Parts N° 524182160

Technical information for

YALE Assistance Service

This manual is addressed only to YALE Assistance

Service specialized technicians

B 457.......... MO10E
 Section: SAFETY RULES SERVICE

GENERAL SAFETY RULES

NEVER CARRY OUT ANY CLEANING, LUBRICATION OR MAINTENANCE INTERVENTION WITH

THE BATTERY CONNECTED.
ELECTRIC

DO NOT WEAR RINGS, WRIST WATCHES, JEWELLERY, LOOSE OR DANGLING CLOTHES

SUCH AS SCARVES, UNBUTTONED JACKETS OR OVERALLS WITH OPEN ZIP FASTENERS
THAT CAN ENTANGLE IN THE MOVING PARTS. ON THE CONTRARY, IT IS ADVISABLE TO
MAKE USE OF APPROVED SAFETY CLOTHES, SUCH AS FOR INSTANCE HELMETS, ANTISLIP
SHOES, GLOVES, SAFETY GLASSES.

NEVER USE PETROL, DIESEL FUEL OR OTHER INFLAMMABLE MATERIALS SUCH AS

CLEANING AGENTS: USE INSTEAD NON-INFLAMMABLE, NON-TOXIC COMMERCIAL
SOLVENTS.

DO NOT SMOKE, DO NOT USE FLAMES, DO NOT CAUSE SPARKS, WHEN EASILY
INFLAMMABLE MATERIALS ARE HANDLED.

„ In case of interventions outside the workshop, position the truck on a flat surface if possible and block
it. If work on a slope is unavoidable, block the truck first and then move it to a level area as soon as
possible with a certain degree of safety.
„ Disconnect the batteries and label all the controls to signal that an intervention is taking place. Block
the truck as well as every attachment that has to be lifted.
„ Use only the prescribed attachment points when towing and make sure the prearranged pins and/or
bolts are locked tightly before pulling. Lift and handle all heavy parts by means of a lifting device with
the suitable capacity. Use the lifting eyebolts arranged for the purpose. Pay attention to the people
near the load that has to be lifted.
„ Avoid twisting chains or wire ropes.
„ Beware of the chains, of bent or damaged ropes: do not use them while lifting or pulling. To handle
them, always make use of safety gloves.
„ Handle all parts carefully. Never put your hands or fingers in between parts.
„ Wear the special-purpose safety clothes such as safety glasses, gloves and shoes.
„ The area where maintenance operations are carried out must be always kept clean and dry. Clean up
any water or oil stains immediately.
„ Do not pile grease or oil-covered clothes. They represent a severe fire risk. Always put them in a
closed metal container.
„ Never carry out any service operation on the machine with anyone sitting in the seat, unless the
operator is fully trained and involved in the operation to be carried out.
„ When using compressed air to clean pads, always wear safety glasses with side shields.

Welding
„ When welding operations are required, use the safety clothing provided: dark glasses, helmets,
overalls, gloves and shoes. The dark glasses should also be worn by anyone in the nearby area
during a welding operation even if he is not performing the work.
Never look at the welding arc without properly protecting your eyes.

Battery
„ lf you have to use batteries, remember the cables shouId be connected to the terminals as specified:(+)
with (+) and (-) with (-).
„ Avoid short circuiting the terminals.
The gas released from the batteries is highiy inflammable. During recharging, leave the battery
compartment uncovered to ensure more effective ventilation and remove the caps.

Page: 2 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: SAFETY RULES

AVOID SPARKS OR FLAMES IN THE BATTERY AREA!

„ Never check the state of charge of the batteries using “bridges” obtained by placing metal objects on
the terminals.
„ Before any service operation, check that no parts are shorted.

ELECTRIC
„ Always disconnect the batteries before carrying out any intervention on the electric system.
For the battery chargers and similar equipment use only auxiliary power supply sources having an
efficient earth connection to avoid possible electric shocks.

Hydraulic System
„ A fluid seeping through a very small hole may be almost invisible and be sufficiently strong to penetra-
te beneath the skin. lf this happens use a piece of card or wood. Never use your hands.
Use the special-purpose equipment to check system pressures.

NOTE: THIS MANUAL DOES NOT REPLACE THE USE AND MAINTENANCE MANUAL, BUT IT IS
ITS INTEGRATION.

NOTES:

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 3

 Section: INDEX SERVICE

Section: ELECTRIC CONTROL “COMBI”

FOR INFORMATION ABOUT CONTROL “COMBI” SEE SERVICE MANUAL, Part N° 272486700

Section: ELECTRIC CONTROL “EPS-AC”

ELECTRIC

FOR INFORMATION ABOUT CONTROL “EPS-AC” SEE SERVICE MANUAL, Part N° 524162540

Section: ELECTRIC SYSTEM

- GENERAL SAFETY RULES .................................................................................................................. 2
1.00 TRUCK DESCRIPTION .......................................................................................................................... 8
2.00 WIRING DIAGRAMS - MOD. M010E FP ................................................................................................ 12
2.01 WIRING DIAGRAMS - MOD. M010E FF/WP ......................................................................................... 14
2.02 WIRING DIAGRAMS - MOD. M010E SL ................................................................................................ 16
2.03 DESCRIPTION OF SENSOR AND PUSH BUTTON FUNCTIONS .......................................................... 17
3.00 ELECTRIC COMPONENTS - MOD. M010E FP ..................................................................................... 18
3.01 ELECTRIC COMPONENTS - MOD. M010E FF/WP .............................................................................. 20
3.02 ELECTRIC COMPONENTS - MOD. M010E SL ...................................................................................... 22
3.03 ELECTRIC COMPONENTS - MOD. M010E SL H3200 .......................................................................... 24
4.00 TABLE OF THE FUNCTION INPUTS ..................................................................................................... 26
5.00 TABLES OF MODULE 2 CONTROL “COMBI” PARAMETERS .............................................................. 28
5.01 TABLES OF MODULE 1 CONTROL “SICOS” PARAMETERS ............................................................... 31
5.02 TABLES OF MODULE 6 CONTROL “EPS-AC” PARAMETERS ............................................................ 34
6.00 MODULE CALIBRATION ACCESS PROCEDURE ................................................................................. 36
6.01 MODULE SEARCH PROCEDURE ........................................................................................................ 37
6.02 BATTERY VOLTAGE SETTING ON CONTROL COMBI ......................................................................... 38
6.03 TRACTION START SEQUENCE ............................................................................................................ 39
6.04 SPEED REDUCTIONS .......................................................................................................................... 40
7.00 MODULE REPLACEMENT PROCEDURE ............................................................................................. 41
7.01 MODULE 2 CONTROL COMBI REPLACEMENT .................................................................................. 41
7.02 MODULE 6 CONTROL EPS-AC REPLACEMENT................................................................................. 42
7.03 MODULE 1 CONTROL SICOS REPLACEMENT ................................................................................... 44
7.05 MAIN CONTACTOR REPLACEMENT .................................................................................................... 45
7.06 COOLING FAN REPLACEMENT ........................................................................................................... 45
7.07 STEER STEPPER MOTOR REPLACEMENT ........................................................................................ 46
7.08 LIFTING AND BRAKING JOYSTICK REPLACEMENT ........................................................................... 47
7.09 GEAR CONTROL POTENTIOMETER CARD REPLACEMENT .............................................................. 49
7.10 INSTRUMENT PANEL PUSH BUTTON REPLACEMENT ...................................................................... 49
7.11 EMERGENCY PUSH BUTTON AND KEY-OPERATED SWITCH REPLACEMENT................................ 50
7.14 OPERATOR PRESENCE SENSOR AND WARNING HORN REPLACEMENT ...................................... 51
7.15 LIFTING CHAIN SENSOR REPLACEMENT .......................................................................................... 52
7.16 WHEEL CENTERING SENSOR REPLACEMENT ................................................................................. 53
7.17 CABIN SIDE GUARD SENSOR REPLACEMENT .................................................................................. 54
8.00 ENCODER, HEIGHT PRESELECTOR ................................................................................................... 55
8.01 ENCODER REPLACEMENT.................................................................................................................. 56
8.02 ENCODER RESETTING TO ZERO SENSOR REPLACEMENT ............................................................. 58
8.03 REPLACEMENT OF MOTOR COMPARTMENT-CABIN INSTRUMENT PANEL CONNECTION CABLE . 59
9.00 SICOS DISPLAY ................................................................................................................................... 61
9.01 CONTROL COMPONENT GENERAL DESCRIPTION ............................................................................ 61.
10.00 HEIGHT PRESELECTOR ...................................................................................................................... 69
11.00 DIAGNOSTICS ...................................................................................................................................... 79
11.01 MODULE 2 CONTROL COMBI .............................................................................................................. 79
11.02 MODULE 1 CONTROL DISPLAY SICOS .............................................................................................. 86
11.03 MODULE 6 CONTROL EPS-AC ............................................................................................................ 90
Page: 4 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE
SERVICE Section: INDEX

Section: ADDITIONAL FUNCTIONS

- SHHET OPTION 1 = FAN KIT FOR THE CABIN ............................................................................................... 2
- SHEET OPTION 2 = KIT FOR READING DESK ............................................................................................... 5
- SHEET OPTION 3 = SAFETY TRACER KIT ..................................................................................................... 7

ELECTRIC
Section: HYDRAULIC SYSTEM

1.00 HYDRAULIC SYMBOL LEGEND ........................................................................................................... 2

1.01 CORRECT ASSEMBLY METHOD FOR FEMALE PIPE FITTINGS ........................................................ 3
2.00 FUNCTIONAL HYDRAULIC DIAGRAM - MOD. M010E FP-FF WP ........................................................ 4
2.02 FUNCTIONAL HYDRAULIC DIAGRAM - MOD. M010E SL ..................................................................... 6
3.00 HYDRAULIC POWER PACK COMPONENTS - MOD. M010E FP ......................................................... 18
3.02 HYDRAULIC POWER PACK COMPONENTS - MOD. M010E FF-FP .................................................... 20
3.04 HYDRAULIC POWER PACK COMPONENTS - MOD. M010E SL .......................................................... 22
4.00 HYDRAULIC SYSTEM COMPONENTS - MOD. M010E FP ................................................................... 24
4.01 HYDRAULIC SYSTEM COMPONENTS - MOD. M010E FF-WP ............................................................ 25
4.02 HYDRAULIC SYSTEM COMPONENTS - MOD. M010E SL ................................................................... 26
4.04 LIFTING CYLINDER COMPONENTS - MOD. ALL MODELS .................................................................. 28
4.05 LIFTING CYLINDER BRAKING OPERATION - MOD. ALL MODELS ...................................................... 29
5.00 VALVE ADJUSTMENT, REPLACEMENT - MOD. M010E FP-FF-WP ..................................................... 30
5.04 VALVE ADJUSTMENT, REPLACEMENT - MOD. M010E SL .................................................................. 32
6.00 FORK LIFTING CYLINDER REMOVAL - MOD. M010E FP .................................................................... 34
6.01 CABIN LIFTING CYLINDER REMOVAL - MOD. M010E FF-WP ............................................................ 36
6.02 FORK LIFTING CYLINDER REMOVAL - MOD. M010E SL ..................................................................... 38
6.03 CABIN LIFTING CYLINDER REMOVAL - MOD. M010E SL .................................................................... 40
7.00 CYLINDER GASKET REPLACEMENT - MOD. ALL MODELS ............................................................... 44
7.01 HYDRAULIC BRAKE VALVE REPLACEMENT - MOD. ALL MODELS .................................................. 45
8.00 FORK CYLINDER HYDRAULIC PIPE REMOVAL - MOD. M010E FP .................................................... 46
8.01 CABIN CYLINDER HYDRAULIC PIPE REMOVAL - MOD. M010E FF-WP ............................................ 47
8.02 FORK CYLINDER HYDRAULIC PIPE REMOVAL - MOD. M010E SL .................................................... 48
8.05 CABIN CYLINDER HYDRAULIC PIPE REMOVAL - MOD. M010E SL ................................................... 51

MECHANICAL Section
1.00 GUIDE TABLES FOR THE CHOICE OF LIFTING STRAPS AND ROPES .............................................. 2
1.01 SCREW DRIVING TORQUE TABLE ...................................................................................................... 3
2.00 TRACTION WHEEL REMOVAL - MOD. ALL MODELS .......................................................................... 4
2.01 LOAD WHEEL REMOVAL - MOD. M010E FP ....................................................................................... 5
2.02 LOAD WHEEL REMOVAL - MOD. M010E FF-SL.WP .......................................................................... 6
2.02 TRACTION MOTOR REMOVAL - MOD. ALL MODELS .......................................................................... 7
2.03 TRACTION MOTOR COMPONENTS - MOD. ALL MODELS .................................................................. 9
2.04 TRACTION MOTOR BEARING REPLACEMENT - MOD. ALL MODELS ................................................ 10
2.05 TRACTION MOTOR BRUSH REPLACEMENT - MOD. ALL MODELS ................................................... 11
2.06 TRACTION AND STEERING MOTOR SCREW DRIVING TORQUE TABLE - MOD. ALL MODELS .......... 12
3.00 MOTOR PUMP UNIT REMOVAL - MOD. M010E FP ............................................................................. 13
3.01 PUMP CASING REPLACEMENT - MOD. M010E FP ............................................................................ 14
3.02 PUMP MOTOR REPLACEMENT - MOD. M010E FP ............................................................................. 15
3.03 PUMP MOTOR BRUSH REPLACEMENT - MOD. M010E FP ................................................................ 16
3.04 MOTOR PUMP UNIT SCREW DRIVING TORQUE - MOD. M010E FP .................................................. 17
3.05 MOTOR PUMP UNIT REMOVAL - MOD. M010E FF-WP ...................................................................... 18
3.06 PUMP CASING REPLACEMENT - MOD. M010E FF-WP ..................................................................... 19
3.07 PUMP MOTOR REMOVAL - MOD. M010E FF-WP ............................................................................... 20

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 5

 Section: INDEX SERVICE

3.08 MOTOR PUMP UNIT REMOVAL - MOD. M010E SL .............................................................................. 21

3.09 PUMP CASING REPLACEMENT - MOD. M010E SL ............................................................................. 22
3.10 PUMP MOTOR REMOVAL - MOD. M010E SL ...................................................................................... 23
3.11 PUMP MOTOR BRUSH REPLACEMENT - MOD. M010E FF-SL WP ................................................... 24
3.12 MOTOR PUMP UNIT SCREW DRIVING TORQUE - MOD. M010E FF-WP-SL ...................................... 25
ELECTRIC

4.00 LIFTING CHAINS - MOD. ALL MODELS ................................................................................................ 26

4.01 FORK LIFTING CHAIN REMOVAL - MOD. M010E FP ........................................................................... 28
4.02 PLATFORM LIFTING CHAIN REMOVAL - MOD. M010E FF h 1200mm ................................................. 29
4.03 FORK LIFTING CHAIN REMOVAL - MOD. M010E SL ........................................................................... 30
4.04 PLATFORM LIFTING CHAIN REMOVAL - MOD. M010E SL-WP h 1700mm .......................................... 31
4.05 PLATFORM LIFTING CHAIN REMOVAL - MOD. M010E SL h 3200mm ................................................. 32
4.06 CABIN REMOVAL - MOD. M010E SL h 3200mm .................................................................................. 33
4.07 MAST REMOVAL - MOD. M010E SL h 3200mm ................................................................................... 35
5.00 PLATFORM SIDE GUARD COMPONENTS - MOD. M010E SL-WP ...................................................... 36
5.02 REMOVAL OF THE GUARD KIT FROM THE TRUCK - MOD. M010E SL-WP ....................................... 38
5.03 SIDE GUARD GAS RETURN SPRING REPLACEMENT - MOD. M010E SL-WP .................................. 39
5.04 UPPER GUARD REMOVAL - MOD. M010E SL-WP ............................................................................. 40
5.05 INTERMEDIATE GUARD REMOVAL - MOD. M010E SL-WP ................................................................ 41
5.06 LOWER GUARD REMOVAL - MOD. M010E SL-WP ............................................................................. 42
5.07 GUARD CONTROL BAR REMOVAL - MOD. M010E SL-WP ................................................................. 43
6.00 MOVABLE FORK UNIT COMPONENTS - MOD. M010E FP-SL ............................................................ 44
6.01 FIXED FORK UNIT COMPONENTS - MOD. M010E FP-SL ................................................................... 45
6.02 MAST BEARING AND SHIM REPLACEMENT - MOD. M010E FP ........................................................ 46
6.04 MOVABLE OR FIXED FORK PLATE BEARING REPLACEMENT - MOD. M010E SL ............................... 44
7.00 STEERING WHEEL PIN BEARING REPLACEMENT ............................................................................ 50

Section: REDUCTION UNIT

1.00 REDUCTION UNIT COMPONENTS ....................................................................................................... 2

1.01 REDUCTION UNIT COMPONENT TABLE .............................................................................................. 3
2.00 REDUCTION UNIT DISASSEMBLY ....................................................................................................... 4
2.01 TRACTION MOTOR SHAFT OIL SEAL REPLACEMENT ....................................................................... 7

Section: BRAKING SYSTEM

1.00 ELECTROMAGNETIC BRAKE COMPONENTS ..................................................................................... 2

2.00 BRAKING SYSTEM ............................................................................................................................... 3
3.00 ELECTRIC BRAKE COIL AND BRAKE LINING REPLACEMENT .......................................................... 4
3.04 ADJUSTMENT AND STARTING ............................................................................................................. 5

USED INSTRUMENT CODES

P/N 2792832 CONSOLE (Electric section) ......................................................................................................... 34
P/N 1527988 ADAPTER (Electric section) .......................................................................................................... 34

Page: 6 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section:
Section: TRUCK
TRUCK DESCRIPTION
DESCRIPTION

ELECTRIC
TRUCK
DESCRIPTION

D TRUCK DESCRIPTION .........................................................................8

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 7

 Section:
Section: TRUCK
TRUCK DESCRIPTION
DESCRIPTION SERVICE

1.00 TRUCK DESCRIPTION

MOD. MO10E

The new trucks model MO10E are different from the previous version for the new truck DESIGN and for
ELECTRIC

the new drive solutions. This makes the operator manoeuvres easier.
This new model allows using several combinations in order to satisfy the ultimate consumer’s various
requests.

All models are equipped with high technology electric/hydraulic systems.

The operator has a complete instrument panel available, from which he controls all the machine operations.

“DISPLAY (Mod. 1 Sicos)” is placed on the instrument panel and shows the operator the truck active
functions, such as platform lifting/lowering, battery charge/discharge, the alarms indicating on which
module the alarm has been activated, height visualization, etc. Moreover some personalizations can be
made or some functions can be enabled by following the access procedure.

“DISPLAY”
Sicos { It communicates with traction and lifting control “COMBI” by “Serial” way.
It communicates with steering motor control “EPS-AC” by “CAN-BUS” way.

The traction and lifting motors are supplied with DIRECT CURRENT, operated by 300+300A control
COMBI (Mod 2).

The steering motor is supplied with ALTERNATE CURRENT, operated by control EPS AC (Mod. 6).

The hydraulic system, according to the type of truck, is operated by proportional and ON/OFF solenoid valves.
The trucks are equipped with name plates, indicating the serial number and the residual capacities.

NOTES

Page: 8 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

1.01 DESCRIPTION OF THE VARIOUS MODELS

1.02 MOD. MO10E FP

ELECTRIC
Truck composed of a fixed platform and movable
forks, which can be lifted to a height variable
between 800mm and 1500mm according to the
requirements.
The truck has a very low platform, which is fit to
the Picking from the ground, and which makes the
operator’s rise and descent easier. Moreover the
truck is equipped with controls allowing the operator
to perform small forward traction movements
(BACKING) and to lift the forks to the desired height
by remaining on the ground.
The platform footboard has been designed so that,
whenever a point is pressed, the sensor
“OPERATOR PRESENCE” is activated.
Moreover the truck is equipped with name plates
located on the operator’s seat back and indicating
the serial number and the residual capacities.

1.03 MOD. MO10E FF

The truck is composed of a rising platform, with
forks fixed to the platform structure and which can
be lifted to a height h2 between 1000mm and
1200mm without protective side guards. It is
equipped with an Encoder, an instrument
measuring the height to which the platform can be
lifted.
The platform footboard has been designed so that,
whenever a point is pressed, the sensor
“OPERATOR PRESENCE” is activated.
Moreover, the truck is equipped with name plates
located on the instrument panel and indicating the
serial number and the residual capacities.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 9

 Section:
Section: TRUCK
TRUCK DESCRIPTION
DESCRIPTION SERVICE

1.04 MOD. MO10E SL

ELECTRIC

The truck is composed of a platform with central

cylinder which can be lifted up to height h2 of
1700mm and with two side cylinders that may be
lifted up to height h2 from 1700mm to 3200m.
The forks can be lifted independently from the
cabin by means of their proper cylinder and they
can be fixed or movable. The cabin is equipped
with side guards. It is equipped with an Encoder,
an instrument measuring how much the platform
can be lifted. It can be equipped with a deceleration
and stop device in order to operate in a wire-guided
aisle.
The platform footboard has been designed so that,
whenever a point is pressed, the sensor
“OPERATOR PRESENCE” is activated.
Moreover, the truck is equipped with name plates
located on the instrument panel and indicating the
serial number and the residual capacities.

1.05 MOD. MO10E WP

The truck is composed of a rising platform with
forks fixed to the platform structure, which can be
lifted over 1200mm. The truck is also equipped
with practicable pallets, with a protective guard
all around the pallet perimeter and with cabin side
guards. The truck also has an Encoder, an
instrument measuring how much the platform can
be lifted. It can be equipped with a deceleration
and stop device in order to operate in a wire-guided
aisle.
The platform footboard has been designed so that,
whenever a point is pressed, the sensor
“OPERATOR PRESENCE” is activated.
Moreover, the truck is equipped with name plates
located on the instrument panel and indicating the
serial number and the residual capacities.

Page: 10 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ELECTRIC
ELECTRIC
SYSTEM
WIRING DIAGRAMS
D WIRING DIAGRAMS - MOD. M010E FP ...............................................12
D WIRING DIAGRAMS - MOD. M010E FF/WP ........................................14
D WIRING DIAGRAMS - MOD. M010E SL ...............................................16
D ELECTRIC COMPONENTS - MOD. M010E FP .....................................18
D ELECTRIC COMPONENTS - MOD. M010E FF/WP ..............................20
D ELECTRIC COMPONENTS - MOD. M010E SL .....................................22
D TABLE OF THE FUNCTION INPUTS .....................................................26
D TABLES OF MODULE 2 COMBI PARAMETERS ..................................28
D TABLES OF MODULE 1 SICOS PARAMETERS ..................................31
D TABLES OF MODULE 6 EPS-AC PARAMETERS ................................34
D MODULE CALIBRATION ACCESS PROCEDURE ................................36
D BATTERY VOLTAGE SETTING .............................................................38
D TRACTION START SEQUENCE ............................................................39
D SPEED REDUCTION ............................................................................40
D MODULE REPLACEMENT PROCEDURE ............................................41
D REPLACEMENT OF VARIOUS ELECTRIC COMPONENTS .................45/60
D SICOS DISPLAY ...................................................................................61
D HEIGHT PRESELECTOR .....................................................................69
D DIAGNOSTICS ......................................................................................79

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 11

 Section: TRUCK DESCRIPTION SERVICE

2.00 LEGEND OF THE WIRING DIAGRAMS

MOD. MO10E FP
ELECTRIC

W IRING DIAGRAM "M O10E FP" SYMBOL DESCRIPTION

Re f. Pa ge Re f. Sym bol
Sym bol de scription
Dia gra m Dia gra m
1/5 MTR Separately excited traction motor 2,5 Kw
1/5 PM Pump motor 2,0 Kw
1/5 MS AC steering m otor - 0,65 Kw
1/5 FU1 Power fuse 425 A of control COMBI
1/5 FU2 Auxiliary fuse 10 A to protect control Combi
1/5 FU3 Auxiliary fuse 10 A placed before the key
1/5 FU4 Auxiliary fuse 10 A to protect the auxiliary lines
1/5 FU3 Power fuse 32 A of control EPS-AC
1/5 SW 1 Ke y Key-operated m ain switch
1/5 SW 2 Em e rge ncy M ain emergency push button
1/5 K1 Ma in Conta ct Power supply m ain contactor EPS-AC
1/5 K2 Ma in Conta ct Power supply m ain contactor Control COMBI
2/5 M1 M otor compartment cooling fan
2/5 EV1 Fork lowering proportional solenoid valve
2/5 EMB Electromagnetic brake unit
2/5 Buzze r Buzzer signalling the truck is moving
2/5 Sa fety Re la y Relay connecting EPS-AC to COMBI
2/5 ENC. M S Steering motor encoder
2/5 SW 3 Steering wheel (traction) centering inductive sensor
2/5 Ste ppe r Motor Steering motor control stepper m otor
2/5 TMS Steering motor thermal switch
3/5 U1 Forward/backward traction control electronic card
3/5 SW 4 Operator presence sensor
3/5 SW 6 Fork lifting control push button with operator on the ground
3/5 SW 7 Fork lowering push button
3/5 SW 11 Push button to select the traction m ode
3/5 SW 12 W arning horn push button
3/5 SW 28/29 Push button to temporarily enable the forward running with operator on the ground
Sensor to block the forks at a height of 150mm with lowering push button activated
3/5 SW 30
by the operator on the ground
3/5 SW 31 Push button to control the fork lowering with operator on the ground
3/5 SW 32 Push button to control the warming resistances
3/5 SW 33 Photoelectric cell to slow down the lifting cylinder at the lim it stop
3/5 J1 Joystick to control the fork lifting/lowering
3/5 J2 Em ergency stop joystick

Page: 12 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ELECTRIC SYSTEM

FUNCTIONAL WIRING DIAGRAM

FU2 = Fuse 10A control FU3 = Fuse 10A before the key- FU4 = Fuse 10A, B+ 24V FU5 = Fuse 10A, B+ 24V
COMBI input instrument panel heating resistance feed POWER AND AUXILIARIES
operated switch sensor feed
MOD. MO10E FP

Page 1/5

DESCRIPTION OF THE GENERAL MAIN CONTACTORS

K1 AND K2

MAIN CONTACTOR CLOSING

25mm Enable the emergency push button (SW2 Emergency), set
POSITIVE
POSITIVI AL TO THE
GRUPPO
RESISTANCE ASSEMBLY IN the key-operated switch (SW1 Key) on 1 (ON); the two main
RESISTENZE

25mm
THE INSTRUMENT PANEL contactors k1 and k2 close at the same time.
25mm 25mm NEL CRUSCOTTO
K1 = The coil is feeded with negative B- direct through the
battery, with positive B+ 24V through the ignition key.
There are two power cables going out the main
contactor: one is used for the control EPS input, the
other one is connected to the power contact of the main
contactor K2

K2 = The coil is feeded direct through control COMBI, the

negative B- comes from the output 2/B and the positi-
ve B+24V comes from the output 13/B. There is only
one power cable and it is used for the control COMBI
input

MAIN CONTACTOR TRIPPING

a) By pressing the emergency push button (SW2) or

setting the key-operated switch (SW1) on 0 (OFF) the
25mm two main contactors open at the same time

b) If control COMBI fails for any reason, the main contactor

K2 opens and the main contactor K1, which allows the
operator to use the steering keeping the machine in
25mm

running position, remains close.

NEGATIVI AL TO
NEGATIVE GRUPPO
THE
RESISTANCE ASSEMBLY IN
RESISTENZE
THE
NELINSTRUMENT
CRUSCOTTO PANEL

*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 12a
SERVICE Section: ELECTRIC SYSTEM

FUNCTIONAL WIRING DIAGRAM

CONTROL COMBI - EPS-AC
MOD. MO10E FP

Page 2/5

*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 12b

SERVICE Section: ELECTRIC SYSTEM

FUNCTIONAL WIRING DIAGRAM

CONNECTOR FOR VISUAL
DISPLAY TERMINAL
CONTROL SICOS (DISPLAY)
CONNECTION MOD. MO10E FP

Page 3/5

J2 = EMERGENCY BRAKE
HOW IT WORKS:
BY PULLING OR PUSHING THE JOYSTICK DURING THE
RUNNING, THE RELEASE BRAKING AND THE CLOSING
OF THE ELECTROMAGNETIC BRAKE ARE ENABLED AND
*ONLY FOR COLD STORE VERSION THE MACHINE STOPS IMMEDIATELY.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 12c

SERVICE Section: ELECTRIC SYSTEM

MOTOR COMPARTMENT SHEATH DIAGRAM

MOD. MO10E FP

Page 4/5

FOR COLD STORE VERSION:

- DISCONNECT THE PIN 1/11
- CONNECT THE PIN 1/11A
CONNECTOR OF VENTIL
*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 12d

SERVICE Section: ELECTRIC SYSTEM

INSTRUMENT PANEL SHEATH DIAGRAM

MOD. MO10E FP

Page 5/5

*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 12e
SERVICE Section: TRUCK DESCRIPTION

NOTES:

ELECTRIC

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 13

 Section: TRUCK DESCRIPTION SERVICE

2.01 LEGEND OF WIRING DIAGRAMS

MOD. MO10E FF - MO10E WP
W IRING DIAGRAM "MO10E FF" = "MO10E W P " SYMBOL DES CRIP TION
Re f. Pa ge Re f. S ym bol
S ym bol De scription
ELECTRIC

Dia gra m Dia gra m

1/5 MTR Separately excited traction m otor 2,5 K w
1/5 PM Pum p motor 3,0 Kw
1/5 MS AC steering m otor - 0,65 Kw
1/5 FU1 Power fuse 425 A of control COMB I
1/5 FU2 Auxiliary fuse 10 A to protect control Combi
1/5 FU3 Auxiliary fuse 10 A placed before the key
1/5 FU4 Auxiliary fuse 10 A to protect the auxiliary lines
1/5 FU3 Power fuse 32 A of control EP S-A C
1/5 SW 1 Ke y Key-operated main switch
1/5 S W 2 Em e rge ncy Main emergency push button
1/5 K1 Ma in Conta ct Main contactor
1/5 K2 Ma in Conta ct Main contactor
2/5 M1 Motor com partement cooling fan
2/5 EV1 Cabin/Fork lowering proportional solenoid valve
2/5 EMB Electromagnetic brake unit
2/5 SW 22 Photoelectric cell to stop at the end of the aisle
2/5 SW 23 Photoelectric cell for slowing down at the end of the aisle
2/5 S W 15/16 Sensors indicating the lifting chain loosening
2/5 SW 24 Right aisle presence photoelectric cell
2/5 S w 25 Left aisle presence photoelectric cell
2/5 Buzze r Buzzer signalling the truck is moving
2/5 S a fe ty Re la y Relay connecting EP S-AC to COMBI
2/5 ECN. MS Steering motor encoder
2/5 SW 3 Steering wheel (traction) centering inductive sensor
2/5 S te ppe r Motor Steering motor control stepper motor
2/5 T.MS Steering motor thermal switch
3/5 U1 Forward/backward traction control electronic card
3/5 SW 4 Operator presence sensor
3/5 SW 5 Cabin lifting by pass push button
3/5 SW 26 Push button to enable the fork and/or cabin lifting and lowering
3/5 SW 6 Fork lifting control pus h button with operator on the ground
3/5 SW 7 Push button to control the fork lowering in the last 150mm
3/5 SW 31 Fork lowering control push button with operator on the ground
3/5 S W 28/29 Push button to tem porarily enable the traction with operator on the ground
3/5 S W 8/9 Sensors to enable the closing of the side guards
3/5 SW 30 Sensor to block the fork lowering at a height of 150mm
3/5 S W 13/14 Cabin overhead guard tracer sensor
Push button to drive with a single hand during the cabin lifting/lowering out of
SW 10
3/5 the aisle
3/5 SW 11 Push button to select the traction mode
3/5 SW 12 W arning horn push button
3/5 SW 17 Push button for selector AUT/MA N with wire guide
3/5 SW 18 Sensor to reset the fork height encoder
3/5 SW 19 Sensor to reset the cabin height encoder
3/5 SW 20 Push button to switch on the working lights
3/5 SW 21 Cabin lifting/lowering encoder control sensor
3/5 ENC. CAB. Cabin lifting/lowering encoder
3/5 ENC. FORKS Fork lifting/lowering encoder
3/5 S W 32 Push button to control the warming resistances
3/5 J1 Joystick to control the cabin lifting/lowering
3/5 J2 Em ergency stop joystick

Page: 14 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ELECTRIC SYSTEM

FUNCTIONAL WIRING DIAGRAM

FU2 = Fuse 10A control FU3 = Fuse 10A before the key- FU4 = Fuse 10A, B+ 24V FU5 = Fuse 10A, B+ 24V POWER AND AUXILIARIES
COMBI input operated switch sensor feed instrument panel heating resistance feed MOD. MO10E FF - MO10E WP

Page 1/5

DESCRIPTION OF THE GENERAL MAIN CONTACTORS

K1 AND K2

MAIN CONTACTOR CLOSING

Enable the emergency push button (SW2 Emergency), set

25mm the key-operated switch (SW1 Key) on 1 (ON); the two main
POSITIVE
POSITIVI AL TO THE
GRUPPO
RESISTANCE ASSEMBLY IN
contactors k1 and k2 close at the same time.
RESISTENZE

25mm
25mm THE INSTRUMENT
NEL CRUSCOTTO PANEL
25mm K1 = The coil is feeded with negative B- direct through the
battery, with positive B+ 24V through the ignition key.
There are two power cables going out the main
contactor: one is used for the control EPS input, the
other one is connected to the power contact of the main
contactor K2

K2 = The coil is feeded direct through control COMBI, the

negative B- comes from the output 2/B and the positi-
ve B+24V comes from the output 13/B. There is only
one power cable and it is used for the control COMBI
input

MAIN CONTACTOR TRIPPING

a) By pressing the emergency push button (SW2) or

setting the key-operated switch (SW1) on 0 (OFF) the
two main contactors open at the same time
25mm
b) If control COMBI fails for any reason, the main contactor
K2 opens and the main contactor K1, which allows the
operator to use the steering keeping the machine in
running position, remains close.
25mm

NEGATIVI AL TO
NEGATIVE GRUPPO
THE
RESISTANCE ASSEMBLY IN
RESISTENZE
THE
NELINSTRUMENT
CRUSCOTTO PANEL
*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 14a

SERVICE Section: ELECTRIC SYSTEM

FUNCTIONAL WIRING DIAGRAM

CONTROL COMBI - EPS-AC
MOD. MO10E FF - MO10E WP

Page 2/5

Instrument panel resistances

*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 14b

SERVICE Section: ELECTRIC SYSTEM
CONNECTOR FOR VISUAL
DISPLAY TERMINAL
FUNCTIONAL WIRING DIAGRAM
CONNECTION CONTROL SICOS (DISPLAY)
MOD. MO10E FF - MO10E WP

Page 3/5

J2 = EMERGENCY BRAKE
HOW IT WORKS:
BY PULLING OR PUSHING THE JOYSTICK DURING THE
RUNNING, THE RELEASE BRAKING AND THE CLOSING
OF THE ELECTROMAGNETIC BRAKE ARE ENABLED AND
*ONLY FOR COLD STORE VERSION THE MACHINE STOPS IMMEDIATELY.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 14c

SERVICE Section: ELECTRIC SYSTEM

MOTOR COMPARTMENT SHEATH DIAGRAM

MOD. MO10E FF - MO10E WP

Page 4/5

FOR COLD STORE VERSION:

- DISCONNECT THE PIN 1/11
- CONNECT THE PIN 1/11A
*ONLY FOR COLD STORE VERSION CONNECTOR OF VENTIL

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 14d

SERVICE Section: ELECTRIC SYSTEM

INSTRUMENT PANEL SHEATH DIAGRAM

MOD. MO10E FF - MO10E WP

Page 5/5

*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 14e
SERVICE Section: TRUCK DESCRIPTION

NOTES:

ELECTRIC

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 15

 Section: TRUCK DESCRIPTION SERVICE
2.02 LEGEND OF WIRING DIAGRAMS
MOD. MO10E SL
W IRING DIAG RAM "M O 10E S L" S YM BOL DES CRIP T IO N
Re f. P a g e Re f. S ym bol
S ym bo l De scrip tion
Dia g ra m Dia gra m
ELECTRIC

1/5 M TR S eparately ex c ited trac tion m otor 2,5 K w

1/5 PM P um p m otor 3,0 K w
1/5 MS A C s teering m otor - 0,65 K w
1/5 FU1 P ower fus e 425 A of c ontrol CO M B I
1/5 FU2 A ux iliary fus e 10 A to protec t c ontrol Com bi
1/5 FU3 A ux iliary fus e 10 A plac ed before the k ey
1/5 FU4 A ux iliary fus e 10 A to protec t the aux iliary lines
1/5 FU3 P ower fus e 32 A of c ontrol E P S -A C
1/5 S W 1 Ke y K ey -operated m ain s witc h
1/5 S W 2 Em e rge ncy M ain em ergenc y pus h button
1/5 K1 M a in Con ta ct M ain c ontac tor
1/5 K2 M a in Con ta ct M ain c ontac tor
2/5 M1 M otor c om partem ent c ooling fan
2/5 EV 1 Cabin/Fork lowering proportional s olenoid valve
2/5 EV 2 Cabin lowering s olenoid valve
2/5 EV 3 F ork lifting/lowering s olenoid valve
2/5 EV 4 Cabin lifting s olenoid valve
2/5 EM B E lec trom agnetic brak e unit
2/5 S W 22 P hotoelec tric c ell to s top at the end of the ais le
2/5 S W 23 P hotoelec tric c ell for s lowing down at the end of the ais le
2/5 S W 15/16 S ens ors indic ating the lifting c hain loos ening
2/5 S W 24 Right ais le pres enc e photoelec tric c ell
2/5 S W 25 Left ais le pres enc e photoelec tric c ell
2/5 Buz e r B uz z er s ignalling the truc k is m oving
2/5 S a fe ty Re la y Relay c onnec ting E P S -A C to CO M B I
2/5 ECN. M S S teering m otor enc oder
2/5 SW 3 S teering wheel (trac tion) c entering induc tive s ens or
2/5 S te ppe r M o tor S teering m otor c ontrol s tepper m otor
2/5 T.M S S teering m otor therm al s witc h
3/5 U1 F orward/bac k ward trac tion c ontrol elec tronic c ard
3/5 SW 4 O perator pres enc e s ens or
3/5 SW 5 Cabin lifting by pas s pus h button
3/5 S W 26 P us h button to enable the fork and/or c abin lifting and lowering
3/5 SW 6 F ork lifting c ontrol pus h button with operator on the ground
3/5 SW 7 P us h button to c ontrol the fork lowering in the las t 150m m
3/5 S W 31 F ork lowering c ontrol pus h button with operator on the ground
3/5 S W 28/29 P us h button to tem porarily enable the trac tion with operator on the ground
3/5 S W 8/9 S ens ors to enable the c los ing of the s ide guards
3/5 S W 30 S ens or to bloc k the fork lowering at 150m m
3/5 S W 13/14 Cabin overhead guard trac er s ens or
P us h button to drive with a s ingle hand during the c abin lifting/lowering out of
S W 10
3/5 the ais le
3/5 S W 11 P us h button to s elec t the trac tion m ode
3/5 S W 12 W arning horn pus h button
3/5 S W 17 P us h button for s elec tor A UT/M A N with wire guide
3/5 S W 18 S ens or to res et the fork height enc oder
3/5 S W 19 S ens or to res et the c abin height enc oder
3/5 S W 20 P us h button to s witc h on the work ing lights
3/5 S W 21 Cabin lifting/lowering enc oder c ontrol s ens or
3/5 ENC. CAB. Cabin lifting/lowering enc oder
3/5 ENC. FO RKS F ork lifting/lowering enc oder
3/5 S W 32 P us h button to c ontrol the warm ing res is tanc es
3/5 J1 Joy s tic k to c ontrol the c abin lifting/lowering
3/5 J2 E m ergenc y s top joy s tic k

Page: 16 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ELECTRIC SYSTEM

FUNCTIONAL WIRING DIAGRAM

FU2 = Fuse 10A control FU3 = Fuse 10A before the key- FU4 = Fuse 10A, B+ 24V FU5 = Fuse 10A, B+ 24V POWER AND AUXILIARIES
COMBI input operated switch sensor feed instrument panel heating resistance feed MOD. MO10E SL

Page 1/5

DESCRIPTION OF THE GENERAL MAIN CONTACTORS

K1 AND K2

MAIN CONTACTOR CLOSING

25mm Enable the emergency push button (SW2 Emergency), set

POSITIVE
POSITIVI TO THE
AL GRUPPO the key-operated switch (SW1 Key) on 1 (ON); the two main
RESISTANCE ASSEMBLY
RESISTENZE IN

25mm
THE INSTRUMENT PANEL
contactors k1 and k2 close at the same time.
25mm 25mm NEL CRUSCOTTO
K1 = The coil is feeded with negative B- direct through the
battery, with positive B+ 24V through the ignition key.
There are two power cables going out the main
contactor: one is used for the control EPS input, the
other one is connected to the power contact of the main
contactor K2

K2 = The coil is feeded direct through control COMBI, the

negative B- comes from the output 2/B and the positi-
ve B+24V comes from the output 13/B. There is only
one power cable and it is used for the control COMBI
input

MAIN CONTACTOR TRIPPING

a) By pressing the emergency push button (SW2) or

setting the key-operated switch (SW1) on 0 (OFF) the
25mm two main contactors open at the same time

b) If control COMBI fails for any reason, the main contactor

K2 opens and the main contactor K1, which allows the
operator to use the steering keeping the machine in
25mm

running position, remains close.

