SERVICE MANUAL

MODELS 20SE

AISLE-MASTER LTD
CLONTIBRET
CO MONAGHAN
IRELAND
TEL + 353 47 80400
FAX + 353 47 80402
Email: info@aisle-master.com
Website: www.aisle-master.com
Table of Contents
1. Maintenance Section Definitions………………………………….…..1-1

2. Initial Service at 100 Hours……………………………….….…..….….1-2

3. Inspection and Maintenance………………………..…………….…….1-3

3.1. Inspection Program. 1-3
3.2. Maintenance Program. 1-3
3.3. Inspection and maintenance Responsibilities 1-3
3.4. Installation Inspection. 1-3
3.5. Routine Maintenance Schedule for forklifts 1-4

4. Inspection and Maintenance Practices……………………………….1-4

5. Inspection and Maintenance Practices for Authorized

facilities only………………………………………………………..….…1-5
5.1. Preparing for inspection maintenance. 1-5
5.2. Performance Testing. 1-5
5.3. Completing Performance Testing 1-6

6. Inspecting Specially Equipped Aisle-Master Forklift Trucks…….1-6

6.1. Identification Plate and Safety Warnings

7. Inspecting Forks…………………………………………………...….…1-7
7.1 Repairing Forks 1-7
7.2 Load Testing Forks 1-8

8. Mast Maintenance………………………………………………….…....1-8
8.1. Chain Maintenance. 1-8
8.2. Measuring Chain stretch 1-8
8.3. Chain Lubrication 1-9
8.4. Chain Adjustment 1-9

9. Brake Fluid……………………………………………………………..….1-9

10. Hydraulic Oil…………………………….………………………….……1-10

10.1 Hydraulic System Maintenance 1-10
10.2 Hydraulic Circuit Maintenance 1-11

11. Checking Side-Shift for leaks……………………………………..….1-11

12. Draining Hydraulic Tank…………………………………………..…..1-12

13. Maintenance Chart………………………………………….…...……..1-13

13.1 Battery Maintenance. 1-13

14. Recommended Battery Charging Procedure……………..……….1-14

14.1 Battery Charging 1-14

Aisle-Master Service Manual I

Table of Contents
15. Battery Removal………………………………………………………...1-15

16. Battery Servicing and Maintenance……………………………...….1-16

17. Care of battery out of service…………………………………..……1-17

17.1 Battery Maintenance. 1-17

18. Grease Point Chart……………………………………….….….…...….2-1

Steering grease points 2-2

19. Wiring Diagram…………………………………………………….…….3-1

20. Fuse Box……………………………………………………….…….…...4-1

21. Dash Diagram……………………………………………….………..….5-1

22. Warning lights & Gauges…………………………………...……...….6-1

23. Hydraulic Functions Circuit……………………………..……...…....7-1

24. Setting load monitor………………………………………………..…..8-1

25. Appendix A………………………………………………….……..…….A-1

26. Operator ’s Daily Checklist………………………….………….....….A-2

27. 100-Hour Service Checklist…………………………….……….....…A-3

28. Every 500-Hour Service Checklist…………………………..….…...A-4

29. Installation Checklist…………………………………….……..….…..A-6

30. Inspection and Maintenance Chart…………………….….……..….A-7

Aisle-Master Service Manual II

 Maintenance Section
1. Maintenance Section Definitions:
This section of your Aisle-Master Service Manual outlines tasks, which must be carried out by
specialized personal. These tasks will ensure that your Aisle-Master forklift stays in correct
working order and also will help to prevent down time within the workplace.

Initial Service at 100 Hours – Describes how authorized service facilities should perform
maintenance on Aisle-Master forklift after the first 100 hours.

Inspection and Maintenance – Describes the tasks involved in per-forming forklift inspections
and preventive maintenance.

Inspection and Maintenance Responsibilities – Details the inspection responsibilities for forklift
operators and service facilities authorized by Aisle-Master Ltd. to perform preventive
maintenance.

Inspection and Maintenance Practices – Describes the precautions and steps you should take
when you perform inspection or preventive maintenance tasks on Aisle-Master forklifts.

Inspecting Specially Equipped Aisle-Master Forklift Trucks – Describes how authorized service
facilities should inspect Aisle-Master forklift trucks designed for special applications.

Identification Plate and Safety Warnings – Describes how to inspect the identification plate and
safety warnings (decals) that are affixed to Aisle-Master forklifts.

Inspecting Forks – Describes how authorized service facilities should inspect Aisle-Master
forklift forks.

Repairing and Load Testing Forks – Describes who is authorized to determine whether a
fork is repairable or needs replacement and how to load test forks after they have been
repaired.

Hydraulic System Maintenance – Describes how authorized service facilities should perform
maintenance on Aisle-Master forklift hydraulic systems.

Mast Maintenance – Describes how authorized service facilities should perform maintenance
on Aisle-Master forklift masts including load roller and chain maintenance.

Side Shift Circuit Maintenance – Describes how authorized service facilities should perform
maintenance on Aisle-Master forklift side shift circuits.

Maintenance Chart – Describes how authorized service facilities should perform

maintenance on Aisle-Master forklift when to change and check parts.

Battery Maintenance – Describes how authorized service facilities should perform

maintenance on Aisle-Master forklift on how a battery should be Charged, Removed from
the Aisle-Master forklift, Serviced and care of the battery out of service.

