Serviço R.1 (D435)

Part no.
: 4065749 Revision: 1 (12/2014)
Technical information for Hyster service

centres
This manual is intended solely for the specialized technicians of

the Hyster service network.
R1.4 R1.6N
R1.6 R1.6HD
D435.....
R2.0 R2.0HD
R2.5
INTRODUCTION SERVICE
IMPORTANT
The Service Manuals are updated regularly, but may not contain the most recent product design modifica-
tions. The updated technical information is in any case available from your nearest authorised Hyster®
dealer. The Service Manuals provide the guidelines for correct maintenance and are designed for use by
appropriately trained technicians. Incorrect maintenance or non-compliance with the instructions contained
in this manual could cause damage to property or injury and even death to people.
We therefore recommend that you read this manual carefully and keep it in a good condition so it is always
decipherable and complete.
This manual does not replace the use and maintenance manual, it is a supplement to it.
Product support group
2
SERVICE INTRODUCTION
GUIDE TO USING THE MANUAL
SECTIONS
This handbook is composed of the following sections:
Section 1: Presentation
Section 2: Installation and settings
Section 3: Diagnostics and measurements
Section 4: Electrical system
Section 5: Hydraulic system
Section 6: Truck base mechanics
Section 7: Mast assembly mechanics
Section 8: Small fork mast mechanics
Section 9: Reduction gear
Section 10: Braking system
Section 11: Standard maintenance
Use the sections index with the numbered black bands to go quickly to the desired section.
SYMBOLS
Signals a danger that can cause accidents to people or damage to the machine.
Signals danger due to high temperatures.
Signals important notes or information to take into particular consideration.
Signals disposal/recycling of harmful substances under the protection of current legislation.
INSTALLATION PROCEDURES
For the installation procedures, carry out the reverse procedure to disassembly, observing any notes and
information given for the truck to function properly.
3
GENERAL SAFETY RULES

PERSONAL SAFETY
• Always wear the personal protective equipment in situations requiring it.
• Pay particular attention to the risk of getting crushed due to moving parts, oscillations, material not
properly secured when performing lifting operations or moving loads.
• Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbut-
toned jackets or tops with open zippers that can get caught up in moving parts.
• Never do any cleaning, lubrication or maintenance work with the battery connected.
• Using compressed air to clean the parts, protect yourself with goggles that have side protection. The
maximum air pressure must not exceed 1 bar.
SAFETY AT THE WORKPLACE

• Make sure that all the work tools are perfectly efficient and ready for use. Keep the work surfaces clean
and clear of debris that can come into contact with parts of the machine and cause damage.
• Make sure you keep sparks, naked lights and cigarettes away from fuels or flammable materials such
as the gas of the batteries and fuels.
• Make sure that the work area is ventilated, well illuminated, dry and clean. Remove any puddles of
water or oil stains.
• Make sure that the equipment, devices or lifting machinery used is able to sustain the load in a stable
manner.
• Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable
and non-toxic trade solvents.
• When working outside the garage, move the machine preferably onto the level and block it. If working
on a slope is inevitable, block the machine beforehand and move it onto a level area as soon as pos-
sible with a certain margin of safety.
• Disconnect the batteries and label all the controls to signal that work is in progress. Block the machine
and every attachment that has to be raised.
• Never perform any servicing on the machine with persons at the controls, unless they are accredited
operators and help with the operation to be performed.
• When towing use solely the prescribed coupling points and check that the pins and/or bolts are firmly
secured before pulling. Lift and handle all the heavy parts with lifting equipment of adequate capacity.
Use the lifting eyebolts intended for this purpose. Make sure no one is near the load to be lifted.
• Avoid twisting chains or metal ropes.
• Do not trust bent or damaged chains or ropes: do not use them for lifting or pulling. Always wear the
safety gloves to handle them.
• Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away
into a closed metal container.
• Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.
Special companies can be employed to dispose of or recycle industrial oils according to the laws in
force in individual countries.
• When welding is necessary, you must use appropriate safety protection: dark goggles, hard hat, overalls,
gloves, safety footwear. Dark goggles must be worn also by those who are not doing the work if they
remain nearby during the welding.
4
• Before using the batteries, make sure that both ends of the cables are connected to the terminals as
prescribed: (+) with (+) and (-) with (-).
• Do not short-circuit the terminals.
• The gas released when charging is highly flammable. When charging, leave the battery compartment
uncovered for more effective ventilation and take off the plugs.
• Never check the battery charge with "jumpers" obtained by putting metal items on the terminals.
• Before taking any action, check that no elements are shorted.
• Always disconnect the battery before working on the electrical system.
• For battery chargers and similar equipment, use solely auxiliary power sources with an effective ground
connection to avoid any electric shocks.
• Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate
under the skin; in such cases, having to make a check, use a card or a piece of wood.
• Having to check the system pressure, use the specific instruments.
BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE

• Keep a record of all the suspension elements used, stating the characteristics of the suspension ele-
ments and the data given on the identification plate .
• Never leave belts, cords or suspension elements in use whose identification plate has been lost.
• Always use belts, ropes or suspension elements of suitable dimensions. Concerning the suspension
elements, take into consideration the lifting angle and any unbalancing of the load.
• The bells on the suspension elements must be sized in proportion to the hook of the overhead travelling
crane and anyhow must be free to move easily.
• Always rest the load in the race of the hook.
• Never load the tip of the hook.
• When lifting, avoid sudden operations that can jerk on the ropes and belts.
• Never do any lifting with the ropes and belts twisted.
• Knots are not permissible. Always protect the ropes and belts when they come into contact with sharp
edges.
• When moving with no load, to prevent impact and accidental hooking, hang the hooks in the bells and
close the safety ones.
Using suspension elements under conditions of unbalanced load

If lifting unbalanced loads it is advised as a precaution to downrate the load capacities of the lifting ele-
ments:
• Slings with 2 booms, consider them as corresponding to 1 boom.
• Slings with 3 and 4 booms, consider them as corresponding to 2 booms.
Tips for maintenance
Periodically examine the belts, ropes and suspension elements according to current legislation to define
their state of service.
Change them in the following cases:
• When the components show: deformation, cracks, hollows, cuts or abrasions.
• When the wear of the components exceeds 10% of the original dimensions.
• When the sling shows signs of overloading.
5
Belt capacity table
Colour
purple 1000 2000 1400 800

green 2000 4000 2800 1600
yellow 3000 6000 4200 2400
grey 4000 8000 5600 3200
red 5000 10000 7000 4000
brown 6000 12000 8400 4800
Working load blue 8000 16000 11200 6400
capacity (kg)
orange 10000 20000 14000 8000
orange 12000 24000 16800 9600
orange 15000 30000 21000 12000
orange 20000 40000 28000 16000
orange 25000 50000 35000 20000
orange 30000 60000 42000 24000
Coefficient 1 2 1.4 0.8
Rope capacity table
Track
Colour
(mm)
black 35 500 1000 700 400

purple 50 1000 2000 1400 800
black 50 1500 3000 2100 1200
green 60 2000 4000 2800 1600
Working load yellow 75 3000 6000 4200 2400
capacity (kg) grey 120 4000 8000 5600 3200
red 150 5000 10000 7000 4000
brown 180 6000 12000 8400 4800
blue 240 8000 16000 11200 6400
orange 300 10000 20000 14000 8000
Coefficient 1 2 1.4 0.8
6
Suspension element capacity table
Colour
purple 1000 1400 2100 2100

green 2000 2800 4200 4200
Working load
yellow 3000 3800 6300 6300
capacity (kg)
grey 4000 5600 8400 8400
red 5000 6600 9800 10500
Coefficient 1 1.4 2.1 2.1
Working load capacity: the working load capacity is calculated with an angle at the
centre of 90°
7
TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS

Before disassembling the various parts
and nuts and bolts, read the following Nominal TORQUE SETTING Nm
carefully. diameter
Class 8 Class 10
To make the threaded matings secure, LOCTITE 270 is M3 4 5.2
used for tightening the screws.
M4 7 9.15
If it is not possible to unscrew the bolts because this
M5 12.14 14.8
product has been used, avoid applying extensions to
the tools, instead slightly heat the area (at most 50°C) M6 17.2 20.9
so as to eliminate the LOCTITE 270 effect. M8 31.8 38.1
In the cases described, reapply LOCTITE 270 during M10 50.5 60.3
installation in a moderate quantity (30% of the mating M12 74.2 88.5
surface). M14 101.2 120.8
The torque setting used for tightening the threaded M16 138.2 164.9
couplings is extremely important to make the coupling
M18 176.6 203.5
secure and the machine safe.
M20 225.4 259.7
M22 278.8 321.2
The tables on this page give the classes of bolts normally
used with the relevant torque settings. M24 324.8 374.2
M27 422.3 486.5
M30 516.1 594.7
TORQUE SETTING Nm
Pre-load N Class 5.8 Class 8.8 Class 10.9
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
M10 1.5 16 8 15825 31.7 23.8 51 38 69 52
M10 1.25 16 8 16700 33.4 25.1 53 40.1 73 55
M12 1.75 18 10 23025 55 41.4 88 66 120 90
M12 1.25 18 10 25150 60 45.3 96 72 130 98
M14 2 21 12 31400 88 66 140 105 190 145
M14 1.5 21 12 34125 96 72 155 115 210 155
M16 2 24 14 42850 135 105 220 165 300 225
M16 1.5 24 14 45600 145 110 235 175 320 240
M20 2.5 30 17 66875 270 200 430 320 580 435
M20 1.5 30 17 74250 295 225 475 355 650 485
= with lubricant
8
CORRECT METHOD FOR APPLYING FEMALE FITTINGS

To assure a reliable seal between female fittings and the adapters in this manual, it is necessary to observe
the following procedure, which differs from the one for assembling rigid pipes.
Female fittings without a gasket (metal/metal joint)
Screw on the nut by hand and then, with the aid of a wrench, tighten by another quarter turn.
Female fittings with O-ring
Screw on the nut by hand and then, with the aid of a wrench, tighten by another half turn.
In every case make sure that the pipe is properly aligned before tightening the nut on the adapter.
TORQUE SETTINGS
METRIC REVOLVING FEMALE REVOLVING FEMALE jic 37°

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

Torque setting Nm Torque setting Nm
UNF UNF
Size
thread Nominal torque max thread Nominal torque max.
G1/4 20 15 - 25 9/16-18 -4 14 16
G3/8 34 27 - 41 11/16-16 -6 24 27
G1/2 60 42 - 76 13/16-16 -8 43 47
G5/8 69 44 - 94 1-14 -10 60 68
G3/4 115 95 - 135 1.3/16-12 -12 90 95
G1 140 115 - 165 1.3/16-12 -14 90 95
G1.1/4 210 140 - 280 1.7/16-12 -16 125 135
G1.1/2 290 215 - 365 1.11/16-12 -20 170 190
G2 400 300 - 500 2-12 -24 200 225
2-1/2-20 -32 460 490
The values given in the tables refer to galvanized steel fittings. Fittings of other materials
have other values.
9
INSTRUCTIONS FOR INSTALLING FLEXIBLE HOSES AND FITTINGS

Inspection of pipes and fittings
When even just one of the following conditions arises the pipe must immediately be disconnected and
replaced:
• a shift of the connector on the pipe;
• the presence of damage, cuts or abrasions on the surface layer;
• hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
• the presence of cracks, damage or bad corrosion on the connector;
• the presence of leaks along the pipe or at the connector;
• the presence of permanent creases, compression, flattening or twists in the pipe;
• the presence of blisters, softening, wear of the external coat.
Pre-installation inspection
Before installing a flexible hose it is necessary to inspect the pipes carefully. First check that the type, size,
reference code and length are correct, then check there is no debris, blockages, bubbles, peeling of the
outer layer or any other visible defects.
Installation
Avoid twisting the pipe, which could cause it to burst under pressure.
There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assem-
bled pipe decreases considerably when below the minimum radius of curvature.
The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly
greater length than the requirement in order to compensate for these changes.
Special wrench for hydraulic couplings
Code:
4075291 (C8 - C10)
4075292 (C12)
4075293 (C16)
10
SECTION CONTENTS
Presentation 1
Installation and settings 2
Diagnostics and measurements 3
Electrical system 4
Hydraulic system 5
Truck base mechanics 6
Mast assembly mechanics 6
7
Small fork mast mechanics 6
8
Reduction gear 7
9
Braking system 10
8
Standard maintenance 11
7
11
12
SERVICE PRESENTATION
Presentation
TRUCK PRESENTATION�� 2
VIEWS OF THE TRUCK�� 3
TRUCK AND LOAD IDENTIFICATION DATA�� 4
TRUCK IDENTIFICATION DATA PLATE�� 4
RESIDUAL LOAD PLATE �� 4
MAST SERIAL NUMBER PUNCHING and location of documentation�� 5
GENERAL SPECIFICATIONS�� 6
BATTERIES TABLE�� 10
1
PRESENTATION SERVICE
TRUCK PRESENTATION
The new range of retractable trucks consists of 7 models with nominal load capacities from 1400 kg to
2500 kg.
Electrical system
All the motors benefit from the use of three phase AC alternate current technology: traction motor, steering
motor and pump motor.
The high battery efficiency is ensured by the regenerative inversion and release braking.
The electronic controls VCM, ACE2 Traction, ACE2 Pump and EPS ACW communicate via a CAN-Bus
system (Controller Area Network Bus). There are two separate CAN-Bus lines to improve the efficiency,
reliability and independence of the modules.
Hydraulic system
The 14 kW pump motor provides excellent performance thanks to the technology with proportional sole-
noid valves for the carriage out/return, lifting/lowering, fork tilting and side shifting operations with smooth
movements of the actuators.
Mast
The masts comprise three stages: external, middle and internal.
The rigidity and stability characteristics of the masts allow the forks to reach maximum heights of between
5 and 12 metres depending on the model.
The lifting cylinders are single-acting plungers.
2
VIEWS OF THE TRUCK
3
TRUCK AND LOAD IDENTIFICATION DATA

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

driver's cab
• Manufacturer's name • Max. battery weight

• Model • Min. battery weight
• Serial number • Battery voltage
• Weight without battery • Nominal load capacity
• Year of manufacture • Persons on board
RESIDUAL LOAD PLATE
The load plate is located on the roof assembly
The load plate bears the following data:

• Model
• Liftable load values up to varying heights up to the maximum load with different distances from the
load centre of gravity of the forks.
Always refer to the load plate to be sure to lift an admissible load to an appropriate
height.
4
MAST SERIAL NUMBER PUNCHING and location of documentation
xxxxxxxx
The mast serial number is stamped on the The truck documentation is stored in the docu-
mast itself. ment holder behind the backrest of the seat.
5
GENERAL SPECIFICATIONS
6
1.2 manufacturer’s type designation R1.4 R1.6 R1.6N
WEIGHTS CHARACTERISTICS
1.3 motor unit: battery, diesel, LPG, petrol, electric electric (battery)
1.4 driving: manual, on ground, standing, seated seated
1.5 load capacity/rated load Q (t) 1.4 1.6 1.6
1.6 load centre of gravity c (mm) 600 600 600
1.8 load distance from load wheel axle - forks x (mm) 258 308 202
1.9 wheelbase (WB) y (mm) 1400 1450 1450
2.1 weight with no load (including battery) kg 3495 3546 3498
2.3 load on axle with no load (front/rear) (5) kg 2055/1440 2103/1443 1955/1543
2.4 load on axle with forks out with load (front/rear) kg 885/4010 810/4336 757/4341
2.5 load on axle with forks retracted with load (front/rear) kg 1711/3184 1779/3367 1514/3584
3.1 tyres: full rubber, polyurethane, vulkollan (front/rear) vulkollan/vulkollan
WHEELS &
3.2 front wheel size ø (mm x mm) 343 x 140 343 x 140 343 x 140
TYRES
3.3 rear wheel size ø (mm x mm) 285 x 100 285 x 100 285 x 100
3.5 wheel quantity (x = traction) (front/rear) 1x/2 1x/2 1x/2
3.7 rear track width b 11 (mm) 1155 1155 1025
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4 2/4
4.2 height of closed mast h1 (mm) 2195 2195 2195
4.3 free lift h2 (mm) 1648 1648 1648
4.4 lifting height h3 (mm) 5000 5000 5000
4.5 height, mast extended (1) h4 (mm) 5563 5563 5563
4.7 height of protective roof assembly (cab) (2) h6 (mm) 2175 2175 2175
4.8 seat height h7 (mm) 1082 1082 1082
4.10 armrest height h8 (mm) 308 308 308
4.19 total length l1 (mm) 2523 2523 2629
4.20 length to face of forks l2 (mm) 1373 1373 1479
4.21 overall width (3) b1/b2 (mm) 1265 1265 1125
DIMENSIONS
4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/80/1150 40/120/1150 40/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A 2A
4.24 fork carriage width b3 (mm) 700 700 700
4.25 outer fork width (min/max) (8) b5 (mm) 220/640 260/680 260/680
4.26 distance between the clamps of the load wheels b4 (mm) 900 900 795
4.28 retractable travel I4 (mm) 441 491 385
4.31 ground clearance under mast with load m1 (mm) 75 75 75
4.32 ground clearance at wheelbase centre m2 (mm) 75 75 75
4.34.1working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2825 2834 2898
4.34.2working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2895 2896 2976
4.35 turning radius Wa (mm) 1671 1718 1700
4.37 length between the wheel arms I7 (mm) 1795 1845 1845
4.42 wheelbase height (from ground to footboard) mm 550 550 550
wheelbase height (between the steps between the footboard and the
4.43 mm 371 371 371
ground)
5.1 traction speed with/without load (7) km/h 11/11(14/14) 11/11(14/14) 11/11(14/14)
5.1.1 traction speed with/without load reverse drive (7) km/h 11/11(14/14) 11/11(14/14) 11/11(14/14)
0,37 / 0,63 0,32 / 0,63 0,32 / 0,63
PERFORMANCE
5.2 lift speed with/without load (7) m/s

(0,47 / 0,73) (0,42 / 0,73) (0,42 / 0,73)
5.3 lowering speed with/without load m/s 0.55 0.55 0.55
5.4 Retractable carriage speed m/s 0,15 / 0,15 0,15 / 0,15 0.15 / 0.15
5.7 grade ability with/without load % 12 / 15 11 / 15 11 / 15
5.8 maximum gradeability with/without load % 12 / 15 12 / 15 12 / 15
5.9 acceleration time, laden/unladen s -/- -/- -/-
5.10 service brake Electrical
6.1 traction motor, power S2 60 minutes kW 6,4 6,4 6,4
MOTOR UNITS
6.2 lifting motor, power S3 15% kW 14 14 14

6.3 battery in compliance with DIN 43531/35/36 A,B,C, no C C B
6.4 battery rated voltage/capacity at 5 hours V/Ah 48/700 (6) 48/700 (6) 48/700 (6)
6.5 battery weight (4) kg 1119 1119 1119
6.6 consumption per VDI cycle kWh/h -/- -/- -/-
8.1 type of drive control AC
OTHER
DATA
10.1 working pressure for additional attachments bar 180 180 180
10.2 volume of oil for additional attachments l/min 20 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7 <69.7
7
1.2 manufacturer’s type designation R2.0 R2.5
1.5 load capacity/rated load Q (t) 2.0 2.5
1.6 load centre of gravity c (mm) 600 600
1.8 load distance from load wheel axle - forks x (mm) 358 431
1.9 wheelbase (WB) y (mm) 1500 1650
2.1 weight with no load (including battery) kg 3801 4230
2.3 load on axle with no load (front/rear) (5) kg 2296/1504 2565/1665
2.4 load on axle with forks out with load (front/rear) kg 770/5030 876/5855
2.5 load on axle with forks retracted with load (front/rear) kg 1971/3829 2306/4424
WHEELS &
3.2 front wheel size ø (mm x mm) 343 x 140 343 x 140
TYRES
3.3 rear wheel size ø (mm x mm) 285 x 100 285 x 140
3.5 wheel quantity (x = traction) (front/rear) 1x/2 1x/2
3.7 rear track width b 11 (mm) 1155 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4
4.2 height of closed mast h1 (mm) 2195 2195
4.3 free lift h2 (mm) 1582 1582
4.4 lifting height h3 (mm) 4650 4650
4.5 height, mast extended (1) h4 (mm) 5263 5263
4.7 height of protective roof assembly (cab) (2) h6 (mm) 2175 2175
4.8 seat height h7 (mm) 1082 1082
4.10 armrest height h8 (mm) 308 308
4.19 total length l1 (mm) 2523 2600
4.20 length to face of forks l2 (mm) 1373 1450
4.21 overall width (3) b1/b2 (mm) 1265 1345
DIMENSIONS
4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150 45/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A
4.24 fork carriage width b3 (mm) 700 700
4.25 outer fork width (min/max) (8) b5 (mm) 260/680 260/680
4.26 distance between the clamps of the load wheels b4 (mm) 900 900
4.28 retractable travel I4 (mm) 541 614
4.31 ground clearance under mast with load m1 (mm) 65 65
4.32 ground clearance at wheelbase centre m2 (mm) 65 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2846 2938
4.34.2 working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2900 2978
4.35 turning radius Wa (mm) 1767 1911
4.37 length between the wheel arms I7 (mm) 1895 2045
4.42 wheelbase height (from ground to footboard) mm 550 550
4.43 mm 371 371
ground)
5.1 traction speed with/without load (7) km/h 14 / 14 14 / 14
5.1.1 traction speed with/without load reverse drive (7) km/h 14 / 14 14 / 14
PERFORMANCE
5.2 lift speed with/without load (7) m/s 0.37 / 0.64 0.30 / 0.64
5.3 lowering speed with/without load m/s 0.55 / 0.50 0.55 / 0.50
5.4 Retractable carriage speed m/s 0,15 / 0,15 0.15 / 0.15
5.7 grade ability with/without load % 10 / 15 8 / 14
5.8 maximum gradeability with/without load % 12 / 15 12 / 15
5.9 acceleration time, laden/unladen s -/- -/-
6.1 traction motor, power S2 60 minutes kW 6,4 6,4
MOTOR UNITS
6.2 lifting motor, power S3 15% kW 14 14

6.3 battery in compliance with DIN 43531/35/36 A,B,C, no C C
6.4 battery rated voltage/capacity at 5 hours V/Ah 48/700 (6) 48/840 (6)
6.5 battery weight (4) kg 1119 1306
6.6 consumption per VDI cycle kWh/h -/- -/-
OTHER
DATA
10.1 working pressure for additional attachments bar 180 180

10.2 volume of oil for additional attachments l/min 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7
8
1.2 manufacturer’s type designation R1.6HD R2.0HD
1.5 load capacity/rated load Q (t) 1.6 2.0
1.6 load centre of gravity c (mm) 600 600
1.8 load distance from load wheel axle - forks x (mm) 308 281
1.9 wheelbase (WB) y (mm) 1450 1500
2.1 weight with no load (including battery) kg 4224 4617
2.3 load on axle with no load (front/rear) (5) kg 2428/1796 2577/2040
2.4 load on axle with forks out with load (front/rear) kg 979/4845 985/5632
2.5 load on axle with forks retracted with load (front/rear) kg 2104/3720 2149/4468
WHEELS &
3.2 front wheel size ø (mm x mm) 343 x 140 343 x 140
TYRES
3.3 rear wheel size ø (mm x mm) 285 x 100 285 x 140
3.5 wheel quantity (x = traction) (front/rear) 1x/2 1x/2
3.7 rear track width b 11 (mm) 1155 1195
4.1 mast tilt / forks forward/backward α/β (°) 2/4 2/4
4.2 height of closed mast h1 (mm) 3227 3227
4.3 free lift h2 (mm) 2680 2614
4.4 lifting height h3 (mm) 7900 7750
4.5 height, mast extended (1) h4 (mm) 8463 8363
4.7 height of protective roof assembly (cab) (2) h6 (mm) 2175 2175
4.8 seat height h7 (mm) 1082 1082
4.10 armrest height h8 (mm) 308 308
4.19 total length l1 (mm) 2523 2600
4.20 length to face of forks l2 (mm) 1373 1450
4.21 overall width (3) b1/b2 (mm) 1265 1345
DIMENSIONS
4.22 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150 45/120/1150
4.23 fork carriage ISO 2328, class/type A,B 2A 2A
4.24 fork carriage width b3 (mm) 700 700
4.25 outer fork width (min/max) (8) b5 (mm) 260/680 260/680
4.26 distance between the clamps of the load wheels b4 (mm) 900 900
4.28 retractable travel I4 (mm) 491 464
4.31 ground clearance under mast with load m1 (mm) 65 65
4.32 ground clearance at wheelbase centre m2 (mm) 65 65
4.34.1 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2834 2903
4.34.2 working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2896 2970
4.35 turning radius Wa (mm) 1718 1767
4.37 length between the wheel arms I7 (mm) 1845 1895
4.42 wheelbase height (from ground to footboard) mm 550 550
4.43 mm 371 371
ground)
5.1 traction speed with/without load (7) km/h 14 / 14 14 / 14
5.1.1 traction speed with/without load reverse drive (7) km/h 14 / 14 14 / 14
PERFORMANCE
5.2 lift speed with/without load (7) m/s 0,42 / 0,73 0,37 / 0,68
5.3 lowering speed with/without load m/s 0.55 0.55
5.4 Retractable carriage speed m/s 0,15 / 0,15 0.15 / 0.15
5.7 grade ability with/without load % 10 / 14 8 / 13
5.8 maximum gradeability with/without load % 12 / 15 12 / 15
5.9 acceleration time, laden/unladen s -/- -/-
6.1 traction motor, power S2 60 minutes kW 6,4 6,4
MOTOR UNITS
6.2 lifting motor, power S3 15% kW 14 14

6.3 battery in compliance with DIN 43531/35/36 A,B,C, no C C
6.4 battery rated voltage/capacity at 5 hours V/Ah 48/700 (6) 48/840 (6)
6.5 battery weight (4) kg 1119 1306
6.6 consumption per VDI cycle kWh/h -/- -/-
OTHER
DATA
10.1 working pressure for additional attachments bar 180 180

10.2 volume of oil for additional attachments l/min 20 20
10.7 noise level at the operating station dB(A) <69.7 <69.7
9
NOTES
(1)
with load grille h4 + 508 mm (all models except for 2 ton and 2.5 ton), h4 + 443 mm (2 ton and 2.5 ton models only)
(2)
with flashing light h6 + 120 mm; with protective grille h6 + 20 mm; with protective screen h6 + 30 mm
(3) with load wheel side cover: 1289 mm (all models except for Narrow, 2.5 ton, HD 2.0 ton versions), 1153 mm (Narrow model only), 1373
mm (2.5 ton, HD 2.0 ton models only)
(4)
This value can vary by ± 5%
(5)
Forks retracted
(6)
see “batteries table”
(7)
the values in
parentheses are optional
(8)
the side shift travel is ± 75 mm on all models. It is reduced to ± 25 mm for the Narrow model
BATTERIES TABLE
1.2 manufacturer’s type designation R1.4
1.8 load distance from load wheel axle - forks x (mm) 402 330 402 330 258
1.9 wheelbase (WB) y (mm) 1400 1400 1400 1400 1400
2.1 weight with no load (including battery) kg 3112 3309 3112 3320 3541
2.3 load on axle with no load (front/rear) (5) kg 1977/1135 2025/1285 1977/1135 2032/1289 2084/1457
2.4 load on axle with forks out with load (front/rear) kg 682/3830 792/3917 682/3830 800/3921 914/4027
load on axle with forks retracted with load (front/
2.5 kg 1778/2735 1753/2956 1778/2735 1760/2960 1741/3201
rear)
4.19 total length l1 (mm) 2379 2451 2379 2451 2523
4.20 length to face of forks l2 (mm) 1229 1301 1229 1301 1373
4.28 retractable travel I4 (mm) 585 513 585 513 441
working aisle for pallet length 1000 x 1200 cross-
4.34.1 Ast (mm) 2718 2771 2718 2771 2826
wise
working aisle for pallet length 800 x 1200 length-
4.34.2 Ast (mm) 2764 2829 2764 2829 2895
wise
4.35 turning radius Wa (mm) 1671 1671 1671 1671 1671
battery in compliance with DIN 43531/35/36 A,B,C,
6.3 C C C "Super" C "Super" C "Super"
no
6.4 battery rated voltage/capacity at 5 hours V/Ah 48/420 48/560 48/465 48/620 48/775
6.5 battery weight (4) kg 750 939 750 950 1165

1.9 wheelbase (WB) y (mm) 1450 1450 1450 1450 1450
2.5 kg 1853/2909 1825/3135 1853/2909 1832/3139 1809/3383
rear)
4.19 total length l1 (mm) 2379 2451 2379 2451 2523
4.34.1 Ast (mm) 2731 2781 2731 2781 2834
wise
4.34.2 Ast (mm) 2767 2830 2767 2830 2896
wise
6.3 C C C "Super" C "Super" C "Super"
no
10
1.2 manufacturer’s type designation R1.6N

1.9 wheelbase (WB) y (mm) 1450 1450 1450 1450 1450
2.5 kg 1680/3032 1606/3303 1682/3033 1611/3306 1524/3590
rear)
4.19 total length l1 (mm) 2449 2539 2449 2539 2629
4.34.1 Ast (mm) 2762 2828 2762 2828 2899
wise
4.34.2 Ast (mm) 2811 2893 2811 2893 2976
wise
6.3 B B B "Super" B "Super" B "Super"
no

1.9 wheelbase (WB) y (mm) 1500 1500 1500
4.19 total length l1 (mm) 2451 2451 2523
4.34.1 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2795 2795 2846
4.34.2 working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2835 2835 2900
6.3 battery in compliance with DIN 43531/35/36 A,B,C, no C C "Super" C "Super"
6.4 battery rated voltage/capacity at 5 hours V/Ah 48/560 48/620 48/775

1.9 wheelbase (WB) y (mm) 1650 1650 1650
4.19 total length l1 (mm) 2528 2528 2600
11
1.2 manufacturer’s type designation R1.6HD

1.9 wheelbase (WB) y (mm) 1450 1450 1450
4.19 total length l1 (mm) 2523 2523 2523
1.2 manufacturer’s type designation R2.0HD

1.9 wheelbase (WB) y (mm) 1500 1500 1500
4.19 total length l1 (mm) 2528 2528 2600
NOTES
(4)
This value can vary by ± 5%
(5)
Forks retracted
The weights from point 2.1 to 2.5 are calculated with the mast lowered and standard forks
All values are nominal and may be subject to tolerances. The values may vary with alterna-
tive configurations.
12
SERVICE INSTALLATION AND SETTINGS
Installation and
settings
BEFORE INSTALLATION�� 2
WEIGHT TABLES�� 2
TRUCK ASSEMBLY�� 6
LIST OF MATERIALS RECEIVED FROM THE DEALER�� 6
UNLOADING OFF THE TRUCK AND FITTING THE MAST TO THE TRUCK BASE�� 8
TOPPING UP THE OIL RESERVOIR�� 10
INSTALLATION OF THE BATTERY�� 11
ASSEMBLY OF MOVING FORKS�� 14
load rack assembly�� 14
CONTRASTING ROLLER ASSEMBLY�� 15
List of the SETTINGS AND ADJUSTMENTS to be carried out�� 16
SETTING THE ACE2 TRACTION AND THE ACE2 PUMP MODULE BATTERY VOLTAGES�� 16
CHECK THE CONDITIONS OF USE OF THE TRUCK�� 18
CHECK THE MOVEMENT OF THE CONTRASTING AISLE ROLLERS�� 18
Enabling and programming of the LEVEL pre-selector.�� 19
ENABLING AND PROGRAMMING MIDDLE FORK LIFTING BLOCKS �� 19
ENABLING AND PROGRAMMING OF THE PASSWORD�� 19
1
INSTALLATION AND SETTINGS SERVICE
BEFORE INSTALLATION
Depending on the size of the mast and the kind of transportation (container, truck, etc.), the carriage may
be shipped:
• complete in vertical position (option A)
• with the mast assembly separate from the truck base (option B).
In the second instance one must check in advance that one is equipped with all the tools necessary to bring
it to the vertical position and fit the column (hire forklift truck, bridge crane, belts, etc.). These machines
are tested for all their functions and the mast assemblies are then dismantled, tying the fork carrier plate to
the base of the column so that it does not run along the inner mast; caps are also put on all the hydraulic
connectors to prevent oil leaking out during transport. When the unit arrives, the column must have been
fitted and testing performed for all the functions.
Before delivering to the client it is very important to check the suitability of the place where the carriage is
to be installed.
Before lifting make sure that the chains are correctly in in place (in the pulleys), and ten-
sioned
WEIGHT TABLES
COMPLETE FORKLIFT TRUCK
Height of mast Height of mast

Weight of Total weight
assembly when assembly when Weight of
retractable (excluding
Model closed open truck base
carriage battery)
(h1) (h3)
mm mm kg kg kg
R1.4 (1)
2195 5000 1125 222 2435
R1.6 (2)
2195 5000 1136 222 2485
R1.6N (3)
2195 5000 1095 210 2432
R2.0 (4)
2195 4650 1324 242 2740
R2.5 (5)
2195 4650 1547 242 2978
R1.6HD (6)
3227 8050 1327 245 3134
R2.0HD (7)
3227 7900 1487 245 3335
(1)
battery 420DinC, forks 80x40x1150
(2)
(3)
battery 420DinB, forks 120x40x1150
(4)
(5)
(6)
(7)
2
BATTERIES
Weight (kg)
Type
min. max.
DIN C 735 810
48/420
DIN B 736 811
DIN C 922 1016
48/560
DIN B 925 1018
DIN C 1099 1211
48/700
DIN B 1104 1216
48/840 DIN C 1282 1413
FORK CARRIAGE
Weight
Models
(kg)
R1.4 R1.6 R1.6N R2.0
115.6
R1.6HD
R2.5 R2.0HD 121.6
FORKS
Dimensions Weight
mm kg
80x40x1150 82.3
80x40x1200 84.8
120x35x800 84.3
120x35x1000 97.4
120x35x1150 107.3
120x35x1200 110.5
120x40x800 95.4
120x40x1000 110.3
120x40x1150 121.6
120x40x1200 125.3
120x40x1500 147.8
120x40x1800 170.2
120x45x800 106.4
120x45x1000 123.3
120x45x1150 135.9
120x45x1200 140.1
120x45x1500 165.4
120x45x1800 190.7
3
MAST ASSEMBLIES
Height, mast Extended
Total auxiliary lift Free Lift
lowered dimensions Weight
Model (mm) (mm)
(mm) (mm) (kg)
h3 h2 h1 h4
5000 1648 2195 5563 911
5250 1734 2281 5813 936
5500 1820 2367 6063 961
5750 1906 2453 6313 986
6000 1992 2539 6563 1010
6250 2078 2625 6813 1035
6500 2164 2711 7063 1060
6750 2250 2797 7313 1090
R1.6N 7000 2336 2883 7563 1115
7250 2422 2969 7813 1140
7500 2508 3055 8063 1164
R1.4
7750 2594 3141 8313 1220
R1.6
8000 2680 3227 8563 1244
8250 2766 3313 8813 1269
8500 2852 3399 9063 1299
8750 2938 3485 9313 1324
9000 3024 3571 9563 1349
9250 3110 3657 9813 1376
9500 3196 3743 10063 1400
9750 3282 3829 10313 1425
10000 3368 3915 10563 1454
10250 3454 4001 10813 1478
10500 3540 4087 11063 1503
4650 1582 2195 5263 958
4900 1668 2281 5513 985
5150 1754 2367 5763 1012
5400 1840 2453 6013 1038
5650 1926 2539 6263 1065
5900 2012 2625 6513 1092
6150 2098 2711 6763 1118
R2.0
R2.5 6400 2184 2797 7013 1150
6650 2270 2883 7263 1177
6900 2356 2969 7513 1204
7150 2442 3055 7763 1230
7400 2528 3141 8013 1288
7650 2614 3227 8263 1314
7900 2700 3313 8513 1341
8150 2786 3399 8763 1373
4

Model (mm) (mm)
(mm) (mm) (kg)
h3 h2 h1 h4
7900 2614 3227 8513 1372
8150 2700 3313 8763 1401
8400 2786 3399 9013 1435
8650 2872 3485 9263 1464
8900 2958 3571 9513 1523
9150 3044 3657 9763 1552
9400 3130 3743 10013 1581
9650 3216 3829 10263 1609
9900 3302 3915 10513 1638
10150 3388 4001 10763 1671
R2.0HD
10400 3474 4087 11013 1699
10650 3560 4173 11263 1728
10900 3646 4259 11513 1757
11150 3732 4345 11763 1786
11400 3818 4431 12013 1814
11650 3904 4517 12263 1843
11900 3990 4603 12513 1872
12150 4076 4689 12763 1901
12400 4162 4775 13013 1929
12650 4248 4861 13263 1958
8050 2680 3227 8613 1346
8300 2766 3313 8863 1374
8550 2852 3399 9113 1408
8800 2938 3485 9363 1436
9050 3024 3571 9613 1495
9300 3110 3657 9863 1524
9550 3196 3743 10113 1552
R1.6HD 9800 3282 3829 10363 1580
10050 3368 3915 10613 1612
10300 3454 4001 10863 1641
10550 3540 4087 11113 1669
10800 3626 4173 11363 1698
11050 3712 4259 11613 1726
11300 3798 4345 11863 1755
11550 3884 4431 12113 1783
5
TRUCK ASSEMBLY
LIST OF MATERIALS RECEIVED FROM THE DEALER
CARRIAGE SOLD WITHOUT BATTERY
4
6 5
The materials received from the dealer may vary according to whether or not optional accessories are
included.
Ref. Description
Truck base and mast assembled (option A)

1
Truck base and mast separate (option B)
2 Contrast rollers (optional)
3 Battery runner rollers
4 Forks
5 Hydraulic fluid canister
6 Batter catch plate
6
CARRIAGE SOLD WITH BATTERY
5
4
7
The materials received from the dealer may vary according to whether or not optional accessories are
included.
Ref. Description
Truck base and mast assembled (option A)

1
Truck base and mast separate (option B)
2 Contrast rollers (optional)
3 Battery runner rollers
4 Forks
5 Hydraulic fluid canister
6 Batter catch plate
7 Battery
7
UNLOADING OFF THE TRUCK AND FITTING THE MAST TO THE TRUCK BASE
Equipment and tools
fork lift truck crane truck or open ended span- lifting sling
load capacity bridge crane ner torque wrench load capacity ladder
2500 kg load capacity 19 mm 2500 kg
2500 kg
Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Phase 1
TRUCK BATTERY - FORK LIFT TRUCK LOAD CAPACITY 2500kg
Connect the battery to the truck base, switch on the forklift and transfer it to a place equipped with a crane
truck or bridge crane. Using the lift truck, fork the pallet on which the mast assembly is secured, raise it
and carry it to the same place as the truck base.
Phase 2
BRIDGE CRANE - LIFT BELT
Remove the packing of the mast assembly.
Slip the lifting belt beneath the upper crossbars of the mast assembly by making a noose and hook the
other end to the bridge crane hook (fig.1).
Start lifting slowly with the bridge crane and raise the mast assembly, separating it from the pallet. Take
the mast assembly into the vertical
position.
Fig. 1
8
Phase 3
Fig. 2
OPEN ENDED SPANNER 19 mm A
Using the open ended spanner, unscrew and remove the screws securing
both side blocks of the mast assembly (ref.A fig.2). Remove the blocks
(ref.B fig.2).
B
Using the bridge crane, slowly lift the mast assembly and rest it vertically
on the truck base in the special housings (ref.C fig.2). Keeping the belt
taut, position both side blocks and, using a torque wrench, tighten the
fixing screws (ref.A fig.2) to a torque of 88 to 97 Nm.
C
Phase 4
BRIDGE CRANE - LADDER - LIFT BELT
Set the ladder next to the mast assembly and climb up.
Insert the lift belt beneath the upper crossbar of the middle section of
the mast assembly by making a noose and hook the ends to the bridge
crane hook (fig.3). Climb down the ladder, raise the bridge crane to
reveal the seats of the screws securing the mast assembly to the truck
base (fig.4).
Phase 5
TORQUE WRENCH - BRIDGE CRANE - LIFT BELT
Using the torque wrench, tighten the bolts securing the mast assembly Fig. 3
to the truck base (ref.D fig.4) to a torque of 300 to 330 Nm.
Using the bridge crane, lower the mast assembly to the ground.
Climb up the ladder and remove the belt from the mast assembly.
Phase 6
Remove the cover to access the hydraulic control valve (fig.5).
Connect the hydraulic pipes from the control valve on the truck base to
the one on the mast assembly (fig.6).
Fig. 4 D
Fig. 5
Fig. 6
9
TOPPING UP THE OIL RESERVOIR

Fig. 1
Before topping up the oil in the hydraulic oil reservoir make sure that the
forks are fully lowered.
Equipment and tools
T handle hex key A

funnel oil resistant gloves
5 mm
Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the carriage to a safe place, away from areas of
transit of other vehicles and all pedestrians. Turn the
keyswitch to OFF and disconnect the battery.
Fig. 2
Phase 1 Fig. 3
T-HANDLE HEX KEY 5 mm
B
Use the T-handle hex key to unscrew and remove the motor cover screw C
(ref.A fig.1).
Completely open the cover (fig.2).
Phase 3
To facilitate the filling of the tank unscrew the breather valve (ref.B fig.3),
so that the air can come out when topping up.
Phase 3
FUNNEL
Fig. 4
Unscrew the reservoir cap (ref.C fig.3), place the funnel in the filler hole
and top up the oil level.
Be sure not to fill the reservoir too much by checking the level via the
marks on the reservoir (fig.4).
Screw the breather valve and the reservoir cap back on.
10
INSTALLATION OF THE BATTERY

WITH VERTICAL REMOVAL
Equipment and tools
Fig. 1
bridge crane open ended
load capacity spreader bar spanner
2000 kg 10 mm
Procedure
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians.
Fig. 2
Fig. 3
BRIDGE CRANE - SPREADER BAR
Pull up the lever in front of the throttle pedal board next to the seat (fig.1)
so as to free the battery housing. Make the battery housing come fully
out (fig.2).
Using the open ended spanner, unscrew and remove the screws fastening
the battery cover (where applicable) (ref.A fig.3). Remove the cover.
Attach the spreader bar to the bridge crane.
Attach the spreader bar to the battery, lift it using the bridge crane and
position it over the battery housing.
A
Lower the battery very carefully into the carriage compartment (fig.4).
Unhook the spreader bar from the battery.
Connect the cables to the battery. Fig. 4
Switch on the truck and, using the controls in the cab, retract the re-
tractable carriage completely so that the battery hooks onto the locking
system.
11
WITH LATERAL REMOVAL

Equipment and tools
bridge crane
load capacity spreader bar rollerway Fig. 1
2000 kg
Fig. 2
Procedure
A
BRIDGE CRANE - SPREADER BAR - ROLLERWAY
Pull up the lever in front of the throttle pedal board next to the seat (fig.1)
so as to free the battery housing. Make the battery housing come fully
out (fig.2). Remove the battery catch (ref.A fig.2).
Position the rollerway alongside the battery housing and adjust the height
so that the top of the rollerway is aligned with the bottom of the battery
compartment.
Attach the spreader bar to the bridge crane.
Attach the spreader bar to the battery; lift it using the bridge crane and
place it on the rollerway.
Unhook the spreader bar from the battery. Push the battery into its hous-
ing (fig.3). Position the battery catch.
Connect the cables to the battery. Fig. 3
Switch on the truck and, using the controls in the cab, retract the re-
tractable carriage completely so that the battery hooks onto the locking
system.
12
CONNECTION OF CABLES TO BATTERY

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

Connection of the cable to the
negative terminal
Tag coloured RED

+ Connect lead to positive
terminal
Negative terminal
coloured BLUE
Positive terminal
_
coloured RED
13
ASSEMBLY OF MOVING FORKS
Procedure
Phase 1
Using the controls in the cab, lift the fork carriage to facilitate fork as-
sembly operations.
Fig. 1
Turn the keyswitch to OFF and disconnect the battery.

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

If the truck was dispatched with the 1000 mm load rack disassembled,
during assembly keep it parallel to the upright, adjusted so as to keep the
greatest distance possible from the upright itself (from the channel).
14
CONTRASTING ROLLER ASSEMBLY

Equipment and tools
open ended span-

ner
19 mm
Procedure
protective clothing. Fig. 1
transit of other vehicles and all pedestrians.
Phase 1
Retrieve the contrast roller and its parts, apply the spacers (ref.A,B
fig.2).
Phase 2
FIXED GAUGE 19 mm SPANNER
Position the roller complete with spacers in its section and fix it with the
two screws to the truck base (ref.C fig.2).
A
B C Fig. 2
15
List of the SETTINGS AND ADJUSTMENTS to be carried out

After assembling all the machine's components as described in the previous pages, the following operations
must be carried out in the sequence given:
• Setting the battery voltage
• Checking the conditions of use of the truck
• Checking the contrast roller movement along the aisle
• Enabling and programming level pre-selection
• Enabling and programming middle fork lifting blocks
• Enabling and programming operator passwords
SETTING THE ACE2 TRACTION AND THE ACE2 PUMP MODULE BATTERY VOLTAGES
If a battery that is not provided by the factory is installed on the truck, the battery voltage on the “VCM”
module must be set.
To carry out this regulation, it is good practice to proceed with an additional charging period for the battery
used on the carriage in order that it may provide the maximum voltage.
Equipment and tools
T handle hex key large Philips

programmer tester
5 mm screw driver
Procedure
Remove the rubber mat at the operator's feet inside the cab. Using the T-handle hex key, unscrew and
remove the screws securing the cover of the electronic controls. Unscrew and remove the screw locking
the bonnet (ref.A fig.1), remove the electronic controls cover and open the bonnet (fig.2).
Using a crosshead screwdriver, unscrew the panel fixing screw to access the VCM control (ref.B fig.3).
With the engine turned off connect the programmer
Turn on the machine (ON switch) and select the following parameter:
VCM module / config menu adjustment / adjust battery
Using the tester, measure the exact voltage of the battery on the “VCM” control between the negative power
connection (-Batt) on one of the two traction or pump inverters and the positive measured on “pin 28” of
connector “A” of the VCM module (fig.4). The parameter "adjust battery" must be set with the value of
this tension.
Turn the machine off (switch key OFF) and disconnect the programmer.
Turn the machine back on (ON switch).
16
Fig. 1
A Fig. 2 Fig. 3
24 35
13 23
1 12
Fig. 4
17
CHECK THE CONDITIONS OF USE OF THE TRUCK

In order to ensure the safety personnel and materials, before proceeding with the opera-
tions described below, it is important to assess the following:
• The type of load to be moved
• The general conditions of the warehouse, aisles and flooring
Having carried out these assessments verify whether the conditions given are compatible with the perform-
ance levels set:
• maximum traction speed
• traction acceleration
• reduction of traction speed
• maximum fork lifting/lowering speed
• braking
If necessary, reduce truck performance by using the programmer to customise the truck configuration pa-
rameter (see "TRUCK FUNCTIONS"section "ELECTRICAL SYSTEM").
In order not to jeopardize the safety of the truck, the only way in which the truck configu-
ration parameters may be modified is by reducing the factory-set values.
Parameter values that exceed the factory-set values are not permitted.
CHECK THE MOVEMENT OF THE CONTRASTING AISLE ROLLERS

Make sure that the truck can enter the aisle easily and that the contrasting rollers are correctly adjusted
(maximum tolerance 5 mmon one side fig.1).
If necessary remove or add shims.
Check the roller movement along the entire length of the aisle.
max 5 mm
b6
Fig. 1
18
Enabling and programming of the LEVEL pre-selector.