NEGATIVI AL TO
NEGATIVE GRUPPO
THE
RESISTANCE ASSEMBLY IN
RESISTENZE
THE
NELINSTRUMENT
CRUSCOTTOPANEL

*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 16a

SERVICE Section: ELECTRIC SYSTEM

FUNCTIONAL WIRING DIAGRAM

CONTROL COMBI - EPS-AC
MOD. MO10E SL

Page 2/5

Instrument panel resistances

*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 16b
SERVICE Section: ELECTRIC SYSTEM

CONNECTOR FOR VISUAL FUNCTIONAL WIRING DIAGRAM

DISPLAY TERMINAL
CONTROL SICOS (DISPLAY)
CONNECTION
MOD. MO10E SL

Page 3/5

J2 = EMERGENCY BRAKE
HOW IT WORKS:
BY PULLING OR PUSHING THE JOYSTICK DURING THE
RUNNING, THE RELEASE BRAKING AND THE CLOSING
OF THE ELECTROMAGNETIC BRAKE ARE ENABLED AND
*ONLY FOR COLD STORE VERSION THE MACHINE STOPS IMMEDIATELY.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 16c

SERVICE Section: ELECTRIC SYSTEM

MOTOR COMPARTMENT SHEATH DIAGRAM

MOD. MO10E SL

Page 4/5

SW 3

FOR COLD STORE VERSION:

- DISCONNECT THE PIN 1/11
- CONNECT THE PIN 1/11A
SW 15 SW 16
CONNECTOR OF VENTIL

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 16d

SERVICE Section: ELECTRIC SYSTEM

INSTRUMENT PANEL SHEATH DIAGRAM

MOD. MO10E SL

Page 5/5

*ONLY FOR COLD STORE VERSION

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 16e
SERVICE Section: TRUCK DESCRIPTION

2.03 DESCRIPTION OF SENSOR AND PUSH BUTTON FUNCTIONS

DES CRIP T IO N O F S ENS O R AND P US H BUT T O N F UNCT IO NS
Dia g ra m
S ym b ol d e scrip tio n
S ym bo l Re f.
SW 1 M ain ignition key -operated switc h

ELECTRIC
SW 2 M ain em ergenc y pus h button
SW 3 W heel pos ition s ens or
SW 4 O perator pres enc e s ens or
Cabin lifting res et pus h button. It re-enables the c abin lifting:
SW 5 a) If a Display -program m ed lifting bloc k is ac tive (P rogram B loc k 1)
b) If the brok en c hain sensor s ignals loos e or broken c hain. It only allows lifting.
Fork lifting push button which c an be activated from the fork s ide and from the ins trum ent panel
SW 6 with operator on the ground
Fork lowering pus h button whic h c an be ac tivated from the fork s ide or from the ins trum ent panel
SW 7 with operator on the ground
S ide panel c los ing s ens or. The truc k is enabled to operate in all its func tions when the c abin is
S W 8/9 at a height of m ore than 1200m m . Under this level the truc k operates without c los ed s ide
panels .
P us h button to drive with a s ingle hand for the enabling of the c abin lifting/lowering outs ide and
inside the ais le:
a) This push button is used in the ais le in order to keep the operator's hands busy .
S W 10
b) This push button is des igned for the c abin lifting and lowering out of the aisle when trac tion is
inac tive. This function m ust be enabled by m eans of the c ons ole (S ic os , s et options "E nable
Cabin" )
S W 11 P us h button to s elec t the running m ode (S tandard, Hard, S oft, S low)
S W 12 W arning horn c ontrol pus h button
Cabin overhead guard trac er sens ors. S afety to be applied on the overhead guard when there are
S W 13/14 low levels in the ais les and the c abin lifting m us t be bloc k ed. It m us t be enabled by m eans of
the c ons ole (S icos , S et O ptions " A ux F unction 2")
S W 15/16 Chain loos ening or breaking sensors (P res s pus h button S W 5 in order to lift the c abin)
S W 17 A UT/M A N s election pus h button when the wire guide is present
S ens or to res et the c abin lifting enc oder. During the cabin lowering, the s ens or resets the c ount
S W 18
to z ero on the dis play .
S ens or to res et the fork lifting enc oder. During the fork lowering, the s ens or resets the c ount to
S W 19
zero on the dis play .
S W 20 W ork ing light s witc h
Redundancy s ensor for the c abin lifting encoder c ontrol. The sens or reads a value on a
S W 21
graduated rod and chec ks the enc oder reading is ex ac t.
P hotoelec tric c ell for the trac tion s top at the end of the ais le. It has an im pulse func tion.
- The truck enters the ais le with a s peed of 4 K m /h
- A t the first im puls e the m ax . s peed is enabled.
S W 22 - A t the s ec ond im puls e (ex it from the aisle), the trac tion stops by m eans of a dy nam ic braking.
- In order to re-enable the traction, the running c ontrol m ust return to its neutral pos ition
- This func tion m us t be enabled by m eans of the cons ole (Com bi, S et O ption "E nd A is le
S afety" )
- P hotoelectric cell to reduc e the s peed at the end of the aisle. It has an im puls e function.
- The truck enters the ais le with a s peed of 4 K m /h
- The truck enters the ais le with a s peed of 4 K m /h
S W 23 - A t the s ec ond im puls e (ex it from the aisle) the s peed is reduc ed to 2,5 K m /h.
- W hen there is a revers al of direc tion, the truc k reac hes full-s peed by entering the ais le.
- This func tion m us t be enabled by m eans of the cons ole (Com bi, S et O ption "E nd A is le
S afety" )
P hotoelec tric c ells s ignalling the pres enc e in the ais le, (they enable the s afeties nec es s ary to
S W 24/25
work in the aisle)
Right/left push buttons on the instrum ent panel to tem porarily enable the forward running when
the operator is on the ground. They m ust be c ontrolled by m eans of the c ons ole (S ic os
S W 28/29
P aram eter Change " B ac k ing S peed" adjus ts the speed and " B ac k ing Tim e" adjus ts the trac tion
tim e).
Fork lowering s top s ens or. The s ensor s tops the fork s at a height of 150m m (in order to re-
S W 30
enable the lowering pres s push button S W 31).
S W 31 Fork lowering pus h button with bloc k.
P us h button to s witc h on the res is tanc es in order to operate with the m achine in a refrigerating
S W 32 room at -30°C.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 17

 Section: TRUCK DESCRIPTION SERVICE

3.00 TABLE OF THE ELECTRIC COMPONENTS

MOD. MO10E FP
ELECTRIC

TRUCK MOD. "MO10E FP" ELECTRIC COMPONENTS

Diagram Diagram
Ref. Component Description
Ref. Page
1 MTR 1/5 Separately excited traction motor 2,5 Kw
2 PM 1/5 Pump motor 2,0 Kw
3 Steer Motor 1/5 Alternating current AC - 0,65 Kw steering motor
4 Logic Combi 2/5 DC electronic control of traction and lifting 300+300 A
Logic Power
5 2/5 AC electronic control for the steering motor
Steering
6 EMB 2/5 Electromagnetic brake unit
7 2/5 Sheath linking connector between the motor compartment and the instrument panel
8 M1 2/5 Motor compartment cooling fan
K1 Main
9 1/5 Main Contactor
Contactor
K2 Main
10 1/5 Main Contactor
Contactor
11 FU2 1/5 10A auxiliary fuse for the protection of control Combi
12 FU3 1/5 10A auxiliary fuse positioned before the key
13 FU4 1/5 10A auxiliary fuse for the protection of the auxiliary lines
14 FU1 1/5 350 A power fuse
15 SW3 2/5 Steering wheel centering (traction) inductive sensor
16 SW4 3/5 Operator presence sensor
17 H1 Horn 3/5 Warning horn
18 SW30 3/5 Sensor to block the forks at a height of 150mm from the ground
19 SW33 3/5 Photoelectric cell to slow down the lifting cylinder at the end of the aisle
20 Retroreflector for the cylinder deceleration photoelectric cell reading
21 SICOS 3/5 Diagnostic display (battery state of charge/discharge, altimeter, alarm display)
22 J1 3/5 Fork lifting/lowering joystick
23 J2 3/5 Emergency braking joystick
SW2
24 1/5 Main emergency push button
Emergency
25 SW1 Key 1/5 Main key-operated switch
Stepper
26 2/5 Steering control stepper motor
Motor
27 SW11 3/5 Push button to change the running mode "Standard, Hard, Soft, Slow".
28 SW12 3/5 Warning horn control push button
29 U1 3/5 Forward/backward speed control keyer
30 SW32 3/5 Push button to insert the resistances in order to work in a refrigerating room at -30°C.
Push button to temporarily enable the forward running when the operator is on the
31 SW28 3/5 ground (left). When the operator is on the truck, it performs the steering self-centering
before running is required.
Push button to temporarily enable the forward running when the operator is on the
32 SW29 3/5 ground (right). When the operator is on the truck, it performs the steer self-centering
before running is required.
33 SW31 3/5 Fork lifting push button with operator on the ground (left side).
34 SW31 3/5 Fork lifting push button with operator on the ground (right side).
35 SW6 3/5 Fork lowering push button with operator on the ground (left side).
36 SW6 3/5 Fork lowering push button with operator on the ground (right side).
37 SW7 3/5 By-pass push button for the fork lowering in the last 150mm

Page: 18 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ELECTRIC SYSTEM

ELECTRIC COMPONENTS
MOD. MO10E FP

9 10 11 12 13 8 5
30 21

24
26
37
27 22
4
7
23
14
28
25 29 6

2
3
31 33 35 36 34 32
1

19

16

20 15
18
17

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 18a

SERVICE Section: TRUCK DESCRIPTION

NOTES:

ELECTRIC

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 19

 Section: TRUCK DESCRIPTION SERVICE

3.01 TABLE OF THE ELECTRIC COMPONENTS

MOD. MO10E FF - MO10E WP

TRUCK MOD. "MO10E FF" ="MO10E WP" ELECTRIC COMPONENTS

ELECTRIC

Diagram Diagram
Ref. Component Description
Ref. Page
1 MTR 1/5 Separately excited traction motor 2,5 Kw
2 PM 1/5 Pump motor 2,0 Kw
3 Steer Motor 1/5 Alternating current AC - 0,65 Kw steering motor
4 Logic Combi 2/5 DC electronic control of traction and lifting 300+300 A
Logic Power
5 2/5 Alternate current electronic control for the steering motor
Steering
6 EMB 2/5 Electromagnetic brake unit
7 2/5 Sheath linking connector between the motor compartment and the instrument panel
8 M1 2/5 Motor compartment cooling fan
K1 Main
9 1/5 Main Contactor
Contactor
K2 Main
10 1/5 Main Contactor
Contactor
11 FU2 1/5 10A auxiliary fuse for the protection of control Combi
12 FU3 1/5 10A auxiliary fuse positioned before the key
13 FU4 1/5 10A auxiliary fuse for the protection of the auxiliary lines
14 FU1 1/5 350 A power fuse
15 SW3 2/5 Steering wheel centering (traction) inductive sensor
16 SW4 3/5 Operator presence sensor
17 H1 Horn 3/5 Warning horn
18 Enc. Cab. 3/5 Cabin height encoder
19 SW19 3/5 Sensor to reset the encoder count to zero
20 SW30 3/5 Sensor to block the forks at 150mm from the ground
21 SICOS 3/5 Diagnostic display (battery state of charge/discharge, altimeter, alarm visualization)
22 J1 3/5 Fork lifting/lowering joystick
23 J2 3/5 Emergency braking joystick
SW2
24 1/5 Main emergency push button
Emergency
25 SW11 3/5 Push button to change the running mode "Standard, Hard, Soft, Slow".
26 SW1 Key 1/5 Key-operated switch
27 U1 3/5 Forward/backward speed control keyer
28 SW12 3/5 Warning horn control push button
29 SW26 3/5 Push button to enable the cabin lifting/lowering
30 SW32 3/5 Push button to enable resistances in order to work in a refrigerating room at -30°C.
Stepper
31 3/5 Steering control motor
Motor
Push button to temporarily enable the forward running when the operator is on the
32 SW28 3/5 ground (left). When the operator is on the truck, it performs the steering self-
centering before running is required.
Push button to temporarily enable the forward running when the operator is on the
33 SW39 3/5 ground (right). When the operator is on the truck, it performs the steering self-
centering before running is required.
34 SW7 3/5 By-pass push button for the cabin descent in the last 150mm
35 SW15 2/5 Chain break signalling sensor
36 SW16 2/5 Chain break signalling sensor

Page: 20 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ELECTRIC SYSTEM

ELECTRIC COMPONENTS
MOD. MO10E FF - MO10E WP

11 12 13 8 5

30 29 31 21

4
14
24 9
10
34

29 25 7 6

2 1
28
26
27
3

32 22 23 33

19

16
18

17

15
35 36 20 OPTIONAL

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 20a

SERVICE Section: TRUCK DESCRIPTION

NOTES:

ELECTRIC

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 21

 Section: TRUCK DESCRIPTION SERVICE

3.02 TABLE OF THE ELECTRIC COMPONENTS

MOD. MO10E SL
TRUCK MOD. "MO10E SL" ELECTRIC COMPONENTS
Diagra m Dia gra m
Re f. Com pone nt De scription
ELECTRIC

Re f. Page
1 MTR 1/5 Separately excited traction motor 2,5 Kw
2 PM 1/5 Pump motor 2,0 Kw
3 Ste e r Motor 1/5 Steering alternating current AC - 0,65 Kw motor
4 Logic Com bi 2/5 DC electronic control of traction and lifting 300+300 A
Logic Pow er
5 2/5 Alternate current electronic control for the steering motor
Stee ring
6 EMB 2/5 Electromagnetic brake unit
7 2/5 Sheath linking connector between the motor compartment and the instrument panel
8 M1 2/5 Motor compartment cooling fan
K1 Ma in
9 1/5 Main Contactor
Conta ctor
K2 Ma in
10 1/5 Main Contactor
Conta ctor
11 FU2 1/5 10A auxiliary fuse for the protection of control Combi
12 FU3 1/5 10A auxiliary fuse positioned before the key
13 FU4 1/5 10A auxiliary fuse for the protection of the auxiliary lines
14 FU1 1/5 350 A power fuse
Fla shing
15 2/5 Flashing light
Be acon
16 SW 3 3/5 Steering wheel centering (traction) inductive sensor
17 SW 8/9 3/5 Right and left side guard closing sensors
18 H1 Horn 3/5 W arning horn
19 SW 4 3/5 Operator presence sensor
20 SW 26 3/5 Push button to enable the fork lifting/lowering
21 SW 6 3/5 Fork lifting push button
22 SW 7 3/5 Fork lowering push button
23 SW 19 3/5 Sensor to reset the encoder count to zero
24 Enc. Ca b. 3/5 Cabin height encoder
25 SW 16 2/5 Lifting chain break signalling sensor
26 SW 15 2/5 Lifting chain break signalling sensor
27 W ork Light 5/5 W ork lights, shelf lighting
28 Spot Light 5/5 W ork lights, cabin lighting
29 SICOS 3/5 Diagnostic display (battery state of charge/discharge, altimeter, alarm visualization)
30 SW 2 1/5 Emergency push button
31 SW 1 Ke y 1/5 Key-operated switch
32 J1 3/5 Cabin lifting/lowering joystick
33 J2 3/5 Emergency braking joystick
34 U1 3/5 Forward/backward speed control keyer
35 SW 12 3/5 W arning horn control push button
36 SW 5 3/5 Cabin lifting by-pass push button
37 SW 11 3/5 Push button to change the running mode (Standard, Hard, Soft, Slow)
38 SW 10 3/5 Push button to enable the cabin lifting
39 SW 32 3/5 Push button to insert resistances in order to work in a refrigerating room at -30°C.
Push button to pass from the automatic to the manual mode by means of a wire
40 SW 17 3/5 guide
41 SW 20 3/5 Push button to switch on the work lights
Push button to temporarily enable the forward running when the operator is on the
42 SW 28 3/5 ground (left). W hen the operator is on the truck, it performs the steering self-
centering before running is required.
Push button to temporarily enable the forward running when the operator is on the
43 SW 29 3/5 ground (right). W hen the operator is on the truck, it performs the steering self-
centering before running is required.
44 SW 6 3/5 Fork lifting push button when the operator is on the ground (left side).
45 SW 6 3/5 Fork lifting push button when the operator is on the ground (right side).
46 SW 7 3/5 Fork lowering push button when the operator is on the ground (left side).
47 SW 7 3/5 Fork lowering push button when the operator is on the ground (right side).

Page: 22 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ELECTRIC SYSTEM

28 ELECTRIC COMPONENTS
39 40 41 38 47 29 MOD. MO10E SL

30 27 27

36
28
38 37

15
35 34 5
31 11 12 13 8

42 44 46 32 33 47 45 43 14

9
10
2
7 6

26 25

19

24 21
23 20
22 17 16
18

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 22a

SERVICE Section: TRUCK DESCRIPTION

NOTES:

ELECTRIC

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 23

 Section: TRUCK DESCRIPTION SERVICE

3.03 TABLE OF THE ELECTRIC COMPONENTS

MOD. MO10E SL - h 3200
ELECTRIC COMPONENTS FOR TRUCK MOD. "MO10E SL" h 3200
Ref. Diagram
Ref. Component description
Diagram page
ELECTRIC

1 MTR 1/5 Separately excited motor 2.5 Kw

2 PM 1/5 Pump motor 2.0 Kw
3 Steer Motor 1/5 Alternating current AC 0,65 Kw steering motor
4 Logic Combi 2/5 DC electronic control for traction and lifting 300+300 A
Logic Power
5 2/5 AC electronic control for steering motor
Steering
6 EMB 2/5 Electromagnetic brake unit
7 2/5 Sheath linking connector between the motor compartment and the instrument panel
8 M1 2/5 Motor compartment cooling fan
K1 Main
9 1/5 Main contactor
Contactor
K2 Main
10 1/5 Main contactor
Contactor
11 FU2 1/5 10A auxiliary fuse for the protection of control Combi
12 FU3 1/5 10A auxiliary fuse positioned before the key
13 FU4 1/5 10A auxiliary fuse for the protection of the auxiliary lines
14 FU1 1/5 350A power fuse
Flashing
15 2/5 Flashing beacon
Beacon
16 SW3 3/5 Steering wheel (traction) centering inductive sensor
17 SW8/9 3/5 Right and left safety guard closing sensors
18 H1 Horn 3/5 Warning horn
19 SW4 3/5 Operator presence sensor
20 SW26 3/5 Push button to enable the fork lifting/lowering
21 SW6 3/5 Fork lifting push button
22 SW7 3/5 Fork lowering push button
23 SW19 3/5 Encoder counting zeroing sensor
24 Enc. Cab. 3/5 Cabin height encoder
25 SW16 2/5 Lifting chain breaking sensor
26 SW15 2/5 Lifting chain breaking sensor
27 Work Light 5/5 Work light, shelf lighting
28 Spot Light 5/5 Work light (cabin lighting)
29 SICOS 3/5 Diagnostic display (state of battery charge/discharge, altimeter, alarm display)
30 SW2 1/5 Emergency push button
31 SW1 Key 1/5 Key switch
32 J1 3/5 Cabin lifting and lowering joystick
33 J2 3/5 Emergency braking joystick
34 U1 3/5 Forward/backward speed control keyer
35 SW12 3/5 Warning horn control push button
36 SW5 3/5 By-pass push button for the cabin lifting
37 SW11 3/5 Push button to change the running mode (Standard, Hard, Soft, Slow)
38 SW10 3/5 Push button to enable the cabin lifting
39 SW32 3/5 Push button to enable the resistances in order to work in a refrigeration room at -30°
40 SW17 3/5 Push button for selecting automatic or manual mode with wire guide
41 SW20 3/5 Push button to switch on the work lights
Push button to temporarily enable the forward running when the operator is on the
42 SW28 3/5 ground (left). When the operator is on the truck, it performs the steer self-centering
before running is required.
Push button to temporarily enable the forward running when the operator is on the
43 SW29 3/5 ground (right). When the operator is on the truck, it performs the steer self-centering
before running is required.
44 SW6 3/5 Fork lifting push button with operator on the ground (left side)
45 SW6 3/5 Fork lifting push button with operator on the ground (right side)
46 SW7 3/5 Fork lowering push button with operator on the ground (left side)
47 SW7 3/5 Fork lowering push button with operator on the ground (right side)
48 Ferrite: limiter of the electromagnetic noise emitted by the traction motor

Page: 24 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Sezione: IMPIANTO ELETTRICO

ELECTRIC COMPONENTS
28
39 40 41 38 47 29 MOD. K1.0L SL - h 3200

30 27 27

36
28
38 37

15
35 34 5
31 11 12 13 8

42 44 46 32 33 47 45 43 14

9
10
2
7 6

24
23

19

21
20
22 17 16
25 26 18

AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Giu. 2004 Part No: 524182160 Pag. 24a

SERVICE Section: TRUCK DESCRIPTION

NOTES:

ELECTRIC

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 25

 Section: TRUCK DESCRIPTION SERVICE

4.00 TABLE OF THE FUNCTION INPUTS

MOD. ALL MODELS

All sensors and microswitches, which are enabled according to the required functions, are specified in
ELECTRIC

the table.

Reading key:

Input = List of the sensor inputs in the modules with indication of

the respective Pin and of the access connectors.

Function descriptions = Description of the function to be performed.

Enabled function = Description of the enabled function.

Control = Enabled control

Pin = Pin indicating the signal output

Status = State of the sensor when the function is required

SW3 = SW33 = Sensors which are enabled according to the required

function

NOTES:

Page: 26 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

TRUTH TABLE
Page1/2

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 24a

SERVICE Section: HYDRAULIC SYSTEM

TRUTH TABLE
Page2/2

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page 24b

SERVICE Section: TRUCK DESCRIPTION

NOTES:

ELECTRIC

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 27

 Section: TRUCK DESCRIPTION SERVICE

5.00 TABLES OF MODULE 2 “COMBI” PARAMETERS

MOD. ALL MODELS

The values of some levels programmed in main menu “PARAMETER CHANGE” are displayed differently
according to the way in which the traction modes have been selected by means of push button “SW1
ELECTRIC

PERFORMANCE MODE”.

By pressing push button SW11, four different truck traction modes can be selected. This push button
also allows the operator to personalize the traction operation without requiring the technician’s intervention.

SOFT = The acceleration, release braking and top speed operations are performed with a lower
level than the standard (8,6 Km/h)
SLOW = Top speed preset by means of the console connected to control COMBI and by operating
on parameter “CUTBACK SPEED 1” (4 Km/h)
STD = The standard acceleration, release braking and top speed parameters are observed
(9,2 Km/h)
HARD = The acceleration, release braking and top speed functions are performed with a higher
level than the standard one (9,8 Km/h)

TABLE “SET OPTIONS & ADJUSTEMENT” OF CONTROL “COMBI”

NOTE: The levels inside the black cell indicate the standard parameter programmed by the firm
(when there are no options)
PARAMETER LEVEL DESCRIPTIONS
When the battery level reaches 20%, the maximum current is
OFF
reduced of 50%. No lifting function is inhibited.
BATTERY CHECK
When the battery level reaches 20%, the cabin and fork lifting
ON
functions are stopped and the maximum current is reduced of 50%.
KEYON The hour counter counts when the key is inserted.
HOUR COUNTER
RUNNING The hour counter counts only when a function is active.
ABSENT The control is set to operate valve EV1 as ON/OFF valve
AUX FUNCTION 2
PRESENT The control is set to operate valve EV1 as proportional valve.
0 The buzzer sounds neither forward nor backward.
HORN DIRECTION
1 The buzzer is selected to sound with the reverse running.
0-1-2
2 The buzzer is selected to sound with the forward running.
The electromagnetic brake intervenes only at the end of the release
OFF
braking when the speed is null.
BRAKE ON RELEASE The electromagnetic brake intervenes when the running lever is
ON released during the release braking in order to increase the braking
effect.
It does not discharge the pressure. Setting to insert for the FP
OFF
machines
RELEASE PRESSURE
At the end stroke forks lift, the EV1 valve opens for 150ms,
ON
discharging the accumulated pressure on the system
0 No safety is present at the end of the aisle
Safety present at the end of the aisle. Only Slowing down or
1
END AISLE SAFETY Stopping
Safety present at the end of the aisle. Only Slowing down or
2
Stopping

Battery voltage adjustment. Battery value read by means of a

ADJUST BATTERY 25,5
multimeter.
It allows adjusting the value at which the battery is considered
ADJUSTMENT # 01 5
charged between 90% and 100%.
It allows adjusting the value at which the battery is considered
ADJUSTMENT # 02 5
charged between 20% and 30%.

Page: 28 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

TABLE “PARAMETER CHANGE” OF CONTROL “COMBI”

PARAMETER LEVEL DESCRIPTION
Acceleration time, minimum time in w hich the motor speed varies from Min. 0
ACCELERATION DELAY 2
0 (steep ramp) to 9 (gentle ramp). Max 9
It allow s to change the field acceleration ramp, the time necessary to Min. 0
FLD ACCELERATION 9
bring the field from 0 to the nominal value. Max 9

ELECTRIC
It adjusts the intensity of the regenerative braking w hen the running Min. 0
DECELERATION DELAY 5
throttle is partially released. Max 9
Time / intensity of the braking current w hen the accelerator is Min. 0
RELEASE BRAKING 6
released. Max 9
Min. 0
INVERS. BRAKING 7 Time / intensity of the braking current during the reversal of direction.
Max 9
Max. speed forw ard obtained by discharging the field energy after Min. 0
MAX SPEED FORW. 8
the condition of max. electricity has been reached on the motor. Max 9
Max. speed backw ard obtained by discharging the field energy after Min. 0
MAX SPEED BACK 8
the condition of max. electricity has been reached on the motor. Max 9
It indicates the max. armature current operated by the traction control Min. 0
TRACTION IMAX 5
both during running and braking. Max 9
It fixes an armature current threshold above w hich the field current is Min. 0
ARMA NOM CURR 5
at least at the nominal value. Max 9
It fixes an armature current threshold above w hich the field current is Min. 0
WEAK DROPOUT 5
gradually increased till the field nominal current is reached. Max 9
It is the minimum field current w hen the potentiometer is betw een 0
Min. 0
FIELD NOM CURRENT 5 and 60%. It must be calibrated by making reference to the motor
Max 9
rating.
PARAMETER CHANGE

Max. field value reached w hen the armature current reaches the Min. 0
FIELD CURR. MAX 9
MAIN MENU

max. value during running. Max 9

It indicates the minimum voltage value applied to the traction motor
Min. 0
CREEP SPEED 0 w hen the running request is activated. It allow s having an immediate
Max 9
response during the starting phase.
Pump motor acceleration time, time necessary to make the voltage Min. 0
PU ACC. DELAY 5
reach the desired value on the pump motor. Max 9
Pump motor deceleration time, time necessary to cancel the voltage Min. 0
PU DECELERATION DELAY 0
on the pump motor during the release phase. Max 9
It indicates the minimum voltage value applied to the pump motor w hen Min. 0
PUMP CREEP 0 the lifting request is present, w ith immediate response during lifting. Max 9

Min. 0
1ST SPEED COARSE 9 Max. lifting speed.
Max 9
Min. 0
FORK LIFT SPEED 7 Fork lifting speed.
Max 9
Min. 0
FORK DOWN SPEED 8 Fork low ering speed.
Max 9
Min. 0
FORK DOWN FINE 5 Fine regulation of the fork low ering speed.
Max 9
Coarse regulation of the proportional valve minimum voltage during Min. 0
MIN EVP COARSE 4
low ering. Max 9
Coarse regulation of the proportional valve maximum voltage during Min. 0
MAX EVP COARSE 3
low ering. Max 9
Fine regulation of the proportional valve minimum voltage during Min. 0
MIN EVP FINE 0
low ering. Max 9
Fine regulation of the proportional valve maximum voltage during Min. 0
MAX EVP FINE 0
low ering. Max 9
Proportional valve acceleration ramp: Min. 0
EVP ACC. DELAY 8
0: shortest ramp, 9: longest ramp Max 9
Proportional valve deceleration ramp: Min. 0
EVP DEC. DELAY 7 0: shortest ramp, 9: longest ramp Max 9

List of the parameters which vary according to the selected traction system (push button SW11)
PARAMETER SOFT STD HARD SLOW
ACCELERATION DELAY 3 2 1 2
RELEASE BRAKING 5 6 7 6
INVERSION BRAKING 6 7 8 7
SPEED MAX 8,6 Km/h 9,2 Km/h 9,8 Km7h 4 Km/h

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 29

 Section: TRUCK DESCRIPTION SERVICE
TABLE “TESTER FUNCTIONS” OF CONTROL “COMBI”
INPUT MONITORED STATUS DESCRIPTIONS
BATTERY VOLTAGE 25,6V Battery voltage measured by the system
MOTOR VOLTAGE 0,0V Motor voltage obtained as VBATT - VMN
MOTOR CURRENT 0A Armature current during traction (positive) or braking (negative)
FIELD CURRENT 0A Field current in the selected running direction
ELECTRIC

EVP VOLTAGE 0,0V Proportional valve field current

TEMPERATURE 17 C° Control temperature
ACCELERATOR 0,0V=0% Traction potentiometer value received by SICOS
LIFTING CONTROL 0,0V=0% Lifting/lowering potentiometer value received by SICOS
Disabled
OFF/GND
function
FORWARD SWITCH Forward running request
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
BACKWARD SWITCH Backward running request
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
LIFTING SWITCH Cabin lifting function request
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
LOWERING SWITCH Cabin lowering function request
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
FORK LIFT SWITCH Fork lifting function request
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
FORK LOW SWITCH Fork lowering function request
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
SW4 (CN : 3E - 13E) Sensor for the slowing down in the aisle
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
SW5 (CN: 1E - 11E) Chain loosening sensor
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
SW6 (CN: 4E - 14E) Emergency "mushroom" sensor
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
SW7 (CN: 6E - 16E) Sensor for the presence in the aisle
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
SW8 (CN: 7E - 17E) Steer control safety input (EPS - AC)
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
SW9 (CN: 8E - 18E) Traction stop sensor at the end of the aisle
Enabled
ON/ +VB
function
Disabled
OFF/GND
function
SECURITY SWITCH Emergency braking
Enabled
ON/ +VB
function
BATTERY CHARGHE 100% Batterry state of charge

Page: 30 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

5.01 TABLES OF MODULE 1 DISPLAY “SICOS” PARAMETERS

MOD. ALL MODELS

ELECTRIC
TABLE “SET OPTIONS & ADJUSTMENT” OF CONTROL “SICOS DISPLAY”

NOTE: The levels inside the black cell indicate the standard parameter programmed by the firm
(when there are no options)

"CONFIG MENU" PARAMETERS

0 It selects the option of not performing the programmed maintenance
CHECK UP TYPE It selects the option "programmed maintenance" every 300 working
1
hours
KEYON The hour counter counts when the key is inserted
HOUR COUNTER
RUNNING The hour counter counts only when a function is active
OFF Programmed maintenance done (to be left during the working phase)
CHECK UP DONE
ON It cancels the hours on the control after 300 maintenance hours
OFF It enables the cabin/fork lifting block
AUX FUNCTION # 1
ON It enables the fork lifting block
OFF The overhead guard tracer sensor blocking the lifting is not enabled
AUX FUNCTION # 2
ON It enables the overhead guard tracer sensor blocking the lifting
OFF It inhibits the encoder control redundant sensor
AUX INPUT #1
ON It enables the encoder control redundant sensor
SET OPTIONS

OFF It inhibits the use of the electrical level preselector

PRE-H SELECTOR
ON It enables the use of the electrical level preselector
CONFIG. MENU

OFF It inhibits the use of the password for the machine operation
PASSWORD
ON It enables the use of the password for the machine operation
OFF It inhibits the use of the push button to enable the fork lifting/lowering
FORKS ENABLE
ON It enables the use of the push button for the fork lifting/lowering
It inhibits the use of the push button to enable the cabin lifting/lowering
OFF
CABIN ENABLE out of the aisle if traction is not activated
ON It enables the use of the push button for the cabin lifting/lowering
0 No encoder is selected
ENCODER TYPE 1 Encoder selection with cabin presence
2 Encoder selection with cabin + fork presence
OFF It inhibits the traction block at a certain cabin height
BLOCK TRACTION
ON It enables the traction block at a certain cabin height
OFF It inhibits the cabin block function at 100mm from the ground
It enables the cabin lowering block at 100mm from the ground. In order
STOP LOWER CAB to continue the lowering, release the lowering control lever in neutral
ON
position, then continue the lowering. It must be enabled on trucks with
fixed forks.
ADJUST

ENCODER It is used to recover the possible encoder play

127
ADJUSTMENT (Min. 1 - Max 255)

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 31

 Section: TRUCK DESCRIPTION SERVICE
TABLE “PARAMETER CHANGE” OF CONTROL “SICOS DISPLAY”

PARAMETER LEVEL DESCRIPTION

Reduction of the traction speed used for conditions of 4 Km/h, also Min. 0
CUTBACK SPEED 1 5
used with push button "SLOW" Max 9
ELECTRIC

Min. 0
CUTBACK SPEED 2 5 Reduction of the traction speed used for conditions of 2,5 Km/h
Max 9
Speed reduction when the steering angle, at its highest value, is
Min. 0
CURVE CUTBACK 5 expressed in % of the max. speed. The speed reduction is proportional
Max 9
to the steering angle.
Min. 0
LIFT SPEED CUTBACK 1 Reduction of the cabin speed during lifting
Max 9
PARAMETER CHANGE

Min. 0
LOW SPEED CTBACK 2 Reduction of the cabin speed during low ering
Max 9
MAIN MENU

Dead area in which there is no reduction of the speed expressed as % Min. 0

STEER DEAD ANGLE 3
of the steer maximum amplitude. Max 9
Min. 0
PRE-H LIFT CUTBACK 3 Reduction of the preselector speed during lifting
Max 9
Min. 0
PRE-H LOW CUTBACK 3 Reduction of the preselector speed during lowering
Max 9
Min. 0
OPTION 03 5 Cabin deceleration distance during lifting
Max 9
Min. 0
OPTION 04 7 Cabin deceleration distance during lowering
Max 9
Min. 0
OPTION 05 5 Store offset (delta to store pallets on the shelf)
Max 9
Min. 0
OPTION 06 5 Withdraw al offset (delta to withdraw pallets from the shelf)
Max 9
Min. 0
BACKING SPEED 2 Max. speed during the backing function
Max 9
Min. 0
BACKING TIME 9 Max. duration of the backing function
Max 9

TABLE “TESTER FUNCTIONS” OF CONTROL “SICOS DISPLAY”

IN P U T M O N ITO RED S TATUS D ES C R IP T I O N

A C C E L ER A T O R 1 ,6 V A c c e le ra t o r th ro tt le vo lt a g e

A N A L O G IN P U T # 1 2 ,5 V L ift in g /lo w e rin g jo y s t ic k vo lt a g e

D is a b le d
O F F/G ND
fu n c tio n
F O R W A R D S W IT C H F o rw a rd ru n n in g in p u t le ve l
E n a b le d
O N/ + V B
fu n c tio n
D is a b le d
O F F/G ND
fu n c tio n
BA CK W A RD S W ITC H B a c k w a rd ru n n in g in p u t le ve l
E n a b le d
O N/ + V B
fu n c tio n
D is a b le d
O F F/G ND
fu n c tio n
S EA T S W I T C H O p e ra to r p re s e n c e s e n s o r in p u t le ve l
E n a b le d
O N/ + V B
fu n c tio n
D is a b le d
O F F/G ND
fu n c tio n
LIFTIN G C UT O U T O ve rh e a d g u a rd s e n s o r in p u t le ve l
E n a b le d
O N/ + V B
fu n c tio n
D is a b le d
O F F/G ND
fu n c tio n
1 S T S P EED S W I T C H C a b in liftin g jo y s t ic k s ta rt in p u t le ve l
E n a b le d
O N/ + V B
fu n c tio n
D is a b le d
O F F/G ND
fu n c tio n
2 N D S P EED S W IT C H C a b in lo w e rin g jo y s t ic k s ta rt in p u t le ve l
E n a b le d
O N/ + V B
fu n c tio n

Page: 32 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

Dis abled
O F F/GND
func tion
3RD S P EED S W ITCH Fork lifting input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion

ELECTRIC
4TH S P EED S W IT CH Fork lowering input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
DIG IT AL INP UT #1 E m ergenc y brak ing input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
DIG IT AL INP UT #2 Lifting bloc k by pas s input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
DIG IT AL INP UT #3 S afety s ide guard input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
DIG IT AL INP UT #4 Input level of the fork lowering with bloc k
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
DIG IT AL INP UT #5 Fork lowering bloc k input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
DIG IT AL INP UT #6 Guide wire m anual/autom atic s elec tion input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
DIG IT AL INP UT #7 Input level for the pres enc e in the ais le
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
S T AT US 1 Fork lifting/lowering c ons ent input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion Input level of the c ons ent to c abin lifting/lowering and trac tion
S T AT US 2
E nabled in the ais le
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
S T AT US 3 Cabin enc oder res et input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
S T AT US 4 Fork enc oder res et input level
E nabled
O N/ + V B
func tion
Dis abled
O F F/GND
func tion
S T AT US 5 Cabin lifting enc oder c ontrol s ens or input level
E nabled
O N/ + V B
func tion
CABIN HG T ENCO DER 150 Reading of c abin enc oder s et m eas ure "O FF S E T"

FO RKS HG T ENCO DER 0 Reading of fork enc oder s et m eas ure "OF FS E T"

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 33

 Section: TRUCK DESCRIPTION SERVICE

5.02 TABLES OF MODULE 6 EPS - AC PARAMETERS

MOD. ALL MODELS

TABLE “SET OPTIONS & ADJUSTMENT” OF CONTROL “EPS-AC”

ELECTRIC

NOTE: The levels inside the black cell indicate the standard parameter programmed by the firm
(when there are no options)
"CONFIG. MENU" PARAMETERS
KEYON The hour counter counts when the key is inserted
HOUR COUNTER
RUNNING The hour counter counts only when a function is active
SET OPTIONS

It sets the level of recognition in the aisle and performs the

AUTO INPUT 1
wheel centering automatically
ACTIVE
0 It does not recognize the presence in the aisle
CONFIG. MENU

OFF It sets the steering rotation at +/- 90°

RANGE 360°
ON It sets the steering rotation at 360°
OFF For truck with limited steering angle of +/- 90°
LIMIT DEVICE
ON For truck with a steering range of 360°

Adjustment used to bring the MDU to the upright position

SET STEER 0-POS 5.000v
during the initial alignment and for a centering operation
ADJUST

Adjustment which specifies the encoder position corresponding

SET MIN ENCODER 3,5v
to a MDU rotated of 90° in counterclockwise direction
Adjustment which specifies the encoder position corresponding
SET MAX ENCODER 6,5v
to a MDU rotated of 90° in clockwise direction
SET 180° ENCODER 10,0v Adjustment used for the encoder scaling

TABLE “PARAMETER CHANGE” OF CONTROL “EPS-AC”

PARAMETER LEVEL DESCRIPTION

It adjusts the MDU max. rotation speed. Such adjustment must be done after Min. 0
SPEED LIMIT 7
setting SET BATTERY TYPE Max 9
It allow s modif ying the max. steering speed reduction w hen the truck speed Min. 0
AUX FUNCTION 3 5 increases. Max 9
It produces an increase of the steer sensibility w ith small changes in the Min. 0
SENSIBILITY 4
steer input. The max. steering speed has no influence. Max 9
Min. 0
AUX FUNCTION 2 5 It varies the steering speed value w hen the steering w heel is turned slow ly
PAMETER CHANGE

Max 9
MAIN MENU

Min. 0
CREEP SPEED 5 It guarantees a great torque for very slow movements of the steering w heel
Max 9
Min. 0
COMPENSATION 2 It guarantees a good torque w hen the battery voltage is low
Max 9
After the steering w heel has been released, it sets the time (few seconds) Min. 0
AUXILIARY TIME 4 the current to the steering motor is kept active before it stops. Max 9
It adjusts the stall torque af ter the steering w heel has been released. This Min. 0
ANTIROLLBACK 40%
parameter is specified as percentage of max. current ( Min. 0% Max 70%) Max 9
It modifies the static precision of the position control during the self -aligning Min. 0
KP 9
phase Max 9
Min. 0
DESENSIBILIZAT 9 It slow s dow n the steer near the centre during the self-aligning phase
Max 9
Min. 0
POS ACCURACY 9 Fine adjustment of KP
Max 9
Min. 0
PURSUIT RAMP 9 Steer speed duing the self-aligning phase
Max 9

Page: 34 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

TABLE “TESTER FUNCTIONS” OF CONTROL “EPS-AC”

INPUT MONITORED STATUS DESCRIPTION
It indicates, in real time, the value of the stepper motor input with
DT 0,00V
its sign (range 0+/-5V).

