Eco P: Repair Manual

REPAIR MANUAL
ECO P
60-70-85
Code 036-0432-00 04/2010

Document changes history:
Edition Changes
036-0432-00 New version
This manual covers the following truck models:
Model Starting serial number Ending serial number

Index-1
SECTION INDEX
GENERAL 0
BATTERY 1
CONTROL SYSTEM 2
MULTI-FUNCTION DISPLAY 3
TROUBLESHOOTING 4
MOTOR 5
DRIVE UNIT & FRONT AXLE 6
REAR AXLE 7
STEERING 8
BRAKE 9
BODY 10
MATERIAL HANDLING SYSTEM 11
MAST 12
CYLINDER 13
OIL PUMP 14
OIL CONTROL VALVE 15
ANNEX 16
17
18
18
18
18
18
18
Index-2
PAGINA INTENZIONALMENTE BIANCA
INTENTIONALLY LEFT BLANK
PAGE INTENTIONNELLEMENT BLANCHE
WEI SEITE
PGINA INTENCIONALMENTE BLANCA

0-1
GENERAL
VEHICLE EXTERIOR VIEW ................................................................................ 3
0
VEHICLE MODELS.............................................................................................. 4
FRAME SERIAL NUMBER .................................................................................. 4
2
TRUCK CAPACITY AND IDENTIFICATION PLATES......................................... 5 2
TECHNICAL DATA .............................................................................................. 6 3
HOW TO USE THIS MANUAL............................................................................. 8
4
EXPLANATION METHOD.................................................................................... 8
TERMINOLOGY................................................................................................... 9 5
ABBREVIATIONS ................................................................................................ 9 6
ILLUSTRATIONS ................................................................................................. 9
7
SI UNITS .............................................................................................................. 10
8
OPERATING TIPS................................................................................................ 11
BATTERY RECYCLING/DISCARDING ............................................................... 12 9
DISCARDING THE BATTERY ............................................................................. 12 10
RECYCLING ........................................................................................................ 12
11
LIFTING THE TRUCK.......................................................................................... 13
HOOKING POINTS FOR THE TRUCK LIFTING................................................. 13
12
WIRE ROPE SUSPENSION ANGLE LIST .......................................................... 14 13
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE ......................... 14 14
COMPONENT WEIGHT....................................................................................... 15
15
LIFTING ANTERIOR TRUCK WHEELS .............................................................. 15
OPERATIONS ON THE MAST ............................................................................ 16
16
TOWING THE TRUCK ......................................................................................... 17 17
ELECTRICAL PARTS INSPECTION ................................................................... 18 18
STANDARD TIGHTENING TORQUE TABLE ..................................................... 19
18
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE .............................. 20
ASSEMBLAGE FOR NIPPLES TYPE PARKER ERMETO E0/ E0-2.................. 20 18
PERIODIC MAINTENANCE................................................................................. 21 18
PERIODIC REMPLACEMENT TABLE ................................................................ 21
18
PERIODIC MAINTENANCE TABLE .................................................................... 22
18
SERVICE DATA ................................................................................................... 27
0-2
LUBRICANT CAPACITY AND TYPE TABLE...................................................... 28

WHEELS & TYRES.............................................................................................. 28
LUBRICATION CHART........................................................................................ 29
VEHICLE DIMENSION......................................................................................... 30
MAST SPECIFICATIONS AND RATED CAPACITIES ........................................ 31
0-3
VEHICLE EXTERIOR VIEW
ECO P 60 0
ECO P 70
2
ECO P 85
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
0-4
VEHICLE MODELS
Vehicle Model Load Capacity Control Method Voltage (V)
ECO P 60 6,0 ton AC Microcomputer controller 80
ECO P 70 7,0 ton
ECO P 85 8,5 ton
FRAME SERIAL NUMBER

Frame serial number location
The frame serial number is stamped on the front cross plate. Please refer to the frame serial number
when making inquiries about your vehicle.
Vehicle model Punching format Punching position
ECO P 60 CE000000
ECO P 70 CE000000
ECO P 85 CE000000
0-5
TRUCK CAPACITY AND IDENTIFICATION PLATES

A) IDENTIFICATION PLATE
B) LOAD CAPACITY PLATE 0
The position of the plates, like shown in the image, is referred to the standard truck: this position could 2
vary in special trucks case.
2
A
3
B 4
5
6
7
8
How to Read the Plates
9
A: Identification plate
3
MODELL Type
2 MOTOR RATED CAPACITY It identifies the lift truck technical data 10
1 kW kg 5 1. Vehicle model
SERIAL N DRAW-BAR PULL (1 h) 2. Motor power 11
4 N
3. Nominal rated capacity
BATTERY MASS
kg kg
SEVICE MASS
Without 7
4. Truck serial number 12
6 min. max. Battery kg 5. Draw-bar pull
MANUFACT. YEAR BATTERY V
V
9 6. Battery weight (min/max) 13
8 7. Truck weight (without battery)
14
Cod.0311014
8. Year of manufacture
9. Battery voltage
10 CESAB Carelli Elevatori S. p. A. 10. Notes 15
Via Persicetana Vecchia 10
40132 - Bologna - Italia
16
B: Load capacity plate
ATTACHMENT OR SPECIAL CONDITION OF USE 12 It identifies the load capacity with a load center 17
11 of 600 mm (except for different indications):
TYRES SERIAL N
13 11. Special model, Attachment model 18
LIFT HEIGHT CENTER OF LOAD DISTANCE mm
12. Truck tyres
mm
14 13. Attachment serial number 18

14. Load center
15. Lift height Rated capacity 18
15 16
Cod 0311013
18
DERATED CAPACITY Kg
18
CESAB Carelli Elevatori S. p. A.
Via Persicetana Vecchia 10
40132 - Bologna - Italia 18
0-6
TECHNICAL DATA
0-7
ECO P 60
ECO P 70
0
ECO P 85
2
2
3
4
5
6
7
8
CAPACITY DIAGRAMS (with SE tyres)

9
Barycentre [mm] Capacity [Kg] ECO P 60 10
6000 6000
600 6000
11
Capacity [Kg]
5500
700 5530 5530
5130
5000
800 5130
900 4790 4500
4790
4490
12
1000 4490 4000
3500
13
600 700 800 900 1000
Barycentre [mm]
14
Barycentre [mm] Capacity [Kg] ECO P 70
7000 7000
15
600 7000
Capacity [Kg]
6500
700 6460 6460
16
6010
800 6010 6000
900 5610 5500 5610
5260
17
1000 5260 5000
4500
600 700 800 900 1000
18
Barycentre [mm] 18
Barycentre [mm] Capacity [Kg] ECO P 85
600 8500 8500 8500 18
Capacity [Kg]
8000
700 7860
800 7310 7500
7860
7310
18
900 6830 7000
6830 18
1000 6420 6500
6420
6000
600 700 800 900 1000 18
Barycentre [mm]
0-8
HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operation procedure
The operation procedure is described in either pattern A or pattern B below.
1) Pattern A: Explanation of each operation step with illustration.
2) Pattern B: Explanation of operation procedure by indicating step numbers in one illustration,
followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B
DISASSEMBLYINSPECTIONREASSEMBLY
Tightening torque unit T = Nm
Sometimes step Nos. are
partially omitted in
illustrations.
When a part requiring
tightening torque instruction is
not indicated in the illustration,
the part name is described in
the illustration frame.
T = 46.1 to 48.1
Disassembly Procedure
1. Remove the cover. [Point 1]]

2. Remove the bushing. [Point 2] Operation explained later
3. Remove the gear
Points of intervention
[Point 1] Explanation of key point for operation with an illustration
Disassembly:

Put a match mark when removing the pump cover

[Point 2]
Inspection:
Measure the bush inside diameter
Limit 19.12 mm
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)
0-9
TERMINOLOGY
Caution:
Important matters, negligence of which may cause accidents. Be sure to observe them. 0
Note:
Important items, negligence of which may cause accidents, or matters in operating procedure 2
which require special attention.
Standard:
2
Value showing the allowable range in inspection or adjustment
3
Limit:
The maximum or minimum value allowed in inspection or adjustment.
4
ABBREVIATIONS
5
Abbreviation Meaning Abbreviation Meaning
ASSY Assembly SAE

Society of Automotive Engineers 6
(USA)
ATT Attachment SAS System of active stability
7
LH Left hand RH Right hand 8
O/S Oversize U/S Undersize
9
PS Power steering SST Special service tool
EHPS
Power steering with total
STD Standard
10
electronic control
Power steering with 11
FHPSx T= Tightening torque
hydraulic control
12
L/ Less (-) T Number of teeth (T)
OPT Option W/ With 13
ILLUSTRATIONS 14
The illustrations are supposed to point out the correct procedures to execute the truck and on his
components, therefore they could not represent exactly the elements of this truck but similar mechanical 15
components.
16
17
18
18
18
18
18
18
0-10
SI UNITS
Meaning of SI
This manual uses SI units. SI represents the International System of Units established to unify the
various systems of units used in the past for smoother international technical communication.
New Units Adopted in SI
Conventional Conversion rate*

Item New unit
unit (1 [conventional unit] = X* [SI unit])
Force (**) N (newton) kgf 1 kgf = 9.80665 N
Torque(**) Nm kgfcm 1 kgfcm = 9.80665 Nm
(Moment)
Pressure (**) Bar kgf/cm2 1 Bar = 1 kgf / cm2
Pressure (**) Pa (Pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
Pressure (**) Pa (Pascal) mmHg 1 mmHg = 0.133322 kPa
Revolving
rpm rpm 1 rpm = 1 r/min (giri al minuto)
speed
Spring
N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
constant (**)
Volume l cc 1 cc = 10-3 x1l
Power W PS system 1 PS = 0.735499 kW
Heat quantity Wh cal 1 kcal = 1.16279 Wh
Specific fuel
g/Wh g/PSh 1 g/PSh = 1.3596 g/kWh
consumption
<Reference>
(*) : 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.
(**): 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.
Conversion between Conventional and SI Units
Equation for conversion
Value in SI unit = Conversion rate Value in conventional unit Conversion rate: Figure corresponding
to X in the conversion rate column in
Value in conventional unit = Value in SI unit Conversion rate the table above
When converting, change the unit of the value in conventional or SI units to the one in the
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.
0-11
OPERATING TIPS
1. Safe operation
(1) After jacking up the vehicle, always support it with wooden blocks or sturdy rigid stands 0
(2) When hoisting the vehicle or a heavy component, use wire rope(s), chains or slings with a
sufficient reserve in load capacity to the load to lift 2
(3) Always disconnect the battery plug before electrical parts inspection or servicing
2. Technical operation to perform 2
(1) Before starting any kind of operation, prepare the tools, necessary measuring instruments
(multimeter, megohmmeter, oil pressure gauge, etc.) and SST (Special Service Tools).
(2) Before disconnecting wiring, always check the cable color and wiring state.
3
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the
parts neatly to prevent confusion. 4
(4) When disassembling and inspecting parts such as the control valve, use clean tools and operate
in a clean location 5
(5) When disassembling, inspecting and reassembling, follow the specified procedures
(6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each 6
time they are disassembled
(7) Always use genuine parts for replacement.
(8) Reassembling, use specified bolts and nuts as shown in the specifications. Observe the 7
specified tightening torque at the time of reassembly (tighten to the average value of the specified
tightening torque range.). If no tightening torque is specified, tighten the bolt or the nut according 8
to the value at the standard tightening torque table
3. Determining the trouble status 9
When a trouble occurs, do not attempt an immediate disassembling and/or replacing of any
components but first determine if disassembly and/or replacement are actually required in order to 10
resolve the defect.
4. Waste fluids and solid refuses disposal 11
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 12
health and destroy the environment. Always collect and sort well this kind of materials, and treat
them properly by requesting disposal by specialized companies and however according to the 13
current laws
5. Greasing up each part 14
In addition to periodic grease-up according to the lubrication chart, apply MP grease (or molybdenum
disulfide grease) to each sliding contact face when repairing a portion (like pedal link) involving 15
sliding contact.
6. Functional parts protection (battery operated vehicles) 16
(1) After vehicle inspection or maintenance, before connecting the battery plug , check thoroughly
each connector for connection failure or imperfect connection. Connectors failure or imperfect 17
connection, especially related to the logic units, may damage elements inside them
7. Disconnect the battery plug 18
When unplugging the battery plug, use the grip. Do not pull up the cable..
18
18
18
18
18
0-12
BATTERY RECYCLING/DISCARDING
The forklift truck uses a lead accumulator and, in the 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.
DISCARDING THE BATTERY

When the working life of the battery in the truck is at an end
(change for a new battery) or if the entire truck is to be
scrapped, special attention to environmental risks must be
paid when disposing/recycling batteries. Contact the
manufacturer about changing or discarding batteries.
RECYCLING
steel, brass, bronze, ABS, plastic-

1 BODYWORK
reinforced fibre-glass, polymers
1 4
steel, copper, nylon, graphite,
2 DRIVE UNIT
polymers
5
6
3 BRAKING UNIT steel, polymers, nylon
steel, copper, silicon, brass,
4 ELECTRIC UNIT aluminium, lead, zinc, graphite,
3
2 nylon, polymers
5 STEERING UNIT steel, bronze, polymers
HYDRAULIC steel, copper, bronze, brass,
6
UNIT aluminium, graphite, polymers
VARIOUS steel, copper, brass, aluminium,
COMPONENTS cast-iron, ABS, nylon, polymers
DISPOSAL OF In compliance with local
MINERAL OILS, directives.
GREASE AND Please dispose of in an
BATTERY environmentally friendly way!
0-13
LIFTING THE TRUCK

HOOKING POINTS FOR THE TRUCK LIFTING
Lifting the vehicle, always observe the specified hooking 0
A points and hoisting methods. Never hoist by any other
attachment section and/or procedure as it is very 2
dangerous.
The hooking points are shown on the truck with the symbol
shown on the side (see figure) 2
If the truck is equipped with mudguard extensions, chains
can only be hooked by previously disassembling the
3
extensions themselves.
4
LIFTING THE TRUCK WITH OVERHEAD
GUARD 5
The following equipment must be used to lift the truck
without cabin: 6
B
A - CHAINS: 18 mm - Degree T (8) - UNI EN 818-2 7
B - HOOKS: for 10 t - UNI/ISO 7597
8
LIFTING THE TRUCK WITH CABIN
The following equipment must be used to lift the truck with 9
cabin:
E - N 2 slings: secondo normativa DIN B2N-UNI9531 9 m 10
min. lenght, 2800 kg capacity
F - N 4 liwer brackets to hold the slings 11
G - N 2 upper brackets to hold the slings
Notes:
12
It is important to remember that the chain (slings)
length must be sufficient to lift the truck in a horizontal 13
position, with the lifting angles () 45 with respect to
the vertical lifting line. 14
Make sure that there are no personnel in the vicinity of the
truck, before carrying out the lifting operation. 15
If any maintenance operations need to be performed on the
truck in a raised position, the vehicle must be rested on
16
appropriate supports, sufficient to bear the overall weight of
the vehicle, keeping the chain (slings) taut. 17
TRUCK WEIGHTS
ON THE AXLE WEIGHT WITHUT LOAD 18
(FRONT / REAR)
60 ~ 10280 kg ~ 5055 / 5225 kg 18
70 ~ 11040 kg ~ 5037 / 6003 kg
85 ~ 12577 kg ~ 5389 / 7188 kg 18
Note:
The weights are refered to trucks with SE tyres, TV dupex mast (h3= 3160) and sideshift fork 18
carriage
18
18
0-14
WIRE ROPE SUSPENSION ANGLE LIST

Lifting Suspension Lifting Suspension
Tension Compression Tension Compression
angle method angle method
0 1.00 time 0 time 90 1.41 time 1.00 time

90
1.0 tf
tf
41
1.
2t 2t
30
30 1.04 time 0.27 time 120 2.00 time 1.73 time
tf
120
1.04
f
2t
2t 2t
60 1.16 time 0.58 time

60
f
6t
1. 1
2t
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load
0 0 30 60 90 0 30 60 90
6 mm 21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
8 mm 31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
10 mm 49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
12.5 mm 76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
14 mm 96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
0-15
COMPONENT WEIGHT
Component Vehicle model Weight (Kg)
60 ~ 1150x2
0
Battery 70 ~ 1150x2 2
85 ~ 1382x2
Traction motor all ~225 2
Lifting motor group (pump + electric motor) all 2 x ~65
Rear axle (without wheels and dry) all ~323
3
60 ~1900
4
Counterweight 70 ~1900
85 ~2650 5
Mast group with fork carriage (with lift cylinder, without 6
all ~ 550
forks, lifting height 3160 mm, 2M TV mast)
7
60 ~10280
Vehicle weight (with battery) 70 ~11040 8
85 ~12577
9
LIFTING ANTERIOR TRUCK WHEELS
10
Before perform certain interventions it is necessary to lift the truck anterior wheels. Support the mast on
two blocks, to avoid the risk of accidents
11
1 Block the steering wheels
2 Tilt back the mast and insert blocks under the mast base 12
3 Tilt ahead the mast: the anterior wheels must be lifted and free of rotate
To carry out correctly all the truck lifting operation it is necessary to have the following tools:
13
a hydraulic jack with up to 5 ton capacity
metal or hard wood blocks 14
Before putting the blocks under the must, check the inclination of the floor, the truck must be parked on a
flat, horizontal surface. 15
16
17
18
18
18
18
18
18
0-16
OPERATIONS ON THE MAST

Always make sure that the mast mobile parts are secured/blocked before performing any maintenance/
repair work or any operations requiring the mast opening.
The mobile parts of the mast can be secured/blocked in two ways:
Blocking with bars/blocks
Blocking with chains
BLOCKING WITH BARS/BLOCKS

It is possible to use two (A) wooden bars/blocks (no
chipboard) tieing inside the mast internal profiles to block it
mechanically and avoid any kind of movement
In the case of F. F.L. mast, adopt the same procedure to

secure also the fork carriage.
No load must be present on the mast.
BLOCKING WITH CHAINS

In alternative to the method previously described a chain
can be used, as shown in picture. Do not twist the chain
round his own axle, but roll up it on the mast and the fork
carriage beams
Secure/fix both ends of the chain with bolt, nut and washers
of appropriate size for the chain used.
No load must be present on the mast.
0-17
TOWING THE TRUCK

Please follow the instructions of chapter 08, paragraph NEGATIVE BRAKES MANUAL
UNBLOCKING
0
The standard fork lift trucks are not suited for towing.
In special case, the rear draw bar can be used to tow a 2
faulty lift truck.
In this case it is obligatory to use a stiff towing bar, fastened 2
between the rear draw bar of the truck and the towing
vehicle. You must proceed carefully and slowly, if possible
on a level surface. 3
while towing, do not carry any other loads on the forks; 4
as far as possible, avoid driving on gradients. In any
case, do not go over the figure for driving on gradients
with a load. 5
Note the cautions below when towing the vehicle with 6
back wheels lifted.
Lift the rear wheels for towing 7
The traveling speed when towing must not exceed the
maximum traveling speed of the forklift. 8
Before starting towing, always set the key switch to OFF,
the direction switch to the neutral position and parking 9
brake of released.
Before towing, either remove the fork or take action to
prevent the fork from coming into contact with the ground
10
due to bouncing.
11
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
12
obstacle.
13
14
15
16
17
18
18
18
18
18
18
0-18
ELECTRICAL PARTS INSPECTION

1. Always disconnect the battery plug before inspecting or servicing electrical parts.
2. Pay sufficient attention when handling electronic parts.
(1) Never subject electronic parts, such as computers

and relays, to impact.
(2) Never expose electronic parts to high temperature
or moisture.
(3) Do not touch connector terminals, as they may be
deformed or damaged due to static electricity.
3. Connect a multimeter to the circuits to match the object and purpose of measurement
Analog multimeter: this type is convenient to detect transitory conditions during measurements
and the operating condition. Measured values are only just as an indication.
Digital multimeter: a fairly accurate reading is possible. However, it is difficult to observe operating
condition or transitory conditions
(1) Difference between measurement results with analog and digital multimeters
The measurement results with analog and digital types can be different.
Differences between the polarities of the analog type and the digital type are described below.
1) Analog multimeter
Direct connection Reverse connection

Example of measurement result
Multimeter range: k
Analog type
Direct Continuity
connection 11 k
Reverse No continuity
connection
2) Digital multimeter
Direct connection Reverse connection Example of measurement result

Multimeter range: 2M
Digital type
Direct No continuity
connection 1
Reverse Continuity
connection 2 M
0-19
STANDARD TIGHTENING TORQUE TABLE

The tables here below are valid for screws and bolts without superficial covering, preventively lubricated
with oil.
0
SCREWS WITH ISO COARSE THREAD
Preloading V STD tightening torque (N) TORQUE Max (Nm) 2

Class nut/bolt 5S/6,6 6S/8,8 8G/10,9 10K/12,9 5S/6,6 6S/8,8 8G/10,9 10K/12,9
M 4 x 0,7 21781 3865 5435 6524 1,7 3 4,2 5,1
2
M 5 x 0,8 3502 6229 8780 10497 3,2 5,8 8,2 9,9 3
M6x1 4974 8849 12459 14911 5,7 10 14,3 17,1
M7x1 7142 12753 17854 21386 9,2 16,6 23 27,8 4
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 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
6
M 14 x 2 28351 50620 71123 85347 74 132 186 223 7
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 8
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 9
M 24 x 3 87309 155979 218763 261927 383 687 961 1148
M 27 x 3 112815 202086 283509 340407 549 991 1393 1668
10
M 30 x 3 138321 247212 347274 415944 755 1354 1893 2276 11
SCREWS WITH ISO FINE THREAD
12
Preloading V STD tightening torque (N) TORQUE Max (Nm)
Class nut/bolt 5S/6,6 6S/8,8 8G/10,9 10K/12,9 5S/6,6 6S/8,8 8G/10,9 10K/12,9 13
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 14
M 12 x1,25 23740 40613 56898 68474 52 89 126 151
15
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 16
M 16 x 1,5 41202 73575 103003 123606 118 211 294 353
M 18 x 1,5 53268 95157 133416 159903 171 304 422 510 17
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 18
M 24 x 2 94667 168732 237402 284490 402 721 1010 1216
18
M 27 x 2 122625 218763 307053 367875 589 1050 1472 1766
M 30 x 2 154017 272718 384552 461070 814 1442 2040 2453 18
18
18
18
0-20
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with
clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact
surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten
the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
4. For conical fittings only
Standard tightening torque (Nm)
Nominal diameter of screw Hose inside diameter (mm)
Standard Tightening range
7/16 20UNF 25 24 to 26 6
9/16 18UNF 34 32 to 36 9
3/4 16UNF 59 56 to 62 12
7/8 14UNF 59 56 to 62 12
7/8 14UNF 78 74 to 82 15
11/16 12UNF 118 112 to 123 19
15/16 12UNF 137 130 to 144 25
PF1/4 25 24 to 26 6
PF3/8 34 32 to 36 9
PF1/2 59 56 to 62 12
PF3/4 118 112 to 123 19
PF1 137 130 to 144 25
ASSEMBLAGE FOR NIPPLES TYPE PARKER ERMETO E0/ E0-2

To tighten all the nipples marked E0/ E0-2 on the truck, act as indicated in the procedure here below:
1. Tighten the nipple with the spanner up to the point of

resistance (without any spanner extension)
2. Tighten the nipple firmly starting with min. 1/ 6 of a turn
(a face of the hexagon), up to max. 1/ 4 of a turn (a
face and half of the hexagon); it is recommended the
use of a spanner extension
0-21
PERIODIC MAINTENANCE
Periodic inspection and maintenance are necessary to keep your forklift truck running smoothly. The
designated number of hours for each inspection cycle is as follows.
Daily (pre-operation check) Every 8 hours 0
Weekly Every 40 hours
6-week Every 250 hours 2
3-month Every 500 hours
6-month Every 1,000 hours 2
12-month Every 2,000 hours
If operating hours in 6 weeks exceed 250 hours, perform inspection according to the operating hours 3
specified in the periodic inspection guide. Pre-operation checks and weekly inspections should
preferably be performed by the user. 6-week, 3-month, 6-month and annual inspections should be 4
performed at your dealer, as high skill and special tools are required.
Refer to the periodic maintenance table to determine inspection and maintenance items and inspection 5
cycles.
Use only genuine original parts for replacement, and use the recommended types of lubricants.
6
PERIODIC REMPLACEMENT TABLE
7
REPLACEMENT CYCLE 1 6
every 3 6 12 18 months 8
(Based on total operating week weeks
months or hours, whichever
every 40 250 500 1000 2000 3000 hours
comes first) 9
Hydraulic oil l
Hydraulic filter l* l
10
Drive unit oil l 11
Oil tank breather filter l
Hoses from power steering unit to 12
(every 30 months or 5000 hours)
steering cylinder
Service brake and parking brake hoses (every 30 months or 5000 hours) 13
Tilt cylinder hydraulic hoses (every 30 months or 5000 hours) 14
Steering system hoses (every 60 months or 10000 hours)
Lifting chains (every 60 months or 10000 hours) 15
Chain securing tie rods (every 60 months or 10000 hours)
16
High pressure hydraulic tubing (every 60 months or 10000 hours)
*: For new vehicles 17
18
18
18
18
18
18
0-22
PERIODIC MAINTENANCE TABLE

INSPECTION METHOD
I: Inspect, correct and replace as required. T: Tighten. C: Clean. L: Lubricate. M: Measure and correct,
and adjust as required.
6
REPLACEMENT CYCLE (Based on total oper- every weeks
3 6 12 months
ating hours or months, whichever comes first)
every 250 500 1000 2000 hours
ELECTRICAL SYSTEM
Motor
Rotation sound I*
Terminal looseness T
Battery
Charging level I
Electrolyte level I
Electrolyte specific gravity M
Terminal looseness I
Abnormality in the upper portion of the battery and/or the
I
case
Voltage measurement of each battery cell after charging M
Magnetic switch
Contact looseness, damage, abrasion I
Auxiliary contact operating, condition, contamination, and
I
abrasion
Mounting condition of the arc shoote I
Operating condition and timings I
Looseness of the coil mounting locations I
Mounting condition and looseness of the main circuit lead
I
wire
Microswitch
Operating condition and timings I
Installation damage and looseness I
Direction switch
Operating condition, damage I
Controller
Operating condition I
Interior contamination and damage C
Motor input voltage M
Fuse
Looseness I
0-23
6
REPLACEMENT CYCLE (Based on total operat- every weeks
3 6 12 months
ing hours or months, whichever comes first)
every 250 500 1000 2000 hours 0
Wiring (including charging cord)
Harness deterioration, damage and looseness of clamp I* I 2
*
Looseness of the connections, taping condition I I
Connecting condition and damage of the battery connector I *
I
2
POWER TRANSMISSION SYSTEM
3
Drive unit
Oil leakage I 4
Oil level I
Bolt or nut looseness T 5
DRIVE SYSTEM
Wheels
6
Tire pressure (OPT) M
7
Tire cuts, damage or uneven treads I
Hub nut looseness T 8
Tread depth M* M
Metal chips, pebbles or other foreign matter trapped in tire *
I I
9
treads
Rim side ring and disc wheel damage I* I 10
*
Front wheel bearing abnormal noise and looseness I I
Rear wheel bearing abnormal noise and looseness I *
I
11
Front axle
12
Deformation and damage I
Rear axle 13
Abnormal noise looseness of rear axle bearing I 14
Loosenes of axle beam in vehicle longitudinal direction M* M
STEERING SYSTEM
15
Steering wheel
16
Play, looseness and loosening I* I
Operating condition I* I 17
Steering valve
Oil leakage I* I 18
*
Mounting looseness T T
Steering system
18
Steering angle to right and left I
18
Power steering
Oil leakage and oil level I 18
Looseness in mounting parts I
Power steering hose damage I 18
18
0-24
6
3 6 12 months
every 250 500 1000 2000 hours
BRAKING SYSTEM
Brake pedal
Braking performance I
Parking brake
Pull margin and operating force I
Braking performance I
Rods and cable
Loosening, looseness or damage I* I
Operating condition I* I
System brake
Oil leak I* I
Disc wear and damage I
MATERIAL HANDLIG SYSTEM
Fork
Damage and wear of fork and stopper pin I
Misalignment between left and right fork fingers I
Cracks at forks root and welded portion I*1
Mast and lift bracket
Deformation, damage and cracks in welded portion I
Wear, damage and rotating condition of roller I
Mast and lift bracket looseness I
Wear and damage of mast support bushing I
Wear and damage of roller pin I
Wear and damage of mast pads I
Chain and chain wheel
Tension deformation, damage and slackness of chain I* I
Chain lubrication I
Abnormality of chain anchor bolt and nut I
Wear, damage and revolution of chain wheel I
Attachment (OPT)
Abnormalities and mounting condition I
0-25
6
3 6 12 months
every 250 500 1000 2000 hours 0
HYDRAULIC SYSTEM
Cylinder
2
Cylinder mounting looseness, damage T 2
Looseness, deformation and damage of rod and rod end I
Cylinder operation I 3
Natural drop, natural forward tilt M
4
Oil leakage and damage I
Pin and cylinder shaft support wear and damage I 5
Uneven movement I
Hydraulic pump
6
Oil leakage and abnormal noise I 7
Hydraulic oil tank
Oil level, contamination I
8
Tank and oil strainer C 9
Oil leakage I
Control lever 10
Operation I
11
Oil control valve
Oil leakage I 12
Relief pressure measurement M
13
Safety valve function I
Hydraulic hose and piping 14
Oil leakage I
15
Linkage looseness T 16
SAFETY DEVICES, ETC.
Head guard 17
Welded portion cracks I
18
Deterioration, damage I
18
18
18
18
18
0-26
6
3 6 12 months
every 250 500 1000 2000 hours
Backrest
Looseness in mounting parts T
Deterioration, cracks and damage I
Lighting system (OPT)
Operation, mounting condition I
Horn
Turn signals (OPT)
Instruments
Operation I
Backup buzzer (OPT)
OPS
Function I* I
Seat
Mounting looseness, damage I
Seat belt damage and operation I
Deadman seat operation I
Seat switch operating condition I* I
Body
Frame, cross member, etc. damage, cracking I
Bolt and nut looseness T
Rear-view mirror (OPT)
Dirt, damage I
Rear reflection I
Other
Lubrication status L
* : For new vehicles
*1: Fissure and crack detector
Note:
In case of hard operating conditions, the service interval of 170 hours or 1 month may be
recommendable.
WARNING:
Complete the information concerning all maintenance operations with those mentioned in the
relevant safety and operator manuals
0-27
SERVICE DATA
Adjustment value table
Item
Vehicle
Eco P 60 Eco P 70 Eco P 85
0
model
20-50 (0.79- 2
Steering wheel play mm (in.)
1.97)
Standard 1.280
2
Battery electrolyte specific grav-
ity (20C) (Reference) Limit 1.150 3
Mpa 21 24 23
Oil control valve set pressure Lift / Tilt
(kg/cm2) (214) (245) (234) 4
0.5-1 (0.02-
Brake pedal play mm (in.)
0.04) 5
Brake pedal floor clearance 75 +/- 2.5
mm (in.) 6
(floor mat) (2.9 +/- 0.1)
480
Front (49) 7
Nm [354]
Hub nut tightening torque (kgf-m)
380
8
[lbf-ft]
Rear (39)
[280] 9
Sound pressure level (LPA) in
accordance with EN 12053 dB (A) =<70 10
Uncertainty K=4 dB(A)
Whole body vibration in accor-
11
dance with in EN 13059
m/s2 0.40 +/- 0.05 12
Uncertainty K=0.3 x a m/s2
(a:listed value)
13
*Note
The vibration values shown above are obtained from the measurements in accordance with EN 14
13059.
The magnitude of hand arm vibration of lift trucks is 2.5m/s2 or below as defined in EN 13059. 15
The whole body vibration values shown above cannnot be used for calculating 8 hour vibration
exposure in 2002/44/EC (Vibration Directive).
If calculated according to the general forklift operation pattern, the result will be lower than 0.5 m/s2.)
16
The sound presure values shown above can be used as the sound level at operators ears. (Values
are in accordance with EN 12053 measurement methods.) 17
18
18
18
18
18
18
0-28
LUBRICANT CAPACITY AND TYPE TABLE
Applicable place Capacity Type

Drive unit - Wet disc brakes 15 l (3.963 US gal) Mobilube HD80W-90
Standard vehicle: Agip Arnica VG46
Hydraulic oil 90 l (23.775 US gal)
Cold storage vehicle: Agip Arnica VG32
Standard vehicle: Mobilgrease Special
Chassis and mast
Proper amount Cold storage vehicle: Mobiltemp
Grease fitting
SHC100
Battery Proper amount Distilled water
WHEELS & TYRES
Tire
Vehicle Wheel
Type Tire size pressure Remarks
model size
bar
Cushion single tyre 713x360-560 option
Superelastic standard
Pneumatic 355/65-15 9.75-15 Marangoni 9,25 option
Non Marking option
Eco P 60 Front Cushion twin tyres 713x254-560 option
Superelastic option
Continental 10
Pneumatic 8,25-15 6.5-15 option
Marangoni 9,25
Non Marking option
Cushion 713x254-560 option
Eco P 70
Front Continental 10
Eco P 85 Pneumatic 8,25-15 6.5-15 option
Marangoni 9,25
Non-Marking option
Eco P 60
Rear Continental 10
Eco P 70 Pneumatic 250-15 7.0-15 option
Marangoni 8,25
Non-Marking option
Eco P 85 Rear Continental 10
Pneumatic 250-15 7.0-15 option
Marangoni 8,25
Non-Marking option
0-29
LUBRICATION CHART
0
2
2
3
4
5
6
7
8
9
1. Mast strip and bearings
2. Tilt cylinder front pin 10
3. Mast support bushing
4. Lift chain 11
5. Drive unit - Wet disc brake
6. Rear axle beam front pin
7. Oil tank
12
8. Steering knuckle king pin
9. Rear wheel bearing 13
10. Tie rod end pin
11. Rear axle cylinder end pin 14
12. Rear axle beam rear pin
13. Side shifter (OPT)
14. Gates locks (OPT)
15
I) Inspect every 8 hours (daily) 16
II) Inspect every 40 hours (weekly)
III) Inspect every 250 hours (6-weeks) 17
IV) Inspect every 1000 hours (semi-annually)
V) Inspect every 2000 hours (annually) 18
Inspection and supply
Replacement
18
* Located both right and left
18
A) Molybdenum disulfide grease
B) Motor oil 18
C) Gear oil
D) Hydraulic oil 18
Note:
In case of hard operating conditions, the service interval of 170 hours or 1 month may be
18
recommendable.
0-30
VEHICLE DIMENSION
ECO P
60 80 85
b1 1750mm / /
b2 1972mm
1472mm
b10
(*)
b11 1230mm
/ 5/10
h1 2525mm 2575mm
h2 100mm
h3 3150mm
h4 4050mm 4100mm
h6 2570mm
h7 1379mm
h10 630
l1 4466mm 4529mm
l2 3246mm
x 595mm 615mm 635mm
y 2000mm
C 600mm
e 200mm
s 60mm 70mm
Wa 3104mm 3255mm
Ast (**) 5099mm 5199mm 5290mm
Data are referred to SE tyres models
(*) 1450mm for non twin tyres (Eco P 60 only)

