Workshop Literature 4032 XE13/3ac, XE15/3ac, XE15ac, XE16/3ac, XE18ac, XE20/3ac

Workshop literature
Series 4032
XE13/3ac, XE15/3ac, XE15ac,
XE16/3ac, XE16ac, XE18/3ac,
XE18ac, XE20/3ac, XE20ac
40328042303 EN
Edition 05/2008
Table of contents
00 General Information
Product information ...................................................................................... 00-1
Instruction and maintenance manual ..................................................................................... 00-1
General Forklift Description ..................................................................................................... 00-1
Definition of travel direction ..................................................................................................... 00-2
Overall dimensions for three-wheel truck .............................................................................. 00-3
Three-wheel truck technical data ............................................................................................ 00-4
Overall dimensions for four-wheel truck ................................................................................ 00-8
Four-wheel truck technical data .............................................................................................. 00-9
Three-wheel truck tyre characteristics .................................................................................. 00-13
Four-wheel truck tyre characteristics .................................................................................... 00-13
Fork lift truck capacities - Model 1300 kg 3 wheels - with vertical masts and forks = 1400
mm max.......................................................................................................................................... 00-14
Fork lift truck capacities - Model 1500 kg 3 / 4 wheels - with vertical masts and forks =
1400 mm max.............................................................................................................................. 00-17
1400 mm max.............................................................................................................................. 00-20
1400 mm max.............................................................................................................................. 00-23
1400 mm max.............................................................................................................................. 00-26
Alternative lift characteristics ................................................................................................ 00-29

Abbreviations key ................................................................................................................... 00-30
Tyre inflation pressure ............................................................................................................ 00-31

Lamps........................................................................................................................................ 00-31
Battery dimensions and weights............................................................................................ 00-31
Internal accessibility ............................................................................................................... 00-32

Safety features ........................................................................................................................ 00-33
Transporting the Forklift.......................................................................................................... 00-35

Forklift towing .......................................................................................................................... 00-36
Loading and unloading the truck............................................................................................ 00-37
Safety precautions ..................................................................................... 00-39
Description of safety symbols................................................................................................ 00-39

Operations Preliminary to Maintenance .............................................................................. 00-39
To avoid accidents................................................................................................................... 00-39
General safety Regulations ................................................................................................... 00-40

Safety Regulations Relative to Operating Materials........................................................... 00-42
Workshop literature - 40328042303 EN - 05/2008

Tabte of contents (bjj)
01 Service
Maintenance ................... . . . . . . . ...................... 01 -1
Preliminary operations before commissioning .................... 01-1
Synoptic Table of Maintenance Operations ................ 01-1
SupplyTable ................................. 01-2
02 Diagnostics
Diagnostic software . ..................... .......... . 02-1
Connection between the diagnostics PC and the forklift ....................... 02-1
Software ...................................... .. ........... ............................. .. 02 2

Description ofthe menus in the WINPCCONSOLE software ....................... 02-3
Description ofthe PARAMETER menu ................................... 02-7
Description ofthe TESTER menu ................. 02-12

TESTER/ Diagnostics Function .................................... 02-13
Parameters ....................................................... 02-16

introduction ....................................................... 02-16
Parameters ofthe DUAL AC module........................................................................................02-16

Parameters ofthe AC2 FLASH module ................................. 02-22
................................................................................................................................................... 02-24
.......................................................................... 02-25
Parameters ofthe ECO DISPLAY module ..................................................................... 02-25

Parameterisation ofthe drive function.................................................................................. 02-29
Parameterisation ofthe steering function ............................................ 02-30
Parameterisation ofthe electric braking function ............................................................... 02-31

Parameterisation ofthe battery state monitoring function ................................................. 02-32
Parameterisation ofthe lifting function ............................................................................... 02-32
Parameterisation ofthe hydrauiicaiiy assisted steering function..................................... 02-33

Parameterisation ofthe tilt, side shift (SLI) and 4th lever functions . ................... 02-34
Alarms ........................................................... 02-35

State ofthe truck during an alarm situation 02-35
.............................................. 02-35
. ....................................................................................................... 02-36
Alarms list ......... 02-37
Analogue signals ..................................... 02-52
Summary of signals from the analogue transducers ................................................... 02-52
Workshop literature. 40328042303 EN.. 05/2008

Table of contents
11 Traction motor
Asynchronous motors .................................................................................. 11-1
Features of the asynchronous motors .................................................................................. 11-1
Checking the asynchronous motors ....................................................................................... 11-4
Front axle motors ......................................................................................... 11-6
Traction motortechnical data ................................................................................................... 11-6

Traction ...................................................................................................................................... 11-6
Traction motor............................................................................................................................. 11-8
Drive motor checks ................................................................................................................. 11-10
Drive motor decomposition ................................................................................................... 11-12
Encoder .................................................................................................................................... 11-14
Replacing the traction encoder.............................................................................................. 11-14
Electrical connections ofthe traction motors ....................................................................... 11-15
Temperature sensor KTY84................................................................................................... 11-16
Insulation testing of traction motor ....................................................................................... 11-18
22 Gearbox
Front axle ..................................................................................................... 22-1
Front axle technical data .......................................................................................................... 22-1
Removal of front axle with traction motors.............................................................................. 22-4
Front axle reassembly ............................................................................................................... 22-7
Reducer gearbox ......................................................................................... 22-8

Front axle reducer gearbox topography ................................................................................ 22-8
Front axle reduction gear disassembly/reassembly............................................................. 22-9
Removal / reassem bly of the drive wheel reducer gearbox............................................... 22-12
Check reducer gearbox oil level .............................................................................................. 22-13
Reducer gearbox oil change ................................................................................................ 22-14
31 Truck
Counterweight.............................................................................................. 31-1
Counterweight removal ............................................................................................................ 31-1
Counterweight reassembly ..................................................................................................... 31-6
Covers ......................................................................................................... 31-8

Cover topography ..................................................................................................................... 31-8
Side covers removal / reassembly ......................................................................................... 31-9

Battery cover removal I reassem bly ...................................................................................... 31-10
Step plate removal/reassembly.............................................................................................. 31-12

Tabs© of contents
Distributor cover removal / reassembly ........... 31-14
Batteries . .............................. 31-17
Battery removal ..................................... 31-17
34 Driver’s seat
Overhead guard .................................................... 34-1
Removal of the overhead guard ....................... 34-1
Reassembly ofthe overhead guard ..................................... 34-3
Fairings . .................. 34-4

Removal/reassembly ofthe steering column panelling ........................ 34-4
Removal/reassembly ofthe control panel panelling ..................................................... 34-5
42 Steering system
Steering distributor .................................................. 42-1
Steering distributor technical data ................ 42-1
Removal/reassembly ofthe steering distributor ............................. 42-3
Steering distributor pressure switch technical data .............................. .. 42-5

Replacing the steering distributor pressure switch ......................... 42-6
Steering column ............................................................... 42-7

Removal/reassembly ofthe steering column .................................................................. 42-7
Steering axle .............. . ................................. . . ...................... . ............... 42-11

Three-wheel truck rear axle technical data ........................................................................ 42-11
Three-wheel truck axle removal ........................................................................................... 42-14

Three-wheel truck axle reassembly ................................. 42-17
Three-wheel axle disassembly .............. ................... 42-19

Three-wheel truck potentiometer technical data ............. 42-23
Replacement ofthe three-wheel steering axle potentiometer.............. 42-25
Four-wheel truck axle technical data.................................................................................... 42-26
Four-wheel axle removal .......................................................... 42-27
Four-wheel truck axle reassembly . . 42-28

Four-wheel axle disassembly.......................................................... 42-30
Four-wheel truck potentiometer technical data ................................................................. 42 35

Replacing the four-wheel truck potentiometer .............................. 42-36
Lubricating the steering axle ..................................................... 42-41
46 Wheels and tyres

General information .......................... ...................................... . ........ . 46-1
Safety regulations for wheels and rims ................................... 46-1
IV Workshop literature. 40328042303 EN.. Ob/2008

@1 Table of contents
General information for changing tyres ................................................................................... 46-2

Tyrewear check.......................................................................................................................... 46-3
Wheel change .............................................................................................. 46-4
Wheel change ............................................................................................................................. 46-4
Wheel decomposition .................................................................................. 46-7
Disassembly/assembly of tyres on rims with movable flange ............................................. 46-7

Quick tyres assembly/disassembly......................................................................................... 46-9
Tightening torques ..................................................................................... 46-12
Check wheel nut tightness (every 10 hours during run-in) ............................................... 46-12
49 Braking system
Parking brake .............................................................................................. 49-1
Removal / reassembly of the parking brake lever.................................................................. 49-1
Parking brake control cable replacement .............................................................................. 49-3
Replacing the parking brake microswitch .............................................................................. 49-5
Parking brake adjustment ....................................................................................................... 49-7
Service brake .............................................................................................. 49-8

Service brake pedal removal ................................................................................................... 49-8
Service brake pedal reassembly.............................................................................................. 49-9
Stop lights microswitch replacement..................................................................................... 49-10

Replacing the service brake pedal potentiometer ............................................................. 49-10
Braking group ............................................................................................. 49-12
Removing/installing the brake group .................................................................................. 49-12
50 Controls
Accelerator pedal ......................................................................................... 50-1
Accelerator pedal ...................................................................................................................... 50-1
Accelerator pedal potentiometer ............................................................................................ 50-2
56 Display elements
Display ......................................................................................................... 56-1
Plate data .................................................................................................................................... 56-1
Connector.................................................................................................................................... 56-1
Multifunction panel ................................................................................................................... 56-2
Setting the date and time .......................................................................................................... 56-8

Speed reductions ..................................................................................................................... 56-12
Functionality of the display buttons......................................................................................... 56-13
Workshop literature-40328042303 EN -05/2008 V

>le of contents
Data modification pushbutton functions .......................... 56-15
Multifunction pane! removal/reassembly .................... 56-16

Alarms .......................................................... 56-17
60 Electronic system
Software versions ....................................................................... . 60-1
Reference software versions ..................................... 60-1
Electronic traction system ......................................... 60-2

Characteristics of the electronic drive system .............................. 60-2
Plate data: traction .............................. .......................... 60-3
Connectors ........................................................ 60-3
Closing the general contactor ........................................... 60-6

Thermal sensor operation ......................................................................................... 60-6
Hydraulic functions electronic system ....................... 60-7

Functions of the AC2 module ................ .......................... 60-7
Plate data: pump .................................................... 60-8
AC2 Connectors ...................................................... 60-8
Control ofthe general contactor ............. 60-9

Lowering solenoid valve operation ............................................................................ 60-10
Thermal sensor operation ..................................................................................................... 60-10
Types of hours counters ....................... 6O-11

Types of hour counters: ......................................................................................................... 60-11
Hours counter management in case of electronic system replacement ........... 60-11
Resetting the machine hours .............................................................. 60-12
Electrical system components ........................................................... 60-13

Electronics panel technical data ...................................... 60-13
Electronics panel removal / reassembly . ................... 60-13
Protection ofthe electrical system ....................... 60-18
Emergency pushbutton ........................................................ 60-19
Replacing the emergency stop butter...................... 60-" "

Assembly/disassembly ofthe lights switch (option) ........................................................ 60-20
Lamp replacement (if applicable) ............................................... ......................................... 60 22
Work iight replacement procedure (optional).............. 60-23

Contactors .............................................................................................................................. 60-24
Location of Fuses .................................................................................................................. 60-25

Changing a fuse ............................................... 60-26
DC/DC Converter ................................................. 60-27
VI Workshop literature - 40328042303 EN. 05/2008

Table of contents
Buzzer ...................................................................................................................................... 60-28
Fans ........................................................................................................................................... 60-28
Encoder description................................................................................................................. 60-29
71 Hydraulic components
Hydraulic circuit ........................................................................................... 71-1
Layout of hydraulic parts .......................................................................................................... 71-1
Hydraulic system assembly diagram ..................................................................................... 71-2
Pump motor.................................................................................................. 71-3

Pump motor technical data....................................................................................................... 71-3
Pump motor removal ................................................................................................................. 71-4

Pump motor reassembly .......................................................................................................... 71-8
Replacing the pump................................................................................................................... 71-9
Replacing the pump motor encoder ..................................................................................... 71-11
Replacing the pump motor temperature sensor.................................................................. 71-12
Oil tank ....................................................................................................... 71-13

Hydraulic oil tank..................................................................................................................... 71-13
Oil tank removal/reassembly .............................................................................................. 71-14
Check hydraulic tank oil level ................................................................................................ 71-17
Hydraulic distributor.................................................................................... 71-19

Hydraulic distributor technical data....................................................................................... 71-19
Hydraulic distributor removal / reassembly ......................................................................... 71-20

Replacing the hydraulic distributor probe ........................................................................... 71-23
Valves......................................................................................................... 71-24
Safety valve (load lowering block) (VBDC) ......................................................................... 71-24
Safety valve layout ................................................................................................................. 71-25
Tilt cylinders................................................................................................ 71-31
Tilt cylinders ............................................................................................................................ 71-31

Tilt cylinder removal/reassembly......................................................................................... 71-31
Air bleeding ofthe tilt cylinders .............................................................................................. 71-34
80 Lifts
Lifts .............................................................................................................. 80-1
Technical data for service ....................................................................................................... 80-1
Lift typologies ............................................................................................................................ 80-2
Simplex Lift ................................................................................................................................. 80-5

Duplex Lift................................................................................................................................... 80-9
Workshop literature - 40328042303 EN -05/2008 Vil

/»f-ents
TriplexLift ....................................................... §0-14
Load chain locking device ............................................ 80-20

Fork carriage retaining device ......................................... 80-20
Assembly ofthe mast/carriage support rollers ........... 80-20

Check ............................................................................................................................ .. 80 22
Disassembly ofthe Simplex lift cylinder ................ . §0-23

Disassembly ofthe side cylinders ofthe Duplex lift .................. §0-24
Disassembly ofthe side cylinders ofthe Triplex lift....................................................... 80-26

Duplex/Triplexcentral cylinder ................................... §0-28
Limit stop dampers ............................................................. 80-30
Disassembly ofthe fork carriage ........................................ §0-31
Tilt cylinder ................................................. ...... 80-32
Lift disconnection ................................................. 80-34
Lift reassembly .................................................... 80-37
Air bleeding ofthe lift cylinders ......................................... 80-38
Lift cylinders ...................................................... 80-40
Annex
A Diagrams
Wiring diagrams ... A-i
Eiectricai circuit diagram 40328020002 .....................................................................................A-1
Electrical connection diagram 40328020001 A-3
Hydraulic diagrams .......................................................... A-5

Hydraulic diagram 40328082502 ................................................................................................ A-5
vm Workshop literature. 40328042303 EN.. 05/2008

General Information 00
Product information
Instruction and maintenance man
ual
This chapter gives information taken from the in
struction and maintenance manual, considered
as of interest for the assistance technician
j NOTE
Consult the truck instruction and maintenance

manual for detailed information on the use ofthe
truck
General Forklift Description

The model described in this manual is an electric dealer which will verify its feasibility and, ifap
forklift with seated operator and counterbalanced plicable, perform the equipment installation, the
forks. updating of the residual capacityplates and the
testing. The equipment will also ha ve to be pro
This model can be equipped with the following
vided with identification plate andAssembly and
main equipment: Instructions Manual.
• side shifts
• positioners j NOTE
• grippers with jaws or forks
The “crane arm“attachment changes the original
• tipping
intended use ofthe forklift, which may not move
• load arms freely oscillating suspended loads. For such ap
plication a specific approval and EC certification
ofconformity is required for the forklift equipped
U NOTE
in this manner, in this regard, it is necessary to
contact the authorized dealer.
For use ofa piece offield equipment after the
sale, it is necessary to apply to the authorized
Workshop literature -40328042303 EN -05/2008 00-1

""
Backwards
1
Forwards D Right
A
S Left
----- ---- 4<yi?«O4?303 EN. - O'oii

--------- 8rpte®«e^'k<oo
Workshop
____________________________ General Information 00
Product information
Overall dimensions for three-wheel truck
OM1494
Workshop literature - 40328042303 EN - 05/2008 00-3

PmduGt jriformatton
Three-wheel truck technical data
VIItti CIVICI (OLIVO
1.2 Model 1300 1500 1600 1800 2000

Power unit: electric -
1.3 diesel - petrol - LPG - Electric Electric Electric Electric Electric
network electricity
Operation: Manual -
Driver Driver Driver Driver Driver
1.4 Pedestrian - Stand-on
seated seated seated seated seated
- Seated
1.5 Capacity "Load" Q(t) 1.3 1.5 1.6 1.8 2.0
Load center-of-gravity c
1.6 500 500 500 500 500
distance (mm)
Fork plane distance X 370 1>2> 380 1)2)
1.8 3651)2) 365 1)2) 365 1>2>
from front axle (mm)
y
1.9 Pitch 1152 1260 1260 1368 1513
(mm)
Weights
2.1 Curb weight kg 2819 2875 3072 3067 3240
Weight on the axle with
2.2 nominal load (front / kg 3585/534 3842/533 4117/555 4369/498 4746/494
rear)
Weight on the axle
2.3 when empty (front / kg 1309/1510 1313/1562 1417/1655 1431/1636 1582/1658
rear)
_____
Wheels and tyres

Tyres: SE - superelas SE/SE3) SE/SE3) SE/SE3’ SE/SE3) SE/SE3)
3.1
tic - PN = pneumatic
18x7-8 3) 18x7-8 3) 18x7-8 3) 18x7-8 3) 200/50-10

3.2 Front wheel size 3)
15x4.5-
3.3 Back wheel size 15x4.5-83' 15x4.5-83) 15x4.5-83) 140/55-93'
83)
Wheels: No. front/No.
3.5 2x12 2x/2 2x/2 2x/2 2x/2
rear (x= driving)
h-in
3.6 Front track 932 4) 932 4> 932 4' 932 4' 945 4'
(mm)
Lu
h-i 4
Rear track width 168 168 168 168 176
______________________ __________ __________
Overall dimensions
Lifting unit inclination De 3° / 9° 5)
4.1 3° / 9° 5) 3° / 9° 5) 3° / 9° 5) 3°/9o5)
(forward / backward) grees
Minimum height of lift hi 2210 6) 2210 6> 2210 6) 22106) 2260 6)
4.2
dimensions ....... .
hz
4.3 Free lift 150 150 150 150 150
[mm]
h3
4.4 Lifting height 3330 3330 3330 3330 3350
imm]
ha
Maximum height of lift ■ '*-r
3905 7) 3905 r> 3905 T> 4046 14)
4.5 ( mm\ 3973
dimensions ....... .
00-4 Workshop literature. 40328042303 EN.. 05/2008

General information 00
Product information
h6 2139 8) 2024 11) 2024 11) 2024 11)

4.7 Height of protective roof 2139
[mm]
h7
4.8 Sitting height 1054 939 1054 939 939
[mm]
hio
4.12 Towing bracket height 523 523 523 523 523
[mm]
4.19 Total length l-i(mm) 2726 1)2) 2834 1)2) 2834 1>2> 2947 1)2) 3102 1>2>
Length including fork 1947 1)2) 2102 1>2>
4.20 l2(mm) 1726 1)2) 1834 1)2) 1834 1)2)
thickness
bi /b2 1067 9) 1067 9> 10679> 1067 9) 11509>
4.21 Maximum width
(mm)
s/e/l 40 / 80 / 40 / 80 / 40/80 / 45/100/ 45/100/
4.22 Fork dimensions
(mm) 1000 1000 1000 1000 1000
Fork carriage according
4.23 to DIN 15173 Class/ 2A 2A 2A 2A 2A
Form A, B
b3 1040 10) 1040 1°) 1040 1°) 1040 10) 1040 10)
4.24 Fork carriage width
(mm)
Mast height above mi 956> 956> 956) 95®) 956)
4.31
ground (underload) (mm)
Chassis height above
m2
4.32 ground at center (under 104 104 104 104 104
(mm)
load)
Aisle width with
Ast 3052 1>2> 3160 1>2> 3160 1>2> 3268 1)2) 3427 1)2)
4.33 1000x1200 pallet and
(mm)
fork insertion 1200
Aisle width with
Ast 3176 1>2) 3284 1)2) 3284 1)2) 3392 1)2) 3552 1>2>
4.34 800x1200 pallet and
(mm)
fork insertion 800
Wa
4.35 Turning radius 1361 1469 1469 1577 1722
(mm)
Minimum distance of
bi3
4.36 the point of rotation from - - - - -
(mm)
the forklift center line
Performance
Lateral movement
5.1 speed (with / without km/h 14/14 14/14 14/14 14/14 14/14
load)
Lifting speed (with /
5.2 m/s 0.51/0.57 0.51/0.57 0.51/0.57 0.4/0.57 0.4/0.48
without load)
Lowering speed
5.3 m/s 0.52/0.41 0.54/0.41 0.54/0.41 0.54/0.41 0.48/0.35
(with/without load)
Towing bracket
tractive force (S2 60
5.5 N 2150/2100 2150/2100 2100/2050 2100/2050 2050/2050
min) (with / without
load)
Max towing bracket
tractive force (S2 5
5.6 N 9250/8950 9250/8950 9250/8900 9300/8950 9400/9000
min) (with / without
load)

00 Generai ^formation
Fred oct hformaibn
Gradeability (S2 30
5.7 min) (with / without % 9.5/13.5 9/13 8/12 8/12 7.5/11.5
load)
1
Max. surmountable
5.8 gradient (S2 5 min) % 23/33 21.5/32 20/29.5 19.5/30 18/28.5
(with / without load)
Acceleration time
5.9 (10 m) (with / without s 4.1/3.8 4.2/S.9 4.3/4 4.5/4.1 4.6/4.2
load)
Elec- Elec- Elec- Elec- Elec-
5.10 Service brake tric/Me- tric/Me- tric/Me- tric/Me- tric/Me-
chanical chanical chanical chanical chanical
—
Electre motor
Drive motor, power
6.1 kW 4x2 4x2 4x2 4x2 4x2
(S2 60min)
Lifting motor, power
6.2 kW 9 9 9 9 9
S3 15%
Type of battery
6.3 according to DIN 43531A 43531A 43531A 43531A 43531A
43531/35/36 A, B, C
Batten/ voltage /
6=4 V/Ah 48/465 48/480 12^ 48/640 48/600 13^ 48/750
capacity ks
6.5 Battery weight kg 749 780 12/ 970 930 13) 1055
Energy consump
6.6 tion according to VD! kWh / h - - - - 6.215-
cycle
Miscellaneous
8.1 Type of gear control Inverter Inverter Inverter Inverter Inverter
Working pressure for
8.2 bar 160 160 160 160 160
equipment
Oil flow for equip
8.3 l/min 30 30 30 30 30
ment (max available)
Noise level in driver’s
8.4 dB(A) <70 <70 <70 <70 <70
ear
Tow coupling,
8.5 - - - - -
iTiodei/DIN type
September 2007, Rev. 2

1) With side shift, + 17 mm.
2) With TX lifts, + 20 mm (+22 mm for load ca
pacity 2000).
3) For alternative wheels, see table.
4) 945 mm with 200/50-10 wheels and 875 mm
with 18x5x12 1/8" wheels (Vulkolan).
5) SX lifts with h3 > 4530 mm / All DX and TX
lifts.
6) For all configurations.
7) 6-roller fork carriage: 3973 mm.
8) h6= 2080 mm for low-roof version,
9) 1150.5 mm with 200/50-10 wheels and 1002
mm with 18x5x12 1/8” wheels (Vulkolan).
10) With S.L.I.= 980 mm.
QO-6 Works ature. 40328042303 EN - 05/2008

Product information
11) h6= 1980 mm for low-roof version.
12) battery options (capacity/weight): 400 Ah
/ 709±5% Kg; 460 Ah 1765±5%Kg; 500 Ah I
780±5% Kg.
13) battery options (capacity/weight): 575 Ah I
915±5%Kg; 625 Ah 1930±5%Kg.
14) six-roller fork carriage only.
15) calculated over 60 cycles/h.
The values shown refer to standard outfits;

they are indicative only and not binding.

Overall dimensions for four-wheel truck
Workshop literature - 40328042303 EN. 05/2008

____________________________General Information 00
Product information
Four-wheel truck technical data
Characteristics
1.2 Model 1500 1600 1800 2000
Power unit: electric - diesel
1.3 - petrol - LPG - network Electric Electric Electric Electric
electricity
Operation: Manual - Pedes Driver Driver Driver
1.4 Driver seated
trian - Stand-on - Seated seated seated seated
1.5 Capacity "Load" Q(t) 1.5 1.6 1.8 2.0
Load center-of-gravity dis c
1.6 500 500 500 500
tance (mm)
Fork plane distance from X 365 1)2) 370 1)2) 380 1)2)
1.8 365 1)2)
front axle (mm)
y 1388 1498
1.9 Pitch 1280 1280
(mm)
Weights
2.1 Curb weight kg 2852 3090 3045 3250
Weight on the axle with
2.2 kg 3809/543 1455/1635 4337/508 4727/523
nominal load (front / rear)
Weight on the axle when
2.3 kg 1295/1557 4170/520 1416/1629 1552/1698
empty (front / rear)
Wheels and tyres

Tyres: SE = superelastic - SE/SE3) SE/SE3) SE/SE3) SE/SE3)
3.1
PN = pneumatic
3.2 Front wheel size 18x7-8 3) 18x7-8 3) 18x7-8 3> 200/50-103)
3.3 Back wheel size 15x4.5-83> 15x4.5-83> 15x4.5-83) 140/55-93)
Wheels: No. front/No. rear
3.5 2x/2 2x/2 2x/2 2x/2
(x= driving)
bio 932 4) 932 4) 932 4) 945 4)
3.6 Front track
(mm)
bi 1
3.7 Rear track width 874 874 874 873
(mm)
Overal dimensions
Lifting unit inclination (for De 3° / 9°5) 3° / 9° 5) 3° / 9° 5) 3° / 9° 5)
4.1
ward / backward) grees
Minimum height of lift di hi 2210 6> 2210®) 2210 6) 2260 6>
4.2
mensions (mm)
h2
4.3 Free lift 150 150 150 150
[mm]
h3
4.4 Lifting height 3330 3330 3330 3350
[mm]
Maximum height of lift di h4 3905 7) 3905 7) 4046 14)
4.5 3973
mensions (mm)
h6 2024 8) 2139 12> 2024 8> 2024 8>
4.7 Height of protective roof
[mm]
h7
4.8 Sitting height 939 1054 939 939
[mm]
Workshop literature-40328042303 EN -05/2008 00-9

00 Generai Information
Product 5 reformation
p—
hio
I 4.12 I owing bracket height 523 523 523 523
I 4.19 [mm]
Total length li(mm) 2910 ’)2> 2910 1>2) 3018 1)2) 3143 1)2)
Length including fork thick 1910 1>2) 1910 1>2) 2018 1)2) 2143 2)
4.20 l2(mm)
ness
bi / b2 1067 9) 1067 9' 1150 9)
4.21 Maximum width 1067 -
(mm)
s/e/l 40 / 80 / 45/100/ 45/100/
4.22 Fork dimensions 40/80/1000
(mm) 1000 1000 1000
Fork carriage according to
4.23 2A 2A 2A 2A
ISO 2328 Class/Form A, B
b3
4.24 Fork carnage width 1040 10) 1040 1°) 1040 1°) 1040 1°)
(mm)
Mast height above ground mi 956)
4.31 956/ 956^ 956)
(underload) (mm)
Chassis height above
m2
4.32 ground at center (under 104 104 104 104
(mm)
load)
Aisle width with 1000x1200
Ast 3480 C 2)
4.33 pallet and fork insertion 3246 1>2) 3246 1)2) 3359 1>2)
(mm)
1200
Aisle width with 800x1200 Ast 3432 1)2) 3677 C 2)

4.34 3432 ^2) 3550 ^2)
pallet and fork insertion 800 (mm)
Wa
4.35 Turning radius 1667 1667 1780 1895
(mm)
Minimum distance of the
D13
4.36 point of rotation from the 407 407 442 477
(mm)
forklift center line
. ............ "
Performance
Lateral movement speed
5.1 km/h 14/14 14/14 14/14 14/14
1 (with / without load)
Lifting speed (with / without
5.2 m/s 0.51/0.57 0.51/0.57 0.4/0.57 0.4/0.48
load)
Lowering speed (with /
5.3 m/s 0.54/0.41 0.54/0.41 0.54/0.41 0.48/0.35
without load)
Towing bracket tractive
5.5 force (S2 60 min) (with / N 2150/2100 2100/2050 2100/2050 2050/2050
without load)
Max towing bracket tractive
5.6 force (S2 5 min) (with / N 9250/8950 9250/8900 9300/8950 9400/9000
without load)
Gradeability (82 30 min)
5.7 % 9/13 8/12 8/12 7.5/11.5
(with/without load)
Max. surmountable gradi
5.8 ent (S2 5 min) (with / without % 21.5/32 20/29.5 19.5/30 18/28.5
load)
0CM0 Workshop literature. 40328042303 EN - 05/2008

Product information
Acceleration time (10 m)
5.9 s 4.2/3.9 4.3/4 4.5/4.1 4.6/4.2
(with / without load)
Elec-
Electric/Me- Electric/Me- Elect ric/Me-
5.10 Service brake tric/Me-
chanical chanical chanical
chanical
Electric motor
Drive motor, power (S2
6.1 kW 4x2 4x2 4x2 4x2
60min)
Lifting motor, power S3
6.2 kW 9 9 9 9
15%
Type of battery according
6.3 43531A 43531A 43531A 43531A
to DIN 43531/35/36 A, B,C
Battery voltage / capacity 48/480 11) 48/600 13>
6.4 V/Ah 48/640 48/750
ks
6.5 Battery weight kg 780 11> 970 930 13) 1055
Energy consumption 6.215)
6.6 kWh/h - - -
according to VDI cycle
Miscellaneous
8.1 Type of gear control Inverter Inverter Inverter Inverter
Working pressure for
8.2 bar 160 160 160 160
equipment
Oil flow for equipment
8.3 l/min 30 30 30 30
(max available)
Noise in forklift driver’s ear
8.4 dB (A) <70 <70 <70 <70
according to EN 12053
Tow coupling, model/DIN
8.5 - - - -
type
September 2007, Rev. 2
1) With side shift, + 17 mm.

2) With TX lifts, + 20 mm (+22 mm for load ca
pacity 2000).
3) For alternative wheels, see table.
4) 945 mm with 200/50-10 wheels and 875 mm
with 18x5x12 1/8” wheels (Vulkolan).
5) SX lifts with h3 > 4530 mm: 3° / 5° / All DX
and TX lifts: 3°/5°.
6) For all configurations.
7) 6-roller fork carriage: 3973 mm.
9) 1150.5 mm with 200/50-10 wheels and 1002
mm with 18x5x12 1/8” wheels (Vulkolan).
10) With S.L.I.= 980 mm.
11) battery options (capacity/weight): 400 Ah
1709±5% Kg; 460 Ah / 765±5%Kg; 500 Ah /
780±5% Kg.
13) battery options (capacity/weight): 575 Ah I
915±5%Kg; 625 Ah / 930±5%Kg.
14) six-roller fork carriage only.
15) calculated over 60 cycles/h.

00
The values shown refer to standard outfits;

they are indicative oniy and not binding.
Workshop literature - 40328042303 EM - 05/2008

IgD!____________________________ General Information 00
Product information
Three-wheel truck tyre characteristics
WHEELS
Superelastic Pneumatic Vulkolan / Superelastic
Type Front
front rear front rear Rear (SE)
(Vulkolan)
1300 Kg/
18x7-8/16 15x4.5-8/12 18x5x12 15x4.5-8
1500 Kg/ - -
(SX-DX) (SX-DX) 1/8” (S.E. white)
1600 Kg
18x7-8 (SX-
DX) 18x7-8/16 15x4.5-8/12 18x5x12 15x4.5-8
1800kg 15x4.5-8
200/50-10 (SX-DX) (SX-DX) 1/8” (S.E. white)
(TX)
18x5x12 140/55-9
2000kg 200/50-10 140/55-9 - -
1/8” (S.E. white)
Four-wheel truck tyre characteristics
WHEELS
Superelastic Pneumatic Vulkolan / Superelastic
Type Front
front rear front rear Rear (SE)
(Vulkolan)
1500 kg/ 18x7-8/16 15x4.5-8/12 18x5x12 15x4.5-8
- -
1600 kg (SX-DX) (SX-DX) 1/8” (S.E. white)
18x7-8 (SX-
DX) 18x7-8/16 15x4.5-8/12 18x5x12 15x4.5-8
1800kg 15x4.5-8
200/50-10 (SX-DX) (SX-DX) 1/8” (S.E. white)
(TX)
18x5x12 140/55-9
2000kg 200/50-10 140/55-9 - -
1/8” (S.E. white)

00 Generai information
Procfoct information
Fork lift truck capacities - Model 1300 kg 3 wheels - with vertical masts and
forks = 1400 mm max.
S.E. SING. (18 x 7 - 8)

TYRES/LIFT (1) PN. SING. (18 x 7 - 8/16pr)
VULKOLAN (18 x 5 x 12 1/8”)
Load WITH SLI WITHOUT SLI WITH SLI WITHOUT SLI
Elev.
center- Maxi 3300 Maxi 3300 Maxi 3300 Maxi
h3 3300 mm
of-gravity mum el mm el mum el mm el mum el mm el mum el
(mm) elevation
(mm) evation evation evation evation evation evation evation
TYPE= SX
500 1300 1300 1300 1300 1300 1300 1300 1300
3330 600 1150 1150 1150 1150 1150 1150 1150 1150
1000 850 850 850 850 850 850 850 850
500 1300 1300 1300 1300 1300 1300 1300 1300

3630 600 1150 1150 1150 1150 1150 1150 1150 1150
dnnn
WWW QEH
UUV QEA
850 OEH ocn orn nrrrx
S WWW ouu OUU
500 1300 1300 1300 1300 1250 1300 1300 1300

4030 600 1150 1150 1150 1150 1100 1150 1150 1150
1000 850 850 850 850 850 850 850 850
a
500 1300 1300 1300 1300 1150 1300 ¡ZUU 1300
4530 600 1150 1150 1150 1150 1050 1150 1100 1150
1000 850 850 850 850 750 850 800 850
500 1300 1300 1300 1300 1100 1300 1150 1300
5030 600 1150 1150 1150 1150 1000 1150 1050 1150
1000 850 850 850 850 750 850 750 850
NOTES:
(1) lift inclination : SX<=4530: Forw. 3°, Back. 9°
SX >= 4530 - DX - TX: Forw. 3°, Back. 5 °
with front cab panel for SX < 4530: Forw. 3°, Back. 5 °
(2) not available with pneumatic tyres
S.E. SING. (18 x 7 - 8)

VULKOLAN (18x5x12 1/8”)
Elev.
uenter- Maxi 3300 Maxi 3300 Maxi 3300 Maxi
h3 3300 mm
(mm) elevation
TYPE= DX GAL
500 1300 1300 1300 1300 1300 1300 1300 1300
2875 600 1150 1150 1150 1150 1150 1150 1150 1150
1000 850 850 850 850 850 850 850 850
500 1300 1300 1300 1300 1300 1300 1300 1300
r>r\rx r-r\
a a A A rf\
áVTJ QUU 1 IOU 1 IOU 1150 1150 1150 1150 1150 1150
1000 850 850 850 850 850 850 850 850
500 1300 1300 1300 1300 1300 1300 1300 1300
3275 600 1150 1150 1150 1150 1150 1150 1150 1150
1000 850 850 850 850 850 850 850 850
00-14 Workshop Hterature - 40328042303 EN - 05/2008

Product information
500 1300 1300 1300 1300 1300 1300 1300 1300

3575 600 1150 1150 1150 1150 1150 1150 1150 1150
1000 850 850 850 850 850 850 850 850
500 1300 1300 1300 1300 1300 1300 1300 1300
3975 600 1150 1150 1150 1150 1150 1150 1150 1150
1000 850 850 850 850 850 850 850 850
NOTES:
SX >= 4530 - DX - TX: Forw. 3°, Back. 5 "
S.E. SING. (18x7-8)

Elev.
h3 3300 mm
(mm) elevation
TYPE= TX GAL (2)
500 1300 1300 1300 1300
4170 600 1150 1150 1150 1150
1000 850 850 850 850
500 1300 1300 1300 1300
4470 600 1150 1150 1150 1150
1000 850 850 850 850
500 1200 1300 1250 1300
4770 600 1100 1150 1150 1150
1000 800 850 800 850
500 1150 1300 1200 1300
5220 600 1050 1150 1100 1150
1000 750 850 800 850
500 1100 1300 1100 1300
5750 600 1000 1150 1000 1150
1000 750 850 750 850
500 800 1300 800 1300
6370 600 700 1150 700 1150
1000 550 850 550 850
500 600 1300 600 1300
6970 600 550 1150 550 1150
1000 400 850 400 850
NOTES:
SX >= 4530 - DX - TX: Forw. 3°, Back. 5 °
with front cab panel for SX < 4530: Forw. 3°, Back. 50
REV. 00 of 01/10/07
Lift types:

00 GeneraB information
• SX: Simplex lift

• DX GAL: Duplex lift with free lifting
■> TX GAL: Triplex lift with free lifting
• WITH SLI: with side shift
• WITHOUT SLI: without side shift
SES: Single superelastic tyres
PN: Pneumatic tyres

TWIN: Twin tyres
Lift inclination: Forward (Forw.) i Backward

(Back.)

Product information
Fork lift truck capacities - Model 1500 kg 3 / 4 wheels - with vertical masts
and forks = 1400 mm max.
S.E. SING. (18 X 7 - 8J)

TYRES/LIFT (1) PN. SING. (18 X 7 - 8/16pr)
VULKOLAN (18x5x 12 11/8”)
Load WITH SLI WITHO UT SLI WITH SLI WITHOUT SLI
Elev.
h3 3300 mm
(mm) elevation
TYPE== SX
500 1500 1500 1500 1500 1500 1500 1500 1500
3330 600 1350 1350 1350 1350 1350 1350 1350 1350
1000 950 950 950 950 950 950 950 950
500 1500 1500 1500 1500 1500 1500 1500 1500

3630 600 1350 1350 1350 1350 1350 1350 1350 1350
1000 950 950 950 950 950 950 950 950
500 1500 1500 1500 1500 1500 1500 1500 1500
4030 600 1350 1350 1350 1350 1350 1350 1350 1350
1000 950 950 950 950 950 950 950 950
500 1450 1500 1500 1500 1400 1500 1450 1500
4530 600 1300 1350 1350 1350 1250 1350 1300 1350
1000 900 950 950 950 900 950 900 950
500 1400 1500 1450 1500 1300 1500 1350 1500
5030 600 1250 1350 1300 1350 1150 1350 1200 1350
1000 900 950 900 950 850 950 850 950
NOTES:
SX >= 4530 - DX - TX: Forw. 3°, Back. 5 °
with front cab panel for SX < 4530: Forw. 3°, Back. 5°
S.E. SING. (18x7-8J)

VULKOLAN (18x5x12 1/8
1 ”)
Elev.
h3 3300 mm
of-gravity mum el mm el mumel mm el mum el mm el mum el
(mm) elevation
TYPE= LDX GAL
500 1500 1500 1500 1500 1500 1500 1500 1500
2875 600 1350 1350 1350 1350 1350 1350 1350 1350
1000 950 950 950 950 950 950 950 950
500 1500 1500 1500 1500 1500 1500 1500 1500
2975 600 1350 1350 1350 1350 1350 1350 1350 1350
1000 950 950 950 950 950 950 950 950
500 1500 1500 1500 1500 1500 1500 1500 1500
3275 600 1350 1350 1350 1350 1350 1350 1350 1350
1000 950 950 950 950 950 950 950 950

Î 500 1500 1500 1500 1500 1500 1500 1500 1500
!
3575 600 1350 1350 1350 1350 1350 1350 1350 1350
4 nnn aea aca aca r\cr\ r\crx r,rr> nrn
1 VW ouu c?w wu VUU □UU ÏWU auu SOU I
500 1500 1500 1500 1500 1500 1500 1500 1500
3975 600 1350 1350 1350 1350 1350 1350 1350 1350
1000 950 950 950 950 950 950 950 950
NOTES:
SX >= 4530 - DX - TX: Forw. 3°, Back. 5 °
| TYRES/LIFT(1) S.E. SING. (18 x 7 - 8)

PN. SING. (18 x 7 - 8/16pr)
Elev.
center- Maxi- 1 3300 Maxi 3300 Maxi 3300 Maxi
h3 3300 mm
of-gravity mum el- | mm el mum el mm el mum el mm el mum el
I ( rnmi elevation
î
i
(mm) evation 1 evation evation evation evation evation evation
| TYPE= TX GAL (2)
500 1500 1500 1500 1500
iI Â i 70 «nn 4È QKfi 1350 OCA
4i v w 1350
i 1000 950 950 950 950
.. ...... ... ........ '
500 1500 1500 1500 1500
A r-
I AA
i /■»rvrv
OUU IOOU 1350 1350 1350
! 1000 950 950 950 950
500 1450 1500 1500 1500
4770 600 1300 1350 1350 1350
1000 900 950 950 950
500 1300 1500 1350 1500
5220 600 1150 1350 1200 1350
1000 850 950 850 950
500 1100 1450 1150 1500
5750 600 1000 1300 1050 1350
1000 700 900 750 950
r~r\r\ nrr A r\r\
a
uuu OUv ì 4UU auu 145G
6370 600 750 1250 800 1300
1000 550 900 550 900
500 650 1350 700 1400
6970 600 550 1200 600 1250
1000 400 850 450 900
NOTES:
SX >- 4530 - DX - TX: Forw. 3°, Back. 5 °
REV. 00 of 01/10/07
Lift types:
Product information
• TX GAL: Triplex lift with free lifting
PN: Pneumatic tyres

TWIN: Twin tyres
Lift inclination: Forward (Forw.) I Backward

(Back.)