ELECTRIC
SET POINT POT. 0,00V Not used
It indicates, in real time, the voltage of the feedback encoder
FEEDBACK ENCODER 5,000V assembled on the MDU if the steer is upright and there are
approximately 5V
It indicates the temperature of the control unit dissipator in
TEMPERATURE 23°C centigrade degrees. If the temperature is higher than 76°C, an
alarm appears
MOTOR TEMPERATURE 25°C It indicates the steering motor temperature in centigrade degrees
It indicates the frequency applied to the steering motor with its
FREQUENCY 0,00Hz
sign
It indicates the voltage applied to the steering motor as % of the
MOTOR VOLTAGE 0%
battery voltage
MOTOR CURRENT 0A It indicates the effective value of the motor phase current
Motor speed expressed as frequency; this information is given by
ENC. SPEED 0,00Hz
the encoder
It indicates the steer sensor status if it is reading and switched
ON 12V
on
PROXIMITY SWITCH
It indicates the steer sensor status if it is not reading and
OFF
switched off
ON +12V
CW LIMIT LEVEL Not used
OFF
ON +12V
ACW LIMIT LEVEL Not used
OFF
Disabled
OFF/GND
function
AUTOMATIC REG. It indicates the steer status: automatic / manual
Enabled
ON/ +VB
function
Disabled
OFF/GND
function It gives an information of active running request. It is ON when a
DIRECTION IMPUTS
Enabled request of forward / reverse running is present
ON/ +VB
function
ON +12V It gives information in real time about the status of the safety
MM ALARM SWITCH
OFF contact controlled by the master microprocessor
ON +12V It gives information in real time about the safety status controlled
SM ALARM SWITCH
OFF by the slave microprocessor

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 35

 Section: TRUCK DESCRIPTION SERVICE

6.00 MODULE CALIBRATION ACCESS PROCEDURE

MOD. ALL MODELS

Each module is identified by a number. Thanks to the connection by means of CAN BUS between Mod.
ELECTRIC

6 EPS and Mod. 1 SICOS display, it is possible to have access to the programming of the two modules
through “MENU SET MODEL”. It is sufficient to connect the console without adapter (Pict. 04) to Module
6 EPS - AC.

Since Module 2 COMBI is connected to SICOS by means of a serial cable, it must be programmed on
its own by using the console with the adapter (Pict. 05).

When a module enters the alarm state, there is a total block of the truck; a description of the alarm and
an indication of the corresponding module appear on the display.

NOTE: Before connecting the console to the module, put the key-operated switch in OFF position.

CONSOLE
COD 272210700
Pict. 04

Pict. 03

Pict. 02

CONSOLE
COD 272210700
ADAPTER
COD. 580036555
Pict. 05

Page: 36 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

6.01 MODULE SEARCH PROCEDURE

MOD. ALL MODELS

ELECTRIC
CONFIG. MENU / SET MODEL

EPS-AC NA 0.15 1) Heading line

DISPLAY 24V 300 A 0000

2) Press ROLLUP+SETUP at the same time

KEYBOARD

3) The heading of menu SET MODEL appears

CONFIG MENU
SET MODEL
4) Press ENTER

5) The number corresponding to the module to which

you are connected appears
CONNECTED TO
1
6) Use key SET UP or SET DOWN in order to modify
the selection of the module to which you want to
connect yourself

CONNECTED TO
1 7) The new selected module appears

8) Press OUT in order to exit from the selection

9) The modification confirmation request appears

ARE YOU SURE?
YES=ENTER NO=OUT
10) Press ENTER in order to confirm the change or
press OUT in order to cancel it

CONFIG MENU 11) The heading of menu SET MODEL appears

SET MODEL
12) Press ROLL DOWN, OUT, SET DOWN at the same
time

SICOS 13) The screenful of the selected module appears.

24V 300 A 0000 Through it you can pass to the display/programming
of all its menus
Pict. 08

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 37

 Section: TRUCK DESCRIPTION SERVICE

6.02 BATTERY VOLTAGE SETTING ON CONTROL “COMBI”

MOD. ALL MODELS

When delivered, the trucks have already been tested in

all parameters by the firm. Notwithstanding this, we B-
ELECTRIC

recommend setting the battery on control COMBI before

delivering the truck to the Customer.

Before performing this operation, carry out a

supplementary charge of the used battery in order to B+
have it at your disposal with its highest voltage.

SETTING PROCEDURE

A) When the truck is stopped, disconnect the serial cable

connector (D) from control COMBI and connect the
MULTIMETER
console adapter to the same connector. Switch on
ADAPTER
the truck (KEY ON), select “CONFIG MENU
ADJUSTMENT”, and select parameter “ADJUST C/D
BATTERY”.

B) By means of the “MULTIMETER” measure the

battery voltage directly from the control by positioning
the multimeter terminals on the tightening yoke (B+ -
B) of the cables coming out of the battery.

Set the value read by the “MULTIMETER” (ex. 25,2V)

CONSOLE
on the console as parameter “ADJUST BATTERY”.
Turn the key off and then on again in order to store the Pict. 06
value.

In order to check if the voltage value has been stored,

turn the key on and select “MAIN MENU TESTER”. Select parameter “BATTERY VOLTAGE”; if the
value does not correspond, repeat the above-described procedure.

NOTE:
If the battery is not fully charged, the battery indicator does not reset and shows the real charge value till
the battery is fully recharged.

Never charge a battery already charged with a value between 70% and 100%. This reduces the life of the
battery itself.

Page: 38 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

6.03 TRACTION START SEQUENCE

MOD. ALL MODELS

Before starting to travel, follow the sequence described here below.

ELECTRIC
TRACTION

1) Get on the platform footboard and enable the operator presence sensor (SW4)
2) Enable the emergency push button (SW2) by pulling it upwards
3) Position the key-operated switch (SW1) on 1 ON (STEER SELF-CENTERING TAKES PLACE)
4) Select the desired running: forward (FW) or reverse (RV)

NOTE: If you get on the machine while it is ‘on’ and press push button SW28/29, the steer self-
centering takes place before the running request

NOTE: If the described sequence is not performed, alarm “INCORRECT START” appears on the display.
By turning off and on the key-operated switch, the alarm disappears.

CABIN OR FORK LIFTING

1) Get on the platform footboard and enable the operator presence sensor (SW4)
2) Enable the emergency push button (SW2) by pulling it upwards
3) Position the key-operated switch (SW1) on 1 ON
4) Activate the lifting/lowering joystick (J1)

NOTE: If the described sequence is not carried out, alarm “INCORRECT START PUMP” appears on
the display. By releasing the lever (J1) in rest position, the alarm disappears.

SW2

FW

SW1
RV

SW28 SW29

SW4

Pict. 07

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 39

 Section: TRUCK DESCRIPTION SERVICE

6.04 SPEED REDUCTIONS

MOD. ALL MODELS

This paragraph describes the speed reductions available on the truck.

ELECTRIC

6.05 BATTERY EXHAUSTED FOR MORE THAN 80%

In this condition alarm “BATTERY LOW” appears on the display. The fork and cabin lifting are stopped
and the truck travels with a traction of 50% of the max. available current.
Parameter not adjustable by means of the console

6.06 SPEED REDUCTION WITH STEERED TRACTION WHEEL

This function allows having a speed reduction, which gradually increases till it reaches its max. value,
corresponding to the one adjusted on parameter “CURVE CUTBACK”.
Parameter Change Module 1 Sicos Display
We recommend keeping the parameters suggested by the firm.

6.07 SPEED REDUCTION WITH PERFORMANCE “SLOW”

This function can be adjusted by means of the console on parameter “CUTBACK SPEED 1” of Parameter
Change - Module 1 Sicos. We recommend keeping the parameter as suggested by the firm.

6.07 CENTERED STEER WHEEL SENSOR: DAMAGED

In this case it is possible to steer but the truck travels in traction with a speed reduction of 50% of the
max. available speed.
Parameter not adjustable by means of the console

6.08 BEHAVIOUR OF THE MACHINE OUTSIDE AND INSIDE THE AISLE

TAB LE O F TH E S P EEDS O UT O F T HE AIS L E

S pe e d Ca bin H e ig ht Fo rk He ig ht U pri gh t S te e r S te e rin g A ng le > 10°
M ax S peed (9,5 K m pe r ho ur) F rom 0 to 500 m m From 0 m m t o 800m m Y es
S peed Reduc tion
"Cutbac k S peed 1" From 500 m m to 1700 m m From 0 m m to 800 m m Y es
(4,5 Km p e r h ou r)
S peed Reduc tion
"Cutbac k S peed 2" F rom 1700 m m to 3200 m m From 0 m m to 800 m m Y es Y es
(2,5 Km p e r h ou r)

T ABL E O F T HE S P EEDS IN T HE AI S LE
S pe e d Ca bin h e ig ht Fo rk He ig ht U pri gh t S te e r S te e rin g A ng le > 10°
M ax S peed (9,5 K m pe r ho ur) From 0 t o 1700 m m From 0 m m to 800 m m Y es
S peed Reduc tion
"Cutbac k S peed 1" F rom 1700 m m to 3200 m m From 0 m m to 800 m m Y es
(4,5 Km p e r h ou r)
S peed Reduc tion
"Cutbac k S peed 2" From 3200 m m and m ore From 0 m m to 800 m m Y es
(2,5 Km p e r h ou r)

Page: 40 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

7.00 MODULE REPLACEMENT PROCEDURE

MOD. ALL MODELS

The procedure to replace each single module is described in the following paragraphs, so that, at the
end of the operation, the truck runs exactly as with the previous module.

ELECTRIC
Before replacing a module, compare the setting table contained in this manual with the parameters
stored on the module to be replaced by means of PARAMETER CHANGE and SET OPTIONS: they
could be different according to the enabled options.
At the end of the module replacement operation, always make sure the new module is programmed
exactly as the previous one.

7.01 MODULE (2) COMBI REPLACEMENT

NECESSARY STANDARD TOOLS

MEDIUM PHILLIPS 5mm ALLEN 13mm ELBOWED 10mm UNIVERSAL CONSOLE WITH
SCREWDRIVER WRENCH WRENCH SOCKET WRENCH ADAPTER

PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage
of pedestrians, lower the forks to the ground, turn the key-operated switch OFF, disconnect the
battery, remove the motor compartment hood.
1) Turn the key-operated switch off, press the emergency push button and disconnect the battery.

2) 13mm ELBOWED WRENCH - Remove the protective caps from the

power cable fixing bolts (Ref. A Pict. 09). Using the wrench unscrew C D
the bolts by releasing the control from the cables. IMPORTANT: before
disconnecting the cables, signal the position of each of them in order
to make the connection on the new control easier. B

3) PHILLIPS SCREWDRIVER - Unscrew the two fixing bolts of the motor A Pict. 09
compartment cables (Ref. B Pict. 09) and disconnect the cables.
Disconnect the auxiliary function connectors checking their positions
have been identified (Ref. C Pict. 09).

4) 5mm ALLEN WRENCH - Unscrew and remove the bolts fixing control
Combi to the support (Ref. D Pict. 09). Remove the control and replace
it.

Install the new control by following the reverse procedure. Remember to

connect screws, connectors and cables in the correct way.

5) By using the table contained in this manual, check that all regulations of
“PARAMETER CHANGE” correspond to the “SET OPTIONS” ones. Test
the truck in all its functions.

Pict. 08

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 41

 Section: TRUCK DESCRIPTION SERVICE

7.02 MODULE 6 “EPS- AC” REPLACEMENT

NECESSARY STANDARD TOOLS

ELECTRIC

10 mm UNIVERSAL CONSOLE WITHOUT

SOCKET WRENCH ADAPTER
PROCEDURE

Before starting to work wear suitable safety clothes. F

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the E Pict. 11
battery, remove the motor compartment hood.

1) 10mm UNIVERSAL SOCKET WRENCH - Unscrew the power cable

fixing bolts (Ref. E Pict. 11). Before removing the cables check their
positions have been identified. Disconnect the auxiliary function
connectors checking the identification of their position.

2) By means of the same wrench unscrew the nuts fixing the control to
the support and remove the module. Install the new module by following
the reverse procedure.

3) After checking the connection of cables and connectors is right, connect

the console to the module, connect the battery, enable the emergency
push button and activate the key-operated switch.
Pict. 10
4) By using the table contained in this manual, check that all regulations of
“PARAMETER CHANGE” correspond to the “SET OPTIONS” ones. Test the truck in all its functions.
Check the steer guide adjustment by following the procedure described in the table on the following
page.

Page: 42 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

 3.02.1 TABLE FOR THE STEER ADJUSTMENT - ACTION AT 90°
NOTE: This table does not replace the procedure described in the Service Manual EPS-AC but it is an indication of quick connection
to the module

UPDATE
CONFIG.
SERVICE

Accessories Module Sequence Parameters Setting Description of the operations to be performed

MENU
While the truck is stopped, connect the console to Module
1 EPS. Put the key-operated switch in ON position and check
the wheel automatically reaches the central position.

0 1
Turn the key-operated switch OFF and then ON. Check the

2
2 SET OPTIONS RANGE 360 OFF wheel automatically reaches the central position. If the

3
wheel is not centered, proceed to the following point.

4
Increase the displayed value in order to correct the wheel
centering clockwise (+5mV). Decrease the displayed value
Displayed
SET STEER in order to correct the wheel centering counterclockwise (-
3 ADJUSTMENT value
0-POS 5mv). Turn the key-operated switch OFF and then ON.
5V
Check the wheel automatically returns to the central
position.
Turn the key-operated switch OFF and then ON. Check the
4 SET OPTIONS LIMIT DEVICE OFF
EPS- AC wheel automatically returns to the central position.

Rotate the steer clockwise till reaching a position of 90°

Displayed (displayed value 7,4V). Save the set value by pressing
5 ADJUSTMENT SET MAX ENC value ENTER, OUT and ENTER again. Then put the key-operated
Section: TRUCK DESCRIPTION

7,2V switch in OFF and ON position. Check the wheel

automatically returns to the central position.

Rotate the steer counterclockwise till reaching a position of

Displayed 90° (displayed value 2,4V). Save the set value by pressing
6 ADJUSTMENT SET MIN ENC value ENTER, OUT and ENTER again. Then put the key-operated
2,6V switch in OFF and then ON position. Check the wheel

5 6 Date: Sept. 2004 Part No: 524182160

automatically returns to the central position.

Put it in ON position. Turn the key-operated switch OFF in

7 SET OPTIONS LIMIT DEVICE ON
order to save the parameters.

Page: 43
ELECTRIC
 Section: TRUCK DESCRIPTION SERVICE

7.03 MODULE 1 “SICOS” DISPLAY REPLACEMENT

NECESSARY STANDARD TOOLS

ELECTRIC

6mm ALLEN MEDIUM PHILLIPS 8mm CONSOLE WITHOUT

WRENCH SCREWDRIVER ELBOWED ADAPTER
WRENCH
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians, lower the
M
forks to the ground, turn the key-operated switch OFF,
disconnect the battery, remove the motor compartment hood.
M Pict. 16

1) 6mm ALLEN WRENCH - By means of the wrench unscrew and

remove the bolt fixing the handle (Ref. G Pict. 14). Remove the handle
(Ref. H Pict. 15)

2) PHILLIPS SCREWDRIVER - Loosen the screws fixing the instrument

board to the coachwork (Ref. I Pict. 13), withdraw it from its seat
and overturn it in order to have access to the “DISPLAY” fixing nuts.
L Pict. 15
3) PHILLIPS SCREWDRIVER, 8mm ELBOWED WRENCH -
Disconnect the connectors from the module checking their
positions have been identified. Place the screwdriver on the
screw heads (Ref. L Pict. 15) and the elbowed wrench on the
screw nuts (Ref. M Pict. 16). Loosen the four fixing screws
and remove the module.

4) Install the new module following the reverse procedure. After

checking the connector connection is correct, fix the
instrument board to the coachwork.

5) Connect the console to module EPS, connect the battery, Pict. 12 H

enable the emergency push button and activate the key-
operated switch.

6) By using the tables contained in this manual, check that all

adjustments of “PARAMETER CHANGE” correspond to “SET
OPTIONS” ones.
I G
Pict. 13 Pict. 14
Test the truck in all its functions.

Page: 44 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

7.04 MAIN CONTACTOR AND COOLING FAN REPLACEMENT

MOD. ALL MODELS

7.05 MAIN CONTACTOR REPLACEMENT

ELECTRIC
NECESSARY STANDARD TOOLS

17 mm OPEN- 3mm ALLEN

ENDED SPANNER WRENCH
N N
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians, lower the
forks to the ground, turn the key-operated switch OFF,
disconnect the battery, remove the motor compartment hood.

1) 17mm - OPEN-ENDED SPANNER - Loosen the screw nuts fixing Pict. 18 O O

the cables to the contactor (Ref. N Pict. 18). Before removing the
cables check their positions have been identified. Disconnect the
coil power supply connector.

2) 3mm - ALLEN WRENCH - Loosen the bolts fixing the contactor to

the support (Ref. O Pict. 18), remove the contactor and replace it.

Install the new contactor following the reverse procedure.

7.06 COOLING FAN REPLACEMENT

1) Turn off the key-operated switch, press the emergency push button,
disconnect the battery.
Pict. 17
2) 3mm - ALLEN WRENCH - Disconnect the fan power supply
connector. By means of the wrench unscrew the three fixing bolts
(Ref. P Pict. 19), remove the fan and replace it.

Install the new fan by following the reverse procedure.

Pict. 19

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 45

 Section: TRUCK DESCRIPTION SERVICE

7.07 STEER STEPPER MOTOR REPLACEMENT

MOD. ALL MODELS

This paragraph explains how to replace the stepper motor for the steering motor control.
ELECTRIC

NECESSARY STANDARD TOOLS

8 mm OPEN- MEDIUM PHILLIPS 3-4-6 mm ALLEN

ENDED SPANNER SCREWDRIVER WRENCH

PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage
of pedestrians, lower the forks to the ground, turn the key-operated switch OFF, disconnect the
battery.
1) 6 mm ALLEN WRENCH - By means of the wrench unscrew and
remove the handle fixing bolt (Ref. G Pict. 22). Remove the handle
(Ref. H Pict. 20).
S
2) PHILLIPS SCREWDRIVER - Loosen the screws fixing the instrument
board to the coachwork (Ref. I Pict. 21), withdraw it from its seat and
overturn it in order to have access to the steering stepper motor. R

3) OPEN-ENDED SPANNER, 4mm ALLEN WRENCH - Disconnect Q

the linking connector, by means of the wrenches unscrew and remove
the four bolts fixing the stepper motor to the support (Ref. Q/R Pict. Pict. 23
23).

4) 3mm ALLEN WRENCH - Loosen the security dowel of the

stepper motor shaft (Ref. S Pict. 23). Remove the stepper
motor and replace it.

Install the new stepper motor following the reverse procedure.

NOTE: After the assembly no special adjustment is

necessary.
H Pict. 20

I Pict. 22 G
Pict. 21

Page: 46 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

7.08 LIFTING AND BRAKING JOYSTICK REPLACEMENT T

MOD. ALL MODELS
U
In order to disassemble the lifting and emergency braking joysticks, it is

ELECTRIC
necessary to follow the procedure described below.

NECESSARY SPECIAL TOOLS

• Self-tapping screw Ø 3,5x40

Pict. 24
NECESSARY STANDARD TOOLS
V
Z

6 mm ALLEN NORMAL MEDIUM SMALL SLOTTED

WRENCH PLIERS PHILLIPS SCREWDRIVER
SCREWDRIVER

PROCEDURE
Before starting to work wear suitable safety clothes.
Pict. 25

Park the truck in a safe area, away from the transit of other motor Z
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the
W
battery.

1) Remove the instrument panel from the coachwork (Follow the pro-
cedure described in paragraph 7.07, section 1/2, on page 44) Y

2) SELF-TAPPING SCREW, MEDIUM PHILLIPS SCREWDRIVER,

NORMAL PLIERS - By means of the screwdriver tighten the screw J
(Ref. T Pict. 24) for 4/5mm into the hole of the joystick knob (Ref. U
Pict. 24). By means of the pliers pull the closing plug upwards and
free the handhole of the knob setscrew (Ref. V Pict. 25)
X
3) MEDIUM PHILLIPS SCREWDRIVER, SMALL SLOTTED
SCREWDRIVER - By means of the Phillips screwdriver loosen and
remove the knob fastening screw (Ref. Z Pict. 26), withdraw the knob
(Ref. W Pict. 26) and remove the protective cap (Ref. Y Pict. 26).
Release completely the joystick shaft and withdraw the sealing O-
ring (Ref. J Pict. 26) by means of the small slotted screwdriver.

Pict. 26

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 47

 Section: TRUCK DESCRIPTION SERVICE

4) MEDIUM PHILLIPS SCREWDRIVER - Loosen and remove the screws

fixing the joystick plate to the instrument panel seat (Ref. X Pict. 26).
Remove the plate (Pict. 28). Withdraw the joystick from the instrument
panel by pulling it downwards, disconnect the linking connector and
ELECTRIC

replace it.

Install the new joystick by following the reverse procedure.

NOTE: After the assembly no special adjustment is necessary.

Pict. 27
NOTES:

Pict. 28

Page: 48 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

7.09 GEAR CONTROL POTENTIOMETER CARD REPLACEMENT

MOD. ALL MODELS

NECESSARY STANDARD TOOLS

ELECTRIC
K

MEDIUM PHILLIPS 3 mm ALLEN 8 mm OPEN-

SCREWDRIVER WRENCH ENDED
SPANNER
PROCEDURE
Before starting to work wear suitable safety clothes. Pict. 29

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians, lower the
forks to the ground, turn the key-operated switch OFF, disconnect
the battery.
1) MEDIUM PHILLIPS SCREWDRIVER - Remove the instrument panel
from the coachwork (Follow the procedure described in paragraph A
7.07 section 1 on page 44)

2) By means of the same screwdriver loosen and remove the screw

fixing the gear control throttle (Ref. K Pict. 29) and withdraw the throttle Pict. 30
from the pin.

3) 3 mm ALLEN WRENCH, 8 mm OPEN-ENDED SPANNER - Insert

the Allen wrench into the fastening screw seat outside the hood (Ref.
A Pict. 30). By means of the 8 mm OPEN-ENDED SPANNER unscrew
and remove the card clamping nuts inside the hood (Ref. B Pict. 31) B
and disconnect the linking connector. Remove the card and replace
it.

Install the new card by following the reverse procedure.

NOTE: After the assembly no special adjustment is necessary.

7.10 PUSH BUTTON REPLACEMENT

MOD. ALL MODELS Pict. 31

All push buttons of the various controls on the instrument panel

(Ref. C Pict. 32) are fixed in their seats. In order to replace the
controls a Phillips screwdriver is necessary to remove the
instrument panel.

1) MEDIUM PHILLIPS SCREWDRIVER - Remove the instrument

panel (Follow the procedure described in paragraph 7.07
section 1 on page 44)

2) Exercise a pressure from inside to outside on the push button

to be replaced (Ref. C Pict. 32), disconnect the cables and C Pict. 32
replace them.

Insert the new push button by following the reverse procedure.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 49
 Section: TRUCK DESCRIPTION SERVICE
7.11 EMERGENCY PUSH BUTTON AND OF KEY-OPERATED SWITCH REPLACEMENT
MOD. ALL MODELS

For the replacement of the two details it is necessary to disconnect

the instrument panel from the cabin.
ELECTRIC

NECESSARY STANDARD TOOLS

MEDIUM PHILLIPS SMALL SLOTTED

SCREWDRIVER SCREWDRIVER
PROCEDURE
Pict. 32
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians, lower D
the forks to the ground, turn the key-operated switch OFF,
disconnect the battery.

7.12 EMERGENCY PUSH BUTTON CONTACT

REPLACEMENT

When the emergency push button does not work electrically, there is
a fault in the switch contact.
E
1) MEDIUM PHILLIPS SCREWDRIVER - Remove the instrument Pict. 33
panel from the cabin (Follow the procedure described in
paragraph 7.07 of section 1 on page 44)
F
2) SMALL SLOTTED SCREWDRIVER - Loosen the screws fixing
the cables to the terminal (Ref. E Pict. 33). Remove the cables. By
means of the same screwdriver exercise a pressure on the tang
blocking the switch (Ref. D Pict. 33). Remove and replace the
switch.

Insert the new switch following the reverse procedure.

7.13 KEY-OPERATED SWITCH REPLACEMENT Pict. 34

1) Remove the instrument panel from the cabin.

2) Withdraw the ignition key, unscrew the ring nut fixing the switch to
the instrument panel (Ref. F Pict. 34). Withdraw the switch body
from inside the instrument panel, disconnect the cables (Ref. G G
Pict. 35) and replace the switch.

Insert the new switch by following the reverse procedure.

Pict. 35

Page: 50 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

7.14 OPERATOR PRESENCE SENSOR AND WARNING HORN REPLACEMENT

MOD. ALL MODELS

The operator presence sensor and the warning horn are placed under H
the cabin footboard. In order to have access to these details it is necessary

ELECTRIC
to disassemble the whole footboard.

NECESSARY STANDARD TOOLS

Pict. 36
13-24 mm OPEN- 5 mm ALLEN
ENDED SPANNER WRENCH
I
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the
battery.

Pict. 37
1) Withdraw the upper footboard from the cabin side guards (Ref. H Pict.
36). Remove the lexan footboard (Ref. I Pict. 37). L

2) 5mm ALLEN WRENCH - Loosen and remove the footboard four

fastening screws (Ref. L Pict. 38). Lift one side of the footboard in order
to have access to the sensor and to the warning horn (Pict. 39).

3) 24mm OPEN-ENDED SPANNER - Disconnect the sensor linking

connector. By means of the wrench unscrew and remove the check
nut (Ref. M Pict. 40), withdraw and remove
the sensor. Then replace it.
L Pict. 38
4) 13mm OPEN-ENDED SPANNER - Disconnect
the warning horn linking connector. By means
of the wrench unscrew and remove the warning
horn fixing screw nut (Ref. N Pict. 41). M
Remove and replace the horn.
Pict. 40
Install the sensor or the warning horn by following
the reverse procedure.
N

Pict. 41 Pict. 39

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 51

 Section: TRUCK DESCRIPTION SERVICE

7.15 LIFTING CHAIN BREAKING/LOOSENING SENSOR REPLACEMENT

MOD. MO10E FF - MO10E WP - MO10E SL
ELECTRIC

The inductive sensors are fixed just next to the washers supporting the chain tension rod springs, and
their function is to constantly monitor the correct voltage of the cabin lifting chains. If one or both sensors
break down, they must be replaced.

NECESSARY SPECIAL TOOLS

= Wooden beam 100x100x1000

NECESSARY STANDARD TOOLS

BEAM

4 mm ALLEN
WRENCH

PROCEDURE

Before starting to work wear suitable safety clothes. Pict. 42

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground.

1) WOODEN BEAM - Lift the cabin and insert a wooden beam under it,
next to the bearing support (Pict. 42). Lower the cabin by activating the
emergency valve located over the valve unit and make the cabin itself
rest on the wooden beam. Put the key-operated switch in OFF position
and disconnect the battery. O
Pict. 43

ATTENTION: The beam has a safety function for the whole phase of disassembly and
sensor assembly. Therefore it must be in a standstill and safe position.

2) 4mm ALLEN WRENCH - By means of the wrench loosen the bolts fixing the sensor to the support,
withdraw the sensor, disconnect the linking connector and replace it.

Install the new sensor following the reverse procedure.

Page: 52 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

7.16 STEER CENTERING SENSOR REPLACEMENT

MOD. ALL MODELS

The steer SENSOR is very important for the operator, because it constantly indicates the wheel position
on the display, and it has the function of making the truck slow down according to the steering angle.

ELECTRIC
Moreover, when turning the key on, the truck controls the driving wheel position by always bringing it
back to the central position (this is very important).

NECESSARY STANDARD TOOLS

24 mm OPEN-
ENDED SPANNER
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the
battery.
Pict. 44
1) OPEN-ENDED SPANNER - Remove the motor compartment hood
(Pict. 44) in order to reach the sensor. Before starting the removal
operation, check the sensor reading distance on the reduction unit
upper part (Ref. Q Pict. 459). By means of the wrench loosen the P
sensor lock nut (Ref. P Pict. 45), unscrew the lower nut, withdraw the
sensor from its seat, disconnect the linking connector and replace
the sensor.

Install the new sensor by following the reverse procedure.

Q

Pict. 45

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 53

 Section: TRUCK DESCRIPTION SERVICE

7.17 CABIN SIDE GUARD SENSOR REPLACEMENT

MOD. MO10E SL - MO10E WP

The trucks equipped with side guards have all functions active till they reach a height of 1200mm when
the side guards are open. Beyond this height, it is compulsory to close the side guards in order to have
ELECTRIC

all functions active. The activation of traction, lifting/lowering, and of all safety functions comes from the
reading sensors of the closed side guards. Therefore, if one of these is broken, it blocks the truck and it
must be replaced.

NECESSAY STANDARD TOOLS

24mm OPEN- 5mm ALLEN

ENDED SPANNER WRENCH
PROCEDURE
Pict. 46
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians, lower the
forks to the ground.

1) 5mm ALLEN WRENCH - Lift the cabin till the height of 1000mm in
order to make the operation easier, put the key-operated switch in
OFF position and disconnect the battery. By means of the same
wrench remove the footboard in order to have access to the sensor
R
connectors (See paragraph 7.14 Page 49). Pict. 47

2) 24mm OPEN-ENDED SPANNER - By means of the wrench loosen the sensor lock nut (Ref. R Pict.
47), unscrew the sensor upper nut and withdraw it from its seat, disconnect the linking connector and
replace it.

Install the new sensor by following the reverse procedure.

Page: 54 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

8.00 ENCODER (HEIGHT PRESELECTOR)

MOD. MO10E FF - MO10E SL - MO10E WP

PRESENTATION

ELECTRIC
The ENCODER is the instrument measuring how much the cabin can lift and lower. The measuring
functions by means of a control cable, which makes the encoder rotate at every minimum vertical
movement of the cabin. By rotating, the encoder produces some impulses and transmits them to display
SICOS, which visualizes its height. At every complete descent of the cabin a sensor resets the measure
to zero. If the truck stops while the cabin is lifted, when the truck is restarted, the alarm RESET ENCODER
reappears and blocks all traction and lifting functions, allowing only the lowering at reduced speed till the
total descent is completed. In that moment the count mistake is reset to zero, allowing the truck regular
operation.

ENCODER UNIT COMPONENTS

3 2

7
5

6
9
8

Pict. 48

TABLE OF ENCODER UNIT COMPONENTS

Ref. Component Description
1 ENCODER bearing
2 Encoder motion pulley
3 Flange to fix the encoder to the support
4 Encoder kit support
5 Pulley fixing washer
6 Cable with connector
7 Bolt to fix the pulley to the washer
8 Bolts to fix the encoder flange
9 Encoder seeger on the support

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 55

 Section: TRUCK DESCRIPTION SERVICE

8.01 HEIGHT ENCODER REPLACEMENT

MOD. MO10E SL - MO10E FF - MO10E WP

NECESSARY STANDARD TOOLS

ELECTRIC

8mm - 13mm No. 2 OPEN- MEDIUM OPENING Pict. 49

ENDED SPANNER SEEGER PLIERS

PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground.

1)13mm No. 2 OPEN-ENDED SPANNERS - Lift the cabin till when, looking S
from the front part of the motor hood side, you can see the encoder free T
from obstacles. Put the key-operated switch in OFF position and Pict. 50
disconnect the battery. By means of the two wrenches unscrew the nuts
(Ref. S Pict. 50) and remove the bolts (Ref. T Pict. 50). Disconnect the
linking connector and remove the encoder. U

2)13mm OPEN-ENDED SPANNER - Place the encoder on a clean work

bench. By means of the wrench unscrew and remove the pulley fixing
bolt (Ref. U Pict. 51), remove the pulley and the tab washer as shown in
Pict. 52.

Pict. 51

ENCODER
ROTATION PULLEY
PULLEY TAB
WASHER

Pict. 52

Page: 56 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

3) 8mm OPEN-ENDED SPANNER - By means of the wrench unscrew and

remove the three bolts fixing the encoder to the support (Ref. See Pict.
53).

ELECTRIC
V
4) Remove the ring with the ecoder from the support (Pict. 54)

5) Separate the ring from the encoder (Pict. 55)

Pict. 53

6) PLIERS FOR SEEGER - By means of the pliers remove the seeger ring
from the encoder bearing (Ref. Z Pict. 56-57) and replace it.

Install the new encoder by following the reverse procedure.

Pict. 54
NOTE: During the assembly phase pay attention to the couplings of the
various parts so that the pulley rotatory movement is free.

Pict. 55
Z

Pict. 57 Pict. 56

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 57

 Section: TRUCK DESCRIPTION SERVICE

8.02 REPLACEMENT OF THE ENCODER ZEROING SENSOR

MOD. MO10E SL - MO10E FF - MO10E WP

K
NECESSARY STANDARD TOOLS
ELECTRIC

8mm 24mm
OPEN - ENDED SPANNER

PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians and lower
the forks to the ground.

1) 24mm OPEN-ENDED SPANNER - Lift the cabin in order to see the

encoder and the sensor without obstacles from the front side of the
motor compartment. Set the key switch to OFF and disable the
battery. By means of the spanner unscrew the sensor locking screw
nut (Ref. K Pict. 58), remove the sensor and disconnect the
connector in order to carry out the replacement.

Install the new sensor by following the reverse procedure.

Pict. 59

Pict. 58

sensor for model

K1.0L SL h 3200 Pict. 59b
Page: 58 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE
SERVICE Section: TRUCK DESCRIPTION

8.03 REPLACEMENT OF THE MOTOR COMPARTMENT- CABIN INSTRUMENT PANEL

CONNECTION CABLE MOD. MO10E SL h 3200

NECESSARY SPECIAL TOOLS

ELECTRIC
= No. 2 100x100x1100 wooden beams

NECESSARY STANDARD TOOLS

No.2 13mm 10mm 5mm MEDIUM SLOTTED ELECTRICIAN’S

OPEN-ENDED OPEN-ENDED ALLEN WRENCH SCREWDRIVER SCISSORS
SPANNERS SPANNER

PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians and lower
the forks to the ground.

1) No.2 WOODEN BEAMS - Lift the cabin till the beams pass under
the cabin itself (Pict. 60). Lower the cabin and rest the beams. Set
the key-operated switch to “OFF” and disconnect the battery.

WARNING: The beams have an important safety function

during the whole phase of cable assembly and disassembly. Pict. 60
Therefore they must be placed in a correct and safe position.

2) MEDIUM SLOTTED SCREWDRIVER- Unscrew and remove the

motor compartment hood fastening screws, take away the hood in
order to have access to the systems (Pict. 61).
Disconnect the connector of the cable coming from the cabin (Pict.
62).

Pict. 62 Pict. 61
UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 59
 Section: TRUCK DESCRIPTION SERVICE

3) 5 mm ALLEN WRENCH - 10 mm OPEN-ENDED SCREW -

Screw out the bolts for fastening the cable clamps (Ref. I Pict.
64) and (Ref. L Pict. 65) and remove the clamps.

NOTE: Pay attention to the pulleys; if they have no guards,

ELECTRIC

they fall.

4) No. 2 13 mm OPEN-ENDED SPANNERS - SCISSORS -

Unscrew and remove the bolts for fastening the cable sliding Pict. 66
pulleys (Ref. M Pict. 66) by means of the two spanners. M
Cut the cable ties by means of the scissors and disconnect the
connector of the cable coming from the motor compartment
(Pict. 67). Remove the damaged cable and replace it.

Install the new cable by following the reverse procedure.

Pict. 63

Pict. 67 L Pict. 65 I
Pict. 64

Page: 60 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

9.00 SICOS (DISPLAY)

MOD. ALL MODELS

9.01 CONTROL COMPONENT GENERAL DESCRIPTION

ELECTRIC
14

100
S
L
O
50

20
W Kmh 00 01

2 3 4 5 6 7 8 9 10 11 12 13
Pict. 01

9.02 DISPLAY SYMBOL DESCRIPTION TABLE

Ref. Symbol Description
1 Display configuration
2 Indication of the battery state of charge
3 Indicator of the selected running operation mode
4 Hour meter indicating the working hours when the truck is moving
5 Speed reduction indicator
Indicator of the running direction and of the steering wheel (driving wheel) sense of
6 rotation
7 Truck speed indicator, hour counter, height display, alarms on modules
8 Indicator of the fork lifting/lowering hydraulic function
9 Indicator of the cabin lifting/lowering hydraulic function
10 Numeric pad for the altimeter/preselector setting
11 Key "ENTER" to be used during the reading of the various menus on the display
12 Keys "DOWN/UP'" to be used during the reading of the various menus on the display
13 Key "OUT" to be used during the reading of the various menus on the display
14 Push button to select the running mode

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 61

 Section: TRUCK DESCRIPTION SERVICE

9.03 BATTERY STATE OF CHARGE INDICATOR

It indicates the battery state of charge. The traction control reads the battery and sends data to the display.
The battery state of charge is indicated on the display by means of 10 dashes. Each dash corresponds
to 10%. When the battery state of charge reaches 30%, the three corresponding dashes start flashing.
ELECTRIC

We recommend recharging the battery. When the state of charge reaches 20%, control “COMBI” sends
a message to the display, which must show a charge of 20%. At the same time this control forbids the
lifting function and only traction remains active, but it is reduced of 50% (this allows the truck to return to
the charge state) (Pict. 02).