To enable and program the height pre-selector see "LEVEL PRE-SELECTOR" section "ELECTRICAL
SYSTEM".
ENABLING AND PROGRAMMING MIDDLE FORK LIFTING BLOCKS

To enable and program the middle cab lifting blocks see "FORK LIFTING/LOWERING BLOCKS" section
"ELECTRICAL SYSTEM".
ENABLING AND PROGRAMMING OF THE PASSWORD

To enable and program the operator passwords see "MAIN MENU 2 / PROGRAMMING ACCESS CODE
WITH COMBINED OPERATOR CODE READING" section "ELECTRICAL SYSTEM".
19
20
SERVICE DIAGNOSTICS AND MEASUREMENTS
Diagnostics and
measurements
DESCRIPTION MODULE CONNECTORS�� 2
ACE2 TRACTION MODULE�� 2
ACE2 PUMP MODULE�� 3
eps acw MODULE�� 4
MASTER CONTROL CARD PREMIUM MODULE�� 5
TESTER MENU�� 7
ACE2 TRACTION MODULE�� 7
ACE2 PUMP MODULE�� 7
EPS ACW MODULE�� 7
Vcm MODULE�� 8
BREAKDOWN SEARCH�� 12
WARNING MEMORIZATION�� 12
ACe2 PUMP AND TRACTION MODULE DIAGNOSIS SYSTEM�� 13
ACE2 PUMP AND TRACTION MODULE ALARMS�� 13
PUMP AND TRACTION ACE2 MODULE ALARM ANALYSIS AND TROUBLESHOOTING�� 22
DIAGNOSIS SYSTEM FOR Vcm MODULE �� 33
Vcm - MASTER MODULE ALARM ANALYSIS AND TROUBLESHOOTING�� 33
Vcm - SLAVE MODULE ALARM ANALYSIS AND TROUBLESHOOTING�� 40
EPS ACW MODULE DIAGNOSIS SYSTEM�� 47
eps acw MODULE ALARM ANALYSIS AND TROUBLESHOOTING�� 47
MODULES ALARM CODE NUMBER�� 59
TRACTION�� 59
PUMP�� 60
EPS�� 61
VCM�� 62
1
DIAGNOSTICS AND MEASUREMENTS SERVICE
DESCRIPTION MODULE CONNECTORS

ACE2 TRACTION MODULE
A1 + 48V logic power supply

A2 + 5V auxiliary power supply for Hall effect sensors
A3 Input of accelerator sensor output 1
A4 drive selector (analogue forward/reverse) (digital forward)
A5 reverse drive selector
A6 Input of service brake sensor output 2
A7 Input CH A motor encoder
A8 + 12V power supply for motor encoder
A9 Horn negative
A10 Input of service brake sensor output 1
A11 CAN communication line 2
A13 Input of accelerator sensor output 1
A14 Input CH B motor encoder
A15 - Batt auxiliary power supply for Hall effect sensors and encoder
A16 Traction main contactor negative
A17 + 48V power supply for main contactor, electromagnetic brake, horn
A18 Electromagnetic brake negative
A19 Man on board sensor output 1
A22 Engine temperature sensor input
A23 - Batt engine temperature sensor
2
ACE2 PUMP MODULE

A2 + 5V auxiliary power supply for Hall effect sensors
A3 Not used
A4 Not used
A5 Not used
A6 Not used
A7 Input CH A motor encoder
A8 + 12V power supply for motor encoder
A9 Flasher negative
A10 Not used
A13 Not used
A14 Input CH B motor encoder
A15 - Batt auxiliary power supply for Hall effect sensors and encoder
A16 Pump main contactor negative
A17 + 48V power supply for main contactor, flasher, fan
A18 Fan negative
A19 Not used
A22 Engine temperature sensor input
A23 - Batt engine temperature sensor
3
eps acw MODULE

A3 Power supply positive
A6 Power supply negative
A9 Fan positive (+48V)
A10 Fan negative
A11 Sensor with driving wheel at 90°
A12 Sensor with driving wheel at 0° straight
A13 Auxiliary power supply negative
A14 Not used
A16 Stepper motor DL line power supply negative
A17 Stepper motor QL line input
A18 Auxiliary power supply positive
A19 Stepper motor QL line power supply negative
A20 Stepper motor DL line input
A21 Auxiliary power supply positive
4
MASTER CONTROL CARD PREMIUM MODULE
B A
A1 + 48V output power supply

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

A29 - Batt logic power supply
A32 not used
A35 not used
B1 Side shift position sensor

B2 not used
B3 Tilt position inclinometer input
B4 Encoder reset sensor input
B5 not used
B6 Pressure transducer sensor input
B7 + 48V output power supply
B8 + 48V auxiliary power supply
B9 Main lifting cylinder position potentiometer transducer input
B10 Main lifting cylinder position potentiometer transducer input
B11 Load cell input
B12 not used
B13 Weighing button
B14 Lifting by-pass button
B15 Negative of pallet recognition laser (PWM) Current controlled
B16 + 5V auxiliary power supply
B17 Free lifting cylinder position potentiometer transducer input
B18 Free lifting cylinder position potentiometer transducer input
B19 - Batt auxiliary power supply
B20 - Batt auxiliary power supply
B21 Pallet presence sensor
B22 not used
B23 Negative of load wheel brakes (PWM 4A) Current controlled
6
TESTER MENU
The main input and output signals can be measured in real time using the TESTER function of the pro-
grammer. The programmer acts as a multimeter capable of reading voltage, current and temperature.
Certain of these menu parameters refer to functions whose status is received via Can bus, others refer to
functions directly connected to the analog/digital inputs of the module. The following list shows the relative
measurements:
ACE2 TRACTION MODULE
MAIN TESTER MENU
PARAMETER measurement unit

BATTERY VOLTAGE Volt
Battery voltage measured on the key input
ACE2 PUMP MODULE
MAIN TESTER MENU

EPS ACW MODULE
MAIN TESTER MENU

7
Vcm MODULE
MAIN TESTER MENU

WORKING HOURS Hours
Indicates the truck's working hours according to the setting of the HOUR COUNTER option
FORK HEIGHT mm
Indicates the fork height off the ground in real time if the HEIGHT INDICATOR option is activated
BATTERY VOLTAGE V
Value of the voltage to 1 decimal place. Level of battery voltage measured at key-switch on
BATTERY CHARGE %
Percentage value. Provides the battery's residual charge as a percentage of the level of the complete charge
STEER ANGLE degrees
Value in degrees. Indicates the current steering angle
RTC HOUR hours

Hour of the Real Time Clock
RTC MINUTES minutes

Minutes of the Real Time Clock
LIFT/LOW POT. %
Percentage value. Level of the LIFT/LOWER control
REACH POT. %
Percentage value. Level of the REACH control
TILT POT. %
Percentage value. Level of the TILT control
SIDE SHIFT POT. %

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

PALLET SWITCH
ON/OFF. Level of the Pallet button
SEATBELT SWITCH
ON/OFF. Level of the seat belt button
SEAT SWITCH
ON/OFF. Level of the Seat button
BATTERY OUT SW1

ON/OFF. Level of the Battery 1 disconnected sensor
BATTERY OUT SW2

ON/OFF. Level of the Battery 2 disconnected sensor
SSHIFT POS. SW %
ON/OFF. Level of the side shift position sensor
TILT POS. SW %
ON/OFF. Level of the tilt position sensor
REACH AN I SENSOR mV
Value in volts. Level of the analog input A23 (truck potentiometer position)
OUTPUT GROUP #1 %
Value %. Percentage of the maximum current applied on output unit #1 (EVP1 and EVP2 lifting/lowering)
OUTPUT GROUP #2 %
Value %. Percentage of the maximum current applied on output unit #2 (EVP3 and EVP4 retractable carriage
backward / forward)
OUTPUT GROUP #3 %
Value %. Percentage of the maximum current applied on output unit #3 (EVP5 and EVP6 tilt down/left side shift -
tilt up/right side shift)
OUTPUT GROUP #4 %
Value %. Percentage of the maximum current applied on output unit #4 (EVP7 and EVP8 tilt / side shift valve sen-
sor - 5th way valve sensor)
NEVP9 OUTPUT %
Value %. Percentage of the maximum current applied on EVP9 (wheel brakes charge)
NEV3 OUTPUT %
Value %. Percentage of battery voltage applied on EV3 (Laser)
NEV2 OUTPUT %
Value %. Percentage of battery voltage applied on EV2 (Back-up alarm)
9

NEV1 OUTPUT %
Value %. Percentage of battery voltage applied on EV1 (not used)
RESET ENCODER #1
ON/OFF. Encoder reset sensor level
ENCODER #1 pulses
Number of pulses ready by encoder 1
ENCODER #2 pulses
Number of pulses ready by encoder 2
RPM PUMP Hz
Value in Hz. Pump motor speed
DIGITAL INPUT #1
ON/OFF. A8 digital input level
DIGITAL INPUT #2
DIGITAL INPUT #3
DIGITAL INPUT #4
DIGITAL INPUT #5
DIGITAL INPUT #6
DIGITAL INPUT #7
DIGITAL INPUT #8
ON/OFF. B13 digital input level
DIGITAL INPUT #9
DIG. INPUT #10

DIG. INPUT #11

10

ANALOG INPUT #1 mV
Value in volts. Level of the analog input A23 (truck potentiometer position)
ANALOG INPUT #2 mV
Value in volts. Level of the analog input A35 (not used)
ANALOG INPUT #3 mV
Value in volts. Level of the analog input B1 (side shift position)
ANALOG INPUT #4 mV
Value in volts. Level of the analog input B2 (not used)
ANALOG INPUT #5 mV
Value in volts. Level of the analog input B3 (tilt position)
ANALOG INPUT #6 mV
Value in volts. Level of the analog input B4 (encoder reset)
ANALOG INPUT #7 mV
ANALOG INPUT #8 mV
Value in volts. Level of the analog input B6 (transducer pressure)
ANALOG INPUT #9 mV
Value in volts. Level of the analog input B11 (load cell)
ANALOG INPUT #10 mV

11
BREAKDOWN SEARCH
WARNING MEMORIZATION
Enter the MAIN MENU 1 /alarms on the display to visualize the last 20 warnings memorized and the infor-
mation relative to the total number of hours worked by the module, the number of times the warning has
been activated and the number that identifies the module.
MODULE 2: ACE2 Traction MODULE 6: EPS ACW

MODULE 5: ACE2 Pump MODULE 1: VCM
12
ACe2 PUMP AND TRACTION MODULE DIAGNOSIS SYSTEM

ACE2 PUMP AND TRACTION MODULE ALARMS
programmer message
description effect state of the truck
message sicos
MC open, EB activated, • Start up
CALL The Watchdog signal is
traction/pump station- • Stand-by
SERVICE not in the correct state.
WATCHDOG ary. • During traction
Re-start procedure:
Re-start up of the key.
Error detected in The control device

CALL
EEPROM or in EEPROM works using the default • Continuous
SERVICE
EEPROM KO management. parameters.
Re-start procedure:
None.
Hardware protection cir- MC not closed, EB ac-

CALL
cuit failure due to high tivated, traction/pump • Start up
SERVICE
LOGIC FAILURE #3 current. stationary.
Re-start procedure:
Make a traction or hydraulic request.
MC open, EB activated, • Switch-on (im-

CALL Motor phase voltage feed-
traction/pump station- mediately after the
SERVICE back circuit failure.
LOGIC FAILURE #2 ary. MC closes)
Re-start procedure:
a condition of undervolt- MC not closed, EB ac- • Start up

CALL
age/overvoltage has been tivated, traction/pump • Stand-by
SERVICE
LOGIC FAILURE #1 detected. stationary. • During traction
Re-start procedure:
MC open, EB activated,
CALL Motor output voltage low- • Start up
traction/pump station-
SERVICE er than expected. • During traction
Vmn low ary.
Re-start procedure:
MC not closed, EB ac-

CALL Motor output voltage high- • Start up
tivated, traction/pump
SERVICE er than expected. • Stand-by
Vmn HIGH stationary.
Re-start procedure:
MC not closed (the

control has not been
CALL
The LC contact is locked activated), EB activat- • Start up
CONTACTOR SERVICE
ed, traction/pump sta-
CLOSED tionary.
Re-start procedure:
13
programmer message
message sicos
• Switch-on (im-
The MC coil has been ac- MC open, EB activated, mediately after the
CALL
tivated, but the MC fails to traction/pump station- MC closes)
CONTACTOR SERVICE
close. ary. • Stand-by
OPEN • During traction
Re-start procedure:
In stand-by conditions (no

current applied to the mo- MC not closed, EB ac-
CALL
tor), current feedback is tivated, traction/pump • Start up
SERVICE
STBY I HIGH outside the permissible stationary.
stand-by limits.
Re-start procedure:
The voltage of the power MC not closed, EB ac-

CALL
capacitors fails to in- tivated, traction/pump • Start up
CAPACITOR SERVICE
crease. stationary.
CHARGE
Re-start procedure:
The control device has The traction control de-

reached the thermal re- vice reduces the maxi-
CALL
duction temperature of mum current linearly • Continuous
SERVICE
TH. PROTECTION 85°C when the current is from IMAX (85°C) to 0A
IMAX. (105°C).
Re-start procedure:
None.
The motor temperature

sensor is open (if dig- The maximum current
CALL
ital) or has exceeded the is halved and the speed • Continuous
MOTOR SERVICE
150°C threshold (if ana- is reduced.
TEMPERAT. logue).
Re-start procedure:
None.
The battery is <= 10% The maximum current

• Start up
CALL when the BATTERY is halved and the speed
• Stand-by
SERVICE CHECK parameter is set is reduced (if CHECK
• During traction
BATTERY LOW to >0 OPTION=1).
Re-start procedure:
Recharge the battery.
The MC driver has short- MC open (the control

• Start up
CALL ed and therefore is not has been released),
• Stand-by
SERVICE capable of opening the EB activated, traction/
DRIVER SHORTED • During traction
contactor. pump stationary.
Re-start procedure:
14
programmer message
message sicos
MC open (the control
CALL The MC coil driver is dam- has been released), • Stand-by
CONTACTOR SERVICE aged (it can't close). EB activated, traction/ • During traction
DRIVER pump stationary.
Re-start procedure:
The value of the

accelerator/lifting
potentiometer is greater • Start up
CALL The traction/pump mo-
than the minimum • Stand-by
SERVICE tor is stationary.
VACC NOT OK recorded value and • During traction
the direction/activation
switches are off.
Re-start procedure:
CALL Incorrect starting se- The traction/pump mo- • Start up

INCORRECT SERVICE quences. tor is stationary. • Stand-by
START TRACT Re-start procedure:
Drive requests active • Start up

CALL
in both directions at the Traction is stationary. • Stand-by
SERVICE
FORW + BACK same time. • During traction
Re-start procedure:
Make a traction request.
CALL Problem in reading the
traction/pump station- • During traction
SERVICE encoder.
ary.
ENCODER ERROR
Re-start procedure:
When switching on, the MC open, EB activated,

CALL
VDC-off logic signal is traction/pump station- • Start up
SERVICE
VDC OFF low. ary.
SHORTED
Re-start procedure:
The software versions for MC open, EB activated,

CALL
the Slave and Master are traction/pump station- • Start up
SERVICE
WRONG SLAVE not the same. ary.
VER.
Re-start procedure:
CALL A condition of overvoltage • Stand-by
traction/pump station-
SERVICE has been detected. • During traction
ary.
VDC LINK OVERV.
Re-start procedure:
Make a valve or traction or hydraulic request.
15
programmer message
message sicos
The Master μC and Slave
• Start up
CALL μC do not have the same
Traction is stationary. • Stand-by
SERVICE value for the tiller input
• During traction
TILLER MISMATCH from the VCM.
Re-start procedure:
The brakes potentiometer No effect. The warning

CALL
input is at the maximum is shown on the con- • Continuous
SERVICE
BRAKE RUN OUT value with no HB request. sole only.
Re-start procedure:
• Start up
CALL EPS sends a request to
Traction is stationary. • Stand-by
STOP RQ. FROM SERVICE stop the motor.
• During traction
EPS
Re-start procedure:
The motor phase voltage

CALL is higher than expected,
traction/pump station- • Start up
SERVICE before activating the
INIT VMN HIGH ary.
bridge.
Re-start procedure:
The motor phase voltage

CALL is lower than expected,
SERVICE before activating the
INIT VMN LOW ary.
bridge.
Re-start procedure:
it is impossible to
CALL
recover the data from the No effect. • Start up
SERVICE
EEPROM KO memory.
Re-start procedure:
Partial/complete
CALL parameter reset has been
No effect. • Start up
SERVICE performed since the last
PARAM RESTORE shutdown.
Re-start procedure:
The program checks the

CALL content of the main RAM
traction/pump station- • Continuous
WRONG RAM SERVICE registers and finds a “dirty
ary.
MEM. value”.
Re-start procedure:
16
programmer message
message sicos
• Start up
CALL The traction rotor is The traction/pump is
• Stand-by
SERVICE blocked. stationary.
STALL ROTOR • During traction
Re-start procedure:
CALL No activation message
SERVICE from the Slave.
WAITING SLAVE ary.
Re-start procedure:
The drivers fail to switch MC not closed, EB ac-

CALL
off with the Watchdog sig- tivated, traction/pump • Start up
HARDWARE SERVICE
nal in an alarm state. stationary.
FAULT
Re-start procedure:
There is a discrepancy
• Start up
CALL between Master and The traction/pump is
• Stand-by
SERVICE Slave on the accelerator stationary.
POT. ACCEL MISM • During traction
signal.
Re-start procedure:
There is a discrepancy be- • Start up

CALL The traction/pump is
tween Master and Slave • Stand-by
SERVICE stationary.
POT. BRAKE MISM on the brake signal. • During traction
Re-start procedure:
The motor heat sensor The maximum current

CALL
output is outside the lim- is halved and the speed • Continuous
SENS MOT TEMP SERVICE
its. is reduced.
KO
Re-start procedure:
None.
The PEV connector (A17)

MC closed, EB acti- • Start up
CALL is not connected to the
vated, traction/pump, • Stand-by
SERVICE battery or the voltage is
PEV NOT OK valves stationary. • During traction
different.
Re-start procedure:
Make a traction or hydraulic or valve request.

CALL When switching on, the
tivated, traction/pump • Start up
VKEY OFF SERVICE Key-off logic signal is low.
stationary.
SHORTED
Re-start procedure:
17
programmer message
message sicos
CALL The program check is not
FLASH SERVICE OK.
stationary.
CHECKSUM
Re-start procedure:
• Switch-on (im-
MC open, EB activated, mediately after the
CALL Short-circuit on the MC
traction/pump station- MC closes)
SERVICE coil.
MC COIL SHOR. ary. • Stand-by
• During traction
Re-start procedure:
No activation signals ar- MC open, EB activated, • Start up

CALL
rive from the other system traction/pump station- • Stand-by
WAITING FOR SERVICE
units. ary. • During traction
NODE
Re-start procedure:
The accelerator input is

outside the Vacc_min
• Start up
CALL to Vacc_max range that The traction/pump mo-
• Stand-by
SERVICE has been acquired with tor is stationary.
VACC OUT RANGE • During traction
the “PROGRAMM VACC”
function.
Re-start procedure:
The truck is on stand-by

CALL
with the tiller switch off for LC opens. • Stand-by
SERVICE
TILLER OPEN longer than 30 seconds.
Re-start procedure:
There is a discrepancy be- MC not closed, EB ac-

CALL • Stand-by
tween Master and Slave tivated, traction/pump
OUTPUT SERVICE • During traction
on the motor control. stationary.
MISMATCH
Re-start procedure:
The Slave μC has not re- MC open, EB activated, • Start up

CALL
ceived the Watchdog sig- traction/pump station- • Stand-by
SERVICE
WD SYNCRO nal from the Master μC. ary. • During traction
Re-start procedure:
CALL No activation message
traction/pump station- • During traction
NO SLAVE SERVICE from the Slave.
ary.
ENABLE
Re-start procedure:
18
programmer message
message sicos
• Start up
CALL The selected direction sig- Traction/pump station-
• Stand-by
DIR SEL OUT SERVICE nal is outside the limits. ary.
• During traction
RANG
Re-start procedure:

CALL Short-circuit on the power
POWER MOS SERVICE MOSFETs.
stationary.
SHORT
Re-start procedure:
• Switch-on (im-
MC open, EB activated, mediately after the
CALL Short-circuit on the EB
traction/pump station- MC closes)
SERVICE coil.
COIL SHOR. EB ary. • Stand-by
• During traction
Re-start procedure:
The maximum current

gain parameters are
the default values. This The control device
CALL • Start up
means that the maximum works, but with a low
SERVICE • Stand-by
Current Gain current adjustment proce- maximum current.
dure has not yet been car-
ried out.
Re-start procedure:
None.
CALL The analogue channel traction/pump station- • Start up
SERVICE reading is not up-to-date. ary. • During traction
Analog input
Re-start procedure:
The main remote-con-

• Start up
CALL trol switch, open power
Tiller failure. • Stand-by
SERVICE bridge, electromagnetic
• During traction
brake activated.
TILLER ERROR
Re-start procedure:
Re-synchronisation of the system:
• release all requests (traction and hydraulic)
• make a traction or hydraulic request or both.
CALL Incorrect starting se- The traction/pump mo- • Start up

INCORRECT SERVICE quences. tor is stationary. • Stand-by
START PEDAL Re-start procedure:
Release the pedal and make a new traction request.
19
programmer message
message sicos
The EVP coil driver is
CALL MC closed, EB activat-
open and is not able to • EVP on
SERVICE ed, EVP stationary.
EVP DRIVER OPEN close.
Re-start procedure:
Make an EVP request.
The checksum test be- MC open, EB activated,

CALL
tween Master and Slave traction/pump station- • Start up
M/S PAR CHK SERVICE
has not been passed. ary.
MISM
Re-start procedure:
The Slave μC has differ- MC open, EB activated, • Start up

CALL
ent values to the inputs traction/pump station- • Stand-by
SERVICE
INPUT MISMATCH from the Master μC. ary. • During traction
Re-start procedure:
The Master cannot trans- MC open, EB activated,

CALL
fer the parameters to the traction/pump station- • Start up
PARAM SERVICE
Slave. ary.
TRANSFER
Re-start procedure:
The Slave μC has detect- MC open, EB activated, • Start up

CALL
ed an incorrect set point traction/pump station- • Stand-by
SERVICE
SP MISMATCH of the Master μC. ary. • During traction
Re-start procedure:
One of the potentiometers • Start up

CALL Traction/pump station-
has not been programmed • Stand-by
SERVICE ary.
Throttle prog. correctly. • During traction
Re-start procedure:
The error between the lq

CALL
set point and the estimat- Traction stationary. • During traction
SERVICE
Iq mismatched ed lq is outside the limits.
Re-start procedure:
The AUX coil driver has MC open, EB activated,

CALL • Stand-by
failed (it cannot operate traction/pump station-
SERVICE • During traction
Aux Driv. Open the brake). ary.
Re-start procedure:
The ID test between hard- MC open, EB activated, • Start up

CALL
ware and software has traction/pump station- • Stand-by
CONTROLLER SERVICE
failed. ary. • During traction
MISMATCH
Re-start procedure:
20
programmer message
message sicos
The maximum current
adjustment procedure is
CALL in progress (NOTE: This
Traction stationary. • Stand-by
DATA SERVICE procedure must be per-
ACQUISITION formed by the Zapi testing
department only).
Re-start procedure:

CALL Communication error with
SERVICE the supervisor.
NO CAN MSG. ary. • During traction
Re-start procedure:
• Start up
CALL it is time to carry out Traction is reduced or
• Stand-by
CHECK UP SERVICE maintenance work. stationary.
• During traction
NEEDED
Re-start procedure:
Switch the key back on, after performing maintenance.
The control device heat The maximum current

CALL
sensor output is outside is halved and the speed • Continuous
THERMIC SENS. SERVICE
the limits. is reduced.
KO
Re-start procedure:
None.
The absolute difference

between the voltage of
CALL the key and the nomi-
SERVICE nal voltage of the battery
Wrong set bat. stationary.
is greater than 20% of
Vbatt nom.
Re-start procedure:
The motor phase voltage MC not closed, EB ac-

CALL
feedback is outside the tivated, traction/pump • Start up
SERVICE
Wrong zero permissible limits. stationary.
Re-start procedure:
The error between the ld MC not closed, EB ac-

CALL
set point and the estimat- tivated, traction/pump • During traction
SERVICE
Field orient. KO ed ld is outside the limits. stationary.
Re-start procedure:
The EB/AUX driver has

CALL shorted and therefore is
SERVICE not capable of opening
aux driv.shrt. ary. • During traction
the contactor.
Re-start procedure:
21
PUMP AND TRACTION ACE2 MODULE ALARM ANALYSIS AND TROUBLESHOOTING
ALARM breakdown search

“Watchdog”
Cause: This alarm could be caused by a malfunctioning of the
canbus shutting off Master-Slave communication.
This is a safety test. it is a self-diagnosis test within the
logic between the Master and Slave micro-controllers.
“Eeprom ko” Try to carry out a CLEAR EEPROM operation (see the
Cause: console manual). Turn off then on again with the key to
verify the result. If the alarm persists, the control device
This alarm is due to a HW or SW defect in the integrated
needs replacing. If the alarm disappears, the param-
non-volatile memory that supports the parameters of the
eters previously reset will be replaced by the default
control device. This alarm does not inhibit machine opera-
parameters.
tion, but the truck will work with the default values.
“Logic failure #3”

This type of failure is not connected to external compo-
Cause: nents, so when it manifests itself the ACE logic board
A hardware problem pertaining to the logic card as a pro- needs replacing.
tection against high current values (overload).

Cause: nents, so when it manifests itself the ACE2 logic board
The fault pertains to the hardware section of the logic card needs replacing.
that manages the retroaction of the phase voltage.
“Logic failure #1” Finding the trouble appearing on start up or in standby,

it is very likely in these cases that the fault is due to un-
dervoltage, so it is advisable to check:
• Diminishing pulsations of the key input signal (be-
neath the undervoltage threshold) due to external
loads, such as switching on DC/DC converters,
switching on relays or contactors, energizing/de-
energizing solenoids.
• Check the connection of the electrical cables to the
battery terminal, positive and negative, to MC and to
the control device +Batt and –Batt, which must be
Cause: tightened to a torque of between 13Nm and 15Nm.
• If no voltage transient is detected on the power sup-
This alarm appears when the control device detects over
ply line and the alarm is present every time the key
or under voltage conditions. The overvoltage threshold is
is switched on, then the fault probably lies with the
45V, the undervoltage threshold is 9V on the 24V control
hardware of the control device and so the logic board
device. On the 48V control device, the overvoltage thresh-
needs replacing.
old is 65V and the undervoltage threshold is 11V.
Finding the trouble appearing during motor operation, in
this case there could be undervoltage or overvoltage.
• If the alarm appears during acceleration while in trac-
tion or operation of the hydraulic functions, it is most
likely due to undervoltage; check the battery charge
and the connection of the electrical cables.
• If the alarm appears during brake release, it is most
likely due to overvoltage; check the contact of the line
contactor and the connection of the electrical cables
of the battery.
22

“Vmn low” If the problem appears on start up (LC doesn't close at
all), check:
Cause 1: • The internal motor connections (ohm continuity)
• The motor power cable connections
Test on start-up. Before switching on the LC, the software • Motor loss to the truck frame
checks the power bridge: it turns on the top side power • If the motor connections are OK, the problem lies
MOSFETs alternately and waits until the phase voltage within the control device, so replace it.
rises up to the value of the capacitor in parallel. If the
voltage of the phases is under 66% of the voltage of the If the alarm takes place while the motor is operating,
capacitor in parallel, this alarm appears. check:
• The motor connections
Cause 2: • If the coil-winding/cables of the motor phases show
Motor operating test. When the motor is operating, the losses towards the truck's bodywork
power bridge is ON and the motor voltage feedback is •
That the LC power contact closes correctly, with a
tested; if it is below the controlled value (considering a good contact
range of values), an error status appears. •
If no trouble is found with the motors, the problem
lies within the control device, so replace it.
“Vmn high”
If the problem appears on start up (LC doesn't close at
Cause 1: all), check:
Before switching on the LC, the software checks the power • The internal motor connections (ohm continuity)
bridge: it turns on the bottom side power MOSFETs alter- • The motor power cable connections
nately and waits until the phase voltage decreases down • If the motor connections are OK, the problem lies
to -BATT. If the voltage of the phases is under 10% of the within the control device, so replace it.
nominal voltage of the battery, this alarm appears. If the problem appears after having closed the LC (LC
closes and then opens again), check:
Cause 2:
• The motor connections
This alarm may appear even once the start-up diagnosis • If the coil-winding/cables of the motor phases show
has been passed and therefore the LC has closed. In losses towards the truck's bodywork
this situation, the phase voltage should be less than 1/2 • If no trouble is found with the motors, the problem
Vbatt. Should it exceed this value, an error status would lies within the control device, so replace it.
appear.
“Contactor closed”
Cause:
Before activating the MC coil, the control device verifies
Please check the LC power contacts and replace it if
whether the contactor is blocked. The control device ac-
necessary.
tivates the bridge for a few tens of milliseconds, trying to
discharge the bank of capacitors If the capacitor voltage
fails to decrease by 20% of the key voltage, an alarm is
generated.
“Contactor open” • It could be a problem with the contacts in the MC not

Cause: working (not inserted), try replacing the MC.
• If the MC contactors work properly, the problem lies
The main contactor coil has been activated by the control
within the control device, so replace it.
device, but the contactor fails to close.
“Stby I high”
This type of error is not connected to external com-
Cause: ponents, so when it manifests itself the control device
The current transducer or the current feedback circuit has needs replacing.
a fault in the control device.
23

“Capacitor charge”
The charging capacitor diagram is shown below:
• There is an external load in parallel with the bank
of capacitors that disperses the current from the
pre-charging circuit of the capacitors of the control
device, thereby preventing the central contacts from
charging. Check if a lamp bulb or a dc/dc converter
or an auxiliary load is positioned in parallel with the
bank of capacitors.
• The charge resistance or PTC is open; add a power
resistance over the electrical terminals of the line
contactor; if the alarm disappears, it means that the
Cause: internal charge resistance of the control device is
damaged.
When the key is turned on, the inverter tries to charge
• The charging circuit is faulty inside the control de-
the power capacitors through a series of PTC and the
vice.
power resistance and it checks whether the capacitors
• There is a problem in the electrical section of the
have charged within a short time frame. If the measured
control device.
capacitor voltage is less than 20% of the nominal voltage
of the battery, an alarm is signalled; the main contactor is
not closed.
“Th. protection” it is necessary to increase the cooling of the control

device. In the case of a finned heat dissipation device,
to achieve adequate cooling, these factors are important:
the flow [m3/h] and temperature [°C] of the cooling air. In
Cause: the case of a heat dissipation device with the base plate
This alarm appears when the base plate temperature is of the control device installed on the truck's bodywork, the
above 85°C. Afterwards, the maximum current decreases thickness of the bodywork and the flatness and rough-
in proportion to the increase in temperature from 85°C to ness of its surface are important. If, when the alarm is
105°C. At 105° the current is limited to 0 Amps. signalled, the control device is cold, the possible causes
could be failure of the thermal sensor or of the logic card.
In this case the control device needs to be replaced.
“Motor temperat.” Check the heat sensor inside the motor (look for MO-
TOR TEMPERATURE in the TESTER menu); check the
Cause: value in ohms of the sensor and the sensor cabling. If
This warning appears when the temperature sensor is the sensor is OK, boost the motor cooling. If the warning
open (if digital) or it has exceeded the 150°C threshold is present when the motor is cold, then the problem is
(if analog). located inside the control device.
“Battery low”
Take the charged battery. If it doesn't work, measure the
Cause: battery voltage with a voltmeter and compare it to the value
It appears when the battery charge is less than or equal to in the BATTERY VOLTAGE parameter. If they are differ-
10% of the total charge and the BATTERY CHECK adjust- ent, adjust the value of the ADJUST BATTERY function.
ment is not 0 (refer to SET OPTION menu).
“Driver shorted” • Check if there is a short circuit or a low pull-down

impedance between NMC (CNA#16) and –BATT.
Cause: • The driver circuit is damaged in the logic board, which
The driver of the main contactor coil has shorted. must be replaced.
24
ALARM troubleshooting
“Contactor driver”
Cause: This kind of failure is not connected to external compo-
nents; replace the ACE2 logic board.
The MC coil driver is not capable of carrying the load. The
device or its pilot circuit is damaged.
“Vacc not ok”

Acquire the maximum and minimum value of the po-
Cause: tentiometer via the PROGRAM VACC function. If the
The test has been performed with the key activated and alarm persists, check the mechanical calibration and
immediately after both drive requests have been deacti- the operation of the potentiometer. If the alarm is not
vated. This alarm appears if the ACCELERATOR reading deactivated, the fault is in the ACE logic board, therefore
in the TESTER menu is 1.0V over the min. PROGRAM proceed with replacement.
VACC acquisition when the throttle is released.
“Incorrect start tract” The possible causes of this alarm are (see the TESTER
items to make troubleshooting easier):
• Active drive request with key activated
• Active man on board sensor with key activated.
Cause: Check the wiring. Check the microswitches. It could also
It is a warning for an incorrect start sequence. be an issue of an incorrect error sequence performed by
the operator. a fault in the logic board is another possibil-
ity; therefore, after checking all the above conditions and
finding nothing, replace the ACE logic board.
“Forw+back” Check the wiring of the inputs of the Fwd and Rev drive
requests (see the TESTER items to make troubleshoot-
ing easier). Check for any faults with the microswitches.
Cause: a fault in the logic board is another possibility. Therefore,
This alarm appears when both the (Fwd and Bwd) motion after checking that the drive request switches work
requests are active at the same time. properly and the wiring is correct, the ACE-2 logic board
needs replacing.
“Encoder error” • Check both the electrical and mechanical operation

of the encoder and check for any constriction of the
cables.
Cause: • Verify the encoder's mechanical installation, check-
ing whether the encoder slides inside its housing,
This fault is signalled under the following conditions: the
producing an alarm condition.
frequency supplied to the motor is greater than 40 Hz and
• E ven an electromagnetic sound on the sensor
the encoder's feedback signal shows leaps of more than
bearing could cause this alarm. In these cases, try
40 Hz in just a few tens of mSec. This behaviour is linked
replacing the encoder.
to an encoder malfunction.
• If the problem persists even after replacing the en-
coder, the fault lies with the control device.
25
“Vdc off shorted” it is very likely that the fault is due to overvoltage, there-
fore you should check:
• The connection of the electrical cables to the battery
terminal, positive and negative, to MC and to the con-
Cause: trol device +Batt and –Batt, which must be tightened
to a torque of between 13Nm and 15Nm.
This fault is displayed when the control device detects
• If no voltage transient is detected on the line +B and
a low logic level of the VDC-off signal during start-up
the alarm is present every time the key is switched
diagnosis.
on, then the fault probably lies with the hardware
of the control device and so the logic board needs
replacing.
“Wrong slave ver.”

Cause: Check the two software versions.
The software versions for the Slave and Master are not
the same.
“Vdc link overv.” Finding the trouble appearing on start up or in stand-

by:
• Check the connection of the electrical cables to the
battery terminal, positive and negative, to LC and to
the control device +Batt and –Batt, which must be
Cause: tightened to a torque of between 13Nm and 15Nm.
This fault is displayed when the control device detects a • If no voltage transient is detected on the power
condition of overvoltage. The overvoltage threshold is 65V line and the alarm is present every time the key is
on the 48V control device. On the 116V control device, the switched on, then the fault probably lies with the
undervoltage threshold is 30V. hardware of the control device and so the logic board
needs replacing.
Finding the trouble appearing during motor operation:
If the alarm appears during brake release, check the
contact of the line contactor and the connection of the
electrical cables of the battery.
“Tiller mismatch” Check the wiring of the Tiller input (use the TESTER
items to make troubleshooting easier). a fault in the logic
Cause: is another possibility. Therefore, after checking that the
The Master and Slave have a different value to the Tiller Tiller switch works properly and the wiring is correct, the
signal from the VCM unit. ACE-2 logic board needs replacing.
“Brake run out” Check the mechanical calibration and the operation of
Cause: the brake potentiometer. If the alarm remains, the fault
lies with the ACE logic board, proceed with replace-
The CPOTBRAKE input read by the microcontroller is at
ment.
the maximum value with no handbrake request.
“Stop rq. from eps”

Cause: Check the EPS.
The EPS sends a signal causing the motor to stop.
26
“Init vmn high” Check:
Cause: • The internal motor connections
Before switching on the LC, the software checks the volt-
• Motor loss to the truck frame
age of the power bridge without activating it. The software
• If the motor connections are OK, the problem lies
expects the voltage to have a “stationary state” value. If
within the control device.
this value is too high, this alarm appears.
“Init vmn low” Check:

Cause: • The internal motor connections (ohm continuity)
Before switching on the LC, the software checks the volt-
• Motor loss to the truck frame
age of the power bridge without activating it. The software
• If the motor connections are OK, the problem lies
expects the voltage to have a “stationary state” value. If
within the control device.
this value is too low, this alarm appears.
“Eeprom ko”
This kind of failure is not connected to external compo-
Cause: nents; replace the ACE2 logic board.
The control device cannot access the memory.
“Param restore” If CLEAR EEPROM has been run before last switching
on the key, this warning only means that the EEPROM
has been completely reset. A drive request or a hydraulic
Cause: request cancels the alarm. If this alarm appears when
This warning appears when the control device has reset the key is activated without CLEAR EEPROM being
to its default values. requested by the operator, then the problem could be
located inside the control device.
“Wrong ram mem”

Cause: Try switching the key off and back on again. If the alarm
The algorithm implemented to check the main RAM reg- still remains, replace the ACE2 logic board.
isters finds incorrect content: the register is “dirty”. This
alarm inhibits machine operations.
“Stall rotor”
Check that the indications of FREQUENCY and EN-
Cause: CODER in the tester menu are the same and are not
The traction rotor is blocked or the encoder signal is not zero during a traction request.
received correctly by the control device.
“Waiting slave”
still remains, replace the ACE2 logic board.
When switching on, there is no activation message from
Slave μC to Master μC.
“Hardware fault”
Cause: nents, so when it manifests itself the ACE logic board
The software versions for the Slave and Master are dif- needs replacing.
ferent.
27
“Pot accel mism” Check the potentiometers. a fault in the logic board is
Cause: another possibility. Therefore, after checking that the
potentiometer works properly and the wiring is correct,
The Master and Slave do not have the same value on the
the ACE-2 logic board needs replacing.
accelerator signal from one of the two potentiometers.
“Pot brake mism” Check the potentiometers. a fault in the logic board is
Cause: another possibility. Therefore, after checking that the
potentiometer works properly and the wiring is correct,
The Master and Slave do not have the same value on the
the ACE-2 logic board needs replacing.
brake signal from one of the two potentiometers.
“Sens mot temp ko” Check the ohm value of the sensor and the wire har-
ness assembly of the sensor. If the sensor is OK, then
Cause: the problem is in the ACE logic board, proceed with
The motor heat sensor output is outside the limits. replacement.
“Pev not ok”

Cause:
The PEV connector (CNA#17) is not connected to the Check the connector A17.
battery or the voltage is different. The traction is station-
ary if AUXOUT is used for electrical braking and PEV is
indispensable (AUX OUT FUNCTION = PRESENT).
“Vkey off shorted” it is very likely that the fault is due to undervoltage,
therefore you should check:
• Diminishing pulsations of the key input signal (be-
neath the undervoltage threshold) due to external
loads, such as switching on DC/DC converters,
switching on relays or contactors, energizing / de-
energizing solenoids.
Cause: • Check the connection of the electrical cables to the
This fault is displayed when the control device detects a low battery terminal, positive and negative, to MC and
logic level of the Key-off signal during start-up diagnosis. to the control device +Batt and –Batt, which must be
tightened to a torque of between 13Nm and 15Nm.
• If no voltage transient is detected on the power sup-
ply line and the alarm is present every time the key
is switched on, then the fault probably lies with the
hardware of the control device and so the logic board
needs replacing.
"Flash checksum" The problem is in the flash memory of the microcontrol-

Cause: ler that could be damaged or in the program saved in
it that could be corrupted. Try reprogramming the logic,
After switching on the key, the software checks the integrity
if the alarm is still signalled, then the problem is in the
of the program saved in the flash memory. If the outcome
microcontroller. Replace the ACE logic board.
of the test is negative, this alarm is generated.
“MC coil shor.” • The most likely cause of this error code is in the wire
harness assembly or in the load coil. Therefore, the
Cause: first step is to check the connections between the
This alarm occurs when there is a short circuit in the MC outputs of the control device and the loads.
coils connected to the output CNA#16. Once the overload • If no faults/problems are found on the outside, the
has been removed the alarm automatically disappears, trouble lies in the control device that must therefore
releasing and therefore re-enabling a drive request. be replaced.
28
“Waiting for node”
Cause: Check the communication channel.
The control device is waiting for the activation signal from
one of the system's units but this signal fails to arrive.
“Vacc out range” Acquire the maximum and minimum value of the poten-
Cause: tiometer via the PROGRAM VACC function. If the alarm
persists, check the mechanical calibration and the opera-
The CPOT input read by the microcontroller is not within
tion of the potentiometer. If the alarm remains, the fault
the Vacc_min to Vacc_max range, programmed via the
is in the ACE logic board, proceed with replacement.
“PROGRAMM VACC” function.
“Tiller open”
Cause: The warning disappears with the next drive request.
This warning appears when the tiller is released, after a set
stand-by time (30 seconds) the main contactor opens.
“Output mismatch”
Cause: This is a fault inside the control device, it is necessary
This is a safety test. The Slave μC checks the command to proceed with replacement.
output data of the motor of the Master μC and finds a
discrepancy.
“Wd syncro”
Cause: This is a fault inside the control device, it is necessary

to proceed with replacement.
The Watchdog signal is not received by the Slave's mi-
crocontroller.
“No slave enable”

still remains, replace the ACE2 logic board.
There is no activation message from the Slave μC to the
Master μC while the control device is in operation.
“Dir sel out rang”

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

Cause:
Before switching on the MC, the software checks the power This kind of failure is not connected to external compo-
bridge: it turns on the bottom and top side power MOSFETs nents; replace the control device.
alternately and waits until the phase voltage decreases
toward -BATT (increase up to +Batt). If the phase voltage
does not follow the commands, this alarm appears.
29
“Coil shor. eb.” • The most likely cause of this error code is in the wire
harness assembly or in the load coil. Therefore, the
Cause: first step is to check the connections between the
This alarm appears when there is a short circuit in the outputs of the control device and the loads.
EB/AUX coils connected to the output CNA#18. Once the • If no faults/problems are found on the outside, the
overload has been removed the alarm automatically disap- trouble lies in the control device that must therefore
pears, releasing and then re-enabling a drive request. be replaced.
“Current gain”
Cause: Request the assistance of a Zapi technician to carry out
the correct adjustment procedure for the current gain
The maximum current gain parameters contain default
parameters.
values, which means that the maximum current adjustment
procedure has not yet been performed.
“Analog input”
Cause:
This alarm appears when the A/D conversion of the analog
If the problem persists, the ACE logic board needs
inputs gives a “frozen” value, on all the converted signals,
replacing.
for longer than 400msec. The aim of this diagnosis is to
find a fault in the A//D converter or a problem in the stream
of codes that omits resetting the conversion of the analog
signal.
“Tiller error” Using a voltmeter check the voltage between the two
Cause: PIN's If the state of one of the inputs is correct, it could
be a problem internal to the module. Replace the mod-
Incongruence between PIN signals (XA2-1) and (XA2-
ule.
15).
“Evp driver open”

The driver circuit is damaged in the logic board, which
Cause: must be replaced.
The EVP driver is not capable of carrying the load.
“M/S par chk mism”

Cause: Try resetting and saving the list of parameters.
When switching on, there is a discrepancy between Master
and Slave in the checksum parameter.
“Input mismatch”
Cause: This is a fault inside the control device, proceed with
replacement.
The Slave μC has different values to the inputs from the
Master μC.
“Param transfer”
replacement.
The Master cannot transfer the list of parameters to the
Slave.
30
“Sp mismatch”
replacement.
This is a safety test. The Master μC has detected an incor-
rect set point of the Slave μC.
“Throttle prog.” Acquire the maximum and minimum value of the po-
tentiometer via the PROGRAM VACC function. If the
Cause: alarm persists, check the mechanical calibration and
the operation of the potentiometer. If the alarm is not
One of the potentiometers has not been programmed
deactivated, the fault is in the ACE logic board, therefore
correctly.
proceed with replacement.
“Iq mismatched”

the correct adjustment of the motor parameters.
The error between the lq set point and the estimated lq is
outside the limits.
“Aux driv.open”
nents; replace the ACE2 logic board.
The EB/AUX coil driver is not capable of carrying the load.
The device or its pilot circuit is damaged.
“Data acquisition”
Cause: The alarm ends when the acquisition is completed.
Acquisition of current gains.
“No can msg.”

Cause: This type of failure is not connected to external compo-
nents, so when it persists the ACE logic board needs
This fault is signalled when there is no communication with
replacing.
the supervisor uC.
“Check up needed”
Cause: it is sufficient to take the CHECK UP DONE option onto
It is only a warning reminding you to call scheduled main- level ON after maintenance has been performed.
tenance.
“Thermic sensor ko”

nents; replace the control device.
The control device heat sensor output is outside the lim-
its.
“Wrong set bat.” • Check that the value of the SET-BATTERY parameter
of the control device corresponds to the nominal volt-
age of the battery.
Cause: • Verify that the TESTER MENU / BATTERY VOLTAGE
On start up, the control device checks the battery volt- parameter has the same value as the battery voltage
age and ensures that it is within a specific range of the measured using a voltmeter. If it does not match, run
nominal value. the ADJUST BATTERY function.
• Replace the battery.

31
“Wrong zero”
It is recommended to check:
• The internal motor connections (ohm continuity)
Cause: • The motor power cable connections
On start up, the high resolution VMN feedback does not • Motor loss to the truck frame
come within the range of permissible values around 2.5V. • If the motor connections are OK, the problem lies
The circuit is damaged in the control device. within the control device, so replace it.
“Field orient ko”

the correct adjustment of the motor parameters.
The error between the ld set point and the estimated ld is
outside the limits.
“Aux driv. shrt.” • Check if there is a short circuit or a low pull-down

impedance between NEB/NAUX (CNA#18) and
Cause: –BATT.
The driver of the coil of the electromechanical brake / • The driver circuit is damaged in the logic board, which
auxiliary solenoid valve has shorted. must be replaced.
“Controller mismatch”
Cause: Replace the control.
Incorrect customer ID code, no matching in the protected
area of the memory where this parameter is saved.
32
DIAGNOSIS SYSTEM FOR Vcm MODULE

Vcm - MASTER MODULE ALARM ANALYSIS AND TROUBLESHOOTING
“Out port pull-up”
The problem is on the logic board, which must be re-
Cause: placed.
This alarm pertains to the hardware configuration.
“Pump inc. start” The probable causes of this alarm (use the TESTER
items to make troubleshooting easier) can be an active
pump request when switching on the key or a pump
request when there is not an active seat input. Check
Cause: the wire harness assemblies. Check the microswitches.
The cause could also be an error in the sequence per-
This signal is displayed for an incorrect start sequence.
formed by the operator or a fault in the logic; if all the
above conditions have been checked and nothing has
been found, replace the control device.
“No can msg. 33”

Cause: First of all, check the wire harness assemblies. If they
are correct, the problem is on the logic board, which
Problem on the CAN-BUS line. The error is reported if the
must then be replaced.
VCM control device does not receive any message from
the CAN-BUS line.

