Hyster s16 Ac PDF

Part No.
: 1668891 Revision: 1 (03/2010)
Technical information for

Hyster customer care centres
This manual is addressed to the skilled technicians of Hyster

service network
C441..... S1.0 - S1.2

C456..... S1.4 - S1.6
S1.4 I.L. - S1.6 I.L.
PREFACE SERVICE
IMPORTANT
This manual contains detailed information about the routine and preventive maintenance, troubleshooting,
disassembly/assembly of components, adjustment procedures for the following Hyster models:
S1.0 - S1.2 - S1.4 - S1.6 - S1.4 IL - S1.6 IL.
These procedures require specific technical knwoledge and they must be carried out only by qualified and
trained staff. Please read this manual carefully in order to prevent damage or accidents to people; it must
be kept in good conditions so that it is always readable and complete in all its parts.
This manual is an integral part of the use and maintenance manual and it does not replace it.

Product support group
2
SERVICE PREFACE
HOW TO USE THE MANUAL
SECTIONS
This manual is divided in the following sections:
Section1: Introduction
Section 2: Installation and settings
Section 3: Diagnostics and measurements
Section 4: Electrical system
Secttion 5: Hydraulic system
Sezione 6: Frame mechanics
Sezione 7: Mast assembly mechanics
Sezione 8: Reduction gear
Sezione 9: Braking system
Sezione 10: Ordinary maintenance
Always refer to the index with the numbered black bands in order to go to the desired section.
SYMBOLS
It indicates the presence of a danger that can cause accidents to people or damage to the
truck.
It indicates a danger due to high temperatures.
It indicates notes or important information to be taken into consideration.
It indicates that, in the electronic version of the manual, by clicking on this symbol it is possi-
ble to display a filmed sequence.
ASSEMBLY PROCEDURE
For the assembly carry out the disassembly procedure in the reverse order complying with the information
and the notes concerning the correct operation of the truck.
3
PREFACE SERVICE
GENERAL SAFETY STANDARDS

PERSONAL SAFETY
• Always use the personal protective equipment when it is required.
• Pay attention to the squashing risks due to moving parts, oscillations, not correctly fastened materials
when lifting operations are carried out or when the loads are moved.
• Do not wear rings, watches, jewels, unbuttoned or hanging clothes such as scarves, unbuttoned jackets
or smocks with open zips that can get entangled in the moving parts.
• Never carry out cleaning, lubrication or maintenance operations when the battery is connected.
• IIf you use compressed air to clean the parts, wear glasses with lateral guards. The air pressure must
not be higher than 1 bar.
SAFETY IN THE WORKPLACE
• Make sure that all working tools are perfectly efficient and ready to use. Keep the working surfaces
clean and free from the deposits that settle on the truck parts and cause damage.
• Keep sparks, free flames and cigarettes at a distance from fuels or flammable materials such as the
gas of the batteries.
• Make sure that the working area is well ventilated, illuminated, dry and clean. Remove any water pud-
dles or oil spots.
• Make sure that the lifting equipment, devices or machines can bear the load.
• ver use petrol, gas oil or other flammable liquids as detergents: use commercial non-toxic and non-
flammable solvents.
• In case the interventions are carried out of the workshop, lay the truck flat and block it. If it is necessary
to carry out the work on slopes, block the truck and bring it in a flat area as soon as possible within a
certain safety limit.
• Disconnect the batteries and label all controls in order to indicate that an intervention is in progress.
Block the truck and any equipment to be lifted.
• Do not carry out any intervention on the truck when the operators are controlling it, except that they are
qualified operators and help to carry out the intervention.
• During towing operations use only the prescribed attachment points and make sure that the pins and/or
bolts are tightly secured. Lift and move all heavy components by means of a lifting device of proper
carrying capacity. Use the proper eyebolts. Make sure that nobody stays near the load to be lifted.
• Do not twist chains or metal ropes.
• Do not use damaged or bent chains or ropes: do not use them during lifting or towing operations. While
handling them always wear safety gloves.
• Do not accumulate cloths soaked with grease or oil: they represent a risk of fire. Always put them in a
closed metal container.
• The oil must be collected and not be let off in the drain pipes; the industrial oils must be disposed of by
specialized companies under the protection of the law in force in every Country.
• When welding operations are carried out, it is necessary to use proper accident-prevention protections:
protective glasses, helmet, overalls, shoes. The protective glasses must be worn also by the people
who do not carry out the works if they stay near a welding area.
4
SERVICE PREFACE
• Before using the batteries, make sure that the cables are connected to the terminals as described: (+)
with (+) and (-) with (-).
• Do not short-circuit the terminals.
• The gas emanated during a recharge is higly flammable. During the recharge of the battery leave the
battery compartment uncovered in order to use a more efficient ventilation and remove the plugs.
• Do not check the condition of the battery charge by means of “jumpers” obtained by placing metal
objects on the terminals.
• Before any intervention check if there are no short-circuit elements.
• Disconnect the batteries before acting on the electric system.
• For the battery chargers and similar equipment, use only auxiliary electric power supply sources in
order to avoid any electric shocks.
• A fluid passing through a very small hole can be almost invisible but strong enough to penetrate into
the skin; in these cases check the fluid by means of a card or a piece of wood.
• To chek the pressure of the plant use the proper devices.
• BANDS, ROPES AND HANGING ROPES: SUGGESTIONS FOR THE USE

• Register all used hanging ropes, whose features and data are shown on the identification plate.
• Do not use bands, ropes or hanging ropes, whose identification plate has been lost.
• Always use bands, ropes or hanging ropes of proper dimensions. As far as the hanging ropes are con-
cerned, take into consideration the lifting angle and the unbalance of the load.
• The hooks of the hanging ropes must have a proper size according to the hook of the bridge crane and
they must move freely.
• Position the load in the hook mouth.
• Do not place the load on the point of the hook.
• During lifting, do not carry out sudden operations that could tear the ropes and the bands.
• Do not carry out lifting operations with twisted ropes and bands.
• Knots are forbidden.Always protect the ropes and the bands when they are near sharp edges.
• During the movements without load in order to avoid unintentional collisions or hooking, fasten the
hooks to the proper seats and lock them.
Use of hanging ropes with unbalanced load

If unbalanced loads must be lifted it is advisable to reduce the carrying capacity of the hanging ropes:
• Slings with 2 arms, consider them as the slings with 1 arm.
• Slings with 3 and 4 arms, consider them as the slings with 2 arms.
Suggestions for maintenance
Check the bands, the ropes and the hanging ropes according to the law in force in order to determine their
working conditions. Carry out the replacement in the following cases:
• When the components are deformed, cut or when there are cracks, hollows, notches or abrasions on
them.
• When the wear of the components is higher than 10% of the initial dimensions.
• When the sling is overloaded.
5
PREFACE SERVICE
Rope capacity table
Colour
violet 1000 2000 1400 800

green 2000 4000 2800 1600
yellow 3000 6000 4200 2400
grey 4000 8000 5600 3200
red 5000 10000 7000 4000
brown 6000 12000 8400 4800
Working blue 8000 16000 11200 6400
capacity (kg)
orange 10000 20000 14000 8000
orange 12000 24000 16800 9600
orange 15000 30000 21000 12000
orange 20000 40000 28000 16000
orange 25000 50000 35000 20000
orange 30000 60000 42000 24000
Coefficient 1 2 1,4 0,8
Band capacity table
Width
Colour
(mm)
black 35 500 1000 700 400

violet 50 1000 2000 1400 800
black 50 1500 3000 2100 1200
green 60 2000 4000 2800 1600
Working yellow 75 3000 6000 4200 2400
capacity (kg) grey 120 4000 8000 5600 3200
red 150 5000 10000 7000 4000
browm 180 6000 12000 8400 4800
blue 240 8000 16000 11200 6400
orange 300 10000 20000 14000 8000
Coefficient 1 2 1,4 0,8
6
SERVICE PREFACE
Hanging rope capacity table
Colour
violet 1000 1400 2100 2100

green 2000 2800 4200 4200
Working
yellow 3000 3800 6300 6300
capacity (kg)
grey 4000 5600 8400 8400
red 5000 6600 9800 10500
Coefficient 1 1,4 2,1 2,1
Working capacity: the working capacity is calculated with an angle in the centre of 90°.
7
PREFACE SERVICE
DRIVING TORQUE OF SCREWS, NUTS AND CONNECTORS

Before the disassembly of the various parts
Nominal DRIVING TORQUE Nm
and of the bolts and screws, read carefully
the instructions below. diameter
Class 8 Class 10
M3 4 5,2
To tighten the screws use the product LOCTITE 270 in M4 7 9,15
order to ensure the safety of the threaded couplings.
M5 12,14 14,8
If it is not possible to loosen the screws because this
M6 17,2 20,9
product is used, do not add extensions to the tools, but
heat the area (maximum 50°C) in oder to eliminate the M8 31,8 38,1
effect of LOCTITE 270. M 10 50,5 60,3
In the above-mentioned cases use a small quantity of M 12 74,2 88,5
LOCTITE 270 in the assembly phase (30% of the con- M 14 101,2 120,8
nection surface). M 16 138,2 164,9
The driving torque with which the threaded couplings M 18 176,6 203,5
are tightened is very important to ensure the safety of
M 20 225,4 259,7
the truck connection.
M 22 278,8 321,2
The bolts and nuts and the corresponding driving torques
are shown in the tables on this page. M 24 324,8 374,2
M 27 422,3 486,5
M 30 516,1 594,7
DRIVING TORQUE Nm
Preloading
Class 5.8 Class 8.8 Class 10.9
N
M4 0,7 7 3 2400 1,92 1,44 3,07 2,3 4,17 3,13

M5 0,8 8 4 3880 3,88 2,91 6,2 4,65 8,43 6,33
M6 1 10 5 5490 6,58 4,94 10,5 7,9 14,3 10,8
M8 1,25 13 6 9990 16 12 25,6 19,2 34,8 26,1
M8 1 13 6 10700 17,1 12,8 27,4 20,5 37,3 27,9
M 10 1,5 16 8 15825 31,7 23,8 51 38 69 52
M 10 1,25 16 8 16700 33,4 25,1 53 40,1 73 55
M 12 1,75 18 10 23025 55 41,4 88 66 120 90
M 12 1,25 18 10 25150 60 45,3 96 72 130 98
M 14 2 21 12 31400 88 66 140 105 190 145
M 14 1,5 21 12 34125 96 72 155 115 210 155
M 16 2 24 14 42850 135 105 220 165 300 225
M 16 1,5 24 14 45600 145 110 235 175 320 240
M 20 2,5 30 17 66875 270 200 430 320 580 435
M 20 1,5 30 17 74250 295 225 475 355 650 485
= with lubricant
8
SERVICE PREFACE
CORRECT METHOD TO APPLY THE FEMALE CONNECTORS

To ensure an optimum connection between the female connectors and the adapters mentioned in this ma-
nual, it is necessary to carry out the following procedure, which is different from the one for the assembly
of the rigid pipes.
Female connectors without gasket (metal/metal connection)
Screw the nut manually and then tigthen 1/4 turn by means of a spanner.
Female connectors with O-RING
Screw the nut manually and then tighten 1/4 turn by means of a spanner.
In any case make sure that the pipe is correctly aligned before tightening the nut to the adapter.
DRIVING TORQUE
ROTARY METRIC FEMALE CONNECTOR ROTARY METRIC FEMALE CONNECTOR jic

Driving torque Nm 37°
External
Thread Driving torque Nm
diameter
UNF Nominal torque min / max Thread
of the pipe Dimension
UNF Nominal torque min / max
M 12x1,5 6 20 15 -25
M 14x1,5 8 38 30 - 45 7/16-20 -4 15 9 - 21
8 1/2-20 -5 20 13 - 27
M 16x1,5 45 38 - 52
10 9/16-18 -6 30 18 - 42
10 3/4-16 -8 50 30 - 70
M 18x1,5 51 43 - 85
12 7/8-14 -10 69 44 - 94
M 20x1,5 12 58 50 - 65 1.1/16-12 -12 98 63 - 133
14 1.3/16-12 -14 118 73 - 163

M 22x1,5 74 60 - 88
15 1.5/16-12 -16 140 90 - 190
M 24x1,5 16 74 60 - 88 1.5/8-12 -20 210 135 - 285
M 26x1,5 18 105 85 - 125 1.7/8-12 -24 290 200 - 380
20 2.1/2-12 -32 450 300 - 600

M 30x2 135 115 - 155
22
25
M 36x2 166 140 - 192
28
M 42x2 30 240 210 - 270
M 45x2 35 290 255 - 325
38
M 52x2 330 280 - 380
42
ROTARY FEMALE CONNECTOR ROTARY FEMALE CONNECTOR ORFS

BSP Driving torque Nm
Driving torque Nm Thread
Dimension
Thread UNF Nominal torque max.
UNF Nominal torque max
9/16-18 -4 14 16
G1/4 20 15 - 25 11/16-16 -6 24 27
G3/8 34 27 - 41 13/16-16 -8 43 47
G1/2 60 42 - 76 1-14 -10 60 68
G5/8 69 44 - 94 1.3/16-12 -12 90 95
G3/4 115 95 - 135 1.3/16-12 -14 90 95
G1 140 115 - 165 1.7/16-12 -16 125 135
G1.1/4 210 140 - 280 1.11/16-12 -20 170 190
G1.1/2 290 215 - 365 2-12 -24 200 225
G2 400 300 - 500 2-1/2-20 -32 460 490
The values shown in the tables refer to to galvanized steel connectors. Different values
correspond to connectors of different materials.
9
PREFACE SERVICE
HYDRAULIC SYSTEM MAINTENANCE INSTRUCTIONS

Before servicing the hydraulic system you must eliminate any residual circuit pressure.
Using the Allen key provided, open valve “A” to discharge any residual pressure from the fork lifting circu-
it.
Close the valve on completion of the maintenance operations.
10
SERVICE PREFACE
INSTRUCTIONS FOR THE INSTALLATION OF HOSES AND CONNECTORS

Visual check of hoses and connectors: if one of the following conditions occurs, the hose must be im-
mediately disconnected and replaced:
• movement of the connector on the hose;
• there are damage, cuts or abrasions on the surface;
• hardening or stiffness of the hose, burned parts or cracks due to heat;
• cracks, damage or corroded parts on the connector;
• leakages from the hose or connector;
• the hose has permanent folds, squashed or twisted parts;
• presence of bubbles, softening and wear of the external surface.
Pre-installation inspection: before installing a hose it is necessary to check the conditions of the pipes.
First of all check if the type, the size, the reference code and the length are correct and then make sure that
there are no impurities, obstructions, bubbles, external layer peeling-off or other visible defects.
Installation:
Do not twist the hose, otherwise it could break due to pressure.
Consider a proper radius of curvature in order to avoid the bending or breaking. If the radius of curvature
is lower than the minimum radius of curvature allowed, the life of the hose is considerably reduced.
The pressure can change the length of the hose, up to + 2%. Therefore it is advisable to consider a length
which is higher than the required one in order to compensate for such changes.
11
PREFACE SERVICE
12
SERVICE PREFACE
SECTION INDEX
Introduction 1
Installation and settings 2
Diagnostics and measurements 3
Electrical system 4
Hydraulic system 5
Frame mechanics 6
Mast assembly mechanics 7
Reduction gear 8
Braking system 9
Routine maintenance 10
13
PREFACE SERVICE
14
SERVICE PRESENTATION
presentation
TRUCK PRESENTATION�� 2
TRUCK VIEWS�� 3
TRUCK AND LOAD IDENTIFICATION DATA�� 4
TRUCK IDENTIFICATION DATA PLATE�� 4
RESIDUAL LOAD PLATE �� 4
TRUCK AND MAST SERIAL NUMBER STAMP�� 5
DATA LOCATION�� 5
GENERAL SPECIFICATIONS�� 6
1
PRESENTATION SERVICE
TRUCK PRESENTATION
The new range of tiller lift trucks is made up of four models, with nominal loads of 1000kg - 1200kg - 1400kg
- 1600kg:
• S1.0
• S1.2
• S1.4
• S1.6
• S1.4 IL
• S1.6 IL
Electrical system
The traction motor benefits from the use of alternate current three phase AC technology.
The high battery efficiency is guaranteed by the regenerative nature of the breaking system and the energy
retrieval achieved during the cab lowering stage with the forks loaded.
The Combi AcO electronic control system communicates via the CAN-Bus system (Controller Area Network
Bus).
Hydraulic system
The 2 kW and 3 kW pump motors guarantee excellent performance thanks to the technology with ON/OFF or
proportional solenoid valves for the fork lifting/lowering operations with fluid movements of the actuators.
Guidance system
These are lift systems with ground operators. The tiller is mounted on the traction assembly. The low
anchor point of the tiller enables no effort steering. Thanks to the SNAIL function one can also operate in
tight corners.
Mast
The masts can be in one, two or three stages.
The rigidity and stability characteristics of the masts allow the forks to reach heights of over 4 meters.
The lift cylinders are of the type with a simple lift effect with an end point slowing system and a simple
plunger effect with a full shaft.
2
TRUCK VIEWS
3
TRUCK AND LOAD IDENTIFICATION DATA

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

base.
• Manufacturer's name. • Max. weight battery

• Model • Min weight battery
• Serial number • Battery voltage
• Weight without battery • Nominal Load capacity
• Year of manufacture • Persons on board
RESIDUAL LOAD PLATE
The load plate is located on the mast crossbar
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.
4
Always refer to the load plate to be sure to lift an admissible load to an appropriate
height.
TRUCK AND MAST SERIAL NUMBER STAMP
The truck Serial number is located in side the The mast serial number is located on the side
engine compartment. of the external mast.
DATA LOCATION
The truck documentation located in the bat-

tery compartment.
5
GENERAL SPECIFICATIONS
S1.0 - S1.2
6
1.2 model S1.0 S1.2
CHARACTERISTICS
1.3 power: battery, diesel, LPG, petrol, electic Battery Battery

1.4 steering: tiller, accompanied, standing, sitting tiller tiller
1.5 load capacity, load Q (t) 1 1.2
1.6 centre of gravity c (mm) 600 600
1.8 load distance from the load bearing wheel axle x (mm) 714 744 (1)
1.9 distance between the axles (WB) y (mm) 1225 1315
2.1 unladen weight kg 880 960 (3)
WEIGHTS
2.2 load per axle when loaded (front/back) kg 660 / 1220 740 / 1420
2.3 load per axle when unladen (front/back) kg 610 / 270 670 / 290
3.1 covering: full rubber, polyurethane, vulkollan, (front/back) polyur. / polyur. polyur. / polyur.
3.2 front wheel size ø 230 x 75 ø 230 x 75
WHEELS AND
3.3 rear wheel size ø 85 x 100 ø 85 x 100

CHASSIS
3.4 additional wheels (size) ø 150 x 50 ø 150 x 50

3.5 wheels: quantity, (x= traction) (front/back) 1x/2 1x/2
3.6 front wheel tread b 10 (mm) 515 515
3.7 rear wheel tread b 11 (mm) 400 400
4.2 height of the upright assembly when closed h1 (mm) See upright assembly cutaway diagram
4.3 free lift h2 (mm) See upright assembly cutaway diagram
4.4 lifting h3 (mm) See upright assembly cutaway diagram
4.5 height of the upright assembly when removed h4 (mm) See upright assembly cutaway diagram
4.9 height of tiller in operating position (min/max) h14 (mm) 695 / 1196 695 / 1196
4.15 height of lowered forks h13 (mm) 90 90
4.19 total length l1 (mm) 1852 1912 (6)
DIMENSIONS
4.20 length of the forks at the heel l2 (mm) 692 752 (6)
4.21 total length b1/b2 (mm) 800/800 800/800
4.22 fork size s/e/l (mm) 65 / 180 / 1160 65 / 180 / 1160
4.24 fork bearing front assembly width b3 (mm) 675 675
4.25 outer fork gauge b5 (mm) 570 570
4.31 free space beneath the loading assembly m1 (mm) 22 22
4.32 free space beneath the centre of the wheelbase m2 (mm) 30 30
4.33 pallet work channel 1000 x 1200 Ast (mm) 2405 2478 (8)
4.34 pallet work channel 800 x 1200 Ast (mm) 2369 2433 (9)
4.35 turning radius Wa (mm) 1540 1626
5.1 transfer speed with/without load km/h 5.5 / 6 5.5 / 6
PERFORMANCE
5.2 fork lifting speed with/without load m/s 0.13 / 0.18 0.12 / 0.18 (12)
5.3 fork lowering speed with/without load m/s 0.3 / 0.25 0.3 / 0.25
5.8 maximum grade ability with/without load % 7 / 10 7 / 10
5.10 service breaks electromagnetic electromagnetic
6.1 traction motor, S2 60 minutes kW 1.2 1.2
ELECTICAL MOTORS
6.2 lifting motor, S3 15%% kW 2 2

6.3 BS battery, DIN 43531/35/36 A,B,C, no no DIN 43535 B
6.4 battery voltage/nominal capacity V/Ah 24 / 150 (150-200) 24 / 220 (210-250)
6.5 battery weight (+/- 5%) kg 150 (144-185) 222 (212)
6.6 consomption under VDI cyclus kWh/h 1,0 1,1
8.1 type of controls AC ~ Mosfet AC ~ Mosfet
(1)
- 50 mm with 3 stage mast assembly (8)
+ 22 mm with 3 stage mast assembly
(3)
+175 kg with three stage mast assembly (9)
+ 38 mm with 3 stage mast assembly
(6)
+ 50 mm with 3 stage mast assembly (12)
0.10 / 0.18 with 3 stage mast assembly
7
S1.4 - S1.6
8
1.2 model S1.4 S1.4 S1.6
CHARACTERISTICS
1.3 power: battery, diesel, LPG, petrol, electic Battery Battery Battery
1.4 steering: tiller, accompanied, standing, sitting tiller tiller tiller
1.5 load capacity, load Q (t) 1.4 1.4 1.6
1.6 centre of gravity c (mm) 600 600 600
1.8 load distance from the load bearing wheel axle x (mm) 712 (2) 712 (2) 712 (2)
1.9 distance between the axles (WB) y (mm) 1315 1385 1385
2.1 unladen weight kg 1000 (4) 1120 (4) 1120 (4)
WEIGHTS
2.2 load per axle when loaded (front/back) kg 570 / 1830 810 / 1710 875 / 1845
2.3 load per axle when unladen (front/back) kg 695 / 305 760 / 360 760 / 360
3.1 covering: full rubber, polyurethane, vulkollan, (front/back) polyur. / polyur.polyur. / polyur.polyur. / polyur.
3.2 front wheel size ø 230 x 75 ø 230 x 75 ø 230 x 75
WHEELS AND
3.3 rear wheel size ø 85 x 70 ø 85 x 70 ø 85 x 70

CHASSIS
3.4 additional wheels (size) ø 150 x 50 ø 150 x 50 ø 150 x 50

3.5 wheels: quantity, (x= traction) (front/back) 1x+1 / 4 1x+1 / 4 1x+1 / 4
3.6 front wheel tread b 10 (mm) 515 515 515
3.7 rear wheel tread b 11 (mm) 400 400 400
4.2 height of the upright assembly when closed h1 (mm) See upright assembly cutaway diagram
4.3 free lift h2 (mm) See upright assembly cutaway diagram
4.4 lifting h3 (mm) See upright assembly cutaway diagram
4.5 height of the upright assembly when removed h4 (mm) See upright assembly cutaway diagram
4.9 height of tiller in operating position (min/max) h14 (mm) 695 / 1196 695 / 1196 695 / 1196
4.15 height of lowered forks h13 (mm) 90 90 90
4.19 total length l1 (mm) 1944 (7)
2013 (7)
2013 (7)
DIMENSIONS
4.20 length of the forks at the heel l2 (mm) 784 (7) 853 (7) 853 (7)
4.21 total length b1/b2 (mm) 800/800 800/800 800/800
4.22 fork size s/e/l (mm) 65/180/1160 65/180/1160 65/180/1160
4.24 fork bearing front assembly width b3 (mm) 675 675 675
4.25 outer fork gauge b5 (mm) 570 570 570
4.31 free space beneath the loading assembly m1 (mm) 22 22 22
4.32 free space beneath the centre of the wheelbase m2 (mm) 30 30 30
4.33 pallet work channel 1000 x 1200 Ast (mm) 2492 (10)
2558 (10)
2558 (10)
4.34 pallet work channel 800 x 1200 Ast (mm) 2457 (11)
2523 (11)
2523 (11)
4.35 turning radius Wa (mm) 1626 1692 1692
5.1 transfer speed with/without load km/h 5.5 / 6 5.5 / 6 5.5 / 6
PERFORMANCE
5.2 fork lifting speed with/without load m/s 0.15 / 0.22 0.15 / 0.22 0.15 / 0.22
5.3 fork lowering speed with/without load m/s 0.3 / 0.25 0.3 / 0.25 0.3 / 0.25
5.8 maximum grade ability with/without load % 7 / 10 7 / 10 7 / 10
5.10 service breaks electromagnetic
6.1 traction motor, S2 60 minutes kW 1.2 1.2 1.2
ELECTICAL MOTORS
6.2 lifting motor, S3 15%% kW 3 3 3

6.3 BS battery, DIN 43531/35/36 A,B,C, no DIN 43535 B DIN 43535 B DIN 43535 B
24 / 220 24 / 330 24 / 330
6.4 battery voltage/nominal capacity V/Ah
(210-250) (315-375) (315-375)
6.5 battery weight (+/- 5%) kg 222 (212) 288 288

6.6 consomption under VDI cyclus kWh/h 1,3 1,3 1.4
8.1 type of controls AC ~ Mosfet AC ~ Mosfet AC ~ Mosfet
(2)
- 18 mm with three stage mast assembly (10)
+ 8 mm with three stage mast assembly
(4)
(7)
9
S1.4 I.L. - S1.6 I.L.
h4
h3
C
h1
h2
(0)
(0) 2
1
h14
(0)
h5
m1
m2
h13
l2 X
181 Y X2
l1
Wa
R
n
b12
b1
b5
l6
a/2 a/2
Ast
10
1.2 model S1.4 IL S1.6 IL
CHARACTERISTICS
1.3 power: battery, diesel, LPG, petrol, electric Battery Battery

1.4 steering: tiller, pedestrian, standing, sitting tiller tiller
1.5 load capacity, load Q (t) 1.4 1.6
1.6 centre of gravity c (mm) 600 600
1.8 load distance from load wheel axle x (mm) 818 (2) 818 (2)
1.9 wheelbase (WB) y (mm) 1529 1529
2.1 unladen weight kg 1200 (4) 1200 (4)
WEIGHTS
2.2 load per axle when loaded (front/rear) kg 900 / 1700 950 / 1850
2.3 load per axle when unladen (front/rear) kg 800 / 400 800 / 400
3.1 tyres: full rubber, polyurethane, vulkollan (front/rear) polyur. / polyur. polyur. / polyur.
3.2 front wheel size ø 230 x 75 ø 230 x 75
WHEELS AND
3.3 rear wheel size ø 85 x 70 ø 85 x 70

CHASSIS
3.4 additional wheels (size) ø 150 x 50 ø 150 x 50

3.5 wheels: quantity, (x= traction) (front/rear) 1x+1 / 4 1x+1 / 4
3.6 front track width b 10 (mm) 515 515
3.7 rear track width b 11 (mm) 375 375
4.2 height of closed mast h1 (mm) See mast section
4.3 free lift h2 (mm) See mast section
4.4 lifting h3 (mm) See mast section
4.5 height of extended mast h4 (mm) See mast section
4.6 initial lift h5 (mm) 130 130
4.9 height of tiller in operating position (min/max) h14 (mm) 695 / 1196 695 / 1196
4.15 fully lowered forks height h13 (mm) 90 90
DIMENSIONS
4.19 total length l1 (mm) 2052 (7)

2052 (7)
4.20 length to fork heel l2 (mm) 892 (7) 892 (7)
4.21 total length b1/b2 (mm) 860/860 860/860
4.22 fork size s/e/l (mm) 65/195/1160 65/195/1160
4.24 fork arm carriage width b3 (mm) 675 675
4.25 width over forks b5 (mm) 570 570
4.31 ground clearance under mast m1 (mm) 30+130 30+130
4.32 ground clearance at wheelbase centre m2 (mm) 30+130 30+130
4.33 working aisle width with 1000 x 1200 pallet Ast (mm) 2587 (10) 2587 (10)
4.34 working aisle width with 800 x 1200 pallet Ast (mm) 2513 (11) 2513 (11)
4.35 turning radius Wa (mm) 1760 1760
5.1 travel speed with/without load km/h 5.0 / 5.0 5.0 / 5.0
PERFORMANCE
5.2 fork lifting speed with/without load m/s 0.15 / 0.22 0.15 / 0.22
5.3 fork lowering speed with/without load m/s 0.3 / 0.25 0.3 / 0.25
5.8 maximum gradeability with/without load % 7 / 10 7 / 10
5.10 service brakes electromagnetic
6.1 traction motor, S2 60 minutes kW 1.2 1.2
ELECTRIC MOTORS
6.2 lift motor, S3 15%% kW 3 3

6.3 battery BS, DIN 43531/35/36 A,B,C, no no no
6.4 battery voltage/nominal capacity V/Ah 24 / 315-375 24 / 315-375
6.5 battery weight (+/- 5%) kg 267-291 267-291
6.6 consumption per VDI cycle kWh/h 1.3 1,4
8.1 type of control AC ~ Mosfet AC ~ Mosfet
(2)
- 18 mm with three stage mast assembly (10)
(4)
(7)
11
12
SERVICE INSTALLATION AND SETTINGS
installation and
settings
BEFORE INSTALLATION�� 2
WEIGHT TABLE�� 2
MACHINE ASSEMBLY�� 3
LIST OF MATERIALS RECEIVED FROM THE DEALER�� 3
TRUCK UNLOADING�� 4
TOPPING UP THE OIL SUMP�� 5
BATTERY INSTALLATION�� 6
List of the SETTINGS AND ADJUSTMENTS to be carried out�� 9
BATTERY VOLTAGE SETTING�� 9
VERIFY THE TRUCK USE CONDITIONS�� 11
1
INSTALLATION AND SETTINGS SERVICE
BEFORE INSTALLATION
Make sure in advance that all the tools required to unload the battery are readily available (bridge crane,
lift truck, lift belts etc.). Before delivering to the client it is very important to check the suitability of the place
where the carriage is to be installed.
WEIGHT TABLE
Weight Battery weight

Battery voltage/
(excluding
Model capacity
battery) min max
kg V/Ah kg kg
24/150 135 153
S1.0 730
24/200 174 196
24/210 201 223
S1.2 738 (1)
24/250 201 223
24/210 201 223
778 (2)
24/250 201 223
S1.4
24/315 274 302
832 (2)
24/375 274 302
24/315 274 302
S1.6 832 (2)
24/375 274 302
24/315 254 280
S1.4 I.L. 933 (2)
24/375 276 306
24/315 254 280
S1.6 I.L. 933 (2)
24/375 276 306
(1)
+175 Kg for a three stage mast assembly
(1)
+115 Kg for a three stage mast assembly
2
MACHINE ASSEMBLY
LIST OF MATERIALS RECEIVED FROM THE DEALER
4 3
The materials received from the dealer may vary depending on the presence or absence of optional ac-
cessories.
Ref. Description
1 Base truck, assembled mast and forks.

