data reaches the display via Can bus with
PDO.
Seat belt indicator.
Appears when the seat belt is not fastened. The data
reaches the display via Can bus with PDO.
Lifting limit stop indicator.
This icon is displayed on reaching the lifting limit. The
data reaches the display via Can bus with PDO.
Fork tilt up indicator.
This icon is displayed during the fork "tilt up" function. The data reaches the display via Can bus
with PDO.
Fork tilt down indicator.
This icon is displayed during the fork "tilt down"
function.
The data reaches the display via Can bus with
PDO.
Fork right side shift indicator.
This icon is displayed during the fork "right side shift"
function.
The data reaches the display via Can bus with
PDO.
Fork left side shift indicator.
This icon is displayed during the fork "left side shift"
function.
The data reaches the display via Can bus with
PDO.

10

SERVICE

ELECTRICAL SYSTEM

ICON

DESCRIPTION
Fork side shift self-centring indicator.
This icon is displayed during the fork "side shift selfcentring" function. Icon blinking while moving, steady
once centred. Optional. The data comes via Can
bus with PDO.
Fork tilt self-levelling indicator.
This icon is displayed during the fork "tilt 0 selflevelling" function. Icon blinking while moving, steady
once centred. Optional. The data reaches the display
via Can bus with PDO.
Indicator for hydraulic 5th way option active.
This icon is displayed when the hydraulic 5th way
option is activated. The data reaches the display via
Can bus with PDO.
IN/OUT hydraulic 5th way function indicator.
This icon is displayed blinking (at a frequency of 2
Hz) when the hydraulic 5th way function is active in
the two work modes. The data reaches the display
via Can bus with PDO.
Forks lowering interlock indicator.
This icon is displayed during the fork lowering function when the fork lowering lock trips. Optional. The
data reaches the display via Can bus with PDO.
Carriage return interlock indicator.
This icon is displayed during the request for carriage
return with the interlock option active. Optional. The
data reaches the display via Can bus with PDO.
Battery out-of-place indicator.
This icon is displayed when the battery is no longer
locked in its correct position. The data reaches the
display via Can bus with PDO.
Alarm indicator.
This icon is displayed in the event of a hardware or
software failure on the electrical system and is associated with a numerical code that identifies the type
of alarm and control involved.
Password prompt indicator.
This icon appears if a password is required for access.

11

SERVICE

ELECTRICAL SYSTEM

ICON

DESCRIPTION
Incorrect password entry indicator.
This icon appears if the access password entry is
incorrect.

Steer wheel 360 position indicator.


This icon is always displayed. The data reaches the
display via Can bus with PDO.

Steer wheel 360 position indicator showing forward gear engaged.


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

Steer wheel 180 position indicator showing forward gear engaged.


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

12

SERVICE

ELECTRICAL SYSTEM

FUNCTIONAL GRAPHIC SCREENS


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

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Worked hours indicator displayed for 5 seconds

SCREEN DISPLAYED 5 SECONDS AFTER SWITCHING ON THE KEY SWITCH


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Speed indicator, expressed in km/h or mph

13

SERVICE

ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH FORWARD DRIVE SELECTED
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator following the steering wheel position indicator
Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH REVERSE DRIVE SELECTED


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Reverse drive indicator following the steering wheel position indicator
Speed indicator, expressed in km/h or mph

14

SERVICE

ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH FORK LIFTING ON AND DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Fork lifting indicator
Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH FORK LOWERING ON AND DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Fork lowering indicator
Speed indicator, expressed in km/h or mph

15

SERVICE

ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH CARRIAGE OUT ON AND DRIVE OFF
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Carriage out indicator
Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH CARRIAGE RETURN ON AND DRIVE OFF


Steering 360

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Carriage return indicator
Speed indicator, expressed in km/h or mph

16

Steering 180

SERVICE

ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH FORK TILT UP ON AND DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Fork tilt up indicator
Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH FORK TILT DOWN ON AND DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Fork tilt down indicator
Speed indicator, expressed in km/h or mph

17

SERVICE

ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH FORK SIDE SHIFT TO RIGHT ON AND DRIVE OFF
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Fork side shift to right indicator
Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH FORK SIDE SHIFT TO LEFT ON AND DRIVE OFF
Steering 360

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Fork side shift to left indicator
Speed indicator, expressed in km/h or mph
18

Steering 180

SERVICE

ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH BATTERY OUT-OF-PLACE


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Battery out-of-place indicator
Fork lifting block indicator
206-01 alarm indicator (Battery out)

SCREEN DISPLAYED WITH BATTERY REMOVAL ON AND DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Carriage out indicator
Battery out-of-place indicator
Fork lifting block indicator
206-01 alarm indicator (Battery out)

19

SERVICE

ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH BATTERY RETURN INTO PLACE ON AND DRIVE OFF
Steering 360

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Carriage return indicator
Battery out-of-place indicator
Fork lifting block indicator
206-01 alarm indicator (Battery out)

20

Steering 180

SERVICE

ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Fork lifting indicator
Carriage return indicator
Tilt up indicator
Speed indicator, expressed in km/h or mph
The screen shown above is an example of combined hydraulic functions.

Possible combinations
Forks up

carriage out

tilt up

Forks up

carriage out

tilt down

Forks up

carriage out

right side shift

Forks up

carriage out

left side shift

Forks up

carriage return

tilt up

Forks up

carriage return

tilt down

Forks up

carriage return

right side shift

Forks up

carriage return

left side shift

Forks lowering

carriage out

tilt up

Forks lowering

carriage out

tilt down

Forks lowering

carriage out

right side shift

Forks lowering

carriage out

left side shift

Forks lowering

carriage return

tilt up

Forks lowering

carriage return

tilt down

Forks lowering

carriage return

right side shift

Forks lowering

carriage return

left side shift

21

SERVICE

ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Fork lifting indicator
Carriage forward indicator
Tilt up indicator
Speed indicator, expressed in km/h or mph
The screen shown above is an example of combined hydraulic functions with the drive on.

Possible combinations

22

Forks up

carriage out

tilt up

for forward/reverse drive

Forks up

carriage out

tilt down

for forward/reverse drive

Forks up

carriage out

right side shift

for forward/reverse drive

Forks up

carriage out

left side shift

for forward/reverse drive

Forks up

carriage return

tilt up

for forward/reverse drive

Forks up

carriage return

tilt down

for forward/reverse drive

Forks up

carriage return

right side shift

for forward/reverse drive

Forks up

carriage return

left side shift

for forward/reverse drive

Forks lowering

carriage out

tilt up

for forward/reverse drive

Forks lowering

carriage out

tilt down

for forward/reverse drive

Forks lowering

carriage out

right side shift

for forward/reverse drive

Forks lowering

carriage out

left side shift

for forward/reverse drive

Forks lowering

carriage return

tilt up

for forward/reverse drive

Forks lowering

carriage return

tilt down

for forward/reverse drive

Forks lowering

carriage return

right side shift

for forward/reverse drive

Forks lowering

carriage return

left side shift

for forward/reverse drive

SERVICE

ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION ON


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Energy Saving indicator
Steering wheel position indicator
Parking brake indicator
Speed indicator, expressed in km/h or mph

SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION, DRIVE AND HYDRAULICS ON


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Energy Saving indicator
Steering wheel position indicator
Forward drive indicator
Fork lifting indicator
Speed indicator, expressed in km/h or mph

23

SERVICE

ELECTRICAL SYSTEM
SCREEN DISPLAYED WITH WARNING SIGNALLING
This screen is displayed after an incorrect sequence performed by the operator.
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Warning indicator
Indication of the problem

The incorrect sequences are:

24

INC. START TRACTION

INC. START REACH OUT

INC. START LIFT

INC. START SHIFT RIGHT

INC. START LOW

INC. START SHIFT LEFT

INC. START TILT UP

INC. START 5TH WAY IN

INC. START TILT DOWN

INC. START 5TH WAY OUT

INC. START REACH IN

GET HOME

SERVICE

ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH ALARM SIGNALLING


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Alarm indicator
Alarm code number indicator
NOTE: 249 = code number of type of alarm.
6 = identification of the control on which the alarm occurred.

SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE OFF.
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Lifting limit stop indicator
Speed indicator, expressed in km/h or mph

25

SERVICE

ELECTRICAL SYSTEM

SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE ON.
Steering 360

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Lifting limit stop indicator
Speed indicator, expressed in km/h or mph

26

Steering 180

SERVICE

ELECTRICAL SYSTEM

DESCRIPTION OF THE OPTIONAL GRAPHIC SCREENS


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

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Seat belt not fastened indicator
Speed indicator, expressed in km/h or mph
When the direction of travel is selected, the above screen will appear if the seat belt is not fastened.
The indicator showing that the seat belt is not fastened blinks at a frequency of 1.5 Hz.

FORK TILT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE OFF.


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Fork tilt self-centring indicator
Speed indicator, expressed in km/h or mph
During the self-centring phase the icon will blink alternately with showing the tilt movement (tilt up/tilt down). If
there is a request for self-centring and the forks are already in the correct position the icon is on steady.
27

SERVICE

ELECTRICAL SYSTEM
FORK TILT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE ON.
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Fork tilt self-centring indicator
Speed indicator, expressed in km/h or mph
During the self-centring phase the icon will blink alternately with showing the tilt movement (tilt up/tilt down). If
there is a request for self-centring and the forks are already in the correct position the icon is on steady.

FORK SIDE SHIFT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE OFF.


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Fork side shift self-centring indicator
Speed indicator, expressed in km/h or mph
During the self-centring phase the icon will blink alternately with showing the side shift movement (side shift
right/side shift left). If there is a request for self-centring and the forks are already in the correct position
the icon is on steady.
28

SERVICE

ELECTRICAL SYSTEM

FORK SIDE SHIFT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE ON.


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Fork side shift self-centring indicator
Speed indicator, expressed in km/h or mph
During the self-centring phase the icon will blink alternately with showing the side shift movement (side shift
right/side shift left). If there is a request for self-centring and the forks are already in the correct position
the icon is on steady.

OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Hydraulic 5th way indicator
Speed indicator, expressed in km/h or mph
29

SERVICE

ELECTRICAL SYSTEM
OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE ON
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Hydraulic 5th way indicator
Speed indicator, expressed in km/h or mph

OPTIONAL SCREEN FOR INPUT HYDRAULIC 5TH WAY WITH DRIVE OFF
Steering 360

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Input hydraulic 5th way indicator
Speed indicator, expressed in km/h or mph
30

Steering 180

SERVICE

ELECTRICAL SYSTEM

OPTIONAL SCREEN FOR OUTPUT HYDRAULIC 5TH WAY WITH DRIVE OFF
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Output hydraulic 5th way indicator
Speed indicator, expressed in km/h or mph

OPTIONAL SCREEN FOR INPUT HYDRAULIC 5TH WAY WITH DRIVE ON


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Input hydraulic 5th way indicator
Speed indicator, expressed in km/h or mph

31

SERVICE

ELECTRICAL SYSTEM
OPTIONAL SCREEN FOR OUTPUT HYDRAULIC 5TH WAY WITH DRIVE ON
Steering 360

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Output hydraulic 5th way indicator
Speed indicator, expressed in km/h or mph

32

Steering 180

SERVICE

ELECTRICAL SYSTEM

OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Parking brake indicator
Fork lifting indicator
Carriage forward indicator
Tilt self-centring indicator
Speed indicator, expressed in km/h or mph

The screen shown above is an example of combined hydraulic functions with the drive on.

Possible combinations

Forks up
Forks up
Forks up
Forks up
Forks lowering
Forks lowering
Forks lowering

carriage out
carriage out
carriage return
carriage return
carriage out
carriage out
carriage return

tilt self-centring
side shift self-centring
tilt self-centring
side shift self-centring
tilt self-centring
side shift self-centring
tilt self-centring

Forks lowering

carriage return

side shift self-centring

33

SERVICE

ELECTRICAL SYSTEM
OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Fork lifting indicator
Carriage forward indicator
Tilt self-centring indicator
Speed indicator, expressed in km/h or mph

The screen shown above is an example of combined hydraulic functions with the drive off.

Possible combinations

34

Forks up
Forks up
Forks up
Forks up
Forks lowering
Forks lowering
Forks lowering

carriage out
carriage out
carriage return
carriage return
carriage out
carriage out
carriage return

tilt self-centring
side shift self-centring
tilt self-centring
side shift self-centring
tilt self-centring
side shift self-centring
tilt self-centring

for forward/reverse drive


for forward/reverse drive
for forward/reverse drive
for forward/reverse drive
for forward/reverse drive
for forward/reverse drive
for forward/reverse drive

Forks lowering

carriage return

side shift self-centring

for forward/reverse drive

SERVICE

ELECTRICAL SYSTEM

OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Fork lifting/lowering indicator
Digital height display measured in metres or feet

OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE ON


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Fork lifting/lowering indicator
Digital height display in metres or feet off the ground
During the forks up or down function with drive on, the measured fork height must always be displayed.
When the machine is stopped, the fork height off the ground is displayed. When the machine is running
only in drive mode, the speed indicator is displayed.
35

SERVICE

ELECTRICAL SYSTEM
OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE AND HYDRAULICS OFF
Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Load weighing indicator in kg or lb
During the load weighing function with drive on, the weight must appear for 5 seconds and then the drive
speed will be displayed.

OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE ON AND HYDRAULICS OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive engaged indicator
Load weighing indicator in kg or lb
During the load weighing function with drive on, the weight must appear for 5 seconds and then the drive
speed will be displayed.
36

SERVICE

ELECTRICAL SYSTEM

FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Forks lowering interlock indicator
Speed indicator, expressed in km/h or mph
The forks lowering indicator blinks at a frequency of 1.5 Hz.

FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Forks lowering interlock indicator
Speed indicator, expressed in km/h or mph
The forks lowering indicator blinks at a frequency of 1.5 Hz.
37

SERVICE

ELECTRICAL SYSTEM

CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF


Steering 360

Steering 180

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Parking brake indicator
Steering wheel position indicator
Carriage return interlock indicator
Speed indicator, expressed in km/h or mph
The carriage return indicator blinks at a frequency of 1.5 Hz.

CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON


Steering 360

Remaining battery life indicator


Battery charge level indicator
Clock
Traction performance indicator (tortoise or hare)
Steering wheel position indicator
Forward drive indicator
Carriage return interlock indicator
Speed indicator, expressed in km/h or mph
The carriage return indicator blinks at a frequency of 1.5 Hz.

38

Steering 180

SERVICE

ELECTRICAL SYSTEM

DESCRIPTION OF THE MENU SCREENS


The graphic screens for each menu are shown below in sequence.
MAIN MENU 1

Pressing the "ENTER" function key takes you from the main screen to MAIN MENU 1 as shown above.
To access the different sub-menus, you need to move the arrow by pressing the "SCROLL" keys and, once
you have made your selection, press ENTER.

MAIN MENU 1 / TESTER


The TESTER function allows you to check the operation of the truck.
Once in the TESTER sub-menu, the TESTER 1 screen will appear, as shown below. Using the SCROLL
keys you can change the screens of the TESTER sub-menu (from TESTER 1 to TESTER 5)

TESTER 1
TRACTION
CURRENT
VOLTAGE
FREQUENCY
TEMPERATURE
MOTOR TEMP
HOURS

= 0000 A
= 000%
= 000 Hz
= 000 C
= 000 C
= 0000 h

TESTER1 enables checking the signals sent by the traction controller.


The display via an SDO will request these data from the traction controller that will respond with an SDO
via Can Bus.

TESTER 2
PUMP
CURRENT
VOLTAGE
FREQUENCY
TEMPERATURE
MOTOR TEMP
HOURS

= 0000 A
= 000%
= 000 Hz
= 000 C
=000 C
= 0000 h

TESTER 2 enables checking the signals sent by the pump controller.


The display via an SDO will request these data from the pump controller that will respond with an SDO
via Can Bus.
39

ELECTRICAL SYSTEM

SERVICE

TESTER 3
STEERING
CURRENT
VOLTAGE
FREQUENCY
TEMPERATURE
MOTOR TEMP
HOURS

= 0000 A
= 000%
= 000 Hz
= 000 C
= 000 C
= 0000 h

TESTER 3 enables checking the signals sent by the steering system controller.
The display via an SDO will request these data from the steering system controller that will respond with
an SDO via Can Bus.

TESTER 4 enables checking the status of the digital inputs.


Empty square = OFF
Solid square = ON
The display via an SDO will request these data from the VMC controller that will respond with an SDO
via Can Bus.

TESTER 5 enables checking the status of the analogue inputs.


The display via an SDO will request these data from the VMC controller that will respond with an SDO
via Can Bus.
By pressing the "OUT" function key, you can exit the screen at any time.

40

SERVICE

ELECTRICAL SYSTEM

MAIN MENU 1 / SET CLOCK


The SET CLOCK function allows you to set the current time.

Once you enter the sub-menu, the hours will flash. Use the numerical keys to set the correct time, then
confirm with "ENTER". The minutes will now blink. Use the numerical keys to set the minutes and confirm
with "ENTER". After this operation you exit the screen automatically.
The display via SDO will send these data to the VMC controller that will respond with an SDO as confirmation. The VMC will have an RTC device with Backup
By pressing the "OUT" function key, you can exit the screen at any time.

MAIN MENU 1 / SOFTWARE VERSION.


The SOFTWARE VERSION function allows you to check the versions of the software used.

The display via an SDO will request these data from the VMC controller that will respond with an SDO
via Can Bus.
By pressing the "OUT" function key, you can exit the screen at any time.

41

ELECTRICAL SYSTEM

SERVICE

MAIN MENU 1 / ALARMS.


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

The code number of the type of alarm.

The time when the alarm occurred.

The number of times it has occurred.

Identifier of the control on which the alarm occurred.

Once in the ALARMS sub-menu, the screen will appear with the first 10 alarms. Using the "SCROLL"
keys, you can change the screens to be able to view all 32 alarms, when there are that many, otherwise
the pages are automatically reduced to display only the alarms present.

The display via an SDO will request these data from the VMC controller that will respond with an SDO
via Can Bus.

By pressing the function key OUT (see page 13), you can exit the screen at any time.

42

SERVICE

ELECTRICAL SYSTEM

MAIN MENU 1 / PARAMETER SETTING.


On these screens, the operator can modify the machine's drive performance, with the ability to lock it with
a password.
Once in the PARAMETER SETTING sub-menu, the screen shown below will appear.

With the "SCROLL" keys you can select the parameter you want to change:
1) TRACTION SPEED from 1.00 km/h to 14.00 km/h
2) ACCELERATION from 1 to 5




1: +1 sec (lower performing)


2: +0.5 sec
3: standard setting
4: -0.3 sec
5: -0.5 sec (higher performing)

3) INVERSION BRAKING from 1 to 5






1: +0.5 sec (lower performing)


2: +0.2 sec
3: standard setting
4: -0.3 sec
5: -0.5 sec (higher performing)

4) RELEASE BRAKING from 1 to 5






1: +0.5 sec (lower performing)


2: +0.2 sec
3: standard setting
4: -0.3 sec
5: -0.5 sec (higher performing)
To change the 4 above parameters, proceed as follows:
a) Position the cursor, using the "SCROLL" keys, on the parameter to be changed
b) Press the "ENTER" key.
c) The value of the parameter will blink and you can now change the value with the "NUMERICAL" keys.
d) Press the "ENTER" key to confirm.

43

ELECTRICAL SYSTEM

SERVICE

5) ENERGY SAVING from OFF to ON. If set ON, the machine traction and lifting performance will be
reduced to save battery power consumption. This function will be indicated by the ECO icon.
To modify this parameter, proceed as follows:
a) Position the cursor, using the "SCROLL" keys, on the parameter to be changed.
b) Press the "ENTER" key.
c) The word OFF will blink and you can now change it to ON using the "SCROLL" keys.
d) Press the "ENTER" key to confirm.
6) LOCK PARAM. from OFF to ON. If set ON, you will be prompted for a password to lock the set
parameters.
To modify this parameter, proceed as follows:
e) Position the cursor, using the "SCROLL" keys, on the parameter to be changed.
f) Press the "ENTER" key.
g) A window will open where you can enter the 4 digits of the PIN that you can set as a password.
Enter the 4-digit password using the "NUMERICAL" keys and press "ENTER" to confirm.
The modified parameters will now be locked and you are taken back to the PARAMETER
SETTING screen and the LOCK PARAM value will be ON. Now, all the parameters are
locked.
If the user attempts to modify the parameters with the lock on, the screen for entering the password will
reappear.
On restarting the machine the screen for entering the password shown below will be displayed.

If you enter the wrong password, the screen shown below will appear for 5 seconds, after which the password prompt screen will return.

With the SUPERVISOR PASSWORD (default 5555) or the ENGINEERING PASSWORD (1959)
it is always possible to unlock the parameters.
The display via an SDO will send these data to the VMC controller that will respond with an
SDO via Can Bus.
By pressing the "OUT" function key, you can exit the screen at any time.
44

SERVICE

ELECTRICAL SYSTEM

MAIN MENU 2
The MAIN MENU 2 function allows you to access the functions that only technical support can modify.
Once in the MAIN MENU 2 sub-menu, the following screen will appear.

Enter the 4-digit password using the "NUMERICAL" keys and press "ENTER" to confirm. If you enter the
wrong password, the screen shown below will appear for 5 seconds, after which the password prompt
screen will return.

When the password is correct, the following screen will be displayed.

With the SUPERVISOR PASSWORD (default 5555) or the ENGINEERING PASSWORD (1959)
it is always possible to access MAIN MENU 2.
To access the different sub-menus, you need to move the arrow by pressing the "SCROLL" keys
and, once you have made your selection, press ENTER.
By pressing the "OUT" function key, you can exit the screen at any time.

45

ELECTRICAL SYSTEM

SERVICE

MAIN MENU 2 \ CLEAR ALARMS


The CLEAR ALARMS function allows you to delete the alarms in the ALARMS menu

When this screen appears, pressing the direction buttons scrolls through the two possible options of YES
and NO.
Pressing the ENTER button with YES displayed clears the saved alarms and takes you back to the MAIN
MENU 2 screen. Pressing the ENTER button with NO displayed exits without clearing the alarms and
takes you back to the MAIN MENU 2 screen.
With the "OUT" button you exit without clearing the alarms.

