Repair Manual: C3E150 C4E150 C3E160 C4E160 C3E160L C4E160L C3E180 C4E180 C3E180L C4E180L C3E200 C4E200

REPAIR MANUAL
C3E150 C4E150
C3E160 C4E160
C3E160L C4E160L
C3E180 C4E180
C3E180L C4E180L
C3E200 C4E200
Code 036-0434-01 12/2010

Document changes history:
Edition Changes
036-0434-00 New version
036-0434-01 Chapter 00: modified the technical data
Chapter 01: general updating
Chapter 03: modified the display layout and any parameters
Chapter 04: modified the alarms 05-10-15-21-1C-1E-65-70-75-35-46-4E-C2
Chapter 15: modified “Mast performance tables”
Chapter 16: new “Main options” chapter
Chapter 17: modified new numeration to the “Appendix” chapter
This manual covers the following truck models:
Model Starting serial number Ending serial number

C3E150 CE351051
C3E160 CE349182
C3E160L CE351054
C3E180 CE351165
C3E180L CEXXXXXX
C3E200 CE348825
C4E150 CE348921
C4E160 CEXXXXXX
C4E160L CE351447
C4E180 CE349242
C4E180L CEXXXXXX
C4E200 CE351081
SECTION INDEX
NAME SECTION
GENERAL 0
BATTERY 1
CONTROLLERS 2
DISPLAY 3
TROUBLESHOOTING 4
MOTOR 5
DRIVE UNIT & FRONT AXLE 6
REAR AXLE 7
STEERING SYSTEM 8
BRAKE 9
BODY & FRAME 10
MATERIAL HANDLING SYSTEM 11
MAST 12
CYLINDER 13
OIL PUMP 14
OIL CONTROL VALVE 15
MAIN OPTIONS 16
APPENDIX 17
0-1
GENERAL
Page
VEHICLE EXTERIOR VIEW.........................................0-2
0
VEHICLE MODELS......................................................0-3
1
CHASSIS NUMBER .....................................................0-3
TRUCK CAPACITY AND IDENTIFICATION 2
PLATES .....................................................................0-4 3
TECHNICAL DATA - 3 WHEELS .................................0-5 4
TECHNICAL DATA - 4 WHEELS .................................0-7
5
HOW TO USE THIS MANUAL.....................................0-9
6
EXPLANATION METHOD ...................................................... 0-9
TERMINOLOGY.................................................................... 0-10 7
OPERATING TIPS......................................................0-12 8
GENERAL INSTRUCTIONS ................................................. 0-12 9
BATTERY RECYCLING/DISCARDING ................................ 0-13
10
JACK-UP POINT........................................................0-14
11
LIFTING THE VEHICLE .............................................0-15
12
MEMBER WEIGHTS ..................................................0-16
TOWING THE TRUCK .......................................................... 0-17 13
ELECTRICAL PARTS INSPECTION .........................0-18 14
TIGHTENING TORQUE TABLE.................................0-19 15
RECOMMENDED LUBRICANT QUANTITY 16
AND TYPES ............................................................0-20
17
PERIODIC MAINTENANCE.......................................0-21
PERIODIC REPLACEMENT TABLE .................................... 0-21 18
PERIODIC MAINTENANCE TABLE ..........................0-22 19
LUBRICATION CHART..............................................0-24 20
21
E
0-2
VEHICLE EXTERIOR VIEW

0-3
VEHICLE MODELS
Supply
Load capacity Control method
voltage (V)
1.5 ton AC microcomputer controller 48
1.6 ton ↑ ↑
1.8 ton ↑ ↑ 0
1.6 ton ↑ ↑
1
1.8 ton ↑ ↑
2.0 ton ↑ ↑
2
3
CHASSIS NUMBER
4
Serial number
Vehicle type Serial number position
format
5
3 Wheels CE000000 6
7
4 Wheels CE000000 8
9
10
11
12
13
14
15
16
17
18
0-4
TRUCK CAPACITY AND IDENTIFICATION PLATES

A) IDENTIFICATION PLATE
B) LOAD CAPACITY PLATE
The position of the plates, like shown in the image, refers to standard truck: this position could vary in case
of special trucks.
A
B
How to Read the Plates
3 A: Identification plate
MODELL Type
2 MOTOR RATED CAPACITY It identifies the lift truck technical data
1 kW kg 5 1. Vehicle model
SERIAL N° DRAW-BAR PULL (1 h)
2. Motor power
4 N
3. Nominal rated capacity
BATTERY MASS SEVICE MASS
kg kg Without 7 4. Truck serial number
6 min. max. Battery kg
5. Draw-bar pull
MANUFACT. YEAR BATTERY V
V
9 6. Battery weight (min/max)
8
7. Truck weight (without battery)
Cod.0311014
8. Year of manufacture
9. Battery voltage
10 CESAB Carrelli Elevatori S. p. A. 10. Notes
Via Persicetana Vecchia 10
40132 - Bologna - Italia
B: Load capacity plate

ATTACHMENT OR SPECIAL CONDITION OF USE 12
It identifies the load capacity with a load center of
11 TYRES SERIAL N° 600 mm (except for different indications)
13 11. Special model, Attachment model
LIFT HEIGHT CENTER OF LOAD DISTANCE mm
mm 12. Truck tyres
14 13. Attachment serial number
14. Load center
15. Lift height Rated capacity
15
Cod 0311013
DERATED CAPACITY Kg
CESAB Carrelli Elevatori S. p. A.

Via Persicetana Vecchia 10
40132 - Bologna - Italia
0-5
TECHNICAL DATA - 3 WHEELS
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0-6
1.5 - 2.0t
a [mm] = 200
CAPACITY DIAGRAMS (with SE tyres)
Barycentre [mm] Capacity [Kg] 1.5t Barycentre [mm] Capacity [Kg] 2.0t
500 1500 500 2000
600 1380 600 1840
700 1270 700 1680
800 1180 800 1500
900 1080 900 1330
1000 980 1000 1180
Barycentre [mm] Capacity [Kg] 1.6t

500 1600
600 1460
700 1340
800 1230
900 1110
1000 980

500 1800
600 1630
700 1480
800 1360
900 1250
1000 1150
0-7
TECHNICAL DATA - 4 WHEELS
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0-8
1.5 - 2.0t
a [mm] = 200
CAPACITY DIAGRAMS (with SE tyres)
Barycentre [mm] Capacity [Kg] 1.5t Barycentre [mm] Capacity [Kg] 2.0t
500 1500 500 2000
600 1380 600 1840
700 1270 700 1680
800 1180 800 1500
900 1080 900 1330
1000 980 1000 1180

500 1600
600 1460
700 1340
800 1230
900 1110
1000 980

500 1800
600 1630
700 1480
800 1360
900 1250
1000 1150
0-9
HOW TO USE THIS MANUAL

EXPLANATION METHOD
1 Operating procedure
(1) Operating procedures are described using either pattern A or pattern B.
(a) Pattern A: Each step of the operation is explained with its own illustration.
(b) Pattern B: The entire operation is indicated by step numbers in one illustration, followed by
cautions, notes, and point operations. 0
Example of pattern B
1
DISASSEMBLY · INSPECTION · REASSEMBLY
Tightening torque unit T=Nm 2
• Some step numbers may be 3
omitted in some illustrations. 4
• When a part requiring 2
1
4
tightening torque instruction is 3
not indicated in the illustration,
the part name is described in
5
the illustration frame. 7
6
5 6
T = 46.1 to 48.1
(470 to 490)
7
[34.0 to 35.5]
8
8
9
5
10
9 1
11
Disassembly Procedure 12
1 Remove the cover [POINT 1] Operation to be explained
2 Remove the bushing [POINT 2]
3 Remove the gear
13
Point Operations
Explanation of operation point with illustration
14
[POINT 1]
Disassembly: 15
Make match marks before removing the pump cover
[POINT 2] 16
Inspection:
Measure the bushing inside diameter. 17
Limit 19.12 mm
18
0-10
Matters omitted from this manual

This manual omits descriptions of the following jobs, but perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)
TERMINOLOGY
Caution:
Important matters, whose negligence may cause accidents. Be sure to observe them.
Note:
Important items, whose negligence may cause accidents or matters during operating so it is
required special attention.
Standard:
Value showing the allowable range in inspection or adjustment.
Limit:
The maximum or minimum value allowed in inspection or adjustment.
ABBREVIATIONS
Abbreviation Meaning Abbreviation Meaning

-- -- RH Right hand
Society of Automotive Engineers
ATT Attachment SAE
(USA)
Electronically controlled fully
EHPS SAS System of active stability
hydraulic power steering
FHPS Fully hydraulic power steering SST Special service tool
LH Left hand STD Standard
L/ Less T= Tightening torque
OPT Option T Number of teeth ( T)
O/S Oversize U/S Undersize
PS Power steering W/ With
ILLUSTRATIONS
Illustrations are supposed to point out the correct methods to work on the machine and its components,
therefore they could not display exactly the same elements.
0-11
SI UNITS
Meaning of SI
This manual uses SI units. SI represents the International System of Units, which was established to unify
the various systems of units used in the past for smoother international technical communication.
New Units Adopted in SI
Conventional Conversion rate(*))

0
Item New unit
unit (1 [conventional unit] = X [SI unit])
Force(**) N (newton) kgf 1 kgf = 9.80665 N 1
Torque(**) N·m kgf·cm 1 kgf·cm = 9.80665 N·m 2
(Moment)
Pressure(**) Bar kgf/cm2 1 Bar = 1 kgf / cm2 3
Pressure(**) Pa (pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
4
↑ ↑ mmHg 1 mmHg = 0.133322 kPa
Revolving speed rpm rpm 1 rpm = 1 r/min 5
Spring constant(**) N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
6
Volume l cc 1 cc = 1 ml
Power W PS system 1 PS = 0.735499 kW 7
Heat quantity W·h cal 1 kcal = 1.16279 W·h 8
Specific fuel consumption g/W·h g/PS·h 1 g/PS·h = 1.3596 g/kW·h
9
<Reference>
(*): X represents the value in SI units as converted from 1 [in conventional units], which can be 10
used as the rate for conversion between conventional and SI units.
(**): In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], 11
which should be used as the unit of force.
Conversion between Conventional and SI Units 12
Equation for conversion
13
Value in SI unit = Conversion rate × Value in conventional unit Conversion rate: Figure corresponding
Value in conventional unit = Value in SI unit ÷ Conversion rate

to X in the conversion rate column in
the table above
14
When converting, change the unit of the value in conventional or SI units to the one in the 15
conversion rate column in the table above before calculation. For example, when converting 100 W
to the value in conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 16
0.735499.
17
18
0-12
OPERATING TIPS
GENERAL INSTRUCTIONS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity
(3) Always disconnect the battery plug before the inspection or servicing of electrical parts
2. Skillful operation
(1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure
gauge, etc.) and SSTs before starting operation
(2) Check the cable color and wiring state before disconnecting any wiring
(3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts
neatly to prevent confusion
(4) When disassembling and inspecting a specific part such as the control valve, use clean tools and
operate in a clean location
(5) Follow the specified procedures for disassembly, inspection and reassembly
(6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each
time they are disassembled
(7) Use genuine Cesab parts for replacement
(8) Use specified bolts and nuts and observe the specified tightening torque when reassembling
(tighten to the medium value of the specified tightening torque range). If no tightening torque is
specified, use the value given in the “standard tightening torque table”
3. Protection of functional parts (battery operated vehicles)
Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each
connector for any connection failure or imperfect connection.
Failure or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers
4. Defect status check
Do not start disassembly and/or replacement immediately, but first check that disassembly and/or
replacement is necessary for the defect
5. Waste fluids and solid refuses disposal
Always use a proper container when draining waste fluids from the vehicle. Careless discharge of oil,
fuel, coolant, oil filter, battery, solid refuses or other harmful substance may adversely affect human
health and destroy the environment. Always collect and sort well this kind of materials, and treat them
properly requesting disposal by specialized companies and according to current laws
0-13
BATTERY RECYCLING/DISCARDING
This forklift truck uses a lead accumulator and, in case of

some battery-powered trucks, a lithium battery.
Materials contained in batteries (also accumulators) are
hazardous to the environment and humans and therefore
discarded batteries should be returned to the manufacturer
for recycling. 0
1
2
DISCARDING THE BATTERY
When the working life of the battery ends up (change for a new battery) or the truck has to be scrapped, it 3
is required a special attention to environmental risks when disposing/recycling batteries. Contact the
manufacturer for changing or discarding batteries. 4
RECYCLING 5
steel, brass, bronze, ABS, 6
1 BODYWORK plastic-reinforced fibre-glass,
4
1 polymers
7
steel, copper, nylon, graphite,
5 2 DRIVE UNIT
polymers
6
8
3 BRAKING UNIT steel, polymers, nylon
3
steel, copper, silicon, brass, 9
2 4 ELECTRIC UNIT aluminium, lead, zinc, graphite,
nylon, polymers 10
5 STEERING UNIT steel, bronze, polymers
HYDRAULIC steel, copper, bronze, brass,
11
6
UNIT aluminium, graphite, polymers
VARIOUS steel, copper, brass, aluminium,
12
COMPONENTS cast-iron, ABS, nylon, polymers
13
DISPOSAL OF In compliance with local
MINERAL OILS, directives.
GREASE AND Please dispose of in an
14
BATTERY environmentally friendly way!
15
16
17
18
0-14
JACK-UP POINT
Always observe the following instructions when jacking up the vehicle:
• When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an
inclined or rough surface.
• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up
at any other point is dangerous.
• Always support the load of jacked-up vehicle with wooden blocks at specified points.
Supporting the vehicle with the jack only is very dangerous.
• Never, under any circumstances, put any part of the body (including hands and feet) under the
jacked-up vehicle.
JACK-UP POINTS
0-15
LIFTING THE VEHICLE

When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist
by any other attachment section as it is very dangerous.
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0-16
MEMBER WEIGHTS
Member Vehicle tonnage 3W 4W Weight (Kg)
1.5 X X 673 ÷ 790
1.6
X X 813 ÷ 919
Battery 1.8
1.6L
1.8L X X 963 ÷ 1090
2.0
Drive motor all models X X 36

Pump motor (Hydraulic pump + electric motor) all models X X 43
Rear axle (without wheels and dry) Type 3 wheels all models X X 52
Rear axle (without wheels and dry) Type 4 wheels all models X X 86
1.5 - 1.8 - 2.0 X 862,11 ± 2%
1.6 - 1.8L X 713,62 ± 2%
Counterweight 1.6L X 565,89 ± 2%
1.5 - 1.8 - 2.0 X 729,19 ± 2%
1.6 - 1.6L - 1.8L X 623,55 ± 2%
Mast with lift brackets (with lift cylinder, without forks,

all models NA
lifting height 4350 mm, 2M TV)
1.5 X 3044
1.6 X 3067
1.6L X 3104
1.8 X 3299
1.8L X 3333
2.0 X 3483
Vehicle weight (w/battery)
1.5 X 2991
1.6 X 3055
1.6L X 3239
1.8 X 3243
1.8L X 3321
2.0 X 3427
0-17
TOWING THE TRUCK

Please follow the instructions of chapter 08, paragraph “NEGATIVE BRAKES MANUAL
UNBLOCKING“
The standard fork lift trucks are not suited for towing.
In special case, the rear draw bar can be used to tow a faulty
lift truck.
In this case it is obligatory to use a stiff towing bar, fastened 0
between the rear draw bar of the truck and the towing
vehicle. You must proceed carefully and slowly, if possible on 1
a level surface.
• while towing, do not carry any other loads on the forks; 2
• as far as possible, avoid driving on gradients. In any case,
do not go over the figure for driving on gradients with a 3
load.
Note the cautions below when towing the vehicle with

4
back wheels lifted.
5
• Lift the rear wheels for towing
• The traveling speed when towing must not exceed the
maximum traveling speed of the forklift
6
• Before starting towing, always set the key switch to OFF,
the direction switch to the neutral position and parking 7
brake of released
• Before towing, either remove the fork or take action to 8
prevent the fork from coming into contact with the ground
due to bouncing 9
When making a curve, towed loads tend to reduce the
curving radius; therefore it is important to widen the entrance 10
radius in order to avoid striking against any obstacle.
11
12
13
14
15
16
17
18
0-18
ELECTRICAL PARTS INSPECTION

1. Always disconnect the battery plug before inspecting or servicing electrical parts.
2. Pay sufficient attention when handling electronic parts.
(1) Never subject electronic parts, such as computers
and relays, to impact.
(2) Never expose electronic parts to high temperature or
moisture.
(3) Do not touch connector terminals, as they may be
deformed or damaged due to static electricity.
3. Use a circuit multimeter that matches the object and purpose of measurement.
Analog type: This type is convenient for observing movement during operation and the operating
condition. Measured value is only a reference
Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or
movement.
Difference between results of measurement with analog and digital types
∗ The results of measurements using the analog type and the digital type may be different.
Differences between the polarities of the analog type and the digital type are described below.
1) Analog circuit multimeter
Forward Reverse
Example of measurement result
Multimeter range: 1 kΩ
Analog type
Continuity
Forward
11 kΩ
No continuity
Reverse
∞
2) Digital circuit multimeter
Forward
Example of measurement result
Reverse
Multimeter range: 2 MΩ
Digital type
No continuity
Forward
1
Continuity
Reverse
2 MΩ
0-19
TIGHTENING TORQUE TABLE

The tables here below are valid for screws and bolts without superficial covering, preventively lubricated
with oil.
SCREWS WITH “ISO” METRIC COARSE THREAD
Nominal PRELOADING V (N) TORQUE Max (Nm)

diameter 6D 8G 10 K 12 K 6D 8G 10 K 12 K 0
mm 6,6 8,8 10,9 12,9 6,6 8,8 10,9 12,9
6524 1,7 3 4,2 5,1
1
M 4 x 0,7 21781 3865 5435
M 5 x 0,8 3502 6229 8780 10497 3,2 5,8 8,2 9,9
M6x1 4974 8849 12459 14911 5,7 10 14,3 17,1 2
M7x1 7142 12753 17854 21386 9,2 16,6 23 27,8
M 8 x 1,25 9025 16088 22661 27174 13,6 24,3 34 41,1 3
M 9 x 1,25 11870 21190 29921 35610 20,1 36 50,8 60,5
M 10 x 1,5 14519 25506 35905 42968 27,8 49 69 82 4
M 12 x1,75 20797 37082 52189 62588 46,5 83 117 140
M 14 x 2 28351 50620 71123 85347 74 132 186 223
M 16 x 2 38750 68866 97119 116739 113 200 283 339
5
M 18 x 2,5 47480 84366 118701 142245 157 279 392 471
M 20 x 2,5 60430 107910 151565 181485 218 388 545 653 6
M 22 x 2,5 74850 133416 187371 224649 294 520 731 883
M 24 x 3 87309 155979 218763 261927 383 687 961 1148 7
M 27 x 3 112815 202086 283509 340407 549 991 1393 1668
M 30 x 3 138321 247212 347274 415944 755 1354 1893 2276 8
SCREWS WITH “ISO” METRIC FINE THREAD
9
Nominal PRELOADING V (N) TORQUE Max (Nm)
diameter 6 D* 8 G* 10 K* 12 K* 6 D* 8 G* 10 K* 12 K* 10
mm 6,6* 8,8* 10,9* 12,9* 6,6* 8,8* 10,9* 12,9*
M8x1 9761 17168 24231 29038 14,5 25,5 36,2 43
11
M 10 x1,25 15107 26879 37867 45420 28,4 51 72 85
M 12 x1,25 23740 40613 56898 68474 52 89 126 151 12
M 12 x1,5 21778 38848 54642 65531 49 87 123 147
M 14 x 1.5 30902 54936 77303 92705 78 140 196 235 13
M 16 x 1,5 41202 73575 103005 123606 118 211 294 353
M 18 x 1,5 53268 95157 133416 159903 171 304 422 510 14
M 20 x 1,5 67689 118701 168242 202086 239 422 598 716
M 22 x 1,5 82404 147150 206010 247212 314 564 790 952
M 24 x 2 94667 168732 237402 284490 402 721 1010 1216
15
M 27 x 2 122625 218763 307053 367875 589 1050 1472 1766
M 30 x 2 154017 272718 384552 461070 814 1442 2040 2453 16
* = screw class 17
18
0-20
RECOMMENDED LUBRICANT QUANTITY AND TYPES

Applicable place Capacity Type
Drive unit, differential 0,35 l - ATF DEXRON II
Hydraulic oil 18,5 l - AGIP ARNICA 46
Hydraulic oil brake 0,25 l - DOT 4
Chassis and mast
Proper amount - MOBIL GREASE SPECIAL
Grease fitting
* = refilling with same type of oil and grease

** = from factory
0-21
PERIODIC MAINTENANCE
Periodic inspection and maintenance are necessary to keep your Cesab industrial vehicle running
smoothly. The designated number of hours for each inspection cycle is as follows.
Daily (pre-operation check) ........................... Every 8 hours
Weekly ............................................................. Every 40 hours
6-week ............................................................. Every 250 hours
3-month ........................................................... Every 500 hours 0
6-month ........................................................... Every 1,000 hours
12-month ......................................................... Every 2,000 hours 1
If operating hours in 6 weeks exceed 250 hours, perform inspection according to the operating hours
specified in the periodic inspection guide. 2
Pre-operation checks and weekly inspections should preferably be performed by the user. 6-week, 3-
month, 6-month and annual inspections should be performed at the Manufacturer’s Service Centre, as 3
high skill and special tools are required.
Refer to the periodic maintenance table to determine inspection and maintenance items and inspection
cycles.
4
Use only genuine original parts for replacement, and use the recommended types of lubricants.
5
PERIODIC REPLACEMENT TABLE
REPLACEMENT CYCLE 1 6
6
every 3 6 12 18 months
(Based on total operating months or WEEK WEEKS
hours, whichever comes first) every 40 250 500 1000 2000 3000 hours 7
Hydraulic oil ←
Hydraulic filter * ← 8
Drive unit oil * ←
Oil tank breather filter *1 ←
9
Brake fluid ←
Hoses from power steering unit to steering
10
(every 30 months or 5000 hours)
cylinder
Service brake and parking brake hoses (every 30 months or 5000 hours) 11
Tilt cylinder hydraulic hoses (every 30 months or 5000 hours)
Steering system hoses (every 60 months or 10000 hours) 12
Lifting chains (every 60 months or 10000 hours)
Chain securing tie rods (every 60 months or 10000 hours) 13
High pressure hydraulic tubing (every 60 months or 10000 hours)
14
*:
For new vehicles
*1: For dusty environments
15
16
17
18
0-22
PERIODIC MAINTENANCE TABLE

INSPECTION METHOD
I: Inspect, correct and replace as required. T: Tighten. C: Clean. M: Measure and correct, and adjust as
required.
1
REPLACEMENT CYCLE (Based on total operating EVERY WEEK 3 6 12 months
months or hours, whichever comes first)
EVERY 40 500 1000 2000 hours
CHASSIS and CONTROLS
Chassis cleaning I ←
Chassis damage and craking I ←
Chassis bolts T* I ←
Operator seat, seat belt I ←
Wheel rims and nuts I ←
Brake fluid I ←
Brake fluid warning light I
Steering system I ←
Steering system seals and hoses I ←
Hoses from power steering unit to steering cylinder I ←
Steering assembly and wheel hubs I ←
DRIVE SYSTEM
Drive system seals T* T ←
Transmission reduction gear oil / Differential oil I ←
Complete system I ←
Brake lining wear I*1
Service brake and accelerator I ←
Service brake hoses I ←
ELECTRICAL SYSTEM
Electronic control unit I ←
Safety systems controls I ←
Electric motors C ←
Motor mountings I ←
Contactors I ←
Cable terminals and sheaths I ←
Battery terminals and poles I ←
Push-buttons I ←
Parking brake I ←
0-23
1
REPLACEMENT CYCLE (Based on total operating EVERY WEEK 3 6 12 months
months or hours, whichever comes first)
EVERY 40 500 1000 2000 hours
MATERIAL HANDLING SYSTEM
Forks deformation, damage and craking I ←
Forks positioning pins I ←
Fork carriage position I ←
Carriage and sideshift guide pads T* I ← 0
Mast deformation, damage and craking of the welded I ←
portion 1
Mast tilting system I ←
Mast fasteners T ← 2
Mast guides I ←
Lifting cylinder collars I ← 3
Lifting chains I ←
Chain securing tie rods I ← 4
Tilt cylinder fasteners I ←
Tilt cylinder nuts T ← 5
Hydraulic seals and connections I ←
Load handling controls I ← 6
*
*1:
: For new vehicles 7
Inspection every 10000 hours
8
Note:
In case of hard operating conditions, the service interval of 170 hours or 1 month may be
recommendable.
9
WARNING: 10
Complete the information concerning all maintenance operations with those mentioned in the
relevant safety and operator manuals 11
12
13
14
15
16
17
18
0-24
LUBRICATION CHART
1. Fork positioning pins

2. Chain securing tie rods
3. Mast guides
4. Lifting chains
5. Mast fasteners
6. Drive units
7. Brake fluid reservoir
8. Oil tank
9. Rear wheels bearing (4 wheels model)
I Every 1000 hours (6 months)
II Every 2000 hours (annually)
Inspection and supply
Replacement
* Located both right and left
(A) Molybdenum disulfide grease
(B) Motor oil
(C) Gear oil
(D) Hydraulic oil
(E) Brake fluid
1-1
BATTERY
Page
BATTERY COMPARTMENT AND REQUIRED
WEIGHT .................................................................... 1-2
BATTERY SERVICE STANDARDS ............................. 1-3 1
DISPLAY ...................................................................... 1-3
BATTERY MANAGEMENT .....................................................1-4
1
ADJUSTING THE BATTERY AND THE 2
INDICATOR ............................................................... 1-5
3
ADJUSTING THE BATTERY VOLTAGE READING...............1-5
4
ADJUSTING THE BATTERY INDICATOR..............................1-6
TROUBLESHOOTING ON THE BATTERY............... 1-10 5
INSPECTION.............................................................. 1-11 6
STATE OF BATTERY CHARGE ................................ 1-13 7
BATTERY CAPACITY ................................................ 1-14
8
GEL BATTERIES ....................................................... 1-15
9
ADJUSTING THE GEL BATTERY INDICATOR ...................1-16
BATTERY ................................................................... 1-17 10
REPLACING BATTERY PLUG TERMINAL .............. 1-19 11
12
13
14
15
16
2
18
1-2
BATTERY COMPARTMENT AND REQUIRED WEIGHT

When the battery is purchased locally, always adjust the weight to satisfy the minimum required weight,
as shown in the table below.
Battery compartment
Battery capacity dimensions [mm] Weight
Vehicle tonnage
(A H) (with case) [Kg]
X Y Z
420 522 830 627 673 ÷ 744
1.5 460 522 830 627 673 ÷ 744
500 522 830 627 673 ÷ 790
525 630 830 627 813 ÷ 899
1.6-1.8 575 630 830 627 813 ÷ 899
625 630 830 627 813 ÷ 919
630 738 830 627 963 ÷ 1064
1.6L-1.8L-2.0 690 738 830 627 963 ÷ 1064
750 738 830 627 963 ÷ 1090
Din standard battery (DIN 43531 48V type A)

1-3
BATTERY SERVICE STANDARDS

Specific gravity (battery charged) 1,290 [30 °C]
Specific gravity (80% battery discharged) 1,130 [30 °C]
Discharge end voltage 48 V 47,28 V *
1
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled or demineralized water 2
Insulation resistance 10MΩ or more
* Battery value on standby (only with key ON and no power consumption)
3
DISPLAY 4
Battery Charge Indicator 5
(A) Diagnostic led
(A) (B) Charge indicator 6
(B) 7
8
9
Charge Acustic
Description Notes
Percentage notice 10
11
Normal working No No performances drop
12
100-20%
13
Performances drop
Speed reduction managed 14
Illuminated (B) from the parameters
No
Indicator T20% BDI REDUCTION (traction) 15
P20% BDI REDUCTION (lifting)
15% (2 led) **
16
Drop of performances
Blinking (A) Led,
Speed reduction managed 17
from the parameters
illuminated (B) No
Indicator
T10% BDI REDUCTION (traction) 18
P10% BDI REDUCTION (lifting)
10% (1 led) **
18
Blinking (A) Led, Discharged battery, managed

18
illuminated (B) Yes from the parameter BDI ADJ MIN
Indicator (priority function for traction) 18
0%***
18
** The drop of performances is due to the selected profile
*** It corresponds to less than 10 % of the nominal battery charge 18
1-4
BATTERY MANAGEMENT
Notes: The values of the parameters for setting the battery indicator refer to the voltage on the
key input of the Master traction logic unit (reference Pin 1 Connector P1)
Battery discharge voltage and status indicator on the dashboard are managed by the Master traction
logic unit.
The personalization of the indicator is effectuated modifying below described parameters.
BDI adjust min

This parameter determines the SET POINT of discharge voltage.
It is expressed in volt and permits an adjustment.
BDI adjust max
This parameter determines the SET POINT of charge voltage.
It is expressed in V and permits an adjustment.
ADJUSTMENT 3
This parameter determines the necessary voltage to effectuate the rearm of battery indicator on the
display.
BDI RESET
This parameter permits the adjustment of rear threshold when it is requested a charge with a status of
battery between 70% - 90%.
The indication of THRESHOLD at 60% shows rearm not available over 70% of battery charge.
Necessary voltage for the rearm

of the battery indicator = 51,020 V
ADJUSTMENT 3
Charge battery indicator = 49,680 V

BDI ADJ MAX
Minimum threshold for battery
indicator rearm = 60%
BDI RESET
Discharge battery indication = 45,360 V

BDI ADJ MIN
Notes:
• The battery indicator can be rearmed if battery charge level is lower then 60%:
• The battery indicator can not be rearmed if:
- “ADJUSTMENT 3” values are less than “BDI MAX”
- After charging, the battery level does not reach a value higher than “BDI MAX”
1-5
ADJUSTING THE BATTERY AND THE INDICATOR

ADJUSTING THE BATTERY VOLTAGE READING
ADJUST BATTERY parameter
Notes: The values of the parameters for setting the battery indicator refer to the voltage on the 1
A correct adjustment allows a precise indication of the battery discharge. 2
The ADJUST BATTERY parameter is used to set the voltmeter inside the MASTER traction logic unit.
Notes: This parameter can be acquired with any battery discharge percentage.
3
4
[POINT 1]
Connect the battery and turn on the truck. Using a 5
multimeter, measure the voltage between Pin 1 of the
connector P1 of the MASTER traction logic unit and the
negative pole of the battery ( - ). 6
Notes: The voltage measured between Pin 1 of the 7
connector P1 of the Master traction logic unit and the
negative pole of the battery ( - ) differs from the real 8
voltage measured between the ( + ) and the ( - ) of the
battery because of a voltage drop due to the truck's
own system.
9
10
[POINT 2] 11
Access the SERVICE menu (see chapter 3, paragraph
SERVICE MENU DESCRIPTION). Set the voltage 12
measured at [POINT 1] in the SERVICE -> LEARNING ->
menu, parameter ADJUST BATTERY 13
14
15
16
17
18
18
18
18
18
Notes: The values shown in the various figures are indicative 18
1-6
ADJUSTING THE BATTERY INDICATOR

Parameters ADJUSTMENT 3 and BDI ADJ MAX
The battery indicator must be adjusted according to the characteristics and type of the battery.
ADJUSTMENT 3
The parameter ADJUSTMENT 3 is used to set the voltage that the battery must exceed at end of charge
to be able to reset the truck battery indicator (indicator at 100%).
BDI ADJ MAX
The parameter BDI ADJ MAX is used to set the voltage at which the first two squares of the battery
indicator switch off (indicator at 90%).
[POINT 1]
At the end of complete charging.
Disconnect the battery from the battery charger and
connect it to the truck.
Notes: Ensure that the battery completes the whole

charge cycle; if the battery does not reach a density of
1.29 kg/l [30°C] on completing the charge, check the
state of the battery (see chapter 1, paragraph
INSPECTION) and of the battery charger.
If necessary, apply to the battery supplier.
[POINT 2]
Let the truck work normally for about 15 minutes.
Using a multimeter, measure the voltage between Pin 1 of
the connector P1 of the Master traction logic unit and the
negative pole of the battery ( - )
Notes: The voltage measured between Pin 1 of the

connector P1 of the Master traction logic unit and the
negative pole of the battery ( - ) differs from the real
voltage measured between the ( + ) and the ( - ) of the
battery because of a voltage drop due to the truck's
own system.
Notes: The values shown in the various figures are indicative.

1-7
[POINT 3]
SERVICE MENU DESCRIPTION). Set the voltage
measured at [POINT 2] in the SERVICE -> TRUCK CONF
-> BATTERY -> menu, parameter BDI ADJ MAX
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
1-8
[POINT 4]
SERVICE MENU DESCRIPTION). Add 0.5 V to the voltage
measured at [POINT 2] and insert it in the SERVICE ->
TRUCK CONF -> BATTERY -> menu, parameter
ADJUSTMENT 3
FORMULA:
ADJUSTMENT 3 = BDI ADJ MAX + 0,5 Volt
Notes: The battery runs down if it is not used.

It is recommended to connect the battery and turn on
the truck when charging is finished, to ensure that the
indicator resets.

1-9
Parameter BDI ADJ MIN

The indicator may be set to modify the minimum battery voltage at which the last square switches off
(indicator at 0%).
At the end of discharging, the density value of the battery elements must not fall below 1.13 kg/l
1
2
[POINT 1]
SERVICE MENU DESCRIPTION). Modify the value in the
3
SERVICE -> TRUCK CONF -> BATTERY -> menu,
parameter BDI ADJ MIN to increase or decrease the 4
maximum battery discharge.
5
Notes: Periodically check the electrolyte density in the 6
battery elements at the end of discharge.
If the density is lower than 1.13 kg/l, increase the
parameter BDI ADJ MIN by a value of 0.24 V for every
7
0.01kg/l up to the limit of 1.13 kg/l.
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
1-10
TROUBLESHOOTING ON THE BATTERY
Plate corrosion Sulfation Plate warpage and active substance freeing
Improper charging
Repeated
Long storage overdischarge
Battery without operations and overcharge
life end Short circuit procedures
between cells
Defect of Excessive charging
the electrolyte current
Insufficient
Defective Electrolyte
electrolyte
Excessive
Battery defect
Overdischarge ambient
temperature
Cells crack
Improper or chipping
Damaged
separator water
supply Imperfect
Overcharge terminal
connection
Depositined of free Fouled terminal or

active substance at connecting plug
bottom of the cells
Short circuit Electrolyte leakage and reduction Loosened or corroded connection
DEFECT CAUSE REMEDY

• Battery runs down rapidly during the work • Battery does not have an adequate capacity for • Moderate current consumption or charge more frequently
period the type of work • If necessary, replace the battery
• Battery is very old • Check the battery charger
• Battery not completely charged
• Battery runs down rapidly • Excessive current consumption • Check the load lifted by the truck
• Low voltage, truck goes slowly during work • Truck motor overloaded, especially when going • Lubricate and check the motor mechanical parts
• Electrolyte heats up up a slope • If necessary, fit a battery with a higher capacity
• Battery charger with high current at end of • Check the battery charger
charge
• Density not the same • Faulty insulation of some electric device in the • Examine the insulation
• Contacts shorting to earth truck or battery • Clean the case and the elements
• Current leakage • Battery has cracked cells or dirty elements • Renew the insulating coating
• Metal case has faulty insulation • Repeat the final charge
• Intermediate current sockets • Eliminate too high and/or continuous intermediate current
sockets
• Battery runs down rapidly • Plates short circuiting in some battery elements • Replace faulty elements
• Truck slow, low voltage
• Acid heats up
• Density not the same
• Density too low while charging
• Charge voltage too low
• High water consumption
• Battery runs down rapidly • Electrolyte density too low due to acid leakage • If the density does not increase with a trickle charge, the
• Electrolyte density too low during • Frequent and excessive top-ups electrolyte density must be restored
charging by adding acid.
• Battery runs down rapidly • Poles loose or oxidized • Tighten the contacts of the poles and clean them accurately
• Truck slow, poor performance
• Charge voltage too high
• Charge current too low
• Acid heats up • Charge time set too long • Adjust the point of intervention of the timer
• Charge time too long The timer intervenes late and prolongs the
• High water consumption charge
• Battery runs down rapidly • Charge time set too short • Adjust the point of intervention of the timer
• Density not the same The timer intervenes early • Increase the recharging time
• Density too low during charging • Insufficient time for recharging • Replace the battery charger with a more powerful one
1-11
INSPECTION
1. Electrolyte levels Inspection:
Before starting the inspection, ensure that the battery has been at rest for at least 30 minutes. Open
the caps of each single battery element and check that electrolyte level is high enough to cover the
element plates. Otherwise the electrolyte level must be restored with distilled or demineralized water
up to cover the superior edge of the plates exceeding for 5÷7 mm. Avoid to fill up over this limit, 1
because it may cause the electrolyte leakage because of his expansion during the operation or next
battery recharge, with consequent risk of battery compartment corrosion, of electric isolation 2
reduction and of battery discharge. Carry out the level control and, if needed, the possible filling, with
charged battery
3
2. Electrolyte inspection:
The battery electrolyte is normal when it is transparent. 4
Check turbidity when inspecting the specific gravity. If
it cannot be checked clearly, put the electrolyte in a
beaker for inspection.
5
The check must always be carried out on several
cells, because the density may differ from one 6
element to another
7
8
9
3. Battery electrolyte specific gravity inspection:
Use a hydrometer to measure the specific gravity of
the electrolyte.
10
Specific gravity upon complete charging .... 11
1.280 [20 °C]
Specific gravity upon end of discharge .... 12
1.150 [20 °C]
13
14
The density measurement varies according to the
electrolyte temperature, it is advisable always to 15
measure the electrolyte temperature at the same time
as the density. 16
To have the exact density value, each measurement
must be considered in relation to the standard 17
temperature of 30°C.
Equation for converting the real measured density
18
with the ideal density at 30°C.
D30 = Dr + [ 0.0007 (Tr - 30) ] 18
D30: Ideal density at 30°C
Dr: Real density measured at temperature Tr °C 18
Tr: Real temperature of the electrolyte (°C)
18
18
18
1-12
* How to use the hydrometer

(1) Insert the nozzle of the hydrometer into the
electrolyte port and allow the electrolyte to be
Hydrometer
sucked into its outer tube.
Rubber (2) Let the hydrometer float correctly without contact
bulb with the outer tube, top or bottom, and read the
Out tube scale at the highest point of the electrolyte surface
as illustrated on the left when the bubbles in the
electrolyte disappear.
Nozzle
(3) After the measurement, wash hydrometer well
inside and outside with clear water and store it after
wiping water off with clean cloth.
4. Insulation resistance inspection

Measure the resistance between battery and battery
case with an insulation resistance meter
(megohmmeter).
Insulation resistance .... 1 MΩ or more
Note:
When the insulation resistance is less than 1 MΩ, wash
the battery with water after removing it from the
vehicle.
Dry washed battery fully and measure the insulation
resistance again. Install battery on the vehicle after
confirming that the insulation resistance is 1 MΩ or
more.
* Battery control table

Prepare a control table for each battery to record and maintain inspection results.
Time and date Specific gravity Temperature Capacity

Inspected element Nr. Note Inspector
Inspection Electrolyte Electrolyte added water
1-13
STATE OF BATTERY CHARGE

The state of charge of a battery is measured by means of the electrolyte density.
Before measuring the electrolyte, ensure that the battery has been at rest for at least 30 minutes (see
previous paragraph).
Notes: The tables below represent ideal discharge values of lead-acid batteries 1
Electrolyte density vs Discharged capacity
2
3
RECOMMENDED
Electrolyte density (kg/l)
DISCHARGE LIMIT 4
5
6
7
8
Discharged capacity (%)
9
It is possible to convert the density (kg/l) approximately into voltage (V) for an indication of the state of
charge.
Formula: Density = (Volt / n° cells) - 0.84
10
Cell voltage vs Discharged capacity 11
12
RECOMMENDED
Cell no-load voltage (V)
DISCHARGE LIMIT
13
14
15
16
17
Discharged capacity (%) 18
Battery discharge limits 18
Discharge protracted beyond the established limits makes recharging more difficult, as a longer time is
required.
This happens on batteries that are removed from charging before they have been completely charged.
18
At the next discharge they may be discharged to an even lower point, triggering an incorrect charge-
discharge cycle which, with time, will cause permanent damage. 18
Notes: The acid density limit below which it is not advisable to discharge the battery may be
roughly considered as 1.13 Kg/l. 18
When the battery has run a long way down, it is important to recharge it as soon as possible.
It is advisable not to leave it completely discharged for more than one day. 18
Discharging the battery by more than 80% of its capacity means considerably reducing its life
cycle.
1-14
BATTERY CAPACITY
The capacity of a battery is the amount of electricity that it can supply to an external circuit
before the voltage falls below the final limit value; it is expressed in Ah (Ampere-hour)
The main factors that influence the capacity of lead-acid batteries are:
(1) Discharge rate
The capacity supplied at high discharge rates (high current intensity) is lower than that supplied at
low discharge rates (low current intensity).
The causes of the decrease in the capacity supplied at high rates are the following:
(a) Sulphation of the plate surface, which closes the pores of the active material;
(b) Limited time for electrolyte diffusion;
(c) Loss of voltage due to the accumulator internal resistance.
(2) Electrolyte specific gravity
The specific gravity of the electrolyte influences the voltage and the capacity for the following
reasons:
(a) It determines the potential of the plates;
(b) It influences the electrolyte viscosity and therefore its diffusion speed.
(3) Electrolyte temperature
Batteries operating in environments at low temperature undergo a temporary decrease of the
capacity available and of the voltage (the rated capacity and voltage values are restored when
the temperature returns to normal).
An increase in the battery temperature leads to an increase in its capacity.
The effect of the temperature on the capacity is due to the variations of the viscosity and
resistance of the electrolyte.
At low temperatures the viscosity increases and this reduces the rate of diffusion of the acid in the
pores of the active material.
The temperature effect is more sensitive at high discharge rates.
Due to the effect of the electrolyte temperature, the battery capacity varies as shown in the
diagram below.
CAPACITY ACCORDING TO ELECTROLYTE TEMPERATURE

Capacity (%)
Temperature (°C)
(4) Battery age

Traction batteries give their rated capacity after a few work cycles (charges and discharges), then
maintain their performance for a considerable period of time (about 1500 cycles), depending on
battery .
1-15
GEL BATTERIES
The following paragraph provides general information on gel batteries.
For more detailed information, refer to the supplier of the installed battery.
It is possible to install and use GEL batteries on the forklift truck; always adapt their weight so as to
respect the minimum weight required, as indicated in the table in the paragraph "BATTERY CASE AND
REQUIRED WEIGHTS".
1
In GEL batteries the electrolyte is immobilized (sulphuric acid in gel form), unlike traditional batteries 2
where the electrolyte is in liquid form.
Notes: In GEL batteries the density cannot be measured. 3
In place of the caps, valves are fitted which perform the function of adjusting the internal pressure of the
elements, opening in the event of excess pressure to let out the excess gases developed during 4
charging and, at the same time, preventing the oxygen in the atmosphere from getting inside.
5
MAINTENANCE
The GEL battery does not need intense maintenance like traditional batteries. 6
• The battery never needs topping up.
• The valve caps must not be removed.
If the valves should accidentally be damaged, contact the service centre of the battery supplier to have
7
them replaced.
8
The battery must be kept clean and dry to prevent current leakage. Any liquid present inside the battery
case must be removed. Immediately repair any breaks in the coating of the case, to prevent drops in
insulation and corrosion of the case. If this operation requires the removal of the elements, call the 9
service centre of the battery supplier.
Every month, at the end of charging and with the battery disconnected from the battery charger, check
10
the battery voltage and the voltage of every single element, recording it on a special chart.
If a significant variation is found with respect to the previous record, carry out a new series of checks on 11
the data found and, if necessary, request the intervention of the service centre of the battery supplier .
If the autonomy is not sufficient, proceed as follows:
12
• Check that the work being done is compatible with the battery capacity;
• Check the state of the rectifier; 13
• Check the discharge limiter.
DISCHARGE
14
In order to guarantee a good battery life, the battery must not be discharged below 80% of the rated 15
capacity (full discharge) which corresponds to 1.83 V per element.
Notes: It is important for the battery temperature to remain between +5°C and + 35 °C during the 16
work cycle. The battery life will be optimal with a temperature between 25-30 °C.
CHARGE 17
The complete charge of the battery must be carried out at the end of every shift. Do not leave the
batteries discharged for long periods of time. 18
The batteries must be charged using high-frequency battery chargers indicated by the battery supplier,
choosing a rectifier different from the one indicated by the supplier may cause damage to the battery. 18
The room where the battery is being charged must be ventilated.
18
NOTES: It is necessary to wait a sufficient time for the battery to cool before using it once
charging is complete.
18
18
18
1-16
ADJUSTING THE GEL BATTERY INDICATOR