2 Batter extension plug (with lateral extraction)
3 External battery charger
4 Rollerway for lateral battery removal (on request)
3
TRUCK UNLOADING
Equipment and tools
fork lift truck bridge crane lift belt

load capacity load capacity load capacity
3000 kg 3000 kg 3200 kg
Procedure
Before starting work, ensure that you are equipped with

all suitable safety clothing.
Phase 1
ELEVATOR TRUCK WITH 3000 kg load
Load the pallet using the lift truck, raise it and carry it to a safe place, far
from the passage of other vehicles and pedestrian traffic.
Phase 2
BRIDGE CRANE - LIFT BELT
Remove the packaging.
Harness the column with the lift belt (fig.1).
Fig. 1
Ensure that the bridge crane is positioned at right angles
to the truck to be lifted.
Hook the belt to the bridge crane, lift and position the truck gradually off
the ground.
4
TOPPING UP THE OIL SUMP

Before topping up the oil in the hydraulic fluid tank make sure that the forks are completely lowered.
Equipment and tools
oil protecting large Philips

funnel
gloves screw driver
Procedure
Move the carriage to a safe place, away from areas of
transit of other vehicles and the pedestrian route. Set the
key switch to OFF and disconnect the battery.
A
A A
Phase 1
LARGE PHILIPS SCREW DRIVER
Use the Philips screwdriver to unscrew and remove the fastening screws
on the motor compartment cover (ref.A fig.1).
Open the engine cover. Fig. 1
Phase 2
OIL PROTECTING GLOVES - FUNNEL
Unscrew the oil sump cap (ref.B fig.2), place the funnel in the filler hole
and top up the oil level.
Make sure the tank is not too full. B
At the end of the operation screw the tank cap back on.
Fig. 2
5
BATTERY INSTALLATION
Fig. 1
Equipment and tools
bridge crane hexagonal "T"

fixed spanner
load capacity spacer bar section spanner
10 mm
1000 kg 5 mm
Procedure
Fig. 2
B
transit of other vehicles and all pedestrians.
A
Phase 1
5 MM HEXAGONAL "T" SECTION SPANNER - FIXED 10 mm SPAN-
NER
Open the battery compartment (fig.1) Fig. 3
Using the fixed gauge spanner hold the nut firm (ref.A fig.2), with the
hexagonal "T" section spanner loosen and remove the fastening screw
of the battery compartment (ref.B fig.2). Perform the same operation on
the other compartment screw.
Remove the battery compartment cover.
Phase 2
BRIDGE CRANE - SPACER BAR
Hook the spacer bar to the bridge crane.
Hook up the spacer bar to the battery, lift by means of the bridge crane
and position on the battery compartment.
Lower the battery very cautiously into the truck compartment (fig.3).
Unhook the spacer bar from the battery.
Phase 3
on the motor compartment cover (ref.C fig.4).
Open the engine cover. C
Insert and tighten the battery catch. C C
On the initial lift version, before securing the battery in

position, connect the battery and raise the straddle legs to
the maximum height so that they clear the slots located on
the truck base. Fig. 4
6
WITH SIDE EXTRACTION

Equipment and tools
bridge crane
load capacity spacer bar rollerway
1000 kg
Fig. 1
Procedure
Before starting work, ensure that you are equipped with A
Phase 1
ROLLERWAY
Position the rollerway alongside the battery compartment and adjust the
Fig. 2
height from the ground to align with the compartment surface.
Lift the cover over the battery compartment (ref.A fig.1).
Phase 2
BRIDGE CRANE - SPACER BAR
With the key provided unblock the side panel (fig.2)..
Remove the truck base panel (fig.3).
Hook the spacer bar to the bridge crane.
Hook the spacer bar to the battery, lift by means of the bridge crane and Fig. 3
position on the rollerway (fig.4).
Detach the spacer bar from the battery and push carefully into the truck
compartment until the battery stop is reached (fig.5).
Phase 3
Reposition the side panel in its seat and fasten it using the key provi-
ded.
Connect the battery cables to the plug and lower the battery compartment
cover.
7
CABLE CONNECTION TO BATTERY

Fig. 4
The battery poles are marked with the colour red or a symbol + to identify
the positive pole, and with the colour blue or the symbol to identify
the negative pole.
The battery connector cables are in turn marked with a stripe in red for
the connection to the positive pole and a stripe in blue for the connection
to the negative pole.
After connecting the clamps to the battery poles, apply

some Vaseline grease to prevent the risk of oxidation.
Fig. 5
_ Clip colour BLUE

Connection of the cable to
the positive pole
Clip colour RED

+ Connection of the cable to
the positive pole
Negative pole
colour BLUE
Positive pole
_
colour RED
8
List of the SETTINGS AND ADJUSTMENTS to be carried out

Having assembled all the machine's components as described in the preceding pages, one must then
perform the following operations in sequence:
• Battery voltage setting
• Verification of the carriage utilisation conditions
BATTERY VOLTAGE SETTING

BATTERY CHARGE LEVEL INDICATOR
The battery charge indicator does not need adjusting.
The preset value can in any case be modified, but only if strictly necessary, or in other words if the indi-
cation on the battery display of battery fully charged or flat does not correspond to the actual state of the
battery.
Equipment and tools
A
precision flat head large Philips
A A
screwdriver screw driver
Procedure
Fig. 1
With the machine off, using the flat head screw adjust the setting screw
placed on the rear of the display (ref.B fig.3), increasing or diminishing
the volt value per cell (beneath which the display shows the uncharged
state of the battery) according to the following table:
Setting Volt/ cell uncharged battery
K 1.57
L 1.63
M 1.68
N 1.73 (factory setting)
O 1.78
P 1.82
Q 1.84
R 1.86
S 1.89
T 1.91
U 1.93 B
Fig. 3
9
WITH "MDI" MODULE OPTIONAL

If a battery that is not provided by the factory is installed on the carriage, the battery voltage on the COMBI
model 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
Procedure
With the engine turned off connect the programmer
Turn on the machine (ON switch) and select the following parameter:
COMBI /config. menu adjustment / adjust battery
With the tester check the exact tension of the battery on the Combi between the negative pole (-Batt) and
the positive pole as shown on "pin 10" of the connector A (fig.3). 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).
It may happen that by using the truck and running down the battery, after the first complete recharge the
battery charge level indicator may show a value below 100%.
If this happens, with the machine off connect the programmer. Turn the machine on (ON switch) and select
the following parameter:
COMBI / config menu adjustment / bat. max adj.
Increase the regulating level to adapt the charge algorithm to the kind of battery.
10
- BATT
A
24 35
13 23
1 12
Fig. 3
VERIFY THE TRUCK USE CONDITIONS

In order to safeguard the safety of people and goods, before undertaking the following
operations, one should first check:
• the kind of loads that are to moved
• the overall conditions of the warehouse, the aisles and the flooring
Having carried out these assessments verify whether the conditions given are compatible with the perfor-
mance levels set:
• maximum traction speed

• traction acceleration
• reduction of traction speed
• maximum speed of fork lifting/lowering
• acceleration slopes for cab lifting/lowering
• breaking
If necessary reduce the performance by personalising the configuration parameters via the programmer
(see "FUNCTIONS OF A TRUCK " section "ELECTRICAL SYSTEM").
In order not to jeopardize the carriage's safety, the configuration parameter customisation
can only be carried out by exclusively reducing factory values.
Parameter values in excess of those introduced at the factory are not allowed.
11
12
SERVICE DIAGNOSTICS AND MEASUREMENTS
diagnostics and
measurements
DESCRIPTION OF MODULE CONNECTORS�� 2
COMBI MODULE�� 2
MENU TESTER�� 4
COMBI MODULE�� 4
BREAKDOWN SEARCH: DIAGNOSIS SYSTEM FOR COMBI MODULE �� 8
ALARMS�� 8
ANALYSIS AND BREAKDOWN SEARCH FOR ALARMS�� 16
WARNINGS�� 24
ANALYSIS AND BREAKDOWN SEARCH WARNINGS�� 28
ELECTRICAL COMPONENT MEASUREMENTS�� 32
SOLENOID VALVE COILS�� 32
ELECTROMAGNETIC BRAKE COILS�� 32
MOTORS�� 33
INDUCTIVE SENSORS�� 33
1
DIAGNOSTICS AND MEASUREMENTS SERVICE
DESCRIPTION OF MODULE CONNECTORS

COMBI MODULE
A1 Tiller digital input

A2 Positive (+24V) - electromagnetic brake coil power supply
A3 Positive (+24V) - auxiliary functions power supply
A4 Negative (-BATT) - electromagnetic brake coil power supply
A5 Negative (GND) - encoder
A6 Lifting lock removal digital input
A7 Belly switch digital input
A8 Unused
A9 Negative (-BATT) - fork lowering solenoid valve Q2
A10 Positive (+ BATT)
A11 Negative (-BATT) - straddle legs lifting/lowering solenoid valve Q3
2
A12 Main remote control switch coil digital output

A13 Phase B encoder
A14 Phase A encoder
A15 Not used
A16 Mode selector digital input
A17 Forks lifting below 1500 mm sensor digital input
A18 Not used
A19 Not used
A20 ENABLE TRUCK digital input
A21 Not used
A22 Traction motor heat sensor digital input
A23 Not used
A24 Negative (-BATT) - proportional lowering solenoid valve Q1
A25 Positive (+12V) - encoder
A26 Acoustic buzzer digital output
A27 Can Low
A28 Can High
A29 Lifting lock sensor digital input
A30 Not used
A31 Fork lifting below 500 mm sensor digital input
A32 Straddle legs down sensor digital input
A33 Negative (-BATT) - forks lifting solenoid valve Q4
A34 Not used
A35 Lifting lock digital input
3
MENU TESTER
The main input and output signals can be measured in real time using the TESTER function of the program-
mer. 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, other refer to functions di-
rectly connected to the Analog/digital module inputs. The following list shows the relative measurements:
COMBI MODULE
MAIN TESTER MENU
PARAMETER unit measure

BATTERY VOLTAGE Volt
Level of battery voltage measured at the F10 input (key)
BATTERY CURRENT Ampére

Current battery level
MOTOR VOLTAGE %
Voltage supplied to the motor by the inverter; it is expressed as a percentage of the maximum voltage (which de-
pends on the battery voltage)
VOLTAGE BOOSTER %
Level of voltage booster supplied to the motor per load; is expressed as a percentage of the maximum voltage
(which depends on the battery voltage)
FREQUENCY Hz
Current and voltage frequency supplied to the motor
ENCODER Hz
Motor speed, expressed in the same unit as the frequency; this information comes from the motor encoder (feed-
back frequency)
SLIP VALUE Hz
Speed difference between the rotation field and the motor rotor, expressed in the same unit as the frequency
CURRENT RMS Ampére

Actual effective motor current
BATTERY CHARGE %
Battery charge percentage level
TEMPERATURE °C
Temperature of the inverter measured on the aluminium heat sink
MOTOR TEMPERATURE °C
Motor temperature
PUMP CURRENT Ampére

Level of continuous current supplied to the pump motor
4

pump vmn %
Voltage supplied to the pump motor by the inverter; it is expressed as a percentage of the maximum voltage (which
depends on the battery voltage)
set point evp %

Starting value for the EV1 electrovalve
ACCELERATOR Volt - %
Voltage/percentage shift of the traction manipulator
TILLER SWITCH ON/OFF

Lowered tiller sensor digital input level
FORWARD SWITCH ON/OFF

Level of the forward motion input
BACKWARD SWITCH ON/OFF

Level of the reverse motion input
lifting control Volt

Value of the proportional lifting and lowering potentiometer
LIFTING SWITCH ON/OFF

Fast fork lifting selection button
DESCENDENT SWITCH ON/OFF

Fast fork descent selection button
INITIAL LIFT SWITCH ON/OFF

Slow fork lifting selector button (or straddle leg lifting)
INITIAL LOW SWITCH ON/OFF

Slow fork lowering selector button (or straddle leg lowering)
AUX SWITCH FWD ON/OFF

Forward auxiliary traction selection button
AUX SWITCH REV ON/OFF

Reverse auxiliary traction selection button
BELLY SWITCH ON/OFF

Emergency reverse selection button
SNAIL SWITCH ON/OFF

"Snail" mode selection button
HORN SWITCH ON/OFF

Acoustic buzzer selection button
5

truck enable ON/OFF
Truck operation enabling input level.
LEGS DOWN SENSOR ON/OFF

Straddle legs down sensor digital input level
FORK UNDER 500 ON/OFF

Fork lift digital sensor input level below 500 mm
FORK UNDER 1500 ON/OFF

Fork lift digital sensor input level below 1500 mm
TOP MAST SENSOR ON/OFF

Maximum height digital sensor input level
UNLOCK LIFT ON/OFF

Lift unblock input level
BDI LOCK LIFTING ON/OFF

Lift block input level with battery charge dropped below 20%
MODE INPUT ON/OFF

Traction mode input level
SELECT INPUT 1 COMBI ON/OFF

Unused
SELECT INPUT 2 COMBI ON/OFF

Unused
ON/OFF
EMERGENCY ON = contacted closed
OFF = contact open
Emergency button digital input
DIGITAL INPUT FREE ON/OFF

Unused
PWM EVP Ampére

Inverter value with which the proportional valve is piloted.
OUTPUT EV2 - OUTPUT EV6 ON/OFF

EVn electrovalve pilot output state
MAIN CONT VOLT %

The voltage supplied to the electromagnetic break by the inverter; is expressed as a percentage of the maximum
voltage.
6

ELECT. BRAKE VOLT %
The voltage supplied to the electromagnetic break by the inverter; is expressed as a percentage of the maximum
voltage.
CAN BYTE 0/7

Byte value relative to Can Bus - Tiller communication
7
BREAKDOWN SEARCH: DIAGNOSIS SYSTEM FOR COMBI MODULE

The diagnosis system is divided into two main groups:
Alarms
When an alarm is detected, the current to the motors of the modules involved is cut off. The remote-control
switch opens and the electromagnetic break is activated.
These alarms are connected to:
• breakdowns in the motors/modules, the power system is no longer able to supply current to the mo-
tors.
• breakdowns connected with safety.
Warnings
When a warning takes place, the module is working properly but it has detected conditions that lead it to
reduce performance or stock the truck, without affecting the power systems.
These warnings are connected to:
• incorrect starting sequences by the operator.
• conditions that require a reduction of performance (as for example high temperatures, ...)
ALARMS
keyboard
description effect state of the truck
message
The general K2 remote-control
The auto diagnosis system within the • Start up
switch, open power bridge,
machine's logic system has been trig- • Stand-by
WATCHDOG electromagnetic break activa-
gered. • During traction
(8) ted.
Re-start procedure:
Re-start up of the key.
The main K2 remote-control

The auto diagnosis system within the • Start up
machine's logic system has been trig- • Stand-by
WATCHDOG 2 electromagnetic break activa-
gered. • During traction
(8) ted.
Re-start procedure:
The main K2 remote-control On start up, immedia-

This fault in the hardware section of
switch open, open power brid- tely after the closing
the logic card that manages the cur-
ge, electromagnetic break acti- of the K2 main remo-
rent hardware protection.
LOGIC FAILURE #3 vated. te control switch.
(17) Re-start procedure:
Re-synchronisation of the system:
• release all requests (traction and hydraulic)
• forward a traction or a hydraulic request or both
Smart driver open, cannot supply the The main K2 remote-control • Start up
positive input to the electric brake on switch open, open power brid- • Stand-by
pin 2. ge • During traction
SMARTDRIVER KO
Re-start procedure:
(22)
8
keyboard
message
The main K2 remote-control • Start up
Low voltage on the pump motor po- switch open, open power brid- • Stand-by
wer capacitors. ge, electromagnetic break acti- • During lifting/
PUMP VMN LOW vated. lowering

High voltage on the pump motor po- switch open, open power brid- • During lifting/
wer capacitors. ge, electromagnetic break acti- lowering
PUMP VMN HIGH vated.
Incorrect voltage on one of the ou- The main K2 remote-control

tputs of the 3 power phases, a fault switch open, open power brid- • Start up
in the power section or in the motor ge, electromagnetic break acti- • During traction
VMN HIGH coils/connections. vated.

• Start up
The electromagnetic break semicon- switch open, open power brid-
• Stand-by
ductor has shorted out. ge, electromagnetic break acti-
• During traction
AUX DRIV. SHRT. vated.
• Start up
The main K2 remote-control • Stand-by (imme-
The battery voltage is not correct:
switch open, open power brid- diately after the
- Vbatt < 80% Vbatt nom
ge, electromagnetic break acti- closing of the K2
- Vbatt > 120% Vbatt nom
WRONG BATTERY vated. main remote con-
(41) trol switch)
Re-start procedure:

The driver of the electromagnetic bre- switch open, open power brid- • Stand-by
ak coil is damaged. ge, electromagnetic break acti- • During traction
AUX DRIV. OPEN vated.
9
keyboard
message
• Start up
- switch open, open power bridge,
• Stand-by
electromagnetic break activated.
EVP2 NOT OK
Re-start procedure:
(47)

The proportional electrovalve EV1 • Start up
switch open, open power bridge,
output has shorted out. • Stand-by
EVP1 NOT OK
Re-start procedure:
(48)

EV1 proportional valve coil missing. switch open, open power bridge, • Stand-by
electromagnetic break activated. • During traction
EVP1 COIL OPEN
Re-start procedure:
(50)

- switch open, open power bridge, • Stand-by
EVP2 COIL OPEN
Re-start procedure:
(51)

Incorrect output voltage of the "hall • Start up
effect" sensor. • Stand-by
STBY I HIGH
Re-start procedure:
(53)

The motor voltage is not correct ( > 3
switch open, open power bridge, • Initialisation
Volt or < 2 Volt)
WRONG ZERO
Re-start procedure:
(53)
The overvoltage detected by the mo- The main K2 remote-control

dule, appears on the power capaci- switch open, open power bridge, • Start up
tors. electromagnetic break activated.
LOGIC FAILURE #1
Re-start procedure:
(54)
10
keyboard
message
• Stand-by
Fault in the hardware section of the • Immediately after
switch open, open power brid-
logic card that manages the retroac- the closing of the
ge, electromagnetic break acti-
tion of the U,V,W phase voltages. K2 main remote
LOGIC FAILURE #2 vated.
control switch.
(55)
Re-start procedure:
The capacitor voltage does not incre- The main K2 remote-control

ase on start up: a fault in the power switch open, open power brid-
• Start up
section, in the logic card or in the mo- ge, electromagnetic break acti-
CAPACITOR tor. vated.
CHARGE
Re-start procedure:
(60)
Incorrect voltage on one of the ou- The main K2 remote-control

tputs of the 3 power phases, a fault switch open, open power brid- • Start up
in the power section or in the motor ge, electromagnetic break acti- • During traction
VMN LOW coils/connections. vated.

The driver of the main remote-control switch open, open power brid-
• Start up
switch coil has shorted out. ge, electromagnetic break acti-
DRIVER SHORTED vated.

The main remote-control switch coil
switch open, open power brid- • Stand-by
is open, not capable of commanding
ge, electromagnetic break acti- • During traction
CONTACTOR the remote-control switch coil.
vated.
DRIVER
Re-start procedure:
(75)
The power contact of the remote-con- The main K2 remote-control

trol switch is closed on start up, pro- switch open, open power brid-
• Start up
bably a block of the remote-control ge, electromagnetic break acti-
CONTACTOR switch's power contact. vated.
CLOSED
Re-start procedure:
(75)
11
keyboard
message
KEY OFF The key-off signal is always low • Start up
switch open, open power bridge.
SHORTED
Re-start procedure:
(76)
Either the main remote-control switch The main K2 remote-control

• Stand-by
or the electromagnetic break coils switch open, open power bridge,
• During traction
COIL SHOR. has shorted out. electromagnetic break activated.
MC-EB Re-start procedure:
(76) Re-synchronisation of the system:

The electromagnetic break driver has • Stand-by
shorted out • During traction
COIL SHOR. EV.
Re-start procedure:
(76)

The remote-control switch doesn't
switch open, open power bridge, • Start up
close.
CONTACTOR electromagnetic break activated.
OPEN Re-start procedure:

Tiller breakdown switch open, open power bridge, • Stand-by
TILLER ERROR
Re-start procedure:
(77)
The positive of the main K2 remote-

control switch is missing due to the
switch open, open power bridge, • Stand-by
opening of the contact of the emer-
EMERGENCY gency button.
A fault in the encoder or in the con-

nection between the encoder and
switch open, open power bridge, • During traction
module, or in the module input circu-
ENCODER ERROR its.
12
keyboard
message
The smart driver output that supplies
switch open, open power brid-
the positive input to the electric brake • Start up
ge, electromagnetic break acti-
POS. EB. is high when the tiller sensor is open.
vated.
SHORTED
Re-start procedure:
(86)

The driver of the main remote-control switch open, open power brid-
• Start up
switch coil has shorted out. ge, electromagnetic break acti-
POWER MOS vated.
SHORT
Re-start procedure:
(89)

Problem with the analog/digital signal switch open, open power brid-
• During traction
conversion. ge, electromagnetic break acti-
ANALOG INPUT vated.

switch, open power bridge, • Start up
-
electromagnetic break activa- • Stand-by
TEACH ERROR ted.

-
END TEACH ted.
ERROR
Re-start procedure:
(0)

-
END TEACH OK ted.
13
keyboard
message
Test on firmware not carried out cor-
FLASH switch, open power bridge, elec- • Start up
rectly.
CHECKSUM tromagnetic break activated.

Problem in accessing RAM. switch, open power bridge, elec- • Start up
WRONG RAM tromagnetic break activated.
(10)
Re-start procedure:

A motor phase is disconnected. switch, open power bridge, elec- • Stand-by
tromagnetic break activated. • During traction
PHASE KO
Re-start procedure:
(27)

Potentiometer pump out of set range switch open, power bridge
• Always
when in rest mode. open, electromagnetic activa-
PUMP VACC. NOT ted.
OK
Re-start procedure:
(45)

switch open, power bridge
High chopper temperature alarm. • Always
open, electromagnetic brake
TH. PROTECTION activated.

Hardware/software error for snail re- switch, open power bridge, • Start up
quest from tiller. electromagnetic break activa- • Stand-by
HS-TIL MISMATCH ted.

General CAN alarm. • Always
open, electromagnetic brake
NO CAN MSG. activated.
14
keyboard
message
Positive output of electric brake has switch, open power bridge, • Start up
short-circuited. electromagnetic break activa- • Stand-by
AUX BATT. SHORT. ted.

Tiller released for more than two mi- switch closed, power bridge
• Stand-by
nutes. closed, electromagnetic brake
INCONS. TILLER activated.

Inconsistency between the belly si- • Start up
gnal to the combi and what is com- • Stand-by
electromagnetic break activa-
municated by the tiller card. • During traction
BELLY ERROR 2 ted.

Inconsistency between the belly si- • Start up
gnal to the combi and what is com- • Stand-by
municated by the tiller card. • During traction
BELLY ERROR 1 ted.

Belly activated with tiller in rest switch open, power bridge
• Stand-by
mode. open, electromagnetic brake
BELLY ERROR 3 activated.
15
ANALYSIS AND BREAKDOWN SEARCH FOR ALARMS
ALARM breakdown search

“Watchdog”
Cause:
The system is provided with a self-diagnosis circuit. A
microchip tests the self-testing circuit to verify its correct
operation.
This circuit's output changes state if the microchip does
not perform the test correctly. In this case the general This is a failure inside the module, it needs to be repla-
remote-control switch K2 is disabled together with the ced.
power section. The electromagnetic break is activated.
The alarm appears when:
• the circuit output does not correspond to the input
during the initial test on the self-testing circuit (start up
diagnosis - START-UP).
• the circuit's output changes during the stand-by or du-
ring the hydraulic functions (STANDBY AND MOTOR
RUNNING diagnosis).
“Logic failure #3”

This type of failure is not connected to external com-
Cause: ponents, so when it manifests itself the module needs
A hardware problem pertaining to the logic card as a pro- replacing.
tection against high current values (overload).
“Smartdriver ko” • Check the cabling and verify that there is a connection
between the PIN (A2) and the brake.
Cause: • If, even when disconnecting the PIN from the con-
With the Smart driver open, no signal reaches the PIN nector, the output maintains a high value then the
(A2) of the electromagnetic brake. problem is inside the module. Replace the module.
“Pump vmn low” If the problem appears on start up (the remote-control

switch doesn't close at all), check:
• the internal motor connections (ohm continuity).
• The motor's power cabling.
• If the motor cabling is okay, then the problem rest
with the module.
If the problem appears after having closed the remote-
control switch (the remote-control switch closes and
opens immediately after), check:
• The motor cabling.
• If the coil-winding/cables of the motor phases show
Cause: losses towards the trucks bodywork.
The motor pump output is lower than expectred, conside- • If no problem connected with the motors is detected,
ring the PWM applied. then the problem lies inside the module.
If the alarm takes place while the motor is operating,
check:
losses towards the trucks bodywork.
• That the power contact of the remote-control switch
closes correctly, with a good contact.
• If no problem connected with the motors is detected,
then the problem lies inside the module.
16

“Pump vmn high” It is advisable to check:
Cause: • If the coil-winding/cables of the motor phases show
This test is carried out when the motor pump is activated. losses towards the trucks bodywork.
The motor pump output is higher than expected, conside- • If no problem connected with the motors is detected,
ring the PWM applied. then the problem lies inside the module.
“Vmn high” If the problem appears on start up (the remote-control

Cause 1: • The internal motor connections (ohm continuity).
Before closing the remote-control switch, the software • The motor power cable connections
check the power section: it turns on the Mosfets alter- • If the motor cabling is okay, then the problem rests
natively and waits until the phase voltage drops down to with the module.
-BATT. If the voltage of the phases does not drop, this If the problem appears after having closed the remote-
alarm appears. control switch (the remote-control switch closes and
Cause 2: opens immediately after), check:
This alarm may appear even when the start-up diagnosis
has been completed and the remote-control switch is clo-
losses towards the truck's bodywork.
sed. In this situation, the phase voltage should be Vbatt/2.
If it is over this value, an error status is recorded.
“Wrong battery” • Ensure that the value of the COMBI/ config adjustment
menu / set battery type corresponds to the nominal
battery voltage.
• Verify that the COMBI /main tester menu / battery
Cause: voltage parameter is the same as the battery vol-
On start up, the module check the battery voltage and tage measured using the multimeter. If they do not
ensures that it is within a specific range of the nominal correspond, carry out the battery voltage setting
value. procedure (see "BATTERY VOLTAGE SETTING” in
the "INSTALLATION AND SETTINGS" section”).
• Replace the battery.
“Aux driv. open”

Cause: Replace the module.
The electromagnetic break driver is not capable of sup-
plying the load.
“Aux driv. shrt.” • Check if there is a short circuit or a low pull-down

impedance between the PIN (A4) and -BATT.
Cause: • The circuit driver is damaged inside the module, which
The electromagnetic break driver has shorted out must be replaced.
“Evp2 not ok” If the alarm shows, then the problem is inside the module.
Even if this alarm is present, it should never appear. Replace the module.
17

“Evp1 not ok”
Cause 1: Check if there is a short circuit or a low pull-down im-
The EV1 electrovalve driver has shorted out. pedance between the electrovalve coil negative and
-BATT.
Cause 2:
If this is not the case the driver circuit is damaged. Re-
The microcontroller detects an incongruence between the place the module.
EV1 electrovalve setpoint and the driver voltage measured
at the output (A24).
“Evp1 coil open” • Check the cabling and verify that the EV1 electrovalve
coil is connected to the right connector and that there
are no interuptions.
Cause: • If, even connecting the wire to the correct connector
The EV1 proportional electrovalve coil is open. PIN or replacing the wire itself, the alarm persists, the
problem is inside the module. Replace the module.
“Evp2 coil open” If the alarm shows, then the problem is inside the module.
"Stby i high”
Cause: This kind of failure is not connected to external compo-
nents. When it appears the module must be replaced.
The current transducer (hall effect sensor) or the current
power supply circuit are damaged inside the module.
“Logic failure #1” If the alarm appears on start up or in standby, it is very

likely that the problem is due to a voltage drop. In this
case the following checks are advisable:
• Diminishing pulsations of the key input signal (bene-
ath the undervoltage level) due to an external load,
such as the start up of a DC/DC converter, the start
up of a relay or a contactor, charging/discharging of
coils.
• If no change in the voltage is detected on the power
supply line and the alarm is present every time the
Cause: key is placed on ON, then the fault probably lies with
This alarm appears when the module detects over or under the module hardware. In this case the module needs
voltage conditions. The overvoltage limit is 35V, the limit to be replaced.
for undervoltage is 9,5V. If the fault appears while in motion, then it could be due
to over or undervoltage.
• If the alarm appears during acceleration while in trac-
tion, it is most likely due to undervoltage; check the
batter charge and the cabling to the power supply.
• If the alarm appears when the break is released, in
all probability it is due to undervoltage: check the
remote-control switch contacts and the cabling to the
power supply.
18

“Wrong zero”
The voltage during the amplifier output intitialisation stage nents. When it appears the module must be replaced.
(used to measure the traction motor voltage) is greater
than 3 volts or lower than 2 volts.
“Logic failure #2”

This type of failure is not connected to external com-
Cause: ponents, so when it manifests itself the module needs
A fault in the hardware section of the logic card that over- replacing.
sees the retroaction of the phase voltage.
“Capacitor charge”
Cause:
To get a better understanding of the significance of this • There's an external load in parallel with the capacitors,
alarm, take a look at the following diagram: that lowers the module pre-charge circuit current,
preventing its charging. Check if a lamp or a dc/dc
converter or an auxiliary load is connected.
• The charge resistance is open; add a power resi-
stance over the remote-control switch terminals; if
the alarm goes off it means that the module's internal
charge resistance is damaged. Replace the modu-
le.
• The charging circuit is faulty inside the module. Re-
place the module.
When the key is turned on at ON, the inverter tries to load • There's a problem in the module's power section.
the condenser through the power resistance and check if Replace the module.
the condenser has charged within a certain time frame.
If this doesn't happen, the alarm appears; the main K2
remote-control switch is not closed.
“Vmn low” If the problem appears on start up (the remote-control

• the internal motor connections (ohm continuity).
• The motor's power cabling.
• If the motor cabling is okay, then the problem rest
Cause 1: start up testing
with the module.
Before closing the remote-control switch, the software
If the problem appears after having closed the remote-
check the power section: it turns on the Mosfets alter-
control switch (the remote-control switch closes and
natively and waits until the phase voltage rises up to the
opens immediately after), check:
condenser values. If the voltage of the phases does not
increase, this alarm appears.
Cause 2: test in stand-by losses towards the trucks bodywork.
This alarm may appear even when the start-up diagnosis • If no problem connected with the motors is detected,
has been completed and the remote-control switch is clo- then the problem lies inside the module.
sed. In this situation, the phase voltages should be Vbatt/2. If the alarm takes place while the motor is operating,
If they are below this value, an error status is recorded. check:
Cause 3: motor running test • The motor cabling.
When the motor is operating, the power bridge is ON and • If the coil-winding/cables of the motor phases show
the motor power supply voltage is monitored; if it is below losses towards the trucks bodywork.
the set value, an error status is recorded. • That the power contact of the remote-control switch
closes correctly, with a good contact.
19

“Driver shorted” • Check if there is a short circuit or a low pull-down
Cause: impedance between the PIN (A12) and -BATT.
• The circuit driver is damaged inside the module,
The driver of the main K2 remote-control switch coil has
which must be replaced.
shorted out.
“Contactor driver”
The remote-control switch coil driver is not capable of nents; replace the module.
piloting the load. This same device of the piloting circuit
is damaged.
“Contactor closed”
Cause:
Before activating the remote-control switch coil, the module Check the remote-control switch power contacts; re-
verifies if the remote-control switch is blocked. The module place the remote-control switch if necessary.
activates the power section for a few milliseconds trying
to discharge the remote-control switch capacitors If this
doesn't happen an error status is recorded.
“Key off shorted” It is very likely that the problem is due to an undervoltage.
In this case the following checks are advisable:
• Diminishing pulsations of the key input signal (bene-
ath the undervoltage level) due to an external load,
such as the start up of a DC/DC converter, the start
up of a relay or a contactor, charging/discharging of
coils.
Cause: • Check the cabling of the positive and negative bat-
The controller identifies a low logic level of the Key-off tery terminals, of the motor and the module. Ensure
signal during the start up diagnosis stage. that the fastening nuts are secured with a torque of
between 5.6 Nm and 8.4 Nm.
• If no voltage is detected on the power supply line and
the alarm appears at every activation, the problem
is in the module hardware. The module needs repla-
cing.
“Coil shor. mc-eb” If the fault occurs on truck start-up, it is likely that the
Cause: hardware of the overload protective circuit is damaged;
in this case the model needs replacing.
This alarm appears when there is a short circuit on one of
If the fault occurs when the module manages the remote-
the coils connected to the combi outputs (remote-control
control switch (immediately after start-up) or the elec-
switch or electromagnetic break coils). Having removed the
tromagnetic break (traction request), the problem should
cause of the overload, the alarm disappears automatically
be sought in the cabling and with the coils.
after having released and enabled a traction request.
“Coil shor. ev.” If the fault occurs on truck start-up, it is likely that the
Cause: hardware of the overload protective circuit is damaged;
in this case the model needs replacing.
This alarm appears when there is a short circuit on one of
If the fault occurs when the module manages the remote-
the coils connected to the combi outputs (remote-control
control switch (immediately after start-up) or the elec-
switch or electromagnetic break coils). Having removed the
tromagnetic break (traction request), the problem should
cause of the overload, the alarm disappears automatically
be sought in the cabling and with the coils.
after having released and enabled a traction request.
20

“Contactor open” • The cables of the remote-control switch coil are in-
terrupted or not connected, check the coil cabling.
Cause: • The problem could also be connected to a remote-
The main remote-control switch coil is activated by the control switch contact that doesn't work. Try replacing
module, but the remote-control switch doesn't close. the remote-control switch.
“Tiller error” Using a voltmeter check the voltage between the two
Cause: PIN's If the state of one of the inputs is correct, it could be
a problem internal to the module. Replace the module.
Incongruent signals between the PIN (A1) and (A29).
“Emergency” If the alarm appears when the contact of the EMERGEN-

CY BUTTON is shut.
• Ensure that the emergency button is functioning
Cause: correctly.
The state of the emergency button is diagnosed by the • Check the cabling of the emergency button.
input (A3) of the COMBI module; if these inputs are not • Using a multimeter measure the input of the COMBI
+BATT but higher, then an error condition is detected. (A3) module; if it exceeds +BATT and, despite this,
the alarm is present, replace the faulty module.
“Encoder error” • Check both the electrical and mechanical efficiency

of the encoder and of the cabling.
Cause: • Verify the encoder's installation, if the encoder slides
inside its housing, causing an alarm condition.
This alarm is triggered by the following conditions: the
• Even an electromagnetic sound on the sensor bea-
frequency supplied to the motor is greater than 50Hz and
ring can cause the alarm. In these cases, replace the
the encoder's feedback signal shows leaps of more than
encoder.
40 hz in just a few mSec. This behaviour is linked to an
• If the problem persists after the replacement of the
encoder malfunction.
encoder, the fault lies in the module.
“Pos. eb. shorted” • Check the cabling and verify that there is a connection
Cause: between the PIN (A2) and the brake.
• If, even when disconnecting the PIN from the con-
The output voltage of the smart driver that powers the
nector, the output maintains a high value then the
electromagnetic brake coil is high when the tiller sensor
problem is inside the module. Replace the module.
is open.
“Power mos short”

Cause:
Before closing the remote-control switch, the software This kind of failure is not connected to external compo-
checks the power section: it turns on the Mosfets alter- nents; replace the module.
natively and waits until the phase voltage drops down to
-BATT. If the voltage of the phases does not follow the
commands, this alarm appears.
“Analog input”
Cause:
The analog/digital conversion has returned a negative • If the problem appears regularly, the module needs
value on all the signals converted for more than 400 msec. replacing.
The aim of this diagnosis is to find a fault in the A//D con-
verter or a problem in the code that omits the updating of
the conversion of the analog signal.
21

"Teach error" If the alarm shows, then the problem is inside the module.
"End teach error" If the alarm shows, then the problem is inside the module.
"End teach OK" If the alarm appears, then the problem is inside the
Even if this alarm is present, it should never appear. module. Replace the module.
"Flash checksum"
Turn off and restart the truck. If the alarm persists, re-
Cause: place the control.
Problem with the internal testing of the control code
"Wrong RAM"
Cause: Turn off and restart the truck. If the alarm persists, re-
place the control.
The control microprocessor has a problem accessing the
RAM.
"Phase ko" Check the cabling and the connections inside the trac-
Cause: tion motor. If no problem related to the motor is detected,
A motor phase is disconnected.
"Pump vacc. not OK" Check that the proportional buttons are not damaged
Cause: or faulty.
If everything is as it should be, the problem lies inside
Value of proportional raising or lowering potentioameter
the module. Replace.
out of range
"Th. protection" Check the temperature of the control.