MAIN MENU 2 \ MEASURING SYSTEM


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

kg into lb

When this screen appears, by using the scroll buttons you can select the available systems of measurement (INTERNATIONAL SYSTEM/IMPERIAL SYSTEM) and, once selected, on pressing the ENTER
button the units of measurement are converted by the display's software and you are taken back to the
MAIN MENU 2 screen. The metric system is present by default on Can Bus.
By pressing the "OUT" function key, you can exit the screen at any time.

46

SERVICE

ELECTRICAL SYSTEM

main menu 2 \ FORKS SETUP


The FORKS SETUP function allows you to change the two fork adjustment values. The first one, FORKS
OFFSET , is the minimum height of the forks off the ground. The second one, FORKS UP LIMIT, allows
you to limit lifting the forks up to the set height.

When this screen appears, on pressing the ENTER button the selected value, for example FORKS OFFSET, will blink. Type in the new offset value in metres, using the NUMERICAL buttons.

Press the "ENTER" key to confirm. The modified value will be displayed steady
The same procedure for changing the value applies to the second value, FORKS UP LIMIT, which can
be selected with the direction buttons.
The display via an SDO will send these data to the VMC controller that will respond with an SDO via
Can Bus.

47

ELECTRICAL SYSTEM

SERVICE

main menu 2 \ PARAMETER ACQUISITION

On this screen you can acquire the electrical values of carriage all in, carriage all out, minimum load cell
value (with no load on the forks) and maximum load cell value (nominal load on the forks).
With the scroll keys you can select the value you want to acquire. To access carriage all out/in acquisition,
proceed as follows:
a) Position the cursor, using the scroll keys, onto the value to be acquired: REACH FULL FWD /
REACH FULL BACK.
b) Press the "ENTER" key and the selected value will start flashing.
c) Move the carriage forwards/backwards until the desired position is reached..
d) Press the "ENTER" key to save the modified value.
e) Press the "OUT" button to exit.
To access acquisition of the load cell minimum and maximum values, proceed as follows:
a) Position the cursor, using the scroll keys, onto the value to be acquired: MIN WEIGHT CELL/MAX
WEIGHT CELL.
b) Press the "ENTER" key and the selected value will start flashing.
c) Raise the forks off the ground by approximately 50mm.
d) Press the "ENTER" key to save the modified value.
e) Press the "OUT" button to exit.

main menu 2 \ PROGRAMMING ACCESS CODE WITH COMBINED OPERATOR CODE READING
This function is optional, therefore the display needs to be enabled via PDO to make it operative on the
truck. The PROG. PIN CODE ACCESS function allows you to create an access code for operator or
supervisor use and to define the driver profile for each access code. Up to a total of 104 codes can be
programmed. If this function is enabled, when switching on the key switch the display will prompt you for
the access code.
With the correct access code, the +12V output of the key relay is enabled, the screen will be displayed
and the operator will be enabled to use the machine. If the truck is not operated for any longer than 10
minutes (message sent by Can Bus via SDO), the display will disable the +12V output of the key relay
and switch off. To be able to restart, simply press any button and the display will prompt you for the access
code again.
The screens and the descriptions for the programming are illustrated below.

48

SERVICE

ELECTRICAL SYSTEM

ACCESS CODE PROGRAMMING SCREEN

To enter the codes, you need to move the arrow by pressing the "SCROLL" keys and, once you have selected
the row, press ENTER. The cursor will now be positioned on the digit of the code to enter that will start
flashing. Type in the four-digit code with the "NUMERIC" keys and confirm with ENTER. The cursor will
automatically move onto "U" that will start flashing. Using the SCROLL buttons you can go from U (user)
to S (supervisor) and pressing ENTER confirms the selection. Lastly, the cursor will move onto "NA"
that will start flashing. Using the SCROLL buttons you can go from NA (not available) to A (available),
pressing ENTER confirms the selection. If NA is confirmed, the cursor will move onto the next row,
whereas confirming A will show the screen to be able to match the driver profile with the access code.

With the "SCROLL" keys you can select the parameter you want to change:
1) TRACTION SPEED from 1.00 km/h to 14.00 km/h
2) ACCELERATION from 1 to 5




1: +1 sec (lower performing)


2: +0.5 sec
3: standard setting
4: -0.3 sec
5: -0.5 sec (higher performing)

3) INVERSION BRAKING from 1 to 5






1: +0.5 sec (lower performing)


2: +0.2 sec
3: standard setting
4: -0.3 sec
5: -0.5 sec (higher performing)

49

ELECTRICAL SYSTEM

SERVICE

4) RELEASE BRAKING from 1 to 5






1: +0.5 sec (lower performing)


2: +0.2 sec
3: standard setting
4: -0.3 sec
5: -0.5 sec (higher performing)

To change the 4 above parameters, proceed as follows:


a) Position the cursor, using the "SCROLL" keys, on the parameter to be changed
b) Press the "ENTER" key.
c) The value of the parameter will blink and you can now change the value with the "NUMERICAL" keys.
d) Press the "ENTER" key to confirm and return to the PROG. PIN CODE ACCESS screen
with the cursor positioned on the next row.
By pressing the "OUT" function key, you can exit the screen at any time.
This procedure applies to all 104 access codes.

ACCESS CODE PROMPT SCREEN

Enter the 4-digit password using the "NUMERICAL" keys and press "ENTER" to confirm. If you enter the
wrong password, the screen shown below will appear for 5 seconds, after which the password prompt
screen will return.

50

SERVICE

ELECTRICAL SYSTEM

main menu 2 \ read user code


The READ USER CODE function enables displaying the last 24 USER codes that have used the machine, saving the start and end of work times.
Use the truck operating hours to calculate the start and end of work.

To be able to view the remaining USER CODES on the other pages, use the SCROLL buttons
By pressing the "OUT" function key, you can exit the screen at any time.

main menu 2 \ clear access code


The CLEAR PIN CODE ACCESS function allows you to delete the access codes, user code reading and
profile settings in the PRG. PIN CODE ACCESS menu.

When this screen appears, pressing the direction buttons scrolls through the two possible options of NO
and YES. On confirming with the ENTER button, the saved codes are deleted and you are automatically
taken back to the MAIN MENU 2 screen.
By pressing the "OUT" function key, you can exit the screen at any time.

51

SERVICE

ELECTRICAL SYSTEM

TRUCK FUNCTIONS
FORWARD/REVERSE TRACTION
CONTROLS
Brake pedal

Dead man pedal

Forward/reverse gear selection


button

Accelerator pedal

To perform forward traction press the gear selection button upwards and press the accelerator while
keeping the dead man pedal depressed.
To perform reverse traction press the gear selection button downwards and press the accelerator
while keeping the dead man pedal depressed.
The driving speed is adjusted by the potentiometer on the accelerator pedal both going forwards
and backwards.

Devices involved
Keyswitch

ON

Emergency switch

ON

Forward/reverse gear selection button

enabled

Dead man pedal

ON

Seat microswitch*

ON

Seat belts fastened sensor*

ON

Accelerator pedal
* where applicable

52

status

forward/reverse traction

Symbol on diagram

SERVICE

ELECTRICAL SYSTEM

CONFIGURATION PARAMETERS

cutback speed
cutback speed 2
pedal brk range

Config menu
set options
load brake
battery check
seatbelt
seat switch
seat sw.combi

ACE2 TRACTION

i min braking
i max braking

Config menu
adjustment

acceler. delay
release braking
tiller braking
invers. braking
decel. braking
pedal braking
speed limit brk.
curve speed 1
curve speed 2
max speed forw
max speed back
max speed limit

EPS

VMC

Main menu
parameter change

speed lim vs trac

For the adjustment values of each individual parameter, see the paragraph "standard
configuration of module parameters".
For a description of each individual parameter see "DESCRIPTION OF MODULE PARAMETERS".

The maximum traction speed and acceleration can be set via the programmer.
Maximum forward and backward traction speed setting
ACE2 TRACTION / main menu parameter change / max speed forw
ACE2 TRACTION / main menu parameter change / max speed back
Setting the acceleration
AC2 TRACTION / main menu parameter change / acceler. delay

53

ELECTRICAL SYSTEM

SERVICE

SPEED REDUCTION
There are two levels of speed reduction available on the machine.

cutback speed

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


This trips when the height of the forks off the ground exceeds the free lift
(h2) or when the retractable carriage is fully out (the speed starts decreasing
when the carriage is over 100 mm out and falls in line with the movement of
the retractable carriage).

cutback speed 2

second reduction in traction speed (4 km/h).


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

Setting of the speed reduction levels


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

maximum speed

with steering angle between 0 and 5 (nonsettable dead zone):


maximum speed

with steering angle between 5 and 20: settable deceleration with


the parameter curve
speed 1

Setting deceleration with steering wheel between 5 and 20


ACE2 TRACTION / menu parameter change / curve speed 1
Setting maximum deceleration with steering wheel 90
ACE2 TRACTION / menu parameter change / curve speed 2

54

with steering angle between 20 and 90: deceleration in proportion


to the steering angle
that can be set with the
parameter curve speed
2

SERVICE

ELECTRICAL SYSTEM

SPEED REDUCTIONS AND TRACTION BLOCK WITH CHECK UP NEEDED WARNING


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

0: no alarm

1: the alarm appears after 300 hours

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

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

ON

SPEED REDUCTIONS AND BRAKING


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

DECELERATION WITH LOW BATTERY


When the level of the battery charge drops below 20% the traction speed is reduced to 24% of the maximum
speed. To restore initial operating conditions of the traction motor the battery must be recharged.
When the charge reaches 40% the low battery indicator is reset and the maximum current is restored on
the traction motor.
It is possible to set the behaviour of the truck with a flat battery.
Setting truck behaviour with a flat battery
VMC / config menu set options / battery check

0: no action
1: the BATTERY LOW alarm appears, the speed
is reduced to 24% of the maximum speed, the
maximum current on the motor is reduced by 50%
2: the BATTERY LOW alarm appears, no other
action
3: the BATTERY LOW alarm appears, the speed
is reduced to 24% of the maximum speed, fork lifting block is enabled

55

ELECTRICAL SYSTEM

SERVICE

TRACTION BLOCKS
Traction is disabled if the seated operator microswitch (optional) and the fastened seat belt sensor (optional) are not active and if you fail to observe the sequence of operator seated seat belt fastened.
it is possible to enable/disable the seated operator microswitch, the fastened seat belt sensor and the
correct sequence check via the programmer.
Enabling/disabling seat microswitch
VMC / config menu set options / seat switch
Enabling/disabling seat belts fastened sensor
VMC / config menu set options / seatbelt
Enabling/disabling correct sequence check
VMC / config menu set options / seat sw.combi

56

SERVICE

ELECTRICAL SYSTEM

BRAKING
The truck is equipped with four braking systems:



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

Tall machines are fitted with electromagnetic brakes on the load wheels that can be operated with the brake
pedal for safer braking.
Truck braking will be performed in different ways according to which of the above systems is implemented. For
further information on the braking systems see "BRAKING SYSTEMS" BRAKING SYSTEM section.
BRAKING SYSTEMS

WHEN APPLIED

Release braking

Traction control accelerator pedal release

Partial release braking

Traction control accelerator pedal partial release

Braking on direction reversal

Inversion of the direction of travel using the gear selection button


Through operation of the emergency button

Emergency braking

Dead man pedal release


an alarm has been generated that requires traction to be halted immediately

Parking brake

The machine is stationary and no traction control is activated

Pedal brake

Brake pedal pressure

It is possible to set the deceleration ramp of the various braking methods using the programmer.
Setting the deceleration ramp for release braking
ACE2 TRACTION / menu parameter change / release braking
Setting the partial release braking deceleration ramp
ACE2 TRACTION / menu parameter change / decel. braking
Setting the deceleration ramp for direction reversal braking
ACE2 TRACTION / menu parameter change / invers. braking
Setting the deceleration ramp for emergency braking
ACE2 TRACTION / menu parameter change / tiller braking
Setting the deceleration ramp for pedal braking
ACE2 TRACTION / menu parameter change / pedal braking

57

ELECTRICAL SYSTEM

SERVICE

STEERING
CONTROLS

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

Devices involved
Keyswitch

ON

Emergency switch

ON

Steering centring sensor


Small steering wheel

58

status

Traction wheel autocentring sequence performed


rotation right/left

Symbol on diagram

SERVICE

ELECTRICAL SYSTEM

CONFIGURATION PARAMETERS

EPS

ACE2
TRACTION

Main menu
Config menu
Config menu
parameter change special adjustment hardware settings

Config menu
set options

Config menu
adjustment

curve speed 1
curve speed 2
-

speed limit
sensitivity
sensitive vs trc
speed lim vs trc

debug output

autoteaching

aux output #1
aux output #2

set steer 0-pos

For the adjustment values of each individual parameter, see the paragraph "standard
configuration of module parameters".
For a description of each individual parameter see "DESCRIPTION OF MODULE PARAMETERS".

The truck is equipped with a multi-turn steering system with a "stepper motor".
When switching on the key switch (S1), by means of the steering centring sensor (B7), the software autocentres the traction wheel.

59

ELECTRICAL SYSTEM

SERVICE

STEERING
When a steering angle of 5 is exceeded the maximum traction speed is reduced.
STEERING SYSTEM CONFIGURATION
The steering motor rotation speed is inversely proportional to the traction speed, as the speed increases
the steering unit reaches the steering angle at an increasing speed.
It is possible to set the steering sensitivity reduction by reducing the steering speed at a given traction
speed for slow or fast steers.
Setting the steering motor speed reduction as the traction speed increases for slow rotation of the steering
handwheel
EPS ACW / menu parameter change / sensitive vs trc
Setting the steering motor speed reduction to the maximum traction speed for fast rotation of the steering
handwheel
EPS ACW / menu parameter change / speed lim vs trc
It is possible to set the speed of rotation of the steering motor according to the speed of rotation of the
handwheel (fast rotation and sensitivity with slow rotation)
Setting decrease in steering motor speed while reaching the position controlled by the steering system
EPS ACW / main menu parameter change / speed limit
Setting steering sensitivity
EPS ACW / main menu parameter change / sensitivity

60

SERVICE

ELECTRICAL SYSTEM

FORK LIFTING/LOWERING
CONTROLS
Standard

Joystick

Standard Version: to raise the forks, pull up the fork lifting/lowering lever, and to lower the forks,
push down the fork lifting/lowering lever.
Joystick Version: to raise the forks, pull the joystick backward, and to lower the forks, push the
joystick forward.

Devices involved

status

Keyswitch

ON

Emergency switch

ON

Abbreviation

Lever backward/forward
Fork lifting/lowering request

Joystick backward/forward

61

SERVICE

ELECTRICAL SYSTEM
CONFIGURATION PARAMETERS

Main menu
parameter change

VMC

accel delay lift


decel delay lift
max lft sp limit
max low sp limit
i min evp1
evp1 opn delay 1
evp1 opn delay 2
evp1 cls delay 1
evp1 cls delay 2
evp2 open delay
evp2 close delay

Config menu
adjustment
mlm deadband
mlm deadband end
joy. deadband
joy. deadb. end
offset fork
lift limit blk m
lift limit blk cm
ctb rng lift lmt
ctb spd lift lmt
low soft rng sp
lower soft speed
lft range ffl ml
lft slow ffl ml
low range ffl ml
low slow ffl ml
lft blk1 hght m
lft blk1 hght cm
lft blk2 hght m
lft blk2 hght cm
height p lft ctb
height p lft ctb r
height p low ctb
height p low ctb r
offset pick
offset place

Config menu
set options
height indicator
slow spd ffl ml
lift limit stop
lower soft stop
1 lift block
2 lift block
interlock forks
interl. frk ovrd
battery check
enc. lock test
height selector

For the adjustment values of each individual parameter, see the paragraph "standard
configuration of module parameters".
For a description of each individual parameter see "DESCRIPTION OF MODULE PARAMETERS".

The maximum fork lifting and lowering speed can be set with the programmer.
Setting the maximum fork lifting speed.
VMC / main menu parameter change / max lft sp limit
Setting the maximum fork lowering speed
VMC / main menu parameter change / max low sp limit

62

SERVICE

ELECTRICAL SYSTEM

ACCELERATION / DECELERATION RAMPS


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

LIMIT STOP SLOWDOWN lifting / LOWERING


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

WITH FORK HEIGHT ENCODER (OPTIONAL)


In the phase of lifting and lowering, the forks start slowing down in the transition between the free lift limit
stop and main lifting.
With the programmer it is possible to set the speed of deceleration and the distance off the ground where
the forks start slowing down.
Setting lifting speed
VMC / config menu adjustment / lft slow ffl ml
Setting deceleration distance when lifting
VMC / config menu adjustment / lft range ffl ml
Setting lowering speed
VMC / config menu adjustment / low slow ffl ml
Setting deceleration distance when lowering
VMC / config menu adjustment / low range ffl ml
These parameters are only considered by the software if the VMC / config menu set options
/ height indicator and slow spd ffl ml parameters are set to PRESENT

63

ELECTRICAL SYSTEM

SERVICE

The forks start slowing down before reaching the maximum lifting height.
With the programmer it is possible to set the reduction in lifting speed and the distance where the forks
start slowing down.
Setting reduction in lifting speed
VMC / config menu adjustment / ctb spd lift lmt
Setting deceleration distance
VMC / config menu adjustment / ctb rng lift lmt
The maximum fork height is indicated in the VMC / config menu adjustment / lift limit blk
m and lift limit blk cm parameters according to the formula (lift limit blk m)x100 + (lift
limit blk cm).
The forks start slowing down before reaching the lowering limit stop.
With the programmer it is possible to set the speed of deceleration and the distance off the ground where
the forks start slowing down.
Setting deceleration speed
VMC / config menu adjustment / lower soft speed
Setting deceleration distance
VMC / config menu adjustment / low soft rng sp

FORK LIFTING/LOWERING BLOCKS (WITH FORK HEIGHT ENCODER)


There are two lifting blocks that can be set with the programmer.
Setting the maximum fork height of the first block
VMC / config menu adjustment / lft blk 1 hght m
VMC / config menu adjustment / lft blk 1 hght cm
Setting the maximum fork height of the second block
VMC / config menu adjustment / lft blk 2 hght m
VMC / config menu adjustment / lft blk 2 hght cm
The height is calculated according to the formula (lft blk 1 hght m)x100 + (lft blk 1 hght
cm).

64

SERVICE

ELECTRICAL SYSTEM

HYDRAULIC FUNCTIONS
CONTROLS
Standard

Joystick

Standard Version: to perform one of the hydraulic functions, pull/push the corresponding lever.
Joystick Version: to perform the carriage out function, move the joystick to the right, and to close
the carriage, move the joystick to the left. For the fork tilt function, move the mini-joystick up/down,
and for the fork side shift function, move the mini-joystick to the right/left.

Devices involved

status

Keyswitch

ON

Emergency switch

ON

Abbreviation

Lever backward/forward
Hydraulic request

Joystick right/left
Mini-joystick up/down - right/
left

65

SERVICE

ELECTRICAL SYSTEM
CONFIGURATION PARAMETERS

VMC

Main menu
parameter change
acc. delay reach
dec. delay reach
reach fw max spd
reach rv max spd
accel delay aux
decel delay aux
opt hyd max spd
evp3 open delay
evp3 close delay
evp4 open delay
evp4 close delay
evp5 open delay
evp5 close delay
evp6 open delay
evp6 close delay

Config menu
adjustment
mlm deadband
mlm deadband end
joy. deadband
joy. deadb. end
reach full fwd
reach full back
reach rng ctb ff
reach rng ctb fb
reach ctb speed
reach ctb speedm

Config menu
set options
autoc. sideshift
autoc. tilt
5th way hydraul.
extended multif.

For the adjustment values of each individual parameter, see the paragraph "standard
configuration of module parameters".
For a description of each individual parameter see "DESCRIPTION OF MODULE PARAMETERS".

RETRACTABLE CARRIAGE ACCELERATION / DECELERATION RAMPS


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

66

SERVICE

ELECTRICAL SYSTEM

CARRIAGE OUT / RETURN LIMIT STOP SLOWDOWN


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

AUXILIARY FUNCTIONS ACCELERATION / DECELERATION RAMPS


On operating the lever of an auxiliary function (fork tilting or side shifting), the forks begin to move with an
acceleration ramp that can be set via the programmer.
Setting the auxiliary function acceleration ramp
VMC / main menu parameter change / accel delay aux
On releasing the lever of an auxiliary function (fork tilting or side shifting), the forks begin to stop with a
deceleration ramp that can be set via the programmer.
Setting the lever release deceleration ramp
VMC / main menu parameter change / decel delay aux

FORK SELF-CENTRING
On pressing the button for the desired self-centring (side shifting, tilting), the forks begin to carry out the
desired self-centring procedure.
With the programmer it is possible to enable/disable these options.
Enabling fork side shift self-centring
VMC / config menu set options / autoc. sideshift
Enabling fork tilt self-centring
VMC / config menu set options / autoc. tilt

67

ELECTRICAL SYSTEM

SERVICE

CONFIGURATION PARAMETER ACCESS PROCEDURE


Thanks to the CAN BUS connection the module parameters can be configured by connecting the console
to the connector in the control panel and accessing the relative menu.
Before connecting the console to the module, turn the keyswitch to OFF.

Each module is identified by a number. Thanks to the CAN BUS connection it is possible to configure the
parameters of the various modules by connecting the console and then searching for the relevant module
via the SET MODEL menu.
Before using the console to select the number of the module to configure, make sure that
the model type option of the control to which it is connected is on 0.
MODULE

MODULE NUMBER

MODEL TYPE

VMC

ACE2 TRACTION

ACE2 PUMP

EPS ACW

MENU SEARCH PROCEDURE and parameter modification

EPSWSM 1Q
24V

50A

NA4.98
00000

Opening heading

Press the Roll h and Set h buttons simultaneously

*CONFIG. MENU*
SET MODEL

The SET MODEL menu heading appears. If another


menu is displayed, press the Roll h or Roll i
buttons until the SET MODEL menu appears.

Press Enter

68

SERVICE

ELECTRICAL SYSTEM

CONNECTED TO
6

The number corresponding to the module you are


connected to appears

Press the Set h or Set i buttons to edit the


selection of the module you wish to connect to

CONNECTED TO
2

The new selected module appears

Press the Roll h button to check the model


type

MODEL TYPE
1

The model type appears

Press the Set h or Set i buttons to scroll


through the model type to value 0.

MODEL TYPE
0

The model type of the selected module appears

Press the key "Out" to exit the selection.

ARE YOU SURE?


YES=ENTER
NO=OUT

The modification confirmation request appears

Press the Enter button to confirm. If one doesn't


want to confirm the choice press the "Out"key.