(**) with pallet 1200mm long
0-31
MAST SPECIFICATIONS AND RATED CAPACITIES
0
2
2
3
4
5
6
7
8
9
10
11
A (h3) B G (h2) J
D (h4) P S
12
C (h1) H I
E F L M N 13
mm mm mm mm mm mm deg deg kg
V FW FSW
14
Wide Visible Mast Wide Visible Full-Free Lift Wide Visible Full-Free
Two-Stage Mast Lift Three-Stage Mast 15
A (h3): Maximum lifting height 16
B: Overall Height
C (h1) Lowered 17
D (h4) Extended
E: Without Load Backrest 18
F: With Standard Load Backrest
G (h2): Free Lift (Top of Forks)
H: Without Load Backrest 18
I: With Standard Load Backrest
J: All tyres 18
K: Tilt Range
N:Load capacity 18
L: Forward
M: Backward
N: 600 mm Load center
18
18
0-32
Eco P 60
B G J
A D P S
C H I
E F L M 600 mm LC
3210 2525 4050 4777 100 100 5 10 6000
3710 2775 4550 5277 100 100 5 10 5800
4210 3025 5050 5777 100 100 5 10 5500
V 4710 3325 5600 6277 100 100 5 10 5200
5010 3475 5900 6577 100 100 5 10 4900
5610 3825 6550 7177 100 100 5 10 4300
6010 4025 6950 7577 100 100 5 10 3600
3710 2825 4675 5277 1800 1258 5 8 5700
4210 3075 5175 5777 2050 1508 5 8 5400
FW
4710 3375 5675 6277 2350 1808 5 8 5000
5510 3775 6475 7077 2750 2208 5 8 4100
4510 2675 5475 6077 1650 1108 5 8 6000
5010 2825 5975 6577 1800 1258 5 8 5800
FSW 5610 3075 6575 7177 2050 1508 5 8 5400
6010 3175 5975 7577 2150 1608 5 8 5100
6510 3375 7475 8077 2350 1808 5 8 4600
Height of standard load backrest is 1627 mm above ground.
Eco P 70
B G J
A D P S
C H I
E F L M 600 mm LC
3210 2575 4105 4777 100 100 5 10 7000
3710 2825 4605 5277 100 100 5 10 6800
4210 3075 5105 5777 100 100 5 10 6500
V 4710 3375 5650 6277 100 100 5 10 6200
5010 3525 5950 6577 100 100 5 10 5900
5610 3825 6550 7177 100 100 5 10 5300
6010 4075 7000 7577 100 100 5 10 4600
3710 2825 4675 5277 1800 1258 5 8 6700
4210 3075 5175 5777 2050 1508 5 8 6400
FW
4710 3375 5675 6277 2350 1808 5 8 6000
5510 3775 6475 7077 2750 2208 5 8 5100
4510 2675 5475 6077 1650 1108 5 8 7000
5010 2825 5975 6577 1800 1258 5 8 6800
FSW 5610 3075 6575 7177 2050 1508 5 8 6400
6010 3175 6975 7577 2150 1608 5 8 6100
6510 3375 7475 8077 2350 1808 5 8 5600
Height of standard load backrest is 1627 mm above ground.
0-33
Eco P 85
B G J
A
C
D
H I
P S 0
E F L M 600 mm LC
mm mm mm mm mm mm deg deg kg 2
3220 2580 4105 4777 100 100 5 10 8500
3720 2830 4605 5277 100 100 5 10 8300
2
4220 3080 5105 5777 100 100 5 10 800
3
V 4720 3380 5650 6277 100 100 5 10 7700
5020 3530 5950 6577 100 100 5 10 7400 4
5620 3830 6500 7177 100 100 5 10 6800
6020 4080 7000 7577 100 100 5 10 6100 5
3720 2830 4675 5277 1800 1273 5 8 8200
4220 3080 5175 5777 2050 1523 5 8 7900
6
FW
4720 3330 5675 6277 2350 1773 5 8 7500
7
5520 3780 6475 7077 2750 2223 5 8 6600
4520 2680 5475 6077 1650 1123 5 8 8500 8
5020 2830 5975 6577 1800 1273 5 8 8300
FSW 5620 3080 6575 7177 2050 1523 5 8 7900 9
6020 3180 6975 7577 2150 1623 5 8 7600
6520 3355 7475 8077 2350 1798 5 8 7100
10
Height of standard load backrest is 1627 mm above ground. 11
12
13
14
15
16
17
18
18
18
18
18
18
0-34
WEI SEITE

1-1
BATTERY
BATTERY COMPARTMENT AND REQUIRED WEIGHT.................................... 3
SERVICE STANDARDS....................................................................................... 4
DISPLAY .............................................................................................................. 4
1
BATTERY MANAGEMENT .................................................................................. 5 2
CORRECTION VALUES FOR BDI MAX. AND BDI MIN. PARAMETERS.......... 6 3
TROUBLESHOOTING ON THE BATTERY ......................................................... 7
4
BATTERY ............................................................................................................. 8
INSPECTION........................................................................................................ 10 5
REPLACING BATTERY PLUG TERMINAL ........................................................ 12 6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
1-2
WEI SEITE

1-3
BATTERY COMPARTMENT AND REQUIRED WEIGHT

When batteries are purchased locally, always adjust the weight to satisfy the minimum required weight,
as shown in the table below.
Dimensions of each one of the 2

Minimum weight of each
Vehicle type
Battery capacity battery compartments [mm]
one of the 2 batteries 1
(A H) (with case) [Kg]
X Y Z
2
60 - 70 640 650 1370 455 1150
60 - 70 720 650 1370 455 1150 3
60 - 70 800 650 1370 455 1150
60 - 70 - 85 1050 650 1370 566 1350 4
60 - 70 - 85 1200 650 1370 626 1350
5
6
7
8
9
10
11
12
13
14
15
Rear battery
16
17
CONNECTORS TYPE
EURO-DIN 320 18
18
18
18
Front battery 18
Din standard battery (DIN 43531 / 35 / 36 A, B, C, No) 18
1-4
SERVICE STANDARDS
Specific gravity (Upon full charge) 1,290 kg/l [20 C]
Specific gravity (Upon end of discharge) 1,140 kg/l [20 C]
Discharge end battery 80 V [2 x 40 V] (2 V x 40 elements) 68 V (1,7 V each element)
Charge end battery voltage 80 V [2 x 40 V] (2 V x 40 elements) 108 V (2,7 V each element)
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled or demineralized water
Insulation resistance 1 M o superiore
DISPLAY
Battery Charge Indicator

B (A) Diagnostic led
A (B) Charge indicator
Charge Acustic
Description Notes
Percentage notice
100-30%
Normal working No No performances drop
Performances drop
20% Speed reduction managed
Illuminated (B) from the parameters
No
Indicator T20% BDI REDUCTION (traction)
P20% BDI REDUCTION (lifting)
**
Drop of performances
10% Speed reduction managed
Blinking (A) Led,
from the parameters
illuminated (B) No
T10% BDI REDUCTION (traction)
Indicator
P10% BDI REDUCTION (lifting)
**
0%
Blinking (A) Led, Discharged battery, managed
illuminated (B) Yes from the parameter BDI ADJ MIN
Indicator (priority function for traction)
***
** The drop of performances is due to the selected profile

*** He corresponds to 20 % of the nominal battery charge
1-5
BATTERY MANAGEMENT
The battery discharge voltage and the battery status indicator on the dashboard are managed by the
Master traction logic unit.
The personalization of the indicator is effectuated modifying the parameters below described.
BDI adjust min

1
This parameter determines the SET POINT of the discharge voltage.
2
BDI adjust max
This parameter determines the SET POINT of the charge voltage.
3
ADJUSTMENT #3
This parameter determines the voltage necessary to effectuate the rearm of the battery indicator on the 4
display.
It is expressed in volts and permits an adjustment in step of 0,080 V
5
BDI RESET
This parameter permits the adjustment of the rears threshold when it is requested a charge with a status 6
of battery between 70% - 90%.
The indication of THRESHOLD at 60% shows rearm not available over 70% of battery charge.
7
V
8
Voltage necessary for the rearm
of the battery indicator = 9
ADJUSTMENT #3 (0 = 85,84 V)
10
Charge battery indicator =
BDI adjust max (3 = 83,52V)
11
Minimum threshold for the battery
indicator rearm = BDI RESET =60% 12
13
14
Discharge battery indication =
BDI adjust min (3 = 77,12 V)
15
16
17
18
18
18
18
18
18
1-6
CORRECTION VALUES FOR BDI MAX. AND BDI MIN. PARAMETERS

BDI MAX.
LEAD BATTERY
CORRECTION VOLT
9 86,16
8 86,68
7 85,28
6 84,80
5 84,40
4 84,00
(STD) 3 83,52
2 83,12
1 82,64
0 82,16
BDI MIN
LEAD BATTERY
CORRECTION VOLT
9 79,76
8 79,28
7 78,88
6 78,40
5 78,00
4 77,60
(STD) 3 77,12
2 76,72
1 76,24
0 75,76
ADJUSTMENT #3
LEAD BATTERY
etc. etc.
+5 86,24
+4 86,16
+3 86,08
+2 86,00
+1 85,92
(STD) 0 85,84
-1 85,76
-2 85,68
-3 85,60
-4 85,52
-5 85,44
etc. etc.
Notes:
The ADJUSTMENT #3 step value is always 0,08 V
The battery indicator can be rearmed if the battery charge level is lower then 60%:
The battery indicator can nor be rearmed if:
- The values of the ADJUSTMENT #3 are less than BDI MAX
- After charging, the battery level does not reach a value higher than BDI MAX
1-7
TROUBLESHOOTING ON THE BATTERY
Plate corrosion Sulfation Plate warpage and active substance freeing
Improper charging
Long storage
Repeated 1
overdischarge
Battery without operations and overcharge
life end Short circuit procedures 2
between cells
Defect of Excessive charging
Insufficient
the electrolyte current 3
Defective Electrolyte
electrolyte 4
Excessive
Battery defect
ambient
Overdischarge
temperature 5
Cells crack
6
Improper or chipping
Damaged
separator water
supply Imperfect
7
Overcharg terminal
connection 8
9
Depositined of free
active substance at
Fouled terminal or 10
connecting plug
bottom of the cells
11
Short circuit Electrolyte leakage and reduction Loosened or corroded connetion
12
13
14
15
16
17
18
18
18
18
18
18
1-8
BATTERY
DISASSEMBLY REASSEMBLY
1. Park the truck on a level surface and activate the parking brake
2. Switch off the truck
3. Open the battery covers and disconnect the battery plugs
4. Remove the lateral sides [Point 1]
5. Remove the battery safety locks [Point 2]
6. Remove the battery [Point 3]
Reassembly Procedure
The installation procedure is the reverse of the disassembly procedure.
1-9
Point Operations
[Point 1]I
Disassembly:
Remove the lateral sides
1
2
3
4
[Point 2]
Disassembly:
5
Remove the battery safety locks
6
7
8
9
10
11
12
13
[Point 3]
Disassembly: 14
Remove the battery from the truck
15
16
17
18
18
18
18
18
18
1-10
INSPECTION
1. Electrolyte levels Inspection:
Open the caps of each single battery element and
check that the electrolyte level is high enough to cover
the element plates. Otherwise the electrolyte level
must be restored with distilled or demineralized water
up to cover the superior edge of the plates exceeding
for 57 mm. Avoid to fill up over this limit, because it
can provoke the electrolyte leakage caused by his
expansion during the operation orduring the next
battery recharge, with consequent risk of battery
compartment corrosion, of electric isolation reduction
and of battery discharge. Carry out the level control
and, if needed, the possible filling, with charged
battery
2. Electrolyte inspection:
The battery electrolyte is normal when it is transparent.
Check turbidity when inspecting the specific gravity. If
it cannot be checked clearly, put the electrolyte in a
beaker for inspection.
.
3. Battery electrolyte specific gravity inspection:
Use a hydrometer to measure the specific gravity of
the electrolyte.
Specific gravity upon complete charging ....
1.280 [20 C]
Specific gravity upon end of discharge ....
1.150 [20 C]
The specific gravity of the electrolyte at 20 C (68 F) is

used.
Equation for converting specific gravity
S20=St+0.0007 (t-20)
S20: Specific gravity at 20 C
St: Specific gravity at t C
t: Electrolyte temperature upon measurement (C)
1-11
* How to use the hydrometer

(1) Insert the nozzle of the hydrometer into the
Hydrometer electrolyte port and allow the electrolyte to be
sucked into its outer tube.
Rubber
bulb
Out tube
(2) Let the hydrometer float correctly without contact 1
with the outer tube, top or bottom, and read the
scale at the highest point of the electrolyte surface
as illustrated on the left when the bubbles in the
2
Nozzle
electrolyte disappear.
3
(3) After the measurement, wash the inside and
outside of the hydrometer well with clear water and
store it after wiping water off with clean cloth.
4
4. Insulation resistance inspection 5
Measure the resistance between the battery and
battery case with an insulation resistance meter
(megohmmeter).
6
Insulation resistance .... 1 M or more 7
Note:
When the insulation resistance is less than 1 M, wash 8
the battery with water after removing it from the
vehicle.
Dry the washed battery fully and measure the insulation
9
resistance again. Install the battery on the vehicle after
confirming that the insulation resistance is 1 M or 10
more.
11
* Battery control table
Prepare a control table for each battery to record and maintain the inspection results. 12
Temperature
Time and date
Inspection
Inspected element Nr.
Specific gravity
Electrolyte Electrolyte
Capacity
added water
Note Inspector 13
14
15
16
17
18
18
18
18
18
18
1-12
REPLACING BATTERY PLUG TERMINAL
1. Disconnect battery plug cable one by one.

Caution:
Never disconnect more than one cable at the same
time. Fatal accident may result by short circuit.
2. Insert a screwdriver from the terminal side, push down

the spring at the bottom of the terminal and pull the
Terminal Screw driver cable to draw out the terminal.
Spring Spring
3. Peel off the tip of the cable for Approx. 30mm, solder
sufficiently and insert it to the contact portion of the new
terminal.
Note:
Be sure to prevent solder from pouring out and adhere
to the contact surface of the terminal.
Crimping method 4. When crimping cables, never bend the terminal with a
crimping tool.
Crimping tool
Pad
(To prevent the contact
piece from bending)
5. Insert the terminal to the battery plug.

Case Terminal Check that the tip of the terminal goes over the tip of
the spring and securely set in the position.
Spring Cable
2-1
CONTROL SYSTEM
GENERAL ............................................................................................................ 3
2
SPECIFICATIONS................................................................................................ 4
COMPONENTS.................................................................................................... 5
2
TRACTION LOGIC UNIT ..................................................................................... 5 2
PUMP LOGIC UNIT ............................................................................................. 5 3
MCB BOARD ....................................................................................................... 6
4
ARMREST BOARD (optional) ............................................................................ 6
FUSE GROUP...................................................................................................... 7 5
BEFORE REPAIR ................................................................................................ 8 6
INSPECTION........................................................................................................ 8
7
CONNECTOR INSPECTION................................................................................ 9
8
MAIN CONTROLLERS ........................................................................................ 10
TRACTION LOGIC UNIT ..................................................................................... 10 9
PUMP LOGIC UNIT ............................................................................................. 12 10
MCB BOARD ....................................................................................................... 14
11
ARMREST BOARD.............................................................................................. 19
CONTACTOR GROUP......................................................................................... 22
12
DASHBOARD ...................................................................................................... 23 13
FUSE GROUP...................................................................................................... 25 14
CONTROL UNIT .................................................................................................. 27
15
MAIN CONTROL UNIT ........................................................................................ 27
OPERATIONAL FEATURES................................................................................ 27
16
DIAGNOSIS ......................................................................................................... 28 17
GENERAL PRECAUTIONS................................................................................. 28 18
PROTECTIONS.................................................................................................... 28
18
CHECK MOTORS PHASES BALANCING.......................................................... 29
CHECK TRACTION MOTOR PHASES BALANCING......................................... 29 18
CHECK PUMP MOTORS PHASES BALANCING .............................................. 30 18
CONTROLLERS REMOVAL AND INSPECTION................................................ 31
18
TRACTION LOGIC UNIT ..................................................................................... 31
18
PUMP LOGIC UNIT ............................................................................................. 32
2-2
MCB BOARD ....................................................................................................... 33

MCB BOARD DESCRIPTION.............................................................................. 34
DC/DC CONVERTER........................................................................................... 35
COOLING FAN..................................................................................................... 37
CONTACTOR GROUP......................................................................................... 39
CONTACTOR GROUP INSPECTION.................................................................. 40
FUSE GROUP...................................................................................................... 41
FUSE GROUP INSPECTION............................................................................... 42
DASHBOARD ...................................................................................................... 43
ARMREST BOARD.............................................................................................. 44
ARMREST BOARD DESCRIPTION .................................................................... 46
VOLTAGES ON ARMREST POTENTIOMETERS............................................... 47
2-3
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 2
the AC motor drive system.
The main controllers have a self-diagnosis function that automatically detects any abnormality of the 2
main traction/lifting circuits, accelerator, brake or any other sensor and displays the corresponding error
code together with a warning beep. 2
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
3
and inspect the main traction / lifting circuits and each operating system and sensors.
4
5
6
CONTACTOR 7
GROUP
8
9
FUSE 10
GROUP
11
12
13
DASHBOARD
14
15
16
17
TRACTION
LOGIC UNIT PUMP 18
LOGIC UNIT
18
18
MCB BOARD 18
18
18
2-4
SPECIFICATIONS
FUSES NAME AND DESCRIPTION All
FB General 750A
FP (pump logic unit) 500A
F1 (key switch) 6,3A
FUSES from General F2 AC-5 & brake solenoid valve supply 5A
F3 DC/DC converter (+V batt. supply) 15A
F4 Heaters (OPT) 25 A
F5 Sesam, dashboard, MCB board +24 V supply 10A
FUSES from DC/DC F6 Motor drivers fan +24 V supply 5A
F7 horn, buzzer, ligts +24 V supply 10A
F8 Optional equipment +24 V supply 30A
FUSES from DC/DC aux.
F9 Heated seat (OPT) ) 10A
F10 (wiper motors) (OPT) 7,5A
F11 (front working lamps) (OPT) 7,5A
F12 (rear working lamps) (OPT) 7,5A
F13 (dipped headlights) (OPT) 10A
FUSES for optional
F14 (beacon lamp) (OPT) 5A
devices
F15 (windscreen washer motors) (OPT) 5A
F16 (rear windows heater) (OPT) 10A
F17 (heater fans) (OPT) 7,5A
F18-F21 (spare)
CT1 (key) SW60B-238 80V
CONTACTORS CT2 (traction logic unit) SU280B-1218 24V
CT3 (pump logic unit) SU280B-1218 24V
2-5
COMPONENTS
TRACTION LOGIC UNIT
2
2
2
3
4
5
6
7
8
9
PUMP LOGIC UNIT
10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-6
MCB BOARD
ARMREST BOARD (optional)

2-7
FUSE GROUP
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-8
BEFORE REPAIR
INSPECTION
1. Insulation resistance measurement

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

The resistance value depends greatly on the vehicle operating state, place
Standard: and weather.
(Approx. 1M 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 are 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 reassembling parts originally coated with this material.
Otherwise, overheating may occur
After installation, check that there is no interference of the bar and harness connection with other
portion
2-9
CONNECTOR INSPECTION
When inspecting each board and the cause of the trouble is found, do not immediately replace the board
but check the following items.
Abnormalies in related harnesses 2
Looseness of the related connectors
Bending or damage of connector pin and defective contact of any related connector pin 2
If any of the above is the cause of the trouble and the board is replaced with a new one, the new board
will be damaged. 2
Always replace the board after careful inspection.
When the trouble derives from a logic unit or board, measure the voltage and resistance of every part
involved in the substitution. Always disconnect the battery plug before measuring the resistance.
3
Warning: 4
Disconnect the battery plug before connecting or disconnecting the logic unit.
Note:
When a logic unit is determined to be the cause of trouble as the result of troubleshooting,
5
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 multemeter to the corresponding connector pin.
7
Warning:
As connection of the wrong connector pin may damage normal portions, make sure to confirm 8
the connector pin number.
(2) Measurement method and standard list 9
How to read the list
10
CN (pin-colour) CN (pin-colour)
Description Standard Notes
From To 11
Arriving connector
12
Starting connector
13
JAT (1-B9) J15 (1-B9) EN1 encoder + V + 12 V
14
15
Colour Value of the
No. connector pin measurement 16
No. connector
17
COLOUR CODING
COLORI COLOURS FARBEN COULEURS COLORES

18
C arancio orange orange orange naranja
A azzurro blue blau bleu azul
18
B bianco white wei blanc blanco
L blu dark blue dunkelblau bleu marine azul intenso 18
G giallo yellow gelb jaune amarillo
H grigio grey grau gris gris 18
M marrone brown braun marron castao
N nero black schwarz noir negro 18
S rosa pink pink rose rosa
R rosso red rot rouge rojo 18
V verde green grn vert verde
Z viola/porpora purple violett violet prpura
2-10
MAIN CONTROLLERS
TRACTION LOGIC UNIT
JAT
JC
Basic conditions (battery plug connected, key switch ON)

See connectors reference names in the electrical diagram.
From To
JC (1) --- Console ---
JC(5) --- Console ---
JAT (1-B9) J15 (1-B9) EN1 encoder + V +12 V
JAT (2-B12) J15 (2-B12) EN1 encoder GND GND
J14 (C-S)
JAT (3-S) Steering Potentiometer + V +10 V
[via J134 (8-S)]
JAT (4-S1) J19 (3-S1)
Seat SW N.O. (output) +5 V
[JCP (5-S1)] [via J134 (11-S1)]
J19 (2-S10)
JAT (5-S10) Seat SW N.C. (output) +5 V
[via J134 (10-S10)]
JAT (6-S12) J49 (11-S12) Low mast SW N.O. INPUT(SAS options) +5 V
JAT (7-S13) J49 (12-S13) Low mast SW N.C. INPUT (SAS options) +5 V
JAT (8) --- Unused ---
JAT (9) --- Unused ---
JAT (10) --- BK Pressure SW (Unused) +5 V
JAT (11) --- ACC. Pressure SW (Unused) +5 V
2-11
From To
JAT (12-L1) JCP (31-L1) Safety (- Batt. from Lifting Unit) GND
2
JAT (13-B11) J15 (4-B11) A Phase EN1 encoder +12 V
JAT (14-B10) J15 (3-B10) B Phase EN1 encoder +12 V 2
J14 (B-S5)
JAT (15-S5)
[via J134 (7-S5)]
Steer Potentiometer GND GND 2
J14 (A-S6)
JAT (16-S6)
[via J134 (6-S6)]
Steer Potentiometer Cursor 0 +10 V 3
JAT (17) --- Unused --- 4
JAT (18-H) JAP (7-H) CAN H (to lifting logic unit) High Signal
JAT (19-Z) JAP (4-Z) CAN L (to lifting logic unit) Low Signal 5
JAT (20) --- Unused ---
6
JAT (21) --- Unused ---
JAT (22) --- Unused --- 7
JAT (23) --- Unused ---
8
JAT (24-B13) J16 (1-B13) Traction motor thermic sensor GND GND
JAT (25-B14) J16 (2-B14) Traction motor thermic sensor supply --- 9
JAT (26-L2) J50 (5-L2) CT2 traction contactor coil GND GND
J50 (6-R01) Supply to CT2 traction contactor coil
10
JAT (27-R 01)
J1 (1-R01) Supply to brake solenoid valve +24 V.
[JAT (29-R 01)]
J52 (4-R01) Supply + V Batt. from CT1 11
JAT (28-A) J1 (2-A) Brake solenoid valve GND GND
12
JAT (29-R 01)
[JAT (27-R 01)]
J1 (1-R01)
J52 (4-R01)
Supply to brake solenoid valve
Supply + V Batt. from CT1
+24 V 13
JAT (30-S11) J49 (13-S11) +V out --- 14
JAT (31) --- Unused ---
JAT (32) --- Unused ---
15
JAT (33-M03)
[JCP (3-M03)]
J35 (1-M03)
J50 (3-M03)
Supply from key switch SW1 +80 V 16
JAT (34) --- Unused --- 17
JAT (35) --- Unused ---
18
18
18
18
18
18
2-12
PUMP LOGIC UNIT
JCP
JAP
JC
Basic conditions (battery plug connected, key switch ON).

From To
JC(5) --- Console ---
J34 (19-H)
JAP (1-H) CAN H High Signal
J137 (1-H)
JAP (2) --- Unused ---
JAP (4-Z) JAT (19-Z) CAN L (from traction logic unit) Low Signal
J34 (21-Z)
JAP (6-Z) CAN L Low Signal
J137 (2-Z)
JAP (7-H) JAT (18-H) CAN H (from traction logic unit) High Signal
2-13
From To
JCP (1-B15) J17 (1-B15) EN2 encoder + V +12 V
2
JCP (2-B18) J17 (4-B18) EN2 encoder GND GND
JCP (3-M03) J35 (1-M03)
Supply from key switch SW1 +80 V
2
[JAT (33-M03)] J50 (3-M03)
J19 (1-S2) Seat SW common (supply) 2
JCP (4-S2) 0 +5 V
via J134 (9-S2)
JCP (5-S1) J19 (3-S1) Seat SW N.O. (output)
3
---
[JAT (4-S1)] via J134 (11-S1)
4
JCP (6) --- Unused ---
JCP (7) --- Unused --- 5
6
JCP (10) --- Unused 7
JCP (11-B23) J22 (1-B23) EN3 encoder + V +12 V
JCP (12-B26) J22 (4-B26) EN3 encoder GND GND 8
JCP (13-B17) J17 (3-B17) A Phase EN2 encoder +12 V
9
JCP (14-B16) J17 (2-B16) B Phase EN2 encoder +12 V
JCP (15) --- Unused --- 10
JCP (16) --- Unused ---
11
JCP (17) --- Unused ---
JCP (18) --- Unused --- 12
JCP (19) --- Unused ---
JCP (20) --- Unused ---
13
JCP (21) --- Unused --- 14
JCP (22-B25) J22 (3-B25) A Phase EN3 encoder +12 V
JCP (23-B24) J22 (2-B24) B Phase EN3 encoder +12 V 15
JCP (24-B19) J18 (1-B19) Left pump motor temp. sensor GND GND
16
Left pump motor temp. sensor
JCP (25-B20) J18 (2-B20) +12 V
supply 17
JCP (26-L3) J50 (7-L2) CT3 pump contactor coil GND GND
JCP (27-B29) J50 (8-B29) CT3 pump contactor coil supply +24 V 18
JCP (28) --- Unused ---
18
JCP (29) --- Unused ---
JCP (30) --- Unused --- 18
JCP (31-L1) JAT (12-L1) Safety (- Batt. to Traction Unit) GND
18
JCP (32) --- Unused ---
JCP (33) --- Unused --- 18
JCP (34-B22) J23 (1-B22) Right pump motor temp. sensor GND GND
JCP (35-B21) J23 (2-B21) Right pump motor temp. sensor supply +12 V
18
2-14
MCB BOARD
J34 J34
(Black connector)
J40 J40
(Connettore bianco)
JAP

From To
J34 (1-B3) J33 (5-B3) Double pedal configuration (input) 0 +5 V
J34 (2-V5) J32 (5-V5) Single pedal march enable SW8 N.O. 0 +5 V
J34 (3-V6) J32 (6-V6) Single pedal march enable SW8 N.C. 0 +5 V
J33 (2-B1) Double pedal FW SW4 N.O.
J34 (4-B1) J39 (7-B1) Hand direction FW SW9 N.O. 0 +5 V
via J35 (7-B1)
J34 (5-B2) J33 (3-B2) Double pedal FW SW4 N.C. 0 +5 V
J33 (8-B4) Double pedal BW SW5 N.O.
J34 (6-B4) J39 (8-B4) Hand direction BW SW10 N.O. 0 +5 V
via J35 (2-B4)
J34 (7-B5) J33 (9-B5) Double pedal BW SW5 N.C. 0 +5 V
J34 (8-A1) J31 (4-A1) Brake pedal SW6 N.C. 0 +5 V
J34 (9-A2) J30 (2-A2) Brake lever SW7 N.O. 0 +5 V
J34 (10) --- Unused ---
J34 (11) --- Unused ---
J34 (12) --- Unused ---
J34 (13) --- Unused ---
J34 (14) --- Unused ---
J34 (15) --- Unused ---
2-15
From To
J34 (16) --- Unused ---
2
J34 (17) --- Unused ---
J34 (18) --- Unused --- 2
J137(1-H)
J34 (19-H)
JAP (1-H)
CAN H High Signal 2
J131 (2-H)
J34 (20-H)
via J134 (14-H)
CAN H (armrest) High Signal 3
J34 (21-Z)
J137 (2-Z)
CAN L Low Signal 4
JAP (6-Z)
J34 (22-Z)
J131 (1-Z)
CAN L (armrest) Low Signal 5
via J134 (15-Z)
J34 (23-N1) --- GND general output GND 6
J34 (24-V4) J49 (9-V4) Unused 0 +5 V
+1,6 +3,2
7
J34 (25-V1) J32 (1-V1) Wiper acceleretor potentiometer
V
8
J34 (26) --- Unused ---
J34 (27) --- Unused --- 9
J34 (28-V2) J32 (2-V2) GND acceleretor potentiometer GND
J34 (29-V11) J49 (8-V11) +V lift & tilt potentiometer (SAS OPT) 0 +10 V
10
J34 (30 V3) J32 (3-V3) +V acceleretor potentiometer 0 +10 V 11
J34 (31-V10) J49 (7-V10) GND lift & tilt potentiometer (SAS OPT) GND
J34 (32) --- Unused ---
12
J34 (33-S3) J49 (6-S3) Unused 0 +5 V 13
J34 (34-S4) J49 (5-S4) Unused 0 +5 V
J34 (35) --- Unused --- 14
JE1 (2-G2)
J40 (1-G2)
via J56 (1-G2)
GND EVP1 lowering 0 + 24 V 15
J40 (2-G3)
JE2 (2-G3)
via J56 (2-G3)
GND EVP2 lifting 0 + 24 V 16
JE1(1-G1) +V EVP1 lowering 17
via J56 (3-G1)
J40 (3-G1) +24 V
JE2 (1-G1) +V EVP2 lifting
via J56 (3-G1)
18
J40 (4-G5)
JE3 (2-G5)
via J56 (4-G5)
GND EVP3 Tilt BW 0 + 24 V 18
J40 (5-G6)
JE3 (3-G6)
GND EVP4 Tilt FW 0 + 24 V 18
via J56 (5-G6)
JE3 (1-G4) +V EVP3 Tilt BW 18
via J56 (6-G4)
J40 (6-G4) + 24 V
JE3 (4-G4) +V EVP4 Tilt FW 18
via J56 (6-G4)
J40 (7-G8)
JE4 (2-G8)
GND EVP5 Sideshift left 0 + 24 V 18
via J56 (4-G8)
2-16
From To
JE4 (3-G9)
J40 (8-G9) GND EVP6 Sideshift right 0 + 24 V
via J56 (5-G9)
JE4 (1-G7) +V EVP5 Sideshift left
via J56 (9-G7)
J40 (9-G7) +24 V
JE4 (4-G7) +V EVP6 Sideshift righ
via J56 (9-G7)
JE5 (2-G11)
J40 (10-G11) GND EVP7 4TH lever 0 + 24 V
via J56 (10-G11)
JE5 (3-G12)
J40 (11-G12) GND EVP8 4TH leve 0 + 24 V
via J56 (11-G12)
JE5 (1-G10) +V EVP7 4TH lever
via J56 (12-G10)
J40 (12-G10) +24 V
JE5 (4-G10) +V EVP8 4TH leve
via J56 (12-G10)
J53 (8-C01)
J40 (13-C01)
J137 (7-C01)
[J40 (16-C01)]
J133 (1-C01)
[J40 (17-C01)] +24 V from DC/DC converter fuse F5 +24 V
J132 (1-C01)
[J40 (18-C01)]
J131 (4-C01)
[J40 (28-C01)]
via J134(16-C01)
J40 (14-N)
[J40 (19-N)]
[J40 (20-N)]
--- GND from DC/DC converter GND
[J40 (21-N)]
[J40 (22-N)]
[J40 (25-N)]
J40 (15-V7) J49 (2-V7) Unused ---
J53 (8-C01)
J40 (16-C01)
J137 (7-C01)
[J40 (13-C01)]
J133 (1-C01)
J132 (1-C01)
[J40 (18-C01)]
J131 (4-C01)
[J40 (28-C01)]
via J134(16-C01)
J53 (8-C01)
J40 (17-C01)
J137 (7-C01)
[J40 (13-C01)]
J133 (1-C01)
J132 (1-C01)
[J40 (18-C01)]
J131 (4-C01)
[J40 (28-C01)]
via J134(16-C01)
J53 (8-C01)
J40 (18-C01)
J137 (7-C01)
[J40 (13-C01)]
J133 (1-C01)
J132 (1-C01)
[J40 (17-C01)]
J131 (4-C01)
[J40 (28-C01)]
via J134(16-C01)
2-17
From To
J40 (19-N)
[J40 (14-N)]
2
[J40 (20-N)]
[J40 (21-N)]
--- GND from DC/DC converter GND 2
[J40 (22-N)]
[J40 (25-N)] 2
J40 (20-N)
[J40 (14-N)] 3
[J40 (19-N)]
[J40 (21-N)] 4
[J40 (22-N)]
[J40 (25-N)]
5
J40 (21-N)
[J40 (14-N)] 6
[J40 (19-N)]
[J40 (20-N)]
[J40 (22-N)]
7
[J40 (25-N)]
J40 (22-N)
8
[J40 (14-N)]
[J40 (19-N)] 9
[J40 (20-N)]
[J40 (21-N)] 10
[J40 (25-N)]
J40 (23) --- Unused --- 11
J40 (24-V8) J49 (3-V8) +V pressure sensor (SAS OPT) ---
12
J40 (25-N)
[J40 (14-N)]
[J40 (19-N)]
13
[J40 (20-N)]
[J40 (21-N)] 14
[J40 (22-N)]
J40 (26-V9) J49 (4-V9) GND pressure sensor (SAS OPT) ---
15
J40 (27-A4) J71 (3-A4) Motor drivers fan signal 1 = Enable 16
J53 (8-C01)
J40 (28-C01)
[J40 (13-C01)]
J137 (7-C01) 17
J133 (1-C01)
J132 (1-C01)
[J40 (17-C01)]
J131 (4-C01)
18
[J40 (18-C01)]
via J134(16-C01)
via J134(2-A5)
18
J93 (2-A5) BW march right light GND
J40 (29-A5)
J92 (2-A5) BW march left light GND
0 = Enable 18
J70 (2-A5) Optional buzzer GND
via J134 (3-A6)
18
J40 (30-A6) J102 (2-A6) Stop right light GND 0 = Enable
J91 (2-A6) Stop left light GND 18
J40 (31-A7) J90/B (1-A7) Direction ligts GND 0 = Enable
18
JE6(2-G14)
J40 (32-G14) GND EVP9 5TH lever 0V
via J56(13-G14)
2-18
From To
JE6(1-G13)
J40 (33-G13) +V EVP9 5TH lever +24 V
via J56(14-G13)
JE6(4-G16)
J40 (34-G16) GND EVP10 5TH lever 0V
via J56(15-G16)
JE6(3-G15)
J40 (35-G15) +V EVP10 5TH lever +24 V
via J56(16-G15)
2-19
ARMREST BOARD
2
JSOLL
2
JBRA 2
JTRA JCAN
3
4
JIV
JAUX
5
JV
6
7
Basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle] 8
See connectors reference names in the electrical diagram
9
From To
10
J131 (1-Z)
JCAN (1-Z) CAN L Low Signal
via J138 (2-Z)
11
J131 (2-H)
JCAN (2-H) CAN H High Signal
via J138 (4-H) 12
J131 (5-N)
JCAN (3-N) GND converter DC/DC GND
via J138 (1-N) 13
JCAN (4) --- Unused ---
J131 (4-C01)
14
JCAN (5-C01) +24 V converter DC/DC +24 V
via J138 (5-C01)
J131 (3-N)
15
JCAN (6-N) GND converter DC/DC
via J138 (3-N)
16
JSOLL (1) --- +V lifting/lowering potentiometer P4 +5 V
JSOLL (2) --- Wiper lifting/lowering potentiometer P4 +2,5 V