Cause: If it is low, the problem lies in the control. Replace the
control.
Temperature of the control higher than 85°.
"Hs-til. mismatch"
Check the cabling of the tiller signal.
Cause: If everything is as it should be, the problem lies in the
There is a snail request from tiller without there being a tiller card. Replace.
matching tiller input (pin A8).
"No Can msg." Check the High CAN - Low CAN cabling and check that
Cause: the resistance is 60Ω.
If no anomaly is detected, then the problem is related
Missing communication via CAN between the tiller cylin-
to the tiller cylinder head or to the control.
der hear and the electronic control.
22

"Aux. batt. short."
With the electromagnetic brake disconnected, check
Cause: that the signal has not short-circuited.
The positive output of the electromagnetic brake has Replace the control.
short-circuited.
"Incons. tiller"
If the allarm shows again within two minutes of turning
Cause: the truck off and starting it up again, the problem is
The tiller is active without any function being requested inside the control. Replace it.
for over two minutes.
"Belly error 2"

Check the tiller cylinder head cabling using a tester
Cause: and the control panel.
Inconsistency between the belly signal to the combi and If no problem with the wire harness is detected, then
what is communicated by the tiller card: input ON while the problem lies inside the cylinder head. Replace it.
tiller states OFF.
"Belly error 1"

Check the tiller cylinder head wire harness using a te-
Cause: ster and the control panel.
Inconsistency between the belly signal to the combi and If no problem with the wire harness is detected, then
what is communicated by the tiller card: input ON while the problem lies inside the cylinder head. Replace it.
tiller states OFF.
"Belly error 3" Check the tiller cylinder head wire harness using a te-
ster and the control panel.
Cause: If no problem with the wire harness is detected, then
Belly request with tiller in rest position the problem lies inside the cylinder head. Replace it.
23
WARNINGS
keyboard
message
BATTERY LOW The maximum current is redu-
The battery is flat • Always
(0) ced by a half.
CHECK UP
Truck maintenance must be perfor- Speed reduction or traction
NEEDED
med. block
(0)
DATA
The alarm appears during data acqui-
ACQUISITION The truck is not operational • Stand-by
sition.
(0)
• Start up
Current sensor not working. The pump motor stops • Stand-by
CURRENT SENS. • During operation
KO Re-start procedure:
• release all hydraulic requests
• carry out a hydraulic request
Lifting/lowering requests are present

The pump motor stops • Always
LIFT + LOWER at the same time.
Release the controls and apply the correct sequence.
The truck is in stand-by with the tiller

K2 main remote-control switch
sensor active for more than 30 se- • Stand-by
open.
conds.
TILLER OPEN
Re-start procedure:
(51)
The pump return current is always 0

Ampére, even when the pump motor The pump motor stops • During operation
is operating.
PUMP I=0 EVER
Re-start procedure:
(52)
Pump boost capacitor current is high • Start up

The pump motor stops
when at rest. • Stand-by
PUMP I NO ZERO Re-start procedure:
24
keyboard
message
The alarm appears when the module
detects a rotor block condition, cau-
sed by a mechanical blockage or a
ENCODER fault in the motor encoder retroaction. The truck stops • During traction
LOCKED When this condition is detected for
(57) more than 5 seconds, an error condi-
tion is signalled.
Re-start procedure:
Release and reapply the traction request.
The module receives a message

from the CAN that another node in
WAITING FOR
the network is faulty; consequently
NODE Depends on the kind of fault • Always
the module itself cannot be operated
(58)
but has to wait for the other module to
exit from its error condition.
The maximum current is redu-

THERMIC SENS.
The heat sensor control output is be- ced by one half and the trucks
KO • Always
yond the limits. traction performance dimini-
(61)
shes.
The maximum current is redu-

MOTOR
High temperature in the traction ced by one half and the trucks
TEMPERATURE • Always
motor traction performance dimini-
(65)
shes.
SENS. MOT TEMP • Start up

The motor temperature sensor is
KO The truck stops • Stand-by
faulty.
(67) • During traction
EEPROM KO Error in eeprom diagnosis on the mo- The module works using de-
• Always
(71) dule logic fault parameters.
The Evn electrovalve coil is absent. Blocked solenoid valve • During operation.
CONT. DRV. EV2 Re-start procedure:

The solenoid valve drive On/Off EV3

Blocked On/Off solenoid val- • Start up
or EV4 orEV5 has shorted out (al-
ves. • Stand-by
DRV. SHOR. ways ON).
EV3/EV4/EV5 Re-start procedure:
The solenoid valve drive On/Off EV2 Blocked On/Off solenoid val- • Start up
or EV6 has shorted out (always ON). ves. • Stand-by
DRV. SHOR. EV26 Re-start procedure:
25
keyboard
message
The Evn electrovalve coil is absent. Blocked solenoid valve • During operation.
CONT. DRV.
Re-start procedure:
EV3/EV4/EV5/EV6
• Start up
INCORRECT Incorrect start up sequence The truck stops • Stand-by
START • During traction
• Start up
Forward/backward motions requests
The truck stops • Stand-by
FORW + BACK are present at the same time.
• During traction
(80)
Re-start procedure:
• Start up
- The truck is not operational
VACC OUT RANGE • Stand-by
The maximum current adjustment

CURRENT GAIN The module works, but with a • Start up
procedure has not yet been carried
(92) lower maximum current. • Stand-by
out.
K2 main remote-control switch

- • Stand-by
open.
DEAD MAN
Re-start procedure:
ABSENT
The value of the traction motor "slip"

parameters are not correct. This • Start up
SLIP PROFILE
alarm is unlikely to appear seeing as The truck stops • Stand-by
(99)
these parameters are set by the pro- • During traction
ducer and cannot be modified.

• Start up
The truck enabling input is missing. • Stand-by
• During traction
TRUCK DISABLED ted.
(/) Re-start procedure:
26
keyboard
message
switch closed, power bridge • Start up
Wrong pump initialisation sequence.
open, electromagnetic brake • Stand-by
PUMP INC. START activated.

Pump control state error at start up.
KEY ON INC. ST. P. electromagnetic break activa- • Stand-by
(94) ted.
Re-start procedure:

Traction control state error at start switch, open power bridge, • Start up
KEY ON INC. ST. T. up. electromagnetic break activa- • Stand-by
(95) ted.
Re-start procedure:

• Start up
Cabling error: fork position not pos- switch closed, power bridge
• Stand-by
sible. open, electromagnetic activa-
• During traction
WIRING INCON. #1 ted.

There is a lift request lasting a longer
time than set by the max lift time pa- • Always
open, electromagnetic activa-
rameter.
LIFTING STOP ted.
27
ANALYSIS AND BREAKDOWN SEARCH WARNINGS
WARNING breakdown search

“Battery low” Recharge the battery. If it doesn't work, measure the bat-
tery voltage using a multimeter and compare it with the
Cause: COMBI / main tester menu/ battery voltage parameter.
If they are different, carry out the battery voltage setting
It appears when the battery charge is calculated beneath
procedure (see "BATTERY VOLTAGE SETTING” in the
20% of full charge.
"INSTALLATION AND SETTINGS" section”).
“Check up needed”
After having carried out the maintenance, set the COMBI
Cause: / main adjustment menu / check up done parameter
This message is only a warning that the time has come to to ON.
carry out the maintenance program.
“Data acquisition”
The alarm disappears when the acquisition is comple-
Cause: ted.
Acquisition of current gains.
“Current sens. ko”

nents; replace the module.
The diagnosis on the current sensor reveals there is a
fault.
“Lift + lower” Check the cabling of the "lifting" and "lowering" requests
(use the MAIN TESTER MENU” to facilitate the brea-
kdown search).
• COMBI / main tester menu / lifting switch
• COMBI / main tester menu / descent switch
Cause: • COMBI / main menu tester / initial lift switch
This alarm only appears when both the fork lifting and • COMBI / main menu tester / initial low switch
lowering requests are activated at the same time. Check the microswitches.
A fault in the card could be possible. Having checked that
the lifting and lowering request switches are working cor-
rectly and the cabling is correct, replace the module.
“Tiller open”
Cause: The traction warning disappears with the next request.
The tiller is at rest, after a set stand-by period (30 seconds)
the remote control switch opens.
“Pump i=0 ever” • Check that there are no interruptions in the pump
motor connections. If the connection is open, the
Cause: current can't flow and the test fails.
The test carried out on the pump motor during operation • If everything is in good condition with the motor, the
verifies if the current on the boost capacitors is not fixed problem could lie with the current sensor or the rela-
at 0. tive circuit.
“Pump i no zero”
In stand-by conditions (pump motor stationary), the return nents; replace the module.
value provided by the current sensor returns a value out-
side allowed limits, because the pump current is not 0.
28

“Encoder locked”
Cause: See the breakdown search referred to the ENCODER
The error message appears when the module detects a ERROR alarm.
motor block due to mechanical blockage of the rotor or a
failure in the encoder feedback.
“Waiting for node”

The AC2 TRACTION module cannot be activated, but
Cause: it has to wait until the other module exits from the error
The module receives the message from the CAN that condition.
another network module is in a breakdown condition.
“Thermic sens. ko”

Cause: This alarm is not connected to external components, the
The interval of the inverter thermal sensor is always module must be replaced.
checked and an alarm is generated if it's beyond the
interval.
“Motor temperature” Check the heat sensor inside the motor ( COMBI para-
meter/main tester menu / motor temperature; check
Cause: the value in ohms of the sensor and the cabling. If the
sensor is OK, improve motor ventilation. If the alarm is
This is a warning that appears when the motor temperature
present when the motor is cold, the problem is located
exceeds 150 °C.
inside the module.
“Sens. mot temp ko”

Check the sensor cabling or that it it has not shorted out
Cause: to the ground.
The diagnosis (undervoltage and overvoltage) on the ther- Replace the sensor.
mal sensor of the motor detects that it is broken.
“Eeprom ko” Try to carry out a reset of the EEPROM (clear eeprom)
Cause: using the programming console. Turn off the key "key-
OFF" and then restart "key-ON" and check the result.
It is due to a defect in the hardware or in the non volatile
If the alarm persists, replace the module. If the alarm
memory software that supports the module parameters.
goes off, the parameters previously memorized will be
This alarm does not block machine operation, but the truck
replaced by default parameters.
operates under default values.
“Cont. drv. EV2/EV3/EV4/EV5/EV6”

Cause: The device of its power supply circuit are damaged.
Replace the module.
The EVn elettrovalve driver is not able to supply the load
(it can't close).
“Drv. shor. EV3/EV4/EV5” • Check if there is a short circuit or a low pull-down

impedance between the coil negative and -BATT.
• This warning appears even if an external laod is not
present but a parameter of the Set Option menu
Cause: relative to the valve has the PRESENT value, in this
case the warning disappears and the parameter is
There is a short circuit in the EVn elettrovalve driver.
set to ABSENT.
• The circuit driver is damaged inside the module,
which must be replaced.
29

“Drv. shor. EV26” • Check if there is a short circuit or a low pull-down
impedance between the coil negative and -BATT.
Cause: • The circuit driver is damaged inside the module, which
The EV2 or EV6 electrovalve driver has shorted out. must be replaced.
“Incorrect start” The possible causes for this are (use the "MAIN TESTER
MENU" to make fault detection easier):
• An active traction request on start up.
Cause: Check cabling. Check the microswitches. It could even
It's an incorrect start sequence alarm. be ascribed to an operator sequence error. A fault in the
card could be possible; if no malfunction is detected,
replace the module.
“Forw+back” Check the cabling of the "forward" and "backwards" (use

the MAIN TESTER MENU” to facilitate the breakdown
search).
• COMBI / main tester menu / forward switch
Cause: • COMBI / main tester menu / backward switch
This alarm only appears when both the (forward and back- Check the microswitches.
ward) motion requests are activated at the same time. A fault in the card could be possible. Having checked
that the traction request switches are working correctly
and the cabling is correct, replace the module.
“Vacc out range” If the alarm shows, then the problem is inside the module.
“Current gain”
Cause: Contact the Zapi service unit to carry out the correct
adjustment procedure for the current gain parameters,
The gain parameters of maximum current have default va-
or replace the module.
lues, therefore the adjustment procedure of the maximum
current has not yet been performed.
“Dead man absent” If the alarm shows, then the problem is inside the module.
“Slip profile”
Contact the Zapi service unit to carry out a check on
Cause: the deviation parameter values of the current gain, or
The deviation parameters of the hardware setting menu replace the module.
are not correct.
30

"Truck disabled" Check the cabling using a tester and the control pa-
nel.
Cause: If no problem with the cabling is detected, then the pro-
Input on A20 pin open blem lies inside the module. Replace it.
"Pump inc. start"

Cause: Check there are no problems with the potentiometer
and that it is secured correctly.
Any request for hydraulic function has been pressed be-
fore the tiller has been lowered.
"Key on inc. st. p” Check cabling. Check buttons. If no problems can be

Cause: found and if the operator performs the correct sequen-
ce, the breakdown is inside the tiller cylinder head.
There is some kind of hydraulic function request at start
Replace it.
up.
"Key on inc. st. t" Check cabling. Check the throttle traction control. If no
problems are found and if the operator has performed
Cause: the correct sequence, the breakdown is inside the tiller
There is a gear request at start up. cylinder head. Replace it.
"Wiring incon. #1"

Cause: Check the cable connections.
The input corresponding to forks below 500 mm is pre- If the problem persists, replace the control.
sent and the input corresponding to forks below 1500 mm
is absent.
"Lifting stop"
Cause: If the lowering button is pressed the truck functions are
There is a request to lift the forks for a longer time than restored.
established by the max lift time parameter (this function
is only active if the lifting block parameter is ON).
31
ELECTRICAL COMPONENT MEASUREMENTS

SOLENOID VALVE COILS
Q2
Q3
Q4
Q1
Q1
ELECTROMAGNETIC BRAKE COILS
Traction wheel electro-

magnetic break
Coil Value measured (Ohm)
Electromagnetic
17,7
break
32
MOTORS
To measure the motor insulation disconnect the cables from the phases (U, V, W). Connect the tester fer-
rule to the U phase and the other ferrule to the bodywork. The resistance value ( ) shown on the tester
must be infinite ( ). Otherwise the motor is not insulated and the module connected to the motor involved
diagnoses the alarm "capacitor charge".
Repeat the operation with the other two phases (V, W).
INDUCTIVE SENSORS
The inductive sensors are powered by a 24V current. They are all of the PNP type with a positive output
signal (10mA).
Nominal Load capacity: 8 mm

Optimal load capacity: 4 mm
Inductive sensor
PNP
Inductive sensor
NPN
33
34
SERVICE ELECTRICAL SYSTEM
electrical system
WIRING DIAGRAMS �� 4
models without initial lift�� 4
models with initial lift�� 6
ELECTRICAL COMPONENTS�� 8
IDENTIFICATION OF ELECTRICAL COMPONENTS�� 8
TILLER DIAGRAM�� 10
CONTROLS �� 12
IDENTIFICATION OF TILLER CONTROLS AND MAIN PANEL�� 12
DISPLAY (battery charge level indicator)�� 14
BATTERY CHARGE LEVEL INDICATOR�� 15
HOUR METER�� 15
MDI (OPTIONAL)�� 16
BATTERY CHARGE LEVEL INDICATOR�� 17
SPEED REDUCTION INDICATOR�� 17
HOUR METER�� 17
WARNINGS INDICATOR�� 17
TRUCK FUNCTIONS�� 18
TRACTION FORWARD/REVERSE�� 18
BREAKING�� 21
STEERING WHEEL�� 24
LIFTING/LOWERING�� 25
CONFIGURATION PARAMETER ACCESS PROCEDURE�� 29
Menu RESEACH PROCEDURE and parameter modification�� 29
STANDARD CONFIGURATION OF MODULE PARAMETERS�� 32
"COMBI AC0" Module�� 32
MODULE PARAMETER DESCRIPTION�� 34
"COMBI AC0" Module�� 34
COMBI AC0 MODULE: INTRODUCTION�� 42
POSITIONING OF THE "PC CONSOLE" CONNECTOR AND CONSOLE�� 43
REPLACEMENT MODULE: INSTRUCTIONS�� 44
REPLACEMENT OF THE COMBI AC0 MODULE�� 44
ELECTRICAL COMPONENT DISMANTLING�� 46
REPLACEMENT OF THE GENERAL EMERGENCY SWITCH�� 46
DISPLAY REPLACEMENT�� 48
1
ELECTRICAL SYSTEM SERVICE
REPLACEMENT OF THE KEY SWITCH�� 49

REPLACEMENT OF THE WARNING BUZZER�� 50
FUSE REPLACEMENT�� 51
tiller diagram: configuration and calibration�� 52
TILLER CARD REPLACEMENT�� 55
REPLACEMENT OF tiller BUTTONS�� 56
REPLACEMENT OF THE TILLER CONTROL SPRINGS�� 57
REPLACEMENT OF THE TILLER ASSENT SENSOR�� 59
RENEWAL OF 'FORKS ABOVE 1500 mm' SENSOR (OPTIONAL) FOR INITIAL LIFT VERSION ONLY�� 60
RENEWAL OF 'FORKS ABOVE 500 mm' SENSOR (OPTIONAL) FOR INITIAL LIFT VERSION ONLY�� 61
RENEWAL OF THE 'FORKS LOWERED' SENSOR FOR INITIAL LIFT VERSION ONLY�� 62
2
3
WIRING DIAGRAMS
models without initial lift
COMPONENTS CONNECTORS
Ref. Description Ref. Description
A1 Combi controller XA1 35 pin male connector

A2 Tiller controller X28 XCJ2 8 pin male connectors
A3 Battery charge level indicator X3 XAJ2
6 pin male connectors
B1 Encoder XJP1
B2 Heat sensor XJP2 XJP10
B4 Tiller sensor 4 pin male connectors
C1 Battery XJP12 X4
F1 Power fuse - 300 A X30 3 pin male connector
F2 5A fuse for 24V power supply to keyswitch X31 XJP11
10 A fuse for 24 V power supply to solenoid
F3 XJP13 XJP14
coils
F4 3 A fuse for 24 V power supply to horn relay XJP15 XJP16 2 pin male connectors
3 A fuse for 24 V power supply to battery char-
F5 XJP17 X6
ge level indicator
K1 Horn relay X7 X14
K2 Main remote control switch coil XFF7 XFF20
K3 Recycling diode XFF8 XFF9
M Complete traction motor XFF10 XFF11
M1 Traction motor XFF15 XFF16
M2 Pump motor XFF18 XFF19
P1 Horn XTF22 XTF23 female terminals
Q1 Solenoid valve 1 XTF24 XTF25
R1 Varistor XTF26 XTF27
R2 Electromagnetic brake XTF28 XTF29
R3 Resistor 120 Ω XFF2 XFF3
S Button not used XFF12 XFF13
S1 Emergency button XTR1 XTR4
ring terminals
S2 Battery charger socket-plug microswitch XTR14 XTR17
S3 Keyswitch
S5 Proportional lift button
S6 Proportional lowering button
S7 On-off lift button
S8 On-off lowering button
S9 Horn button
S10 Belly switch
S11 Snail button
S12 Auxiliary function forward button
S13 Auxiliary function reverse button
T1 Battery charger
4

24V +Batt.
24V +Batt. 240 24V +Batt.
2.1
24V +Valv. 5-A 5 24V +Valv.
2.1
24V +Aux. 3
24V +Key 10 10 24V +Key

-XTF29 -XTF25 -XTF23 2.1
2
280-B 12V +Enc.

2.1
-F5 -F3 -F2
3A 10A 5A
M
-M1 3 -B1 -B2
1
-XTF28 -XTF24 -XTF22 -XFF19 *

-M
1
35
W
V
U
36
1
-X4 -X6
-XFF16 -XTF26
* When T1 and S2 are not present (no load on
2
1
2
4
1
-XTR17
37
board) connect XFF19 to terminal 30 of S3.

2
1
-S1 -F4 -S2

-K2
10-Q
/2.8
5-D
** As reference use the colour X of the indi-
10
10-P
2
-XTR14
-XFF15 -XTF27 vidual wire (or the number printed on it, if the
** wire is black)
4
G
Br
2
Y
-XFF8
280-A
102-B
578
101
367
577
30
L+
-K1
/2.7
30
30
87a
87
-XFF9
-S3
15.54
M
-M2
201
-C1 -XFF10
XFF18
10-A
-P1 -R1
U 280-B 280-B 280-B
10-E
-XFF11 /.7
14
25
10
22
31
17
32
29
13
6
-XA1
L-
NENC
GND Encoder
+12V
PENC
S.<1500mm forks
Remove lift block

Thermal sensor in
S.<500mm forks
S.top mast level

S.legs down
Encoder B
Encoder A
THMOT
ENC A
ENC B
DI4
DI9
+KEY
DI8
DI3
DI2
W
+B
V
-P
-A1
-T1
-B
14
-XTR4 -XTR1
/.7
0V -Batt. 102-B
0V -Batt.
0V -Batt. 102-A 0V -Batt.
0V -Batt. 2.1
0V -Batt. 13-B 0V -Batt.
0V -Batt. 2.1
0V -Batt. 13-U 0V -Batt.
2.1
0V -Batt. 13-H 0V -Batt.
2.1
4a
1.12
24V +Batt. 240 24V +Batt. 3.1
1.12
24V +Valv. 5
24V +Key 10 10 10 10 24V +Key

1.12 3.1
10-C 24V +Aux.
3.1
12V +Enc. 280-B 280-B 280-B 280-B 12V +Enc.
1.12 3.1
10-B
5-E
-XFF3 -XFF12
1
1
-X7 -X14
86
-R2 -Q1 -K3 -K1 -K2
85
-X7 -X14
-XFF2 -XFF13
2
*
* As reference use the colour X of the indi-
3
4
vidual wire (or the number printed on it, if the
wire is black)
200-A
200-B
5-B
721
840
843
800
24
11
33
34
15
18
19
21
30
23
26
12
16
8
3
-XA1
LOWER EVP1
Flash diagnosis
- main cont. coil
HORN OUT
Optional in
Optional in
Optional in
Optional in
Optional in
CPOTTR
Mode In
CPOTL
+ Aux.
PAUX
NMC
EVP2
DI10
+ Brake
- horn
- Brake
DI11
DI12
- Q1
NEB
EV1
EV3
EV5
EV2
EV4
DI5
PEB
- Q5
- Q2
- Q6
- Q3
- Q4
-A1

1.12 3.1
1.12 3.1
0V -Batt. 13-U 0V -Batt.
1.12 3.1
0V -Batt. 13-H 0V -Batt.
1.12 3.1
4b
2.12
24V +Batt.

2.12 24V +Key 10 wire is black)
2.12
24V +Aux. 10-C
10-M
10-D
2.12
12V +Enc. 280-B 280-B
1
2
-X31
-XFF20
TO CONSOLE/
TO OPTIONAL MDI
UNUSED UNUSED
-S5 -S6
10-C
10-H
10-F
10-I
240
- o + - o + -S7 -S8 -S12 -S13 -S -S
2
1
4
2
4
2
- Hours meter
2
3
1
2
2
- Hours meter
1
+ Key switch
-XJP10 -XJP12 -XJP14 -XJP15 -XJP16 -XJP17 -XJP11 -XJP13
- Relay (out)
-A3
GND
+5V
+5V
GND
+ Relay
GND
+5V
+5V
GND
+5V
+5V
A D A D D D D D D D
+5V
-B
+24V
-X28 -S9
-A2
+24V
4
2
8
1
7
Belly out NO
Belly out NC
Belly out NC
+24V (out)
Snail + tiller
Data out
Data out
Clock in
UNUSED
+24 in
CAN-H
UNUSED
Tiller in
CAN-L
GND
+24V
GND
GND
Sel 0
Sel 2
Sel 1
GND
GND
GND
-P10
-XJP1 -XJP2 -XCJ2 -XAJ2
3
3
G 1
1
1
5
2
7
5
6
1
4
*
Y
o -
540-B
102-A
-X3
519
-X3
TO PC TOOLS
4
6
G 2
5
1
Fe
Y
+
-X30
540-A
541
13-B
C
B
A
540-B -B4
1
900-A
901-A
-R3 -XFF7
Can High 901-B
2
10-F
13-B
Belly switch
Tiller switch
Can Low 900-B
/.3 /.5
35
20
27
28
7
1
-XA1 Snail + Tiller in
CANL
CANH
Enable truck
Lift block
Belly in
DI6
DI7
DI1
DI0
-A1
13-H
13-U
/.3 /.5
2.12
0V -Batt. 102-A
2.12
0V -Batt. 13-B
2.12
0V -Batt. 13-U
2.12
0V -Batt. 13-H
4c
5
models with initial lift
COMPONENTS
A1 Combi controller S8 On-off lowering button

A2 Tiller controller S9 Horn button
A3 Battery charge level indicator S10 Belly switch
B1 Encoder S11 Snail button
B2 Heat sensor S12 Auxiliary function forward button
B4 Tiller sensor S13 Auxiliary function reverse button
B5 'Forks above 500mm' position sensor S14 Lifting release button
B6 'Forks above 1500mm' position sensor S15 Mode selector button
B7 Lift lock sensor T1 Battery charger
B8 'Straddle legs down' sensor
C1 Battery
F1 Power fuse - 300 A
CONNECTORS
F2 5A fuse for 24V power supply to keyswitch
10 A fuse for 24 V power supply to solenoid Ref. Description
F3
coils
F4 3 A fuse for 24 V power supply to horn relay XA1 35 pin male connector
3 A fuse for 24 V power supply to battery char- X28 XCJ2 8 pin male connectors
F5
ge level indicator X19 X3
K1 Horn relay XAJ2 XJP1
K2 Main contactor coil X4 X18
K3 Recycling diode X24 XJP2 4 pin male connectors
M Complete traction motor XJP10 XJP12
M1 Traction motor X33
M2 Pump motor X18A X18B
3-way male connectors
P1 Horn X19A X24A
Q1 Solenoid valve 1 X23 X30
Q6 Solenoid valve 6 X31 XJP11
R1 Varistor XJP13 XJP14
R2 Electromagnetic brake XJP15 XJP16
R3 Resistor 120 Ω XJP17
S Button not used X19B 6-way female connector
S1 Emergency button X18C X24C 4-way female connector
S2 Battery charger socket-plug microswitch X33B X23A 3-way female connector
S3 Keyswitch X24B 2-way female connector
S5 Proportional lift button
S6 Proportional lowering button
S7 On-off lift button
6

24V +Batt.

2.1
24V +Valv. 5-A 5 24V +Valv.
2.1
24V +Aux. 3
5-D
24V +Key 10 24V +Key
-XTF29 -XTF25 -XTF23 2.1
1
-X19
2
2
-X19B 11-A 24V +Valv.
10-Q
1
2.1
10-P
-F5 -F3 -F2
3A 10A 5A 12V +Enc. 280-B 280-B 12V +Enc.
2.1
M
-M1 -B1 -B2
1
3 -X18 -X24
1
-X18C -X24C
11-B
1
1
-XTF28 -XTF24 -XTF22 -XFF19
*
1
-M
35
W
V
U
36
1
-F1 -X4 -X6

-XFF16 -XTF26
300A
2
1
2
4
1
1
1
-XTR17 -X18A -X18B -X24A -X24B -X19A
37
2
1
-F4 **
G
+ + + +
2
Br
Y
-S1 -S2
-K2 3A
-B5 Fe -B6 Fe -B7 Fe -S14 -B8 Fe
/2.11
10
2
-XTR14
- o - o - o - o
-XFF15 -XTF27
4
-X18A -X18B -X24A -X24B -X19A
2
2
3
3
2
2
-XFF8
102-B
280-A
578
101
367
577
19
15
30
L+
-K1
2
2
4
3
2
3
-X18C -X18C -X24C -X24C -X19B
/2.10 -X18 -X18 -X24 -X24 -X19
6
2
2
3
3
87a
30
30
87
* When T1 and S2 are not present (no load on

-XFF9
-S3 board) connect XFF19 to terminal 30 of S3.
M
15.54
-M2
201
13-M
13-N
517
513
516
515
514
13-E
-C1
** As reference use the colour X of the indi-
-XFF10
XFF18
10-A
wire is black)
-P1 -R1
U
280-B
10-E
-XFF11 /.6 /.8 /.9 /.11
14
25
22
10
31
17
29
32
13
6
-XA1
L-
GND Encoder
NENC
PENC
+12V
S.legs down
Encoder A
Encoder B
ENC A
ENC B
THMOT
+KEY
S.<1500mm forks
DI4
DI8
DI3
DI2
DI9
+B
U
W
V
-P
-A1
-T1
-B
14
-XTR4 -XTR1
/.6 /.8 /.9 /.11

0V -Batt. 102-B
0V -Batt.
0V -Batt. 102-A 102-A 0V -Batt.
0V -Batt. 2.1
13-M
13-N
13-E
0V -Batt. 13-B 13-B 0V -Batt.
0V -Batt. 2.1
0V -Batt. 13-A 13-A 0V -Batt.
2.1
6a
4d

1.12 3.1
24V +Valv. 5 5
1.12
5-E
5-F
24V +Key 10 10 10 10 24V +Key
1.12 3.1
1
-X33
-X33B
24V +Valv. 11-A 11-A 24V +Valv. 10-C 24V +Aux.
1.12
1
3.1
12V +Enc. 280-B 280-B 280-B 280-B 280-B 280-B 280-B 12V +Enc.
1.12 3.1
200-B
10-L
200-A
10-B
11-C
11-D
11-E
-XFF6
-XFF3 -XFF12
1
1
1
-X7 -X14 -X8 -X9 -X10 -X11 -X12
1
86
-S15
-R2 -Q1 -K3 -Q2 -Q3 -Q4 -Q5 -Q6 -K1 -K2
3
2
85
-X7 -X14 -X8 -X9 -X10 -X11 -X12
-XFF5 -XFF21 -XFF2 -XFF13
2
2
*
4
3
16
17
18
3
4
-X19B -X19B -X19B -X33B -X33B vidual wire (or the number printed on it, if the
-X19 -X19 -X19 -X33 -X33
wire is black)
3
801
530
840
200-A
5-B
200-B
800
721
843
802
803
804
805
806
24
26
12
16
23
11
33
34
9
8
3
-XA1
LOWER EVP1
HORN OUT
Flash diagnosis
- main cont. coil

Mode In
NMC
+ Aux.
+ Brake
- Brake
PAUX
EVP2
- Q1
EV5
EV3
EV4
EV1
EV2
DI10
- Q6
- horn
- Q2
- Q5
NEB
- Q4
- Q3
PEB
-A1

1.12 3.1

1.12 3.1

1.12 3.1
6b
4e

2.12
2.12
2.12
2.12
2.12
2.12
2.12
0V -Batt.
0V -Batt.
0V -Batt.
24V +Key
24V +Aux.
12V +Enc.
24V +Batt.
SERVICE
240
102-A
-A3
-X28
8
-A1
+ battery sense (>24V)
7
+ Battery sense (24V)
540-B 6
- Hours meter
102-A 5
/.3
/.3
-B
-XA1
10
10-C
280-B
DI7 35 519 4
- Relay (out)
Lift block
3
+ Relay
13-B
2
+ Key switch
1
- Hours meter
540-B
10-H
10-H
10-I
10-I
-X23
-X23
-X23A
-X23A
DI1 20 518 2 2 1 1 10-F
Enable truck
10-C
13-C 13-C 3 3
/.4
/.4
*
-A2
-S5
-XJP1
-XJP10
540-B
-X3
6 1
6 1 1
-
13-B
+24V GND
280-B
5 2 +5V
o
13-B 5 2 2
/.5
/.5
-S9
A
GND
4 4
+
DI6 7 Belly switching 541 4 5 Belly out NC 4

-X31
+5V 2
Belly in
3 3
DI0 1 Tiller switching 540-A 3 3 Snail + tiller 3
D
1 10-M
TO CONSOLE/
TO OPTIONAL MDI
-S11
4
-S6
-XJP12
Data out
1
-
GND
6 Belly out NO
o
2
A
-XJP2
+24V
+
1 4
+24V (out) +5V
-XFF20
-B4
10-D
+
o
3 3
D
Tiller in
-S7
2
Fe
GND
-XJP14
13-A
1
+5V
4
UNUSED
2
D
-X3
-XCJ2
G G
ELECTRICAL SYSTEM
-S8
27 900-A 2 1
CANL CAN-L
-XJP15
Y Y
28 901-A 1 2 1
CANH CAN-H +5V
3 2
D
Sel 0
15 4
-S12
CPOTTR
Can High
GND
Can Low
Optional in
-XJP16
DI11 18
5 1
Optional in Sel 1 +5V
DI5 19
Optional in 6 2
D
DI12 21 GND
Optional in
CPOTL 30 7
-S13
wire is black)
Sel 2
901-B
900-B
Optional in
-XJP17
8 1
GND +5V
-X30
A
2
D
-XAJ2
-R3
2 1 1
UNUSED
-S
2
-XJP11
GND
TO PC TOOLS
1
B GND
3
Data out
2
UNUSED
13-U C
4
Clock in
-S
13
5 Belly out NC
-XJP13
1
XFF7
13-H GND
6
+24 in
2
UNUSED
6c
4f
7
ELECTRICAL COMPONENTS
IDENTIFICATION OF ELECTRICAL COMPONENTS
Ref. Description Ref. wiring diagram
1 Traction motor M1
2 Pump motor M2
3 Electromagnetic break R2
4 Tiller control sensor B4
5 Battery C1
6 Tiller diagram A2
7 acoustic buzzer P1
8 Horn relay K1
9 Key fuse switch - 5 A F2
10 Solenoid valve coil fuse - 10 A F3
11 horn relay fuse - 3 A F4
12 Battery charge level indicator fuse - 3 A F5
13 Power fuse - 300 A F1
14 COMBI AC0 Module A1
15 Battery charger T1
16 General remote control switch - emergency button S1
17 General remote control coil contacts K2
18 Auxiliary general remote control connector contacts
19 Battery charge level indicator A3
20 3 way connector for control panel connection X30
21 2 wayconnector for control panel connection X31
22 'Straddle legs down' sensor (initial lift only) B8
23 'Forks above 500 mm' position sensor ( initial lift only) B5
24 'Forks above 1500 mm' position sensor ( initial lift only) B6
8
24
19 6
18
17 23
16
22
2
7
3
15
13
14
21
8
20 4
12 11 10 9
8a
9
TILLER DIAGRAM
Ref. wiring
Ref. Description
diagram
1 LED display for traction throttle calibration
2 Micro quick reverse mode S10
3 Micro slow progress enabling with vertical tiller S11
4 Tiller control cable connection connector XJP1
5 Tiller enabling sensor connection connector XJP2
6 Unused connector XAJ2
7 Configuration selector bridge
8 Proportional fork lifting button connection connector XJP10
9 Can Bus Connection connector XCJ2
10 Proportional fork lowering button connection connector XJP12
ON/OFF slow lifting button connection connector
11 XJP14
Straddle leg lifting ON/OFF button wiring connector (initial lift only)
ON/OFF slow lowering button connection connector
12 XJP15
Straddle leg lowering ON/OFF button wiring connector (initial lift only)
13 ON/OFF button connection connector for auxiliary functions XJP16
14 ON/OFF button connection connector for auxiliary functions XJP17
15 Unused connector XJP11
16 Unused connector XJP13
17 Micro enabling acoustic buzzer S9
10
2
1
17
16
15
14
13
12
11
10
9
7 6
5 4
11
CONTROLS
IDENTIFICATION OF TILLER CONTROLS AND MAIN PANEL
4 5 6 7
3
1
12
10
Ref. wiring
Ref. Description
diagram
1 Quick reverse button S10
2 acoustic buzzer button S9
3 Forward reverse traction throttle
Slow fork lowering button
4 S8
Straddle leg lowering button (initial lift only)
Slow fork lifting button
5 S7
Straddle leg lifting button (initial lift only)
6 Proportional* fork lifting button S5
7 Proportional* fork lowering button S6
8 Slow progress enabling button with tiller in rest position S11
9 Emergency button S1
10 Key switch S3
* The buttons are of the ON/OFF variety for trucks with nominal load capacity of 1000/1200 kg
13
DISPLAY (battery charge level indicator)
Ref. Description
1 Battery charge level indicator

2 Total work hour indicator
14

The battery charge level is indicated by the display with ten notches,
each of which corresponds to 10%.
When the charge reaches 30% the third notch starts to flash.
When the charge reaches 20% the first two notches start to flash and
the fork lift system is immediately inhibited.
To reset the low battery charge indicator recharge the battery. When
the recharge reaches 100% the low battery charge indicator is reset,
and the fork lift system is restored.
If a battery is installed in the truck that is not provided

by the factory, in order for the battery charge indicator
to work correctly the "BATTERY VOLTAGE SETTING"
procedure performed on installation must be performed (see “INSTALLATION AND SET-
TINGS” section).
HOUR METER
When any function is active (lowered tiller, traction, lift/lowering) the
hour meter flashes, indicating that the battery level indicator is recor-
ding the hours of work.
When the battery charge level display is replaced the

truck working hours will be lost.
15
MDI (OPTIONAL)
1 2
5 6
Ref. Description
1 Total work hour indicator and warnings

2 Battery charge level indicator
3 Light emitting diode - LED in warning state
4 Hour meter
5 Speed reduction status indicator
6 Programmed maintenance and warning status indicator
16

The battery charge level is indicated by the display with ten notches,
each of which corresponds to 10%.
When the battery charge state reaches 30% the battery symbol placed
beneath the notches starts to flash.
When the battery charge state reaches 20% the fork lifting is inhibi-
ted.
To reset the low battery charge indicator recharge the battery. When
the recharge reaches 100%% the low battery charge indicator is reset,
and the fork lift system is restored.
If a battery is installed in the truck that is not provided

by the factory, in order for the battery charge indicator
to work correctly the "BATTERY VOLTAGE SETTING" procedure performed on installation
must be performed (see “INSTALLATION AND SETTINGS” section).
SPEED REDUCTION INDICATOR