00 General Sriformation
and forks = 1400 mm max
S.E. SING. (18 x 7 - 8)

Elev.
h3 3300 mm
(mm) elevation
TYPE= SX
500 1600 1600 1600 1600 1600 1600 1600 1600
3330 600 1450 1450 1450 1450 1450 1450 1450 1450
1000 1050 1050 1050 1050 1050 1050 1050 1050
500 1600 1600 1600 1600 1600 1600 1600 1600
3630 600 1450 1450 1450 1450 1450 1450 1450 1450
1000 1050 1050 1050 1050 1050 1050 1050 1050
500 1600 1600 1600 1600 1600 1600 1600 1600
4030 600 1450 1450 1450 1450 1450 1450 1450 1450
1000 1050 1050 1050 1050 1050 1050 1050 1050
500 1600 1600 1600 1600 1500 1600 1550 1600
4530 600 1450 1450 1450 1450 1400 1450 1450 1450
1000 1050 1050 1050 1050 1000 1050 1050 1050
500 1550 1600 1600 1600 1450 1550 1500 1550
5030 600 1400 1450 1450 1450 1300 1400 1400 1450
1000 1000 1050 1050 1050 950 1000 1000 1050
NOTES:
SX >= 4530 - DX - TX: Forw. 3°, Back. 5 °
S.E. SING. (18 X 7 - 8)

TYRES / L! FT (1) PN. SING. (18 x 7 - 8/16pr)
VULKOLAN (18 x 5 x 12 1/8”)
Elev.
œnifei- Maxi 3300 Maxi 3300 Maxi 3300 Maxi
h3 3300 mm
(mm) elevation
TYPE= DX GAL
500 1600 1600 1600 1600 1600 1600 1600 1600
2875 600 1450 1450 1450 1450 1450 1450 1450 1450
1000 1050 1050 1050 1050 1050 1050 1050 1050
500 1600 1600 1600 1600 1600 1600 1600 1600
2975 600 1450 1450 1450 1450 1450 1450 1450 1450
1000 1050 1050 1050 1050 1050 1050 1050 1050
500 1600 1600 1600 1600 1600 1600 1600 1600
3275 600 1450 1450 1450 1450 1450 1450 1450 1450
1000 1050 1050 1050 1050 1050 1050 1050 1050
00-20 Workshop literature - 40328042303 EN. 05/2008

Product information
500 1600 1600 1600 1600 1600 1600 1600 1600
3575 600 1450 1450 1450 1450 1450 1450 1450 1450
1000 1050 1050 1050 1050 1050 1050 1050 1050
500 1600 1600 1600 1600 1600 1600 1600 1600
3975 600 1450 1450 1450 1450 1450 1450 1450 1450
1000 1050 1050 1050 1050 1050 1050 1050 1050
NOTES:
SX >= 4530 - DX - TX: Forw. 3°, Back. 5 °
S.E. SING. (18 X 7 - 8)

VULKOLAN (18 X 5 X 12 1/8”)
Elev.
h3 3300 mm
(mm) elevation
TYPE= TX GAL (2)
500 1600 1600 1600 1600
4170 600 1450 1450 1450 1450
1000 1050 1050 1050 1050
500 1600 1600 1600 1600
4470 600 1450 1450 1450 1450
1000 1050 1050 1050 1050
500 1600 1600 1600 1600
4770 600 1400 1450 1400 1450
1000 1000 1050 1000 1050
500 1450 1600 1500 1600
5220 600 1300 1450 1350 1450
1000 950 1050 1000 1050
500 1150 1600 1150 1600
5750 600 1000 1450 1000 1450
1000 750 1050 750 1050
500 850 1550 850 1600
6370 600 750 1450 750 1450
1000 550 1050 550 1050
500 700 1550 700 1600
6970 600 650 1450 650 1450
1000 450 1050 500 1050
NOTES:
SX >= 4530 - DX - TX: Forw. 3°, Back. 5 °
REV. 00 of 01/10/07
Lift types:
Workshop literature-40328042303 EN- 05/2008 00-21

00
Product ^formatters
’ DX GAL: Duplex lift with free lifting

PN: Pneumatic tyres
TWIN: Twin tyres
Lift inclination: Forward (Forw.) / Backward
(Back.)
0002 Workshop iiterature - 40328042303 EN. 05/2008

Product information
S.E. SING. (18 x 7 - 85)

VULKOLAN (18x5 x 12 11/8”)
Elev.
h3 3300 mm
(mm) elevation
TYPE== SX
500 1800 1800 1800 1800 1700 1700 1800 1700
3330 600 1600 1600 1600 1600 1600 1600 1600 1600
1000 1150 1150 1150 1150 1150 1150 1150 1150
500 1800 1800 1800 1800 1650 1650 1800 1700

3630 600 1600 1600 1600 1600 1550 1600 1600 1600
1000 1150 1150 1150 1150 1100 1150 1150 1150
500 1750 1800 1800 1800 1650 1650 1700 1700
4030 600 1550 1600 1600 1600 1550 1600 1600 1600
1000 1100 1150 1150 1150 1100 1150 1150 1150
500 1700 1800 1750 1800 1600 1650 1650 1650
4530 600 1500 1600 1550 1600 1450 1550 1500 1600
1000 1050 1150 1100 1150 1000 1150 1050 1150
500 1650 1800 1700 1800 1400 1600 1450 1650
5030 600 1450 1600 1500 1600 1250 1550 1350 1600
1000 1050 1150 1050 1150 900 1150 950 1150
NOTES:
SX >= 4530 - DX - TX: Forw. 3°, Back. 5 °
with front cab panel for SX < 4530: Forw. 3°, Back. 5°
S.E. SING. (18 x 7 - 8î)

VULKOLAN (18x5x 12 1/8 1 ”)
Elev.
h3 3300 mm
(mm) elevation
TYPE= CDX GAL
500 1800 1800 1800 1800 1750 1750 1750 1750
2875 600 1600 1600 1600 1600 1600 1600 1600 1600
1000 1150 1150 1150 1150 1150 1150 1150 1150
500 1800 1800 1800 1800 1700 1700 1750 1750
2975 600 1600 1600 1600 1600 1600 1600 1600 1600
1000 1150 1150 1150 1150 1150 1150 1150 1150
500 1800 1800 1800 1800 1700 1700 1700 1700
3275 600 1600 1600 1600 1600 1600 1600 1600 1600
1000 1150 1150 1150 1150 1150 1150 1150 1150

00
| 500 1800 | 1800 1800 1800 1650 | 1650 1700 1700

3575 | 600 1600 1600 1600 1600 1550 1600 1600 1600
4 4 f\f\ 4 4 rr\ 4 4 r-r\ 4 4 m
¡ g i v vv 1 1 vv 1 1 w 1 1 w i IJU 1 1 UU 1 1 UU 1 IUU I I OU 1
1 500
1750 1800 1800 1800 1650 1650 1700 1700
3975 I 600 1550 1600 1600 1600 1550 1600 1600 1600
1 1
1 IUUU
1100 1150 1150 1150 1100 1150 1150 1150
NOTES:
(1) lift inclination : SX<=4530: Forw. 3°, Back. 9° 1
5
SX >= 4530 - DX - TX: Forw. 3°, Back. 5
with front cab panel forSX < 4530: Forw. 3°, Back. 5 °
S.E. SING. 200/50-10

TYRES/LIFT (1)
rio» I Load WITH SLI WITHOUT SLI
I! center- Maxi- Ì 3300 Maxi- | 3300 !
J ƒ mnc \ of-gravity mum el- | mm el mum el-1 mm el
(\m rri/ì
...... evation I evation evation | evation a
TYPE= TX GAL (2)

500 1700 | 1800 | 1750 j 1800
r
yn cnn
VW 1500 | 1600 ccn
4i vvv 1600 L
1000 1050 | 1150 1100 1150 j

500 1650 1800 1700 1800
1
4470 ouu 1500 1600 1500 1600
1000 1050 1150 1050 1150
500 1600 1800 1650 1800
4770 600 1450 1600 1450 1600
1000 1000 1150 1050 1150
500 1450 1800 1500 1800
5220 600 1300 1600 1350 1600
I 1000 950 1150 950 1150
l_.. J
500 1250 1750 1250 1800
5770 600 1100 1550 1100 1600
1000 800 1100 800 1150
I rnn 4
Uuu t UU v 1700 1 Vw i Í OU
6370 600 900 1500 900 1550
1
1000 650 1050 650 1100
500 850 1700 850 1750
6970 600 750 1500 750 1550
1000 550 1050 550 1100
NOTES:
SX >- 4530 - DX. - TX.: Forw. 3°, Back. 5 °
REV. 00 of 01/10/07
Lift types:
Product information
PN: Pneumatic tyres
TWIN: Twin tyres

(Back.)

00
S.E. SING. (200/50=10)

TYRES/LIFT (1)
VULKOLAN (18 x 5 x 12 1/8”)
Elev.
h3 3300 mm
(mm) elevation
TYPE= SX
500 2000 2000 2000 2000
3350 600 1800 1800 1800 1800
1000 1250 1250 1250 1250
500 2000 2000 2000 2000

3650 600 1800 1800 1800 1800
'innn
6 WWW 1250 1250 1250 1250
500 2000 2000 2000 2000
4050 600 1800 1800 1800 1800
I 1000 1250 1250 1250 1250
500 1900 2000 1950 2000
i 600
4550 1700 1800 1750 1800
*8 mah
i UUU 1200 1250 1250 1250
IT......... i
500 1800 2000 1850 2000
5050 600 1600 1800 1650 1800
1000 1150 1250 1150 1250
NOTES:
SX >= 4550 - DX - TX: Forw. 3°, Back. 5 °
S.E. SING. (200/50-10)

TYRES/LIFT (1)
Elev.
h3 rvsirr» 1
oNgiaviiy mum el mm el mum el mm el mum el mm el mum el
(mm) elevation
TYPE= DX GAL
500 2000 2000 2000 2000
2970 600 1800 1800 1800 1800
1000 1250 1250 1250 1250
500 2000 2000 2000 2000
3270 600 1800 1800 1800 1800
«1 OKA
4 nnn
i WWW
4 ocn
I £-WW
4 ocn
i ¿-WW i £-U\J
-fOKA
i
500 2000 2000 2000 2000

3570 600 1800 1800 1800 1800
1000 9^n
41 ¿.ww 1 £-WW
41 £_WW 49HA
1 £-WW
L........ ..... .JL........
Workshop literature. 40328042303 EN - 05/2008

Product information
500 2000 2000 2000 2000

3970 600 1800 1800 1800 1800
1000 1250 1250 1250 1250
NOTES:
SX >= 4550 - DX - TX: Forw. 3°, Back. 50
S.E. SING. (200/50-10)

TYRES/LIFT (1)
VULKOLAN (18 x 5 x 12 1/8”)
Elev.
h3 3300 mm
(mm) elevation
TYPE= 'rx GAL
500 1800 2000 1850 2000
4465 600 1600 1800 1650 1800
1000 1150 1250 1200 1250
500 1700 2000 1750 2000
4765 600 1500 1800 1550 1800
1000 1100 1250 1100 1250
500 1550 1950 1600 2000
5215 600 1400 1750 1450 1800
1000 1000 1250 1050 1250
500 1350 1900 1400 1950
5665 600 1200 1700 1250 1750
1000 850 1200 900 1250
500 1100 1850 1150 1900
6265 600 1000 1650 1050 1700
1000 700 1200 750 1200
500 950 1800 1000 1850
6865 600 850 1600 900 1650
1000 600 1150 650 1200
NOTES:
SX >= 4550 - DX - TX: Forw. 3°, Back. 5 °
REV. 00 of 01/10/07
Lift types:
PN: Pneumatic tyres
TWIN: Twin tyres

00

(Back.)
00-28 4032804
Product information
Alternative lift characteristics
Standard (Simplex)
1300 kg/ Lift height h3 mm 3330 3630 4030 4530 5030
1500 kg/ Minimum height of di
1600 kg (3 hi mm 2210 2360 2560 2810 3060
mensions
wheels)
Maximum height of
1500 kg/ h4 mm 3905 4205 4605 5105 5605
dimensions
1600 kg (4
wheels)
4-ROLLER Free lift h2 mm 150 150 150 150 150
fork
carriage (*)
1800 kg (3 Lift height h3 mm 3330 3630 4030 4530 5030
wheels) Minimum height of di
1800 kg (4 hi mm 2210 2360 2560 2810 3060
mensions
wheels)
Maximum height of
6-ROLLER h4 mm 3973 4273 4673 5173 5673
dimensions
fork
carriage Free lift h2 mm 150 150 150 150 150
2000 kg (3 Lift height h3 mm 3350 3650 4050 4450 5050
2000 kg (4 hi mm 2260 2410 2610 2860 3110
mensions
wheels)
Maximum height of
6-ROLLER h4 mm 4046 4346 4746 5246 5746
dimensions
fork
Duplex
1300 kg/ 3575
Lift height h3 mm 2875 2975 3275 (**) 3975
1500 kg/
1600 kg (3 Minimum height of di
wheels) hi mm 1960 2010 2160 2310 2510
mensions
1500 kg/
Maximum height of
1600 kg (4 h4 mm 3450 3550 3850 4150 4550
dimensions
wheels)
4-ROLLER
fork Free lift h2 mm 1312 1362 1512 1662 1862
carriage (*)
1800 kg (3 3575
Lift height h3 mm 2875 2975 3275 (**) 3975
wheels)
1800 kg (4 Minimum height of di
hi mm 1960 2010 2160 2310 2510
wheels) mensions
6-ROLLER Maximum height of
h4 mm 3543 3643 3943 4243 4643
fork dimensions
2000 kg (3 Lift height h3 mm 2970 3270 3570 3970
2000 kg (4 hi mm 2010 2160 2310 2510
mensions
wheels)
Maximum height of
6-ROLLER h4 mm 3646 3946 4246 4646
dimensions
fork
carriage Free lift h2 mm 1445 1595 1745 1945

Product information
Tri olex
1300 kg/ 4470 5220
Lift height h3 mm 4170 4770 (..n 5770 6370 6970
1500 kg (“*)
i 1600 Minimum height
kg (3 hi mm 1960 2060 2160 2310 2560 2760 2960
of dimensions
wheels) Maximum height
1500 kg h4 mm 4745 5045 5345 5795 6345 6945 7545
of dimensions
/1600
kg (4
wheels)
4-ROLLEF Free lift h2 mm 1312 1412 1512 1662 1912 2112 2312
fork car
riage (*)
1800 4470 5220
Lift height h3 mm 4170 (...) 4770 (...) 5770 6370 6970
kg (3
wheels) Minimum height
1800 hi mm 1960 2060 2160 2310 2560 2760 2960
of dimensions
kg (4 Maximum height
wheels) h4 mm 4838 5138 5438 5888 6438 7038 7638
of dimensions
6-KOLLEF
fork car Free lift h2 mm 1312 1412 1512 1662 1912 2112 2312
riage
2000 Lift height h3 mm 4465 4765 5215 5665 6265 6865
kg (3 Minimum height
wheels) hi mm - 2060 2160 2310 2460 2660 2860
of dimensions
2000
Maximum height
kg (4 h4 mm - 5156 5456 5906 6356 6956 7556
of dimensions
wheels)
6-ROLLEF
fork car Free lift h2 mm - 1495 1595 1745 1895 2095 2295
riage
(*) with fork carriage option (6 rollers)

(**) hi - 2260 mm for the low-roof version
(***) h1 = 2010 mm for the low-roof version
h4= h4 + 68 mm (SX)
h4= h4 + 93 mm (DX-TX)
h2= h2 - 93 mm (DX-TX)
Abbreviations key
Lift. = Lift Opt. = Optional
DX- Duplex lift All lifts = Ali the lifts
SX - Simplex lift S.E. - Superelastic
TX = Triplex lift S. = Single
Sing. - Single tyre PN. - Pneumatic
Twin. = Twin tyres RVE = Reverse while empty
00-30 Workshop literature. 40328042303 Eh!.. 05/2008

Product information
Tyre inflation pressure
AXLE SIZE PRESSURE

Front 18x7 - 8/16 p.r. 10 bar
Rear 15x4.5 - 8/16 p.r. 10 bar
Lamps
Tail and stop lights, "standard" Dual filament lamp 24V - 4W

Tail and stop lights for "use on public roads"* Dual filament lamp 24V - 4W
Reversing lights 24V - 21W
Licence plate lights * 24V - 5W
Side lights* 24V - 5W
Dipped-beam lights* 24V - 50W
Direction indicators* 24V - 21W
Work lights* 24V - 70W
Flash headlight "without use on public roads"* 10/100V - 5W
Flash headlight "with use on public roads”* 9/32V - 30W
* Option
Battery dimensions and weights
Truck type Voltage V Capacity Ah Weight kg±5%

465 749
1300 kg (3 wheels) 48 ff
460 765
>»
1500 kg (3/4 wheels) 48
500 780
>»
620 970
1600 kg (3/4 wheels) 48 >, if
575 915
ff
1800 kg (3/4 wheels) 48
625 930
fl
750 1055
2000 kg (3/4 wheels) 48 !»
Table No. 1403/90 - Revision: 11
A DANGER
The minimum and maximum weights of the batteries
must be guaranteed.
Workshop literature -40328042303 EN - 05/2008 00-31

00
Internal accessibility
j j | NOTE
oil filter), proceed as follows:
The battery cover is held open by a gas spring (6).

release the distributor assembly (2), then lift
the assembly towards the front part of the truck • To close the cover and distributor assembly,
to its end position and block it using the retainer follow the instructions above in the reverse
(3). order.
insert the key in the lock; press the pushbutton
(4) to release the battery cover (5) and raise it.
00-32 Workshop Hterafcre 05/2008

Product information
Safety features
Sollevatore: 6 Chain tension rod retaining device

1 Load carrying grate (optional) 7 Net for the overhead guard to protect against
2 Fork stop latches small falling objects (option)
3 Fork retaining device 8 Shear protection net (if applicable) depending
4 Fork carriage retaining device on the type of lift
5 Chain retaining device
j NOTE
The chain retaining device (5) is present on DX

and TX lifts only.

00
Cairo: 12 Overhead guard

-in
I V/ "Seat switch" microswitch that blocks oper 13 Alarm horn
ation of the truck when the operator is not 14 Reverse gear warning buzzer
seated on the driver’s seat 15 Emergency stop button
4 4 ID i »-> i nn
s\«5bi.i Qii iii uvil
The operator must be aware of the presence of [ jj NOTE

the safety devices cited above.
Th3S& de viCeS iTiOSt be checked daily. aS descri

bed in Chapter 4
00-34
Product information
Transporting the Forklift

The forklift is normally transported by truck and
train complete with hoist. If the forklift’s dimen
sions exceed the max. clearance size allowed, it
is transported disassembled. The sales network
is in charge of the disassembly and reassembly
operations. The forklift must be secured to the
transport means during transport using appro
priate restraint systems. Block the wheels with
wedges to prevent even the slightest movement.

00
Product information
Forklift towing
A CAUTION
During the towing operation, the operator must be on

board the truck in orderto perform the steering and bra
king operations.
NOTE
Use non-metallic cables fortowing.
Version with reversing on the steering wheel

> Before towing models with reversing lever on
the steering wheel, check that this lever (1) is
in the central position.
dv Workshop literature - 40328 '.008

Product information
Loading and unloading the truck
Use an inclined plane or movable loading ramp A DANGER

to load and unload the truck. If the truck is not
Use a crane with a suitable lifting capacity for the
operational or does not have the battery, lift it as weight of the truck, indicated on its designation plate.
described below. Also take into account the weight of the mounted bat
tery (if applicable), consulting the relevant designation
plate. The lifting operations must be performed by
qualified personnel. DO NOT stand within the crane’s
radius of action or near the forklift. Use non metallic
cables. Make sure that the lifting capacity of the slings
is suitable for the weight of the truck.

00
To lift the truck, proceed as follows: A CAUTION

» Insert a non-metallic sling (1) into the rear tow The cables should have a suitable length so as to not
coupling (2) of the truck. Check that the sling graze the roofer any additional equipment during lif
adheres to the upper part of the slot in the ting. Use a iifting beam if necessary. The slings must
counterweight. be pulled vertically.
9 Pass two slings (3), one on each side, through

the upper crossmember (4) of the lift’s fixed
A CAUTION
mast.
9 Connect the free ends ofthe cables to the hook Any other lifting and transport method ofthe forklift is
forbidden.
of the crane and lift without tearing.
Workshop literature 40328042303 EN. 05/2008

Safety precautions
Description of safety symbols
This document gives the danger warnings Each A WARNING
of such danger warnings consists of a graphic
This warning indicates the risk of damaging the truck or
symbol, followed by a description of the danger parts of the same.
and its consequences, and the description of how
It may be accompanied by additional comments.
it can be avoided. The types of warnings used are
described below.
A DANGER t NOTE
This warning indicates serious risks forthe safety of the This symbol indicates important communications
operator and maintenance staff. forthe assistance technician.
ENVIRONMENT NOTE
A CAUTION The instructions given here must be followed in

This warning indicates serious risk of damaging the
order to avoid causing damage to the environ
truck. ment.
Operations Preliminary to Maintenance

Do the following before performing maintenance • Switch off the vehicle.
operations: • Press the emergency pushbutton.
• Place the forklift on a flat surface and make
A DANGER
sure that it cannot move accidentally.
• Lower the forks fully. Before performing any intervention on the electric sys
tem, disconnect the battery outlet from the relative
Plug.
To avoid accidents
Most accidents that occur in workshops are their consequences, scrupulously following the
caused by failure to observe some simple and safety rules.
fundamental rules of prudence and safety.
A careful and wise mechanic is the best guaran
Forthis reason, accidents can be avoided in most tee against accidents.
cases by the necessary care and prudence, pay
ing attention to possible causes of accident and

00 Generai information
-,
General safety Regulations
ADANGER • The brakes are not activated when they are

manually released for maintenance or repair
Failure to observe the safety provisions can cause se
rious harm to technical staff and to the truck. operations: in this case provide for control of
the machine using suitable chocks or similar.
During maintenance and repair procedures, scrupu
lously follow the prescriptions indicated below and the • Ensure that no one is within range of any move
instructions given in this manual. Maintenance ope ment of the machine or equipment.
rations must be performed by gualified technical per
sonnel authorized by the manufacturer. Always work = Do not carry out any maintenance or repair on
within the limits of safety, according to the standards in the machine with a person sitting in the seat,
force. unless the person is qualified and necessary
for execution of the operation.
» Do not switch on the machine or activate its
ENVIRONMENT NOTE
equipment from any position other than sitting
Carefully follow the safety regulations pursuant in the driver’s seat.
to the provisions in force when handling working • To avoid improper use or use in unsafe condi
materials. tions, label all controls to mark that repairs are
in progress
NOTE = Do not leave the machine unattended with
parts in movement.
Importantinformation regarding kno w/edge ofthe
° Immobilise the machine and all equipment or
truck andits safe use along with basic information
parts that are subject to maintenance while
on truck maintenance are given in the Instruction
raised, or which could accidentally move.
and maintenance manual.
° When carrying out operations from beneath
the truck, always use a maintenance well or a
bridge crane of adequate capacity.
Do not carry out any cleaning, lubricating or mainte
nance activities when the battery is connected. • The areas for maintenance must be ievei, and
if maintenance operations are carried out with the bat must be kept dry and clean; any puddles of wa
tery connected, the machine may accidentally be star ter or oil stains must be removed immediately.
ted, or sparks may cause harm to the technical staff • Do not pile up rags soaked in grease or oil: they
or to the machine itself. The battery must therefore be
represent a serious fire hazard. Always place
kept disconnected, unless expressly prescribed by the
maintenance or repair instructions. them inside a closed metal container.
» If working on a sloping surface is inevitable, im
• Aii service actions must be carried out with mobilise the machine before starting to work,
maximum care and attention. and move it to a level surface as soon as this
• During maintenance operations, approved can be done with a certain margin of safety.
protective clothing must be worn, such as over • Service stepladders and platforms used in the
alls helmets, nmtective footwear with nnn-slin workshop or on the worksite and other equip
soles, gloves and safety goggles. ment must conform with the accident preven
• Do not wear rings, wrist watches, jewellery, tion standards in force.
unfastened or hanging garments such as ties, » After completing maintenance operations, the
torn clothing, scarves, unbuttoned jackets or truck must be returned to normal conditions
blouses, or open zips, which could be caught of use, taking care to check the correct instal
in the moving parts. lation of all prescribed safety and protective
» Operate in separate work areas specifically devices. Take care to remove all equipment
intended for maintenance or specially marked from the machine, and check accurately that
off to indicate work in progress. all parts are firmly fixed.
• During maintenance operations, engage the • To tow the truck, comply with the instruction
parking brake, turn off the truck and remove in this manual, using the provided connection
the keys from the dashboard, unless expressly points exclusively. Make all connections care-
required by the operation being carry out. fully/ensure than pins and/or latches foreseen
are f¡rmly fixed before starting to tow the truck.
• Ensure that the machine cannot be moved
Do not remain in the vicinity of the tow bar,
accidentally.
ropes or chains working under tension.

Safety precautions
• To move a machine that has broken down, protective side guards, helmets, protective
use a trailer or a truck with a lowered loading footwear and safety gloves.
platform, if available. • During welding operations, always use protec
• When transporting the truck, follow the indi tive accident-prevention devices. Protective
cations in this manual. To load and unload goggles must also be worn by anyone in the
the machine on and off the transport means, vicinity, even if not carrying out work. Never
choose a level area with a solid surface to sup look at the welding arc without adequate eye
port the wheels of the trailer or lorry. Anchor protection.
the machine firmly to the loading platform of • With use, metal cables become frayed: when
the lorry or trailer and block the wheels. handling them, always use adequate protec
• The chains must be firmly fixed: make sure tion (gloves, goggles, etc.). Do not use chains
that the anchorage is sufficiently resistant to or ropes that are worn or bent for lifting or
support the foreseen load. No one must be pulling.
within the vicinity of the chain or rope anchor
age points under tension.
Electrical system - batteries
• Handle each part with extreme care. Keep
hands and fingers away from interstices, ro A DANGER
tating parts and similar.
Before performing any operation on the electrical sys
• When lifting or transporting heavy parts, use tem, disconnect the battery outlet from the relative
pulleys or similar of adequate capacity, and plug.
keep all persons at a safe distance. • When using the batteries, it must be remem
• Move with great care when carrying out work bered that both ends of the cables must be
beneath the machine, and also when in the linked to the terminals in the correct manner:
vicinity of the same. (+)to(+)and (-)to(-).
• Stop the motor and make sure that there is • Avoid short circuiting the battery terminals.
no pressure in the hydraulic circuits before • The gas released from the battery is highly in
removing caps or covers. flammable. When recharging, leave the bat
• If any part is blocked, free the same only when tery compartment open to allow for more effec
the motor is off and the battery is disconnected. tive ventilation and remove the caps. Ensure
• Do not check or top up the fuel tank, the hy that ventilation is adequate in order to avoid the
draulic oil or the battery while smoking since possibility of accidental explosions due to the
the fluids used are inflammable. accumulation of gas released during recharg
ing.
• Never pour petrol or diesel oil into open, wide
or low recipients because of the risk of in • Never check the state of the battery by means
flammable vapours and spills. of a “bridge” created by placing a metal object
on the terminals.
• Never use petrol, diesel oil or inflammable flu
ids for cleaning: always use non-toxic com • Avoid sparks and flames in the battery area.
mercial solvents. • Do not smoke near the battery or in the main
• When using compressed air for cleaning small tenance area in order to avoid the risk of explo
parts, use protective goggles with side guards; sions.
use a maximum pressure of 2.1 bars according • Before any operation, check that there are no
to local or national legislation in force. electrolyte leaks: eliminate such leaks before
• When handling easily inflammable material, proceeding with the work.
do not smoke, do not use open flames, and do • Refer to the specific Instruction and Mainte
not cause sparks in the vicinity. nance Manual of the drive battery.
• Do not use flames as a means of illumina • Before any operation, check that no elements
tion when proceeding with operations or when are short circuited: eliminate such short cir
searching for leaks on the machine. cuits before proceeding with the work.
• Do not carry objects in pockets which could • For electric heaters, battery chargers and sim
accidentally fall into the open parts of the ma ilar appliances, use only effectively earthed
chine. auxiliary power sources in order to avoid the
• When there is any possibility of being hit by possibility of electric shocks.
metallic parts or similar, use goggles with

Hydraulic system Disconnections and reconnections
A DANGER DANGER
ömaii high pressure jets of oil can penetrate the skin. Before removal and instaiiation of any component, dis
Penetration of the skin by hydraulic oil under pressure connect the relative plug from the battery outlet.
spurting from the hydraulic system is dangerous. If this • Lift and handle all particularly heavy parts by
type of lesion should occur, contact a doctor immedia
tely. Small leaks should be sought by the aid of a piece means of lifting gear of an adequate capacity.
of cardboard ora piece of wood. Avoid using the hands • Ensure that pieces are supported by appropri
to look for leaks. ate harnesses and hooks.
• Use the lifting rings specifically provided for
• Use special instruments to check the pressure
the purposes. Pay attention to persons in the
of the hydraulic system.
vicinity of the load to be lifted.
» Handle all pieces with great care.
s Do not place hands or fingers between one
piece and another.
• Avoid twisting the chains and metal cables.
Safety Regulations Relative to Operating Materials

Rules for handling and disposing of operat The replaced parts must always be disposed of in
ing materials accordance with the anti-pollution laws.
ENVIRONMENT NOTE ENVIRONMENT NOTE
Improper use and disposal ofoperating and clea The incorrect or unlawful use of brake fluid is
ning materials can cause serious damage to the harmful to peopie’s health and the environment.
environment.
Always use and handle the operating materials in Oils

a suitable manner and follow the manufacturer’s ' Do not allow to come into contact with the skin.
instructions for the product’s use.
• Do not inhale oil vapors.
Keep the operating materials only in containers ° Wear appropriate means of individual pro
intended for this purpose and in a location that tection during forklift maintenance operations
satisfies the requirements. (gloves, goggles, etc.) to prevent the oi! from
The operating materials may be flammable, so coming into contact with your skin.
avoid contact with hot objects or open flames.
When topping up the operating materrale, only ENVIRONMENT NOTE

clean containers should be used.
The used oils (brake, motor, transmission, gear
Follow the manufacturer’s safety and disposal box and hydraulic oil) and relative filters contain
instructions regarding the operating and cleaning substances hazardous to the environment and
materials. must be disposed ofaccording to current regu
lations. We advise you to contact the authorised
Do not disperse oils or other operating liquids!
service network.
Any spilt liquid must be immediately collected and
neutralised with a binding material (such as an oil A DANGER
binder) and then disposed of in accordance with
current regulations. The penetration in the skin of hydraulic oii that has lea
ked under pressure from the forklift’s hydraulic system
Always abide by the regulations of the anti-pollu is dangerous. If this type of lesion should occur, con
tion laws! tact a doctor immediately.
Before carrying out work that involves lubrication,

filter replacement or hydraulic equipment inter
ventions, the area in question must be thoroughly
cleaned.
00-42 Workshop Hterature - 40328042303 EN 05/2008

Safety precautions
A DANGER
j| NOTE
Small high pressure jets of oil can penetrate the skin.
Look for any leaks using a piece of cardboard.
Forgreater information, consult the specific bat
tery manual that comes with the battery.
Battery Acid
• Do not inhale the vapor: it is poisonous. ENVIRONMENT NOTE
• Use adequate means of individual protection
The batteries contain substances that are hazar
to prevent contact with the skin.
dous to the en vironment. The replacement and
• Battery acid is corrosive: if it should come into
disposal of the life-expired battery must be car
contact with your skin, rinse abundantly with ried out as required by law. We advise you to con
water.
tact the authorised service network that is equip
• Explosive gas mixtures can form when charg ped for eco-friendly disposal in accordance with
ing the battery; therefore, the rooms in which current regulations.
the battery is charged must be in compliance
with the specific regulations on the subject
(e.g. CEI-EN 50272-3,...).
• DO NOT smoke or use open flames and lights
within a 2 m radius from the charged battery
and in the battery charging area.

00
Workshop literature 40328042303 tN - 05/2008

@) Service 01
Maintenance
Preliminary operations before commissioning
Below are listed the operations that must be per • Check the inching pedal linkage, fan belt ten
formed on the forklift before delivering it to the sion, handbrake tension and adjust if neces
customer: sary.
• General test of the forklift. • Check and restore, if necessary, the wheel nut
• Check and top-up, if necessary, the oil in the tightening, retaining screws fastening the lift
hydraulic system tank. to the truck, counterweight, protective roof,
lifting chains and their anchorage, clearance
• Visually check the seal of the lift cylinder gas
between movable parts, pneumatic pressure.
kets, tilt cylinders, steering control cylinder and
side shift, distributor, oil pump, hydraulic sys • Check the operation of the electrical recharg
tem piping and fittings; eliminate any leaks. ing system, ignition, control instruments, and
Check the oil level and top-up, if necessary, battery liquid level.
for the motor, hydraulic and differential trans • Forklift lubrication and greasing.
mission, reducers; eliminate any leaks. • Lift greasing (mast, rolling tracks).
• Check the brake fluid level and top-up, if nec • Check of the safety devices
essary; visually check the seal of the brake
system, service brakes and parking brake; j NOTE
eliminate any leaks.
• Check the motor cooling water level and top- For the description ofthe operations, refer to the
up, if necessary; visually check the seal of the relative paragraphs.
motor cooling circuit; eliminate any leaks.
Synoptic Table of Maintenance Operations
hours
Operation
1000 3000 or 2 years
Check wheel nut tightening •
Parking brake check •
Chain tension check and adjustment •
Check hydraulic tank oil level •
Cleaning of the electronic panel •
Lubricating the steering axle •
Fork carriage guide lubrication •
Service brake check •
Trunnions greasing •
Reduction gear oil level check •
Rolling tracks greasing •
Grease rear wheel bearings (4 wheels) •
Seat belt blocking system check •
Lubricate lift chain •
Chain check and maintenance .(1)
Change gearbox oil .(3)
Check and adjust lift clearances •

Change hydraulic oil filter cartridge •
Protective roof tightening screws check •
Check fork wear .(1)

01 Service
---------------------------- 1
Check brake oil level «
Change hydraulic system oil •
i Axiai mainÍRnanr.R i i
I Change brake oili
= To be carried out absolutely every 3 months • Follow the safety precautions for the lubricant:
or according to current legislation. 8 Before lubricating, carefully clean the compo
(2) = Every 1000 hours or at least every 12 nent to be lubricated;
months. 8 Use suitable binders if the lubricating product
should spill;
=First change after 1000 hours, then every
3000 hours. • Keep the product in a suitable and compliant
place, as per the instructions supplied with the
product;
ENVIRONMENT NOTE
« Dispose of the lubricating product in compli
Proceed as follows at each lubrication operation: ance with the current laws.
Supply Table
lj : : . ....... .. . .
International spec
Element to be supplied Quantity Lubricants
ifications
DIN 51524
min 251 for SX Oil:
Hydraulic circuit DIN 51525
max 351 for TX IDRAULICAR AP 46
■SO VG 46 _
Bearings and grease Grease:
0.1 kg NLGI 2
nipples TUTELA MR2
Grease:
Axle support
MOLYCOTE Type P40
SAE 80W-90APIGL5
Oil:
Reductions 0.6 ! (or SAE 85W - 90
AMBRAAXF80W90
API GL4)
Lubricant:
Chains STRUCTOViS ISO VG 150
CL-IF'.
I I I u/
Oil:
Oii-immersed brakes 0.2 1
SHELL DONAX TX
Workshop Heratae -40328042303 EN - 05/2008

Diagnostics 02
Diagnostic software
Connection between the diagnos
tics PC and the forklift
The diagnostics PC connects to the forklift
through theZAPI interface cable, code 9847105.
The connection can be performed on all modules.
A CAUTION
The connection between PC and forklift must be per
formed with the forklift turned off.
A CAUTION
The diagnostics unit must be used by trained personnel
only. The variation of some parameters or configurati
ons maycause hazardous situations for the operator.

02 Diagnostics
Software
The software to be used for the parameterization
°nc! diagnostics 'S WiNPCCONSO^ E
Instructions:
• Connect the PC to one of the electronic mod
ules using the interface cable.
A CAUTION
The connection between PC and forklift must be per
formed with the forklift turned off.
Access the software through the relative icon.

The software opens with the following screen:
-IQl x|
File Corifigwot.uii ConnGcUoFi FunctiO; i i sctp
j...... Start
Connected ;o.
Nominal Voltage:
Stop
Nominal Cwenl.
IfHiOsW: rr ::oW:s:
ALARM:
CONNECTION STATUS: NOT CONNECTED
W30334
Switch on the forklift (closing the key contact).

Select the “Start” button to start the connection.

Diagnostics 02
Diagnostic software
Pt Cumule Versaw 1,01 IBi
Ffe O(MA0UHÜM CWMBtJWI
C&nrascivdta = ■* * » • • '
Mo^Votaogt •V
Nomrai Curarti
Ho-j h
AURm
CONNECTION STATUS CONNECTED
W30335
The software has five menus:

• FILE
• CONFIGURATION
• CONNECTION
• FUNCTION
• HELP
Description of the menus in the

WINPCCONSOLE software
FILE menu
File Configuration Connection Function Help

'■■pen Ctrl+Fli
7 r-urn file Shift+Fll
S-T'C Shift+F12
:ruted >o.
f-i r.r Shift+Ctrl+F12
nal Voltage, . :V
Stop i
Fit Ctrl+Alt+X rial Cuiient
Heur : h
ALARM
CONNECTION STATUS: CONNECTED
W30336

02 öjagnostscs
Diagnostic software
The FILE menu allows to perform operations with
the files:
• |Qpen|: t0 display the parameters contained in
a previously saved file in the program
. |Txfromfiie|: to load the parameters contained
in a previously saved file into the memory of the
microcontroller
° |save|: to save the parameters present in the
microcontroller in a fiie
• |Print|; to print
• [Exit]; to exit the program
CONFIGURATION menu
-IOI xj
File Configuration Connection Function Help
id W
I
language
r ocup
Nominal Current.
Hour.
ALARM.
CONNECTION STATUS: CONNECTED
\ A /onoo-7
The CONFIGURATION menu allows to enter a

password. Its use is reserved to the central Tech
nical Service Department personnel It is used
to enable the last 2 submenus of the FUNCTION
menu. Entering the password also enables the
option ¡Change Password| that allows to change the
password.
fj] NOTE
The only way to restore the originalpassword is

to install the software again.

Diagnostics 02
Diagnostic software
CONNECTION menu
_]□: X
iS- Crinfirjii-.ihr :i i Connect.ji i Fi.'-"hnn Hep
Itop Ctrl+X
.S_
Hu.iirijIVij'ljge
S l
I Sk-p
Honi'nal Zurient
Hour h
ALARM
CONNECTED
W30338
The CONNECTION menu allows to begin (|start|)

and end (I Stopp the connection with the electronic
module.
FUNCTION menu
_ 'fl. x
File Configuration Connection Fiitxtr-ti He’p
~ ar ameter
Tester Ctr l-i-T
Alarm Logbcok Ctrl r A
Program VACC Ctrl-*- v
Muh .i L'jr.-j
j: Step '[
Hol
ALA
CONNECTION STATUS: L JNNECTED
W30339
The FUNCTION menu is subdivided into 6 sub

menus:
• Parameter
• Tester
• Alarm logbook
• Program VACC
• Motor Data

02 Diagnostics
Diagnostic software
° RAM Function
» EEPROM Function
i ho Hsrsmstor snd ! osier menus ere de-
scribed in detail in special paragraphs.
The RAM Function and EEPROM Function
menus are accessible only by password and
are reserved to the Central Technical Service
Department.
The Motor Data menu is not available.
> The Alarm Logbook menu allows to access the >

list of alarms containing the alarm name, oc
ACTIJALAlARM.
currence, temperature and hour in which they
ifWjwhkv, J Hous
occurred. i- '• - ■" ;i ft
3b
The following operations can be performed:
, ....... , WT
. |Update|; update the alarm list 1
. |Clear]: cancel the alarm list

e ¡dose]: close the active window __
• ¡Print): print the alarm list UtxJs'e Ctose i
Selecting the Clear key causes a dialog window

to appear: the cancellation occurs only after an
additional confirmation.
> The Program Vacc menu allows to calibrate i> _n x
the potentiometers. The analog signal acqui

FORWARD
sition procedure is described in the chapter
v..........
■’Anaiog signals". Mffxmuw T
BACKWARD
__-----------
Himw F V*
¡.fat,
'.'’.'3034’

Diagnostics 02
Diagnostic software
HELP menu
fêl
File Cnniqii’allem
Contents
Coniwuied to. »t. I
\ r
Nominal Voltage:
Sh-,p
Humilia) Luriunt jA
Hout !-i
ALARM
CONNECTION STATU CONNECTED
W30342
The HELP menu allows to access the online

guide; it is possible to access an index in which to
select the desired subject (|index|) or enter a key
word to search (|find|).
Description of the PARAMETER

menu
The PARAMETER menu is subdivided into 6 sub
menus:
• | Parameter Change|
• | Set Options]
. |Set Model]
• ¡Adjustment]
• | Special Adjust|
• | Hardware Settings!

Parameter Change
Parameters -
Parametet Change | Sei Option; | Set Model; Adjustment! Special Ad]u;t j Hardware Settings!
Store
W30343
This menu allows the display and modification of

a list of parameters. When opened, the Parame
ter Change window is empty.
Selecting the key |Receive| ¡t is possible to load all
the parameters relative to the electronic module
chosen using the SET Model function. Selecting
the key I Receive Me~nu| only the parameters relative
to the current page are loaded.
At the end of reception, ail the available parame
ters will be listed in the window.
To modify a parameter, click on the value to be
modified; this activates the right part (1) of the
window where the new value can oe set. s he pa
rameter can be modified by entering a number
from 0 to 9 which corresponds to a step variation
that differs according to the parameter.

Diagnostics 02
Diagnostic software
Set Options
file Memxy
P««neta Change 5*WedelI A#*rttaert| SgerielAdiM* | HaKhweSetthg»|
•Parami« Name Pwamciw Value

3
i
i 0N 1 j
- ' 7 «L1 * > r OFF
LEVEL-0 .. ............ .„J
F-;»rer^ | &HW
W30346
This menu allows the display and modification of

an additional list of parameters, mainly connected
with the selection of optional setups.
When opened, the Set Options window may be

empty.
The loading and modification of the parameters

occurs using the same procedures as the Param
eter Change menu.

02
Set Model
IP?. - Parameters -ini xj
Parameter Change ! Set Options ; Set Model :| Adfustment j Special Ad|ust - Hardware Settings
¡Parameter Name
c
Receive Close «
W30347
This menu allows to select/change the electronic

module to be connected to.
The window shows a single parameter: con
nected to.
The value of the parameter (1) represents which

electronic module or CAN BUS node is currently
connected.
To select another module Z CAN BUS node, click
on the parameter value (1). This activates the
right part (2) of the window, where it is possible to
seiect another module using the selection menu
(3).
[j] NOTE
There is no correspondence between the para

meter value (1) (CAN BUS node) and the item in
the selection menu (3).
NOTE
it is also possible to select non-existent nodes.

For example the MHYRIO module, which is pre
sent only with the Joystick, is always selectable.
Be careful when making the selection.
After having changed the module, it is necessary

to click on istorej to enable the modification.
02T0 Workshop Hterature - 40328042303 EM - 05/2008

Diagnostics 02
Diagnostic software
Adjustment
-JI. X.:
Porofflute? Chnngv
I ;■
i -
-S
Rrcwe Menu
:l
i»
Close I
W30348
This menu allows to access additional parame

ters.
The loading and modification of the other param
eters occurs using the same procedures as the
Parameter Change menu.
Special Adjust
This menu allows the modification of additional
parameters.

eter Change menu.
Hardware Settings
This menu allows the modification of additional
parameters.
eter Change menu.