0 +5 17
V
JSOLL (3) --- Unused (lifting/lowering) --- 18
JSOLL (4) --- GND lifting/lowering potentiometer P4 GND
18
JSOLL (5) --- Lifting/lowering micro SW 17 +5 V
JSOLL (6) --- Lifting/lowering micro SW 18 +5 V 18
JSOLL (7) --- Unused (lifting/lowering) ---
JSOLL (8) --- GND Lifting/lowering micros SW 17 &18 GND
18
JBRA (1) --- +V tilting potentiometer P5 +5 V 18
0 +5
JBRA (2) --- Wiper tilting potentiometer P5 +2,5 V
V 18
JBRA (3) --- Unused (tilting) ---
2-20
From To
JBRA (4) --- GND tilting potentiometer P5 GND
JBRA (5) --- Tilting micro SW 19 +5 V
JBRA (6) --- Tilting micro SW 20 +5 V
JBRA (7) --- Unused (tilting) ---
JBRA (8) --- GND tilting micros SW 19 & 20 GND
JTRA (1) --- +V sideshift potentiometer P6 +5 V
0 +5
JTRA (2) --- Wiper sideshift potentiometer P6 +2,5 V
V
JTRA (3) --- Unused (sideshift) ---
JTRA (4) --- GND sideshift potentiometer P6 GND
JTRA (5) --- Sideshift micro SW 21 +5 V
JTRA (6) --- Sideshift micro SW 25 +5 V
Unused (sideshift) [Micro PB11 (optional
JTRA (7) --- ---
attacment for joystick)]
GND tilting micros SW 21, 22 [& micro
JTRA (8) --- GND
PB11 (optional attacment for joystick)]
JIV (1) --- +V 4th lever potentiometer P7 +5 V
0 +5
JIV (2) --- Wiper 4th lever potentiometer P7 +2,5 V
V
JIV (3) --- Unused (4th lever) ---
th
JIV (4) --- GND 4 lever potentiometer P7 GND
th
JIV (5) --- 4 lever micro SW 23 +5 V
th
JIV (6) --- 4 lever micro SW 24 +5 V
JIV (7) --- Unused (4th lever) ---
th
JIV (8) --- GND 4 lever micros SW 23 & 24 GND
JV (1) --- Unused ---
JV (2) --- Unused ---
JV (3) --- Unused ---
JV (4) --- Unused ---
JV (5) --- Unused ---
JV (6) --- Unused ---
JV (7) --- Unused ---
JV (8) --- Unused ---
JAUX (1) --- +V march single pedal potentiometer P8 +5 V
JAUX (2) --- Wiper march single pedal potentiometer P8 0 +5 V
JAUX (3) --- GND march single pedal potentiometer P8 GND
Hand lever micro PB13 BW march
JAUX (4) --- ---
enabling
Hand lever micro PB14 FW march
JAUX (5) --- ---
enabling
2-21
From To
INPUT (unused)
JAUX (6) --- [Micro PB11 (optional attachment for ---
2
fingertip)]
2
JAUX (7) --- INPUT (unused) ---
JAUX (8) --- INPUT (unused) --- 2
JAUX (9) --- INPUT (unused) ---
GND hand lever micros PB13 & 14
3
JAUX (10) --- [& micro PB11 (optional attachment for GND
fingertip)] 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
2-22
CONTACTOR GROUP
J50
J51

From To
J50 (1-M) J52 (1-M) F1 supply + 80 V
J50 (2-R) J52 (2-R) F2 supply + 80 V
J35 (1-MO3)
CT1 line contactor coil supply
J50 (3-M03) JCP (3-M03 + 80 V
from key switch SW1
JAT (33-M03)
J97 (2-N) CT1 line contactor coil GND
J50 (4-N) GND
J96 (2-N) (General battery GND)
J50 (5-L2) JAT (26-L2) CT2 traction contactor coil GND GND
JAT (27-R 01) Supply input traction unit
J50 (6-R01) + 24 V
J52 (4-R01) Supply to brake solenoid valve
J50 (7-L3) JCP (23-L3) CT3 pump contactor coil GND GND
J50 (8-B29) JCP (27-B29) CT3 pump contactor coil supply + 24 V
J51 (1-R) J53 (2-R) F4 supply + 80 V
J51 (2-R) J53 (1-R) F3 supply + 80 V
2-23
DASHBOARD
2
2
2
3
4
5
6
7
PIN 14 8
J137
9
PIN 1
10
11
Basic conditions (battery plug connected, key switch ON) 12
13
From To 14
J133 (3-H)
J137(1-H) CAN H High Signal
J34 (19-H) 15
J133 (4-Z)
J137 (2-Z)
J34 (21-Z)
CAN L Low Signal 16
J137 (3-N)
[J137 (14-N)]
DC/DC converter GND GND 17
J137 (4-A8) J37 (3-A8) PB2 (from speed reduction)
18
J137 (5-A9) J36 (2-A9) PB3 (from L-P-H selector) GND
J137 (6) --- Unused --- 18
J53 (8-C01)
J40 (13-C01) 18
J40 (16-C01)
J137 (7-C01) +24 V from DC/DC converter fuse F5 +24 V
J40 (17-C01) 18
J40 (18-C01)
J40 (28-C01) 18
J132 (3-H) CAN H (can bus interface)
J137 (8-H) High Signal
JAP (1-H) CAN H (Pump logic unit) 18
2-24
From To
J132 (4-Z) CAN L (can bus interface)
J137 (9-Z) Low Signal
JAP (6-Z) CAN L (Pump logic unit)
J137 (10-S8) J140 (1-S8) PB7 (accumulator pressure micro) + 80 V
J137 (11-S9) J139 (1-S9) PB6 (brake pressure micro)
J137 (12) --- Unused ---
J69 (2-A11)
J137 (13-A11) Buzzer GND GND
VIA J35 (5-A11)
J137 (14-N)
DC/DC converter GND GND
[J137 (3-N)]
2-25
FUSE GROUP
2
2
2
3
4
5
6
7
8
9
10
See connectors reference names in the electrical diagram. 11
CN (pin-colour) CN (pin-colour) 12
From To
J52 (1-M) J50 (1-M) +V batt + 80 V 13
J52 (2-R) J50 (2-R) +V batt from CT1 contactor + 80 V
J52 (3-M01) J21 (1-M01) To key SW1 via emergency PB1 + 80 V
14
J50 (6-R01) Supply to CT2 traction contactor coil 15
J52 (4-R01)
J1 (1-R01) Supply to brake solenoid valve
16
J52 (5-C02) J71 (2-C02)
Motor driver fan supply from DC/DC
converter
+24 V 17
J52 (6) Unused --- 18
J53 (1-R) J51(2-R) +V batt from CT1 contactor + 80 V
J53 (2-R) J51 (1-R) +V batt from CT1 contactor + 80 V
18
J53 (3-R02)
J96 (1-R02)
J97 (1-R02)
DC/DC converter supply + 80 V 18
J53 (4-R03)
J107 (1-R03)
Heater supply + 80 V 18
J108 (1-R03)
J53 (5-C) J96(4-C) +24 V supply fron DC/DC converter +24 V 18
J53 (6-C05) J90/A (1-C05) +24 V supply fron DC/DC converter aux +24 V
J53 (7-C04) J97 (4-C04) +24 V supply fron DC/DC converter aux
18
2-26
From To
J40 (13-C01)
J40 (16-C01)
J40 (17-C01)
J40 (18-C01)
J40 (28-C01)
J53 (8-C01) +24 V from DC/DC converter fuse F5 +24 V
J137 (7-C01)
J133 (1-C01)
J132 (1-C01)
J131 (4-C01)
via J134(16-C01)
J53 (8-C01)
J40 (13-C01)
J137 (7-C01)
[J40 (16-C01)]
J133 (1-C01)
J132 (1-C01)
[J40 (18-C01)]
J131 (4-C01)
[J40 (28-C01)]
via J134(16-C01)
J102 (1-C03)
J90/B(5-C03)
J53 (9-C03) J70 (1-C03) +24 V from DC/DC converter fuse F7 +24 V
J92 (1-C03)
J91 (1-C03)
+24 V supply from DC/DC converter aux
J53 (10-C06) +24 V
(Unused)
J53 (11) --- Unused ---
J53 (12) --- Unused ---
J53 (13) --- Unused ---
J53 (14) --- Unused ---
2-27
CONTROL UNIT
MAIN CONTROL UNIT
2
Traction Logic Unit Lifting Logic Unit DUAL AC2
AC5 Master Slave 2
Inverter for AC asynchronous
3-phase motors
2
Regenerative braking functions

3
4
Can-bus interface
5
Flash Memory
6
Digital control based upon a
microcontroller 7
Voltage 80 V 80 V 80 V 8
Maximum current 1000 A (RMS) 400 A (RMS) 400 A (RMS)
Operating frequency 8 Khz 8 Khz 8 Khz

9
External temperature range -30 C + 40 C -30 C + 40 C -30 C + 40 C 10
Maximum inverter temperature 75 C 75 C 75 C
11
OPERATIONAL FEATURES
12
Speed control
Very good behaviour on a slope due to the speed feedback
The motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the set
13
point of operation
Stable speed in every position of the accelerator 14
Regenerative release braking based upon deceleration ramps
Regenerative braking when the accelerator pedal is partially released (deceleration) 15
Direction inversion with regenerative braking based upon deceleration ramp
Regenerative braking and direction inversion without contactors: only the two main contactors are
present
16
The release braking ramp can be modulated by an analog input, so that a proportional brake feature is
obtained 17
Very good sensitivity at low speeds
Voltage boost at the start and with overload to obtain more torque (with current control) 18
High efficiency of motor and battery due to high frequency commutations
Self diagnosis with indication of the fault shown by numeric display 18
Modification of parameters through the programming instrument panel interface
Internal hour-meter with values that can be displayed on the console
Memory of the last five alarms with relative hour-meter and temperature displayed on the console
18
Test function within console for checking main parameters
18
18
18
2-28
DIAGNOSIS
The microprocessor continually monitors the inverter and carries out a diagnostic procedure on the main
functions. The diagnosis is made in 4 points:
1 Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging,
phases voltages, contactor drives, can-bus interface, if the switch sequence for operation is correct
and if the output of the accelerator unit is correct
2 Standby diagnosis at rest that checks: watchdog circuit, phases voltages, contactor driver, current
sensor, can-bus interface
3 Diagnosis during operation that checks: watchdog circuits, contactor driver, current sensors, can-bus
interface
4 Continuous diagnosis that checks: temperature of the inverter
Diagnosis is provided in two ways:
the diagnostic ERROR DISPLAY placed to the dashboard that shows the code number for a given
alarm
the digital console, which gives more detailed information about the failure
GENERAL PRECAUTIONS
Do not connect the inverter to a battery with a nominal value different from the value indicated on the
chopper plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit does not
"power up"
During the battery charge, disconnect the INVERTER from the battery
Supply the INVERTER only with battery for traction; do not use a power supply
When the chopper is installed, make tests with the wheels raised from the ground, in order to avoid
dangerous situations due to connection errors
After the chopper is switched off (key off), the filter capacitors remain charged for some minutes; if you
need to work on the inverter, discharge them using a 10W -- 100W resistance connected from the
+Batt to the -Batt
Before carrying out any arc-welding on the trucks, disconnect the battery and short-circuit the unit
between positive (+) and negative (-)
PROTECTIONS
Connection Errors:
All inputs are protected against connection errors.
Thermal protection:
If the chopper temperature exceeds 75C, the maximum current is reduced in proportion to the thermal
increase. The temperature can never exceeds 100C.
External agents:
The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP54.
Protection against uncontrolled movements:
The main contactor is not closed if:
the Power unit is not functioning.
the Logic is not functioning perfectly.
the output voltage of the accelerator does not fall below the minimum voltage value stored, with 1V
added
running microswitch in closed position
protection against accidental starting
A precise sequence of operations are necessary before the machine starts.
Operation cannot begin if these operations are not carried out correctly.
Drive requests must be made after closing the key switch.
2-29
CHECK MOTORS PHASES BALANCING

When traveling or material handling operation seems abnormal, it is possible to accurately judge
if the controller is functioning correctly or not by measuring the motor phase balancing.
CHECK TRACTION MOTOR PHASES BALANCING 2
Measuring method Procedure using a clamp amperometer 2
(1) Remove the footboardr
(2) Jack up the front wheels 2
(3) Connect a clamp amperometer
(4) Selct a direction,shift the direction switch to the forward (or backward) position, and start the 3
machine with low speed
(5) Check the value of the current of each phase
(6) If the value of one phase is higher or lower respect the others it means that the system is not 4
balanced and the motor goes jerkling. In this situation the logic unit must be replace.
Measuring method Procedure using a multemeter
5
(1) Remove the footboard
(2) Jack up the front wheels 6
(3) Set the multemeter on V~
(4) Connect the negative of the multemeter on the battery negative 7
(5) Connect the positive on one of the phase of the logic unit
(6) Check the value of the voltage of each phase 8
(7) If the value of one phase is higher or lower respect the others it means that the system is not
balanced and the motor goes jerkling. In this situation the logic unit must be replace.
9
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 amperometers for each phases. This because the tool have
different tollerance respect each others.
10
11
12
13
14
15
16
Measuring method procedure Measuring method procedure

17
using a clamp amperometer using a multemeter
18
18
18
18
18
18
2-30
CHECK PUMP MOTORS PHASES BALANCING

Measuring method Procedure using a clamp amperometer
(2) Connect a clamp amperometer
(3) Select the lifting movement on joystick, or fingertip with low speed
(4) Check the value of the current of each phase (master and then slave)
(5) If the value of one phase is higher or lower compared to the others it means that the system is not
balanced and the motor goes jerkling. In this situation the logic unit must be replaced
Measuring method Procedure using a multemeter
(2) Set the multemeter on V~
(3) Connect the negative of the multemeter 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 (master and then slave)
(6) If the value of one phase is higher or lower compared to the others it means that the system is not
balanced and the motor goes jerkling. 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 amperometers for each phases. This because the tool have
different tollerance respect each others.
2-31
CONTROLLERS REMOVAL AND INSPECTION

TRACTION LOGIC UNIT
DISASSEMBLY REASSEMBLY 2
Caution:
Before starting the job, disconnect the battery plug and measure the voltage between + and GND; 2
(logic units side) if there is any voltage, insert a resistor at approx. 100 between + and GND to
discharge the capacitor. 2
3
4
5
6
7
8
9
10
11
12
13
Disassembly Procedure 14
1. Disconnect the battery plug
2. Remove the footboard 15
3. Disconnect the wiring harness and power cables from the traction logic unit.
4. Remove the 4 fixing bolts
5. Remove the traction logic unit
16
Reassembly Procedure 17
The reassembly procedure is the reverse of the disassembly procedure.
Note: 18
Before connecting the wiring connectors or the cables, check the connector No. or the cable tags
to ensure correct connection.
18
18
18
18
18
2-32
PUMP LOGIC UNIT

Caution:
Before starting the job, disconnect the battery plug and measure the voltage between + and GND;
discharge the capacitor.
2. Remove the footboard
3. Disconnect the wiring harness and power cables from the pump logic unit.
5. Remove the pump logic unit
.
Note:
Before connecting the wiring connectors or the cables, check the connector No. or the cable tags
2-33
MCB BOARD
Caution:
2
2
3
4
5
6
7
8
9
10
11
12
3. Disconnect the wiring harness connectors from the MCB board 13
5. Remove the MCB board 14
.
15
Note:
Before connecting the wiring connectors or the cables, check the connector No. or the cable tags 16
17
18
18
18
18
18
18
2-34
MCB BOARD DESCRIPTION

The board is placed on the right side of the truck, under the footboard. The MCB is the main control and
management board of the vehicle.
The board is composed by two microprocessors:
TRCB = traction control board

EVCB = electric valve control board
TRCB is the parameter manager of the traction logic units.

EVCB is the parameter manager of electronic contol valve and of the pump logic unit.
MAIN FUNCTIONS
Performances management (traction and pump parameters)
Management/control of the stop and backward direction lights
Electroproportional distributor control (optional)
Vehicle configuration identification
Comunication Master between all cards
Traction control Master
Pump control Master
1 1. J34 connector
Used to check the pedals system, the parking/service
brake, the negative brakes unlocking sensor and the
mechanical distributor micros
2. J40 connector
Used to check the electric distributor electrovalves, the
tilting potentiometer, the rear lights and the cooling fan
2
2-35
DC/DC CONVERTER
2
2
2
3
4
5
6
7
8
STANDARD MACHINE (STANDARD 360 W DC / DC CONVERTER)
9
The standard truck absorbs 206 W and is equipped with a
STANDARD DC /DC CONVERTER 360W DC/DC converter (80V - 24V) for the supplying of: 10
rear lights (brake and reverse direction)
console 11
brakes unlocking sensor
The standard DC /DC converter is located on the right side 12
under the pedals footboard
13
14
15
MACHINE WITH OPTIONAL DEVICES 16
For the supplying of optional devices, an aux DC/DC 17
AUX. DC /DC CONVERTER converter must be installed. In order to establish the
complessive aux converter power, add the power of all the
foreseen optional devices. Select the converter rounding
18
up the obtained power and keeping the 10% more of the
theoretical required power. 18
The aux DC /DC converter is located on the right side into
the lifting motor compartment
18
18
18
18
2-36
OPTIONAL DEVICES
Reverse direction acustic signaller 5W
Flash light 3W
Homologated rotating lamp 70 W
2 Wind-screen wipers + 2 screen wash tanks 200 + 72 W
2 working lights 30 W
Complete lights 242 W
Road lights 280 W
2 fan for heating 120 W
Heated rear window 120 W
Radio 80 W
Converter IP
144 W 54
360 W 54
720 W 20
2-37
COOLING FAN
2
2
2
3
4
5
6
7
The revolving speed of the fan is based on the temperature of the traction and lifting logic units.
8
Switching on the vehicle, the fan reaches the maximum number of turns, then it decreases after few
seconds if the controllers have a temperature lower than 30C. 9
Temperature managing: 10
- temperature < 30C = fan speed 50%
- temperature 30C 50C = fan speed 70%
- temperature > 50C = fan speed 100% 11
At the maximum speed and with the air filter cleaned, the fan provides 200mc/h of air to guarantee a fast
cooling of the logic units
12
FAN FILTER 13
14
15
16
17
18
18
18
18
18
18
2-38
TEMPERATURES MANAGEMENT
The logic units (traction and pump) use the signal from the temperature sensor to drive the electric
motor, so that it is possible to avoid overheatings and possible damages.
The logic unit reduces the motor performances according to the data here below.
Reduction of the maximum current in relation with the motors temperature

Traction and lifting
0 120C no reduction
120 155C 80% - 50% / C
> 155C -100%
Increase of the traction motor acceleration times in relation to the increase of the traction
motor temperature
0 120C no reduction
120 125C 0,3 s
125 130C 0,7 s
130 135C 1,1 s
135 140C 1,6 s
140 145C 2,3 s
145 150C 3,0 s
150 155C 6,0 s
> 155C 6,0 s
Reduction of the speed as regards to the traction motor temperature
0 140C no reduction
140 150C 20% reduction
> 155C speed to 0
Increase of the pump motors acceleration times in relation to the increase of the pump motors
temperature
0 130C no reduction
130 140C 0,5s
140 150C 1,0s
> 150C 2,0s
Reduction of the speed as regards to the pump motors temperature
0 130C no reduction
>155C 70% reduction
2-39
CONTACTOR GROUP
Caution:
Before starting the job, disconnect the battery plug and measure the voltage between + and GND
2
2
3
4
5
6
7
8
9
10
11
12
13
1. Disconnect the battery plug.
14
2. Open the right compartiment cover under the footstep
3. Disconnect the wiring harness connectors and power cables from the contactor group. 15
4. Remove the fixing bolts
5. Remove the contactor group. 16
17
Note:
Before connecting the connectors or the cables, check the connector No. or the cable tags to 18
ensure correct connection.
18
18
18
18
18
2-40
CONTACTOR GROUP INSPECTION
CONTACTORS
Inspection method
Disconnect the J50 and J51 connectors and measure the resistance between the involved terminal pins.
Portion to be Measurement Multimeter range Multimeter range
Standard
inspected terminals (with digital multimeter) (with analog multimeter)
CT1 coil J50-3 J50-4 60 x 100 x1
CT2 coil J50-5 J50-6 46,6 x 100 x1
CT3 coil J50-7 J50-8 46,6 x 100 x1
2-41
FUSE GROUP
Caution:
2
2
3
4
5
6
7
8
9
10
11
12
13
14
2. Open the right compartiment cover under the footstep
3. Disconnect the wiring harness connectors from the fuse group. 15
4. Remove the fixing bolts
5. Remove the fuse group. 16
17
Note: 18
Before connecting the connectors or the cables, check the connector No. or the cable tags to
ensure correct connection.
18
18
18
18
18
2-42
FUSE GROUP INSPECTION
FUSES
Inspection method
Disconnect the J53 and J53 connectors and measure the resistance between the involved terminal pins.
Portion to be Measurement Stan- Tester

Name and description A
inspected terminals dard range
F1 (key switch) 6,3A J52-1 J52-3 0 x1
FUSES F2 AC-5 & brake solenoid valve supply 5A J52-2 J52-4 0 x1

+ V batt F3 DC/DC converter (+V batt. supply) 15A J53-1 J53-3 0 x1
F4 Heaters 25 A J53-2 J53-4 0 x1
F5 Sesam, dashboard, MCB-I/O +24 V supply 10A J53-5 J53-8 0 x1
FUSES from
F6 Motor drivers fan +24 V supply 5A J53-5 J52-5 0 x1
DC/DC
F7 horn, buzzer, ligts +24 V supply 10A J53-5 J53-9 0 x1
FUSES from F8 Optional equipment +24 V supply 30A J53-6 J53-7 0 x1
DC/DC aux. F9 Available 10A J53-7 J53-10 0 x1
2-43
DASHBOARD
In case of trouble in the dashboard, measure the voltage at the connector to which voltage is applied.
2
2
2
3
4
5
6
7
8
PIN 7 PIN 14
9
PIN 3
10
11
12
J137 connector basic condition (Battery plug connected) 13
From To
Description Standard Notes 14
J137 (3-N)
J137 (14-N)
GND from DC/DC converter GND 15
J137 (7-C01) +24 V from DC/DC converter fuse F5 +24 V 16
17
18
18
18
18
18
18
2-44
ARMREST BOARD
Joystick
Fingertips
Disassembly procedure
1 Park the truck on a level surface and activate the parking brake
2 Switch off the truck
3 Open the battery cover and disconnect the battery
4 Disconnect the wiring placed in the armrest back part [Point 1]
5 Remove the armrest pads
6 Remove the fixing screws placed in the armrest lower side [Point 2]
7 Open the armrest
8 Disconnect the armrest board wirings and remove the armrest board 4 fixing screws [Point 3]
9 Remove the armrest board
Reassembly procedure
The installation procedure is the reverse of the disassembly procedure.
2-45
Point Operations
[Point 1]
Disassembly:
A Disconnect the (A) wiring, placed in the armrest back 2
part
2
2
3
4
[Point 2]
Disassembly: 5
B
Remove the 4 fixing screws (B) placed in the armrest
lower side 6
7
8
B
9
10
[Point 3]
Disassembly: 11
Disconnect the armrest board wirings and remove the
armrest board 4 fixing screws
12
13
14
15
16
17
18
18
18
18
18
18
2-46
ARMREST BOARD DESCRIPTION
JSOLL
JBRA
JTRA JCAN
JIV
JAUX
JV
COMPONENTS
JSOLL Connector for the lifting
JBRA Connector for the tilting
JTRA Connector for the sideshift
JIV Connector for the 4th lever
JV Connector for the 5th lever
JAUX Connector for auxiliary commands: forward/backward direcdion button, horn button
JCAN Connector for the CAN-BUS
This card purpose is to pilot the horn button, forward and backward speed buttons (version with FW/BW
button) and the fingertip/joystick signals.
Operating a lever on the armrest this card converts the analog signal into a digital signal that is then
transferred via CAN-BUS to the lifting logic unit and to the MCB (ENCB) which converts it from digital to
analog.
The card uses printed circuits that must be powered to decode the CAN-BUS signals. To supply the card
we use a DC-DC converter, which, by supplying an internal circuit, creates a voltage of 5 volts to supply
the joysticks or fingertips potentiometers.
The card is used in both configurations (fingertip or joystick).
2-47
VOLTAGES ON ARMREST POTENTIOMETERS

FINGERTIP version
RED: 5V 2
GREEN: 0 -- 5 (AT REST 2.5 V)
BLACK: 0 2
2
P4-P5-P6-P7
3
4
SW17-SW19-SW21-SW23
5
JSOLL
SW18-SW20-SW22-SW24
JBRA 6
JTRA
JIV
JV 7
JOYSTICK version
8
ORANGE: 5V GREEN: 5V
YELLOW: 0 -- 5 (AT REST 2.5 V) BLACK: 0 -- 5 (AT REST 2.5 V) 9
RED: 0V WHITE: 0V
10
P4-P6
JSOLL-JTRA 11
12
SW17-SW21
13
SW18-SW22
14
P5-P7
JBRA-JIV
15
16
SW19-SW23
17
SW20-SW24 18
18
18
18
18
18
2-48
WEI SEITE

3-1
MULTI-FUNCTION DISPLAY
MULTI-FUNCTION DISPLAY (DASHBOARD) .................................................... 3
5
GENERAL ............................................................................................................ 3
USER MENU MAP ............................................................................................... 6
2
USER MENU DESCRIPTION .............................................................................. 7 2
HOUR METER ..................................................................................................... 9 3
TRIP ..................................................................................................................... 9
4
CLOCK................................................................................................................. 9
ALARMS .............................................................................................................. 10 5
DISPLAY SETTING.............................................................................................. 10 6
MAPS FOR USING THE DASHBOARD.............................................................. 12
7
SERVICE MENU .................................................................................................. 12
8
SERVICE MENU DESCRIPTION......................................................................... 13
SERVICE MENU MAP ......................................................................................... 15 9
SOFT VERS ......................................................................................................... 16 10
PARAM CHANGE ................................................................................................ 17
11
TRUCK CONF...................................................................................................... 22
SERVICE RENT ................................................................................................... 29
12
CHANGE PASSWORD ........................................................................................ 32 13
TESTER ............................................................................................................... 33 14
ALARMS .............................................................................................................. 34
15
LEARNING........................................................................................................... 35
DEFAULT RST ..................................................................................................... 36
16
TESTER PARAMETER DESCRIPTION .............................................................. 37 17
TRACTION ........................................................................................................... 37 18
LIFTING MCB - JOYSTICK / FINGERTIPS......................................................... 38
18
NECESSARY ADJUSTMENT AFTER A COMPONENT REPLACING............... 40
18
18
18
18
3-2
WEI SEITE

3-3
MULTI-FUNCTION DISPLAY (DASHBOARD)

Multi-function dashboard helps operators to identify various information easily by changing screens
depending on the vehicle conditions.
GENERAL 5
2
2
3
4
5
6
7
8
9
PIN 14
J137 10
PIN 1 11
12
13
Icon Description
14
Discharge battery warning light:
it flashes when the battery reaches the 20% of charge 15
Parking brake on warning light 16
Deadman device warning light: 17
the pilot light comes on when the driver leaves the driving seat without switching off the truck:
under these conditions, the traction and the lifting movement are disabled 18
Adjustable electronic hour meter: 18
it counts the truck working hours. It shows the working hours and the hourly fractions
18
Speed reduction indication light
18
Selected direction indication light 18
18
3-4
Icon Description
Time indication light
Timer indication light
Selected program indication light
Turn direction indication light
Hour meter modality indication:

lifting motor, traction motor or key switch
Password:
indication of the button on the board
Board:
it permits to digit the access password and to navigate between the menus
Brakes system warning light:

Average in the brake system. The signal is visualized when the pressure in the brake system
is inadequate to unblock the brakes
Steering direction indication:

it shows the running direction
3-5
INCORRECT START MANAGEMENT

The INCORRECT START are recoverables errors, generated by:
an incorrect starting procedure 5
an incorrect sequence of use of the controls
These alarms block temporarily the truck functioning, generating an alarm icon on the display. 2
Summary table of the INCORRECT START
2
Icon Description Configuration Notes
3
Double pedal system
Direction pedal pressed during the Traction: NO
starting procedure
or balanced pedal
system
Lifting: YES 4
5
Traction: NO
Manual inversor in direction position Single pedal system
Lifting: YES 6
Hydraulic request during the starting proce-
7
Electric distributor
dure
8
Double pedal system
Double request of direction set or balanced pedal
Traction: NO 9
Lifting: YES
system
10
Traction: NO
Direction request with applyed parking brake All
Lifting: NO
11
12
Seat micro opened during the direction or Traction: NO
All
during the hydraulic request Lifting: NO 13
Brakes system warning light: 14
Average in the brake system. The signal is
visualized when the pressure in the brake
system is inadequate to unblock the brakes
All 15
In case of alarm the truck reduces the max.
speed to 15%. 16
17
18
18
18
18
18
18
3-6
USER MENU MAP
hh:mm
gg/mm/aa
TRIP H:M 00000:00

3-7
USER MENU DESCRIPTION

The "user"menu is accessible to any operator it allows to modify the parameters series contained in the
chart USER MENU.
5
USER MENU PASSWORD
Notes on the password insertion 2
1. Making sure to operate on the display membrane buttons using fingers only. Sharped or pointed
tools can damage the buttons 2
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 could be defective.
3
USER MENU PASSWORD INSERTION PROCEDURE 4
5
6
7
8
9
10
11
12
Procedure Operations Truck feedback
13
1 Turn on the truck
2 Operate the parking brake 14
3 Press contemporaneously the LPH and turtle buttons Short acoustic warning
4 Press the OK button for a few seconds to enter the menu
15
16
17
18
18
18
18
18
18
3-8
USER MENU
Menu Description Notes

If not otherwise
The display shows the effectuated working hours of: specified, the count of
WORKING: lifting motor working the hours is
HOUR TRACTION: traction motor working effectuated on the use
METER KEY: truck on (inserted key) of the lifting potenti-
RENT: rental time counter ometer and it is possi-
SERVICE: truck working since the last service intervention ble to reset it by the
service staff
It is possible to reset it
by the operator press-
TRIP It is a partial hour meter on the lifting motor use
ing the OK button for
some seconds
CLOCK It permits to modify hours and date
The activated alarm is
ALARMS It allows, if enabled, to set an alarm as memo shown on the display
with the relevant light
Permits to modify:
- the counting of the truck working hours visualized on the diplay:
None: no visualization
Key: it visualize the key working hours
DISPLAY Working: it visualizes the pump working hours
SETTING Traction: it visualizes the traction working hours
- the language visualized by the user menu
(5 languages: ita,en,fr,es,de)
- the visualisation of the direction wheels position
(linear or radial modality)
3-9
HOUR METER
Operate the parking brake and press contemporaneously
the LPH and turtle buttons to enable the keyboard 5
2
2
Press to visualize the information referred to the hour
meter 3
To exit the menu use the lateral flowing arrows
4
5
TRIP
Operate the parking brake and press contemporaneously 6
the LPH and turtle buttons to enable the keyboard
7
8
Press to visualize the information referred to the trip. 9
Press OK to reset the hours count
To exit the menu use the lateral flowing arrows
10
TRIP H:M 00000:00
11
CLOCK 12
Enter the user menu
[see USER MENU PASSWORD INSERTION 13
PROCEDURE paragraph]
14
15
Press OK to enter into the clock menu
16
17
Notes:
The clock icon flashes 18
Press or to modify the setting.
24 Press OK to confirm. 18
Notes: 18
The selected modality has a flag beside
hh:mm 18
Use the flowing arrows to set the hours.
Press OK to confirm 18
Use the flowing arrows to set the date.
gg/mm/aa Press OK to confirm 18
Press OUT to exit the menu
3-10
ALARMS
SETTING
Enter the user menu
[see USER MENU PASSWORD INSERTION
Use to reach the clock alarm menu
Press OK to confirm
Notes:
The clock icon flashes
hh:mm Press OK to confirm

Use the flowing arrows to set the hours
Press OK to confirm
Use the flowing arrows to set the date.
gg/mm/aa Press OK to confirm
DEACTIVATION
Enter the user menu
Use to reach the clock alarm menu.
Press OK to confirm
Press the buttons or to disable the clock alarm

Notes:
The clock icon flashes
Press OK to confirm
DISPLAY SETTING
TRUCK HOUR METER
Enter the user menu
Use to reach the display setting menu.
Press OK to confirm
Press OK to confirm
Press OK to confirm
3-11
Use the flowing arrows to set the hour meter modality

visualized on the display.
Press OK to confirm
Press OUT to exit the menu 5
LANGUAGE
2
Enter the user menu
[see USER MENU PASSWORD INSERTION 2
Use to reach the display setting menu. 3
Press OK to confirm
4
Use to reach the language setting menu
5
6
Press OK to confirm
7
8
Use to select the desired language.
Press OK to confirm
9
10
STEERING DIRECTION
Enter the user menu 11
PROCEDURE paragraph] 12
Use to reach the display setting menu.
Press OK to confirm 13
Use to reach the steering direction setting menu 14
15
16
Press OK to confirm
17
18
Use to select the desired visualisation. 18
Press OK to confirm
18
18
18
18
3-12
MAPS FOR USING THE DASHBOARD