Cause:
The parameters are saved in both the Master and Slave Try saving the parameters again.
EEPROM. These two non-volatile memories must contain If the trouble still remains when the key switch is reac-
the same parameter values and must be periodically com- tivated, replace the board.
pared. This alarm is generated if any differences are found.
This alarm does not prevent the machine from working,
but the default parameters are used.
Cause: Try saving the parameters again.
The parameters are saved in both the Master and Slave If the trouble still remains when the key switch is reac-
EEPROM. These two non-volatile memories must contain tivated, replace the board.
the same values for each parameter and the values must
be periodically compared. If the Master cannot transfer the
parameters to the Slave, an alarm is generated.
“Reset encoder” The cause of this alarm (use the TESTER items to
make troubleshooting easier) is due to the fact that the
encoder reset input is not active.
First of all, lower the forks until the encoder reset input
Cause: is active.
VCM waits for the encoder reset input to be active before If the trouble remains, check the wire harness assem-
enabling any hydraulic function (only the lowering function blies and check that the microswitches work correctly.
is permitted). it is possible that there is also a fault in the logic; if all
the above conditions have been checked and nothing
has been found, replace the control device.
33
“Analog input”
Cause: This is a fault inside the microcontroller, replace the
board.
Problem in the analog-digital module of the microcontroller.
All the functions are stopped.
“Watchdog”
Cause:
This is an internal error, the module needs replacing.
A software watchdog is programmed for each microcon-
troller. Its function is to check that the software is working
properly. All the functions are stopped.
“Reset encoder ko” The cause of this alarm (use the TESTER items to make
troubleshooting easier) depends on the fact that the en-
coder reset input is active in an incorrect fork position.
Cause: If the trouble remains, check the wire harness assem-
blies and the operation of the microswitches. it is also
VCM displays the active encoder reset input in a different
possible that there is a fault in the logic; if all the above
position to the expected one.
conditions have been checked and nothing has been
found, replace the control device.
“Logic failure #1” Depends on the cause of the alarm:

• There has been a real drop in voltage. The alarm
should simply disappear upon switching the key off
Cause: and back on again. The cause of the undervoltage is
to be determined according to the conditions in which
This alarm signals that a condition of undervoltage has
it occurs. For example: a truck function that requires
been detected upon inserting the key. All the functions
a high voltage can reduce the battery voltage.
are stopped.
• Fault in the circuit detecting undervoltage conditions.
The board must be replaced.
“Battery out” The cause of this alarm (use the TESTER items to make
troubleshooting easier) depends on the fact that the
inputs of the disconnected battery are not active.
First of all, insert the battery into the correct position in
the truck's bodywork.
VCM waits to see that the inputs of the disconnected bat- blies and check that the microswitches work correctly
tery are active before enabling any functions. according to the settings of the parameters. it is also
“Waiting for node”

Cause:
The control device receives a message from the CAN The COMBI module cannot be activated, but it has to wait
indicating that another control device in the network has until the other module exits from the error condition.
failed; consequently the VCM control device cannot be
operated but has to WAIT for the other control device to
exit from its error condition.
34
“Valve enable”
Check whether there is an alarm on the supervisor uC.
Cause: If there are no alarms, the fault is in the hardware and
It occurs when uC Master tries to activate an output but the board needs replacing.
the supervisor uC does not enable it.
“Tiller mismatch” The cause of this alarm (use the TESTER items to
make troubleshooting easier) derives from a different
reading of the condition of the "dead man" switch by
VCM and traction.
Misalignment between VCM and traction for the dead blies and the operation of the microswitches. it is also
man input. possible that there is a fault in the logic; if all the above
“Battery low”
Recharge the battery. If it doesn't work, measure the
Cause: battery voltage with a voltmeter and compare it to the
value of the BATTERY VOLTAGE parameter. If the
It occurs when the battery charge level is less than or equal
values are different, adjust the value of the ADJUST
to 10% of the total charge and the BATTERY CHECK set-
BATTERY function.
ting is not 0 (refer to SET OPTION menu).
“Wrong ram mem.”

Cause: Try switching the key off and then on; if the alarm still
The algorithm included to check the main RAM registers remains, replace the logic board.
has found incorrect content: the register is “dirty”. This
alarm prevents the machine's functions.
“Eeprom ko”
Cause: If the fault persists after the key has been reactivated,
replace the module. If the fault disappears, the previ-
A fault in the area of memory containing the parameters or
ously saved parameters will be replaced by the default
problems existing during the operations of reading/writing
parameters.
to this memory. This alarm does not prevent the machine
from working, but the default parameters are used.
“Controller mism.”
Cause: Replace the control device.
Incorrect customer ID code in the protected area of the
memory where this parameter is saved.
“Param restore” If CLEAR EEPROM mode was active before last switch-
ing on the key, this message indicates that the EEPROM
has been correctly deleted. The alarm disappears on
Cause: making a drive or pump request. If this alarm occurs
This message appears when the control device has reset when switching on the key without CLEAR EEPROM
to its default values. being requested by the operator, there could be a prob-
lem in the control device.
“Sdo trac” Check the communication between the two control de-
Cause: vices, if the communication is correct then replace the
board.
HM communication trouble between VCM and traction.
35
“Encoder locked #1” Check whether ENCODER1 in the tester menu is other
than zero during a lifting request. Verify the wire harness
Cause: assembly and the operation of the sensor. it is also
The encoder is blocked or the encoder signals are not
“Encoder locked #2” Check whether ENCODER2 in the tester menu is other
than zero during a lifting request. Verify the wire harness
Cause: assembly and the operation of the sensor. it is also
The encoder is blocked or the encoder signals are not
“Hm mismatch”
Cause: Check the settings of the hour meter parameters.
Inconsistency between VCM and traction for the hour
meter.
“Lift/low lever”
Cause: Check the mini-lever.
The mini-lever in relation to the lifting/lowering lever is in
an alarm status.
“Pump in alarm”
Cause: Check the alarm on the pump control device.
Alarm on the pump control device.
“Wrong slave ver.”

Install the correct software release on the supervisor
Cause: uC.
Incorrect software release on the supervisor uC.
“No can msg. 5”

Cause: Check the pump control device.
No CAN message from the pump control device.
“No can msg. A”

No CAN message from the mini-lever.
“Interlock fork” Check whether Reach pot is acquired correctly. If it is

not, then it must be acquired. Verify the wire harness
assembly and the operation of the sensor. it is also
Cause: possible that there is a fault in the logic; if all the above
VCM is not able to run the interlock function. conditions have been checked and nothing has been
“Carriage lever”
The mini-lever in relation to the retractable carriage lever
is in an alarm status.
36
“Tilt lever”
The mini-lever in relation to the tilt lever is in an alarm
status.
“Side shift lever”

The mini-lever in relation to the side shift lever is in an
alarm status.
“Wrong config”
Check the configuration of the parameters for this func-
Cause: tion. Download the configuration file again.
Incorrect communication between VCM and traction.
“No config master”

Incorrect configuration file in Master uC.
“No config backup”

Incorrect configuration file in the supervisor uC.
“Pcf timeout”
Cause: Check the configuration of the parameters for this func-
tion. Download the configuration file again.
Time expired when checking the configuration file between
VCM and traction.
“Waiting pcf”
Cause: Wait for the update to be completed.
Waiting to check the configuration file between VCM and
traction.
“Preselector” Check which function generates the alarm condition.

Verify the wire harness assemblies and the operation of
Cause: the sensor. it is also possible that there is a fault in the
VCM is not able to run the height pre-selection function logic; if all the above conditions have been checked and
correctly. nothing has been found, replace the control device.
37
“Overload” Check that the weight load on the forks does not exceed
the rated load capacity indicated on the identification data
plate. If so, remove the excess load.
Cause: If the alarm persists, check that the load cells are
functioning properly and that the parameters are set
The load is greater than the capacity of the truck.
properly.
If the alarm persists, replace the module.
“Wrong parameter”
Cause: Check the parameters.
Throttle configuration parameters.
“Reach sens out r”

Check that the sensor is working correctly, check its
Cause: wiring.
The carriage position analogue sensor is out of range.
“Reach acq. sens.”

Cause: Repeat the acquisition.
The maximum value acquired by the carriage position
analogue sensor is out of range.
“Check up”
Cause: it is sufficient to take the CHECK UP DONE option onto
It is only a warning reminding you to call scheduled main- level ON after maintenance has been performed.
tenance.
“Seat”
Check the seat and the dead man switch
Cause: Check the wiring.
The dead man switch is operating but the seat sensor is If the alarm persists, replace the module.
not active
“No can msg 2” Check the CAN connection on the traction controller.
Cause: Check that the traction communicates on the CAN
Bus.
No CAN message from the traction controller device
“No can msg 6” Check the CAN connection on the steering controller.
Cause: Check that the steering wheel communicates on the
CAN Bus.
No CAN message from the EPS control device.
38
“No can msg 10”
Check the CAN connection on the display. Check that
Cause: the display communicates on the CAN Bus.
No CAN message from the display.
“Can bus display”

Cause: Check the relay
The key relay driven from the display is open
“Cantiller”
Cause:
The Can Tiller is connected to the CAN Bus. The VCM
Disconnect the Can Tiller and turn on and off the truck
carries out the hydraulic control that arrives from the Can
to restore normal operation.
Tiller. Any other controls arriving from the Joystick or from
the MLM is ignored.
“Trolley blocked”
Check that the carriage sensor is working correctly,
Cause: check its wiring.
The SEN signal coming from the carriage does not move Check the wiring.
during the carriage forward or carriage backward func- If the problem persists, replace the control.
tion.
39
Vcm - SLAVE MODULE ALARM ANALYSIS AND TROUBLESHOOTING
“Drv. shrt A” • Check if there is a short circuit or low impedance
between one of the outputs and –BATT.
The driver of one the first eight outputs has shorted. must then be replaced.
“Drv. open A”
This kind of failure is not connected to external compo-
Cause: nents; replace the logic board.
VCM is not able to enable one of the first eight outputs.
“Watchdog master”
Cause: This is an internal error, the module needs replacing.
A hardware watchdog enables synchronising the micro-
controllers. All the functions are blocked.
“No can msg. 2”

Cause: First of all, check the wire harness assemblies. If they
are correct, the problem lies with the logic board, which
There is a problem connected with the CAN-BUS line. The
must be replaced.
error is reported if the supervisor uCr does not receive any
messages from the CAN-BUS line.
“Pev drv. short.” • Check if there is a short circuit or low impedance

between pin A13 and +BATT.
The top driver of the PEVP1 output has shorted. must be replaced.
“Pev drv. open”

nents; replace the logic board.
VCM is not able to enable the top driver of the PEVP1
output.
“Coil open A” • It is recommended to check the wire harness assem-

bly to see whether the coil is connected to the correct
Cause: pin and whether the connection is broken.
This fault occurs when no load is connected between one • If, in spite of connecting the coil to the correct pin or
of the outputs NEVP1, NEVP2….NEVP8 and the positive replacing it, the alarm remains, the problem is in the
pole. logic board, which must then be replaced.
“Valve mism. out”

Cause:
Alarm of the SLAVE currently disabled. Set point calculated
by the SLAVE different to the set point of the MASTER.
“Watchdog”
Cause: This is an internal error, the module needs to be
There is watchdog software in each microcontroller. Its replaced.
function is to check that the software is working properly.
All the functions are blocked.
40
“Out port pull-up”
The problem is on the logic board, which must be re-
Cause: placed.
This alarm pertains to the hardware configuration.
“Analog input”
Cause: This is a fault inside the microcontroller, replace the
board.
There is a problem in the "from analog to digital" module
of the microcontroller. All the functions are blocked.
“Logic failure #1” Depends on the cause that generated the alarm:
• In the case of a real drop in voltage, the alarm will
disappear by simply turning the key off and then back
Cause: on. The cause of the undervoltage is to be determined
according to the conditions in which it occurs. For
This alarm signals that a condition of undervoltage has
example: a truck function that requires a high voltage
occurred upon inserting the key. All the functions are
can reduce the battery voltage.
blocked.
• Fault in the circuit detecting undervoltage conditions.
The board must be replaced.
“No can msg. 5”
Cause: Check the pump control device.

No CAN message from the pump control device.
“No can msg. A”

No CAN message from the mini-lever.
“In. mism. D”
Compare the values read by Master and Slave with the
Cause: panel's tester menu.
Incorrect match on the digital input between Master and Contact Zapi technical support.
Slave.
“In. mism. A/E”

Compare the values read by Master and Slave with the
Cause: panel's tester menu.
Incorrect match on the analog inputs or on the inputs of Contact Zapi technical support.
the encoder between Master and Slave.
“Wrong ram mem.”

Cause: Try turning the key off and back on; if the alarm still
The algorithm implemented to check the main RAM reg- remains, replace the logic board.
isters finds incorrect content: the register is “dirty”. This
alarm inhibits the operation of the machine.
“Eeprom ko”
Cause: If the fault persists after the key has been reactivated,
replace the module. If the fault disappears, the previ-
A fault in the area of memory containing the parameters
ously saved parameters will be replaced by the default
or problems during the operations of reading/writing to
parameters.
this memory. This alarm does not inhibit the machine from
working, but the default parameters are used.
41
“Controller mism.”
Cause: Replace the control device.
Incorrect customer ID code in the protected area of the
memory where this parameter has been saved.
“Param restore” If CLEAR EEPROM mode was active before last switch-
ing on the key, this message indicates that the EEPROM
has been correctly deleted. The alarm disappears on
Cause: making a drive or pump request. If this alarm appears
This message appears when the control device has reset when switching on the key without CLEAR EEPROM be-
to its default values. ing requested by the operator, there could be a problem
in the control device.
“Drv. shrt B” • Check for a short circuit or low impedance between

Cause: one of the outputs and –BATT.
• The driver circuit is damaged in the logic board, which
The driver of one the outputs NEVP9, NEV1,..NEV3 has
must then be replaced.
shorted.
“Dvr. open B”
nents; replace the logic board.
VCM is not able to enable one of the outputs NEVP9,
NEV1,..NEV3.
“Coil open B” • It is recommended to check the wire harness assem-

bly to see whether the coil is connected to the correct
Cause: pin and there are no breaks.
• If, in spite of connecting the coil to the correct pin
This fault occurs when no load is connected between one
or replacing it, the alarm remains, the problem is in
of the outputs NEVP1, NEVP2….NEVP8 and the positive
the logic board of the control device, which must be
pole.
replaced.
“Out 1/2 coil sh.” • The most likely cause of this error code is in the wire
Cause: harness assembly or in the load coil. Therefore, first
of all check the connections between the outputs of
This alarm occurs when there is a short circuit of the coil
the control device and the loads.
of EVP1 or EVP2. Once the overload has been removed
• If no problems are found on the outside, the trouble
the alarm automatically disappears, releasing and then
lies with the control device that must be replaced.
re-enabling a drive request.
42
“Laser coil sh.” • The most likely cause of this error code is in the wire
of EV1. Once the overload has been removed the alarm
automatically disappears, releasing and then re-enabling
a drive request.
“Bat out coil sh.”

• The most likely cause of this error code is in the wire
a drive request.
“Load brk coil sh” • The most likely cause of this error code is in the wire
is in the control device that must be replaced.
a drive request.
“Alarm coil sh.” • The most likely cause of this error code is in the wire
is in the control device that must be replaced.
a drive request.
43
“Drv. shrt. evp1”
This error does not depend on external components.
Cause:
Replace the module.
VCM is not able to run the EVP1 output

Cause:
Replace the module.

Cause:
Replace the module.

Cause:
Replace the module.

Cause:
Replace the module.

Cause:
Replace the module.

Cause:
Replace the module.

Cause:
Replace the module.
44
“Drv. open brake”
Cause:
Replace the module.
VCM is not able to run the brake output
“No can msg. 1”

Switch the truck off and then back on.
Cause:
Timout on the local CAN Bus
“Drv. shrt. ev1” Check if there is a short circuit or a low pull-down imped-
ance between the output and -BATT
Cause: The circuit of the driver of the logic board is damaged,
Short circuit on the EV1 output replace the module.
“Drv. shrt. brake” Check if there is a short circuit or a low pull-down imped-
Short circuit on the brake output replace the module.
“Coil open ev1” It is recommended to check the wire harness assembly

Cause: to understand whether the coils are connected to the
correct pin of the connector and if the line is broken.
Connection error between the EV1 output and the posi-
tive.

tive.
45
“Coil open brake” It is recommended to check the wire harness assembly
Connection error between the brake output and the posi-
tive.

tive.
“Coil open evp1” It is recommended to check the wire harness assembly

Connection error between the EVP1 output and the posi-
tive.

tive.

tive.

tive.

tive.

tive.

tive.

tive.
46
EPS ACW MODULE DIAGNOSIS SYSTEM

eps acw MODULE ALARM ANALYSIS AND TROUBLESHOOTING

“Watchdog”
Cause:
MuC and SuC communicate via a Can Bus local commu- If this alarm is repeated, the problem lies with the control
nication system. Communication between them requires device.
bit stuffing (the bit stuffing must be reversed for each new
frame). If the bit stuffing remains “frozen” for longer than
100msec, this alarm is generated.
“Eeprom ko”
Cause:
Each microcontroller has its own EEPROM with two lists
Run Clear Eeprom. If the problem persists, replace the
of parameters (to have a local backup). Each list has its
control device.
own checksum. When both checksums are wrong, this
alarm is generated. If one list of parameters has an incor-
rect checksum, it will be settled by using the second list
(backup with correct checksum).

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

Cause:
This alarm occurs with the steering system at rest if the it is necessary to replace the control device.
amplifier on the connected voltage Vu-Vw is in the range
of +/- 250mV around Vuw_zero for 96msec (sampling time
8msec for 12 consecutive samples).
“Vmn not ok”

Cause:
This alarm occurs with the key enabled if at least one volt-
age amplifier on the connected voltage Vv-Vu and Vu-Vw If the alarm is repeated, the control device needs re-
is in the range of +/- 300mV around 2.4Vdc for 50msec placing.
(sampling time 10msec for 5 consecutive samples). (Per-
missible outputs at rest from 2.1V to 2.7V). On completing
the diagnosis, the offset value of the voltage amplifiers
(Vvu_zero and Vuw_zero) will be acquired.
47
“Main cont. open”
Cause: This is not a problem related to Eps. When this warning
is generated, it means that the contactor is open (or not
This warning is active when the steering system control
yet closed).
device receives the information that the current contactor
is open via CAN BUS.
“Stby I high”
Cause:
This alarm occurs in two ways:
• With the key enabled, if at least one current amplifier
on the U and W phase is in the range of +/- 300mV
around 2.5Vdc for 50msec (sampling time 10msec
for 5 consecutive samples). (Permissible outputs of If the alarm is repeated, the control device needs re-
current amplifiers with key enabled are from 2.2V to placing.
2.8V). On completing the diagnosis, the offset value
of the current amplifiers (IU_zero and IW_zero) will be
acquired.
• With the steering system at rest, if at least one cur-
rent amplifier on the U and W phase is in the range
of +/- 150mV around IU_zero or IW_zero for 96msec
(sampling time 8msec for 12 consecutive samples).
“Capacitor charge” Some cases:

• If this alarm occurs only in the control device of the
steering system, check the continuity of the cables
at CNA#3-4-5 from the battery and from Eps.
• If the cables at CNA #3-4-5 are OK, measure the
voltage CNA#3-4-5 and –B within 3 sec of enabling
the key. Only if the measured voltage is greater than
Cause: 14Vdc (and on a short duration on STATUS#5 it is
instead lower) replace the control device.
This alarm occurs with the key enabled, if the DC Bus
• If the voltage measured between CNA#3-4-5 and –B
(capacitors in parallel) fails to reach a minimum value of
14Vdc within 3.2secs. STATUS #5 gives the value in real is close to 0 there are two possibilities:
time of the battery connection (+B) on a short duration. - Short circuit on DC rail and –B in Eps (discon-
nect CNA#3-4-5 and measure the voltage in the
DC bus of the traction control device (+B to –B):
replace Eps if the voltage of the DC bus of the
traction device is greater than 14Vdc.
- Short circuit on DC rail and –B on another unit in
the truck.
“High temperature”
Cause:
This alarm occurs when the temperature in the MOSFET
cases is: Improve the cooling system of the control device. Other-
• greater than 80°C for longer than 3.84secs @ MAXI- wise, it is necessary to replace the control device.
MUM CURRENT=70A
O
• greater than 90°C for longer than 3.84secs @ MAXI-
MUM CURRENT=50A.
48
“Motor temperat.”
Cause:
This alarm occurs only when DIAG MOTOR TEMP is
Check whether the heat sensor in the motor is working
ON and the heat sensor at the motor input measures a
correctly. If it is, improve the motor cooling system.
temperature greater than 120°C. It also occurs when the
motor resistance has been acquired with a temperature
in the motor greater than 120°C (also with DIAG MOTOR
TEMP ON).
“High current”
Cause:
If the alarm is repeated, the control device needs re-
This alarm occurs with the key enabled, if the the circuit
placing.
is always active in order to limit the maximum current via
hardware (it may be due to a fault with the current ampli-
fier).
“Power failure #3” If the alarm is repeated, check that the battery is con-
Cause: nected to the control device. Otherwise, the problem
can be a fault in the three-phase bridge or in the motor
Current in phase W of the motor less than 5.4Arms for
connection to the terminal W.
100msec even if controlled at more than 28% Imax.
Current in phase V of the motor less than 5.4Arms at
connection to the terminal V.
Current in phase U of the motor less than 5.4Arms at
connection to the terminal U.
“Bad steer 0-set”

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

Cause:
This alarm occurs when the steering potentiometer (XA1-8 Replace the potentiometer.
XA1-9) varies with a peak broader than 1 Volt in 16 msec.
This alarm is used to identify a discontinuity in the control
potentiometer voltages.
“Steer hazard”
Cause: Turn the steering wheel in the opposite direction.
This warning occurs when the steered wheel reaches the
maximum angle.
49
“Selfcheck #2”
Cause:
This warning appears when SELFCHECKING routine #2
is in progress and the outcome of the check has not yet
been determined. This self-checking routine monitors the
encoder and the current in the motor when it is operated to Turn the key back on to clear the warning SELFCHECK
move at a fixed speed of 25Hz. It is recommended to run #2.
SELFCHECK #2 with the steered wheel raised. The aim of
this self-test is to check the operation of the encoder and
mechanical components (transmission, sensor bearings,
gears, pinion). Once the collected data have been proc-
essed and there is an unexpected outcome, this warning
message turns into an alarm message.
“Selfcheck #1”
Cause:
This warning appears when SELFCHECKING routine #1
is in progress and the outcome of the check has not yet
been determined. This self-checking routine measures the
Turn the key back on to clear the warning SELFCHECK
resistances of the motor between phases V and W (Rvw)
#1.
and between phases W and U (Rwu) with a multimeter,
using a fixed current of 14.7Adc. The aim of this self-test is
to check the operation of the motor and the power bridge
of the three phases. Once the collected data have been
processed and there is an unexpected outcome, this warn-
ing message turns into an alarm message.
“Can bus warn”

The problem could concern the cables of the Can Bus
Cause: or the Can Bus transceiver inside the traction, the Eps
If a node fails to receive the Can Bus message of the or another unit on the truck. To identify the root of the
traction (Can ID 0x388 for MuC and 0x389 for SuC) for problem, a Can Bus is required.
longer than 200msec, this alarm will appear.
50
“SP mismatch”
Cause:
Depending on the command, MuC and SuC calculate
the set point of the steering motor speed independently
of each other. SuC is concerned that the values it is cal-
culating in real time match the values calculated by MuC.
This alarm is generated when there is no such match. SuC
specifies the condition that led to a discrepancy with a hex
code (see YY pair above).
Incorrect conditions between MuC and SuC may be: If the alarm is repeated, the problem lies with the control
• With no limitation on the closed loop maximum angle, device.
there is a discrepancy on the point of setting the steer-
ing motor speed greater than 10Hz. YY = 01h.
• With a limitation on the closed loop maximum angle,
there is a discrepancy due to the fact that MuC has
detected the limitation of the maximum angle and SuC
has not detected it (or vice versa). YY = 02h.
• With a closed loop due to resetting at rest, there is a
discrepancy due to the fact that MuC has detected the
condition for resetting at rest and SuC has not detected
it (or vice versa). YY = 04h.
“Out mismatch”
Cause:
MuC and SuC read the commands and calculate the set
point of the steering motor independently of each other.
Then MuC activates the motor; SuC checks, in real time,
that the operation on the motor conforms to the value of
the set point of the steering motor. This alarm is generated
if the above does not occur. SuC specifies the condition
leading to a discrepancy with a hex code (see YY pair
above).
Incorrect conditions between MuC and SuC may be:
• The present and controlled steering motor speeds (set
point) have a greater movement than 10Hz and with
opposite signs. YY = 03h.
If the alarm is repeated, the problem lies with the control
• The present and controlled steering motor speeds (set
device.
point) have the same sign, one movement greater
than 10Hz, but the present speed is 50% less than
the controlled speed. YY = 05h.
• At least one of the above discrepancies occurs. The
present and controlled pair currents (set point) have a
greater movement than 3Aac and with opposite sign
YY = 0Bh when the first discrepancy mentioned above
occurs; 0Dh when the second discrepancy mentioned
above occurs.
• At least one discrepancy between point 1 and 2 occurs.
The present and controlled pair currents have the same
sign, one movement greater than 3Aac, but the present
pair current is 50% less than the controlled pair current.
YY = 13h when condition 1 occurs; 15h when condition
2 occurs.
51
“W.D. syncro”
Cause:
Every 32 measurements of the input values (analog and
digital) (e.g. every 4msec) MuC generates a falling edge
on an input of the SuC used as Request Interrupt. This IR Reactivate the key. If the alarm is repeated, the prob-
works as a synchronizing mechanism for SuC allowing it to lem is in the control device. It could also be a problem
start the first of the 32 measurements of the input values. related to ESD.
When MuC has completed the second A/D conversion
(second of the 32 AD conversions in autoscan mode), it
triggers the Synchro input at a higher level. SuC generates
this alarm when no falling edge is detected on the Synchro
input for more than 90 msec.
“Wrong slave ver”

Cause: Download the same software release (same number)
on both microcontrollers.
This alarm is generated by MuC if the Software releases on
MuC and SuC do not match (different releases).
“Wrong ram memory”
Cause:
• The process (running the code) does not pass through
one (at least) of the main steps of the stream of codes
for a time longer than 80msec (e.g. function for reading
inputs, functions to calculate the set point values for
the steering motor, function to supervise the state of
the steering system, ISRs to operate the motor control
device).
device.
O
• Deterministic Finite Automaton (DFA) is characterised
by state transitions. As a protective measure, every
transition state is controlled by assigning two variables
(state label and its complement). These two variables
identify the new state (redundancy on the label). This
redundancy has been designed to prevent a failure in
the RAM leading to an incorrect destination status for
DFAs. If the two state labels are inconsistent or not
complementary, this alarm is generated.
“Param restore”
Cause: Reactivate the key.
This alarm is a confirmation that a Clear Eeprom parameter
has been run correctly.
“Can bus ko m/s”

Cause:
If the alarm is repeated, the problem lies with the steer-
MuC and SuC communicate via a local Can Bus com-
ing system control device.
munication system (integrated). If a node receives no
response from another node for any longer than 100msec,
this alarm is generated.
52
“Stepper motor mism”
Cause:
This alarm appears in two ways:
• Channels D and Q of the stepper motor are processed
in two ways: A/D conversion and alignment encoder
interface. When the A/D conversion gives a fast move- Check that there is no short circuit between CNA#20 or
ment (breadth of line D or Q greater than the crest 4.6V) CNA#17 and GND. Check that the stepper motor is type
and the alignment encoder gives a slow movement approved. If it is, replace the stepper motor and check the
(less than 2 pulses in 80msec: e.g. 25Hz) for more than wire harness assembly. If the problem persists, replace
200msec. the control device.
O
• If the crest value of a channel of the stepper motor
(DL or QL) is less than 0.61V while the crest value of
the second channel is greater than 2V for more than
120msec (it detects a short circuit between one channel
of the stepper motor and GND).
“Motor locked”
Cause:
Too much torque required for steering or trouble with the
This alarm occurs if the current in the motor remains
encoder (run selfcheck #2).
greater than 90% Imax for more than 1 sec, when the trac-
tion speed is greater than 15% (the delay time becomes 5
sec, when the traction speed is less than 5%).

Check which are the different parameters between
Cause: MuC and SuC and update (write) the parameters that
MuC compares its own checksum for the list of parameters do not match. To identify the problem easily run Clear
with the checksum of the list of parameters in SuC. If there Eeprom.
are any discrepancies, MuC generates this alarm.
“Fb jerk”
Cause: Interference or defect of the encoder or encoder cables.
This alarm occurs if the position of the steered wheel meas- One possibility is that the correct phase movement of
ured with the encoder has a step (discontinuity) greater 90 degrees between CHA and CHB in the encoder has
than 21 degrees (turn 244/4096) in 16msec and the step been lost.
does not return to having a smaller gap for 13 consecutive
sample measurements (total 208msec).
“Current gain”
Cause:
This alarm occurs when the gains of the current amplifiers Contact Zapi technical support or replace the control.
(ADJUSTMENT #03 and ADJUSTMENT #04) are set on
default values (Imax has not yet been adjusted).
53
“Position error”
Cause:
This alarm occurs due to an error in the feedback sensor
redundancy test. Here we have one encoder and one (two)
toggle switch. This alarm occurs if the sector count (toggle
switch configuration) and the encoder count do not match.
The sector is equipped with a FEEDBACK SECTOR reader
in the tester menu; the encoder count device is equipped
If the alarm occurs when installing a new control device,
with STEER ANGLE reading in the tester menu.
make sure that AUX FUNCTION 11 corresponds to the
If there are two toggle switches: layout of the toggle switches and that PULSE IN 180
DEG. has been set correctly. If the alarm occurs after the
FEEDBACK set-up has been performed properly, search for a fault
STEER ANGLE on a toggle switch or on the encoder. Troubleshooting
SECTOR
[degrees] consists in comparing the STEER ANGLE and FEED-
permitted
BACK SECTOR when an alarm occurs. In the event of
from -15 to +15 1° or 4°
an alarm, it is expected that these values will not observe
the permitted matches given in the tables alongside. The
from +15 to +75 1°
problem could concern a sensor (check PROX SWITCH
from +75 to +105 1° or 2° 1 and PROX SWITCH 2) or the encoder (check STEER
from +105 to +165 2° ANGLE and FEEDBACK SECTOR).
from +165 to -165 2° or 3°
A list of possible fault modes is given below:
from -165 to -105 3°
• A switch changes its level even though it has not
from -105 to -75 3° or 4°
been engaged by the iron plate (cam) on the steered
from -75 to -15 4° wheel.
• If the encoder is composed of a bearing with a sen-
If there is only one toggle switch:
sor, a ring of the sensor bearing has slippage (the
FEEDBACK sensor bearing has two rings: one is connected to
STEER ANGLE the rotor shaft, the other to the motor chassis). Check
SECTOR
[degrees] that these two rings are each firmly joined to their
permitted
structure with no slippage.
from +15 to +165 1° • Fault in the encoder with low resolution (such as a
from -165 to -15 4° loose magnet or a fault with the Hall sensor).
• The STEER ANGLE has slipped it could also occur
When the FEEDBACK SECTOR and STEER ANGLE do when the truck is stationary) due to interference on
not match, there is a POSITION ERROR alarm in less the encoder channels.
than 100msec.
NOTE: The permitted STEER ANGLE thresholds for each

FEEDBACK SECTOR given in the above tables refer to an
ideal situation with STEER 0-POS DEG set to 0 degrees
(no offset between SW1 and null angle) and a cam of length
180 degrees. The actual thresholds concerning the offset
SW1 and the length of the cam are shown in real time in
the FEEDBACK SECTOR message.
54
“Slave alarm”
Cause:
When SuC generates an alarm, the power supply is cut off
and the steering motor can no longer be activated. MuC
then generates this warning. On the Zapi panel, MuC
specifies the LSByte of the alarm code of SuC on position
XX. For example:
device.
1. LOGIC FAILURE #4: SLAVE ALARM 10
2. OUTPUT MISMATCH: SLAVE ALARM D0
3. INPUT MISMATCH: SLAVE ALARM FA
4. SP MISMATCH: SLAVE ALARM CF
“Waiting master”
Cause:
If the warning is repeated, the problem lies with the
With the key activated, SuC waits for MuC to send a ”ready
control device.
to steer” frame on the local CAN Bus communication sys-
tem. If the message fails to arrive for longer than 4sec,
this warning will appear.
“Eps not aligned”

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

Cause: Reactivate the key. If the error is repeated, the problem
lies with the control device.
This alarm appears if the 13.5V logic power voltage that ac-
tuates the three phase power bridge is less than 11Vdc.
55
“Fb sensor locked”
Cause:
It is closed loop monitoring. This alarm occurs if the current
speed (freq_enci measured with the main encoder) does
not follow the controlled speed (set point) (freq_req deriving
This alarm may be due to:
from pre-processing the outputs of the stepper motor) for
• At least one encoder channel is broken
longer than 500msec and the traction speed is greater than
• Too much friction in the transmission
15% (at the lowest traction speed, the delay time increases
• A fault in the control device
up to 2.5sec, when the traction speed is less than 5%).
• A fault in the motor (e.g. a blocked encoder or a
This alarm occurs if the misalignment between the current
broken phase of the motor).
speed and the controlled speed remains greater than 30%
of the controlled speed and greater than 5Hz above the
delay time of 500msec (variable depending on the speed
of the truck). Monitoring is suspended for 400ms whenever
the error sign (freq_req_freq_enc.) changes from positive
to negative or vice versa.
“Q line sensor ko”

Cause: Check the continuity of the stepper motor connections.
In particular the resistance between CNA#17 and the
This alarm occurs when the average voltage on the step-
negative pole of the battery (with the stepper motor at
per motor alignment line (connection CNA#17) is not zero:
rest) should be very low (around 30 Ohms).
the voltage on each stepper motor line is a sinusoid with
zero average voltage.
“D line sensor ko”

Cause: Check the continuity of the stepper motor connections.
In particular the resistance between CNA#20 and the
This alarm occurs when the average voltage on the step-
negative pole of the battery (with the stepper motor at
per motor direct line (connection CNA#20) is not zero: the
rest) should be very low (around 30 Ohms).
voltage on each stepper motor line is a sinusoid with zero
average voltage.
Cause:
Master uC and Slave uC have their own list of parameters
(with their own local backup). Parameter modification is Try changing a parameter again. If the problem persists,
controlled by MuC only. MuC writes its own parameters replace the control device.
and instructs SuC to do the same for its own list of param-
eters. Running the writing parameter on SuC is password
protected. This alarm is generated by the MuC should SuC
refuse to run the writing command.
“Data acquisition”
Cause:
This alarm occurs when adjusting the maximum current Reactivate the key.
(set in the factory) and when a procedure is run for acquir-
ing the motor resistance. Acquiring motor resistance has
not yet been implemented.
56

“Can bus ko”
The problem may consist in an incorrect Can Bus con-
Cause: nection or depend on the traction control device being
If on both MuC and SuC there are no Can Bus messages switched off or not fitted. To identify the root of the
pertaining to traction (Can ID 0x388 for MuC and 0x389 for problem, a Can Bus analyser is required.
SuC) for longer than 200msec, this alarm is generated.
“Input mismatch”
Cause:
MuC and SuC read the values of the inputs independ-
ently of each other. SuC is concerned that the values it is
reading match, in real time, the values MuC is reading. If
this does not occur, this alarm is generated. SuC specifies
which input is responsible for the discrepancy with a hex
code (see YY pair above).
The faulty inputs between MuC and SuC may be:
• Discrepancy on straight or 90° switch (SW1 on CNA#12
device.
and SW2 on CNA#11). YY = 83h.
• Discrepancy in the quadrant of the MDU in a turn of
360° (SW1 vs. SW2 vs. AUX FUNCTION #11 setting).
YY=08h.
• Discrepancy in the speed of the stepper motor greater
than max_stepper_motor_speed/5 (CNA#20 and
CNA#17).YY=04h.
• Discrepancy in the encoder count greater than 10
counts (one count of 2296 corresponds to an MDU at
180°) (CNG#1 and CNG#3). YY=20h.
“Init vmn not ok” Try and disconnect the motor terminals from the control
device, reactivate the key and read STATUS #5. If the
long duration value (e.g. 1st value) is in the range be-
Cause: tween 8 and 13.5Vdc, the problem is a dispersion (loss of
After activating the key with the three-phase bridge disa- motor isolation). Otherwise, replace the control device.
bled, the DC bus voltage should reach 14Vdc in 3.2sec
(CAPACITOR CHARGE alarm, if this does not occur). At
the same time the steering control device monitors the volt-
age common to the motor terminals (see STATUS #5 1st
value) and generates this alarm after the 3.2sec. and:
• The common voltage is less than 7Vdc (bottom MOS-
FET shorted –B).
O
• The common voltage is blocked at DC Bus (top MOS-
FET shorted +B). (it is considered blocked if it is in a
range of +/- 1Vdc around the DC Bus). STATUS #5 in
the TESTER menu gives the value in real time of this
common voltage on long duration.
57
“Analog”
Cause:
• With the key activated, the A/D converter is on and
should complete an initial conversion of the analog
inputs within 16msec. If this does not occur, this alarm Reactivate the key. If the problem persists, replace the
is generated. control device.
• Under conditions of stationary status, the main signals
(currents of the motor and sensor in the wheel of the
steering system) require a new A/D conversion every
250usec. Should no conversion successfully conclude
within 1.25msec, this alarm will be generated (e.g. after
5 consecutive failed conversions).
“Acq aborted”
Cause: Reactivate the key. If the problem persists, replace the

control device.
This alarm occurs if the wheel self-centering was nega-
tive
“Enc pulses acq”
Cause: Wait for the self-centering to be completed.

This warning occurs to indicate that the wheel self-
centering is in progress.
58
MODULES ALARM CODE NUMBER

TRACTION
ALARM CODE ALARM CODE

WATCHDOG 8 POT BRAKE MISM. 215
LOGIC FAILURE #3 17 SENS MOT TEMP KO 218
LOGIC FAILURE #2 18 PEV NOT OK 219
LOGIC FAILURE #1 19 VKEY OFF SHORTED 220
VMN LOW 30 MC COIL SHOR. 223
VMN HIGH 31 WAITING FOR NODE 224
CONTACTOR CLOSED 37 VACC OUT RANGE 226
CONTACTOR OPEN 38 TILLER OPEN 228
STBY I HIGH 53 OUTPUT MISMATCH 229
CAPACITOR CHARGE 60 WD SYNCRO 230
TH. PROTECTION 62 NO SLAVE ENABLE 231
MOTOR TEMPERAT. 65 DIR SEL OUT RANG 232
BATTERY LOW 66 POWER MOS SHORT 233
DRIVER SHORTED 74 COIL SHOR. EB. 235
CONTACTOR DRIVER 75 CURRENT GAIN 236
VACC NOT OK 78 ANALOG INPUT 237
INCORRECT START TRACT 79 CONTROLLER MISM. 239
FORW + BACK 80 INPUT MISMATCH 241
ENCODER ERROR 82 SP MISMATCH 242
INCORECT START PEDAL 199 THROTTLE PROG. 243
WRONG SLAVE VER. 201 IQ MISMATCHED 245
VDC LINK OVERV. 202 AUX DRIV.OPEN 246
TILLER MISMATCH 203 DATA ACQUISITION 247
BRAKE RUN OUT 204 NO CAN MSG. 248
STOP RQ.FROM EPS 205 THERMIC SENS. KO 250
INIT VMN HIGH 206 WRONG SET BAT. 251
INIT VMN LOW 207 WRONG ZERO 252
EEPROM KO 208 FIELD ORIENT. KO 253
PARAM RESTORE 209 AUX DRIV.SHRT. 254
WRONG RAM MEM. 210
STALL ROTOR 211
WAITING SLAVE 212
HARWARE FAULT 213
POT ACCEL MISM. 214
59
PUMP

WATCHDOG 8 NO SLAVE ENABLE 231
LOGIC FAILURE #3 17 POWER MOS SHORT 233
LOGIC FAILURE #2 18 COIL SHOR. EB. 235
LOGIC FAILURE #1 19 CURRENT GAIN 236
VMN LOW 30 ANALOG INPUT 237
VMN HIGH 31 CONTROLLER MISM. 239
CONTACTOR CLOSED 37 INPUT MISMATCH 241
CONTACTOR OPEN 38 SP MISMATCH 242
STBY I HIGH 53 IQ MISMATCHED 245
CAPACITOR CHARGE 60 AUX DRIV.OPEN 246
TH. PROTECTION 62 DATA ACQUISITION 247
MOTOR TEMPERAT. 65 NO CAN MSG. 248
DRIVER SHORTED 74 THERMIC SENS. KO 250
CONTACTOR DRIVER 75 WRONG SET BAT. 251
ENCODER ERROR 82 WRONG ZERO 252
WRONG SLAVE VER. 201 FIELD ORIENT. KO 253
VDC LINK OVERV. 202 AUX DRIV.SHRT. 254
BRAKE RUN OUT 204
INIT VMN HIGH 206
INIT VMN LOW 207
EEPROM KO 208
PARAM RESTORE 209
WRONG RAM MEM. 210
STALL ROTOR 211
WAITING SLAVE 212
HARWARE FAULT 213
SENS MOT TEMP KO 218
PEV NOT OK 219
VKEY OFF SHORTED 220
MC COIL SHOR. 223
WAITING FOR NODE 224
TILLER OPEN 228
OUTPUT MISMATCH 229
WD SYNCRO 230
60
EPS

WATCHDOG 8 Q LINE SENSOR KO 242
EEPROM KO 13 D LINE SENSOR KO 243
LOGIC FAILURE #4 16 PARAM TRANSFER 244
LOGIC FAILURE #3 17 DATA ACQUISITION 245
VMN NOT OK 32 CAN BUS KO 247
MAIN CONT. OPEN 48 INPUT MISMATCH 250
STBY I HIGH 53 INIT VMN NOT OK 251
CAPACITOR CHARGE 60 ACQ ABORTED 202
HIGH TEMPERATURE 61 ENC PULSES ACQ 203
MOTOR TEMPERAT. 65
HIGH CURRENT 70
POWER FAILURE #3 71
POWER FAILURE #2 72
POWER FAILURE #1 73
STEER SENSOR KO 84
STEER HAZARD 85
CAN BUS WARN 206
SP MISMATCH 207
OUT MISMATCH 208
W.D. SYNCRO 209
WRONG SLAVE VER. 210
WRONG RAM MEM. 212
PARAM RESTORE 213
SP JERK 214
CAN BUS KO M/S 215
STEPPER MOT MISM 219
MOTOR LOCKED 220
M/S PAR CHK MISM 221
CURRENT GAIN 225
POSITION ERROR 228
SLAVE ALARM
237
WAITING MASTER
EPS NOT ALIGNED 238
KEYOFF 240
FB SENSOR LOCKED 241
61
VCM
MASTER
ALLARME CODICE ALLARME CODICE

WATCHDOG 8 NO CONFIG BACKUP 236
LOGIC FAILURE #1 19 NO CONFIG MASTER 237
OVERLOAD 199 PCF TIMEOUT 238
WRONG PARAMETER 200 REACH SENS OUT R 239
WRONG SLAVE VER. 201 REACH ACQ. SENS. 240
HM MISMATCH 202 M/S PAR CHK MISM 241
TILLER MISMATCH 203 PARAM TRANSFER 242
BATTERY LOW 204 PRESELECTOR 243
RESET ENCODER 205 CHECK UP 244
BATTERY OUT 206 SEAT 245
EEPROM KO 208 NO CAN MSG. 2 246
PARAM RESTORE 209 NO CAN MSG. 6 247
WRONG RAM MEM. 210 NO CAN MSG. 10 248
PUMP INC. START 211 CAN BUS DISPLAY 249
ENCODER LOCKED 1 213 CANTILLER 250
ENCODER LOCKED 2 214 TROLLEY BLOCKED 251
OUT PORT PULL-UP 215
ANALOG INPUT 217
RESET ENCODER KO 218
VALVE ENABLE 219
LIFT/LOW LEVER 222
NO CAN MSG. 33 223
WAITING FOR NODE 224
CONTROLLER MISM. 225
PUMP IN ALARM 226
NO CAN MSG. 5 227
NO CAN MSG. A 228
SDO TRAC. 229
INTERLOCK FORK 230
CARRIAGE LEVER 231
TILT LEVER 232
SIDE SHIFT LEVER 233
WAITING PCF 234
WRONG CONFIG 235
62
SLAVE
ALLARME CODICE ALLARME CODICE

WATCHDOG 8 DRV. OPEN B 234
LOGIC FAILURE #1 19 DRV. SHRT. EV1 235
DRV. SHRT. EVP1 185 DRV. SHRT. EV2 236
DRV. SHRT. EVP2 186 DRV. SHRT BRAKE 237
DRV. SHRT. EVP3 187 DRV. SHRT. EV3 238
DRV. SHRT. EVP4 188 COIL OPEN EV1 239
DRV. SHRT. EVP6 190 COIL OPEN BRAKE 241
DRV. SHRT. EVP8 192 COIL OPEN EVP1 244
OUT1/2 COIL SH. 199 COIL OPEN EVP2 245
LASER COIL SH. 203 COIL OPEN EVP6 249
BAT OUT COIL SH. 204 COIL OPEN EVP7 250
LOAD BRK COIL SH 205 COIL OPEN EVP8 251
ALARM COIL SH. 206
WARNINGS PER DISPLAY
WATCH DOG MASTER 207
EEPROM KO 208
ALLARME CODICE
PARAM RESTORE 209 INC. START TRAC 1
WRONG RAM MEM. 210 INC. START LIFT 2
PEV DRV. OPEN 211 INC. START LOW 3
PEV DRV. SHORT. 212 INC. START TILT U. 4
VALVE MISM. OUT 213 INC. START TILT D. 5
DRV. OPEN BRAKE 214 INC. START SIDE SH. RH. 6
OUT PORT PULL-UP 215 INC. START SIDE SH. LH. 7
ANALOG INPUT 217 INC. START REACH IN 8
IN. MISM. D 218 INC. START REACH OUT 9
IN. MISM. A/E 219 INC. START 5 VIA IN 10
NO CAN MSG. 2 223 INC. START 5 VIA OUT 11
NO CAN MSG. 1 224 RESET ENCODER 12
CONTROLLER MISM. 225 BATTERY LOW 13
NO CAN MSG. 5 227 GET HOME 14
NO CAN MSG. A 228 OVERLOAD 15
DRV. OPEN A 232 CHECK UP 16

SEAT SWITCH 17
63
64
SERVICE ELECTRICAL SYSTEM
Electrical system
ELECTRICAL WIRING DIAGRAMS �� 4
CONTROLS �� 6
IDENTIFICATION OF ARMREST, PEDAL UNIT AND MAIN PANEL CONTROLS �� 6
STANDARD DISPLAY�� 8
KEYPAD AND SYMBOLS DISPLAYED �� 8
DISPLAY BRIGHTNESS CONTROL�� 9
SOFTWARE�� 9
ICONS ASSOCIATED WITH THE GRAPHIC SCREENS�� 9
FUNCTIONAL GRAPHIC SCREENS�� 13
DESCRIPTION OF THE OPTIONAL GRAPHIC SCREENS�� 27
DESCRIPTION OF THE MENU SCREENS�� 39
MAIN MENU 1�� 39
MAIN MENU 1 / TESTER�� 39
MAIN MENU 1 / SET CLOCK�� 41
MAIN MENU 1 / SOFTWARE VERSION.�� 41
MAIN MENU 1 / ALARMS.�� 42
MAIN MENU 1 / PARAMETER SETTING.�� 43
MAIN MENU 2�� 45
MAIN MENU 2 \ CLEAR ALARMS�� 46
MAIN MENU 2 \ MEASURING SYSTEM�� 46
main menu 2 \ FORKS SETUP�� 47
main menu 2 \ PARAMETER ACQUISITION�� 48
main menu 2 \ PROGRAMMING ACCESS CODE WITH COMBINED OPERATOR CODE READING�� 48
main menu 2 \ read user code�� 51
main menu 2 \ clear access code�� 51
PREMIUM DISPLAY�� 52
SOFTWARE�� 53
ICONS ASSOCIATED WITH THE GRAPHIC SCREENS�� 53
FUNCTIONAL GRAPHIC SCREENS�� 58
OPTIONAL GRAPHIC SCREENS�� 72
height pre-selector�� 88
DESCRIPTION OF THE MENU SCREENS�� 98
DISPLAY SOFTWARE UPDATE.�� 125
TRUCK FUNCTIONS�� 128
1
ELECTRICAL SYSTEM SERVICE
FORWARD/REVERSE TRACTION�� 128

SPEED REDUCTION �� 130
BRAKING�� 133
STEERING�� 134
STEERING�� 136
FORK LIFTING/LOWERING�� 137
ACCELERATION / DECELERATION RAMPS�� 139
LIMIT STOP SLOWDOWN lifting / LOWERING �� 139
FORK LIFTING/LOWERING BLOCKS (WITH FORK HEIGHT ENCODER)�� 140
HYDRAULIC FUNCTIONS�� 141
RETRACTABLE CARRIAGE ACCELERATION / DECELERATION RAMPS�� 142
CARRIAGE OUT / RETURN LIMIT STOP SLOWDOWN�� 143
AUXILIARY FUNCTIONS ACCELERATION / DECELERATION RAMPS�� 143
FORK SELF-CENTRING�� 143
CONFIGURATION PARAMETER ACCESS PROCEDURE�� 144
MENU SEARCH PROCEDURE and parameter modification�� 144
CDF file loading procedure�� 149
STANDARD CONFIGURATION OF MODULE PARAMETERS�� 153
“VCM” MODULE�� 153
“ACE2 TRACTION” MODULE�� 155
“ACE2 PUMP” MODULE�� 156
“EPS ACW” MODULE �� 156
DESCRIPTION OF MODULE PARAMETERS�� 157
“VCM” MODULE 1�� 157
“ACE2 TRACTION” MODULE�� 166
“ACE2 PUMP” MODULE�� 168
“EPS ACW” MODULE�� 168
MODULES: INTRODUCTION�� 170
POSITIONING OF THE "PC TOOL" CONNECTORS�� 170
“INVERTER ACE2” MODULE�� 171
“EPS ACW” MODULE�� 172
“VCM” MODULE �� 173
REPLACEMENT OF MODULES: INSTRUCTIONS�� 174
REPLACING THE "ACE2 INVERTER" MODULE�� 174
REPLACEMENT OF THE “EPS ACW” MODULE�� 176
“VCM” MODULE REPLACEMENT�� 178
REMOVAL OF ELECTRICAL COMPONENTS�� 180
REPLACEMENT OF ENCODER�� 180
ENCODER RESET SENSOR REPLACEMENT �� 182
LOAD CELL REPLACEMENT �� 183
REPLACEMENT OF THE HORN�� 184
2
REPLACEMENT OF THE CONTACTORS �� 185

FUSE REPLACEMENT�� 186
REPLACEMENT OF THE MOTOR COMPARTMENT COOLING FAN�� 188
REPLACEMENT OF ARMREST AND MAIN PANEL CONTROLS:�� 190
SIDE SHIFT POSITION SENSOR REPLACEMENT�� 197
PALLET PRESENCE SENSOR REPLACEMENT�� 198
TILT POSITION SENSOR REPLACEMENT�� 199
90° WHEEL SENSOR AND STEERED WHEEL SENSOR REPLACEMENT�� 200
BATTERY OUT SENSOR REPLACEMENT�� 201
OPERATOR PRESENCE PEDAL REPLACEMENT�� 202
ACCELERATOR AND BRAKE PEDALS REPLACEMENT�� 203
3
ELECTRICAL WIRING DIAGRAMS
COMPONENTS
Ref. Description Ref. Description
A1 Standard display M1 Traction motor
A2 Type of drive control M2 Pump motor
A3 Pump control M3 Steering motor
A4 Steering control M4 Stepper motor
A5 Master card control P1 Horn
A6 Mast connector card P2 Flashing
A7 Multi-lever board P5 Fan
A8 Premium display P6 Fan
A9 Relay-fuse board P7 Reversing buzzer
A10 Multi-function joystick board P8 Work light
A11 Cab heater control P9 Work light
A12 Multi-function joystick P10 Work light
B1 Traction motor encoder Q1 Lowering proportional solenoid valve
B2 Traction motor heat sensor Q2 Lifting proportional solenoid valve
B3 Pump motor encoder Q3 Carriage in proportional solenoid valve
B4 Pump motor heat sensor Q4 Carriage out proportional solenoid valve
B5 Steering motor encoder Q5 Left hydraulic function proportional solenoid valve
B6 Steer motor heat sensor Q6 Right hydraulic function proportional solenoid valve
B7 Centred wheel sensor Q7 Tilt-shift diverter solenoid valve
B8 90° steered wheel sensor Q8 Hydraulic 5th way diverter solenoid valve
B9 Battery out sensor R1 Varistor
B10 Tilt position sensor R2 Electromagnetic brake
B11 Mast lifting encoder R3 Accelerator pedal sensor
B12 Side shift position sensor R4 Brake pedal sensor
B13 Pallet presence sensor R5 Carriage position potentiometer
B14 Encoder reset sensor R8 Right load wheel electromagnetic brake
B15 Free lift encoder R9 Left load wheel electromagnetic brake
B16 Temperature sensor R10 Load cell
C1 Battery R11 Laser
C2 Electrolyte capacitor 100 μF 50V S1 Key switch
F1 Fuse for emergency push-button and contactors (10A) S2 Emergency button
F2 Contactor fuse (10A) S3 Operator presence switch
F3 Key relay fuse (2A) S4 Drive direction switch
F4 Drive power fuse S5 Seat belt microswitch
F5 Pump power fuse S6 Work lights switch
F6 Steering power fuse S7 Steering mode 180°/360°
K1 Drive contactor coil S8 Traction speed reduction
K2 Pump contactor coil S9 Weighing device button
K3 Key relay S10 Lift by-pass button
K4 Horn relay S12 Lifting-lowering potentiometer lever
K5 Auxiliary relay S13 Carriage out-in potentiometer lever
K6 Auxiliary relay +5/+12V S14 Tilt potentiometer lever
K7 Work lights relay S15 Side shift potentiometer lever
K8 Work light relay S16 Automatic tilt centring button
K9 Diode (1A) S17 Automatic side shift centring button
K10 Diode (1A) S18 Hydraulic 5th way button
K11 Diode (1A) S19 Horn button
K12 Diode (1A) S20 Drive direction switch
K13 Diode (1A) S21 Work light switch
K14 Diode (1A) S22 Seat microswitch (optional)
K15 Diode (1A) T1 DC/DC 48V/24V converter
K16 Optional relay T2 DC/DC 48V/12V converter
K17 Diode (1A)
M Motor assembly
4
4a
4b
4c
4d
NOTES
(2) as a reference use the colour X of the

individual wire (or the number printed on it,
if the wire is black)
(3) standard for the Heavy-duty version, option-
al for the other versions
4e
4f
4g
NOTES
(2) as a reference use the colour X of the individual wire (or the number printed on it, if the wire is black)
4h
4i
NOTES

individual wire (or the number printed
on it, if the wire is black)
(4) if B15 is not mounted, use B14 for drive
speed reduction and Free Lift/Main Lift
lifting
4j
4k
NOTES
(1) connected on the multi-lever version only
(2) as a reference use the colour X of the indi-

vidual wire (or the number printed on it, if the
wire is black)
4l

application diagram - MULTI-FUNCTION JOYSTICK (optional)
NOTES
(2) as a reference use the colour X of the indi-

vidual wire (or the number printed on it, if the
wire is black)
4m
4n
application diagram - PREMIUM DISPLAY (optional) application diagram - COLD STORE STANDARD DISPLAY (optional)
(see also page (a) for the connections) (see also page (a) for the connections)
NOTE (2)
application diagram - COLD STORE CAB (optional) application diagram - DC/DC CONVERTER (optional)
(see also page (b) for the connections) (see also page (h) for the connections)
DC/DC DOUBLE CONVERTER (OPTIONAL)

individual wire (or the number printed on it,
if the wire is black)
NOTES
4o
4p
5
CONTROLS
IDENTIFICATION OF ARMREST, PEDAL UNIT AND MAIN PANEL CONTROLS
4
5
6 9
7
10
11
2
1
12
13 13
14
18
17
14
23 15
22
15
21
24 18
20
17 16
16 19
6
27
25 26
Ref. Description Wiring diagram ref.

