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Dear Customer,
You have chosen the Aisle-Master articulated VNA (very narrow aisle)
fork lift truck. Thank you for showing your faith in the Aisle-Master
product. You now own a machine designed and manufactured in Ireland
by our team of experienced engineers using the most up to date design
techniques and technology with the sole aim of producing a machine
that is safe, reliable and efficient and the right tool for your material
handling needs. This is what makes the Aisle-Master one of the leading
products in the material handling industry.
In order to familiarise yourself with your truck in a quick comprehensive

manner please read this manual attentively. In addition to the
information regarding operation, this manual also contains important
maintenance checks and instructions for ensuring the continuous
reliable operation of your truck. Should you have any questions or
problems relating to your truck, please contact your Aisle-Master partner
who will be happy to respond to your questions, suggestions and/or
comments. We at Aisle-Master are confident that you will be wholly
satisfied with your Aisle-Master VNA truck.
Table of Contents
Page
Safety ...........................................................................................................S-1
The Meaning of Safety Statements ...............................................................S-2
Aisle-Master Forklift Safety Statements ........................................................S-2
Location of Decals ........................................................................................S-3
Decals ...........................................................................................................S-4
Safe Operation..............................................................................................S-5
Battery Charging ...........................................................................................S-5
Operating in Hazardous Areas......................................................................S-5
Introduction .................................................................................................1-1
Vehicle Description .......................................................................................1-2
Terminology Used in Manual ........................................................................1-2
Illustrations Used in Manual ..........................................................................1-2
Questions and Comments ............................................................................1-2
Component Identification ..............................................................................1-3
Information Plates .........................................................................................1-4
Serial Number ...............................................................................................1-5
Model Description .........................................................................................1-6
Before You Begin ........................................................................................2-1

Operator Training ..........................................................................................2-2
Operator Safety ............................................................................................2-2
Understanding Stability .................................................................................2-2
Knowing the Rated Capacity.........................................................................2-5
Understanding Workplace Conditions ...........................................................2-9
Operating Your Aisle-Master Forklift ........................................................3-1

Controls and Indicators .................................................................................3-2
Operator’s Pre-Use Checks ..........................................................................3-7
Operating Instructions – Basic Procedures ...................................................3-9
Operating Instructions – Handling a Load .....................................................3-13
Transporting an Aisle-Master Forklift ............................................................3-24
Aisle-Master Operator’s & Service Manual ii

Table of Contents
Page
Inspection and Maintenance ......................................................................4-1
Initial Service at 100 Hours ...........................................................................4-2
Inspection and Maintenance .........................................................................4-3
Inspection and Maintenance Responsibilities ...............................................4-4
Inspection and Maintenance Practices .........................................................4-4
Routine Maintenance (Maintenance Chart) ..................................................4-7
Fork Maintenance .........................................................................................4-8
Mast Maintenance ........................................................................................4-9
Brake Maintenance .......................................................................................4-13
Hydraulic Oil .................................................................................................4-16
Hydraulic System Maintenance ....................................................................4-16
Steering Support Oil (If Applicable) ...............................................................4-18
Drive Transmission Oil ..................................................................................4-19
Battery Maintenance .....................................................................................4-20
Greasing .......................................................................................................4-23
Steering Chain Maintenance (If Applicable) ..................................................4-26
Putting a Truck in Storage ............................................................................4-27
Final Decommissioning .................................................................................4-27
Schematic Circuit Diagrams ......................................................................5-1

Standard Electric Circuit Diagram .................................................................5-2
Hydraulic Circuit Diagram – Motor Steering ..................................................5-8
Hydraulic Circuit Diagram – Chain Steering..................................................5-9
Fuse Box & Relays .......................................................................................5-10
Appendix A (Checklists).............................................................................A-1
Operator’s Pre-Use Checklist .......................................................................A-2
Initial 100 Hour Service Checklist .................................................................A-3
500 Hour Service Interval Checklist ..............................................................A-4
Installation Checklist .....................................................................................A-5
Appendix B (FAQs) .....................................................................................B-1

Calibrating the Load Monitor .........................................................................B-2
Adjusting the Pressure Switch ......................................................................B-3
Mast Fitting Guide .........................................................................................B-4
Mast Mirror Fitting Guide ..............................................................................B-6
Battery Removal ...........................................................................................B-7
Appendix C (Diagnostics) ..........................................................................C-1

Motor Controller Diagnostics & Troubleshooting ...........................................C-2
Aisle-Master Custom Fault Codes ................................................................C-12
Appendix D (Warranty Registration) .........................................................D-1
Aisle-Master Operator’s & Service Manual iii

General Information
Preface Intended Use

This manual describes how to operate, maintain
and repair the Aisle-Master truck safely and Warning
efficiently. It is essential that this manual remain Unintended use can endanger the
with the machine at all times. It is essential that the lives of operating personnel or other
operator and all persons involved in work with the persons in the vicinity of the truck.
truck read this manual before attempting to operate Unintended use can cause
or service the truck. extensive damage to the truck
and/or to property or materials
Follow all local laws and regulations with regard to being handled.
the operation of lift trucks where they apply at the
place of use. Operation of the truck by
Follow all instructions, prohibitive or otherwise,
inexperienced users or in an
found in this manual. They are there to protect the unintended manner can result in
lives of the operator and others working in the hazards that can lead to personal risk
vicinity of the truck. and subsequent harm to the operator
and persons in the operating area of
Always perform the Pre-Use Inspection as the truck.
indicated in this manual according to the checklist
located in appendix A and follow the guidelines on The intended use is described in this
service intervals. Ensure that the truck is in good manual. Do not make any changes to
mechanical condition at all times. Report any fault the truck and use only Aisle-Master
and have it corrected immediately otherwise even approved attachments.
minor faults may result in major failures and
dangerous operating conditions.
About This Manual

The descriptions and illustrations contained in this
manual are not in any way binding. Aisle-Master
must reserve the right to make changes without
prior notice in the interest of enhancement of the
product.
Some trucks may be customised to suit the needs

of individual customers. Therefore these trucks may
deviate slightly from the descriptions contained
within this manual.
Every effort has been made to ensure that the

information contained herein is accurate at the time
of writing. However it cannot be guaranteed that all
of the statements in this manual are completely
correct.
Aisle-Master Operator’s & Service Manual iv

Safety
Aisle-Master Ltd. has made every effort to provide you with the safest
forklift trucks on the market. This section describes the proper
procedures for safely operating and maintaining your lift truck.
After you review this section you will understand the meaning of the
following safety symbols and safety statements:
• Safety Alert Symbol
• Danger
• Warning
• Caution
• Note
Aisle-Master Operator’s & Service Manual S-1

Safety
The Meaning of Safety Aisle-Master Forklift

Statements Safety Statements
You will find various types of safety information on The safety statements contained in this
the following pages and on the machine signs manual relate to the operation and
(decals) attached to the vehicle. This section maintenance of Aisle-Master forklift
explains their meaning. trucks.
Note:
This is the Safety Alert Symbol. It is used to Make sure you read and understand
alert the reader to potential hazards. the information contained in this
manual and on the machine signs
(decals) before you attempt to operate
or maintain this vehicle.
Danger
Danger indicates a hazardous situation
which if not avoided will result in serious The location of each machine sign on the
injury or death. Aisle-Master forklift is illustrated in image
1 on the next page and a representation
of each machine sign is shown in image
Warning 2 on page S-4.
Warning indicates a hazardous situation
which if not avoided could result in serious Make sure you check each machine sign
injury or death. before you operate your Aisle-Master
forklift and replace any that are no longer
legible, missing or damaged.
Caution
Caution indicates an unsafe practice which
if not avoided could result in serious injury
or property damage.
Note:
Used without the safety symbol indicates a
situation that if not avoided could result in
damage to the equipment or property.

Safety
Location of Decals
NOTE: Number 8 is located
behind the side panel.
13
10
10 2
1
8 2 5 11
9
7
6
3
2 4
1
12
5
12
11
1 10
Note: See next page for number reference.

Safety
Decals
ATTENTION RECOMMENDED
DO NOT POWER WASH HYDRAULIC
NEAR ELECTRICAL PARTS FLUID ONLY
8
THIS MACHINE IS
2 SUPPLIED WITH HIGH
VISCOSITY OIL (GRADE 46)
CPD00032-00
ACCELERATOR TIE DOWN

3 PEDAL POINT 9
1 10
BRAKE / INCHING
4 PEDAL 11
CPD00006
CPD00009
13
5
CPD00003
12

Safety
Safe Operation Battery Charging

 Aisle-Master Ltd will not assume any liability Charging installations must be sited in
for injuries or damage arising from or caused designated areas that are well ventilated and
by the removal of any safety devices from properly equipped. Batteries contain sulphuric
their vehicles. acid and generate explosive gasses when
 Fully trained, qualified and authorised drivers being charged. They must be charged in
must only operate this forklift truck. designated, well ventilated areas by trained
 Ensure that the truck is suitable for the area and authorised personnel only.
in which it is to be operated.
 Before raising or lowering forks, give clear When checking electrolyte levels do not use a
indication of your intentions to other people cigarette lighter, matches or anything else that
and ask them to stand clear. may cause ignition for illumination.
 Do not allow anyone to walk or stand
beneath elevated forks. When transporting and charging batteries the
 Do not exceed the rated load capacity of the operator should wear protective clothing and
truck. In no circumstances should goggles and take particular care not to spill or
counterweights be added to increase come into contact with electrolyte (battery
capacity. acid).
 If the mast mechanism malfunctions or
becomes stuck in a raised position, operate Firefighting equipment and a supply of clean
the mast control lever to eliminate any slack fresh water must be readily available in the
in the chains. DO NOT go under the elevated charging area at all times in case of accidents.
parts of the truck to attempt to carry out
repairs. In the event of an accident flush acid away
from the eyes and/or skin using plain water
and seek medical attention immediately.
General
If battery acid is spilled on the floor, clean up
These forklift trucks are designed for use in promptly using a neutraliser such as baking
ambient temperatures ranging from -16°C soda.
(+3.2°F) to +45°C (+113°F) if the correct
hydraulic oils and greases are used. For Warning
operation outside these temperatures, please
Batteries produce flammable gases that
consult the manufacturer as special
may form an explosive mix. Keep all
modifications and lubricants may be required.
arcs, sparks, and flames and lighted
tobacco away from the batteries.
Standard trucks must not be operated in
flammable areas, corrosive atmospheres, or in
areas containing a high degree of dust
contamination. Only trucks specifically designed Operating In
or modified to operate in these conditions can
enter such areas. Hazardous Areas
The safe maximum load capacity of the truck with No spark proofing is fitted to the truck as
relation to the load centre and fork heights, which standard; consequently it MUST NOT be
MUST NOT BE EXCEEDED, is stated on the used in flammable or explosive areas. For
capacity plate.
further details contact the manufacturer.
The truck must be operated strictly in accordance
with the operating instructions provided in this The truck MUST NOT be used in corrosive
manual in conjunction with the safety regulations atmospheres or in areas containing a high
of the country in which the forklift truck is being degree of dust contamination.
operated.

SECTION 1
Introduction
It is the responsibility of employers to assess their fork truck
operations, and introduce safe working procedures to reduce or
limit the risk as far as possible. Safety procedures include operator-
training, procedures for the control of pedestrians and traffic and
the implementation of proper maintenance procedures.
Safe and efficient forklift operation requires operators to be skilled

and alert. Operators must be familiar with the vehicle, understand
its capabilities, and follow the operating procedures and safety
instructions recommended in this manual. According to rules
issued by OSHA (occupational health and safety authority), or the
relevant local Health and Safety Authority in the country where the
machine will operate, employers must make training available to
ensure that operators are competent to safely operate the type of
forklift that they will be using in the workplace.
Safe and efficient operation also depends on correct maintenance

of the vehicle. An Operator’s Pre-Use Checklist, which outlines
checks that must be performed each time the vehicle is put into
operation, is located in Appendix A. The checklist is part of a
complete preventive Maintenance Schedule. Make certain that the
vehicle is correctly maintained and is in good mechanical condition
at all times. Report any failure immediately for correction.
Otherwise, even minor failures or damage may result in major
failures, or create unsafe operating conditions.
Note:
This manual is not designed for purposes of extensive
maintenance work. Such work must be performed by
approved professionals.
Aisle-Master Operator’s & Service Manual 1-1

Introduction
Vehicle Description
The Aisle-Master is a narrow aisle type lift truck.
The principle of this type of truck is that the
weight of the load, which is carried on the forks
in front of the load wheels, is offset by the
combined weight of the heavy truck chassis.
Aisle-Master forklifts are available in capacities 1

up to 3000Kg (6600lbs.). The front end of the
truck can be over-articulated. This permits the
vehicle to act as a conventional forklift as well
as a very narrow aisle forklift.
Terminology Used in
Manual
2
Whenever front and rear, right and left are 1
mentioned throughout this manual, it is
assumed that you are standing behind the
vehicle looking toward the forks. Questions and Comments
If you have any questions or comments
Illustrations Used in Manual about this manual, or any procedure or
description within it please contact:
This manual makes use of many illustrations to
help you locate components on your forklift and
to follow the procedures outlined. Aisle-Master Ltd,
Gallinagh,
You will note that each illustration has an Co. Monaghan,
identifying numeral 1 in one of the corners and Ireland.
each item in the illustration that is referenced in the Tel: +353 47 80400
text is identified with a number 1 Fax +353 47 80402
Email: info@aisle-master.com
In the text, illustration references appear in bold
square brackets [1], and the item numbers are
in standard brackets (item 1). Let’s look at an
example:
The accelerator pedal (item 1) [1], is located on

the floor to the right of the steering wheel
towards the outside of the truck.
The brake pedal (item 2) [1], is located on the
floor to the right of the steering wheel towards
the inside of the truck.

Introduction
Component Identification
The following illustration shows the location of
some of the main components on the Aisle-
Master.
Forks (item 1) [2] Wheels (item 8) [2]

Mast (item 2) [2] Control Pod/Armrest (item 9) [2]
Chassis (item 3) [2] Flashing Beacon (item 10) [2]
Mast Carrier (item 4) [2] Work Lights (item 11) [2]
Overhead Guard (item 5) [2] Seat with Seat Belt (Item 12) [2]
Mast Serial Number (Item 6) [2] Steering Wheel (Item 13) [2]
Fork Carriage (item 7) [2] Access Handle (Item 14) [2]
10 11 6
2
12 13
5 14
7
1
3
8
2

Introduction
Information Plates
The illustration below shows where this
The serial plate (item 1) [3] and the capacity information will appear on your Aisle-
plate (item 2) [3] show the rated capacity, serial Master forklift.
number, and other vehicle characteristics.
The lever plate (item 3) [3] illustrates how the

direction control lever and hydraulic control
levers function.
1 2

Introduction
Serial Number
The serial number of the forklift (item 1)
[5] is located on the serial plate.
The serial number consists of 5 numerical digits
Aisle-Master Serial Number e.g.

1
31200
Caution
The serial number is also stamped on the
left side of the frame (item 1) [4]. Raise
the seat to access the serial number
stamp. You must compare the serial
number listed on the identification plate
with the serial number on the frame of the
truck before operating the truck. Contact
Aisle-Master if these numbers do not
match.
31200 1

Introduction
Model Description
Principle of Operation
The battery supplies power for the traction motor, the hydraulic pump motor and the control panel
and instruments. The motors are controlled by an electronic control system.
Forward or reverse travel may be selected by a direction control lever mounted to the right of the
driver on the front of the control pod.
The drive speed is controlled by means on an accelerator pedal.
A brake pedal applies the hydraulic service brakes at the rear wheels. The parking brake is
applied by a lever situated to the right of the driver.
The truck is equipped with a digital display console that includes a battery discharge indicator, an
hour meter and a number of other indicators.
Key Switch
The key switch (item 2) [6] has 2 positions "OFF" and "ON". Insert the key and turn clockwise to
the "ON" position.
"Power On" Indication

When the key switch (item 2) [6] is turned to the "ON" position the digital display console [8] will
power up, indicating that the truck is ready for operation.
Battery Plug
The battery plug (item 2) [7], is wired to the battery. When connected to the truck plug (item 1) [7],
it enables power to flow to the trucks electrics. The battery plug is also used to connect the battery
to the charger for recharging.
Truck Plug
The truck plug (item 1) [7] is situated at the rear of the truck and is connected to the trucks
electrical system. Lift the rear bonnet to gain access to the truck plug.
Battery State of Charge

The display console [8] shows the battery's state of charge on the left hand side. With a fully
charged battery all the bars are displayed. As the battery is discharged the bars turn off
progressively. When only the last – red - bar is displayed the truck will go into slowdown mode i.e.
the operating speed is reduced.
Display Console
The display console [8] displays a number of warning and indicator symbols including the hour
meter, travel speed and direction etc. It also allows control over the operation of certain functions
such as the lights and auxiliary mast functions.

Introduction
Isolator Switch
The isolator switch is used to disconnect the battery in the event of an emergency. In the unlikely
event of an electrical failure that causes the vehicle to go out of control, push this button (item 3)
[7], to immobilise the vehicle.
Parking Brake Lever

The parking brake lever (item 1) [6], is used to apply the parking brake. Press in the button on the
end of the lever and lower the lever to release the parking brake. An alarm sounds if the operator
gets off the seat without apply the parking brake.
1
1
2
2
6 7

SECTION 2
Before You Begin
This section of your Aisle-Master Forklift Operator’s & Service
Manual discusses the following concepts that must be
thoroughly understood before you can operate an Aisle-Master
forklift:
Operator Training – Discusses the operator training required

by Health and Safety Authorities, and its implications for
operators of forklifts.
Operator Safety – Reviews the safety guidelines operators

need to be aware of before they operate an Aisle-Master forklift.
Understanding Stability – In this section you will learn about

the stability triangle and how to use it to help prevent your Aisle-
Master forklift from tipping over.
Knowing the Rated Capacity – The meaning of rated capacity

and how it relates to how high you lift the load, the load centre,
and attachments used are detailed using several examples.
Understanding Workplace Conditions – This section makes

you aware of hazards in the workplace that you must
understand to avoid accidents. You need to stay aware of
changing conditions in your workplace such as potholes,
overhead obstructions, and pedestrian traffic that may change
on a daily basis. You also need to understand how to load and
unload transport vehicles.

Before You Begin
Warning Understanding Stability

Read the Operator’s Manual and
machine signs (decals) before using the
forklift. Failure to do so can cause Warning
serious injury or death. Never load the truck beyond its rated
capacity. Loading beyond rated
capacity can cause the axle(s) to
break, the truck to tip over, the load
Operator Training to fall and/or serious injury or death.
See identification and capacity plates
for capacity ratings and load centre
Warning information.
Every forklift operator must be trained in
accordance to the rules provided by the
relevant local Health and Safety Warning
Authority (HSA). Never allow anyone to stand beneath
Employers must ensure that each or pass under the lifting mechanism.
powered industrial truck operator is The load could fall causing serious
competent to operate a powered injury or death.
industrial truck safely, as demonstrated
by the successful completion of the
relevant training as specified by the Warning
relevant local authority. Operating a Make sure that the load is centred
powered industrial truck without the and the forks are fully engaged.
proper training can cause serious injury Failure to do so can cause the load to
or death. fall, or the truck to tip over, resulting
in serious injury or death.
Operator Safety
Before commencing use of the Aisle-Master
forklift operators must become familiar with its
capabilities and thoroughly read and understand
the material contained in this Operator’s Manual
along with the meanings of the various machine
signs (decals) found on the truck.
Whether you are a new operator or have used

forklifts for many years, read through the
following guidelines. They provide step-by-
step instructions to help you operate your
Aisle-Master forklift in a safe and efficient
manner.