02 Diagnostics
Diagnostic software
Description of the TESTER menu
î
You can see 4 tester variables.
Click on the left table to select them.
A second click will erase the parameter from the right table.
üdwmwi
The TESTER menu allows to monitor the most

useful variables for diagnostic purposes.
The variables are provided in a list (1) in which it
is possible to select and deselect the quantities to
monitor.
The selected variables appear in the right part of

the screen (2).
Only four quantities can be monitored simultane

ously.
[j| NOTE
To select a variable to monitor, click on the name

ofthe variable in the list (1); to deselect the vari
able, dick again on the name ofthe variable in the
Hst(1).
The button functions are described below:
. I Advanced! ■_ t.o select the sampling time (mini
mum 1/10 second) and the number of samples
desired.
. [start Rec.|: to begin recording the samples.
. [stop Rec.I; to stop recording the samples.
= [Save Rec.| to save the recorded samples in a
file so that they can be viewed and analyzed.
02-12 Workshop literature

Diagnostics 02
Diagnostic software
. |Print| to print the values of the variables.
. |ciose| to exit the active window.
TESTER / Diagnostics Function

DUAL AC MASTER TESTER
Name Function
Voltage applied to the right traction motor, expressed in percentage
MOTOR VOLTAGE
of the maximum voltage applicable.
Frequency of the voltage and current applied to the right traction
FREQUENCY
motor.
ENCODER Speed of the right traction motor expressed in rpm.
SLIP VALUE Slip of the right traction motor expressed in Hz.
CURRENT RMSDX Effective value of the right traction motor current.
TEMPERATURE Temperature measured on the traction drive heat sink.
TEMPERATURE#1 Temperature measured on the traction motor.
TEMPERATURE#2 Temperature measured on the traction motor.
Displays the voltage present on the accelerator potentiometer; the
ACCELERATOR
value in percentage must also be displayed at the same time.
Displays the voltage present on the brake potentiometer; the value
BRAKE PEDAL POT
in percentage must also be displayed at the same time.
STEER ANGLE Displays the steering angle value in degrees.
STEER INPUT Displays the voltage present on the steering axle potentiometer.
Displays the speed reduction applied to the internal wheel; in prac
INTERNAL WHEEL CUTBACK
tice, it shows the ratio between the speeds of the two wheels.
SEAT SWITCH Displays the state of the seat microswitch.
FORWARD SWITCH Displays the state of the forward gear selection microswitch.
BACKWARD SWITCH Displays the state of the reverse gear selection microswitch.
Displays the state of the single-pedal microswitch that enables the
ENABLE SWITCH gear microswitch (only for version with reversing lever on the steer
ing wheel and joystick).
Displays the state of the contact for enabling hydraulically assisted
EXCLUSIVE HYDRO
steering (e.g. pressure switch).
HAND BRAKE Displays the state of the handbrake microswitch
Displays the booster voltage applied to the traction motors, ex
VOLTAGE BOOSTER TRAC.
pressed in percentage of the maximum voltage.
BATTERY VOLTAGE Displays the value of the battery voltage.
BATTERY CHARGE Displays the percentage value of the battery charge.
CUTBACK SWITCH Displays the state of the speed reduction microswitch.
WORKHOUR Displays the hours worked in the day.
DUAL AC SLAVE TESTER
Name Function
Voltage applied to the left traction motor, expressed in percentage
MOTOR VOLTAGE
of the maximum voltage applicable.
Frequency of the voltage and current applied to the left traction mo
FREQUENCY
tor.
ENCODER Speed of the left traction motor expressed in rpm.

02 Diagnostics
SLIP VALUE Slip of the left traction motor expressed in Hz.

CURRENT RMS Effective value of the left traction motor current.
TEMPERATURE Temperature measured on the traction drive heat sink.
FORWARD SWITCH Displays the state of the forward gear selection microswitch.
BACKWARD SWITCH Displays the state of the reverse gear selection microswitch.
Displays the state of the single-pedal microswitch that enables the
ENABLE SWITCH
gear microswitch in the case of manual reversing lever and joystick.
Displays the booster voltage applied to the traction motors, ex
VOLTAGE BOOSTER
pressed in percentage of the maximum voltage.
SEAT BELT Displays the state of the seat belt microswitch.
AC2 FLASH TESTER
Name Function
Voitage applied to the pump motor, expressed in percentage of the
MOTOR VOLTAGE
maximum voltage applicable.
FREQUENCY Frequency of the voltage and current applied to the pump motor.
ENCODER Speed of the pump motor expressed in rpm.

SLIP VALUE Slip of the pump motor expressed in Hz.
CURRENT RMS Effective value of the pump motor current.
TEMPERATURE Temperature measured on the pump drive heat sink.
MOTOR TEMPERATURE Temperature measured on the pump motor.
Displays the voltage present on the HALL sensor output of the lifting
ACCELERATOR lever; the percentage value of travel must also be displayed at the
same time.
TILT SWITCH Displays the state of the tilt microswitch.
SHIFT SWITCH Displays the state of the side shift microswitch.
4 ND SPEED SWITCH Displays the state of the 4th lever microswitch.
JOY. ANALOG INPUT#1 Voltage and percentage with respect to the x-axis of the joystick.
JOY. ANALOG INPUT#2 Voltage and percentage with respect to the y-axis of the joystick.
Displays the state of the joystick microswitch for fork arm lifting re-
JOY. DIGITAL INPUT #1
auest.
Displays the state of the joystick microswitch for fork arm lowering
JOY. DIGITAL INPUT#2
request.
JOY. DIGITAL INPUT#3 Displays the state of the joystick microswitch for tilt forward request.
Displays the state of the joystick microswitch for tilt backward re
JOY. DIGITAL INPUT#4
quest.
JOY. DIGITAL INPUT#5 Displays the state of the joystick microswitch for SLI request.
JOY. DIGITAL INPUT #6 Displays the state of the joystick microswitch for 4th route request.
JOY. DIGITAL INPUT#? Displays the state of the joystick microswitch for Sth route request.
Displays whether or not the fork arm lifting solenoid valve is acti
EV#1
vated.
Displays whether or not the fork arm lowering solenoid valve is acti
EV#2
vated.
EV#3 Displays whether or not the solenoid dump valve is activated.
EV#4 —
02-14 Workshop literature-40328042303 EN -05/2008

Diagnostics 02
Diagnostic software
EV#5 Displays whether or not the tilt forward solenoid valve is activated.
EV#6 Displays whether or not the tilt backward solenoid valve is activated.
EV#7 Displays whether or not the left SLI solenoid valve is activated.
EV#8 Displays whether or not the right SLI solenoid valve is activated.
Displays the state of the contact for enabling hydraulically assisted
HYDRO SPEED REQ
steering (e.g. pressure switch).
Displays the booster voltage applied to the pump motor, expressed
VOLTAGE BOOSTER
in percentage of the maximum voltage.
BATTERY CHARGE Displays the percentage value of the battery charge.
After entering the desired date, not more than xx days prior to the
WORKHOUR
current date, displays the hours worked.
CUTBACK SPEED HW Displays the state of the input of pin E13.
AUX POT # 1 Not used
LIFTING SWITCH Lifting microswitch.
EMERGENCY SWITCH Emergency stop pushbutton.
DISPLAY TESTER
Name Function
After entering the desired date, not more than xx days prior to the
WORKHOUR
current date, displays the hours worked.
STATUS # 1 Displays the state of pushbutton 1 - "Profile"
STATUS #2 Displays the state of pushbutton 2
STATUS #3 Displays the state of pushbutton 3 - "Tortoise"
STATUS #4 Displays the state of pushbutton 4
STATUS#5 Displays the state of pushbutton 5

Parameters
Introduction
It is possible to customize the truck by changing MIN PEDAL BRAKING
the programming parameters through a PC (DI
SPEED LIMIT BRAKING
AGNOSTIC CASE or XCONSOLLE).
MAX SPEED FW
When the PC is connected to the drive, the follo
wing will have to appear on the screen: MAX SPEED BW
• 1. code of the software installed on each drive; ACC DELAY (pump)
• 2. work hours accumulated by each drive. MAX SPEED UP
Three performance profiles are available: The other parameters are common to the three
» "HARD" Rapid: this profile favours the rapidity profiles, and thus any changes will be activated
of operations and therefore productivity; it is a for ail three.
factory setting and cannot be changed.
• "STANDARD" This profile sets the machine
for normal operation. The settings can be These parameters can be changed only for the STAN
changed by the technical service department. DARD profile; for the other profiles, they can be viewed
but not changed.
8 "ECONOMIC" Endurance: this profile favours
the working endurance of the truck; it is a fac
Al! the parameters are shown in the following ta
tory setting and cannot be changed.
bles.
Each of the three profiles loads different values
The arrows in the tables have the following mean
for the foiiowing parameters:
ings:
ACCEL REDUCTION
» The symbol indicates that the parameter
ACCEL REDUCTION START level must be decreased in order to decrease
ACC DELAY (traction) the function value.
• The symbol indicates that the parameter
RELEASE BRAKING
ievel must be increased in order to increase the
INVERSION BRAKING function value.
PEDAL BRAKING The highlighted boxes refer to the default values.
Parameters of the DUAL AC mod

ule
PARAMETER CHANGE Menu
Programmee value
Name
U 0 1 2 3 4 5 6 7 8 9
MODE TYPE
Displays the profile set using the -
display.
Er; ;
ACC DELAY “STANDARD”
s
Determines the acceleration 2.0 2.5 3 3.5 4 4.5 5 5.5 6 6.5
ramp in the STANDARD profile
ACC DELAY “HARD”
Determines the acceleration
ramp in the HARD profile
s
I 25 3 3.5 4 4.5 5 5.5 6 6.5
02-16 Workshop literature - 40328042303 Ehl - 05/2008

Diagnostics 02
Parameters
ACC DELAY “ECONOMIC”
Determines the acceleration s 2.0 2.5 3 3.5 4 4.5 5 5.5 6 6.5
ramp in the ECONOMIC profile
ACCEL REDUCTION “STAN
DARD”
Sets the acceleration reduction
that occurs when the speed set % 4 7 10 15 20 30 40 60 80 100
by ACCEL REDUCTION START
is exceeded in the STANDARD
profile
ACCEL REDUCTION “HARD”
that occurs when the speed set % 4 7 10 15 20 30 40 60 80
is exceeded in the HARD profile
ACCEL REDUCTION “ECO
NOMIC”
that occurs when the speed set % 4 7 10 15 20 30 40 60 80 100
is exceeded in the ECONOMIC
profile
ACCEL REDUCTION START
“STANDARD”
Sets the speed threshold above
which the acceleration is re km/h 5 6 7 8 9 10 11 12 13 14
duced by the value set with the
ACCEL REDUCTION parameter
in the STANDARD profile
“HARD”
which the acceleration is re km/h 5 6 7 8 9 10 11 12 13
in the HARD profile
“ECONOMIC”
which the acceleration is re km/h 5 6 7 8 9 10 11 12 13 14
in the ECONOMIC profile
I BOOST MAX TIME
Sets the duration of the current s 0 0.5 1.1 1.6 2.2 2.7 3.3 3.8 4.4 5.0
boost in number of seconds.
RELEASE BRAKING “STAN
DARD”
Determines the deceleration
ramp when the accelerator is s
20 5 4.5 4 3.5 3 2.5 2 - -
released, or if the truck is put in
neutral for the versions with the
gear lever on the steering wheel
and with the joystick
RELEASE BRAKING “HARD”
s 20 5 4.5 4 3.5 3 2.5 1.5 1
HARD profile

02 Diagnostics
Parameters
RELEASE BRAKING “ECO
NOMIC” s 20 5 4.5 4 3.5 3 2.5 2 1.5 1
ECONOMIC profile
INVERSION BRAKING “STAN
DARD”
s
Determines the deceleration 5.5 5 4.5 4 3.5 3 2.5 2 1.5
ramp when reversing the direc
tion of travel
INVERSION BRAKING “HARD”
HARD profile
s 5.5 5 4.5 4 3.5 3 2.5 ■ 1.5 1
INVERSION BRAKING “ECO

NOMIC” s 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
ECONOMIC profile
SEAT BRAKING
Sets the intensity of the braking
between the opening of the mi s
20 5 4.5 4 3.5 3 2.5 2 -
croswitch (after the bounce-free
filter) and the opening of the con
tactors.
PEDAL BRAKING “STAN
DARD”
s
Determines the braking intensity 4 3.5 3 2.5 1.5 1 - - -
corresponding to the limit switch
of the brake pedal.
PEDAL BRAKING “HARD”
s 4 3.5 3 2.5 2 1 0.7 0.5 0.3
HARD profile
PEDAL BRAKING “ECO
NOMIC” s 4 3.5 3 2.5 2 1/5. 1 0.7 0.5 0.3
ECONOMIC profile
MIN PEDAL BRAKE “STAN
DARD”
Determines the intensity of the s 20 5 4.5 4 3.5 3 2.5 2 - -
braking that occurs as soon as
the brake pedal is pressed
MIN PEDAL BRAKE “HARD”
HARD profile
5 20 5 4.5 4 3.5 ■ 2.5 2 1.5 1
MIN PEDAL BRAKE “ECO

s 20 5 4.5 4 3.5 3 2.5 2 1.5 1
NOMIC " ECONOMIC profile
SPEED LiMl i BRAKING
Determines the deceleration s
8.9 8.3 7.7 7.1 6.6 6 5.5 4.9 4.4 3.8
ramp when the accelerator pedal
is partially released.
BRAKE CUTBACK
Determines the deceleration
ramp when the speed reduction
s
is activated with the truck in 5.5 5 4.5 4 3.5 3 2.5 - - -
motion, through the tortoise
button or the opening of the
contact on pin C10.
PBBRK CTB
Maximum speed when the brake %
6 8 10 13 15 18 20 22 24 27
and accelerator pedals are
pressed simultaneously.

Diagnostics 02
Parameters
MAX SPEED FORWARD
“STANDARD”
Determines the maximum trac
tion speed forward; it is ex km/h 6 7 8 9 10 11 12 13 14 -
pressed in km/h or mph accord

ing to the setting made on the dis
play.
MAX SPEED FORWARD
“HARD” km/h 6 7 8 9 10 11 12 13 i T4 -
HARD profile
MAX SPEED FORWARD “ECO
NOMIC” km/h 6 7 8 9 10 11 12 13 14 -
ECONOMIC profile
MAX SPEED BACKWARD
“STANDARD”
Determines the maximum trac
tion speed backward; it is ex km/h 6 7 8 9 10 11 12 13 14 -
pressed in km/h or mph accord
ing to the setting made on the dis
play.
MAX SPEED BACKWARD
“HARD” km/h 6 7 8 9 10 11 12 13
HARD profile
MAX SPEED BACKWARD
“ECONOMIC” km/h 6 7 8 9 10 11 12 13 14
ECONOMIC profile
CUTBACKSPEED SW
Determines the percentage of re
duction of the maximum speed
%
set (which depends on the pro 10 20 30 40 50 60 70 80 90 100
file selected) to be activated
by pressing the tortoise button
100% = no reduction
CUTBACK SPEED HW
Determines the maximum speed
of the truck corresponding to the
opening of the external contact
on pin 10 of the connector C. km/h 2 3 4 5 6 8 10 12 14 16
By default, it must be set to 0.
NOTE: If the cutback speed is
greater than MAX SPEED FW,
it must not be activated.
ACC SMOOTH
Introduces a parabolic degree
on the acceleration ramp for
departing from stationary, up to X
Hz where X is set with the STOP - 1 1.2 1.5 1.7 2 2.2 2.5 2.7 3 3.5
SMOOTH parameter. If set to
1, the ramp is linear; increasing
the parameter increases the
parabolic degree.
STOP SMOOTH
Defines the first X Hz at which the
parabolic degree of the accelera Hz 5 7 10 12 15 17 20 22 25 27
tion curve can be changed start
ing from stationary or reversing.

Parameters
SMOOTH BRAKE
Manages the braking intensity
upon release at low speeds,
* 1 1.5 1.7 2 2.2 2.7 ! 3 3n i
introducing a parabolic degree
similartothatoftheacc. smooth
parameter
SEAT MICRO TIME
Defines the time, in steps from
5 to 50 minutes, that elapses
between the situation of truck on Min 5 15 20 25 30 35 40 45 50
and inoperative with operator on
board and the activation of the
"SEAT" alarm.
KEY TIME
Defines the time, in steps from
5 to 50 minutes, that elapses
Min 5 15 20 25 30 35 40 45 50
between the situation of operator
absent and the activation of the
"KEY" alarm.
■ ...
X CURVE CUTBACK
Percentage of reduction of the
%
accelerator when the steering 40 45 50 55 60 70 - - -
angle reaches 20° (3-wheei
truck). ■
■
X CURVE CUTBACK4
Percentage of reduction of the
%
accelerator when the steering 40 45 50 55 60 65 70 80 -
angle reaches 20° (4-wheel
truck).
CURVE CUTBACK
Additional reduction on curves
%
for steering angles over 20°. The 10 15 20 - - - -
reduction is proportional to the
steering angle (3-wheel truck).
CURVE CUTBACK4
Additional reduction on curves
%
for steering angles over 20°. The 10 15 20 25 - - - - -
reduction is proportional to the
steering angle (4-wheel truck).
STAR!ANGLE RED !
Steering angle from which the o 10....... ....20°
speed reduction on curves is Default 20“ |
active.
PROGRAM VACC menu
Programmed value
Name
u 012345678 9
VACC SETTING.
Acquires the end-of-scale value V
of the accelerator pedal.
02-20 Workshop literature - 40328042303 EN - 05/2008

Diagnostics 02
Parameters
SET OPTIONS Menu
Programmed value
Name
U 0 1 2 3 4 5 6 7 8 9
BATTERY CHECK
ON: when the battery charge
level reaches 10%, the max
- OFF ON
current is reduced by 50% and
the max speed attainable drops
to 5 km/h.
BATTERY CAPACITY
Sets the capacity of the battery
installed;
0: the parameters ADJ#1 and
ADJ#2 are used 0 1 2 3 4
1: 460 Ah
2: 575 Ah
3: 625 Ah
4: 750 Ah
GEAR SELECTOR
Selects the type of gear selector:
OFF: twin accelerator pedal. OFF ON
ON: reversing lever on the steer
ing wheel.
SRO
Enables the traction only when
starting from neutral (only for OFF ON
version with reversing lever on
the steering wheel).
ADJUSTMENT Menu
Programmed value
Name
U 0 1 2 3 4 5 6 7 8 9
SET POTBRKMIN
[0;10]
Stores the minimum value of the V
Step 0.04
brake pedal potentiometer
SET POT BRK MAX
[0;10]
Stores the maximum value of the V
Step 0.04
brake pedal potentiometer.
ADJUST BATTERY
(0.75;1.25)V_bat
Calibration of the battery voltage V
Step V_bat/1000
value (Vbat)
SET STEER RIGHT
Sets the steering voltage with the [0;5]
V
wheels turned completely to the Step 0.04
right.
SET STEER LEFT
Sets the steering voltage with the [0;5]
V
wheels turned completely to the Step 0.04
left.
THROTTLE 0 ZONE
Initial dead zone on the acceler % 0 1 3 5 7 9 11 13 15 17
ator.

02
THROTTLE X POINT
Programming of the X coordi
nate of the pedal curve: this rep- 0/_ /IK 70 Ô4 on d1 nn
1 /u 18 27 QC
ww 54 WW S w a WW |
i coci no ii ic ii ipui pcucii vaiuc
which the potentiometric value Y

is associated.
THROTTLE Y ZONE
Programming of the Y coordinate % 4 15 25 36 47 57 68 78 83 100
of the pedal curve.
ADJUSTMENT# 01
%
Adjusts the highest level of the -28 -22 -17 -11 -6 0 6 11 16 28
battery discharge table.
ADJUSTMENT# 02
%
Adjusts the lowest level of the -28 -22 -17 -11 -6 0 6 11 16 28
battery discharge table.
AUX TIME #1
The battery discharge algorithm
acquires the values with the truck
at rest. A 5% decrease of the
min 10 14 18 22 24 26 30 34 36 40
battery charge is forced after
each period indicated by this
parameter (very intensive use
without pauses).
SET MODEL Menu
Programmed value
Name
U 0 1 2 3 4 5 6 7 8 9
CONNECTED TO:
Allows the connection to the
electronic modules:
3: DUAL AC2 module (MAS
TER)
4: DUAL AC2 module (SLAVE)
5: AC2 FLASH module
3: MHYRiO module
16: ECO DISPLAY
Mode I
not
STEER TABLE
4-wheel 3-wheel con
Selects the steering table.
fig
ured. _____
1
Parameters of the AC2 FLASH

module
PARAMETER CHANGE Menu
Programmed value
Name
U 0 1 2 3 4 5 6 7 8 9
MODE TYPE
Stan- Eco
Displays the profile set using the
display. Hi dard nomi! :
literature - 40328042303 EN. 05/2008

Diagnostics 02
Parameters
ACC DELAY “STANDARD”.
s
Determines the acceleration 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
ramp of the pump motor.
ACC DELAY “HARD”. ■
s 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
HARD profile
ACC DELAY “ECONOMIC”.
s 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
ECONOMIC profile
DECELERATION DELAY.
s
Determines the deceleration 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
ramp of the pump motor.
MAX SPEED UP “STANDARD”
Determines the maximum lifting rpm 2340 2460 2580 2700 2820 2940 3060 3180 3300 3450
speed.
CUTBACK SPEED SW
%
Speed reduction in the tortoise 10 20 30 40 50 60 70 80 90 100
function.
CUTBACKSPEED 2nd
Determines the maximum speed
of the pump motor for the tilt
function. Press tortoise button
rpm 480 540 630 690 780 840 930 990 1080 1200
to activate.
NOTE: If greater than the 2nd
speed, this function must not be
activated.
CUTBACK SPEED HW
Maximum speed of the pump
motor for the lifting function with
the contact on C11 open. By
default, this must be set to the
rpm 2340 2460 2580 2700 2820 2940 3060 3180 3300 3450
maximum value set for MAX
SPEED UP. This function must
not be activated if CUTBACK
SPEED HW is greater than MAX
SPEEDUP.
2ND SPEED [480-1200]
Pump speed adjustment for tilt rpm Step 30
function. DEFAULT : 810
TILT + HYDRO SPEED
[0-34]
Pump speed adjustment for tilt
DEFAULT : 1020
function + hydraulic steering.
3RD SPEED [480-1500]
Pump speed adjustment for third rpm Step 30
function (usually side shift). DEFAULT : 900
4TH SPEED [480-2190]
Pump speed adjustment for rpm Step 30
fourth function. DEFAULT : 900
5TH SPEED [480-2190]
Pump speed adjustment for fifth rpm Step 30
function. DEFAULT : 900
HYDRO SPEED HI
Pump speed adjustment for [480-750]
hydraulically assisted steering rpm Step 30
function with truck speed up to DEFAULT : 630
about 2 km/h.

02______
Parameters
HYDRO SPEED LOW
[300-450]
Pump rpm adjustment for hy
rpm Step 30
draulic steering function with lift
DEFAULT : 300
truck speed at 14 km/h.
HYDRO SPEED RED.
Enables hydraulically assisted
steering speed reduction with
increasing truck speed. If the None
function is disabled, the pump
goes to the HYDRO SPEED HI
speed.
AUX HYDRO TIME
Delay time for hydraulically as
sisted steering deactivation at s 0 0.2 0.4 0.8 n 1.5 2 3 4 5
the end of the request from the ■■I
■■■■
pressure switch. ■■
ADJUSTMENT Menu
Programmed value !
Name
U 0 1 2 3 4 5 6 7 8 9 1
ADJUST BATTERY
[0.75; 1.25] v_batt
Calibrates the battery voltage V
Step: v_batt/1000
read by the drive.
I— i
THROTTLE OZONE
Initial dead zone of the lifting po % 0 1 3 5 7 9 11 13 15 17
tentiometer (see figure below).
THROTTLE X POINT
Programming of the X coordinate
% 18 27 36 45 54 72 81 90 100
of the lifting potentiometer curve ■
(see figure below).
THROTTLE Y POINT
Programming of the Y coordinate
% 4 15 25 36 47 57 68 78 89 i vv
of the lifting potentiometer curve
(see figure below).
Workshop literature - 40328042303 EM. 05.

Diagnostics 02
Parameters
SET OPTION menu
Programmed value
Name
U 0 1 2 3 4 5 6 7 8 9
JOYSTICK
Indicates whether or not the joy
stick is present. Changes be OFF ON
come effective when the system
is switched back on.
BATTERY CHECK
ON: when the residual battery
capacity reaches 10%, the hy
draulic functions, except for the
hydraulically assisted steering, - OFF ON
drop to a minimum (useful only
to terminate the manoeuvre in
progress).
OFF: No limitation.
PROGRAM VACO menu
Programmed value
Name
U. 0 1 2 3 4 5 6 7 8 9
VACC SETTING.
Acquires the end-of-scale
V
value of the lifting HALL sen
sor.
SET MODEL Menu
Programmed value
Name
U 0 1 2 3 4 5 6 7 8 9
CONNECTED TO:
electronic modules:
TER) -
4: DUAL AC2 module (SLAVE)
5: AC2 FLASH module
9: MHYRIO module
16: ECO DISPLAY
Parameters of the ECO DISPLAY module
Programmed value
Name
U 0123456789

02
1 PROFILE: selects the truck pro F“"'

file
1 Option #1 : selects the “en-
I <-J> ~--- ---- -------------------- x:i_ Op op
uui di lue pci luinicu iuü pi umu.
tion tion tion
Option #2: selects the “standard”
#1 #2 #3
performance profile.
Option #3: selects the “rapid”
LANGUAGE: selects the lan
guage
LEVEL 0: Italian
Leve Leve Leve Level Leve
LEVEL 1:English -
0 1 2 3 4
LEVEL 2: French
LEVEL 3: German
LEVEL 4: Spanish Ï
MANUFACTURER: selects the
legend “OM PIMESPO” or “KO
MATSU” that appears on the dis
Op Op
play at switch-on.
tion tion
OPTION #1 : selects the legend
#1 #2
“OM PIMESPO”
OPTION#2: selects the legend
“KOMATSU”
SPEED UNÎT: sets the units of
Op Op
measure for the speed
- tion tion
OPTION #1: km/h
#1 #2
OPTION #2: mph
HOUR COUNTER: selects the
hours counter to be displayed 1i
OPTION #1 : machine hours
Op Op Op Op
counter
- tion tion tion tion
OPTION #2: traction hours ■#
#1 #2 TT Q TT *TA
4i
counter
OPTION #3: seat hours counter
OPTION #4: daily hours counter
TYPE CUTBACK: selects the i
module (traction, pump or both) i1
on which to apply the speed re
duction activated by the tortoise
hi ifrrvri Op wa~
OPTION#1 : the reduction acts tion tion tion

on the traction #1 #2 #3
...
OPTION #2: the reduction acts
on the pump
OPTION #3: the reduction acts 1
on both the pump and traction
_____ ____________

Diagnostics 02
Parameters
RESET HOUR: allows the ma
chine, traction, and seat hours
counters to be reset only if the
number of hours on the machine
hours counter is less than 100.
This operation can be performed - OFF ON
only once.
OFF: does not reset the hours
ON: resets the hours. After
having selected ON, switch the
truck off and then on again.
BLOCK PROFILE: allows to
enable/disable the operator to
change the performance.
OFF: the operator is enabled to
change the profile using the keys - OFF ON
>,», »>
ON: the operator is not enabled
to change the profile. The STAN
DARD profile is active.
MAXIMUM LOAD
Load capacity of the truck:
0: 13 quintals
1: 15 quintals
2: 18 quintals
3: 20 quintals
4: 16 quintals
5: 20 quintals HEAVY DUTY 0 1 2 3 4 5 6
6: not configured.
Note: At switch-on, if the param
eter is at level 6, the legend 360
CAPACITY NOT CONFIGURED
appears on the display, the red
alarm indicator lights up and lift
ing is inhibited.
CHECK UP TYPE: defines the
behaviour of the truck when
maintenance must be per
formed.
LEVEL 0: no indication of
CHECK UP NEEDED
LEVEL 1: CHECK UP NEEDED
alarm occurs after 250 hours.
LEVEL 2: CHECK UP NEEDED Leve Leve Leve Level Leve
-
alarm occurs after 250 hours and 0 1 2 3 4
speed reduction to 7 km/h after
300 hours.
alarm occurs after 500 hours.
alarm occurs after 500 hours and
speed reduction to 7 km/h after
550 hours.

Parameters
BUZZER: buzzer activation con ! I-
ditions:
0: no activation.
11 ■ activation in reverse gear. n *11 n o i
V
2: activation in both directions of
travel.
3: activation in forward gear.
SEATBELT: allows to en-
able/disable the seat belt di
agnosis.
OFF: seat belt function disabled.
If the seat belt is not fastened, no
alarm appears on the display.
OFF ON
ON: seat belt function enabled.
If the seat belt is not fastened,
the legend "BELT" flashes on the
display and the buzzer sounds
for 2s at first and then emits 30
beeps.
L- = 4
ADJUSTMENT Menu
Programmee value
Name
U. 0 1 2 3 4 5 6 7 8 9
CHECK UP DONE: if ON, it
allows the hours counter of the OFF ON
last maintenance to be zeroed.
SYNCHOURCOUNTER
ON: Allows to perform the syn
chronisation of the hours coun
ters to clear the alarm 365
OFF ON
WRONG HOUR COUNTER:
once the synchronisation has
been performed, the parameter
automatically returns to OFF.
SET MODEL Menu
Programmed value
Name
si...... .S3.....
U 0 1 2 3 4 5 6 7 8 9
CONNECTED TO:
electronic modules:
TER)
4: DUALAC2 module (SLAVE)
5: AC2 FLASH module
9: MHYRIO module
I
16: ECO DISPLAY module
Workshop Cerature -40328042303 EN - 05/2008

Diagnostics 02
Parameters
Parameterisation of the drive func
tion
Using the accelerator pedal, the operator pro
vides the speed reference (pin C2) and direction
of travel, forward (pin C6) or backward (pin C7).
The speed reference is processed simultane

ously by the MASTER and SLAVE in the DUAL
AC module.
When the general contactor is closed (absence
of alarms) and the operator is on board (seat
microswitch activated), if the accelerator pedal is
pressed to provide the travel selection and speed
reference, the electronic controller rotates the
motors in an identical manner if the wheels are
straight or differently if the wheels are turned.
The speed of rotation is always within the range

from 0 to MAX SPEED FORW/BACK; when turn
ing, these maximum speeds are reduced by a
factor depending on the steering angle (equal to
CURVE CUTBACK for the maximum steering an
gle).
The acceleration and deceleration times depend
on the following parameters:
ACCELERATION DELAY
RELEASE BRAKING
INVERSION BRAKING
SPEED LIMIT BRAKING

BRAKE CUTBACK
The parameters used for the drive and their

meanings are listed in the following table:
Parameter Range Meaning

ACCELERATION
2 - 6.5 s Time to accelerate the motor from 0 to 100Hz.
DELAY
Time to decelerate the motor from 100 to 0Hz when the
RELEASE BRAKING 20 -2s
accelerator pedal is completely released.
INVERSION BRAKING 5.5- 1.5 s
direction of travel is reversed.
SPEED LIMIT BRAKING 8.9-3.8 s
accelerator pedal is partially released.
Time to decelerate the motor from 100 to 0Hz when a
BRAKE CUTBACK 5.5 - 2.5 s
speed reduction is activated (tortoise).
THROTTLE 0 ZONE % Determines the dead zone on the accelerator curve.
THROTTLE X POINT % Changes the accelerator potentiometer curve.
THROTTLE Y POINT % Changes the accelerator potentiometer curve.
Determines the maximum rotation speed of the motor
MAX SPEED FORW 12- 14 km/h
with the FORWARD input active.
Determines the maximum rotation speed of the motor
MAX SPEED BACK 12- 14 km/h
with the BACKWARD input active.

02___________
Parameters
Minimum frequency applied to the motor (unchange
FREQUENCY CREEP 0.3 + 3 Hz
able).
PprrhPntariA nf mrli mtinn nf the» rlriws cnnnd '.A/hnn the
CTB SP TRAC SW 10 + 100% speed reduction is activated using the tortoise button
on the display.
CTB SPD TRAC HW 2-16 km/h Maximum speed with the contact on pin C10 open.
Deceleration speed when the steering angle reaches
CURVE BRAKING s
20°.
Defines the percentage of speed reduction when the
XCURVE CUTBACK %
steering angle exceeds 20°.
CURVE CUTBACK 10-100% Speed reduction at the maximum steering angle.
VACC MIN V Minimum voltage of the accelerator potentiometer.
VACC MAX V Maximum voltage of the accelerator potentiometer.
Parameterisation of the steering

function
The following ADJUSTMENT menu parameters
are stored using a PC:
SET STEER RIGHT by turning the wheels com

pletely to the right;
SET STEER LEFT by turning the wheels com-
pieteiy to the left.
Turning the steering wheel varies the output volt
age from the steering potentiometer (pin Cl 7 of
the DUAL AC): the voltage increases when turn
ing to the right and decreases 'when turning to the
left.
The electronic controller associates the steering

angle to the value of the output voltage from the
potentiometer, thus obtaining the speed reduc-
tion for the 2 drive wheeis when turning.
The steering parameters are listed in the follow

ing table:

Acquires the steering potentiometer output with wheels
SET STEER RiGHT V
turned completely to the right.
Acquires the steering potentiometer output with wheels
SET STEER LEFT V
turned completely to the left.
o
MAX STEER RIGHT Maximum steering angle to the right.
o
MAX STEER LEFT Maximum steering angle to the left.
OPTION#0 OPTION#0: 4-wheel truck steering table.
STEER TABLE
OPTION#! OPTION#!: 3-wheei truck steering table.

Diagnostics 02
Parameters
Parameterisation of the electric
braking function
The following ADJUSTMENT menu parameters
are stored using a PC:
SET POT BRK MIN by pressing the brake pedal

slightly,
SET POT BRK MAX by pressing the brake pedal
completely.
The electric braking occurs in the following cases:
• 1. Completely releasing the accelerator pedal:
RELEASE BRAKING parameter.
• 2. Partially releasing the accelerator pedal:
SPEED LIMIT BRAKING parameter.
• 3. Pulling the handbrake lever (opening mi
croswitch C9): similar to release braking.
• 4. Pressing the brake pedal varies the output
voltage from the pedal (input C18). The brak
ing intensity is defined by two points: the first,
associated with the pedal only slightly pressed
(MIN PEDAL BRAKE), and the second, as
sociated with the pedal completely pressed
(PEDAL BRAKING).
• 5. Reversing the direction of travel: INVER
SION BRAKING parameter.
• 6. Pressing the accelerator and brake pedals
simultaneously: PB BRK CUTBACK parame
ter.
The braking parameters are described in the fol
lowing table:

Time necessary to decelerate the motor from 100 to
RELEASE BRAKING 20-2s
0Hz when the accelerator pedal is completely released.
SPEED LIMIT BRAKING 8.9 - 3.8 s
0Hz when the accelerator pedal is partially released.
This is the minimum braking intensity corresponding to
MIN. PEDAL BRAKE 20 - 2 s
the brake pedal being pressed slightly.
INVERSION BRAKING 5.5 - 1 s
0Hz after reversing the direction of travel.
This is the maximum braking intensity corresponding
PEDAL BRAKING 4 - 1 s to the brake pedal being pressed completely (with the
accelerator pedal released).
Stores the minimum value of the brake pedal poten
SET POT BRK MIN V
tiometer.
Stores the maximum value of the brake pedal poten
SET POT BRK MAX V
tiometer.
BRAKE CUTBACK 5.5-2.5 s
0Hz when a speed reduction is activated.
Sets the speed (%) of the truck when the brake and
PB BRK CUTBACK 6-27
accelerator pedals are pressed simultaneously.

Parameters
Parameterisation of the battery
state monitoring function
Ths battery charge ievel ¡5 constantly monitored
by the MASTER of the DUAL AC2 drive system.
The key input voltage (pin C3) of the micropro

cessor where the average value of the readings
sampled is compared with the battery discharge
table provided.
The value of the battery charge state thus ob

tained is communicated via CAN to the display.
If the charge state drops below 10%, the BAT
TERY LOW alarm is generated.
The parameters necessary for the parameterisa
tion / monitoring of the battery state are provided
in the following table.

Moves the high level of the battery discharge table (the
V
ADJUSTMENTS higher the level, the higher the level of voltage that de
Levels 0 + 9
termines the ’charged battery’ state).
Moves the low level of the battery discharge table (the
V
ADJUSTMENTS higher the level, the higher the level of voltage that de
Levels 0 + 9
termines the ’low battery’ state).
Enables (ON) or disables (OFF) the performance ¡imi
BATTERY CHECK ON/OFF
tation due to the ’low battery’ condition.
Parameterisation of the lifting func

tion
Operating the lifting lever, the operator varies the
output voltage of the HALL sensor which is sup
plied to the drive on pin El.
If the general contactor is closed (no blocking

alarms and the seat microswitch closed), then
the system powers the motor, taking it to a speed
proportional to the input signal (E1). The lifting
speed, if no speed reduction is requested, will
always be within the range from MIN SPEED UP
to MAX SPEED UP, otherwise the upper limit
will be that set with CUTBACK SPEED SW and
CUTBACK SPEED HW (depending on whether
the request is made on the display or with contact
E13).
The parameters used for lifting and their mean
ings are listed in the following table.

Time necessary to accelerate the motor
PU ACCEL DELAY 0.5 + 5.5 s
from 0 to 10uHz.
DECELERATION Time necessary to decelerate the motor from 100 to
0.5 + 5.5 s
DELAY 0Hz.

Diagnostics 02
Parameters
MAX SPEED UP 2340 - 3450 rpm Determines the maximum lifting speed.
Determines the minimum lifting speed
MIN SPEED UP 300 * 1380 rpm
(unchangeable).
THROTTLE 0 ZONE % Dead zone in the lifting signal curve.
THROTTLE X POINT % Changes the lifting HALL input curve.
THROTTLE Y POINT % Changes the lifting HALL input curve.
VACC MIN V Minimum lifting potentiometer voltage.
VACC MAX V Maximum lifting potentiometer voltage.
Minimum frequency corresponding to the lifting HALL
FREQUENCY CREEP Hz dead zone
(unchangeable).
CTB SPDPUMPSW 10-100% Maximum speed with tortoise function activated.
CTB SPDPUMPHW 2340 - 3450 rpm Maximum speed with the contact on pin E13open.
Parameterisation of the hydrauli

cally assisted steering function
The hydraulically assisted steering function is ac
tivated as follows:
• 1 With the truck stationary, by turning the

steering wheel (opening the steering pressure
switch contact E6).
• 2 With the truck stationary, as soon as the ac

celerator pedal is pressed.
• 3 Upon gear request (twin accelerator pedal

version).
• 4 Always, when the truck is in motion.
The drive, if the general contactor and seat mi

croswitch are closed, powers the pump motor at a
rotation speed within the range set between HY
DRO SPEED LOW/HIGH, proportionally to the
speed of the truck.
The parameters used for the management of the

hydraulically assisted steering and their mean
ings are provided in the following table.

Time necessary to accelerate the motor from 0 to
PU ACCEL DELAY 0.5 - 5.5 s
100Hz.
DECELERATION DE Time necessary to decelerate the motor from 100 to
0.5 - 5.5 s
LAY 0Hz.
Speed for the hydraulically assisted steering function
HYDRO SPEED LOW 300 - 450 rpm
with maximum drive speed.
Speed for the hydraulically assisted steering function
HYDROSPEEDHIGH 480 - 750 rpm
with minimum truck speed.
Additional time of operation of the hydraulically as
AUX HYDRO Tl ME 0-5s sisted steering at the end of the request coming from
the pressure switch.

Parameterisation of the tilt, side
shift (SLI) and 4th lever functions
Through the reiaiive iever, the operator cioses the
microswitch of the desired function (E7 = tilt, E14
= SLI, E12 = 4th lever), provided that the general
contactor is closed (no blocking alarms) and the
operator is on board (seat microswitch closed).
The drive will power the pump motor, taking it to
the chosen rpm.
For the tilt function, the CUTBACK SPEED 2ND
parameter is available that allows reduction of the
motor rpm each time the tortoise function is acti
vated through the display.
The parameters used for the parameterisation of
these functions are listed in the following table.

