Control SME

SB4200E02
Jan.2011
MicroController
Control System (SME)
Specification
System Operation
Testing & Adjusting
B20S-5, B25S-5, B30S-5, B32S-5

BC20S-5, BC25S-5 BC30S-5, BC32S-5
BC25SE-5
for Electric Lift Trucks

Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING” as
shown below.
The meaning of this safety alert symbol is as follows:
Attention ! Become Alert ! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DOOSAN dealers have the most current information
available.
1
Index
Specifications Eye Software Interface
Component Measurements ................................... 5
Controller AS Specification .................................... 6 General Information............................................145
BC20/25/30/32S-5 Motors ..................................... 7 Installation ..........................................................146
B20/25/30/32S-5 Motors ........................................ 8 Features .............................................................147
Instrument Panel Layout ........................................ 9 Main Menu..........................................................149
Fuses ................................................................... 10 Troubleshooting of Eye Program .......................179
Assembly Layout of Controller ............................. 10
Assembly Layout of Motors (36/48/80 V) ............ 10
Control Panel Layout ........................................... 11 Appendix
Appendix A : 36[V] Parameter List .....................180

Systems Operation Appendix B : 48[V] Parameter List .....................183
Appendix C : 80[V] Parameter List .....................186
Glossary ............................................................... 12 Appendix D : Parameter List ..............................189
General Information ............................................. 14 Appendix E : Error Code List..............................192
Installation and Wiring ......................................... 18 Appendix F : Contraction for dot matrix display. 198
F1. Alarm Code ................................... 198
F2. Calibration Code ........................... 199
Testing and Adjusting F3. Diagnostic Code ........................... 201
Preparation Tests and Check .............................. 27

Programmable Parameters.................................. 30
BC20/25/30/32S-5 ............................................... 31
B20/25/30/32S-5 .................................................. 43
Some Functions Management ............................. 48
Diagnostic and Troubleshooting
General Description ............................................. 49

Alarm List ............................................................. 49
Classified troubleshooting according to error
cords .................................................................... 58
Troubleshooting Problem List .............................. 79
System Tests and Adjustments ......................... 121
Electrical System Adjustment ............................ 122
Instrument Panel
Instrument Panel................................................ 125

Display Keys Utilization ..................................... 129
Parameter Calibration ........................................ 130
Sensor Initial Setting .......................................... 139
Default Setting ................................................... 139
Diagnostic Mode ................................................ 140
List of diagnostic ................................................ 141
Accessing Stored Error Codes .......................... 142
3
Specifications
Component Measurements
36/48V 80V
SPECIFICATIONS
Multimeter Setting (+) Test Lead (-) Test Lead Results
Resistance +BATT Each U,V,W About 1.9 Mohms
Resistance -BATT Each U,V,W About 1.9 Mohms
Resistance U Terminal V Terminal About 4.0-5.0 Mohms
Resistance U Terminal W Terminal About 4.0-5.0 Mohms
Resistance V Terminal W Terminal About 4.0-5.0 Mohms
5
Controller AS Specification
TYPE 36/48 V 80 V
BATTERY VOLTAGE 24-60 V
MAXIMUM IMPULSIVE DRIVE INVERTER
750 A 450A
CURRENT
MAXIMUM IMPULSIVE PUMP INVERTER
750 A 450A
CURRENT
SWITCHING FREQUENCY 3-6-9 KHz ←
EFFICIENCY 95 % ←
PROTECTION LEVEL IP54 ←
MECHANICAL SIZE 400x395x148 454x277x150
WEIGHT 24 Kg
VIBRATION 5g 10-500Hz in X,Y,Z axis ←
TEMPERATURE RANGE - 30 °C ¸ + 40 °C ←
MAXIMUM MODULE TEMPERATURE 100°C ←
Complies with EN 1175-1
CONTROLLER ←
EN 12895-1
MAIN CONTACTOR 600A 250A
MAIN FUSE 800A 425A
KEY FUSE 10A 10A
36/48V 80V
6
BC20/25/30/32S-5 Motors
Drive Motor Specification Pump Motor Specification
TYPE 36/48 V 80 V TYPE 36/48 V 80 V

POWER 16 KW 16 KW POWER 21 KW 21 KW
VOLTAGE 30 V 50 V VOLTAGE 30 V 50 V
CURRENT 441 A 259 A CURRENT 580 A 348 A
RATED SPEED 1500 RPM ← RATED SPEED 1540 RPM ←
MAXIMUM SPEED 4500 RPM ← MAXIMUM SPEED 4500 RPM ←
FREQUENCY 75 Hz ← FREQUENCY 77 Hz ←
Cos φ 0.79 0.83 Cos φ 0.79 ←
SERVICE S2 60' ← SERVICE S3 15% ←
INSULATION CLASS F ← INSULATION CLASS F ←
PROTECTION DEGREE IP 54 ← PROTECTION DEGREE IP 54 ←
BEARINGS 6208 2RS ← BEARINGS 6208 2RS ←
WEIGHT 122 Kg ← WEIGHT 95 Kg ←
7
B20/25/30/32S-5 Motors
Drive Motor Specification Pump Motor Specification
TYPE 48 V TYPE 48 V
POWER 15.5 KW POWER 17 KW
VOLTAGE 30.3 V VOLTAGE 30.0 V
CURRENT 405 A CURRENT 450 A
RATED SPEED 1735 RPM RATED SPEED 1550 RPM
MAXIMUM SPEED 4500 RPM MAXIMUM SPEED 4500 RPM
FREQUENCY 90 Hz FREQUENCY 55 Hz
Cos φ 0.83 Cos φ 0.86
SERVICE S2 60' SERVICE S3 15%
INSULATION CLASS F INSULATION CLASS F
PROTECTION DEGREE IP 20 PROTECTION DEGREE IP 20
8
Instrument Panel Layout
9
Fuses Assembly Layout of Motors
(36/48/80 V)
Line ........................................................ 36/48 V:800A
............................................................. 80 V:425A
Key ........................................................................ 10A
Horn ...................................................................... 10A
DC / DC Converter ................................................ 10A
Light ..................................................................... 10A
Option light ............................................................ 10A
Assembly Layout of Controller

<36/48 V>
<80 V>
10
Control Panel Layout
36/48V
80V
Apply a small amount of D557047 Thermal Joint Compound on control panel plate and mating surface prior to
assembly. Communication cable’s assembly with power units and logic control unit uses the micro screw
driver(2.5*100mm)
Communication cable's assembly with Power Unit and Logic Control Unit uses Micro Screw Driver
(1) Logic Board. Use a screw driver to hold screws

(2) Drive Motor Power Unit. Use a hex bit socket(5mm) wrench(100mm) or L-wrench to hold bolts
(3) Pump Motor Power Unit
(4) FUSE. Use a socket wrench(13mm) and a wrench(13mm) to hold bolts
(5) Line Contactor
(6) Bus Bar. Use a socket wrench(13mm) and a socket wrench(17mm) to hold bolts
11
Systems Operation
Glossary
NAME DESCRIPTION
Accelerator A device that converts mechanical movement into a analog voltage pattern to the
logics for variable drive motor speed.
Ampere (or Amp) The unit of measurement of current flow. The amount of current that one volt can
push through a resistance of one ohm.
Analog to Digital A device that converts an analog voltage into a pattern of digital HIGH and LOW
Converter voltage signals.
Battery Two or more cells connected together for a supply of electric current.
BDI Battery Discharge Indicator - An electrically controlled display showing the operator
the state of batter y charge.
Bus Bar A heavy electrical conductor to which other smaller wires are connected.
Capacitor Device used to store electrical energy for short periods of time.
Circuit A way for current to go from the positive (+) side of an electrical power source to the
negative (-) side of an electrical power source. This can be through wires and
electrical components.
Coil A component made from many circles or turns of wire used to concentrate a
magnetic field.
Connector Part of a wire assembly or harness that connects with another wire assembly or
harness. Used for ease of assembly and disassembly.
Contactor Assembly An electrical component consisting of an electromagnetic coil and a set of heavy
contact tips. Control current passes through the coil, building a magnetic field which
closes or opens the contact tips.
Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly.
Contact Tips or Contacts The portion of a switch, relay or contactor where the circuit can be opened or closed.
Current The movement or flow of electricity through a conductor. A circuit must be complete
for current to flow.
Current Limit The maximum allowable armature current of a stalled drive motor during pulsing.
Digital Signal A signal in which the elements may be either of two distinct values.
For example high voltage, low voltage.
Diode A semiconductor device that allows current to flow in one direction, from the anode to
the cathode.
Display An electrical device that converts voltage inputs to a visual output.
Electrical Assist Braking Electrically trying to rotate the drive motor opposite to the direction of truck
(EAB) movement.
Fuse A component in an electrical circuit that will open the circuit if too much current goes
through it.
Harness An assembly made of two or more wires that are held together.
Heat Sink A mounting frame used for semiconductor cooling.
Indicator LCD that gives an indication of some vehicle condition when it turns on or flashes.
LCD Liquid Crystal Display.
Logic Control Unit The main printed circuit board containing a microprocessor and circuits to condition
the voltage signals that go into or come out of the logics. It electronically monitors
and controls the truck's functions.
12
NAME DESCRIPTION
Microprocessor A small computer chip preprogrammed to control the various electrical functions on a
lift truck.
Normal Condition Words used with a switch or relay. Their normal condition is their condition when they
are not controlled by the application of force, temperature, pressure, or electricity.
MOSFET A semiconductor component used in electric lift trucks as an electronic switch. A
MOSFET most often has three terminals, a GATE(G), a DRAIN(D), a SOURCE(S). A
MOSFET is a voltage-controlled device and required only a small input current. The
switching speed is very high.
Ohm The unit of measurement of resistance. The amount of resistance that will let one volt
push only one ampere of current through it.
ON-Time The amount of time current flows through a transistor.
Open Circuit Wiring or components of a circuit that have no continuity.
Overload The presence of voltage or current which is greater than an electrical circuit or
component is designed to handle.
Plugging A portion of electrical braking where the generated current is directed back through
the armature.
Relay An electrical component consisting of an electromagnetic coil and a set of small
contact tips. Control current passes through the coil, building a magnetic field which
closes or opens the contact tips. When the contact tips are closed, low current can
flow in a separate isolated circuit.
Resistor A component made of a material that has a specific resistance to the flow of current.
Rotor Part that rotate of motor
Schematic A line drawing of an electrical or electronic assembly which uses symbols to show
individual components. It shows how the components, wires and connectors function
electrically.
Short Circuit An electrical connection between two or more components that is not desired.
Socket The female contact of a connector that slips over a male contact (pin) of another
connector.
Solid State Reference to semiconductor components or circuits that use semiconductor
components that have no moving parts, such as diodes and transistors.
Stator Fixed part in driving state of motor
Switch A component used to control an electric circuit. It can close or open a circuit.
Systems The electrical components, circuits, and connections that deliver power to perform
specific tasks.
Terminal An electrical connection point on an electrical component.
Thermal Sensor A sensor that activates at a set temperature.
Volt The unit of measurement of electromotive force. One volt is the force needed to
make one ampere of current flow through one ohm of resistance in a circuit.
Watt The unit of measurement of power. The amount of power used when one volt pushes
one ampere of current through a resistance of one ohm. The result of amperes
(current) multiplied by volts (voltage) is watts (power).
Wire A conductor used to provide a path for current to flow to and from electrical
components.
Wiring Diagram A drawing using visual representation of components the way they actually look. It is
used to show the locations of components and the connections between them.
Zener Diode A special diode used to regulate voltage or as an over-voltage (too high a voltage)
protector.
13
General Information
Advantage of AC motor Comparison between AC and DC
motor
AC induction motors are the most diffused for power
conversion in industrial application. In the battery- Motor Characteristics
fed lift-truck applications DC motors are more used,
because they are easy to control in torque with a
simple chopper drive with a current limitation. AC Motor systems DC Motor system
1 Little components More complex
To reach the traction requirements the AC control
has to be very advanced and the motor parameters 2 Decreasing price Increasing price
have to be known by the control algorithms.
3 More reliable Less reliable
The reason of their recent diffusion are related to
the technological development and to deeper Practically Continuous maintenance
4
studies about this matter. maintenance free to brushes
The advantages of using AC motors instead of 5 High speed Low speed

DC motors are many: High torque
1. More robust and easy to build Low torque performance
6 performance at high
2. Less complex and more reliable at high speed
speed
3. Practically maintenance free (no continuous
brush maintenance) High braking Poor braking
4. Higher speed 7 performance at high performance at high
5. More performance at high speed especially in speed speed
regeneration 8 Safer Less safe
6. Absence of contactors for speed inversion
7. Continuous torque control during inversion (no
delay with zero torque)
Controller Characteristics
8. Safer because AC motor is not supplied and it
doesn’t work in case of short circuit
AC Motor systems DC Motor system
See following tables and relative explanation for a 9 Complex controller Simple controller
comparison between AC and DC motor systems.
Presence of auxiliary
10 No auxiliary contactor
contactors
4 quadrants Torque discontinuity and
11
continuous transition delay
Precise and smooth
12 Poor regulation
regulation
14
AC and DC Motors Difference Explanation
DC motor is made with a rotor with power windings

and a stator with excitation windings and brushes.
The AC motor is composed by a rotor and a stator
with windings.
Because of great diffusion of AC motors and the

automatic industrial production process, their prices
continue to decrease.
Because of DC motor more complexity, brush

presence and poor environmental protection, the life
of DC motor is greatly reduced, compared with AC
motor.
The maintenance of DC motor must be continuous

because of consumption of brushes.
The most critical component for AC motor are the
bearings. AC motor reaches higher speed because
of DC sparkling limitation of brushes.
AC motor has higher torque at high speed because

of DC sparkling limitation of brushes. AC motor has
much more regenerative braking torque at high
speed because of DC sparkling limitation of brushes.
AC motor is safer than DC because if a short circuit

happens in armature, DC motor accelerates. The
AC motor needs an AC voltage to accelerate.
The AC controller is much more complex of a DC

one. The reason why is the AC control algorithms
requires the use of a very powerful microprocessor
which performs a fast real time control.
In most of DC controllers are present auxiliary

breakers which operate every drive inversion,
introducing delays and compromising the controller
life.
Most of DC controller systems has zero torque

delays during inversion causing a poor driving
performance. In AC the transition between forward
and reverse and acceleration and braking is
continuous giving an optimum performance even at
very low speed and in sharp ramp.
Because of 4 quadrants continuous transition and

the presence of a sophisticated controller the
regulation of AC system is superior in precision,
stability, smoothness and safety to DC one.
15
Main ITC(Intelligent Torque Control) Software control algorithm is customized in order to
features best fit lift truck characteristics; you can set the
value of a wide range of parameters, in order to
Most important features of Intelligent Torque optimize system performance and to adjust the
Control system developed by DHIM the settings of main functions in compliance with user’s
following: needs.
1. Control unit: One panel assembly containing User can interact with control board making use of a
three power inverters for drive and pump and a software application (named EYE) developed by
control board; main board, wired directly to the DHIM, or with COMPACT display. In both cases, it’s
power modules, could manage up to 4 inverters. possible to obtain an exhaustive “on line” diagnostic
The presence of 2 DSP (Digital Signal for all lift truck functional parameters and also to
Processors), working in mutual redundant adjust them.
control, guarantees powerful software
performance: in case of such a system, You can upgrade control board internal software
managing both drive and pump motors, high connecting a PC via serial port (or via USB 1.x or
dynamic performance in vectorial torque control higher, inserting the appropriate serial port-USB
can be obtained. adapter); in fact, working with RS232
communication standard, EYE application permit to
2. Two asynchronous three-phase drive motors load and upgrade panel software in any working
equipped with magnetic sensors(64 impulses/ conditions, if only control board is correctly fed on .
rotation).
3. An asynchronous three-phase pump motor for

lifting equipped with magnetic sensor (64
impulses/ rotation).
4. Instrument Panel.
Instrument Panel
16
Basic ITC ITC system characteristics
Following basic hardware and software You can obtain high performance for the lift
functions characterize DHIM Company system: truck with DHIM system, thanks to following
specific features:
1. Protection against reverse battery polarity
2. Anti-roll-back, with adjustable ramp stop time 1. DSPs(Digital Signal Processor) high
3. Anti-roll-down performance control with custom software: this
4. Regenerative braking is resident in the internal FLASH memory, and
5. Electrically assisted braking allows to control 3 independent AC motors.
6. Management of static return to off function 2. One serial asynchronous RS232 interface for
(SRO) PC communication in order to obtain:
7. Drive speed compensation (load/unload) a. Software update
8. Drive speed acceleration/deceleration b. Diagnosis of truck functionalities
9. Drive speed reduction c. Parameters modification, in order to
10. Redundant control of acceleration pedal customize the system
(applying a control switch or a double 3. One accelerator (0 - 5 V) and all on/off
potentiometer) emergency micro-switches interface.
11. Continuous lift speed control 4. One encoder (0 - 5 V) interface for traction and
12. Pump speed compensation (load/unload) pump motors.
13. Lift speed acceleration/deceleration 5. Motor torque control by speed and current loop.
14. Continuous control of main contactor applied to 6. Controlled acceleration and deceleration ramps
DC power line of drive and pump motors in order to avoid
15. Seat switch open check with delay time uncontrolled jolts of the load due to oversights
16. Battery discharged indicator with adjustable of the operator.
reset value 7. Automatic truck speed limitation depending on
17. Overtemperature protection for inverters and steering angle.
motors 8. Ramp stop of the lift truck.
18. Low and high battery voltage limit 9. Automatic energy recovery at each truck
19. Drive/pump speed feedback braking.
20. Zero speed drive in ramp 10. LIN (Local Interconnect Network) display
21. Standby for supply interface.
22. Diagnostics and stored error code 11. Automatic truck speed limitation, depending on
23. Power line fault detection (fuse/contactor) the height of the load lifted(option).
24. Continuous temperature measuring (Controller, 12. Automatic truck maximum speed limitation, in
drive/pump motor) function of:
13. Weight present on the forks(option)
a. Fork height
b. Battery voltage level
c. Any thermal alarm
d. Full protection of drives against overcurrent
of the motors, overheating of the power
transistors and both maximum and minimum
battery voltage.
14. Low maintenance costs by using A.C induction
motors
17
Installation and Wiring
General
1. A metallic container encloses control board (Fig.

1).
2. There are three power modules (see fig 2 for

single module) assembled to main board as
shown in Fig. 4 and Fig. 5.
3. A 42 pins AMP connector (named K1), permits

Fig. 1: Logic control board
to interface control board to lift truck
electrical/electronic sub-devices. See Fig. 4 for
a view of K1- 42 ways connector.
4. Three 26 ways connectors (named Drive and

Pump) permit to wire and control 2 power
inverters. No details are given about the pin-out
of these connectors t, because they are not
user accessible for maintenance or diagnostic
operations. Power modules shall be connected
also to battery supply (wire named +B and -B)
and to corresponding motor phases.
Fig. 2: Single power module (36/48V)
Working on electrical systems is potentially

dangerous; you should protect yourself
against :
Uncontrolled operation: some conditions could
cause the motor to run out of control:
disconnect the motor or jack up the vehicle and
get the drive wheels off the ground before
attempting any work on motor control circuitry.
High current arcs: batteries can supply very
high power, and arcs can occur if they are short
circuited. Always open the battery circuit
ground before working on motor control circuit.
Fig. 3: Single power module (80V)
Wear safety glasses and use properly insulated
tools to prevent shorts.
Lead acid batteries: charging or discharging
generates hydrogen gas, which can build up
and go around the batteries. Follow the battery
manufacturer’s safety
Fig. 4: Power modules assembly with main contactor and

fuses, logic board (80V).
18
Fig. 5: Power modules assembly with main contactor and
fuses, logic board (36/48V).
Fig. 6: View of accessible terminals on 42 ways connector
19
K1 connector: list of all terminals
Pin
Use Name Function
number
K1 – 1 IN -Battery -Battery Negative supply voltage of control board
K1 – 2 IN +Battery +Battery Control unit supply voltage; V = Vali
IN Key switch +Battery key input Supply voltage of key and coils;
K1 – 3
Vkey=Vali
OUT Not used Optional Open collector power output
K1 – 4
D Vmax = Vsupply; Imax = 2A
IN Weight sensor Pressure sensor (optional)
A Proportional voltage signal (0-5V); you can connect a
K1 – 5
pressure linear sensor, made by SME cod.B00ID160
working correctly in 0 -250 bars pressure range
IN Not used Brake pedal sensor (optional)
A Proportional voltage signal (0-5V); you can connect a
K1 – 6
pressure linear sensor, made by SME cod.B00ID168
working correctly in 0 -250 bars pressure range
IN Lift sensor
K1 – 7 Lift sensor. Proportional voltage signal (0-12V)
A
IN Height switch 2
K1 – 8 Limitation height switch 2 (optional), internal pull-up
D
IN Accelerator pedal 2 Accelerator input 2 pedal. Proportional voltage signal (0-
K1 – 9
A 5V), managed as accelerator pedal input
IN Seat switch Seat switch Seat switch signal, N.O., with internal pull-up
K1 – 10
D and Vmax = 12V
IN Not used
K1 – 11 Optional Proportional voltage signal (0-12V), input
A
IN Aux 1 switch
K1 – 12 Aux1. N.O., internal pull-up, Vmax = 12V
D
IN Tilt switch
K1 – 13 Tilt. N.O., internal pull-up, Vmax = 12V
D
OUT Fan Fans command (optional)
K1 – 14 D Open Collector power output, to command fans (or other
devices); Imax = 2A; Vmax = 60V;
OUT - Coil contactor Coil main contactor Positive command of contactor coil;
K1 – 15
Imax = 2A
OUT +5V +5 V encoder supply +5V supply voltage (self-protected
K1 – 16 electronic component) with : Idc (nominal) =500mA
Imax = 1Adc
OUT +12V +12 V supply +12V supply voltage (self-protected
K1 – 17 electronic component) with: Idc (nominal) =500mA
Imax = 1Adc
IN Accelerator pedal 1 Accelerator input 1 pedal. Proportional voltage signal (0-
K1 – 18
A 5V), managed as accelerator pedal input
20
Pin
Use Name Function
number
IN Start switch for accelerator pedal START signal,
K1 –19 Not used
D N.O. with internal pull-up and Vmax=12V
IN Forward drive direction signal,
K1 – 20 Forward direction switch
D N.O., with internal pull-up and Vmax=12V
IN Reverse direction switch Reverse drive direction signal,
K1 – 21
D N.O., with internal pull-up and Vmax = 12V
IN Park brake switch Park brake switch Park brake signal, N.C., with
K1 – 22
D internal pull-up and Vmax = 12V
IN Pedal brake switch Pedal brake switch Activation signal for park brake,
K1 – 23
D N.O., internal pull-up and Vmax = 12V
IN Aux 2 switch Aux2. N.O. internal pull-up, Vmax = 12V
K1 – 24
D
IN Aux 3 switch Aux3. N.O. internal pull-up, Vmax = 12V
K1 – 25
D
IN/OUT Not used CAN . L (not used) L line input for CAN component;
K1 – 26
D presence of internal termination resistance
IN/OUT Not used CAN . H (not used) H line input for CAN (Controller
K1 – 27 D Area Network) component; presence of internal
termination resistance
IN/OUT Lift solenoid Optional N.O. internal pull-up: Vmax(in) = 12V
K1 – 28 D Self-protected open collector power output;
Vmax = 12V,Imax = 0.5A
OUT +Coil contactor + coil main contactor Main breaker coil reference
K1 – 29
signal ;Imax = 2A
OUT GND GND Negative supply voltage for data type signals,
K1 – 30 with self-protection against noises coming from DC
power line
IN Steering angle sensor Steering angle sensor voltage (optional)
K1 – 31 A Proportional voltage signal (0-12V) or (0-5V), used as
input for steering sensor circuit
IN PHASE A of drive motor encoder PHASE A of drive motor encoder PHASE A signal of
K1 – 32 D the sensor bearing mounted into the motor 1; internal
pull-up; Vin:(0.5V)
IN PHASE B of drive motor encoder PHASE B of drive motor encoder PHASE B signal of
pull-up; Vin:(0.5V)
IN Thermal sensor-drive Drive motor thermal sensor/switch Analogue input (or
K1 – 34 A/D digital as optional) used for motor 1 thermal sensor (0-
12V); internal pull-up
IN PHASE A of pump motor encoder PHASE A of pump motor encoder PHASE A signal of
pull-up; Vin:(0.5V)
IN PHASE B of pump motor encoder PHASE B of pump motor encoder PHASE B signal of
pull-up; Vin:(0.5V)
21
Pin
Use Name Function
number
IN Thermal sensor-pump Motor 2 thermal sensor/switch Analogue input (or digital
K1 – 37 A/D as optional) used for motor 2 thermal sensor (0-12V) ;
internal pull-up
IN Asynchronous RS232 serial RX RX input for asynchronous RS232 serial
K1 – 38
D input communication standard
OUT Asynchronous RS232 serial TX TX output for asynchronous RS232 serial
K1 – 39
D input communication standard
IN/OUT Heght switch input 1 Limitation height switch 1, internal pull-up.
K1 – 40 D Self-protected open collector power output:
Vmax = 12V,Imax = 0.5A
IN/OUT LIN data LIN data line (Display in/out) Data line of LIN interface for
K1 – 41
D COMPACT display
OUT Buzzer command Buzzer command Open Collector power output, to
K1 – 42 D command buzzer
activation; Vmax = 12V; Inom=30mA; Imax=100mA
NOTES:
D : digital signal, with boolean values (ON/OFF)
A : analogue signal, assuming values in
[Vground -Vmax] range
A/D : signal that could be both analogue and digital
NO : normally open
NC : normally close
IN : signal used as input
OUT : signal used as output
NOTICE
Remember the controller contains ESD(Electro
Static dischange) sensitive components.
Use appropriate precautions in connecting,
disconnecting and handling it.
22
System Circuit
Power Circuit
If divide greatly composition of electric controller

system of this vehicles, is consisted of 1 Logic
control board, Power Unit (Drive, Pump) 2, Line
Contactor 1.
Each power unit controls each motor's speed, logic

control board vehicles situation and driver's select
receiving feedback vehicles control.
23
Actuation Circuit
This circuit supplies power to the Logic Control When the seat switch is closed, current will flow
Board and the Instrument Panel(Display). It must be from the logic K1-10 through the seat switch to
activated before power steering, hydraulics or drive controller negative. The logics then activates the
will operate. line contactor by allowing current to flow from K1-29
through the line contactor coil (+) and K1-15 the line
When the battery is connected and the key switch is contactor coil (-).
closed, current flows from battery positive through
the key fuse, key switch, wire #3 to the logic control With the line contactor tips closed the logics
board (logic) contactor K1-3. continues its checks for any “Run Time” faults. If no
The logic connection to battery negative is at K1-1. faults are detected the display will indicate the
The logic circuits are powered up to accept voltage battery charge level, the power steering (IDLE)
inputs and create voltage outputs whenever the system operates, the pump and drive power circuits
battery is connected and the key is turned to ON. receive battery voltage and the logics receives
battery voltage.
24
Hydraulic Pump Motor Circuit
Only one hydraulic pump motor is used for all power

steering, lift, tilt and auxiliary hydraulic functions. To
activate the pump circuit, the seat switch, key switch
and line contactor must be closed first as explained
in the topic, Actuation Circuit.
Power Steering Circuit
The power steering speed of this vehicles operate

by speed (default 500 rpm) that specify in pump
motor calibration.
Lift Control Circuit Location Components