The symbol indicates that the speed reduction function is active
(for speed reduction see “TRUCK FUNCTIONS”).
HOUR METER
When any function is active (lowered tiller, traction, lift/lowering) the
hour meter flashes, indicating that the MDI is recording the hours of
work.
When the MDI or COMBI modules are replaced, one can

maintain the truck operating hours and memorize them
on the new modules (see "replacement module:
INSTRUCTIONS").
WARNINGS INDICATOR
The MDI provides an indication of the truck's warning status. When a
warning in generated, the light emitting diode - LED starts to flash and
the spanner symbol appears.
The error code that has generated the warning appears on the dis-
play (XXAYY), comprised of a number that identifies the module (XX)
and one (YY) that identifies the kind of error (see “DIAGNOSTICS"
section).
The error code 16A06 corresponds to the NO COMMU-

NICATION warning. Indicates that there is a communica-
tion problem between the MDI and the COMBI. Verify the
cable connections.
17
TRUCK FUNCTIONS
TRACTION FORWARD/REVERSE
IMPLEMENTATION CONTROLS
Forward travel (operator side) Reverse travel (fork side)
Implementors involved state Initials on diagram
Key switch ON S3
Emergency switch ON S1
Tilted tiller sensor ON* S9
Forward reverse traction throttle forward/reverse rotation
* OFF when the button (S11) "snail" is pressed
18
CONFIGURATION PARAMETERS
Main menu Main menu Config menu Config menu

parameter change tester set options adjustment
acceleration delay battery voltage stop on ramp adjust battery
release braking battery current quick inversion throttle 0 zone
invers braking motor voltage motor selection throttle x point
decel braking voltage booster auxiliary function throttle y point
speed limit braking frequency buzzer function
max speed forwd encoder flash beacon
max speed back slip value brake on release
cutback speed 1 current rms
COMBI
cutback speed 2 battery charge

snail speed temperature
frequency creep motor temperature
acc smooth accelerator
inv smooth tiller switch
stop smooth forward switch
brk smooth backward switch
stop brk smooth snail switch
auxiliary time fork under 500
emb insertion delay fork under 1500
elct. brake voltage
For the regulation values of each individual parameter see the paragraph "standard
configuration of MODULE parameters".
For the description of each individual parameters see "MODULE PARAMETER DESCRIP-
TION".
The maximum traction speed and acceleration are settable through the programmer.
Maximum forward and backward traction speed setting.
COMBI / main menu parameter change / max speed forwd
COMBI / main menu parameter change / max speed back
Acceleration setting
COMBI / main menu parameter change / acceleration delay
19
SPEED REDUCTIONS
There are two levels of speed reduction available on the machine.
• cutback speed 1 Average traction speed reduction(between 50% AND 100 % of the maximum spe-
ed)
• cutback speed 2 Average traction speed reduction(between 5% AND 50% of the maximum speed)
Setting of the speed reductionlevels

COMBI / main menu parameter change / cutback speed 1
COMBI / main menu parameter change / cutback speed 2
In the presence of fork height sensors, when the forks exceed a height of 500 mm a first speed reduction
cuts in cutback speed 1. When the forks exceed a height of 1500 mm a second speed reduction cuts in
cutback speed 2
cutback speed 2
1500 mm
cutback speed 1
h
500 mm
maximum speed
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.
COMBI / config menu adjustment / check up type
NONE: no alarm
OPTION #1: the warning appears after 300 hours
OPTION #2: the warning appears after 300 hours and a reduction in
speed takes place after 340 hours.
OPTION #3: the warning appears after 300 hours, a speed reduction ta-
kes 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
COMBI / config menu adjustment / check up done ON
20
BREAKING
The truck is equipped with four breaking systems:
• Release breaking.
• Breaking on direction reversal.
• Emergency breaking.
• Stationary handbrake.
The truck breaks in a different way depending on which of the above listed systems comes into play.
For further information on the breaking systems see "BREAKING SYSTEMS" “BREAKING SYSTEM”
section.
BREAKING SYSTEMS WHEN DOES IT COME INTO OPERATION?
Release breaking Traction control throttle release
Inversion of the direction of motion through the traction control throt-

Breaking on direction reversal
tle
Through operation of the emergency breaking button

Emergency breaking
A warning has been triggered that requires immediate traction stop-
page.
Stationary handbrake The machine is stationary and no traction control is activated
Through the programmer one can set the deceleration slope of the release breaking, of the partial release
breaking and of the reverse breaking.
Setting the release breaking deceleration slope

COMBI / main menu parameter change / release braking
Setting the partial release breaking deceleration slope
COMBI / main menu parameter change / decel braking
Setting the reverse breaking deceleration slope
COMBI / main menu parameter change / inverse braking
SPEED REDUCTIONS AND BREAKING

When the truck speed is reduced this causes a gradual deceleration of the truck through a breaking process
that can be set by the programmer.
Setting the deceleration slope for speed reduction
COMBI / main menu parameter change / speed limit braking
21
EMERGENCY REVERSE MANOEUVRE

The emergency reverse manoeuvre is a safety function
in the event that the operator, when driving forwards
(direction of the traction wheel), hits an object. If this
happens, by pressing the S10 button, the truck goes into
immediate reverse, with the aim of avoiding the operator
being crushed.
The emergency reverse procedure is activated with the
truck in forward gear, in driving position (tiller sensor B4
active) and the "BELLY SWITCH" button pressed. emergency reverse
function activation
It is possible to program the "emergency reverse" function
button
so that it is possible to go into reverse mode on continuous
basis, with a time delay (approx. 5 seconds) or disabled.
Enabling/disabling of the emergency reverse mode

COMBI / config menu set options / quick inversion none: disabled
belly: active and operated by pressing on the
belly switch button
timed: active and delayed with operation through
the belly switch button
It is possible to program the Belly button function in such a way that the truck performs the direction reversal
or stops.
Enabling/disabling of the emergency reverse mode

COMBI / config menu set options / belly with inv. on: by exerting pressure on the S10 button a
reverse manoeuvre is performed
off: by exerting pressure on the S10 button
the truck is stopped.
BELLY WITH INV. ON BELLY WITH INV. OFF
forward movement forward movement
"Belly Switch" button "Belly Switch" button

pressure pressure
Stopping the truck
direction reversal
22
SNAIL FUNCTION
The "snail" function enables the traction even when the tiller is in the rest position (tiller sensor B4 is not
active). This allows to operator to drive the truck even when there is not enough room to lower the tiller.
The "snail" function is activated by pressing the button on the tiller head (S11). Once the "snail" button is
pressed, the traction request is performed by the potentiometric throttle.
Thanks to the programmer it is possible to set the traction speed in the "snail" mode.
Setting of the traction speed in "snail" mode.
COMBI / main menu parameter change / snail speed
tiller sensor potentiometric throttle (accelerator)
snail function activa-

tion button
23
STEERING WHEEL
To steer to the right or to the left rotate the steering tiller to the right or to the left
Key switch ON S3
Tilted tiller sensor ON B4
Tiller rotation right/left
24
LIFTING/LOWERING
D c A B
To lift the forks quickly press the potentiometric button“A”.

To lower the forks slowly press the pontentiometric button “B”.
To lift the forks slowly press the on/off button “C”.
To lower the forks slowsly press the on/off button “D”.
VERSION WITH INITIAL LIFT

To lift the straddle legs, press the on/off button “C”.
To lower the straddle legs, press the on/off button “D”.
Key switch ON S3
proportional* lifting/lowe-
Quick fork lifting/lowering S5 - S6
ring button active
Slow fork lifting/lowering
or ON/OFF button for lifting/
S7 - S8
Straddle leg lifting/lowering (with initial lift lowering activated
only)
Tilted tiller sensor ON** B4
* The buttons are of the ON/OFF variety for trucks with nominal load capacity of 1000/1200 kg
** Only where the forks are being lowered (OFF if the (S11) “snail” button is pressed)
25
CONFIGURATION PARAMETERS
Main menu Main menu Config menu Config menu

parameter change tester set options adjustment
pu. acceler delay battery voltage auxiliary function adjust battery
pu. deceler delay battery current lifting block
speed limit pump current ev2
initial lift pump vmn ev3
initial lower set point evp ev4
creep speed lifting control
compensation lifting switch
min evp descent switch
max evp initial lift switch
evp open delay initial low switch
evp close delay truck enable
COMBI
lift max time fork under 500

fork under 1500
top mast sensor
unlock lift
bdi block lifting
emergency
pwm evp
output ev2
output ev3
output ev4
output ev5
output ev6
output ev6
For the regulation values of each individual parameter see the paragraph "standard
configuration of MODULE parameters".
For the description of each individual parameters see "MODULE PARAMETER DESCRIP-
TION".
When the tiller is in the rest position, to enable lifting, press the ‘slow’ drive push-button
simultaneously with the normal lifting buttons.
Via the programmer it is possible to set the maximum fork lifting/lowering speed.
Setting the maximum proportional fork lifting speed.
COMBI / main menu parameter change / speed limit
Setting the maximum proportional fork lowering speed
COMBI / main menu parameter change / min evp
COMBI / main menu parameter change / max evp
Setting the maximum on/off lifting/lowering speed for the forks/straddle legs
COMBI / main menu parameter change / initial lift
COMBI / main menu parameter change / initial lower
26
ACCELERATION/DECELERATION SLOPES
By activating the proportional lift button (S5), the forks begin to rise with an acceleration slope that can be
set via the programmer.
Setting the fork lift acceleration slope
COMBI / main menu parameter change / pu. acceler delay
By releasing the proportional lift button (S5), the forks start to stop with a deceleration slope that can be
Setting the proportional fork lift button release deceleration slope
COMBI / main menu parameter change / pu. deceler delay
By activating the proportional descent button (S6), the forks begin to descend with an acceleration slope
that depends on the opening slope of the solenoid valve Q1.
Setting the fork lowering acceleration slope
COMBI / main menu parameter change / evp open delay
By releasing the proportional descent button (S6), the forks begin to stop with a deceleration slope that
depends on the closing slope of the solenoid valve Q1.
Setting the proportional fork lowering button release deceleration slope
COMBI / main menu parameter change / evp close delay
FORK LOWERING AND BUT- FORK LIFT AND BUTTON

TON RELEASE RELEASE
button “ “ON”” stop
settable acceleration slope: “evp settable deceleration slope: “pu.

open delay” deceler delay"
button release
maximum lowering speed setta- maximum lift speed settable:

ble: “min evp” “max evp” “speed limit”
button release
settable deceleration slope: “evp settable deceleration slope: “pu.

close delay” acceler delay”
stop button “ “ON””
27
LIFT BLOCK WITH FLAT BATTERY

When the level of the battery charge drops below 20% the fork lifting is disabled. To restore initial operating
conditions one must recharge the batttery.
When the battery charge reaches 100% the flat battery indicator resets itself and the normal fork operation
is restored.
TIMER LIFT BLOCK

BY activating the lift button (S5/S7) the forks start to rise for a maximum time that may be set with the
programmer.
Setting the maximum proportional fork lift time.
SICOS / main menu parameter change / lift max time
Once this time is elapsed, to continue lifting, one must first press the lowering button and then the lift button
once more.
It is possible to enable/disable the timed fork lift block.

Enabling/disabling of the timer fork lift block
COMBI / config menu set options / lifting block off: disabled
on: enabled
END POINT SLOWDOWN lifting/LOWERING FORKS

In the lifting stage the forks reach the maximum height without any slowdown effect coming into play, the
halt is determined by the mechanical end point of the cylinders.
In the lowering stage the forks reach their descent end point without any slowdown effect, the halt is deter-
mined by the mechanical end point.
VERSION WITH INITIAL LIFT: ‘STRADDLE LEGS DOWN’ AND ‘FORKS ABOVE 1500 mm’ SENSORS
On versions with initial lift, if the straddle legs are in a raised position (‘straddle legs down’ sensor B8 not
activated), and the forks are lifted above 1500 mm (‘forks above 1500 mm’ sensor B6 not activated), the
straddle legs will be lowered to the ground automatically.
If automatic straddle leg lowering is not enabled, when the forks are raised above 1500 mm (‘forks above
1500 mm’ sensor B6 not activated), truck traction will be inhibited until the operator lowers the straddle
legs to the ground (‘straddle legs down’ sensor B8 activated). Various truck operating parameters can be
Setting automatic straddle leg lowering
COMBI / config menu set options / autolo. straddle legs off: disabled
on: enabled
28
CONFIGURATION PARAMETER ACCESS PROCEDURE

Thanks to the CAN BUS connection one may configure the module parameters by connecting the console
to the 3 pin (X30) and 2 pin (X31) connectors proceding with the search of the required menu.
Before connecting the console to the module, position the key switch on “OFF”.
If the optional MDI is installed, disconnect it from the connector X31 before connecting the
console.
Menu RESEACH PROCEDURE and parameter modification

To access the config menu one must press the two buttons top left and top right, then scrol until the desired
menu appears and press "Enter".
To access a main menu one must press "Enter", then scroll until the desired menu appears then press
"Enter".
CA0Z2A ZP1.00
Opening heading
24V 200A 00000
Press the keys "Roll h" and “Set h” at the same

time
*CONFIG. MENU* The SET MODEL menu heading appears.

SET MODEL
Press the "Roll h” or “Roll i” keys until the desired

config menu appears.
*CONFIG. MENU*
The SET OPTION menu heading appears.
SET OPTION
Press the "Enter" key
29
The heading of the first parameter with its current

HOUR COUNTER value appears. To scroll through the parameters
RUNNING press the keys "Roll h” or “Roll i”
Press the keys "Set h” or “Set i” to modify the

value.
HOUR COUNTER
The new value appears.
KEY ON
Press the key "Out" to exit the selection.
ARE YOU SURE?

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

to confirm the choice press the "Out" key.
*CONFIG. MENU* After having pressed the enter key the heading of
SET OPTION the SET OPTION menu reappears.
Press the "Out" key to return to the opening hea-

ding
CA0Z2A ZP1.00
Opening heading
24V 200A 00000
30
CA0Z2A ZP1.00
Opening heading
24V 200A 00000
Press the "Enter"key to enter the main menu
The PARAMETER CHANGE menu heading appe-

*MAIN MENU* ars. If another menu is displayed, press the "Roll h”
or “Roll i” keys until the PARAMETER CHANGE
PARAMETER CHANGE
menu appears.
Press the "Enter" key
The heading of the first parameter with its current

ACCELERATION DELAY
value appears. To scroll through the parameters
LEVEL = 3 press the keys "Roll h” or “Roll i”
Press the keys "Set h” or “Set i” to modify the

value.
ACCELERATION DELAY
The new value appears.
LEVEL = 5
Press the key "Out" to exit the selection.
ARE YOU SURE?

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

to confirm the choice press the "Out" key.
31
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 based on the client's request, the characteristics of the
warehouse and the materials to be moved, but no parameter must be changed if this je-
opardises the safety of the truck.
"COMBI AC0" Module

COMBI / main menu parameter change /
COMBI / config menu set options /
COMBI / config menu adjustment /
MAIN MENU PARAMETER CHANGE

initial initial
PARAMETER std PARAMETER std
lift lift
ACCELERATION DELAY 1,8 1,8 INITIAL LOWER 30% 30%
RELEASE BRAKING 1,1 1,1 AUX SPEED FWD 30% 30%
INVERS BRAKING 0,9 0,9 AUX SPEED REV 30% 30%
DECEL BRAKING 1 1 CREEP SPEED 10% 10%
SPEED LIMIT BRAKING 2,8 2,8 COMPENSATION 10% 10%
MAX SPEED FORWD 100% 100% MIN EVP 5,8% 5,8%
MAX SPEED BACK 100% 100% MAX EVP 43,9% 46,2%
CUTBACK SPEED 1 100% 100% EVP OPEN DELAY 0,5 0,5
CUTBACK SPEED 2 25% 25% EVP CLOSE DELAY 0,0 0,0
SNAIL SPEED 15% 15% LIFT MAX TIME 40 40
FREQUENCY CREEP 0,6 0,6
ACC SMOOTH 1 1
INV SMOOTH 1 1
STOP SMOOTH 10 10
BRK SMOOTH 1 1
STOP BRK SMOOTH 10 10
AUXILIARY TIME 0,4 0,4
EMB INSERTION DELAY 1,6 1,6
PU. ACCELER DELAY 0,5 0,5
PU. DECELER DELAY 0,4 0,4
SPEED LIMIT 100% 100%
INITIAL LIFT 30% 30%
32
CONFIG MENU SET OPTIONS

PARAMETER std initial lift
HOUR COUNTER Running Running
BATTERY CHECK Off Off
STOP ON RAMP On On
QUICK INVERSION Belly Belly
BELLY WITH INV. On On
DRIVE MODE Off Off
AUTOLO. BASE ARMS Off On
AUXILIARY FUNCTION Off Off
BUZZER FUNCTION Option #2 Option #2
FLASH BEACON Option #2 Option #2
LIFTING BLOCK Off Off
BRAKE ON RELEASE Off Off
EV2 Absent Present
EV3 Absent Present
EV4 Absent Present
MOTOR SELECTION 0 0
REDUNDANCY Off Off
CONFIG MENU ADJUSTMENT

PARAMETER std initial lift
ADJUST BATTERY 25,03 V 25,03 V
THROTTLE 0 ZONE 10% 10%
THROTTLE X POINT 50% 50%
THROTTLE Y POINT 35% 35%
THROTTLE 0 PROP 0% 0%
THROTTLE X PROP 10% 10%
THROTTLE Y PROP 40% 40%
THROTTLE X1 PROP 30% 30%
THROTTLE Y1 PROP 70% 70%
BAT. MIN ADJ. 5 5
BAT. MAX ADJ. 3 3
LOAD HM FROM MDI Off Off
CHECK UP DONE Off Off
CHECK UP TYPE None None
33
MODULE PARAMETER DESCRIPTION

"COMBI AC0" Module
COMBI / main menu parameter change /
COMBI / config menu set options /
COMBI / config menu adjustments /
PARAMETER level = 0 level = 9

ACCELERATION DELAY 0.3 sec 10 sec
traction acceleration slope
RELEASE BRAKING 0.3 sec 5 sec

Release breaking deceleration slope
INVERS BRAKING 0.3 sec 5 sec

Direction reversal breaking deceleration slope
DECEL BRAKING 0.3 sec 5 sec

Deceleration slope with throttle released but not completely.
SPEED LIMIT BRAKING 0.3 sec 10 sec

Deceleration slope when a speed limit is active
MAX SPEED FORWD 10% 100%

Maximum forward traction speed
MAX SPEED BACK 10% 100%

Maximum backward traction speed
CUTBACK SPEED 1 50% 100%

Average traction reduction speed (a percentage of the maximum speed)
CUTBACK SPEED 2 5% 50%

Maximum traction reduction speed (a percentage of the maximum speed)
SNAIL SPEED 3% 30%

Traction speed in SNAIL mode (percentage of maximum speed)
FREQUENCY CREEP 0.6 Hz 5 Hz

Minimum frequency applied with a forward or backward motion request is present but the traction control throttle is
in the minimum position.
ACC SMOOTH 1 sec 5 sec

Associates a parabolic shape to the acceleration slope
34

INV SMOOTH 1 sec 5 sec
Associates a parabolic shape to the acceleration slope for reverse breaking
STOP SMOOTH 3 Hz 20Hz

Sets the frequency level at which the effect of the parabolic shape of the acceleration slope ceases to have any
effect
BRK SMOOTH 1 sec 5 sec

Associates a parabolic shape to the deceleration slope
STOP BRK SMOOTH 3 Hz 20Hz

Sets the frequency level at which the effect of the parabolic shape of the deceleration slope ceases to have any
effect
AUXILIARY TIME 0 sec 10 sec
If the COMBI / config menu set options / stop on ramp ON, indicates the time that elapses before disactivating
the truck's electrical stop positioned on the ramp when the traction control throttle is released.
EMB INSERTION DELAY 0.2 sec 10 sec
If the parameter COMBI / config menu set options / brake on release ON, indicates the time that elapses before
the electromagnetic break is triggered when the tiller and the traction control throttle are released.
PU. ACCELER DELAY 0.1 sec 10 sec
Fork lifting/lowering acceleration slope (acceleration time)
PU. DECELER DELAY 0.1 sec 10 sec
Fork lifting/lowering deceleration slope (deceleration time)
SPEED LIMIT 5% 100%
Limits the maximum fork lifting/lowering speed
INITIAL LIFT 5% 100%
Limits maximum lifting speed for slow fork lifting (or straddle leg lifting on versions with initial lift)
INITIAL LOWER 5% 100%
Limits maximum lowering speed for slow fork lowering (or straddle leg lowering on versions with initial lift)
AUX SPEED FWD 5% 100%
Unused
AUX SPEED REV 5% 100%
Unused
CREEP SPEED 2% 100%

Minimun speed of the pump connected to the value of the COMBI / main menu parameter change / frequency
creep parameter
35

COMPENSATION 0% 100%
Estabilshes the compensation voltage (∆V) applied to the engine when the proportional lift is active. The value of
this compensation applied to the engine is a function of the engine current. The purpose of this function is to reduce
the difference in speed between laden and unladen.
MIN EVP 3% 100%
Minimum current present on the solenoid valve coil EV1.
MAX EVP 10% 100%
Maximum current present on the solenoid valve coil EV1.
EVP OPEN DELAY 0 sec 12.75 sec

Solenoid valve EV1 opening slope
EVP CLOSE DELAY 0 sec 12.75 sec

Solenoid valve EV1 closing slope
LIFT MAX TIME 3 sec 100 sec

If the COMBI / config menu set options / lifting block ON, indicates the duration of the fork lift before these are
blocked. After the block, one has to press one of the descent buttons before being able to proceed with another
lift.
PARAMETER level
KEY ON: record of truck start up
HOUR COUNTER RUNNING: record of an active
request
Select the hourmeter mode
ON = test performed
BATTERY CHECK
OFF = test not performed
Enables/disables the test of the battery level charge loss. If battery check ON, when the battery level reaches
20%, the fork lifting function is disabled and traction speed is reduced.
ON: the stop is enabled

STOP ON RAMP
OFF: the stop is disabled
Enables/disables the electric stop on the truck on a tilted ramp when the traction control throttle is released but the
tiller sensor remains active. The duration of the electrical stop can be set using the parameter COMBI / main menu
parameter change / auxiliary time. At the end of the electrical stop time the 3-phase bridge is released and the
electromagnetic break is activated.
36
PARAMETER level
NONE: inversion disabled
TIMED: inversion enabled for 5
QUICK INVERSION
seconds
BELLY: inversion always enabled
Select the emergency reverse mode if the parameter COMBI / config menu set options / belly with inv. ON.
ON: reverse enabled

BELLY WITH INV.
OFF: reverse disabled
Enabling/disabling of the direction reversal with the Belly button pressed. If the parameter is OFF, by pressing the
Belly button the truck stops.
DRIVE MODE
Unused
ON: lowering enabled

AUTOLO. STRADDLE LEGS
OFF: lowering disabled
For initial lift version only.
Enabling/disabling of automatic lowering of the straddle legs when the fork lifting height exceeds 1500 mm
ON: outputs managed respectively

like valves EV5 and EV6
AUXILIARY FUNCTION OFF: outputs managed respectively
as acoustic buzzer buzzer and
warning light.
Setting of the control designed to manage the ouputs 34 and 8
OPTION#1: active with forward

gear
BUZZER FUNCTION
OPTION#2: active with backward
gear
If the parameter COMBI / config menu set options / auxiliary function OFF, sets the buzzer operation mode.
OPTION#1: active with tiller low-

ered
FLASH BEACON
OPTION#2: active with any truck
functions active
If the parameter COMBI / config menu set options / auxiliary function OFF, sets the flash beacon operation
mode.
ON: enabled
LIFTING BLOCK
OFF: disabled
Enabled/disabled fork lifting after a time established by the parameter COMBI / main menu parameter change / lift
max time
37
PARAMETER level
ON: enabled
BRAKE ON RELEASE
OFF: disabled
ON: the electromagnetic brake is activated after a delay depandant on the parameter COMBI / main menu para-
meter change / emb insertion delay
OFF: the electromagnetic break is activated at the end of the electrical breaking when the speed is nil
PRESENT: checks performed

EV2
ABSENT: checks not performed
Presence/absence of the solenoid valve EV2

EV3

EV4
0 = Shabmüller
MOTOR SELECTION
1 = ABM
Motor traction present (it is advisable not to modify this parameter)
ON: enabled
REDUNDANCY
OFF: disabled
Enabling/disabling of the checks on the A15 input of the controller so that there is an analog signal that varies
between 5 V and 10 V (5 V and 0 V) when the traction command throttle has a value of between 2.5 V and 5 V (2.5
V and 0 V). If this does not take place, then the controller signals an alarm.
38
PARAMETER level
ADJUST BATTERY Value expressed in Volts
Exact value of battery charged measured at the inverter This value is not altered by a CLEAR EEPROM
THROTTLE 0 ZONE Value expressed in percentage

Sets the breadth of the initial dead zone of the throttle pontentiometer.1
THROTTLE X POINT Value expressed in percentage

Together with the parameter throttle y pointmodifices the charcteristics of the acceleration curve: when the traction
control throttle is rotate by x% the corresponding truck speed will be y% of the maximum speed. The relationship
between the position of the throttle and the truck speed is linear between the e throttle 0 zoneand X and between
X and the position of maximum accelaration of the throttle, but with a different slope (fig.1).
THROTTLE Y POINT Value expressed in percentage

Together with the parameter throttle X pointmodifices the charcteristics of the acceleration curve: when the traction
control throttle is rotate by x% the corresponding truck speed will be y% of the maximum speed. The relationship
between the position of the throttle and the truck speed is linear between the e throttle 0 zoneand X and between
X and the position of maximum accelaration of the throttle, but with a different slope(fig.1).
Fig. 1
39
PARAMETER level
THROTTLE 0 PROP Value expressed in percentage
Sets the breadth of the initial dead zone of the throttle potentiometer (fig.2)
THROTTLE X PROP Value expressed in percentage

Establishes the coordinates on the X axis of the first point of the cross-section on which we approximate the curve
of the proportional valve (fig.2)
THROTTLE Y PROP Value expressed in percentage

Establishes the coordinates on the y axis of the first point of the cross-section on which we approximate the curve
of the proportional valve (fig.2)
THROTTLE X1 PROP Value expressed in percentage

Establishes the axis X of the second point of the cross-section on which we approximate the curve of the propor-
tional valve (fig.2)
THROTTLE Y1 PROP Value expressed in percentage

Establishes the coordinates on the y axis of the second point of the cross-section on which we approximate the
curve of the proportional valve (fig.2)
A Fig. 2
A: percentage of the maximum value of the current in the proportional valve

B: percentage of the maximum value of the travel distance of the proportional
button
40
PARAMETER level
0 = minimum value
BAT. MIN. ADJ.
9 = maximum value
Adjusts the lower value of the battery charge state table.
0 = minimum value
BAT. MAX. ADJ.
9 = maximum value
Adjusts the upper value of the battery charge state table.
ON: saving enabled

LOAD HM FROM MDI
OFF: saving disabled
Enable/disable the saving of the operating hours from the MDI module (optional) to the COMBI.
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
NONE: disabled
OPTION#1: warning after 300
hours
CHECK UP TYPE OPTION#2: like option#1 plus
speed reduction after 340 hours
OPTION#3: like option#2 plus truck
block after 380 hours
Enables/disables the programmed maintenance mode and warning At the end the maintenance set the parameter
COMBI / config menu adjustment / check up done ON
41
COMBI AC0 MODULE: INTRODUCTION

The “COMBI AC0 INVERTER" has been developed to carry out all the electrical functions normally present
on the truck:
• controlling the 1.2 Kw AC motor
• controlling the 2Kw hydraulic pump
• driver for the porportional solenoid valve
• CanBus interface
• Interface with the tiller Can Bus
• Warnings
• performances
Technical specifications:
Asynchronous three phase inverter for AC motors and chopper for DC pump motors
Regenerative breaking functions
Digital control via microcontroller
Voltage: ........................................................................................24V - 36V - 48V
Maximum inverter current (24V):...................................................200A (RMS) for 2’
Continuous current output (24V)...................................................70A (RMS) for 2’
Operating inverter frequency: .......................................................8 kHz
Maximum chopper current (24 V):.................................................270A (RMS) for 2’
Chopper operating frequency: ......................................................16 kHz
External temperature limit.............................................................-40°C ÷ 40°C
Maxmum inverter temperature (at maximum power):...................85°C
42
The module is connected and communicates via the CANBUS network, which allows access to the dia-
gnostics or programming of the truck via PC (or laptop) or console.
The connector for the cable kit interface connection "PC CONSOLE") is connected to the “COMBI AC0"
module and can be accessed from the engine compartment.
The module is equipped with a flash memory, which enables the software to be updated by connecting a
PC to the CANBUS netowork (Can flash).
POSITIONING OF THE "PC CONSOLE" CONNECTOR AND CONSOLE
pc console connector and console

additional console connector
pc interface cable kit

cod.1534010
console cable kit

cod.4600073
43
REPLACEMENT MODULE: INSTRUCTIONS

REPLACEMENT OF THE COMBI AC0 MODULE
Equipment and tools
hexagonal pipe resistence

large philips
wrench 100 Ohm 25w
screwdrivers
10 mm isolated
A
A A
Procedure
transit of other vehicles and the pedestrian route. Set the Fig. 1
Fig. 2
Phase 1
Volt

Open the engine cover.
Phase 2
RESISTENCE 100 Ohm 25 W
Connect the resistence betwen the positive (B+) and negative (B-) of
the module (fig.2).
Wait approximately 10 seconds for the internal capacitors to lose their
charge and then disconnect the resistence.
To avoid short circuit, it is important that the resistence by

isolated.
If it is not possible to have an external resistence to run down the capaci-

tors, it will be necessary to wait at least 90 seconds before disconnecting
the power cables.
44
Phase 3
HEXAGONAL 10 mm "T" SECTION SOCKET WRENCH C
Using the hexagonal pipe wrench loosen and remove the power cable C
fastening screws.
Disconnect the module connection connector.
Earmark the power cables for reassembly and disconnect them.
B
Phase 4
HEXAGONAL 10 mm "T" SECTION PIPE WRENCH
Fig. 3
Usint the hexagonal pipe wrench loosen and remove the screws fastening
the module to the truck chassis (ref.B fig.3), recover the washers and remove the cable fasteners (ref.C
fig.3).
Remove the module including the heat sink and procede with the replacement.
CONFIGURATION
ADAPTER - PROGRAMMER
Connect the adaptor to the “PC CONSOLE" connector.
Connect the USB connector of the interface cable to the USB port on the PC.
Connect the battery and turn on the machine (ignition key to ON). Start the PC Console program.
Create a new configuration and copy the factory configuration or a customised configuration.
ACQUISITION OF WORK HOURS (with MDI optional)

The hours of operation of the truck are memorised on the “COMBI” module and on the “MDI” module.
On ignition the system assesses the hours recorded on the two modules. If the difference is greater than
20 hours the warning “98” appears and traction is disabled. In this case there are 5 minutes available to
load the operating hours on the new “COMBI” by loading them up from the “MDI” module.
Procedure
With the machine off (key switch OFF) connect the programmer.
Turn the machine on (Key switch ON) and select the parameter COMBI / config menu adjustment / load
hm from mdi.
Set the parameter on “ON” and save the information.
Turn off the truck (Key switch OFF) and turn it back on again ( Key switch ON).
At this point the new module will receive the operating hours recorded on the “MDI” module.
If when turning the truck on the ”98” warning appears and the operating hour acquisition
procedure is not performed, after 5 minutes the “MDI” module will load the hours recorded
on the “COMBI” module (0 if the controller is new).
45
ELECTRICAL COMPONENT DISMANTLING

REPLACEMENT OF THE GENERAL EMERGENCY SWITCH
Equipment and tools
medium/
pin extractor fixed spanner
large Phillips
Ø 3 mm 13 mm
screwdriver
A
A A
Procedure
transit of other vehicles and the pedestrian route. Lower
Fig. 1
the forks to the ground, position the key switch on OFF
and disconnect the battery.
Phase 1
on the motor compartment cover (ref.A fig.1). Fig. 2
Phase 2
PIN EXTRACTOR
Slip the end of the pin extractor into the hole beneath the red general
emergency knob (ref.B fig.2). C C
Rotate the knob until the pin extractor fits into the inner knob shaft .
Unscrew and remove the knob.
Phase 3
FIXED 13 mm spanner
Using the fixed spanner loosen the nuts fastening the remote-control Fig. 3
switch power cable (ref.C fig.3).
46
Phase 4
D
MEDIUM PHILIPS SCREWDRIVER E
Unscrew the fastening screws of the general emergency switch (ref.D
fig.4), retrieve the washers(ref.E fig.4).
Pull downwards towards the remote control switch (fig.4).
Phase 5
Disconnect the connectors and proceed with the replacement. Fig. 4
ASSEMBLY
Before connecting them again, make sure the fastons are

suitably tight. If this is not the case tighten the connectors
with faston pliers.
47
DISPLAY REPLACEMENT
Equipment and tools
large Philips A
screw driver A A
Procedure
Fig. 1
Fig. 2
When the battery charge state display is replaced the B

truck working hours will be lost.
Phase 1
LARGE PHILIPS SCREW DRIVER Fig. 3
Phase 2 D
Disconnect the connector of the electrical connection (ref.B fig.2).
Loosen the stop nuts of the blocking bracket (ref.C fig.3). Remove the
C
bracket (ref.D fig.3).
Remove the display (Fig.4) and proceed with the replacement.
Fig. 4
ACQUISITION OF WORK HOURS (with MDI optional)

On turning on the truck the “98” warning appears and
traction is disabled, after 5 minutes the “MDI” module will
automatically acquire the operating hours recorded on the
“COMBI” module (0 if the controller is new).
48
REPLACEMENT OF THE KEY SWITCH

