Cesab Centauro AC 1di2

Cesab Centauro AC
Tensione Batteria : 48V
Questo è un manualetto per uso interno con varie info e manuale in

UK ma si capisce e OK , verificare sempre la versione e i vari
aggiornamenti e occhi sempre aperti .
Cesab Centauro AC , versione 48V con Chopper di potenza ACE3 by

Zapi per trazione Sx , trazione Dx e pompa .
Poi loro moduli in/out vedi nel manuale
Cesab Centauro AC ho aggiunto anche il manuale Zapi

dell’AC3 e del Daul AC , montati sulla versione 80V , verificando
sempre la versione del carrello
PASSWORD
Se Vi dovesse chiedere la Password ho avuto queste info , ma

logicamente prendete con cautela e malizia perché puo
dipendere dalla versione e eprom , mi risulta simile anche per il
modello Blitz .
Attenzione Vi consiglio , diciamo per evitare casini terribili e
altro , mai provare più di due volte a inserire la password e caso
mai spegni , meglio staccare la batteria e attendere almeno 180s
by 3min e poi riprovare , altrimenti può succedere quello che
sappiamo ed è meglio non dirlo .
Sperando che altri non come noi non abbiano smanettato e
l’abbiano cambiata , inutile dire il perché .
Se dovesse chiederti una password in accensione , mi risulta
sia :
- 0323 ( standard Cesab )
- 1234
- 4321
- 0000
- 5555 ( standard Hyster e Yale ma la usano per ingannare )
- 9999
- Anno in corso
- Anno di Nascita operatore
Quella Service e generale se richiesta :
- anno di produzione 2017 : 0322230130 o 0322230150
- anno di produzione 2018 : 2241310014
- anno di produzione 2019 : 0324410332
Valutando la versione ( eprom ci capiamo ) mi hanno detto e vi
dico che non lo mai provato e visto , che via display puoi
verificare e cambiare l'anno di produzione ( logicamente nel
sistema eprom - memory ) , penso e ritengo dopo una prima
entrata in modo che poi si possa settare la password
corrispondente by service nel manuale dovrebbe vedersi .
REPAIR MANUAL
cenTAURO
160L- 200L
Code 036-0417-02 07/2012

Document changes history:
Edition Changes
036-0417-00 New version
036-0417-01 General updating
036-0417-02 General updating
This manual covers the following truck models:
Model Starting serial number Ending serial number

160L CE367233
200L CE366690
INDEX
GENERAL 0
BATTERY 1
CONTROLLERS 2
DISPLAY 3
TROUBLESHOOTING 4
MOTOR 5
DRIVE UNIT & FRONT AXLE 6
REAR AXLE 7
STEERING SYSTEM 8
BRAKES 9
BODY & FRAME 10
MATERIAL HANDLING SYSTEM 11
MAST 12
CYLINDER 13
OIL PUMP 14
OIL CONTROL VALVE 15
PROGRAMMER 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.......................................................0-5 4
HOW TO USE THIS MANUAL.....................................0-7
5
EXPLANATION METHOD ...................................................... 0-7
TERMINOLOGY...................................................................... 0-8
6
ABBREVIATIONS ................................................................... 0-8 7
ILLUSTRATIONS .................................................................... 0-8 8
SI UNITS ................................................................................. 0-9 9
OPERATING TIPS......................................................0-10
10
GENERAL INSTRUCTIONS ................................................. 0-10
11
BATTERY RECYCLING/DISCARDING ................................ 0-11
JACK-UP POINT........................................................0-12 12
MEMBER WEIGHTS ..................................................0-13 13
TOWING THE TRUCK .......................................................... 0-14 14
ELECTRICAL PARTS INSPECTION .........................0-15 15
TIGHTENING TORQUE TABLE.................................0-16
16
LUBRICANTS CAPACITY AND TYPE TABLE .........0-17
17
PERIODIC MAINTENANCE.......................................0-18
PERIODIC REPLACEMENT TABLE .................................... 0-18
18
PERIODIC MAINTENANCE TABLE ..........................0-19 19
LUBRICATION CHART..............................................0-25 20
21
E
0-2
VEHICLE EXTERIOR VIEW

0-3
VEHICLE MODELS
Supply
Load capacity Control method
voltage (V)
1.6 ton AC microcomputer controller 48
2.0 ton ↑ ↑
0
CHASSIS NUMBER 1
Serial number
Vehicle type
format
Serial number position 2
3
160L CE000000
4
5
200L CE000000
6
7
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
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0-6
1.6L - 2.0L t
a [mm] = 200
CAPACITY DIAGRAMS (with SE tyres)
Barycentre [mm] Capacity [Kg] 1.6L t

500 1550
600 1350
CAPACITY [kg]
700 1250
800 1150
900 1050
1000 950
BARYCENTRE [mm]
Barycentre [mm] Capacity [Kg] 2.0L t

500 1850
600 1600
CAPACITY [kg]
700 1450
800 1350
900 1200
1000 1100
BARYCENTRE [mm]
0-7
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
0-8
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.
0-9
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
Item New unit Conventional Conversion rate(*)) 0

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
(Moment) 2
Pressure(**) Bar kgf/cm2 1 Bar = 1 kgf / cm2
3
Pressure(**) Pa (pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
↑ ↑ mmHg 1 mmHg = 0.133322 kPa 4
Revolving speed rpm rpm 1 rpm = 1 r/min
5
Spring constant(**) N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
Volume l cc 1 cc = 1 ml
6
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
<Reference>
9
(*): X represents the value in SI units as converted from 1 [in conventional units], which can be
used as the rate for conversion between conventional and SI units. 10
(**): In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf],
which should be used as the unit of force. 11
Conversion between Conventional and SI Units
12
Equation for conversion
Value in SI unit = Conversion rate × Value in conventional unit Conversion rate: Figure corresponding
13
to X in the conversion rate column in
Value in conventional unit = Value in SI unit ÷ Conversion rate 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
0.735499. 16
17
18
0-10
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
0-11
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
DISCARDING THE BATTERY 2
When the working life of the battery ends up (change for a new battery) or the truck has to be scrapped, it
is required a special attention to environmental risks when disposing/recycling batteries. Contact the
3
manufacturer for changing or discarding batteries.
4
RECYCLING
5
steel, brass, bronze, ABS,
1 BODYWORK plastic-reinforced fibre-glass, 6
4
1 polymers
steel, copper, nylon, graphite, 7
5 2 DRIVE UNIT
6 polymers
3 BRAKING UNIT steel, polymers, nylon 8
steel, copper, silicon, brass,
3
4 ELECTRIC UNIT aluminium, lead, zinc, graphite,
9
2
nylon, polymers
10
5 STEERING UNIT steel, bronze, polymers
6
HYDRAULIC steel, copper, bronze, brass, 11
UNIT aluminium, graphite, polymers
VARIOUS steel, copper, brass, aluminium, 12
COMPONENTS cast-iron, ABS, nylon, polymers
DISPOSAL OF In compliance with local 13
MINERAL OILS, directives.
GREASE AND Please dispose of in an 14
BATTERY environmentally friendly way!
15
16
17
18
0-12
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.
0-13
MEMBER WEIGHTS
Component Vehicle model Weight (Kg)
Battery 1.6L - 2.0L ~ 1300
Drive motor 1.6L - 2.0L ~ 31

Pump motor (Hydraulic pump + electric motor) 1.6L - 2.0L ~ 40 0
Rear axle (without wheels and dry) 1.6L - 2.0L ~ 86
1.6L ~ 550 1
Counterweight
2.0L ~ 755
2
Mast with lift brackets (with lift cylinder, without forks, lifting height
1.6L - 2.0L ~ 550
4350 mm, 2M TV) 3
Vehicle weight (w/battery)

1.6L ~ 3415 4
2.0L ~ 3620
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0-14
TOWING THE TRUCK
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
between the rear draw bar of the truck and the towing
vehicle. You must proceed carefully and slowly, if possible on
a level surface.
• while towing, do not carry any other loads on the forks;
• as far as possible, avoid driving on gradients. In any case,
do not go over the figure for driving on gradients with a
load.
Note the cautions below when towing the vehicle with

back wheels lifted.
• Lift the rear wheels for towing
• The traveling speed when towing must not exceed the
maximum traveling speed of the forklift
• Before starting towing, always set the key switch to OFF,
the direction switch to the neutral position and parking
brake of released
• Before towing, either remove the fork or take action to
prevent the fork from coming into contact with the ground
due to bouncing
When making a curve, towed loads tend to reduce the
curving radius; therefore it is important to widen the entrance
radius in order to avoid striking against any obstacle.
0-15
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
0
deformed or damaged due to static electricity.
1
2
3. Use a circuit multimeter that matches the object and purpose of measurement. 3
Analog type: This type is convenient for observing movement during operation and the operating
condition. Measured value is only a reference 4
Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or
movement.
5
(1) 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. 6
Differences between the polarities of the analog type and the digital type are described below.
1) Analog circuit multimeter 7
Example of measurement result
Forward Reverse
Multimeter range: kΩ 8
Analog type
Continuity
9
Forward
11 kΩ
10
No continuity
Reverse
∞ 11
2) Digital circuit multimeter 12
Forward Reverse
Example of measurement result
Multimeter range: 2MΩ
13
Digital type 14
Non continuit
Forward
1 15
Continuità
Reverse
2 MΩ 16
17
18
0-16
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
mm 6,6 8,8 10,9 12,9 6,6 8,8 10,9 12,9
M 4 x 0,7 21781 3865 5435 6524 1,7 3 4,2 5,1
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
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
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
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
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
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
M 27 x 3 112815 202086 283509 340407 549 991 1393 1668
M 30 x 3 138321 247212 347274 415944 755 1354 1893 2276
SCREWS WITH “ISO” METRIC FINE THREAD
Nominal PRELOADING V (N) TORQUE Max (Nm)

diameter 6 D* 8 G* 10 K* 12 K* 6 D* 8 G* 10 K* 12 K*
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
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
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
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
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
M 27 x 2 122625 218763 307053 367875 589 1050 1472 1766
M 30 x 2 154017 272718 384552 461070 814 1442 2040 2453
* = screw class
0-17
LUBRICANTS CAPACITY AND TYPE TABLE
Applicable place Capacity Type

Drive gear units;
0,35 l (x2) ATF DEXRON II or equivalent
wet disk brakes
Standard vehicle: Agip Arnica 46 or equivalent
Hydraulic oil 20,0 l 0
Cold storage vehicle: Agip Arnica VG32
Standard vehicle: Mobilgrease Special o equivalente
Chassis and mast; Proper 1
grease fitting amount Cold storage vehicle: Mobiltemp SHC100 or
equivalent 2
Proper
Mast lifting chains Rexnord kædespray REXOIL or equivalent
amount 3
Brake fluid 0,30 l Dot 4
Battery
Proper
Distilled water
4
amount
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0-18
PERIODIC MAINTENANCE
Periodic inspection and maintenance are necessary to keep your forklift truck running smoothly, and must
be performed by specialized technicians: ask your Dealer Service Centre.
Maintenance intervals are based on total operating hours, or months of truck life cycle, whichever comes
first (i.e. most inspections are scheduled every 1000 operating hours, or at least every six months).
Trucks operating under multi-shift work conditions must reduce intervals by:
15% for 2 daily shifts
30% for 3 daily shifts
INSPECTION METHOD:
I: Inspect, correct and replace as required
M: Measure and correct, and adjust as required
T: Tighten
C: Clean
(*) New trucks: weekly / 40h inspections are referred to new trucks only (whether under multi-shifts or not)
PERIODIC REPLACEMENT TABLE
REPLACEMENT CYCLE every 1 week 12 30 60 months

(Based on total operating hours or months of truck life
every 40 2000 5000 10000 hours
cycle, whichever comes first)
Drive unit oil *
Hydraulic oil
Hydraulic filter *
Oil tank breather filter

Brake fluid
Service brake and parking brake hoses
Tilt cylinder hydraulic hoses
Steering system hoses
Lifting chains
Chain securing tie rods
High pressure hydraulic hoses
0-19
PERIODIC MAINTENANCE TABLE

MAINTENANCE CYCLE every 1 week 6 12 months
(Based on total operating hours or months of truck life cycle,
every 40 1000 2000 hours
whichever comes first)
DRIVE SYSTEM
Wheels
Tyre cuts, damage or uneven treads I ← 0
Metal chips, pebbles or other foreign matter trapped in tire tread I*, C* I, C ←
Tread depth I* I ←
1
Tyre pressure (pneumatic tyres) M* M ← 2
Hub nut tightening torque T* T ←
Rim side ring and disc wheel integrity I* I ← 3
Front and rear wheel bearing abnormal noise and fastening I* I ←
Front axle 4
Body deformation and damage I
Body to frame fastening I ←
5
Abnormal noise and fastening I ← 6
Rear axle
Body deformation and damage I 7
Body to frame fastening I ←
Abnormal noise and fastening I ← 8
Axle beam fastening in vehicle longitudinal direction I* I ←
Hub play I* I ←
9
Mechanical end stroke I ← 10
Steering cylinders leakage (if present) I* I ←
Steering cylinders integrity and deformation (if present) I ← 11
Steering cylinders tightening torque (if present) I ←
Steering king pin (if present) I ← 12
Linkages play (if present) I ←
13
POWER TRANSMISSION SYSTEM 14
Drive unit
General condition, integrity, cleaning I, C ← 15
Oil leakage I ←
Oil level and status I* I ←
16
Bolts and nuts fastening I
17
Wheel nuts tightening T* T ←
Motor to transmission fixing bolts tightening torque T ← 18
Drive unit to frame fixing bolts tightening torque T ←
Oil screw plugs cleaning and tightening T ←
Air breezer condition and cleaning I, C ←
0-20

ELECTRICAL SYSTEM
General
Truck insulation I ←
Static strap integrity (if present) I ←
Motor
Cleaning I, C ←
Fastening I ←
Rotation sound I ←
Insulation resistance I ←
Power cables tightening torque T ←
Battery
Abnormality in upper portion of the battery and / or the case I ←
Presence of spilled liquid inside the case I, C ←
Plug status and cleaning I, C ←
Power cables status I ←
Terminal cleaning and fastening I, C ←
Insulation resistance I ←
Charging level I ←
Electrolyte level I ←
Electrolyte specific gravity M ←
Voltage measurement of each battery cell after charging M
Magnetic switch - Contactors
Contacts integrity, cleaning, fastening I ←
Auxiliary contact operating condition, integrity, cleaning I, C ←
Arc shooter mounting condition (if present) I ←
Coil mounting locations fastening I ←
Main circuit lead wire mounting condition and fastening I ←
Connected cables tightening torque T ←
Function test of all equipments connected I ←
Microswitch - Potentiometers
Installation integrity and fastening I ←
Operating condition and timings I ←
Accelerator and brake pedals potentiometers operating condition I ←
Armrest levers potentiometer operating condition (if present) I ←
Direction switch (if present)
Integrity and operating condition I ←
Wiring connections I ←
0-21

Controller
Integrity, cleaning and operating condition I, C ←
Presence of alarms in the logbook I ←
Connected power cables tightening torque T ← 0
Wiring connections I ←
Connector status I ← 1
Case cleaning (with compressed air) C ←
Electric fan fucntionality (if present) I ←
2
Electric fan filter and convoyer cleaning (if present) C ← 3
Fuses and Relays
Wiring fastening I ← 4
Functionality of all functions protected by fuses and relays I ←
Wiring 5
Harness condition, integrity, fastening I ←
Wire harness coating integrity I ←
6
Connections fastening and taping condition I ← 7
STEERING SYSTEM 8
Steering wheel
Play and fastening I* I ←
9
Steering valve
10
Oil leakage I* I ←
Mounting fastening I* I ← 11
Max pressure M ←
Steering system 12
Steering angle to right and left I
Power steering - Hydraulic steering motor (if present)
13
Oil leakage I ←
14
Power steering hose integrity I
15
BRAKING SYSTEM
General 16
Braking performance I ←
Brake liquid / oil level (if present) I ←
17
Liquid / oil leakages (if present) I ←
18
Brake system bleeding (if present) I ←
Low fluid level warning light (if present) I
0-22

Brake pedal
Pedal stroke and play I ←
Return stroke I ←
Linkages I* I ←
Parking brake
Braking performance I ←
Lever pull margin and operating force (if present) I ←
Parking switch operating condition (if present) I ←
Magnetic discs play, wear and cleaning (if present) I ←
Brake discs
Disc wear and damage I
MATERIAL HANDLING SYSTEM

Forks
Forks and stopper pins integrity and wear I ←
Alignment between left and right fork fingers I ←
Fork heels wear I ←
Welded portions cracking I ←
Mast and lift bracket
Welded portions deformation, damage, cracking I ←
Roller rotating condition, wear, damage I ←
Mast support bushing wear and damage I ←
Mast pads adjustment, wear, damage I ←
Roller pin wear and damage I ←
Mast and lift bracket fastening I ←
Fork carriage side, lower and upper pads condition I* I ←
Chains and chain wheels
Chain tension deformation, damage, slackness I* I ←
Chain lubrication I ←
Chain anchor bolt and nut abnormality I ←
Chain wheel wear and damage I ←
Chain wheel revolution I ←
Attachment (if present)
Abnormalities and mounting condition I ←
0-23

HYDRAULIC SYSTEM
Cylinders
Oil leakage I ←
Rod and rod end integrity, deformation, fastening I ← 0
Tilt cylinders mounting integrity, fastening, operating condition I ←
Natural drop, natural forward tilt I ←
1
Mast cylinders mounting integrity and fastening I ←
2
Lifting and lowering speed I ←
Uneven movement I ← 3
Hydraulic pump
Oil leakage and abnormal noise I ← 4
Hydraulic oil tank
Oil leakage I ←
5
Oil level and contamination I ←
6
Tank and oil strainer condition I ←
Hydraulic filter 7
Cleaning C
Control levers (if present) 8
Operating condition I ←
Oil control valve
9
Oil leakage I ←
10
Safety valve function I ←
Relief pressure measurement M 11
Hydraulic hose and piping
Oil leakage I ← 12
Deformation and damage I ←
Linkage fastening I ←
13
14
SAFETY DEVICES, etc.
Body 15
Frame, cross member, etc. damage and cracking I
Bolts and nuts fastening I 16
Overhead guard
Integrity I ←
17
Welded portions cracking I ←
18
Backrest
Deterioration, damage, cracking I ←
Mounting parts fastening I ←
0-24

Seat
Mounting integrity and fastening I ←
Seat switch operating condition I* I ←
Seat belt integrity and operating condition I ←
OPS
Operating conditions I* I ←
Emergency stop button
Operating conditions I ←
Instrument panel
Horn
Operating and mounting conditions I ←
Lighting system (OPT)
Turn signals (OPT)
Reverse acoustic warning (OPT)
Rear-view mirrors (OPT)
Integrity and cleaning I ←
Rear reflection I ←
Cabin (OPT)
Roof integrity I ←
Doors, side window, tailgate integrity and operating condition I ←
Heated windows integrity and operating condition I ←
Wiper integrity and operating condition I ←
Heater integrity and operating condition I ←
Lubrication
General status - see Lubrication Chart section I ←
WARNING:
Complete the information concerning all maintenance operations with those mentioned in the
relevant safety and operator manuals
0-25
LUBRICATION CHART
0
1
2
3
4
5
6
7
1. Side Shifter
8
2. Fork positioning pins
3. Chain securing tie rods 9
4. Mast guides
5. Mast fasteners 10
6. Lifting chains
7. Drive units 11
8. Brake fluid reservoir
9. Oil tank
10. Rear wheels bearings
12
I Every 1000 hours (6 months) 13
II Every 2000 hours (annually)
Inspection and supply 14
Replacement
(A) Molybdenum disulfide grease 15
(B) Chain spray
(C) Gear oil 16
(D) Hydraulic oil
(E) Brake fluid 17
18
0-26
1-1
BATTERY
Page
BATTERY CASING AND REQUIRED WEIGHT.......... 1-2
BATTERY SERVICE STANDARDS ............................. 1-3
DISPLAY ...................................................................... 1-3 1
MANAGING THE BATTERY ...................................................1-4
1
ADJUSTING THE BATTERY AND THE
INDICATOR ............................................................... 1-5 2
ADJUSTING THE BATTERY VOLTAGE READING...............1-5 3
ADJUSTING THE BATTERY INDICATOR..............................1-6
4
TROUBLESHOOTING ON THE BATTERY............... 1-10
5
INSPECTION.............................................................. 1-11
STATE OF BATTERY CHARGE ................................ 1-13 6
BATTERY CAPACITY ................................................ 1-14 7
GEL BATTERIES ....................................................... 1-15 8
ADJUSTING THE GEL BATTERY INDICATOR ...................1-16
9
BATTERY ................................................................... 1-17
10
REPLACING BATTERY PLUG TERMINAL .............. 1-19
11
12
13
14
15
16
2
18
1-2
BATTERY CASING AND REQUIRED WEIGHT

if you purchase the battery locally, it must be of at least the following weight, as shown in the table
Capacity Size
of battery casing [mm] Weight
Vehicle model Battery
(with casing) [Kg]
(A H) X Y Z
640 963 816 575 1275
1.6L -2.0L 720 963 816 575 1275
840 963 816 575 1275
1-3
BATTERY SERVICE STANDARDS

Specific gravity (battery charged) 1.290 [20 °C]
Specific gravity (80% battery discharged) 1.140 [20 °C]
Discharge end voltage 48 V 47.3 V
1
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled water 2
Insulation resistance 10MW or more
* Battery value on standby (only with key ON and no power consumption)
3
DISPLAY 4
Battery Charge Indicator 5
(A) Diagnostic led
(B) Charge indicatorCharge 6
(B) 7
(A) 8
9
Acusticnotic
Percentage Description Notes
e 10
11
Normal working No No performances drop
12
100-20%
13
Drop of performances
Speed reduction managed from the 14
illuminated (B) 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 from the 17
parameters
illuminated (B) No
Indicator
T10% BDI REDUCTION (traction) 18
P10% BDI REDUCTION (lifting)
10% (1 led) **
18
Blinking (A) Led,

<g id="1225">Discharged battery, </ 18
g>managed<g id="1228">from the
illuminated (B) Yes
Indicator
parameter</g> BDI ADJ MIN (priority 18
function for traction)
%***
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
MANAGING THE BATTERY

The battery discharge voltage and battery status indicator on the dashboard are controlled by the drive
logic.
The indicator can be customized with the following parameters.
BDI adjust min

This parameter determines the SET POINT of discharge voltage.
Expressed in volts, it can be adjusted.
BDI adjust max
This parameter determines the SET POINT of charge voltage.
Expressed in volts, it can be adjusted.
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 = 51,50 V
ADJUSTMENT 3
Charge battery indicator = 50,16 V

BDI ADJ MAX
Minimum battery indicator rearm
threshold = 60%
BDI RESET
Discharge battery indication = 46,32 V

BDI ADJ MIN
Remarks:
• 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
A correct adjustment allows a precise indication of the battery discharge.
1
The ADJUST BATTERY parameter is used to set the voltmeter inside the MASTER traction logic unit.
2
Notes: This parameter can be acquired with any battery discharge percentage.
3
[POINT 1]
Connect the battery and turn on the truck. Use a multimeter 4
to measure the voltage across the battery positive (+) and
- negative (-) 5
50.6 V
+ Y
ER
BA
TT 6
7
8
[POINT 2]
Access the SERVICE menu (see chapter 3, paragraph 9
SERVICE MENU SERVICE MENU DESCRIPTION). Set the voltage
PASSWORD
measured at [POINT 1] in the SERVICE -> LEARNING ->
menu, parameter ADJUST BATTERY 10
11
Press 7 times
12
LEARNING 13
14
Press OK and then 2 times 15
ADJUST 16
BATTERY
17
18
Press OK
18
50.6 V
18
18
to modify 18
OK to save/confirm
OUT to return to the previous menu 18
Remarks: The values shown in the various figures are indicative.
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 [20°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.
Use a multimeter to measure the voltage across the battery
positive (+) and negative (-)
-
50.16 V
+ Y
ER
ATT
B

1-7
[POINT 3]
Access the SERVICE menu (see chapter 3, paragraph
SERVICE MENU
SERVICE MENU DESCRIPTION). Set the voltage
PASSWORD
measured at [POINT 2] in the SERVICE -> TRUCK CONF -
> BATTERY -> menu, parameter BDI ADJ MAX
1
Press twice
2
TRUCK CONF 3
4
BATTERY
6
7
8
Press OK and then 3 times
9
BDI ADJ MAX
10
11
Press OK
12
50.16 V 13
14
to modify
15
OK to save/confirm
OUT to return to the previous menu
16
17
18
18
18
18
18
18
1-8
[POINT 4]
Access the SERVICE menu (see chapter 3, paragraph
SERVICE MENU
SERVICE MENU DESCRIPTION). Add 0.5 V to the voltage
PASSWORD
measured at [POINT 2] and insert it in the SERVICE ->
TRUCK CONF -> BATTERY -> menu, parameter
ADJUSTMENT 3
Press twice FORMULA:

ADJUSTMENT 3 = BDI ADJ MAX + 0,5 VoltNotes:
TRUCK CONF
BATTERY
ADJUSTMENT 3
Press OK
51.50 V
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.
to modify
OK to save/confirm

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
[POINT 1]
SERVICE MENU
Access the SERVICE menu (see chapter 3, paragraph 2
SERVICE MENU DESCRIPTION). Modify the value in the
PASSWORD
SERVICE -> TRUCK CONF -> BATTERY -> menu,
parameter BDI ADJ MIN to increase or decrease the
3
maximum battery discharge.
4
Press twice
Notes: Periodically check the electrolyte density in the
battery elements at the end of discharge. 5
TRUCK CONF
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 6
0,01kg/l up to the limit of 1.13 kg/l.
7
BATTERY 9
10

11
12
BDI MIN
13
14
Press OK
15
46.32 V 16
17
to modify
18
OK to save/confirm
18
18
18
18
18
1-10
TROUBLESHOOTING ON THE BATTERY
Plate corrosion Sulfation Plate warpage and active substance freeing
Improper charging
Long time Repeated procedures
overdischarge at over-discharge
End of life Short circuit without operation and overcharge
of battery between cells
of the battery Charging current
Defect of electrolyte excessive
Electrolyte
Electrolyte insufficient
defective
Ambient Temperature
overdischarge capacity
Battery defect
of the battery excessive
Crack or
Improper chipping of cell
Spacer of the cells
defective supply
water Imperfect
Overcharge connection
of the terminal
Deposition of free Fouled terminal or

active substance connecting plug
at bottom of cell
Short circuit Electrolyte leakage end 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
• Battery charger with high current at end of higher capacity
charge • Check the battery charger
• 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
• High water consumption prolongs the 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 level 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 the electrolyte level is high enough to
cover the element plates. if it is not, top up with distilled or demineralised water to 5 - 7 mm over the
top of the plates. Do not fill beyond this point, since this can cause leaks due to the fluid expanding 1
during use or during recharging cycles, with teh risk fo corrosion of the casing, reduced electrical
isolation and discharging. Check the level and top it up with the battery charged 2
3
2. Electrolyte inspection:
The battery fluid should be transparent. Check for
clouding during the density check. In case of difficulty,
4
pour it into a cup for the inspection.
The check must always be carried out on several 5
cells, because the density may differ from one
element to another. 6
7
8
3. Checking the battery fluid density.
Use a hydrometer to measure the density of the 9
electrolyte.
Density at full charge .... 10
1.290 kg / l [20 °C]
Density when completely discharged.... 11
1.130 kg / l [20 °C]
12
13
The density measurement varies according to the 14
electrolyte temperature; it is advisable always to
measure the electrolyte temperature at the same time 15
as the density.
To have the exact density value, each measurement must be 16
considered in relation to the standard temperature of 20°C.
Equation for converting the real measured density 17
with the ideal density at 20°C.
D20 = Dr + [ 0.0007 (Tr - 20) ] 18
D20: Ideal density at 20°C
Dr: Real density measured at Tr °C
Tr: Real temperature of the electrolyte (°C)
18
18
18
18
18
1-12
* How to use the hydrometer:

(1) Fit the tube into the hole in the element containing
the fluid, press the pump, release it and let the fluid
Hydrometer
flow.
Rubber (2) Allow the hydrometer to float without touching the
bulb external tube, or top or bottom, and when the
Out tube bubbles in the fluid disappear, read the highest
value of the scale on the fluid's surface, as shown in
the figure.
Nozzle
(3) After the measurement, carefully wash the inside
and outside of the hydrometer with water and put it
away after drying with a clean cloth.
4. Insulation resistance measurement

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

Prepare a control table for each battery to record and maintain the inspection results.
Date and time Density Temperature Quantity

Inspection number Notes 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. 10
Formula: Density = (Volt / n° cells) - 0.84
Cell voltage vs Discharged capacity 11

12
RECOMMENDED 13
DISCHARGE LIMIT
Cell no-load voltage (V)
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. 18
This happens on batteries that are removed from charging before they have been completely charged.
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 IN RELATION TO FLUID 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.
MAINTENANCE 5
The GEL battery does not need intense maintenance like traditional batteries.
• The battery never needs topping up.
6
• The valve caps must not be removed.
If the valves should accidentally be damaged, contact the service center of the battery supplier to have 7
them replaced.
The battery must be kept clean and dry to prevent current leakage. Any liquid present inside the battery 8
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 center 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
capacity (full discharge) which corresponds to 1.83 V per element. 15
Notes: Notes:It is important for the battery temperature to remain between +5°C and + 35 °C
during the work cycle. The battery life will be optimal with a temperature between 25-30 °C. 16
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.
The room where the battery is being charged must be ventilated.
18
Remarks: It is necessary to wait a sufficient time for the battery to cool before using it once 18
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 = 51,50 V
ADJUSTMENT 3
Charge battery indicator = 50,16 V

BDI ADJ MAX
Minimum battery indicator rearm
threshold = 60%
BDI RESET
Discharge battery indication = 46,32 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
REMOVAL • INSTALLATION
1
2
3
4
5
6
7
8
9
10
Dismantling procedure
1. Park the truck on a level surface and activate the parking brake 11
2. Turn off the truck
3. Open the compartment and disconnect the battery 12
4. Remove the battery safety locks [Point 1]
5. Remove the battery [Point 2]
13
Assembly procedure
The reassembly procedure is the reverse of the disassembly procedure 14
15
16
17
18
18
18
18
18
18
1-18
Point Operations
[Point 1]
Disassembly:
Remove the battery safety locks (A)
[Point 2]
Disassembly:
Remove the battery from the truck
1-19
REPLACING BATTERY PLUG TERMINAL

Important:
• Disconnect the battery cables 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

the front 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
INSPECTION ...........................................................................2-4 2
CONNECTOR INSPECTION...................................................2-5 3
MAIN CONTROLLERS ................................................ 2-6 4
MASTER TRACTION LOGIC UNIT ........................................2-6
5
SLAVE TRACTION LOGIC UNIT............................................2-8
6
LIFTING LOGIC UNIT ...........................................................2-10
MCB CARD ...........................................................................2-12
7
ARMREST CARD..................................................................2-15 8
CONTACTOR GROUP ..........................................................2-17 9
DASHBOARD........................................................................2-19
10
24V FUSE BOARD................................................................2-20
11
CONTROL UNIT ........................................................ 2-21
MCB CONTROL CARD ............................................. 2-27
12
DC/DC CONVERTER ............................................................2-28 13
CONTACTOR GROUP............................................... 2-29 14
DASHBOARD........................................................................2-32 15
ARMREST CARD..................................................................2-33
16
ARMREST BOARD DESCRIPTION .....................................2-35
17
ACCELERATOR POTENTIOMETER
ADJUSTMENT ........................................................ 2-36 18
NECESSARY ADJUSTMENTS AFTER A 19
HARDWARE COMPONENT REPLACED .............. 2-37
20
21
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.
DASHBOARD
LOGIC UNIT LOGIC UNIT LOGIC UNIT

LIFTING TRACTION SLAVE TRACTION MASTER MCB CARD
2-3
SPECIFICATIONS
1.6 - 2.0 t 2
FT1 (Master traction logic unit) 250 A
2
POWER FUSES FT2 (Slave traction logic unit) 250 A
FP (Lifting logic unit) 350 A 2
F1 (Key) 10A 3
F2 (Warning horn) 5A
F3 (Reversing warning horn) 1A
4
FUSES (+Vb)
Cylindrical 6.3x32 F4 (Controls fan)
Time-Delay
5A 5
Ceramic F5 (Heater) 35A
250 V 6
F6 (Positive cards and controls) 10A
F7 (DC/DC Converter) 20A 7
F8 (Optional DC-DC converter) 20A
8
CT1 (Line) SW60B-258 48V CO
CONTACTORS CT2 (Master+Slave traction logic unit) SU280B-1166 48V 9
CT3 (Lifting logic unit) SU280B-1166 48V 10
FA (Wind-screen wipers) Blade fuse 7.5 A
FB (Work lights) Blade fuse 15 A
11
FC (Rotating/flashing beacon lamp) Blade fuse 2 A 12
FD (Spare) ---
13
FE (low beam/position lights) Blade fuse 7.5 A
FF (Spare) --- 14
FG (Spare) --- 15
ARMREST FH (Spare) ---
24V FUSES FI (Heating) Blade fuse 5 A
16
FL (Heated rear window) Blade fuse 7.5 A 17
FM (Radio) Blade fuse 5 A
18
FN (Spare) ---
FO (Diode D7 (Relay BY-PASS)) Blade diode 1 A 18
FP (Diode D6 (pwr. MCB/DISPLAY)) Blade diode 1 A
18
FQ (+24V Console) Blade fuse 1 A
FR (Diode D5 (Relay Coil)) Blade diode 1 A 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 operating status of the
Standard: vehicle, the place and weather conditions
(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.
• Anomalies 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
Important: 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 the multimeter to the corresponding connector pin
7
Important:
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)
From ⇔ To
Description Standard Notes 11
12
Arriving connector
Starting connector 13
JAT (1-B9) J15 (1-B9) EN1 encoder + V + 12 V
14
15
Colour Value of the 16
Connector pin n. measurement
Connector n. 17
COLOUR CODING
18
COLORI COLOURS FARBEN COULEURS COLORES
C arancio orange orange orange naranja 18
A azzurro blue blau bleu azul
B bianco white weiß blanc blanco 18
L blu dark blue dunkelblau bleu marine azul intenso
G giallo yellow gelb jaune amarillo 18
H grigio grey grau gris gris
M marrone brown braun marron castaño 18
N nero black schwarz noir negro
S rosa pink pink rose rosa
R rosso red rot rouge rojo
18
V verde green grün vert verde
2-6
Z viola/porpora purple violett violet púrpura

MAIN CONTROLLERS
MASTER TRACTION LOGIC UNIT
Basic conditions (battery plug connected, key switch ON).