69

ELECTRICAL SYSTEM

*CONFIG. MENU*
SET MODEL

SERVICE

Having pressed the enter key the heading of the


SET MODEL menu appears.

Simultaneously press Roll i, Out and Set i

CONNECTED TO
ACE2 TRACTION

NA----

ACE2 TRACTION

NA-.--

1V

1A

0h

The display shows the connection to the selected


module for a moment

The selected module screen appears; here you can


configure the different parameters

Press the Roll h and Set h buttons simultaneously

*CONFIG. MENU*
SET MODEL

The SET MODEL menu heading appears.

Press the Roll h or Roll i button until the desired menu appears.

*CONFIG. MENU*
SET OPTION

The SET OPTION menu heading appears.

Press Enter

70

SERVICE

ELECTRICAL SYSTEM

HOUR COUNTER
RUNNING

The heading of the first parameter with its current


value appears. To scroll through the parameters
press Roll h or Roll i

Press the Set h or Set i buttons to modify the


value.

HOUR COUNTER
KEY ON

The new value appears.

Press the key "Out" to exit the selection.

ARE YOU SURE?


YES=ENTER NO=OUT

The modification confirmation request appears

Press the Enter button to confirm. If one doesn't


want to confirm the choice press the "Out"key.

*CONFIG. MENU*
SET OPTION

After having pressed the enter key the heading of


the SET OPTION menu reappears.

Press the "Out" key to return to the opening heading

EPSWSM 1Q
24V

50A

NA4.98
00000

Opening heading

71

ELECTRICAL SYSTEM

EPSWSM 1Q
24V

50A

NA4.98
00000

SERVICE

Opening heading

Press the "Enter"key to enter the main menu

*MAIN MENU*
PARAMETER CHANGE

The PARAMETER CHANGE menu heading appears. If another menu is displayed, press the
Roll h or Roll i buttons until the PARAMETER
CHANGE menu appears.

Press Enter

ACCELER. DELAY
LEVEL = 2.6

The heading of the first parameter with its current


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

ACCELER. DELAY
LEVEL = 3.0

The new value appears.

Press the key "Out" to exit the selection.

ARE YOU SURE?


YES=ENTER NO=OUT

The modification confirmation request appears

Press the Enter button to confirm. If one doesn't


want to confirm the choice press the "Out"key.

72

SERVICE

ELECTRICAL SYSTEM

STANDARD CONFIGURATION OF MODULE PARAMETERS


It is advisable to retain the factory settings seeing as they have been designed to achieve
the best compromise between performance and part wear and tear. It is however possible
to customise the performance to suit the customer's requirements, the characteristics of
the warehouse and the materials to be moved, but no parameters must be changed if this
jeopardises the safety of the truck.

VCM MODULE
VCM / main menu parameter change /
VCM / config menu special adjustment /
VCM / config menu hardware setting /
VCM / config menu set options /
VCM / config menu adjustment /
MAIN MENU PARAMETER CHANGE

MAIN MENU PARAMETER CHANGE

PARAMETER

level

PARAMETER

level

ACCEL DELAY LIFT

0.7

EVP5 OPEN DELAY

0.5

DECEL DELAY LIFT

0.5

EVP5 CLOSE DELAY

0.5

MAX LOW SP LIMIT

0.55 m/s

EVP6 OPEN DELAY

0.5

ACC. DELAY REACH

0.5

EVP6 CLOSE DELAY

0.5

DEC. DELAY REACH

0.5

REACH FW MAX SPD

35 Hz

REACH RV MAX SPD

22 Hz

ACCEL DELAY AUX

0.1

PARAMETER

level

DECEL DELAY AUX

0.1

PRESENT

OPT HYD MAX SPD

25 Hz

PREMIUM DISPLAY

I MIN EVP1

20%

I MIN BRAKING

25.1%

I MAX BRAKING

100%

EVP1 OPN DELAY 1

0.1

EVP1 OPN DELAY 2

0.6

EVP1 CLS DELAY 1

0.3

EVP1 CLS DELAY 2

0.6

EVP2 OPEN DELAY

0.8

EVP2 CLOSE DELAY

0.7

EVP3 OPEN DELAY

EVP3 CLOSE DELAY

EVP4 OPEN DELAY

EVP4 CLOSE DELAY

CONFIG MENU Special Adjustment

CONFIG MENU Hardware Setting


PARAMETER

level

SET CONFIGURAT

73

ELECTRICAL SYSTEM

CONFIG MENU Set Option

74

SERVICE

CONFIG MENU Adjustment

PARAMETER

level

PARAMETER

level

HOUR COUNTER

RUNNING

MLM DEADBAND

0%

BACKUP ALRM MODE

LEVEL = 0

MLM DEADBAND END

0%

HEIGHT INDICATOR

ABSENT

JOY. DEADBAND

19%

SLOW SPD FFL ML

ABSENT

JOY. DEADB. END

18%

LIFT LIMIT STOP

ABSENT

OFFSET FORK

350

LOWER SOFT STOP

ABSENT

LIFT LIMIT BLK M

AUTOC.SIDESHIFT

ABSENT

LFT LIMIT BLK CM

95

AUTOC.TILT

ABSENT

CTB RNG LIFT LMT

500

WEIGHT

ABSENT

CTB SPD LIFT LMT

0.20 m/s

LASER

ABSENT

LOW SOFT RNG SP

550

LOAD BRAKE

ABSENT

LOWER SOFT SPEED

0.08 m/s

5TH WAY HYDRAUL.

ABSENT

LFT RANGE FFL ML

500

PIN ACCESS CODE

ABSENT

LFT SLOW FFL ML

0.40 m/s

SEATBELT

ABSENT

LOW RANGE FFL ML

250

SEAT SWITCH

ABSENT

LOW SLOW FFL ML

0.32 m/s

SEAT SW.COMBI

ABSENT

CUTBACK SPEED

7.0 km/h

1 LIFT BLOCK

ABSENT

CUTBACK SPEED 2

4.0 km/h

2 LIFT BLOCK

ABSENT

LFT BLK1 HGHT M

INTERLOCK FORKS

ABSENT

LFT BLK1 HGHT CM

INTERL. FRK OVRD

ABSENT

LFT BLK2 HGHT M

BATTERY CHECK

LEVEL = 3

LFT BLK2 HGHT CM

50

TRANSFER HOURS

LEVEL = 0

REACH FULL FWD

3.7 V

EXTENDED MULTIF.

ABSENT

REACH FULL BACK

0.5 V

ENC. LOCK TEST

PRESENT

REACH RNG CTB FF

10.2%

HEIGHT SELECTOR

ABSENT

REACH RNG CTB FB

20%

PALLET SENSOR

ABSENT

REACH CTB SPEED

14.9%

NEV1

ABSENT

REACH CTB SPEEDM

50.2%

CHECK UP DONE

ABSENT

MAX WGT CELL

4.4 V

CHECK UP TYPE

NONE

MIN WGT CELL

0.0 V

PEDAL BRK RANGE

50.2%

ADJUST BATTERY

49.58 V

BAT. MIN ADJ.

LEVEL = 2

BAT. MAX ADJ.

LEVEL = 1

WATCH HOURS

WATCH MINUTES

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU Adjustment


PARAMETER

level

WATCH MINUTES

HEIGHT P LFT CTB

0.07

HEIGHT P LFT CTB R

350

HEIGHT P LOW CTB

0.08

HEIGHT P LOW CTB R

350

OFFSET PICK

100

OFFSET PLACE

100

ACE2 TRACTION MODULE


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

MAIN MENU PARAMETER CHANGE


PARAMETER

level

PARAMETER

level

ACCELER. DELAY

2.6

HOUR COUNTER

RUNNING

RELEASE BRAKING

2.2

M.C. FUNCTION

ON

TILLER BRAKING

2.2

AUX OUT FUNCT.1

PRESENT

INVERS. BRAKING

1.9

AUX OUT FUNCT.2

PRESENT

DECEL. BRAKING

PULSE DIR INPUT

OPTION #1

PEDAL BRAKING

0.3

SPEED LIMIT BRK.

2.8

CURVE SPEED 1

10.0 km/h

CURVE SPEED 2

6.5 km/h

MAX SPEED FORW

5.0 km/h

MAX SPEED BACK

5.0 km/h

MAX SPEED LIMIT

5.0 km/h

ACCEL DISPLAY

2.6

MAX SPEED DISP

5.0 km/h

REL BRK DISPLAY

2.2

INV BRK DISPLAY

1.9

75

ELECTRICAL SYSTEM

SERVICE

ACE2 PUMP MODULE


ACE2 PUMP / config menu set option /
config menu set option
PARAMETER

level

M.C. FUNCTION

ON

AUX OUT FUNCT.1

ABSENT

AUX OUT FUNCT.2

ABSENT

EPS ACW MODULE


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

config menu adjustments

PARAMETER

level

PARAMETER

level

SPEED LIMIT

LEVEL = 6

SET STEER 0-POS.

2500 mV

SENSITIVITY

LEVEL = 3

SENSITIVE VS TRC

40%

SPEED LIM VS TRC

50%

config menu special adjustment


PARAMETER

level

DEBUG OUTPUT

15

config menu hardware setting


PARAMETER

level

AUTOTEACHING

OFF

config menu set option

76

PARAMETER

level

AUX OUTPUT #1

ABSENT

AUX OUTPUT #2

ABSENT

SERVICE

ELECTRICAL SYSTEM

DESCRIPTION OF MODULE PARAMETERS


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

MAIN MENU PARAMETER CHANGE


PARAMETER

level = 0

level = 9

ACCEL DELAY LIFT


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

77

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PARAMETER CHANGE


PARAMETER

level = 0

level = 9

OPT HYD MAX SPD


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

78

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PARAMETER CHANGE


PARAMETER

level = 0

level = 9

level = 0

level = 9

level = 0

level = 9

EVP4 OPEN DELAY


Seconds. Determines the acceleration ramp on EVP4.
EVP4 CLOSE DELAY
Seconds. Determines the deceleration ramp on EVP4.
EVP5 OPEN DELAY
Seconds. Determines the acceleration ramp on EVP5.
EVP5 CLOSE DELAY
Seconds. Determines the deceleration ramp on EVP5.
EVP6 OPEN DELAY
Seconds. Determines the acceleration ramp on EVP6.
EVP6 CLOSE DELAY
Seconds. Determines the deceleration ramp on EVP6.

config menu special adjustment


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

config menu hardware setting


LEVEL 4
SET CONFIGURAT
1: with the NO CFG MASTER alarm it copies the EEPROM of the traction device to VCM
2: with the WRONG CONFIG alarm it copies from VCM to the traction device
3: with the WRONG CONFIG alarm it copies from the traction device to VCM

79

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU set options


PARAMETER

level
KEY ON: record of truck start up

HOUR COUNTER

RUNNING: record of an active traction request

Select the hourmeter mode


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

80

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU set options


LEVEL 4

level = 0

level = 9

SEATBELT
This parameter enables the seat belt presence switch
SEAT SWITCH
This parameter enables the seat presence switch
SEAT SW.COMBI
This parameter enables the sequence of the seat switch and then the seat belt switch
1 LIFT BLOCK
If set to PRESENT with HEIGHT INDICATOR it enables the first intermediate block
2 LIFT BLOCK
If set to PRESENT with HEIGHT INDICATOR and option 1 LIFT BLOCK it enables the second intermediate block
INTERLOCK FORKS
If set to PRESENT with HEIGHT INDICATOR it enables stopping fork lowering at a height of 600mm
INTERL. FRK OVRD
If set to PRESENT it is possible to by-pass the fork interlock with the override button
BATTERY CHECK
The battery charge level is checked:

0: no action
1: the BATTERY LOW alarm appears, the speed is reduced to 24% of the maximum speed, the maximum
current on the motor is reduced by 50%
2: the BATTERY LOW alarm appears, no other action
3: the BATTERY LOW alarm appears, the speed is reduced to 24% of the maximum speed, fork lifting
block is enabled
TRANSFER HOURS
LEVEL 1= if there is any discrepancy between the traction hour meter and VCM, an alarm is signalled and the value
on the traction is saved in the VCM
LEVEL 2= if there is any discrepancy between the traction hour meter and VCM, an alarm is signalled and the value
in the VCM is saved in the traction
EXTENDED MULTIF.
If set to PRESENT, three combined functions are permitted
ENC. LOCK TEST
Enables the diagnosis of encoder locked for encoder 1 and encoder 2. If the encoder is locked, an alarm is
generated and the pump stops

81

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU set options


LEVEL 4

level = 0

level = 9

NEV1
Enables output No.1 of the voltage that controls the battery block relay
ON =programmed maintenance
performed

CHECK UP DONE

OFF = programmed maintenance


not performed

Maintenance programme performed when enabled. When set to ON at the end of the maintenance it resets the
maintenance hourmeter and the CHECK UP NEEDED warning
0: disabled
1: alarm after 300 hours
2: like 1 plus speed reduction after
340 hours
3: like 2 plus truck block after 380
hours

CHECK UP TYPE

Enables/disables the programmed maintenance mode and warning . At the end of maintenance set the parameter
VMC / config menu set options / check up done ON
HEIGHT SELECTOR
If set to PRESENT with HEIGHT INDICATOR the operator can control up to 40 levels for picking up and positioning
the load
PALLET SENSOR
When set to PRESENT with the height pre-selector, pallet presence is checked

config menu adjustment


LEVEL 4

level = 0

level = 9

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

82

SERVICE

ELECTRICAL SYSTEM

config menu adjustment


LEVEL 4

level = 0

level = 9

LIFT LIMIT BLK M


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

83

SERVICE

ELECTRICAL SYSTEM

config menu adjustment


LEVEL 4

level = 0

level = 9

LFT BLK1 HGHT CM


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

84

SERVICE

ELECTRICAL SYSTEM

config menu adjustment


LEVEL 4

level = 0

level = 9

BAT. MAX ADJ.


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

85

ELECTRICAL SYSTEM

SERVICE

ACE2 TRACTION MODULE


ACE2 TRACTION / main menu parameter change /
ACE2 TRACTION / config menu set options /
MAIN MENU PARAMETER CHANGE
PARAMETER

level

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

86

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PARAMETER CHANGE


PARAMETER

level

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

CONFIG MENU SET OPTIONS


PARAMETER

level
KEY ON: record of truck start up

HOUR COUNTER

RUNNING: record of an active request

Select the hourmeter mode


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

87

ELECTRICAL SYSTEM

SERVICE

ACE2 PUMP MODULE


ACE2 PUMP / config menu set options /
CONFIG MENU set options
PARAMETER

level

M.C. FUNCTION
See M.C.FUNCTION traction
AUX OUT FUNCT.1
See AUX. OUT FUNCT.1 traction
AUX OUT FUNCT.2
See AUX. OUT FUNCT.2 traction

EPS ACW MODULE


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

MAIN MENU parameter change


PARAMETER

level

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

88

SERVICE

ELECTRICAL SYSTEM

config menu special adjustment


PARAMETER

level

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


config menu hardware setting
PARAMETER

level

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

config menu set option


PARAMETER

level

AUX OUTPUT #1
Enables/disables the auxiliary function on pin 10

AUX OUTPUT #2
Enables/disables the auxiliary function on pin 14

config menu adjustments


PARAMETER

level

SET STEER 0-POS.


Determines the position of the steer wheel after self-centring.

89

ELECTRICAL SYSTEM

SERVICE

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

PC interface cable kit


code 580039670

90

pc tool connector

SERVICE

ELECTRICAL SYSTEM

INVERTER ACE2 MODULE


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

- BATT

+ BATT

91

ELECTRICAL SYSTEM

SERVICE

EPS ACW MODULE


The module is integrated in the steering motor.
Technical specifications:
Digital control by two microprocessors; both microprocessors connected via CAN Bus
Encoder interface
Interface for stepper motor
Analog input for thermal sensor
Operating frequency:.....................................................................8kHz with PWM aligned in the centre
Maximum inverter temperature:....................................................80C
Protection:.....................................................................................IP65

+ BATT

- BATT

92

SERVICE

ELECTRICAL SYSTEM

VCM MODULE
Functions:
BDI
Hour meter
Alarms
Performance
Height gauge
Technical specifications (standard version)
Voltage: ........................................................................................36-48V
Digital inputs (n):..........................................................................7
Analog inputs (n):.........................................................................2
Outputs supplied at 12V (no.)........................................................1
Outputs supplied at 5V (no.)..........................................................1
Protection......................................................................................IP65
Outside working temperature limits...............................................-40C to 50C
Technical specifications (premium version):
Voltage: ........................................................................................36-48V
Digital inputs (n):..........................................................................11
Analog inputs (n):.........................................................................10
Outputs supplied at 12V (no.)........................................................1
Outputs supplied at 5V (no.)..........................................................2
Protection......................................................................................IP65
Outside working temperature limits...............................................-40C to 50C

93

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF MODULES: INSTRUCTIONS


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

T handle hex key


5 mm

resistance 33 to
100 50W insulated

large flat blade


screwdriver

22 mm socket
wrench with
ratchet
13 mm

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the carriage to a safe place, away from areas of
transit of other vehicles and all pedestrians. Turn the
keyswitch to OFF and disconnect the battery.

Phase 1
5 mm T-handle hex key
Fig. 2
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet, remove the electronic controls
cover and open the bonnet (fig.1).
Phase 2
RESISTOR
Using the screwdriver, remove the caps protecting the contacts.
Connect a resistor that can have a value of between 33 and 100 Ohm 50W between the positive (B+) and
negative (B-) of the module (fig.2).
Wait approximately 10 seconds for the internal capacitors to discharge and then disconnect the resistor.
To avoid short circuits, it is important that the resistor is isolated.

If it is not possible to use an external resistor to run down the capacitors, it will be necessary to wait at least
90 seconds before disconnecting the power cables.
94

SERVICE

ELECTRICAL SYSTEM

Phase 3
socket wrench with ratchet size 13 mm - MEDIUM FLAT
BLADE SCREWDRIVER
Using the screwdriver, remove the caps protecting the contacts.
Using the socket wrench and ratchet unscrew and remove the screws
fastening the electric cables, fuse, copper connecting bars and power
cables. Unscrew and remove the nut fastening the fuse too.
Mark the electric cables and the copper bars for reassembly and disconnect them. Disconnect the connector.

B
A
Fig. 3

Phase 4
5 mm FLEXIBLE T-HANDLE HEX KEY
Unscrew the four screws fastening the module to the panel (ref.A fig.3).
Extract the module and remove it.
Recover the fuse (ref.B fig.3) and proceed with the replacement.

CONFIGURATION
ADAPTER - PROGRAMMER OR CONSOLE
Connect the adaptor to the PC TOOL" connector.
Connect the USB connector of the interface cable to the USB port on the PC.
Connect the battery and switch on the truck (starter key to ON). Start the PC Tool programme.
Create a new configuration and copy the factory configuration or a customised configuration.

SETTING THE BATTERY VOLTAGE


Carry out the procedure for setting the battery voltage. See SETTING THE BATTERY VOLTAGE section
INSTALLATION AND SETTINGS.

ACQUISITION OF OPERATING HOURS acE2 traction module


The hours of operation of the truck are memorised on the VCM module and on the "ACE2 TRACTION"
module.
On ignition the system assesses the hours recorded on both modules. If the difference is greater than 20
hours the hm mismatch alarm appears and all the truck functions are disabled. After 2 minutes the higher
value is saved on both modules and all the truck functions are restored.

95

SERVICE

ELECTRICAL SYSTEM
REPLACEMENT OF THE EPS ACW MODULE
Equipment and tools

Fig. 1

T handle hex key medium cross5-6 mm


head screwdriver

resistance 33 to open-ended spanner


100 50W insu8 mm
lated

Procedure

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the carriage to a safe place, away from areas of
transit of other vehicles and all pedestrians. Turn the
keyswitch to OFF and disconnect the battery.

Phase 1
T-HANDLE HEX KEY 5 mm
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.A fig.1).
Completely open the cover (fig.2).
Phase 2
RESISTOR
Using the screwdriver, remove the caps protecting the contacts.
Connect a resistor that can have a value of between 33 and 100 Ohm
50W between the positive (B+) and negative (B-) of the module (fig.3).
Wait approximately 10 seconds for the internal capacitors to discharge
and then disconnect the resistor.
To avoid short circuits, it is important that the resistor is
isolated.
If it is not possible to use an external resistor to run down the capacitors,
it will be necessary to wait at least 90 seconds before disconnecting the
power cables.

96

Fig. 2
Fig. 3

SERVICE

ELECTRICAL SYSTEM

Phase 3
8 mm open ended spanner
Using the open ended spanner, unscrew and remove the screws fastening the electrical cables and fuse. Disconnect the connector.

Fig. 4

Phase 4
MEDIUM CROSSHEAD SCREWDRIVER - 6 mm T-HANDLE HEX
KEY
With the screwdriver, unscrew and remove the screws fastening the upper
cover of the electrical box (ref.B fig.4). Remove the cover.
Unscrew and remove the three fastening screws of the motor phase
terminals (ref.C fig.5).
Unscrew and remove the fastening screws of the EPS module (ref.D
fig.6). Remove the module and proceed with replacement.

Fig. 5

C
CONFIGURATION
ADAPTER - PROGRAMMER OR CONSOLE
Connect the adaptor to the PC TOOL" connector.
Connect the USB connector of the interface cable to the USB port on
the PC.
Connect the battery and switch on the truck (starter key to ON). Start the
PC Tool programme.
Create a new configuration and copy the factory configuration or a customised configuration.

Fig. 6

97

SERVICE

ELECTRICAL SYSTEM
VCM MODULE REPLACEMENT
Equipment and tools

Fig. 1

T handle hex key medium cross4-5 mm


head screwdriver

Procedure

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the carriage to a safe place, away from areas of
transit of other vehicles and all pedestrians. Turn the
keyswitch to OFF and disconnect the battery.

Phase 1
5 mm T-HANDLE HEX KEY - MEDIUM CROSSHEAD SCREWDRIVER
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.A fig.1).
Completely open the cover (fig.2).
Using a crosshead screwdriver, unscrew the panel fixing screw to access
the VCM control (ref.B fig.3).

