BT Forklift C3E150 C3E200 C4E150 C4E200 Repair Manual 036 0437 00 (251 400)

4-63
3A SAFETY OUTPUT - NOT USED
3B SLIP PROFILE
Condition for error detection

Error in the memory data where the flowing parameters are loaded.
RESET the lifting logic unit to re-load the default parameters.
0
If the error persists when the machine is switched back on, install the last version of the software using
the programmer. 1
If the problem persists replace the logic unit.
2
3C ANALOG INPUT
3
Condition for error detection 4
Control internal error.
• check the tuck and motor insulation (INSULATION CONTROL PROCEDURE and MOTOR WINDING 3
CONTROL PROCEDURE)
• check the connections and wiring harnesses 6
• check the sensors and potentiometers connected to the logic unit
Replace the logic unit. 7
3D HARDWARE FAULT 8
Control internal error. 10
• check the tuck and motor insulation (INSULATION CONTROL PROCEDURE and MOTOR WINDING
CONTROL PROCEDURE)
• check the connections and wiring harnesses 11
• check the sensors and potentiometers connected to the logic unit
13
14
15
16
17
18
4-64
M
3E POWER MOS SHORTED

The alarm signals a power circuit failure.
Verify the correct connection of the motor to the logic:
• One or more motor phases could be disconnected
• Power cables connection
• Truck insulation and motor state see paragraph INSULATION CONTROL PROCEDURE and MOTOR
WINDING CONTROL PROCEDURE)
• Continuity values obtained directly on the control, with disconnected power cables:
Values on control with disconnected motor

Red cap Black cap Resistance
If an open circuit is detected, replace the logic unit
If there are no problems on the motor or the cables replace the logic unit
3F FLASH CHECKSUM

• Restore the default parameters using the RESET lifting logic unit function
• If the error persists when the machine is switched back on, install the last version of the software using
the programmer.
• If the defect persists when the machine is switched on again, replace the lifting logic unit.
4A SOFTWARE ERROR

Error in the memory data where the flowing parameters are loaded.
RESET the lifting logic unit to re-load the default parameters.
• If the error persists when the machine is switched back on, install the last version of the software using
the programmer.
• If the problem persists replace the lifting logic unit.
4-65
4B THERMIC MOT KO

Interrupted or disconnected motor temperature sensor.
Verify:
- The state of the wiring harness and the temperature sensor connector
- Connect a 600 ohm resistance to the sensor connector: 0
• If the alarm disappears, replace the temperature sensor
• If the alarm persists replace the logic unit.
1
4C ENCODER LOCK 2
Interrupted or disconnected motor encoder.
The alarm appears after 10 seconds approximately with the accelerator pedal pressed. 4
The machine works at reduced speed and at maximum current.
Check the encoder status. 3
Disconnect the hydraulic pump and check if it is blocked
6
Encoder basic electric diagram.
The figure shows only one signal (A).
The encoders used generate two equal signals,
7
with a 90° difference (A-B).
1. Connect the tester positive point (red) to the 8
encoder positive terminal.
14.Connect the tester COM point (black) to the 9
encoder signal (A).
According to the engine position, the following 10
values will be displayed:
• low signal: 0.5 -- 1.5 Volt
• high signal: 10.5 -- 11.5 Volt
11
Intermediate values cannot be read as the motor 12
is stopped.
If the motor is working, the multimeter will
automatically read the Mv (medium value)
13
Mv= 5,5 - 6,5 Volt 14
Carrying out this test directly on the logic
connectors it is possible to determine if the 15
signals are good (see upper description) or if the
channels are opened or in short circuit. If the
signals are good, the problem should be
16
attributed to the logic unit.
17
18
4D UNUSED
4-66
4E CONTACTOR CLOSED

K1 contactor driver failure. The logic unit cuts the current to the coil, but the controls remain closed.
Disconnect the battery and check:
- The K1 contactor windings and the relevant wiring harness
- Clean the contactor connections
- Check the control of the contactor directly on connector P3 pins 16 and 17 of the logic unit
- Invert the connections between K1 and K2:
• If alarm 19 occurs replace the contactor K1
• If alarm 49 appears, replace the logic unit
Reference wiring diagram page 2/7 (chapter 17, section WIRING DIAGRAMS)
4F IQ MISMATCHED

Verify:
- Presence of others alarms
- Check the tuck and motor insulation (INSULATION CONTROL PROCEDURE and MOTOR WINDING
CONTROL PROCEDURE)
- Update the logic unit to the latest version of the software via the PROGRAMMER
- Replace the logic unit
5A CHOPPER NOT CONF - UNUSED
5B STEER WIRE KO - NOT USED
5C GAIN ACQUISITION

This warning communicates that the logic is in current acquisition phase.
In this phase the logic doesn't work.
Reset the lifting logic unit with the RESET function and repeat all acquisitions.
Update the logic unit to the latest version of the software via the PROGRAMMER and repeat all acquisi-
tions
If the alarm persists replace the logic unit
4-67
5D WRONG 0 VOLT

• check the tuck and motor insulation (INSULATION CONTROL PROCEDURE and MOTOR WINDING
CONTROL PROCEDURE)
• check the power circuit and the battery 0
• check the connections and wiring harnesses
• check the sensors and potentiometers connected to the logic unit. 1
• Replace the logic unit.
2
5E HANDBRAKE - NOT USED
3
5F WRONG RAM MEMORY 4
3
Activated protection against the electrostatic charges. 6
Switch the machine off and back on again.
7
8
9
10
11
12
13
14
15
16
17
18
4-68
MCB CONTROL BOARD (section EVCB)

A1 DOUBLE REQ - NOT USED
A2 RELOAD_PARAM_WARN

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

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

The alarm signals that the MCB board is waiting informations. The truck remains in pre-operational
status.
- Insert truck serial number (function LEARNING parameter SERIAL NUMBER)
- Repeat the accelerator and lifting potentiometers acquisitions (only with mechanical
control valve): LEARNING function
Switch off and switch on again the truck.
A5 CHKSUM_ERROR - NOT USED
A6 BOOT_ERROR

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

The alarm signals an internal problem of the MCB board.
- Replace the MCB board.
0
A8 EV1_1 OPEN
1
The alarm signals a failure at the coil of the PE02 (EVP1) lowering solenoid valve. The coil could be
opened or disconnected. 3
Check:
- Value in Ohm of the coils and the relevant wiring harness .
If the problem persists replace the MCB board.
4
3
A9 EV2_1 OPEN
6
The alarm signals a failure at the coil of the PE01 lifting solenoid valve. The coil could be opened or
disconnected. 8
Check:
- Value in Ohm of the coils and the relevant wiring harness. 9
10
AA EV1_2 OPEN 11