See the reference names of the connectors in the electrical diagram.
Description Standard Notes
From ⇔ To
JT1 (1-M) J35 (6-M) Key positive +Vb
JT1(2-H) J14 (3-H) Steering potentiometer positive 11.3V
JT1 (3) --- ---
JT1 (4) --- ---
JT1 (5-N) J14(2-N) Negative Steer potentiometer GND
J25 (3-HZ)
JT1 (6-HN) Seat 26V
[via J20(2-HN)]
~ 0.4V
JT1 (7-LV) J15 (4-LV) Channel A EN1 Encoder
~ 11.6V
JT1 (8-RV) J15 (1-RV) +V EN1 Encoder 12V
J25 (1-NL)
JT1 (9-NL) Seat negative GND
[via J20(1-NL)]
JT1 (10-R) J14 (1-R) Cursor Steer potentiometer 2.2 - 9.7V
JT1 (11-CN) JT2 (19-CN) Safety IN GND
JT1 (12) --- ---
JT1 (13) --- ---
~ 0.4V
JT1 (14-LH) J15 (3-LH) Channel B EN1 Encoder
~ 11.6V
JT1 (15-MV) J15 (2-MV) Negative Encoder EN1 GND
JT1 (16-BG) J50/B (3-BG) CT2 contactor coil negative GND
JT1 (17-S03) J52/A (2-S03) Power supply positive +Vb
2-7
From ⇔ To
JT1 (18) --- --- GND
2
JT1 (19-LG) JT2 (11-LG) Safety OUT GND
JT2 (20-HG) 2
JT1 (20-HG) JP (20-HG) CAN L
CN1 (21-HG) 2
JT2 (21-AN)
JT1 (21-AN) JP (21-AN) CAN H 3
CN1 (19-AN)
JT1 (22-RL) J15 (6-RL) Thermic TS1 1.5V (20°) 4
JT1 (23-L) J15 (5-L) Negative Thermic TS1 GND
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
JT2 (2) --- ---
JT2 (3) --- ---
JT2 (5) --- ---
J25 (3-HZ)
JT2 (6-HN) Seat GND
[via J20(2-HN)]
~ 0.4V
JT2 (7-BL) J16 (4-BL) Channel A EN2 Encoder
~ 11.6V
JT2 (8-BS) J16 (1-BS) +V EN2 Encoder 12V
JT2 (9) --- ---
JT2 (10) --- ---
JT2 (11-LG) JT1 (19-LG) Safety IN GND
JT2 (12) --- ---
JT2 (13) --- ---
~ 0.4V
JT2 (14-NV) J16 (3-NV) Channel B EN2 Encoder
~ 11.6V
JT2 (15-BV) J16 (2-BV) Negative Encoder EN2 GND
JT2 (16) --- ---
JT2 (17-S03) J52/A (2-S03) Power supply positive +Vb
JT2 (18) --- --- GND
JT2 (19-CN) JT1 (11-CN) Safety OUT GND
2-9
From ⇔ To
JT1 (20-HG)
JT2 (20-HG) JP (20-HG) CAN L
2
CN1 (21-HG)
2
JT1 (21-AN)
JT2 (21-AN) JP (21-AN) CAN H
CN1 (19-AN)
2
JT2 (22-SL) J16 (6-SL) Thermic TS2 1.5V (20°) 3
JT2 (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
LIFTING LOGIC UNIT

From ⇔ To
JP (1-M) J35 (6-M) Key positive +Vb
JP (2) --- Unused
JP (3) --- Unused
JP (4) --- Unused
JP (5) --- Unused
JP (6) --- Unused
~ 0.4V
JP (7-HV) J12(4-HV) Channel A EN3 Encoder
~ 11.6V
JP (8-BZ) J12(1-BZ) +V EN3 Encoder 12V
JP (9-H) JP (11-H) Safety OUT GND
JP (10) --- Unused
JP (11-H) JP (9-H) Safety IN GND
JP (12) --- Unused
JP (13) --- Unused
~ 0.4V
JP (14-AV) J12(3-AV) Channel B EN3 Encoder
~ 11.6V
JP (15-GN) J12(2-GN) Negative EN3 Encoder GND
JP (16-A) P50 (10-Z) Negative K1coil GND
JP (17-S03) J52/A (2-S03) Power supply positive 48V
JP (18) --- Unused
JP (19) --- Unused
2-11
From ⇔ To
JT1 (20-HG)
JP (20-HG) JT2 (20-HG) CAN L
2
CN1 (21-HG)
2
JT1 (21-AN)
JP (21-AN) JT2 (21-AN) CAN H
CN1 (19-AN)
2
JP (22-SN) P13 (1-LG) Thermic TS3 1.5V (20°) 3
JP (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 CARD
CN1
(black connector)
CN2
(white connector)

From ⇔ To
CN1 (1-LG) J33 (5-LG) Double pedal configuration 0-5V
CN1 (2-RV) J32 (5-RV) Single pedal enabling 0-5V
CN1 (3-BV) J32 (6-BV) Single pedal enabling 0-5V
J33 (2-RH)
CN1 (4-RH) Forward drive enabling 0-5V
J35 (2-RH)
CN1 (5-BH) J33 (3-BH) Forward drive enabling 0-5V
J33 (3-RN)
CN1 (6-RN) Reverse drive enabling 0-5V
J35 (8-RN)
CN1 (7-BN) J33 (9-BN) Reverse drive enabling 0-5V
CN1 (8-BZ) J31 (2-BZ) Service brake pedal 0-5V
CN1 (9-NZ) J30 (3-NZ) Parking brake 0-5V
CN1 (10-BG) J53 (1-BG)] Lifting lever 0-5V
CN1 (11-GM) J53 (2-GM)] Signal for Speed cutback 1 0-5V
CN1 (12-BM) J53 (3-BM)] Forward tilting lever 0-5V
CN1 (13-MV) J53 (4-MV)] Reverse tilting lever 0-5V
CN1 (14-ZN) J53 (5-ZN)] Sideshifting lever 0-5V
CN1 (15-NV) J53 (6-NV)] 4th way lever 0-5V
CN1 (16-BS) J53 (7-BS)] 5th lever 0-5V
CN1 (17-N) J1 (-) Common negative GND
2-13
From ⇔ To
CN1 (18-LN) J49/B (10-LN) Input of signal for Speed cutback 2
2
JT1 (21-AN)
CN1 (19-AN) JT2 (21-AN) CAN H 2
JP (21-AN)
CN1 (20-AN) J137 (1-AN) CAN H 2
JT1 (20-HG)
CN1 (21-HG) JT2 (20-HG) CAN L 3
JP (20-HG)
CN1 (22-HG) J137 (2-HG) CAN L 4
5
Tilt potentiometer cursor
CN1 (24-SB) J49 (1-SB)
(option) 6
CN1 (25-R) J32 (3-R) Cursor traction potentiometer 0 - 5V
CN1 (26-LV) J53 (9-LV)] Cursor lifting potentiometer 0 - 10V 7
CN1 (27) --- ---
8
CN1 (28-G) J32 (2-G) Negative traction potentiometer GND
CN1 (29-AG) J53 (10-AG) Lifting potentiometer positive 10V 9
CN1 (30-V) J32 (3-V) Traction potentiometer positive 5V
CN1 (31-HN) J53 (11-HN) Negative lifting potentiometer GND
10
CN1 (32-N) J53 (8-N) General negative OCV microswitch GND 11
CN1 (33-H) J49/B (5-H) Height mast microswitch N.C. (option)
CN1 (34-AR) J49/B (6-AR) Height mast microswitch N.O. (option)
12
CN1 (35) --- --- 13
CN2 (1-GM) J51 (1-GM) GND EVP1 lowering GND
CN2 (2-BG) J51 (2-BG) GND EVP2 lifting GND 14
CN2 (3-G) J51 (3-G) Positive EVP1 and EVP2 48V
15
CN2 (4-BM) J51 (4-BM) GND EVP3 Tilt backward GND
CN2 (5-MV) J51 (5-MV) GND EVP4 Tilt forward GND 16
CN2 (6-MC) J51 (6-MC) Positive EVP3 and EVP4 48V
17
CN2 (7-AZ) J51 (7-AZ) GND EVP5 left sideshift GND
CN2 (8-BZ) J51 (8-BZ) GND EVP6 right sideshift GND 18
CN2 (9-Z) J51 (9-Z) Positive EVP5 and EVP6 48V
CN2 (10-BV) J51 (10-BV) GND EVP7 4th way GND
18
CN2 (11-NV) J51 (11-NV) GND EVP8 4th way GND 18
CN2 (12-V) J51 (12-V) Positive EVP7 and EVP8 48V
CN2 (13-M01) J90/B (2-M01) Key positive 48V 18
18
CN2 (15-SN) J49/B (7-SN) Pressure sensor cursor
CN2 (16-S03) J52/A (2-S03) Power supply positive 48V 18
CN2 (17-S03) J52/A (2-S03) Power supply positive 48V
2-14
From ⇔ To
CN2 (23-BC) J90/B (10-BC) Optional output negative
CN2 (24-AG) J90/B (9-AG) Pressure sensor positive 5V
CN2 (26-AV) J49/B (8-AV) Pressure sensor negative GND
CN2 (27-G) J71 (3-G) Controls fan signal GND
CN2 (29-MN) J92 (2-MN) Rear lights positive GND
CN2 (30-AM) J91 (2-AM) Brake lights positive GND
CN2 (31-SL) J90/B (1-SL) Direction lights positive GND
CN2 (32-NL) J70 (1-NL) Reversing warning horn negative GND
CN2 (33) --- ---
Negative of relay of power supply for
CN2 (34-NZ) J90/B (12-NZ) GND
holding
CN2 (35) --- ---
2-15
ARMREST CARD
2
JSOLL
2
JBRA 2
JTRA 3
JCAN
4
JIV
JAUX 5
JV
6
7
Basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle].
See the reference names of the connectors in the electrical diagram. 8
CN (pin-colour) ⇔ CN (pin-colour) 9
From ⇔ To
J137 (7-HG) 10
JCAN (1-HG) [via J138 (1-HG)] CAN L
[via J131 (1-HG)]
11
J137 (6-AN)
JCAN (2-AN) [via J138 (2-AN)] CAN H
[via J131 (2-AN)]
12
JCAN (3-N) --- GND IN GND 13
JCAN (4-SHD) --- Unused
J137 (5-M)
14
JCAN (5-M) [via J138 (5-M)] +V IN from Display 48V
[via J131 (5-M)] 15
JCAN (6-N) --- GND IN GND
16
JAUX (1-H) --- +V Manual inversor 5V
JAUX (2-S) --- Cursor GND Hand direction lever 0-5V 17
JAUX (3-BR) --- GND Manual inversor GND
JAUX (4-LC) --- Reverse
18
JAUX (5-V) --- Forwards 18
JAUX (6-L) J142 (2-L) Input
JAUX (7) --- Unused 18
JAUX (8-Z) J141 (3-Z) Input 18
JAUX (9) --- Unused
JAUX (10-N) --- GND GND 18
JSOLL (1) --- +V Pot 5V
18
JSOLL (2) --- Pot slide 0-5V
2-16
From ⇔ To
JSOLL (3) --- Unused
JSOLL (4) --- Potentiometer GND GND
JSOLL (5) --- Microswitch 5V
JSOLL (6) --- Microswitch 5V
JSOLL (7) --- Unused
JSOLL (8) --- GND Microswitch GND
JBRA (1) --- +V Pot 5V
JBRA (2) --- Pot slide 0-5V
JBRA (3) --- Unused
JBRA (4) --- Potentiometer GND GND
JBRA (5) --- Microswitch 5V
JBRA (6) --- Microswitch 5V
JBRA (7) --- Unused
JBRA (8) --- GND Microswitch GND
JTRA (1) --- +V Pot 5V
JTRA (2) --- Pot slide 0-5V
JTRA (3) --- Unused
JTRA (4) --- Potentiometer GND GND
JTRA (5) --- Microswitch 5V
JTRA (6) --- Microswitch 5V
JTRA (7) --- Unused
JTRA (8) --- GND Microswitch GND
JIV (1) --- +V Pot 5V
JIV (2) --- Pot slide 0-5V
JIV (3) --- Unused
JIV (4) --- Potentiometer GND GND
JIV (5) --- Microswitch 5V
JIV (6) --- Microswitch 5V
JIV (7) --- Unused
JIV (8) --- GND Microswitch GND
JV (1) --- +V Pot 5V
JV (2) --- Pot slide 0-5V
JV (3) --- Unused
JV (4) --- Potentiometer GND GND
JV (5) --- Microswitch 5V
JV (6) --- Microswitch 5V
JV (7) --- Unused
JV (8) --- GND Microswitch GND
2-17
CONTACTOR GROUP
2
2
2
3
4
5
6
7
8
9
10
See the reference names of the connectors in the electrical diagram. 11
CN (pin-colour) ⇔ CN (pin-colour) 12
From ⇔ To
J50/A (1-R) J52/A (10-R) Battery positive +Vb
13
J50/A (2) --- --- 14
J50/A (3-S) J52/A (5-S) Input for fuses F8 - F7 - F6 +Vb
J50/A (4-S) J52/A (4-S) Input for fuse F5 +Vb 15
J50/B (1-S03) J52/A (2-S03) CT2 contactor power supply +Vb
16
J50/B (2-S03) J52/A (2-S03) CT3 contactor power supply +Vb
J50/B (3-BG) JT1 (16-BG) Negative of the contactor CT2 GND 17
J50/B (4-A) JP (16-A) Negative of the contactor CT3 GND
18
J50/B (5-M) J35 (6-M) CT1 contactor power supply +Vb
J50/B (6-N) J1 (-) Negative of the contactor CT1 GND 18
J52/A (1-S04) J96 (1-S04) +48V DC-DC converter +Vb
18
18
18
18
2-18
From ⇔ To
J50/B (1-S03) CT2 contactor power supply
J50/B (2-S03) CT3 contactor power supply
JT1 (17-S03) Traction Master module power supply
JT2 (17-S03) Traction Slave module power supply
JP (17-S03) Pump module power supply
J52/A (2-S03) +Vb
CN2 (16-S03) MCB card power supply
J51 (14-S03) ---
J52/A (3-S02) J107 (1-S02) Heater power supply +Vb
J52/A (4-S) J50/A (4-S) Input for fuses F8 - F7 - F6 +Vb
J52/A (5-S) J50/A (3-S) Input for fuse F5 +Vb
J52/A (6-S05) J97 (1-S05) +48V optional DC-DC converter +Vb
J52/A (7) --- ---
J52/A (8) --- ---
J52/A (9) --- ---
J52/A (10-R) J50/A (1-R) Battery input
J52/B (1-R01) J21/1 (1-R01) Key positive +Vb
J52/B (2-R02) J11 (1-R02) Warning horn positive +Vb
J52/B (3-R03) J70 (1-R03) Reversing warning horn positive +Vb
J52/B (4-S01) J71 (2-S01) Controls fan positive +Vb
2-19
DASHBOARD
2
2
2
3
4
5
6
7
8
PIN 14
J137
9
PIN 1
10
11
12
Basic conditions (battery plug connected, key switch ON). 13
14
From ⇔ To
15
J137 (1-AN) CN1 (20-AN) CAN H
J137 (2-HG) CN1 (22-HG) CAN L 16
J137 (3-N) J1 (-) Battery negative
17
J137 (4-CL) J35 (10-CL) Turtle button signal
J137 (5-RG) J35 (9-RG) LPH button signal 18
J137 (6-RA) J4 (1-RA) Brakes oil level signal
J137 (7-M01) J90/B (7-M01) Key positive
18
J137 (8-AN) J132 (3-AN) CAN H 18
J137 (9-HG) J132 (4-HG) CAN L
J137 (10) --- --- 18
J137 (11) --- ---
18
J137 (12) --- ---
J137 (13-A) J90/B (8-A) Alarm buzzer negative 18
J137 (14-N) J1 (-) Battery negative
2-20
24V FUSE BOARD

From ⇔ To
J90/A (1-C) J96 (4-C) +24V from the DC-DC converter +24V
J90/A (2-N) J96 (5-N) Negative from the DC-DC converter GND
J90/A (3-N) J97 (5-N) Negative from the opt. DC-DC converter GND
J90/A (4-V) J97 (4-V) +24V from the opt. DC-DC converter +24V
J90/B (1-SL) CN2 (31-SL) Direction lights negative GND
J90/B (2-M01) CN2 (13-SL) Key positive +Vb
J90/B (3-C01) J132 (1-C01) + 24V console +24V
J102 (6-RC)
J90/B (4-RC) Rear lights signal GND
J91 (6-RC)
J90/B (5-RA) J91 (5-RA) Left direction light signal GND
J90/B (6-RH) J102 (5-RH) Right direction light signal GND
J90/B (7-M01) J137 (7-M01) Key positive +Vb
J90/B (8-A) J137 (13-A) Alarm buzzer negative GND
J90/B (9-M) J35 (6-M) Key positive +Vb
J90/B (10-BC) CN2 (23-BC) Optional output negative GND
J90/B (11-Z) J52/B (1-R01) Battery positive +Vb
J90/B (12-NZ) CN2 (34-NZ) Relay coil negative GND
2-21
CONTROL UNIT
MAIN CONTROL UNIT
2
Logic Unit
Traction Logic Unit
Master ACE-2
Traction Logic Unit
Slave ACE-2
Lifting 2
ACE-2
Inverter for AC asynchronous

2
3-phase motors
3
Regenerative braking functions
4
Can-bus interface
5
Flash Memory 6
Digital control based upon a 7
microcontroller
Power 48 V 48 V 48 V
8
Maximum current 350 A (RMS) 350 A (RMS) 450 A (RMS) 9
Operating frequency 8 Khz 8 Khz 8 Khz
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
2-22
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) Jack up the front wheels.
(2) Connect a clamp amperometer
(3) Select a direction,shift the direction switch to forward (or backward) position, and start the
machine with low speed
(4) Check the value of the current of each phase.
(5) If the value of one phase is higher or lower respect the others it means that the system is not
balanced and the motor is jerking. In this situation the logic unit must be replaced.
Measuring method, procedure using a multimeter
(1) Jack up the front wheels.
(2) Set the multimeter on V~
(3) Connect the negative of the multimeter on the battery negative
(4) Connect the positive on one of the phase of the logic unit.
(5) Check the value of the voltage of each phase.
balanced and the motor goes jerking. In this situation the logic unit must be replaced.
In order to compare the value of the phases it is necessary to use the same tool and not different
type of multimeters or clamp ammeters for each phases. This because the tool have different
tolerance respect each others.
Measuring method, procedure Measuring method Procedure using

using a multimeter a clamp amperometer
2-23
CHECK LIFTING MOTOR PHASES BALANCING

Measuring method Procedure using a clamp amperometer
(1) Connect a clamp amperometer
(2) Select the low speed lifting movement 2
(3) Check the value of the current of each phase.
(4) If the value of one phase is higher or lower respect the others it means that the system is not 2
balanced and the motor is jerking. In this situation the logic unit must be replaced.
Measuring method, procedure using a multimeter 2
(1) Set the multimeter on V~
(2) Connect the negative of the multimeter on the battery negative 3
(3) Connect the positive on one of the phase of the logic unit.
(4) Check the value of the voltage on each phase. 4
balanced and the motor goes jerking. In this situation the logic unit must be replaced.
5
In order to compare the value of the phases it is necessary to use the same tool and not different
type of multimeters or clamp ammeters for each phases. This because the tool have different 6
tolerance respect each others.
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-24
TEMPERATURES MANAGEMENT
The logic units (Master-Slave-Pump) use the signal coming from temperature sensor to control the
electric motors, so that it is possible to avoid overheating and possible damage.
The logic unit reduces the motor performance according to the following data.
• Pump motor speed reduction in relation to the increase in their temperature

0° to 130°C no reduction
130° to 140°C reduction of 20%
140° to 150°C reduction of 20%
> 150°C reduction of 70%
The motor current drops in line with the increase in motor temperature
100
80
60
I%
40
20
0
100 110 120 130 140 150 160 170 180 °C
• Increase in pump motor acceleration time in relation to the increase in their temperature
0° to 130°C no reduction
130° to 140°C + 0.5s
140° to 150°C + 1.0s
> 150°C + 2.0s
• Drive motor speed reduction in relation to the increase in their temperature

The two drive motors are equipped with digital temperature sensors.
On reaching the threshold of 140°C the two drive logic elements cut off the current to the motors.
2-25
Before starting, disconnect the battery plug and measure the voltage across (+) and GND; if
voltage is present, fit a 100Ω resistance between (+) and GND to discharge the condensers.
2
2
2
3
4
5
6
7
8
9
Dismantling procedure 10
1. Park the vehicle on a level surface and apply the parking brake
2. Turn off the truck 11
3. Open the compartment and disconnect the battery
4. Remove the metal side cover [Point 1]
5. Disconnect power cables from the logic unit [Point 2] 12
6. Remove lifting logic unit and/or drive logic units.
13
Assembly procedure
Remarks:
For the necessary adjustments to be made after the logic change, see section “NECESSARY
15
ADJUSTMENT AFTER AN HARDWARE COMPONENT REPLACING”
16
17
18
18
18
18
18
18
2-26
Point Operations
[Point 1]
Disassembly:
Remove the metal side cover
[Point 2]
Disassembly:
Disconnect power cables from the logic unit
2-27
MCB CONTROL CARD (Main Control Board)

The board is placed on the left side of the truck, under the panel. MCB is the main control and
management board of the vehicle. 2
The board is made up by two microprocessors:
TRCB = traction control board 2
EVCB = electric valve control board
TRCB is the section which controls the applications: manages the parameters of the traction and Master 2
of the drive logic units.
EVCB is the vehicle communication master: it manages lifting parameters (mechanical control valve 3
version and mini-lever version) and is Master of the lifting logic unit.
4
MAIN FUNCTIONS
• Performances management (traction and lifting parameters with lever distributor) 5
• Management/control of stop and reverse direction lights
• Electro-proportional distributor control (optional) 6
• Vehicle configuration identification
• Communication Master between all cards
• Traction control Master
7
• Pump control Master
8
1. Connector CN1:
Used to check pedals system, parking/service brake,
9
1 negative brakes unlocking sensor and the mechanical
distributor micros 10
2. Connector CN2:
Used to check electric distributor solenoid valves, 11
tilting potentiometer, rear lights and cooling fan
12
2
13
14
15
17
4. Remove the side panel
5. Disconnect the connectors of the card 18
6. Remove the card
18
Assembly procedure
18
18
18
2-28
DC/DC CONVERTER
The machine is equipped with a DC/DC converter (48V - 24V) to power the rear lights and the 24V fuse
box.
The machine can be equipped with a second DC/DC converter (48V - 24V) to power additional optional
systems
OPTIONAL 24V SYSTEMS
Converter IP Standard machine 144 W

Flash lamp 3 W
144 W 54 Type-approved rotating lamp 70 W
360 W 54 Wind-screen wiper 100 W
720 W 20 2 Work lights 140 W
Complete lights 200 W
Lights for occasional traffic on roads 240W
Heating 150 W
Radio 40W
4th and 5th way exchanger solenoid valve 36W
To determine the total power at 24V, sum the power of the standard machine to that of the
optional equipment installed.
Select the 24V power unit and round the calculated power up with a 10% margin.
A 140W converter is installed on the standard truck, that consumes 86W; this means that
approximately 40W are available for the optional circuits.
2-29
CONTACTOR GROUP
Important: 2
Before starting, disconnect the battery plug and measure the voltage across (+) and GND; if
voltage is present, fit a 100Ω resistance between (+) and GND to discharge the condensers.
2
2
3
4
5
6
7
8
9
10
4. Remove the side panel 13
5. Disconnect the power cables of the contactors
6. Remove the two fixing screws on the contactor unit [Point 1]
7. Remove the contactors 14
Assembly procedure 15
The reassembly procedure is the reverse of the disassembly procedure
16
Point Operations
17
[Point 1]
Disassembly: 18
Remove the fixing screws (A) on the contactor unit
18
18
A 18
18
18
2-30
INSPECTION
1. CONTACTORS
Inspection method
Disconnect connector from wiring harness and
measure the resistance of the coil
Part to be Measurement Multimeter
Standard
inspected terminals range
Approx.
Both
CT3 coil 100 Ω (at Ω ×1
terminals
20°C)
Approx.
Both
Coil CT2 100 Ω (at Ω ×1
terminals
20°C)
Approx.
Both
Coil CT1 420 Ω (at Ω ×1
terminals
20°C)
2. FUSE
Inspection method
Disconnect fuse and measure the insulation resistance
Portion to be Measurement Multimeter
Standard
inspected terminals range
Both
Fuses 0Ω Ω ×1
terminals
2-31
DESCRIPTION OF CONTACTORS
CT3 = Lifting contactor
2
Lifting logic Contactor Description V V holding
J52/A (2-S03) CT3 Coil power supply +Vb 70% +Vb 2

JP (16-A) CT3 Coil negative GND 2
CT2 = Traction contactor 3
Drive logic Contactor Description V V holding 4
J52/A (2-S03) CT2 Coil power supply +Vb 80% +Vb 5
JT1 (16-BG) CT2 Coil negative GND
6
K3 = Line contactor
7
Display Contactor Description V V holding 8
J35 (6-M) CT1 Coil power supply +Vb +Vb
9
- Vb CT1 Coil negative GND
10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-32
DASHBOARD
If the cause of trouble is in the display, measure the voltage at connector to whom voltage is applied.
PIN 14
J137
PIN 1
J137 connector basic condition (Battery plug connected)
From ⇔ To
J137 (9-N) J1 (-) GND from battery GND
P137 (8-R3) J1 (+) +V from battery +V
4. Remove the front board.
5. Disconnect the wiring harness from the dashboard
6. Remove the dashboard fixing screws
2-33
ARMREST CARD
COMPONENTS
2
2
Joysticks
2
3
4
Fingertip
5
6
7
8
9
10
1 Armrest 8 Armrest card
11
2 Wiring 9 Direction switch
3 Internal cabling 10 Guard 12
4 Guard 11 Finger-tip
5 Cushion 12 Wiring 13
6 Knob 13 Guard
7 Joystick 14
15
4.
5.
Disconnect the wiring in the rear of the armrest [Point 1]
Remove the arm pad.
18
6. Remove the fixing screws located under the armrest [Point 2]
7. Open the armrest 18
8. Disconnect the cabling and remove the 4 bolts securing the armrest card [Point 3]
9. Remove the armrest card 18
Assembly procedure
18
18
18
2-34
Point Operations
[Point 1]
Disassembly:
A Disconnect wiring (A), placed in the armrest back part
[Point 2]
Disassembly:
B Remove the 4 fixing screws (B) placed in the armrest
lower side
[Point 3]
Disassembly:
Disconnect armrest board wirings and remove the
armrest board 4 fixing screws
2-35
ARMREST BOARD DESCRIPTION
2
JSOLL 2
JBRA
2
3
JTRA JCAN
4
JIV
JAUX 5
JV 6
7
COMPONENTS 8
JSOLL Connector for lifting
9
JBRA Connector for tilting
JTRA Connector for sideshift 10
JIV Connector 4th lever
JV Connector 5th lever 11
JAUX Connector for auxiliary controls: forwards/reverse drive button, horn button
JCAN Connector for the CAN-BUS
12
The purpose of this card is to pilot the horn button, forward and reverse speed buttons (FW/BW button
13
version) and the fingertip and joystick signals.
Operating a lever on the armrest, the analog signal is converted into a digital signal that is then 14
transferred via CAN-BUS to the lifting logic unit and to the MCB (EVCB) card which converts it from
digital to analog. 15
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).
16
17
18
18
18
18
18
18
2-36
ACCELERATOR POTENTIOMETER ADJUSTMENT
1. Check the ON/OFF condition of the switch

1.1. SW8 (single pedal)
1.2. SW4 - SW5 (double pedal)
Measurement terminals Status
Pedal not
∞Ω
Standard: operated:
Pedal operated Continuity
2. Adjustment of Accelerator Potentiometer (P2)

Installation
(1) Before installing a new traction potentiometer it is
suggest to check it with an analogue multimeter.
Move slowly the potentiometer lever until the
maximum stroke and in the same time check if the
multimeter increases or decreases the value
proportionally with the movement.
(2) Install the potentiometer and connect it to the wiring
loom of the machine.
(3) After closing the microswitch the voltage on the
slider of the potentiometer has to be approximately
1.4V and 3.5V at the maximum stroke. This
measure is referred to its negative.
(4) Once the potentiometer is installed, do the setting
(see LEARNING menu -> LEARN TRAC POT).
(5) After adjusting the switch ON/OFF operation, apply
yellow paint to the head of a set screw.
Measurement terminals Status

J32 (1-R) ~ 1,6V - ~ 3,5V
Standard: J32 (2-G) GND
J32 (3-V) 5V
2-37
NECESSARY ADJUSTMENTS AFTER A HARDWARE COMPONENT

REPLACED
MCB CARD
2
ACQUISITION: Accelerator potentiometer (LEARN TRAC POT)
Lifting potentiometer (only in the mechanic distributor version) (LEARN LIFT POT)
2
Balanced pedal configuration (SWAYING PEDAL)
Speed reduction in case of mast with height more than 6250mm (HIGH MAST) 2
MASTER TRACTION LOGIC UNIT 3
ACQUISITION: Steering potentiometer (SET STEER ZERO/SET STEER LEFT/SET STEER RIGHT)
4
Acquisition not required 5
LIFTING LOGIC UNIT 6
Acquisition not required
7
ARMREST CARD
• Optional 5th way configuration via fingertips (VTH ENABLE) 8
• Optional attachment pilotage button activation (CLAMPS)
9
DASHBOARD
Date and hour regulation 10
ACQUISITION: Battery indicator (ADJUST BATTERY)
11
12
13
14
15
16
17
18
18
18
18
18
18
2-38
3-1
DISPLAY
Page
MULTIFUNCTION DISPLAY .................................. 3-2
GENERAL ........................................................................ 3-2
0
MAPS FOR USING THE DASHBOARD ................ 3-4
1
USER MENU .......................................................... 3-4
2
USER MENU MAP ........................................................... 3-5
USER MENU DESCRIPTION................................. 3-6 3
HOUR METER ................................................................. 3-8 4
TRIP ................................................................................. 3-8 5
CLOCK............................................................................. 3-9
6
ALARMS ........................................................................ 3-10
DISPLAY SETTING.........................................................3-11 7
MAPS FOR USING THE DASHBOARD .............. 3-14 8
SERVICE MENU DESCRIPTION ......................... 3-15 9
“INCORRECT START“ MANAGEMENT ............. 3-68 10
11
12
13
14
15
16
17
18
3-2
MULTIFUNCTION DISPLAY (INSTRUMENT PANEL)

The multi-function instrument panel helps operators to identify various information easily by changing
screens depending on the vehicle conditions.
GENERAL
PIN 14
J137
PIN 1
Icon Description
Flat battery indicator

It flashes when battery drops below 20% charge
Parking brake indicator enabled
Dead man device indicator:

The indicator comes ON when the driver leaves the driving seat without switching OFF the truck;
under these conditions, the traction and lifting movements are disabled.
Adjustable electronic hour meter:

it counts truck working hours. It shows the working hours and hour fractions
Speed reduction indicator

3-3
Icon Description
Selected gear indicator
0
Hour indicator
1
Timer indicator 2
3
Selected program indicator
4
Steering direction indicator

5
6
7
Hour meter mode indicators
lifting motor, traction motor or key switch
8
9
10
Password:
The option activation button permits to digit the access password 11
12
Board:
it permits to navigate between the menus 13
14
Brakes liquid level warning light:
Braking system fault. The warning appears when the brake system pressure is insufficient to
release the brakes
15
Steering direction indication: 16
indicates the steering wheel direction
17
18
19
20
21
E
3-4
MAPS FOR USING THE DASHBOARD
USER MENU
3-5
USER MENU MAP
0
1
2
3
4
hh:mm
5
6
gg/mm/aa
7
8
9
TRIP H:M 00000:00

10
11
12
13
14
15
16
17
18
19
20
21
E
3-6
USER MENU DESCRIPTION

The "user" menu is accessible to any operator, and allows to modify the 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
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
USER MENU PASSWORD INSERTION PROCEDURE
4
5
6
7
8
9
10
11
12
Procedure Operations Vehicle reactions 13
1 Turn the truck on
2 Pull on the parking brake 14
Short acoustic 15
3 Press the LPH and turtle keys at the same time
warning
4 Press OK for a few seconds to enter the menu 16
17
18
19
20
21
E
3-7
USER MENU
Menu Description Notes
The display shows the completed working hours of: Unless specified other-
WORKING: lifting motor working wise, the hour count is
TRACTION: traction motor working made on the utilization of 0
HOUR METER KEY: truck on (inserted key) the lifting motor and can
RENT: rental time counter be reset by the service 1
SERVICE: truck working since last service intervention staff
Unless otherwise indicated, count of the hours is 2
Can be reset
TRIP It is a partial hour meter on the lifting motor use by the operator 3
seconds
CLOCK It permits to modify hours and date 4
The active alarm is
indicated on the display
5
ALARMS It allows, if enabled, to set an alarm as memo
by a specific warning
light 6
It permits to modify:
- the counting of the truck working hours visualized
7
on the display:
None: nothing displayed 8
Key: the key working hours
DISPLAY Working: the pump working hours 9
Traction: the traction working hours
- the language visualized by the “user“ menu 10
(5 languages: it, en, fr, es, de)
- visualization of the direction wheels position 11
(linear or radial modality)
12
13
14
15
16
17
18
19
20
21
E
3-8
HOUR METER
Enter the user menu

[see USER MENU PASSWORD INSERTION PROCEDURE
paragraph]
Press or to view the information referred to the hour
meter
To exit the menu use lateral flowing arrows
TRIP
Press to view the information referred to the trip
Press OK to reset the hours count
To exit the menu use lateral flowing arrows
TRIP H:M 00000:00
3-9
CLOCK
Enter the user menu

paragraph] 0
1
2
Press OK to enter into the clock menu
Remarks:
3
The clock icon flashes
4
5
Press or to modify the setting.

6
Press OK to confirm.
7
24 Remarks:
The selected modality has a flag beside 8
Use the flowing arrows to set the hours. 9
Press OK to confirm
hh:mm 10
11
Use the flowing arrows to set the date. 12
Press OK to confirm
gg/mm/aa Press OUT to exit the menu
13
14
Notes:
To change the YEAR the programmer must be connected 15
to the truck CAN-BUS; otherwise it is possible only to
change the month and day 16
17
18
19
20
21
E
3-10
ALARMS
SETTING
Enter the user menu
paragraph]
Use to reach the clock alarm menu
Press OK to confirm
Remarks:
Press OK to confirm
Use the flowing arrows to set the hours
hh:mm Press OK to confirm
Use the flowing arrows to set the date.

Press OK to confirm
gg/mm/aa Press OUT to exit the menu
DEACTIVATION
Enter the user menu
paragraph]
Use to reach the alarm menu
Press OK to confirm
Press or to disable the alarm

Remarks:
Press OK to confirm
Press OUT to exit the menu

3-11
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

3-12
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
Press OK to confirm 5
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
3-13
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 visualization.