Time necessary to accelerate the motor from 0 to
PU ACCEL DELAY 0.5+ 5.5 s
100Hz.
DECELERATION Time necessary to decelerate the motor from 100 to
0.5 + 5.5 s
DELAY 0Hz.
2ND, 3RD.4THSPEED rpm Motor speed in tilt, side shift and 4th lever function.
Sets maximum speed with tortoise function activated
CUTBACKSPEED2ND 480 + 1200 rpm
(tilt function only).
Workshop literature. 40328042303 EN.. &

Diagnostics 02
Alarms
State of the truck during an alarm
situation
When an alarm situation occurs, the buzzer emits
3 BEEPS.
The following appear on the display:
> The alarm indication with respective number >

(e.g.: 18).
ALLARME 18
> The text "SEE MANUAL" (in the selected lan
guage) if the alarm involves a malfunction that
the operator cannot eliminate (a critical power
VEDERE MANUALE
part failure, for example).
> A text, in the selected language, that indicates t>

the cause of the alarm in the eventthe operator
can remedy it (e.g.: "FLAT BATTERY") (in the
ALLARME 20
selected language).
The list below provides full indication of each
BATTERIA SCARICA
alarm that may appear; the first 5 columns indi
cate the "display text" (in the selected language),
and the 6th column indicates the "alarm number."
FUNGO D’EMER EMER EMERGEN

URGENCE VORFALL 245
GENZA GENCY CIA
FREIN HAND FRENO DE
FRENO A MANO INSERTED
À MAIN BREMSE MANO EN 50
INSERITO HANDBRAKE
ENGAGÉ BETÄTIGT GRANADO
MARCIA AVANTI + FORW +
/ / / 51
MARCIA INDIETRO BACK
ER
BATTERY BATTERIE BATERÍA
BATTERIA SCARICA SCHÖPFTE 20
DISCHARGE FAIBLE AGOTADA
BATTERIE
BATTERIE
BATTERIA SBAGLI WRONG BATTERIE BATERIA IN
INCOR 21
ATA BATTERY FALSCH CORRECTA
RECTE
PEDALE BESCHLE PEDAL
PUSH AC
PEDALE ACC.PRE ACCELER UNIGUNG ACELER
CELERATOR 52
MUTO ATEUR EN PED. ADOR PRE
PEDAL
GAGE BETÄTIGT SIONADO
PETICION
MARCIA SELEZION SELECTED DEMAMDE ANFRAGE
DE MAR 105
ATA GEAR MARCHE GANG
CHA
MANUTEN
MANUTENZIONE OVERHAUL ENTRETIEN WARTEN 399
CIÓN
COMP EITSCHAL- TIMER
TIMER SEAT
TIMER SEDILE TEUR TUHR SITZ ASIENTO
TO STAND 102
ALZARSI SIEGE SE /SICH ER- LEVAN
UP
LEVER HEBENZ TARSE

02
ZEITSCHAL-
TUHR
COMP TIMER
SCHLUS
TIMER CHIAVE TIMER KEY TEUR CLE LLAVE
SEL
SPEGNERE/ RIAC TO SWITCH ETEIN- APAGER/ 103
AUSS-
CENDERE OFF/ON DRE/RAL REENCEN
CHALTEN/
LUMER DER
EINSCHAL-
TEN
MARCHE GANG MARCHA
MARCIA NON CON NO GEAR
NON CON NICHT KON NO CON 60
FIGURATA SET-UP
FIGUREE FIGURIERT FIGURADA
RAG- CAPACI
NO LOAD PORTEE
PORTATA NON CON FAHIGKEIT DAD NO
CAPACITY NON CON 360
FIGURATA NICHT KON CONFIGU
SET-UP FIGUREE
FIGURIERT RADA
ACTIVA HY
TO ACTI MANDO
RICHIESTA TION SYS DRAULIS
VATE HY HIDRAULICO 252
IDRAULICAATTIVA TEME HY- CHE FUNK-
DRAULICS ACTIVO
DRAUL TION AKTIV
NICHT KON
STEER NOT DIRECTION VOLANTE
STERZO NON CON FIGURI
CONFIGU PAS CON NON CON 160
FIGURATO ERTES
RATED FIGURE FIGURADO
LENKRAD
FEHLER CONFIG
CONFIGU
HAFTE URACION
CONFIGURAZIONE STEER RATION DE
LENKRAD- VOLANTE 59
STERZO ERRATA HAZARD DIRECTION
KONFIGU- NO CON
ERRONÉ
RAHON FORME
> If the seat belts are notfastened, the respective >

symbol appears on the display; at the same
time, the buzzer sounds for 2 seconds and then
emits 30 BEEPS (until the seat belts are fas
tened). The activation of this function can be
selected through the diagnostic software.
The alarm remains fixed on the display until it has
been cleared; this does not include alarms 399
CHECK UP NEEDED and 333 OIL FILTER that
remain on the display only foi i minute.
The alarms caused by high temperatures (75,80,
81, 115,116, 216,275, 281) are displayed for 1
minute, and then the display returns to normal;
the respective display indicator light (common for
all high-temperature alarms) also lights up. The
indicator light remains lit until the alarm has been
cleared. If the alarm is still present when the truck
is switched back on, it is shown on the display
for 1 minute; in the case of several temperature
alarms, they are all displayed; if the temperature
alarm triggered by exceeding the second temper
ature threshold of the motors is in progress (115,
116, 216), the alarm regarding the first threshold
(80, 81,281) Is not displayed.
02-36 Workshop ifterature - 40328042303 EN - 05/2008

Diagnostics 02
Alarms
In the event of several simultaneous alarms, the
alarms are displayed in rotation if they come from
different drives (nodes); if they come from the
same electronic component the most important
alarm is displayed.
Alarms list
To facilitate identification of the electronic equip
ment that has generated an alarm, the alarms are
numerically coded as follows:
0-199: DUAL AC
200-299: AC2 FLASH

300-399: ECO DISPLAY and MHYRIO
DUAL AC module
Note:
In the "Block" column, the number:

1 indicates : blocking alarm with opening of the
general contactor; requires the key to be switched
off and then on again to restart;

general contactor; requires a gear request to
restart;
3 indicates : blocking alarm without opening of

the general contactor; requires a gear request to
restart;
4 indicates : no block;
the origin of the alarm is also indicated:
M indicates : MASTER;
5 indicates : SLAVE.
Code Alarm Probable causes Corrective action Block

Check the power fuse.
Check the integrity of the 180 Ohm resistance
on the contactors.
The capacitors Disconnect the battery outlet, discharge the
1
1 CAP.CHARGE do not charge at capacitors with a resistance (180 Ohm 5 W
M/S
switch-on. between the battery positive and negative on
the drive) and check that there are no short
circuits between the motor terminals and the
battery negative.
Check that the power connections of the motor
Low voltage on the are correct.
power outputs of Check that there is no insulation loss in the 2
2 RVMNLOW
the right traction motor. M
motor. Check that there are no short circuits between
the phases and the battery negative.

02

Low voltage on
are correct.
the power outputs 2
3 LVMNLOW Check that there is no insulation loss in the r*
of the left traction O 1
motor. Check that there are no short circuits
motor.
between the phases and the battery negative.
High voltage on the are correct.
power outputs of Check that there is no insulation loss in the 2
4 RVMNHIGH
the right traction motor. M
the phases and the battery positive.
High voltage on are correct.
the power outputs Check that there is no insulation loss in the 2
5 LVMNHIGH
of the left traction motor. S
High right traction
RGTSTRYI 2
10 motor current at Replace the DUAL AC drive.
HIGH M
rest.
High left traction
LEFT STBY i 2
11 motor current at Replace the DUAL AC drive.
HIGH S
rest.
Error in the over
2
14 HIGH LOAD load protection cir Replace the DUAL AC drive.
M/S
cuit.
Error in the U,V, W
1
15 R FEEDBACK feedback circuit on Check the power wiring of the motor.
M
the right motor.
Error in the U, V, W
1
16 L FEEDBACK feedback circuit on Check the power wiring of the motor.
S
the left motor.
An overvoltage
H / L VOLT or undervoltage 1
17 Switch off and then on again.
AGE condition has been M
detected.
Battery charge Check the battery charge with a densimeter.
level below 10%. With the battery not fully discharged, check
BATTERY Reduction of the that the voltage on the key input corresponds 4
20
LOW traction currents to the value read on the TESTER menu and, M
and block of the in case of error, set the ADJUST BATTERY
lifting. parameter as needed.
Switch off and then on again.
Check the battery charge with a densimeter.
With the battery not fully discharged, check
WRONG SET incorrect battery 1
21 that the voltage on the key input corresponds
BATTERY voltage. M
to the value read on the TESTER menu and,
in case of error, set the ADJUST BATTERY
parameter as needed.
Check the AC2 FLASH key input (Fl). Check
No reception of
CAN BUS KO the continuity of the CAN wiring between the 2
30 CAN signal from
POMPA DUAL AC (pins A1 and A6) and the AC2 (pins M
the pump module.
CSandCI).
02-38 Workshop Hterature ^40328042303 EN. 05/200S

Diagnostics 02
Alarms
No reception
of the CAN
signal from the
Check the continuity of the CAN wiring be
CAN BUS KO display. Activation 4
31 tween the DUAL AC (pins A4 and A7) and the
DISP of the traction M
display (pins A4 and A3).
speed reduction
( CUT.SPEED
SW.).
Check that the wiring of the TG2 contactor is
not open circuit. 2
40 DRIVER 2 KO No current on TG2.
Check the ohmic continuity of the TG2 contac M
tor coil.
COIL 2 Short circuit on the not short-circuited. 2
42
SHORTED TG2 coil. Check that the contactor coil is not short-cir M
cuited.
not short-circuited.
DRIVER 2 Short circuit on the 2
43 Check that the contactor coil is not short-cir
SHORTED DRIVER of TG2. M
cuited.
Replace the DUAL AC2.
Check that the preload resistance in parallel
with the contactors is not short-circuited.
CONTACTOR TG1 is closed at Check that the contacts of the TG1 contactor 1
44
1 CLSD switch-on. are not stuck. M
Check that alarm 243 is not also present; if so,
replace the pump module (AC2 FLASH).
CAN BUS No reception of
Internal failure of the DUAL AC electronics; if it 2
46 KO MASTER CAN signal from
persists, replace the module. S
TRAZ MASTER.
No reception of
CAN BUS KO Internal failure of the DUAL AC electronics; if it 2
47 CAN signal from
SLAVE TRAZ persists, replace the module. M
the SLAVE.
Starting away
with handbrake
applied. The
traction is blocked, Check that the handbrake wiring is not broken;
3
50 HANDBRAKE but with a delay of check the correct operation of the handbrake
M
about 2 seconds microswitch (normally open).
in order to allow
starting away
uphill.
Valid only for
the version with
reversing lever
Check that one of the two gear selection mi
FORW + on the steering 3
51 croswitches is not short-circuited or mechani
BACK wheel and joystick. M
cally blocked.
Simultaneous
presence of two
gear requests.

02
Twin-pedal version: check that the mi

croswitches of the pedals are not short-cir
cuited. Check that the GEAR SELECTOR
a i i
parameter on SET OPTION of the DUAL AC
ACC.INC. Incorrect gear 3
52 MASTER is OFF.
START request sequence. M
Single-pedal version:check that the mi
croswitch of the accelerator pedal is not
short-circuited (input C8 of the DUAL AC al
ways at battery positive).
Check the microswitches of the gears.
Check that the accelerator voltage at rest (pin
The accelerator
C21) is correct.
voltage is greater
Check that the spring on the accelerator pedal
VACC NOT than VACC MIN 3
54 is working properly.
OK by more than 1V M
With the twin-pedal version, check that pin C8
while no gears are
is at + 48 V and that the GEAR SELECTOR
active.
parameter on SET OPTION of the DUAL AC
MASTER is OFF.
Check on pin C21 that the voltage of the accel
The accelerator
erator potentiometer is effectively outside the
ACC OUT OF voltage is outside 3
56 maximum value set, if so, replace the wiring or
RANGE the permissible M
the potentiometer.
range.
If the voltage is correct, replace the drive.
Check that the voltage on the potentiometer
(pin Cl7) is equal to the value observed with
The voltage on the software (maximum difference 0.2 Volt).
the steering Check the wiring and the steering potentiome
potentiometer has ter for the entire rotation range of the wheels.
STEER abnormal values. The values normally found are: 3
58
SENSOR KO The traction is 3 wheels: to the left = 2V; centred - 6V; to the M
reduced to a right= 10.2V
maximum speed of 4 wheels: to the left = 2.3V: centred = 5.5V; to
4km/h. the right = 9.2V.
Check the power supply of the potentiometer
(11.8 V).
The calibration of
the right and left
steering limits is
not compatible with
STEER 3
59 the truck model Calibrate the stearines limits
HazaRD IV!
selected (3/4
wheels). Traction
is blocked, but the
brakes work.
With GEAR
SELECTOR
on PEDAL, the
input C8 is not
NO GEAR constantly at +48V. If the truck has twin pedals, check the pres 4
60
SETUP The traction is ence of the battery positive on pin C8. M
reduced to 5km/h
and the hydraulic
functions are
active.
02-40 Workshop literature. 40328042303 EN - 05/2008

Diagnostics 02
Alarms
The left traction
Check that the encoder is assembled correctly
motor speed
onto the left traction motor.
sensor is not
Check the encoder wiring and that the power
working correctly.
supply voltage is correct (11,5V).
If this error occurs
ENCODER Use an oscilloscope to check that when the 1
61 while driving,
ERROR L motor is rotating there are two square wave S
the buzzer emits
forms on pins A22 and A23, phase-shifted by
10 beeps (not
90°; if not, replace the encoder.
diagnosed with
Check that there are no short circuits between
the brake pedal
a motor phase and the chassis.
depressed).
The right traction
Check that the encoder is assembled correctly
motor speed
onto the right traction motor.
sensor is not
Check the encoder wiring and that the power
working correctly.
supply voltage is correct (11,5V).
If this error occurs
ENCODER Use an oscilloscope to check that when the 1
62 while driving,
ERROR R motor is rotating there are two square wave M
the buzzer emits
forms on pins A22 and A23, phase-shifted by
10 beeps (not
90°; if not, replace the encoder.
diagnosed with
the brake pedal
a motor phase and the chassis.
depressed).
Check that the potentiometer voltage is within
the maximum limits (at rest = 0.85V and with
pedal completely depressed = 3.25V, poten
tiometer power supply = 11.5V); otherwise, ac
The brake poten quire the end-of-scale values.
BRAKE RUN tiometer signal is Physically check that the potentiometer output 4
64
OUT outside the permis voltage is correct (pin C18). M
sible range. Check the wiring of the potentiometer.
If the negative wire of the brake potentiometer
is broken, the truck does not go into alarm but
behaves as if the brake pedal were completely
depressed, and thus the gear current is halved.
Faulty control 2
70 WATCHDOG If it persists, replace the DUAL AC.
circuit. M/S
Error in the
EEPROM; the
traction drive will
use the default 4
72 EEPROM KO Replace the DUAL AC.
parameters, and M
the maximum
current is reduced
to 75%.
The traction drive
temperature is
higher than 75°C
(depends on If this alarm appears under normal conditions
the maximum of use: Check that the heater fan of the drive
current set); as works correctly; check the fan power supply 4
75 HIGHTEMP.T
the temperature (24V). Check that neither the electronics heat M
increases, the sink nor the cooling air feed duct are dirty.
performance If it persists, replace the DUAL AC2.
decreases until the
complete blocking
of the functions.

02 Diagnostics
Check that there is no dirt accumulated on the

external finning of the right motor. Use an ac
curate multimeter to check that the resistance
ui mt: r i v »uii&ui (pins ctnu ui n its
DUAL AC with the connector disconnected)
with the motor at room temperature is about
The right traction
600 Ohms (25°C); if the alarm appears, the
motor temperature
MOTOR resistance read must be above 1000 Ohms. 4
80 is high.
TEMP. R Thus if the alarm is present and the resistance M
Performance is
is less than 1000 Ohms, then there is a prob
reduced.
lem with the drive; if, on the other hand, the re
sistance is above 1000 Ohms with the motor at
room temperature (25°C), then the PTC sen
sor of the traction motor is faulty (the sensor
cannot be replaced).
Check the wiring of the PTC sensor.
external finning of the left motor. Use an ac
curate multimeter to check that the resistance
of the PTC sensor (pins C34 and C35 of the
DUAL AC with the connector disconnected)
with the motor at room temperature is about
The temperature of
600 Ohms (25°C); if the alarm appears, the
one or both traction
MOTOR resistance read must be above 1000 Ohms. 4
81 motors is high.
TEMP. L Thus if the alarm is present and the resistance M
Performance is
is less than 1000 Ohms, then there is a prob
reduced.
lem with the drive; if, on the other hand, the re
sistance is above 1000 Ohms with the motor at
room temperature (25°C), then the PTC sen
sor of the traction motor is faulty (the sensor
cannot be replaced).
Check the wiring of the PTC sensor.
Check that the PTC sensor is not short-cir
The temperature
MOT.TH.SENS cuited and that there is a resistance of about 3
82 'sensor of the right
KO 600 Ohms at its ends. M
motor is faulty.
Check the wiring.
The temperature
sensor of the
MASTER or the
THERMIC SLAVE is out of 4
G4 if it persists, s spisss ths DUAL AO2.
SENSOR KO range. M/S
The maximum
current is reduced
by 50%.
The microcon
troller of the trac
tion inverter has
MC POMPA 1
85 detected a mal If it persists, replace the AC2 FLASH.
KO M
function in the mi
crocontroller of the
pump inverter.

Diagnostics 02
Alarms
The microcon
trollers of the
DUAL AC have
detected an in
compatibility be
INPUT tween the state of 1
87 Replace the DUAL AC2.
MISMATCH their internal in S
puts (SEAT, FOR
WARD GEAR, RE
VERSE GEAR,
ACCELERATOR
ENABLING).
Check that the pins C28-29 of the DUAL AC
Overcurrent alarm
are not short-circuited. Replace the DUAL
AUX OUTPUT on the setup for 2
88 AC2.
KO electromagnetic M
Check the coil and wiring of the electromag
brake.
netic brake.
The traction drive
WAITING signals that the If it persists and if the AC2 FLASH has no 2
89
FORPUMP pump drive is in alarm, replace the DUAL AC2. M
alarm.
The seat mi
croswitch has re
mained closed with Switch the key off and on again.
2
102 SEAT TIME the truck inactive Check that the seat microswitch has not been
M
for longer than the bypassed and that it is not short-circuited.
time set in SEAT
MICRO TIME.
The seat contact If the alarm occurs with the operator on board,
has remained open check that the seat microswitch works and that
1
103 KEY for longer than the the respective wiring is intact.
M
time set in KEY If the alarm occurs with the operator absent,
TIME. switch the key off and then on again.
Only for version
with reversing
lever on the
GEAR INC. steering wheel: Check that the gear selection microswitches 3
105
START Gear engaged on the steering wheel are not defective. M
at switch-on or
closure of the seat
microswitch.
The signals from
the left motor Check that the left traction motor encoder is
encoder are assembled correctly and check its wiring.
absent. The truck Check the power supply of the encoder.
STALL 4
106 can move only Use an oscilloscope to check that when the ro
ROTOR SX M
at a very much tor is moving there are two square waveforms
reduced speed. on pins A22 and A23, phase-shifted by 90°; if
The buzzersounds not, replace the encoder.
intermittently.

02
The signals from Check that the right traction motor encoder is
the right motor assembled correctly and check its wiring.
ENCODER are Check the power supply of the encoder.
abSeTit^ The tfUCk Use an oscilloscope to check that when the ro
STALL 4
107 can move only tor is moving there are two square waveforms
ROTOR DX M
at a very much on pins Al 3 and A14, phase-shifted by 90°; if
reduced speed. not, replace the encoder.
The buzzer sounds Check that the right traction motor encoder is
intermittently. assembled correctly.
Check that the voltage of the accelerator po
Output of the
tentiometer (pin C21) is not above the maxi
accelerator
mum value allowed (at rest = 0.4V: maximum
potentiometer
PEDAL WIRE value - 5.7V). 3
108 above the limits.
KO Check the power supply of the potentiometer S
The truck brakes;
(11-1 V).
the pump functions
Otherwise, check the wiring and the poten
remain active.
tiometer; calibrate the accelerator.
The tempera
ture of the mo
tor has reached
a value ADJUST-
HIGH MOTOR The temperature of the motors must drop to 3
115 MENT#5°C higher
TEMP RIGHT 90°C. M
than the first
threshold value.
The traction cur
rent is halved.
The temperature
of the motor has Check that there is no dirt accumulated on the
reached a value external finning of the stator. Use a multimeter
15°C higher than to check that the resistance of the PTC sensor
the value set for the with the motor at room temperature (25°C) is
first threshold. 1100 Ohms. The resistance of the PTC starts
HIGH MOTOR 3
116 Maximum traction at a vaiue of 1000 Ohms at 0°C and increases
TEMP M
current is reduced by about 3.9 Ohms per degree. Check with the
to 50%. tester function ofthe PC that the motor temper
The functions are ature read by the DUAL AC drive corresponds
restored when the to that obtained from the measurement of the
temperature has PTC sensor.
dropped to 90°C.
The microcon
troller of the MAS
TER has detected Switch off and then on again; if it persists, re 1
117 SLAVE KO
an error on the mi place the DUAL AC. M
crocontroller of the
SLAVE.
The DUAL
AC MASTER
microcontroller
SLAVE signals the Switch off and then on again; if it persists, re 4
118
WARNING presence of an place the DUAL AC. M
active WARNING
on the DUAL AC
SLAVE.
The slipping of
SLIP PRO the machine is not Switch off and then on again; if it persists, re 4
113
FILE consistent with that place the DUAL AC. M
expected.
02-44 Workshop Hterature. 40328042303 EN - 05/2008

Diagnostics 02
Alarms
Check that the wiring of the coil power supply
One of the
is correct (48 V). With the contactors closed,
contactor contacts
CONTACTOR check the power wiring and the tightening of 2
120 is open after it has
OPEN the power nuts on the contactors and on the M
been instructed to
drive.
close.
Check the power fuse.
The SLAVE
microcontroller
has detected a Switch off and then on again; if it persists, re 1
121 MASTER KO
malfunction in place the DUAL AC. S
the MASTER
microcontroller.
The SLAVE
microcontroller
WAITING
signals that Switch off and then on again; if it persists, re 2
122 FOR MAS
the MASTER place the DUAL AC. S
TER
microcontroller is
in alarm.
Check that the preload resistance in parallel on
the contactors is not short-circuited.
The 2nd contactor
CONTACTOR Check that the contacts of the TG2 contactor 1
124 is closed at switch
2CLSD are not stuck. M
on.
If alarm 43 (DRIVER TG2 FAULT) is also
present, replace the DUAL AC.
No steering table
has been selected.
The accelerator
pedal is forced
STEER NOT 4
160 almost to zero Configure the STEER TABLE parameter.
CONF. M
(max 1350 rpm).
The truck may
travel only at a
reduced speed.
The temperature
MOT.TH.SENS cuited and that there is a resistance of about 3
182 sensor of the left
LEFT. KO 600 Ohms at its ends. M
motor is faulty.
Check the wiring.
The thermal
sensor of the
THERMIC SLAVE is faulty. Switch off and then on again; if it persists, re 4
184
SENSOR KO N.B.: The number place the DUAL AC. 5
84 appears on the
display.
AC2 FLASH module

Note:
In the "Block" column, the number:


restart;
Workshop literature - 40328042303 EN -05/2008 02-45

02 Diagnostics
Alarms
restart;
4 indicates : no block.

Check the power fuse. Check the integrity of
the 180 Ohm preload resistance on the contac
tors.
The capacitors Disconnect the battery outlet, discharge any
CAP.CHARGE
201 do not charge at charge on the capacitors with a resistance (180 1
POMPA
switch-on. Ohm 5 W between the battery positive and
negative on the drive) and check that there are
no short circuits between the motor terminals
and the battery negative.
are correct.
Low voltage on the
VMNLOW Check that there is no insulation loss in the
202 power outputs of 7
POMPA motor.
the pump motor.
the phases and the battery negative.
are correct.
High voltage on the
VMN HIGH Check that there is no insulation loss in the
204 power outputs of 2
POMPA motor.
the pump motor.
There is no
feedback from the
motor encoder. Check the wiring of the pump encoder.
The pump motor Check the power supply voltage of the encoder
rotates at a speed (10V).
STALL of about 12 Hz (in Even In case of alarm the hydraulically assisted
205 4
ROTORP order to guarantee steering function must be active and, checking
the hydraulically with the oscilloscope, there must be two square
assisted steering waveforms on pins D3 and D5, phase-shifted
function). by 90°; otherwise, replace the encoder.
The buzzer
sounds.
Check the powei supply of the Hall, sensor
The output signal (10 Volts between E2 and E3).
LIFT WIRE from the lifting Check that the output of the HALL sensor, pin
208 3
KO HALL sensor is out El, is the following: 7.4V with the lever back
of range. (lifting); 5.3V at rest; 3.2V with the lever forward
(lowering).
High pump motor
210 STBYI HIGH Replace the AC2 FLASH drive. 2
current at rest.
Error in the
214 HIGH LOAD hardware overload Replace the AC2 FLASH drive. 2
protection circuit.
Error in the U, V, W
215 P FEEDBACK feedback circuit on Check the power wiring of the pump motor. 1
the pump motor.
02-46 Workshop Siterature. 40328042303 EN.. 05/2008

Diagnostics 02
Alarms
The temperature
of the motor has Check that there is no dirt accumulated on the
reached a value external finning of the motor.
10°C higher than Use a multimeter to check that the resistance
the value set for the of the PTC (pins F6-F12 with the connector
first threshold. disconnected) with the motor at room temper
HIGH MO
216 The hydraulic ature (25°C) is about 600 Ohms. The alarm 3
TORTEMP
functions are occurs with a resistance of more than 1000
blocked (except for Ohms; based on the multimeter readings and
the hydraulically the value read with the diagnostic software,
assisted steering check the wiring and the sensor (the sensor
that works at a cannot be replaced) or replace the drive.
speed of 17 Hz).
If the alarm occurs frequently, check the bat
tery conditions and/or recharge the battery. If
possible, check the battery voltage on the drive
with an oscilloscope and check that, during use
H/L VOLT Overvoltage, of the truck, there are no voltage values greater
217 1
AGE undervoltage. than 63V.
Use the oscilloscope to also check that there
are no voltage values less than 12.5V on the
key input (pin F1).
Replace the drive.
WRONG SET The battery voltage Check that the nominal voltage of the battery is
221 1
BATTERY is incorrect. correct.
No reception of
Check the CAN wiring between the DUAL AC
CAN BUS KO CAN signal from
230 (pins A1 and A6) and the AC2 module (pins A18 2
JOY the MHYRIO
and A19).
(setup).
No reception of
CAN signal from
the display.
CAN BUS KO (A1 and A6) and the AC2 (C3 and C1 ) and also
231 Activation of the 4
DISP between the display (A3 and A4) and the DUAL
speed reduction
AC (A7 and A4).
(CUT.SPEED
SW).
TheTGI contactor Check the wiring of theTGI.
240 DRIVER 1 KO 2
driver is faulty. Check the TG1 contactor coil.
Check that the wiring of the TG1 contactor or
Short circuit of the
of the fork arms lowering stop solenoid valve is
TG1 coil or of the
COIL 1 not short-circuited.
242 fork arms lowering 2
SHORTED Check that the TG1 coil and the fork arms low
stop solenoid valve
ering stop solenoid valve coil are not short-cir
coil.
cuited.
Short circuit on the Check that the wiring or the coil of the TG1
DRIVER 1
243 driver of the TG1 contactor is not short-circuited. 2
SHORTED
contactor. Replace the AC2 FLASH.
The emergency
EMER Check the connection and wiring of the emer
245 stop pushbutton is 2
GENCY gency stop pushbutton.
pressed.
No reception of Check the key input (F1). Check the CAN
CAN BUS KO
246 CAN signal from wiring between the DUAL AC (pins A1 and A6) 2
TRAZIONE
the DUAL AC. and the AC2 FLASH (pins C3 and C1).

Alarms
The hydraulically
assisted steering Check that the hydraulically assisted steering
HYDRO pressure switch pressure switch works (contact closed at rest
250 Lx » n L^
iiao *-* *"* M"* i Xivi
vwi i -ûpci —Kie ai IM UjJGI I VVI IUI I QIWI II iyy<,
30 consecutive Check that the connection wiring is not broken.

minutes.
Presence of a
hydraulic request Check that the joystick / distributor levers are
(other than not blocked.
PUMP iNC hydraulically Check that the inputs E7,E14, E12 of the AC2
3
START assisted steering) FLASH are not active (0 V).
at switch-on or Check that when the lifting lever is at rest, the
closure of the seat input E1 is at about 4.5 V.
microswitch.
Lever version:
The lifting Hall
sensor is outside
the permissible
range. Block of Lever version:
the lifting but not Check the voltage of the lifting lever HALL sen
of the hydraulically sor and calibrate it if necessary. Check the re
assisted steering. spective wiring.
LFTOUTOF
257 Joystick version: Joystick version:
RANGE
The y-axis Check the joystick voltage on the y-axis. Check
potentiometer the wiring and the signal presenton Cl of the
signal is outside MHYRIO card.
the permissible Replace the MHYRIO.
range. Block of
the lifting but not
of the hydraulically
assisted steering.
The control re
ceives messages
from the MHYRIO
card with the JOY
STICK parameter
WRONG Sftttr.QFF
260 Clear the alarm.
CONFIG
Hydraulic func
tions inhibited ex
cept for the hy-
a radically assistea
steering.
Check that the pump motor encoder is assem
The pump motor bled correctly. Check the wiring of the pump
speed sensor is not motor encoder.
working correctly. Check the power supply of the pump motor
The hydraulic encoder.
ENCODER
functions are Use an oscilloscope to check that when the hy
ERRORP
blocked (operation draulically assisted steering is operated (oper
of the hydraulically ational even when alarms are present), there
assisted steering is are two square waveforms on pins D3 and D5,
guaranteed). phase-shifted by 90°; if not, replace the en
coder.
02-48 Workshop iiterature 40328042303 EN. 05/2008

Diagnostics 02
Alarms
Check that when the joystick is operated on the
x-axis, the respective microswitch closes: tilt
Joystick version: forward (pin A2), tilt backward (pin A3 of the
AUX POT X-axis potentiome MHYRIO card).
266 3
NOTOK ter signal high with Check that the output of the x-axis potentiome
switches open. ter of the joystick (pin C4 of the MHYRIO card)
falls within the correct values at rest. Replace
the MHYRIO.
Joystick version:
The x-axis
potentiometer
signal is outside Check the end-of-scale value of the joystick
AUX OUT OF the permissible x-axis. Check the wiring and the signal present
267 3
RANGE range. on C4 of the MHYRIO card. Replace the
Block of the lifting MHYRIO.
but not of the
hydraulically
assisted steering.
Joystick version:
2 HY Check that the four microswitches of the joy
Two switches
269 DRAULIC RE stick are open when the joystick lever is at rest. 3
closed on the same
QUEST Replace the MHYRIO.
axis.
Faulty control
270 WATCHDOG Replace the AC2 FLASH. 2
circuit.
Error in the
EEPROM; the
pump drive will
use the default
272 EEPROM KO Replace the AC2 FLASH. 4
parameters, and
the maximum
current is reduced
to 75%.
Check that the heater fan of the drive works
The pump inverter correctly (24V).
HIGH
275 temperature is Check that neither the electronics heat sink nor 4
TEMP.P
above 75°C. the cooling air feed duct are dirty.
Replace the AC2 FLASH.
external finning of the motor.
Use a multimeter to check that the resistance
of the PTC sensor (pins F6-F12 with the con
The pump motor
nector disconnected) with the motor at room
MOTOR temperature is
281 temperature (25°C) is about 600 Ohms; if the 4
TEMP.P high. Performance
alarm appears, the resistance read is above
is reduced.
1000 Ohms.
Consequently the fault is in the PTC sensor
(the sensor cannot be replaced) or its wiring,
or in the drive.
The pump motor
MOT.TH.SENS cuited and that there is a resistance of about
282 PTC sensor is 3
KO 600 Ohms at its ends.
above the limits.
Check the wiring.
The temperature
THERMIC sensor of the Switch off the truck and allow it to cool down; if
284 4
SENSOR KO electronics is the alarm persists, change the AC2 module.
above the limits.

02
The microcon
troller of the pump
MC
drive has detected Check that there are no alarms on the DUAL
i 285 TRAZIONE 1 1
a maifunction in the AC2; if it persists, replace the DUAL AC2.
KO
microcontroller of
the traction drive.
The driver of the Check that there are no short circuits on the coil
EV LOWER hydraulic functions of the hydraulic functions stop solenoid valve
288 2
ING KO stop solenoid valve by checking on pins F3-F9. Consequently re
is faulty. place the coil, the wiring or the drive.
The seat input is Check that the seat microswitch and respective
289 NO SEAT 2
open. wiring are working correctly.
The pump drive
microcontroller
WAITING
signals that the Check that there are no alarms on the DUAL
290 FOR TRAC 2
traction drive AC; if it persists, replace the DUAL AC.
TION
microcontroller is
In alarm.
ECO DISPLAY module and MHYRIO

Note:
!n the "Block" column, ths number:


restart;
restart;
4 indicates : no block.

Short-circuit
protection of the
onuNT ON / OFF soienoio
300 Clear the alarm. 3
VALVES valves controlled
by the MHYRIO
card
No reception of
CAN BUS KO (pins Al and A6) and the AC2 (pins C3 and Cl)
330 CAN signal from 4
PUMP and also between the display (pins A3 and A4)
the AC2 module.
and the DUAL AC (pins A7 and A4).
CAN BUS KO CAN BUS alarm for
332 4
JOY joystick setup.
Joystick version:
Check that the supply oil filter is not blocked.
The pressure
Check that the wiring is not broken (pin A2).
333 OIL FILTER switch signalling a 4
Check that the pressure switch works (in air, it
blocked oil filter is
must have the contact closed).
open.

Diagnostics 02
Alarms
No reception of
CAN BUS KO (pins A1 and A6) and the AC2 (pins C3 and C1)
346 CAN signal from 2
TRAZIONE and also between the display (pins A3 and A4)
the DUAL AC.
and the DUAL AC (pins A7 and A4).
Joystick version:
DRIVER EVP Raising / lowering
GR1 solenoid valve
DRIVER anomaly.
Joystick version:
DRIVER EVP Outlet solenoid
GR2 valve DRIVER
anomaly.
Joystick version:
DRIVER EVP
349 Tilt DRIVER Clear the alarm. 3
GR3
anomaly.
The truck’s load
capacity has not
been selected;
NO LOAD the parameter
360 CAPACITY MAXIMUM LOAD Select the load capacity. 3
SETUP of the display is
at level 6. The
hydraulic functions
are inhibited.
The hours coun
WRONG
ters of the drives Synchronise the hours counters with the SINC
365 HOUR 4
are not synchro HOUR COUNTER parameter.
COUNTER
nised.
Error in the
EEPROM; the
372 EEPROM KO display will If it persists, replace the display. 4
use the default
parameters.
It is time to
CHECK UP Have the maintenance performed and update
399 perform scheduled 4
NEEDED the timer.
maintenance.

02JÄgnostics
Analogue signals
Summary of signals from the
analogue transducers
j NOTE
The values provided in the tables are indicative

only, since they depend on the mechanical tole
rances ofthe system.
3-Wheel steering potentiometer

pins C15-17 on DUAL AC or pins 1-2 on steering potentiometer connector
Wheels turned to the left Wheels straight Wheels turned to the right
[V] [V] [V]
2 6 10.2
NOTE: Between the reading performed with the TESTER and the reading performed with the PC, there
may be a difference of
± 200mV
Potentiometer power supply, C15-16 on DUAL AC: 11.80 V
4-Wheel steering potentiometer

pins C15-17 on DUAL AC or pins 1-2 on steering potentiometer connector
Wheels turned to the left Wheeis straight Wheeis turned to the right
[ Vj [ V ] [V]
2.3 5.2 3.2
NOTE: Between the reading performed with the TESTER and the reading performed with the PC, there
may be a difference of
± 200mV
Potentiometer power supply, C15-16 on DUAL AC : 11.80 V
Brake potentiometer
pins C19-18 on DUAL AC or pins 1-2 on brake potentiometer connector
Brake pedal at rest Brake pedal at end-of-scale
L V j [ V j
0.85 3.25
NOTE: Between the reading performed with the TESTER and the reading performed with the CON
SOLE, there may be a difference of x 200rnV
Potentiometer power supply, C19-33: 11.80 V
The ena-of-scaie vaiue varies depending on how

the brake pedal is pressed and how the braking
system is calibrated.
Accelerator potentiometer
pins C20-21 or pins A-C on accelerator potentiometer connector
Minimum value Maximum value
[ V ] [ V j
0.4 5.7
NOTE: Between the reading performed with the TESTER and the reading performed with the CON-
SOLE, there may be a difference of ± 200mV
Potentiometer power supply, C20-33: 11.10V
02-52 Workshop literature. 40328042303 EN 05/2008

Diagnostics 02
Analogue signals
A CAUTION
The reading with the CONSOLE menu TESTER is re

ferenced to the battery negative; if referenced to pin
C20, the reading would show about 0.7 V less.
Lifting HALL sensor

pins E1-E3 or pins "earth"-2 on HALL connector
Lever back Lever forward
Lever at rest
(lifting) (lowering)
[V]
[V] [V]
7.4 5.3 3.2
NOTE: Between the reading performed with the TESTER and the reading performed with the CON
SOLE, there may be a difference of ± 200mV
Sensor power supply, E2-E3: 10 V
A CAUTION
The reading with the CONSOLE menu TESTER is re
ferenced to the battery negative; if referenced to pin
A15, the reading would show about 0.7 V less.

Traction motor 11
Asynchronous motors
Features of the asynchronous mo
tors
The three-phase asynchronous motors do not re
quire particular maintenance, since they are not
subject to problems of wear due to the absence
of brushes and manifold. The stator is on the
internal perimeter, and housed in special slots
on the ferromagnetic core are triads of windings
arranged in an equidistant manner, on which the
power supply is applied. The rotor is a "squirrel
cage” rotor with a system of windings composed
of conducting bars axial to the rotor, housed in
slots along the entire external perimeter of the
ferromagnetic core, in a circular form, composed
of a sheet pack stacked axially to the axis and
separated by thin layers of insulating paint (see W30372
drawing to the side). The ends of the bars that
emerge from both faces of the rotor are short
circuited and mechanically fastened with two
conducting rings. With the motor axis fixed, an
extremely compact and robust rotor is obtained.
When the stator windings are powered with a
balanced system of three-phase voltages, a
magnetic field is generated that induces currents
in the rotor conductors that produce a reaction
field. As long as the relative velocity between the
inductive field and the rotor is non-zero, the mov
ing field cuts through the lines of current flowing
in the bars, and thus a torque is generated on the
rotor, causing it to move. But its speed can never
reach that of the rotating magnetic field, since this
would eliminate the relative motion between the
rotating magnetic field and the induced system,
and thus the current would no longer be induced
which gives rise to the motion. The rotation speed
of the inductive magnetic field is also called the
synchronism speed. The following figure shows
the mechanical characteristics obtained with
constant voltage and increasing frequency. The
motor works with "constant power available",
while the useful torque decreases as the speed
A Rings
increases.
S Bars
P Lamination pack

11
W30374
Vr = Rotor speed
The curves show how the motor is able to start

by itself by providing a certain starting torque; the
torque increases with the rotation speed up to
a maximum value near the synchronism speed
where it reduces rapidly to zero (because when
the rotor rotates at the same speed as the rotating
magnetic field, their relative velocity becomes
zero as does the induced electromotive force and
induced currents). With the increase of the rel
ative velocity between rotor and magnetic field,
the induced electromotive force increases both
in amnlitude as well as frenuencv Electrically
the rotor windings are equipped with a given
impedance that increases with the increase of
the frequency and thus decreases the amplitude
of the induced currents and the phase; for this
reason, the torque is reduced.
Changing the power supply frequency appropri
ately varies the synchronism speed and maxi
mum torque, thus it is easy to change the stable
working speed. During the starting phase, using
a low frequency allows to obtain a smaiier relative
velocity, thus the rotor impedance decreases and
the currents have larger amplitudes and phases,
thereby obtaining a larger torque.
The following figure shows the mechanical char

acteristics obtained with a variation of frequency
Workshop tera/ure-40328042303 EN. 05/2008

Il
in the operating range

Asynchronous motors
onstant torque available.
Vr = Rotor speed (or frequency)

W303Z5
11-3
Checking the asynchronous motors
> Given the frequencies in play, it is possible The switches working only open or in short cir-
to vary the power supply amplitude and fre lit mi ict rliacino+o r»nl\/ limi+nrl
VVII» ■ ■ awioîb *-« i w W I f-» «-■« few VI ■ ■ ■ I ■ I 11 1.0 VI
Th^ nnu/Ar
> I I IV
quency of the motor without having problems to be dissipated is mainly due to the fact that the
of heat loss on the electronic power compo closed switch in short circuit always has a min
nents and avoiding energy waste. This is imum resistance over which a certain potential
achieved thanks to the solid-state electronic difference occurs while the current can be max
switches (MOSFET) to be used in two unique imum. When the switch is open, there is always
operating conditions: open or closed. These some current that passes through it, even if mini
switches are connected in pairs in a bridge and mum, while the potential difference is maximum.
powered with a continuous dual power supply. The greatest cause of dissipation, however, oc
Making the switches commutate rapidly in a curs during commutation of the switches that al
complementary manner, at a set frequency, ways takes place over a short but non-negligible
causes the average output voltage Vu, ob time. During this phase, the voltage at the ends of
tained over a time period much longer than the the switch and the current change value gradually
commutation period, to be proportional to the from a maximum to zero and vice versa in a com
duty cycle of Vu itself, which is: plementary manner. The following figure shows
the pattern of the voltage, current and power over
time for a switch during commutation.
ti + t2
W30389
T = Voltage CR = Current
Cm = Commutation p
= Pows*"
The technique to obtain a square wave with duty pulse width modulation (PWM), is illustrated in
cycle proportional to a control voltage, called the diagram:
Workshop literature - 40328042303 EEN - 05/2008

Traction motor 11
Asynchronous motors
D. = Sawtooth
The control signal v(t) is compared with a saw switches assume one of the two possible condi
tooth signal with a larger amplitude and a fre tions.
quency much larger than v(t). When v(t), for ex
ample, exceeds the value of the sawtooth, the

11 Tractton motor
Front axie motors

Traction motor technical data
Manufacturer Juli
Designation AE 18 = 06 AC
Operating voltage 48V
Motor type 4-pole, three-phase AC motor with cage rotor
Connection Delta
Design voltage (nominal) 3 x 28V
Design current (nominal) 112 A
Design speed (nominal) 2300rpm
Maximum speed 3517 at 14 km/h
Design output (nominal) 2 x 4 kW
Operating mode (nominal) S2 (60 min)
Protection type iP 54
insulation class F
Weight Approximately 56 kg for each motor
Cooling Surface / convection
Temperature sensor KTY84 - 130
Speed sensor Rheintacho Co.
Traction
General information
X Travel direction 5 Multi-disc brake

1 Right traction motor 6 Motor connections
2 Left traction motor ~r JOI IOVI o
3 Left drive wheel 8 Temperature sensors
4 Right drive wheei 9 Brake actuator
Both traction motors are fully integrated into the

drive axie.

Traction motor 11
Front axle motors
The traction motors are connected via the motor
housing. An oil-immersed multi-disc brake is lo
cated between the motors.
On each side there is a drive wheel unit outside

the traction motors.
The motor connections U, V, W are fed to external
threaded connectors on the motors.
The speed sensors are inserted in the axle from
the outside, sealed with an O-ring and secured
with a screw.
The temperature sensors are embedded in the
stator winding. The connections are external to
the motors.
Traction motor
The traction motors are three-phase AC asyn
chronous motors, which are equipped with short-
circuited cage rotors.
Aluminium conductors are fused into the grooving
of the rotor core, which are connected at the ends
with short-circuit rings. The conductors with the
short-circuit rings form the cage rotors and hold
the rotor core together.
The stator consists of the 4-pole stator core and
the stator windings, which are incorporated as a
single unit in the motor stator.
The applied voltage is induced in the rotor bars by
the stator windings and causes a current to flow
in the rotor. The resulting rotor current and the
rotating field present on the stator generate the
torque.
Method of operation
The motors are each controlled by an IN
VERTER. The change in speed takes place
principally via a change in the frequency and
voltage of the applied AC voltage.
In the motor, each of the three phases is dis
tributed in turn to four poles in the stator, thereby
generating the rotating field. The electric motors
are operated in a star circuit and supplied with
voltage pulses by the INVERTER.
The electric motors are controlled using pulse
width modulation atafrequency of approximately
16 kHz.

11
Front axte motors
Traction motor
General Information
1 Right traction motor 4 Brake actuator

2 Left traction motor 5 Multi-disc brake
3 Drive wheel 6 Brake oil filler plug
The two traction motors are almost identical to

each other in mirror image and, together with the
drive wheel units, form the drive axle.
The multi-disc brake is located centrally between
the traction motors. The drive wheel units are on
the left and right-hand sides.
To change a traction motor, the entire drive axle
must be removed from the truck and dismantled.
Removal
r»”'i
i <■ j NO 11
• Removal ofthe individual units is described in
detail in the corresponding chapters.
• Drain the gear lubricant oil and brake oil at an
early stage so that the oil has time to drain off
completely.
> Park the vehicle safely.

> Apply the parking brake.
> Drain the gear lubricant oil.

> Disconnect the battery plug.
> Remove the lift mast.
> Loosen the wheel bolts, but do not unscrew
them completely.
> Remove the lift mast; see the chapter "Lift

mast: installation/removal".