Fig. 2

Phase 2
T-HANDLE HEX KEY 4 mm
Disconnect the module connector.
Using the T-handle hex key, unscrew the screws securing the module
to the carriage (ref.C fig.4). Remove the module and proceed with replacement.
CONFIGURATION
ADAPTER - PROGRAMMER OR CONSOLE
Connect the adaptor to the PC TOOL" connector.
Connect the USB connector of the interface cable to the USB port on
the PC.
Connect the battery and switch on the truck (starter key to ON). Start the
PC Tool programme.
Create a new configuration and copy the factory configuration or a customised configuration.
98

Fig. 3

SERVICE

ELECTRICAL SYSTEM

SETTING THE BATTERY VOLTAGE


Carry out the procedure for setting the battery voltage. See SETTING
THE BATTERY VOLTAGE section INSTALLATION AND SETTINGS.

ACQUISITION OF VCM module OPERATING HOURS

Fig. 4

The hours of operation of the truck are memorised on the VCM module
and on the "ACE2 TRACTION" module.
On ignition the system assesses the hours recorded on both modules. If
the difference is greater than 20 hours the hm mismatch alarm appears
and all the truck functions are disabled. After 2 minutes the higher value
is saved on both modules and all the truck functions are restored.

99

SERVICE

ELECTRICAL SYSTEM

REMOVAL OF ELECTRICAL COMPONENTS


REPLACEMENT OF ENCODER
Equipment and tools

ladder

safety harness

open-ended
spanner
7-8 mm
2 x 10 mm

socket wrench
7 mm

ratchet

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

Fig. 1

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Remove the hydraulic control valve cover to facilitate the disassembly
procedure (fig.2).

Turn the keyswitch to OFF and disconnect the battery.

REMOVING THE FREE LIFT ENCODER


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

100

Fig. 2

SERVICE

ELECTRICAL SYSTEM

REMOVING THE MAIN LIFT ENCODER


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

Fig. 3

Fig. 4

A
B
Fig. 5

Fig. 6

Fig. 7

Fig. 8

101

ELECTRICAL SYSTEM

SERVICE

ENCODER RESET SENSOR REPLACEMENT


Equipment and tools

open ended
spanner
2 x 28 mm

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).

Turn the keyswitch to OFF and disconnect the battery.

Phase 2
2 x 28 mm OPEN ENDED SPANNERS
Loosen the ring nuts fastening the sensor to the support plate (fig.3).
Disconnect the connector, unscrew the sensor and proceed with replacement.

Fig. 2

Fig. 3

102

SERVICE

ELECTRICAL SYSTEM

LOAD CELL REPLACEMENT


Equipment and tools
Fig. 1

wooden beam

taper end pliers

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

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Phase 2
WOODEN BLOCK
Raise the forks just enough to be able to pass the wooden block underneath.
Place the wooden block under the forks (fig.2). Lower the forks to rest
on the block and continue until the end stroke of the cylinder.

Fig. 2

Position the key switch to OFF and disconnect the battery.


Phase 3
TAPE END PLIERS
Using the taper end pliers remove the cotter pins and the hinge pins securing the load cell to the chain and to the fork mast (ref.A fig.3). Disconnect
the connector, remove the load cell and proceed with replacement.

Fig. 3

ASSEMBLY
Do not reuse the chain anchoring safety pins, use new
cotter pins, ensuring they are the correct size.
103

SERVICE

ELECTRICAL SYSTEM
REPLACEMENT OF THE HORN
Equipment and tools

T handle hex key


5 mm

open ended
spanner
13 mm

Allen key
6 mm

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

Fig. 1

Fig. 2

A
Phase 1
5 mm T-handle hex key
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet,
remove the electronic controls cover and open the bonnet (fig.1).

Phase 2
FIXED 13 mm SPANNER - 6 mm ALLEN KEY
Using the open ended spanner, counterhold the nut (ref.A fig.2), and
with the bent Allen key unscrew and remove the screw securing the horn
(ref.B fig.2).
Disconnect the connectors, remove the horn and proceed with replacement.

INSTALLATION
Before connecting them again, make sure the Faston connectors are suitably tight. If not, tighten the connectors
with Faston pliers.

104

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE CONTACTORS


Equipment and tools

T handle hex key


4-5 mm

open ended
spanner
13 mm

medium flat blade


screwdriver

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the carriage to a safe place, away from areas of
transit of other vehicles and all pedestrians. Turn the
keyswitch to OFF and disconnect the battery.

Phase 1
5 mm T-handle hex key
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet,
remove the electronic controls cover and open the bonnet (fig.1).

Phase 2
MEDIUM FLAT BLADE SCREWDRIVER - 13 mm OPEN ENDED SPANNER
Using the screwdriver, remove the caps protecting the contacts.
Using the open ended spanner unscrew and remove the nuts fastening
the electrical cables and copper bar to the contactor (ref.A fig.2).
Disconnect the cables and connectors, noting down their position to make
assembly easier.

A
Fig. 2

Fig. 3
Phase 3
4 mm T-handle hex key
Using the T handle hex key, unscrew and remove the screws securing
the contactor (ref.B fig.3).
Remove the contactor and proceed with replacement.

105

SERVICE

ELECTRICAL SYSTEM
FUSE REPLACEMENT





2A fuse key relay (F3)


10A fuse emergency push-button and contactors (F1)
10A fuse contactors (F2)
power fuse traction controller (F4)
power fuse pump controller (F5)
power fuse steering controller (F6)

Equipment and tools

medium/large
medium flat blade
T handle hex key
crosshead screwscrewdrivers
5 mm
driver

22 mm socket
wrench with
ratchet
13 mm

open-ended
spanner
8 mm

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

Fig. 1

A
A
FUSES F1,F2,F3
Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.A fig.1).
Remove the panel.

Phase 2
Remove the desired fuse from the control board (fig.2) and proceed with
replacement.

106

Fig. 2

SERVICE

ELECTRICAL SYSTEM

POWER FUSE F6

Fig. 3

Phase 1
T-HANDLE HEX KEY 5 mm
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.B fig.3).
Completely open the cover (fig.4).
Phase 2
8 mm open ended spanner
Using the open ended spanner, unscrew and remove the nuts fastening
the fuse (ref.C fig.5). Remove the fuse and proceed with replacement.

POWER FUSES F4,F5


Phase 1
5 mm T-handle hex key
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet,
remove the electronic controls cover and open the bonnet (fig.4).

Fig. 4
Fig. 5

Phase 2
socket wrench with ratchet size 13 mm - MEDIUM FLAT
BLADE SCREWDRIVER
Using the screwdriver, remove the caps protecting the contacts.
Using the socket wrench and the ratchet, unscrew and remove the
screws securing the fuse (ref.D fig.6). Remove the fuse and proceed
with replacement.

Fig. 6
107

SERVICE

ELECTRICAL SYSTEM
REPLACEMENT OF THE MOTOR COMPARTMENT COOLING FAN
Equipment and tools

Fig. 1

medium/large
T handle hex key
T handle hex key
crosshead screw4 mm
5 mm
driver

22 mm socket
wrench with
ratchet
13 mm

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

MOTOR COMPARTMENT FAN


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

Fig. 3

Phase 2
4 mm FLEXIBLE T-HANDLE HEX KEY
Using the flexible T-handle hex key, unscrew and remove the screws
securing the fan bracket (ref.B fig.4).
Remove the bracket together with the fan, disconnect the connector and
proceed with replacement.
Fig. 4

108

SERVICE

ELECTRICAL SYSTEM

ADDITIONAL TRACTION MOTOR FAN

Fig. 5

Phase 2
3 mm FLEXIBLE T-HANDLE HEX KEY
Using the flexible T-handle hex key, unscrew and remove the screws
securing the fan bracket (ref.C fig.6).
Remove the bracket together with the fan, disconnect the connector and
proceed with replacement.

Fig. 6

109

SERVICE

ELECTRICAL SYSTEM
REPLACEMENT OF ARMREST AND MAIN PANEL CONTROLS:






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

Equipment and tools


Fig. 1

hexagonal "T"
section spanner
1.5-3 mm

hex bit socket


10-13 mm

medium/large
small/medium flat
crosshead screwblade screwdriver
driver

ratchet

open-ended
spanner
7-10-13-14 mm

Torx key

C spanner

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

KEY SWITCH (version with premium display)


Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.A fig.1).
Remove the panel.

110

Fig. 2

Fig. 3

SERVICE

ELECTRICAL SYSTEM

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

Fig. 4

INSTALLATION
Before connecting them again, make sure the Faston connectors are suitably tight. If not, tighten the connectors
with Faston pliers.

Fig. 5

DASHBOARD PUSH-BUTTONS

D
Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.A fig.1).
Remove the panel.

Fig. 6

Phase 2
LARGE CROSSHEAD SCREWDRIVER - 10 mm open ended spanner
Use the screwdriver and the open ended spanner to unscrew and remove
the screws fastening the dashboard (ref.C-D fig.4-5).
Turn over dashboard.
Phase 3
10 mm open ended spanner
Use the screwdriver and the open ended spanner to unscrew and remove
the screws fastening the dashboard (ref.C-D fig.4-5).

Fig. 7
Phase 4
14 mm open ended spanner
For the round buttons, use the open ended spanner to loosen the ring
nut locking the button (ref.E fig.6). Unscrew and remove the button,
disconnect the connectors and proceed with replacement.
For the rectangular buttons, press the tabs at the sides of the buttons
(fig.8). Extract the button, disconnect the connectors and proceed with
replacement.

Fig. 8

111

SERVICE

ELECTRICAL SYSTEM
ARMREST BUTTONS

Fig. 9

Phase 1
13 mm open ended spanner
Using the controls in the cab, move the retractable carriage fully against
the battery.
Pull up the lever in front of the throttle pedal board next to the bonnet so
as to free the battery.
Using the controls in the cab, make the retractable carriage come fully
out together with the battery.

Turn the keyswitch to OFF and disconnect the battery.


Fig. 10
Using the open ended spanner unscrew and remove the nuts fastening
the armrest from the battery compartment (ref.F fig.10).
Remove the armrest and turn it over.
Phase 2
MEDIUM PHILIPS SCREWDRIVER
Using the screwdriver, unscrew and remove the screws fastening the
lower cover of the armrest (ref.G fig.11).
Remove the cover.
Phase 3
MEDIUM PHILIPS SCREWDRIVER
Use the screwdriver to unscrew and remove the fastening screws of the
electronic board (ref.H fig.11).
Remove the cover.
Phase 4
14 mm open ended spanner
For the round buttons of the auxiliary functions, use the open ended
spanner to loosen the ring nut locking the button (ref.E fig.6). Unscrew
and remove the button, disconnect the connectors and proceed with
replacement.
For the horn and direction of travel buttons, press the tabs at the sides
of the buttons (fig.12). Extract the button, disconnect the connectors and
proceed with replacement.

112

Fig. 11

Fig. 12

SERVICE

ELECTRICAL SYSTEM

MAIN EMERGENCY SWITCH

Fig. 13

Phase 1
13 mm open ended spanner
Using the controls in the cab, move the retractable carriage fully against
the battery.
Pull up the lever in front of the throttle pedal board next to the bonnet so
as to free the battery.
Using the controls in the cab, make the retractable carriage come fully
out together with the battery.
Turn the keyswitch to OFF and disconnect the battery.

Fig. 14

Using the open ended spanner unscrew and remove the nuts fastening
the armrest from the battery compartment (ref.I fig.14).
Remove the armrest and turn it over.

Phase 2
MEDIUM PHILIPS SCREWDRIVER
Using the screwdriver, unscrew and remove the screws fastening the
lower cover of the armrest (ref.J fig.15).
Remove the cover.

Phase 3
C SPANNER FOR SELF-LOCKING RING NUTS - SMALL FLAT BLADE
SCREWDRIVER
Using the C spanner, unscrew and remove the self-locking ring nut of
the emergency button (ref.K fig.16). Using the small screwdriver, free
the tabs of the push-button (fig.16), remove the button, disconnect the
connectors and proceed with replacement.

Fig. 15

Fig. 16

113

SERVICE

ELECTRICAL SYSTEM
STEERING HANDWHEEL STEPPER MOTOR

Fig. 17

Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.L fig.17).
Remove the panel.
Phase 2
small flat blade screwdriver - 13 mm hex socket wrench
- ratchet
Using the flat blade screwdriver, remove the cover located over the
handwheel (ref.M fig.18).
Using the socket wrench and the ratchet, unscrew and remove the screw
securing the handwheel to the assembly (ref.N fig.18). Remove the
handwheel.

l
l

Fig. 18

M
N

Phase 3
MEDIUM PHILIPS SCREWDRIVER
Use the screwdriver to unscrew and remove the screws of the covers of
the steering handwheel assembly (fig.19).
Remove the two covers.

If there is any difficulty in unscrewing the upper screws


under the control panel, remove the dashboard.

Phase 4
7 mm open ended spanner - 1.5-3 mm T-HANDLE HEX KEY
Using the 1.5 mm T-handle hex key unscrew and remove the grub screw
(ref.O fig.20).
Using the open ended spanner hold the nut firm (ref.P fig.20), with the
T-handle hex key unscrew and remove the screw fastening the stepper
motor to the bearing block (ref.Q fig.20).
Remove the motor and proceed with replacement.

Fig. 19
Fig. 20

114

SERVICE

ELECTRICAL SYSTEM

JOYSTICK

Phase 1
SMALL FLAT BLADE SCREWDRIVER - 10 mm HEX SOCKET
WRENCH - ratchet
Using the small screwdriver, remove the cover under the joystick (ref.R
fig.21).
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the joystick to the armrest (ref.S fig.21). Remove the joystick
and proceed with replacement or disassembly.

MINI-LEVERS

Fig. 21

Fig. 22

Phase 1
TORX KEY
Using the Torx key, unscrew and remove the screws fastening the minilever (ref.T fig.22).
Remove the mini-lever and proceed with replacement.

STANDARD DISPLAY

Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER - medium flat
blade screwdriver
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.L fig.17).
Remove the panel.
Disconnect the connector from the display. Using the flat blade screwdriver, prise on the lower tab of the display (fig.23), put outwards and
remove.

Fig. 23

115

SERVICE

ELECTRICAL SYSTEM
PREMIUM DISPLAY

Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER - 10 mm HEX SOCKET
WRENCH - RATCHET
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.L fig.17).
Remove the panel.
Disconnect the connector from the display. Using the socket wrench and
ratchet, unscrew and remove the lock nut on the rear of the display (ref.U
Fig.24). Remove the display outwards.

116

Fig. 24

SERVICE

ELECTRICAL SYSTEM

SIDE SHIFT POSITION SENSOR REPLACEMENT


Equipment and tools

open ended
spanner
2 x 28 mm

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

Fig.1
Phase 1
2 x 28 mm OPEN ENDED SPANNERS
Unscrew the ring nuts fastening the sensor to the support plate (ref.A
fig.2).
Disconnect the connector, unscrew the sensor and proceed with replacement.

Fig.2

117

SERVICE

ELECTRICAL SYSTEM
PALLET PRESENCE SENSOR REPLACEMENT
Equipment and tools

Fig.1

external circlip
pliers

Allen key
2-3 mm

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

A
A
Phase 1
SMALL EXTERNAL CIRCLIP PLIERS
Use the pliers to remove the two circlips securing the pin of the plate with
the cam (ref.A fig.2). Remove the pin and the plate.

Phase 2
2-3 mm ALLEN WRENCH
Using the 2 mm Allen wrench, unscrew the grub screw securing the sensor (ref.B fig.3). Using the 3 mm Allen wrench, unscrew and remove the
screws securing the sensor bracket (ref.C fig.3).
Unscrew the sensor, disconnect the connector and extract it inside the
liner. Proceed with replacement

118

Fig.2

C
Fig.3

SERVICE

ELECTRICAL SYSTEM

TILT POSITION SENSOR REPLACEMENT


Equipment and tools
Fig.1

open-ended
spanner
8 mm
2 x 28 mm

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

Phase 1
8 mm OPEN ENDED SPANNER
Using the open ended spanner loosen the screws securing the bracket
of the sensor (ref.A fig.2).
Disconnect the connector, remove the bracket together with the sensor

Fig.2

Phase 2
2 x 28 mm OPEN ENDED SPANNERS
Loosen the ring nuts fastening the sensor to the support plate (ref.B
fig.3).
Unscrew the old sensor and fit the new one.

Fig.3

119

SERVICE

ELECTRICAL SYSTEM
90 WHEEL SENSOR AND STEERED WHEEL SENSOR REPLACEMENT
Equipment and tools

Fig. 1

T handle hex key


5 mm

open-ended
spanner
16 mm

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

Phase 1
5 mm T-handle hex key
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover
of the electronic controls. Unscrew and remove the screw locking the
bonnet (ref.A fig.1), remove the electronic controls cover and open the
bonnet (fig.2).

Fig. 2
Fig. 3

Phase 2
FIXED GAUGE 16 mm SPANNER
With the open ended spanner, unscrew the ring nut securing the sensor
to the supporting plate (ref.B fig.4).
Disconnect the connector, unscrew the sensor from the supporting plate
and proceed with replacement.

Fig. 4

120

SERVICE

ELECTRICAL SYSTEM

BATTERY OUT SENSOR REPLACEMENT


Equipment and tools

T handle hex key


5 mm

open-ended
spanner
16 mm

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

Fig. 1
Fig. 2

Phase 1
5 mm T-handle hex key
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet,
remove the electronic controls cover and open the bonnet (fig.2).

Fig. 3

Phase 2
10mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the nut securing
the sensor bracket (ref.A fig.3).
Disconnect the connector, remove the bracket together with the sensor

Phase 3
2 x 28 mm OPEN ENDED SPANNERS
Loosen the ring nuts fastening the sensor to the support plate (ref.B
fig.4).
Unscrew the old sensor and fit the new one.

Fig. 4

121

SERVICE

ELECTRICAL SYSTEM
OPERATOR PRESENCE PEDAL REPLACEMENT
Equipment and tools

T handle hex key


5 mm

open ended
spanner
7 mm

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

Phase 1
5 mm T-handle hex key
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet,
remove the electronic controls cover and open the bonnet (fig.2).

Phase 2
7 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws fastening the operator presence pedal (ref.A fig.2).
Remove the pedal and proceed with replacement.

122

Fig. 1
Fig. 2

SERVICE

ELECTRICAL SYSTEM

ACCELERATOR AND BRAKE PEDALS REPLACEMENT


Equipment and tools

T handle hex key


5 mm

open ended
spanner
13 mm

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

Fig. 1
Fig. 2

Phase 1
5 mm T-handle hex key
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet,
remove the electronic controls cover and open the bonnet (fig.2).

Phase 2
13 mm OPEN ENDED SPANNER - 5 mm T-HANDLE HEX KEY
Using the open ended spanner, counterhold the nuts (ref.A fig.2), and
with the T-handle hex key unscrew and remove the screws securing the
pedal (ref.B fig.2).
Remove the pedal and proceed with replacement.

123

ELECTRICAL SYSTEM

124

SERVICE

SERVICE

HYDRAULIC SYSTEM

Hydraulic system
HYDRAULIC FUNCTIONS 3
HYDRAULIC DIAGRAMS 4
symbols 4
MAIN HYDRAULIC DIAGRAM 5
HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS 8
SOLENOID VALVE OPERATION CHART 8
HYDRAULIC FORK LIFTING DIAGRAM 9
HYDRAULIC FORK LOWERING DIAGRAM 10
HYDRAULIC RETRACTABLE CARRIAGE OUT DIAGRAM 11
HYDRAULIC RETRACTABLE CARRIAGE IN DIAGRAM 12
HYDRAULIC FORK UPWARD TILTING DIAGRAM 13
HYDRAULIC FORK DOWNWARD TILTING DIAGRAM 14
HYDRAULIC FORK LEFT SIDE SHIFT DIAGRAM 15
HYDRAULIC FORK RIGHT SIDE SHIFT DIAGRAM 16
HYDRAULIC EMERGENCY LOWERING DIAGRAM 17
HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE 18
HYDRAULIC COMPONENTS  20
HYDRAULIC COMPONENT IDENTIFICATION 20
DISTRIBUTOR COMPONENT IDENTIFICATION 22
DISTRIBUTOR DISMANTLING 23
gasket replacement 23
REMOVAL OF THE PRESSURE RELIEF VALVE 25
CALIBRATION OF THE PRESSURE RELIEF VALVE  26
CARTRIDGE SOLENOID VALVES 27
IDENTIFICATION of SOLENOID VALVE CARTRIDGE COMPONENTS 27
SOLENOID VALVE DISMANTLING 28
CYLINDERS 29
SINGLE ACTING CYLINDER 29
IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS 30
IDENTIFICATION OF THE SIDE LIFT CYLINDER COMPONENTS 31
IDENTIFICATION OF THE RETRACTABLE CARRIAGE CYLINDER COMPONENTS 32
IDENTIFICATION OF THE FORK TILT CYLINDER COMPONENTS 33
IDENTIFICATION OF THE FORK SIDE SHIFT CYLINDER COMPONENTS 34
CENTRAL LIFT CYLINDER DISMANTLING 35
DISMANTLING OF LATERAL LIFT CYLINDER  37
LIFTING CYLINDER: AIR BLEEDING 39
REMOVAL OF THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER 40

HYDRAULIC SYSTEM

SERVICE

REMOVAL OF THE FORK TILT CYLINDER 42


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

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC FUNCTIONS







Fork Lifting
Fork Lowering
Fork right side shift
Fork left side shift
Fork tilt up
Fork tilt down
Retractable carriage out
Retractable carriage in

HYDRAULIC SYSTEM

SERVICE

HYDRAULIC DIAGRAMS
symbols

ELECTRIC MOTOR

LINE CONNECTION

RESERVOIR
PUMP
SINGLE ACTING
CYLINDER

DUAL ACTION PUMP

DOUBLE ACTING
CYLINDER

HYDRAULIC MOTOR
PRESSURE RELIEF
VALVE

FILTER
DIVERTER VALVE
FILTER CLOGGING
INDICATOR
TWO-POSITION VALVE
MANUAL COCK

ONE-WAY VALVE

CHECK VALVE

THREE-POSITION
VALVE

SERVICE

HYDRAULIC SYSTEM

MAIN HYDRAULIC DIAGRAM

HYDRAULIC SYSTEM
BACK: VERSION WITH 5TH WAY

SERVICE

SERVICE

HYDRAULIC SYSTEM

BACK: VERSION WITHOUT 5TH WAY

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS FOR VARIOUS


FUNCTIONS









Fork Lifting
Fork Lowering
Fork tilt up
Fork tilt down
Fork right side shift
Fork left side shift
Retractable carriage out
Retractable carriage in
Emergency mast lowering
The hydraulic control valve in the motor compartment
is equipped with a screw to open the emergency lowering valve. Unscrew the valve gradually by no more
than two turns so that the mast is lowered slowly. Once
the forks have been lowered, close the valve.
Oil drain through the pressure relief valve

Emergency
lowering valve

relief valve

SOLENOID VALVE OPERATION CHART

Function
Fork Lifting

Pump

Q1

Q2

Q3

Q4

Q5

Q6

+
+

Fork Lowering
Retractable carriage out

Retractable carriage in

Fork right side shift

Fork left side shift

Fork tilt up

Fork tilt down

Oil drain through the pressure relief


valve

= pump in operation
P
+
= solenoid valve coil energised

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC FORK LIFTING DIAGRAM

Oil delivery
Oil return

HYDRAULIC SYSTEM

SERVICE

HYDRAULIC FORK LOWERING DIAGRAM

Oil delivery
Oil return

10

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC RETRACTABLE CARRIAGE OUT DIAGRAM

Oil delivery
Oil return

11

HYDRAULIC SYSTEM
HYDRAULIC RETRACTABLE CARRIAGE IN DIAGRAM

Oil delivery
Oil return

12

SERVICE

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC FORK UPWARD TILTING DIAGRAM


Oil delivery
Oil return

13

HYDRAULIC SYSTEM

SERVICE

HYDRAULIC FORK DOWNWARD TILTING DIAGRAM


Oil delivery
Oil return

14

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC FORK LEFT SIDE SHIFT DIAGRAM


Oil delivery
Oil return

15

HYDRAULIC SYSTEM

SERVICE

HYDRAULIC FORK RIGHT SIDE SHIFT DIAGRAM


Oil delivery
Oil return

16

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC EMERGENCY LOWERING DIAGRAM

17

HYDRAULIC SYSTEM

SERVICE

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


18

Pressure control not suitable for the truck load capacity.