Press OK to confirm

3-14
0
1
2
3
4
5
MAPS FOR USING THE DASHBOARD 6
7
8
SERVICE MENU 9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-15
SERVICE MENU DESCRIPTION

The "service" menu allows enabling all necessary functions for assistance, maintenance and rental
activities.
The access to this menu is for authorized personnel only.
SERVICE MENU PASSWORD
Notes on password insertion
1. Make sure to operate on the display membrane buttons using fingers only. The use of sharp or pointed
tools could damage the buttons.
2. If, during the password entry, an error is committed, turn off the vehicle with the key and start from the
beginning. If the menu of the hidden functions doesn't appear after a few attempts, the system could
be defective.
SERVICE MENU PASSWORD INSERTION PROCEDURE
Procedure Operations Vehicle reactions

1 Turn the truck on
2 Pull on the parking brake
3 Press the LPH and turtle keys at the same time Short acoustic warning
Enter the combination as shown in the following sequence
4 Short acoustic warning
Insert the password (the password is dynamics and changes

automatically each January the 1st):
The password is composed by a sequence of numbers:
5 the correspondence between the keyboard buttons and the num-
bers composing the password is available on the display. The
OUT button, indicated as OFF, in the display, allows to cancel the
last number typed by each pressure
3-16
SERVICE MENU MAP
PLEASE INSERT
SERV. PASSWORD
SOFT VERS
PARAM CHANGE
TRUCK CONF
SERVICE RENT
PSW MODIFY
TESTER
ALARMS
LEARNING
DEFAULT RST
3-17
Menu Description
SOFT VERS Visualizes the software version of boards and logic units
PARAM CHANGE Modify the selected program parameters
TRUCK CONF Modify the configuration parameters 0
SERVICE RENT It allows to set up the programmed maintenance menu and rent menu
1
PSW MODIFY It allows to modify the passwords or to restore default ones
TESTER Visualizes analog and digital values to analyze the truck status 2
Memorizes truck alarm codes (maximum 20 alarms).
ALARMS
This function visualizes alarms in real time 3
Used to set the truck serial number, to acquire the status of the 4
LEARNING
potentiometers and execute the ADJUST BATTERY
DEFAULT RST It allows to restore the default parameters of the truck 5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-18
SOFT VERS
Enter the service menu

[see SERVICE MENU PASSWORD INSERTION
PROCEDURE paragraph] 0
1
2
Press OK to confirm
3
SOFT VERS 4
5
Use right and left arrows board buttons to navigate the menu
6
SOFT VERS
7
“board” 8
“x.xx” 9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-19
SOFT VERS MENU MAP
PLEASE INSERT
SERV. PASSWORD
SOFT VERS
1 - EVCB
2 - TRCB
3 - AMREST
4 - MASTER
5 - SLAVE
6 - PUMP
7 - DISPLAY
SOFT VERS FUNCTION

The SOFT VERS function is used to display the versions of the board and logic unit software installed in
the truck.
Card Description Notes

EVCB Identify the MCB lifting section
TRCB Identify the MCB traction section
Available only with
ARMREST Identify the armrest board
electric control valve
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
The Display reads the software versions of the other boards in real time via the CAN-BUS.
If a card does not communicate or is not present on the CAN-BUS line, the display will not be able
to show the required software version.
3-20
PARAM CHANGE

1
2
Press till reach the PARAM CHANGE menu
Press OK to enter the menu 3
PARAM CHANGE 4
5
Keep OK pressed for approximately 5 sec (until ADVANCE 6
appears)
PARAM CHANGE
7
ADVANCE 8
Use to select
9
PARAM CHANGE TRACTION (traction parameters)
o 10
MAT. HANDLING (hydraulic function parameters)
MAT. HANDLING 11
Press OK to confirm
12
Use buttons and to navigate the menu
PC MAT. HAND Press OK to select the required parameter 13
XXXXXXXXX Use the button to select the set [L-P-H]
14
XXXHZ P PROF 0 Use to select the profile [0-1-2-3-4]
15
PARAMETER
Press or to modify the value 16
Press OK to confirm
17
XX HZ
18
Press OK to save; on the display the message SAVE 19
PARAMETER SUCCESSFUL appears, therefore press OUT to return to the
menu 20
HZ
SAVE? Press OK to exit without saving 21
OK OUT
E
3-21
PARAMETER CHANGE MENU MAP
PLEASE INSERT
SERV. PASSWORD
SOFT VERS
PARAM CHANGE
PARAM CHANGE BASIC PARAM CHANGE ADVANCED
TRACTION MAT. HANDLING TRACTION MAT. HANDLING
1 - MAX SPEED FW 1 - MIN SPEED UP 1 - MAX SPEED FW 1 - MIN SPEED UP

2 - MAX SPEED BW 3 - TILT SPEED FINE 2 - MAX SPEED BW 2 - MAX SPEED UP
3 - T ACC DELAY 4 - SHIFT SPEED FINE 3 - T ACC DELAY 3 - TILT SPEED FINE
23 - CURVE CUTBACK MAX 5 - IV WAY SPEED FINE 4 - THROTTLE 0 4 - SHIFT SPEED FINE
25 - PEDAL BRK 6 - V WAY SPEED FINE 5 - FREQ CREEP 5 - IV WAY SPEED FINE
27 - INVERSIONBK 7 - HYDRO SPEED FINE 6 - THROTTLE X1 6 - V WAY SPEED FINE
28 - RELEASE BRK 7 - THROTTLE X2 7 - HYDRO SPEED FINE
8 - THROTTLE X3 8 - P TURTLE CUTBACK
9 - THROTTLE Y1 9 - P CUTBACK SPEED1
10 - THROTTLE Y2 10 - P CUTBACK SPEED2
11 - THROTTLE Y3 11 - P 20 BDI CUTBACK
12 - TRAC TORQUEPOF 12 - P 10 BDI CUTBACK
13 - T 20 BDI CUTBACK 13 - P ACC DELAY
14 - T 10 BDI CUTBACK 14 - P DEC DELAY *
15 - T TURTLE CUTBACK 15 - P THROTTLE *
16 - T SPEED CUTBACK1 16 - P THROTTLE X **
17 - T SPEED CUTBACK2 17 - P THROTTLE Y *
18 - T CURVE DEC DEL 18 - PUMP TORQUE PROF
19 - ANGLE START 19 - CURVE MODE *
20 - ANGLE INC
21 - ANGLE MAX
22 - % CURVE CTB INC
23 - CURVE CUTBACK MAX
24 - T BRAKE CUTBACK
25 - PEDAL BRK
26 - SPEED LIMTBRK
* Only for version with electro-proportional distributor 27 - INVERSION BRK
28 - RELEASE BRK
** Only for version with mechanical distributor
3-22
TRACTION FUNCTION
The Traction function is used to view/modify the traction system parameters.
N. PARAMETER DESCRIPTION MIN MAX STEP UNIT
Determines the maximum forward speed
km/h = (Hz x 30) / 220 0
1 Max speed fw Note: when the HIGH MAST (TRUCK CONF - OPTIONS) 20 110 5 Hz
parameter is set to ON the MAX SPEED FW parameter is not
useable
1
Determines the maximum reverse speed
km/h = (Hz x 30) / 220
2
2 Max speed bw Note: when the HIGH MAST (TRUCK CONF - OPTIONS) 20 110 5 Hz
parameter is set to ON the MAX SPEED BW parameter is not 3
useable
Determines the acceleration ramp. 4
3 T acc delay Minimum setting = maximum acceleration 2.0 10.0 0.1 Sec
Maximum setting = minimum acceleration
5
This parameter determines a 0 value zone in the
4 Throttle 0 acceleration bend 0 30 2 %
(Image reference 1)
6
Determines the minimum frequency applied to the
5 Freq creep motor 0.20 1.00 0.2 Hz 7
(Image reference 1)
Determines an X1 value zone in the acceleration
8
6 Throttle X1 curve 22 100 2 %
(Image reference 1) 9
Determines an X2 value zone in the acceleration
7 Throttle X2 curve 22 100 2 % 10
(Image reference 1)
Determines an X3 value zone in the acceleration 11
8 Throttle X3 curve 22 100 2 %
Determines a Y1 value zone in the acceleration
9 Throttle Y1 curve 4 100 2 % 13
(Image reference 1)
Determines a Y2 value zone in the acceleration 14
10 Throttle Y2 curve 4 100 2 %
Determines a Y3 value zone in the acceleration
11 Throttle Y3 curve
(Image reference 1)
4 100 2 % 16
ACCELERATOR POTENTIOMETER CURVE 17
SWAYING PEDAL SYSTEM
STANDARD PEDAL SYSTEM
Speed (%) Speed (%)
Max Speed Max Speed

18
19
20
Throttle Y3 Throttle Y3
y
y
la
la
de
de
C
C
AC
AC
T
Throttle Y2
Throttle Y1
Throttle Y2
Throttle Y1
21
Freq Creep Freq Creep
Potenziometer Potenziometer
Throttle 0 Throttle X1 Throttle X2 Throttle X3 100% Stroke (%)
IMAGE 1
Throttle 0 Throttle X1 Throttle X2 Throttle X3 100% Stroke (%)
E
3-23
N PARAMETER DESCRIPTION MIN MAX STEP UNIT

Determines the traction motor torque
12 Trac torque prof Minimum setting = minimum torque 0 4 1
Maximum value = maximum torque
Determines the speed reduction when the battery
13 T 20 BDI cutback reaches 20% 0 100 5 %
Minimum setting = maximum reduction
Maximum setting = no reduction
Determines the speed reduction when the battery
14 T 10 BDI cutback reaches 10% 0 80 5 %
Determines the speed reduction of turtle function
15 T turtle cutback Minimum setting = maximum reduction 5 100 5 %
This parameter determines the traction speed
reduction in relation to the state of the microswitch
(normally closed N.C.) between pin 11 connector
T speed cutback1 CN1 and the GND of one of the micros on the
16 Reduction available only MCB board: 0 100 5 %
for version with electro- microswitch open = reduction on
proportional spool valve microswitch closed = reduction off
(Image reference 2)
This parameter determines traction speed
reduction in relation to the state of microswitch
(normally open N.O.) between pin 18 connector
CN1 and the GND of one of micros on MCB board:
17 T speed cutback2 microswitch open = reduction disabled 0 100 5 %
microswitch closed = reduction on
(Image reference 2)
SIMPLE WIRING DIAGRAM

CN 12 CN 2
J53 1 1
2 2
1
3 3
2
4 4
3
5 5
N .C . 4
5
6 6
7 7
6
8 8
7
9 9
GM
8
10 10
9
10
11
12
T speed cutback1 11
12
11
13 13
12
14 14
13
15 15
14
16 16
LN 17 17
J49/B 18
19
T speed cutback2 18
19
1 20 20
2 21 21
3 22 22
4 23 23
N.O. 24 24
5
6
7
8
9
25
26
27
28
MCB 25
26
27
28
10 29 29
11 30 30
12
13
N 31
32
31
32
14 33 33
34 34
35 35
IMAGE 2
3-24

This parameter determines the deceleration ramp
18 T curve dec del between the steering angle defined by "Angle Inc" 0.4 3.0 0.2 Sec
and the steering angle defined by "Angle Max"
(Image reference 3)
0
This parameter determines the steering angle
19 Angle start 0 10 1 °a
without speed reduction
(Image reference 3)
1
Starting from "Angle start" this parameter 2
determines a steering angle on reaching which a
speed reduction is activated, the maximum value
20 Angle inc
of which is defined by the parameter "% curve
12 35 1 °a 3
cutback inc"
Determines the steering angle in which the
21 Angle max maximum speed reduction is defined 50 90 1 °a
5
by the parameter “Curve cutback max”
This parameter determines the speed reduction on
reaching the steering angle defined by "Angle Inc" 7
and it is a percentage of the speed reduction fixed
22 % Curve cutb inc 10 100 5 %
by the parameter "Curve cutback max"
8
This parameter determines the maximum curve
speed reduction on reaching the angle fixed by the 10
parameter "Angle Max". Modifying this parameter
23 Curve cutback max also affects the parameter "%curve cutback inc" 4 100 2 % 11
(Image reference 3)
12
GRAPH OF SPEED REDUCTION ON A CURVE 13
14
15
16
Tc
urv
e dec
del
17
18
19
20
IMAGE 3 21
E
3-25

This determines the speed reduction on closing
24 T brake cutback the micro-switch of the service brake pedal. 0 100 5 %
Minimum setting = minimum deceleration
Maximum setting = maximum deceleration
Determines the deceleration ramp when the brake
25 Pedal brk pedal is pressed 1.0 10.0 0.1 Sec
Determines the deceleration ramp when the
26 Speed limit brk accelerator pedal is partially released 1.0 20.0 0.5 Sec
27 Inversion brk direction is inverted 1.0 10.0 0.1 Sec
28 Release brk accelerator pedal is released. 1.0 10.0 0.1 Sec
3-26
MAT. HANDLING
The Mat. The Handling function is used to view/modify the hydraulic system parameters.
Determines the minimum lifting speed
1 Min speed up Minimum setting = minimum speed 5 25 2 Hz 0
Maximum value = maximum speed
Determines the maximum lifting speed 1
2 Max speed up Minimum setting = minimum speed 50 120 5 Hz
Maximum value = maximum speed 2
Determines the maximum tilting speed
3 Tilt speed fine Minimum setting = minimum speed 18 90 2 Hz 3
4 Shift speed fine

Determines the maximum sideshift speed
18 90 2 Hz
4
Minimum setting = minimum speed
Determines the maximum 4th way speed
5
5 IV way speed fine Minimum setting = minimum speed 18 90 2 Hz
Maximum value = maximum speed 6
Determines the maximum 5th way speed
6 V way speed fine Minimum setting = minimum speed 18 90 2 Hz 7
Determines the frequency supplied to the pump 8
7 Hydro speed fine motor to the hydraulic steering system 0 40 2 Hz
Minimum setting = slow steer
Maximum value = Fast steer
9
8 P turtle cutback
Determines the speed reduction of the turtle function
Minimum setting = maximum reduction 5 100 5 %
10
11
12
13
14
15
16
17
18
19
20
21
E
3-27

This parameter determines the speed reduction for
the hydraulic functions in relation to the state of the
microswitch (normally closed N.C.) between pin 11
connector CN1 and the GND of one of the micros on 0
9 P cutback speed1 the MCB board: 0 100 5 %
microswitch open = reduction on 1
microswitch closed = reduction off
2
(Image reference 4)
This parameter determines the speed reduction for 3
the hydraulic functions in relation to the state of the
microswitch (normally open N.O.) between pin 18 4
connector CN1 and the GND of one of the micros on
10 P cutback speed2 the MCB board: 0 100 5 % 5
microswitch open = reduction on
microswitch closed = reduction off
6
SIMPLE WIRING DIAGRAM
8
CN 2 CN 2
J53
1
1
2
3
1
2
3
9
2
4 4
3
5 5
NC
. . 4
5
6
7
6
7
8
6
7
8
10
9 9
8
9 GM 10 10
P cutback speed1
10
11
12
11
12
13
11
12
13
11
14 14
13
15 15
14
J49/B
LN
16
17
18 P cutback speed2
16
17
18
12
19 19
1 20 20
2
3
4
5
21
22
23
21
22
23
13
NO
. . 24 24
6
7
8
9
25
26
27
28
MCB 25
26
27
28
14
10 29 29
11 30 30
12 N 31 31
13
14
32
33
34
32
33
34
15
35 35
16
IMAGE 4
Determines the speed reduction for the hydraulic 17
11 P 20 BDI cutback functions when the battery reaches 20% 0 100 5 %
Minimum setting = maximum reduction 18
Determines the speed reduction for the hydraulic 19
12 P 10 BDI cutback functions when the battery reaches 10% 0 80 5 %
20
21
E
3-28

Determines the acceleration ramp of the pump motor
13 P acc delay Minimum setting = maximum acceleration 0.5 25.0 0.5 Sec
Maximum setting = minimum acceleration
P dec delay Determines the deceleration ramp of the pump motor
Only for version with
14 Minimum setting = maximum acceleration 0.5 25.0 0.5 Sec
electro-proportional
Maximum setting = minimum deceleration
distributor
P throttle 0 This parameter determines a 0 value zone in the
15 Only for version with acceleration bend 0 12 2 %
mechanical distributor (Image reference 5)
P throttle X Determines an X value zone in the acceleration
16 Only for version with curve 10 100 10 %
P throttle Y Determines an Y value zone in the acceleration
17 Only for version with curve 10 100 10 %
LIFTING POTENTIOMETER CURVE
MAX SPEED UP
AY
DEL
P THROTTLE Y CC
PA
MIN SPEED UP
V
VPOT MIN. P THROTTLE 0 P THROTTLE X VPOT MAX.
IMAGE 5
Determines the pump motor torque

18 Pump torque prof Minimum setting = minimum torque 0 4 1
Maximum value = maximum torque
3-29

Curve mode Determines the sensitivity of the joystick according to
Only for version the potentiometer stroke
19 with electro- Minimum setting = very sensitive 0 3 1 ---
proportional Maximum setting = insensitive 0
distributor (Image reference 6)
1
LIFTING POTENTIOMETER CURVE FINGERTIPS/JOYSTICK
CURVE MODE 0 2
% EVP % RPM
100 100 3
4
5
10 50 40 90
% POT % POT
6
CURVE MODE 1 7
% EVP % RPM
100 100 8
9
10
10 40 30 90
% POT % POT
11
CURVE MODE 2 12
% EVP % RPM
100 100 13
14
15
10 30 20 90
% POT % POT
16
CURVE MODE 3 17
% EVP % RPM
100 100 18
60
19
20
20
10 40 50 35 70 90
% POT % POT
21
IMAGE 6
E
3-30
TRUCK CONF

PROCEDURE paragraph]
Press till reach the TRUCK CONF menu

Press OK to confirm
TRUCK CONF
Use and to select the required menu

TRUCK CONF
Press OK to confirm
OPTIONS
Use or to navigate inside the menu and select the

OPTIONS required parameter
PARAMETER Press OK to confirm
Press or to modify the value

PARAMETER
Press OK to confirm
OFF
Press OK to save; on the display the message SAVE

PARAMETER SUCCESSFUL appears, therefore press OUT to return to the
menu
OFF
SAVE? Press OK to exit without saving
OK OUT
3-31
TRUCK CONFIGURATION MENU MAP
1 - PROFILE 13 - HIGH MAST

2 - SET 14 - HIMAST SPLM 0
3 - LOC ET 15 - CURVE ACC ENAL
4 - START ICN 16 - STEER ACC DELAY
5 - PIN CODE 17 - STEER THRESHOLD 1
6 - DY PIN ENABLE 18 - AUX FUNCTION P
OPTION 7 - SWAYING PEDAL 19 - AUX OUT VOLT P
8 - TEST MODE 20 - AUX RID P 2
9 - VTH ENABL 21 - KEYS TONE
10 - CLAMPS
11 - GEAR RTO
22 - HYDRO DELYACC
23 - HYDRO DELAY BRK
3
12 - STOP ON RAP
PLEASE INSERT 4
SERV. PASSWORD
1 - SLIP RH 5 - P MAX CURRENT
5
2 - SLIP LH 6 - TRAC SENS TEM
MOTORS 3 - SLIP PUP
4 - T MAX CURET
7 - PUMP SENS TEMP 6
SOFT VERS 7
1 - OUT1 BLINK 9 - OUT2 FW 8
2 - OUT1 FW + BW 10 - OUT2 BW
OUTPUT
3 - OUT1 ANY PUMP
4 - OUT1 SEAT
11 - OUT2 ANY PUMP
12 - OUT2 SEAT 9
PARAM CHANGE MCB 5 - OUT1 JOY 1 13 - OUT2 JOY 1
6 - OUT1 JOY 2
7 - OUT1 JOY 3
14 - OUT2 JOY 2
15 - OUT2 JOY 3
10
8 - OUT1 JOY 4 16 - OUT2 TURTE
11
TRUCK CONF
1 - RESET JOY FLAG
12
2 - RESET PUMP HM
RESET 3 - RESET TRAC HM 13
4 - RESET KEY HM
14
1 - BDI TO 100 % 5 - ADJUSTMENT 3 15
2 - BDI RESET 6 - BDI GEL
BATTERY 3 - BDI ADJ MIN
4 - BDI ADJ MAX 16
17
1 - MIN CURR LOW
2 - MIN CURR LIFT
9 - MAX CURR LOW
10 - MAX CURR LIFT
18
3 - MIN CURR TILT FW 11 - MAX CURR TILT FW
VALVE 4 - MIN CURR TILT BW 12 - MAX CURR TILT BW 19
CURRENT 5 - MIN CURR SSH LH 13 - MAX CURR SSH LH
6 - MIN CURR SSH RH 14 - MAX CURR SSH RH
7 - MIN CURR 4 WAY 1 15 - MAX CURR 4 WAY 1 20
8 - MIN CURR 4 WAY 2 16 - MAX CURR 4 WAY 2
21
E
3-32
OPTIONS FUNCTION
The options function is used to enable/disable the machine configuration options.
N. Parameter Description Notes

1 Profile This parameter determines the profile loaded at the start up 0,1,2,3,4
2 Set Select the setting [L-P-H] L,P,H
This parameter enables/disables the LPH push button working:
3 Lock set ON = enabled ON-OFF
OFF = disabled
This parameter determines which logo must be visualized at the
4 Start icon Cesab-BT
starting
This parameter enables/disables the Pin insertion request:
5 Pin code NONE = disabled
DISPLAY = enabled
6 DY Pin enable This parameter determines the number of Pin Codes used 1÷40
This parameter enables/disables with balanced pedal system
ON = enabled
7 Swaying pedal OFF = disabled ON-OFF
Note: if the parameter is modified the traction potentiometer acquisition must be
repeated
This parameter allows

• Activation of the lifting motor, keeping it at a constant rotation
8 Test mode speed (power steering function frequency) ON-OFF
• 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 5 way lever working
9 VTH enable ON = enabled ON-OFF
OFF = disabled
This parameter enables/disables the functioning of the button PB5
(enabling optional equipment)
10 Clamps ON-OFF
ON = enabled
OFF = disabled
This parameter determines the reduction ratio of the reduction gear
11 Gear ratio n°
in relation to the truck speed calculus
This parameter enables/disables the truck automatic braking
12 Stop on ramp ON = enabled ON-OFF
OFF = disabled
Enables/Disables the reduction in speed for masts higher than
6250mm
13 High mast The maximum speed is set by the parameter HIMAST SP LIM ON-OFF
Note: when the parameter is set to ON the MAX SPEED FW & BW parameter is not
useable
If High mast is enabled, determines the maximum speed in

14 Himast Sp lim Hz
forward or reverse in the case of a mast higher than 6250mm
This parameter enables/disables the following functions:
15 Curve acc delay - STEER ACC DELAY ON-OFF
- STEER THRESHOLD
3-33

This parameter determines the acceleration with steered direction
16 Steer acc delay wheels (the steering angle can be selected by the STEER Sec.
THRESHOLD parameter)
This parameter determines the direction wheels angle beyond which 0
17 Steer threshold a°
the COMP STEER ACC parameter is enabled
18 Aux function P Enables/Disables the pump auxiliary output (JP connector pin18) ON-OFF
1
19 Aux out volt P Voltage of the pump auxiliary output (JP connector pin18) expressed % 2
as a percentage of the battery voltage
20 Aux out rid P Holding voltage of the pump auxiliary output (JP connector pin18) % 3
expressed as a percentage of AUX OUT VOLT P
21 Keys tone Enables/Disables keypad tones ON-OFF 4
Determines the delay of the power steering turning off when the
22 Hydro delay acc
accelerator pedal is released
Sec. 5
23 Hydro delay brk
Determines the delay of the power steering turning off when the
brake pedal is released
Sec. 6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-34
MOTORS FUNCTION
The motors function is used to enable/disable the electric motor parameters.

This parameter enables/disables the right traction motor encoder
control:
1 SLIP RH ON-OFF
ON = enabled
OFF = disabled
This parameter enables/disables the left traction motor encoder con-
trol:
2 SLIP LH ON-OFF
ON = enabled
OFF = disabled
Enables/disables the
lifting motor encoder control
3 SLIP PUMP ON-OFF
ON = enabled
OFF = disabled
Determines the traction motor current expressed in
percentage of the maximum current:
4 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:
5 P MAX CURRENT %
- minimum setting = minimum voltage
- maximum setting = maximum voltage
This parameter enables/disables the lifting motor temperature
sensor
6 TRAC SENS TEMP ANALOG = analog
DIGITAL = digital
NONE = disabled
This parameter enables/disables the lifting motor temperature
lifting motor encoder control
7 PUMP SENS TEMP ANALOG = analog
DIGITAL = digital
NONE = disabled
3-35
MCB OUTPUT FUNCTION

Enables and disables the MCB outputs.
If the truck is equipped with the direction indicators option the output CN2 pin 31 (OUT1) will not be available

0
Enables/Disables the 24V output with activation of the direction
1 OUT1 BLINK
indicator (connector CN2 pin 31 of the MCB card)
ON-OFF
1
ON = enabled
OFF = disabled
Characteristics of the electric applicable load: +24V/ 42W
2
Enables/Disables the 24V output with activation of the direction of 3
travel (connector CN2 pin 31 of the MCB card)
2 OUT1 FW+BW ON = enabled ON-OFF 4
OFF = disabled
Characteristics of the electric applicable load: +24V/ 42W 5
Enables/Disables the 24V output with activation of any hydraulic
function except for the power steering (connector CN2 pin 31 of the 6
3 OUT1 ANY PUMP MCB card) ON-OFF
ON = enabled 7
OFF = disabled
Enables/Disables the 24V output with activation of the seat
microswitch (connector CN2 pin 31 of the MCB card) 9
4 OUT1 SEAT ON = enabled ON-OFF
OFF = disabled 10
Enables/Disables the 24V output with activation of the 5th way 11
(connector CN2 pin 31 of the MCB card)
5 OUT1 JOY 1 ON = enabled ON-OFF 12
OFF = disabled
Enables/Disables the 24V output with activation of the JAUX function
pin 7 (connector CN2 pin 31 of the MCB card) 14
6 OUT1 JOY 2 ON = enabled ON-OFF
OFF = disabled 15
Enables/Disables the 24V output with activation of the JAUX function 16
pin 8 (connector CN2 pin 31 of the MCB card)
7 OUT1 JOY 3 ON = enabled ON-OFF 17
OFF = disabled
pin 9 (connector CN2 pin 31 of the MCB card) 19
OFF = disabled 20
21
E
3-36

Enables/Disables the 24V output with activation of the forward
direction of travel (connector CN2 pin 23 of the MCB card)
9 OUT2 FW ON = enabled ON-OFF
OFF = disabled
Enables/Disables the 24V output with activation of the reverse
direction of travel (connector CN2 pin 23 of the MCB card)
10 OUT2 BW ON = enabled ON-OFF
OFF = disabled
Enables/Disables the 24V output with activation of any hydraulic
function except for the power steering (connector CN2 pin 23 of the
11 OUT2 ANY PUMP MCB card) ON-OFF
ON = enabled
OFF = disabled
Enables/Disables the 24V output with activation of the seat
microswitch (connector CN2 pin 23 of the MCB card)
12 OUT2 SEAT ON = enabled ON-OFF
OFF = disabled
Enables/Disables the 24V output with activation of the 5th way
(connector CN2 pin 23 of the MCB card)
OFF = disabled
OFF = disabled
OFF = disabled
Enables/Disables the 24V output with activation of the tortoise
function (connector CN2 pin 23 of the MCB card)
16 OUT2 TURTLE ON = enabled ON-OFF
OFF = disabled
3-37
RESET FUNCTION
Reset of the hours counter and Fingertips-Joystick configuration
1 RESET JOY FLAG

MCB board configuration reset 0
(Mechanical/electro-proportional distributor)
2 RESET PUMP HM Pump hours counter reset 1
3 RESET TRAC HM Traction hours counter reset
2
4 RESET KEY HM Key hours counter reset
3
BATTERY FUNCTION
Used to modify the battery indicator parameters. 4
N. Parameter Description Notes 5
This parameter allows the immediate rearmament of the battery
1 BDI TO 100%
indicator 6
2 BDI RESET
This parameter determines the adjustment of the reset threshold
when a charge is required with the battery state between 70% and %
7
90%
8
This parameter determines the set point of the discharging voltage.
It fixes the minimum battery voltage corresponding to the 9
3 BDI ADJ MIN last mark of the indicator switching off (indicator on 0%). V
(See chapter 1, paragraph ADJUSTING THE BATTERY AND THE 10
INDICATOR)
This parameter determines the set point of the charging voltage. 11
It fixes the battery voltage at which the first two squares of the bat-
4 BDI ADJ MAX tery indicator switch off (indicator at 90%).
(See chapter 1, paragraph ADJUSTING THE BATTERY AND THE
V 12
INDICATOR)
13
This determines the necessary voltage to reset
5 ADJUSTMENT 3
the battery indicator on the display.
V 14
(See chapter 1, paragraph ADJUSTING THE BATTERY AND THE
INDICATOR) 15
This parameter enables the discharge curve of in case of GELbat-
6 BDI GEL ON/OFF
tery 16
17
18
19
20
21
E
3-38
VALVE CURRENT FUNCTION

Displays and modifies the currents of the solenoid valves of the electro-proportional distributor.

This parameter determines the min. current to the lower coil 0
1 MIN CURRENT LOW min. = 100 mA mA
max. = 500 mA 1
This parameter determines the min. current to the lift coil
2 MIN CURRENT LIFT min. = 100 mA mA 2
max. = 500 mA
This parameter determines the min. current to tilt fw coil 3
3 MIN CURRENT TILT FW min. = 100 mA mA
max. = 500 mA 4
This parameter determines the min. current to the tilt bw coil
4 MIN CURRENT TILT BW min. = 100 mA mA 5
max. = 500 mA
This parameter determines the min. current to the side shift lh
6
coil
5 MIN CURRENT SSH LH
min. = 100 mA
mA 7
max. = 500 mA
8
This parameter determines the min. current to the side shift rh
coil
6 MIN CURRENT SSH RH
min. = 100 mA
mA 9
max. = 500 mA
10
This parameter determines the min. current to the 4°way coil
7 MIN CURRENT 4 WAY 1 min. = 100 mA
max. = 500 mA
mA 11
This parameter determines the min. current to the 4°way coil 12
8 MIN CURRENT 4 WAY 2 min. = 100 mA mA
max. = 500 mA 13
This parameter determines the min. current to the lower coil
9 MAX CURRENT LOW min. = 600 mA mA 14
max. = 1500 mA
This parameter determines the max. current to the lift coil 15
10 MAX CURRENT LIFT min. = 600 mA mA
max. = 1500 mA 16
This parameter determines the max. current to tilt fw coil
11 MAX CURRENT TILT FW min. = 600 mA mA 17
max. = 1500 mA
This parameter determines the max. current to the tilt bw coil
18
12 MAX CURRENT TILT BW min. = 600 mA mA
max. = 1500 mA
19
This parameter determines the max. current to the side shift lh 20
coil
13 MAX CURRENT SSH LH mA
min. = 600 mA
max. = 1500 mA
21
E
3-39

This parameter determines the max. current to the side shift rh
coil
14 MAX CURRENT SSH RH mA
min. = 600 mA
max. = 1500 mA 0
This parameter determines the max. current to the 4° way coil
15 MAX CURRENT 4 WAY 1 min. = 600 mA mA 1
max. = 1500 mA
This parameter determines the max. current to the 4° way coil
2
16 MAX CURRENT 4 WAY 2 min. = 600 mA mA
max. = 1500 mA 3
Valve
4
Total valve opening 5
6
100%
7
8
Zone not to be used
9
10
100 200 500 600 700 1500 mA
11
MIN CURR MAX CURR 12
MIN CURR:
13
Increasing or decreasing the value affects the sensitivity of the fingertip control in the
initial phase. 14
MAX CURR:
Increasing or decreasing the value affects the maximum opening of the valve. 15
16
17
18
19
20
21
E
3-40
SERVICE RENT
The SERVICE RENT function is used to set a time interval (days or hours of pump operation) after which
the display cuts in speed reductions.
0
1
2
NO REDUCTIONS NO REDUCTIONS NO REDUCTIONS
3
PERFORMANCE
WARNING WARNING 4
ON ON
SWITCH ON SWITCH ON
WARNINGS 5
ON THE DISPLAY
WARNING
FIXED 6
REDUCTIONS ACTIVE
ON THE DISPLAY
7
WORK HOURS/DAYS
8
9
10
11
12
Press till reach the SERVICE RENT menu 13
Press OK to confirm
Use right and left arrows board buttons to navigate the menu 14
SERVICE RENT
Press OUT to exit the menu 15
16
17
18
19
20
21
E
3-41
SERVICE RENT MENU MAP
0
1
2
PLEASE INSERT 3
SERV. PASSWORD 4
5
SOFT VERS 6
7
8
PARAM CHANGE
9
10
TRUCK CONF 11
12
SERVICE RENT 13
14
1 - SERV TIMER EN WITH “RENT TIME/DAY” = DAY
15
2 - RESET SERV HM 12 - RESET RENT HM
3 - SERV REQ TIME 13 - RENT REQ TIME 16
4 - SERV TIME BLIK 14 - RENT TIME BLINK
5 - SERV CUT TIME 15 - RENT CUT TIME 17
6 - T SERV CUTBACK
7 - P SERV CUTBACK
WITH “RENT TIME/DAY” = DAY
12 - RENT END DAY
18
8 - RENT TIMER EN
13 - RENT DAY BLINK
9 - RENT TIME/DAY
14 - RENT CUT DAY 19
10 - T RENT CUTBACK
11 - P RENT CUTBACK
20
21
E
3-42
N. Function Description Notes

SERV TIMER EN Enables/disables the
1
(service timer enable) programmed maintenance timer
RESET SERV HM 0
2 (reset service This function resets the SERV TIMER EN timer
hour meter) 1
When the set
SERV REQ TIME
This function determines the maintenance interval:
time expires the 2
3 A reference (PROGRAMMED MAINTENANCE
(service request time) red led starts to
DIAGRAM)
blink 3
Spanner icon and
SERV TIME BLINK
SERV REQ TIME expired notice: red led 4
4 C reference (PROGRAMMED MAINTENANCE flash when the
(service time blink)
DIAGRAM) truck is switched 5
on
This function determines, SERV REQ TIME expired, 6
after how much time the truck enters in limited working
SERV CUT TIME
5
(service cutback time)
system: 7
B reference (PROGRAMMED MAINTENANCE
DIAGRAM)
8
Sets the percentage of
T SERV CUTBACK traction system reduction when the SERV REQ TIME 9
6 (traction service expires:
cutback) D reference (PROGRAMMED MAINTENANCE
DIAGRAM)
10
P SERV CUTBACK
This function sets the percentage of working reduction 11
when SERV CUT TIME is expired;
7 (pump service
cutback)
D reference (PROGRAMMED MAINTENANCE 12
DIAGRAM)
8
RENT TIMER EN This function enables/disables the timer of the rental 13
(rental timer enable) duration
This function determines (selects) the Timer Rent WH = hours 14
9 RENT TIME/DAY working in hours or days; if the DAY function is selected DAY = days
it is not possible to modify the date in the USER menu 15
T RENT CUTBACK Sets the percentage of
10 (traction rental traction system reduction when the RENT CUT TIME or 16
cutback) RENT CUT DAY expires
P RENT CUTBACK Sets the percentage of
17
11 (pump rental lifting system reduction when the RENT CUT TIME or
cutback) RENT CUT DAY expires
18
RESET RENT HM 19
12 (reset rental This function resets the timer RENT TIMER EN
hour meter) 20
This function determines the rent interval;
RENT REQ TIME
13
(rental request time)
A reference (PROGRAMMED 21
RENT DIAGRAM)
E
3-43
N. Function Description Notes

RENT icon and
RENT REQ TIME expired notice:
RENT TIME BLINK red led flash
14 C reference (PROGRAMMED RENT DIAGRAM)
(rental time blink) when the truck is
RENT DIAGRAM)
switched on 0
This function determines, RENT REQ TIME expired,
RENT CUT TIME
15
(rental cutback time)
after how much time the truck enters in limited working 1
system
12 RENT END DAY

Defines the day in which the Rent time expires; 2
A reference (PROGRAMMED with DAY selected)
This function determines, RENT END DAY expired, Max duration15 3
after how much time the truck enters in limited working days
13 RENT DAY BLINK system 4
C reference (PROGRAMMED RENT DIAGRAM)
with DAY selected 5
This function defines activation time of speed reduc- Max duration15
14 RENT CUT DAY
tion; B reference (PROGRAMMED RENT DIAGRAM) days 6
PROGRAMMED MAINTENANCE DIAGRAM 7
During this interval the icon and the During this interval the icon and the
red led start blinking at the truck ignition red led start are always lit 8
C A B
100% 9
Lifting 30% of the max speed
Traction 30% of the max speed
10
11
D
30% 12
13
0 480 500 520 t (wh)
(STEP±1) (STEP±50) (STEP±5) 14
PROGRAMMED RENT DIAGRAM
Speed (Hz) During this interval the RENT icon and the During this interval the RENT icon
15
red led start blinking at the truck ignition and the red led are always on
C A B
16
100%
Lifting 30% of the max speed
17
Traction 30% of the max speed
18
19
D
30%
20
0 480 500 520 t (wh) 21
(STEP±1) (STEP±100) (STEP±1)
E
3-44
PSW MODIFY
The PSW MODIFY function is used to associate profiles and modify the truck switch on code passwords.