(2) Lift Sensor. (3) Magnet.
When the operator pulls the lift lever, magnet (3)

moves closer to the lift sensor (2). The sensor
1 detects the increasing magnetic field and sends an
increasing voltage to the valve control card.
The input to the logics at K1-7.
The logics uses these changing voltages to
determine what speed to operate the pump motor.
The logics then controls the pump power unit.
Location Components
(1) Valve control card.
This control panel accept a linear speed lift signals

and tilt/aux lever signals. The lift control system is
controlled by valve control card (1) mounted at the
top of the control valve.
The drive control card uses a hall-effect transducer

(Lift Sensor) and magnet to sense lift lever
movement. The closer the magnet is to the
transducer the greater the hydraulic pump motor
speed.
25
Thermal protection circuit Accessory Circuits
Control Panel Horn Circuit
If the Power Unit’s MOSFETs overheat, a thermal The horn will operate when the battery is connected
senders mounted in the MOSFET heatsink will give and the horn button is pushed. Current flows from
a voltage signal to logic. If the temperature is over battery positive through horn fuse, horn switch and
than preset value(100°C), the Instrument Panel will horn, back to battery negative.
display a “Run Time” diagnostic symbol and E1, E3.
The logics will decrease the speed of the drive
motors and the pump motor. The amount of current DC-DC Converter Circuit
allowed to flow through the MOSFETs is decreased
to permit them to cool. When the heatsink cools off
the truck will return to normal operation. But due to
the reduced speed, acceleration performance will
be decreased. Each error code is stored in memory.
Drive Motor
If the drive motor overheats a thermal sensor

mounted in the stator coil of drive motor will warn at
a predetermined temperature (155°C).
If reach in overheating temperature, the Instrument
Panel will display a “Run Time” diagnostic symbol
and E4.
To decrease the amount of current allowed to flow
through the drive motor, the logics will reduce the
speed. When the drive motor cools off, the truck will
return to normal operation. Drive system
acceleration performance and top travel speed is
affected by an overheated drive motor. “MOTOR
TEMPERATURE” will be stored for Drive Motor
overheating in memory.
The 12 volt output of the converter is protected
against short circuits and overloading by an internal
Hydraulic Pump Motor 15 amp current limit circuit. A fuse on the converter
protects it from reverse connection of the battery
If the drive motor overheats a thermal sensor voltage.
mounted in the stator coil of drive motor will warn at
a predetermined temperature (155°C). Do not connect the 12 volt negative output of the
If reach in overheating temperature, the Instrument DC-DC converter to battery negative.
Panel will display a “Run Time” diagnostic symbol Damage to system components could
and E6. To decrease the amount of current allowed occur.
to flow through the pump motor, the logics will
reduce the speed. When the pump motor cools off, The DC-DC converter changes the lift truck battery
the truck will return to normal operation. “MOTOR voltage to 12 volts. This 12 volts is used to power
TEMPERATURE” will be stored for Pump Motor accessories such as floodlights, brakes/side lights
overheating in memory. and backup alarms.
The positive of the 12 volt output is common to the

positive of the batter y voltage. The negative of the
12 volt output is pulsed to maintain a steady 12 volt
supply.
26
Testing and Adjusting Battery Load Test
1. Turn the range switch on the multimeter to read

Preparation Tests and Check battery voltage.
Battery Tests 2. Connect the battery.
A weak battery can cause or contribute to problems <36/48 V>

in the Logic Control Board and power circuits. Verify
the battery is good before investigating other
possibilities.
1. Verify proper polarity at the battery connector

and the control panel. Positive cable should be
at the line fuse and negative at the negative on
control panel.
2. If the lift truck is operational, perform a battery

load test.
3. If the truck is not operational and the battery is

suspected, perform a cell voltage or specific
gravity test. <80 V>
Battery Voltage Test.

(1) Positive cable connection. (2) Negative cable connection.
3. Connect the multimeter leads between positive

(+) cable connection (1), and negative (-) cable
connection (2).
4. In a safe area, operate the hydraulic system,

(hold tilt lever to maximum position
momentarily) while reading the voltage
indicated on the multimeter.
5. If the indication is less than 45.6V(48 V truck),

34.5V(36 V truck), 75.7V(80 V truck) the battery
needs to be charged or repaired before
continuing to troubleshoot.
27
Cell Voltage Test 3. Charge the battery correctly. A battery should
be discharged to 80% of its capacity then fully
With the truck powered up and the pump(Idle) motor recharged. It should cool four to eight hours to
running, measure the voltage at each cell. Normal allow the voltage to stabilize before being put
voltage should be between 1.95V and 2.12V per cell. back in use. The battery should have an
If the voltage on each cell is below 1.95V the battery equalizing charge (an extra three or four hour
must be charged or repaired before continuing to charge at a low finish rate) once a month to
troubleshoot. make sure all cells are in a fully charged
condition. Properly charged batteries should be
The indication between cells should not differ more identified to prevent low batteries from being
than 0.05 volts. If it does, the battery must installed in trucks.
have an equalizing charge or be repaired.
4. Operation with a low battery must be prevented.
Low battery operation may damage the battery
Hydrometer Test and will cause higher than normal current in the
electrical system. High current draw due to a
Test each cell of the battery with a hydrometer. low battery will damage contactor tips and
If the specific gravity indication is below 1.140, the shorten motor brush life.
battery must be charged. The battery is fully
charged if the indication is 1.265 to 1.285. 5. The battery's maximum temperature is critical.
The electrolyte temperature should never
The indication between cells should not differ more exceed 43°C (110˚F) either while operating or
than 1.020 If it does, the battery needs an charging. Overcharging a battery will cause
equalizing charge or needs to be repaired. over heating and warp the batter y plates.
Maximum battery life will result from maintaining
25˚C (77˚F) electrolyte temperature. Most of the
Battery Maintenance charging equipment is fully automatic but should
be checked periodically to assure proper
It is important that all batteries be charged and working order.
maintained according to the battery
manufacturers instructions. 6. Keep accurate battery records. Regular battery
readings should be taken with a battery tester or
The care and maintenance of batteries is most voltmeter and a written record kept. Specific
important to maximize battery life and efficient truck gravity and voltage of each cell should be
operation. Periodic inspection and service will checked and recorded at least once each month.
increase the life of batteries. Special attention This inspection should be made after an
should be given to the rules that follow: equalizing charge. Readings should never be
taken directly after water has been added.
1. Keep batteries clean at all times. Cleaning will Records of all battery maintenance should be
prevent corrosion, current leakage and shorts to made and filed so it will be known which
chassis. Tighten all vent plugs, wash the battery batteries are being abused or wearing out.
with water and a brush, then dry with an air
hose. It may be necessary to use a baking soda Repairs should be made immediately otherwise the
solution if water alone will not clean the top of battery may become damaged. Batteries stored in a
the battery. discharged condition may be difficult to recharge
due to sulfate formation.
2. Add enough water to cover the plates before
charging. This will ensure the proper chemical
reaction over the entire plate surface. After
charging is complete, add water until it is about
12.7 mm (.50 in) above the plates. Use distilled
water or water that has tested free from
minerals.
28
Visual Checks
1. Verify all components and wires are in their

proper place. Check fuses, components,
contactor tips, wires and connections. Verify
that they are not burned, broken or loose.
2. Verify there is no mechanical binding or

interference in the contactor.
3. Visually check the parking brake switch, the

hydraulic switches and accelerator linkage for
adjustment or interference problems.
Resistance to Chassis Checks
Resistance between any point in the truck wiring

and the chassis should be a minimum of 10,000
ohms or more.
Many malfunctions are caused by shorts to chassis.

Usually, two shorts must exist before a malfunction
will occur. But, since batteries can have chassis
leakage, only one short to chassis in the truck wiring
can cause problems. To prevent problems because
of shorts, do the following:
1. Disconnect the battery and discharge the Power

Uint.
2. Randomly measure any component connection

or wiring connection in respect to the lift truck
chassis for a minimum resistance of 10,000
ohms. Any test point with low resistance must
have the short to chassis removed.
3. Always keep batteries clean to minimize current

leakage to the chassis.
4. Routinely clean the brush dust from the motors.
5. Be sure that all attachments, such as horns and

lights are designed for no chassis connection (a
two wire system).
29
Programmable Parameters
Adjustable Parameters Description
The possibility of interfacing by PC with the system

allows to have an exhaustive real time analysis of
the system working and of the condition of its
components; moreover, you can choose among a
wide range of parameters in order to reach the
optimum operating of the system in compliance with
your needs.
Adjustable parameters are listed below, divided by

functional groups, both for a 36V, a 48V and a 80V
system. We briefly explain what’s the meaning of
each programmable parameter, and which is the
effect of its changes in lift truck performance.
30
BC20/25/30/32S-5
<36 V SYSTEM>
Drive Motor
Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
as high it is as quickly the truck decreases
Deceleration
5 its speed if the truck driver is turning the rpm/s 0 3,000 5,000
steering ramp 1
wheel quickly
its speed in relation to the drive speed of
Deceleration
6 truck. This parameter increases the rpm/s 400 800 2,000
steering ramp 2
deceleration ramp while the driver is steering
at high speed.
Buzzer on If it’s ON, the buzzer will be alarmed when OFF = 0 (Default)
30 digit
forward direction the direction switch is moved to forward. ON = 1
Buzzer on If it’s ON, the buzzer will be alarmed when OFF = 0
31 digit
reverse direction the direction switch is moved to reverse. ON = 1 (Default)
The cooling Fan runs when the temperature
Starting of motors reaches to set value. And the
32 140 311
35 temperature of cooling Fan stops when the motors cools ℉(℃)
(0) (60) (155)
motor's Fans down below 60℃ from set value(The
minimum of stop temperature is 25℃).
Drive maximum Drive motors maximum current (expressed
41 % 20 100 100
current in per cent of high energetic mode value)
Maximum forward lift truck speed with no
Forward
42 speed limitation rpm 1,000 4,500 4,500
maximum speed
(no alarms present and turtle not active)
Maximum reverse lift truck speed with no
Reverse
maximum speed
Drive limitation Maximum lift truck speed with speed
44 rpm 500 2,000 3,500
maximum speed limitation (turtle active)
High lift switch 1 Maximum travel speed when switch 1 was
46 rpm 0 1,000 4,500 option
drive max speed "ON"
Steer limitation drive Maximum speed reference in the angle in
47 rpm 400 800 2,000
maximum speed which the internal wheel is mechanically still.
Lift truck acceleration with accelerator pedal
48 Acceleration ramp rpm/s 500 900 2,000
pressed
49 Inversion ramp Lift truck deceleration in inversion rpm/s 500 900 2,000
Lift truck deceleration with accelerator pedal
50 Release ramp rpm/s 40 800 2,000
released
Lift truck deceleration with pedal brake
51 Pedal brake ramp rpm/s 40 1,000 2,000
pressed
If the truck speed is greater then this
threshold, the speed reference becomes a
52 Creep speed rpm 100 300 2,000
parabolic function of the accelerator
potentiometer voltage.
Diameter of drive
53 Drive tire's diameter mm 300 510 700
tires
High lift switch 2 Maximum travel speed when switch 1 and
54 rpm 0 1,000 4,500 option
drive max speed switch 2 was "ON"
Parameter that softens the drive inversion
59 Partial release ramp ramp if the traction motors are working with rpm/s 10 40 500
low rpm
If parameter is set to1, speed limitation is
Disable = 0(Default)
94 Slow speed active; otherwise lift truck speed is managed digit
Enable = 1
as usual.
If parameter is set to 1, values are
Normal = 0
95 British unit expressed in British unit, otherwise in digit
British unit = 1(Default)
international ones.
31
Display
96 Display's brightness adjustment digit 0 5 8
brightness
If this parameter is set to 1, it is possible to
Disable = 0
97 E-S-H enable change the value of the power mode with digit
the display Enable = 1(Default)
Time meter / If parameter is set to 1, odometer indication
Timer meter = 0(Default)
98 Odometer on appears on display ; otherwise display digit
Odometer = 1
display shows the hour meter.
99 Maintenance time Can set truck's maintenance period. h 0 0 10,000
Sensors and Potentiometers

Steering Steering sensor voltage with wheels turned
18 mV 500 10,300 11,500
anticlockwise on right
19 mV 500 1,200 11,500
clockwise on left
20 Steering middle Steering voltage with wheels straight ahead mV 500 6,300 11,500
Minimum Accelerator sensor voltage with pedal
23 mV 200 1,000 4,500
accelerator released
Maximum Accelerator sensor voltage with pedal
24 mV 2,000 3,600 4,500
accelerator completely pressed
Lift sensor voltage with lift lever completely
32 Maximum lift mV 3,000 11,500 12,000
pressed
33 Minimum lift Lift sensor voltage with lift lever released mV 0 2,300 12,000
Lift lever potentiometer voltage to which the
34 Middle lift lifting becomes proportional to the shift of mV 1,000 2,750 12,000
the lever
Pump Motor

if it's OFF, the pump motor works like it does now,
that is, the reference speed of pump motor, in
case of many simultaneous commands (LIFT +
TILT, LIFT + AUX1, TILT + AUX1.......), will be the
Lift priority for OFF = 0
27 highest of every single command; if it's ON the digit
speed reference ON = 1 (Default)
reference speed of pump motor, in case of many
simultaneous commands, will be the lowest of
those reference speed required by every single
command.
Weight of the
36 Load measurement kg 0 0
load on the forks future
37 No load pressure Load measurement bar·10 0 0 2,200 option
38 Load pressure Load measurement bar·10 0 0 2,200
Limitation 212 311
39 Start temperature of performance reduction ℉(℃)
temperature (100) (155)
Lift maximum Pump motor maximum current with lift
61 % 20 80 100
current function active
Auxiliary Pump motor maximum current with lift lever
62 % 10 65 100
maximum current released
Lift maximum
63 Maximum lift speed rpm 1,000 2,000 3,000
speed
64 Tilt speed Pump motor speed with lift function active rpm 500 1,000 2,000
Auxiliary 1
65 Pump motor speed with 1st auxiliary function active rpm 500 900 2,800
function speed
Auxiliary 2 Pump motor speed with 2nd auxiliary function
66 rpm 500 900 2,800
function speed active
Auxiliary 3 Pump motor speed with 3rd auxiliary function
67 rpm 500 900 2,800
32
Lift minimum
68 Minimum lift speed rpm 500 700 1,500
speed
High lift 1 switch Maximum pump motor speed with forks above the
69 rpm 0 1,500 3,000 option
lift max speed critical height
70 Hydro speed Pump motor speed when steering rpm 300 600 800
Pump motor speed with direction command lever
71 Hydro idle speed not in neutral, acceleration pressed and no pump rpm 300 400 600
command active
Pump
72 Lift acceleration rpm/s 1,000 7,000 10,000
acceleration ramp
Pump Pump motor deceleration after the end of a
73 rpm 1,000 7,000 10,000
deceleration ramp command
High lift 2 switch Maximum lift speed when switch 1 and switch 2
74 rpm 0 1,500 3,000 option
lift max speed was "ON"
High lift 1 switch
75 Maximum tilt speed when switch 1 was "ON" rpm 0 500 2,000 option
tilt max speed
High lift 2 switch Maximum tilt speed when switch 1 and switch 2
76 rpm 0 500 2,000 option
tilt max speed was "ON"
High lift 1 switch
Maximum auxiliary 1 speed when switch 1 was
77 auxiliary 1 max rpm 0 500 2,800 option
"ON"
speed
High lift 2 switch
Maximum auxiliary 1 speed when switch 1 and
switch 2 was "ON"
speed
High lift 1 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1 was
79 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1 and
80 rpm 0 500 2,800 option
function max switch 2 was "ON"
speed
High lift 1 switch
83 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
84 rpm 0 500 2,800 option
speed
33
Timers

Time interval between seat switch opening
11 Seat switch delay s 1 3 9
and drive and pump motors stopping
Time delay between last command given to
12 Chat time a drive or pump motor and chat mode s 1 6 9
signaling
Time interval when pump motor works (with
13 Hydro time s 1 10 20
hydro speed) after the end of a command
Stop on slop Without stepping on pedal brake, time that is
26 s 1 5 10
timer doing stop in slope
Battery

Battery reset Minimum battery voltage necessary to reset
9 V*10 348 352 377
value battery discharged voltage alarm
Program Service

99 Maintenance time Maintenance period decision h 0 0 10,000
Maintenance time Disable = 0 (Default)
14 Maintenance time inserting enable digit
inserting enable Enable = 1
34
<48 V SYSTEM>
Drive Motor

Deceleration
steering ramp 1
wheel quickly
Deceleration
steering ramp 2
at high speed.
30 digit
31 digit
reverse direction the direction switch is moved to reverse. ON = 1
35 temperature of cooling Fan stops when the motors cools ℃ 0 60 155
41 % 20 100 100
Forward
maximum speed
Reverse
maximum speed
44 rpm 500 2,000 3,500
46 rpm 0 1,000 4,500 option
47 rpm 400 800 2,000
Acceleration Lift truck acceleration with accelerator pedal
48 rpm/s 500 900 2,000
ramp pressed
released
pressed
Diameter of drive
tires
54 rpm 0 1,000 4,500 option
Partial release
59 ramp if the traction motors are working with rpm/s 10 40 500
ramp
low rpm
Enable = 1
as usual.
Normal = 0(Default)
British unit = 1
international ones.
96 Display brightness Display's brightness adjustment digit 0 5 8
35
Disable = 0
Enable = 1(Default)
the display
Time meter / If parameter is set to 1, odometer indication Timer meter =
98 Odometer on appears on display ; otherwise display digit 0(Default)
display shows the hour meter. Odometer = 1

18 mV 500 10,300 11.500
19 mV 500 1,200 11.500
clockwise on left
23 mV 200 1,000 4,500
24 mV 2,000 3,600 4,500
32 Maximum lift mV 3,000 11,500 12,000
pressed
Lift lever potentiometer voltage to which the lifting
34 Middle lift mV 1,000 2,750 12,000
becomes proportional to the shift of the lever
Pump Motor

that is, the reference speed of pump motor, in case
Lift priority for OFF = 0 (Default)
27 of many simultaneous commands (LIFT + TILT, digit
speed reference ON = 1
LIFT + AUX1, TILT + AUX1.......), will be the highest
of every single command; if it's ON the reference sp
Weight of the
Limitation
39 Start temperature of performance reduction ℃ 100 155
temperature
61 % 20 80 100
62 % 10 65 100
Lift maximum
speed
Auxiliary 1
function speed
66 rpm 500 900 2,800
67 rpm 500 900 2,800
Lift minimum
speed
69 rpm 0 1,500 3,000 option
36
command active
Pump
acceleration ramp
73 rpm 1,000 7,000 10,000
74 rpm 0 1,500 3,000 option
High lift 1 switch
tilt max speed
76 rpm 0 500 2,000 option
High lift 1 switch
"ON"
speed
High lift 2 switch
switch 2 was "ON"
speed
High lift 1 switch
79 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
80 rpm 0 500 2,800 option
speed
High lift 1 switch
83 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
84 rpm 0 500 2,800 option
speed
37
Timers

signaling
26 s 1 5 10
Battery

9 V*10 464 470 501
Program Service

38
<80 V SYSTEM>
Drive Motor

Deceleration
steering ramp 1
wheel quickly
Deceleration
steering ramp 2
at high speed.
30 digit
31 digit
41 % 20 100 100
Forward
maximum speed
Reverse
maximum speed
44 rpm 500 2,000 3,500
46 rpm 0 1,000 4,500 option
47 rpm 400 800 2,000
48 rpm/s 500 900 2,000
ramp pressed
released
pressed
Diameter of drive
tires
54 rpm 0 1,000 4,500 option
Partial release
ramp
low rpm
Enable = 1
as usual.
Normal = 0(Default)
British unit = 1
international ones.
Disable = 0
Enable = 1(Default)
the display
39

18 mV 500 10,300 11.500
19 mV 500 1,200 11.500
clockwise on left
23 mV 200 1,000 4,500
24 mV 2,000 3,600 4,500
32 Maximum lift mV 3,000 11,500 12,000
pressed
34 Middle lift mV 1,000 2,750 12,000
Pump Motor