Grease Point Chart – Describes how authorized service facilities should perform
maintenance on Aisle-Master forklift on all the grease points on the machine.

Aisle Master Service Manual 1-1

Maintenance Section
2. Initial service at 100 Hours
• Check Battery electrolyte levels.

• Check all bolts and fittings are tight.

• Check all wheel nuts for tightness.

Front Wheel Nuts. (305N/m)

Rear Wheel Nuts. (176N/m)

• Grease all points. (See grease point chart)

• Check mast chains; lubricate and adjust. (If Necessary)

• Check for hydraulic leaks.

• Check hydraulic oil level.

• Check load monitor is working correctly (if fitted).

• Check Brake fluid level.

• Adjust handbrake if required. (If Necessary)

Note: Lubricate all grease points weekly (See Grease Point Chart)

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Maintenance Section
3. Inspection and Maintenance
3.1 Inspection Program
The inspection program designed by Aisle-Master
Ltd. periodically checks the integrity of Aisle-
Master forklift systems such as:
• Checking performance of operator functions
Such as lift, tilt, side shift, attachment, and
Traction systems
• Checking for leaks
• Checking fluid levels
• Making sure components are securely
attached
• Checking the tyres
To make sure these and other systems are
Checked periodically, Aisle-Master Ltd. has
developed a system of checklists. A blank copy
of each checklist can be found in Appendix A.
These checklists include:
• Operator ’s Daily Checklist
• Initial service at 100 Hours
• Every 500 Hour Service and Inspection
Checklist
• Installation Checklist / Predelivery Inspection
(PDI)
3.2 Maintenance Program
In addition to the inspection program, Aisle-Master
Ltd. has set up a preventive Maintenance
program. Preventive maintenance procedures
include:
• Clean hydraulic reservoir suction screens
• Change hydraulic oil and filter
• Lubricate mechanical systems
Aisle Master Service Manual
Warning
Never perform any maintenance or service
procedures unless specifically indicated in this
manual or requested by your supervisor. All other
service and maintenance on your Aisle-Master
forklift must be provided by a facility authorized
by Aisle-Master Ltd. to perform these services.
Failure to follow these guidelines can cause
serious injury or death.
Preventive maintenance tasks are usually
performed by a service and maintenance facility
that is approved by Aisle-Master Ltd. Operators
may be asked to assist in some routine
maintenance procedures. Never perform any of
these maintenance procedures unless directed by
your supervisor.
3.3 Inspection and Maintenance
Responsibilities
Initial 100 and every 500 Hour
Service Checklist
During these inspections technicians from an
authorized service and maintenance facility will
inspect all mechanical and electrical systems and
perform preventive maintenance operations
designated by Aisle-Master Ltd.
3.4 Installation Inspection
When your Aisle-Master forklift is installed, the
authorized service facility is required to complete
an Installation Checklist. The installation report
initiates the warranty for the vehicle.
1-3
Maintenance Section
3.5 Routine Maintenance Schedule
for Forklifts
The Routine Maintenance Schedule for
Forklifts are located in Appendix A. Note that
each task should be performed at the time
interval or number of operation hours indicated,
which ever comes first.
!
Warning
Never perform any maintenance or service
Procedures unless specifically indicated in
This manual or requested by you’re
supervisor. All other service and maintenance
on your forklift must be provided by a facility
authorized by Aisle-Master Ltd. to perform
these services. Failure to follow these
guidelines can cause serious injury or death.
Typically an authorized service and maintenance
facility performs preventive maintenance
!
procedures. At times operators may be
requested to assist in performing routine
maintenance, such as doing routine lubrication. If
requested to do so, make sure you read and
understand the guidelines discussed in the
“Inspection and maintenance Practices for Aisle-
Master Forklift Operators,” section in this manual.
Warning
To help avoid fire hazards:
• Have fire protection equipment present in
the work area.
• Do not use an open flame to check fluid
level, leaking oil, or electrolyte.
• Do not use fuel or flammable cleaning fluids
to clean parts.
Failure to follow these guidelines can
cause serious injury or death.
Warning
Batteries produce flammable and explosive
gases. Keep arcs, sparks, flames, and lighted
tobacco away to prevent an explosion. Keep
the area well ventilated. Failure to follow
these guidelines can cause serious injury or
death.
Warning
Failure to use lifting equipment of adequate
capacity to lift and move your forklift can
cause lifting equipment failure, which can
lead to serious injury or death.

4. Inspection and
Maintenance Practices
This section explains the general cautions and
warnings you should observe during inspection
and maintenance procedures. In addition, the
duties of the operator and service and
maintenance technician are explained. Finally,
these specific procedures are explained:
• Preparing for Inspection or Maintenance
• Performance Testing
• Completing Performance Testing

Warning
Wipe up any spills immediately to prevent
serious injury or death from slipping, fire,
explosion, or contact with hazardous
Materials.