[see SERVICE MENU PASSWORD INSERTION 0
1
2
Press till reach the PSW MODIFY menu 3
Press OK to confirm
4
PSW MODIFY
Press OK to enter parameters modification and follow the 5
instructions visualized on the display
7
Function Description Notes
This function allows to modify pin code and related Code = switch on code 8
profile
PR = profile associated to the 9
PSW CHANGE switch on code
CHANGE 10
CODE PR
00323 0 11
12
Reset all the default passwords Reference to the
DEFAULT
PIN CODE table 13
14
15
16
17
18
19
20
21
E
3-45
PSW MODIFY MENU MAP
0
1
2
PLEASE INSERT 3
SERV. PASSWORD 4
5
SOFT VERS 6
7
8
PARAM CHANGE
9
10
TRUCK CONF 11
12
SERVICE RENT 13
14
15
PSW MODIFY
16
17
1 - CHANGE 2 - DEFAULT 18
19
20
21
E
3-46
SWITCHING THE TRUCK ON USING THE PIN CODE

The truck can be switched on using a 5-digit pin code by enabling the parameter PIN CODE = DISPLAY
Activating the pin code request, every time the truck is switched the display will request the pin code
insertion.
0
Using the parameter DY PIN ENABLE it is possible to enable from 1 to a maximum of 40 different switch
on codes. 1
The table below shows the 40 standard pin codes and relative associated profiles 2
PIN CODE table 3
ASSOCI- ASSOCI- ASSOCI- ASSOCI-
Re
f.
PIN
CODE
ATED PRO-
Re
f.
PIN
CODE
ATED PRO-
Re
f.
PIN
CODE
ATED PRO-
Re
f.
PIN
CODE
ATED PRO- 4
FILE FILE FILE FILE
1 00323 0 11 11404 0 21 22433 0 31 34132 0

5
2 01034 1 12 12403 1 22 23013 1 32 34343 1 6
3 02021 2 13 13042 2 23 23401 2 33 40010 2
7
4 02102 3 14 14143 3 24 24431 3 34 40143 3
5 03033 4 15 14021 4 25 30001 4 35 41342 4 8

6 03421 0 16 14322 0 26 30204 0 36 41414 0
9
7 04031 1 17 20102 1 27 32040 1 37 42231 1
8 04432 2 18 21020 2 28 33300 2 38 43001 2

10
9 10043 3 19 22010 3 29 33410 3 39 43203 3 11
10 11020 4 20 22344 4 30 34010 4 40 44044 4
12
PROFILE DESCRIPTION
It is possible to modify the performance (traction and hydraulic functions) of the truck by creating up to five
13
different machine profiles (0 - 1 - 2 - 3 - 4), each profile can in turn by modified in L-P-H mode
14
In the standard configuration the machine has all five profiles configured with the same values and when
the truck is switched on Profile 0 is loaded in P mode. 15
To modify the parameters of the various profiles refer to chapter 03 paragraph PARAM CHANGE 16
17
18
19
20
21
E
3-47
TESTER
The tester function is used to view the electronic components present on the truck (current, voltage,
temperature, status, etc.)
Enter the service menu 0

2
3
Press to reach the TESTER menu
4
TESTER Press OK to enter the menu 5

7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-48
TESTER MENU MAP
1-
SPD SET 9-
FW 0
RH MOT SPD NOT FW
2-
SPD SET
LH MOT SPD
10 - BW
NOT BW
1
3 - RH MOT TMP 11 - EN
LH MOT TMP NOT EN 2
4-
RH CTR TMP 12 - TRAC POT
TRACTION LH CTR TMP TRAC ACC
13 - SERVICE BRAKE
3
5 - RH SLIP
PLEASE INSERT LH SLIP 14 - PARKING BRAKE
6 - RH FREQ
15 - MCB VOLT INPUT 4
SERV. PASSWORD LH FREQ 16 - BATTERY VOLTAGE
7 - RH CURR RMS
LH CURR RMS
17 - BATTERY CHARGE
18 - DIR LEVER JOY
5
8 - CFG 19 - STEER ANGLE
6
SOFT VERS
7
8
mechanical distributor version
PARAM CHANGE 1-
LIFE PUMP 7 - LIFT 9
LIFE KEY LIFT POT
8 - TILT
2 - P SPD SET
P MOT SPD 9 - SIDESHIFT 10
10 - IV WAY
3 - P MOT TMP
P CTR TMP
11 - V WAY
11
TRUCK CONF 4 - P SLIP
5 - P FREQUECY
6 - P CURR RMS
12
13
electro-proportional distributor version
SERVICE RENT MAT. HANDLING 1-
LIFE PUMP 12 -
IN6 1 14
LIFE KEY IN6 2
2 - P SPD SET
P MOT SPD
13 -
IN6 3
IN6 4
15
IN6 5
3 - P MOT TMP
PSW MODIFY P CTR TMP
14 -
IN6 6 16
4 - P SLIP LIFT POT
15 -
5 - P FREQUECY
6 - P CURR RMS
LIFT SET
TILT POT
17
16 -
LIFT SW TILT SET
7-
LIFT PB 17 -
SSH POT 18
TESTER 8 - TILT SW
SSH SET
TILT PB
SSH SW
18 - IV POT
IV SET
19
9-
SSH PB 19 - V POT
10 - IV SW
V SET 20
IV PB
11 - V SW
V PB
21
E
3-49
TRACTION FUNCTION
Views the traction system values
Re
Parameter Description Notes
f. 0
SPD SET Theoretical speed requested to the motor Hz
1
RH MOT SPD Frequency encoder right motor Hz
1
2
SPD SET Theoretical speed requested to the motor Hz 2
LH MOT SPD Frequency encoder left motor Hz
RH MOT TMP Right motor temperature C°
3
3
LH MOT TMP Left motor temperature C° 4
RH CTR TMP Temperature of the Master traction logic unit C°
4
LH CTR TMP Temperature of the Slave traction logic unit C°
5
Flowing values of the right motor, or speed difference between rotat- 6
RH SLIP ing magnetic field and motor rotor: Hz
5
RH SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz) 7
Flowing values of the left motor, or the speed difference between
LH SLIP the rotating magnetic field and the motor rotor: Hz 8
LH SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz)
Frequency of the voltage and current applied to the right-hand 9
RH FREQU Hz
6 motor
LH FREQU Frequency of the voltage and current applied to the left-hand motor Hz
10
7
RH CUR RMS Current (RMS) supplied to the right-hand drive motor Amp 11
LH CUR RMS Current (RMS) supplied to the left-hand drive motor Amp
Pedal system input
12
8 CFG 1 = single pedal
2 = double pedal or balanced pedal 13
FW
Forward direction micro
OFF / GND = non-active input, open switch ON-OFF
14
9 ON / +Vb = active input, closed switch
15
NOT FW Denied FW march micro ON-OFF
Reverse direction micro 16
BW OFF / GND = non-active input, open switch ON-OFF
10 ON / +Vb = active input, closed switch 17
NOT BW Denied FW march micro ON-OFF
18
Consent micro state
EN OFF / GND = non-active input, closed switch ON-OFF
11 ON / +Vb = active input, open switch
19
NOT EN Denied consent micro state ON-OFF 20
Accelerator pedal potentiometer
TRAC POT V 21
12 Value in volt of the potentiometer
TRAC ACC Time to reach the maximum speed Sec
E
3-50
Re
f.
Brake pedal microswitch
13 SERV BRK OFF = not active input, open switch ON-OFF
ON = active input, closed switch 0
Parking brake microswitch
14 PARKING BRAKE OFF = not active input, open switch ON-OFF 1
ON = active input, closed switch
Reading of the voltage present on pin 13 of the connector CN2 of
2
15 MCB VOLT INPUT V
the MCB board (EVCB) with respect to the battery negative pole
3
Reading of the voltage present on pin 1 of the connector JT1 by the
16
BATTERY
VOLTAGE
Master traction logic unit with respect to the battery negative pole.
This voltage reading may be set with the parameter ADJUST BAT-
V 4
TERY (see paragraph LEARNING)
5
Percentage value of the battery charge level read by the Master
17 BATTERY CHARGE %
traction logic unit 6
18 DIR JOY FW/BW directions potentiometer on the arm V
19 STEER ANGLE Steering angle in degrees a°
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-51
MAT. HANDLING
Displays the hydraulic system settings for the mechanical version
Re
f. 0
LIFE PUMP Pump working hour counter from the first start Hours
1 1
LIFE KEY Key working hour counter from the first start Hours
P SPD SET Motor theoretical speed requested referred to speed reduction Hz 2
2
P MOT SPD Lifting motor encoder frequency Hz
3
P MOT TMP Pump motor temperature: C°
3
P CTR TMP Temperature of the pump logic unit C° 4
Flowing values of the left motor, or the speed difference between
4 P SLIP the rotating magnetic field and the motor rotor: Hz 5
P SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz)
5 P FREQUENCY Frequency of the voltage and current applied to the pump motor Hz
6
6 P CURR RMS Current supplied to the pump motor A 7
LIFT Lifting microswitch ON-OFF
7
LIFT POT Lifting potentiometer V
8
8 TILT Tilt microswitch ON-OFF 9
9 SIDESHIFT Sideshift microswitch ON-OFF
10 IV WAY IV way microswitch ON-OFF
10
11 V WAY V way microswitch ON-OFF 11
12
13
14
15
16
17
18
19
20
21
E
3-52
MAT. HANDLING
Displays the hydraulic system settings for the electro-proportional version
Re
f. 0
LIFE PUMP Pump working hour counter from the first start Hours
1 1
LIFE KEY Key working hour counter from the first start Hours
P SPD SET Motor theoretical speed requested referred to speed reduction Hz 2
2
P MOT SPD Lifting motor encoder frequency Hz
3
P MOT TMP Pump motor temperature: C°
3
P CTR TMP Temperature of the pump logic unit C° 4
Flowing values of the left motor, or the speed difference between the
4 P SLIP rotating magnetic field and the motor rotor: Hz 5
P SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz)
5 P FREQUENCY Frequency of the voltage and current applied to the pump motor Hz
6
6 P CURR RMS Current supplied to the pump motor A 7
LIFT SW Lifting fingertips/joysticks S1 and S2 microswitches status ON-OFF
7
LIFT PB Auxiliary digital input status (optional): not used OFF
8
8
TILT SW Tilting fingertips/joysticks S1 and S2 microswitches status ON-OFF 9
TILT PB Auxiliary digital input status (optional): not used OFF
SSH SW Tilting fingertips/joysticks S1 and S2 microswitches status ON-OFF
10
9
SSH PB Auxiliary digital input status (optional): not used OFF 11
IV SW 4th way fingertips/joysticks S1 and S2 microswitches status ON-OFF
10
IV PB Auxiliary digital input status (optional): not used OFF
12
11
V SW 5th way fingertips/joysticks S1 and S2 microswitches status ON-OFF 13
V PB 5th way microswitch OFF
IN6 1 Reverse direction micro ON-OFF
14
12
IN6 2 Forward direction micro ON-OFF 15
IN6 3 Button for 4th way activation OFF
13
IN6 4 Unused OFF
16
14
IN6 5 Unused OFF 17
IN6 6 Available lifting speed reduction (optional) OFF
LIFT POT Lifting potentiometer (neutral position 2,45V ± 0,2 V) V
18
15
LIFT SET
Current value requested from the armrest board to the EVCB for
Amp 19
lifting/lowering group
TILT POT Tilting potentiometer (neutral position 2,45V ± 0,2 V) V 20
16 Current value requested from the armrest board to the EVCB for tilt-
TILT SET
ing group
Amp 21
E
3-53
Re
f.
SSH POT Sideshift potentiometer (neutral position 2,45V ± 0,2 V) V
17 Current value requested from the armrest board to the EVCB for
SSH SET
sideshift group
Amp 0
IV POT 4th way potentiometer (neutral position 2,45V ± 0,2 V) V 1
18 Current value requested from the armrest board to the EVCB for the
IV SET Amp
4th way group 2
V POT 5th way potentiometer (neutral position 2,45V ± 0,2 V) V
19
3
Current value requested from armrest board to the EVCB for the 5th
V SET Amp
way group 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-54
ALARMS
The alarms function is used to view the error codes present on the truck in real time and the last 20 errors
memorized in the display
1
2
Press till reach the ALARMS menu 3
Press OK to confirm
Use right and left arrows board buttons to navigate the menu 4
ALARMS
6
REALTIME This function visualizes alarms in real time See diagnostic code list
7
LOGBOOK Used to view/delete the alarms in the memory See diagnostic code list 8
LOGBOOK 9
This function visualizes last 20 alarms saved to move to following
10
error code
CODE YY to move to the next
11
N X WH XX screen linked to the same error
BATT % XX code 12
PIN XXXXX
Code = error code 13
N = order in memory (from 1 to
CODE YY 20) 14
TM DRV TMP + XX C WH = pump working hours
BATT = charge percentage 15
TM MOT TMP + XX C PIN = operator pin code
READ TM DRV TMP = master trac-
tion control unit temperature
16
CODE YY TM MOT TMP = right-hand
TS DRV TMP + XX C drive motor temperature 17
TS DRV TMP = slave traction
TS MOT TMP + XX C control unit temperature 18
TS MOT TMP = left-hand drive
CODE YY motor temperature 19
P DRV TMP = pump control
P DRV TMP + XX C unit temperature 20
P MOT TMP = pump motor
P MOT TMP + XX C temperature 21
CLEAR This function deletes alarm list E
3-55
ALARMS MENU MAP
0
1
2
PLEASE INSERT
3
SERV. PASSWORD
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
REALTIME LOGBOOK
19
20
1 - READ 2 - CLEAR
21
E
3-56
LEARNING
The learning function is used to memorize in the various cards and logic units the minimum and maximum
traction, lifting, steering potentiometer settings and to indicate the battery voltage and truck serial number
1
2
Press till reach the LEARNING menu
3
Press OK to confirm
4
LEARNING Press OK to enter parameters modification and follow the 5
instructions visualized on the display
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-57
ALARMS MENU MAP
0
1
2
PLEASE INSERT
3
SERV. PASSWORD
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
LEARNING 18
19
1 - SERIAL NUMBER 5 - SET STEER ZERO
2 - LEARN TRAC POT 6 - SET STEER RIGHT 20
3 - LEARN LIFT POT 7 - SET STEER LEFT
4 - ADJUST BATTERY
21
E
3-58
Re
f.
This function identifies the truck serial number Acquisition of the serial
number must be
LEARNING repeated every time 0
that a card or a logic
SERIAL NUMBER unit is replaced from 1
the carriage.
2
OK To enter in the menu
3
SERIAL NUMBER 4
000XXXXXX
5
CHANGE ?
To confirm and start

6
OK acquisition
7
1 SERIAL NUMBER
SERIAL NUMBER
8
000XXXXXX
9
To select the field 10
To select the field
11
OK To end acquisition
12
SERIAL NUMBER 13
LEARN
SUCCESSFUL 14
15
OUT To return to the first screen
16
17
18
19
20
21
E
3-59
Re
f.
Accelerator potentiometer acquisition The traction potentiom-
eter acquisition
LEARNING must be repeated 0
whenever the MCB
LEARN TRAC POT card or
potentiometer is
1
replaced.
2
To enter the menu and
OK start acquisition If the
display does not 3
LEARN TRAC POT save the acquisition
data, 4
PRESS FW PED AND repeat the SERIAL
RELEASE THEN BW
PED AND RELEASE
NUMBER acquisition 5
and afterwards repeat
2 LEARN TRAC POT THEN PRESS OK all the remaining
acquisitions
6
Press the accelerator pedal (forwards)
to the limit and release slowly
Repeat the operation with 7
the backwards pedal (if present on the truck)
OK To end acquisition
8
9
LEARN TRAC POT
LEARN 10
SUCCESSFUL
11
12
13
14
15
16
17
18
19
20
21
E
3-60
Re
f.
Lifting potentiometer acquisition The lifting potentiome-
ter acquisition
LEARNING is 0
available only on ver-
LEARN LIFT POT sions with
a lever-operated
1
mechanical spool valve
2
To enter the menu and
OK start acquisition The lifting potentiome-
ter acquisition 3
LEARN LIFT POT must be repeated
whenever the 4
PULL LIFT LEVER MCB card or the poten-
TO THE END
PED AND RELASE
tiometer is replaced. 5
3 LEARN LIFT POT THEN PRESS OK If the
display does not
6
Pull the lifting lever to save the acquisition
to the limit and release slowly
data,
7
repeat the SERIAL
OK To end acquisition NUMBER acquisition 8
and afterwards repeat
all the remaining 9
LEARN LIFT POT acquisitions
LEARN 10
SUCCESSFUL
11
12
13
14
15
16
17
18
19
20
21
E
3-61
Re
f.
Parameter used to set the voltmeter inside the Master See chapter 1, para-
traction logic unit for reading the battery voltage graph ADJUSTING
LEARNING
THE BATTERY AND 0
THE INDICATOR
ADJUST BATTERY If the

1
display does not
save the acquisition 2
data,
OK To enter the menu and
start acquisition repeat the SERIAL 3
NUMBER acquisition
ADJUST BATTERY
and afterwards repeat 4
all the remaining
48.6 V
acquisitions 5
ADJUST
4
BATTERY 6
To modify the setting 7
OK To end acquisition 8
ADJUST BATTERY
9
LEARN 10
SUCCESSFUL
11
12
13
14
15
16
17
18
19
20
21
E
3-62
Re
f.
Steering potentiometer acquisition in central position The steering potenti-
(direction wheels straight) ometer acquisition
LEARNING
must be repeated 0
whenever the master
traction logic unit or
SET STEER ZERO potentiometer is
1
replaced.
2
If the
start acquisition display does not save 3
the data
SET STEER ZERO
of the acquisition, 4
repeat the SERIAL
PLEASE TURN THE
NUMBER acquisition 5
WHEELS STRAIGHT and afterwards repeat
5 SET STEER ZERO THEN PRESS OK all the remaining
acquisitions
6
7
To center the steering wheels
8
SET STEER ZERO
10
LEARN 11
SUCCESSFUL
MATCH X.XX V 12
13
14
15
16
17
18
19
20
21
E
3-63
Re
f.
Steering potentiometer acquisition in right limit switch The steering potenti-
position (steering wheels turned fully to the right) ometer acquisition
LEARNING
must be repeated 0
whenever the master
SET STEER RIGHT potentiometer is
1
replaced.
2
If the
start acquisition display does not 3
save the acquisition
SET STEER RIGHT
data, repeat the 4
SERIAL NUMBER
PLEASE TURN THE
acquisition and 5
WHEELS TO RIGHT afterwards repeat all
6 SET STEER RIGHT THEN PRESS OK the remaining
acquisitions
6
To place the steering wheels
7
fully to the right
8
SET STEER RIGHT
10
LEARN 11
SUCCESSFUL
MATCH X.XX V 12
13
14
15
16
17
18
19
20
21
E
3-64
Re
f.
Steering potentiometer acquisition in left limit switch The steering potenti-
position (steering wheels turned fully to the left) ometer acquisition
LEARNING
must be repeated 0
whenever the master
SET STEER LEFT potentiometer is
1
replaced.
2
If the
start acquisition display does not 3
save the acquisition
SET STEER LEFT
data, repeat the 4
SERIAL NUMBER
PLEASE TURN THE
acquisition and 5
WHEELS TO LEFT afterwards repeat all
7 SET STEER LEFT THEN PRESS OK the remaining
acquisitions
6
To place the steering wheels
7
fully to the left
8
SET STEER LEFT
10
LEARN 11
SUCCESSFUL
MATCH X.XX V 12
13
14
15
16
17
18
19
20
21
E
3-65
DEFAULT RST

1
2
Press till reach the DEFAULT RST menu
Press OK to confirm 3
DEFAULT RST 4
Press OK to enter parameters modification and follow the
instructions visualized on the display 5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-66
DEFAULT RST 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
PSW MODIFY 12
13
TESTER 14
15
ALARMS 16
17
LEARNING 18
19
DEFAULT RST
20
1 - EVCB
2 - TRCB
5 - SLAVE
6 - PUMP
21
3 - ARMREST 7 - DISPLAY
4 - MASTER E
3-67
Re
f.
See paragraph
NECESSARY ADJUSTMENTS
1 EVCB This function allows to reset the EVCB board
AFTER A HARDWARE COMPO- 0
NENT REPLACED
See paragraph
1
2 TRCB This function allows to reset the TRCB board
AFTER A HARDWARE COMPO-
NENT REPLACED 2
3 ARMREST Used to reset the arm rest card
See paragraph
3
This function allows to reset the MASTER traction NECESSARY ADJUSTMENTS
4 MASTER
logic AFTER A HARDWARE COMPO- 4
NENT REPLACED
This function allows to reset the SLAVE traction 5
5 SLAVE
logic
6 PUMP This function allows to reset the PUMP logic
6
See paragraph
7
7 DISPLAY This function allows to reset the DISPLAY
AFTER A HARDWARE COMPO-
NENT REPLACED 8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
3-68
“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
Manual reverser in selected direction Pedal system Traction: NO
position single Lifting: YES:
6
Hydraulic request during the starting BOARD Traction: NO 7
procedure microswitch Lifting: NO
8
Hydraulic request during the starting pro-
Electric distributor
Traction: NO 9
cedure Lifting: NO
10
Double pedal system
Traction: NO
Double drive request signal or balanced pedal
Lifting: YES: 11
system
12
Direction request with Traction: NO
All
parking brake on Lifting: NO 13
Seat micro opened during movement or Traction: NO 14
All
hydraulic request Lifting: NO
15
Brakes liquid level warning light:
the brakes liquid is going to finish; the 16
The signal is displayed when the Traction: YES:
brakes oil level is too low.
All
Lifting: YES: 17
In case of alarm the truck reduces the
maximum speed to about 5Km/ h 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
INSULATION CONTROL PROCEDURE .....................4-5
MOTOR WINDING CONTROL PROCEDURE.............4-5
4
MECHANIC DISTRIBUTOR SYSTEM
CONFIGURATION.....................................................4-6 5
ELECTRIC DISTRIBUTOR SYSTEM 6
CONFIGURATION.....................................................4-7 7
DIAGNOSIS CODE LIST .............................................4-8
8
WHEN AN ERROR CODE IS DISPLAYED................4-16
9
MASTER TRACTION LOGIC UNIT ...................................... 4-16
SLAVE TRACTION LOGIC UNIT...............................4-32 10
LIFTING LOGIC UNIT ................................................4-44 11
MCB CONTROL BOARD (section EVCB)................4-59 12
DASHBOARD ............................................................4-66 13
MCB CONTROL BOARD (section TRCB)................4-69 14
ARMREST CARD.......................................................4-73
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 Ω 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: 10 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.
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 of
extraction.
Defective contact may exist at a terminal where the
extracting force is less than that of other terminals
Notes:
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
INSULATION CONTROL PROCEDURE

When any trouble occurs, first inspect the truck insulation and its components, according to the following
procedure:
Truck insulation check
1. Disconnect the battery from the truck
2. Measure the resistance between the truck plug positive
and the chassis (in an unpainted point)
3. Measure the resistance between the truck plug negative
and the chassis (in an unpainted point) 1
Standard: 10 MΩ or more
2
3
Battery insulation check
4. Disconnect the battery from the truck 4
5. Measure the resistance between the battery plug
positive and the case (in an unpainted point)
6. Measure the resistance between the battery plug
negative and the case (in an unpainted point) 6
7
8
Motor insulation check
7. Disconnect the battery from the truck 9
8. Measure the resistance between a phase and the motor
body (in an unpainted point)
10
9. turning the rotor slowly by hand, measure the resistance
between a phase and the motor body (in an unpainted 11
point)
13
MOTOR WINDING CONTROL PROCEDURE 14
When any trouble occurs, check the state of the motors, following the procedure described below:
Motor phase continuity check 15
1. Disconnect the battery from the truck
2. disconnect the three power cables 16
3. Check the continuity between the motor cables
Standard: U-V 0 Ω 17
V-W 0 Ω
U-W 0 Ω
18
4-6
MECHANIC DISTRIBUTOR SYSTEM CONFIGURATION
READER
DASHBOARD
MASTER OF THE
SYSTEM
BOARD
microswitch
MCB
Potentiometers,
microswitches
LOGIC UNIT LOGIC UNIT

LOGIC UNIT
TRACTION TRACTION
LIFTING
SLAVE MASTER
Encoder Encoder Steering Encoder

potentiometer
CAN BUS ANALOGUE

4-7
ELECTRIC DISTRIBUTOR SYSTEM CONFIGURATION
DASHBOARD
MASTER OF THE
LIFTING
0
READER 1
2
ARMREST MASTER OF THE 3
CARD SYSTEM
4
3
6
MCB Potentiometers,
microswitches 7
8
9
10
11
12
LOGIC UNIT LOGIC UNIT 13

LOGIC UNIT
TRACTION TRACTION
LIFTING 14
SLAVE MASTER
15
16
17
Encoder Encoder Steering Encoder
potentiometer 18
CAN BUS ANALOGUE
4-8
DIAGNOSIS CODE LIST
When an Error Code is Displayed

Part
Alarm Error mode Page
Number
01 WATCHDOG MASTER TRACTION LOGIC UNIT: Self-diagnostic test 4-16
02 EEPROM KO MASTER TRACTION LOGIC UNIT: Fault in the memory area 4-16
03 LOGIC FAILURE #3 MASTER TRACTION LOGIC UNIT: Logic defect. 4-16
04 LOGIC FAILURE #2 MASTER TRACTION LOGIC UNIT: Fault in the hardware section 4-17
MASTER TRACTION LOGIC UNIT: Protection from
05 LOGIC FAILURE #1 4-17
undervoltage/overvoltage
06 VMN LOW MASTER TRACTION LOGIC UNIT: Failure in the VMN test. 4-18
07 VMN HIGH MASTER TRACTION LOGIC UNIT: Failure in the VMN test. 4-19
MASTER TRACTION LOGIC UNIT: Failure on the contactor
08 CONTACTOR OPEN 4-20
driver
MASTER TRACTION LOGIC UNIT: Failure on the current
09 STBY I HIGH 4-20
sensor
CAPACITOR
10 MASTER TRACTION LOGIC UNIT: Capacitors not charged 4-21
CHARGE
HIGH MASTER TRACTION LOGIC UNIT: Logic unit’s temperature
11 4-21
TEMPERATURE higher than 85°C
MOTOR MASTER TRACTION LOGIC UNIT: Traction motor temperature
12 4-21
TEMPERATURE upper to 140°C
13 ENCODER ERROR MASTER TRACTION LOGIC UNIT: Fault of the encoder’s circuit 4-22
THERMIC MASTER TRACTION LOGIC UNIT: Logic unit thermal detector
14 4-23
SENS KO out of range
15 SAFETY IN MASTER TRACTION LOGIC UNIT: Logic unit arrest 4-23
MASTER TRACTION LOGIC UNIT: It is detecting communication
16 CAN BUS KO 4-23
of another card
17 WAITING FOR NODE MASTER TRACTION LOGIC UNIT: UNUSED 4-23
18 AUX OUTPUT KO MASTER TRACTION LOGIC UNIT: UNUSED 4-23
MASTER TRACTION LOGIC UNIT: Failure on the contactor
19 DRIVER SHORTED 4-24
driver
CONTACTOR MASTER TRACTION LOGIC UNIT: Failure on the contactor
20 4-24
DRIVER driver
AUX COIL MASTER TRACTION LOGIC UNIT: Failure on the contactor
21 4-24
SHORTED driver
MASTER TRACTION LOGIC UNIT: Steering
22 VACC NOT OK 4-24
potentiometer setting not correct
PUMP INCORRECT
23 MASTER TRACTION LOGIC UNIT: UNUSED 4-24
START
MASTER TRACTION LOGIC UNIT: Closed microswitch not
24 SEAT MISMATCH 4-25
closed
WRONG SET
25 MASTER TRACTION LOGIC UNIT: Battery voltage out of range 4-25
BATTERY
4-9

Part
Number
26 REMOTE INPUT MASTER TRACTION LOGIC UNIT: UNUSED 4-25
27 BAD STEER 0-SET MASTER TRACTION LOGIC UNIT: UNUSED 4-25
MASTER TRACTION LOGIC UNIT: Potentiometer out of range or
28 STEER SENSOR KO 4-25
not connected
29 FORW + BACK MASTER TRACTION LOGIC UNIT: UNUSED 4-25
0
31 WATCHDOG LIFTING LOGIC UNIT: Self-diagnostic test 4-44 1
32 EEPROM KO LIFTING LOGIC UNIT: Fault in the memory area 4-44
33 LOGIC FAILURE #3 LIFTING LOGIC UNIT: Logic defect. 4-44 2
34 LOGIC FAILURE #2 LIFTING LOGIC UNIT: Fault in the hardware section 4-44
LIFTING LOGIC UNIT: Protection from 3
36 VMN LOW LIFTING LOGIC UNIT: Failure in the VMN test. 4-46 4
37 VMN HIGH LIFTING LOGIC UNIT: Failure in the VMN test. 4-47
38 CONTACTOR OPEN LIFTING LOGIC UNIT: Contactor driver failure 4-48
3
39 STBY I HIGH LIFTING LOGIC UNIT: Current sensor failure 4-48 6
CAPACITOR
40 LIFTING LOGIC UNIT: Capacitors not charged 4-49
CHARGE 7
HIGH
41 LIFTING LOGIC UNIT: Logic unit’s temperature higher than 85°C 4-49
TEMPERATURE 8
MOTOR LIFTING LOGIC UNIT: Traction motor temperature upper to
42 4-50
TEMPERATURE 140°C 9
43 ENCODER ERROR LIFTING LOGIC UNIT: Encoder circuit fault 4-51
44 THERMIC SENS KO LIFTING LOGIC UNIT: Logic unit thermal detector out of range 4-52 10
45 SAFETY IN LIFTING LOGIC UNIT: Protection activated 4-52
LIFTING LOGIC UNIT: It is detecting communication of another 11
46 CAN BUS KO 4-52
card
WAITING FOR 12
47 LIFTING LOGIC UNIT: UNUSED 4-52
NODES
48 AUX OUTPUT KO LIFTING LOGIC UNIT: UNUSED 4-52 13
49 DRIVER SHORTED LIFTING LOGIC UNIT: Failure on the contactor driver 4-53
CONTACTOR
14
50 LIFTING LOGIC UNIT: Failure on the contactor driver 4-53
DRIVER
51 AUX COIL SHORTED LIFTING LOGIC UNIT: Failure on the contactor driver 4-53
15
55
WRONG SET
LIFTING LOGIC UNIT: Battery voltage out of range 4-54 16
BATTERY
56 REMOTE INPUT XX LIFTING LOGIC UNIT: UNUSED 4-54 17
57 WAITING MHYRIO LIFTING LOGIC UNIT: UNUSED 4-54
58 I=0 EVER LIFTING LOGIC UNIT UNUSED 4-54 18
59 UNUSED UNUSED 4-54
61 WATCHDOG SLAVE TRACTION LOGIC UNIT: Self-diagnostic test 4-32
4-10

Part
Number
62 EEPROM KO SLAVE TRACTION LOGIC UNIT: Fault in the memory area 4-32
63 LOGIC FAILURE #3 SLAVE TRACTION LOGIC UNIT: Logic defect. 4-32
64 LOGIC FAILURE #2 SLAVE TRACTION LOGIC UNIT: Fault in the hardware section 4-32
SLAVE TRACTION LOGIC UNIT: Protection from
66 VMN LOW SLAVE TRACTION LOGIC UNIT: Failure in the VMN test. 4-34
67 VMN HIGH SLAVE TRACTION LOGIC UNIT: Failure in the VMN test. 4-35
68 CONTACTOR OPEN SLAVE TRACTION LOGIC UNIT: Contactor driver failure 4-36
69 STBY I HIGH SLAVE TRACTION LOGIC UNIT: Current sensor failure 4-36
CAPACITOR
70 SLAVE TRACTION LOGIC UNIT: Capacitors not charged 4-37
CHARGE
HIGH SLAVE TRACTION LOGIC UNIT: Logic unit’s temperature higher
71 4-37
TEMPERATURE than 85°C
MOTOR SLAVE TRACTION LOGIC UNIT: Traction motor temperature
72 4-37
TEMPERATURE upper to 140°C
73 ENCODER ERROR SLAVE TRACTION LOGIC UNIT: Encoder circuit fault 4-38
SLAVE TRACTION LOGIC UNIT: Logic unit thermal detector out
74 THERMIC SENS KO 4-39
of range
75 SAFETY IN SLAVE TRACTION LOGIC UNIT: Logic unit arrest 4-39
SLAVE TRACTION LOGIC UNIT: It is detecting communication of
76 CAN BUS KO 4-39
another card
77 WAITING FOR NODE SLAVE TRACTION LOGIC UNIT: UNUSED 4-39
78 AUX OUTPUT KO SLAVE TRACTION LOGIC UNIT: UNUSED 4-39
79 DRIVER SHORTED SLAVE TRACTION LOGIC UNIT: UNUSED 4-39
CONTACTOR
80 SLAVE TRACTION LOGIC UNIT: UNUSED 4-39
DRIVER
81 AUX COIL SHORTED SLAVE TRACTION LOGIC UNIT: UNUSED 4-39
82 VACC NOT OK SLAVE TRACTION LOGIC UNIT: UNUSED 4-40
PUMP INCORRECT
83 SLAVE TRACTION LOGIC UNIT: UNUSED 4-40
START
SLAVE TRACTION LOGIC UNIT: Closed microswitch not
84 SEAT MISMATCH 4-40
closed
WRONG SET
85 SLAVE TRACTION LOGIC UNIT: Battery voltage out of range 4-40
BATTERY
86 REMOTE INPUT SLAVE TRACTION LOGIC UNIT: UNUSED 4-40
94 CHKSUM_ERROR MCB: Software error 4-72
4-11