Attempt to lift a load in excess of the truck's load capacity
Faulty or stuck valve

SERVICE

HYDRAULIC SYSTEM

19

HYDRAULIC SYSTEM

HYDRAULIC COMPONENTS
HYDRAULIC COMPONENT IDENTIFICATION

Ref.

20

Description

Distributor

Lift pump

Tank

Filter

Retractable carriage cylinder

Fork lift cylinder

Mast lift cylinders

Fork side shift cylinder

Fork tilt cylinders

SERVICE

SERVICE

HYDRAULIC SYSTEM

6
8
4

21

SERVICE

HYDRAULIC SYSTEM
DISTRIBUTOR COMPONENT IDENTIFICATION

10

4
5

Ref.

22

Description

Solenoid valve

Solenoid valve

Solenoid valve

Solenoid valve

Solenoid valve

Solenoid valve

Fork pressure relief valve

Side shift/tilt pressure relief valve

Retractable carriage pressure relief valve

10

Emergency lowering valve

SERVICE

HYDRAULIC SYSTEM

DISTRIBUTOR DISMANTLING

gasket replacement

The gaskets must be replaced when an oil leak is identified or when the truck is used in a cold store.
Equipment and tools

Fig. 1

open ended
spanner
13mm

oil resistant gloves

Schfer wrenches
for connectors

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Lower the forks to the
ground..
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
Make the retractable carriage come fully out (fig.1).
Remove the cover to access the hydraulic control valve (fig.2).

Fig. 2

Turn the keyswitch to OFF and disconnect the battery.


Phase 2
SHFER WRENCHES FOR CONNECTORS - OIL RESISTANT
GLOVES
Wear the oil resistant gloves.
Label the hydraulic pipes in order to reassemble them correctly.
Unscrew the hydraulic pipe connectors with the Shfer wrenches
(fig.3).
Disconnect the solenoid valve supply connectors.

Fig. 3

23

SERVICE

HYDRAULIC SYSTEM
Phase 3
FIXED GAUGE 13 mm SPANNER
Using the open ended spanner, unscrew and remove the screws fastening the control valve at the bottom of the truck (ref.A fig.5).
Remove the control valve assembly.
Remove the O-rings from the seat, carefully clean the parts and install
the new gasket set.

Fig. 4

A
Fig. 5

24

SERVICE

HYDRAULIC SYSTEM

REMOVAL OF THE PRESSURE RELIEF VALVE


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

large flat blade


screwdriver

oil protecting
gloves

socket wrench
22 mm

ratchet

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Lower the forks to the
ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
Make the retractable carriage come fully out (fig.1).
Remove the cover to access the hydraulic control valve (fig.2).
Phase 2
RATCHET - 22 mm SOCKET WRENCH - OIL PROTECTING LOVES
Put the oil proof gloves on.
Use the spanner to unscrew and remove the valve assembly (ref.A fig.3)
and proceed with the replacement.

Fig. 2

Fig. 3

INSTALLATION
On installation, tighten the valve with a torque wrench to
10 to 12 Nm.

25

HYDRAULIC SYSTEM

SERVICE

CALIBRATION OF THE PRESSURE RELIEF VALVE


The pressure relief valve must be calibrated following replacement.
Equipment and tools

oil resistant gloves

open ended
spanner
10 mm

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

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

B
26

Fig. 2

SERVICE

HYDRAULIC SYSTEM

CARTRIDGE SOLENOID VALVES


The distributor solenoid valves are of the screw on cartridge type.
This kind of valve is comprised of a chassis with a hexagon nut attached to the chassis, a threaded part,
a range of static seal gaskets; inside a mobile element allows communication between the various holes.

IDENTIFICATION of SOLENOID VALVE CARTRIDGE COMPONENTS

1
2

Ref.

Description

Coil

Valve body

27

SERVICE

HYDRAULIC SYSTEM
SOLENOID VALVE DISMANTLING

Fig. 1

Equipment and tools

oil resistant gloves

fixed gauge spanner


29 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Lower the forks to the
ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Fig. 2
Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Remove the cover to access the hydraulic control valve (fig.2).

Fig. 3

B
Turn the keyswitch to OFF and disconnect the battery.

Phase 2
OIL RESISTANT GLOVES - 29 mm OPEN ENDED SPANNER
Disconnect the solenoid valve supply connector.
Unscrew the coil retaining nut (ref.A fig.3). Withdraw the coil.
Using the open ended spanner, unscrew the nut securing the valve body
to the control unit (ref.B fig.3). Proceed with replacement
On refitting the valve body, tighten the retaining nut to a
torque of 29 Nm.

28

SERVICE

HYDRAULIC SYSTEM

CYLINDERS
SINGLE ACTING CYLINDER
Single acting cylinders receive and discharge the oil through a single pipe and the pressurised oil acts
on just one side of the piston (single acting pushing cylinders) or on the flat face of the rod in the case of
plunger type cylinders.
Single-acting plunger type cylinders
In this type of cylinder the piston is replaced by the flat end face of the piston rod or plunger; these cylinders
are usually mounted vertically or in other positions in which the force of gravity returns the plunger to the
rest position. Usually the diameter of the lower end of the rod is increased by a few millimetres in order to
avoid it slipping out at the end of it's upstroke; this gives rise to a hydraulic damping effect during the last
stages of the stroke which helps the slowing of the rod and avoids recoil on the upper end cap. Static seals
located in the end cap prevent oil leaking outside the cylinder.
To replace these seals it is necessary to unscrew the seal carrier bush.
Single acting cylinder with hollow rods differ in that before the lifting stroke begins the rod is also filled with
oil. This solution is used on particularly tall truck masts to increase the resistance of the cylinders at the
maximum height and make it possible to use smaller cylinder barrels and rods.
Static seals and dynamic seals
Dynamic seals, installed on the piston, prevent oil from leaking between the chambers of the cylinder barrel, while the static seals, located at the joint between two parts (seal carrier bush - barrel) or between the
sliding parts (rod barrel), prevent oil leaking from the inside to the outside of the cylinder.

29

SERVICE

HYDRAULIC SYSTEM
IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS
The cylinder is of the single-acting plunger type.

1
2
3
4
5

Ref.
1

Description
Bushing

2
3
4

Gaskets

5
6

Piston rod

Seal

Piston

9
10
11

Gaskets

7
8
9
10
11

12
13

Valve

14

Barrel

15

Parachute valve

12
13

14
15

30

SERVICE

HYDRAULIC SYSTEM

IDENTIFICATION OF THE SIDE LIFT CYLINDER COMPONENTS


The cylinder is of the single-acting plunger type.
After replacing the cylinder, bleed the air through the bleed valve.

2
3
4

Ref.

Description

Seal

Bushing

3
4

Gaskets

Barrel

Piston rod

Parachute valve

31

SERVICE

HYDRAULIC SYSTEM
IDENTIFICATION OF THE RETRACTABLE CARRIAGE CYLINDER COMPONENTS

Ref.

Description

Grease nipple

Barrel

Piston rod

Grease nipple

5
6
7

Gaskets

8
9
10

Nut

11

Piston

12

Bushing

13

Ring

14

Bearing

4
5
6
7
8
9
10
11
12

32

13
14

SERVICE

HYDRAULIC SYSTEM

IDENTIFICATION OF THE FORK TILT CYLINDER COMPONENTS

3
1

5
7

2
4

6
8

Ref.

Description

Barrel

Bushing

3
4
5

Gaskets

6
7
8

Rod and piston

Elastic ring

33

SERVICE

HYDRAULIC SYSTEM
IDENTIFICATION OF THE FORK SIDE SHIFT CYLINDER COMPONENTS

2
3
4

6
5

Ref.
1

Description
Barrel

2
3

Gaskets

34

Piston rod

Seal

SERVICE

HYDRAULIC SYSTEM

CENTRAL LIFT CYLINDER DISMANTLING


Equipment and tools

hoist
load capacity
1000kg

lifting sling
load capacity
1000kg

ratchet

hex bit socket


13 mm

taper end pliers

Shfer wrench for


connectors

wooden block

open-ended spanner
28 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Lower the forks to the
ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
WOODEN BLOCK
Using the controls in the cab, make the retractable carriage come fully
out.
Raise the forks just enough to be able to pass the wooden block underneath.
Place the wooden block under the forks (fig.1). Lower the forks to rest
on the block and continue until the end stroke of the cylinder.
Phase 2
TAPER END PLIERS - SHFER WRENCH FOR CONNECTORS
Using the taper end pliers remove the cotter pin and the chain hinge pin
at the top (ref.A fig.2). Rest the chain on the forks.
Using the Shfer wrench, detach the hydraulic pipes on the control valve of
the fork carriage. Disconnect the electric cables from the fork carriage.

Fig. 1
Fig. 2

35

SERVICE

HYDRAULIC SYSTEM
Phase 3
Raise the cylinder using the controls in the cab until the fork carriage is
fully extracted from below.
Set the fork carriage in a safe place.

Fig. 3

Phase 4
28 mm open ended spanner
Lower the forks until you can see the screw fastening the cylinder at the
bottom in the inner mast (fig.3).
Using the open ended spanner, unscrew and remove the screw fastening
the cylinder (ref.B fig.4).
Lower the cylinder down to the ground to its limit stop.
Using the Shfer wrench, remove the connector of the hydraulic pipe
connected to the cylinder (ref.C fig.5).

Phase 5
HOIST - LIFT BELT - HEXAGONAL 13mm SOCKET WRENCH - RATCHET
Harness the cylinder with the lift belt.
Set the hoist at right-angles on the belt, hook the belt to the hoist and lift
to make it taut.
Using the socket wrench and ratchet, unscrew the screws of the cylinder
block and remove it (ref.D fig.6).
With the aid of the hoist, remove the cylinder, place it on a clean work
bench and proceed with replacement.

Fig. 4

Fig. 6

Fig. 5

36

SERVICE

HYDRAULIC SYSTEM

DISMANTLING OF LATERAL LIFT CYLINDER


Equipment and tools
Fig. 1

hoist
load capacity
2000 kg

lifting sling
load capacity
2000 kg

medium external
circlip pliers

2 open ended
spanners
15 mm

oil resistant gloves

Shfer wrench for


connectors

ladder

Allen key
6 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place of a sufficient height for the
fully raised column, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground.

Fig. 2

The hydraulic fluid gets very hot during system operation


and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out and raise the forks until you can see the top of the side cylinder rod
(fig.1).
Phase 2
MEDIUM EXTERNAL CIRCLIP PLIERS - ladder - 2 OPEN ENDED
SPANNERS SIZE 15 mm
Set the ladder next to the column. Climb up and use the pliers to remove
the circlip securing the cylinder (ref.A fig.2).
Using the open ended spanners, unscrew and remove the screws fastening the cylinder locking bracket (ref.B fig.3). Remove the bracket.
Using the cab controls, lower the forks completely down to the ground.

Fig. 3

37

SERVICE

HYDRAULIC SYSTEM
Phase 3
OIL RESISTANT GLOVES - SHFER WRENCH FOR CONNECTORS
Wear the oil resistant gloves.
Remove the cover to access the hydraulic control valve (fig.4).
Using the Shfer wrench, detach the hydraulic pipe at the base of the
cylinder (ref.C fig.5).

Phase 3
BRIDGE CRANE - LIFT BELT
Hook the lifting belt at the top of the inner mast and hook both ends of
the belt to the bridge crane (fig.6).
Start lifting with just the cylinder connected and at the same time raise
the bridge crane up to the maximum height and keep the belt taut.

Phase 3
LIFT BELT - LIFT - 6 mm ALLEN WRENCH - TRESTLES
Harness the cylinder with the lift belt, hook it onto the lift and take up the
slack.
Using the Allen wrench, unscrew and remove the screw securing the
cylinder (ref.D fig.5). Lift the cylinder upwards until the bottom comes
away from the seat by the mast bottom, lower bending it outwards and
make it come out from the front of the truck. Set it horizontally and place
it on the two trestles and proceed with dismantling or replacement.

After installation, bleed the air from the cylinder (see


LIFTING CYLINDER: AIR BLEEDING).

38

Fig. 4

D
Fig. 5

SERVICE

HYDRAULIC SYSTEM

LIFTING CYLINDER: AIR BLEEDING


Equipment and tools

oil resistant gloves

open ended spanner


13 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the carriage to a safe place, away from areas of
transit of other vehicles and all pedestrians. Set the key
switch to OFF and disconnect the battery.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
OIL RESISTANT GLOVES - 13 mm OPEN ENDED SPANNER - LADDER
Wear the oil resistant gloves. Set the ladder next to the column and climb
up.
Using the spanner, unscrew the air bleed screw by two turns (ref.B
fig.1).

Connect the battery and turn the starter key to ON.

Fig. 1

A
B

Phase 2
FIXED GAUGE 13 mm SPANNER
Using the controls in the cab, raise the forks with no load by approximately
300mm, stop and wait for approximately 10 seconds, repeat this process
until all the air has come out of the bleed valve (fig.1).
Take the forks to full height, stop and tighten the screw (ref.B fig.1).
Wipe the cylinder with a clean cloth.

39

SERVICE

HYDRAULIC SYSTEM
REMOVAL OF THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER
Equipment and tools

Fig. 1

T handle hex key


Shfer wrench for
oil resistant gloves
3 - 5 mm
connectors

hex socket
wrench
24 mm

ratchet

open-ended spanner
8 - 24 mm

extension

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Fig. 2

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Remove the cover to access the hydraulic control valve (fig.2).
Fig. 3
Phase 2
5 mm T-handle hex key
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet,
remove the electronic controls cover and open the bonnet (fig.3).

40

SERVICE

HYDRAULIC SYSTEM

Phase 3
3 mm T-HANDLE HEX KEY - 8-24 mm OPEN ENDED SPANNER
Using the 8mm open ended spanner and the T-handle hex key, unscrew
and remove the screw fastening the potentiometer to the cylinder (ref.A
fig.4).
Using the 24mm open ended spanner unscrew and remove the bolt fastening the cylinder to the retractable carriage (ref.B fig.4).

Phase 4
24 mm HEX SOCKET WRENCH - RATCHET - EXTENSION
Using the open ended spanner, through the electronic controls compartment, unscrew and remove the bolt fastening the cylinder to the retractable carriage (ref.C fig.5).
Raise the cylinder rod to extract it from the pin.
Using the controls in the cab, make the rod come fully into the cylinder.

B
A

Fig. 4

Phase 5
OIL RESISTANT GLOVES - SHFER WRENCH FOR CONNECTORS
Wear the oil resistant gloves.
Using the Shfer wrench, detach the connectors of the hydraulic pipes
on the cylinder (ref.D fig.6).
Raise the cylinder to extract it from the pin.
Remove the cylinder, place it on a clean work bench and proceed with
dismantling or replacement.

C
Fig. 5

Fig. 6

41

SERVICE

HYDRAULIC SYSTEM
REMOVAL OF THE FORK TILT CYLINDER
Equipment and tools

T handle hex key


6 mm

Allen key
10 mm

tackle
load capacity
1000 kg

2 lifting slings
load capacity
1000 kg

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

medium flat blade


screwdriver

Fig. 1

The hydraulic fluid gets very hot during system operation


and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

A
Phase 1
Remove the forks.
Using the controls in the cab, make the retractable carriage come fully
out and raise the forks by approximately one metre.

Turn the keyswitch to OFF and disconnect the battery.


Phase 2
10 mm Allen wrench
Using the Allen wrench, unscrew and remove the screws securing the
anti-turnover block (ref.A fig.1). Remove the block.

Phase 3
HOIST - 2 LIFTING SLINGS
Harness the movable frame with the lift belts. Hook the lift belts onto the
hoist.
Turning the movable frame, raise it with the hoist and extract it from the
fixed frame (fig.2).

42

Fig. 2

SERVICE

HYDRAULIC SYSTEM

Phase 4
MEDIUM FLAT BLADE SCREWDRIVER - 14 mm OPEN ENDED SPANNER - 6 mm T-HANDLE HEX KEY
Using the medium flat blade screwdriver, lever on and remove the lower
sliding block (ref.B fig.3).
Using the open ended spanner, unscrew and remove the hydraulic pipes
from the connectors (ref.C fig.4).
Using the T-handle hex key, unscrew and remove the screws securing
the flange (ref.D fig.3) and remove it.
Extract the cylinder from its seat and dismantle or replace.

Fig. 3

B
Fig. 4

43

SERVICE

HYDRAULIC SYSTEM
CYLINDER DISMANTLING

gasket replacement
replacing the parachute valve

Equipment and tools

workbench

vice

oil protecting
gloves

fixed gauge spanner

small flat blade


screwdrivers

oil syringe

brush

C spanner

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

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

44

oil pan

round nose pliers

SERVICE

HYDRAULIC SYSTEM

REPLACING THE GASKET


Phase 3
SMALL FLAT HEAD SCREWDRIVER - BRUSH
Using the screwdriver, remove the internal seals and the seals external
to the bush and proceed with replacement.

Fig. 1

Fitting the seals is a delicate stage in the lift cylinder assembly procedure. Most maintenance operations are to
be ascribed to gasket leakage. Do not damage the parts
during assembly.
Clean the seal carrier bush and lubricate the seal contact
faces in the bush and the seals themselves with clean
hydraulic oil before installation.

DISMANTLING OF THE PARACHUTE VALVE (LIFT CYLINDERS)


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

INSTALLATION

Fig. 2

The bush should be tightened during assembly to:


353-380 Nm (middle lift cylinder)
358 Nm (side lift cylinders)
Lubricate all the inner parts of the cylinder with clean hydraulic oil. Use new gaskets.

45

HYDRAULIC SYSTEM

lift pump
KEY TO LIFT PUMP COMPONENTS

Ref.
1

Cover

Gear wheel

Seal

Upper flange

5
6

46

Description

Gaskets

Upper bearing

Stator

Rotor

10

Lower bearing

11

O-ring

12

Lower flange

13

Heat sensor

SERVICE

SERVICE

HYDRAULIC SYSTEM

1
2

13

5
6
7

10
11

12

47

SERVICE

HYDRAULIC SYSTEM
LIFT PUMP DISMANTLING
Equipment and tools

workbench

hex socket
wrench
15

ratchet

extension

open ended spanShfer wrench for T handle hex key


ner
oil resistant gloves
connectors
5 mm
17 mm

hoist
load capacity
1000 kg

lift belt
load capacity
1000 kg

eyebolt

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Lower the forks to the
ground. Turn the keyswitch to OFF and disconnect the
battery.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Before starting work, drain the oil reservoir.

Phase 1
5 mm T-HANDLE HEX KEY
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.A fig.1).
Completely open the cover (fig.2).

48

Fig. 2

SERVICE

HYDRAULIC SYSTEM

Phase 2
17 mm open ended spanner
Using the fixed spanner, unscrew the nuts fastening the pump motor power cables.
Take note of the position of the cables. Remove the cables and disconnect the connectors.

Phase 3
15 mm SOCKET WRENCH - RATCHET - EXTENSION - Shfer WRENCH FOR CONNECTORS - OIL
RESISTANT GLOVES
Wear the oil resistant gloves.
Using the Shfer wrench, disconnect the connector of the hydraulic pipe connected to the pump block
(ref.B fig.3). Use the open ended spanner to unscrew the fastening screw of the elastic strip that fastens
the inlet pipe (ref.C fig.3).
Using the socket wrench, ratchet and extension, unscrew the two nuts securing the pump hydraulic block
(ref.D fig.3), loosen the nut (ref.E fig.3).
Phase 4
HOIST - LIFT BELT - EYEBOLT
Screw the eyebolt onto the pump. Insert the lift belt into the eyebolt and hook it onto the hoist.
Very carefully take up the slack in the belt with the hoist, remove the pump carrier plate from the slot (ref.F
fig.3) and slowly start raising the assembly.
Place it on a work bench or on a pallet and proceed with dismantling.

C
D

F
49

SERVICE

HYDRAULIC SYSTEM
REPLACEMENT OF THE PUMP
Equipment and tools

hex socket
wrench
17 mm

ratchet

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

Fig. 1

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

Phase 2
17mm SOCKET WRENCH - RATCHET
Using the socket wrench and the ratchet, unscrew and remove both
screws securing the pump to the flange (ref.A fig.1).
Remove the pump and proceed with the replacement.

INSTALLATION
During the assembly stage tighten the nuts that fasten the
pump to the flange with a torque wrench set at 45 Nm.

50

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC PIPES
PIPE PLACEMENT FOR HYDRAULIC CIRCUIT

51

SERVICE

HYDRAULIC SYSTEM
RENEWAL OF THE MIDDLE LIFT CYLINDER FEED PIPE
Equipment and tools

Fig. 1

hexagonal socket
wrench
17 mm

ratchet

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Lower the forks to the
ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Remove the cover to access the hydraulic control valve (fig.2).