Weight of the
Limitation
temperature
61 % 20 85 100
62 % 10 65 100
Lift maximum
speed
Auxiliary 1
function speed
66 rpm 500 900 2,800
67 rpm 500 900 2,800
Lift minimum
speed
69 rpm 0 1,500 3,000 option
command active
Pump
acceleration ramp
40
73 rpm 1,000 7,000 10,000
74 rpm 0 1,500 3,000 option
High lift 1 switch
tilt max speed
76 rpm 0 500 2,000 option
High lift 1 switch
"ON"
speed
High lift 2 switch
switch 2 was "ON"
speed
High lift 1 switch
79 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
80 rpm 0 500 2,800 option
speed
High lift 1 switch
83 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
84 rpm 0 500 2,800 option
speed
41
Timers

signaling
26 s 1 5 10
Battery

9 V*10 752 773 829
Program Service

42
B20/25/30/32S-5
Drive Motor

Deceleration
steering ramp 1
wheel quickly
Deceleration
steering ramp 2
at high speed.
30 digit
31 digit
41 % 20 100 100
Forward
maximum speed
Reverse
maximum speed
44 rpm 500 2,000 3,500
46 rpm 0 1,000 4,500 option
47 rpm 400 800 2,000
48 rpm/s 500 900 2,000
ramp pressed
released
pressed
Diameter of drive
tires
54 rpm 0 1,000 4,500 option
Partial release
ramp
low rpm
Enable = 1
as usual.
Normal = 0(Default)
British unit = 1
international ones.
43
Disable = 0
Enable = 1(Default)
the display

18 mV 500 10,300 11.500
19 mV 500 1,200 11.500
clockwise on left
23 mV 200 1,000 4,500
24 mV 2,000 3,600 4,500
32 Maximum lift mV 3,000 11,500 12,000
pressed
34 Middle lift mV 1,000 2,750 12,000
Pump Motor

Weight of the
Limitation
temperature
61 % 20 76 100
62 % 10 65 100
Lift maximum
speed
Auxiliary 1
function speed
66 rpm 500 900 2,800
67 rpm 500 900 2,800
Lift minimum
speed
69 rpm 0 1,500 3,000 option
44
command active
Pump
acceleration ramp
73 rpm 1,000 7,000 10,000
74 rpm 0 1,500 3,000 option
High lift 1 switch
tilt max speed
76 rpm 0 500 2,000 option
High lift 1 switch
"ON"
speed
High lift 2 switch
switch 2 was "ON"
speed
High lift 1 switch
79 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
80 rpm 0 500 2,800 option
speed
High lift 1 switch
83 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
84 rpm 0 500 2,800 option
speed
45
Timers

signaling
26 s 1 5 10
Battery

9 V*10 464 470 501
Program Service

46
E-S-H Energetic Modes Parameters
Some parameters value depend on selected energetic mode: in following tables are listed parameter default
values for each operating mode (Economic, Standard and High)
In case of 36 V system:
PARAMETER ECONOMIC MODE STANDARD MODE HIGH MODE

Maximum drive current 62 76 100
Maximum forward speed [rpm] 3000 4000 4500
Maximum reverse speed [rpm] 3000 4000 4500
Drive acceleration ramp [rpm/s] 700 800 900
Drive inversion ramp [rpm/s] 700 800 900
Drive release ramp [rpm/s] 600 700 800
Lift maximum current 74 75 80
Maximum lift speed [rpm]v 1350 1800 2000


47
Some Functions Management
Static Return to Off Buzzer Management
To ensure operator safety, when switching on the lift The buzzer is activated in the following cases:
truck, a number of inputs are analyzed; if one of 1. Alarm condition
these signals indicates a wrong start condition or 2. Switching your device on you find wrong start
any likely danger situation, main breaker is not conditions:
closed and all system modes are disabled. a. Accelerator pedal pressed or directional
(forward or reverse) switch inserted.
If the anomalous input assumes the correct value, b. One of pump motor command levers not
main breaker is closed and it’s now possible go on released.
with usual truck management. 3. Parking lever is pot pulling and no one is in the
seat.
The analyzed inputs are the followings: 4. The trucks moves in reverse/forward direction
1. Seat switch (the closing is checked) (Select the truck-Setup Menu or Calibration No.
2. Directional switch (the insertion of a selected 30,31)
direction is checked)
3. Accelerator (the system controls if the pedal is
pressed) B.D.I. Measure Management
To measure battery voltage one of the following

Pump Motor Modes conditions must be true :
1. Chat mode
Control of a command lever moving when 2. Lift with drive and pump motors still
starting 3. Drive motors still and pump motor working to its
minimum speed (idle speed)
When switching on the key, in case an hydraulic
command is active, the lift, lateral shift, tilt and If this conditions are fulfilled for at least 2 seconds,
auxiliary functions are disabled. battery voltage begins to be evaluated, using a low–
pass filtering. After 15 seconds of voltage
Only when the activated lever and/or the requested processing, the filter output signal is uses to
command assumes the released position, operator evaluate the battery charge level.
can return to the usual operative condition.
If the battery is discharged for at least two
Pump motor commands management Switching on consecutive sampling periods, low battery voltage
the key, the motor works at minimum speed (idle alarm is signaled and following limitations are
speed, adjustable by PC). activated:
1. Limitation of drive motor speed and maximum
If the operator moves a command lever or the torque
steering wheel, the speed takes on a value that can 2. Limitation of maximum pump motor speed
be adjusted, depending on the type of the active 3. Lift, tilt and auxiliary functions are disabled
command and on the possible presence of
limitations (caused by thermal or low battery alarms). If the alarm is observed switching on the key, the
first received pump command is keep active for 3
After the active command is switched off, motor seconds and then is disabled. Battery voltage must
speed assumes idle speed value for an adjustable exceed an adjustable limit value (Battery reset value,
time (idle time), relating to the start of hydro guide; if see Chapter4) to return to normal operative
no command is activated during this period of time, the condition after a low battery voltage alarm.
speed returns to no operation value (0 rpm)
48
Diagnostic and Troubleshooting
General Description Alarm List
Diagnostic information about anomalous working Maximum battery voltage
condition is provided by COMPACT display or by
PC (using EYE software utility). 1. Eye alarm code: 1
This chapter explains how to manage any detected 2. Display alarm code: F0
fault and how to return to a normal working 3. Alarm level: 1
situation; suggestions to be applied in case of each 4. Alarm cause: battery voltage, measured by a
possible alarm are listed in a growing order, i.e. circuit inside logic, exceeds following levels:
from the least to the most serious one. a. 63 V, in case of systems working at 36 V
b. 63 V, in case of systems working at 48 V
If an alarm condition is detected by main board, c. 106 V, in case of systems working at 80 V
software control inhibits some lift truck functions, to
guarantee operator safety. If the controller detects such a fault, refer to
Anomalous working conditions are indicated by following troubleshooting procedure:
different alarm levels, classified as follows, 1. Such an alarm can be caused also by the
depending on their effects on the system: presence of regeneration currents; when lift
1. Main breaker is opened and both pump and truck is on release or reverse braking ramp,
drive motors are stopped; buzzer and red led on motors work as generators, and battery voltage
the upper right corner of COMPACT display, can exceed overvoltage limit. In a case like that,
signal the presence of such an alarm. the battery condition should be verified ( if the
2. Pump and drive motors are stopped. battery is new it is necessary to do some
3. Drive motors speed is limited to 2000 rpm. charge-discharge cycles before reaching the
Moreover, in presence of such an alarm, first rating declared by the constructor) or has a high
command given to pump motor is inhibited 3 internal resistance. If the case is the second
seconds after activation, together with all pump and it is not possible to change the battery, the
motor functions (except hydro functions). solution may be to reduce the release and
4. Drive and pump motors speed is limited to 800 reverse braking ramp.
rpm; buzzer signals the presence of such an 2. Incorrect wiring to battery positive or negative
alarm. terminals.
5. Drive motors speed is limited to 800; over 3. Verify if battery is still in good conditions.
temperature alarms are signaled by. buzzer 4. Replace the logic.
activation.
6. Pump motor speed is limited to 800; buzzer Minimum battery voltage
signals the presence of such an alarm.
7. No effects on system performance. 1. Eye alarm code: 2
※ 2000 rpm = about 9 km/n [6 mph] 2. Display alarm code: F1
800 rpm = about 4 km/n [2 mph] 3. Alarm level: 1
4. Alarm cause: battery voltage, measured by an
internal circuit, is lower than following levels :
NOTICE a. 24 V , in case of systems working at 36 V
If more than one faulty condition is detected, b. 24 V , in case of systems working at 48 V
Compact displays shows alarm code referring to c. 46 V , in case of systems working at 80 V
the most serious one (the one characterized by
lower alarm level).
Following section gives useful suggestions covering

a wide range of possible faults, listing
corresponding alarm cause identified by its alarm
code.
49
In case of minimum battery voltage alarm, follow Eeprom alarm
these steps:
1. Incorrect wiring to battery, or corroded positive 1. Eye alarm code: 5
or negative terminals; 2. Display alarm code: F
2. Verify battery conditions: if the electrolyte inside 3. Alarm level: 1
is partially exhausted, an under voltage alarm 4. Alarm cause: eeprom does not work properly, or
can sometimes be detected from the controller; one of memorized values is out of correct limits.
even in case of low battery charge (<10%), high
current rates (i.e. both pump and drive motors In case of alarm follow this procedure:
working in full load conditions) could cause an 1. Load default values for eeprom variables, both
under voltage alarm, in particular in presence of using PC with serial communication software
an exhausted battery. and Instrument panel;
3. Replace the logic. 2. Replace the logic.
Pedal trimmer fault Pre-charge capacitors low voltage

alarm (Capacitors not charged)
1. Eye alarm code: 3
2. Display alarm code: F2 1. Eye alarm code: 6
3. Alarm level: 2 2. Display alarm code: A
4. Alarm cause: voltage measured on accelerator 3. Alarm level: 1
circuit exceeds the value calculated averaging 4. Alarm cause: voltage level of pre-charge
calibration and reachable voltages; moreover, capacitors is less then 70 % of nominal battery
start switch seems to be open. level. It could happen, in example, if the power
module is working with main breaker open.
In case of such an alarm, follow these Capacitors voltage decreases cause energy
troubleshooting steps : spent to keep motors in motion.
1. Verify if the accelerator initial set-up is correct; if
not, repeat calibration procedure. (You can use In case of alarm follow this procedure:
both PC with serial communication software and 1. Verify if main breaker coil and power terminals
Instrument panel). are in good conditions;
2. Verify if the following the 42pin main connector 2. Verify if supply lines power fuse is damaged;
terminals are correctly wired to their 3. Verify if main breaker coils are correctly wired to
correspondent inputs in accelerator circuit: their correspondent inputs :
a. K1-16 (5 V) a. K1-29 (positive terminal)
b. K1-30 (ground) b. K1-15 (negative terminal)
c. K1-18 (pedal output-A) 4. Replace main breaker;
d. K1-9 (pedal output-B) 5. Replace logic.
3. In case of correct wiring, replace the accelerator
itself.
4. Replace logic
50
Inverter desaturation or overcurrent Pump motor power module
alarm overtemperature
1. Eye alarm code: 1. Eye alarm code: 10

8 (for drive motor power module) 2. Display alarm code E3:
25 (for pump motor power module) 3. Alarm level: 6
2. Display alarm code: 4. Alarm cause: the power module temperature
F3 (for drive motor power module) (measured with a temperature connector),
F5 (for pump motor power module) exceeds 100 °C, or is inside [95 °C, 100 °C]
3. Alarm level: 1 range at least 30 s.
4. Alarm cause: actual current exceeds limits ;
1400A(36/48V), 783A(80V) In case of alarm follow this procedure:
1. Alarm could be caused by ineffective
In case of alarm follow this procedure: temperature dissipation. Verify thermal coupling
1. With such an alarm present when you turn on between power module block and aluminum
lift truck, disconnect the power cable between plate, and between aluminum plate and truck
the malfunctioning power module and the ballast. The presence of a correct amount of
corresponding motor (first, turn off the system, thermal grease in the coupling is essential to
of course). ensure an efficient heat exchange;
2. Replace cable connecting the output pump of
If turning lift truck on again, alarm is not active, the logic to the pump power module;
then: 3. If temperature readings seem too high in
1. Replace the cable connecting logic and power function of total time interval of lift truck using,
module. replace pump power module causing the alarm.
2. Replace the power module; You can read temperature measures using
3. Replace logic. “Instrument Panel” display or “EYE”
communication software.
If turning lift truck on again, alarm is active, 4. Replace logic.
then :
1. Replace the power module;
2. Replace the motor.
Power module capacitors pre-charge

too fast

2. Display alarm code: A
3. Alarm level: 1
4. Alarm cause: pre-charge capacitors voltage
increases too fast when you turn the system on.
In case of too fast pre-charge alarm, follow this

procedure:
1. Inspect whether the main connector is not loose.
2. Inspect whether the drive connector is not loose.
3. Replace the main breaker.
4. Replace the drive power module.
5. Replace the logic.
51
Capacitors too charged on start Drive motor overtemperature
1. Eye alarm code: 11 1. Eye alarm code: 13

2. Display alarm code: A 2. Display alarm code: E4
3. Alarm level: 1 3. Alarm level: 5
4. Alarm cause: when you turn on the system, 4. Alarm cause: The measure of drive motor
capacitors are not completely discharged by temperature exceeds 155 °C.
pump motor. In fact, if you turn suddenly on the
lift truck, after a turning off, capacitors voltage In case of alarm, follow this procedure:
level is too high. You have to discharge them Presence of alarm with cold motors:
before checking the presence of any fault (both 1. With a handheld multimeter (in resistance
of capacitors and of logic) operating mode) you have to measure a
resistance of about 10 kohm between the two
In case of alarm follow this procedure: wires of the temperature sensor (execute the
1. Verify the correctness of wiring from pump measure at ambient temperature of 25°C). If the
motor and relative power module; measure is not correct it is necessary to replace
2. Replace wire connecting "pump" with the the temperature sensor.
corresponding power module or if not possible 2. Disconnect the temperature sensor and check
because the pump motor power module box the wiring insulation between signal wire and
integrates the outlet wire, substitute the power ground wire (towards logic);
module box 3. Replace logic.
3. Verify if main breaker has stuck closed
terminals: in such a case replace it Presence of alarm with hot motors:
4. Replace the wire connecting "drive" in logic to 1. If temperature value (you can read it from
right drive motor power module: a defective wire Instrument or via PC) seems correct, verify if
could give a wrong measure for capacitors fans (if present) work properly; fault is caused
voltage by on inefficient motor refreshing, or by
5. Replace the logic. operating out of nominal maximum ranges.
Low battery alarm

2. Display alarm code: EL
3. Alarm level: 3
4. Alarm cause: battery voltage level is lower than
minimum charge value expected, referred to
table 3 in Instrument panel technical
documentation.
In case of low battery alarm, follow this

procedure:
1. Measure battery voltage with a tester and, if
different from the value reported on Instrument,
replace logic;
2. Otherwise recharge battery.
52
Pump motor overtemperature Main breaker fault

2. Display alarm code: E6 2. Display alarm code: 17
4. Alarm cause: The measure of pump motor 4. Alarm cause: overcurrent on main breaker coil.
temperature exceeds 155 °C.
In case of alarm follow this procedure:
In case of alarm follow this procedure: 1. Replace main breaker
Presence of alarm with cold motors: 2. Replace logic.
1. With a handheld multimeter in resistance
operating mode, you have to measure about Watchdog timer alarm
10kohm at ambient temperature of 25°C
between the two wires of the temperature 1. Eye alarm code: 18
connector. If the measure is not correct it is 2. Display alarm code: F
necessary to replace the temperature connector. 3. Alarm level: 1
2. Disconnect the temperature sensor and check 4. Alarm cause: improper communication between
the wiring insulation between signal wire and DSPs present on logic, or/and defective logic.
ground wire (towards logic);
3. Replace logic. In case of alarm follow this procedure:
1. Using EYE program interface, try to program
Presence of alarm with hot motors: control board flash memory;
1. If temperature value (you can read it from 2. Replace logic.
Instrument panel or via PC) seems correct,
verify if fans (if present) work properly; fault is
caused by an inefficient motor refreshing, or by
operating out of nominal maximum ranges.
Motor current offset alarm
1. Eye alarm code: 15 for drive motor

36 for pump motor
2. Display alarm code: F6 for drive motor
F8 for pump motor
3. Alarm level: 1
4. Alarm cause: non-zero phase currents when
you turn lift truck on.
In case of motor current offset alarm, follow this

procedure:
1. Replace the wire connecting inverter to logic.
2. Replace inverter.
3. Replace logic.
53
Drive motor power module Alarm on 5 V encoder voltage
overtemperature
1. Eye alarm code: 20 for right drive motor 2. Display alarm code: FH
2. Display alarm code: E1 for right drive motor 3. Alarm level: 1
3. Alarm level: 5 4. Alarm cause: K1-16 terminal (5 V output)
4. Alarm cause: power module temperature, voltage is lower than 4.3 V.
measured with a probe, exceed 100 °C.
In case of alarm follow this procedure: 1. Verify if 5 V output is grounded, cause an
1. Alarm could be caused by ineffective incorrect encoder wiring.
temperature dissipation; verify thermal coupling 2. Verify if 5 V output is grounded, cause any
between power module block and aluminum encoder malfunction. In that case, replace the
plate and between aluminum plate and truck defective one.
ballast. The presence of the correct amount of 3. Replace logic.
thermal grease in the coupling are essential to
ensure a correct heat exchange; Alarm on 12 V output voltage
2. Check cable connecting the communication
output connector of the logic to the 1. Eye alarm code: 38
corresponding power module; 2. Display alarm code: FA
3. If temperature readings seem too high in 3. Alarm level: 1
function of total time interval of lift truck using, 4. Alarm cause: K1-17 terminal (12 V output)
replace power module unit causing the alarm. voltage is lower than 10.5 V.
You can read temperature measures using
“Instrument Panel” display or “EYE” In case of an alarm on 12 V output voltage,
communication software. follow this procedure:
4. Replace logic. 1. Verify if 12 V output is grounded, cause an
incorrect wiring to:
Serial communication alarm a. Steering sensor
b. Buzzer
1. Eye alarm code: 21 c. Display
2. Display alarm code: F 2. Replace defective device;
3. Alarm level: 1 3. Replace logic.
4. Alarm cause: error in serial communication
between the two DSP; DSP present on main
board make a mutual software control, to insure
fast diagnosis of such a fault.

1. Switch on the system and the turn it on again.
2. Program pump and drive DSP again; maybe
software present in flash memory was corrupted.
(REFLASH)
3. Try to the default setting (LOAD EEPRON
DEFAULT-TOTAL LOAD EEPROM)
54
Pump motor commands active on Seat switch open on start
start
1. Eye alarm code: 50 2. Display alarm code: EE (flash)
2. Display alarm code: FL 3. Alarm level: warning; main breaker is opened
3. Alarm level: warning; while the fault condition is and pump and drive motors are stopped.
active, all pump motor functions (except hydro 4. Alarm cause: when you start working, you find
functions) are inhibited. seat switch open, or, after the main breaker is
4. Alarm cause: you find a pump motor command closed, the seat switch remains opened for at
active when you turn your system on. least “ seat switch delay” s.
In case of alarm follow this procedure: In case of alarm follow this procedure:
1. Before starting to operate, turn off any active 1. Verify if seat switch is defective;
command (both levers and switches); 2. Replace the logic.
2. Be sure that lift, tilt and auxiliary command
switches, are not active; Wrong start
3. Replace the valve board.
Battery miss matching 2. Eye alarm code: EE
3. Alarm level: warning; main breaker is opened
1. Eye alarm code: 60 and pump and drive motors are stopped.
2. Display alarm code: 60 4. Alarm cause: when you start working, you find
3. Alarm level: 7 accelerator pedal pressed or a forward/ reverse
4. Alarm cause: battery is not suitable voltage to switch active.
controller
In case of alarm follow this procedure: 1. Verify if a switch was active or the pedal
1. Check battery voltage at the each system. (36V- pressed, when you turn on the lift truck;
36V battery, 48V-48V battery, 80V- 80V battery) 2. Verify if start, forward or reverse switches are
stuck close;
Drive motor shunt down temperature 3. Verify if pedal circuit voltage exceeds 1/3 its
maximum range (measured in Volt);
1. Eye alarm code: 61 4. Replace logic.
2. Display alarm code: 61
3. Alarm level: 1
4. Alarm cause: The measure of drive motor
temperature exceeds 165 °C.

Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
operating mode) you have to measure a
wires of the temperature connector (execute the
measure at ambient temperature of 25°C) . If
the measure is not correct it is necessary to
replace the temperature connector;
2. Disconnect the temperature connector and
check the wiring insulation between signal wire
an ground wire ( towards logic);
Presence of alarm with hot motors:

1. If temperature value (you can read it from
55
Pump motor shunt down temperature Pump motor Encoder alarm

2. Display alarm code: 65 2. Display alarm code: 76
4. Alarm cause: The measure of pump motor 4. Alarm cause: an encoder channel is
temperature exceeds 165 °C. disconnected, and motor is working.
In case of alarm follow this procedure: In case of alarm, follow this procedure:
Presence of alarm with cold motors: 1. Verify if the encoder is correctly connected to:
1. With a handheld multimeter in resistance a. Motor itself
operating mode, you have to measure about b. Ground : K1- 30 terminal
10kohm at ambient temperature of 25°C c. + 5 V: K1- 16 terminal
between the two wires of the temperature d. A channel:
connector. If the measure is not correct it is K1- 35 terminal (for right drive motor
necessary to replace the temperature encoder)
connector; e. B channel:
2. Disconnect the temperature connector and K1- 36 terminal (for right drive motor
check the wiring insulation between signal wire encoder)
and ground wire ( towards logic); 2. If correctly wired, replace the encoder;
3. Replace the logic. 3. Replace logic.

Alarm of motor thermal sensor
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
1. Eye alarm code:
inefficient motor refreshing, or by operating out
77 (for drive motor thermal sensor)
of nominal maximum ranges.
79 (for pump motor thermal sensor).
2. Display alarm code:
Drive motor encoder alarm 77 (for drive motor thermal sensor)
79 (for pump motor thermal sensor).
1. Eye alarm code: 74 3. Alarm level: 7
2. Display alarm code: Fc 4. Alarm cause: Temperature difference between
3. Alarm level: 1 both motors results greater than 70 °C
4. Alarm cause: an encoder channel is
disconnected, and motor is working. In case of alarm, follow this procedure:
1. Verify if the wiring is correct;
In case of alarm follow this procedure: 2. Replace the sensor;
1. Verify if the encoder is correctly connected to: 3. Replace logic.
a. Motor itself
b. Ground : K1- 30 terminal
c. + 5 V: K1- 16 terminal
d. A channel:
K1- 32 terminal (for right drive motor
encoder)
B channel:
e. K1- 33 terminal (for right drive motor
encoder)
2. If correctly wired, replace the encoder;
3. Replace logic.
56
Alarm of a inverter temperature Steering sensor alarm
thermal sensor
1. Eye alarm code: 2. Display alarm code: F9
80 (for drive motor power module thermal 3. Alarm level: 5
sensor) 4. Alarm cause: steer circuit voltage is out of
82 (for pump motor power module thermal nominal range.
sensor)
2. Display alarm code: In case of a steering sensor alarm follow this
80 (for drive motor power module thermal procedure:
sensor) 1. Verify correctness of wiring with :
82 (for pump motor power module thermal a. K1-17 (12 V),
sensor) b. K1-30 (ground)
3. Alarm level: 7 c. K1-31 (steering sensor input);
4. Alarm cause: Temperature difference between 2. If correctly wired, replace steering sensor;
both inverters is greater than 70°C. 3. Replace logic.