If the truck is equipped with a GEL battery, the following adjustments must be made to calibrate the
battery indicator.
Necessary voltage for the rearm

of the battery indicator = 51,020 V
ADJUSTMENT 3
Charge battery indicator = 50,640 V

BDI ADJ MAX
Minimum threshold for battery
indicator rearm = 60%
BDI RESET
Discharge battery indication = 46,464 V

BDI ADJ MIN
(1) Set the discharge curve for gel batteries:

Parameter BDI GEL set ON (see chapter 3 paragraph TRUCK CONF)
(2) Adjust the internal voltmeter of the MASTER traction logic unit:
Parameter ADJUST BATTERY (see paragraph Adjusting the battery voltage reading)
(3) Adjust the indicator reset threshold:
Parameter ADJUSTMENT 3 (see paragraph Adjusting the battery indicator)
(4) Adjust the charge threshold corresponding to 90% residual charge:
Parameter BDI ADJ MAX (see paragraph Adjusting the battery indicator)
(5) Adjust the maximum discharge threshold corresponding to 0% residual charge:
Parameter BDI ADJ MIN
(the value of this parameter must not fall below 43.92 V laden and 47.52V unladen)
Periodically check the voltage of the single battery elements at the end of discharge.
The voltage must not be lower than 1.83 V per element laden and 1.98 V unladen
(corresponding to a total charge of 43.92V laden and 47.52V unladen) at the end of
discharge (corresponding to 0% of the battery indicator on the display).
Otherwise increase the value of the parameter BDI ADJ MIN until it reaches the allowed
limit threshold of 1.83 V laden and 47.52V unladen.
If the battery indicator is not adjusted, it will not be possible to have a correct reading of the
battery charge, risking serious damage to the battery itself.
1-17
BATTERY
DISASSEMBLY • REASSEMBLY
1
2
3
4
5
6
7
8
9
10
Disassembly Procedure
1. Park the truck on a level surface and activate the parking brake 11
2. Switch off the truck
3. Open the battery covers and disconnect the battery plugs 12
4. Remove the lateral sides [Point 1]
5. Remove the battery safety locks [Point 2]
6. Remove the battery [Point 3]
13
Reassembly Procedure 14
The installation procedure is the reverse of the disassembly procedure.
15
16
17
18
18
18
18
18
18
1-18
Point Operations
[Point 1]
Disassembly:
Remove the lateral sides
[Point 2]
Disassembly:
Remove the battery safety lock (A)
[Point 3]
Disassembly:
Remove the battery from the truck
1-19
REPLACING BATTERY PLUG TERMINAL

Caution:
• Disconnect battery plug cable one by one
• Never disconnect more than one cable at the same time. Fatal accident may result by short
circuit
1
1. Remove the self-tapping screws and the cable clamps.
2
3
4
5
6
2. Remove the keeper/contact assembly from the 7
connector housing with a screw driver and at the same
time pull the cables. 8
9
10
11
12
3. Remove the contacts from the contact keeper and cut
the old ones. 13
14
15
16
17
4. Strip Wires per specified length:
Main Contacts: 20.0 mm for 10 mm² through 70 mm².
Insert wire into contact crimp barrel until wire bottoms
18
in barrel. Solder or crimp contacts.
Insert terminated contacts into the contact keeper. 18
Use caution to observe proper polarity of the contacts
when assembling contacts to the keeper. 18
Main contacts snap into the keeper from opposite
sides with an inward motion. 18
18
18
1-20
5. Slide the keeper/contact assembly into connector

housing until the keeper locks into place, secure
cables using cables clamps and the provided self-
tapping screws.
6. Insert the voltage key into the hex shaped opening in

themating face of the connector. Use caution to
observe that the proper battery voltage is displayed in
the voltage window. Apply pressure to the key to
ensure it is fully inserted and locked into the housing.
2-1
CONTROLLERS
Page
GENERAL .................................................................... 2-2
0
SPECIFICATIONS........................................................ 2-3
1
BEFORE REPAIR ........................................................ 2-4
MAIN CONTROLLERS ................................................ 2-6 2
MASTER TRACTION LOGIC UNIT ........................................2-6 3
SLAVE TRACTION LOGIC UNIT............................................2-8 4
PUMP LOGIC UNIT...............................................................2-10
5
MCB BOARD.........................................................................2-12
6
ARMREST BOARD ...............................................................2-16
CONTACTOR GROUP ..........................................................2-18
7
DASHBOARD........................................................................2-19 8
24V FUSES BOARD .............................................................2-22 9
CONTROL UNIT ........................................................ 2-25 10
MAIN CONTROL UNIT..........................................................2-25
11
CHECK TRACTION MOTOR PHASES
BALANCING ........................................................... 2-26 12
CHECK LIFTING MOTOR PHASES 13
BALANCING .......................................................... 2-27
14
TEMPERATURES MANAGEMENT ......................................2-28
15
MCB CONTROL CARD (Main Control Board) ........ 2-31
DC/DC CONVERTER ............................................................2-33 16
CONTACTOR GROUP............................................... 2-34 17
DASHBOARD........................................................................2-37 18
ARMREST BOARD ...............................................................2-38
19
ACCELERATOR POTENTIOMETER
ADJUSTMENT ........................................................ 2-41 20
NECESSARY ADJUSTMENT AFTER REPLACING 21
A HARDWARE COMPONENT ............................... 2-42
E
2-2
GENERAL
The truck is equipped with traction & lifting logic units that control traveling and material handling system.
They are multi-functional controllers equipped with micro computers.
The traction & lifting logic units provide high performance in a wide range by means of inverter control of
the AC motor drive system.
The main controllers have a self-diagnosis function that automatically detects any abnormality of the
main traction/lifting circuits, accelerator, brake or any other sensor and displays the corresponding error
code together with a warning beep.
At the same time, an action such as traction disabling, lifting disabling or restriction of traveling speed is
automatically taken to ensure safety.
In addition, setting the display in analyzer mode (fault analysis) it is possible to identify faulty portions
and inspect the main traction / lifting circuits and each operating system and sensors.
MCB Board
Fuse Group Contactor Group DC/DC Converter
Master Traction Pump Logic Unit

Slave Traction Logic Unit
Logic Unit
2-3
SPECIFICATIONS
1.5 - 2.0 t
2
FT1 (Master traction logic unit) 250 A
POWER FUSES FT2 (Slave traction logic unit) 250 A
2
FP (Lifting logic unit) 350 A 2
F1 (Dashboard power supply) 5A
3
F2 (Horn) 5A
F3 (K1,K2,EB1,EB2,EVP1÷8) 10 A 4
F4 (Flashing lamp) 2A
GLASS FUSES 5
(+Vb) F5 (Working lights) 3.15 A
F6 (Buzzer) 1A 6
F7 (DC/DC Converter) *A 7
F8 (Heater) 30 A
K1 (Pump logic unit) SU280B-1166 48V
8
CONTACTORS K2 (Master+Slave traction logic unit) SU280B-1166 48V 9
K3 (Line) SW60B-258 48V
10
FS1 (Autoradio) 5A
FS2 (Rear window heater) 10 A 11
FS3 (Tail/Dipper front lights) 10 A
12
FS4 (Direction lights) 3A
FS5 (Front/Rear window washer) 5A
13
24V FUSE
BOARD FS6 (Rotanting lamp) 10 A 14
FS7 (Rear lights) 2A
15
FS8 (Front windscreen wiper) 7.5 A
FS9 (heater) 5A 16
FS10 (Rear windscreen wiper) 7.5 A
17
RL1 CM1-P-24V
RELE’ RL2 CM1-P-24V 18
RL3 CM1-P-24V 18
18
* 5 A with 144W DC/DC Converter
10 A with 360W DC/DC Converter
20 A with 720W DC/DC Converter
18
18
18
2-4
BEFORE REPAIR
INSPECTION
1. Insulation resistance measurement

Note:
Always carry out the measurement before inspecting
the traction/lifting units.
(1) Disconnect the battery plug and measure the
resistance between the plug and the battery body
Measurement terminals Logic units side of battery plug-body

The resistance value depends greatly on the vehicle operating state, place
Standard: and weather.
(Approx. 1MΩ or more)
Some components can be inspected after they are removed from the vehicle, other ones can only be
inspected as installed on the vehicle.
The logic units must be inspected on the vehicle since the battery voltage must be applied.
This explanation is mainly for inspection of the controller as removed from the vehicle.
• Overhauling the control panels is rarely necessary. In most cases, failed parts are replaced after
finding out the cause of the failure from inspection. Therefore, make sure to repair correctly by
referring to the figures of configuration and assembly.
• Do not disassemble traction / lifting logic units and the other main controllers, as they should be
replaced in a form of group not disassembled.
Caution for part replacement
• Observe the specified bolts tightening torque. An insufficient or excessive tightening torque may
cause other failure.
• When disconnecting the bars and harness, record the connecting location and place tags. When
connecting them again, be sure to confirm with the record and tags to prevent incorrect connection.
Incorrect connection may cause other failure.
• Always apply new silicon grease when reassemble parts originally coated with this material.
Otherwise, overheating may occur.
• After installation, check there is no interference of the bar and harness connection with other portion.
2-5
CONNECTOR INSPECTION
When inspect each board and find the cause of the trouble, do not replace the board immediately but
check the following items.
• Abnormalies in related harnesses
2
• Looseness of the related connectors
• Bending or damage of connector pin and defective contact of any related connector pin 2
If any of the above is the cause of the trouble and the board is replaced with a new one, the new board
will be damaged. 2
Always replace the board after careful inspection.
When the trouble derives from a logic unit or board, measure the voltage and resistance of every part
involved in the substitution. Always disconnect the battery plug before measuring the resistance.
3
Warning: 4
Disconnect the battery plug before connecting or disconnecting the logic unit.
Note: 5
When a logic unit is determined to be the cause of trouble as the result of troubleshooting,
always measure the applied voltage and resistance of each related portion when replacing.
6
(1) Setting Method
(a) Key switch OFF and battery plug disconnected.
(b) Connect multimeter to corresponding connector pin.
7
Warning:
As connection of the wrong connector pin may damage normal portions, make sure to confirm 8
the connector pin number.
(2) Measurement method and standard list
9
How to read the list
10
CN (pin-colour) ⇔ CN (pin-colour)
Description Standard Notes
From ⇔ To 11
Arriving connector
12
Starting connector
13
JAT (1-B9) J15 (1-B9) EN1 encoder + V + 12 V
14
15
Colour Value of the
No. connector pin measurement 16
No. connector
17
COLOUR CODING
18
COLORI COLOURS FARBEN COULEURS COLORES
C arancio orange orange orange naranja
A azzurro blue blau bleu azul
18
B bianco white weiß blanc blanco
L blu dark blue dunkelblau bleu marine azul intenso
18
G giallo yellow gelb jaune amarillo
H grigio grey grau gris gris 18
M marrone brown braun marron castaño
N nero black schwarz noir negro 18
S rosa pink pink rose rosa
R rosso red rot rouge rojo 18
V verde green grün vert verde
Z viola/porpora purple violett violet púrpura
2-6
MAIN CONTROLLERS
MASTER TRACTION LOGIC UNIT
Basic conditions (battery plug connected, key switch ON).

See connectors reference names in the electrical diagram.
From ⇔ To
P1 (1-M) P137 (5-M) +V Key from Display 48V
P1(2-H) P14 (C-H) +V Steer potentiometer 11.3V
P1 (3) --- Unused
P1 (4) --- Unused
P1 (5-N) P14(B-N) Negative Steer potentiometer GND
J25 (3-HZ)
P1 (6-HN) Seat 26V
[via J20(2-HN)]
~ 0.4V
P1 (7-V) J15 (4-V) Channel A EN1 Encoder
~ 11.6V
P1 (8-RV) J15 (1-RV) +V EN1 Encoder 12V
J25 (1-NL)
P1 (9-NL) Negative seat GND
[via J20(1-NL)]
P1 (10-R) P14 (A-R) Cursor Steer potentiometer 2.2 - 9.7V
P1 (11-CN) P2 (19-CN) Safety IN GND
P1 (12) --- Unused
P1 (13) --- Unused
~ 0.4V
P1 (14-LH) J15 (3-LH) Channel B EN1 Encoder
~ 11.6V
P1 (15-MV) J15 (2-MV) Negative EN1 Encoder GND
P1 (16-A) P50(12-A) Main contactor coil out GND
P1 (17-S3) P50(3-S3) +V Main contactor coil out / Brake valve coil 48V
P1 (18-SL) P6 (1-SL) EB1 Brake valve coil out GND
2-7
From ⇔ To
P1 (19-LG) P2 (11-LG) Safety out GND
2
P2 (20-HG)
P1 (20-HG) P3 (20-HG) CAN L 2
P4 (21-HG)
P2 (21-AN) 2
P1 (21-AN) P3 (21-AN) CAN H
P4 (19-AN) 3
P1 (22-RL) J15 (6-RL) Thermic TS1 1.5V (20°)
P1 (23-L) J15 (5-L) Negative Thermic TS1 GND 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-8
SLAVE TRACTION LOGIC UNIT

From ⇔ To
P2 (2) --- Unused
P2 (3) --- Unused
P2 (5) --- Unused
J25 (3-HZ)
P2 (6-HN) Seat GND
[via J20(2-HN)]
~ 0.4V
P2 (7-BL) J16 (4-BL) Channel A EN2 Encoder
~ 11.6V
P2 (8-BS) J16 (1-BS) +V EN2 Encoder 12V
P2 (9) --- Unused
P2 (10) --- Unused
P2 (11-LG) P1 (19-LG) Safety IN GND
P2 (12) --- Unused
P2 (13) --- Unused
~ 0.4V
P2 (14-NV) J16 (4-NV) Channel B EN2 Encoder
~ 11.6V
P2 (15-BV) J16 (2-BV) Negative EN2 Encoder GND
P2 (16) --- Unused
P2 (18-SN) P7 (1-SN) EB2 Brake valve coil out GND
P2 (19-CN) P11 (11-CN) Safety out GND
2-9
From ⇔ To
P1 (20-HG)
P2 (20-HG) P3 (20-HG) CAN L
2
P4 (21-HG)
2
P1 (21-AN)
P2 (21-AN) P3 (21-AN) CAN H
P4 (19-AN)
2
P2 (22-SL) J16 (6-SL) Thermic TS2 1.5V (20°) 3
P2 (23-L) J16 (5-L) Negative Thermic TS2 GND
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-10
PUMP LOGIC UNIT

From ⇔ To
P3 (2) --- Unused
P3 (3) --- Unused
P3 (4) --- Unused
P3 (5) --- Unused
P3 (6) --- Unused
~ 0.4V
P3 (7-HV) J12(4-HV) Channel A EN3 Encoder
~ 11.6V
P3 (8-BZ) J12(1-BZ) +V EN3 Encoder 12V
P3 (9-H) P3 (11-H) Safety OUT GND
P3 (10) --- Unused
P3 (11-H) P3 (9-H) Safety IN GND
P3 (12) --- Unused
P3 (13) --- Unused
~ 0.4V
P3 (14-AV) J12(3-AV) Channel B EN3 Encoder
~ 11.6V
P3 (15-GN) J12(2-GN) Negative EN3 Encoder GND
P3 (16-Z) P50 (10-Z) Negative K1coil GND
P3 (18) --- Unused
P3 (19) --- Unused
2-11
From ⇔ To
P1 (20-HG)
P3 (20-HG) P2 (20-HG) CAN L
2
P4 (21-HG)
2
P1 (21-AN)
P3 (21-AN) P2 (21-AN) CAN H
P4 (19-AN)
2
P3 (22-LG) P13 (1-LG) Thermic TS3 1.5V (20°) 3
P3 (23-L) P13 (2-L) Negative Thermic TS3 GND
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-12
MCB BOARD
P4
(Black connector)
P5
(White connector)

From ⇔ To
P4 (1-LG) P33 (5-LG) Double pedal configuration 0-5V
P4 (2-RV) P33 (11-RV) Single pedal microswitch SW6 N.O. 0-5V
P4 (3-BV) P33 (12-BV) Single pedal microswitch SW6 N.C. 0-5V
P33 (2-RL) Double pedal microswitch SW3 N.O.
P4 (4-RL) or or 0-5V
P35 (2-RL) Hand direction lever steering column SW7
P4 (5-BH) P33 (3-BH) Double pedal microswitch SW3 N.C. 0-5V
P33 (8-RN) Double pedal microswitch SW4 N.O.
P4 (6-RN) or or 0-5V
P35 (3-RN) Hand direction lever steering column SW8
P4 (7-BN) P33 (9-BN) Double pedal microswitch SW4 N.C. 0-5V
P4 (8-BZ) P31 (2-BZ) Brake pedal microswitch SW5 N.C. 0-5V
P4 (9) --- Unused 0-5V
P42 (3-BG)
P4 (10-BG) Lifting microswitch SW9 0-5V
[via J53 (1-BC)]
P42 (3-GM)
P4 (11-GM) Lowering microswitch SW10 0-5V
[via J53 (2-GM)]
P42 (3-BM)
P4 (12-BM) Tilt FW microswitch SW11 0-5V
[via J53 (3-BM)]
P42 (3-MV)
P4 (13-MV) Tilt BW microswitch SW12 0-5V
[via J53 (4-MV)]
2-13
From ⇔ To
P42 (3-ZN)
P4 (14-NZ)
[via J53 (5-ZN)]
Sideshift microswitch SW13 0-5V 2
P4 (15-NV)
P42 (3-NV)
4th way microswitch SW14 0-5V 2
[via J53 (6-NV)]
P4 (16-BS)
P42 (3-BS)
5th way microswitch SW15 0-5V 2
[via J53 (7-BS)]
P4 (17-B) P135 (1-B) 3/4 wheels configuration jump 0-5V 3
P4 (18-MN) J49 (10-MN) Switch N.C. speed reduction (optional)
4
P1 (21-AN)
P4 (19-AN) P2 (21-AN) CAN H
P3 (21-AN) 5
P4 (20-AN) P137 (10-AN) CAN H 6
P1 (20-HG)
P4 (21-HG) P2 (20-HG) CAN L 7
P3 (20-HG)
P4 (22-HG) P137 (11-HG) CAN L 8
P4 (23-N) --- General GND GND
P4 (24-SB) J49 (1-SB) Cursor tilt potentiometer (optional)
9
P4 (25-R) J32 (3-R) Cursor traction potentiometer 10
J41(2-LV)
P4 (26-LV) Cursor lifting potentiometer
[via J53 (9-LV)] 11
P4 (27-SN) J30 (3-SN) Cursor brake potentiometer
P4 (28-V) J32 (2-V) Negative traction potentiometer GND
12
J41(1-AG)
+V lifting potentiomer 13
[via J53 (10-AG)]
P4 (29-AG) and 9.9V
and
J49 (3-AG)
+V tilt potentiomer (optional) 14
J32 (1-G) +V traction potentiometer 15
P4 (30-G) and and 5V
J30 (1-G) +V brake potentiometer
16
J41(3-HV)
Negative lifting potentiometer
[via J53 (1-HV)]
and
and 17
P4 (31-HV) Negative brake potentiometer GND
J30 (2-HV)
and
and
Negative tilt potentiometer (optional)
18
J49 (2-HV)
P4 (32-N) J53 (8-N)] General negative OCVmicroswitch GND 18
P4 (33-H) J49 (5-H) Height mast microswitch N.C. (option)
18
P4 (34-AR) J49 (6-AR) Height mast microswitch N.O. (option)
P4 (35-RV) J49 (12-RV) Mast microswitch speed ruduction (option) 18
J107 (2-GM)
P5 (1-GM)
[via J51 (1-GM)]
GND EVP1 lowering GND 18
J108 (2-BG)
P5 (2-BG)
[via J51 (2-BG)]
GND EVP2 lifting GND 18
2-14
From ⇔ To
J107 (1-G)
[via J51 (3-G)] +V EVP1 lowering
P5 (3-G) and 48V
J108 (1-G) +V EVP2 lifting
[via J51 (3-G)]
J109 (2-BM)
P5 (4-BM) GND EVP3 tilt forward GND
[via J51 (4-BM)]
J110 (2-MV)
P5 (5-MV) GND EVP4 tilt backward GND
[via J51 (5-MV)]
J109 (1-MC)
[via J51 (6-MC)] +V EVP3 tilt forward
P5 (6-MC) and 48V
J110 (1-MC) +V EVP4 tilt backward
[via J51 (6-MC)]
J111 (2-AZ)
P5 (7-AZ) GND EVP5 left sideshift GND
[via J51 (7-AZ)]
J112 (2-BZ)
P5 (8-BZ) GND EVP6 right sideshift GND
[via J51 (8-BZ)]
J111 (1-Z)
[via J51 (9-Z)] +V EVP5 left sideshift
P5 (9-Z) and 48V
J112 (1-Z) +V EVP6 right sideshift
[via J51 (9-Z)]
J113 (2-BV)
P5 (10-BV) GND EVP7 4th way GND
[via J51 (10-BV)]
J114 (2-NV)
P5 (11-NV) GND EVP8 4th way GND
[via J51 (11-NV)]
J113 (1-V)
[via J51 (12-V)] +V EVP7 4th way
P5 (12-V) and 48V
J114 (1-V) +V EVP8 4th way
[via J51 (12-V)]
P5 (13-M) --- +V KEY 48V
P5 (14-N) --- GND IN GND
P5 (15-SN) J49 (7-SN) Cursor load sensor
P5 (16-SL) P70 (1-SL) Out buzzer 48V
P5 (17-S3) --- +V battery 48V
P5 (18-S3) --- +V battery 48V
P5 (23) --- Unused
P5 (24-AL) J49 (9-AL) +V load sensor 5V
2-15
From ⇔ To
P5 (26-AV) J49 (8-AV) GND load sensor GND
2
P5 (27-C) P96 (4-C) +24V IN from DC/DC converter 24V
P5 (28-S3) --- +V battery 48V 2
P102 (1-CN)
P5 (29-CN)
[via J145 (2-CN)]
+V right stop light 24V 2
P91 (1-CR)
P5 (30-CR)
[via J145 (4-CR)]
+V left stop light 24V 3
P92 (1-BC) 4
[via J145 (3-BC)]
P5 (31-BC) and +V backing light 24V
P93 (1-BC) 5
[via J145 (3-BC)]
J115 (2-H)
6
P5 (32-H) GND EV9 5th way GND
[via J51 (13-H)]
7
J115 (1-BH)
P5 (33-BH) +V EV9 5th way 48V
[via J51 (14-BH)]
8
J116 (2-A)
P5 (34-A) GND EV9 5th way GND
[via J51 (15-A)] 9
J116 (1-BS)
P5 (35-BS) +V EV9 5th way 48V
[via J51 (16-BS)] 10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-16
ARMREST BOARD
JSOLL
JBRA
JTRA JCAN
JIV
JAUX
JV
Basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle].
From ⇔ To
P137 (7-HG)
JCAN (1-HG) [via J138 (1-HG)] CAN L
[via J131 (1-HG)]
P137 (6-AN)
JCAN (2-AN) [via J138 (2-AN)] CAN H
[via J131 (2-AN)]
JCAN (3-N) --- GND IN GND
JCAN (4-SHD) --- Unused
P137 (5-M)
JCAN (5-M) [via J138 (5-M)] +V IN from Display 48V
[via J131 (5-M)]
JCAN (6-N) --- GND IN GND
JAUX (1-H) --- +V Hand direction lever 5V
JAUX (2-S) --- Cursor GND Hand direction lever 0-5V
JAUX (3-BR) --- GND Hand direction lever GND
JAUX (4-LC) --- Backward
JAUX (5-V) --- Forward
JAUX (6-L) J142 (2-L) Input
JAUX (7) --- Unused
JAUX (8-Z) J141 (3-Z) Input
JAUX (9) --- Unused
JAUX (10-N) --- GND GND
JSOLL (1) --- +V Potentiometer 5V
JSOLL (2) --- Cursor Potentiometer 0-5V
2-17
From ⇔ To
JSOLL (3) --- Unused
2
JSOLL (4) --- GND Potentiometer GND
JSOLL (5) --- Micro 5V 2
JSOLL (6) --- Micro 5V
2
JSOLL (7) --- Unused
JSOLL (8) --- GND Micro GND 3
JBRA (1) --- +V Potentiometer 5V
JBRA (2) --- Cursor Potentiometer 0-5V
4
JBRA (3) --- Unused 5
JBRA (4) --- GND Potentiometer GND
JBRA (5) --- Micro 5V
6
JBRA (6) --- Micro 5V 7
JBRA (7) --- Unused
JBRA (8) --- GND Micro GND 8
JTRA (1) --- +V Potentiometer 5V
9
JTRA (2) --- Cursor Potentiometer 0-5V
JTRA (3) --- Unused 10
JTRA (4) --- GND Potentiometer GND
JTRA (5) --- Micro 5V
11
JTRA (6) --- Micro 5V 12
JTRA (7) --- Unused
JTRA (8) --- GND Micro GND
13
JIV (1) --- +V Potentiometer 5V 14
JIV (2) --- Cursor Potentiometer 0-5V
JIV (3) --- Unused 15
JIV (4) --- GND Potentiometer GND
16
JIV(5) --- Micro 5V
JIV(6) --- Micro 5V 17
JIV (7) --- Unused
18
JIV (8) --- GND Micro GND
JV (1) --- +V Potentiometer 5V 18
JV (2) --- Cursor Potentiometer 0-5V
JV (3) --- Unused
18
JV (4) --- GND Potentiometer GND 18
JV(5) --- Micro 5V
JV(6) --- Micro 5V 18
JV (7) --- Unused
18
JV (8) --- GND Micro GND
2-18
CONTACTOR GROUP
K3
K1
K2

From ⇔ To
J50 (1-R1) J1 (+) +V OUT F1
J50 (2-S2) J1 (+) +V OUT F2
J50 (3-S3) J1 (+) +V OUT F3
J50 (4-S4) J1 (+) +V OUT F4
J50 (5-S5) J1 (+) +V OUT F5
J50 (6-S6) J1 (+) +V OUT F6
J50 (7-M) K3 (+) Coil contact K3 (aux)
J50 (8-N) K3 (-) GND contactor K3 (aux)
J50 (9-S3) K1 (+) Coil contact K1(aux)
J50 (10-Z) K1 (-) GND contactor K1 (aux)
J50 (11-S3) K2 (+) Coil contact K2 (aux)
J50 (12-A) K2 (-) GND contactor K2 (aux)
J60 (1-S8) J1(+) OUT F8
J60 (2-S7) J1(+) OUT F7
2-19
DASHBOARD
2
2
2
3
4
5
6
7
8
9
10
11
35 14
12
13
P134
P137 14
15
1 1 16
17
18
18
From ⇔ To
18
J155 (1-RH)
P137 (1-RH) Input Right turn light 5V
[via P35 (6-RH)]
18
J155 (3-RV)
P137 (2-RV) Input Left turn light 5V
[via P35 (8-RV)] 18
J8 (1-BM)
P137 (3-BM) Input Horn 5V
[via P35 (4-BM)] 18
P137 (4-RN) P17 (1-RN) Input Oil brake 5V
2-20
From ⇔ To
P50 (7-M)
P1 (1-M)
P2 (1-M)
P2 (4-M)
P3 (1-M)
P137 (5-M) +V key OUT 48V
P5 (13-M)
JCAN (5-M)
[via J131 (5-M)]
[via J138 (5-M)]
P132 (1-M)
P137 (6-AN) P4 (19-AN) CAN H
P137 (7-HG) P4 (21-HG) CAN L
J50 (1-R1)
P137 (8-R3) + V battery IN 48V
[via J133 (1-R1)]
P137 (9-N) J1 (-) GND GND
P137 (10-AN) P4 (20-AN) CAN H
P137 (11-HG) P4 (22-HG) CAN L
Digital
P137 (12-B) P11 (2-B) Horn OUT
GND
P137 (13-HG) P132 (A-HG) CAN L
P137 (14-AN) P132 (3-AN) CAN H
P102 (3-AC)
[via J145 (5-AC)]
P134 (1-AC) and Rear tail lights +24V
P91 (3-AC)
[via J145 (5-AC)]
P134 (2-V) P90 (4-V) Heather fun +24V
P134 (3-RN) P90 (16-RN) Left dipped headlights GND
P134 (4-RH) P90 (7-RH) Right turn lights GND
P134 (5) --- Unused
P134 (6) --- Unused
P134 (7) --- Unused
P134 (8) --- Unused
P134 (9-CL) P90 (14-CL) Rotanting lamp GND
P134 (10-SN) P90 (13-SN) Front windscreen washer GND
P134 (11-BN) P90 (12-BN) Rear windscreen washer GND
P134 (12-RC) P90 (5-RC) Front tail lights GND
P134 (13) --- Unused
P134 (14-C) P96 (4-C) +V IN DC/DC converter +24V
P134 (18-N) J1 (-) GND IN
2-21
From ⇔ To
P134 (19-N) J1 (-) GND IN
2
P134 (20-N) J1 (-) GND IN
P134 (21-N) J1 (-) GND IN 2
P134 (22-N) J1 (-) GND IN
2
P134 (23) --- Unused
P134 (24-NH) P106 (2-NH) Flashing lamp GND 3
P134 (25-GN) P90 (10-GN) Front windscreen washer fast +24V
P134 (26-LG) P90 (1-LG) Front windscreen washer slow +24V
4
P134 (27-ZN) P90 (11-ZN) Rear windscreen washer +24V 5
P134 (28-RN) P90 (8-RN) Right dipped headlights GND
P134 (29-SB) P90 (3-SB) Heater +24V
6
P134 (30-BV) P90 (2-BV) Rear window heater GND 7
P134 (31-BV) P90 (2-BV) Rear window heater GND
P134 (32-NV) P104 (4-NV) Front working lights GND 8
P134 (33-NL) P104 (2-NL) Rear working lights GND
9
P134 (34-CL) P90 (15-CL) Rotanting lamp GND
P134 (35-RA) P90 (6-RA) Left turn lights GND 10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-22
24V FUSES BOARD
FS6
FS7 FS9 FS10 FS8
CN6 CN5 CN2
CN9
CN4
FS1 FS4 FS2 FS3
CN7 CN8
FS5
CN3 RL3 RL2 RL1 CN1

From ⇔ To
CN1 (1-N) P96 (5-N) Negative input GND
CN1 (2) P5 (27-C) +24V input 24V
CN2 (1-LG) P134 (26-LG) Front windscreen wiper slow 24V
P134 (30-BV)
CN2 (2-BV) Rear windows heater 24V
P134 (31-BV)
CN2 (3-SB) P134 (29-SB) Heater 24V
CN2 (4-V) P134 (2-V) Heater fan 24V
CN2 (5-RC) P134 (12-RC) Front tail light 24V
CN2 (6-RA) P134 (35-RA) Left turn lights 24V
CN2 (7-RH) P134 (4-RH) Right turn lights 24V
CN2 (8-RN) P134 (28-RN) Right dipper headlight 24V
P91 (2-N)
P92 (2-N)
CN2 (9-N) Negative output to rear lights GND
P93 (2-N)
P102 (2-N)
CN2 (10-GN) P134 (25-GN) Front windscreen wiper fast 24V
CN2 (11-ZN) P134 (27-ZN) Rear windscreen wiper 24V
CN2 (12-BN) P134 (11-BN) Rear windscreen washer 24V
2-23
From ⇔ To
CN2 (13-SN) P134 (10-SN) Front windscreen washer 24V
2
CN2 (14-CL) P134 (9-CL) Rotanting lamp 24V
CN2 (15-CL) P134 (34-CL) Rotanting lamp 24V 2
CN2 (16-RN) P134 (3-RN) Left dipped headlights 24V
2
CN3 (1-AB) J126 (31b-AB) Zero point, front windscreen washer 24V
CN3 (2-H) J126 (53b-H) Second speed, front windscreen washer 24V 3
CN3 (3-AN) J128 (53a-AN) Supply, rear windscreen washer 24V
J126 (31-N)
4
CN3 (4-N) Negative, front windscreen washer GND
via Fuse FS8
5
J128 (31-N)
CN3 (5-N) Negative, rear windscreen washer GND
via Fuse FS10
6
CN3 (6-AN) J126 (53a-AN) Supply, front windscreen washer 24V
CN3 (7-AB) J128 (31b-AB) Zero point, rear windscreen washer 24V 7
CN3 (8-A) J126 (53-A) First speed, front windscreen washer 24V
8
CN3 (9-A) J128 (53-A) First speed, rear windscreen washer 24V
P129 (1-C25) 9
CN4 (1-C25) via P143 (1-C05) Negative front windscreen washer motor GND
via Fuse FS5 10
P144 (1-C25)
CN4 (2-C25) via P143 (2-C05) Negative rear windscreen washer motor GND 11
via Fuse FS5
CN4 (3-SN)
P129 (2-SN)
+24V front windscreen washer motor 24V
12
via P143 (3-SN)
CN4 (4-CN)
P144 (2-CN)
+24V rear windscreen washer motor 24V
13
via P143 (4-CN)
JLP12 (1-C06) 14
CN5 (1-C06) +24V rotanting lamp 24V
via Fuse FS6
CN5 (2-CL) JLP12 (2-CL) Negative rotanting lamp GND
15
CN6 (1-C06)
JLP13 (1-C06)
+24V rotanting lamp 16
via Fuse FS6
CN6 (2-CL) JLP13 (2-CL) Negative rotanting lamp 17
CN7 (1-RN) JLP17 (1-RN) Negative front dipper light, left side GND
CN7 (2-C04)
18
JLP16 (1-C04) +24 right turn light 24V
via fuse FS4
CN7 (3-C04)
18
JLP19 (1-C04) +24 feft turn light 24V
via fuse FS4
18
CN7 (4-RN) JLP14 (1-RN) Negative front dipper light, right side GND
JLP14 (2-C03)
+24V front light (dipped and tail), right
18
CN7 (5-C03) JLP15 (2-C03) 24V
side
via Fuse FS3 18
JLP17 (2-C03)
CN7 (6-C03) JLP18 (2-C03) +24V front light (dipped and tail), left side 24V 18
via Fuse FS3
2-24
From ⇔ To
CN7 (7-RM) JLP16 (2-RM) Negative right turn light GND
CN7 (8-RV) JLP19 (2-RV) Negative left turn light GND
CN7 (9) --- Unused
CN7 (10) --- Unused
CN7 (11-RC) JLP15 (1-RC) Negative front tail light, right side GND
CN7 (12-RC) JLP18 (1-RC) Negative front tail light, left side GND
CN8 (1-AV) J121 (1-AV) +24V heater contactor coil 24V
CN8 (2-V) J122 (1-V) +24V heater fan 24V
J122 (2-N)
CN8 (3-N) Negative heater fun GND
vai Fuse FS9
J121 (2-N)
CN8 (4-N) Negative heater contactor GND
vai Fuse FS9
CN8 (5-BV) J124 (1-BV) Negative heater rear window GND
J124 (2-C02)
CN8 (6-C02) +24V heater rear window 24V
via Fuse FS2
JDC/DCRADIO (1)
CN9 (1) +24V DC/DC autoradio 24V
via Fuse FS1
CN9 (2) --- Unused
CN9 (3) JDC/DCRADIO (3) Negative DC/DC autoradio GND
2-25
CONTROL UNIT
MAIN CONTROL UNIT
2
Traction Logic Unit Traction Logic Unit Lifting Logic Unit
Master ACE-2 Slave ACE-2 ACE-2 2
Inverter for AC asynchronous
3-phase motors
2
Regenerative braking functions
3
4
Can-bus interface
5
Flash Memory
6
Digital control based upon a
microcontroller 7
Voltage 48 V 48 V 48 V
8
Maximum current 350 A (RMS) 350 A (RMS) 450 A (RMS)
Operating frequency 8 Khz 8 Khz 8 Khz 9

External temperature range -30° C + 40° C -30° C + 40° C -30° C + 40° C
10
Maximum inverter temperature 75° C 75° C 75° C
11
12
13
14
15
16
17
18
18
18
18
18
18
2-26
CHECK TRACTION MOTOR PHASES BALANCING

When traveling or material handling operation seems abnormal, it is possible to judge accurately
if the controller is functioning correctly or not, measuring motor phase balancing.
Measuring method Procedure using a clamp amperometer
(1) Remove rear metal cover
(2) Jack up front wheels
(3) Connect a clamp amperometer
(4) Select a direction,shift the direction switch to forward (or backward) position, and start the
machine with low speed
(5) Check the value of the current of each phase
(6) If the value of a phase is higher or lower compared with the others, it means that the system is not
balanced and the motor goes jerkling. In this case, the logic unit must be replaced.
Measuring method Procedure using a multimeter
(3) Set multimeter on V~
(4) Connect the negative of the multimeter on the battery negative
(5) Connect the positive on one of the phase of the logic unit
(6) Check the value of the voltage of each phase
In order to compare the value of the phases, it is necessary to use the same tool so no different
type of multimeters or clamp amperometers for each phases, because each tool has a different
tolerance.
Measuring method Procedure using a Measuring method Procedure using

multimeter a clamp amperometer
2-27
CHECK LIFTING MOTOR PHASES BALANCING

Measuring method Procedure using a clamp amperometer
(2) Jack up front wheels 2
(3) Connect a clamp amperometer
(4) Select a direction, shift the direction switch to forward (or backward) position, and start the 2
machine with low speed
(5) Check the value of the current of each phase 2
3
Measuring method Procedure using a multimeter
(1) Remove rear metal cover 4
(3) Set multimeter on V~
(4) Connect the negative of the multimeter on the battery negative
5
(5) Connect the positive on one of the phase of the logic unit
(6) Check the value of the voltage of each phase 6
balanced and the motor goes jerkling. In this case, the logic unit must be replaced. 7
In order to compare the value of the phases, it is necessary to use the same tool so no different
type of multimeters or clamp amperometers for each phases, because each tool has a different 8
tolerance.
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-28
TEMPERATURES MANAGEMENT
Logic units (Master-Slave-Lifting) use the signal coming from temperature sensor to drive the electric
motor, so that it is possible to avoid overheatings and possible damages.
The logical unity reduces motor performances according to data here below.
• Reduction of the maximum current in relation to motor temperature

Traction and lifting
0° ÷ 140°C no reduction
140° ÷ 155°C 80% - 4% / °C
> 155°C -100%
• Increase of traction motors acceleration times in relation to the increase of the traction motors
temperature
120° ÷ 125°C 0,1s
125° ÷ 130°C 0,3s
130° ÷ 135°C 0,7s
135° ÷ 140°C 1,1s
140° ÷ 145°C 1,6s
145° ÷ 150°C 2,3s
150° ÷ 155°C 3,0s
> 155°C 6,0s
• Reduction of speed translation in relation to traction motor temperature
140° ÷ 150°C 20% reduction
150° ÷ 155°C 50% reduction
> 155°C speed to 0
• Increase of lifting motor acceleration times in relation to the increase of the lifting motor
temperature
130° ÷ 140°C 0,5s
140° ÷ 150°C 1,0s
> 150°C 2,0s
• Speed reduction in respect to lifting motor temperature
140° ÷ 150°C 20% reduction
> 150°C 70% reduction
2-29
Before starting the job, measure the voltage between (+) and GND; if there is any voltage, insert a
resistor at approx. 100Ω between (+) and GND to discharge the capacitor.
2
2
2
3
4
5
6
DRIVE LOGIC UNIT LIFTING LOGIC UNIT 7
1. Park the truck on a level surface and apply the parking brake
2. Switch off the truck 9
3. Open the compartment and disconnect the battery
4.
5.
Remove the rear metal cover [Point 1]
Disconnect the power cables from the logic unit [Point 2]
10
6. Remove the lifting logic unit and/or the drive logic unit [Point 3]
11
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
12
Notes: 13
For the necessary adjustments to be made after the logic change, see section “NECESSARY
ADJUSTMENT AFTER AN HARDWARE COMPONENT REPLACING”
Whenever one of the logic units has been disassembled, remember to restore the layer of the thermo
14
conductive paste whose purpose is to favour the thermic transmission between the logic unit and the
heat radiant structure: the counterweight. Spread approximately 150 grams of pasta. This white colour 15
product consisting of powdered metal oxides (ceramic) compounded in a silicone oil base. Using a broad
knife, it must be spreaded in a thiny and uniform film on the logic unit contact surface and then you can 16
proceed to the reassembly.
17
18
18
18
18
18
18
2-30
Points of Operation
[Point 1]
Disassembly:
Remove rear metal cover
[Point 2]
Disassembly:
Disconnect power cables from the logic unit
[Point 3]
Disassembly:
Remove lifting logic unit and/or drive logic unit
TRACTION SLAVE PUMP

TRACTION MASTER
2-31
MCB CONTROL CARD (Main Control Board)
The board is placed on the left side of truck, under the

footboard. MCB is the main control and management board
2
of the vehicle.
The board is made up by two microprocessors: 2
TRCB = traction control board
EVCB = electric valve control board
2
TRCB is the section that controls applications: it manages 3
traction parameters and Master of the traction logic units.
EVCB is the master of the vehicle comunication: it
manages lifting parameters (mechanical control valve
4
version and mini-lever version) and Master of the lifting
logic unit. 5
MAIN FUNCTIONS 6
• Performances management (traction and lifting parameters with lever distributor)
• Management/control of stop and reverse direction lights 7
• Electroproportional distributor control (optional)
• Vehicle configuration identification 8
• Comunication Master between all cards
• Traction control Master
• Pump control Master
9
10
1. P4 connector:
Used to check pedals system, parking/service brake, 11
1 negative brakes unlocking sensor and the mechanical
distributor micros 12
2. P5 connector:
Used to check electric distributor electrovalves, tilting
potentiometer, rear lights and cooling fan
13
14
2
15
16
17
18
18
18
18
18
18
2-32
1. Park the truck on a level surface and apply the parking
brake
4. Remove the footboard
5. Disconnect the connectors of the card
6. Remove the card
The reassembly procedure is the reverse of the
disassembly procedure.
2-33
DC/DC CONVERTER
2
2
2
3
4
5
6
7
8
MACHINE WITH OPTIONAL DEVICES (24V)
For supplying optional devices, an aux DC/DC converter
9
DC /DC CONVERTER
must be installed. In order to establish all aux converter
power, add the power of all the foreseen optional devices. 10
Select the converter rounding up the obtained power and
keeping the 10% more of the theoretical required power. 11
The aux DC /DC converter is placed on right side into the
lifting motor compartment. 12
13
14
OPTIONAL DEVICES
Rotanting lamp
Rear system lights (stop / tail + back lights)
70 W
10 W
15
Complete light equipment 190 W
2 Windscreen wipers + 2 windscreen washer 200 + 72 W 16
Road circulation lighting system 280 W
Heater fan + contactor 60 W 17
Rear window heater 192 W (R= 3 Ohm±0,7)
Autoradio 40 W 18
Converter IP 18
144 W 54
360 W 54 18
720 W 20
18
To define the 24V total power, to add power of provided equipment. To round up the calculation
and choose corresponding 24V DC/DC converter 18
18
2-34
CONTACTOR GROUP
Caution:
Before starting the job, measure the voltage between (+) and GND; if there is any voltage, insert a
resistor at approx. 100Ω between (+) and GND to discharge the capacitor.
4. Remove the rear metal cover
5. Disconnect the power cables of the contactors
6. Remove the fixing screws on the contactor unit [Point 1]
7. Remove the contactors
Points of operation
[Point 1]
A Disassembly:
A
Remove the fixing screws (A) on the contactor unit
A
K1 K2 K3
2-35
INSPECTION
1. CONTACTOR
Inspection method 2
Disconnect connector from wiring harness and
measure the resistance of the coil
2
Portion to
Measurement Multimeter
be
terminals
Standard
range 2
inspected
Coil K1
Both coil Ca. 100 Ω
Ω ×1
3
terminals (a 20°C)
4
Coil K2 Ω ×1
terminals (a 20°C)
5
Coil K3 Ω ×1
terminals (a 20°C)
6
7
2. FUSE
Inspection method
8
Disconnect fuse and measure the insulation resistance
9
Portion to
Measurement Multimeter
be Standard
inspected
terminals range 10
Fuses
Both fuse
0Ω Ω ×1 11
terminals
12
13
14
15
16
17
18
18
18
18
18
18
2-36
DESCRIPTION OF CONTACTORS
K1 = Pump contactor
Pump logic unit Contactor Description V V holding
+ Vb K1 Coil power supply +Vb 70% +Vb
P3 (16-Z) K1 Coil negative GND
K2 = Traction contactor
Traction logic unit Contactor Description V V holding
+ Vb K2 Coil power supply +Vb 80% +Vb
P1 (16-A) K2 Coil negative GND
K3 = Line contactor
Display Contactor Description V V holding
P137 (5-M) K3 Coil power supply +Vb +Vb
- Vb K3 Coil negative GND