Before You Begin
Basic Principles • You drive with the load raised.
• The load is not distributed properly (always
The concepts concerning stability are actually keep the heavier items near the face of the
quite simple. As the angle between the forks and forks).
the body of the truck approaches 90 to the right • You drive across a slope.
[1] or left [2], the truck is in its least stable • You drive on a slope with the load facing
position. downhill
• A battery is used that weighs less than the
Unlike an automobile, which has four points of battery that was originally supplied with the
suspension, Aisle-Master forklift trucks operate truck.
on a three-point suspension. When the forks are
turned nearly 90 to the right, two of the The same holds true when the forks are turned
suspension points are on the rear axle (item 1) almost 90to the left. The suspension points are
[1] and (item 2) [1]. The third suspension point is (item 1) [2], (item 2) [2], and (item 3) [2]. The
the centre point of the front axle (item 3) [1]. The fulcrum is between (item 1) [2] and (item 3) [2].
centre of gravity i.e. the point at which the truck’s The centre of gravity is at (item 4) [2] when the
weight may be considered to act, is located as forks are turned nearly 90 to the left, the truck is
shown (item 4) [1] when: not carrying a load, and the truck is at rest. If the
centre of gravity shifts (item 6) [2] so it falls
• The forks are turned nearly 90 to the right outside of the stability triangle, the truck will tip
• No load is placed on the forks around the fulcrum.
• The truck is at rest.
Note:
In this position, the fulcrum, or axis around which The illustration on the following page
the truck will tip, is between suspension point conveys a greater understanding stability.
(item 2) [1] and (item 3) [1]. Some trucks have a wider wheel base to
improve stability.
If you try to pick up a load that is too heavy, the
truck may tip around the fulcrum. Let’s see why. 1
Imagine a triangle (item 5) [1] is drawn between
the three suspension points (item 1) [1], (item2)
3
[1], and (item 3) [1]. This triangle is commonly
called the stability triangle. The centre of gravity
is not a fixed point, it will shift for various reasons 4
that we will explore in a moment. The crucial
thing to remember is, as long as the centre of
gravity of the truck remains within the border of 6
5
the stability triangle, the truck will not tip.
2
If the centre of gravity shifts (item 6) [1] so it falls
outside of the border of the stability triangle, the 1
truck will tip around the fulcrum.
The centre of gravity will shift if:

1
• The load exceeds the rated capacity listed on 5
6
the serial plate.
• The load exceeds the load centre dimensions
listed on the serial plate.
• The forks are not fully placed into the pallet, 4
called “tip loading”.
• You take a corner too fast (with the truck unloaded 3
or loaded).
2 2

Before You Begin

Before You Begin
Knowing the Rated Before you begin to operate your Aisle-Master

forklift, you need to know some basic
Capacity principles of how it works. This includes
! knowing how much weight it can carry and
how to properly carry a load to maintain
Warning stability.
Never load the truck above its rated
capacity. Loading above the rated One of the most important facts you need to
capacity can cause axles to break, the know about your forklift is its rated capacity
truck to tip over, the load to fall and/or (how much weight it can safely lift). This
serious injury or death. See serial and weight is listed as the rated capacity on the
capacity plates for rated capacity and serial plate. The rated capacity varies for each
load centre information. load depending on:
Before you begin to operate your Aisle-Master • Where the horizontal and vertical load
forklift, you need to know some basic principles centres are.
of how it works. This includes knowing how • The height you plan to lift the load
much weight it can carry and how to properly • Attachments used.
carry a load to maintain stability.

Before You Begin
Serial Plate Capacity Plate

The following list explains each item that appears Actual Capacity (item 7) [3], the actual
on the serial plate and capacity plate shown in [3] capacity is stated with the forks at various
in the Introduction and below. fork heights. As you lift the load higher, the
rated capacity of the forklift decreases.
Model (item 1) [3], the model number of your
Aisle-Master forklift appears here. Height (item 8) [3], this is the fork height
stated in both millimetres and inches. It is the
Serial No. (item 2) [3], the serial number of distance between the ground and the top
your forklift appears here. vertical face of the forks where the load sits.
Rated Capacity (item 3) [3], this is the Weight (item 9) [3], the load capacity of the
capacity in kilograms (kg) or pounds (lbs) that forklift at various fork heights stated in
the fork truck will lift. kilograms and pounds.
Load Centre (item 4) [3], this is the distance Horizontal Load Centre (item 10) [3], the
from the front face of the forks to the centre horizontal load centre is equal to one-half the
of gravity of the load. width of the rated load when the weight is
evenly distributed.
Un-laden Weight (item 5) [3], this is the
weight of the forklift with no load on the forks. Vertical Load Centre (item 11) [3], the
vertical load centre is equal to one half the
Manufactured Date (item 6) [3], the date on height of the rated load when the weight is
which the fork truck was manufactured. evenly distributed.
7 9 10
1
2
3
8
4
5
6
11

Before You Begin
Load Centre Always make sure the load is flush against

the front vertical face of the forks (item 3) [4],
(or the load backrest if fitted) and that loads
Warning that are unbalanced horizontally are loaded
Make sure the actual horizontal and with the heaviest end of the load nearest to
vertical load centres do not exceed the the truck.
maximum load centres stated on the data
plate. Failure to do this can cause the The vertical load centre (item 4) [4], is equal to
forklift to tip over causing serious injury or one-half the height of the load when the weight
death. is evenly distributed. For example, a load that
is 122 cm (48 in) high has a vertical load
centre of 61 cm (24 in).
You need to consider two types of load centres.
The horizontal load centre (item 1) [4], is equal
Always make sure that loads that are
to one-half the depth of the load when the
unbalanced vertically are loaded with the
weight is evenly distributed. For example, a
heaviest end of the load nearest to the
load that is 122 cm (48 in) long has a horizontal
horizontal face of the forks (item 5) [4].
load centre of 61 cm (24 in). The further the
load centre is from the fulcrum (item 2) [4], the
less stable the forklift.
3 4
2
5
4

Before You Begin
Maximum Fork Height Attachments to the forks may affect the load
centre. When the factory, dealer, or distributor
Warning installs attachments approved by, Aisle-
Master Ltd. an additional identification plate
The load capacity of your forklift
should be attached to the truck. The new plate
decreases the higher you raise the forks.
identifies the type of attachment, the changes
Refer to the rated capacity at various
in the load centres, and the rated capacity.
heights listed on the capacity plate. Failure
to heed these guidelines can cause your
forklift to tip over causing serious injury or
death. Determining the Weight of the
Load
The maximum fork height (item 1) [5], is the In addition to the rated capacity you must
highest position your Aisle-Master forklift can lift determine the weight of the load before you
a load. This is measured from the floor to the attempt to lift it with your Aisle-Master forklift:
forks when they are raised in their highest posit-
ion. The higher the forks are raised, the less • Weight is listed on pallet wrapper
stable the Aisle-Master forklift becomes. • Weight is listed on Bill of Lading
• Weight is determined by multiplying the weight
of each small container/bag by the number of
Tilting Considerations small containers/bags on a pallet. Each small
The amount of forward and rearward tilt you container should be marked with its weight.
should use is governed by the application. • Ask your supervisor when in doubt.
When you travel with the truck loaded tilt the mast
back and keep the load low. This will help
stabilize loads with an uneven weight distribution. 5
When you load at high elevations, tilt the load
back far enough to seat it against the front vertical
faces of the forks or the load back rest (if fitted).
When you unload at high elevations, make sure

you only use enough tilt to place the load onto the
rack or stack.
Attachments
1
Warning
Never modify your Aisle-Master forklift in
any manner. Only options and
attachments approved by Aisle-Master Ltd.
may be installed on the truck. Other
modifications will void the warranty and
can cause serious injury or death.

Before You Begin
Understanding Workplace Dock Boards (Bridge Plates)

Conditions Dock boards are designed and maintained so
! that one end contacts the dock (or loading
platform) and the other end contacts the
Warning transport vehicle. When you load or unload the
Workplace situations are constantly transport vehicle, the dock board must be
changing. Check your area before locked in place to prevent it from rocking or
beginning work for the day. If in doubt, sliding. Dock boards must have a high friction
check with your supervisor. Failure to surface designed to reduce the possibility of
observe new workplace conditions can people or trucks slipping.
lead to serious injury or death.
Special rules should be followed if you’re
In addition to stability, you need to be aware of workplace uses dock boards on loading docks:
special situations in your workplace to avoid
forklift accidents. Even if you work in the same • Never exceed the carrying capacity marked
area each day, there could be changes that affect on portable or powered dock boards.
your safety, such as:
• Portable dock boards must be secured in
• Contractors doing maintenance position, using anchors or other devices that
• Wet areas prevent slipping.
• Overhead repair work
Be on the lookout for anything that might present

a hazard. Other situations that could present Trailers and Rail Cars
special operating conditions include:
1. Before you load or unload a trailer, or rail
• Potholes car, make sure it does not move
• Pedestrian traffic unintentionally:
• Very narrow aisle ways
• Overhead obstructions • Set the brakes
• Poor lighting making it hard to see hazards • Chock the wheels
• Wet, oily, or rough terrain
• Other equipment or vehicles operated in the 2. In addition to setting the brakes and
area chocking the wheels, if a semi-trailer is not
coupled to a tractor, make sure that all four
Note: corners are supported to prevent upending
Standard Aisle-Master trucks are not or corner dipping.
equipped to operate in cold stores,
flammable or explosive areas, corrosive 3. Maintain a safe distance from the edge of
atmospheres or areas containing a high ramps, platforms, or other similar
degree of dirt contamination. working surfaces.
Remember: Do not block the following items with 4. Never attempt to move a trailer with the
your Aisle-Master forklift or the materials you are Aisle-Master.
moving:
• Electrical panels
• Fire exits
• Emergency stop buttons
• Aisle ways
• Fire extinguishers/hoses

Before You Begin
Warning Devices
Sound the horn at an intersection. Stop and look
for other vehicles and/or pedestrians and proceed
with caution.
Your Aisle-Master forklift may have the following

warning devices installed. Make sure they are in
working order before you start work:
• An amber overhead strobe warning light

• Flashing backup light
• Rear safety light package
• Reversing/Backup alarm (bleeping or talking)
• Park brake warning alarm
• Convex rear view mirror
Power Lines
Warning
Contact between the truck and live
electrical wires may result in serious
injury or death.
Keep all parts of the truck at a sufficient distance

from electrical lines (see table below).
If contact with a live electric source occurs:
 Do not leave the loader until the electricity

has been disconnected and a qualified
technician directs the operator to leave the
machine.
 If possible, drive the loader away from the
danger area.
 Warn any people around the loader not to get
any closer and not to touch the machine.
 Arrange to have the power turned off.
Nominal voltage Clearance distance

Up to 1000 V 1 m (1.1 yd)
Over 1 kV up to 110 kV 3 m (3.3 yd)
Unknown nominal voltage 5 m (5.5 yd)

SECTION 3
Operating Your Aisle-Master
Forklift
This section of your Aisle-Master Forklift Operator’s & Service Manual
discusses the following concepts that must be thoroughly understood
to operate an Aisle-Master forklift:
Operator’s Pre-Use Checklist – Inspecting your Aisle-Master forklift

before you begin work is a mandatory requirement. The procedure for
performing this inspection is explained.
Controls and Indicators – The location of each control and indicator

is illustrated as well as its operation.
Operating Instructions – Basic Procedures – Basic procedures

such as getting on and off the Aisle-Master forklift, driving position,
starting and travelling, turning, stopping, and parking are discussed.
Operating Instructions – Handling a Load – This section describes

the proper procedures for loading and unloading your Aisle-Master
forklift, travelling with a load, what to do in case of a tip over and going
up and down an incline.
Using Lifting Equipment to Move an Aisle-Master Forklift to

Another Location – This section describes the proper procedure for
lifting and moving Aisle-Master trucks.

Operating Your Aisle-Master Forklift
Controls and Indicators There are two braking systems on the

Aisle-Master:
Before operating the truck it is crucial to
become familiar with all of the controls and 1. For precise speed control and braking
indicators. This section contains during normal operation of the truck, use
explanations of how each of the controls the electronic braking system. To stop the
function it also contains descriptions of each truck release the accelerator pedal and the
indicator on the display console. truck will come to a controlled stop.
2. For more rapid braking use the service

Accelerator Pedal brakes on the rear axle. Depress the brake
The accelerator pedal (item 1) [1], is located pedal to bring the truck to a stop.
on the floor and is closest to the right hand
side of the truck. Key Switch
The key switch (item 1) [2], is located to the
Operation - Pressing the accelerator pedal right side of the steering column. It is a two
down starts the truck moving in the direction position (ON, OFF) switch. Turn the key
you selected, see discussion of the clockwise to set the switch to the ON position.
“Direction Lever” on page 3-4. The closer All controls are inactive when the key switch is
you press the accelerator pedal to the floor in the OFF position. Turn the key fully counter
the faster the truck moves. clockwise to the OFF position.
Brake Pedal Steering Wheel

The brake pedal (item 2) [1], is located on The steering wheel (item 3) [2], is equipped
the floor to the left of the accelerator pedal. with a steering knob (item 4) [2], which should
be held firmly at all times.
Operation – Pressing the brake pedal down
applies the service brake.
4
2 1
1
Note that your Aisle-Master forklift also has 2 6
a parking brake. For more information see
page 3-4.

 Save & Exit
The steering column tilt angle can be easily  Cancel
adjusted to suit the operator. To adjust the
angle: Use the arrow buttons to change the desired
item. To set “Hour”, use the up or down arrow
1. Turn the Locking Lever (item 2) [2] Anti- buttons to highlight “Set Hour”, then press
Clockwise to loosen. right arrow button to highlight number. Then
press up or down arrows to reach desired
2. Adjust the angle of the steering column to
value. To move on to setting additional items,
the desired position.
press left arrow button once and follow similar
3. Turn the locking lever clockwise to procedure to change other items.
tighten. When finished setting all desired values,
choose “Save & Exit”.
Dash Display D. Battery Charge Meter – Displays the level
The Dash Display (item 6) [2] is mounted of charge remaining in the battery. When
behind the steering wheel. It displays a the battery is low the truck will go into
record of operating time in hours and also slowdown mode i.e. the operating speed
incorporates various warning lights and will be reduced.
indicators, see below for a detailed layout of
the display. E. Auxiliary Hydraulic Function Icon (If
C B A Used) - is located on the display console.
Press the second button from the left once
to activate the optional auxiliary function.
L This may be fork positioning, telescopic
M K forks, lift/drop forks, etc. Press the auxiliary
function button a second time to deactivate
D the auxiliary function. The Aux symbol will
J be displayed when the auxiliary function is
I active.
H F. Menu System Icon – Press the button
below the menu icon to activate the menu
system. Use the arrow buttons to navigate
E F G through the menu system.
A. Hour Meter – Displays the total number
of hours the truck has been operated for G. Work Lights Icon - The work lights icon is
to date in hours and tenths of an hour. displayed when any of the work lights are
illuminated.
B. Speedometer - The speedometer is Press the button below the icon to
used to determine the velocity of the illuminate the front work light.
truck. Press the button a second time to
illuminate rear work light.
C. Clock - The clock displays the day and Press the button a third time to illuminate
time in analogue and digital format. To all work lights.
set the clock press the menu/select Press the button a fourth time to extinguish
button on the dash console, now using all work lights.
the arrow buttons choose “User
Functions” then “Time/Date”. The H. Park Brake/Direction Indicator – The
following list will appear: park brake indicator is displayed when the
 Set Hour park brake is applied. When the park brake
 Set Minutes is released it changes to the direction
 Set Year indicator. The position of the direction lever
 Set Month is indicated by:
 Set Day N - When the truck is in neutral.
 Set Weekday F - When the truck is in forward.
R - When the truck is in reverse.

I. Seat Switch Indicator – This indicator is Parking Brake
displayed when the operator is not sitting The parking brake lever (item 5) [2], is located
on the seat. The truck will not operate if to the right hand side of the driver.
this indicator is displayed.
Operation – Pull the parking brake lever
J. Seat Belt Indicator (If used) – This upwards to apply the brake. Push the button
indicator is displayed when the operator on the end of the lever and lower it to release
does not have their seatbelt buckled. the brake.
The truck will not operate if this indicator
is displayed. If the operator vacates the seat while the
parking brake is released a warning buzzer
K. Service Indicator – This indicator is will sound.
displayed when a service is due. The
service indicator can only be reset be
connecting a handheld programmer or a Warning
laptop. Never leave the operators enclosure
without applying the park brake.
L. Service Countdown Clock – The
service countdown clock displays the
hours remaining until the next service is
due. It can only be reset be connecting a
handheld programmer or a laptop.
M. Fault Warning Indicator – The fault

warning indicator is displayed when a
fault has been detected by the electrical
controllers. A fault message will also
flash on the screen.
Direction (F-N-R) Lever
The direction lever (item 1) [3], is located in
The truck must not be operated while
the middle of the control pod to the right hand
this icon is displayed as damage to the
side of the seat. It has 3 positions Forward
electrical components may occur.
(F), Neutral (N) and Reverse (R).
Certain faults will cause the machine to
shut down automatically. Other less
The lever has a safety lock mechanism built
serious faults will allow the machine to
in whereby it must be pressed (towards the
be driven to a safe location.
operator) in the direction marked by the arrow
Refer to Appendix C - Diagnostics for
A below before a drive direction can be
fault codes and troubleshooting.
selected. This mechanism is to avoid
unintended drive selection.
Caution
If a fault is caused by elevated To select forward drive press the lever in the
temperature of any component allow direction of arrow A and push in the direction
sufficient time for the truck to cool of arrow F.
before investigating the cause of the
elevated temperature. To select reverse drive press the lever in the
direction of arrow A and pull in the direction of
arrow R.
R
A

Horn
The horn button (item 5) [3], is located in the
4 3 2 5 middle of the control pod beside the
direction lever.
1
Operation – Press and hold the button to
sound the horn.
Battery Isolator Switch

The battery isolator switch (item 1) [4] is
located on the rear of the control pod to the
right hand side of the seat. It is used to
disconnect power from the battery in the
event of an emergency. Turn the switch to
3 ‘OFF’ by pressing it down until it clicks into
the closed position. The truck will not power-
up unless the switch is returned to the ‘ON’
Lift Lever position by pulling the switch up.
The lift lever (item 2) [3], is located at the
front of the control pod. It is the lever
nearest the operator.
Operation - Pull the lever back to lift the
forks; push it forward to lower the forks.
The lift lever can only be operated when
the operator is seated.
Tilt Lever 1
The second lever (item 3) [3], from the
operator at the front of the control pod
controls the tilt function.
Operation - Pull the lever back for
backward tilt; push it forward for forward tilt.
The tilt lever can only be operated when
the operator is seated.
Side Shift Lever

The third lever (item 4) [3], from the
operator at the front of the control pod
controls the side shift function.
Operation - Pull the lever back to shift the
fork carriage to the right; push it forward to
4
shift the fork carriage to the left.

Seat Adjustments (Grammer MSG65) Seat Adjustments (Kab 211)
2 4
4
1 1
2 3
3
5 6
Horizontal Adjustment Horizontal Adjustment
The Grammer MSG65 seat can be moved The Kab 211 seat can be moved forward or
forward or back as the operator requires. back as the operator requires. Lift the seat
Lift the seat slide lever (item 1) [5] to slide lever (item 1) [6] to release the catch
release the catch then slide the seat to the then slide the seat to the desired position.
desired position.
Weight Adjustment
Weight Adjustment The weight adjustment is controlled by pulling
The weight adjustment is controlled by the weight adjustment lever (item 2) [6], forward,
folding out the weight adjustment lever lifting it up and moving it right or left to increase
(item 2) [5], holding it at the front and or decrease the firmness of the seat base
moving it up or down accordingly. There suspension. There are 5 weight settings from 50-
are 10 weight settings from maximum to 120 kg (110-265lbs).
minimum. Before each new movement fold
the lever in fully and check the position of Thigh Support Angle Adjustment
the arrow in the viewing window. Keep The thigh support angle can be adjusted by
adjusting until the arrow is in the middle of pulling up the thigh support lever (item 3) [6], to
the window. release the catch and leaning forward or back.
There are 2 positions. Release the lever to lock
Backrest Adjustment the backrest angle
The angle of the backrest can be adjusted
by pulling up the backrest locking lever Backrest Adjustment
(item 3) [5], to release the backrest catch. The angle of the backrest can be adjusted by
Lean forward to allow the backrest to tilt pulling the backrest locking lever (item 4) [6],
forward or lean back to force it to tilt back to release the backrest catch. Lean forward
backwards. Release the lever to lock the to allow the backrest to tilt forward or lean back
backrest angle. to force it to tilt backwards. Release the lever to
lock the backrest angle.
Lumbar Support Adjustment
Turn the lumbar support adjustment knob Seat Sensor
(item 4) [5], clockwise towards 1 to adjust The operators seat has a sensor pad fitted that
the curvature of the upper part of the detects when the operator leaves the seat. This
backrest cushion. Turn the knob cuts out the drive and locks the lift and tilt levers.
anticlockwise towards 2 to adjust the
curvature of the lower part of the backrest
cushion.