Part
Number
0A SAFETY OUTPUT MASTER TRACTION LOGIC UNIT: Logic unit safety driver defect 4-26
0B SLIP PROFILE MASTER TRACTION LOGIC UNIT: Error in the memory data 4-26
0
0C ANALOG INPUT MASTER TRACTION LOGIC UNIT: Control internal error 4-26
0D HARDWARE FAULT MASTER TRACTION LOGIC UNIT: Control internal error 4-26 1
POWER MOS
0E MASTER TRACTION LOGIC UNIT: Power circuit failure 4-27
SHORTED 2
0F FLASH CHECKSUM MASTER TRACTION LOGIC UNIT: Control internal error 4-27
1A SOFTWARE ERROR MASTER TRACTION LOGIC UNIT: Error in parameters memory 4-27 3
MASTER TRACTION LOGIC UNIT: Right motor temperature
1B THERMIC MOT KO
sensor failure
4-28 4
1C RIGHT ENC LOCK MASTER TRACTION LOGIC UNIT: Right motor encoder failure 4-28
1D LEFT ENC LOCK MASTER TRACTION LOGIC UNIT: Left motor encoder failure 4-29
3
CONTACTOR MASTER TRACTION LOGIC UNIT: Failure on the contactor 6
1E 4-30
CLOSED driver
CHOPPER NOT 7
2A MASTER TRACTION LOGIC UNIT: UNUSED 4-30
CONF
2B STEER WIRE KO MASTER TRACTION LOGIC UNIT: Steering potentiometer failure 4-30 8
MASTER TRACTION LOGIC UNIT: The logic unit is during the
2C GAIN ACQUISITION 4-30
data acquisition phase 9
2D WRONG 0 VOLT MASTER TRACTION LOGIC UNIT: Control internal error 4-31
2E UNUSED UNUSED 4-31 10
WRONG RAM
2F MASTER TRACTION LOGIC UNIT: Activated antistatic protection 4-31
MEMORY 11
3A SAFETY OUTPUT LIFTING LOGIC UNIT: UNUSED 4-54
3B SLIP PROFILE LIFTING LOGIC UNIT: Error in the memory data 4-54 12
3C ANALOG INPUT LIFTING LOGIC UNIT: Control internal error 4-54
3D HARDWARE FAULT LIFTING LOGIC UNIT: Control internal error 4-55
13
3E
POWER MOS
SHORTED
LIFTING LOGIC UNIT: Power circuit failure 4-55 14
3F FLASH CHECKSUM LIFTING LOGIC UNIT: Control internal error 4-55 15
4A SOFTWARE ERROR LIFTING LOGIC UNIT: UNUSED 4-55
4B THERMIC MOT KO LIFTING LOGIC UNIT: Right motor temperature sensor failure 4-56 16
4C ENCODER LOCK LIFTING LOGIC UNIT: Motor encoder failure 4-57
CONTACTOR 17
4E LIFTING LOGIC UNIT: Failure on the contactor driver 4-58
CLOSED
LIFTING LOGIC UNIT: The logic unit is during the data acquisition 18
phase
5E WRONG 0 VOLT LIFTING LOGIC UNIT: UNUSED 4-58
4-12

Part
Number
WRONG RAM
5F LIFTING LOGIC UNIT: Activated antistatic protection 4-58
MEMORY
6A SAFETY OUTPUT SLAVE TRACTION LOGIC UNIT: Logic unit safety driver defect 4-40
6B SLIP PROFILE SLAVE TRACTION LOGIC UNIT: Error in the memory data 4-41
6C ANALOG INPUT SLAVE TRACTION LOGIC UNIT: Control internal error 4-41
6D HARDWARE FAULT SLAVE TRACTION LOGIC UNIT: Control internal error 4-41
POWER MOS
6E SLAVE TRACTION LOGIC UNIT: Power circuit failure 4-41
SHORTED
6F FLASH CHECKSUM SLAVE TRACTION LOGIC UNIT: Control internal error 4-42
7A SOFTWARE ERROR SLAVE TRACTION LOGIC UNIT: Error in the parameters memory 4-42
SLAVE TRACTION LOGIC UNIT: Left motor temperature sensor
7B THERMIC MOT KO 4-42
failure
CONTACTOR
7E SLAVE TRACTION LOGIC UNIT: UNUSED 4-42
CLOSED
SLAVE TRACTION LOGIC UNIT: Difference in the signals reading
7F SP MISMATCH 4-42
between Master and Slave logics
CHOPPER NOT
8A SLAVE TRACTION LOGIC UNIT: UNUSED 4-42
CONF
8B UNUSED UNUSED 4-42
SLAVE TRACTION LOGIC UNIT: The logic unit is during the data
acquisition phase
8D WRONG 0 VOLT SLAVE TRACTION LOGIC UNIT: Control internal error 4-43
8E UNUSED UNUSED 4-43
WRONG RAM
8F SLAVE TRACTION LOGIC UNIT: Activated antistatic protection 4-43
MEMORY
A1 DOUBLE REQ MCB: UNUSED 4-59
RELOAD_PARAM_W
A2 MCB: Occurred parameters loading signal 4-59
ARN
PARAM LOAD
A3 MCB: Error in the parameters loading in memory 4-59
ERROR
A4 NOT_REP_ERROR MCB: Board in waiting information 4-59
A5 CHKSUM_ERROR MCB: UNUSED 4-59
A6 BOOT_ERROR MCB: Board in waiting information from the Master or lifting logic 4-59
HI SIDE DRIVER
A7 MCB: Board internal problem 4-60
SHORT
A8 EV1_1 OPEN MCB: PE02 solenoid valve coil failure 4-60
A9 EV2_1 OPEN MCB: PE01 solenoid valve coil failure 4-60
AA EV1_2 OPEN MCB: PE04 solenoid valve coil failure 4-60
AB EV2_2 OPEN MCB: PE03 solenoid valve coil failure 4-61
AC EV1_3 OPEN MCB: PE05 solenoid valve coil failure 4-61
AD EV2_3 OPEN MCB: PE06 solenoid valve coil failure 4-61
4-13

Part
Number
AE EV1_4 OPEN MCB: PE07 solenoid valve coil failure 4-61
AF EV2_4 OPEN MCB: PE08 solenoid valve coil failure 4-62
TRCB_MICRO_
B0 MCB: Board internal problem 4-62
ERROR
GROUP1 DRIVER MCB: Failure on a group 1 coil of the electroproportional
0
B1 4-62
SHORT distributor
1
B2 4-62
SHORT distributor
2
B3 4-63
SHORT distributor
3
B4 4-63
SHORT distributor
MCB: Failure on a group 5 coil of the electroproportional
4
B5 AUX_OUT_SHORT 4-63
distributor
MCB: Communication problem between the MCB and the
3
B6 DASH_KO 4-63
dashboard
B7 ERR_SEAT MCB: Seat micro open with activated hydraulic functions 4-64
6
B8
JOY_STUFFING_
ERR
MCB: Communication problem between the MCB and the joystick
board
4-64 7
B9
SET_SERIAL_
MCB: Automatic setting of the serial not occurred 4-64 8
NUMBER
BA POT TILT NOT OK MCB: Incorrect reading of the tilting potentiometer voltage 4-64 9
PUMP INCORRECT
C1 MCB: Incorrect starting procedure. 4-69
START 10
BAD_CONF_
C2 MCB: UNUSED 4-69
WHEELS 11
C3 PEDAL WIRE KO MCB: Failure in the signal of the accelerator potentiometer at rest 4-69
C4 BAD MICROSWITCH MCB: Pedal micro or direction lever failure 4-69 12
WARN_CONF_
C5 MCB: UNUSED 4-69 13
ERROR
C6 BAD_VACC MCB: Accelerator potentiometer setting not correct 4-70
C7 ERR_SEAT MCB: Does not see the seat microswitch closed 4-70
14
BAD BRK
C8
MICROSWITCH
MCB: Brake Pedal micro failure 4-70 15
PARKING_
C9
SELECTED
MCB: Parking brake applied and one of the function activated 4-71 16
PARAM LOAD
CA
ERROR
MCB: Error in the truck ignition 4-71 17
CB UNUSED UNUSED 4-71
18
TRAC_STUFFING_ MCB: Problem of communication with the Master traction logic
CC 4-71
ERR unit
CD UNUSED UNUSED 4-71
4-14

Part
Number
CE UNUSED UNUSED 4-72
CF FW+BW MCB: Double request activated. 4-72
DASHBOARD: The Master traction logic unit it is not read by the
D1 TRAC_KO 4-66
dashboard
DASHBOARD: The MCB control board it is not read by the
D2 MCB_TRAC_KO 4-66
dashboard
DASHBOARD: The Slave traction logic unit it is not read by the
D3 SLAVE_KO 4-66
dashboard
D4 PUMP_KO DASHBOARD: The lifting logic unit it is not read by the dashboard 4-67
DASHBOARD: The MCB control board it is not read by the
D5 MCB_MHY_KO 4-67
dashboard
D6 JOY_KO DASHBOARD: The dashboard does not see the armrest board 4-67
D7 UNUSED UNUSED 4-67
ERROR_READ_PIN_ DASHBOARD: The MCB control board prevents the password
D8 4-67
CODE reading
D9 UNUSED UNUSED 4-68
DA UNUSED UNUSED 4-68
DE UNUSED UNUSED 4-68
DF EEPROM ERROR DASHBOARD: Defect in the memory area 4-68
4-73
ARMREST CARD Incorrect starting procedure (fingertips/joystick
INCORRECT_
E1 version)
START 4-64
MCB: Incorrect starting procedure (mechanic distributor version)
4-74
ARMREST CARD Lifting potentiometer failure (fingertips/joystick
E2 BAD LIFT POT version)
4-65
MCB: Lifting potentiometer failure (mechanic distributor failure)
E3 BAD TILT POT ARMREST CARD Failure on the lifting potentiometer. 4-75
E4 BAD SIDESH. POT ARMREST CARD Sideshift potentiometer failure 4-75
E5 BAD IV POT ARMREST CARD 4th way potentiometer failure 4-76
E6 BAD V POT ARMREST CARD 5th way potentiometer failure 4-76
E7 ERR_SEAT ARMREST CARD Does not see the seat microswitch closed 4-77
INVALID RESTORE ARMREST CARD Failure of the restore default parameter
E8 4-77
STATE operation
EEPROM_CHKSUM_
E9 ARMREST CARD Error during the Eprom data uploading 4-77
ERR
DEFAULT
EA ARMREST CARD Uploading of the flash memory data 4-77
RESTORED
ARMREST CARD Uploading of the data of the 4-77
POT NOT flash memory (fingertips/joystick version)
EB
ACQUIRED MCB: Request for acquisition of the lifting 4-65
potentiometer (mechanical spool valve version)
4-15

Part
Number
RAM_CHKSUM_
EC ARMREST CARD Uploading RAM data failed 4-77
ERR
MHYRIO_STUFFING
ED ARMREST CARD Communication problem 4-78
_ERR
ARMREST CARD Communication problem 4-78 0
PUMP_STUFFING_ (fingertips/joystick version)
EE
ERR MCB: Communication problem 4-65 1
(version with mechanical spool valve)
EF FW + BW ARMREST CARD UNUSED 4-78 2
F1 LIGHT SHORTED UNUSED 4-78
3
4
3
6
7
8
9
10
11
12
13
14
15
16
17
18
4-16
WHEN AN ERROR CODE IS DISPLAYED

MASTER TRACTION LOGIC UNIT
01 WATCHDOG
Condition for error detection

The test is made in both running and standby. It is a self-diagnosing test within the logic.
This alarm could also be caused by the can-bus malfunctioning.
Checkpoints:
- check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)
- check the can-bus connections
- replace the electronic control
02 EEPROM KO

Defect in area of memory storing settings; alarm disables operation of the machine, the unit loads the default
settings.
Use the function RESET MASTER for reload the default parameters (see paragraph DEFAULT RST).
If the error persists when the machine is switched back on, install the last version of the software using
the programmer.
If the defect persists when the machine is switched back on again, replace the module.
If the alarm disappears then the previously saved parameters will be deleted and the default parameters
of the electronic control unit will automatically be loaded.
03 LOGIC FAILURE #3

Logic defect.
- Replace the logic unit.
4-17
04 LOGIC FAILURE #2

Fault in the hardware section of the logic board which manages the phase voltage feedback.
The alarm appears also if the CT2 contactor is open during operation.
Check:
- pins 1 and 3 of the J50/A connector. It could be present a false connection 0
- the contactor coil (100 ohm)
- check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) 1
- the state of the power cables connected to the motor (tightness of connections, sheath wear, connec-
tion stapling)
- replace the logic unit
2
3
05 LOGIC FAILURE #1
4
This alarm signals that the interruption of protection against under voltage /over voltage has been trigge- 3
red.
- POWERED: the logic unit keeps controlled the key input (pin 1, connector JT1, M cable of the MD1 6
Master logic). If the voltage has a low peak, the alarm is signaled.
OVER voltage: the logic unit controls the voltage on the internal condensers. If the voltage has a hight 7
peak during the braking, the alarm is signaled.
The possible reasons are: 8
a. Under voltage / over voltage of the battery, or loss of voltage after the ignition key or after the battery
connector.
9
b. If the alarm is signaled at the truck ignition and appears with the alarm 35 of the lifting logic unit and 10
the alarm 65 of the Slave logic unit, check:
• the key switch (false contact, rusted contacts on the key cylinder) 11
• the battery plug-socket (false contact, damaged contacts)
• the state of the battery elements (see chapter 01 BATTERY) 12
c. The alarm appears also when one or more motor phases do not present a correct isolation at a move-
ment request. 13
• check the motor insulation (see paragraph INSULATION CONTROL PROCEDURE).
• the insulation of the power cables connected to the motor (tightness of connections, sheath wear, 14
connection stapling)
• check that the motor phases (U-V-W) are shorted among them (see paragraph MOTOR WINDING 15
CONTROL PROCEDURE)
d. Defect in the logic hardware section that controls the protection against the overvoltage.
16
Logic defect. Replace the logic unit.
17
Wiring diagram reference page 2/8 (see chapter 17)
18
4-18
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 CT2 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
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
- Operate the parking brake and switch off the machine
- Open the compartment and disconnect the battery
- Check the power cables on the motor are tight
- Check the power cables on the logic unit are tight
- Check the continuity values between the following points on the control unit using a tester:
Red Tip Black Tip
Um - (+) = 13 Kohm
Vm - (+) = 13 Kohm
Wm - (+) = 13 Kohm
Um - (-) = 13 Kohm If the measurements are very different to the re-
Vm - (-) = 13 Kohm ference ones described alongside, disconnect
Wm - (-) = 13 Kohm all the power cables from the logic unit and che-
Um - Vm = 0 ohm ck the values directly on the control unit
Um - Wm = 0 ohm
Vm - Wm = 0 ohm
Values on the control with disconnected motor:
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
Self-diagnostic
Connect the Master traction logic unit to the motor Slave and check if on the display appears the “06”
alarm code.
YES: replace the Master logic unit
If alarm “66“ appears check the motor state (see paragraph INSULATION CONTROL PROCEDURE and
MOTOR WINDING CONTROL PROCEDURE)
4-19
07 VMN HIGH

This test starts when the ignition key is turned ON and there is no current consumption (machine
stationary) 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. 0
1
2
3
4
3
To determine the cause of the fault, proceed by running one of the tests described below:
TEST 1 6
7
- Check the continuity values between the following points on the control unit using a tester: 8
Red Tip Black Tip
Um - (+) = 13 Kohm 9
Vm - (+) = 13 Kohm
Wm - (+) = 13 Kohm 10
Um - (-) = 13 Kohm If the measurements are very different to the re-
Vm - (-) = 13 Kohm ference ones described alongside, disconnect
Wm - (-) = 13 Kohm all the power cables from the logic unit and che- 11
Um - Vm = 0 ohm ck the values directly on the control unit
Um - Wm = 0 ohm 12
Vm - Wm = 0 ohm
Values on the control with disconnected motor: 13
Um - (+) = 32 Kohm
Vm - (+) = 27 Kohm
Wm - (+) = 32 Kohm
14
Um - (-) = 32 Kohm
Vm - (-) = 27 Kohm 15
Um - Vm = 46 Kohm 16
Um - Wm = 46 Kohm
Vm - Wm = 46 Kohm 17
Self-diagnostic
Connect the Master traction logic unit to the motor Slave and check if on the display appears the “07”
alarm code. 18
YES: replace the Master logic unit
4-20
08 CONTACTOR OPEN

Failure on the CT2 contactor. The contactor is powered, but the contacts do not close.
- Check the main contactor coil CT2 (100 Ω) and relevant cables
- Check the state of the two-directional diode (D3)
- Check the contacts status (current passage not permitted)
- Invert the contactor CT2 with CT3:
if alarm 38 appears the problem is caused by the contactor
if alarm 08 persists, the problem is caused by the wiring harness or the logic unit
09 STBY I HIGH

Failure on the current sensor.
- Replace the Master traction logic unit
4-21
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 0
- Check the voltage at the key input (pin 1, connector JT1, cable M on the Master logic unit MD1: there
must be battery voltage 1
- Disconnect the J15 connector. If the alarm disappears check the status of the temperature sensor
- If the alarm persist, replace the logic unit 2
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. 3
-Using a multimeter, check the voltage between the positive (+BF) and the negative (-B) of both logic
units 4
-Replace the logic unit with voltage between -B and +BF close to zero.
3
6
11 HIGH TEMPERATURE
7
Condition for error detection 8
Logic unit temperature is higher than 85°C. The maximum current is reduced proportionally to the tempe-
rature increase.
9
At 105°C the current is reduced to 0 and the module stops.
Check: 10
- the fan works correctly
- the air duct must be clear 11
- the RH CONTR TEMP parameter (menu TESTER of the dashboard). If below 85°C, replace the Master
traction logic unit. 12
12 MOTOR TEMPERATURE
13
14
This alarm appears when the motor temperature sensor reaches 140°C. 15
If the alarm appears when the motor is cold, check:
- that the wiring harness circuit of the temperature sensor is correctly connected 16
- that the temperature sensor is always open (replace the sensor)
17
18
4-22
13 ENCODER ERROR

This alarm shows that the encoder information are incorrect or absents.
The encoder transmits signals only when the motor is running. The alarm is noticed by the logics when
40Hz are passed.
If on the dashboard appears the alarm and the operator makes the reset with the key with the machine
stopped, the alarm disappears.
If the alarm signal is given before reaching 40 Hz, the problem may be linked to the incorrect insulation of
a power cable on the chassis: without the correct encoder signals, the machine stays still or moves very
slowly. To determine whether the problem is to be attributed to the encoder or to the logic, proceed as
follows:
Set up SLIP CONTROL on OFF and accelerate slowly.
The increase of the motor speed does not shows necessarily that the problem is connected at the
encoder. One of the following components may be defective:
- The logic internal circuit
- Cabling
- Encoder
Use an analogical or digital multimeter to determine where is located the problem.
Encoder basic electric diagram.

The figure shows only one signal (A).
The encoders used generate two equal signals,
with a 90° difference (A-B).
1. Connect the tester positive point (red) to the
encoder positive terminal.
2. Connect the tester COM point (black) to the
encoder signal (A).
According to the engine position, the following
values will be displayed:
• low signal: 0.5 -- 1.5 Volt
• high signal: 10.5 -- 11.5 Volt
Intermediate values cannot be read as the motor
is stopped.
If the motor is working, the multimeter will
automatically read the Mv (medium value)
Mv= 5,5 - 6,5 Volt
Carrying out this test directly on the logic
connectors it is possible to determine if the
signals are good (see upper description) or if the
channels are opened or in short circuit. If the
signals are good, the problem should be
attributed to the logic unit.
4-23
14 THERMIC SENSOR KO

Logic unit thermal detector out of range.
0
15 SAFETY IN
1
Arrest of the Master traction logic.
Verify: 3
- Alarms in the MD2 Slave logic unit
• If YES, the alarm it is only a consequence. Verify the Slave diagnostic 4
• If NO, presence/connection of wiring harness on JT1 connector, pin11, cable CN of the MD1 Master
logic 3
• If NO, that pin 19, connector JT2, cable CN of the MD2 Slave logic is a GND
• If NO, internal fault of the logic unit
6
7
16 CAN BUS KO 8
9
Can-bus communication failure. The alarm appears if the traction logic unit does not receive the 10
information from the MCB board or from the lifting logic unit or from the Slave logic unit.
Before to replace every board, verify: 11
- The dashboard alarms, to identify exactly the board that does not communicate
- Enter the SOFT VERS menu to see which card is not present on the can-bus line
- Can-bus pull-up resistance presence
12
• dashboard 180 Ohm
• MCB 180 Ohm 13
• armrest 180 Ohm
14
17 WAITING FOR NODE - UNUSED 15
18 AUX OUTPUT KO - UNUSED 16
17
18
4-24
19 DRIVER SHORTED

Verify:
- integrity of fuse F6 (10 A)
- correct fixing of the pins of the connectors J52/A and J50/A and of the relevant wiring harnesses
- that between pin 16, connector JT1, cable A of the Master logic (MD1) and GND there is no continuity.
If YES: replace the Master traction logic unit (M11);
20 CONTACTOR DRIVER

Failure on the CT2 contactor driver.
- Replace the (MD1) Master traction logic unit.
21 AUX COIL SHORTED

Failure on the CT2 contactor.
- Check the state of the coil (100 ohm)
- Check that there is no short circuit on the wiring harness
If the defect is due to external causes, replace the logic unit.
22 VACC NOT OK

Fault in the steering potentiometer.
Effect the steering potentiometer setting (LEARN STEER POT).
23 INCORRECT START - UNUSED

4-25
24 SEAT MISMATCH

Seat switch open during traction.
Verify:
- The SW1 microswitch status
- Connection HN cable, pin 6, JT1 connector of the Master logic (MD1) 0
- Connection HZ cable, pin 6, JT2 connector of the Slave logic (MD2)
If the information of the seat micro is not arriving on both traction logics the alarm is signaled. 1
25 WRONG SET BATTERY
2
3
When the key is turned ON, the logic unit checks the battery voltage and compares it with the “SET BAT- 4
TERY” parameter setting. If the actual value is 20% higher or lower than the nominal value, there is a
fault. 3
- Check the battery status and, if necessary, replace the battery.
6
26 REMOTE INPUT - UNUSED
7
27 BAD STEER 0-SET - UNUSED 8
9
28 STEER SENSOR KO
10
This alarm signals a failure to the steering potentiometer cursor or to the relevant wiring harness.
Verify: 12
- The correct functioning of the potentiometer with a multimeter
- The correct connection of the wiring harness 13
- Effect again the steering potentiometer setting (LEARN STEER POT)
14
29 FORW + BACK - UNUSED 15
16
17
18
4-26
0A SAFETY OUTPUT

Slave SAFETY IN control output.
Master logic SAFETY driver defect.
Check the wiring harness and connector JT1 pin 19
Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)
Replace the Master logic unit.
0B SLIP PROFILE

Error in the memory data where the flowing parameters are loaded.
Make a RESET MASTER to re-load the default parameters.
the programmer.
If the problem persists replace the logic unit.
0C ANALOG INPUT

Control internal error.
Replace the logic unit.
0D HARDWARE FAULT

4-27
0E POWER MOS SHORTED

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
• Power cables connection 0
• Truck insulation and motor state see paragraph INSULATION CONTROL PROCEDURE and MOTOR
WINDING CONTROL PROCEDURE)
• Continuity values obtained directly on the control, with disconnected power cables:
1
Um - (+) = 32 Kohm
Vm - (+) = 27 Kohm 2
Wm - (+) = 32 Kohm
Um - (-) = 32 Kohm 3
Vm - (-) = 27 Kohm
Um - Vm = 46 Kohm
4
Um - Wm = 46 Kohm
Vm - Wm = 46 Kohm 3
0F FLASH CHECKSUM
6
7
Control internal error. 8
- Restore the default parameters using the RESET MASTER function
- If the error persists when the machine is switched back on, install the latest version of the software using 9
the programmer.
If the defect persist when the key is switched OFF and ON again, replace the logic unit. 10
1A SOFTWARE ERROR 11

12
Error in the memory data where the flowing parameters are loaded. 13
Make a RESET SLAVE to re-load the default parameters.
- If the error persists when the machine is switched back on, install the latest version of the software
using the programmer.
14
15
16
17
18
4-28
1B THERMIC MOT KO

Interrupted or disconnected right motor temperature sensor.
Verify:
- Cabling
- Temperature sensor always open (replace the sensor)
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.
JT1 must be connected to the MASTER logic unit.
JT2 must be connected to the SLAVE logic unit.

encoder signal (A).
is stopped.
Mv= 5,5 - 6,5 Volt
4-29
1D LEFT ENC LOCK

Interrupted or disconnected left motor encoder.
The alarm appears after 10 seconds approximately with the accelerator pedal pressed.
The machine works at reduced speed and at maximum current.
JT1 must be connected to the MASTER logic unit. 0
JT2 must be connected to the SLAVE logic unit.
1
2
1. Connect the tester positive point (red) to the 3
2. Connect the tester COM point (black) to the 4
encoder signal (A).
According to the engine position, the following 3
6
Intermediate values cannot be read as the motor 7
is stopped.
8
Mv= 5,5 - 6,5 Volt 9
connectors it is possible to determine if the 10
channels are opened or in short circuit. If the 11
12
13
14
15
16
17
18
4-30
1E CONTACTOR CLOSED

CT2 contactor driver failure. The logic unit cuts the current to the coil, but the controls remain closed.
Disconnect the battery and check:
- The CT2 contactor windings and the relevant wiring harnesses
- Clean the contactor connections
- Check the control of the contactor directly on connector JT1 pin 16 of the MASTER logic unit
if alarm 4E appears the problem is caused by the contactor
if alarm 1E persists, the problem is caused by the wiring harness or the 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:
- Wiring harness continuity (see paragraph WIRE HARNESS AND CONNECTOR INSPECTION PRO-
CEDURE)
- Correct functioning of the potentiometer using a multimeter
- Correct wiring harness connection (positive and negative)
2C GAIN ACQUISITION

This warning communicates that the logic is in current acquisition phase.
In this phase the logic doesn't work.
If the alarm persists after the key reset, replace the logic unit.
4-31
2D WRONG 0 VOLT

Control internal error. Replace the logic unit.
2E UNUSED 0
1
2F WRONG RAM MEMORY
2
3
Activated protection against the electrostatic charges.
Switch the machine off and back on again. 4
3
6
7
8
9
10
11
12
13
14
15
16
17
18
4-32

61 WATCHDOG

Checkpoints:
62 EEPROM KO

settings.
Use the RESET SLAVE function to reload the default parameters (see DEFAULT RST paragraph).
the programmer.
63 LOGIC FAILURE #3

64 LOGIC FAILURE #2

The alarm appears also if the CT2 contactor is open during operation.
Check:
- pins 1 and 3 of the J50/A connector. It could be present a false connection
tion stapling)
4-33
65 LOGIC FAILURE #1

This alarm signals that the interruption of protection against under voltage /over voltage has been trigge-
red.
- POWERED: the logic unit keeps controlled the key input (pin 1, connector JT2, M cable of the MD2
Master logic). If the voltage has a low peak, the alarm is signaled. 0
OVER voltage: the logic unit controls the voltage on the internal condensers. If the voltage has a hight
peak during the braking, the alarm is signaled. 1
The possible reasons are:
2
connector.
3
b. If the alarm is signaled 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: 4
• the key switch (false contact, rusted contacts on the key cylinder)
• the battery plug-socket (false contact, damaged contacts) 3
• the state of the battery elements (see chapter 01 BATTERY)
6
ment request.
• Check the motor insulation (see paragraph INSULATION CONTROL PROCEDURE). 7
• the insulation of the power cables connected to the motor (tightness of connections, sheath wear,
connection stapling) 8
• Check that the motor phases (U-V-W) are shorted among them (see paragraph MOTOR WINDING
CONTROL PROCEDURE) 9
d. Defect in the logic hardware section that controls the protection against the overvoltage.
10
Wiring diagram reference page 2/8 (see chapter 17) 11
12
13
14
15
16
17
18
4-34
66 VMN LOW

The test begins at switch-on; check the connections of the 3 supply cables from the logic unit to the drive
motor, the condition of the cables and the status of the coil of the CT3 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 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 the measurements are very different to the re-
Vs - (-) = 13 Kohm ference ones described alongside, disconnect
Ws - (-) = 13 Kohm all the power cables from the logic unit and che-
Us - Vs = 0 ohm ck the values directly on the control unit
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
Self-diagnostic
Connect the SLAVE traction logic unit to the MASTER motor and check whether the display shows the
alarm code “66”.
YES: replace the SLAVE logic unit
4-35
67 VMN HIGH

1
2
3
4
3
TEST 1
- Operate the parking brake and switch off the machine 6
- Check the power cables on the motor are tight 7
Red Tip Black Tip
Us - (+) = 13 Kohm
Vs - (+) = 13 Kohm
9
Ws - (+) = 13 Kohm
Us - (-) = 13 Kohm If the measurements are very different to the re- 10
Vs - (-) = 13 Kohm ference ones described alongside, disconnect
Ws - (-) = 13 Kohm all the power cables from the logic unit and che- 11
Us - Vs = 0 ohm ck the values directly on the control unit
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
Self-diagnostic 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
4-36
68 CONTACTOR OPEN

Failure on the CT2 contactor. The contactor is powered, but the contacts do not close.
69 STBY I HIGH

- Replace the Slave traction logic unit
4-37
70 CAPACITOR CHARGE

- Check the voltage at the key input (pins 1, connector JT2, cable M on the Slave logic unit MD2): there
must be battery voltage 1
- Disconnect the connector J16. If the alarm disappears check the status of the temperature sensor
- If the alarm persist, replace the logic unit
2
If the alarm appears along with alarm 10 of the Master logic unit, check as follows to find the faulty con-
trol: 3
-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 4
units
-Replace the logic unit with voltage between -B and +BF close to zero.
3
6
71 HIGH TEMPERATURE
7
8
Logic unit temperature is higher than 85°C. The maximum current is reduced proportionally to the tempe-
rature increase. 9
At 105°C the current is reduced to 0 and the module stops.
Check:
- the fan works correctly
10
- the air duct must be clear
- the LH CONTR TEMP parameter (menu TESTER of the dashboard). If below 85°C, replace the Slave 11
traction logic unit.
12
13
This alarm appears when the motor temperature sensor reaches 140°C.
If the alarm appears when the motor is cold, check: 15
- that the wiring harness circuit of the temperature sensor is correctly connected
- that the temperature sensor is always open (replace the sensor) 16
17
18
4-38
73 ENCODER ERROR

40Hz are passed.
If on the dashboard appears the alarm and the operator makes the reset with the key with the machine
If the alarm signal is given before reaching 40 Hz, the problem may be linked to the incorrect insulation of
follows:
The increase of the motor speed does not shows necessarily that the problem is connected at the
- The logic internal circuit
- Cabling
- Encoder

encoder signal (A).
is stopped.
Mv= 5,5 - 6,5 Volt
4-39

75 SAFETY IN
0
1
Arrest of the Master traction logic.
2
Verify:
- 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 of wiring harness on connector JT2, pin11, cable LG of the MD2 Slave 4
logic
• If NO, that pin 19, connector JT1, 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
3
• If NO, internal fault of the logic unit
6
7
76 CAN BUS KO
8
Can-bus communication 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 Master logic unit. 10
Before to replace every board, verify:
- The dashboard alarms, to identify exactly the board that does not communicate 11
- Can-bus pull-up resistance presence 12
• MCB 180 Ohm
• armrest 180 Ohm 13
14
77 WAITING FOR NODE - UNUSED
15
78 AUX OUTPUT KO - UNUSED 16
79 DRIVER SHORTED - UNUSED 17
80 CONTACTOR DRIVER - UNUSED

18
81 AUX COIL SHORTED - UNUSED

4-40
82 VACC NOT OK - UNUSED
83 INCORRECT START - UNUSED
84 SEAT MISMATCH

Seat switch open during traction.
Verify:
- The SW1 microswitch status
- Connection HN cable, pin 6, connector JT2 of the Slave logic (MD2)
- Connection HN cable, pin 6, connector JT1 of the Master logic (MD1)
If the information of the seat micro is not arriving on both traction logics the alarm is
signaled
CCondition for error detection

When the key is turned ON, the logic unit checks the battery voltage and compares it with the “SET BAT-
fault.
86 REMOTE INPUT - UNUSED
6A SAFETY OUTPUT

Master SAFETY IN control output.
Slave logic SAFETY driver defect.
Check the wiring harness and connector JT2 pin 19
Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)
Replace the Slave logic unit.
4-41
6B SLIP PROFILE

Make a RESET MASTER to re-load the default parameters.
the programmer. 0
1
6C ANALOG INPUT 2

3
3
6D HARDWARE FAULT
6
7
8
6E POWER MOS SHORTED 9
The alarm signals a power circuit failure.
11
• One or more motor phases could be disconnected
• Power cables connection 12
• Truck insulation and motor state see paragraph INSULATION CONTROL PROCEDURE and MOTOR
WINDING CONTROL PROCEDURE) 13
Um
Vm
-
-
(+)
(+)
= 32 Kohm
= 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
18
4-42
6F FLASH CHECKSUM

- Restore the default parameters using the RESET SLAVE function
- If the error persists when the machine is switched back on, install the latest version of the software using
the programmer.
7A SOFTWARE ERROR

Make a RESET SLAVE to re-load the default parameters.
- If the error persists when the machine is switched back on, install the latest version of the software
using the programmer.
7B THERMIC MOT KO

Interrupted or disconnected left motor temperature sensor.
Verify:
- Cabling
- Temperature sensor always open (replace the sensor)
7E CONTACTOR CLOSED - UNUSED
7F SP MISMATCH

The alarm signals an incongruity between the signals read from the Master logic and the Slave logic.
Verify:
- Presence of others alarms on the dashboard
- Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)
- Replace the logic unit
8A CHOPPER NOT CONF - UNUSED
8B UNUSED
4-43
8C GAIN ACQUISITION

0
8D WRONG 0 VOLT 1
2
Control internal error. Replace the logic unit. 3
4
8E UNUSED
3
8F WRONG RAM MEMORY
6
Switch the machine off and back on again.
8
9
10
11
12
13
14
15
16
17
18
4-44
LIFTING LOGIC UNIT

31 WATCHDOG

Checkpoints:
32 EEPROM KO

settings.
Use the function PUMP RESET to reload the default parameters (see paragraph DEFAULT RST).
the programmer.
33 LOGIC FAILURE #3

34 LOGIC FAILURE #2

The alarm appears also if the contactor CT3 is open during operation.
Check:
- pins 2 and 4 of the J50/A connector. It could be present a false connection
tion stapling)
4-45
35 LOGIC FAILURE #1

This alarm signals that the interruption of protection against under voltage /over voltage has been trigge-
red.
POWERED: the logic unit keeps controlled the key input (pin 1, connector JP, M cable of the MD3 PUMP
logic). If the voltage has a low peak, the alarm is signaled. 0
OVER voltage: the logic unit controls the voltage on the internal condensers. If the voltage has a hight
peak during the braking, the alarm is signaled. 1
The possible reasons are:
2
connector. 3
b. If the alarm is signaled at the truck ignition and appears with the alarm 05 of the Master logic unit and
the alarm 65 of the Slave logic unit, check:
4
• the key switch (false contact, rusted contacts on the key cylinder)
• the battery plug-socket (false contact, damaged contacts) 3
• the state of the battery elements (see chapter 01 BATTERY)
6
ment request. 7
• Check the motor insulation (see paragraph INSULATION CONTROL PROCEDURE).
• the insulation of the power cables connected to the motor (tightness of connections, sheath wear,
connection stapling)
8
• Check that the motor phases (U-V-W) are shorted among them (see paragraph MOTOR WINDING
CONTROL PROCEDURE) 9
d. Defect in the logic hardware section that controls the protection against the overvoltage. 10