2-37
DASHBOARD
In case of trouble in the dashboard, measure the voltage at the connector to which voltage is applied.
2
2
2
3
4
5
6
7
8
9
10
11
35 14 12
13
P137
P134 14
15
1 1
16
J137 connector basic condition (Battery plug connected)

17
18
From ⇔ To
P137 (9-N) J1 (-) GND from battery GND 18
P137 (8-R3) J1 (+) +V from battery +V
18
Disassembly procedure
3. Open the battery cover and disconnect the battery 18
4. Remove the front cover
5. Disconnect the wiring harness fromthe dashborad 18
6. Remove the dashboard fixing screws
2-38
ARMREST BOARD
COMPONENTS
Joystick
Fingertip
1 Armrest 8 Armrest board

2 Wiring harness 9 Direction switch
3 Inner wiring harness 10 Cover
4 Cover 11 Fingertip
5 Seat cushion 12 Wiring harness
6 Knob 13 Cover
7 Joystick
1. Park the truck on a level surface and activate the parking brake
3. Open the battery cover and disconnect the battery
4. Disconnect the wiring placed in the armrest back part [Point 1]
5. Remove the armrest pads
6. Remove the fixing screws placed in the armrest lower side [Point 2]
7. Open the armrest
8. Disconnect the armrest board wirings and remove the armrest board 4 fixing screws [Point 3]
9. Remove the armrest board
Reassembly procedure
2-39
Point Operations
[Point 1]
A
Disassembly: 2
Disconnect wiring (A), placed in the armrest back part
2
2
3
4
[Point 2] 5
B Disassembly:
Remove the 4 fixing screws (B) placed in the armrest 6
lower side
7
8
B 9
10
[Point 3]
Disassembly: 11
Disconnect armrest board wirings and remove the
armrest board 4 fixing screws 12
13
14
15
16
17
18
18
18
18
18
18
2-40
ARMREST BOARD DESCRIPTION
JSOLL
JBRA
JTRA JCAN
JIV
JAUX
JV
COMPONENTS
JSOLL Connector for lifting

JBRA Connector for tilting
JTRA Connector for sideshift
JIV Connector for the 4th lever
JV Connector for the 5th lever
JAUX Connector for auxiliary commands: forward/backward direction button, horn button
JCAN Connector for the CAN-BUS
The card purpose is to pilot the horn button, forward and backward speed buttons (version with FW/BW
button) and the fingertip/joystick signals.
Operating a lever on the armrest, this card converts the analog signal into a digital signal that is then
transferred via CAN-BUS to the lifting logic unit and to the MCB (EVCB) which converts it from digital to
analog.
The card uses printed circuits that must be powered to decode the CAN-BUS signals.
The card is used in both configurations (fingertip or joystick).
2-41
ACCELERATOR POTENTIOMETER ADJUSTMENT
1. Check the ON/OFF condition of the switch

1.1. SW8 (single pedal)
2
1.2. SW4 - SW5 (double pedal)
2
Measurement terminals Status
Pedal not
∞Ω
2
Standard: operated
Pedal operated Continuity 3
4
5
6
2. Adjustment of Accelerator Potentiometer (P2) 7
Installation
(1) Before installing a new traction potentiometer it is
suggested to check it with an anlalogical
8
multemeter. Move slowly the potentiometer lever
until the maximum stroke and in the same time 9
check if the multimeter increases or decreases the
value proportionally with the movement. 10
(2) Install the potentiometer and connect it to the wiring
loom of the machine.
(3) After closing the microswitch the voltage on the
11
potentiometer lever of the potentiometer has to be
aproximately 1,6V and 4,5V to the maximum stroke. 12
This measure is referred to its negative.
(4) Once the potentiometer is well fixed do the setting 13
(see LERNING menu -> LERN TRAC POT).
(5) After adjusting the switch ON/OFF operation, apply 14
yellow paint to the head of a set screw.
15
Measurement terminals Status
J32 (1-G) 5V 16
Standard: J32 (2-V) GND
17
J32 (3-R) ~ 1,6V - ~ 4,5V
18
18
18
18
18
18
2-42
NECESSARY ADJUSTMENT AFTER REPLACING A HARDWARE

COMPONENT
MCB CARD
ACQUISITION: Serial number (SERIAL NUMBER)
Accelerator potentiometer (LEARN TRAC POT)
Lifting potentiometer (only in the mechanic distributor version) (LEARN LIFT POT)
Balanced pedal configuration (SWAYING PEDAL)
Speed reduction in case of mast with height more than 6250mm (HIGH MAST)

Steering potentiometer (SET STEER ZERO/SET STEER LEFT/SET STEER RIGHT)
3/4 wheels configuration (STEER TABLE)

No acquisition required
LIFTING LOGIC UNIT

No acquisition required
ARMREST BOARD
• Optional 5th way configuration via fingertips (VTH ENABLE)
• Optional attachment pilotage button activation (CLAMPS)
DASHBOARD
Date and hour regulation
3-1
DISPLAY
Page
DISPLAY................................................................. 3-2
MAPS FOR USING THE DASHBOARD ................ 3-5 0
USER MENU .......................................................... 3-5
1
USER MENU MAP ........................................................... 3-6
2
USER MENU DESCRIPTION................................. 3-7
HOUR METER ................................................................. 3-9 3
TRIP ................................................................................. 3-9 4
CLOCK........................................................................... 3-10 5
ALARMS .........................................................................3-11
6
DISPLAY SETTING........................................................ 3-12
MAPS FOR USING THE DASHBOARD .............. 3-16 7
SERVICE MENU DESCRIPTION ......................... 3-17 8
SERVICE MENU MAP ................................................... 3-19 9
SOFT VERS ................................................................... 3-20 10
PARAM CHANGE .......................................................... 3-21
11
TRUCK CONF................................................................ 3-33
PROFILE DESCRIPTION .............................................. 3-36 12
SERVICE RENT ............................................................. 3-47 13
PSW MODIFY ................................................................ 3-50 14
TESTER ......................................................................... 3-51
15
ALARMS ........................................................................ 3-56
LEARNING..................................................................... 3-57 16
DEFAULT RST ............................................................... 3-58 17
“INCORRECT START“ MANAGEMENT ............. 3-59 18
3-2
DISPLAY
If the cause of trouble is in the display, measure the voltage at connector to whom voltage is applied.
No. connector ⇔ No. connector Conditions Standard Note

P137 (5-M) P137 (9-N) Power supply +Vb
Discharge battery warning light:

it flashes when battery reaches 15% of charge
Parking brake on warning light
Deadman device warning light:

the pilot light comes on when the driver leaves the driving seat without switching off the truck:
under these conditions, the traction and the lifting movement are disabled
Heated seat warning light
Adjustable electronic hour meter:

it counts truck working hours. It shows the working hours and the hourly fractions
Speed reduction indication light
Selected direction indication light
Steering direction indication:

it shows the running direction
3-3
Time indication light
Timer indication light 0

1
Selected program indication light
2
3
Turn direction indication light
4
5
Hour meter modality indication: 6
lifting motor, traction motor or key switch
7
8
Password: 9
The option activation button permits to digit the access password
10
Board: 11
it permits to navigate between the menus
12
ON push button:
it permits to switch on the truck and to enter to the user and service menu
13
14
OFF push button:
it permits to switch off the truck 15
16
Rotary and flash light push button:
it activates the rotary or flash lamp
17
Tail and dipper light push button:
18
it activates the tail or dipper lamp
19
Working light push button: 20
it activates the tail or dipper lamp
21
E
3-4
Front wiper washer push button:

it activates the front wiper washer
Rear wiper washer push button:

it activates the rear wiper washer
Heater push button:

it activates fan an heater system
Hazard light push button:

it activates hazard lightsystem
Brakes liquid level warning light:

the brakes liquid is going to finish; the warning message persists until the specific tank is refilled
3-5
0
1
2
3
4
MAPS FOR USING THE DASHBOARD 5
6
7
8
USER MENU
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-6
USER MENU MAP
TRIP H:M 00000:00
hh:mm
gg/mm/aa
3-7
USER MENU DESCRIPTION

The "user" menu is accessible to any operator, and allows to modify parameters series contained in the
chart USER MENU.
USER MENU PASSWORD
Notes on password insertion
0
1. Make sure to operate on the display membrane buttons using fingers only. Sharped or pointed tools
may damage the buttons
1
2. If, during the password insertion, an error is committed, turn the vehicle off with the key and restart
from the beginning. If the menu of hidden functions doesn't appear after a few attempts, the system 2
could be defective.
3
USER MENU PASSWORD INSERTION PROCEDURE
4
5
6
7
8
9
10
11
12
13
Procedure Operations Truck feedback
14
1 Turn the truck on 15
Short acoustic warning
2 Press the ON button for 3 sec.
(3 bips) 16
17
18
19
20
21
E
3-8
USER MENU
Menu Description Notes
The display shows the effectuated working hours of: Unless otherwise indicated,
WORKING: lifting motor working count of the hours is
HOUR TRACTION: traction motor working effectuated on the use of the
METER KEY: truck on (inserted key) lifting potentiometer and it is
RENT: rental time counter possible to reset it by the
SERVICE: truck working since the last service intervention service staff
It is possible to reset it by the
operator pressing the OK
TRIP It is a partial hour meter on the lifting motor use
button for some
seconds
CLOCK It permits to modify hours and date
The activated alarm is shown
ALARMS It allows, if enabled, to set an alarm as memo on the display with the
relevant light
It permits to modify:
- the counting of the truck working hours visualized on the
diplay:
None: no visualization
Key: it visualizes the key working hours
DISPLAY
Working: it visualizes pump working hours
SETTING
Traction: it visualizes traction working hours
- the language visualised by the “user“ menu
(5 languages: ita,en,fr,es,de)
- visualisation of the direction wheels position
(linear or radial modality)
HEATER
FAN AND
HEATER It permits to activate the follow device:fan, front heater or
REAR/ rear heater.
FRONT
WINDOWS
3-9
HOUR METER
Enter the user menu

[see USER MENU PASSWORD INSERTION PROCEDURE
paragraph] 0
Press or to visualize the information referred to the
hour meter 1
To exit the menu use lateral flowing arrows
2
TRIP 3
Press to visualize the information referred to the trip. 4
Press OK to reset the hours count
To exit the menu use lateral flowing arrows
5
TRIP H:M 00000:00
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-10
CLOCK
Enter the user menu

paragraph]
Press OK to enter into the clock menu

Notes:
The clock icon flashes
Press or to modify the setting.

Press OK to confirm.
24 Notes:
The selected modality has a flag beside
Use the flowing arrows to set the hours.

Press OK to confirm
hh:mm
Use the flowing arrows to set the date.

Press OK to confirm
gg/mm/aa Press OUT to exit the menu
3-11
ALARMS
SETTING
Enter the user menu
paragraph] 0
Use to reach the clock alarm menu
1
2
Press OK to confirm 3
Notes:
The clock icon flashes 4
5
Press OK to confirm
Use the flowing arrows to set the hours 6
hh:mm Press OK to confirm
7
8
Use the flowing arrows to set the date.
gg/mm/aa Press OUT to exit the menu 10
11
DEACTIVATION
Enter the user menu
12
paragraph] 13
Use to reach the clock alarm menu.
Press OK to confirm
14
15
Press the buttons or to disable the clock alarm 16
Notes:
The clock icon flashes 17
18
Press OK to confirm
19
Press OUT to exit the menu
20
21
E
3-12
DISPLAY SETTING
TRUCK HOUR METER
Enter the user menu
paragraph]
Use to reach the display setting menu.
Press OK to confirm
Press OK to confirm
Press OK to confirm
Use flowing arrows to set the hour meter modality visualized

on the display.
Press OK to confirm

3-13
LANGUAGE
Enter the user menu
paragraph]
Use to reach the display setting menu. 0
Press OK to confirm
1
Use to reach the language setting menu 2
3
4
6
7
Use to select the desired language. 8
Press OK to confirm
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-14
STEERING DIRECTION
Enter the user menu
paragraph]
Use to reach the display setting menu.
Press OK to confirm
Use to reach the steering direction setting menu
Press OK to confirm
Use to select the desired visualisation.

Press OK to confirm

3-15
HEATER FAN AND HEATED REAR WINDOWS (OPT)

Press button to access the Heater menu.
The heating menu appears if the options are enabled in the
service menu.
(see chapter 3, paragraph TRUCK CONF). 0
1
The menu shows the available optional devices: 2
• Fan
• Front defroster 3
• Heated rear window
• Heated seat 4
5
6
7
8
9
Select the device by arrow and arrow.
Select the device ON or OFF mode by LEFT arrow and 10
RIGHT arrow.
When the heated rear window and the heated seat are 11
turned on, the two icons appear on the display.
Both options switch off automatically after 15 minutes. 12
13
14
15
16
17
18
19
20
21
E
3-16
MAPS FOR USING THE DASHBOARD
SERVICE MENU
3-17
SERVICE MENU DESCRIPTION

The "service" menu allows to enable all necessary functions for assistance/maintenance/rental activities.
The access to this menu is for authorized personnel only.
SERVICE MENU PASSWORD
Notes on password insertion
0
1. Make sure to operate on the display membrane buttons using fingers only. Sharped or pointed tools
can damage the buttons
1
2. If, during the password insertion, an error is committed, turn off the vehicle with the key and restart
from the beginning. If the menu of the hidden functions doesn't appear after a few attempts, the system 2
could be defective.
3
SERVICE MENU PASSWORD INSERTION PROCEDURE
4
5
6
7
8
9
10
11
12
13
Procedure Operations Truck feedback 14
1 Turn the truck on
Short acoustic warning 15
2 Press the ON button for 5 sec.
(6 bips)
16
Insert the password (the password is dynamics and changes
automatically each January the 1st):
The password is composed by a sequence of numbers: the
17
3 correspondence between the keyboard buttons and the
numbers composing the password is available on the display. 18
The OUT button, indicated as OFF, in the display, allows to cancel
the last number typed by each pressure. 19
20
21
E
3-18
Menu Description
SOFT VERS Visualises the software version of boards and logic units
PARAM CHANGE Modify the selected program parameters
TRUCK CONF Modify the configuration parameters
SERVICE RENT It allows to set up the programmed maintenance menu and rent menu
PSW MODIFY It allows to modify the passwords or to restore default ones
TESTER Visualises analogic and digital values to analyze the truck status
Memorizes truck alarm codes (maximum 20 alarms).
ALARMS
It visualize the alarms in real time
Permits to set the truck serial number, to acquire the potentiometer status and to
LEARNING
effectuate the ADJUST BATTERY
DEFAULT RST It allows to restore the default parameters of the truck
3-19
SERVICE MENU MAP
0
1
PLEASE INSERT 2
SERV. PASSWORD 3
4
SOFT VERS 5
6
PARAM CHANGE 7
8
TRUCK CONF 9
10
SERVICE RENT 11
12
PSW MODIFY 13
14
TESTER 15
16
ALARMS 17
18
LEARNING 19
20
DEFAULT RST 21
E
3-20
SOFT VERS
Enter the service menu

[see SERVICE MENU PASSWORD INSERTION
PROCEDURE paragraph]
Press OK to confirm
SOFT VERS
Use right and left arrows board buttons to navigate the menu
SOFT VERS
“board”
“x.xx”
Keep pressed for 5 seconds to disable the parking
brake
SOFT VERS
Board Description Notes

EVCB Identify the MCB lifting section
TRCB Identify the MCB traction section
Available only with the
ARMREST Identify the armrest board
electric distributor
MASTER Identify the Master traction logic unit
SLAVE Identify the Slave traction logic unit
PUMP Identify the lifting logic unit
DISPLAY Identify the dashboard
X.XX Identify the software version
3-21
PARAM CHANGE

PROCEDURE paragraph] 0
1
2
Press till reach the PARAM CHANGE menu
Press OK to confirm
3
Use right and left arrows board buttons to select TRACTION
PARAM CHANGE or MAT. HANDLING 4
5
Press OK to confirm
PARAM CHANGE 6
7
MAT. HANDLING
8
9
PC MAT. HAND Press OK to modify the parameter
XXXXXXXXX 10
Use the button to select the set [L-P-H]
XXXHZ P PROF 0 Use the button to select the profile [0-1-2-3-4] 11

12
Press or to modify the value
PARAMETER Press OK to confirm 13
14
XX HZ
15
PARAMETER
Press OK to save; on the display the message SAVE 16
SUCCESSFUL appears, therefore press OUT to return to the
HZ
menu 17
Press OK to exit without saving
SAVE? 18
OK OUT
19
brake 20
PARAM CHANGE 21
E
3-22
TRACTION FUNCTION
The Traction function visualizes traction apparatus parameters. Parameter values could vary within an
established range.
Parameter Description Notes
This parameter determines the maximum FW speed. The maximum
speed can vary if the truck is equipped with 3 or 4 wheels
Max speed FW (Vmax 3 wheels= 145Hz; Vmax 4 wheels= 165Hz) HZ
- minimum setting = minimum speed
- maximum setting = maximum speed
This parameter determines the maximum BW speed. The
maximum speed can vary if the truck is equipped with 3 or 4 wheels
Max speed BW (Vmax 3 wheels= 145Hz; Vmax 4 wheels= 165Hz) Hz
This parameter determines the acceleration bend. Changing the param-
eter changes the acceleration time:
T ACC delay sec
- minimum setting = maximum acceleration
- maximum setting = minimum acceleration
T Throttle 0 This parameter determines a 0 value zone in the acceleration bend %
T Throttle X This parameter changes the characteristics of the acceleration bend %
T Throttle Y This parameter changes the characteristics of the acceleration bend %
Traction motors acceleration curve
SPEED (Hz)
MAX SPEED
Y
E LA
D
TROTTLE Y POINT CC
TA
0,7 Hz
V
VPOT MIN
TROTTLE 0 ZONE TROTTLE X POINT VPOT MAX
This parameter determines the motor torque on the basis of the selected
Trac torque prof 0,1,2,3,4
profile
3-23

This parameter determines the speed reduction when the battery indica-
tor reaches the 20% (battery nominal value residual charge=15%):
T 20 BDI cutback %
- minimum setting = minimum cutback
- maximum setting = maximum cutback 0
This parameter determines the speed reduction when the battery indica-
tor reaches the 10% (battery nominal value residual charge=more than 1
T 10 BDI cutback 10%): %
- minimum setting = minimum cutback 2
- maximum setting = maximum cutback
This parameter determines the speed reduction with the “low speed 3
selector“ push-button (turtle function) pressed:
T turtle cutback
- minimum setting = maximum cutback
% 4
- maximum setting = minimum cutback
This parameter determines the traction speed reduction in relation to the
5
state of the microswitch (normally closed N.C.) between pin 11 connec-
tor P4 and the GND of one of the micros on the board MCB. 6
T cutback speed1 - micro open = reduction on %
- micro closed = reduction off 7
- minimum setting 0% = maximum cutback
- maximum setting 100% = minimum cutback 8
This parameter determines the traction speed reduction in relation to the
state of the microswitch (normally open N.O.) between pin 18 connector 9
P4 and the GND of one of the micros on the board MCB.
- micro open = reduction on 10
T cutback speed2 - micro closed = reduction off %
- minimum setting 0% = maximum cutback 11
- maximum setting 100% = minimum cutback
Notes: Se la macchina è equipaggiata del microswitch SW16 (OPT) sul
montante, il parametro determina la riduzione di velocità in relazione allo
12
stato del micro.
13
Simplified wiring diagram T cutback speed 1 & 2
Microswitch
mast (OPT)
14
SW16
15
16
17
18
19
Microswitch N.C.
20
T cutback speed1
Microswitch N.O.
21
T cutback speed2
E
3-24

This parameter determines the deceleration ramp between the steering
T curve dec del angle defined by "Angle Inc" and the steering angle defined by "Angle sec.
Max"
Angle start This parameter determines the steering angle without speed reduction a°
Starting from "Angle start" this parameter determines a steering angle
Angle Inc on reaching which a speed reduction is activated, the maximum value of a°
which is defined by the parameter "% curve cutback inc"
This parameter determines the steering angle in which the maximum
Angle Max a°
speed reduction is defined by the parameter "Curve cutback max"
This parameter determines the speed reduction on reaching the steer-
ing angle defined by "Angle Inc" and it is a percentage of the speed
% curve cutb inc reduction fixed by the parameter "Curve cutback max" %
10% = Minimum speed reduction
100% = Maximum speed reduction
This parameter determines the maximum curve speed reduction on
reaching the angle fixed by the parameter "Angle Max". Modifying this
Curve cutb max parameter also affects the parameter "%curve cutback inc" %
4% = Maximum speed reduction
100% = Minimum speed reduction
Speed reduction diagram

SPEED
T cu
rve
dec
del
ANGLE°
Determines the rate of the brake potentiometer from which the drive
B throttle start %
speed reduction is started
Rate of the brake potentiometer value where reduction speed is fixed by
B throttle inc %
“T brake cutback Inc”
B throttle max Rate of the brake potentiometer value where reduction speed is the max %
This parameter determines the deceleration ramp according with B
T brake cutb inc %
throttle Inc
This parameter determines the deceleration ramp when the pedal brake
Pedal BRK start micro is pressed and the accelerator pedal is released: sec
the deceleration ramp according with “B throttle start”
3-25

Pedal BRK min Determines the deceleration ramp according with “B throttle max” sec
This parameter determines the deceleration ramp when the pedal brake
micro is pressed and the accelerator pedal is released:
BRK delay start
- minimum setting = minimum deceleration
sec 0
- maximum setting = maximum deceleration
1
This parameter determines the deceleration ramp where the reduction
speed is given by “B throttle max”:
BRK delay min
- minimum setting = minimum deceleration
sec 2
3
Initial BRK This parameter determines the braking beginning delay %
This parameter determines the deceleration ramp, varying the position 4
of the accelerator pedal but without releasing completely the pedal:
Speed limit BRK sec
- minimum setting = minimum deceleration 5
Reversing the direction this parameter determines the deceleration 6
ramp:
Inversion BRK sec
This parameter determines the deceleration ramp on releasing the 8
pedal. Changing the parameter changes the deceleration time:
Release BRK sec
10
11
12
13
14
15
16
17
18
19
20
21
E
3-26
Deceleration ramp with brake pedal and accelerator pressed

Traveling
speed
SPEED (%)
T brake
cutback
inc
Micro B throttle B throttle B throttle V brake

brake start inch max pot max
BRAKE POTENTIOMETER STROKE (%)
Deceleration ramp with brake pedal and accelerator pressed
Brake
delay
TIME (Sec.)
start
Brake
delay
min
Micro B throttle B throttle V brake

brake start max pot max
Deceleration ramp with accelerator pedal released and brake pedal pressed
Pedal
BRK
TIME (Sec.)
start
Pedal
BRK
min
Micro B throttle B throttle V brake

brake start max pot max

3-27
MAT. HANDLING FUNCTION

The Mat. Handling function visualizes lifting apparatus parameters. Parameter values could vary within an
established range.
MECHANICAL CONTROL VALVE VERSION

0
This parameter determines the minimum lifting speed with only the micro 1
closed. Changing the parameter changes the speed:
Min speed up Hz
- minimum setting = minimum speed 2
This parameter determines the minimum lifting speed. Changing the 3
parameter changes the speed:
Max speed up Hz 4
This parameter determines the tilting speed. Changing the parameter 5
changes the speed:
Tilt speed fine
Hz 6
This parameter determines the sideshift speed. Changing the parameter
7
changes the speed:
Shift speed fine
Hz 8
This parameter determines the 4th lever (IV way) speed. Changing the
9
IV WAY speed fine
Hz 10
This parameter determines the 5th lever (V way) speed. Changing the
11
V WAY speed fine
Hz 12
13
This parameter determines the power steering speed. Changing the
Hydro speed fine
Hz 14
15
This parameter determines the speed reduction with the “low speed
P turtle cutback
% 16
17
This parameter determines the lifting speed reduction in relation to the
state of the microswitch (normally closed N.C.) between pin 11 connec- 18
tor P4 and the GND of one of the micros on the board MCB.
P cutback speed1 - micro open = reduction on %
- micro closed = reduction off
19
- maximum setting 100% = minimum cutback 20
21
E
3-28

state of the microswitch (normally open N.O.) between pin 18 connector
- micro open = reduction off
- micro closed = reduction on
P cutback speed2 - minimum setting 0% = maximum cutback %
- maximum setting 100 % = minimum cutback
Notes: If the machine is equipped with the microswitch SW16 (OPT) on

the mast, the parameter determines the speed reduction in relation to the
state of the micro.
Simplified wiring diagram P cutback speed 1 & 2

Microswitch
mast (OPT)
SW16
Microswitch N.C.
P cutback speed1
Microswitch N.O.
P cutback speed2
This parameter determines the speed reduction when the battery

indicator reaches the 20% (battery nominal value residual charge=15%):
P 20 BDI cutback %
- minimum setting = minimum cutback
indicator reaches the 10% (battery nominal value residual charge=more
P 10 BDI cutback 10%): %
This parameter determines the acceleration bend of the pump motor.
Changing the parameter changes the acceleration time of the hydraulic
P ACC delay functions: sec
3-29

P Throttle 0 This parameter determines a 0 value zone in the acceleration bend %
P Throttle X This parameter changes the characteristics of the acceleration bend % 0
P Throttle Y This parameter changes the characteristics of the acceleration bend %
1
Lifting acceleration curve
2
SPEED (Hz)
MAX SPEED
3
Y 4
LA
TROTTLE Y POINT DE
CC 5
TA
6
7
0,7 Hz
8
V
VPOT MIN. 9
TROTTLE 0 ZONE TROTTLE X POINT VPOT MAX.
10
This parameter determines the motor torque on the basis of the selected 0,1,2,3,
Pump torque prof
profile 4 11
12
13
14
15
16
17
18
19
20
21
E
3-30
ELECTRIC CONTROL VALVE VERSION

This parameter determines the minimum lifting speed with only the micro
closed.
Min speed up Changing the parameter the speed changes: Hz
This parameter determines the minimum lifting speed.
Changing the parameter changes the speed:
Max speed up Hz
This parameter determines the tilting speed.
Tilt speed fine Hz
This parameter determines the sideshift speed.
Shift speed fine Hz
This parameter determines the 4th lever (IV way) speed.
IV WAY speed fine Hz
This parameter determines the 5th lever (V way) speed.
V WAY speed fine Hz
This parameter determines the power steering speed.
Hydro speed fine Hz
This parameter determines the speed reduction with the “low speed
P turtle cutback %
state of the microswitch (normally closed N.C.) between pin 11 connec-
tor P4 and the GND of one of the micros on the board MCB.
P cutback speed1 - micro open = reduction on %
- micro closed = reduction off
- maximum setting 100% = minimum cutback
3-31

state of the microswitch (normally open N.O.) between pin 18 connector
0
- micro open = reduction off
- micro closed = reduction on 1
P cutback speed2 - minimum setting = maximum cutback %
- maximum setting = minimum cutback 2
Notes:
If the machine is equipped with the microswitch SW16 (OPT) on the 3
mast, the parameter determines the speed reduction in relation to
the state of the micro. 4
Simplified wiring diagram P cutback speed 1 & 2 5
Microswitch
mast (OPT)
6
SW16
7
8
9
10
11
Microswitch N.C.
12
P cutback speed1
Microswitch N.O. 13
P cutback speed2
14
15
indicator reaches the 20% (battery nominal value residual charge = 16
P 20% BDI cutback 15%): %
- minimum setting = minimum cutback 17
This parameter determines the speed reduction when the battery 18
indicator reaches the 10% (battery nominal value residual charge =
P 10% BDI cutback more 10%): % 19
- maximum setting = minimum cutback 20
21
E
3-32

This parameter determines the acceleration ramp of the pump motor.
Changing the parameter changes the acceleration time of the hydraulic
P ACC delay functions: sec
This parameter determines the deceleration ramp of the pump motor.
Changing the parameter changes the deceleration time of the hydraulic
P DEC delay functions: sec
This parameter determines the motor torque on the basis of the selected 0,1,2,3,
Pump torque profile
profile 4
This parameter determines the joystick sensibility as a function of the 0,1,2,3,
Curve mode
potentiometer stroke 4
3-33
TRUCK CONF

1
2
Press till reach the TRUCK CONF menu
Use the right and left arrows board buttons to navigate the
TRUCK CONF menu
4
Press OUT to exit the menu 5

6
brake
7
TRUCK CONF
8
9
Function Description 10
OPTIONS Allows the machine configuration options to be enabled/disabled. 11
ROTARY LAMP 1 This function allows to enable/disable the rotary lamp 1 and to set the activation mode
ROTARY LAMP 2 This function allows to enable/disable the rotary lamp 1 and to set the activation mode
12
FLASH LAMP This function iallows to enable/disable the flash lamp and to set the activation mode 13
TAIL LIGHT This function allows to enable/disable the tail light
14
DIPPED LIGHT This function allows to enable/disable the dipped light
WORK LAMP This function allows to enable/disable the work lamp and to set the activation mode 15
WIPERS/ This function allows to enable/disable the wiper washer and to set the activation 16
WASHER mode
DIR LIGHTS This function allows to enable/disable the direction light 17

HEATER This function allows to enable/disable the heater, fan and rear windows 18
MOTORS This function visualizes the motors parameters
19
MCB OUT This function visualizes the MCB board parameters
RESET Reset of the hours counter and Fingertips-Joystick configuration 20

BATTERY This function visualizes battery parameters. 21
VALVE CURR Displays and modifies the currents of the solenoid valves of the electric distributor.
E
3-34
OPTIONS
Profile This parameter determines the profile loaded at the start up 0,1,2,3,4
Set This parameter determines the L-P-H setting
This parameter enables/disables the LPH push button working:
Lock set ON = enabled ON-OFF
OFF = disabled
This parameter determines which logo must be visualized at the
Start icon Cesab-BT
starting
This parameter enables/disables the Pin insertion request:
NONE = disabled
Pin code DISPLAY = enabled
DHU = [unused]
SESAM = [unused]
DY Pin enable This parameter determines the number of Pin Codes used 1÷40
This parameter enables/disables with balanced pedal system
Swaying pedal ON = enabled ON-OFF
OFF = disabled
This parameter identifies the truck: configuration
3W = 3 wheels (reduced maximum speed) 3W/4W/4W-
Steer table
4W = 4 wheels WA
4W-WA = [unused]
This parameter allows
• Activation of the lifting motor, keeping it at a constant rotation speed
(motor frequency 22Hz)
Test mode ON-OFF
• Release of the electric parking brakes
• Disabling of the electric braking of the traction motors, leaving only
the mechanical service braking of the traction reduction gears
This parameter enables/disables the 5th lever working
VTH enable ON = enabled ON-OFF
OFF = disabled
This parameter enables/disables the functioning of the button PB5
(enabling optional equipment)
Clamps ON-OFF
ON = enabled
OFF = disabled
This parameter enables/disables the tilting angle sensor
[unused]
Tilt sensor ON-OFF
ON = enabled
OFF = disabled
This parameter determines the tilting speed as a function of the
tilting angle measurement [optional]:
Tilt 2 speed Hz
This parameter determines the reduction ratio of the reduction gear
Gear ratio n°
in relation to the truck speed calculus
3-35
OPTIONS
This parameter enables/disables the buzzer when the seat micro is
open
Buzzer seat
ON = enabled
ON-OFF 0
OFF = disabled
1
Enables/disables the horn when the display button is activated.
Keys tone ON = enabled ON-OFF 2
OFF = disabled
This parameter enables/disables the truck automatic braking 3
Stop on ramp ON = enabled ON-OFF
OFF = disabled 4
This parameter enables/disables the speed reduction in case of
mast with height superior to 6250mm (for 3 wheels version the 5
High mast parameters MAX SPEED FW and MAX SPEED BW are ON-OFF
automatically disabled and the maximum speed depends on the 6
value setted in HIMAST SP LIM)
Himast Sp lim
If enabled, high mast determines the maximum FW or BW speed in
Hz
7
case of mast with height superior to 6250mm
This parameter enables/disables the following functions: 8
Curve acc delay - STEER ACC DELAY ON-OFF
- STEER THRESHOLD 9
This parameter determines the acceleration with steered direction
Steer acc delay wheels (the steering angle can be selected by the STEER Sec. 10
THRESHOLD parameter)
11
Steer threshold This parameter determines the direction wheels angle beyond which a°
the COMP STEER ACC parameter is enabled 12
This parameter determines the time to activate the auto power off
Time auto off Min.
function 13
Determines the delay of the power steering turning off when the
Hydro delay acc Sec.
request is switched off 14
Determines the delay of the power steering turning off when the
Hydro delay brk
request is switched off
Sec. 15
16
17
18
19
20
21
E
3-36
PROFILE DESCRIPTION
It is possible to modify the vehicle performances changing the set of parameters in the programs L-P-H or
loading a different profile in switch on phase.
PROFILE 0: standard profile
Trough default the vehicle is setted to load the profile 0 in modality P.
It is possible to select L-P-H depending of the operator requests using the button setting selector.
PROFILE 1: high performances
Contains the programs L-P-H regulated to have high performances of the vehicle.
To enter the profile is requested a password.
PROFILE 2/3: this profiles are available with the same setting of profile 0(L-P-H)
PROFILE 4: new operator
Contains the programs P with limited performances in order to help a new operator trusting the vehicle.
PIN CODE REQUEST ACTIVATION

Activating the pin code request, every time the truck is switched the display will request the pin code
insertion.
PIN CODE
The pin code permits to load a different profile from the default one “profile 0“.
At the switching on of the truck it is requested the insertion of a pin code.
Following the pin code list and the relevant profile.
PIN Profile PIN Profile PIN Profile PIN Profile PIN Profile
00323 0 10043 3 20102 1 30001 4 40010 2
01034 1 11020 4 21020 2 30204 0 40143 3
02021 2 11404 0 22010 3 32040 1 41342 4
02102 3 12403 1 22344 4 33300 2 41414 0
03033 4 13042 2 22433 0 33410 3 42231 1
03421 0 14143 3 23013 1 34010 4 43001 2
04031 1 14021 4 23401 2 34132 0 43203 3
04432 2 14322 0 24431 3 34343 1 44044 4
Pin codes and profiles can be modified using the PSW MODIFY menu .
3-37
ROTARY LAMP 1
This parameter enables/disables the rotary lamp (1)
LAMP ON = enabled ON-OFF
0
OFF = disabled
1
This parameter enables/disables the signal from the dashboard
when a turtle button is selected
WHIT TURTLE
ON = enabled
ON-OFF 2
OFF = disabled
3
when a traction function is selected 4
TRACTION ON-OFF
ON = enabled
OFF = disabled
5
when a hydraulic function is selected (no hydraulic requirement for 6
ANY PUMP power steering) ON-OFF
ON = enabled
OFF = disabled
7
SEAT
ON-OFF 8
when the seat micro is closed
This parameter enables/disables the signal from the dashboard 9
when the lifting/lowering potentiometer is selected
JOY 1 ON-OFF
ON = enabled 10
OFF = disabled
when the tilting potentiometer is selected
JOY 2 ON-OFF
ON = enabled 12
OFF = disabled
when the side shift potentiometer is selected
JOY 3 ON-OFF
ON = enabled 14
OFF = disabled
when the IV potentiometer is selected
JOY 4
ON = enabled
ON-OFF 16
OFF = disabled
This parameter enables/disables the rotary lamp according with the
17
parameter speed value
SPEED
ON = enabled
ON-OFF 18
OFF = disabled
This parameter is use to set the reference speed of the parameter
19
SPEED VALUE ON-OFF
speed
20
21
E
3-38
ROTARY LAMP 2
This parameter enables/disables the rotary lamp (2)
OFF = disabled
WHIT TURTLE ON-OFF
ON = enabled
OFF = disabled
when a traction function is selected
TRACTION ON-OFF
ON = enabled
OFF = disabled
when a hydraulic function is selected (no hydraulic requirement for
ON = enabled
OFF = disabled
SEAT ON-OFF
JOY 1 ON-OFF
ON = enabled
OFF = disabled
JOY 2 ON-OFF
ON = enabled
OFF = disabled
JOY 3 ON-OFF
ON = enabled
OFF = disabled
JOY 4 ON-OFF
ON = enabled
OFF = disabled
SPEED ON-OFF
ON = enabled
OFF = disabled
SPEED VALUE ON-OFF
speed
3-39
FLASH LAMP
This parameter enables/disables the flash lamp (1)
0
OFF = disabled
1
WHIT TURTLE
ON = enabled
ON-OFF 2
OFF = disabled
3
when a traction function is selected 4
TRACTION ON-OFF
ON = enabled
OFF = disabled
5
when a hydraulic function is selected (no hydraulic requirement for 6
ON = enabled
OFF = disabled
7
SEAT
ON-OFF 8
JOY 1 ON-OFF
ON = enabled 10
OFF = disabled
JOY 2 ON-OFF
ON = enabled 12
OFF = disabled
JOY 3 ON-OFF
ON = enabled 14
OFF = disabled
JOY 4
ON = enabled
ON-OFF 16
OFF = disabled
17
SPEED
ON = enabled
ON-OFF 18
OFF = disabled
19
SPEED VALUE ON-OFF
speed
20
21
E
3-40
TAIL LIGHT
LIGHTS This parameter enables/disables the tail light ON-OFF
DIPPED LIGHT
LIGHTS This parameter enables/disables the dipped light ON-OFF
WORK LAMP
This parameter enables/disables the front working lamp
LAMP FW ON = enabled ON-OFF
OFF = disabled
This parameter enables/disables the rear working lamp
LAMP BW ON = enabled ON-OFF
OFF = disabled
This parameter enables/disables the working lamp according with
the traction direction
MOTION ON-OFF
ON = enabled
OFF = disabled
Whit this parameter the front working lamp are always active and the
rear lamp only if the BW direction are selected
AUTO BW ON-OFF
ON = enabled
OFF = disabled
NOTE: To use the other options, the parameters 1 and 2 must be activated
WIPERS/WASHER
This parameter enables/disables the front wiper
FW ON = enabled ON-OFF
OFF = disabled
This parameter enables/disables the rear wiper
BW ON = enabled ON-OFF
OFF = disabled
This parameter enables/disables the wiper according with the trac-
tion direction
MOTION ON-OFF
ON = enabled
OFF = disabled
Whit this parameter the front wiper is always active and the rear only
if BW direction is selected
AUTO BW ON-OFF
ON = enabled
OFF = disabled
3-41
WIPERS/WASHER
This parameter enables/disables the front washer
WASHER FW ON = enabled ON-OFF
OFF = disabled
0
This parameter enables/disables the rear washer 1
WASHER BW ON = enabled ON-OFF
OFF = disabled 2
NOTE: To use the other options, the parameters 1 and 2 must be activated
3
DIR LIGHTS 4
Parameter Description Notes 5
This parameter enables/disables the turn light
2 FW + STOP ON = enabled ON-OFF 6
OFF = disabled
This parameter enables/disables the turn light for the road circulation 7
lighting system
2FW + 2 BW ON-OFF
ON = enabled 8
OFF = disabled
9
HEATER 10
This parameter enables/disables the heater
HEATER ON = enabled ON-OFF 12
OFF = disabled
This parameter enables/disables the heater fan 13
FAN ON = enabled ON-OFF
OFF = disabled 14
This parameter enables/disables the rear heated window
REAR W HEATER ON = enabled ON-OFF 15
OFF = disabled
Enables/disables the heated seat
16
HEATED SEAT ON = enabled ON-OFF
OFF = disabled 17
Enables/disables the auto-off function of the heating and of the heat-
ing fan by activating the seat micro
18
AUTO HEAT OFF ON-OFF
ON = enabled
OFF = disabled
19
Enables/disables the auto-off function of the heated rear window by 20
activating the seat micro
AUTO RWH OFF ON-OFF
ON = enabled
OFF = disabled
21
E
3-42
MOTORS
This parameter enables/disables the right traction motor encoder
control:
SLIP RH ON-OFF
ON = enabled
OFF = disabled
This parameter enables/disables the left traction motor encoder
control:
SLIP LH ON-OFF
ON = enabled
OFF = disabled
This parameter enables/disables the lifting motor encoder control:
SLIP PUMP ON = enabled ON-OFF
OFF = disabled
This parameter determines the traction motor current expressed in
percentage of the maximum current:
T MAX CURRENT %
- minimum setting = minimum voltage
- maximum setting = maximum voltage
This parameter determines the lifting motor current expressed in per-
centage of the maximum current:
P MAX CURRENT %
- minimum setting = minimum voltage
- maximum setting = maximum voltage
This parameter enables/disables the traction motor temperature
sensor
TRAC SENS TEMP ANALOG = analog
DIGITAL = digital
NONE = disabled
This parameter enables/disables the lifting motor temperature
sensor
PUMP SENS TEMP ANALOG = analog
DIGITAL = digital
NONE = disabled
3-43
MCB OUT
This parameter determines the supply voltage for the solenoid valves
PWM OUTPUT EV9 and EV10 (PWM1_EN and PWM2_EN). % 0
The value is a percentage of the battery voltage.
Enables/disables control of the solenoid valve EV9 1
PWM1 EN ON-OFF
(MCB connector P5 pin32)
Enables/disables control of the solenoid valve EV10
2
PWM2 EN ON-OFF
(MCB connector P5 pin34)
3
This parameter enables/disables the negative output on MCB card,
P5 connector, 23 pin when BW direction is selected: 4
OUT BW ON = enabled ON-OFF
OFF = disabled
Characteristics of the electric applicable load: +24V/ 42W
5
This parameter enables/disables the negative output on MCB card, 6
P5 connector, 23 pin when a hydraulic function is selected (no
hydraulic requirement for power steering)
OUT ANY PUMP
ON = enabled
ON-OFF 7
OFF = disabled
Characteristics of the electric applicable load: +24V/ 42W 8
P5 connector, 23 pin pin when the seat micro is closed:
9
OUT SEAT ON = enabled ON-OFF
OFF = disabled
10
11
P5 connector, 23 pin pin when the card arm, JAUX connector, 6 pin
is connected to a negative:
12
OUT JOY 1 ON-OFF
ON = enabled
OFF = disabled 13
14
is connected to a negative:
15
OUT JOY 2 ON-OFF
ON = enabled
OFF = disabled 16
17
is connected to a negative: 18
OUT JOY 3 ON-OFF
ON = enabled
OFF = disabled 19
20
P5 connector, 23 pin when turtle push-button is active:
OUT TURTLE ON = enabled ON-OFF 21
OFF = disabled
Characteristics of the electric applicable load: +24V/ 42W E
3-44
MCB OUT
P5 connector, 23 pin when the FW direction is selected
OUT FW ON = enabled ON-OFF
OFF = disabled
RESET
RESET JOY FLAG MCB board configuration reset (mechanical/electric control valve)
RESET PUMP HM Pump hours counter reset
RESET TRAC HM Traction hours counter reset
RESET KEY HM Key hours counter reset
BATTERY
This parameter allows the immediate rearmament of the battery
BDI TO 100%
indicator
This parameter determines the regulation of the rearmament
BDI RESET threshold when is required a charge with the battery state between %
the 70% and 90%
This parameter determines the set point of the discharging voltage.
It fixes the minimum battery voltage at which the last square on the
BDI ADJ MIN indicator switches off (indicator at 0%). V
(See chapter 1, paragraph ADJUSTING THE BATTERY AND THE
INDICATOR)
This parameter determines the set point of the charging voltage.
It fixes the battery voltage at which the first two squares of the bat-
BDI ADJ MAX tery indicator switch off (indicator at 90%). V
INDICATOR)
This parameter determines the voltage needed to rearm the battery
indicator on the display.
ADJUSTMENT 3 V
INDICATOR)
This parameter enables the discharge curve of in case of GEL
BDI GEL ON/OFF
battery
3-45
VALVE CURR
This parameter determines the min. current to the lower coil
MIN CURRENT
min. = 100 mA mA
0
LOW
max. = 500 mA
1
This parameter determines the min. current to the lift coil
MIN CURRENT LIFT min. = 100 mA mA
max. = 500 mA
2
MIN CURRENT TILT
This parameter determines the min. current to tilt fw coil 3
min. = 100 mA mA
FW
max. = 500 mA 4
This parameter determines the min. current to the tilt bw coil
MIN CURRENT TILT
BW
min. = 100 mA mA 5
max. = 500 mA
MIN CURRENT SSH