SERVICE MENU
3-13
SERVICE MENU DESCRIPTION

The "service" menu allows to enable all the necessary functions for assistance/maintenance/rental
activities.
To acces to the menu is allowed exclusively to authorized personnel. 5
SERVICE MENU PASSWORD 2
Notes on the password insertion
1. Making sure to operate on the display membrane buttons using fingers only. Sharped or pointed 2
tools can damage the buttons
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
3
system could be defective.
4
SERVICE MENU PASSWORD INSERTION PROCEDURE
5
6
7
8
9
10
11
12
Procedure Operations Truck feedback 13
1 Turn on the truck
14
2 Operate the parking brake
3 Press contemporaneously the LPH and turtle buttons Short acoustic warning 15
Insert the combination as shown in the sequence here below
16
4 Short acoustic warning 17
18
Insert the password (the password is dynamic and changes 18
automatically each January the 1st):
The password is composed by a sequence of numbers: the 18
5 correspondence between the keyboard buttons and the
numbers composing the password is available on the display. 18
The OUT button, indicated as C, in the display, allows to cancel
the last number typed by each pressure.
18
Notes: to use the truck, unlock the parking brake. To visualize the alarms in real time use the
ALARMS-REAL TIME menu. 18
3-14
Menu Description
SOFT VERS Visualise the software version of boards and logic units
PARAM CHANGE Modify the selected program parameters
TRUCK CONF Modify the configuration parameters
SERVICE RENT It allows to set up the programmed maintenance menu and rent menu
PSW MODIFY It allows to modify the passwords or to restore default ones
TESTER Visualise the analogic and digital values to analyze the truck status
Memorize the truck alarm codes (maximum 20 alarms).
ALARMS
It visualize the alarms in real time
Permits to set the truck serial number, to acquire the potentiometer status and to
LEARNING
effectuate the ADJUST BATTERY
DEFAULT RST It allows to restore the default parameters of the truck
3-15
SERVICE MENU MAP
5
2
2
COMBINATION PASSWORD
3
4
5
6
SOFT VERS
7
8
PARAM CHANGE
9
10
TRUCK CONF
11
SERVICE RENT
12
13
PSW MODIFY 14
15
TESTER 16
17
ALARMS 18
18
LEARNING 18
18
DEFAULT RST 18
18
3-16
SOFT VERS
Enter the service menu

[see SERVICE MENU PASSWORD INSERTION
Press OK to confirm
SOFT VERS
Use the right and left arrows board buttons to navigate the
SOFT VERS menu

board
x.xx
Board Description Notes

EVCB Identify the MCB lifting section
TRCB Identify the MCB traction section
ARMREST Identify the armrest board
TRAC Identify the traction logic unit
PUMP M Identify the master pump logic unit
PUMP S Identify the slave pump logic unit
DISPLAY Identify the dashboard
X.XX Identify the software version
3-17
PARAM CHANGE

[see SERVICE MENU PASSWORD INSERTION 5
2
2
Press till reach the PARAM CHANGE menu
3
Press OK to confirm
PARAM CHANGE 4
Use the right and left arrows board buttons to select
TRACTION or MAT. HANDLING
5
6
Press OK to confirm
PARAM CHANGE
7
MAT. HANDLING
8
9
10
PC MAT. HAND menu
TILT SPEED FINE Press OK to modify the parameter 11
HZ XPROF 0
12
13
Press or to modify the value
PARAMETER Press OK to confirm 14
HZ
15
16
Press OK to save; on the display the message SAVE

17
SUCCESSFUL appears, therefore press OUT to return to
PARAMETER
HZ the menu 18
SAVE?
OK OUT
Press OK to exit without saving
18
18
18
18
18
3-18
TRACTION FUNCTION
The Traction function visualizes the traction apparatus parameters. The parameter values could vary
between an established range.
Parameter Description Notes
This parameter determines the speed reduction with the low speed selector
push-button (turtle function) pressed:
T turtle cutback %
- minimum setting = maximum cutback
- maximum setting = minimum cutback
T curve cutback Speed reduction in a bend %
This parameter determines the speed reduction with brake pedal micro
pressed and accelerator pedal released :
T brake cutback %
- minimum setting = minimum cutback
- maximum setting = maximum cutback
This parameter determines the speed reduction if enabled.
To enable the cutback, connect a normally closed micro between the CN1
connector, 11 pin of the MCB card, and the GND of one of the MCB card
micros:
T speed cutback1 %
- micro open = reduction on
- micro closed = reduction off
This parameter determines the speed reduction if enabled. To enable the cut-
back, connect a normally closed micro between the CN1 connector, 18 pin of
the MCB card, and the GND of one of the MCB card micros:
T speed cutback2 - micro open = reduction on %
This parameter determines the speed reduction when the battery
indicator reaches the 20% (battery nominal value residual charge=40%):
T 20 BDI reduct %
T 10 BDI reduct %
This parameter determines the steering angle in which the maximum speed
Max angle a
reduction acts
Angle threshold This parameter determines the steering angle without speed reduction a
Starting from "Angle threshold" this parameter determines the steering angle
Angle threshold2 activing a speed reduction up to the maximum value definite from "Angle a
reduction Y"
This parameter determines the speed reduction percentage of the "Angle
threshold 2":
Angle reduct Y a
This parameter determines the maximum FW speed.
Max speed FW - minimum setting = minimum speed Hz
- maximum setting = maximum speed
3-19

This parameter determines the maximum BW speed.
Max speed BW - minimum setting = minimum speed Hz
5
This parameter determines the acceleration ramp. Changing the parameter 2
changes the acceleration time:
T ACC delay sec
- minimum setting = maximum acceleration
- maximum setting = minimum acceleration
2
This parameter determines the deceleration ramp, varying the position of the 3
accelerator pedal without releasing completely the pedal :
Speed limit BRK sec
- minimum setting = minimum deceleration
- maximum setting = maximum deceleration 4
Reversing the direction this parameter determines the
deceleration ramp:
5
Inversion BRK sec
This parameter determines the deceleration ramp on releasing the pedal.
Changing the parameter changes the deceleration time: 7
Release BRK sec
This parameter determines the deceleration ramp when the pedal brake micro
is pressed and the accelerator pedal is released: 9
Pedal BRK sec
This parameter determines a 0 value zone in the acceleration diagram entry
T Throttle 0
(see diagram here below)
% 11
T Throttle X This parameter changes the characteristics of the acceleration diagram entry %
12
T Throttle Y This parameter changes the characteristics of the acceleration diagram entry %
13
SPEED (Hz)
14
MAX SPEED
15
16
17
TROTTLE Y POINT 18
FREQ. CREEP
V
18
TROTTLE X POINT
VACC MIN. VACC MAX. 18
TROTTLE 0 ZONE
18
This parameter determines the motor torque on the basis of the selected 1,2,3,
Trac torque prof
profile 4
18
Initial BRK This parameter determines the braking beginning delay % 18
3-20
MAST HANDLING FUNCTION

The Mast Handling function visualizes the lifting apparatus parameters. The parameter values could vary
in an established range.
ELECTRIC CONTOL VALVE VERSION

This parameter determines the minimum lifting speed with only the micro
closed. Changing the parameter changes the speed:
Min speed up Hz
- minimum setting = minimum speed
This parameter determines the minimum lifting speed . Changing the parame-
ter changes the speed:
Max speed up Hz
This parameter determines the tilting speed . Changing the parameter
changes the speed:
Tilt speed fine Hz
This parameter determines the sideshift speed . Changing the parameter
changes the speed:
Shift speed fine Hz
This parameter determines the 4th lever (IV way) speed . Changing the
IV WAY speed parameter changes the speed:
Hz
fine - minimum setting = minimum speed
This parameter determines the 5th lever (V way) speed . Changing the param-
V WAY speed eter changes the speed:
Hz
fine - minimum setting = minimum speed
This parameter determines the power steering speed . Changing the parame-
ter changes the speed:
Hydro speed fine Hz
This parameter determines the speed reduction with the low speed selector
push-button (turtle function) pressed:
P turtle cutback %
This parameter determines the speed reduction if enabled.
To enable the cutback, connect a normally closed micro between the J34
connector, 11 pin of the MCB card, and the GND of one of the MCB card
P cutback micros:
%
speed1 - micro open = reduction on
3-21

This parameter determines the speed reduction if enabled. To enable the cut-
back, connect a normally closed micro between the J34 connector, 18 pin of
the MCB card, and the GND of one of the MCB card micros:
5
P cutback
- micro open = reduction on %
speed2
- micro closed = reduction off 2
- maximum setting = minimum cutback 2
P 20% BDI reduct
%
3
- maximum setting = maximum cutback 4
P 10% BDI reduct
%
5
- maximum setting = minimum cutback 6
This parameter determines the acceleration ramp. Changing the parameter
P ACC delay
changes the acceleration time:
sec 7
- minimum setting = maximum acceleration
- maximum setting = minimum acceleration 8
This parameter determines the deceleration ramp. Changing the parameter
P DEC delay
changes the deceleration time:
sec 9
- minimum setting = maximum deceleration
- maximum setting = minimum deceleration
10
Pump torque pro- This parameter determines the motor torque on the basis of the selected pro- 1,2,3,
file file 4 11
This parameter determines the joystick sensibility as a function of the potenti- 1,2,3,
Curve mode
ometer stroke 4 12
13
14
15
16
17
18
18
18
18
18
18
3-22
TRUCK CONF

Press till reach the TRUCK CONF menu

Press OK to confirm
TRUCK CONF
menu
Function Description Notes

This function visualizes the traction apparatus parameters. The parameter val-
OPTIONS
ues could vary in an established range.
This function visualizes the motors parameters. The parameter values could
MOTORS
vary in an established range.
This function visualizes the MCB board parameters. The parameter values
MCB OUT
could vary in an established range.
RESET Reset of the hours counter and of the Fingertips-Joystick configuration
This function visualizes the battery parameters. The parameter values could
BATTERY
vary in an established range.
OPTIONS

Profile This parameter determines the profile loaded at the start up 0,1,2,3,4
Set This parameter determines the L-P-H setting
This parameter enables/disables the L-P-H push button working:
Lock set ON = enabled ON-OFF
OFF = disabled
This parameter determines which logo must be visualized at the
Start icon Cesab-BT
starting
This parameter enables/disables the Pin insertion request:
NONE = disabled
Pin code DISPLAY = enabled
DHU = [unused]
SESAM = [unused]
DY Pin enable This parameter determines the number of Pin Codes used 140
This parameter enables/disables with balanced pedal system
Swaying pedal ON = enabled ON-OFF
OFF = disabled
Test mode This parameter temporarily activates the lifting pump ON-OFF
3-23

th
This parameter enables/disables the 5 lever working
VTH ENABLE ON = enabled ON-OFF
OFF = disabled
5
This parameter enables/disables the functioning of the device 2
(clamps) on the mast (if present)
CLAMPS ON-OFF
ON = enabled
OFF = disabled
2
This parameter enables/disables the descent solenoid valve 3
LOWER VALVE ON = enabled ON-OFF
OFF = disabled
4
This parameter enables/disables the tilting angle sensor
[unused]
TILT SENSOR
ON = enabled
ON-OFF 5
OFF = disabled
This parameter determines the tilting speed as a function of the
6
tilting angle measurement [optional]:
TILT 2 SPEED
Hz 7
This parameter determines the reduction ratio of the reduction gear
8
GEAR RATIO n
in relation to the truck speed calculus
9
This parameter enables/disables the buzzer when the seat micro is
open
BUZZER SEAT
ON = enabled
ON-OFF 10
OFF = disabled
This parameter enables/disables the truck automatic braking
11
STOP ON RAMP ON = enabled ON-OFF
OFF = disabled 12
This parameter enables/disables the speed reduction in case of
Height mast
mast with height superior then 6250mm
ON-OFF 13
Himast Sp lim
If enabled, High mast determines the maximum FW or BW speed in
case of mast with height superior to 6250mm
Hz 14
This parameter enables/disables the following functions: 15
Curve turtle - COMP STEER ACC ON-OFF
- STEER THRESHOLD
16
This parameter determines the acceleration with steered direction
Comp steer acc wheels (the steering angle can be selected by the STEER THRESH- seconds 17
OLD parameter)
Steer threshold
This parameter determines the direction wheels angle beyond
degrees 18
which the COMP STEER ACC parameter is enabled
Pumps enable
This parameter enables/disables the master or the slave pump logic
ON-OFF
18
unit
Truck capacity Unused 18
18
18
18
3-24
MOTORS

This parameter enables/disables the traction motor encoder control:
SLIP TRAC ON = enabled ON-OFF
OFF = disabled
This parameter enables/disables the master pump motor encoder
control:
SLIP PUMP M ON-OFF
ON = enabled
OFF = disabled
This parameter enables/disables the slave pump motor encoder
control:
SLIP PUMP S ON-OFF
ON = enabled
OFF = disabled
This parameter determines the traction motor voltage expressed in
percentage of the maximum voltage:
T MAX CURRENT %
- minimum setting = minimum voltage
- maximum setting = maximum voltage
This parameter determines the master pump motor voltage
P M MAX expressed in percentage of the maximum voltage:
%
CURRENT - minimum setting = minimum voltage
This parameter determines the slave pump motor voltage
P S MAX expressed in percentage of the maximum voltage:
%
CURRENT - minimum setting = minimum voltage
This parameter enables/disables the traction motor temperature
sensor
TRAC SENS TEMP ANALOG = analog
DIGITAL = digital
NONE = disabled
This parameter enables/disables the master pump motor
temperature sensor
PUMP M
ANALOG = analog
SENS TEMP
DIGITAL = digital
NONE = disabled
This parameter enables/disables the slave pump motor
temperature sensor
PUMP S
ANALOG = analog
SENS TEMP
DIGITAL = digital
NONE = disabled
MCB OUT

This parameter selects the output between PWM1_EN and
PWM OUTPUT %
PWM2_EN in accordance with the battery voltage
PWM1 EN This parameter determines the EV9 solenoid valve control ON-OFF
PWM2 EN This parameter determines the EV10 solenoid valve control ON-OFF
3-25

This parameter enables/disables the negative output on MCB card,
J34 connector, 32 pin :
OUT1 BLINK ON = enabled ON-OFF
5
OFF = disabled
Characteristics of the electric applicable load: +24V/ 42W 2
J34 connector, 32 pin when the FW or BW direction is selected:
2
OUT1 FW+BW ON = enabled ON-OFF
OFF = disabled 3
Characteristics of the electric applicable load: +24V/ 42W
This parameter enables/disables the negative output on MCB card, 4
J34 connector, 32 pin when a hydraulic function is selected (no
OUT1 ANY PUMP
hydraulic requirement for power steering)
ON-OFF
5
ON = enabled
OFF = disabled 6
J34 connector, 32 pin when the seat micro is closed:
OUT1 SEAT ON = enabled
OFF = disabled
ON-OFF 8
9
J34 connector, 32 pin when the card arm, JAUX connector, 6 pin is
connected to a negative:
10
OUT1 JOY 1 ON-OFF
ON = enabled
OFF = disabled 11
OUT1 JOY 2
ON-OFF
13
ON = enabled
OFF = disabled 14
OUT1 JOY 3
ON-OFF 16
ON = enabled
OFF = disabled
OUT1 JOY 4
ON = enabled
ON-OFF 18
OFF = disabled
J40 connector, 23 pin when the FW or BW direction is selected 18
OUT2 FW+BW ON = enabled ON-OFF
OFF = disabled 18
18
3-26

J40 connector, 23 pin when a hydraulic function is selected (no
hydraulic requirement for power steering)
OUT2 ANY PUMP ON-OFF
ON = enabled
OFF = disabled
J40 connector, 23 pin when the seat micro is closed:
OUT2 SEAT ON = enabled ON-OFF
OFF = disabled
J40 connector, 23 pin when the armrest board, JAUX connector, 6
pin is connected to a negative:
OUT2 JOY 1 ON-OFF
ON = enabled
OFF = disabled
OUT2 JOY 2 ON-OFF
ON = enabled
OFF = disabled
OUT2 JOY 3 ON-OFF
ON = enabled
OFF = disabled
J40 connector, 23 pin when turtle push-button is active:
OUT2 JOY 4 ON = enabled ON-OFF
OFF = disabled
J40 connector, 23 pin when the FW direction is selected
OUT2 FW ON = enabled ON-OFF
OFF = disabled
RESET

RESET PUMP HM Pump hours counter reset
RESET TRAC HM Traction hours counter reset
RESET KEY HM Key hours counter reset
3-27
BATTERY

5
This parameter allows the immediate rearmament of the battery indi-
BDI TO 100%
cator 2
This parameter determines the regulation of the rearmament thresh-
BDI RESET old when is required a charge with the battery state between the % 2
70% and 90%
BDI ADJ MIN

This parameter determines the set point of the charging voltage. It is
0-9
3
settable from 0 to 9
This parameter determines the set point of the charging voltage. It is 4
BDI ADJ MAX 0-9
settable from 0 to 9
This parameter determines the voltage needed to rearm the battery 5
ADJUSTMENT 3 indicator on the display. Expressed in percentage, it allows a regula- %
tion in step of 0.1% referred to the nominal tension (0,1%= 0,080V) 6
BDI GEL This parameter enables the discharge curve in case of GEL battery %
7
CURRENT LIST 8
Parameter Description Notes 9
This parameter determines the min. current to EV1 1 coil
Min current EV1 1 min. = 100 mA mA 10
max. = 500 mA
This parameter determines the min. current to EV1 2 coil 11
Min current EV1 2 min. = 100 mA mA
max. = 500 mA 12
max. = 500 mA
max. = 500 mA 15
max. = 500 mA
max. = 500 mA 18
max. = 500 mA
This parameter determines the max. current to EV1 1 coil 18
Max current EV1 1 min. = 500 mA mA
max. = 1500 mA 18
This parameter determines the max. current to EV1 2 coil
Max current EV1 2 min. = 500 mA mA 18
max. = 1500 mA
18
3-28

max. = 1500 mA
max. = 1500 mA
max. = 1500 mA
max. = 1500 mA
max. = 1500 mA
3-29
SERVICE RENT

2
2
Press till reach the SERVICE RENT menu
3
Press OK to confirm
SERVICE RENT 4
menu
5
6
Function Description Notes 7
SERV TIMER EN This function enables/disables the timer of programmed
(service timer enable) maintenance interventions 8
RESET SERV HM
(reset service This function resets the SERV TIMER EN timer 9
hourmeter)
This function determines the maintenance interval: When the set time
10
SERV REQ TIME
A reference (PROGRAMMED MAINTENANCE expires the red led
(service request time)
DIAGRAM) starts to blink 11
This function determines, SERV REQ TIME expired, after
how much time the truck enters in limited working sys- 12
SERV CUT TIME
tem:
(service cutback time) 13
B reference (PROGRAMMED MAINTENANCE
DIAGRAM)
The wrench icon 14
SERV REQ TIME expired notice:
SERV TIME BLINK and the red led
C reference (PROGRAMMED MAINTENANCE
(service time blink)
DIAGRAM)
start blinking at the 15
truck ignition
T SERV CUTBACK
This function sets the percentage of working reduction 16
when SERV CUT TIME is expired;
(traction service
cutback)
D reference (PROGRAMMED MAINTENANCE 17
DIAGRAM)
P SERV CUTBACK
This function sets the percentage of working reduction 18
when SERV CUT TIME is expired;
(pump service
cutback)
D reference (PROGRAMMED MAINTENANCE 18
DIAGRAM)
RENT TIMER EN This function enables/disables the timer of the rental 18
(rental timer enable) duration
This function determines (selects) the Timer Rent 18
working in hours or in days; if the DAY function is WH = hours
RENT TIME/DAY
selected it is not possible to modify the date in the USER DAY = days 18
menu
18
3-30

T RENT CUTBACK
This function sets the percentage of working reduction
(traction rental
when RENT CUT TIME or RENT CUT DAY are expired;
cutback)
P RENT CUTBACK
This function sets the percentage of working reduction
(pump rental
when RENT CUT TIME or RENT CUT DAY are expired;
cutback)
RESET RENT HM
(reset rental This function resets the timer RENT TIMER EN
hourmeter)
RENT REQ TIME This function determines the rent interval;
(rental request time) A reference (PROGRAMMED RENT DIAGRAM)
RENT CUT TIME This function determines, RENT REQ TIME expired, after
(rental cutback time) how much time the truck enters in limited working system
The RENT icon
RENT TIME BLINK RENT REQ TIME expired notice: and the red led
(rental time blink) B reference (PROGRAMMED RENT DIAGRAM) start blinking at the
truck ignition
This function defines the day when the Rent time stops A
RENT END DAY reference (PROGRAMMED RENT DIAGRAM)
with DAY selected
This function defines the activation time of the speed
Max duration
RENT CUT DAY reduction;
15 days
B reference (PROGRAMMED RENT DIAGRAM)
This function determines, RENT END DAY expired, after
how much time the truck enters in limited working system Max duration
RENT DAY BLINK
C reference (PROGRAMMED RENT DIAGRAM) 15 days
with DAY selected
3-31
PROGRAMMED MAINTENANCE DIAGRAM
During this interval the , icon and the

red led start blinking at the truck ignition 5
C A B 2
100%
Lifting 30% of the max speed

2
Traction 30% of the max speed
3
D
4
30%
5
480 500 520 t (wh) 6

0
(STEP1) (STEP50) (STEP5)
7
PROGRAMMED RENT DIAGRAM
8
During this interval the RENT icon and the
red led start blinking at the truck ignition 9
Speed (Hz)
10
C A B
100% 11
Lifting 30% of the max speed
Traction 30% of the max speed 12
13
D
30% 14
15
520 t (wh)
0 480 500
(STEP1) (STEP100) (STEP1) 16
17
18
18
18
18
18
18
3-32
CANGE PPASSWORD

Press till reach the PSW MODIFY menu

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

This function allows to modify the pin code and related
CHANGE
profile
DEFAULT This function sets the default password
3-33
TESTER

2
2
Press till reach the TESTER menu
3
TESTER
Use the right and left arrows board buttons to navigate the 4
menu
Press OUT to exit the menu 5
6
7
TRACTION This function visualizes the traction system values
9
MAT. HANDLING This function visualizes the lifting system values
10
Notes:
The complete list of the parameters relevants to the TESTER menu can be consulted at the 11
section TESTER PARAMETERS DESCRIPTION
12
13
14
15
16
17
18
18
18
18
18
18
3-34
ALARMS

Press till reach the ALARMS menu

Press OK to confirm
ALARMS
menu

See diagnostic
REALTIME This function visualizes the alarms in real time
code list
This function allows to visualize the stored alarms and
LOGBOOK
erase them
LOGBOOK
See diagnostic
READ This function visualizes the last 20 alarms saved
code list
CLEAR This function deletes the alarm list
3-35
LEARNING

2
2
Press till reach the LEARNING menu
3
Press OK to confirm
LEARNING 4
menu
5
the instructions visualized on the display 6
7
SERIAL NUMBER This function identifies the truck serial number
This function determines the acceleration potentiometer minimum ~ 0,1V
9
LEARN TRAC POT
stroke maximum ~3,4V
10
ADJUST This function controls the real value of the battery volt- Modifiy with the
BATTERY age arrows and
11
This function determines the central position of the
SET STEER ZERO ~ 2,7V
direction wheels 12
This function determines the maximum right position of The acquired voltage
SET STEER RIGHT
the direction wheels has to be 4,1 V 13
This function determines the maximum left position of The acquired voltage
SET STEER LEFT
the direction wheels has to be 1,7 V 14
15
16
17
18
18
18
18
18
18
3-36
DEFAULT RST

Press till reach the DEFAULT RST menu

Press OK to confirm
DEFAULT RST
menu
the instructions visualized on the display

See paragraph NECESSARY
ADJUSTMENTS AFTER A
EVCB This function allows to reset the EVCB board
HARDWARE COMPONENT
REPLACEMENT
ADJUSTMENTS AFTER A
TRCB This function allows to reset the TRCB board
HARDWARE COMPONENT
REPLACEMENT
ARMREST This function allows to reset the ARMREST board
ADJUSTMENTS AFTER A
TRAC This function allows to reset the traction logic unit
HARDWARE COMPONENT
REPLACEMENT
This function allows to reset the MASTER PUMP
PUMP M
logic unit
This function allows to reset the SLAVE PUMP logic
PUMP S
unit
3-37
TESTER PARAMETER DESCRIPTION

TRACTION
TESTER: display of the main imput and output signals 5
1. SPD SET 2
Theoretical speed of the motor requested referred to the speed reduction
2. LH MOTOR SPEED 2
Frequency encoder motor
3. MOTOR TEMP
Motor temperature 3
4. CONTR TEMP
Traction logic unit temperature 4
5. SLIP
Flowing values of the right motor, or the speed difference between the rotating magnetic field and the 5
motor rotor:
SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz)
6. FREQUENCY
6
Frequency of the voltage and current signals supplyed to the motor
7. SERVICE BRAKE 7
Brake pedal micro
OFF = not active input, open switch 8
ON = active input, closed switch
8. TRACTION POT
Accelerator pedal potentiometer
9
Value in volt of the potentiometer
9. PARKING BRAKE 10
Parking brake micro
OFF = not active input, open switch 11
10. BRAKE REL SENS 12
Negative brakes unblocking sensor
OFF = not active input, open switch
13
11. BATT VOLT INPUT
Battery voltage readed from the MCB 14
12. CFG
Pedal system input 15
1 = single pedal
2 = double pedal or balanced pedal
13. BATTERY VOLTAGE
16
Battery voltage readed from the traction logic
14. BATTERY CHARGE 17
Percentage of the battery charge level, read by the traction logic unit
15. DIR JOY 18
FW/BW directions potentiometer on the armrest
18
18
18
18
18
3-38
LIFTING MCB - JOYSTICK / FINGERTIPS

TESTER: display of the main imput and output signals
1. LIFE HM
Working hour counter from the first start
2. PM SPD SET
Master pump motor teoric speed requested referred to the speed reduction
PM MOT SPD
Master pump motor encoder frequency
3. PS SPD SET
Slave pump motor teoric speed requested referred to the speed reduction
PS MOT SPD
Slave pump motor encoder frequency
4. PM MOT TMP/PS MOT TMP
Master/Slave pump motor temperature
5. PM CTR TMP/PS CTR TMP
Temperature of the hardware section that controls the master/slave pump motor
6. PM SLIP/PS SLIP
Flowing values of the left motor, or the speed difference between the rotating magnetic field and the
master/slave pump motor rotor:
PM SLIP/PS SLIP (Hz) = FREQUENCY (Hz) - ENCODER (Hz)
7. PM FREQ/PS FREQ
Frequency of the voltage signals supplied from the master/slave pump logic units to the master/slave
pump motors
8. LIFTING SWITCH
Lifting fingertips/joysticks S17 and S18 microswitches status
9. LIFTING
Auxiliary digital input status (optional): unused
10. TILTING SWITCH
Tilting fingertips/joysticks S19 and S20 microswitches status
11. TILTING
12. SIDESHIFT SWITCH
Tilting fingertips/joysticks S21 and S22 microswitches status
13. SIDESHIFT
14. IV WAY SWITCH
4th way fingertips/joysticks S23 and S24 microswitches status
15. IV WAY
16. V WAY SWITCH
5th way fingertips/joysticks S25 and S26 microswitches status
17. V WAY
18. IN6_1
Backward direction micro
19. IN6_2
Forward direction micro
20. IN6_3
Habilitation button for the 4th way activation
21. IN6_4
Unused
22. IN6_5
Unused
23. IN6_6
Available lifting speed reduction (optional)
24. LIFT LOWER J
Lifting potentiometer (neutral position 2,45V 0,2 V)
3-39
25. TILT J
Tilting potentiometer (neutral position 2,45V 0,2 V)
26. SIDESHIFT J
Sideshift potentiometer (neutral position 2,45V 0,2 V) 5
27. IV WAY J
4th way potentiometer (neutral position 2,45V 0,2 V)
28. V WAY J
2
5th way potentiometer (neutral position 2,45V 0,2 V)
29. 1st GRP SETPOINT 2
Current value requested from the armrest board to the EVCB for the lifting/lowering group
30. 2nd GRP SETPOINT 3
Current value requested from the armrest board to the EVCB for the tilting group
31. 3rd GRP SETPOINT
Current value requested from the armrest board to the EVCB for the sideshift group
4
32. 4th GRP SETPOINT
Current value requested from the armrest board to the EVCB for the 4th way group 5
33. CURRENT RMS
Current value requested from the armrest board to the EVCB for the 4th way group 6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
3-40
NECESSARY ADJUSTMENT AFTER A COMPONENT REPLACING

MCB CARD
ACQUISITION: Accelerator potentiometer (LEARN TRAC POT)
Balanced pedal configuration (SWAYING PEDAL)
TRACTION LOGIC UNIT AC5

ACQUISITION: Steering potentiometer (SET STEER ZERO/SET STEER LEFT/SET STEER RIGHT)
PUMP LOGIC UNIT DUAL AC2

No acquisition required
ARMREST BOARD
Optional 5th way configuration via fingertips (VTH ENABLE)
Optional attachment pilotage button activation (CLAMPS)
DASHBOARD
Date and hour regulation
4-1
TROUBLESHOOTING
BEFORE TROUBLESHOOTING ......................................................................... 3
5
CONNECTOR HANDLING................................................................................... 3
WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE.................. 3
2
SYSTEM CONFIGURATION................................................................................ 5 2
DIAGNOSIS CODE LIST ..................................................................................... 6 2
WHEN AN ERROR CODE IS DISPLAYED ......................................................... 10
4
TRACTION LOGIC UNIT AC5 ............................................................................. 10
PUMP MASTER LOGIC UNIT ............................................................................. 27 5
PUMP SLAVE LOGIC UNIT................................................................................. 40 6
MCB BOARD (section EVCB) ............................................................................ 53
7
ARMREST BOARD.............................................................................................. 59
8
DASHBOARD ...................................................................................................... 67
MCB BOARD (section TRCB) ............................................................................ 69 9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-2
WEI SEITE

4-3
BEFORE TROUBLESHOOTING
CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or 5
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
2
unlocking it.
To connect, push the connector fully until it is locked in 2
position.
2
3. Bring a tester probe into contact with a connector
terminal from the rear side of the coupler (harness 4
side).
4. If insertion from the rear side is impossible, as in the
case of a waterproof connector, bring the tester probe 5
carefully into contact with the terminal so as not to
cause deformation of the connector terminal. 6
5. Do not touch connector terminals directly with your
hand. 7
6. When bringing tester probes into contact with live
terminals, prevent two tester probes from coming into
contact with each other.
8
WIRE HARNESS AND CONNECTOR 9
INSPECTION PROCEDURE
When any trouble occurs, first inspect the connectors and 10
wire harness of the related circuit according to the following
procedure: 11
Continuity check
1. Disconnect the connectors at both ends of the 12
corresponding harness.
2. Measure the resistance between corresponding 13
terminals of the connectors at both ends.
Standard:10 or less 14
Note:
Measure while lightly shaking the wire harness up and 15
down and sideways.
It is unusualto have a break of the circuit along vehicle
wiring mostly on the connectors or close to them.
16
Inspect especially the sensor connectors with
sufficient care. 17
18
18
18
18
18
18
4-4
Short circuit check

1. Disconnect the connectors at both ends of the
1. Measure the resistance between the corresponding
connector terminal and N1. Always inspect the
connectors at both ends.
Standard: 1 M or above
Measure while lightly shaking the wire harness up and

down and sideways.
2. Measure the resistance between a terminal
corresponding to the connector terminal and N1.
Always inspect the connectors at both ends.
Standard: 1 M or above
The wiring may short-circuit due to pinching by the

body or defective clamping.
Visual and contact pressure checks

Disconnect the connectors at both ends of the
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 same as that of the terminal to a

female connector and check the extracting force.
Defective contact may exist at a terminal where the
extracting force is less than that of other terminals.
Note:
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.
Caution:
Always disconnect the battery plug before SST connection and disconnection. If the battery plug
is kept connected, various boards may be damaged.
4-5
SYSTEM CONFIGURATION
5
DASHBOARD READER
2
2
2
4
MASTER OF
THE LIFTING
MASTER OF 5
THE SYSTEM
6
7
ARMREST 8
MCB
BOARD Potentiometers,
microswitches 9
10
11
12
13
14
TRACTION PUMP MASTER PUMP SLAVE
LOGIC UNIT LOGIC UNIT LOGIC UNIT 15
16
17
Encoder Steering Encoder Encoder
potentiometer
18
18
CAN BUS ANALOGIC
18
18
18
18
4-6
DIAGNOSIS CODE LIST

When an Error Code is Displayed
Code Alarm specification Board Error mode Page

01 WATCHDOG TRACTION LOGIC UNIT Self-diagnostic test 10
02 EEPROM KO TRACTION LOGIC UNIT Fault in the memory area 10
03 LOGIC FAILURE #3 TRACTION LOGIC UNIT Logic defect 10
04 LOGIC FAILURE #2 TRACTION LOGIC UNIT Fault in the hardware section 10
05 LOGIC FAILURE #1 TRACTION LOGIC UNIT Undervoltage/overvoltage protection 11
06 VMN LOW TRACTION LOGIC UNIT Failure on VMN test 12
07 VMN HIGH TRACTION LOGIC UNIT Failure on VMN test 13
08 CONTACTOR OPEN TRACTION LOGIC UNIT Contactor driver failure 14
09 STBY I HIGH TRACTION LOGIC UNIT Current sensor failure 14
10 CAPACITOR CHARGE TRACTION LOGIC UNIT Capacitors not charged 15
11 HIGH TEMPERATURE TRACTION LOGIC UNIT Logic unit temperature 16
12 MOTOR TEMPERAT TRACTION LOGIC UNIT Traction motor temperature upper to 17
140C
13 ENCODER ERROR TRACTION LOGIC UNIT Encoder circuit failure 18
14 THERMIC SENS KO TRACTION LOGIC UNIT Logic unit termic sensor out of range 18
15 SAFETY IN TRACTION LOGIC UNIT Logic unit arrest 19
16 CAN BUS KO TRACTION LOGIC UNIT Notices the comunication of another board 19
17 WAITING FOR NODES TRACTION LOGIC UNIT Notices a delay in the 20
data transfer
18 AUX OUTPUT KO TRACTION LOGIC UNIT Failure on the drivers that controls the 20
solenoid valve coil
19 DRIVER SHORTED TRACTION LOGIC UNIT Contactor driver failure 20
20 CONTACTOR DRIVER TRACTION LOGIC UNIT Contactor driver failure 21
21 COIL SHORTED TRACTION LOGIC UNIT Contactor driver failure 22
22 STEER ACQ TRACTION LOGIC UNIT Steering potentiometer setting not correct 22
23 INCORRECT START TRACTION LOGIC UNIT Incorrect start procedure 22
24 STEER WIRE KO TRACTION LOGIC UNIT Steering potentiometer failure 23
28 STEER SENSOR KO TRACTION LOGIC UNIT Potentiometer out of range or not 23
connected
29 FORW + BACK TRACTION LOGIC UNIT Incorrect starting procedure 24
31 WATCHDOG PUMP MASTER LOGIC UNIT Self-diagnostic test 27
32 COIL SHORTED PUMP MASTER LOGIC UNIT Contactor driver failure 27
33 LOGIC FAILURE #3 PUMP MASTER LOGIC UNIT Logic defect 28
34 CAPACITOR CHARGE PUMP MASTER LOGIC UNIT Capacitors not charged 28
35 VMN LOW PUMP MASTER LOGIC UNIT Failure on VMN test 29
36 ENCODER ERROR PUMP MASTER LOGIC UNIT Encoder circuit failure 30
37 CONTACTOR DRIVER PUMP MASTER LOGIC UNIT Contactor driver failure 30
38 VMN HIGH PUMP MASTER LOGIC UNIT Failure on VMN test 31
39 I=0 EVER PUMP MASTER LOGIC UNIT Failure on the current sensor 31
40 MOTOR STALL PUMP MASTER LOGIC UNIT Motor encoder failure 34
41 SLAVE WARNING PUMP MASTER LOGIC UNIT Logic internal error 35
42 WAITING FOR NODE PUMP MASTER LOGIC UNIT Notices a delay in the data transfer 35
43 WRONG SET BATT PUMP MASTER LOGIC UNIT Battery voltage out of range 35
44 HIGH TEMPERATURE PUMP MASTER LOGIC UNIT Logic unit temperature 35
45 BATTERY LOW PUMP MASTER LOGIC UNIT Battery voltage is low 35
46 EEPROM OFFLINE PUMP MASTER LOGIC UNIT Fault in the memory area 36
4-7