NOTE: The battery charge indicator works correctly only if the procedure “ADJUST BATTERY” is
correctly performed before the truck is delivered (see the electric system section).

BATTERY
100
S
CHARGE L
O
50

00 01
INDICATOR

20
W Kmh

Pict. 02

9.04 SPEED REDUCTION INDICATOR

It appears when the traction ‘SLOW’ mode is selected, by pressing the push button with symbol
(the same symbol appears on the display) and the truck moves at a speed of 4,5 Km/hour (Pict. 03).
This indicator also appears when there are speed reductions.
TABLE OF SPEEDS OUT OF THE AISLE
Speed Cabin Height Fork Height Upright Steering Steering Angle >10°
M a x S p e e d (9,5 Km /hour) From 0 to 500 mm From 0mm to 800mm Yes
Speed Reduction
"Cutback Speed 1" (4,5 From 500mm to 1700mm From 0mm to 800mm Yes
Km/hour)
Speed Reduction
"Cutback Speed 2" (2,5 From 1700mm to 3200mm From 0mm to 800mm Yes Yes
Km/hour)

TABLE OF SPEEDS IN THE AISLE

Speed Cabin Height Fork Height Upright Steering Steering Angle >10°
M a x S p e e d (9,5 Km /hour) From 0 to 1700 mm From 0mm to 800mm Yes
Speed Reduction
"Cutback Speed 1" (4,5 From 1700mm to 3200mm From 0mm to 800mm Yes
Km/hour)
Speed Reduction
"Cutback Speed 2" (2,5 3 2 0 0 m m a n d o ver From 0mm to 800mm Yes
Km/hour)

SPEED
REDUCTION 100
S
L
INDICATOR
PUSH
O
50

00 01
BUTTON TO

W
SELECT THE
20 Kmh
SPEED
REDUCTION
Pict. 03

Page: 62 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

9.05 DRIVING WHEEL (STEER) RUNNING DIRECTION AND DIRECTION OF ROTATION

INDICATOR

This indicator has two functions which are very useful for the operator: it indicates the machine direction

ELECTRIC
and the position of the steering wheel (with releases of 45°).
The position of the driving/steering wheel and the truck running direction are indicated by the arrow
inside the truck logotype.
During the truck use, the arrow lights up according to the operator’s choice when he selects the forward/
reverse running by enabling the throttle.
Throttle forward, the arrow for the forward running lights up, in the operator’s direction.
Throttle backward, the arrow for the backward running lights up, in the fork direction.
During the running phase, rotating the steering wheel to the right or to the left, the arrow moves with
releases of 45° and indicates the truck direction (Pict. 04).

S
STEERING
100
WHEEL
ROTATION AND
RUNNING O
F
50

00 01
INDICATOR
20
T Kmh

Pict. 04

9.06 HYDRAULIC FUNCTION INDICATION

The hydraulic function which is being carried out is represented by means of an arrow on the display,
both for the cabin and for the forks, as shown by the picture (Pict. 05).

CABIN
100
S MOVEMENT

O
INDICATION

F
50

20
T Kmh 00 01 FORK
MOVEMENT
INDICATION
Pict. 05

9.07 TRACTION OPERATING MODE INDICATOR

It indicates the traction operating mode selected by means of the special push button . This function
allows the operator to personalize the truck traction functions without the technician’s intervention.
Four different functions can be programmed and they are visualized on the display (Pict. 06).

SOFT / SLOW / STD / HARD

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 63

 Section: TRUCK DESCRIPTION SERVICE

SOFT = The acceleration, release braking and max. speed performances are carried out with a
lower level than the programmed ones (8,6 Km/h).
SLOW = Max. speed predefined by means of the console connected to control COMBI and by operating
on parameter CUTBACK SPEED 1 (SICOS), (4 Km/h).
STD = The acceleration, release braking and max. speed standard programmed parameters are
ELECTRIC

observed (9,2 Km/h).

HARD = The acceleration, release braking and max. speed functions are performed with a higher
level than the standard one (9,8 Km/h).

100
S
L
O
50

20
W
100
S
100
S
T
O
F
50 50

20 D 20
T Kmh 00 01
100
H
A PUSH BUTTON TO SELECT
50
R THE TRACTION MODE

20
D Pict. 06

9.08 HOUR COUNTER INDICATOR

The hour meter starts flashing and counting the working hours when any forward/reverse running or
truck lifting/lowering function is being carried out (Pict. 07).

For two seconds after the truck ignition, it indicates the truck total number of hours stored in module
2 COMBI. This indication is then replaced by the truck speed visualization. It is possible to visualize
the truck hours without turning the key off, by pressing key ENTER to reach the main menu and then
key OUT to exit. The truck working hours are displayed for two seconds.

NOTE: When module SICOS is replaced, the stored working hours are lost. On the contrary, when
control COMBI and steer control EPS are replaced, the hours remain stored in module SICOS.

100
S
O
WORKING
HOUR

F
50

00 01
COUNTER
INDICATOR
20
T Kmh

Pict. 07

Page: 64 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

9.09 DISPLAY (SICOS) MENU

In order to enter the various display menus from the general configuration, press push button ENTER. In
this way you can enter page MAIN MENU 1 (Pict. 08).
By pressing the arrow UP or DOWN push button, you can move the arrow cursor to the entry corresponding

ELECTRIC
to reading.
The MAIN MENU 1 submenus are explained in the following paragraphs.

ARROW
main menu 1 UP

TESTER DISPLAY
ALARMS OUT
PROGRAM OFFSET
INSERT PASSWORD ARROW
DOWN
ENTER

Pict. 08

9.10 MENU “TESTER”

By entering menu “tester”, the main information about control COMBI status parameters is displayed.
TESTER 1 refers to traction and lifting with values expressed in mV and to the cabin and fork encoder
operation with values expressed in pulses (Pict. 09).

tester 1
TRACTION ACCEL = 0000 mV
LIFT ACCEL = 2392 mV
CABIN ENCODER = 00000
FORK ENCODER = 00000

Pict. 09

By pressing the arrow UP push button you can pass to screenful TESTER 2 (Pict. 10), which displays
the truck function active inputs.

TESTER 2

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 65

 Section: TRUCK DESCRIPTION SERVICE

FUNCTION INPUT DESCRIPTION

In the display page (Pict. 10) some numbers are highlighted just next to the cells that light up when some
functions are performed.
The numbers indicate the push buttons or sensors which are enabled according to the required function.
ELECTRIC

The corresponding cell that lights up indicates the function is active. The table represented below indicates
which are the functions that refer to the display number and to the functional wiring diagram.

INPUT CORRESPONDENCE TABLE

Ref.
Ref. Displayed Input Description
Diagram
I1 FW It indicates that the truck is moving with forward running
I2 RV It indicates that the truck is moving with reverse running
I3 SW4 It indicates that the operator presence push button is pressed
I4 SW13-14 It indicates that the "lifting block" device has intervened on the mast or on the overhead guard
I5 SW6 It indicates that the fork lifting push button has been pressed
I6 SW7 It indicates that the fork lowering push button has been pressed
I7 J2 It indicates that the emergency braking has been activated
I8 SW5 It indicates that push button BY PASS of the lifting unit has been pressed
I9 SW8-9 It indicates that the cabin side guards are closed
I 10 SW31 It indicates that the fork lifting push button has been pressed
I 11 SW30 It indicates the fork lowering block at 150mm
I 12 SW17 It indicates the truck manual or automatic operation with wire guide
I 13 SW10 It indicates that the push button for the drive in the aisle and for the cabin lifting/lowering has been pressed
Software coding key. It modifies the serial communication between the two controls in order to improve the
I 14 SW10 performance
I 15 J1 It indicates that the cabin lifting Joystick central microswitch is active
I 16 SW19 It indicates the fork lifting encoder reset to zero
I 17 SW18 It indicates the cabin lifting encoder reset to zero
I 18 SW24-25 It indicates the photo electric cell reading when the truck is in the aisle
I 19 SW28-29 It indicates that the backing push button has been pressed (truck moving forward with operator on the ground)
I 20 SW21 It indicates the reading of the sensor that checks the cabin encoder good working

9.11 MENU “ALARMS”

By entering menu ALARMS the last 5 stored alarms are displayed with information about the
corresponding module, the number of times the alarm has appeared, the temperature, the hour it
happened and the corresponding module (Pict. 11). By pressing ENTER, CLEAR ALARMS appears; by
pressing OUT, the alarms remain stored, while by pressing ENTER they are cancelled.
MOD 1 = Display “SICOS”
MOD 2 = Control “COMBI”
MOD 6 = Control “EPS-AC”

ALARMS HOURS NUM NTC MOD

1) EMERGENCY 0002 01 49 02
2) SERIAL ERROR # 1 0001 02 23 01
3) EVP NOT OK 0001 01 31 02
4) LINE SHORTED 0000 01 37 06
5) V FIELD NOT OK 0000 01 37 02
Pict. 11

Page: 66 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

9.12 INSERT PASSWORD

Submenu to insert the password enabling the truck use (This option is useful when the access passwords
are inserted in paragraph “PROGRAM PASSWORD”).

ELECTRIC
9.13 MAIN MENU 2

Besides MAIN MENU 1, there is MAIN MENU 2: this menu is hidden to the operator and it can be reached
only by turning the key off.
Press push button OUT and, at the same time, turn the key on. The main screenful appears. By pressing
ENTER, the page MAIN MENU 1 appears, from which, by pressing key ARROW DOWN, you can enter MAIN
MENU 2 (Pict. 12).

main menu 1

TESTER DISPLAY ENTER

ALARMS
PROGRAM OFFSET
INSERT POSSWORD

main menu 2
ARROW
PROGRAM BLOCK 1
PROGRAM BLOCK 2 DOWN
PROGRAM BLOCK F
PROGRAM PASSWORD
RESD USERS
PROGRAM BLOCK T Pict. 12

If you press ENTER from a certain position of the arrow cursor, you can reach the page of the desired
entry.

9.14 PROGRAM PASSWORD

Five passwords can be set, allowing 5 different operators to have access to the truck.
In order to set the passwords in the menu, it is necessary to perform the procedure described below:

1) When the truck is stopped, connect the console to module SICOS (display) (Connect it to module EPS-
AC, see procedure on Page 34) and turn the key on (KEY ON).
2) By means of the console, enter menu CONFIG MENU and select SET OPTIONS.
3) By means of keys ROLL / UP select parameter PASSWORD and put it in ON position, press OUT,
then press ENTER in order to store. Turn the key off (KEY OFF) and disconnect the console.
4) Perform the procedure in order to enter MAIN MENU 2.
5) By means of arrow UP/DOWN choose parameter PROGRAM PASSWORD and press ENTER in
order to enter the page (Pict. 13).

set password
PASS1 = 1986
PASS2 = 0000
PASS3 = 0000
PASS4 = 0000
PASS5 = 0000
Pict. 13
UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 67
 Section: TRUCK DESCRIPTION SERVICE

6) Set the four number password by using the display numeric pad (Pict. 16).
7) Press ENTER to store the set password. Entry MEMO appears to confirm.
8) Press KEY OFF, then press KEY ON to store.

From this moment on, in order to have access to the truck functions, it is necessary to insert one of the
ELECTRIC

predefined passwords.

If function PASSWORD is enabled, when the truck is started (KEY ON), ALARM ON MOD 1 PASSWORD
NEEDED (Pict. 15) appears on the display.

100
S
L
O
50
ALARM ON MOD 1
20
W PASSWORD NEEDED

Pict. 15

In order to insert the access password perform the procedure described below:

1) Press ENTER to enter MAIN MENU 1 of the main display.

2) Select parameter INSERT PASSWORD by using arrow UP/DOWN. Then press ENTER.
3) Set the four number stored password by using the display numeric pad (Pict. 16).

INSERT YOUR
PASSWORD !

1986

Pict. 16

4) Press ENTER to return to the main screenful and to the truck enabling.

9.15 MENU “READ USERS”

By entering menu READ USERS of MAIN MENU, the truck working hours at the end of each operator’s
shift (Pict. 17) are displayed.

users log book

USERS = 1986
HOURS = 0006

Pict. 17

Page: 68 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

10.00 HEIGHT INDICATOR (PRE HEIGHT SELECTOR)

MOD. MO10E FF - MO10E SL - MO10E WP

All trucks equipped with a cabin that may be lifted are also equipped with an height indicator, which consists
in the installation on the cabin structure of an ENCODER and of a sensor to reset the measure to zero.

ELECTRIC
The measuring is effected by means of a control cable (fixed on the structure), which makes the encoder
rotate at each minimum vertical movement of the cabin.
During the rotation the encoder produces some pulses and transmits them to display SICOS, which
displays the encoder height.
At every complete descent of the cabin, the sensor resets the measure to zero. If the truck stops while
the cabin is being lifted, when the truck is restarted, alarm “RESET ENCODER” reappears and blocks
all traction and lifting functions, allowing only the lowering at reduced speed till the total descent is
completed. In that moment the count is reset to zero, allowing the truck regular operation.
The preselector allows the operator to constantly see how much the cabin is lifted from the floor. Moreover,
it can program the cabin lifting block next to obstacles which can be found in the aisles.

SENSOR TO RESET THE

MEASURE TO ZERO

DISPLAY “SICOS”
CONTROL CABLE

HEIGHT ENCODER Pict. 01

Before programming the various “PRESELECTOR” functions, check that parameter “ENCODER
TYPE” in “Set Options” is set on “1” (cabin encoder present) on control “SICOS” display.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 69

 Section: TRUCK DESCRIPTION SERVICE

10.01 PROGRAM OFFSET

It must be set only when the height indicator and vertical preselector functions are present.
The height indicator encoder must be set so that the reading takes place when the forks start lifting the
pallet. Parameter PROGRAM OFFSET allows calculating the platform footboard height from the ground
ELECTRIC

(in mm). This value must be added by the display module to the count of the height indicator encoder.

Value setting:

1) Start the truck KEY ON

2) With cabin and forks lowered, measure the fork height from
the ground as shown in Pict. 02
3) Press ENTER on the display and enter MAIN MENU 1
4) Select menu PROGRAM OFFSET by means of arrow UP/
DOWN
5) Press key ENTER to enter PROGRAM OFFSET

h 180mm
6) Set the value (in mm) of the fork height from the ground on
the display by means of the numeric pad (Pict. 12)
7) Press ENTER. “MEMO” appears to confirm the set value
8) Put the key-operated switch in KEY OFF and then KEY
ON position in order to store (Pict. 03)
Pict. 02

adjustment

OFFSET VALUE = 00180

Pict. 03

10.02 PROGRAM BLOCK 1 (CABIN LIFTING FIRST BLOCK)

It allows setting a first block of the cabin lifting.

Before programming, connect the console and enter module 1 “SICOS” (see the access procedure of
the modules on Page 34). Select Config. Menu “Set Options”, select parameter “AUX FUNCTION
#1” and put it in “ON” position. Select parameter “CABIN ENABLE” and put it in “ON” position.

DISPLAY PROGRAMMING PROCEDURE

1) Press push button OUT and, at the same time, turn the key on (KEY ON). Keep the push button
pressed until the main display appears (Pict. 04). Release the push button.

Page: 70 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

100
S
O
F
50

00 01

ELECTRIC
20
T Kmh

Pict. 04

2) Press key ENTER to enter MAIN MENU 1

3) By means of arrow UP/DOWN select paragraph PROGRAM OFFSET, press ENTER and check the
correctness of the platform height from the ground set value
4) Press key OUT twice in order to enter the main menu
5) Lift the cabin up to the desired height
6) Follow the procedure to enter MAIN MENU 2

ENTER
main menu 2
PROGRAM BLOCK 1
PROGRAM BLOCK 2
PROGRAM BLOCK F
PROGRAM PASSWORD
READ USERS
PROGRAM BLOCK T ARROW
Pict. 05 DOWN

7) By means of arrow UP/DOWN select parameter PROGRAM BLOCK 1 (Pict. 05), press ENTER in
order to enter the page (Pict. 06).

autoteaching
HEIGHT VALUE = 00180
ENCODER VALUE = 00000

Pict. 06
8) Set the desired measure (in mm) by using the display numeric pad (Pict. 07)
9) Press ENTER in order to store the set value. Entry MEMO appears for confirmation
10) Press KEY OFF and then KEY ON in order to store (Pict. 07).

autoteaching
HEIGHT VALUE = 00180

ENCODER VALUE = 02500

Pict. 07

In order to re-enable the lifting, press push button “SW 11” and, at the same time, activate the lifting
lever.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 71

 Section: TRUCK DESCRIPTION SERVICE

10.03 PROGRAM BLOCK 2 (CABIN LIFTING SECOND BLOCK)

It allows setting a second block of the cabin lifting. Before programming, connect the console and enter
module 1 “SICOS” (see the module access procedure on Page 34). Select Config. Menu “Set Options”,
select parameter “AUX FUNCTION # 1” and put it in “ON” position. Select parameter “CABIN ENABLE”
ELECTRIC

and put it in “ON” position.

DISPLAY PROGRAMMING PROCEDURE

1) Press push button OUT and, at the same time, turn the key on (KEY ON). Keep the push button
pressed till when the main display appears (Pict. 08). Release the push button.

100
S
O
F
50

20
T Kmh 00 01
Pict. 08

2) Press key ENTER in order to enter MAIN MENU 1

3) By means of arrow UP/DOWN select paragraph PROGRAM OFFSET, press ENTER and check
the correctness of the fork height from the ground set value
4) Press key OUT twice in order to enter the main menu
5) Lift the forks up to the desired height
6) Perform the procedure to enter MAIN MENU 2

ENTER
main menu 2
PROGRAM BLOCK 1
PROGRAM BLOCK 2
PROGRAM BLOCK F
PROGRAM PASSWORD
READ USERS
PROGRAM BLOCK T ARROW
DOWN
Pict. 09

7) By means of arrow UP/DOWN select parameter “PROGRAM BLOCK 2” (Pict. 09), press ENTER
in order to enter the page (Pict. 10).

autoteaching
HEIGHT VALUE = 00180

ENCODER VALUE = 00000

Pict. 10

Page: 72 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

8) Set the desired measure (in mm) by using the display numeric pad (Pict. 11)
9) Press ENTER in order to store the set value. Entry MEMO appears for confirmation
10) KEY OFF then KEY ON in order to store (Pict. 11).

ELECTRIC
autoteaching

HEIGHT VALUE = 00180

ENCODER VALUE = 03000

Pict. 11
In order to re-enable the lifting, press push button “SW 11” and, at the same time, activate the lifting
lever.

10.04 PROGRAM BLOCK F (FORK LIFTING INTERMEDIATE BLOCK)

It allows setting a block of the fork lifting. Before programming, connect the console and enter module 1
“SICOS” (see the access procedure of the modules on Page 34). Select Config. Menu “Set Options”,
select parameter “AUX FUNCTION # 1” and put it in “ON” position. Select parameter “FORKS
ENABLE” and put it in “ON” position.

DISPLAY PROGRAMMING PROCEDURE

1) Press push button OUT and, at the same time, turn the key on (KEY ON). Keep the push button
pressed till the main display appears (Pict. 12). Release the push button.

100
S
O
F
50

20
T Kmh 00 01
Pict. 12

2) Press push button ENTER in order to enter MAIN MENU 1

3) By means of arrow UP/DOWN select paragraph PROGRAM OFFSET, press ENTER and check the
correctness of the fork height from the ground set value
4) Press key OUT twice in order to enter the main menu
5) Lift the forks up to the desired height
6) Perform the procedure to enter MAIN MENU 2

ENTER
main menu 2
PROGRAM BLOCK 1
PROGRAM BLOCK 2
PROGRAM BLOCK F
PROGRAM PASSWORD
READ USERS
PROGRAM BLOCK T ARROW
DOWN
Pict. 13

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 73

 Section: TRUCK DESCRIPTION SERVICE

7) By means of arrow UP/DOWN choose parameter “PROGRAM BLOCK F” (Pict. 13), press ENTER
in order to enter the page (Pict. 14)

autoteaching
ELECTRIC

HEIGHT VALUE = 00180

ENCODER VALUE = 00000

Pict. 14
8) Set the desired measure (in mm) by using the display numeric pad (Pict. 15)
9) Press ENTER in order to store the set value. Entry MEMO appears for confirmation
10) Press KEY OFF and then KEY ON in order to store (Pict. 15).

autoteaching

HEIGHT VALUE = 00180

ENCODER VALUE = 00500

Pict. 15
In order to re-enable the lifting, press push button “SW 11” and, at the same time, activate the lifting push
button.

10.05 PROGRAM BLOCK T (TRACTION BLOCK WHEN THE CABIN IS AT A CERTAIN

HEIGHT)

It allows setting a traction block when the cabin is at a certain height. Before programming, connect the
console and enter module 1 “SICOS” (see the access procedure of the modules on Page 34). Select
Config. Menu “Set Options”, select parameter “BLOCK TRACTIONS” and put it in “ON” position.

DISPLAY PROGRAMMING PROCEDURE

1) Press push button OUT and, at the same time, turn the key on (KEY ON). Keep the push button
pressed till the main display appears (Pict. 16). Release the push button.

100
S
O
F
50

20
T Kmh 00 01
Pict. 16
2) Press key ENTER to enter MAIN MENU 1
3) By means of arrow UP/DOWN select paragraph PROGRAM OFFSET, press ENTER and check the
correctness of the fork height from the ground set value
4) Press key OUT twice in order to enter the main menu
5) Lift the forks up to the desired height
6) Perform the procedure to enter MAIN MENU 2

Page: 74 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ENTER
main menu 2

PROGRAM BLOCK 1
PROGRAM BLOCK 2
PROGRAM BLOCK F

ELECTRIC
PROGRAM PASSWORD
READ USERS
PROGRAM BLOCK T ARROW
DOWN
Pict. 17
7) By means of arrow UP/DOWN choose parameter “PROGRAM BLOCK T” (Pict. 17), press ENTER
in order to enter the page (Pict. 18)

autoteaching

HEIGHT VALUE = 00180

ENCODER VALUE = 00000

Pict. 18
8) Set the desired measure (in mm) by using the display numeric pad (Pict. 19)
9) Press ENTER in order to store the set value. Entry MEMO appears for confirmation
10) Press KEY OFF and then KEY ON in order to store (Pict. 19).

autoteaching
HEIGHT VALUE = 00180
ENCODER VALUE = 02500

Pict. 19
In order to re-enable the traction, activate the cabin descent under the traction block set level.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 75

 Section: TRUCK DESCRIPTION SERVICE

10.06 CONFIGURATION OF THE DISPLAY FOR THE SLOWING DOWN/STOP OF THE

TRUCK WITH PREARRANGED ROLLERS IN THE CORRIDORS WITH SIDE GUIDES

The trucks, on request, can be equipped with a system for slowing down and stopping at the aisle end,
ELECTRIC

and are equipped with photoelectric cells signalling the presence in the aisle. These photoelectric cells
activate all safety devices necessary to operate. When the system for slowing down and stopping is
prearranged, the display has another configuration (Pict. 20): the truck is in the middle of the aisle with
four small squares on the left side. These squares light up when the truck passes on the four magnets
positioned in the aisle, on the ground.

100

PILOT LIGHTS
SIGNALLING THE 50

D 09 80
TRUCK PASSAGE ON
THE MAGNETS 20 Kmh

TRUCK IN THE AISLE WITH MECHANICAL GUIDES Pict. 20

If the slowing down system is assembled afterwards by the dealer, it is necessary to vary the setting of
parameter “END AISLE SAFETY” after the installation.
Connect the console to module 2 “COMBI”, select Config. Menu “Set Options”, select parameter
“END AISLE SAFETY” and set the parameter according to the requirements:

a) 0 = No safety device at the end of the aisle

b) 1 = Only slowing down or stop at the end of the aisle
c) 2 = Slowing down and stop at the end of the aisle

EXAMPLE OF MAGNET POSITIONING IN THE AISLE

WITH WIRE GUIDE

Page: 76 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

10.07 TRUCK OPERATION IN THE AISLE AND VISUALIZATION ON THE DISPLAY

1) By entering the aisle, the truck travels at a max. speed of 4 Km/h

2) By reading magnets one and two (Pict. 21-22), the truck max. speed becomes 9,80Km/h
NOTE: The truck speed in the aisle depends on the height at which you operate with the cabin

ELECTRIC
Speed Cabin Height Fork Height Steer Upright
Max Speed (9,5 Km/hour) From 0 to 1700 mm From 0 mm to 800 mm Yes
Speed Reduction
"Cutback Speed 1" (4,5 From 1700 mm to 3200 mm From 0 mm to 800 mm Yes
Km/hour)
Speed Reduction
"Cutback Speed 2" (2,5 From 3200 mm and over From 0 mm to 800 mm Yes
Km/hour)

100
S
O
F
50

20
T Kmh 09 0
FIRST MAGNET READING Pict. 21

100

50

20 D Kmh 09 80
SECOND MAGNET READING Pict. 22
3) By reading the third and fourth magnet (Pict. 23-24), the truck slows down till it travels at a speed of 2,5 Km/
h and stops, or just slows down or stops according to parameter “END AISLE SAFETY” setting.

100

50

20 D Kmh 09 80
THIRD MAGNET READING Pict. 23

100

50

20 D Kmh 09 80
FOURTH MAGNET READING Pict. 24
In order to re-enable the truck, leave the running potentiometer in rest position. If you use the reverse running
and you enter the aisle, the truck travels at the max. speed. When going out of the aisle, the truck travels at a
speed of 4 Km/h till the aisle change has been completed.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 77

 Section: TRUCK DESCRIPTION SERVICE
10.08 CONFIGURATION OF THE DISPLAY FOR THE TRUCK SLOWING DOWN/STOP
WITH PREARRANGED WIRE GUIDE
The operation of the truck with wire guide in the aisle is the same one of the truck with side guides. The
display is configured with a straight line in the centre of the truck logotype, indicating that the truck is
equipped with wire guide.
ELECTRIC

100
S
O
F
50

20
T Kmh 00 01
CONFIGURATION OF THE TRUCK WITH WIRE GUIDE IN THE AISLE Pict. 25

100
S
O
F
50

20
T Kmh 09 80
,

READING OF THE FIRST MAGNET Pict. 26

100

50

20 D Kmh 09 80
READING OF THE SECOND MAGNET Pict. 27

100

50

20 D Kmh 09 80
READING OF THE THIRD MAGNET Pict. 28

100

50

20 D Kmh 09 80
READING OF THE FOURTH MAGNET Pict. 29

Page: 78 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

11.00 DIAGNOSTICS

In this section the alarm codes identifying the possible defects are described. During operation the control
stores the last 5 anomalies, the alarm identification code, the number of times the same alarm has
occured, the working hours and the control temperature at which it has occured.

ELECTRIC
These alarms are visualized on display SICOS and the module on which the alarm has occured is
identified.

11.01 MODULE 2 = CONTROL “COMBI”

DESCRIPTION AND MEANING OF THE DISPLAYED ALARMS

ALARM VISUALIZATION ON ALARM DESCRIPTION

DISPLAY SICOS AND ON THE POSSIBLE CAUSES
CONSOLE SOLUTIONS TO BE ADOPTED

EVP NOT OK Tha alarm appears when there are problems in the solenoid
valve.
Possible causes:
a) disabled open proportional valve;
b) proportional valve too much open or too much closed.
c) wrong connection of the mains cables
Solutions:
a, b) replace the solenoid valve
c) restore the connections as indicated in the diagram

BRAKE DRIVER KO The alarm appears when there is a problem on the

electromagnetic brake driver.
Possible causes:
a) shorted driver
b) broken driver, unable to control the electromagnetic
brake
c) shorted brake coil during running
Solutions:
a, b) replace the control
c) replace the electromagnetic brake

VFIELD NOT OK The test is performed when the main contactor is disabled.
In this condition the voltage on both field connections must
be of about 1/2 VBatt.
The alarm appears whenever the voltage is different from
that value.
Possible causes:
a) motor earth-leakage;
b) the motor field is not connected to the control;
c) fault of the power unit section of the field.
Solutions:
a) clean the motor and restore the insulation or replace the
motor
b) restore the correct connection as in the diagram
c) replace the control

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 79

 Section: TRUCK DESCRIPTION SERVICE
ALARM DESCRIPTION
ALARM VISUALIZATION ON
POSSIBLE CAUSES
DISPLAY SICOS AND ON THE CONSOLE
SOLUTIONS TO BE ADOPTED
PUMP VACC NOT OK The alarm appears when the truck is started or stopped, if
the joystick potentiometer value is 1V higher. There must
ELECTRIC

be a problem in the Joystick.

Possible causes:
a) wrong connection of the sheath to the Joystick
b) the potentiometer is faulty;
c) the potentiometer is badly calibrated.
Solutions:
a) perform the right connections as shown in the diagram
b) replace the lifting Joystick
c) perform the correct programming

LOGIC FAILURE # 3 The alarm appears because the running and intermittent
running command is not correctly transmitted between Sicos
and control COMBI, with operator on the ground.
Possible causes:
a) the auxiliary contacts of the main contactor do not close
b) false contacts on the linking connector between Combi and
Sicos
Solutions:
a) replace the main contactor
b) replace the flexible cord

SERIAL ERROR # 2 The alarm appears because of a serial lack of

communication between control Combi and card Sicos
Possible causes:
a) the serial flexible cord between Combi and Sicos is
disconnected
b) the control does not answer to the signals sent by Sicos
c) card Sicos is faulty.
Solutions:
a) replace the serial flexible cord
b) replace control Combi
c) replace card Sicos
WATCHDOG The alarm appears because of the intervention on circuit
watchdog inside the control.
Possible causes:
a) the watchdog hardware circuit does not work correctly
b) the software does not work correctly
Solutions:
a, b) if turning the key off and on, the alarm does not
disappear, replace the control
EEPROM KO The alarm appears because of a fault in the EEPROM
memory area in which the configured parameters are
stored. Turn the key off and on. If the fault persists:
- if by turning the key off and on, the alarm does not
disappear, replace the control.

Page: 80 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ALARM VISUALIZATION ON ALARM DESCRIPTION

DISPLAY SICOS AND ON THE CONSOLE POSSIBLE CAUSES
SOLUTIONS TO BE ADOPTED

FORW + BACK The alarm appears when forward and reverse running are
enabled at the same time

ELECTRIC
Possible causes:
a) faulty wiring
b) driving microswitch closed
c) wrong operator manoeuvre
Solutions:
a) perform the right wiring as shown in the diagram
b) replace the steering wheel card
c) perform the correct starting operation

VMN NOT OK The test is performed with the truck at rest, with the main
contactor closed, and during running. At rest, if the VMN
voltage is lower than the battery value, an alarm intervenes.

Possible causes:
a) motor earth-leakage
b) shorted traction motor
c) wrong cable connections between the traction motor
and the control
d) fault in Combi field section
Solutions:
a) clean and blow with air in order to remove the dust
b) replace the traction motor
c) restore the wiring as in the wiring diagram
d) replace control Combi

CONTACTOR CLOSED Test performed before any closing of the main contactor. It
checks the main contactor contact is actually open.
Possible causes:
a) main contactor contact closed;
b) faulty Combi power unit
Solutions:
a) replace the main contactor
b) replace control Combi

I = 0 EVER This test is performed with the truck moving. It checks the
traction current is higher than a minimum threshold value. If
this does not happen, the alarm appears and clears all truck
functions.
Possible causes:
a) faulty control Combi current sensor
b) fault of the logic feedback circuits
Solutions:
a, b) replace the control

STBY I HIGH Test performed during the initial diagnosis and at rest. It
checks if the current signals are null. If this does not happen,
the alarm appears and clears all truck functions.

P.T.O.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 81

 Section: TRUCK DESCRIPTION SERVICE

ALARM DESCRIPTION
ALARM VISUALIZATION ON
POSSIBLE CAUSES
DISPLAY SICOS AND ON THE CONSOLE
SOLUTIONS TO BE ADOPTED
Possible causes:
ELECTRIC

a) faulty control Combi current sensor

b) fault of the logic feedback circuits
Solutions:
a, b) replace the control

HIGH FIELD CURRENT. Fault in the control or traction motor field current measurement
Possible causes:
a) short circuit in the traction motor field
b) fault of control Combi transducer
c) fault of Combi power unit
Solutions:
a) replace the traction motor
b, c) replace the control

NO FIELD CURRENT Anomaly in the control field current.

Possible causes:
a) anomaly in the current transducer;
b) defect in the field power unit.
c) field cables not connected or badly connected
Solutions:
a, b) replace control Combi
c) reset the cable connection as shown in the wiring
diagram

CAPACITOR CHARGE The test is performed during the initial diagnosis. The alarm
appears if, 500ms after KEY ON, the capacitors have not yet
started to charge. A probable cause is a defect in the power
unit.
Possible causes:
a) faulty main contactor
b) shorted brush cable with motor casing
c) fault in the logic unit
Solutions:
a) replace the main contactor
b) replace the traction motor and dust blowing brushes
c) replace the control

BATTERY LOW It reduces the traction current and blocks the lifting.
Exhausted battery alarm, signalled with 20% of residual
charge. If the alarm appears when the battery is charged,
check the battery value read in the console menu TESTER;
if it is wrong, perform a fine adjustment of CONFIG MENU
- ADJUSTMENT.

Page: 82 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ALARM VISUALIZATION ON ALARM DESCRIPTION

DISPLAY SICOS AND ON THE CONSOLE POSSIBLE CAUSES
SOLUTIONS TO BE ADOPTED
THERM PROTECTION Alarm for temperature > 80°C; the maximum armature

ELECTRIC
current is reduced till it is between 0 and 90°C; the alarm is
reset if the temperature is lower than 70°C; the current
reduction however starts at 75°C. If the temperature is <-
10°C the maximum current is reduced to 80%.
Possible causes:
a) faulty control when the temperature exceeds 80°C
Solutions:
a) replace the control

POWER FAILURE #1 The alarm appears when there is a short circuit on the
control external components
Possible causes:
a) shorted solenoid valve ON/OFF
b) shorted main contactor coil
c) shorted electromagnetic brake coil
Solutions:
a) replace the solenoid valve
b) replace the main contactor
c) replace the electromagnetic brake

DRIVER SHORTED The test is performed with main contactor open. It checks
the main contactor driver is not shorted.
Possible causes:
a) shorted control driver;
b) fault in the feedback circuit of the main contactor coil
voltage;
c) fault in the main contactor coil wiring
d) fault in the hardware protection circuit
Solutions:
a, b, d) replace the control
c) perform the correct wiring as shown in the diagram

CONTACTOR DRIVER The test is performed with closed main contactor and checks
the driver is not open.
Possible causes:
a) coil driver open;
b) fault in the main contactor coil voltage feedback circuit.
Solutions:
a, b) replace the control

VACC NOT OK The alarm indicates that the traction accelerator voltage
received by the traction potentiometer is 1V higher than the
one present when the truck is started.
Possible causes:
P.T.O.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 83

 Section: TRUCK DESCRIPTION SERVICE
ALARM DESCRIPTION
ALARM VISUALIZATION ON
POSSIBLE CAUSES
DISPLAY SICOS AND ON THE CONSOLE
SOLUTIONS TO BE ADOPTED
a) wrong connection of the traction potentiometer
b) the traction potentiometer is faulty
ELECTRIC

c) wrong programming of the traction potentiometer

Solutions:
a) perform the correct wiring as shown in the diagram.
b) replace the potentiometer
c) perform the correct programming

INCORRECT START The alarm is caused by a wrong start sequence.

Possible causes:
a) wrong running sequence
b) when the truck is started, the control detects an anomaly
in the accelerator card
Solutions:
a) release the throttle, the alarm disappears, perform the
correct sequence
b) replace the accelerator card

COIL SHORTED The alarm appears when there is an overcurrent of the main
contactor driver
Possible causes:
a) wrong wiring connections
b) shorted main contactor coil
c) fault in the hardware protection circuit
Solutions:
a) perform the correct wiring as shown in the diagram
b) replace the main contactor
c) replace the control

SAFETY The alarm appears if the safety input on control EPS

remains open when the key is turned on.
Possible causes:
a) the safety connection between EPS and Combi is
interrupted
b) the signal output from EPS card is null
Solutions:
a) restore the connections as shown in the wiring diagram
b) replace control EPS

SECURITY INCORRECT START The alarm appears when the safety input on control EPS
is closed when the key is turned on.
Possible causes:
a) the safety relay is closed
Solutions:
a) replace control EPS

EMERGENCY The alarm appears when the emergency push button is

pressed while the key is turned on.
Turn the key off and enable the main push button, switch
on the truck in the correct way.

Page: 84 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ALARM VISUALIZATION ON ALARM DESCRIPTION

DISPLAY SICOS AND ON THE CONSOLE POSSIBLE CAUSES
SOLUTIONS TO BE ADOPTED
CHAIN The alarm is caused by the reading sensor of the cabin

ELECTRIC
lifting chains. This sensor indicates that the chains have
been loosened.
Possible causes:
a) faulty reading sensor
b) loosened chains
Solutions:
a) replace the sensor
b) restore the chains to their original state by means of the
chain tightener or replace them if they have been lengthened
over the standard value

AISLE AT KEY ON The alarm appears when the truck is started and signals
that it is in the aisle
Possible causes:
a) the aisle photoelectric cell is interrupted
b) the photoelectric cell connecting cable is broken
Solutions:
a) replace the photoelectric cell
b) replace the connecting cable

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 85

 Section: TRUCK DESCRIPTION SERVICE

11.02 MODULE 1 = DISPLAY “SICOS”

DESCRIPTION AND MEANING OF THE DISPLAYED ALARMS

ELECTRIC

ALARM VISUALIZATION ON ALARM DESCRIPTION

DISPLAY SICOS AND ON THE CONSOLE POSSIBLE CAUSES
SOLUTIONS TO BE ADOPTED
FORW + BACK The alarm appears when the forward and backward running
are enabled at the same time.
Possible causes:
a) faulty wiring
b) driving microswitch closed
c) operator wrong manoeuvre
Solutions:
a) perform the correct wiring as shown in the diagram
b) replace the steering wheel card
c) perform the correct starting operation

EMERGENCY The alarm appears when the emergency push button is

pressed while the key is turned on.
Turn the key off and enable the main push button, start the
truck correctly.