12
The alarm signals a failure at the coil of the PE03 (EVP3) backward tilting solenoid valve. The coil could 13
be opened or disconnected.
Check: 14
- Value in Ohm of the coils and the relevant wiring harness.
15
16
17
18
4-70
AB EV2_2 OPEN

The alarm signals a failure at the coil of the PE04 forward tilting solenoid valve. The coil could be opened
or disconnected.
Check:
AC EV1_3 OPEN

The alarm signals a failure at the coil of the PE06 right sideshift solenoid valve. The coil could be opened
or disconnected.
Check:
AD EV2_3 OPEN

The alarm signals a failure at the coil of the PE05 left sideshift solenoid valve. The coil could be opened
or disconnected.
Check:
AE EV1_4 OPEN

The alarm signals a failure at the coil of the PE07 4th way solenoid valve. The coil could be opened or
disconnected.
Check:
4-71
AF EV2_4 OPEN

The alarm signals a failure at the coil of the PE08 4th way solenoid valve. The coil could be opened or
disconnected.
Check:
- Value in Ohm of the coils and the relevant wiring harness. 0
1
B0 TRCB_MICRO_ERROR 2

3
The alarm signals an internal problem of the MCB board. 4
- Replace the MCB board.
3
B1 GROUP1 DRIVER SHORT 6
7
The alarm signals a failure at one of the coils of the group 1 of the electro-proportional distributor: PE02 8
lowering solenoid valve or PE01 lifting solenoid valve.
A coil could be opened or disconnected.
Check:
9
If the problem persists replace the MCB board. 10
11
B2 GROUP2 DRIVER SHORT
12
The alarm signals a failure at one of the coils of the group 2 of the electro-proportional distributor: PE03
backward tilting solenoid valve or PE04 forward tilting solenoid valve. 14
Check:
15
16
17
18
4-72

right sideshift solenoid valve or PE05 left sideshift solenoid valve.
Check:

4th way solenoid valve or PE08 4th way solenoid valve.
Check:
B5 AUX_OUT_SHORT

The alarm signals a failure at one of the coils of the group 5 of the electro-proportional distributor: EVP9
5th way solenoid valve or EVP10 5th way solenoid valve.
Check:
B6 DASH_KO

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

The alarm signals the seat micro opened with activated hydraulic functions.
B8 JOY_STUFFING_ERR 0
1
The alarm signals a communication problem between the MCB board and the joystick board.
2
Use the RESET JOY FLAG function for re-establish the communication between the cards; if the
problem persists, verify: 3
- The can-bus connections between the MCB board and the joystick board
- Joystick board supplying (JCAN connector pin 5 cable M and pin 6 cable N) 4
- Replace the joystick card
3
B9 SET_SERIAL_NUMBER 6
7
The alarm signals the failed automatic serial number setting. 8
- Insert truck serial number (function LEARNING parameter SERIAL NUMBER)
Switch off and switch on again the truck.
9
BA POT TILT NOT OK 10
11
The alarm signals an incorrect reading of the voltage of the tilting potentiometer (optional):
12
- Repeat the tilting potentiometer acquisition
-If the alarm persists, check the potentiometer status and the relevant wiring harness. 13
14
E1 INCORRECT_START
15
Incorrect start sequence (mechanical control valve version). Check:
- The forward and reverse microswitches and their respective cables 17
- The parking brake microswitch and its respective cables
- The mechanic distributor microswitches 18
4-74
E2 BAD LIFT POT

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

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

The logic unit does not receive the information from the lifting logic unit.
If the armrest is present, the alarm is sent by the armrest board.
4-75
DASHBOARD
D1 TRAC_KO

Can-bus communication failure. The alarm appears if the display does not receive information from the
MASTER traction logic unit. 0
Before replacing any board:
- Check if the board is powered
- Enter the SOFT VERS menu to see which card is not present on the can-bus line
1
- Can-bus pull-up resistance presence
• Instrument panel 180 Ohm 2
• MCB 180 Ohm
• Arm rest 180 Ohm 3
- Check the connections, pins and wiring harness on the can-bus
See paragraph SYSTEM CONFIGURATION WITH MECHANICAL/ELECTRIC DISTRIBUTOR 4
D2 MCB_TRAC_KO 3
6
7
MCB board.
Before replacing any board: 8
- Enter the SOFT VERS menu to see which card is not present on the can-bus line 9
• MCB 180 Ohm
• Arm rest 180 Ohm
- Check the connections, pins and wiring harness on the can-bus 11
See paragraph SYSTEM CONFIGURATION WITH MECHANICAL/ELECTRIC DISTRIBUTOR
12
D3 SLAVE_KO 13
SLAVE traction logic unit.
15
- Check if the board is powered 16
- Can-bus pull-up resistance presence 17
• Instrument panel 180 Ohm
• MCB 180 Ohm 18
4-76
D4 PUMP_KO

Lifting logic unit.
• MCB 180 Ohm
D5 MCB_MHY_KO

MCB board.
• MCB 180 Ohm
D6 JOY_KO

Arm rest board.
• MCB 180 Ohm
4-77
D7 BRAKE LEVEL

Brakes oil level low.
Check the wiring harness and the microswitch on the brake oil tank
0
D8 ERROR_READ_PIN_CODE 1

2
Configuration error between the I/O card and the instrument panel 3
If the key reset does not eliminate the alarm:
• RESET the instrument panel and the MCB card 4
• Install the latest version of the software via the PROGRAMMER
3
D9 DHU KO
6
DHU board. 8
- Check if the board is powered 9
• MCB 180 Ohm
11
12
DA SHOCK LOCKOUT 13
14
Can-bus communication failure. The alarm appears if the display does not receive information from the 15
SHOCK SENSOR.
Before replacing any board: 16
17
• MCB 180 Ohm
• Arm rest 180 Ohm 18
4-78
BOM UNUSED
DC UNUSED
DD UNUSED
DE KEY ERROR

- Check the voltage at the key output (pin 5, connector 137, cable M: there must be battery voltage)
- Verify the correct connection of the pin 5, cable M of the connector J137
DF EEPROM ERROR

Instrument panel memory failure.
Before replacing the instrument panel carry out the following operations:
• Reset the instrument panel using the key reset
• Clear the logbook of error codes
• RESET the instrument panel
Install the latest version of the software via the PROGRAMMER
4-79
MCB CONTROL BOARD (section TRCB)