47 SENS MOT TEMP KO PUMP MASTER LOGIC UNIT Motor temperature upper to 140C 37
48 THERMIC SENS KO PUMP MASTER LOGIC UNIT Logic unit termic sensor out of range 37 5
49 MOTOR PUMP MASTER LOGIC UNIT Traction motor temperature upper to 38
TEMPERAT 140C
61 WATCHDOG PUMP SLAVE LOGIC UNIT Self-diagnostic test 40
2
62 COIL SHORTED PUMP SLAVE LOGIC UNIT Contactor driver failure 40
2
63 LOGIC FAILURE #3 PUMP SLAVE LOGIC UNIT Logic defect 41
64 CAPACITOR
CHARGE
PUMP SLAVE LOGIC UNIT Capacitors not charged 41
2
65 VMN LOW PUMP SLAVE LOGIC UNIT Failure on VMN test 42
66 ENCODER ERROR PUMP SLAVE LOGIC UNIT Encoder circuit failure 43
4
67 CONTACTOR DRIVER PUMP SLAVE LOGIC UNIT Contactor driver failure 43
5
68 VMN HIGH PUMP SLAVE LOGIC UNIT Failure on VMN test 44
Failure on the current sensor 44
69 I=0 EVER PUMP SLAVE LOGIC UNIT
Motor encoder failure 48
6
70 MOTOR STALL PUMP SLAVE LOGIC UNIT
48
71 NO CAN MESG N.11 PUMP SLAVE LOGIC UNIT UNUSED 7
72 HIGH TEMPERATURE PUMP SLAVE LOGIC UNIT Logic unit temperature upper to 85C 49
73 INPUT MISMATCH PUMP SLAVE LOGIC UNIT Control internal error 49 8
74 EEPROM OFFLINE PUMP SLAVE LOGIC UNIT Fault in the memory area 49
Motor temperature sensor failure 50
76 SENS MOT TEMP KO PUMP SLAVE LOGIC UNIT 9
77 THERMIC SENS KO PUMP SLAVE LOGIC UNIT Logic unit termic sensor out of range 50
78 MOTOR TEMPERAT PUMP SLAVE LOGIC UNIT Motor temperature to 140C 51
10
79 MASTER WARNING PUMP SLAVE LOGIC UNIT Logic internal error 52
93 NOT REP ERROR MCB (TRCB) Comunication error in pre-operation 71
11
94 CHKSUM ERROR MCB (TRCB) Software error 71
1A I=0 EVER TRACTION LOGIC UNIT Failure on the current sensor 24 12
1E CONTACTOR TRACTION LOGIC UNIT Contactor driver failure 21
CLOSED 13
2A SEAT ERROR TRACTION LOGIC UNIT Closed microswitch not noticed 25
2C GAIN ACQUISITION TRACTION LOGIC UNIT The logic unit is in data acquisition phase 25 14
2D ENCODER LOCKED TRACTION LOGIC UNIT Motor encoder failure 26
3A STBY I HIGH PUMP MASTER LOGIC UNIT Current sensore failure 32 15
3B CONTACTOR OPEN PUMP MASTER LOGIC UNIT Contactor driver failure 32
3C DRIVER SHORTED PUMP MASTER LOGIC UNIT Contactor driver failure 32 16
3D AUX OUTPUT KO PUMP MASTER LOGIC UNIT Failure on the contactor driver 32
3E LOGIC FAILURE #1 PUMP MASTER LOGIC UNIT Undervoltage/overvoltage protection 33 17

3F LOGIC FAILURE #2 PUMP MASTER LOGIC UNIT Fault in the hardware section 34
4A DATA ACQUISITION PUMP MASTER LOGIC UNIT The logic unit is in data acquisition phase 39 18
4B NO CAN MSG N PUMP MASTER LOGIC UNIT Notices the comunication of an another 39
card 18
4C SLAVE KO PUMP MASTER LOGIC UNIT Comunication failure with Slave pump 39
logic unit 18
6A STBY I HIGH PUMP SLAVE LOGIC UNIT Current sensor failure 45
6B DRIVER PUMP SLAVE LOGIC UNIT Contactor driver failure 45 18
SHORTED
45
6C AUX OUTPUT KO PUMP SLAVE LOGIC UNIT Failure on the contactor driver 18
6D LOGIC FAILURE #1 PUMP SLAVE LOGIC UNIT Undervoltage/overvoltage protection 46
6E LOGIC FAILURE #2 PUMP SLAVE LOGIC UNIT Fault in the hardware section 47 18
6F WAITING FOR MAST PUMP SLAVE LOGIC UNIT Notices a delay in the data transfer 47
4-8

7A DATA ACQUISITION PUMP SLAVE LOGIC UNIT The logic unit is in data acquisition phase 52
7B NO CAN MSG N PUMP SLAVE LOGIC UNIT Notices the comunication of another card 52
7C MASTER KO PUMP SLAVE LOGIC UNIT Comunication failure with Master pump 52
logic unit
A1 DOUBLE REQ MCB (EVCB) UNUSED 53
A2 RELOAD PARAM MCB (EVCB) Occurred parameters loading signal 53
WARN
A3 PARAM LOAD ERROR MCB (EVCB) Error in the parameters loading in memory 53
A4 NOT REP ERROR MCB (EVCB) Board in waiting information 53
A5 CHKSUM ERROR MCB (EVCB) UNUSED 53
A6 BOOT ERROR MCB (EVCB) Board in waiting information from the 53
Traction or lifting logic
A7 HI SIDE DRIVER MCB (EVCB) Board internal problem 54
SHORT
A8 EV1 1 OPEN MCB (EVCB) EVP1 solenoid valve coil failure 54
A9 EV2 1 OPEN MCB (EVCB) EVP2 solenoid valve coil failure 54
AA EV1 2 OPEN MCB (EVCB) EVP3 solenoid valve coil failure 54
AB EV2 2 OPEN MCB (EVCB) EVP4 solenoid valve coil failure 54
AC EV1 3 OPEN MCB (EVCB) EVP5 solenoid valve coil failure 55
AD EV2 3 OPEN MCB (EVCB) EVP6 solenoid valve coil failure 55
AE EV1 4 OPEN MCB (EVCB) EVP7 solenoid valve coil failure 55
AF EV2 4 OPEN MCB (EVCB) EVP8 solenoid valve coil failure 55
B SLIP PROFILE TRACTION LOGIC UNIT Error in the memory data 14
B0 TRCB MICRO ERROR MCB (EVCB) Board internal problem 55
B1 GROUP1 DRIVER MCB (EVCB) Failure on a group 1 coil of the 56
SHORT electroproportional distributor
B5 AUX OUT SHORT MCB (EVCB) Failure on a group 5 coil of the 57
electroproportional distributor
B6 DASH KO MCB (EVCB) Comunication problem between the MCB 57
and the dashboard
B7 ERR SEAT MCB (EVCB) Seat micro open with activated hydraulic 57
functions
B8 JOY STUFFING ERR MCB (EVCB) Comunication problem between the MCB 57
and the joystick board
B9 SET SERIAL NUMBER MCB (EVCB) Automatic setting of the serial not occurred 57
BA POT TILT NOT OK MCB (EVCB) Incorrect reading of the tilting 58
potentiometer voltage
C1 INCORRECT START MCB (TRCB) Incorrect starting procedure 69
C2 BAD CONF WHEELS MCB (TRCB) Error of configuration in the 3-4 wheels 69
version
C3 PEDAL WIRE KO MCB (TRCB) Failure in the signal of the accelerator 69
potentiometer at rest
C4 BAD MICROSWITCH MCB (TRCB) Pedal micro or direction lever failure 70
C5 WARN CONF ERROR MCB (TRCB) UNUSED 70
4-9

C6 BAD VACC MCB (TRCB) Accelerator potentiometer setting not cor- 70
rect
C7 ERR SEAT MCB (TRCB) Closed microswitch not noticed 70
5
C9 PARKING SELECTED MCB (TRCB) Parking brake applyed and one of the 71
function activated
2
CA PARAM LOAD ERROR MCB (TRCB) Error in the truck ignition 71
CC TRAC STUFFING ERR MCB (TRCB) Problem of comunication with the 71
2
traction logic unit
CF FW+BW MCB (TRCB) Double request activated 71
2
D1 TRAC KO DASHBOARD The traction logic unit it is not read 67
by the dashboard 4
D2 MCB TRAC KO DASHBOARD The MCB control board it is not read by the 67
dashboard 5
D4 PUMP KO DASHBOARD The lifting logic unit it is not read by the 67
dashboard 6
D5 MCB MHY KO DASHBOARD The MCB control board it is not read by the 67
dashboard 7
D6 JOY KO DASHBOARD The armrest board it is not read by the 68
dashboard 8
D8 ERROR READ PIN DASHBOARD The MCB prevents the password reading 68
DC HYDRO KO DASHBOARD The slave lifting logic unit is not read by the
dashboard
68 9
Error during the eepreom data uploading 68
DF EEPROM ERROR DASHBOARD 10
E1 INCORRECT START ARMREST BOARD Incorrect starting procedure 59
E2 BAD LIFT POT ARMREST BOARD Lifting potentiometer failure 60 11
E3 BAD TILT POT ARMREST BOARD Tilting potentiometer failure 61
E4 BAD SIDESH. POT ARMREST BOARD Sideshift potentiometer failure 62 12
E5 BAD IV POT ARMREST BOARD 4th way potentiometer failure 63
E6 BAD V POT ARMREST BOARD 5th way potentiometer failure 64 13
E7 ERR SEAT ARMREST BOARD Closed microswitch not noticed 64
E8 INVALID RESTORE ARMREST BOARD Failed predefined parameters restore 64 14
STATE
E9 EEPROM CHK ARMREST BOARD Error during the Eprom data uploading 65 15
SUMERR
EA DEFAULT RESTORED ARMREST BOARD Unploading of the flash memory data 65
16
EB POT NOT ACQUIRED ARMREST BOARD Uploading of the flash memory data 65
EC RAM CHK SUMERR ARMREST BOARD Uploading RAM data failed 65 17
ED MHYRIO STUFFING ARMREST BOARD Comunication problem 65
ERR
18
EE PUMP STUFFING ARMREST BOARD Comunication problem 65
ERR
EF FW+BW ARMREST BOARD Balanced inversor failure 66
18
18
18
18
18
4-10
WHEN AN ERROR CODE IS DISPLAYED

TRACTION LOGIC UNIT AC5
In this session, in the description "Condition for error detection" if not expressly specified, the wording
"traction logic unit" is refered to the TRACTION LOGIC UNIT TLU AC5
01 WATCHDOG
Condition for error detection

Self-diagnostic test. The test is executed in working and in standby status .
This alarm can be caused also by an incorrect can-bus functioning.
Check:
- the truck insulation
- the can-bus connections
- replace the traction logic unit
02 EEPROM KO

Fault in memory area where the adjustment parameters are registered; this alarm inhibits the truck working,
the unit will load the default parameters.
Use the function RESET TRAC for reload the default parameters (see paragraph DEFAULT RST).
If the defect continues at the truck switching on, replace the traction logic unit.
If the alarm desappears the parameters previously stored will be cancelled and automatically will be
loaded the traction logic unit default parameters.
Set again a possible personalization of the parameters.
03 LOGIC FAILURE #3

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

Fault in the hardware section
Failure in the logic hardware section that manages the phase voltage feedback.
The alarms appears also if the CT2 contactor is opened during the running.
Check:
- the pins 5 and 6 of the J50 connector. It could be present a false connection
- the contactor coil (~ 50 ohm)
- the status of the power supply cables connected at the motor
- replace the traction logic unit
4-11
05 LOGIC FAILURE #1

5
Undervoltage/overvoltage protection. This alarm signals that an interruption, produced by an 2
undervoltage/overvoltage protection, is started.
- UNDER voltage: the logic unit keeps controlled the key imput (pin 33, connector JAT, M03 cable of the
traction logic unit). If the voltage has a low peak, the alarm is signalled.
2
- OVER voltage: the logic unit controls the internal capacitors voltage. If the voltage has a high peak
during the braking, the alarm is signalled. 2
The possible reasons are:
a. Battery undervoltage/overvoltage, lost of voltage after the ignition key or after the battery connector.
4
b. If the alarm is signalled at the truck ignition and appears with the alarm 3E of the
PUMP MASTER LOGIC UNIT and the alarm 6D of the PUMP SLAVE LOGIC UNIT, check: 5
the key switch
the battery plug 6
the battery components status
c. The alarm appears also when one or more motor phases do not present a correct insulation at a 7
movement request. Check the motor insulation (with disconnected battery): it has to be upper of
10 Mohm. To check the insulation verify the resistance value between the motor power cable and a
screw on the chassis. If noticed a low voltage value proceed to remove the single components in 8
order to establish the problem source. Or check the motor power cables insulation
d. Defect in the logic hardware section that controls the protection against the overvoltage. 9
Logic defect. Replace the traction logic unit.
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-12
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 (~ 50 ohm).
If the coil is damaged or disconnected, the truck will signal the alarm at the switching on. If the coil
value is ok, proceed following the test below described in order to establish if the failure is produced by
an internal or external cause to the traction logic unit:
To determine the cause of the fault, proceed by running one of the tests described below:
- Apply the parking brake and switch off the truck
- Open the compartment and disconnect the battery
- Check the tightening of the power cables on the motor
- Check the tightening of the power cables on the logic
- Check the continuity values between the following points on the traction logic unit using a multimeter
(with the logic unit totally disconnected):
Red tip Black tip
U - +Vb ~ 5 Kohm
V - +Vb ~ 80 Kohm
W - +Vb ~ 80 Kohm
If noticed values very different from the beside one, disconnect all the cables from the logic unit and
verify the values directly on the traction logic unit
If an opened circuit is noticed replace the traction logic unit.
4-13
07 VMN HIGH

5
Failure in the VMN test. 2
The test starts when the ignition key is turned on and there is no current consumption (machine
stationery). The alarm appears if the power circuit connections are open; check the connection of the 3
power cables from the logic unit to the traction motor and the cables condition.
2
2
4
5
6
7
8
- Check the tightening of the power cables on the motor 9
- Check the continuity values between the following points on the traction logic unit using a multimeter 10
Red tip Black tip 11
U - +Vb ~ 5 Kohm
V - +Vb ~ 80 Kohm 12
W - +Vb ~ 80 Kohm
13
verify the values directly on the traction logic unit
14
If an opened circuit is noticed replace the traction logic unit.
15
16
17
18
18
18
18
18
18
4-14
08 CONTACTOR OPEN

Contactor driver failure. The contactor CT2 is supplied but the contact is not closed.
- Check the coil of the CT2 contactor (~ 50 ohm) and the relevand cables
- Check the contacts status (current passage not permitted)
09 STBY I HIGH

Current sensor failure.
- Replace the traction logic unit
B SLIP PROFILE

Error in the memory data where the flowing parameters are loaded.
Make a RESET MASTER to re-load the default parameters.
If the problem presists replace the logic unit.
4-15
10 CAPACITOR CHARGE

5
Capacitors not charged. At the ignition, the logic unit tries to charge the capacitors by an internal power 2
resistance and an internal diode, and checks that the capacitors are charged in a fixed time. If this does
not occur, an alarm is sent; the main contactor remains opened.
- Check the negative connection between the logic unit and the battery
2
- Check the voltage at the key entrance (pin 33, connector JAT, cable M03 of the traction logic unit):
the battery voltage must be present 2
- Carry out a bridge between the pins of the key switch (SW1). If the alarms disappears replace
the key switch 4
- Disconnect the J15 and J16 connectors. If the alarm disappears check the status of the temperature
sensor and the motor encoder
- If the alarm persists, replace traction logic unit
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-16
11 HIGH TEMPERATURE

Logic unit temperature.
The logic unit temperature is upper of 75C. The maximum current is proportionally reduced at the tem-
perature increase.
At 100C the current is reduced at 0 and the logic unit is arrested
Check:
- the correct functioning of the fan
- the air channel must be free
- the CONTR TEMP parameter (menu TESTER of the dashboard).
If it happens under 75C, with the alarm displayed, replace the traction logic unit.
If it happens over 100C leave the truck stopped whith the key in order to cool down the logic unit.
If it happens over 100C but the logic unit is cold, replace the traction logic uni
4-17
12 MOTOR TEMPERATURE

5
Traction motor temperature upper to 140C. 2
This alarm appears when the motor temperature sensor reaches 140C.
After the 140C the logic unit reduces the acceleration proportionally and the current until 150C.
After the 155C completely cuts the current.
2
If the alarm appears when the motor is cold, check:
- that the wiring harness circuit of the temperature sensor is correctly connected 2
- that the temperature sensor is always opened or has a voltage value upper to the relative voltage
value (140C see the following table) 4
AMBIENT TEMPERATURE RESISTANCE TEMP. 5
(C) (F) (%/K) MIN. TYP. MAX ERROR
(K)
-40 -40 0,84 340 359 379 6,48
6
-30 -22 0,83 370 391 411 6,36
-20 -4 0,82 403 424 446 6,26 7
-10 14 0,80 437 460 483 6,16
0 32 0,79 474 498 522 6,07 8
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
9
30 86 0,73 599 626 652 5,79
40 104 0,71 645 672 700 5,69 10
50 122 0,70 694 722 750 5,59
60 140 0,68 744 773 801 5,47 11
70 158 0,66 797 826 855 5,34
80 176 0,64 852 882 912 5,21 12
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 13
120 248 0,58 1089 1127 1164 5,73
130 266 0,57 1152 1194 1235 6,17 Reduction of current 14
140 284 0,55 1216 1262 1309 6,63 Reduction of current
160 320 0,53 1350 1407 1463 7,59
170 338 0,52 1420 1482 1544 8,1
180 356 0,51 1492 1560 1628 8,62
16
190 374 0,49 1566 1640 1714 9,15
200 392 0,48 1641 1722 1803 9,71 17
210 410 0,47 1719 1807 1894 10,28
220 428 0,46 1798 1893 1988 10,87 18
230 446 0,45 1879 1982 2085 11,47
240
250
464
482
0,44
0,44
1962
2046
2073
2166
2184
2286
12,09
12,73
18
260 500 0,42 2132 2261 2390 13,44
270 518 0,41 2219 2357 2496 14,44 18
280 536 0,38 2304 2452 2600 15,94
290 554 0,34 2384 2542 2700 18,26 18
300 572 0,29 2456 2624 2791 22,12
18
18
4-18
13 ENCODER ERROR

Encoder circuit failure.
This alarm shows that the encoder information are uncorrected or absent. The encoder transmits
signals only when the motor is working. The alarm is noticed by the logics when 40Hz are passed.
If the alarm appears on the dashboard and the operator makes the reset of the key with the machine
stopped, the alarm disappears. If the alarm is signalled before to reach 40 Hz, the problem could be an
incorrect insulation of a supplying cable on the chassis: without the correct encoder signals, the
machine remains stopped or it moves very slowly. To determine if the problem is from the encoder or
from the logic, proceed as follows:
Set up SLIP TRAK 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 followings components could be defective:
- Internal logic unit circuit
- Wiring harness
- Encoder
Use an analogic or digital multimeter to determine where the problem is located.
Encoder basic electric diagram.

In the picture it is shown only a signal (A).
The encoder generates two same signals, but out
of phase of 90(A-B).
1. Connect the positive tip of the tester (red) to
the positive one of the encoder.
2. Connect the COM tip of the tester (black) to
the encoder signal (A).
Depending on the motor position, it will show the
following values:
low signal: 0,5 - 1,5 Volt
hight signal: 10,5 - 11,5 Volt
It is not possible to read intermediate values with
the motor 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 either
signals are good (see upper description) or if the
channels are opened or in short circuit. If the
signals are good, the problem could be on the
logic unit
14 THERMIC SENSOR KO

Logic unit termic sensor out of range.
4-19
15 SAFETY IN

5
Stop of the traction logic unit. 2
Check:
- Alarms in the traction logic unit
If YES, the alarm it is only a consequence. Verify the traction logic unit diagnostic
2
If NO, presence/connection wiring harness on JCP connector, pin 31, cable L1 of the PUMP LOGIC
UNIT DUALAC2 2
If NO, that the pin 12, connector JAT, cable L1 of the traction logic unit is a GND
4
5
6
7
8
9
10
11
12
13
14
16 CAN BUS KO 15

16
Notice the communication of another board. 17
Can-bus comunication failure. The alarm appears if the traction logic unit does not receive information
from the MCB board or from the pump logic unit master or slave.
Before replacing any board or logic unit, verify:
18
- The dashboard alarms, to identify exactly the board or logic unit that does not comunicate
- Can-bus pull-up resistance presence 18
dashboard 180 Ohm
MCB 180 Ohm 18
armrest 180 Ohm
18
18
18
4-20
17 WAITING FOR NODE

Notice a delay in the data transfer.
This warning alarm signals that the PUMP MASTER LOGIC UNIT and/or the PUMP SLAVE LOGIC
UNIT have noticed an alarm.
Check:
- All the alarms referred to the PUMP MASTER LOGIC UNIT and/or the PUMP SLAVE LOGIC UNIT.
18 AUX OUTPUT KO (AUX DRIVER OPEN/AUX DRIVER SHORTED)

Failure the driver that controls the solenoid valve coil of the negative brakes.
Verify:
- Correct connection of the EV1 negative brakes solenoid valve coil
- Resistive value of the EV1 (25 Ohm) negative brakes solenoid valve coil; if different replace the coil
If the first two conditions are ok, proceed as following:
- Switch off the truck and disconnect the coil
- Verify that between the 28 PIN, JAT connector, cable A of the traction logic unit and GND there is no
continuity
If YES: replace the traction logic unit;
If NO: verify again the connections and the coil status
19 DRIVER SHORTED

Contactor driver failure
Verify:
- the F2 (5 A) fuse integrity
- that between the pin 26, JAT connector, cable L2 of the the traction logic unit and the GND there is no
continuity.
If YES: replace the traction logic unit
If NO: verify the EV1 negative brakes solenoid valve coil status: (Resistive value: 25 Ohm)
4-21
1E CONTACTOR CLOSED

5
Contactor driver failure. 2
The logic unit cuts the curret to the CT2 contactor coil, but the contacts remain closed.
Disconnect the battery and check:
- The CT2 contactor windings and the relevant wiring harness
2
- Clean the contactor connections
2
4
5
6
7
8
9
10
11
12
13
14
20 CONTACTOR DRIVER
15
Condition for error detection 16
Defect to the driver that controls the CT2 contactor. 17
18
18
18
18
18
18
4-22
21 COIL SHORTED

CT2 contactor defect.
- Check the coil (50 ohm) status
- Check that there is no short circuit on the wiring harness
If the defect has external causes, replace the traction logic unit.
22 STEER ACQ

Steering potentiometer setting not correct
Fault in the steering potentiometer.
Effect the steering potentiometer setting (LEARN TRAC POT).
23 INCORRECT START

Incorrect starting procedure.
4-23
24 STEER WIRE KO

5
Steering potentiometer failure 2
This alarm signals a failure in the steering potentiometer or in the relevant wiring harness.
Verify:
- Correct functioning of the pontentiometer using a multemeter
2
- Correct wiring harness connection (positive and negative)
2
28 STEER SENSOR KO 4
5
This alarm signals a failure of the steering potentiometer cursor or of the relevant wiring harness. 6
Verify:
- The correct functioning of the potentiometer with a multimeter 7
- The correct connection of the wiring harness
- Effect again the steering potentiometer setting (LEARN TRAC POT) 8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-24
29 FORW + BACK

Check:
- Microswitches for the backward and forward direction and the relevant wiring harness
1A I=0 EVER

Failure on the current sensor.
4-25
2A SEAT ERROR

5
Closed microswitch not noticed 2
Opened seat micro during the traction.
Verify:
- The S2 micro status
2
- Connection S1 cable, pin 4, JAT connector of the traction logic unit
- Connection HZ cable, pin 5, JCP connector of the LIFTING LOGIC UNIT DUALAC2 2
If the information of the seat micro is not arriving on both logics the alarm is signalled.
4
2C GAIN ACQUISITION 5

6
The logic unit is in data acquisition phase. 7
This warning communicates that the logic is in current acquisition phase.
In this phase the logic is not working. 8
If the alarm persists after the key reset, replace the logic unit.
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-26
2D ENCODER LOCKED

Motor encoder failure
Interrupted or disconnected motor encoder.
The alarm appears after 20 seconds approximately with the accelerator pedal pressed.
The machine works at reduced speed and at maximum current.
The encoders generate two same signals, but out
following values:
the motor stopped.
If the motor is working, the multemeter will
Mv= 5,5 - 6,5 Volt
channels are opened or in shour circuit. If the
signals are good, the problem could be on the the
logic unit.
4-27
PUMP MASTER LOGIC UNIT

"pump logic unit" is refered to the PUMP LOGIC UNIT PLU DUALAC2
5
31 WATCHDOG
2
2
This alarm can be caused also by an incorrect functioning of the can-bus.
Check:
2
- check the truck insulation
- check the can-bus connections 4
- replace the pump logic unit
5
32 COIL SHORTED 6
7
Contactor driver failure 8
- Check the coil (50 ohm) status 9
If the defect has external causes, replace the pump logic unit.
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-28
33 LOGIC FAILURE #3

Logic defect.
- Replace the pump logic unit.
34 CAPACITOR CHARGE

Capacitors not charged. At the ignition, the logic unit tries to charge the capacitors by an internal power
resistance and an internal diode, and checks that the capacitors are charged in a fixed time.
If this does not occur, an alarm is sent; the main contactor remains opened.
- Check the negative connection between the logic unit and the battery
- Check the voltage at the key entrance (pin 3, connector JCP, cable M03 of the pump logic unit):
the battery voltage must be present
the key switch
sensor and motor encoder
- If the alarm persists, replace the pump logic unit
4-29
35 VMN LOW

5
If the coil is damaged or disconnected, the truck will signal the alarm at the switching on. If the coil
2
value is ok, proceed following the test below described in order to establish if the failure is produced by
an internal or external cause to the pump logic unit: 2
4
5
6
7
8
- Apply the parking brake and switch off the truck 9
- Check the tightening of the power cables on the motor 10
- Check the continuity values between the following points on the pump logic unit using a multimeter 11
( with the logic unit totally disconnected):
Red tip Black tip 12
Um - +Vb ~ 7 Kohm
Vm - +Vb ~ 90 Kohm 13
Wm - +Vb ~ 90 Kohm
14
verify the values directly on the pump logic unit
15
If an opened circuit is noticed replace pump logic unit.
16
17
18
18
18
18
18
18
4-30
36 ENCODER ERROR

Encoder circuit failure.
If the alarm appears on the dashboard and the operator makes the reset of the key with the machine
incorrect insulation of a supplying cable on the chassis: without the correct encoder signals, the
from the logic, proceed as follows:
Set up SLIP PUMP M on OFF and accelerate slowly.
- Internal logic unit circuit
- Wiring harness
- Encoder
Use an analogic or digital multimeter to determine where the problem is located.

The encoder generates two same signals, but out of
phase of 90(A-B).
1. Connect the positive tip of the tester (red) to the
positive one of the encoder.
2. Connect the COM tip of the tester (black) to the
encoder signal (A).
following values:
It is not possible to read intermediate values with the
motor stopped.
Mv= 5,5 - 6,5 Volt
Carrying out this test directly on the logic connectors
it is possible to determine if the either signals are
good (see upper description) or if the channels are
opened or in short circuit. If the signals are good, the
problem could be on the logic unit.
37 CONTACTOR DRIVER

Defect to the driver that controls the CT3 contactor.
4-31
38 VMN HIGH

5
The test starts when the ignition key is turned on and there is no current consumption (machine
stationery). The alarm appears if the power circuit connections are open; check the connection of the 3
power cables from the logic unit to the the pump motor and the cables condition.
2
2
4
5
6
7
8
- Open the compartment and disconnect the battery 9
- Check the tightening of the power cables on the logic 10
- Check the continuity values between the following points on the pump logic unit using a multimeter
(with the logic unit totally disconnected): 11
Red tip Black tip
Um - +Vb ~ 7 Kohm 12
Vm - +Vb ~ 90 Kohm
Wm - +Vb ~ 90 Kohm 13
14
If an opened circuit is noticed replace the pump logic unit. 15
39 I=0 EVER
16
17
18
18
18
18
18
18
4-32
3A STBY I HIGH

Current sensor failure.
- Replace the pump logic unit
3B CONTACTOR OPEN

Contactor driver failure. The contactor CT3 is supplyied but the contact is not closed.
- Check the coil of the CT3 contactor (~ 50 ohm) and the relevand cables
- Check the contacts status (current passage not permitted)
3C DRIVER SHORTED

Switch off the truck and disconnect the CT3 contactor coil.
Verify:
- that between the pin 26, JCP connector, cable L3 of the lifting logic and the GND there is no
continuity.
If YES: replace the pump logic unit
If NO: verify the CT3 contactor coil status: (Resistive value: 50 Ohm)
3D AUX OUTPUT KO

Failure on the contactor driver.
- If appears replace the pump logic unit
4-33
3E LOGIC FAILURE #1

5
Undervoltage/overvoltage protection. This alarm signals that an interruption, produced by an 2
- UNDER voltage: the logic unit keeps controlled the key input (pin 3, connector JCP, M03 cable of the
pump logic unit). If the voltage has a low peak, the alarm is signalled.
2
during the braking, the alarm is signalled. 2
4
b. If the alarm is signalled at the truck ignition and appears with the alarm 05 of the
TRACTION LOGIC UNIT and the alarm 6D of the PUMP SLAVE LOGIC UNIT, check: 5
the key switch
the battery plug 6
c. The alarm appers also when one or more motor phases do not present a correct insulation at a 7
10 Mohm. To check the insulation verify the resistence value between the motor power cable and a
screw on the chassis. If noticed a low voltage value proceed to remove the single components in 8
d. Defect in the logic hardware section that controls the protection against the overvoltage. 9
Logic defect. Replace the pump logic unit.
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-34
3F LOGIC FAILURE #2

Fault in the hardware section
Failure in the hardware section of the logic that manages the phase voltage feedback.
The alarms apperas also if the CT3 contactor is open during the running.
Check:
- the contactor coil (~ 50 ohm)
- the status of suppling cables connected at the motor
40 MOTOR STALL

The alarm appears after 8 seconds approximately with the motor pump request.
In picture it is shown only a signal (A).
following values:
the motor stopped.
Mv= 5,5 - 6,5 Volt
logic unit.
4-35
41 SLAVE WARNING

5
Internal logic error 2
2
42 WAITING FOR NODE
2
This warning alarm signals that the TRACTION LOGIC UNIT and/or the PUMP SLAVE LOGIC UNIT
5
notice an alarm.
Check: 6
- All the alarms referred to the TRACTION LOGIC UNIT and/or the PUMP SLAVE LOGIC UNIT.
7
43 WRONG SET BATTERY 8
9
Battery voltage out of range 10
If the key is inserted on ON, the controller verify the battery voltage and compares it with the parameter
set in "SET BATTERY" (Battery setting). If the real value is upper or lower of 20% of the nominal 11
values, it is present a failure.
- Check the battery status and, if necessary, replace the battery.
Note: parameter set battery diplayed in the menu Adjustment, reachable by console
12
13
44 HIGH TEMPERATURE
14
Logic unit temperature.
The logic unit temperature is upper of 75C. The maximum current is proportionally reduced at the tem- 16
perature increase.
At 100C the current is reduced at 0 and the logic unit is arrested 17
Check:
- the correct functioning of the fan
18
- the PM MOT TMP parameter (menu TESTER of the dashboard).
If it happens under 75C, with the alarm displayed, replace the pump logic unit. 18
If it happens over 100C but the logic unit is cold, replace the pump logic uni 18
18
45 BATTERY LOW
18
18
Battery discharged
4-36
46 EEPROM OFFLINE

the unit will load the default parameters.
If the defect continues after the truck is switched on, replace the pump logic unit.
If the alarm desappears, remember that the parameters previously stored are cancelled and replaced
by the default parameters.
4-37
47 SENS MOT TEMP KO

5
Interrupted or disconnected pump master motor temperature sensor.
Verify:
2
- Wiring harness
- Sensor resistive value 2
(K) 4
-40 -40 0,84 340 359 379 6,48
-30 -22 0,83 370 391 411 6,36 5
-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 6
10 50 0,77 514 538 563 5,98
20 68 0,75 555 581 607 5,89 7
25 77 0,74 577 603 629 5,84
30 86 0,73 599 626 652 5,79 8
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 9
70 158 0,66 797 826 855 5,34
80 176 0,64 852 882 912 5,21 10
90 194 0,63 910 940 970 5,06
100 212 0,61 970 1000 1030 4,9 11
110 230 0,60 1029 1062 1096 5,31
120 248 0,58 1089 1127 1164 5,73
12
160 320 0,53 1350 1407 1463 7,59
170 338 0,52 1420 1482 1544 8,1 14
180 356 0,51 1492 1560 1628 8,62
190
200
374
392
0,49
0,48
1566
1641
1640
1722
1714
1803
9,15
9,71
15
210 410 0,47 1719 1807 1894 10,28
220 428 0,46 1798 1893 1988 10,87 16
230 446 0,45 1879 1982 2085 11,47
240 464 0,44 1962 2073 2184 12,09 17
250 482 0,44 2046 2166 2286 12,73
260 500 0,42 2132 2261 2390 13,44 18
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
18
300 572 0,29 2456 2624 2791 22,12
18
18
18
18
4-38
49 MOTOR TEMPERAT

Pump master motor temperature upper to 140C.
- that the wiring harness circuit of the temperature sensor is correctly connected
value (140C see the following table)
AMBIENT TEMPERATURE RESISTANCE TEMP.