Equipment and tools
large Philips A
screw driver A A
Procedure
Before starting work, ensure that you are equipped with Fig. 1
transit of other vehicles and the pedestrian route. Lower Fig. 2
Phase 1
Use the Philips screwdriver to unscrew and remove the fastening screws Fig. 3
Phase 2
Remove the ignition key (fig.2).
Unscrew the ferrule (ref.B fig.2), remove the switch block from the da-
shboard (fig.3).
Disconnect the connectors and proceed with the replacement.
ASSEMBLY

with faston plyers.
49
REPLACEMENT OF THE WARNING BUZZER

Equipment and tools
n..2 fixed gauge

large Philips
spanners
screw driver
10 mm
A
A A
Procedure
transit of other vehicles and the pedestrian route. Set the Fig. 1
Fig. 2
Phase 1
Phase 2
N.2 FIXED GAUGE 10 mm SPANNERS
With a fixed gauge spanner block the nut (ref.C fig.3), while with the
other key you loosen and remove the warning buzzer fastening screws
(ref.B fig.3).
Disconnect the connectors, remove the buzzer and proceed with the
replacement.
B
C
Fig. 3
ASSEMBLY

with faston plyers.
50
FUSE REPLACEMENT
• 24V solenoid valve coils (F3) power supply fuse
• 24V Horn relay (F4) power supply fuse
• 24V Battery charge level indicator (F5) power supply fuse
• key switch ( F2) fuse
Equipment and tools
small flat head large Philips

screwdriver screw driver
A
Procedure A A
key switch to OFF and disconnect the battery. Fig. 1
Phase 1
Fig. 2
Phase 2
SMALL FLAT HEAD SCREWDRIVER
Using the small flat head screwdriver press the flaps (ref.B Fig.3) and
remove the fuse holder cover.
Remove the fuse and procede with the replacement. B
F5 F4
F3 F2
Fig. 3
51
tiller diagram: configuration and calibration

configuration
When should one carry out this procedure?
- When I replace the tiller card.
In order to avoid accidentally triggering the horn micro during configuration, it is advisa-
ble to carry out the procedure before inserting the card into the tiller housing.
C
A
Fig. 1
Procedure
Set the key switch to OFF and disconnect the battery.
Phase 1
Fig. 2
Move the configuration bridge of the tiller card from the position P (Par-
king) to the position C (Configuration) (fig.1).
Connect the battery and position the ignition key on ON.
Fig. 3
Phase 2
The LED display will show the letter (trucks with on-off type lifting and
lowering buttons) identifying the configuration type that has been saved on the board (fig.2).
Press the Snail microswitch (ref.A fig.1) to increase the value until the LED display shows the configuration
letter D (trucks with proportional lifting and lowering buttons).
To decrease the value, press the horn microswitch (ref.B fig.1).
Phase 3
Confirm the configuration by pressing the Bellyswitch microswitch (ref.C fig.1). On the LED display, a de-
cimal point appears after the configuration letter (fig.3).
52
Phase 4
Turn off the truck.
Move the configuration bridge of the tiller card from the position C (Con-
figuration) to the position P (Parking) (fig.1).
Phase 5 Fig. 4
Insert the card into its proper position in the tiller housing.
Fig. 5
D
Calibration
When should one carry out this procedure?
- When I replace the tiller card.
- When at top speed the truck does not proceed at a uniform speed.
- When the traction stops at the end point of the throttle valve.
- When there is a considerable difference in speed between the forward
gear and the reverse gear.
Procedure
Before starting work check that all the lifting and lowering
buttons are connected to the tiller card and that it is well
lodged in its case.
Position the key switch on OFF.
Phase 1
Move the configuration bridge of the tiller card from the position P (Par-
king) to the position T (Teaching) (fig.1).
Position the key switch on ON. Fig. 6
Phase 2 Fig. 7
The LED display shows zero. E
Press and release the lift button located on the left-hand side of the tiller
casing (JP14, ref.D fig.5) to save the neutral position of the butterfly
control.
If the LED display shows the value 8, indicating that at the

moment the position was saved, the butterfly control was
not in neutral position (at exactly 90° relative to the axis of
rotation).
Phase 3
The LED display will show a dash (fig.4).
Rotate the butterfly control fully to the right and hold it in this position
(fig.5). Press and release the lift button located on the left-hand side of
the tiller casing (JP14, ref.D fig.5).
The LED display will show another dash, indicating that the butterfly
position has been successfully saved (fig.6).
53
Phase 4
Release the butterfly control.
Rotate the butterfly control fully to the right and hold it in this position
(fig.7). Press and release the lowering button located on the left-hand
side of the tiller casing (JP15, ref.E fig.7).
The LED display will show another dash, indicating that the butterfly
position has been successfully saved (fig.8). Fig. 8
Phase 5
Release the traction throttle.
Move the configuration bridge of the tiller card from the position T (Tea-
ching) to the position P (Parking) (fig.1).
A decimal point appears on the LED display (fig.9).
Fig. 9
Position the key switch on OFF.
If the truck is turned off before having moved the confi-

guration bridge onto the position P (parking), the calibra-
tion values will be lost and the procedure will have to be
repeated.
54
TILLER CARD REPLACEMENT

Equipment and tools
hexagonal "T"
small flat head
section spanner A
screwdriver
2.5 - 5 mm B
Fig. 1 C
Procedure
and disconnect the battery. D
Fig. 2
EF G
Phase 1
H
HEXAGONAL 5mm "T" SECTION SPANNER
Unscrew the nuts holding the upper frame housing in place (ref.A,B,C
fig.1).
Phase 2
Lift the upper chassis housing and remove it from the lower frame housing
(fig.2). Disconnect the connector connecting the serial cable (ref.D fig.2)
and place the cover on a clean work bench. Fig. 3
Phase 3
HEXAGONAL 2,5 mm "T" SECTION SPANNER
Loosen the screw holding one of the two throttle valves (ref.E fig.3) and
retrieve the washer (ref.F fig.3). Slip the throttle valve away from the
gudgeon(ref.G fig.3). Remove the other throttle valve complete with
guide pivot (ref.H fig.3).
Phase 4
SMALL FLAT HEAD SCREWDRIVER K
Unscrew the tiller card latch fastening nut (ref.I fig.4). Remove the latch
(ref.J fig.4) and the card from its seat (ref.K fig.4), disconnect the con-
nectors of the various micro commands.
Proceed with the replacement.
J
Fig. 4 I
After the assembly carry out the new card configuration
and calibration procedure (see "TILLER DIAGRAM: CON-
FIGURATION AND CALIBRATION").
55
REPLACEMENT OF tiller BUTTONS

Equipment and tools
A B
Fig. 1 C
hexagonal "T"
small flat head
section spanner
screwdriver
5 mm
Procedure
Move the carriage to a safe place, away from areas of D
the forks to the ground, position the key switch on OFF Fig. 2
Fig. 3
Phase 1
HEXAGONAL 5 mm "T" SECTION SPANNER
Unscrew the nuts holding the upper chassis housing in place (ref.A,B,C
fig.1).
Phase 2
Lift the frame of the upper housing and remove it from the lower frame
housing (fig.2). Disconnect the connector connecting the serial cable
(ref.D fig.2) and place the cover on a clean work bench.
Phase 3
Fig. 4
SMALL FLAT HEAD SCREWDRIVER
Using the screwdriver prise open the stop catches (fig.4) and apply
pressure to the button to prise it out of its seat (fig.4,5).
Proceed with the replacement
Fig. 5
56
REPLACEMENT OF THE TILLER CONTROL SPRINGS

Equipment and tools
T handle hex key small flat blade

2.5 - 4 mm screwdriver
Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and pedestrians. Lower the forks to the
ground, turn the keyswitch to OFF and disconnect the
battery.
A B
Fig. 1 C
Phase 1
4 mm T HANDLE HEX KEY
Unscrew the bolts securing the upper casing (ref.A,B,C fig.1).
D
Fig. 2
Phase 2
Lift the upper casing and detach it from the lower casing (fig.2). Discon-
nect the serial cable connector (ref.D fig.2) and place the cover on a
clean work bench. Fig. 3
EF G
H
Phase 3
2.5 mm T HANDLE HEX KEY
Loosen the screw securing one of the two butterflies (ref.E fig.3) and
recover the washer (ref.F fig.3). Slide the butterfly off the pin (ref.G
fig.3). Remove the other butterfly control complete with the guide pin
(ref.H fig.3).
57
BUTTERFLY CONTROL SPRING

Fig. 4
Phase 4
SMALL FLAT BLADE SCREWDRIVER J
With the screwdriver, prise out the butterfly control guide bush (ref.I fig.4).
In the same way, prise out the butterfly control spring (ref.J fig.4).
BELLY AND HORN BUTTON SPRINGS
Phase 4 Fig. 5
SMALL FLAT BLADE SCREWDRIVER
With the screwdriver, apply leverage under the belly switch in correspon-
dence with the locking pin (fig.5). Remove the button (ref.K fig.6) and
recover the spring (ref.L fig.6).
In the same way, apply leverage under the horn button in correspondence
with the locking pin (fig.5). Remove the button (ref.M fig.6) and recover
the spring (ref.N fig.6).
Fig. 6
K
L
N
58
REPLACEMENT OF THE TILLER ASSENT SENSOR

Equipment and tools
A B
Fig. 1 C
hexagonal "T"
small philips
section spanner
screwdriver
3 - 5 mm
Procedure
transit of other vehicles and the pedestrian route. Lower D
the forks to the ground, position the key switch on OFF Fig. 2
Fig. 3
Phase 1
Unscrew the nuts holding the upper chassis housing in place (ref.A,B,C
fig.1).
Phase 2 Fig. 4
Lift the frame of the upper housing and remove it from the lower frame
housing (fig.2). Disconnect the connector of the tiller sensor cable con-
nection (ref.D fig.2).
E
Phase 3 E
HEXAGONAL 3 mm “T” SHAPED SPANNER - SMALL PHILIPS
SCREWDRIVER
Keeping the tiller lowered, using the hexagonal "T" section spanner un-
screw and remove the sensor holder bridle (ref.E fig.4). Using the small
philips screwdriver loosen the sensor fastening screw (ref.F fig.5).
Remove the sensor from the bridle (fig.5), retrieve the cable and procede
with the replacement.
The optimal sensor sensitivity distance from the cam is 4 F

mm. Fig. 5
59
RENEWAL OF 'FORKS ABOVE 1500 mm' SENSOR (OPTIONAL)

FOR INITIAL LIFT VERSION ONLY
Equipment and tools
open ended span-

large flat blade
ner scissors
screwdriver
24 mm A
Procedure
battery.
Phase 1
LARGE FLAT BLADE SCREWDRIVER
Fig. 1
Using the screwdriver, loosen and remove the screws securing the wire
mesh guard (ref.A fig.1) and recover the washers. Remove the wire
mesh guard.
Fig. 2
Phase 2 B
24 mm OPEN ENDED SPANNER - SCISSORS
With the spanner, unscrew and remove the nut securing the sensor to
the bracket (ref.B fig.2). With the scissors, cut the straps securing the
sensor wire, then disconnect the connector.
Remove the old sensor, recover the wire and fit the new sensor.
The optimal distance between the sensor and the cam is 4

mm.
60
RENEWAL OF 'FORKS ABOVE 500 mm' SENSOR (OPTIONAL)

Equipment and tools
Fig. 1
T handle hex key wooden beam

scissors
3-5 mm 100x100x1000 mm
Procedure A
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
WOODEN BEAM
Raise the forks by 1500 mm. Position the beam under the forks (ref.A
fig.1), and lower the forks so that they rest on the beam.
B
Turn the keyswitch to OFF and disconnect the battery.
Phase 2
4 mm T HANDLE HEX KEY - SCISSORS
With the T handle hex key, unscrew and remove the screws securing the sensor support clamp (ref.B fig.2).
With the scissors, cut the straps securing the sensor wire, then disconnect the connector.
Remove the clamp complete with the sensor and recover the wire.
Extract the old sensor and fit the new one.
The optimal distance between the sensor and the cam is 4 mm.
61
RENEWAL OF THE 'FORKS LOWERED' SENSOR

Equipment and tools
large cross-head open ended

screwdriver spanner scissors
24 mm
A
A A
Procedure
Fig. 1
battery.
Phase 1
LARGE CROSS-HEAD SCREWDRIVER
Use the cross-head screwdriver to unscrew and remove the fastening
screws on the motor compartment cover (ref.A fig.1).
Open the motor compartment cover.
Fig. 2
Phase 2
Fig. 3
24 mm OPEN ENDED SPANNER - SCISSORS
With the spanner, unscrew and remove the nut securing the sensor to
the bracket (ref.B fig.3). With the scissors, cut the straps securing the
sensor wire, then disconnect the connector.
Remove the sensor, recover the wire and proceed with the replace-
ment.
B
The optimal distance between the sensor and the cam is 4
mm.
62
SERVICE HYDRAULIC SYSTEM
hydraulic system
HYDRAULIC FUNCTIONS�� 3
HYDRAULIC CIRCUIT POWER SUPPLY�� 4
PRESSURE REGULATING VALVES�� 4
DIRECTIONAL VALVES�� 5
HYDRAULIC PLANS�� 6
symbols�� 6
COMPLETE HYDRAULIC BLUEPRINT version without initial lift�� 7
MAIN HYDRAULIC DIAGRAMversion with initial lift�� 10
HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS�� 11
OPERATION TABLES - SOLENOID VALVES�� 11
HYDRAULIC DIAGRAM - forks lifting (without initial lift)�� 12
HYDRAULIC DIAGRAM - forks lifting (with initial lift)�� 13
HYDRAULIC DIAGRAM - forks lowering (without initial lift)�� 14
HYDRAULIC DIAGRAM - forks lowering (with initial lift)�� 15
HYDRAULIC DIAGRAM - straddle legs lifting (with initial lift)�� 16
HYDRAULIC DIAGRAM - straddle legs lowering (with initial lift)�� 17
HYDRAULIC DIAGRAM - emergency forks lowering (with initial lift)�� 18
HYDRAULIC PLAN FOR OIL RELEASE INTO THE TANK THROUGH THE PRESSURE RELIEF VALVE�� 19
HYDRAULIC COMPONENT�� 20
RELIEF VALVE DISMANTLING (all models)�� 20
PRESSURE RELIEF VALVE CALIBRATION (all models)�� 21
REMOVAL OF THE PRESSURE RELIEF VALVE (initial lift version only)�� 22
CALIBRATION OF THE PRESSURE RELIEF VALVE (initial lift version only)�� 23
REMOVAL OF THE LOWERING FLOW RATE CONTROL VALVE (for initial lift version only)�� 24
calibration of the lowering oil flow rate control valve (for initial lift version only)�� 25
CARTRIDGE SOLENOID VALVES�� 26
IDENTIFICATION OF THE COMPONENTS OF A CARTRIDGE SOLENOID VALVE�� 26
SOLENOID VALVE DISMANTLING�� 27
CYLINDERS�� 29
SINGLE ACTING CYLINDER�� 29
LIFTING CYLINDERS: COMBINATIONS�� 29
KEY TO INITIAL LIFT CYLINDER COMPONENTS�� 30
IDENTIFICATION OF THE LATERAL LIFT CYLINDER COMPONENTS�� 31
IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS�� 32
1
HYDRAULIC SYSTEM SERVICE
DISMANTLING OF LATERAL LIFT CYLINDER �� 34

CENTRAL LIFT CYLINDER DISMANTLING�� 37
REMOVAL OF THE "INITIAL LIFT" CYLINDER�� 40
LIFT CYLINDERS: AIR BLEEDING�� 44
BLEEDING THE INITIAL LIFT CYLINDER�� 45
REPLACEMENT OF STATIC GASKETS ON LATERAL LIFT CYLINDERS�� 46
REPLACEMENT OF STATIC GASKETS ON THE CENTRAL LIFT CYLINDER�� 48
SMALL MAST LIFT CYLINDER SEPARATION INTO PARTS�� 51
lift pump�� 54
IDENTIFICATION OF THE LIFT PUMP COMPONENTS all models excluding initial lift models�� 54
IDENTIFICATION OF THE LIFT PUMP COMPONENTSmodels with initial lift�� 56
LIFT PUMP DISMANTLING all models excluding initial lift models�� 58
LIFT PUMP DISMANTLINGmodels with initial lift�� 60
PUMP REPLACEMENT�� 62
HYDRAULIC PIPES�� 64
PIPE PLACEMENT FOR HYDRAULIC CIRCUIT�� 64
REPLACEMENT OF CYLINDER FEED PIPES�� 67
REPLACEMENT OF THE HYDRAULIC PIPE HOSE SHEAVE�� 69
RENEWAL OF THE OIL SUPPLY PIPE TO THE INITIAL LIFT CYLINDER �� 70
2
HYDRAULIC FUNCTIONS
• Fork Lifting
• Fork Lowering
• Straddle legs lifting (initial lift version only)
• Straddle legs lowering (initial lift version only)
INITIAL LIFT
FORK LIFTING/LOWERING
The fork lifting speed is determined by the revs that the pump motor transmits to the pump drive shaft.
In the descent stage the one-directional stops the flow of the fluid through the pump and the oil flows into
the tank through the flow regulator valve.
The proportionality of the lowering phase is handled by the Q1 proportional solenoid valve.
3
HYDRAULIC CIRCUIT POWER SUPPLY

Fixed cylinder capacity pumps
With fixed capacity cylinders, the oil flow is constant, providing the
speed of crank shaft rotation remains unchanged.
A reduction in the drive shaft revs lowers the load capacity: if
the revs are reduced so is the flow and vice versa; the pressure,
providing the load is unchanged, remains constant.
PRESSURE REGULATING VALVES

Pressure limiting valves
The "pressure limiting" or "pressure relief" valves are mainly used
to guarantee the maximum pressure admitted into the system and
to protect the pump from experiencing pressure that might exceed
its own structural specifications.
The use of pressure limitators does not only cover the functions
mentioned above, but they are commonly used in many devices
for which it is crucial to avoid pressure build ups. An example are
anti-shock and anti-knock valves. Pump
So long as the circuit is not affected by excess pressure condi-
tions, the limiting valve remains in the closed position: the force
exerted by the pressurized oil is lower than that exerted by the opposing spring. With the piston at its ma-
ximum extension or if an abnormal situation may arise which requires an effort in excess of the set level
(for example with a load in excess of the load capacity), the over pressured oil overcomes the force of the
spring and flows towards the oil outlet.
Parachute valves (LB)

These are blocking valves fixed directly onto the lift cylinders and
are designed to stop an uncontrolled lowering of the load in the
event of a pipe subject to high pressure should break.
If the pressure exceeds the set value (80 litres/min) a plate, which is
lifted through elastic reaction from the seat of the valve, is pressed
by the electrodynamic forces involved, against the valve chassis,
leading to the closure of the valve itself. They are equipped with
a draining hole.
Oil flow control valves (SB) Parachute valve

The flow control valves act as 'brakes' on the cylinders during
lowering manoeuvres to ensure a constant lowering speed, re-
gardless of the weight of the load.
The valves are comprised of a sliding cylinder, (B), complete with spool (C) and spring (D), and diaphragm
bushing (A).
oil inlet
A B
C D
Oil flow control valve
4
DIRECTIONAL VALVES
One-directional and restraining valves.
The function of "one-directional" or "non-return" valves is to allow the oil to flow in one direction only, while
the flow in the opposite direction is not permitted.
They are essentially comprised of a fixed part connected to the end of the pipe; in the appropriate inner
housing runs the moving element which might be a bearing or a conical plug.
The "restraining" valves, as opposed to the latter ones are equipped with an opposing spring mechanism.
In the direction of free flow, the oil pressure must exceed the force exerted by the spring.
5
HYDRAULIC PLANS
symbols
TWO POSITION SOLENOID THREE POSITION

VALVE SOLENOID VALVE
ONE-DIRECTIONAL
FILTER
VALVE
DOUBLE ACTING
CYLINDER PROPORTIONAL VALVE
SINGLE ACTING CYLINDER PUMP
TANK HYDRAULIC MOTOR
LINE CONNECTION M ELECTRIC MOTOR
SAFETY VALVE FLOW VALVE
MANUAL TAP BY-PASS VALVE
6
COMPLETE HYDRAULIC BLUEPRINT

version without initial lift
SINGLE STAGE MAST
LB
C2
P T
CH
Q1
(Evp)
RELIEF 1
CH
P
F SB
7
TWO STAGE MAST
LB LB
C2
P T
CH
Q1
(Evp)
RELIEF 1
CH
P
F SB
8
THREE STAGE MAST
LB LB LB
C2
P T
CH
Q1
(Evp)
RELIEF 1
CH
P
F SB
9
MAIN HYDRAULIC DIAGRAM

version with initial lift
INITIAL LIFT
SB LB LB LB
C1 C2
Q3 Q2
RV2
Q4
Q1
(evp)
CV1
RV1
SB
TANK
10
HYDRAULIC DIAGRAMS FOR VARIOUS FUNC- Version without

TIONS initial lift
• Forks lifting
• Forks lowering
• Straddle legs lifting (version with initial lift)
• Straddle legs lowering (version with initial lift)
• Emergency forks lowering (version with initial lift) Q1
The hydraulic control valve in the motor compart-
ment is equipped with a 5 mm Allen key, which is re-
quired to open the emergency forks lowering valve.
Open the valve gradually, so that the forks are lowered
slowly. Once the forks have been lowered, close the val-
ve.
• Oil drain through the pressure relief valve
pressure relief
valve
OPERATION TABLES - SOLENOID VALVES
VERSION WITHOUT INITIAL LIFT

Version with
Function Pump Q1 initial lift
Slow fork lifting P - Q2 Emergency

Q3 lowering
Slow fork lowering + valve
Q4
Q1
Proportional fork lifting P -
Proportional fork lowering +
Oil drain through pressure relief
valve P - relief valve
Function Pump Q1 Q2 Q3 Q4
Straddle legs lifting P - - + -

Straddle legs lowering + - + -
Forks lifting P - - - +
Forks lowering + + - -
P
= pump in operation
+
= solenoid valve coil energised
11
HYDRAULIC DIAGRAM - forks lifting (without initial lift)
LB LB LB
C2
P T
CH
Q1
(Evp)
RELIEF 1
CH
P
F SB
12
HYDRAULIC DIAGRAM - forks lifting (with initial lift)
INITIAL LIFT
SB LB LB LB
C1 C2
Q3 Q2
RV2
Q4
Q1
(evp)
CV1
RV1
SB
TANK
13
HYDRAULIC DIAGRAM - forks lowering (without initial lift)
LB LB LB
C2
P T
CH
Q1
(Evp)
RELIEF 1
CH
P
F SB
14
HYDRAULIC DIAGRAM - forks lowering (with initial lift)
INITIAL LIFT
SB LB LB LB
C1 C2
Q3 Q2
RV2
Q4
Q1
(evp)
CV1
RV1
SB
TANK
15
HYDRAULIC DIAGRAM - straddle legs lifting (with initial lift)
INITIAL LIFT
SB LB LB LB
C1 C2
Q3 Q2
RV2
Q4
Q1
(evp)
CV1
RV1
SB
TANK
16
HYDRAULIC DIAGRAM - straddle legs lowering (with initial lift)
INITIAL LIFT
SB LB LB LB
C1 C2
Q3 Q2
RV2
Q4
Q1
(evp)
CV1
RV1
SB
TANK
17
HYDRAULIC DIAGRAM - emergency forks lowering (with initial lift)
INITIAL LIFT
SB LB LB LB
C1 C2
Q3 Q2
RV2
Q4
Q1
(evp)
CV1
RV1
SB
TANK
18
HYDRAULIC PLAN FOR OIL RELEASE INTO THE TANK THROUGH THE PRESSURE RELIEF
VALVE
The pressure relief or pressure limiting valves are used in hydraulic systems in order to gua-
rantee the extreme pressures introduced into the system and to protect and safeguard the
system against sudden pressure increases that could seriously damage the components.
The pressure relief valve may come into operation in the following instances:
• Pressure regulation not suitable for the truck load capacity.
• Attempts to lift a load in excess of the truck's load capacity
• Blocked or faulty valve
CV1
RV1
LB LB LB
C2
Fork pressure relief valve (initial

lift) Q2
RV2
Q4
Q1
(evp)
RV1
19
HYDRAULIC COMPONENT
RELIEF VALVE DISMANTLING (all models)
The relief valve malfunction can be caused by the presence of dirt or a weakening of the inner spring.
In the first case a thorough cleaning is required, in the second case the valve needs to be replaced.
Equipment and tools
socket wrench
large Philips oil protecting
int. 22 mm ratchet
screw driver gloves
ext. Ø 26.5 mm
A
A A
Procedure
The hydraulic fluid, after system operation, is very hot
may cause scalding. It is recommended that oil protecting
gloves resistant to high temperatures be used.
Phase 1
Fig. 3
Phase 2
RATCHET - 22 mm SOCKET WRENCH - OIL PROTECTING GLOVES
Put the oil proof gloves on. B
Use the wrench to remove the complete valve (ref.B fig.3) and proceed
ASSEMBLY
During the assembly stage tighten the valve with a dyna-

mometric wrench set to 10 Nm.
20
PRESSURE RELIEF VALVE CALIBRATION (all models)

The calibration of pressure relief valve is required following replacement.
Equipment and tools
socket wrench hexagonal "T"

int. 10 mm ratchet section spanner
ext. Ø 13.5 mm 4 mm
Procedure
Fig. 2
A
Phase 1
Connect the battery and turn on the machine (ignition key to ON).
Position a load equivalent to the truck's load capacity, printed on the
truck's specification nameplate, on the truck's forks.
Phase 2 Fig. 3
RATCHET - 10 MM SOCKET WRENCH - 4 mm T HANDLE HEX KEY
Using the socket wrench, loosen the lock nut (ref.A fig.2).
Using the T handle hex key, loosen the adjusting screw (ref.B fig.3) tur- B
ning it counter-clockwise until, while pressing the fork lifting button on the
tiller (fig.4), 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 (or the straddle legs on
the initial lift version) 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 Fig. 4
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 socket wrench to tighten the lock nut (ref.A fig.2) to lock the
adjusting screw in position.
21
REMOVAL OF THE PRESSURE RELIEF VALVE (initial lift version only)

Equipment and tools
open ended
large cross-head
oil resistant gloves spanner
screwdriver
19 mm
A
A A
Procedure
of other vehicles and pedestrians. Lower the forks to the Fig. 1
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
LARGE CROSS-HEAD SCREWDRIVER
Use the screwdriver to unscrew and remove the screws securing the
motor compartment cover (ref.A fig.1). Fig. 2
Fig. 3
Phase 2
RATCHET - 19 mm SPANNER - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Use the spanner to remove the complete valve assembly (ref.B fig.3) B
and proceed with the replacement.
INSTALLATION
Install the valve and tighten with a torque wrench to 12
Nm.
22
CALIBRATION OF THE PRESSURE RELIEF VALVE (initial lift version only)

The pressure relief valve must be calibrated following replacement.
Equipment and tools
open ended
T handle hex key
spanner
5 mm
17 mm
Procedure
Before starting work, ensure that you are wearing suitable Fig. 1
Fig. 2
A
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 indi-
cated on the truck's dataplate.
Phase 2 Fig. 3
17 mm OPEN ENDED SPANNER - 5 mm T HANDLE HEX KEY
Loosen the lock nut with the spanner (ref.A fig.2).
Using the hexagonal "T" section spanner loosen the adjusting screw
(ref.B fig.3) turning it counter-clockwise until, while pressing the fork lif- B
ting button on the tiller (fig.4), 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 Fig. 4
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.
23
REMOVAL OF THE LOWERING FLOW RATE CONTROL VALVE

(for initial lift version only)
Malfunction of the flow rate control valve can be caused by dirt causing the spool to stick or by weakening
of the spring.
In the first case thorough cleaning is required, in the second case the valve needs to be replaced.
Equipment and tools
large flat blade T handle hex key

oil resistant gloves
screw driver 10 mm
Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from areas of transit of other vehicles and 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 ad-
visable to wear gloves that are resistant to oil and high
temperatures. Fig. 1
Phase 1
Carry out the procedure to remove the lift pump (see "REMOVAL OF
THE LIFT PUMP (INITIAL LIFT ").
Phase 2
OIL RESISTANT GLOVES - 10 mm T HANDLE HEX KEY - FLAT BLADE
SCREWDRIVER
Using the T handle hex key, unscrew and remove the blanking plug (ref.A
fig.2). With the flat blade screwdriver, unscrew and remove the valve from
its seat (ref.B fig.2) and proceed with the replacement.
Fig. 2
INSTALLATION A
Before installing the new valve, carry out the adjustment
procedure On installation, tighten the valve to a torque of
12 Nm and the plug to 29 Nm.
B
24
calibration of the lowering oil flow rate control valve

(for initial lift version only)
The oil flow rate can be varied between 20 and 30 litres by adjusting the spring preload by way of the
adjuster nuts.
Increasing spring compression increases the resistance of the slide to the diaphragm and therbey increases
the clyinder stroke on lowering.
Reducing spring preload reduces the resistance of the valve slide to the diaphragm and thereby reduces
the speed at which the cylinder performs the lowering stroke.
Before installing the valve on the hydraulic unit, measure the length of the spring. If the measured spring
length is the same as that of the previously removed valve, proceed with the installation of the new valve
on the hydraulic unit.
If the measured spring length is greater or less than that of the old valve, adjust the length of the spring
accordingly.
Equipment and tools
Fig. 1
open ended A
spanner pliers caliper
6-7 mm
Fig. 2
Procedure

Phase 1
Fig. 3
6-7 mm OPEN ENDED SPANNER - CALIPER
Using the pliers and a small piece of cloth, restrain the valve on the screw
(ref.A fig.1).
Using the 6 mm spanner, loosen the locknut (ref.B fig.2).
Using the 7 mm spanner, loosen or tighten the spring adjuster nut (ref.C
fig.3).
With the caliper, measure the length of the spring (fig.4) and turn the C
adjuster nut as necessary to obtain the correct measurement.
Using the 6 mm spanner, tighten the locknut (ref.B fig.2).
Fig. 4
25
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 THE COMPONENTS OF A CARTRIDGE SOLENOID VALVE
1 2
INITIAL LIFT
1 2 1 2
Ref. Description
1 Coil
2 Chassis valve
3 Washer
4 Elastic ring
26
SOLENOID VALVE DISMANTLING

Equipment and tools
oil protecting large/small Philips medium sized flat fixed spanner

gloves screw driver head screwdriver 14-19-22-26 mm
Procedure
The hydraulic fluid, after system operation, is very hot and
SOLENOID VALVE Q1
A
Phase 1 A A
Fig. 1
Phase 2
SMALL PHILIPS SCREWDRIVER
Unscrew the fastening screws and disconnect the energy supply con-
nector of the solenoid valve coil (fig.2).
Phase 3
OIL PROTECTING GLOVES - MEDIUM SIZES FLAT HEAD SCREWDRI-
VER - FIXED 14 mm SPANNER
Use the screwdriver to lift up the elastic ring (ref.B fig.3) and remove
it.
Slip the washer off (ref.C fig.3), the coil (ref.D fig.3) and retrieve the
Fig. 2
gaskets.
27
Use the fixed gauge spanner to unscrew the chassis valve from the
hydraulic block and proceed with the replacement.
ASSEMBLY B C
D
During the assembly stage tighten the valve fastening
screws with a torque of 40 Nm.
Fig. 3
INITIAL LIFT: SOLENOID VALVES Q2 AND Q4
Phase 4
SMALL CROSS-HEAD SCREWDRIVER
Unscrew the retaining screw and disconnect the connector of the power
supply to the solenoid coil.
E
Phase 5 Fig. 4
OIL RESISTANT GLOVES - 19-22 mm OPEN ENDED SPANNER
With the 19 mm spanner, unscrew the nut securing the coil (ref.E fig.4).
Withdraw the coil. Fig. 5
Using the 22 mm spanner, unscrew the nut securing the valve body to
the hydraulic unit (ref.F fig.5. Proceed with replacement
F
On installation, tighten the nut securing the valve body to
a torque of 35 Nm. Tighten the coil retaining nut to a torque
of 6 Nm.
INITIAL LIFT: SOLENOID VALVE Q3

G Fig. 6
Phase 6
Unscrew the retaining screw and disconnect the connector of the power
supply to the solenoid coil.
Phase 7 H
OIL RESISTANT GLOVES - 26mm OPEN ENDED SPANNER
Unscrew the coil retaining nut (ref.G fig.6). Withdraw the coil.
Using the spanner, unscrew the nut securing the valve body to the hydrau-
lic unit (ref.F fig. Proceed with replacement
On refitting the valve body, tighten the retaining nut to a

torque of 29 Nm.
28
CYLINDERS
SINGLE ACTING CYLINDER
The single acting cylinders receive and discharge the oil from a single pipe and the pressurised oil acts
on a single piston face (single action cylinders during the thrust stage) or on the plane face of the shaft for
plunging cylinders.
Single plunge action cylinders
With these cylinders it is the same flat side of the shaft that replaces the piston and is usually positioned
vertically or in other positions in which in any case it is the force of gravity that returns it to the rest position.
Usually the diameter of the bottom of the shaft is increased by a few millimetres in order to avoid it slipping
out at the top of it's upstroke; this gives rise to a hydraulic damping effect during the last stages of it's stroke
which helps the slowing of the shaft and avoids recoils on the upper cylinder head. Place in the latter, the
necessary static sealing gaskets which avoid seepage of oil to the exterior.
In order to replace these gaskets one must unscrew the gasket case bushing.
The hollow shaft simple action cylinders differ in that before beginning the lift stroke even the shaft is filled
with oil. This solution is used on particularly tall masts to increase the resistance of the cylinders at the
greater heights and make it possible to use smaller barrels and shafts.
Static and dynamic gaskets
The dynamic gaskets, assembled on the piston, avoid the seepage of the fluid from one barrel chamber
to the next, the static gaskets, placed in the points where the parts meet (gasket case bushing - barrel) or
between the sliding parts (shaft- chamber), avoid oil seepage from inside to outside.
LIFTING CYLINDERS: COMBINATIONS
Shaft
Mast Mast Mast Height H3
Type of cylinder diameter
1 stage 2 stages 3 stages mm
mm
Type “A” with simple plunging effect

and solid shaft
35 l l 2603 - 4627
Type “B” with a simple push effect 50 l l l 1260 - 4627
Single-acting plunger type “C” with

solid rod (initial lift only)
50 l l h5 130
H3
29
KEY TO INITIAL LIFT CYLINDER COMPONENTS

The cylinder is of the single-acting plunger type.
After replacing the cylinder, bleed the air through the bleed valve.
7
6
5
4 2 1 3
Ref. Description
1 Barrel and end cap

2 Piston rod
3 Rod end cap
4 Piston
5 Guide ring
6 Seal kit
7 Air bleed screw
30
IDENTIFICATION OF THE LATERAL LIFT CYLINDER COMPONENTS

It is a simple action plunging cylinder.
After the replacement of the entire cylinder one must carry out the bleeding of the air through the bleeding
valve.
The static gaskets are replaced with the cylinder mounted in the machine.
5 7
4
3 1 2 6
Ref. Description
1 Barrel
2 Shaft
3 Guide bushing
4 "LB" Parachute valve
5 Air bleeding valve
6 Gasket set
7 Gasket housing bushing
31
IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS

It is a simple action thrusting cylinder with a slowing system on the upstroke before the end point.
The static gaskets contained in the gasket case bushing are replaced with the cylinder mounted in the
machine, while the replacement of the dynamic gaskets on the piston require the cylinder to be removed
from the machine and dismantled.
6 7 8 9 10
5
4 12 3 1 2 11
Ref. Description
1 Barrel
2 Shaft
3 Chamber
4 Check valve
5 "LB" Parachute valve
6 Elastic ring
7 Guide ring
8 Dynamic gasket
9 Air bleeding valve
10 Gasket housing bushing
11 Gasket set
12 Piston
32
OPERATION
During the lifting stage the air contained in the cylinder barrel enters into the shaft inner chamber
through a hole (ref.A). When the piston approaches the stroke end point it presses the oil against the
gasket housing bushing, the increase in pressure forces the oil into the chamber through a second
hole (ref.B).
The oil is thus compressed in the chamber together with the air generating a "cushioning" effect that
slows the cylinder stroke over the last 40/50 mm, thus ensuring that the piston does not knock against
the mechanical end point stop.
B A
inner shaft chamber
shaft
piston
33
DISMANTLING OF LATERAL LIFT CYLINDER