C1 PUMP INCORRECT START

Incorrect start sequence (mechanical control valve version). Check:
- The forward and reverse microswitches and their respective cables 0
- The parking brake microswitch and its respective cables
- The mechanic distributor microswitches
1
C2 BAD_CONF_WHEELS 2
3
This alarm signals an error in the 3-4 wheels configuration identification.
4
The hardware and software configuration must respect what following:
3
3 WHEELS CONFIGURATIONS
Hardware: bridge on the J135 connector not present (see MCB connector P4 pin 17)
Software: 3W (see menu TRUCK CONF -> OPTIONS parameter STEER TABLE)
6
4 WHEELS CONFIGURATIONS 7
Hardware: bridge on the J135 connector present (see MCB connector P4 pin 17)
Software: 4W (see menu TRUCK CONF -> OPTIONS parameter STEER TABLE)
8
The alarm does not block the truck, but the management of the elctric differential gear and of the speed
reduction in turn are altered. 9
C3 PEDAL WIRE KO
10
11
12
Failure on the acceleration potentiometer signal at rest. Check:
- Steering potentiometer that could be damaged
- The traction potentiometer wiring harness
13
14
C4 BAD MICROSWITCH
15
Microswitch of the pedal or of the hand direction lever damaged.
17
C5 WARN_CONF_ERROR - NOT USED 18
4-80
C6 BAD_VACC

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

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

The brake pedal microswitch is broken or sticked.
C9 PARKING_SELECTED

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

The alarm appears when the truck is switched on or if the change
program button is pressed.
Reset the MCB card (TRCB) in the RESET menu and repeat the acquisitions see chapter 02 (Adjust-
ments required after replacing a hardware component)
Replace the MCB logic unit.
CB UNUSED
4-81
CC TRAC_STUFFING_ERROR

Problem of communication with the Master traction logic unit.
The alarm disappears after the key reset.
If the alarm appears frequently and blocks the truck, check the can-bus connections between the Master
logic unit and MCB. 0
1
CD BRAKE WIRE KO
2
Failure at the brake potentiometer at rest. Check:
- Brake potentiometer could be damaged 4
- The brake potentiometer wiring harness
3
CE BRAKE BAD VACC 6
7
The alarm signals an incorrect voltage reading of the brake potentiometer: 8
- Repeat the brake potentiometer acquisition (function LEARNING parameter LEARN BRK POT)
-If the alarm persists, check the potentiometer status and the relevant wiring harness.
9
90 UNUSED 10
11
91 UNUSED
12
92 UNUSED 13
93 UNUSED
14
15
94 CHKSUM_ERROR
16
Software error.
18
Replace the MCB logic unit.
4-82
ARMREST CARD
E1 INCORRECT_START

Logic unit incorrect starting procedure.
- Check if one of the potentiometers is activated before to pass the key on ON
- Verify by dashboard
Enter the function TESTER menu MAT HANDLING and verify the potentiometer status at rest condition
IN1 1 (LIFTING SWITCH) = OFF
IN2 1 (TILTING SWITCH) = OFF
IN3 1 (SIDESHIFT SWITCH) = OFF
IN4 1 I(V WAY SWITCH) = OFF
IN5 1 (V WAY SWITCH) = OFF
LIFT LOWER J = 2,5 ± 0,2 V
TILT J = 2,5 ± 0,2 V
SIDESHIFT J = 2,5 ± 0,2 V
IV WAY J = 2,5 ± 0,2 V
V WAY J = 2,5 ± 0,2 V
Once identified the potentiometer with the different values proceed as follows:
• reverse the potentiometer with one other potentiometer on the board(fingertips version)
• exchange the lifting potentiometer with the sideshift potentiometer or the tilting potentiometer with the
4th way potentiometer (joystick version)
- If the alarm persists in the same position, replace the board.
If the problem appears on a different potentiometer (according to where the defective potentiometer has
been connected) replace the potentiometer
E2 BAD LIFT POT

Failure at the RP1 lifting potentiometer in the joystick-fingertip group.
Check the voltages on the potentiometer at rest
Enter the function TESTER menu MAT HANDLING and verify the parameters IN1 1(LIFTING SWITCH)
and LIFT LOWER J.
Conditions of rest:
- LIFT LOWER J = 2,5 ± 0,2 V
- IN1 1(LIFTING SWITCH) = OFF
If the conditions of rest are different the potentiometer could be mechanically jammed or defective.
Check:
• exchange the lifting potentiometer with the tilting potentiometer (fingertips version) and verify the
correct operation through console
• exchange the lifting potentiometer with the sideshift potentiometer (joystick version) and verify the
If the alarm persists replace the logic unit.
4-83
E3 BAD TILT POT

Failure on the RP2 tilting potentiometer in the fingertips / joysticks group.
Enter the function TESTER menu MAT HANDLING and verify the parameters IN2 1(TILTING SWITCH)
and TILT J. 0
Conditions of rest:
- TILT J = 2,5 ± 0,2 V
- IN2 1(TILTING SWITCH) = OFF
1
If the conditions of rest are different the potentiometer could be mechanically jammed or defective. 2
Check:
• exchange the tilting potentiometer with the lifting potentiometer (fingertips version) and verify the
3
• exchange the tilting potentiometer with the 4th way potentiometer (joystick version) and verify the
correct operation through console 4
3
E4 BAD SIDESH. POT
6
7
Failure at the RP3 sideshift potentiometer in the joystick-fingertip group. 8
Enter the function TESTER menu MAT HANDLING and verify the parameters IN3 1(SIDESHIFT 9
SWITCH) and SIDESHIFT J.
Conditions of rest:
- SIDESHIFT J = 2,5 ± 0,2 V
10
- IN3 1(SIDESHIFT SWITCH) = OFF
11
Check:
• exchange the sideshift potentiometer with the tilting potentiometer (fingertips version) and verify the
12
• exchange the sideshift potentiometer with the lifting potentiometer (joystick version) and verify the 13
14
15
16
17
18
4-84
E5 BAD IV POT

Failure at the RP4 4th way potentiometer in the joystick-fingertip group.
Enter the function TESTER menu MAT HANDLING and verify the parameters IN4 1(IV WAY SWITCH)
and IV WAY J.
Conditions of rest:
- IV WAY J = 2,5 ± 0,2 V
- IN4 1(IV WAY SWITCH) = OFF
Check:
• exchange the 4th way potentiometer with the sideshift potentiometer (fingertips version) and verify the
• exchange the 4th way potentiometer with the tilting potentiometer (joystick version) and verify the
E6 BAD V POT