The Pre-Use checks must be carried out at the
Operator Pre-Use Checks start of each working day before the machine
commences operation. Alternatively if a multi shift
Note: system is being operated the checks should be
The truck must be maintained in a carried out at the beginning of each shift.
condition that is safe and without risk to
safety and health. Pre-Use checks play a The details of the inspection should be recorded
vital role in ensuring the truck is in safe on a copy of the Pre-Use checklist (appendix A
working condition. Contact local page A2) and a record of these inspections
authorities in order to find out what should be kept on file within the company records.
regulations are in place regarding Pre-
Use checks of industrial equipment of The following visual checks must be
this nature. performed prior to using the truck:
Warning  Overall condition – Check the condition of

protective covers. Look for missing or loose
Before performing any inspection or
nuts and bolts. Look around and under the
maintenance on the truck:
truck for leaking oil, battery electrolyte or brake
fluid.
 Park in a suitable area on level ground
with adequate space and headroom  Wheels & Tyres – Check wheels for damage.
around the truck to perform all tests Check that wheel nuts are present and secure.
and checks safely. Check tyres for cuts and foreign objects.
 Release any residual pressure in the
hydraulic system i.e. lower the mast  Forks - Inspect the forks for excessive wear,
fully and tilt the mast fully forward. cracks, fractures, deformation. Ensure they are
 Isolate the battery and remove the equally spaced and locating pins are engaged.
isolator key – unless performing
operational checks.  Access – Steps and grab handles secure,
 Smoking and naked lights are clean and in good condition.
prohibited.  Load Backrest (if fitted) – Check for
 Ensure the relevant personal deformation or cracks. Ensure it is fixed
protective equipment (PPE) is worn i.e. securely.
gloves, safety boots, eye protection,
clothing.  Hydraulics - Inspect the hydraulic hoses for
kinks, routing and wear. Check all seals and
Escaping fluid under pressure can couplings for damage and leaks.
penetrate the skin causing serious injury.
Protect hands and body from high  Mast - Inspect the mast channels, chains
pressure fluids. and bearings for excessive wear, damage,
deformation and cracks. Check the mast
 Employers must ensure that the Pre-Use chains for missing links or pins. Check
checks are performed and that records chains are of equal tension and well
are kept. lubricated. Check end stops are secure.
 Fork carriage – Check for excessive wear,

 Operators must perform the checks and damage, deformation and cracks.
report any defects to their supervisor.
 Overhead Guard - Check for damage or
 Never operate a truck that has not been cracks. Ensure it is fixed securely.
checked or that has failed on any of the
checks.  Safety Sign Decals – Present, Legible.
 If a truck becomes unsafe during a shift,  Hydraulic Tank – Check for damage or
stop operating the truck and report the leaks. Check the hydraulic oil level with the
problem immediately. mast fully lowered.

 Battery - Check the battery connections  Load Monitor (if fitted) – Check it is
are secure. Check the cells for damage operating normally.
and leaks. Check leads for loose or bare
wires.
Note:
 Serial and Capacity plates – Check they Details on how to perform these checks can
are present and securely attached and be found in the inspection and maintenance
check the rated capacity. section of this manual.
 Electrical Connections/Terminals –
Check they are securely connected and
undamaged.
 Rear View Mirror – Check it is present,

clean and in good condition.
 Motors – Check the pump motor and

drive motor for any unusual sounds or
smells.
The following operational checks must be

performed prior to using the truck:
 Seat Belt - Look for cuts in the belt.

Check the retractor and retainer are
functioning.
 Drive, Braking & Direction Control –

Drive the truck in forward and reverse and
test the service and park brakes.
 Steering - Check in both directions whilst

stationary and on the move. Look for
excessive freedom or stiffness.
 Seat – Check it is anchored securely and

that runners and sliders operate freely.
Check for objects under the seat that may
interfere with the seat switch.
 Hydraulic controls – ensure smooth

operation of all controls through the full
extent of their movement.
 Horn, Lights, Reverse Bleeper &

Beacon – Test and check for normal
operation.
 Display Console – Check the hour meter

is working. Check all warning and
indicators lights are functioning correctly.

Operating Instructions – Getting On and Off the Aisle-

Master Forklift
Basic Procedures
! • Always maintain a three-point contact when
you get on and off the Aisle-Master forklift.
Warning
Check all systems before operating this • Use the step (item 1) [7], and handrails (item
vehicle. Report unsafe conditions and 2) [7] and (item 3) [7] provided for this
correct them before operating the vehicle. purpose.
Do not operate the vehicle unless trained
and authorised to do so. Failure to follow • Enter and exit the forklift from the left hand
these guidelines can result in serious side under normal circumstances. Only enter
injury or death. or exit from the right hand side in the case of
! emergencies.
Warning
Every forklift operator must be trained in
accordance with the rules provided by
the relevant health and safety authority in 3
the location where the truck is operating.
Employers must ensure that each
powered industrial truck operator is
competent to operate a powered
industrial truck safely, as demonstrated
by the successful completion of training
and evaluation as specified by the
relevant Health and Safety authority.
Operating a powered industrial truck
without the proper training can cause
serious injury or death. It is also against
the law in many locations.
Warning
Look in the direction you intend to travel 2
before you begin to drive the forklift.
Failure to look in the direction you are
travelling can cause serious injury or
death.
Before you operate your forklift, get used to

the controls and indicators and practice
going forward, backward, turning, stopping
and parking without a load on the truck. After
you become familiar with the truck’s
1
operation, learn how to load and unload it.

Driving Position Starting and Travelling
!
Note:
Warning Make sure all accessories (lights, etc.) are
Only operate the vehicle from the off before continuing.
operator’s seat with the seat belt
fastened. Do not place any part of your 1. Make sure your right foot is not on the
body outside the vehicle. Do not carry accelerator pedal.
passengers. Failure to follow these
guidelines can result in serious injury or 2. Set the direction lever (item 1) [9], to
death. neutral.
Only use the right foot to operate both
the accelerator and brake pedals. 3. Turn the key switch (item 3) [10] clockwise
!
to the ON position.
Refer to Figure [8] for proper seating
position.
4. Use the lift lever (item 2) [9], to raise the
forks 102 to 152 mm (4 to 6 in) off the
1. Adjust the seat for comfortable operation
ground and the tilt lever (item 3) [9], to tilt
of the Aisle-Master forklift controls. You
the mast back. This is the recommended
must be correctly seated with all body
travelling position.
parts inside the cab. Use your right foot
(item 1) [8], on both the accelerator and
brake pedals and keep your left foot (item
2) [8], on the floor of the cab at all times. 3 2
2. Fasten your seatbelt. 1
!
1
9
5. Release the Parking brake (item 1) [10]
and hold the steering knob (item 2) [10]
firmly with your left hand.
6. Note the position of the front wheels. The

truck will move in the direction the front
wheels are pointed.
2 7. Make sure the way is clear and select the

8 direction of travel with the direction lever
(item 1) [9].
Warning
Remain in your seat with the seat belt 8. When travelling in reverse look in that
fastened while the truck is moving. Your direction. A convex rear view mirror is fitted
seatbelt will help you remain inside the to assist with visibility and alert the operator
cab should the truck tip over. Never jump to potential hazards.
from the truck if it begins to tip. In most
cases the truck will land on you causing 9. Gently press the accelerator pedal (item 1)
serious injury or death. [11], with your right foot until the truck
begins to move. Increase pressure on the
accelerator pedal to increase truck speed.

Turning
Warning
A lateral tip-over can occur if your
2 truck is improperly operated. Slow
down before turning! Failure to slow
down can cause serious injury or
death.
When you reach an intersection:

1
 Slow down. Even if the forklift is not
3 carrying a load it can tip-over if you turn at
high speed.
 Sound the horn as you reach an

intersection to warn pedestrians and other
equipment operators you are approaching
the intersection.
 Always follow the rules of the road and

yield to other equipment operators and
pedestrians as required.
10
Stopping
Warning
When you stop, stay inside the cab
until the truck comes to a complete
stop. Failure to stay inside the cab
can result in serious injury or death.
!
1 Warning
Do not apply brakes abruptly. If you
stop abruptly the load may dislodge
from the forks causing serious injury
or death.
!
To slow down, release the accelerator.
To perform an emergency stop release the

2 accelerator pedal and press hard on the
11 brake pedal (item 2) [11] with your right foot.

Stopping Distance When parking the Aisle-Master forklift always:
Stopping distances change with the incline 1. Apply the parking brake.
and quality of the road surface.
2. Tilt the mast forward.
To make sure you come to a safe stop:
3. Lower the forks to the ground.
 Reduce speed
 Reduce load size 4. Turn the key switch to the ‘OFF’ position.
 Allow adequate distance between the
truck and any other vehicle, object or 5. Remove the key.
person.
Note:
Changing Direction Make sure all accessories are off (lights,
etc.) before you turn the key switch to the
Release the accelerator pedal and allow the
‘Off’ position.
truck to come to a smooth controlled stop.
If the operator vacates the seat while the
Select change of direction by using the
parking brake is released a warning buzzer
direction lever then gradually apply pressure
will sound.
to the accelerator pedal until the truck is
travelling at the desired speed.
Warning
Never leave the operators enclosure
Parking without applying the park brake.
!
Warning
Before you exit the vehicle, place
controls in neutral and apply the parking
brake.
If the truck is to be left unattended, fully
lower the mast, turn the key to the ‘Off’
position and remove the key.
Failure to properly exit and park your
forklift can cause serious injury or death.
Before you park the vehicle make sure:
 The parked truck will not cause an

obstruction or safety hazard.
 The parked truck is clear of fire exits, fire
equipment, and stairways.
 The truck is not left unattended on an
incline.
If the truck cannot be driven and it must be

left parked on an incline, securely chock the
wheels and remove the key.

Operating Instructions –
Handling a Load
Warning Warning
Look in the direction you will travel Do not handle unstable or loosely
before you begin to drive the forklift. stacked loads.
Make sure the forks are set so the Use caution when you handle long, high
spacing between them is equal to one- or deep loads.
half the opening between the end
stringers on the pallet. See “Setting the Do not allow anyone to stand beneath or
Forks” [13] on the following page. pass under the mast.
Make sure you insert forks fully into the Never use the forklift to elevate anyone
pallet. Do not “tip load” [12]. without the use of an approved man up
cage.
Be aware of rear end swing when turning.
Never carry passengers on the truck.
Obey site rules and take particular care

when there are pedestrians who should
be given priority.
Use banks men if operating in congested

or busy areas.
Never load your Aisle-Master forklift

beyond its rated capacity. Rated capacity
is stated on the truck’s identification
plate. Loading the truck beyond its rated
capacity can cause axle(s) to break, the
truck to tip over and the load to fall.
Make sure the load centre of the load

does not exceed the load centre rating
stated on the truck’s capacity plate.
If the mast continues to rise after the lift

lever is released, turn the key switch to
the ‘OFF’ position immediately.
Failure to follow these guidelines can

cause serious injury or death. Refer to
the serial and capacity plates on the truck
12 for rated capacity and load centre
information.

Setting the Forks
Before operating the Aisle-Master forklift make 3. Move the forks until the spacing between
sure the spacing between the forks (item 1) [13], them is equal to one-half the opening
is properly set: between the end stringers on the pallet.
Make sure the forks are seated in a
1. Measure the opening between the end carriage notch and equidistant from the
stringers on the pallet (item 2) [13]. ends of the carriage (item 4) [13].
2. Lift the fork locks (item 3) [13], up. 4. Press the fork locks down to ensure
locking.
2
13
Alternatively if the truck is fitted with
hydraulic fork positioning use this
function to adjust the distance between
the forks.

* Load Moment Indicator

 Please note this device is only an indication
 The Load Moment indicator (when fitted) that a dangerous operation may be taking
is a visual and audible device intended to place it does NOT prevent the operator
continuously monitor the longitudinal Load from tipping the machine over; therefore
Moment effect of the fork load on the the weights, lift height and load centre as
machine by measuring the load on a stated on the capacity plate should never
suitable vehicle part. be exceed.
 The load sensor is mounted on the mast  Operators should check the Load Moment
carrier and the Load Indicator Display is Indicator is functioning correctly prior to use
mounted inside the roll cage, in the at the beginning of each shift. The unit is
middle of the front cross member, within tested by pressing the “TEST” button. This
the driver’s view. The display has a will cause all lights to flash on and the
vertical arrangement of five lights (three audible warning to sound. The “TEST”
green, one amber and one red) the lights button can also be pressed at any time
progressively illuminate or go out to during operation. If in doubt park the
indicate the percentage of the rated machine and contact your supervisor.
capacity being carried by the forks.
* If Fitted
 The actual rated capacities are those
referred to on the capacity plate located
on the front of the machine to the right
hand side of the driver console when
seated on the machine seat.
 When the machine ignition is turned to

‘On’ (and the machine is not carrying any
load) the load indicator display will show
only the green “power on” light. The first
display light will illuminate when the load
reaches approximately 45% of the rated
capacity. Each successive light is
equivalent to approximately 15% of rated
capacity.
 When the display has reached 100% (all

green lights plus the amber light flashing)
the vehicle is carrying its maximum rated
capacity. The red light plus the audible
alarm represents 110% of the rated
capacity and greater, there is no further
visual or audible change from there on to
the “tip up condition”.
Warning
If the alarm sounds and/or the red light
illuminates, the driver should act
immediately to minimise the instability,
by stopping driving, lowering the load
and tilting the mast back. Failure to do
so could result in serious injury or
death.

Retrieving a Load 3 1
The following steps outline the proper
procedure to be followed when retrieving a
load.
The black arrows indicate the direction to

turn the steering wheel and the grey arrows 4
indicate the truck drive and mast
carrier/fork directions.
1. Drive straight down the middle of the

aisle (item 1) [14] and slow down when
2
approaching the load (item 2) [14].
2. For narrow aisles bear to the side of

the aisle that is opposite to the load 14
(item 3) [14]. Maintain a distance of
approximately 150mm (6 inches)
between the side of the truck and the
side of the aisle. For wider aisles stay
in the centre of the aisle
3. Centre the forks using the side shift.
Warning
If the forks or load jam or catch during
a stacking operation, do not attempt to
free them by reaching through the
mast. Failure to follow this guideline
4. Drive forward until the centres of the

front wheels are aligned with the centre
of the pallet/load to be lifted (item 4)
[14], stop the truck and put the direction 15 1
lever into neutral.
5. Lift the forks to the required height and

use the tilt to level the forks.
6. Turn the steering wheel/forks towards

the load to be lifted (anticlockwise for
LHS). Stop turning when the fork
nearest to the load (item 1) [15] is
approximately 100mm (4 inches) from
the face of the rack/stack.
7. Set the direction lever to reverse. Slowly

reverse the truck and simultaneously
turn the steering wheel/forks towards
the load (anticlockwise for LHS) until the
forks are aligned central to the sides of
the load/pallet to be lifted [16].
16

Note:
When turning the steering with the truck
stopped do not apply the foot brake or
the park brake.
8. Set the direction lever to forward. Drive

the truck forward towards the load and
simultaneously turn the steering
wheel/forks (clockwise for LHS) so that
the forks stay aligned parallel and
central to the sides of the load/pallet to
be lifted [17]. Use the side shift to centre
the forks with the load if necessary.
9. Lift the load just enough to clear the

rack/floor, otherwise it may catch on the
rack above. 17
S
turn the steering wheel/forks
(anticlockwise for LHS) so that the
load/pallet stays aligned parallel and
central to the sides of adjacent
loads/pallets [18]. Use the side shift to
centre the load with the adjacent pallets
if necessary.
Note:
If there is not enough clearance to
remove the load/pallet drive forward and
1
try the removal process again. To get
more clearance, don’t start turning the
forks until you have backed out 200 to
400mm (8 to 16 in.) 18
11. When the front right hand corner of the

load (item 1) [18] clears the racking,
stop reversing and turn the steering
wheel (clockwise for LHS) to align the
sides of the load/pallet with the sides of
the aisle.
12. Lower the forks until they are 100 to

150mm (4 to 6 in.) off the ground and
slowly drive the truck forward while
using the steering to straighten the truck
in the centre of the aisle. Drive to the
next location observing the safety rules
previously stated.
19

In Case the Aisle-Master 3. Brace your feet [22].
Forklift Tips Over
The following conditions can cause an Aisle-
Master forklift to tip over:
 Tip Loading (forks not inserted fully into

pallet)
 A load that is too heavy
 A load with a load centre exceeding that
stated on the capacity plate 22
 Taking a corner too fast
 Driving with the load elevated 4. Don’t jump out of the cabin [23].
 A load that is not distributed properly
(keep the load centre nearest the load
backrest / fork carriage)
 Driving across a slope
 Driving on a slope with the load facing
downhill.
 Using a battery that weighs less than the
original battery supplied with the truck.
23
Warning
result in serious injury or death. Turning
If you sense your forklift is going to tip
over, follow these instructions:
1. Lean away from the direction the truck is

tipping [20].
24
Warning
A lateral tip-over can occur if your truck
is improperly operated [24]. Slow down
before turning! Failure to slow down can
20 cause serious injury or death.
2. Hold on to the steering wheel [21]. Follow these rules when turning with a load to
help prevent the truck from tipping:
 Slow down. Your Aisle-Master forklift can
tip over if you turn at high speed.
 Sound the horn as you reach an
intersection to warn pedestrians and other
equipment operators you are
approaching.
 Always follow the rules of the road and
21 yield to other equipment operators and
pedestrians as required.

Transporting a Load
Follow these guidelines when you transport a
load:
 Do not speed.
 Use the horn to warn others of danger.
 Make sure the load is seated firmly
against the load backrest / vertical front
face of the fork.
 Tilt the mast back.
 Lower the load so the forks are 100 to
150mm (4 to 6 in.) off of the ground. 25
 Be alert to overhead obstructions such
as low doorways, racking, and pipes.  If vision is obscured, arrange for a
Make sure you know the raised and “spotter” to guide you.
lowered heights of the mast.
 If you are not carrying a load, travel with
 Make sure the load is not wider than the
the forks facing uphill when travelling up
width of the gangways or aisles,
an incline and with the forks facing
especially if you are backing a bulky load
downhill when travelling down an incline
down an incline.
[26].
Travelling On Inclines
!
Warning
Use extra caution when operating on
slopes. Travel slowly and do not turn.
When carrying a load always travel with
the forks facing uphill whether driving
up or down the slope.
result in serious injury or death.
When you travel up or down an incline,

follow these guidelines:
 Always drive straight on inclines.
 Make sure the gradient does not exceed

15% (8.5°).
Warning
When carrying a load always travel with
the forks facing uphill whether travelling
up or down an incline. That means you
must back down an incline when you 26
are carrying a load [25].

Warning
Never travel across a slope [27]. This
can cause the truck to tip-over laterally
and can result in serious injury or death.
27
Note:
Use the brake pedal to keep the truck
speed under control when travelling down
an incline.
Raise the forks as necessary to prevent the

forks or load from hitting the ground and getting
damaged as the road surface changes gradient
going up or down an incline [28]. Lower the
forks to 100 to 150mm (4 to 6 in.) off the
ground when clear of the change in gradient.
28

Unloading Your Forklift
3 1
The following steps outline the proper
procedure to be followed when unloading the
truck.
The black arrows indicate the direction to
turn the steering wheel and the grey arrows
indicate the truck drive and mast 4
carrier/fork directions.
1. Drive straight down the middle of the

aisle (item 1) [29] and slow down when
approaching the location where the load
2
is to be placed (item 2) [29].
2. For narrow aisles bear to the side of

the aisle that is opposite to the 29
space/stack (item 3) [29]. Maintain a
distance of approximately 150mm (6
inches) between the side of the truck
and the side of the aisle. For wider
aisles stay in the centre of the aisle.
3. Centre the forks using the side shift.
Warning
If the forks or load jam or catch during
a stacking operation, do not attempt to
free them by reaching through the
mast. Failure to follow this guideline
4. Drive forward until the centres of the

front wheels are aligned with the centre 1
of the space/stack where the load is to
be placed (item 4) [29] stop the truck 30
and set the direction lever to neutral.
5. Lift the load to the required height and

use the tilt to level the forks.
6. Turn the steering wheel/forks towards

the space/stack (anticlockwise for LHS).
Stop turning when the near front corner
of the load (item 1) [30] is approximately
100mm (4 inches) from the face of the
rack/stack.

turn the steering wheel/load towards the
space (anticlockwise for LHS) until the
near front corner of the load clears the
racking [31]. Stop and set the direction 31
lever to neutral.