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Maintenance Section
5. Inspection and Maintenance
Practices for Authorized 5.2 Performance Testing
Facilities ONLY Note: Make sure all accessories (lights, etc.)
are off before continuing.
• Follow the procedures outlined in “Before You
Inspect the Truck or Perform Service,” “Before 1. Make sure you are in the operator’s seat.
You Check Performance,” and “After
Performance Testing is Complete.” 2. Make sure your right foot is on the floor of
the operator’s cab.
• Inspect and maintain wheel hubs and
protective devices. 3. Set the direction lever (item 1) [1], in the
neutral position.
• Only use replacement parts, including tyres,
that are equal to, or exceed, the quality of
the parts supplied by the original equipment
manufacturer. Install parts, including tyres,
according to procedures established by
Aisle-Master Ltd.

• When you remove tyres, follow industry 1

safety practices.

5.1 Preparing for Inspection or

Maintenance

• Inspect the truck in an area that has 1

sufficient clearance to check all operators
functions. 4. Turn the key switch, (item 1) [2], to the START
position.
• Lower forks to the ground and tilt mast
forward. 1
• If you need to operate the truck to perform
operator functions, raise the drive wheels to
clear the floor.

• Block the mast to prevent it from engaging.

• If you need to hoist the truck, ensure the

hoisting equipment has adequate size and
capacity to move the equipment.

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Maintenance Section
5. Set the direction lever (item 1) [1], in the
forward position.
6. Check functions described on the
Operator’s Daily Checklist or every 500
Hour Checklists.
5.3. Completing Performance Testing
Note: Make sure all accessories are off
(lights, etc.) before you turn the key
switch to the Off position.
1. Apply the Handbrake (item 1) [3].
2. Tilt the mast forward.
3. Lower the forks to the ground.
4. Turn the key switch to the OFF position.
5. Remove the key.
1
3
Before you leave the truck make sure that:
• The forklift will not cause an obstruction or
safety hazard.
• The forklift is clear of fire exits, fire
equipment, and stairways.
• The truck is not left unattended on an incline.

The truck is inoperative and if you must leave it
parked on an incline, securely block the
wheels and remove the key.
Aisle Master Service Manual
6. Inspecting Specially Equipped
Aisle-Master Forklift Trucks
The following information is provided for
authorized service facilities ONLY.
Forklift trucks that were designed to meet
special applications should be inspected and
tested to make sure they meet original design
criteria described by the specific (local)
agency.
6.1 Identification Plate and Safety Warnings
Warning
Make sure that the identification plate and
safety warnings (decals) located on the
truck are legible and the information
provided match the characteristics of the
truck. Failure to follow this guideline can
result in serious injury or death.
The following information is provided for
authorized service facilities ONLY.
Contact Aisle-Master Ltd. if any accessories that
modify the capacity and truck operation are
planned. After the factory reviews your request,
new identification tags will be issued to update
the rated capacity and other operation
characteristics.
1-6
Maintenance Section
7. Inspecting Forks
The following information is provided for
authorized service facilities ONLY.
Check the forks, and associated components, as
required by the various checklists located in
Appendix A. The following discussion provides
detailed procedures necessary to provide a
complete fork inspection.
! exceeds 3% of the length of the blade, repair or
Warning
If you find any defect in the forks or mounting
components, take the Aisle-Master forklift out
of service until the fork is repaired or replaced.
Failure to follow this guideline can cause the
load to fall resulting in serious injury or death.
Rated Capacity and Load Centre – The rated
capacity of each fork must be at least half of the
rated capacity stated on the identification plate.
The load centre of each fork must match the load
centre stated on the data plate. If the values do
not match, replace the fork with one that has the
correct characteristics.
Cracks :
Visually examine the forks for cracks and, if
considered necessary, perform a non-destructive
crack detection test. Pay special attention to:
• Fork heel
• Welds that attach mounting components to
the fork blank
• Top clip retaining pin
Straightness of Blade and Shank:
Check the straightness of the upper face of each
blade and the front face of each shank. If the
deviation from straightness exceeds 0.5% of the
length of the blade and/or the height of the shank,
respectively, repair or replace the fork set.
Aisle Master Service Manual
Fork Angle :
Check the angle between the upper face of each
fork blade and the load face of each shank. If the
deviation exceeds 3 from the original specification,
repair or replace the
fork.
Difference in Height between Fork Tips :
Check the difference in height between each fork
blade (measured at the tip) with the fork mounted
on the fork carrier. If the difference in tip heights
replace the fork.
Positioning Lock:
Check the positioning lock on each fork to make
sure it functions properly. If any problems are
noted, repair or replace the fork.
Wear:
Two different areas of the fork and fork attachment
should be checked for wear.
Fork Blade and Shank – Check each fork blade
and shank for wear, pay special attention to the
area surrounding the heel of the fork. If the
thickness is reduced to 90% of the original
thickness, repair or replace the fork.
Fork Hooks – Check the support face of the top
hook and the retaining faces of both hooks for
wear, crushing, and other local deformations. If
any of these deficiencies cause excessive
clearance between the fork and the fork carrier,
repair or replace the fork.
Fork Marking:
If the fork marking is not clearly legible, the fork
manufacturer, or their representative should remark
it.
7.1 Repairing Forks:
If you suspect that a fork needs to be repaired,
return it to the manufacturer or other expert of
equal competence, for repair. Never try to repair
surface cracks or wear by welding the fork. If you
need to reset a fork, make sure it is heat-treated
before it is returned to service.
1-7
 Maintenance Section
7.2 Load Testing Forks:
A fork that has undergone repairs, other than
Repair or replacement of the positioning lock
and/or marking, must be load tested before it is
returned to service. The testing facility must test
the forks to a limit of 2.5 times the rated capacity
marked on the fork.
! Correct the misalignment. If wear is excessive,
8. Mast Maintenance:
The following information is provided for
Authorized service facilities ONLY.
Perform maintenance on the mast as required
by the every 500 hour checklists and Routine
Maintenance Schedule for Aisle-Master
Forklifts located in Appendix A. Guidelines are
provided in the following paragraphs.
Warning
Never work on the mast with a load on the
forks or attachment in the raised position
without supports or while anyone is near the
lift truck control handles.
• Protruding or turned pins: Replace both
Strands of chain.
• Side wear: If pins and outside plates show
signs of wear, check for misalignment of
sheaves, anchors or other components.
replace both strands of chain.
• Worn, broken or misaligned chain anchors:
Replace or adjust as required.
If the chains stretch beyond the recommended
amount, they should be replaced in pairs. Chain
stretch can be measured with a chain wear scale
(item1) [4]. The scale indicates whether the
distance between two chain links is with-in
tolerance. The shaded area in the illustration
(item 2) [4] compares a stretched chain (item 3)
[4], to a new chain (item 4) [4]. Measure the
chains according to the instructions printed on
the chain wear scale, without a load on the car
riage.