Failure at the 5th way potentiometer (optional) in the joystick-fingertip group.
Enter the function TESTER menu MAT HANDLING and verify the parameters IN5 1(V WAY SWITCH)
and V WAY J.
Conditions of rest:
- V WAY J = 2,5 ± 0,2 V
- IN5 1(V WAY SWITCH) = OFF
Check:
• exchange the 5th way potentiometer with the 4th way potentiometer
E7 ERR_SEAT

The alarm signals the seat micro opened with activated hydraulic functions.
Verify the seat micro status.
4-85
E8 INVALID RESTORE STATE

Incomplete restore of the parameters. Repeat the operation.
E9 EEPROM_CHKSUM_ERR 0
Eeprom data loading unsuccessful.
If the alarm persists at the key reset,
2
EA DEFAULT RESTORED
4
3
Flash memory data loading. Switch off and switch off again the truck.
6
7
EB POT NOT ACQUIRED
8
9
Flash memory data loading. Switch off and switch off again the truck.
10
EC RAM_CHKSUM_ERR
11
12
RAM data loading unsuccessful.
If the alarm persists at the key reset, 13
Replace the logic unit.
14
ED MHYRIO_STUFFING_ERR 15
The logic unit has a communication problem with the EVCB (MCB) unit. 17
Check on the dashboard others alarms.
18
4-86
EE PUMP STUFFING ERROR

The logic unit does not receive the information from the lifting logic unit.
If the armrest is not present, the alarm is send by the MCB control board.
EF FW + BW - NOT USED
F1 LIGHT SHORTED

The alarm appears when a short circuit is triggered on the horn or lighting system (except rotary lamp).
Check the dashboard or the relative wiring harness
5-1
MOTOR
Page
DRIVE MOTOR ............................................................ 5-2
0
GENERAL ...............................................................................5-2
ENCODER REPLACING.........................................................5-8
1
ENCODER ................................................................... 5-9 2
TEMPERATURE SENSOR REPLACING .................. 5-10 3
PUMP MOTORS ........................................................ 5-11 4
GENERAL .............................................................................5-11
5
TEMPERATURE SENSOR REPLACING .................. 5-15
6
ENCODER REPLACING.......................................................5-16
7
ENCODER ................................................................. 5-17
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
5-2
DRIVE MOTOR
GENERAL
SPECIFICATIONS
DRIVE MOTOR
VOLTAGE 32 Vac
POWER 6 kW
CURRENT 152 A
FREQUENCY 70 Hz
SPEED 2045 rpm
FACTOR POWER (cosφ) 0.79
EFFICIENCY (η) 87.0 %
DEGREE OF PROTECTION (IP CODE) IP 20
METHOD OF COOLING (IC CLASS) IC 00
SERVICE S2-60 min
TYPE OF CONNECTION Δ
ENCODER(Imp\Turn) 64
NUMBER OF POLES 4
5-3
COMPONENTS
2
2
2
3
5
5
6
7
8
9
1 Motor de tracción 8 Central body
2 Seal 9 Washer 10
3 Plate (shhet of metal) 10 Turn sensor
4 Snap ring 11 Wheel sensor 11
5 Ring 12 Cover
6 Snap ring 13 Temperature sensor 12
7 Pad
13
14
15
16
17
18
18
18
18
18
18
5-4
REMOVAL • INSTALLATION
24 Nm ± 15%
15 Nm +/- 10%
Disassembly Procedure
1.Park the vehicle on a level surface and apply the parking brake
2.Tilt backward until the end stroke and place 2 wooden or metal blocks under the mast
3.Tilt the mast forward until the end stroke
4.Switch off the truck
5.Open the compartment and disconnect the battery
6.Remove the footboard
7.Disconnect the temperature sensor wiring, the encoder wiring, the electric brake wiring and the motor
power cables [Point 1]
8.Disconnect the wirings of the braking system [Point 2]
9.Remove the wheel [Point 3]
10.Remove the oil from the reduction gears [Point 4]
11.Remove the complete gearmotor [Point 5]
12.Remove the motor [Point 6]
13.Remove the pinion [Point 7]
Assembly procedure
The reassembly procedure is the reverse of the disassembly procedure.
5-5
Point Operation
[Point 1]
A Disassembly: 2
C Disconnect the temperature sensor and encoder
wiring harness (A), the electric brake wiring (C) and 2
the power cables of the motor (B)
B Assembly: 2
Power cable W connected to phase W
Power cable V connected to phase V 3
Power cable U connected to phase U
Tightening torque of the cables 15 Nm 5
5
[Point 2]
Disassembly: 6
Disconnect the pipes from the braking system (D)
ATENCIÓN:
7
When brake system hose is disconnected, the brake
fluid (type DOT 4) will leak 8
D 9
10
[Point 3] 11
Disassembly:
Remove the wheel
12
Assembly:
After installation, tightening torque of the wheel bolts = 13
140 Nm.
14
15
16
17
18
18
18
18
18
18
5-6
[Point 4]
Disassembly:
Carefully clean the area around the oil filler (E) and
drain caps (F); place a container under the drain cap
E and remove both caps to allow all oil to flow out.
Clean any residues from the cap (F) and put it back on
Assembly:
Pour fresh oil into the hole (E) until it starts overflowing
(Q.ty about 0.35 liters) then put the cap back on.
When filling is complete, clean any overflow; after a
F short functioning period, check the oil level again
Maintenance:
After the first 40 hours of operation
- change the oil
Every 1000 hours
- take off the front wheels, check the oil level, cold, with the
truck on a level surface and top up if needed; use
transmission oil such as ATF Dexron II or equivalent; the
correct level is obtained when the oil starts to escape from
the holes (E);
- check there are no oil leakages
- check that all screws on the unit are tight
Every 2000 hours
- change the oil
Remarks:
• For a better oil outflow, it is better to empty the
reduction gears after a few turns of heating, moving
the truck for a few minutes;
• To compromise a good reduction gears running
don't insert more oil than the necessary.
5-7
[Point 5]
Disassembly:
G Remove the fixing screws (G) of the motor reduction
gear and insert a M14 bar (H) in the hole 2
2
G
2
3
Remove the remaining 6 fixing screws and extract the 5
motor reduction gear as shown in the picture
Assembly: 5
H
After installation, tightening torque of fixing screws
= 130 Nm 6
Remarks: 7
Use Loctite 243
8
9
[Point 6]
Disassembly: 10
Remove the 3 fixing screws (I) and extract the motor
Assembly:
11
I After installation, tightening torque of fixing screws
= 23 Nm 12
13
14
15
[Point 7]
16
L
Disassembly:
Mount the seal (M) 17
Remove the pinion (N) using an extractor separator
Assembly: 18
Insert the tongue (L) in the right place.
M Insert the pinion (N) and tighten the seal (M) to a 18
tightening torque of 55 Nm
Remarks: 18
In case of complete reduction gear substitution,
replace the pinion also 18
N
18
18
5-8
ENCODER REPLACING
0.8 ÷ 0.3 mm
Dismantling procedure
3.Open the battery cover, disconnect the battery and remove it
5.Disconnect the encoder connector from the auxiliary wiring
6.Disconnect the electric brake connector from the auxiliary wiring
7.Remove the 3 fixing screws from the electric brake
8.Remove the electric brake from the motor shaft
9.Unscrew the encoder A from its seat
Assembly procedure
5-9
ENCODER
The encoder generates a feedback signal from the motor and sends it to the command logic to monitor:
motor status, rpm and direction of rotation. 2
The encoder is positioned in the back part of the motor.
2
Irreversible damage:
• +V > 13 Volts
2
• Short circuit between the signal and the power supply
• Heating by induction 3
• Assembly with hammer
5
0.8 ÷ 0.3 mm
5
6
7
Direction of the gear wheel motion
in FW march
8
Channel image on oscilloskope:

9
FW march 10
11
12
BW march
13
14
15
Time
16
Channel B / Wire:white
Channel A / Wire:yellow 17
18
18
18
18
18
18
5-10
TEMPERATURE SENSOR REPLACING
5.Cut damaged sensor wiring near the motor carcass [Point 1]
Assembly procedure
1.Place the new sensor on the coil of the motor and secure it with silicone paste (see Service Tools List)
2.Connect it to the wiring harness
Point Operation
[Point 1]
Disassembly:
Cut the sensor cabling (A)
A
5-11
PUMP MOTORS
GENERAL
2
2
2
3
5
5
6
7
SPECIFICATIONS
8
LIFTING MOTOR
9
VOLTAGE 30 Vac
POWER 15.8 kW
10
CURRENT 284 A 11
FREQUENCY 80 Hz
12
SPEED 2314 rpm
FACTOR POWER 0.83

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

2 Seal 7 Pad
3 Plate (shhet of metal) 8 Central body
4 Temperature sensor 9 Washer
5 Cover 10 Turn sensor
5-13
15 Nm ± 10% 2
2
2
3
5
5
15 Nm ± 10%
6
45 Nm ± 5%
7
Dismantling procedure 8
2.Switch off the truck 9
4.Remove the battery 10
5.Disconnect the temperature sensor wiring, the encoder wiring, and the motor power cables [Point 1]
6.Remove the pump motor fixing screws [Point 2] 11
7.Remove the bolts of the motor [Point 3]
8.Lift and remove the motor
12
Assembly procedure
The reassembly procedure is the reverse of the disassembly procedure, taking care that the motor 13
cables are fitted correctly as illustrated below:
14
• Power cable W connected to phase W
• Power cable U connected to phase U 15
• Power cable V connected to phase V
16
17
18
18
18
18
18
18
5-14
Point Operation
[Point 1]
B Disassembly:
Disconnect the temperature sensor wiring harness (A),
A the encoder wiring (B) and the motor power cables (C)
[Point 2]
Disassembly:
Remove the two pump fixing nuts (D).
Assembly:
After the installation, pump fixing bolts tightening
torque = 45 ± 5 Nm
D
D
[Point 3]
Disassembly:
Remove the motor fixing screws from the chassis (E)
E E
5-15
TEMPERATURE SENSOR REPLACING
1.Park the vehicle on a level surface and apply the parking
brake 2
2.Turn off the truck
5.Cut damaged sensor wiring near the motor carcass
3
5
5
A Assembly procedure 6
1.Position the new sensor (A) on the coil of the motor and
secure it with silicone paste (see Service Tools List)
7
2.Connect it to the wiring harness
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
5-16
ENCODER REPLACING
3.Open the battery cover and remove the battery
5.Disconnect the encoder connector A from the auxiliary wiring
6.Remove the fixing screws B from the cover
7.Unscrew the encoder C from its seat
Assembly procedure
5-17
ENCODER
The encoder generates a feedback signal from the motor and sends it to the command logic to monitor:
motor status, rpm and direction of rotation.
2
The encoder is positioned in the back part of the motor.
2
Irreversible damage: 2
• + V > 13 Volts
• Short circuit between the signal and the power supply 3
• Heating by induction
• Assembly with hammer 5
0.8 ÷ 0.3 mm
5
6
7
Direction of the gear wheel motion
in FW march
8
9
Channel image on oscilloskope: 10
FW march
11
12
BW march
13
14
15
Time
16
Channel B / Wire:white 17
Channel A / Wire:yellow
18
18
18
18
18
18
5-18
6-1
DRIVE UNIT & FRONT AXLE

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

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

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

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

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

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

The adjustment of the limit switch steering angle is possible only in 4 wheels version.
7-5
2
2
2
3
4
5
6
7
8
9
1.Park the vehicle on a level surface and apply the parking brake 10
3.Open the compartment and disconnect the battery 11
4.Remove the battery
5.Jack up the back part of the vehicle and position apposite blocks under the chassis [Point 1] 12
6.Remove the boot
7.Remove the counterweight (*)
8.Disconnect the wiring of the potentiometer [Point 2]
13
9.Disconnect the cylinder pipes of the steering axle
10.Loosen and remove the fixing screws [Point 3] 14
11.Remove the steering axle
Assembly procedure
15
16
(*)Warning:
Always make sure to lock temporaly the overhead guard before remove the counterweight 17
18
18
18
18
18
18
7-6
Point Operation
[Point 1]
Disassembly:
Jack up the back part of the vehicle and position
apposite blocks under the chassis
A [Point 2]
Disassembly:
Disconnect the wiring of the potentiometer (A)
[Point 3]
Disassembly:
Loosen and remove the 5 steering axle fixing screws
Assembly:
After installation, tightening torque for the 5 screws =
240 Nm
Remarks:
Use Loctite 243
7-7
BEARING ADJUSTMENT
Steering wheel bearings require an adjustment once a year.
2
2
2
4 3
4
5
2
5
1 6
3 7
8
9
10
11
12
13
Steering wheels
• lift the steering wheels; 14
• remove cap (1);
• tighten the ring nut (3) with a torque=6 daNm
• turn the hub by 2-3 turns in both directions;
15
• loosen the ring nuts (3) and retighten with tightening torque 2-1 daNm;
• check that the wheels turn smoothly (max. rolling final torque:0.2 daNm) and that there is no side 16
clearance (maximum axial clearance of 0.05 mm);
• reassemble the cap (1); 17
• lower the wheels again and check that all nuts (5) fixing the wheel rim (4) to hub (2) are well tightened.
18
18
18
18
18
18
7-8
REAR AXLE (4 wheels)