VACC NOT OK The alarm indicates that the traction accelerator voltage
received from the traction potentiometer is 1V higher than
the one present when the truck is started.
Possible causes:
a) wrong connection of the traction potentiometer
b) faulty traction potentiometer
c) wrong programming of the traction potentiometer
Solutions:
a) perform the correct wiring as shown in the diagram.
b) replace the potentiometer
c) perform the correct programming

EEPROM KO The alarm appears for a fault in the EEPROM memory

area in which the configured parameters are stored. If the
fault persists after turning the key off and on:

-REPLACE the EPS control

INCORRECT START The alarm is caused by a wrong start sequence during

traction.
Possible causes:
a) wrong running sequence
b) when the truck is started, the control detects an anomaly
in the accelerator card
Solutions:
a) release the throttle, the alarm disappears, perform the
correct sequence
b) replace the accelerator card

Page: 86 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ALARM DESCRIPTION
ALARM VISUALIZATION ON
POSSIBLE CAUSES
DISPLAY SICOS AND ON THE CONSOLE
SOLUTIONS TO BE ADOPTED
POT # 1 NOT OK The alarm identifies that the voltage on the lifting

ELECTRIC
potentiometer (Joystick) is 1V higher than the one present
when the truck is started.
Possible causes:
a) wrong joystick connection
b) faulty potentiometer
c) wrong progamming of the potentiometer
Solutions:
a) perform the correct wiring as shown in the diagram
b) replace the joystick
c) perform the correct programming of the potentiometer

ST. NOT STRAIGHT The alarm is caused by the steer when it is not upright,
with request of self-aligning, active when the truck is
started.
Possible causes:
a) wrong wiring, the request does not reach control EPS
Solutions:
a) perform the wiring correctly as shown in the diagram

LOGIC FAILURE # 1 The alarm is caused by the fact that the presence in the
aisle signal on control Combi does not correspond to the
one present on display Sicos
Possible causes:
a) wrong wiring
Solutions:
a) perform the wiring correctly, as shown in the diagram

LOGIC FAILURE # 2 The alarm is caused by the fact that the backing input signal
on control Combi does not correspond to the one present
on display Sicos
Possible causes:
a) wrong wiring
Solutions:
a) perform the wiring correctly, as shown in the diagram

LOGIC FAILURE # 3 The alarm is caused by the fact that the forward/reverse
running input signal on control Combi does not correspond
to the one present on display Sicos
Possible causes:
a) wrong wiring
Solutions:
a) perform the wiring correctly, as shown in the diagram

INCORRECT START PUMP The alarm is caused by the wrong lifting start or by the
lifting request when the truck is started.
Solutions:
release the lifting lever and perform the correct sequence.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 87

 Section: TRUCK DESCRIPTION SERVICE

ALARM DESCRIPTION
ALARM VISUALIZATION ON
POSSIBLE CAUSES
DISPLAY SICOS AND ON THE CONSOLE
SOLUTIONS TO BE ADOPTED
SERIAL ERROR # 1 The alarm is caused by a lack of serial communication
ELECTRIC

between control Combi and display Sicos

Possible causes:
a) serial linking cable interrupted
b) serial cable wrong wiring
Solutions:
a) replace the serial cable
b) perform the correct wiring, as shown in the diagram

PEDAL WIRE KO The alarm appears when the accelerator minimum and
maximum values are out of the programmed standards.
Possible causes:
a) potentiometer power supply short circuit
b) disconnected positive mains cable
Solutions:
a) replace the potentiometer
b) perform the correct wiring, as shown in the diagram

POWER FAILURE # 1 The alarm is caused by the lack of output of the digital signals
Possible causes:
a) external short circuit on the wiring
b) output transistor short circuit
Solutions:
a) remove the short circuit
b) replace the control

FORK ENCODER ERROR The alarm is caused by the lack of fork lifting encoder count
Possible causes:
a) faulty encoder
b) interrupted flexible cord
Solutions:
a) replace the encoder
b) restore the flexible cord

CHECK UP NEEDED The alarm appears when the set number of working hours
(300) is reached after the request of programmed
maintenance.
Call the Technical Assistance for maintenance.

CAN BUS KO EPS The alarm appears when the messages are not received
via CAN BUS by control EPS
Possible causes:
a) fault of the wiring on the CAN connection between EPS
and SICOS
b) the can driver on the control is broken
Solutions:
a) perform the correct wiring, as shown in the diagram
b) replace the control

Page: 88 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ALARM DESCRIPTION
ALARM VISUALIZATION ON
POSSIBLE CAUSES
DISPLAY SICOS AND ON THE CONSOLE
SOLUTIONS TO BE ADOPTED

PASSWORD NEEDED The alarm appears because the access password to use

ELECTRIC
the truck has not been inserted
Insert the access password

EMERGENCY BRAKE The alarm appears because the emergency brake is

pressed when the truck is started.
Possible causes:
a) wrong wiring
b) faulty joystick microswitch
Solutions:
a) perform the wiring correctly, as shown in the diagram
b) replace the joystick

RESET ENCODER The alarm is caused by the fact that the cabin or fork height
encoder has not been reset to zero
Possible causes:
a) wrong wiring
b) reset sensor not set at the right distance
c) faulty reset sensor
Solutions:
a) perform the wiring correctly, as shown in the diagram
b) adjust the sensor distance correctly
c) replace the sensor

HEIGHT ENCODER ERROR The alarm is caused by the cabin lifting encoder lack of
count.
Possible causes:
a) wrong wiring
b) break of the nylon wire causing the encoder to rotate
c) faulty encoder
Solutions:
a) perform the wiring correctly as shown in the diagram
b) replace the nylon wire
c) replace the encoder

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 89

 Section: TRUCK DESCRIPTION SERVICE

11.03 MODULE 6 = STEER CONTROL “EPS-AC”

DESCRIPTION AND MEANING OF THE DISPLAYED ALARMS

ELECTRIC

ALARM DESCRIPTION
ALARM VISUALIZATION ON
POSSIBLE CAUSES
DISPLAY SICOS AND ON THE CONSOLE
SOLUTIONS TO BE ADOPTED
MICRO SLAVE KO The alarm appears when no particular number is specified.
It means that the Master Microprocessor (MM) has detected
a status signal coming from Supervisor Microprocessor
(SM) not in compliance with the present control values.
“MM and SM” compare in real time the control they are
reading (stepper motor, aisle end, automatic request). If
“MM” reads a control different from “SM”, the alarm appears.
Solutions:
If the alarm persists, replace the control.

MICRO SLAVE # 1 The alarm appears for a lack of reading of the pulses
between (SM) supervisor microprocessor and (MM) main
microprocessor.
Causes:
SM detects that the synchronization pulse lasts more than
100msec.
Solutions:
If the alarm persists, replace the control.

MICRO SLAVE # 2 The alarm appears when SM has detected that the safety
contacts are closed before being operated.
Solutions:
If the alarm persists, replace the control.

MICRO SLAVE # 5 The alarm is caused by the supervisor microprocessor

(SM), which has detected that the steering motor is
standstill, while the control is active.
Solutions:
If the alarm persists, replace the control.

MICRO SLAVE # 6 The alarm is caused by the supervisor microprocessor

(SM) which has detected that the steering motor direction
of rotation is opposite to the one of the stepper motor
control.
Solutions:
If the alarm persists, replace the control.

Page: 90 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ALARM VISUALIZATION ON ALARM DESCRIPTION

DISPLAY SICOS AND ON THE CONSOLE POSSIBLE CAUSES
SOLUTIONS TO BE ADOPTED
MICRO SLAVE # 7 The alarm is caused by supervisor microprocessor (SM),

ELECTRIC
which has opened its safety contact without specifying the
reason on the local status bus.
Causes:
Broken SM logic
Solutions:
Replace the control

KM CLOSED The alarm is caused when the main control (MM) detects
its safety contact is closed before being controlled.
Causes:
a) Wrong wiring
b) A safety relay contact is closed.
Solutions:
a) Perform the correct wiring as shown in the diagram
b) Replace the control

SAFETY RELAY WIRING DIAGRAM

Steering Safety

7/B <+ 24V by key-

operated switch

1/B > al Pin 8/E

control COMBI

KS CLOSED The alarm appears when the main microprocessor (MM)

detects that the safety contact of the supervisor
microprocessor (SM) is closed before being controlled.

Causes:
a) Wrong control installation
b) A safety relay contact is closed.
Solutions:
a) Perform the correct wiring as shown in the diagram
b) Replace the control

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 91

 Section: TRUCK DESCRIPTION SERVICE

ALARM VISUALIZATION ON ALARM DESCRIPTION

DISPLAY SICOS AND ON THE CONSOLE POSSIBLE CAUSES
SOLUTIONS TO BE ADOPTED
KM OPEN The alarm appears when the main microprocessor detects
ELECTRIC

that its safety contact is open after being controlled.

Causes:
a) Mechanical fault of the safety relay.
b) Fault in the relay pilot system
Solutions:
a) b) Replace the control.

KS OPEN The alarm is caused by the main microprocessor (MM)

which detects that the contact of the supervisor
microprocessor (SM) safety relay is open after being
controlled.
Causes:
a) Mechanical fault of the safety relay.
b) Fault in the relay pilot system
Solutions:
a) b) Replace the control.

POWER FAILURE # 1 # 2 # 3 The alarm is caused by the interruption of phases U, V, W

of the steering motor.
Causes:
a) Interrupted mains cable
b) Shorted motor winding
c) Interrupted power fuse
d) Fault in the control
Solutions:
a) Perform the cable connection, replace them if necessary
b) Replace the steering motor
c) Replace the fuse
d) Replace the control

LOGIC FAILURE # 1 The alarm appears when the average voltage value
between phases U and V is null
Solutions:
If the alarm persists, replace the control.

LOGIC FAILURE # 2 The alarm appears when the average voltage value
between phases U and V is null
Solutions:
If the alarm persists, replace the control.

Page: 92 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ALARM VISUALIZATION ON ALARM DESCRIPTION

DISPLAY SICOS AND ON THE CONSOLE POSSIBLE CAUSES
SOLUTIONS TO BE ADOPTED

HIGH CURRENT The alarm appears when the current coming out of the

ELECTRIC
amplifiers is higher than the maximum current. The fault is
in the power or in the logic card.
Solutions:
Replace the control.

MAIN CONT. OPEN The alarm appears during the synchronization via CAN-
BUS with the traction module (Combi) if the main contactor
does not close.
Solutions:
Check control Combi.

KEY OFF The alarm appears when the key is turned on (ON) and
comes from module 6 SICOS, which signals via CAN-BUS
to the EPS that the key is OFF.
Solutions:
Check that the emergency push button is released.

CAN-BUS KO The alarm appears if there are problems of connection via

CAN-BUS between module 6 (SICOS) and module 1 (EPS)
Causes:
a) the connection via Can-Bus is interrupted
b) the Can-Bus driver is burnt
Solutions:
a) restore the Can-Bus connection
b) replace the control

D LINE SENSOR KO The alarm appears when the stepper motor channel on
pole n° 3 of connector CNB is open.
Solutions:
a) check the stepper motor wire and measure the
resistance between pole n° 3 and the earth (it must be 30
Ohm)
b) if the value corresponds, replace the stepper motor.

Q LINE SENSOR KO The alarm appears when the stepper motor channel on
pole n° 9 of connector CNB is open.
Solutions:
a) check the stepper motor wire and measure the
resistance between pole n° 9 and the earth (it must be 30
Ohm)
b) if the value corresponds, replace the stepper motor.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 93

 Section: TRUCK DESCRIPTION SERVICE

ALARM DESCRIPTION
ALARM VISUALIZATION ON
POSSIBLE CAUSES
DISPLAY SICOS AND ON THE CONSOLE
SOLUTIONS TO BE ADOPTED

MOTOR LOCKET The alarm appears when the steering motor encoder does
ELECTRIC

not work
Causes:
a) Connection wires interrupted or badly connected
b) Badly connected connector
Solutions:
a) Repair or replace the interrupted wires, perform the wiring
as shown in the diagram
b) Connect the connector correctly.

EPS NOT ALIGNED The alarm appears when the steer position sensor is broken
or badly adjusted
Solutions:
a) Replace the sensor
b) Adjust the sensor distance correctly

JUMPING ENCODER The alarm appears when, during the steering phase, the MDU
exceeds the previously set limits.
Causes:
a) After the calibration, parameter LIMIT DEVICE has not
been put in ON position.
b) Wrong wiring of the steering motor encoder
c) Faulty steering motor encoder
d) Wrong reading of the steer centering sensor
e) Faulty steer centering sensor.
Solutions:
a) Put in ON position parameter LIMIT DEVICE
b) Perform the encoder correct wiring as shown in the
diagram
c) Replace the steering motor encoder.
d) Position the centering sensor correctly.
e) Replace the steer centering sensor.

JUMPING ENCODER # 2 It appears when the encoder position indicates an excessive

speed value.
Solutions:
This alarm should never appear. If it does, apply to ZAPI
technicians.

BAD ENCODER SIGN This alarm appears for a reversal of the encoder phases
(inputs 16A and 17A) or of the steering motor cables.
Solutions:
Perform the correct wiring as shown in the diagram.

Page: 94 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: TRUCK DESCRIPTION

ALARM DESCRIPTION
ALARM VISUALIZATION ON
POSSIBLE CAUSES
DISPLAY SICOS AND ON THE CONSOLE
SOLUTIONS TO BE ADOPTED

EEPROM KO The alarm appears because of a hardware or software

ELECTRIC
fault in the parameters of the memory on board.
In order to check this, perform the procedure CLEAR
EEPROM.
Procedure:
-When the truck is stopped, connect the console to control
EPS
-Start the truck and enter MENU “ALARM”
-Press at the same time the two push buttons on the right
(Param/Set) in order to enter ZAPI MENU.
-Press the push buttons on the left, up or down, till
parameter “CLEAR EEPROM” appears on the display,
press key “ENTER” twice.
If the alarm persists, replace the control.
NOTE: The above-described operation must be
performed before the “EEPROM” version is replaced.

GAIN EEPROM KO The alarm appears when the truck is started and detects
some EEPROM damaged cells.
Solutions:
Replace the control.

HIGH TEMPERATURE The alarm appears when the dissipator base temperature
is higher than 76°C.
Solutions:
Make the unit get cold. If the alarm appears after the cooling,
check the dissipator is connected in the right way.

STBY I HIGH The alarm appears when the key is turned on. The current
signal, between phases U and W, is lower or higher than
2,5V dc.
Solutions:
Replace the control.

VMN NOT OK This alarm appears when the key is turned off, and detects
a voltage on one of the phases.
Solutions:
If the alarm persists, replace the control.

LOGIC FAILURE # 3 The alarm appears when the motor phase Vv - Vu voltage
is high while the truck is stopped.
Solutions:
If the alarm persists, replace the control.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 95

 Section: TRUCK DESCRIPTION SERVICE

ALARM VISUALIZATION ON ALARM DESCRIPTION

DISPLAY SICOS AND ON THE CONSOLE POSSIBLE CAUSES
SOLUTIONS TO BE ADOPTED
LOGIC FAILURE # 4 The alarm appears when the motor phase Vv - Vu voltage
ELECTRIC

is high while the truck is stopped.

Solutions:
If the alarm persists, replace the control.

NOTES:

Page: 96 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

HYDRAULIC
SYSTEM

HYDRAULIC
D HYDRAULIC SYMBOL LEGEND................................................................... 2
D CORRECT ASSEMBLY METHOD FOR FEMALE PIPE FITTINGS ............... 3
D FUNCTIONAL HYDRAULIC DIAGRAM - MOD. M010E FP-FF-WP ............... 4
D FUNCTIONAL HYDRAULIC DIAGRAM - MOD. M010E SL ............................ 6
D FUNCTIONAL HYDRAULIC DIAGRAM - MOD. M010E h3200 ....................... 12
D HYDRAULIC POWER PACK COMPONENTS - MOD. M010E FP ................. 18
D HYDRAULIC POWER PACK COMPONENTS - MOD. M010E FF-WP .......... 20
D HYDRAULIC POWER PACK COMPONENTS - MOD. M010E SL ................. 22
D HYDRAULIC SYSTEM COMPONENTS - MOD. M010E FP .......................... 24
D HYDRAULIC SYSTEM COMPONENTS - MOD. M010E FF- WP .................. 25
D HYDRAULIC SYSTEM COMPONENTS - MOD. M010E SL .......................... 26
D HYDRAULIC SYSTEM COMPONENTS - MOD. M010E SL h3200 ................ 27
D HYDRAULIC CYLINDER COMPONENTS - MOD. ALL MODELS .................. 28
D CYLINDER BRAKING OPERATION - MOD. ALL MODELS ........................... 29
D VALVE ADJUSTMENT - MOD. M010E FP-FF-WP ........................................ 30
D VALVE REPLACEMENT - MOD. M010E FP-FF-WP ..................................... 31
D VALVE ADJUSTMENT - MOD. M010E SL ..................................................... 32
D LIFTING CYLINDER REMOVAL - MOD. M010E FP ...................................... 34
D LIFTING CYLINDER REMOVAL - MOD. M010E FF-WP ............................... 36
D FORK LIFTING CYLINDER REMOVAL - MOD. M010E SL ............................ 38
D CABIN LIFTING CYLINDER REMOVAL - MOD. M010E SL ........................... 40
D CABIN LIFTING CYLINDER REMOVAL - MOD. M010E SL h3200 ................ 42
D CYLINDER GASKET REPLACEMENT - MOD. ALL MODELS ...................... 44
D HYDRAULIC PIPE REMOVAL - MOD. M010E FP ......................................... 46
D HYDRAULIC PIPE REMOVAL - MOD. M010E FF-WP .................................. 47
D FORK CYLINDER HYDRAULIC PIPE REMOVAL - MOD. M010E SL ............ 48
D FORK CYLINDER HYDRAULIC PIPE REMOVAL - MOD. M010E SL h3200 . 50
D CABIN CYLINDER HYDRAULIC PIPE REMOVAL - MOD. M010E SL ........... 51

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 1

 Section: HYDRAULIC SYSTEM SERVICE

1.00 HYDRAULIC SYMBOL LEGEND

The symbols used in the diagrams of this section (with their corresponding meaning) are indicated here
below.

TWO POSITION THREE POSITION

SOLENOID VALVE SOLENOID VALVE
HYDRAULIC

FILTER NON-RETURN VALVE

DOUBLE-ACTING PROPORTIONAL VALVE

CYLINDER

SINGLE-ACTING PUMP
CYLINDER

TANK HYDRAULIC MOTOR

LINE CONNECTION ELECTRIC MOTOR

MAXIMUM PRESSURE FLOW VALVE

VALVE

MANUAL TAP BY-PASS VALVE

Page: 2 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

1.01 CORRECT ASSEMBLY METHOD FOR FEMALE PIPE FITTINGS

In order to obtain a connection without leaks between the female pipe fittings and the adapters shown in
this manual, follow the procedure described below, which is different from the one used for flexible pipes.

FEMALE PIPE FITTINGS WITHOUT GASKETS (METAL/METAL JOINT)

Screw the nut manually, then tighten it just another one-fourth of a turn by means of a wrench.

FEMALE PIPE FITTINGS WITH O-RING SEAL 12

Screw the nut manually, then tighten it just another half turn by means of a wrench.

HYDRAULIC
In all cases, check the pipe is correctly aligned before tightening the nut on the adapter.

Note: The values indicated in the tables are used to obtain the recommended assembly method
when the fitting material is galvanized. With different materials, different values must be used.

TORQUE VALUES

TORQUE V ALUES TORQUE VALUES

METRIC FEM ALE FITTING ORFS
Nm
M ETRIC Nm
THREAD ø EX TERNAL
NOM INAL MIN./M AX THREAD UNF SIZE
MIN MAX
M12x 1,5 6 20 15-25
M14x 1,5 8 38 30-45 9/16-18 -4 14 16
8 11/16-16 -6 24 27
M16x 1,5 45 38-52
10 13/16-16 -8 43 47
10 1-14 -10 60 68
M18x 1,5 51 43-58
12
1.3/16-12 -12 90 95
M20x 1,5 12 58 50-65
14
1.3/16-12 -14 90 95
M22x 1,5 74 60-88 1.7/16-12 -16 125 135
15
M24x 1,5 16 74 60-88 1.11/16-12 -20 170 190
M26x 1,5 18 105 85-125 2-12 -24 200 225
20
M 30x 2 135 115-155
22 Table 2
25
M 36x 2 166 140-192
28
M 42x 2 30 240 210-270
M 45x 2 35 290 255-325
38
M 52x 2 330 280-380
42

Table 1
TORQUE VALUES
FEMALE FITTING JIC 37° TORQUE VALUES
Nm FEMALE FITTING BS P
THREAD UNF SIZE
NOMINAL MIN./MAX Nm
THREAD BS PP
7/16-20 -4 15 9-21 NOMINAL MIN./MAX
1/2-20 -5 20 13-27
9/16-18 -6 30 18-42 G1/4 20 15-25
3/4-16 -8 50 30-70 G3/8 34 27-41
7/8-14 -10 69 44-94 G1/2 60 42-76
1.1/16-12 -12 98 63-133 G5/8 69 44-94
1.3/16-12 -14 118 73-163 G3/4 115 95-135
1.5/16-12 -16 140 90-190 G1 140 115-165
1.5/8-12 -20 210 135-285 G1.1/4 210 140-280
1.7/8-12 -24 290 200-380 G1.1/2 290 215-365
2.1/2-12 -32 450 300-600 G2 400 300-500

Table 3 Table 4
UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 3
 Section: HYDRAULIC SYSTEM SERVICE

2.00 LIFTING AND LOWERING FUNCTIONAL HYDRAULIC DIAGRAM

MOD. MO10E FP - MO10E FF - MO10E WP
HYDRAULIC

EV1 EV1

HYDRAULIC CIRCUIT CONDITIONS HYDRAULIC CIRCUIT CONDITIONS

DURING THE LIFTING PHASE DURING THE LOWERING PHASE

Page: 4 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

2.01 FUNCTIONAL HYDRAULIC DIAGRAM TO DRAIN THE OIL

WHEN THE NOMINAL PRESSURE IS EXCEEDED
MOD. MO10E FP - MO10E FF - MO10E WP

HYDRAULIC
EV1

HYDRAULIC CIRCUIT CONDITIONS

DURING THE OIL DRAIN PHASE WHEN THE SET
PRESSURE VALUE IS EXCEEDED

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 5

 Section: HYDRAULIC SYSTEM SERVICE

2.02 FORK LIFTING FUNCTIONAL HYDRAULIC DIAGRAM

MOD. MO10E SL
HYDRAULIC

BLOCK A

Page: 6 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

2.03 FORK LOWERING FUNCTIONAL HYDRAULIC DIAGRAM

MOD. MO10E SL

HYDRAULIC
BLOCK A

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 7

 Section: HYDRAULIC SYSTEM SERVICE

2.04 PLATFORM LIFTING FUNCTIONAL HYDRAULIC DIAGRAM

MOD. MO10E SL
HYDRAULIC

BLOCK A

Page: 8 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

2.05 PLATFORM LOWERING FUNCTIONAL HYDRAULIC DIAGRAM

MOD. MO10E SL

HYDRAULIC
BLOCK A

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 9

 Section: HYDRAULIC SYSTEM SERVICE

2.06 FUNCTIONAL HYDRAULIC DIAGRAM TO DRAIN THE OIL

WHEN THE MAXIMUM PRESSURE IS EXCEEDED
MOD. MO10E SL
HYDRAULIC

BLOCK A

PHASE OF THE OIL DRAIN BY MEANS PHASE OF THE OIL DRAIN BY MEANS
OF THE MAX. PRESSURE VALVE WHEN OF THE MAX. PRESSURE VALVE WHEN
THE PRESSURE VALUE SET ON THE THE PRESSURE VALUE SET ON THE
FORKS IS EXCEEDED PLATFORM IS EXCEEDED

Page: 10 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

2.07 FUNCTIONAL HYDRAULIC DIAGRAM FOR THE EMERGENCY

DESCENT IN CASE OF ELECTRICAL FAULT
MOD. MO10E SL

HYDRAULIC
BLOCK A

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 11

 Section: HYDRAULIC SYSTEM SERVICE

2.08 FORK LIFTING FUNCTIONAL HYDRAULIC DIAGRAM

MOD. MO10E SL - h 3200
HYDRAULIC

BLOCK A

Page: 12 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

2.09 FORK LOWERING FUNCTIONAL HYDRAULIC DIAGRAM

MOD. MO10E SL - h 3200

HYDRAULIC
BLOCK A

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 13

 Section: HYDRAULIC SYSTEM SERVICE

2.10 PLATFORM LIFTING FUNCTIONAL HYDRAULIC DIAGRAM

MOD. MO10E SL - h 3200
HYDRAULIC

BLOCK A

Page: 14 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

2.11 PLATFORM LOWERING FUNCTIONAL HYDRAULIC DIAGRAM

MOD. MO10E SL - h 3200

HYDRAULIC
BLOCK A

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 15

 Section: HYDRAULIC SYSTEM SERVICE

2.12 FUNCTIONAL HYDRAULIC DIAGRAM TO DRAIN THE OIL

WHEN THE MAXIMUM PRESSURE IS EXCEEDED MOD. MO10E SL - h 3200
HYDRAULIC

BLOCK A

PHASE OF THE OIL DRAIN BY MEANS PHASE OF THE OIL DRAIN BY MEANS OF
OF THE MAX . PRESSURE VALVE WHEN THE MAX. PRESSURE VALVE WHEN THE
THE PRESSURE VALUE SET ON THE PRESSURE VALUE SET ON THE
FORKS IS EXCEEDED PLATFORM IS EXCEEDED

Page: 16 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

2.13 FUNCTIONAL HYDRAULIC DIAGRAM FOR THE EMERGENCY

DESCENT IN CASE OF ELECTRICAL FAULT
MOD. MO10E SL - h 3200

HYDRAULIC
BLOCK A

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 17

 4 Section: HYDRAULIC SYSTEM SERVICE

3.00 HYDRAULIC POWER PACK COMPONENTS

2,00 KW MOTOR PUMP, PROPORTIONAL SOLENOID VALVE
MOD. MO10E FP

1
HYDRAULIC

15

6 2
3

5
16
4
12
10
11 9

14

13

Pict. 01

Page: 18 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

3.01 HYDRAULIC POWER PACK COMPONENT TABLE

2,00 KW MOTOR PUMP, PROPORTIONAL SOLENOID VALVE
MOD. MO10E FP

In the following table the various hydraulic unit components are described.

Reading key
Ref. Component reference on the exploded view
Component Description Component function

Ref. Component Description

HYDRAULIC
1 2,00 Kw pump motor
2 Power pack unit
3 Proportional solenoid valve
4 3,2cc lifting pump casing
5 Maximum pressure valve
6 Oil flow adjustment valve
7 Nonreturn or relief valve
8 Oil filter
9 Pipe connecting the oil filter to the pump casing
10 Oil drain pipe when the valve maximum pressure is exceeded
11 Oil drain pipe during the lowering phase
12 Bolts fixing the pump casing to the power pack unit
13 Oil container (tank)
14 Container plug for the oil charge
15 Joint connecting the pump motor to the pump casing
16 Emergency descent valve

NOTE: Look for the Yale codes of the various components in the spare parts catalogue

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 19

 Section: HYDRAULIC SYSTEM SERVICE

3.02 HYDRAULIC POWER PACK COMPONENT TABLE

3,00 KW MOTOR PUMP, PROPORTIONAL SOLENOID VALVE
MOD. MO10E FF - MO10E WP

1
HYDRAULIC

15
6
2
3
5

4
12 10

9
14 11
8

13

Pict. 02

Page: 20 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

3.03 HYDRAULIC POWER PACK COMPONENT TABLE

3,00 KW MOTOR PUMP, PROPORTIONAL SOLENOID VALVE
MOD. MO10E FF - MO10E WP

In the following table the various hydraulic unit components are described.

Reading key
Ref. Component reference on the exploded view
Component Description Component function

Ref. Component Description

HYDRAULIC
1 2,00 Kw pump motor
2 Power pack unit
3 Proportional solenoid valve
4 3,2cc lifting pump casing
5 Maximum pressure valve
6 Oil flow adjustment valve
7 Nonreturn or relief valve
8 Oil filter
9 Pipe connecting the oil filter to the pump casing
10 Oil drain pipe when the valve maximum pressure is exceeded
11 Oil drain pipe during the lowering phase
12 Bolts fixing the pump casing to the power pack unit
13 Oil container (tank)
14 Container plug for the oil charge
15 Joint connecting the pump motor to the pump casing

NOTE: Look for the Yale codes of the various components in the spare parts catalogue

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 21

 Section: HYDRAULIC SYSTEM SERVICE

3.04 HYDRAULIC POWER PACK COMPONENT TABLE

3,00 KW MOTOR PUMP, SOLENOID VALVE UNIT
MOD. MO10E SL

16 EV3
HYDRAULIC

23
5 21
18 EV2
15
22
2 20
19 EV1
7

4
12
6
9 10 3
24
11 17 EV4
8 14

13

Pict. 03

Page: 22 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

3.05 HYDRAULIC POWER PACK COMPONENT TABLE

3,00 KW MOTOR PUMP, SOLENOID VALVE UNIT
MOD. MO10E SL

In the following table the various hydraulic unit components are described.

Reading key
Ref. Component reference on the exploded view
Component Description Component function

Ref. Component Description

HYDRAULIC
1 3,00 Kw pump motor
2 Power pack unit
3 Solenoid valve unit
4 3,2cc lifting pump casing
5 Fork cylinder maximum pressure valve
6 Oil flow adjustment valve
7 Nonreturn or relief valve
8 Oil filter
9 Pipe connecting the oil filter to the pump casing
10 Oil drain pipe when the valve maximum pressure is exceeded
11 Oil drain pipe during the lowering phase
12 Bolts fixing the pump casing to the power pack unit
13 Oil container (tank)
14 Container plug for the oil charge
15 Joint connecting the pump motor to the pump casing
16 Fork lifting/lowering solenoid valve (EV3)
17 Platform (Cabin) lifting solenoid valve (EV4)
18 Platform (Cabin) lowering solenoid valve (EV4)
19 Platform and fork lowering proportional solenoid valve (EV1 Prop)
20 Platform cylinder maximum pressure valve
21 Platform emergency descent valve
22 Wrench to be used for the emergency descent valve
23 Bolts fixing the pump motor to the power pack
24 Bolts fixing the valve unit to the power pack unit

NOTE: Look for the Yale codes of the various components in the spare parts catalogue

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 23

 Section: HYDRAULIC SYSTEM SERVICE

4.00 HYDRAULIC SYSTEM COMPONENTS

MOD. MO10E FP
HYDRAULIC

3
6 7
4
5

M O10E FP HYDRAULIC CO M P ONENT TABLE

Re f. Com pone nt De scription
1 2,00 K w pum p m otor
2 Fork lifting cy linder
3 P ower pac k unit
4 Tank (oil c ontainer)
5 Lowering proportional solenoid valve
Hy draulic pipe connecting the power pack to the
6 c ylinder
7 V alve LB to bloc k the lowering in cas e of pipe break Pict. 04

NOTE: Look for the Yale codes of the various components in the spare parts catalogue

Page: 24 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

4.01 HYDRAULIC SYSTEM COMPONENTS

MOD. MO10E FF h2 1200mm

HYDRAULIC
1

3 2

5 6 7

M O 10E FF HYDRAULIC COM P ONENT TABLE

Re f. Com pone nt De scription
1 2,00 K w pum p m otor
2 P latform lifting c ylinder
3 P ower pac k unit
4 Tank (oil c ontainer)
5 Lowering proportional solenoid valve
Hydraulic pipe c onnec ting the power pack to the
6 c ylinder
7 V alve LB to bloc k the lowering in c as e of pipe break Pict. 05

NOTE: Look for the Yale codes of the various components in the spare parts catalogue

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 25

 Section: HYDRAULIC SYSTEM SERVICE
4.02 HYDRAULIC SYSTEM COMPONENTS
MOD. MO10E SL h2 1700mm
HYDRAULIC

10 8

9
4
7

12
2

1 11

12

3 6

M O 10E S L HYDR AU L I C S YS T EM CO M P O N EN T T A B L E
R e f. C o m p o n e n t De scrip ti o n
1 S olenoid valve unit
2 3, 00 K w m ot or pum p
3 Ta nk , oil c ontainer
4 C abin (platform ) lifting c y linder
5 F ork lifting c y linder
6 C abin c y linder hy draulic feed pipe
7 1 s t hy draulic pipe to feed the fork c y linder
8 2 n d hy draulic pipe to feed t he fork c y linder
9 3 rd rigid hy draulic pipe t o feed the fork c y linder
10 F itting to c on nec t the firs t and the s ec ond p ipe
11 F itting to c on nec t the s ec ond and the third pipe
12 V alve LB t o bloc k the low ering in c as e of pipe break Pict. 06

NOTE: Look for the Yale codes of the various components in the spare parts catalogue

Page: 26 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

4.03 HYDRAULIC SYSTEM COMPONENTS

MOD. MO10E SL h 3200mm

HYDRAULIC
11
4
5

12 11

4 10

7
2
6

12

7
6
3
1

MO10E SL - h 3200 HYDRAULIC SYSTEM COMPONENT TABLE

Ref. Component description
1 Solenoid valve unit
2 3,00 Kw motor pump
3 Tank, oil container
4 Cabin (platform) lifting cylinder
5 Fork lifting cylinder
6 Cabin cylinder hydraulic feed pipe
7 1st hydraulic pipe to feed the fork cylinder
8 2nd hydraulic pipe to feed the fork cylinder
9 3d hydraulic pipe to feed the fork cylinder
10 Fitting to connect the first and the second pipe
11 Fitting to connect the second and the third pipe
12 LB valve to block the lowering in case of pipe break Pict. 07

NOTE: Look for the Yale code of the various components in the spare part catalogue

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 27

 Section: HYDRAULIC SYSTEM SERVICE

4.04 CABIN AND FORK LIFTING CYLINDER COMPONENTS

WITH SLOWING DOWN DURING LIFTING
MOD. MO10E FP - MO10E FF - MO10E SL

10 11 2 3 13 7 6 5
HYDRAULIC

12 9 8 4
1
Pict. 07

CYLINDER COMPONENT TABLE

Ref. Component Description
1 Complete cylinder
2 Cylinder external barrel
3 Internal rod
4 Gasket holding bush
5 Seal
6 Dust cover
7 Bush O-Ring
8 Dual-seal piston ring
9 Rod guide
10 Block valve LB in case of pipe break
11 Rod piston
Valve to drain the excessive oil caused by the
12 deceleration during the lifting
13 Oil feeding plug in case of deceleration during the lifting

NOTE: Look for the Yale codes of the various components in the spare parts catalogue

Page: 28 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

4.05 CYLINDER BRAKING OPERATION DURING LIFTING IN THE LAST 40mm

MOD. MO10E FP - MO10E FF - MO10E SL

C D OIL FEEDING PLUG A

OF 50CC
AIR CHAMBER
E

HYDRAULIC
OIL LEVEL D
F C B

G
Pict. 08

INTRODUCTION

The lifting cylinders of the new set of order pickers model MO10E are single-acting, and the oil is pushed
up to the rod piston. At each lifting operation, in the last 50/40mm, the piston performs a hydraulic
deceleration, which avoids the mechanical shock of the end of the stroke.

The deceleration takes place thanks to the design of new piston “F”, in which valve “G” has been
inserted, and of the rod, in which slot “E” has been created for the oil and air recovery. Moreover, two
holes “D” have been made for the passage of air, and two holes “C” for the passage of oil.

The cylinders are equipped with “50cc” of oil inserted into the barrel. In case of gasket replacement,
after the cylinder has been disassembled and reassembled, insert “50cc” of oil through plug “A”.

OPERATION

a) During the lifting phase the air contained in the barrel enters chamber “E” of the rod. When piston “F”
reaches the end of the stroke, it pushes the oil against bush “B”, thus creating a higher pressure,
which makes the oil enter slot “E” of the rod through hole “C”. The oil is compressed in the air-filled
slot, thus making the pressure increase. This slows down the cylinder stroke in the last 40/50mm.

b) During the lowering phase the pressure pushing the rod downwards causes a depression inside the
cylinder, which makes the air and the oil flow out of slot “E” into the cylinder barrel, thus creating the
conditions for deceleration during the following lifting phase.

c) If, by mistake, you insert more oil than the prescribed quantity of “50cc”, the excessive oil is pushed
into the natural circuit by means of valve “G”, leaving the prescribed quantity in the barrel.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 29

 Section: HYDRAULIC SYSTEM SERVICE

5.00 MAXIMUM PRESSURE VALVE REPLACEMENT AND ADJUSTMENT

MOD. MO10E FP - MO10E FF

According to the standards, a maximum pressure valve must be installed inside the truck hydraulic
system in order to protect it from sudden pressure increases, which could seriously damage the various
components. The maximum pressure valve is installed on the flange of the integrated hydraulic power
pack.
The valve adjustment procedure is described here below. It applies to all models.

NECESSARY STANDARD TOOLS

HYDRAULIC

4mm ALLEN RATCHET WITH 10-22mm

WRENCH SOCKET WRENCH

5.01 MAXIMUM PRESSURE VALVE REPLACEMENT PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key OFF, disconnect the battery.

1) RATCHET, 22mm SOCKET WRENCH - Remove the motor

compartment hood. By means of the wrench unscrew and remove
the complete valve (Ref. A Pict. 10) and replace it.

Install the new valve by following the reverse procedure.

Pict. 09
NOTE: Tighten the new valve to 10 Nm

2) Lower the forks to the ground and lift a load corresponding to the nominal
A
carrying capacity indicated on the name plate. B

3) RATCHET, 10mm SOCKET WRENCH, 4mm ALLEN WRENCH - By means

of the socket wrench and the ratchet, loosen the valve block lock nut (Ref. B
Pict. 10). By means of the Allen wrench, loosen the screw (anticlockwise) C
(Ref. C Pict. 10) till, by activating the pump, the lifting phase begins. Reverse Pict. 10
the screw direction of rotation (clockwise), activate the lifting pump and tighten
the valve till the cylinder starts lifting. Block the lifting and tighten the valve
again one fifth of a turn. Carry out some lifting and lowering operations with the loaded forks, and make
sure the preset pressure does not change. By means of the socket wrench tighten the valve lock nut.

Page: 30 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

5.03 PROPORTIONAL VALVE REPLACEMENT

MOD. MO10E FP - MO10E FF

NECESSARY STANDARD TOOLS

D
14mm OPEN-ENDED SMALL SLOTTED
SPANNER SCREWDRIVER

PROCEDURE

HYDRAULIC
E
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians, lower the Pict. 11
forks to the ground, turn the key OFF, disconnect the battery.

1) OPEN-ENDED SPANNER, SCREWDRIVER - Remove the motor compartment hood. By means of

the screwdriver loosen the screw fixing the coil power supply connector (Ref. D Pict. 11) and remove
the connector. By means of the wrench unscrew and remove the complete solenoid valve (Ref. E
Pict. 11). Then replace it.

Install the new solenoid valve by following the reverse procedure.

NOTE: Tighten the valve body to 30+/-3 Nm

NOTE: After it has been replaced, it does not need any electronic adjustment.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 31

 Section: HYDRAULIC SYSTEM SERVICE

5.04 MAXIMUM PRESSURE VALVE REPLACEMENT AND F

H
ADJUSTMENT
MOD. MO10E SL

According to the standards, a maximum pressure valve must be installed

in the truck hydraulic system in order to protect the system from sudden
pressure increases, which could seriously damage the various G
components. The maximum pressure valves are installed as follows: the
first valve in the integrated hydraulic power pack flange, the second valve
VALVE 2
in the valve unit. Pict. 12

NECESSARY STANDARD TOOLS

HYDRAULIC

,5
13
Ø

10mm SOCKET WRENCH 17-19-22mm OPEN- 4-6mm ALLEN

(OUTSIDE Ø 13,5mm) ENDED SPANNER WRENCH

VALVE 2
5.05 MAXIMUM PRESSURE VALVE 1 REPLACEMENT
PROCEDURE
VALVE 1 Pict. 13
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key OFF, disconnect the battery.
I
1) 22mm OPEN-ENDED SPANNER - Remove the motor compartment
hood. By means of the wrench unscrew and remove the complete
M
valve (Ref. I Pict. 14). Then replace it.
L
Install the new valve by following the reverse procedure.
NOTE: Tighten the new valve to 10 Nm
VALVE 1 Pict. 14
5.06 MAXIMUM PRESSURE VALVE 2 REPLACEMENT
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage
of pedestrians, lower the forks to the ground, turn the key OFF, disconnect the battery.

2) 19mm OPEN-ENDED SPANNER - Remove the motor compartment hood. By means of the wrench
unscrew and remove the complete valve (Ref. F Pict. 12). Then replace it.

Install the new valve by following the reverse procedure.

NOTE: Tighten the new valve to 12 Nm

Page: 32 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

5.07 MAXIMUM PRESSURE VALVE ADJUSTMENT PROCEDURE

MOD. MO10E SL

The maximum pressure valves of the valve unit must be adjusted in sequence.

A) Valve No. 1 - it adjusts the pressure necessary to lift the fork mast with the nominal load indicated on
the name plate
B) Valve No. 2 - it adjusts the pressure necessary to lift the platform and the loaded forks.

Follow the procedure indicated here below. We recommend performing it very carefully in order to obtain
a good adjustment.