Traction motor 11
Front axle motors
> Jack up the front of the truck; see the chapter
entitled "Safety instructions".
> Remove the wheel bolts and take off the drive
wheels.
> Release the parking brake.
> Remove the drive axle; see the chapter entitled

"Removing/installing the drive axle".
> Retain and reuse the spring elements of the
support bearings.
> Before disassembling the left-hand traction
motor, the brake control must be removed.
A WARNING
Once the connecting screws have been removed, the
drive axle splits into two parts.
Chock the two axle shafts.
> To separate the traction motors, loosen the

four M16 connecting screws.
> Remove the individual parts of the multi-disc

brake and putthem aside.
> Unscrew the drive wheel unit from the traction

motor housing.
Installation
® NOTE
• Installation ofthe individual units is described

in detail in the corresponding chapters.
• Check the tightening torques and screw qua
lity.
• Check the quality ofthe gear lubricant oil and
brake oil.
• For values, see the "General technical data "in
the chapter "Drive axle".
> Screw the drive wheel unit onto the traction

motor housing.

11 Traction motor
> Insert the brake disc packs onto the drive axle
in the order of installation.
> Insert the O ring between the two axle shafts.

> Bring the two axle shafts together so that the
guide pins go into the holes.
> Tighten the four connecting screws.

> To assemble the left-hand traction motor,
screw on the brake control.
> Install the drive axle; see the chapter entitled

"Removing/installing the drive axle".
> Fill both drive wheels with reducer gearbox oil.
> Fill the multi-disc brake with brake oil.
> Assemble the drive wheels.
> install the lift mast; see the chapter "Lift mast:
installation/removal".
> Lower the truck.
> Connect the battery plug.
> Check the traction drive for correct operation.
Drive motor checks

if the drive motor does not acceierate after activa
tion of the truck speed control device, it is possi
ble that an error has occurred in the power supply
section or control system or that there is a prob
lem in the main circuit of the motor.
Visual inspection
If a defect in the motor operation is suspected,
first perform the following checks.
Visually inspect the outside of the motor, looking

for any signs of corrosion, dirt, interruptions, tigh
tening of:
• U, V, W motor connections
• Connectorof the rpm sensor
• Connector of the heat sensor
Also check the following:

• Correct fasten!ng of the motor cables
• Correct fastening of the heat sensor on the
right drive motor
li-IO Workshop literature. 40328042303 EN.. 05/2008

Traction motor 11
Front axle motors
• Correct fastening of the speed sensor
• Fastening ofthe support plates
• Rotatability ofthe rotor (bearing damage)
• Cleanliness ofthe motor (oil, grease, dirt)
Checks during operation

During normal operation ofthe drive motors, it is
possible to perform the following checks:
• Temperature ofthe two drive motors
• Noise of the bearings
Insulation check
The insulation resistance of the motor casing
windings is important for proper operation of the
truck. A check of the motor insulation will be
valid only if it is performed using a measurement
device with a suitable test voltage.
A CAUTION
The testvoltage ofthe insulation measuring instrument
provided by the manufacturer is 500 V. This high test
voltage makes it necessary to remove all the lines of
the drive motors and the plug-in connector connecting
the control cards before beginning the test.
The insulation resistance ofthe stator windings:

U, V or W to the motor casing is greater than 48
KQ.
Checking the rotor

After disassembly, the rotor must be thoroughly
cleaned and checked, paying particular atten
tion to any cracks or disjunction ofthe terminal
clamps. The current will be reduced in the
cracked area due to the high resistance.
It is also necessary to check that the rotor is not
too hot or locally overheated which produces a
discoloration ofthe rotor.
Terminals
Three cables are connected at the U, V, W con
nections. The eyelet terminals ofthe motor ca
bles are fastened with hexagon nuts (tightening
torque 20 Nm). The motor cables must not be in
terchanged. After tightening the hexagon nuts,
the protective cover must be placed on the bolts.

11 _________
Front siete motors
Drive motor decomposition
1 Rotor S Shim
2 Flange 10 Washer
Q
v
Di»
i ii i 11 Terminal board
4 Pin 12 Gasket
5 O-ring 13 Terminal
A Roarinn
—vv<l <> 14 Screw
7 Seeger 15 Washer
8 Seeger
In order to replace the bearings, it is necessary

to remove the transmission axle from the truck,
separate the two halves of the transmission and
remove the reducer peerbox.
Remove the rpm sensor.
Heat to melt the Loctite that blocks the 2+2 side

pins (3 e 4) and remove them.
Extract the sealing gasket (12).
Workshop literature-40328042303 EN -05/2008

Traction motor 11
Front axle motors
Insert 2 M8 screws (A) into the appropriate holes
to facilitate the extraction of the cover; the rotor
(1) comes out along with the cover.
Heat the area of the bearing’s protective dust seal

in order to remove it.
Remove the 2 locking Seeger rings (7 e 8) from

the bearing.
Use the extractor to extract the bearings (6).
Using an extractor, remove the cover from the ro

tor.
A CAUTION
When a press is used to fit the bearing, only the outer
ring of the bearing can be subject to pressure. If pres
sure is applied to the inner ring, the bearing will be da
maged. Once removed, the bearings cannot be reused
since their internal rolling surfaces are damaged during
removal.

11 Traction motor
Front axle motors
Encoder
Generai information
As a speed sensor, each traction motor is equip- >
ped with a two-track pin sensor (2), which is in
serted into the axle from the back and scans the
front-end toothing of the brake disc (1).
The speed sensor is sealed with an O-ring and
fixed in the motor housing by a screw.
The speed sensors have a 11V supply from the

respective inverters. The speed signals (A and
B) are monitored by the traction INVERTER.
Technical data
Supplier | Kheintacho co.

1106 pulses per revolution
190° ±45°
Phase delay
Temperature range | -30 to+150 °C
¡11V |
Supply voltage
Replacing the traction encoder

Disconnect the battery.
Remove the step plate as indicated in the respec
tive paragraph.

Traction motor 11
Front axle motors
> Unscrew the fixing screw (2) and remove the
sensor with the bracket.
Replace the sensor and reassemble by perform

ing the disassembly operations in reverse.
Electrical connections of the trac

tion motors
Wiring diagram
The windings of the traction motors are wired in
delta configuration inside the motors.
Location of the electrical connections
(Traction motors viewed from above).
> TMTD: Right traction motor temperature sen

sor.
> TMTS: Left traction motor temperature sensor.

> ETD: Right traction motor temperature en
coder.
> ETS: Left traction motor temperature encoder.
Location and type of electrical connections:

11 Traction motor
= Similar to the insulated and watertight

threaded connectors, the main power connec
tions U/V/W are located externally to the motor
by means of a remo vable terminal board.
» ETS and ETD speed sensor — 4-pin "Junior
Power Timer" connector.
• TMTS and TMTD temperature sensor — 3-pin
connector.
Temperature sensor KTY84

General Information
Each traction motor is monitored by a tempera
ture sensor.
The watertight temperature sensors are embed
ded in the stator winding and are led out of the
motors through a removable terminal board.
The signals are evaluated in the INVERTERS.
Technical data
Type KTY84-130 ä
Supply approx. 1.7 mA j
Electrical connections
The temperature sensor is connected with a 3-pin
connector in which;
PIN 1 Brown cable (sensor positive)

PIN 2 Not Used
PIN 3 Blue cable (sensor negative)
A CAUTION
An improperly conducted insulation test can perma
nently damage the temperature sensor.
Before conducting the insulation test, jumper the tem
perature sensor connections.
Testing
Use a multimeter to check the resistance measu
red between PINs 1 and 3 of the 3-pin connector.
Compare the resistance value to the table. r.. .

iMAili
Reference values for temperature measure
ment
Temperature (°C) Resistance (il)
-40 355
!
i -30 386
Ti -16 Workshop iterators. 40328042303 EN 05/2008

Traction motor 11
Front axle motors
Temperature (°C) Resistance (Si)
-20 419
-10 455
0 493
10 533
20 576
25 598
30 621
40 668
50 718
60 769
70 824
80 880
90 939
100 1000
110 1063
120 1129
130 1197
140 1268
150 1340
160 1415
170 1493
180 1572
190 1654
200 1739
210 1825
220 1914
Replacing the temperature sensor
A defective temperature sensor can be replaced

with the aid of a repair kit containing a temper
ature sensor and the two-component balancing
mastic.
> Knead both components (yellow and blue) of
the mastic together until the mass has a uni
form green colour.
> Continue kneading the green mass for at least

2 minutes until it becomes noticeably warm.
> Unscrew the terminal board with the main
power connections.
> Press the sensor against the side of the wind

ing using the balancing mastic.
j NOTE
Make sure that no mastic gets between the sen

sor and winding, as otherwise the temperature
measurement will be incorrect.

11 Trsictiori motor
> The balancing mastic is fully hardened after

approx. 2.5 hours.
Insulation testing of traction motor

Genera! Information
Insufficient insulation values in the truck can lead
to undefined errors that may not be detected
through a diagnosis.
Test configuration
> Disconnect the battery connector.
> De-energise the traction motor INVERTERS
by disconnecting all the power cables "U, V,
The test voltage may damage the INVERTERS.

You must disconnect the traction motor’s connections
(power supply cables) from the INVERTERS.
> Jumper the traction motor’s temperature sen

sor at the connections.
The test voltage may damage the temperature sen

sors.
The temperature sensors must be jumpered at the con
nections.
Traction motor measurement

Test voltage: 100 V DC.
> Measurement of windings U, V. W of the trac
tion motor in relation to the housing.
Traction motor test value

The insulation of the electrical system and the
traction motor must have a minimum value of
lOOOfi/Volt.
t note
Ifthe value is less than this threshold: the insula

tion is insufficient.
End of test
When the test has been completed, or any nec
essary repairs have been carried out, all connec
tions must be restored and the jumpers must be
removed from the temperature sensors.
VMS Workshop literature - 40328042303 Ehl - 05/2008

Gearbox 22
Front axle
Front axle technical data
W30930
1 reducer gearbox oil filling screw M18x1.5, 4 brake oil level screw M10x1, tightening torque
tightening torque Ma= 70 Nm Ma= 20 Nm
2 reducer gearbox oil drain screw M10x1, tight 5 brake oil filling screw M10x1, tightening torque
ening torque Ma= 20 Nm Ma= 20 Nm
3 reducer gearbox oil level screw M10x1, tight 6 brake oil drain screw M 10x1, tightening torque
ening torque Ma= 20 Nm Ma= 20 Nm

Fírorrt axte
Viewx
> Detail of the service and parking brake actu
ating lever. The maximum actuating forces of
the lever are provided in the technical specifi
cations. The lever has a travel of 4 mm which
is the space between the brake discs.
A18-06AC technical specifications

Battery Voltage ¡J Batt = 48 V
Electric motor (operating mode S2 - 60 Min.)
voltage U = 3 X 28 V
Rated current Inom =116 A
Rated power Pnom-2x4 kW
Rated rpm nnom = 2300 rpm
Rated frequency fnom - 80 Hz
Maximum rpm Hmax ” 3517 rpm
Axle
Maximum load on the axle Fmax - 5200 N
Max. tractive force Ftrac. max = 6020 N
Maximum truck speed Vmax =14 km/h
Maximum wheel speed Nmax wheel - 172 rpm
200/50- 10
Tyres
rdyn = 217 mm
Reducer gearbox i = 20.45
Oil conierii per side 0.3 i i
See the "Supply table" !
Type of oil
Brakes
Braking torque on the wheel Mar - 1538 Nm
FlBr = 1760 N
Take-off force at the lever
F2Br = 1960N
With deceleration a = 27%
With the weight of the truck m = 5270 kg (p friction = 0.12)
Fl =6360 N
Max. force on the brake lever
F2 = 6360 N
Oil qty. 0.151
T\/hq of nil See the "Supply table"
Works 5328042303 EN - 05/2008

Gearbox 22
Front axle
Speed sensor pin-out >
1 U B+
2 Channel A
3 UB-
4 Channel B
Temperature sensor pin-out
W30933
1
2
3 Blue -

22 Gearbox
Removal of front axle with traction

motors
= Disconnect the battery socket or operate the
emergency stop button.
• Remove the step plate as indicated in the re
spective chapter.
• Remove the lift as described in the respective
chapter.
> Raise the truck using a hydraulic jack, taking

care to position it underneath a sturdy point of
the chassis.
> Position solid, stable supports underneath the

chassis and then Iowerthe jack and completely
unscrew me wneei fixing screws, men remove
the wheels.
Workshop literature. 40328042303 EN-05/2008

Gearbox 22
Front axle
>
Disconnect the brake actuation cables from the
axle as follows
> release the retaining pins (2) and remove

them.
> Loosen the nut and lock nut (3) that block the
cable on the bracket
> Free the electrical wiring by unscrewing the

screw (4) that blocks the cable sleeve tie.

22 Gearbox
Front axte
> Raise the caps and detach the power cables
(5) to the motors, marking them to facilitate cor
rect reassembly.
> Position the fork arms of a truck or pallet truck

(7) under the front axle and bring them into con
tact. Unscrewthe screws (8) fastening the axle
to the chassis.
> Extract the front axle by backing up with the

truck or with the pallet truck
A WARNING
Rn namfi il not tn strike nr damage the Components nr
details ot me machine during this phase.

Gearbox 22
Front axle
Front axle reassembly
Axle assembly diagram
W30945
Reassemble the front axle by performing the re

moval operations in reverse, paying particular at
tention to the following operations:
• Fastening of the front axle to the chassis with
tightening of the screws as per the assembly
diagram.
• Reassembly of the wheels by screwing on the
screws in the sequence and to the tightening
torque described in the respective chapter
Cables connection diagram
W30946
Reclamp the power cables to the terminals (1) of

the motors, to a torque of 12 Nm, comparing the
references of the cables with the references of the
connection diagram.

Reducer gearbox
Front axle reducer gearbox topography
W30514
Shaft of the sun wheel. 10 Wheel shaft.

Reducer gearbox housing. 11 Radial shaft gland
Washer. 12 Tapered roller bearing
Socket-head screw. 13 Slotted nut.
14 Planet gear carrier 2
10 (O
Oil filling screw.

Spacer ring. 15 Oil drain screw.
Planet gear carrier 1
N
Rim. 16
17
00
\A/hanl error*/
V V I IWI UVI . O-ring.
0)
Oil level screw.

Gearbox 22
Reducer gearbox
Front axle reduction gear disas-
sembly/reassembly
Remove the wheels as described in the relative
paragraph "Removal of the front wheels".
Disassembly
> Extract the first spider (1 a) together with the
sun wheel (1 b) from the reduction gear hous
ing.
> Heat the cheese-headed screw (2a) (to melt

the Loctite) and unscrew it. Extract the second
spider (2b) from the housing of the transmis
sion.

22
> Heat the ring nut (3) (to melt the Loctite).
> Unscrew the ring nut using the sector wrench

(5) and the wrench for a universal cardan joint
(4). (Hold the wheel shaft firmly motionless,
e.g. in a vice)
> Screw the extractor (6) onto the wheel shaft.

Gearbox 22
Reducer gearbox
> Extract the wheel shaft from the housing of the

transmission, tapping the housing lightly on a
wooden surface.
W30507
> Disassembled wheel shaft
• 7. Reduction gear housing

• 8. Wheel shaft
• 9. Bearing
• 10. Spacer
> Remove the oil seal (11) from the housing.
Reassembly
The oil seal, the first part to be remounted, must
be lubricated with max 50% grease inside and
then Loctite n. 243 must be put on the outer di
ameter.
After having cleaned all the components, re

assemble by following the reverse order. Fix the
nut (3) and the screws (2a) with Loctite n. 270
Tightening torque for the screws (2a): 25 Nm
Tightening torque for the nut (3): 1200 Nm.
Install the wheel shaft of the sun wheel, checking W30509

that the chamfer is turned towards the sun wheel.
j NOTE
For the type ofoil to use, refer to the "Supply Ta

ble" in this manual.

22 Gearbox
Removal / reassembly of the drive

wheel reducer gearbox
Removal
> Disconnect the battery connector.
> Loosen the wheel bolts.

> Jack up the front of the truck; see the chapter
entitled "Safety instructions".
> Release the parking brake.
> Remove the wheel bolts and then the wheel.

> Place a collection vessel for the gear lubricant
oil under the drive wheel.
> Drain the gearbox oil.

> Unscrew the drive wheel unit from the traction
motor housing (No. 16 screws).
> Screw two M8 screws into ihe threaded holes

provided (at the 5 o’clock and 11 o’clock posi
tions) and extract the drive wheel unit.
> Remove the reducer gearbox.
Reassembly
fÏj NOTE
* Tnrniifândsnrpvifth¡¿¡¡iti&v i/ary nn
the axle type.
• Check the Quality ofthe gear lubricant oil.
» For values, see the "Genera! technical data "in
> Assemble the planet gear carrier on the drive

wheel unit.
> Insert a new sealing ring into the groove.
Workshop literature. 40328042303

Gearbox 22
Reducer gearbox
> To aid assembly, screw two guide pins into the

traction motor housing.
> Assemble the reducer gearbox unit onto the
traction motor housing using the guide pins.
The oil filling opening must face upwards.
> Screw the reducer gearbox unit onto the trac

tion motor housing, tightening the screws in
cross order.
> Fill with gear lubricant oil via the upper filling
opening.
> Assemble the wheel and tighten the wheel
bolts.
> Lower the truck.
> Check the tightening torque.
> Connect the battery connector.
> Functional test.
Check reducer gearbox oil level

U NOTE
The oil level check must be performed with warm

oil, so use the truck to warm up the oil and, before
checking the level, stop the truck on a flat surface
and wait until the oil level stabilizes.
• Stop the truck so that the wheel locking screw
(1 ) is positioned on top and the oil level screw
(2) is located about 26 mm under the horizontal
line.
• Unscrew the oil level screw (2). The oil level
must correspond with the lower edge of the
hole.
• Screw in the oil level screw (2) and tighten it to W50267
20 Nm.

22 Gearbox
Reducer gearbox oil change
The oil change must be performed with warm oil.

• Stop the truck so that the wheel lucking screw
(1) is positioned on top and the oil level screw
(2) is located about 26mm under the horizontal
line.
• Remove the wheel as described in the respec
tive paragraph "Front wheel removal".
• Clean the area surrounding the oil level screw
(2), the drain screw (3) and the filling screw (4).
- Arrange an oil collection basin underneath the
drain screw (3).
• Unscrew the oil level screw (2). the drain
W50268
screw (3) and the filling screw (4) and com
pletely drain the oil from the reducer gearbox.
» Clean the magnetic cap of the drain screw (3).
» Screw in the drain screw (3) and tighten it to 20
Nm.
’ Pour the oil into the opening ofthe filling screw
and waits min.
• The oil level must correspond with the lower
edge ofthe hole for the oil level screw (2).
• Screw in the oil level screw (2) and tighten it to
20 Nm.
- Screw in the filling screw (4) and tighten it to 70
Nm.
Workshop literature. 40328042303 EN -05/2008

Truck 31
Counterweight
Counterweight removal
Three-wheel truck counterweight removal
A DANGER
Before carrying out the operations described below,
the lift must absolutely be completely lowered and tilted
backwards. Rest the fork arms or any other equipment
on the ground and position suitable, stable supports
under the fixed masts or lift supports. Failure to abide
by these precautions may lead to truck instability with
the risk of tipping over.
Remove the battery as described in the respec

tive paragraph.
> Unscrew the screws (1) fastening the over

head guard to the counterweight.
> Unscrew the fixing screws (2) of the DC/DC

converter support bracket (if applicable).

31 Truck
Workshop liter ature - 40328042303 EN. 05/2008

Truck 31
Counterweight
> Insert non-metallic slings with a suitable lifting
capacity into the slits of the counterweight.
A WARNING
Compare the lifting capacity of the slings with the coun
terweight weights listed in the table.
Counterweight weights
Model Weight (kg)
133-163 795.0
3-wheel 153-183 834.0
203 796.0
15-16-18-
4-wheel 740.0
20
>
A WARNING
Be careful not to accidentally hook the sling to the cross
traverse (6) of the overhead guard.
> Tension the slings on the counterweight.

31
W30979
Workshop starature - 40328042303 EN •■■■■ 05/2008

Truck 31
Counterweight
> Lift the counterweight and backup, removing it

from the chassis. Set the counterweight on the
ground.
j NOTE
The procedure described above refers to the

three-wheel truck model. The only difference
with respect to the four-wheel truck model is the
number ofcounterweight fixing screws.
Four-wheel truck counterweight removal

The only difference with respect to the three-
wheel truck model is in the number of coun
terweight fixing screws, see the paragraph
"Four-wheel truck counterweight assembly dia
gram".
j NOTE
For the remo vai operations, operate as indica

ted in the paragraph "Three-wheel truck counter
weightremoval".

Counterweight reassembly
Three-wheel counterweight assembly dia-
Counterweight Screw M18x2.5x50

Chassis assembly Screw M18x1.5x180
Workshop iiterature -40328042303 EN - 05/2008

Truck 31
Counterweight
Four-wheel counterweight assembly dia
gram
W30983
1 Counterweight 3 Screw M20x2.5x190

2 Chassis assembly 4 Screw M20x2.5x100
Follow the removal instructions in reverse,

scrupulously abiding by the screw tightening
torques indicated in the assembly diagrams.

31 Truck
Covers
Cover tonoaraohv
The following covers are present on the truck:

< NOTE
• the right side cover (1);
• the left side cover (2); See the paragraphs in the “Truck" chapter for
• the battery cover (3); the removai/reassembiv operations ofthe covers
and the "Driver’s seat" chapter for the panelling.
<= the distributor cover (4);
• the control panel panelling (5) and the steering
column panelling (6).
31-8 Workshop Mterature -40328042303 EN. 05/2008

Truck 31
Covers
Side covers removal / reassembly
> Secure the truck by applying the handbrake.
Disconnect the battery socket. Raise the bat
tery cover (1) as described in the chapter "In
ternal accessibility".
Left side cover removal

> Unscrew the screw (1) of the left side cover
bracket located on the front part of the cover.
> Unscrew the screw (2) located on the rear part

of the cover. Remove the left side cover (3).

31 Truck
Covers
Right side cover removal
> Remove the right side cover (4) by releasing
the latches (5) in the direction of the arrow.
Side covers reassembly

Perform the removal operations in reverse.
Battery cover removal / reassem

bly
Battery cover removal
Disconnect the battery socket. Remove the
operator’s seat as described in the respec
tive chapter. Raise the battery cover (1) as
described in the paragraph "internal accessi
bility".
A CAUTION
The removal of the battery cover must be carried out by
two operators: one keeps the cover raised, while the
other performs the removal operations.

Truck 31
Covers
> Disconnect the connector (2) that connects the >
wiring to the seat microswitch.
> Disconnectthe gas spring (3) on the cover side >

by unscrewing the respective fixing screw.
> Unscrew the fixing screws of the hinge sup- >

ports (4).

31 Truck
> Remove (with two operators working together)

the battery cover (1) complete with hinges.
Battery cover reassembly

Perform the removal operations in reverse, tak
ing care to reconnect the seat microswitch wiring
correctly.
Step plate removal / reassembly

Removal
r'lier'Qri nar*T thcs hoTTnrv nrsArcTrs
emergency stop button. Remove the rubber
mat (1).

Truck 31
Covers
> Unscrew the 2 screws (2) fixing the step plate
to the chassis.
> Raise the step plate (3) slightly and disconnect

the accelerator pedal connector (4) and the ac
celerator potentiometer connector (5).
> Remove the step plate (3) complete with accel

erator pedal.
Reassembly
Reassemble by performing the removal opera
tions in reverse.
Workshop literature - 40328042303 EM - 05/2008 31-13

Distributor cover removal / re
assembly
Distributor cover removai
Disconnect the battery socket. Unscrew the
four screws (1) of the mask (2).
> Raise the mask (2), loosen the lock nut (3) and
unscrew the levers of the hydraulic distributor
(4).
NOTE
Mark the respective positions on the levers in or

der to facilitate reassembly.

Truck 31
Covers
> Raise the distributor and unscrew the two

screws (6).
[J] NOTE
In order to raise the distributor cover correctly,

see the paragraph “Internal accessibility”.
> Extract the switches (7) from the cover by

pressing them upwards lightly from below (A).
fj~| NOTE
Mark the respective positions on the connectors

in order to facilitate reassembly.

31 _____
> Remove the starting switch (9) by unscrewing

the locking ring nut and the emergency stop
button as indicated in the respective para
graph.
Distributor cover reassembly

Follow the removal instructions in reverse, taking
care to reconnect the wiring correctly.
Workshop literature
Truck 31
Batteries
Battery removal
Battery disconnection
• Secure the truck by applying the handbrake.
• Disconnect the battery socket or operate the
> Open the battery cover (1) as described in the

paragraph "Internal accessibility", and remove
the right side panel (2).
> Hook a crane or a truck with a rocker or slings

with a suitable lifting capacity to the battery in
the four lifting points provided.
A WARNING
Check the weights of the batteries in the respective pa
ragraph.
A CAUTION
Use only non metallic slings or metallic chains only if
covered with insulating rubber.
Raise the battery and extract it from the compart

ment.
Battery reconnection
Perform the disconnection operations in reverse.

31 .Fruck
workshop Hterature-40328Ö423Ö3 [FM —05/2008

Driver’s seat 34
Overhead guard
Removal of the overhead guard
Disconnect the battery socket or operate the
emergency stop button. Raise the battery
compartment cover as described in the para
graph "Internal accessibility". Unscrew the
screws (1) fastening the overhead guard to the
counterweight in the rear.
> Remove the DC/DC converter (2), including

the support, by unscrewing the respective
screws.
> Disconnect the connectors (3) of the rear

lights.

34
> Remove the front lights (if applicable) with the

support brackets by unscrewing the respective
fixing screws (4).
> Unscrew the screws (5) fastening the over

head guard to the front panelling.
> Slowly lift the overhead guard using suitable

equipment and remove it, being careful not to
interfere with any parts of the truck (wiring, cov-
hu’ '

Driver's seat 34
Overhead guard
Reassembly of the overhead guard
Assembly diagram
W31002
1 Screw M 12x1.25x25
2 Button-head screw M10x1.5x25
Perform the removal operations in reverse, abid

ing by the screw tightening torques indicated in
the assembly diagrams.

on
Fairings
Removal / reassembly of the steer
ing column panelling
Removal of the steering column panelling
> Secure the truck by applying the parking
brake. Operate the emergency stop button or
disconnect the battery. Unscrew the nut (1)
and remove the steering wheel inclination ad
justment knob (2), being carefui of the iocking
bush.
'> Unscrew ths screws (3) from both sides.
Workshop literature 40328042.303 EM “ 05/2008

Driver's seat 34
Fairings
> Remove the two shells (4) from the steering

column.
Reassembly of the steering column pan

elling
> Assembly diagram
• 1= Steering wheel
• 2= Horn
• 3= Steering column
• 4= Locking bush
• 5= Nut
• 6= Steering wheel adjustment knob
Reassemble the shells by performing the removal

operations in reverse, taking care to correctly re
assemble the locking bush before reassembling
the steering wheel inclination adjustment knob,
as shown in the assembly diagram.
Removal / reassembly of the con

trol panel panelling
Removal of the panelling
> Securethetruck by applying the parking brake. >
Operate the emergency stop button or discon
nect the battery. Unscrew the five top screws
(1) and remove the cover (2).

34
Workshop irte rature - 40328042303 EN - 05/2008

Driver’s seat 34
Fairings
> Unscrew the four fixing screws (5) of the con- >
sole connector.
> Remove the connector (6) from the panelling. >
> Carefully move the panelling (7) to disconnect >

the connector of the display (8), and then com
pletely remove the panelling.

34
>
Daoeeamhki r\f tho nortallinH

■ XVMWVI I I VIJT VI M IV fuZVIl IVIIII ijj
Reassemble the panelling by performing the re

moval operations in reverse, being careful to re
connect the wiring to the display.
Workshop
Steering system 42
Steering distributor
Steering distributor technical data
49,a
cn
s
29 I 44
W31003
Steering distributortype OSPF 50 LS EL T= Drain, G 1/2

Maximum steering pressure 90 P= Distributor supply, G 1/2
Shockproof valve 150-170 bar L= Left steering cylinder supply, G 1/2
Anti-cavitation valve included R= Right steering cylinder right, G 1/2
Checkvalve on P line included LS= Load sensing signal, G 1/4
Hydraulic connections: EL= Pressure switch connection, M10x1
The steering unit consists of a valve and a rotary flow-rate controller to the inlet connection of the L
flow-rate controller. Operation of the column con or R cylinder, depending on the direction of rota
nects the hydraulically assisted steering with the tion. The flow-rate controller measures the quan
turning wheels of the vehicle. When the steer tity of oil directed to the steering cylinder in pro
ing wheel is rotated, the oil arriving from the sys portion to the rotation angle of the steering wheel.
tem pump is directed through the valve and rotary

42 ^-gering system
Manual steering pressure quickly. This protects the hydraulically assisted
steering by limiting pressure loads arriving from
Under normal operating conditions, with the
the cylinders due to external factors. In this man
pump feeding the steering unit an adequate flow
ner the pressure drop between L and T and be
for the required pressure, the torque that must
tween R and T is also limited. The valves are cal
be applied to the steering wheel is not more than
ibrated at 1 l/min and the set value is 150+15bar.
0.5 daNm. If the flow is lacking or insufficient,
the steering unit will automatically operate as a
manual pump. In this manner the emergency
steering of the truck is ensured. The table below
indicates the pressure values in case of manual
steering (Pm) for a torque of 12 daNm applied to
the steering wheel.
OPSF 50=Pm 90 (bar)
This value is considered to the maximum torque

that an average operator could exercise.
Maximum-pressure valve
The maximum-pressure valve limits the maxi
mum pressure of the steering unit to the set value,
thus protecting the system. It also ensures the by
pass when the cylinder is at stroke-end.
[prigG+Sbai-.y ~ ..............|
Anticavitation valve
The anticavitation valves guarantee the cylinders
the capability to suction oil when, under special
circumstances, a vacuum could form inside them
(cavitation).
Non-retum valve
The non-return valve protects the driver from
kickbacks that could be transmitted to the steer
ing wheel. It prevents the return of the oil toward
the pump when the steering opposes the pres-
in th*-> nylindpr Thp non-r*afi «rrr v£iK/a ic
eluded inside the hydraulically assisted steering,
in the opening P.
Double antishock valve

The double antishock vaive in the OSPF steer
ing unit is direct-acting and thus responds very
42-2 Workshop tterator - 40328042303 EN - 05/2008

Steering system 42
Supplier diagram
W31005

ing distributor
Steering distributor removal
spective chapter.
> Remove the steering distributor feed barrels

(1).
U NOTE
Mark the respective positions on the piping in or


42 Steerina system
_____________________ _______________
> Unscrew the four fixing screws (2).
> Disconnect the two faston connectors (3) from >

> Remove the steering distributor (4) from the >

truck.
Workshop literature-40328042303 EN ~~ 05/2008

Steering system 42
Steering distributor reassembly

> Perform the removal operations in reverse, >
taking care to reconnect the hydraulic piping, if
not previously marked, as shown in the figure
to the side.
Hydraulic connections:
• T= Drain
• P= Distributor supply
• L= Left steering cylinder supply
• R= Right steering cylinder supply
• LS= Load sensing signal
• EL= Connection to the pressure switch
W31010
Steering distributor pressure

switch technical data
Calibration: 0.7 bar
Tolerance at 2O°C+0,1 _0
A) adjustment screw
B) faston connector 6.3x 0.6
C) size 24 key

42 sSi@@rinoW1_system
_____________ _______
Replacing the steering distributor
pressure switch
° Secure the truck by applying the handbrake.
> Remove the step plate as indicated in the re

spective chapter. Replace the pressure switch
(1) as follows:
> Disconnect the two fasten connectors (2) from


Steering system 42
Steering column
ing column
Removal of the steering column
• Secure the truck by applying the parking brake.
• Operate the emergency stop button or discon
nect the battery.
• Remove the steering column cladding panels
and the control panel panelling as described in
the respective paragraphs.
• Remove, if applicable, the light switching de
vice or manual reversing lever.
> Disconnect the electrical contacts (1), after >

having removed the horn button (2) from the
steering wheel.
A WARNING
Take care to avoid damaging the electrical contacts.
> Unscrew the nut (3) and remove the steering >
wheel.

42 -Peering system
Steering column
420 Workshop literature. 40328042303 EN - 05/2008

Steering system 42
Steering column
> Remove the steering column inclination ad
justment pin (6) with respective locking bush.
> Unscrew the two screws (7) that fix the column
to the chassis.
> Remove the steering column (8).
[j~] NOTE
The procedure described above provides for the

disassembly ofthe complete steering column. If
necessary and/or useful, the steering column can
be disassembled without disassembling the stee
ring wheel, thus avoiding the first two operations.

42 Steering system
Reassembly of the steering column (Assembly diagram)
W31022
1 Locking bush 6 Steering wheel

2 Spring pin 7 Steering column
3 Column locking pin 8 Hydraulically assisted steering spindle
4 Steering wheel adjustment knob 9 Steering art. screw
5 Locking bush

tions in reverse, tightening the screws (9) to the
tightening torque indicated in the assembly dia
gram.
Workshop literature - 40328042303 EN 05/2008

Steering system 42
Steering axle
Three-wheel truck rear axle techni
cal data
Pivoting, fixed to the chassis.
Includes the steering cylinder which, supplied by

the steering distributor, provides for the rotation
of the axle casing through a toothed rod. A poten
tiometer connected to the axle casing allows to
realize the electrical differential.
1 Axle casing fixing screw. *= Tighten the screw 3 Nut for closing the cylinder liners. Apply Loc
with a torque of 15 Nm. Measure the dimen tite 243; clean, degreased and dry threads.
sion "S", rounding the dimension for the shim 4 Screw fastening axle to chassis.
up to the next tenth and tighten the screw to 5 Wheel hub locking nut.
a torque of 195 Nm. Apply Loctite 270; clean, 6 Potentiometer fixing screw.
degreased and dry threads. 7 Potentiometer driving disc fixing screw.
2 Potentiometer support fixing screw. 8 Wheel locking nut.

42
Track = 168 mm. cold-storage room use, filled with low-temper

>CD
Strake = 103.7 mm. ature grease.

Forwards travel direction.
U O
Support on the sieering unit filled wiih saponi

fied lithium grease (TUTELA MR2) during as
sembly. Grease quantity: 250g. For the as
sembly for cold-storage room use, filled with
iow-temperature grease.
E During assembly, filled with saponified lithium
grease (TUTELA MR2). For the assembly for

Steering system 42
Steering axle
W31025
Steering axle pivoting type

wheel angle range 90°
toe-in /

42
wheel inclination /
incidence !
Tightening torque
wheel hub 145 Nm
wheel locking nuts 200 Nm
axle casing fastening 195 Nm
steering cylinder stroke 103.7 Nm
hexagon nut on the stub axle bolt
Lubricant
Tutela MR2
wheel hub support Lithium grease
Consistency N.L.G.I.2
Tutela MR2
stub axle support Lithium grease
Consistency N.L.G.I.2
Three-wheel truck axle removal

> Secure the truck by applying the handbrake. !>
emergency stop button. Raise the rear of
the truck, resting it on solid, stable supports,
and biock the front wheels (with handbrake
and wooden blocks) to prevent the truck from
moving.
A DANGER
Without the battery and counterweight, the equilibrium
of the truck can become compromised; there is a risk
that the truck will tip over!
Raise the battery cover as indicated in the re

spective paragraph.
Workshop literature. 40328042303 EM ■ 05/2003

Steering system 42
Steering axle
> Disassemble the wheels (2) of the rear axle.
A WARNING
For greater clarity, the description and the photos that
follow have been realized without the counterweight. If
A
you must work without the counterweight and the bat
tery, it is advisable to lift the truck and rest it on four so
lid, stable supports, lower the lift completely in the til-
ted-back position and place suitable, stable supports
under either the fixed masts or the lift supports.
> Disconnect the supply piping of the steering

cylinder from the special compartments in the
chassis.
>
[J] NOTE
With the counterweight assembled there is less

operating room for the spanners, and on the right
side it may become necessary to disassemble
the Battery socket support. Or to disconnect the
piping working from below.

42 Steering system
> Underneath the axle (3), place a jack or pal

let truck (4) and move it into contact with the
same.
> Support the axie vertically and lower the jack

until freeing the cylinder from the rear rein
forcements of the chassis in order to remove
it. Withdraw the jack to remove the axle from
the chassis.
Workshop literature - 4032804b

Steering system 42
Steering axle
> If the presence of the counterweight is neces
sary during the extraction of the axle, rotate the
same in order to allow the cylinder to clear the
dimensions of the counterweight.
Three-wheel truck axle reassembly

> Perform the removal operations in reverse,
applying the correct tightening torques for the
screws fastening the axle to the chassis and
the wheel fixing screws.
1 - Screw TEM16x1.5x65
> Axle to chassis tightening torque: 195Nm
Pi] NOTE
Secure the screw with the glue FK5 WN12612

42
> Wheel tightening torque: 200 Nm
WorksKoD hl'F’rst-jri'’" ■4-03?80,4-?303 FIN. OfNCFOOfi

_______________________________Steering system 42
Steering axle
Three-wheel axle disassembly
1 Potentiometer support 4 Drive ring

2 Drive ring 5 Locking pin
3 Screw 6 Guard ring

42 ering system
7 Shims 13 Wiper
8 Axle casing 14 Cylinders
9 Steering unit 15 Pistons
a
10 Upper tapered roller bearing 1 U Gaskets
11 Snap ring 17 Toothed rod
12 Lower tapered roller bearing
Disassembly
» Disassemble the potentiometer support (1)
and drive ring (2) of the potentiometer.
» Loosen and remove the screw (3).
• Remove the ring (4) with the locking pin (5).
• Remove the guard ring (6) and shims (7).
• Pull the axle casing (8) out of the steerina unit
(9) .
® Retrieve the inner race of the upper bearing
(10) and remove the snap ring (11) from the
steering unit in order to remove the outer race
of the upper bearing.
» Then remove the races of the lower bearing
(12) and the wiper (13).
Steering unit disassembly

• Loosen and unscrew the cylinders (14).
• Remove the pistons (15) and the gaskets (16).
• Finally extract the toothed rod (17) from the
steering unit.
42-20 Workshop iiterature - 40328042303 EN - 05/2008

Steering system 42
Steering axle
Steering unit reassembly

Perform the steps described above in reverse,
taking care to apply Loctite 243 on the threads
(clean, degreased and dry) of the cylinders (1)
that should be tightened to a torque of 145 Nm.
Axle support reassembly

• Fill the compartments (2) with saponified
lithium grease (Tutela MR2).
• Position the steering unit (complete with bear
ing races and wiper) on the axle support com
plete with lower bearing, insert the upper bear
ing and adjust the bearings as described be
low.
[j] NOTE
Check that the shaft seating ring (3) is installed

in the correct assemblyposition. The tip must be
facing the taperedroller. Fill the shaft sealing ring
(3) with saponified lithium grease (Tutela MR2).
• In order to ensure a symmetric wheel steering

range, place the toothed rod in the central po
sition: the reference marks "0" on the rod and
on the sprocket must coincide. In this situation
the wheel pins must be parallel to the steering
cylinder.
Axle casing bearings adjustment

• The bearings are adjusted using the shims (4) 1 Apply Loctite 243
2 Apply Loctite 270
available with values of 0.1 - 0.5 and 1 mm.
Proceed as follows:
• Once the assembly of the axle support and the
steering unit has been completed as described
above, insert the guard ring (5), some lead wire
in the zone (4) and the ring (6).
• Screw in the screw (7) and tighten it to 15 Nm.
• Remove the screw and the ring and measure
the thickness "S" of the lead wire.
• Insert the shim (4) with the value "S" corre
sponding to the measured value, rounding up
to the next tenth.
• Complete the process by tightening the screw
(7) to 195 Nm after having applied Loctite 270.

42 Steering system
'i'O'
Disassembly of the wheel hub

° Unscrew the wheel locking nuts (1) and re
move the rim (2).
Remove the cover (3).
« Undo the prevailing torque nut (4).
• Extract the shim (5) with the locking pin (6).
<• Extract the wheel hub (7).
<■ Disassemble the double bearing (8).
• Remove the shaft sealing ring (9).
Assembly of the wheel hub

« Reassemble everything by performing the dis
assembly steps in reverse.
° Fill the appropriate compartment (11) with
saponified lithium grease (MR2).
• Clean the nut (4) and the threaded pin to elim W31040
inate any grease residue, and tighten it to 145

Nm. 1 Wheel clamping screw
2 Rim
» Fill the shaft sealing ring with saponified lithium 3 Cover
grease. Check that the ring has been assem 4 Nut
bled in the correct position: the lip must be fac 5 Shim
ing the tapered roller bearing. 6 Locking pin
7 Wheel hub
8 Bearing
9 Shaft sealing ring
10 Axle casing
11 Grease compartment
Workshop Hterature - 40328042303 E N - 05/2008

Steering system 42
Steering axle
Three-wheel truck potentiometer technical data
Potentiometer diagram
The wiper is shown in the base position.
A Chamber
Electrical data
Electrical angle 250° ± 3°
±3% from 0° to 25° and from 225° to 250°
Linearity ±1 % from 25° to 80° and from 170° to 225°
±1.5% from 80° to 170°
Resistance at the ends of the potentiometer 4 kOhm ± 20%
Resistance of the wiper 1.7kOhm±20%
Load resistance >400 kOhm
Maximum current of the wiper 15 mA for max. 1 min.
Rated current of the wiper <100 uA
at 40° C 0.5 W
Power absorbed
at 125° C 0.05 W
Mechanical data

42 Steering system
Mechanical angle 240° ± 3°

Moment of the spring’s returning action at the end
< 7.5 Ncm
of the rail
Strength of the stop 60 Ncm
Direction of the spring’s returning action Clockwise
General data
Operating temperature range /m°r* Mx-mcor
“"TV V» IV ■ 1 V»
Storage temperature range -55°C to+135°C

Cycles 50x106
DegroG of protection IP 66
Workshop literature -40328042303 EN - 05/2008

Steering system 42
Steering axle
Replacement of the three-wheel
steering axle potentiometer
> Move the steering wheel completely to the right
(turning it clockwise to the limit stop). Apply the
handbrake. Open the battery cover. Discon
nect the battery socket. Loosen and remove
the fixing screws (1) of the potentiometer sup
port bracket (2).
> Open the safety catch and disconnect the po

tentiometerwiring (3) from the panel.
> Remove the potentiometer complete with

bracket (4), sliding it into the counterweight
compartment.
Reinsert the wiring of the new potentiometer in

order to later connect it to the panel.

42
> Reposition the potentiometer on the driving

disc (5), being careful to insert the control pin
of the potentiometer correctly in mark "A" of the
driving disc. Rotate the bracket until the holes
on the same line up with the threaded holes on
the axle support.
> Screw in and tighten the two fixing screws (6).