GENERAL
7-9
COMPONENTS
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1 Axle 9 Support 17 Grease nipple 18
2 Cover 10 Axle support 18 Seal
3 Steering potentiometer 11 Plate 19 Pad 18
4 Shaft 12 Cylinder 20 Wheel hub
5 Plug 13 Plug 21 Pad 18
6 Flange 14 Dowel pin 22 Nut
7 Bolt 15 Nut 23 Cover 18
8 Cover 16 Spacer 24 Split pin
18
7-10
CONTROL OF REAR AXLE

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

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

2
2
3
4
5
6
7
8
10
5.Jack up the back part of the vehicle and position apposite blocks under the chassis [Point 1]
6.Disconnect the steering axle cylinder lines [Point 2] 12
7.Disconnect the wiring of the potentiometer [Point 3]
8.Keep the steering axle raised with a pallet truck [Point 4]
9.Loosen and remove the fixing screws [Point 5]
13
10.Remove the steering axle
14
Assembly procedure
The reassembly procedure is the reverse of the disassembly procedure. 15
Point Operation 16
[Point 1]
Disassembly:
17
Jack up the back part of the vehicle and position
apposite blocks under the chassis 18
18
18
18
18
18
7-12
[Point 2]
Disassembly:
Disconnect the steering axle cylinder hoses (A) (one
per side)
A
[Point 3]
Disassembly:
Disconnect the wiring of the potentiometer (B)
B
[Point 4]
Disassembly:
Position a trans-pallet under the steering axle
[Point 5]
Disassembly:
C Loosen and remove the 4 steering axle fixing screws
(C)
Assembly:
After installation, tightening torque for the 4 screws =
200 Nm
7-13
BEARING ADJUSTMENT
Steering wheel bearings require an adjustment once a year.
2
2
2
4
3
5 4
2 5
1 6
3 7
8
9
10
11
12
Steering wheels 13
• lift the steering wheels;
•
•
remove cap (1);
tighten the ring nut (3) with a torque=6 daNm
14
• turn the hub by 2-3 turns in both directions;
• loosen the ring nuts (3) and retighten with tightening torque 2-1 daNm; 15
• check that the wheels turn smoothly (max. rolling final torque:0.2 daNm) and that there is no side
clearance (maximum axial clearance of 0.05 mm); 16
• reassemble the cap (1);
• lower the wheels again and check that all nuts (5) fixing the wheel rim (4) to hub (2) are well tightened. 17
18
18
18
18
18
18
7-14
8-1
STEERING SYSTEM
Page
STEERING SYSTEM....................................................8-2
0
COMPONENTS ...................................................................... 8-2
1
HYDRAULIC DIAGRAM......................................................... 8-3
STEERING COMMAND.......................................................... 8-7 2
POWER STEERING (ORBITROL)...............................8-8 3
SPECIFICATIONS .................................................................. 8-8 4
STEERING UNIT ........................................................ 8-11 5
CHECKING SEALS AND CLEANING POWER
STEERING SYSTEM..........................................................8-11 6
INSPECT AND ADJUST THE PRESSURE 7
RELIEF VALVE.................................................................. 8-12
8
PRIORITY VALVE ......................................................8-13
9
GENERAL............................................................................. 8-13
10
11
12
13
14
15
16
17
18
19
20
21
E
8-2
STEERING SYSTEM
COMPONENTS
P
L
LS
R
8
L
LS R
2
CF
3 6 L
5
1 R
4
1 Bomba hidráulica 8 Tank

2 Priority valve CF - P Orbitrol inlet
3 Seal LS LS channel
4 Joint L Steering wheel turn left side
5 Turn sensor T Orbitrol outlet
6 Temperature sensor R Steering wheel turn right side
7 Anti-vibrant
8-3
HYDRAULIC DIAGRAM
3 wheel version with lever control valve
2
2
2
3
2
2
2
8
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
8-4
3 wheel version with electro-proportional distributor

8-5
2
2
2
3
2
2
2
8
8
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
8-6

8-7
STEERING COMMAND
The steering uses the same oil as the lifting by means of a priority valve
The pump delivery is sent to the priority valve so that there is always a sufficient flow of oil to the power
steering 2
The flow rate is controlled by the LS (Load-sensing) signal output by the steering unit and is done in
such a way that the flow to the power steering is suited to actual demand. 2
The exceeding delivery is sent to the control valve for other functions.
When the steering wheel is turned, the steering unit “measures” a volume of oil proportional to the above 2
rotation and sends it into the steering cylinder. The steering unit automatically returns to neutral when
the manoeuvre is completed.
The steering wheel hardness depends proportionally from the truck traction speed, as shown in the
3
diagram here below.
Increasing traction speed, pump R.P.M. decrease. 2
This allows an improvement of truck speed control.
2
2
25
20 8
Lifting speed (Hz)
15
10 8
5
9
20 40 60 80 100 120 140 160
Traction speed (Hz)
10
11
12
13
14
15
16
17
18
18
18
18
18
18
8-8
POWER STEERING (ORBITROL)
SPECIFICATIONS
Capacity 1.5 - 2.0 t

Parts 3 wheels 4 wheels
Power steering type Dynamic
Discharge cc (cm3) 50 80
Dynamic power steering Oil flow rate: l 5 8
Maximum pressure: Bar ~120
8-9
2
36 Nm
40 Nm
2
2
3
36 Nm
2
2
2
36 Nm 8
36 Nm 8
9
2.Switch off the truck 11
4.Remove the front panel [Point 1]
5.Remove the steering column covers [Point 2]
12
6.Remove lh steering pipes cover [Point 3]
7.Disconnect the lines 13
8.Unscrew the 4 fixing screws of the orbitrol
9.Remove the power steering [Point 4] 14
Assembly procedure 15
Remarks:
16
Add grease at the coupling between the steering shaft and steering valve using paste type
CASTROL OPTIMOL T WHITE 17
18
18
18
18
18
18
8-10
Point Operation
[Point 1]
FRONT VIEW
Disassembly:
Remove the front fascia by unscrewing the fixing
screws (A)
REAR VIEW
[Point 2]
Disassembly:
Remove the steering column covers
[Point 3]
Disassembly:
Remove lh steering pipes cover
[Point 4]
Disassembly:
Remove the power steering by unscrewing the 4 fixing
screws (B) (Tightening torque 15 Nm ± 10%)
B
8-11
STEERING UNIT
CHECKING SEALS AND CLEANING POWER STEERING SYSTEM
3 wheels version 2
Every 1000 hours
• check the entire system to identify any leaks; any 2
intervention must be carried out without pressure in the
system 2
Every 5000 hours
F • replace the hoses (F) connecting the power steering to 3
F the steering cylinder
Every 10 000 hours
2
• replace the hydraulic piping system
2
2
4 wheels version
Every 1000 hours
8
• check the entire system to identify any leaks; any
F intervention must be carried out without pressure in the 8
system
Every 5000 hours
9
• replace the hoses (F) connecting the power steering to
the steering cylinder 10
Every 10 000 hours
• replace the hydraulic piping system
11
12
13
14
15
16
17
18
18
18
18
18
18
8-12
INSPECT AND ADJUST THE PRESSURE RELIEF VALVE