This parameter determines the min. current to the side shitft lh coil 6
min. = 100 mA mA
LH
max. = 500 mA 7
This parameter determines the min. current to the side shift rh coil
MIN CURRENT SSH
min. = 100 mA mA 8
RH
max. = 500 mA
This parameter determines the min. current to the 4°way coil
9
MIN CURRENT 4
min. = 100 mA mA
WAY 1
max. = 500 mA 10
MIN CURRENT 4
This parameter determines the min. current to the 4°way coil
min. = 100 mA mA
11
WAY 2
max. = 500 mA
12
This parameter determines the min. current to the lower coil
MAX CURRENT
LOW
min. = 600 mA mA 13
max. = 1500 mA
MAX CURRENT
This parameter determines the max. current to the lift coil 14
min. = 600 mA mA
LIFT
max. = 1500 mA 15
This parameter determines the max. current to tilt fw coil
MAX CURRENT 16
min. = 600 mA mA
TILT FW
max. = 1500 mA
This parameter determines the max. current to the tilt bw coil 17
MAX CURRENT
min. = 600 mA mA
TILT BW
max. = 1500 mA 18
This parameter determines the max. current to the side shift lh coil
MAX CURRENT
min. = 600 mA mA
19
SSH LH
max. = 1500 mA
20
This parameter determines the max. current to the side shift rh coil
MAX CURRENT
min. = 600 mA mA
SSH RH
max. = 1500 mA
21
E
3-46
VALVE CURR
This parameter determines the max. current to the 4° way coil
MAX CURRENT 4
min. = 600 mA mA
WAY 1
max. = 1500 mA
This parameter determines the max. current to the 4° way coil
MAX CURRENT 4
min. = 600 mA mA
WAY 2
max. = 1500 mA
Valve
Total valve opening
100%
Zone not to be used
100 200 500 600 700 1500 mA
MIN CURR MAX CURR
MIN CURR:
Increasing or decreasing the value affects the sensitivity of the fingertip control in the initial phase.
MAX CURR:
Increasing or decreasing the value affects the maximum opening of the valve.
3-47
SERVICE RENT

1
2
Press till reach the SERVICE RENT menu
SERVICE RENT 4
5
6
brake
7
SERVICE RENT
8
9
10
Function Description Notes
11
SERV TIMER EN This function enables/disables the timer of programmed
(service timer enable) maintenance interventions 12
RESET SERV HM
(reset service This function resets the SERV TIMER EN timer 13
hourmeter)
This function determines the maintenance interval: When the setted 14
SERV REQ TIME time expires red
A reference (PROGRAMMED MAINTENANCE
(service request time) led starts to blink 15
DIAGRAM)
The wrench icon
SERV TIME BLINK
SERV REQ TIME expired notice:
and the red led 16
C reference (PROGRAMMED MAINTENANCE
(service time blink) start blinking at the
DIAGRAM)
truck ignition 17
This function determines, SERV REQ TIME expired, after
SERV CUT TIME
how much time the truck enters in limited working sys- 18
tem:
(service cutback time)
B reference (PROGRAMMED MAINTENANCE 19
DIAGRAM)
This function sets the percentage of working reduction 20
T SERV CUTBACK
when SERV CUT TIME is expired;
(traction service
cutback)
D reference (PROGRAMMED MAINTENANCE 21
DIAGRAM)
E
3-48

This function sets the percentage of working reduction
P SERV CUTBACK
when SERV CUT TIME is expired;
(pump service
D reference (PROGRAMMED MAINTENANCE
cutback)
DIAGRAM)
RENT TIMER EN This function enables/disables the timer of the rental
(rental timer enable) duration
This function determines (selects) the Timer Rent WH = hours
RENT TIME/DAY working in hours or days; if the DAY function is selected it DAY = days
is not possible to modify the date in the USER menu
T RENT CUTBACK
(traction rental
when RENT CUT TIME or RENT CUT DAY are expired;
cutback)
P RENT CUTBACK
(pump rental
when RENT CUT TIME or RENT CUT DAY are expired;
cutback)
RESET RENT HM
(reset rental This function resets the timer RENT TIMER EN
hourmeter)
RENT REQ TIME This function determines the rent interval;
(rental request time) A reference (PROGRAMMED RENT DIAGRAM)
the RENT icon and
RENT TIME BLINK RENT REQ TIME expired notice: the red led starts
(rental time blink) C reference (PROGRAMMED RENT DIAGRAM blinking at truck
ignition
RENT CUT TIME This function determines, RENT REQ TIME expired, after
(rental cutback time) how much time the truck enters in limited working system
This function defines the day when Rent time stops A ref-
RENT END DAY erence (PROGRAMMED RENT DIAGRAM)
with DAY selected
This function determines, RENT END DAY expired, after Max duration
how much time the truck enters in limited working system 15 days
RENT DAY BLINK
C reference (PROGRAMMED RENT DIAGRAM)
with DAY selected
This function defines the activation time of the speed Max duration
RENT CUT DAY reduction; 15 days
B reference (PROGRAMMED RENT DIAGRAM)
3-49
PROGRAMMED MAINTENANCE DIAGRAM
During this interval the icon and the During this interval the icon and the
red led start blinking at the truck ignition red led are always lit
C A B
0
100%
1
Lifting 30% of the max speed
Traction 30% of the max speed 2
3
D
30% 4
5
0 480 500 520 t (wh)
(STEP±1) (STEP±50) (STEP±5) 6
PROGRAMMED RENT DIAGRAM
7
During this interval the RENT icon and the During this interval the RENT icon and the 8
red led start blinking at the truck ignition red led start are always lit
Speed (Hz) 9
C A B
10
100%
Lifting 30% of the max speed
11
Traction 30% of the max speed
12
13
D
30%
14
t (wh)
15
0 480 500 520
(STEP±1) (STEP±100) (STEP±1) 16
17
18
19
20
21
E
3-50
PSW MODIFY

Press till reach the PSW MODIFY menu

Press OK to confirm
PSW MODIFY menu
Press OK to enter the parameters modification and follow the
instructions visualized in the display

brake
PSW MODIFY

This function allows to modify pin code and related
CHANGE
profile
DEFAULT This function sets default password
3-51
TESTER

1
2
Press till reach the TESTER menu
3
menu
TESTER 4
5
6
brake
7
TESTER
8
9
10
11
TRACTION This function visualizes traction system values 12
MAT. HANDLING This function visualizes lifting system values
13
14
15
16
17
18
19
20
21
E
3-52
TRACTION
Theoretical speed of the external motor requested, in function to the
SPEED SETPOINT Hz
speed reduction
RH MOT SPD Frequency encoder right motor Hz
LH MOT SPD Frequency encoder left motor Hz
RH MOT TMP Right motor temperature C°
LH MOT TMP Left motor temperature C°
RH CTR TMP Master traction logic unit C°
LH CTR TMP Slave traction logic unit C°
Flowing values of the right motor, or speed difference between
RH SLIP rotating magnetic field and motor rotor: Hz
RH SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz)
Flowing values of the left motor, or the speed difference between
LH SLIP rotating magnetic field and motor rotor: Hz
LH SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz)
RH FREQU Frequency of the voltage and current signals supplyed to right motor Hz
LH FREQU Frequency of the voltage and current signals supplyed to left motor Hz
RH CUR RMS Root Mean Square value of the Rh traction motor current Amp
LH CUR RMS Root Mean Square value of the Lh traction motor current Amp
Pedal system input
CFG 1 = single pedal
2 = double pedal or balanced pedal
Forward direction micro
FW OFF / GND = non-active input, open switch ON-OFF
ON / +Vb = active input, closed switch
NOT FW Denied FW march micro ON-OFF
Backward direction micro
BW OFF / GND = non-active input, open switch ON-OFF
ON / +Vb = active input, closed switch
NOT BW Denied FW march micro ON-OFF
Consent micro state
EN OFF / GND = non-active input, closed switch ON-OFF
ON / +Vb = active input, open switch
NOT EN Denied consent micro state ON-OFF
Accelerator pedal potentiometer
TRAC POT V
Value in volt of the potentiometer
TRAC ACC Time to reach the maximun speed Sec.
Brake pedal micro
SERV BRK OFF = not active input, open switch ON-OFF
ON = active input, closed switch
3-53
TRACTION
Brake pedal potentiometer
BRAKE POT V
Potentiometer value in volt
0
Parking brake micro
PARKING BRAKE OFF = not active input, open switch ON-OFF 1
ON = active input, closed switch
Negative brakes unblocking sensor 2
BRAKE REL SENS OFF = not active input, open switch ON-OFF
ON = active input, closed switch 3
Reading of the voltage present on pin 13 of the connector P5 of the
MCB VOLT INPUT
board MCB (EVCB) with respect to the battery negative pole
V 4
Reading of the voltage present on pin 1 of the connector P1 by the
BATTERY Master traction logic unit with respect to the battery negative pole.
5
V
VOLTAGE This voltage reading may be set with the parameter ADJUST
BATTERY (see paragraph LEARNING) 6
Percentage value of the battery charge level read by the Master trac-
BATTERY CHARGE
tion logic unit
% 7
DIR JOY FW/BW directions potentiometer on the arm V 8
Steering angle potentiometer
STEER ANGLE a°
Value in volt of the potentiometer 9
10
MAT. HANDLING - MCB
11
LEVERS
LIFE PUMP Working hour counter from the first start Hours
13
LIFE KEY Working hour counter from the first start Hours
P SPD SET Motor theoretical speed requested referred to speed reduction Hz 14
P MOT SPD Lifting motor encoder frequency Hz
15
P MOT TMP Motor temperature C°
P CTR TMP Temperature of the hardware section that controls the motor C° 16
Flowing values of the left motor, or the speed difference between the
P SLIP rotating megnetic field and the motor rotor: Hz
17
P SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz)
18
P FREQU Frequency of the current and voltage signals supplied to the motor Hz
CURRENT RMS Current supplied to the lifting motor A 19
LIFT Lifting micro ON-OFF
20
LIFT POT Lifting potentiometer V
TILT Tilting micro ON-OFF 21
SIDESHIFT Sideshift micro ON-OFF
E
3-54
MAT. HANDLING - MCB

LEVERS
IV WAY 4th way micro ON-OFF
V WAY 5th way micro ON-OFF
LIFTING - MCB
JOYSTICK / FINGERTIPS
LIFE PUMP Working hour counter from the first start Hours
LIFE KEY Working hour counter from the first start Hours
P SPD SET Motor theoretical speed requested referred to speed reduction Hz
P MOT SPD Lifting motor encoder frequency Hz
P MOT TMP Motor temperature C°
P CTR TMP Temperature of the hardware section that controls the motor C°
Flowing values of the left motor, or the speed difference between the
P SLIP rotating megnetic field and the motor rotor: Hz
P SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz)
P FREQU Frequency of the current and voltage signals supplyed to the motor Hz
LIFT Lifting fingertips/joysticks S1 and S2 microswitches status ON-OFF
LIFT AUX Auxiliary digital input status (optional): unused OFF
TILT Tilting fingertips/joysticks S1 and S2 microswitches status ON-OFF
TILT AUX Auxiliary digital input status (optional): unused OFF
SSH Tilting fingertips/joysticks S1 and S2 microswitches status ON-OFF
SSH AUX Auxiliary digital input status (optional): unused OFF
IV 4th way fingertips/joysticks S1 and S2 microswitches status ON-OFF
IV AUX Auxiliary digital input status (optional): unused OFF
V 5th way fingertips/joysticks S1 and S2 microswitches status ON-OFF
V AUX 5th way micro OFF
IN6_1 Backward direction micro ON-OFF
IN6_2 Forward direction micro ON-OFF
IN6_3 Button for 4th way activation OFF
IN6_4 Unused OFF
IN6_5 Unused OFF
IN6_6 Available lifting speed reduction (optional) OFF
LIFT POT Lifting potentiometer (neutral position 2,45V ± 0,2 V) V
Current value requested from the armrest board to the EVCB for
LIFT SET Amp
lifting/lowering group
3-55
LIFTING - MCB
JOYSTICK / FINGERTIPS
TILT POT Tilting potentiometer (neutral position 2,45V ± 0,2 V) 0
TILT SET
tilting group
Amp 1
SSH POT Sideshift potentiometer (neutral position 2,45V ± 0,2 V) 2
SSH SET Amp
sideshift group 3
IV POT 4th way potentiometer (neutral position 2,45V ± 0,2 V)
Current value requested from the armrest board to the EVCB for the
4
IV SET Amp
4th way group
5
V POT 5th way potentiometer (neutral position 2,45V ± 0,2 V)
Current value requested from armrest board to the EVCB for the 5th 6
V SET Amp
way group
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-56
ALARMS

Press till reach the ALARMS menu

Press OK to confirm
ALARMS

brake
ALARMS

See diagnostic
REALTIME This function visualizes alarms in real time
code list
This function allows to visualize stored alarms and to erase
LOGBOOK
them
LOGBOOK
See diagnostic
READ This function visualizes last 20 alarms saved
code list
CLEAR This function deletes alarm list
3-57
LEARNING

1
2
Press till reach the LEARNING menu
Press OK to confirm
3
LEARNING 4
Press OK to enter parameters modification and follow
instructions visualized on the display
Press OUT to exit the menu 5
Keep pressed for 5 seconds
brake
to disable the parking 6
LEARNING 7
8
9
SERIAL NUMBER This function identifies the truck serial number
10
LEARN TRAC POT
This function determines acceleration potentiometer minimum ~ 1,8V 11
stroke maximum ~4,0V
LEARN BRAKE POT This function determines brake potentiometer stroke

minimum ~ 2.0V 12
maximum ~ 2.7V
Available only with 13
lever distributor
LEARN LIFT POT This function determines lifting potentiometer stroke
minimum ~ 0,1V 14
maximum ~9,8V
Parameter used to set the voltmeter inside the MASTER Modifiy with the 15
ADJUST traction logic unit for reading the battery voltage (see arrows and
BATTERY chapter 1, paragraph ADJUSTING THE BATTERY AND 16
THE INDICATOR)
SET STEER ZERO

This function determines the central position of the ~ 5,5V(3W) 17
direction wheels ~ 4,2V(4W)
The acquired voltage 18
has to be lower or
This function determines the maximum right position of
SET STEER RIGHT
the direction wheels
equal to: 19
~ 9,3V(3W)
~ 9,7V(4W) 20
The acquired voltage
This function determines the maximum left position of the
has to be bigger or 21
SET STEER LEFT equal to:
direction wheels
~ 1,5V(3W)
~ 1,5V(4W)
E
3-58
DEFAULT RST

1
2
Press till reach the DEFAULT RST menu
DEFAULT RST 4
Press OK to enter parameters modification and follow the
instructions visualized on the display 5
6
brake 7
DEFAULT RST
8
9
10
See paragraph NECESSARY
11
ADJUSTMENT AFTER
EVCB This function allows to reset the EVCB board
REPLACING A HARDWARE 12
COMPONENT
See paragraph NECESSARY 13
ADJUSTMENT AFTER
TRCB This function allows to reset the TRCB board
REPLACING A HARDWARE 14
COMPONENT
ARMREST This function allows to reset the ARMREST board 15
See paragraph NECESSARY
This function allows to reset the MASTER traction ADJUSTMENT AFTER 16
MASTER
logic REPLACING A HARDWARE
COMPONENT 17
This function allows to reset the SLAVE traction
SLAVE
logic 18
PUMP This function allows to reset the PUMP logic
19
DISPLAY This function allows to reset the DISPLAY
20
21
E
3-59
“INCORRECT START“ MANAGEMENT

The “INCORRECT START“ are recoverable errors, generated by:
• an incorrect starting procedure
• an incorrect sequence of use of the controls
These alarms block truck functioning temporarily, generating an alarm icon on the display. 0
Summary table of the “INCORRECT START“ 1
2
Icon Description Configuration Notes
Double pedal system

3
Direction pedal pressed during the Traction: NO
or balanced pedal
starting procedure
system
Lifting: YES 4
5
Traction: NO
Manual inversor in direction position Single pedal system
Lifting: YES
6
Hydraulic request during the starting Traction: NO 7
Mechanic distributor
procedure Lifting: NO
8
Hydraulic request during the starting
Electric distributor 9
procedure
10
Double pedal system
Traction: NO
Double request of direction setted or balanced pedal
Lifting: YES 11
system
12
Direction request with applyed parking Traction: NO
All
brake Lifting: NO 13
Seat micro opened during the direction or Traction: NO 14
All
during the hydraulic request Lifting: NO
15
Brakes liquid level warning light: the
brakes liquid is going to finish; the 16
warning message persists until the
appropriate tank is refilled.
All 17
In case of alarm the truck reduces the
maximum speed to about 5Km/ h 18
19
20
21
E
3-60
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
4-1
TROUBLESHOOTING
Page
CONNECTOR CHECK.................................................4-2
0
BEFORE TROUBLESHOOTING............................................ 4-2
1
WIRE HARNESS AND CONNECTOR
INSPECTION PROCEDURE .....................................4-3 2
MECHANIC DISTRIBUTOR SYSTEM
CONFIGURATION.....................................................4-5
4
ELECTRIC DISTRIBUTOR SYSTEM
CONFIGURATION.....................................................4-6 5
DIAGNOSIS CODE LIST .............................................4-7 6
WHEN AN ERROR CODE IS DISPLAYED................4-15 7
MASTER TRACTION LOGIC UNIT ...................................... 4-15
8
SLAVE TRACTION LOGIC UNIT...............................4-36
9
LIFTING LOGIC UNIT ................................................4-51
MCB CONTROL BOARD (section EVCB)................4-68 10
DASHBOARD ............................................................4-75 11
MCB CONTROL BOARD (section TRCB)................4-78 12
ARMREST BOARD....................................................4-83 13
14
15
16
17
18
19
20
21
E
4-2
CONNECTOR CHECK
BEFORE TROUBLESHOOTING
1. Disconnect the battery plug before connecting or

disconnecting each connector or terminal
2. When disconnecting a connector, do not pull it at the
harness but hold the connector itself and pull it after
unlocking it. To connect, push the connector fully until it
is locked in position
3. Bring a tester probe into contact with a connector

terminal from the rear side of the coupler (harness side)
4. If insertion from the rear side is impossible, as in the
case of a waterproof connector, bring the tester probe
carefully into contact with the terminal so as not to cause
deformation of the connector terminal
5. Do not touch connector terminals directly with your hand
6. When bringing tester probes into contact with live
terminals, prevent two tester probes from coming into
contact with each other
4-3
WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE

When any trouble occurs, first inspect the connectors and wire harness of the related circuit according to
the following procedure:
Continuity check
1. Disconnect the connectors at both ends of the
corresponding harness
2. Measure the resistance between corresponding
terminals of the connectors at both ends 0
Standard: 10 W or less
Notes: 1
Measure while lightly shaking the wire harness up and
down and sideways. 2
Reference:
Open circuit at the wire harness occurs rarely partway 3
through a vehicle wiring but mostly at connectors.
Inspect especially the sensor connectors with sufficient care 4
Short circuit check

3
3. Disconnect the connectors at both ends of the
corresponding harness 6
4. Measure the resistance between the corresponding
connector terminal and negative. Always inspect the 7
connectors at both ends
Standard: 1 MΩ or more 8
Notes:
Measure while lightly shaking the wire harness up and 9
down and sideways.
10
11
5. Measure the resistance between a terminal
corresponding to the connector terminal and N1. Always 12
inspect the connectors at both ends
Standard: 1 MΩ or more 13
Notes:
The wiring may short-circuit due to pinching by the body 14
or defective clamping.
15
16
17
18
4-4
Visual and contact pressure checks

• Disconnect the connectors at both ends of the
corresponding harness
• Visually inspect that there is neither rust nor foreign matter
trapped at connector terminals
• Inspect that there is no loosening or damage at the locked
portion. Also, lightly pull the wire harness from the
connector to check that it does not come off
• Insert a male terminal the same as that of the terminal to
check into a female connector and check the force if
extraction.
Defective contact may exist at a terminal where the
extracting force is less than that of other terminals
Notes:
Even if there is rust or foreign matter trapped at the
terminal, or the contact pressure between male and
female terminals is low, abnormal contact condition may
be changed to normal by disconnecting and
reconnecting the connector. In that case, repeat
connector connection and disconnection several times.
If defect is perceived even once, terminal contact may be
defective.
The above information, concerning the inspection of the connectors, are referred to specific type as shown
in the drawing. The same procedure must be apply for all type found on the machines.
4-5
MECHANIC DISTRIBUTOR SYSTEM CONFIGURATION
READER
DASHBOARD
MASTER OF 0
THE SYSTEM
1
2
Mechanic 3
distributor
MCB 4
Potentiometers,
microswitches. 3
6
7
8
9
10
TRACTION TRACTION 11
LIFTING
LOGIC UNIT LOGIC UNIT
SLAVE MASTER
LOGIC UNIT 12
13
14
Encoder Encoder Steering Encoder

15
potentiometer
16
17
18
CAN BUS ANALOGIC
4-6
ELECTRIC DISTRIBUTOR SYSTEM CONFIGURATION
DASHBOARD
MASTER OF
THE LIFTING
READER
ARMREST MASTER OF
BOARD THE SYSTEM
MCB Potentiometers,
microswitches
TRACTION TRACTION
LIFTING
LOGIC UNIT LOGIC UNIT
LOGIC UNIT
SLAVE MASTER
Encoder Encoder Steering Encoder

potentiometer
CAN BUS ANALOGIC

4-7
DIAGNOSIS CODE LIST
When an Error Code is Displayed

Displayed
Alarm specification Error mode Page
code
01 WATCHDOG MASTER TRACTION LOGIC UNIT: Self-diagnostic test 15
02 EEPROM KO MASTER TRACTION LOGIC UNIT: Fault in the memory area 15
0
03 LOGIC FAILURE #3 MASTER TRACTION LOGIC UNIT: Logic defect 15
04 LOGIC FAILURE #2
MASTER TRACTION LOGIC UNIT: Fault in the hardware
15 1
section
05 LOGIC FAILURE #1
MASTER TRACTION LOGIC UNIT: Undervoltage/overvoltage
16 2
protection
06 VMN LOW MASTER TRACTION LOGIC UNIT: Failure on VMN test 17 3
07 VMN HIGH MASTER TRACTION LOGIC UNIT: Failure on VMN test 18
08 CONTACTOR OPEN MASTER TRACTION LOGIC UNIT: Contactor driver failure 19 4
09 STBY I HIGH MASTER TRACTION LOGIC UNIT: Current sensor failure 19
CAPACITOR
3
10 MASTER TRACTION LOGIC UNIT: Capacitors not charged 20
CHARGE
HIGH MASTER TRACTION LOGIC UNIT: Logic unit temperature
6
11 21
TEMPERATURE upper to 85°C
MOTOR MASTER TRACTION LOGIC UNIT: Traction motor
7
12 22
TEMPERATURE temperature upper to 140°C
13 ENCODER ERROR MASTER TRACTION LOGIC UNIT: Encoder circuit failure 23
8
THERMIC MASTER TRACTION LOGIC UNIT: Logic unit termic sensor out
14
SENS KO of range
24 9
15 SAFETY IN MASTER TRACTION LOGIC UNIT: Logic unit arrest 24
10
MASTER TRACTION LOGIC UNIT: Notices the comunication of
16 CAN BUS KO 25
an another card
11
WAITING FOR MASTER TRACTION LOGIC UNIT:
17 25
NODE UNUSED 12
MASTER TRACTION LOGIC UNIT: Failure on the drivers that
18 AUX OUTPUT KO 25
controls the solenoid valve coil 13
19 DRIVER SHORTED MASTER TRACTION LOGIC UNIT: Contactor driver failure 26
20
CONTACTOR
MASTER TRACTION LOGIC UNIT: Contactor driver failure 26
14
DRIVER
21
AUX COIL
MASTER TRACTION LOGIC UNIT: Contactor driver failure 26
15
SHORTED
22 VACC NOT OK
MASTER TRACTION LOGIC UNIT: Steering potentiometer set-
27
16
ting not correct
23 INCORRECT START MASTER TRACTION LOGIC UNIT: UNUSED 27 17
MASTER TRACTION LOGIC UNIT: Closed microswitch not
24 SEAT MISMATCH 27
noticed 18
WRONG SET
25 MASTER TRACTION LOGIC UNIT: Battery voltage out of range 27
BATTERY
4-8

Displayed
code
MASTER TRACTION LOGIC UNIT:
26 REMOTE INPUT 27
UNUSED
MASTER TRACTION LOGIC UNIT:
27 BAD STEER 0-SET 27
UNUSED
MASTER TRACTION LOGIC UNIT: Potentiometer out of range
28 STEER SENSOR KO 28
or not connected
29 FORW + BACK MASTER TRACTION LOGIC UNIT: UNUSED 28
31 WATCHDOG LIFTING LOGIC UNIT: Self-diagnostic test 51
32 EEPROM KO LIFTING LOGIC UNIT: Fault in the memory area 51
33 LOGIC FAILURE #3 LIFTING LOGIC UNIT: Logic defect 51
34 LOGIC FAILURE #2 LIFTING LOGIC UNIT: Fault in the hardware section 51
35 LOGIC FAILURE #1 LIFTING LOGIC UNIT: Undervoltage/overvoltage protection 52
36 VMN LOW LIFTING LOGIC UNIT: Failure on VMN test 53
37 VMN HIGH LIFTING LOGIC UNIT: Failure on VMN test 54
38 CONTACTOR OPEN LIFTING LOGIC UNIT: Contactor driver failure 55
39 STBY I HIGH LIFTING LOGIC UNIT: Current sensore failure 55
CAPACITOR
40 LIFTING LOGIC UNIT: Capacitors not charged 56
CHARGE
HIGH
41 LIFTING LOGIC UNIT: Logic unit temperature upper to 85°C 57
TEMPERATURE
MOTOR LIFTING LOGIC UNIT: Traction motor temperature upper to
42 58
TEMPERATURE 140°C
43 ENCODER ERROR LIFTING LOGIC UNIT: Encoder circuit failure 59
44 THERMIC SENS KO LIFTING LOGIC UNIT: Logic unit termic sensor out of range 60
45 SAFETY IN LIFTING LOGIC UNIT: Activated protection 60
LIFTING LOGIC UNIT: Notices the comunication of an another
46 CAN BUS KO 61
card
WAITING FOR
47 LIFTING LOGIC UNIT: UNUSED 61
NODES
LIFTING LOGIC UNIT:
48 AUX OUTPUT KO 61
UNUSED
49 DRIVER SHORTED LIFTING LOGIC UNIT: Contactor driver failure 61
CONTACTOR
50 LIFTING LOGIC UNIT: Contactor driver failure 61
DRIVER
AUX COIL
51 LIFTING LOGIC UNIT: Contactor driver failure 62
SHORTED
WRONG SET
55 LIFTING LOGIC UNIT: Battery voltage out of range 63
BATTERY
56 REMOTE INPUT XX LIFTING LOGIC UNIT: UNUSED 63
57 WAITING MHYRIO LIFTING LOGIC UNIT: UNUSED 63
58 I=0 EVER LIFTING LOGIC UNIT: UNUSED 63
4-9

Displayed
code
59 UNUSED UNUSED 63
60 UNUSED UNUSED 63
61 WATCHDOG SLAVE TRACTION LOGIC UNIT: Self-diagnostic test 36
62 EEPROM KO SLAVE TRACTION LOGIC UNIT: Fault in the memory area 36
0
63 LOGIC FAILURE #3 SLAVE TRACTION LOGIC UNIT: Logic defect 36
64 LOGIC FAILURE #2
SLAVE TRACTION LOGIC UNIT: Fault in the hardware
36 1
section
65 LOGIC FAILURE #1
SLAVE TRACTION LOGIC UNIT: Undervoltage/overvoltage
37 2
protection
66 VMN LOW SLAVE TRACTION LOGIC UNIT: Failure on VMN test 38 3
67 VMN HIGH SLAVE TRACTION LOGIC UNIT: Failure on VMN test 39
68 CONTACTOR OPEN SLAVE TRACTION LOGIC UNIT: Contactor driver failure 40 4
69 STBY I HIGH SLAVE TRACTION LOGIC UNIT: Current sensor failure 40
CAPACITOR
3
70 SLAVE TRACTION LOGIC UNIT: Capacitors not charged 41
CHARGE
HIGH SLAVE TRACTION LOGIC UNIT: Logic unit temperature upper
6
71 42
TEMPERATURE to 85°C
MOTOR SLAVE TRACTION LOGIC UNIT: Traction motor temperature
7
72 43
TEMPERATURE upper to 140°C
73 ENCODER ERROR SLAVE TRACTION LOGIC UNIT: Encoder circuit failure 44
8
74 THERMIC SENS KO
SLAVE TRACTION LOGIC UNIT: Logic unit termic sensor out of
range
45 9
75 SAFETY IN SLAVE TRACTION LOGIC UNIT: Logic unit arrest 45 10
SLAVE TRACTION LOGIC UNIT: Notices the comunication of
76 CAN BUS KO 46
an another card 11
WAITING FOR
77 SLAVE TRACTION LOGIC UNIT: UNUSED 46
NODE 12
SLAVE TRACTION LOGIC UNIT: Failure on the drivers that
78 AUX OUTPUT KO 46
controls the solenoid valve coil 13
79 DRIVER SHORTED SLAVE TRACTION LOGIC UNIT: UNUSED 46
80
CONTACTOR
SLAVE TRACTION LOGIC UNIT: UNUSED 46
14
DRIVER
81
AUX COIL
15
SHORTED
82 VACC NOT OK SLAVE TRACTION LOGIC UNIT: UNUSED 46 16
83 INCORRECT START SLAVE TRACTION LOGIC UNIT: UNUSED 46
SLAVE TRACTION LOGIC UNIT: Closed microswitch not 17
84 SEAT MISMATCH 47
closed
WRONG SET
18
85 SLAVE TRACTION LOGIC UNIT: Battery voltage out of range 47
BATTERY
86 REMOTE INPUT SLAVE TRACTION LOGIC UNIT: UNUSED 47
87 BAD STEER 0-SET SLAVE TRACTION LOGIC UNIT: UNUSED 48
4-10

Displayed
code
88 STEER SENSOR KO SLAVE TRACTION LOGIC UNIT: UNUSED 48
89 FORW+BACK SLAVE TRACTION LOGIC UNIT: Incorrect starting procedure 49
90 UNUSED UNUSED 82
91 UNUSED UNUSED 82
92 UNUSED UNUSED 82
93 UNUSED UNUSED 82
94 CHKSUM_ERROR MCB: Software error 82
95 UNUSED UNUSED 82
96 UNUSED UNUSED 82
97 UNUSED UNUSED 82
MASTER TRACTION LOGIC UNIT: Logic unit safety driver
0A SAFETY OUTPUT 29
defect
0B SLIP PROFILE MASTER TRACTION LOGIC UNIT: Error in the memory data 29
0C ANALOG INPUT MASTER TRACTION LOGIC UNIT: Control internal error 29
0D HARDWARE FAULT MASTER TRACTION LOGIC UNIT: Control internal error 29
POWER MOS
0E MASTER TRACTION LOGIC UNIT: Power circuit failure 29
SHORTED
0F FLASH CHECKSUM MASTER TRACTION LOGIC UNIT: Control internal error 30
1A SOFTWARE ERROR MASTER TRACTION LOGIC UNIT:UNUSED 30
MASTER TRACTION LOGIC UNIT: Right motor temperature
1B THERMIC MOT KO 31
sensor failure
1C RIGHT ENC LOCK MASTER TRACTION LOGIC UNIT: Right motor encoder failure 32
1D LEFT ENC LOCK MASTER TRACTION LOGIC UNIT: Left motor encoder failure 33
CONTACTOR
1E MASTER TRACTION LOGIC UNIT: Contactor driver failure 34
CLOSED
CHOPPER NOT UNITA’ LOGICA TRAZIONE MASTER:
2A 34
CONF UNUSED
MASTER TRACTION LOGIC UNIT: Steering potentiometer
2B STEER WIRE KO 34
failure
MASTER TRACTION LOGIC UNIT: The logic unit is in data
2C GAIN ACQUISITION 34
acquisition phase
2D WRONG 0 VOLT MASTER TRACTION LOGIC UNIT: Control internal error 35
2E UNUSED UNUSED 35
WRONG RAM MASTER TRACTION LOGIC UNIT: Activated antistatic
2F 35
MEMORY protection
LIFTING LOGIC UNIT:
3A SAFETY OUTPUT 63
UNUSED
3B SLIP PROFILE LIFTING LOGIC UNIT: Error in the memory data 63
3C ANALOG INPUT LIFTING LOGIC UNIT: Control internal error 63
3D HARDWARE FAULT LIFTING LOGIC UNIT: Control internal error 63
4-11

Displayed
code
POWER MOS
3E LIFTING LOGIC UNIT: Power circuit failure 64
SHORTED
3F FLASH CHECKSUM LIFTING LOGIC UNIT: Control internal error 64
4A SOFTWARE ERROR LIFTING LOGIC UNIT: UNUSED 64
4B THERMIC MOT KO LIFTING LOGIC UNIT: Right motor temperature sensor failure 65
0
4C ENCODER LOCK LIFTING LOGIC UNIT: Motor encoder failure 66 1
CONTACTOR
4E LIFTING LOGIC UNIT: Contactor driver failure 67
CLOSED 2
5A UNUSED UNUSED 67
5C GAIN ACQUISITION
LIFTING LOGIC UNIT: The logic unit is in data acquisition
67 3
phase
5E WRONG 0 VOLT LIFTING LOGIC UNIT: UNUSED 67 4
WRONG RAM
5F LIFTING LOGIC UNIT: Activated antistatic protection 67
MEMORY 3
6A SAFETY OUTPUT SLAVE TRACTION LOGIC UNIT: Logic unit safety driver defect 47
6B SLIP PROFILE SLAVE TRACTION LOGIC UNIT:Error in the memory data 47 6
6C ANALOG INPUT SLAVE TRACTION LOGIC UNIT: Control internal error 47
6D HARDWARE FAULT SLAVE TRACTION LOGIC UNIT: Control internal error 48
7
6E
POWER MOS
SHORTED
SLAVE TRACTION LOGIC UNIT: Power circuit failure 48 8
6F FLASH CHECKSUM SLAVE TRACTION LOGIC UNIT: Control internal error 48 9
7A SOFTWARE ERROR SLAVE TRACTION LOGIC UNIT: Error in a memory data 48
7B THERMIC MOT KO
SLAVE TRACTION LOGIC UNIT: Left motor temperature
49
10
sensor failure
7E
CONTACTOR
11
CLOSED
7F SP MISMATCH
SLAVE TRACTION LOGIC UNIT: Difference in the signals
50
12
reading between Master and Slave logics
8A
CHOPPER NOT
13
CONF
8B UNUSED UNUSED 50 14
SLAVE TRACTION LOGIC UNIT: The logic unit is in data
acquisition phase 15
8D WRONG 0 VOLT SLAVE TRACTION LOGIC UNIT: Control internal error 50
8E UNUSED UNUSED 50 16
WRONG RAM
8F
MEMORY
SLAVE TRACTION LOGIC UNIT: Activated antistatic protection 50 17
A1 DOUBLE REQ MCB: UNUSED 68
18
RELOAD_PARAM_W
A2 MCB: Occurred parameters loading signal 68
ARN
PARAM LOAD
A3 MCB: Error in the parameters loading in memory 68
ERROR
4-12

Displayed
code
A4 NOT_REP_ERROR MCB: Board in waiting information 68
A5 CHKSUM_ERROR MCB: UNUSED 68
MCB: Board in waiting information from the Master or lifting
A6 BOOT_ERROR 68
logic
HI SIDE DRIVER
A7 MCB: Board internal problem 69
SHORT
A8 EV1_1 OPEN MCB: EVP1 solenoid valve coil failure 69
A9 EV2_1 OPEN MCB: EVP2 solenoid valve coil failure 69
AA EV1_2 OPEN MCB: EVP3 solenoid valve coil failure 69
AB EV2_2 OPEN MCB: EVP4 solenoid valve coil failure 70
AC EV1_3 OPEN MCB: EVP5 solenoid valve coil failure 70
AD EV2_3 OPEN MCB: EVP6 solenoid valve coil failure 70
AE EV1_4 OPEN MCB: EVP7 solenoid valve coil failure 70
AF EV2_4 OPEN MCB: EVP8 solenoid valve coil failure 71
TRCB_MICRO_
B0 MCB: Board internal problem 71
ERROR
GROUP1 DRIVER MCB: Failure on a group 1 coil of the electroproportional
B1 71
SHORT distributor
B2 71
SHORT distributor
B3 72
SHORT distributor
B4 72
SHORT distributor
MCB: Failure on a group 5 coil of the electroproportional
B5 AUX_OUT_SHORT 72
distributor
MCB: Comunication problem between the MCB and the
B6 DASH_KO 72
dashboard
B7 ERR_SEAT MCB: Seat micro open with activated hydraulic functions 73
JOY_STUFFING_ MCB: Comunication problem between the MCB and the joystick
B8 73
ERR board
SET_SERIAL_
B9 MCB: Automatic setting of the serial not occurred 73
NUMBER
BA POT TILT NOT OK MCB: Incorrect reading of the tilting potentiometer voltage 73
C1 INCORRECT START MCB: Incorrect starting procedure 78
BAD_CONF_
C2 MCB: Error of configuration in the 3-4 wheels version 78
WHEELS
MCB: Failure in the signal of the accelerator potentiometer at
C3 PEDAL WIRE KO 79
rest
C4 BAD MICROSWITCH MCB: Pedal micro or direction lever failure 79
WARN_CONF_
C5 MCB: UNUSED 79
ERROR
4-13

Displayed
code
C6 BAD_VACC MCB: Accelerator potentiometer setting not correct 80
C7 ERR_SEAT MCB: Closed microswitch not noticed 80
BAD BRK
C8 MCB: Brake Pedal micro failure 80
MICROSWITCH
PARKING_
0
C9 MCB: Parking brake applyed and one of the function activated 81
SELECTED
PARAM LOAD
1
CA MCB: Error in the truck ignition 81
ERROR
CB UNUSED UNUSED 81
2
CC
TRAC_STUFFING_
ERR
MCB: Problem of comunication with the Master traction logic
unit
81 3
CD UNUSED UNUSED 81 4
CE UNUSED UNUSED 82
CF FW+BW MCB: Double request activated 82 3
DASHBOARD: The Master traction logic unit it is not readed by
D1 TRAC_KO 75
the dashboard 6
DASHBOARD: The MCB control board it is not readed by the
D2 MCB_TRAC_KO 75
dashboard 7
DASHBOARD: The Slave traction logic unit it is not readed by
D3 SLAVE_KO 75
the dashboard 8
DASHBOARD: The lifting logic unit it is not readed by the
D4 PUMP_KO 75
dashboard 9
DASHBOARD: The MCB control board it is not readed by the
D5 MCB_MHY_KO 76
dashboard 10
DASHBOARD: The armrest board it is not readed by the
D6 JOY_KO 76
dashboard 11
D7 UNUSED UNUSED 76
ERROR_READ_PIN DASHBOARD: The MCB control board prevents the password 12
D8 76
_CODE reading
D9 DHU KO DASHBOARD: Problem of communication with DHU device 76 13
DA SHOCK LOCKOUT DHU device asks for a speed reduction 76
14
DE KEY ERROR DASHBOARD: key signal not present. 77
DF EEPROM ERROR DASHBOARD: Defect in the memory area 77 15
ARMREST BOARD: Incorrect starting procedure (fingertips/ 83
E1
INCORRECT_ joystick version) 16
START MCB: Incorrect starting procedure (mechanic distributor 73
version)
17
84
ARMREST BOARD: Lifting potentiometer failure (fingertips/
E2 BAD LIFT POT joystick version)
74
18
MCB: Lifting potentiometer failure (mechanic distributor failure)
E3 BAD TILT POT ARMREST BOARD: Lifting potentiometer failure 85

E4 BAD SIDESH. POT ARMREST BOARD: Sideshift potentiometer failure 86
4-14

Displayed
code
E5 BAD IV POT ARMREST BOARD: 4th way potentiometer failure 87
E6 BAD V POT ARMREST BOARD: 5th way potentiometer failure 88
E7 ERR_SEAT ARMREST BOARD: Closed microswitch not noticed 88
INVALID RESTORE
E8 ARMREST BOARD: Failed predefined parameters restore 88
STATE
EEPROM_CHKSUM
E9 ARMREST BOARD: Error during the Eprom data uploading 89
_ERR
DEFAULT
EA ARMREST BOARD: Unploading of the flash memory data 89
RESTORED
ARMREST BOARD: Uploading of the flash memory data (fin- 89
POT NOT gertips/joystick version)
EB
ACQUIRED MCB: Lifting potentiometer acquisition request (mechanic distri- 74
butor version)
RAM_CHKSUM_
EC ARMREST BOARD: Uploading RAM data failed 89
ERR
MHYRIO_STUFFING
ED ARMREST BOARD: Comunication problem 89
_ERR
ARMREST BOARD: Comunication problem (fingertips/joystick 89
PUMP_STUFFING_E
EE version)
RR
MCB: Comunication problem (mechanic distributor version) 74
EF FW + BW ARMREST BOARD: UNUSED 89
F1 LIGHT SHORTED DASHBOARD: Board internal problem 90
4-15
WHEN AN ERROR CODE IS DISPLAYED

01 WATCHDOG
Condition for error detection

The test is executed is working status and in standby. Logic self-diagnostic test. 0
This alarm can be caused also by an incorrect functioning of the can-bus.
Check: 1
- check the truck isolation
- check the can-bus connections
- replace the electronic control
2
3
02 EEPROM KO
4
Condition for error detection 3
Defect in the memory area where the adjustment parameters are registered; this alarm inhibits the truck
working, the unit will load the default parameters.
6
Use the function RESET MASTER for reload the default parameters (see paragraph DEFAULT RST).
If the defect continues at the truck switching on, replace the control unit. 7
If the alarm desappears the parameters previously stored will be cancelled and automatically will be
loaded the default parameters of the electronic control. 8
9
03 LOGIC FAILURE #3
10
11
Logic defect.
- Replace the logic unit. 12
04 LOGIC FAILURE #2
13
14
Failure in the hardware section of the logic that manages the phase voltage feedback.
15
The alarms apperas also if the K2 contactor is open during the running.
Check: 16
- the pins 11 and 12 of the J50 connector. It could be present a false connection
- the contactor coil (100 ohm) 17
- the status of supplying cables connected at the motor
- replace the logic unit 18
4-16
05 LOGIC FAILURE #1

This alarm signals that it is started the interruption of the undervoltage/overvoltage protection.
- UNDER voltage: the logic unit keeps controlled the key input (pin 1, connector P1, M cable of the MD1
Master logic). If the voltage has a low peak, the alarm is signalled.
- OVER voltage: the logic unit controls the internal capacitors voltage. If the voltage has a hight peak
during the braking, the alarm is signalled.
The possible reasons are:
a. Battery undervoltage/overvoltage, lost of voltage after the ignition key or after the battery
connector.
b. If the alarm is signalled at the truck ignition and appears with the alarm 35 of the lifting logic unit
and the alarm 65 of the Slave logic unit, check:
• Key switch (DISPLAY)
• the battery plug
• the battery components status
• the status of the coils of the brakes solenoid valves EB1 and EB2
c. The alarm appers also when one or more motor phases do not present a correct isolation at a
movement request. Check the motor isolation (with disconnected battery): it has to be upper of
10 Mohm. To check the isolation verify the resistance value between the motor power cable and a
screw on the chassis. If noticed a low voltage value proceed to remove the single components in
order to establish the problem source. Or check the motor power cables isolation
d. Defect in the logic hardware section that controls the protection against the overvoltage.
Logic defect. Replace the logic unit.
4-17
06 VMN LOW

Failure in the VMN test.
The test begins at the switching on; check the connections of the 3 supplying cables from the logic unit to
the traction motor, the status of the cables and the status of the coil of the K2 contactor (100 Ohm). If the
coil is interrupted the truck will signal the alarm at the switching on. If the coil value is ok, proceed 0
following one of the test below described in order to establish if the failure is produced by a cause
internal or external to the logic: 1
2
3
4
3
6
TEST 1
- Apply the parking brake and switch off the truck
- Open the compartment and disconnect the battery
7
- Check the tightening of the power cables on the motor
- Check the tightening of the power cables on the logic 8
- Check the continuity values between the following points on the control using a tester:
Red tip Black tip 9
Um - (+) = 13 Kohm
Vm - (+) = 13 Kohm 10
Wm - (+) = 13 Kohm
Um - (-) = 13 Kohm If noticed values very different from the beside
Vm - (-) = 13 Kohm one, disconnect all the logic power cables and 11
Wm - (-) = 13 Kohm verify the values directly on the control
Um - Vm = 0 ohm 12
Um - Wm = 0 ohm
Vm - Wm = 0 ohm 13
Values on the control with disconnected motor:
Um - (+) = 32 Kohm
Vm - (+) = 27 Kohm
14
Wm - (+) = 32 Kohm
Um - (-) = 32 Kohm 15
Vm - (-) = 27 Kohm
Wm - (-) = 32 Kohm If an opened circuit is noticed replace the control. 16
Um - Vm = 46 Kohm
Um - Wm = 46 Kohm 17
Vm - Wm = 46 Kohm
TEST 2
Connect the Master traction logic unit to the motor Slave and check if on the display appears the “06” 18
alarm code.
YES: replace the Master logic unit
If the “66” alarm appers verify the motor status
4-18
07 VMN HIGH

The test starts when the ignition key is turned in ON position and there is no current consuption (machine
stationery). The alarm appears if the power circuit connections are open; check the connection of the 3
power cables from the logic unit to the traction motor and the cables condition.
To determine the cause of the fault, proceed by running one of the tests described below:
TEST 1
- Apply the parking brake and switch of the truch
- Check the tightening of the power cables on the logic
Red tip Black tip
Um - (+) = 13 Kohm
Vm - (+) = 13 Kohm
Wm - (+) = 13 Kohm
Um - (-) = 13 Kohm If noticed values very different from the beside
Vm - (-) = 13 Kohm one, disconnect all the logic power cables and
Wm - (-) = 13 Kohm verify the values directly on the control
Um - Vm = 0 ohm
Um - Wm = 0 ohm
Vm - Wm = 0 ohm
Um - (+) = 32 Kohm
Vm - (+) = 27 Kohm
Wm - (+) = 32 Kohm
Um - (-) = 32 Kohm
Vm - (-) = 27 Kohm
Wm - (-) = 32 Kohm If an opened circuit is noticed replace the control.
Um - Vm = 46 Kohm
Um - Wm = 46 Kohm
Vm - Wm = 46 Kohm
TEST 2
Connect the Master traction logic unit to the motor Slave and check if on the display appears the “07”
alarm code.
4-19
08 CONTACTOR OPEN

K2 contactor failure. The contactor is supplyied but the controls not close.
- Check the coil of the K2 main contactor (100 Ω) and the relevand cables
- Check the contacts status (current passage not permitted)
0
1
2
3
4
3
6
7
8
09 STBY I HIGH
9
10
11
Current sensor failure.
- Replace the Master traction logic unit
12
13
14
15
16
17
18
4-20
10 CAPACITOR CHARGE

At the ignition, the logic unit tries to charge the condensers by an internal power resistance and an inter-
nal diode, and checks that the condensers are charged in the arranged time. If this does not occur, an
alarm is send; the main contactor remains open.
- Check the negative connection between the logic unit and the battery
- Check the voltage at the key entrance (pin 1, connector P1, cable M of the MD1 Master logic):
the battery voltage must be present
- Verify the correct connection of the pin 5, calble M of the connector J137
- Disconnect the J15 connector. If the alarm disappears check the status of the temperature sensor
and of the motor encoder
- If the alarm persist, replace the logic unit
If the alarm appears along with alarm 70 of the Slave logic unit, check as follows to find the faulty control:
- Disconnect the cable (T+) from the Master logic unit and the cable (+) from the Slave logic.
- Using a multimeter, check the voltage between the positive (+BF) and the negative (-B) of both logic
units
- Replace the logic unit with voltage between -B and +BF close to zero.
4-21
11 HIGH TEMPERATURE

The logic unit temperature is upper of 85°C. The maximum current is proportionally reduced at the tem-
perature increase.
At 105°C the current is reduced at 0 and the control unit is arrested
Check: 0
- the RH CONTR TEMP parameter (menu TESTER of the dashboard). If below 85°C, replace the
Master traction logic unit. 1
2
3
4
3
6
7
8
9
10
11
12
13
14
15
16
17
18
4-22
12 MOTOR TEMPERATURE

This alarm appears when the motor temperature sensor reaches 140°C.
After the 140°C the logic unit reduces the acceleration proportionally and the current until 150°C.
After the 155°C completely cuts the current.
If the alarm appears when the motor is cold, check:
- that the wiring harness circuit of the temperature sensor is correctly connected
- that the temperature sensor is always open or that has a voltage value upper to the relative voltage
value (140°C see the following table)
AMBIENT TEMPERATURE RESISTANCE TEMP.