Reconnect the panel wiring connector.
A CAUTION
If alarm 58 appears on the display when the key is tur
ned on, calibrate the potentiometer as described in the
respective chapter.
Four-wheel truck axle technical data
W31046
Workshop 40328042303
Steering system 42
Steering axle
In welded steel, the axle is composed of the cas 3= Screw fastening steering cylinder onto axle
ing, stub axles, hubs and the double-acting cylin casing M12x1.25x63: approx. 120 Nm
der connected to the stub axles through the con 4= Screw fastening steering cylinder heads:
necting rods. The trunnions are assembled on approx. 45 (b)
roller bearings, lubricated by grease nipples. The W The tightening torques indicated are for
wheel hubs are assembled on tapered roller bear
screws without the addition of lubricants
ings. The group oscillates on elastic supports lo
cated at the centre of the chassis. <b) Values with tolerance +5%, -15%
W To be realized progressively and working

Characteristics and data across diagonals
Rear wheel bearing play: 0.06 + 0.1 mm Max. left steering angle: 54.5° ± 1° 30’
Max. right steering angle: 78° ± 1 ° 30’
Tightening torques^
Adjustment of the rear wheel bearings (5)
1= Hexagon-head screw fastening axle sup
port to chassis M 16x1.5x60: approx. 200 Adjust the bearings as described in the respective
Nm(b) paragraph.
2= Hexagon-head screw fastening supports to
axle casing M 16x1.5x40: approx. 170 Nm <b)
Four-wheel axle removal

emergency stop button. Raise the rear of the
truck, resting it on solid, stable supports, and
chock the front wheels (with wooden blocks)
to prevent the truck from moving. Loosen the
fastening bolts of the rear wheels.
> Remove the rear wheels.
> Use a screwdriver to open the safety catch and

disconnect the potentiometer connector (1).

42 Steering system
> Loosen the bolts (3) fastening the front and

rear axle supports to the chassis.
> Position a pallet truck under the axle and raise

it until coming into contact with the same. Re
move the fixing bolts (3) of the supports. Lower
the pallet truck and back it up, being careful
not to strike the axle against the chassis or the
counterweight.
Four-wheel truck axle reassembly

Reassemoie ine axie oy penormmg tne removal
operations in reverse, tightening the locking
—..I— — -1 XL.— ...L ——I — 1 —> IL- --_ _„:i_--- 1
uvuo ui ii ic ctAiu cu iu u iu wi teeis iu u its pit:t>ui iueu
torque value.
> Axie to chassis tightening torque: 200 Nm.
W31053

Steering system 42
Steering axle
> Wheel tightening torque: 120 Nm.

42 Steering system
Four-wheel axle disassembly

Disassembly » Remove the feed line connections of the steer
ing cylinder.
° Disconnect the cylinder from the connecting
rods (1) by loosening the dowels (2) and pulling
out the pins (3.)
8 Loosen and remove the fixing screws of the
steering cylinder and extend the it from the
axle.
» To disassemble the cylinder, loosen and re
move the locking nuts of the two closing heads
of the cylinder and remove them both.
» Then extend the rod complete with piston.
’ The connecting rod can be disconnected from
the stub axle (4) by loosening the dowel (5) and
pulling out the pin (6).
• Disconnect the stub axle from the axle by loos
ening the stop screw (7).
» Remove the bottom (8) and top covers (9) of
the kingpin and pull it out.
» Disassemble the wheel hub from the stub axle
by removing the cover (9), ioosening the ring
nut (10) and extending the hub from the pin.
■ For the disassembly of the two axle supports
(11), remove the fixing screws (12).
Refer also to the following diagrams.
42-30 Works
Steering system 42
Steering axle

W31056
Steering system 42
Steering axle
To reassemble the axle, perform the above steps and to follow the assembly rules and apply the
in reverse, being careful to adjust the wheel hub tightening torques provided below,
bearings as indicated in the respective paragraph

42 Steering system
Steerino axis
1= Fill with Fiat MR2 grease. Caution: too 7=The tightening torques indicated are valid
much grease may cause the gasket to overturn for screws and nut screws without the addition
during hub assembly. of lubricating substances.
2= It is imperative that the bearing be assem 8= Set the reference mark as indicated so as
bled as indicated in the drawing, with the top to allow correct assembly of the self-locking
fifth wheel free to rotate in its box. screw.
3= Tightening torque (~ 120+5% ■15%), to be re 9= Assemble the gaskets as indicated in the
alized progressively and working across diag drawing.
onals. 10= Tightening torque: Nm 20 +5% "15%.
4- Tightening torque: kgm 17 +5%‘15%(Nm A= Forward travel.
170 1 5%^ Wheel bearing play: 0.06 + 0.1 mm.
5= Spread Fiat MRM2 grease (Molikote) on the
spherical surfaces.
Rear axle cylinder
6= Fill with Fiat MR2 grease.
W31059
'I ightening torque: Nm 45 +5% "5%. ■ o be real has been completed, check that the error in
ized progressively, working across diagonals the shape of the support surface is that indi-
snd so 3S not to producs any rsistivo rotation cstsd
between the two heads. When the operation E Stroke= 155

Steering system 42
Steering axle
Four-wheel truck potentiometer technical data
Potentiometer diagram
The wiper is shown in the base position.
A Chamber
Electrical data
Electrical angle 250° ± 3°
±3% from 0° to 25° and from 225° to 250°
Linearity ±1 % from 25° to 80° and from 170° to 225°
±1.5% from 80° to 170°
Resistance at the ends of the potentiometer 4 kOhm ± 20%
Resistance of the wiper 1.7kOhm±20%
Load resistance >400 kOhm
Maximum current of the wiper 15 mA for max. 1 min.
Rated current of the wiper <100 uA
at 40° C 0.5 W
Power absorbed
at125°C0.05W
Mechanical data

Mechanical angle 240° ± 3°
Moment of the spring’s returning action at the end
< 7.5 Ncm
1 of the rail
Strength of the stop 60 Ncm
Direction of the spring’s returning action Clockwise
General data
OnnrpfinH tornonroti irza ronna ¿(VP -L'fOCOr
Glii ly lc>i i ijjui uiui v iuii^v
Storage temperature range -55°Cto+135°C

Cycles 50x106
Degree of protection IP 66
Replacing the four-wheel truck

potentiometer
> Apply the handbrake, lift the rear part of the
truck and rest it on suitable, stable supports.
Turn the steering wheel compieteiy to the right,
activating the hydraulically assisted steering,
and disconnect the battery socket. The poten
tiometer (1) is positioned as shown in the fig
ure. It is protected by a cover (2) fixed onto the
axle by means of two cross-slotted screws (3)
and a socket-head screw (4) and is operated
by the rotation of the kingpin.
> Using a small cross-head screwdriver, un

screw and remove the two screws (3) that
fix the cover of the potentiometer on the
wheel-side as indicated in the figure.
Workshop literature - 40328042303 EiM. 05/2008

Steering system 42
Steering axle
> Reconnect the battery and turn the wheels
completely to the left; rock the axle by lifting
the left wheel.
> Using an Allen key, loosen the screw (4) that >
fixes the cover (2) on the inner side. Slip the
cover (2) off outwards in order to remove it.
Return the wheels completely to the right, activat

ing the hydraulically assisted steering.
> Raise the cover and disconnect the battery

socket, resting it on the battery itself.
> Using a small cross-head screwdriver, un

screw and remove the two screws (5) that fix
the potentiometer in its seat.

42
> Extract the potentiometer (1) by raising it, be

ing careful of the control pin of the same, and
rest it on the axle.
>
Fil NOTE
Carry out this operation without forcing anything,

so as to a void damaging the potentiometer!
> Remove the right side using the appropriate

latches (A-B).
A= Front latch.
VVorkshoD hteraturo 40328042303 EN 05/2008

Steering system 42
Steering axle
>
B= Rear latch.
> Disconnect the connector (6) in the panel com

partment.
> Fix the connector (6) which has just been dis- >
connected to a string (7) with a length of at least
1.5 m.
W31073

42 * Bering system
> Keeping the string (7) fixed to the connector

(6), puli the other end of the cable gripping the
potentiometer (1) and slip it off without detach
ing the string.
t NOTE
ration.
Reassembly
> Replace the potentiometerfl), fix the string (7)
used to extract the previous potentiometer to
the connector (6) of the new potentiometer and
repeat the above operations in reverse.
Do not force anything when carrying out this ope

ration.
[Ï1 NOTE
if the alarm ??? or ??? appears on the display

when the key is turned on, calibrate the potentio
meter as described in the respective paragraph.

Steering system 42
Steering axle
Lubricating the steering axle

Turn off the forklift and perform the operations
preliminary to maintenance.
U NOTE
Before greasing, dean the heads ofthe grease

nippies.
Grease the axle using the grease nipples (1) until

grease seeps from the bearings.
note
For the type oflubricant to use, follow the indica

tions pro vided in the "Supply" table at the end of
this chapter.

42
Wheels and tyres 46
General information
Safety regulations for wheels and rims
General Precautions for assembly
A DANGER During assembly, check the integrity and confor

mity of the parts used. In the rims with removable
Wheels and rims, important parts for vehicle safety, rings, make sure that the rings are remounted on
require correct use, periodic checks and continuous
the same rim from which they were removed and
maintenance by the user. In particular, during tyre as
sembly and disassembly, it is necessary to follow some make sure, after a first short intake of air (about
basic safety precautions in order to prevent possible 0.3-0.5 bar) with the rim in a horizontal position,
errors and imprudence that may cause serious acci that the rings are concentric and housed well in
dents. their seats. The inflation of the tyre to the final pre
• Damaged or deformed wheels must never be scribed pressure - not to be exceeded - must be
repaired or used in service; performed within a sturdy cage or safety devices
that can provide sufficient protection against very
• Neverrepairrimsordisksbymeansofwelding,
rare but not impossible events. For the dismount
for any reason whatsoever;
able disk wheels, the use of the cage also when
• The defective parts should always be replaced disassembling the wheel tyre is certainly a good
with parts of the same type, shape and dimen safety measure; the need for systematic and
sions; meticulous checks, particularly under harsh and
• All the coupling surfaces must be cleaned well abnormal working conditions, is thus well-justi
and protected against rust. fied: the reliability and safety margin foreseen
during the design phase can in fact be compro
A DANGER mised by severe corrosion and wear, deforma
Before beginning to disassemble a wheel of the ve tions due to collisions, improper use or failure to
hicle, make sure that the tyre carcass or the rim is not follow the safety regulations.
damaged and deflate the tyre completely in any case.
A DANGER
If the wheels are dismountable disk wheels, the
accidental disassembly of joint nuts, with the For safety reasons, do not use wheels or fastening
wheel still coupled onto the hubs, is prevented parts different than those provided originally. Do not
lubricate the wheel clamping screws and nuts to facili
with suitable devices. In the twin-tyre versions, tate disassembly and reassembly. After every assem
loosen the fixing nuts by just a few turns and make bly, periodically check the tightening of the wheel nuts
sure, with the wheels lifted off the ground, that the as indicated in the use and maintenance manual. It is
same are “free” from any interference that would advisable to use homogenous rims and tyres on the
indicate structural failure. Before proceeding with same axle: from the same supplier and with the same
design.
any subsequent operation, completely deflate the
tyre (if not already deflated) and remove the cen
tral body of the valve for a more complete and se
cure discharge of the air.

iftjrmîstjon
General information for changing

tyres
To fully appreciate the features of stability and
safety of the tyres equipping our forklifts, check
the inflation pressure (for inflated tyres) respect
ing the values shown in your Owner’s Handbook.
Also check tread depth. It is advisable to change
the tyres (inflated and full) if wear or damage
caused by collisions appear.
For big wheels, perform this operation with the
use of a -wheel extraction trolley (see figure 1 ) or
tool as shown in figure 2 with a crane or hoist.
A DANGER
In order to ensure a correct truck attitude, indispen
sable for working in complete safety, it is absolutely ne
cessary to change both wheels on the same axle at the
same time, using wheels of the same type and manuf
acturer.
A DANGER
Work in safety by inserting solid stable supports bet
ween the bottom part of the truck (chassis, fixed up
rights, or ballast) and the ground, using blocks to block
the wheels which stay on the ground during replace
ment.
A DANGER
In the case of pneumatic tyres, completely deflate the
tyre to change before taking off the wheel.
46-2 Workshop literature. 40328042303 EN

Wheels and tyres 46
General information
Tyrewear check
The tyre should be changed when it is clearly
worn or the tread is damaged, in particular:
PNEUMATIC tyres
Must be changed when the height of the tread is
equal or less thanl .6 mm.
I
OM1041-1
SUPERELASTIC tyres
The superelastic tyres should be changed before
reaching the maximum wear allowed, which is in
dicated by the tyre manufacturer on the side of
the tyre by a line (1) along the circumference.
A DANGER
Ifthe forklift is used on wet or slippery surfaces, replace
the tyres before the thickness of the tread drops below
1,6 mm.

46 (Wj)
Wheel change
Wheel change
Changing a rear wheel (3-wheel version)
• Turn the rear wheel (1) so that the fixing screws
are accessible.
» Turn off the forklift and perform the operations
• Partially loosen the wheel locking nuts (2).
» Pass a sling (3) through the tow coupling (4)
and hook the other end to a crane with a suit
able capacity (for further information, see the
chapter "Forklift transport and lifting").
8 Lift the rear part of the truck and place suitable
supports (5) under the counterweight (6).
s Lower the truck so that it rests on the supports,
keeping the sling tensioned.
• Completely unscrew the nuts (2) and puli off
the wheel. OM1466
= Fit the new wheel, positioning it in such a way
that any inflation valve is always on the outside.
» Tighten the fixing screws, following the se
quence indicated in the paragraph regarding
the next stages.
•> Slightly tighten the screws so that the wheel is
well seated against the hub.
• Tighten the screws to 50% of the prescribed
torque.
• Raise the truck to free the supports.
• Remove the supports.
= Lower the truck to the ground.
• Tighten the fixing screws.
• Completely tighten the fastening screws (see OM1467
associated paragraph).
• When changing wheels with tyres, inflate to the
prescribed pressure.
■ Repeat the operations described above to
change the second wheel.

Wheels and tyres 46
Wheel change
Changing a rear wheel (4-wheel version)

• Turn off the forklift and perform the operations
• Partially loosen the wheel locking nuts (1 ).
• Pass a sling (2) through the tow coupling (3)
and hook the other end to a crane with a suit
able capacity (for further information, see the
chapter "Forklift transport and lifting").
• Lift the rear part of the truck and place suitable
supports (4) under the counterweight (5).
• Lower the truck so that it rests on the supports,
• Completely unscrew the screws (1) and pull off
the wheel.
• Fit the new wheel, positioning it in such a way
• Tighten the fixing screws, following the se
quence indicated in the paragraph regarding
the next stages.
• Slightly tighten the screws so that the wheel is
• Tighten the screws to 50% of the prescribed
torque.
• Raise the truck to free the supports.
• Remove the supports.
• Lower the truck to the ground.
• Tighten the fixing screws.
• Completely tighten the fastening screws (see

46 (bjj)
Front wheel change.

» Turn off rhe forkiiff and perform the operations
' Partly slacken the wheel fixing nuts (1 ).
• Pass a sling (2) over the top crossmember (3)
of the fixed mast of the lift and hook the other
end to a crane with suitable capacity.
’ Lift the front partofthetruck and place suitable
supports near the wheel to be changed.
• Lower the truck so that it rests on the supports,
’ Completely unscrew the screws (1) and pull off
the wheel.
° Fit the new wheel, positioning it in such a way
- Tighten the fixing screws, following the se
quence indicated in the paragraph regarding OM1106
the next stages.
» Slightly tighten the screws so that the wheel is
e Tighten the screws to 50% of the prescribed
torque.
° Raise the truck to free the supports.
8 Remove the supports.
» Lower the truck to the ground.
° Tighten the fixing screws.
• Completely tighten the fastening screws (see
46-6 Workshop literature - 40328042303 EM - 05/2008

Wheels and tyres 46
Wheel decomposition
Disassembly/assembly of tyres on
rims with movable flange
A press is required for this operation. Check the
integrity and conformity of the components.
Tyre disassembly
j NOTE
During disassembly, mark or identify the remo

vable rings so that these can then be reassemb
led onto the same rim from which they were re
moved.
> Position the moulded support ring (A) under

neath the wheel complete with tyre.
> With the aid of the press and the moulded ring
(B), push the external ring (2) downwards until
it can be freed and the clamping ring (3) can be
extracted.
> Rest the rim on a support ring (F) and take the
tyre off the rim using a pressure ring (G) and
the press.

46 Wheels and tyre» Igoj
Wheel decomposition
Tyre assembly
rjj NOTE
Make sure that the removable rings are reas

sembled onto the same rim from which they were
removed. Spread a solution ofsoap and water
(01:20) or special tyre assembly grease on the
tyre base and the throat of the rim. Never use
lubricants.
> Fit the tyre complete with inner tube onto the
rim, and position the air valve in the special
opening on the rim.
> Press down the tyre bead.
A CAUTION
Do not overturn ring 1 during assembly.
> Rest the shoulder ring (1) around the bead of

the rim and press it with the moulded ring (C)
so that the space (“f”) can be created to house
the external ring and clamping ring.
> Put the external ring (2) on. >

> Apply a cone-shaped moulded ring (D) and fit
the clamping ring (3) on it.
> Press the ring (3) with the moulded ring (B).
| j] NOTE
For some types ofrims, the shoulder rings (1) and

externa! ring (2) are a single piece.

Wheels and tyres 46
Wheel decomposition
> With the aid of a hammer and tools (E), make >
the clamping ring (3) enter into the throat of the
rim so as to fix the external ring (2).
> Make sure, after a first short intake of air (about

0.3-0.5 bar) with the rim in a horizontal position,
that the rings are concentric and housed well in
their seats;
A DANGER
Move away to the side of the tyre and remain there in
order to correct its pressure.
> When the wheel is complete, inflate the tyre by
first arranging the wheel inside a sturdy cage
in compliance with accident prevention regula
tions.
> Do not exceed the maximum allowed pres

sure.
Quick tyres assembly/disassembly

Disassembly >
> Place the flange-saving base (1) on the surface
of the press and fit the wheel onto the base (1).
Center and block the tapered bead (2) on the
hook edge (3) of the rim.
> After having arranged the disassembly thrust

ring (4), push to insert the Teflon ring (6) into
the seat of the rim (external hook). Once the
Teflon ring has been fit, before releasing it,
grease the ring thoroughly. When finished,
release the thrust ring (4).
> Place a shim pipe (7) on the press surface,

turn over the tapered bead/rim/tyre group and
place it on the shim pipe, then push through the
same disassembly ring (4) until the complete
disassembly of the tyre from the rim. Remove
the Teflon ring (6) from the rim.

46 Wheeis and tyres
4 3
Assembly
[jj NOTE
A press and some rings are necessary to perform

this operation. Before beginning, using only spe
cial tyre assembly grease, lubricate the entire in
ternalsurface ofthe tyre beadplus the exterior of
the Quick edge. Grease the entire surface ofthe
rim in contact with the tyre, paying particular at
tention to the area ofthe external hook plus the
final section ofthe tapered bead.
> Place the flange-saving base (1) on the
press surface and then position the rim to be
mounted above the base.
> Arrange the tapered bead (2) on the hook edge W30595
(3) of the rim and center it if necessary.
> Fit the tyre to be mounted on the bead and, af

ter having arranged the thrust ring (4), push
until the tyre is completely fit along the profile
of the rim and then release.
> In case of excessive pushing, evaluate >

whether or not it is necessary to perform a
pressing of the tyre/rim group while pushing
with the same disassembly equipment con
trary to the direction of assembly in order to
normalize the position of the Quick tyre on the
rim.
W30597

Wheels and tyres 46
Wheel decomposition
> In case of non-uniform or incomplete insertion >
along the circumference of the tyre edge, exert
suitable pressure with a normalization pipe (5)
on the edge until complete insertion.

46
Tightening torques
Check wheel nut tightness (every
10 hours during run-in)
« Check the wheei nut tightening according to
the intervais indicated in the preceding mainte
nance table and when a wheel is replaced.
° Follow the instructions provided in the relative
chapter when replacing a wheel.
• The figure to the side indicates the tightening
order of the wheei locking nuts.
The tightening torque values for the wheel nuts

are indicated below:
» Front wheels = 200 Nm
’ Rear wheels (Three-wheel version) = 200 Nm
° Rear wheels (Four-wheel version) = 120 Nm
< note
The tightening torques indicated are for clean,

degreased screws without the application oflu
bricants.
Ttofufvyp Hterature. 40328042303 EN.. 05/2008

Braking system 49
Parking brake
Removal / reassembly of the park
ing brake lever
Removal
> Operate the emergency stop button or discon
nect the battery. Chock the wheels to prevent
accidental movements. Remove the step plate
the respective paragraphs. Loosen the nut and
lock nut (1) that fasten the cable to the lever
support bracket.

49 Braking system
4S-2 Workshop literature - 40328042303 EN - 05/2008

Braking system 49
Parking brake
Reassembly - Assembly diagram >

tions in reverse, taking care to tighten the fixing
screws to the tightening torque indicated in the
assembly diagram.
[J] NOTE
Once the assembly has been completed, adjust

the parking brake as indicated in the respective
paragraph.
A Parking brake lever

B Microswitch actuation bracket
C Hexagon-head screw M8x1.25x16 - Torque
20 Nm
D Parking brake control cable
Parking brake control cable re

placement
> Operate the emergency stop button or discon
nect the battery. Chock the wheels to prevent
accidental movements. Remove the step plate
the respective paragraphs. Loosen the nut and
lock nut (1) that fasten the cable to the lever
support bracket.

49
> Remove the plug (5) by releasing the safety >

catch.

Braking system 49
Parking brake
> Unscrewthenutand lock nut (6) that fasten the
cable onto the front axle bracket, free the cable
(4) and replace it.
[~f] NOTE
Once the replacement has been completed, ad

just the parking brake as indicated in the respec
tive paragraph.
Replacing the parking brake mi

croswitch
> To replace the microswitch (1), proceed as fol
lows:

nect the battery.
• Apply the parking brake.
• Remove the control panel panelling as indi
cated in the respective chapter.

49 Braking system
Parking brake
> Disconnect the wiring (2) from the microswitch.
> Unscrew the screws (3) and remove the mi

croswitch (1). Replace it with a new one.
j NOTE
Once the replacement has boon completed,

make certain that when the brake lever is com
pletely released the microswitch is pressed
completely; ifnecessary, it is possible to adjust
the position of the bracket (4)by loosening the
screws (5)
4Q-6 Workshop literature - 40328042303 EN - 05/2008

Braking system 49
Parking brake
Parking brake adjustment >

Remove the operator step plate and the panelling
as described in the paragraphs "Removal of the
operator step plate" and "removal/reassembly of
the panelling".
> Check that the parking brake lever (1) is in rest
position (parking brake off).
> Pull the lever (1) to engage the brake and

check that on the 5th click of the lever there is
a force of 310 ± 10 N.

Service brake
Service brake pedal removal
nect the battery.
» Chock the wheels to prevent accidental move
ments.
• Remove the step plate and the control panel
panelling as described in the respective para
graphs.
> Unscrew the three screws (1) that fix the ser- >
vice brake pedal to the chassis.
> Disconnect the fasten connections (2) of the

stop lights microswitch (3).

Braking system 49
Service brake
Service brake pedal reassembly
A Screw M8x20

49 Braking system
> Reassemble by performing the removal oper

ations in reverse, being careful to adjust the
pedal as follows:
» Phase 1: depress the pedal until the brake

lever (1) located on the axle moves.
• Phase 2: Check that the brake potentiome
ter voltage at the console output is 3V±0.56V.
Adjust, if necessary, using the nuts (2) of the
brake actuation cable, and repeat from phase
1.
Stop lights microswitch replace

ment
’ Operate the emergency stop button or discon
nect the battery.
- Chock the wheels to prevent accidental move
ments.
° Remove the step plate as indicated in the re
spective paragraph.
> Remove the brake pedal as indicated in the

respective chapter. Disconnect the electri
cal wires from the stop lights microswitch
.
(1) Unscrew the lock nut(2) and remove the
microswitch. Replace it with a new one and re
assemble by performing the above procedure
in reverse.
Replacing the service brake pedal

potentiometer
= Operate the emergency stop button or discon
nect the battery.
• Chock the wheels to prevent accidental move
ments.
• Remove the step plate as indicated in the re-
□jjUvii VG p'cti cty i c<i<si i.

Braking system 49
Service brake
> Using an Allen key and a spanner, unscrew the
two fixing screws (1) of the brake pedal poten
tiometer.
> Remove the potentiometer (2) and replace it

with a new one.
For the adjustment of the potentiometer, see

"Service brake pedal reassembly".

49 Braking system
Braking group
Removing / installing the brake
group
Removing the brake group
j NOTE
* Remo va! ofthe individual assemblies is descri

bed in detail in the respective chapters.
• Drain the hydraulic oil at an early stage so that
the oil has time to drain offcompletely.
Park the truck safely.
Apply the parking brake.
Drain the brake oil.

Disconnect the battery connector.
Loosen the drive wheel ball-seat nuts, but do not

unscrew them completely.
Remove the lift mast; see the chapter "Lift mast:
installation / removal".
Jack up the front of the truck; see the chapter en

titled "Safety instructions".
Remove the drive wheels.

Remove the drive axle; see the chapter "Remov-
ing/installing the drive axle".
A WARNING
Once the connecting screws have been removed, the
drive axle splits into two parts.
Chock the two axle shafts.

Braking system 49
Braking group
The brake group assembly
(A) Traction motors
(1) Brake lever
(2) Pin
(3) Bearing
(4) Seeger
(5) O-ring
(6) Plug
(7) Pressure plate
(8) Dowel pin
(9) Spacer
(10) Brake disc

(11) Phonic wheels
(12) O-ring
(13) Spring
(14) Pin
(15) Brake disc
(16) KIT

49 Braking svstem
__________________
To separate the traction motors (A), remove the

four M16 connecting screws.
Once the motors (A) have been separated, it is

possible to remove:
the brake discs (10) and (15),
the phonic wheels (11),

the springs (13),
the pins (14),
the spacers (9) and the sealing O-ring (12) be
tween the two motors,
then the pressure plate (7),
and finally the dowel pin (8).
To remove the brake actuating lever (1), first it is

necessary to remove the plug (6) and the gasket
with an Alien key.

Braking system 49
Braking group
Unscrew the retaining clamp of the gasket so that
the lever can be extracted from its seat.
Adjusting the clearance

The clearance must be checked after the follow
ing operations:
- Installation of new brake parts (brake discs,
discs, thrust piece).
- Installation of a new traction motor.
The clearance is set using the shim ring. The
clearance and the shim ring depth can be deter
mined as follows:
> Measure the depth on both traction motor
housings, clean and empty, using a ring gauge
or depth gauge
> To establish the depth of the left axle shaft, two

measurements are required: measurement Ai
and measurement A2
Adding together the two measurements of the left

axle shaft gives measurement A.
Ai + A2 = A
> The depth of the right axle shaft is measure
ment B.
> To determine the total depth of both axle
shafts, add both measurements together.
A+B=C

49 Braking system
> Pile up the complete armature stack without >

the springs and load it with approx. 6kg
1
Z1
> The height of the loaded armature stack mea t ,/W / wi I
sured with the sliding gauge gives measure ' , ’ / i
ment D
'■i’Si.W .
..f' !
These measurements can be used to determine './/zvl ...
iwZ'W
the shim ring depth:
1 /(F i
C - D - clearance O.8+0,2 = shim ring depth. W (j./ H
........ -IK
(i d!
installation -'fix'
Fj] NOTE W50261
• Installation of the individual assemblies is de

scribed in detail in the respective chapters.
• Check tightening torques and screw quality.
= Check the quality ofthe gear lubricant oil and
brake oi!
• For values, see the "Genera! technical data "in
> Assembly of the brake actuating lever (1);

> Assembly of the pressure plate (7).
> Screw the brake control onto the left axle shaft
using two cylinder screws.
> Assemble the brake discs (10) and (15) and the
springs (13), being carefui to follow the correct
assembly sequence.
> Insert the O-ring between the two axle shafts.
> Bring the two axle shafts together so that the

guide pins go into the guide holes.
> Tighten the four connecting screws,
> Install the drive axle on the truck.
r Fili oom anve wneets wun gear lUDricani on

> Fill the multi-disc brake with brake oil.
> Attach the wheels.

> Attach the lift mast.
> Lower the truck.
> Connect the battery connector.

v Check the sen» ice brake and traction drive for
correct operation-
Workshop literature-40328042303 EN
Controls 50
Accelerator pedal
Accelerator pedal
This component has the task of transmitting the
following information to the DUAL AC control:
• direction of travel (through the selection of one
of the two microswitches)
• set speed (through the variable output of the
potentiometer).
The accelerator pedal is composed of:
> Driving pedals (1) marked by a red arrow indi

cating the direction.
> Potentiometer with self-regulating polymers

(2).
> Return spring (3).
> Adjustable rest stop pad (4).
> Forward gear microswitch (5).
> Reverse gear microswitch (6).
> Reversing lights control microswitch (7).

For the description of the potentiometer and/or
the calibration procedure, see the appropriate
paragraphs.

Accelerator pedal potentiometer
> This potentiometer is mounted on the acceler
ator pedai and is controlled by the DUAL AC.
Technical characteristics:
• Mechanical angle:-! 13°±5
s Effective angle: 106°±3
° Degree of protection: IP 64
> Theconnectorthatisused is a watertight AMP

connector with 3 terminals, two for the power
supply (A and C) and one forthe signal (B).
The standard voltage values are provided in the

following table.
ACCELERATOR POTENTIOMETER
PIN C20-21 or PIN A-C CONNECTOR POT. ACCELERATOR
Minimum value Maximum value
[ V ] [ V ]
0.70 5.65
Potentiometer power supply C20-33
11.11 V
The values provided in the table should be con

sidered approximate since they depend on the
mechanics ofthe system; for this reason, signa!
acquisition is performed. Between the reading

Controls 50
Accelerator pedal
performed with the testerand the reading perfor
med with the console, there maybe a difference
of±200mV.
A CAUTION
CAUTION: the values in the table are for readings with
the tester referenced to the -B; when reading with the
tester referenced to pin C20, the measurements incre
ase by about 0.7V.
The performance of the forklift can be adapted to

the needs of the customer using the parameters
THROTTLE 0 POINT and THROTTLE X POINT
and THROTTLE Y POINT on the DUAL AC con
trol. The use of these parameters is illustrated in
the figure.

50 Contrais
Accélérâtes pedal
50-4 Workshop literatura-40328042303 EN - 05/2008

Display elements 56
Display
Plate data
Supply voltage 48V ± 30%

CAN-BUS transmission 1
LED 5
Display 120 x 68 pixel active matrix
Degree of protection IP65
Dimension 51 x26 mm
Connector
Connector A: 23-pin AMPSEAL
PIN Function
1 Battery negative
2 Battery negative
3 CAN H
4 CANL
5 Not used
6 Key+48V

56 eements
Multifunction panel
1 Led "Alarms" 6 Pushbutton "Performance selection"

2 LED "Operator absence" 7 Pushbutton "Date/time selection"
3 Led "Parking brake applied" 8 Pushbutton "Speed reduction On / Off
4 Led "Reduced speed engaged" 9 Pushbutton "Enter / Exit the menu"
5 LED "Temperature alarm" 10 DISPLAY
The multifunction panel is the interface between

truck and operator. It displays information on the
display, and some adjustments can be made us
ing the respective pushbuttons.
LfJ NOTE
At temperatures below 0 °C, the display may not

indicate any signal. This does not preclude nor
maloperation ofthe truck, but the display of the
alarms is blocked.
Led "Alarms" (1)

This LED becomes steady-on when an alarm oc
curs or the operator performs an operation which
is not allowed. The number and description of
the alarm appears on the display, and the buzzer
sounds 3 times.
'f... Workshop literature - 40328042303 EN. 05/2008

Display elements 56
Display
service department.

56 ~ __ "
Pushbutton "Performance selection" (6)

° The type of performance changes each time
this pushbutton is pressed. According to the
type of performance selected, the following
symbols appear on the display:
la = Endurance
Sets truck operation in its minimum performance
(acceleration, braking, speed).
Maximum travel speed equal to 13 km/h.
[j~] NOTE
This performance type allows to obtain significant

electric power saving.
1 b = Standard
Sets truck operation in its standard performance
(acceleration, braking, speed).
Maximum travel speed equal to 14 km/h.
1c = Quick > I-
I•»—-------- 1a
Sets truck operation in its maximum performance
(acceleration, braking, speed). I >> H1b
Maximum travel speed equal io 14 km/h.
Pj] NOTE [»>]—1c

OM1445
This performance type results in greater electric

power consumption.
042303
Display elements 56
Display
Pushbutton "Date/time selection" (7)

This pushbutton is used in the Date/time modifi
cation menu to move to the right within the values
to be modified.
Pushbutton "Speed reduction On / Off" (8)

• When this pushbutton is pressed, itturns on/off
the speed reduction function.
The traction drive speed, pump speed or both

are reduced by a percentage previously set
according to the maximum value set for each
[T] NOTE
The percentage value for the speed reduction

must be set by the service department.

56 Display elements
Display (10)
When the start/stop key is turned to "I", the dis
play lights up and displays the following screen
image (where XXXXX indicates the truck model);
the buzzer will sound continuously for one sec
ond.
[ j ] NOTE
The logic willperform a self-diagnosis; ifthe test

is successful the standard screen image will ap
pear on the display, otherwise the alarm type will
be displayed.
The display will show different information de
pending on whether the truck in stationary or
moving.

Display elements 56
Display
Display with the truck stationary >
The following information will be shown on the

display:
• A: Type of performance
• B: Battery charge status expressed in percent
age
• C: Travel direction selected
• D: Steering indicator
• E: Indication that maintenance is required
• F: Time
• G: Date
• H: Operating hours (hm-ht-hs-hd)
OM1439
Display in reverse gear
Display in forward gear
Display with the truck moving

The following information will be shown on the
display:
• A: Type of performance
• B: Battery charge status expressed in percent
age
• C: Travel speed in km/h or mph.

Setting the date and time
Turn the ignition key to position "I".
Set the date and time

> Press the button (1 ) to enter the data modifi
cation menu. The following screen image will
appear on the display:
OM1485
40328042303 L3M — 03/200o

Display elements 56
Display
> Press the button (1 ) to enter the data modifica
tion mode and the first modifiable field will be
selected and underscored; to scroll through
the modifiable fields, press the button (2) to
move right or the button (3) to move left.
OM1486

> Press the button (4) to increase the value or the
button (5) to decrease the value, then press the
button (2) to confirm the setting and pass to the
next modifiable field.
OM1487
Display elements 56
Display
> To exit the date/time modification phase and
confirm the set data, press the button (1).

56 Drsptay etements
Dsspîay
Speed reductions
"TORTOISE" reduction activated using the but
ton on the display.
Parameters involved Description

CUTBACK SPEED SW Sets a percentage reduction of the maximum
Traction on PARAMETER CHANGE speed set with MAX SPEED FW/BW
of the DUAL AC module 100% = no limitation
CUTBACK SPEED SW Sets a percentage reduction ofthe maximum
. on PARAMETER CHANGE speed set with MAX SPEED UP
of the AC2 FLASH module 100% = no limitation
Pump
CUTBACK SPEED 2ND
on PARAMETER CHANGE Sets the pump motor speed for the tilt function.
ofthe AC2 FLASH module
This parameter is used to define the electronics
on which the speed reduction must be activated.
TYPE CUTBACK OPTION 1 = Traction
OPTION 2 = Pump
OPTION 3 = Traction + pump
“HARDWARE” reduction activated by means of

the specific HW input
.............. . .... ------ - -- ---
rarameters involved Description
Sets the maximum speed of the truck with the mi
croswitch on input C10 open (or the input discon
nected). Under these conditions, the speed re
CUTBACK SPEED HW duction is active. The speed reduction can be de
on PARAMETER CHANGE activated by making a connection between +48V
of the DUAL AC module and the pin C10.
The CUTBACK SPEED HW parameter is set by
default to level 9 (16km/h); to set a lower speed,
the parameter must be reduced.
Sets the maximum speed ofthe pump with the mi
croswitch on input E13open (or the input discon
nected). Under these conditions, the speed re
CUTBACK SPEED HW duction is active. The speed reduction can be de
on PARAMETER CHANGE activated by making a connection between +48V
ofthe AC2 FLASH module and the pin E13.
Tha
c
iTUAPiz4’ Ws
W -
C'DiCZiZr^ i
t__ »__ —»■ i J H - pi-ss Ca» ii i W
u,,
UVt, wj
default to level 9 (maximum speed); to set a lower

speed, the parameter must be reduced.
sa-12 Workshop iterative - 40328042303 EN 05/2008

Display elements 56
Display
Functionality of the display buttons
12:00 20 SETT 2006
»ATA/ORA (-1)
mp 13:00 20 SETT 2006
¿2J-* 13:00 20 SETT2006 13:00 20 SETT 2006
XT^LOOTA’ (-2)
(*7) C10) (•11)
mH
C8) C9)
3... ^ppAONaô'
E
LINGUA (’3) ITALIANO
HIE INGLESE
mH FRANCESE
(*12) (*13) (-14)
TARTARUGA (*4)
HI? .POMPA "*j 3 TRAZIONE + POMPA TRAZIONE
(*15) (*16) (•17) (‘18)
CONTAORE MOTORE TRAZIONE

¿Ir SEDILE GIORNO MACCHINA
REGISTRO C6)
mp 20 SETT 2006 li
mp 21 SETT 2006 5h
■*LlR >0 SETT 2006 7h
(•19)
CONFERM A ED ESCE
W50247
Workshop literature™40328042303 EN ™ 05/2008 56-13

56
(*1)Date/time
(*2)Speed
(*3)Language
(*4)Tortoise
(*5)Hours counter
(*6)Log
(*7)ltalian
(*8)English
(*9) French
(*10)German
(*11)Spanish
(* 12)Pump
(*13)Traction + pump
(*14)Traction
(*15)Traction motor
(*l6)Seat
(*l7)Daiiy
(*18)Machine
(*19)Confirm and exit
-40328042303 EN
Display elements 56
Display
Data modification pushbutton func
tions
> Pushbutton: "Performance selection"(1)
• This pushbutton (1) is used to:

> scroll backwards through the submenus;
> decrease the hour/minutes/month/year value

in the DATE/TIME menu;
> set the km/h units of measure in the SPEED

menu;
> display the operating hours of the previous

days in the LOG menu.
> Pushbutton: "Speed reduction On/Off "(2)
• This pushbutton (2) is used to:

> scroll through the submenus and the submenu
values, displaying the following fields:
- DATE/TIME: Parameters that are modifiable

by the user;
- SPEED: The user can choose the type of
measurement, km/h or mph;
- LANGUAGE: The user can choose among
those available;
- TORTOISE: The speed reduction is available
on the following components: pump, drive plus
pump, drive;
- HOUR METER: The user can choose among
the four types of hour meters described below:
Types of hour meters:

• hm: Machine hours: effective working hours
(pump motor);
• ht: Traction motor hours: hours of operation of
the traction motor;
• hs: Seat hours: hours of seat microswitch con
nection;
• hd: Day hours: daily hours of machine opera
tion.
> increase the hour/minutes/month/year value in

the DATE/TIME menu;
> set the mph units of measure in the SPEED
menu;

56 ' \!, ■ ” < . ;
> increment the date for the display of the hours

of operation in the LOG menu up to the last
date available.
- LOG: Records and displays the hours of truck

operation for up to 45 previous days.
> Pushbutton: "Enter/Exit the menu"(3)
This pushbutton has two functions:

° Pressing the pushbutton for about 2 seconds
enters/exits the data setting menu.
» Pressing the pushbutton during data modifi
cation confirms the data entered and exits the
data setting phase.
Multifunction panel removal / re

assembly
Removal
° Disconnect the battery socket or operate the
> Remove the control panel panelling as indi

cated in the respective chapter. Disconnect
trie wiring connector (i).
Display elements 56
Display
> Loosen and remove the two ring nuts (2) and
remove the bracket (3).
> Remove the multifunction panel (4).
Reassembly
Perform the removal operations in reverse.
Alarms
Alarms may occur automatically during operation
of the truck, some of which can be switched off by
the operator.

56 Display elements
> The alarm is signalled by the flashing light of

the indicator (1) and the buzzer that sounds
with 3 beeps; the alarm code appears on the
top line (2) of the display, and a written expla
nation of the type of alarm or an indication of
the need to consult the manual appears on the
bottom line (3).
[~f~| NOTE
The alarm legendremains fixed on the display un

til the removal ofthe alarm.
List of the alarms viewed on the display:
> Safety belt not fastened (option)

When the operator sits on the truck seat, the sym
bol (1) immediately appears on the display and,
if the belt is not fastened within 10 seconds, the
buzzer sounds continuously for 2 seconds and
then alternately 30 times. The alarm switches off
when the belt is fastened.
* Low battery charge (alarm number 20)
When this alarm occurs, it indicates that the
battery is low; the functions of the truck are
slowed down
[~f") NOTE
Do not use the truck under these conditions; it is

recommended that you recharge the battery as
indicated in the relative paragraph.
Display elements 56
Display
• Incorrect battery (alarm number 21)
This alarm occurs when, after the battery has
been changed, a battery is installed with volt
age less than that indicated by the manufac
turer in the technical data and on the truck iden
tification plate located on the truck. The forklift
does not work with this type of battery.
• Handbrake (alarm number 50)
This alarm indicates that the parking brake is
applied; release the parking brake in order to
use the truck.
• Forward driving + Reverse driving (alarm num
ber 51)
This alarm indicates that the forward and
reverse driving pedals are pressed simulta
neously. To switch off the alarm, release the
pedal and press it again choosing the side of
the desired direction of travel.
• Acc. pedal pressed (alarm number 52)
This alarm indicates that the accelerator pedal
is pressed when the start key is turned to "I".
Release the accelerator pedal to switch the
alarm off.
• Seat timer (alarm 102)
The operator has remained seated with the
truck inactive for longer than the set time.
Stand up and sit back down.
• Key timer (alarm 103)
The stationary truck, without an operator on
board, has remained inactive for longer than
the set time. Switch truck off and on again.
• Gear selected (alarm 105) (only for version
with reversing lever on the steering wheel)
This alarm indicates that a gear is selected
when the start key is turned to "I". Release
the accelerator pedal and position the gear
selection lever on the steering wheel in neutral
to switch off the alarm.
• Emergency stop pushbutton (alarm number
245)
This alarm indicates that the emergency stop
pushbutton is engaged, release the emer
gency stop pushbutton in order to use the
truck.
• Hydraulic request active (alarm number 252)
This alarm indicates that the Joystick or one
of the levers is engaged when the start key
is turned to position "I"; return the Joystick or
lever to the neutral position.
• Maintenance (alarm number 399)
The forklift requires maintenance. Contact the
Technical Service Department authorized by
the manufacturer.