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

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

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

value, adjust the orbitrol setting screw (B)
B
8-13
PRIORITY VALVE
GENERAL
2
36 Nm
40 Nm 2
2
3
36 Nm
2
2
2
36 Nm 8
36 Nm 8
9
10
8 Nm 11
12
13
14
15
36 Nm
16
17
18
18
18
5.Disconnect the hoses from the priority valve
6.Remove the priority valve. 18
8-14
9-1
BRAKES
Page
BRAKING SYSTEM .....................................................9-2
0
GENERAL............................................................................... 9-2
1
COMPONENTS ............................................................9-3
BRAKE PEDAL ...................................................................... 9-3 2
SERVICE BRAKE ........................................................9-4 3
BRAKE FLUID SYSTEM BLEEDING .......................... 9-6 4
SERVICE BRAKE................................................................... 9-7
5
DISK BRAKES .............................................................9-8
6
REPLACE DISK BRAKES...........................................9-9
7
BRAKES LEVER........................................................9-17
PARKING BRAKE......................................................9-21
8
GENERAL............................................................................. 9-21 9
RELEASING THE PARKING BRAKE .................................. 9-23 10
EMERGENCY RELEASE OF THE PARKING BRAKE........ 9-24
11
ADJUSTING THE NOMINAL PLAY ..................................... 9-25
12
REPLACING THE BRAKE DISK AND CHECKING
THE WEAR........................................................................ 9-26 13
ELECTRIC BRAKE TROUBLESHOOTING......................... 9-27 14
15
16
17
18
19
20
21
E
9-2
BRAKING SYSTEM
GENERAL
The reduction gears are equipped with a braking system with multiples disks in oil bath that act directly
on the wheel axle.
The discs are lubricated with the same oil as the reduction gear, ATF Dexron II.
In addition to mechanical braking, the vehicle uses a motor brake controlled electronically via the traction
control system (see chapter 03 for the parameter settings).
The activation of the brake disks is executed pressing the brake pedal (A).
9-3
COMPONENTS
BRAKE PEDAL
2
2
2
3
4
5
6
7
9
9
Pressing the pedal, the cap practice a pression on the piston. The piston puts in motion the oil that 10
pressing on the plate compress the brake disk.
The limit switch is regulated by the screw, while pedal return in neutral position is regulated by the spring. 11
The microswitch must trip when the cap touches the pump piston.
If making adjustments, make sure that there is a gap of 0.2-

12
0,2 ÷ 0,5 mm
0.5 mm between the cap and pump piston, otherwise there
is the risk of the truck remaining braked which would cause 13
early brake disc wear
14
15
16
17
18
18
18
18
18
18
9-4
SERVICE BRAKE
SERVICE BRAKE SYSTEM SCHEMATIC DIAGRAM
C (A) Reduction gear

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

When the fluid in the brake tank reaches a too low level, the
warning light indicating the low level liquid brakes on the
L dashboard shall light up (see 04 chapter, INCORRECT
STARTS MANAGEMENT section).
G Use the push button SW2 (L) to check the warning light
works properly
Fill up the brake fluid tank (DOT 4- Qt.0.25 l)
9-5
2
2
2
3
4
5
3.Open the compartment and disconnect the battery 7
5.Disconnect the horn and brake pedal system and horn wiring harness 9
6.Empty the oil brake circuit. Collect the oil in a dedicated container, disconnecting the rigid pipe from the
brake pump [Point 1]
7.Remove the 3 screws fastening the pedal to the chassis [Point 2]
9
8.Remove the brake pedal
10
Assembly procedure
The reassembly procedure is the reverse of the disassembly procedure 11
Points of Operation
12
[Point 1]
Disassembly: 13
Disconnect the rigid pipe (A) from the brake pump
14
Assembly:
After installation, tightening torque of bolt on brake 15
pump 28 Nm
16
A
17
[Point 2]
Disassembly:
18
Remove the 3 screws (B) fastening the pedal to the
chassis 18
18
18
B
18
18
9-6
BRAKE FLUID SYSTEM BLEEDING

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

brake pedal and let go out a small quantity of oil
3.Screw in the bleeding screw, and press the brake pedal
several times
4.Keep the oil level constant
5.Repeat points 2, 3 and 4 until bleeding screw doesn't go
out only the oil
A 6.Repeat the procedure on the other reduction gear
9-7
SERVICE BRAKE
2
2
Main piston 2
Pad
3
4
Brake pin
5
6
Brake cylinder
7
9
Oil brake tube
9
10
Wheel cylinder
11
Oil area
12
Spring
Brake disks group 13
The braking effect is due to the rotation of the brake cylinder hinged to the reduction gear through a pivot 14
fixed by two seegers.
The parking brake lever or service brake pedal operation causes the cylinder rotation and, consequently,
the braking system intervention. 15
When the brake pedal is pressed, the oil pressure pushes out of brake cylinder that, acting on the
reduction, causes to the rotation of the cylinder itself. 16
The cylinder turns around the fulcrum and presses against the brake pin that pushes the pad.
The pad pushes the main piston that compacts the brake disks, obtaining the braking effect. 17
When the brake pedal is released the springs push the main piston in neutral position, freeing the disks.
18
18
18
18
18
18
9-8
DISK BRAKES
Pinion
Transmission
unit 2
Plate disk
Transmission
unit 1
Reduction gear body
The brake cylinder movement triggers the braking effect. The disk brake cylinder pushes the free
cylinder and the pad. The pivot-pad is used to stop the pad that otherwise would be free to turn together
with the brake disks.
The wheel pinion with Gear group 2 while Gear group 1 and the brake discs are fixed.
The brake disks have a tooted shape on the external diameter in order to fix them fully with the reduction
gear body. The counter disks have a toothed shape on the internal diameter in order to fix them to be
integral with the Gear group 1.
Pressing the brake pedal all disks come packaged and the Group gears 1 is blocked by the contact of
the mobile counter disks with the fixed brake disks.
Brake system antagonist springs are present in order to recover the Group gears 1 normal operation
position and that happens when the brake pedal is released.
9-9
REPLACE DISK BRAKES