8.1 Chain Maintenance:

Regular inspection and lubrication of the chains will
increase their service life and reduce downtime.
When you perform chain maintenance, make sure
you follow the guidelines in “Chain Inspection”
“Chain Lubrication ”,“ Chain Adjustment ” and
“Measuring Chain Stretch ”.

8.2. Measuring Chain Stretch:

Inspect the chains as required by Inspection and

maintenance charts. Check for the following:

• Chain wear: If one strand appears to be

worn replace both strands of the pair.

• Rust and corrosion: .If chain joints become tight

from rust and corrosion loosen them with SAE
40W oil or penetrating oil. If they cannot be
loosened, or if bent pins, plates, or penned plate
edges cause the tight joints, replace both strands
of chain. To check the free lift chains, raise the carriage
1 ft (30 cm) off the ground to put tension on the
• Cracked side plates: Replace both strands of chains.
chain.

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Maintenance Section
To check the main lift chains, raise the mast until
the inner upright starts to extend putting tension
on the chains.
8.3 Chain Lubrication:
Caution
The chains must be coated with a film of
lubricant at all times.
To lubricate the chains, use oil with a viscosity
that will remain fluid at all occurring ambient
temperature conditions, lubricating oils with a
viscosity from SAE20 to SAE40 are suitable.
The following are examples of commercially
available chain-lubricating products:
1. Rexnord high performing chain spray
2. BP Energol Transmission Oil 80
3. ESSO Transmission Oil ST80
4. Shell Tonna Oil T200.
Each pair of chains has been factory
lubricated using heat and pressure to force
the lubricant thoroughly into the chain links.
Avoid removal or contamination of this
factory-applied lubricant. Do not wash, sand
blast, etch, steam clean, or paint the
chains.
Aisle Master Service Manual
8.4 Chain Adjustment:
The chains must be adjusted so each strand is
under equal tension for proper load distribution
and mast operation.
To determine whether the chains are properly
adjusted:
1. Remove load from forks.
2. Extend the mast to put the chains under
tension.
3. Press the centre of a strand of chain with
your thumb, and then press at the same
place on the other chain of the pair.
4. Each chain in a pair should have equal
“give ”. If tension is not equal, adjust them
as described in the manufacturer’s mast
service manual.
9. Brake fluid:
The brake fluid used on the Aisle-Master
Forklift is a standard brake and clutch fluid.
The machine is supplied with a Brake fluid,
which meets SAE J 1703 and ISO 4925
Specifications.
1-9
Maintenance Section
10. Hydraulic Oil:
The hydraulic oil used in the Aisle-Master
Forklift should conform to the International
Standard I.S.O. G344 HV grade oils with
improved viscosity / temperature
characteristics. It should also have the correct
temperature range for the ambient
temperature in which the machine is being
operated. If the operating temperature is
outside the standard range, the standard oil
should be replaced with the correct grade.
Low Range
AMBIENT -20ºC to 25ºC
TEMPERATURE -4ºF to 77ºF
Castrol: Hyspin AWH 32
B.P. Bartran HV 32
Esso: Univis N 32
Mobil: 13 M
Shell: Tellus Oil T32
Texaco: HDZ 32
The hydraulic oil tank has a total capacity
of 72 litres. 65 litres is required to bring
the oil level to the centre of oil level
gauge.
10.1 Hydraulic System Maintenance:
The following information is provided for
authorized service facilities ONLY.
Maintain the hydraulic system, and associated
components, as required by the various
checklists and the Routine Maintenance
Schedule for Aisle-Master Forklifts located in
Appendix A. Guidelines for hydraulic system
maintenance is provided in the following
paragraphs.
Caution
Do not allow hydraulic fluid level to drop
significantly or allow the reservoir to run dry.
This will induce air into the system and cause
damage to hydraulic system components.
Aisle Master Service Manual
Ensure that the correct type is used in the
relevant ambient temperature.
NOTE: The machine is supplied with an AWH46
hydraulic fluid when leaving the factory. Please
check if this is suitable for the ambient temperature
in which the machine is to be operated.
NOTE: Before adding hydraulic oil, ensure that all
cylinders are retracted and fill to upper level.
Standard Range High Range
-10ºC to 35ºC 0ºC to 45ºC
+14ºF to 95ºF 32ºF to 113ºF
AWH 46 AWH 68
HV 46 HV 68
N46 N 68
15 M 16 M
T46 T68
HDZ 46 HDZ 60
Cylinders and Valves:- Check these
components for drift and leakage.
Refer to Aisle-Master Ltd. and other
vendor service information for
specifications.
Hoses and Tube lines: – Check for cracks,
hardening, or other signs of wear. Reroute
any usable hoses that are kinked, severely
bent, or rest against / wearing hot parts.
Look for leaks, especially at couplings and
fittings. Replace any hoses or tube-lines that
don’t meet system flow and pressure
ratings.
Hydraulic Fluid: – Check fluid level and
look for air bubbles. Check the filter.
Other Hydraulic System Components: –
Visually check other components to see if they
are loosely mounted show signs of leaks, or
other damage or wear.
1-10
Maintenance Section
10.2 Hydraulic Circuit Maintenance: 11. Checking Side Shift for
The following information is provided for Leaks:
Authorized service facilities ONLY.
To check side shift circuit performance:
Perform maintenance on the Hydraulic
circuit as required by the every 500 hour
1. Side shift completely to the left and hold
checklists and Routine Maintenance
the control handle in this position for 5
Schedule for Aisle-Master Forklifts located
seconds. Check for external leaks at the
in Appendix A. Guidelines are provided in
cylinder, fittings and hoses.
the following paragraphs.
2. Side shift completely to the right and hold
the control handle in this position for 5
Warning seconds. Check for external leaks at the
• Before you remove any hoses or tubes, cylinder, fittings and hoses.
relieve hydraulic system pressure. With
the truck off, open the truck auxiliary
control valve(s) several times in both
directions.