Phase 2
WOODEN BEAM
Raise the forks by approximately one metre using the controls in the
cab.
Position the wooden beam beneath the fork carriage (ref.A fig.3).
Lower the forks and rest them on the beam, continue the descent until
the fork lift cylinder hydraulic power feed pipe becomes loose.

Turn the keyswitch to OFF and disconnect the battery.

52

Fig. 2

Fig. 3

SERVICE

HYDRAULIC SYSTEM

Phase 3
Shfer WRENCH FOR CONNECTORS - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Using the Shfer wrench, disconnect the connector of the hydraulic pipe
connected to the middle lift cylinder (ref.B fig.4).
Using the Shfer wrench, disconnect the connector of the hydraulic pipe
connected to the hydraulic block (ref.C fig.5).
Extract the pipe from the hose sheave and fit the new one

Fig. 4

C
Fig. 5

53

SERVICE

HYDRAULIC SYSTEM
RENEWAL OF THE FORK HYDRAULIC FUNCTIONS SUPPLY PIPES
Equipment and tools

Fig. 1

hexagonal socket
wrench
17 mm

ratchet

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Lower the forks to the
ground.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Remove the cover to access the hydraulic control valve (fig.2).

Fig. 2

Phase 2
10 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws fastening the pipe clamps (ref.A fig.3).
Phase 3
WOODEN BEAM
Raise the forks by approximately one metre using the controls in the
cab.
Position the wooden beam beneath the fork carriage (ref.B fig.4).
Lower the forks and rest them on the beam, continue the descent until
the fork hydraulic functions supply pipe becomes loose.

54

Fig. 2

SERVICE

HYDRAULIC SYSTEM

Fig. 4

Set the key switch to OFF and disconnect the battery.

Phase 4
Shfer WRENCH FOR CONNECTORS - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Using the Shfer wrench, disconnect the connector of the hydraulic pipe
connected to the hydraulic block on the fork carriage (ref.C fig.5).
Using the Shfer wrench, disconnect the connector of the hydraulic pipe
connected to the hydraulic block (ref.D fig.5).
Extract the pipe from the hose sheave and fit the new one

Fig. 5

55

HYDRAULIC SYSTEM

56

SERVICE

SERVICE

TRUCK BASE MECHANICS

TRUCK BASE MECHANICS


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

TRUCK BASE MECHANICS

WHEELS & TYRES


IDENTIFICATION OF TRACTION WHEEL COMPONENTS

Ref.

Description

Vulkollan ring complete with hub

Drive wheel flanged retaining nut

SERVICE

SERVICE

TRUCK BASE MECHANICS

REMOVAL OF THE DRIVE WHEEL


Equipment and tools

hydraulic jack

wooden block

T handle hex key


5 mm

hex socket
wrench
12 mm

ratchet with
extension bar

M6 screw
2 x 70 mm

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Lower the forks to the
ground, turn the keyswitch to OFF and disconnect the
battery.

Phase 1
5 mm T-HANDLE HEX KEY
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover
of the electronic controls. Unscrew and remove the screw locking the
bonnet (ref.A fig.1), remove the electronic controls cover and open the
bonnet (fig.2).
Phase 2
HYDRAULIC JACK - WOODEN BLOCK
Position the hydraulic jack beside the drive wheel and lift until the wooden
block can pass beneath.
Position the wooden block to the side of the truck, lower the jack to rest
the truck on the block and take up the slack on the jack (fig.3).

Fig. 2

Phase 3
2 M6 SCREWS 70 mm LONG
Insert the screws into the holes above the electromagnetic brake (fig.4),
screw them in to reach the lower disk and then tighten by a further turn
The purpose of this procedure is to disconnect the electromagnetic brake so as to free the wheel.
Fig. 3
3

SERVICE

TRUCK BASE MECHANICS


Phase 4
12 mm SOCKET WRENCH - RATCHET - EXTENSION
Turn the wheel by hand so as to set it parallel to the truck. Using the socket
wrench, ratchet and extension, unscrew and remove the nuts securing
the drive wheel to the reduction unit (ref.B fig.5).
Raise with the hydraulic jack until the wheel passes under the truck (fig.6).
Proceed with replacement

Fig. 4

INSTALLATION
The traction wheel retaining nuts must be tightened using
a torque wrench to a torque of 130 Nm.
Unscrew and remove the two screws used to disconnect
the electromagnetic brake.

Fig. 6

Fig. 5

SERVICE

TRUCK BASE MECHANICS

KEY TO LOAD WHEEL COMPONENTS

4
5

7
8

9
10
11
12
13

Ref.

Description

Electromagnetic brake

Brake disk

Springs

Bush

Screws fastening to the truck base

Wheel

Brake regulator

Wheel-brake fixing screw

bearing

10

Elastic ring

11

Spacer

12

Ring

13

Self-locking ring nut

SERVICE

TRUCK BASE MECHANICS


REMOVING THE LOAD WHEEL
Equipment and tools

hydraulic jack

wooden block

socket wrench for


self-locking ring
nut

ratchet

internal circlip
pliers

T handle hex key


6 mm

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

Fig. 1

Phase 1
HYDRAULIC JACK - WOODEN BLOCK
Position the hydraulic jack beside the load wheel and lift until the wooden
stock can pass beneath.
Set the wooden block under the clamp, lower the jack to rest the truck
on the block and take up the slack on the jack (fig.1).
Phase 2
SOCKET WRENCH FOR SELF-LOCKING RING NUT - RATCHET
Using the socket wrench for the self-locking ring nut and the ratchet,
unscrew and remove the ring nut (ref.A fig.2), remove the toothed
washer.
Extract the wheel from the hub and dismantle or replace.

a
Fig. 2

Fig. 3
REMOVAL OF THE WHEEL BEARING
Phase 3
LARGE INTERNAL CIRCLIP PLIERS
Use the internal circlip pliers to remove the circlip securing the bearing
(ref.B fig.3). Remove the bearing (ref.C fig.3) and proceed with the
replacement.

SERVICE

TRUCK BASE MECHANICS

REMOVAL OF THE BRAKE DISK


Phase 4
HEXAGONAL 6 mm "T" SECTION SPANNER
Using the T-handle hex key, remove the screws securing the brake disk to
the wheel together with the bush and spring (ref.D fig.4). When removing
the disk, pay attention to the springs (ref.E fig.4).

Fig. 4

INSTALLATION
The screws securing the brake disk must be tightened using a torque wrench to a torque of 25 Nm. Apply Loctite
270.

SERVICE

TRUCK BASE MECHANICS

BATTERY BLOCK
RENEWAL OF THE BATTERY BLOCK
Equipment and tools

hex socket
wrench
15 mm

ratchet

open-ended span- hexagonal "T"


ner
section spanner
10 - 13 mm
5 - 6 mm

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Lower the forks to the
ground.

Phase 1
Using the controls in the cab, move the retractable carriage fully against
the battery.
Pull up the lever in front of the throttle pedal board next to the bonnet so
as to free the battery.
Using the controls in the cab, make the retractable carriage come fully
out.

Turn the keyswitch to OFF and disconnect the battery.


Phase 2
5 mm T-HANDLE HEX KEY
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover
of the electronic controls. Unscrew and remove the screw locking the
bonnet (ref.A fig.1), remove the electronic controls cover and open the
bonnet (fig.2).

Fig. 2
Fig. 3

B
C

SERVICE

TRUCK BASE MECHANICS

Phase 3
10 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws fastening the bracket inside the motor compartment (ref.B fig.3). Remove the
bracket (ref.C fig.3).

Fig. 4

Phase 4
15 mm HEXAGONAL SOCKET WRENCH - RATCHET
Using the hex socket wrench and the ratchet, unscrew and remove the
screws securing the battery block (ref.D fig.4). Remove the battery block
and proceed with replacement or disassembly.

BLOCK DISMANTLING
Phase 5
6 mm T-HANDLE HEX KEY - 13 mm OPEN ENDED SPANNER
Using the open ended spanner, loosen the nut (ref.E fig.5) and, using
the T-handle hex key, unscrew and remove the screw (ref.F fig.5). Extract the pin including the spring and proceed with replacement of the
components.

Fig. 5

F
E

TRUCK BASE MECHANICS

SERVICE

MOTORS
KEY TO TRACTION MOTOR COMPONENTS

1
2
3

10
11

12
13

14

15

16

17

18
Ref.

10

Description

Ref.

Description

upper flange fastening screws

11

Stator

Upper flange

12

Lower flange

Circlip

13

Bush

Circlip

14

Seal

O-ring

15

Lower bearing

Upper bearing

16

Elastic ring

Elastic ring

17

Circlip

Gear wheel

18

O-ring

Rotor

10

Sensor

SERVICE

TRUCK BASE MECHANICS

REMOVAL OF THE TRACTION MOTOR


Equipment and tools

tackle
load capacity
1000 kg

lift belt
load capacity
1000 kg

open ended spanT handle hex key


ner
5-6 mm
13 mm

eyebolt

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable


protective clothing.

Phase 1
5 mm T-HANDLE HEX KEY
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover
of the electronic controls. Unscrew and remove the screw locking the
bonnet (ref.A fig.1), remove the electronic controls cover and open the
bonnet (fig.2).

Phase 2
Carry out the electromagnetic brake removal procedure (see "REMOVAL
OF THE ELECTROMAGNETIC BRAKE" in the "BRAKING SYSTEM"
section).
Phase 3
FIXED GAUGE 13 mm SPANNER
Unscrew the traction motor power cable fastening nuts. Note the position of the cables prior to removing them. Disconnect the sensor cable
connector.
Phase 4
6 mm T-HANDLE HEX KEY
Using the T-handle hex key, unscrew and remove the 6 screws fastening
the traction motor to the reduction unit (ref.B fig.3).

Fig. 2
Fig. 3

11

SERVICE

TRUCK BASE MECHANICS


Phase 5
HOIST - LIFT BELT - EYEBOLT
Screw the eyebolt onto the rotor shaft. Insert the lift belt into the eyebolt
and hook it onto the hoist.
Very carefully start slowly lifting the motor (fig.4).
Place it on a work bench or on a pallet and proceed with dismantling.

INSTALLATION
Before installing the motor on the reduction unit, lubricate
the drive shaft with a thin, even layer of special grease:
SHELL GADUS S2 OGH 0/00.
During the coupling stage, carefully rotate the wheel shaft
to help the motor shaft engage with the pinion.

12

Fig. 4

SERVICE

TRUCK BASE MECHANICS

REPLACEMENT OF TRACTION MOTOR BEARINGS


Equipment and tools
Fig. 1

A
T handle hex key
5 mm

medium
adjustable pliers

plastic hammer

bush

internal circlip
pliers

external circlip
pliers

Procedure

Before starting work, ensure that you are wearing suitable


protective clothing.

Phase 1
MEDIUM ADJUSTABLE PLIERS - EXTERNAL CIRCLIP PLIERS
Using the adjustable pliers, extract the key securing the brake guide
(ref.A fig.1).
Use the external circlip pliers to remove the circlip securing the flange to
the shaft (ref.B fig.1).

Phase 2
HEXAGONAL 6 mm "T" SECTION SPANNER
Using the T-handle hex key, unscrew and remove the screws fastening the
upper flange to the lower flange (ref.C fig.2). Recover both flanges.

Fig. 2

13

SERVICE

TRUCK BASE MECHANICS


Phase 3
INTERNAL CIRCLIP PLIERS
Use the circlip pliers to remove the circlip securing the upper bearing to
the flange (ref.D fig.3).
Recover the bearing and proceed with replacement.

Fig. 3

Phase 4
INTERNAL CIRCLIP PLIERS - EXTERNAL CIRCLIP PLIERS - MEDIUM
ADJUSTABLE PLIERS
Remove the pinion from the shaft. Using the adjustable pliers, extract
the pinion coupling key. Use the circlip pliers to remove the two circlips
securing the lower bearing and the bush to the shaft (ref.E-F fig.4).
Recover the bearing and proceed with replacement.

INSTALLATION
During the assembly stage replace all the gaskets with new
gaskets.
Assemble the new bearings using a plastic hammer and
a bushing.

14

F
E

Fig. 4

SERVICE

TRUCK BASE MECHANICS

KEY TO STEERING MOTOR COMPONENTS

6
1
7
8
9
2

10
11

3
12

13

14
15

Ref.

Description

Ref.

Description

upper flange fastening screws

11

Upper bearing

Sensor

12

Elastic ring

Upper flange

13

Rotor

Stator

14

Lower bearing

Lower flange

15

Ring

Elastic ring

Ring

Elastic ring

Magnet

10

Circlip
15

SERVICE

TRUCK BASE MECHANICS


STEERING MOTOR DISASSEMBLY
Equipment and tools

open ended spanT handle hex key


ner
5 mm
13 mm

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable


protective clothing.

Phase 1
5 mm T-HANDLE HEX KEY
Remove the rubber mat at the operator's feet inside the cab. Using the
T-handle hex key, unscrew and remove the screws securing the cover
of the electronic controls. Unscrew and remove the screw locking the
bonnet (ref.A fig.1), remove the electronic controls cover and open the
bonnet (fig.2).

Phase 2
FIXED GAUGE 13 mm SPANNER
Disconnect the connector. Using the socket wrench, unscrew and remove
the three screws fastening the steering motor to the plate (ref.B fig.3).
Remove the steering motor without damaging the gear wheel and proceed
with dismantling or replacement.
Fig. 2
Fig. 3

B
16

SERVICE

TRUCK BASE MECHANICS

STEERING MOTOR DISMANTLING


Equipment and tools
Fig. 1

A
hexagonal "T"
section spanner
3-4-5-6 mm

medium crosshead screwdriver

plastic hammer

bush

internal circlip
pliers

external circlip
pliers

Fig. 2

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

C
REMOVAL OF THE ELECTRICAL BOX
Phase 1
MEDIUM CROSSHEAD SCREWDRIVER - 6 mm T-HANDLE HEX
KEY
With the screwdriver, unscrew and remove the screws fastening the upper
cover of the electrical box (ref.A fig.1). Remove the cover.
Unscrew and remove the three fastening screws of the motor phase
terminals (ref.B fig.2).
Unscrew and remove the screws that fasten the side cover (ref.C fig.3).
Remove the cover together with the printed circuit board. Disconnect the
internal connector.
Using the T-handle hex key, unscrew the screws fastening the box to
the motor flange.

Fig. 3

17

SERVICE

TRUCK BASE MECHANICS


BEARING REMOVAL
Phase 2
4-5-6 mm T-HANDLE HEX KEY
Using the 5 mm T-handle hex key unscrew and remove the pinion fixing
screw (ref.D fig.4). Remove the washer (ref.E fig.4) and take out the
pinion (ref.F fig.4).
Using the 6 mm T-handle hex key, unscrew and remove the screws securing the triangular bracket (ref.G fig.4). Remove the bracket.
Using the 4 mm T-handle hex key, unscrew and remove the screws securing the steering box (ref.H fig.4). Remove the box.

Phase 3
3-4 mm T-HANDLE HEX KEY - EXTERNAL CIRCLIP PLIERS - INTERNAL CIRCLIP PLIERS
Using the 3 mm T-handle hex key, unscrew and remove the screws securing the motor cover (ref.I fig.5). Remove the cover.
Use the external circlip pliers to remove the circlip securing the flange
to the crankshaft.
Using the 4 mm T-handle hex key, unscrew and remove the screws
joining the upper flange to the lower flange (ref.J fig.5). Recover both
flanges.
Use the circlip pliers to remove the circlip securing the upper bearing to
the flange.
Recover the bearing and proceed with replacement.

INSTALLATION
During the assembly stage replace all the gaskets with new
gaskets.
Assemble the new bearings using a plastic hammer and
a bushing.

18

Fig. 4

E
F
G

Fig. 5

I
J

SERVICE

TRUCK BASE MECHANICS

STEERING SYSTEM ASSEMBLY


KEY TO STEERING SYSTEM ASSEMBLY COMPONENTS

12

3
4
5
6
13

8
9
14

10

11

Ref.

Description

Ref.

Description

Small steering wheel

11

Stepper motor

Driving

12

Bearing

Adjuster plate

13

Spring

Block

14

Bearing

Pin

Spring

Pushrod

Elastic ring

Ball bearing

10

Shaft
19

SERVICE

TRUCK BASE MECHANICS


RENEWAL OF STEERING SYSTEM ASSEMBLY BEARING
Equipment and tools

small flat blade


screwdriver

internal circlip
pliers

hex socket
wrench
7-13 mm

ratchet

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

Phase 1
To recover the block together with the bearing, see REPLACING THE
ARMREST AND MAIN PANEL CONTROLS: STEERING WHEEL STEPPER MOTOR in the ELECTRICAL SYSTEM section.
Phase
internal circlip pliers
Use the internal circlip pliers to remove the circlip securing the bearing
(ref.A fig.1). Remove the bearing and proceed with the replacement.

20

Fig. 1

SERVICE

TRUCK BASE MECHANICS

retractable carriage
KEY TO RETRACTABLE CARRIAGE COMPONENTS

3
4
7

Ref.

Description

Cover for access to the hydraulic control valve

Circlip

Bearing

Pin

bearing

Adjuster roller

Self-locking ring nut

Buffer

Adjusting screw

21

SERVICE

TRUCK BASE MECHANICS


REMOVAL OF THE RETRACTABLE CARRIAGE
Equipment and tools

B
bridge crane
load capacity
2000 kg

2 lifting slings
load capacity
2000 kg

hex socket
wrench
10 mm

ratchet and
extension

Fig. 1
Fig. 2
hexagonal "T" open-ended spanShfer wrench for
section spanner
ner
oil resistant gloves
connectors
3-14 mm
8-24 mm

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

Phase 1
Carry out the mast removal procedure (see REMOVAL OF THE BEARINGS in the MAST MECHANICS section).

Phase 2
OIL RESISTANT GLOVES - SHFER WRENCH FOR CONNECTORS
Wear the oil resistant gloves.
Using the Shfer wrench, detach the connectors of the hydraulic pipes
on the hydraulic control valve.
Disconnect the connectors from the solenoid valves.

22

C
Fig. 3

Fig. 4

SERVICE

TRUCK BASE MECHANICS

Phase 3
3 mm T-HANDLE HEX KEY - 8-24 mm OPEN ENDED SPANNER
Using the 8mm open ended spanner and the T-handle hex key, unscrew
and remove the screw fastening the potentiometer to the cylinder (ref.A
fig.1).
Using the 24mm open ended spanner unscrew and remove the bolt fastening the cylinder to the retractable carriage (ref.B fig.1).
Raise the cylinder to extract it from the pin.

Fig. 5

Phase 4
10 mm socket wrench - extension - ratchet
Using the socket wrench, extension and ratchet, unscrew and remove
the screws securing the carriage of the plate on which is secured the
pipe carrier chain (ref.C fig.3).

Phase 5
14 mm T-HANDLE HEX KEY
Using the T-handle hex key, unscrew and remove the limit stop screws
of the retractable carriage (ref.D fig.4).

Phase 6
BRIDGE CRANE - 2 LIFTING SLINGS
Harness the retractable carriage with the lift belts on the two crossbars
(fig.5). Hook the lift belts onto the bridge crane. Take up the slack on the
belts and extract the retractable carriage horizontally, place it on a pallet
and proceed with dismantling.

INSTALLATION
The limit stop screws must be tightened using a torque
wrench with a tightening torque of 300 - 330 Nm.

23

SERVICE

TRUCK BASE MECHANICS


RENEWAL OF BEARINGS AND RETRACTABLE CARRIAGE PINS
Equipment and tools

external circlip
pliers

open ended
spanner
24 mm

socket wrench for


self-locking ring
nut

ratchet

driving tool
10 mm

hammer

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

Phase 1
Carry out the retractable carriage removal procedure (see REMOVAL
OF THE RETRACTABLE CARRIAGE).

A
Fig. 1

Phase 2
external circlip pliers
Use the circlip pliers to remove the circlip securing the bearing block (ref.A
fig.1). Remove the bearing and proceed with the replacement.
Phase 3
24 mm OPEN ENDED SPANNER - SOCKET WRENCH FOR SELFLOCKING RING NUT - RATCHET. CLAMP GUDGEON - HAMMER
Using the open ended spanner, unscrew the nut securing the roller adjusting screw (ref.B fig.2). Unscrew and remove the screw (ref.C fig.2).
Using the hammer and the clamp gudgeon extract the roller (ref.D
Fig.2).
Using the socket wrench for self-locking ring nuts, unscrew and remove
the ring nut (ref.E fig.2).
Using the hammer and clamp gudgeon extract the pin from the carriage
(ref.F fig.2).

INSTALLATION
Coat the new bearings with a layer of special lubricating
grease RETINAX HDX2 for standard applications or
AERO SHELL GREASE 6 for applications in a cold
store.

24

C
B

Fig. 2

SERVICE

TRUCK BASE MECHANICS

REMOVING THE RETRACTABLE CARRIAGE POTENTIOMETER


Equipment and tools
Fig. 1

T-handle hex key


3 mm

open-ended spanner
8 mm

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

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Remove the cover to access the hydraulic control valve (fig.2).

Turn the keyswitch to OFF and disconnect the battery.

Fig. 2

Phase 2
3 mm T-HANDLE HEX KEY - 8 mm OPEN ENDED SPANNER
Using the T-handle hex key, unscrew and remove the screw securing the
potentiometer to the cylinder (ref.A fig.3).
Using the open ended spanner, unscrew and remove the nut securing
the potentiometer to the carriage (ref.B fig.3).
Disconnect the connector and proceed with replacement.

Fig.3

25

TRUCK BASE MECHANICS

26

SERVICE

SERVICE

MAST ASSEMBLY MECHANICS

Mast assembly
mechanics
MAST CHARACTERISTICS 2
MAST ELEVATION 4
3 STAGE MAST 8
IDENTIFICATION OF THE 3 STAGE MAST ASSEMBLY COMPONENTS 8
BEARING REPLACEMENT  9
REPLACEMENT OF CHAINS AND CHAIN TENSIONER 14
RENEWAL OF THE MIDDLE SECTION CHAIN SHEAVES 17
RENEWAL OF THE MIDDLE CYLINDER CHAIN SHEAVE 19

MAST ASSEMBLY MECHANICS

SERVICE

MAST CHARACTERISTICS
The masts used have three stages.
These masts have machined channels so as to reduce the distance between the channel chamber and
the rollers. The channels are machined with special machinery to permit smooth movement of the mast
assembly, less oscillation, less friction, low wear, and less noise.
Wider rollers permit handling heavier loads. Hassle-free setting of the correct axis of the bearings without
having to remove the roller entirely.