8. Continue turning the steering wheel/load

towards the space (anticlockwise for
LHS) until the load is centred with the
space [32].
Note:
When turning the steering with the truck
stopped do not apply the foot brake or
the park brake.
32
9. Set the direction lever to forward. Drive

the truck forward towards the
space/stack and simultaneously turn the
steering wheel/load (clockwise for LHS)
so that the load stays aligned parallel
and central to the sides of the
space/stack [33]. Use the side shift to
centre the load if necessary.
10. Position the load in the space or over

the stack [33], set the direction lever to
neutral and lower the load until it sits
firmly on the rack/stack. Continue to
lower the forks until they are clear of the
bottom of the load (item 1) [34].
33
Warning
When lowering the forks clear of the
bottom of the load (item 1) [34], make 1
sure to not lower them too far. If the
forks are lowered too far the mast, rack,
or other containers on the stack could
get damaged. This could result in
serious injury or death.
11. Use the tilt to level the forks if required.
34

turn the steering wheel/forks
(anticlockwise for LHS) so that the forks
stay aligned parallel and central to the
sides of load/pallet [35]. Use the side
shift to centre the forks with the
load/pallet if necessary.
Warning 1
Do not attempt to withdraw the forks
until they have been lowered clear of the 35
bottom of the load. Failure to follow this
guideline can cause the load to fall off
the rack/stack causing serious injury or
death.
13. When the front of the forks (item 1) [35]

clear the rack/stack, stop reversing and
turn the forks away from the rack/stack
(clockwise for LHS) [36].
36
14. Lower the forks until they are 100 to

150mm (4 to 6 in.) off the ground. Set
the direction lever to forward and slowly
drive the truck forward while using the
steering to straighten the truck in the
centre of the aisle [37]. Drive to the next
location observing the safety rules
previously stated.
37

Transporting an Aisle- Tying-Down

Master Forklift Failure to securely tie down the truck when
transporting can allow it to shift. This can lead
to instability in the behaviour of the transport
Lifting with a Hoist vehicle or the truck being lost from the vehicle.
Use wheel chocks to prevent the truck from
Warning rolling. Only use the front tie down point (item
Failure to use lifting equipment of 1) [39] and rear tie down points (items 2) [39]
adequate capacity to lift and move your to tie down the truck in order to avoid
forklift can cause lifting equipment failure, damaging other parts of the truck. Use ratchet
which can lead to serious injury or death. straps that are sufficiently rated to restrain the
mass of the truck.
If you use lifting equipment to move the Aisle-
Master forklift to another location make sure Warning
the equipment has adequate size and
capacity to lift the truck. Confirm that the lifting Failure to tie down the truck securely
devices are in serviceable condition according with adequate equipment during
to their ratings. transit can allow the truck to break
loose which may result in serious
If you need to use a hoist to lift your Aisle- injury or death.
Master forklift:
1. Pass a suitable strap (item 1) [38], under

the truck just behind the rear wheels.
Ensure the strap is directly under the flat
area.
2. Pass another suitable strap (item 2) [38],

under the cross braces of all sections at the
top of the mast.
2
1
39 2
38
Note:
Use suitable packing when lifting the
truck to avoid damage.

SECTION 4
Inspection and Maintenance
discusses the following concepts that must be thoroughly understood
before you inspect or perform maintenance on a forklift:
Initial 100 Hour Service - Describes the maintenance tasks that

must be performed after the first 100 hours of operating.
Inspection and Maintenance – Describes the tasks involved in

performing forklift inspections and preventive maintenance.
Inspection and Maintenance Responsibilities – Details the

inspection responsibilities for forklift operators and service facilities
authorised by Aisle-Master Ltd. to perform preventive maintenance.
Inspection and Maintenance Practices – Describes the precautions

and steps you should take when you perform inspection or preventive
maintenance tasks on Aisle-Master forklifts.
Operator Maintenance – Describes the tasks that must be

performed at the beginning of each shift before the truck can be used.
Routine Maintenance – Describes the routine maintenance tasks

that should be carried out regularly on your Aisle-Master forklift.
Fork Maintenance – Describes how inspection tasks should be

carried out on the forks of the Aisle-Master forklift.
Mast Maintenance – Describes the maintenance tasks that should

be carried out on the mast on your Aisle-Master forklift.
Brake Maintenance – Describes the maintenance tasks that should

be carried out on the brakes on your Aisle-Master forklift.
Hydraulic Maintenance – Describes the maintenance tasks that

should be carried out regularly on the hydraulic system and
components on your Aisle-Master forklift.
Transmission Maintenance – Describes the maintenance tasks that

should be performed on the transmission on your Aisle-Master forklift.
Battery Maintenance – Describes the maintenance tasks that should

be carried out regularly on the battery in your Aisle-Master forklift.
Greasing – Describes the procedure that should be followed when

greasing components on your Aisle-Master forklift.
Putting a Truck in Storage – Describes how to store a truck.
Final Decommissioning – Describes how to dispose of a truck.

Initial Service at 100 Hours

An initial service is required after the first 100 hours of operation to ensure that the truck is in
optimum working condition. The initial 100 hour service is conducted as follows:
 Check battery electrolyte levels.
 Check all electrical connections/terminals.
 Check emergency stop button.
 Check all bolts and fittings are tight.
 Torque wheel nuts
 Front Wheel Nuts (305N/m)

 Rear Wheel Nuts (176N/m)
 Grease all points (See grease point chart on Page 4-23).
 Check mast chains - lubricate and adjust if required.
 Check mast channels – lubricate if required.
 Check for leaks - hydraulic oil, brake fluid, battery electrolyte.
 Replace hydraulic oil return filter element
 Check hydraulic oil level.
 Change transmission oil (front axle).
 Check load monitor is working correctly (if fitted).
 Check brake fluid level.
 Adjust handbrake if required.
 Check tyres for cracks and debris.
 Change steering support oil (if applicable).
 Check steering chains and lubricate (if applicable).
 Check steering.
Note: Lubricate all grease points weekly (See Grease Point Chart Page 4-23)
Note: An initial service checklist is located in Appendix A at the back of this

manual.

Inspection and Maintenance Warning

Before conducting a maintenance
General procedure ensure the battery is
This section contains a MAINTENANCE disconnected, and the mast and
SCHEDULE and the instructions for maintenance forks are fully lowered.
and inspection.
Inspection Program
Industrial trucks are thoroughly examined, tested
and lubricated before leaving the factory; however, The inspection program designed by Aisle-
regular maintenance and lubrication are necessary Master Ltd. periodically checks the integrity
to ensure smooth running and long life. of Aisle-Master forklift systems such as:
The recommended maintenance periods are for  Checking performance of operator
trucks operating in normal, clean conditions. For functions such as lift, tilt, side shift,
abnormal temperatures, dust contamination areas attachment, and traction systems
or moist conditions, etc., more frequent  Checking for leaks
maintenance will be required.  Checking fluid levels
 Making sure components are securely
The maintenance work covered in this manual is attached
divided into sections:  Checking the tyres
1. Checks and adjustments (where no special Except for the Operator’s Pre-Use Checks,
skills are required) that may be performed by these tasks are usually performed by a
the operator. service and maintenance facility that is
2. Repairs and adjustments that must be done by approved by Aisle-Master Ltd.
trained service people.
To make sure these and other systems are
Warning checked periodically, Aisle-Master Ltd. has
developed a system of checklists. A blank
Do not operate a lift truck that is in need of copy of each checklist can be found in
repair. Report the need for repair Appendix A. These checklists include:
immediately. If repair is necessary, put a
"DO NOT OPERATE" label in the operator's  Operator’s Pre-Use Checklist
area. Remove the key from the key switch.  Initial service at 100 Hours
 Every 500 Hour Service Checklist
 Installation Checklist / Pre-delivery
Inspection (PDI)
Warning
Never perform any maintenance or service
procedures unless specifically indicated in Maintenance Program
this manual or requested by your
supervisor. All other service and In addition to the inspection program, Aisle-
maintenance on your Aisle-Master forklift Master Ltd. has set up a preventive
must be provided by a facility authorised by Maintenance program. Preventive
Aisle-Master Ltd. to perform these services. maintenance procedures include:
Failure to follow these guidelines can cause
serious injury or death.  Changing transmission oil
 Changing hydraulic oil and filters
 Lubricating mechanical systems

Preventive maintenance tasks are usually Regular Service intervals in normal use are:
performed by a service and maintenance facility
that is approved by Aisle-Master Ltd. Operators  500 hours of operation or 3 months
may be asked to assist in some routine (whichever comes first)
maintenance procedures. Never perform any of  2000 hours of operation or 12 months
these maintenance procedures unless directed (whichever comes first)
by your supervisor.
Typically an authorised service and
maintenance facility performs preventive
Inspection and maintenance procedures. At times operators
may be requested to assist in performing
Maintenance routine maintenance, such as doing routine
Responsibilities lubrication. If requested to do so, make sure
you read and understand the guidelines
discussed in the “Inspection and Maintenance
500 and 2000 Hour Service Practices for Aisle-Master Forklift Operators,”
section on the following page of this manual.
During these inspections technicians from an
authorised service and maintenance facility will
inspect all mechanical and electrical systems and Inspection and
perform preventive maintenance operations
designated by Aisle-Master Ltd. Maintenance Practices
This section explains the general precautions
and warnings that must be observed during
Installation Inspection inspection and maintenance procedures. In
addition, the duties of the operator and service
When your Aisle-Master forklift is installed, the and maintenance technician are explained.
authorised service facility is required to complete Finally, these specific procedures are
an Installation Checklist. The installation report explained:
initiates the warranty for the vehicle.
 Preparing for Inspection or Maintenance
Routine Maintenance Schedule  Performance Testing
 Completing Performance Testing
The Routine Maintenance Schedule is located on
Page 4-7. Note that each task should be Warning
performed at the time interval or number of
Wipe up any spills immediately to prevent
operation hours indicated, whichever comes first.
serious injury or death from slipping, fire,
explosion, or contact with hazardous
Warning materials.
Never perform any maintenance or service
procedures unless specifically indicated in Warning
this manual or requested by your supervisor.
All other service and maintenance on your To help avoid fire hazards:
forklift must be provided by a facility • Have fire protection equipment present
authorised by Aisle-Master Ltd. to perform in the work area.
these services. Failure to follow these • Do not use an open flame to check fluid
guidelines can cause serious injury or death. level, leaking oil, or electrolyte.
• Do not use fuel or flammable cleaning
fluids to clean parts.

cause serious injury or death.

Warning Inspection and Maintenance

Batteries produce flammable and explosive Practices for Authorised Facilities
gases. Keep arcs, sparks, flames, and lighted ONLY
tobacco away to prevent an explosion. Keep
the area well ventilated. Failure to follow these  Follow the procedures outlined in this
guidelines can cause serious injury or death. manual.
Warning  Inspect and maintain wheel hubs and

Failure to use lifting equipment of adequate protective devices.
capacity to lift and move your forklift can
cause lifting equipment failure, which can lead  Only use replacement parts, including
to serious injury or death. tyres that are equal to, or exceed, the
quality of the parts supplied by the original
! equipment manufacturer. Install parts,
Inspection and Maintenance including tyres, according to procedures
Practices for Aisle-Master Forklift established by Aisle-Master Ltd.
Operators  When you remove tyres, follow industry
safety practices.
These guidelines will help prevent downtime for
your Aisle-Master forklift and maintain it in a safe
operating condition:
Preparing for Inspection or
 Perform the tasks listed on the Operator’s Maintenance
Pre-Use Checklist even if you are taking
responsibility of the truck from another Inspect the truck in an area that has sufficient
operator. You are responsible for the clearance to check all operating functions.
condition of the forklift on your shift. Work
together as a team with your co-workers, Lower forks to the ground and tilt mast forward.
supervisor, and authorised service facility to
keep the truck in peak operating condition.  If you will not be operating the truck to
Accidents happen when you assume check operator functions, disconnect the
another operator has checked out the battery and chock the wheels.
forklift.
 If you need to hoist the truck, make sure
 Keep your truck clean to minimise fire the hoisting equipment has adequate size
hazards and facilitate detection of loose or and capacity to move the equipment. See
defective parts. ‘lifting with a hoist’ on page 3-24.
If you are asked or required to perform basic

lift truck maintenance, make special note of
the following:
 Before you perform service or maintenance

on an Aisle-Master forklift, read and
understand the Aisle-Master Forklift
operator’s and service manual, and machine
safety signs.

Performance Testing 4. Turn the key switch, (item 1) [2], to the ‘ON’
position.
Note:
Make sure all accessories (lights, etc.) are off 5. Set the direction lever (item 1) [1], to the
before continuing. forward position.
1. Make sure you are in the operator’s seat. 6. Check functions described on the Operator’s
Pre-Use Checklist (Page A-2).
2. Make sure your right foot is on the floor of
the operator’s cab.
Completing Performance Testing
3. Set the direction lever (item 1) [1], to the
neutral (centre) position.
Note:
Make sure all accessories are off (lights,
etc.) before you turn the key switch to the
1 ‘Off’ position.
1. Apply the parking brake (item 2) [2].
2. Tilt the mast forward.
3. Lower the forks to the ground.
4. Turn the key switch to the ‘OFF’ position.
5. Remove the key.

1
Before you leave the truck make sure that:
• The parked truck will not cause an

obstruction or safety hazard.
• The forklift is clear of fire exits, fire

equipment, and stairways.
• The truck is not left unattended on an incline.
If the truck cannot be driven and you must

leave it parked on an incline, securely chock the
1 wheels and remove the key.

Inspecting Specially Equipped Aisle- The forklift trucks are built with quality
components; the use of inferior spare parts can
Master Forklift Trucks result in inadequate safety and poor reliability.
The following information is provided for Only use genuine approved parts.
authorised service facilities ONLY.
Maintenance Chart
Forklift trucks that were designed to meet special
applications should be inspected and tested to The following tasks must be performed at the
make sure they meet original design criteria intervals indicated in order to keep the truck in
described by the specific (local) agency. optimum working condition.
Service Interval
Information Plate and Safety (Hrs)
Item
Warnings 500 2000
Check All Electrical Connections/Terminals ●
Warning Visually Inspect The Brake Shoes & Drum ●
Make sure that the identification plate and Inspect the Brake Cylinder & Adjuster ●
safety warnings (decals) located on the truck Check All Nuts And Bolts Are Present & Secure ●
are legible and that the information provided Check Drive Transmission Oil Level ●
matches the characteristics of the truck.
Change Drive Transmission Oil ●
Failure to follow this guideline can result in
serious injury or death. Change Steering Support Oil (If Applicable) ●
Check Motor Mounts & Mounting Bolts ●
The following information is provided for Check Pump Operation & Mounting Bolts ●
Check Cooling Fan ●
Contact Aisle-Master Ltd. if any accessories that Check Hydraulic Oil Level ●
modify the capacity and truck operation are Change Hydraulic Oil ●
planned. After the factory reviews your request, Change Hydraulic Return Filter Cartridge ●
new identification tags will be issued to update the
rated capacity and other operation characteristics. Change Hydraulic In-Tank Strainer Filter ●
Grease Slew Ring Bearing (If Applicable) ●
●
Routine Maintenance Check Park Brake & Adjust Park Brake Cables
Check Mast Mounting Points ●

Routine maintenance may be carried out by the Check Load Monitor Operation (If Fitted) ●
users / operators, but only if the correct facilities Check Mast Bearings ●
and replacement parts, e.g. filters are used. Adjust Mast Bearing Wear Pads ●
Check Lubricate & Adjust Mast Chains ●
The service intervals are given in both operating
hours (recorded on the lift truck hour meter) and in Check & Lubricate Steering Chains (If Applicable) ●
calendar time. Grease Mast Channels ●
Check Service Brake Master Cylinder Fluid Level ●
Service the machine at the interval that occurs
first. These intervals are based on normal
Torque Front Wheel Nuts – 305Nm (225ft-lb) ●
operation of 8 hours per day. The time intervals Torque Rear Wheel Nuts – 176Nm (130ft-lb) ●
must be decreased from the recommendations in Check Hydraulic Hoses for Wear and Leaks ●
the maintenance schedule for the following
500 hours or 3 months (Whichever Occurs First)
reasons:
2000 hours or 12 months (Whichever Occurs First)
 If the lift truck is used more than 8 hours per
day. Top up Battery Electrolyte Level Weekly.
 If the lift truck must work in harsh operating Grease all Points Marked on the Grease Point
Chart weekly (see page 4-23).
environments.
Grease the steering pinion every 250 hours.

Fork Maintenance Fork Angle:

Check the angle between the front vertical face
of each fork and the load face of each shank. If
Warning the deviation exceeds 3° from the original
Never operate your Aisle-Master forklift if you specification withdraw the fork from service.
suspect the forks are damaged. Report any
fork damage to your supervisor immediately. Difference in Height between Fork Tips:
Failure to follow this recommendation can Check the difference in height between tips of
cause serious injury or death. the forks with the forks mounted on the fork
carriage. If the difference in tip heights exceeds
The following information is provided for 3% of the length of the blade, the forks should
authorised service facilities ONLY. be removed from service.
Check the forks, and associated components, as Positioning Lock:
required by the various checklists located in Check the positioning lock on each fork to
Appendix A. The following discussion provides make sure it functions properly. If any problems
detailed procedures necessary to perform a are noted, repair or replace the fork.
complete fork inspection.
! Wear:
Warning Two different areas of the fork and fork
attachment should be checked for wear.
If you find any defect in the forks or mounting
components, take the Aisle-Master forklift out
Fork Blade and Shank – Check each fork blade
of service until the fork is repaired or replaced.
and shank for wear, pay special attention to the
Failure to follow this guideline can cause the
area surrounding the heel of the fork. If the
load to fall resulting in serious injury or death.
thickness is reduced to 90% of the original
thickness, remove the fork from service.
Rated Capacity and Load Centre:
The rated capacity of each fork must be at least Fork Hooks – Check the support face of the top
half of the rated capacity stated on the hook and the retaining faces of both hooks for
identification plate. The load centre of each fork wear, crushing, and other local deformations. If
must match the load centre stated on the data any of these deficiencies cause excessive
plate. If the values do not match, replace the fork clearance between the fork and the fork
with one that has the correct characteristics. carriage, remove the fork from service.
Cracks: Fork Marking:

Visually examine the forks for surface cracks. Pay If the fork marking is not clearly legible, the fork
special attention to: manufacturer, or their representative should
remark it.
 Fork heel
 Welds that attach mounting components to the
fork blank Repairing Forks
If you suspect that a fork needs to be repaired
Forks with surface cracks should not be returned
or replaced, return it to the manufacturer or
to service
other expert of equal competence who shall
decide if it may be repaired or if it must be
Straightness of Blade and Shank: replaced with a new fork. Never try to repair
Check the straightness of the upper face of each surface cracks or wear by welding the fork. If
blade and the front face of each shank. If the you need to reset a fork, make sure it is
deviation from straightness exceeds 0.5% of the subjected to an appropriate heat-treatment
length of the blade and/or the height of the shank, before it is returned to service.
respectively withdraw the fork from service.