• Check for hydraulic fluid leaks using a

piece of cardboard or wood. Do not use
your bare hands. Remember to wear
safety glasses.

Hydraulic oil can be under very high

pressure. A pinhole leak is not easily
seen and if it pierces your skin, can
cause gangrene, and possibly death, if
not treated immediately by a physician
familiar with this type of injury.

• Check the hydraulic system pressure at

the carriage hose terminal. The minimum
recommended pressure is 2000 psi (140
bar). System pressure must not
exceed 3500-psi (245) bar.

• Check the hydraulic system flow volume at

the carriage hose terminal. The
recommended flow volume is 2 GPM (7.5
L/min.).

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Maintenance Section
12. Draining hydraulic Tank:
1. Tilt Aisle-master machine to one side using
suitable equipment.
2. Place a suitable size receptacle directly
underneath the outlet (item 2) [5], to prevent
any oil spillage.

Remove drain screw (item 2) [5] by

turning anti-clockwise to drain system.

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Maintenance Section
13. Maintenance Chart:
Schedule: A = Every 500 HOURS / 3 MONTHS (OR WHICHEVER OCCURS FIRST).
B = Every 2000 HOURS.

Check Change
Traction Motor Mount Bolts. A
Pump Motor and Steering Motor Mounting Bolts. A
Hydraulic Oil. A B
Tank internal Filter. B
Controller Cooling Fan. A
Handbrake Adjustment. A
Mast Pivot Points. A
Return Filter. A
Front Wheel Nuts (305 N/m). A
Rear Wheel Nuts (176 N/m). A
Mast Chain Adjustment. A
Check Wiring. A
Service Grease Fittings. A
Check Mast Cylinder Lifting Brackets. A
Check Hydraulic Oil Pump Operation. A
Check Load Monitor (If Fitted). A
Brake Fluid Level. A
Handbrake Adjustment. A

Check Battery Electrolyte level weekly.

13.1 Battery Maintenance:

WARNING
Batteries produce explosive gases during operation and charging. Keep
your Aisle-Master in a designated area while you are charging or
changing batteries. The area must be properly ventilated to remove the
gases produced while it is charging. Keep all sparks, arcs, and lighted
tobacco away from the batteries. Failure to do this can cause serious
injury or death.

Aisle Master Service Manual 1-13

 Maintenance Section
14. Recommended Charging Procedure:

• Park your Aisle-Master in the battery bay.

• Open the Rear Battery Cover.
• Disconnect the battery plug.
• Check the charger cable and plug for frayed insulation and broken connectors and
connect it to the battery plug.
• When the batteries are fully charged disconnect the charger cable and reconnect the
battery cable to the truck cable.

CAUTION
• Make sure top of batteries are clean and dry.
• Check the electrolyte levels and top off with distilled water after batteries are
completely charged.
• Check the charger cable and plug for frayed insulation.

Never use a battery that weighs less than the weight range listed on the
identification plate as the battery is part of the counterweight, too little
battery weight can cause the truck to tip.

14.1 Battery Charging:

Do not opportunity charge the battery. Charging cycle times should be completed in full
to the specified charging time. Failure to conform will result in premature battery failure
and invalidate any manufacturers warranty.