(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
4-39
0
4A DATA ACQUISITION

5
This warning communicates that the logic is in current acquisition phase. 2
In this phase the logic is not working.
If the alarm persists after the key reset, replace the pump logic unit.
2
4B NO CAN MSG N 2
4
Notice the communication of another board.
5
Can-bus communication failure. The alarm appears if the logic unit does not receive the
information from the MCB board, from the traction logic units, or from the slave pump logic unit. 6
Before replacing any board, verify:
- The dashboard alarms, to identify exactly the board that does not comunicate 7
- Can-bus pull-up resistance presence
Dashboard 180 Ohm 8
MCB 180 Ohm
Armrest 180 Ohm
9
4C SLAVE KO 10
11
Communication fault with SLAVE pump logic unit. The alarm can be originated by:
12
1. Interferences on the CAN-BUS: in this condition the alarm appears in combination with other
alarms 13
Check:
- truck insulation 14
- presence of the antistatic discharger if the truck is equipped with no marking tyres
- verify pump logic unit connectors JCP; all the pins must be in line and not lifted 15
- verify MCB connector J34 and J40; all pin must be correctly connected
2. Defective logic unit
Check: 16
- communication between MASTER pump logic unit and SLAVE pump logic unit by the console
YES: see point 1 17
NO: replace pump logic unit
18
18
18
18
18
18
4-40
PUMP SLAVE LOGIC UNIT

"pump logic unit" is refered to the PUMP LOGIC UNIT PLU DUALAC2
61 WATCHDOG

This alarm can be caused also by an incorrect functioning of the can-bus.
Check:
- check the truck insulation
- check the can-bus connections
62 COIL SHORTED

- Check the coil (50 ohm) status
If the defect has external causes, replace the pump logic unit.
4-41
63 LOGIC FAILURE #3

5
Logic defect. 2
2
64 CAPACITOR CHARGE
2
Capacitors not charged. At the ignition, the logic unit tries to charge the capacitors by an internal power
resistance and an internal diode, and checks that the capacitors are charged in a fixed time. If this does
5
not occur, an alarm is sent; the main contactor remains open.
- Check the negative connection between the logic unit and the battery 6
- Check the voltage at the key entrance (pin 3, connector JCP, cable M03 of the pump logic unit):
the battery voltage must be present 7
the key switch 8
sensor and of the motor encoder
- If the alarm persists, replace the pump logic unit 9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-42
65 VMN LOW

If the coil is damager or disconnected, the truck will signal the alarm at the switching on. If the coil value
is ok, proceed following the test below described in order to establish if the failure is produced by an
internal or external cause to the pump logic unit:
Red tip Black tip
Us - +Vb ~ 7 Kohm
Vs - +Vb ~ 90 Kohm
Ws - +Vb ~ 90 Kohm
If an opened circuit is noticed replace the pump logic unit.
4-43
66 ENCODER ERROR

5
Encoder circuit failure. 2
If the alarm appears on the dashboard and the operator makes the reset with the key with the machine
2
incorrect insulation of a supplying cable on the chassis: without the correct encoder signals, the 2
from the logic, proceed as follows: 4
Set up SLIP PUMP S on OFF and accelerate slowly.
5
- Internal logic unit ciruit
- Wiring harness 6
- Encoder
Use an analogic or digital multimeter to determine where the problem is located. 7
Encoder basic electric diagram. 8
The encoder generates two same signals, but out o
phase of 90(A-B).
9
1. Connect the positive tip of the tester (red) to th
positive one of the encoder. 10
2. Connect the COM tip of the tester (black) to th
encoder signal (A). 11
following values: 12
13
It is not possible to read intermediate values with th
motor stopped. 14
15
Mv= 5,5 - 6,5 Volt
Carrying out this test directly on the logic connector 16
it is possible to determine if the either signals are
good (see upper description) or if the channels are 17
opened or in short circuit. If the signals are good, th
problem could be on the logic unit. 18
18
67 CONTACTOR DRIVER
18
18
Defect to the driver that controls the CT3 contactor.
18
18
4-44
68 VMN HIGH

The test starts when the ignition key is turned in ON position and there is no current consumption
(machine stationery). The alarm appears if the power circuit connections are open; check the
connection of the 3 power cables from the logic unit to the pump motor and the cables condition.
Red tip Black tip
Us - +Vb ~ 7 Kohm
Vs - +Vb ~ 90 Kohm
Ws - +Vb ~ 90 Kohm
If an opened circuit is noticed replace the pump logic unit.
69 I=0 EVER

4-45
6A STBY I HIGH

5
Current sensor failure. 2
- Replace the pump logic unit
2
6B DRIVER SHORTED
2
Switch off the truck and disconnect the CT3 contactor coil.
5
Verify:
- that between the pin 26, JCP connector, cable L3 of the lifting logic and the GND there is no 6
continuity.
If YES: replace the pump logic unit 7
If NO: verify the CT3 contactor coil status: (Resistive value: 50 Ohm)
8
6C AUX OUTPUT KO
9
10
Failure on the contactor driver. 11
12
13
14
15
16
17
18
18
18
18
18
18
4-46
6D LOGIC FAILURE #1

Undervoltage/overvoltage protection. This alarm signals that an interruption, produced by an
- UNDER voltage: the logic unit keeps controlled the key imput (pin 3, connector JCP, M03 cable of the
pump logic unit). If the voltage has a low peak, the alarm is signalled.
during the braking, the alarm is signalled.
b. If the alarm is signalled at the truck ignition and appears with the alarm 05 of the
TRACTION LOGIC UNIT and the alarm 3E of the PUMP MASTER LOGUC UNIT, check:
the key switch
the battery plug
c. The alarm appears also when one or more motor phases do not present a correct insulation at a
10 Mohm. To check the insulation verify the resistence value between the motor power cable and a
screw on the chassis. If noticed a low voltage value proceed to remove the single components in
d. Defect in the logic hardware section that controls the protection against the overvoltage.
Logic defect. Replace the pump logic unit.
4-47
6E LOGIC FAILURE #2

5
Fault in the hardware section 2
Failure in the hardware section of the logic that manages the phase voltage feedback.
The alarms appearas also if the CT3 contactor is opened during the running.
Check:
2
- the contactor coil (~ 50 ohm) 2
- the status of supplying cables connected at the motor
- replace the pump logic unit 4
5
6F WAITING FOR MAST
6
7
This warning alarm signals that the TRACTION LOGIC UNIT and/or the PUMP MASTER LOGIC UNIT 8
notice an alarm.
Check:
- All the alarm referred to the TRACTION LOGIC UNIT and/or the PUMP SLAVE LOGIC UNIT. 9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-48
70 MOTOR STALL

The alarm appears after 8 seconds approximately with the accelerator pedal pressed.

following values:
the motor stopped.
Mv= 5,5 - 6,5 Volt
electronic control.
71 NO CAN MESG N. 11 - UNUSED

4-49
72 HIGH TEMPERATURE

5
Logic unit temperature. 2
The logic unit temperature is upper of 75C. The maximum current is proportionally reduced at the tem-
perature increase.
At 100C the current is reduced at 0 and the logic unit is arrested
2
Check:
- the correct functioning of the fan 2
- the PS MOT TMP parameter (menu TESTER of the dashboard). 4
If it happens under 75C, with the alarm displayed, replace the traction logic unit.
If it happens over 100C but the logic unit is cold, replace the pump logic unit
5
6
73 INPUT MISMATCH
7
Control internal error.
Replace the pump logic unit. 9
10
74 EEPROM OFFLINE
11
12
the unit will load the default parameters. 13
If the defect continues after the truck is switched on, replace the pump logic unit.
If the alarm desappears, remember that the parameters previously stored are cancelled and replaced 14
by the default parameters.
15
16
17
18
18
18
18
18
18
4-50
76 SENS MOT TEMP KO

Interrupted or disconnected pump slave motor temperature sensor.
Verify:
- Wiring harness
- Sensor resistive value
AMBIENT TEMPERATURE RESISTANCE TEMP.

(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

4-51
78 MOTOR TEMPERAT

5
Pump slave motor temperature upper to 140C. 2
2
- that the wiring harness circuit of the temperature sensor is correctly connected 2
value (140C see the following table) 4
(K)
-40 -40 0,84 340 359 379 6,48
6
-30 -22 0,83 370 391 411 6,36
-20 -4 0,82 403 424 446 6,26 7
-10 14 0,80 437 460 483 6,16
0 32 0,79 474 498 522 6,07 8
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
9
30 86 0,73 599 626 652 5,79
40 104 0,71 645 672 700 5,69 10
50 122 0,70 694 722 750 5,59
60 140 0,68 744 773 801 5,47 11
70 158 0,66 797 826 855 5,34
80 176 0,64 852 882 912 5,21 12
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 13
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
16
190 374 0,49 1566 1640 1714 9,15
200 392 0,48 1641 1722 1803 9,71 17
210 410 0,47 1719 1807 1894 10,28
220 428 0,46 1798 1893 1988 10,87 18
230 446 0,45 1879 1982 2085 11,47
240
250
464
482
0,44
0,44
1962
2046
2073
2166
2184
2286
12,09
12,73
18
260 500 0,42 2132 2261 2390 13,44
270 518 0,41 2219 2357 2496 14,44 18
280 536 0,38 2304 2452 2600 15,94
290 554 0,34 2384 2542 2700 18,26 18
300 572 0,29 2456 2624 2791 22,12
18
18
4-52
0
79 MASTER WARNING

Internal logic error
7A DATA ACQUISITION

This warning communicates that the logic is in current acquisition phase.
In this phase the logic is not working.
If the alarm persists after the key reset, replace the pump logic unit.
7B NO CAN MSG N

Notice the communicatiun of another board.
Can-bus communication failure. The alarm appears if the logic unit does not receive information from
the MCB board, from the traction logic units, or from the master pump logic unit.
Before to replace every board, verify:
- The dashboard alarms, to identify exactly the board that does not comunicate
- Can-bus pull-up resistance presence
Dashboard 180 Ohm
MCB 180 Ohm
Armrest 180 Ohm
7C MASTER KO

Communication fault from MASTER pump logic unit. The alarm can be originated by:
1. Interferences on the CAN-BUS: in this condition the alarm appears in combination with other
alarms
Check:
- truck insulation
- presence of the antistatic discharger if the truck is equipped with no marking tyres
- verify pump logic unit connectors JCP; all the pins must be in line and not lifted
- verify MCB connector J34 and J40; all pin must be correctly connected
2. Defective logic unit
Check:
- communication between SLAVE pump logic unit and MASTER pump logic unit by the console
YES: see point 1
NO: replace pump logic unit
4-53
MCB BOARD (section EVCB)

"board" is refered to the MCB BOARD
5
A1 DOUBLE REQ - UNUSED
2
A2 RELOAD_PARAM_WARN
2
The alarm signals the occured parameters loading. The truck remains in pre-operational status.
- Switch off and switch on again the truck. 4
5
A3 PARAM. LOAD ERROR
6
The alarm signals that the board has not loaded the memory parameters. The truck remains in pre-
operational status. 8
Switch off and switch on again the truck:
- If the alarm persists, replace the board
- If the alarm disappears, but the truck has a rough behavior replace the board.
9
10
A4 NOT_REP_ERROR
11
The alarm signals that the board is waiting information. The truck remains in pre-operational status.
- Insert the truck serial number (LEARNING function SERIAL NUMBER parameter) 13
Switch off and switch on the truck.
14
A5 CHKSUM_ERROR - UNUSED
15
Error in the board ram 17
- Switch off and switch on the truck
- If the alarm persists, replace the board
18
A6 BOOT_ERROR 18
18
The alarm signals that the board is waiting for information from the traction logic unit or the lifting logic 18
unit. The truck remains in pre-operational status. Verify:
- Alarms on the dashboard to identify which logic unit is not communicating. 18
18
4-54
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 EVP1 lowering solenoid valve. The coil could be opened or
disconnected.
Check:
- Value in Ohm of the coils and the relevant wiring harness (see chapter 15)
If the problem persists replace the MCB board.
A9 EV2_1 OPEN

The alarm signals a failure at the coil of the EVP2 lifting solenoid valve. The coil could be opened or
disconnected.
Check:
AA EV1_2 OPEN

The alarm signals a failure at the coil of the EVP3 backward tilting solenoid valve. The coil could be
opened or disconnected.
Check:
AB EV2_2 OPEN

The alarm signals a failure at the coil of the EVP4 forward tilting solenoid valve. The coil could be
Check:
4-55
AC EV1_3 OPEN

5
The alarm signals a failure at the coil of the EVP6 right sideshift solenoid valve. The coil could be 2
Check:
2
2
AD EV2_3 OPEN 4
5
The alarm signals a failure at the coil of the EVP5 left sideshift solenoid valve. The coil could be 6
Check: 7
If the problem persists replace the MCB board. 8
AE EV1_4 OPEN
9
10
11
The alarm signals a failure at the coil of the EVP7 4th way solenoid valve. The coil could be opened or
disconnected.
Check:
12
14
AF EV2_4 OPEN
15
The alarm signals a failure at the coil of the EVP8 4th way solenoid valve. The coil could be opened or
disconnected. 17
Check:
18
18
B0 TRCB_MICRO_ERROR
18
The alarm signals an internal problem of the MCB board.
- Replace the MCB board. 18
18
4-56
B1 GROUP1 DRIVER SHORT

The alarm signals a failure at one of the coils of the group 1 of the electroproportional oil control valve:
EVP1 lowering solenoid valve or EVP2 lifting solenoid valve.
A coil could be opened or disconnected.
Check:

EVP3 backward tilting solenoid valve or EVP4 forward tilting solenoid valve.
Check:

EVP6 right sideshift solenoid valve or EVP5 left sideshift solenoid valve.
Check:

EVP7 4th way solenoid valve or EVP8 4th way solenoid valve.
Check:
4-57
B5 AUX_OUT_SHORT

5
The alarm signals a failure at one of the coils of the group 5 of the electroproportional oil control valve: 2
EVP9 5th way solenoid valve or EVP10 5th way solenoid valve.
Check:
2
4
B6 DASH_KO
5
The alarm signals a comunication problem between the MCB board and the dashboard.
The alarm remains stored in the logbook of the MCB board alarms. 7
- Replace the dashboard.
8
B7 ERR_SEAT
9
10
The alarm signals the seat micro opened with activated hydraulic functions. 11
B8 JOY_STUFFING_ERR
12
13
14
The alarm signals a communication problem between the MCB board and the armrest board.
Verify:
- The can-bus connections between the MCB board and the armrest board
15
- Armrest board supplying (J CANconnector pin 5 cable C03 and pin 6 cable N)
- Replace the armrest board 16
17
B9 SET_SERIAL_NUMBER
18
The alarm signals the failed automatic serial number setting.
- Insert truck serial number (function LEARNING parameter SERIAL NUMBER) 18
Switch the truck off and on again.
18
18
18
4-58
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 persits, check the potentiometer status and the relevant wiring harness.
4-59
ARMREST BOARD
"board" is refered to the ARMREST BOARD
5
E1 INCORRECT_START
2
2
- Check if one of the potentiometers is activated before to turn the key in the ON position
- Verify by dashboard
2
Enter the function TESTER menu MAT HANDLING and verify the potentiometer status at rest condition
4
LIFTING SWITCH = OFF
TILTING SWITCH = OFF 5
SIDESHIFT SWITCH = OFF
IV WAY SWITCH = OFF
V WAY SWITCH = OFF 6
LIFT LOWER J = 2,5 0,2 V
TILT J = 2,5 0,2 V
7
SIDESHIFT J = 2,5 0,2 V
IV WAY J = 2,5 0,2 V 8
V WAY J = 2,5 0,2 V
Once identificated the potentiometer with different values proceed as follows:
9
reverse the potentiometer with another one of the board (fingertips version)
reverse the lifting potentiometer with the sideshift one or the tilting with the 4th way one (joystick 10
version)
- If the problem remains in the same position replace the board 11
- If the problem is noticed on an different potentiometer (where has been connected the faulty
potentiometer) replace the potentiometer 12
13
14
15
16
17
18
18
18
18
18
18
4-60
E2 BAD LIFT POT

Failure at the P4 lifting potentiometer in the joystick-fingertip group.
Verify the potentiometer status at rest.
Enter the function TESTER menu MAT HANDLING and verify the paramenters LIFTING SWITCH and
LIFT LOWER J.
Rest conditions:
- LIFT LOWER J = 2,5 0,2 V
- LIFTING SWITCH = OFF
If the rest conditions are different the potentiometer could be mechanically blocked or faulty.
Check:
reverse the lifting potentiometer with the tilting one (fingertips version) and verify the correct
functioning by display
reverse the lifting potentiometer with the sideshift one (joystick version) and verify the correct
joystick version fingertip version
If the alarm persists replace the board.

4-61
E3 BAD TILT POT

5
Failure at the P5 tilting potentiometer in the joystick-fingertip group. 2
Enter the function TESTER menu MAT HANDLING and verify the paramenters TILTING SWITCH and
TILT J.
2
Rest conditions:
- TILT J = 2,5 0,2 V 2
- TILTING SWITCH = OFF
4
Check:
reverse the tilting potentiometer with the lifting one (fingertips version) and verify the correct 5
reverse the tilting potentiometer with the 4th way one (joystick version) and verify the correct 6
joystick version fingertip version 7

8
9
10
11
12
13
14
15
16
If the alarm persists replace the board
17
18
18
18
18
18
18
4-62
E4 BAD SIDESH. POT

Failure at the P6 sideshift potentiometer in the joystick-fingertip group.
Enter the function TESTER menu MAT HANDLING and verify the paramenters SIDESHIFT SWITCH
and SIDESHIFT J.
Rest conditions:
- SIDESHIFT J = 2,5 0,2 V
- SIDESHIFT SWITCH = OFF
Check:
reverse the sideshift potentiometer with the tilting one (fingertips version) and verify the correct
reverse the sideshift potentiometer with the lifting one (joystick version) and verify the correct

4-63
E5 BAD IV POT

5
Failure at the P7 4th way potentiometer in the joystick-fingertip group. 2
Enter the function TESTER menu MAT HANDLING and verify the paramenters IV WAY SWITCH and
IV WAY J.
2
Rest conditions:
- IV WAY J = 2,5 0,2 V 2
- IV WAY SWITCH = OFF
4
Check:
reverse the 4th way potentiometer with the sideshift one (fingertips version) and verify the correct 5
reverse the 4th way potentiometer with the tilting one (joystick version) and verify the correct 6
joystick version fingertip version 7

8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-64
E6 BAD V POT

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

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

Incompleated restore of the parameters. Repeat the operation.
4-65
E9 EEPROM_CHKSUM_ERR

5
Eprom data loading unsuccessuful. 2
If the alarm persists at the key reset, replace the board.
2
EA DEFAULT RESTORED
2
Flash memory data loading. Switch the truck off and ON twice.
5
EB POT NOT ACQUIRED
6
7
Flash memory data loading. Switch the truck off and off again.
8
9
EC RAM_CHKSUM_ERR
10
RAM data loading unsuccessuful.
If the alarm persists at the key reset, replace the board. 12
13
ED MHYRIO_STUFFING_ERR
14
The logic unit has a communication problem with the MCB board (EVCB) unit.
Check the other alarms on the dashboard. 16
17
EE PUMP_STUFFING_ERR
18
The logic unit does not receive the information from the lifting logic unit.
If the armrest is not present, the alarm is sent by the MCB board. 18
18
18
18
4-66
EF FW + BW

Balanced switch on armrest faulty. Verify:
- The connections of the JAUX wiring harness, joystick board. Replace the balanced switch.
4-67
DASHBOARD
"board" is refered to the DASHBOARD
5
D1 TRAC_KO
2
2
This alarm signals that the traction logic unit is not communicating.
Check:
- The supplying: 80V must be present in the connector JAT pin 33 cable M03 of the traction logic unit
2
- The can-bus connections
If the supply is ok, but it does not permit the truck working, replace the traction logic unit. 4
5
D2 MCB_TRAC_KO
6
This alarm signals that the MCB logic unit is not communicating.
Check: 8
- The supplying: 24V must be present in the connector J40 pin 13 cable C01 of the MCB board
- The can-bus connections 9
If the supply is ok, but it does not permit the truck working, replace the MCB boardt.
10
D4 PUMP_KO
11
This alarm signals that the pump logic unit is not communicating. 13
Check:
- The supplying: 80V must be present in the connector JCP pin 3 cable M03 of the pump logic unit
- The can-bus connections 14
If the supply is ok, but it does not permit the truck working, replace the pump logic unit.
15
D5 MCB_MHY_KO 16
17
This alarm signals that the MCB logic unit is not communicating. 18
Check:
- The supplying: 24V must be present in the connector J40 pin 13 cable C01 of the MCB board 18
If the supply is ok, but it does not permit the truck working, replace the MCB board.
18
18
18
18
4-68
D6 JOY_KO

This alarm signals that the (JA/FA) armrest logic unit is not communicating.
(FA: fingertips version - JA: joysticks version)
- The supplying: 24V must be present in the connector JCAN pin 5 cable C01 of the armrest board
If the supply is ok, but it does not permit the truck working, replace the armrest board.
D8 ERROR READ PIN

This alarm signals that the MCB board does not permit the password reading.
It is the MCB section that manages the signals
- The supplying: 24V must be present in the connector J40 pin 13 cable C01 of the MCB board.
Replace the MCB board.
DC HYDRO_KO

This alarm signals that the Slave pump logic unit is not communicating.
Check:
- The supplying: 80V must be present in the connector JCP pin 3 cable M03 of the pump logic unit
If the supply is ok, but it does not permit the truck working, replace the pump logic unit.
DF EEPROM ERROR

Error during the eepreom data uploading
Fault in memory area where the adjustment parameters are registered.
When the alarm desappears the parameters previously stored will be cancelled and automatically the
dashboard default parameters will be loaded.
4-69
MCB BOARD (section TRCB)

"board" is refered to the MCB BOARD
5
C1 INCORRECT START
2
2
Check:
- The forward and backward microswitches and the relevant cables
2
-The parking brake microscwitch and the relevant cables
4
C2 BAD_CONF_WHEELS - UNUSED 5
6
C3 PEDAL WIRE KO
7
Failure at the accelerator potentiometer at rest. Check:
- Steering potentiometer that could be damaged 9
- The traction potentiometer wiring harness
10
11
12
13
14
15
16
17
18
18
18
18
18
18
4-70
C4 BAD MICROSWITCH

The pedal microswitch or the manual direction lever is broken.
C5 WARN_CONF_ERROR - UNUSED
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 fuction is activated while the seat microswitch is opened.
4-71
C9 PARKING_SELECTED

5
One of the function is activated while the parking brake is applied. 2
CA PARAM. LOAD ERROR

2
2
4
The alarm appears when the truck is switched on or if the change progam button is pressed.
Replace the MCB logic unit.
5
CC TRAC_STUFFING_ERROR
6
7
Problem of communication with the traction logic unit.
8
The alarm disappears after the key reset.
If the alarm appears frequently and blocks the truck, check the can-bus connections between the trac- 9
tion logic unit and MCB.
10
CF FW + BW 11
12
Double request activated. 13
The backward/forward direction microswitches are closed at the same time.
14
93 NOT_REP_ERROR 15

16
The alarm signals that the MCB board is waiting informations. The truck remains in pre-operational 17
status.
- Insert the truck serial number (LEARNING function SERIAL NUMBER parameter)
Switch the truck off and on.
18
18
94 CHKSUM_ERROR
18
Software error.
Replace the board. 18
18
4-72
WEI SEITE

5-1
MOTORS
DRIVE MOTOR ........................................................................................................ 3
2
GENERAL ................................................................................................................ 3
TEMPERATURE SENSOR REPLACEMENT (TRACTION MOTOR)...................... 7
2
ENCODER REPLACEMENT (TRACTION MOTOR) .............................................. 8 2
ENCODER................................................................................................................ 10 3
PUMP MOTORS....................................................................................................... 11
5
GENERAL ................................................................................................................ 11
TEMPERATURE SENSOR REPLACEMENT (PUMP MOTORS) ........................... 15 5
ENCODER REPLACEMENT (PUMP MOTORS)..................................................... 16 6
ENCODER................................................................................................................ 18
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
5-2
WEI SEITE

5-3
DRIVE MOTOR
GENERAL
2
2
2
3
5
5
6
7
8
9
SPECIFICATIONS
10
TRACTION MOTOR
RATED OUTPUT POWER 27,1 kW

11
DIMENSIONS 348 546 12
NOMINAL VOLTAGE 53 V (AC)
13
NOMINAL MAX. CURRENT 371 A
FREQUENCY 42 Hz
14
POWER FACTOR (cos phi) 0,92 15
INSULATION CLASS 00 16
PROTECTION CLASS (IP) 43
17
SERVICE S2 60
POLES NUMBER 4 18
R.P.M. 1205 rpm 18
18
18
18
18
5-4
2
2
2
3
5
5
6
7
8
1. Park the truck on a level surface and apply the parking brake
2. Switch off the truck 10
3. Open the front battery cover, disconnect the battery plugs and remove the front battery
4. Remove the footboard mat and the footboard 11
5. Remove all the pedals (accelerator and brake)
6. Disconnect the power cables and the auxiliary wiring harness connectors from the traction and pump
logic units
12
7. Disconnect the air conveyor for the logic unit cooling
8. Hook the logic units support plate with a suitable chain to a bridge crane, unscrew the fixing bollts 13
and remove the group (plate + logic units)
9. Disconnect the thermic sensor and the encoder connectors [POINT 1] 14
10. Insert and screw on an eyebolt in the concerned threaded hole, in the middle of the motor, hook the
eyebolt by a chain to the bridge crane, pull the chain until tightened [POINT 2]
11. Remove the motor fixing nuts to the shock absorbers [POINT 3]
15
12. Remove the motor fixing bolts to the traction group
13. Lift the motor from the frame paying attention to the plastic cross joint integrity 16
14. Recover the plastic cross joint from the motor shaft [POINT 4]
17
The reassembly procedure is the reverse of the disassembly procedure 18
18
18
18
18
18
5-5
Point Operations
[POINT 1]
Disassembly
Disconnect the thermic sensor and the encoder
2
connectors.
2
2
3
[POINT 2] 5
Disassembly
Insert and screw on an eyebolt in the threaded hole B,
in the middle of the motor, hook the eyebolt by a chain
5
B
to the bridge crane, pull the chain until tightened
6
7
d
[POINT 3]
Disassembly 8
Remove the motor fixing nuts C to the shock
absorbers 9
10
C
11
[POINT 4] 12
Disassembly
Recover the plastic cross joint D from the motor shaft 13
14
D
15
16
D 17
18
18
D 18
18
18
18
5-6
INSPECTION
Inspection:
1. Measure the insulation resistance of the stator.
2
Measurement terminals: between motor cable and
body 2
Standard: 10 M or more
2
3
5
2. Check continuity between motor cables:
Measurement terminals: U-V, V-W, W-U: 0
5
6
7
8
9
10
3. Measure the resistance of the thermo-sensor. 11
Measurement terminals:
Both terminals of temperature sensor connector 12
Standard: 0
(see table reported in chapter 04, alarm no. 12: 13
MOTOR TEMPERATURE)
14
15
16
17
18
18
18
18
18
18
5-7
TEMPERATURE SENSOR REPLACEMENT (TRACTION MOTOR)

1. Park the truck on a level surface and operate the 2
parking brake
3. Remove the traction motor (see the appropriate
2
section)
4. Mark the position of the back cover as regards the 2
stator
5. Take off the pins from the temperature sensor 3
connector
6. Loosen and remove the 12 fixing Alen screws 5
7. Remove the cover,
8. Let slide out the sensor cable through the cover hole
B 5
9. Cut the damaged sensor wiring close to the motor
carcass 6
B 7
8
9
10
11
1. Position the new sensor A on the motor winding and
12
fix it with silicone paste (see Service Tools List)
2. Let slide in the sensor cable through the cover hole 13
3. Assemble the cover as according the markings made
on the cover and the stator during the disassembly; 14
pay attention to the status of the bearing
4. Screw the 12 fixing Alen screws 15
5. Insert the sensor pins into the temperature sensor
connector
A 6. The traction motor reassembly procedure is the
16
reverse of the disassembly procedure (see the
appropriate section) 17
18
18
18
18
18
18
5-8
ENCODER REPLACEMENT (TRACTION MOTOR)
1. Park the truck on a level surface and operate the parking brake
3. Open the battery cover and disconnect the battery
4. Remove the front battery
5. Remove the encoder connector A from its support
6. Disconnect the encoder connector A from the auxiliary wiring
7. Unscrew the encoder B from its seat
5-9
The reassembly procedure is the reverse of the disassembly procedure
Warning: 2
Take care that the new encoder is fitted correctly, with the black point A aligned according with
the motor motion, as shown in the picture below 2
2
3
5
5
6
7
C
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
5-10
ENCODER
The encoder generates feedback signals from the motor
and send them to the control logic unit, monitoring the
motor state, the R.P.M and the sense of rotation.
The encoder is positioned in the traction motor back part.
Encoder
Encoder connector
Pin 1 brown (+)
Pin 2 green (-)
Pin 3 yellow (A signal)
Pin 4 white (B signal)
Irreversible damages:
+V > 13Volts
Short circuit between the signal and the power supply
Heating by induction
Assembly with hammer
Direction of the gear wheel motion

in FW march
Channel image on oscilloskope:

FW march
BW march
Time
Channel B / Wire:white
Channel A / Wire:yellow
5-11
PUMP MOTORS
GENERAL
2
2
2
3
5
5
6
7
SPECIFICATIONS 8
PUMP MOTORS 9
RATED OUTPUT POWER 20 kW
10
DIMENSIONS 218 420
NOMINAL VOLTAGE 50 V (AC) 11

NOMINAL MAX. CURRENT 350 A 12
FREQUENCY 85 Hz
13
POWER FACTOR (cos phi) 0,9
INSULATION CLASS F
14
PROTECTION CLASS (IP) 20 15
SERVICE S3 22 %
16
POLES NUMBER 4
17
R.P.M. 2450 rpm
PUMP CAPACITY 19 l/m at 1000 rpm 18

18
18
18
18
18
5-12
RIGHT PUMP MOTOR

LEFT PUMP MOTOR
3. Disconnect the battery
4. Remove the concerned side compartment cover
5. Disconnect motor power cables, encoder and temperature sensor connectors
6. Remove the pump fixing bolts and remove the concerned pump [Point 1]
7. Unscrew and remove the motor support fixing bolts to the frame [Point 2]
8. Insert 2 eyebolts with a chain, lift and remove, by a bridge crane, the concerned
pump motor [Point 3]
5-13
The reassembly procedure is the reverse of the disassembly procedure, taking care that the motor
cables are fitted correctly as illustrated below:
2
Left pump motor (MASTER, contol valve)
WM VM UM Power cable UM connected to phase U
Power cable VM connected to phase V
2
Power cable WM connected to phase W
2
Right pump motor (SLAVE steering)
Power cable US connected to phase U 3
Power cable VS connected to phase V
Power cable WS connected to phase W 5
To fix the power cable lugs to the motor terminals, the nuts
W V U
tightening torque is 15 Nm 5
Points of operation 6
[Point1 ] 7
Removal:
Remove the pump fixing bolts and remove the pump 8
pump fastening screws 45 Nm (do not remove)
9
10
screws fastening pump to motor 45Nm 11
12
[Point 2]
D Unscrew and remove motor support fixing bolts D 13
from the frame
D
14
15
16
17
[Point 3]
Insert the 2 eyebolts (C) with the chain and lift the 18
C motor by a bridge crane
C 18
18
18
18
18
5-14
INSPECTION
Inspection:
1. Measure the insulation resistance of the stator.
Measurement terminals: between motor cable and
body
Standard: 10 M or more
2. Check continuity between motor cables:

Measurement terminals: U-V, V-W, W-U: 0
3. Measure the resistance of the thermo-sensor.