(°C) (°F) (%/K) MIN. TYP. MAX ERROR
(K)
-40 -40 0,84 340 359 379 ±6,48
-30 -22 0,83 370 391 411 ±6,36
-20 -4 0,82 403 424 446 ±6,26
-10 14 0,80 437 460 483 ±6,16
0 32 0,79 474 498 522 ±6,07
10 50 0,77 514 538 563 ±5,98
20 68 0,75 555 581 607 ±5,89
25 77 0,74 577 603 629 ±5,84
30 86 0,73 599 626 652 ±5,79
40 104 0,71 645 672 700 ±5,69
50 122 0,70 694 722 750 ±5,59
60 140 0,68 744 773 801 ±5,47
70 158 0,66 797 826 855 ±5,34
80 176 0,64 852 882 912 ±5,21
90 194 0,63 910 940 970 ±5,06
100 212 0,61 970 1000 1030 ±4,9
110 230 0,60 1029 1062 1096 ±5,31
120 248 0,58 1089 1127 1164 ±5,73
130 266 0,57 1152 1194 1235 ±6,17 Reduction of current
160 320 0,53 1350 1407 1463 ±7,59
170 338 0,52 1420 1482 1544 ±8,1
180 356 0,51 1492 1560 1628 ±8,62
190 374 0,49 1566 1640 1714 ±9,15
200 392 0,48 1641 1722 1803 ±9,71
210 410 0,47 1719 1807 1894 ±10,28
220 428 0,46 1798 1893 1988 ±10,87
230 446 0,45 1879 1982 2085 ±11,47
240 464 0,44 1962 2073 2184 ±12,09
250 482 0,44 2046 2166 2286 ±12,73
260 500 0,42 2132 2261 2390 ±13,44
270 518 0,41 2219 2357 2496 ±14,44
280 536 0,38 2304 2452 2600 ±15,94
290 554 0,34 2384 2542 2700 ±18,26
300 572 0,29 2456 2624 2791 ±22,12
4-23
13 ENCODER ERROR

This alarm shows that the encoder information are incorrect or absents.
The encoder transmits signals only when the motor is working. The alarm is noticed by the logics when
40Hz are passed.
If on the dashboard appers the alarm and the operator makes the reset with the key with the machine 0
stopped, the alarm disappears.
If the alarm is signalled before to reach 40 Hz, the problem could be an incorrect isolation of a supplying 1
cable on the chassis: without the correct encoder signals, the machine remains stopped or it moves very
slowly. To determine if the problem is from the encoder or from the logic, proceed as follows:
Set up SLIP CONTROL on OFF and accelerate slowly.
2
The increase of the motor speed does not shows necessarily that the problem is connected at the
encoder. One of the followings components could be defective: 3
- Internal logic ciruit
- Wiring harness 4
- Encoder
Use an analogic or digital multimeter to determine where is located the problem. 3
Encoder basic electric diagram.
In picture it is shown only a signal (A).
6
The encoder generates two same signals, but out
of phase of 90°(A-B). 7
1. Connect the positive tip of the tester (red) to
the positive one of the encoder. 8
2. Connect the COM tip of the tester (black) to
the encoder signal (A). 9
In base of the motor position, it will show the
following values:
• low signal: 0,5 - 1,5 Volt
10
• hight signal: 10,5 - 11,5 Volt
11
It is not possible to read intermediate values with
the motor stopped.
If the motor is working, the multemeter will
12
automatically read the Mv (medium value)
13
Mv= 5,5 - 6,5 Volt
Carrying out this test directly on the logic 14
connectors it is possible to determine if the
signals are good (see upper description) or if the
channels are opened or in shour circuit. If the
15
signals are good, the problem could be on the
electronic control. 16
17
18
4-24
14 THERMIC SENSOR KO

Logic unit termic sensor out of range.
- Replace the logic unit.
15 SAFETY IN

Arrest of the Master traction logic.
Check:
- Alarms in the MD2 Slave logic unit
• If YES, the alarm it is only a consequence. Verify the Slave diagnostic
• If NO, presence/connection wiring harness on P1 connector, pin11, cable CN of the MD1 Master logic
• If NO, that the pin A19, connector P2, cable CN of the MD2 Slave logic is a GND
• If NO, check the status of the coils of the brakes solenoid valves EB1 and EB2
• If NO, internal fault of the logic unit
4-25
16 CAN BUS KO

Can-bus comunication failure. The alarm appears if the traction logic unit does not receive the
information from the MCB board or from the lifting logic unit or from the Slave logic unit.
Before to replace every board, verify:
- The dashboard alarms, to identify exactly the board that does not comunicate 0
- Can-bus pull-up resistance presence
• dashboard 180 Ohm 1
• MCB 180 Ohm
• armrest 180 Ohm 2
17 WAITING FOR NODE - UNUSED

3
4
18 AUX OUTPUT KO (AUX DRIVER OPEN/AUX DRIVER SHORTED)
3
Failure the driver that controls the elecric brake.
Verify: 7
- Correct connection of the EB1 electric brake.l
- Resistive value of the EB1 (34 Ohm) electric brake; if different replace the brake.
- Verify the F3(10A) fuse integrity.
8
If the first two condition are ok, proceed as following:
- Switch off the truck and disconnect the coil 9
- Verify thet between the 18, P1 connector, cable CL of the (MD1) Master logic and GND there is no con-
tinuity 10
If YES: replace the (MD1) Master traction logic unit;
If NO: verify again the connections and the electric brake status. 11
12
13
14
15
16
17
18
4-26
19 DRIVER SHORTED

Verify:
- the F3 (10 A) fuse integrity
- that between the pin 16, P1 connector, cable A of the (MD1) Master logic and the GND there is no con-
tinuity.
If YES: replace the (M11) Master traction logic unit
If NO: verify the (EB1)electric brake
Resistive value (34Ohm)
20 CONTACTOR DRIVER

Defect to the driver that controls the K2 contactor.
- Replace the (MD1) Master traction logic unit.
21 AUX COIL SHORTED

K2 contactor defect.
- Check the coil (100 ohm) status
- Check that there is no short circuit on the wiring harness
- Check the status of the coils of the brakes solenoid valves EB1 and EB2 (34 Ohm)
If the defect is dued to external causes, replace the logic unit.
4-27
22 VACC NOT OK
Condizione rilevamento errore

Fault in the steering potentiometer.
Effect the steering potentiometer setting (LEARN STEER POT).
0
23 INCORRECT START - UNUSED
1
24 SEAT MISMATCH 2
3
Opened seat micro during the traction. 4
Verify:
- The SW1 micro status 3
- Connection HN cable, pin 6, P1 connector of the (MD1) Master logic
- Connection HZ cable, pin 6, P2 connector of the (MD2) Slave logic 6
If the information of the seat micro is not arriving on both traction logics the alarm is signalled.
7
25 WRONG SET BATTERY
8
If the key is inserted on ON, the controller verify the battery voltage and compares it to the parameter set-
ted in "SET BATTERY" (Battery setting). If the real value is upper or lower of 20% of the nominal values, 10
it is present a failure.
- Check the battery status and, if necessary, replace the battery. 11
12
26 REMOTE INPUT - UNUSED
13
27 BAD STEER 0-SET - UNUSED
14
15
16
17
18
4-28
28 STEER SENSOR KO

This alarm signals a failure to the steering potentiometer cursor or to the relevant wiring harness.
Verify:
- The correct functioning of the potentiometer with a multemeter
- The correct connection of the wiring harness
- Effect again the steering potentiometer setting (LEARN STEER POT)
29 FORW + BACK - UNUSED

4-29
0A SAFETY OUTPUT

Slave SAFETY IN pilotage exit.
Master logic SAFETY driver defect.
Replace the Master logic unit.
0
0B SLIP PROFILE
1
Error in the memory data where the flowing parameters are loaded.
Make a RESET MASTER to re-load the default parameters. 3
If the problem presists replace the logic unit.
4
0C ANALOG INPUT
3
Control internal error.
Replace the logic unit. 7
0D HARDWARE FAULT 8
9
Control internal error. 10
Replace the logic unit.
11
0E POWER MOS SHORTED
12
13
The alarm signals a power circuit failure.
Verify the correct connection of the motor to the logic:
• One or more motor phases could be disconnected
14
• Power cables connection
Continuity values obtained directly on the control, with disconnected power cables: 15
Um - (+) = 32 Kohm
Vm - (+) = 27 Kohm 16
Wm - (+) = 32 Kohm
Um - (-) = 32 Kohm 17
Vm - (-) = 27 Kohm
Wm - (-) = 32 Kohm If an opened circuit is noticed replace the control.
Um - Vm = 46 Kohm
18
Um - Wm = 46 Kohm
Vm - Wm = 46 Kohm
4-30
0F FLASH CHECKSUM

- Restore the default parameters using the RESET MASTER function
1A SOFTWARE ERROR - UNUSED

4-31
1B THERMIC MOT KO

Interrupted or disconnected right motor temperature sensor.
Verify:
- Wiring harness
- Sensor resistive value 0

1
(K)
2
-40 -40 0,84 340 359 379 ±6,48
-30 -22 0,83 370 391 411 ±6,36 3
-20 -4 0,82 403 424 446 ±6,26
-10 14 0,80 437 460 483 ±6,16 4
0 32 0,79 474 498 522 ±6,07
10 50 0,77 514 538 563 ±5,98
20 68 0,75 555 581 607 ±5,89
3
25 77 0,74 577 603 629 ±5,84
30 86 0,73 599 626 652 ±5,79 6
40 104 0,71 645 672 700 ±5,69
50 122 0,70 694 722 750 ±5,59 7
60 140 0,68 744 773 801 ±5,47
70 158 0,66 797 826 855 ±5,34
80 176 0,64 852 882 912 ±5,21
8
90 194 0,63 910 940 970 ±5,06
100 212 0,61 970 1000 1030 ±4,9 9
110 230 0,60 1029 1062 1096 ±5,31
120 248 0,58 1089 1127 1164 ±5,73 10
11
160 320 0,53 1350 1407 1463 ±7,59
170 338 0,52 1420 1482 1544 ±8,1 12
180 356 0,51 1492 1560 1628 ±8,62
190 374 0,49 1566 1640 1714 ±9,15 13
200 392 0,48 1641 1722 1803 ±9,71
210 410 0,47 1719 1807 1894 ±10,28
220 428 0,46 1798 1893 1988 ±10,87
14
230 446 0,45 1879 1982 2085 ±11,47
240 464 0,44 1962 2073 2184 ±12,09 15
250 482 0,44 2046 2166 2286 ±12,73
260 500 0,42 2132 2261 2390 ±13,44 16
270 518 0,41 2219 2357 2496 ±14,44
280 536 0,38 2304 2452 2600 ±15,94
290 554 0,34 2384 2542 2700 ±18,26
17
300 572 0,29 2456 2624 2791 ±22,12
18
4-32
1C RIGHT ENC LOCK

Interrupted or disconnected right motor encoder.
The alarm appears after 10 seconds approximately with the accelerator pedal pressed.
The machine works at reduced speed and at maximum current.
P1 must be connected to the MASTER logic unit.
P2 must be connected to the SLAVE logic unit

The encoders generate two same signals, but out
of phase of 90°(A-B).
the positive one of the encoder.
the encoder signal (A).
following values:
the motor stopped.
Mv= 5,5 - 6,5 Volt
Carrying out this test directly on the logic
electronic control.
4-33
1D LEFT ENC LOCK

Interrupted or disconnected left motor encoder.
0
In picture it is shown only a signal (A). 1
2
2. Connect the COM tip of the tester (black) to 3
In base of the motor position, it will show the 4
following values:
• low signal: 0,5 - 1,5 Volt 3
It is not possible to read intermediate values with 6
the motor stopped.
If the motor is working, the multemeter will 7
Mv= 5,5 - 6,5 Volt 8
connectors it is possible to determine if the 9
channels are opened or in shour circuit. If the 10
12
13
14
15
16
17
18
4-34
1E CONTACTOR CLOSED

K2 contactor driver failure. The logic unit cuts the curret to the coil, but the controls remain closed.
Disconnect the battery and check:
- The K2 contactor windings and the relevant wiring harness
- Clean the contactor connections
- Check the control of the contactor directly on connector P1 of the MASTER logic unit.
2A CHOPPER NOT CONF - UNUSED
2B STEER WIRE KO

This alarm signals a failure in the steering potentiometer or in the relevant wiring harness.
Verify:
- Correct functioning of the pontentiometer using a multemeter
- Correct wiring harness connection (positive and negative)
2C GAIN ACQUISITION

This warning comunicates that the logic is in current acquisition phase.
In this phase the logic is not working.
If the alarm persists after the key reset, replace the logic unit.
4-35
2D WRONG 0 VOLT

Control internal error. Replace the logic unit.
2E UNUSED 0
1
2F WRONG RAM MEMORY
2
3
Activeted protection against the electrostatic charges.
Switch off and switch on again the machine. 4
3
6
7
8
9
10
11
12
13
14
15
16
17
18
4-36

61 WATCHDOG

The test is executed is working status and in standby. Logic self-diagnostic test.
This alarm can be caused also by an incorrect functioning of the can-bus.
Check:
62 EEPROM KO

If the defect continues at the truck switching on, replace the control unit.
If the alarm desappears the parameters previously stored will be cancelled and automatically will be
loaded the default parameters of the electronic control.
63 LOGIC FAILURE #3

Logic defect.
64 LOGIC FAILURE #2

Failure in the hardware section of the logic that manages the phase voltage feedback.
Check:
- the contactor coil (100 ohm)
- the status of supplying cables connected at the motor
- replace the logic unit
4-37
65 LOGIC FAILURE #1

Slave logic). If the voltage has a low peak, the alarm is signalled.
- OVER voltage: the logic unit controls the internal capacitors voltage. If the voltage has a hight peak 0
The possible reasons are: 1
a. Battery undervoltage/overvoltage, lost of voltage after the ignition key or after the battery
connector. 2
b. If the alarm is signalled at the truck ignition and appears with the alarm 35 of the lifting logic unit
and the alarm 05 of the Master logic unit, check:
• key switch (DISPLAY)
3
• the battery components status 4
c. The alarm appers also when one or more motor phases do not present a correct isolation at a 3
movement request. Check the motor isolation (with disconnected battery): it has to be upper of
10 Mohm. To check the isolation verify the resistence value between the motor power cable and a
screw on the chassis. If noticed a low voltage value proceed to remove the single components in
6
order to establish the problem source. Or check the motor power cables isolation
d. Defect in the logic hardware section that controls the protection against the overvoltage. 7
8
9
10
11
12
13
14
15
16
17
18
4-38
66 VMN LOW

coil is interrupted the truck will signal the alarm at the switching on. If the coil value is ok, proceed
following one of the test below described in order to establish if the failure is produced by a cause internal
or external to the logic:
TEST 1
Red tip Black tip
Us - (+) = 13 Kohm
Vs - (+) = 13 Kohm
Ws - (+) = 13 Kohm
Us - (-) = 13 Kohm If noticed values very different from the beside
Vs - (-) = 13 Kohm one, disconnect all the logic power cables and
Ws - (-) = 13 Kohm verify the values directly on the control
Us - Vs = 0 ohm
Us - Ws = 0 ohm
Vs - Ws = 0 ohm
Us - (+) = 32 Kohm
Vs - (+) = 27 Kohm
Ws - (+) = 32 Kohm
Us - (-) = 32 Kohm
Vs - (-) = 27 Kohm
Ws - (-) = 32 Kohm If an opened circuit is noticed replace the control
Us - Vs = 46 Kohm
Us - Ws = 46 Kohm
Vs - Ws = 46 Kohm
TEST 2
Connect the Master traction logic unit to the motor Slave and check if on the display appears the “06”
alarm code.
4-39
67 VMN HIGH

power cables from the logic unit to the traction motor and the cables condition. 0
1
2
3
4
3
TEST 1
- Apply the parking brake and switch of the truch 6
- Check the tightening of the power cables on the motor 7
- Check the continuity values between the following points on the control using a tester: 8
Red tip Black tip
Us - (+) = 13 Kohm
Vs - (+) = 13 Kohm
9
Ws - (+) = 13 Kohm
Us - (-) = 13 Kohm If noticed values very different from the beside 10
Vs - (-) = 13 Kohm one, disconnect all the logic power cables and
Ws - (-) = 13 Kohm verify the values directly on the control 11
Us - Vs = 0 ohm
Us
Vs -
- Ws
Ws
= 0 ohm
= 0 ohm
12
Us - (+) = 32 Kohm 13
Vs - (+) = 27 Kohm
Ws - (+) = 32 Kohm 14
Us - (-) = 32 Kohm
Vs - (-) = 27 Kohm 15
Ws - (-) = 32 Kohm If an opened circuit is noticed replace the control
Us - Vs = 46 Kohm
Us - Ws = 46 Kohm
16
Vs - Ws = 46 Kohm
TEST 2 17
Connect the Slave traction logic unit to the motor Master and check if on the display appears the “67”
alarm code. 18
YES: replace the Slave logic unit
4-40
68 CONTACTOR OPEN

69 STBY I HIGH

Current sensor failure.
- Replace the Slave traction logic unit
4-41
70 CAPACITOR CHARGE

- Check the negative connection between the logic unit and the battery 0
- Check the voltage at the key entrance (pin 1, connector P2, cable M of the MD2 Slave logic): the battery
voltage must be present 1
and of the motor encoder 2
If the alarm appears along with alarm 10 of the Master logic unit, check as follows to find the faulty
3
control:
- Disconnect the cable (T+) from the Master logic unit and the cable (+) from the Slave logic. 4
- Using a multimeter, check the voltage between the positive (+BF) and the negative (-B) of both logic
units 3
- Replace the logic unit with voltage between -B and +BF close to zero.
6
7
8
9
10
11
12
13
14
15
16
17
18
4-42
71 HIGH TEMPERATURE

perature increase.
Check:
- the correct functioning of the fan
- the air channel must be free
- the LH CONTR TEMP parameter (menu TESTER of the dashboard). If below 85°C, replace the
Slave traction logic unit.
4-43
72 MOTOR TEMPERATURE

If the alarm appears when the motor is cold, check: 0
- that the temperature sensor is always open or that has a voltage value upper to the relative voltage 1
2
(°C) (°F) (%/K) MIN. TYP. MAX ERROR 3
(K)
-40 -40 0,84 340 359 379 ±6,48 4
-30 -22 0,83 370 391 411 ±6,36
-20 -4 0,82 403 424 446 ±6,26 3
-10 14 0,80 437 460 483 ±6,16
0 32 0,79 474 498 522 ±6,07
10 50 0,77 514 538 563 ±5,98 6
20 68 0,75 555 581 607 ±5,89
25 77 0,74 577 603 629 ±5,84 7
30 86 0,73 599 626 652 ±5,79
40
50
104
122
0,71
0,70
645
694
672
722
700
750
±5,69
±5,59
8
60 140 0,68 744 773 801 ±5,47
70 158 0,66 797 826 855 ±5,34 9
80 176 0,64 852 882 912 ±5,21
90 194 0,63 910 940 970 ±5,06 10
100 212 0,61 970 1000 1030 ±4,9
110
120
230
248
0,60
0,58
1029
1089
1062
1127
1096
1164
±5,31
±5,73
11
140 284 0,55 1216 1262 1309 ±6,63 Reduction of current 12
160 320 0,53 1350 1407 1463 ±7,59 13
170 338 0,52 1420 1482 1544 ±8,1
180
190
356
374
0,51
0,49
1492
1566
1560
1640
1628
1714
±8,62
±9,15
14
200 392 0,48 1641 1722 1803 ±9,71
210 410 0,47 1719 1807 1894 ±10,28 15
220 428 0,46 1798 1893 1988 ±10,87
230 446 0,45 1879 1982 2085 ±11,47 16
240 464 0,44 1962 2073 2184 ±12,09
250
260
482
500
0,44
0,42
2046
2132
2166
2261
2286
2390
±12,73
±13,44
17
270 518 0,41 2219 2357 2496 ±14,44
280 536 0,38 2304 2452 2600 ±15,94 18
290 554 0,34 2384 2542 2700 ±18,26
300 572 0,29 2456 2624 2791 ±22,12
4-44
73 ENCODER ERROR

40Hz are passed.
If on the dashboard appers the alarm and the operator makes the reset with the key with the machine
If the alarm is signalled before to reach 40 Hz, the problem could be an incorrect isolation of a supplying
encoder. One of the followings components could be defective:
- Wiring harness
- Encoder
Use an analogic or digital multimeter to determine where is located the problem.

following values:
the motor stopped.
Mv= 5,5 - 6,5 Volt
electronic control.
4-45

75 SAFETY IN
0
1
Arrest of the Master traction logic.
2
Check:
- Alarms in the MD1 Master logic unit 3
• If YES, the alarm it is only a consequence. Verify the Slave diagnostic
• If NO, presence/connection wiring harness on P2 connector, pin11, cable LG of the MD2 Slave logic 4
• If NO, that the pin19, connector P1, cable LG of the MD1 Master logic is a GND
• If NO, check the status of the coils of the brakes solenoid valves EB1 and EB2
• If NO, internal fault of the logic unit
3
6
7
8
9
10
11
12
13
14
15
16
17
18
4-46
76 CAN BUS KO

information from the MCB board or from the lifting logic unit or from the Master logic unit.
- The dashboard alarms, to identify exactly the board that does not comunicate
• dashboard 180 Ohm
• MCB 180 Ohm
• armrest 180 Ohm
78 AUX OUTPUT KO

Failure the driver that controls the elecric brake.
Verify:
- Correct connection of the EB2 electric brake.l
- Resistive value of the EB2 (34 Ohm) electric brake; if different replace the brake.
- Verify the F3(10A) fuse integrity.
If the first two condition are ok, proceed as following:
- Switch off the truck and disconnect the coil
- Verify thet between the 18, P1 connector, cable SN of the (MD2) Slave logic and GND there is no conti-
nuity
If YES: replace the (MD2) Master traction logic unit;
If NO: verify again the connections and the electric brake status.
79 DRIVER SHORTED - UNUSED
80 CONTACTOR DRIVER - UNUSED
81 AUX COIL SHORTED - UNUSED
82 VACC NOT OK - UNUSED
83 INCORRECT START - UNUSED

4-47
84 SEAT MISMATCH

Opened seat micro during the traction.
Verify:
- The S2 micro status
- Connection HN cable, pin 6, P2 connector of the (MD2) Slave logic 0
- Connection HN cable, pin 6, P1 connector of the (MD1) Master logic
If the information of the seat micro is not arriving on both traction logics the alarm is signalled. 1
85 WRONG SET BATTERY 2
CCondition for error detection

3
If the key is inserted on ON, the controller verify the battery voltage and compares it to the parameter set- 4
ted in "SET BATTERY" (Battery setting). If the real value is upper or lower of 20% of the nominal values,
- Check the battery status and, if necessary, replace the battery.
3
6
86 REMOT INPUT - UNUSED
7
6A SAFETY OUTPUT 8
9
Master SAFETY IN pilotage exit. 10
Slave logic SAFETY driver defect.
Replace the Slave logic unit. 11
12
6B SLIP PROFILE
13
14
Make a RESET SLAVE to re-load the default parameters.
15
16
6C ANALOG INPUT
17
4-48
6D HARDWARE FAULT


Verify the correct connection of the motor to the logic:
Continuity values obtained directly on the control, with disconnected power cables:
Um - (+) = 32 Kohm
Vm - (+) = 27 Kohm
Wm - (+) = 32 Kohm
Um - (-) = 32 Kohm
Vm - (-) = 27 Kohm
Wm - (-) = 32 Kohm
Um - Vm = 46 Kohm If an opened circuit is noticed replace the control.
Um - Wm = 46 Kohm
Vm - Wm = 46 Kohm
6F FLASH CHECKSUM

- Restore the default parameters using the RESET SLAVE function
7A SOFTWARE ERROR - UNUSED

Make a RESET SLAVE to re-load the default parameters.
4-49
7B THERMIC MOT KO

Interrupted or disconnected right motor temperature sensor.
Verify:
- Wiring harness
AMBIENT TEMPERATURE RESISTENCE TEMP.

1
(°C) (°F) (%/K) MIN. TIP. MAX ERROR
(K)
2
-40 -40 0,84 340 359 379 ±6,48
-30 -22 0,83 370 391 411 ±6,36 3
-20 -4 0,82 403 424 446 ±6,26
-10 14 0,80 437 460 483 ±6,16 4
0 32 0,79 474 498 522 ±6,07
10 50 0,77 514 538 563 ±5,98
20 68 0,75 555 581 607 ±5,89
3
25 77 0,74 577 603 629 ±5,84
30 86 0,73 599 626 652 ±5,79 6
40 104 0,71 645 672 700 ±5,69
50 122 0,70 694 722 750 ±5,59 7
60 140 0,68 744 773 801 ±5,47
70 158 0,66 797 826 855 ±5,34
80 176 0,64 852 882 912 ±5,21
8
90 194 0,63 910 940 970 ±5,06
100 212 0,61 970 1000 1030 ±4,9 9
110 230 0,60 1029 1062 1096 ±5,31
120 248 0,58 1089 1127 1164 ±5,73 10
11
160 320 0,53 1350 1407 1463 ±7,59
170 338 0,52 1420 1482 1544 ±8,1 12
180 356 0,51 1492 1560 1628 ±8,62
190 374 0,49 1566 1640 1714 ±9,15 13
200 392 0,48 1641 1722 1803 ±9,71
210 410 0,47 1719 1807 1894 ±10,28
220 428 0,46 1798 1893 1988 ±10,87
14
230 446 0,45 1879 1982 2085 ±11,47
240 464 0,44 1962 2073 2184 ±12,09 15
250 482 0,44 2046 2166 2286 ±12,73
260 500 0,42 2132 2261 2390 ±13,44 16
270 518 0,41 2219 2357 2496 ±14,44
280 536 0,38 2304 2452 2600 ±15,94
290 554 0,34 2384 2542 2700 ±18,26
17
300 572 0,29 2456 2624 2791 ±22,12
18
4-50
7E CONTACTOR CLOSED - UNUSED
7F SP MISMATCH

The alarm signals an incongruity between the signals readed from the Master logic and the Slave logic.
Verify:
- Presence of others alarms on the dashboard
- Correct insolation of the truck
- Replace the logic unit
8A CHOPPER NOT CONF - UNUSED
8B UNUSED
8C GAIN ACQUISITION

If the alarm persists after the key reset, replace the logic unit.
8D WRONG 0 VOLT

8E UNUSED
8F WRONG RAM MEMORY

Activeted protection against the electrostatic charges.
Switch off and switch on again the machine.
4-51
LIFTING LOGIC UNIT

31 WATCHDOG

The test is executed is working status and in standby. Logic self-diagnostic test.
This alarm can be caused also by an incorrect functioning of the can-bus. 0
Check:
1
2
32 EEPROM KO 3

4
Defect in the memory area where the adjustment parameters are registered; this alarm inhibits the truck 3
working, the unit will load and use the default parameters.
If the defect continues at the truck switching on, replace the control unit.
If the alarm desappears, remember that the parameters previously stored are cancelled and replaced by
6
the default parameters. Set again a possible personalization of the parameters.
7
33 LOGIC FAILURE #3 8
9
Logic defect. 10
11
34 LOGIC FAILURE #2 12

13
Failure in the hardware section of the logic that manages the phase voltage feedback. 14
Check:
15
- the contactor coil (100 ohm)
- the status of supplying cables connected at the motor 16
- replace the logic unit
17
18
4-52
35 LOGIC FAILURE #1

lifting logic). If the voltage has a low peak, the alarm is signalled.
- OVER voltage: the logic unit controls the internal capacitors voltage. If the voltage has a hight peak
The possible reasons are:
a. Battery undervoltage/overvoltage, lost of voltage after the ignition key or after the battery connector.
b. If the alarm is signalled at the truck ignition and appears with the alarm 05 of the Master traction logic
unit and the alarm 65 of the Slave logic unit, check:
• the battery components status
• the key switch (DISPLAY)
c. The alarm appers also when one or more motor phases do not present a correct isolation at a move-
ment request. Check the motor isolation (with disconnected battery): it has to be upper of 10 Mohm. To
check the isolation verify the resistence value between the motor power cable and a screw on the chas-
sis. If noticed a low voltage value proceed to remove the single components in order to establish the pro-
blem source. Or check the motor power cables isolation
d. Defect in the logic hardware section that controls the protection against the overvoltage.
4-53
36 VMN LOW

coil is interrupted the truck will signal the alarm at the switching on. If the coil value is ok, proceed 0
following one of the test below described in order to establish if the failure is produced by a cause
internal or external to the logic: 1
2
3
4
3
6
TEST 1
7
- Check the tightening of the power cables on the logic 8
Red tip Black tip 9
U - (+) = 13 Kohm
V - (+) = 13 Kohm 10
W - (+) = 13 Kohm
U - (-) = 13 Kohm If noticed values very different from the beside
V - (-) = 13 Kohm one, disconnect all the logic power cables and 11
W - (-) = 13 Kohm verify the values directly on the control
U - V = 0 ohm 12
U - W = 0 ohm
V - W = 0 ohm 13
Values on the control with disconnecyed motor:
U - (+) = 32 Kohm
V - (+) = 27 Kohm
14
W - (+) = 32 Kohm
U - (-) = 32 Kohm 15
V - (-) = 27 Kohm
W - (-) = 32 Kohm If an opened circuit is noticed replace the control. 16
U - V = 45 Kohm
U - W = 60 Kohm 17
V - W = 45 Kohm
TEST 2
Connect the lifting logic unit to the traction Master motor and check if on the display appears the “36” 18
alarm code.
4-54
37 VMN HIGH

power cables from the logic unit to the traction motor and the cables condition.
TEST 1
- Apply the parking brake and switch of the truch
Red tip Black tip
U - (+) = 13 Kohm
V - (+) = 13 Kohm
W - (+) = 13 Kohm
U - (-) = 13 Kohm If noticed values very different from the beside
V - (-) = 13 Kohm one, disconnect all the logic power cables and
W - (-) = 13 Kohm verify the values directly on the control
U - V = 0 ohm
U - W = 0 ohm
V - W = 0 ohm
U - (+) = 32 Kohm
V - (+) = 27 Kohm
W - (+) = 32 Kohm
U - (-) = 32 Kohm
V - (-) = 27 Kohm
W - (-) = 32 Kohm If an opened circuit is noticed replace the control.
U - V = 45 Kohm
U - W = 60 Kohm
V - W = 45 Kohm
TEST 2
Connect the lifting logic unit to the traction Master motor and check if on the display appears the “67”
alarm code.
YES: replace the logic unit
4-55
38 CONTACTOR OPEN

0
1
2
3
4
3
6
7
8
39 STBY I HIGH 9
10
Current sensor failure. 11
- Replace the lifting logic unit
12
13
14
15
16
17
18
4-56
40 CAPACITOR CHARGE

- Check the negative connection between the logic unit and the battery
- Check the voltage at the key entrance (pin 1, connector P3, cable M of the MD3 lifting logic): the
battery voltage must be present
- Carry out a bridge between the ends of the key switch. If the alarms disappears replace
the key switch
- Disconnect the J12 connector. If the alarm disappears check the status of motor encoder
4-57
41 HIGH TEMPERAURE

perature increase.
Check: 0
- the correct functioning of the fan
- the air channel must be free 1
- the P CONTR TEMP parameter (menu TESTER of the dashboard). If below 85°C, replace the lifting
logic unit. 2
3
4
3
6
7
8
9
10
11
12
13
14
15
16
17
18
4-58
42 MOTOR TEMPERAURE

If the alarm appears when the motor is cold, check:
- that the temperature sensor is always open or that has a voltage value upper to the relative voltage

(K)
-40 -40 0,84 340 359 379 ±6,48
-30 -22 0,83 370 391 411 ±6,36
-20 -4 0,82 403 424 446 ±6,26
-10 14 0,80 437 460 483 ±6,16
0 32 0,79 474 498 522 ±6,07
10 50 0,77 514 538 563 ±5,98
20 68 0,75 555 581 607 ±5,89
25 77 0,74 577 603 629 ±5,84
30 86 0,73 599 626 652 ±5,79
40 104 0,71 645 672 700 ±5,69
50 122 0,70 694 722 750 ±5,59
60 140 0,68 744 773 801 ±5,47
70 158 0,66 797 826 855 ±5,34
80 176 0,64 852 882 912 ±5,21
90 194 0,63 910 940 970 ±5,06
100 212 0,61 970 1000 1030 ±4,9
110 230 0,60 1029 1062 1096 ±5,31
120 248 0,58 1089 1127 1164 ±5,73
160 320 0,53 1350 1407 1463 ±7,59
170 338 0,52 1420 1482 1544 ±8,1
180 356 0,51 1492 1560 1628 ±8,62
190 374 0,49 1566 1640 1714 ±9,15
200 392 0,48 1641 1722 1803 ±9,71
210 410 0,47 1719 1807 1894 ±10,28
220 428 0,46 1798 1893 1988 ±10,87
230 446 0,45 1879 1982 2085 ±11,47
240 464 0,44 1962 2073 2184 ±12,09
250 482 0,44 2046 2166 2286 ±12,73
260 500 0,42 2132 2261 2390 ±13,44
270 518 0,41 2219 2357 2496 ±14,44
280 536 0,38 2304 2452 2600 ±15,94
290 554 0,34 2384 2542 2700 ±18,26
300 572 0,29 2456 2624 2791 ±22,12
4-59
43 ENCODER ERROR

40Hz are passed.
If on the dashboard appers the alarm and the operator makes the reset with the key with the machine 0
If the alarm is signalled before to reach 40 Hz, the problem could be an incorrect isolation of a supplying 1
2
encoder. One of the followings components could be defective: 3
- Wiring harness 4
- Encoder
Use an analogic or digital multimeter to determine where is located the problem. 3
6
of phase of 90°(A-B). 7
the positive one of the encoder. 8
the encoder signal (A). 9
following values:
10
11
the motor stopped.
12
13
Mv= 5,5 - 6,5 Volt
Carrying out this test directly on the logic 14
15
17
18
4-60

45 SAFETY IN

Blocked truck.
Pin 11 of the P3 connector (negative input) of the (MD3) lifting logic. If the negative is absent the logic
unit arrests the machine with the security alarm. The alarm can appear for the following situations:
(1) The cable H pin 11 P3 connector it is not well connected
(2) If the cable is well connected, replace the lifting logic unit
4-61
46 CAN BUS KO

information from the MCB board or from the traction logic units.
- The dashboard alarms, to identify exactly the board that does not comunicate 0
• dashboard 180 Ohm 1
• MCB 180 Ohm
• armrest 180 Ohm
If the alarm appears alone, update/replace the DISPLAY
2
3
4
48 AUX OUTPUT KO - UNUSED 3
49 DRIVER SHORTED
6
7
K1 contactor driver defect. 8
Switch off the truck and disconnect the K1 contactor coil.
Verify: 9
- F3 (10A) fuse integrity
- that between the pin 16, P3 connector, cable Z of the lifting logic and the GND there is no 10
continuity.
If YES: replace the lifting logic unit
If NO: verify the K1 contactor coil status
11
Resistive value (100 Ohm)
12
50 CONTACTOR DRIVER 13

14
Defect to the driver that controls the K3 contactor. 15
- Replace the lifting logic unit.
16
17
18
4-62
51 COIL SHORTED

K1 contactor defect.
- Check the coil (100 ohm) status
- Check that there is no short circuit on the wiring harness
If the defect is dued to external causes, replace the logic unit.
4-63
55 WRONG SET BATTERY

If the key is inserted on ON, the controller verify the battery voltage and compares it to the parameter set-
ted in "SET BATTERY" (Battery setting). If the real value is upper or lower of 20% of the nominal values,
- Check the battery status and, if necessary, replace the battery.
0
56 REMOTE INPUT XX - UNUSED 1
2
57 WAITING MHYRIO - UNUSED
3
58 I = 0 EVER - UNUSED 4
59 UNUSED
3
6
60 UNUSED
7
3A SAFETY OUTPUT - UNUSED 8
9
3B SLIP PROFILE
10
11
Make a RESET PUMP to re-load the default parameters.
12
13
3C ANALOG INPUT
14
Replace the logic unit. 16
3D HARDWARE FAULT 17
18
4-64

Verify:
- Correct connection of the motor to the logic:
3F FLASH CHECKSUM

- Restore the default parameters using the RESET PUMP function
4A SOFTWARE ERROR -

Make a RESET PUMP to re-load the default parameters.
4-65
4B THERMIC MOT KO

Interrupted or disconnected lifting motor temperature sensor.
Verify:
- Wiring harness
1
(°C) (°F) (%/K) MIN. TYP. MAX ERROR 2
(K)
-40 -40 0,84 340 359 379 ±6,48 3
-30 -22 0,83 370 391 411 ±6,36
-20 -4 0,82 403 424 446 ±6,26
-10 14 0,80 437 460 483 ±6,16 4
0 32 0,79 474 498 522 ±6,07
10 50 0,77 514 538 563 ±5,98 3
20 68 0,75 555 581 607 ±5,89
25 77 0,74 577 603 629 ±5,84 6
30 86 0,73 599 626 652 ±5,79
40 104 0,71 645 672 700 ±5,69
50 122 0,70 694 722 750 ±5,59 7
60 140 0,68 744 773 801 ±5,47
70 158 0,66 797 826 855 ±5,34 8
80 176 0,64 852 882 912 ±5,21
90 194 0,63 910 940 970 ±5,06 9
100 212 0,61 970 1000 1030 ±4,9
110 230 0,60 1029 1062 1096 ±5,31
120 248 0,58 1089 1127 1164 ±5,73 10
140 284 0,55 1216 1262 1309 ±6,63 Reduction of current 11
160 320 0,53 1350 1407 1463 ±7,59 12
170 338 0,52 1420 1482 1544 ±8,1
180 356 0,51 1492 1560 1628 ±8,62
190 374 0,49 1566 1640 1714 ±9,15 13
200 392 0,48 1641 1722 1803 ±9,71
210 410 0,47 1719 1807 1894 ±10,28 14
220 428 0,46 1798 1893 1988 ±10,87
230 446 0,45 1879 1982 2085 ±11,47 15
240 464 0,44 1962 2073 2184 ±12,09
250 482 0,44 2046 2166 2286 ±12,73
260 500 0,42 2132 2261 2390 ±13,44 16
270 518 0,41 2219 2357 2496 ±14,44
280 536 0,38 2304 2452 2600 ±15,94 17
290 554 0,34 2384 2542 2700 ±18,26
300 572 0,29 2456 2624 2791 ±22,12 18
4-66
4C ENCODER LOCK

Interrupted or disconnected motor encoder.

following values:
the motor stopped.
Mv= 5,5 - 6,5 Volt
electronic control.
4-67
4E CONTACTOR CLOSED

K1 contactor driver failure. The logic unit cuts the curret to the coil, but the controls remain closed.
Disconnect the battery and check:
- The K1 contactor windings and the relevant wiring harness
- Clean the contactor connections 0
- Check the control of the contactor directly on connector P13 of the logic unit.
1
2
3
4
3
6
7
8
0
10
11
If the alarm persists after the key reset, replace the logic unit. 12
13
5E WRONG 0 VOLT - UNUSED
14
5F WRONG RAM MEMORY 15

16
Activeted protection against the electrostatic charges. 17
Switch off and switch on again the machine.
18
4-68
MCB CONTROL BOARD (section EVCB)

A1 DOUBLE REQ - UNUSED
A2 RELOAD_PARAM_WARN

The alarm signals the occured parameters loading. The truck remains in pre-operational status.
- Switch on and switch off again the truck.
A3 PARAM. LOAD ERROR