SERVICE

MAST ASSEMBLY MECHANICS

MAST ASSEMBLY MECHANICS

MAST ELEVATION

SERVICE

SERVICE

Model

MR16N
MR14
MR16

MR20
MR25

MAST ASSEMBLY MECHANICS

Total auxiliary lift


(mm)

Free Lift
(mm)

Height, mast
lowered
(mm)

Extended
dimensions
(mm)

h3

h2

h1

h4

5000

1648

2195

5563

911

5250

1734

2281

5813

936

5500

1820

2367

6063

961

5750

1906

2453

6313

986

6000

1992

2539

6563

1010

6250

2078

2625

6813

1035

6500

2164

2711

7063

1060

6750

2250

2797

7313

1090

7000

2336

2883

7563

1115

7250

2422

2969

7813

1140

7500

2508

3055

8063

1164

7750

2594

3141

8313

1220

8000

2680

3227

8563

1244

8250

2766

3313

8813

1269

8500

2852

3399

9063

1299

8750

2938

3485

9313

1324

9000

3024

3571

9563

1349

9250

3110

3657

9813

1376

9500

3196

3743

10063

1400

9750

3282

3829

10313

1425

10000

3368

3915

10563

1454

10250

3454

4001

10813

1478

10500

3540

4087

11063

1503

4650

1582

2195

5263

958

4900

1668

2281

5513

985

5150

1754

2367

5763

1012

5400

1840

2453

6013

1038

5650

1926

2539

6263

1065

5900

2012

2625

6513

1092

6150

2098

2711

6763

1118

6400

2184

2797

7013

1150

6650

2270

2883

7263

1177

6900

2356

2969

7513

1204

7150

2442

3055

7763

1230

7400

2528

3141

8013

1288

7650

2614

3227

8263

1314

7900

2700

3313

8513

1341

8150

2786

3399

8763

1373

Weight
(kg)

MAST ASSEMBLY MECHANICS

Model

MR20HD

MR16HD

SERVICE

Total auxiliary lift


(mm)

Free Lift
(mm)

Height, mast
lowered
(mm)

Extended
dimensions
(mm)

h3

h2

h1

h4

7900

2614

3227

8513

1372

8150

2700

3313

8763

1401

8400

2786

3399

9013

1435

8650

2872

3485

9263

1464

8900

2958

3571

9513

1523

9150

3044

3657

9763

1552

9400

3130

3743

10013

1581

9650

3216

3829

10263

1609

9900

3302

3915

10513

1638

10150

3388

4001

10763

1671

10400

3474

4087

11013

1699

10650

3560

4173

11263

1728

10900

3646

4259

11513

1757

11150

3732

4345

11763

1786

Weight
(kg)

11400

3818

4431

12013

1814

11650

3904

4517

12263

1843

11900

3990

4603

12513

1872

12150

4076

4689

12763

1901

12400

4162

4775

13013

1929

12650

4248

4861

13263

1958

8050

2680

3227

8613

1346

8300

2766

3313

8863

1374

8550

2852

3399

9113

1408

8800

2938

3485

9363

1436

9050

3024

3571

9613

1495

9300

3110

3657

9863

1524

9550

3196

3743

10113

1552

9800

3282

3829

10363

1580

10050

3368

3915

10613

1612

10300

3454

4001

10863

1641

10550

3540

4087

11113

1669

10800

3626

4173

11363

1698

11050

3712

4259

11613

1726

11300

3798

4345

11863

1755

11550

3884

4431

12113

1783

SERVICE

MAST ASSEMBLY MECHANICS

MAST ASSEMBLY MECHANICS

3 STAGE MAST
IDENTIFICATION OF THE 3 STAGE MAST ASSEMBLY COMPONENTS

Ref.

Description

Outer upright

Intermediate upright

Inner upright

Roller

Chain tensioner

Buffer

Hose sheave

Side lift cylinder

Middle lift cylinder

10

Hydraulic pipe

SERVICE

SERVICE

Mast assembly mechanics

4
6

5
7
8

10
5
6
7
4

5
4

8a

SERVICE

MAST ASSEMBLY MECHANICS

BEARING REPLACEMENT
3 STAGE MAST
To allow bearing replacement the mast assembly must be removed from the truck base.

Equipment and tools

bridge crane
load capacity
3000 kg

ladder

safety harness

n. 3 iron trestles

wooden block

oil resistant gloves

Shfer wrench for


connectors

lifting sling
load capacity
3000 kg

Allen key
6 - 2.5 mm

24 mm socket
wrench

ratchet

plastic hammer

taper end pliers

open ended spanmedium elastic


ner
ring opening pliers
size 19 - 2x24 2x15 mm

Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from the transit areas of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.
The hydraulic fluid gets very hot during system operation and can cause burns. It is
advisable to wear gloves that are resistant to oil and high temperatures.

SERVICE

MAST ASSEMBLY MECHANICS


MAST ASSEMBLY REMOVAL
Phase 1
Using the controls in the cab, make the retractable carriage come fully
out.
Remove the cover to access the hydraulic control valve (fig.3).

Phase 2
WOODEN BLOCK
Raise the forks just enough to be able to pass the wooden block underneath.
Place the wooden block under the forks (fig.1). Lower the clamps to rest
on the blocks and continue until the end stroke of the cylinder.

Fig. 1
Fig. 2

Phase 3
TAPER END PLIERS - SHFER WRENCH FOR CONNECTORS
Using the taper end pliers remove the cotter pin and the chain hinge pin
at the top (ref.A fig.2). Rest the chain on the forks.
Using the Shfer wrench, detach the hydraulic pipes on the control valve of
the fork carriage. Disconnect the electric cables from the fork carriage.

Phase 4
Raise the cylinder using the controls in the cab until the fork carriage is
fully extracted from below.
Set the fork carriage in a safe place. Fully retract the cylinder.

Position the key switch to OFF and disconnect the battery.

Phase 5
BRIDGE CRANE - LADDER - SAFETY HARNESS - LIFT BELT
Climb up the ladder with the tools and secure the safety harness to the
cab.
Insert the lift belt beneath the upper crossbar of the middle section of the
mast assembly by making a noose and hook the ends to the bridge crane
hook (fig.4). Climb down the ladder, raise the bridge crane to reveal the
screws securing the mast assembly to the truck base.

Fig. 3

Fig. 4
10

SERVICE

MAST ASSEMBLY MECHANICS

Phase 6
24 mm SOCKET WRENCH - RATCHET - BRIDGE CRANE - LIFT
BELT
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the mast assembly to the truck base (ref.B fig.5).
Using the bridge crane, lower the mast assembly to the ground.
Climb the ladder again.
Slip the lift belt beneath the upper crossbars of the mast assembly by
making a noose and hook the ends to the bridge crane hook (fig.6). Lift
the bridge crane and take up the slack in the belt.

Fig. 5

Phase 7
SHFER WRENCH FOR CONNECTORS
Using the Shfer wrench, detach the hydraulic pipes on the control valve
of the mast assembly (ref.C fig.7).

Phase 8
19 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws securing
both side blocks of the mast assembly (ref.D fig.8). Remove the blocks
(ref.E fig.8).
Using the bridge crane slowly lift the mast assembly and separate it from
the truck base. Position the mast assembly on two iron trestles and rest
it on the ground on wooden beams (fig.9).

Fig. 6

Fig. 7

Fig. 8

Fig. 9

11

MAST ASSEMBLY MECHANICS

SERVICE
Fig. 10

J
H

REMOVAL OF CHAINS AND CYLINDERS


Phase 9
TAPER END PLIERS - 2 OPEN ENDED SPANNERS SIZE 24 mm
Using the taper end pliers remove the cotter pin on the chain tensioner (ref.F fig.10) and the one on the
pin (ref.G fig.10).
Using the open ended spanners, unscrew and remove the nuts fastening the chain tensioner to the mast
assembly (ref.H fig.10). Remove the pin and extract the chain from the hose sheave. Perform the same
procedure on the opposite side of the mast assembly.
Phase 10
MEDIUM EXTERNAL CIRCLIP PLIERS - 2 OPEN ENDED SPANNERS SIZE 15 mm - SHFER WRENCH
FOR CONNECTORS - ALLEN WRENCH SIZE 6 mm
Use the pliers to remove the circlip securing the cylinder (ref.I fig.10).
Using the open ended spanners, unscrew and remove the screws fastening the cylinder locking bracket
(ref.J fig.10). Remove the bracket.
Using the Shfer wrench, detach the hydraulic pipe at the base of the cylinder (ref.K fig.10).
Using the Allen wrench, unscrew and remove the screw securing the cylinder (ref.L fig.10).
Remove the cylinder and carry out the same procedure on the other cylinder.

12

SERVICE

MAST ASSEMBLY MECHANICS

BEARING REMOVAL

Fig. 11

Phase 11
Shift the inner upright in such a way as to get a view of the bearings.
Phase 12
2.5 mm ALLEN WRENCH - PLASTIC HAMMER
Using the Allen wrench, unscrew and remove the screws securing the
bearing to the mast assembly (ref.M fig.11). With the aid of the hammer,
remove the bearing and proceed with the replacement.

INSTALLATION

Fig. 12

The new bearings do not need to be greased.


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

13

SERVICE

MAST ASSEMBLY MECHANICS


REPLACEMENT OF CHAINS AND CHAIN TENSIONER
3 STAGE MAST

Never just replace the worn part of a chain. Replace the entire chain. Similarly, never
replace just one chain of a couple, always replace both.
Equipment and tools
Fig. 1

bridge crane
load capacity
1200 kg

lifting sling
load capacity
1200 kg

wooden beam

ladder

safety harness

open-ended spanner
2x24 mm

taper end pliers

Fig. 2

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

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).

Fig. 3

14

SERVICE

MAST ASSEMBLY MECHANICS

MAST ASSEMBLY CHAIN TENSIONER AND CHAIN


Phase 2
WOODEN BEAM
Raise the forks by approximately two metres using the controls in the
cab.
Place the wooden beam beneath the inner mast channel (ref.A fig.2).
Lower the forks until they rest on the beam, continue the descent until
the chains are loose.

Position the key switch to OFF and disconnect the battery.

Fig. 4

Fig. 5

Phase 3
BRIDGE CRANE - LADDER - SAFETY HARNESS - LIFT BELT
Climb up the ladder with the tools and secure the safety harness to the
cab.
Insert the lift belt beneath the upper crossbar of the inner upright of the
mast assembly by making a noose and hook the ends to the bridge crane
hook (fig.3). Climb down the ladder, raise the bridge crane and take up
the slack in the belt.
Phase 4
TAPER END PLIERS - 2 OPEN ENDED SPANNERS SIZE 24 mm
Using the taper end pliers remove the cotter pin on the chain tensioner
on the inner upright of the mast assembly (ref.B fig.6).
Using the open ended spanners, unscrew and remove the nuts fastening
the chain tensioner (ref.C fig.6). Extract the chain tensioner upwards.
Using the taper end pliers remove the cotter pin and the hinge pin securing the chain to the chain tensioner (ref.D fig.6).

Phase 5
TAPER END PLIERS - 2 OPEN ENDED SPANNERS SIZE 24 mm
Using the taper end pliers remove the cotter pin on the chain tensioner
at the top on the outer upright of the mast assembly (ref.E fig.4).
Using the open ended spanners, unscrew and remove the nuts fastening
the chain tensioner (ref.F fig.4). Extract the chain tensioner upwards,
retrieve the chain by sliding it on the hose sheave and proceed with the
replacement.

Fig. 6

B
15

SERVICE

MAST ASSEMBLY MECHANICS


FORK CHAIN TENSIONER AND CHAIN
Phase 2
WOODEN BLOCK
Raise the forks just enough to be able to pass the wooden block underneath.
Place the wooden block under the forks (fig.7). Lower the forks to rest
on the block and continue until the end stroke of the cylinder.

Position the key switch to OFF and disconnect the battery.


Fig. 7
Phase 3
TAPER END PLIERS - 2 OPEN ENDED SPANNERS SIZE 24 mm
Using the taper end pliers remove the cotter pin and the chain hinge pin
at the top (ref.G fig.8). Rest the chain on the forks.
Using the open ended spanners, unscrew and remove the nuts fastening
the chain tensioner (ref.H fig.9). Extract the chain tensioner upwards.
Using the taper end pliers remove the cotter pin and the chain hinge pin
at the bottom (ref.I fig.10).
Retrieve the chain and proceed with the replacement.

Fig. 8

ASSEMBLY
Fig. 9

Do not reuse the chain anchoring safety pins, use new


cotter pins, ensuring they are the correct size.

Fig. 10

16

SERVICE

MAST ASSEMBLY MECHANICS

RENEWAL OF THE MIDDLE SECTION CHAIN SHEAVES


3 STAGE MAST
Equipment and tools
Fig. 1

bridge crane
load capacity
1200 kg

lifting sling
load capacity
1200 kg

external circlip
pliers

wooden beam

ladder

safety harness

Fig. 2

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

Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Phase 2
WOODEN BEAM
Raise the forks by approximately two metres using the controls in the
cab.
Place the wooden beam beneath the inner mast channel (ref.A fig.2).
Lower the forks until they rest on the beam, continue the descent until
the chains are loose.

Fig. 3

17

MAST ASSEMBLY MECHANICS

SERVICE
Fig. 4

Turn the ignition key to OFF and disconnect the battery.

Phase 3
BRIDGE CRANE - LADDER - SAFETY HARNESS - LIFT BELT
Climb up the ladder with the tools and secure the safety harness to the
cab.
Insert the lift belt beneath the upper crossbar of the inner upright of the
mast assembly by making a noose and hook the ends to the bridge crane
hook (fig.3). Climb down the ladder, raise the bridge crane and take up
the slack in the belt.

Phase 4
MEDIUM SIZE ELASTIC RING OPENING PLIERS
Use the pliers to remove the circlip securing the sheave (ref.B fig.4).
Remove the hose sheave and proceed with the replacement.

18

SERVICE

MAST ASSEMBLY MECHANICS

RENEWAL OF THE MIDDLE CYLINDER CHAIN SHEAVE


3 STAGE MAST
Equipment and tools
Fig. 1

A
fixed gauge spanT handle hex key
ner
6 mm
18 mm

hammer

clamp gudgeon

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

Phase 1
Carry out the fork chain dismantling procedure (see "CHAIN AND CHAIN
TENSIONER REPLACEMENT").

Phase 2
18 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws fastening
the two hose sheaves at the sides of the chain sheave (ref.A fig.1).
Remove the two sheaves.

Phase 3
6 mm "T" HANDLE HEX KEY - HAMMER - CLAMP GUDGEON 30
mm
Using the T-handle hex key, unscrew and remove the sheave pin retaining screw (ref.B fig.2).
Using the hammer and clamp gudgeon extract the pin, remove the sheave
and proceed with replacement.

Fig. 2

19

MAST ASSEMBLY MECHANICS

20

SERVICE

SERVICE

SMALL FORK MAST MECHANICS

Small fork mast


mechanics
FORK CARRIAGE 2
KEY TO FORK CARRIAGE COMPONENTS 2
REMOVAL OF THE FORK CARRIAGE 3
REMOVAL OF THE SLIDING BLOCKS 4
BEARING REPLACEMENT 6

SERVICE

SMALL FORK MAST MECHANICS

FORK CARRIAGE
KEY TO FORK CARRIAGE COMPONENTS

10
8
3

11
12

6
5

Ref.

Description

Ref.

Description

Forks

Bearing

Hydraulic block

Side shift cylinder

Fixed frame

Upper sliding block

Movable frame

10

Anti-overturning system block

Flange

11

Movable frame sliding blocks

Tilt cylinder

12

Lower sliding block

SERVICE

SMALL FORK MAST MECHANICS

REMOVAL OF THE FORK CARRIAGE


Equipment and tools

Shfer wrench for


connectors

wooden block

taper end pliers

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

Fig. 1
Fig. 2

The hydraulic fluid gets very hot during system operation


and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

A
Phase 1
Using the controls in the cab, make the retractable carriage come fully
out. Remove the cover to access the hydraulic control valve (fig.3).
Phase 2
WOODEN BLOCK
Using the controls in the cab, make the retractable carriage come fully out.
Raise the forks just enough to be able to pass the wooden block underneath. Place the wooden block under the forks (fig.1). Lower the clamps
to rest on the blocks and continue until the end stroke of the cylinder.
Phase 3
TAPER END PLIERS - SHFER WRENCH FOR CONNECTORS
Using the taper end pliers remove the cotter pin and the chain hinge pin
at the top (ref.A fig.2). Rest the chain on the forks. Using the Shfer
wrench, detach the hydraulic pipes on the control valve of the fork carriage. Disconnect the electric cables from the fork carriage.

Fig. 3

Phase 4
Raise the cylinder using the controls in the cab until the fork carriage is fully extracted from below. Set the
fork carriage in a safe place and proceed with dismantling.

SERVICE

SMALL FORK MAST MECHANICS


REMOVAL OF THE SLIDING BLOCKS
The sliding blocks must be replaced in the event of wear, that is if their thickness is:
upper sliding blocks: less than 4.5mm
movable sliding blocks: less than 3mm
Equipment and tools

Allen key
10 mm

tackle
load capacity
1000 kg

2 lifting slings
load capacity
1000 kg

flat head screwdriver

Procedure

hammer

pin punch

Fig. 1

Before starting work, ensure that you are wearing suitable


protective clothing.
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians.
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.

A
Phase 1
Remove the forks.
Using the controls in the cab, make the retractable carriage come fully
out and raise the forks by approximately one metre.

Turn the keyswitch to OFF and disconnect the battery.


Phase 2
10 mm Allen wrench
Using the Allen wrench, unscrew and remove the screws securing the
anti-turnover block (ref.A fig.1). Remove the block.
Phase 3
HOIST - 2 LIFTING SLINGS
Harness the movable frame with the lift belts. Hook the lift belts onto the
hoist.
Turning the movable frame, raise it with the hoist and extract it from the
fixed frame (fig.2).
4

Fig. 2

SERVICE

SMALL FORK MAST MECHANICS

REMOVAL OF THE LOWER SLIDING BLOCK

Fig. 3

Phase 4
MEDIUM FLAT BLADE SCREWDRIVER
Using the medium flat blade screwdriver, lever between the sliding block
and the fixed frame. Remove the lower sliding block (ref.B fig.3) and
proceed with replacement.

REMOVAL OF THE UPPER SLIDING BLOCKS


Phase 4
MEDIUM FLAT BLADE SCREWDRIVER
Using the flat blade screwdriver, prise out the upper sliding block (ref.C
fig.4). Proceed with replacement

Fig. 4

REMOVAL OF THE MOVABLE FRAME SLIDING BLOCKS


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

Fig. 5

SERVICE

SMALL FORK MAST MECHANICS


BEARING REPLACEMENT
Equipment and tools

T-handle hex key


2.5 mm

plastic hammer

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

Phase 1
Carry out the fork carriage removal procedure (see REMOVAL OF THE
FORK CARRIAGE).

Phase 2
2.5 mm T-HANDLE HEX KEY - PLASTIC HAMMER
Using the Allen wrench, unscrew and remove the screws securing the
bearing to the mast assembly (ref.A fig.1). With the aid of the hammer,
remove the bearing and proceed with the replacement.

Fig. 1

SERVICE

REDUCTION GEAR

Reduction gear
KEY TO REDUCTION UNIT COMPONENTS 2
REMOVAL OF THE REDUCTION UNIT 4
REPLACEMENT OF TRACTION MOTOR DRIVE SHAFT RADIAL O-RING 6
REPLACEMENT OF WHEEL SHAFT RADIAL O-RING 7
CHANGING THE REDCUTION UNIT OIL 9

SERVICE

REDUCTION GEAR

KEY TO REDUCTION UNIT COMPONENTS

1
2

41
3
4
5

6
7
8

10

11
13

12

15

14

17

16

18

19
22
23

20
21

42

32
40

39

38

37 36 35 34 33

24 25 26 27 28 29 30 31

type gearbox

serial number
TYPE

42
PARTS LIST N

gearbox model

CUSTOMER CODE N

SERIAL-N

TOTAL RATIO

gearbox transmission

SERVICE

Ref.

REDUCTION GEAR

Description

Ref.

Description

Revolving ring bearing

22

Spring pin

Cap screws

23

Reduction unit housing

Steering pinion

24

Elastic dowel

Steering ring

25

Crown wheel

Washer

26

Circlip

Hex nut

27

Taper roller bearing

Helical gear

28

Spacer

Taper roller bearing

29

O-ring

Radial seal ring

30

Reduction unit housing cover

10

Spacers

31

Cap screw

11

Elastic ring

32

Seal rings

12

Ball bearing

33

Oil drain plug

13

Taper roller bearing

34

Oil filler plug

14

Crown wheel coupling pinion

35

Taper roller bearing

15

Bevel pinion

36

Spacer

16

Hex nut

37

Radial seal ring

17

Screw cap

38

Wheel shaft

18

Seal ring

39

Wheel pin

19

Ball bearing

40

Wheel shaft guard

20

Cover

41

Gearbox type punching

21

Cap screw

42

Data plate

SERVICE

REDUCTION GEAR

REMOVAL OF THE REDUCTION UNIT


Equipment and tools

open ended spanner


10 mm

tackle
load capacity
1000 kg

2 lifting slings
load capacity
1000 kg

socket wrench
16 mm

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

ratchet

torque wrench

Fig. 1

A
B

Phase 1
Perform the traction wheel dismantling procedure (see DISMANTLING
THE TRACTION WHEEL in the BASE TRUCK MECHANICS section).
Phase 2
Perform the traction motor dismantling procedure (see DISMANTLING
THE TRACTION MOTOR in the BASE TRUCK MECHANICS section).
Phase 3
Perform the steering motor dismantling procedure (see DISMANTLING
THE STEERING MOTOR in the BASE TRUCK MECHANICS section).

Fig. 2

Phase 4
Empty the reducer of all oil (see REPLACEMENT OF REDUCER
OIL).
Phase 5
10 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws fastening the bracket inside the motor compartment (ref.A fig.1). Remove the
bracket (ref.B fig.1).