1 Keyswitch S1
2 Small steering wheel
3 Standard or premium display A1 - A8
4 Speed reduction button S8
5 Weighing button S9
6 180°/360° steering mode button S7
7 Auxiliary function button
8 Auxiliary function button
9 Work lights switch S6
10 Work lights switch S21
11 Auxiliary function switch
12 PC tool connection port compartment X40-X41
13 Emergency button S2
14 Horn button S19
15 Drive direction switch S4
16 Automatic tilt centring button S16
17 Automatic side shift centring button S15
18 Hydraulic 5th way button S18
19 Fork lifting/lowering mini-lever S12
20 Carriage in/out mini-lever S13
21 Forks up/down tilt mini-lever S14
22 Forks right/left shift mini-lever S15
23 Joystick A12
24 Fork tilt/shift lever
25 Operator presence pedal S3
26 Brake pedal R4
27 Accelerator pedal R3
7
STANDARD DISPLAY
KEYPAD AND SYMBOLS DISPLAYED
1 1
5 6
3 2
Ref. Description
1 Numerical keys from 0 to 9

2 Forward or upward scroll key
3 Backward or downward scroll key
4 Ignition switch with or without key
5 OUT function key
6 ENTER function key
8
DISPLAY BRIGHTNESS CONTROL

a) Disconnect the emergency button with the key switch in position 1
b) Reset the emergency button with the numerical button “0” pressed
c) When the display lights up, use the two scroll buttons to change the brightness
d) Once you reach the desired brightness, press the "ENTER" function key to save it
SOFTWARE
The software is loaded by the supplier.
The software release is indicated on the label on the component.
When switching on, the display has to send an “SDO” to the VMC identification controller that will respond
with another “SDO” for confirmation. When the key switch is turned off the display must warn the VMC
150ms before cutting off the +12V supplying the key relay.
ICONS ASSOCIATED WITH THE GRAPHIC SCREENS

The icons used in the various functions shown on the display are illustrated below.
ICON DESCRIPTION
Battery charge level indicator.

The system continuously monitors the battery charge
indicated by the number of solid segments.
5 segments = from 100% to 76%
1 segment = from 20% to 0
Segments 5-4-3 shown steady. Segments 2-1 shown
blinking. The battery charge status data will be sent
to the display via “Can bus” with “PDO”.
Parking brake indicator.
The data reaches the display via “Can bus” with
“PDO”.
9
ICON DESCRIPTION
Remaining battery life indicator.

Indicates the remaining hours and minutes of battery
life. The data will be sent to the display via “Can bus”
with “PDO”.
Daily clock, indicates the hours and minutes.
24:00 The data reaches the display via “Can bus” with
“PDO”
Worked hours indicator.
0001 h The data reaches the display via “Can bus” with
“SDO”.
Traction speed indicator.
10.50 km/h The data reaches the display via “Can bus” with
“PDO”.
Indicator of fork height off the ground.
10.50 m The data reaches the display via “Can bus” with
“PDO”.
Weighing Indicator.
0150 kg The data reaches the display via “Can bus” with
“SDO”.
Reduced speed indicator.
“PDO”.
Maximum speed indicator.
“PDO”.
Seat belt indicator.

Appears when the seat belt is not fastened. The data
reaches the display via “Can bus” with “PDO”.
Lifting limit stop indicator.

This icon is displayed on reaching the lifting limit. The
data reaches the display via “Can bus” with “PDO”.
Fork tilt up indicator.

This icon is displayed during the fork "tilt up" func-
tion. The data reaches the display via “Can bus”
with “PDO”.
Fork tilt down indicator.
This icon is displayed during the fork "tilt down"
function.
“PDO”.
Fork right side shift indicator.
This icon is displayed during the fork "right side shift"
function.
“PDO”.
Fork left side shift indicator.
This icon is displayed during the fork "left side shift"
function.
“PDO”.
10
ICON DESCRIPTION
Fork side shift self-centring indicator.

This icon is displayed during the fork "side shift self-
centring" function. Icon blinking while moving, steady
once centred. Optional. The data comes via “Can
bus” with “PDO”.
Fork tilt self-levelling indicator.
This icon is displayed during the fork "tilt 0° self-
levelling" function. Icon blinking while moving, steady
once centred. Optional. The data reaches the display
via “Can bus” with “PDO”.
Indicator for hydraulic 5th way option active.
This icon is displayed when the hydraulic 5th way
option is activated. The data reaches the display via
“Can bus” with “PDO”.
IN/OUT hydraulic 5th way function indicator.
This icon is displayed blinking (at a frequency of 2
Hz) when the hydraulic 5th way function is active in
the two work modes. The data reaches the display
Forks lowering interlock indicator.
This icon is displayed during the fork lowering func-
tion when the fork lowering lock trips. Optional. The
Carriage return interlock indicator.

This icon is displayed during the request for carriage
return with the interlock option active. Optional. The
Battery out-of-place indicator.
This icon is displayed when the battery is no longer
locked in its correct position. The data reaches the
display via “Can bus” with “PDO”.
Alarm indicator.
This icon is displayed in the event of a hardware or
software failure on the electrical system and is as-
sociated with a numerical code that identifies the type
of alarm and control involved.
Password prompt indicator.
This icon appears if a password is required for ac-
cess.
11
ICON DESCRIPTION
Incorrect password entry indicator.

This icon appears if the access password entry is
incorrect.
Steer wheel 360° position indicator.

This icon is always displayed. The data reaches the
Steer wheel 360° position indicator showing for-

ward gear engaged.
This icon, with the arrow indicating the direction of
travel, is displayed after making the selection and
throughout the duration of the function. The direction
indication follows the position of the steer wheel. The
Steer wheel 360° position indicator showing re-

verse gear engaged.
Steer wheel 180° position indicator.

Steer wheel 180° position indicator showing for-

ward gear engaged.
Steer wheel 180° position indicator showing re-

verse gear engaged.
12
FUNCTIONAL GRAPHIC SCREENS

The graphic screens for each single function are shown below in sequence.
SCREEN DISPLAYED ON SWITCHING ON THE KEY SWITCH
Steering 360° Steering 180°
• Remaining battery life indicator

• Battery charge level indicator
• Clock
• Traction performance indicator (tortoise or hare)
• Steering wheel position indicator
• Parking brake indicator
• Worked hours indicator displayed for 5 seconds
SCREEN DISPLAYED 5 SECONDS AFTER SWITCHING ON THE KEY SWITCH

• Clock
• Speed indicator, expressed in km/h or mph
13
SCREEN DISPLAYED WITH FORWARD DRIVE SELECTED

• Clock
• Forward drive indicator following the steering wheel position indicator
SCREEN DISPLAYED WITH REVERSE DRIVE SELECTED

• Clock
• Reverse drive indicator following the steering wheel position indicator
14
SCREEN DISPLAYED WITH FORK LIFTING ON AND DRIVE OFF

• Clock
• Fork lifting indicator
SCREEN DISPLAYED WITH FORK LOWERING ON AND DRIVE OFF

• Clock
• Fork lowering indicator
15
SCREEN DISPLAYED WITH CARRIAGE OUT ON AND DRIVE OFF

• Clock
• Carriage out indicator
SCREEN DISPLAYED WITH CARRIAGE RETURN ON AND DRIVE OFF

• Clock
• Carriage return indicator
16
SCREEN DISPLAYED WITH FORK TILT UP ON AND DRIVE OFF

• Clock
• Fork tilt up indicator
SCREEN DISPLAYED WITH FORK TILT DOWN ON AND DRIVE OFF

• Clock
• Fork tilt down indicator
17
SCREEN DISPLAYED WITH FORK SIDE SHIFT TO RIGHT ON AND DRIVE OFF

• Clock
• Fork side shift to right indicator
SCREEN DISPLAYED WITH FORK SIDE SHIFT TO LEFT ON AND DRIVE OFF

• Clock
• Fork side shift to left indicator
18
SCREEN DISPLAYED WITH BATTERY OUT-OF-PLACE

• Clock
• Forward drive indicator
• Battery out-of-place indicator
• Fork lifting block indicator
• 206-01 alarm indicator (Battery out)
SCREEN DISPLAYED WITH BATTERY REMOVAL ON AND DRIVE OFF

• Clock
19
SCREEN DISPLAYED WITH BATTERY RETURN INTO PLACE ON AND DRIVE OFF

• Clock
20
SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF

• Clock
• Tilt up indicator
The screen shown above is an example of combined hydraulic functions.
Possible combinations
Forks up carriage out tilt up

Forks up carriage out tilt down
Forks up carriage out right side shift
Forks up carriage out left side shift
Forks up carriage return tilt up
Forks up carriage return tilt down
Forks up carriage return right side shift
Forks up carriage return left side shift
Forks lowering carriage out tilt up
Forks lowering carriage out tilt down
Forks lowering carriage out right side shift
Forks lowering carriage out left side shift
Forks lowering carriage return tilt up
Forks lowering carriage return tilt down
Forks lowering carriage return right side shift
Forks lowering carriage return left side shift
21
SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON

• Clock
• Carriage forward indicator
The screen shown above is an example of combined hydraulic functions with the drive on.
Forks up carriage out tilt up for forward/reverse drive

Forks up carriage out tilt down for forward/reverse drive
Forks up carriage out right side shift for forward/reverse drive
Forks up carriage out left side shift for forward/reverse drive
Forks up carriage return tilt up for forward/reverse drive
Forks up carriage return tilt down for forward/reverse drive
Forks up carriage return right side shift for forward/reverse drive
Forks up carriage return left side shift for forward/reverse drive
Forks lowering carriage out tilt up for forward/reverse drive
Forks lowering carriage out tilt down for forward/reverse drive
Forks lowering carriage out right side shift for forward/reverse drive
Forks lowering carriage out left side shift for forward/reverse drive
Forks lowering carriage return tilt up for forward/reverse drive
Forks lowering carriage return tilt down for forward/reverse drive
Forks lowering carriage return right side shift for forward/reverse drive
Forks lowering carriage return left side shift for forward/reverse drive
22
SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION ON


• Clock
• Energy Saving indicator
SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION, DRIVE AND HYDRAULICS ON

• Clock
23
SCREEN DISPLAYED WITH WARNING SIGNALLING
This screen is displayed after an incorrect sequence performed by the operator.

• Clock
• Warning indicator
• Indication of the problem
The incorrect sequences are:
• INC. START TRACTION • INC. START REACH OUT

• INC. START LIFT • INC. START SHIFT RIGHT
• INC. START LOW • INC. START SHIFT LEFT
• INC. START TILT UP • INC. START 5TH WAY IN
• INC. START TILT DOWN • INC. START 5TH WAY OUT
• INC. START REACH IN • GET HOME
24
SCREEN DISPLAYED WITH ALARM SIGNALLING


• Clock
• Alarm indicator
• Alarm code number indicator
NOTE: 249 = code number of type of alarm.

6 = identification of the control on which the alarm occurred.
SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE OFF.

• Clock
• Lifting limit stop indicator
25
SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE ON.

• Clock
26
DESCRIPTION OF THE OPTIONAL GRAPHIC SCREENS
The graphic screens for each single optional function are shown below in sequence.
OPERATOR SEAT BELT OPTIONAL SCREEN

• Clock
• Seat belt not fastened indicator
When the direction of travel is selected, the above screen will appear if the seat belt is not fastened.
The indicator showing that the seat belt is not fastened blinks at a frequency of 1.5 Hz.
FORK TILT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE OFF.

• Clock
• Fork tilt self-centring indicator
During the self-centring phase the icon will blink alternately with showing the tilt movement (tilt up/tilt down). If
there is a request for self-centring and the forks are already in the correct position the icon is on steady.
27
FORK TILT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE ON.

• Clock
During the self-centring phase the icon will blink alternately with showing the tilt movement (tilt up/tilt down). If
there is a request for self-centring and the forks are already in the correct position the icon is on steady.
FORK SIDE SHIFT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE OFF.

• Clock
• Fork side shift self-centring indicator
During the self-centring phase the icon will blink alternately with showing the side shift movement (side shift
right/side shift left). If there is a request for self-centring and the forks are already in the correct position
the icon is on steady.
28
FORK SIDE SHIFT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE ON.

• Clock
During the self-centring phase the icon will blink alternately with showing the side shift movement (side shift
right/side shift left). If there is a request for self-centring and the forks are already in the correct position
the icon is on steady.
OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE OFF

• Clock
• Hydraulic 5th way indicator
29
OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE ON

• Clock
• Hydraulic 5th way indicator
OPTIONAL SCREEN FOR INPUT HYDRAULIC 5TH WAY WITH DRIVE OFF

• Clock
• Input hydraulic 5th way indicator
30
OPTIONAL SCREEN FOR OUTPUT HYDRAULIC 5TH WAY WITH DRIVE OFF

• Clock
• Output hydraulic 5th way indicator
OPTIONAL SCREEN FOR INPUT HYDRAULIC 5TH WAY WITH DRIVE ON

• Clock
31
OPTIONAL SCREEN FOR OUTPUT HYDRAULIC 5TH WAY WITH DRIVE ON

• Clock
32
OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF

• Clock
• Tilt self-centring indicator
The screen shown above is an example of combined hydraulic functions with the drive on.
Forks up carriage out tilt self-centring

Forks up carriage out side shift self-centring
Forks up carriage return tilt self-centring
Forks up carriage return side shift self-centring
Forks lowering carriage out tilt self-centring
Forks lowering carriage out side shift self-centring
Forks lowering carriage return tilt self-centring
Forks lowering carriage return side shift self-centring
33
OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON

• Clock
The screen shown above is an example of combined hydraulic functions with the drive off.
Forks up carriage out tilt self-centring for forward/reverse drive

Forks up carriage out side shift self-centring for forward/reverse drive
Forks up carriage return tilt self-centring for forward/reverse drive
Forks up carriage return side shift self-centring for forward/reverse drive
Forks lowering carriage out tilt self-centring for forward/reverse drive
Forks lowering carriage out side shift self-centring for forward/reverse drive
Forks lowering carriage return tilt self-centring for forward/reverse drive
Forks lowering carriage return side shift self-centring for forward/reverse drive
34
OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE OFF

• Clock
• Fork lifting/lowering indicator
• Digital height display measured in metres or feet
OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE ON

• Clock
• Digital height display in metres or feet off the ground
During the forks up or down function with drive on, the measured fork height must always be displayed.
When the machine is stopped, the fork height off the ground is displayed. When the machine is running
only in drive mode, the speed indicator is displayed.
35
OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE AND HYDRAULICS OFF

• Clock
• Load weighing indicator in kg or lb
During the load weighing function with drive on, the weight must appear for 5 seconds and then the drive
speed will be displayed.
OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE ON AND HYDRAULICS OFF

• Clock
• Forward drive engaged indicator
36
FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF

• Clock
• Forks lowering interlock indicator
The forks lowering indicator blinks at a frequency of 1.5 Hz.
FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON

• Clock
37
CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF

• Clock
• Carriage return interlock indicator
The carriage return indicator blinks at a frequency of 1.5 Hz.
CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON

• Clock
38
DESCRIPTION OF THE MENU SCREENS
The graphic screens for each menu are shown below in sequence.
MAIN MENU 1
Pressing the "ENTER" function key takes you from the main screen to “MAIN MENU 1” as shown above.
To access the different sub-menus, you need to move the arrow by pressing the "SCROLL" keys and, once
you have made your selection, press “ENTER”.
MAIN MENU 1 / TESTER

The “TESTER” function allows you to check the operation of the truck.
Once in the “TESTER” sub-menu, the “TESTER 1” screen will appear, as shown below. Using the “SCROLL”
keys you can change the screens of the “TESTER” sub-menu (from “TESTER 1” to “TESTER 5”)
TESTER 1
TRACTION
CURRENT = 0000 A
VOLTAGE = 000%
FREQUENCY = 000 Hz
TEMPERATURE = 000 °C
MOTOR TEMP = 000 °C
HOURS = 0000 h
“TESTER1” enables checking the signals sent by the traction controller.

The display via an “SDO” will request these data from the traction controller that will respond with an “SDO”
via “Can Bus”.
TESTER 2
PUMP
CURRENT = 0000 A
VOLTAGE = 000%
FREQUENCY = 000 Hz
MOTOR TEMP =000 °C
HOURS = 0000 h
“TESTER 2” enables checking the signals sent by the pump controller.
The display via an “SDO” will request these data from the pump controller that will respond with an “SDO”
via “Can Bus”.
39
TESTER 3
STEERING
CURRENT = 0000 A
VOLTAGE = 000%
FREQUENCY = 000 Hz
MOTOR TEMP = 000 °C
HOURS = 0000 h
“TESTER 3” enables checking the signals sent by the steering system controller.
The display via an “SDO” will request these data from the steering system controller that will respond with
an “SDO” via “Can Bus”.
“TESTER 4” enables checking the status of the digital inputs.

Empty square = OFF
Solid square = ON
The display via an “SDO” will request these data from the VMC controller that will respond with an “SDO”
via “Can Bus”.
“TESTER 5” enables checking the status of the analogue inputs.

via “Can Bus”.
By pressing the "OUT" function key, you can exit the screen at any time.
40
MAIN MENU 1 / SET CLOCK
The “SET CLOCK” function allows you to set the current time.
Once you enter the sub-menu, the hours will flash. Use the numerical keys to set the correct time, then
confirm with "ENTER". The minutes will now blink. Use the numerical keys to set the minutes and confirm
with "ENTER". After this operation you exit the screen automatically.
The display via “SDO” will send these data to the VMC controller that will respond with an “SDO” as con-
firmation. The VMC will have an RTC device with Backup
MAIN MENU 1 / SOFTWARE VERSION.
The “SOFTWARE VERSION” function allows you to check the versions of the software used.
via “Can Bus”.
41
MAIN MENU 1 / ALARMS.
These four screens are used for saving and displaying up to 32 different alarms that have occurred while
using the machine. They display:
• The code number of the type of alarm.

• The time when the alarm occurred.
• The number of times it has occurred.
• Identifier of the control on which the alarm occurred.
Once in the “ALARMS” sub-menu, the screen will appear with the first 10 alarms. Using the "SCROLL"
keys, you can change the screens to be able to view all 32 alarms, when there are that many, otherwise
the pages are automatically reduced to display only the alarms present.
via “Can Bus”.
By pressing the function key “OUT”, you can exit the screen at any time.
42
MAIN MENU 1 / PARAMETER SETTING.
On these screens, the operator can modify the machine's drive performance, with the ability to lock it with
a password.
Once in the “PARAMETER SETTING” sub-menu, the screen shown below will appear.
With the "SCROLL" keys you can select the parameter you want to change:
1) TRACTION SPEED from 1.00 km/h to 14.00 km/h
2) ACCELERATION from 1 to 5
1: +1 sec (lower performing)
2: +0.5 sec
3: standard setting
4: -0.3 sec
5: -0.5 sec (higher performing)
3) INVERSION BRAKING from 1 to 5

1: +0.5 sec (lower performing)
2: +0.2 sec
3: standard setting
4: -0.3 sec
4) RELEASE BRAKING from 1 to 5

2: +0.2 sec
3: standard setting
4: -0.3 sec
To change the 4 above parameters, proceed as follows:

a) Position the cursor, using the "SCROLL" keys, on the parameter to be changed
b) Press the "ENTER" key.
c) The value of the parameter will blink and you can now change the value with the "NUMERI-
CAL" keys.
d) Press the "ENTER" key to confirm.
43
5) ENERGY SAVING from OFF to ON. If set ON, the machine traction and lifting performance will be
reduced to save battery power consumption. This function will be indicated by the “ECO” icon.
To modify this parameter, proceed as follows:
a) Position the cursor, using the "SCROLL" keys, on the parameter to be changed.
c) The word OFF will blink and you can now change it to ON using the "SCROLL" keys.
d) Press the "ENTER" key to confirm.
6) LOCK PARAM. from OFF to ON. If set ON, you will be prompted for a password to lock the set
parameters.
To modify this parameter, proceed as follows:
e) Position the cursor, using the "SCROLL" keys, on the parameter to be changed.
f) Press the "ENTER" key.
g) A window will open where you can enter the 4 digits of the PIN that you can set as a password.
Enter the 4-digit password using the "NUMERICAL" keys and press "ENTER" to confirm.
The modified parameters will now be locked and you are taken back to the “PARAMETER
SETTING” screen and the “LOCK PARAM” value will be “ON”. Now, all the parameters are
locked.
If the user attempts to modify the parameters with the lock on, the screen for entering the password will
reappear.
On restarting the machine the screen for entering the password shown below will be displayed.
If you enter the wrong password, the screen shown below will appear for 5 seconds, after which the pass-
word prompt screen will return.
With the “SUPERVISOR PASSWORD” (default 5555) or the “ENGINEERING PASSWORD” (1959)
it is always possible to unlock the parameters.
The display via an “SDO” will send these data to the VMC controller that will respond with an
“SDO” via “Can Bus”.
44
MAIN MENU 2
The “MAIN MENU 2” function allows you to access the functions that only technical support can modify.
Once in the “MAIN MENU 2” sub-menu, the following screen will appear.
Enter the 4-digit password using the "NUMERICAL" keys and press "ENTER" to confirm. If you enter the
wrong password, the screen shown below will appear for 5 seconds, after which the password prompt
screen will return.
When the password is correct, the following screen will be displayed.
With the “SUPERVISOR PASSWORD” (default 5555) or the “ENGINEERING PASSWORD” (1959)
it is always possible to access “MAIN MENU 2”.
To access the different sub-menus, you need to move the arrow by pressing the "SCROLL" keys
and, once you have made your selection, press “ENTER”.
45
MAIN MENU 2 \ CLEAR ALARMS
The “CLEAR ALARMS” function allows you to delete the alarms in the “ALARMS” menu
When this screen appears, pressing the direction buttons scrolls through the two possible options of “YES”
and “NO”.
Pressing the “ENTER” button with “YES” displayed clears the saved alarms and takes you back to the “MAIN
MENU 2” screen. Pressing the “ENTER” button with “NO” displayed exits without clearing the alarms and
takes you back to the “MAIN MENU 2” screen.
With the "OUT" button you exit without clearing the alarms.
MAIN MENU 2 \ MEASURING SYSTEM
The “MEAS. SYSTEM TYPE” function allows you to convert the following units of measurement simultane-
ously, as follows:
• km/h into mph
• m into ft
• kg into lb
When this screen appears, by using the scroll buttons you can select the available systems of measure-
ment (“INTERNATIONAL SYSTEM”/”IMPERIAL SYSTEM”) and, once selected, on pressing the “ENTER”
button the units of measurement are converted by the display's software and you are taken back to the
“MAIN MENU 2” screen. The metric system is present by default on “Can Bus”.
46
main menu 2 \ FORKS SETUP
The “FORKS SETUP” function allows you to change the two fork adjustment values. The first one, “FORKS
OFFSET ”, is the minimum height of the forks off the ground. The second one, “FORKS UP LIMIT”, allows
you to limit lifting the forks up to the set height.
When this screen appears, on pressing the “ENTER” button the selected value, for example “FORKS OFF-
SET”, will blink. Type in the new offset value in metres, using the “NUMERICAL” buttons.
Press the "ENTER" key to confirm. The modified value will be displayed steady
The same procedure for changing the value applies to the second value, “FORKS UP LIMIT”, which can
be selected with the direction buttons.
The display via an “SDO” will send these data to the VMC controller that will respond with an “SDO” via
“Can Bus”.
47
main menu 2 \ PARAMETER ACQUISITION
On this screen you can acquire the electrical values of carriage all in, carriage all out, minimum load cell
value (with no load on the forks) and maximum load cell value (nominal load on the forks).
With the scroll keys you can select the value you want to acquire. To access carriage all out/in acquisition,
proceed as follows:
a) Position the cursor, using the scroll keys, onto the value to be acquired: REACH FULL FWD /
REACH FULL BACK.
b) Press the "ENTER" key and the selected value will start flashing.
c) Move the carriage forwards/backwards until the desired position is reached..
d) Press the "ENTER" key to save the modified value.
e) Press the "OUT" button to exit.
To access acquisition of the load cell minimum and maximum values, proceed as follows:
a) Position the cursor, using the scroll keys, onto the value to be acquired: MIN WEIGHT CELL/MAX
WEIGHT CELL.
b) Press the "ENTER" key and the selected value will start flashing.
c) Raise the forks off the ground by approximately 50mm.
d) Press the "ENTER" key to save the modified value.
e) Press the "OUT" button to exit.
main menu 2 \ PROGRAMMING ACCESS CODE WITH COMBINED OPERATOR CODE READING
This function is optional, therefore the display needs to be enabled via “PDO” to make it operative on the
truck. The “PROG. PIN CODE ACCESS” function allows you to create an access code for operator or
supervisor use and to define the driver profile for each access code. Up to a total of 104 codes can be
programmed. If this function is enabled, when switching on the key switch the display will prompt you for
the access code.
With the correct access code, the +12V output of the key relay is enabled, the screen will be displayed
and the operator will be enabled to use the machine. If the truck is not operated for any longer than 10
minutes (message sent by ”Can Bus” via “SDO”), the display will disable the +12V output of the key relay
and switch off. To be able to restart, simply press any button and the display will prompt you for the access
code again.
The screens and the descriptions for the programming are illustrated below.
48
ACCESS CODE PROGRAMMING SCREEN
To enter the codes, you need to move the arrow by pressing the "SCROLL" keys and, once you have selected
the row, press “ENTER”. The cursor will now be positioned on the digit of the code to enter that will start
flashing. Type in the four-digit code with the "NUMERIC" keys and confirm with “ENTER”. The cursor will
automatically move onto "U" that will start flashing. Using the “SCROLL” buttons you can go from “U” (user)
to “S” (supervisor) and pressing “ENTER” confirms the selection. Lastly, the cursor will move onto "NA"
that will start flashing. Using the “SCROLL” buttons you can go from “NA” (not available) to “A” (available),
pressing “ENTER” confirms the selection. If “NA” is confirmed, the cursor will move onto the next row,
whereas confirming “A” will show the screen to be able to match the driver profile with the access code.
With the "SCROLL" keys you can select the parameter you want to change:
2) ACCELERATION from 1 to 5
1: +1 sec (lower performing)
2: +0.5 sec
3: standard setting
4: -0.3 sec
3) INVERSION BRAKING from 1 to 5

2: +0.2 sec
3: standard setting
4: -0.3 sec
49
4) RELEASE BRAKING from 1 to 5

2: +0.2 sec
3: standard setting
4: -0.3 sec
To change the 4 above parameters, proceed as follows:

a) Position the cursor, using the "SCROLL" keys, on the parameter to be changed
c) The value of the parameter will blink and you can now change the value with the "NUMERI-
CAL" keys.
d) Press the "ENTER" key to confirm and return to the “PROG. PIN CODE ACCESS” screen
with the cursor positioned on the next row.
This procedure applies to all 104 access codes.
ACCESS CODE PROMPT SCREEN
Enter the 4-digit password using the "NUMERICAL" keys and press "ENTER" to confirm. If you enter the
wrong password, the screen shown below will appear for 5 seconds, after which the password prompt
screen will return.
50
main menu 2 \ read user code
The “READ USER CODE” function enables displaying the last 24 “USER” codes that have used the ma-
chine, saving the start and end of work times.
Use the truck operating hours to calculate the start and end of work.
To be able to view the remaining “USER CODES” on the other pages, use the “SCROLL” buttons
main menu 2 \ clear access code
The “CLEAR PIN CODE ACCESS” function allows you to delete the access codes, user code reading and
profile settings in the “PRG. PIN CODE ACCESS” menu.
When this screen appears, pressing the direction buttons scrolls through the two possible options of “NO”
and “YES”. On confirming with the “ENTER” button, the saved codes are deleted and you are automatically
taken back to the “MAIN MENU 2” screen.
51
PREMIUM DISPLAY
52
SOFTWARE
The software is loaded by the supplier.
The software release is indicated on the label on the component.
When switching on, the display has to send an “SDO” to the VMC identification controller that will respond
with another “SDO” for confirmation. When the key switch is turned off the display must warn the VMC
150ms before cutting off the +12V supplying the key relay.
ICONS ASSOCIATED WITH THE GRAPHIC SCREENS

The icons used in the various functions shown on the display are illustrated below.
ICON DESCRIPTION
Battery charge level indicator.

The system continuously monitors the battery charge
indicated by the colour and fill level of the battery
symbol.
• From 100% to 40% = green
• From 40% to 20% = yellow
• From 20% to 0% = red
The battery displays 10 different charge levels, in

10% steps.
The battery charge status data will be sent to the
Parking brake indicator.

“PDO”.
Remaining battery life indicator.

Indicates the remaining hours and minutes of battery
life. The data will be sent to the display via “Can bus”
with “PDO”.
Clock and date, indicates the hours and minutes

and day.
“PDO”
53
ICON DESCRIPTION
Worked hours indicator.

“SDO”.
Traction speed indicator.

“PDO”.
Indicator of fork height off the ground.

“PDO”.
Weighing Indicator.
“SDO”.
Reduced speed indicator.

“PDO”.
Maximum speed indicator.

“PDO”.
180° steering mode indicator

“PDO”.
360° steering mode indicator

“PDO”.
Energy saving indicator.

The data will be sent to the “VCM” (vehicle muster
control) via “Can bus” with “PDO”.
WARNING indicator.
This icon appears along with an indication of an incor-
rect sequence performed by the operator. The data
Seat belt indicator.

Appears when the seat belt is not fastened. The data
54
ICON DESCRIPTION
Fork lifting indicator.

This icon is displayed during the "fork lifting" func-
with “PDO”.
Fork lowering indicator.
This icon is displayed during the "fork lowering"
function. The data reaches the display via “Can bus”
with “PDO”.
Carriage out indicator.
This icon is displayed during the "carriage out" func-
with “PDO”.
Carriage return indicator.
This icon is displayed during the "carriage return"
with “PDO”.
Lifting limit stop indicator.
This icon is displayed on reaching the lifting limit. The
Fork tilt up indicator.

This icon is displayed during the fork "tilt up" func-
with “PDO”.
Fork tilt down indicator.

This icon is displayed during the fork "tilt down"
with “PDO”.
Fork right side shift indicator.

This icon is displayed during the fork "right side shift"
with “PDO”.
Fork left side shift indicator.

This icon is displayed during the fork "left side shift"
with “PDO”.
Fork side shift self-centring indicator.
This icon is displayed during the fork "side shift self-
centring" function. Icon blinking while moving, steady
once centred. Optional. The data comes via “Can
bus” with “PDO”.
Fork tilt self-levelling indicator.
This icon is displayed during the fork "tilt 0° self-
levelling" function. Icon blinking while moving, steady
once centred. Optional. The data reaches the display
55
ICON DESCRIPTION
Indicator for hydraulic 5th way option active.

This icon is displayed when the hydraulic 5th way
option is activated. The data reaches the display via
“Can bus” with “PDO”.
IN/OUT hydraulic 5th way function indicator.
This icon is displayed blinking (at a frequency of 2
Hz) when the hydraulic 5th way function is active in
the two work modes. The data reaches the display
Forks lowering interlock indicator.
This icon is displayed during the fork lowering func-
tion when the fork lowering lock trips. Optional. The
Carriage return interlock indicator.

This icon is displayed during the request for carriage
return with the interlock option active. Optional. The
Battery out-of-place indicator.

This icon is displayed when the battery is no longer
locked in its correct position. The data reaches the
Alarm indicator.
This icon is displayed in the event of a hardware or
software failure on the electrical system and is as-
sociated with a numerical code that identifies the type
of alarm and control involved.
Password prompt indicator.
This icon appears if a password is required for ac-
cess.
Incorrect password entry indicator.

This icon appears if the access password entry is
incorrect.
56
ICON DESCRIPTION
Steering wheel position indicator.

Steering wheel position indicator showing for-

ward gear engaged.
Steering wheel position indicator showing re-

verse gear engaged.
throughout the duration of the function. The direc-
tion indication follows the position of the steer wheel
. The
57
FUNCTIONAL GRAPHIC SCREENS

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

• Clock, date
• Steering mode indicator (180° or 360°)
• Worked hours indicator
• Menu access button
SCREEN DISPLAYED ON SWITCHING ON WITH OPERATOR ACCESS THROUGH PINCODE.

• Clock, date
• OFF button
58
SCREEN DISPLAYED WITH FORWARD DRIVE SELECTED.

• Clock, date
• Forward drive indicator following the steering wheel position indicator
SCREEN DISPLAYED WITH REVERSE DRIVE SELECTED.

• Clock, date
• Reverse drive indicator following the steering wheel position indicator
59
SCREEN DISPLAYED WITH FORK LIFTING ON AND DRIVE OFF.

• Clock, date
SCREEN DISPLAYED WITH FORK LOWERING ON AND DRIVE OFF.

• Clock, date
• Fork lowering indicator
60
SCREEN DISPLAYED WITH CARRIAGE OUT ON AND DRIVE OFF.

• Clock, date
SCREEN DISPLAYED WITH CARRIAGE RETURN ON AND DRIVE OFF.

• Clock, date
61
SCREEN DISPLAYED WITH FORK TILT UP ON AND DRIVE OFF.

• Clock, date
• Fork tilt up indicator
SCREEN DISPLAYED WITH FORK TILT DOWN ON AND DRIVE OFF.

• Clock, date
• Fork tilt down indicator
62
SCREEN DISPLAYED WITH FORK SIDE SHIFT TO RIGHT ON AND DRIVE OFF.

• Clock, date
• Side shift to right indicator
SCREEN DISPLAYED WITH FORK SIDE SHIFT TO LEFT ON AND DRIVE OFF

• Clock, date
• Side shift to left indicator
63
SCREEN DISPLAYED WITH BATTERY OUT-OF-PLACE.

• Clock, date
SCREEN DISPLAYED WITH BATTERY REMOVAL ON AND DRIVE OFF.

• Clock, date
64
SCREEN DISPLAYED WITH BATTERY RETURN INTO PLACE ON AND DRIVE OFF.

• Clock, date
65
SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF.

• Clock, date
The screen displayed above is an example of combined hydraulic functions.
The possible combinations are:
• Forks up - carriage forward - tilt up

• Forks up - carriage forward - tilt down
• Forks up - carriage forward - side shift right
• Forks up - carriage forward - side shift left
• Forks up - carriage return - tilt up
• Forks up - carriage return - tilt down
• Forks up - carriage return - side shift right
• Forks up - carriage return - side shift left
• Forks down - carriage forward - tilt up
• Forks down - carriage forward - tilt down
• Forks down - carriage forward - side shift right
• Forks down - carriage forward - side shift left
• Forks down - carriage return - tilt up
• Forks down - carriage return - tilt down
• Forks down - carriage return - side shift right
• Forks down - carriage return - side shift left
66
SCREEN DISPLAYED WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON.

• Clock, date
The screen displayed above is an example of combined hydraulic functions with the drive on.
• Forks up - carriage forward - tilt up - forward/reverse drive

• Forks up - carriage forward - tilt down - forward/reverse drive
• Forks up - carriage forward - side shift right - forward/reverse drive
• Forks up - carriage forward - side shift left - forward/reverse drive
• Forks up - carriage return - tilt up - forward/reverse drive
• Forks up - carriage return - tilt down - forward/reverse drive
• Forks up - carriage return - side shift right - forward/reverse drive
• Forks up - carriage return - side shift left - forward/reverse drive
• Forks down - carriage forward - tilt up - forward/reverse drive
• Forks down - carriage forward - tilt down - forward/reverse drive
• Forks down - carriage forward - side shift right - forward/reverse drive
• Forks down - carriage forward - side shift left - forward/reverse drive
• Forks down - carriage return - tilt up - forward/reverse drive
• Forks down - carriage return - tilt down - forward/reverse drive
• Forks down - carriage return - side shift right - forward/reverse drive
• Forks down - carriage return - side shift left - forward/reverse drive
67
SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION ON.

• Clock, date
SCREEN DISPLAYED WITH ENERGY SAVING FUNCTION, DRIVE AND HYDRAULICS ON.

• Clock, date
68
SCREEN DISPLAYED WITH WARNING SIGNALLING.

This screen is displayed after an incorrect sequence performed by the operator.

• Clock, date
• Warning indicator
• Indication of the problem
NOTE: The incorrect sequences and anomaly warnings are:

• INC. START TRACTION
• INC. START LIFT
• INC. START LOW
• INC. START TILT UP
• INC. START TILT DOWN
• INC. START REACH IN
• INC. START REACH OUT
• INC. START SHIFT RIGHT
• INC. START SHIFT LEFT
• INC. START 5TH WAY IN
• INC. START 5TH WAY OUT
• GET HOME
• RESET ENCODER
• BATTERY LOW
• OVERLOAD
• CHECK UP
• SEAT SWITCH
69
SCREEN DISPLAYED WITH ALARM SIGNALLING

This screen is displayed after a hardware or software failure on the electrical system.

• Clock, date
• Alarm indicator
• Alarm code number indicator
NOTE: 213 = code number of type of alarm.

01 = identification of the control on which the alarm occurred.
70
SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE OFF.

• Clock, date
SCREEN DISPLAYED WITH FORK LIFTING LIMIT STOP INDICATOR WITH DRIVE ON.

• Clock, date
71
OPTIONAL GRAPHIC SCREENS

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

• Clock, date
• Seat belt not fastened indicator
When the direction of travel is selected, the above screen will appear if the seat belt is not fastened.
The indicator showing that the seat belt is not fastened blinks at a frequency of 1.5 Hz.
72
FORK TILT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE OFF.

• Clock, date
During the self-centring phase the icon will blink alternately with showing the tilt movement (tilt up/tilt
down). If there is a request for self-centring and the forks are already in the correct position the icon is on
steady.
73
FORK TILT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE ON.

• Clock, date
During the self-centring phase the icon will blink alternately with showing the tilt movement (tilt up/tilt
down). If there is a request for self-centring and the forks are already in the correct position the icon is on
steady.
74
FORK SIDE SHIFT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE OFF.

• Clock, date
During the self-centring phase the icon will blink alternately with showing the side shift movement (side
shift right/side shift left). If there is a request for self-centring and the forks are already in the correct posi-
tion the icon is on steady.
75
FORK SIDE SHIFT SELF-CENTRING OPTIONAL SCREEN WITH DRIVE ON.

• Clock, date
During the self-centring phase the icon will blink alternately with showing the side shift movement (side
shift right/side shift left). If there is a request for self-centring and the forks are already in the correct posi-
tion the icon is on steady.
76
OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE OFF.

• Clock, date
• Active hydraulic 5th way indicator
OPTIONAL SCREEN FOR HYDRAULIC 5TH WAY WITH DRIVE ON

• Clock, date
77
OPTIONAL SCREEN FOR INPUT HYDRAULIC 5TH WAY WITH DRIVE OFF.

• Clock, date
OPTIONAL SCREEN FOR OUTPUT HYDRAULIC 5TH WAY WITH DRIVE OFF.

• Clock, date
78
OPTIONAL SCREEN FOR INPUT HYDRAULIC 5TH WAY WITH DRIVE ON.

• Clock, date
OPTIONAL SCREEN FOR OUTPUT HYDRAULIC 5TH WAY WITH DRIVE ON.

• Clock, date
79
OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE OFF.

• Clock, date
This shown above is an example of combined hydraulic functions with the drive off.

• Forks up - carriage forward - tilt self-centring
• Forks up - carriage forward - side shift self-centring
• Forks up - carriage return - tilt self-centring
• Forks up - carriage return - side shift self-centring
• Forks down - carriage forward - tilt self-centring
• Forks down - carriage forward - side shift self-centring
• Forks down - carriage return - tilt self-centring
• Forks down - carriage return - side shift self-centring
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OPTIONAL SCREEN WITH COMBINED HYDRAULIC FUNCTIONS AND DRIVE ON.

• Clock, date
This shown above is an example of combined hydraulic functions with the drive off.

• Forks up - carriage forward - tilt self-centring - forward/reverse drive
• Forks up - carriage forward - side shift self-centring - forward/reverse drive
• Forks up - carriage return - tilt self-centring - forward/reverse drive
• Forks up - carriage return - side shift self-centring - forward/reverse drive
• Forks down - carriage forward - tilt self-centring - forward/reverse drive
• Forks down - carriage forward - side shift self-centring - forward/reverse drive
• Forks down - carriage return - tilt self-centring - forward/reverse drive
• Forks down - carriage return - side shift self-centring - forward/reverse drive
81
OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE OFF.

• Clock, date
• Digital height display measured in metres or feet
OPTIONAL SCREEN WITH DIGITAL HEIGHT DISPLAY AND DRIVE ON.

• Clock, date
• Digital height display in metres or feet off the ground
During the forks up or down function with drive on, the measured fork height must always be displayed.
When the machine is stopped, the fork height off the ground is displayed. When the machine is running
only in drive mode, the speed indicator is displayed.
82
OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE AND HYDRAULICS OFF.

• Clock, date
During the load weighing function with drive off, the weight must appear for 5 seconds and then it must
disappear. If the altimeter option is active the forks height will be displayed again.
83
OPTIONAL SCREEN WITH WEIGHING DEVICE, DRIVE ON AND HYDRAULICS OFF.

• Clock, date
• Forward drive engaged indicator
84
FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF.