The alarm signals that the MCB board has not loaded the memory parameters. The truck remains in
pre-operational status.
Switch off and switch on again the truck:
- If the alarm persist replace the MCB board
- If the alarm disappears, but the truck has a rough behavior replace the MCB board.
A4 NOT_REP_ERROR

The alarm signals that the MCB board is waiting informations. The truck remains in pre-operational
status.
- Insert the truck serial number (LEARNING function SERIAL NUMBER parameter)
- Repeat the accelerator and lifting potentiometers acquisitions (only with mechanical control valve):
LEARNING function
Switch on and switch off the truck.
A5 CHKSUM_ERROR - UNUSED
A6 BOOT_ERROR

The alarm signals that the MCB board is waiting informations from the Master logic unit or the lifting logic
unit. The truck remains in pre-operational status. Verify:
- Alarms on the dashboard to identify which board is not comunicating.
4-69
A7 HI SIDE DRIVER SHORT

The alarm signals an internal problem of the MCB board.
- Replace the MCB board.
0
A8 EV1_1 OPEN
1
The alarm signals a failure at the coil of the EVP1 lowering solenoid valve. The coil could be opened or
disconnected. 3
Check:
- Value in Ohm of the coils and the relevant wiring harness .
If the problem persists replace the MCB board.
4
3
A9 EV2_1 OPEN
6
The alarm signals a failure at the coil of the EVP2 lifting solenoid valve. The coil could be opened or
disconnected. 8
Check:
- Value in Ohm of the coils and the relevant wiring harness . 9
10
AA EV1_2 OPEN 11

12
The alarm signals a failure at the coil of the EVP3 backward tilting solenoid valve. The coil could be 13
opened or disconnected.
Check: 14
15
16
17
18
4-70
AB EV2_2 OPEN

The alarm signals a failure at the coil of the EVP4 forward tilting solenoid valve. The coil could be opened
or disconnected.
Check:
AC EV1_3 OPEN

The alarm signals a failure at the coil of the EVP6 right sideshift solenoid valve. The coil could be opened
or disconnected.
Check:
- Value in Ohm of the coils and the relevant wiring harness.
AD EV2_3 OPEN

The alarm signals a failure at the coil of the EVP5 left sideshift solenoid valve. The coil could be opened
or disconnected.
Check:
AE EV1_4 OPEN

The alarm signals a failure at the coil of the EVP1 4th way solenoid valve. The coil could be opened or
disconnected.
Check:
4-71
AF EV2_4 OPEN

The alarm signals a failure at the coil of the EVP8 4th way solenoid valve. The coil could be opened or
disconnected.
Check:
- Value in Ohm of the coils and the relevant wiring harness. 0
1
B0 TRCB_MICRO_ERROR 2

3
The alarm signals an internal problem of the MCB board. 4
- Replace the MCB board.
3
B1 GROUP1 DRIVER SHORT 6
7
The alarm signals a failure at one of the coils of the group 1 of the electroproportional distributor: EVP1 8
lowering solenoid valve or EVP2 lifting solenoid valve.
A coil could be opened or disconnected.
Check:
9
If the problem persists replace the MCB board. 10
11
B2 GROUP2 DRIVER SHORT
12
The alarm signals a failure at one of the coils of the group 2 of the electroproportional distributor: EVP3
backward tilting solenoid valve or EVP4 forward tilting solenoid valve. 14
Check:
15
16
17
18
4-72

right sideshift solenoid valve or EVP5 left sideshift solenoid valve.
Check:

4th way solenoid valve or EVP8 4th way solenoid valve.
Check:
B5 AUX_OUT_SHORT

5th way solenoid valve or EVP10 5th way solenoid valve.
Check:
B6 DASH_KO

The alarm signals a comunication problem between the MCB board and the dashboard.
The alarm remains stored in the logbook of the MCB board alarms.
- Replace the dashboard.
4-73
B7 ERR_SEAT

The alarm signals the seat micro opened with activated hydraulic functions.
B8 JOY_STUFFING_ERR 0
1
The alarm signals a comunication problem between the MCB board and the joystick board.
2
Use the RESET JOY FLAG function for re-establish the communication between the cards; if the
problem persists, verify: 3
- The can-bus connections between the MCB board and the joystick board
- Joystick board supplying (JCANconnector pin 5 cable M and pin 6 cable N) 4
If the supply is ok, but it do not permits the truck working, replace the armrest logic unit
3
B9 SET_SERIAL_NUMBER 6
7
The alarm signals the failed automatic serial number setting. 8
- Insert truck serial number (function LEARNING parameter SERIAL NUMBER)
Switch off and switch on again the truck.
9
BA POT TILT NOT OK 10
11
The alarm signals an incorrect reading of the voltage of the tilting potentiometer (optional):
12
- Repeat the tilting potentiometer acquisition
- If the alarm persits, check the potentiometer status and the relevant wiring harness. 13
14
E1 INCORRECT_START
15
Incorrect starting procedure (mechanic distributor version). Check:
- The forward and backward microswitches and the relevant cables 17
-The parking brake microscwitch and the relevant cables
- The mechanic distributor microswitches 18
4-74
E2 BAD LIFT POT

The alarm signals a failure at the P2 lifting potentiometer. The potentiometer could be disconnected,
broken or not well adjusted.
- Repeat the potentiometer acquisition (function LEARNING parameter LEARN LIFT POT)
- Verify the potentiometer status and the relevant wiring harness
EB POT NOT ACQUIRED

The alarm signals that the MCB board requests the P4 lifting potentiometer acquisition.
- Repeat the potentiometer acquisition (function LEARNING parameter LEARN LIFT POT)
EE PUMP_STUFFING_ERR

The logic did not receives the lifting logic unit informations.
If the armrest is present, the alarm is sent by the armrest board.
4-75
DASHBOARD
D1 TRAC_KO

This alarm signals that the (MD1) Master traction logic unit is not comunicating.
Check: 0
- The supplying: 48V must be present in the connector P1 pin 1 cable M
- The can-bus connections
If the supply is ok, but it do not permits the truck working, replace the Master traction logic unit.
1
2
D2 MCB_TRAC_KO
3
This alarm signals that the MCB logic unit is not comunicating.
Check: 3
- The can-bus connections 6
If the supply is ok, but it do not permits the truck working, replace the MCB logic unit.
7
D3 SLAVE_KO
8
This alarm signals that the (MD2) Slave traction logic unit is not comunicating.
Check: 10
- The can-bus connections 11
If the supply is ok, but it do not permits the truck working, replace the Slave traction logic unit.
12
D4 PUMP_KO 13

14
This alarm signals that the (MD3) lifting logic unit is not comunicating. 15
Check:
- The supplying: 48V must be present in the connector P3 pin A1 cable M 16
If the supply is ok, but it do not permits the truck working, replace the lifting logic unit.
17
18
4-76
D5 MCB_MHY_KO

This alarm signals that the MCB logic unit is not comunicating.
Check:
If the supply is ok, but it do not permits the truck working, replace the MCB logic unit.
D6 JOY_KO

This alarm signals that the armrest logic unit is not comunicating.
Use the RESET JOY FLAG function for re-establish the communication between the cards; if the
problem persists, verify
- The supplying: 48V must be present in the connector JCAN pin 5 cable M
If the supply is ok, but it do not permits the truck working, replace the armrest logic unit.
D7 UNUSED
D8 ERROR_READ_PIN_CODE

This alarm signals that the (SC1) MCB logic unit does not permits the password reading.
(SC1 is the MCB section that manages the signals)
- The supplying: 48V must be present in the connector CN2 pin 13 cable M
Replace the MCB logic unit.
D9 DHU KO

Problem of communication with DHU device.
Check others alarms on the dashboard.
DA SHOCK LOCKOUT

DHU device asks for a speed reduction
4-77
DE KEY ERROR

- Check the voltage at the key output (pin 5, connector 137, cable M: the battery voltage must be present
0
DF EPPROM ERROR
1
3
If the defect continues at the truck switching on, replace the dashboard.
If the alarm desappears the parameters previously stored will be cancelled and automatically will be 4
loaded the default parameters of the electronic control.
3
6
7
8
9
10
11
12
13
14
15
16
17
18
4-78
MCB CONTROL BOARD (section TRCB)

C1 INCORRECT START

Incorrect starting procedure (mechanic distributor version). Check:
- The forward and backward microswitches and the relevant cables
-The parking brake microscwitch and the relevant cables
- The mechanic distributor microswitches
C2 BAD_CONF_WHEELS

This alarm signals an error in the 3-4 wheels configuration identification.
The hardware and software configuration must respect what following:
3 WHEELS CONFIGURATION
Hardware: bridge on the J135 connector not present (see MCB connector P4 pin 17)
Software: 3W (see menu TRUCK CONF -> OPTIONS parameter STEER TABLE)
4 WHEELS CONFIGURATIONS
Hardware: bridge on the J135 connector present (see MCB connector P4 pin 17
Software: 4W (see menu TRUCK CONF -> OPTIONS parameter STEER TABLE)
The alarm does not block the truck, but the management of the elctric differential gear and of the speed
reduction in turn are altered.
4-79
C3 PEDAL WIRE KO

Failure at the accelerator potentiometer at rest. Check:
- Steering potentiometer that could be damaged
- The traction potentiometer wiring harness
0
1
2
3
4
3
6
7
8
9
10
11
12
C4 BAD MICROSWITCH
13
14
The pedal microswitch and the manual direction lever is broken.
15
C5 WARN_CONF_ERROR - UNUSED
16
17
18
4-80
C6 BAD_VACC

The alarm signals an incorrect voltage reading of the accelerator potentiometer:
- Repeat the P3 accelerator potentiometer acquisition(function LEARNING parameter LEARN TRAC
POT)
-If the alarm persists, check the potentiometer status and the relevant wiring harness
C7 ERR_SEAT

One of the fuction is activated, while the seat microswitch is opened.
C8 BAD BRAKE MICRO SWITCH

The brake pedal microswitch is broken or sticked.
4-81
C9 PARKING_SELECTED

One of the fuction is activated, while the parking brake is applyed.
CA PARAM. LOAD ERROR 0

1
The alarm appears at the truch switching on or if pressed the change progam button 2
3
CB UNUSED 4
CC TRAC_STUFFING_ERROR
3
6
7
Problem of comunication with the Master traction logic unit.
The alarm disappears after the key reset.
If the alarm appears frequently and blocks the truck, check the can-bus connections between the Master
8
logic unit and MCB.
9
CD BRAKE WIRE KO 10
11
Failure at the brake potentiometer at rest. Check: 12
- Steering potentiometer that could be damaged
- The brake potentiometer wiring harness 13
14
15
16
17
18
4-82
CE BRAKE BAD VACC

The alarm signals an incorrect voltage reading of the brake potentiometer:
- Repeat the J30 brake potentiometer acquisition(function LEARNING parameter LEARN BRK POT)
-If the alarm persists, check the potentiometer status and the relevant wiring harness.
CF UNUSED
90 UNUSED
91 UNUSED
92 UNUSED
93 UNUSED
94 CHKSUM_ERROR

Software error.
95 UNUSED
96 UNUSED
97 UNUSED
4-83
ARMREST BOARD
E1 INCORRECT_START

Logic unit incorrect starting procedure.
- Check if one of the potentiometers is activated before to pass the key on ON
- Verify by dashboard
0
Enter the function TESTER menu MAT HANDLING and verify the potentiometer status at rest condition
1
IN1 1 (LIFTING SWITCH) = OFF
IN2 1 (TILTING SWITCH) = OFF
IN3 1 (SIDESHIFT SWITCH) = OFF 2
IN4 1 I(V WAY SWITCH) = OFF
IN5 1 (V WAY SWITCH) = OFF 3
LIFT LOWER J = 2,5 ± 0,2 V
TILT J = 2,5 ± 0,2 V 4
SIDESHIFT J = 2,5 ± 0,2 V
IV WAY J = 2,5 ± 0,2 V 3
V WAY J = 2,5 ± 0,2 V
Once identificated the potentiometer with different values proceed as follows: 6
• reverse the potentiometer with another one of the board (fingertips version)
• reverse the lifting potentiometer with the sideshift one or the tilting with the 4th way one (joystick 7
version)
- If the problem remains in the same position replace the logic unit 8
- If the problem is noticed on an different potentiometer (where has been connected the faulty
potentiometer) replace the potentiometer
9
10
11
12
13
14
15
16
17
18
4-84
E2 BAD LIFT POT

Failure at the RP1 lifting potentiometer in the joystick-fingertip group.
Verify the potentiometer status at rest.
Enter the function TESTER menu MAT HANDLING and verify the paramenters IN1 1(LIFTING SWITCH)
and LIFT LOWER J.
Rest conditions:
- LIFT LOWER J = 2,5 ± 0,2 V
- IN1 1(LIFTING SWITCH) = OFF
If the rest conditions are different the potentiometer could be mechanically blocked or faulty.
Check:
• reverse the lifting potentiometer with the tilting one (fingertips version) and verify the correct
functioning by console
• reverse the lifting potentiometer with the sideshift one (joystick version) and verify the correct
fingertip version joystick version
If the alarm persists replace the logic unit.

4-85
E3 BAD TILT POT

Failure at the RP2 lifting potentiometer in the joystick-fingertip group.
Enter the function TESTER menu MAT HANDLING and verify the paramenters IN2 1(TILTING SWITCH)
and TILT J. 0
Rest conditions:
- TILT J = 2,5 ± 0,2 V
- IN2 1(TILTING SWITCH) = OFF
1
If the rest conditions are different the potentiometer could be mechanically blocked or faulty. 2
Check:
• reverse the tilting potentiometer with the lifting one (fingertips version) and verify the correct
3
• reverse the tilting potentiometer with the 4th way one (joystick version) and verify the correct
functioning by console 4
3
6
7
8
9
10
11
12
13
14
15
16
17
18
4-86
E4 BAD SIDESH. POT

Failure at the RP3 sideshift potentiometer in the joystick-fingertip group.
Enter the function TESTER menu MAT HANDLING and verify the paramenters IN3 1(SIDESHIFT
SWITCH) and SIDESHIFT J.
Rest conditions:
- SIDESHIFT J = 2,5 ± 0,2 V
- IN3 1(SIDESHIFT SWITCH) = OFF
Check:
• reverse the sideshift potentiometer with the tilting one (fingertips version) and verify the correct
• reverse the sideshift potentiometer with the lifting one (joystick version) and verify the correct

4-87
E5 BAD IV POT

Failure at the RP4 4th way potentiometer in the joystick-fingertip group.
Enter the function TESTER menu MAT HANDLING and verify the paramenters IN4 1(IV WAY SWITCH)
and IV WAY J. 0
Rest conditions:
- IV WAY J = 2,5 ± 0,2 V
- IN4 1(IV WAY SWITCH) = OFF
1
If the rest conditions are different the potentiometer could be mechanically blocked or faulty. 2
Check:
• reverse the 4th way potentiometer with the sideshift one (fingertips version) and verify the correct
3
• reverse the 4th way potentiometer with the tilting one (joystick version) and verify the correct
functioning by console 4
3
6
7
8
9
10
11
12
13
14
15
16
17
18
4-88
E6 BAD V POT

Failure at the 5th way potentiometer (optional) in the joystick-fingertip group.
Enter the function TESTER menu MAT HANDLING and verify the paramenters IN5 1(V WAY SWITCH)
and V WAY J.
Rest conditions:
- V WAY J = 2,5 ± 0,2 V
- IN5 1(V WAY SWITCH) = OFF
Check:
• reverse the 5th way potentiometer with 4th way one (fingertips version) and verify the correct
E7 ERR_SEAT

The alarm signals the seat micro opened with activated hydraulic functions.
Verify the seat micro status.
E8 INVALID RESTORE STATE

Incompleated restore of the parameters. Repeat the operation.
4-89
E9 EEPROM_CHKSUM_ERR

Eprom data loading unsuccessuful.
If the alarm persists at the key reset, replace the logic unit.
EA DEFAULT RESTORED
0
1
Flash memory data loading. Switch off and switch off again the truck.
2
3
EB POT NOT ACQUIRED
4
3
Flash memory data loading. Switch off and switch off again the truck.
6
EC RAM_CHKSUM_ERR
7
8
RAM data loading unsuccessuful.
If the alarm persists at the key reset, replace the logic unit. 9
ED MHYRIO_STUFFING_ERR 10

11
The logic unit has a comunication problem with the EVCB (MCB) unit. 12
Check the others alarms on the dashboard.
13
EE PUMP_STUFFING_ERR
14
The logic unit does not receive the information from the lifting logic unit.
If the armrest is not present, the alarm is send by the MCB control board. 16
EF FW + BW - UNUSED
17
18
4-90
F1 LIGHT SHORTED

It is activated when triggered a Short circuit on the horn or lights device (except rotary lamp).
Please check the dashboard or the relatives wiring harness
5-1
MOTOR
Page
DRIVE MOTOR ............................................................ 5-2
0
GENERAL ...............................................................................5-2
ENCODER REPLACEMENT...................................................5-8
1
ENCODER ................................................................... 5-9 2
TEMPERATURE SENSOR REPLACING .................. 5-10 3
PUMP MOTORS ........................................................ 5-11 4
GENERAL .............................................................................5-11
5
TEMPERATURE SENSOR REPLACING .................. 5-15
6
ENCODER REPLACEMENT.................................................5-16
7
ENCODER ................................................................. 5-17
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
5-2
DRIVE MOTOR
GENERAL
SPECIFICATIONS
TRACTION MOTOR
VOLTAGE 32 Vac
RATED OUTPUT 6 kW
CURRENT 152 A
FREQUENCY 70 Hz
SPEED 2045 rpm
FACTOR POWER (cosφ) 0,79
EFFICIENCY (η) 87,0 %
DEGREE OF PROTECTION (IP CODE) IP 20
METHOD OF COOLING (IC CLASS) IC 00
TYPE OF DUTY S2-60 min
TYPE OF CONNECTION Δ
ENCODER(Imp\Turn) 64
POLES 4
5-3
COMPONENTS
2
2
2
3
5
5
6
7
8
9
1 Drive motor 8 Central body
2 Gasket 9 Washer 10
3 Plate 10 Turn sensor
4 Elastic ring 11 Wheel sensor 11
5 Ring 12 Cover
6 Elastic ring 13 Temperature sensor 12
7 Ball bearing
13
14
15
16
17
18
18
18
18
18
18
5-4
REMOVAL • INSTALLATION
2. Tilt backward until the end stroke and place 2 wooden or metal blocks under the mast
3. Tilt the mast forward untill the end stroke
7. Disconnect the temperature sensor wiring, the encoder wiring, the electric brake wiring and the
motor power cables [Point 1]
8. Disconnect the brake system hoses [Point 2]
9. Remove the wheel [Point 3]
10. Remove the oil from the reduction gears [Point 4]
11. Extract the complete motor gear group [Point 5]
12. Remove the motor [Point 6]
13. Remove the pinion [Point 7]
Installation Procedure
5-5
Points of operation
[Point 1]
A Removal: 2
C
Disconnect the temperature sensor wiring and the
encoder wiring (A), the electric brake wiring (C) and 2
the motor power cables (B)
B Installation: 2
Power cable W connected to phase W
Power cable V connected to phase V 3
Power cable U connected to phase U
Tightening torque of the cable 15 Nm 5
5
[Point 2]
Removal: 6
Disconnect brakes system hose (D)
Warning:
7
When brake system hose is disconnected, the brake
fluid (type DOT 4) will leak 8
D 9
10
[Point 3] 11
Removal:
Remove the wheel
12
Installation:
After installation, tightening torque of the wheel nuts = 13
140 Nm
14
15
16
17
18
18
18
18
18
18
5-6
[Point 4]
Removal:
Clean the area around the oil filling (E) carefully and
draining (F) caps; place a suitable container below the
E drain cap and then remove both the filling and the
draining caps and allow the oil to drain out completely;
Clean any residues from the cap (F) and put it back on
Installation:
Pour fresh oil into the hole (E) until it starts overflowing
(Q.ty about 0,35 liters) then put the cap back on.
F When filling is complete, clean any overflow; after a
short functioning period, check the oil level again
Maintenance:
After the first 40 hours
- change the oil
Every 1000 hours
- take off the front wheels, check the oil level, cold, with the
truck on a level surface and top up if needed; use
transmission oil such as AGIP ATF II 422 or equivalent; the
correct level is obtained when the oil starts to escape from
the holes (E);
- check there are no oil leakages
- check that all screws on the unit are tight
Every 2000 hours
- change the oil
Notes:
• For a better oil outflow, it is better to empty the
reduction gears after a few turns of heating, moving
the truck for a few minutes;
• To compromise a good reduction gears running
don't insert more oil than the necessary.
5-7
[Point 5]
Removal:
G Remove the fixing bolt (G) of the motor reduction gear
and insert a M14 bar (H) in the hole 2
2
G
2
3
Remove the remaining 6 fixing screws and extract the 5
motor reduction gear as shown in the picture
Installation: 5
H
After installation, tightening torque of fixing screws
= 130 Nm 6
Notes: 7
Use Loctite 243
8
9
[Point 6]
Removal: 10
Remove the 3 fixing screws (I) and extract the motor
Installation:
11
I After installation, tightening torque of fixing screws
= 23 Nm 12
13
14
15
[Point 7]
16
L
Removal:
Remove the ring nut (M). 17
Remove the pinion (N) using an extractor separator
Installation: 18
Insert the tongue (L) in the appropriate seat.
M Insert the pinion (N) and screw the ring nut (M) with a 18
tightening torque of 55 Nm
Note: 18
In case of complete reduction gear substitution,
replace the pinion also 18
N
18
18
5-8
ENCODER REPLACEMENT
1. Park the truck on a level surface and operate the parking brake
3. Open the battery cover and disconnect the battery plug
5. Disconnect the encoder connector from the auxiliary wiring
6. Disconnect the electric brake connector from the auxiliary wiring
7. Remove the 3 fixing screws from the electric brake
8. Remove the electric brake from the motor shaft
9. Unscrew the encoder A from its seat
5-9
ENCODER
The encoder generates feedback signals from the motor and send them to control logic unit, monitoring
the motor state, the R.P.M and the sense of rotation. The encoder is positioned in the back part of the 2
motor.
2
Irreversible damages:
• +V > 13 Volts
2
• Short circuit between the signal and the power supply
• Heating by induction 3
• Assembly with hammer
5
5
6
7
Direction of the gear wheel motion
in FW march
8
Channel image on oscilloskope:

9
FW march 10
11
12
BW march
13
14
15
Time
16
Channel B / Wire:white
Channel A / Wire:yellow 17
18
18
18
18
18
18
5-10
TEMPERATURE SENSOR REPLACING
5. Cut the damaged sensor wiring harness near the casing of the motor [Point 1]
1. Place the new sensor on the coil of the motor and secure it with silicone paste (see Service Tools
List)
2. Connect it to the wiring harness
Points of operation
[Point 1]
Removal:
Cut the sensor wiring harness (A)
A
5-11
PUMP MOTORS
GENERAL
2
2
2
3
5
5
6
7
SPECIFICATIONS
8
PUMP MOTORS
9
VOLTAGE 30 Vac
RATED OUTPUT 15,8 kW

10
CURRENT 284 A 11
FREQUENCY 80 Hz
12
SPEED 2314 rpm
FACTOR POWER 0,83

13
DEGREE OF PROTECTION (IP CODE) IP 20 14
INSULATION CLASS F 15
TYPE OF DUTY S3-15 %
16
TYPE OF CONNECTION Δ
ENCODER(Imp\Turn) 64 17
POLES 4 18
18
18
18
18
18
5-12
COMPONENTS
1 Pump motor 6 Wheel sensor

2 Gasket 7 Ball bearing
3 Plate 8 Central body
4 Temperature sensor 9 Washer
5 Cover 10 Turn sensor
5-13
2
2
2
3
5
5
6
7
4. Remove the battery 10
5. Disconnect the temperature sensor wiring, the encoder wiring and the motor power cables [Point 1]
6. Remove the pump fixing screws on the motor [Point 2] 11
7. Remove the fixing motor nuts [Point 3]
8. Lift and remove the motor
12
The reassembly procedure is the reverse of the disassembly procedure, taking care that the motor 13
cables are fitted correctly as illustrated below:
14
• Power cable W connected to phase W
• Power cable U connected to phase U 15
• Power cable V connected to phase V
16
17
18
18
18
18
18
18
5-14
Points of operation
[Point 1]
B Removal:
Disconnect the temperature sensor wiring (A), the
A encoder wiring (B) and the motor power cables (C)
[Point 2]
Removal:
Remove the two pump fixing bolts (D)
Installation:
After the installation, pump fixing bolts tightening
torque is= 45 ± 5 Nm
D
D
[Point 3]
Removal:
Remove motor fixing nuts from the chassis (E)
E E
5-15
TEMPERATURE SENSOR REPLACING
brake 2
4. Remove the battery 2
5. Cut damaged sensor wiring near the motor carcass
3
5
5
A Installation Procedure 6
1. Place the new sensor (A) on the coil of the motor and
secure it with silicone paste (see Service Tools List)
7
2. Connect it to the wiring harness
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
5-16
ENCODER REPLACEMENT
1. Park the truck on a level surface and operate the parking brake
3. Open the battery cover, disconnect the battery and remove it
5. Disconnect the encoder connector A from the auxiliary wiring
6. Remove the fixing B screws of the cover
7. Unscrew the encoder C from its seat
5-17
ENCODER
The encoder generates feedback signals from the motor and send them to control logic unit, monitoring
the motor state, the R.P.M and the sense of rotation.
2
The encoder is positioned in the back part of the motor.
2
Irreversible damages: 2
• +V > 13 Volts
• Short circuit between the signal and the power supply 3
• Heating by induction
• Assembly with hammer 5
5
6
7
Direction of the gear wheel motion
in FW march
8
9
Channel image on oscilloskope: 10
FW march
11
12
BW march
13
14
15
Time
16
Channel B / Wire:white 17
Channel A / Wire:yellow
18
18
18
18
18
18
5-18
6-1
DRIVE UNIT & FRONT AXLE

Page
TRANSMISSION ..........................................................6-2
1
COMPONENTS ...................................................................... 6-2
SPECIFICATIONS .................................................................. 6-3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
6-2
TRANSMISSION
COMPONENTS
1 Left reduction gear GP25 7 Electromagnetic service brake

2 Right reduction gear GP25 8 Cap
3 Brake pipe 9 Brake pump
4 Connection 10 Oil tank
5 Brake cylinder 11 Plug
6 Brakes bleed screw 12 Washer
6-3
SPECIFICATIONS
DESCRIPTION VALUES
2
Transmission ratio 1:22
2
Note: DO NOT USE SYNTHETIC OR VEGETABLE OIL WITHOUT ATF DEXRON II
THE MANUFACTURER'S APPROVAL
2
Epicycloidal gear box quantity of oil RIGHT side 0.35 litres
Epicycloidal gear box quantity of oil LEFT side 0.35 litres

3
Brake type With discs in oil bath 2
Nr. brake discs 4
6
Brake disc rated thickness 1.80 mm
Nr. brake counter-discs 3

6
Brake counter-disc rated thickness 1.80 mm 7
Brake piston rated stroke 0.90 mm
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
6-4
DISASSEMBLY · REASSEMBLY
For the disassembly procedure of the gearbox please see chapter 5.
7-1
REAR AXLE
Page
REAR AXLE (3 wheels)...............................................7-2
0
GENERAL............................................................................... 7-2
COMPONENTS ...................................................................... 7-3
1
CONTROL OF REAR AXLE................................................... 7-4 2
STEERING STROKE END ANGLE ADJUSTMENT .............. 7-4 3
BEARING ADJUSTMENT ...................................................... 7-7
4
REAR AXLE (4 wheels)...............................................7-8
5
GENERAL............................................................................... 7-8
COMPONENTS ...................................................................... 7-9
6
CONTROL OF REAR AXLE................................................. 7-10 7
STEERING STROKE END ANGLE ADJUSTMENT ............ 7-10 8
BEARING ADJUSTMENT .................................................... 7-14 9
STEERING POTENTIOMETER ADJUSTMENT........ 7-15
10
3 WHEELS VERSION........................................................... 7-15
4 WHEELS VERSION........................................................... 7-15
11
SPEED REDUCTION IN A BEND ........................................ 7-16 12
13
14
15
16
17
18
19
20
21
E
7-2
REAR AXLE (3 wheels)

GENERAL
7-3
COMPONENTS
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1 Axle 10 Seal 19 Ring 18
2 Cover 11 Cover 20 Gasket
3 Steering potentiometer 12 Seal 21 Ball bearing 18
4 Flange 13 Cylinder liner 22 Hub
5 Support 14 Gasket 23 Ball bearing 18
6 Shaft 15 Cylinder head 24 Washer
7 Nut 16 Ball bearing 25 Nut 18
8 Ring nut 17 Seal 26 Cover
9 Washer 18 Shaft 27 Split pin 18
7-4
CONTROL OF REAR AXLE
• For the steering group (A) it is not necessary greasing or

A lubrication
Every 1000 hours
• Control and adjust the ball bearing of the wheel hub
eventually (see section BEARING ADJUSTMENT)
STEERING STROKE END ANGLE ADJUSTMENT

The adjustment of the limit switch steering angle is possible only in 4 wheels version.
7-5
Tightening torque T =Nm
2
2
2
3
4
5
6
7
8
9
10
11
4. Remove the battery
5. Lift the back part of the vehicle and place specifics shims under the chassis [Point 1] 12
7. Remove the counterweight (*) 13
8. Disconnect the potentiometer wiring harness [Point 2]
9. Disconnect the cylinder pipes of the steering axle
10. Loosen and remove the fixing screws [Point 3]
14
11. Remove the steering axle
15
The reassembly procedure is the reverse of the disassembly procedure. 16
(*)Warning:
Always make sure to lock temporaly the overhead guard before remove the counterweight 17
18
18
18
18
18
18
7-6
Point Operations
[Point 1]
Disassembly:
Jack up the back part of the vehicle and position
apposite blocks under the chassis
A [Point 2]
Disassembly:
Disconnect the potentiometer wiring harness (A)
[Point 3]
Disassembly:
Loosen and remove the 5 steering axle fixing screws
Reassembly:
After the installation, tightening torque for the 5 screws
= 240 Nm
Note:
Use Loctite 243
7-7
BEARING ADJUSTMENT
Steering wheel bearings require an adjustment once per year.
2
2
2
4 3
4
5
2
5
1 6
3 7
8
9
10
11
12
13
Steering wheels
• lift the steering axle; 14
• remove the cap (1);
• tight the ring nut (3) with torque of 6 daNm;
• rotate the hub of 2-3 turn in both directions;
15
• loosen the ring nut (3) and tight again with a tightening torque of 2-1 daNm;
• check that the wheels turn smoothly (maximum rolling final torque 0.2 daNm) and that there is no side 16
clearance (maximum axial play of 0,05 mm);
• reassemble tha cap (1); 17
• lower the wheels again and check that all nuts (5) fixing the wheel (4) to the hub (2) are well tightened.
18
18
18
18
18
18
7-8
REAR AXLE (4 wheels)
GENERAL
7-9
COMPONENTS
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1 Axle 9 Support 17 Grease nipple 18
2 Cover 10 Axle support 18 Gasket
3 Steering potentiometer 11 Plate 19 Ball bearing 18
4 Shaft 12 Cylinder 20 Wheel hub
5 Plug 13 Plug 21 Ball bearing
18
6 Flange 14 Dowel pin 22 Nut
7 Screw 15 Nut 23 Cover
18
8 Cover 16 Spacer 24 Split pin
18
7-10
CONTROL OF REAR AXLE

Every 1000 hours
• lubricate the steering group articulations, using
appropriate grease nipples (A)
• control the steering locks
• check the conditions of the wheel hub bearings too and
adjust them if necessary
If any abnormal wear on the wheel tread is noticed, carry the following controls out:
• check the parallelism of the steered wheels
• check that wheel lock is the same on both directions
STEERING STROKE END ANGLE ADJUSTMENT
1. Drive the steering cylinder to the stroke end

2. Check the steering angle as shown in the picture here
above
3. To vary the steering stroke end angle, act on the grub
screw (B) opposite to the wheel to adjust.
B
Std value 95°
4. Repeat the same operation on the other wheel
7-11
Tightening torque T=N·m
Coppia di serraggio M=Nm=83 Nm (±10%) 2

2
2
3
4
5
6
7
8
9
3. Open the battery cover and disconnect the battery 11
4. Remove the battery
5. Jack up the back part of the vehicle and position apposite blocks under the chassis [Point 1]
6. Disconnect the steering axle cylinder hoses [Point 2] 12
7. Disconnect the potentiometer wiring [Point 3]
8. Hold the steering axle lifted by a trans-pallet [Point 4] 13
9. Loosen and remove the fixing screws [Point 5]
10. Remove the steering axle 14
Installation procedure
15
16
17
18
18
18
18
18
18
7-12
Point Operations
[Point 1]
Disassembly:
Jack up the back part of the vehicle and position
apposite blocks under the chassis
[Point 2]
Disassembly:
Disconnect the steering axle cylinder hoses (A) (one
for side)
A
[Point 3]
Disassembly:
Disconnect the potentiometer wiring (B)
B
[Point 4]
Disassembly:
Position a trans-pallet under the steering axle
7-13
[Point 5]
Disassembly:
C Loosen and remove the 4 steering axle fixing screws 2
(C)
Installation: 2
After installation, tightening torque for the 4 screws =
200 Nm 2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
7-14
BEARING ADJUSTMENT
Steering wheel bearings require an adjustment once a year.
Steering wheels
• lift the steering wheels;
• remove cap (1);
• tighten the ring nut (3) with a torque=6 daNm
• turn the hub by 2-3 turns in both directions;
• loosen the ring nuts (3) and retighten with tightening torque 2-1 daNm;
• check that the wheels turn smoothly (max. rolling final torque: 0.2 daNm) and that there is no side
clearance (maximum axial clearance of 0.05 mm);
• reassemble the cap (1);
• lower the wheels again and check that all nuts (5) fixing the wheel rim (4) to hub (2) are well tightened.
7-15
STEERING POTENTIOMETER ADJUSTMENT

The truck is equipped with a steering potentiometer used to manage the two traction motors and the
steering position indication on the dashboard. 2
The traction logic unit uses the signal coming from the potentiometer to pilot the electronic differential
gear in order to reduce the speed of the internal wheel in steering phase. 2
3 WHEELS VERSION 2
Characteristics
Resistance 2,2 Kohm
3
Supply voltage 12 V
4
Voltage values obtained with the dashboard
5
Right (MAX STEER RIGHT) ~ 8.7 V
Left (MAX STEER LEFT) ~ 1.9 V
Centre (SET 0-POS) ~ 5,4 V
6
7
8
9
10
4 WHEELS VERSION
Voltage values obtained with the dashboard
11
Right (MAX STEER RIGHT) ~ 7.92 V (**) 12
Left (MAX STEER LEFT) ~ 1.68 V (*)
Centre (SET 0-POS) ~ 4.23 V 13
14
15
16
17
18
18
18
18
18
18
7-16
SPEED REDUCTION IN A BEND

The speed in a bend is managed by the Master traction logic unit using the steer angle readed from the
steering potentiometer.
The customization of the speed reduction in a bend is carry out by modifying the parameters as shown
here below:
8-1
STEERING SYSTEM
Page
STEERING SYSTEM....................................................8-2
0
COMPONENTS ...................................................................... 8-2
1
3 WHEELS VERSION ..................................................8-3
STEERING SYSTEM .............................................................. 8-3
2
HYDRAULIC DIAGRAM......................................................... 8-4 3
STEERING COMMAND.......................................................... 8-6 4
POWER STEERING (ORBITROL)...............................8-7 5
SPECIFICATIONS .................................................................. 8-7
6
STEERING UNIT ........................................................8-10
7
CHECKING SEALS AND CLEANING POWER
STEERING SYSTEM......................................................... 8-10 8
INSPECTING AND ADJUSTING THE RELIEF VALVE ....... 8-10
9
PRIORITY VALVE ...................................................... 8-11
10
GENERAL..............................................................................8-11
11
4 WHEELS VERSION ................................................8-13
STEERING SYSTEM ............................................................ 8-13 12
GENERAL............................................................................. 8-13 13
HYDRAULIC DIAGRAM....................................................... 8-14 14
STEERING COMMAND........................................................ 8-15
15
POWER STEERING (ORBITROL).............................8-16
16
SPECIFICATIONS ................................................................ 8-16
STEERING UNIT ........................................................8-19 17
CHECKING SEALS AND CLEANING POWER 18
STEERING SYSTEM......................................................... 8-19
19
INSPECT AND ADJUST THE PRESSURE RELIEF
VALVE ............................................................................... 8-19 20
PRIORITY VALVE ........................................................ 20 21
GENERAL................................................................................ 20
E
8-2
STEERING SYSTEM
COMPONENTS
1 Hydraulic pump 8 Tank

2 Priority valve CF - P Orbitrol inlet
3 Gasket LS LS channel
4 Joint L Steering wheel turn left side
5 Turn sensor T Orbitrol outlet
6 Temperature sensor R Steering wheel turn right side
7 Anti-vibrant
8-3
3 WHEELS VERSION
STEERING SYSTEM
GENERAL 2
2
2
3
2
2
2
8
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
8-4
HYDRAULIC DIAGRAM
8-5
2
2
2
3
2
2
2
8
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
8-6
STEERING COMMAND
It uses the same oil as lifting one by means of a priority valve.
The pump delivery is sent to the priority valve so that there is always a sufficient flow of oil to the power
steering.
The division of the flow rate is controlled by the LS (Load-Sensing) signal from the steering unit and
takes place so that the flow rate sent to the power steering is equal to its actual requirement.
The exceeding delivery is sent to the control valve for other functions.
When the steering wheel is turned, the steering unit “measures” a proportional volume of oil to the
rotation and sends it to the steering cylinder. The steering unit automatically goes back into its neutral
position when the manoeuvre is ended.
The steering wheel hardness depends proportionally from the truck traction speed, as shown in the
diagram here below.
Increasing traction speed, pump R.P.M. decrease.
This allows an improvement of truck speed control.
Lifting speed (Hz)
25
20
15
10
5
20 40 60 80 100 120 140 160

Traction speed (Hz)
8-7
POWER STEERING (ORBITROL)
2
2
2
3
2
2
2
8
8
9
10
11
12
13
14
15
16
SPECIFICATIONS 17
Load capacity
1,5 - 2,0 t 18
Parts
Power steering type Dynamic 18
Discharge cc (cm3) 50
18
Dynamic power steering Oil flow rate: l·min 5
Maximum pressure: Bar ~120 18
18
DISASSEMBLY • REASSEMBLY 18
8-8
3. Open the battery cover and disconnect the battery plug
4. Remove the front panel cover [Point 1]
5. Remove the steering column covers [Point 2]
6. Remove the lh steering pipes cover [Point 3]
7. Disconnect the pipes
8. Unscrew the 4 fixing screws of the orbitrol
9. Remove the power steering (orbitrol) [Point 4]
Notes:
Add grease at the coupling between the steering shaft and steering valve using paste type
CASTROL OPTIMOL T WHITE
8-9
Point Operations
[Point 1]
FRONT VIEW
Disassembly: 2
Remove the front panel cover unscrewing fixing
screws (A)
2
A
2
3
2
REAR VIEW
2
[Point 2]
Disassembly: 2
Remove steering column covers
8
8
9
10
11
[Point 3]
Disassembly:
Remove lh steering pipes cover
12
13
14
15
16
17
[Point 4]
18
Disassembly:
Remove the power steering unscrewing 4 fixing 18
screws (B)
18
18
B 18
18
8-10
STEERING UNIT
CHECKING SEALS AND CLEANING POWER STEERING SYSTEM
Every 1000 hours
• check the entire system to identify any leaks; any
intervention must be carried out without pressure in the
system
Every 5000 hours
F • replace the hoses connecting (F) the power steering to
F the steering cylinder
Every 10 000 hours
• replace the hydraulic piping system
INSPECTING AND ADJUSTING THE RELIEF VALVE

1. Connect a pressure gauge on pump pressure point
(A)
A 2. When the steering wheel is rotated untill the stroke

end, relief state is achieved, so read the pressure on
the pressure gauge at that time
Standard
3 wheels version 4 wheels version

Bar Max. 120 Max. 120
Ampere Max. 60 Max.60
3. If the relief pressure is greater or lower than the

standard value, adjust the orbitrol setting screw (B)
B
8-11
PRIORITY VALVE
GENERAL
2
2
2
3
2
2
2
8
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
8-12
T = 8Nm
5. Disconnect the hoses from the priority valve
6. Remove the priority valve
8-13
4 WHEELS VERSION
STEERING SYSTEM
GENERAL 2
2
2
3
2
2
2
8
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
8-14
HYDRAULIC DIAGRAM
8-15
STEERING COMMAND
It uses the same oil as lifting one by means of a priority valve.
The pump delivery is sent to the priority valve so that there is always a sufficient flow of oil to the power
steering. 2
The division of the flow rate is controlled by the LS (Load-Sensing) signal from the steering unit and
takes place so that the flow rate sent to the power steering is equal to its actual requirement. 2
The exceeding delivery is sent to the control valve for other functions.
When the steering wheel is turned, the steering unit “measures” a proportional volume of oil to the
rotation and sends it to the steering cylinder. The steering unit automatically goes back into its neutral
2
position when the manoeuvre is ended.
3
The steering wheel hardness depends proportionally from the truck traction speed, as shown in the
diagram here below. 2
Increasing traction speed, pump R.P.M. decrease.
This allows an improvement of truck speed control.
2
2
Lifting speed (Hz)
25
20 8
15
10
8
5 9
20 40 60 80 100 120 140 160
10
Traction speed (Hz)
11
12
13
14
15
16
17
18
18
18
18
18
18
8-16
POWER STEERING (ORBITROL)
SPECIFICATIONS
Load capacity
1,5 - 2,0 t
Parts
Power steering type Dynamic
3)
Discharge cc (cm 80
Dynamic power steering Oil flow rate: l·min 8
Maximum pressure: Bar ~ 120
8-17
2
2
2
3
2
2
2
8
8
9
2.
3.
Switch off the truck
Open the battery cover and disconnect the battery plug
11
4. Remove the front panel cover [Point 1]
5. Remove the steering column covers [Point 2] 12
6. Remove the lh steering pipes cover [Point 3]
7. Disconnect the pipes 13
8. Unscrew the 4 fixing screws of the orbitrol
9. Remove the power steering (orbitrol) [Point 4] 14
15
Notes: 16
Add grease at the coupling between the steering shaft and steering valve using paste type
CASTROL OPTIMOL T WHITE
17
18
18
18
18
18
18
8-18
Point Operations
[Point 1]
FRONT VIEW
Disassembly:
Remove the front panel cover unscrewing fixing
screws (A)
REAR VIEW
[Point 2]
Disassembly:
Remove steering column covers
[Point 3]
Disassembly:
Remove lh steering pipes cover
[Point 4]
Disassembly:
Remove the power steering unscrewing 4 fixing
screws (B)
B
8-19
STEERING UNIT
CHECKING SEALS AND CLEANING POWER STEERING SYSTEM
Every 1000 hours 2
• check the entire system to identify any leaks; any
F intervention must be carried out without pressure in the 2
system
Every 5000 hours 2
• replace the hoses connecting (F) the power steering to
the steering cylinder 3
Every 10 000 hours
• replace the hydraulic piping system 2
2
INSPECT AND ADJUST THE PRESSURE RELIEF VALVE
2
1. Connect a pressure gauge on pump pressure point (A)
8
2. When the steering wheel is rotated untill the stroke
A end, relief state is achieved, so read the pressure on
the pressure gauge at that time
8
9
10
11
12
13
Standard
14
3 wheels version 4 wheels version
Bar Max. 120 Max. 120 15
Ampere Max. 60 Max. 60
16
3. If the relief pressure is greater or lower than the
standard value, adjust the orbitrol setting screw (B)
17
18
18
18
B 18
18
18
8-20
PRIORITY VALVE
GENERAL
8-21
2
T = 8Nm
2
2
3
2
2
2
8
1. Park the truck on a level surface and apply the parking brake 8
3. Open the compartment and disconnect the battery 9
5. Disconnect the hoses from the priority valve
6. Remove the priority valve 10
12
13
14
15
16
17
18
18
18
18
18
18
8-22
9-1
BRAKE
Page
BRAKING SYSTEM .....................................................9-2
0
GENERAL............................................................................... 9-2
1
COMPONENTS ............................................................9-3
PEDAL BRAKE ...................................................................... 9-3 2
SERVICE BRAKE ........................................................9-4 3
BRAKE FLUID SYSTEM BLEEDING .......................... 9-6 4
SERVICE BRAKE................................................................... 9-7
5
DISK BRAKES .............................................................9-8
6
REPLACE DISK BRAKES...........................................9-9
7
BRAKES LEVER........................................................9-18
PARKING BRAKE......................................................9-22
8
GENERAL............................................................................. 9-22 9
UNBLOCKING PARKING BRAKE LEVER.......................... 9-23 10
ELECTRIC BRAKES MANUAL UNBLOCKING .................. 9-24
11
ADJUSTING THE NOMINAL PLAY ..................................... 9-25
12
ELECTRIC BRAKE TROUBLESHOOTING......................... 9-26
13
14
15
16
17
18
19
20
21
E
09-2
BRAKING SYSTEM
GENERAL
The reduction gears are equipped with a braking system with multiples disks in oil bath that act directly
on the wheel axle.
The disks are lubricated with the same oil of the reduction gears, AGIP ATF II D.
Besides mechanic braking the vehicle uses a motor brake ruled in electronic way by the traction
command (see chapter 03 for the parameters regulation).
The activation of the brake disks is executed pressing the brake pedal (A).
09-3
COMPONENTS
PEDAL BRAKE
2
2
2
3
4
5
6
7
9
9
Pressing the pedal, the cap practice a pression on the piston. The piston puts in motion the oil that 10
pressing on the plate compress the brake disk.
The limit switch is regulated by the screw, while pedal return in neutral position is regulated by the spring. 11
The microswitch has to click when the cap press on the pump piston.
In case of recordings/regulations be sure that between the

12
0,2 ÷ 0,5 mm
cap and the pump piston there is an opening/play of 0,2 ÷
0,5 mm, if not the risk is that the truck remains always on 13
braking with a consequence of a early usury of the brake
disks. 14
15
16
17
18
18
18
18
18
18
09-4
SERVICE BRAKE
SERVICE BRAKE SYSTEM SCHEMATIC DIAGRAM
C (A) Reduction gears

A
B (B) Bleeding screw
(C) Electric traction motor
(D) Brake hoses
(E) Distribution block
D (F) Service brake pedal
(G) Tank
(H) Brake command pump
Every 1000 hours
E
- check that the liquid level in the tank (G) has not dropped;
if so, check the system
- control the pedal functioning that must be smooth and
with no jamming
F
Every 2000 hours
- change the braking system liquid
H - functional check of fluid brake tank: by pressing button
the warning light on the dashboard shall light up
G
Every 5000 hours
- replace brake hoses (D)
BRAKE FLUID TANK (G)

When the fluid in the brake tank reaches a too low level, the
warning light indicating the low level liquid brakes on the
L dashboard shall light up (see 04 chapter, INCORRECT
STARTS MANAGEMENT section).
G Use the button SW2 (L) to verify the correct warning light
functioning.
Fill up the brake fluid tank (DOT 4- Qt.0.25 lt.)
09-5
2
2
2
3
4
5
3. Open the cover and disconnect the battery plug 7
5. Disconnect the horn and brake pedal system and horn wiring harness 9
6. Empty the oil brake circuit. Recover the oil in a proper container, by disconnecting the hose of the
brake pump [Point 1]
7. Remove the three screws that fix the pedal to the chassis [Point 2]
9
8. Remove the brake pedal system
10
The installation procedure is the reverse of the disassembly procedure. 11
Point Operations
12
[Point 1]
Disassembly: 13
Disconnect the hose (A) of the brake pump
14
Reassembly:
After the installation, tightening torque of the bolt on 15
the brake pump 28 Nm
16
A
17
[Point 2]
Disassembly:
18
Remove the 3 screws (B) that fix the pedal to the
chassis 18
18
18
B
18
18
09-6
BRAKE FLUID SYSTEM BLEEDING

The bleeding procedure of the brake system it is necessary to remove completely the air from the
system. The oil used in this braking system is: DOT4.
Bleeding procedure
1. Fill up the brake fluid tank (DOT4)
2. Loosen the bleeding screw (A), press deeply the

service brake pedal and let go out a small quantity of
oil
3. Screw in the bleeding screw, and press the brake
pedal several times
4. Keep the oil level constant
5. Repeat points 2, 3 and 4 until bleeding screw doesn't
A go out only the oil
6. Repeat the procedure on the other reduction gear
09-7
SERVICE BRAKE
2
2
Main piston 2
Pad
3
4
Brake pin
5
6
Brake cylinder
7
9
Oil brake tube
9
10
Wheel cylinder
11
Oil area
12
Spring
Brake disks group 13
The braking effect is due to the rotation of the brake cylinder hinged to the reduction gear through a pivot 14
fixed by two seegers.
The parking brake lever or service brake pedal operation causes the cylinder rotation and, consequently,
the braking system intervention. 15
When the brake pedal is pressed, the oil pressure pushes out of brake cylinder that, acting on the
reduction, causes to the rotation of the cylinder itself. 16
The cylinder turns around the fulcrum and presses against the brake pin that pushes the pad.
The pad pushes the main piston that compacts the brake disks, obtaining the braking effect. 17
When the brake pedal is released the springs push the main piston in neutral position, freeing the disks.
18
18
18
18
18
18
09-8
DISK BRAKES
Pinion
Gear group 2
Plate disk
Gear group 1
Reduction gear body
The brake cylinder movement triggers the braking effect.