Load Testing Forks Worn Surfaces on Outer Plates/Pin Heads:

Check alignment and adjust as necessary
A fork that has undergone repairs - other than If wear is excessive replace chains
repair or replacement of the positioning lock or
marking - must be load tested before it is returned
to service. The test load must correspond to 2.5
times the rated capacity marked on the fork.
Tight Joints:
Mast Maintenance Dirt – clean and lubricate
Corrosion or damage – replace chains
The following information is provided for
Perform checks on the mast as required by the

operator’s pre-use checklist and maintenance as
Cracked Side Plates:
required by the initial 100 hour service checklist
Replace both strands of chain
and 500 hour service checklist for Aisle-Master
Eliminate high load condition or dynamic
Forklifts located in Appendix A. Guidelines are
overloading
provided in the following paragraphs.
Warning
Never work on the mast with a load on the Abnormal Protruding or Turned Pins:
forks or attachment in the raised position Replace chains and improve lubrication.
without supports or while anyone is near the
lift truck control handles.
Chain Maintenance
Regular inspection and lubrication of the chains will Fractured Plates:
vastly increase their service life and reduce Replace chains and correct cause of overload
downtime. When you perform chain maintenance,
make sure you follow the guidelines in ‘Chain
Inspection’, ‘Measuring Chain Stretch’, ‘Chain
Lubrication’ and ‘Chain Adjustment’.
Arc like Cracked Plates:
Replace chains and correct from hostile
environment
Chain Inspection
Inspect the chains as required by the inspection
and maintenance charts. Check for the following:
Enlarged Holes:
Worn Contours: Replace chains and correct cause of overload
Normal wear - replace when 5% worn
Abnormal wear – check alignment and adjust
Corrosion Pitting:
Replace chains and protect from hostile
environment
Worn, broken or misaligned chain anchors:

Replace or adjust as required.

Measuring Chain Stretch It is recommended that the lubricant used on

the chains has the following properties:
Leaf chain failure is usually a result of gradual
elongation as the chain wears. Measure the chain  Satisfactory corrosion protection and
elongation with a chain wear gauge that displays lubrication
the elongation of the chain as a percentage value.  Ability to penetrate through / under water
Follow the chain wear gauge instructions.  Continuously viscous after application
 Good adhesion properties
Chains should ideally be cleaned and measured  Layer thickness and protective film able
in situ while placed under load. It is acceptable for to withstand later aggression (rain / hail
the chain to be tensioned by the weight of the etc.)
carriage and forks.
The following lubricants (available in an
When checking for chain wear it is vital that the aerosol can) are recommended:
section that passes over the pulley is measured
as this section experiences the most wear during Fuchs anticorit bw366
normal operation. Molykote mkl-n
Kluber structovis bhd 75s
Warning
If a chain has reached a level of 2% elongation, Where chains are encased in dirt and dust
a safe time limit must be set for the chains to the lubricant will be prevented from flowing to
be replaced. If a chain has reached 3% the vital load bearing contact areas of the
elongation, it must be taken out of service chain between the link plates and pins.
immediately.
It is essential that leaf chains should be
To check the free lift chains, raise the carriage 1ft removed of all dirt and debris prior to
(30 cm) off the ground to put tension on the chains. lubrication.
To check the main lift chains, raise the mast Recommended jet equipment cleaning
until the inner upright starts to extend putting method for leaf chain:
tension on the chains.
The following method is recommended
when the use of jet cleaning equipment
cannot be avoided in leaf chain and
Chain Lubrication forklift chain maintenance:
Caution 1. Cleaning - Clean the leaf chain using

The chains must be kept lubricated at all steam or hot water only. Absolutely no
times. additives should be used.
2. Compressed Air - Immediately after
Running the chain dry can substantially shorten its cleaning the leaf chain, all water should
life. Oil must be reapplied on a regular basis to be removed both from the surface and
ensure the chains maximum life is achieved. from inside the chain joints using high
pressure compressed air. The
The frequency of this operation is at the discretion articulating links of the chain should be
of the user and essentially depends upon the moved several times during this process.
working conditions and the workplace. 3. Re-lubricating – Make sure that
the chain is slack and then spray with a
Ensure that the chain is slack during the preservative and lubricant. Articulate
lubrication process so that the lubricant can the chain several times so that the
flow between the chain link plates and pins. lubricant penetrates the chain joints.

Chain Adjustment Fork Chain Adjustment

The chains connecting the fork carriage to the
Chain elongation due to stretch (see ‘Measuring inner mast stage must be adjusted so that the
Chain Stretch’ on the previous page) can be bottom faces of the forks are approximately
compensated for by adjusting the chain anchors 6mm of the ground with the truck parked on a
(item 1) [3], [4]. The chain anchors are located on smooth level surface and the mast unloaded
the fork carriage and also on the mast stages. and tilted forward fully.
To set the clearance between the upper stops

on the fork carriage and the inner stage of the
mast, remove the forks and raise the fork
1 carriage fully. Adjust the chain anchors so that
there is a clearance of approximately 1mm
between the stops. When the forks and a load
are present the clearance will increase to a
desirable value of approximately 5mm.
3
1
1 2
4
5
Mast Chain Adjustment
The chains connecting the mast stages must be Chain Tension Adjustment
adjusted in such a way as that the vertical mast The chains on the mast must be adjusted so
channels are approximately flush with each other that each chain acting as one of a pair is
at the bottom and not in contact with the bottom under equal tension to the opposite chain in
plate when the mast is unloaded and fully lowered. the pair for proper load distribution and mast
operation.
To adjust a mast stage, tighten or loosen the
adjusting nut on one of the chain anchors to To check and set the chain tension:
achieve the desired dimension. Adjust the 1. With the mast unloaded raise the
opposite chain of the pair to achieve equal tension sections to put the chains under tension.
in the chains. 2. Press the centre of a strand of chain with
a suitable rod and then press at the same
Raise the mast fully and check that a clearance of place on the opposite chain of the pair.
at least 1mm exists between the end of run stops 3. Each chain in a pair should have equal
(item 1) [5], (item 2) [5] on each of the mast “give”.
stages. 4. If the tension is not equal, tighten the bolt
on the anchor of the slack chain.
5. Test the tension again. Tighten the bolt
until the tension is equal.
Note:
Never place hands inside the mast to
check chain tension.

Greasing Mast Channels Note:

All roller surfaces must be greased periodically The mast bearing wear pads must be
where the fork carriage and mast section roller adjusted evenly on both sides of the mast.
bearings run [6]. The frequency of this operation is
at the discretion of the user and essentially To adjust the mast bearing wear pads:
depends upon the working conditions and the 1. Turn the locking nut (item 1) [7]
workplace. anticlockwise a couple of turns to loosen.
2. Turn the adjusting screw (item 2) [7]
Perform checks on the mast channel lubrication as clockwise until the wear pad comes into
required by the initial 100 hour service checklist contact with the adjacent mast channel.
and 500 hour service checklist for Aisle-Master 3. Repeat steps 1 and 2 on the bearing
Forklifts located in Appendix A. directly opposite.
4. Turn the adjusting screw ¼ turn
A lubrication interval of about 500 hours can be anticlockwise then tighten the locking nut.
taken as a typical value, under normal working 5. Repeat step 4 on the bearing directly
conditions. For this purpose use graphite grease, opposite.
avoid spray greases. 6. Repeat steps 1-5 until the wear pads
have been adjusted on all mast bearings.
Check for cracks or flat areas on the surface

of the bearings and also check for restrictions
to rolling. Replace if any of these are detected
and try to eliminate the cause(s) of the failure.
Principle Causes of Bearing Failure
Shocks
Violent frontal collisions during loading can
cause bearings to fail.
The external surface will show cracks (item 1)
[8] that cut the surface parallel to the rolling
axis.
6 1 2
Mast Bearings
The bearings on the mast do not require periodic
greasing.
The mast bearing wear pads must be adjusted
every 500 hours. 8
Large Load Centre
Another possible cause of breakage is the
1 mounting of special equipment to handle
loads with a very large load centre e.g.
carpets, even if their weight is lower than the
rated capacity.
This condition creates oscillations that cause
2 the detachment of the external hardened
surface of the bearing. In this case
circumferential cracks (item 2) [8] will appear
7 and will run completely around the roller.

Visually inspect the brake cylinder (item 3) [9]
Brake Maintenance for excessive wear, damage or leaks. Use only
The following information is provided for a spirit to clean the cylinder. Never use mineral
authorised service facilities ONLY. oil containing cleaning agents. The cylinder
may not be repaired. If necessary replace the
complete cylinder.
Caution
Before commencing maintenance and Visually inspect the automatic adjuster
repair work on the brakes, the vehicle assembly (item 4) [9] for damage. Apply a
must be secured to prevent it from rolling little heat resistant grease to the threads of the
off. adjusting bolts (item 5) [9]. Use only
compressed air to clean the adjuster. Do not
Before commencing work on the brake, dismantle individual components. The adjuster
ensure that the brake cannot be operated may not be repaired. If necessary replace the
unintentionally. complete unit.
3
Brake Inspection
1
The thickness of the lining (item 1) [9] on the
brake shoes (item 2) [9] should be visually
inspected at every 500 hour service interval.
To inspect the thickness of the brake linings jack

up the truck and remove the wheels and brake
drums. Remove all dirt and corrosion from the
brake drum and linings.
The brake shoes must be replaced if:

2
1. The thickness of the brake lining has worn
down to 2mm or less at the thinnest point.
4 5
9
2. The brake surface is glazed.
3. The brake lining is damaged or cracked. Brake Servicing

Removing the Drum
4. The brake shoes are excessively worn
damaged or deformed. 1. Jack the truck up with a suitable jack.
2. Place supports under the truck that are
5. The brake operation is insufficient. capable of safely supporting the weight of
the truck.
3. Release the parking brake and remove the
Caution wheels.
Replace all brake shoes on both sides of 4. Take the brake drum off by removing the
the truck to avoid unequal braking. two M8 countersunk hex head bolts from the
Replace only complete shoes. holes they are in and inserting two M8x30
hex head bolts into the two open holes.
Visually inspect the brake drums for excessive Tighten both bolts evenly to push the drum
wear and grooves on the internal brake surface off normal to the hub.
and for cracks on all surfaces. Replace if 5. With the drum removed perform the checks
necessary (replace both drums to avoid unequal described under brake inspection.
breaking).

Changing the Brake Shoes
2 10
1. Unhook the tension and compression springs 3
from the brake shoes using spring pliers and
compressors.
2. Remove the old brake shoes.
3. Reset the adjuster assembly. See ‘automatic
adjuster setting’ below.
4. Fit the new brake shoes.
5. Fit new tension and compression springs to the 1
brake shoes.
Caution 11
Replace all brake shoes on both sides of
the truck to avoid unequal braking.
Replace only complete shoes.
Automatic Adjuster Setting

The automatic adjusters must be set when:
 They are replaced, removed or remounted.

 New brake shoes and or drums are fitted.
 Any repair work is done where the basic setting 5. Adjust the park brake cables in such a way
of the adjusting bolts (item 1) [10] is altered. that the brake diameter is not altered. To
access the cable adjuster the battery must
be removed (see appendix B page B-7 at
the back of this manual).
To set the automatic adjusters:
Note:
1. Apply a little heat resistant grease to the
The cables must not be pre-tensioned
threads of the adjusting bolts (item 1) [10].
otherwise the adjuster may not function
2. Carefully move the adjusting lever (item 2) [10]
correctly.
away from the adjusting wheel (item 3) [10]
and turn the adjusting wheel – using suitable
6. Mount the drum (see ‘refitting the drum’ on
tools - in the direction indicated by the grey
the following page) and fit the wheels.
arrow in [10] to screw the adjusting bolt back
7. Only if the automatic adjuster has been
into the assembly.
renewed, removed or remounted loosen the
3. Ensure the distance between the bottom of the
hex bolt that fastens the adjuster and
notch in the adjusting bolt and the outer face of
actuate the brakes several times to centre
the adjusting wheel ‘x’ [11] is equal on both
the brake shoes/adjuster in the drum.
sides.
Torque the hex bolt to 90Nm.
4. Stop screwing the bolts into the adjuster when
8. Lightly apply the handbrake and check that
the distance between the notches in the
both the rear wheels are equally difficult to
adjusting screws is equal to 79mm. See [11].
turn. If one wheel is easier to turn, correct
the imbalance at the park brake cable
Note: adjuster.
Precise setting of the automatic adjuster is of 9. Lower the truck to the ground and perform
critical importance for the function of the approximately 10 stops from the trucks
adjuster. maximum speed. The automatic adjuster is
now set.

Refitting the Drum Bleeding the Brakes

1. Ensure the park brake is disengaged. Bleeding the brakes should only ever be
2. Line up the two countersunk holes in the drum necessary if a part of the hydraulic brake
with the two M8 threaded holes in the wheel system has leaked or has been replaced.
hub and slide the drum onto the hub over the Repair any leaks in the system before
wheel studs. bleeding.
3. Screw the two M8x20 countersunk hex bolts -
that were taken out when removing the drum - Caution
back into the hub. Before commencing any work on the
brakes the truck must be secured to
Caution prevent it from rolling off.
Brake parts are safety critical. Use only
original spare parts. Bleeding the brakes requires two people.
Aisle-Master accepts no responsibility
for the use of non-original spare parts. Before the brakes can be bled the battery must
be removed from the truck (see appendix B
page B-7 at the back of this manual).
Brake Fluid
The Aisle-Master truck is supplied with Dot 4 To bleed the brakes:
(SAE J 1704/ISO 4925 – class 4) brake fluid.
1. Park the truck on level ground.
To check the brake fluid level: 2. Secure the truck to prevent it from rolling off
and remove the battery.
1. Park the truck on a level surface and apply the 3. Connect a length of clear tubing to the
park brake. bleed adapter (item 1) [13] on one of the
2. Remove the floor inspection panel (item 1) [12] rear wheel hubs (item 2) [13] and run to a
3. Check that the fluid in the brake master clear container to collect the escaping fluid.
cylinder reservoir (item 2) [12] is between the 4. Pump the brake pedal to compress the air
max and min level marks. in the system then hold pressure on it.
4. Top up if necessary with Dot 4 (SAE J 5. Unscrew the bleed adapter (item 1) [13] to
1704/ISO 4925 – class 4) brake fluid and check let out fluid and air; then tighten the adapter
for leaks in the system. after the pedal has landed (to prevent air
being sucked back in on the upstroke).
Repeat the process (typically 5-10 times for
each wheel).
6. Refill the master cylinder reservoir (item 2)
[12] frequently; if it is emptied the entire
process must be restarted.
7. Repeat steps 3-6 for the opposite hub
8. The cap on the reservoir must be left loose
so that the fluid may be drawn, but should
be in place so that fluid does not squirt out
1 on the return stroke.
9. A block may be placed under the pedal so
2 that it does not bottom out during this
procedure, as the master cylinder seals
could be damaged.
10. Top the reservoir up to the maximum mark
after the brakes have been effectively bled.
12

Note:
1 Before adding hydraulic oil, ensure that
all cylinders are retracted and fill to the
maximum mark on the dipstick.
2
Checking Hydraulic Oil Level
 Park the truck on a level surface.
 Lower the forks fully, tilt the mast forward
fully and retract all cylinders on any
attachments.
 Loosen the hydraulic oil filler cap to release
pressure from the tank before checking the
level on the dipstick.
13
 Remove the dipstick and wipe clean with a
Hydraulic Oil lint free cloth.
 Insert the dipstick fully into the tank and
Clean ISO grade hydraulic oils with improved remove again.
viscosity / temperature characteristics must be  Check that the oil level is between the
used in the Aisle-Master lift truck. Oil must also minimum and maximum marks.
have the correct temperature range for the  If necessary top up to the maximum mark.
ambient temperature in which the machine is  Replace the dipstick and tighten the filler
being operated. If the operating temperature is cap.
outside the standard range, the standard oil
should be replaced with the correct grade.
The correct grade of oil for the relevant Hydraulic System

operating temperature range can be
determined using the following table:
Maintenance
HYDRAULIC OIL CHART The following information is provided for
FLUID OPERATING
-11°C to 66°C -4°C to 74°C 4°C to 89°C
TEMPERATURE 12°F to 150°F 24°F to 166°F 39°F to 193°C
RANGE
RECOMMENDED Maintain the hydraulic system, and
FLUIDS associated components, as required by the
Castrol Hyspin AWH various checklists and the Routine
BP Bartran HV Maintenance Schedule for Aisle-Master
ISO GRADE
ISO GRADE
ISO GRADE
Mobil Univis N Forklifts located in Appendix A. Guidelines

32
46
68
Mobil DTE 10 Excel for hydraulic system maintenance are

Shell Tellus Oil T
provided in the following paragraphs.
Chevron Rando HDZ
Maxol Multivis Caution

Do not allow hydraulic fluid level to drop
Note: significantly or allow the reservoir to
Use of hydraulic oil that does not meet the run dry. This will induce air into the
required grade or temperature range may cause system and cause damage to hydraulic
poor operation, reduced efficiency and/or system components.
damage to hydraulic components.
Note: Cylinders and Valves: Check for leaks,

The machine is supplied with ISO 46 hydraulic damage and excessive wear. Ensure they are
fluid when leaving the factory. Please check if securely mounted.
this is suitable for the ambient temperature in
which the machine is to be operated.

Hoses: Check for cracks, hardening, or other Changing Hydraulic Oil
signs of wear. Reroute any usable hoses that are
kinked, severely bent, or rest against wearing or To drain the oil from the hydraulic tank:
hot parts. Look for leaks, especially at couplings
and fittings. 1. Park the truck on level ground.
2. Retract all hydraulic cylinders i.e. lower
Hydraulic Fluid: Check fluid level and look for air the forks, tilt the mast forward etc.
bubbles. Check the filters. 3. Place a suitable size receptacle directly
underneath the drain screw (item 2)
Other Hydraulic System Components: [14], to prevent any oil spillage.
Visually check other hydraulic system 4. Remove the drain screw by turning anti-
components for signs of leaks damage or wear. clockwise to drain the system.
Ensure they are securely mounted 5. Allow time for the tank to drain
completely
Warning
 Allow the truck time to cool to a safe Once completed fill the system to the
working temperature before commencing appropriate level with Hydraulic oil of the same
any service work on the hydraulic grade as that, which was in the tank.
system.
 Relieve residual pressure from the

hydraulic system before commencing
any service work on the system. Lower
the forks until they are resting on the
ground. With the truck off, actuate all of
the controls several times in both 1
directions and open the steering
cartridge valves.
 Never use the hands or any other body

part to check for fluid leaks. Use a piece
of solid material. Remember to wear
safety glasses.
Leaking fluid under high pressure can

penetrate body tissue resulting in infection
or death.
If fluid is injected into the eyes or skin, seek
treatment immediately from a doctor
familiar with this type of injury 2
14
Checking Side Shift for Leaks
To check side shift circuit: Hydraulic Tank Capacity
1. Side shift completely to the left and hold 40 litres (42 quarts) of oil are required to
the control handle in this position for 5 bring the oil level to the centre of the oil
seconds. Check for external leaks at the level marker on the dipstick (item 1) [14].
cylinder, fittings and hoses.
2. Side shift completely to the right and hold

the control handle in this position for 5
seconds. Check for external leaks at the
cylinder, fittings and hoses.