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 Maintenance Section
15. Battery Removal:
The truck uses a 48V DC battery, with various
Amp- Hour capacities to suit the truck's duty 1
cycle. Always consult the truck's technical
specification before attempting to fit or connect 4
a battery voltage to the truck's electrical
system. It is also important to check the charge
specification to ensure that it is compatible with
the battery before charging. Read the charger
handbook before connecting.
3
Note: Battery chargers should only be installed
by a qualified electrician.
2
• Disconnect battery plug (item 1) [4]. 5
• Release right hand latch devise (item ––––––
1) [5] & left hand latch devise (item 2)
[5]
• Loosen bolt (item 2) [4] & rotate bracket
anti-clockwise (item 3) [4].
• Lift battery (item 4) [5]. Approximately
20mm using a forklift truck or a hand
pallet truck (item 3) [5].
• Withdraw battery from truck.

1.

2 3
4

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Maintenance Section
16. Battery Servicing and Charging
Safety Precautions:
Warning
Keep all flames and lit cigarettes away from
the battery, especially during or soon after
charging, as the gases involved can produce
an explosive mixture.
Warning
Never do anything that could cause an electric
spark on or near the battery.
Warning
Never lay tools on top of the battery.
Warning
Isolate electrical connections before working
on the battery. Use only insulated tools.
Warning
Wear suitable protective clothing and eye
protection when working on the battery.
Warning
Charge batteries only in the special area
allocated for charging of batteries. When
charging batteries, keep the vent plugs clean.
The battery charger area must have ventilation
to remove the explosive fumes. Open the
battery cover and secure in position during
charging.
Aisle Master Service Manual
Warning
The acid in the battery electrolyte can
cause injury if it is spilled. Make the acid
neutral with a solution of sodium
bicarbonate (soda) and water.
Warning
ADD NOTHING TO THE CELLS BUT
PURE WATER and do this often to keep
the separator guard always covered
(electrolyte visible). Top up electrolyte
with the battery in its fully charged
condition.
Warning
Ensure that the battery vent plugs are
replaced after charging.
Warning
Never connect the battery charger plug to
the plug of the lift truck. You can damage
the traction control circuit.
Warning
Ensure that the charger voltage is the
correct voltage for the battery.
Warning
Always switch off charger before
disconnecting battery.
1-16
Maintenance Section
17. Care of Battery out of Service:

If a battery is to be taken out of service for a

time, or if a new charged battery cannot be put
into service immediately, it should be given an
equalising charge and stored in a cool dry
place. Disconnect detachable connectors.
Every month, check acid levels and give an
equalising charge.

If a truck is used at irregular intervals, the

battery should be given an equalising charge
every month and the battery disconnected
from the truck during idle periods.

17.1 Battery Maintenance:

• Batteries contain sulphuric acid and

generate explosive gases when being
charged.
• Trained and authorised personnel only must
charge them in designated, well-ventilated
areas.
• In the event of an accident flush acid away
from the eyes and/or skin using plain water
and obtain medical attention immediately.
• Check level of electrolyte in each battery
cell and top-up if necessary, using only
clean distilled water. Bring level up to
markers.

Note
A smear of petroleum jelly applied to clean
terminals will offer protection against acid
corrosion.

Warning
Protective clothing and goggles should be
worn and particular care taken not to
come into contact with or spill electrolyte
when checking its level. Keep the battery
clean and dry, and terminals free from
corrosion. Check that the ventilation holes
in battery caps are clear. Temperature
must not exceed of 38° C (100° F) during
charging. Smoking and the use of naked
lights in the charging area are strictly
prohibited.

Aisle Master Service Manual 1-17

 Grease Point Chart
7 5 3 1

6 4 2

7 5 3 1

6 4 2

1. Rear Tilt Ram (RH) 2. Rear Tilt Ram (LH) 3. Front Tilt Ram (RH) 4. Front Tilt Ram (LH)
5. Mast pivot (RH) 6. Mast Pivot (LH) 7. Side Shift Top 8. Side Shift Bottom

Note: Item 8 grease points are underneath the bottom side bar.
Lubricate all points weekly using MP2 grease. Also Lubricate all grease points on
the mast, and attachments where fitted.

Aisle-Master Service Manual 2-1

Steering Grease Points

Every 500 hours apply a light

amount of grease through grease
nipples shown. (Use Mobile
Mobilux EP2 NLGI 2 grease)

Every 250 hours apply grease.

(Use Castrol – Pyroplex black
EP Lithium + Mo 52 NLGI 2)

Aisle-Master Service Manual 2-2

 Electric Aisle-Master Wiring Diagram.