The disk brake cylinder pushes the free cylinder and the pad. The pivot-pad is used to stop the pad that
otherwise would be free to turn together with the brake disks.
The pinion turns with the Gear group 2 while the Gear group 1 and the brake disks are still.
The brake disks have a tooted shape on the external diameter in order to fix them fully with the reduction
gear body. The counter disks have a tooted shape on the internal diameter in order to fix them to be
integral with the Gear group 1.
Pressing the brake pedal all disks come packaged and the Group gears 1 is blocked by the contact of
the mobile counter disks with the fixed brake disks.
Brake system antagonist springs are present in order to recover the Group gears 1 normal operation
position and that happens when the brake pedal is released.
09-9
REPLACE DISK BRAKES

2. Place 2 shims under the mast 2
3. Tilt the mast forward until the stoke end
5. Open the cover and disconnect the battery
6. Remove the gearmotor
7. Remove the brake lever from housing cover 3
8. Remove the bolts from the housing cover [Point 1]
9. Realease the housing cover [Point 2] 4
10. Remove the housing cover from the housing [Point 3]
11. Undo the Torx bolts [Point 4] 5
12. Remove the retaining plate from the spur gear [Point 5]
13. Remove the pressure springs from the spur gear [Point 6]
14. Remove the inner disc carrier from the pressure disc [Point 7]
6
15. Remove the pressure disc from the spur gear [Point 8]
16. Lever the axial bearing out of the housing cover and remove [Point 9] 7
17. Remove the brake disc set from the internal gear [Point 10]
9
1. Drive the cylindrical pin into the housing cover [Point 11] 9
2. Insert the axial bearing in the housing cover by hand [Point 12]
3. Assure proper position of the axial bearing related to the cylindrical pin [Point 13] 10
4. Insert the spur gear retaining ring [Point 14]
5. Place the pressure plate on the spur gear by hand [Point 15]
6. Fit the inner disc carrier onto the spur gear by hand [Point 16]
11
7. Insert the pressure springs into the inner disc carrier by hand [Point 17]
8. Place the fixing plate over the pressure spring by hand [Point 18] 12
9. Insert the Torx bolts into the fixing plate and screw them down into the spur gear [Point 19]
10. Tighten the Torx bolts [Point 20] 13
11. Determining the thickness of the pressure disc [Point 21]
12. Place the disc set into the internal gear [Point 22] 14
13. Arrange the driven discs [Point 23]
14. Apply Loctite 243 as a locking agent in the threaded holes for the bolts [Point 24]
15. Coat the mating surface of the housing and the housing cover [Point 25] 15
16. Fit the housing cover to the housing by hand [Point 26]
16
17
18
18
18
18
18
18
09-10
Point of operation
[Point 1]
Removal:
Undo the 8 Allen bolts and remove from the housing
cover
[Point 2]
Removal:
Release the housing cover using assembly levers and
raise slightly and evenly
[Point 3]
Removal:
Remove the housing cover from the housing
[Point 4]
Removal:
Undo the 6 Torx bolts
09-11
[Point 5]
Removal:
Manually remove the retaining plate from the spur gear
together with the 6 Torx bolts 2
2
2
3
[Point 6]
4
Removal:
Manually remove the 3 pressure springs 1.6x8.0x21.5 5
from the spur gear
6
7
9
9
[Point 7]
Removal: 10
Manually remove the inner disc carrier from the
pressure disc 11
12
13
14
[Point 8]
15
Removal:
Manually remove the pressure disc from the spur gear 16
17
18
18
18
18
18
18
09-12
[Point 9]
Removal:
Lever the axial bearing out of the housing cover using
a screw driver and remove
[Point 10]
Removal:
Remove the brake disc set from the internal gear
Note:
When changing the disc set in one gearbox, the disc of
the gearbox on the other side of the vehicle shall also
be changed. If this is disregarded, there may be a
pronounced difference in braking effect between the
left-hand and right-hand gearbox. The difference in
braking effect may lead to longer braking distances or
to the vehicle breaking out to the side
09-13
[Point 11]
Installation:
Drive the cylindrical pin into the housing cover to a size 2
of 5.5 mm-0.3
Note: 2
Check the heigh of the cylindrical pin (109.020) for a
value of 5.5 mm-0.3. If the measured value is found 2
different from the given specification please remove
the cylindrical pin (109.020) by using pliers and replace 3
it by a new one installed at the correct mounting height
4
[Point 12]
Installation: 5
Insert the axial bearing in the housing cover by hand.
The lubrication groove of the axial bearing shall face 6
upwards
7
9
9
[Point 13] 10
Installation:
Please assure proper position of the axial bearing 11
related to the cylindrical pin (109.020)
12
13
14
15
[Point 14]
Installation: 16
Insert the spur gear retaining ring
17
18
18
18
18
18
18
09-14
[Point 15]
Installation:
Place the pressure plate on the spur gear by hand
Note:
• The bulge in the pressure plate shall be at the top
• The holes in the pressure plate and the spur gear
shall be positioned on top of each other
[Point 16]
Installation:
Fit the inner disc carrier onto the spur gear by hand
Note:
• The inner disc carrier fits onto the spur gear in one
position only. Find out by trial and error the position
in which the inner disc carrier needs to be set in
relation to the spur gear
[Point 17]
Installation:
Insert the 3 pressure springs 1.6x8.0x21.5 into the
inner disc carrier by hand
[Point 18]
Installation:
Place the fixing plate over the pressure spring by hand
Note:
• The spring shall be firmly seated in the recesses in
the retaining ring
09-15
[Point 19]
Installation:
Insert the 6 Torx bolts into the fixing plate and screw
them down into the spur gear 2
Note:
The bolts shall be tightened in a crosswise pattern 2
2
3
4
5
6
7
9
[Point 20] 9
Installation:
Tighten the 6 Torx bolts to a tightening torque of 70 Nm 10
using an adjustable torque wrench
11
12
13
[Point 21] 14
Installation:
Determining the thickness of the pressure disc
W = X+Y
15
Z = V-W
16
Z [mm] Pressure disc thickness
5.58 to 6.10 4.8 mm thick
6.11 to 6.70 5.3 mm thick
17
6.71 to 7.22 5.8 mm thick
18
X = is the distance between the plane face of the cover and
plane face of the pressure disc
Y = is the thickness of the disc set when it is compressed 18
W = is a reference dimension calculated by adding X and Y
V = is the distance between the plane face of the housing 18
and the contact surface of the pressure disc in the internal
gear 18
Z = is a reference dimension calculated by subtracting V
and W
18
18
09-16
[Point 22]
Installation:
Place the disc set (consist of 3 driven discs, 4 drive
discs and 1 pressure disc) into the internal gear
(1) Insert the pressure disc
(2) Insert a drive disc
(3) Insert a driven disc
(4) Insert drive and driven disc alternately
Note:
Insert the driven discs so that the side on which the
teeth are rounded off faces upwards. The driven disc
are completely even in circumference direction. They
are non-sinusoidal.
You do not need to bring them in a specific order prior
installation
[Point 23]
Installation:
Arrange the driven discs
Note:
The teeth on all driven discs shall be positioned
precisely in line with each other
[Point 24]
Installation:
Apply Loctite 243 as a locking agent in the threaded
holes for the bolts
09-17
[Point 25]
Installation:
Coat the mating surface of the housing and the
housing cover with Loctite 574 2
2
2
3
[Point 26] 4
Installation:
Fit the housing cover to the housing by hand
5
Note:
Care shall be taken to ensure that the guide of the inner 6
disc carrier comes to rest in the needle slave
7
9
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
09-18
BRAKES LEVER
2. Place 2 shims under the mast
3. Tilt the mast forward until the stoke end
5. Open the cover and disconnect the battery
6. Remove the gearmotor
7. Remove the grover from the pivot of the brake lever [Point 1]
8. Remove the pivot of the brake lever [Point 2]
9. Remove the brake lever
10. Remove the pressure pin [Point 3]
1. Insert the brake lever in the housing cover [Point 4]
2. Measure the brake lever play [Point 5]
3. Test the brake manually [Point 6]
09-19
Point of operation
[Point 1]
Removal: 2
Remove the elastic washer from the cylinder pivot
2
2
3
4
[Point 2] 5
Removal:
Extract from the seat (ref.02), the pivot (ref.03) of the 6
lever (ref.01)
7
9
9
10
[Point 3]
Removal: 11
Remove the pressure pin
12
13
14
15
[Point 4] 16
Installation:
Insert the brake lever in the housing cover: 17
(1) Select the pressure according to length
18
Note:
The play on the brake lever may be 0.4mm+0.6. Select a 18
pressure pin which is able to guarantee the specified
amount of brake lever play 18
18
18
18
09-20
(2) Coat the sealing ring with grease
(3) Manually insert the pressure pin in the sealing ring

in the housing cover
(4) Remove the circlip from the retaining pin of the

brake lever and remove the retaining pin from the
brake lever
(5) Fit the brake lever in the guide in the housing cover
(6) Fasten the brake lever to the housing cover with the
retaining pin
(7) Fit the retaining pin circlip
[Point 5]
Installation:
Measure the brake lever play
(1) Select the dial gauge sensor on the brake lever
(2) Adjust the dial gauge to 0
(3) Press the brake lever down by hand
09-21
(4) Read off the brake lever play from the dial gauge
2
2
2
3
[Point 6]
4
Installation:
Test the brake manually: 5
Turn the wheel shaft by hand. At the same time, push
the brake lever up, using a screwdriver 6
7
9
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
09-22
PARKING BRAKE
GENERAL
The parking brake is made up of a single stage electro mechanical disk brake fitted on the drive motor
(one for each drive motor) which is engaged by means of spring pressure. the parking brake is released
electrically (DC voltage).
1 - Inductor
2 - Friction disc
3 - Hub
4 - Flange
5 - Assembly screws
6 - Adjusting screws
Technical specifications
Nominal torque 70 Nm
Nominal play 0,25 mm
Tightening torque of fitting M6* on Ø132mm C = 9,1Nm
screws M8* on Ø145mm C = 22Nm
M6 on Ø168mm C = 9,1Nm
Max. rotation speed 5000 rpm
Activation voltage 48 V
Maintenance voltage 24 V
Coil Resistance 34 Ω
09-23
UNBLOCKING PARKING BRAKE LEVER
• Parking brake button (A)

A 2
2
2
3
4
5
For inserting the parking brake push the button (A).
B The icon (B) will be appears on the display. 6
For the unbloking push again the button (A).
7
9
9
Note:
If the operator activates any possible hydraulic application and the selector (A) is in position 1, 10
the required hydraulic function will be available, but accompanied with an acoustic warning
signal and, the INCORRECT START relative message will appear on the display 11
12
13
14
15
16
17
18
18
18
18
18
18
09-24
ELECTRIC BRAKES MANUAL UNBLOCKING

The manual unblocking of electric brakes is executed using the two screws on top side of the brake.
If the manual unblocking of the electric brakes is requested, it is possible to act on the two screws
(screws dimention: TE UNC 1/4”-20x1 1/4”-8.8) to create pressure on the branch for the compression
of the brakes springs.
2. Place 2 shims under the mast
3. Tilt the mast forward until the end stroke
5. Open the cover and disconnect the battery plug
7. Remove brake and accelerator pedals
8. Disconnect the electric brake wiring harness [Point 1]
9. Unscrew the 3 bolts [Point 2]
10. Remove the electric brake
Points of intervention
[Point 1]
Disassembly:
Disconnect the electric brake wiring harness
[Point 2]
A Disassembly:
Unscrew the 3 bolts (A)
A
09-25
ADJUSTING THE NOMINAL PLAY

To adjust the nominal play, undo the fitting screws then take off the brake.
Undo the assembly screws (5) and adjust the screws (6) in order to get the necessary value
(Nominal play = 0,25 mm). 2
Check the value of the airgap at several points. Make several motor manoeuvres, then check the value
of the airgap again. 2
Assembly screws must be tightened with a torque of 5,1 Nm.
2
3
Nominal play
4
Assembly
screw 5
6
7
Adjusting screw
9
9
10
1 - Inductor
2 - Friction disc 11
3 - Hub
4 - Flange 12
5 - Assembly screws
6 - Adjusting screws
13
14
15
16
17
18
18
18
18
18
18
09-26
ELECTRIC BRAKE TROUBLESHOOTING
Troubleshooting and fault elimination

Fault Cause Remedy
Brake not - Power supply is too low - Adjust power supply
release - Power supply is interrupted - Reconnect power supply
- Airgap too large - Re-adjust the airgap
- Worn disc - Change disc and readjust the airgap
- Coil is damaged - Replace the brake
- Airgap too small - Re-adjust the airgap
Brake does - Voltage present at switch off position - Check the customer’s power supply
not brake - Grease on friction faces - Change the disc and re-adjust the airgap
Nuisance - Power supply is too low - Adjust power supply
braking
10-1
BODY & FRAME

Page
COMPONENTS ..........................................................10-2
0
BATTERY HOODS .....................................................10-4
1
BATTERY CONNECTOR ..................................................... 10-4
OVERHEAD GUARD .................................................10-5 2
COUNTERWEIGHT....................................................10-6 3
OPERATOR’S SEAT ..................................................10-7 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
10-2
COMPONENTS
1 Overhead guard 8 Fender

2 Plate (shhet of metal) 9 Hood
3 Counterweight 10 Hook
4 Pin 11 Gas spring
5 Side plate 12 Bracket
6 Support 13 Battery stopper
7 Frame
10-3
2
2
2
3
4
5
6
6
8
9
10
11
12
13
14
15
16
17
1 Steering wheel 9 Emergency button 17 Rubber footboard
2 Plug 10 Cover 18 Metal footboard
18
3 Clacson button 11 Display 19 Metal footboard
4 Direction switch 12 Dashboard 20 Cover
18
5 Steering column 13 Hydraulic steering hub 21 Cover
18
6 Cover 14 Orbitrol 22 Cover
7 Handle 15 Joint 18
8 Wiring harness 16 Horn
18
18
10-4
BATTERY HOODS
BATTERY COVER LIFTING
Unblock the hooking (J) then raise the hood cover; two air
springs make easier the complete lifting of hood cover
BATTERY COVER DISASSEMBLY PROCEDURE

1. Disconnect the battery plug
2. Open the battery cover
3. Tie the battery cover with the seat to the head guard
roof or to a bridge crane
4. Disconnect the seat and armrest wirings to the
auxiliary wiring
6. Disconnect the battery cover gas spring (on the cover
side)
7. Remove the fixing bolt
8. Remove the battery cover with the seat
BATTERY CONNECTOR
The battery connector is black (48 V) and is located inside
the rear compartment, under the hood cover.
10-5
OVERHEAD GUARD
Tightening torque T =Nm 2
2
2
3
4
5
6
6
8
Fixing points
T = 80 Nm 9
10
3. Open the battery covers and disconnect the battery plug 12
4. Remove the battery cover (see “battery cover disassembly procedure” in this chapter)
5. Remove the footboard 13
6. Remove the front plastic cover near the front OHG pillars
7. Remove the dashboard plastic covers
8. Disconnect all hydraulic pipe and all electic wires
14
9. Sling the overhead guard using appropriate belts in order to avoid its falling down when removed
from the frame 15
10. Remove the OHG fixing bolts
11. Remove the OHG 16
17
18
18
18
18
18
18
10-6
COUNTERWEIGHT
Note: Check the weight of the counterweight and choose the appropriate wire, rope or chain to
handle it
3 wheels
4 wheels
3. Open the battery covers and disconnect the battery plugs
4. Remove the battery cover (see “Back cover disassembly procedure” in this chapter)
5. Disconnect the rear light cables from the auxiliary wiring, if present
6. Remove the reflectors (or the rear lights if present)
7. Fit two wire ropes, slings or belts, having proportionate load capacity (is advisable to use belts with a
capacity of 1000kg under linear traction), through the rear light holes, hook them on a bridge crane
and lift until they are tight
8. Remove the OHG rear fixing bolts
9. Remove the counterweight fixing bolts
10. Remove the counterweight
Note:
• The lifting system MUST be able to support the counterweight weight
• Tightening torque of fixing bolts of the counterweight = 300 Nm
• Always make sure to lock temporaly the overhead guard before remove the counterweight
10-7
OPERATOR’S SEAT
2
1. Park the truck on a level surface and apply the parking 2
brake
3. Tie the seat to a bridge crane
4. Open the battery compartment
3
6. Disconnect the seat microswitch and the armrest
wiring from the auxiliary wiring 4
7. Remove the set of nuts fastening the operator’s seat
(take care not to drop the operator's seat) 5
8. Remove the operator’s seat
9.
(use a sling, not the seat belt)
Open the battery cover
6
6
The reassembly procedure is the reverse of the 8
disassembly procedure.
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
10-8
11-1
MATERIAL HANDLING SYSTEM

Page
HYDRAULIC CIRCUIT ............................................... 11-2
0
HYDRAULIC SYSTEM............................................... 11-5
1
PUMPS SYSTEM...................................................................11-5
STEERING SYSTEM .............................................................11-6 2
TILTING SYSTEM..................................................................11-6 3
BRAKES SYSTEM ................................................................11-7 4
COMPONENTS .......................................................... 11-8
5
HYDRAULIC OIL TANK ........................................................11-8
6
HYDRAULIC SYSTEM OIL FILTER .......................... 11-9
HYDRAULIC OIL...................................................... 11-10
7
LIFTING LOAD DOWN TEST .................................. 11-11 8
OIL LEAK TEST....................................................... 11-12 9
LIFTING CYLINDERS .........................................................11-12 10
TILTING CYLINDERS..........................................................11-12
11
12
13
14
15
16
17
18
19
20
21
E
11-2
HYDRAULIC CIRCUIT
3 wheels
11-3
4 wheels
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
11-4
3-4 wheels
11-5
HYDRAULIC SYSTEM
PUMPS SYSTEM
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
11-6
STEERING SYSTEM
TILTING SYSTEM
11-7
BRAKES SYSTEM
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
11-8
COMPONENTS
HYDRAULIC OIL TANK
The tank filter plug is positioned under the footboard, on the left side.
The tank capacity is 18.5 litres.
Lifting
cylinders
breather
Pump suction
Drain plug
Orbitrol oil
Plug drain
Oil drain from

control valve
Ventilation
filter
11-9
HYDRAULIC SYSTEM OIL FILTER

2
2
2
3
4
A
5
6
B
A 6
8
3. Open the front battery cover and disconnect the battery plugs
4. Remove the footboard and the tank plug (A)
9
5. Remove the filter
6. Loose and remove all oil drain pipes from the filter 11
7. Unscrew the oil filter fixing screw ((B) T = 15 Nm)
8. Remove the oil filter group 12
13
14
15
16
17
18
18
18
18
18
18
11-10
HYDRAULIC OIL
REPLACEMENT
A T= 20-25Nm
Replacement Procedure
3. Open the front battery cover and disconnect the battery plugs
4. Remove the footboard and the tank plug
5. Remove the filter
6. Lift the truck
7. Loose and remove the oil drain plug (A)
8. Let flow all the oil in a suitable recipient
9. Check the oil level using the oil dipstick
10. Reposition the plug (A)
11. Introduce new oil
12. Reinsert the filter
13. Reposition the plug and the footboard
Notes:
• Check the state of seals and if there are no oil leakages;
• Check the oil level in the tank, using the dip-stick (B) with mast in vertical position and forks
lowered.
Oil/filter changing:
After the first 40 hours
• first changing of the filter
Every 1000 hours
• check the oil level in the tank using the dipstick (B)
Every 2.000 hours
• change the oil of the system and the filter
11-11
LIFTING LOAD DOWN TEST

1. Set mast in vertical position with the standard load on
the forks 2
2. Lift forks at 1,5 m and leave the key switch ON
3. Take the measure between forks and ground with a
meter or draw datum lines on the inner and outer
2
masts
2
3
4
5
4. Make the measurement between forks and ground or
between the datum lines on the inner and outer masts
again after 10 minutes
6
Limit: A = 100 mm
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
11-12
OIL LEAK TEST

LIFTING CYLINDERS

forks
2. Lift forks at 1,5 m and take the measure between the
forks and ground with a meter and leave the key
switch ON
3. Make the measurement between forks and ground or
between the datum lines on the inner and outer masts
again after 10 minutes
Limit: A = 100 mm
4. If there are oil leakages on the body of the lifting
cylinders, check if cylinder connections are well tight.
Replace the cylinder if necessary.
TILTING CYLINDERS
forks, lift forks at 1,5 m and leave the key switch ON
2. Secure the lead rope on the front edge of the top of the
mast; measure the distance between the rope and the
mast 1 m lower
3. Perform the same measurement 10 minutes after.
(1° = 17.5 mm)
Limit: Maximum forward angle (°) <= 0.5 (°/min)
Time (10 min)
4. If the truck is out of the above limit lower completely
the mast and turn the key switch OFF
5. Invert the tilting hoses with the sideshift hoses (if
present) on the control valve. This operation is
necessary to understand if there is any internal
leakage inside the tilting cylinder or the control valve
6. Turn the key switch ON and repeat the test from point
1 to 3; after that
a) The test result is within the set limits:
replace the control valve
b) The test result is not within the set limits:
replace the tilting cylinders
12-1
MAST
Page
MAST..........................................................................12-2
GENERAL............................................................................. 12-2
0
MAST SECTION ................................................................... 12-3 1
MAST GROUP ...........................................................12-4 2
COMPONENTS .................................................................... 12-4 3
T.V. - F.F.L. MAST, MAST CHAIN AND CHAIN WHEEL
GROUP.............................................................................. 12-4
4
MAST FORK CARRIAGE (ALL MODELS).......................... 12-5 5
FORKS (ALL MODELS)....................................................... 12-6 6
FORK CARRIAGE GROUP AND MAST REMOVAL ........... 12-7
7
MAST GROUP (WITH FORK CARRIAGE).......................... 12-9
8
T.V. MAST GROUP ..................................................12-10
9
2M F.F.L. MAST GROUP.......................................... 12-11
3M F.F.L. MAST GROUP..........................................12-12 10
FORK CARRIAGE ...................................................12-13 11
FORK CARRIAGE GUIDE SHOES 12
REPLACING..........................................................12-16
13
MAST CHAINS CHECK ..................................................... 12-19
POSITION OF THE FORK CARRIAGE ............................. 12-20
14
FORKS................................................................................ 12-21 15
MAST LUBRICATION ..............................................12-22 16
MAST .................................................................................. 12-22 17
SAFETY FORK CARRIAGE LIMIT STOPS ....................... 12-23
18
MAST UNIT TILTING SETTING............................... 12-24
19
20
21
E
12-2
MAST
GENERAL
The profile of the mast has a double strengthening wing having great rigidity to bending and twisting.
It allows wide visibility thanks to reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside profiles.
The mast group is roller type with a variable center distance (i.e. a fixed roller is fitted on the outer mast
and a mobile one on the inner mast). This solution ensures better grip and stability during operation.
Others: side clearance adjustable from outside. Plastic guide shoes.
Lifting cylinders:
Double mast T.V. No. 2 rear cylinders

2M F.F.L. No. 2 rear cylinders
No. 2 front cylinders
Triple mast 3M F.F.L. No. 2 rear cylinders
No. 2 front cylinders
Setting screw Guide shoe Roller

12-3
MAST SECTION
A B
2
2
outer rail
2
121.30
82.00
135.40
91.00
3
inner or middle rail 4
5
135.00
121.00
53.00
61.00
6
6
1.5 1.6 1.8 2.0

8
T.V. (3005÷4005) A A B B 9
T.V. (4205÷5005) B B B B
2M F.F.L. (3005÷4005) A A B B 9
2M F.F.L. (4205÷5005) B B B B
9
3M F.F.L. (4005÷7500) B B B B
12
13
14
15
16
17
18
18
18
18
18
18
12-4
MAST GROUP
COMPONENTS
T.V. - F.F.L. MAST, MAST CHAIN AND CHAIN WHEEL GROUP
2M T.V.
3M F.F.L.
1 Dowel pin 11 Outer mast 21 Washer

2 Guide roller 12 Cylinder 22 Outer mast
3 Elastic ring 13 Collar 23 Middle mast
4 Guide shoe 14 Collar 24 Inner mast
5 Grease nipple 15 Chain 25 Chain for free lift
6 Articulated joint 16 Chain tension rod 26 Collar
7 Screw 17 Pulley 27 Support
8 U bolt (bracket) 18 Middle mast 28 Pulley
9 Washer (Nord-Lock) 19 Washer 29 Bracket
10 Elastic washer 20 Ring nut 30 Antiderailment puffer
12-5
MAST FORK CARRIAGE (ALL MODELS)
2
2
2
3
4
5
6
6
8
9
9
9
12
13
14
15
16
17
18
18
1 Dowel pin 6 Fork carriage 11 Rod 18
2 Guide roller 7 Sideshift fork carriage 12 Bushing
3 Elastic ring 8 Plate (sheet of metal) 13 Gasket 18
4 Guide shoe 9 Upper guide shoed 14 Guide shoe
5 Grease nipple 10 Stop 15 Shim
18
18
12-6
FORKS (ALL MODELS)

12-7
FORK CARRIAGE GROUP AND MAST REMOVAL

2
2
2
3
4
5
6
6
8
9
9
9
1. Set the mast in vertical position and lower the forks completly
2. Disconnect the chain from the mast side
3. Remove the chain wheel, if needed
12
4. Remove the fork carriage (raise the inner mast until it comes off the fork carriage, and slowly run the
vehicle in reverse to detach from the fork carriage) 13
5. Disconnect the overflow hose and high pressure hoses (before hose disconnection, fully lower the
mast completly) 14
6. Hoist the mast slightly [Point 1]
7. Remove the bolts of the mast [Point 2] 15
8. Remove the tilt cylinder front pin from the mast side [Point 3]
9. Remove the mast support cap
10. Remove the mast 16
11. Verify the bushing condition on the mast support
17
The reassambly procedure is the reverse of the disassembly procedure. 18
Note:
• Apply molybdenum disulfide grease on the mast support bushing and mast support cap 18
interior surfaces. Apply MP grease to the tilt cylinder front pin
• Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced
18
• Adjust the chain tension after installation
18
18
18
12-8
Point Operations
Inspection:
Remove forks, lower the fork carriage completely and
measure the height X:
Standard measure X = 76 mm.
(see “POSITION OF THE FORK CARRIAGE”)
If the height has a different measure, set the
adjustment nuts of the chains.
Inspection:
Fork carriage Check the clearence between inner mast and pad of
lift bracket:
Standard clearence: 0.2-0.4 mm
0.2-0.4mm
Outer mast Inner mast

0.2-0.4mm
[Point 1]
Disassembly:
To remove the mast, use the eyebolt at the top of fix
mast
[Point 2]
Disassembly:
Remove 4 bolts (A) that fix the mast to the bottom of
the frame
Reassembly:
After installation, tightening torque for the mast screws
= 50±10% Nm
[Point 3]
Disassembly:
Remove the 2 screws (B) of the safety plates and
extract the pins of the tilting cylinders (C)
Reassembly:
C After installation, tightening torque for the 2 screws of
the safety plates of the 2 pins of the tilting cylinders =
24 Nm
B
12-9
MAST GROUP (WITH FORK CARRIAGE)

2
2
2
3
4
5
6
6
8
9
9
1. Set mast in vertical position and lower forks completly
2. Remove the forks
9
3. Disconnect the overflow hose and high pressure hoses (before hose disconnection, fully lower the
inner mast) 12
4. Tie the fork carriage and outer mast with a wire rope
5. Slightly hoist the mast [Point 1] 13
6. Remove the tilt cylinder front pin
7. Remove the mast support cap 14
8. Remove the mast group with the fork carriage
The reassambly procedure is the reverse of the disassembly procedure.
Note:
16
• Apply chassis special grease to the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin 17
• Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced 18
• Adjust the chain tension after installation
Point Operations
18
[Point 1] 18
Disassembly:
To remove the mast, use the eyebolt at the top of fix 18
mast
18
18
12-10
T.V. MAST GROUP

DISASSEMBLY • INSPECTION • REASSEMBLY
OUTER MAST INNER MAST
1. Remove the overflow hose and high pressure hoses
2. Disconnect the chain
3. Remove the fork carriage group (raise the inner mast until it comes off the fork carriage, and run
slowly the vehicle in reverse to detach from the fork carriage)
4. Remove each cylinder rod end set bolt, and take each rod end off
5. Remove each cylinder support
6. Remove each cylinder bottom set bolt, and remove each lift cylinder
7. Remove the outer mast
12-11
2M F.F.L. MAST GROUP

2
OUTER MAST INNER MAST
2
2
3
4
5
6
6
8
9
9
9
12
13
3. Remove the fork carriage group (raise the inner mast until it comes off the fork carriage, and run 14
4. Remove the pulley support (Chain and hydraulic pipes) 15
5. Remove the front lifting cylinder support and the bottom set bolts
6. Remove the front lifting cylinder 16
7. Remove each cylinder rod end set bolt, and take each rod end off
8. Remove each cylinder support
9. Remove each cylinder bottom set bolt, and remove each rear lift cylinder
17
10. Remove the outer mast in rollers and inner mast rollers
18
18
18
18
18
12-12
3M F.F.L. MAST GROUP

OUTER MAST MIDDLE MAST INNER MAST
3. Remove the fork carriage group (raise the inner mast until it comes off the fork carriage, and run
4. Remove the pulley support
5. Remove each front lift cylinder rod end set bolts and take each rod end off
6. Remove the front lift cylinder support and the bottom set bolts
7. Remove the front lift cylinder
8. Remove the chains of middle mast
9. Remove each rear lift cylinder rod end set bolts and take each rod end off
10. Remove the rear lift cylinder support and the bottom set bolts
11. Remove the rear lift cylinder support
12. Slide the inner mast downward and remove the lift rollers and pads
13. Remove the inner mast
14. Slide the middle mast downward and remove the lift rollers and pads
15. Remove the central mast
12-13
FORK CARRIAGE
2
2
2
3
4
5
6
6
8
4. Remove the two forks from the carriage
5. Disconnect the hydraulic hoses from the fork carriage [Point 1] 9
6. Secure and lift the carriage [Point 2]
7. Remove the safety pin from the chain tie rod [Point 3] 12
8. Remove the stop nut from the chain tie rod. Extract the chain from the opposite side [Point 4]
9. Remove the complete fork carriage from the bottom of the mast 13
10. Remove the guide shoes with the aid of a tool [Point 5]
11. Remove the snap ring and extract the guide roller [Point 6]
14
16
17
18
18
18
18
18
18
12-14
Points of Operation
[Point 1]
Disassembly:
Disconnect hydraulic hoses from the fork carriage
[Point 2]
Disassembly:
Secure and lift the carriage
[Point 3]
Disassembly:
Remove the safety pin from the chain tie rod
[Point 4]
Disassembly:
Remove the stop nut from the chain tie rod. Extract the
chain from the opposite side
12-15
[Point 5]
Disassembly: 2
Remove guide shoes with the aid of a tool
2
2
3
4
5
[Point 6]
Disassembly:
Loosen the adjuster grub screw on the opposite side of
6
the guide shoes, remove the snap ring (A) and extract
the guide roller 6
8
A
9
9
9
12
13
14
15
16
17
18
18
18
18
18
18
12-16
FORK CARRIAGE GUIDE SHOES REPLACING

4. Remove the two forks from the carriage
5. Remove one of the two side panels from the sideshift [Point 1]
6. Replace the upper and lower guide shoes [Point 2]
7. Make sure you insert the shims under the lower guide shoes
12-17
Points of Operation
[Point 1]
Disassembly: 2
Remove one of two side panels (A) from the sideshift.
Extract the mobile portion (B) of the sideshift 2
B
2
3
A 4
5
[Point 2]
Disassembly: 6
Replace the upper (C) and lower (D) guide shoes
C 6
8
D 9
9
9
12
13
14
15
16
17
18
18
18
18
18
18
12-18
MAST AND FORK CARRIAGE PADS ADJUSTMENT
MAST FORK CARRIAGE
Lift bracket
clearance
0.2-0.4 mm
Inner mast
50mm
clearance
0.2-0.4 mm push
push 350mm
clearance
0.2-0.4 mm
Inner mast
clearance
0.2-0.4 mm
Outer mast
Standard clearance 0.2-0.4 mm (1) Unscrew the adjustment screw

(2) Set frames (mast or fork carriage) as shown in the
Outer mast Fork carriage figure above
0.2-0.5 mm (3) Put frames (mast or fork carriage) in one side
(4) Measure the clearance between the frame and the
Adjustment pads
screw (5) Adjust RH pads (upper and lower) for half of
clearance (considering that for each turn the screw
Roller move 1.25mm: 1/4=0.3mm)
(6) Put shim (0.3mm (0.0118 in)) on the LH side and
Pad Inner mast
tight the adjustment screw until the shim does not
0.2-0.5 mm
move
(7) Remove the shim
12-19
MAST CHAINS CHECK

Every 500 hours (in any case check the chains every 3 months)
• check the condition of chains which must not be worn or faulty. To check the links for wear, use the 2
appropriate gauge
Every 1000 hours 2
• remove the chains, clean them thoroughly, refit them inverting the original working position and
lubricate them 2
Every 10000 hours
• replace the chains and the fixing tie rods 3
Original chains use guarantee that comply with safety requirements stated in regulations in force
4
INSPECTION • ADJUSTEMENT
5
Inspections:
1. Check if the chain links are worn out, use the 6
appropriate rule:
6
8
9
9
2. The chains must be replaced when, in a portion
corresponding to 34 pitches, only 33 pitches are found.
9
Note:
Perform measurement without removing the chain 12
from the vehicle.
Inspect elongation over the entire chain length as it
may be localized.
13
14
15
Adjustment
brake
16
2. Put the mast in vertical position
5. Remove the forks 18
6. To compensate for any chain sag, turn the self-locking
nut on the fork carriage
7. Check to see if the chain tension is equal on left and
18
right sides
8. Check that the chains are not twisted 18
9. Check that the lifting higher meets the standard
10. In the upper position, check that the end stroke plate is 18
not in contact with the fork carriage
11. Check that the measurement X agrees with the ISO 18
tables in “POSITION OF THE FORK CARRIAGE”
18
12-20
POSITION OF THE FORK CARRIAGE

Every 500 hours
After testing chains, with the truck on an even surface and the mast in vertical position, check the
position of the fork carriage plate, as follows:
• remove forks, lower the fork carriage completely, measure the height (X) and compare it with the value
corresponding to the truck capacity in kg, as shown in the table below
example: the correct value of (X) for a truck with a capacity of 2000 kg (class II A), must be
152 ± 5 mm.
ISO 2328 - 1993
Class Capacity (kg) “X” (± 5)
IA 0 ÷ 999 76 mm
II A 1000 ÷ 2500 76 mm
III A 2500 ÷ 4999 76 mm
IV A 5000 ÷ 8000 127 mm
VA 8001 ÷ 10999 127 mm
Class Capacity (kg) “X” (± 5)
IB 0 ÷ 999 114 mm
II B 1000 ÷ 2500 152 mm
III B 2500 ÷ 4999 203 mm
IV B 5000 ÷ 8000 254 mm
X = 76 mm (A) VB 8001 ÷ 10999 257 mm
x = 152 mm(B)
12-21
FORKS
brake 2
2. Lift the fork to approx. 20 cm from the ground
3. Place a wood block under the notched section of the 2
fork rail
4. Unlock the fork by lifting the fork stopper pin and shift 3
one fork per time to the fork carriage bottom notch
5. Slowly lower the fork for removal
4
G
The reassembly procedure is the reverse of the
disassembly procedure. 6
E
6
8
F
9
D
9
Inspection
Fork arm inspection must be carried out carefully by trained personnel able to detect any damage, 9
failure, deformation, etc., which may impair safe use
1. Surface cracks:
12
The fork arm must be thoroughly examined visually for cracks giving special attention to the heel (D)
and top (E) and bottom (F) hooks. If necessary, the forks may be subjected to a non-destructive 13
crack detection process.
2. Difference in height of fork tips 14
Check the difference in height between the tips on each pair of forks; this must not be more than 3%
of the thickness of the forks fitted on the fork plate 15
3. Positioning lock
Check that the fork positioning lock (G) is in good working order
4. Legibility of marking
16
If the fork arm marking is not clearly readable, it must be renewed by the original fork supplier
5. Fork wear control 17
The fork arm blade and shank must be thoroughly checked for wear, paying special attention to the
area around the heel (D). When maximum wear is detected, with thickness reduced to 90% of the 18
original, the fork arm must be replaced
6. Fork mounting wear control 18
The horizontal supporting surface of the top hook (E) and the contact surfaces of both hooks (E) and
(F) must be checked for wear and any damage
7. Withdrawal of the forks from service 18
Any fork with defects revealed during the above controls must be withdrawn from service
Note:
18
Any component or system tampering can endanger the vehicle safety. Any repair and
replacement operation should be performed only by authorised and well trained personnel. 18
18
12-22
MAST LUBRICATION
MAST
Every 1000 hours
• Lubricate with grease mast sliding guides using the grease nipples
• Lubricate jack tilting joints and frame connection joints
(A) Tilting jack joints

A
Nr. 2+2 grease nipples
(B) Joints between mast and chassis

Nr. 1+1 grease nipples
B
FORK MOUNTING CARRIAGE AND SIDESHIFT

Every 1000 hours
• Lubricate the sideshift guides with grease, through the grease nipples
• Lubricate the fork positioning pins and notches with grease
(C) Sideshift unit

upper part nr. 2 grease nipples for
bronze pads lubrication
C upper part no grease nipples for
resin pads without maintenance
bottom part no grease nipples
12-23
SAFETY FORK CARRIAGE LIMIT STOPS

The lifting unit is equipped with a mechanical safety limit stop to avoid the accidental escape of the fork
carriage from the top or bottom of the mast.
The limit stops (A) consists of plates\round bar on the upper profile of the mast.
2
2
MASTS T.V. MASTS F.F.L.
2
3
4
5
6
6
8
9
9
9
12
13
14
15
16
17
18
18
18
18
18
18
12-24
MAST UNIT TILTING SETTING

Every 500 hours
• Check the tilting of the mast; standard values are:
α = 5° FORWARD
FORWARD - BACKWARD
β = 7° BACKWARD (standard)
β = 5° BACKWARD (optional)
The tilt angle can easily be checked using a plumb-line

dropped from the front outside edge of the top of the fixed
masts and measuring the distance between the line and the
front edge at a metre from the top of masts.
NB. 1 tilting degree corresponds to a 17.4 mm movement
on 1 m
α = 5° FORWARD = 87,5 mm
β = 7° BACKWARD (standard) = 122,7 mm
β = 5° BACKWARD (optional) = 87,5 mm
1° = 17,4 mm
13-1
CYLINDER
Page
LIFT CYLINDER ...................................................13-2
0
GENERAL ...................................................................... 13-2
1
LIFTING CYLINDERS SPECIFICATIONS ...........13-4
REAR LIFTING CYLINDERS (T.V.)................................ 13-4
2
FRONT LIFTING CYLINDERS 3
(2M F.F.L. / 3M F.F.L.)................................................... 13-4
4
REAR LIFTING CYLINDERS (2M F.F.L.)....................... 13-4
5
REAR LIFTING CYLINDERS (3M F.F.L.)....................... 13-4
PARACHUTE VALVE (SAFETY DOWN VALVE)........... 13-5 6
FRONT DISPLACEMENT CYLINDER WITH 7
BRAKING EFFECT ON LIFTING .......................13-6
8
REAR TELESCOPIC CYLINDER WITH
BRAKING EFFECT ON LOWERING .................13-7 9
FRONT DISPLACEMENT CYLINDER WITH 10
BRAKING EFFECT ON LIFTING AND 11
LOWERING ........................................................13-8
12
REAR TELESCOPIC CYLINDER WITHOUT
BRAKING EFFECT ............................................13-9 13
REAR DISPLACEMENT CYLINDER WITH 14
BRAKING EFFECT ON LOWERING ...............13-10
15
CYLINDER CHECKING METHODS...................13-13
16
UPPER FIXING SCREW ADJUSTMENT .................... 13-14
LOWERING VALVE ............................................13-15 17
SPECIFICATIONS ........................................................ 13-15 18
TILTING CYLINDER ...........................................13-16 19
GENERAL .................................................................... 13-16 20
ADJUSTMENT ............................................................. 13-18
21
E
13-2
LIFT CYLINDER
GENERAL
FRONT CYLINDER
1.5 to 1.8 t 2.0 t
T.V.
2 displacement cylinders with brake effect on the lifting 2 displacement cylinders with brake effect on the lifting
(standard) (standard)
2-3M
2 displacement cylinders with brake effect on the 2 displacement cylinders with brake effect on the
lowering (optional) lowering ( optional) F.F.L.
13-3
REAR CYLINDER
1.5 to 1.8 t 2.0 t
2 telescopic cylinders without braking effect (standard) 2 telescopic cylinders without braking effect (standard)
0
2 displacement cylinders with brake effect on the 2 displacement cylinders with brake effect on the
T.V.
1
lowering (optional) lowering (optional)
2
3
2 displacement cylinders with brake effect on the 2 displacement cylinders with brake effect on the 4
lowering (standard) lowering (standard)
2M 5
F.F.L.
6
2 telescopic cylinders with brake effect on the lowering 2 telescopic cylinders with brake effect on the lowering 7
(standard) (standard)
3M 8
F.F.L.
9
10
11
12
13
14
15
16
17
Mast’s type Tilting angle (std) Tilting angle (opt) Note
T.V. 5° FW - 7° BW 5° FW - 7° BW 18
2M F.F.L. 5° FW - 7° BW 5° FW - 5° BW (std W cabin)
3M F.F.L. 5° FW - 7° BW 5° FW - 5° BW (std W cabin) 19
20
21
E
13-4
LIFTING CYLINDERS SPECIFICATIONS

REAR LIFTING CYLINDERS (T.V.)
Load capacity 1,5 - 2,0 t

0
Cylinder type Simple effect
Cylinder bore mm 40 1
Piston outside diameter mm 36
Parachute valve mm 1,8
2
3
FRONT LIFTING CYLINDERS (2M F.F.L. / 3M F.F.L.)
4
5
Parachute valve mm 1,8
7
REAR LIFTING CYLINDERS (2M F.F.L.)