56 Display etemerrts
A DANGER
Call the service department for all alarms not indicated
in the previous list.
A DANGER
If, when eliminating the cause of the alarm, the alarm
persists, contact the authorised sales and service net
work.
Workshop literature. 40328042303 EN -05/2008

Electronic system 60
Software versions
Reference software versions
The drive is composed of the following:
• Inverter for traction motors;

• inverter for pump motor;
• graphic display with multifunction control
panel.
The reference software versions are listed in the
following table:
Electronic module Code

DUAL AC-MASTER XEAC 2ATRAM A00P
Inverter for traction motors
DUALAC-SLAVE XEAC2ATRAS A00P
Inverter for pump motor AC2 FLASH XEAC 2A PUMP A00P
Display ECO DISPLAY XEAC2ADISPA00P

60
Electronic traction system

Characteristics of the
electronic drive system
The drive powers two three-phase asynchronous » closure of the accelerator pedal microswitch
traction motors with speed and torque control. contact (normally open contact);
It supplies a three-phase AC output voltage with » accelerator potentiometer activated.
variable frequency between 0 and 200Hz.
The reversing lever on the steering wheel must be
The motor speed is controlled by checking infor in neutral position when the seat contact closes,
mation provided by two encoders that detect the otherwise the GEAR.INC.START alarm appears
number of revolutions of the traction motors. (this function can be changed using software: pa
rameter SRO on SET OPTION of the drive MAS
The drive is equipped with watertight AMPSEAL
TER).
connectors.
Handbrake: when the handbrake is applied, the
The software program resides in a FLASH
respective contact opens the circuit on pin C9 of
EPROM and is programmable by PC.
the DUAL AC module. If the handbrake is not
The main functions are the following: applied and the dead man’s switch contact is
open (no operator present), the reversing buzzer
Regenerative electronic braking underthe follow
sounds intermittently.
ing conditions:
in this situation:
“ Pression of the brake pedal (not enabled If
the brake pedal and accelerator are pressed » travel is inhibited;
simultaneously);
° if the accelerator pedal is pressed, the traction
= release ofthe accelerator pedal; motors are powered for two seconds in order
to facilitate departing on a slope.
- reversa! of the travel direction.
Slow travel (tortoise): a slow (tortoise) speed
Braking: the braking intensity is proportional to
can be set, with reduction percentage modifiable
the travel of the brake pedal and determined by
through software (CUTBACK SPEED SW), that
the analogue signal coming from the potentiome
can be turned on and off using a button on the
ter on the brake pedal.
display. It is also possible to reduce the speed by
Accelerator pedal: the speed of the truck is regu opening a contact on pin C10; the relative maxi
lated by the accelerator pedal using the accelera mum speed will be set using the software param
tor potentiometer signal. The acceleration curve eter CUTBACK SPEED HW. The siow speed (tor
can be changed. toise) function is also possible for the pump mo
tor. When the accelerator pedal and brake are
Buzzer: the buzzer is intermittent and can be pro
pressed simultaneously, the speed of the truck is
grammed to be enabled during backward or for
reduced hv a percentage vali re defined hv the ae
ward travel or disabtea compietesy.
rometer PB BRK CTB.
Thermal protection: the thermal protection on the
Slow cornering: The traction motors are con
electronic system intervenes at 75° C with linear
trolled as a function of the steering angie, mea
reduction of performance up to 100°C and then
sured by a potentiometer installed on the steering
the total blocking of functions when the tempera
axle. The 3-wheel truck allows counter-rotation of
ture reaches 100°C. The performance reduction
the motors so that the truck can turn itself around.
occurs without abrupt speed or torque variations.
The steering angles are the following:
Travel direction selection: the travel direction is
selected using the twin accelerator pedal or the • 4 wheels:+86°/-60.5°
reversing lever on the steering wheel. With the
• 3 wheels:+90°/-90°
reversing iever on the steering wheel, travel is en
abled only if the following sequence is observed: The speed, acceleration and deceleration of the
truck vary as a function of the steering angle, with
• closure of the seat microswitch contact (nor
the objective of increasing the active safety of
mally open contact);
the truck (programming parameters X CURVE
• closure of the forward or backward travel se CUTBACK and CURVE CUTBACK).
lection contact (normally open contact);
6G-2 Workshop literature - 40328042303 EM -- 05/2008

Seat microswitch: As soon as the seat mi Potentiometer calibrations: The calibration of the
croswitch opens (micro-openings, due to pot accelerator, steering and brake potentiometers is
holes for example, are not considered), two carried using software so as to remedy any toler
independent timers are activated, a 1,8-second ances in the components.
software timer and a 3-second hardware timer,
Indication of the battery charge state: The per
that cut off power to the two contactors. During
centage indicating the battery charge may in
the software delay the electronic controller at
crease only if the battery is effectively recharged;
tempts to brake the machine; at the end of the
it does not increase by stopping the truck or by
delay, it opens the contactors and resets the
turning the key off and then on again.
current in order to avoid damaging the contacts.
Plate data: traction
Supply voltage 48 V ± 30%

Maximum current per single motor 330 Arms (3 min)
Booster 10% Imax current for max 5 s
Switching frequency 8 kHz
Maximum rated operating temperature 75°C
Analogue inputs 3
Digital inputs 6
PTC (thermal) sensor inputs 2
Connectors
Connector A:
8-pin AMPSEAL
PIN Function
1 CAN H input
2 Not used
3 Not used
4 CAN L output
5 Not used
6 CAN L input
7 CAN H output
8(*) Not used
(*) Not protected against short circuit to battery +.
Connector B:
8-pin MOLEXSPOX
PIN Function
1o Serial reception positive
20 Serial reception negative
30 Serial transmission positive
40 Serial transmission negative

60
5(*) Diagnostics power supply negative

6 0 Diagnostics power supply positive
-7 /*\
' k > FLASH programming
8 0 FLASH programming
Connector C:
35-pin AMPSEAL
PIN
1 (*) Right drive encoder positive (+11 V) (***)
20 Right drive encoder negative
3 Key input (+ 48 V)
4(0 Microswitch common + 48 V; positive for emergency stop pushbutton
5 Seat belt digital input+ 48 V. (change-over point ~ 12 V; Vmax = 71 V)
Forward gear microswitch input N.O. + 48 V (change-over point ~ 12 V; Vmax =
6
71 V)
Reverse gear microswitch input N.O. + 48 V (change-over point ~ 12 V; Vmax =
7
......... J 71 V)
Manual reversing lever option: Accelerator microswitch input N.O. (In the twin
8
pedal version it must be at + 48 V)
Handbrake microswitch input N.O. + 48 V. (change-over point = 12 V; Vmax = 71
3
V)
10 Speed reduction microswitch input N.C. + 48 V (to be enabled through software)
11 o Left drive encoder positive (+ 11 V) (***)
12 0 Left drive encoder negative
13 0 Right drive encoder channel A
14 0 Right drive encoder channel 8
15 0 Steering potentiometer negative
16 Steering potentiometer positive (11.3 V) (“*)
17 Steering potentiometer input
18 Brake potentiometer input
19 O Brake potentiometer negative
20 O Accelerator potentiometer negative
21 Accelerator potentiometer input
22 O Left drive encoder channel A
23 O Left drive encoder channel B
24 (*) Right motor thermal sensor negative
25 O Right motor thermal sensor positive
26 Disconnecting switch on battery - contactor coil 2
27 (“) Not used
28 Not used
29 (“) Not used (setup for negative brake solenoid valve positive)
30 (**) Not used
31 O Buzzer negative
32 O Not used (battery negative)
33 Accelerator and brake potentiometers power supply (11.3 V) (***)
60-4 Works
34(‘) Left motor thermal sensor negative

35 O Left motor thermal sensor positive

(**) Not protected against short circuit to battery
(***) The values indicated are load-referenced

where the value read must correspond to the in
dicated value with a tolerance of ± 0.2 V.
N.C: Normally closed.
N.O: Normally open.

60 Etectronic system
Closing the general contactor

The DUAL AC drive controls the activation of the
general Contactor TG2 through the output C26
When the logic controls the opening of TG2, the

power to the motors is cut off; this occurs in the
folio-wing cases:
° key switch open;
‘ seat switch open;
• type 1 and 2 blocking alarms (see table
"Alarms").
If the truck has been left for long periods with

the key in the ON position, closing the seat mi
croswitch will not cause the TG2 to close.
In this case the truck must be switched off and

then on again.
Thermal sensor
operation
The sensor used on the traction motors is a PTC
sensor connected to the drive through pins C25
and C24 (right motor) and pins C34 and C35 (left
motor); the electronics feed DC to the PTC sen
sor so that the voltage on the PTC is temperature
dependent.
If the temperature of the motor exceeds the first
threshold set for the maximum temperature, the
controller limits the maximum current to the motor
so as to stabilize the temperature, if the temper
ature rises another 15°C, the maximum current is
halved. The truck will return to normal operation
only after the temperature has fallen below 90°C.
60-6 Workshop literature -40328042303 EN. 05/2008

Hydraulic functions electronic system

Functions of the AC2 module
The AC2 drive controls a three-phase asyn threshold, an alarm occurs which blocks the func
chronous pump motor. tions, except for the hydraulically assisted steer
ing which will have just enough speed to safely
The motor speed is controlled through the en
manoeuvre the truck.
coder assembled on the motor.
The motor speed during fork arm lifting is pro
The drive enables the pump motor (hydraulically
portional to the inclination of the relative lever,
assisted steering function) when a travel direction
through a voltage signal coming from the HALL
is selected or the steering wheel is turned (pres
sensor. During the tilt manoeuvre with hydrauli
sure switch). The hydraulically assisted steering
cally assisted steering active, a speed can be set
is always active when the truck is in motion.
through the TILT + HYDRO SPEED parameter
The rpm of the pump motor, in hydraulically as using the single signal coming from the pressure
sisted steering, is inversely proportional to the switch.
truck speed (the higher the truck speed, the lower
Using the tortoise button located on the display,
the rpm of the pump motor) through the HYDRO
the speed of the lift and tilt function can be re
SPEED REDUCTION parameter.
duced by an amount adjustable through software.
The thermal protection intervenes at 75°C, with
It is also possible to reduce the maximum speed
linear reduction of performance up to 100°C and
attainable by opening the contact (pin E13); the
then total blocking of functions above 100°C.
maximum speed will be set through a parameter.
If the temperature of the drive reaches 90°C, the
When the operator is absent all hydraulic func
traction drive is inhibited; this is to prevent the
tions are inhibited, including the lowering of
sudden failure of hydraulically assisted steering
the load, using a N.C. solenoid valve (normally
while the truck is in motion.
closed).
Athermal protection is provided on the pump mo
The software program resides in a FLASH
tor so that, when reaching the limit temperature,
EPROM and is programmable through diagnos
the rpm of the pump motor in the lifting function
tics software.
is limited to a value equal to the frequency set
with MIN SPEED UP plus 60Hz. If the temper
ature rises another 10°C with respect to the set

Plate data: pump

Maximum current 450 Arms (3 min)
Max operating temperature 75°C
Analogue inputs 2
Digital inputs 7
AC2 Connectors
Connector A: 8-pin MOLEXSPOX
PIN Function
1 (*) Serial reception positive
2?) Serial reception negative
3 (*) Serial transmission positive
4(4) Serial transmission negative
5 (*) Diagnostics power supply negative
6(*) Diagnostics power suppiy positive
Connector B: MOLEX MINIFIT
PIN Function
1 Not used (battery negative)
2 | Not used
Connector C: MOLEX MINIFIT
PIN Function
1 CAN - L input
2 CAN termination 120 ohms
3 CAN - H input
4 CAN termination 120 ohms
Connector D: MOLEX MINÌFIT
PIN Function
1 Encoder stabilised positive supply (***) (+1IV)
2 Encoder power supply negative
3 Channel A input
4 Not used
AS /HAAG
Workshop literature
________ Electronic system 60
Hydraulic functions electronic system
5 Channel B input
6 Not used
(***) The values indicated are load-referenced

where the value read must correspond to the in
dicated value with a tolerance of ± 0.2 V.
Connector E: MOLEX MINIFIT
PIN Function
1 Lifting potentiometer input (HALL sensor)
2 Lifting potentiometer positive supply (+ 10 V stabilised)
3 Lifting potentiometer negative supply
Battery positive used to power the signal SWITCHes (hydraulically assisted steer
4
ing pressure switch and distributor).
5 Not used
Hydraulically assisted steering pressure switch input, normally open + 48V
6
(change-over point«12 V; Vmax = 71 V)
7 Tilt input, normally open + 48V (change-over point ~ 12 V; Vmax = 71 V)
8 Not used
9 Not used (power supply + 11.3 V)
11 Battery negative
12 4th route input, normally open
13 Not used (lifting speed reduction input, normally open + 48V)
14 Side shift input, normally open + 48 V (change-over point = 12 V; Vmax = 71 V)
Connector F: MOLEX MINIFIT
PIN Function
1 Key input + 48V
2 Not used
3 Lowering stop solenoid valve positive + 24V
4 Not used
5 Seat microswitch input (battery negative)
6 Pump motor PTC sensor analogue input
7 Not used (battery positive)
8 TG1 coil negative
9 Lowering stop solenoid valve negative
10 Emergency stop pushbutton input, normally closed (battery positive)
12 Pump motor PTC sensor negative
Control of the general contactor

The AC2 FLASH drive controls the excitation of
the general contactor TG1 through a power driver
by means of the output F8.

When the logic instructs TG1 to open, power to

the motors is cut off, and this always occurs in the
following cases:
• Key switch open.

’ Seat switch open.
° Type 1 and 2 blocking alarms (see the DUAL

AC2 Alarmstable).
If the truck has been left for long periods, clos
ing the seat switch will not cause TG1 to close. In
this case, the key must be turned off and then on
again.
Lowering solenoid valve operation

The AC2 drive controls a solenoid valve assem
bled on the hydraulic circuit for fork arm lowering.
The coil of the solenoid valve is connected be

tween the battery positive (F3) and the output
(F9) controlled with a PWM signal so as to supply
a voltage of 24V to the coil.
The solenoid valve is enabled to allow fork arm
lowering when:
° The key switch is dosed.
• The seat microswitch is closed (operator on

board).
• The overcurrent protection circuit is not in the

alarm state.
Thermal sensor
operation
The temperature sensor installed on the pump
motor is a PTC sensor connected to the drive
thrniiah nins FR and F12- fha Alectrnnir.«
with a constant current to the PTC sensor so
that the voltage on the PTC is proportional to the
temperature. When the temperature of the motor
exceeds the maximum temperature threshold
set, the controller limits the pump motor rpm in
the lifting function, reducing it to about 60Hz.
If the temperature exceeds the set limit, the
controller will block the pump motor and only
the hydraulically assisted steering function will
be possible at the minimum rpm necessary to
guarantee movement of the steering wheel.
60-10 Workshop literature

Types of hours counters

Types of hour counters:
There are five different types of hour counters:
• Machine: the hours increase when the pump

motor is powered. These hour counters can
be viewed on the display or through a PC.
• Electronics: counts the hours of operation of

each electronic component (DUAL AC, AC2
FLASH, ECO DISPLAY); the hours increase
when the components are powered (KEY
ON). These hour counters can be viewed only
through a PC.
• Traction motor: counts the hours of operation
of the traction drive motor. These hour coun
ters can be viewed on the display or through a
PC.
• Seat: counts the hours of operator presence
on board (seat contact closed).
• Hours worked in the day: displays the hours

worked during the day, corresponding to the
hours of pump motor operation; using the PC,
the hours worked in the previous thirty days
can also be viewed.
Hours counter management in

case of electronic system replace
ment
In order to be able to recover the accumulated
hours, in case of replacement of one or more
electronic components, these hours are stored
on both the DUAL AC and the ECO DISPLAY.
The hours counter for the daily hours worked re

sides on the ECO DISPLAY only, however, since
losing the daily hours is acceptable if the display
must be replaced. To avoid any "drift", if at any
time the two counts of the same hours counter
differ by 5 hours, the two hours counters are syn
chronised to the higher value.
In case of replacement, the hours counters stored

on the two electronics will not be synchronised
with one another and the non-blocking alarm 365
WRONG HOUR COUNTER will appear on the
display when the truck is switched on.
In order to clear the alarm, the hours counters
must be synchronised through the SINC HOUR
COUNTER parameter.

Types of hours counters
At synchronisation, the hours counter showing
fewer hours with respect to the other will synchro
nise with the counter having the larger number of
hours.
The synchronisation of the hours should never be

performed for the "electronics" hours of the com
ponents.
An example is provided below:
A machine that has been in operation for 450

hours on which the DUAL AC must be replaced.
Initial situation:
DUAL AC ECO DISPLAY HOUR COUNTER

450 450 Machine
450 450 Electronics
400 400 T raction
550 550 Seat
Situation after having replaced the DUAL AC, be

fore synchronisation:

0 .. 450 Machine
_.._o .... _...... 450 Electronics
.... ...... .
0 400 Traction
0 550 Seat
Situation after having replaced the DUAL AC, af

ter synchronisation:

450 450 Machine
0 450 Electronics
400 400 Traction
550 550 Seat
■ t ■
* s j NOTE
In order for the system to work property, it is es

sential that the spare electronic component has
the hours counter at zero or at least with a num
ber ofhours less than that on the hours counter of
the original component.
Resetting the machine hours

if the machine hours are less than 100, the foi
lowing hour counters can be reset through the
RESET HOUR parameter in the SET OPTIONS
menu of the ECO DISPLAY: machine, traction,
seat, daily hours.
This operation can be performed only once.
60-12 Workshop literature. 40328042303 EM - 05/2003

Electrical system components

Electronics panel technical data
Plate data: traction

Maximum current per single motor 330 Arms (3 min)
Booster 10% Imax current for max 5 s
Maximum rated operating temperature 75°C
Analogue inputs 3
Digital inputs 6
Plate data: pump

Maximum current 450 Arms (3 min)
Max operating temperature 75°C
Analogue inputs 2
Digital inputs 7
Electronics panel removal I re

assembly
Electronics panel removal
• Raise the battery cover as indicated in the
chapter "Internal accessibility".

60

> Disconnect all the wiring connections from the >
top part of the electronics panel.
(J) NOTE
Mark the respective positions on the cables in or

W31106
>

60
.... .. :
> Raise the electronics panel sideways and dis
connect the power supply cables (3) from the
modules.
note

80-16 Workshop literature -40328042303 EN - 05/2008

> Remove the electronics panel (5).
Electronics panel reassembly

tions in reverse.

60 Eiectronto system
Protection of the electrical system

The following protections are provided (in addi « if the distributor lever (or the joystick) is oper
tion to ail the other protections intrinsic to the con ated before putting the key in the ON position,
trols orthose described previously): the relative hydraulic function must not be en
• The safety circuits of the controls must be diag abled, and the lever must be released to re
nosed by the microcontroller. The correct op store forklift operation.
eration of the microcontroller must be checked • If the negative wire of the accelerator, brake,
by a watchdog circuit. In addition, the micro steering or lifting potentiometer power sup
controllers of the drive and pump controls must ply should break, the control must go into
check one another using the serial can-bus alarm; this check is carried out through an
connection, through implementation of a spe out-of-range diagnosis of the output signal of
cific protocol (based on stuffing bit or other sim the potentiometers; thus the potentiometers,
ilar techniques). The Dual AC has two micro during normal operation, must have a working
controllers that share the inputs and that check stroke that guarantees the presence of volt
one another; for example, if a micro enables age intervals outside the allowed range, so
the gear because it “sees” the relative input as to permit the aforesaid diagnosis; a differ
change state, but the other micro does not see ent alarm code must be coded for each poten
any change of state on the same input, the con tiometer .
trol must go Into alarm. • Without an operator on board, the hydraulic
• if the accelerator is pressed, before putting the functions are disabled, including descent.
key in the ON position, the contactor closes but
the forklift does not move, it is necessary to
completely release the pedal in order to restore
forklift operation.
60-18 Workshop literature - 40328042303 EM. 05/2008

Emergency pushbutton
> The emergency pushbutton is a contact which
is normally closed, and it allows to interrupt
the passage of current on the electronic sys
tem so as to immobilize the forklift in case of
emergency. It can be used in all situations of
danger; the pushbutton must be used only and
exclusively in case of sudden loss of control of
the machine. To reset the button, just rotate it
clockwise by 1/4 of a turn. The control, as soon
as it “hears” the pressing of the emergency
pushbutton, zeros the current; the de-energiz-
ing is independent from the control and occurs
through the emergency pushbutton wiring/coil.
Replacing the emergency stop but

ton
• Secure the truck by applying the parking brake.
• Disconnect the battery.
• Remove the panelling of the hydraulic distribu
tor as indicated in the respective paragraph.
• Disconnect the wiring from the emergency
stop button.
> Remove the body by pressing the "Open" key

(1).

> Use an appropriate crescent wrench to un

screw the ring nut (2).
Repiace the pushbutton with a new- one, and re-

assemble the same by performing the disassem
bly operations in reverse.
Assembly / disassembly of the

lights switch (option)
Disassembly of the lights switch
= Secure the truck by applying the parking brake.
« Operate the emergency stop button or discon
nect the battery.
• Remove the panelling of the steering column
as indicated in the respective paragraph.

> Remove the shell (2).
> Unscrew the screws (3) and remove the lock

ing ring (4).
> Disconnect the wiring (5) and remove the lights

switch device (6).

s
Assembly of the lights switch
> For the assembly, perform the disassembly
operations in reverse.
pj~] NOTE
Be careful that the plug (7) is correctly inserted

into the seat (8) ofthe steering column.
Lamp replacement (if applicable)

Before replacing a lamp, check that the respec
tive fuse is intact (see the paragraph ""Fuse re
placement""). Replace the lamp with another one
having the same characteristics (see the techni
cal data chapter).
Workshop literature - 40328042303 — Ob/2006

Rear lights unit lamps
Follow the instructions in the points below in order

to change a lamp in the rear lights unit.
• Remove the transparent cover (1 ) by unscrew
ing the two screws (2).
• Lightly press and turn the burnt-out lamp to re
move it from the bayonet fitting, and then re
place it with a new one. The lamp positions are
as follows:
Reversing lights lamp (3)
Stop lights lamp (4)
• Put the transparent cover (1 ) back on.
(H NOTE
The indications refer to the left rear lights unit.
Work light replacement procedure >

(optional)
> To replace a working lamp bulb, loosen the
screws (1) and remove the light cluster (2).
> Release the bulb (3) by releasing the spring
pins (4), then disconnect the plug (5) and
change the bulb.
> Refitting is the reverse of removal.

Contactors
> The system is equipped with 2 Albright SW200
power contactors. Two contactors are pro
vided to satisfy EN 1175-1 standards that
require redundancy to ensure safety. The line
contactors have contacts in series but with the
coils controlled independently; these open ev
ery time a failure is detected in any circuit that
can lead to full-power running movements, as
dictated by the reference standards.
Upon ignition, the contacts of the contactors (LC1

and LC2) are checked according to the following
sequence:
° 1) The system closes LC1, and tries to pass
current; if the voltage Vcond drops, everything
is fine, otherwise LC2 is stuck.
° 2) LC1 is opened.
current; if the voltage Vcond drops, everything
is fine, otherwise LC1 is stuck.
current; if Vcond drops, a contactor is open; ¡fit
does not drop, everything is fine.
The contactors protect against battery polarity
reversals and uncontrolled movements; in fact,
they must not close if the following occurs:
» the power unit doesn’t work
• the logic is not working properly
* the operator present contact is not closed (in
cluding the safety belt contact as well)
Moreover, once closed, the contactors must
open when there is any type of failure in any
circuit that would lead to the loss of control of
the forkiift and/or uncontrolled movements of the
forklift. The maximum operate time must be <
200msec.
| j j NOTE
The line contactors always open and dose in the

absence ofcurrent except during failure.
Workshop Hteroture - 40328042303 EN - 05/2008

Location of Fuses
OM1449
To access the fuses, the battery cover (1) must special box (3) located on the right side of the
be raised as indicated in the relative paragraph. panel.
The power fuses (2) are positioned on the elec

tronic units; the other fuses are positioned in a

60_____
Changing a fuse
Turn off the forklift and perform the operations • Raise the battery cover (1) as indicated in the
preliminary to maintenance. relative paragraph.
• The power fuses (2) and (3) are positioned on
A CAUTION
the electronic units, while the service fuses (4,
Before changing a fuse, eliminate the cause that led to 5,6, 7, 8, 9) are positioned in the relative fuse
its blowing. The biown-out fuse must be replaced with box (10).
a fuse of the same amperage only. Do not tamper with
the forklift’s electrical system. Power Fuses (2) and (3)
° Loosen the screws (11) and replace the fuse,
then retighten the screws (11).
60-26 Workshop Hterature - 40328042303 EE! - 05/2008

Service and Auxiliary Fuses (4,5,6,7,8,9) "4" = Blade fuse for lights converter 25A - 80V
• Change the blown fuse in the fuse box. "5" = Blade fuse for horn 10A - 80V
"6" = Blade fuse for starting switch 15A - 80V
Fuse Values
"7" = Services fuse 5A - 32V
• "2" = Traction power fuse 355A -250V
"8" = Stop lights fuse 10A - 32V
• "3" = Pump power fuse 355A -250V
"9" = Reversing lights fuse 10A - 32V
DC/DC Converter
> The series converter has the task of taking the
battery voltage and reducing it to 24V, sup
plying a power of 100W. When the converter
works properly, the green LED (1) is lit.
The converter powers:

• the stop and reversing lights
• the electronics panel cooling fan
• the buzzer
With the use of this component, a smoothed dis
charge is obtained for all the elements making up
the battery, thus improving its performance and
lifetime.
A maximum of two 300W converters are provided
for the optional equipment.
> The connector used is a watertight 5-pin
Amp connector. This component is powered
through pins 1 (+battery) and 4 (-battery),
while its activation occurs on pin 5 with the bat
tery positive, after key contact. The identifica
tion of the pins considering the converter-side
(2) wiring is described in the table:
Position Colour Function

1 black IN+
2 blue IN-
3 red OUT+ W30396
4 blue OUT-
5 orange ENABLE
j NOTE
The ENABLE input must be connected to the po

sitive pole ofthe battery after key contact.
The technical specifications of the series con

verter are listed in the table.
Parameter Min Max Unit Test conditions

Input voltage 30 150 V
Output voltage 23.5 24.5 V

60 Etectrpnic system
¡Output current 0 4.2 A Continuous use

Efficiency 88 % Vin=48V, lout=4.2A
!o=0-4.2A, Vin=48V
Static load adjustment 500 mV
T= 25°C
Vin=30-150V, lout=4.2A
Static line adjustment 200 mV
T= 25 °C
Short-circuit protection Yes
Current output limit 4.7 5.7 A Vin= 30-150V, Vout=24V
Enabling voltage (ENABLE) +20 +150 V Referred to "IN-"
Input inversion protection Yes
Diode in series with the output Yes
Output protection with crowbar 30 V optional double crowbar
Output voltage indicator LED Yes
Thermal protection 90 °C Yes
Operating environment temperature -20 +55 °C
Storage temperature -40 +70 °C
Degree of protection IP65 (connector excluded)
Buzzer
> This acoustic signal is powered at 24V by the
DC/DC converter and receives the negative
from pin 31 of the C connector of the DUAL AC
module. It can be parameterized via software
in the "Display Parameters" menu through the
DI I77CD +
uuz_i-i_i\ pai a11 icid .
Fans
Panel fans
> The three fans protect both the drives ( DUAL
AC and AC2) from overheating; they are pow
ered directly by the 24V DC/DC.
Workshop Hteratiire. 40328042303 EN.. 05/2008

Encoder description
> Three encoders are assembled on the truck
to measure the angular rotation speed, one
for each motor (two traction motors and one
pump motor); the encoders are composed of a
sprocket and an inductive sensorthat "counts"
the teeth. The encoders are pick-up encoders
with apparently identical structures but with dif
ferent numbers of teeth on the sprocket.
LZL
TZU—
W30403

60 .._________ -
> The connector used is shown in the figure, and

the four terminals are described in the table.
Terminai Function
1 +B
2 Signal A
3 GND
4 Signal B
In addition to the supply terminals, there are two

channels on which two signals are transmitted,
signal A and signal B. These two signals are
necessary because the logic acquires both for
ward and reverse gear information. The signals
consist in a sequence of phase-shifted square
waves; when the signal A - B is greater than zero,
the truck is in forward gear, otherwise if A - B is
less than zero, it’s in reverse gear. Clearly there
is only a single direction for the encoder on the
pump motor.
AN A r
B B A OR
I
jDQBBil
B A i I
i i i
i i i I
J I
i
§ i s i i I
I
s s
!
i
/ '(///
W30406
AN= Anticlockwise
OR= Clockwise
S= Sensor

Traction motor encoders
> The inductive sensors have an 11V regulated
power supply; they are powered by the DUAL
AC (pin C1 for the right traction motor encoder
and pin C11 for the left traction motor encoder
). Both traction motors have 64 teeth on the en
coder wheel. The connector used is shown in
the figure.
Pump motor encoder

> The inductive sensors have an 11.3 V regu
lated power supply, and they are powered by
the AC2 ( pin C1). There are 96 teeth on the
phonic wheel. The connector used is shown in
the figure.
W30408

60
î A/q Hz c
Hydrauliccomponents_ 71
Hydraulic circuit
Layout of hydraulic parts
8 Oil filter
Lifting distributor 9 Tilt stop valve
1 Lift cylinders
Steering cylinder 10
2 Metering valve
Tilt cylinders 11 described in the
3 Safety valves (arranged as
4 Oil tank 12
pump with priority valve respective chapter).
5
6 Pump motor - steering con-
Hydraulically assisted steering
7
trol distributor
71-1
71
Hydraulic system assembly dia

gram
Î NOTE
7776 assembly diagrams of the entire hydraulic

part of the truck are pro vided below; for the dia
gram with ISO symbols, see the appendix chap
ter located at the end ofthis manual.
Assembly diagram - part 1
1 barrel 5 Right cylinder rigid supply barrel

2 Fitting 6 Barrel (elevated)
3 Valve A For the version without SLi and without equip
4 Left cylinder rigid supply barrel ment, replace with 35Nm plug and gasket.
7 Barrel 12 Flange
8 Barrel for three/four-wheel versions 13 Washers
9 Fitting 14 Screws
10 Barrel for four-wheel version only B 2.0-3.0 rev.
11 Barrel for three-wheel version only
15 Barrel (elevated) 18 Collar

16 Fitting C 2.0-3.0 rev
17 Barrel
71W Workshop Hterature -40323042:

Hydraulic components 71
Pump motor
Pump motor technical data
3 R
Motor specifications
Three-phase asynchronous squirrel-cage motor
Marking of the terminals and direction of rotation
in conformity with the standard I EC 60034-8
Temperature sensor specifications
Temperature sensor KTY 84-130

T
Connector configuration
A Motor
AMP 2-965421-1 1 red B Pump side
2 blue C Direction of rotation - right
Specifications of the speed sensor output

signal

71
Pump motor removal

- Disconnect the baiiery socket or operate the
’ Secure the truck by applying the handbrake.
« Remove the operator step plate as indicated in
the respective chapter.
> Loosen and remove the fixing screws of the

brake pedai support (2). Disconnect the wiring
and remove the brake pedal support (2).

Pump motor
> Disconnect the motor power supply cables (5).
[j~] NOTE


71
> Disconnect the delivery piping from the tank (7) >
by loosening the respective clamp.
> Disconnect the feed barrels from the pump to >

the hydraulic distributor (8) and the steering
distributor (9).
> Disconnect the load sensing signal barrel (10). >
Workshop Hterature - 40328042303 EN - 05/2008

Pump motor
> Hook the pump-motor unit(11)to an eye bolt
and a sling with suitable lifting capacity, and
tension the sling using a hoist or lift truck.
Completely unscrew the screws (6) which
were loosened previously, then lift the pump
motor and remove it from the chassis.
A CAUTION
In this photo the steering wheel has been removed, ho
wever this is not necessary. If present during this ope
ration, be careful not to strike the steering wheel!

Pump motor reassembly
Perform the remove! operations in reverse, tak
ing care to tighten the various components to the
tightening torques indicated in the assembly dia
grams.
Assembly of the pump motor to the chassis >
W31185
1 Motor support
2 Pump motor
3 Oil pump
4 Screw M8x16
5 Screw M8x40
Assembly of the pump onto the motor

Reassemble by performing the disassembly op
erations in reverse, being careful to position the
driving disc (6) correctly.
W31186
6 Driving disc

Pump motor
W31187
A See detail A
Detail A
7 Screws non involved in fixing the pump

8 Screw M 10x130
9 Screw M 10x120
Replacing the pump

• Remove the pump motor with the pump con
nected, as indicated in the respective chapter.
• Position the motor on the work bench.

Pump motor
Replacing the pump motorencoder

• Remove the operator step plate as indicated in
> Disconnect the wiring from the connector (1) of

the pump motor encoder.
> Loosen and remove the fixing screw (2) of the

encoder bracket. Remove the encoder (3) and
replace it with a new one.

71
Replacing the pump motor temper

ature senso«"
> Disconnect the wiring from the connector (1) of

the temperature sensor.
> Use a spanner to unscrew the locking nut (2) of

the sensor
> Remove the sensor (3) and replace it with a

ngu/ one.
Workshop Cerature -40328042303 EH-05/2008

Oil tank
Hydraulic oil tank
> The oil tank complete with filter has a 23-litre
capacity. For the disassembly of the tank, fol
low the instructions provided in the respective
chapter.
1= Oil inlet
2= Oil filter
3= Oil dipstick
4= Airvent
5= Sleeve for pump suction connection
6= Drain plug
7= Filter cartridge

Oil tank removal / reassembly
Removal
» Position the truck over a work pit.
• Remove the service brake pedal as indicated
in the respective chapter.
> Completely drain the oil contained in the hy- >

drauiic system tank by unscrewing the plug
(1). Remove the plate (2) by unscrewing the
screws (3).
> Disconnect the piping (4) that goes from the >
tank to the hydraulic distributor.
> Disconnect the suction barrel (5) from the tank >
to the pump by loosening the pipe clamp on the

Oil tank
> Disconnect the piping (6) from the tank. t>
> Unscrew the screws of the brackets (7) fixing >

the tank (rear and side brackets).
> >

71 lory
>
> Remove the tank (8) by extracting it out from

below the truck.
pi] NOTE
Ifa work pit is unavailable, the tank can be disas

sembledfrom abo ve byremoving the pump motor
unit and the hydraulic distributor co ver.
Reassembly
Perform the disassembly operations in reverse,
reassembling the plate with the help of another
operator who will support the tank from above.

Oil tank
Check hydraulic tank oil level
Turn off the forklift and perform the operations (6) of the accelerator pedal (7) and remove the
preliminary to maintenance. step plate.
• To check the hydraulic oil level, extract the
A CAUTION
dipstick (8) and check that the level is between
The hydraulic oil level must be checked by positioning the notches for maximum "MAX" and minimum
the truck on a flat surface with the fork arms at the ma "MIN".
ximum elevation and the lift tilted forward.
• Top up, if necessary, by unscrewing the filter
cap (9).
• Remove the rubber mat.
• Remove the two side panels (1) by unscrewing
the relative screws (2), if applicable. j NOTE
• Unscrew the two screws (3) that fix the step Use the type ofoil indicated in the supply table
plate (4), disconnect the connectors (5) and provided in this chapter.

71
Uili tank
When the oil check and top-up operation is com

pleted, reassemble the parts proceeding in the
reverse order.
Workshop literature. 40328042303 EM.. 05/2008

Hydraulic distributor
Hydraulic distributor technical data
1 Maximum lowering speed calibration 4 Moving

2 Lifting (tilting up) 5 Manual lowering (unscrew 1.5 turns at most)
3 Lowering (tilting down)
Technical data
Rated pressure 250 bar

Dimensions NG10/NG6
Operating temperature -30°C to +80°C
O-Ring material NBR80
Axial forces <150N (max. 2000N)
Maximum torque on the coil <15Nm
P, A1-B3, H:265 bar
Maximum permissible pressure
R: 15 bar
P, H, R: 45 l/min (<10 cm3/min)
Nominal flow
A1, B3: 30 l/min 150 bar, 32cS
P, H, R: G1/2” (70Nm)
Hydraulic connections (torque) A1-B3: G3/8” (30Nm)
M:M14x1.5
Rated voltage ml 24 VDC/30W/100%ED
Electrical connection ml for AM P J PT 2-pi n (828657-1 ) /1P65

71
Hydraulic distributor removal / re

assembly
Removal
> Lower the lift completely and operate the levers
of the hydraulic distributor in both directions to
release the pressure from the hydraulic circuit.
Secure the truck by applying the handbrake.
Disconnect the battery socket. Remove the
distributor cover as described in the respective
chapter.
> Disconnect ali the piping (1) on the hydraulic

distributor.
ijj NOTE
Mark the respective positions on the piping in or
Workshop literature -40328042303 EN - 05/2008

>

71
> Unscrew the three screws (4) that fix the dis
tributor to the chassis.
> Remove the distributor (5).
> To remove the support frame of the hydraulic

distributor, loosen and remove two fixing
screws (6) of the same.
Reassembly
Follow the removal instructions in reverse, tak
ing care to tighten the fittings as indicated in the
chapter "Hydraulic system".
rsn
I 1 J NOTE
When the operations have been completed,

bleed the air from the hydraulic system as descri
bedin the respective paragraph.
A CAUTiON
After this replacement, you will probably need to recali
brate the Haii sensor concerning the lifting element in
this case, follow the instructions in the respective para
graph.

Replacing the hydraulic distributor
probe
Open the distributor as indicated in the paragraph
"Internal accessibility".
> Disconnect the connector (1) from the wiring

using a screwdriver as a lever to release the
catch. Use the appropriate equipment to ex
tract the respective PIN of the probe being re
placed.
> Unscrew the screws (2) of the probe to be re

placed.
> Remove the probe (3) and replace it with a new

one, then insert the new PIN into the connec
tor.
A CAUTION
After replacement of the Hall sensor regarding the lif

ting element, it will probably need to be recalibrated. In
this case, follow the instructions in the respective para
graph.

Valves
Safety valve (load lowering block)
(VBDC)
> This device provides protection against barrel
breakage, as it prevents the uncontrolled and
accelerated movement of loaded hydraulic
equipment in the event the hydraulic counter
pressure fails due to broken delivery piping.
W31143
The device is screwed directly into the oil inlet
of the equipment to be protected, and it con
sists of a disc that is lifted from its seat in rest
position, by means of a spring, thus allowing
the passage of oil through the predetermined
section. When the flow-rate increases, the
hydraulic forces exceed the force exerted by
the spring and the valve closes immediately.
There is a hole on the disc of the valve that,
regardless of force due to the size of the load,
allows a constant outflow of oil which is suit
able to lower the load slowly until it rests on the
bottom.
s-->B= How during supply
F<-B= Flow during draining
j NOTE
For the position ofthe valves assembled on the

various lift types, see the illustrated tables in the
respective paragraph.

Valves
Safety valve layout
Safety valve positioning on the Simplex lift
SIN Left
DES Right

71;nponerrts lory
A CAUTION
The valve (A) is assembled only on the elevations

4.03m/4.53m.
A CAUTION
Forthe type of valve to be used, refer to the Spare Parts
Catalogue only.

Valves
Safety valve positioning on the Duplex lift
A-B-C-D Safety valves

SIN Left
DES Right

71
fl ‘ ' - ííOOg feö
A CAUTION
Forthe type of valve to be used, referto the Spare Parts
Catalogue only.

Valves
Safety valve positioning on the Triplex lift
A-B-C-D Safety valves DES Right

SIN Left 1 Caulk in 3 points

71 Ifiüi
A CAUTION
1_ r 4 a 4» in 4f> : i c* o *H roio5" 4z^. 44^/5 Cjr>.<? rc* D*3!yf Çî
Catalogue only.
7 Workshop hterature -40328042303 EN - 05/2008

Tilt cylinders
Tilt cylinders
1 Apply Loctite 270

2 Sealed with Loctite 270
3 Apply Loctite 270
A Stroke 78 - For elevation 2975 + 4030 mm
B Stroke 52 - For elevation 4450 + 6970 mm
Tilt cylinder removal / reassembly

Removal
A DANGER
It is prohibited to remove both tilt cylinders from the
truck as this may cause the lift to move; remove one
cylinder at a time.
• Place the lift in the vertical position.

• Move the fork carriage down to the lower limit
stop.
• Release the pressure from the cylinders (lift
and tilt cylinders as well as those of the SLI or
any other equipment) by moving the respec
tive levers of the hydraulic system distributor in
both directions several times.
spective chapter.

> Disconnect the feed barrels (1) of the tilt cylin
ders.
I; A DANGER
The supply circuit of the cylinders is under pressure, so
remove the supply barrels of the cylinders with great
care, loosening the fittings first to release the pressure
before unscrewing them completely.
> Remove the locking snap rings (2) from the

coupling pins of the lift-side tilt cylinders.
> Extend the pins using a punch (3) with suitable

length.
A DANGER
Use suitable tools. Do not place hands or fingers bet
ween one piece and another.
> Remove the locking snap rings (4) from the

coupling pins of the chassis-side tilt cylinders.

Tilt cylinders
> Remove the mudguard (6).
> Using a punch (3) with suitable length, extend

the pins through the slot in the chassis.
A DANGER
Use suitable tools. Do not place hands or fingers bet
ween one piece and another.

71
> Extend the cylinder (7) bylifting it from the rear.
Reassembly
Perform the removal operations in reverse, be
ing careful to grease the joints before reassembly
with the type of lubricant described in the "Supply
table". When reassembly has been completed,
bleed the cylinders as described in the relative
paragraph.
Air bleeding of the tilt cylinders

> Tilt the lift completely to the limit stop forwards
and backwards several times. The bleeding
occurs automatically. At the end of the opera
tions, check the oil level.
ENVIRONMENT NOTE
For disposa' ofthe waste oil, abide by current re

gulations on the subject.
Workshop iiterature - 40328042303 EN - 05/2008

Lifts 80
Lifts
Technical data for service
Lift support screws Tightening torque = 280 Nm

Roller screws Tightening torque = 60 Nm ± 6 Nm
Maximum elongation: 2% according to accident
Load chains
prevention rules
Lowering speed Maximum admissible 0.55 / 0.50 m/sec.

80 Lifts
Lifts
Lift typologies
Simplex Lift
During lifting, the dimensions of the lift are always
higher than the load. Composed of two lift cylin
ders and two masts (fixed and moving).
Workshop literature-40328042303 EN. 05/2008

Lifts 80
Lifts
Duplex Lift
Composed of three lift cylinders (two side cylin
ders and one central cylinder), and two masts
(fixed and moving). During lifting, the extended
mast is never higher than the load being lifted.