Equipment and tools
lifting belt tackle pliers to open me-

fixed spanner
load capacity load capacity dium size elastic
19 mm
1000 kg 1000 kg rings
Fig. 1
oil protecting
n. 2 wood beams n. 2 iron trestles "Parker" cap
gloves
hammer ladder
Size of wood beams

width 100 mm
depth: 100 mm
The lengths vary based on the mast elevation.
B B
Fig. 2
34
Procedure
Fig. 3
the forks to the ground.
Phase 1
Wood BEAMS
Raise the mast using one of the buttons on the rudder.
Place the wooden beam beneath the inner mast upright (rif.B fig.2).
Move the mast downwards until it rests on the beams.
Phase 2
LADDER - pliers TO OPEN ELASTIC RINGS MEDIUM
Climb up the ladder with the tools.
Using the pliers remove the elastic ring from the top of the cylinder to be
dismantled (ref.A fig.1).
Activate the fork descent command, continue the descent until the shaft
is once again housed completely inside the cylinder (fig.3).
Position the key switch to OFF and disconnect the batte-

ry. Fig. 4
Fig. 5
Phase 3
fixed spanner 19mm - pliers FOR ELASTIC RING OPENING
MEDIUM SIZE- OIL PROOF GLOVES - PARKER CAP
Put the oil proof gloves on.
Unscrew the coupling on the cylinder feed pipe (ref.C fig.5) and apply D
the cap.
Using the elastic ring pliers remove the ring at the cylinder base (ref.D
C
fig.5).
35
Phase 4
Fig. 6
TACKLE - LIFT BELT - LADDER
Place the tackle above the mast, beside the cylinder to be removed.
Climb up the ladder with the lift belt.
Make a slipknot at one end of the rope and tie the cylinder beneath the
air bleeding valve (fig.6). Tighten the slipknot.
Hook the other end of the rope to the tackle hook and make taught.
Phase 5
LADDER - HAMMER
Use the hammer to remove the cylinder stop ring (ref.E fig.7). Remove
the ring.
Phase 6
TACKLE - TRESTLES
Lift the cylinder upwards using the tackle until the bottom comes away
from the base of the mast (fig.8).
Extract the cylinder, place it on the two trestles and proceed with the
separation into parts or replacement. E
Fig. 7
ASSEMBLY
Before tightening the hydraulic connections, consult the

table of reference (see "CORRECT METHOD TO APPLY
THE FEMALE CONNECTORS” "PREFACE" section).
After the assembly perform the air bleeding procedure

from the cylinder (see “LIFT CYLINDERS: AIR BLEE-
DING”).
Fig. 8
36
CENTRAL LIFT CYLINDER DISMANTLING

The central cylinder is mounted on trucks with one and three stage masts and, depending on the time of
column, it performs the following functions:
• 3-stage mast: lift the forks followed by the fork extensions
• single stage mast: lift the forks
Equipment and tools
tackle n. 2 wooden
fixed spanner
load capacity N. 2 lift belts beams
13 -19 - 22 mm
1000 kg 100x100x500 mm
pliers to open hexagonal "T"

oil protecting
taper end pliers medium size section spanner
gloves
elastic rings 5 mm
A A
Fig. 1
"Parker" cap "Parker" cap

Fig. 2
Procedure
B
all suitable safety clothing. C
Move the carriage to a safe place, away from areas of B
37
Phase 1
Wooden beams 100x100x500 mm
Raise the mast using one of the buttons on the tiller.
Position the wooden beams beneath the forks (ref.A fig.1). Move the
mast downwards until the forms rest on the beams. Continue the descent
in order to loosen the chains.

ry.
D
Phase 2 Fig. 3
FIXED GAUGE 13 mm SPANNER
Unscrew and remove the bracket fastening screws (ref.B fig.2), retrieve
the elastic washers and remove the bracket (ref.C fig.2).
e
Phase 3 g
TAPER END PLIERS
Using the pliers remove the safety pin and the hinge pins (ref.D fig.3) f
that secure the chains to the chain tensioner positioned on the truck
bulkhead.
Remove the chains from the guide way pulleys and rest them on the Fig. 4
forks.
Fig. 5
Phase 4
MEDIUM SIZE PLIERS TO OPEN ELASTIC RINGS
Use the elastic ring pliers to remove the elastic ring blocking the pulley
base plate (ref.E fig.4).
Slip the complete pulley base plate away from the cylinder shaft (ref.F
fig.4), retrieving the spreaders (ref.G fig.4).
Connect the battery and position the ignition key on ON
Phase 5
38
Position the key switch to OFF and disconnect the batte- Fig. 6
ry.
Phase 6
TACKLE - N° 2 LIFT BELTS
Secure the fork carrying plate with the two lift belts.
Hook the belts on the tackle and lift 1000 mm (fig.6).
Remove the wooden beams.
Phase 7
OIL PROTECTION GLOVES - FIXED 19-22 mm SPANNER - "PARKER"
CAPS - MEDIUM SIZE PLIERS TO OPEN ELASTIC RINGS
Unscrew the cylinder hydraulic feed tube connector positioned at the
base of the cylinder itself (ref.H fig.7).
Apply the caps to the connectors.
Use the elastic ring pliers to remove the elastic ring blocking the cylinder
(ref.I fig.7).
Phase 8
Using the hexagonal "T" section spanner remove the screws from the
cylinder stop bracket (ref.J fig.8) and retrieve the washers.
Slip the bracket away and remove it (fig.8).
Remove the cylinder and proceed with the replacement or the separation
into parts.
ASSEMBLY
i
Do not reuse the chain anchoring safety pins, use new h
safety pins, ensuring they are the correct size.
Fig. 7
Before tightening the hydraulic connections, consult the
table of reference (see "CORRECT METHOD TO APPLY
THE FEMALE CONNECTORS” "PREFACE" section).
After the assembly perform the cylinder air bleeding pro-

cedure (see “LIFT CYLINDERS: AIR BLEEDING”).
J
J
Fig. 8
39
REMOVAL OF THE "INITIAL LIFT" CYLINDER

Equipment and tools
hoist 2 lifting slings

medium cross- T handle hex key battery extension
load capacity load capacity wooden pallet
head screwdriver 4 mm lead
2000 kg 1500 kg
Allen key socket long driving tool

"Parker" cap ratchet extension
5 mm 9 mm Ø 15 mm
open ended
slide hammer
long cable ties hammer spanner
puller
18-19 mm
Procedure
of other vehicles and pedestrians. Lower the forks and the
straddle legs to the ground. Turn the keyswitch to OFF
Phase 1
LARGE CROSS HEAD SCREW DRIVER A
Use the cross head screwdriver to unscrew and remove the screws se- A A
curing the motor compartment cover (ref.A fig.1).
Fig. 1
40
Phase 2
Fig. 2
"Parker" service plug
Carry out the mast removal procedure (see “REMOVAL OF THE MAST
ASSEMBLY” in the “MAST MECHANICS” section).
Fit a “Parker”plug to the connection fitting of the hydraulic pipe on the
truck base (ref.B fig.2).
Phase 3
B
BATTERY EXTENSION LEAD
Remove the battery (reverse the installation procedure, see “BATTERY
INSTALLATION, “INSTALLATION AND SETTINGS” section).
After removing the battery, place it near the truck so that

Fig. 3
it can be used with the aid of the extension lead.
Connect the battery and turn the keyswitch to ON.
Phase 4
Wooden pallet - long cable ties
Using the straddle leg lifting button located under the tiller (fig.3), raise
the straddle legs to the maximum height. Fig. 4
Position the wooden pallet under the straddle legs (fig.4). Lower the
straddle legs so that they rest on the pallet. Fasten the straddle legs to
the pallet with the ties.
Phase 5
hoist - lifting sling
Pass the lifting sling between the front and rear bodies, using the hole to
the left of the motor compartment (fig.5).
Attach the lifting sling to the hoist positioned directly above the truck and
take up the slack. Fig. 5
Phase 6
4 mm T HANDLE HEX WRENCH - HAMMER - SLIDE HAMMER PUL-
LER
Using the T handle hex key, unscrew and remove the screw securing the
cylinder pin (ref.C fig.6).
Using the hammer and the slide hammer puller, remove the initial lift
cylinder pin (ref.D fig.6)
Using the straddle legs lowering button on the tiller (fig.7), retract the
cylinder to its stroke end.
41
Fig. 6
Turn the ignition key to OFF and disconnect the battery.
C
Phase 7
Remove the lift pump (see “LIFT PUMP REMOVAL- MODELS WITH
INITIAL LIFT”).
D
Phase 8
Pass the second lifting sling between the front and rear body assemblies,
Fig. 7
using the hole to the right of the motor compartment (fig.8).
Attach the lifting sling to the hoist and take up the slack in both the slings
attached to the rear body.
Phase 9
19 mm open ended spanner
Using the spanner, unscrew the connection fitting of the hydraulic pipe
(ref.E fig.9).
Fig. 8
Phase 10
9 mm SOCKET WRENCH - RATCHET - EXTENSION
Using the socket wrench, ratchet and extension, unscrew and remove
the grease nipples from the two pins securing the tie-rods to the frame
(ref.F fig.10).
Phase 11
5 mm ALLEN KEY
With the Allen key, unscrew and remove the grub screws securing the
tie-rod/frame pivot pins (ref.G fig.11).
Phase 12
HAMMER - LONG DRIVING TOOL
Using the hammer and the driving tool, remove the tie-rod/frame pivot
pins (ref.H fig.12).
E
Phase 13
HOIST - 2 WOODEN BLOCKS
With the aid of the hoist, separate the rear body from the front body,
(fig.13) taking care to withdraw the battery cable.
Place the rear body on two wooden blocks in a safe place, keeping the Fig. 9
lifting slings under tension (fig.14).
42
Phase 14
Fig. 10
18 mm OPEN ENDED SPANNER
Using the spanner, unscrew the four bolts securing the cylinder (ref.F
fig.15) and recover the washers.
F
Remove the cylinder and proceed with replacement or disassembly.
INSTALLATION
Before tightening the hydraulic connection fittings, con-

sult the reference table, (see "CORRECT METHOD FOR
APPLYING FEMALE FITTINGS”, "FOREWORD" section).
After installing the cylinder, carry out the air bleeding pro-
cedure (see “BLEEDING THE INITIAL LIFT CYLINDER”).
Fig. 11
G
Fig. 12
Fig. 14
F
Fig. 13
Fig. 15
43
LIFT CYLINDERS: AIR BLEEDING

Equipment and tools
hexagonal "T"
oil protecting
section spanner
gloves
3 mm
Procedure
Phase 1
OIL PROTECTING GLOVES - 3 mm HEXAGONAL "T" SECTION SPAN-
Fig. 1
NER
With the hexagonal "T" section spanner loosen the air bleeding valve
(ref.B fig.1).
Connect the battery and position the ignition key on ON. A
Phase 2 B
3 mm HEXAGONAL "T" SECTION SPANNER
Lift the forks using the button placed on the tiller, continue lifting until oil
pours out of the air bleeding valve (ref.A fig.1).
Stop lifting and tighten the screw (ref.B fig.1).
Wipe the cylinder with a clean cloth.
44
BLEEDING THE INITIAL LIFT CYLINDER

Equipment and tools
open ended
oil resistant gloves spanner
10 mm
Procedure
of other vehicles and pedestrians. Turn the keyswitch to
OFF and disconnect the battery.
Fig. 1
Phase 1
OIL RESISTANT GLOVES - 10mm OPEN ENDED SPANNER
Using the spanner, loosen the air bleed screw (ref.B fig.1).
A
Connect the battery and turn the starter key to ON. B
Phase 2
10mm OPEN ENDED SPANNER
Lift the straddle legs using the button located on the tiller; continue lifting
until oil flows out of the bleed valve (ref.A fig.1).
Stop lifting and tighten the bleed screw (ref.B fig.1).
Wipe the cylinder with a clean cloth.
45
REPLACEMENT OF STATIC GASKETS ON LATERAL LIFT CYLINDERS

Equipment and tools
pliers to open me-

small sized flat oil protecting
ladder dium size elastic
head screwdriver gloves
rings
Fig. 1
n. 2 wood beams brush hook wrench chain pipe wrench
Size of wood beams

width 100 mm
depth: 100 mm
The lengths vary based on the mast elevation.
Procedure
B B
Fig. 2
46
Phase 1
Fig. 3
Wood BEAMS
Place the wooden beam beneath the inner mast upright (rif.B fig.2).
Move the mast downwards until it rests on the beams.
Phase 2
LADDER - MEDIUM SIZED pliers TO OPEN ELASTIC RINGS
Using the pliers remove the elastic ring from the top of the cylinder to be
dismantled (ref.A fig.1).

ry.
Fig. 4
Phase 3
LADDER - OIL PROTECTION GLOVES - HOOK WRENCH - CHAIN
PIPE WRENCH
Apply the hook wrench in conjunction with the pin hole in the gasket case
bushing and the pipe wrench on the cylinder barrel. Unscrew the casing C
from the cylinder (ref.C fig.4) slip it away from the shaft and place it on
the workbench.
Phase 4
SMALL FLAT HEAD SCREWDRIVER - BRUSH
Remove the external gaskets using the screwdriver (ref.D fig.5), the
gaskets external to the bushing (ref.E fig.5) and proceed with the sub-
stitution.
ASSEMBLY
The fitting of the sealing gaskets is a delicate stage of the

D
lift cylinder assembly procedure. Most maintenance ope-
rations are to be ascribed to gasket leakage.
Clean the gasket housing bushing and lubricate the gasket

seats with clean hydraulic oil as well as the gaskets them-
selves before assembling them.
During the assembly stage tighten the bush to 340 Nm. E Fig. 10
Fig. 5
47
REPLACEMENT OF STATIC GASKETS ON THE CENTRAL LIFT CYLINDER

Equipment and tools
tackle
wooden beam
workbench load capacity N. 2 lift belts
100x100x500 mm
1000 kg
small flat head

hook wrench chain pipe wrench brush
screwdriver
A A
Fig. 1
pliers to open me-
oil protecting fixed spanner
dium size elastic taper end pliers
gloves 13 mm
rings Fig. 2
Procedure B
Before starting work, ensure that you are equipped with C
B
48
Phase 1
mast downwards until the forks rest on the beams. Continue the descent

ry.
D
Phase 2 Fig. 3
Phase 3
e
g
TAPER END PLIERS
Using the pliers remove the safety pin and the hinge pins (ref.D fig.3) f
bulkhead.
Remove the chains from the guide way pulleys and rest them on the Fig. 4
forks.
Fig. 5
Phase 4
MEDIUM SIZE PLIERS TO OPEN ELASTIC RINGS
Slip the complete pulley base plate away from the cylinder shaft (ref.F
Connect the battery and position the ignition key on ON
Phase 5
49
Position the key switch to OFF and disconnect the batte- Fig. 6
ry.
Phase 6
Secure the fork carrying plate with the two lift belts.
Hook the belts on the tackle and lift 1000 mm (fig.6).
Remove the wooden beams.
Phase 7
OIL PROTECTION GLOVES - HOOK WRENCH - CHAIN PIPE WREN-
CH
Apply the hook wrench in conjunction with the pin on the gasket case
bushing and the pipe wrench on the cylinder barrel. Unscrew the bushing
from the cylinder (ref.H fig.7) slip it away from the shaft and place it on
the workbench.
Phase 8
SMALL FLAT HEAD SCREWDRIVER - BRUSH
Remove the internal gaskets using the screwdriver (ref.I fig.8), the Fig. 7
gaskets external to the bushing (ref.E fig.8) and proceed with the sub-
stitution. H
ASSEMBLY

lift cylinder assembly procedure. Most maintenance ope-
Clean the gasket housing bushing and lubricate the gasket

seats with clean hydraulic oil as well as the gaskets them-
selves before assembling them. I
Do not reuse the chain anchoring safety pins, use new
safety pins, ensuring they are the correct size.
During the assembly stage tighten the bush to 340 Nm.
J Fig. 10
Fig. 8
50
SMALL MAST LIFT CYLINDER SEPARATION INTO PARTS

• Dismantling of the parachute valve
• replacement of the dynamic gasket
• Replacement of the check valve
Equipment and tools
oil protecting fixed spanner medium size taper

workbench vice hook wrench
gloves 22 mm end pliers
medium elastic small flat head

chain pipe wrench oil syringe brush
ring closing pliers screwdriver
Procedure
all suitable safety clothing. A
Phase 1
Carry out the central lift cylinder dismantling procedure (see “CENTRAL
LIFT CYLINDER DISMANTLING”).
Fig. 2
Phase 2
Unscrew and remove the cylinder connector (ref.A fig.1).
51
DISMANTLING OF THE PARACHUTE VALVE

Phase 3
WORKBENCH - OIL PROTECTION GLOVES - MEDIUM SIZE TAPER D
END PLIERS
Using the medium size taper end pliers unscrew from the seat and extract
the parachute valve (ref.B fig.2). Proceed with the cleaning and elimina-
tion of any dirt residue or the adjustment of the spring load.
Replace if broken.
REPLACEMENT OF THE DYNAMIC GASKET E

Fig. 3
Phase 4
WORKBENCH - VICE - OIL PROTECTING GLOVES - HOOK WRENCH
- PIPE WRENCH - SMALL FLAT HEAD SCREWDRIVERS
Secure the cylinder in the vice, placing a rubber protection between the
clamp jaws and the cylinder barrel.
Apply the hook wrench in conjunction with the pin on the gasket housing
bushing (ref.D fig.3) and the pipe wrench on the cylinder barrel (ref.E
fig.3). Unscrew the bushing from the cylinder and slide it away from the
shaft (fig.3).
Remove the shaft from the cylinder (fig.4).
Using the flat head screwdrivers remove the piston gasket (ref.F fig.5).
Fig. 4
REPLACEMENT OF THE CHECK VALVE
Phase 5
WORKBENCH - OIL PROTECTING GLOVES F
Using the elastic ring pliers remove the valve stop elastic ring (ref.G fig.6)
e retrieve the spreader (ref.H fig.6).
Extract the valve (ref.I fig.6).
Fig. 5
ASSEMBLY
lift cylinder assembly procedure. Most maintenance ope- G
H
Do not damage the parts during assembly.
Lubricate all the inner parts of the cylinder with clean

I
hydraulic oil.
Use new gaskets.
Ensure that the arrow placed on the check valve is direc-

ted towards the piston base.
During the assembly stage tighten the bush to 340 Nm. Fig. 6
52
53
lift pump
IDENTIFICATION OF THE LIFT PUMP COMPONENTS
all models excluding initial lift models
Ref. Description
1 Pump motor
2 Distributor
3 Pump chassis
4 Tank
5 Proportional Q1 solenoid valve
6 Motor brushes
7 Safety valve
8 Oil extractor pipe
9 Oil drainage pipe
10 Check valve
11 Filter
54
10
11
55
IDENTIFICATION OF THE LIFT PUMP COMPONENTS

Ref. Description
1 Pump motor
2 check valve
3 Coupling
4 Oil flow control valve
5 Adapter
6 Directional control valve gaskets
7 Reservoir gasket
8 Pressure relief valve
9 Pump chassis
10 Oil drainage pipe
11 Oil intake pipe
12 Filter
13 Reservoir
14 Solenoid operated proportional valve Q1
15 Fork pressure relief valve
16 Directional control valve
17 Fork lowering solenoid valve Q2
18 Fork lifting solenoid valve Q4
19 Straddle legs lifting/lowering solenoid valve Q3
56
19
18
2 3
4
17
5
16
15
6 8
7
14
10
11
13
12
57
LIFT PUMP DISMANTLING

all models excluding initial lift models
They hydraulic unit is the same on all the different lift truck series. The only difference lies in the pump
engine which on the trucks with a load capacity of 1000/1200 kg has a power rating of 2000 W and on the
trucks with a load capacity of 1400/1600 kg has a power rating of 3000 W. All the other components are
the same and are dismantled in the same way.
Equipment and tools
large - small
fixed spanner oil protecting
workbench Philips screw
13-17-22 mm gloves
driver
A
A A
Procedure
the forks to the ground. Position the key switch to OFF
Fig. 2
gloves resistant to high temperatures be used. B
Phase 1
Phase 2
FIXED GAUGE 13 mm SPANNER C
Having removed the lug protection caps, use the fixed spanner to unscrew
the fastening nuts of the pump motor energy feed cables (ref.B fig.2).
Take note of the cable positions. Slide the cables out and disconnect the
connectors.
58
Phase 3
Fig. 4
SMALL PHILIPS SCREWDRIVER
Unscrew the fastening screws and disconnect the energy supply con-
nector of the solenoid valve coil (Ref.C fig.3).
D
Phase 4
OIL PROTECTING GLOVES - fixed spanner 22mm
Using the fixed spanner unscrew the connector of the hydraulic pipe
(ref.D fig.4).
Fig. 5
Phase 4
fixed gauge 17 mm spanner
Using the fixed spanner unfasten the bolts that secure the motor to the
truck base (ref.E fig.5), retrieve the washers, extract the pump chassis
and place it on a workbench.
59
LIFT PUMP DISMANTLING

Equipment and tools
open ended span- large - small

workbench ner cross-head screw oil resistant gloves
13-17-18 mm drivers
A
A A
Procedure
of other vehicles and pedestrians. Lower the forks to the Fig. 1
ground. Turn the keyswitch to OFF and disconnect the
battery.
Fig. 2
are resistant to oil and high temperatures. B
Phase 1 Fig. 3
LARGE CROSS-HEAD SCREW DRIVER
Use the screwdriver to unscrew and remove the screws securing the
motor compartment cover (ref.A fig.1). C
Phase 2
13 mm OPEN-ENDED SPANNER
Having removed the terminal covers, use the spanner to unscrew the
fastening nuts of the pump motor power supply cables (ref.B fig.2).
Make a note of the cable positions. Remove the cables and disconnect
the connectors.
60
Phase 3
Fig. 4
Unscrew the fastening screws and disconnect the power supply connec- E
tors of the four solenoid coils (ref.C fig.3). D
Phase 4
OIL RESISTANT GLOVES -18mm OPEN ENDED SPANNER
Using the spanner, unscrew the hydraulic pipe connection fittings (ref.D,E
fig.4).
Fig. 5
Phase 4
17 mm open-ended spanner
Using the spanner, unfasten the bolts that secure the motor to the truck
base (ref.F fig.5), recover the washers, extract the pump body and place
it on a workbench.
61
PUMP REPLACEMENT
Equipment and tools
hexagonal "T"
fixed spanner small flat head oil protecting
section spanner
10 mm screwdriver gloves
5 mm
Procedure
Phase 1 A
Carry out the lift pump dismantling procedure (see "LIFT PUMP DISMAN-
TLING"). Fig. 2
Phase 2
FIXED 10 mm SPANNER - A SMALL FLAT HEAD SCREWDRIVER
Loosen the screw that holds the steel clip that fastens the tank to the
flange (ref.A fig.2). Unscrew and remove the four screws that fasten the
tank to the flange using the fixed spanner (ref.B fig.3), and slip away the
solenoid pump complete with flange from the tank.
Phase 3
B
Lower the thin fastening plate of the pipe together with the filter (ref.C
fig.4) and slip the pipe away from the pump chassis. Unscrew and remove
the nuts that fasten the pump chassis to the flange (ref.D fig.4), remove
the pump and proceed with the replacement.
Fig. 3
62
ASSEMBLY
During the assembly stage tighten the nuts that fasten the
pump to the flange with a torque wrench set at 29 Nm. Use
medium size Loctite
D
Fig. 4
63
HYDRAULIC PIPES
PIPE PLACEMENT FOR HYDRAULIC CIRCUIT
2 STAGES 1 STAGE
64
3 STAGE FFL 2 STAGE FFL
65
INITIAL LIFT
66
REPLACEMENT OF CYLINDER FEED PIPES

3 STAGE MAST
Equipment and tools
Fig. 1
bridge crane lifting belt

load capacity load capacity
19 - 22 mm gloves
2000 kg 2000 kg
large flat head n. 2 wood beams

ladder "Parker" caps
screw driver 100x100x1500 mm
Fig. 2
Procedure
Before starting work, ensure that you are equipped with B
DISMANTLING FLEXIBLE HYDRAULIC PIPE
Phase 1
Harness the two inner moving struts with the lift belt (fig.1). Lift the moving
struts to loosen the hydraulic pipe that feeds the fork lift cylinder.
67
Phase 2
OIL PROTECTING GLOVES - FIXED 19 mm GAUGE SPANNER - "PAR-
KER" CAPS
Wear the oil proof gloves.
Using the fixed spanner unscrew the connector of the hydraulic pipe
(ref.A-B fig.2).
Apply the caps to the connectors. Retrieve the hydraulic pipe and proceed
DISMANTLING OF RIGID HYDRAULIC PIPE Fig. 3
Phase 3
LARGE FLAT HEAD SCREWDRIVER
Using the screwdriver unscrew and remove the fastening screws of the
lexan protective cover (ref.C fig.3) and retrieve the washers.
Retrieve the protective panel.
Phase 4
D
BRIDGE CRANE - LIFT BELT - N.2 WOODEN BEAMS MEASURING
100x100x1500 mm
Use the bridge crane to lift the inner moving struts by around 1600 mm
Position the wooden beams beneath the intermediate upright assembly
channel (ref.E fig.5). Move the mast downwards until it rests on the Fig. 5
beams.
Phase 5
LADDER - FIXED 22 mm GAUGE SPANNER - "PARKER" CAPS
Using the fixed spanner unscrew the hydraulic pipe coupling connecting
it to the upright assembly base (ref.F fig.6).
Apply the connector cap.
Climb the ladder. Using the fixed spanner unscrew the coupling of the
hydraulic pipe on the outer upright (ref.D fig.4).
Apply the connector cap.
Extract the hydraulic pipe from the moving strut and proceed with repla-
cement.
F E E
Fig. 5
68
REPLACEMENT OF THE HYDRAULIC PIPE HOSE SHEAVE

3 STAGE MAST
Equipment and tools
Fig. 1

taper end pliers "Parker" cap
gloves 19 - 20 mm
Procedure
A
Fig. 2
Phase 1
OIL PROTECTING GLOVES - FIXED 19 mm GAUGE SPANNER - "PAR-
KER" CAP B
Using the fixed spanner unscrew the coupling of the hydraulic pipe (ref.A
fig.1).
Apply the cap to the coupling, and rest the hydraulic pipe on the forks.
Phase 2
TAPER END PLIERS
Using the pliers remove the cotter pins of the chain tensioner placed on
Fig. 3
the outer upright. Remove the pins (ref.B fig.2).
Lower the chains onto the forks.
D
Phase 3
Using the fixed spanner loosen and remove the fastening screws of the
hydraulic pipe hose sheave pin (ref.C fig.3).
Extract the pin (ref.D fig.3) and retrieve the hose sheave (ref.E fig.3). E
Proceed with the replacement C
ASSEMBLY
After assembly grease the hose sheave bearings by using
a cartridge greasing nipple.
69
RENEWAL OF THE OIL SUPPLY PIPE TO THE INITIAL LIFT

CYLINDER
Equipment and tools
A
A A
bridge crane lifting sling open-ended

load capacity load capacity spanner oil resistant gloves Fig. 1
2000 kg 2000 kg 19 -22 mm
Fig. 2
large flat blade 2 wooden beams

ladder "Parker" cap
screw driver 100x100x1500 mm
Procedure Fig. 3

ground.
Phase 1
LARGE CROSS-HEAD SCREW DRIVER
Use the cross-head screwdriver to unscrew and remove the fastening
Open the motor compartment cover. Fig. 4
Phase 2
wooden beam
Using the straddle leg lifting button on the tiller (fig.2), raise the straddle
legs to the maximum height.
Position the beams under the straddle legs (fig.3). Lower the straddle
legs so they rest on the beam.
B
70
Phase 3
OIL RESISTANT GLOVES - 18 mm OPEN ENDED SPANNER - "PAR-
KER" PLUG
With the spanner, unscrew the hydraulic pipe connection fitting from the
base of the frame (ref.B fig.4).
Fit the Parker plug to the connection fitting.
Using the straddle legs lifting button the tiller (fig.2), raise the straddle
legs, remove the wooden beam and lower the legs to the ground.

C
Fig. 5
Phase 4
INITIAL LIFT”).
Phase 5 D
5 mm T HANDLE HEX KEY
Using the T handle hex key through the opening in the motor compartment,
unscrew and remove the screws of the plate securing the hydraulic hose
(ref.C fig.5). Recover the plate.
Fig. 6
Phase 6
Using the open ended spanner, unscrew the connection fitting of the
hydraulic pipe (ref.D fig.6).
Recover the hydraulic pipe and proceed with replacement.
INSTALLATION

sult the reference table, (see "CORRECT METHOD FOR
71
72
SERVICE FRAME MECHANICS
frame mechanics
TRACTION WHEEL�� 2
IDENTIFICATION OF TRACTION WHEEL COMPONENTS�� 2
DISMANTLING THE TRACTION WHEEL�� 3
PIVOTING WHEEL ASSEMBLY�� 5
IDENTIFICATION OF PIVOTING WHEEL ASSEMBLY COMPONENTS�� 5
DISMANTLING OF PIVOT WHEEL ASSEMBLY�� 6
LOAD WHEELS�� 8
IDENTIFICATION OF LOAD WHEEL COMPONENTS (all models excluding initial lift models)�� 8
KEY TO LOAD WHEEL COMPONENTS (models with initial lift)�� 9
LOAD WHEEL REPLACEMENT (all models excluding initial lift models)�� 10
REPLACEMENT OF THE LOAD WHEELS (models with initial lift)�� 12
LOAD WHEEL ASSEMBLY REPLACEMENT (models with initial lift)�� 14
LINKAGE ASSEMBLY (models with initial lift only)�� 15
KEY TO LINKAGE ASSEMBLY COMPONENTS�� 15
REMOVAL OF THE LINKAGE ASSEMBLY�� 16
ADJUSTMENT OF THE LINKAGE ASSEMBLY�� 20
TIE-RODS ASSEMBLY GREASING POINTS�� 21
TILLER�� 22
IDENTIFICATION OF TILLER COMPONENTS�� 22
TILLER DISMANTLING�� 23
TILLER SPRING REPLACEMENT�� 25
traction motor�� 27
IDENTIFICATION OF TRACTION motor COMPONENTS�� 27
TRACTION MOTOR DISMANTLING�� 28
OIL SEAL REPLACEMENT�� 30
BEARING REPLACEMENT�� 32
1
FRAME MECHANICS SERVICE
TRACTION WHEEL
IDENTIFICATION OF TRACTION WHEEL COMPONENTS
2
1
Ref. Description
1 Vulkollan ring complete with hub

2 Traction wheel fastening nut
2
DISMANTLING THE TRACTION WHEEL

Equipment and tools
large Philips socket wrench

hydraulic jack n. 2 wood stocks
screw driver 19 mm
ratchet with
extension torque wrench
extension
Procedure
the forks to the ground, push the forks against an obstacle
in order to keep the truck blocked when it is lifted using
the hydraulic jack , position the ignition key on OFF and A
disconnect the battery. A A
Fig. 1
On versions with initial lift, before disconnecting the bat-
tery, raise the straddle legs to the maximum height.
Phase 1
Phase 2
HYDRAULIC JACK - N. 2 WOODEN STOCKS
Position the hydraulic jack at the centre of the bodywork (fig.2) and lift
until the wooden stocks can slip beneath.
Position the wooden stocks at the side of the truck (fig.2), lower the jack
Fig. 2
and lower the truck onto the stocks.
3
Phase 3
19 mm socket wrench - ratchet - extension - TORQUE
WRENCH
Through the hole in the side of the bodywork (ref.B fig.3) unscrew and
remove the traction wheel fastening nuts (ref.C fig.4), retrieve the wa-
shers and extract the wheel.
ASSEMBLY
The traction wheel fastening nut must be tightened using

a torque wrench with a torque power of 85 Nm.
Fig. 3
C
Fig. 4
4
PIVOTING WHEEL ASSEMBLY

IDENTIFICATION OF PIVOTING WHEEL ASSEMBLY COMPONENTS
7
5
6
3 4
3 2
4
1 Wheel 6 Self-locking nut
2 Bush 7 Forks
3 Wheel bearing 8 Spacers
Flanged screwssecuring the pivoting wheel

4 Bush 9
assembly to the bodywork
5 Pivoting wheel fastening screws
5
DISMANTLING OF PIVOT WHEEL ASSEMBLY

Equipment and tools
large Philips socket wrench

hydraulic jack n. 2 wood stocks
screw driver 19 mm
A
A A
ratchet with Fig. 1

extension torque wrench
extension
Procedure
the hydraulic jack , position the ignition key on OFF and
disconnect the battery.
Fig. 2
Phase 1
C
on the motor compartment cover (ref.A fig.1). B
Phase 2
B
C
Position the hydraulic jack at the centre of the bodywork (fig.2) and lift Fig. 3
6
Phase 3
15 mm socket wrench - ratchet
Using the socket wrench unscrew and remove the two screws fastening
the pivoting wheel assembly to the bodywork (ref.B fig.3) and loosen the
other two screws (ref.C fig.3). Retrieve the shims (fig.4) and extract the
wheel assembly making the fastening screws pass through the holes in
the bodywork (ref.D fig.5).
DISMANTLING OF PIVOTING WHEEL
Phase 4
socket wrench 19 mm- ratchet - 19 mm FIXED gauge span- Fig. 4
ner
Using the fixed gauge spanner hold the self-blocking nut of the pivoting
wheel steady (ref.E fig.6), while with the socket wrench and the ratchet
unscrew and remove the fastening screws of the pivoting wheel (ref.F.
fig.6). Retrieve the screws and the self-blocking nut and extract the wheel
from its lodging.
ASSEMBLY
The fastening nut of the pivoting wheel must be tightened

using a torque wrench with a torque power of 85 Nm. Fig. 5
Fig. 6
E F
7
LOAD WHEELS
IDENTIFICATION OF LOAD WHEEL COMPONENTS
(all models excluding initial lift models)
1 3
8
2
6
7 1
5
Ref. Description
1 Load wheel
2 Pin
3 Elastic dowel
4 Dust cap
5 Spacer
6 Bearing
7 Bushing
8 Grease nipple
8
KEY TO LOAD WHEEL COMPONENTS

(models with initial lift)
1
1
2
2
13
4
14
3
4 2
8 11 12
7
8
6
9
4
10
9
1 Spring pin 8 Spacer

2 Bush 9 bearing
3 Tie-rod pivot pin 10 Load wheel bush
4 Grease nipple 11 Load wheel
5 Wheel pin locking screw 12 Load wheel screw
6 Wheel pin 13 Straddle leg pivot pin
7 Dust cover 14 Wheel
9
LOAD WHEEL REPLACEMENT

(all models excluding initial lift models)
Equipment and tools
tackle lift belt

wooden beam
load capacity load capacity wooden stock
100x100x1500 mm
1000 kg 1000 kg
clamp gudgeon
pin extractor
hydraulic jack 15 mm in steel hammer
5 mm in diameter
diameter
small flat head cartridge grease

screwdriver nipple
Procedure
Phase 1
TACKLE - LIFT BELT
Lift the forks by 1500 mm using the lift button. Harness the inner upright
using the lift belt (fig.1).
Attach the belts to the tackle and raise until taught.
Fig. 1
10

ry.
Phase 2
HYDRAULIC JACK - WOODEN STOCK - WOODEN BEAM
Position the hydraulic jack beside the load wheel and lift until the wooden b
stock can pass beneath.
Position the wooden stock beneath the clamp and rest the truck on the
stock (ref.A fig.2).
a Fig. 2
Place the wooden beam beneath the forks for greater

safety when working (ref.B fig.2).
D
Phase 3
5 mm PIN EXTRACTOR - CLAMP GUDGEON - STEEL HAMMER C
Fig. 3
Using the hammer and the pin extractor expel the elastic dowel of the
pivot (ref.C fig.3). Extract the pivot (ref.D fig.3) using the clamp gudgeon
and the hammer.
Extract the load wheel assembly from its lodging, retrieve the spacers
and proceed with the disassembly or replacement.
F
LOAD WHEEL DISASSEMBLY E