11
12
13
14
15
16
17
18
4-46
36 VMN LOW

The test begins at switch-on; check the connections of the 3 supply cables from the logic unit to the drive
motor, the condition of the cables and the status of the coil of the CT3 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 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
U - (+) = 13 Kohm
V - (+) = 13 Kohm
W - (+) = 13 Kohm
U - (-) = 13 Kohm If the measurements are very different to the re-
V - (-) = 13 Kohm ference ones described alongside, disconnect
W - (-) = 13 Kohm all the power cables from the logic unit and che-
U - V = 0 ohm ck the values directly on the control unit
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 “36”
alarm code.
YES: replace the logic unit
4-47
37 VMN HIGH

1
2
3
4
3
TEST 1 6
7
Red Tip Black Tip
U - (+) = 13 Kohm 9
V - (+) = 13 Kohm
W - (+) = 13 Kohm 10
U - (-) = 13 Kohm If the measurements are very different to the re-
V - (-) = 13 Kohm ference ones described alongside, disconnect
W - (-) = 13 Kohm all the power cables from the logic unit and che- 11
U - V = 0 ohm ck the values directly on the control unit
U - W = 0 ohm 12
V - W = 0 ohm
Values on the control with disconnected motor: 13
U - (+) = 32 Kohm
V - (+) = 27 Kohm
W - (+) = 32 Kohm
14
U - (-) = 32 Kohm
V - (-) = 27 Kohm 15
W - (-) = 32 Kohm If an opened circuit is noticed replace the control.
U - V = 45 Kohm 16
U - W = 60 Kohm
V - W = 45 Kohm 17
TEST 2
Connect the lifting logic unit to the traction Master motor and check if on the display appears the “67”
alarm code. 18
YES: replace the logic unit
4-48
38 CONTACTOR OPEN

CT3 contactor failure. The contactor is powered, but the contacts do not close.
if alarm 08 or 68 appears the problem is caused by the contactor
39 STBY I HIGH

- Replace the lifting logic unit
4-49
40 CAPACITOR CHARGE

- Check the voltage at the key input (pin 1, connector JP, cable M of the MD3 logic):
the battery voltage must be present 1
- 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 the temperature sensor
- Disconnect the J13 connector. If the alarm disappears check the status of the temperature sensor 2
- If the alarm persist, replace the logic unit
3
4
41 HIGH TEMPERATURE 3
6
Chopper temperature greater than 85 °C. The maximum current is proportionally reduced as the tempe- 7
rature increases.
At 105°C the current is reduced to 0 and the module stops. 8
Check:
- the fan works correctly 9
- the air duct must be clear
- the P CONTR TEMP parameter (menu TESTER of the dashboard). If below 85°C, replace the lifting
logic unit.
10
11
12
13
14
15
16
17
18
4-50

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 155°C it cuts completely 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)
ENVIRONMENT TEMP. 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 Current reduction
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
4-51
43 ENCODER ERROR

40Hz are passed.
If on the dashboard appears the alarm and the operator makes the reset with the key with the machine 0
If the alarm signal is given before reaching 40 Hz, the problem may be linked to the incorrect insulation of 1
follows:
2
The increase of the motor speed does not shows necessarily that the problem is connected at the 3
- The logic internal circuit 4
- Cabling
- Encoder 3

6
The encoders used generate two equal signals, 7
encoder signal (A).
10
• high signal: 10.5 -- 11.5 Volt 11
is stopped.
12
automatically read the Mv (medium value) 13
Mv= 5,5 - 6,5 Volt
14
15
signals are good, the problem should be 16
17
18
4-52

- Replace the logic units
45 SAFETY IN

Stopped truck.
Pin 11 of the connector JP (negative input) of the lifting logic (MD3). 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 connector P3 is not connected properly
(2) If the cable is well connected, replace the lifting logic unit
46 CAN BUS KO

Can-bus communication failure. The alarm appears if the traction logic unit does not receive the
information from the MCB board or from the traction logic units.
Before to replace every board, verify:
- The dashboard alarms, to identify exactly the board that does not communicate
- Can-bus pull-up resistance presence
• MCB 180 Ohm
• armrest 180 Ohm
If the alarm appears alone, update/replace the DISPLAY
47 WAITING FOR NODE - UNUSED
48 AUX OUTPUT KO - UNUSED

4-53
49 DRIVER SHORTED

CT3 contactor driver defect.
Switch off the truck and disconnect the CT3 contactor coil.
Verify:
- integrity of fuse F6 (10A) 0
- correct fixing of the pins of the connectors J52/A and J50/A and of the relevant wiring harnesses
- that between pin 16, connector JP, cable A of the lifting logic and GND there is no continuity. 1
If YES: replace the Lifting logic unit
If NO: verify the CT3 contactor coil status
Resistive value (100 Ohm) 2
if alarm 19 appears the problem is caused by the contactor 3
4
50 CONTACTOR DRIVER
3
Failure on the CT3 contactor driver.
- Invert the contactor CT3 with CT2: 7
if alarm 50 persists, the problem is caused by the wiring harness or the logic unit 8
9
51 COIL SHORTED
10
CT3 contactor defect.
- Check the state of the coil (100 ohm)
12
- Check that there is no short circuit on the wiring harness
- Invert the contactor CT3 with CT2: 13
if alarm 51 persists, the problem is caused by the wiring harness or the logic unit 14
If the defect is due to external causes, replace the logic unit.

15
16
17
18
4-54

When the key is turned ON, the logic unit checks the battery voltage and compares it with the “SET BAT-
fault.
56 REMOTE INPUT XX - UNUSED
57 WAITING MHYRIO - UNUSED
58 I = 0 EVER - UNUSED
59 UNUSED
60 UNUSED
3A SAFETY OUTPUT - UNUSED
3B SLIP PROFILE

Make a RESET PUMP to re-load the default parameters.
the programmer.
3C ANALOG INPUT

4-55
3D HARDWARE FAULT

0
3E POWER MOS SHORTED
1
The alarm signals a power circuit failure. 2
• One or more motor phases could be disconnected 3
• Power cables connection
• Truck insulation and motor state see paragraph INSULATION CONTROL PROCEDURE and MOTOR 4
WINDING CONTROL PROCEDURE)
Um - (+) = 32 Kohm
3
Vm - (+) = 27 Kohm
Wm - (+) = 32 Kohm 6
Um - (-) = 32 Kohm
Vm - (-) = 27 Kohm 7
Um
Um
-
-
Vm
Wm
= 46 Kohm
= 46 Kohm
8
Vm - Wm = 46 Kohm
9
3F FLASH CHECKSUM 10
11
- Restore the default parameters using the RESET PUMP function
the programmer.
If the defect persist when the key is switched OFF and ON again, replace the logic unit.
14
4A SOFTWARE ERROR 15
16
- Restore the default parameters using the RESET PUMP function
the programmer.
If the defect persist when the key is switched OFF and ON again, replace the logic unit.
4-56
4B THERMIC MOT KO

Interrupted or disconnected lifting motor temperature sensor.
Verify:
- Cabling
- Sensor resistive value
ENVIRONMENT TEMP. 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
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
4-57
4C ENCODER LOCK

Interrupted or disconnected motor encoder.
The alarm appears after approximately 10 seconds with a hydraulic function selected.
Remove the pump from the motor; using only lifting it is possible to determine whether the alarm is
generated by the encoder or whether the lifting pump is blocked. 0
If the pump is not blocked, proceed to inspect the encoder.
1
2
encoder signal (A).
According to the engine position, the following 3
6
Intermediate values cannot be read as the motor 7
is stopped.
8
Mv= 5,5 - 6,5 Volt 9
connectors it is possible to determine if the 10
channels are opened or in short circuit. If the 11
12
13
14
15
16
17
18
4-58
4E CONTACTOR CLOSED

CT3 contactor driver failure. The logic unit cuts the current to the coil, but the controls remain closed.
Disconnect the battery and check:
- The CT3 contactor windings and the relevant wiring harnesses
- Clean the contactor connections
- Check the control of the contactor directly on connector JP pin 16 of the logic unit
if alarm 1E appears the problem is caused by the contactor
if alarm 4E persists, the problem is caused by the wiring harness or the logic unit
5C GAIN ACQUISITION

5E WRONG 0 VOLT - UNUSED
5F WRONG RAM MEMORY

Switch the machine off and back on again.
4-59
MCB CONTROL BOARD (section EVCB)

A1 DOUBLE REQ - UNUSED
A2 RELOAD_PARAM_WARN

The alarm signals the occurred parameters loading. The truck remains in pre-operational status.
- Switch on and switch off again the truck.
1
2
A3 PARAM LOAD ERROR
3
The alarm signals that the MCB board has not loaded the memory parameters. The truck remains in pre-
operational status. 3
Switch off and switch on again the truck:
- If the alarm persist replace the MCB board 6
- If the alarm disappears, but the truck has a rough behavior replace the MCB board.
7
A4 NOT_REP_ERROR
8
The alarm signals that the MCB board is waiting informations. The truck remains in pre-operational
status. 10
- Insert truck serial number (function LEARNING parameter SERIAL NUMBER)
- Repeat the accelerator and lifting potentiometers acquisitions (only with mechanical
control valve): LEARNING function
11
Switch off and switch on again the truck.
12
A5 CHKSUM_ERROR - UNUSED 13
14
A6 BOOT_ERROR
15
16
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 communicating.
17
18
4-60
A7 HI SIDE DRIVER SHORT

The alarm signals an internal problem of the MCB board.
- Replace the MCB board.
A8 EV1_1 OPEN

The alarm signals a failure at the coil of the PE02 lowering solenoid valve. The coil could be opened or
disconnected.
Check:
- Value in Ohm of the coils and the relevant wiring harness .
If the problem persists replace the MCB board.
A9 EV2_1 OPEN

The alarm signals a failure at the coil of the PE01 lifting solenoid valve. The coil could be opened or
disconnected.
Check:
- Value in Ohm of the coils and the relevant wiring harness.
AA EV1_2 OPEN

The alarm signals a failure at the coil of the PE04 backward tilting solenoid valve. The coil could be
opened or disconnected.
Check:
4-61
AB EV2_2 OPEN

The alarm signals a failure at the coil of the PE03 forward tilting solenoid valve. The coil could be opened
or disconnected.
Check:
- Value in Ohm of the coils and the relevant wiring harness. 0
1
AC EV1_3 OPEN 2

3
The alarm signals a failure at the coil of the PE05 right sideshift solenoid valve. The coil could be opened 4
or disconnected.
Check: 3
6
AD EV2_3 OPEN 7
8
The alarm signals a failure at the coil of the PE06 left sideshift solenoid valve. The coil could be opened
9
or disconnected.
Check: 10
If the problem persists replace the MCB board. 11
12
AE EV1_4 OPEN
13
14
The alarm signals a failure at the coil of the PE07 4th way solenoid valve. The coil could be opened or
disconnected.
Check:
15
17
18
4-62
AF EV2_4 OPEN

The alarm signals a failure at the coil of the PE08 4th way solenoid valve. The coil could be opened or
disconnected.
Check:
B0 TRCB_MICRO_ERROR

The alarm signals an internal problem of the MCB board.
- Replace the MCB board.
B1 GROUP1 DRIVER SHORT

The alarm signals a failure at one of the coils of the group 1 of the electro-proportional distributor: PE02
lowering solenoid valve or PE01 lifting solenoid valve.
A coil could be opened or disconnected.
Check:

backward tilting solenoid valve or PE03 forward tilting solenoid valve.
Check:
4-63

right sideshift solenoid valve or PE06 left sideshift solenoid valve.
Check: 0
2
3
4
4th way solenoid valve or PE07 4th way solenoid valve. 3
Check:
6
7
B5 AUX_OUT_SHORT 8
9
The alarm signals a failure at one of the coils of the group 5 of the electro-proportional distributor: EVP9 10
5th way solenoid valve or EVP10 5th way solenoid valve.
A coil could be opened or disconnected. 11
Check:
12
13
B6 DASH_KO
14
The alarm signals a communication problem between the MCB board and the dashboard.
The alarm remains stored in the logbook of the MCB board alarms. 16
- Replace the dashboard.
17
18
4-64
B7 ERR_SEAT

The alarm signals the seat micro opened with activated hydraulic functions.
B8 JOY_STUFFING_ERR

The alarm signals a communication problem between the MCB board and the joystick board.
Use the RESET JOY FLAG function for re-establish the communication between the cards; if the
problem persists, verify:
- The can-bus connections between the MCB board and the joystick board
- Joystick board supplying (JCAN connector pin 5 cable M and pin 6 cable N)
- Replace the joystick card
B9 SET_SERIAL_NUMBER

The alarm signals the failed automatic serial number setting.
- Insert truck serial number (function LEARNING parameter SERIAL NUMBER)
Switch off and switch on again the truck.
BA POT TILT NOT OK

The alarm signals an incorrect reading of the voltage of the tilting potentiometer (optional):
- Repeat the tilting potentiometer acquisition
-If the alarm persists, check the potentiometer status and the relevant wiring harness.
E1 INCORRECT_START

Incorrect start sequence (mechanical control valve version). Check:
- The forward and reverse microswitches and their respective cables
- The parking brake microswitch and its respective cables
- The mechanic distributor microswitches
4-65
E2 BAD LIFT POT

The alarm signals a failure at the P3 lifting potentiometer. The potentiometer could be disconnected,
broken or not well adjusted.
- Adjust the lever's microswitch and repeat the potentiometer acquisition (function LEARNING parameter
LEARN LIFT POT) 0
- Verify the potentiometer status and the relevant wiring harness
1
EB POT NOT ACQUIRED 2

3
The alarm signals that the MCB board requests the P3 lifting potentiometer acquisition. 4
- Repeat the potentiometer acquisition (function LEARNING parameter LEARN LIFT POT)
3
EE PUMP_STUFFING_ERR 6
7
The logic unit does not receive the information from the lifting logic unit. 8
If the armrest is present, the alarm is sent by the armrest board.
9
10
11
12
13
14
15
16
17
18
4-66
DASHBOARD
D1 TRAC_KO

This alarm signals that the (MD1) Master traction logic unit is not communicating.
Check:
- The supplying: 48V must be present on the connector JT1 pin 1 wire M
- The can-bus connections
If the supply is ok, but it do not permits the truck working, replace the Master traction logic unit.
D2 MCB_TRAC_KO

This alarm signals that the MCB logic unit is not communicating.
Check:
- The supplying: 48V must be present in the connector P5 pin 13 cable M
If the supply is ok, but it do not permits the truck working, replace the MCB logic unit.
D3 SLAVE_KO

This alarm signals that the (MD2) Slave traction logic unit is not communicating.
Check:
- The supplying: 48V must be present on the connector JT2 pin 1 wire M
If the supply is ok, but it do not permits the truck working, replace the Slave traction logic unit.
4-67
D4 PUMP_KO

This alarm signals that the (MD3) lifting logic unit is not communicating.
Check:
- The supplying: 48V must be present on the connector JP pin 1 wire M
0
If the supply is ok, but it do not permits the truck working, replace the lifting logic unit. 1
D5 MCB_MHY_KO
2
3
This alarm signals that the MCB logic unit is not communicating.
4
Check:
- The supplying: 48V must be present in the connector P5 pin 13 cable M 3
- Enter the SOFT VERS menu to see which card is not present on the can-bus line 6
If the supply is ok, but it do not permits the truck working, replace the MCB logic unit.
7
D6 JOY_KO
8
9
This alarm signals that the armrest logic unit is not communicating.
Use the RESET JOY FLAG function for re-establish the communication between the cards; if the 10
problem persists, verify
- The supplying: 48V must be present in the connector JCAN pin 5 cable M
11
If the supply is ok, but it do not permits the truck working, replace the armrest logic unit. 12
13
D7 UNUSED
14
D8 ERROR_READ_PIN_CODE 15
16
This alarm signals that the MCB logic unit does not permit password reading. 17
Check:
- The supplying: 48V must be present in the connector CN2 pin 13 cable M 18
Replace the MCB logic unit.
4-68
D9 UNUSED
DA UNUSED
DE UNUSED
DF EPPROM ERROR

Defect in the memory area where the adjustment parameters are registered; this alarm inhibits the truck
working, the unit will load the default parameters.
Delete the alarms in the logbook of the service menu
Install the latest version of the software using the programmer.
If the defect continues at the truck switching on, replace the dashboard.
If the alarm disappears the parameters previously stored will be cancelled and automatically will be
loaded the default parameters of the electronic control.
4-69
MCB CONTROL BOARD (section TRCB)

C1 PUMP INCORRECT START

Incorrect start sequence (mechanical control valve version). Check:
- The forward and reverse microswitches and their respective cables 0
- The parking brake microswitch and its respective cables
- The mechanic distributor microswitches
1
C2 BAD_CONF_WHEELS - UNUSED 2
3
C3 PEDAL WIRE KO
4
Failure on the acceleration potentiometer signal at rest.
Repeat the accelerator pedal potentiometer acquisition 6
Check:
- Steering potentiometer that could be damaged 7
- The traction potentiometer wiring harness
Wiring diagram reference page 3/8 (see chapter 17) 8
9
C4 BAD MICROSWITCH
10
11
Microswitch of the pedal or of the hand direction lever damaged.
Repeat the accelerator pedal potentiometer acquisition 12
Adjust the microswitch
Check the change in status of the microswitch with the Tester menu 13
C5 WARN_CONF_ERROR - UNUSED
14
15
16
17
18
4-70
C6 BAD_VACC

The alarm signals an incorrect voltage reading of the accelerator potentiometer:
- Repeat the P2 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 function is activated, while the seat microswitch is opened.
C8 BAD BRAKE MICRO SWITCH

The brake pedal microswitch is broken
Adjust the microswitch
Check the change in status of the microswitch with the Tester menu.
4-71
C9 PARKING_SELECTED

One of the functions is activated, while the parking brake is applied.
CA PARAM LOAD ERROR 0

1
The alarm appears when the truck is switched on or if the change 2
program button is pressed.
Use the RESET TRCB and EVCB function to reload the default parameters (see paragraph DEFAULT RST). 3
the programmer.
4
3
CB UNUSED
6
CC TRAC_STUFFING_ERROR 7
8
Problem of communication with the Master traction logic unit. 9
The alarm disappears after the key reset.
If the alarm appears frequently and blocks the truck, check the can-bus connections between the Master 10
logic unit and MCB.
Enter the SOFT VERS menu to see which card is not present on the can-bus line 11
CD UNUSED
12
13
14
15
16
17
18
4-72
CE UNUSED
CF UNUSED
90 UNUSED
91 UNUSED
92 UNUSED
93 UNUSED
94 CHKSUM_ERROR

Software error.
Use the RESET TRCB and EVCB function to reload the default parameters (see paragraph DEFAULT RST).
the programmer.
95 UNUSED
96 UNUSED
97 UNUSED
4-73
ARMREST CARD
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 identified the potentiometer with the different values proceed as follows: 6
• reverse the potentiometer with one other potentiometer on the board(fingertips version)
• exchange the lifting potentiometer with the sideshift potentiometer or the tilting potentiometer with the 7
4th way potentiometer (joystick version)
- If the alarm persists in the same position, replace the board. 8
If the problem appears on a different potentiometer (according to where the defective potentiometer has
been connected) replace the potentiometer
9
10
11
12
13
14
15
16
17
18
4-74
E2 BAD LIFT POT

Failure at the RP1 lifting potentiometer in the joystick-fingertip group.
Check the voltages on the potentiometer at rest
Enter the function TESTER menu MAT HANDLING and verify the parameters IN1 1(LIFTING SWITCH)
and LIFT LOWER J.
Conditions of rest:
- LIFT LOWER J = 2,5 ± 0,2 V
- IN1 1(LIFTING SWITCH) = OFF
If the conditions of rest are different the potentiometer could be mechanically jammed or defective.
Check:
• exchange the lifting potentiometer with the tilting potentiometer (fingertips version) and verify the
correct operation through console
• exchange the lifting potentiometer with the sideshift potentiometer (joystick version) and verify the
If the alarm persists replace the logic unit.
Wiring diagram reference pages 7-8/8 (see chapter 17)

4-75
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 parameters IN2 1(TILTING SWITCH)
and TILT J. 0
Conditions of rest:
- TILT J = 2,5 ± 0,2 V
- IN2 1(TILTING SWITCH) = OFF
1
If the conditions of rest are different the potentiometer could be mechanically jammed or defective. 2
Check:
• exchange the tilting potentiometer with the lifting potentiometer (fingertips version) and verify the
3
• exchange the tilting potentiometer with the 4th way potentiometer (joystick version) and verify the
correct operation through console 4
3
6
E4 BAD SIDESH. POT 7

8
Failure at the RP3 sideshift potentiometer in the joystick-fingertip group. 9
Enter the function TESTER menu MAT HANDLING and verify the parameters IN3 1(SIDESHIFT
SWITCH) and SIDESHIFT J.
10
Conditions of rest:
- SIDESHIFT J = 2,5 ± 0,2 V 11
- IN3 1(SIDESHIFT SWITCH) = OFF
12
Check:
• exchange the sideshift potentiometer with the tilting potentiometer (fingertips version) and verify the 13
• exchange the sideshift potentiometer with the lifting potentiometer (joystick version) and verify the 14
If the alarm persists replace the logic unit. 15
Wiring diagram reference pages 7-8/8 (see chapter 17) 16
17
18
4-76
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 parameters IN4 1(IV WAY SWITCH)
and IV WAY J.
Conditions of rest:
- IV WAY J = 2,5 ± 0,2 V
- IN4 1(IV WAY SWITCH) = OFF
Check:
• exchange the 4th way potentiometer with the sideshift potentiometer (fingertips version) and verify the
• exchange the 4th way potentiometer with the tilting potentiometer (joystick version) and verify the
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 parameters IN5 1(V WAY SWITCH)
and V WAY J.
Conditions of rest:
- V WAY J = 2,5 ± 0,2 V
- IN5 1(V WAY SWITCH) = OFF
Check:
• exchange the 5th way potentiometer with the 4th way potentiometer

4-77
E7 ERR_SEAT

The alarm signals the seat micro opened with activated hydraulic functions.
Verify the seat micro status.
E8 INVALID RESTORE STATE 0

1
Incomplete restore of the parameters. Repeat the operation. 2
E9 EEPROM_CHKSUM_ERR 3

4
Eprom data loading unsuccessful. 3
Use the RESET ARMREST function to reload the default parameters (see paragraph DEFAULT RST).
the programmer.
6
If the alarm persists at the key reset, replace the logic unit.
7
EA DEFAULT RESTORED 8
Flash memory data loading. Switch off and switch off again the truck.
10
EB POT NOT ACQUIRED 11

12
Flash memory data loading. Switch off and switch off again the truck. 13
EC RAM_CHKSUM_ERR 14
15
RAM data loading unsuccessful. 16
Use the RESET ARMREST function to reload the default parameters (see paragraph DEFAULT RST).
If the error persists when the machine is switched back on, install the last version of the software using 17
the programmer.
If the alarm persists at the key reset, replace the logic unit.
18
4-78
ED MHYRIO_STUFFING_ERR

The logic unit has a communication problem with the EVCB (MCB) unit.
Check on the dashboard others alarms.
EE PUMP_STUFFING_ERR

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.
EF FW + BW - UNUSED
F1 UNUSED
5-1
MOTOR
Page
DRIVE MOTOR ............................................................ 5-2
0
GENERAL ...............................................................................5-2
REMOVING THE GEARMOTOR UNIT ...................................5-4
1
REMOVING THE ENCODER BALL BEARING ......................5-8 2
FITTING THE ENCODER BALL BEARING............................5-9 3
TEMPERATURE SENSOR REPLACING .............................5-10
4
LIFTING MOTOR ....................................................... 5-11
5
GENERAL .............................................................................5-11
TEMPERATURE SENSOR REPLACING .............................5-15
6
ENCODER REPLACING.......................................................5-16 7
ENCODER .............................................................................5-16 8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
5-2
DRIVE MOTOR
GENERAL
SPECIFICATIONS
DRIVE MOTOR
MOTOR TYPE ASYNCHRONOUS TSA200A-26
POWER 4.5 kW
NOMINAL VOLTAGE 27 V
CURRENT 152 A
FREQUENCY 80 Hz
FACTOR POWER (cosφ) 0.915
INSULATION CLASS F
DEGREE OF PROTECTION (IP CODE) IP 20
SERVICE S2-60 min
NUMBER OF POLES 4
R.P.M. 2295 rpm

5-3
COMPONENTS
2
2
2
3
5
5
6
7
8
9
1 Drive motor 6 Bolt
2 O Ring 7 Ring 10
3 Seal 8 Washer
4 Pad 9 Encoder ball bearing 11
5 Rotor
12
13
14
15
16
17
18
18
18
18
18
18
5-4
REMOVING THE GEARMOTOR UNIT
2. Tilt backward until the end stroke and place 2 wooden or metal blocks under the mast
3. Tilt the mast forward until the end stroke
4. Switch off the truck
6. Remove the footboard
7. Disconnect the temperature sensor wiring, the encoder wiring, and the motor power cables [Point 1]
8. Disconnect the wirings of the braking system [Point 2]
9. Remove the wheel [Point 3]
10. Remove the oil from the reduction gears [Point 4]
11. Remove the complete gearmotor [Point 5]
12. Remove the motor [Point 6]
13. Remove the pinion [Point 7]
Assembly procedure
The reassembly procedure is the reverse of the disassembly procedure.
5-5
Point Operation
[Point 1]
A Disassembly: 2
Disconnect the temperature sensor and encoder
wiring harness (A) and the power cables of the motor 2
(B)
Assembly: 2
Power cable W connected to phase W
B Power cable V connected to phase V 3
Power cable U connected to phase U
Tightening torque of the cables 15 Nm 5
5
[Point 2]
Disassembly: 6
Disconnect the brakes system pipe (C) and the cable
D
of the parking brake (D) 7
Important:
When brake system hose is disconnected, the brake 8
fluid (type DOT 4) will leak
C 9
10
11
[Point 3]
Disassembly: 12
Remove the wheel
Assembly:
13
After installation, tightening torque of the wheel bolts =
140 Nm. 14
15
16
17
18
18
18
18
18
18
5-6
[Point 4]
Disassembly:
E
Carefully clean the area around the oil filler (E) and
drain caps (F); place a suitable container under the
drain cap and remove both caps to allow all oil to flow
out.
Clean any residues from the cap (F) and put it back on
F Assembly:
Pour fresh oil into the hole (E) until it starts overflowing
(Q.ty about 0.35 liters) then put the cap back on.
When filling is complete, clean any overflow; after a
short functioning period, check the oil level again
Maintenance:
After the first 40 hours of operation
- 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 ATF DEXRON II 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
Remarks:
• 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
G [Point 5]
Disassembly:
Remove the fixing screws (G) of the motor reduction
gear and insert a M14 bar (H) in the hole 2
2
2
3
5
Remove the remaining 6 fixing screws and extract the
motor reduction gear as shown in the picture
5
Assembly:
H
After installation, tightening torque of fixing screws 6
= 130 Nm
Remarks:
7
Use Loctite 243
8
9
[Point 6] 10
Disassembly:
Remove the 3 fixing screws (I) and extract the motor 11
Assembly:
I After installation, tightening torque of fixing screws 12
= 23 Nm
13
14
15
16
L
[Point 7]
Disassembly: 17
Mount the seal (M)
Remove the pinion (N) using an extractor separator
18
Assembly:
Insert the tongue (L) in the right place. 18
M Insert the pinion (N) and tighten the seal (M) to a
tightening torque of 55 Nm
18
Remarks:
In case of complete reduction gear substitution, 18
replace the pinion also
N
18
18
5-8
REMOVING THE ENCODER BALL BEARING
1. Remove the motor from the truck (see under the heading REMOVING THE GEARMOTOR UNIT)
2. Mark the position of two the support plates (ref 300) and (ref 400) with respect to the stator (ref 51)
3. Unscrew the 4 cheese-head screws (ref 515) and remove the support plates (ref 400)
4. Extract the encoder ball bearing (ref 500) with the appropriate extractor
Use a seeger, during extraction, to

prevent mechanically damaging the ball bearing
Seeger dimensions
diameter = 60 mm
height = 8 mm
thickness = 2 mm
5-9
FITTING THE ENCODER BALL BEARING
3 4 2
2
2
2
3
5
5
6
7
8
1
9
10
1. Position the driving shaft in the guide against the plate (ref.1) paying attention to apply no pressure
on the sealing guide 12
2. Position the encoder (ref.2) on the driving shaft
3. Using an appropriate tool, press on the inside ring of the encoder, as per drawing (ref.3) and secure 13
everything with the two long screws
4. Press on the sensor and screw in the screw (ref.4) ensuring that the pressure is applied on the inside
ring of the encoder
14
5. Secure the encoder cable to the motor cable with a clamp
6. Examine the o-ring inside the support plate and replace it if damaged 15
7. Reassemble the support plates paying attention not to crush the cables. Refer to the markings made
previously for correctly coupling the plates with the stator. 16
Remarks: Do not use a hammer for fitting the encoder
ENCODER 17
The encoder generates a feedback signal from the motor and sends it to the command logic to monitor:
motor status, rpm and direction of rotation. 18
The encoder is positioned in the back part of the motor.
18
Irreversible damage:
• +V > 13 Volts
18
• Short circuit between the signal and the power supply
• Heating by induction 18
• Assembly with hammer
18
18
5-10
TEMPERATURE SENSOR REPLACING
1. Remove the motor from the truck (see under the heading REMOVING THE GEARMOTOR UNIT)
2. Remove the support plate to reach the temperature sensor
3. Remove the sensor from the winding of the motor paying attention not to damage the coil
Assembly procedure
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
3. Reassemble the support plate paying attention not to crush the cables
5-11
LIFTING MOTOR
GENERAL
2
2
2
3
5
5
6
7
8
9
SPECIFICATIONS
LIFTING MOTOR
10
MOTOR TYPE ASYNCHRONOUS MOTOR (TSA170-210) 11
POWER 10 kW 12
NOMINAL VOLTAGE 28 V
13
CURRENT 250 A
FREQUENCY 80 Hz 14
FACTOR POWER (cosφ) 0.83 15
INSULATION CLASS F
16
DEGREE OF PROTECTION (IP CODE) IP 20
SERVICE S3-26%
17
NUMBER OF POLES 4 18
R.P.M. 2314 rpm
18
18
18
18
18
5-12
COMPONENTS
1 Pump 10 Lift motor

2 Washer 11 Seal
3 Bolt 12 Pad
4 Support 13 Rotor
5 Vibration damping 14 Bolt
6 Washer 15 Washer
7 Washer 16 Encoder ball bearing
8 Bolt 17 Ring
9 Nut 18 Cover
5-13
REMOVING THE PUMP MOTOR UNIT
2
2
2
3
5
5
6
7
2. Switch off the truck 9
4. Remove the battery 10
5. Disconnect the temperature sensor wiring, the encoder wiring, and the motor power cables [Point 1]
6. Remove the screws fixing the motor to the pump [Point 2] 11
7. Remove the bolts of the motor [Point 3]
8. Lift and remove the motor
12
Assembly procedure
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
Point Operation
B
[Point 1]
C Disassembly:
Disconnect the encoder wiring harness (A), the
temperature sensor wiring harness (B) and the motor
power cables (C)
A
[Point 2]
Disassembly:
Remove the two pump fixing nuts (D).
Assembly:
After the installation, pump fixing bolts tightening
torque = 45 ± 5 Nm
D
D
[Point 3]
Disassembly:
Remove the motor fixing screws from the chassis (E)
E E
5-15
TEMPERATURE SENSOR REPLACING
2
2
2
3
5
5
6
7
1. Remove the motor from the truck (see under the heading REMOVING THE PUMP MOTOR UNIT)
2. Remove the motor terminal board
9
3. Take out the 4 screws fastening the support plates to the central body
4. Remove the support plate 10
5. Remove the sensor from the winding of the motor paying attention not to damage the coil
11
Assembly procedure
1. Position the new sensor on the coil of the motor and secure it with silicone paste 12
(see Service Tools List)
2. Connect it to the wiring harness 13
14
15
16
17
18
18
18
18
18
18
5-16
ENCODER REPLACING
3. Open the battery cover, disconnect the battery and remove it
4. Remove the battery
5. Disconnect the encoder connector A from the auxiliary wiring
6. Remove the fixing screws B from the cover
7. Unscrew the encoder C from its seat
Assembly procedure
ENCODER
The encoder generates a feedback signal from the motor and sends it to the command logic to monitor:
motor status, rpm and direction of rotation.
The encoder is positioned in the back part of the motor.
Irreversible damage:
• + V > 13 Volts
• Short circuit between the signal and the power supply
• Heating by induction
• Assembly with hammer
6-1
DRIVE UNIT & FRONT AXLE

Page
TRANSMISIONES........................................................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
TRANSMISIONES
COMPONENTS
1 Kit 7 Kit
2 Kit 8 Vent
3 Kit 9 Seal
4 Kit 10 Plug
5 Kit 11 Nut
6 Kit 12 Bolt
6-3
SPECIFICATIONS
DESCRIPTION VALUES
2
Transmission ratio 1:18.2
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
For the disassembly procedure of the gearbox please see chapter 5.
Assembly procedure
7-1
REAR AXLE
Page
REAR AXLE .................................................................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 ...................................................... 7-8
4
STEERING CYLINDER .......................................................... 7-9
5
STEERING POTENTIOMETER ADJUSTMENT........ 7-16
SPEED REDUCTION IN A BEND ........................................ 7-16
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
7-2
REAR AXLE
GENERAL
7-3
COMPONENTS
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1 Axle 9 Support 17 Grease nipple 18
2 Cover 10 Axle support 18 Seal
3 Steering potentiometer 11 Plate 19 Pad
18
4 Shaft 12 Cylinder 20 Wheel hub
5 Plug 13 Plug 21 Pad
18
6 Flange 14 Dowel pin 22 Nut
18
7 Bolt 15 Nut 23 Cover
8 Cover 16 Spacer 24 Split pin 18
18
7-4
CONTROL OF REAR AXLE
Every 1000 hours