PROCEDURE

HYDRAULIC
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage
of pedestrians, lower the forks to the ground.

VALVE 1 ADJUSTMENT

1) Lift a load corresponding to the nominal carrying capacity indicated on the

name plate.

2) RATCHET, 10mm SOCKET WRENCH, 4mm ALLEN WRENCH - By means

of the socket wrench and the ratchet, loosen the valve lock nut (Ref. L
Pict. 14a). By means of the Allen wrench loosen the screw (anticlockwise)
(Ref. M Pict. 14a) till, by activating the pump, the lifting phase begins.
Reverse the screw direction of rotation (clockwise), activate the lifting pump M
and tighten the valve till the cylinder starts lifting. Block the lifting and tighten
L
the valve once again one fifth of a turn. Carry out some lifting and lowering
operations with the loaded forks, and make sure the preset pressure does
not change. By means of the socket wrench tighten the valve lock nut.
VALVE 1 Pict. 14a
VALVE 2 ADJUSTMENT

3) 17mm OPEN-ENDED SPANNER, 6mm ALLEN WRENCH - Leave the load on the forks. By means of
the open-ended spanner loosen the Allen screw lock nut (Ref. G Pict. 12a). By means of the Allen
wrench loosen the screw (Ref. H Pict. 12a) (anticlockwise) till, by activating
the pump, the platform lifting phase begins. Reverse the screw direction
of rotation (clockwise), enable the platform lifting and tighten the valve till H
the cylinder starts lifting. Block the lifting and tighten the valve again half
turn. Carry out some lifting and lowering operations, with the platform and
then with the loaded forks, checking the set pressure does not change.
By means of the open-ended spanner tighten the valve lock nut.

VALVE 2 Pict. 12a

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 33

 Section: HYDRAULIC SYSTEM SERVICE

6.00 FORK LIFTING CYLINDER REMOVAL

MOD. MO10E FP N
The continuous lifting of the forks can cause some oil leaks through the O
gaskets of the rod guide bush. To stop leaks, disassemble the cylinder
from the truck in order to replace the gaskets.

NECESSARY SPECIAL TOOLS

* Wooden beam 100x100x (500 or 1100) according to the fork height

* Plugs for pipe fittings R
HYDRAULIC

NECESSARY STANDARD TOOLS S

Pict. 15

MEDIUM 3-5-6mm ALLEN 13-19 OPEN- NORMAL

OPENING SEEGER WRENCH ENDED SPANNER PLIERS
PLIERS
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor P
vehicles and from the passage of pedestrians.

1) WOODEN BEAM - Lift the forks till the beam passes under the Pict. 16
bearing support (Ref. P Pict. 16), lower the forks and lean them on
the beam. Lower the forks till the cylinder closes completely. Turn
the key off and disconnect the battery.

WARNING: The beam has an important safety function

during the whole phase of cylinder disassembly and
Pict. 17
assembly. Therefore it must be placed in a standstill and
safe position.

2) 5mm ALLEN WRENCH, 19mm OPEN-ENDED SPANNER - By

means of the Allen wrench remove the footboard from the platform
in order to reach the hydraulic pipe fitting. By means of the open-
ended spanner unscrew the feed pipe fitting (Ref. Q Pict. 18) and
put the plugs on the pipe and cylinder fittings, so as to avoid any oil
leaks.
Q

Pict. 18

Page: 34 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

3) NORMAL PLIERS, 13mm OPEN-ENDED SPANNER - By means of

the open-ended spanner unscrew and remove the bolts fixing the
guard that prevents the chains from slipping off the pulley (Ref. S
Pict. 15). Remove the guard. By means of the normal pliers remove
the split pins and the chain hinge pins (Ref. T Pict. 19). Detach the T T
chains and remove them from the pulleys.

4) SEEGER PLIERS - Remove the pulley support locking seeger (Ref. U

N Pict. 15), and the space washers (Ref. O Pict. 15) and Pict. 19
disassemble the pulley support from the cylinder (Ref. R Pict. 15).

Pict. 20

HYDRAULIC
5) 3-6mm ALLEN WRENCH - By means of the 3mm Allen wrench
loosen the cylinder setscrew (Ref. V Pict. 21). By means of the 6mm
Allen wrench unscrew and remove the bolts fixing the cylinder stop
collar (Ref. U Pict. 19). Lift the cylinder by making it come out of the
supporting plate seat and place it on a bench with vise.

Install the new cylinder by following the reverse procedure.

NOTE: Before tightening the hydraulic fittings, see the reference

table on Page 3.

V Pict. 21

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 35

 Section: HYDRAULIC SYSTEM SERVICE

6.01 CABIN LIFTING CYLINDER REMOVAL

MOD. MO10E FF

NECESSARY SPECIAL TOOLS

* Wooden beam 100x100x800

Z
* Plugs for pipe fittings Pict. 22

NECESSARY STANDARD TOOLS

HYDRAULIC

MEDIUM OPENING 4-5-6mm ALLEN 13-19 OPEN- NORMAL

SEEGER PLIERS WRENCH ENDED SPANNER PLIERS W
PROCEDURE
W

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other Pict. 23
motor vehicles and from the passage of pedestrians.

1) 5mm ALLEN WRENCH - By means of the Allen wrench loosen the four screws fixing the hood under
the instrument panel (Ref. W Pict. 23). Remove the hood in order to reach the cylinder.

2) SEEGER PLIERS, 13mm OPEN-ENDED SPANNER - By means of the open-ended spanner unscrew
and remove the bolts fixing the guard that prevents the chains from slipping off the pulley (Ref. Y Pict.
25). Remove the guard. By means of the seeger pliers remove the pulley support locking split ring
(Ref. K Pict. 25), remove the washers (Ref. J Pict. 25) and the pulley support from the cylinder (Ref.
S Pict. 25).

S Y

Y Pict. 25 Pict. 24

Page: 36 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

3) WOODEN BEAM - Lift the forks till the beam passes between the
anchoring hook and the platform next to the bearing sliding profile
(Ref. F Pict. 27), lower the forks and lean the platform on the beam. B
B
Lower the forks until the cylinder closes completely. Turn the key off
and disconnect the battery. A A

WARNING: The beam has an important safety function during

the whole phase of cylinder disassembly and assembly.
Therefore it must be placed in a standstill and safe position. D

SW15 SW16
4) NORMAL PLIERS - By means of the pliers remove the chain hinge pin
Pict. 26

HYDRAULIC
locking split pins (Ref. A Pict. 26). By means of the same tool remove
the pins (Ref. B Pict. 26) and release the chains by withdrawing them
from the pulleys. Remove the pulley support by withdrawing it from
the cylinder rod. Z
U

5) 19mm OPEN-ENDED SPANNER, 6mm ALLEN WRENCH - By

means of the open-ended spanner unscrew and remove the cylinder
feed pipe fitting (Ref. C Pict. 28). Put a plug on the pipe and cylinder F
fitting in order to avoid any oil leaks. By means of the Allen wrench
unscrew and remove the two bolts fixing the cylinder fastening bracket
(Ref. D Pict. 26) and remove the latter in order to release the cylinder.

6) Rotate the cylinder towards the coachwork in order to make the fitting
come out of the fastening bracket (Ref. E Pict. 28). Lift and remove
the cylinder from its seat. Replace the complete cylinder and
disassemble it in order to replace the gaskets.
Pict. 27
Install the new cylinder by following the reverse procedure.

IMPORTANT: E
After the cylinder has been assembled and the safety beam has been
removed, make sure the two sensor LEDs (SW15/16 Pict. 26) are on.
This means they are working and the chains are tensioned.

C
Pict. 28

NOTE: Before tightening the hydraulic fittings, see the reference table on Page 3.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 37

 Section: HYDRAULIC SYSTEM SERVICE

6.02 FORK LIFTING CYLINDER REMOVAL

MOD. MO10E SL G

The continuous lifting of the forks can cause some oil leaks through the H
gaskets of the rod guide bush. To stop leaks, disassemble the cylinder
from the truck in order to replace the gaskets.

NECESSARY SPECIAL TOOLS

* Wooden beam 100x100x500 I

* Plugs for pipe fittings L
HYDRAULIC

NECESSARY STANDARD TOOLS Pict. 29

MEDIUM OPENING 3-5-6mm ALLEN 13-19 OPEN- NORMAL

SEEGER PLIERS WRENCH ENDED PLIERS
SPANNER
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor Pict. 30
vehicles and from the passage of pedestrians.

1) 13mm OPEN-ENDED SPANNER - By means of the wrench unscrew

and remove the bolts fixing the guard that prevents the chains from
slipping off the pulley (Ref. L Pict. 29). Remove the guard.

2) WOODEN BEAM - Lift the forks till the beam passes under the bearing
support (Ref. M Pict. 31), lower the forks and lean them on the beam. M
Lower the forks till the cylinder closes completely. Turn the key off
and disconnect the battery.

WARNING: The beam has an Pict. 31

important safety function
during the whole phase of
cylinder disassembly and
assembly. Therefore it must
be placed in a standstill and O N
safe position.

P
Pict. 33 Q Pict. 32

Page: 38 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

3) NORMAL PLIERS - Remove the split pins and the chain hinge pins
(Ref. N/O Pict. 33), detach the chains and remove them from the
pulleys.

4) SEEGER PLIERS - Remove the pulley support locking seeger (Ref.

G Pict. 29) and the space washers (Ref. H Pict. 129), and
disassemble the pulley support from the cylinder (Ref. I Pict. 29). R

5) 5mm ALLEN WRENCH, 19mm OPEN-ENDED SPANNER - By

means of the Allen wrench remove the platform footboard (Ref. R
Pict. 34) in order to reach the hydraulic pipe fitting (Pict. 35). By means Pict. 34

HYDRAULIC
of the open-ended spanner unscrew the feed pipe fitting (Ref. S Pict.
36) and put the plugs on the pipe and cylinder fitting so as to avoid
any oil leaks.

5) 3-6mm ALLEN WRENCH - By means of the 3mm Allen wrench loosen

the cylinder setscrew (Ref. Q Pict. 32). By means of the 6mm Allen
wrench unscrew and remove the bolts fixing the cylinder stop collar
(Ref. P Pict. 33). Lift the cylinder by making it come out of the
supporting plate seat and place it on a bench with vise. Replace the Pict. 35
gaskets and the complete cylinder.

Install the new cylinder by following the reverse procedure.

S
NOTE: Before tightening the hydraulic fittings, see the reference
table on Page 3.
Pict. 36

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 39

 Section: HYDRAULIC SYSTEM SERVICE

6.03 CABIN LIFTING CENTRAL CYLINDER REMOVAL

MOD. MO10E SL h2 1700mm

NECESSARY SPECIAL TOOLS

* Wooden beam 100x100x1000

* Plugs for pipe fittings

NECESSARY STANDARD TOOLS

HYDRAULIC

MEDIUM OPENING 5-6mm ALLEN 13-19 OPEN-ENDED NORMAL

SEEGER PLIERS WRENCH SPANNER PLIERS

PROCEDURE

Before starting to work wear suitable safety clothes. Pict. 37

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians.

1) WOODEN BEAM - Lift the forks till the beam passes under the bearing
support (Ref. V Pict. 38), lower the forks and lean them on the beam.
Lower the forks till the lifting chains and the hydraulic pipe are loose
V
enough to be removed from the pulley. Turn the key off and disconnect
the battery.

WARNING: The beam has an important safety function during

the whole phase of cylinder disassembly and assembly.
Therefore it must be placed in a standstill and safe position.

2) 5mm ALLEN WRENCH, 13mm Pict. 38

OPEN-ENDED SPANNER - By
means of the open-ended spanner W
unscrew and remove the bolt fixing the J
guard that prevents the chains from
slipping off the pulley (Ref. A Pict. 41). K
By means of the Allen wrench
Y
unscrew and remove the bolt fixing the
pipe sliding pulley (Ref. X Pict. 41), the
pulley with the pipe and the guard that
prevents the chains from slipping off Z
the pulley (Ref. B Pict. 41). SW15 SW16
Pict. 40 Pict. 39

Page: 40 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

3) SEEGER PLIERS - Remove the pulley support locking seeger (Ref.

T Pict. 41), and the space washers (Ref. U Pict. 41). T

4) 19mm OPEN-ENDED SPANNER, HYDRAULIC PIPE PLUGS - By U

means of the open-ended spanner unscrew the cylinder feed pipe
fitting (Ref. Z Pict. 39) and put the plugs on the pipe and cylinder
fitting so as to avoid any oil leaks. B
A

5) NORMAL PLIERS, 6mm ALLEN WRENCH - By means of the pliers

remove the split pins and the chain hinge pins (Ref. K-W Pict. 40),
detach the chains and remove them from the pulleys, remove the
pulley support from the cylinder (Ref. C Pict. 40). By means of the X

HYDRAULIC
C
Allen wrench unscrew and remove the bolts fixing the cylinder stop
collar (Ref. J Pict. 40). Remove the collar.
Turn the cylinder one fourth of a turn towards the coachwork, in order Pict. 41
to make the pipe fitting come out of the bracket (Ref. Y Pict. 39).
Remove the cylinder and place it on a clean bench. Replace the
gaskets or the complete cylinder.

Install the new cylinder by following the reverse procedure.

IMPORTANT:
After the cylinder has been assembled and the safety beam has been
removed, make sure the two sensor LEDs (SW15/16 Pict. 40) are on.
This means they are working and the chains are tensioned.

NOTE: Before tightening the hydraulic fittings, see the reference

table on Page 3.

Pict. 42

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 41

 Section: HYDRAULIC SYSTEM SERVICE

6.04 REMOVAL OF THE CABIN LIFTING CYLINDERS

MOD. MO10E SL h 3200

The cylinders can be removed in order to replace the gaskets or the whole
cylinder when the cabin is fastened to the mast.
The cylinders must be replaced one at a time by following the procedure
described below.

NECESSARY SPECIAL TOOLS

Wooden beam 100x100x1000

Bridge crane with proper carrying capacity
Lifting band with proper capacity
HYDRAULIC

NECESSARY STANDARD TOOLS

Pict. 01

FEMALE HYDRAULIC MALE HYDRAULIC 10-19-24 mm OPEN-

PLUG PLUG ENDED SPANNER

C Pict.02

MEDIUM 90° OPENING NORMAL STEPLADDER

SEEGER PLIERS PLIERS

PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians and lower the forks
to the ground.
1) WOODEN BEAM - Lift the cabin so that the beam passes under the
inner mast, then place the beam, lower the cabin and rest the mast on
the beam (Pict. 01).
Set the key-operated switch to “OFF” and disconnect the battery.
WARNING: The beam has an
important safety function during the
whole phase of cable assembly and
disassembly. Therefore it must be placed
in a correct and safe position.

B
A Pict.04 Pict.03

Page: 42 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

2) BRIDGE CRANE - LIFTING BAND - Fasten

the band to the upper part of the cabin and
fix the end parts of the band to the hook of
the bridge crane. Tension the band (Pict.
03).

3) STEPLADDER - NORMAL PLIERS - Put

the stepladder beside the truck near the
cylinder to be removed. Take away the split
pin for fastening the chain hinge pin (Ref. A D Pict.05
Pict. 04) and remove the pin (Ref. B Pict.
04). Climb the ladder and remove the chain from the pulley of the cylinder
to be removed, then place it in such a way that it does not hinder the

HYDRAULIC
cylinder removal.

4) 24 mm OPEN-ENDED SPANNER- Climb the ladder and unscrew and

remove the bolt for fastening the cylinder unit to the inner mast (Ref.C
Pict. 02).
Pict.06
5) In the motor compartment, remove the allen wrench from the valve unit of
the hydraulic power pack and enable the valve for the emergency descent.
Lower the cylinder completely (Ref. D Pict. 05).

6) 19 mm OPEN-ENDED SPANNER - MALE HYDRAULIC PLUG - FEMALE

G
HYDRAULIC PLUG - Screw the fitting out of the cylinder feed pipe (Ref. E
Pict. 07) by means of the spanner; put the female plug on the nipple of the F
cylinder and fix the male plug to the pipe fitting. Tighten by means of the
spanner.

7) SEEGER PLIERS - Remove the elastic ring for fastening the cylinder to E
its support (Ref. F Pict. 07) and take the washer (Ref. G Pict. 07). Pict.07

8) Lift the cylinder 100 m by withdrawing it from its support and take it away
from the mast (Pict. 08). Place the cylinder on a clean working table and
replace the gaskets or the whole cylinder.

Install a new cylinder by following the reverse procedure.

Pict.08

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 43

 Section: HYDRAULIC SYSTEM SERVICE

7.00 CYLINDER GASKET REPLACEMENT

MOD. MO10E FP - MO10E FF - MO10E SL

NECESSARY STANDARD TOOLS

PIN WRENCH SMALL SLOTTED OIL PROOF Pict. 43

WITH PIN Ø 5/6 SCREWDRIVER GLOVES
BUSH Ø 60÷80
HYDRAULIC

PROCEDURE
Pict. 44 G
Before starting to work wear suitable safety clothes.
I H

1) OIL PROOF GLOVES - Put on the gloves and place the cylinder,
wrapped in a rubber plate, into the vise (Pict. 43). Tighten carefully so
as to avoid the barrel ovalization.

Pict. 45
2) PIN WRENCH - By means of the wrench unscrew the gasket holding
bush (Ref. G Pict. 44) and withdraw it from the rod (Pict. 45). A

3) SLOTTED SCREWDRIVER - Before removing the gaskets, check

the direction in which they are positioned in order to reinstall the kit in
the same position. By means of the screwdriver remove the bush
external (Ref. H-I Pict. 45) and internal gaskets (Ref. A-B Pict. 46).
Clean the bush and lubricate the gasket seats carefully in order to
make the assembly operations easier. Install the new kit. B
Pict. 46

4) SLOTTED SCREWDRIVER - Withdraw the rod from the barrel (Pict.

47) and place it on a clean bench. By means of the screwdriver remove
the gaskets (Ref. C-D Pict. 48), clean and lubricate the gasket seats
and install the new kit.

Reassemble the cylinder by following the reverse procedure.

Pict. 47
NOTE: Tighten the bush to 340/410 Nm D

WARNING: After the cylinder has been installed on the machine,

pour 50cc oil through the plug placed under the bush
before use. C
Pict. 48

Page: 44 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

7.01 VALVE REPLACEMENT ON THE PISTON

MOD. MO10E FP - MO10E FF - MO10E SL

The continuous lifting of the forks can cause the lack of deceleration in
the last 50/40mm. There are two causes for this defect:
Pict. 49
a) Leak of the deceleration oil through the piston gasket. In this case the
gaskets must be replaced (see Paragraph 7.00)

b) Leak of the deceleration oil through the piston valve. In this case the
valve must be replaced by following the procedure described here
below.

HYDRAULIC
NECESSARY STANDARD TOOLS

E
Pict. 50

CLOSING SEEGER OPENING SEEGER OIL PROOF

PLIERS PLIERS GLOVES
FOR RING Ø 30mm WITH TIPS
PROCEDURE FOR HOLE Ø 10mm

Before starting to work wear suitable safety clothes.

Pict. 51

1) Withdraw the rod from the cylinder (see the procedure of paragraph
7.00) and place it on a clean bench.

2) CLOSING SEEGER PLIERS - By means of the pliers remove the

valve locking seeger (Ref. E Pict. 50 and Pict. 51). Remove the space
washer (Pict. 52).

3) SEEGER PLIERS WITH TIPS FOR HOLE Ø 10mm - Insert the tips of F
the pliers into the valve hole (Ref. F Pict. 52), open them in order to
make the tips adhere to the valve side walls and pull towards the outside Pict. 52
to withdraw the valve from its seat (Pict. 53). Replace it (Pict. 54).

Install the new valve by following the reverse procedure.

Reassemble the cylinder.

NOTE: Tighten the bush to 340 Nm

Pict. 53
WARNING: After the cylinder has been installed on the machine,
pour 50cc oil through the plug placed under the bush
before use (see Pict. 8 on Page 22).

Pict. 54

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 45

 Section: HYDRAULIC SYSTEM SERVICE

8.00 CYLINDER FEED HYDRAULIC PIPE REMOVAL

MOD. MO10E FP

NECESSARY STANDARD TOOLS

I
19mm OPEN- 5mm ALLEN SCISSORS OIL PROOF
ENDED SPANNER WRENCH GLOVES
HYDRAULIC

PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key OFF, disconnect the battery. Pict. 55

1) 5mm ALLEN WRENCH - Remove the rubber mat from the platform
footboard, remove the lexan plate, and by means of the wrench loosen
and remove the screws fixing the footboard (Ref. G Pict. 42). Remove
the footboard in order to reach the hydraulic pipe fitting (Ref. H Pict.
43). Remove the motor compartment hood in order to reach the
hydraulic power pack.
Pict. 56

2) 19mm OPEN-ENDED SPANNER, SCISSORS, OIL PROOF

GLOVES - Put on the oil proof gloves, by means of the scissors cut
and remove the clamps binding cables or other things to the pipe, H
thus releasing it from any hindrance. By means of the wrench unscrew
the fitting of the pipe connected to the lifting cylinder (Ref. H Pict. 43)
and the one of the pipe connected to the power pack (Ref. I Pict. 41).
Remove the pipe and replace it.

Install the new pipe by following the reverse procedure.

Pict. 57

NOTE: Before tightening the pipe fittings, see the reference table
on Page 3.

Page: 46 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

8.01 CYLINDER FEED HYDRAULIC PIPE REMOVAL

MOD. MO10E FF

NECESSARY SPECIAL TOOLS L

* WOODEN BEAM 100X100X800

* Plugs for fittings
NECESSARY STANDARD TOOLS

HYDRAULIC
19mm OPEN-ENDED SCISSORS OIL PROOF
SPANNER GLOVES Pict. 58

PROCEDURE
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians

1) WOODEN BEAM - Lift the forks till the beam passes between the
anchoring hook and the platform next to the bearing sliding profile Pict. 59
(Ref. N Pict. 46), lower the forks and lean the platform on the beam.
Turn the key off and disconnect the battery.

WARNING: The beam has an important safety function during

the whole phase of cylinder disassembly and assembly.
Therefore it must be placed in a standstill and safe position.
N

2) 19mm OPEN-ENDED SPANNER, SCISSORS, OIL PROOF

GLOVES - Remove the motor compartment hood and put on the
gloves. By means of the scissors cut the clamps binding cables or
other things to the pipe. By means of the open-ended spanner
unscrew and remove the fitting of the pipe connected to the power
pack (Ref. L Pict. 44) and the one of the pipe connected to the cylinder
Pict. 60
(Ref. M Pict. 47). Put the plugs on the cylinder and valve unit fittings in
order to avoid any oil leaks. Remove the pipe and replace it.

Install the new pipe by following the reverse procedure.

NOTE: Before tightening the pipe fittings, see the reference table
on Page 3.
M
Pict . 61
UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 47
 Section: HYDRAULIC SYSTEM SERVICE

8.02 FORK CYLINDER FEED HYDRAULIC PIPE REMOVAL

MOD. MO10E SL h2 1700mm

The pipe feeding the fork lifting cylinder is subdivided into three sections,
two of which consist of Parker flexible pipes and the last one, which is
connected to the cylinder, is a rigid pipe. This section explains how to
remove the pipe first section, which comes out of the valve unit and
reaches the first joint, and how to remove the second section, which
comes out of the first joint and, through the sliding pulley, reaches the
second joint.
O
8.03 PIPE FIRST SECTION REMOVAL
HYDRAULIC

NECESSARY SPECIAL TOOLS

* Wooden beam 100X100X1000mm

* Plugs for pipe fittings
NECESSARY STANDARD TOOLS
Pict. 62

Q
19mm OPEN- SCISSORS 5mm ALLEN OIL PROOF
ENDED SPANNER WRENCH GLOVES
PROCEDURE
P
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians

1) WOODEN BEAM - Lift the forks till the beam passes under the bearing Pict. 63
support (Ref. O Pict. 62), lower the forks and lean them on the beam.
Turn the key off and disconnect the battery.
2) 19mm OPEN-ENDED SPANNER, SCISSORS, OIL PROOF
GLOVES - Remove the motor compartment hood and put on the
gloves. By means of the scissors cut the clamps binding cables or
other things to the pipe. By means of the open-ended spanner
R
unscrew and remove the fitting of the pipe connected to the power
pack (Ref. R Pict. 64) and the one of the pipe connected to the first
joint (Ref. P Pict. 63). Put the plugs on the intermediate pipe fitting
and on the valve unit fittings in order to avoid any oil leaks. Remove
the pipe and replace it.

Install the new pipe by following the reverse procedure.

NOTE: Before tightening the pipe fittings, see the reference table
on Page 3. Pict. 64

Page: 48 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: HYDRAULIC SYSTEM

8.03 PIPE SECOND SECTION REMOVAL

1) WOODEN BEAM - Lift the cabin till the pipe holding pulley (Pict. 65)
and the pipe fitting (Pict. 67) are in the working position (Ref. A Pict.
66). Place a beam of adequate size under the bearing support (Ref.
O Pict. 62), lower the forks and lean them on the beam. Lower the S
forks till the hydraulic pipe is loose enough to be removed from the
pulley. Turn the key off and disconnect the battery.
Pict. 65

2) 5mm ALLEN WRENCH - Unscrew and remove the bolt fixing the
pipe sliding pulley (Ref. S Pict. 65). Remove the pulley and release

HYDRAULIC
the pipe.

3) 19mm OPEN-ENDED SPANNER, OIL PROOF GLOVES - Put on

the gloves. By means of the open-ended spanner unscrew and remove
the fitting of the pipe connected to the first joint (Ref. Q Pict. 63) and A
the fitting of the pipe connected to the second joint (Ref. T Pict. 67).
Put the plugs on the intermediate pipe and second pipe fitting so as
to avoid any oil leaks. Remove the pipe and replace it.

Install the new pipe by following the reverse procedure.

NOTE: Before tightening the pipe fittings, see the reference table
on Page 3.

Pict. 66

Pict. 67

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 49

 Section: HYDRAULIC SYSTEM SERVICE

8.04 REPLACEMENT OF THE FORK CYLINDER FEED HYDRAULIC PIPE

MOD. MO10E h 3200mm

NECESSARY SPECIAL TOOLS

* No.2 100X100X1100 wooden beams

NECESSARY STANDARD TOOLS

No. 2 19 mm
OPEN-ENDED
SPANNER
HYDRAULIC

PROCEDURE

Before starting to work wear suitable safety clothes.

Pict. 01

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians and lower the forks
to the ground.

1) WOODEN BEAMS - Lift the cabin so that the beams pass under the
cabin itself. Place the beams (Pict. 01). Lower the cabin and rest it
on the beams; keep on lowering the cabin until the pipe is loose.
Set the key-operated switch to “OFF” and disconnect the battery.

WARNING: The beams have an important safety function during

the whole phase of cable assembly and disassembly. Therefore C
they must be placed in a correct and safe position. Pict. 02

2) 19mm OPEN-ENDED SPANNER - Unscrew and remove the pipe

fitting fastened to the base truck (Ref. A Pict. 05). Unscrew and remove
the pipe fitting fixed to the cabin (Ref. B Pict. 04).
Unscrew the bolt fastening the pipe sliding pulley (Ref. C Pict. 02)
with the two open-ended spanners, remove the pulley and take off the
pipe. Carry out the replacement.
Install a new pipe by following the reverse procedure.

A B Pict. 04 Pict. 03
Pict. 05
Page: 50 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE
SERVICE Section: HYDRAULIC SYSTEM

8.05 CABIN CYLINDER FEED HYDRAULIC PIPE REMOVAL

MOD. MO10E SL h2 1700mm

NECESSARY SPECIAL TOOLS

* Wooden beam 100X100X1000mm

* Plugs for pipe fittings
NECESSARY STANDARD TOOLS U

HYDRAULIC
19mm OPEN-ENDED SCISSORS OIL PROOF
SPANNER GLOVES

PROCEDURE
Pict. 68
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians

1) WOODEN BEAM - Lift the forks till the beam passes under the bearing
support (Ref. U Pict. 68), lower the forks and lean them on the beam.
Turn the key off and disconnect the battery.
V

2) 19mm OPEN-ENDED SPANNER, SCISSORS, OIL PROOF GLOVES Pict. 69

- Remove the motor compartment hood and put on the gloves. By means
of the scissors cut the clamps binding cables or other things to the Z
pipe. By means of the open-ended spanner unscrew and remove the
fitting of the pipe connected to the power pack (Ref. Z Pict. 70) and the
fitting of the pipe connected to the cabin lifting cylinder (Ref. V Pict. 69).
Put the plugs on the valve unit and cylinder fittings in order to avoid any
oil leaks. Remove the pipe and replace it.

Install the new pipe by following the reverse procedure.

NOTE: Before tightening the pipe fittings, see the reference table
on Page 3.

Pict. 70

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2004 Part No: 524182160 Page: 51

 Section: HYDRAULIC SYSTEM SERVICE

NOTES:
HYDRAULIC

Page: 52 Part No: 524182160 Date: Sept. 2004 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

MECCANICA
MECHANICAL
SECTION

MECHANICAL
D GUIDE TABLE FOR THE CHOICE OF LIFTING STRAPS....................... 2
D SCREW DRIVING TORQUE TABLE ........................................................ 3
D TRACTION WHEEL REMOVAL - MOD. ALL MODELS ........................... 4
D LOAD WHEEL REMOVAL - MOD. M010E FP ......................................... 5
D LOAD WHEEL REMOVAL - MOD. M010E FF-SL-WP ............................. 6
D TRACTION MOTOR REMOVAL - MOD. ALL MODELS ........................... 7
D TRACTION MOTOR COMPONENTS - MOD. ALL MODELS .................. 9
D TRACTION MOTOR BEARING REPLACEMENT .................................... 10
D TRACTION MOTOR BRUSH REPLACEMENT ....................................... 11
D MOTOR PUMP UNIT REMOVAL - MOD. M010E FP ............................... 13
D MOTOR PUMP UNIT REMOVAL - MOD. M010E FF-WP ........................ 18
D MOTOR PUMP UNIT REMOVAL - MOD. M010E SL ...............................21
D LIFTING CHAINS - MOD. ALL MODELS .................................................26
D LIFTING CHAIN REMOVAL - MOD. ALL MODELS ..................................28
D LIFTING CHAIN REMOVAL - MOD. M010E h3200 ................................. 32
D PLATFORM SIDE GUARD COMPONENTS - MOD. M010E SL-WP .......36
D SIDE GUARD REPAIR AND REMOVAL - MOD. M010E SL-WP .............38
D MOVABLE FORK UNIT COMPONENTS - MOD. M010E FP-SL .............44
D FIXED FORK UNIT COMPONENTS - MOD. M010E FP-SL .................... 45
D BEARING REPLACEMENT ON THE FORK UNITS ................................ 46
D STEERING WHEEL UNIT BEARING REPLACEMENT ........................... 50

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 1

 MECHANICAL Section SERVICE
1.00 GUIDE TABLE FOR THE CHOICE OF LIFTING STRAPS
COMPLYING WITH THE MACHINE DIRECTIVE “No. 89/392 CE” AND WITH THE
FOLLOWING AMENDMENTS
COMPLYING WITH THE MACHINE DIRECTIVE “No. 91/36 CE” AND WITH THE
FOLLOWING AMENDMENTS
In order to work safely, before lifting any truck or similar things, it is necessary to evaluate its
weight and dimensions. This is useful in the choice of straps with slots or ropes with hooks.
The tables represented here below are an important guide to the choice of the strap or rope to
be used.
A) TABLE FOR THE CHOICE OF A STRAP WITH SLOTS
THE LENGTH OF THE STRAP WITH SLOT-SHAPED ENDS DEPENDS ON THE DIMENSIONS OF THE
OBJECT TO BE LIFTED
USE OF THE STRAP ACCORDING TO THE WEIGHT
Vertical U Triangle Circular

Strap
STRAP COLOUR Width

mm Kg Kg Kg Kg
MECHANICAL

BLACK 35 500 1.000 700 400

VIOLET 50 1.000 2.000 1.400 800
BLACK 50 1.500 3.000 2.100 1.200
GREEN 60 2.000 4.000 2.800 1.600
YELLOW 75 3.000 6.000 4.200 2.400
GREY 120 4.000 8.000 5.600 3.200
RED 150 5.000 10.000 7.000 4.000
BROWN 180 6.000 12.000 8.400 4.800
BLUE 240 8.000 16.000 11.200 6.400
ORANGE 300 10.000 20.000 14.000 8.000

B) TABLE FOR THE CHOICE OF ROPES WITH HOOKS

THE LENGTH OF THE ROPE WITH HOOKS VARIES BETWEEN 0,50 AND 2,00 mt AND
DEPENDS ON THE DIMENSIONS OF THE OBJECT TO BE LIFTED
USE OF THE ROPES ACCORDING TO THE WEIGHT
1 Rope 2 Ropes 3 Ropes 4 Ropes

ROPE COLOUR

Kg Kg Kg Kg
VIOLET 1.000 1.400 2.100 2.100
GREEN 2.000 2.800 4.200 4.200
YELLOW 3.000 3.800 6.300 6.300
GREY 4.000 5.600 8.400 8.400
RED 5.000 6.600 9.800 10.500

Page: 2 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

1.01 SCREW DRIVING TORQUE TABLE

NOTE: before disassembling and reassembling the various components, bolts and screws,
read carefully what is specified here below.

In order to tighten the screws, product LOCTITE 270 is used to prevent the unscrewing of the threaded
couplings.

By loosening the screws, you can notice a certain resistance. If it is not possible to unscrew them by
means of standard tools, do not use any extensions (the screw heads could break), but heat the area

MECCANICA
slightly, in order to avoid the Loctite effect (max 50°c).

In the previously described cases use the Loctite in moderate quantity during the assembly phase (usually
the 30% of the coupling surface must be covered).

The torque with which the threaded joints are tightened is of the utmost importance for the safety of the
joint itself and of the truck.

In the following table there is a description of the classes of bolts and nuts that are generally used with
the corresponding driving torques.

MECHANICAL
NOM SIZE TENSILLE PROPERTY CLASS 5.8 PROPERTY CLASS 8.8 PROPERTY CLASS 10.9
X STRESS CLAMP TORQUE (N.m CLAMP TORQUE (N.m) CLAMP TORQUE (N.m)
PITCH AREA LOAD DRY LUBEET LOAD DRY LUBED LOAD DRY LUBED
As (mm) W (N) K=0.20 K=0.15 W (N) K=0.20 K=0.15 W (N) K=0.20 K=0.15

M4 x 0,5 8,78 2 400 1,92 1,44 3 830 3,07 2,30 5 220 4,17 3,13
M5 x 0,8 14,20 3 880 3,88 2,91 6 200 6,20 4,65 8 430 8,43 6,33
M6 x 1 20,10 5 490 6,58 4,94 8 770 10,50 7,90 11 950 14,30 10,80

M8 x 1,25 36,60 9 990 16,00 12,00 15 975 25,60 19,20 21 750 34,80 26,10
M8 x 1 39,20 10 700 17,10 12,80 17 100 27,40 20,50 23 275 37,30 27,90
M10 x 1,5 58,00 15 825 31,70 23,80 25 325 51,00 38,00 34 450 69,00 52,00
M10 x 1,25 61,20 16 700 33,40 25,10 25 725 53,00 40,10 36 350 73,00 55,00

M12 x 1,75 84,30 23 025 55,00 41,40 36 800 88,00 66,00 50 075 120,00 90,00
M12 x 1,25 92,10 25 150 60,00 45,30 40 200 96,00 72,00 54 700 130,00 98,00
M14 x 2 115,00 31 400 88,00 66,00 50 200 140,00 105,00 68 300 190,00 145,00
M14 x 1,5 125,00 34 125 96,00 72,00 54 550 155,00 115,00 74 250 210,00 155,00

M16 x 2 157,00 42 850 135,00 105,00 68 525 220,00 165,00 93 250 300,00 225,00
M16 x 1,5 167,00 45 600 145,00 110,00 72 900 235,00 175,00 99 200 320,00 240,00
M20 x 2,5 245,00 66 875 270,00 200,00 106 950 430,00 320,00 145 550 580,00 435,00
M20 x 1,5 272,00 74 250 295,00 225,00 118 750 475,00 355,00 161 550 650,00 485,00
Table.1

NOTE: In order to assemble the machine use bolts PROPERTY CLASS 8.8 - LUBED

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 3

 MECHANICAL Section SERVICE

2.00 TRACTION WHEEL REMOVAL

MOD. ALL MODELS

NECESSARY SPECIAL TOOLS

* No. 2 Wooden blocks 100x100x100

NECESSARY STANDARD TOOLS

SOCKET WRENCH WITH HYDRAULIC

22MM RATCHET JACK
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other Pict. 01
motor vehicles and from the passage of pedestrians, lower the
MECHANICAL

forks to the ground, turn the key-operated switch OFF,

disconnect the battery.

1) HYDRAULIC JACK, WOODEN BLOCKS - Remove the motor

compartment hood. Place the jack in front of the coachwork in the
position indicated by the arrow and lift it up to the passage of the
wooden blocks (Pict. 01). Place the wooden blocks under the
coachwork and lower the jack by leaning the coachwork on the
wooden blocks. Remove the jack.

2) SOCKET WRENCH WITH 22MM RATCHET - From inside the motor

compartment unscrew and remove the nuts fixing the wheel to the Pict. 02
reduction unit (Pict. 02). Remove the wheel and replace it.

Install the new wheel by following the reverse procedure.

IMPORTANT: Tighten the nuts with a twist of 200 Nm

Page: 4 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

2.01 LOAD WHEEL REMOVAL

MOD. MO10E FP

NECESSARY SPECIAL TOOLS

* Wooden block 100x100x100

NECESSARY STANDARD TOOLS

MECCANICA
Pict. 03

4mm ALLEN THREADED ROD Ø 8 HYDRAULIC

WRENCH WITH STOP CYLINDER JACK

PROCEDURE
Pict. 04
Before starting to work wear suitable safety clothes.

MECHANICAL
Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians, lower
the forks to the ground, turn the key-operated switch OFF, A
disconnect the battery. B

1) HYDRAULIC JACK, WOODEN BLOCK - Position the jack under Pict. 05

the truck anchoring hook in the position indicated by the arrow (Pict.
03) and lift it up to the passage of the wooden block under the
anchoring hook. Position the wooden block as shown in Pict. 04
and lower the jack by leaning the coachwork on the wooden block.

2) 4mm ALLEN WRENCH, THREADED ROD WITH STOP CYLINDER A

- By means of the wrench loosen and remove the screws fixing the
pin (Ref. A Pict. 05/06). Screw the rod into the pin threaded hole
(Ref. B Pict. 05/06), and, by means of the stop cylinder, beat till the
pin has been completely withdrawn. Take the wheel and replace it B
(Pict. 06). Pict. 06

Install the new wheel by following the reverse procedure.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 5

 MECHANICAL Section SERVICE

2.02 LOAD WHEEL REMOVAL

MOD. MO10E FF - MO10E SL - MO10E WP

The hinge pins of the load wheels must be withdrawn from the inside of
the machine anchoring hooks. Therefore the cabin must be lifted enough
to remove the hinge pins.
JACK
NECESSARY SPECIAL TOOLS
BEAM
* Wooden block 100x100x100
* Wooden beam of adequate size
Pict. 07
NECESSARY STANDARD TOOLS

D
C
4mm ALLEN THREADED ROD Ø M8/10 HYDRAULIC
MECHANICAL

WRENCH WITH STOP CYLINDER JACK

PROCEDURE Pict. 08

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians and lower the forks
to the ground.

JACK
1) WOODEN BEAM - Lift the cabin till the beam passes under the bearing
support, lower the cabin and lean it on the beam. Put the key-operated
switch in OFF position and disconnect the battery. BEAM

Pict. 09
1) HYDRAULIC JACK, WOODEN BLOCK - Position the jack under the
truck anchoring hook in the position indicated by the arrow (Pict. 07-
09) and lift it up to the passage of the wooden block under the anchoring hook. Position the wooden
block as shown in Pict. 08 and lower the jack by leaning the coachwork on the wooden block.