1. Check the wiring connecting logic and inverter; Capacitors pre-charge too slow
2. Replace the inverter;
3. If alarm is still present, replace logic. 1. Eye alarm code: 98
2. Display alarm code: A
CRC(Cyclic Redundancy Check) fault 3. Alarm level: 1
alarm 4. Alarm cause: pre-charge capacitor voltage
grows too slowly, when you turn on the system.
2. Display alarm code: 83 In case of alarm follow this procedure:
3. Alarm level: 1 1. Check assembly of the 42pin main connector.
4. Alarm cause: Faulty eeprom or mismatching 2. Check cable connecting the Drive/Pump output
software release. of the logic with the corresponding inverter.
3. Replace the logic;
1. Restore eeprom with EYE application software, Capacitors pre-charge timeout
using the “RESTORE” item present in main
page 1. Eye alarm code: 99
2. Try to the default setting (LOAD EEPROM 2. Display alarm code: A
DEFAULT-TOTAL LOAD EEPROM) 3. Alarm level: 1
3. if alarm is still present, replace the logic.CRC : 4. Alarm cause: pre-charge capacitor voltage
Cyclic Redundancy Checking error. grows too slowly, when you turn on the system.
Bank CRC(Cyclic Redundancy Check) In case of alarm follow this procedure:

restored 1. Check assembly of the 42pin main connector.
2. Check cable connecting the Drive/Pump output
1. Eye alarm code: 84 of the logic with the corresponding inverter.
2. Display alarm code: 84 3. Replace the logic;
3. Alarm level: 1
4. Alarm cause: there was an eeprom restore,
caused by a CRC(Cyclic Redundancy Check)
alarm.

1. Switch on the system and the turn it on again
2. Try to the default setting (LOAD EEPROM
DEFAULT-TOTAL LOAD EEPROM)
57
Classified troubleshooting according to error cords
1. Inverter overtemperature
; E1(D/Inverter-R), E2(D/Inverter-L), E3 (P/Inverter)
"E1, E2, E3" Alarm/ Drive/Pump Inverter Overtemperature

EYE code "20, 22, 10" (Traction/Pump Speed down)
● Cause
☞ Inverter overtemperature ; Exceed 100☞
● Troubleshooting
☞ Check the inverter temperature

in the Diagnostic mode/ Eyeplus program
→ E1 : Diagnostic No 7
E2 : Diagnostic No 8
E3 : Diagnostic No 14 750A, 48V
☞ Replace inverter module if temperature seems

too high as compared with the total time of truck
using
☞ If the temperature value is normal,

replace Logic board.
→ After replacing logic, you have to do the
sensor initial setting (steer, accelerator, lift
sensor)
450A, 48V
58
2. Motor overtemperature
; E4(D/Motor-R), E5(D/Motor-L), E6 (Pump Motor)
"E4, E5, E6" Alarm / Drive/Pump motor Overtemperature

EYE code "13, 19, 14" (Traction/Pump Speed down)
● Cause
☞ Motor overtemperature ; Exceed 155℃
● Troubleshooting
☞ Check the motor temperature

in the Diagnostic mode/ Eyeplus program
☞ If the resistance value of sensor is not correct,

replace the motor temperature sensor.
(Normal status : about 10 ㏀ at ambient 25℃)
☞ Check the wire connection between temperature

sensor and Logic Board.
☞ If sensor & wire connection are OK,

sensor initial setting
(steer, accelerator and lift sensor)
59
3. Drive Wrong Start : SRO
"EE" Alarm / EYE code "64" Operation of SRO function

(Line contactor ; OFF, No lift truck operation)
● Cause
☞ Accel pedal is pressed or F/R switch is activated

before Key ON.
● Troubleshooting
☞ Before Key ON, the followings are required.

- F/R Lever in neutral
- Accel. Pedal in neutral
☞ Check the operation of F/R switch and accel

pedal in the Diagnostic mode/ Eyeplus program
- Forward : Diagnostic No 34 → 0 or E
- Reverse : Diagnostic No 33 → 0 or E
- Accel signal A : Diagnostic No 11 → about '400'
- Accel signal B : Diagnostic No 12 → about '4,200'
☞ Check the wire connection
☞ If F/R Lever, Accel pedal & wire connection are

OK, replace Logic board.
60
4. Seat switch Alarm
"EE" flashing / EYE code "63" Seat switch open

● Cause
☞ Seat switch open after the truck starts normally

or seat switch defective
● Troubleshooting
☞ Check the operation of seat switch in the

Diagnostic mode/ Eyeplus program
- Diagnostic No 30 → 0 or E
☞ If the seat switch is OK, check the wire

connection
☞ If the seat switch & wire connection are OK,

61
5. Low Battery Alarm
"EL" alarm / EYE code “12" Battery overdischarging

(Traction/Pump Speed down)
● Cause
☞ Battery voltage level is lower than minimum

charge value expected.
● Troubleshooting
☞ Measure total battery voltage with a tester and if

the total value is lower than 45V, recharge
battery.
In addition, measure the total battery voltage
and each cell’s voltage and if the total value is
lower than 45V or cells are abnormal, recharge
battery.
☞ If the value is over 45 Volt, replace Logic board.

sensor initial setting (steer, accelerator and
lift sensor)
62
6. Maximum battery voltage
“F0" alarm/ EYE code “1" Maximum battery voltage

● Cause
☞ Battery voltage level exceeds 63V, in case of

48V system.
● Troubleshooting

its total value is over 63 V, check battery in detail.
☞ If the value is lower than 63 Volt, replace Logic

board.
lift sensor)
63
7. Minimum battery voltage
“F1" alarm / EYE code“2" Minimum battery voltage

● Cause
☞ When Battery voltage level is about 24 ~ 30 Volt,

in case of 48V system.
● Troubleshooting

its total value is about 24 ~ 30 Volt, check
battery in detail.
☞ If the value is over 24~30 Volt, replace Logic

board.
lift sensor)
64
8. Pedal trimmer fault
“F2" alarm / EYE code “3" Accelerator defect

(No lift truck operation)
● Cause
☞ the output voltage of accelerator is incorrect.
● Troubleshooting
☞ Check accelerator output “A”, “B” signal and

“start” signal in the Diagnostic mode/ Eyeplus
program
RELEASE FULL PRESS
SIGNAL ‘A’ 0.4±0.1 V 3.6±0.15 V
SIGNAL ‘B’ 4.5±0.1 V 1.39±0.15 V
☞ If the accelerator signals are OK, check the wire

connection
☞ If the wire connections are OK,

replace accelerator.
→ After replacing accelerator, you have to do
the pedal initial setting
☞ Replace Logic board.

lift sensor)
65
9. Module Over Current;
F3(D/Module-R), F4(D/Module-L), F5(P/Module)
“F2" alarm / EYE code “3" Drive( or Pump) Module Over Current
● Cause
☞ Actual current exceeds the limit currents
● Troubleshooting
☞ After disconnecting the power cables (U,V &W)

from motor and inverter, check the resistance
between each terminal and motor body with the
tester. If its value is 0 Ω, replace the motor.
☞ If the resistance of inverter U, V & W is not

proper, replace the module (refer to the below
list)
SPECIFICATIONS
(+) Test (-) Test

Mode Result
Lead Lead
Each About 1.9
resistance +BATT
U,V,W Mohms
Each About 1.9
resistance -BATT
U,V,W Mohms
About 3.0- 5.0
resistance U V
Mohms
About 3.0- 5.0
resistance U W
Mohms
About 3.0- 5.0
resistance V W
Mohms
☞ If the motor & module are normal, replace Logic

board.
lift sensor)
66
10. Unusual Motor Current ;
F6, F7, F8
“F6, F7, F8" alarm / “F6, F7, F8" alarm /

EYE code “15, 16, 36" EYE code “15, 16, 36"
● Cause
☞ Non-zero phase currents when the key switch is

ON
● Troubleshooting
☞ Disconnect the power cables (U,V &W) from

motor and then the key switch is on. If there are
not any fault codes on the instrument, replace
the motor.
☞ Check the motor current on the Eyeplus program,

if its value is normal, replace the module.
☞ If the motor & module are normal, replace Logic

board.
lift sensor)
67
11. Steering angel sensor fault or
Setting problem
“F9" alarmb/ EYE code “91" Steering angel sensor fault

(Traction Speed down)
● Cause
☞ Steering angel sensor fault or Setting problem
● Troubleshooting
☞ Reset the Steering angel sensor on the Eyeplus

program,
- ANTICLOCK/CLOCK/MIDDLE
☞ If the output signal of sensor is not OK, check

the wire connection.
☞ If the wire connection is OK, replace the steering B20T(X)-5

angle sensor.
→ After replacing steering sensor, you have to
do the pedal initial setting.
☞ If the wire connection & steering sensor are

normal, replace Logic board.
lift sensor)
B(C)25S-5
68
* Output of Steering angle sensor
1. A244980 : B20T(X)-5
resistance 0~5 ㏀
Electric operation angle 300˚± 3˚
Mechanical angle 360˚
angle 0 ~ 30˚ 30˚~ 330˚ 330˚~ 360˚
output output(%) 0 0 ~ 100 100
resistance 0 ㏀ 0~5 ㏀ 5 ㏀
2. A484016 : B(C)25S-5
Step 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output (V) 1.53 1.95 2.37 2.78 3.18 3.60 4.02 4.44 4.86 5.28 5.71 6.13 6.55 6.97 7.40 7.82 8.24 8.66 9.08
69
12. Motor Speed sensor (Encoder) ;
Fc(D/Motor Encoder-R),
Fd(D/Motor Encoder-L),
76(Pump Motor Encoder)
“Fc, Fd, 76" alarm Motor Speed sensor (Encoder)

/ EYE code “74,75,76"
● Cause
☞ Motor Speed sensor (Encoder)
● Troubleshooting
☞ Check A & B signal of Motor speed sensor on

the Eyeplus program,
☞ If the output A & B are OK, check the wire

connection.
☞ If the wire connection is OK, replace the speed

sensor.
☞ If the wire connection & speed sensor are

normal, replace Logic board.
lift sensor)
70
13. +12V output of Logic board
“FA" alarm/ EYE code “38" +12V output fault

● Cause
☞ +12V output is lower than +10.5 Voltage.
● Troubleshooting
☞ Check +12 Voltage in the Diagnostic mode/

Eyeplus program
→ Diagnostic No. 45
☞ Check wire connection & all parts connected to

+12V.
☞ If the wire connection & parts are normal,

lift sensor)
71
14. +5 V output of Logic board
“FH" alarm / EYE code “37" +5V output fault

● Cause
☞ +5V output is lower than +4.3 Voltage.
● Troubleshooting
☞ Check + 5 Voltage in the Diagnostic mode/

Eyeplus program
→ Diagnostic No. 44
☞ Check wire connection & all parts connected to

+5V.
☞ If the wire connection & parts are normal,


lift sensor)
72
15. Unusual signal of Lift/Tilt/Aux
Pump motor commands active on start
“FL" alarm / EYE code “50" (all pump motor functions are inhibited)
● Cause
☞ Pump motor commands active when you turn

truck on.
● Troubleshooting
☞ Lift Sensor & Magnet adjustment
1) Loosen Setscrew(1)
2) Adjust screw(2) to make clearance

1.0mm between lift sensor and magnet
when the lift lever is activated fully. Lift Sensor
3) Tighten Setscrew(1). Check lift sensor circuit.

The valve control card may need adjusting.
☞ Check lift sensor/Tilt & Aux switch and replace

switch if nessary.
Lift Spool
Magnet
☞ Set lift sensor initial setting in the Diagnostic

mode/ Eyeplus program
→ LIFT : Diagnostic No. 5
→ TILT : Diagnostic No. 41
→ AUX 1 : Diagnostic No. 37
→ AUX 2 : Diagnostic No. 38
☞ Check wire connection
☞ If the wire connection, replace Logic board.

sensor initial setting( steer, accelerator and
lift sensor)
73
16. “A" fault code (6)
“A" alarm/ EYE code“6" Pre-charge capacitor low voltage

● Cause
☞ Fault of Main Contactor, Main Fuse, Wire

connection or Logic board
● Troubleshooting
☞ Check Main Fuse with tester and replace it if
necessary.
☞ Check the coil resistance of Main Contactor.

- BT(X), B15S, Reach Type : 70 ~ 110Ω
- B(C)25S : 30 ~ 50Ω
☞ Check the wire connection.
☞ If the wire connection, replace Logic board.

lift sensor)
74
“A" alarm / EYE code“9" Inverter capacitors precharge too fast

● Cause
☞ Fault of Main Contactor, Inverter or Logic Board.
● Troubleshooting
☞ Check Main Contactor with tester and replace

it if necessary.
☞ Check the resistance of inverter terminals( U, V,

W, +, -) with tester, replace the inverter if its
value is 0Ω.
☞ If alarm is continuous on the instrument, replace

Logic board.
lift sensor)
75
“A" alarm/ EYE code “11" Capacitors too charged on start

(Line contactor; OFF, No lift truck operation)
● Cause
☞ Fault of Main Contactor, Inverter or Logic Board.
● Troubleshooting
☞ Check the resistance of main contactor terminals

with tester and if its value is 0Ω, replace the
main contactor.
☞ Check the resistance of Inverter terminals(U, V,

value is 0Ω.

Logic board.
lift sensor)
76
19. “A" fault code (98, 99)
“A" alarm/ EYE code “98,99" Capacitors pre-charge too slow

● Cause
☞ Fault of Inverter or Logic Board.
● Troubleshooting
☞ Check the resistance of Inverter terminals( U, V,

value is 0Ω

Logic board.
sensor initial setting( steer, accelerator and
lift sensor)
77
20. Main contactor fault
“17" alarm / EYE code“17" Main contactor fault

● Cause
☞ fault of Contactor’s electric contacts or coil or

Logic board
● Troubleshooting
☞ Check the electric contacts with tester and if its
value is 0Ω, replace it.
☞ Check the coil resistance of Main Contactor.

- BT(X), B15S, Reach Type : 70 ~ 110Ω
- B(C)25S : 30 ~ 50Ω
☞ Check the wire connection.

Logic board.
lift sensor)
78
Troubleshooting Problem List
Problem # TROUBLESHOOTING PROBLEM LIST EYE Abrm code
1 CVMS does not work, with no lift truck operation. -
2 CVMS does not work at all, lift truck operation normal. -
Display portion of CVMS seems random or wrong.
3 -
Lift truck operation normal.
4 Direction switch circuit defect. -
5 Lift sensor circuit defect. -
6 Tilt switch circuit defect. -
7 Auxiliary switch circuit defect. -
8 Park brake switch circuit defect. -
9 Pedal brake switch circuit defect. -
10 Display="E1", The max speed of drive motor is reduced. 20
11 Display="E3", The max speed of pump motor is reduced. 10
12 Display="E4", The max speed of drive motor is reduced. 13
13 Display="E6", The max speed of pump motor is reduced. 14
Display="EL", The max speed and max torque of drive &pump motor is reduced
14 12
to minimum value
15 Display="EE", No lift truck operation 64
16 Display="EE(Flashing)", No lift truck operation 63
17 Display="F", No lift truck operation 5, 18, 21
18 Display="F0", No lift truck operation 1
25 Display="F9",The max speed of pump motor is reduced. 91
26 Display="FH", No lift truck operation 21,37
27 Display="Fc", No lift truck operation 74
28 Display="FA", No lift truck operation 38
29 Display="FL", No lift truck operation 50
30 Display="A", No lift truck operation 6, 9, 11, 98, 99
31 Display="60", Lift truck operation 60
32 Display="61", No lift truck operation 61
41 Display does work normal, Lift truck operation abnormal. -
79
PROBLEM 1
Central Vehicle Monitoring System (CVMS) does not work,

with no lift truck operation.
POSSIBLE CAUSE
Battery polarity not correct on control panel;

Key fuse open circuit; Key switch defect; Logics
CHECKS
With battery connected, check control panel battery connections for correct polarity.
Positive battery connected to line fuse and negative battery connected to B - on controller.
If correct If not correct
Push horn button to close horn switch. Make correction to cables.
Horn work Horn does not work
Disconnnect battery and check the horn

fuse for continuity.
Continuity No continuity
Check for shorts and

replace fuse.
Close key switch. Measure voltage on K1-3 Measure voltage on horn (wire #90) with
depressing the horn switch.
Battery Less than Check continuity the negative wire of horn
Voltage Battery voltage
Battery Less than
Voltage Battery voltage
Replace logics.
Replace horn or Repair or replace

check the battery. open wire
Replace key switch or repair broken wire
#23 between key switch and K1-23.
80
PROBLEM 2
CVMS does not work at all, lift truck operation normal.

If only part of CVMS works.
POSSIBLE CAUSE
Open circuit from K1-17 to CVMS connector PIN 8;

Open circuit from K1-30 to CVMS connector PIN 7;
CVMS defect.
CHECKS
Make sure CVMS connector is connected to CVMS.
If connected If not connected
Connect multimeter positive lead to K1-17 Connect CVMS connector.

and negative lead to K1-30.
Measure the voltage.
12 volts 0 volts
Replace the CVMS module. Repair or replace open circuit between 5 wires
from controller to CVMS.
81
PROBLEM 3
Display portion of the CVMS seems random or wrong.

Lift truck operation normal.
POSSIBLE CAUSE
Connection defect; Wiring defect; Logics defect;

Display defect.
CHECKS
Check continuity from logics to CVMS connector
Check for shorts to battery negative from Repair or replace open wire.
PIN 1 to PIN 8 on CVMS connector.
No shorts found Shorted
Replace logics. Repair or replace shorted wire.
82
PROBLEM 4
Direction switch circuit defect.
POSSIBLE CAUSE
Direction switch defect; Wiring to direction

switch defect;
CHECKS
Disconnect the battery.

Disconnect K-1 connector.
Check continuity from K1-30 to K1-20 harness connector;
With direction lever in forward should have a closed circuit,
in neutral should be open.
Check OK Check failed
Check continuity from K1-30 to K1-21. Disconnect direction switch connector.

With direction lever in reverse should have a Check continuity between Pin2 and Pin3.
closed circuit, in neutral should be open.
Replace logics. Repair or replace direction switch.
Check wiring for open/short circuits Check wiring for open/short circuits
between harness connector K1-30 and K1-21. between harness connector K1-30 and K1-20.
Repair any open/short circuit found. Repair any open/short circuit found.
Replace direction switch.
83
PROBLEM 5
Lift sensor circuit defect.
POSSIBLE CAUSE
Lift sensor not adjusted properly or defective;

Lift sensor wiring defect; Valve control card (board)
defect; Logics defect.
CHECKS
Retest lift sensor circuit in self diagnostics.
Circuit passes Circuit fails

“Diagnostics” “Diagnostics”
Perform Problem 11,12 Tilt Key switch ON.

or Connect multimeter negative lead to Pin5
and the positive lead to Pin2 and Pin7.
Measure the voltage.
Battery Voltage 0 Volt
Measure voltage from Pin7 to Pin5 battery Repair or replace broken wire
negative as the lever is pulled and released. between Pin1 and Pin5(wire #30)
or between Pin5 and battery
9.0 to 11.0 and .2v 9.0 to 11.0 and .2V negative(-).
Measured NOT measured
Replace logics. Replace Valve Control Card.
Before lift truck is placed into operation, connect tilt and auxliary switches and verify proper adjustment. Refer to
Valve Control Card Adjustments.
84
PROBLEM 6
Tilt switch circuit defect.
POSSIBLE CAUSE
Tilt switch defect; Wiring defect; Logics defect.
CHECKS
Disconnect K1 connector. Pull tilt lever to maximum.

Check continuity from K1-13 to K1-30.
Replace logics. Check continuity of wire #54.
Check continuity from K1-13 of wire #13 to Repair or replace wire.

Pin5 of valve board connector.
Replace tilt switch. Repair or replace wire.
85
PROBLEM 7
Auxiliary switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Auxiliary switch defect; Logics defect.
CHECKS
Disconnect K1 connector. Pull auxiliary lever to maximum.

Check continuity from K1-30 to K1-12 or K1-24.
Replace logics. Check continuity of wire #12 or #24.
Check continuity from K1-30 of wire #30 to Repair or replace wire.

Pin1 of valve board connector.
Replace AUX switch. Repair or replace wire.
86
PROBLEM 8
Park brake switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Park brake switch defect; Logics defect.
CHECKS
Disconnect K1 connector. Release park brake lever.

Check continuity from K1-22 of wire Repair or replace wire.

#22 to terminal of park brake switch.
Replace park brake switch. Repair or replace wire.
87
PROBLEM 9
Pedal brake switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Pedal brake switch defect; Logics defect.
CHECKS
Disconnect K1 connector. Push down the brake pedal.

Check continuity from K1-30 of wire Repair or replace wire.

#30 to Pin2 of pedal brake switch.
Replace park brake switch. Repair or replace wire.
88
PROBLEM 10
Display=“E1”
The max speed of drive motor is reduced.
POSSIBLE CAUSE
Drive power module over temperature.

Control board failed
CHECKS
Let the truck cool for 15 minutes.
Continuity Normal
Check temperature of drive If repeat occur, check drive motor

power module seem too high. current draw or operating cycle for
excessive ramp climbing or towing.
You can read temperature
measures using ”COMPACT”
display or “EYE” software.
Yes No
Replace right power module Repair logic board
89
PROBLEM 11
Display=“E3”
The max speed of pump motor is reduced.
POSSIBLE CAUSE
Pump power module over temperature.

CHECKS
Continuity Normal
Check temperature of pump I If repeat occur, check pump

power module seem too high motor current draw or operating
cycle for excessive ramp climbing
You can read temperature or towing
measures using “COMPACT”
display or “EYE” software.
Yes No
Replace pump power module Repair logic board
90
PROBLEM 12
Display=“E4”
The max speed of drive motor is reduced
POSSIBLE CAUSE
Right drive motor over temperature ; Drive motor thermal

sensor defect; Control board failed
CHECKS
Continuity Normal
You have to measure a If repeat occur, check drive

resistance about 10kohm motor current draw or operating
between two wires of the cycle for excessive ramp climbing
thermal sensor of drive motor or towing
Yes No
Replace control board Replace thermal sensor
91
PROBLEM 13
Display=“E6”
POSSIBLE CAUSE
Right drive motor over temperature ;

Drive motor thermal sensor defect ;
CHECKS
Continuity Normal
You have to measure a If repeat occur, check pump motor

resistance about 10kohm current draw or operating cycle for
between two wires of the excessive ramp climbing or
thermal sensor of pump motor. towing
Yes No
Replace control board. Replace thermal sensor.
92
PROBLEM 14
Display=“EL”
The max speed and max torque of drive &
pump motor is reduced to minimum value.
POSSIBLE CAUSE
Battery discharged; Logic defect
CHECKS
Connect battery, turn on the key switch, close seat switch

And measure voltage from B+ to B- on controller.
Voltage must be greater than 34.5V at 36V system.
Voltage OK Voltage low
With key on, seat switch and main Check battery

contactor closed, measure voltage connection ;
at BATT+ on controller.
Charge or replace battery
Battery voltage
Replace logic
93
PROBLEM 15
Display=“EE”
No left truck operation
POSSIBLE CAUSE
Static Return to Off(SRO) circuit activated by

Improper operation sequence; Direction switch defect
Accelerator linkage not fully release.
Accelerator control defect; Logic defect.
CHECKS
Check SRO by release of accelerator, release park brake

Move the direction lever to neutral, reselect direction and
Press the accelerator.
No change Lift truck operation ok
Check accelerator, Inform operator of correct start-up

F/R switch. procedure. Also, that the direction lever
must be left in neutral when leaving the
truck.
If no faulty component is
found, replace logics.
94
PROBLEM 16
Display=“EE(Flashing)”
No left truck operation
POSSIBLE CAUSE
No operator in seat; Seat switch defect;

Open wire.
CHECKS
Disconnect K1 connector Check continuity from wire #10

to wire #30 .Should be closed circuit when seat is
pressed on and open circuit when seat release.
No continuity Check OK
Disconnect seat switch connector. Replace logics

Push on the seat and check the
continuity across the seat switch.
Replace seat switch
Check wiring for open circuits

Between harness #10 and #30.
Repair any open circuit found.
95
PROBLEM 17
Display=“F”
No lift truck operation
POSSIBLE CAUSE
Improper communication between DSP,

Logic board defect.
CHECKS
Try default setting and pedal/steering/lift resetting.
OK If not ok
Normal operating. Replace logic board
96
PROBLEM 18
Display=“F0”,
Lift truck operation.
POSSIBLE CAUSE
Battery voltage exceeds 63V at 36/48V.