Fig. 3

SERVICE

REDUCTION GEAR

Phase 6
16 mm SOCKET WRENCH - RATCHET
Disconnect the connector of the centring sensor.
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the plate to the frame (ref.C fig.2).

Phase 7
HOIST - 2 LIFT BELTS - 16 mm SOCKET WRENCH - RATCHET
Secure the reduction unit plate with the two lift belts. Attach the belts to
the hoist (fig.3).
Using the hoist, slowly lift the plate together with the reduction unit and
rest it on a work surface.
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the reduction unit to the plate (ref.D fig.4). Remove the plate
and proceed with dismantling the reduction unit.

Fig. 4

INSTALLATION
The screws securing the reduction unit to the plate must
be tightened using a torque wrench to a torque of 88 Nm.

REDUCTION GEAR

SERVICE

REPLACEMENT OF TRACTION MOTOR DRIVE SHAFT RADIAL O-RING


Equipment and tools

small flat blade


screwdriver

brush

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

Phase 1
Perform the traction motor dismantling procedure (see DISMANTLING
THE TRACTION MOTOR in the BASE TRUCK MECHANICS section).

Phase 2
SMALL FLAT BLADE SCREWDRIVER
Using the screwdrivers extract the radial o-ring from it's seat (fig.1) and
proceed with its replacement.

INSTALLATION
In the assembly stage apply a uniform layer of "SHELL
ALVANIA R3" grease over the o-ring radial gasket.

Fig. 1

SERVICE

REDUCTION GEAR

REPLACEMENT OF WHEEL SHAFT RADIAL O-RING


Equipment and tools

workbench

puller

seelant
Loctite 574

hex socket
wrench
8 mm

clamp gudgeon

hammer

small flat blade


screwdriver

brush

ratchet

medium elastic
ring opening pliers

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

Phase 1
Carry out the reduction unit removal procedure (see REMOVAL OF THE
REDUCTION UNIT).
Phase 2
HEXAGONAL 8 mm "T" SECTION SPANNER - RATCHET
Unscrew and remove the screws fastening the reducer box casing (ref.A
fig.1).
Remove the cover (fig.1).

Fig. 1

Phase 3
EXTRACTOR - MEDIUM SIZE ELASTIC RING OPENING PLIERS
Using the extractor remove the conical roller bearing (ref.B fig.2) from
the wheel drive shaft.
Use the elastic ring pliers to remove the elastic ring holding the wheel
drive shaft bearing (ref.C fig.2).
Fig. 2

SERVICE

REDUCTION GEAR
Phase 4
CLAMP GUDGEON - HAMMER
Position the clamp gudgeon against the wheel drive shaft (fig.3) and use
the hammer to expel the shaft out the other side (ref.D fig.4). Retrieve
the wheel shaft protection (ref.E fig.4).
Phase 5
Remove the bevel gear ring (ref.F fig.5).
Retrieve the spacers (ref.H fig.5) and the conical roller bearing (ref.H
fig.5).

Fig. 3
Phase 6
SMALL FLAT HEAD SCREWDRIVER
Using the screwdrivers extract the radial o-ring gasket from it's seat (ref.I
fig.6) and proceed with its replacement.

D E
INSTALLATION
In the assembly stage apply a uniform layer of "SHELL
ALVANIA R3" grease over the o-ring radial gasket.

Fig. 4

During the assembly stage apply "LOCTITE 574" seelant


to the reducer casing cover.

HS

G
Fig. 5

Fig. 6
8

SERVICE

REDUCTION GEAR

CHANGING THE REDCUTION UNIT OIL


Equipment and tools

oil resistant gloves

oil pan

hex socket
wrench
6-12 mm

extension

torque wrench

T handle hex key


5 mm

ratchet

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

Fig. 1

Use caution as the oil in the reduction unit will be hot


after use of the truck. It is advisable to wear gloves that
are resistant to oil and high temperatures.
Do not dispose of used oil in the ground or by pouring it
down the drain. Contact a waste disposal company specialised in the disposal and recycling of industrial oils.

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

SERVICE

REDUCTION GEAR
Phase 2
OIL PROTECTIVE GLOVES - OIL RECOVERY SUMP
Clean the area around the oil filler and drain plugs thoroughly. Place a
suitably sized oil pan beneath the drain plug.
Phase 3
OIL PROTECTION GLOVES - HEXAGONAL 6 mm SOCKET WRENCH
- RATCHET - EXTENSION - TORQUE WRENCH - OIL SYRINGE
Using the hexagonal socket wrench, the ratchet and the extension
unscrew the oil filler plug (ref.C fig.3), remove the cap and the gasket.
Using the same tools unscrew the oil drainage cap (ref.D fig.3), remove
the cap and gasket. Empty the oil sump completely.
Clean the drain plug thoroughly from accumulated impurities that may
have collected during reducer operation and screw back on together with
a new gasket.

D
Fig. 3

The tightening of the oil drain cap must be done using a


torque wrench with a torque tightening power of 22 Nm.

Model
reduction unit

Oil type

Quantity

GK20

Standard and Cold Store

~2.2 litres

GK25

FUCHS
TITAN CYTRAC HSY SAE 75W-90

~3.3 litres

To top up use a pressure aspiration syringe (fig.4), that will easily enable
the gearbox to be topped up with oil.
The correct level and quantity of oil is achieved when the oil surface
reaches the lower lip of the oil filler neck or at worst when the oil pours
out of the oil filler neck.

L
OI

The oil filler plug must be tightened using a torque wrench


to a torque of 22 Nm.
Fig. 4

10

SERVICE

BRAKING SYSTEM

Braking system
KEY TO THE TRACTION MOTOR ELECTROMAGNETIC BRAKE COMPONENTS 2
KEY TO THE LOAD WHEEL ELECTROMAGNETIC BRAKE COMPONENTS 3
OPERATION 4
BRAKING systems 4
REMOVAL OF THE BRAKES 5
REMOVAL OF THE DRIVE WHEEL ELECTROMAGNETIC BRAKE 5
REMOVAL OF THE LOAD WHEEL ELECTROMAGNETIC BRAKE 7

SERVICE

BRAKING SYSTEM
KEY TO THE TRACTION MOTOR ELECTROMAGNETIC BRAKE COMPONENTS

2
3
4
5

Ref.

Description

Retaining screw

Electromagnet

Brake plate

Circlip

Pinion

Friction disc

Dust cover

Disc

SERVICE

BRAKING SYSTEM

KEY TO THE LOAD WHEEL ELECTROMAGNETIC BRAKE COMPONENTS

1
3

Ref.

Description

Electromagnet with brake liner

Brake disk

Spring

Bush

Brake regulator

BRAKING SYSTEM

SERVICE

OPERATION
BRAKE FITTED ON THE TRACTION MOTOR
The electromagnetic brake mounted on the traction motor is only a parking brake and it is a spring-operated
brake.
When the electromagnet is powered, it attracts the brake plate and releases the friction disc, allowing the
latter to rotate freely.
When the power supply to the electromagnet is cut, the springs push the brake plate down onto the friction
disc, thus applying the brake.
BRAKE FITTED ON THE LOAD WHEELS
Tall machines are fitted with electromagnetic brakes on the load wheels for safer braking.
The electromagnet is secured on the base of the wheel pin while the brake disk is secured to the wheel
with screws, the brake regulator and the springs.
Braking is activated by pressing on the brake pedal in the cab, the electromagnet attracts the brake disk
against the brake liner creating friction between these two parts.
BRAKING systems
There are 4 braking systems used:



Release braking
Braking on direction reversal
Emergency braking
Parking brake

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

SERVICE

BRAKING SYSTEM

REMOVAL OF THE BRAKES


REMOVAL OF THE DRIVE WHEEL ELECTROMAGNETIC BRAKE
Equipment and tools
Fig. 1

T handle hex key


5 mm

external circlip
pliers

large flat blade


screwdriver

puller

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

When replacing the rotor, the pinion must also be replaced.


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

Fig. 3

Phase 2
5 mm T-handle hex key
Remove the dust cover.
Using the T handle hex key, unscrew the three screws securing the electromagnetic brake to the traction motor (ref.B fig.3).
Disconnect the connector from the brake and withdraw it from the tab.
Remove the electromagnetic brake from the motor.

SERVICE

BRAKING SYSTEM
Phase 3
EXTERNAL CIRCLIP PLIERS - PULLER
Slide out rotor (ref.D fig.4) from the pinion.
Using the circlip pliers, remove the circlip from the drive shaft (ref.E fig.4).
Using the extractor remove the pinion (ref.F fig.4).

INSTALLATION
After mounting the electromagnetic brake does not require
adjustment.
Fig. 4

SERVICE

BRAKING SYSTEM

REMOVAL OF THE LOAD WHEEL ELECTROMAGNETIC BRAKE


Equipment and tools

hydraulic jack

wooden block

socket wrench for


self-locking ring
nut

ratchet

T handle hex key


6 mm

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

Phase 1
HYDRAULIC JACK - WOODEN BLOCK
Position the hydraulic jack beside the load wheel and lift until the wooden
stock can pass beneath.
Set the wooden block under the clamp, lower the jack to rest the truck
on the block and take up the slack on the jack (fig.1).

Fig. 1

Phase 2
SOCKET WRENCH FOR SELF-LOCKING RING NUT - RATCHET
Using the socket wrench for the self-locking ring nut and the ratchet,
unscrew and remove the ring nut (ref.A fig.2), remove the toothed
washer.
Extract the wheel from the hub and dismantle or replace.
Phase 3
HEXAGONAL 6 mm "T" SECTION SPANNER
Using the T-handle hex key, remove the screws securing the brake disk to
the wheel together with the bush and spring (ref.b fig.3). When removing
the disk, pay attention to the springs (ref.C fig.3).

a
Fig. 2

Fig. 3

SERVICE

BRAKING SYSTEM
Phase 4
8 mm T HANDLE HEX KEY
Using the T-handle hex key, remove the screws fastening the electromagnetic brake at the base of the wheel pin (ref.D fig.4). Disconnect the
connector and remove the brake.

INSTALLATION
The screws securing the brake disk to the wheel must be
tightened using a torque wrench to a torque of 25 Nm. Apply Loctite 270.

Fig. 4

SERVICE

STANDARD MAINTENANCE

Standard maintenance
OILS AND LUBRICANTS 4
CLEANING PRODUCTS 4
SCHEDULED MAINTENANCE 5
MAINTENANCE PROCEDURES 8
frame, cab, roof assembly 8

STANDARD 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 shortcircuiting and possibly damage or injury.

The batteries generate explosive gases. Keep the vents clean. Keep sparks and flames well away
from the battery compartment. Pay attention not to create any sparks when disconnecting the battery
cables. Disconnect the battery during maintenance work.

Always use a spreader bar and slings to raise the battery vertically with the specific eyelets. Do not
use chains or slings without a spreader bar, you would risk damaging the battery casing. Check that
the battery compartment is clean and dry. When the battery is in service, the aeration plugs must all be
installed. If the aeration plugs are not installed, electrolyte can come out, corroding the battery casing
and compartment.

The acid in the electrolyte can cause injury. If the electrolyte gets spilled it should be cleaned up with
water. Neutralize the acid with a solution of sodium bicarbonate (soda). Areas of the skin that come
into contact with the acid must be rinsed with water immediately. Acid splashed into the eyes must be
washed away with water constantly for at least 10 minutes, then call a doctor.

SERVICE

STANDARD MAINTENANCE

The batteries belong to the counterweight system of the lift truck. When installing a battery that is too
small, the lift truck might not have enough weight for the nominal load. When replacing a battery, see
the truck identification data plate to check that the battery has the rated capacity and correct dimensions. See TRUCK AND LOAD CAPACITY IDENTIFICATION DATA in the PRESENTATION section for the exact battery specifications for the lift truck at issue.

Do not work under a raised carriage. Lower the carriage or use a safety chain to prevent the carriage
from lowering during maintenance work on the mast and on the lifting chains.

Never repair damaged forks using heat or welding. The forks are made of steel that is hardened with
special procedures. Replace damaged forks.

Before servicing the hydraulic system you must eliminate any residual pressure inside it.
Close the valves at the end of the maintenance work.

The maintenance and repair procedures must be carried out only by specialist service technicians with
the relevant authorizations and appropriate training. Repairs carried out incorrectly can create hazardous work conditions for the operator.

Do not utilize a truck if it requires repairs. Affix a DO NOT USE label on the steering wheel. Remove
the key and disconnect the battery.

SERVICE

STANDARD MAINTENANCE

OILS AND LUBRICANTS


Application
OIL for lubrication of the
HYDRAULIC CIRCUIT

Std

Cold
store

Trademark

Type

Shell

TELLUS S2 V 46

Shell

AEROSHELL FLUID 41

OIL for lubrication of the


REDUCTION UNIT

Fuchs

TITAN CYTRAC HSY


SAE 75W-90

GREASE for lubrication of


REDUCTION UNIT OUTER GEAR
(STEERING CROWN WHEEL AND PINION)

Shell

GADUS S2 OGH 0/00

Klber
KlberOIL 4UH 1-150N
Lubrication
VG 150

OIL for lubrication of


LIFTING CHAINS

GREASE for lubrication of


MAST BEARINGS SLIDING GUIDES
RETRACTABLE CARRIAGE BEARINGS SLIDING
GUIDES
BATTERY TRAY SLIDING BLOCKS
SIDE SHIFT GUIDES
SIDE SHIFT SLIDING BLOCKS
GREASE for lubrication of
RETRACTABLE CARRIAGE CYLINDER JOINT
BEARINGS
Insulation of BATTERY TERMINALS

Rexnord Kette

REXOIL VG 150

Klber
Lubrication

KlberOIL 4UH 1-68N


VG 68

Klber
GRAFLOSCON C-SG - 0
Lubrication
ULTRA

Shell

GADUS S2 V100 2

Shell

AEROSHELL GREASE 6

Pure Vaseline

CLEANING PRODUCTS
Casing and plastic cover cleaning - Cleaning of painted truck parts
For general cleaning of the truck, use only dry air, damp rags or degreasing detergents.
Do not use water jets, vapours, solvents or flammable products that may damage the
truck or that can be dangerous for the operator.
Motor and electronic system cleaning
For general cleaning purposes use dry air at low pressure and a clean dry brush.
Do not use wet rags, water jets, vapour, solvents or flammable products that may damage
the truck or that may be dangerous for the operator.
Cleaning MAST AND RETRACTABLE CARRIAGE BEARINGS SLIDING GUIDES
Use degreasing solvents.
Do not use water jets, vapour, solvents or flammable products that may damage the small
mast or be harmful to the operator.

SERVICE

STANDARD MAINTENANCE

SCHEDULED MAINTENANCE
= checks and maintenance to be performed by the operator or the person assigned to truck maintenance
(refer to the instructions given in the MAINTENANCE section of the operator's manual)
= checks and maintenance operations that should only be performed by a technician authorised by the truck manufacturer
(refer to the instructions given under the following headings in this section)
x = replacement of parts that should only be performed by a skilled technician authorised by the truck manufacturer
(refer to the instructions given in the sections of this manual)

Maintenance intervals
every
8 hours
1 day

every
every
every
1000 hours 3000 hours 5000 hours
1 year
2 years
3 years

Check the screws and bolts

Check the integrity of the cab and frame fixing supports

Check the conditions of the guides for sliding the retractable


carriage

Clean the guides for sliding the retractable carriage

Check the height of the outriggers off the ground

(1)

BRAKING SYSTEM

Visually check the main welds

MOTORS

HYDRAULIC SYSTEM

FRAME, CAB, OVERHEAD GUARD

Operation description

Dynamic braking action check

Reverse braking action check

Normal braking action check

Emergency braking action check

Electromagnetic parking brake and coil efficiency check


Load wheels brake liner wear check

REDUCTION
UNIT

(2)

Oil leak check

Valve operation check

Tank oil level check

Check the condition and tension of the hoses(3)

Tank oil change

Renew oil filter cartridge

Renew plug with air cleaner

Motor insulation check

Cable connection check

Fixing nut condition check

Bearing noise check

General cleaning

Oil leak check

Check oil level

Change oil in reduction unit(4)


General cleaning

Check reduction unit outer gear teeth wear (steering crown


wheel and pinion)

Check condition and wear of drive wheel(2)


WHEELS & TYRES

Electromagnetic parking brake liner wear check(2)

Check drive wheel fixing nuts

Check condition and wear of load wheels(2)


Check load wheel fixing nuts

Check conditions of load wheel bearings(2)

Check condition and wear of steering side rollers

(2)

Check steering side rollers fixing nuts


Check condition of steering side rollers bearings

(2)

SERVICE

STANDARD MAINTENANCE

Maintenance intervals
every
8 hours
1 day

Operation description

Check the screws and bolts

Check conditions of bearings of retractable carriage and


mast(2)

Check the fork support device screws

Check play of side shift outrigger sliding blocks

GREASING POINTS

RETRACTABLE CARRIAGE,
MAST, FORKS

fork support
device

Adjust retractable carriage side rollers


Check chain tensioner conditions(2)
Check lifting chain link and pin wear

(2)

Check lift chains stretch

Check conditions of chain pulleys, tubes and cables

Clean mast bearings sliding guides

Check conditions of mast bearings sliding guides

Check fork condition

Check wear of side shift upper and lower sliding blocks(2)

Check conditions of fork support device bearings

(2)

Grease reduction unit outer gear (steering crown wheel and


pinion)

Grease battery tray sliding blocks

Grease retractable carriage cylinder joint bearings

Grease retractable carriage bearings sliding guides

Grease mast bearings sliding guides

Lubricate lifting chains

Grease side shift guides

CONTROLS,
INSTRUMENTS

CAB

ELECTRICAL
SYSTEM

Check the seat conditions and operation

Check seat belt conditions and operation

Check machine functions with actuating controls and


instrumentation

Battery plug/socket integrity check

Check conditions of electrical power connections

Check conditions of electronic controllers auxiliary


connections

Electrical wiring check

Sensor operation check

General cleaning of electrical panel

Battery charge check

Cable connection check


BATTERY

Check side shift and tilt cylinder rods and check steering
bushes(2)

Grease side shift sliding blocks

every
every
every
1000 hours 3000 hours 5000 hours
1 year
2 years
3 years

Liquid leaks check

Electrolyte density check

Electrolyte level check

(5)

Battery insulation check

General cleaning

SERVICE

STANDARD MAINTENANCE

Maintenance intervals

SAFETY DECALS

Operation description

every
8 hours
1 day

every
every
every
1000 hours 3000 hours 5000 hours
1 year
2 years
3 years

Check safety labels and decals

Clean safety labels and decals

(1)

check also when replacing the drive wheel

(2)

replace if necessary

replace in the following situations:


a shift of the connection on the pipe;
the presence of damage, cuts or abrasions on the superficial layer;
hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
the presence of cracks, damages or strong corrosion on the connection;
the presence of leaks along the pipe or at the coupling joint;
the presence of permanent creases, compression, flattening or twists in the pipe;
the presence of blisters, softening, wear of the external coat.
(3)

(4)

change recommended after 7500 hours or 5 years

(5)

fill up whenever the electrolyte levels falls to 5-10 mm (0.19-0.39 in) from the splash guard

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

STANDARD MAINTENANCE

SERVICE

MAINTENANCE PROCEDURES
frame, cab, roof assembly
CHECK HEIGHT OF OUTRIGGERS OFF GROUND
Equipment and tools
Fig. 1

caliper

open-ended spanner
46 mm

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

Phase 1
CALIPER
Check that the two outriggers have not been damaged and have not
come loose.
Use the caliper to measure the height of the outriggers off the ground
(fig.2).
The correct value of X is given in the following table:
Model

X = 27 mm

X = 20 mm

X = 10 mm

1.4-1.6 ton

5000 < h3 < 8200 8200 < h3 < 9400

h3 > 9400

1.6 ton Narrow

5000 < h3 < 7100 7100 < h3 < 8200

h3 > 8200

2.0-2.5 ton

4650< h3 < 7500

h3 > 7500

1.6 ton HD

h3 > 8200

h3 > 8200

2.0 ton HD

h3 > 8200

h3 > 8200

A
X 2 mm

B
floor

Fig. 2

h3 = lift height (see MAST MECHANICS section).

Phase 2
46 mm open ended spanner
Loosen the outrigger locking nut with the open ended spanner (ref.A fig.2). Unscrew or screw in the outrigger (ref.B fig.2) to reach the desired height. Tighten the locking nut.
8

SERVICE

STANDARD MAINTENANCE

CHECK CHAINS
Equipment and tools

caliper

Replace the chains if they have stretched beyond 3% of their length or if the links, hinge pins or chain
tensioner are worn to such an extent that replacement is indispensable
Measure the extension with a callipers (fig.1) on many sections 10 steps apart taken in the more stressed
sections.
A) Pin wear
B) Pin damage
C) Link damage
D) Link edge wear
E) Wear and ovalization of the links
F) Too much play between the links
G) Oxidization check
H) Wear and ovalization of the chain tensioner
I) Wear of the chain hinge gudgeon

c
h

b
G

Fig. 1

f
e

Fig. 2

Fig. 3

If chains are not excessively worn and stretched, replace them every 3 years (5000 hours) under normal
working conditions. Replace chains every 2 years (3000 hours) when the truck is used in cold rooms or
in corrosive environments.

STANDARD MAINTENANCE

SERVICE

CHECK FORKS
Equipment and tools

rule

There must be no cracks in the structure of the forks and particularly at welded joins (ref.A fig.1). If any
cracks are visible, replace the fork. Do not attempt any repairs by welding;
Measure the thickness of the heel (ref.B fig.1). If the thickness of the heel is less than 90% of the thickness
of the vertical bracket (ref.C fig.1) replace the fork.
The fork tips must be aligned to within 3% of the length of the fork at the time of installation on the carrier
plate (ref.D fig.1). Do not attempt to correct the alignment of the forks by altering the angle of the bend or
the connection between the carrier plate and the forks. Certain improvements can be obtained by shifting
the forks from one side of the carrier plate to the other, or by selecting other forks of corresponding length
from the equipment store.
In cases where there is a permanent deflection between the vertical bracket (ref.E fig.1) and the blade
(ref.F fig.1), the maximum acceptable angle is 93 degrees. If the angle (ref.G fig.1) exceeds 93, the fork
must be replaced.

C
A

E
G

Fig. 1

10

SERVICE

STANDARD MAINTENANCE

11

Code: 550066261

Revision: 0 (01/2014)