2) 4mm ALLEN WRENCH, THREADED ROD WITH STOP CYLINDER - By means of the wrench loosen
and remove the screws fixing the pin (Ref. C Pict. 08). Screw the rod into the pin threaded hole (Ref.
D Pict. 08), and, by means of the stop cylinder, beat till the pin has been completely withdrawn. Take
the wheel and replace it.

Install the new wheel by following the reverse procedure.

Page: 6 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

2.03 TRACTION MOTOR REMOVAL

MOD. ALL MODELS

The traction and steering motors are installed very close to one another,
as you can see in Pict. 10. Therefore, before disassembling the traction
motor, it is necessary to disassemble the steering motor.

NECESSARY STANDARD TOOLS

MECCANICA
Pict. 10

3-5mm ALLEN 13 OPEN-ENDED

WRENCH SPANNER
PROCEDURE
E
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor

MECHANICAL
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the Pict. 11
battery.

1) 3mm ALLEN WRENCH - Remove the motor compartment hood and

disassemble the steering motor. By means of the wrench loosen and
F
remove the screws fixing the steering motor upper cover (Ref. E Pict.
11). Remove the cover. By means of the same wrench loosen the
screws fixing the motor feeding cables (Ref. F Pict. 12) and remove
the cables.
Pict. 12

2) 5mm ALLEN WRENCH - Unscrew and remove the bolt fixing the
steering pinion to the driving shaft (Ref. G Pict. 13) and withdraw the
pinion from the shaft (Pict. 14).

3) 13mm OPEN-ENDED SPANNER - Unscrew and remove the bolts

fixing the steering motor to the reduction unit support (Ref. H Pict.
14), withdraw the steering motor from the support (Pict. 15) and
position it on a bench. G

Pict. 13

NOTE: The above described procedure

must also be followed also when
only the steering motor is to be
replaced.

Pict. 15 Pict. 14

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 7

 MECHANICAL Section SERVICE

4) 13mm OPEN-ENDED SPANNER - Remove the caps from the motor

terminal board nuts and, by means of the wrench, unscrew and
remove the nuts fixing the motor feeding cables (Ref. I F Pict. 17).
Remove the terminal board cables and disconnect the brake
connector.

5) By means of the same wrench, unscrew and remove the nuts fastening L
the motor to the reduction unit (threaded rods) (Ref. L Pict. 16), Pict. 16
withdraw the motor from the reduction unit threaded rods (Pict. 18)
and position it on a clean bench with vise. Replace or disassemble it
in order to repair it.

Install the new motor by following the reverse procedure.

I
MECHANICAL

Pict. 17

Pict. 18

Page: 8 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

2.03 TRACTION MOTOR COMPONENTS

MOD. ALL MODELS

8 4
6

MECCANICA
7 5

MECHANICAL
3

TRACTION MOTOR COMPONENT TABLE

Ref. Component Description
1 2,500 Kw complete motor
2 Stator frame
3 Rotor
4 Upper flange bearing
5 Terminal board for the cable connection
6 Brushes (No. 8)
7 Brush pressure springs
8 Brush protective band
Pict. 19

NOTE: Look for the Yale spare parts of the various components in the spare parts catalogue

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 9

 MECHANICAL Section SERVICE

2.04 MOTOR BEARING REPLACEMENT

MOD. ALL MODELS

After the motor has been removed from the machine,

disassemble it in order to replace the only bearing of the rotor.

NECESSARY STANDARD TOOLS

Pict. 20

MEDIUM OPENING MEDIUM CLOSING M

SEEGER PLIERS SEEGER PLIERS

PIN VULCOLAN
HAMMER
MECHANICAL

PROCEDURE

Before starting to work wear suitable safety clothes. Pict. 21

1) MEDIUM OPENING SEEGER PLIERS - Position the motor

on a clean bench. By means of the pliers remove the
locking seegers (Ref. M Pict. 21) and withdraw the rotor
Pict. 22
from the stator. Put the stator in vertical position (Pict. 23).

2) CLOSING SEEGER PLIERS, HAMMER, PIN - By means of the pliers

remove the bearing locking seeger (Ref. N Pict. 24). Put the stator in
horizontal position and, by means of the hammer and the pin, take out
the bearing from its seat towards the internal part of the stator. Replace
it and reassemble completely the whole group.

Install the bearing and assemble the motor by following the reverse
procedure.
Pict. 23

Pict. 24

Page: 10 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

2.05 TRACTION MOTOR BRUSH REPLACEMENT

MOD. ALL MODELS
O
NECESSARY STANDARD TOOLS

MEDIUM SLOTTED SPRING

SCREWDRIVER TENSIONER

MECCANICA
PROCEDURE Pict. 25

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians, lower the
forks to the ground, turn the key-operated switch OFF,
disconnect the battery.

MECHANICAL
1) Remove the motor compartment hood in order to reach the systems. Pict. 26
Remove the brush protective band (Ref. O Pict. 25)

P Q
2) SCREWDRIVER, TENSIONER - By means of the screwdriver loosen
and remove the screw fixing the brushes (Ref. P Pict. 27). By means
of the tensioner lift the brush pressure spring (Ref. Q Pict. 27) and
withdraw the brushes from their seat in order to replace them.

Pict. 27
Install the brushes by following the reverse procedure.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 11

 MECHANICAL Section SERVICE

2.06 TRACTION AND STEERING MOTOR NUT AND BOLT DRIVING TORQUE
MOD. ALL MODELS

After the motors have been assembled, observe the driving torques of bolts and nuts as shown in Pict. 28.

No. 3 BOLTS FIXING THE

ELECTRIC BRAKE
TIGHTEN TO 14Nm

No. 4 NUTS (M8X1,25)

FIXING THE CABLES
TIGHTEN TO 8,5 Nm
MECHANICAL

No. 4 NUTS (M8X1,25)

FIXING THE MOTOR
TIGHTEN TO 34,8 Nm

No. 4 BOLTS FIXING THE

STEERING MOTOR
TIGHTEN TO 26 Nm
LOCTITE # 243

No. 1 BOLT FIXING THE PINION TO

THE STEERING MOTOR
TIGHTEN TO 14Nm LOCTITE # 243 Pict. 28

Page: 12 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

3.00 MOTOR PUMP UNIT REMOVAL

MOD. MO10E FP

The hydraulic unit must be removed when it is necessary to replace the

pump unit, which is fixed on the flange inside the tank.

NECESSARY STANDARD TOOLS

MECCANICA
17mm SOCKET 13-19 OPEN- MEDIUM SLOTTED
WRENCH ENDED SPANNER SCREWDRIVER
PROCEDURE
Before starting to work wear suitable safety clothes. T
Pict. 29
Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians, lower the

MECHANICAL
forks to the ground, turn the key-operated switch OFF, disconnect
the battery.

1) Remove the motor compartment hood in order to reach the hydraulic

unit. The motor pump unit is fixed on the coachwork right side (driver’s S Pict. 30
side) by means of two bolts, which are screwed inside the battery
compartment. Therefore it is necessary to withdraw the battery in order
to reach the bolts. Remove the battery lock (Ref. T Pict. 29) from the
opposite side where the unit is located, withdraw the battery for about P
300mm till you reach the bolts fixing the unit (Pict. 30).
Q
2) 19mm OPEN-ENDED SPANNER, PHILLIPS SCREWDRIVER - By
means of the wrench unscrew the pipe hydraulic fitting (Ref. Q Pict.
31) and detach the pipe from the unit. By means of the screwdriver
R
loosen and remove the solenoid valve feeding connector (Ref. R Pict.
31).

3) 13mm OPEN-ENDED SPANNER - Remove the rubber caps from the

cable connecting terminals and, by means of the wrench, unscrew
and remove the fixing nuts (Ref. P Pict. 31). Detach the cables from Pict. 31
the motor.

4) 17mm SOCKET WRENCH WITH RATCHET - Unscrew and remove the two bolts fixing the unit to the
coachwork from the battery compartment (Ref. S Pict. 30), disassemble the complete unit and replace
or disassemble it in order to repair it.

Install the new unit by following the reverse procedure.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 13

 MECHANICAL Section SERVICE

3.01 PUMP CASING REPLACEMENT

MOD. MO10E FP

After removing the motor pump unit, place it on a clean bench.

NECESSARY STANDARD TOOLS

10mm OPEN-ENDED MEDIUM SLOTTED 5mm ALLEN

SPANNER SCREWDRIVER WRENCH
Pict. 32
PROCEDURE

Before starting to work wear suitable safety clothes.

1) 10mm OPEN-ENDED SPANNER, SLOTTED SCREWDRIVER - By

MECHANICAL

means of the screwdriver loosen the screw that tightens the steel clamp Pict. 33 U V
fastening the tank to the flange (Ref. U Pict. 33). By means of the
open-ended spanner loosen and remove the four screws fixing the
tank to the flange (Ref. V Pict. 33) and withdraw the motor pump with
flange from the tank (Pict. 34).

2) 5mm ALLEN WRENCH - Lower the thin blade locking the pipe with
filter (Ref. W Pict. 34) and withdraw the pipe from the pump casing. By
means of the wrench unscrew and remove the two bolts fixing the
pump casing to the flange (Ref. Z Pict. 34), remove the pump and
replace it.

Install the pump casing by following the reverse procedure.

Z
W
NOTE: Pump bolt driving torque of 22Nm.

Pict. 34

Page: 14 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

3.02 PUMP MOTOR REMOVAL K

MOD. MO10E FP

NECESSARY STANDARD TOOLS

Y
11-13mm OPEN-

MECCANICA
ENDED SPANNER
PROCEDURE

Before starting to work wear suitable safety clothes. Pict. 35

Park the truck in a safe area, away from the transit of other motor K
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the
battery.

MECHANICAL
1) 13mm OPEN-ENDED SPANNER - The motor must be replaced while J
the hydraulic power pack is still fixed on the machine. Remove the
motor compartment hood. Remove the caps from the bolts fixing the
cables to the motor and, by means of the wrench, unscrew and remove
the nuts (Ref. Y Pict. 35). Detach the cables from the motor.

2) 11mm OPEN-ENDED SPANNER - Unscrew and remove the two bolts

fixing the motor to the flange (Ref. K Pict. 35/36), lift up the complete
Pict. 36
motor, take it and replace it.

WARNING: pay attention to the joint connecting the motor to the pump. It must be reused and positioned
in the middle. It must be placed on the pump upper part (Ref. J Pict. 36).

Install the new pump by following the reverse procedure.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 15

 MECHANICAL Section SERVICE

3.03 BRUSH REPLACEMENT PROCEDURE

MOD. MO10E FP
X A
NECESSARY STANDARD TOOLS

11mm OPEN- MEDIUM SLOTTED SPRING

ENDED SPANNER SCREWDRIVER TENSIONER
Pict. 33
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the
battery.

1) 11mm OPEN-ENDED SPANNER - Remove the motor compartment

MECHANICAL

hood. By means of the wrench unscrew and remove the two bolts
fixing the motor to the flange (Ref. X Pict. 33), lift the cover (Ref. A
Pict. 33) by blocking the motor on the flange and putting the brush
holder where it can be seen (Pict. 34).
Pict. 34

2) SLOTTED SCREWDRIVER, SPRING TENSIONER - By means of

the screwdriver loosen and remove the screws fixing the brushes to
the brush holder (Ref. B Pict. 35) and, by means of the spring tensioner,
lift the spring pressing the brush on the rotor (Ref. C Pict. 35). Withdraw
the brushes and replace them.
C

Install the new brushes by following the reverse procedure. B

Pict. 35

Page: 16 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

3.04 HYDRAULIC POWER PACK BOLT AND NUT DRIVING TORQUE WITH 2,00 Kw PUMP
MOTOR
MOD. MO10E FP

After the motors have been assembled, respect the driving torques of bolts and nuts as shown in Pict. 36.

No. 2 BOLTS FIXING THE

MOTOR TO THE HYDRAULIC

MECCANICA
POWER PACK. TIGHTEN TO
5Nm
No. 2 NUTS
(M8X1,25)
FIXING THE CABLES
TIGHTEN TO 12Nm MAXIMUM PRESSURE
VALVE BODY
SOLENOID VALVE BODY TIGHTEN TO 10Nm
TIGHTEN TO 30Nm

MECHANICAL
No. 4 BOLTS
FIXING THE TANK
TIGHTEN TO 4Nm

No. 2 BOLTS FIXING THE

PUMP CASING
TIGHTEN TO 22Nm

Pict. 36

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 17

 MECHANICAL Section SERVICE

3.05 MOTOR PUMP UNIT REMOVAL

MOD. MO10E FF - MO10E WP

The hydraulic unit must be removed when it is necessary to replace the

pump casing, which is fixed on the flange inside the tank.

NECESSARY STANDARD TOOLS

17mm SOCKET 17-19 OPEN- MEDIUM SLOTTED

WRENCH ENDED SPANNER SCREWDRIVER
PROCEDURE

Before starting to work wear suitable safety clothes. H Pict. 37

Park the truck in a safe area, away from the transit of other motor
MECHANICAL

vehicles and from the passage of pedestrians, lower the forks to

the ground, turn the key-operated switch OFF, disconnect the
battery.

1) The motor pump unit is fixed on the coachwork right side (driver’s G Pict. 38
side) by means of two bolts, which are screwed inside the battery
compartment. Therefore it is necessary to withdraw the battery in order
to reach the bolts. Remove the battery lock (Ref. H Pict. 37) from the
F
opposite side where the unit is located, withdraw the battery for about
300mm till you reach the bolts fixing the unit (Pict. 38).

2) 19mm OPEN-ENDED SPANNER, SLOTTED SCREWDRIVER - By E

means of the wrench unscrew the pipe hydraulic fitting (Ref. D Pict.
39) and detach the pipe from the unit. By means of the screwdriver
loosen and remove the solenoid valve feeding connector (Ref. E Pict.
39).

3) 17mm OPEN-ENDED SPANNER - Remove the rubber caps from the

D
cable connecting terminals and, by means of the wrench, unscrew
and remove the fixing nuts (Ref. F Pict. 39). Detach the cables from
the motor.

3) 17mm SOCKET WRENCH WITH RATCHET - From the battery

compartment unscrew and remove the two bolts fixing the unit to the
coachwork (Ref. S Pict. 38), take the complete unit and replace or Pict. 39
disassemble it in order to repair it.

Install the new unit by following the reverse procedure.

Page: 18 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

3.06 PUMP CASING REPLACEMENT

MOD. MO10E FF - MO10E WP

After removing the hydraulic unit, place it on a clean bench.

NECESSARY STANDARD TOOLS

MECCANICA
10mm OPEN- MEDIUM SLOTTED 5mm ALLEN
ENDED SPANNER SCREWDRIVER WRENCH

PROCEDURE

Before starting to work wear suitable safety clothes.

Pict. 40

MECHANICAL
1) 10mm OPEN-ENDED SPANNER, SLOTTED SCREWDRIVER - By
means of the screwdriver loosen the screw that tightens the steel clamp N
fastening the tank to the flange (Ref. N Pict. 41). By means of the
open-ended spanner loosen and remove the four screws fixing the
tank to the flange (Ref. I Pict. 41), withdraw the motor pump with flange
from the tank (Pict. 42).
I Pict. 41

2) 5mm ALLEN WRENCH - Lower the thin blade locking the pipe with
filter (Ref. L Pict. 42) and withdraw the pipe from the pump casing. By
means of the wrench unscrew and remove the two bolts fixing the
pump casing to the flange (Ref. M Pict. 42), remove the pump and
replace it.

Install the pump casing by following the reverse procedure.

NOTE: Pump bolt driving torque of 22Nm.

Pict. 42

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 19

 MECHANICAL Section SERVICE

3.07 PUMP MOTOR REMOVAL

MOD. MO10E FF - MO10E WP

NECESSARY STANDARD TOOLS O

6mm ALLEN 17mm OPEN-ENDED

WRENCH SPANNER

PROCEDURE
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the Pict. 43
MECHANICAL

battery.

1) 17mm OPEN-ENDED SPANNER - The motor must be replaced while

the hydraulic power pack is still fixed on the machine. Remove the
motor compartment hood. Remove the caps from the bolts fixing the
cables to the motor and, by means of the wrench, unscrew and remove
the nuts (Ref. O Pict. 43). Detach the cables from the motor.

P
2) 6mm ALLEN WRENCH - Unscrew and remove the three bolts fixing
the motor to the flange (Ref. P Pict. 44), lift the complete motor and
replace it. Q

WARNING: Pay attention to the joint connecting the motor to the pump.
It must be reused and positioned in the middle. It must be
placed on the pump upper part (Ref. Q Pict. 44).

Install the new pump by following the reverse procedure.

Pict. 44

Page: 20 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

3.08 MOTOR PUMP UNIT REMOVAL

MOD. MO10E SL

The hydraulic unit must be removed when it is necessary to replace the

pump casing, which is fixed on the flange inside the tank.

NECESSARY STANDARD TOOLS

MECCANICA
17mm SOCKET 17-19 OPEN- MEDIUM SLOTTED
WRENCH ENDED SPANNER SCREWDRIVER
PROCEDURE R
Pict. 45
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor

MECHANICAL
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the
battery.
S Pict. 46
1) Remove the motor compartment hood in order to reach the hydraulic
unit. The motor pump unit is fixed on the coachwork left side (driver’s
side) by means of two bolts, which are screwed inside the battery
compartment. Therefore it is necessary to withdraw the battery in order V
to reach the bolts. Remove the battery lock (Ref. R Pict. 45) from the
opposite side where the unit is located, withdraw the battery for about
300mm till you reach the bolts fixing the unit (Pict. 46).
T
2) 19mm OPEN-ENDED SPANNER, SLOTTED SCREWDRIVER - By
means of the wrench unscrew the pipe hydraulic fitting (Ref. T Pict.
47) and detach the pipes from the unit. By means of the screwdriver
loosen and remove the solenoid valve feeding connector (Ref. U Pict. U
47).
D
3) 17mm OPEN-ENDED SPANNER - Remove the rubber caps from the
motor cable connecting terminals. By means of the wrench, unscrew
and remove the fixing nuts (Ref. V Pict. 47). Detach the cables from Pict. 47
the motor.

4) 17mm SOCKET WRENCH WITH RATCHET - Unscrew and remove the two bolts
fixing the unit to the coachwork from the battery compartment (Ref. S Pict. 46), remove
the complete unit and replace or disassemble it in order to repair it.

Install the new unit by following the reverse procedure.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 21

 MECHANICAL Section SERVICE

3.09 PUMP CASING REPLACEMENT

MOD. MO10E SL

After removing the hydralic unit, place it on a clean bench.

NECESSARY STANDARD TOOLS

10mm OPEN- MEDIUM SLOTTED 5mm ALLEN

ENDED SPANNER SCREWDRIVER WRENCH

PROCEDURE

Before starting to work wear suitable safety clothes. Pict. 49

MECHANICAL

1) 10mm OPEN-ENDED SPANNER, SLOTTED SCREWDRIVER - By Z

means of the screwdriver loosen the screw that tightens the steel clamp
fastening the tank to the flange (Ref. Z Pict. 50). By means of the
open-ended spanner loosen and remove the four screws fixing the
tank to the flange (Ref. W Pict. 50) and withdraw the motor pump with
flange from the tank (Pict. 51).
W Pict. 50
2) 5mm ALLEN WRENCH - Lower the thin blade locking the pipe with
filter (Ref. K Pict. 51) and withdraw the pipe from the pump casing. By
means of the wrench unscrew and remove the two bolts fixing the
pump casing to the flange (Ref. J Pict. 51), remove the pump and
replace it.

Install the pump casing by following the reverse procedure.

NOTE: Pump bolt driving torque of 22Nm.

Pict. 51

Page: 22 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

3.10 PUMP MOTOR REMOVAL

MOD. MO10E SL

In order to remove the pump motor, it is necessary to remove the

complete hydraulic power pack by following the procedure on Page 21
Paragraph 3.08 and to position it on a clean bench.

NECESSARY STANDARD TOOLS

MECCANICA
6mm ALLEN 17mm OPEN-ENDED
WRENCH SPANNER

PROCEDURE

Before starting to work wear suitable safety clothes.

Pict. 52

MECHANICAL
Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the A
battery.

2) 6mm ALLEN WRENCH - Unscrew and remove the four bolts fixing the
valve unit to the hydraulic power pack (Ref. Y Pict. 53). By removing
the valve unit, make sure you do not lose the coupling O-Rings and
the flow adjustment valve. By means of the same wrench unscrew
and remove the three bolts fixing the motor to the flange (Ref. A Pict. Y
53), take the pump motor and replace it.
B
WARNING: Pay attention to the joint connecting the motor to the pump.
It must be reused and positioned in the middle. It must be
placed on the pump upper part (Ref. B Pict. 53).
Pict. 53

Install the new pump motor by following the reverse procedure.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 23

 MECHANICAL Section SERVICE

3.11 BRUSH REPLACEMENT PROCEDURE

MOD. MO10E FF - MO10E WP - MO10E SL

The procedure to replace the brushes of the 3,00Kw pump motor is the
same both for the one solenoid valve unit and for the four solenoid valve
unit.

NECESSARY STANDARD TOOLS

HYDRAULIC UNIT
MO10E SL

8mm OPEN-ENDED MEDIUM SLOTTED SPRING

SPANNER SCREWDRIVER TENSIONER

PROCEDURE
Before starting to work wear suitable safety clothes.
MECHANICAL

HYDRAULIC UNIT
Park the truck in a safe area, away from the transit of other motor
MO10E FF/WP
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the
battery.
Pict. 54

1) 8mm OPEN-ENDED SPANNER, SLOTTED SCREWDRIVER -

Remove the motor compartment hood. By means of the wrench and C
the screwdriver loosen and remove the bolt fixing the brush protective
band (Ref. C Pict. 55). Remove the band and the cardboard cover
(Ref. D Pict. 56), by putting the brush holder where it can be seen
(Pict. 57).
Pict. 55
2) SLOTTED SCREWDRIVER, SPRING TENSIONER - By means of the
screwdriver loosen and remove the screws fixing the brushes to the
brush holder (Ref. E Pict. 57) and, by means of the spring tensioner,
D
lift the spring pressing the brush on the rotor (Ref. F Pict. 57). Withdraw
the brushes and replace them.

Install the new brushes by following the reverse procedure.

Pict. 56

Pict. 57

Page: 24 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

3.12 3,00 Kw PUMP MOTOR HYDRAULIC POWER PACK BOLT AND NUT DRIVING
TORQUE
MOD. MO10E FF - MO10E WP - MO10E SL

1 1
7 8 9

MECCANICA
10

6 6
2
2
5
5

3 3
11

MECHANICAL
4
4

Driving
Ref. Detail Description
torque
1 No. 2 nuts M8 fixing the feeding cables 12 Nm
2 No. 3 nuts M8 fixing the motor to the hydraulic power pack 6 Nm
3 No. 4 bolts M6 fixing the tank to the hydraulic power pack 4 Nm
4 No. 2 bolts M6 fixing the pump casing to the hydraulic power pack 29 Nm
5 Maximum pressure valve body RV1 10 Nm
6 Proportional solenoid valve body EV1 30 Nm
7 Platform lowering solenoid valve body EV2 30 Nm
8 Fork lifting/lowering solenoid valve body EV3 30 Nm
9 Platform lifting solenoid valve body EV4 30 Nm
10 Maximum pressure valve body RV2 12 Nm
11 No. 4 bolts M3 fixing the valve unit 31 Nm

Pict. 58

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 25

 MECHANICAL Section SERVICE

4.00 LIFTING CHAIN

MOD. ALL MODELS

The chains used are of traction model “Fleyer set AL and BL” and have the
features of a high-quality product.
They are used to bear much lower stresses than their breaking load.

CHAIN GREASING

The element that gives a long life to the chains is their lubrication.
Therefore a periodical lubrication with a proper oil must be performed by means
of a brush (as shown in Pict. 59) or by means of aerosol cans.
Pict.59
The frequency with which this operation must be repeated depends much on
the type of work and the environmental conditions, but usually every 300/400
working hours.

CHAIN ELONGATION

With the use, the chains tend to stretch.

Such elongation can be disassembled by acting on the chain tightener.
The chain elongation can be disassembled of 2% at a maximum. When this value is exceeded, the chain
MECHANICAL

must be replaced.

CHAIN MEASURE

Measure the elongation on more sections of 10 pitches, measured on the most stressed sections. This
control must be performed about every 1500/2000 working hours. The measure of the 10 pitches is
represented in the table below (Pict. 60) with also an indication of the corresponding chain.

LIFTING CHAIN ELONGATION CONTROL TABLE

Sa mple Le ngth e qua l Ma x imum Allow e d Elongation

Type of Pitch Length
to No. 10 Pitche s in Re ferre d to the S am ple Le ngth in
cha in "P" m m
"m m " "m m"
BL 534 15,857 158,75 162
Pict. 60

If, before the control, the chains have undergone negligible elongations, lower than 2%, this does not mean
the chain has remained intact and without any defect.
On the contrary, you can have deformations caused by the stress; therefore it is better to carefully check the
whole chain in order to control the wear state of the links, hinge pins, the chain tightener and the chain
tightener pin.

Page: 26 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

CONTROL OF LINKS, PINS AND CHAIN TIGHTENERS

A B
Before performing the control, clean the chain enough by using paraffin or a
paraffin derivative.
It is possible to check the chain when it is positioned.
Check the chain and its associated components (Pict. 61-62): G D
F
A) Worn pin
B) Damaged pin C
C) Crack of the links

MECCANICA
D) Wear of the link borders Pict.61 E
E) Wear and ovalization of the link hole
F) Excessive play between the links
G) Oxidation check
H) Wear and ovalization of the chain tightener hole
I) Worn chain hinge pin

If the chains show one or more of the above-mentioned wear problems, they H
must be replaced.

MECHANICAL
Pict.62 I

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 27

 MECHANICAL Section SERVICE

4.01 FORK LIFTING CHAIN REMOVAL C

MOD. MO10E FP

If, before the control, the lifting chains are worn out or stretched, they
must be replaced in order to put the machine in safety conditions.

NECESSARY SPECIAL TOOLS

E Pict. 63
* Wooden beam 100x100x500 With forks h 800
100X100X1000 With forks h 1500

NECESSARY STANDARD TOOLS

NORMAL 13mm OPEN-ENDED

PLIERS SPANNER
PROCEDURE D
MECHANICAL

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor Pict. 64
vehicles and from the passage of pedestrians.

1) WOODEN BEAM - Lift the forks till the beam passes under the fork F
plate bearing support, position the beam (Ref. D Pict. 64), lower the
cylinder and lean the forks on the beam. Continue the lowering phase H
till the chains become loose. Put the key-operated switch in OFF
position and disconnect the battery.
Pict. 65
WARNING: The beam has an important safety function during
the whole phase of chain replacement. Therefore it must be
placed in a correct and safe position.

2) NORMAL PLIERS - Remove the split pins fixing the chain hinge pins
to the chain tighteners (Ref. F Pict. 65). Remove also the split pins of
Pict. 66
the chain tighteners fixed on the fork plate (Ref. G Pict. 67). Withdraw
the chain hinge pins (Ref. H Pict. 65-67) and release the chains.

3) 13mm OPEN-ENDED SPANNER - Unscrew and remove the bolts G

fixing the bracket that prevents the chains from slipping off the pulley
(Ref. E Pict. 63). Remove the bracket (Ref. C Pict. 63), take the chains
and replace them.
H
Install the new chains by following the reverse procedure.

Adjust the chain tension by means of the chain tightener, screwing till
Pict. 67
the fork end of stroke, during the lowering phase, can be borne by the
chains.

Page: 28 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

4.02 PLATFORM LIFTING CHAIN REMOVAL

MOD. MO10E FF h 1200mm

If, before the control, the lifting chains are worn out or stretched, they must be replaced in order to put the
machine in safety conditions.

NECESSARY SPECIAL TOOLS

* Wooden beam 100x100x800

NECESSARY STANDARD TOOLS M O

MECCANICA
P

NORMAL 13mm OPEN-ENDED

PLIERS SPANNER Pict. 69
PROCEDURE

Before starting to work wear suitable safety clothes.

MECHANICAL
Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians.

1) WOODEN BEAM - Lift the forks till the beam passes under the platform
bearing support, position the beam (Ref. H Pict. 68), lower the cylinder
and lean the platform on the beam. Continue the lowering phase till
the chains become loose. Put the key-operated switch in OFF position
and disconnect the battery.

WARNING: The beam has an important safety function during H

the whole phase of chain replacement. Therefore it must be
placed in a correct and safe position.

2) NORMAL PLIERS - Remove the split pins fixing the chain hinge pins
to the chain tighteners (Ref. I Pict. 70), and the split pins of the chain Pict. 68
tighteners fixed on the platform (Ref. M Pict. 69). Withdraw the chain
hinge pins (Ref. L-N Pict. 69-70) and release the chains.

3) 13mm OPEN-ENDED SPANNER - Unscrew and remove the bolts

fixing the bracket that prevents the chains from slipping off the pulley
(Ref. O Pict. 6). Remove the bracket (Ref. P Pict. 69), take the chains
and replace them.
L I
Install the new chains by following the reverse procedure.

Adjust the chain tension by means of the chain tightener, screwing till
the fork end of stroke, during the lowering phase, can be borne by the
chains.

Pict. 70

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 29

 MECHANICAL Section SERVICE

4.03 FORK LIFTING CHAIN REMOVAL

MOD. MO10E SL

If, before the control, the lifting chains are worn out or stretched, they must be replaced in order to put the
machine in safety conditions.

NECESSARY SPECIAL TOOLS Z

* Wooden beam 100x100x500

NECESSARY STANDARD TOOLS

T
Pict. 72

NORMAL 13mm OPEN-ENDED

PLIERS SPANNER
PROCEDURE

Before starting to work wear suitable safety clothes.

MECHANICAL

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians.
Pict. 73 U V

1) WOODEN BEAM - Lift the forks till the beam passes under the fork
plate, position the beam (Ref. Q Pict. 74), lower the cylinder and lean
the fork plate on the beam. Continue the lowering phase till the chains
become loose. Put the key-operated switch in OFF position and
disconnect the battery.

WARNING: The beam has an important safety function during

the whole phase of chain replacement. Therefore it must be
placed in a correct and safe position.

2) NORMAL PLIERS - Remove the locking split pins of the hinge pins Q
between the chains and the chain tighteners fixed on the cylinder
locking support (Ref. R Pict. 75). Remove the split pins of the chain
tighteners fixed on the platform (Ref. U Pict. 73). Withdraw the chain
hinge pins (Ref. S-V Pict. 73-75) and release the chains.
Pict. 74
3) 13mm OPEN-ENDED SPANNER - Unscrew and remove the bolts
fixing the bracket that prevents the chains from slipping off the pulley
(Ref. T Pict. 72). Remove the bracket (Ref. Z Pict. 72), take the chains
and replace them.

Install the new chains by following the reverse procedure.

Adjust the chain tension by means of the chain tightener, screwing till S R
the fork end of stroke, during the lowering phase, can be borne by the
chains.
Pict. 75

Page: 30 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

4.04 PLATFORM LIFTING CHAIN REMOVAL

MOD. MO10E SL - MO10E WP h 1700mm
B
If, before the control, the lifting chains are worn out or stretched, they must be
replaced in order to put the machine in safety conditions.

NECESSARY SPECIAL TOOLS C

* Wooden beam 100x100x500

NECESSARY STANDARD TOOLS Pict. 76

MECCANICA
Y

A
5mm ALLEN NORMAL 13mm OPEN-ENDED
WRENCH PLIERS SPANNER
PROCEDURE Pict. 77
Before starting to work wear suitable safety clothes.

MECHANICAL
Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians.

1) WOODEN BEAM - Lift the forks till the beam passes under the fork
plate, position the beam (Ref. K Pict. 78), lower the cylinder and lean
the fork plate on the beam. Continue the lowering phase till the chains
become loose. Put the key-operated switch in OFF position and
disconnect the battery.

WARNING: The beam has an important safety function during

the whole phase of chain replacement. Therefore it must be
placed in a correct and safe position. K
2) NORMAL PLIERS - Remove the split pins fixing the chain hinge pins
to the chain tighteners (Ref. X Pict. 79). Remove the split pins of the
chain tighteners fixed on the platform (Ref. B Pict. 76). Withdraw the Pict. 78
chain hinge pins (Ref. C-J Pict. 76-79) and release the chains.

3) 5mm ALLEN WRENCH, 13mm OPEN-ENDED SPANNER - By means X

of the Allen wrench unscrew and remove the bolt fixing the pipe
holding pulley (Ref. Y Pict. 77). By means of the open-ended spanner J
unscrew and remove the bolt fixing the bracket that prevents the
chains from slipping off the pulley (Ref. A Pict. 77), remove the bracket,
take the chains and replace them.

Install the new chains by following the reverse procedure.

Adjust the chain tension by means of the chain tightener, screwing till
the fork end of stroke, during the lowering phase, can be borne by the
chains.
Pict. 79

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 31

 MECHANICAL Section SERVICE

4.05 REMOVAL OF THE PLATFORM LIFTING CHAINS

MOD. MO10E SL - h 3200 mm

NECESSARY SPECIAL TOOLS

* No. 2 100x100x1100 wooden beams

NECESSARY STANDARD TOOLS

NORMAL
PLIERS

PROCEDURE

Before starting to work wear suitable safety clothes.

Pict. 01
Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians.
B
MECHANICAL

1) WOODEN BEAMS - Lift the cabin so that the beams pass under the
cabin itself. Position the beams (Pict. 01). Lower the cabin and rest it
on the beams, keep on lowering the cylinders until the chains are loose.
Set the key-operated switch to “OFF” and disconnect the battery.

WARNING: The beam has an important safety function during

the whole phase of chain assembly and disassembly. Therefore
it must be placed in a correct and safe position A
Pict. 02
2) NORMAL PLIERS - By means of the pliers remove the split pins fastening
the chain hinge pin to the chain tightening pulley (Ref. A Pict. 02) then
remove the chain pin (Ref. B Pict. 02).

3) By means of the same tool remove the split pin fastening the chain
hinge pin to the cabin (Ref. C Pict. 04) withdraw the pin (Ref. D Pict.
04) and take the chain.
Carry out the replacement.

Install the new chains by following the reverse procedure.

D
C Pict. 04 Pict. 03

Page: 32 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

4.06 CABIN REMOVAL FOR BEARING REPLACEMENT

MOD. MO10E SL - h 3200 mm

NECESSARY SPECIAL TOOLS

Bridge crane with proper carrying capacity

No.2 lifting bands with proper capacity

NECESSARY STANDARD TOOLS

MECCANICA
D
Pict. 05

NORMAL MEDIUM OPENING 5 mm ALLEN VULCOLAN

PLIERS SEEGER PLIERS WRENCH HAMMER

No. 2 13 mm MEDIUM SLOTTED 10-19 mm

MECHANICAL
OPEN-ENDED SCREWDRIVER OPEN-ENDED
SPANNER SPANNER
PROCEDURA

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians.

1) Lift the cabin until the hydraulic fittings of the fork cylinder feed pipe
and the chain connections can be easily reached. Set the key-operated
switch to ”OFF” and disconnect the battery.

2) BRIDGE CRANE - BAND - By means of one band fasten the cabin to

the roof near the right mast and, by means of the other band, fasten it to
the roof near the left mast. Fix the end parts of the two bands to the
hook of the bridge crane (Pict. 06) and lift the cabin until the chains and
the cable are loose. Pict. 06

3) NORMAL PLIERS - Remove the split pin

fastening the chain hinge pin to the cabin,
remove the pin (Ref. A,B Pict. 08) and take
the chains out of the cabin, then place them
on the mast.

B
C
A Pict. 08 Pict. 07

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 33

 MECHANICAL Section SERVICE

4) Remove the fork cylinder feed pipe (see section 8.04 on page 50 -
hyraulic system section).

5) Remove the electric cable connecting the motor compartment /cabin

(see section 8.03 on page 59 - electric system section).

6) Disconnect the encoder cable from the spring located on the inner
mast (Ref. C Pict. 07).

7) 5 mm ALLEN WRENCH - Unscrew and remove the two bolts fastening

the cabin to the upper part of the inner mast (Ref. D Pict. 05).

8) On the electric power unit there is an allen wrench (Ref. E Pict. 10);
remove the wrench (Ref. F Pict. 10) and open the valve for the
emergency descent of the cylinders by means of the wrench itself.
Lower the cylinders completely in order to close the mast.
Pict. 09
9) Lift the cabin by means of the bridge crane in order to withdraw the
mast completely. Position the cabin on the ground (Pict. 12).

10) SEEGER PLIERS - VULCOLAN HAMMER- By means of the pliers

remove the elastic rings fastening the bearing (Ref. H Pict. 14) and
remove the shims (Ref. I Pict. 14). Withdraw the bearings (Ref. L Pict.
MECHANICAL

14) and carry out the replacement.

NOTE: the same amount of shims removed during the disassembly

phase must be put in the same position during the assembly phase .
E
NOTE: the roll used is made up of a ball bearing inserted in a steel F Pict. 10
shell with a rounded edge. It is inserted in a welded pin inclined in
such a way that the rounded part of the roll slides on the inner corner
of the mast (Ref. G Pict. 11).
Proper shims are used to reduce the lateral and frontal clearance to
a minimum; the shims must be inserted in the pin before the bearing
and after the bearing before the elastic ring.

NOTE: upon fastening the cabin to the mast take into consideration
the clearances. G
If the cabin has a lateral clearance, remove the shims (Pict. 14) and
insert them in the pin behind the roll (Ref. M Pict. 14).
Pict. 11
NOTE: what is described above is valid for the replacement of the
mast rolls, too.

M
L

H Pict. 14 Pict. 13 Pict. 12

Page: 34 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

4.07 MAST REMOVAL

MOD. MO10E SL - h 3200 mm

NECESSARY SPECIAL TOOLS

Bridge crane with proper carrying capacity

Lifting band with proper capacity

NECESSARY STANDARD TOOLS

MECCANICA
24 mm
SOCKET SPANNER
WITH RATCHET

PROCEDURE

Before starting to work wear suitable safety clothes.

Pict. 15

MECHANICAL
Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians.

1) Remove the cabin (see section No. 4.06 on page 33 - mechanic

section).
A
2) BRIDGE CRANE - LIFTING BAND - By means of a band bind the
upper part of the mast, fix the end parts of the band to the hook of the
bridge crane and tension (Pict. 15).

3) 24 mm SOCKET SPANNER WITH RATCHET- Unscrew and remove Pict. 16

the bolts (No.8) fastening the mast to the truck base (Ref. A Pict. 16).
Lift the mast 100 mm and move it towards the outside, out of the
anchoring hooks of the truck base (Pict. 17).
Position the mast on two stands and start the disassembly phase in
order to replace the rolls. For the disassembly withdraw the inner
mast.
The roll replacement is similar to the cabin replacement (see section
No. 4.06 on page 34 mechanic section).

Install the mast by following the reverse procedure.

Pict. 17

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 35

 MECHANICAL Section SERVICE

5.00 PLATFORM SIDE GUARD COMPONENTS

MOD. MO10E SL - MO10E WP

16

3
8
15
9

2 12
6

1
MECHANICAL

4 15

9
11

5
15
10

13

14

Pict. 80

Page: 36 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

5.01 PLATFORM SIDE GUARD COMPONENT TABLE

MOD. MO10E SL - MO10E WP

The components represented on the previous page are described in the table here below.