Hydraulic Filters In-Tank Strainer Filter:

The In-Tank Strainer Filter (item 2) [15],
There are 2 separate hydraulic filters in the located inside the tank must be replaced at
hydraulic system that must be replaced at certain intervals of every 2000 hours (or 12 months
intervals. These filters are: depending on which occurs first). The
strainer filter can only be accessed when the
1. The Return Filter (item 1) [15] hydraulic tank has been drained.
2. The In-Tank Strainer Filter (item 2) [15]
To replace the In-Tank Strainer Filter:
The locations of these filters are shown below. 1. Remove the floor plate to access the top
of the hydraulic tank.
2. Drain the hydraulic oil tank by removing
3 the bung on the bottom right hand
corner of the tank.
3. Remove the access panel (item 3) [15]
1 from the top of the tank.
4. Insert your hand into the tank and
remove the filter by rotating it anti-
clockwise.
5. Fit the new strainer filter. Only use a
genuine Combilift component.
6. Replace the access panel remembering
to correctly fit the access panel O-ring
seal.
2 Steering Support Oil

1. Place a suitable size receptacle directly
15 underneath the drain screw (item 2)
[16], to prevent any oil spillage.
Return Filter: 2. Remove the fill screw (item 1) [16] and
The return filter element - located inside the drain screw (item 2) [16] by turning anti-
return filter housing (item 1) [15] on the top of the clockwise to drain the system.
hydraulic tank - must be replaced at intervals of 3. Allow time for the support to drain
every 500 hours (or 3 months depending on completely.
which occurs first). 4. Replace the drain screw and refill the
support with the specified quantity of the
To replace the Return Filter element: recommended oil through the drain
1. Remove the floor plate to access the top of screw.
the hydraulic tank.
2. Loosen the lid on the filter housing by Grade: API-GL4 Gear Oil 80W/90
turning it anticlockwise. Steering Support Oil Volume: 0.5L (0.53 qt)
3. Remove the lid to gain access to the filter
element.
4. Remove the retaining spring from the top
of the filter element 1
5. Remove the old filter element and replace
with the new filter element. Only use a
genuine Combilift component.
6. Fit the retaining spring to the top of the 2
new filter element and refit the housing lid.
7. Tighten the lid onto the filter housing by
turning it clockwise.
16

Drive Transmission Oil Drive Transmission Oil

(Standard) (Narrow)
Note: Note
It is essential that the machine is parked on The two sides of the narrow front axle are
level ground to ensure accurate oil level lubricated separately.
checking and changing.
Thoroughly clean the area around the oil Checking Oil Level
plugs on the axle to prevent any dirt or
contamination from entering the axle. 1. At the axle casing remove fill/level plugs
(item 1) [18]. Oil should be level with the
Checking Oil Level bottom of the fill/level hole.
1. At the axle casing remove fill/level plug (item 1) 2. If necessary, top up with recommended oil
[17]. Oil should be level with the bottom of the (see below). Clean and refit fill/level plugs
fill/level hole. (item 1) [18].
2. If necessary, top up with recommended oil (see

below). Clean and refit fill/level plug (item 1)
[17].
18 2
Changing Oil
17 2 1
1. Remove the fill/level plugs (item 1) [18]
and drain plugs (item 2) [18] from the axle
Changing Oil casing. Allow time for the oil to drain out
into a suitable container. Oil should be
1. Remove the fill/level plug (item 1) [17] and warm when draining.
drain plug (item 2) [17] from the axle casing.
Allow time for the oil to drain out into a suitable 2. Thoroughly clean and refit the drain plugs
container. Oil should be warm when draining. (item 2) [18]. Torque to 25 Nm (18 ft-lb).
2. Thoroughly clean and refit the drain plug (item 3. Fill the axle with the specified quantity of
2) [17]. oil (see below) through the fill/level plugs
(item 1) [18]. Torque to 25 Nm (18 ft-lb).
3. Fill the axle with the specified quantity of oil
(see below) through the fill/level plug (item 1) 4. Thoroughly clean and refit the fill/level
[17]. plugs (item 1) [18].
4. Thoroughly clean and refit the fill/level plug Oil Grade: API-GL4 Gear Oil 80W/90
(item 1) [17]. Capacity: 1.2 L (1.27 qt) LH Side
0.5 L (0.53 qt) RH Side
Oil Grade: API-GL4 Gear Oil 80W/90 Note:
Capacity: 1.8 L (1.9 qt) Do not pour fluids into the ground, down a
drain or into a stream, pond or lake.
Observe relevant environmental protection
regulations when disposing of oil.

Battery Maintenance 

Pull up the battery isolator switch.
Turn the key switch clockwise to the ‘ON’
position to power up the trucks electrical
Battery Charging system.
Correct operation of the battery charger is
important. Follow the instructions of the charger
manufacturer. 1
Never permit the battery to discharge below the
minimum value given by the battery manufacturer.
Generally 80% discharge.
2
Never charge a battery at a rate that will raise the
electrolyte temperature above the recommended 3
level.
19
Recharge the battery daily except when only
lightly discharged.
Note:
Do not leave the battery in a discharged state. Never use a battery that weighs more or
less than the original battery supplied with
Supplementary (Opportunity) charging may be the truck. The combined weight of the
performed in the middle of a shift but is only battery and the truck must be equal to the
beneficial when the battery charge has fallen unladen weight quoted on the serial plate.
below 75%.
Safety Precautions
Recommended Charging Procedure
Warning
 Park the truck in a designated battery
charging area. Keep all flames and lit tobacco away
 Turn the key switch to the ‘OFF’ position. from the battery during or soon after
 Isolate the battery by pressing in the battery charging as the gases evolved can form
isolator switch (large red button to the right an explosive mixture.
hand side of the seat).
 Open the rear battery cover (item 1) [19]
and leave open during charging to allow Warning
evolved gases to disperse.
 Disconnect the battery plug (item 3) [19] Never do anything that could cause an
from the truck plug (item 2) [19]. electric spark on or near the battery.
 Check the charger cable for damage such
as frayed leads or broken connectors.
 Check that the charger is switched on and Warning
the ammeter is working. Never lay tools or any other objects
 If the cable is free from damage attach the capable of conducting electricity on top
charger plug to the battery plug (item 3) of the battery.
[19].
 Charging will start automatically.
 When the battery is fully charged, it should Warning
be left connected to the charger until
required. Isolate electrical connections before
 The charger must be paused by pressing working on the battery. Use only
the pause button before disconnecting the insulated tools.
charger cable from the battery plug.
 Reconnect the battery plug to the truck plug.

Warning Caution
Wear suitable protective clothing and eye Never connect the battery charger plug
protection when working on the battery. to the plug of the lift truck. You can
damage the traction control circuit.
Warning
Caution
Batteries must only be charged in
designated charging areas. When charging Ensure that the charger voltage is the
batteries, keep the vent plugs closed. correct voltage for the battery.
The battery charging area must have
adequate ventilation to allow the evolved
gases to disperse. Keep the battery cover
open during charging. Warning
Ensure to pause the charger before
disconnecting the battery.
Warning
Ensure the electrical circuit is safe before
making a connection to the battery Warning
Check bolted connections on the
battery for tightness and ensure they
Warning are clean.
The acid in the battery electrolyte will cause
burns or irritation if it comes into contact
with the skin or eyes. Warning
If acid is spilled on the floor, neutralise as
quickly as possible, using an alkali such as Ensure the insulating shrouds on the
soda ash, sodium bicarbonate or dilute cell connectors are in position.
ammonia.
If acid is spilled on clothing, wash as soon
as possible. Note
If acid comes into contact with skin, wash A smear of petroleum jelly applied to
off immediately with plenty of clean water. clean terminals will offer protection
If acid splashes into the eye, immediately against acid corrosion.
flood the eye with copious quantities of
water; then obtain medical attention at
once. Warning
Protective clothing and goggles should
be worn and particular care taken not to
Caution come into contact with or spill
electrolyte when checking its level.
Add nothing to the cells but distilled, Keep the battery clean and dry, and
deionised or approved water and do this terminals free from corrosion. Check
often enough to keep the visible that the ventilation holes in battery caps
components just covered (electrolyte are clear. Temperature must not exceed
visible). Top up electrolyte with the battery 43° C (110° F) during charging.
in its fully charged state.

Care of Battery out of Service

If a battery is to be taken out of service for a time,
or if a new battery cannot be put into service
immediately, it should be given a charge and
stored in a cool dry place. Disconnect detachable
connectors.
Every month, give a charge and check electrolyte

levels.
If a truck is used at irregular intervals, the battery

should be given a charge every month and the
battery disconnected from the truck during idle
periods. Charge and check the electrolyte levels
before returning to service.
Disposal of Batteries
Careless disposal of a battery
can harm the environment and
can be dangerous to persons.
Always dispose of batteries to

an authorised dealer.
Do not attempt to open or dismantle a battery or

cell.

Greasing
Weekly Grease Point Chart
7 5 3 1
6 4 2
20
7 5 3 1
6 4 2
1. Back of RH Tilt 2. Back of LH Tilt 3. Front of RH Tilt 4. Front of LH Tilt

Cylinder Cylinder Cylinder Cylinder
5. Right Hand Mast Pivot 6. Left Hand Mast Pivot 7. Side Shift Top 8. Side Shift Bottom
Note:
(Item 8) [20] grease points are underneath the bottom side shift bar.
Lubricate all points weekly using EP2 grease.
Also Lubricate all grease points on the mast, and attachments where fitted.

Standard Steering Slew Ring Grease Points (500 Hr Interval)
Does not apply to narrow front trucks with chain steering.
There are 2 grease points on the front steering slew ring that must be greased every 500 hours.
The following procedure describes how to grease the steering grease points.
 Park in a suitable area ensuring that you have enough room to turn the mast to 90°.
 Turn the steering wheel left or right until the mast is turned to at least 90° as shown.
 Remove the bottom nose cone (item 1) [21].
 Apply EP2 grease (Mobilux NLGI 2 is Recommended) lightly through the grease nipples
(items 2) [21].
 Replace the bottom nose cone (item 1) [21].
21

Steering Pinion Greasing (250 Hr Interval)
Does not apply to narrow front trucks with chain steering.
The steering pinion (item 1) [22] must be greased every 250 hours. The following procedure
describes how to grease the steering pinion.
 Park in a suitable area with the mast pointing straight forward.

 The steering pinion (item 1) [22] can only be accessed from underneath the truck.
 Apply EP2 grease (Pyroplex Black NLGI 2 is Recommended) between the pinion teeth.
22

Steering Chain Maintenance It is recommended that the lubricant used on

the chains has the following properties:
(If Applicable)
 Satisfactory corrosion protection and
The following information is provided for lubrication
authorised service facilities ONLY.  Ability to penetrate through / under
water
Perform maintenance on the steering chains as  Continuously viscous after application
required by the initial 100 hour service checklist  Good adhesion properties
and 500 hour service checklist. Guidelines are  Layer thickness and protective film able
provided in the following paragraphs. to withstand later aggression (rain / hail
etc.)
Chain Maintenance
The following lubricants (available in an
Regular inspection and lubrication of the chains aerosol can) are recommended:
will increase their service life and reduce
downtime. When you perform chain maintenance, Fuchs anticorit bw366
make sure you follow the guidelines in ‘Chain Molykote mkl-n
Inspection’ and ‘Chain Lubrication’. Kluber structovis bhd 75s
Chain Inspection
23
To locate the steering chains (item 1) [23] remove
the front nose cover (item 2) [23].
The following checks should be performed:
See ‘Chain Inspection’ on page 4-9
Chain Lubrication
Caution 2 1
The chains must be kept lubricated at all
times.
Running the chain dry can substantially shorten its

life. Oil must be reapplied on a regular basis to
ensure the chains maximum life is achieved.
The frequency of this operation is at the discretion

of the user and essentially depends upon the
working conditions and the workplace.
Ensure that the chains are slack during the

lubrication process so that the lubricant can
flow between the chain link plates and pins.

Putting a Truck in Storage Final Decommissioning

To prevent problems, the lift truck must be correctly Drain all fluids into suitable containers and
serviced and maintained during storage. dispose of in accordance with the relevant
local environmental protection regulations.
Components that need extra care during storage
are electric motors, hydraulic components and Note:
electric truck batteries. Do not pour fluids into the ground, down
a drain or into a stream, pond or lake.
Electric trucks can best be protected by being Observe relevant environmental
operated for a short period of time each month. protection regulations when disposing of
oil and electrolyte.
Before putting any truck in storage, you must
choose an area which is clean, dry and free from Dismantle and recycle the individual
dust or fumes in the air that can harm the lift truck. components separately.
Electric drive motors must be operated to keep Note:

them free of rust and dirt caused by condensation Local regulations governing the correct
over periods when the truck is not used. Operate recycling and disposal of waste must be
the truck for at least five minutes. observed.
Before operating, perform the pre-use inspection.

Take care of any problems immediately. Also,
check the fluid level in the hydraulic tank and brake
master cylinder.
Electric trucks must not have batteries installed

during storage. A fully charged battery must be
available to operate a lift truck.
Warning
Do not use a battery charger as a power
source for any reason.
All hydraulic cylinders should be put through a

complete operation cycle several times each
month. This will help keep the seals active and
coat the interior walls with oil. Fully extend and
retract each cylinder.
To protect the cylinder rods, park your truck with

the mast lowered and tilted fully forward (cylinders
fully retracted)
When parked with the power off, operate each

control handle to release hydraulic pressure.
Masts should be stored fully lowered
Coat any exposed area of the cylinder rods with

fresh high grade S.A.E. 30 or 40 engine oil.
Put chocks at the front and rear of a drive tyre
when parked. Do not use the hand brake.

SECTION 5
Schematic Circuit Diagrams
This section contains detailed hydraulic circuit diagrams and information that
can be used to assist with repairs.
 Standard Electric Circuit Diagram
 Hydraulic Circuit Diagram – Motor Steering
 Hydraulic Circuit Diagram – Chain Steering
 Fuse Box and Relays

Standard Electric Circuit Diagram






Hydraulic Circuit Diagram – Motor Steering

Hydraulic Circuit Diagram – Chain Steering

The following table shows the electric circuit

Fuse Box & Relays related to each of the fuses in the fuse box:
Fuse Box Fuse Circuit Rating
Work Light Relays, Speed Reduction
The fuse box (item 1) [1] is located behind the 1 Input (12V) 10A
right hand side panel (item 2) [1]. Raise the 2 High Mast Cut-Out Proximity (12V) 7.5A
seat base and remove the side panel by lifting 3
Optional Camera, Wipers, Heated
7.5A
up and out to gain access to the fuses. Windows (12V)
Mast Tilt & Lift Lockout, Handbrake
4 Alarm, Brake Fluid Level (12V) 7.5A
5 2-Way Direction Lever (12V) 7.5A
22 Cooling Fans, Hydraulic System
6 Pressure Switch (12V) 7.5A
22a
Auxiliary Hydraulic Function
LL 7 Solenoid (12V) 7.5A
TL
3 8 Spare (12V) 7.5A
32 9 Air Seat Pump (12V) 15A
10 Horn (12V) 7.5A
11 Work Lights (48V) 7.5A
12 Reverse Bleeper (48V) 7.5A
4 13 Flashing Beacon (48V) 7.5A
14 Spare (48V) 7.5A

related to each of the inline fuses
Fuse Circuit Rating

CF1 Key Switch Supply 7.5A
1 CF2 DC/DC Converter 20A
CF3 Engage VI Supply 1A
CF4 Fuse Box Fuses 11-14 10A
Relays
2 The relay bank (item 3) [1] is located behind

the right hand side panel (item 2) [1] and
1 under the armrest/control pod cover (item 4)
[1]. Raise the seat base and remove the side
panel by lifting up and out to gain access to
Fuse Box Layout the relays. The armrest/control pod cover (item
4) [1] can also be removed to improve access
Fuse 5 Fuse 10 if necessary.
Fuse 14
Fuse 4 Fuse 9 related to each of the relays:
Fuse 13
Fuse 3 Fuse 8 Relay Circuit Rating
Fuse 12 22 Front Work Lights 12v 20/40A
Fuse 2 Fuse 7 22a Rear Work Lights 12v 20/40A
Fuse 11 LL Lift Lockout Solenoid 12v 20/40A
Fuse 1 Fuse 6 TL Tilt Lockout Solenoid 12v 20/40A
32 Auxiliary Mast Function 12v 20/40A

Appendix A (Checklists)
includes the following checklists and maintenance schedules:
 Operator’s Pre-Use Checklist

 Initial service at 100 Hours Checklist
 Every 500 Hour Inspection Checklist
 Installation Checklist
Aisle-Master Operator’s & Service Manual A-1

Aisle-Master
Operator's Pre-Use Checklist
Pre-Use inspection requirement. It is important that these inspections are documented
Date Inspector Record Fluid Added:

Truck No. Model No. Hydraulic Oil
Location Serial No.
Shift Drive Hour
PRE-USE SAFETY & OPERATION CHECKS

Have a qualified mechanic correct all problems. O.K. (X) Needs Maintenance
Overall Condition – Protective Covers, Missing Or Loose Nuts & Bolts
Leaks - Hydraulic Oil, Brake Fluid, Battery Electrolyte
Tyres – Cuts, Cracks, Foreign Objects.
Wheels – Damage, Wheel Nuts Present & Secure (Not Hand Tight)
Forks – Excessive Wear, Cracks, Fractures, Deformation, Equal Spacing,
Locating Pins Engaged
Access – Steps and grab handles secure, clean and in good condition
Load Backrest (If Fitted) – Deformation, Cracks, Securely Mounted
Hydraulic Hoses – Wear, Damage, Leaks, Kinks, Routing
Mast - Bearings, Chains, Channels, Stops – Wear, Damage, Deformation, Cracks
Mast Chains – Wear, Deformation, Cracks, Equal Tension, Lubricated
Steering Chains – Wear, Deformation, Cracks, Equal Tension, Lubricated
Fork Carriage – Excessive Wear, Damage, Deformation, Cracks
Overhead Guard – Damage, Cracks, Securely Mounted
Safety Warnings - Attached
Hydraulic Tank – Damage, Leaks, Oil Level
Battery – Connections Secure, Cell Damage, Leaks, Electrolyte Levels, Leads
Serial Plate & Capacity Plate - Securely Attached, Information Matches
Model, Serial Number on Chassis Matches
Seat Belt, Buckle and Retractor – Cuts In Belt, Functioning Smoothly
Seat – Anchored Securely, Runners Operating Freely, No Objects Underneath
Electrical Connections/Terminals – Securely Connected, Undamaged
Motors - Unusual Noises, Smells
Accelerator - Functioning Smoothly In Forward & Reverse
Park Brake & Service Brake – Functioning
Steering Operation - Functioning Smoothly In Both Directions, No Excessive
Freedom/Stiffness
Drive Control - Forward/Reverse - Functioning Smoothly
Hydraulic Controls – Forward/Back Smooth Operation Through Full Extent
Horn, Lights, Reversing Bleeper & Flashing Beacon – Functioning Normally
Rear View Mirror & Mast Mirror – Securely Attached, Clean, In Good Condition
Display Console /Hour Meter - Functioning
Warning Indicators – Functioning/Extinguished
Load Monitor (If Fitted) – Functioning Normally

Aisle-Master
Initial Service at 100 Hour Checklist
To be performed after first 100 hours of truck operation in addition to the required pre-use inspection.

Location Serial No.
Shift Drive Hour
FIRST 100 HOUR SERVICE

SAFETY & OPERATIONAL CHECKS O.K. (X) Needs Maintenance
Check Battery Electrolyte Levels
Adjust Handbrake if Required
Change Hydraulic Return Filter Cartridge
Check Hydraulic Oil Level
Change Transmission Oil (Front Axle)
Grease All Points.
Check all Electrical Connections/Terminals
Check all Bolts and Fittings are Tight.
Check Mast Chains - Lubricate and Adjust
Check Mast Channels – Lubricate if required
Tyres - Check for Cuts, Cracks & Debris
Wheel Nuts - Torque to (Front - 305Nm), (Rear - 176 Nm)
Check steering operation
Load Monitor – Functioning correctly
Check Service Brake Master Cylinder Fluid Level
Check Drive Axle for Gear Oil
Check Emergency Stop button
Change steering support oil (If applicable)
Check & Lubricate steering chains (If applicable)

Aisle-Master
Every 500 Hour Service Checklist
To be performed after every 500 hours of truck operation in addition to the required pre-use inspection.

Location Serial No.
Shift Drive Hour
EVERY 500 HOUR SERVICE
SAFETY & OPERATIONAL CHECKS O.K. (X) Comments

Visually Inspect the Brake Shoes & Drum
Inspect the Brake Cylinder & Adjuster
Wheels – Damage, Wheel Nuts Present - Torque to (Front - 305Nm), (Rear - 176 Nm)
Mast Bearings, Chains, Channels, Stops – Wear, Damage Deformation, Cracks
Check all Bolts are Present and Secure
Mast Chains – Equal Tension, Lubricated
Check Motor Mounts & Mounting Bolts
Grease Mast Channels
Check Torque on pump mounting bolts
Check All Connections for Proper Torque
Check Brake Fluid Level
Check Hydraulic Tank – Damage, Leaks, Oil Level
Check Drive Transmission Oil Level
Check Pump Operation & Mounting Bolts
Check Cooling Fan
Change Hydraulic Return Filter Cartridge
Check Slew Ring - Functions Smoothly, Wear
Grease Slew Ring Bearing (If Applicable)
Adjust Handbrake if Required
Check Mast Mounting Points
Adjust Mast Chains – If Necessary
Grease Mast Channels
Check Service Brake Master Cylinder Fluid Level
Emergency Stop Button - Functioning

Aisle-Master
Installation Checklist
QUALITY CONTROL SHEET Remit Copy to Aisle-Master Ltd.