Measurement terminals:
Both terminals of temperature sensor connector
Standard: 0
(see table reported in chapter 04, alarm no. 47 or 76:
SENS MOT TEMP KO)
5-15
TEMPERATURE SENSOR REPLACEMENT (PUMP MOTORS)

1. Park the truck on a level surface and apply the parking 2
brake
2
4. Remove the left or right pump motor
5. Mark the position of the cover (item 400) with regards 2
to the stator
6. Loosen the four M8 Alen screws (item 515) and 3
remove the cover (item 400)
7. Cut the motor power cables fastening wrappers 5
8. Cut the damaged sensor wiring close to the motor
carcass
5
A
1. Position the new sensor (A) on the motor winding and 6
fix it with silicone paste (see Service Tools List)
2. Crimp the pins to the sensor wires 7
3. Insert the sensor wiring pins into the connector
4. The reassembly procedure is the reverse of the
disassembly procedure, paying attention that the
8
power an the sensor cables must be mounted
correctly 9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
5-16
ENCODER REPLACEMENT (PUMP MOTORS)
1. Park the truck on a level surface and operate the parking brake
4. Remove the left and/or right pump motor
5. Mark the position of the cover (item 300) and of the opposite cover (item 400) as regards the stator
(item 51)
6. Loosen the four M8 Alen screws (item 515) and remove the cover (item 400)
7. Extract the encoder (item 500) from the rotor (item 700) using an appropriate extractor
Note:
For the encoder extraction use a separator extractor type
Warning:
During the extraction be sure to act only on the bearing involved parts excluding the encoder
parts
5-17
1. Insert the new encoder (item 500) into the rotor shaft
(item 700) axle and push on its inner ring with a slight 2
pressure up to the attainment of the correct position.
For this purpose use a bushing. 2
2. Insert the cover (item 400) on the encoder (item 500),
placed on the rotor (item 700) axle, according to the 2
marked position between of the stator (item 51) and
the cover. Push it slightly up to the attainment of the
correct position. 3
Warning:
In the lifting motor, to prevent any contact between the
5
cables with the rotor and any compression, drive them
through the proper cover hole 5
6
7
3. Fit the cover (item 400) screwing the 4 cylindrical M8
screws (item 515) with a tightening torque = 20 Nm 8
4. Crimp the pins to the sensor wires
5. Insert the sensor wiring pins to the connector 9
6. Reassembly the left and/or the right pump motor
10
11
12
13
14
15
16
17
18
18
18
18
18
18
5-18
ENCODER
The encoder generates feedback signals from the motor
and send them to the control logic unit, monitoring the
motor state, the R.P.M and the sense of rotation.
The encoder has positioned in the bearing mounted in the
motor back part.
ENCODER
Encoder signals connector

Irreversible damages:
+V > 13Volts
Short circuit between the signal and the power supply
Heating by induction
Assembly with hammer
6-1
FRONT AXLE
FRONT AXLE....................................................................................................... 3
2
GENERAL ............................................................................................................ 3
COMPONENTS.................................................................................................... 4
2
DRIVE UNIT HUB ................................................................................................ 5 2
PLANETARY GEAR............................................................................................. 8 3
FRONT AXLE GROUP ........................................................................................ 9
2
6
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
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18
6-2
WEI SEITE

6-3
FRONT AXLE
GENERAL
2
2
2
3
2
6
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
6-4
COMPONENTS
6-5
DRIVE UNIT HUB

2
2
2
3
2
6
6
7
8
9
10
11
3. Open the front battery cover and disconnect the battery plugs
4. Jack up the front part of the vehicle and place wooden or metallic blocks under the chassis. Block the 14
steering wheels by wedges [Point 1]
5. Remove the front wheels
6. Remove the oil from the hub [Point 2]; let il flow into suitable containers
15
7. Remove the hub [Point 3]
16
The installation procedure is the reverse of the removal procedure 17
18
18
18
18
18
18
6-6
Point Operations
[Point 1]
Disassembly:
Jack up the front part of the vehicle and place wooden
or metallic blocks A under the chassis. Block the
steering wheels by wedges B
A B
[Point 2]
Disassembly:
Remove the oil from the hub:
Turn the hub until plug C reaches the lowest position.
Remove the plug and let flow out all the used oil in a
suitable container with a capacity of ~ 10 liters
Reassembly:
Rotate the hub of 90 in counterclockwise direction
until the hole of the plug C is in the middle of the axle.
Fill with new oil, of the same type of the old one, from
C the plug C hole, until the oil grazes the hole inferior
edge. If the hub is completely empty, around 2 kg of oil
are needed. (each hub). Mount again the plug C with
its washer.
Control of the oil levels
Check the oil levels with cold vehicle to avoid that the
oil in circle induces an inappropriate oil refill
[Point 3]
Disassembly:
Remove the screws 1 fixing the planet carrier 2 to the
wheel hub . Extract the planet carrier 2 of approx. 15
mm from the hub.
If completely extracted, the planet spider group can fall
down to the ground. It weighs about 25 kg. Support it
with appropriate tools. Support the planetary drive
with a sling, hold it allined with the hub and extract it
completely.
Pull out the sun gear 3 and the axle shaft 4
Remove the screws 5, the flange 6 and the adjusting
shims.
Maintain the hub 7 (it weighs approx. 17kg) in position
and pull out the crown 8 and the crown plate 9 from the
seat 10.
Slide out the hub from the seat supporting it with a
sling and a crane. Be careful because the bearing
can fall down and pay attention to not ruin the oil
splash guard 11.
The hub weighs about 30 kg.
6-7
Reassembly:
Insert the O-ring seal 8 on the spindle 7. Clean and
degrease the seal. Insert the wear sleeve 9. Mount 2
the bearing 6 on the spindle. Mount the bearing cone
6 and the oil seal 10 on the wheel hub 11. Insert the
hub on the spindle 7, taking care to prevent damage
2
to the oil seal 10. Insert the bearing cone 14 on the
hub. Mount the crown 17 on the crown plate 12 2
and block them together with the retaining ring 16.
Mount the bearing 14 on the crown plate 12 and 3
insert the crown plate on the spindle. Put in place the
adjusting shims 4 and the flange 9 and to block the 2
flange with the screw 5. Tighten the screws 5 to the
torque of 120 Nm and check for taper bearings
adjustment by turning the wheel hub. The bearing 6
adjustment is correct if the resistant torque is about
28-32 Nm. Otherwise increase or decrease the 6
adjusting shims until this value is reached.
Note: a higher preload causes overheating and a 7
rapid bearings damaging.
Remove the screws 5, clean them and apply medium
strength threadlocker on their threads. Mount them
8
and tighten to the specified torque of 120 Nm.
Mount the sun gear 3 on the axle shaft 1. 9
Screw the bolt 15 with threadlocker on it.
Insert the axle shaft, matching the differential teeth. 10
Fit the O-ring seal on the wheel hub 13.
Insert the planet carrier group, slightly turning it to
match the gears.
11
Mount the two M12 screws 15 fixing the hub 11 to the
planetary gear with threadlocker on the thread. 12
13
14
15
16
17
18
18
18
18
18
18
6-8
PLANETARY GEAR
DISASSEMBLYREASSEMBLY
34
7 5
1. Execute the DRIVE UNIT HUB disassembly procedure
2. Remove the three snap rings 1 of arrest of the three satellit gear support pins
3. Remove the three satellit gear support pins 2 by the suitable extractor
4. Remove the satellit gears 3 (three satellit gears each pin), spacer rings 4, needles 5, and external
thrust washers 6.
1. Check that the three satellit gears 3 are perfectly clean. Spread their central holes with a film of hard
grease. Use grease type FINA MARSON EPL 3, NLGI:3 degree or equivalent..
2. Position the needles 5 inside the gears 3 so that it's fully filled, placing a spacer ring 4 between each
row of needles.
3. Insert the three pins 2 into the spider holes 7
4. Insert on the pin the thrust washers and the gears. Position the external thrust washers pos.6.
5. Insert the snap rings 1
6. Execute the DRIVE UNIT HUB reassembly procedure
6-9
FRONT AXLE GROUP

2
2
2
3
2
6
6
7
8
1. Park the truck on a level surface and apply the parking brake 9
3.
4.
Open the front battery cover, disconnect the battery plugs
Remove the forks and the mast (see chapter 12f)
10
5. Jack up the front part of the vehicle and place wooden or metallic blocks under the chassis. Block
the steering wheels by wedges [Point 1] 11
6. Remove the front wheels
8. Remove all the pedals (accelerator and brake)
9. Insert and screw on an eyebolt in the traction motor threaded hole, in the middle of the motor, hook 13
the eyebolt by a chain, to the bridge crane, pull the chain until it is tightened [Point 2]
10. Support the traction motor weight placing a wooden block between the traction motor and the
chassis.
14
11. Remove the motor fixing bolts to the traction group
12. Remove pipes and wirings from axle brakes 15
13. Place a transpallet under the front alxle. Place a wooden block on the transpallet forks to support the
front axle flange [Point 3]. Lift the front axle group 16
14. Unscrew all the bolts fixing the front axle to the chassis [Point 4] and remove the axle paying
attention to the plastic cross joint integrity [Point 5] 17
The installation procedure is the reverse of the removal procedure 18
18
18
18
18
18
6-10
Point Operations
[Point 1]
Disassembly:
Jack up the front part of the vehicle and place wooden
or metallic blocks A under the chassis. Block the
steering wheels by wedges B
A B
[Point 2]
Disassembly
Insert and screw an eyebolt in the threaded hole C, in
the middle of the motor, hook the eyebolt by a chain,
C to the bridge crane, pull the chain until tightened
[Point 3]
Disassembly:
Place a transpallet under the front alxle. Place a
wooden block D on the transpallet forks to support the
front axle flange
[Point 4]
E Disassembly
Unscrew all the 18 E bolts (9 in the lelt side and 9 in
the right side) fixing the front axle to the chassis
Reassembly:
After the installation, tightening torque for the 18 E
fixing bolts = 900 Nm
6-11
[Point 5]
Disassembly
Pay attention to the plastic cross joint F integrity. 2
2
2
F 3
2
F
6
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
6-12
WEI SEITE

7-1
REAR AXLE
REAR AXLE......................................................................................................... 3
2
GENERAL ............................................................................................................ 3
REAR AXLE CYLINDER ..................................................................................... 3
2
SPECIFICATIONS................................................................................................ 5 2
REAR AXLE......................................................................................................... 6 3
GENERAL ............................................................................................................ 6
4
COMPONENTS.................................................................................................... 6
CONTROL OF REAR AXLE ................................................................................ 7 5
STEERING STROKE END ANGLE ADJUSTMENT ........................................... 7 6
STEERING POTENTIOMETER ........................................................................... 10
7
SPEED REDUCTION IN A BEND........................................................................ 12
8
9
10
11
12
13
14
15
16
17
18
18
18
18
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18
7-2
WEI SEITE

7-3
REAR AXLE
GENERAL
2
2
2
3
4
5
6
7
8
9
REAR AXLE CYLINDER
10
11
12
13
14
15
16
17
18
18
18
18
18
18
7-4
DISASSEMBLYINSPECTIONREASSEMBLY
1. Remove the piston rod guide
2. Remove the piston rod [Point 1]
3. Inspect the cylinder [Point 2]
Note:
Coat hydraulic oil before reassembly.
Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
Standard: 75 mm
Limit: 74,94 mm
Inspection:
Measure the bend of the piston rod.
Limit: 0.2 mm (0.020 in)
Reassembly:
Warm the seal ring to a little below 80C (176F) in hot
oil or water before installation. Do not stretch it
excessively.
Caution:
Operation carefully to avoid scalding.
[Point 2]
Inspection:
Measure the rear axle cylinder.
Standard: 105 mm
Limit: 105,09 mm
7-5
SPECIFICATIONS
Rear axle type Elliot type

Rear axle suspension type Center-supported right-left rocking type
2
Toe-in mm min 0 - max 13 2
Wheel alignment
Camber degree 1 each side
2
Maximum turning radius (outermost) degree 75
Cylinder type Double acting 3
Rear axle cylinder Piston rod outsidediameter mm 75 4
Cylinder boremm (in) 105
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
7-6
REAR AXLE
GENERAL
COMPONENTS
7-7
CONTROL OF REAR AXLE

Every 1000 hours
C lubricate the steering group articulations, using the 2
appropriate grease nipples (C)
control the steering locks
check the conditions of the wheel hub bearings and
2
adjust them if necessary
2
C 3
4
If any abnormal wear on the wheel tread is noticed, carry out the following controls:
check the parallelism of the steered wheels 5
check that wheel lock is the same on both directions
STEERING STROKE END ANGLE ADJUSTMENT
6
REAR AXLE 7
8
9
10
11
12
13
(1) Drive the steering cylinder to the stroke end 14
(2) Check the steering angle as shown in the picture
above 15
(3) To vary the steering stroke end angle, act on the
grub screw (A):
Std value 70 16
(4) Repeat the same operation on the other wheel
17
A
18
STEERING
POTENTIOMETER
SHAFT 18
18
18
18
18
7-8
3. Open the compartment and disconnect the battery
4. Lift the rear part of the vehicle and place shims under the chassis [Point 1]
5. Disconnect the pipes of the steering axle cylinder and plug them
6. Disconnect the potentiometer connector from the wiring harness [Point 2]
7. Keep the steering axle raised with a transpallet
8. Loosen and remove the fixing screws [Point 3]
9. Remove the steering axle
7-9
Point Operations
[Point 1]
Disassembly: 2
Lift the rear part of the vehicle and place wooden or
metallic blocks under the chassis
2
2
3
[Point 2] 4
A Disassembly:
Disconnect the potentiometer connector (A) from the 5
wiring harness
6
7
8
[Point 3]
Disassembly:
Loosen and remove the 4 axle fixing screws B
9
Reassembly: 10
After the installation, tightening torque for the 4 screws
= 545 Nm
B 11
12
13
14
15
16
17
18
18
18
18
18
18
7-10
STEERING POTENTIOMETER
1. Disconnect the potentiometer connector from the auxiliary wiring
2. Remove the potentiometer cover fixing screws [Point 1]
3. Remove the potentiometer from the axle [Point 2]
4. Remove the potentiometer fixing screws from his support [Point 3]
7-11
Point Operations
[Point 1]
Disassembly: 2
Remove the potentiometer cover fixing screws
2
2
3
4
[Point 2]
Disassembly:
5
Remove the potentiometer from the axle
6
7
8
9
[Point 3] 10
Disassembly:
Remove the potentiometer fixing screws from his 11
support (foto P1010012)
12
13
14
15
16
17
18
18
18
18
18
18
7-11
Point Operations
[Point 1]
Disassembly: 2
Remove the potentiometer cover fixing screws
2
2
3
4
[Point 2]
Disassembly:
5
Remove the potentiometer from the axle
6
7
8
9
[Point 3] 10
Disassembly:
Remove the potentiometer fixing screws from his 11
support (foto P1010012)
12
13
14
15
16
17
18
18
18
18
18
18
8-1
STEERING
STEERING SYSTEM ........................................................................................... 3
2
GENERAL ............................................................................................................ 3
HYDRAULIC DIAGRAM ...................................................................................... 4
2
STEERING COMMAND ....................................................................................... 5 2
POWER STEERING (ORBITROL) ...................................................................... 6 3
SPECIFICATIONS................................................................................................ 6
2
DYNAMIC POWER STEERING........................................................................... 7
TROUBLESHOOTING ......................................................................................... 7 2
POWER STEERING (ORBITROL) ...................................................................... 9 2
STEERING UNIT (ORBITROL)............................................................................ 11
8
CHECKING SEALS AND CLEANING THE POWER STEERING SYSTEM ....... 11
8
INSPECT AND ADJUST THE PRESSURE RELIEF VALVE............................... 11
MASTER VALVE .................................................................................................. 12 9
GENERAL HYDRAULIC DIAGRAM.................................................................... 13 10
MASTER VALVE HYDRAULIC DIAGRAM.......................................................... 14
11
12
13
14
15
16
17
18
18
18
18
18
18
8-2
WEI SEITE

8-3
STEERING SYSTEM
GENERAL
2
2
2
3
2
2
2
8
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
8-4
LEGEND:
1 = oil filter
2 = pump
3a = brake priority valve
3b = steering priority valve
4 = orbitrol
5
5 = negative brake
6 = oil tank
7 = solenoid valve
HYDRAULIC DIAGRAM
8 = brake valve
A = slave pump
B = master pump
4
5
TO OIL CONTROL VALVE

FROM OIL CONTROL VALVE
3a
8
3b
2
2
6 6
6 6 6
8-5
STEERING COMMAND
The steering uses the same oil as the lifting by means of the steering priority valve (inside the master
valve).
The oil flow is delivered from the 2 pumps to the steering priority valve so that there is always a sufficient
oil flow to the power steering.
The flow rate partition is controlled by the LS (Load-Sensing) signal from the steering unit and it happens
so that the flow rate sent to the power steering is equal to its real requirement.
The exceeding delivery is sent to the control valve for other functions.
When the steering wheel is turned, the steering unit measures an oil volume proportional to the rotation
and sends it to the steering cylinder. The steering unit automatically goes back into its neutral position
when the manoeuvre is ended.
The steering wheel hardness depends proportionally from the truck traction speed, as shown in the
diagram here below.
Increasing the traction speed the pump R.P.M. decrease.
This allows an improvement of the truck speed control.
Traction speed [Hz] Steerig pump speed [Hz]

0 38
40 38
100 30
110 30
40
Steerig pump speed [Hz]
35
30
25
20
15
10
0 20 40 60 80 100 120
Traction speed [Hz]]

8-6
POWER STEERING (ORBITROL)
SPECIFICATIONS
Load capacity
60 - 70 - 85
Parts
Steering wheel diameter mm 360
Steering wheel clearence mm 20 ~ 50
Power steering (orbitrol) type Dynamic
Oil flow rate: lmin 24
Dynamic power steering
Maximum pressure: Bar ~ 160
8-7
DYNAMIC POWER STEERING

TROUBLESHOOTING
Only hydraulic related items are listed. 2
Symptom Probable cause Action
2
The piping is damaged Replace
The steering wheel cannot
be rotated
The shaft from the steering wheel to the
Inspect and adjust or 2
power steering is incorrectly installed or
replace
damaged 3
Tyre pressure is low Adjust the tyre pressure
Inspect and adjust the 2
The oil pressure does not rise
The steering wheel is heavy pressure relief valve(**)
The high and low pressure pipes are 2
Correct or replace
connected in reverse
The high and low pressure pipes are
2
Correct or replace
connected in reverse
8
The oil pressure does not Pressure relief valve faulty or not closed Inspect and correct
rise
Oil pump function is deteriorated
replace
Hydraulic oil level is low Add 9
Tyre pressure is low Adjust the tyre pressure
The steering wheel does not 10
Correct or replace the
return properly into The orbitrol shuttle does not move easily
orbitrol
neutral 11
The rear axle does not move smoothly Add lubricant or correct
The orbitrol shuttle does not move easily

Correct or replace the 12
orbitrol
The steering wheel pulls to The steering valve drive shaft is 13
Replace the steering valve
one side when released damaged
The piping is blocked (crushed or Inspect and correct or
14
clogged) replace
Oil moves in the steering valve Replace the steering valve
15
The orbitrol shuttle does not move easily
Correct or replace the 16
Play is excessive and the orbitrol
vehicle wobbles
Air is sucked from the piping
replace
The steering shaft is defective Correct or replace 18
The steering wheel
shimmies
The shaft is not installed correctly Correct or replace 18
The tyres are steered
opposite to the steering
The piping to the hydraulic motor is Inspect and correct the pipe 18
connected in reverse connections
wheel operated direction
18
18
18
8-8
Symptom Probable cause Action

Check and adjust the
The pressure relief valve is defective
pressure
Inspect and adjust or
Abnormal noise is generated Air is sucked from the piping
replace
The piping is blocked (crushed or Inspect and correct or
clogged) replace
The steering wheel is heavy damaged priority valve (obstructed,
Inspect or replace
to rotate clogged or out of order)
8-9
POWER STEERING (ORBITROL)

2
2
2
3
2
2
2
8
8
9
10
11
12
13
14
15
16
17
1. Park the truck on a level surface and activate the parking brake 18
2. Lift the forks for 1,5 2 m to facilitate the power steering replacement [Point 1]
5. Remove the front cover
6. Empty the steering oil circuit 18
7. Disconnect the pipes
8. Remove the power steering (orbitrol) by unscrewing the 4 support fixing screws [Point 2] 18
18
Notes: 18
Add grease to the coupling between the steering shaft and steering valve using paste type
CASTROL OPTIMOL T WHITE.
8-10
Point Operations
[Point 1]
Disassembly:
Lift the forks for 1,5 2 m to facilitate the power
steering replacement
[Point 2]
Disassembly:
Remove the power steering unscrewing the support
fixing screws (B)
B
B
8-11
STEERING UNIT (ORBITROL)

CHECKING SEALS AND CLEANING THE POWER STEERING SYSTEM
Every 1000 hours 2
check the entire system, to identify any leaks; any
F intervention must be carried out without pressure in the 2
system
Every 5000 hours 2
replace the hoses connecting (F) the power steering to
the steering cylinder 3
Every 10 000 hours
replace the hydraulic piping system 2
INSPECT AND ADJUST THE PRESSURE RELIEF VALVE

2
1. Open the right side compartment 2
A
2. Connect a pressure gauge on the pump pressure point
(A) 8
3. 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
8
4. Open the right side compartment
5. Connect a pressure gauge on the pump pressure point 9
(A)
6. When the steering wheel is rotated until the stroke 10
A end, relief state is achieved, so read the pressure on
the pressure gauge at that time 11
12
13
14
Standard
B
Bar Max. 160
15
7. If the relief pressure is greater or lower than the

16
standard value, adjust the orbitrol setting screw (B)
17
18
18
18
B
18
18
18
8-12
MASTER VALVE
This group is an exchange valve which divides the master pump oil flow for different applications
according to the following priorities:
1. Steering
2. Accumulator for brake system
8-13
GENERAL HYDRAULIC DIAGRAM
SLAVE PUMP
FROM MASTER & SLAVE PUMP 2
2
P MASTER PUMP
EF 2
3
2
2
2
TO BRAKES & NEGATIVE BRAKES 8
R
R 8
X
N
T 9
B
10
11
12
ACCUMULATOR
13
14
15
16
TO STEERING POWER
17
18
ST 18
18
LS ST
18
18
18
8-14
MASTER VALVE HYDRAULIC DIAGRAM
Orbitrol LS
Orbitrol ST
Brake Pedal
OCV
Master Pump
Slave Pump
Negative
Brake
Oil Tank
8-15
2
2
2
3
2
2
2
8
8
9
2. Lift the forks for 1,5 2 m to facilitate the master valve replacement; please refer to paragraph
11
"OPERATION ON THE MAST [Point 1]
3. Switch the truck off 12
5. Remove the front cover and the footboard 13
6. Empty the oil circuit
7. Disconnect the pipes and the wiring harness from the pressure switch and solenoid valve. 14
8. Unscrew the 3 fixing screws and remove the master valve from the truck [Point 2]
9. Remove the accumulator pressure switch
10. Remove the solenoid valve 15
11. Remove the accumulator charging valve
12. Remove the master priority valve 16
18
18
18
18
18
18
8-16
Point Operations
[Point 1]
Disassembly:
Lift the forks for 1,5 2 m to facilitate the power
steering replacement
[Point 2]
Disassembly:
B
Remove the power steering unscrewing the 3 fixing
screws (B)
B
09-1
BRAKES
GENERAL ............................................................................................................ 3
2
HYDRAULIC DIAGRAM ...................................................................................... 3
PARKING BRAKE................................................................................................ 4
2
BRAKE PEDAL.................................................................................................... 4 2
HYDRAULIC BRAKE CYLINDER ....................................................................... 5 3
BRAKE DISC WEAR CONTROL AND ADJUSTMENT ...................................... 6
4
BRAKE DISCS SOBSTITUTION ......................................................................... 7
BRAKE BLEEDING PROCEDURE ..................................................................... 9 5
DIFFERENTIAL GEARS...................................................................................... 10 6
BRAKE PEDAL.................................................................................................... 12
7
ACCUMULATOR.................................................................................................. 13
9
GENERAL ............................................................................................................ 13
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
09-2
WEI SEITE

09-3
GENERAL
2
BRAKE GROUP
2
2
3
4
5
6
7
9
HYDRAULIC DIAGRAM 9
10
11
12
13
14
15
OCV
16
17
18
18
18
18
18
18
09-4
PARKING BRAKE
PARKING BRAKE (ACTIVED)
BRAKE PEDAL
Accumulator Brakes
Tank
09-5
HYDRAULIC BRAKE CYLINDER

2
2
2
3
4
5
6
7
F
A
brake
B 2. Switch off the truck
3. Open the front battery cover, disconnect the battery
9
N plugs
E I L M H D C G 5. Remove the A rear plug and extract the B spring
6. Unscrew completely the C locknut and the D nut 11
7. Unscrew the E nuts and remove the brake cylinder
from the seat. In case use a plastic hammer to unstick
it from the silicone seal.
12
8. Apply the O key to the cover F and unscrew it.
9. Take off the G piston, the H spring and the I piston 13
Replace all the damaged gaskets
O Note: gaskets, seals and joints replacement is always 14
suggested to avoid a subsequent equipment stop
because of a oil blow-by 15
P
1. Verify that all the the seal surfaces are not marked or 16
damged and that they could guarantee the correct
pressure seal 17
2. Mount the gaskets on the pistons in the correct way as
shown in the pictures P and in Q
3. Insert the I piston, with its gaskets in the L cylinder 18
4. Proceed with the hydraulic brake cylinder reassembly
procedure. The reassembly procedure is the reverse 18
of the disassembly procedure.
Q
Note: 18
Pay a particular attention to avoid gaskets damage during
the pieces assemblage: if gaskets are damged and/or the
seal surfaces are marked the brake does not work
18
correctly.
18
18
09-6
BRAKE DISC WEAR CONTROL AND ADJUSTMENT

C
5 4
BRAKE DISC WEAR CONTROL

Park the truck on a level surface and apply the parking brake
Switch off the truck
Open the front battery cover, disconnect the battery plugs
Remove the footboard mat and the footboard
On the hydraulic brake cylinder, unscrew the 1 plug, then, with a caliber dipstick, measure the value of
the B dimension. If the dimension is between 24,5 and 29,5 mm the brake is in perfect state and it
doesn't require any adjustment. If the measure is less then 24,5 mm the brake needs to be adjusted..
If the brake has been previously adjusted verify if the disks are not completely weared out
To do this unscrew the 2 plug, remove the 3 spring, then, with a caliber dipstick, measure the value of
the C dimension. If the value is equal or less then15 mm the brake disks need to be replaced
BRAKE DISC WEAR ADJUSTMENT
Unscrew the 1 and 2 plugs
Remove the 3 spring
By the 6 key , unscrew the 4 lock nut
Through the 1 hole measure the B dimension
By the 6 key , screw the 5 nut until the B dimension reach the max. value of 29,5 mm
Reassembly and tighten the 4 lock nut then verify once again the B dimension as described here
above. If the B dimension is wrong once again, repeat all the operations as described here above
Reassembly the 3 spring and screw on the 1 and 2 plugs
Note:
If the B dimension goes over 29,5 mm the complete brake unblocking is not allowed, therefore the
brake gets overheated with a quick. deterioration
WARNING!!
A wrong adjustment could cause serious damages and rapid destruction of the brakes. If the 4
and 5 are excessively unscrewed the truck doesn't brake!
09-7
BRAKE DISCS SOBSTITUTION

2
2
2
3
4
5
6
7
9
9
10
11
1. Remove the front axle group (see chapter 06f) 12
2. Remove the planetary gear and the drive unit hub (see chapter 06f)
3.
4.
Remove the hydraulic brake cylinder (see concerned section in this chapter)
Put the axle in vertical position with one hub on the top and the other on the bottom.
13
5. Unscrew the fixing screws and remove the half-housing [Point 1]
6. Unscrew the the six fixing screws and remove the brake cover [Point 2] 14
7. Extract the first series of discs, the actuator and the second series of discs [Point 3]. Remove the
brake housing to reach the differential gears, if required 15
16
17
18
18
18
18
18
18
09-8
Point Operations
[Point 1]
Disassembly:
Unscrew the 14 A screws and remove the B
half-housing
[Point 2]
C Disassembly:
D
Unscrew the the six C fixing screws and remove the D
brake cover
[Point 3]
Disassembly:
Extract the E first series of discs, the F actuator and
the G second series of discs. . Remove the H brake
housing to reach the differential gears, if required
E
H
09-9
BRAKE BLEEDING PROCEDURE

After the first power steering pump starting (the steering pump feeds the service and parking brake
hydraulic system) proceed as in the following procedure: 2
1. Keeping the wheels stopped, operate the service
brake pedal several times
2
2
3
4
5
2. Keeping the brake pedal pressed, loosen the bleeding 6
screws on the axle brake cylinders till the total leakage
of the air inside the system; then tighten the bleeding 7
screws
9
9
10
3. Perform several braking actions with truck the running 11
12
13
14
15
16
17
18
18
18
18
18
18
09-10
DIFFERENTIAL GEARS
1. Remove the front axle group (see chapter 06f)
2. Remove from the front axle group left side the planetary gear and the drive unit hub (see chapter
06f). The axle left side is the side of the bevel ring gear of the differential gears
3. Remove the left side hydraulic brake cylinder (see concerned section in this chapter)
4. Remove the brake discs with the brake housing, to reach the differential gears, (see concerned
section in this chapter)
5. Extract the differential unit [Point 1]
6. Remove the bevel gear [Point 2]
09-11
Point Operations
[Point 1]
B
Disassembly: 2
A Extract the differential unit:
Remove the eight A screws to divide the housing into 2
its two parts B and E. Then take out all the gears.
To separate the C bevel ring gear from its B support 2
unscrew the D screws
3
4
D E
5
C
6
[Point 2]
Disassembly: 7
1 Remove the bevel gear:
2 Unscrew the eight 3 screws and remove the pinion 9
group. Unscrew the 6 pinion nut. Push out the pinion
and extract the 5 coupling hub. Remove the 7 oil seal 9
and the 8 snap-ring. Extract the 1 and 2 bearings from
their support.
10
11
12
8 7 6 5 4 3 13
14
15
16
17
18
18
18
18
18
18
09-12
BRAKE PEDAL
3. Open the front battery cover, disconnect the battery plugs
4. Remove the footboard mat and the footboard
5. Disconnect the brake pedal micro wirings from the auxiliary wiring
6. Disconnect all pipes from pedal brake valve
7. Unscrew and remove the 3 pedal fixing bolts from the over head guard and remove the pedal
The installation procedure is the reverse of the removal procedure
09-13
ACCUMULATOR
GENERAL
2
The accumulator is a tank with hydraulic oil under pressure (min 70Bar - max 120 Bar). The oil under
pressure is sent to the brake system through the brake valve on the service brake pedal. 2
In case the accumulator pressure drops down lower than 2
70 bar an alarm is displayed on the dashboard.
This pressure is kept under control using a pressure sensor 3
located on the Master valve (see dedicated section).
4
5
DISASSEMBLYREASSEMBLY 6
7
9
9
10
11
12
1. Park the truck on a level surface and apply the parking brake 13
14
5. Push the brake pedal for ~ 30 times (to lower the pressure)
6. Disconnect the nipple - Note: this operation generates oil leakages. 15
7. Remove the fixing nut of the accumulator
8. Remove the accumulator 16
17
18
18
18
18
18
18
09-14
WEI SEITE

10-1
BODY
COMPONENTS.................................................................................................... 3
2
BATTERY HOODS............................................................................................... 4
BATTERY CONNECTOR ..................................................................................... 5
2
COUNTERWEIGHT.............................................................................................. 6 2
OPERATORS SEAT............................................................................................ 7 3
4
5
6
6
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
10-2
WEI SEITE

10-3
COMPONENTS
2
2
2
3
4
5
6
6
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
10-4
BATTERY HOODS
FRONT BATTERY COVER LIFTING
Unblock the J hooking then raise the hood cover; two air
springs make easier the complete lifting of hood cover
I BACK BATTERY COVER LIFTING

Rotate the two knobs then raise the hood cover; two air
springs make easier the complete lifting of hood cover
FRONT COVER DISASSEMBLY PROCEDURE

2. Open the battery cover.
3. Tie the battery cover with the seat to the head guard
roof or to a bridge crane
4. Disconnect the seat and armrest wirings to the
auxiliary wiring
K 5. Disconnect the battery cover gas spring (on the frame
side)
6. Remove the battery cover pivots K
7. Remove the battery cover with the seat
BACK COVER DISASSEMBLY PROCEDURE

2. Open the battery cover.
3. Remove the battery
4. Tie the battery cover to a bridge crane
5. Disconnect the battery cover gas spring (on the
counterweight side)
L L 6. Remove the 4 battery cover fixing bolts L
7. Remove the battery cover
10-5
NOTE:
Before performing all the described operations it could
be necessary a battery sides disassembly
2
2
2
3
4
5
6
BATTERY CONNECTOR
6
The general battery connector H is the black (80 V) one 8
and is located inside the front battery hood cover, at the
L back. 9
It is the result of the serial connection of the two 40 V
batteries; the grey connector L is to be connected to the 10
front battery
H
11
12
13
14
15
16
17
18
18
18
18
18
18
10-6
COUNTERWEIGHT
Note:
Check the weight of the counterweight and select an appropriate wire, rope or chain to handle it
V1
V3
V2
3. Open the battery covers and disconnect the battery plugs
4. Remove the back battery (see 01 battery chapter)
5. Remove the battery cover (see Back cover disassembly procedure in this chapter)
6. Disconnect the rear light cables from the auxiliary wiring
7. Remove the rear lights
8. Fit two wire ropes, slings or belts, having proportionate load capacity (is advisable to use belts with a
capacity of 2000kg under linear traction) , through the rear light holes, hook them on a bridge crane
and lift until they are tight
9. Remove the counterweight set bolts (V1, V2 and V3 ).
10. Remove the counterweight.
Note:
- The lifting system used MUST be able to support the counterweight weight.
- Tightening torque of the 3 bolts of the counterweight = 300 Nm. (Tighten the bolts with the
sequence: V3, V1, V2)
V1
V2
V3
10-7
OPERATORS SEAT
2
brake
3. Tie the seat to a bridge crane
4. Open the battery compartment
3
6. Disconnect the seat microswitch and the armrest
wiring from the auxiliary wiring 4
7. Remove the set of nuts fastening the operators seat
(take care not to drop the operator's seat) 5
8. Remove the operators seat (use a sling, not the seat
9.
belt)
Open the battery cover.
6
6
The reassembly procedure is the reverse of the
disassembly procedure. 9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
10-8
WEI SEITE

11-1
MATERIAL HANDLING SYSTEM

HYDRAULIC CIRCUIT ......................................................................................... 3
2
HYDRAULIC SYSTEM......................................................................................... 4
PUMPS SYSTEM ................................................................................................. 4
2
STEERING SYSTEM ........................................................................................... 4 2
TILTING SYSTEM ................................................................................................ 5 3
BRAKES SYSTEM............................................................................................... 5
4
MAST 2M T.V........................................................................................................ 6
MAST 2M F.F.L..................................................................................................... 6 5
MAST 3M F.F.L..................................................................................................... 7 6
COMPONENTS.................................................................................................... 8
6
HYDRAULIC OIL TANK....................................................................................... 8
8
HYDRAULIC SYSTEM OIL FILTER .................................................................... 10
HYDRAULIC OIL ................................................................................................. 11 9
LIFTING LOAD DOWN TEST.............................................................................. 12 9
TILTING LOAD DOWN TEST .............................................................................. 12
11
OIL LEAK TEST................................................................................................... 13
LIFTING CYLINDERS .......................................................................................... 13
12
TILTING CYLINDERS .......................................................................................... 13 13
14
15
16
17
18
18
18
18
18
18
11-2
WEI SEITE

11-3
HYDRAULIC CIRCUIT
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
STEERING SYSTEM
11-5
TILTING 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
MAST 2M T.V.
MAST 2M F.F.L.
11-7
MAST 3M F.F.L.
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
11-8
COMPONENTS
HYDRAULIC OIL TANK
The tank filter plug is positioned under the footboard, on the left side.
The tank capacity is 90 liters.
Valve
Orbitrol Dipstick
drain
oil
drain
Master
valve
drain
Lifting
cylinders
breather
Oil drain from

control valve
Suction
Left
pump
suction
Drain plug
11-9
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
11-10
HYDRAULIC SYSTEM OIL FILTER

4. Remove the footboard and the tank plug (A)
5. Remove the filter. [Point 1]
Point Operations
A [Point 1]
B Disassembly:
1) Remove the plug A
C 2) Remove the ring B
3) Remove the filter C
Note:
Holding the filter with the handle pointed up, insert it into
the tank.
11-11
HYDRAULIC OIL
REPLACEMENT
2
2
F
2
3
4
5
E 6
E
6
Replacement Procedure 8
4. Remove the footboard and the tank plug
5. Remove the filter 9
6. Lift the truck
7. Loose and remove the oil discharge plug E 11
8. Let flow all the oil in a suitable recipient
9. Check the oil level using the oil dipstick F 12
10. Reposition the plug E
11. Introduce new oil
12. Reinsert the filter 13
13. Reposition the plug and the footboard
14
Notes:
Check the state of the seals and if there are no oil leaks. 15
Check the oil level in the tank, using the dip-stick (D) with the mast in vertical position and the
forks lowered 16
Oil/filter changing: 17
After the first 50 hours
first changing of the filter 18
Every 500 hours
check the oil level in the tank using the dipstick F
18
Every 2.000 hours 18
change the oil of the system and the filter
18
18
18
11-12
LIFTING LOAD DOWN TEST

1. Set the mast in vertical position with the standard load
on the fork,
2. Lift the fork at 2,5 to 3 m and leave the key switch ON
3. Take the measure between the forks and the ground
with a meter or draw datum lines on the inner and
outer masts
4. Make the measurement between the forks and the

ground or between the datum lines on the inner and
outer masts again after 10 minutes
Limit: A = 100 mm
TILTING LOAD DOWN TEST

1. Set the mast in vertical position with the standard load
on the fork
2. Lift the fork by 500 mm and leave the key switch ON
3. Measure the tilting cylinder rod extension after 10

minutes.
Limit: 20 mm or less
11-13
OIL LEAK TEST

LIFTING CYLINDERS
1. Set the mast in vertical position with the standard load 2
on the fork
2. Lift the fork at 2,5 to 3 m and take the measure 2
between the forks and the ground with a meter and
leave the key switch ON 2
3. Make the measurement between the forks and the
ground again after 10 minutes
Limit: A = 100 mm
3
4. If oil leakages are present on the body of the lifting
cylinders, check if the cylinder connections are well 4
tight. Replace the cylinder if necessary.
TILTING CYLINDERS
5
1. Set the mast in vertical position with the standard load 6
on the fork, lift the fork at 2,5 to 3 m and leave the key
switch ON 6
8
9
9
2. Secure the lead rope on the front edge of the top of the
mast; measure the distance between the rope and the 11
mast 1 m lower
3. Perform the same measurement 10 minutes after. 12
(1 = 17.5 mm).
Limit: Maximum forward angle () <= 0.5 (/min) 13
Time (10 min)
4. If the truck is out of the above limit lower completely 14
the mast and turn the key switch OFF
5. Invert the tilting hoses with the sideshift hoses (if
present) on the control valve. This operation is
15
necessary to understand if there is any internal
leakage inside the tilting cylinder or inside the control 16
valve
6. Turn the key switch ON and repeat the test from point 17
1 to 3; after that
a) The test result is within the set limits: 18
replace the control valve.
b) The test result is not within the set limits:
replace the tilting cylinders. 18
18
18
18
18
11-14
WEI SEITE