Reading key

Ref.: Detail reference

Component Description: Detail function

MECCANICA
S IDE G UA RD C O M P O N EN T T AB L E
R e f. C o m p o n e n t De scrip ti o n
1 C om plete s ide guard k it
2 S ide guard s u pport
3 U pper s ide gu ard
4 Interm ediate s ide guard
5 Low er s ide gu ard
C ontrol rod betw een the upper and the interm ediat e s ide
6 guard
C ontrol rod betw een the interm ediat e and the low er s ide
7 guard
Junc tion fork s betwe en the c ontrol rods and the s ide

MECHANICAL
8 guards
9 S ide guard fork joint rings
10 O pera tor's foo t protec tion s p ring
11 G as s pring for the opening a nd c los ing of the s ide guards
12 C los ing c over
13 U pper guard horiz ontal adjus tm ent bolt
14 Low er guard horiz ontal adjus tm ent bolt
15 Threaded holes M 10 for the general fix ing to t he c abin
16 B olts fix ing the c los ing c over

NOTE: Look for the Yale spare parts in the spare parts catalogue

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 37

 MECHANICAL Section SERVICE

5.02 REMOVAL OF THE GUARD KIT FROM THE TRUCK

MOD. MO10E SL - MO10E WP

In order to replace the various side guard components, it is necessary

to remove the whole unit from the machine.

NECESSARY STANDARD TOOLS

Pict. 81

D
6mm ALLEN
WRENCH

PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other D
motor vehicles and from the passage of pedestrians, lower the
MECHANICAL

forks to the ground, turn the key-operated switch OFF, disconnect

the battery.

1) 6mm ALLEN WRENCH - Lower the side guards as indicated in Pict.

81. By means of the wrench unscrew and remove the three bolts
fixing the side guards to the cabin (Ref. D Pict. 82). Remove the
whole unit (Pict. 83) and position it on a clean bench. Disassemble it
in order to replace the damaged components. D

Install the side guard kit by following the reverse procedure.

Pict. 82

Pict. 83

Page: 38 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

5.03 SIDE GUARD GAS RETURN SPRING REPLACEMENT

MOD. MO10E SL - MO10E WP

After the side guards have been removed from the cabin, position the unit on
a bench and place the side guards vertically as shown in Pict. 84.

NECESSARY STANDARD TOOLS

MECCANICA
Pict. 84
6mm ALLEN
WRENCH
PROCEDURE E

MECHANICAL
Before starting to work wear suitable safety clothes.

1) 5mm ALLEN WRENCH - The side guard vertical position allows releasing the Pict. 85
spring and makes its removal easier. By means of the wrench unscrew and remove
the bolt for the spring upper fixing (Ref. E Pict. 85), withdraw the spring lower part
from the pin (Ref. F Pict. 87). Take the spring and replace it.

Install the side guard kit by following the reverse procedure.

Pict. 86

F
Pict. 87

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 39

 MECHANICAL Section SERVICE

5.04 UPPER GUARD REMOVAL

MOD. MO10E SL - MO10E WP

By using the side guards some breaks can occur, such as the bending of
the threaded control rods or of the side guards, caused by possible L O N
collisions. On these pages there are indications on how to do repairs. In
order to perform these operations it is necessary to remove the whole kit
of the machine side guard (Paragraph 5.02 on page 34).

NECESSARY STANDARD TOOLS M

H
I
13mm OPEN-ENDED NORMAL 5mm ALLEN
SPANNER PLIERS WRENCH
PROCEDURE

Before starting to work wear suitable safety clothes. Pict. 88

MECHANICAL

1) 5mm ALLEN WRENCH - After removing the side guard kit from the
machine, position it on a bench. By means of the wrench unscrew and
remove the bolts fixing the cover (Ref. G Pict. 89). Remove the cover.

2) NORMAL PLIERS - Open the side guards by positioning them at 45° as

G
shown in Pict. 89. This is used to remove the side guard rear part from
the bracket (Ref. L Pict. 88). By means of the pliers remove the joint ring
with the hinge pin (Ref. H Pict. 88) and withdraw the fork (Ref. I Pict. 88)
from the side guard rear part. Withdraw the side guard from the pin (Ref. G
M Pict. M), take it and replace it.

Install the new side guard by following the reverse procedure.

After the side guard has been assembled, put it in a horizontal position as
shown in Pict. 90. Make sure the upper side guard is in a perfect horizontal G
position. Otherwise, adjust it by means of the adjusting screw (Ref. O Pict.
88).

PROCEDURE

3) 13mm OPEN-ENDED SPANNER. 5mm ALLEN WRENCH

- By means of the open-ended spanner loosen the
nut (Ref. N Pict. 88). By means of the Allen wrench
loosen the screw (Ref. O Pict. 88) in order to lower
the side guard. Tighten the screw in order to lift the
side guard. Tighten the nut after the adjustment. G

Pict. 90 Pict. 89

Page: 40 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

5.05 INTERMEDIATE GUARD REMOVAL

MOD. MO10E SL - MO10E WP

In order to remove the intermediate side guard, position the side guards
vertically as shown in Pict. 91. This allows releasing the gas spring and
makes the removal easier.

NECESSARY STANDARD TOOLS

MECCANICA
NORMAL 5mm ALLEN
PLIERS WRENCH G
PROCEDURE
G
Before starting to work wear suitable safety clothes.

1) 5mm ALLEN WRENCH - Unscrew and remove the bolts fixing the
cover (Ref. G Pict. 91) and remove it. By means of the same wrench

MECHANICAL
remove the gas spring (Ref. R Pict. 92) by following the procedure G
described in Paragraph 5.03 on Page 35.

2) NORMAL PLIERS - By means of the pliers remove the two joint rings
with the pin (Ref. P Pict. 92). Withdraw the forks (Ref. Q Pict. 92) from
the side guard bracket. Withdraw the side guard from the hinge pin
(Ref. S Pict. 92), disassemble it and replace it.

Install the new side guard by performing the reverse procedure. G

Pict. 91

P S

Q
P

Pict. 92

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 41

 MECHANICAL Section SERVICE

5.06 LOWER GUARD REMOVAL

MOD. MO10E SL - MO10E WP
The lower side guard removal can be performed with the kit assembled on the truck by closing the side
guards, as shown in Pict. 93.

NECESSARY STANDARD TOOLS

13mm OPEN-ENDED 5-6mm ALLEN

SPANNER WRENCH
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key-operated switch OFF, disconnect the
MECHANICAL

battery.
Pict. 93

1) 6mm ALLEN WRENCH - The lower side guard is assembled with the
kit from the outside of the cover by means of a pin inserted into the
support (Ref. T Pict. 94) and it is fastened by means of a bolt (Ref. U
Pict. 94), which allows it to open and close together with the
mechanism. In order to remove it, insert the key into the cover hole
(Pict. 95) and loosen the fixing bolt (Ref. U Pict. 94-95). Withdraw the
side guard from its seat and replace it. U
T
Install the new side guard by performing the reverse procedure.

After the side guard has been assembled, make sure the side guard is in a
perfect horizontal position. Otherwise adjust it by means of the adjusting
screw (Ref. Z Pict. 96). Pict. 94

PROCEDURE

3) 13mm OPEN-ENDED SPANNER. Z

5mm ALLEN WRENCH - By means
of the open-ended spanner loosen
the nut (Ref. V Pict. 96). By means
of the Allen wrench loosen the screw
(Ref. Z Pict. 88) to lower the side V
guard. Tighten the screw in order to
lift the side guard. After the U
adjustment, tighten the nut.
Pict. 96 Pict. 95

Page: 42 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

5.07 GUARD CONTROL ROD REMOVAL

MOD. MO10E SL - MO10E WP
W
With use, the side guard opening and closing control rods can bend
because of possible collisions. For safety and good operation we
recommend replacing them. Remove the kit by following the procedure
described in Paragraph 5.02 on Page 34.
W
NECESSARY STANDARD TOOLS
C

MECCANICA
B
A

13mm OPEN-ENDED NORMAL 5-6mm ALLEN

SPANNER PLIERS WRENCH
PROCEDURE
Before starting to work wear suitable safety clothes.

1) 5mm ALLEN WRENCH - After removing the side guard kit from the
machine, position it on a bench and open it by putting the side guards

MECHANICAL
in vertical position in order to allow the gas spring to be released. By W
means of the wrench unscrew and remove the bolts fixing the cover
(Ref. W Pict. 97) and remove the cover.

2) NORMAL PLIERS - By means of the pliers remove the two joint rings
with the pin (Ref. B-E Pict. 97). Withdraw the forks from the side A
guard brackets and replace the complete rods.

3) 13mm OPEN-ENDED SPANNER - If you want to replace only the

B
threaded rods and to disassemble the forks, by means of the wrench
loosen the locking nut (Ref. A-D Pict. 97), unscrew the fork and C
retighten it on the new rod.
F
Install the new complete rods by performing the reverse procedure.
E
D

E
F

Pict. 97

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 43

 MECHANICAL Section SERVICE

6.00 MOVABLE FORK UNIT COMPONENTS

MOD. MO10E FP MO10E SL

4
5 6
2
3
9

8
1
MECHANICAL

MOVABLE FORK COMPONENT TABLE

Ref. Component Description
1 Complete fork unit
2 No. 4 Slide bearings
3 Bearing back shim
4 Bearing locking seeger
5 Shimming sliding block
6 Sliding block fastening screw
7 Fork locking bolt
8 Movable forks
9 Fork locking hook
Pict. 98

NOTE: Look for the Yale spare parts in the spare parts catalogue

Page: 44 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

6.01 FIXED FORK UNIT COMPONENTS

MOD. MO10E FP MO10E SL

3 2
5 1

MECCANICA
6

MECHANICAL
FIXED FORK COMPONENT TABLE
Ref. Component Description
1 Complete fork unit
2 No. 4 Slide bearings
3 Bearing back shim
4 Bearing locking seeger
5 Shimming sliding block
6 Sliding block fastening screw
Pict. 99

NOTE: Look for the Yale spare parts in the spare parts catalogue

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 45

 MECHANICAL Section SERVICE

6.02 MAST BEARING REPLACEMENT

MOD. MO10E FP H

In order to replace the mast bearings it is necessary to withdraw

it from the sliding mast. The same procedure can be followed
also for the movable fork plate.

NECESSARY SPECIAL TOOLS

* Wooden beam 100x100x of adequate height

* Lifting rope with 3 hooks ROPE WITH 3
of adequate carrying capacity and measure HOOKS
* Overhead travelling crane or other lifting device of adequate
carrying capacity Pict. 01
NECESSARY STANDARD TOOLS

8mm ALLEN MEDIUM OPENING NORMAL

MECHANICAL

WRENCH SEEGER PLIERS PLIERS F G

PROCEDURE
Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians. Pict. 02

1) WOODEN BEAM - Lift the forks till the beam passes under the bearing support of the fork plate,
position the beam and lower the cylinder. Lean the forks on the beam. Continue the lowering phase
till the chains become loose. Put the key-operated switch in OFF position and disconnect the battery.

WARNING: The beam has an important safety function during the whole phase of mast
disassembly and assembly. Therefore it must be placed in a correct and safe position.

2) NORMAL PLIERS - Remove the split pins fixing the chain hinge pins to the chain tighteners (Ref. G
Pict. 02) fixed on the fork plate. Withdraw the chain hinge pins, detach the chains and release the fork
plate.

3) LIFTING ROPES, OVERHEAD TRAVELLING CRANE, 8mm ALLEN WRENCH - Hook the forks as
shown in Pict. 01 and stretch the ropes. By means of the wrench loosen and remove the fork set
screw at the mast end (Ref. H Pict. 01), continue the lifting phase, withdraw the forks from the mast
and position them on a bench.

4) SEEGER PLIERS - Remove the bearing locking seeger (Ref. G Pict. 02), withdraw the bearings and
replace them.

Install the new bearings and reinstall the forks on the mast by following the reverse procedure.

Page: 46 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

6.03 MAST SHIM REPLACEMENT

MOD. MO10E FP

Some shims have been inserted in order to avoid the fork

lateral oscillation. Their thickness can decrease because of
the continuous lifting and lowering operations, thus causing
some fork lateral oscillations. In order to eliminate the play,
they must be replaced.

NECESSARY STANDARD TOOLS

MECCANICA
Pict. 03

4mm ALLEN
WRENCH I
PROCEDURE L

Before starting to work wear suitable safety clothes.

MECHANICAL
Park the truck in a safe area, away from the transit of other
motor vehicles and from the passage of pedestrians. I
L

1) Lift the forks till the shim screws are well visible in order to work
safely. Put the key-operated switch in OFF position and disconnect Pict. 04
the battery.

2) ALLEN WRENCH - Loosen and remove the shim fastening screws (Ref. I Pict. 04), remove the shims
(Ref. L Pict. 48) and replace them.

Install the shims by following the reverse procedure.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 47

 MECHANICAL Section SERVICE

6.04 MOVABLE FORK PLATE BEARING REPLACEMENT

MOD. MO10E SL

The procedure for the removal of the movable fork plate is the same as the
one used to remove the fixed fork plate.

NECESSARY SPECIAL TOOLS

* Lifting rope with two hooks for movable forks
* Lifting rope with three hooks for fixed forks
NECESSARY STANDARD TOOLS

O O

8mm ALLEN MEDIUM OPENING NORMAL

WRENCH SEEGER PLIERS PLIERS
PROCEDURE
MECHANICAL

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians.
Pict. 05

1) 8mm ALLEN WRENCH - Unscrew and remove the two fork bolts (Ref. O
Pict. 05). Pull the forks towards the external part of the right and left plate.

2) ROPE WITH TWO HOOKS OF ADEQUATE CARRYING CAPACITY - Lift

the cabin of 1000mm, fasten the rope hooks to the fork plate as shown in
Pict. 07 and the upper hook to a hoist or hoister, stretch and lift it till the
chains are loose. Put the key-operated switch in OFF position and disconnect
Pict. 06 M N
the battery.

3) NORMAL PLIERS - By means of the pliers remove the locking split pins of
the hinge pins (Ref. M Pict. 06). By means of the same tool withdraw the
pins from the chain tightener and detach the fork plate from the chains.
Lower the fork plate by means of the lifting device (arrow direction) and
withdraw the mast. Take the plate and place it on a bench.

4) SEEGER PLIERS - Remove the bearing locking seegers (Ref. P Pict. 09),
withdraw the bearings and replace them.

Install the new bearings and reassemble the fork plate on the mast by following
the reverse procedure.

Pict. 07

Page: 48 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

6.05 FORK PLATE SHIM REPLACEMENT

MOD. MO10E SL

Some shims have been inserted in order to avoid the lateral oscillation
of the forks. Their thickness can decrease because of the continuous
lifting and lowering operations, thus causing some lateral oscillations of
the forks. In order to eliminate the play, the shims must be replaced.

NECESSARY STANDARD TOOLS Pict. 08

MECCANICA
4mm ALLEN
WRENCH
P
PROCEDURE
Q
R
Before starting to work wear suitable safety clothes.

MECHANICAL
Park the truck in a safe area, away from the transit of other Pict. 09
motor vehicles and from the passage of pedestrians.

1) Disassemble the machine fork plate (Paragraph 6.04 Page 44) and position it on a bench.

2) ALLEN WRENCH - Loosen and remove the shim set screws (Ref.Q Pict. 09), remove the shims (Ref.
R Pict. 09) and replace them.

Install the shims and the fork plate on the truck by following the reverse procedure.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 49

 MECHANICAL Section SERVICE

7.00 REPLACEMENT OF THE STEER HARDENING

STEERING WHEEL PIN BEARING
MOD. ALL MODELS

If, during the maneuvers of steering to the right or to the left, the steering
wheel is too flexible and sensible, this is probably due to the fact that the
brake shims are too worn. If, on the contrary, the steering wheel is too
hard, this is probably caused by the block of the steering wheel shaft
bearing.
Here below there is a description on how to operate mechanically in
order to solve the problems. Pict. 10
NECESSARY STANDARD TOOLS
S

SMALL SLOTTED MEDIUM PHILLIPS 3-5mm ALLEN

SCREWDRIVER SCREWDRIVER WRENCH
MECHANICAL

Pict. 10

8mm OPEN- MEDIUM OPENING PIN STEEL HAMMER

ENDED SEEGER PLIERS Ø 10x 200 OF 500g
SPANNER

7.01 STEERING WHEEL HARDENING PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other Pict. 11
motor vehicles and from the passage of pedestrians, lower the
forks to the ground, turn the key-operated switch OFF, disconnect
the battery.
U
1) SMALL SLOTTED SCREWDRIVER, 5mm ALLEN WRENCH - By
means of the screwdriver lever under the cover in the middle of the
steering wheel (Ref. S Pict. 10). By means of the Allen wrench
unscrew and remove the steering wheel locking bolt (Ref. T Pict.
10), lift it and remove the steering wheel by uncovering the teflon V
“cap-brake” (Pict. 11).
Z
2) Remove the cap (Ref. U Pict. 12), remove the spring (Ref. V Pict. 12) Pict. 12
and add shims and washers (Ref. Z Pict. 12), till you reach the steering
wheel hardening.

Install the steering wheel by following the reverse procedure.

Page: 50 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE MECHANICAL Section

7.02 STEERING WHEEL SHAFT BEARING REPLACEMENT

PROCEDURE X

1) Remove the steering wheel (See paragraph 6.01 on Page 20)

2) MEDIUM PHILLIPS SCREWDRIVER - Loosen and remove the

instrument panel fastening screws (Ref. D Pict. 16), detach the
instrument panel from the coachwork and disconnect the linking
connectors, making sure they are marked so as to make connections

MECCANICA
easier. Position the instrument panel on a clean bench.
Pict. 13

K
3) 3mm ALLEN WRENCH, 8mm OPEN-ENDED SPANNER - By means
of the wrenches loosen and remove the screws and the nuts fixing Y
the steering wheel unit to the instrument panel (Ref. X-K Pict. 13-14)
and detach the unit. By means of the same wrenches loosen and
remove the screws and the nuts fixing the stepper motor (Ref. J Pict.
14) and detach it from the unit. By using the same wrench loosen
and remove the screws fixing the bearing holding flange (Ref. Y Pict.
14). J

MECHANICAL
Pict. 14

4) SEEGER PLIERS, HAMMER, PIN - By means of the seeger pliers A

remove the bearing locking seeger (Ref. A Pict. 15). By means of the
hammer take out the pin (Ref. C Pict. 15) from the top downwards as B
indicated by the arrow. By means of the hammer and the pin take out
the bearing (Ref. B Pict. 15) from its seat as indicated by the arrow
C
and replace it.

Install the new bearing by performing the reverse procedure.

Reassemble and install the instrument panel by performing the reverse

procedure.

Pict. 15
D

D Pict. 16

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 51

 MECHANICAL Section SERVICE
NOTES:
MECHANICAL

Page: 52 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ADDITIONAL FUNCTIONS

ADDITIONAL
FUNCTIONS
ADDITIONAL
FUNCTIONS
D SHEET OPTION 1
Fan kit for the cabin .......................................................................... 2
D SHEET OPTION 2
Kit for reading desk .......................................................................... 5
D SHEET OPTION 3
Safety tracer kit ................................................................................ 7

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182162 Page: 1

 Section: ADDITIONAL FUNCTIONS SERVICE

SHEET OPTION No. 1

X NECESSARY ADDITIONAL COMPONENTS

- FAN KIT
ADDITIONAL
FUNCTIONS

X MODULES CONFIGURATION

- NONE

FAN KIT COMPONENTS

5
6
2

1
4

9
7 Pict. 01

TABLE FOR FAN KIT COMPONENTS

Ref. Description of Components

1 Fan support
2 Fan
3 Upper protection fixed to the fan
4 Lower cogged protection
5 M6 fitting bolt (No. 2) to fix the fan support to the overhead guard
6 Check nuts to fix the fan support to the overhead guard
7 M4 check nuts (No. 4) to fix the fan to the support
8 Check nuts to fix the fan to the support
9 Feeding cable

Page: 2 Part No: 524182162 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ADDITIONAL FUNCTIONS

SHEET OPTION No. 1/A

X INSTALLATION NOTES

NECESSARY STANDARD TOOLS

ADDITIONAL
FUNCTIONS
2,5-5mm ALLEN MEDIUM PHILLIPS 8-13mm OPEN-
WRENCH SCREWDRIVER ENDED SPANNER
INSTALLATION PROCEDURE

Before starting to work wear safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage
of pedestrians, lower the forks to the ground, turn the key-operated switch OFF, disconnect the
battery.

The fan is equipped with a kit made of a connection sheath and of fixing screws which is fastened in the
middle under the overhead guard towards the battery (as shown in Pict. 02).

1) PHILLIPS SCREWDRIVER - Unscrew the fixing screws from the board panel and remove it in order
to get to the SICOS module.

2) 13mm OPEN-ENDED SPANNER - There are two holes of Ø 6,5mm on the point where the fan has
to be fixed. In these holes the support, already equipped with the fan assembled on the worktable
beforehand, has to be fixed.

Let the sheath go through the gap of the right steering column of the cabin and let it out just next to the
board panel, connect the sheath to the connector (C/26) next to the SICOS module.

Gap for
cable passage

Connector (C/26) ready and placed

next to the SICOS module

Pict. 02 Pict. 03

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182162 Page: 3

 Section: ADDITIONAL FUNCTIONS SERVICE
SHEET OPTION No. 1/B FAN CONNECTION DIAGRAM FOR
CABIN COOLING
ADDITIONAL
FUNCTIONS

Page: 4 Part No: 524182162 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ADDITIONAL FUNCTIONS

SHEET OPTION No. 2

X NECESSARY ADDITIONAL COMPONENTS

- READING DESK KIT

ADDITIONAL
FUNCTIONS
X MODULES CONFIGURATION

- NONE

READING DESK
FOR
DOCUMENTS

Pict. 04

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182162 Page: 5

 Section: ADDITIONAL FUNCTIONS SERVICE

SHEET OPTION No. 2/A

X INSTALLATION NOTES
ADDITIONAL
FUNCTIONS

NECESSARY STANDARD TOOLS

ALLEN WRENCH
2,5-5mm

ASSEMBLY PROCEDURE

Before starting to work wear safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage
of pedestrians, lower the forks to the ground, turn the key-operated switch OFF, disconnect the
battery.

The reading desk for documents is made of a strong plate equipped with a fold back clip for A4 paper.
The plate is equipped with two holes: the upper one is eyelet-shaped in order to get a suitable inclination
to read the documents better. The kit is equipped with two Ø M8x1,25 bolts (Pict. 06).

The reading desk has to be fixed to the left mast of the overhead guard which is already equipped with two
M8x1,25 threaded holes (Pict. 06).

M8X1,25 BOLTS

M8X1,25 THREADED
Pict. 05 Pict. 06 HOLES

Page: 6 Part No: 524182162 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ADDITIONAL FUNCTIONS

SHEET OPTION No. 3

X NECESSARY ADDITIONAL COMPONENTS

- SAFETY TRACER KIT ON THE OVERHEAD GUARD OF THE CABIN

ADDITIONAL
FUNCTIONS
X MODULES CONFIGURATION

- NONE

4
5

3
2

Ref. Description of the component

1 Safety tracer for lifting
2 SW 14 sensor
3 Connection cable
4 Return springs
5 Bolts equipped with nuts and washers
Fig. 07

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182162 Page: 7

 Section: ADDITIONAL FUNCTIONS SERVICE

SHEET OPTION No. 3/A

X INSTALLATION NOTES
ADDITIONAL
FUNCTIONS

NECESSARY STANDARD TOOLS

24-17mm N° 2 MEDIUM PHILLIPS

OPEN-ENDED SCREWDRIVER
SPANNER

INSTALLATION PROCEDURE

Before starting to work wear safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage
of pedestrians, lower the forks to the ground, turn the key-operated switch OFF, disconnect the
battery.

1) PHILLIPS SCREWDRIVER - Unscrew the fixing bolts from the board panel and remove it in order to get to
the SICOS module.

2) 24mm OPEN-ENDED SPANNER - Fix the sensor (Ref. 2) in the eyelet on the central cross member of
the overhead guard. Let the connection sheath go through (Ref. 3) the gap of the right steering column of
the cabin next to the board panel and connect it to the connector (C/18) on the SICOS module (See wiring
diagram on page 9). Put the parameter “AUX FUNCTION 2” of the Set Option of SICOS module in ON
position (See setting procedure on page 10).

3) 17mm No. 2 OPEN-ENDED SPANNER - Insert the bearing bolts of the tracer into the brackets on the
overhard guard (Ref.
5), insert the springs
into the bolts (Ref. 4)
and fix with nuts and 1
washers. Place the
tracer on the bolts (Ref. 4
1) and fix it with nuts 5
and washers. Springs
have to be
compressed so that
the cam (Ref. 6)
exceeds the sensor 6
reading while pressing
the tracer.

3 2
Pict. 08

Page: 8 Part No: 524182162 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ADDITIONAL FUNCTIONS

SHEET OPTION No. 3/B TRACER SENSOR

CONNECTION DIAGRAM

ADDITIONAL
FUNCTIONS
+ 24V 0V
B att. -Batt.

OVER HEAD SAFETY

SENSOR

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182162 Page: 9

 Section: ADDITIONAL FUNCTIONS SERVICE

SHEET OPTION No. 3/C

ENABLING PROCEDURE OF SAFETY TRACER FUNCTION

ADDITIONAL
FUNCTIONS

The console is fundamental in order to perform this operation and to configurate the SICOS module for
the enabling procedure of the safety tracer function.

NOTE: This operation does not replace the procedure described in the Service Manual, but it is simply a
piece of advice for a faster configuration of the function.

TABLE FOR MODULE CONFIGURATION

CONFIG Description of the

Accessories Module Sequence Parameters Setting
MENU operations to be performed
While the machine is switched off,
connect the console to the SICOS
1
module; put the key-operated switch
in ON position.
SICOS
Press ENTER, then OUT and ENTER
again in order to save the set value;
AUX
2 SET OPTIONS ON then put the key-operated switch in
FUNCTION 2
OFF position, then in ON and check if
the value is correct.

NOTES:

Page: 10 Part No: 524182162 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: REDUCTION UNIT

REDUCTION
UNIT
D REDUCTION UNIT COMPONENTS ................................................. 2

D REDUCTION UNIT COMPONENT TABLE ........................................ 3

D REDUCTION UNIT DISASSEMBLY ................................................. 4

D TRACTION MOTOR SHAFT OIL SEAL REPLACEMENT ................. 7

REDUCTION UNIT

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 1

 Section: REDUCTION UNIT SERVICE

1.00 REDUCTION UNIT COMPONENTS

MOD. ALL MODELS

16

15

19

18
5

6
17
8 4
REDUCTION UNIT

3
2
11

13

7 10

1
14
12
Pict. 01

Page: 2 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: REDUCTION UNIT

1.01 REDUCTION UNIT COMPONENT TABLE

MOD. ALL MODELS

The components represented in the previous page are described in the following table.

Reading key

Ref. = Component reference

Component description = Component description

Ref. Component Description

1 Complete reduction unit
2 Steering control crown for the steering motor pinion coupling
3 Conical coupling crown
4 Conical pinion coupled to the crown
5 Upper transmission crown
6 Traction motor shaft coupling pinion
7 Traction wheel shaft
8 Traction wheel shaft great conical bearing
9 Traction wheel shaft small conical bearing
10 Traction wheel shaft locking ring nut
11 Traction wheel shaft oil seal
12 Oil seal protection
13 Traction wheel fastening pin
14 Oil drain plug
15 Oil charge plug
16 Traction motor shaft oil seal
17 Conical bearings for conical pinion

REDUCTION UNIT
18 Traction motor shaft pinion bearings
19 Upper rim locking ring nut
20 Traction wheel shaft spacer
21 Conical pinion spacer

NOTE: Look for the Yale codes of the various components in the spare parts catalogue

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 3

 Section: REDUCTION UNIT SERVICE

2.00 REDUCTION UNIT REMOVAL

MOD. ALL MODELS

The reduction unit is disinstalled from the machine when it is necessary

to completely replace it or the traction wheel shaft oil seal. In this
paragraph there are indications on how to remove it from the machine A B
and on how to replace the wheel shaft oil seal.

NECESSARY SPECIAL TOOLS

* Lifting rope with two hooks of adequate

carrying capacity and measure
* Wooden plugs 100x100x100 No. 2 12
12
12
12
* Male eyebolt M8 No. 2 12

* Overhead travelling crane of adequate MALE OVERHEAD

carrying capacity EYEBOLT TRAVELLING Pict. 02
CRANE
* Low container for oil recovery

NECESSARY STANDARD TOOLS

HYDRAULIC STEEL HAMMER 10mm ALLEN SMALL POINT

JACK OF 500g WRENCH CHISEL
REDUCTION UNIT

C
Pict. 03

13/24/40mm SOCKET 13/24mm OPEN- LARGE FLAT BAR

WRENCH ENDED SLOTTED
WITH RATCHET SPANNER SCREWDRIVER
PROCEDURE
Before starting to work wear suitable safety clothes.
D
Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key OFF, disconnect the battery.

1) HYDRAULIC JACK, WOODEN BLOCKS - Position the jack in the middle

of the coachwork next to the traction wheel and lift till the wooden blocks
pass under the coachwork. Position the wooden blocks on the jack sides
at a distance of about 200mm and lower them by leaning the coachwork on
the wooden blocks. Remove the jack.
Pict. 04
2) Remove the motor compartment hood in order to reach the equipment.

3) Remove the traction motor and the steering motor (See Paragraph 2.02 on Page 6 of the mechanical
Section)
Page: 4 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE
SERVICE Section: REDUCTION UNIT

5) 10mm ALLEN WRENCH, OIL CONTAINER - Position the container F

under the reduction unit next to the drain plug (Ref. C Pict. 03). By
means of the wrench unscrew and remove the plug and drain the oil
from the reduction unit.
E

4) EYEBOLTS, LIFTING ROPE, OVERHEAD TRAVELLING CRANE -

Screw the two eyebolts in the threaded holes in order to insert the
traction motor locking bars, opposite to one another. Fix the lifting
rope hooks to the eyebolts and the rope end to the hook of the
overhead travelling crane (Pict. 04).
Pict. 05

5) 24mm SOCKET WRENCH, 24mm OPEN-ENDED SPANNER - After

hooking the reduction unit, lift the overhead travelling crane and
tension the lifting rope. By means of the wrenches unscrew and
remove the four bolts fixing the reduction unit to the coachwork (Ref.
D Pict. 04). Take the reduction unit and position it on a bench.

6) 24mm SOCKET WRENCH, REDUCTION UNIT SUPPORT -

Position the reduction unit on an adequate support (Ref. E Pict. 05)
and, by means of the wrench and of the two bolts used for the fixing
to the coachwork, fasten the reduction unit so as to disassemble it
in safety conditions. G Pict. 06

7) 13mm SOCKET WRENCH - Loosen and remove the six screws

fixing the cover to the reduction unit (Ref. G Pict. 06). Remove the

REDUCTION UNIT
cover in order to reach the wheel shaft locking ring nut (Pict. 07).

8) STEEL HAMMER, POINT CHISEL - By means of the two tools lift the
calking that blocks the locking ring nut of the shaft wheel kit and of
the bearings (Pict. 08) till the ring nut can be released.

Pict. 07

Pict. 08

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 5

 Section: REDUCTION UNIT SERVICE

9) 40mm SOCKET WRENCH, FLAT BAR - Position the flat bar between I
the traction wheel locking bolts (Ref. H Pict. 09), rotate the shaft so
that one end of the bar gets stuck between the wheel bolts, and the
other one rests on the bench or on the reduction unit upper part. In
this way the shaft is blocked when the ring nut is unscrewed. By means
of the wrench unscrew and remove the locking ring nut (Ref. I Pict.
09). H
Pict. 09

10) Remove the conical bearing (Pict. 10)

11) Remove the conical crown (Pict. 11) and, at the same time, withdraw
the wheel shaft (Pict. 12).

WARNING: When you disassemble the crown and the shaft,

there are shims of various sizes, which must be removed and
then replaced in their original position.
Pict. 10

12) Remove the conical spacer (Pict. 13)

12) SLOTTED SCREWDRIVER - By means of the screwdriver remove

the oil seal from the reduction unit seat (Pict. 14) and replace it.

Install the new oil seal by following the reverse procedure.

REDUCTION UNIT

Pict. 11

WARNING: After the reduction unit has been assembled on the

machine, fill with 1,750 Kg of oil Sheel Spirax A80 W-90.

Pict. 12

ROD

OIL CHARGE 2/3mm

PLUG

OIL LEVEL

IN ORDER TO MEASURE THE LEVEL, BEFORE

Pict. 13
PUTTING THE PLUG, INSERT A RIGID ROD
TILL IT TOUCHES THE GEAR, REMOVE THE
ROD AND CHECK THE POINT IS WETTED WITH
OIL FOR 2/3mm.
-if the level is lower, add some oil.
-if the level is higher, remove some
Pict. 15 oil. Pict. 14

Page: 6 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: REDUCTION UNIT

2.01 TRACTION MOTOR SHAFT OIL SEAL

REPLACEMENT
MOD. ALL MODELS

NECESSARY STANDARD TOOLS

MEDIUM SLOTTED
SCREWDRIVER
PROCEDURE

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor Pict. 16
vehicles and from the passage of pedestrians, lower the forks to
the ground, turn the key OFF, disconnect the battery.

1) Remove the traction motor and the steering motor (See paragraph
2.02 on Page 7 of the mechanical Section)

2) SLOTTED SCREWDRIVER - By means of the screwdriver remove the

oil seal from the reduction unit flange seat (Ref. L Pict. 18) and replace it.

REDUCTION UNIT
Install the new oil seal by performing the reverse procedure. Pict. 17

Pict. 18

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 7

 Section: REDUCTION UNIT SERVICE

NOTES:
REDUCTION UNIT

Page: 8 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: BRAKING SYSTEM

BRAKING
SYSTEM
D ELECTROMAGNETIC BRAKE COMPONENTS .......................................... 2

D BRAKING SYSTEM .................................................................................... 3

D COIL AND BRAKE LINING REPLACEMENT ............................................... 4

D ADJUSTMENT AND STARTING .................................................................. 5

BRAKE

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 1

 Section: BRAKING SYSTEM SERVICE

1.00 ELECTROMAGNETIC BRAKE COMPONENTS

MOD. ALL MODELS

1
5
4

Pict. 01

1.01 ELECTROMAGNETIC BRAKE COMPONENT DESCRIPTION TABLE

BRAKE

READING KEY
Ref. = Component reference
Component Description = Component function description
Ref. Component Description
1 Complete electromagnetic brake
2 Electric brake coil
3 Brake lining
4 Brake lining guide pinion
5 Pinion locking seeger
6 Friction disk
7 Electromagnetic brake locking bolts
NOTE: Look for the Yale codes of the various components in the spare parts catalogue

Page: 2 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: BRAKING SYSTEM

2.00 BRAKING SYSTEM

MOD. ALL MODELS

The trucks are equipped with 4 braking systems:

A) Service or inversion braking

B) Regenerative or release braking
C) Emergency braking
D) Parking braking

A) INVERSION BRAKING

The inversion braking, also called “Energy regenerative braking” (Regen Braking), consists in reversing
the current on the motor, by changing the running direction when the truck is being moved. During the
reversal, the truck starts slowing down with an intensity proportional to the current value set by means of
the programming console in parameter “INVERSION BRAKING”.
The braking current must be adjusted so that the truck stops within a space not lower than the length of
the truck itself.

B) RELEASE BRAKING

The release braking, also called “Release braking or Energy recovery”, takes place when the throttle
is released as the machine moves in one of the two running directions; it performs a regenerative braking
with an intensity proportional to the current value set by means of the programming console in parameter
“REALESE BRAKING”.

The excessive reduction of the the braking space, and therefore the increase of current on the motor
could damage the good operation of some truck components, because during the phase of inversion
and release braking, the motor current reaches very high values, thus causing (in case of wrong
adjustment) an early wear of the brushes, of the traction motor manifold and of the driving wheel. We
recommend following the suggestions indicated in our manuals.

C) EMERGENCY BRAKING

The emergency braking is enabled by pushing the right JOYSTICK

forward and backward. By pushing the JOYSTICK, the “Release
Braking” is activated and, at the same time, the “Electric brake” is
enabled. The two braking systems stop the machine immediately. In
order to restore the running, just let the JOYSTICK in its vertical position.
The emergency braking is not adjustable by means of the console, but it
BRAKE
results from the adjustment of “REALESE BRAKING” and from the
mechanic adjustment of the “PARKING BRAKING”.
Pict. 02
D) PARKING BRAKING

The parking braking is enabled when the operator gets off the footboard. The operator presence sensor
is deactivated, thus disabling the traction and enabling the electric brake blocking the truck.
The braking must be adjusted so that the truck stops within a space not lower than the length of the truck
itself. The braking adjustment is carried out by means of the ring nut placed on the electric brake coil.

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 3

 Section: BRAKING SYSTEM SERVICE

3.00 ELECTRIC BRAKE COIL REPLACEMENT

BRAKE LINING REPLACEMENT
MOD. ALL MODELS

NECESSARY STANDARD TOOLS

5mm ALLEN MEDIUM OPENING 13mm OPEN-

WRENCH SEEGER PLIERS ENDED SPANNER

3.01 ELECTRIC BRAKE COIL REPLACEMENT

Pict. 03
PROCEDURE

Before starting to work wear suitable safety clothes. B

Park the truck in a safe area, away from the transit of other motor
vehicles and from the passage of pedestrians, lower the forks to D A
the ground, turn the key OFF, disconnect the battery.
E
1) ALLEN WRENCH, OPEN-ENDED SPANNER - Remove the motor
compartment hood, disconnect the coil feeding connector. By means C
of the open-ended spanner loosen the three check nuts (Ref. A ). By
means of the Allen wrench completely unscrew the three bolts fixing
the electric brake to the motor (Ref. B). Remove the coil and replace
it.

Install the new coil by following the reverse procedure.

Adjust the braking by performing the procedure indicated on Page 5.

3.02 BRAKE LINING REPLACEMENT

2) Remove the coil by performing the previously described procedure.

Pict. 04
3) SEEGER PLIERS - Withdraw the brake lining from the pinion (Ref.
C). By means of the pliers remove the assembled pinion locking seeger
(Ref. D), withdraw the pinion (Ref. E) and replace completely the brake lining and the pinion.
BRAKE

Install the new brake lining by following the reverse procedure.

Adjust the braking by performing the procedure described on Page 5.

3.03 INSPECTION AND MAINTENANCE

- Check the wear of the brake lining disk. Its thickness can not be lower than 5 mm
- Check the state of the Belleville washers
- Check the good operation of the coupling and releasing coil
- Check the state of the pinion/disk toothing.

Page: 4 Part No: 524182160 Date: Sept. 2003 0 1 2 3 4 5 6 UPDATE

SERVICE Section: BRAKING SYSTEM

3.04 ADJUSTMENT AND STARTING

MOD. ALL MODELS

NECESSARY STANDARD TOOLS

5 mm ALLEN THICKNESS 13mm OPEN-

WRENCH GAUGE ENDED
SPANNER
1) After reassembling the brake unit, before using the truck, it is necessary to adjust the brake lining.

2) In order to obtain a good braking, distance “F” between the plate with brake lining and the electromagnet
must not be upper than 0,2,5/3 mm. Therefore a thickness gauge of that size is necessary.

3) By means of the 5mm Allen wrench loosen the three bolts “V” one fourth of a turn, insert the thickness
gauge into slot “F”, near the adjusting nut “R”, and tighten the nut by means of the 13mm open-
ended spanner. Bring the plate to a distance sufficient to withdraw the thickness gauge with a bit of
friction. Repeat this operation on all three nuts “R”. By means of the 5mm Allen wrench tighten bolts
“V” to a driving torque of 14Nm.

5) Reset of the stop-running braking: Start the truck and move it at the maximum speed. Turn off the
power fom the electric brake coil by pressing the emergency push button. The truck must brake within
a space not lower or upper than the length of the truck itself.
In order to optimize the braking, operate on ring nut “G”:
a) By screwing it, the braking distance is reduced,
b) By unscrewing it, the braking distance is increased.

V V

V BRAKE

F
R Pict. 05

UPDATE 0 1 2 3 4 5 6 Date: Sept. 2003 Part No: 524182160 Page: 5

Parts N° 524182160