Battery voltage exceeds 106V at 80V.
Failed logic
CHECKS
Disconnect battery, measure voltage at battery

connector terminal.
More than 63V/106V Not
Battery discharge Replace logic board
97
PROBLEM 19
Display=“F1”
POSSIBLE CAUSE
Battery voltage is lower than 24V at 36/48V.

Battery voltage is lower than 46V at 80V.
Failed logic
CHECKS
Disconnect battery, measure voltage at battery

connector terminal.
Lower than 24V/46V Not
Battery charge Replace logic board
98
PROBLEM 20
Display=“F2”
No lift truck operation.
POSSIBLE CAUSE
Accelerator sensor failure. Accelerator

connector disconnect. Failed logic.
CHECKS
Check Accelerator connector.
Connection Disconnection
Accelerator resetting; value must be lower Connect Accelerator

than Min 0.2V and higher than Max 3.0V connector.
(You can read temperature measures
using “COMPACT” display or “EYE”
software.)
Replace logic board
99
PROBLEM 21
Display=“F3”
POSSIBLE CAUSE
Drive power module overcurrent.

(Actual current exceeds limit 1400A at 36/48V
Actual current exceeds limit 783A at 80V)
Failed logic board or power module.
CHECKS
Key switch off and on again.
Display=F3 Drive operation normal
Measure the resistance between U,V,W terminals and

shell on the right motor
Open 0 ohm
Replace drive motor
Measure the resistance between U,V,W terminals on

the drive power module.
About 4.4 Mohm 0 ohm or open
Replace logic board Replace drive power module.
100
PROBLEM 22
Display=“F5”
POSSIBLE CAUSE
Pump power module overcurrent.

(Actual current exceeds limit 1400A at 36/48V
Actual current exceeds limit 783A at 80V)
Failed logic board or power module.
CHECKS
Key switch off and on again.
Display=F5 Drive operation normal

shell on the pump motor
Open 0 ohm
Replace pump motor

shell on the pump motor.
About 4.4 Mohm 0 ohm or open
Replace logic board Replace pump power module
101
PROBLEM 23
Display=“F6”
POSSIBLE CAUSE
Disconnect communication cable from drive power

module to drive motor; Drive power module defect.
Logic board defect.
CHECKS
Check the cable connecting from drive power

module to drive motor.
Connect communication cable
Check current of drive power module when you turn on the lift
truck. (You can read temperature measures
using ”COMPACT” display or “EYE” software.)
Zero current Non zero current
Replace logic board Replace drive power module
102
PROBLEM 24
Display=“F8”
POSSIBLE CAUSE
Disconnect communication cable from pump power

module to Pump motor; Pump power module defect;
Logic board defect.
CHECKS
Check the cable connecting from pump power module to

Pump motor.
Connect communication cable
Check current of pump power module when you turn on the

lift truck.(You can read temperature measures
using ”COMPACT” display or “EYE” software.)
Zero current Non zero current
Replace logic board. Replace pump power module
103
PROBLEM 25
Display=“F9”
POSSIBLE CAUSE
Steering angle sensor fault.

Wiring defect.
CHECKS
Check continuity from K-17(12V) to pin3.; Check continuity from

K-30(Gnd) to pin1.; Check continuity from K-31(out) to pin2.
Check the housing.
No continuity Continuity
Repair or replace wire Replace angle sensor
104
PROBLEM 26
Display=“FH”
POSSIBLE CAUSE
5V Encoder not ok.

Voltage of K1-16 terminal is lower than 4.3V
CHECKS
Measure voltage from K1-16 terminal of encoder to

K1-30 (GND) terminal of encoder.
5 voltage Lower than 4.3 voltage
Replace logic board Replace defective one

(Drive, pump encoder,
accelerator)
105
PROBLEM 27
Display=“Fc”
POSSIBLE CAUSE
Drive motor encoder defect.

An encoder channel is disconnected and
motor is working.
CHECKS
Check right drive motor encoder connection.
Check continuity from K1-33 to Connect correctly encoder

encoder (pin 4) and from K1-32 connector
to encoder (pin 3).
Check the diagnostic No.49
If correct If no correct
Replace logic board Repair or replace wire
106
PROBLEM 28
Display=“FA”
POSSIBLE CAUSE
12V output not ok.

Voltage of K1-17 terminal is lower than 10.5V.
CHECKS
Measure voltage from K1-17 to K1-30.
12 voltage Lower than 10.5 voltage
Replace logic board Replace defective device one

(Instrument, steering sensor,
valve board)
107
PROBLEM 29
Display=“FL”
POSSIBLE CAUSE
Valve control card defect, Lift setting fault.
CHECKS
Key switch on. Seat switch on.

Measure voltage at K1-7
Over minimum setting voltage No voltage
Resetting lift calibration. Replace logic board
Ok If not ok
Adjust valve board
Ok If not ok
Replace valve board
108
PROBLEM 30
Display=“A”
POSSIBLE CAUSE
Capacitor discharge; Main contactor fail,

Logic board fail
CHECKS
Key switch off and on again. Key switch off and

measure resistance of the main contactor.
About 85~90Ω Other resistance
Check continuity from K-29 to Replace main contactor

main contactor terminal.
Check continuity from K-15 to

main contactor terminal.
Check power fuse Repair or replace wire
Normal Open
Replace logic board Replace logic board
109
PROBLEM 31
Display=“60”
Lift truck operation
POSSIBLE CAUSE
Battery miss matching;

Logic board fail
CHECKS
Check battery voltage at the each system.

(36V system must use 36V battery, 48V system must
use 48V battery)
OK If not ok
Replace logic board Replace battery
110
PROBLEM 32
Display=“61”
POSSIBLE CAUSE
Blocking overtempature of drive motor.;

Drive motor thermal sensor defect;
CHECKS
Continuity Normal

between two wires of the cycle for excessive ramp
thermal sensor of drive motor. climbing or towing
YES NO
111
PROBLEM 33
Display=“65”
POSSIBLE CAUSE
Blocking over temperature pump motor.;

Pump motor thermal sensor defect;
CHECKS
Continuity Normal

between two wires of the cycle for excessive ramp
thermal sensor of pump motor. climbing or towing
YES NO
112
PROBLEM 34
Display=“76”
POSSIBLE CAUSE
Pump motor encoder fail.

An encoder channel is disconnected and
motor is working.
CHECKS
Check left drive motor encoder connection.
Check continuity from K1-35 to Connect correctly encoder

encoder (pin 4) and from K1-36 connector
to encoder (pin 3).
If correct If no correct
Replace logic board. Repair or replace wire.
113
PROBLEM 35
Display=“77”
POSSIBLE CAUSE
Thermal sensor wire of drive motor open.

Logic board fail
CHECKS
Check continuity from K1-30 to thermal sensor pin1.

Replace thermal sensor. Repair or replace wire.
114
PROBLEM 36
Display=“79”
POSSIBLE CAUSE
Thermal sensor wire of pump motor open.

Logic board fail
CHECKS

Replace thermal sensor. Repair or replace wire.
115
PROBLEM 37
Display=“80”
POSSIBLE CAUSE
Wrong drive power module’s thermal sensor.

Logic board fail
CHECKS
Check temperature of drive power module.

(You can read temperature measures using ”COMPACT”
display or “EYE” software)
Normal Abnormal
Replace logic board. Replace drive power module
116
PROBLEM 38
Display=“82”
POSSIBLE CAUSE
Wrong pump power module thermal sensor

Logic board fail
CHECKS
Check temperature of pump power module.

(You can read temperature measures using “COMPACT”
display or “EYE” software)
Normal Abnormal
Replace logic board. Replace pump power module
117
PROBLEM 39
Display=“83”
POSSIBLE CAUSE
Faulty eeprom or mismatching software release

Logic board fail
CHECKS
Restore EEPROM (default setting) with EYE application,

Eye software install
Normal Still problem
Replace logic board.
118
PROBLEM 40
Display=“84”
POSSIBLE CAUSE
CRC alarm
CHECKS
System turn off/on again. Try default setting.

Eye software reinstall.
Normal Still problem
Replace logic board.
119
PROBLEM 41
Display does work normal

Lift truck operation abnormal.
POSSIBLE CAUSE
Encoder defect;
Logic board defect
CHECKS
In case detected motor is operating, RPM of defected motor

is about zero(0) rpm and current of defected motor is
waving from 100A to 600A.
You can see diagnostic mode of display panel.
Parameter No.
15, 16, 17: Drive motor current,
21, 22, 23: Pump motor current
2: Drive motor rpm
9: Pump motor rpm
49 : Drive motor encoder channels
51 : Pump motor encoder channels
Or you can see test mode of eye program by Pc.
OK If not ok
Check cable (U,V,W) of

detected motor
YES If not ok
Replace defected motor
Check wiring for open circuit.

Wiring No.#16,#30,#32,#33 of drive motor and
#16,#30,#35,#36 of pump motor.
Check connection of encoder connector.
OK If not ok
Replace encoder
120
System Tests and Adjustments Hydrometer
Test Equipment Hydrometers are usually available from any battery

supplier. Battery maintenance is a crucial par t of
maintaining the electric vehicle. The ability to
measure specific gravity and adjust the battery
discharge indicator to match battery manufacturers
specifications is an important part in the total
maintenance of the electric vehicle.
There are various pieces of electric truck test
equipment that DOOSAN recommends for all
service personnel. This equipment is available from
a number of world wide manufacturers and local
electronic suppliers. Contact your DOOSAN dealer
or the factory for further recommendations.
Handheld Multimeter
There are various pieces of electric truck test
equipment that DOOSAN recommends for all A digital multimeter that measures DC voltage,
service personnel. This equipment is available from resistance, and has a diode tester, is required. It is
a number of world wide manufactures and local recommended that a high quality meter that is drop
electronic suppliers. Contact your DOOSAN dealer protected, or comes with a drop proof case, be
or the factory for further recommendations. purchased. Autoranging features, fast becoming an
industry standard, are convenient for the service
personnel, but are not required for servicing the lift
truck. A variety of miniature test leads, alligator clips,
and needle probes are also useful, and some of
these usually come with the multimeter.
Clamp-on Current Probe
The electric lift truck testing and adjusting

procedures require the measurement of average
DC currents. Currents in excess of 600 amps may
be present, so a clamp-on meter that will exceed
this level is required. It is also highly recommended
that a device that has a voltage output, as well as a
visible display, be used. This makes viewing and
adjusting currents from the operator's seat possible.
The jaws of the current probe should be able to
accept at least a 19mm (.75 inch) cable diameter.
121
Electrical System Adjustment Lift Sensor
Parking Brake Switch 1. Disconnect the battery and discharge the head
capacitor.
The lift truck can move suddenly. Injury to

personnel or damage to the lift truck is possible. 1
Safely lift the drive wheels off the floor. Put 3
blocks of wood under the frame so both drive
wheels are free to turn. Keep away from drive
wheels that turn.
4
2
Lift Sensor Adjustment

(1) Lift Sensor(transducer) (2) Magnet. (3) Screw.
(4) Setscrew. (A) 1.0 mm (.039 in) Clearance.
NOTICE
Lift sensor may be damaged. Do not allow the
magnet (2) to make contact with the plastic
bracket when the lift lever is activated.
Parking Brake Switch Adjustment
(1) Switch. (2) Plate. (3) Bolts.
2. Loosen setscrew (4).
1. Close the seat switch and turn the key to ON.
3. Adjust screw (3) to make clearance (A) 1.0mm
3. Release the parking brake and put the truck in (.039 in) between lift sensor (1) and magnet (2)
forward. when the lift lever is activated fully (pulled all the
way back).
4. Reposition plate (2) so the switch (1) actuator is
against the bracket. Tighten bolts (3). 4. Tighten setscrew (4). Check lift sensor circuit.
The valve control card may need adjusting.
5. Engage the parking brake and the park brake
symbol will be displayed. Repeat the procedure 5. Set lift sensor initial setting.
until adjustment is correct. Refer to “Sensor Initial Setting”.
122
Tilt and Auxiliary Switches
Because each tilt and auxiliary switch can turn on

the pump motor, it is recommended that only one be
connected to start with. After adjusting the first
switch proceed with the next one.
1. Disconnect the battery and discharge the head

capacitor. Disconnect all but one switch
connector.
Tilt and Auxiliary Switch Adjustment

(1) Screw. (2) Screws.
2. With valve spool in neutral position, loosen

screws (2) and adjust screw (1) to center the
switch roller on cam.
3. After adjusting switch in or out to obtain correct

switch point, tighten screws (1) and (2) to lock
switch into position.
4. Connect the battery, close the seat switch and

turn the key to on. Readjust switch if needed, so
that the pump motor turns on before the control
valve opens.
This must be adjusted for each lever direction
(pushed or pulled).
5. Connect the next switch and repeat this

procedure.
123
Instrument Panel
LCD Instrument panel shows information about
system main analogue and digital parameters,
as follows:
1. Truck speed
2. Park brake insertion
3. Steering angle
4. Seat switch closure
5. Maintenance period expiry
6. Low speed insertion
7. Battery charge level
8. Energetic operating mode
To find further technical data and useful information

about Compact display refer its own user manual.
We briefly mention two important functions:
Diagnostic Mode
This operating mode enables you to test main
analogical and digital signals managed by your
system.
Parameter Calibration
This procedure allows to adjust the main operating
parameters of the system.
You can enter calibration mode before working as
usual with your lift truck.
It is also possible to update the parameters with
default values.
(Notice this way you loose calibration values).
124
Instrument Panel Display Segments
Monitoring Systems The display gives the following information about the
operating state of the system:
Indicator (Compact Display)
Lift truck speed (expressed in km/h or
mp/h)
Handbrake active, indicated by the

warning symbol
Safety contact open, indicated both by

EE blinking message visualized in
timemeter area and by relative symbol
With any directional switch active and safety contact

still open, lift truck can’t be moved, even after seat
switch is closed; in such a case, after safety contact is
closed, the symbol disappears.
EE code disappears only after active directional switch

is turned off.
Time meter or, otherwise, odometer
Steering angle
Maintenance time expiry, indicated by

warning symbol
Slow speed operation, indicated by
Lift truck speed level, range from 0 (NO

speed) to 9 (MAXIMUM speed) segment,
as in symbol
Battery level, indicated by a 9 segments

symbol.
In following Table 1, you can read the generic relation

between battery charge level and number of
visualized bars . See Table 2 in case of an 36V
system and Table 3 in case of a 48V system. Display
signals with alarm code EL the fact battery is
completely discharged.
125
Relation between battery charge level and Table 4 : Case of a 80V system (BC25S – 80V)
number of visualized bars BATTERY CHARGE BATTERY VOLTAGE
LEVEL [V]
Table 1 : Case of a generic system Discharged battery Voltage < 75.7 V
BATTERY CHARGE 10 % 75.7 V ÷ 76.5 V
DISPLAY INDICATION
LEVEL 20 % 76.5 V ÷ 77.3 V
No segments Discharged battery 30 % 77.4 V ÷ 78.2 V
1 flashing segment 10 % 40 % 78.3 V ÷ 79.1 V
1 segment 20 % 50 % 79.2 V ÷ 80.0 V
2 segments 30 % 60 % 80.1 V ÷ 80.9 V
3 segments 40 % 70 % 81.0 V ÷ 81.8 V
4 segments 50 % 80 % 81.9 V ÷ 82.7 V
5 segments 60 % 90 % 82.8 V ÷ 83.6 V
6 segments 70 % Full charged battery Voltage > 83.6 V
7 segments 80 %
8 segments 90 %
9 segments Full charged battery Table 5 : Contraction for dot matrix display Alarm Code
Display
Description Contraction
Table 2 : Case of an 36V system (BC25S – 36V) Code
CONTACTOR
BATTERY CHARGE BATTERY VOLTAGE 17 Main breaker fault
FAULT
LEVEL [V]
Battery/inverter BATT
Discharged battery Voltage < 34.5 V 60
mismatch MISMATCH
10 % 34.5 V ÷ 35.1 V Blocking
20 % 35.1 V ÷ 35.5 V R-MOTOR
61 Overtemperature of
SHUTDOWN
30 % 35.5 V ÷ 35.9 V motor (over 165☞)
40 % 35.9 V ÷ 36.2 V Blocking
50 % 36.2 V ÷ 36.5 V Overtemperature of P-MOTOR
65
60 % 36.5 V ÷ 36.8 V pump motor (over SHUTDOWN
165☞)
70 % 36.8 V ÷ 37.1 V
Pump motor P-MOTOR
80 % 37.1 V ÷ 37.4 V 76
Encoder ENCODER.
90 % 37.4 V ÷ 37.6 V Wrong traction
Full charged battery Voltage > 37.6 V R-M TEMP
77 motor thermal
SENSOR
switch
Wrong pump motor P-M TEMP
Table 3: Case of a 48V system (B(C)25S – 48V) 79
thermal probe SENSOR
BATTERY CHARGE BATTERY VOLTAGE Wrong traction
LEVEL [V] R-INV T
80 module thermal
Discharged battery Voltage < 45.6 V SENSOR
probe
10 % 45.6 V ÷ 46.4 V Wrong pump
P-INV T
20 % 46.4 V ÷ 47 V 82 module
SENSOR
30 % 47 V ÷ 47.6 V thermal probe
40 % 47.6 V ÷ 48.2 V 83 CRC fault CRC FAULT
CRC
50 % 48.2 V ÷ 48.7 V 84 Bank CRC restored
RESTORED
60 % 48.7 V ÷ 49.2 V
Capacitors not
70 % 49.2 V ÷ 49.7 V A charged : fast FAST CHARGE
80 % 49.7 V ÷ 50.1 V charge
90 % 50.1 V ÷ 50.4 V Trans.precharge in
Full charged battery Voltage > 50.4 V A Short / Cap. Too TOO CHARGED
charged
Capacitors not
CAP SLOW
A charged :
CHARGE
slow charge
Capacitors not TIME OUT
A
charged : time out CHARGE
Capacitors not CAP NOT
A
charged CHARGED
126
Drive module R-INV - Pressing PROGRAMMABLE WORKING you can
E1
Overtemperature OVERTEMP manage 3 further options (limit 1, limit 2, and limit
Pump module P-INV 3). You can set parameters value, that are
E3
Overtemperature OVERTEMP expressed in per cent of high energetic mode;
Drive motor R-MOTOR changing active limitation (among L1, L2 or L3),
E4
Overtemperature OVERTEMP related per cent data are used to calculate actual
Pump motor P-MOTOR parameters value.
E6
Overtemperature OVERTEMP
Percent values can be modified only with EYE
EE Wrong start WRONG START
Calibration – E-S-H menu.
EE
(FLASI Seat switch SEAT SW OPEN
NG) Pressing PROGRAMMABLE WORKING you can
LOW BATT manage economic, standard or high operating
EL Low battery voltage mode too.
VOLT
F Wrong Eeprom EEPROM FAULT
WD Timer/Enable WD TIMER COMPACT display shows different symbols in
F function of selected energetic mode:
micro signals FAULT
Serial
F COMM FAULT
communication - E-S-H management disabled: no symbol
Maximum battery MAX BATT visualized.
F0
voltage VOLT - E-S-H management enabled: active mode
Minimum battery is indicated by symbol.
F1 MIN BATT VOLT
voltage
F2 Pedal trimmer fault ACCEL FAULT - PROGRAMMABLE WORKING management
Drive module R-INVERTER enabled: in case you have chosen one of L1, L2
F3
Desat/overcurrent FAULT or L3 operating modes, and lift truck is stopped,
Pump module P-INVERTER
F5 one of the segments of speed indicator symbol
Desat/overcurrent FAULT
(see Table 5) blinks to show selected energetic
Drive motor R-MOTOR I
F6 mode.
current Offset OFFSET
Pump motor current P-MOTOR I
F8 Table 6 : selected energetic mode
Offset OFFSET
STEER DISPLAY
F9 Steer sensor fault SENSOR VISUALISATION OPERATING MODE
OUT (from symbol left side)
FH 5V encoders not ok 5V NOT OK 1st segment L1 (Limit 1)
Drive motor R-MOTOR 5st segment L2 (Limit 1)
Fc
Encoder ENCODER 9st segment L3 (Limit 1)
FA 12V out not ok 12V NOT OK
Pump input on at
FL the PUMP SIGN ON
start Otherwise symbol indicates, as usual,
selected operating mode.
Lift truck operation mode

NOTE: as usual, if lift truck is moving, symbol
Pressing E-S-H button, you can set indicates speed level
energetic operating mode for your
system.
This function is enabled using EYE menu named

Calibration – ESH, to select desired operating
mode. In particular you can choose between E-S-H
or PROGRAMMABLE WORKING :
- Pressing E-S-H (economic, standard, high) button,

you change energetic mode and update related
parameters with a value, corresponding to
selected operating mode, that operator can’t
modify.
127
if active mode is one of L1, L2 or L3 limitations and Low oil level of the brakes; red colour LED.
you change operating mode (from
PROGRAMMABLE WORKING to E-S- H), Seat Belt warning (Option) : red color
software automatically sets operating mode LED for 10 seconds.
to economic one
Alarm message, indicated by an alpha-numerical Alarm LED is managed as follows:

code in the display area where usually lift truck
speed appears. - Display normally working: LED lights up
See Table 6 for the meaning of alarm codes. briefly switching on /off your system
- Display not communicating with control
Over-temperature warning, indicated by the board: after 3 seconds from the moment
warning light In case the temperature of in which the communication stops, alarm
power transistors exceeds the warning limit LED brightens
and relative light blink. - Display board microprocessor not
If this light is on, there is possibility that cooling fan working: alarm LED brightens.
is breakdown. Inspect cooling fan.
No Alarm, No Movement
Hour meter separation point, usually blinking,
stops In case the truck does not move forward or
in following cases: reverse direction, check to see if the service
- Seat switch open. brake switch is activated.
- Serial communication between display and
control unit not active
- Main breaker open
Turning your lift truck on, some alphanumeric codes,

visible for 3 seconds, appear where usually is
visualized speed indicator symbol; those codes help
to identify system in use (see Table 7).
Where usually is visualized hour meter, on left side
appears feed voltage in VDC, and on right side,
maximum weight industrial truck can lift, expressed
in quintals.
Table 7
CODE MEANING
C0 or C1 4 WHEEL/ 3 WHEEL
36 or 48 or 80 BATTERY VOLTAGE
30 or 32 MAX. CAPACITY
LED Indicators
On left side, COMPACT display has four LED

indicators which, when switched on, give
information as follows:
Alarm message; red color LED
Message of lamps; green color LED
Indicator lights activated; green color

LED(OPTION)
128
Display Keys Utilization
As you can see in Fig.1, on right side of display front there are four keys: E-S-H, UP (TURTLE), DOWN and
ENTER.
The function of each of them is described as E-S-H key

follows: With this key, you can modify the device operating
condition, in a circular sequence, as described in
ENTER key Table 7 :
1. When you switch your device on, this key,
pressed for 3 consecutive seconds, allows Current Working Working Condition After
entering both to parameter calibration and to Condition the Key Pressure
diagnostic mode.
Economic (E) Standard (S)
2. During usual operations, this key, pressed for 3
consecutive s, allows you to access merely to Standard (S) High (H)
diagnostic mode. High (H) Limitation 1 (L1)
Limitation 1 (L1) Limitation 2 (L2)
Remember that if the display is operating in Limitation 2 (L2) Limitation 3 (L3)
diagnostic mode during typical operations, you can
Limitation 3 (L3) Economic (E)
exit this procedure pressing once ENTER key.
Moreover, ENTER key is used to confirm the new Table 7
value of the parameter in calibration procedure.
You can modify system operating modes only after
enabling their management with EYE
UP key applicative software.
1. Pressing of this key, in calibration and
diagnostic mode, you increase the number of Pressing this key when you are in diagnostic mode
the parameter displayed. you can see a circular list of 10 latest
2. In calibration phase, you increase the numeric alarms.
value of the parameter displayed.
TURTLE key
Remember that pressing this key you can toggle
between slow running and normal working condition
(if the lift truck is already in speed limitation mode).
DOWN key
1. Pressing of this key, in calibration and
diagnostic mode, you decrease the number of
the parameter displayed.
2. In calibration phase, you decrease the numeric
value of the parameter displayed.
129
Parameter Calibration The parameter number (blinking) appears on the
display area usually reserved to lift truck speed and
This chapter describes the way to adjust the main alarm codes, and its value is shown in the time-
operating parameters of the system. meter area.
You inhibit the access to this menu with EYE Moreover, appear a number of segments
submenu named “Lift truck setup”. proportional to the parameter value.
To calibrate your parameters, read following
instructions: If you see that the numeric data have been modified
in the time meter area, it means that the value of the
To enter calibration mode: chosen parameter has really been updated into
1. Switching on your system, press ENTER key control board memory.
until a blinking “0” (zero) appears.
2. Press UP key: the entry to the chosen Remember that parameter values can be modified
calibration mode is indicated by “C”; this symbol only by discrete increments.
persists until the first parameter will be selected. See Table 8 for the list of all adjustable
parameters and relative minimum available
If calibration procedure is not enabled using EYE variations.
“Lift truck setup” menu, UP key pressure
has no effect.
You can exit this operating mode only switching off

your system.
To execute the calibration:

1. Select parameter 10 using UP and DOWN keys,
and confirm your choice pressing ENTER key.
2. Use UP and DOWN keys to set at 4 the value of
this parameter, and confirm with ENTER key.
3. Repeat the above operations to fix parameter
17 value at 6 Notice: it doesn’t matter if you first
modify parameter 10 and then 17, or vice versa.
Only after this procedure, you allow operator to

change the value of other parameters:
1. Select the parameter to change, using UP or
DOWN key; press ENTER to confirm.
2. Now adjust the value of the selected parameter
with UP and DOWN keys; confirm your choice
typing ENTER key.
130
<36 V>
No Parameter Unit Minimum Default Maximum Remark

5 Deceleration steering ramp 1 rpm/s 0 3,000 5,000
9 Battery reset value V*10 348 352 377
First parameter for calibration enable
10
(1st password)
12 Chat time s 1 6 9
Disable = 0 (Default)
Enable = 1
Second parameter for calibration enable
17
(2nd password)
18 Steering anticlockwise mV 500 10,300 11,500
19 Steering clockwise mV 500 1,200 11,500
20 Steering middle mV 500 6,300 11,500
23 Minimum accelerator mV 200 1,000 4,500
24 Maximum accelerator mV 2,000 3,600 4,500
26 Stop on slop timer s 1 5 10
OFF = 0
27 Lift priority for speed reference digit
ON = 1 (Default)
OFF = 0 (Default)
30 Buzzer on forward direction digit
ON = 1
OFF = 0 (Default)
31 Buzzer on reverse direction digit
ON = 1
32 Maximum lift mV 3,000 11,500 12,000
33 Minimum lift mV 0 1000 12,000
34 Middle lift mV 1,000 2,750 12,000
35 Starting temperature of motor's Fans ℉(℃) 0 140(60) 311(155)
36 Weight of the load on the forks (option) kg 0 0
Future
37 No load pressure (option) bar·10 0 0 2,200
option
38 Load pressure (option) bar·10 0 0 2,200
39 Limitation temperature ℉(℃) 0 212(100) 311(155)
41 Drive maximum current % 20 100 100
42 Forward maximum speed rpm 1,000 4,500 4,500
43 Reverse maximum speed rpm 1,000 4,500 4,500
44 Drive limitation maximum speed rpm 500 2,000 3,500
46 High lift switch 1 drive max speed rpm 0 1,000 4,500 Option
47 Steer limitation drive maximum speed rpm 400 800 2,000
49 Inversion ramp rpm/s 500 900 2,000
131
52 Creep speed rpm/s 100 300 2,000
53 Diameter of drive tires mm 300 510 700
54 High lift switch 2 drive max speed+B17 rpm 0 1,000 4,500 Option
59 Partial release ramp rpm/s 10 40 500
61 Lift maximum current % 20 80 100
62 Auxiliary maximum current % 10 65 100
63 Lift maximum speed rpm 1,000 2,000 3,000
64 Tilt speed rpm 500 1,000 2,000
65 Auxiliary 1 function speed rpm 500 900 2,800
68 Lift minimum speed rpm 500 700 1,500
69 High lift 1 switch lift max speed rpm 0 1,500 3,000 Option
70 Hydro speed rpm 300 600 800
71 Hydro idle speed rpm 300 400 600
72 Pump acceleration ramp rpm/s 1,000 7,000 10,000
73 Pump deceleration ramp rpm/s 1,000 7,000 10,000
75 High lift 1 switch tilt max speed rpm 0 500 2,000 Option
77 High lift 1 switch side shift max speed rpm 0 500 2,800 Option
79 High lift 1 switch auxiliary 2 function max speed rpm 0 500 2,800 Option
94 Slow speed digit
Enable = 1
Normal = 0
95 British unit digit
British unit = 1 (Default)
96 Display brightness digit 0 5 8
Disable = 0
97 E-S-H enable digit
Enable = 1 (Default)
Timer meter = 0 (Default)
98 Time meter / Odometer on display digit
Odometer = 1
99 Maintenance time h 0 0 10,000
132
<48 V>

6 Deceleration steering ramp 2 rpm/s 400 800 2,000
10
(1st password)
Enable = 1
17
(2nd password)
OFF = 0 (Default)
ON = 1
OFF = 0 (Default)
ON = 1
OFF = 0 (Default)
ON = 1
32 Maximum lift mV 3,000 11,500 12,000
33 Minimum lift mV 0 1,000 12,000
34 Middle lift mV 1,000 2,750 12,000
35 Starting temperature of motor's Fans ℃ 0 60 155
Future
37 No load pressure (option) bar·10 0 0 2,200 option
39 Limitation temperature ℃ 0 100 155
133
64 Tilt speed rpm 500 1,000 2,000
94 Slow speed digit
Enable = 1
Normal = 0 (Default)
British unit = 1
Disable = 0
Timer meter = 0(Default)
Odometer = 1
134
<80V>

10
(1st password)
14 Maintenance time inserting enable digit Disable = 0 (Default)Enable = 1
17
(2nd password)
OFF = 0
ON = 1 (Default)
OFF = 0 (Default)
ON = 1
OFF = 0 (Default)
ON = 1
32 Maximum lift mV 3,000 11,500 12,000
33 Minimum lift mV 0 1,000 12,000
34 Middle lift mV 1,000 2,750 12,000
Future
39 Limitation temperature ℃ 100 155
135
64 Tilt speed rpm 500 1,000 2,000
94 Slow speed digit
Enable = 1
Normal = 0
British unit = 1 (Default)
Disable = 0
Odometer = 1
136
10
(1st password)
Enable = 1
17
(2nd password)
OFF = 0 (Default)
ON = 1
OFF = 0 (Default)
ON = 1
OFF = 0 (Default)
ON = 1
32 Maximum lift mV 3,000 11,500 12,000
33 Minimum lift mV 0 1,000 12,000
34 Middle lift mV 1,000 2,750 12,000
Future
39 Limitation temperature ℃ 0 100 155
137
64 Tilt speed rpm 500 1,000 2,000
69 High lift 1 switch lift max speed rpm 0 500 3,000 Option
94 Slow speed digit
Enable = 1
Normal = 0 (Default)
British unit = 1
97 E-S-H enable digit Disable = 0 Enable = 1 (Default)
Odometer = 1
138
Sensor Initial Setting Default Setting
In case that initial settings of sensors are not It is also possible to update the parameters with
performed accordingly, the machine performance default values.
can be lowered.
So, in the following cases, initial setting for each As for the procedure explained below, use UP,
sensor should be done to secure the correct DOWN and ENTER keys to set parameter 10 value
machine performance. to 5 and parameter 17 value to 2. Once more, the
order you adopt to change the two parameters is
- Replacing Logic not important.
- Updating flash memory (Update EEPROM) or The loading of default data is indicated by the
Resetting EEPROM symbols d S (default set);
- Replacing or adjusting Sensor
- Default Setting All parameters whose value is related to selected
energetic operating mode (economic,
STEERING SENSOR (parameter 13): standard, high, limitation 1, limitation 2,
Enter diagnostic mode to visualize steering sensor limitation 3) are updated with default values
voltage. corresponding to the active one.
Minimum value calibration: turn wheels completely Pressing E-S-H key on display, and
on left and read sensor voltage value from display; selecting a different working mode, you
enter calibration mode and set parameter 19 to the immediately change the value of all
value measured. parameters related. Such parameters, as
well as their default values, are listed in
Maximum value calibration: turn wheels completely Table 10 (*)
on right and read sensor voltage value from display;
enter calibration mode and set parameter 18 to the
Econom Standar Hige
value measured. Parameter
ic Mode d Mode Mode
Maximum drive
Central value calibration: put wheels straight and 62 76 100
current
read sensor voltage value from display; enter
Maximum forward
calibration mode and set parameter 20 to the value 2300 3400 4500
speed [rpm]
measured.
Maximum reverse
2300 3400 4500
ACCELERATOR SENSOR (parameter 11): speed [rpm]
Enter diagnostic mode to visualize speed sensor Drive acceleration
700 800 900
voltage. ramp [rpm/s]
Minimum value calibration: read from display sensor Lift maximum
70 73 80
voltage corresponding to start switch closure (when current
all segments dedicated to speed level visualization Maximum lift speed
2500 2750 2950
are active); enter calibration mode and set [rpm]
parameter 23 to the value measured. Drive inversion ramp
700 800 900
[rpm/s]
Maximum value calibration: read sensor voltage Drive release ramp
600 700 800
value from display, with pedal completely pressed; [rpm/s]
enter calibration mode and set parameter 24 to the Table 10 (*) Its values are actually implemented into the
value measured. software of 48 V lift truck
LIFT LEVER SENSOR (parameter 5): Once default data have been loaded, if you further
Enter diagnostic mode to visualize lift lever voltage. need to modify parameters value, you have
Minimum value calibration: read from display sensor to switch your system off, before entering
voltage with lift lever released; enter calibration calibration mode again.
mode and set parameter 33 to the value read.
Parameter 94 is visualized only in case E-S-H
Maximum value calibration: read from display management procedure is enabled with
sensor voltage with lift lever completely pressed; relative EYE software calibration menu.
enter calibration mode and set parameter 32 to the
value measured.
Central value calibration: enter calibration mode and
modify parameter 34.
139
Diagnostic Mode
This operating mode enables you to test main
analogical and digital signals managed by your
system.
Enter diagnostic mode if you are switching on

your lift truck:
1. Press ENTER key (for 3 consecutive seconds)
until the symbol “0” lights up.
2. Press DOWN key to enter diagnostic mode; the

symbol “d” is visualized and it persists until the
first parameter has been selected.
Enter diagnostic mode if you are working as

usual with your lift truck:
1. Press ENTER key (for 3 consecutive seconds)
until symbol “d” appears; it will persist as long
as the first parameter has been selected.
After diagnostic operation mode has been enabled,

you can choose the parameter you want to analyse
using UP and DOWN keys (parameter number
increases using UP key and decreases with DOWN
key).
Here, in Table 11, you have a list of the parameters

you can analyze with their respective displaying
order :
140
List of diagnostic
Parameter No. Description Unit
1 Drive motor speed [rpm]
2 Drive motor speed reference [rpm]
5 Lift voltage [mV]
6 Battery voltage [V·10]
7 Drive motor power module temperature [☞ / °F]
8 Pump motor power module temperature [☞ / °F]
9 Pump motor speed [rpm]
10 Pump motor speed reference [rpm]
11 Accelerator potentiometer voltage [mV]
12 Accelerator second potentiometer voltage [mV]
13 Steering sensor voltage [mV]
15 Drive motor phase current U [A rms]
16 Drive motor phase current V [A rms]
17 Drive motor phase current W [A rms]
21 Pump motor phase current U [A rms]
22 Pump motor phase current V [A rms]
23 Pump motor phase current W [A rms]
24 Drive motor temperature [☞ / °F]
26 Pump motor temperature [☞ / °F]
27 Seat switch hour meter [h]
28 Drive motor hour meter [h]
29 Pump motor hour meter [h]
30 Seat switch [digit]
31 Park brake switch [digit]
32 Start switch [digit]
33 Reverse traction direction switch [digit]
34 Forward traction direction switch [digit]
35 Pedal brake switch [digit]
37 Auxiliary 1 function (Side shift) switch [digit]
38 Auxiliary 2 function switch [digit]
39 Auxiliary 3 function switch [digit]
40 High lift switch 1 [digit]
41 Tilt switch [digit]
42 High lift switch 2 [digit]
43 Main breaker command [digit]
44 5V out [digit] [digit]
45 12V out [mV] [mV]
46 24V out [digit] [digit]
47 Buzzer command [digit] [digit]
48 Fans command [digit] [digit]
49 Drive motor encoder channels -
51 Pump motor encoder channels -
52 Lift pressure [bar · 10] [bar • 10]
53 Pressure sensor voltage [mV] [mV]
54 Weight of the load on the forks [kg] [kg]
141
In diagnostic mode selected parameter is Accessing Stored Error Codes
visualized as follows:
1. In the area dedicated to speed and alarm The B18X series of remembers the last 10 error
signals, appears parameter number ( flashing) codes. This is case the truck has had an intermittent
2. Its actual value is displayed in the area reserved problem, but the operator cannot remember which
to the time meter. code appeared on the display. Also by analyzing the
contents of the last 10 error codes, it may be
In particular, if the selected parameter is: possible to determine what sort of application the
Analogue input: Instrument panel shows the truck has been working in.
parameter value, expressed in the unit of Table 11
The stored error codes are accessed at diagnostic
Digital input: if the command activated by the mode by using E-S-H button.
operator corresponds to the parameter selected, the
value of the quantity is visualized. 1. Access the diagnostic mode.
Other way the symbol E (error) appears, except 2. Press E-S-H button. And then, the stored error
in following case: code will be shown with SMU hours, if any.
1. Seat switch active, for any selected digital input.
3. By pressing UP or DOWN key, more error
To exit diagnostic mode, type ENTER key again. codes can be shown.
If an alarm occurs when diagnostic mode is enabled, 4. Pressing again E-S-H key, you return to
and the system is working as usual, display diagnostic mode.
returns automatically to its typical
visualization mode.
However you can enter diagnostic mode
again, pressing ENTER key (for 3
consecutive s), until the last parameter
displayed before exiting is visualized.
If the selected parameter is a temperature,

also thermal alarm symbol is visualized.
142
Eye Software Interface
EYE is a diagnostic software environment designed
to communicate with the forklift truck.
It can be run from a PC with serial or USB (1.x o2.x)

port. Connection between PC and Main harness’s
Serial Communication connector is characterized by
a 38,4 kBaud/s Baud-rate.
User can communicate with lift truck during working

operations, and can analyse on line main electrical
variables value/ status.
EYE software interface is user friendly and intuitive:

it guides the operator through the process of
parameter setting and is an effective data analysis
instrument, helping to identify faults and causes of
malfunctioning.
Following functions are in particular very useful:

1. Diagnostic: User can receive relevant control
data from the main board (such as current,
voltage, rpm, temperatures etc ) evaluating lift
truck performance and detecting any faulty
circuit
2. Calibration: User can transmit parameters and
settings to the truck in order to tune its
performance.
3. Flash memory software update
143
To find further technical data and useful information about EYE software, refer its own user manual.
144
General Information PC-Controller Communication
Minimum Requirements Connect serial port of PC and harness with picture

below.
1. 350MHz Pentium class or higher
microprocessor
2. 128Mb or greater of RAM
3. Serial port or USB port
36 V/48 V Serial port
Serial port
80 V Serial port
USB port
4. Graphic card 1Mb

5. Windows 98SE/NT/XP/ME/2000
6. 1024x768 resolution video adapter
Recommended Requirements
1. 1GHz Pentium class or higher microprocessor

2. 512Mb of RAM
3. Serial port or USB port
4. Graphic card 2Mb
5. Windows 98SE/NT/XP/ME/2000
6. 1024x768 resolution video adapter
145
Installation
To install EYE software, complete following
steps:
1. Check computer requirements
2. Start Setup.exe application
3. Select destination path then press FINISH
4. At the end press OK and then reboot
5. You can create a short-cut of EYE.exe on
desktop
If there is an old release installed, you must

uninstall it.
To uninstall you must execute Setup.exe application
from CD and confirm any step
146
Features
If EYE software installation is successful, starting the application from Windows “Programs” Menu, or using short-
cut on desktop (Fig.1), you can access main menu (Fig.2-1, 2-2).
Fig.1: Short-cut
Date: xx-xx-xx (Software version)
Fig.2-1: Select System
“SINGLE DRIVE MOTOR” button.
147
Date: xx-xx-xx (Software version)
Fig.2-2: Main menu – operator mode
To quit application or exit a submenu, press ESC key or select Exit menu.
In case of any problems, refer to section 4 “TROUBLESHOOTING”.
WARNING
Some menus, items or calibration parameters described in this manual are optional lift truck functions: so
they could be not implemented.
148
Main Menu
On left side, there are some notes about software release, operating mode and serial communication setting.
Below lift-truck picture, there are actual active alarms (code level and description);
In case of more alarms with the same priority level, the first occurred is visualized.
In operator mode, you can access following menus:

1. “Setup”
2. “Test”
3. “Data logging”
4. “Password”
5. “About”
Even before starting of serial communication between lift truck and PC (Fig.3), you can access “Setup”,
“Password” and “About” menus (Fig.4). In such a case some data field are missing.
In case of faults during a serial communication data flow, any submenu is aborted and main menu front panel is
reinitialized.
Fig.3: operator mode – serial communication faulty
Fig.4: About menu
149
Password Insertion
Fig.5: Password insertion
Selecting Password mode from menu-bar, you can access Supervisor mode (Fig.6) inserting the correct password
(Fig.5).
Contact EYE software developer to know correct password.
Fig.6: main menu – supervisor mode
In case wrong password insertion (Fig.7), following message becomes visible:
Fig.7: unauthorized user
150
In Supervisor mode, you can access these further menus:
1. “Calibration”
2. “Flash”
“Password” menu disappears from menu-bar.

In case of faulty serial communication, main menu front panel is reinitialized as follows (Fig.8):
WARNING
“PANEL BLANK” message is used to distinguish case of not programmed flash memory, so Flash menu
is obviously active.
Fig.8: supervisor mode – communication faulty
You can select active menus directly from main panel menu bar (any grayed menu is not accessible in that
moment); you can also access present sub panels with a further selection by a pop-up menu (Fig.9)
Fig.9: Submenu selection
151
Not Actual Software / Eeprom Crc Fault
A CRC alarm message is visualized both in case of failed EEPROM memory writing and of using a software
version without the CRC control procedure.
Pressing the visualized button, you can load in EEPROM default values: if you don’t execute this procedure,
calibration functions are inhibited. You have now to execute calibration procedure (see inverter manual).
A message signals also the presence of not actual software loaded on inverter panel.
In such a case you can access only basic EYE functions: some menus, for compatibility reasons, will be inhibited.
Submenus
Print function is accessible from many of listed submenus: you can send active front panel image to printer or
save it on file; in that case destination directory is <EYE PATH>\EYE\ images.
BEWARE: if more than one window is in use, only the one relative to the inner submenu is active and all others
work in background.
If you select a non active window, you can’t communicate\ interact with inverter panel.
152
Configuration Menu (Setup)
Fig.10: Setup menu
From setup menu (Fig.10) you can select communication serial port and image file format used by Print function.
153
Test
This pop-up menu includes of following subjects:

1. “Drive” (Fig.11)
2. “Pump” (Fig.12)
3. “Battery” (Fig.13)
4. “Timers” (Fig.14)
Drive (Traction)
Fig.11: Drive menu
Following items appear in Drive menu front panel:

1. Accelerator pedal voltage
2. Pedal brake pressure (in bar)
3. Drive motors phase currents: you can select current phase from pop-up menu
4. Both modules temperature: you can select measure unit between °C and °F.
Temperature above 60°C is signaled by a red color; temperature above 90°C is signaled by a flashing display.
5. Steering angle in percent, using following criteria:
6. 0% steering completely on left
7. 50% straight wheels
8. 100% steering completely on right
9. Steering sensor voltage
10. Request RPM and motor speed for both motors, with an arrow signaling direction
11. Both motors temperature: you can select measure unit between °C and °F.
In case of an overheating alarm, the corresponding green led becomes red.
12. Active output command status
13. Steering switch status
14. Customizable input switch status
15. Start, forward and reverse switches status
16. Drive motors encoder diagnostic leds, both for A and B channel
17. Pedal brake, hand brake and seat switches status
154
Pump
Fig.12: Pump menu
Following items appear in Pump menu front panel:

1. Voltage on lift command circuit
2. Hydraulic lift circuit pressure
3. Pump motor current : you can select current phase from pop-up menu
4. Module temperature: you can select measure unit between °C and °F.
Temperature above 60°C is signaled by a red color; temperature above 90°C is signaled by a flashing display.
5. Request RPM and motor speed, with an arrow signaled direction
6. Motor temperature: you can select measure unit between °C and °F. In case of an overheating alarm, the
green led becomes red
7. Electrovalves output status
8. Customizable input switches status
9. Tilt, lift and high lift digital input status
10. Encoder diagnostic leds, both for A and B
155
Battery
Fig.13: Battery menu
Following items appear in Battery menu front panel:

1. Battery and inverter voltages
2. Battery charge level
3. Code, description and level of active more serious alarm for both microprocessors; if there is more than one
alarm of same level, the latest is visualized.
4. There is a chronological list of latest 10 alarms, with code, description, time and temperature. First listed alarm
is the first occurred.
Temperature value is obviously referred to faulty module or faulty motor (if there are no faulty modules or
motors, this is a no meaning data field).
With “Reset alarms” menu, you can reset alarm list.
156
Timers
Fig.14: Timers menu
Following items appear in Timers menu front panel: total inverter working hours, drive motor and pump motor hour
meter.
157
Calibration
For safety, you can access all calibration menus only in Supervisor mode and with park brake on.
A confirmation is asked to quit a calibration menu without saving changes.
You can’t set a value out of fixed limits: the message “OUT OF LIMIT” signals a case like that.
By a pop-up menu, you can access following calibration functions:

1. “Battery“: Battery reset voltage calibration (Refer to page 125)
2. “Timers“: Timers calibration (Refer to page 126)
3. “Steering“: Steering sensor (Refer to page 127)
4. “Pedal“: Pedal accelerator calibration (Refer to page 128) (**)
5. “Lift“: Lift calibration (Refer to page 129)
6. “ESH“: E/S/H parameters calibration and limits (Refer to page 130)
7. “Steering parameters“: Steering parameters calibration (Refer to page 132)
8. “Program service“: Program service interval setting (Refer to page 133)
9. “Drive motor“: Drive motors parameters calibration (Refer to page 134)
10. “Pump motor“: Pump motors parameters calibration (Refer to page 135)
11. “Critical height switches“: Speed limits calibration in case of critical height (Refer to page 136)
12. “Weight sensor“: Weight sensor calibration (Refer to page 137) (*)
13. “Cab lift“: Cab lift speed calibration (Refer to page 138) (*)
14. “Timer reset“: Timers meters reset (Refer to page 139)
15. “Truck setup“: Some lift truck parameters setup (Refer to page 140) (*)
16. “Backing mode“: Slow mode calibration (Refer to page 141) (*)
17. “Load eeprom default“: EEPROM configuration (Refer to page 142)
18. “Parameters image”: Parameter store or Restore. (Refer to page 143)
(*): Optional menu

(**): Menu present in standard or optional version
158
Battery reset voltage calibration
Fig.15: Battery reset and Discharged battery voltage menu.
In that menu front panel, you can find following data about battery reset voltage: description, actual value, new
value you want to set, measure unit, default value, minimum and maximum settable values.
You can execute following operations:
Load default value:

1. Press DEFAULT button ; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field too will be updated
Change actual value:

1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.
Discard changes:
1. Press CANCEL button; initial value will be restored in NEW data field
2. Press SAVE button and confirm; OLD data field too is restored with initial value
Discharged battery voltage : If battery’s performance is bad, select the discharged battery voltage high.
159
Timers calibration
Fig.16: Timers calibration menu
In that menu front panel, you can find following data about timer parameters: description, actual value, new value
you want to set, measure unit, default value, minimum and maximum settable values.
Load default value:

1. Press DEFAULT button ; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields too will be updated

Discard changes:
1. Press CANCEL button; initial values will be restored in NEW data fields
2. Press SAVE button and confirm; OLD data fields too are restored with initial values
160
Steering sensor calibration
Fig.17: Steering calibration menu
There are following data about steering parameters: description, actual value, measure unit, default values,
minimum and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with steering sensor actual voltage.
Load default value:

1. Press DEFAULT button; VALUE data fields will be automatically updated with default values
Change parameters value:

1. Select ANTICLOCK parameter
2. Turn steering completely anticlockwise
3. Press SAVE button and confirm
4. Select CLOCK parameter
5. Turn steering completely clockwise
7. Select MIDDLE parameter
8. Put wheels straight ahead
Discard changes:
1. Press CANCEL button; initial value will be restored in VALUE data fields
If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any
lift truck fault.
161
Accelerator pedal calibration
Standard version
Fig.18: Accelerator pedal calibration menu
There are following data about accelerator parameters: description, actual value, measure unit, default values,
minimum and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with pedal sensor actual voltage.
Load default value:

1. Press DEFAULT button; VALUE data field will be automatically updated with default value

1. Select MIN ACCELERATOR parameter
2. Release accelerator pedal
4. Select MAX ACCELERATOR parameter
5. Press completely accelerator pedal
Discard changes:
1. Press CANCEL button; initial value will be restored in VALUE data fields
lift truck fault.
In this window front panel there are 3 green leds, expressing actual state of forward, reverse and start switches.
Optional version
There is a second pedal sensor.