• Clock, date
The forks lowering indicator blinks at a frequency of 1.5 Hz
FORKS LOWERING INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON.

• Clock, date
85
CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE OFF.

• Clock, date
CARRIAGE RETURN INTERLOCK INDICATOR OPTIONAL SCREEN WITH DRIVE ON

• Clock, date
86
OPTIONAL SCREEN WITH ACTIVE ACCESS CODE PIN.

When the truck is turned on with active pin code, the following user recognition screen will appear:
Enter the 4-digit password using the numerical keypad and press "OK" to confirm. If you enter the wrong
password, the screen shown below will appear for 5 seconds, after which the password prompt screen will
return.
87
height pre-selector
PRE-SELECTOR OPTIONAL SCREEN.
The main screen with the pre-selector option on appears as follows.

• Date/time indicator
• Work hours indicator
• Steering mode indicator
• Digital height display
• Pre-selector options button
To activate the pre-selection functions, press the “HEIGHT PRESELECTOR” button.
88
PRE-SELECTOR SHELF SELECTION SCREEN WITHOUT PALLET SENSOR OPTION

The following screen appears to permit selecting the shelf:
To select the area, press one of the area selection buttons on the bar at the top of the screen (by default
after going into the menu the selected area is “AREA A”). For each of the 4 areas there are 10 levels, for
a total of 40 settable levels.
To select the desired shelf, press the buttons to the side of the chosen area.
In particular:
• If you have a load on the forks and you want to put the pallet on the shelf, you should select the follow-
ing button next to the chosen level:

• If you do not have a load on the forks and you want to take the pallet from the shelf, you should select
the following button next to the chosen level:
PRE-SELECTOR SHELF SELECTION SCREEN WITH PALLET SENSOR OPTION, WITH NO LOAD ON
THE FORKS
When the pallet sensor function is combined with the pre-selector function, pallets are automatically de-
tected on the forks.
If the pallet sensor does not detect a pallet on the forks, it means that the truck is ready for picking up and
the pre-selector screen will only allow taking from the shelf:
after going into the menu the selected area is “AREA A”).
To activate picking up, press the button next to the chosen level.
89
PRE-SELECTOR SHELF SELECTION SCREEN WITH PALLET SENSOR OPTION, WITH LOAD ON
THE FORKS
When the pallet sensor function is combined with the pre-selector function, pallets are automatically de-
tected on the forks.
If the pallet sensor detects a pallet on the forks, it means that the truck must put the load down on the shelf
and the pre-selector screen will only allow putting down the load:
after going into the menu the selected area is “AREA A”).
To activate picking up, press the button next to the chosen level.
SCREEN FOR PICKING UP LOAD WITH SELECTED LEVEL ABOVE FORK HEIGHT
After selecting the shelf for picking up, you go back to the main screen:
A box appears in the middle of the screen providing information on the selected shelf and at the bottom in
the middle there is the height to reach for picking up. The icon indicating the control to carry out (fork lifting,
in this case) will blink in the middle of the screen at a frequency of 1.5 Hz. You can exit the selected level
at any time by pressing the “EXIT” button on the screen.
90
After operating the forks up control and reaching the set height, the icon will stop blinking and the following
screen will appear:
On releasing the up control you can fork the load on the shelf and the icon for the request to operate the
forks up control will activate. Now, on operating the up lever the forks will rise 100 mm to allow picking up
the pallet (see picture below).
On completing this operation the system will go back into manual mode and the main screen will return as
follows:
91
SCREEN FOR PUTTING DOWN LOAD WITH SELECTED LEVEL ABOVE FORK HEIGHT
After selecting the shelf for putting down, you go back to the main screen:
the middle there is the height to reach for putting down. The icon indicating the control to carry out (fork
lifting, in this case) will blink in the middle of the screen at a frequency of 1.5 Hz. You can exit the selected
level at any time by pressing the “EXIT” button on the screen.
After operating the forks up control and reaching the set height, the icon will stop blinking and the following
screen will appear:
On releasing the up control you can position the forks to release the load on the shelf and the icon for
the request to operate the forks down control will activate. Now, on operating the down lever the forks will
lower 100 mm to allow putting down the pallet.
92
follows:
93
SCREEN FOR PICKING UP LOAD WITH SELECTED LEVEL BELOW FORK HEIGHT
After selecting the shelf for picking up, you go back to the main screen:
the middle there is the height to reach for picking up. The icon indicating the control to carry out (fork low-
ering, in this case) will blink in the middle of the screen at a frequency of 1.5 Hz. You can exit the selected
level at any time by pressing the “EXIT” button on the screen.
After operating the down control and reaching the set height, the icon will stop blinking and the following
screen will appear:
On releasing the down control you can fork the load on the shelf and the icon for the request to operate
the forks up control will activate. Now, on operating the up lever the forks will rise 100 mm to allow picking
up the pallet.
94
follows:
95
SCREEN FOR PUTTING DOWN LOAD WITH SELECTED LEVEL BELOW FORK HEIGHT
After selecting the shelf for putting down, you go back to the main screen:
the middle there is the height to reach for putting down. The icon indicating the control to carry out (fork
lowering, in this case) will blink in the middle of the screen at a frequency of 1.5 Hz. You can exit the se-
lected level at any time by pressing the “EXIT” button on the screen.
After operating the forks down control and reaching the set height, the icon will stop blinking and the fol-
lowing screen will appear:
On releasing the down control you can position the forks to release the load on the shelf and the icon for
the request to operate the forks down control will activate. Now, on operating the down lever the forks will
lower 100 mm to allow putting down the pallet.
96
On completing this operation the system will go back into manual mode and the main screen will return
as follows:
97
DESCRIPTION OF THE MENU SCREENS

The graphic screens for each menu are shown below in sequence.
DESCRIPTION OF THE USER MENU SCREEN.
From the main screen press the “MENU” button to access the “USER MENU” shown above.
To access the different sub-menus, it is necessary to press the desired sub-menu on the screen in the
rectangle around the function.
To go back to the main menu, press “EXIT”.
DESCRIPTION OF THE DIAGNOSTICS SCREEN.
From the menu screen press the “DIAGNOSTICS” button to access the “DIAGNOSTICS” submenu shown
above.
To access the different diagnostic sub-menus, you need to press the desired sub-menu on the screen in
the rectangle around the function.
To go back to the “USER MENU” screen, depress “EXIT”.
98
Description of the "TESTER" screens

The "DIAGNOSTICS" function allows you to check the operation of the truck.
Once in the "DIAGNOSTICS" sub-menu, pressing “TRACTION”, the screen shown in the figure will ap-
pear. it is possible to return to the “DIAGNOSTICS” submenu pressing the “EXIT” button.
The “TRACTION” menu enables checking the signals sent by the traction controller.
The display via an “SDO” will request these data from the traction controller that will respond with an “SDO”
via “Can Bus”.
The “PUMP” menu enables checking the signals sent by the pump controller.
The display via an “SDO” will request these data from the pump controller that will respond with an “SDO”
via “Can Bus”.
The “PUMP” submenu is displayed pressing the “PUMP” button on the "DIAGNOSTICS" submenu.
It is possible to return to the “DIAGNOSTICS” submenu pressing the “EXIT” button.
99
The “STEERING” menu enables checking the signals sent by the steering controller.
The display via an “SDO” will request these data from the steering system controller that will respond with
an “SDO” via “Can Bus”.
The “STEERING” submenu is displayed pressing the “STEERING” button on the "DIAGNOSTICS" sub-
menu.
The “DIGITAL INPUTS MONITOR” allows you to check the status of the digital inputs.
Grey box with a 0 = INPUT OFF
Grey box with a 1 = INPUT ON
via “Can Bus”.
The “DIGITAL INPUTS MONITOR” submenu is displayed pressing the “DIGITAL INPUTS MONITOR” but-
ton on the "DIAGNOSTICS" submenu.
100
The “ANALOG INPUTS MONITOR” allows you to check the status of the analogue inputs.
via “Can Bus”.
The “ANALOG INPUTS MONITOR” submenu is displayed pressing the “ANALOG INPUTS MONITOR”
button on the "DIAGNOSTICS" submenu.
it is possible to return to the “DIAGNOSTICS” submenu pressing the “EXIT” button.
101
DESCRIPTION OF THE CLOCK AND DATE SETTING SCREEN
The “SET CLOCK & DATE” function allows you to set the current time and date.
Once you enter the sub-menu, the hours will flash. Use the numerical keys to set the correct time and
confirm with "OK". The minutes will now blink. Use the numerical keys to set the minutes and confirm with
"OK".
Now it is possible to set the date.
Then the next screen in which the day flashes is displayed. Use the numerical keys to set the day and
confirm with the "OK" button. Now the month will flash. Use the numerical keys to set the month and con-
firm with the "OK" button. Repeat the same operation for the year. After confirming with the “OK” button,
the screen exits automatically. The display via “SDO” will send these data to the VMC controller that will
respond with an “SDO” as confirmation. The VMC will have an RTC device with Backup.
NOTE: By pressing the “EXIT” button you can go back to the “USER MENU” screen at any time, but losing
the set data.
102
DESCRIPTION OF THE SOFTWARE VERSION SCREEN.
The "SOFTWARE VERSION" function allows you to check the versions of the software used.
via “Can Bus”.
NOTE: It is possible to return to the "USER MENU" by pressing the "EXIT" button at any time.
103
Description of the ALARMS SCREENS.
the alarms screen shows these four screens used for saving and displaying up to 32 different alarms that
have occurred while using the machine. They display:
• The code number of the type of alarm.
• The time when the alarm occurred.
• The number of times it has occurred.
• Identifier of the control on which the alarm occurred.
Once in the “ALARMS” sub-menu, the screen will appear with the first 8 alarms. Using the SCROLL
keys (Up and Down arrow), you can change the screens to be able to view all 32 alarms when they are
present.
via “Can Bus”.
NOTE: By pressing the "EXIT" function key, you can exit the screen at any time.
104
DESCRIPTION OF THE PARAMETERS SETTING SCREEN.
On these screens, the operator can modify the machine's drive performance, with the ability to lock it with
a password.
Once in the “PARAMETER SETTING” sub-menu, the screen shown below will appear.
By pressing in the parameters area shown in blue, you can select the parameter you want to change:
1. TRACTION SPEED from 1.00 km/h to 14.00 km/h
To change the above parameter, proceed as follows:
a) Press in the blue area that contains the current value of the parameter, this screen will appear.
b) Use the digital numerical keypad to enter a new value for the parameter and press.
c) Press the "OK" button to confirm.
105
2. ACCELERATION on a scale from 1 to 5.
Scale of settings Changes in performance
1 +1 Sec.
2 +0.5 Sec.
3 Standard Setting
4 -0.5 Sec.
5 -1 Sec.
3. INVERSION BRAKING on a scale from 1 to 5.
1 +0.5 Sec.
2 +0.2 Sec.
3 Standard Setting
4 -0.2 Sec.
5 -0.5 Sec.
4. RELEASE BRAKING on a scale from 1 to 5.
1 +0.5 Sec.
2 +0.2 Sec.
3 Standard Setting
4 -0.2 Sec.
5 -0.5 Sec.
106
To change the 3 parameters listed above (from 2 to 4), proceed as follows:
b) Select the desired value on the digital scale of permissible values for the parameter, and the “PA-
RAMETERS SETTING” menu is displayed again.
c) The parameter has been changed.
5. ENERGY SAVING from OFF to ON. If set ON, the machine traction and lifting performance will be
reduced to save battery power consumption. This function will be indicated by the “ECO” icon.
To modify the above parameter, proceed as follows:

a) Press in the blue area on the current value of the parameter.
b) Tap to change the parameter status (if it was “OFF” it will become “ON” and vice versa).
107
6. LOCK PARAM. from OFF to ON. If set ON, you will be prompted for a password to lock the set param-
eters.
To modify the above parameter, proceed as follows:

a) Press in the blue area that contains the current value of the parameter, now this screen will ap-
pear.
b) Enter the 4-digit password using the numerical keypad and press "OK" to confirm. The modified
parameters will now be locked and you are taken back to the “PARAMETER SETTING” screen
and the “LOCK PARAMETERS” value will be “ON”. Now, all the parameters are locked.
NOTE: If the user attempts to modify the parameters with the lock on, the screen for entering the
password will reappear.
108
DESCRIPTION OF THE SERVICE MENU SCREEN.

The “SERVICE MENU” function in the “USER MENU” allows to access functions that only the service can
change. Once pressed the “SERVICE MENU”button, the following screen will appear.
Enter the 4-digit password using the numerical keypad and press "OK" to confirm. If you enter the wrong
password, the screen shown below will appear for 5 seconds, after which the password prompt screen will
return.
NOTE: With the “SUPERVISOR PASSWORD” (default 5555) it is possible to access the “SERVICE
MENU”.
NOTE: By pressing the "EXIT" button, you can exit the screen at any time.
When the password is correct, the following screen will be displayed.
NOTE: By pressing the "EXIT" button, you can exit the screen and return to the user menu at any time.
109
DESCRIPTION OF THE ALARMS CLEARING SCREEN.

The “CLEAR ALARMS” function allows you to delete the alarms in the “ALARMS” menu
When this screen appears, the two possible options of “YES” and “NO” appear.
Pressing the “YES” button clears the saved alarms and displays the “SERVICE MENU" screen again.
Pressing the “NO” button exits without clearing the alarms and displays the “SERVICE MENU" screen
again.
With the "EXIT" button you exit without clearing the alarms.
DESCRIPTION OF THE UNIT OF MEASURE SETTING SCREEN.

The "UNIT OF MEASURE” function allows you to convert the following units of measurement simultane-
ously, as follows:
• km/h into mph (miles per hour)
• m into ft (feet)
• kg into lb (pounds)
From the service menu you can select the measurement systems available ("METRIC"/"ANGLO-AMER-
ICAN"), simply by pressing the blue box that displays the current value. After changing the current value,
the units of measure are converted by the display software. The metric system is present by default on
“Can Bus”.
NOTE: By pressing the "EXIT" function key, you can exit the screen at any time and go back to the "USER
MENU" screen.
110
DESCRIPTION OF THE HEIGHT SETTING SCREEN.

The “HEIGHT SETUP” function allows you to change the two fork adjustment values.
The first one, “RESET HEIGHT”, is the Reset value set for the height indicator.
The second one, “END STOP”, allows you to limit lifting the forks up to the set height.
The third one, “LIFT STOP 1”, allows you to set the first forks lifting interlocking to at the height set.
The fourth one, “LIFT STOP 2”, allows you to set the first forks lifting interlocking to at the height set.
In this screen, to change a parameter, press on one of the blue boxes that shows the current value of the
parameter.
Now the screen shows the following display:
Enter the desired parameter using the numerical keypad and then press "OK" to confirm. The "HEIGHT
SETUP" menu and the changed value is updated to the value entered.
The same procedure for changing the value applies to the second value “END STOP”, to the third value
“LIFT STOP 1” and to the fourth value “LIFT STOP 2”.
The display via an “SDO” will send these data to the VMC controller that will respond with an “SDO” via
“Can Bus”.
NOTE: By pressing the "EXIT" function key, you can exit the screen at any time and return to the “HEIGHT
SETUP” screen.
111
DESCRIPTION OF THE PARAMETERS ACQUISITION SCREEN.
On this screen you can acquire the electrical values of carriage all in, carriage all out, minimum load cell
value (with no load on the forks) and maximum load cell value (nominal load on the forks).
The first one, “REACH FULL FWD”, is the analogue value with carriage fully out.
The second one, “REACH FULL BACK”, is the analogue value with carriage fully in.
The third "MIN LOAD CELL" is the analogue value acquired of the load cell signal, with no weight on the
forks.
The four 'MAX LOAD CELL" is the analogue value acquired of the load cell signal, with the maximum
nominal weight on the forks provided for the truck.
To access to the acquisition of the minimum and maximum values of the carriage, press on one of the blue
boxes that display the current value of the parameter (for example "REACH FULL FWD").
The following screen will appear:
To acquire the carriage out, proceed in this way:

a) Move the lever of the mini-lever/joystick related to the carriage forward/backward function, up to the
maximum allowable desired carriage out position.
b) Press the "CONFIRM" button on the screen to acquire the value.
NOTE: Press the “ABORT” button to cancel the acquisition without storing the changed value.
NOTE: Press the “EXIT” button to exit the screen without storing the value.
112
To proceed with the acquisition of the carriage in, press on one of the blue boxes that display the current
value of the parameter in the "ACQUIRE PARAMETERS" menu and proceed as follows:
a) Move the lever of the mini-lever/joystick related to the carriage forward/backward function, up to the
desired carriage return position.
b) Press the "CONFIRM" button on the screen to acquire the value.
To access the acquisition of the minimum and maximum values of the load cell, press on one of the blue
boxes that display the current value of the parameter (for example "MIN LOAD CELL").
The following screen will appear:
Proceed as follows:
a) To acquire the value of the empty load cell, bring the forks at half height of the free lift.
b) Now press the "CONFIRM" button to acquire the value in volts of the load cell that will be indicatively
0 kg on the forks.
To access the acquisition of the maximum value of the load cell, press on one of the blue boxes that dis-
plays the current value of the parameter in the "MAX LOAD CELL” menu and proceed as follows:
a) Load on the forks the maximum nominal load provided for the carriage, raise the forks from the ground
with the nominal load.
Press the “CONFIRM” button on the screen to acquire the value in Volts relative to the weight.
113
DESCRIPTION OF THE OPERAOR ACCESS SCREEN.
This function is optional, therefore the display needs to be enabled via “PDO” to make it operative on the
truck. Once you select "OPERATOR ACCESS" in the "SERVICE MENU" the "OPERATOR ACCESS" sub-
menu is displayed:
Description of the options:

• “NEW” : creates a new operator enabled to use the truck.
• “MODIFY”: modifies an existing operator code.
• “DELETE”: deletes an existing operator code.
• “VIEW ALL”: displays all existing operator codes.
• “DELETE ALL”: deletes all the operator database present.
114
DESCRIPTION OF THE NEW ACCESS CODE PROGRAMMING SCREEN.
Pressing the "NEW" button, you can create a new user, and the following screen is displayed:
To enter the "PIN CODE" press in the blue area that displays the value. The following screen appears:
After entering the code with the digital numeric keypad press the "OK" button to return to the "NEW" menu.
Select the type of profile "USER/ADMIN" by simply pressing the blue box on the "ACCESS MODE" field.
With "USER" profile it is not possible to change the parameters in the "PARAMETERS SETTING" menu,
while with "ADMIN" you can do it.
If you want to set an operator profile for the pin code entered press the "SET PROFILE" button in the
"NEW" menu to enable the submenu shown below:
115
To change your guide profile, select in the blue box the parameter you want to change. You can change
the parameters in the following ranges:

2) ACCELERATION on a scale from 1 to 5.
3) INV. BRAKING on a scale from 1 to 5.
4) REL. BRAKING on a scale from 1 to 5.
To modify the “TRACTION SPEED” parameter, proceed as follows:

b) Use the digital numerical keypad to enter a new value for the parameter and press.
c) Press the "OK" button to confirm.
NOTE: By pressing the "EXIT" function key, you can exit the screen at any time, without storing the val-
ue.
116
To change the "ACCELERATION", "INVERSE BRAKING" and "RELEASE BRAKING" parameters the
procedure is the same for all three parameters.
Considering the parameter "ACCELERATION" as an example:
a) Press in the blue area that contains the current value of the parameter, this screen will appear:
b) Select the desired value on the digital scale of permissible values for the parameter, and once selected
the value the "NEW" menu is automatically displayed.
c) The parameter has been changed.
By pressing the "EXIT" function key, you can exit the screen at any time and the following screen is dis-
played:
Press the “YES” button to save the pin code created, press the “NO” button to exit without saving, press
the “EXIT” button to return to the “NEW” screen.
117
DESCRIPTION OF THE OPERATOR DATA MODIFICATION SCREEN

Pressing the "MODIFY" button, you can create a new user, and the following screen is displayed:
Enter the Pin to be changed (for example 3333) and then press the "OK" button. At this point the "NEW"
screen related to the code to be modified is displayed:
To change the code the procedure is exactly as in the "NEW" menu.
118
DESCRIPTION OF THE OPERATOR CODE DELETE SCREEN.

Press the "DELETE" button on the "OPERATOR ACCESS" menu to access the following screen:
Enter the 4-digit operator code using the digital numeric keypad and press "OK" to confirm the code to be
deleted. At this point the "OPERATOR ACCESS" menu is automatically displayed again and the operator
code cancellation can be checked by the "VIEW ALL" menu.
DESCRIPTION OF OPERATOR CODE READING SCREEN.

The "VIEW ALL" function allows you view the last 100 "USER/ADMIN" codes of who used the machine.
Using the two arrows (page Up and page Down) it is possible to scroll through the pages.
NOTE: By pressing the "EXIT" function key, you can exit the screen at any time.
119
DESCRIPTION OF THE ACCESS PIN CODES CLEARING SCREEN.

The “CLEAR ALL CODES” function allows you to clear the access codes, the operator code reading and
profile settings in the “VIEW ALL” menu.
Pressing the “YES” button clears the saved operator profiles and displays the “OPERATOR ACCESS"
screen again. Pressing the “NO” button exits without clearing the operator codes and displays the “OP-
ERATOR ACCESS" screen again.
NOTE: By pressing the "EXIT" function key, you can exit the screen at any time and return to the “OPERA-
TOR ACCESS” screen.
120
DESCRIPTION OF THE PRE-SELECTOR CONFIGURATION SCREEN

To configure the pre-selector press "HEIGHT PRESELECTOR" button on the "SERVICE MENU".
This displays the height pre-selector configuration screen as follows:
This displays the height pre-selector configuration screen as follows:
The two sub-menus are:

• "SET HEIGHTS" allows you to set the height of the different levels and areas.
• "CLEAR ALL HEIGHTS" allows you to delete all the pre-selector configuration data input.
121
DESCRIPTION OF THE PRESELECTOR - SET HEIGHTS CONFIGURATION SCREEN

If the “SET HEIGHTS” menu is selected the following screen appears:
To select the area to be configured, press one of the area selection buttons on the bar at the top of the
screen (by default after going into the menu the selected area is “AREA A”). For each of the 4 areas to be
configured there are 10 levels, for a total of 40 settable levels.
The options for each level are 2:

• With the "EDIT" button you can manually set the height, the following window is displayed with the
digital keypad that allows entering the height.
Once inserted the desired height to confirm press the "OK" button.
It is possible to return to the "SET HEIGHTS" submenu by pressing the "EXIT" button at any time.
122
• With the "AUTO" button is set the height of the selected layer in semi-automatic mode. Once you press
the button, the screen looks like this:
The height flashes at a frequency of 1.5 Hz and turns yellow, raising/lowering the forks it is therefore pos-
sible to set the level height.
Once positioned the forks as desired, press the "SAVE" button to save the height. It is possible to return to
the "SET HEIGHTS" submenu pressing the "ABORT" button at any time.
123
DESCRIPTION OF PRESELECTOR CONFIGURATION SCREEN - CLEAR ALL HEIGHTS

By pressing the "CLEAR ALL HEIGHTS" button in the "SET HEIGHTS" menu, the following screen ap-
pears:
By selecting the "YES" button all set levels are deleted..

Instead press the "NO" or "EXIT" buttons to return to the "HEIGHT PRESELECTOR" submenu.
124
DISPLAY SOFTWARE UPDATE.

Procedure for updating the display software.
1. Download the required files in a USB stick
2. Turn on the carriage
3. Pull the the USB cable from the connectors cover (see photo below) and insert the stick into the con-
nector.
4. Now the screen shows the following display:
5. Press "YES" if you want to apply the update to "NO" or "EXIT" to end the operation without executing
the software.
6. Once you click on "YES" the display updates and reboots.
7. Check in the USER menu under "SOFTWARE VERSION", that the software version was changed.
125
SOFTWARE SCREEN ALREADY UPDATED

If the SW is already updated the following screen appears:
Press "OK" and remove the USB stick
NOTE: By pressing the "EXIT" function key, you can exit the screen at any time and return to the main
screen.
126
NOTES
127
TRUCK FUNCTIONS
FORWARD/REVERSE TRACTION
CONTROLS
Brake pedal
Dead man pedal
Forward/reverse gear selection

button Accelerator pedal
To perform forward traction press the gear selection button upwards and press the accelerator while
keeping the dead man pedal depressed.
To perform reverse traction press the gear selection button downwards and press the accelerator
while keeping the dead man pedal depressed.
The driving speed is adjusted by the potentiometer on the accelerator pedal both going forwards
and backwards.
Devices involved status Symbol on diagram
Keyswitch ON
Emergency switch ON
Forward/reverse gear selection button enabled
Dead man pedal ON
Seat microswitch* ON
Seat belts fastened sensor* ON
Accelerator pedal forward/reverse traction
* where applicable
128
CONFIGURATION PARAMETERS
Main menu Config menu Config menu

parameter change adjustment set options
i min braking cutback speed load brake
i max braking cutback speed 2 battery check
VMC
pedal brk range seatbelt

seat switch
seat sw.combi
acceler. delay
release braking
tiller braking
invers. braking
ACE2 TRACTION
decel. braking
pedal braking
- -
speed limit brk.
curve speed 1
curve speed 2
max speed forw
max speed back
max speed limit
EPS
speed lim vs trac - -
For the adjustment values of each individual parameter, see the paragraph "standard
configuration of module parameters".
For a description of each individual parameter see "DESCRIPTION OF MODULE PARAM-
ETERS".
The maximum traction speed and acceleration can be set via the programmer.
Maximum forward and backward traction speed setting
ACE2 TRACTION / main menu parameter change / max speed forw
ACE2 TRACTION / main menu parameter change / max speed back
Setting the acceleration
AC2 TRACTION / main menu parameter change / acceler. delay
129
SPEED REDUCTION
There are two levels of speed reduction available on the machine.
• cutback speed first reduction in traction speed (7 km/h).
This trips when the height of the forks off the ground exceeds the free lift
(h2) or when the retractable carriage is fully out (the speed starts decreasing
when the carriage is over 100 mm out and falls in line with the movement of
the retractable carriage).
• cutback speed 2 second reduction in traction speed (4 km/h).

This trips when the height of the forks off the ground exceeds 9 metres (ap-
plicable only with the fork encoder option).
Setting of the speed reduction levels

VMC / config menu adjustment / cutback speed
VMC / config menu adjustment / cutback speed 2
DECELERATION WITH STEERING TRACTION WHEEL

This function reduces the maximum traction speed in proportion to the increase in the steering angle. The
dead zone within which deceleration does not trigger is between 0° and 5°.
Above 5° there is an initial slowdown (10 km/h) that remains steady if the steering angle is between 5°
and 20°. Above 20° a second deceleration triggers that increases as the steering angle increases. This
deceleration reaches a maximum of 6.5 km/h with the wheel turned 90°.
maximum speed with steering angle be- with steering angle be- with steering angle be-
tween 0° and 5° (non- tween 5° and 20°: set- tween 20° and 90°: de-
settable dead zone): table deceleration with celeration in proportion
maximum speed the parameter “curve to the steering angle
speed 1” that can be set with the
parameter “curve speed
2”
Setting deceleration with steering wheel between 5° and 20°

ACE2 TRACTION / menu parameter change / curve speed 1
Setting maximum deceleration with steering wheel 90°
ACE2 TRACTION / menu parameter change / curve speed 2
130
SPEED REDUCTIONS AND TRACTION BLOCK WITH “CHECK UP NEEDED” WARNING

When the programmed maintenance control is enabled, if it is not performed, depending on the parameter
values it is possible that the truck may first be subject to a reduction in speed and then to a traction block.
One can set what actions will occur to the truck via the programmer.
Setting the action that follows a maintenance warning.
VMC / main menu adjustment / check up type
0: no alarm
1: the alarm appears after 300 hours
2: the alarm appears after 300 hours and a reduction in speed takes
place after 340 hours
3: the alarm appears after 300 hours, a speed reduction takes place
after 340 hours and the traction is blocked after 380 hours
Once the programmed maintenance is performed, to reset the "check up needed" warming, one must set
the parameter:
Reset the hourmeter of the maintenance hours
VMC / main menu adjustment / check up done ON
SPEED REDUCTIONS AND BRAKING

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

When the level of the battery charge drops below 20% the traction speed is reduced to 24% of the maximum
speed. To restore initial operating conditions of the traction motor the battery must be recharged.
When the charge reaches 40% the low battery indicator is reset and the maximum current is restored on
the traction motor.
It is possible to set the behaviour of the truck with a flat battery.
Setting truck behaviour with a flat battery
VMC / config menu set options / battery check 0: no action
1: the BATTERY LOW alarm appears, the speed
is reduced to 24% of the maximum speed, the
maximum current on the motor is reduced by 50%
2: the BATTERY LOW alarm appears, no other
action
3: the BATTERY LOW alarm appears, the speed
is reduced to 24% of the maximum speed, fork lift-
ing block is enabled
131
TRACTION BLOCKS
Traction is disabled if the seated operator microswitch (optional) and the fastened seat belt sensor (op-
tional) are not active and if you fail to observe the sequence of operator seated → seat belt fastened.
it is possible to enable/disable the seated operator microswitch, the fastened seat belt sensor and the
correct sequence check via the programmer.
Enabling/disabling seat microswitch
VMC / config menu set options / seat switch
Enabling/disabling seat belts fastened sensor
VMC / config menu set options / seatbelt
Enabling/disabling correct sequence check
VMC / config menu set options / seat sw.combi
132
BRAKING
The truck is equipped with four braking systems:
• Release braking.
• Braking on direction reversal.
• Emergency braking.
• Parking brake
Tall machines are fitted with electromagnetic brakes on the load wheels that can be operated with the brake
pedal for safer braking.
Truck braking will be performed in different ways according to which of the above systems is implemented. For
further information on the braking systems see "BRAKING SYSTEMS" “BRAKING SYSTEM” section.
BRAKING SYSTEMS WHEN APPLIED
Release braking Traction control accelerator pedal release
Partial release braking Traction control accelerator pedal partial release
Braking on direction reversal Inversion of the direction of travel using the gear selection button
Through operation of the emergency button
Emergency braking Dead man pedal release
an alarm has been generated that requires traction to be halted im-

mediately
Parking brake The machine is stationary and no traction control is activated
Pedal brake Brake pedal pressure
It is possible to set the deceleration ramp of the various braking methods using the programmer.
Setting the deceleration ramp for release braking

ACE2 TRACTION / menu parameter change / release braking
Setting the partial release braking deceleration ramp
ACE2 TRACTION / menu parameter change / decel. braking
Setting the deceleration ramp for direction reversal braking
ACE2 TRACTION / menu parameter change / invers. braking
Setting the deceleration ramp for emergency braking
ACE2 TRACTION / menu parameter change / tiller braking
Setting the deceleration ramp for pedal braking
ACE2 TRACTION / menu parameter change / pedal braking
133
STEERING
CONTROLS
To steer to the right or to the left rotate the steering handwheel in the corresponding direction.
Devices involved status Symbol on diagram
Keyswitch ON
Emergency switch ON
Traction wheel auto-
Steering centring sensor centring sequence per-
formed
Small steering wheel rotation right/left
134
Main menu Config menu Config menu Config menu Config menu
parameter change special adjustment hardware settings set options adjustment
curve speed 1
TRACTION
curve speed 2
ACE2
speed limit debug output autoteaching aux output #1 set steer 0-pos
sensitivity aux output #2
EPS
sensitive vs trc
speed lim vs trc
ETERS".
The truck is equipped with a multi-turn steering system with a "stepper motor".
When switching on the key switch (S1), by means of the steering centring sensor (B7), the software auto-
centres the traction wheel.
135
STEERING
When a steering angle of 5° is exceeded the maximum traction speed is reduced.
STEERING SYSTEM CONFIGURATION

The steering motor rotation speed is inversely proportional to the traction speed, as the speed increases
the steering unit reaches the steering angle at an increasing speed.
It is possible to set the steering sensitivity reduction by reducing the steering speed at a given traction
speed for slow or fast steers.
Setting the steering motor speed reduction as the traction speed increases for slow rotation of the steering
handwheel
EPS ACW / menu parameter change / sensitive vs trc
Setting the steering motor speed reduction to the maximum traction speed for fast rotation of the steering
handwheel
EPS ACW / menu parameter change / speed lim vs trc
It is possible to set the speed of rotation of the steering motor according to the speed of rotation of the
handwheel (fast rotation and sensitivity with slow rotation)
Setting decrease in steering motor speed while reaching the position controlled by the steering system
EPS ACW / main menu parameter change / speed limit
Setting steering sensitivity
EPS ACW / main menu parameter change / sensitivity
136
FORK LIFTING/LOWERING
CONTROLS
Standard Joystick
Standard Version: to raise the forks, pull up the fork lifting/lowering lever, and to lower the forks,
push down the fork lifting/lowering lever.
Joystick Version: to raise the forks, pull the joystick backward, and to lower the forks, push the
joystick forward.
Devices involved status Abbreviation
Keyswitch ON
Emergency switch ON
Lever backward/forward
Fork lifting/lowering request Joystick backward/for-
ward
137

accel delay lift mlm deadband height indicator
decel delay lift mlm deadband end slow spd ffl ml
max lft sp limit joy. deadband lift limit stop
max low sp limit joy. deadb. end lower soft stop
i min evp1 offset fork 1 lift block
evp1 opn delay 1 lift limit blk m 2 lift block
evp1 opn delay 2 lift limit blk cm interlock forks
evp1 cls delay 1 ctb rng lift lmt interl. frk ovrd
evp1 cls delay 2 ctb spd lift lmt battery check
evp2 open delay low soft rng sp enc. lock test
evp2 close delay lower soft speed height selector
lft range ffl ml
VMC
lft slow ffl ml

low range ffl ml
low slow ffl ml
lft blk1 hght m
lft blk1 hght cm
lft blk2 hght m
lft blk2 hght cm
height p lft ctb
height p lft ctb r
height p low ctb
height p low ctb r
offset pick
offset place
ETERS".
The maximum fork lifting and lowering speed can be set with the programmer.
Setting the maximum fork lifting speed.
VMC / main menu parameter change / max lft sp limit
Setting the maximum fork lowering speed
VMC / main menu parameter change / max low sp limit
138
ACCELERATION / DECELERATION RAMPS

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

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

In the phase of lifting and lowering, the forks start slowing down in the transition between the free lift limit
stop and main lifting.
With the programmer it is possible to set the speed of deceleration and the distance off the ground where
the forks start slowing down.
Setting lifting speed
VMC / config menu adjustment / lft slow ffl ml
Setting deceleration distance when lifting
VMC / config menu adjustment / lft range ffl ml
Setting lowering speed
VMC / config menu adjustment / low slow ffl ml
Setting deceleration distance when lowering
VMC / config menu adjustment / low range ffl ml
These parameters are only considered by the software if the VMC / config menu set options
/ “height indicator” and “slow spd ffl ml” parameters are set to PRESENT
139
The forks start slowing down before reaching the maximum lifting height.
With the programmer it is possible to set the reduction in lifting speed and the distance where the forks
start slowing down.
Setting reduction in lifting speed
VMC / config menu adjustment / ctb spd lift lmt
Setting deceleration distance
VMC / config menu adjustment / ctb rng lift lmt
The maximum fork height is indicated in the VMC / config menu adjustment / “lift limit blk
m” and “lift limit blk cm” parameters according to the formula (lift limit blk m)x100 + (lift
limit blk cm).
The forks start slowing down before reaching the lowering limit stop.
With the programmer it is possible to set the speed of deceleration and the distance off the ground where
the forks start slowing down.
Setting deceleration speed
VMC / config menu adjustment / lower soft speed
Setting deceleration distance
VMC / config menu adjustment / low soft rng sp
FORK LIFTING/LOWERING BLOCKS (WITH FORK HEIGHT ENCODER)

There are two lifting blocks that can be set with the programmer.
Setting the maximum fork height of the first block
VMC / config menu adjustment / lft blk 1 hght m
VMC / config menu adjustment / lft blk 1 hght cm
Setting the maximum fork height of the second block
VMC / config menu adjustment / lft blk 2 hght m
VMC / config menu adjustment / lft blk 2 hght cm
The height is calculated according to the formula (lft blk 1 hght m)x100 + (lft blk 1 hght
cm).
140
HYDRAULIC FUNCTIONS
CONTROLS
Standard Joystick
Standard Version: to perform one of the hydraulic functions, pull/push the corresponding lever.
Joystick Version: to perform the carriage out function, move the joystick to the right, and to close
the carriage, move the joystick to the left. For the fork tilt function, move the mini-joystick up/down,
and for the fork side shift function, move the mini-joystick to the right/left.
Devices involved status Abbreviation
Keyswitch ON
Emergency switch ON
Lever backward/forward
Hydraulic request Joystick right/left

Mini-joystick up/down - right/
left
141

acc. delay reach mlm deadband autoc. sideshift
dec. delay reach mlm deadband end autoc. tilt
reach fw max spd joy. deadband 5th way hydraul.
reach rv max spd joy. deadb. end extended multif.
accel delay aux reach full fwd
decel delay aux reach full back
opt hyd max spd reach rng ctb ff
VMC
evp3 open delay reach rng ctb fb

evp3 close delay reach ctb speed
evp4 open delay reach ctb speedm
evp4 close delay
evp5 open delay
evp5 close delay
evp6 open delay
evp6 close delay
ETERS".
RETRACTABLE CARRIAGE ACCELERATION / DECELERATION RAMPS

On operating the carriage out/return lever, the carriage begins to move with an acceleration ramp that can
be set via the programmer.
Setting the carriage out/return acceleration ramp
VMC / main menu parameter change / acc. delay reach
On releasing the carriage out/return lever, the carriage begins to stop with a deceleration ramp that can be
set via the programmer.
VMC / main menu parameter change / dec. delay reach
The maximum carriage out and return speed can be set with the programmer.
Setting the maximum carriage out speed
VMC / main menu parameter change / reach fw max spd
Setting the maximum carriage return speed
VMC / main menu parameter change / reach rv max spd
142
CARRIAGE OUT / RETURN LIMIT STOP SLOWDOWN

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

On operating the lever of an auxiliary function (fork tilting or side shifting), the forks begin to move with an
acceleration ramp that can be set via the programmer.
Setting the auxiliary function acceleration ramp
VMC / main menu parameter change / accel delay aux
On releasing the lever of an auxiliary function (fork tilting or side shifting), the forks begin to stop with a
deceleration ramp that can be set via the programmer.
VMC / main menu parameter change / decel delay aux
FORK SELF-CENTRING
On pressing the button for the desired self-centring (side shifting, tilting), the forks begin to carry out the
desired self-centring procedure.
With the programmer it is possible to enable/disable these options.
Enabling fork side shift self-centring
VMC / config menu set options / autoc. sideshift
Enabling fork tilt self-centring
VMC / config menu set options / autoc. tilt
143
CONFIGURATION PARAMETER ACCESS PROCEDURE

Thanks to the CAN BUS connection the module parameters can be configured by connecting the console
to the connector in the control panel and accessing the relative menu.
Before connecting the console to the module, turn the keyswitch to “OFF”.
Each module is identified by a number. Thanks to the CAN BUS connection it is possible to configure the
parameters of the various modules by connecting the console and then searching for the relevant module
via the “SET MODEL” menu.
Before using the console to select the number of the module to configure, make sure that
the “model type” option of the control to which it is connected is on 0.
MODULE MODULE NUMBER MODEL TYPE
VMC 1 0
ACE2 TRACTION 2 0
ACE2 PUMP 5 0
EPS ACW 6 0
MENU SEARCH PROCEDURE and parameter modification
EPSWSM 1Q NA4.98
Opening heading
24V 50A 00000
Press the “Roll h” and “Set h” buttons simultane-

ously
The SET MODEL menu heading appears. If another

*CONFIG. MENU* menu is displayed, press the “Roll h” or “Roll i”
SET MODEL buttons until the SET MODEL menu appears.
Press “Enter”
144
CONNECTED TO The number corresponding to the module you are

6 connected to appears
Press the “Set h” or “Set i” buttons to edit the

selection of the module you wish to connect to
CONNECTED TO
The new selected module appears
2
Press the “Roll h” button to check the “model

type”
MODEL TYPE
The model type appears
1
Press the “Set h” or “Set i” buttons to scroll

through the “model type” to value 0.
MODEL TYPE
The model type of the selected module appears
0
Press the key "Out" to exit the selection.
ARE YOU SURE?

The modification confirmation request appears
YES=ENTER NO=OUT
Press the “Enter” button to confirm. If one doesn't

want to confirm the choice press the "Out"key.
145
*CONFIG. MENU* Having pressed the enter key the heading of the
SET MODEL SET MODEL menu appears.
Simultaneously press “Roll i”, “Out” and “Set i”
CONNECTED TO The display shows the connection to the selected

module for a moment
ACE2 TRACTION NA----
ACE2 TRACTION NA-.-- The selected module screen appears; here you can
configure the different parameters
1V 1A 0h
Press the “Roll h” and “Set h” buttons simultane-

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

SET MODEL
Press the “Roll h” or “Roll i” button until the de-

sired menu appears.
*CONFIG. MENU*
The SET OPTION menu heading appears.
SET OPTION
Press “Enter”
146
The heading of the first parameter with its current

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

value.
HOUR COUNTER
The new value appears.
KEY ON
ARE YOU SURE?

YES=ENTER NO=OUT

*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 head-

ing
EPSWSM 1Q NA4.98
Opening heading
24V 50A 00000
147
EPSWSM 1Q NA4.98
Opening heading
24V 50A 00000
Press the "Enter"key to enter the main menu
The PARAMETER CHANGE menu heading ap-

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

ACCELER. DELAY
value appears. To scroll through the parameters
LEVEL = 2.6 press “Roll h” or “Roll i”
Press the “Set h” or “Set i” buttons to modify the

value.
ACCELER. DELAY
The new value appears.
LEVEL = 3.0
ARE YOU SURE?

YES=ENTER NO=OUT

148
CDF file loading procedure

Requirements:
• Windows XP 32-64 bit, Windows 7 32-64 bit, not tested for Windows 8
Installation:
• Create a folder on your C: drive called C:\cdf_program
• Create a folder on your C: drive called C:\temp_cdf.
• Extract the files from the .zip file in the folder C:\cdf_program
The folder C:\cdf_program should contain two files:

1. ZAPI.EXE
2. cdf_upload_tool.exe
Use:
• Copy the CDF file, previously downloaded from the TRD website, in the folder C:\temp_cdf.
• Connect the IFAK cable to the connector of the carriage (X40).
• Run the file C:\cdf_program\cdf_upload_tool.exe.
• Enter the serial number of the carriage into the window and press "Enter"
149
The program looks for the CDF file in the folder C:\temp_cdf (DXXXT01401L_01.txt in this example)
If the file is found correctly, the CHK button is enabled.
Press the CHK button to continue
The program checks the syntax of the CDF file and the CAN communication.
Each error is reported and the update execution is stopped (see error list).
Correct the problem or exit.
150
If all checks are successful, the GO button is enabled
151
Press the GO button to start loading the CDF file.