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

1. Check the steering angle as shown in the picture here
above
2. To vary the steering stroke end angle, act on the grub
screw (B) opposite to the wheel to adjust.
B Std value 95°
3. Repeat the same operation on the other wheel
7-5
Tightening torque T=N·m
2
2
2
3
4
5
6
7
8
9
1. Park the vehicle on a level surface and apply the parking brake 10
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 lines [Point 2] 12
7. Disconnect the wiring of the potentiometer [Point 3]
8. Keep the steering axle raised with a pallet truck [Point 4] 13
9. Loosen and remove the fixing screws [Point 5]
10. Remove the steering axle 14
Assembly procedure
15
16
17
18
18
18
18
18
18
7-6
Point Operation
[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
per side)
A
[Point 3]
Disassembly:
Disconnect the wiring of the potentiometer (B)
B
[Point 4]
Disassembly:
Position a trans-pallet under the steering axle
7-7
[Point 5]
Disassembly:
C Loosen and remove the 4 steering axle fixing screws 2
(C)
Assembly: 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
7-8
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.
7-9
STEERING CYLINDER
REMOVAL
2
[Point 1]
Secure the cylinder in the vice with aluminum jaws.
Hold the rod at the limit stop; work first on one side and
2
then on the other.
Secure the body paying attention not to ruin the surface. 2
3
4
5
[Point 2]
Firstly remove the external seeger with pliers. 6
7
8
9
[Point 3] 10
Keep the tool for assembling the gaskets fixed in the
cylinder on the first seal. 11
Strike the tool with a plastic mallet and push the seal into
the seat by approximately 20 to 30 mm. 12
13
14
[Point 4] 15
Use a flat screwdriver to remove the internal seeger from
the seat. 16
17
18
18
18
18
18
18
7-10
.
[Point 5]
Take the rod tool and tighten it on the rod.
Press the rod with the hammer on one side so that the first
seal comes out from the opposite side.
[Point 6]
Extract the bar.
Don't worry about damaging the gaskets and guide rings
because they will in any case be replaced.
[Point 7]
Use the pliers to remove the external seeger on the
opposite side of the body.
[Point 8]
Match up the assembled tool on the seal.
Using a plastic mallet, strike the seal and push it inside the
body by 20 to 30 mm.
[Point 9]
Use a flat screwdriver to remove the internal seeger from
the seat.
7-11
CHANGING GASKETS
[Point 10]
The piston and the two seals removed from the cylinder 2
must be sealed separately again.
Use a screwdriver and hammer to break the guide ring. 2
2
3
4
[Point 11]
Use a screwdriver to remove the guide ring from the piston. 5
6
7
8
9
[Point 12]
Use a screwdriver to remove the o-ring from the piston. 10
11
12
13
14
[Point 13]
Make sure you keep the new gaskets kit separate from the 15
worn parts.
Carefully clean the piston and all the grooves. 16
Open the bag with the gaskets kit.
Apply the seal of the housing on the piston and insert
the o-ring so that it slides on the housing.
17
18
18
[Point 14]
Insert the external guide ring of the piston gasket onto the 18
o-ring just fitted, in this way:
Position the ring on the housing, take the pressure tool and 18
press until it matches the piston. The gasket will be inserted
automatically.
18
18
7-12
[Point 15]
FOR PTFE GASKETS ONLY (this operation is not
necessary for polyurethane gaskets), resize the gasket with
the gauge.
[Point 16]
Remove both gaskets and the anti-extrusion ring from the
seal with a screwdriver.
Use the screwdriver with caution, avoid marking the groove
of the gasket.
[Point 17]
Remove the static external gasket paying attention not to
mark the surface of the groove.
[Point 18]
Clean the gaskets carefully and check whether any dirt
remains, before fitting the new gaskets; any remaining
materials could damage the inside surface of the cylinder.
[Point 19]
Fit the rod gasket.
CAUTION: check the orientation of the edges: the lip
gasket will be orientated towards the oil pressure (cylinder
inside)
7-13
[Point 20]
Use a screwdriver to insert the rod gasket into the groove,
paying attention not to damage it.
2
2
2
3
[Point 21]
Mount the anti-extrusion ring paying attention to the right-
4
hand orientation of the lip.
5
6
7
8
[Point 22]
Mount the seals.
9
CAUTION: check the orientation of the edges: the lip 10
gasket will be orientated towards the oil pressure (cylinder
inside) 11
12
13
[Point 23]
Manually fit the static gasket on the seals.
14
15
16
17
18
18
18
18
18
18
7-14
INSTALLATION
[Point 24]
Position a gasket on one side of the seat, adjacent to it
place a plastic housing; hit the housing with a hammer to
insert it by approximately 20 to 30 mm into the tube.
[Point 25]
Manually insert the seeger into the cavity.
[Point 26]
Tighten the housing on the rod and make it slide in the
seat.
Slide the mounted piston/rod to reach the seal just fitted on
the opposite side.
[Point 27]
Use the hammer to completely press the piston/rod fitted
inside the body, until the piston stops and touches the seal
just fitted.
Take care not to damage the piston gasket.
[Point 28]
Unscrew the housing and tighten it to the opposite side of
the rod.
7-15
[Point 29]
Manually insert the second seal in the body.
2
2
2
3
[Point 30]
Use a hammer to press the seal into the body by
4
approximately 20 to 30 mm.
5
6
7
8
[Point 31]
Position the seeger on the seal.
9
10
11
12
13
[Point 32]
Use the pliers to mount the seeger on the first seal.
14
Use the hammer to completely press the piston/rod fitted
inside the body, until the piston stops and touches the 15
opposite seal.
Assemble the seeger on the second seal. 16
The cylinder is now ready to be used.
17
18
18
18
18
18
18
7-16
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.
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.
Voltage values obtained with the dashboard

Right (MAX STEER RIGHT)~ 7.92 V
Left (MAX STEER LEFT)~ 1.60 V
Center (SET 0-POS) ~ 4.23 V
SPEED REDUCTION IN A BEND

The speed on a bend is managed by the Master traction logic unit using the steer angle read by 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
HYDRAULIC DIAGRAM
(mechanical distributor version) ...................................... 8-3 2
HYDRAULIC DIAGRAM 3
(electro-proportional distributor version)........................ 8-4
STEERING COMMAND.......................................................... 8-5 4
POWER STEERING (ORBITROL)...............................8-6 5
SPECIFICATIONS .................................................................. 8-6 6
TROUBLESHOOTING............................................................ 8-8
7
STEERING UNIT ........................................................8-10
8
CHECKING SEALS AND CLEANING POWER
STEERING SYSTEM......................................................... 8-10 9
INSPECT AND ADJUST THE PRESSURE 10
RELIEF VALVE.................................................................. 8-10
PRIORITY VALVE ...................................................... 8-11
11
GENERAL..............................................................................8-11 12
13
14
15
16
17
18
19
20
21
E
8-2
STEERING SYSTEM
COMPONENTS
1 Clamp 11 Power steering

2 External 12 Washer
3 Connection 13 Connection
4 Valve 14 Tube
5 Connection 15 Connection
6 Connection 16 External
7 External 17 External
8 Tube 18 External
9 Connection 19 External
10 Connection
8-3
HYDRAULIC DIAGRAM (mechanical distributor version)
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 (electro-proportional distributor version)

8-5
STEERING COMMAND
The steering uses the same oil as the lifting 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 flow rate is controlled by the LS (Load-sensing) signal output by the steering unit and is done in such
a way that the flow to the power steering is suited to actual demand. 2
The exceeding delivery is sent to the control valve for other functions.
When the steering wheel is turned, the steering unit “measures” a volume of oil proportional to the above
rotation and sends it into the steering cylinder. The steering unit automatically returns to neutral when the
2
manoeuvre is completed.
The steering wheel hardness depends proportionally from the truck traction speed, as shown in the 3
diagram here below.
Increasing traction speed, pump R.P.M. decrease. 2
This allows an improvement of truck speed control.
2
25
2
20 8
Lifting speed (Hz)
15
10 8
5
9
20 40 60 80 100 120 140 160
Traction speed (Hz)
10
11
12
13
14
15
16
17
18
18
18
18
18
18
8-6
POWER STEERING (ORBITROL)
SPECIFICATIONS
Capacity
1.6 - 2.0 t
Parts
Steering wheel diameter mm 360
Steering wheel clearance mm 20 ~ 50
Power steering type Dynamic
8-7
2
2
2
3
2
2
2
8
4. Remove the front fascia to facilitate the operations of replacing the power steering [Point 1]
5. Remove the steering column covers
6. Disconnect the lines
10
7. Remove the power steering (orbitrol) by taking out the 4 fixing screws [Point 2]
11
Assembly procedure
Remarks:
Add grease at the coupling between the steering shaft and steering valve. 13
14
Point Operation
[Point 1]
Disassembly:
15
Remove the front fascia by unscrewing the fixing
screws (A) 16
A 17
A 18
[Point 2] 18
Disassembly:
B Remove the power steering by unscrewing the fixing
B
screws (B)
18
18
18
18
8-8
TROUBLESHOOTING
Only hydraulic malfunctions are listed.
Symptom Possible cause Action
• damaged lines replace
the steering wheel cannot • The shaft from the steering wheel to the
be rotated power steering is incorrectly installed or inspect and adjust or replace
damaged
• Tyre pressure is low Adjust the tyre pressure
Inspect and adjust the relief
• the oil pressure does not rise
the steering wheel is heavy pressure
• the high and low pressure lines are con-
inspect and adjust
nected in reverse
• the high and low pressure lines are con-
inspect and adjust
nected in reverse
the oil pressure does not • the relief valve is faulty or not closed inspect and correct
rise
• oil pump function defective inspect and adjust or replace
• hydraulic fluid level low top up
• Tyre pressure is low Adjust the tyre pressure
The steering wheel does
inspect and adjust or replace
not return properly into • the orbitrol shuttle does not move easily
the orbitrol
properly
• the rear axle does not move smoothly add lubricant or adjust
• the orbitrol shuttle does not move easily
the orbitrol
The steering wheel pulls to • The steering valve drive shaft is dam-
replace the orbitrol
one side when released aged
• the lines are blocked (crushed or
unblock or replace
clogged)
• oil moving in the orbitrol replace the orbitrol
play is excessive and the • the orbitrol shuttle does not move easily
the orbitrol
vehicle wobbles
• air aspirated from the lines inspect and adjust or replace
• the steering shaft is defective inspect and adjust
8-9
Symptom Possible cause Action

the steering wheel shim-
mies
• the shaft is not installed correctly inspect and adjust 2
the wheels steer contrary to • the lines to the hydraulic motor are con- inspect and correct the line
the steering direction nected in reverse connections
2
• The pressure relief valve is defective
check and adjust the pres- 2
sure
Abnormal noise is gener-
ated • air aspirated from the lines inspect and adjust or replace 3
• lines blocked (crushed or clogged) unblock or replace
2
2
2
8
8
9
10
11
12
13
14
15
16
17
18
18
18
18
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
F intervention must be carried out without pressure in the
system
Every 5000 hours
• replace the hoses (F) connecting the power steering to
the steering cylinder
Every 10 000 hours
• replace the hydraulic piping system
INSPECT AND ADJUST THE PRESSURE RELIEF VALVE

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

end, relief state is achieved, so read the pressure on
the pressure gauge at that time
Standard
B On all models
Bar ~90
3. If the relief pressure is greater or lower than the

standard value, adjust the orbitrol setting screw (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
Tightening torque T =Nm
5. Disconnect the hoses from the priority valve
6. Remove the priority valve.
Assembly procedure
9-1
BRAKES
Page
BRAKE SYSTEM .........................................................9-2
0
GENERAL............................................................................... 9-2
1
COMPONENTS ............................................................9-3
BRAKE PEDAL ...................................................................... 9-3 2
SERVICE BRAKE ........................................................9-4 3
BRAKE FLUID SYSTEM BLEEDING .......................... 9-5 4
SERVICE BRAKE................................................................... 9-6
5
DISK BRAKES .............................................................9-7
6
REPLACE DISK BRAKES...........................................9-8
7
BRAKES LEVER........................................................9-17
PARKING BRAKE......................................................9-21
8
GENERAL............................................................................. 9-21 9
UNLOCKING PARKING BRAKE LEVER ............................ 9-21 10
11
12
13
14
15
16
17
18
19
20
21
E
09-2
BRAKE 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 discs are lubricated with the same oil as the reduction gear, ATF DEXRON II.
In addition to mechanical braking, the vehicle uses a motor brake controlled electronically via the traction
control system (see chapter 03 for the parameter settings).
The brake discs are operated by pressing the brake pedal (A) or using the hand-operated parking brake
(B).
09-3
COMPONENTS
BRAKE PEDAL
2
Oil inlet 2
2
B
3
4
A 5
C 6
7
9
D 9
Pressing the pedal, the cap (B) applies pressure on the piston (C). The piston puts in motion the oil that 10
pressing on the plate compress the brake disk.
The limit stop is adjusted by the screw (A), while the return into the neutral position of the pedal is 11
governed by the spring (D).
The microswitch must trip when the cap touches the pump piston.
12
If making adjustments, make sure that there is a gap of 1.5
1.5 mm
mm between the cap and pump piston, otherwise there is 13
the risk of the truck remaining braked which would cause
early brake disc wear. 14
15
16
17
18
18
18
18
18
18
09-4
SERVICE BRAKE
SERVICE BRAKE SYSTEM DIAGRAM
C (A) Reduction gear

A
B (B) Bleed screw
(C) Electric drive motor
(D) Brake pipes
(E) Distribution lock
D (F) Brake pedal
(G) Tank
(H) Brake pump
Every 1000 hours
E
- check that the liquid level in tank (G) has not dropped;
otherwise check the unit
- control the pedal functioning that must be smooth and
G with no jamming
F
Every 2000 hours
- change the braking system liquid
H - check the oil brake tank warning light: when the button is
pressed the warning light must come on
Every 5000 hours
- replace the pipes (D) of the brake
BRAKE FLUID TANK (G)

L When the fluid in the brake tank reaches a too low level, the
warning light indicating the low level liquid brakes on the
dashboard shall light up (see 04 chapter, INCORRECT
STARTS MANAGEMENT section).
Use the push button SW3 (L) to check the warning light
G works properly.
Fill up the brake fluid tank (DOT 4- Qt.0.30 l)
09-5
BRAKE FLUID SYSTEM BLEEDING

The bleeding procedure is necessary to take out completely the air from the system. The oil used in this
braking system is: DOT4.
2
Bleeding procedure
2
1. Fill the brake fluid tank (DOT4)
2
3
4
5
6
2. Loosen the bleeding screw (A), press deeply the 7
service brake pedal and let go out a small quantity of
oil 9
3. Screw in the bleeding screw, and press the brake
pedal several times 9
4. Keep the oil level constant
10
5. Repeat points 2, 3 and 4 until bleeding screw doesn't
A go out only the oil 11
6. Repeat the procedure on the other reduction gear
12
13
14
15
16
17
18
18
18
18
18
18
09-6
SERVICE BRAKE
Main piston
Pad
Brake pin
Brake cylinder
Oil brake tube
Wheel cylinder
Oil area
Spring
Brake disks group
The braking effect is due to the rotation of the brake cylinder hinged to the reduction gear through a pivot
fixed by two seegers.
The parking brake lever or service brake pedal operation causes the cylinder rotation and, consequently,
the braking system intervention.
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.
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.
When the brake pedal is released the springs push the main piston in neutral position, freeing the disks.
09-7
DISK BRAKES
2
Pinion
2
2
Transmission
unit 2 3
Plate disk
4
5
Transmission
unit 1 6
7
9
9
10
11
Reduction gear body
12
13
14
15
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.
16
The wheel pinion with Gear group 2 while Gear group 1 and the brake discs are fixed.
The brake disks have a tooted shape on the external diameter in order to fix them fully with the reduction 17
gear body. The counter disks have a toothed shape on the internal diameter in order to fix them to be
integral with the Gear group 1. 18
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. 18
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.
18
18
18
18
09-8
REPLACE DISK BRAKES

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

in the housing cover 2
2
2
3
(4) Remove the circlip from the retaining pin of the

4
brake lever and remove the retaining pin from the
brake lever 5
(5) Fit the brake lever in the guide in the housing cover 6
(6) Fasten the brake lever to the housing cover with the 7
retaining pin
9
9
(7) Fit the retaining pin circlip
10
11
12
13
14
[Point 5]
15
Assembly:
Measure the brake lever play 16
(1) Select the dial gauge sensor on the brake lever
17
(2) Adjust the dial gauge to 0
(3) Press the brake lever down by hand 18
18
18
18
18
18
09-20
(4) Read off the brake lever play from the dial gauge
[Point 6]
Assembly:
Test the brake manually:
Turn the wheel shaft by hand. At the same time, push
the brake lever up, using a screwdriver
09-21
PARKING BRAKE
GENERAL
2
A
2
2
B
3
4
5
6
7
9
The hand parking brake operates, via lever (A), on the same discs as the service brake. 9
The microswitch (B) is normally closed and prevents the vehicle from moving when it is open.
10
UNLOCKING PARKING BRAKE LEVER
11
• Parking and emergency brake lever (A)
B • Push button to unlock parking brake (B)
12
13
A 14
15
To engage the parking brake, pull the lever (1) in direction
B.
16
To unlock press the push button (2) and push the lever in
direction A. 17
18
18
18
When the parking brake is engaged, the icon (C) will
C appear on the display. 18
18
18
09-22
10-1
BODY & FRAME

Page
COMPONENTS ..........................................................10-2
0
BATTERY HOODS .....................................................10-4
1
OVERHEAD GUARD .................................................10-5
COUNTERWEIGHT....................................................10-6 2
OPERATOR’S SEAT ..................................................10-7 3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
10-2
COMPONENTS
1 Guard 20 Hook
2 Conveyor 21 Closing
3 Bracket 22 Handle
4 RH hinge 23 Plate
5 LH hinge 24 Side door
6 Head guard 25 Plate (sheet of metal)
7 Bin 26 Bolt
8 Compartment 27 Washer
9 Shock absorber 28 Washer
10 Attachment 29 Cover
11 Light 30 Seal
12 Bulb 31 Side door
13 Light glass 32 Stop
14 Light 33 Self-locking nut
15 Bulb 34 Terminal
16 Light glass 35 Profile
17 Bracket 36 Crosspiece
18 Split pin 37 Bolt
19 Pin
10-3
2
2
2
3
4
5
6
6
8
9
10
11
12
1 Dashboard 21 Guard 41 Elastic washer
2 Bracket 22 Horn 42 Brake
13
3 Panel 23 Emergency button 43 Bolt
4 Plug 24 Key switch 44 Spacer
14
5 Complete dashboard 25 Start key 45 Washer
15
6 RH dashboard cover 26 Wiring 46 Nut
7 LH cover 27 Contact 47 Bolt 16
8 Bracket 28 Horn button 48 Pulley
9 Washer 29 Steering column casing 49 Pin 17
10 Washer 30 Plug 50 Microswitch
11 Bolt 31 Plug 51 Plate 18
12 Bolt 32 Steering wheel 52 Brake cable
13 Washer 33 Knob 53 Bolt 18
14 Washer 34 Snap ring 54 Washer
15 Handle 35 Button 55 Floor mat
18
16 Spacer 36 Button 56 Footboard
17 Pin 37 Bolt 57 Terminal
18
18 Pin 38 Steering column 58 Nut
18
19 Bolt 39 Steering column casing 59 Washer
20 Bolt 40 Bolt 18
10-4
BATTERY HOODS
photo A photo B
4. Disconnect the wiring of the seat microswitch
5. Remove the gas springs (photo B) supporting the battery cover (chassis side only)
6. Close the battery cover
7. Remove the battery cover hinge set bolts (photo A)
8. Remove the battery cover W/ seat.
Assembly procedure
10-5
OVERHEAD GUARD
Tightening torque T =Nm 2
2
2
3
4
5
6
6
8
Fixing points
T = 90 Nm 9
10
4. Remove the battery hood (see paragraph "BATTERY HOOD")
5. Remove the footboard 13
6. Remove the front board.
7. Disconnect all hydraulic pipe and all electric cables 14
8. Sling the overhead guard using appropriate belts in order to avoid its falling down when removed
from the frame 15
9. Remove the OHG rear fixing bolts
10. Remove the OHG
16
Assembly procedure
18
18
18
18
18
18
10-6
COUNTERWEIGHT
2. Tilt the mast back and put shims under the profiles
5. Remove the battery (see chapter 01)
6. Disconnect the cables of the tail lights and the wiring harness of the seat microswitch
7. Remove the hood to facilitate removing the counterweight
8. Remove the rear lights
9. Install the lifting belts or use an attachment (as shown in the figure) and remove the counterweight
bolts (note: use belts rated for 2000kg in straight traction lines)
10. Remove the counterweight.
Assembly procedure
Tightening torque of the 3 bolts of the counterweight = 300 Nm.
Note: Tighten the bolts with the sequence V1, V2, V3]
V1
V3
V2
10-7
OPERATOR’S SEAT
2
1. Park the vehicle on a level surface and apply the 2
parking brake
2
4. Disconnect the wiring of the seat microswitch
5. Remove the set of nuts fastening the operator’s seat 3
(take care not to drop the operator's seat)
6. Remove the operator’s seat. 4
5
6
Assembly procedure
The reassembly procedure is the reverse of the
6
disassembly procedure
8
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
MECHANICAL CONTROL VALVE........................................11-2
ELECTROPROPORTIONAL DISTRIBUTOR........................11-3
1
HYDRAULIC SYSTEM............................................... 11-4 2
PUMPS SYSTEM...................................................................11-4 3
STEERING SYSTEM .............................................................11-5 4
BRAKES SYSTEM ................................................................11-5
5
COMPONENTS .......................................................... 11-6
6
HYDRAULIC OIL TANK ........................................................11-6
HYDRAULIC OIL AND FILTER ................................. 11-7 7
LIFTING LOAD DOWN TEST .................................... 11-8 8
OIL LEAK TEST......................................................... 11-9 9
LIFTING CYLINDERS ...........................................................11-9 10
TILTING CYLINDERS............................................................11-9
11
12
13
14
15
16
17
18
19
20
21
E
11-2
HYDRAULIC CIRCUIT
MECHANICAL CONTROL VALVE
11-3
ELECTROPROPORTIONAL DISTRIBUTOR
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
HYDRAULIC SYSTEM
PUMPS SYSTEM
11-5
STEERING SYSTEM
2
2
2
3
4
5
6
6
8
9
9
BRAKES SYSTEM
11
12
13
14
15
16
17
18
18
18
18
18
18
11-6
COMPONENTS
HYDRAULIC OIL TANK
The tank is positioned under the footboard.
The tank capacity is 19 litres.
11-7
HYDRAULIC OIL AND FILTER

2
2
2
C
A 3
4
D E
5
6
6
5. Remove the tank filler cap (A) and the filter (B) [Point 1] 9
6. Disconnect the oil tank outlet pipe (E) then let all the oil flow out into an appropriate container
7. Switch on the truck
8. Depress the brake pedal to allow the system to drain [notes: after emptying the tank, switch off
11
the truck with the key in order to avoid damage to the pump]
9. Insert the new filter (B) 12
10. secure the drainage pipe again and fill with new oil
Assembly procedure
13
14
Remarks:
Check the state of the seals and that there are no oil leaks. 15
Check the oil level in the tank using the dip-stick (D) with the mast in a vertical position and the
forks lowered.
16
Point Operation
[Point 1]
17
Disassembly:
To change the hydraulic oil unscrew the plug (A) and 18
remove the cartridge of the oil filter (B)
B Oil/filter changing:
18
After the first 50 hours of operation 18
• first changing of the filter
Every 500 hours 18
• check the level of oil in the tank using the dip-stick (D)
A • check and clean the tank breather valve filter (C) 18
Every 2,000 hours
• change the oil of the system and the filter 18
11-8
LIFTING LOAD DOWN TEST

1. Set the mast in the vertical position with the standard
load on the fork
2. Lift the forks 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
masts
4. After 10 minutes take the measure between forks and

ground or between the datum lines on the inner and
outer masts
Limit: A = 100 mm
11-9
OIL LEAK TEST

LIFTING CYLINDERS
2
2.
load on the fork
Lift the forks 1.5 m, measure the distance between the
2
forks and the ground and leave the key switch ON
3. After 10 minutes take the measurement between the 2
forks and the ground again
Limit: A = 100 mm 3
4. If there are oil leakages on the body of the lifting
cylinders, check if cylinder connections are well tight. 4
Replace the cylinder if necessary.
5
6
TILTING CYLINDERS
6
load on the fork, lift the fork to 1.5 m and leave the key 8
switch ON
9
9
11
12
13
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
14
3. Perform the same measurement 10 minutes after.
(1° = 17,5 mm) 15
Limit: Maximum forward angle (°) <= 0.5 (°/min)
Time (10 min)
16
4. If the truck is out of the above limit lower completely
the mast and turn the key switch OFF 17
5. Invert the tilting hoses with the sideshift hoses (if
present) on the control valve. This operation is 18
necessary to understand if there is any internal
leakage inside the tilting cylinder or inside the control
valve.
18
6. Turn the key switch ON and repeat the test from point
1 to 3. 18
(a) a) The test result is within the set limits:
replace the control valve. 18
(b) b) The test result is not within the set limits:
replace the tilting cylinders. 18
18
11-10
12-1
MAST
Page
MAST..........................................................................12-2
GENERAL............................................................................. 12-2
0
MAST SECTION ................................................................... 12-3 1
COMPONENTS .................................................................... 12-4 2
CHAINS & CHAIN ROLLERS....................................12-5 3
COMPONENTS .................................................................... 12-6
4
CHAINS & CHAIN ROLLERS....................................12-7
5
FORK CARRIAGE .....................................................12-8
POSITION OF THE FORK CARRIAGE ............................... 12-8
6
MAST..........................................................................12-9 7
MAST AND FORK CARRIAGE ROLLERS ............. 12-11 8
FORK CARRIAGE GUIDE SHOES 9
REPLACING..........................................................12-14
10
MAST CHAINS.........................................................12-18
CHECK MAST CHAINS ..................................................... 12-19
11
FORK........................................................................12-20 12
MAST ADJUSTMENTS............................................12-21 13
MAST GUIDE SHOES AND ROLLERS ............................. 12-21 14
FORK CARRIAGE SHOES AND ROLLERS ..................... 12-21
15
MAST LUBRICATION ..............................................12-22
16
MAST .................................................................................. 12-22
SAFETY FORK CARRIAGE END STOPS ......................... 12-23 17
T.V. MAST ........................................................................... 12-23 18
F.F.L. MAST ........................................................................ 12-23 19
MAST UNIT TILTING SETTING............................... 12-24
20
21
E
12-2
MAST
GENERAL
The profile of the mast with a double strengthening wing features great rigidity to bending and twisting.
It allows wide visibility thanks to the reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside the profiles.
The mast group is a 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 on operation
Other characteristics: side clearance adjustable from outside. Plastic guide shoes. Roller bearings
with grease nipples, ball joints on axle couplings and tilt cylinders.
Lifting cylinders:
Duplex mast T.V. n. 2 lateral cylinders
F.F.L. n. 2 lateral cylinders
n. 2 central cylinders
Triplex mast T.V. n. 2 lateral cylinders
F.F.L. n. 2 lateral cylinders
n. 2 central cylinders
Grease nipple Setting screw Guide shoe Roller

12-3
MAST SECTION
2
2
Intermediate
profile 2
Inner Outer
3
profile profile
4
5
6
6
8
9
9
9
Middle
cylinders 12
13
Side
cylinders 14
15
16
17
18
18
18
18
18
18
12-4
COMPONENTS
2M T.V.
3M T.V.
12-5
CHAINS & CHAIN ROLLERS

2M T.V.
2
2
2
3
4
5
6
6
8
9
9
3M T.V.
9
12
13
14
15
16
17
18
18
18
18
18
18
12-6
COMPONENTS
2M F.F.L.
3M F.F.L.
12-7
CHAINS & CHAIN ROLLERS

2M F.F.L.
2
2
2
3
4
5
6
6
8
9
9
3M F.F.L.
9
12
13
14
15
16
17
18
18
18
18
18
18
12-8
FORK CARRIAGE
Remarks:
The fork carriage differs depending on the type of mast
POSITION OF THE FORK CARRIAGE

Every 1000 hours
After testing the chains, with the truck on an even surface and the mast in a vertical position, check the
position of the fork carriage plate, as follows
• remove the forks, completely lower the fork carriage and measure the height (X), comparing it with the
value shown in the table, corresponding to the capacity in kg of the truck
example: the correct value of (X) for a truck with a capacity of 2000 kg (class II B), 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
X = 76 mm (A) IV B 5000 ÷ 8000 254 mm
x = 152 mm (B) VB 8001 ÷ 10999 257 mm
12-9
MAST
2
2
2
3
4
5
6
6
8
9
9
4. Secure a belt or chain to the mast and lift [Point 1] 13
5. Disconnect the hoses of the hydraulic system from the mast (lifting, sideshift, ...)
6. Remove the bolts and the U-bolts fixing the mast [Point 2] 14
7. Remove the pins from the tilting cylinders [Point 3]
8. Remove the mast
15
Assembly procedure
Remarks:
Apply suitable lubricating grease on the bushings of the mast supports, on the internal surfaces 17
of the covers of the mast supports and on the front pins of the tilting cylinders (see oils and
greases table). 18
18
18
18
18
18
12-10
Point Operation
[Point 1]
Disassembly:
Lower the mast completely.
Before removing the mast, hook the chains as shown
in the figure
[Point 2]
Disassembly:
Remove the 4 bolts (A) that fix the mast to the bottom
of the frame
Assembly:
After installation, tightening torque for the mast screws
= 50 Nm
[Point 3]
Disassembly:
Remove the 2 screws (B) of the safety plates and
extract the pins of the tilting cylinders (C)
Assembly:
C After installation, tightening torque for the 2 screws of
the safety plates of the 2 pins of the tilting cylinders =
24 Nm
B
12-11
MAST AND FORK CARRIAGE ROLLERS

2
2
2
3
4
5
6
6
8
9
9
9
12
13
14
4. Remove the two forks from the carriage 17
5. Disconnect the hydraulic hoses from the fork carriage [Point 1]
6. Secure and lift the carriage [Point 2] 18
7. Remove the safety pin from the chain tie rod [Point 3]
8. Remove the stop nut from the chain tie rod. Extract the chain from the opposite side [Point 4]
9. Remove the two safety screws [Point 5] 18
10. Remove the complete fork carriage from the bottom of the mast
11. Remove the guide shoes with the aid of a tool [Point 6] 18
12. Remove the circlip and extract the guide roller [Point 7]
18
18
12-12
Point Operation
[Point 1]
Disassembly:
Disconnect the 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
12-13
[Point 5]
Disassembly:
Remove the two safety screws
2
2
2
3
4
[Point 6]
Disassembly: 5
Remove guide shoes with the aid of a tool
6
6
8
9
9
[Point 7]
Disassembly: 9
Loosen the adjuster grub screw on the opposite side of
the guide shoes, remove the snap ring (A) and extract
the guide roller
12
13
A
14
15
16
17
18
18
18
18
18
18
12-14
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 [Point 3]
Assembly procedure
12-15
Point Operation
[Point 1]
Disassembly: 2
Remove one of the two side panels (B) from the
C
sideshift. 2
Extract the mobile portion (C) of the sideshift
2
3
B
4
5
[Point 2]
Disassembly: 6
Replace the upper (D) and lower (E) guide shoes
D 6
8
E 9
9
9
[Point 3]
Assembly: 12
F Make sure you insert the right number of shims (F)
under the lower guide shoes 13
14
15
16
17
18
18
18
18
18
18
12-16
INSPECTIONS • ADJUSTMENTS
Check:
the clearance between roller pad and inner mast
profile (Y)
Standard clearance: 0.2 - 0.4 mm
Adjustment:
Adjust the guide shoe by turning the setting screw (A)
A
12-17
Check:
the clearance between roller and inner mast profile (X)
Standard clearance: 0.2 - 0.4 mm 2
Adjustment:
It is not possible to adjust this clearance.
2
2
3
4
5
6
6
8
9
9
9
12
13
14
15
16
17
18
18
18
18
18
18
12-18
MAST CHAINS
INSPECTIONS • ADJUSTMENTS
Inspections
1. To check if the chain links are worn out, follow the
appropriate rules:
2. The chain must be replaced when, in a portion

corresponding to 34 links there are only 33 links
Remarks:
Make the measurement without removing the chain
from the mast; make the measurement along the entire
length of the chain since the stretch may be local
Adjustment
1. Park the vehicle on a level surface and apply the
parking brake
2. Set the mast to the vertical position.
5. Remove the forks
6. Check that dimension X agrees with the ISO tables

(section: position of fork carriage)
7. To compensate for any chain sag, turn the self-locking
nut on the fork carriage
8. Check to see if the chain tension is equal on left and
right sides
9. Check that the chain is not twisted.
10. Check that the lifting higher meets the standard
11. In the upper position, check that the end stroke plate is
not in contact with the fork carriage
12-19
CHECK MAST CHAINS

Every 1000 hours
• check the condition of the chains which must not be worn or faulty. To check the links for wear, use the 2
appropriate gauge
• remove the chains, clean them thoroughly, refit them inverting the original working position and
lubricate them
2
Every 10000 hours 2
• replace the chains and the fixing tie rods
The use of original chains will guarantee that the safety requirements stated by the regulations in 3
force are complied with.
4
5
6
6
8
9
9
9
12
13
14
15
16
17
18
18
18
18
18
18
12-20
FORK
REMOVAL • INSTALLATION • INSPECTION
1. Park the vehicle on a level surface and apply the
parking brake
2. Lift the fork to approx. 20 cm from the ground
3. Place a wood block under the notched section of the
fork rail
4. Unlock the fork by lifting the fork stopper pin and shift
one fork per time to the fork carriage bottom notch
5. Slowly lower the fork for removal.
G Assembly procedure
The reassembly procedure is the reverse of the
disassembly procedure
E
F
D
Inspection
Fork arm inspection must be carried out carefully by trained personnel to detect any damage, failure,
deformation, etc., which may impair safe use
1. Surface cracks:
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
crack detection process.
2. Difference in height of fork tips
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
3. Positioning lock
check that the fork positioning lock (G) is in good working order
4. Legibility of marking
If the fork arm marking is not clearly readable, it must be renewed by the original fork supplier
5. Fork wear control
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
original, the fork arm must be replaced
6. Fork mounting wear control
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
Any fork with defects revealed during the above controls must be withdrawn from service
12-21
MAST ADJUSTMENTS
MAST GUIDE SHOES AND ROLLERS
After the first 50 hours of operation 2
• Adjust the guide shoes with the Allen screw (D).
Use a 0.2 to 0.4 mm thickness gauge, fit it from the 2
D bottom upwards to the socket head screw (D) centre,
passing behind roller (E) and creeping on the external 2
L mast
Every 1000 hours 3
• Grease the mast guide rollers (L);
E
• Check the condition of the mast guide rollers (E); they 4
must rotate freely without blocking and not excessively
worn;
5
FORK CARRIAGE SHOES AND ROLLERS 6
After the first 50 hours of operation
• Adjust the guide shoes with the Allen screw (G).
6
F For the adjustment, use a 0.2 to 0.4 mm thickness
G gauge, inserted from below and up to the centre of the 8
Allen screw (G), passing behind the roller (H) and
rubbing against the external mast 9
Every 1000 hours
H
• Adjust the guide shoes; 9
• Grease the Carriage guide rollers (F);
• Check the condition of the guide rollers; they must rotate 9
freely without blocking and not excessively worn.
12
13
14
15
16
17
18
18
18
18
18
18
12-22
MAST LUBRICATION
MAST
Every 1000 hours
• Lubricate with grease the mast sliding guides using the grease nipples
• Lubricate the jack tilting joints and the frame connection joints
(A) Tilting jack joints

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

Nr. 1+1 grease nipples
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

top n. 2 grease nipples
C bottom no nipples
12-23
SAFETY FORK CARRIAGE END 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.
2
T.V. MAST
The lower limit stops (A) consist of two allen screws with locknut. The upper limit stops (B) consist of two 2
plates on the upper profile of the mast.
To remove the fork carriage, first of all unscrew the end stops.
2
3
B
A 4
5
6
6
8
F.F.L. MAST 9
The lower limit stops (A) consist of four Allen screws on the fork carriage. The upper limit stops (B)
consist of two plates on the upper profile of the mast. 9
To remove the fork carriage, first of all unscrew the end stops.
9
12
B
13
14
A 15
16
17
18
18
18
18
18
18
12-24
MAST UNIT TILTING SETTING

Every 500 hours
• Check the mast's tilt; the standard values are as follows:
α = 2.30° FORWARDS
FORWARD - BACKWARD
β = 6° BACK
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.
Note: A tilt angle of 1° corresponds to a gap of 17.4 mm
α = 2.30° FORWARDS = 40.0 mm
β = 6° BACK = 104.4 mm
1° = 17.4 mm
13-1
CYLINDER
Page
LIFTING CYLINDERS ..........................................13-2
0
GENERAL ...................................................................... 13-2
1
LIFTING CYLINDERS SPECIFICATIONS ...........13-3
2
LIFTING CYLINDERS ..........................................13-4
FRONT DISPLACEMENT CYLINDER WITH 3
BRAKING EFFECT ON LIFTING .......................13-6 4
LATERAL DISPLACEMENT JACK WITH 5
BRAKING EFFECT ON THE LOWERING .........13-7
6
SIDE TELESCOPIC CYLINDER WITH BRAKING
EFFECT ON LOWERING (with ball) .................13-8 7
TELESCOPIC CYLINDER WITHOUT 8
BRAKING EFFECT ............................................13-9
9
CYLINDER CHECKING METHODS...................13-10
10
SIDE CYLINDERS .............................................. 13-11
FIRST STAGE CYLINDER POSITION 11
ADJUSTMENT ........................................................... 13-14
12
CENTRAL CYLINDERS .....................................13-15
13
LOWERING VALVE ............................................13-17
14
SPECIFICATIONS ........................................................ 13-17
TILTING CYLINDERS.........................................13-19
15
GENERAL .................................................................... 13-19 16
SPECIFICATIONS ........................................................ 13-19 17
COMPONENTS ............................................................ 13-19 18
SETTING ...................................................................... 13-21
19
20
21
E
13-2
LIFTING CYLINDERS
GENERAL
1.6-2.0t CENTRAL CYLINDERS SIDE CYLINDERS
2 telescopic cylinders without braking effect
2M T.V.
2 telescopic cylinders without braking effect
3M T.V.
2 displacement cylinders with braking effect on lifting 2 displacement cylinders with braking effect on lowering
2M
F.F.L.
2 displacement cylinders with braking effect on lifting 2 displacement cylinders with braking effect on lowering
3M
F.F.L.
13-3
LIFTING CYLINDERS SPECIFICATIONS

SIDE LIFTING CYLINDERS (2M T.V.)
Load capacity 1.6 - 2.0 t

0
Cylinder type Simple effect
Cylinder inside diameter mm 40 1
Piston outside diameter mm 36
Parachute valve mm 1.2
2
SIDE LIFTING CYLINDERS (3M T.V.)