Location Serial No.
Shift Drive Hour
SAFETY & OPERATION CHECKS

Have a qualified mechanic correct all problems. O.K. (X) Needs Maintenance
Overall Condition – Protective Covers, Missing Or Loose Nuts & Bolts
Tyres – Cuts, Foreign Objects
Wheels – Damage, Wheel Nuts Present - Torque (Front - 305Nm), (Rear - 176 Nm)
Forks – Excessive Wear, Cracks, Fractures, Deformation, Equal
Spacing, Locating Pins Engaged
Load backrest extension - Attached
Hydraulic Hoses - Check for Wear, Damage Leaks, Kinks, Routing
Finger Guards - Attached
Overhead Guard - Attached
Safety Warning Decals - Attached (Refer to Pages S-3 & S-4 of this Manual)
Brake Fluid Level
Hydraulic Fluid Level
Operators Compartment Capacity Plate Attached - Information Matches
Model, Serial No. And Attachments
Seat Belt, Buckle and Retractor - Functioning Smoothly
Controls (Turn Power On) Investigate Unusual Noises Immediately
Accelerator - Functioning Smoothly
Hand Brake - Functioning
Steering operation - Functioning Smoothly
Drive Control - Forward/Reverse - Functioning Smoothly
Tilt Controls - Forward and Back - Functioning Smoothly
Lift and Lowering Control - Functioning Smoothly
Attachment Controls - Operational
Check Emergency Stop Button - Functioning
Horn - Functioning
Lights - Functioning
Gauges: Hour Meter – Functioning
Warning light - Functioning
Load Monitor - Functioning
Reverse Warning Bleeper - Functioning
Check Drive Axle for Gear Oil

Appendix B (FAQs)
describes how to perform the tasks related to the following frequently asked
questions:
 How to calibrate the load monitor?

 How to adjust the pressure switch?
 How to fit a mast?
 How to remove the battery?
Aisle-Master Operator’s & Service Manual B-1

FAQs
Calibrating the Load Monitor
Calibration of the Load Monitor requires the setting up of two reference points, 0% and 100%.
A magnetic “key” is required to initiate the set up procedure. This must be held in position on
the front panel, just above the TEST button.
PROCEDURE:
1. Place the vehicle in the 0% calibration position, i.e. vehicle level, park brake on, steering
straight ahead, forks lowered but not resting on the ground, and no load on the forks.
2. Leave the ignition turned on as normal.
3. Press and hold the TEST button. The display will show all LEDs flashing and the sounder on.
Keep holding the TEST button and place the magnet in position on the front panel at the top
right hand corner of the test switch. The correct position is indicated when the sounder stops
and all the LEDs stay on, fully lit. KEEP HOLDING THE TEST BUTTON AND MAGNET IN
PLACE for a period until the display changes again to show the red LED only lit. This indicates
that the system is now in calibration mode, and waiting for the first reference point. Release
the button and remove the calibration magnet. (If the button or key is released too early the
display will revert back to normal operation.) Short intermittent beeps will then be emitted to
indicate the system is waiting for an input.
4. Check that the vehicle is still positioned correctly for the 0% reference, and press the TEST
button ONCE. The system will give a single, short beep indicating that the 0% point is set. The
display will change to show one red LED and one amber LED (and continuing intermittent
beeps), indicating that the system is ready and waiting for the 100% reference. (NOTE - if a
long beep is emitted from the sounder during calibration, this indicates a fault condition - see
below).
5. With the vehicle level, and the park brake on, pick up the calibrated 100% load and LIFT to a
height of 1 metre (39 inches).
6. When in position press the TEST button ONCE to set the 100% reference. The display will
again give a single beep to confirm that it is set.
7. The display should now change back to normal operation, and show 100%, i.e. all green and
amber LEDs lit and flashing.
8. System calibration has now been completed. No further action is required.
NOTES:
1. The system allows five minutes for each part of the calibration procedure to be completed.
During these times the system will emit a short beep every five seconds to remind the operator
that it is in calibration mode.
2. If a part of the calibration procedure is not completed within the five minutes allowed the
system will automatically revert to normal operation with the previous calibration settings.
3. If the ignition is switched off during calibration the system will automatically revert to the
previous calibration settings.

FAQs
Adjusting the Pressure Switch
The pressure switch is located on the pressure supply line into the valve chest. The switch is
set before the truck leaves the factory so that the pump motor runs at a low speed when only
the steering is required but will then run at a higher speed when any of the fork functions are
used e.g. the lift, tilt, side shift etc.
It may be the case that after a certain ‘run in’ period the pressure switch needs to be adjusted
to keep the pump motor running at the correct speeds for the steering and fork functions. The
following procedure describes how the pressure switch should be adjusted.
1. Remove the armrest panel (item 1) [1] to gain access to the pressure switch (item 2) [1].
2. Remove the rubber boot (item 3) [1] from the pressure switch (item 2) [1].
1
1
3
2
2
1
3. Adjust the pressure switch setting by turning the setting screw (item 1) [2] using a flat head
screwdriver
4. If the truck will not go in to high speed, i.e. the hydraulic functions are operating slowly turn the
screw anticlockwise. Test by using the lift function with no load on the forks. Keep turning the
screw anticlockwise until the lift speed changes to high speed.
5. If the truck is always running in high speed turn the screw clockwise until it goes to low speed
or steering speed, this will be noticeable when steering the truck. Keep turning the screw
clockwise and turning the steering until the steering goes into low speed.

FAQs
Mast Fitting Guide
Note: Make sure to apply a little thread 3. Fit the bearings (item 2) [2] and shims (if
locking fluid to the threads on each of the applicable) to the upper bosses on the
bolts used to fasten the mast and associated mast. Remove the tilt cylinder fasteners
parts. (item 3) [2] from the bosses (item 6) [1]
on the bottom of the mast.
1. Remove the upper mast bearing blocks (item
1) [1] along with the bearings (item 2) [1] and 4. Place a piece of timber or some other
shims (item 3) [1] from the mast carrier. suitable packer (item 1) [3] on the front
axle mast hook (item 2) [3] to prevent the
1 mast from coming into contact with the
bulkheads/hoses on the front of the mast
carrier (item 3) [3] during fitting. The
packer must be approximately 3cm deep.
4
1
2
2. Pass a suitable strap (item 1) [2] around all of

3
the upper cross members on the mast and lift
the mast. Suitable lifting equipment with
capacity to lift a mass weighing up to 2300kg
must be used.
2 1
1 2
3
5. Swing the tilt cylinders (item 1) [4] out
towards the outer side of the mudguards
(item 2) [4] and allow them to rest on top
of the mudguards. Use some packing to
avoid damage to the paintwork.
2
1
2

FAQs
6. Manoeuvre the mast/truck until the bearings on 9. Connect the hydraulic lines and camera
the mast are aligned with the lower mast bearing plug (if applicable). Ensure the hydraulic
blocks (item 2) [5] on the truck and lower the fittings are tight.
mast until the bearings are seated on the blocks.
10. Tilt the mast back and remove the
packer from behind the mast.
2
3
1
2
5
7. Fit the upper mast bearing blocks (item 1) [5] 1

to the lower mast bearing blocks (item 2) [5]
and fasten using the bolts and washers
provided. Apply a little thread lock to the
threads of the M12 socket cap bolts (item 3) 7
[5] before inserting.
Note: Torque the M12 socket cap (plated) 11. Fit the forks to the fork carriage ensuring
bolts to 100 Nm (74 ft lb). that the fork pins are engaged in one of
the notches in the upper fork bar (item
8. Fit the tilt cylinders (item 1) [6] onto the 2) [7].
bosses on the bottom of the mast and fasten
using the tilt cylinder fasteners. Apply a little Note: On trucks with hydraulic fork
thread lock to the threads of the M10 hex positioners the top fork bar will not
head bolts (item 2) [6] before inserting. be notched. The fork positioner
cylinders will need to be attached to
Note: Torque the M10 hex head bolts to 50 the bosses on the back of the forks.
Nm (37 ft lb).
12. When the mast has been fitted test each
function i.e. the lift, tilt, side-shift etc.
Check that the camera and monitor are
operating correctly (if applicable).
Note: When testing the lift function

ensure all hoses are travelling freely
1 around the hose rollers and are not at
risk of incurring damage from the moving
mast sections.
Make any necessary adjustments.
6 2

FAQs
Mast Mirror Fitting Guide
Note: The mast mirror is placed inside the
battery compartment on top of the battery
before the truck is shipped to prevent
damage to the mirror during shipping. Open
the rear boot lid to access the mirror and its
fasteners.
1. Fasten the mast mirror bracket (item 1) [1] to

the mirror mounting block (item 2) [1] on the
mast cross member using the M8x20 bolts
and M8 spring and flat washers supplied.
3
2
2. Mount the mast mirror (item 3) [1] loosely on

the bracket.
3. Adjust the mirror so that the tips of the forks

are visible to the operator when properly
seated on the truck [2].
4. Fasten the mirror securely.

FAQs
Battery Removal Guide
The truck uses a 48v DC battery, with various
Amp-Hour capacities to suit the truck's duty cycle.
Always consult the truck's technical specification
before attempting to fit or connect a battery
voltage to the truck's electrical system. It is also
important to check the charger specification to 1
ensure that it is compatible with the battery before
charging. Read the charger handbook before 2
connecting.
3
Note: Battery chargers should only be
installed by a qualified electrician.
To unlatch the battery for removal:
 Open the rear bonnet (item 1) [1].
 Disconnect the battery plug (item 2) [1] from 2

the truck plug (item 3) [1].
Note: There are two different battery
 Release the latches (items 4) [1] to the left and systems available for the electric Aisle-
right hand sides of the battery by rotating them Master truck.
as indicated.
 Release the seat panel latch (item 1) [2] to

allow the seat panel (item 2) [2] to open.
 Rotate the front battery latch bracket (item 3) A B

[2] clockwise as indicated.
4
1 1 2
3
3 3
1.
4 In the case of ‘battery system A’ fork

2 pockets (item 1) [3] are incorporated in the
battery platform. To remove the battery from
the truck the battery platform must also be
removed.
1
In the case of ‘battery system B’ fork
pockets (item 2) [3] are incorporated in the
battery therefore the battery can be
removed without the need to remove the
battery platform.
Note: If using a pallet truck it is not

possible the battery without also
removing the battery platform.

FAQs
To remove the battery from a truck fitted with  Raise the battery by approximately 20mm
‘battery system A’ using another forklift truck: and back it out clear of the chassis.
 Follow the instructions on the previous page to  Ensure the sides of the battery remain
unlatch the battery for removal. parallel to the sides of the truck until clear.
 Set the forks on a forklift truck the appropriate  Set the battery down in a safe designated
distance apart and insert the forks into the fork location such as a battery charging bay.
pockets (item 1) [4] in the platform under the
battery. Note: The battery platform remains in the
truck with this system.
To remove the battery from a truck using

a pallet truck:
 Follow the instructions on the previous

page to unlatch the battery for removal.
1  Centre the pallet truck with the battery and

push the pallet truck in underneath the
4 battery platform.
 Raise the battery by approximately 20mm

 Raise the battery by approximately 20mm and and back it out clear of the chassis.
back it out clear of the chassis.
 Ensure the sides of the battery remain
 Ensure the sides of the battery remain parallel parallel to the sides of the truck until clear.
to the sides of the truck until clear.
 Set the battery and platform down in a safe
 Set the battery and platform down in a safe designated location such as a battery
designated location such as a battery charging charging bay.
bay.
Note:
To remove the battery from a truck fitted with If a pallet truck is used to remove the
‘battery system B’ using another forklift truck: battery it cannot be placed directly on the
ground. Battery stands (item 1) [6] are
 Follow the instructions on the previous page to available for placing batteries on when not
unlatch the battery for removal. in service. See section 4 of the trucks
spare parts manual for battery stand part
 Set the forks on a forklift truck the appropriate numbers.
distance apart and insert the forks into the fork
pockets (item 1) [5] in the battery.
1
1
5 6

Diagnostics
Appendix C (Diagnostics)
This section of your Aisle-Master Forklift Operator’s & Service
Manual describes how to diagnose and remedy faults on the
trucks electrical controllers.
 Traction Motor Controller

 Pump Motor Controller
 Custom Faults
Aisle-Master Operator’s & Service Manual C-1

Diagnostics
Traction & Pump Motor Controllers Diagnostics

& Troubleshooting
The motor controllers detect a wide variety of faults or error conditions. Faults
can be detected by the operating system or by the VCL (Vehicle Control
Language) code. This section describes the faults detected by the operating
system.
Diagnostics
There are two methods of obtaining diagnostics information:
1. By reading the display on a 1313 handheld or 1314 PC programmer.

2. By observing the fault codes issued by the status LEDs.
See Table 1 for a summary of LED display formats.
The 1313/1314 programmer will display all faults that are currently set as well
as a history of the faults that have been set since the history log was last
cleared. The programmer displays the faults by name.
The pair of LEDs built into the controller (one red, one yellow) produce flash
codes displaying all the currently set faults in a repeating cycle. Each code
consists of two digits. The red LED flashes once to indicate that the first digit
of the code will follow; the yellow LED then flashes the appropriate number of
times for the first digit. The red LED flashes twice to indicate that the second
digit of the code will follow; the yellow LED flashes the appropriate number of
times for the second digit.
Example: Battery Under voltage (code 23).

In the Fault menu of the 1313/1314 programmer, the words Under voltage
Cutback will be displayed; the real-time battery voltage is displayed in the
Monitor menu (“Key switch Voltage”).
The controller’s two LEDs will display this repeating pattern:
red yellow red yellow
✱ ✱ ✱
✲ ✲ ✲ ✲ ✲
(first digit) (2) (second digit) (3)
The numerical codes used by the yellow LED are listed in the troubleshooting
chart (Table 6.2), which also lists possible fault causes and describes the
conditions that set and clear each fault.

Diagnostics
Summary of LED display formats
The two LEDs have four different display modes, indicating the type of
information they are providing.
Table 1 TYPES OF LED DISPLAY
DISPLAY STATUS
Neither LED illuminated Controller is not powered on; or

vehicle has dead battery; or
severe damage.
Yellow LED flashing Controller is operating normally.
Yellow and red LEDs both on solid Controller is in Flash program mode.
Red LED on solid No software loaded, or an internal hard-

ware fault detected by the Supervisor
or Primary microprocessor. Cycle KSI
to clear. Reload software or replace
controller if necessary.
Red LED and yellow LED flashing Controller has detected a fault.
alternately 2-digit code flashed by yellow LED
identifies the specific fault; one or two
flashes by red LED indicate whether
first or second code digit will follow.
Troubleshooting
The troubleshooting chart, Table 2, provides the following information on all

the controller faults:
 fault code
 fault name as displayed on the programmer’s LCD
 the effect of the fault
 possible causes of the fault
 fault set conditions
 fault clear conditions.
Whenever a fault is encountered and no wiring or vehicle fault can be found,

turn the Key switch (KSI) to the ‘OFF’ position then back to the ‘ON’ position
to see if the fault clears. If it does not, turn off the KSI and remove the 35-pin
connector from the motor. Check the connector for corrosion or damage,
clean it if necessary, and re-insert it.

Diagnostics
Table 2 Troubleshooting Chart
PROGRAMMER LCD DISPLAY
CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS
EFFECT OF FAULT
12 Controller Overcurrent 1. External short of phase U,V, or W Set: Phase current exceeded the current
ShutdownMotor; motor connections. measurement limit.
ShutdownMainContactor; 2. Motor parameters are mis-tuned. Clear: Cycle KSI.
ShutdownEMBrake; 3. Controller defective.
ShutdownThrottle; 4. Speed encoder noise problems.
FullBrake.
13 Current Sensor Fault 1. Leakage to vehicle frame from phase Set: Controller current sensors have
ShutdownMotor; U, V, or W (short in motor stator). invalid offset reading.
ShutdownMainContactor; 2. Controller defective. Clear: Cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
14 Precharge Failed 1. See Monitor menu » Set: Precharge failed to charge the capacitor
ShutdownMotor; Battery: Capacitor Voltage. bank to the KSI voltage.
ShutdownMainContactor; 2. External load on capacitor bank Clear: Cycle Interlock input or use VCL
ShutdownEMBrake; (B+ connection terminal) that function Enable_Precharge().
ShutdownThrottle; prevents the capacitor bank from
FullBrake. charging.
15 Controller Severe Undertemp 1. See Monitor menu » Set: Heatsink temperature below -40°C.
ShutdownMotor; Controller: Temperature. Clear: Bring heatsink temperature
ShutdownMainContactor; 2. Controller is operating in an extreme above -40°C, and cycle interlock or KSI.
ShutdownEMBrake; environment.
ShutdownThrottle;
FullBrake.
16 Controller Severe Overtemp 1. See Monitor menu » Set: Heatsink temperature above +95°C.
ShutdownMotor; Controller: Temperature. Clear: Bring heatsink temperature
ShutdownMainContactor; 2. Controller is operating in an extreme below +95°C, and cycle interlock or KSI.
ShutdownEMBrake; environment.
ShutdownThrottle; 3. Excessive load on vehicle.
FullBrake.
17 Severe B+ Undervoltage 1. Battery Menu parameters Set: Capacitor bank voltage dropped
Reduced drive torque. are misadjusted. below the Severe Undervoltage limit
2. Non-controller system drain on battery. (see page 58) with FET bridge enabled.
3. Battery resistance too high. Clear: Bring capacitor voltage above
4. Battery disconnected while driving. Severe Undervoltage limit.
5. See Monitor menu »
Battery: Capacitor Voltage.
6. Blown B+ fuse or main
contactor did not close.
18 Severe B+ Overvoltage 1. See Monitor menu » Set: Capacitor bank voltage exceeded
ShutdownMotor; Battery: Capacitor Voltage. the Severe Overvoltage limit with FET
ShutdownMainContactor; 2. Battery menu parameters bridge enabled.
ShutdownEMBrake; are misadjusted. Clear: Bring capacitor voltage below
ShutdownThrottle; 3. Battery resistance too high for given Severe Overvoltage limit, and then
FullBrake. 4. Battery disconnected while regen braking.

Diagnostics
Table 2 Troubleshooting Chart continued
EFFECT OF FAULT
22 Controller Overtemp Cutback 1. See Monitor menu » Set: Heatsink temperature exceeded 85°C.
Reduced drive and brake Controller: Temperature. Clear: Bring heatsink temperature below
torque. 2. Controller is performance-limited 85°C.
at this temperature.
3. Controller is operating in an extreme
environment.
4. Excessive load on vehicle.
5. Improper mounting of controller.
23 Undervoltage Cutback 1. Normal operation. Fault shows Set: Capacitor bank voltage dropped below
Reduced drive torque. that the batteries need recharging. the Undervoltage limit (see page 58) with
Controller is performance limited the FET bridge enabled.
at this voltage. Clear: Bring capacitor voltage above the
2. Battery parameters are misadjusted. Undervoltage limit.
3. Non-controller system drain on battery.
4. Battery resistance too high.
5. Battery disconnected while driving.
7. Blown B+ fuse or main
contactor did not close.
24 Overvoltage Cutback 1. Normal operation. Fault shows that Set: Capacitor bank voltage exceeded the
Reduced brake torque. regen braking currents elevated the Overvoltage limit (see page 58) with the
Note: This fault is declared battery voltage during regen braking. FET bridge enabled.
only when the controller is Controller is performance limited Clear: Bring capacitor voltage below
running in regen. at this voltage. the Overvoltage limit.
2. Battery parameters are misadjusted.
3. Battery resistance too high for given
regen current.
4. Battery disconnected while regen braking.
25 +5V Supply Failure 1. External load impedance on the Set: +5V supply (pin 26) outside the
None, unless a fault action +5V supply (pin 26) is too low. +5V±10% range.
is programmed in VCL. 2. See Monitor menu » outputs: Clear: Bring voltage within range.
5 Volts and Ext Supply Current.
26 Digital Out 6 Open/Short 1. External load impedance on Digital Set: Digital Output 6 (pin 19) current
Digital Output 6 driver Output 6 driver (pin 19) is too low. exceeded 15 mA.
will not turn on. Clear: Remedy the overcurrent cause
and use the VCL function Set_DigOut()
to turn the driver on again.
27 Digital Out 7 Open/Short 1. External load impedance on Digital Set: Digital Output 7 (pin 20) current
Digital Output 7 driver Output 7 driver (pin 20) is too low. exceeded 15 mA.
will not turn on. Clear: Remedy the overcurrent cause
and use the VCL function Set_DigOut()
to turn the driver on again.