The program loads the file and executes a rereading.
If the operation is successful, the window is restored to the initial conditions, with the field blank and the
buttons disabled.
Errors and corrections
Error code Definition and corrective action

OK
0
No action is required.
Parameters not correct
1
Ask for assistance to the Service
CDF file not found
2 Check that the file was saved in the folder C:\temp_cdf. If it is not present ask for assistance
by the Service.
CheckSum Error
3
The CDF file may be corrupt, report the problem to the Service.
Wrong IFAK configuration
4
Check the configuration of the IFAK and tray again.
Wrong CANbus configuration
5
Check the CANbus connection and switch on the carriage.
CAN master communication setting error.
6
Check the CANbus connection and switch on the carriage.
CDF file loading error.
7-8-9
Return to the Service
Serial number not matching
100
The CDF file refers to another carriage, loading is forbidden
Software running on the carriage is not valid for the CDF file
200
Check the software version on the carriage, contact the Service
Parameters not found
211
Contact the Service
152
STANDARD CONFIGURATION OF MODULE PARAMETERS

It is advisable to retain the factory settings seeing as they have been designed to achieve
the best compromise between performance and part wear and tear. It is however possible
to customise the performance to suit the customer's requirements, the characteristics of
the warehouse and the materials to be moved, but no parameters must be changed if this
jeopardises the safety of the truck.
“VCM” MODULE
VCM / main menu parameter change /
VCM / config menu special adjustment /
VCM / config menu hardware setting /
VCM / config menu set options /
VCM / config menu adjustment /
MAIN MENU PARAMETER CHANGE MAIN MENU PARAMETER CHANGE
PARAMETER level PARAMETER level

ACCEL DELAY LIFT 0,9 EVP5 OPEN DELAY 0.5
DECEL DELAY LIFT 0,5 EVP5 CLOSE DELAY 0.5
MAX LFT SP LIMIT 0,70 EVP6 OPEN DELAY 0.5
MAX LOW SP LIMIT 0,55 m/s EVP6 CLOSE DELAY 0.5
ACC. DELAY REACH 0,5
DEC. DELAY REACH 0,5
REACH FW MAX SPD 38 Hz CONFIG MENU Special Adjustment
REACH RV MAX SPD 24 Hz PARAMETER level
ACCEL DELAY AUX 0,1 PREMIUM DISPLAY PRESENT
DECEL DELAY AUX 0,1
OPT HYD MAX SPD 25 Hz
I MIN EVP1 20% CONFIG MENU Hardware Setting
I MIN BRAKING 25,1% PARAMETER level
I MAX BRAKING 100%
SET CONFIGURAT 0
EVP1 OPN DELAY 1 0,1
EVP1 OPN DELAY 2 0,6
EVP1 CLS DELAY 1 0,3
EVP1 CLS DELAY 2 0,6
EVP2 OPEN DELAY 0,8
EVP2 CLOSE DELAY 0,7
EVP3 OPEN DELAY 0,8
EVP3 CLOSE DELAY 0,9
EVP4 OPEN DELAY 1
EVP4 CLOSE DELAY 1
153
CONFIG MENU Set Option CONFIG MENU Adjustment

HOUR COUNTER RUNNING MLM DEADBAND 3%
BACKUP ALRM MODE LEVEL = 0 MLM DEADBAND END 0%
HEIGHT INDICATOR ABSENT JOY. DEADBAND 19%
SLOW SPD FFL ML ABSENT JOY. DEADB. END 22%
LIFT LIMIT STOP ABSENT OFFSET FORK 350
LOWER SOFT STOP ABSENT LIFT LIMIT BLK M 4
AUTOC.SIDESHIFT ABSENT LFT LIMIT BLK CM 95
AUTOC.TILT ABSENT CTB RNG LIFT LMT 500
WEIGHT ABSENT CTB SPD LIFT LMT 0,20 m/s
LASER ABSENT LOW SOFT RNG SP 550
LOAD BRAKE ABSENT LOWER SOFT SPEED 0,08 m/s
5TH WAY HYDRAUL. ABSENT LFT RANGE FFL ML 500
PIN ACCESS CODE ABSENT LFT SLOW FFL ML 0,40 m/s
SEATBELT ABSENT LOW RANGE FFL ML 250
SEAT SWITCH ABSENT LOW SLOW FFL ML 0,32 m/s
SEAT SW.COMBI ABSENT CUTBACK SPEED 7,0 Km/h
1 LIFT BLOCK ABSENT CUTBACK SPEED 2 4,0 Km/h
2 LIFT BLOCK ABSENT LFT BLK1 HGHT M 3
INTERLOCK FORKS ABSENT LFT BLK1 HGHT CM 0
INTERL. FRK OVRD ABSENT LFT BLK2 HGHT M 3
BATTERY CHECK LEVEL = 3 LFT BLK2 HGHT CM 50
TRANSFER HOURS LEVEL = 0 REACH FULL FWD 3,7 V
EXTENDED MULTIF. ABSENT REACH FULL BACK 0,5 V
ENC. LOCK TEST PRESENT REACH RNG CTB FF 11,4%
HEIGHT SELECTOR ABSENT REACH RNG CTB FB 15,3%
PALLET SENSOR ABSENT REACH CTB SPEED 14,9%
NEV1 ABSENT REACH CTB SPEEDM 50,2%
CHECK UP DONE ABSENT CUTBACK SPEED 3 7,0 Km/h
CHECK UP TYPE NONE MAX WGT CELL 4,4 V
OVERLOAD TEST PRESENT MIN WGT CELL 0,0 V
QUADRUPLEX ABSENT PEDAL BRK RANGE 50,2%
5TH WAY HYD SAFE ABSENT ADJUST BATTERY 49,58 V
BAT. MIN ADJ. LEVEL = 2
BAT. MAX ADJ. LEVEL = 1
WATCH HOURS 0h
154
CONFIG MENU Adjustment
PARAMETER level
WATCH MINUTES 0 min
HEIGHT P LFT CTB 0,07 m/s
HEIGHT P LFT CTB R 350 mm
HEIGHT P LOW CTB 0,08 m/s
HEIGHT P LOW CTB R 350 mm
OFFSET PICK 100 mm
OFFSET PLACE 100 mm
EXCHANGE VLV ON 800
“ACE2 TRACTION” MODULE

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

ACCELER. DELAY 2.6 HOUR COUNTER RUNNING
RELEASE BRAKING 2.2 M.C. FUNCTION ON
TILLER BRAKING 2.2 AUX OUT FUNCT.1 PRESENT
INVERS. BRAKING 1.9 AUX OUT FUNCT.2 PRESENT
DECEL. BRAKING 3 PULSE DIR INPUT OPTION #1
PEDAL BRAKING 0.3
SPEED LIMIT BRK. 2.8
CURVE SPEED 1 10.0 km/h
CURVE SPEED 2 6.5 km/h
MAX SPEED FORW 5.0 km/h
MAX SPEED BACK 5.0 km/h
MAX SPEED LIMIT 5.0 km/h
ACCEL DISPLAY 2.6
MAX SPEED DISP 5.0 km/h
REL BRK DISPLAY 2.2
INV BRK DISPLAY 1.9
155
“ACE2 PUMP” MODULE

ACE2 PUMP / config menu set option /
config menu set option
PARAMETER level
M.C. FUNCTION ON
AUX OUT FUNCT.1 ABSENT
AUX OUT FUNCT.2 ABSENT
“EPS ACW” MODULE

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

SPEED LIMIT LEVEL = 6 AUX OUTPUT #1 ABSENT
SENSITIVITY LEVEL = 3 AUX OUTPUT #2 ABSENT
SENSITIVI VS TRC 40%
SPEED LIM VS TRC 50%
config menu special adjustment
PARAMETER level
DEBUG OUTPUT 15
REV STEEL WHEEL OFF
config menu hardware setting
PARAMETER level
AUTOTEACHING OFF
0-POS TEACHING OFF
156
DESCRIPTION OF MODULE PARAMETERS

“VCM” MODULE 1
VCM / main menu parameter change /
VCM / config menu special adjustment /
VCM / config menu hardware setting /
VCM / config menu set options /
VCM/ config menu adjustment /
MAIN MENU PARAMETER CHANGE
PARAMETER level = 0 level = 9

ACCEL DELAY LIFT
Seconds. Determines the acceleration ramp during a lifting function. This parameter sets the time needed to
accelerate the pump motor from 0Hz to 100Hz
DECEL DELAY LIFT

Seconds. Determines the deceleration ramp when the lifting control has been lowered or not completely released.
This parameter sets the time needed to decelerate the pump motor from 100Hz to 0Hz
MAX LFT SP LIMIT

Defines the maximum lifting speed in m/s
MAX LOW SP LIMIT

Defines the maximum lowering speed in m/s
ACC. DELAY REACH

Seconds. Determines the acceleration ramp during a retractable function. This parameter sets the time needed to
accelerate the pump motor from 0Hz to 100Hz
DEC. DELAY REACH

Seconds. Controls the deceleration ramp when the retractable control has been lowered or not completely released.
This parameter sets the time needed to decelerate the pump motor from 100Hz to 0Hz
REACH FW MAX SPD

Defines the maximum speed of the pump motor during a retractable carriage out function
REACH RV MAX SPD

Defines the maximum speed of the pump motor during a retractable carriage in function
ACCEL DELAY AUX

Seconds. Determines the acceleration ramp during an auxiliary function (tilting or side shifting). This parameter sets
the time needed to accelerate the pump motor from 0Hz to 100Hz
DECEL DELAY AUX

Seconds. Controls the deceleration ramp when the auxiliary function control (tilting or side shifting) has been
lowered. This parameter sets the time needed to decelerate the pump motor from 100Hz to 0Hz
157

OPT HYD MAX SPD
Defines the maximum speed of the pump motor during the optional hydraulic 5th function
I MIN EVP1
From 0 to 100. This parameter determines the minimum current applied on EVP1 when the position of the control
is at the minimum (lowering)
I MIN BRAKING
From 0 to 100. This parameter determines the maximum current applied to the load wheel brakes when the position
of the control is at the minimum
I MAX BRAKING
From 0 to 100. This parameter determines the maximum current applied to the load wheel brakes when the position
of the control is at the maximum
EVP1 OPN DELAY 1

Seconds. Determines the acceleration ramp on EVP1.
EVP1 OPN DELAY 2

EVP1 CLS DELAY 1

Seconds. Determines the deceleration ramp on EVP1.
EVP1 CLS DELAY 2

EVP2 OPEN DELAY

EVP2 CLOSE DELAY

EVP3 OPEN DELAY

EVP3 CLOSE DELAY

158

EVP4 OPEN DELAY
EVP4 CLOSE DELAY

EVP5 OPEN DELAY

EVP5 CLOSE DELAY

EVP6 OPEN DELAY

EVP6 CLOSE DELAY

LEVEL 4 level = 0 level = 9

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

SET CONFIGURAT
1: with the NO CFG MASTER alarm it copies the EEPROM of the traction device to VCM
2: with the WRONG CONFIG alarm it copies from VCM to the traction device
3: with the WRONG CONFIG alarm it copies from the traction device to VCM
159
CONFIG MENU set options
PARAMETER level
KEY ON: record of truck start up
HOUR COUNTER RUNNING: record of an active trac-
tion request
Select the hourmeter mode
BACKUP ALRM MODE

LEVEL 0: Backup alarm disabled- LEVEL 1: the backup alarm is activated when the truck moves in reverse drive-
LEVEL2: the backup alarm is activated when the truck moves in forward drive LEVEL3: Backup alarm activated
when the truck moves in either forward or reverse drive
HEIGHT INDICATOR
This parameter enables the fork height indicator. When set to ON, the height encoder is managed by the VCM and
the fork height is shown on the display
SLOW SPD FFL ML

If set to PRESENT with HEIGHT INDICATOR, the lifting and lowering speed is automatically decreased in the
transition from FREE LIFT to MAIN LIFT
LIFT LIMIT STOP

If set to PRESENT with HEIGHT INDICATOR it enables blocking lifting at the maximum height
LOWER SOFT STOP

If set to PRESENT with HEIGHT INDICATOR the lowering speed is decreased before reaching the ground
AUTOC.SIDESHIFT
This parameter enables the side-shift self-centring option
AUTOC.TILT
This parameter enables the tilt self-centring option
WEIGHT
This parameter enables the weighing option
LASER
If set to PRESENT with HEIGHT INDICATOR the Laser is automatically activated on the FREE LIFT zone
LOAD BRAKE
This parameter enables the brakes of the load wheel
5TH WAY HYDRAUL.

This parameter enables the hydraulic 5th function
PIN ACCESS CODE

If set to PRESENT, a password will be required to enable the truck functions
160

SEATBELT
This parameter enables the seat belt presence switch
SEAT SWITCH
This parameter enables the seat presence switch
SEAT SW.COMBI
This parameter enables the sequence of the seat switch and then the seat belt switch
1 LIFT BLOCK
If set to PRESENT with HEIGHT INDICATOR it enables the first intermediate block
2 LIFT BLOCK
If set to PRESENT with HEIGHT INDICATOR and option 1 LIFT BLOCK it enables the second intermediate block
INTERLOCK FORKS
If set to PRESENT with HEIGHT INDICATOR it enables stopping fork lowering at a height of 600mm
INTERL. FRK OVRD

If set to PRESENT it is possible to by-pass the fork interlock with the override button
BATTERY CHECK
The battery charge level is checked:
0: no action
1: the BATTERY LOW alarm appears, the speed is reduced to 24% of the maximum speed, the maximum
current on the motor is reduced by 50%
2: the BATTERY LOW alarm appears, no other action
3: the BATTERY LOW alarm appears, the speed is reduced to 24% of the maximum speed, fork lifting
block is enabled
TRANSFER HOURS
LEVEL 1= if there is any discrepancy between the traction hour meter and VCM, an alarm is signalled and the value
on the traction is saved in the VCM
LEVEL 2= if there is any discrepancy between the traction hour meter and VCM, an alarm is signalled and the value
in the VCM is saved in the traction
EXTENDED MULTIF.
If set to PRESENT, three combined functions are permitted
ENC. LOCK TEST

Enables the diagnosis of “encoder locked” for encoder 1 and encoder 2. If the encoder is locked, an alarm is
generated and the pump stops
161

NEV1
Enables output No.1 of the voltage that controls the battery block relay
ON =programmed maintenance
performed
CHECK UP DONE
OFF = programmed maintenance
not performed
Maintenance programme performed when enabled. When set to ON at the end of the maintenance it resets the
maintenance hourmeter and the “CHECK UP NEEDED” warning
0: disabled
1: alarm after 300 hours
2: like 1 plus speed reduction after
CHECK UP TYPE
340 hours
3: like 2 plus truck block after 380
hours
Enables/disables the programmed maintenance mode and warning . At the end of maintenance set the parameter
VMC / config menu set options / check up done ON
HEIGHT SELECTOR
If set to PRESENT with HEIGHT INDICATOR the operator can control up to 40 levels for picking up and positioning
the load
PALLET SENSOR
When set to PRESENT with the height pre-selector, pallet presence is checked
config menu adjustment

MLM DEADBAND
Determines an unused band in the set point value of the mini-lever in the zero position
MLM DEADBAND END

Determines an unused band in the set point value of the mini-lever in the final position
JOY. DEADBAND
Determines an unused band in the set point value of the joystick in the zero position
JOY. DEADB. END

Determines an unused band in the set point value of the joystick in the final position
OFFSET FORK
This parameter defines the height of the forks off the ground when the encoder reset sensor is OFF just after the
cam
162

LIFT LIMIT BLK M
This parameter defines the maximum height of the forks off the ground in metres, where the lifting block is applied.
The limit is defined by the formula LIFT LIMIT BLK M + LIFT LIMIT BLK CM
LFT LIMIT BLK CM

This parameter defines the centimetres to add to LIFT LIMIT BLK M to define the maximum height of the forks off
the ground, where the lifting block is applied
CTB RNG LIFT LMT

Defines the distance from the LIFT LIMIT BLOCK height where the speed starts to be reduced
CTB SPD LIFT LMT

Defines the lifting speed reduction before the LIFT LIMIT BLOCK
LOW SOFT RNG SP

Defines the height off the ground where the lowering speed is set to LOW SOFT SPEED, if the LOW SOFT STOP
and HEIGHT INDICATOR options are activated
LOWER SOFT SPEED

Defines the lowering speed, when the LOW SPEED SOFT option is activated
LFT RANGE FFL ML

Defines the height of the forks off the ground, within which the lifting speed is reduced to LFT SLOW FFL ML in
the transition from FREE LIFT to MAIN LIFT, when the SLOW SPD FFL ML and HEIGHT INDICATOR options are
activated.
LFT SLOW FFL ML

Defines the lifting speed, when SLOW SPD FFL ML is activated
LOW RANGE FFL ML

Defines the height of the forks off the ground, within which the lowering speed is reduced to LOW SLOW FFL ML
in the transition from MAIN LIFT to FREE LIFT, when the SLOW SPD FFL ML and HEIGHT INDICATOR options
are activated.
LOW SLOW FFL ML

Defines the lowering speed in LOW RANGE FFL ML, when SLOW SPD FFL ML is activated
CUTBACK SPEED
Defines the first traction speed reduction.
CUTBACK SPEED 2
Defines the second traction speed reduction.
LFT BLK1 HGHT M

This parameter defines the maximum height of the forks off the ground in metres, where the lifting block 1 is applied.
The limit is defined by the formula LIFT BLK1 M + LIFT BLK1 CM
163

LFT BLK1 HGHT CM
This parameter defines the centimetres to add to LIFT BLK1 M to determine the height of the forks off the ground,
where the lifting block 1 is applied
LFT BLK2 HGHT M

This parameter defines the maximum height of the forks off the ground in metres, where the lifting block 2 is applied.
The limit is defined by the formula LIFT BLK2 M + LIFT BLK2 CM
LFT BLK2 HGHT CM

This parameter defines the centimetres to add to LIFT BLK2 M to determine the height of the forks off the ground,
where the lifting block 2 is applied
REACH FULL FWD
Value of the position sensor when the retractable carriage is in the fully out position
REACH FULL BACK

Value of the position sensor when the retractable carriage is in the fully in position
REACH RNG CTB FF

Defines the distance from the fully out position where REACH CTB SPEED is applied
REACH RNG CTB FB

Defines the distance from the fully in position where REACH CTB SPEED is applied
REACH CTB SPEED

Defines the retractable speed when speed reduction is applied
REACH CTB SPEEDM

Defines the retractable speed when speed reduction is applied during a combined function
MAX WGT CELL

Defines the maximum weight with the nominal load on the forks
MIN WGT CELL

Defines the maximum weight without the nominal load on the forks (0kg)
PEDAL BRK RANGE

Defines the value of the brake potentiometer at which VCM starts up to control the load wheel brakes
ADJUST BATTERY
Correct adjustment of the battery voltage measured by the control device
BAT. MIN ADJ.

Adjusts the lower level of the battery discharge table. It is used to calibrate the discharge algorithm with the
battery of the application.
164

BAT. MAX ADJ.
Adjusts the upper level of the battery discharge table. It is used to calibrate the discharge algorithm with the battery
of the application.
WATCH HOURS
Used to set the hour of the Real Time Clock
WATCH MINUTES
Used to set the minutes of the Real Time Clock
HEIGHT P LFT CTB

In PRESELECTOR mode, it defines the final lifting speed when the desired height is reached
HEIGHT P LFT CTB R

In PRESELECTOR mode, it defines the distance from the final height where HEGHT P LFT CTB is applied
HEIGHT P LOW CTB

In PRESELECTOR mode, it defines the final lowering when the desired height is reached
HEIGHT P LOW CTB R

In PRESELECTOR mode, it defines the distance from the final height where HEGHT P LOW CTB is applied
OFFSET PICK
In PRESELECTOR mode, it defines the offset to add to the desired final height during a pick-up operation
OFFSET PLACE
In PRESELECTOR mode, it defines the offset to add to the desired final height during a placement operation
CUTBACK SPEED 3
Defines the third traction speed reduction with carriage out.
EXCHANGE VLV ON
Defines the delay of the fork tilt/side shift valve
165
“ACE2 TRACTION” MODULE

ACE2 TRACTION / main menu parameter change /
ACE2 TRACTION / config menu set options /
PARAMETER level
ACCELER. DELAY
traction acceleration slope
RELEASE BRAKING
Release braking deceleration ramp
TILLER BRAKING
Deceleration ramp for emergency braking
INVERS. BRAKING
Direction reversal braking deceleration ramp
DECEL. BRAKING
Deceleration ramp with mini-lever released but not completely (partial release braking)
PEDAL BRAKING
Pedal braking deceleration ramp
SPEED LIMIT BRK.

Deceleration ramp when a speed limit is active
CURVE SPEED 1
Maximum traction speed when there is a speed reduction with the wheel turned more than between 5° and 20°
CURVE SPEED 2
Maximum traction speed with wheel turned 90°
MAX SPEED FORW

Maximum forward traction speed
MAX SPEED BACK

Maximum backward traction speed
MAX SPEED LIMIT

Maximum settable speed
166
PARAMETER level
ACCEL. DISPLAY
Maximum traction acceleration ramp that can be set with the display
MAX SPEED DISP

Maximum speed that can be set with the display
REL BRK DISPLAY

Maximum release braking deceleration ramp that can be set with the display
INV BRK DISPLAY

Maximum reverse braking deceleration ramp that can be set with the display
CONFIG MENU SET OPTIONS
PARAMETER level
KEY ON: record of truck start up
HOUR COUNTER RUNNING: record of an active re-
quest
Select the hourmeter mode
M.C. FUNCTION
OFF: no main contactor
ON: main contactor present
OPTION#1: traction + pump only 1 main contactor
OPTION#2: Traction + Pump 2 main contactors
AUX OUT FUNCT.1

When PRESENT is set the electromechanical brake is controlled after a traction request if all the relevant diagnosis
is passed.
If ABSENT is set, no diagnosis is performed and the brake is not closed after a traction request
AUX OUT FUNCT.2

When PRESENT is set the auxiliary coil is controlled after a traction request if all the relevant diagnosis is passed.
If ABSENT is set, no diagnosis is performed and the coil is not closed after a traction request
PULSE DIR INPUT

This parameter decides where there is the input for the forward/reverse traction request.
OPTION#1: the analogue input is on the mini-lever
OPTION#2: the digital inputs are on the joystick
OPTION#3: the two-state input is on the mini-lever
167
“ACE2 PUMP” MODULE

ACE2 PUMP / config menu set options /
PARAMETER level
M.C. FUNCTION
See M.C.FUNCTION traction
AUX OUT FUNCT.1

See AUX. OUT FUNCT.1 traction
AUX OUT FUNCT.2
See AUX. OUT FUNCT.2 traction

EPS ACW / main menu parameter change /
EPS ACW / config menu special adjustment /
EPS ACW / config menu hardware setting /
EPS ACW / config menu set option /
EPS ACW / config menu adjustments /
MAIN MENU parameter change
PARAMETER level
SPEED LIMIT
Determines the ratio between the handwheel rotation speed and the steering motor rotation speed, but only if
the handwheel is turned quickly. As the value of this parameter increases, the steering motor rotation speed is
increased
SENSITIVITY
Determines the ratio between the handwheel rotation speed and the steering motor rotation speed, but only if
the handwheel is turned slowly. As the value of this parameter increases, the steering motor rotation speed is
increased
SENSITIVE VS TRC
Reduction in steering sensitivity at the maximum traction speed due to slow rotation of the handwheel
SPEED LIM VS TRC

Reduction in steering sensitivity at the maximum traction speed due to fast rotation of the handwheel
168
PARAMETER level
DEBUG OUTPUT
This parameter is used to temporarily modify the truck configuration or inhibit some diagnoses to aid
troubleshooting.
Remember to take the value of this parameter back to level 15 after finishing with troubleshooting.
Level 0: auto-acquisition of the stepper motor offset in open cycle applications. It automatically returns to
level 15 after acquisition
Level 1: manual setting wheel 180°
Level 2-10: reserved
Level 11: disables the FB SENS LOCKED and MOTOR LOCKED alarms until this parameter is next
modified
Level 12-13: not used
Level 14: disables the FB SENS LOCKED and MOTOR LOCKED alarms. It automatically returns to level
15 after switching the truck back on
Level 15: standard value, no special function active
REV STEER WHEEL
PARAMETER level
AUTOTEACHING
This parameter set to ON runs the auto-acquisition procedure. Switching the truck off and back on again starts the
acquisition procedure. During this process the display shows the warning ENC PULSES ACQ. If the readings taken
are not consistent, they will not be saved and the display will show the message ACQ.ABORTED #1 or #2.
0-POS TEACHING
Determines the position of the steer wheel after self-centring.
config menu set option
PARAMETER level
AUX OUTPUT #1
Enables/disables the auxiliary function on pin 10
AUX OUTPUT #2
Enables/disables the auxiliary function on pin 14
config menu adjustments
PARAMETER level
SET STEER 0-POS.
Determines the position of the steer wheel after self-centring.
169
MODULES: INTRODUCTION
The module electronic system for AC motor control is composed of:
• “ACE2 INVERTER - traction” module for managing the AC traction motor
• “ACE2 INVERTER - pump” module for managing the AC pump motor
• “EPS ACW” module for managing the AC steering motor
• “VCM” module with graphic display for managing the various truck functions
The modules are connected and communicate through the CANBUS network, which allows access to truck
diagnostics or programming via PC.
The connector (X40 or X41) for the cable kit interface connection ("PC TOOL") is connected to the modules
and can be accessed from the control panel.
The modules are equipped with flash memory, which enables the software to be updated by connecting a
PC to the CANBUS network (Can flash).
POSITIONING OF THE "PC TOOL" CONNECTORS
PC interface cable kit

code 1534010
pc tool connector
170
“INVERTER ACE2” MODULE

Technical specifications:
Inverter for three-phase asynchronous AC motors
Regenerative braking functions
Digital control via microcontroller
Voltage: ........................................................................................24V - 36V - 48V - 80V - 96V
Maximum current (48V-350A):......................................................350A (RMS) for 3’
Maximum current (48V-400A):......................................................400A (RMS) for 3’
Current evaluation 1 hour (48V-350A)...........................................170A (RMS)
Current evaluation 1 hour (48V-400A)...........................................200A (RMS)
Operating frequency:.....................................................................8 kHz
Outside working temperature limits...............................................-30°C to 40°C
Maximum inverter temperature (at maximum power):...................75°
- BATT + BATT
U V W
171

The module is integrated in the steering motor.
Technical specifications:
Digital control by two microprocessors; both microprocessors connected via CAN Bus
Encoder interface
Interface for stepper motor
Analog input for thermal sensor
Operating frequency:.....................................................................8kHz with PWM aligned in the centre
Maximum inverter temperature:....................................................80°C
Protection:.....................................................................................IP65
U V W
+ BATT
- BATT
172
“VCM” MODULE
Functions:
BDI
Hour meter
Alarms
Performance
Height gauge
Technical specifications (standard version)

Voltage: ........................................................................................36-48V
Digital inputs (n°):..........................................................................7
Analog inputs (n°):.........................................................................2
Outputs supplied at 12V (no.)........................................................1
Outputs supplied at 5V (no.)..........................................................1
Protection......................................................................................IP65
Technical specifications (premium version):

Voltage: ........................................................................................36-48V
Digital inputs (n°):..........................................................................11
Analog inputs (n°):.........................................................................10
Outputs supplied at 12V (no.)........................................................1
Outputs supplied at 5V (no.)..........................................................2
Protection......................................................................................IP65
B A
173
REPLACEMENT OF MODULES: INSTRUCTIONS

The hours of operation of the truck are memorised on the “VCM” module and on the "ACE2
TRACTION" module. After replacing the “ACE2 TRACTION” module, it is necessary to
acquire the operating hours by loading them from the “VCM” module.
REPLACING THE "ACE2 INVERTER" MODULE

Equipment and tools
resistance 33 to 22 mm socket
T handle hex key large flat blade
100Ω 50W insu- wrench with
5 mm screwdriver
lated ratchet
13 mm
Procedure Fig. 1
Phase 1
5 mm T-handle hex key
Remove the rubber mat at the operator's feet inside the cab. Using the Fig. 2
T-handle hex key, unscrew and remove the screws securing the cover of
the electronic controls. Unscrew and remove the screw locking the bonnet, remove the electronic controls
cover and open the bonnet (fig.1).
Phase 2
RESISTOR
Using the screwdriver, remove the caps protecting the contacts.
Connect a resistor that can have a value of between 33 and 100 Ohm 50W between the positive (B+) and
negative (B-) of the module (fig.2).
Wait approximately 10 seconds for the internal capacitors to discharge and then disconnect the resistor.
To avoid short circuits, it is important that the resistor is isolated.
If it is not possible to use an external resistor to run down the capacitors, it will be necessary to wait at least
90 seconds before disconnecting the power cables.
174
Phase 3
socket wrench with ratchet size 13 mm - MEDIUM FLAT
BLADE SCREWDRIVER
Using the socket wrench and ratchet unscrew and remove the screws B
fastening the electric cables, fuse, copper connecting bars and power
cables. Unscrew and remove the nut fastening the fuse too.
Mark the electric cables and the copper bars for reassembly and discon-
nect them. Disconnect the connector. A
Fig. 3
Phase 4
5 mm FLEXIBLE T-HANDLE HEX KEY
Unscrew the four screws fastening the module to the panel (ref.A fig.3).
Extract the module and remove it.
Recover the fuse (ref.B fig.3) and proceed with the replacement.
CONFIGURATION
ADAPTER - PROGRAMMER OR CONSOLE
Connect the adaptor to the “PC TOOL" connector.
Connect the USB connector of the interface cable to the USB port on the PC.
Connect the battery and switch on the truck (starter key to ON). Start the PC Tool programme.
Create a new configuration and copy the factory configuration or a customised configuration.
SETTING THE BATTERY VOLTAGE

Carry out the procedure for setting the battery voltage. See “SETTING THE BATTERY VOLTAGE” section
“INSTALLATION AND SETTINGS”.
ACQUISITION OF OPERATING HOURS “acE2 traction” module

The hours of operation of the truck are memorised on the “VCM” module and on the "ACE2 TRACTION"
module.
On ignition the system assesses the hours recorded on both modules. If the difference is greater than 20
hours the “hm mismatch” alarm appears and all the truck functions are disabled. After 2 minutes the higher
value is saved on both modules and all the truck functions are restored.
175
REPLACEMENT OF THE “EPS ACW” MODULE

Equipment and tools
Fig. 1
resistance 33 to open-ended span-

T handle hex key medium cross-
100Ω 50W insu- ner
5-6 mm head screwdriver
lated 8 mm
Procedure
Before starting work, ensure that you are wearing suitable A
Phase 1
Use the T-handle hex key to unscrew and remove the motor cover screw
(ref.A fig.1).
Completely open the cover (fig.2). Fig. 2
Phase 2 Fig. 3
RESISTOR
Connect a resistor that can have a value of between 33 and 100 Ohm
50W between the positive (B+) and negative (B-) of the module (fig.3).
Wait approximately 10 seconds for the internal capacitors to discharge
and then disconnect the resistor.
To avoid short circuits, it is important that the resistor is

isolated.
If it is not possible to use an external resistor to run down the capacitors,

it will be necessary to wait at least 90 seconds before disconnecting the
power cables.
176
Phase 3
Fig. 4
8 mm open ended spanner
Using the open ended spanner, unscrew and remove the screws fasten- B
ing the electrical cables and fuse. Disconnect the connector.
Phase 4
MEDIUM CROSSHEAD SCREWDRIVER - 6 mm T-HANDLE HEX
KEY
With the screwdriver, unscrew and remove the screws fastening the upper
cover of the electrical box (ref.B fig.4). Remove the cover.
Unscrew and remove the three fastening screws of the motor phase
terminals (ref.C fig.5).
Unscrew and remove the fastening screws of the EPS module (ref.D Fig. 5
fig.6). Remove the module and proceed with replacement.
C
CONFIGURATION
Connect the USB connector of the interface cable to the USB port on
the PC.
Connect the battery and switch on the truck (starter key to ON). Start the
PC Tool programme.
Create a new configuration and copy the factory configuration or a cus-
tomised configuration.
D
Fig. 6
177
“VCM” MODULE REPLACEMENT

Equipment and tools
Fig. 1
T handle hex key medium cross-

4-5 mm head screwdriver
Procedure
Phase 1
5 mm T-HANDLE HEX KEY - MEDIUM CROSSHEAD SCREWDRIV-
ER
Fig. 2
(ref.A fig.1).
Using a crosshead screwdriver, unscrew the panel fixing screw to access
the VCM control (ref.B fig.3).
Phase 2
Disconnect the module connector. B
Using the T-handle hex key, unscrew the screws securing the module
to the carriage (ref.C fig.4). Remove the module and proceed with re-
placement.
CONFIGURATION Fig. 3

Connect the USB connector of the interface cable to the USB port on
the PC.
Connect the battery and switch on the truck (starter key to ON). Start the
PC Tool programme.
Create a new configuration and copy the factory configuration or a cus-
tomised configuration.
178
SETTING THE BATTERY VOLTAGE

Fig. 4
Carry out the procedure for setting the battery voltage. See “SETTING
THE BATTERY VOLTAGE” section “INSTALLATION AND SETTINGS”.
C
ACQUISITION OF “VCM” module OPERATING HOURS
The hours of operation of the truck are memorised on the “VCM” module
and on the "ACE2 TRACTION" module.
On ignition the system assesses the hours recorded on both modules. If
the difference is greater than 20 hours the “hm mismatch” alarm appears
and all the truck functions are disabled. After 2 minutes the higher value
is saved on both modules and all the truck functions are restored.
179
REMOVAL OF ELECTRICAL COMPONENTS

REPLACEMENT OF ENCODER
Equipment and tools
open-ended
socket wrench
ladder safety harness spanner ratchet
7 mm
7-8 mm
2 x 10 mm
Procedure
Phase 1
Using the controls in the cab, make the retractable carriage come fully
out (fig.1).
Remove the hydraulic control valve cover to facilitate the disassembly
procedure (fig.2).
REMOVING THE FREE LIFT ENCODER
Phase 2
7 mm OPEN ENDED SPANNER - 7 mm SOCKET WRENCH - RATCHET
- 8 mm open ended spanner
Using the 7 mm spanner, lock the nut securing the encoder wire (ref.A Fig. 2
fig.5). Using the socket wrench and the ratchet, unscrew and remove
the screw securing the encoder wire (ref.B fig.5).
With the 8 mm open ended spanner, unscrew and remove the screws
securing the encoder (ref.C fig.3). Remove the encoder and proceed
with replacement.
180
REMOVING THE MAIN LIFT ENCODER
Phase 2
ladder - safety harness - 7 mm OPEN ENDED SPANNER - No.2 x 10 mm open ended span-
ners
Using the 7 mm spanner, lock the nut securing the encoder wire (ref.D fig.8). Using the socket wrench and
the ratchet, unscrew and remove the screw securing the encoder wire (ref.E fig.8).
Climb up the ladder with the tools and secure the safety harness to the cab.
Using one 10 mm open ended spanner lock the nut securing the encoder (ref.F fig.6), while with the other
open ended spanner unscrew and remove the screw fastening the encoder (ref.G fig.6). Remove the en-
coder and proceed with replacement.
Fig. 3 Fig. 4
C
A
B
Fig. 5
Fig. 6
E
D
F G
Fig. 7 Fig. 8
181
ENCODER RESET SENSOR REPLACEMENT

Equipment and tools
open ended
spanner
2 x 28 mm
Procedure
Fig. 1
Phase 1
out (fig.1).
Phase 2
2 x 28 mm OPEN ENDED SPANNERS
Loosen the ring nuts fastening the sensor to the support plate (fig.3).
Disconnect the connector, unscrew the sensor and proceed with replace-
ment. Fig. 2
Fig. 3
182
LOAD CELL REPLACEMENT

Equipment and tools
Fig. 1
wooden beam taper end pliers
Procedure
of other vehicles and pedestrians. Lower the forks to the
ground.
Phase 1
out (fig.1).
Phase 2
WOODEN BLOCK Fig. 2
Raise the forks just enough to be able to pass the wooden block under-
neath.
Place the wooden block under the forks (fig.2). Lower the forks to rest
on the block and continue until the end stroke of the cylinder.
Position the key switch to OFF and disconnect the bat-

tery. A
Phase 3
TAPE END PLIERS
Fig. 3
Using the taper end pliers remove the cotter pins and the hinge pins secur-
ing the load cell to the chain and to the fork mast (ref.A fig.3). Disconnect
the connector, remove the load cell and proceed with replacement.
ASSEMBLY
Do not reuse the chain anchoring safety pins, use new

cotter pins, ensuring they are the correct size.
183
REPLACEMENT OF THE HORN

Equipment and tools
open ended
T handle hex key Allen key
spanner
5 mm 6 mm
13 mm
Procedure
Fig. 1
Fig. 2
A
Phase 1
B
Remove the rubber mat at the operator's feet inside the cab. Using the
the electronic controls. Unscrew and remove the screw locking the bonnet,
remove the electronic controls cover and open the bonnet (fig.1).
Phase 2
FIXED 13 mm SPANNER - 6 mm ALLEN KEY
Using the open ended spanner, counterhold the nut (ref.A fig.2), and
with the bent Allen key unscrew and remove the screw securing the horn
(ref.B fig.2).
Disconnect the connectors, remove the horn and proceed with replace-
ment.
INSTALLATION
Before connecting them again, make sure the Faston con-

nectors are suitably tight. If not, tighten the connectors
with Faston pliers.
184
REPLACEMENT OF THE CONTACTORS

Equipment and tools
open ended
T handle hex key medium flat blade
spanner
4-5 mm screwdriver
13 mm
Procedure Fig. 1
Phase 1
T-handle hex key, unscrew and remove the screws securing the cover of A
Fig. 2
Phase 2
MEDIUM FLAT BLADE SCREWDRIVER - 13 mm OPEN ENDED SPAN-
NER
Using the open ended spanner unscrew and remove the nuts fastening B
the electrical cables and copper bar to the contactor (ref.A fig.2).
Disconnect the cables and connectors, noting down their position to make
assembly easier.
Fig. 3
Phase 3
Using the T handle hex key, unscrew and remove the screws securing
the contactor (ref.B fig.3).
Remove the contactor and proceed with replacement.
185
FUSE REPLACEMENT
• 2A fuse key relay (F3)
• 10A fuse emergency push-button and contactors (F1)
• 10A fuse contactors (F2)
• power fuse traction controller (F4)
• power fuse pump controller (F5)
• power fuse steering controller (F6)
Equipment and tools
medium/large 22 mm socket open-ended

medium flat blade T handle hex key
crosshead screw- wrench with spanner
screwdrivers 5 mm
driver ratchet 8 mm
13 mm
Procedure
transit of other vehicles and all pedestrians. Set the key
switch to OFF and disconnect the battery.
A
A A
FUSES F1,F2,F3
Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER
Using the screwdrivers, unscrew and remove the screws fastening the
panel located under the control panel (ref.A fig.1).
Remove the panel.
Phase 2
Remove the desired fuse from the control board (fig.2) and proceed with
replacement.
Fig. 2
186
POWER FUSE F6
Fig. 3
Phase 1
(ref.B fig.3).
Phase 2
B
Using the open ended spanner, unscrew and remove the nuts fastening
the fuse (ref.C fig.5). Remove the fuse and proceed with replacement.
POWER FUSES F4,F5
Phase 1
the electronic controls. Unscrew and remove the screw locking the bonnet, Fig. 4
Fig. 5
Phase 2
socket wrench with ratchet size 13 mm - MEDIUM FLAT
BLADE SCREWDRIVER C
Using the socket wrench and the ratchet, unscrew and remove the
screws securing the fuse (ref.D fig.6). Remove the fuse and proceed
with replacement.
Fig. 6
187
REPLACEMENT OF THE MOTOR COMPARTMENT COOLING FAN

Equipment and tools
Fig. 1
medium/large 22 mm socket
T handle hex key T handle hex key
crosshead screw- wrench with
5 mm 4 mm
driver ratchet
13 mm
Procedure
protective clothing. A
MOTOR COMPARTMENT FAN

Fig. 2
Phase 1
T-HANDLE HEX KEY 5 mm Fig. 3
(ref.A fig.1).
Phase 2
Using the flexible T-handle hex key, unscrew and remove the screws
securing the fan bracket (ref.B fig.4).
Remove the bracket together with the fan, disconnect the connector and
Fig. 4
188
ADDITIONAL TRACTION MOTOR FAN

Fig. 5
Phase 2
Using the flexible T-handle hex key, unscrew and remove the screws
securing the fan bracket (ref.C fig.6).
Remove the bracket together with the fan, disconnect the connector and
Fig. 6
189
REPLACEMENT OF ARMREST AND MAIN PANEL CONTROLS:

• keyswitch
• buttons
• main emergency switch
• steering handwheel stepper motor
• joystick
• mini-levers
• display
Equipment and tools
Fig. 1
hexagonal "T" medium/large

section spanner crosshead screw-
small/medium flat
Torx key
A
blade screwdriver
1.5-3 mm driver
A A
hex bit socket

open-ended B
ratchet spanner C spanner
10-13 mm
7-10-13-14 mm
Procedure
switch to OFF and disconnect the battery. Fig. 3
KEY SWITCH (version with premium display)
Phase 1
Remove the panel.
190
Phase 2
Fig. 4
Remove the key switch.
C
Unscrew the nut (ref. B fig.2), remove the switch block from the console
(fig.3).
Disconnect the wiring connectors and proceed with the replacement.
INSTALLATION
Before connecting them again, make sure the Faston con-

nectors are suitably tight. If not, tighten the connectors
with Faston pliers.
Fig. 5
DASHBOARD PUSH-BUTTONS
D
Phase 1
Fig. 6
Remove the panel.
E
Phase 2
LARGE CROSSHEAD SCREWDRIVER - 10 mm open ended spanner
Use the screwdriver and the open ended spanner to unscrew and remove
the screws fastening the dashboard (ref.C-D fig.4-5).
Turn over dashboard.
Phase 3
Use the screwdriver and the open ended spanner to unscrew and remove
the screws fastening the dashboard (ref.C-D fig.4-5).
Fig. 7
Phase 4
14 mm open ended spanner Fig. 8
For the round buttons, use the open ended spanner to loosen the ring
nut locking the button (ref.E fig.6). Unscrew and remove the button,
disconnect the connectors and proceed with replacement.
For the rectangular buttons, press the tabs at the sides of the buttons
(fig.8). Extract the button, disconnect the connectors and proceed with
replacement.
191
ARMREST BUTTONS
Fig. 9
Phase 1
Using the controls in the cab, move the retractable carriage fully against
the battery.
Pull up the lever in front of the throttle pedal board next to the bonnet so
as to free the battery.
out together with the battery.

Fig. 10
Using the open ended spanner unscrew and remove the nuts fastening
the armrest from the battery compartment (ref.F fig.10).
Remove the armrest and turn it over.
F
Phase 2
MEDIUM PHILIPS SCREWDRIVER
Using the screwdriver, unscrew and remove the screws fastening the
lower cover of the armrest (ref.G fig.11).
Remove the cover. Fig. 11
Phase 3
Use the screwdriver to unscrew and remove the fastening screws of the
G H
electronic board (ref.H fig.11).
Remove the cover.
Phase 4
For the round buttons of the auxiliary functions, use the open ended
spanner to loosen the ring nut locking the button (ref.E fig.6). Unscrew
and remove the button, disconnect the connectors and proceed with
replacement.
For the horn and direction of travel buttons, press the tabs at the sides
Fig. 12
of the buttons (fig.12). Extract the button, disconnect the connectors and
192
MAIN EMERGENCY SWITCH

Fig. 13
Phase 1
the battery.
out together with the battery.

Fig. 14
Using the open ended spanner unscrew and remove the nuts fastening
the armrest from the battery compartment (ref.I fig.14).
Remove the armrest and turn it over.
I
Phase 2
Using the screwdriver, unscrew and remove the screws fastening the
lower cover of the armrest (ref.J fig.15). Fig. 15
Remove the cover.
Phase 3 J
C SPANNER FOR SELF-LOCKING RING NUTS - SMALL FLAT BLADE
SCREWDRIVER
Using the C spanner, unscrew and remove the self-locking ring nut of
the emergency button (ref.K fig.16). Using the small screwdriver, free
the tabs of the push-button (fig.16), remove the button, disconnect the
connectors and proceed with replacement.
Fig. 16
K
193
STEERING HANDWHEEL STEPPER MOTOR

Fig. 17
Phase 1
l
panel located under the control panel (ref.L fig.17).
Remove the panel. l l
Phase 2
small flat blade screwdriver - 13 mm hex socket wrench
- ratchet Fig. 18
Using the flat blade screwdriver, remove the cover located over the
M
handwheel (ref.M fig.18). N
Using the socket wrench and the ratchet, unscrew and remove the screw
securing the handwheel to the assembly (ref.N fig.18). Remove the
handwheel.
Phase 3
Use the screwdriver to unscrew and remove the screws of the covers of
the steering handwheel assembly (fig.19).
Remove the two covers.
If there is any difficulty in unscrewing the upper screws

under the control panel, remove the dashboard.
Phase 4
7 mm open ended spanner - 1.5-3 mm T-HANDLE HEX KEY
Using the 1.5 mm T-handle hex key unscrew and remove the grub screw Fig. 19
(ref.O fig.20).
Using the open ended spanner hold the nut firm (ref.P fig.20), with the
T-handle hex key unscrew and remove the screw fastening the stepper Fig. 20
motor to the bearing block (ref.Q fig.20).
P
Remove the motor and proceed with replacement. O
194
JOYSTICK
Fig. 21
s
Phase 1
SMALL FLAT BLADE SCREWDRIVER - 10 mm HEX SOCKET
WRENCH - ratchet
Using the small screwdriver, remove the cover under the joystick (ref.R
fig.21).
Using the socket wrench and the ratchet, unscrew and remove the screws
securing the joystick to the armrest (ref.S fig.21). Remove the joystick R
and proceed with replacement or disassembly.
MINI-LEVERS
Fig. 22 T
Phase 1
TORX KEY
Using the Torx key, unscrew and remove the screws fastening the mini-
lever (ref.T fig.22).
Remove the mini-lever and proceed with replacement.
STANDARD DISPLAY
Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER - medium flat
blade screwdriver
Remove the panel.
Disconnect the connector from the display. Using the flat blade screw-
driver, prise on the lower tab of the display (fig.23), put outwards and
remove.
Fig. 23
195
PREMIUM DISPLAY
Fig. 24
Phase 1
MEDIUM/LARGE CROSSHEAD SCREWDRIVER - 10 mm HEX SOCKET
WRENCH - RATCHET
Using the screwdrivers, unscrew and remove the screws fastening the U
Remove the panel.
Disconnect the connector from the display. Using the socket wrench and
ratchet, unscrew and remove the lock nut on the rear of the display (ref.U
Fig.24). Remove the display outwards.
196
SIDE SHIFT POSITION SENSOR REPLACEMENT

Equipment and tools
open ended
spanner
2 x 28 mm
Procedure
Fig.1
Phase 1
Unscrew the ring nuts fastening the sensor to the support plate (ref.A
fig.2).
Disconnect the connector, unscrew the sensor and proceed with replace-
ment.
A
Fig.2
197
PALLET PRESENCE SENSOR REPLACEMENT

Equipment and tools
Fig.1
external circlip Allen key

pliers 2-3 mm
Procedure
Phase 1
SMALL EXTERNAL CIRCLIP PLIERS Fig.2
Use the pliers to remove the two circlips securing the pin of the plate with
the cam (ref.A fig.2). Remove the pin and the plate.
Phase 2
2-3 mm ALLEN WRENCH
Using the 2 mm Allen wrench, unscrew the grub screw securing the sen-
sor (ref.B fig.3). Using the 3 mm Allen wrench, unscrew and remove the
screws securing the sensor bracket (ref.C fig.3).
Unscrew the sensor, disconnect the connector and extract it inside the C
liner. Proceed with replacement B
C
Fig.3
198
TILT POSITION SENSOR REPLACEMENT

Equipment and tools
Fig.1
open-ended
spanner
8 mm
2 x 28 mm
Procedure
keyswitch to OFF and disconnect the battery. A
Phase 1
8 mm OPEN ENDED SPANNER Fig.2
Using the open ended spanner loosen the screws securing the bracket
of the sensor (ref.A fig.2).
Disconnect the connector, remove the bracket together with the sensor
B
Phase 2
Loosen the ring nuts fastening the sensor to the support plate (ref.B
fig.3).
Unscrew the old sensor and fit the new one.
Fig.3
199
90° WHEEL SENSOR AND STEERED WHEEL SENSOR REPLACEMENT

Equipment and tools
Fig. 1
open-ended
T handle hex key
spanner
5 mm
16 mm
Procedure
protective clothing. A
Phase 1
Remove the rubber mat at the operator's feet inside the cab. Using the Fig. 2
T-handle hex key, unscrew and remove the screws securing the cover
of the electronic controls. Unscrew and remove the screw locking the
bonnet (ref.A fig.1), remove the electronic controls cover and open the Fig. 3
bonnet (fig.2).
Phase 2
With the open ended spanner, unscrew the ring nut securing the sensor
to the supporting plate (ref.B fig.4).
Disconnect the connector, unscrew the sensor from the supporting plate
and proceed with replacement.
Fig. 4
200
BATTERY OUT SENSOR REPLACEMENT

Equipment and tools
open-ended
T handle hex key
spanner
5 mm
16 mm
Procedure
Fig. 1
Move the carriage to a safe place, away from areas of Fig. 2
Phase 1
the electronic controls. Unscrew and remove the screw locking the bonnet, Fig. 3
Phase 2
10mm OPEN ENDED SPANNER A
Using the open ended spanner, unscrew and remove the nut securing
the sensor bracket (ref.A fig.3).
Disconnect the connector, remove the bracket together with the sensor
Fig. 4
Phase 3
Loosen the ring nuts fastening the sensor to the support plate (ref.B
fig.4).
Unscrew the old sensor and fit the new one.
B
201
OPERATOR PRESENCE PEDAL REPLACEMENT

Equipment and tools
open ended
T handle hex key
spanner
5 mm
7 mm
Procedure
Fig. 1
Phase 1 A
Phase 2
7 mm OPEN ENDED SPANNER
Using the open ended spanner, unscrew and remove the screws fasten-
ing the operator presence pedal (ref.A fig.2).
Remove the pedal and proceed with replacement.
202
ACCELERATOR AND BRAKE PEDALS REPLACEMENT

Equipment and tools
open ended
T handle hex key
spanner
5 mm
13 mm
Procedure
Fig. 1
Phase 1
5 mm T-handle hex key A
Phase 2
13 mm OPEN ENDED SPANNER - 5 mm T-HANDLE HEX KEY
Using the open ended spanner, counterhold the nuts (ref.A fig.2), and
with the T-handle hex key unscrew and remove the screws securing the
pedal (ref.B fig.2).
Remove the pedal and proceed with replacement.
203
204
SERVICE HYDRAULIC SYSTEM
Hydraulic system
HYDRAULIC FUNCTIONS�� 3
HYDRAULIC DIAGRAMS�� 4
symbols�� 4
MAIN HYDRAULIC DIAGRAM�� 5
HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS�� 8
SOLENOID VALVE OPERATION CHART�� 8
HYDRAULIC FORK LIFTING DIAGRAM�� 9
HYDRAULIC FORK LOWERING DIAGRAM�� 10
HYDRAULIC RETRACTABLE CARRIAGE OUT DIAGRAM�� 11
HYDRAULIC RETRACTABLE CARRIAGE IN DIAGRAM�� 12
HYDRAULIC FORK UPWARD TILTING DIAGRAM�� 13
HYDRAULIC FORK DOWNWARD TILTING DIAGRAM�� 14
HYDRAULIC FORK LEFT SIDE SHIFT DIAGRAM�� 15
HYDRAULIC FORK RIGHT SIDE SHIFT DIAGRAM�� 16
HYDRAULIC EMERGENCY LOWERING DIAGRAM�� 17
HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE�� 18
HYDRAULIC COMPONENTS �� 20
HYDRAULIC COMPONENT IDENTIFICATION�� 20
DISTRIBUTOR COMPONENT IDENTIFICATION�� 22
DISTRIBUTOR DISMANTLING�� 23
gasket replacement�� 23
REMOVAL OF THE PRESSURE RELIEF VALVE�� 25
CALIBRATION OF THE PRESSURE RELIEF VALVE �� 26
CARTRIDGE SOLENOID VALVES�� 27
IDENTIFICATION of SOLENOID VALVE CARTRIDGE COMPONENTS�� 27
SOLENOID VALVE DISMANTLING�� 28
CYLINDERS�� 29
SINGLE ACTING CYLINDER�� 29
IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS�� 30
IDENTIFICATION OF THE SIDE LIFT CYLINDER COMPONENTS�� 31
IDENTIFICATION OF THE RETRACTABLE CARRIAGE CYLINDER COMPONENTS�� 32
IDENTIFICATION OF THE FORK TILT CYLINDER COMPONENTS�� 33
IDENTIFICATION OF THE FORK SIDE SHIFT CYLINDER COMPONENTS�� 34
CENTRAL LIFT CYLINDER DISMANTLING�� 35
DISMANTLING OF LATERAL LIFT CYLINDER �� 37
LIFTING CYLINDER: AIR BLEEDING�� 39
REMOVAL OF THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER�� 40
1
HYDRAULIC SYSTEM SERVICE
REMOVAL OF THE FORK TILT CYLINDER�� 42