Phase 4
PIN EXTRACTOR - CLAMP GUDGEON - STEEL HAMMER - SMALL
I
FLAT HEAD SCREWDRIVER H
Using the hammer and the pin extractor expel the elastic dowel of the G
Fig. 4
pivot (ref.E fig.4). Extract the pivot (ref.F fig.4) using the clamp gudgeon
and the hammer.
Extract the load wheel from its lodging.
Using the small sized flat head screwdriver extract the dust cap (ref.G
fig.4) retrieve the spacers (ref.H fig.4)and the bearings (ref.I fig.4). J
ASSEMBLY
Fig. 5
Following the assembly of the new load wheels grease the
bearings using the grease nipple cartridge (ref.J fig.5).
11
REPLACEMENT OF THE LOAD WHEELS

Equipment and tools
T handle hex key small flat blade wooden block

hammer
8 mm screwdriver 100x100x1000 mm
driving tool
grease gun
Ø 12 mm
Procedure
protective clothing. Fig. 1
of other vehicles and pedestrians. Raise the straddle legs
to the maximum height, turn the keyswitch to OFF and
Phase 1
WOODEN BLOCK
Place the wooden block under the straddle legs (fig.1). Lower the straddle
legs so that they rest on the wooden block and continue lowering until
the load wheels are raised off the ground by about 2 cm.
B
A C
Fig. 2
12
Phase 2
8 mm "T" HANDLE HEX KEY - HAMMER - DRIVING TOOL D
Using the T handle hex key, unscrew and remove the wheel pin retaining F
screw (ref.A fig.2). Using the hammer and the driving tool, drive out the pin
of the load wheel (ref.B Fig.2). Withdraw the load wheel from its support E
(ref.C fig.2) and proceed with its disassembly or replacement.
Phase 3
SMALL FLAT BLADE SCREWDRIVER
Using the small flat blade screwdriver, extract the dust cap (ref.D fig.3), G
remove the bearings (ref.E fig.3), spacers (ref.F fig.3) and bush (ref.G
fig.3).
E
Proceed with replacement
F
D Fig. 3
INSTALLATION
Following installation of new load wheels, grease the be-

arings using a grease gun.
13
LOAD WHEEL ASSEMBLY REPLACEMENT

Equipment and tools
driving tool wooden block pin punch

hammer
Ø 15 mm 100x100x1000 mm Ø 4 mm
Procedure
protective clothing. Fig. 1
of other vehicles and pedestrians. Raise the straddle legs
to the maximum height.
Phase 1
WOODEN BLOCK
Place the wooden block under the straddle legs (fig.1). Lower the straddle
legs so that they rest on the wooden block and continue lowering until
the load wheels are raised off the ground by about 2 cm.
Raise the forks by 500 mm. B
A
Phase 2 Fig. 2
HAMMER - PIN PUNCH - DRIVING TOOL
Using the hammer and the pin punch, drive out the spring pin securing
the pivot pin (ref.A fig.2). Drive out the pivot pin (ref.B fig.2) using the
driving tool and the hammer.
C
D
Phase 3
Using the hammer and the pin punch, drive out the spring pin securing
the pivot pin (ref.C fig.3). Drive out the pivot pin (ref.D fig.3) using the
driving tool and the hammer. Withdraw the load wheel assembly from Fig. 3
its housing.
Proceed with replacement.
14
LINKAGE ASSEMBLY (models with initial lift only)

KEY TO LINKAGE ASSEMBLY COMPONENTS
4 3
5
2
1
3
5 2
6 2 7
2
8
10
5 5
2
2
3
5
2 11
14
2 2 12 3
14 5
13
1 Load wheels assembly 8 Tie rod adjuster pin

2 Bush 9 Tie rod adjuster locknut
3 Spring pin 10 Tie rod
4 Pivot pin for load wheels - straddle leg 11 Truck base pivot pin
5 Grease nipple 12 Linkage assembly pin
6 Tie rod pivot pin - load wheels 13 Drive unit pivot pin
7 Adjustable tie rod end 14 Pin locking screw
15
REMOVAL OF THE LINKAGE ASSEMBLY

Equipment and tools
hoist 2 lifting slings

medium cross- T handle hex key battery extension
load capacity load capacity wooden pallet
head screwdriver 4 mm lead
2000 kg 1500 kg
Allen key socket long driving tool

"Parker" cap ratchet extension
5 mm 9 mm Ø 15 mm
open ended
slide hammer
pin punch hammer spanner scissors long cable ties
puller
19 mm
Procedure
of other vehicles and pedestrians. Lower the forks and the
straddle legs to the ground. Turn the keyswitch to OFF
Phase 1
LARGE CROSS-HEAD SCREW DRIVER A
Use the cross-head screwdriver to unscrew and remove the fastening A A
Fig. 1
16
Phase 2
Fig. 2
"Parker" service plug
Carry out the mast removal procedure (see “REMOVAL OF THE MAST
ASSEMBLY” in the “MAST MECHANICS” section).
Fit a “Parker”plug to the connection fitting of the hydraulic pipe on the
truck base (ref.B fig.2).
Phase 3
B
BATTERY EXTENSION LEAD
Remove the battery (reverse the installation procedure, see “BATTERY
INSTALLATION, “INSTALLATION AND SETTINGS” section).
When the battery has been removed, place it near the truck
Fig. 3
so that it can be used with the aid of the extension lead.
Connect the battery and turn the ignition key to ON.
Phase 4
Wooden pallet - long ties
Using the straddle leg lifting button located under the tiller (fig.3), raise
the straddle legs to the maximum height. Fig. 4
Position the wooden pallet under the straddle legs (fig.4). Lower the
straddle legs so that they rest on the pallet. Fasten the straddle legs to
the pallet with the ties.
Phase 5
Pass the lifting sling between the front and rear bodies, using the hole to
the left of the motor compartment (fig.5).
Attach the lifting sling to the hoist positioned directly above the truck and
take up the slack in the sling. Fig. 5
Phase 6
4 mm T HANDLE HEX KEY - HAMMER - SLIDE HAMMER PULLER
Using the T handle hex key, unscrew and remove the screw securing the
cylinder pin (ref.C fig.6).
Using the hammer and the slide hammer puller, remove the initial lift
cylinder pin (ref.D fig.6)
Using the straddle legs lowering button on the tiller (fig.7), retract the
cylinder to its stroke end.
17
Fig. 6
Turn the ignition key to OFF and disconnect the battery.
C
Phase 7
INITIAL LIFT”, in the section “ “HYDRAULIC SYSTEM”).
D
Phase 8
Pass the second lifting sling between the front and rear body assemblies,
Fig. 7
using the hole to the right of the motor compartment (fig.8).
Attach the lifting sling to the hoist and take up the slack in both the slings
attached to the rear body.
Phase 9
Using the spanner, unscrew the connection fitting of the hydraulic pipe
(ref.E fig.9).
Fig. 8
Phase 10
9 mm SOCKET WRENCH - RATCHET - EXTENSION
Using the socket wrench, ratchet and extension, unscrew and remove the
grease nipples from the two tie-rod/frame pivot pins (ref.F fig.10).
Phase 11
5 mm ALLEN KEY
With the Allen key, unscrew and remove the grub screws securing the
tie-rod/frame pivot pins (ref.G fig.11).
Phase 12
HAMMER - LONG DRIVING TOOL
Using the hammer and the driving tool, remove the tie-rod/frame pivot
pins (ref.H fig.12).
Phase 13 E
HOIST
With the aid of the hoist, separate the rear body from the front body,
(fig.13) taking care to withdraw the battery cable.
Rest the rear body in a safe place and detach the lifting slings.
Fig. 9
18
Phase 14
Fig. 10
HOIST - LIFTING SLING - SCISSORS
Taking great care, with the aid of the hoist and lifting sling, turn over the
front bodywork and place it in the optimal position for disassembling the
F
linkage (fig.14).
Phase 15
Using the pin punch and hammer, drive out the split pins securing the
pivot pins to the straddle legs (ref.I fig.14) Drive out the pivot pins (ref.J
fig.14) using the driving tool and the hammer.
Phase 16
Using the pin punch and hammer, drive out the split pin securing the pivot
pins to the truck base (ref.K fig.14) Drive out the pivot pin (ref.L fig.14)
using the driving tool and the hammer.
Raise and remove the linkage assembly from the bodywork and rest it
on a workbench.
Dismantle or replace. Fig. 11
G
INSTALLATION
Fig. 12
sult the reference table, (see "CORRECT METHOD FOR H
I
J
K
I
J
Fig. 13
Fig. 14
19
ADJUSTMENT OF THE LINKAGE ASSEMBLY

In order to adjust the linkage well, the truck must be equipped with a full set of new, drive, pivot and load
wheels. It must be set on a perfectly level surface raised off the floor to permit screwing in and unscrewing
the adjusters.
The tie rods must be adjusted when, with forks and straddle legs fully lowered, the height of the forks off the
ground measured with a metre rule is greater or less than the optimal height (88 mm - fig.1). In addition, the
adjustment must also be made when a pair of load wheels does not touch the ground (fig.2). This means
that a tie rod has been incorrectly adjusted.
Equipment and tools
Fig. 1
88 mm
open ended
rule spanner
36-41 mm
Procedure
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians. Fig. 2
36 - 41 mm OPEN END SPANNER

A
Set the truck on a perfectly flat base plate so that, after adjustment, all
the support points (wheels) adhere completely to the floor.
B
Raise the forks by 500 mm.
Raise the straddle legs to the cylinder stroke end.
Using the 41 mm open ended spanner, loosen the lock nuts of the adju-
sters (ref.A fig.3).
Using the 36 mm open ended spanner, lengthen or shorten the tie-rod
adjusters (ref.B fig.3) to obtain the desired distance.
After adjusting the tie rods, use the 41 mm open ended spanner to tighten Fig. 3
the lock nuts.
20
TIE-RODS ASSEMBLY GREASING POINTS
Access to the two grease

nipples on the linkage
pivot pins is through the
battery compartment. Grease gun
Remove the battery befo-
re proceeding.
Raise the straddle legs.
21
TILLER
IDENTIFICATION OF TILLER COMPONENTS
3
12
4
2
7 8
6
10
5
11
8 7
Ref. Description
1 Tiller casing
2 Spring
3 Tiller spring stop
4 Tiller spring screw
5 Pin
6 Buffer
7 Pin
8 Bushing
9 Tiller fastening screw
10 Spacer
11 Washer
12 Cap
22
TILLER DISMANTLING
Equipment and tools
hexagonal "T" hexagonal socket

large Philips
section spanner wrench extension ratchet
screw driver
5 mm 6 mm
Procedure
A
A A
Phase 1
Fig. 2
Phase 2 B
5 MM HEXAGONAL "T" SECTION SPANNER
With the hexagonal "T" section spanner unscrew and remove the engine
cover fastening screws (ref.B fig.2). C
Remove the motor cover (ref.C fig.2).
23
Phase 3
Fig. 3
HEXAGONAL 6 mm SOCKET WRENCH - EXTENSION - RATCHET
Disconnect the tiller connector (ref.D fig.3).
Using the hexagonal socket wrench, the extension and the ratchet un-
screw the screws fastening the tiller to the steering motor (ref.E fig.4).
Remove the tiller frame tiller and proceed with its dismantling or repla- D
cement.
E
Fig. 4
24
TILLER SPRING REPLACEMENT

Equipment and tools
hexagonal "T"
large Philips pin extractor
pliers hammer section spanner
screw driver 6 mm in diameter
6 mm
Procedure
A
A A
Phase 1
Fig. 2
B
Phase 2
PLIERS
Lower the tiller and unscrew and remove the tiller buffers using the pliers
(ref.B fig.2). Retrieve the washers.
The removal of the buffers helps to release the pressure

of the tiller spring so that it is easier to dismantle and as-
semble.
25
Phase 3
HAMMER - PIN EXTRACTOR
Bring the tiller back to the rest position
Insert the pin extractor into the hole through which the spring catch pin
fits (ref.D fig.3). With the help of the hammer extract the pin and free
the lower part of the spring (ref.D fig.3).
Phase 4 D
With the hexagonal "T" section spanner unscrew the fastening screw
C
Fig. 3
holding the upper part of the spring (ref.E fig.4).
Extract the spring from the tiller (fig.4) and proceed with the replace-
ment.
Fig. 4
26
traction motor
IDENTIFICATION OF TRACTION motor COMPONENTS
18 1 2
19
18
3
4
7
17
8
16
15
14 9
13
12
11
10

1 upper flange fastening screws 11 lower flange
2 Speed sensor 12 Elastic ring
3 Upper flange 13 Lower bearing
4 corrugated washer 14 Elastic ring
5 Upper bearing 15 Reducer coupling pinion key
6 Tolerance ring 16 Rotor
7 cogwheel 17 Break rail coupling ring
8 Elastic ring 18 Cable fastening nut
9 Stator 19 Washer
10 Oil seal
27
TRACTION MOTOR DISMANTLING

Equipment and tools
hexagonal "T"
fixed spanner
section spanner brush
10 mm
6 mm
Procedure
Phase 1
Carry out the tiller group dismantling procedure (see "TILLER DISMAN-
TLING").
Phase 2
Carry out the electromagnetic break dismantling procedure (see "DI-
SMANTLING OF THE ELECTROMAGNETIC BREAK", "BRAKING
SYSTEM" section).
Fig. 1
Phase 3
Remove the cable end protection caps.
Unscrew the traction motor power cable fastening nuts(fig.1). Note the
position of the cables and then slip then out. Disconnect the encoder and
thermal sensor cables.
A
Phase 4
6 MM PIVOTING HEXAGONAL "T" SECTION SPANNER
Unscrew and remove the screws fastening the traction motor to the re-
ducer (ref.A fig.2).
Fig. 2
28
Phase 5
Lift the motor until the drive shaft is completely free of the reducer.
Remove it from the bodywork and proceed with it's replacement or di-
smantling.
ASSEMBLY
Before assembling the motor to the reducer, grease the
drive shaft with a thin and uniform layer of special lubricant
grease "SHELL STAMINA GREASE RL 2" or "ALBIDA GRE-
ASE EP2".
During the coupling stage, rotate the wheel shaft, until the
drive shaft engages with the pinion cog (fig.3).
Before screwing the traction motor power cable nuts back
on ensure that the nuts behind the cable ends are not lo-
ose.
Fig. 3
29
OIL SEAL REPLACEMENT

Equipment and tools
fixed spanner medium medium flat head

extractor
13 mm adjustable pliers screwdriver
plastic hammer bushing torque wrench
Procedure

Phase 1
Perform the traction motor dismantling procedure (see “TRACTION MO-
TOR DISMANTLING”). B
A Fig. 1
Phase 2
FIXED 13 mm SPANNER - MEDIUM ADJUSTABLE PLIERS - CLOTH
Wrap the upper part of the rotor in the cloth and use the adjustable pliers
to held the rotor still. Using the fixed gauge spanner remove the fastening
nut (ref.A fig.1) of the reducer coupling pinion. Retrieve the washer.
C Fig. 2
30
Phase 3
EXTRACTOR - MEDIUM ADJUSTABLE PLIERS
Using the extractor remove the reducer coupling pinion (ref.B fig.1).
Using the adjustable pliers extract the pinion stop key (ref.C fig.2).
Phase 4
MEDIUM FLAT HEAD SCREWDRIVER
Using the flat head screwdriver remove the oil seal from its lodging (ref.D
fig.3).
D
Fig. 3
ASSEMBLY
Assemble the new oil seal using the plastic hammer and
the bushing.
The fastening of the reducer coupling pinion fastening
nuts must be carried out using a torque wrench with a
torque power of 35 Nm.
31
BEARING REPLACEMENT
Equipment and tools
Fig. 1
hexagonal "T"
medium medium elastic
section spanner extractor
adjustable pliers ring opening pliers
5 mm
plastic hammer bushing
B
Procedure

Phase 1
Carry out the oil seal replacement procedure (see "OIL SEAL REPLA-
CEMENT").
Phase 2
MEDIUM ADJUSTABLE PLIERS
Using the adjustable pliers extract the break rail coupling key (ref.A
fig.1).
Phase 2
5 MM HEXAGONAL "T" SECTION SPANNER
Fig. 2
With the hexagonal "T" section spanner unscrew and remove the two
fastening screws that connects the upper to the lower flange (ref.B fig.2).
Retrieve both flanges.
32
Phase 2
Fig. 3
BEARING EXTRACTOR - MEDIUM SIZE ELASTIC RING OPENING C
PLIERS
Use the elastic ring pliers to remove the elastic ring securing the lower
bearing (ref.E fig.3). D
Remove the corrugated washer (ref.C fig.3).
Use the extractor to remove the bearings from their seats (ref.D fig.3).
ASSEMBLY
During the assembly stage replace all the gaskets with new
gaskets.
Assemble the new bearings using a plastic hammer and
a bushing.
33
34
SERVICE MAST ASSEMBLY MECHANICS
mast assembly
mechanics
MAST CHARACTERISTICS�� 2
mast elevation�� 4
SINGLE STAGE MAST ASSEMBLY�� 5
2 STAGE MAST ASSEMBLY - "C" PROFILE�� 5
2 STAGE MAST ASSEMBLY - "J" PROFILE�� 5
TWO STAGE FFL MAST�� 6
THREE STAGE FFL MAST�� 6
MAST ASSEMBLY COMPONENTS�� 8
IDENTIFICATION OF THE 2 STAGE MAST ASSEMBLY COMPONENTS�� 8
IDENTIFICATION OF THE 2 STAGE FFL MAST ASSEMBLY COMPONENTS�� 8
IDENTIFICATION OF THE 3 STAGE FFL MAST ASSEMBLY COMPONENTS�� 10
DISMANTLING INNER Upright�� 12
DISMANTLING INTERMEDIATE UPRIGHT: THREE STAGE FFL MAST�� 18
DISMANTLING COMPLETE SUPPORT COLUMN�� 20
BEARING REPLACEMENT �� 22
REPLACEMENT OF CHAINS AND CHAIN TENSIONER�� 23
REPLACEMENT OF CHAIN GUIDEWAY PULLEYS�� 27
SMALL MAST�� 30
IDENTIFICATION SMALL MAST COMPONENTS�� 30
DISMANTLING OF THE SMALL MAST LIFT CHAINS�� 32
SMALL MAST DISMANTLING: 2 stage upright assembly with a “c” or “j” channel profile �� 34
SMALL MAST DISMANTLING: 2 stage and 3 stage FFL mast assembly�� 36
SMALL MAST DISMANTLING: single stage mast�� 38
BEARING AND SLIDING SKID REPLACEMENT �� 39
SMALL MAST PULLEY ASSEMBLY�� 40
IDENTIFICATION OF THE SMALL MAST PULLEY ASSEMBLY COMPONENTS�� 40
REPLACEMENT OF SMALL MAST CHAIN GUIDEWAY PULLEYS�� 41
1
MAST ASSEMBLY MECHANICS SERVICE
MAST CHARACTERISTICS
SINGLE STAGE MAST
For lifts up to a maximum height of 1760 mm, comprised of a fixed mast assembly, a central cylinder which
lifts the forks and a plate compete with forks supported by 4 radial rollers (70 mm).
TWO STAGE MAST

For lifts up to a maximum height of 4230 mm (up to 4165 mm with a J channel) comprised of a fixed mast
assembly, an movable inner mast supported by 6 radial rollers (4 with the J profile), to side cylinders and a
place complete with the forks supported by 6 radial rollers mm (70 mm). The forks are raised at the same
time as the mast.
TWO STAGE FFL MAST

For lifts of up to 4003 mm, comprised of a fixed mast assembly, a movable inner mast supported by 4 radial
rollers (83 mm), two side cylinders and one central one and a plate compete with forks supported by 4 radial
rollers (83 mm). This type of mast assembly allows the forks to be lifted freely, which means the forks can
be lifted before the masts are lifted.
THREE STAGE FFL MAST

For lifts of up 5397 mm, comprised of a fixed mast assembly, an intermediate moving mast supported by 4
radial rollers (83 mm), an inner moving mast supported by 2 radial rollers (83 mm), one plate complete with
forks supported by 4 radial rollers (83 mm), two side cylinders and one central one. This type of mast as-
sembly allows the forks to be lifted freely, which means the forks can be lifted before the masts are lifted.
1 stage
2
2 stage "J" channel 2 stage "C" channel
2 stage FFL 3 stage FFL
3
mast elevation
4
SINGLE STAGE MAST ASSEMBLY
height of the Height of mast

Lifting Maximum fork lift mast assembly Free lift assembly when
Model when closed open
h3 h3 + h13 h1 h2 h4
1260 1350 1820 1260 1830
1360 1450 1920 1360 1930
S1.0
1460 1550 2020 1460 2030
S1.2
1560 1650 2120 1560 2130
1760 1850 2320 1760 2330
2 STAGE MAST ASSEMBLY - "C" PROFILE

h3 h3 + h13 h1 h2 h4
2830 2920 1870 * 100 3383
3030 3120 1970 * 100 3583
S1.0 3230 3320 2070 * 100 3783
3430 3520 2170 * 100 3983
3830 3920 2370 * 100 4383
2830 2920 1870 * 100 3383
3030 3120 1970 * 100 3583
3230 3320 2070 * 100 3783
S1.2
3430 3520 2170 * 100 3983
3830 3920 2370 * 100 4383
4230 4320 2570 * 100 4785
* forks lifted by 100 mm
2 STAGE MAST ASSEMBLY - "J" PROFILE

h3 h3 + h13 h1 h2 h4
2765 2855 1870 * 100 3335
2965 3055 1970 * 100 3535
S1.4
S1.6 3165 3255 2070 * 100 3735
S1.4 IL 3365 3455 2170 * 100 3935
S1.6 IL 3765 3855 2370 * 100 4335
4165 4255 2570 * 100 4735
* forks lifted by 100 mm
5
TWO STAGE FFL MAST

h3 h3 + h13 h1 h2 h4
2603 2693 1820 1260 3164
2803 2893 1920 1360 3364
S1.2
3003 3093 2020 1460 3564
S1.4
S1.6 3203 3293 2120 1560 3764
S1.4 IL 3403 3493 2220 1660 3964
S1.6 IL 3603 3693 2320 1760 4164
4003 4093 2520 1960 4564

h3 h3 + h13 h1 h2 h4
S1.2 4027 4117 1820 1260 1588
S1.4
S1.4 IL 4327 4417 1920 1360 4888
4027 4117 1820 1260 1588

4327 4417 1920 1360 4888
S1.6 4627 4717 2020 1460 5188
S1.6 IL
4797 4887 2120 1560 5358
5097 5187 2220 1660 5658
5397 5487 2320 1760 5958
6
7
MAST ASSEMBLY COMPONENTS

IDENTIFICATION OF THE 2 STAGE MAST ASSEMBLY COMPONENTS
Ref. Description
1 Outer upright
2 Inner upright
3 Bearing
4 Spacer
5 Elastic ring
6 Lift cylinder
7 Chain guideway pulley
8 Pulley chain hinge pin
9 Chain
10 Truck chassis chain fastening buffer
11 Chain tensioner
12 Buffer
13 Mechanical stop point screw
14 Sliding skid
IDENTIFICATION OF THE 2 STAGE FFL MAST ASSEMBLY COMPONENTS
Ref. Description
1 Outer upright
2 Inner upright
3 Bearing
4 Spacer
5 Elastic ring
6 Lift cylinder
7 Chain tensioner
8 Cylinder stop bracket
9 Fork lift cylinder
10 Chain tensioner
8
TWO STAGE MAST TWO STAGE FFL MAST

13
11
12
8
7
1
1
6 6
2 7
9
2
14
10 10
3
4 5
3 5
8a
9
IDENTIFICATION OF THE 3 STAGE FFL MAST ASSEMBLY COMPONENTS
Ref. Description
1 Outer upright
2 Intermediate upright
3 Inner upright
4 Lift cylinder
5 Lift chain
6 Chain tensioner
7 Hose sheave
8 Pulley chain hinge pin
10 bearing
11 Spacer
12 Elastic ring
13 Chain tensioner
14 Cylinder stop bracket
15 Fork lift cylinder
16 Fork lift chain
17 Chain tensioner
18 Buffer
10
6 18
8
13
14
11
15
16
12
10
17
10a
11
DISMANTLING INNER Upright

TWO STAGE MAST
Equipment and tools Fig. 1

wooden beam
load capacity load capacity n. 2 iron trestles
100x100x1000 mm
2000 kg 2000 kg
A
bent hexagonal
medium elastic
taper end pliers wrench ladder
ring opening pliers
8 mm
Procedure
B
Phase 1 Fig. 2
WOODEN BEAM
Using the controls on the tiller lift the forks 500 mm off the ground.
Position the wooden beam beneath the forks (ref.A fig.1). Fig. 3
Lower the forks until they rest on the beam (fig.1), continue the descent
until the chains are loose.

ry.
Phase 2
TAPER END PLIERS
the outer upright. Extract the pins (ref.B fig.2) and lower the chains onto
the forks.
12
Phase 3
Fig. 4
LADDER - MEDIUM SIZED pliers TO OPEN ELASTIC RINGS C
Using the pliers remove the elastic rings at the ends of the side cylinders
(ref.C Fig.4) and retrieve the washers.
Phase 4
BENT HEXAGONAL 8 mm SPANNER
If the upright is provided with a “C” channel, loosen and remove the me-
chanical end point bolt on the inner upright (ref.D fig.4). D
Fig. 5
Phase 5
BRIDGE CRANE - LIFT BELT - N.2 trestles
Secure the inner upright using the lift belt (fig.5).
Hook the belt onto the bridge crane and lift until it comes away comple-
tely.
Lower the upright onto the trestles.
13
TWO STAGE FFL MAST

Equipment and tools

load capacity load capacity n. 2 iron trestles ladder
22 mm gloves
2000 kg 2000 kg
hexagonal "T"
medium elastic
"Parker" cap section spanner
ring opening pliers
5 mm
Procedure
B
Phase 1
LIFT CYLINDER DISMANTLING” in the "HYDRAULIC SYSTEM" sec-
tion).
Phase 2
OIL PROOF GLOVES - FIXED SPANNER 22 mm - 5 mm HEXAGONAL
"T"" SECTION SPANNER - "PARKER" PLUG
Using the hexagonal "T" section spanner loosen and remove the pipe A
stop screw on the inner upright (ref.A fig.1).
Using the fixed gauge spanner unscrew the hydraulic pipe connector Fig. 1
(ref.B fig.1) and apply the plug.
Retrieve the hydraulic pipe.
14
Phase 3
Fig. 2
Using the pliers remove the elastic rings at the ends of the side cylinders C
(ref.C Fig.2) and retrieve the washers.
Phase 4
Hook the belt to the bridge crane and lift until you reach the bearing
passage eyelets (ref.D fig.3), move the upright outwards.
Fig. 3
15

Equipment and tools
Fig. 1
B
fixed spanner
load capacity load capacity n. 2 iron trestles
15 mm
2000 kg 2000 kg
large flat head oil protecting

taper end pliers "Parker" caps
screw driver gloves
A
Procedure
Phase 1
LIFT CYLINDER DISMANTLING” in the "HYDRAULIC SYSTEM" sec-
tion).
Phase 2
C
OIL PROTECTING GLOVES - FIXED 15mm GAUGE SPANNER - "PAR-
KER" CAPS
Wear the oil proof gloves. Fig. 2
Using the fixed spanner unscrew the coupling of the hydraulic pipe
(ref.A-B fig.1).
Apply the caps to the couplings and retrieve the hydraulic pipe.
16
Phase 3
Fig. 3
Using the screwdriver loosen and remove the screws fastening the lexan
protective panel (ref.C fig.2) and retrieve the washers.
Phase 4
Hook the lift belt to the bridge crane, watching out for the chain, lift until the
chain fastening buffers on top of the mast become visible (ref.D fig.3).
Phase 5
TAPER END PLIERS
Using the pliers remove the cotter pins of the chain fastening buffers
positioned on the upright. Remove the pins (ref.D fig.3).
Phase 6
Lift the upright assembly until the chain passage eyelets are reached,
then move the upright outwards.
D
17
DISMANTLING INTERMEDIATE UPRIGHT: THREE STAGE FFL MAST

Equipment and tools
Fig. 1
A

load capacity load capacity ladder n. 2 iron trestles
2000 kg 2000 kg
medium elastic
taper end pliers
ring opening pliers
Procedure
Move the carriage to a safe place, away from areas of B
Fig. 2
Fig. 3
Phase 1
Carry out the internal mast assembly dismantling procedure (see "DI-
SMANTLING INNER UPRIGHT: 3 STAGE FFL MAST").
Phase 2
Using the pliers remove the elastic rings at the ends of the side cylinders
(ref.A fig.1) and retrieve the washers.
18
Phase 3
TAPE END PLIERS
positioned on the upright. Remove the pins (ref.B fig.2).
Phase 4
Secure the intermediate upright using the lift belt (fig.3).
Hook the belt to the bridge crane and lift until you reach the bearing
passage eyelets (ref.C fig.3), move the upright outwards.
19
DISMANTLING COMPLETE SUPPORT COLUMN

Equipment and tools
A
A A
bridge crane lifting belt hexagonal "T"

fixed spanner
load capacity load capacity section spanner
15 -22 mm
2000 kg 2000 kg 14 mm
Fig. 1
large Philips
"Parker" cap
screw driver
Procedure
all suitable safety clothing. Fig. 2
Phase 1
B Fig. 3
Phase 2
OIL RESISTANT GLOVES - 15mm OPEN ENDED SPANNER - “PAR-
KER” PLUG Fig. 3bis
VERSION WITHOUT INITIAL LIFT
Using the open ended spanner, unscrew the union of the hydraulic pipe
(ref.B fig.3). B
Fit the plug to the connection fitting and move the pipe aside.
Raise the straddle legs to the maximum height. Using the spanner, un-
screw the connection fitting of the hydraulic pipe (ref.B fig.3).
Fit the plug to the connection fitting.
Disconnect the forks sensor wire located on the mast.
20
Phase 3
Fig. 4
BRIDGE CRANE - LIFT BELTS - HEXAGONAL 14 mm "T" SECTION
SPANNER
Harness the two inner uprights with the lift belt (fig.4).
Hook the belt to the bridge crane and lift to around 1500 mm. With the
hexagonal "T" section spanner unscrew and remove the two support
fastening screws that connect it to the truck base (ref.C fig.5). Lower
the uprights to the ground.
All caution must be exercised at this stage. Do not stand

in front of the forks.
Phase 4
Harness the complete support with the lift belt.
Hook the lift belt to the bridge crane, position it so that it is slightly shifted
away from the support and take up the slack (fig.6).
Phase 5
Lever up on the forks so as to detach the lower crossbar of the mast
upright from the seat of the truck base. Bring the bridge crane back into
the upright position relative to the support column, lift and move the sup-
port column making sure to retrieve the hydraulic pipe (fig.7).
C Fig. 5
ASSEMBLY
The traction wheel fastening nut of the truck base column

Fig. 6
must be tightened using a torque wrench with a torque
power of 175 Nm. Use Loctite 222 on the nut thread before
tightening.
Fig. 7
21
BEARING REPLACEMENT
Equipment and tools
medium elastic
ring opening pliers
Procedure
all suitable safety clothing. Fig. 1
transit of other vehicles and the pedestrian route. Lower C
A B D
Phase 1
Depending on the bearings that need replacing, carry out the appropriate mast dismantling procedure (see
"INNER/INTERMEDIATE MAST ASSEMBLY DISMANTLING").
Phase 2
MEDIUM SIZE ELASTIC RING OPENING PLIERS
Use the elastic ring pliers to remove the elastic ring securing the bearing (ref.A fig.1).
Extract the bearing (ref.B fig.1), retrieve the spacers (ref.C-D fig.1) and proceed with the replacement.
Repeat the procedure for the other bearings.
The new bearings do not need to be greased.
ASSEMBLY
After assembly ensure that the bearings slide correctly in the channel.
In the event that there is play or chafing move the spacers from the "C" position to the "D"
position (fig.1) or vice versa.
22
REPLACEMENT OF CHAINS AND CHAIN TENSIONER

2 STAGE MAST
Never just replace the worn part of a chain. Replace the entire chain. Similarly, never re-
place just one chain of a couple, always replace both.
Equipment and tools
Fig. 1
wooden beam fixed spanner

taper end pliers
100x100x1000 mm 24 mm
Procedure
A
Phase 1
WOODEN BEAM
Position the wooden beam beneath the forks (ref.A fig.1).

ry.
Phase 2
TAPER END PLIERS
Using the pliers remove the cotter pins of the chain fastening buffers B
positioned on the fork support plate. Remove the pins (ref.B fig.2).
Fig. 2
23
Phase 3
TAPER END PLIERS
the outer upright. Remove the pins (ref.C fig.3).
Retrieve the chains and proceed with the replacement.
C
Phase 4
TAPER END PLIERS- FIXED GAUGE 24 mm SPANNER
Using the taper end pliers remove the cotter pin at the base of the chain
tensioner (ref.D fig.4).
Using the fixed gauge spanner loosen and remove the chain tensioner Fig. 3
fastening nut (ref.E fig.4).
Extract the chain tensioner.
Fig. 4
ASSEMBLY
cotter pins, ensuring they are the correct size.
The chain tensioners should be adjusted so that, when

unladen, the forks should not rest on the ground.
Fig. 4
D E
24
3 STAGE MAST
Equipment and tools
Fig. 1
B
load capacity load capacity
15 - 24 mm gloves
2000 kg 2000 kg
large flat head

taper end pliers "Parker" caps
screw driver
Procedure
Phase 1
KER" CAPS
Using the fixed spanner unscrew the coupling of the hydraulic pipe
(ref.A-B fig.1).
Apply the caps to the couplings and retrieve the hydraulic pipe.
Phase 2
C
Using the screwdriver loosen and remove the screws fastening the lexan
protective panel (ref.C fig.2) and retrieve the washers.
Fig. 2
25
Phase 3
Fig. 3
Hook the belt to the bridge crane and minding the chain, lift until the chain
fastening buffers are visible positioned on the upright.
Phase 4
TAPER END PLIERS
positioned on the upright. Remove the pins (ref.D fig.3).
Lower the upright assembly.
Phase 5
TAPER END PLIERS
the outer upright. Remove the pins (ref.E fig.4).
Retrieve the chains and proceed with the replacement.
Phase 6
Using the taper end pliers remove the cotter pin at the base of the chain
tensioner (ref.F fig.4).
Using the fixed gauge spanner loosen and remove the fastening nut of
the chain tensioner (ref.G fig.4).
Extract the chain tensioner.
D
ASSEMBLY
Do not reuse the chain anchoring safety pins, use new Fig. 4
The chain tensioners should be adjusted so that, when

unladen, the forks should not rest on the ground.
E
F G
26
REPLACEMENT OF CHAIN GUIDEWAY PULLEYS