80 Lifts
Lifts
Triplex Lift
Composed of three lift cylinders (two side cylin
ders and one central Cylinder), and three masts
(fixed, inner and moving). Similar to the duplex
lift, during lifting, the extended mast is never
higher than the ioad being iifted.
All the lift typologies provide excellent visibility.
The section of the mast is an H-section. The fork
carriage and the sections of the masts are guided
by support rollers that also absorb transverse
stress.
Forthe assembly and disassembly of the lift, refer
to the respective paragraph.
[j] NOTE
To limit wear, the sliding tracks of the rollers

should be greased as needed with high-pressure
adhesive lubricant.
wtoiKs, i - 40328042303 EN - 05/2008

Lifts 80
Lifts
Simplex Lift
Simplex lift functional description ▻
The two cylinders are housed in the section of
the outer mast and are supplied by piping that
branches off from the metering valve.
The two pistons are connected on top with the

cross traverse of the inner mast (or moving mast).
When the cylinders are powered, the two pistons

emerge and raise the inner mast.
The limit stop inside the cylinder.
The load chains are fixed to the outer (fixed) mast
and passed around the inner mast through chain
rollers, while at the other end they are connected
to the fork carriage.
In this manner the lift is extracted with respect to
the fork carriage in the proportion of 1 : 2.
A lowering brake (metering valve) incorporated
in the rigid piping limits the maximum lowering
speed to 0.55 / 0.50 m/sec.
The retaining device prevents the accidental
overrun of the fork carriage from the moving mast
(see the respective paragraph).
W31390
1 Fork carriage retaining device

1 Metering valve
2 Safety valve (present on all elevations)
3 Safety valve (present on the 4.03- 4.53 m ele
vations only)
The oil inlet is located at the metering valve (1).

From that point the oil reaches the two cylinders
by passing through the piping. The safety vaives,
fitted inside the cylinders, prevent a rapid and un
controlled lowering of the load in case the piping
breaks.
i'tj NOTE
fA/îiictman/c'ir/^
I KJ! ! k/j-'Ull tj Ctf IS !nn/
HJ I HUtlUU IS! ƒ U /ISJiS
valves. In case ofmalfunctioning or anomalies,
replace the valves. For the type of valve, refer to
the Spare Parts Catalogue only.
Works? iop nî.oroiuro 403280423GP cW — 05/2üu8

Lifts 80
Lifts
Adjusting the Simplex lift load chain
> The load chains must be adjusted uniformly
using the tensioning attachments (1).
The centre of the upper rollers of the fork carriage

(four-roller carriage) or, depending on the case,
the centre of the middle rollers of the carriage (six-
roller carriage), must remain inside the section
of the inner mast for a dimension at least greater
than "X" (see respective diagram) when the pis
tons of the lift cylinders are completely extended
(up to the limit stop inside the cylinder).
A CAUTION
Never compensate tyre wear by adjusting the load
chain tension.
When adjusting the load chains, a minimum dis

tance of 2 mm must be kept from the fork carriage
retaining device (see adjustment in the respec
tive paragraph).
> For the load chain locking device according to

the sketch shown on the side, see the respec
tive paragraph.
j NOTE
The wear, possible damage and elongation ofthe

load chains should be checked according to the
accidentprevention rules and as describedin the
Userand Maintenance Manual.

hs Fork carriage travel: hs= 2 x external dimen For the 1.2 ton and 1.5 ton versions: choice of
sions -1070 four-roller or six-roller fork carriage.
h4 Maximum dimensions (Four-roller carriage): For the 1.8 ton version: six-roller fork carriage
h4= 2 x external dimensions -515 only.
h4 Maximum dimensions (Six-roller carriage):
h4= 2 x external dimensions - 447
Simplex 1.2t - 1.5t - I.St

Nominal lifting height mm 3330 3630 4030 4530 5030
External dimensions hi mm 2210 2360 2560 2810 3060
Free lift height h2 mm 150 150 150 150 150
Height above ground —1 A f\f\ a
u mm IUU IUU 100 100 100
Lift support pin x mm 71 71 71 71 71
Pin diameter mm 35 35 35 35 35

Lifts 80
Lifts
Duplex Lift
Duplex lift functional description >
The lift is fitted with three cylinders.
The intermediate cylinder allows the large free lift

height simply by means of a telescopic effect in
side the moving mast.
The chain is fixed to the moving mast and is

passed around the central cylinder by means of a
chain roller while the other end is fixed to the fork
carriage.
In this manner the fork carriage rises without in
creasing the dimensions of the lift.
The two outer cylinders are located in the H-sec-

tion of the outer (fixed) mast.
The pistons of the outer cylinders are connected

to the inner (moving) mast.
If the cylinders are filled with oil, the first piston to

be extended is that of the intermediate cylinder,
since it has the largest surface area.
Then the two pistons of the outer cylinders
emerge and raise the inner mast.
A lowering metering valve limits the maximum

lowering speed to 0.55 / 0.50 m/s.
The retaining device prevents the accidental

overrun of the fork carriage from the moving
mast (for its adjustment, see the respective para
W31395
graph).

Hydraulic circuit for powering the Duplex lift cylinders
______________________________ W31396
-i
iviulgi ii ikj vaivc. A
-T ocuciy vaivc
2 Safety valve 5 Safety valve
3 Safety valve A From the distributor
The oil enters at the metering valve(l). From this

point it passes ihrougn the side piping to the ouier
nwiinriarc
>>. . —W.
f'in. thn
K.
Mi iniov iitt thn
vi
nil
wn
nou/arc the
w n.v
central cylinder through the left outer cylinder and

the vertical piping. Due to the difference in the
surface area of the two pistons, the first piston to
be extended is that of the central cylinder.
fttrnko 1= nnarofac the fnrU rorriorm nnl\/
** *■ w.w ■ Wfywi VI IW ■ wa a v wv<«i I iwyw Ml nj-
Stroke 2= extends the inner (moving) mast.

(refer to the respective diagrams).
Lifts 80
Lifts
The safety valves are fitted in the cylinders and
prevent the rapid and uncontrolled lowering of the
load in case the piping breaks.
I NOTE
Adjustments orrepairs are notpermitted on these

valves, in case ofmalfunctioning or anomalies,
Adjusting the load chains of the Duplex lift

> The load chains must be adjusted uniformly
using the tensioning attachments (1 ).
The centre of the upper rollers of the four-roller
fork carriage or, depending on the case, the cen
tre of the middle rollers of the six-roller carriage,
must remain inside the section of the inner mast
for a dimension at least greater than "X" (see re
spective diagram) when the piston of the lift cylin
der is completely extended (up to the limit stop
inside the cylinder).
Never compensate tyre wear by adjusting the
load chain tension.

tive paragraph).
> For the load chain locking device according to

the sketch shown on the side, see the respec
tive paragraph.
j| NOTE

toad chains should be checked according to the
accidentprevention rules and as describedin the
User and Maintenance Manual.

QA
VV
6
Duplex 1.21-1,5t lifting diagram
1 Fork carriage travei Corsa 1 1 = external dimensions - 430

2 Lift height of the mast Corsa 2 2= external dimensions - 495
hs Fork carriage travel: hs= 2 x external dimen h2 Free lift height (Four-roller carriage): h2= ex
sions - 925 ternal dimensions - 598
h4 Maximum dimensions (Four-roller carriage): K2 Free lift height (Six-roller carriage): h2= exter
h4= 2 x external dimensions - 370 nal dimensions-641
h4 Maximum dimensions (Six-roller carriage):
For the 1.2 ton and 1.5 ton versions: choice of
Duplex 1.2t - 1.5t

Nominal lifting height mm 2975 3275 3575 3975
External dimensions hi mm 1960 2110 2260 2460
Height above ground a mm 100 100 100 100
I ift qi
», r...
mnnrf nin
x
mm
■ i ii i i
7-1
t 1
74
t I
7*1
I I
7*1
! !
Pin diameter mm 35 35 35 35
Workshop i iteratu re. 40328042303 EN - 05/2008

® Lifts 80
Lifts
Duplex 1.8t lifting diagram
1 Fork carriage travel Corsa 11 = external dimensions - 480

2 Lift height of the mast Corsa 2 2= external dimensions - 545
hs Fork carriage travel: hs= 2 x external dimen- h2 Free lift height: h2= external dimensions-648
sions-1025
h4 Maximum dimensions: h4= 2 x external di
mensions - 377
Six-roller fork carriage.
Duplex 1.8t
Nominal lifting height mm 2975 3275 3575 3975
External dimensions hi mm 2010 2160 2310 2510
Height above ground d mm 100 100 100 100
Lift support pin X mm 71 71 71 71
Pin diameter mm 35 35 35 35

80 Lifts
Lifts
Triplex Lift
Triplex lift functional description
The ¡¡ft is fitted with three cylinders. The central
cylinder allows the large free lift height, yet with
out exceeding the externa! dimensions, simply by
means of a telescopic effect inside the inner mast.
The two outer cylinders are located in the H-sec-
tion of the outer or fixed mast
The pistons of the side cylinders are connected to

the intermediate mast.
The load chains for stroke 2 (see the lifting dia
gram) are fixed to the outer (fixed) mast at the top
and the inner (moving) mast at the bottom.
If the cylinders are filled with oil, the first piston to
be extended is that of the central cylinder, since it
has the iargest surface area.
Then the pistons of the two outer cylinders

emerge to raise the intermediate mast. The
intermediate mast raises the inner mast through
the chain connection in the proportion of 1 : 2.
A lowering metering valve limits the maximum
lowering speed to 0.55 / 0.50 m/s.
The fork carriage retaining device prevents the

accidental overrun of the fork carriage from the
inner mast (for its adjustment, see the respective
paragraph).
1 Fork carriage retaining device
80-14 Workshop literature - 40328042303 EM - 05/2008

Lifts 80
Lifts
Hydraulic circuit for powering the Triplex lift cylinders
W31401

3 Lowering metering valve A F rom the d istri butor
The oil from the lowering metering valve(3) sup

plies the outer cylinders through the side piping.
The central cylinder is supplied through the left
outer cylinder and piping. Due to the difference in
the surface area of the two pistons, the first pis
ton to be extended is that of the central cylinder.
Once the latter has reached the limit stop, the pis
tons of the outer cylinders emerge.
Stroke 1: operates the fork carriage only.
Stroke 2: extends the intermediate and inner
mast (referto the respective diagrams).

The safety valves are fitted in the cylinders and
prevent the rapid and uncontrolled lowering of the
load in case the piping breaks.
NOTE
Adjustments orrepairs are notpermitted on these

valves. in case ofmalfunctioning or anomalies,
Adjusting the lifting chains on the Triplex lift

> Outer chains: the outer lifting chains should be
adjusted uniformly using the tensioning attach
ments (1).
> intermediate chain: the load chain is adjusted

using the tensioning attachment (2).
The centre of the upper rollers of the four-roller

fork carriage or, depending on the case, the cen
tre of the middle rollers of the six-roller carriage,
must remain inside the section of the inner mast
for a dimension at least greater than "X" (see re
spective diagram), when the piston of the inter
mediate cylinder is completely extended (up to
the limit stop inside the cylinder).
Never compensate tyre wear by adjusting the
load chain tension

tive paragraph).
pjj NOTE

toad chains should be checked according to the
accidentprevention rules and as described in the
User and Maintenance Manual.
80-16 Workshop fflerature. 40328042303 EN - 05/2008

Lifts 80
Lifts
Triplex 1.2t -1.5t lifting diagram
1 Fork carriage travel

2 Lift height of the mast
e=381 up to external dimensions 2360:
hs= Fork carriage travel

hs= 3 x external dimensions -1540
h4= Maximum dimensions (Four-roller car
riage)
h4= Maximum dimensions (Six-roller carriage)
Stroke 1
1 = external dimensions - 430
Stroke 2
2= 2 x external dimensions -1110
h2= Free lift height
h2= external dimensions - 598
e= 481 from external dimensions 2460:

hs= 3 x external dimensions -1740
h4= Maximum dimensions (Four-roller car
riage)
h4= 3 x external dimensions -1185
h4= Maximum dimensions (Six-roller carriage)
h4= 3 x external dimensions -1142
Stroke 1
Stroke 2
2= 2 x external dimensions-1310
For the 1.2 ton and 1.5 ton versions: choice of

four-roller or six-roller fork carriage.

80 Lifts____________________________________________ ®
Triplex 1.2t - 1.5t

Nominai lifting height j mm 4470 4770 5220 5770 6370 6970
oni n o-nn oocn 071 A AA 4 A
II !
hi
Height above ground d mm 100 100 100 100 100 100

Lift support pin X mm 71 71 71 71 71 71
Pin diameter mm 35 35 35 35 35 35
fS 41
11 ipit?A 1.01
O 4- ! * it s
iiiiiiiij
¿sa ¿=J S
uiayicxm
» aa ira«-»
1 Fork carriage travel

2 Lift height of the mast
e=431 up to external dimensions 2360:

hs= 3 xexternal dimensions - I960
h4= Maximum dimensions
h4= 3 x externa! dimensions -1042
Stroke 1
Stroke 2
n2= Free lift height
e= 531 from external dimensions 2460:

hs- 3 x external dimensions -1890
h4= Maximum dimensions
h4- 3 x external dimensions -1242
Stroke 1
1 - external dimensions - 480
Stroke 2
H2- external dimensions - 648
80-18 Workshop Hleralure - 40328042303 EN. 05/2008

Lifts 80
Lifts
Six-roller fork carriage.
Triplex 1.8t
Nominal lifting height mm 4470 4770 5220 5770 6370 6970
External dimensions hi mm 2060 2160 2310 2560 2760 2960
Height above ground d mm 100 100 100 100 100 100
Lift support pin X mm 71 71 71 71 71 71
Pin diameter mm 35 35 35 35 35 35

80 Dfts____________________________________________ ®
Lifts
Load chain locking device
> The intermediate chain of the Duplex and
Triplex lifts and the outer chains of the Simplex
and Triplex lifts are secured on the lifts as
illustrated in the sketch to the side.
1- Cap.
2= M6 Socket head screw with Tuflok coating.
Fork carnage retaining device

> When the load chains are adjusted, it is neces
sary to ensure that when the lift is completely
extended, the limit stop is not beyond the
stroke of the lift cylinder, i.e., that the block (1)
and the fork carriage retaining device (2) must
not touch one another. You must absolutely
ensure that between the biock (1) and the
fork carriage retaining device (2) there is an
opening of at least 2 mm.
Fjl NOTE
On the lifts with a considerable elevation, it is

simple to determine the size of the opening by
sticking a iittie piasticine on the biock (1), raising
the fork carriage up to the limit stop and then
measuring the thickness ofthe plasticine with a
gauge.
Assembly of the mast / carriage

support rollers
Dimension A Dimen-
Roller 0
sion B
over upto
75.3 - 75.9 0.6
75.6 - 76.2 0.6
75.9 - 76.5 0.6
76.2 76.5 -
Permissible radial clearance (dimension X): min.

0.05 i max. 0.4 at the narrowest point, otherwise
max. 0.6.
80-20 Workshop Htsrature. 40328042303 EN 05/2008

Lifts 80
Lifts
I NOTE
The dimension "A "mustbe measuredin the point

in which the sliding track of the support roller
changes radius.
Dimension "A" with the new lift: 75.4 + 0.8.
1 = Support roller
2= Adjustment shims
3= Tightening torque = 60Nm ±6Nm. Counter
sunk-head screw.
> Total permissible side clearance (B): min. 0.1

/ max. 0.3 in the narrowest point, otherwise
max. 1.1. For six-roller fork carriages: the
clearance of the intermediate rollers must be
0.2 more than the clearance of the top rollers.
C= Carriage or mast
D= Shims

Lifts
Check
Determine the side clearance and the dimen
sion "a" usino -- -feeiRr
------ w a ------- woauoA
-----w -
The indication of the dimension "X" = 0.6 mm rep
resents an indicative value for the insertion of the
next-largest support roller during the running-in,
i.e., with the new profile (dimension "A" = 75.4 +
0.8), at the beginning, the material of the profile
will be compacted at the sliding points of the sup
port rollers.
After a certain running-in period, which varies de

pending on the application, the dimension "X" will
almost completely stop varying: it will stabilize.
To minimize wear, it is important that adhesive

lubricant be applied on the sliding tracks of the
rollers after having cleaned the tracks.
The figures on the right show how io determine
the dimension "X” of the fork carriage support
rollers.
° Raise the fork carriage.

° Insert wooden wedges under the fork arms.
• Lower the fork carriage.
The support rollers will stop on the side opposite

the sliding track.
At this point it is possible to determine the dimen

sion "X".
Workshop literature 40328042303 EN a s' a g

Lifts 80
Lifts
Disassembly of the Simplex lift

cylinder
• Position the lift vertically.
• Extend the lift piston (approx. 20 cm) until the
top fastening becomes easily accessible in or
der to remove the lock ring.
• Remove the lock ring from the upper piston fas
tening.
• Use slings to hook the top cross traverse of the
inner mast to a crane and keep the mast in this
position.
• Lower the lift completely (the pistons will lower
and come off the cross traverse). Operate the
emergency stop button and then move the dis
tributor levers in both directions to release all
the pressure from the hydraulic system.
• Loosen the bottom feed line connection.
• Loosen the cylinder bracket and remove the
cylinder from the lift.
Replacing the set of gaskets:

• Clamp the cylinder in a vice.
• Unscrew the cylinder head using a hook span
ner for ring nuts. If the cylinder head is difficult
to unscrew, heat it with a flame. The cylinder
head is fixed with Loctite 243 in three points on
the perimeter.
Reassembly of the Simplex lift cylinder

erations in reverse.
[~il note
During reassembly, the cylinder head (3) should

be tightened completely after having applied
Loctite243in three points on the perimeter ofthe
thread. When finished reassembling, bleed the
hydraulic system as describedin the respective 1 Gasket
paragraph. 2 Sealing gasket
3 Cylinder head
4 bleed screw
5 O-ring
6 Piston
7 Cylinder
8 Snap ring
9 Guide bush
10 Safety valve

Disassembly of the side cylinders of the Duplex lift
Left Right
• Position the i¡ft vertically.

• Apply the handbrake.
• Operate the emergency stop switch.
Lifts 80
Lifts
• Use slings to hook the top cross traverse of the Assembly
moving mast to a crane.
• Move the distributor levers in both directions to erations in reverse.
release the pressure from the circuit.
• Disconnect the supply piping of the central j NOTE
cylinder and the bottom connections of the side
cylinders. When reassembling the adapter (1), the cylinder
• Remove the snap rings fastening the pistons head (3) and the piston (4), proceed as follows:
to the cross traverse. • Adapter (1): Tighten completely, after having
• Use a crane to raise the moving mast until ex applied Loctite 275 on the thread and Loctite
tending the pistons from the cross traverse 243 on the support surface "D".
(use a screwdriver to help, if necessary). • Cylinder head (3): Tighten completely, after
• Loosen and remove the cylinder brackets. having applied Loctite 243 in three points on
• Retrieve the cylinders. the perimeter of the thread.
• Piston (4): Tighten with a tightening torque of
1 = Adapter.
30 + 10 Nm, after having applied Loctite 275 on
2= O-ring (insert it with some grease during
the thread.
assembly).
3= Cylinder head. When finished reassembling, bleed the hydraulic
4= Piston. system as described in the respective paragraph.
5= Safety valve.
6= bleed screw.

80 li y
Disassembly of the side cylinders of the Triplex lift

Left Right

• Operate the handbrake and the emergency
stop switch.
4032804230
Lifts 80
Lifts
• Use slings to hook the top cross traverse of the 3= Cylinder head.
intermediate mast to a crane. 4= Safety valve.
• Move the distributor levers in both directions 5= Snap ring.
to release the pressure from the hydraulic sys 6= Guide ring.
tem. 7= Piston.
A= Caulk in 3 points on the perimeter.
• Disconnect the supply piping of the central
cylinder (top of side cylinder).
• Disconnect the bottom connections of the side Assembly
cylinders. Reassemble by performing the disassembly op
• Remove the snap rings fastening the side erations in reverse.
cylinder pistons to the cross traverse of the
mast. j NOTE
• Use a crane to raise the intermediate mast un
til freeing the pistons from the cross traverse (if When reassembling the adapter (1), the cylinder
they are not freed automatically, use a screw head (3) and the piston (7), proceed as follows:
driver to help). Adapter (1): Tighten completely, after having
applied Loctite 275 on the thread.
U NOTE Cylinder head (3): Tighten completely, after
having applied Loctite 243 in three points on
During this phase the inner mast, pulled by the the perimeter of the thread.
chains, will rise together with the central cylinder Piston (7): Tighten with a tightening torque of
and the fork carriage: CHECK THA T THERE /S 150 + 50 Nm, after having applied Loctite 275
NO INTERFERENCE, JAMMING OR RISK OF on the thread and on the contact surface of the
BREAKAGE! piston.
• Loosen and remove the brackets of the side When finished reassembling, bleed the hydraulic
cylinders. system as described in the respective paragraph.
• Retrieve the cylinders.
1 = Adapter.
2= O-ring (insert it with some grease during
assembly).

AO H
wV o
Duplex / Triplex central cylinder

1 Double gasket.
2 Sealing ring.
3 Bleed screw.
4 Cylinder head.
5 O-ring,
6 Plunger.
7 Cylinder.
8 Plunger piston.
9 Gasket.
10 Guide ring.
11 Safety valve.
The cylinder is a single-action cylinder (plunger

cylinder). The cylinder liner and the cylinder base
are welded. The cylinder head is screwed onto
the cylinder linerand secured with Loctite 243.
The seal between the cylinder liner and the cylin
der head is guaranteed by an O-ring. The seal
between the cylinder head and the plunger is pro
vided by the gasket 2. The limit stop is realized
by the piston screwed onto the plunger and fixed
with Loctite 275. A safety valve is screwed onto
the cylinder base and prevents the rapid and un
controlled lowering of the load in case the piping
breaks.
The intermediate cylinder is fitted with end damp

ing (holes A and B).
Disassembly of the intermediate cylinder:

- Raise the fork carriage. Hook up the fork car
riage using slings and a crane or hoist. Posi
tion a solid, stable support underneath the fork
carriage and lower it to rest on the support. Re
lease the chain.
• Operate the emergency stop button and move
the distributor levers in both directions to re
lease the pressure from the circuit.
• Disassemble the hydraulic connection from
the cylinder base.
• Disassemble the cylinder bracket.
• Extract the lift cylinder.
= Clamp the cylinder pipe in a vice positioned
near the cylinder base (so that the vice does
not deform the cylinder barrel).
• Unscrew the cylinder head using a hook span
@@ (g)
ner. If the cylinder head cannot be unscrewed,

heat it with a flame.
• Extract the plunger from the cylinder barrel.
• Ciamp the piunger in a vice using the protective
jaws and unscrew the pulley support fork. The
support fork is secured with Loctite 243.
- Extract the cylinder head from the plunger.
W31419
Workshop Jiteraiure -40328042303 EN - 05/2008

Lifts 80
Lifts
Assembly When finished reassembling, bleed the hydraulic
system as described in the respective paragraph.
Reassemble by reversing the disassembly se
quence.
j NOTE
j NOTE When replacing the set ofgaskets, do not disas

semble the plungerpiston.
To reassemble the cylinder head (4) and the pis
ton (8), proceed as follows:
Cylinder head (4): Tighten completely, after
having applied Loctite 243 in three points on
the perimeter of the thread.
Piston (8): Tighten with a tightening torque of
350 + 50 Nm, after having applied Loctite 275
on the entire surface of the thread (C).

80 Lifts
Limit stop dampers

The limit stop dampers ensure that during the Operation:
lowering of the lift, precisely during the passage
from stroke two to stroke one, with the Duplex
and Triplex lifts, the piston of the outer cylinder is
hydraulically braked right before reaching its final
position. Thus preventing a metallic impact.
VV314201
1 Plunger piston 4 Compression spring

2 Sleeve 5 Snap ring
3 Diaphragm 6 Piston
If the cylinder is supplied with oil under pressure, before the piston reaches its final position, the
during the lifting process the sleeve (2) is pushed sleeve (2) encounters the base of the cylinder.
by the spring force of the compression spring (4) The sleeve (2) is then pushed towards the piston,
towards the base of the cylinder, until the snap while the oil under pressure flows out from cham
ring (5) reaches the limit. The oil under pressure ber B into chamber A through the hole in the di
flows through the hole of the diaphragm (3) from aphragm (3). In this manner the lift is hydraulically
chamber A to chamber B, until a state of pres braked, due to the effect of this pressure compen
sure equilibrium is reached. During the lowering, sation.
40328 05/2008
Lifts 80
Disassembly of the fork carriage

• Disassemble the fork arms and any other
equipment, if applicable.
• Raise the fork carriage slightly. Rest it on a
solid, stable support.
• Completely lower the inner mast using the hy
draulic system.
• Unhook the load chains from the fork carriage.
• Remove the screw of the fork carriage retain
ing device from the inner mast.
• Pull the fork carriage up and off the inner mast.
Adjustment of the support rollers: See func 1 Safety screw to prevent the fork arms from
tional unit in the respective paragraph. slipping outwards.
Adjustment of the fork carriage retaining de 2 Safety screwto prevent the last link of the load
vice: See functional unit in the respective para chain from becoming unhooked.
graph.

Lifts
Tilt cylinder
Disassembly
Clamp the cylinder in a vice positioned near the
cylinder base. Unscrew the threaded connector
on the cylinder head side (the threaded connec
tor extends into the cylinder chamber). Remove
the protective cover (15). and push the cylinder
head (9) back slightly. Compress the snap ring
(11) through the small hole on the cylinder liner
using a plug remover, and remove the snap ring
by lifting it with a screwdriver (see figure A). Pull
hard on the piston rod to extract the cylinder head
from the cylinder.
[j] NOTE
When damping the piston rod in the vice for any

other disassembly operations, use the protective
jaws!
1 Piston locking nut. 11 Snap ring.

2 Piston locking bush. 12 Wiper.
3 Piston guide ring. 13 Hexagon head screw for clamping the eyelet
4 Piston sealing gasket. terminal.
5 Piston. 14 Eyelet terminal.
6 Piston rod. 15 Protective cover.
7 Seeger ring. C Stroke 78 - For elevation 2975 * 4030 mm.
8 Sealing ring. Cl Stroke 52 - For elevation 4450 + 6970 mm.
9 Cylinder head. L Length between the two pins.
10 O-ring.
Workshop
Lifts 80
Lifts
Assembly
Check all the parts for wear. The piston (5) is
sealed on the piston rod (6) with Loctite 270
applied on the surface A. The hexagon nut (1) or,
depending on the case, the spacer bush (2) are
secured with Loctite 270 applied on the thread B.
During assembly of the piston guide ring, the
sealing gasket and the set of gaskets for the
cylinder head, when inserting the cylinder head
into the cylinder, care must be taken so that
the compartment on the cylinder head is facing
towards the hole of the threaded connection.
During assembly, check the dimension X with the

cylinder closed!
Before proceeding with the assembly of the tilt
cylinder bolts, grease the holes in which the bolts
will be housed!
The ball joints are secured against sideslip, as
they are lodged on both sides. The ball joints are
lodged at the points marked with the arrow (figure
B).
When assembling the cylinders onto the truck,
check the contemporaneity of the limit stop and
the inclination angles as per the respective para
graph and that the dimension Y is 46 ± 8 mm.
Fig. B

80_____
Lifts
Lift disconnection
» Place the lift in the vertical position.
• ivlcve the fork carriage down tn the lower iirnit
stop.
• Remove the fork arms from the movable car
riage.
• Disconnect the batter/ socket or operate the
• Release the pressure from the cylinders (lift
and tilt cylinders as well as those of the SLI or
any other equipment) by moving the respec
tive levers of the hydraulic system distributor in
both directions several times.
> Use a crane to hook slings with a suitable lifting

capacity (check the weight of the lift) onto the
lift using the points provided.
A WARNING
To identify the sling attachment points provided on the
lift, see the Userand Maintenance Manual.
° Tension the slings.

° Remove the pins of the lift-side tilt cylinders as
indicated in the respective paragraph.
LIFT WEIGHTS
Without SLI With SLI
Elsvstion (m)
Weight (kg) Weight (kg)
3 33 360 333
3.63 377 410
Sx 4.03 400 433
4.53 438 461
5.03 467 490
n Q7E 349 382
Q O7K 366 399
Dx QQQ A -1IU
C 1I
3-wheel 3.575 T
3.975 406 433 1
4.47 471 504
4.77 487 520 1
5.22 R19 cztc 1
Tx 586 I
5.77 553
6.37 586 619
6.97 619 652
Workshop literature. 40328042303 EìM

@>________________________________________ Lifts 80
Lifts
3.33 376 409
3.63 393 426
Sx 4.03 416 449
4.53 444 477
5.03 473 506
2.975 365 398
3.275 382 415
Dx
4-wheel 3.575 399 432
3.975 422 455
4.47 487 520
4.77 503 536
5.22 528 561
Tx
5.77 569 602
6.37 602 635
6.97 635 688
These are the weights of the XE12-18 lift, request

confirmation and also the weights of the 20q ver
sion.

> Unscrew the screw (3) and free the barrels
from the support that fixes them to the lift.
> Unscrew the fixing screws (4) of the lift sup

ports.
> Raise and remove the entire lift from the truck.
Workshop Hterature. 40328042303 EN-05/2008

Lifts 80
Lifts
Lift reassembly
Follow the removal instructions in reverse, adher A WARNING

ing to the tightening torques indicated for the lift
If the lift has been replaced with another having a diffe
supports. When the operations have been com rent elevation, check that the tilt cylinders are the cor
pleted, bleed the air from the hydraulic system as rect ones by referring to the respective paragraph.
described in the respective paragraph.
j NOTE
Ifthe lift has been replaced with a different type of

lift, replace the capacityplate as well.

Air bleeding of the lift cylinders
Air bleeding for the Simplex lift
• Appiy a load on the fork arms (200 - 300 kg are
sufficient).
=> Loosen the air bleeder screw (A) located on the
top part of the lift cylinders (1/2 turn + 1 turn is
sufficient; do not over-loosen).
• Carefully move the fork arm lifting lever into the
fork arm raising position.
s Retighten the screws (A) once the air or oil
mixed with air stops coming out.
Workshop ’iterature - 403280« 3 EM-05/2008

Lifts 80
Lifts
Air bleeding for the Duplex and Triplex lifts

• Apply a load on the fork arms (200 - 300 kg are
sufficient).
• Loosen the air bleeder screw (B) located on the
top part of the side lift cylinders and the central
cylinder (it is enough to loosen the screw by 1/2
turn * 1 turn; do notover-loosen).
• Carefully move the fork arm lifting lever into the
fork arm raising position.
• Retighten the screws (B) once the air or oil
mixed with air stops coming out from the
same.
ENVIRONMENT NOTE
For disposal ofthe waste oil, abide by current re

gulations on the subject.

Lift cylinders
Right/left Simplex
1 — Apply Loctite 243
2= Air bleed screw
Workshop Hteraiure - 40328042303 EhJ - 05/2008

Lifts 80
Lifts
Left Duplex
1 = Apply Loctite 243
2= Air bleed screw
3= Apply Loctite 275

80 Lifts
Right Duplex
1-Apply Loctite 243
2= Air bleed screw
Apply Loctite 275
W31139
■’A/nrkshnn hh:'V’?L'
Lifts 80
Lifts
Central Duplex
2= Air bleed screw

80 Lifts
Lifts
Left Triplex
2= Air bleed screw
4= Caulk in 3 points
W31141
Workshop iiterature. 40328042303 EN

Lifts 80
Lifts
Right Triplex
2= Air bleed screw

80 Lifts
Central iriplex
1- Apply Loctite 243
2- Air bleed screw
3- Apply Loctite 275
W31140
Copyright by
OM Carrelli Elevatori S.p.A.
Viaie De Gasperi, 7
1-20020 Lainate
www.om-mh.com
40328042303 EN - Edition 05/2008

Workshop literature
Series 4032
XE13/3ac, XE15/3ac, XE15ac,
XE16/3ac, XE16ac, XE18/3ac,
XE18ac, XE20/3ac, XE20ac
Annex
40328042303 EN
Edition 05/2008
Diagrams A
Wiring diagrams
Electrical circuit diagram 40328020002
Workshop literature-40328042303 EN -05/2008 A-1

A
(1*) Batt.= Battery 48V (20*) I.E.= Emergency stop switch (39*) POT.3= Steering potentiometer (58*) WH= White
(2*) B.Z - Reversing buzzer ! j .f = Rotating beacon switch (40*) R.P.= Capacitor precharge resistance 180 Ohm - SOW (59*) BU= Blue
(3*) CL = Horn 48V (22*) L.A.S./D.= Left / right stop lamp 24V - 21W (41*) S.CL.= Horn suppressor 3A - 600V (60*) YE= Yellow
(4*) C.C.S.= Seat belt contact (23*) L.F.= Rotating beacon (42*) S.H.P. 1/2= Hal! probes (61*) GY= Grey
(5*) CH.= Start switch 48V (24*) L.R.S./D.= Left/right reversing lamp 24V-21W (43*) T.G. 1/2= Disconnecting switches 250A - 48V (62*) BN= Brown
(6*) D.= Distributor (25*) M.A.= Forward travel microswitch (44*) T.M.T.D./S.= Right/ left traction motor thermoswitch (63*) BK= Black
(7*) D.S.= Smart display (26*) M.F.M.= Handbrake microswitch (45*) V.P.= Panel fan 24V =18W (64*) PK= Pink
(8*) DC/DC= Voltage converter for services 48/24V -100W (27*) M.l.= Backward travel microswitch (46*) To fights converters (65*) RD= Red
(9‘) E.P.= Pump motor encoder (28*) M.P.= Pump motor 360A- 45V - 22kW (47*) Flash light variant (66*) GN= Green
(10*) E.S.F.= Fork safety electromagnetic valve (29*) M.R.= Reversing lights microswitch (48*) Flash programming (67*) VT= Violet
(11*) E.T.S./D.= Left/right traction motor encoder (30*) M.S.= Stop lights microswitch (49*) Power (68*) PIN 8 Actuation
(12*) F.C.F.= Headlight converter fuse 25A-80V (31*) M.SED.= Seat microswitch (50*) Connector "B" (69*) Connector "E"
(13*) F.CH.= Key fuse 15A- 80V (32*) M.T.D./S.= Right / left traction motor 48V-8kW (51*) Connector "A" (70*) Connector "F"
(14*) F.CL.= Hom fuse 10A - 8O’v (33*) P.CL.= Horn pushbutton (52*) Connector "C" (71*) Connector "D"
(15*) F.L.A.= Stop lights fuse 10A- 32V (34*) P.F.= Brake pedal (53*) Encoder (72*) Manual reversing lever variant.
(16*) F.L.R.= Reversing lights fuse 10A- 32V (35*) P.ID.= Hydraulically assisted steering pressure switch (54*) Manual reversing lever setup (73*) Manual reversing lever
(17*) F.P.P.= Pump motor power fuse 355A-250V (36*) P.T.= Drive pedal (55*) Drive pedal
(18*) F.P.T.= Traction motor power fuse 355A - 250V (37*) POT.1= Accelerator potentiometer (56*) OG= Orange
(19*) F.S.= Services fuse 5A - 32V (38*) POT.2= Braking potentiometer (57*) A= Azure
A-2 Workshop literature - 40328042303 EM - 05/2008

Diagrams A
Wiring diagrams
Electrical connection diagram 40328020001
(45*)
RD-YE (Cavallotto solo per
varianti da 300 e 600w senza
D.D.1 eD.D.2)
RD-YF
DC/DC1
LE (26* Carro base
BN
BK
300W
DC/DC2 (6
OG-A OG OG ARANCIO
OG(2.5) BK A AZZURRO
BK '2 51 BK WH BIANCO
Display Carro BU BLU
YE GIALLO
3now GY GRIGIO
BN MARRONE
BK NERO
PK ROSA
RD ROSSO
GN VERDE
VT VIOLA
-j Y -j Y
BN(2.5)
3N(2.5I
40328020001 - Rev 00 - 08-05-07
Workshop literature - 40328042303 EN - 05/2008 A-3

(OH)
(V) Batt.= Battery 48V (13*) I.D.F.F.= 2-way headlight flash switch (28*) L.P.P.D./S.= Right / left rear side lamp 24V - 5W (43*) GN= Green
(2*) CH.= Start switch (14*) I.D.F.L.A./P.= 2-way front / rear work light switch (29*) L.T.= Plate lamp 24V - 5W (44*) VT= Violet
(3*) D.D.1-2= Decoupling diodes 3A-600V (15*) I.F.F.= Headlight flash lightswitch (30*) M.T.= Windscreen wiper motor (45*) RD-YE (Jumper only for 300 and 600 W variants with
(4*) D.L.B.= Blinker LED diode (basic truck) (16*) I.F.L.P.= Rear work lightswitch (31*) M.V.A.= Windscreen washer motor out D.D.1 and D.D.2.)
(5*) D.L.P./A.= Side/dipped-beam lights LED diode (basic (17*) I.L.C.- Interior light switch (32*) S.T.R.= Heated seat (46*) Basic truck
truck) (18*) I.L.E.= Hazard warning lights switch (33*) OG= Orange (47*) Basic truck display
(6*) DC/DC 1 -2= Voltage converters 48/24V - 300W (19*) I.M.T.P.= Rear windscreen wipers motor switch (34*) A= Azure (48*) Flash and work light triple variant
(7*) DL.= Lights switch (20*) i.S.T.R.= Heated seat switch (35*) WH= White (49*) Heated seat variant
(8*) F.CH.= Insertion fuse (basic truck) (21*) I.T.A.= Front windscreen wipers switch (36*) BU= Blue (50*) Headlight flash double variant
(9*) F.F.= Right / left road-approved headlight flash (22*) L.A.N.D./S.= Right/left dipped beam lamp 24V - SOW (37*) YE= Yellow (51*) Flash and work lights double variant
10-100V (23*) L.C.= Interior light (38*) GY= Grey (52*) Headlight flash wired on basic truck variant
(10*) F.F.O.D./S.= Right/left road-approved headlight flash (24*) L.D. A.D./S.= Right / left front turn lamp 24V - 21W (39*) BN= Brown (53*) Steel cab variant
9/32V (25*) L.D.P.D./S.= Right / left rear turn lamp 24V - 21W (40*) BK= Black (54*) FTP and FT cab variant
(11*) F.L.A.D./S.= Right / left front work light 24V - 70W (26*) L.E.= Electronic flasher 24V - 10/100W (41*) PK= Pink (55*) Flash and work light quadruple variant
(12*) F.L.P.D./S.= Right ƒ left rear work light 24V - 70W (27*) L.P.A.D./S.= Right/left front side lamp 24V-5W (42*) RD= Red
Workshop Irteraiure. 40328042303 EN - 05/2008

Diagrams A
Hydraulic diagrams
Hydraulic diagram 40328082502
CCS o*)
(14*) (14*)
_fi—(24 *)— L_. cs CS CSL(13*)
rz4.VAU^
vbd(15*)
90
max
A3 B3
----------------- ©—(
>-----------
-i
£i
CF EF VP (9*) wj
VV\ =£= V M. □ 4 P
-4
VSI (5*)
-4 I-
.J
4 F
Z50 BAR
max
jFcin
40328082502 - Rev. 05 -16-12-07
Workshop literature -40328042303 EN -05/2008 A-5

A Diagrams
(V) CCS= Steering control cylinder (7*) M= Pump motor (13*) CSL= Side shift cylinder (19*) VS1= Steering distributorsafety valve
(2*i DS= Lift distributor (8*) PI = Hydraulic system supply pump (14*) CS= Lift cylinder (20*) VAC = Anticavitation valve
VS= Lift distributor safety valve (9*) VP= Priority valve (15*) VBD= Load descent stop valve (21*) VAU= Antishock valve
(4*) VBB= Tilt stop valve (10*) S= Oil tank (16*) VRD= Load descent metering valve (22*) VS3= Maximum-pressure valve
(5*) VSI= ISO Safety valve (11*) F= Oil filter (17*) CB= Tilt cylinder
(6*) RE= Emergency valve (12*) VS2= Safety valve (filter blockage) (18*) DCS= Steering distributor
Workshop literature. - 40328042303 EN. 05/2008

Diagrams A
Hydraulic diagrams

A-7
40328042303 EN - Edition 05/2008

Workshop Literature 4032 XE13/3ac, XE15/3ac, XE15ac, XE16/3ac, XE18ac, XE20/3ac

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Workshop Literature 4032 XE13/3ac, XE15/3ac, XE15ac, XE16/3ac, XE18ac, XE20/3ac

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Workshop literature

Alternative lift characteristics ................................................................................................ 00-29

Tyre inflation pressure ............................................................................................................ 00-31

Battery dimensions and weights............................................................................................ 00-31

Internal accessibility ............................................................................................................... 00-32

Transporting the Forklift.......................................................................................................... 00-35

Loading and unloading the truck............................................................................................ 00-37

Safety precautions ..................................................................................... 00-39

Description of safety symbols................................................................................................ 00-39

To avoid accidents................................................................................................................... 00-39

General safety Regulations ................................................................................................... 00-40

Workshop literature - 40328042303 EN - 05/2008

Synoptic Table of Maintenance Operations ................ 01-1

SupplyTable ................................. 01-2

Software ...................................... .. ........... ............................. .. 02 2

Description ofthe TESTER menu ................. 02-12

Parameters ....................................................... 02-16

Parameters ofthe DUAL AC module........................................................................................02-16

Parameters ofthe ECO DISPLAY module ..................................................................... 02-25

Parameterisation ofthe steering function ............................................ 02-30

Parameterisation ofthe electric braking function ............................................................... 02-31

Parameterisation ofthe hydrauiicaiiy assisted steering function..................................... 02-33

Alarms ........................................................... 02-35

Alarms list ......... 02-37

Analogue signals ..................................... 02-52

Summary of signals from the analogue transducers ................................................... 02-52

Workshop literature. 40328042303 EN.. 05/2008

Checking the asynchronous motors ....................................................................................... 11-4

Front axle motors ......................................................................................... 11-6

Traction motortechnical data ................................................................................................... 11-6

Temperature sensor KTY84................................................................................................... 11-16

Insulation testing of traction motor ....................................................................................... 11-18

Reducer gearbox ......................................................................................... 22-8

Reducer gearbox oil change ................................................................................................ 22-14

Counterweight reassembly ..................................................................................................... 31-6

Covers ......................................................................................................... 31-8

Side covers removal / reassembly ......................................................................................... 31-9

Step plate removal/reassembly.............................................................................................. 31-12

Workshop literature - 40328042303 EN - 05/2008

Distributor cover removal / reassembly ........... 31-14

Batteries . .............................. 31-17

Battery removal ..................................... 31-17

Fairings . .................. 34-4

Steering distributor pressure switch technical data .............................. .. 42-5

Steering column ............................................................... 42-7

Steering axle .............. . ................................. . . ...................... . ............... 42-11

Three-wheel truck axle removal ........................................................................................... 42-14

Three-wheel axle disassembly .............. ................... 42-19

Four-wheel truck axle technical data.................................................................................... 42-26

Four-wheel axle removal .......................................................... 42-27

Four-wheel truck axle reassembly . . 42-28

Four-wheel truck potentiometer technical data ................................................................. 42 35

Lubricating the steering axle ..................................................... 42-41

46 Wheels and tyres

IV Workshop literature. 40328042303 EN.. Ob/2008

General information for changing tyres ................................................................................... 46-2

Wheel change .............................................................................................. 46-4

Wheel change ............................................................................................................................. 46-4

Wheel decomposition .................................................................................. 46-7

Disassembly/assembly of tyres on rims with movable flange ............................................. 46-7

Tightening torques ..................................................................................... 46-12

Replacing the parking brake microswitch .............................................................................. 49-5

Parking brake adjustment ....................................................................................................... 49-7