3
4

5
Parachute valve mm 1.5 7
CENTRAL LIFTING CYLINDERS (2M F.F.L. / 3M F.F.L.) 8
Load capacity 1.6 - 2.0 t 9
Cylinder type Simple effect 10
Cylinder inside diameter mm 50
11
Parachute valve mm 1.2 12
SIDE LIFTING CYLINDERS (2M F.F.L.) 13
Load capacity 1.6 - 2.0 t 14
15
Cylinder inside diameter mm 35
Piston outside diameter mm 28 16
17
SIDE LIFTING CYLINDERS (3M F.F.L.)
18
19
21
E
13-4
LIFTING CYLINDERS
COMPONENTS
2M T.V.
0
1
2
3
4
5
6
7
8
9
10
3M T.V. 11
12
13
14
15
16
17
18
19
20
21
E
13-5
2M F.F.L.
0
1
2
3
4
5
6
7
8
9
3M F.F.L.
10
11
12
13
14
15
16
17
18
19
20
21
E
13-6
FRONT DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON

LIFTING
When acting on the control valve, the oil flows into the
Rod 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 C. The bar protrudes to
close the channels.
This movement is produced by the flow of oil from the
Air
bleed chamber A to the chamber B via the above-mentioned
screw 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.
The outcome is a decrease in speed (braking effect).
Opening the supply circuit (oil inlet) allows the stern to come
Chamber A 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 check valves D and E that
by opening avoid jerking.
After passing the cylinder head the oil flow between the two
Channels
1/2 chambers passes through channels 1 and 2 which are now
open
One-way
valves
D-E
Channels
3
Chamber
B
Check valve D-E

Surface
C
Oil
inlet
Parachute
safety
valve
13-7
LATERAL DISPLACEMENT JACK WITH BRAKING EFFECT ON THE

LOWERING
When the control valve is operated the oil flows into the
Channel A
To the cylinders cylinder from the “Oil inlet" Flowing through chamber B and 0
First stage
air bleed screw channel A it fills first the first stage cylinders, then the
Chamber B chamber A, through hole F, and the unidirectional valve C. 1
The oil exerts thus an upward force against the surface D, 2
which sets off the outward sliding of the rod.
This movement is allowed by the oil flow from chamber A to
chamber B through hole F and the guide ring. 3
The downward sliding of the rod is allowed by the opening of
the “Oil inlet” circuit, so that the oil can be retrieved into the 4
Rod tank by means of the control valve.
In this phase the oil flows between the two chambers only
5
through the hole F, as valve C is closed.
The downward speed of the rod remains constant until hole F 6
is closed by profile E. The remarkable reduction of oil flow
has a slowing-down or “Braking effect". 7
Air 8
bleed
screw
for
9
chamber A
10
11
12
13
Chamber A 14
Hole F 15
Surface D
Guide
16
ring
Profile E 17
Chamber
B 18
19
Parachute
safety valve
20
One-way safety
valve 21
Oil inlet
E
13-8
SIDE TELESCOPIC CYLINDER WITH BRAKING EFFECT ON LOWERING

(with ball)
Lifting phase:
By operating on the control valve with the lifting lever, the oil
flows to the cylinder through the cylinder cap. It reaches
channels 1 and 2 until the hydraulic pressure formed in
chamber A produces a thrust upwards on the surface C,
Rod
thereby stem extraction.
The internal snap ring is used so prevent the ball coming out
of channel 2 during stem extraction
Chamber B
Lowering phase:
Lowering is permitted by operating on the hydraulic control
Cylinder valve, opening the oil return circuit to the tank through the
control valve.
The drop in pressure in chamber A causes the ball to drop
down to the circlip.
At the start of this lowering phase, all the oil in chamber A
flows out through channel 1.
Only afterwards, when the ball contacts the top of channel 1,
does the braking action start, directing the oil through hole F
only, which is much smaller and thus slows the oil flow
(braking effect).
Rod
Channel 2
Hole F
Seal
ring
Surface C
Chamber A
Channel 1
Oil inlet
Cap
Parachute
safety
valve
13-9
TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT

Cylinders are single-acting type (fig. A)
Dust control ring (6) In these cylinders a seal (1) has been fitted on the piston (2)
Anti-friction ring (5)
that works on the inner surface of the cylinder liner (3) 0
The rod guide is made by the top cap (4) and by the piston
through anti-friction rings (5) 1
The dust control ring (6) prevents any dirt and water from
penetrating the cylinder
2
Cap (4)
Drain hole (7) Slight leakages that may occur are directed to the tank 3
through the drain pipe connected to the drain hole (7)
The drain pipe shall reach the oil tank (fig. B). 4
A small quantity of oil will always remain in the loop formed 5
by the pipe before connecting to the tank. It acts as a trap
and constantly wets the cylinder liner, when it is completely
closed (fig. B). 6
7
8
9
10
Surface (3) 11
Piston (2)
12
13
14
Fig. B
15
Seal (1)
16
Cap (4) 17
18
Safety
valve 19
Oil inlet 20
Fig. A 21
E
13-10
CYLINDER CHECKING METHODS
1st CONTROL
Remove the drain line 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 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 leakages on the distributor
and the gasket is in good condition.
In the presence of leakages, it will be necessary to replace
the seal Should this be the case, inspect the cylinder liner
2nd CONTROL
(To be carried out if the 1st inspection has been successful or
after gasket replacement).
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. 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 should be still present, the cylinder is
damaged and then it must be replaced
13-11
SIDE CYLINDERS
2. Position the mast in a vertical position and lift the mast by 10/15 cm
4. Block the mast with a wooden bar [Point 1]
6. Disconnect the cylinder pipes
7. Remove the upper fixing bolts [Point 2]
8. Remove the supply pipes [Point 3]
9. Remove the lower fixing bolts [Point 4]
10. Lift the mast in order to release the cylinders
11. Extract the cylinders from the mast
Assembly procedure
Remarks:
After installing the lift cylinders, follow the steps below:
1. Without load repeat full stroke lifting and lowering of the cylinder to bleed air and check normal
functioning.
2. Check the hydraulic oil level and add if insufficient.
3. Inspect lifting cylinders for uneven lifting, and make any necessary adjustment.
13-12
Point Operation
[Point 1]
Disassembly:
Block the mobile part of the mast with a wooden bar as
shown in the figure 0
1
2
3
4
[Point 2]
Disassembly: 5
Remove the 2 upper fixing bolts situated under the 2
plugs (A) 6
7
A 8
9
10
[Point 3]
Disassembly:
11
Remove the supply pipes (B)
12
13
14
15
B
16
[Point 4]
17
Disassembly:
Remove the 2 lower fixing bolts (C) 18
19
Assembly: 20
After installation, perform adjustment if necessary in
order to have following clearance of the upper fixing 21
bolts of the cylinders (A)
C
clearance = 4 (0 / -0.3) mm E
13-13
UPPER LIFTING CYLINDER FIXING SCREW ADJUSTMENT

2M T.V.
The cylinder stroke is adjusted by adding or removing shims
(A)
A
3M T.V.
(B)
2M F.F.L.
(C)
3M F.F.L.
(D)
D
13-14
FIRST STAGE CYLINDER POSITION ADJUSTMENT
if the first stage cylinders have to be removed and reinstalled, they must be positioned correctly.
The air bleed screw on the cylinder must be facing inwards (as shown) so as not to interfere with the chain.
Remarks:
Make sure that the face of the cylinder (A) and the face of
the support (B) are parallel to each other
A
13-15
CENTRAL CYLINDERS
0
1
2
3
4
5
6
7
8
9
2. Set the mast in the vertical position and fully lower the forks 11
5. Remove the pulley supports (chains and hydraulic pipes) [Point 1]
6. Disconnect the cylinder pipes 13
7. Remove the lower fixing bolts [Point 2]
8. Remove the upper fixing cylinder bracket [Point 3] 14
9. Remove the central cylinder
16
Remarks:
After installing the lift cylinders, follow the steps below: 17
1. Without load repeat full stroke lifting and lowering of the cylinder to bleed air and check normal
functioning. 18
2. Check the hydraulic oil level and add if insufficient.
19
20
21
E
13-16
Point Operation
[Point 1]
Disassembly:
Remove the screw (A) to remove the pulley supports of
the chains and hydraulic pipes (if applicable)
[Point 2]
Disassembly:
Remove the lower fixing nuts (B)
[Point 3]
Disassembly:
Remove the two screws of the upper cylinder bracket
(C)
C
13-17
LOWERING VALVE
SPECIFICATIONS
0
1
2
3
4
5
6
7
8
9
10
11
12
S
13
Settings of valve on mast from 1.6 to 2.0 t 14
Mast type Valve type S (mm)
2M T.V. sb 25 c 15 15
3M T.V. sb 27 c 17.5 16
2M F.F.L. sb 25 c 17.5
3M F.F.L. sb 25 c 17.5 17
18
19
20
21
E
13-18
Remarks:
The explanation here is for the flow regulator valve for all the mast.
0
1
2
3
4
5
6
7
A 8
9
10
2. Set the mast in vertical position and lift it up to reach the valve.
12
5. Secure the mast with a chain or a belt or with a block of wood to prevent it lowering
6. Disconnect the flexible hose (A) that is connected to the control valve 14
7. Remove the lowering valve
Assembly procedure
15
17
18
19
20
21
E
13-19
TILTING CYLINDERS
GENERAL
0
T = 477 Nm T = 477 Nm
1
2
3
4
5
6
7
8
SPECIFICATIONS
9
Mast Lift height Forward / Backward
(angles referred to std machine) 10
2M all models 2°30’ / 6°
11
2M F.F.L. all models 2°30’ / 6°
3M all models 2°30’ / 6°

12
3M F.F.L. all models 2°30’ / 6°
13
14
COMPONENTS
15
16
17
18
19
20
21
E
13-20
Tightening torque M=Nm
2. Set the mast to the vertical position.
6. Disconnect the hoses (after lowering the remaining pressure in the tilting cylinders by operating the
tilting lever a number of times)
7. Remove the tilting cylinder front pin [Point 1]
8. Remove the tilting cylinder rear pin [Point 2]
9. Remove the tilting cylinder
Remarks:
If both tilting cylinders are removed fix the mast with a
chain in order to avoid the mast falling
Assembly procedure
Remarks:
• Lubricate the insertion portions of the tilting cylinder front and rear pins
• 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
• Check the hydraulic oil level and add if insufficient.
13-21
Point Operation
[Point 1]
Disassembly:
Remove the safety screws and the front pin of the tilting
cylinder
0
Assembly: 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
Assembly: 7
After installation, tightening torque for the safety plates =
24 Nm 8
9
10
SETTING 11
Remarks:
• Adjust the mast forward and backward tilting angle (to prevent uneven tilting) whenever the 12
tilting cylinder or mast are replaced or disassembled
13
Adjustment:
Turn the tilting cylinder rod with a spanner in the
appropriate direction and then tighten the locknut with a
14
tightening torque of 477 Nm
15
16
17
18
19
20
21
E
13-22
14-1
OIL PUMP 2
Page
2
SERVICE PUMP.........................................................14-2
2
GENERAL............................................................................. 14-2
TEST METHOD ..........................................................14-4 3
COMPONENTS .................................................................... 14-6 4
5
6
6
8
9
9
9
12
9
14
15
16
17
18
18
18
18
18
18
14-2
SERVICE PUMP
GENERAL
Vehicle model 1.6 - 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
4. Remove the footboard and the battery 9
5. Empty the oil tank
6. Disconnect the delivery and suction pipes from the pump and from the priority valve 9
7. Remove the pump fixing bolts [Point 1]
12
Note:
9
Before assembly, grease the pump-motor coupling
with CASTROL OPTIMOL T WHITE type paste. Clean 14
the flange that meets the motor before installation.
15
16
17
18
Point Operation 18
[Point 1]
Disassembly: 18
Remove the two pump fixing bolts (C).
C Assembly: 18
After installation, tightening torque for pump fixing
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 = 230 - 240 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
MAST PERFORMANCE TABLE

LIFTING LOGIC UNIT
Q1: max load
1.6L t
Q2: max load at maximum height
2
load FFL TV
kg
Q1 0.30
m/sec
0.50 max
amp
240 max
bar
175 0.30
m/sec
0.50 max
amp
270
bar
max 190
2
lowering
Q1 max 0.60 max 0.60 2
end of stoke
max 280 max 230
2.0L t 3
load FFL TV
kg
Q1 0.30
m/sec
0.50 max
amp
260 max
bar
195 0.28
m/sec
0.50 max
amp
290
bar
max 210
4
lowering
Q1 max 0.60 max 0.60 5
end of stoke
max 300 max 240
TILTING AND SIDESHIFT

6
STD. Tilt 2.5° FW. 6°BW. Test performed at 3 m height with Q1 load
MECHANICAL CONTROL VALVE 6
Operation End of stoke
BW-FW 3.7
Sec
4.1 max
amp
60 max
bar
25 max
amp
160
bar
max 160
8
FW-BW 3.5 3.9 max 90 max 80 max 170 max 160
ELECTRIC CONTROL VALVE
Sec amp bar amp bar
9
BW-FW 3.7 4.1 max 60 max 25 max 160 max 240
FW-BW 3.5 3.9 max 90 max 80 max 170 max 240 9
STD sideshift stoke: 100 mm (visual check)
9
12
9
14
15
16
17
18
18
18
18
18
18
14-6
COMPONENTS
G
A
I H F
B
1. Remove the 2 pump fixing bolts (A) and remove the oil pump
2. Place the cover (B) on a surface and remove the 2 bolts (C)
3. Remove the cover (D), the gasket (E) and the first figure 3 gasket group (F)
4. Remove the gear (G) and the gear (H)
5. Remove the second figure 3 gasket group (I)
Assembly procedure
Note:
• Wash each part, blow compressed air and apply hydraulic oil before installation
• Always use new seals for reassembly
15-1
OIL CONTROL VALVE

Page
MECHANICAL CONTROL VALVE ............................15-2
0
GENERAL............................................................................. 15-2
TECHNICAL DATA ............................................................... 15-3
1
HYDRAULIC DIAGRAM ............................................15-4 2
MECHANICAL CONTROL VALVE ............................15-5 3
PRESSURE RELIEF VALVE ADJUSTMENT ............15-7 4
MANUAL RELEASE OF THE SOLENOID
5
VALVE EVP1 ..................................................................... 15-7
ELECTROPROPORTIONAL DISTRIBUTOR ............15-8 6
GENERAL............................................................................. 15-8 7
HYDRAULIC DIAGRAM ..........................................15-10 8
ELECTRIC CONTROL VALVE ................................ 15-11 9
PRESSURE RELIEF VALVE ADJUSTMENT ..........15-12
10
EMERGENCY LOWERING VALVE .........................15-13
11
12
13
14
15
16
17
18
19
20
21
E
15-2

GENERAL
CONTROL VALVE
C
F C
3-WAY 4-WAY
15-3
TECHNICAL DATA
Capacity
Lifting Qmax 55 l/min 2
Tilting, Qmax 55 l/min
sideshift fingertip Qmax 55 l/min 2
4th Way Qmax 55 l/min
Pressure
2
Lifting pressure relief valve 180 bar
3
Pressure relief valve 2nd, 3rd, 4th way 130 bar
Coil
4
Valve Connector Function resistance Nominal voltage Nominal current
(20°C) 5
EVP1 JE1 Lowering lock 21 ohm ± 7 % 24 V 0.95 A 6
EV3 JE3 Tilting lock 21 ohm ± 7 % 24 V 0.95 A
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
15-4
HYDRAULIC DIAGRAM
15-5

Note: 2
Operate the control levers to bring the mast and fork to the vertical and lowermost positions,
respectively, to release the residual pressure in the hydraulic system before starting 2
disassembly.
2
3
4
5
6
6
8
9
9
11
12
13
14
EV3 15
EVP1
16
17
4. Remove the cowling 18
5. Disconnect the piping and wiring
6. Remove the pin of each control valve lever [Point 1] 18
7. Remove the control valve
18
Remarks:
• Adjust the limit switch after installing the oil control valve (See [Point 1] ) 18
• Apply grease to all all oil control valve lever linkages
• Check the hydraulic oil level and top up as required
15-6
Point Operations
[Point 1]
Disassembly
Remove the pin (A) of each lever.
Microswitch adjustment:
After the installation perform the following
ROD TO
adjustments:
CONTROL 1. Mount the microswitch in the 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.
CONTROL ROD
2. Secure the microswitch in order to have the possibility
LEVER to move it on the lower hole of the support.
BUTTON
CASTOR 3. Adjust the microswitch position in order to activate it to
the minimum stroke of the microswitch lever and by
releasing the latter the microswitch has to return to the
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):
P • after installation, adjust the lifting potentiometer
15-7
PRESSURE 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
• Check the maximum pressure if the relief valve is replaced according to the mast used
2
Pressure relief valve
sideshift pressure Pressure relief valve
to left lifting pressure 2
3
auxiliary Pressure relief valve
auxiliary function tilting pressure 4
tilting pressure
5
Pressure relief valve 6
auxiliary
auxiliary function 6

8
sideshift pressure Pressure relief valve
tilting pressure
to right
back 9
1. Remove the plug of the pressure measuring point on the lifting pump and connect a pressure gauge. 9
Pressure gauge end stroke reading: 250 bar o superior.
2. Loosen the counter nut on the relief valve and adjust the screw (Allen screw for lifting, square screw 11
for tilting, side shift and other lever).
3. Adjust the oil pressure as follows:
(a) Turn the key switch ON 12
(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: 13
screwing in = increasing of pressure
screwing out = decreasing of pressure 14
(d) Tighten the counter nut when the measured pressure reaches the correct value according
to the mast performance table
4. Repeat point 3 for the other functions too (tilting, side shift, …) once each time.
15
5. Remove the pressure gauge and screw in the plug.
16
MANUAL RELEASE OF THE SOLENOID VALVE EVP1
Push rod (A) in the direction of the arrow to manually

17
release the solenoid valve in the event of a power shortage
or failure of the valve, then use the lowering lever to lower
18
the mast.
18
A 18
18
18
18
15-8
ELECTROPROPORTIONAL DISTRIBUTOR
GENERAL
P = Pump inlet
R = Oil tank drain
H = Lifting inlet
M = manometer pressure point
auxiliary
PE01
R P
B B B
H
A A A
PE02
Emergency lowering
valve
4th-way
a b

auxiliary
15-9
TECHNICAL DATA
Capacity
P, H, R Qmax 80 l/min 2
Tilting, 4th-way Qmax 25 l/min
sideshift fingertip Qmax 16 l/min 2
Pressure
Pressure relief valve Pmax 250 bar
2
Pressure relief valve 4th way (a, b) 160 bar
3
Coil 4
Valve Connector Function resistance Nominal voltage Maximum current
(20°C) 5
PE01 JE1 Lifting 18 ohm 24 V 0.93 A
6
PE02 JE2 Lowering 18 ohm 24 V 0.93 A
PE03 Forward tilting 28 ohm 24 V 0.58 A 6
JE3
PE04 Backward tilting 28 ohm 24 V 0.58 A
8
PE05 Right sideshift 28 ohm 24 V 0.58 A
JE4 9
PE06 Left sideshift 28 ohm 24 V 0.58 A
PE07
JE5
4th Way 28 ohm 24 V 0.58 A 9
PE08 4th Way 28 ohm 24 V 0.58 A
11
12
13
14
15
16
17
18
18
18
18
18
18
15-10
HYDRAULIC DIAGRAM
15-11

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 T=Nm
2
Pressure relief valve 3
4th-way
4
5
6
6
8
9
9
11
Pressure relief
valve auxiliary 12
Emergency lowering
valve 13
15
4. Remove the footboard and the distributor cover 16
5. Disconnect the hoses and the wiring harnesses
6. Remove the control valve 17
Assembly procedure
18
Remarks: 18
Check the hydraulic oil level, and add if insufficient
18
18
18
18
15-12
PRESSURE RELIEF VALVE ADJUSTMENT

Remarks:
• 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.
P
PE01
PE02
H
M
auxiliary
R
Safety
A
Maximum
auxiliary
B
A
B
b
B
a
1. Remove the plug of the pressure gauge on the priority valve and connect a manometer. Pressure
gauge end stroke reading: 250 bar o superior.
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 in the plug.
15-13
EMERGENCY LOWERING VALVE

Tightening torque T=N·m
2
Emergency lowering valve
P
PE01
T = 5 Nm 2
2
PE02
H
3
R
4
A
5
B
A
6
B
A 6
B
8
9
• Loosen the emergency lowering valve to manually lower the forks.
Note:
9
Always retighten the emergency lowering valve after a repair. If the valve is left loose, much
hydraulic oil is released from the pump and the lifting speed is significantly decreased, resulting 11
in difficulty in smooth operation.
12
13
14
15
16
17
18
18
18
18
18
18
15-14
MAST PERFORMANCE TABLES

Definitions:
Q1: max load Q2: max load at max height
Operational conditions:
The proofs must be performed with electrolyte density >1,22. <g id="1710">E</g>lectrolyte and oil
temperature >15°C.
Environment temperature not inferior to 18°C.
The performance refers to mode P and profile 0.
LIFTING
Q1: max load Q2: max load at maximum height
1.6L t
load FFL TV
kg m/sec amp bar m/sec amp bar
Q1 0.30 0.50 max 240 max 175 0.30 0.50 max 270 max 190
lowering
Q1 max 0.60 max 0.60
end of stoke
max 280 max 230
2.0L t
load FFL TV
kg m/sec amp bar m/sec amp bar
Q1 0.30 0.50 max 260 max 195 0.28 0.50 max 290 max 210
lowering
Q1 max 0.60 max 0.60
end of stoke
max 300 max 240
TILTING AND SIDESHIFT

STD. Tilt 2.5° FW. 6°BW. Test performed at 3 m height with Q1 load
Operation End of stoke
Sec amp bar amp bar
IN-AV 3.7 4.1 max 60 max 25 max 160 max 160
AV-IN 3.5 3.9 max 90 max 80 max 170 max 160
Sec amp bar amp bar
IN-AV 3.7 4.1 max 60 max 25 max 160 max 240
AV-IN 3.5 3.9 max 90 max 80 max 170 max 240
STD sideshift stoke: 100 mm (visual 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
PROGRAMMER
Page 0
PROGRAMMER .........................................................16-2 1
GENERAL............................................................................. 16-2
2
PROGRAMMER CONNECTION BY CAN-BUS................... 16-4
3
PROGRAMMER SERIAL CONNECTION ............................ 16-5
PROGRAMMER FUNCTION ................................................ 16-6 4
AUTO MODE ........................................................................ 16-6 5
MANUAL MODE ................................................................... 16-8 6
SAVE FUNCTION ............................................................... 16-11
7
RESTORE FUNCTION ....................................................... 16-14
8
DELETE FUNCTION........................................................... 16-17
INFORMATION MESSAGES.............................................. 16-19 9
SERIAL CONNECTION ...................................................... 16-20 10
SD CARD SOFTWARE UPDATE ....................................... 16-23 11
12
13
14
15
16
17
18
19
20
21
E
16-2
PROGRAMMER
GENERAL
The programmer allows programming of the logic units and cards on the truck.
WIRING CONNECTOR
F1 F2 F3
OK
OUT
SD CARD
FUNCTIONS
PROGRAMMER for updating software
SAVE/RESTORE for saving/copying operator profiles
16-3
LEGEND
Function buttons 2
2
Possible choices
2
Confirm choice
3
4
5
Change screen
6
6
Confirm 8
9
Return to previous screen
9
OLD Software version out of date 11
12
UPDATE Software version updated
13
NOT CONNECTED Card not connected or not powered

14
16
16
16
17
18
18
18
18
18
16-4
PROGRAMMER CONNECTION BY CAN-BUS

Procedure
1. Put the truck in a safe position, parking it on a flat
surface and raising the drive wheels.
2. Insert the SD card in the programmer and connect the

interface wiring.
3. Connect the CAN-BUS connector of the programmer

to the CAN-BUS connector (J132) of the truck, located
under the display.
4. Turn on the truck.

16-5
PROGRAMMER SERIAL CONNECTION

Procedure
1. Put the truck in a safe position, parking it on a flat 2
surface and raising the drive wheels.
2
2
3
4
2. Insert the SD card in the programmer and connect the 5
interface wiring.
6
6
8
9
3. Connect the CAN-BUS connector of the programmer
to the CAN-BUS connector (J132) of the truck, located 9
under the display
11
4. Connect the serial connector of the programmer to the
serial connector of the card to be programmed. 12
13
14
5. Connect the card to be programmed to the machine 16
wiring, ensuring that it receives power, and turn on the
truck,
16
16
17
18
18
18
18
18
16-6
PROGRAMMER FUNCTION
The programmer function allows the updating of the software present in the logic units and cards on the
truck. It is possible to update the cards in two different ways:
• AUTO the programmer automatically recognizes the truck and the latest software version to be
installed.
• MANUAL for selecting the truck family and the software version you intend to install;
in MANUAL mode it is also possible to install previous versions of the software.
AUTO MODE
Procedure
1. Connect the programmer and turn on the truck (see
specific paragraph)
Wait a few seconds for the data to load
2. Press F1 to select the Programmer function

Please select funct
Programmer
Save/Restore
PROG S/R
F1 F2 F3
OK
OUT
3. Press F1 to select Auto mode

Programmer selected
Please select
Program mode Wait a few seconds for the data to load
AUTO MANUAL
F1 F2 F3
OK
OUT
4. Use the buttons to change screen and view

EVCB X.XX Old the cards present on the truck
TRCB X.XX Updated
PUMP X.XX Old
F1 F2 F3
Use the buttons to select the card to be
updated
F1 F2 F3
F1 selects line 1
OK
F2 selects line 2
F3 selects line 3
OUT
16-7
5. Press F1 to select programming by CAN-BUS

Please select
Program type
Press F3 to select programming by SERIAL
VIA CAN SERIAL
CONNECTION 2
F1 F2 F3
2
OK
2
OUT
3
6. Press F1 to confirm your choice and start
Do you want to program
programming
EVCB with vers X.XX? 4
YES NO Press F3 to return to the previous screen
F1 F2 F3
5
OK
6
OUT 6
Please wait
7. Wait until the end of programming. 8
Program Running
Note: 9
Do not turn off the truck, disconnect the programmer
or the battery during programming.
F1 F2 F3
9
OK
11
OUT
12
8. Programming ended
Program Successful
13
Press OK to move on to the next screen
14
F1 F2 F3
“Please key OFF and ON”
Turn the truck off and on again.

16
OK
OUT
16
In the case of updating the Logic Units, the request to use the CLEAR EEPROM function will appear on
16
the last screen
17
9. Press F1 to perform the function
Program successful
Do you want to clear
eeprom? Press F3 to not perform the function 18
YES NO
F1 F2 F3
10. Wait for this message to appear: 18
“PROGRAM AND CLEAR EEPROM SUCCESSFUL
OK
PLEASE KEY OFF AND ON”
18
OUT
Turn the truck off and on again. 18
18
16-8
MANUAL MODE
Procedure
1. Connect the programmer and turn on the truck (see
specific paragraph)
Wait a few seconds for the data to load
2. Press F1 to select the Programmer function

Please select funct
Programmer
Save/Restore
PROG S/R
F1 F2 F3
OK
OUT
3. Press F3 to select Manual mode

Programmer selected
Please select
Program mode
AUTO MANUAL
F1 F2 F3
OK
OUT
4. Press F1 to confirm your choice

Manual download mode
selected proceed?
Press F3 to return to the previous screen
YES NO
F1 F2 F3
OK
OUT
Please select
5. Use F1 if the truck to be updated is CESAB
truck type
CESAB BT
Use F3 if the truck to be updated is BT
F1 F2 F3
OK
OUT
16-9

1 BLITZ312-420 AC FN
2 ECOP CESAB the truck models
3 B315-420
1 2 3
Use the buttons F1 F2 F3
to select the truck 2
model connected to the programmer
F1 F2 F3
2
F1 selects line 1
F2 selects line 2
OK
F3 selects line 3
2
OUT
3
EVCB X.XX Old the cards present on the truck 4
TRCB X.XX Updated
PUMP X.XX Old
Use the buttons F1 F2 F3
to select the cards to 5
be updated
F1 F2 F3
F1 selects line 1
6
OK
F2 selects line 2
F3 selects line 3 6
OUT
8
8. Press F1 to select programming by CAN-BUS
Please select
Program type
9
Press F3 to select programming by SERIAL
VIA CAN SERIAL CONNECTION 9
F1 F2 F3
11
OK
12
OUT
13
9. Press OK to confirm your choice
Please press OK to
enter in prog file
selection
14
16
F1 F2 F3
16
OK
16
OUT

17
1 version X.XX
the software versions
2 version
3 version
X.XY
X.XZ 18
1 2 3
F1 F2 F3
Use the buttons to select the software
F1 F2 F3
version to be installed 18
OK
F1 selects line 1 18
F2 selects line 2
F3 selects line 3
OUT
18
18
16-10
11. Press F1 to confirm your choice and start

Do you want to program
EVCB with vers X.XX?
programming
YES NO Press F3 to return to the previous screen

F1 F2 F3
OK
OUT
12. Wait until the end of programming.

Please wait
Program Running
Note:
Do not turn off the truck, disconnect the programmer
F1 F2 F3
or the battery during programming.
OK
OUT
13. Programming ended

Program Successful
Press OK to move on to the next screen
F1 F2 F3
“Please key OFF and ON”
OK
OUT
In the case of updating the Logic Units, the request to use the CLEAR EEPROM function will appear on
the last screen
14. Press F1 to perform the function
Program successful
Do you want to clear
eeprom? Press F3 to not perform the function
YES NO
F1 F2 F3
15. Wait for this message to appear:
OK
“PROGRAM AND CLEAR EEPROM SUCCESSFUL
PLEASE KEY OFF AND ON”
OUT

Cesab Centauro AC 1di2

Caricato da

Copyright:

Formati disponibili

Cesab Centauro AC 1di2

Caricato da

Informazioni sul documento

Descrizione originale:

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Cesab Centauro AC 1di2

Caricato da

Copyright:

Formati disponibili

Cesab Centauro AC

Tensione Batteria : 48V

Questo è un manualetto per uso interno con varie info e manuale in

Cesab Centauro AC , versione 48V con Chopper di potenza ACE3 by

Cesab Centauro AC ho aggiunto anche il manuale Zapi

Se Vi dovesse chiedere la Password ho avuto queste info , ma

Code 036-0417-02 07/2012

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.

CAPACITY DIAGRAMS (with SE tyres)

Barycentre [mm] Capacity [Kg] 1.6L t

Barycentre [mm] Capacity [Kg] 2.0L t

HOW TO USE THIS MANUAL

Matters omitted from this manual

Abbreviation Meaning Abbreviation Meaning

Item New unit Conventional Conversion rate(*)) 0

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

Battery 1.6L - 2.0L ~ 1300

Drive motor 1.6L - 2.0L ~ 31

Vehicle weight (w/battery)

TOWING THE TRUCK

Note the cautions below when towing the vehicle with

ELECTRICAL PARTS INSPECTION

TIGHTENING TORQUE TABLE

Nominal PRELOADING V (N) TORQUE Max (Nm)

SCREWS WITH “ISO” METRIC FINE THREAD

Nominal PRELOADING V (N) TORQUE Max (Nm)

LUBRICANTS CAPACITY AND TYPE TABLE

Applicable place Capacity Type

PERIODIC REPLACEMENT TABLE

REPLACEMENT CYCLE every 1 week 12 30 60 months

Oil tank breather filter

PERIODIC MAINTENANCE TABLE

MAINTENANCE CYCLE every 1 week 6 12 months

MAINTENANCE CYCLE every 1 week 6 12 months

MAINTENANCE CYCLE every 1 week 6 12 months

MATERIAL HANDLING SYSTEM

MAINTENANCE CYCLE every 1 week 6 12 months

MAINTENANCE CYCLE every 1 week 6 12 months

BATTERY CASING AND REQUIRED WEIGHT

BATTERY SERVICE STANDARDS

Blinking (A) Led,

MANAGING THE BATTERY

BDI adjust min

Necessary voltage for the rearm

Charge battery indicator = 50,16 V

Discharge battery indication = 46,32 V

ADJUSTING THE BATTERY AND THE INDICATOR

ADJUSTING THE BATTERY INDICATOR

Notes: Ensure that the battery completes the whole

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

Press twice FORMULA:

Press OK and then 4 times

Press OK and then 4 times