12-1
MAST
MAST ................................................................................................................... 3
2
GENERAL ............................................................................................................ 3
MAST SECTION .................................................................................................. 4
2
MAST GROUP ..................................................................................................... 5 2
COMPONENTS.................................................................................................... 5 3
2M TV MAST, MAST CHAIN AND CHAIN WHEEL GROUP .............................. 5
4
2M FFL MAST, MAST CHAIN AND CHAIN WHEEL GROUP ............................ 5
3M FFL MAST, MAST CHAIN AND CHAIN WHEEL GROUP ............................ 6 5
MAST FORK CARRIAGE (ALL MODELS) ......................................................... 7 6
FORKS (ALL MODELS) ...................................................................................... 8
6
FORK CARRIAGE GROUP AND MAST REMOVAL .......................................... 9
8
MAST GROUP (WITH FORK CARRIAGE) ......................................................... 11
2M TV MAST GROUP.......................................................................................... 12 9
2M FFL MAST GROUP........................................................................................ 13 9
3M FFL MAST GROUP........................................................................................ 14
9
SIDE SHIFT CYLINDER ...................................................................................... 15
FORK CARRIAGE ............................................................................................... 16
12
FORK CARRIAGE GUIDE SHOES REPLACING ............................................... 17 13
MAST CHAINS CHECK....................................................................................... 19 14
POSITION OF THE FORK CARRIAGE ............................................................... 20
15
FORKS ................................................................................................................. 21
MAST UNIT TILTING SETTING........................................................................... 22
16
17
18
18
18
18
18
18
12-2
WEI SEITE

12-3
MAST
GENERAL
The profile of the mast with a double strengthening wing features great rigidity to bending and twisting. 2
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.
2
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. 2
Others: side clearance adjustable from outside. Plastic guide shoes.
3
Lifting cylinders:
Double mast 2M TV No. 2 rear cylinders

4
2M FFL No. 2 rear cylinders 5
No. 2 front cylinders
6
Triple mast 3M FFL No. 2 rear cylinders
No. 2 front cylinders
6
8
Grease nipple Setting screw Lock nut Guide shoe Roller
9
9
9
12
13
14
15
16
17
18
18
18
18
18
18
12-4
MAST SECTION
2M Fork carriage 3M
Internal profile
Intermediate
profile
External profile
6,0 t 7,0 t 8,5 t

PROFILE
12-5
MAST GROUP
COMPONENTS
2M TV MAST, MAST CHAIN AND CHAIN WHEEL GROUP 2
2
2
3
4
5
6
6
8
9
9
9
12
2M FFL MAST, MAST CHAIN AND CHAIN WHEEL GROUP
13
14
15
16
17
18
18
18
18
18
18
12-6
3M FFL MAST, MAST CHAIN AND CHAIN WHEEL GROUP

12-7
MAST FORK CARRIAGE (ALL MODELS)
2
2
2
3
4
WITH SIDESHIFT 5
6
6
8
9
9
9
12
13
14
15
SIDESHIFT HYDRAULIC DIAGRAM
16
17
18
18
18
18
18
18
12-8
FORKS (ALL MODELS)

12-9
FORK CARRIAGE GROUP AND MAST REMOVAL

2
2
2
3
4
5
6
6
8
9
9
9
1. Set the mast the vertical position and lower the forks completly
2. Disconnect the chain from the mast side
3. Remove the chain wheel, if needed
12
4. Remove the fork carriage (raise the inner mast until it comes off the fork carriage, and slowly run the
vehicle in reverse to detach from the fork carriage) 13
5. Disconnect the overflow hose and high pressure hoses. (Before hose disconnection, fully lower the r
mast completly.) 14
6. Slightly hoist the mast. [Point 1]
7. Remove the tilt cylinder front pin from the mast side. 15
8. Remove the mast support cap.
9. Remove the mast.
10. Verify the bushing condition on the mast support 16
The reassambly procedure is the reverse of the disassembly procedure.
Note: 18
Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin. 18
Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced.
Adjust the chain tension after installation.
18
18
18
18
12-10
Point Operations
Inspection:
Remove the fork, completely lower the fork carriage
and measure the height X:
Standard measure X = 127 mm.
(see POSITION OF THE FORK CARRIAGE)
If the height have a different measure, set the
adjustment nuts of the chains.
Inspection:
Fork carriage Check the clearence between the inner mast and the
pad of lift bracket:
Standard clearence: 0.2-0.4 mm
0.2-0.4mm
Outer mast Inner mast

0.2-0.4mm
[Point 1]
Disassembly:
To remove the mast, use the eyebolt at the top of fix
mast.
12-11
MAST GROUP (WITH FORK CARRIAGE)

2
2
2
3
4
5
6
6
8
9
9
1. Set the mast in vertical position and lower the forks completly 9
2. Remove the forks
3. Disconnect the overflow hose and high pressure hoses. (Before hose disconnection, fully lower the 12
inner mast)
4. Tie the fork carriage and outer mast with a wire rope
5. Slightly hoist the mast [Point 1] 13
6. Remove the tilt cylinder front pin
7. Remove the mast support cap 14
8. Remove the mast group with the fork carriage
The reassambly procedure is the reverse of the disassembly procedure.
16
Note:
Apply chassis special grease to the mast support bushing and mast support cap interior surfaces. 17
Apply MP grease to the tilt cylinder front pin
Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced 18
Adjust the chain tension after installation
18
Point Operations
[Point 1] 18
Disassembly:
To remove the mast, use the eyebolt at the top of fix
mast.
18
18
18
12-12
2M TV MAST GROUP
DISASSEMBLY INSPECTION REASSEMBLY
OUTER MAST INNER MAST
1. Remove the overflow hose and high pressure hoses
2. Disconnect the chain
3. Remove the fork carriage group (Raise the inner mast until it comes off the fork carriage, and run
slowly the vehicle in reverse to detach from the fork carriage)
4. Remove each cylinder rod end set bolt, and take each rod end off
5. Remove each cylinder support
6. Remove each cylinder bottom set bolt, and remove each lift cylinder
7. Remove the outer mast
12-13
2M FFL MAST GROUP

2
OUTER MAST INNER MAST
2
2
3
4
5
6
6
8
9
9
9
12
13
1. Remove the overflow hose and high pressure hoses.
15
slowly the vehicle in reverse to detach from the fork carriage) 16
4. Remove the pulley support (Chain and hydraulic pipes)
5. Remove the front lifting cylinder support and the bottom set bolts 17
6. Remove the front lifting cylinder
7. Remove each cylinder rod end set bolt, and take each rod end off 18
8. Remove each cylinder support
9. Remove each cylinder bottom set bolt, and remove each rear lift cylinder
10. Remove the outer mast in rollers and inner mast rollers 18
18
18
18
12-14
3M FFL MAST GROUP

OUTER MAST MIDDLE MAST

INNER MAST
1. Remove the overflow hose and high pressure hoses
slowly the vehicle in reverse to detach from the fork carriage)
4. Remove the pulley support.
5. Remove each front lift cylinder rod end set bolts and take each rod end off
6. Remove the front lift cylinder support and the bottom set bolts
7. Remove the front lift cylinder
8. Remove the chains of middle mast
9. Remove each rear lift cylinder rod end set bolts and take each rod end off
10. Remove the rear lift cylinder support and the bottom set bolts
11. Remove the rear lift cylinder support
12. Slide the inner mast downward and remove the lift rollers and pads
13. Remove the inner mast
14. Slide the middle mast downward and remove the lift rollers and pads
15. Remove the central mast
12-15
SIDE SHIFT CYLINDER

2
2
2
3
4
5
6
6
8
9
9
1. Set the mast in vertical position and lower the forks completly 9
2. Disconnect the pipes from the cylinder
3. Disconnect the cylinder from the side 12
4. Disconnect the cylinder from the fork carriage
14
15
16
17
18
18
18
18
18
18
12-16
FORK CARRIAGE
1. Remove the guide shoes
2. Loosen the adjuster screw
3. Remove the snap ring
4. Remove the roller
12-17
FORK CARRIAGE GUIDE SHOES REPLACING

2
2
2
3
4
5
6
6
8
9
1. Park the truck on a flat surface and apply the parking brake
9
4. Remove the 2 forks from the fork carriage 12
5. Remove the lower security locks
6. Remove the sideshift carriage 13
7. Unscrew the brass fixing screws
15
16
17
18
18
18
18
18
18
12-18
MAST AND FORK CARRIAGE PADS ADJUSTMENT
MAST FORK CARRIAGE
Lift bracket
clearance
0.2-0.4 mm
Inner mast
50mm
clearance
0.2-0.4 mm push
push 350mm
clearance
0.2-0.4 mm
Inner mast
clearance
0.2-0.4 mm
Outer mast
Standard clearance 0.2-0.4 mm (1) Unscrew the adjustment screw

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

Every 500 hours (in any case check the chains every 3 months)
check the condition of the chains which must not be worn or faulty. To check the links for wear, use the 2
appropriate gauge
Every 1000 hours 2
remove the chains, clean them thoroughly, refit them inverting the original working position and
lubricate them 2
Every 10000 hours
replace the chains and the fixing tie rods 3
The original chains use guarantee the complied with safety requirements stated in the
regulations in force 4
INSPECTION ADJUSTEMENT 5
Inspections:
1. Check if the chain links are worn out, use the 6
appropriate rule:
6
8
9
9
2. The chains must be replaced when, in a portion
corresponding to 34 pitches, only 33 pitches are found.
9
Note:
Perform measurement without removing the chain 12
from the vehicle.
Inspect elongation over the entire chain length as it 13
may be localized
14
15
Adjustment
16
1. Park the truck on a level surface and apply the parking
brake 17
2. Put the mast in vertical position
5. Remove the forks 18
6. To compensate for any chain sag, turn the self-locking
nut on the fork carriage
7. Check to see if the chain tension is equal on left and 18
right sides
8. Check that the chains are not twisted 18
9. Check that the lifting higher meets the standard
10. In the upper position, check that the end stroke plate is 18
not in contact with the fork carriage
11. Check that the measurement X agrees with the ISO
tables in POSITION OF THE FORK CARRIAGE
18
12-20
POSITION OF THE FORK CARRIAGE

Every 500 hours
After testing the chains, with the truck on an even surface and the mast in vertical position, check the
position of the fork carriage plate, as follows:
remove the forks, lower the fork carriage completely, measure the height (X) and compare it with the
value corresponding to the truck capacity in kg, as shown in the table below
example: the correct value of (X) for a truck with a capacity of 6000 kg (class IV B), must be
254 5 mm.
ISO 2328 - 1993
Class Capacity (kg) X ( 5)
IA 0 999 76 mm
II A 1000 2500 76 mm
III A 2500 4999 76 mm
IV A 5000 8000 127 mm
VA 8001 10999 127 mm
Class Capacity (kg) X ( 5)
IB 0 999 114 mm
II B 1000 2500 152 mm
III B 2500 4999 203 mm
IV B 5000 8000 254 mm
X = 127 mm (A) VB 8001 10999 257 mm
x = 254 mm (B)
12-21
FORKS
1. Park the truck on a level surface and apply the parking
brake 2
2. Lift the fork to approx. 20 cm from the ground
3. Place a wood block under the notched section of the 2
fork rail
4. Unlock the fork by lifting the fork stopper pin and shift 3
one fork per time to the fork carriage bottom notch
5. Slowly lower the fork for removal
4
G
The reassembly procedure is the reverse of the
disassembly procedure. 6
E
6
8
F
9
D
9
Inspection
Fork arm inspection must be carried out carefully by trained personnel abble to detect any damage, 9
failure, deformation, etc., which may impair safe use
1. Surface cracks:
12
The fork arm must be thoroughly examined visually for cracks giving special attention to the heel (D)
and top (E) and bottom (F) hooks. If necessary, the forks may be subjected to a non-destructive 13
crack detection process.
2. Difference in height of fork tips 14
Check the difference in height between the tips on each pair of forks; this must not be more than 3%
of the thickness of the forks fitted on the fork plate 15
3. Positioning lock
Check that the fork positioning lock (G) is in good working order
4. Legibility of marking
16
If the fork arm marking is not clearly readable, it must be renewed by the original fork supplier
5. Fork wear control 17
The fork arm blade and shank must be thoroughly checked for wear, paying special attention to the
area around the heel (D). When maximum wear is detected, with thickness reduced to 90% of the 18
original, the fork arm must be replaced
6. Fork mounting wear control 18
The horizontal supporting surface of the top hook (E) and the contact surfaces of both hooks (E) and
(F) must be checked for wear and any damage
7. Withdrawal of the forks from service 18
Any fork with defects revealed during the above controls must be withdrawn from service
Note: 18
Any component or system tampering can endanger the vehicle safety. Any repair and
replacement operation should be performed only by authorised and well trained personnel. 18
18
12-22
MAST UNIT TILTING SETTING

Every 500 hours
Check the tilting of the mast; the standard values are:
= 5FORWARD
FORWARD - BACKWARD
= 10BACKWARD (standard)
= 8BACKWARD (optional)
= 6BACKWARD (optional)
The tilt angle can easily be checked using a plumb-line
dropped from the front outside edge of the top of the fixed
masts and measuring the distance between the line and the
front edge at a metre from the top of the masts
NB. 1 tilting degree corresponds to a 17.4 mm movement
on 1 m
= 5FORWARD= 87,5 mm
= 10BACKWARD (standard)= 176,3 mm
= 8BACKWARD (optional)= 140,5 mm
= 6BACKWARD (optional)= 105,1 mm
1 = 17,4 mm
13-1
CYLINDER
LIFTING CYLINDERS .......................................................................................... 3
2
GENERAL ............................................................................................................ 3
SPECIFICATIONS................................................................................................ 6
2
PARACHUTE VALVE (SAFETY DOWN VALVE) ................................................ 7 2
FRONT DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON LIFTING 8 3
REAR TELESCOPIC CYLINDER WITH BRAKING EFFECT ON LOWERING .. 9
4
REAR TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT...................... 10
TILTING CYLINDER............................................................................................. 12 5
6
6
8
9
9
9
12
13
14
15
16
17
18
18
18
18
18
18
13-2
WEI SEITE

13-3
LIFTING CYLINDERS
GENERAL
2
FRONT CYLINDERS
6,0 to 7,0 t 8,5 t 2
2
2M
TV 3
4
3M 5
TV
6
2 displacement cylinders with brake effect on 2 displacement cylinders with brake effect on
the lifting the lifting 6
2M
FFL 8
9
2 displacement cylinders with brake effect on 2 displacement cylinders with brake effect on
the lifting the lifting 9
3M
FFL
9
12
13
14
15
16
17
18
18
18
18
18
18
13-4
REAR CYLINDERS
6,0 to 7,0 t 8,5 t
2 telescopic cylinders without brake effect 2 telescopic cylinders without brake effect
2M
TV
3M
TV
2 telescopic cylinders with brake effect on the 2 telescopic cylinders with brake effect on the
lowering lowering
2M
FFL
2 telescopic cylinders with brake effect on the 2 telescopic cylinders with brake effect on the
lowering lowering
3M
FFL
13-5
TILTING CYLINDER SPECIFICATION

Piston rod
Forward Backward Cylinder inside
Mark Stroke (mm) outside
tilting degree tilting degree diameter (mm)
diameter (mm)
2
A standard 5 10 156,5 120 50
2
B optional 5 8 135 120 50
C optional 5 6 113,5 120 50 2
3
4
5
6
6
8
9
9
9
12
13
14
15
16
17
18
18
18
18
18
18
13-6
SPECIFICATIONS
REAR LIFTING CYLINDER 2M TV MAST
6,0 t 7,0 t 8,5 t

Cylinder type Single effect
Cylinder inside diameter mm 75 75 85
Piston rod outside diameter mm 60 60 70
Parachute valve R mm 2,2 2,2 2,2
REAR LIFTING CYLINDER 2M FFL-3M FFL MAST
6,0 t 7,0 t 8,5 t

FRONT LIFTING CYLINDER 2M FFL-3M FFL MAST
6,0 t 7,0 t 8,5 t

13-7
PARACHUTE VALVE (SAFETY DOWN VALVE)
The parachute valve enables the locking of the load in the

position where the actuator is in the moment of failure (as it 2
might happen in case of hose failure, the flow is blocked)
2
R
Note:
We recommend to verify the valve integrity and replace
it in case of a pressure spike, generated by hose 2
failure, particurarly dangerous to damage some valve
components permanently.
R= Setting portion Standard: 6,0 to 8,5 t 2.2 mm
3
4
5
6
6
8
9
9
9
12
13
14
15
16
17
18
18
18
18
18
18
13-8
FRONT DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON

LIFTING
6,0 - 7,0 t 8,5 t
Chamber A Chamber A
Channels 1 & 2 Channels 1 & 2
Channel 3 Channel 3
Surface X Surface X
Chamber B Chamber B
Oil inlet Oil inlet
Parachute valve Parachute valve
Lifting phase:
When acting on the control valve, the oil flows into the cylinder via the oil inlet. Through channels 1, 2
and 3 the oil fills the chamber A until the internal pressure of the oil exerts an upward thrust against the
surface X. The rod coming out will close the above mentioned channels.
Near the limit of the stem, the channels 1 and 2 are plugged by the head, so the oil flowing between the
two chambers passes only through channel 3 (calibrated hole), obtaining a lower flow of oil.
Lowering phase:
Opening the supply circuit (oil inlet) allows the stern to come down so that the oil can return to the tank
via the control valve. At the start of this phase, chamber A contains no oil. Better constant filling is
enabled by the channel 3 that by opening avoid jerking.
After passing the cylinder head, the oil flow between the two chambers passes through channels 1 and 2
which are now open.
13-9
REAR TELESCOPIC CYLINDER WITH BRAKING EFFECT ON

LOWERING
2
6,0 - 7,0 t 8,5 t
2
2
3
4
5
6
6
8
Chamber A
Surface X Chamber A 9
9
Sphere Sphere
9
Channels 1
Channels 2 Channels 2 12
Parachute valve Parachute valve 13
14
Oil inlet Oil inlet
15
16
17
Lifting phase:
By operating on the control valve with the lifting lever, the oil flows to the cylinder through the oil inlet. 18
It reaches channels 1 and 2 until the hydraulic pressure formed in chamber A produces a thrust upwards
on the surface X thereby stem extraction. 18
Lowering phase:
Lowering is permitted by operating on the hydraulic control valve, opening the oil return circuit to the tank 18
through the control valve.
At the start of this phase, all the oil in chamber A flows out through the channel 1. Only afterwards, when 18
the sphere comes into contact with the top of the brake body, does the braking action begin, directing the
oil through the cannel on the brake body, which being very small in proportion causes the oil coming out 18
to slow down (braking effect).
18
13-10
REAR TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT
6,0 - 7,0 t 8,5 t
Dust control ring Dust control ring

Anti-friction ring Anti-friction ring
Cap
Cap
Piston
Piston
Seal
Surface X
Surface X
Seal
Parachute valve
Parachute valve
Oil inlet Oil inlet
These cylinders are fitted with a seal on the piston that works on the inner surface of the cylinder liner.
The rod guide is made by the top cap and by the piston through anti-friction rings.
The dust control ring prevents any dirty and water to penetrate into the cylinder.
Lifting phase:
By operating on the control valve with the lifting lever, the oil flows to the cylinder through the oil inlet.
Through this channels the oil fills the chamber A until the internal pressure of the oil exerts an upward
thrust against the surface X thereby stem extraction.
Lowering phase:
Opening the supply circuit (oil inlet) allows the stem to come down so that the oil can return to the tank
via the control valve.
13-11
FRONT DISPLACEMENT CYLINDER
6,0 - 7,0 t 8,5 t WITH BRAKING EFFECT ON LIFTING 2
2
2
3
4
5
REAR TELESCOPIC CYLINDER
6,0 - 7,0 t 8,5 t WITH BRAKING EFFECT ON LOWERING
6
6
8
9
9
9
REAR TELESCOPIC CYLINDER 12
6,0 - 7,0 t 8,5 t WITHOUT BRAKING EFFECT
13
14
15
16
17
18
1. Remove the cylinder cup (upper side)
2. Remove the cylinder rod guide 18
3. Remove the piston rod
4.
5.
Remove the seals on the piston rod
Remove the cylinder cup (botton side)
18
6. Remove the brake system (bushing brake body)
7. Remove the parachute valve (safety down valve) 18
8. Remove the cylinder
18
The reassambly procedure is the reverse of the removal procedure.
13-12
TILTING CYLINDER
2. Set the mast in vertical position
6. Disconnect the hoses
7. Remove the tilting cylinder front pin
8. Remove the tilting cylinder rear pin
9. Remove the tilting cylinder.
Note:
If both tilting cylinders are removed, fix the mast with a
chain in order to avoid the mast overturning.
The reassembly procedure is the reverse of the removal procedure.
Notes:
Before installation apply grease to the insertion portions of the cylinder front and rear pins .
Dont tilt the mast backward maximum before adjust the mast tilt angle.
Check the hydraulic oil level and add if insufficient.
After the installation, tilt slowly the mast forward and backward a few times without charge to
bleed the air in the hydraulic circuit and to check the normal functioning.
Adjust the mast forward and backward tilting angle (to prevent uneven tilting) when the tilting
cylinder and mast are replaced or disassembled
13-13
2
2
2
3
T = 2080 Nm 4
5
6
6
8
T = 160 Nm
9
1. Remove the rod connection.
2. Loosen the rod guide
9
3. Extract the piston rod W/piston.
4. Loosen the piston nuts. 12
5. Inspect the cylinder [Point 1]
6. Inspect the piston rod [Point 2] 13
The installation procedure is the reverse of the removal procedure.
14
Note: 15
Apply hydraulic oil to packings, O-rings and dust seal lips.
Apply antioxidant on rod eye threads.
Replace the piston nut after every removal procedure.
16
17
18
18
18
18
18
18
13-14
Point Operations
[Point 1]
Inspection:
Measure the cylinder bore.
Standard: 120 mm
Limit: 120,087 mm
[Point 2]
Inspection:
Measure the piston rod outside diameter.
Standard: 50.0 mm
Limit: 50,05 mm
Inspection:
Measure the bend of the piston rod.
Limit: 0.2 mm
14-1
SERVICE PUMPS
SERVICE PUMPS ................................................................................................ 3
2
GENERAL ............................................................................................................ 3
SPECIFICATIONS................................................................................................ 3
2
TEST METHOD.................................................................................................... 5 2
PERFORMANCE TABLE..................................................................................... 5 3
COMPONENTS.................................................................................................... 6
4
5
6
6
8
9
9
9
12
9
14
15
16
17
18
18
18
18
18
18
14-2
WEI SEITE

14-3
SERVICE PUMPS
GENERAL
2
2
2
3
4
5
6
SPECIFICATIONS
6
Vehicle model 6,0 - 7,0 - 8,5 t
Oil pump name Gear pump 8
Oil pump model WSP 20.18
9
Transmission Direct motor drive
Capacity (at 1000 rpm) l/m 19,37 9
3
Theoretical displacement cm 19,376
9
12
9
14
15
16
17
18
18
18
18
18
18
14-4
1 Park the truck on a level surface and activate the parking brake
2 Switch off the truck
3 Open the battery cover and disconnect the battery
4 Remove the footboard
5 Empty the oil tank (see chapter 11f)
6 Remove the left and / or the right panel
7 Disconnect the delivery and suction pipes from the pump
8 Remove the pump fixing bolts [Point 1]
Note:
Before the assembly, grease the pump-motor coupling
with CASTROL OPTIMOL T WHITE paste type. Always,
before the assemblage, clean the flange of interface
between pump and motor
Point Operations
[Point 1]
Disassembly:
Remove the 2 pump fixing bolts (C)
Reassembly:
After installation, tightening torque for pump fixing
C bolts = 45 Nm
14-5
TEST METHOD
For strict testing, a bench test should be performed, but it is generally impossible in service operation,
so, the pump performance can be judged, with the pump installed on the truck, by cylinder operation.
Verify that the battery charge is sufficient by observing the battery charge indicators. 2
Check that the oil control valve set relief pressure is as specified.
Lift relief pressure = 250 bar 2
Perform all measures with the hydraulic oil temperature at 50 to 55 C. Calculate the lifting speed.
However, caused by lifting logic unit soft start, the lifting speed is 10 to 20 mm/sec lower than the table
value. Calculate the lifting speed more accurately measuring the full stroke time excluding the start.
2
The lifting speed depends by different conditions: battery status, hydraulic oil temperature and mast
adjustment. The values below are refered to certain conditions. 3
PERFORMANCE TABLE
4
LIFTING
Q1 MAX LOAD
Q2 MAX LOAD MAX HIGT
5
Perform the test with the electrolyte density from 1,18 to1,26 kg\l and electrolytetemperature from 20 C to 50 C
6.0 t 6
Load FFL TV
Kg m/sec amp bar m/sec amp bar 6
0 0,35 0,37 max 165 max 35 0,40 0,42 max 227 max 62
Q1
Lowering
0,28 0,30 max 481 max 151 0,30 0,32 max 536 max 190
8
Q1 max 0,48 max 0,60
Lifting end stoke (max. pressure valve adjustment) max 654 max 220 9
7.0 t
Load FFL TV 9
Kg m/sec amp bar m/sec amp bar
Q1
0 0,34
0,25
0,36
0,27
max
max
189
510
max
max
44
170
0,39
0,25
0,41
0,27
max
max
257
568
max
max
85
205
9
Lowering
Q1 max 0,43 max 0,49
12
Lifting end stoke (max. pressure valve adjustment) max 711 max 255
8.5 t 9
Load FFL TV
0 0,26 028 max 155 max 35 0,30 0,32 max 173 max 55
Q1 0,22 0,24 max 490 max 175 0,22 0,24 max 530 max 202
Lowering
15
Q1 max 0,30 max 0,44
TILTING
Test to be done at 1m. height with Q1 charge
17
STD. Tilt 5 FW 10BW (standard) 18
sec amp bar
BW-FW 6,2 7,5 max 120 max 75 18
FW-BW 5,0 6,2 max 220 max 145
STD. Tilt 5 FW. 8BW. (optional)
sec amp bar
18
BW-FW 5,0 6,0 max 120 max 75
FW-BW 4,0 5,0 max 220 max 145 18
sec amp bar 18
BW-FW 3,7 4,5 max 120 max 75
FW-BW 3,0
Tilting end stroke
3,7 max
max
220
---
max
max
145
255
18
STD sideshift visible check
14-6
COMPONENTS
i G F
B H
1. Remove the 2 (A) pump fixing bolts and remove the oil pump
2. Place the front cover (B) face downward, and remove the 2 (C) bolts
3. Remove the (D) rear cover, (E) gasket and the (F) figure 3 gasket first group
4. Remove the drive gear, driven gear and side plate. [Point 3]
5. Remove the (G) driver gear, the (H)driven gear and side plate. [Point 4]
6. Remove the and the (I) figure 3 gasket second group
Note:
Wash each parts, blow compressed air and apply hydraulic oil before installation.
Always use new seals for reassembly.
15-1
OIL CONTROL VALVE

OIL CONTROL VALVE ........................................................................................ 3
2
GENERAL ............................................................................................................ 3
PERFORMANCE TABLE..................................................................................... 7
2
COMPONENTS.................................................................................................... 8 2
MANUAL DOWN VALVE ..................................................................................... 10 3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
15-2
WEI SEITE

15-3
OIL CONTROL VALVE

GENERAL
EVP5 EVP3 EVP1
2
3 WAYS
2
2
3
4
5
6
6
EVP6 EVP4 EVP2
EVP7 EVP5 EVP3 EVP1 8
4 WAYS
9
9
11
12
13
14
EVP8 EVP6 EVP4 EVP2
15
EVP9 EVP7 EVP5 EVP1
EVP3
5 WAYS 16
17
18
18
18
18
18
EVP10 EVP8 EVP6 EVP4 EVP2 18
15-4
Valve Function Value in ohms of the coils Voltage on the coils

EVP1 Lifting 19,2 ohm 024 V
EVP2 Lowering 19,2 ohm 024 V
EVP3 Backward tilting 26,6 ohm 024 V
EVP4 Forward tilting 26,6 ohm 024 V
EVP5 Left sideshift 26,6 ohm 024 V
EVP6 Right sideshift 26,6 ohm 024 V
EVP7 4th way 26,6 ohm 024 V
th
EVP8 4 way 26,6 ohm 024 V
th
EVP9 5 way 26,6 ohm 024 V
th
EVP10 5 way 26,6 ohm 024 V
15-5
RELIEF VALVES ADJUSTMENT SCREW
2
SECONDARY RELIEF VALVES
ADJUSTMENT SCREWS
2
2
3
4
5
6
6
MAIN RELIEF VALVE
ADJUSTMENT SCREW 8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
15-6
HYDRAULIC CIRCUIT DIAGRAM
3 WAYS
TO THE OIL TANK
4 WAYS
TO THE OIL TANK
5 WAYS
TO THE OIL TANK

15-7
PERFORMANCE TABLE
LIFTING
Q1 MAX LOAD
Q2 MAX LOAD MAX HIGT
2
6.0 t 2
Load FFL TV
0 0,35 0,37 max 165 max 35 0,40 0,42 max 227 max 62
Q1
Lowering
0,28 0,30 max 481 max 151 0,30 0,32 max 536 max 190
3
Q1 max 0,48 max 0,60
7.0 t
Load FFL TV 5
Kg m/sec amp bar m/sec amp bar
Q1
0 0,34
0,25
0,36
0,27
max
max
189
510
max
max
44
170
0,39
0,25
0,41
0,27
max
max
257
568
max
max
85
205
6
Lowering
Q1 max 0,43 max 0,49
6
Lifting end stoke (max. pressure valve adjustment) max 711 max 255
8.5 t 8
Load FFL TV
0 0,26 028 max 155 max 35 0,30 0,32 max 173 max 55
Q1
Lowering
0,22 0,24 max 490 max 175 0,22 0,24 max 530 max 202
9
Q1 max 0,30 max 0,44
TILTING
Test to be done at 1m. height with Q1 charge
12
STD. Tilt 5 FW 10BW (standard) 13
sec amp bar
BW-FW 6,2 7,5 max 120 max 75 14
FW-BW 5,0 6,2 max 220 max 145
sec amp bar
15
BW-FW 5,0 6,0 max 120 max 75
FW-BW 4,0 5,0 max 220 max 145 16
sec amp bar 17
BW-FW 3,7 4,5 max 120 max 75
FW-BW 3,0
Tilting end stroke
3,7 max
max
220
---
max
max
145
255
18
STD sideshift visible check
18
WARNING:
The installation of a hydraulic control valve finalized to operate a clamp (for example a paper roll)
18
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). 18
18
18
15-8
COMPONENTS
3 WAYS
4 WAYS
5 WAYS
15-9
Note:
Operate the control lever to bring the mast and fork to the vertical and lowermost positions, 2
respectively, to release the residual pressure in the material handling system before starting
removal.
2
2
3
4
5
6
6
8
9
9
11
12
1. Park the truck on a level surface 13
2. Set the mast in vertical position and lower fully the mast to reach the lowest pressure.
14
6. Empty the oil circuit 15
7. Disconnect the hoses.
8. Sling the oil control valve bracket by belts. 16
9. Unscrew the oil control valve support fixing bolts .
10. Remove the oil control valve with its support. 17
18
Note:
Check the hydraulic oil level, and add if insufficient. 18
18
18
18
18
15-10
MANUAL DOWN VALVE
MANUAL DOWN VALVE
If the forks do not descend due to a malfunction or other cause, loosen the manual down valve to lower
the forks in emergencies.
When loosening the manual down valve, do not rotate it more than one full turn.
After making repairs, tighten it securely.
16-1
APPENDIX
AUXILIARY WIRING HARNESS ......................................................................... 3
2
CONNECTORS .................................................................................................... 4
ELECTRIC DIAGRAMS ....................................................................................... 6
2
LIGHTS EQUIPMENT ELECTRIC DIAGRAM ..................................................... 12 2
WORKING LAMPS ELECTRIC DIAGRAM ......................................................... 13 3
FLASH / ROTATING BEACON ELECTRIC DIAGRAM....................................... 14
4
REAR WINDOW HEATER ELECTRIC DIAGRAM .............................................. 14
ROAD CIRCULATION ELECTRIC DIAGRAM .................................................... 15 5
WINDSCREEN ELECTRIC DIAGRAM ................................................................ 16 6
6
8
9
9
11
12
13
14
16
16
17
17
18
18
18
18
18
16-2
WEI SEITE

16-3
AUXILIARY WIRING HARNESS
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
16
17
17
18
18
18
18
18
16-4
CONNECTORS
16-5
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
16
17
17
18
18
18
18
18
16-6
ELECTRIC DIAGRAMS
16-7
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
16
17
17
18
18
18
18
18
16-8
16-9
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
16
17
17
18
18
18
18
18
16-10
16-11
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
16
17
17
18
18
18
18
18
16-12
LIGHTS EQUIPMENT ELECTRIC DIAGRAM

16-13
WORKING LAMPS ELECTRIC DIAGRAM
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
16
17
17
18
18
18
18
18
16-14
FLASH / ROTATING BEACON ELECTRIC DIAGRAM
REAR WINDOW HEATER ELECTRIC DIAGRAM

16-15
ROAD CIRCULATION ELECTRIC DIAGRAM
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
16
16
17
17
18
18
18
18
18
16-16
WINDSCREEN ELECTRIC DIAGRAM

WEI SEITE

CESAB S.p.A
via Persicetana Vecchia, 10 40132 Bologna - Italy
Tel.(0039) 051.20 54 11
Fax (0039) 051.72 80 07
E-mail: cesab@cesab.it

Eco P: Repair Manual

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REPAIR MANUAL

Code 036-0432-00 04/2010

This manual covers the following truck models:

Model Starting serial number Ending serial number

PAGINA INTENZIONALMENTE BIANCA

INTENTIONALLY LEFT BLANK

PAGE INTENTIONNELLEMENT BLANCHE

PGINA INTENCIONALMENTE BLANCA

LUBRICANT CAPACITY AND TYPE TABLE...................................................... 28

VEHICLE EXTERIOR VIEW

FRAME SERIAL NUMBER

Vehicle model Punching format Punching position

TRUCK CAPACITY AND IDENTIFICATION PLATES

14 13. Attachment serial number 18

CAPACITY DIAGRAMS (with SE tyres)

900 5610 5500 5610

HOW TO USE THIS MANUAL

1. Remove the cover. [Point 1]]

Put a match mark when removing the pump cover

Matters omitted from this manual

ASSY Assembly SAE

Conventional Conversion rate*

DISCARDING THE BATTERY

steel, brass, bronze, ABS, plastic-

LIFTING THE TRUCK

WIRE ROPE SUSPENSION ANGLE LIST

0 1.00 time 0 time 90 1.41 time 1.00 time

60 1.16 time 0.58 time

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

OPERATIONS ON THE MAST

BLOCKING WITH BARS/BLOCKS

In the case of F. F.L. mast, adopt the same procedure to

BLOCKING WITH CHAINS

TOWING THE TRUCK

ELECTRICAL PARTS INSPECTION

(1) Never subject electronic parts, such as computers

Direct connection Reverse connection

Direct connection Reverse connection Example of measurement result

STANDARD TIGHTENING TORQUE TABLE

Preloading V STD tightening torque (N) TORQUE Max (Nm) 2

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

ASSEMBLAGE FOR NIPPLES TYPE PARKER ERMETO E0/ E0-2

1. Tighten the nipple with the spanner up to the point of

PERIODIC MAINTENANCE TABLE

LUBRICANT CAPACITY AND TYPE TABLE

Applicable place Capacity Type

WHEELS & TYRES

(*) 1450mm for non twin tyres (Eco P 60 only)

MAST SPECIFICATIONS AND RATED CAPACITIES

PAGINA INTENZIONALMENTE BIANCA

INTENTIONALLY LEFT BLANK

PAGE INTENTIONNELLEMENT BLANCHE

PGINA INTENCIONALMENTE BLANCA

PAGINA INTENZIONALMENTE BIANCA

INTENTIONALLY LEFT BLANK

PAGE INTENTIONNELLEMENT BLANCHE

PGINA INTENCIONALMENTE BLANCA