CYLINDER DISMANTLING�� 44
lift pump�� 46
KEY TO LIFT PUMP COMPONENTS�� 46
LIFT PUMP DISMANTLING�� 48
REPLACEMENT OF THE PUMP�� 50
HYDRAULIC PIPES�� 51
PIPE PLACEMENT FOR HYDRAULIC CIRCUIT�� 51
RENEWAL OF THE MIDDLE LIFT CYLINDER FEED PIPE�� 52
RENEWAL OF THE FORK HYDRAULIC FUNCTIONS SUPPLY PIPES�� 54
2
HYDRAULIC FUNCTIONS
• Fork Lifting
• Fork Lowering
• Fork right side shift
• Fork left side shift
• Fork tilt up
• Fork tilt down
• Retractable carriage out
• Retractable carriage in
3
HYDRAULIC DIAGRAMS
symbols
LINE CONNECTION
ELECTRIC MOTOR
RESERVOIR
PUMP
SINGLE ACTING
CYLINDER
DUAL ACTION PUMP

DOUBLE ACTING
CYLINDER
HYDRAULIC MOTOR
PRESSURE RELIEF
VALVE
FILTER
DIVERTER VALVE
FILTER CLOGGING
INDICATOR
TWO-POSITION VALVE
MANUAL COCK
THREE-POSITION
VALVE
ONE-WAY VALVE
CHECK VALVE
4
MAIN HYDRAULIC DIAGRAM
5
BACK: VERSION WITH 5TH WAY
6
BACK: VERSION WITHOUT 5TH WAY
7
HYDRAULIC DIAGRAMS FOR VARIOUS

FUNCTIONS
• Fork Lifting
• Fork Lowering
• Fork tilt up
• Fork tilt down
• Fork right side shift
• Fork left side shift
• Retractable carriage out
• Retractable carriage in
• Emergency mast lowering
• The hydraulic control valve in the motor compartment
is equipped with a screw to open the emergency low-
ering valve. Unscrew the valve gradually by no more Emergency relief valve
than two turns so that the mast is lowered slowly. Once lowering valve
the forks have been lowered, close the valve.
• Oil drain through the pressure relief valve
SOLENOID VALVE OPERATION CHART
Function Pump Q1 Q2 Q3 Q4 Q5 Q6 Q7
Fork Lifting P +
Fork Lowering +
Retractable carriage out P +
Retractable carriage in P +
Fork right side shift P + +
Fork left side shift P + +
Fork tilt up P +
Fork tilt down P +
Oil drain through the pressure relief
valve P - - - - - - -
P
= pump in operation
+
= solenoid valve coil energised
8
HYDRAULIC FORK LIFTING DIAGRAM
Oil delivery
Oil return
9
HYDRAULIC FORK LOWERING DIAGRAM
Oil delivery
Oil return
10
HYDRAULIC RETRACTABLE CARRIAGE OUT DIAGRAM
Oil delivery
Oil return
11
HYDRAULIC RETRACTABLE CARRIAGE IN DIAGRAM
Oil delivery
Oil return
12
HYDRAULIC FORK UPWARD TILTING DIAGRAM
Oil delivery
Oil return
13
HYDRAULIC FORK DOWNWARD TILTING DIAGRAM
Oil delivery
Oil return
14
HYDRAULIC FORK LEFT SIDE SHIFT DIAGRAM
Oil delivery
Oil return
15
HYDRAULIC FORK RIGHT SIDE SHIFT DIAGRAM
Oil delivery
Oil return
16
HYDRAULIC EMERGENCY LOWERING DIAGRAM
17
HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE
Pressure relief or pressure limiting valves are used in hydraulic systems to maintain the pressures permit-
ted by the system and to protect and safeguard the system against sudden pressure surges that could
seriously damage the components.
The pressure relief valve may intervene in the following cases:
• Pressure control not suitable for the truck load capacity.
• Attempt to lift a load in excess of the truck's load capacity
• Faulty or stuck valve
18
19
HYDRAULIC COMPONENTS
HYDRAULIC COMPONENT IDENTIFICATION
Ref. Description
1 Distributor
2 Lift pump
3 Tank
4 Filter
5 Retractable carriage cylinder
6 Fork lift cylinder
7 Mast lift cylinders
8 Fork side shift cylinder
9 Fork tilt cylinders
20
7 7
9 3 2
21
DISTRIBUTOR COMPONENT IDENTIFICATION
10 4 6
5
4
5
7
6
2
3
Ref. Description
1 Solenoid valve
2 Solenoid valve
3 Solenoid valve
4 Solenoid valve
5 Solenoid valve
6 Solenoid valve
7 Fork pressure relief valve
8 Side shift/tilt pressure relief valve
9 Retractable carriage pressure relief valve
10 Emergency lowering valve
22
DISTRIBUTOR DISMANTLING
• gasket replacement
The gaskets must be replaced when an oil leak is identified or when the truck is used in a cold store.
Equipment and tools
Fig. 1
open ended
Schäfer wrenches
spanner oil resistant gloves
for connectors
13mm
Procedure
ground..
The hydraulic fluid gets very hot during system operation
and can cause burns. It is advisable to wear gloves that
are resistant to oil and high temperatures.
Phase 1 Fig. 2
Make the retractable carriage come fully out (fig.1).
Phase 2
SHÄFER WRENCHES FOR CONNECTORS - OIL RESISTANT
GLOVES
Wear the oil resistant gloves. Fig. 3
Label the hydraulic pipes in order to reassemble them correctly.
Unscrew the hydraulic pipe connectors with the Shäfer wrenches
(fig.3).
Disconnect the solenoid valve supply connectors.
23
Phase 3
Fig. 4
ing the control valve at the bottom of the truck (ref.A fig.5).
Remove the control valve assembly.
Remove the O-rings from the seat, carefully clean the parts and install
the new gasket set.
Fig. 5
24
REMOVAL OF THE PRESSURE RELIEF VALVE

Malfunction of the pressure relief valve can be caused by the presence of dirt or weakening of the internal
spring.
In the first case thorough cleaning is required, in the second case the valve needs to be replaced.
Equipment and tools
Fig. 1
large flat blade oil protecting socket wrench

ratchet
screwdriver gloves 22 mm
Procedure
ground.
Phase 1
Make the retractable carriage come fully out (fig.1). Fig. 2
Phase 2 Fig. 3
A
RATCHET - 22 mm SOCKET WRENCH - OIL PROTECTING LOVES
Put the oil proof gloves on.
Use the spanner to unscrew and remove the valve assembly (ref.A fig.3)
and proceed with the replacement.
INSTALLATION
On installation, tighten the valve with a torque wrench to
10 to 12 Nm.
25
CALIBRATION OF THE PRESSURE RELIEF VALVE

The pressure relief valve must be calibrated following replacement.
Equipment and tools
open ended
oil resistant gloves spanner
10 mm
Procedure
Phase 1
Connect the battery and switch on the truck (starter key to ON).
Place on the forks a load equivalent to the truck's load capacity, as indicated on the truck's dataplate. Wear
the oil resistant gloves.
Phase 2
10mm OPEN ENDED SPANNER
Loosen the lock nut with the spanner (ref.A fig.2).
Using the open ended spanner loosen the adjusting screw (ref.B fig.2) turning it counter-clockwise until,
while pressing the fork lifting button, the pressure decreases and the oil drains back to tank (the lifting ac-
tion ceases). At this point, turn the adjuster screw in the opposite direction (clockwise) to the point where
the forks start to lift again.
Release the lifting button and tighten the screw by a further 1/4 turn.
Carry out a few trial lifts and lowering manoeuvres with the load on the forks, checking that the pressure
setting is sufficient to cope with the pressure surge during the initial lifting stage.
If this is not the case, tighten the screw by a further 1/4 turn.
Use the spanner to tighten the lock nut (ref.A fig.2), to lock the adjusting screw in position.
B A
Fig. 2
26
CARTRIDGE SOLENOID VALVES

The distributor solenoid valves are of the screw on cartridge type.
This kind of valve is comprised of a chassis with a hexagon nut attached to the chassis, a threaded part,
a range of static seal gaskets; inside a mobile element allows communication between the various holes.
IDENTIFICATION of SOLENOID VALVE CARTRIDGE COMPONENTS
Ref. Description
1 Coil
2 Valve body
27
SOLENOID VALVE DISMANTLING

Fig. 1
Equipment and tools
fixed gauge span-

oil resistant gloves ner
29 mm
Procedure
ground.
Fig. 2
Phase 1
out (fig.1). Fig. 3
A
Phase 2
OIL RESISTANT GLOVES - 29 mm OPEN ENDED SPANNER
Disconnect the solenoid valve supply connector.
Unscrew the coil retaining nut (ref.A fig.3). Withdraw the coil.
Using the open ended spanner, unscrew the nut securing the valve body
to the control unit (ref.B fig.3). Proceed with replacement
On refitting the valve body, tighten the retaining nut to a

torque of 29 Nm.
28
CYLINDERS
SINGLE ACTING CYLINDER
Single acting cylinders receive and discharge the oil through a single pipe and the pressurised oil acts
on just one side of the piston (single acting pushing cylinders) or on the flat face of the rod in the case of
plunger type cylinders.
Single-acting plunger type cylinders
In this type of cylinder the piston is replaced by the flat end face of the piston rod or plunger; these cylinders
are usually mounted vertically or in other positions in which the force of gravity returns the plunger to the
rest position. Usually the diameter of the lower end of the rod is increased by a few millimetres in order to
avoid it slipping out at the end of it's upstroke; this gives rise to a hydraulic damping effect during the last
stages of the stroke which helps the slowing of the rod and avoids recoil on the upper end cap. Static seals
located in the end cap prevent oil leaking outside the cylinder.
To replace these seals it is necessary to unscrew the seal carrier bush.
Single acting cylinder with hollow rods differ in that before the lifting stroke begins the rod is also filled with
oil. This solution is used on particularly tall truck masts to increase the resistance of the cylinders at the
maximum height and make it possible to use smaller cylinder barrels and rods.
Static seals and dynamic seals
Dynamic seals, installed on the piston, prevent oil from leaking between the chambers of the cylinder bar-
rel, while the static seals, located at the joint between two parts (seal carrier bush - barrel) or between the
sliding parts (rod barrel), prevent oil leaking from the inside to the outside of the cylinder.
29
IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS

The cylinder is of the single-acting plunger type.
4
5
6
Ref. Description
1 Bushing
2
3
Gaskets
4 7
5
6 Piston rod
8
7 Seal
8 Piston
9
9
10 10
Gaskets
11
11
12
13 Valve 12
14 Barrel
15 Parachute valve 13
14
15
30
IDENTIFICATION OF THE SIDE LIFT CYLINDER COMPONENTS

The cylinder is of the single-acting plunger type.
After replacing the cylinder, bleed the air through the bleed valve.
3
4
Ref. Description 5
1 Seal
2 Bushing
3
Gaskets 6
4
5 Barrel
6 Piston rod
7 Parachute valve
31
IDENTIFICATION OF THE RETRACTABLE CARRIAGE CYLINDER COMPONENTS
Ref. Description 2
1 Grease nipple
2 Barrel
3 Piston rod
4 Grease nipple
5 3
6
7 Gaskets
8
9
10 Nut
11 Piston
12 Bushing 4
13 Ring 5
14 Bearing 6
7
8 13
9 14
10
11
12
32
IDENTIFICATION OF THE FORK TILT CYLINDER COMPONENTS
1
5
7
2
9 6
Ref. Description
1 Barrel
2 Bushing
3
4
5 Gaskets
6
7
8 Rod and piston
9 Elastic ring
33
IDENTIFICATION OF THE FORK SIDE SHIFT CYLINDER COMPONENTS
2
3
4 6
Ref. Description
1 Barrel
2
3 Gaskets
4
5 Piston rod
6 Seal
34
CENTRAL LIFT CYLINDER DISMANTLING

Equipment and tools
hoist lifting sling open-ended span-

Shäfer wrench for
load capacity load capacity taper end pliers wooden block ner
connectors
1000kg 1000kg 28 mm
hex bit socket

ratchet
13 mm
Procedure
ground.
Phase 1
WOODEN BLOCK Fig. 1
out.
Fig. 2
neath.
Phase 2
TAPER END PLIERS - SHÄFER WRENCH FOR CONNECTORS
B
Using the taper end pliers remove the cotter pin and the chain hinge pin
at the top (ref.A fig.2). Rest the chain on the forks.
Using the Shäfer wrench, detach the hydraulic pipes on the control valve of
the fork carriage. Disconnect the electric cables from the fork carriage.
35
Phase 3
Fig. 3
Raise the cylinder using the controls in the cab until the fork carriage is
fully extracted from below.
Set the fork carriage in a safe place.
Phase 4
Lower the forks until you can see the screw fastening the cylinder at the
bottom in the inner mast (fig.3).
Using the open ended spanner, unscrew and remove the screw fastening
the cylinder (ref.B fig.4).
Lower the cylinder down to the ground to its limit stop.
Using the Shäfer wrench, remove the connector of the hydraulic pipe
connected to the cylinder (ref.C fig.5).
Phase 5
HOIST - LIFT BELT - HEXAGONAL 13mm SOCKET WRENCH - RATCH-
ET
Fig. 4
Harness the cylinder with the lift belt.
Set the hoist at right-angles on the belt, hook the belt to the hoist and lift
to make it taut.
Using the socket wrench and ratchet, unscrew the screws of the cylinder
block and remove it (ref.D fig.6).
With the aid of the hoist, remove the cylinder, place it on a clean work
bench and proceed with replacement. B
Fig. 6
Fig. 5
C
36
DISMANTLING OF LATERAL LIFT CYLINDER

Equipment and tools
Fig. 1
hoist lifting sling 2 open ended

medium external
load capacity load capacity spanners
circlip pliers
2000 kg 2000 kg 15 mm
Shäfer wrench for Allen key

oil resistant gloves ladder
connectors 6 mm
Procedure
Fig. 2
Move the truck to a safe place of a sufficient height for the
fully raised column, away from areas of transit of other ve-
hicles and pedestrians. Lower the forks to the ground. A
Phase 1
out and raise the forks until you can see the top of the side cylinder rod
(fig.1).
Phase 2
MEDIUM EXTERNAL CIRCLIP PLIERS - ladder - 2 OPEN ENDED B
SPANNERS SIZE 15 mm
Set the ladder next to the column. Climb up and use the pliers to remove
the circlip securing the cylinder (ref.A fig.2).
Using the open ended spanners, unscrew and remove the screws fasten-
ing the cylinder locking bracket (ref.B fig.3). Remove the bracket. Fig. 3
Using the cab controls, lower the forks completely down to the ground.
37
Phase 3
OIL RESISTANT GLOVES - SHÄFER WRENCH FOR CONNECTORS
Wear the oil resistant gloves.
Using the Shäfer wrench, detach the hydraulic pipe at the base of the
cylinder (ref.C fig.5).
Phase 3
BRIDGE CRANE - LIFT BELT Fig. 4
Hook the lifting belt at the top of the inner mast and hook both ends of
the belt to the bridge crane (fig.6).
Start lifting with just the cylinder connected and at the same time raise
the bridge crane up to the maximum height and keep the belt taut.
C
Phase 3
LIFT BELT - LIFT - 6 mm ALLEN WRENCH - TRESTLES
Harness the cylinder with the lift belt, hook it onto the lift and take up the
slack. D
Using the Allen wrench, unscrew and remove the screw securing the
cylinder (ref.D fig.5). Lift the cylinder upwards until the bottom comes Fig. 5
away from the seat by the mast bottom, lower bending it outwards and
make it come out from the front of the truck. Set it horizontally and place
it on the two trestles and proceed with dismantling or replacement.
After installation, bleed the air from the cylinder (see

“LIFTING CYLINDER: AIR BLEEDING”).
38
LIFTING CYLINDER: AIR BLEEDING

Equipment and tools
open ended span-

13 mm
Procedure
Phase 1
Fig. 1
OIL RESISTANT GLOVES - 13 mm OPEN ENDED SPANNER - LAD-
DER
Wear the oil resistant gloves. Set the ladder next to the column and climb
up.
Using the spanner, unscrew the air bleed screw by two turns (ref.B
fig.1). A
Connect the battery and turn the starter key to ON. B
Phase 2
Using the controls in the cab, raise the forks with no load by approximately
300mm, stop and wait for approximately 10 seconds, repeat this process
until all the air has come out of the bleed valve (fig.1).
Take the forks to full height, stop and tighten the screw (ref.B fig.1).
Wipe the cylinder with a clean cloth.
39
REMOVAL OF THE RETRACTABLE CARRIAGE SIDE SHIFT CYLINDER

Equipment and tools
Fig. 1
open-ended span-
T handle hex key Shäfer wrench for
3 - 5 mm connectors
8 - 24 mm
hex socket
wrench ratchet extension
24 mm
Procedure
Fig. 2
Phase 1
out (fig.1).
Fig. 3
Phase 2
40
Phase 3
3 mm T-HANDLE HEX KEY - 8-24 mm OPEN ENDED SPANNER
Using the 8mm open ended spanner and the T-handle hex key, unscrew B
and remove the screw fastening the potentiometer to the cylinder (ref.A
fig.4).
Using the 24mm open ended spanner unscrew and remove the bolt fas- A
tening the cylinder to the retractable carriage (ref.B fig.4).
Fig. 4
Phase 4
24 mm HEX SOCKET WRENCH - RATCHET - EXTENSION
Using the open ended spanner, through the electronic controls compart-
ment, unscrew and remove the bolt fastening the cylinder to the retract-
able carriage (ref.C fig.5).
Raise the cylinder rod to extract it from the pin.
Using the controls in the cab, make the rod come fully into the cylinder.
Phase 5
Using the Shäfer wrench, detach the connectors of the hydraulic pipes
on the cylinder (ref.D fig.6).
Raise the cylinder to extract it from the pin.
Remove the cylinder, place it on a clean work bench and proceed with C
dismantling or replacement.
Fig. 5
D
Fig. 6
41
REMOVAL OF THE FORK TILT CYLINDER

Equipment and tools
tackle 2 lifting slings

T handle hex key Allen key medium flat blade
load capacity load capacity
6 mm 10 mm screwdriver
1000 kg 1000 kg
Procedure
Fig. 1
A
Phase 1
Remove the forks.
Using the controls in the cab, make the retractable carriage come fully Fig. 2
out and raise the forks by approximately one metre.
Phase 2
10 mm Allen wrench
Using the Allen wrench, unscrew and remove the screws securing the
anti-turnover block (ref.A fig.1). Remove the block.
Phase 3
HOIST - 2 LIFTING SLINGS
Harness the movable frame with the lift belts. Hook the lift belts onto the
hoist.
Turning the movable frame, raise it with the hoist and extract it from the
fixed frame (fig.2).
42
Phase 4
Fig. 3
MEDIUM FLAT BLADE SCREWDRIVER - 14 mm OPEN ENDED SPAN-
NER - 6 mm T-HANDLE HEX KEY
Using the medium flat blade screwdriver, lever on and remove the lower
sliding block (ref.B fig.3).
Using the open ended spanner, unscrew and remove the hydraulic pipes
from the connectors (ref.C fig.4). D
Using the T-handle hex key, unscrew and remove the screws securing
the flange (ref.D fig.3) and remove it.
Extract the cylinder from its seat and dismantle or replace.
Fig. 4
43
CYLINDER DISMANTLING
• gasket replacement
• replacing the parachute valve
Equipment and tools
oil protecting fixed gauge span-

workbench vice oil pan round nose pliers
gloves ner
small flat blade

oil syringe brush C spanner
screwdrivers
Procedure

Phase 1
Carry out the removal procedure for the relevant cylinder (see paragraphs
above).
Phase 2
WORK BENCH WITH VICE - OIL RESISTANT GLOVES - C SPANNER
- oil pan
Lock the cylinder in the vice, placing a rubber guard between the jaws and
the cylinder and tighten carefully in order not to deform the pipe. Place the
underneath the bush of the cylinder. Apply the C spanner at the notches
on the seal carrier bush. Unscrew the bushing from the cylinder (ref.A
fig.1) extract it from the shaft and place it on the workbench. Remove
the rod from the cylinder (fig.1).
44
REPLACING THE GASKET

Fig. 1
Phase 3
SMALL FLAT HEAD SCREWDRIVER - BRUSH
A
Using the screwdriver, remove the internal seals and the seals external
to the bush and proceed with replacement.
Fitting the seals is a delicate stage in the lift cylinder as-

sembly procedure. Most maintenance operations are to
be ascribed to gasket leakage. Do not damage the parts
during assembly.
Clean the seal carrier bush and lubricate the seal contact
faces in the bush and the seals themselves with clean
hydraulic oil before installation.
DISMANTLING OF THE PARACHUTE VALVE (LIFT CYLINDERS)

Malfunction of the parachute valve can be caused by dirt causing the
spool to stick.
Clean carefully.
Phase 4
OIL RESISTANT GLOVES - ROUND NOSE PLIERS - OPEN ENDED
SPANNER
Use the open ended spanner to unscrew and remove the connector C
from the cylinder (ref.B fig.2). Use the pliers to remove the valve from
B
its seat (ref.C fig.2). Proceed with the cleaning and elimination of any
dirt residue.
Replace if broken.
INSTALLATION Fig. 2
The bush should be tightened during assembly to:

353-380 Nm (middle lift cylinder)
358 Nm (side lift cylinders)
Lubricate all the inner parts of the cylinder with clean hy-
draulic oil. Use new gaskets.
45
lift pump
KEY TO LIFT PUMP COMPONENTS
Ref. Description
1 Cover
2 Gear wheel
3 Seal
4 Upper flange
5
Gaskets
6
7 Upper bearing
8 Stator
9 Rotor
10 Lower bearing
11 O-ring
12 Lower flange
13 Heat sensor
46
2
13
3
5
6
7
10
11
12
47
LIFT PUMP DISMANTLING

Equipment and tools
hex socket hoist lift belt

workbench wrench ratchet extension load capacity load capacity
15 1000 kg 1000 kg
open ended span-

Shäfer wrench for T handle hex key
ner oil resistant gloves eyebolt
connectors 5 mm
17 mm
Procedure
Fig. 1
ground. Turn the keyswitch to OFF and disconnect the
battery.
Before starting work, drain the oil reservoir.
Phase 1
5 mm T-HANDLE HEX KEY
(ref.A fig.1).
Completely open the cover (fig.2). Fig. 2
48
Phase 2
Using the fixed spanner, unscrew the nuts fastening the pump motor power cables.
Take note of the position of the cables. Remove the cables and disconnect the connectors.
Phase 3
15 mm SOCKET WRENCH - RATCHET - EXTENSION - Shäfer WRENCH FOR CONNECTORS - OIL
RESISTANT GLOVES
Using the Shäfer wrench, disconnect the connector of the hydraulic pipe connected to the pump block
(ref.B fig.3). Use the open ended spanner to unscrew the fastening screw of the elastic strip that fastens
the inlet pipe (ref.C fig.3).
Using the socket wrench, ratchet and extension, unscrew the two nuts securing the pump hydraulic block
(ref.D fig.3), loosen the nut (ref.E fig.3).
Phase 4
HOIST - LIFT BELT - EYEBOLT
Screw the eyebolt onto the pump. Insert the lift belt into the eyebolt and hook it onto the hoist.
Very carefully take up the slack in the belt with the hoist, remove the pump carrier plate from the slot (ref.F
fig.3) and slowly start raising the assembly.
Place it on a work bench or on a pallet and proceed with dismantling.
D
E
F
49
REPLACEMENT OF THE PUMP

Equipment and tools
hex socket
wrench ratchet
17 mm
Procedure
ground. Turn the keyswitch to OFF and disconnect the
battery.
Phase 1
Carry out the procedure to remove the lift pump (see "REMOVAL OF
THE LIFT PUMP").
Phase 2
17mm SOCKET WRENCH - RATCHET A
Using the socket wrench and the ratchet, unscrew and remove both
screws securing the pump to the flange (ref.A fig.1).
Remove the pump and proceed with the replacement.
INSTALLATION
During the assembly stage tighten the nuts that fasten the
pump to the flange with a torque wrench set at 45 Nm.
50
HYDRAULIC PIPES
PIPE PLACEMENT FOR HYDRAULIC CIRCUIT
51
RENEWAL OF THE MIDDLE LIFT CYLINDER FEED PIPE

Equipment and tools
Fig. 1
hexagonal socket
wrench ratchet
17 mm
Procedure
ground.
Phase 1 Fig. 2
out (fig.1).
Remove the cover to access the hydraulic control valve (fig.2). Fig. 3
Phase 2
WOODEN BEAM
Raise the forks by approximately one metre using the controls in the
cab.
Position the wooden beam beneath the fork carriage (ref.A fig.3).
Lower the forks and rest them on the beam, continue the descent until A
the fork lift cylinder hydraulic power feed pipe becomes loose.
52
Phase 3
Shäfer WRENCH FOR CONNECTORS - OIL RESISTANT GLOVES
Using the Shäfer wrench, disconnect the connector of the hydraulic pipe
connected to the middle lift cylinder (ref.B fig.4).
connected to the hydraulic block (ref.C fig.5).
Extract the pipe from the hose sheave and fit the new one
B
Fig. 4
Fig. 5
53
RENEWAL OF THE FORK HYDRAULIC FUNCTIONS SUPPLY PIPES

Equipment and tools
Fig. 1
hexagonal socket
wrench ratchet
17 mm
Procedure
ground.
Phase 1 Fig. 2
out (fig.1).
Phase 2 A
ing the pipe clamps (ref.A fig.3).
Phase 3
WOODEN BEAM
Raise the forks by approximately one metre using the controls in the Fig. 2
cab.
Position the wooden beam beneath the fork carriage (ref.B fig.4).
Lower the forks and rest them on the beam, continue the descent until
the fork hydraulic functions supply pipe becomes loose.
54
Fig. 4
Set the key switch to OFF and disconnect the battery.
Phase 4
Shäfer WRENCH FOR CONNECTORS - OIL RESISTANT GLOVES
connected to the hydraulic block on the fork carriage (ref.C fig.5).
B
connected to the hydraulic block (ref.D fig.5).
Extract the pipe from the hose sheave and fit the new one
D C
Fig. 5
55
56
SERVICE TRUCK BASE MECHANICS
TRUCK BASE MECHANICS

WHEELS & TYRES�� 2
IDENTIFICATION OF TRACTION WHEEL COMPONENTS�� 2
REMOVAL OF THE DRIVE WHEEL�� 3
KEY TO LOAD WHEEL COMPONENTS�� 5
REMOVING THE LOAD WHEEL �� 6
BATTERY BLOCK�� 8
RENEWAL OF THE BATTERY BLOCK�� 8
MOTORS�� 10
KEY TO TRACTION MOTOR COMPONENTS�� 10
REMOVAL OF THE TRACTION MOTOR�� 11
REPLACEMENT OF TRACTION MOTOR BEARINGS�� 13
KEY TO STEERING MOTOR COMPONENTS�� 15
STEERING MOTOR DISASSEMBLY�� 16
STEERING MOTOR DISMANTLING�� 17
STEERING SYSTEM ASSEMBLY�� 19
KEY TO STEERING SYSTEM ASSEMBLY COMPONENTS�� 19
RENEWAL OF STEERING SYSTEM ASSEMBLY BEARING�� 20
retractable carriage�� 21
KEY TO RETRACTABLE CARRIAGE COMPONENTS�� 21
REMOVAL OF THE RETRACTABLE CARRIAGE�� 22
RENEWAL OF BEARINGS AND RETRACTABLE CARRIAGE PINS�� 24
REMOVING THE RETRACTABLE CARRIAGE POTENTIOMETER�� 25
1
TRUCK BASE MECHANICS SERVICE
WHEELS & TYRES

IDENTIFICATION OF TRACTION WHEEL COMPONENTS
Ref. Description
1 Vulkollan ring complete with hub

2 Drive wheel flanged retaining nut
2
REMOVAL OF THE DRIVE WHEEL

Equipment and tools
hex socket
T handle hex key ratchet with M6 screw
hydraulic jack wooden block wrench
5 mm extension bar 2 x 70 mm
12 mm
Procedure
Fig. 1
ground, turn the keyswitch to OFF and disconnect the
battery.
Phase 1
A
bonnet (ref.A fig.1), remove the electronic controls cover and open the
bonnet (fig.2).
Phase 2
HYDRAULIC JACK - WOODEN BLOCK
Position the hydraulic jack beside the drive wheel and lift until the wooden
block can pass beneath.
Fig. 2
Position the wooden block to the side of the truck, lower the jack to rest
the truck on the block and take up the slack on the jack (fig.3).
Phase 3
2 M6 SCREWS 70 mm LONG
Insert the screws into the holes above the electromagnetic brake (fig.4),
screw them in to reach the lower disk and then tighten by a further turn
The purpose of this procedure is to disconnect the elec-

tromagnetic brake so as to free the wheel.
Fig. 3
3
Phase 4
Fig. 4
12 mm SOCKET WRENCH - RATCHET - EXTENSION
Turn the wheel by hand so as to set it parallel to the truck. Using the socket
wrench, ratchet and extension, unscrew and remove the nuts securing
the drive wheel to the reduction unit (ref.B fig.5).
Raise with the hydraulic jack until the wheel passes under the truck (fig.6).
Proceed with replacement
INSTALLATION
The traction wheel retaining nuts must be tightened using

a torque wrench to a torque of 130 Nm.
Unscrew and remove the two screws used to disconnect

the electromagnetic brake.
B Fig. 5
Fig. 6
4
KEY TO LOAD WHEEL COMPONENTS
2
1
3
4
8
6
10
11
12
13
Ref. Description
1 Electromagnetic brake
2 Brake disk
3 Springs
4 Bush
5 Screws fastening to the truck base
6 Wheel
7 Brake regulator
8 Wheel-brake fixing screw
9 bearing
10 Elastic ring
11 Spacer
12 Ring
13 Self-locking ring nut
5
REMOVING THE LOAD WHEEL

Equipment and tools
socket wrench for

internal circlip T handle hex key
hydraulic jack wooden block self-locking ring ratchet
pliers 6 mm
nut
Procedure
battery.
Phase 1 Fig. 1
Position the hydraulic jack beside the load wheel and lift until the wooden
stock can pass beneath.
Set the wooden block under the clamp, lower the jack to rest the truck
on the block and take up the slack on the jack (fig.1).
Phase 2
SOCKET WRENCH FOR SELF-LOCKING RING NUT - RATCHET a
Using the socket wrench for the self-locking ring nut and the ratchet,
unscrew and remove the ring nut (ref.A fig.2), remove the toothed Fig. 2
washer.
Extract the wheel from the hub and dismantle or replace.
Fig. 3
REMOVAL OF THE WHEEL BEARING
Phase 3 B
LARGE INTERNAL CIRCLIP PLIERS
Use the internal circlip pliers to remove the circlip securing the bearing
(ref.B fig.3). Remove the bearing (ref.C fig.3) and proceed with the
replacement.
C
6
REMOVAL OF THE BRAKE DISK

E Fig. 4
Phase 4
HEXAGONAL 6 mm "T" SECTION SPANNER D
Using the T-handle hex key, remove the screws securing the brake disk to
the wheel together with the bush and spring (ref.D fig.4). When removing
the disk, pay attention to the springs (ref.E fig.4).
INSTALLATION
The screws securing the brake disk must be tightened us-

ing a torque wrench to a torque of 25 Nm. Apply Loctite
270.
7
BATTERY BLOCK
RENEWAL OF THE BATTERY BLOCK
Equipment and tools
hex socket open-ended span- hexagonal "T"

wrench ratchet ner section spanner
15 mm 10 - 13 mm 5 - 6 mm
Procedure Fig. 1
ground.
Phase 1 A
the battery.
out.
Phase 2
Fig. 2
Fig. 3
bonnet (fig.2).
B
8
Phase 3
Fig. 4
ing the bracket inside the motor compartment (ref.B fig.3). Remove the D
bracket (ref.C fig.3).
Phase 4
15 mm HEXAGONAL SOCKET WRENCH - RATCHET
Using the hex socket wrench and the ratchet, unscrew and remove the
screws securing the battery block (ref.D fig.4). Remove the battery block
and proceed with replacement or disassembly. Fig. 5
BLOCK DISMANTLING
F
Phase 5
6 mm T-HANDLE HEX KEY - 13 mm OPEN ENDED SPANNER E
Using the open ended spanner, loosen the nut (ref.E fig.5) and, using
the T-handle hex key, unscrew and remove the screw (ref.F fig.5). Ex-
tract the pin including the spring and proceed with replacement of the
components.
9
MOTORS
KEY TO TRACTION MOTOR COMPONENTS
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18

1 upper flange fastening screws 11 Stator
2 Upper flange 12 Lower flange
3 Circlip 13 Bush
4 Circlip 14 Seal
5 O-ring 15 Lower bearing
6 Upper bearing 16 Elastic ring
7 Elastic ring 17 Circlip
8 Gear wheel 18 O-ring
9 Rotor
10 Sensor
10
REMOVAL OF THE TRACTION MOTOR

Equipment and tools
tackle lift belt open ended span-

T handle hex key
load capacity load capacity ner eyebolt
5-6 mm
1000 kg 1000 kg 13 mm
Procedure
Fig. 1
Phase 1
T-handle hex key, unscrew and remove the screws securing the cover A
bonnet (fig.2).
Phase 2
Carry out the electromagnetic brake removal procedure (see "REMOVAL
OF THE ELECTROMAGNETIC BRAKE" in the "BRAKING SYSTEM"
section).
Phase 3
FIXED GAUGE 13 mm SPANNER Fig. 2
Unscrew the traction motor power cable fastening nuts. Note the posi-
tion of the cables prior to removing them. Disconnect the sensor cable
connector. Fig. 3
Phase 4
Using the T-handle hex key, unscrew and remove the 6 screws fastening
the traction motor to the reduction unit (ref.B fig.3). B
11
Phase 5
HOIST - LIFT BELT - EYEBOLT
Screw the eyebolt onto the rotor shaft. Insert the lift belt into the eyebolt
and hook it onto the hoist.
Very carefully start slowly lifting the motor (fig.4).
Place it on a work bench or on a pallet and proceed with dismantling.
INSTALLATION
Before installing the motor on the reduction unit, lubricate
the drive shaft with a thin, even layer of special grease: Fig. 4
“SHELL GADUS S2 OGH 0/00”.
During the coupling stage, carefully rotate the wheel shaft
to help the motor shaft engage with the pinion.
12
REPLACEMENT OF TRACTION MOTOR BEARINGS

Equipment and tools
Fig. 1
B
A
T handle hex key medium internal circlip external circlip
5 mm adjustable pliers pliers pliers
plastic hammer bush
C
Procedure

Phase 1
MEDIUM ADJUSTABLE PLIERS - EXTERNAL CIRCLIP PLIERS
Using the adjustable pliers, extract the key securing the brake guide
(ref.A fig.1).
Use the external circlip pliers to remove the circlip securing the flange to
the shaft (ref.B fig.1).
Phase 2
HEXAGONAL 6 mm "T" SECTION SPANNER
Using the T-handle hex key, unscrew and remove the screws fastening the
upper flange to the lower flange (ref.C fig.2). Recover both flanges. Fig. 2
13
Phase 3
Fig. 3
INTERNAL CIRCLIP PLIERS
Use the circlip pliers to remove the circlip securing the upper bearing to
the flange (ref.D fig.3). D
Recover the bearing and proceed with replacement.
Phase 4
INTERNAL CIRCLIP PLIERS - EXTERNAL CIRCLIP PLIERS - MEDIUM
ADJUSTABLE PLIERS
Remove the pinion from the shaft. Using the adjustable pliers, extract
the pinion coupling key. Use the circlip pliers to remove the two circlips
securing the lower bearing and the bush to the shaft (ref.E-F fig.4).
Fig. 4
F
INSTALLATION
During the assembly stage replace all the gaskets with new E
gaskets.
Assemble the new bearings using a plastic hammer and
a bushing.
14
KEY TO STEERING MOTOR COMPONENTS
6
1
7
8
9
10 2
11 3
12
13
4
14
15 5

1 upper flange fastening screws 11 Upper bearing
2 Sensor 12 Elastic ring
3 Upper flange 13 Rotor
4 Stator 14 Lower bearing
5 Lower flange 15 Ring
6 Elastic ring
7 Ring
8 Elastic ring
9 Magnet
10 Circlip
15
STEERING MOTOR DISASSEMBLY

Equipment and tools
open ended span-

T handle hex key
ner
5 mm
13 mm
Procedure
Fig. 1
Phase 1
T-handle hex key, unscrew and remove the screws securing the cover A
bonnet (fig.2).
Phase 2
Disconnect the connector. Using the socket wrench, unscrew and remove
the three screws fastening the steering motor to the plate (ref.B fig.3).
Remove the steering motor without damaging the gear wheel and proceed
with dismantling or replacement.
Fig. 2
Fig. 3
16
STEERING MOTOR DISMANTLING

Equipment and tools
Fig. 1
hexagonal "T"
medium cross- internal circlip external circlip
section spanner
head screwdriver pliers pliers
3-4-5-6 mm
Fig. 2
plastic hammer bush
Procedure

C
REMOVAL OF THE ELECTRICAL BOX
Phase 1
MEDIUM CROSSHEAD SCREWDRIVER - 6 mm T-HANDLE HEX
KEY
With the screwdriver, unscrew and remove the screws fastening the upper
cover of the electrical box (ref.A fig.1). Remove the cover.
Unscrew and remove the three fastening screws of the motor phase Fig. 3
terminals (ref.B fig.2).
Unscrew and remove the screws that fasten the side cover (ref.C fig.3).
Remove the cover together with the printed circuit board. Disconnect the
internal connector.
Using the T-handle hex key, unscrew the screws fastening the box to
the motor flange.
17
BEARING REMOVAL
Fig. 4
D
Phase 2
4-5-6 mm T-HANDLE HEX KEY E
Using the 5 mm T-handle hex key unscrew and remove the pinion fixing
screw (ref.D fig.4). Remove the washer (ref.E fig.4) and take out the
pinion (ref.F fig.4). F
Using the 6 mm T-handle hex key, unscrew and remove the screws se-
curing the triangular bracket (ref.G fig.4). Remove the bracket. G
curing the steering box (ref.H fig.4). Remove the box.
Phase 3 H
3-4 mm T-HANDLE HEX KEY - EXTERNAL CIRCLIP PLIERS - INTER-
NAL CIRCLIP PLIERS
curing the motor cover (ref.I fig.5). Remove the cover.
Use the external circlip pliers to remove the circlip securing the flange
to the crankshaft.
Using the 4 mm T-handle hex key, unscrew and remove the screws
joining the upper flange to the lower flange (ref.J fig.5). Recover both Fig. 5
flanges.
Use the circlip pliers to remove the circlip securing the upper bearing to
the flange. I
J
INSTALLATION
During the assembly stage replace all the gaskets with new
gaskets.
Assemble the new bearings using a plastic hammer and
a bushing.
18
STEERING SYSTEM ASSEMBLY

KEY TO STEERING SYSTEM ASSEMBLY COMPONENTS
12
2
3
4
5
6
13 7
9
14
10
11

1 Small steering wheel 11 Stepper motor
2 Driving 12 Bearing
3 Adjuster plate 13 Spring
4 Block 14 Bearing
5 Pin
6 Spring
7 Pushrod
8 Elastic ring
9 Ball bearing
10 Shaft
19
RENEWAL OF STEERING SYSTEM ASSEMBLY BEARING

Equipment and tools
hex socket
small flat blade internal circlip
wrench ratchet
screwdriver pliers
7-13 mm
Procedure

a
Phase 1
To recover the block together with the bearing, see “REPLACING THE
ARMREST AND MAIN PANEL CONTROLS: STEERING WHEEL STEP-
PER MOTOR” in the “ELECTRICAL SYSTEM” section.
Phase
internal circlip pliers
Use the internal circlip pliers to remove the circlip securing the bearing
(ref.A fig.1). Remove the bearing and proceed with the replacement.
20
retractable carriage
KEY TO RETRACTABLE CARRIAGE COMPONENTS
5
2
6
4
7
9
Ref. Description
1 Cover for access to the hydraulic control valve
2 Circlip
3 Bearing
4 Pin
5 bearing
6 Adjuster roller
7 Self-locking ring nut
8 Buffer
9 Adjusting screw
21
REMOVAL OF THE RETRACTABLE CARRIAGE

Equipment and tools
bridge crane 2 lifting slings hex socket

ratchet and A
load capacity load capacity wrench
extension
2000 kg 2000 kg 10 mm
Fig. 1
Fig. 2
hexagonal "T" open-ended span-

Shäfer wrench for
section spanner ner oil resistant gloves
connectors
3-14 mm 8-24 mm
Procedure
Phase 1 C
Carry out the mast removal procedure (see “REMOVAL OF THE BEAR-
INGS” in the “MAST MECHANICS” section).
Fig. 3
Phase 2 Fig. 4
Using the Shäfer wrench, detach the connectors of the hydraulic pipes
on the hydraulic control valve.
D
Disconnect the connectors from the solenoid valves.
22
Phase 3
Fig. 5
3 mm T-HANDLE HEX KEY - 8-24 mm OPEN ENDED SPANNER
Using the 8mm open ended spanner and the T-handle hex key, unscrew
and remove the screw fastening the potentiometer to the cylinder (ref.A
fig.1).
Using the 24mm open ended spanner unscrew and remove the bolt fas-
tening the cylinder to the retractable carriage (ref.B fig.1).
Raise the cylinder to extract it from the pin.
Phase 4
10 mm socket wrench - extension - ratchet
Using the socket wrench, extension and ratchet, unscrew and remove
the screws securing the carriage of the plate on which is secured the
pipe carrier chain (ref.C fig.3).
Phase 5
Using the T-handle hex key, unscrew and remove the limit stop screws
of the retractable carriage (ref.D fig.4).
Phase 6
BRIDGE CRANE - 2 LIFTING SLINGS
Harness the retractable carriage with the lift belts on the two crossbars
(fig.5). Hook the lift belts onto the bridge crane. Take up the slack on the
belts and extract the retractable carriage horizontally, place it on a pallet
and proceed with dismantling.
INSTALLATION
The limit stop screws must be tightened using a torque

wrench with a tightening torque of 300 - 330 Nm.
23
RENEWAL OF BEARINGS AND RETRACTABLE CARRIAGE PINS

Equipment and tools
open ended socket wrench for

external circlip driving tool
spanner self-locking ring ratchet hammer
pliers Ø 10 mm
24 mm nut
Procedure

Phase 1
Carry out the retractable carriage removal procedure (see “REMOVAL A
OF THE RETRACTABLE CARRIAGE”). Fig. 1
Phase 2
external circlip pliers
D
Use the circlip pliers to remove the circlip securing the bearing block (ref.A F
fig.1). Remove the bearing and proceed with the replacement.
Phase 3
24 mm OPEN ENDED SPANNER - SOCKET WRENCH FOR SELF-
LOCKING RING NUT - RATCHET. CLAMP GUDGEON - HAMMER C
Using the open ended spanner, unscrew the nut securing the roller adjust-
ing screw (ref.B fig.2). Unscrew and remove the screw (ref.C fig.2). B E
Using the hammer and the clamp gudgeon extract the roller (ref.D Fig. 2
Fig.2).
Using the socket wrench for self-locking ring nuts, unscrew and remove
the ring nut (ref.E fig.2).
Using the hammer and clamp gudgeon extract the pin from the carriage
(ref.F fig.2).
INSTALLATION
Coat the new bearings with a layer of special lubricating
grease “RETINAX HDX2” for standard applications or
“AERO SHELL GREASE 6” for applications in a cold
store.
24
REMOVING THE RETRACTABLE CARRIAGE POTENTIOMETER

Equipment and tools
Fig. 1
open-ended span-
T-handle hex key
ner
3 mm
8 mm
Procedure

Phase 1
out (fig.1).
Turn the keyswitch to OFF and disconnect the battery. Fig. 2
Phase 2
3 mm T-HANDLE HEX KEY - 8 mm OPEN ENDED SPANNER
Using the T-handle hex key, unscrew and remove the screw securing the
potentiometer to the cylinder (ref.A fig.3).
Using the open ended spanner, unscrew and remove the nut securing
B A
the potentiometer to the carriage (ref.B fig.3).
Disconnect the connector and proceed with replacement.
Fig.3
25
26
SERVICE MAST ASSEMBLY MECHANICS
Mast assembly
mechanics
MAST CHARACTERISTICS�� 2
MAST ELEVATION�� 4
3 STAGE MAST�� 8
IDENTIFICATION OF THE 3 STAGE MAST ASSEMBLY COMPONENTS�� 8
BEARING REPLACEMENT �� 9
REPLACEMENT OF CHAINS AND CHAIN TENSIONER�� 14
RENEWAL OF THE MIDDLE SECTION CHAIN SHEAVES�� 17
RENEWAL OF THE MIDDLE CYLINDER CHAIN SHEAVE�� 19
1
MAST ASSEMBLY MECHANICS SERVICE
MAST CHARACTERISTICS
The masts used have three stages.
These masts have machined channels so as to reduce the distance between the channel chamber and
the rollers. The channels are machined with special machinery to permit smooth movement of the mast
assembly, less oscillation, less friction, low wear, and less noise.
Wider rollers permit handling heavier loads. Hassle-free setting of the correct axis of the bearings without
having to remove the roller entirely.
2
3
MAST ELEVATION
4

Model (mm) (mm)
(mm) (mm) (kg)
h3 h2 h1 h4
5000 1648 2195 5563 911
5250 1734 2281 5813 936
5500 1820 2367 6063 961
5750 1906 2453 6313 986
6000 1992 2539 6563 1010
6250 2078 2625 6813 1035
6500 2164 2711 7063 1060
6750 2250 2797 7313 1090
R1.6N 7000 2336 2883 7563 1115
7250 2422 2969 7813 1140
7500 2508 3055 8063 1164
R1.4
7750 2594 3141 8313 1220
R1.6
8000 2680 3227 8563 1244
8250 2766 3313 8813 1269
8500 2852 3399 9063 1299
8750 2938 3485 9313 1324
9000 3024 3571 9563 1349
9250 3110 3657 9813 1376
9500 3196 3743 10063 1400
9750 3282 3829 10313 1425
10000 3368 3915 10563 1454
10250 3454 4001 10813 1478
10500 3540 4087 11063 1503
4650 1582 2195 5263 958
4900 1668 2281 5513 985
5150 1754 2367 5763 1012
5400 1840 2453 6013 1038
5650 1926 2539 6263 1065
5900 2012 2625 6513 1092
6150 2098 2711 6763 1118
R2.0
6400 2184 2797 7013 1150
R2.5
6650 2270 2883 7263 1177
6900 2356 2969 7513 1204
7150 2442 3055 7763 1230
7400 2528 3141 8013 1288
7650 2614 3227 8263 1314
7900 2700 3313 8513 1341
8150 2786 3399 8763 1373
5