2 STAGE MAST
Equipment and tools
hexagonal "T"
cartridge grease
section spanner taper end pliers hammer clamp gudgeon
nipple
5 mm
Procedure
the forks to the ground. c
a
Phase 1
Carry out the chain dismantling procedure (see "CHAIN AND CHAIN
TENSIONER REPLACEMENT"). Fig. 1
Phase 2
HEXAGONAL 5 mm "T" SECTION SPANNER - TAPER END PLIERS - HAMMER - GUDGEON HEAD
With the hexagonal "T" section spanner unscrew and remove the lynch pin fastening screw of the chain hose
pulley (ref.A fig.1). Using the taper end pliers remove the cotter pin of the chain pulley pin (ref.B fig.1).
Using the clamp gudgeon and the hammer extract the pulley pin (ref.C fig.1), extract the pulley and pro-
ceed with the replacement.
ASSEMBLY
Do not reuse the chain anchoring safety pins, use new cotter pins, ensuring they are the
correct size.
After assembly grease the pulley bearings by using a cartridge greasing nipple.
27
3 STAGE MAST
Equipment and tools
hexagonal "T"
section spanner taper end pliers
gloves 15 -19 mm
5 mm
cartridge grease
hammer clamp gudgeon "Parker" cap
nipple
Procedure
Fig. 1
Phase 1
KER" CAP
Fig. 2
Using the fixed spanner unscrew the coupling of the hydraulic pipe (ref.A
fig.1).
Apply the cap to the coupling, and rest the hydraulic pipe on the forks.
B
Phase 2
TAPER END PLIERS
the outer upright. Remove the pins (ref.B fig.2).
Lower the chains onto the forks.
28
Phase 3
Fig. 3
Using the fixed spanner loosen and remove the fastening screws of the
hydraulic pipe hose sheave pin (ref.C fig.3). D
Extract the pin (ref.D fig.3) and retrieve the hose sheave (ref.E fig.3).
Phase 4
HEXAGONAL 5 mm "T" SECTION SPANNER - TAPER END PLIERS -
E
HAMMER - GUDGEON HEAD C
With the hexagonal "T" section spanner unscrew and remove the pin
fastening the chain pulley (ref.F fig.4). Using the taper end pliers remove
the cotter pin of the chain pulley pin (ref.G fig.4).
Using the clamp gudgeon and the hammer extract the pulley pin (ref.H
fig.4), extract the pulley and proceed with the replacement.
ASSEMBLY
H
cotter pins, ensuring they are the correct size. F
After assembly grease the pulley bearings by using a car- G

tridge greasing nipple.
Fig. 4
29
SMALL MAST
IDENTIFICATION SMALL MAST COMPONENTS
2
11
4
9 10
3
8
1
5
Ref. Description
1 Load support plate

2 Fixed fork
3 Chain tensioner
4 Pin
5 Cotter pin
6 Nut
7 Bearing
8 Sliding skid
9 Spacers
10 Sliding skid fastening screws
11 Mechanical stop point screws
30
9
8
1
7 4
6
Ref. Description
1 Load support plate

2 Fixed fork
3 Chain fastening buffer
4 Pin
5 bearing
6 Sliding skid
7 Spacers
8 Sliding skid fastening screws
9 Mechanical stop point screws
31
DISMANTLING OF THE SMALL MAST LIFT CHAINS

Never replace just one chain, always replace both chains.
When the chains are replaced the chain tensioner must also be replaced.
Equipment and tools
fixed gauge hexagonal socket

wooden beam
spanner taper end pliers ratchet wrench
100x100x1000 mm
13 -24 mm 24 mm
Procedure
Phase 1
WOODEN BEAM
Position the wooden beam beneath the forks (ref.A fig.1). A
Fig. 1
Fig. 2
ry.
B
C
Phase 2 B
32
Phase 3
Using the pliers remove the cotter pins on the chain tensioner positioned
on the cab backrest (ref.D fig.3).
Using the 24 mm fixed gauge spanner unscrew and remove the nuts of
the chain tensioner block (ref.E fig.4).
Phase 4 D
TAPER END PLIERS - RATCHET - 24 mm HEXAGONAL SOCKET
WRENCH
Using the pliers remove the cotter pins on the chain tensioner positioned
E
Fig. 3
on the fork support plate (ref.F fig.3).
Using the ratchet and the hexagonal socket wrench unscrew and remove
the chain tensioner blocking nuts (ref.G fig.4).
Slip off the chains including the chain tensioners and proceed with the
replacement.
ASSEMBLY

G
After assembly adjust the chain tensioners so that, in the F
completely lowered position, the chains remain taught. Fig. 4
For a correct sliding of the bearings along the backrest
guide rails it is essential that the chains have the same
tension, otherwise the guide rails could be damaged.
33
SMALL MAST DISMANTLING: 2 stage upright assembly with

a “c” or “j” channel profile
Equipment and tools
tackle bent hexagonal

workbench load capacity N° 2 lifting cables wrench
1000 kg 10 mm Fig. 1
taper end pliers
Procedure
Fig. 2
Phase 1
Unscrew and remove the small mast mechanical lift stop screw (ref.A
fig.1).
Phase 2
Secure the fork base plate with the two lift belts.
Hook the belts to the tackle and pick up the slack until the chains are
loose (fig.2).
Fig. 3
34
Phase 3
Fig. 4
TAPE END PLIERS
positioned on the fork support plate. Remove the pins (ref.B fig.3).
Phase 4
Using the button on the tiller begin lifting until the small mast extends
completely beyond the mast assembly rail (fig.4).

ry.
Phase 5
Using the tackle move the small mast away from the truck and place it
on a workbench.
35
SMALL MAST DISMANTLING: 2 stage and 3 stage FFL mast

assembly
Equipment and tools
A
tackle bent hexagonal
1000 kg 10 mm Fig. 1
Procedure
Phase 1
Carry out the inverse procedure to the dismantling of the small mast lift
chains (see "DISMANTLING OF THE SMALL MAST LIFT CHAINS").
Fig. 2
Phase 2 Fig. 3
Unscrew and remove the small mast mechanical lift stop screw (ref.A
fig.1).
Phase 3
Attach the belts to the tackle and raise until taught (fig.2).
36
Phase 4
Using the button on the tiller begin lifting until the small mast extends
completely beyond the small mast assembly rail (fig.3).

ry.
Phase 5
on a workbench.
37
SMALL MAST DISMANTLING: single stage mast

Equipment and tools
tackle bent hexagonal A

1000 kg 10 mm
Fig. 1
Procedure

Phase 1
Carry out the inverse procedure to the dismantling of the small mast lift
chains (see "DISMANTLING OF THE SMALL MAST LIFT CHAINS").
Phase 2
Unscrew and remove the small mast mechanical lift stop screw (ref.A Fig. 2
fig.1).
Fig. 3
Phase 3
Hook the belts to the tackle and lift the small mast upwards until it extends
completely beyond the mast assembly rail (fig.3).
Phase 4
on a workbench.
38
BEARING AND SLIDING SKID REPLACEMENT

Equipment and tools
hexagonal "T"
medium elastic fixed spanner
section spanner
ring opening pliers 10 mm
4 mm
Procedure

BEARING REPLACEMENT
Phase 1
WORKBENCH - MEDIUM SIZE PLIERS TO OPEN ELASTIC RINGS
Using the elastic ring opening pliers remove the elastic ring (ref.A fig.1),
slip away the bearing (ref.B fig.1) and retrieve the spacer (ref.C fig.1).
Repeat the operation for the other bearings and proceed with the repla-
cement.
A
C
B Fig. 1
Fig. 2
REPLACEMENT OF SLIDING SKIDS
Phase 2 E
WORKBENCH - HEXAGONAL “T” SECTION SPANNER 4 mm - FIXED
GAUGE SPANNER 10 mm
Using the fixed spanner block the sliding skid block nut (ref.D fig.2),
while with the hexagonal "T" section spanner loosen and remove the
fastening screws (ref.E fig.2). Retrieve the skid (ref.F fig.2) and the
F G
spacers (ref.G fig.2).
Repeat the operation for the other skid and proceed with the replace-
ment. D
39
SMALL MAST PULLEY ASSEMBLY

IDENTIFICATION OF THE SMALL MAST PULLEY ASSEMBLY COMPONENTS
8
7 3
6
4
1
4
5
Ref. Description
1 Pulley base plate

3 Bracket
4 Spacer
5 Elastic ring
6 Flat washer
7 Screw
8 Elastic washer
40
REPLACEMENT OF SMALL MAST CHAIN GUIDEWAY PULLEYS

Equipment and tools
fixed gauge
n. 2 wood beams
workbench vice spanner
100x100x500 mm
13 mm
medium elastic
taper end pliers extractor
ring opening pliers
Procedure
A A
Fig. 1
Phase 1
Fig. 2
mast downwards until the forks rest on the beams. Continue the descent
B
C
Position the key switch to OFF and disconnect the batte- B
ry.
Phase 2
41
Phase 3
TAPER END PLIERS
Using the pliers remove the safety pin and the hinge pins (ref.D fig.3)
bulkhead.
Remove the chains from the guide way pulleys and rest them on the
forks.
Phase 4
MEDIUM SIZE ELASTIC RING OPENING PLIERS D
Slip the complete pulley base plate away from the cylinder shaft (ref.F Fig. 3
Phase 5
MEDIUM SIZE ELASTIC RING OPENING PLIERS - EXTRACTOR
Use the elastic ring pliers to remove the elastic ring blocking the pulley e
g
(ref.H fig.5). Retrieve the spacer (ref.I fig.5).
Using the extractor slip off the pulley from the base hose sheave base-
board (ref.L fig.5) and retrieve the spacer (ref.M fig.5). f
Repeat the operation for the other pulley and proceed with the replace-
ment.
Fig. 4
I
ASSEMBLY
H LM
Fig. 5
42
SERVICE REDUCTION GEAR
reduction gear
IDENTIFICATION OF REDUCER COMPONENTS�� 2
REDUCER DISMANTLING�� 4
REDUCER DISassembly�� 6
REPLACEMENT OF REDUCER OIL�� 9
1
REDUCTION GEAR SERVICE
IDENTIFICATION OF REDUCER COMPONENTS
2
3
27 4
26
29
25
28
24
23 5
22
21
6
20 19
7
18
17
10
11
12
16
11
13
10
14
15
type gearbox supplier code
TYP.
part code COD. 29

C.P.N.
production date DATE NR Serial number
2
1 Traction motor 16 Traction wheel

2 O-Ring motor flange 17 Hexagonal head screw
3 Steering pinion 18 Washer
4 Fifth wheel fastening screws 19 Bevel gear pair
5 Grease nipple 20 Bevel gear pair pinion
6 Oil filling screw cap 21 Pinion blocking tab
7 Reducer casing 22 Lower conical roller bearing
8 Oil emptying screw on cap 23 Shims
9 Bevel gear ring 24 Spacer
10 O-ring 25 Upper conical roller bearing
11 Spacer 26 Cylindrical bevel gear
12 Ball bearings 27 Hexagonal nut
13 Seeger safety ring 28 Reducer cover, steering fifth wheel
14 Seeger ring 29 Identification nameplate
15 Oil seal
3
REDUCER DISMANTLING
Equipment and tools

load capacity hydraulic jack n. 2 wood stocks load capacity
2000 kg 2000 kg
Fig. 1
Fig. 2
hexagonal "T" fixed gauge

ladder oil recovery sump section spanner spanner
8 mm 17 mm
Procedure
Move the carriage to a safe place, away from areas of tran-
sit of other vehicles and the pedestrian route. Lower the
forks to the ground, push the forks against an obstacle in
order to keep the truck blocked when it is lifted using the
hydraulic jack. Set the key switch to OFF and disconnect
the battery.
Phase 1
and rest the truck on the stocks.
Phase 2 A
BRIDGE CRANE - LIFT BELT - LADDER
Climb up the ladder with the lift belt. Harness the complete support with
the lift belt (fig.2).
Attach the belt to the bridge crane and raise until taught.
Fig. 3
4
Phase 3
Perform the traction wheel dismantling procedure (see “DISMANTLING
THE TRACTION WHEEL” in the “FRAME MECHANICS” section).
Phase 4
Perform the tiller dismantling procedure (see “TILLER DISMANTLING”
in the “FRAME MECHANICS” section).
Fig. 4
Phase 5
Perform the traction motor dismantling procedure (see “TRACTION MO-
TOR DISMANTLING” in the “FRAME MECHANICS” section).
B
Phase 6
B B
OIL RECOVERY SUMP - 8 mm PIVOTING HEXAGONAL "T" SECTION
SPANNER
Place the sump beneath the reducer. Using the pivoting hexagonal "T"
section spanner unscrew and remove the oil drain plug (ref.A fig.3),
remove the cap. Empty the oil into the sump completely.
Clean the drain plug thoroughly from accumulated impurities that may B
have collected during reducer operation and screw it back in place.
Fig. 5
Phase 7
HYDRAULIC JACK - FIXED GAUGE 17 mm SPANNER
Position the hydraulic jack beneath the reducer (fig.4) and lift until it is
resting against it.
Using the fixed gauge spanner unscrew the screws fastening the reducer
to the chassis (ref.B fig.5). Retrieve the washers.
Watching out for the reducer, lower the jack completely.
Phase 8
BRIDGE CRANE - WORKBENCH
Use the bridge crane to lift the truck so that the reducer can be completely
extracted (fig.6). Retrieve the reducer, place it on the clean workbench Fig. 6
and proceed with replacement or dismantling.
ASSEMBLY
The screws securing the reducer to the chassis must be

tightened using a torque wrench with a tightening torque
of 45 Nm.
5
REDUCER DISassembly
Equipment and tools
hexagonal socket
medium/large
vice wrench ratchet
bearing extractor
8 mm
A
Fig. 1
percussion fixed spanner
clamp gudgeon hammer
extractor 30 mm
C
B
oil protecting medium elastic large elastic ring medium flat head
gloves ring opening pliers closing pliers screwdrivers
Procedure Fig. 2
D
Phase 1
OIL PROTECTING GLOVES
Carry out the reducer dismantling procedure (see “REDUCER DISMAN-
TLING”).
Fig. 3
6
Phase 2
VICE - MEDIUM SIZE FLAT HEAD SCREWDRIVER F
Position the reducer in the vice and clamp firmly. E
Using the flat head screwdriver lever up and remove the oil seal (ref.A
fig.1).
Phase 3 Fig. 4
LARGE ELASTIC RING CLOSING PLIERS
Use the elastic ring pliers to remove the elastic ring blocking the bevel
ring gear pair (ref.B fig.2). Retrieve the spacers (ref.C fig.2).
G
Phase 4
PERCUSSION EXTRACTOR
Screw the threaded part of the extractor shaft into the hub hole (ref.D
fig.3). Extract the complete bevel gear pair (fig.3). Fig. 5
H
Phase 5
MEDIUM SIZE ELASTIC RING OPENING PLIERS
Use the elastic ring pliers to remove the elastic ring blocking the bearings
(ref.E fig.4). Retrieve the spacers (ref.F fig.4).
Phase 6
LARGE BEARING EXTRACTOR
Use the bearing extractor to remove the two hub bearings (ref.G fig.5).
Phase 7
Fig. 6
HEXAGONAL 6 mm SOCKET WRENCH - RATCHET
Using the hexagonal socket wrench and the ratchet unscrew and remove
the fastening screws of the steering fifth wheel (ref.H fig.6). Retrieve the I
complete fifth wheel.
Phase 8
FIXED GAUGE 30 mm SPANNER - HAMMER - CLAMP GUDGEON
Using the fixed gauge spanner loosen and remove the nuts fastening the
bevel pinion to the upper bevel gear (ref.I fig.7). Using the hammer and
the clamp gudgeon extract the bevel pinion by slipping it through inside
the reducer (fig.7). Extract the bevel gear (ref.J fig.8) and retrieve the
pinion blocking tabs (ref.K fig.8).
Fig. 7
7
Phase 9
MEDIUM SIZE BEARING EXTRACTOR J K
Retrieve the upper bearing (ref.L fig.9) and the spacers (ref.M,N
fig.9).
Using the bearing extractor remove the bearing from the pinion (ref.O
fig.9) and retrieve the spacers (ref.P,Q,R fig.9).
ASSEMBLY
To facilitate bearing assembly, during the dismantling ple-

ase take care to note spacer positioning.
During assembly of the specific elements use Loctite 243 Fig. 8
and tighten the bolts according to the diagram provided
in fig.10.
P M
L N
Q
O
Fig. 9
shaft Ø20 - 59 Nm
shaft Ø17 - 32 ÷ 35 Nm
60 ÷ 70 Nm 45 ÷ 50 Nm
silicone
20 ÷ 25 Nm
85 ÷ 109 Nm 20 ÷ 25 Nm
Fig. 10
8
REPLACEMENT OF REDUCER OIL

Equipment and tools
oil protecting
oil recovery sump hydraulic jack n. 2 wood stocks
gloves
hexagonal "T"
section spanner oil syringe torque wrench
8 mm
Procedure
the hydraulic jack , position the ignition key on OFF and
A
A A
After using the reducer, beware of the high oil temperatu-
re. It is recommended that oil protecting gloves resistant
to high temperatures be used.
Do not get rid of the spent oil in the ground or by pouring Fig. 1
down the drain. Special companies must be charged with
disposal or the recycling of industrial oils.
Phase 1
Fig. 2
9
Phase 2
Position the wooden stocks at the side of the truck (fig.2), lower the jack B
Phase 3
OIL PROTECTIVE GLOVES - OIL RECOVERY SUMP
Clean the area around the filler neck and oil drain thoroughly. Place a
suitably sized oil pan beneath the drain plug.
Phase 4
OIL PROOF GLOVES - OIL RECOVERY SUMP - PIVOTING HEXA-
GONAL "T" SECTION SPANNER 8 mm - TORQUE WRENCH - OIL
SYRINGE Fig. 3
Using the pivoting hexagonal "T" section spanner loosen the oil filler cap
(ref.B fig.3), remove the cap.
Using the same spanner loosen and remove the oil drain plug (ref.C
fig.4), remove the cap. Empty the oil into the sump completely.
Clean the drain plug thoroughly from accumulated impurities that may
have collected during reducer operation and screw it back in place.
The tightening of the oil drain cap must be done using a

torque wrench with a torque tightening power of 22 Nm.
C
Use Oil type Quantity
Standard ESSO UNIFARM 15W - 40 1 litres Fig. 4

Cold store SHELL TRANSAXLE 75 W 90 1 litres
To top up use a pressure aspiration syringe (fig.5), 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.
The tightening of the oil filler cap must be done using a

torque wrench with a torque tightening power of 22 Nm.
L
OI
Fig. 5
10
SERVICE BRAKING SYSTEM
braking system
IDENTIFICATION of the electromagnetic brake components�� 2
OPERATION�� 3
BrakING systems�� 3
DISMANTLING OF THE electromagnetic Brake�� 4
ELECTROMAGNETIC Brake ADJUSTMENT�� 6
1
BRAKING SYSTEM SERVICE
IDENTIFICATION of the electromagnetic brakE components
5 4
8 7
10
Ref. Description
1 Fastening screw
2 Electromagnet
3 Brake plate
4 Elastic ring
5 Adjusting screw
6 Pinion
7 Rotor
8 Ferode
9 Dust cap
10 Disc
2
OPERATION
The electromagnetic brake attached to the traction motor is a spring brake.
When the electromagnet is powered it attracts the brake plate and unblocks the ferode allowing to turn
freely.
As soon as the power to the electromagnet is cut, the springs push downwards on the brake plate above
the ferode triggering the braking.
BRAKING systems
4 braking systems are envisaged: gear request release
• Release braking
• Braking on direction reversal
• Emergency braking
• Stationary handbrake
A) Release braking
Checks the deceleration ramp when the gear request is released.
B) Braking on direction reversal

Checks the deceleration ramp when the gear request is inverted.
The “braking on direction reversal" also know as counter current braking, direction reversal
consists in a current reversal on the motor which changes the direction
of travel when the truck is in motion.
The braking current must be adjusted so that the truck stop in a space
that is at least not less than the length of the machine itself.
C) Emergency braking
Emergency braking takes place when an alarm is triggered that requires
immediate traction arrest of when the tiller sensor is disactivated (tiller
in rest position or completely lowered).
The braking is performed by the electromagnetic brake attached to the
traction motor.
D) Stationary brake
The "stationary brake" is performed by the electromagnetic brake and takes place when the machine is
stationary and the tiller is in the rest position.
3
DISMANTLING OF THE electromagnetic Brake

Equipment and tools
hexagonal "T"
fixed spanner elastic ring ope- large Philips
section spanner scissors extractor
15 mm ning pliers screw driver
5 mm
Procedure
A
A A
When replacing the rotor, the pinion must also be repla-

ced.
Fig. 1
Phase 1
Phase 2
fixed gauge spanner - hexagonal 5 mm "t" section spanner-
scissors
Remove the dust cap (ref.B fig.2)
Use the fixed gauge spanner to loosen the three adjustment nuts (ref.C C
fig.2).
Using the hexagonal "T" section spanner unscrew the three screws fa-
stening the electromagnetic brake to the traction motor (ref.D fig.3).
Use the scissors to cut the electrical cable tie to free the solenoid brake
power cable. Disconnect the connector and slip it out from the tongue.
Remove the solenoid brake from the motor (fig.3).
4
Phase 3
Fig. 3
ELASTIC RING OPENING PLIERS - EXTRACTOR D
Extract the rotor (ref.E fig.4) from the pinion.
Using the elastic ring pliers remove the elastic ring from the drive shaft
(ref.F fig.5). Using the extractor remove the pinion (ref.F fig.5).
ASSEMBLY
After assembly proceed with the adjustment of the electro-

magnetic brake.
Fig. 4
E
Fig. 5
F
G
5
ELECTROMAGNETIC Brake ADJUSTMENT
Fig. 1
After having reassembled the electromagnetic brake assembly, before using the truck, one must see to the
adjustment of the ferode.
In order to obtain good braking, the distance between the ferode and brake plate (ref.A fig.1) must not be
greater than 0.35 mm. For this purpose one must use a feeler gauge of this size.
With the three nuts loose (ref.B fig.1), insert the feeler gauge close to one of the bolts, tighten the fastening
screw (ref.C fig.1) with the Allen key and place the plate at such a distance that enables the feeler gauge
to be slipped out with a little friction. Repeat the operation with all three bolts.
Tighten the nuts using the fixed gauge spanner (ref.B fig.1).
6
SERVICE ORDINARY MAINTENANCE
ordinary maintenance
OILS AND LUBRICANTS�� 4
PRODUCTS FOR THE CLEANING�� 4
PLANNED MAINTENANCE�� 5
1
ORDINARY MAINTENANCE SERVICE
WARNINGS
• If maintenance operations are carried out immediately after the truck stop, some parts of the motor or
of the hydraulic system may be hot. Always wear the individual protection devices, if it is required.
• Do not wear rings, watches, jewells, untied clothes such as scarfs, undone shoes, unbuttoned coats or
blouse with the opened zip that may get stuck in the moving parts.
• Never carry out cleaning, lubrication or maintenance operations if the battery is connected.
• Do not carry out any operation on the truck if there are operators working with it, unless they are au-
thorized and are assisting the operation to be carried out.
• To clean the components use compressed air and during this operation wear proper goggles with lateral
protections. The maximum air pressure must not exceed 1 bar.
• Never use petrol, oil or other inflammable liquids as detergents: we recommend using not inflammable
and not toxic solvents.
• Do not accumulate rags soaked in grease or oil: they may cause fire risk. Always put them in a closed
metallic container.
• The capacitors located in the transitor gearcase may keep an electric charge also after the battery has
been disconnected. To avoid electrical shock and personal injuries, discharge the capacitors before
checking or repairing any component of the electric compartment. Wear goggles. Make sure that the
battery has been disconnected.
• Do not file or lubricate the remote control switch contacts. This may cause the union of the contacts
and therefore the loss of control, damage to things or personal injuries.
• Drain oil must be gathered. Avoid letting it off in the common discharge ducts. Qualified companies must
dispose of or recycle the industrial oils, according to the laws in force in each Country.
• An apparently invisible fluid might come out of a small hole and have enough force to pass through
the skin In such cases we recommend checking the penetration force by means of a piece of card or
a piece of wood.
• During the fluid check or the filter replacement prevent dirt from contaminating the hydraulic system.
• Never enable the pump if the fluid in the hydraulic system is not enough. If the hydraulic fluid levels are
low, the hydraulic pump will be damaged.
• Do not put tools on the battery. Metall objects on the battery may cause short circuits and possible
damages or injuries.
• The batteries produce explosive gases. Keep the air outlets always clean. Keep sparks and flames
away from the battery compartment. Do not produce sparks when disconnecting the battery cables.
Disconnect the battery during the maintenance operations.
• Always use a space bar and slings to lift the battery vertically by means of the proper eyelets. Do not
use chains or slings without using the space bar, because this might damage the battery case. Check
that the battery compartment is clean and dry. When the battery is in operation, the aeration plugs must
be installed. If the plugs are not installed, the electrolyte, might come out and corrode the battery case
and compartment.
2
• The acid contained in the electrolyte may cause damage. If the electrolyte is accidentally released, clean
carefully with water. Neutralize the acid with a sodium bicarbonate solution (baking soda). In case of
contact with the skin, immediately flush the skin with water. In case of contact with the eyes, wash the
eyes thoroughly with water for at least 10 minutes, then seek medical advice.
• The batteries are a part of the truck counterweight system. By installing a too small battery, the truck
might not weigh enough to reach the rated capacity. When replacing the battery, check that the rated
capacity and dimensions of the battery comply with the data indicated on the plate. Refer to the “ TRUCK
AND LOAD IDENTIFICATION DATA” of the section “PRESENTATION”, in order to know the correct
battery specifications for the truck in object.
• Do not work under the lifted roller plate. Lower the roller plate or use a safety chain in order to avoid
that the roller plate lowers during the maintenance operations on the mast and on the lifting chains.
• Never repair damaged forks by heating or welding them. The forks are made up of tempered steel..
Replace the damaged forks.
• Before proceeding with the maintenance of the hydraulic system, it is necessary to remove any possible
residual pressures inside it.
At the end of the maintenance operations, close the valves.
3
OILS AND LUBRICANTS
Application Std Cold Trademark Type Specifications

store
OIL  Shell TELLUS T32 DIN 51524

for the lubrication of the
HYDRAULIC CIRCUIT AEROSHELL FLUID
 Shell 41 MIL-H-5606G
API GL-5
OIL  Shell SPIRAX A 80W-90
MIL-L-2105D
GEARBOX TRANSAXLE OIL API GL-4
 Shell 75W-90 API GL-5
GREASE
MUST PROFILES and  Shell ALVANIA EP0
PULLEY PINS
GREASE ALBIDA GREASE

for the lubrication of
 Shell
EP2
MAST BEARINGS (1) AEROSHELL
and CABIN BEARINGS (1)  Shell GREASE 6 MIL-G-24139A
SPRAY
ADVANCE TEFLON
for the lubrication of the   Shell CHAIN
CHAINS (2)
(1)
The lubrication is not necessary; the bearings are already screened and greased for life.
(2)
New chains are already lubricated.
PRODUCTS FOR THE CLEANING

GUARD AND PLASTIC COVER CLEANING - TRUCK PAINTED PART CLEANING
For the truck general cleaning use only dry water, wet rags or degreasing solvents.
Do not use water jets, vapours, solvents or inflammable products that may damage the
truck or that can be dangerous for the operator.
motor and electronic system cleaning

For the general cleaning use only dry water at low pressure and a clean dry brush.
Do not use wet rags, water jets, vapour, solvents or products that may damage the truck
or that may be dangerous for the operator.
MAST PROFILE AND MAST CLEANING

Use degreasing solvents.
Do not use water jets, vapour, solvents or inflammable products that may damage the
mast or that may be dangerous for the operator.
4
PLANNED MAINTENANCE
 = check and maintenance
 = operator check Maintenance intervals
x = replacement
every every every every every
Operation description 8 hours 500 h 1000 h 2000 h 3000 h
1 day 6 months 12 months 24 months 36 months
Check welded joints 
Lubrification of tiller gudgeon 
Grease tie rod pins 
TRUCK BASE
Lubrication of linkage pivot pins-forks-carriage (3) 

Check efficiency of tiller gas spring 
Check tiller control housing 
Check steering thrust block bearing  
Lubrification of steering thrust block 
General cleaning 
Check the efficiency of the electromagnetic brake coil  
BRAKING SYSTEM
Check brake lining wear (1) 

Check release braking  
Check reverse braking  
Check emergency braking  
Check parking mode braking  
Check motor insulation 
MOTORS
Check cable connections 

Check fastening bolts 
General cleaning with compressed air 
Check for oil leaks at pump connections  
HYDRAULIC SYSTEM
Check for oil leaks at cylinder head connections  

Check for oil leaks at motor housing distributor connections  
Check for oil leaks in pipe connections on mast  
Check hydraulic pipes 
Check flexible pipes (2) 
Replace oil in hydraulic tank x
Oil filter cleaning 
Check valve operation 
Reducer oil replacement x
REDUCER
Visual oil leak check  

Check general condition of reducer 
Check steering crown gear and steering pinion wear 
Check lifting chain link and pin wear (2) 
Check chain elongation (2) 
Check chain tensioner (2)  
Clean chains (3) 
Lubricate chains (3)

Lubricate mast profiles 
MAST
Check chain slip bearings 

Check cable slip bearings 
Lubrification of chain and pipe bearing pins 
Check guide bearing wear 
Check mast bearings 
Check tightening of mast fastening bolts  
5
 = check and maintenance

 = check by operator Maintenance intervals
x = replacement
every every every every every
Operation description 8 hours 500 h 1000 h 2000 h 3000 h
1 day 6 months 12 months 24 months 36 months
Check link and pin wear on lift chains (4) 
Check chain elongation (4)

Check chain tensioner (4)  
FORK BASE PLATE
Clean chains (3)

SMALL MAST AND

Chain lubrification (3)

Bearing check 
Check state of forks (7)  
Check fork heel wear (8)
 
Check fork point alignment (9)  
Check that forks are parallel  
Check aperture angle (10)  
Check all electrical connections 
ELECTRICAL
Check the condition of electric cables 

PLANT
Sensor check 
General cleaning of electrical panel, remote-control switches

and contacts using dry air at low pressure
Check traction wheel wear (1) 
Check the tightening of traction wheel fastening nuts
WHEELS

Check tightening of pivoting wheel fastening nuts 
Check load bearing wheel wear (1) 
Check load bearing wheel bearings (1)

Check cable connections 
Check for liquid leakage 
BATTERY
Check battery insulation 

Check electrolyte density 
Check electrolyte level (5) 
General cleaning (6) 
Check all machine functions using activation controls 
(1)
replace if it is necessary
(2)
replace in the following situations:
• movement of the pipe fittings;
• damage, cuts, or abrasions on the surface layer;
• hardening or stiffness of the pipe, presence of burnings or cracks due to heat;
• cracks, damage or corrosion on the pipe fitting;
• leaks on the pipe or on the pipe fitting;
• permanent folds, squashings, flattenings or twists on the pipe;
• blisters, softening or wear of the external layer.
the chains must be cleaned with paraffin, petrol, gas oil or oil of turpentine.
(3)
Lubricate with spray can (see oil and lubricants table)

Usually a universal grease layer is applied on the chains for the cold room or in wet environments.
6
(4)
Replace, if chains have undergone a stretching which is higher than 3% or if the links, the hinge pins or the chain
tightener are worn and they need to be replaced.
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
A
b h
i
f
G
e d
Fig. 1 Fig. 2 Fig. 3
If the chains do not seem to be worn or stretched, replace them anyway every 3 years (6000 hours) in case of nor-
mal operation conditions. Replace them every 2 years (4000 hours) in case of operation in cold room or in corrosive
environments.
(5)
top up whenever the electrolyte level decreases to 5-10 mm with respect to the plate unit .
(6)
keep the battery clean and dry by using, if possible, antistatic clothes
the forks must not have cracks in the structure and especially in the welded joints (ref.A fig.4). If there are visible
(7)
cracks, replace the fork. Do not carry out repairs by welding the fork;
(8)
measure the bead thickness (ref.B fig.4). If the the thickness is lower than 90% of the vertical bracket thickness
(ref.C fig.4) replace the fork.
(9)
during the installation on the carriage the fork ends must be aligned within 3% of the fork length (ref.D fig.4). Do not
correct the alignment by modifying the bending or the connection between the carriage and the forks. The alignment
can be improved by moving the forks along the sides of the carriage or by choosing forks of the same length;
in case of permanent deviation between the vertical bracket (ref.E fig.4) and the blade (ref.F fig.4), the maximum
(10)
angle allowed is equal to 93 degrees. If the angle (ref.G fig.4) exceeds 93 degrees, the forks must be replaced.
7
A
E
A
G
B F
D
Fig. 4
E A
G
F
Fig. 4
8
9
Code: 1668891 Revision: 1 (03/2010)

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Part No.

: 1668891 Revision: 1 (03/2010)

Technical information for

This manual is addressed to the skilled technicians of Hyster

C441..... S1.0 - S1.2

Product support group

HOW TO USE THE MANUAL

It indicates a danger due to high temperatures.

It indicates notes or important information to be taken into consideration.

GENERAL SAFETY STANDARDS

• BANDS, ROPES AND HANGING ROPES: SUGGESTIONS FOR THE USE

Use of hanging ropes with unbalanced load

Rope capacity table

violet 1000 2000 1400 800

Band capacity table

black 35 500 1000 700 400

Hanging rope capacity table

violet 1000 1400 2100 2100

DRIVING TORQUE OF SCREWS, NUTS AND CONNECTORS

M4 0,7 7 3 2400 1,92 1,44 3,07 2,3 4,17 3,13

CORRECT METHOD TO APPLY THE FEMALE CONNECTORS

ROTARY METRIC FEMALE CONNECTOR ROTARY METRIC FEMALE CONNECTOR jic

M 20x1,5 12 58 50 - 65 1.1/16-12 -12 98 63 - 133

14 1.3/16-12 -14 118 73 - 163

M 24x1,5 16 74 60 - 88 1.5/8-12 -20 210 135 - 285

M 26x1,5 18 105 85 - 125 1.7/8-12 -24 290 200 - 380

20 2.1/2-12 -32 450 300 - 600

ROTARY FEMALE CONNECTOR ROTARY FEMALE CONNECTOR ORFS

HYDRAULIC SYSTEM MAINTENANCE INSTRUCTIONS

INSTRUCTIONS FOR THE INSTALLATION OF HOSES AND CONNECTORS

Installation and settings 2

Diagnostics and measurements 3

Mast assembly mechanics 7

TRUCK AND LOAD IDENTIFICATION DATA

The truck identification data plate is located on the truck

• Manufacturer's name. • Max. weight battery

RESIDUAL LOAD PLATE

The load plate is located on the mast crossbar

The load plate bears the following data:

TRUCK AND MAST SERIAL NUMBER STAMP

The truck documentation located in the bat-

1.3 power: battery, diesel, LPG, petrol, electic Battery Battery

3.3 rear wheel size ø 85 x 100 ø 85 x 100

3.4 additional wheels (size) ø 150 x 50 ø 150 x 50

6.2 lifting motor, S3 15%% kW 2 2

3.3 rear wheel size ø 85 x 70 ø 85 x 70 ø 85 x 70

3.4 additional wheels (size) ø 150 x 50 ø 150 x 50 ø 150 x 50

6.2 lifting motor, S3 15%% kW 3 3 3

6.5 battery weight (+/- 5%) kg 222 (212) 288 288

S1.4 I.L. - S1.6 I.L.

1.3 power: battery, diesel, LPG, petrol, electric Battery Battery

3.3 rear wheel size ø 85 x 70 ø 85 x 70

3.4 additional wheels (size) ø 150 x 50 ø 150 x 50

4.19 total length l1 (mm) 2052 (7)

6.2 lift motor, S3 15%% kW 3 3

Weight Battery weight

1 Base truck, assembled mast and forks.

fork lift truck bridge crane lift belt

Before starting work, ensure that you are equipped with

TOPPING UP THE OIL SUMP

Equipment and tools

oil protecting large Philips

bridge crane hexagonal "T"