NO. WIRE FROM Fuse Position Amp. FUSE BOX

NO. WIRE FROM 1 KEY SWITCH INPUT 1 Park Brake / Low
Brake Fluid (Red)
1 KEY SWITCH INPUT 2 INTERLOCK INPUT 2 F.N.R Control 7.5A
2 3 BRAKE 3 Mast Solenoid Low Battery (Red) Brushware (Amber)
INTERLOCK INPUT 7.5A
7 PUMP SPEED 1 9 KEY SWITCH INPUT 4 Load Cell 1A
4 8
8 PUMP SPEED 2 10 FORWARD 5 Maintenance (Red)
11 Motor Temperature
11 THROTTLE (N.A) 11 REVERSE 6 (Red)
Lights 3 7 Logo
17 PUMP CONTACTOR SWITCH 13 +5V 7 20A
10 Logo
15 THROTTLE 8
17 Horn 2 6 Push Button
MAIN CONTACTOR SWITCH 9 7.5A
10 Cooling Fan 7.5A 9 Push Button
17 17 15 13 11 Beacon 7.5A 1 5
LCD Display

24 24
1 1 NO. WIRE FROM NO. WIRE FROM
1 Battery Negative 1

2 Lift Lock Out 2

11 8 7 2 1 11 10 9 3 2 1
3 Uninterupted Positive 3

B+ 4 4 Hour Meter Enable

5 Brushes Low(Pump/Drive) 5

6 6

7 Motor Over Temp(Pump/Drive) 7 Key Switch Supply

PUMP CONTROLLER TRACTION CONTROLLER
8 8

9
Park Brake +
Low Brake
Fluid

Brushware
Motor Temp

Main
10 Park Brake
Contactor B-
Coil

3.3kO

B-
24 24 5kO -0
1 1
Pump Throttle Brake Pedal
Contactor
Coil

B- M- B+ B- M- B+ F9 F11 F7 F10 F4 F3 F2
F1 F2
7.5 7.5 20A 7.5 1A 7.5 7.5
Interlock

Dash
Light

S1 Fuse Fuse
Keyswitch Spot F R
Light
N
A2 A1
Contactor Contactor Load Cell
Spot Link
A2 F1 F2 Control Fuse Light

48v DC Spot
Control

Light
DC-DC
B- B+ 48V Power 12V
supply
Horn
Drive
Fan

Lights
Cooling

Beacon
Mast
Reverse
Bleeper

Solenoid
Maintenance Section
Balloon No. 5 : 30 Amp Relay

Aisle-Master Service Manual 5-1

Warning Lights & Gauges

1/2
F
H
0 1
I E

8888 D

A B C

(A)---Push Button

(B)---LCD Display

(C)---Push Button

(D)---Motor Temperature

(E)---Brush Wear

(F)---Park Brake

(G)---Battery Power Level

(H)---Low Battery

(I)----Maintenance

Aisle-Master Operator’s Manual 6-1

 Setting load monitor

STAGE 1

1. Hold left thumb on test.

2. With right hand hold the magnet beside your left thumb for 15-20secs until red light
appears on display. (SEE PHOTO 1)
3. Remove finger from test button.
4. Then press test until orange light appears under red. (SEE PHOTO 2)

STAGE 2

1. Drive machine onto weight making sure weight is fully to the back of the forks.
2. Lift weight ---1 meter (39 inches) --- off the ground, making sure the mast is in the
middle of a tilt stroke.
3. Press test, and take out the loop (SEE PHOTO 3)
4. Then press test again.
5. Put loop back into place and press test again, until orange and green light appear
(SEE PHOTO 2 AGAIN).

Aisle-Master Service Manual 8-1

Aisle-Master Service Manual 8-2
 Appendix A
This section of your Aisle-Master Forklift Service Manual includes the
following checklists and maintenance schedules:

• Operator ’s Daily Checklist

• Initial service at 100 Hours
• Every 500 Hour Inspection Checklist
• Installation Checklist
• Inspection and Maintenance Chart

Aisle-Master Service Manual A-1

 Aisle-Master
Operator's Daily Checklist

Daily pre-shift inspection requirement. It is important that these inspection are documented

Date Inspector Record Fluid Added:

Truck No. Model No. Hydraulic Oil
Location Serial No.
Shift Drive Hour

SAFETY & OPERATION CHECKS

Have a qualified mechanic correct all problems. O.K. ( X ) Need Maintenance
Leaks - Hydraulic Oil, Brake Fluid
Tyres- Check for Debris; - Torque to (Front - 305N/m), (Rear - 176 N/m).
Forks, Top Clip Retaining Pin and Heel - Condition
Load backrest extension – Attached (Optional)
Hydraulic Hoses, Mast Chains and Stops - Check Visually (Note Bracket Location)
Overhead Guard - Attached
Safety Warnings - Attached
Hydraulic Fluid Level
Check Battery Electrolyte Levels.
Operators Compartment Capacity Plate Attached - Information Matches
Model, Serial No. and Attachments
Seat Belt, Buckle and Retractor - Functioning Smoothly
Controls (Turn Power On) Investigate Unusual Noises Immediately
Accelerator - Functioning Smoothly
Handbrake – Functioning
Steering operation - Functioning Smoothly
Drive Control - Forward/Reverse - Functioning Smoothly
Tilt Controls - Forward and Back - Functioning Smoothly
Hoist and Lowering Control - Functioning Smoothly
Attachment Controls – Operational (Optional)
Horn - Functioning
Lights - Functioning
Rear View Mirror - Attached
Gauges: Hour Meter - Functioning
Warning Light - Functioning
Reverse Warning Bleeper - Functioning
Load Monitor – Functioning (Optional)

Aisle-Master Service Manual A-2

 Aisle-Master
Initial Service at 100 Hour

To be performed after first 100 hours of truck operation in addition to the required pre-shift daily inspection.