Diagnostics
EFFECT OF FAULT
28 Motor Temp Hot Cutback 1. Motor temperature is at or above Set: Motor temperature is at or above the
Reduced drive torque. the programmed Temperature Temperature Hot parameter setting.
Hot setting, and the current is Clear: Bring the motor temperature
being cut back. within range.
2. Motor Temperature Control
Menu parameters are mis-tuned.
3. See Monitor menu » Motor:
Temperature and » Inputs:
Analog2.
4. If the application doesn’t use a motor
thermistor, Temp Compensation
and Temp Cutback should be
programmed Off.
29 Motor Temp Sensor Fault 1. Motor thermistor is not connected Set: Motor thermistor input (pin 8) is at
MaxSpeed reduced (LOS, properly. the voltage rail (0 or 10V).
Limited Operating Strategy), 2. If the application doesn’t use a motor Clear: Bring the motor thermistor input
and motor temperature thermistor, Motor Temp Sensor voltage within range.
cutback disabled. Enable should be programmed Off.
3. See Monitor menu » Motor:
Temperature and » Inputs:
Analog2.
31 Coil1 Driver Open/Short 1. Open or short on driver load. Set: Driver 1 (pin 6) is either open or
ShutdownDriver1. 2. Dirty connector pins. shorted. This fault can be set only when
3. Bad crimps or faulty wiring. Main Enable = Off.
Clear: Correct open or short, and cycle driver.
31 Main Open/Short 1. Open or short on driver load. Set: Main contactor driver (pin 6) is
ShutdownMotor; 2. Dirty connector pins. either open or shorted. This fault can be
ShutdownMainContactor; 3. Bad crimps or faulty wiring. set only when Main Enable = On.
ShutdownEMBrake; Clear: Correct open or short, and cycle driver
ShutdownThrottle;
FullBrake.
ShutdownDriver2. 2. Dirty connector pins. shorted. This fault can be set only when
3. Bad crimps or faulty wiring. EM Brake Type = 0.
Clear: Correct open or short, and cycle driver.
32 EMBrake Open/Short 1. Open or short on driver load. Set: Electromagnetic brake driver (pin 5)
ShutdownEMBrake; 2. Dirty connector pins. is either open or shorted. This fault can
ShutdownThrottle; 3. Bad crimps or faulty wiring. be set only when EM Brake Type >0.
FullBrake. Clear: Correct open or short, and cycle driver.
ShutdownDriver3. 2. Dirty connector pins. shorted.
3. Bad crimps or faulty wiring. Clear: Correct open or short, and cycle driver.
ShutdownDriver4. 2. Dirty connector pins. shorted.
35 PD Open/Short 1. Open or short on driver load. Set: Proportional driver (pin 2) is either
ShutdownPD. 2. Dirty connector pins. open or shorted.

Diagnostics
CODE POSSIBLE CAUSE SET/CLEAR CONDITION
EFFECT OF FAULT
36 Encoder Fault 1. Motor encoder failure. Set: Motor encoder phase failure
ShutdownEMBrake; 2. Bad crimps or faulty wiring. detected.
ShutdownThrottle. 3. See Monitor menu » Clear: Cycle KSI.
Motor: Motor RPM.
37 Motor Open 1. Motor phase is open. Set: Motor phase U, V, or W detected

ShutdownMotor; 2. Bad crimps or faulty wiring.` open.
ShutdownMainContactor; Clear: Cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
38 Main Contactor Welded 1. Main contactor tips are welded Set: Just prior to the main contactor
ShutdownMotor; closed. closing, the capacitor bank voltage (B+
ShutdownMainContactor; 2. Motor phase U or V is connection terminal) was loaded for a
ShutdownEMBrake; `disconnected or open. short time and the voltage did not
ShutdownThrottle; 3. An alternate voltage path (such as an discharge.
FullBrake. external precharge resistor) is Clear: Cycle KSI
providing a current to the capacitor
bank (B+ connection terminal).
39 Main Contactor Did Not Close 1. Main contactor did not close. Set: With the main contactor commanded
ShutdownMotor; 2. Main contactor tips are oxidized, closed, the capacitor bank voltage (B+
ShutdownMainContactor; burned, or not making good contact. connection terminal) did not charge to B+.
ShutdownEMBrake; 3. External load on capacitor bank Clear: Cycle KSI.
ShutdownThrottle; (B+ connection terminal) that pre-
FullBrake. vents capacitor bank from charging.
4. Blown B+ fuse.
41 Throttle Wiper High 1. See Monitor menu » Set: Throttle pot wiper (pin 16) voltage
ShutdownThrottle. Inputs: Throttle Pot. is higher than the high fault threshold
2. Throttle pot wiper voltage too high. (can be changed with the VCL function
Setup_Pot_Faults()).
Clear: Bring throttle pot wiper voltage
below the fault threshold.
42 Throttle Wiper Low 1. See Monitor menu » Set: Throttle pot wiper (pin 16) voltage
ShutdownThrottle. Inputs: Throttle Pot. is lower than the low fault threshold
2. Throttle pot wiper voltage too low. (can be changed with the VCL function
Clear: Bring throttle pot wiper voltage
above the fault threshold.
43 Pot2 Wiper High 1. See Monitor menu » Set: Pot2 wiper (pin 17) voltage
FullBrake. Inputs: Pot2 Raw. is higher than the high fault threshold
2. Pot2 wiper voltage too high. (can be changed with the VCL function
Clear: Bring Pot2 wiper voltage below
the fault threshold.
44 Pot2 Wiper Low 1. See Monitor menu » Inputs: Set: Pot2 wiper (pin 17) voltage
FullBrake. Pot2 Raw. is lower than the low fault threshold
2. Pot2 wiper voltage too low. (can be changed with the VCL function
Clear: Bring Pot2 wiper voltage
above the fault threshold.

Diagnostics
EFFECT OF FAULT
45 Pot Low Overcurrent 1. See Monitor menu » Set: Pot low (pin 18) current exceeds 10mA.
ShutdownThrottle; Outputs: Pot Low. Clear: Clear pot low overcurrent condition
FullBrake. 2. Combined pot resistance and cycle KSI.
connected to pot low is too low.
46 EEPROM Failure 1. Failure to write to EEPROM Set: Controller operating system tried to
ShutdownMotor; memory. This can be caused by write to EEPROM memory and failed.
ShutdownMainContactor; EEPROM memory writes initiated Clear: Download the correct software (OS)
ShutdownEMBrake; by VCL, by the CAN bus, by and matching parameter default settings
ShutdownThrottle; adjusting parameters with the into the controller and cycle KSI.
ShutdownInterlock; programmer, or by loading new
ShutdownDriver1;
ShutdownDriver2; software into the controller.
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
47 HPD/Sequencing Fault 1. KSI, interlock, direction, and Set: HPD (High Pedal Disable) or
ShutdownThrottle. throttle inputs applied in incorrect sequencing fault caused by incorrect
sequence. sequence of KSI, interlock, direction, and
2. Faulty wiring, crimps, or switches throttle inputs.
at KSI, interlock, direction, or Clear: Reapply inputs in correct
throttle inputs. sequence.
47 Emer Rev HPD 1. Emergency Reverse operation has Set: At the conclusion of Emergency
ShutdownThrottle; concluded, but the throttle, forward Reverse, the fault was set because various
ShutdownEMBrake. and reverse inputs, and interlock inputs were not returned to neutral.
have not been returned to neutral. Clear: If EMR_Interlock = On, clear the
interlock, throttle, and direction inputs.
If EMR_Interlock = Off, clear the
throttle and direction inputs.
49 Parameter Change Fault 1. This is a safety fault caused by a Set: Adjustment of a parameter setting
ShutdownMotor; change in certain parameter that requires cycling of KSI.
ShutdownMainContactor; settings so that the vehicle will not Clear: Cycle KSI.
ShutdownEMBrake; operate until KSI is cycled.
ShutdownThrottle; For example, if a user changes the
FullBrake. Throttle Type this fault will appear
and require cycling KSI before the
vehicle can operate.
51 Pump Controller Fault 1. Check the pump controller fault Clear: Clear pump controller fault codes.
ShutdownMotor; codes. Cycle KSI
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.

Diagnostics
EFFECT OF FAULT
52 Pump Communication Fault 1. Broken CAN bus wires. Clear: Repair the fault.
ShutdownMotor; 2. Poor connections between the Cycle KSI
ShutdownMainContactor; master controller and the pump
ShutdownEMBrake; controller.
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
53 Screen Communication Fault 1. Broken CAN bus wires. Clear: Repair the fault.
ShutdownMotor; 2. Poor connections between the Cycle KSI
ShutdownMainContactor; master controller and the
ShutdownEMBrake; screen.
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.

Diagnostics
Table 6.2 Troubleshooting Chart continued
EFFECT OF FAULT
68 VCL Run Time Error 1. VCL code encountered a Set: Runtime VCL code error condition
ShutdownMotor; runtime VCL error
ShutdownMainContactor; Clear: Edit VCL application software to
2. Controller is performance-limited fix this error condition; flash the new
ShutdownEMBrake; See Monitor menu » Controller:
ShutdownThrottle; compiled software and matching
ShutdownInterlock; VCL Error Module and VCL parameter defaults; cycle KSI.
ShutdownDriver1; Error.
ShutdownDriver2; This error can then be compared
ShutdownDriver3; to the runtime VCL module ID
ShutdownDriver4; and error code definitions found
ShutdownPD; in the specific OS system
FullBrake. information file.
69 External Supply Out of Range 1. External load on the 5V and 12V Set: The external supply current (combined
None, unless a fault action is sullies draws either too much or current used by the 5V supply [pin 26]
programmed in VCL too little current. and 12V supply [pin 25]) is either greater
2. Fault Checking Menu parameters than the upper current threshold or lower
Ext Supply Max and Ext Supply than the lower current threshold. The two
Min are mistuned. thresholds are defined by the External
3. See Monitor menu »Outputs: Supply Max and External Supply Min
Ext Supply Current. parameter settings (page 53).
Clear: Bring the external supply current
within range.
71 OS General 1. Internal controller fault. Set: Internal controller fault detected.
ShutdownMotor; Clear: Cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
72 PDO Timeout 1. Time between CAN PDO messages Set: Time between CAN PDO messages
ShutdownThrottle; received exceeded the PDO Timeout received exceeded the PDO Timeout
CAN NMT State set Period. Period.
to Pre-operational. Clear: Cycle KSI or receive CAN NMT
message.
73 Stall Detected 1. Stalled motor. Set: No motor encoder movement detected.

ShutdownEMBrake; 2. Motor encoder failure. Clear: EithercycleKSI,or
ShutdownThrottle; 3. Bad crimps or faulty wiring. detect valid motor encoder signals while
Control Mode changed 4. Problems with power supply for the operating in LOS mode and return
to LOS (Limited motor encoder. Throttle Command = 0 and Motor
Operating Strategy). RPM = 0.
5. See Monitor menu » Motor: Motor
RPM.

Diagnostics
EFFECT OF FAULT
74 Fault On Other Traction Dual Drive fault: see Dual Drive manual.
Controller
75 Dual Severe Fault Dual Drive fault: see Dual Drive manual.
77 Supervisor Fault 1. The Supervisor has detected a Set: Mismatched redundant readings;
ShutdownMotor; mismatch in redundant damaged Supervisor; illegal switch inputs.
ShutdownMainContactor; readings. Clear: Check for noise or voltage drift in
ShutdownEMBrake; 2. Internal damage to all switch inputs; check connections;
ShutdownThrottle; Supervisor microprocessor. cycle KSI.
ShutdownInterlock; 3. Switch inputs allowed to be within
ShutdownDriver1;
upper and lower thresholds for over
ShutdownDriver2;
ShutdownDriver3; over 100 milliseconds.
ShutdownDriver4;
ShutdownPD;
FullBrake.
78 Supervisor Incompatible 1. The main OS is not compatible Set: Incompatible software.
ShutdownMotor; with the Supervisor OS. Clear: Load properly matched OS code
ShutdownMainContactor; or update the Supervisor code; cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
82 Bad Calibrations 1. Internal controller fault. Set: Internal controller fault detection.
ShutdownMotor; Clear: Cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
83 Driver Supply Fault 1. Internal controller fault in the voltage Set: Internal controller fault detection.
ShutdownMotor; supply for the driver circuits. Clear: Cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
FullBrake.

Diagnostics
EFFECT OF FAULT
87 Motor Characterization Fault Set: Motor characterization failed

1. Motor characterization failed during
ShutdownMotor; characterization process. See Monitor during the motor characterization
ShutdownEMBrake; menu » Controller: Motor process.
ShutdownThrottle; Characterization Error for cause: Clear: Correct fault; cycle KSI.
FullBrake. 0 = none
1 = encoder signal seen, but step size
not determined; set Encoder Step Size
manually.
2 = motor temp sensor fault.
3 = motor temp hot cutback fault.
4 = controller overtemp cutback fault.
5 = controller undertemp cutback fault.
6 = undervoltage cutback fault.
7 = severe overvoltage fault.
8 = encoder signal not seen, or one or
both channels missing.
9 = motor parameters out of
characterization range.
88 Encoder Pulse Error 1. Encoder Steps parameter does not Set: Motor lost IFO control and
ShutdownMotor; match the actual motor encoder. accelerated without throttle command.
ShutdownMainContactor; Clear: Ensure the Encoder Steps
ShutdownEMBrake; parameter matches the actual encoder;
ShutdownThrottle; cycle KSI.
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
89 Motor Type Fault 1. The Motor_Type parameter value is Set: Motor_Type parameter is set to
ShutdownMotor; out of range. an illegal value.
ShutdownMainContactor; Clear: Set Motor_Type to correct
ShutdownEMBrake; value and cycle KSI.
ShutdownThrottle;
FullBrake.
91 VCL/OS Mismatch 1. The VCL software in the controller Set: VCL and OS software do not
ShutdownMotor; does not match the OS software in the match; when KSI cycles, a check is
ShutdownMainContactor; controller. made to verify that they match and a
ShutdownEMBrake; fault is issued when they do not.
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1; Clear: Download the correct VCL and
ShutdownDriver2; OS software into the controller.
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.

Diagnostics
EFFECT OF FAULT
92 EM Brake Failed to Set Vehicle movement sensed after the Set: After the EM Brake was commanded
1.
ShutdownEMBrake; EM Brake has been commanded to to set and time has elapsed to allow the
ShutdownThrottle;
set. brake to fully engage, vehicle
Position Hold is engaged when movement has been sensed.
Interlock=On. 2. EM Brake will not hold the motor
from rotating. Clear: Activate the throttle.
93 Encoder LOS (Limited 1. Limited Operating Strategy (LOS) Set: Encoder Fault (Code 36) or Stall
Operating Strategy) control mode has been activated, as Detect Fault (Code 73) was activated
Enter LOS control mode a result of either an Encoder Fault and Brake or Interlock has been applied
(Code 36) or a Stall Detect Fault to activate LOS control mode, allowing
(Code 73). limited motor control.
2. Motor encoder failure. Clear: Cycle KSI or, if LOS mode was
3. Bad crimps of faulty wiring. activated by the Stall Fault, clear by
4. Vehicle is stalled. ensuring encoder senses proper
operation, Motor RPM = 0 and Throttle
Command = 0
94 EMR Rev Timeout 1. Emergency Reverse was activated Set: Emergency Reverse was activated
ShutdownEMBrake; and concluded because the EMR and ran until the EMR Timeout timer
ShutdownThrottle; Timeout timer has expired. expired.
2. The emergency reverse input is stuck Clear: Turn the emergency reverse
On. input Off.
98 Illegal Model Number 1. Model_Number variable contains Set: Illegal Model_Number variable;
ShutdownMotor; illegal value. when KSI cycles, a check is made to
ShutdownMainContactor; 2. Software and hardware do not match. confirm a legal Model_Number and a
ShutdownEMBrake; 3. Controller defective. fault is issued if one is not found.
ShutdownThrottle;
FullBrake. Clear: Download appropriate software
for your controller model.
99 Dualmotor Parameter Dual Drive fault: see Dual Drive
Mismatch manual.

Warranty Registration
Appendix D
(Warranty Registration)
The warranty registration form can be filled and submitted online
at:
www.combilift.com/warranty
Please complete the warranty registration online within 30 days of

receipt of the truck.
Alternatively the warranty registration form on the following page

can be used.
Aisle-Master Operator’s & Service Manual D-1

WARRANTY REGISTRATION FORM
Please complete the form below and return this to us within 30 days of delivery to Customer.
Form can be submitted online @ www.combilift.com/warranty
DEALER DETAILS: (Supplier)
Dealer Name: ___________________________________Tel: _________________________
First Name: ________________________ Last Name: ______________________________
E-mail: ____________________________ Position/Role: ____________________________
Street: ____________________________ Address Line 2: __________________________
City: ______________________________ Zip/Postal Code: __________________________
County/State:_______________________ Country: ________________________________
MACHINE DETAILS
MODEL: ___________________ SERIAL NO.
Delivery / installation date: _ _ / _ _ _ / _ _ _ _
CUSTOMER DETAILS (please state address where truck is located)
Customer Business Name: ________________________ Tel: _________________________
First Name: ________________________ Last Name: ______________________________
E-mail: ____________________________ Position/Role: ____________________________
Street: ____________________________ Address Line 2: __________________________
City: ______________________________ Zip/Postal Code: __________________________
County/State:_______________________ Country: ________________________________
I have received my Aisle-Master forklift and read the Operators Manual and am satisfied with both.
*Customer’s Signature: ________________________________ Date: _____________________
WHEN COMPLETED PLEASE RETURN TO:
BY POST TO: Combilift, Gallinagh, Monaghan, County Monaghan, Ireland.
BY EMAIL TO: warranty@combilift.com
Failure to complete Warranty Registration Form may impact the Warranty Claim Process.

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Dear Customer,

In order to familiarise yourself with your truck in a quick comprehensive

Before You Begin ........................................................................................2-1

Operating Your Aisle-Master Forklift ........................................................3-1

Aisle-Master Operator’s & Service Manual ii

Schematic Circuit Diagrams ......................................................................5-1

Appendix B (FAQs) .....................................................................................B-1

Appendix C (Diagnostics) ..........................................................................C-1

Appendix D (Warranty Registration) .........................................................D-1

Aisle-Master Operator’s & Service Manual iii

Preface Intended Use

About This Manual

Some trucks may be customised to suit the needs

Every effort has been made to ensure that the

Aisle-Master Operator’s & Service Manual iv

• Safety Alert Symbol

Aisle-Master Operator’s & Service Manual S-1

The Meaning of Safety Aisle-Master Forklift

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ACCELERATOR TIE DOWN

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Safe Operation Battery Charging

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Safe and efficient forklift operation requires operators to be skilled

Safe and efficient operation also depends on correct maintenance

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Aisle-Master forklifts are available in capacities 1

The accelerator pedal (item 1) [1], is located on

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Forks (item 1) [2] Wheels (item 8) [2]

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The lever plate (item 3) [3] illustrates how the

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The serial number consists of 5 numerical digits

Aisle-Master Serial Number e.g.

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The drive speed is controlled by means on an accelerator pedal.

"Power On" Indication

Battery State of Charge

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Parking Brake Lever

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Operator Training – Discusses the operator training required

Operator Safety – Reviews the safety guidelines operators

Understanding Stability – In this section you will learn about

Knowing the Rated Capacity – The meaning of rated capacity

Understanding Workplace Conditions – This section makes

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Warning Understanding Stability

Whether you are a new operator or have used

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The centre of gravity will shift if:

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Knowing the Rated Before you begin to operate your Aisle-Master

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Serial Plate Capacity Plate

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Load Centre Always make sure the load is flush against

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When you unload at high elevations, make sure

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