Calibration procedure is like standard one, except that START led present (Fig.18) turns ON only after software
verifies that the voltages on both pedal sensors are equal to Vmin + 0,5 V voltage, obtained slowly pressing
accelerator pedal.
162
Lift calibration
Fig.19: Lift sensor calibration menu
There are following data about lift parameters: description, actual value, measure unit, default values, minimum
and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with lift sensor actual voltage.
Load default value:

1. Press DEFAULT button; VALUE data fields will be automatically updated with default values

1. Select MIN LIFT parameter
2. Release lift command lever
4. Select MAX LIFT parameter
5. Press completely lift command lever
7. Select MIDDLE LIFT parameter
8. Press lift command lever to select start acceleration point for pump motor
9. If lift sensor actual value is inside permitted range, press SAVE button and confirm
Discard changes:
1. Press CANCEL button; VALUE data fields will be restored with initial values
lift truck fault.
163
E/S/H parameters and L1, L2, L3 limits calibration
Fig.20: E/S/H calibration menu
In that menu front panel, you can find following data about E/S/H parameters: description, actual value, new value
you want to set, measure unit, default values for E, S, and H operating mode, settable per cent values for
parameters in L1,L2,L3 operating mode
Select default value:

1. Press DEFAULT button ; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field too will be updated

Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
This calibration procedure is optional, and you can enable/disable it with the ESH button.
In any case, you can disable limits calibration section (L1, L2 and L3 parameters) with PROGRAMMABLE
WORKING button.
N.B.: if “programmable working” section is disabled, and you select one of L1, L2 or L3 operating modes,
a message will advise user and E operating mode will be forced .
With E_S_H, pop-up menu you can select one of lift truck possible energetic operating modes (Economic,
Standard and High); selected operating mode default values are so loaded on characteristic parameters.
The message in Fig. 21 appears if you have selected a different energetic mode using Compact display; pressing
OK button, parameters are updated loading new values from control board.
164
Fig.21: Parameters externally changed
If PROGRAMMABLE WORKING section is enabled, pressing MODIFY LIMITS button you enter Fig. 22 window;
you can now modify per cent values for L1, L2 and L3 limits, remembering that every single data change require
to be confirmed.
Fig.22: Percent parameters menu
In that menu front panel, there are data about L1, L2 and L3 parameters: description, measure unit, modifiable
values expressed in per cent, minimum and maximum settable values.

1. Insert new value
2. Confirm
If actually selected operating mode percent values are now modified, exiting to ESH calibration menu, user can
load new default values. Every parameter per cent value is referred to High mode data.
165
Steering parameters calibration
Fig.23: Steering parameters calibration menu
In that menu front panel, you can find following data about steering parameters: description, actual value, new
value you want to set, measure unit, default values minimum and maximum settable values.

1. Press DEFAULT button ; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields too will be updated

Discard changes:
166
Program service calibration
Fig. 24: "Program service" menu
To modify assistance interval, you have to enable apposite function.

1. Set button INCREASE properly to select if increase or decrease service interval
2. Change assistance interval value using HOURS INCREASE pop-up menu
3. Press SAVE AND EXIT button and confirm
167
Drive motor parameters calibration
Fig.25: Drive motors calibration
In that menu front panel, you can find following data about drive motor parameters: description, actual value, new
value you want to set, measure unit, default values minimum and maximum settable values, actual value in
percent.

1. Press DEFAULT button; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; both OLD data fields and first 3 parameters will be updated

1. Insert changed value in NEW data field (or modify one of first 3 parameters)
signaled and NEW data field (or one of first 3 parameters) initial value is restored.
Discard changes:
2. Press SAVE button and confirm; OLD data fields and first 3 parameters are restored with initial values
First 3 parameters, for their particular meaning, are visualized and managed in a more user friendly way.
168
Pump motor parameters calibration
Fig.26: Pump motor calibration menu
In that menu front panel, you can find following data about pump motor parameters: description, actual value, new
value you want to set, measure unit, default values minimum and maximum settable values, actual value in
percent.

2. Press SAVE button and confirm; OLD data fields will be updated

Discard changes:
2. Press SAVE button and confirm; OLD data fields are restored with initial values
169
Critical height: speed limits calibration(Optional Menu)
Fig.27: Maximum speed calibration menu
You can set maximum speed of pump and drive motors in case of a fork height superior to critical one (that
condition is signaled by two switches present on lift truck forks)
In that menu front panel, you can find following data about critical maximum speeds: description, actual value,
new value you want to set, measure unit, default values minimum and maximum settable values, actual value in
percent.


Discard changes:
2. Press SAVE button and confirm; OLD data fields are restored with initial values
170
Weight sensor calibration (Optional Menu)
Fig.28: Fork weight calibration menu
In that menu front panel, you can find following data about parameters: description, actual value, measure unit,
default values, minimum and maximum settable values. Pressing SAVE button, visualized pressure value is saved
on actually selected parameter.

1. Press DEFAULT button; VALUE data fields will be automatically updated with default value
Calibrate weight sensor:

1. Select NO LOAD parameter
2. Hoist lift truck forks till 50 cm height
3. Wait for 5 s
4. Press SAVE button and confirm to record weight sensor reading in case of no load on forks
5. Put on lift truck forks a known value load
6. Select LOAD parameter
7. Set, in weight data field, lifted load value
8. Hoist lift truck forks till 50 cm height
9. Wait for 5 s
10. Press SAVE button and confirm to record weight sensor reading in case of known load on forks
Discard changes:
1. Press CANCEL button; VALUE data fields will be restored with initial values
171
Timers reset
Fig.30: Timers reset menu
In that menu you can reset timers signaling lift truck working hours; remember that if you press that button, a
double confirmation is necessary.
This menu is use possibility developer.
172
Lift truck setup (Optional Menu)
Fig.31: Lift truck setup menu
In that menu front panel, you can find following data: parameters description, actual status (ON or OFF), new
status you want to set, and default status.

1. Press DEFAULT button; NEW data fields will be automatically updated with default status

1. Insert changed status in NEW data field
signaled and NEW data field initial status is restored.
Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial status
2. Press SAVE button and confirm; OLD data fields are restored with initial status
173
Eeprom reset menu
That menu has two important functions:

1. In case of Eeprom alarm, you have to use complete EEPROM reset procedure.
2. If you have updated flash memory software, and you want to load default Eeprom configuration, you have to
use complete Eeprom reset; to maintain already calibrated values you can use partial EEPROM reset
procedure.
Pay attention that using complete reset procedure you loose already calibrated values.
Both procedures, in any case, don’t modify timers value and alarm history.
Partial EEPROM reset:

1. Press PARTIAL LOAD EEPROM button
2. Give a confirmation to load default values
Fig. 33: Eeprom configuration menu
Complete EEPROM reset:

1. Press TOTAL LOAD EEPROM button
2. Give a confirmation to load default values
3. Give a further confirmation (Fig. 34)
Fig. 34: Further confirmation
174
Parameters Image menu
Fig 35: Parameters image menu
In that menu, You can store and restore about calibration parameters except Lift, pedal, steering setting value.
Parameter Store
1. Press Export button
2. Store calibration parameters
Parameter Restore (other trucks)

1. Press Import button
2. Restore calibration parameters
175
Data Logging
With that menu (Fig. 36) you can save on file the values of a certain number of variables with a certain frequency;
the resulting file is logging out, saved in <EYE PATH>\EYE\out directory.
Fig. 36: Data logging menu
Data acquisition procedure is following:

1. Select Nmax, the number of variables you want to save
2. Select the variables whose value you want to record, with apposite pop-up menu
3. You can modify sampling period, expressed in seconds.
4. Pressing START button, saving procedure begins; in that phase you can’t modify acquisition parameters
During acquisition procedure (Fig. 37), following data are visualized:

1. A led signals saving instant
2. A gauge scans time between 2 saving instants
3. Indication of number of saved frames
4. Flashing message SAVING…
To stop saving procedure you can press START button, or simply exiting the menu.
176
Fig. 37: Data logging menu – saving mode
Logging.out file format is:

FIRST ROW: name of NMAX variables to be saved followed by saving date and time;
SUCCESSIVE ROWS: NMAX recorded values separated by space.
177
Flash
Fig. 38: Flash programming phase
To upgrade main controller software, with Flash menu (Fig. 36) follow these steps:
1. Disable all commands
2. Verify if C:\SOURCE_FILE directory exists (otherwise create it)
3. Source directory must contain only 2 source files
4. Select FLASH item from menu-bar
5. Give confirmation to start programming phase
6. In case of troubles with source files, (missing files, wrong version,...) there will be an error message and flash
memory will not programmed .
7. After a synchronization phase, flash programming will start; a bar gives the percent indication of already
programmed memory.
8. In case of problems with serial communication, there will be an error message and flash programming phase
will be stopped.
9. After traction micro successful programming, begins pump micro programming phase (step 7 and 8)
10. A message will signal the end of programming phase, and its result; give confirmation to exit the menu.
See troubleshooting section in case of any error.
If programming phase fails after synchronization, panel has to be programmed with correct software before being
used.
Enforce necessarily following item after Flash.

1. Click the total load EEPROM of LOAD EEPROM DEFAULT MENU
2. Re-set the lift, pedal, steering sensor
178
Troubleshooting of Eye Program
Generality Flash Programmation
Often you can solve problems reading error If panel programming phase fails, when you try
messages and following suggestions. to load source files:
1. Verify if c:\source_file directory exists
2. Verify if c:\source_file directory contains only 2
Software Installation source files
3. Be sure that source files are the ones provided
In case of failed EYE software installation, by DI’s Homepage.
follow these steps:
1. Verify if your PC complies minimal requirements If you program memory successfully, but
2. Be sure of having PC administrator rights inverter doesn’t work correctly:
3. Close all active applications and disable 1. Be sure that source files are the ones provided
antivirus before installation by S.M.E
4. Verify installation, step by step
In case of transmission error:
In case of successful installation, if application 1. Verify system ground connections
has a runtime error: 2. Control serial connection cable: you must use a
1. Verify if your PC complies minimal requirements shielded one
2. Turn off PC and try again after turning it on 3. Verify if serial port works correctly
3. Uninstall and install again EYE software 4. Verify if there are any active commands
Serial Communication Other Problems
If application doesn’t work and message “not Application works slowly:

connected” appears: 1. Verify if your PC complies minimal requirements
1. Verify system ground connections
2. Verify if inverter panel works correctly Application doesn’t work properly:
3. Control serial connection cable: you must use a 1. Verify if your PC complies minimal requirements
shielded one
4. Verify if serial port works correctly Text and ”objects” on main panel are not centred:
5. Use Setup menu to verify serial port 1. Verify if your PC complies minimal requirements
configuration 2. Don’t modify window size
6. Verify no other applications serial port
Monitor doesn’t display correctly text and
“objects”
1. Verify if monitor refresh frequency is at least
75Hz
2. Verify if your PC complies minimal requirements
179
Appendix A : 36[V] Parameter List
Deceleration as high it is as quickly the truck decreases
5 steering ramp its speed if the truck driver is turning the rpm/s 0 3,000 5,000
1 wheel quickly
as high it is as quickly the truck decreases its
Deceleration speed in relation to the drive speed of truck.
6 steering ramp This parameter increases the deceleration rpm/s 400 800 2,000
2 ramp while the driver is steering at high
speed.
9 V*10 348 352 377
Seat switch Time interval between seat switch opening
11 s 1 3 9
delay and drive and pump motors stopping
Time delay between last command given to a
drive or pump motor and chat mode signaling
Maintenance
14 time inserting Maintenance time inserting enable digit
Enable = 1
enable
18 mV 500 10,300 11,500
19 mV 500 1,200 11,500
clockwise on left
Steering
20 Steering voltage with wheels straight ahead mV 500 6,300 11,500
middle
23 mV 200 1,000 4,500
24 mV 2,000 3,600 5,000
26 s 1 5 10
if it's OFF, the pump motor works like it does now, that is,
the reference speed of pump motor, in case of many
simultaneous commands (LIFT + TILT, LIFT + AUX1,
Lift priority for
TILT + AUX1.......), will be the highest of every single OFF = 0
27 speed digit
command; if it's ON the reference speed of pump motor, ON = 1 (Default)
reference
in case of many simultaneous commands, will be the
lowest of those reference speed required by every single
command.
Buzzer on
If it’s ON, the buzzer will be alarmed when the OFF = 0 (Default)
30 forward digit
direction switch is moved to forward. ON = 1
direction
Buzzer on
31 reverse digit
direction switch is moved to reverse. ON = 1
direction
32 Maximum lift mV 3,000 11,500 12,000
pressed
34 Middle lift lifting becomes proportional to the shift of the mV 1,000 2,750 12,000
lever
℉ 140 311
35 temperature of cooling Fan stops when the motors cools 0
(℃) (60) (155)
motor's Fans down below 140℉(60℃) from set value(The
minimum of stop temperature is 77℉(25℃)).
Weight of the
load on the forks
future
No load
37 Load measurement bar·10 0 0 2,200 option
pressure
180
Limitation 212 311
39 Start temperature of performance reduction ℉(℃) 0
Drive
Drive motors maximum current (expressed in
41 maximum % 20 100 100
per cent of high energetic mode value)
current
Forward Maximum forward lift truck speed with no
42 maximum speed limitation rpm 1,000 3,800 3,800
speed (no alarms present and turtle not active)
Reverse Maximum reverse lift truck speed with no
Drive limitation
Maximum lift truck speed with speed
44 maximum rpm 500 2,000 2,500
limitation (turtle active)
speed
High lift switch
Maximum travel speed when switch 1 was
46 1 drive max rpm 0 1,000 4,500 Option
"ON"
speed
Steer limitation
Maximum speed reference in the angle in
47 drive maximum rpm 400 1,200 2,000
which the internal wheel is mechanically still.
speed
48 rpm/s 400 1,100 2,000
ramp pressed
Inversion
49 Lift truck deceleration in inversion rpm/s 400 1,300 2,000
ramp
released
Pedal brake Lift truck deceleration with pedal brake
51 rpm/s 40 1,200 2,000
ramp pressed
Diameter of
53 Drive tyre's diameter mm 300 510 700
drive tires
High lift switch
Maximum travel speed when switch 1 and
switch 2 was "ON"
speed
Partial release
ramp
low rpm
61 % 20 80 100
Auxiliary
Pump motor maximum current with lift lever
62 maximum % 10 65 100
released
current
Lift maximum
speed
64 Tilt speed Pump motor speed with lift function active rpm 500 900 2,000
Auxiliary 1 Pump motor speed with 1st auxiliary function
65 rpm 500 900 2,800
66 rpm 500 900 2,800
67 rpm 500 900 2,800
Lift minimum
speed
High lift 1
Maximum pump motor speed with forks
69 switch lift max rpm 0 1,500 3,000 Option
above the critical height
speed
Pump motor speed with direction command
Hydro idle
71 lever not in neutral, acceleration pressed and rpm 200 300 500
speed
no pump command active
181
Pump
acceleration ramp
73 rpm 1,000 7,000 10,000
High lift 2 switch Maximum lift speed when switch 1 and switch
74 rpm 0 1,500 3,000 Option
lift max speed 2 was "ON"
High lift 1 switch
75 Maximum tilt speed when switch 1 was "ON" rpm 0 500 2,000 Option
tilt max speed
High lift 2 switch Maximum tilt speed when switch 1 and switch
76 rpm 0 500 2,000 Option
tilt max speed 2 was "ON"
High lift 1 switch
Maximum auxiliary 1 speed when switch 1
77 auxiliary 1 max rpm 0 500 2,800 Option
was "ON"
speed
High lift 2 switch
and switch 2 was "ON"
speed
High lift 1 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1
79 rpm 0 500 2,800 Option
function max was "ON"
speed
High lift 2 switch
80 rpm 0 500 2,800 Option
function max and switch 2 was "ON"
speed
High lift 1 switch
83 rpm 0 500 2,800 Option
speed
High lift 2 switch
84 rpm 0 500 2,800 Option
speed
Enable = 1
as usual.
If parameter is set to 1, values are expressed Normal = 0
in British unit, otherwise in international ones. British unit = 1 (Default)
Display
brightness
Disable = 0
97 E-S-H enable change the value of the power mode with the digit
display
98 Odometer on appears on display ; otherwise display shows digit
Odometer = 1
display the hour meter.
Maintenance Can set truck's maintenance period.
99 h 0 0 10,000
time (Maintenance period decision)
182
Appendix B : 48[V] Parameter List
1 wheel quickly
speed.
9 V*10 464 470 501
11 s 1 3 9
Maintenance
Enable = 1
enable
18 mV 500 10,300 11,500
19 mV 500 1,200 11,500
clockwise on left
Steering
middle
23 mV 200 1,000 4,500
24 mV 2,000 3,600 5,000
26 s 1 5 10
Lift priority for
TILT + AUX1.......), will be the highest of every single OFF = 0 (Default)
27 speed digit
command; if it's ON the reference speed of pump motor, ON = 1
reference
command.
Buzzer on
30 forward digit
direction
Buzzer on
31 reverse digit
direction
32 Maximum lift mV 3,000 11,500 12,000
pressed
lever
℉ 140 311
(℃) (60) (155)
Weight of the
load on the forks
future
No load
pressure
183
Parameter Mini Def Maxi
No mum ault mum
Limitation 212 311
39 Start temperature of performance reduction ℉(℃) 0
Drive
41 maximum % 20 100 100
current
Drive limitation
44 maximum rpm 500 2,000 2,500
speed
High lift switch
"ON"
speed
Steer limitation
speed
48 rpm/s 400 1,100 2,000
ramp pressed
Inversion
ramp
50 Release ramp rpm/s 40 1,000 2,000
released
51 rpm/s 40 1,200 2,000
ramp pressed
Diameter of
drive tires
High lift switch
switch 2 was "ON"
speed
Partial release
ramp
low rpm
61 % 20 80 100
Auxiliary
62 maximum % 10 65 100
released
current
Lift maximum
speed
64 Tilt speed Pump motor speed with lift function active rpm 500 900 2,000
65 rpm 500 900 2,800
66 rpm 500 900 2,800
67 rpm 500 900 2,800
Lift minimum
speed
High lift 1
69 switch lift max rpm 0 1,500 3500 Option
speed
Hydro idle
speed
184
Pump
acceleration ramp
73 rpm 1,000 7,000 10,000
74 rpm 0 1,500 3,500 Option
High lift 1 switch
tilt max speed
76 rpm 0 500 2,000 Option
High lift 1 switch
was "ON"
speed
High lift 2 switch
speed
High lift 1 switch
79 rpm 0 500 2,800 Option
speed
High lift 2 switch
80 rpm 0 500 2,800 Option
speed
High lift 1 switch
83 rpm 0 500 2,800 Option
speed
High lift 2 switch
84 rpm 0 500 2,800 Option
speed
Enable = 1
as usual.
If parameter is set to 1, values are expressed Normal = 0 (Default)
in British unit, otherwise in international ones. British unit = 1
Display
brightness
Disable = 0
display
Odometer = 1
99 h 0 0 10,000
185
Appendix C : 80[V] Parameter List
1 wheel quickly
speed.
9 V*10 752 773 829
11 s 1 3 9
Maintenance
Enable = 1
enable
18 mV 500 10,300 11,500
19 mV 500 1,200 11,500
clockwise on left
Steering
middle
23 mV 200 1,000 4,500
24 mV 2,000 3,600 5,000
26 s 1 5 10
Lift priority for the reference speed of pump motor, in case of many
OFF = 0 (Default)
27 speed simultaneous commands (LIFT + TILT, LIFT + AUX1, digit
ON = 1
reference TILT + AUX1.......), will be the highest of every single
command; if it's ON the reference sp
Buzzer on
30 forward digit
direction
Buzzer on
31 reverse digit
direction
32 Maximum lift mV 3,000 11,500 12,000
pressed
lever
℉ 140 311
(℃) (60) (155)
Weight of the
load on the forks
future
No load
pressure
186
Limitation ℉ 212 311
39 Start temperature of performance reduction 0
temperature (℃) (100) (155)
Drive
41 maximum % 20 100 100
current
Drive limitation
44 maximum rpm 500 2,000 2,500
speed
High lift switch
"ON"
speed
Steer limitation
speed
48 rpm/s 400 1,100 2,000
ramp pressed
Inversion
ramp
released
51 rpm/s 40 1,200 2,000
ramp pressed
Diameter of
drive tires
High lift switch
switch 2 was "ON"
speed
Partial release
ramp
low rpm
61 % 20 85 100
Auxiliary
62 maximum % 10 65 100
released
current
Lift maximum
speed
65 rpm 500 900 2,800
66 rpm 500 900 2,800
67 rpm 500 900 2,800
Lift minimum
speed
High lift 1
speed
Hydro idle
speed
187
Pump
acceleration ramp
73 rpm 1,000 7,000 10,000
74 rpm 0 1,500 3,500 Option
High lift 1 switch
tilt max speed
76 rpm 0 500 2,000 Option
High lift 1 switch
was "ON"
speed
High lift 2 switch
speed
High lift 1 switch
79 rpm 0 500 2,800 Option
speed
High lift 2 switch
80 rpm 0 500 2,800 Option
speed
High lift 1 switch
83 rpm 0 500 2,800 Option
speed
High lift 2 switch
84 rpm 0 500 2,800 Option
speed
Enable = 1
as usual.
Display
brightness
Disable = 0
display
Odometer = 1
99 h 0 0 10,000
188
Appendix D : Parameter List
1 wheel quickly
speed.
9 V*10 464 470 501
11 s 1 3 9
Maintenance
Enable = 1
enable
18 mV 500 10,300 11,500
19 mV 500 1,200 11,500
clockwise on left
Steering
middle
23 mV 200 1,000 4,500
24 mV 2,000 3,600 5,000
26 s 1 5 10
Lift priority for
TILT + AUX1.......), will be the highest of every single OFF = 0 (Default)
27 speed digit
command; if it's ON the reference speed of pump motor, ON = 1
reference
command.
Buzzer on
30 forward digit
direction
Buzzer on
31 reverse digit
direction
32 Maximum lift mV 3,000 11,500 12,000
pressed
lever
Weight of the
36 Load measurement kg 0 0 -
load on the forks
future
No load
pressure
189
Parameter Mini Def Maxi
No mum ault mum
Limitation
39 Start temperature of performance reduction ℃ 0 100 155
temperature
Drive
41 maximum % 20 100 100
current
Drive limitation
44 maximum rpm 500 2,000 2,500
speed
High lift switch
"ON"
speed
Steer limitation
speed
48 rpm/s 400 1,100 2,000
ramp pressed
Inversion
ramp
released
51 rpm/s 40 1,200 2,000
ramp pressed
Diameter of
drive tires
High lift switch
switch 2 was "ON"
speed
Partial release
ramp
low rpm
61 % 20 76 100
Auxiliary
62 maximum % 10 65 100
released
current
Lift maximum
speed
65 rpm 500 900 2,800
66 rpm 500 900 2,800
67 rpm 500 900 2,800
Lift minimum
speed
High lift 1
speed
Hydro idle
speed
190
Pump
acceleration ramp
73 rpm 1,000 7,000 10,000
74 rpm 0 1,500 3,000 Option
High lift 1 switch
tilt max speed
76 rpm 0 500 2,000 Option
High lift 1 switch
was "ON"
speed
High lift 2 switch
speed
High lift 1 switch
79 rpm 0 500 2,800 Option
speed
High lift 2 switch
80 rpm 0 500 2,800 Option
speed
High lift 1 switch
83 rpm 0 500 2,800 Option
speed
High lift 2 switch
84 rpm 0 500 2,800 Option
speed
Enable = 1
as usual.
Display
brightness
Disable = 0
display
Odometer = 1
99 h 0 0 10,000
191
Appendix E : Error Code List
EYE Error
Description Level Cause Troubleshooting
Code Code
1. Such an alarm can be caused also by the
presence of regeneration currents; when lift
truck is on release or reverse braking ramp,
motors work as generators, and battery voltage
Battery voltage, measured can exceed overvoltage limit. In a case like
by a circuit inside logic, that, the battery condition should be verified ( if
exceeds following levels: the battery is new it is necessary to do some
Maximum 63 V, in case of systems charge-discharge cycles before reaching the
1 F0 battery 1 working at 36 V rating declared by the constructor) or has a
voltage 63 V, in case of systems high internal resistance.
working at 48 V If the case is the second and it is not possible
106V, in case of to change the battery, the solution may be to
systems working at 80 V reduce the release and reverse braking ramp.
2. Incorrect wiring to battery positive or negative
terminals.
3. Verify if battery is still in good conditions.
1. Incorrect wiring to battery, or corroded positive
Battery voltage, measured
or negative terminals;
by an internal circuit, is
2. Verify battery conditions: if the electrolyte
lower than following
inside is partially exhausted, an under voltage
levels :
Minimum alarm can sometimes be detected from the
24 V , in case of systems
2 F1 battery 1 controller; even in case of low battery charge
working at 36 V
voltage (<10%), high current rates (i.e. both pump and
drive motors working in full load conditions)
working at 48 V
could cause an under voltage alarm, in
particular in presence of an exhausted battery.
working at 80 V
1. Verify if the accelerator initial set-up is correct;
if not, repeat calibration procedure.(You can
use both PC with serial communication
software and Instrument panel).
Voltage measured on
2. Verify if the following the 42pin main connector
accelerator circuit exceeds
terminals are correctly wired to their
the value calculated
Pedal correspondent inputs in accelerator circuit:
3 F2 2 averaging calibration and
trimmer fault - K1-16 (5 V)
reachable voltages;
- K1-30 (ground)
moreover, start switch
- K1-18 (pedal output-A)
seems to be open.
- K1-9 (pedal output-B)
3. In case of correct wiring, replace the
accelerator itself.
Eeprom does not work 1. Load default values for eeprom variables, both
Eeprom properly, or one of using PC with serial communication software
5 F 1
alarm memorized values is out of and Instrument panel.
correct limits. 2. Replace the logic.
Voltage level of pre -
charge capacitors is less
1. Verify if main breaker coil and power terminals
then 70 % of nominal
Pre -charge are in good conditions.
battery level.
capacitors 2. Verify if supply lines power fuse is damaged.
It could happen, in
low voltage 3. Verify if main breaker coils are correctly wired
example, if the power
6 A alarm 1 to their correspondent inputs :
module is working with
(Capacitors - K1-29 (positive terminal)
main breaker open.
not - K1-15 (negative terminal)
Capacitors voltage
charged) 4. Replace the main breaker.
decreases cause energy
spent to keep motors in
motion.
192
EYE Error
Code Code
Drive motor 1. With such an alarm present when you turn on
8 F3 power 1 lift truck, disconnect the power cable between
module the malfunctioning power module and the
corresponding motor (first, turn off the system,
of course).
If turning lift truck on again, alarm is not active,
then:
Actual current exceeds
1. Replace the cable connecting logic and
Pump motor limits 929 A
power module.
25 F5 power 1
2. Replace the power module.
module
If turning lift truck on again, alarm is active,
then :
1. Replace the power module.
2. Replace the motor.
1. Inspect whether the main connector is not
power loose.
Pre-charge capacitors
module 2. Inspect whether the drive connector is not
voltage increases too fast
9 A capacitors 1 loose.
when you turn the system
pre-charge 3. Replace the main breaker.
on.
too fast 4. Replace the drive power module.
temperature dissipation.
Verify thermal coupling between power module
block and aluminium plate, and between
aluminium plate and truck ballast.
The presence of a correct amount of thermal
The power module
grease in the coupling is essential to ensure an
Pump motor temperature
efficient heat exchange.
power (measured with a
2. Replace cable connecting the output pump of
10 E3 module 6 temperature connector),
the logic to the pump power module;
overtemper exceeds 100☞, or is
3. If temperature readings seem too high in
ature inside [95☞, 100☞] range
function of total time interval of lift truck using,
at least 30 s.
replace pump power module causing the
alarm.
Instrument panel or “EYE” communication
software.
1. Verify the correctness of wiring from pump
When you turn on the
motor and relative power module
system, capacitors are not
2. Replace wire connecting "pump" with the
completely discharged by
corresponding power module or if not possible
pump motor.
because the pump motor power module box
In fact, if you turn
integrates the outlet wire, substitute the power
Capacitors suddenly on the lift truck,
module box
11 A too charged 1 after a turning off,
3. Verify if main breaker has stuck closed
on start capacitors voltage level is
terminals: in such a case replace it
too high. You have to
4. Replace the wire connecting "drive" in logic to
discharge them before
right drive motor power module: a defective
checking the presence of
wire could give a wrong measure for capacitors
any fault (both of
voltage
capacitors and of logic)
193
EYE Error
Code Code
Battery voltage level is
lower than minimum 1. Measure battery voltage with a tester and, if
Low battery charge value expected, different from the value reported on Instrument
12 EL 3
alarm referred to table 3 in panel, replace the logic;
Instrument panel technical 2. Otherwise recharge battery.
documentation.
wires of the temperature connector ( execute
the measure at ambient temperature of 25°C) .
If the measure is not correct it is necessary to
Drive motor The measure of drive 2. Disconnect the temperature connector and
13 E4 over 5 motor temperature check the wiring insulation between signal wire
temperature exceeds 155☞. an ground wire (towards logic);
Presence of alarm with hot motors :