Date Inspector Record Fluid Added:

Truck No. Model No. Hydraulic Oil
Location Serial No.
Shift Drive Hour

FIRST 100 HOUR SERVICE

Needs
SAFETY & OPERATIONAL CHECKS O.K. (X) Maintenance
Check Battery Electrolyte levels.
Adjust handbrake if required
Check Hydraulic oil level
Brake fluid Level.
Grease All Points.
Check all Bolts and fitting, are tight.
Leaks - Hydraulic Oil, Brake Fluid.
Check Mask Chains - Lubricate and Adjust.
Tyres- Check for Debris; - Torque to (Front - 305N/m), (Rear - 176 N/m)
Check steering.
Load Monitor - Functioning
Check Brake Fluid level
Check Drive Axle for Gear Oil.
Check Emergency Stop button

Aisle-Master Service Manual A-3

 Aisle-Master
Every 500 Hour Service Checklist

To be performed after every 500 hours of truck operation in addition to the required pre-shift daily inspection.

Date Inspector Record Fluid Added:

Truck No. Model No. Hydraulic Oil
Location Serial No.
Shift Drive Hour

EVERY 500 HOUR SERVICE

SAFETY & OPERATIONAL CHECKS O.K. (X) Comments

Leaks - Hydraulic Oil,
Tyres - Check for Debris; - Torque to (Front - 305N/m), (Rear - 176 N/m)
Forks, Top Clip Retaining Pin and Heel - Condition
Load Backrest Extension – Attached (Optional)
Hydraulic Hoses - Check for Wear / Rubbing
Mast chains - Lube with SAE 40 wt. Oil or Bowman Heavy Load Red Grease – Check for
Wear adjust / replace as necessary.
Check Torque on pump mounting bolts
Check All Connections for Proper Torque
Brake Fluid Level
Hydraulic Fluid Level
Check Electrical Connections – corrosion
Operators Compartment Capacity Plate Attached - Information Matches
Model, Serial No. And Attachments
Seat Belt, Buckle and Retractors - Functioning Smoothly
Controls (Turn Power On) Investigate Unusual Noises Immediately
Accelerator - Functioning Smoothly
Handbrake - Functioning
Steering operation - Functioning Smoothly
Drive Control - Forward/Reverse - Functioning Smoothly
Tilt Controls - Forward and Back - Functioning Smoothly
Hoist and Lowering Control - Functioning Smoothly
Attachment Controls – Operational
Horn – Functioning
Lights - Functioning
Gauges: Hour Meter – Functioning
Warning Lights – Functioning
Slew Ring - Functions Smoothly / Wear
Emergency Stop Button - Functioning
Load Monitor – Functioning
Reversing Warning Bleeper
Check Drive Axle for Gear Oil

Aisle-Master Service Manual A-4

 Aisle-Master
Installation Checklist

QUALITY CONTROL SHEET Remit Copy to Aisle-Master Ltd.

Date Inspector Record Fluid Added:

Truck No. Model No. Hydraulic Oil
Location Serial No.
Shift Drive Hour

SAFETY & OPERATION CHECKS

Need
Have a qualified mechanic correct all problems. O.K. (X) Maintenance
Leaks - Hydraulic Oil
Tyres- Conditions; - (Front - 305N/m), (Rear - 176 N/m)
Forks, Top Clip Retaining Pin and Heel - Condition
Load backrest extension - Attached
Hydraulic Hoses, Mast Chains and Stops - Check Visually (Note Bracket
Location)
Finger Guards - Attached
Overhead Guard - Attached
Safety Warnings - Attached (Refer to Parts Manual for Location)
Brake Fluid Level
Hydraulic Fluid Level
Operators Compartment Capacity Plate Attached - Information Matches
Model, Serial No. And Attachments
Seat Belt, Buckle and Retractor - Functioning Smoothly
Controls (Turn Power On) Investigate Unusual Noises Immediately
Accelerator - Functioning Smoothly
Hand Brake - Functioning
Steering operation - Functioning Smoothly
Drive Control - Forward/Reverse - Functioning Smoothly
Tilt Controls - Forward and Back - Functioning Smoothly
Hoist and Lowering Control - Functioning Smoothly
Attachment Controls - Operational
Check Emergency Stop Button - Functioning
Horn - Functioning
Lights - Functioning
Gauges: Hour Meter – Functioning
Warning light - Functioning
Load Monitor - Functioning
Reverse Warning Bleeper-Functioning
Check Drive Axle for Gear Oil

Aisle-Master Service Manual A-5

Inspection and Maintenance Chart

13. Maintenance Chart:

Schedule: A = Every 500 HOURS / 3 MONTHS (OR WHICHEVER OCCURS FIRST).
B = Every 2000 HOURS.

Check Change
Traction Motor Mount Bolts. A
Pump Motor and Steering Motor Mounting Bolts. A
Hydraulic Oil. A B
Tank internal Filter. B
Controller Cooling Fan. A
Handbrake Adjustment. A
Mast Pivot Points. A
Return Filter. A
Front Wheel Nuts (305 N/m). A
Rear Wheel Nuts (176 N/m). A
Mast Chain Adjustment. A
Check Wiring. A
Service Grease Fittings. A
Check Mast Cylinder Lifting Brackets. A
Check Hydraulic Oil Pump Operation. A
Check Load Monitor (If Fitted). A
Brake Fluid Level. A
Handbrake Adjustment. A

Aisle-Master Service Manual A-6