8
9

10
Parachute valve mm 1,8 12
REAR LIFTING CYLINDERS (3M F.F.L.) 13
Load capacity 1,5 - 2,0 t 14
Cylinder type Simple effect 15
Cylinder bore mm 40
16
Parachute valve mm 1,8 17
18
19
20
21
E
13-5
PARACHUTE VALVE (SAFETY DOWN VALVE)
The parachute valve enables the locking of the load in the

position where the actuator is in the moment of failure (as it
might happen in case of hose failure, the flow is blocked). 0
R Note:
We recommend to verify the integrity of the valve and 1
replace it in case the pressure spike generated by hose
failure was such to damage some valve components 2
permanently.
R= Setting portion Standard: 1.5 to 2.0 t 1.8 mm (0.071 in) 3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
13-6
FRONT DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON

LIFTING
Lifting phase:
When acting on the control valve, the oil flows into the
cylinder via the “oil inlet”. Through channels 1, 2 and 3 the oil
fills the chamber A until the internal pressure of the oil exerts
an upward thrust against the surface X. The rod coming out
will close the above mentioned channels.
Near the limit of the stem, the channels 1 and 2 are plugged
by the head, so the oil flowing between the two chambers
passes only through channel 3 (calibrated hole), obtaining a
lower flow of oil.
Lowering phase:
Opening the supply circuit (oil inlet) allows the stern to come
down so that the oil can return to the tank via the control
valve. At the start of this phase, chamber A contains no oil.
Better constant filling is enabled by the channel 3 that by
opening avoid jerking.
After passing the cylinder head, the oil flow between the two
chambers passes through channels 1 and 2 which are now
open.
Channel 1/2
Channel 3
Chamber A
Surface X
Chamber B
Parachute valve
13-7
REAR TELESCOPIC CYLINDER WITH BRAKING EFFECT ON LOWERING

Lifting phase:
By operating on the control valve with the lifting lever, the oil
flows to the cylinder through the oil inlet.
It reaches channels 1 and 2 until the hydraulic pressure 0
formed in chamber A produces a thrust upwards on the
surface X thereby stem extraction. 1
Lowering phase: 2
Lowering is permitted by operating on the hydraulic control
valve, opening the oil return circuit to the tank through the
control valve.
3
At the start of this phase, all the oil in chamber A flows out
through the channel 1. Only afterwards, when the bush 4
comes into contact with the top of the brake body, braking
action begins, directing oil through surface Y, that is very 5
small in proportion causes oil coming out to slow down
(braking effect) surface X. 6
7
8
9
10
11
12
13
Chamber 2
Brake body
14
Bush 15
Surface Y 16
Surface X
17
Channel 1
18
Parachute valve
19
20
21
E
13-8
FRONT DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON

LIFTING AND LOWERING
Lifting phase:
When acting on the control valve, the oil flows into the
cylinder via the “oil inlet”. Through channels 1, 2 and 3 the oil
fills the chamber A until the internal pressure of the oil exerts
an upward thrust against the surface X. The rod coming out
will close the above mentioned channels.
Near the limit of the stem, the channels 1 and 2 are plugged
by the head, so the oil flowing between the two chambers
passes only through channel 3 (calibrated hole), obtaining a
lower flow of oil.
Lowering phase:
control valve.
through the channel 3. Only afterwards, when the bush
action begins, directing the oil through surface Y, that is very
small in proportion causes the oil coming out to slow down
(braking effect).
Channel 1/2
Channel 3
Chamber A
Surface Y
Brake body
Bush
Surface X
Chamber B
Parachute valve
13-9
REAR TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT

A seal has been fitted on the piston of these cylinders,
working on the inner surface of the cylinder liner.
The rod guide is made by the top cap and by the piston
through anti-friction rings. 0
The dust control ring prevents any dirty and water from
penetrating the cylinder. 1
Lifting phase: 2
By operating on the control valve with the lifting lever, the oil
flows to the cylinder through the oil inlet.
Through this channels the oil fills the chamber A until the
3
internal pressure of the oil exerts an upward thrust against
the surface X thereby stem extraction. 4
Lowering phase: 5
Opening the supply circuit (oil inlet) the stem comes down so
that the oil can return to the tank via control valve. 6
7
8
9
10
11
12
13
14
Seal
15
Surface X
16
Oil inlet
17
18
Parachute valve
19
20
21
E
13-10
REAR DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON

LOWERING
Chamber A Lifting phase:
Air bleed screw
to the front channel B When the control valve is operated, the oil flows into the
cylinder cylinder from the “oil inlet”.
Flowing through channel A and chamber B it fills first primary
cylinder (front). The oil exerts an upward force against the
surface X, which set off the outward sliding of the road.
Lowering phase:
control valve.
through the channel 1. Only afterwards, when the bush
action begins, directing the oil through surface Y, that is very
small in proportion causes the oil coming out to slow down
(braking effect).
Chamber A
Chamber B
Brake body
Bush
Surface X
One way
valve
Parachute valve
13-11

T=N·m (kgf·cm) [ft·lbf]
T.V. F.F.L.
2 1
T= 445 to 455
3 (4539 to 4641)
[328.3 to 335.7]
3 2
1
8
8
4
6
6
T= 445 to 455 4
T= 445 to 455
(4539 to 4641) (4539 to 4641)
[328.3 to 335.7] [328.3 to 335.7]
5 5
7
7
1. Remove the cylinder cap (upper side)
2. Remove the cylinder rod guide
3. Remove the piston rod [Point 1]
4. Remove the seals on the piston rod
5. Remove the cylinder cup (botton side)
6. Remove the brake system (bushing brake body)
7. Remove the parachute valve (safety down valve) [Point 2]
8. Remove the cylinder [Point 3]
Notes:
• Apply hydraulic oil to packings, O-rings and dust seal lips
• Apply sealant (Loctite 222) to the threaded portion of the cylinder cup (upper-botton side)
• Add 50±20 ml of hydraulic oil to the cylinder from its top, before installing the cylinder cup
13-12
Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
0
Inspection:
Measure the bend of the piston rod. 1
Limit: 2.0 mm (0.079 in)
2
3
[Point 2] 4
Removal:
SST SST09610-T1000-71 5
T= 3 N·m (30.6 kgf·cm) [2.2 ft·lbf]
6
7
8
9
[Point 3]
Inspection: 10
Measure the lift cylinder bore
11
12
13
14
15
16
17
18
19
20
21
E
13-13
CYLINDER CHECKING METHODS
1st CHECK
Remove the drain pipe from the cylinder (fig. C)
Lift the cylinder some times to end stroke, so as to discharge
any residual oil.
Put a load on the forks and lift it so the cylinder moves by at
least 200 mm.
After 10 minutes, measure the amount by which the load has
lowered (lowering by a few millimetres is to be considered
natural since there is always some seepage in the control
valve).
Now send the cylinder to its limit stop:
if no oil leaks from the drain pipe coupling, it means that the
load lowering is only due to the seepage on the control valve
and that the packing is in a good state of repair.
In case of leakages, it will be necessary to replace the seal.
Should this be the case, inspect the cylinder liner.
2nd CHECK
(To be carried out if the 1st inspection has been successful
and after seal replacement).
Fig. C Remove the drain pipe from the cylinder.
Lift the cylinder a few times to end stroke, in order to
discharge any residual oil.
Put a load on the forks. Lift and lower it for 10 minutes,
making sure that the limit stop is never reached.
Send the cylinder to its limit stop.
If any leakages will be still present, the cylinder is damaged
and must be replaced.
13-14
UPPER FIXING SCREW ADJUSTMENT

T.V. - 2M F.F.L.
The cylinder stroke is adjusted by adding or removing shims
(D)
2M F.F.L. - 3M F.F.L.
E The cylinder stroke is adjusted by adding or removing shims

(E)
13-15
LOWERING VALVE
SPECIFICATIONS
0
1
2
3
4
5
6
7
8
9
10
11
12
S
13
Settings of valve on mast from 1.2 to 2.0 t 14
Mast type Valve type S (mm)
2M T.V. sb 25 c 15 15
2M F.F.L. sb 25 c 15 16
3M F.F.L. sb 25 c 15
17
18
19
20
21
E
13-16
TILTING CYLINDER
GENERAL
T =N·m (kgf·cm) [ft·lbf]
T = 300 N·m
Cylinder specification
Piston rod outside
Cylinder inside diameter Stroke
Tilting degree diameter
mm (in) mm (in)
mm (in)
5° front - 5° back 32 (1.25) 65 (2.55) 71.5 (2.81)
5° front - 7° back 32 (1.25) 65 (2.55) 86.5 (3.41)
13-17
Tightening torque unit M=Nm
0
1
2
3
4
5
6
7
8
2. Put the mast in vertical position
10
6. Disconnect the hoses (after lowering the remaining pressure in the tilting cylinders by operating the 11
tilting lever a number of times)
7. Remove the tilting cylinder front pin [Point 1] 12
8. Remove the tilting cylinder rear pin [Point 2]
9. Remove the tilting cylinder 13
Notes:
If both tilting cylinders are removed fix the mast with a 14
chain in order to avoid its falling
15
16
17
18
Notes:
• Lubricate the insertion portions of the tilting cylinder front and rear pins
20
• After installation, slowly tilt forwards and backwards a few times without a load to bleed the air
in the hydraulic circuit and test normal operation 21
• Check the hydraulic oil level and add if insufficient
E
13-18
Points of Operation
[Point 1]
Disassembly:
Remove the safety screws and the front pin of the tilting
cylinder
0
Reassembly: 1
After installation, tightening torque for the safety plates =
24 Nm 2
3
4
[Point 2]
5
Disassembly:
Remove the safety screw and then the tilting cylinder 6
rear pin
7
Reassembly:
After installation, tightening torque for the safety plates = 8
24 Nm
9
10
ADJUSTMENT 11
Notes:
• Adjust the mast forward and backward tilting angle (to prevent uneven tilting) when the tilting 12
cylinder and mast are replaced or disassembled
13
Adjustment:
Turn the tilting cylinder rod with a spanner on the 14
appropriate sense and then tighten counter nut with a
tightening torque of 300 Nm 15
16
17
18
19
20
21
E
13-19
0
1
2
3
4
5
6
7
8
9
Removal Procedure
2. Remove the tilt cover
3.
4.
Set the mast in vertical position and disconnect the hose
Remove the tilting cylinder front pin
11
5. Remove the tilting cylinder rear pin
6. Remove the tilting cylinder 12
Note:
If both tilting cylinder are removed, fix the mast with a
13
chain in order to avoid its overturning.
14
15
16
17
Installation Procedure 18
The installation procedure is the reverse of the removal procedure.
Note: 19
• Apply grease to the insertion portions of the tilting cylinder front and rear pins before
installation (Shell Mobil Grease special or equivalent) 20
• Don’t tilt the mast backward maximum before adjust the mast tilt angle
• Check the hydraulic oil level and add if insufficient 21
• After the installation, slowly tilt the mast forward and backward a few times without change to
bleed the air in the hydraulic circuit and to check the normal functioning
E
13-20

T= 285 to 315
(2907 to 3213)
1. Remove the rod connection
2. Loosen the rod guide [Point 1]
3. Extract the piston rod W/piston
4. Loosen the piston nuts
5. Inspect the cylinder [Point 2]
6. Inspect the piston rod [Point 3]
The installation procedure is the reverse of the removal procedure.
Note:
• Apply hydraulic oil to packings, O-rings and dust seal lips
• Apply antioxidant on rod eye threads
• Replace the piston nut after every removal procedure
13-21
Point Operations
[Point 1]
Removal:
Loosen the rod guide
0
1
2
3
[Point 2]
4
Inspection:
Measure the cylinder bore 5
Standard: 65 (2.55)
Limit: 65.35 mm (2.563 in) 6
7
8
9
[Point 3]
Inspection: 10
Measure the piston rod outside diameter
Standard: 32 (1.25) 11
Limit: 31.92 mm (1.246 in)
Inspection:
12
Measure the bend of the piston rod
Limit: 0.2 mm (0.0079 in) 13
14
15
16
17
18
19
20
21
E
13-22
14-1
OIL PUMP 2
Page
2
SERVICE PUMPS ......................................................14-2
2
GENERAL............................................................................. 14-2
TEST METHOD ..........................................................14-4 3
COMPONENTS .................................................................... 14-5 4
5
6
6
8
9
9
9
12
9
14
15
16
17
18
18
18
18
18
18
14-2
SERVICE PUMPS
GENERAL
Vehicle model 1,5 - 2,0 t

Oil pump name Gear pump
Oil pump model WSP 20-14
Transmission Direct motor drive
Capacity (at 1000 rpm) l/m 14
3/rev
Theoretical displacement cm 14,4
14-3
2
2
2
3
4
5
6
Disassembly procedure 6
5. Empty the oil tank
6. Disconnect the delivery and suction pipes from the pump and from the priority valve 9
7. Remove pump fixing bolts [Point 1]
8. Remove the priority valve
9
Note: 9
Before assembly, grease the pump-motor coupling
with CASTROL OPTIMOL T WHITE paste type and
clean the flange of interface between pump and motor
14
15
16
17
18
Point Operations
[Point 1]
18
Disassembly:
Remove 2 pump fixing bolts (C) 18
C Reassembly:
After installation, tightening torque for pump fixing
18
bolts = 45 Nm
18
18
14-4
TEST METHOD
A bench test should be conducted for strict testing, but as it is generally impossible in practical
service operation, install the oil pump on the vehicle and judge the oil pump discharge
performance by means of cylinder operation.
• Check that the battery charge is sufficient by observing the battery charge indicators
• Check that the oil control valve set relief pressure is as specified
Lift relief pressure = 210 - 250 bar
• Measure the time of full stroke of the lift cylinder, with the hydraulic oil temperature at 50~55°C (122~
131°F), and calculate the lifting speed; however, due to soft start by the lifting logic unit, lifting speed is
10 ~ 20 mm/sec lower than the value obtained from the table. The lifting speed can be calculated more
accurately by measuring the full stroke operation time excluding the soft start period.
The lifting speed may differ depending on the conditions of the battery, hydraulic oil temperature and
mast adjustment.
The values below are based on a certain condition.
14-5
COMPONENTS
C 2
G
A 2
C
2
3
D
4
E 5
6
I H F
6
B
8
1. Remove the 2 pump fixing bolts (A) and remove the oil pump
2. Place the front cover (B) face downward, and remove the 2 bolts (C) 9
3. Remove the rear cover (D), gasket (E) and the (F) figure 3 gasket first group
4. Remove the driver gear (G), the driven gear (H) and side plate 9
5. Remove the and the figure 3 gasket second group (I)
Note:
9
• Wash each part, blow compressed air and apply hydraulic oil before installation
• Always use new seals for reassembly 14
15
16
17
18
18
18
18
18
18
14-6
15-1
OIL CONTROL VALVE

Page
MECHANICAL CONTROL VALVE ............................15-2
0
GENERAL............................................................................. 15-2
MECHANICAL CONTROL VALVE (3 LEVERS) .................. 15-3
1
MECHANICAL CONTROL VALVE (4 LEVERS) .................. 15-4 2
HYDRAULIC CIRCUIT DIAGRAM 3 WHEELS .........15-5 3
HYDRAULIC CIRCUIT DIAGRAM 4 WHEELS .........15-6 4
SPECIFICATIONS ................................................................ 15-6
5
MECHANICAL CONTROL VALVE ............................15-7
6
RELIEF VALVE ADJUSTMENT ................................. 15-9
7
ELECTRIC CONTROL VALVE (FINGERTIPS
AND JOYSTICKS) ................................................15-10 8
GENERAL........................................................................... 15-10 9
HYDRAULIC CIRCUIT DIAGRAM 3 WHEELS ....... 15-11
10
HYDRAULIC CIRCUIT DIAGRAM 4 WHEELS .......15-12
11
SPECIFICATIONS .............................................................. 15-12
ELECTRIC CONTROL VALVE ................................15-13 12
RELIEF VALVE ADJUSTMENT ............................... 15-14 13
LIFTING LOCKING AND UNLOCKING 14
SCREW .................................................................15-15
15
16
17
18
19
20
21
E
15-2
MECHANICAL CONTROL VALVE

GENERAL
CONTROL VALVE
15-3
MECHANICAL CONTROL VALVE (3 LEVERS)
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
15-4
MECHANICAL CONTROL VALVE (4 LEVERS)

15-5
HYDRAULIC CIRCUIT DIAGRAM 3 WHEELS
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
15-6
SPECIFICATIONS
Model
All Models
Item
Type Mechanical
Lifting 195 ÷ 240 bar
Maximum pressure
Tilting 150 bar
Others Built-in lifting and tilting lock valves
15-7

Note: 2
Operate the control lever to bring the mast and fork to the vertical and lowermost positions,
respectively, to release the residual pressure in the material handling system before starting 2
removal.
2
3
4
5
6
6
8
9
9
11
12
2. Remove footboard, lateral plastic cover and tilt forward the control valve cover 14
3. Disconnect the pipes and the wirings
4. Remove the pin set from control valve and lever [Point 1] 15
5. Remove the control valve
16
Notes:
• Adjust the limit switch after installing the oil control valve (See [Point 1]) 18
• Apply grease to all oil control valve lever linkages
• Check the hydraulic oil level, and add if insufficient 18
18
18
18
18
15-8
Points of Operation
[Point 1]
Removal:
Remove the pin A of each lever
Microswitch adjustment:
After the installation perform the following
CONTROL ROD
adjustments:
1. Keep the microswitch in rest position as shown in the
drawing according to the following points:
MICROSWITCH • The castor of the microswitch has to be in contact with
the surface of the command rod
• The microswitch lever has to be in contact with the push
button of the microswitch, without activating it
2. Tighten the microswitch in order to have the possibility
to move it on the button hole of the support.
CONTROL ROD 3. Adjust the microswitch position in order to activate it to

LEVER the minimum stroke of the microswitch lever and by
CASTOR
PUSH BUTTON releasing the latter the microswitch has to return in rest
position. The activation of the microswitch could be
detected:
• by eyes (by checking the angular stroke on the
microswitch lever)
• by ears (by listening to the closing of the microswitch
contacts)
• by multimeter (by checking the microswitch output
signals)
4. Tighten the microswitch screws with a tightening

torque of 0.39-0.59 Nm.
Adjustment (lifting potentiometer P):
after installation, adjust the lifting potentiometer
P • assemble the potentiometer on the contol valve;
• connect an analogic multimeter, setted it at least on the
range 10kOhm, to the potentiometer connector pins, in
the following way: the red terminal (+) to the pin 2; the
black terminal (-) to the pin 3;
• move the lifting lever up to the lifiting micro turns off; the
value on the multimeter must be 5 kOhm.
After the installation perform the lifting potentiometer
adjustment (see chapter 03).
15-9
RELIEF VALVE ADJUSTMENT

• Always follow the procedure below for adjustment. Careless adjustment may cause high-
pressure generation, resulting in damage to hydraulic units such as the service pump
• No adjustment is needed when the relief valve is not disassembled or the mast is replaced 2
• If the relief valve is replaced, check the maximum pressure according to the mast used
2
2
3
4
5
Pressure relief valve
auxiliary
function pressure 6
6
Pressure relief valve
Lifting pressure 8
9
9
Pressure relief valve Pressure relief valve
sideshift pressure tilting pressure
11
1. Remove the plug of the pressure measuring point on the pump and connect a pressure gauge.
Pressure gauge end stroke: 250 bar or more. 12
2. Loosen the counter nut on the relief valve and adjust the screw (allen screw for lifting, square screw
for tilting, side shift and other lever). 13
3. Adjust the oil pressure as follows:
(a) Turn the key switch ON
(b) Lift the mast to the end stroke and check the pressure on the pressure gauge (without load) 14
(c) Adjust the pressure if necessary bearing in mind that:
screwing in = increasing of pressure 15
screwing out = decreasing of pressure
(d) Tighten the counter nut when the measured pressure reaches the correct value according 16
to the mast performance table
4. Repeat point 3 for the other functions too (tilting, side shift, …) once each time.
5. Remove the pressure gauge and screw in the plug.
17
18
18
18
18
18
18
15-10
ELECTRIC CONTROL VALVE (FINGERTIPS AND JOYSTICKS)

GENERAL
CONTROL VALVE
EVP8 EVP7
EVP6 EVP5
EVP4 EVP3
EVP1
EVP2
Value in ohms Tension Value Tension Value

Valve Connector Function
of the coils (connected coil) (disconnected coil)
EVP1 JE1 Lowering 18 ohm 0÷24 V +Vb
EVP2 JE2 Lifting 18 ohm 0÷24 V +Vb
EVP3 JE3 Backward tilting 19 ohm 0÷24 V +Vb
EVP4 JE4 Forward tilting 19 ohm 0÷24 V +Vb
EVP5 JE5 Left sideshift 19 ohm 0÷24 V +Vb
EVP6 JE6 Right sideshift 19 ohm 0÷24 V +Vb
EVP7 JE7 4th way 19 ohm 0÷24 V +Vb
EVP8 JE8 4th way 19 ohm 0÷24 V +Vb

15-11
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
15-12
SPECIFICATIONS
Model
All Models
Item
Type Electric
Maximum lifting pressure 240 bar
Maximum other functions pressure 240 bar
15-13
ELECTRIC CONTROL VALVE

Note: 2
Before starting removal, operate levers in order to bring mast in vertical position and forks to
lowest position, releasing the residual pressure in the hydraulic system. 2
Tightening torque M=Nm
2
3
4
5
6
6
8
9
9
11
12
13
15
4. Remove the footboard and the lateral cover 16
5. Disconnect the hoses and the wiring harnesses
6. Remove the control valve 17
18
Note: 18
Check the hydraulic oil level, and top up if insufficient
18
18
18
18
15-14
RELIEF VALVE ADJUSTMENT

Notes:
• Always follow the procedure below for adjustment. Careless adjustment may cause high-
pressure generation, resulting in damage to equipment such as the oil pump.
• There is no adjustment if the pressure relief valve is replaced in conformity with the mast
supplied with the vehicle.
Relief valve
1. Remove the plug of the pressure measuring point on the priority valve and connect a pressure
gauge. Pressure gauge end stroke: 250 bar or more.
2. Loosen the counter nut on the relief valve adjustment screw and adjust the screw (only for lifting
section).
3. Adjust the oil pressure as follows:
(a) Turn the key switch ON
(b) Lift the mast to the end stroke and check the pressure on the pressure gauge (without load)
(c) Adjust the pressure if necessary bearing in mind that:
screwing in = increasing of pressure
screwing out = decreasing of pressure
(d) Tight the counter nut when the detected pressure reach the correct value according to the
table below
4. Remove the pressure gauge and screw the plug in.
15-15
LIFTING LOCKING AND UNLOCKING SCREW

Tightening torque T=N·m
2
2
2
3
4
5
6
6
8
Lifting locking-unlocking screw
9
1. Loosen the lifting locking-unlocking screw to lower the forks manually
Note:
9
Always retighten the locking bolt after an operation. If lift locking and unlocking bolt is left loose,
much hydraulic oil is released from the pump and the lifting speed is significantly decreased, 11
resulting in difficulty in smooth operation.
12
13
14
15
16
17
18
18
18
18
18
18
15-16
MAST PERFORMANCE TABLES

Definitions:
Q1: max. charge Q2: max. charge to the max. height
Operational conditions:
The proofs must be performed with electrolyte density >1,22. Electrolyte and oil temperature >15°C.
Environment temperature not inferior to 18°C.
Performances are referred to P setting and profile 0.
LIFTING
Q1: max. charge Q2: max. charge to the max. height
1.5 t
load FFL TV
Kg m/sec amp bar m/sec amp bar
Q1 0,35 min max 290 max 170 0,34 min max 315 max 190
lowering
Q1 0,40 0,60 max 0,60
stroke end
max 335 max 210
1.6 t 1.6 L t
load FFL TV
lowering
Q1 0,40 0,60 max 0,60
stroke end
max 345 max 220
1.8 t 1.8 L t
load FFL TV
lowering
Q1 0,40 0,60 max 0,60
stroke end
max 360 max 235
2.0 t
load FFL TV
lowering
Q1 0,40 0,60 max 0,60
stroke end
max 370 max 250
TILTING AND SIDESHIFT

STD. Tilt 5° FW. 7°BW. Test to be done at 1m. Height with Q1 charge
Exercise Stroke end
sec amp bar amp bar
BW-FW 3,4 4,6 max 45 max 60 max 100 max 170
FW-BW 2,6 3,6 max 80 max 130 max 100 max 170
ELECTRIC CONTROL VALVE
sec amp bar amp bar
BW-FW 3,3 4,5 max 45 max 60 max 180 max 240
FW-BW 2,6 3,6 max 100 max 150 max 180 max 240
STD sideshift stoke: 200mm (visible check)
WARNING:
The installation of a hydraulic control valve finalized to operate a clamp (for example a paper roll)
implicates an obligatory application of a double command device avoiding the risk of accidental
release of the load (ISO 3691-1, 5.4.4.1).
16-1
MAIN OPTIONS
Page 0
DC-DC CONVERTER (48V-12V) ............................... 16-2 1
24V FUSE BOARD .................................................... 16-4 2
REVERSE ACOUSTIC WARNING ............................ 16-6
3
FLASH BEACON ....................................................... 16-8
4
ROTARY BEACON .................................................. 16-10
COMPLETE LIGHTING - FRONT PART ................. 16-12
5
COMPLETE LIGHTING - REAR PART ................... 16-14 6
WORK SPOTLIGHT................................................. 16-16 7
SWAYING PEDAL................................................... 16-18 8
SINGLE PEDAL WITH REVERSE SELECTOR ON 9
STEERING COLUMN / ARMREST....................... 16-20
10
HEATING.................................................................. 16-22
FRONT AND REAR WINDSCREEN WIPER 11
SYSTEM ................................................................ 16-24 12
13
14
15
16
17
18
19
20
21
E
16-2
DC-DC CONVERTER (48V-12V)

GENERAL
All models may be fitted with a DC-DC converter.
The converter is connected directly to the standard machine wiring.
A converter must be installed in the presence of optional systems installed on the truck.
NOTES: It is necessary to calculate the total absorption of the optional systems in order to select the
correct converter. See chapter 2, paragraph DC/DC CONVERTER.
COMPONENTS
1 DC-DC converter Optional

2 Machine wiring Standard
Removal Procedure
1. Disconnect the battery connector
3. Fix the converter to the plate of the contactor group
4. Connect the converter to the machine wiring through the connector P96
16-3
SIMPLE WIRING DIAGRAM
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-4
24V FUSE BOARD

GENERAL
All models may be fitted with the fuse board.
The board is connected directly to the standard machine wiring.
The fuse board must be installed in the presence of optional systems installed on the truck.
NOTES: The fuse board must always be installed with the DC-DC converter.
COMPONENTS
1 24V fuse board Optional

2 Machine wiring Standard
Removal Procedure
2. Remove the front board
3. Fix the board onto the overhead guard
4. Connect the board to the machine wiring through the connector P89 and P90
5. Install the necessary fuses in accordance with the optional systems present on the machine
16-5
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-6
REVERSE ACOUSTIC WARNING

GENERAL
All models may be fitted with the reverse acoustic warning
The acoustic warning is connected directly to the standard machine wiring and supplied with voltage from
the battery.
COMPONENTS
1 Acoustic warning Optional
Removal Procedure
2. Fix the acoustic warning to the truck chassis
3. Connect the wiring of the acoustic warning to the main wiring of the truck through the connector P70
16-7
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-8
FLASH BEACON
GENERAL
All models may be fitted with the beacon.
The beacon is connected directly to the standard machine wiring and supplied with voltage from the
battery.
COMPONENTS
1 Flash beacon Optional

2 Flash beacon wiring Optional
3 Fuse F4 Optional
Removal Procedure
2. Install the flash beacon at the rear of the overhead guard
3. Pass the beacon wiring inside the overhead guard bringing it out through the left front leg
4. Connect the beacon wiring to the main wiring of the truck through the connector P106
5. Check the presence of the fuse F4 (2A) in the contactor group (see chapter 2, paragraph
SPECIFICATIONS)
6. Select SERVICE MENU -> TRUCK CONF -> FLASH LAMP to enable the type of operation: manual -
automatic (see chapter 3, paragraph TRUCK CONF)
16-9
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-10
ROTARY BEACON
GENERAL
It is possible to fit up to two rotary beacons on the truck, with a 24V power supply.
To install the rotary beacon, the truck must be equipped with the 24V fuse board and with a 48 / 24V
converter.
COMPONENTS
1
1
1 Rotary beacon Optional

2 Beacon wiring Optional
Removal Procedure
2. Install the 48 / 24V converter if it is not present on the machine
3. Install the 24V fuse board if it is not present on the machine
4. In position FS6, use a 5A fuse for a single beacon or a 10A fuse for a double beacon
5. Fix the beacon or beacons onto the overhead guard
6. Pass the beacon wiring inside the overhead guard bringing it out through the left front leg
7. Connect the beacon wiring to the CN5 connector of the 24V fuse board
8. Connect the wiring of the second beacon to the CN6 connector of the 24V fuse board
9. Select SERVICE MENU -> TRUCK CONF -> ROTARY LAMP 1 - 2 to enable the type of operation:
manual - automatic (see chapter 3, paragraph TRUCK CONF)
16-11
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-12
COMPLETE LIGHTING - FRONT PART

GENERAL
The complete lighting for the front part consists of:
• 2 Lights (dipper light + side light)
• 2 Direction indicators
To install the complete lighting for the front part, the truck must be equipped with the 24V fuse board and
with a 48 / 24V converter.
If the overhead guard does not already have points for fixing the headlamps and direction indicators, holes
must be drilled in the overhead guard during assembly.
COMPONENTS
1 2
1 Lights Optional
2 Direction indicators Optional
3 Lights wiring Optional
Removal Procedure
4. Insert a 3A fuse in position FS4 and a 10A fuse in position FS3
5. Fix the lights and the direction indicators onto the overhead guard
6. Pass the lights wiring inside the overhead guard
7. Connect the wiring to the CN7 connector of the 24V fuse board
8. Install the direction indicator switch on the steering column and connect the connector J115
9. Select SERVICE MENU -> TRUCK CONF -> DIPPER LIGHT / DIR LIGHT to enable the type of
operation: manual - automatic (see chapter 3, paragraph TRUCK CONF)
16-13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-14
COMPLETE LIGHTING - REAR PART

GENERAL
All models may be fitted with the rear lights
To install the complete lighting for the rear part, the truck must be equipped with the 24V fuse board and
with a 48 / 24V converter.
COMPONENTS
1 Lights Optional
Removal Procedure
4. Insert a 2A fuse in position FS6
5. Remove the four retroreflectors from the counterweight
6. Install the four lights on the counterweight
7. Connect the lights wiring to the four rear lights and the connector J145 to the machine wiring
8. Select SERVICE MENU -> TRUCK CONF -> TAIL LIGHT to enable the lights and SERVICE MENU -
> TRUCK CONF -> DIR LIGHTS to enable the direction indicators (see chapter 3, paragraph TRUCK
CONF)
16-15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-16
WORK SPOTLIGHT
GENERAL
All models may be fitted with the front and rear work spotlights.
The lights are connected directly to the standard machine wiring and supplied with voltage from the
battery.
COMPONENTS
1 2
1 Work spotlights Optional

2 Spotlights wiring Optional
3 Fuse F5 Optional
Removal Procedure
2. Install the work spotlights on the overhead guard
3. Pass the spotlight wiring inside the overhead guard bringing it out through the left front leg
4. Connect the spotlight wiring to the main wiring of the truck through the connector P104
5. Check the presence of the fuse F5 (3.15A) in the contactor group (see chapter 2, paragraph
SPECIFICATIONS)
6. Select SERVICE MENU -> TRUCK CONF -> WORK LAMP to enable the type of operation: manual -
automatic (see chapter 3, paragraph TRUCK CONF)
16-17
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-18
SWAYING PEDAL
GENERAL
All models may be fitted with the swaying pedal.
COMPONENTS
1 Swaying pedal Optional
Removal Procedure
2. Remove the rubber footboard and the metal plate
3. Remove the accelerator pedal and the brake pedal
4. Fix the swaying pedal to the chassis
5. Connect the connectors J33 (by means of the interface wiring) J32 J31 J30 to the machine wiring.
6. Fit the rubber footboard, swaying pedal version
7. Select SERVICE MENU -> TRUCK CONF -> OPTION -> SWAYING PEDAL to enable operation of
the swaying pedal (see chapter 3, paragraph TRUCK CONF)
8. Perform drive and brake potentiometer acquisition. (see chapter 3, paragraph LEARNIING)
16-19
P5
0
1
2
3
4
5
6
P4 7
8
9
10
11
12
13
14
15
16
18
18
16-20
SINGLE PEDAL WITH REVERSE SELECTOR ON STEERING COLUMN /

ARMREST
GENERAL
All models may be fitted with the single pedal with reverse selector on the steering column or, if present,
on the armrest.
COMPONENTS
1 Reverse selector on the steering Optional

column
2 Reverse selector on the armrest Optional
Removal Procedure
2. Remove the rubber footboard and the metal plate
3. Remove the single accelerator pedal wiring
4. Fix the accelerator pedal to the chassis
5. Connect the connectors J33 J32 J31 J30 and P17 to the machine wiring
6. Fit the rubber footboard, single accelerator pedal version
7. Select SERVICE MENU -> TRUCK CONF -> OPTION -> SWAYING PEDAL to disable the swaying
pedal if previously fitted (see chapter 3, paragraph TRUCK CONF)
8. Perform drive and brake potentiometer acquisition (see chapter 3, paragraph LEARNING)
16-21
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-22
HEATING
GENERAL
It is possible to install a heating system on the truck.
To install the heating system, the truck must be equipped with the 24V fuse board and with a 48 / 24V
converter.
COMPONENTS
1 Heater Optional
2 Heater wiring Optional
Removal Procedure
4. Install the heater unit on the front right hand side of the truck
5. Connect the heater wiring to the 24V fuse board (CN8) and to the auxiliary wiring (P108)
6. Select SERVICE MENU -> TRUCK CONF -> HEATER to enable the type of operation (see chapter 3,
paragraph TRUCK CONF)
16-23
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-24
FRONT AND REAR WINDSCREEN WIPER SYSTEM

GENERAL
It is possible to install a windscreen wiper system on the truck.
To install the windscreen wiper system, the truck must be equipped with the 24V fuse board and with a
48 / 24V converter.
COMPONENTS
1 2
1 Front wiper motor Optional

2 Windscreen washer tank Optional
Removal Procedure
4. Install the front wiper motor on the overhead guard
5. Install the windscreen washer tank in the rear compartment of the truck
6. Connect the wiring of the wiper motors to the 24V fuse board (CN3) and the tank wiring (CN4)
7. Select SERVICE MENU -> TRUCK CONF -> WIPERS/WASHER to enable the type of operation (see
chapter 3, paragraph TRUCK CONF)
16-25
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
18
16-26
17-1
APPENDIX
Page
ELECTRIC COMPONENTS .......................................17-2
0
AUXILIARY WIRING HARNESS ...............................17-3
1
CONNECTORS ..........................................................17-4
ELECTRIC DIAGRAMS .............................................17-9 2
COMPLETE LIGHTING EQUIPMENT .....................17-16 3
FRONT/REAR WINDSCREEN WIPER 4
SYSTEM ................................................................17-17
5
ROTATING BEACON SYSTEM ............................... 17-18
6
HEATING SYSTEM ..................................................17-19
ROAD CIRCULATION LIGHTING SYSTEM............17-20
7
HAZARD SYSTEM...................................................17-21 8
9
10
11
12
13
14
15
15
17
18
19
20
21
E
17-2
ELECTRIC COMPONENTS
1 K3 contactor (key) 7 Master traction command 13 Right traction motor

2 K2 contactor (traction) 8 Pump command 14 Left traction motor
3 K1 contactor (pump) 9 Slave traction command 15 Fuse card 24V
4 Converter DC - DC 10 Battery plug 16 Auxiliary wiring harness
5 Support 11 MCB 17 Can-Bus resistence
6 Ferrites 12 Pump motor 18 Chassis
12
13
14
16
17
17
18
18
18
18
18
11
2
2
2
3
4
5
6
6
8
9
9
17-3
CONVERTER
PROGRAMMER
24V FUSE BOX
SOLENOID VALVE
(+24V) from
CONTACTOR-FUSES
CONTACTOR-FUSES
HEATER
LEVER OCV
P89
P108
P90 P132
J53 J51
J15 ENC. + TEMP. SENS.
RH TRAC MOTOR P50
P60
SESAM KEYPAD
J133 P133
P137
DISPLAY
14
P2
10
1
35
12
SLAVE
OIL BRAKE
P134
24
1
TANK
P17
ACC. PEDAL POT.
P6
J32
RH TRAC MOT.
P70
EL. BRAKE
J81 GND
BRAKE PEDAL POT.
P33
STEERING J30 ACC. PEDAL MICRO. P1
COLOUMN P35
P31 MASTER
P11 HORN
BRAKE PEDAL MICRO.
PUMP
FORKS SIDE
P3
EL. BRAKE LH TRAC MOTOR
P7 STEER POT.
PUMP MOTOR TEMP. SENSOR
P14
P13
ENC. + TEMP. SENS. J16
24
12
AUXILIARY WIRING HARNESS
LH TRAC MOTOR P5 WATER TANK FW. ARMREST or R3
MCB
35
1
P144
24
12
J12 J131
P4
35
PUMP MOTOR ENCODER P20
1
P129
SEAT
P135 WATER TANK BW.
CONFIG. 3-4 WHEELS
P96
OPT. AUTO MAST CONTROL
P49 J49 DC - DC CONVERTER
REAR LIGHTS
P145
FRONT WIPER
J143 P143
FLASHING LAMP P106
WORKING LIGHTS P104
P21 EMERGENCY PUSH BUTTON
17-4
CONNECTORS
17-5
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
17
17
18
18
18
18
18
17-6
17-7
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
17
17
18
18
18
18
18
17-8
17-9
ELECTRIC DIAGRAMS
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
17
17
18
18
18
18
18
17-10
17-11
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
17
17
18
18
18
18
18
17-12
17-13
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
17
17
18
18
18
18
18
17-14
17-15
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
17
17
18
18
18
18
18
17-16
COMPLETE LIGHTING EQUIPMENT

17-17
FRONT/REAR WINDSCREEN WIPER SYSTEM
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
17
17
18
18
18
18
18
17-18
ROTATING BEACON SYSTEM

17-19
HEATING SYSTEM
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
17
17
18
18
18
18
18
17-20
ROAD CIRCULATION LIGHTING SYSTEM

17-21
HAZARD SYSTEM
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
17
17
18
18
18
18
18
17-22
CESAB S.p.A
via Persicetana Vecchia, 10 40132 Bologna - Italy
Tel.(0039) 051.20 54 11
Fax (0039) 051.72 80 07
E-mail: [email protected]

Repair Manual: C3E150 C4E150 C3E160 C4E160 C3E160L C4E160L C3E180 C4E180 C3E180L C4E180L C3E200 C4E200

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REPAIR MANUAL

Code 036-0434-01 12/2010

This manual covers the following truck models:

Model Starting serial number Ending serial number

VEHICLE EXTERIOR VIEW

TRUCK CAPACITY AND IDENTIFICATION PLATES

How to Read the Plates

B: Load capacity plate

CESAB Carrelli Elevatori S. p. A.

TECHNICAL DATA - 3 WHEELS

CAPACITY DIAGRAMS (with SE tyres)

Barycentre [mm] Capacity [Kg] 1.6t

Barycentre [mm] Capacity [Kg] 1.8t

TECHNICAL DATA - 4 WHEELS

CAPACITY DIAGRAMS (with SE tyres)

Barycentre [mm] Capacity [Kg] 1.6t

Barycentre [mm] Capacity [Kg] 1.8t

HOW TO USE THIS MANUAL

Matters omitted from this manual

Abbreviation Meaning Abbreviation Meaning

Conventional Conversion rate(*))

Value in conventional unit = Value in SI unit ÷ Conversion rate

This forklift truck uses a lead accumulator and, in case of

LIFTING THE VEHICLE

1.5 X X 673 ÷ 790

Drive motor all models X X 36

Mast with lift brackets (with lift cylinder, without forks,

TOWING THE TRUCK

Note the cautions below when towing the vehicle with

ELECTRICAL PARTS INSPECTION

2) Digital circuit multimeter

TIGHTENING TORQUE TABLE

Nominal PRELOADING V (N) TORQUE Max (Nm)

RECOMMENDED LUBRICANT QUANTITY AND TYPES

* = refilling with same type of oil and grease

PERIODIC MAINTENANCE TABLE

1. Fork positioning pins

BATTERY COMPARTMENT AND REQUIRED WEIGHT

Din standard battery (DIN 43531 48V type A)

BATTERY SERVICE STANDARDS

Blinking (A) Led, Discharged battery, managed

BDI adjust min

Necessary voltage for the rearm

Charge battery indicator = 49,680 V

Discharge battery indication = 45,360 V

ADJUSTING THE BATTERY AND THE INDICATOR

ADJUSTING THE BATTERY INDICATOR

Notes: Ensure that the battery completes the whole

Notes: The voltage measured between Pin 1 of the

Notes: The values shown in the various figures are indicative.

Notes: The battery runs down if it is not used.

Notes: The values shown in the various figures are indicative.

Parameter BDI ADJ MIN

TROUBLESHOOTING ON THE BATTERY

Plate corrosion Sulfation Plate warpage and active substance freeing

Depositined of free Fouled terminal or

Short circuit Electrolyte leakage and reduction Loosened or corroded connection

DEFECT CAUSE REMEDY

* How to use the hydrometer