operating mode, you have to measure about
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor The measure of pump 2. Disconnect the temperature connector and
14 E6 over 6 motor temperature check the wiring insulation between signal wire
temperature exceeds 155☞. and ground wire (towards logic);

1. Replace the wire connecting power module to
Drive motor
Non-zero phase currents logic.
15 F6 current 1
when you turn lift truck on. 2. Replace the power module.
offset alarm
Main Overcurrent on main 1. Replace the main breaker.
17 17 1
breaker fault breaker coil. 2. If alarm is still present, replace the logic.
Improper communication
1. Using EYE program interface, try to program
Watchdog between DSPs present on
18 F 1 logic flash memory. (default setting)
timer alarm logic, or/and defective
2. Replace the logic .
logic.
194
EYE Error
Code Code
temperature dissipation; verify thermal coupling
between power module block and aluminium
plate and between aluminium plate and truck
ballast. The presence of the correct amount of
thermal grease in the coupling are essential to
Drive motor power module ensure a correct heat exchange;
power temperature, measured 2. Check cable connecting the communication
20 E1 module 5 with a connector, exceed output connector of the logic to the
overtemper 100☞, or is inside corresponding power module;
ature [100☞] range at least 30 s. 3. If temperature readings seem too high in
function of total time interval of lift truck using,
replace power module unit causing the alarm.
“Instrument panel” or “EYE” communication
software.
Error in serial 1. Switch on the system and the turn it on again.
communication between 2. Program pump and drive DSP again; maybe
Serial the two DSP; DSP present software present in flash memory was
21 F communicat 1 on logic make a mutual corrupted. (REFLASH)
ion alarm software control, to insure 3. Try to the default setting (LOAD EEPRON
fast diagnosis of such a DEFAULT-TOTAL LOAD EEPROM)
fault. 4. Replace the logic.
1. Replace the wire connecting power module to
Pump motor
Non-zero phase currents logic.
36 F8 current 1
when you turn lift truck on. 2. Replace the power module.
offset alarm
1. Verify if 5 V output is grounded, cause an
incorrect encoder wiring.
Alarm on 5 logic K1-16 terminal
2. Verify if 5 V output is grounded, cause any
37 FH V encoder 1 (5 V output) voltage is
encoder malfunction. In that case, replace the
voltage lower than 4.3 V.
defective one.
1. Verify if 12 V output is grounded, cause an
incorrect wiring to:
Alarm on 12 logic K1-17 terminal - Steering sensor
38 FA V output 1 (12 V output) voltage is - Buzzer
voltage lower than 10.5 V. - Display
2. Replace defective device;
1. Before starting to operate, turn off any active
Pump motor
You find a pump motor command (both levers and switches);
commands
50 FL 1 command active when you 2. Be sure that lift, tilt and auxiliary command
active on
turn your system on. switches, are not active;
start
3. Replace the valve board.
Check battery voltage at the each system.
Battery miss Battery is not suitable
60 60 1 (36V system must use 36V battery, 48V system
matching voltage to controller.
must use 48V battery)
195
EYE Error
Code Code
wires of the temperature connector (execute
the measure at ambient temperature of 25°C) .
If the measure is not correct it is necessary to
Drive motor The measure of right drive 2. Disconnect the temperature connector and
61 61 shutdown 1 motor temperature check the wiring insulation between signal
temperature exceeds 165☞. wire an ground wire ( towards logic);
Presence of alarm with hot motors :

When you start working,
you find seat switch open,
Seat switch
EE or, after the main breaker 1. Verify if seat switch is defective;
63 open on 1
(flash) is closed, the seat switch 2. Replace the logic.
start
remains opened for at least
“ seat switch delay” s.
1. verify if a switch was active or the pedal
pressed, when you turn on the lift truck;
When you start working,
2. verify if start, forward or reverse switches are
you find accelerator pedal
64 EE Wrong start 1 stuck close;
pressed or a forward/
3. verify if pedal circuit voltage exceeds 1/3 its
reverse switch active.
maximum range (measured in Volt);
operating mode, you have to measure about
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor The measure of pump 2. Disconnect the temperature connector and
65 65 shutdown 1 motor temperature check the wiring insulation between signal wire
temperature exceeds 165☞. and ground wire ( towards logic);

1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K1- 30 terminal
Drive motor An encoder channel is
- + 5 V: K1- 16 terminal
74 Fc Encoder 1 disconnected, and motor
- A channel: K1- 32 terminal
alarm is working.
- B channel: K1- 33 terminal
196
EYE Error
Code Code
1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K1- 30 terminal
Pump motor An encoder channel is
- + 5 V: K1- 16 terminal
76 76 encoder 1 disconnected, and motor
- A channel: K1- 35 terminal
alarm is working.
- B channel: K1- 36 terminal
Alarm of
drive motor
77 77
thermal
Temperature difference 1. Verify if the wiring is correct;
connector
7 between both motors 2. Replace the connector;
Alarm of
results greater than 70☞. 3. Replace the logic.
pump motor
79 79
thermal
connector
Alarm of
drive motor
80 80 7
module Temperature difference 1. Check the wiring connecting control unit and
connector between both power power module;
Alarm of modules results greater 2. Replace the power module;
pump motor than 70☞. 3. If alarm is still present, replace the logic.
82 82 7
module
connector
1. restore eeprom with EYE application software,
using the “RESTORE” item present in main
Faulty eeprom or page
CRC fault
83 83 1 mismatching software 2. Try to the default setting (LOAD EEPROM
alarm
release. DEFAULT-TOTAL LOAD EEPROM)
3. if alarm is still present, replace the logic.
CRC : Cyclic Redundancy Checking error.
There was an eeprom 1. Switch on the system and the turn it on again
Bank CRC
84 84 1 restore, caused by a CRC 2. Try to the default setting (LOAD EEPROM
restored
alarm. DEFAULT-TOTAL LOAD EEPROM)
1. verify correctness of wiring with :
- K1-17 (12 V),
Steering
Steer circuit voltage is out - K1-30 (ground)
91 F9 sensor 5
of nominal range. - K1-31 (steering sensor input);
alarm
2. if correctly wired, replace the steering sensor;
1. Check assembly of the 42pin main connector.
Pre-charge capacitor
Capacitors 2. Check cable connecting the Drive/Pump
voltage grows too slowly,
98 A pre -charge 1 output of the logic with the corresponding
when you turn on the
too slow power module.
system.
3. Replace the logic;
Pre-charge capacitors 1. Check assembly of the 42pin main connector.
Capacitors voltage does not reach the 2. Check cable connecting the Drive/Pump
99 A pre-charge 1 rated battery voltage output of the logic with the corresponding
too slow within a limit time, when power module.
you turn on the system. 3. Replace the logic;
197
Appendix F : Contraction for dot matrix display.
F1. Alarm Code
[Display Code] [Description] [Contraction]

17 Main breaker fault CONTACTOR FAULT
60 Battery/controller mismatch BATT MISMATCH
61 Drive Motor Shutdown Temperature R-MOTOR SHUTDOWN
65 Pump Motor Shutdown Temperature P-MOTOR SHUTDOWN
76 Pump motor Encoder P-MOTOR ENCODER
77 Wrong drive motor thermal sensor R-M TEMP SENSOR
79 Wrong pump motor thermal sensor P-M TEMP SENSOR
80 Wrong drive power module thermal probe R-INV T SENSOR
82 Wrong pump module thermal probe P-INV T SENSOR
83 CRC fault CRC FAULT
84 Bank CRC restored CRC RESTORED
A Capacitors not charged : fast charge FAST CHARGE
A Trans. precharge in short/Cap. too charged TOO CHARGED
A Capacitors not charged : slow charge CAP SLOW CHARGE
A Capacitors not charged : time out TIME OUT CHARGE
A Capacitors not charged CAP NOT CHARGED
E1 Drive power module Overtemperature R-INV OVERTEMP
E3 Pump module Overtemperature P-INV OVERTEMP
E4 Drive motor Overtemperature R-MOTOR OVERTEMP
E6 Pump motor Overtemperature P-MOTOR OVERTEMP
EE Wrong start WRONG START
EE(FLASING) Seat switch SEAT SW OPEN
EL Low battery voltage LOW BATT VOLT
F Eeprom EEPROM FAULT
F WD Timer/Enable micro signals WD TIMER FAULT
F Serial communication COMM FAULT
F0 Maximum battery voltage MAX BATT VOLT
F1 Minimum battery voltage MIN BATT VOLT
F2 Pedal trimmer fault ACCEL FAULT
F3 Drive power module Desat/overcurrent R-INVERTER FAULT
F5 Pump module Desat/overcurrent P-INVERTER FAULT
F6 Drive motor current Offset R-MOTOR I OFFSET
F8 Pump motor current Offset P-MOTOR I OFFSET
F9 Steer sensor fault STEER SENSOR OUT
FH 5V encoders not ok 5V NOT OK
Fc Drive motor Encoder R-MOTOR ENCODER
FE 24V out 24V NOT OK
FA 12V out not ok 12V NOT OK
FL Pump input on at the start PUMP SIGN ON
198
F2. Calibration Code

5 Deceleration steering ramp 1 STEERING DECEL1
6 Deceleration steering ramp 2 STEERING DECEL2
9 Battery reset value BATT RESET VALUE
10 First parameter for calibration enable 1ST PASSWARD
11 Seat switch delay SEAT SW DELAY
12 Chat time CHAT TIME
13 Hydro time HYDRO TIME
14 Maintenance time inserting enable SERVICE TIME ON
17 Second parameter for calibration enable 2ND PASSWARD
18 Steering sensor value : handle turned on the Max. left HANDLE TURN-L
19 Steering sensor value : handle turned on the Max. right HANDLE TURN-R
20 Steering sensor value : wheels on straight position WHEEL STRAIGHT
23 Accelerator pedal minimum value ACCEL MIN VALUE
24 Accelerator pedal maximum value ACCEL MAX VALUE
26 Stop on slop timer SLOP TIMER
27 Lift priority for speed reference LIFT PRI SPEED
30 Buzzer on forward direction FORWARD ALARM
31 Buzzer on reverse direction BACK UP ALARM
32 Lift sensor maximum value LIFT MAX VALUE
33 Lift sensor minimum value LIFT MIN VALUE
34 Lift sensor middle value LIFT START VALUE
35 Starting temperature of motor's Fans START MOTOR FAN
36 Weight of the load on the forks LOAD WEIGHT
37 No load pressure NO LOAD PRESSURE
38 Load pressure LOAD PRESSURE
39 Limitation temperature LIMIT TEMP
41 Drive maximum current DRIVE MAX I
42 Forward maximum speed FWD MAX SPEED
43 Reverse maximum speed REV MAX SPEED
44 Drive limitation max speed D LIMIT MAX SPD
46 High lift switch 1 drive max speed HIGH1 DRIVE MAX
47 Steer limitation drive max speed STEER LIMIT SPD
48 Drive acceleration ramp D ACCEL RAMP
49 Drive inversion ramp D INVERSION RAMP
50 Drive release ramp D RELEASE RAMP
51 Pedal brake ramp PEDAL BRAKE RAMP
52 Creep speed CREEP SPEED
53 Diameter of drive tires TIRES DIA
54 High lift switch 2 drive max speed HIGH2 DRIVE MAX
59 Partial release ramp PARTIAL RELEASE
61 Lift max current LIFT MAX CURRENT
62 Auxiliary max current AUX MAX CURRENT
63 Lift max speed LIFT MAX SPEED
64 Tilt max speed TILT MAX SPEED
65 Auxiliary 1 function speed AUX 1 SPEED
68 Lift min speed LIFT MIN SPEED
69 High lift 1 switch lift max speed HIGH1 LIFT LIMIT
70 Hydro speed HYDRO SPEED
71 Hydro idle speed IDLE SPEED
72 Pump acceleration ramp PUMP ACCEL RAMP
73 Pump deceleration ramp PUMP DECEL RAMP
74 High lift 2 switch lift max speed HIGH2 LIFT LIMIT
75 High lift 1 switch tilt max speed HIGH1 TILT LIMIT
199
76 High lift 2 switch tilt max speed HIGH2 TILT LIMIT
77 High lift 1 switch auxiliary 1 max speed HIGH1 AUX1 LIMIT
78 High lift 2 switch auxiliary 1 max speed HIGH2 AUX1 LIMIT
79 High lift 1 switch auxiliary 2 function max speed HIGH1 AUX2 LIMIT
94 Slow speed SLOW SPEED
95 British unit BRITISH UNIT
96 Display brightness LCD BRIGHTNESS
97 E-S-H enable E-S-H
98 Time meter / Odometer on display TIMER-ODOMETER
99 Maintenance time SERVICE PERIOD
200
F3. Diagnostic Code

1 Drive motor speed RIGHT MOTOR SPD
2 Drive motor speed reference R-MOTOR REF SPD
5 Lift lever voltage LIFT SENSOR OUT
6 Battery voltage BATT VOLTAGE
7 Drive motor power module temperature R-INVERTER TEMP
8 Pump motor power module temperature P-INVERTER TEMP
9 Pump motor speed PUMP MOTOR SPD
10 Pump motor speed reference P-MOTOR REF SPD
11 Accelerator potentiometer voltage ACCEL 1ST OUT
12 Accelerator second Potentiometer voltage ACCEL 2ND OUT
13 Steering sensor voltage STEER SENSOR OUT
15 Drive motor phase current R-MOTOR I-U
16 Drive motor phase current R-MOTOR I-V
17 Drive motor phase current R-MOTOR I-W
21 Pump motor phase current P-MOTOR I-U
22 Pump motor phase current P-MOTOR I-V
23 Pump motor phase current P-MOTOR I-W
24 Drive motor temperature R-MOTOR TEMP
26 Pump motor temperature P-MOTOR TEMP
27 Seat switch hour meter SEAT H METER
28 Drive motor hour meter DRIVE H METER
29 Pump motor hour meter PUMP H METER
30 Seat switch SEAT SWITCH
31 Park brake switch PARK SWITCH
32 Start switch SRART SWITCH
33 Reverse traction direction switch REV SELECT SW
34 Forward traction direction switch FWD SELECT SW
35 Pedal brake switch PEDAL BRAKE SW
37 Auxiliary 1 switch AUX 1 OUTPUT
40 High lift 1 switch HIGH LIFT 1 SW
41 Tilt switch TILT SWITCH OUT
42 High lift 2 switch HIGH LIFT 2 SW
43 Main breaker command CONTACTOR
44 5V out 5V OUT
45 12V out 12V OUT
46 24V out 24V OUT
47 Buzzer command BUZZER
48 Fans command FANS
49 Drive motor encoder channels R-MOTOR ENCODER
51 Pump motor encoder channels P-MOTOR ENCODER
52 lift pressure LIFT PRESSURE
53 Pressure sensor voltage PRESSURE OUTPUT
54 Weight of the load on the forks LOAD WIGHT
201

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What safety precautions are mentioned in the document?

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What components are described in the system specifications section?

What components are described in the system specifications section?

SB4200E02

B20S-5, B25S-5, B30S-5, B32S-5

for Electric Lift Trucks

The meaning of this safety alert symbol is as follows:

Attention ! Become Alert ! Your Safety is Involved.

Appendix A : 36[V] Parameter List .....................180

Preparation Tests and Check .............................. 27

Diagnostic and Troubleshooting

General Description ............................................. 49

Instrument Panel................................................ 125

TYPE 36/48 V 80 V TYPE 36/48 V 80 V

Assembly Layout of Controller

(1) Logic Board. Use a screw driver to hold screws

The advantages of using AC motors instead of 5 High speed Low speed

DC motor is made with a rotor with power windings

Because of great diffusion of AC motors and the

Because of DC motor more complexity, brush

The maintenance of DC motor must be continuous

AC motor has higher torque at high speed because

AC motor is safer than DC because if a short circuit

The AC controller is much more complex of a DC

In most of DC controllers are present auxiliary

Most of DC controller systems has zero torque

Because of 4 quadrants continuous transition and

3. An asynchronous three-phase pump motor for

1. A metallic container encloses control board (Fig.

2. There are three power modules (see fig 2 for

3. A 42 pins AMP connector (named K1), permits

4. Three 26 ways connectors (named Drive and

Fig. 2: Single power module (36/48V)

Working on electrical systems is potentially

Fig. 4: Power modules assembly with main contactor and

Fig. 6: View of accessible terminals on 42 ways connector

If divide greatly composition of electric controller

Each power unit controls each motor's speed, logic

Only one hydraulic pump motor is used for all power

Power Steering Circuit

The power steering speed of this vehicles operate

Lift Control Circuit Location Components

When the operator pulls the lift lever, magnet (3)

This control panel accept a linear speed lift signals

The drive control card uses a hall-effect transducer

Control Panel Horn Circuit

If the drive motor overheats a thermal sensor

The positive of the 12 volt output is common to the

1. Turn the range switch on the multimeter to read

Battery Tests 2. Connect the battery.

A weak battery can cause or contribute to problems <36/48 V>

1. Verify proper polarity at the battery connector

2. If the lift truck is operational, perform a battery

3. If the truck is not operational and the battery is

Battery Voltage Test.

3. Connect the multimeter leads between positive

4. In a safe area, operate the hydraulic system,