Model (mm) (mm)
(mm) (mm) (kg)
h3 h2 h1 h4
7900 2614 3227 8513 1372
8150 2700 3313 8763 1401
8400 2786 3399 9013 1435
8650 2872 3485 9263 1464
8900 2958 3571 9513 1523
9150 3044 3657 9763 1552
9400 3130 3743 10013 1581
9650 3216 3829 10263 1609
9900 3302 3915 10513 1638
10150 3388 4001 10763 1671
R2.0HD
10400 3474 4087 11013 1699
10650 3560 4173 11263 1728
10900 3646 4259 11513 1757
11150 3732 4345 11763 1786
11400 3818 4431 12013 1814
11650 3904 4517 12263 1843
11900 3990 4603 12513 1872
12150 4076 4689 12763 1901
12400 4162 4775 13013 1929
12650 4248 4861 13263 1958
8050 2680 3227 8613 1346
8300 2766 3313 8863 1374
8550 2852 3399 9113 1408
8800 2938 3485 9363 1436
9050 3024 3571 9613 1495
9300 3110 3657 9863 1524
9550 3196 3743 10113 1552
R1.6HD 9800 3282 3829 10363 1580
10050 3368 3915 10613 1612
10300 3454 4001 10863 1641
10550 3540 4087 11113 1669
10800 3626 4173 11363 1698
11050 3712 4259 11613 1726
11300 3798 4345 11863 1755
11550 3884 4431 12113 1783
6
7
3 STAGE MAST
IDENTIFICATION OF THE 3 STAGE MAST ASSEMBLY COMPONENTS
Ref. Description
1 Outer upright
2 Intermediate upright
3 Inner upright
4 Roller
5 Chain tensioner
6 Buffer
7 Hose sheave
8 Side lift cylinder
9 Middle lift cylinder
10 Hydraulic pipe
8
SERVICE Mast assembly mechanics
4
6
8 4
10
5
6
7
4
4
5 9
4
8a
BEARING REPLACEMENT
3 STAGE MAST
To allow bearing replacement the mast assembly must be removed from the truck base.
Equipment and tools
bridge crane
load capacity ladder safety harness n. 3 iron trestles wooden block oil resistant gloves
3000 kg
lifting sling
Shäfer wrench for Allen key 24 mm socket
load capacity ratchet plastic hammer
connectors 6 - 2.5 mm wrench
3000 kg
open ended span-

medium elastic
taper end pliers ner
ring opening pliers
size 19 - 2x24 -
2x15 mm
Procedure
Move the truck to a safe place, away from the transit areas of other vehicles and pedes-
trians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the bat-
tery.
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.
9
MAST ASSEMBLY REMOVAL
Phase 1
out.
Phase 2
WOODEN BLOCK
neath.
Place the wooden block under the forks (fig.1). Lower the clamps to rest Fig. 1
on the blocks and continue until the end stroke of the cylinder.
Fig. 2
Phase 3
at the top (ref.A fig.2). Rest the chain on the forks.
Using the Shäfer wrench, detach the hydraulic pipes on the control valve of
the fork carriage. Disconnect the electric cables from the fork carriage.
A
Phase 4
Raise the cylinder using the controls in the cab until the fork carriage is
fully extracted from below.
Set the fork carriage in a safe place. Fully retract the cylinder.

tery.
Phase 5
BRIDGE CRANE - LADDER - SAFETY HARNESS - LIFT BELT
Climb up the ladder with the tools and secure the safety harness to the Fig. 3
cab.
Insert the lift belt beneath the upper crossbar of the middle section of the
mast assembly by making a noose and hook the ends to the bridge crane
hook (fig.4). Climb down the ladder, raise the bridge crane to reveal the
screws securing the mast assembly to the truck base.
Fig. 4
10
Phase 6
24 mm SOCKET WRENCH - RATCHET - BRIDGE CRANE - LIFT
BELT
securing the mast assembly to the truck base (ref.B fig.5).
Using the bridge crane, lower the mast assembly to the ground.
Climb the ladder again.
Slip the lift belt beneath the upper crossbars of the mast assembly by
making a noose and hook the ends to the bridge crane hook (fig.6). Lift
the bridge crane and take up the slack in the belt.
Fig. 5
Phase 7
SHÄFER WRENCH FOR CONNECTORS
Using the Shäfer wrench, detach the hydraulic pipes on the control valve
of the mast assembly (ref.C fig.7).
Phase 8
Using the open ended spanner, unscrew and remove the screws securing
both side blocks of the mast assembly (ref.D fig.8). Remove the blocks
(ref.E fig.8).
Using the bridge crane slowly lift the mast assembly and separate it from Fig. 6
the truck base. Position the mast assembly on two iron trestles and rest
it on the ground on wooden beams (fig.9).
Fig. 7
Fig. 8
D
Fig. 9
11
Fig. 10
L
K
F
G
J
H
REMOVAL OF CHAINS AND CYLINDERS
Phase 9
TAPER END PLIERS - 2 OPEN ENDED SPANNERS SIZE 24 mm
Using the taper end pliers remove the cotter pin on the chain tensioner (ref.F fig.10) and the one on the
pin (ref.G fig.10).
Using the open ended spanners, unscrew and remove the nuts fastening the chain tensioner to the mast
assembly (ref.H fig.10). Remove the pin and extract the chain from the hose sheave. Perform the same
procedure on the opposite side of the mast assembly.
Phase 10
MEDIUM EXTERNAL CIRCLIP PLIERS - 2 OPEN ENDED SPANNERS SIZE 15 mm - SHÄFER WRENCH
FOR CONNECTORS - ALLEN WRENCH SIZE 6 mm
Use the pliers to remove the circlip securing the cylinder (ref.I fig.10).
Using the open ended spanners, unscrew and remove the screws fastening the cylinder locking bracket
(ref.J fig.10). Remove the bracket.
Using the Shäfer wrench, detach the hydraulic pipe at the base of the cylinder (ref.K fig.10).
Using the Allen wrench, unscrew and remove the screw securing the cylinder (ref.L fig.10).
Remove the cylinder and carry out the same procedure on the other cylinder.
12
BEARING REMOVAL
Fig. 11
Phase 11
Shift the inner upright in such a way as to get a view of the bearings.
Phase 12
2.5 mm ALLEN WRENCH - PLASTIC HAMMER
bearing to the mast assembly (ref.M fig.11). With the aid of the hammer, M
remove the bearing and proceed with the replacement.
INSTALLATION Fig. 12
The new bearings do not need to be greased.
When fitting the new bearings, use a plastic hammer and

a pipe as wide as the black part of the bearing (fig.12).
Position the pipe on the black part of the bearing and ham-
mer until you hear the metal of the mast channel.
During the assembly stage, tighten the nuts securing the

mast assembly to the truck base with a torque wrench to
300-330 Nm.
During the assembly stage, tighten the screws fastening

both side blocks of the mast assembly (ref.D fig.8) with a
torque wrench set at 88-97 Nm.
13
REPLACEMENT OF CHAINS AND CHAIN TENSIONER

3 STAGE MAST
Never just replace the worn part of a chain. Replace the entire chain. Similarly, never
replace just one chain of a couple, always replace both.
Equipment and tools
Fig. 1
bridge crane lifting sling

load capacity load capacity wooden beam taper end pliers
1200 kg 1200 kg
open-ended span-
ladder safety harness ner
Fig. 2
2x24 mm
Procedure
of other vehicles and pedestrians. Lower the forks to the A
ground.
Phase 1
out (fig.1).
Fig. 3
14
MAST ASSEMBLY CHAIN TENSIONER AND CHAIN
Phase 2
WOODEN BEAM
Raise the forks by approximately two metres using the controls in the E
cab.
Place the wooden beam beneath the inner mast channel (ref.A fig.2).
Lower the forks until they rest on the beam, continue the descent until
the chains are loose.
Position the key switch to OFF and disconnect the bat- F

tery. Fig. 4
Phase 3 Fig. 5
Climb up the ladder with the tools and secure the safety harness to the
cab.
Insert the lift belt beneath the upper crossbar of the inner upright of the
hook (fig.3). Climb down the ladder, raise the bridge crane and take up
the slack in the belt.
Phase 4
Using the taper end pliers remove the cotter pin on the chain tensioner
on the inner upright of the mast assembly (ref.B fig.6).
Using the open ended spanners, unscrew and remove the nuts fastening
the chain tensioner (ref.C fig.6). Extract the chain tensioner upwards.
Using the taper end pliers remove the cotter pin and the hinge pin secur-
ing the chain to the chain tensioner (ref.D fig.6).
Phase 5
Using the taper end pliers remove the cotter pin on the chain tensioner
at the top on the outer upright of the mast assembly (ref.E fig.4).
Using the open ended spanners, unscrew and remove the nuts fastening Fig. 6
the chain tensioner (ref.F fig.4). Extract the chain tensioner upwards,
retrieve the chain by sliding it on the hose sheave and proceed with the
D
replacement.
C B
15
FORK CHAIN TENSIONER AND CHAIN
Phase 2
WOODEN BLOCK
neath.

tery.
Fig. 7
Phase 3
TAPER END PLIERS - 2 OPEN ENDED SPANNERS SIZE 24 mm Fig. 8
at the top (ref.G fig.8). Rest the chain on the forks.
Using the open ended spanners, unscrew and remove the nuts fastening
the chain tensioner (ref.H fig.9). Extract the chain tensioner upwards.
at the bottom (ref.I fig.10).
Retrieve the chain and proceed with the replacement. G
ASSEMBLY
Do not reuse the chain anchoring safety pins, use new Fig. 9
cotter pins, ensuring they are the correct size.
Fig. 10
16
RENEWAL OF THE MIDDLE SECTION CHAIN SHEAVES

3 STAGE MAST
Equipment and tools
Fig. 1

load capacity load capacity ladder safety harness
1200 kg 1200 kg
external circlip
wooden beam
pliers Fig. 2
Procedure
ground. A
Phase 1
out (fig.1).
Phase 2
WOODEN BEAM
Raise the forks by approximately two metres using the controls in the
cab.
Place the wooden beam beneath the inner mast channel (ref.A fig.2). Fig. 3
Lower the forks until they rest on the beam, continue the descent until
the chains are loose.
17
Fig. 4
Turn the ignition key to OFF and disconnect the battery.
Phase 3
cab.
Insert the lift belt beneath the upper crossbar of the inner upright of the
mast assembly by making a noose and hook the ends to the bridge crane A
hook (fig.3). Climb down the ladder, raise the bridge crane and take up
the slack in the belt.
Phase 4
MEDIUM SIZE ELASTIC RING OPENING PLIERS
Use the pliers to remove the circlip securing the sheave (ref.B fig.4).
Remove the hose sheave and proceed with the replacement.
18
RENEWAL OF THE MIDDLE CYLINDER CHAIN SHEAVE

3 STAGE MAST
Equipment and tools
Fig. 1
fixed gauge span-

T handle hex key
ner hammer clamp gudgeon
6 mm
18 mm
Procedure
ground.
Phase 1
Carry out the fork chain dismantling procedure (see "CHAIN AND CHAIN
TENSIONER REPLACEMENT").
Phase 2
Using the open ended spanner, unscrew and remove the screws fastening B
the two hose sheaves at the sides of the chain sheave (ref.A fig.1).
Remove the two sheaves.
Fig. 2
Phase 3
6 mm "T" HANDLE HEX KEY - HAMMER - CLAMP GUDGEON Ø30
mm
Using the T-handle hex key, unscrew and remove the sheave pin retain-
ing screw (ref.B fig.2).
Using the hammer and clamp gudgeon extract the pin, remove the sheave
and proceed with replacement.
19
20
SERVICE SMALL FORK MAST MECHANICS
Small fork mast

mechanics
FORK CARRIAGE�� 2
KEY TO FORK CARRIAGE COMPONENTS�� 2
REMOVAL OF THE FORK CARRIAGE�� 3
REMOVAL OF THE SLIDING BLOCKS�� 4
BEARING REPLACEMENT�� 6
1
SMALL FORK MAST MECHANICS SERVICE
FORK CARRIAGE
KEY TO FORK CARRIAGE COMPONENTS
10
11
12 6 7
5
4

1 Forks 7 Bearing
2 Hydraulic block 8 Side shift cylinder
3 Fixed frame 9 Upper sliding block
4 Movable frame 10 Anti-overturning system block
5 Flange 11 Movable frame sliding blocks
6 Tilt cylinder 12 Lower sliding block
2
REMOVAL OF THE FORK CARRIAGE

Equipment and tools
Shäfer wrench for

wooden block taper end pliers
connectors
Procedure
Fig. 2
A
Phase 1
out. Remove the cover to access the hydraulic control valve (fig.3).
Phase 2
WOODEN BLOCK
Using the controls in the cab, make the retractable carriage come fully out.
neath. Place the wooden block under the forks (fig.1). Lower the clamps
to rest on the blocks and continue until the end stroke of the cylinder.
Phase 3
at the top (ref.A fig.2). Rest the chain on the forks. Using the Shäfer Fig. 3
wrench, detach the hydraulic pipes on the control valve of the fork car-
riage. Disconnect the electric cables from the fork carriage.
Phase 4
Raise the cylinder using the controls in the cab until the fork carriage is fully extracted from below. Set the
fork carriage in a safe place and proceed with dismantling.
3
REMOVAL OF THE SLIDING BLOCKS

The sliding blocks must be replaced in the event of wear, that is if their thickness is:
• upper sliding blocks: less than 4.5mm
• movable sliding blocks: less than 3mm
Equipment and tools
tackle 2 lifting slings

Allen key flat head screw-
load capacity load capacity hammer pin punch
10 mm driver
1000 kg 1000 kg
Procedure Fig. 1
A
Phase 1
Remove the forks. Fig. 2
out and raise the forks by approximately one metre.
Phase 2
10 mm Allen wrench
anti-turnover block (ref.A fig.1). Remove the block.
Phase 3
HOIST - 2 LIFTING SLINGS
Harness the movable frame with the lift belts. Hook the lift belts onto the
hoist.
Turning the movable frame, raise it with the hoist and extract it from the
fixed frame (fig.2).
4
REMOVAL OF THE LOWER SLIDING BLOCK

Fig. 3
Phase 4
MEDIUM FLAT BLADE SCREWDRIVER
Using the medium flat blade screwdriver, lever between the sliding block
and the fixed frame. Remove the lower sliding block (ref.B fig.3) and
REMOVAL OF THE UPPER SLIDING BLOCKS B
Phase 4
Fig. 4
MEDIUM FLAT BLADE SCREWDRIVER C
Using the flat blade screwdriver, prise out the upper sliding block (ref.C
fig.4). Proceed with replacement
REMOVAL OF THE MOVABLE FRAME SLIDING BLOCKS
Phase 4
MEDIUM FLAT BLADE SCREWDRIVER - hammer - pin punch
With the flat head screwdriver unscrew the screws fastening the sliding
block (ref.D fig.5). Using the hammer and pin punch, strike the pins (ref.E
fig.5), remove the sliding block and proceed with replacement. Fig. 5
5
BEARING REPLACEMENT
Equipment and tools
T-handle hex key

plastic hammer
2.5 mm
Procedure
Phase 1
Carry out the fork carriage removal procedure (see “REMOVAL OF THE A
FORK CARRIAGE”).
Phase 2
2.5 mm T-HANDLE HEX KEY - PLASTIC HAMMER
bearing to the mast assembly (ref.A fig.1). With the aid of the hammer,
remove the bearing and proceed with the replacement.
6
SERVICE REDUCTION GEAR
Reduction gear
KEY TO REDUCTION UNIT COMPONENTS�� 2
REMOVAL OF THE REDUCTION UNIT�� 4
REPLACEMENT OF TRACTION MOTOR DRIVE SHAFT RADIAL O-RING�� 6
REPLACEMENT OF WHEEL SHAFT RADIAL O-RING�� 7
CHANGING THE REDCUTION UNIT OIL�� 9
1
REDUCTION GEAR SERVICE
KEY TO REDUCTION UNIT COMPONENTS
41
3
4
5
6
8
9 10
11
12 13
15
14
17
16
18
19
20
22
21
23
42
32
40 39 38 37 36 35 34 33 24 25 26 27 28 29 30 31
type gearbox serial number

TYPE SERIAL-N°
42
PARTS LIST N° TOTAL RATIO
gearbox model CUSTOMER CODE N° gearbox transmission
2
1 Revolving ring bearing 22 Spring pin

2 Cap screws 23 Reduction unit housing
3 Steering pinion 24 Elastic dowel
4 Steering ring 25 Crown wheel
5 Washer 26 Circlip
6 Hex nut 27 Taper roller bearing
7 Helical gear 28 Spacer
8 Taper roller bearing 29 O-ring
9 Radial seal ring 30 Reduction unit housing cover
10 Spacers 31 Cap screw
11 Elastic ring 32 Seal rings
12 Ball bearing 33 Oil drain plug
13 Taper roller bearing 34 Oil filler plug
14 Crown wheel coupling pinion 35 Taper roller bearing
15 Bevel pinion 36 Spacer
16 Hex nut 37 Radial seal ring
17 Screw cap 38 Wheel shaft
18 Seal ring 39 Wheel pin
19 Ball bearing 40 Wheel shaft guard
20 Cover 41 Gearbox type punching
21 Cap screw 42 Data plate
3
REMOVAL OF THE REDUCTION UNIT

Equipment and tools
open ended span- tackle 2 lifting slings

socket wrench
ner load capacity load capacity ratchet torque wrench
16 mm
10 mm 1000 kg 1000 kg
Procedure
Fig. 1
A
B
Phase 1
Perform the traction wheel dismantling procedure (see “DISMANTLING
THE TRACTION WHEEL” in the “BASE TRUCK MECHANICS” sec-
tion).
Phase 2
Perform the traction motor dismantling procedure (see “DISMANTLING C
THE TRACTION MOTOR” in the “BASE TRUCK MECHANICS” sec-
tion).
Phase 3
Perform the steering motor dismantling procedure (see “DISMANTLING Fig. 2
THE STEERING MOTOR” in the “BASE TRUCK MECHANICS” sec-
tion).
Phase 4
Empty the reducer of all oil (see “REPLACEMENT OF REDUCER
OIL”).
Phase 5
ing the bracket inside the motor compartment (ref.A fig.1). Remove the
bracket (ref.B fig.1).
Fig. 3
4
Phase 6
16 mm SOCKET WRENCH - RATCHET D
Disconnect the connector of the centring sensor.
securing the plate to the frame (ref.C fig.2).
Phase 7
HOIST - 2 LIFT BELTS - 16 mm SOCKET WRENCH - RATCHET
Secure the reduction unit plate with the two lift belts. Attach the belts to Fig. 4
the hoist (fig.3).
Using the hoist, slowly lift the plate together with the reduction unit and
rest it on a work surface.
securing the reduction unit to the plate (ref.D fig.4). Remove the plate
and proceed with dismantling the reduction unit.
INSTALLATION
The screws securing the reduction unit to the plate must

be tightened using a torque wrench to a torque of 88 Nm.
5
REPLACEMENT OF TRACTION MOTOR DRIVE SHAFT RADIAL O-RING

Equipment and tools
small flat blade

brush
screwdriver
Procedure

Phase 1
Perform the traction motor dismantling procedure (see “DISMANTLING
THE TRACTION MOTOR” in the “BASE TRUCK MECHANICS” sec-
tion).
Phase 2
SMALL FLAT BLADE SCREWDRIVER
Using the screwdrivers extract the radial o-ring from it's seat (fig.1) and
proceed with its replacement.
INSTALLATION
Fig. 1
In the assembly stage apply a uniform layer of "SHELL
ALVANIA R3" grease over the o-ring radial gasket.
6
REPLACEMENT OF WHEEL SHAFT RADIAL O-RING

Equipment and tools
hex socket
seelant medium elastic
workbench puller wrench ratchet
Loctite 574 ring opening pliers
8 mm
small flat blade

clamp gudgeon hammer brush
screwdriver
Procedure

A
Phase 1
Carry out the reduction unit removal procedure (see “REMOVAL OF THE
REDUCTION UNIT”). Fig. 1
Phase 2
HEXAGONAL 8 mm "T" SECTION SPANNER - RATCHET
Unscrew and remove the screws fastening the reducer box casing (ref.A
fig.1).
Remove the cover (fig.1). C B
Phase 3
EXTRACTOR - MEDIUM SIZE ELASTIC RING OPENING PLIERS
Using the extractor remove the conical roller bearing (ref.B fig.2) from
the wheel drive shaft.
Use the elastic ring pliers to remove the elastic ring holding the wheel
drive shaft bearing (ref.C fig.2).
Fig. 2
7
Phase 4
CLAMP GUDGEON - HAMMER
Position the clamp gudgeon against the wheel drive shaft (fig.3) and use
the hammer to expel the shaft out the other side (ref.D fig.4). Retrieve
the wheel shaft protection (ref.E fig.4).
Phase 5
Remove the bevel gear ring (ref.F fig.5).
Retrieve the spacers (ref.H fig.5) and the conical roller bearing (ref.H
fig.5).
Fig. 3
Phase 6
SMALL FLAT HEAD SCREWDRIVER
Using the screwdrivers extract the radial o-ring gasket from it's seat (ref.I
fig.6) and proceed with its replacement.
D E
INSTALLATION
In the assembly stage apply a uniform layer of "SHELL

ALVANIA R3" grease over the o-ring radial gasket.
Fig. 4
During the assembly stage apply "LOCTITE 574" seelant

to the reducer casing cover.
HS
F
G
Fig. 5
Fig. 6
8
CHANGING THE REDCUTION UNIT OIL

Equipment and tools
hex socket
oil resistant gloves oil pan wrench ratchet
6-12 mm
T handle hex key

extension torque wrench
5 mm
Procedure
Fig. 1
battery.
Use caution as the oil in the reduction unit will be hot
after use of the truck. It is advisable to wear gloves that
Do not dispose of used oil in the ground or by pouring it
down the drain. Contact a waste disposal company spe-
cialised in the disposal and recycling of industrial oils. A
Phase 1
(ref.A fig.1).
Fig. 2
9
Phase 2
OIL PROTECTIVE GLOVES - OIL RECOVERY SUMP
Clean the area around the oil filler and drain plugs thoroughly. Place a
suitably sized oil pan beneath the drain plug.
C
Phase 3
OIL PROTECTION GLOVES - HEXAGONAL 6 mm SOCKET WRENCH
- RATCHET - EXTENSION - TORQUE WRENCH - OIL SYRINGE
Using the hexagonal socket wrench, the ratchet and the extension
unscrew the oil filler plug (ref.C fig.3), remove the cap and the gasket.
Using the same tools unscrew the oil drainage cap (ref.D fig.3), remove
the cap and gasket. Empty the oil sump completely.
Clean the drain plug thoroughly from accumulated impurities that may
D
have collected during reducer operation and screw back on together with
a new gasket.
Fig. 3
The tightening of the oil drain cap must be done using a
torque wrench with a torque tightening power of 22 Nm.
Model
Oil type Quantity
reduction unit
GK20 Standard and Cold Store ~2.2 litres
FUCHS
GK25 TITAN CYTRAC HSY SAE 75W-90 ~3.3 litres
To top up use a pressure aspiration syringe (fig.4), that will easily enable L
OI
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 oil filler plug must be tightened using a torque wrench

to a torque of 22 Nm.
Fig. 4
10
SERVICE BRAKING SYSTEM
Braking system
KEY TO THE TRACTION MOTOR ELECTROMAGNETIC BRAKE COMPONENTS�� 2
KEY TO THE LOAD WHEEL ELECTROMAGNETIC BRAKE COMPONENTS�� 3
OPERATION�� 4
BRAKING systems�� 4
REMOVAL OF THE BRAKES�� 5
REMOVAL OF THE DRIVE WHEEL ELECTROMAGNETIC BRAKE�� 5
REMOVAL OF THE LOAD WHEEL ELECTROMAGNETIC BRAKE�� 7
1
BRAKING SYSTEM SERVICE
KEY TO THE TRACTION MOTOR ELECTROMAGNETIC BRAKE COMPONENTS
Ref. Description
1 Retaining screw
2 Electromagnet
3 Brake plate
4 Circlip
5 Pinion
6 Friction disc
7 Dust cover
8 Disc
2
KEY TO THE LOAD WHEEL ELECTROMAGNETIC BRAKE COMPONENTS
2 5
Ref. Description
1 Electromagnet with brake liner

2 Brake disk
3 Spring
4 Bush
5 Brake regulator
3
OPERATION
BRAKE FITTED ON THE TRACTION MOTOR
The electromagnetic brake mounted on the traction motor is only a parking brake and it is a spring-operated
brake.
When the electromagnet is powered, it attracts the brake plate and releases the friction disc, allowing the
latter to rotate freely.
When the power supply to the electromagnet is cut, the springs push the brake plate down onto the friction
disc, thus applying the brake.
BRAKE FITTED ON THE LOAD WHEELS

Tall machines are fitted with electromagnetic brakes on the load wheels for safer braking.
The electromagnet is secured on the base of the wheel pin while the brake disk is secured to the wheel
with screws, the brake regulator and the springs.
Braking is activated by pressing on the brake pedal in the cab, the electromagnet attracts the brake disk
against the brake liner creating friction between these two parts.
BRAKING systems
There are 4 braking systems used:
• Release braking
• Braking on direction reversal
• Emergency braking
• Parking brake
A) Release braking
Controls the deceleration ramp when the drive control is released.
B) Braking on direction reversal

Controls the deceleration ramp when the travel direction is inverted.
“Braking on direction reversal", also know as counter current braking, consists of reversing the current
supplied to the motor, thus changing the direction of travel when the truck is in motion.
The braking current must be adjusted so that the truck stops in a distance that is at least not less than the
length of the truck itself.
C) Emergency braking
Emergency braking occurs when the dead man's pedal is released or an alarm is triggered that requires an
immediate arrest of truck traction or when one of the emergency buttons on the truck is pressed.
The braking action is performed by the electromagnetic brake mounted on the traction motor and by the
load wheels (when fitted).
D) Parking brake
The "parking brake" action is performed by the electromagnetic brake and is applied when the truck is
stationary and the dead man's pedal is released.
4
REMOVAL OF THE BRAKES

REMOVAL OF THE DRIVE WHEEL ELECTROMAGNETIC BRAKE
Equipment and tools
Fig. 1
T handle hex key external circlip large flat blade

puller
5 mm pliers screwdriver
Procedure
ground, turn the key switch to OFF and disconnect the
battery.
When replacing the rotor, the pinion must also be re-

placed.
Fig. 2
Phase 1
5 mm T-HANDLE HEX KEY Fig. 3
Use the T-handle hex key to unscrew and remove the motor cover screw B
(ref.A fig.1).
Phase 2
Remove the dust cover.
Using the T handle hex key, unscrew the three screws securing the elec-
tromagnetic brake to the traction motor (ref.B fig.3).
Disconnect the connector from the brake and withdraw it from the tab.
Remove the electromagnetic brake from the motor.
5
Phase 3
EXTERNAL CIRCLIP PLIERS - PULLER E
Slide out rotor (ref.D fig.4) from the pinion. F
Using the circlip pliers, remove the circlip from the drive shaft (ref.E fig.4).
Using the extractor remove the pinion (ref.F fig.4).
D
INSTALLATION
After mounting the electromagnetic brake does not require

adjustment.
Fig. 4
6
REMOVAL OF THE LOAD WHEEL ELECTROMAGNETIC BRAKE

Equipment and tools
socket wrench for

T handle hex key
hydraulic jack wooden block self-locking ring ratchet
6 mm
nut
Procedure
battery.
Phase 1 Fig. 1
Position the hydraulic jack beside the load wheel and lift until the wooden
stock can pass beneath.
Set the wooden block under the clamp, lower the jack to rest the truck
on the block and take up the slack on the jack (fig.1).
Phase 2
SOCKET WRENCH FOR SELF-LOCKING RING NUT - RATCHET
Using the socket wrench for the self-locking ring nut and the ratchet,
a
unscrew and remove the ring nut (ref.A fig.2), remove the toothed
washer. Fig. 2
Extract the wheel from the hub and dismantle or replace.
C Fig. 3
Phase 3
HEXAGONAL 6 mm "T" SECTION SPANNER
Using the T-handle hex key, remove the screws securing the brake disk to
B
the wheel together with the bush and spring (ref.b fig.3). When removing
the disk, pay attention to the springs (ref.C fig.3).
7
Phase 4
8 mm T HANDLE HEX KEY
Using the T-handle hex key, remove the screws fastening the electro-
magnetic brake at the base of the wheel pin (ref.D fig.4). Disconnect the
connector and remove the brake.
D
INSTALLATION Fig. 4
The screws securing the brake disk to the wheel must be

tightened using a torque wrench to a torque of 25 Nm. Ap-
ply Loctite 270.
8
SERVICE ROUTINE MAINTENANCE
routine maintenance
OILS AND LUBRICANTS�� 4
CLEANING PRODUCTS�� 4
SCHEDULED MAINTENANCE�� 5
MAINTENANCE PROCEDURES�� 8
CHECK HEIGHT OF OUTRIGGERS OFF GROUND�� 8
CHECK THE SCREWS AND BOLTS�� 9
CHECK CHAINS�� 14
CHECK FORKS�� 15
CHECK WEAR ON ELECTROMAGNETIC BRAKE LINERS�� 16
CHECK OIL LEVEL IN TANK�� 16
1
ROUTINE MAINTENANCE SERVICE
WARNINGS
• If maintenance operations are carried out immediately after the truck is stopped, some components of
the motor and of the hydraulic system could be hot. Always wear the personal protective equipment in
situations requiring it.
• Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbut-
toned jackets or tops with open zippers that can get caught up in moving parts.
• Never do any cleaning, lubrication or maintenance work with the battery connected.
• Never perform any servicing on the machine with persons at the controls, unless they are accredited
operators and help with the operation to be performed.
• Using compressed air to clean the parts, protect yourself with goggles that have side protection. The
maximum air pressure must not exceed 1 bar.
• Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable
and non-toxic trade solvents.
• Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away
into a closed metal container.
• The capacitors in the transistor control unit can keep an electric charge even after disconnecting the
battery. To avoid electric shocks and personal injury, discharge the capacitors before inspecting or
repairing any component in the electric compartment. Wear safety glasses. Make sure the battery has
been disconnected.
• Do not file or lubricate the contacts of the contactors. This could cause the contacts to stick and, as a
result, loss of control and damage to property or injury to people.
• Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.
Special companies can be employed to dispose of or recycle industrial oils according to the laws in
force in individual countries.
• Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate
under the skin; in such cases, having to make a check, use a card or a piece of wood.
• Protect the hydraulic system from dirt or contaminants getting inside when checking the fluid level of
changing the filter.
• Never operate the pump without an adequate quantity of fluid in the hydraulic system. Operation with
low levels of hydraulic fluid will damage the hydraulic pump.
• Do not place any tools on the battery. Metal items on the battery can generate accidental short-
circuiting and possibly damage or injury.
• The batteries generate explosive gases. Keep the vents clean. Keep sparks and flames well away
from the battery compartment. Pay attention not to create any sparks when disconnecting the battery
cables. Disconnect the battery during maintenance work.
• Always use a spreader bar and slings to raise the battery vertically with the specific eyelets. Do not
use chains or slings without a spreader bar, you would risk damaging the battery casing. Check that
the battery compartment is clean and dry. When the battery is in service, the aeration plugs must all be
installed. If the aeration plugs are not installed, electrolyte can come out, corroding the battery casing
and compartment.
• The acid in the electrolyte can cause injury. If the electrolyte gets spilled it should be cleaned up with
water. Neutralize the acid with a solution of sodium bicarbonate (soda). Areas of the skin that come
into contact with the acid must be rinsed with water immediately. Acid splashed into the eyes must be
washed away with water constantly for at least 10 minutes, then call a doctor.
2
• The batteries belong to the counterweight system of the lift truck. When installing a battery that is too
small, the lift truck might not have enough weight for the nominal load. When replacing a battery, see
the truck identification data plate to check that the battery has the rated capacity and correct dimen-
sions. See “TRUCK AND LOAD CAPACITY IDENTIFICATION DATA” in the “PRESENTATION” sec-
tion for the exact battery specifications for the lift truck at issue.
• Do not work under a raised carriage. Lower the carriage or use a safety chain to prevent the carriage
from lowering during maintenance work on the mast and on the lifting chains.
• Never repair damaged forks using heat or welding. The forks are made of steel that is hardened with
special procedures. Replace damaged forks.
• Before servicing the hydraulic system you must eliminate any residual pressure inside it.
Close the valves at the end of the maintenance work.
• The maintenance and repair procedures must be carried out only by specialist service technicians with
the relevant authorizations and appropriate training. Repairs carried out incorrectly can create hazard-
ous work conditions for the operator.
• Do not utilize a truck if it requires repairs. Affix a “DO NOT USE” label on the steering wheel. Remove
the key and disconnect the battery.
3
OILS AND LUBRICANTS
Application Std Cold Trademark Type

store
OIL for lubrication of the  Shell TELLUS S2 V 46

HYDRAULIC CIRCUIT
 Shell AEROSHELL FLUID 41
OIL for lubrication of the SPIRAX S6 AXME 75W-
REDUCTION UNIT   Shell 90
GREASE for lubrication of
REDUCTION UNIT OUTER GEAR   Shell GADUS S2 OGH 0/00
(STEERING CROWN WHEEL AND PINION)
Klüber KlüberOIL 4UH 1-150N
 Lubrication VG 150
OIL for lubrication of
LIFTING CHAINS  Rexnord Kette REXOIL VG 150
Klüber KlüberOIL 4UH 1-68N
 Lubrication VG 68
MAST BEARINGS SLIDING GUIDES Klüber GRAFLOSCON C-SG - 0
door closing device (cab for application   Lubrication ULTRA
in cold room)
RETRACTABLE CARRIAGE BEARINGS SLIDING  Shell GADUS S2 V100 2
GUIDES
BATTERY TRAY SLIDING BLOCKS
SIDE SHIFT GUIDES
SIDE SHIFT SLIDING BLOCKS  Shell AEROSHELL GREASE 6
GREASE RETRACTABLE CARRIAGE CYLINDER
JOINT BEARINGS
Insulation of BATTERY TERMINALS Pure Vaseline
CLEANING PRODUCTS
Casing and plastic cover cleaning - Cleaning of painted truck parts
For general cleaning of the truck, use only dry air, damp rags or degreasing detergents.
Do not use water jets, vapours, solvents or flammable products that may damage the
truck or that can be dangerous for the operator.
Motor and electronic system cleaning

For general cleaning purposes use dry air at low pressure and a clean dry brush.
Do not use wet rags, water jets, vapour, solvents or flammable products that may damage
the truck or that may be dangerous for the operator.
Cleaning MAST AND RETRACTABLE CARRIAGE BEARINGS SLIDING GUIDES

Use degreasing solvents.
Do not use water jets, vapour, solvents or flammable products that may damage the small
mast or be harmful to the operator.
4
SCHEDULED MAINTENANCE
 = checks and maintenance to be performed by the operator or the person assigned to truck maintenance
(refer to the instructions given in the MAINTENANCE section of the operator's manual)
 = checks and maintenance operations that should only be performed by a technician authorised by the truck manufacturer
(refer to the instructions given under the following headings in this section)
x = replacement of parts that should only be performed by a skilled technician authorised by the truck manufacturer
(refer to the instructions given in the sections of this manual)
Maintenance intervals
Operation description every every every every

8 hours 1000 hours 3000 hours 5000 hours
1 day 1 year 2 years 3 years
Check the screws and bolts 
Check the integrity of the cab and frame fixing supports 
Check the conditions of the guides for sliding the retractable

carriage
Clean the guides for sliding the retractable carriage 
Check the height of the outriggers off the ground (1)

FRAME, CAB, OVERHEAD GUARD
Visually check the main welds 

Check the functionality of the levers for emergency exit (cab
for 
application in cold room)
Check the adjustment of the door closing device and lubrica-
tion (Cab for application in cold room) (6)
Check the conditions of the door hinge bearings (cab for ap-
plication in cold room) (6) (2)
Replacement of heater filter (cab for application in cold room)
(6)
Dynamic braking action check  

BRAKING SYSTEM
Reverse braking action check  

Normal braking action check  
Emergency braking action check  
Electromagnetic parking brake and coil efficiency check 
Electromagnetic parking brake liner wear check (2)

Load wheels brake liner wear check(2) 
Oil leak check  
HYDRAULIC SYSTEM
Valve operation check 

Tank oil level check 
Check the condition and tension of the hoses (3)

Tank oil change x
Renew oil filter cartridge x
Renew plug with air cleaner x
Motor insulation check 
Cable connection check
MOTORS

Fixing nut condition check 
Bearing noise check 
General cleaning 
Oil leak check  
REDUCTION
Check oil level 

Change oil in reduction unit
UNIT
(4)
Check reduction unit outer gear teeth wear (steering crown

wheel and pinion)
5

Adjust retractable carriage side rollers 
Check the screws and bolts
RETRACTABLE CARRIAGE,

Check chain tensioner conditions(2) 
Check lifting chain link and pin wear (2)
MAST, FORKS

Check lift chains stretch 
Check conditions of chain pulleys, tubes and cables 
Clean mast bearings sliding guides 
Check conditions of mast bearings sliding guides 
Check fork condition  
Check conditions of bearings of retractable carriage and

mast(2)
Check the fork support device screws 
fork support
3 STAGE MAST
Check play of side shift outrigger sliding blocks 

device
Check side shift and tilt cylinder rods and check steering

bushes(2)
Check wear of side shift upper and lower sliding blocks(2) 
Check conditions of fork support device bearings (2)

fork support
Check the screws securing the hooks and the tilt cylinders 
4 STAGE MAST
device
Tilt cylinders integrity check 
Check wear on slide blocks (2) 
Check conditions of fork support device bearings (2) 
Grease reduction unit outer gear (steering crown wheel and


pinion)
GREASING POINTS
Grease battery tray sliding blocks 

Grease retractable carriage cylinder joint bearings 
Grease retractable carriage bearings sliding guides 
Grease mast bearings sliding guides 
Lubricate lifting chains 
Grease side shift 
Check the seat conditions and operation  
Check seat belt conditions and operation  
INSTRUMENTS
CONTROLS,
CAB
Check machine functions with actuating controls and

 
instrumentation
Battery plug/socket integrity check  

Check conditions of electrical power connections 
ELECTRICAL
SYSTEM
Check conditions of electronic controllers auxiliary


connections
Electrical wiring check 
Sensor operation check 
General cleaning of electrical panel 
6

SAFETY DECALS
Check safety labels and decals  
Clean safety labels and decals  
Check condition and wear of drive wheel(2)  

Check drive wheel fixing nuts
WHEELS & TYRES

Check condition and wear of load wheels (2)
 
Check load wheel fixing nuts 
Check conditions of load wheel bearings (2)

Check condition and wear of steering side rollers(2) 
Check steering side rollers fixing nuts 
Check condition of steering side rollers bearings(2)  
Battery charge check  

Cable connection check 
BATTERY
Liquid leaks check  

Electrolyte density check 
Electrolyte level check(5) 
Battery insulation check 
(1)
check also when replacing the drive wheel
(2)
replace if necessary
(3)
replace in the following situations:
• a shift of the connection on the pipe;
• the presence of damage, cuts or abrasions on the superficial layer;
• hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
• the presence of cracks, damages or strong corrosion on the connection;
• the presence of leaks along the pipe or at the coupling joint;
• the presence of permanent creases, compression, flattening or twists in the pipe;
• the presence of blisters, softening, wear of the external coat.
(4)
change recommended after 7500 hours or 5 years
(5)
fill up whenever the electrolyte levels falls to 5-10 mm (0.19-0.39 in) from the splash guard
(6)
every 500 hours
Trucks working in cold stores must be lubricated every 500 hours, or even more frequent-
ly in the case of particularly intensive use.
7
MAINTENANCE PROCEDURES
CHECK HEIGHT OF OUTRIGGERS OFF GROUND
Equipment and tools
Fig. 1
open-ended span-
caliper ner
46 mm
Procedure
Phase 1
CALIPER
Check that the two outriggers have not been damaged and have not A
come loose.
Use the caliper to measure the height of the outriggers off the ground
(fig.2).
The correct value of X is given in the following table: X ± 2 mm
B
Model X = 27 mm X = 20 mm X = 10 mm floor
1.4-1.6 ton 5000 < h3 < 8200 8200 < h3 < 9400 h3 > 9400 Fig. 2
1.6 ton Narrow 5000 < h3 < 7100 7100 < h3 < 8200 h3 > 8200
2.0-2.5 ton 4650< h3 < 7500 h3 > 7500 -
1.6 ton HD - h3 > 8200 h3 > 8200
2.0 ton HD - h3 > 8200 h3 > 8200
h3 = lift height (see MAST MECHANICS section).
Phase 2
Loosen the outrigger locking nut with the open ended spanner (ref.A fig.2). Unscrew or screw in the outrig-
ger (ref.B fig.2) to reach the desired height. Tighten the locking nut.
8
CHECK THE SCREWS AND BOLTS

Equipment and tools
open ended span- hexagonal "T"

torque wrench
ners section spanners
Procedure
Move the carriage to a safe place, away from areas of transit of other vehicles and all
pedestrians. Set the key switch to OFF and disconnect the battery.
TORQUE WRENCH - OPEN ENDED SPANNER

Check the wear of the screws and bolts of the truck and check that they are sufficiently tight according to
the following table:
Tightening
Screw or nut Tolerance Ref. figure
(Nm)
Screws fastening the mast to the retractable carriage 300÷330 - fig.2
Screws fastening the bracket to the mast block - fig.4
Limit stop screws of the retractable carriage - fig.5
Screws fastening the left boom of the safety roof to the chassis 55 + 0÷10% fig.9
Screws fastening the right boom of the safety roof to the chassis 55 fig.11
Screws fastening the chassis to the cab 220 fig.14-15
Ferrules fastening the load wheels - fig.16
Screws fastening the drive wheel 140 - fig.17
Screw fastening the MDU assy plate to the chassis 88 - fig.18
Screws fastening the traction motor to the reduction unit 34 fig.18
Screws fastening the reduction unit to the MDU assy 88 fig.18
Screws fastening the steering motor to the MDU assy plate 88 fig.19
9

load capacity load capacity ladder safety harness
3000 kg 3000 kg

cab.
Fig. 1
Insert the lift belt beneath the upper crossbar of the middle section of the
hook (fig.1). Climb down the ladder, raise the bridge crane to reveal the
screws securing the mast assembly to the truck base (fig.2).
Fig. 2
Fig. 3
OPEN ENDED SPANNER 19 mm
Using the torque wrench, check the tightening of the screws securing
both side blocks of the mast assembly (fig.4).
Fig. 4
10

Fig. 5
Using the torque wrench check the tightening of the limit stop screws of
the retractable carriage (ref.D fig.4).
Fig. 6
Using the T-handle hex key, unscrew and remove the screw locking the
bonnet (ref.B fig.2) and open the bonnet (fig.7).

Using the torque wrench, check the tightening of the screws fastening
the left boom of the safety roof to the chassis (fig.9).
Fig. 9 Fig. 8
Fig. 7
11
Fig. 10
medium/large
crosshead screw- B
driver
B B
panel located under the control panel (ref.B fig.10).
Remove the panel.

Using the torque wrench, check the tightening of the screws fastening
the right boom of the safety roof to the chassis (fig.11).
Fig. 11
5 mm T-HANDLE HEX KEY Fig. 12

bonnet (fig.13).
24 mm OPEN ENDED SPANNER - 24 mm HEX SOCKET WRENCH

Using the torque wrench check the tightening of the screws fastening the
cab to the chassis (fig.14-15).
Behind the electronic controls panel Behind the oil reservoir of the hydrau-
lic system
Fig. 15 Fig. 14 Fig. 13
12
SOCKET WRENCH FOR SELF-LOCKING FERRULES

Using the torque wrench check the tightening of the ferrules fastening
the load wheels(fig.16).
Fig. 16

bonnet (fig.13).
12 mm SOCKET WRENCH - RATCHET - EXTENSION

Using the torque wrench check the tightening of the screws fastening
the drive wheel (fig.17).
B Fig. 17

Fig. 18
of the electronic controls. Unscrew and remove the screw locking the A
bonnet (fig.13).
13-16 mm HEX SOCKET WRENCH

Using the torque wrench, check the tightening of the screws fastening the B
MDU as(ref.A fig.18), of the traction motor to the reduction unit (ref.B C
fig.18), of the reduction unit to the plate (ref.C fig.18), of the steering
motor to the plate (fig.19).
Fig. 19
13
CHECK CHAINS
Equipment and tools
caliper
Replace the chains if they have stretched beyond 3% of their length or if the links, hinge pins or chain
tensioner are worn to such an extent that replacement is indispensable
Measure the extension with a callipers (fig.1) on many sections 10 steps apart taken in the more stressed
sections.
A) Pin wear
B) Pin damage
C) Link damage
D) Link edge wear
E) Wear and ovalization of the links
F) Too much play between the links
G) Oxidization check
H) Wear and ovalization of the chain tensioner
I) Wear of the chain hinge gudgeon
c
A
b h
i
f
G
e d
Fig. 1 Fig. 2 Fig. 3
If chains are not excessively worn and stretched, replace them every 3 years (5000 hours) under normal
working conditions. Replace chains every 2 years (3000 hours) when the truck is used in cold rooms or
in corrosive environments.
14
CHECK FORKS
Equipment and tools
rule
There must be no cracks in the structure of the forks and particularly at welded joins (ref.A fig.1). If any
cracks are visible, replace the fork. Do not attempt any repairs by welding;
Measure the thickness of the heel (ref.B fig.1). If the thickness of the heel is less than 90% of the thickness
of the vertical bracket (ref.C fig.1) replace the fork.
The fork tips must be aligned to within 3% of the length of the fork at the time of installation on the carrier
plate (ref.D fig.1). Do not attempt to correct the alignment of the forks by altering the angle of the bend or
the connection between the carrier plate and the forks. Certain improvements can be obtained by shifting
the forks from one side of the carrier plate to the other, or by selecting other forks of corresponding length
from the equipment store.
In cases where there is a permanent deflection between the vertical bracket (ref.E fig.1) and the blade
(ref.F fig.1), the maximum acceptable angle is 93 degrees. If the angle (ref.G fig.1) exceeds 93°, the fork
must be replaced.
A
E
A
G
B F
D
Fig. 1
15
CHECK WEAR ON ELECTROMAGNETIC BRAKE LINERS

See "REMOVAL OF THE BRAKE" in the "BRAKING SYSTEM" section.
CHECK OIL LEVEL IN TANK

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

funnel oil resistant gloves
5 mm
Procedure Fig. 1
A
Phase 1
(ref.A fig.1).
Fig. 2
16
Phase 2
Fig. 3
Check the oil level via the marks on the reservoir (fig.3).
If it is necessary to fill up oil, unscrew the reservoir cap (ref.C fig.4), un-
screw the breather valve (ref.B fig.4), place the funnel into the filler hole
and top up using the oil suggested in the table "OILS AND LUBRICANTS"
at the beginning of this section.
Screw the breather valve and the reservoir cap back on.
Fig. 4
B
C
17
Code: 4065749 Revision: 1 (12/2014)

Serviço R.1 (D435)

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Serviço R.1 (D435)

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Part no.

: 4065749 Revision: 1 (12/2014)

Technical information for Hyster service

This manual is intended solely for the specialized technicians of

Product support group

GUIDE TO USING THE MANUAL

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

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

GENERAL SAFETY RULES

SAFETY AT THE WORKPLACE

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE

Using suspension elements under conditions of unbalanced load

Belt capacity table

purple 1000 2000 1400 800

Rope capacity table

black 35 500 1000 700 400

Suspension element capacity table

purple 1000 1400 2100 2100

TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS

M4 0.7 7 3 2400 1.92 1.44 3.07 2.3 4.17 3.13

CORRECT METHOD FOR APPLYING FEMALE FITTINGS

METRIC REVOLVING FEMALE REVOLVING FEMALE jic 37°

REMOVING FEMALE BSP REVOLVING FEMALE ORFS

INSTRUCTIONS FOR INSTALLING FLEXIBLE HOSES AND FITTINGS

Special wrench for hydraulic couplings

VIEWS OF THE TRUCK

TRUCK AND LOAD IDENTIFICATION DATA

The truck identification data plate is located inside the

• Manufacturer's name • Max. battery weight

RESIDUAL LOAD PLATE

The load plate is located on the roof assembly

The load plate bears the following data:

MAST SERIAL NUMBER PUNCHING and location of documentation

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

6.2 lifting motor, power S3 15% kW 14 14 14

6.2 lifting motor, power S3 15% kW 14 14

10.1 working pressure for additional attachments bar 180 180

6.2 lifting motor, power S3 15% kW 14 14

10.1 working pressure for additional attachments bar 180 180

1.2 manufacturer’s type designation R1.6

1.2 manufacturer’s type designation R1.6N

1.2 manufacturer’s type designation R2.0

1.2 manufacturer’s type designation R2.5

1.2 manufacturer’s type designation R1.6HD

1.2 manufacturer’s type designation R2.0HD

Height of mast Height of mast

R2.5 R2.0HD 121.6

Height, mast Extended

Truck base and mast assembled (option A)

CARRIAGE SOLD WITH BATTERY

Truck base and mast assembled (option A)

TOPPING UP THE OIL RESERVOIR

Equipment and tools

T handle hex key A

INSTALLATION OF THE BATTERY

WITH LATERAL REMOVAL

CONNECTION OF CABLES TO BATTERY

_ Tag coloured BLUE

Tag coloured RED

ASSEMBLY OF MOVING FORKS

Turn the keyswitch to OFF and disconnect the battery.

load rack assembly