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

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

4
brake lever and remove the retaining pin from the
brake lever 5
(5) Fit the brake lever in the guide in the housing cover 6
(6) Fasten the brake lever to the housing cover with the 7
retaining pin
9
9
(7) Fit the retaining pin circlip
10
11
12
13
14
[Point 5]
15
Assembly:
Measure the brake lever play 16
(1)Select the dial gauge sensor on the brake lever
17
(2)Adjust the dial gauge to 0
(3)Press the brake lever down by hand 18
18
18
18
18
18
9-20
(8) Read off the brake lever play from the dial gauge
[Point 6]
Assembly:
Test the brake manually:
Turn the wheel shaft by hand. At the same time, push
the brake lever up, using a screwdriver
9-21
PARKING BRAKE
GENERAL
The parking brake is made up of a single stage electro mechanical disk brake fitted on the drive motor 2
(one for each drive motor) which is engaged by means of a pressure spring. The parking brake is
released electrically (DC voltage). 2
The parking brake is enabled/disabled in the following ways:
2
• The parking brake is enabled automatically when the truck stops (negative brake function). It is
possible to remove the negative brake function using the parameter STOP ON RAMP (see chapter 03
paragraph TRUCK CONF)
3
• The brake is released when the accelerator pedal is pressed. 4
• If the parking brake icon is lit up on the display select the parking brake selector to release the brake
(see paragraph RELEASEING THE PARKING BRAKE) 5
• The parking brake icon comes on automatically when the truck is switched on or after 30 seconds
without a drive request. 6
7
1 - Inductor
2 - Friction disc 9
3 - Hub
4 - Flange
5 - Assembly screws 9
6 - Adjusting screws
10
11
12
13
14
15
Technical specifications
16
Nominal torque 70 Nm
Nominal play 0.35 mm 17
Tightening torque of fitting screws M6* on Ø132mm C = 9,1Nm
M8* on Ø145mm C = 22Nm 18
M6 on Ø168mm C = 9,1Nm
Max. rotation speed 5000 rpm 18
Activation voltage 48 V
Maintenance voltage 36 V 18
Coil Resistance 34 Ω
New disc rated thickness 6.9 - 7.0 mm
18
Maximum disk wear 6.4 - 6.5 mm
18
18
9-22
2.Place 2 shims under the mast
7.Remove brake and accelerator pedals
8.Disconnect the electric brake wiring harness
9.Unscrew the 3 screws [Point 1]
10.Remove the electric brake
Assembly procedure
The reassembly procedure is the reverse of the disassembly procedure
Point Operations
[Point 1]
A Disassembly:
Unscrew the 3 screws (A)
(Tightening torque 25-30 Nm)
A
Assembly:
Make sure that the clutch disk (2) is mounted perfectly
in the center of the inducer body (1), to prevent the two
bodies from coming into contact when the disk is
rotating.
9-23
RELEASING THE PARKING BRAKE

• Parking brake selector (A)
A
2
2
2
3
4
To engage the parking brake, press the push button (A). 5
B The icon (B) appears on the display.
To release, push the push button (A) again.
6
7
9
Remarks:
9
If the operator activates any possible hydraulic application and the selector (A) is in position 1,
the required hydraulic function will be available, but accompanied with an acoustic warning 10
signal and, the INCORRECT START relative message will appear on the display
11
12
13
14
15
16
17
18
18
18
18
18
18
9-24
EMERGENCY RELEASE OF THE PARKING BRAKE

In the event of a truck malfunction, if there is still communication between the instrument panel and the
Master and Slave traction logics, it is possible to release the parking brake using the TEST MODE
function
Access the service menu and set the TEST MODE

parameter to ON
TEST MODE See chapter 03, paragraph TRUCK CONF.

ON
If it is not possible to release the parking brake using the TEST MODE function, it is possible to release
the brakes mechanically as described below.
Screw two screws onto the brake plate
(TE UNC 1/4”-20x1 1/4”-8.8) to compress the springs and
release the brake
9-25
ADJUSTING THE NOMINAL PLAY
5
2
4
7 2
Thickness gauge = 0.35 mm 2
1
3
6
Fig. a 4
4
6 2 5
1 - Inductor
2 - Friction disc
6
3 - Hub
4 - Flange
7
7
5 - Assembly screws
6 - Adjusting screws 9
7 - Pressure plate
3
1 9
5
Fig. b 10
Nominal clearance = 0.35 mm
11
Air
assembly (5)
12
13
14
Adjusting screw (6)

15
Fig. c 16
Procedure 17
1.Remove the electric brake from the motor
2.Loosen the fixing screws (5) 18
3.Turn the adjusting screws (6) to achieve the nominal clearance across the whole brake surface
(nominal clearance = 0.35 mm). 18
4.Tighten the assembly screws (5) to a torque of 5.1 Nm.
5.Check in several places (Fig. a) that the nominal clearance is the same across the whole brake surface 18
6.Assemble the brake on the motor
7.Check using the TEST MODE function that the wheels are free and that the brake does not turn with
the clutch inserted 18
Notes: 18
Replace the clutch disk after the third clearance adjustment or when the wear limit has been
reached (maximum disk wear 6.4 - 6.5 mm) 18
9-26
REPLACING THE BRAKE DISK AND CHECKING THE WEAR

Procedure
Every 2000 hours
- check the nominal clearance and the wear on the brake
disks
1.Remove the electric brakes from the drive motors
see paragraph PARKING BRAKE - DISASSEMBLY •

ASSEMBLY
2.Mechanically release the brake with the two screws

supplied with the truck
see EMERGENCY RELEASE OF THE PARKING BRAKE
3.Unscrew the three assembly screws and remove the

flange
Tightening torque 5.1 Nm
4.Remove the clutch disk and check the state of wear
Maximum disk wear = 6.4 - 6.5 mm

New disk nominal thickness = 6.9 - 7.0 mm
Notes:
Replace the clutch disk after the third clearance
adjustment or when the wear limit has been reached
5.Place the clutch disk in its seat and assemble the flange
6.Adjust the nominal clearance
see paragraph ADJUSTING THE NOMINAL CLEARANCE
9-27
ELECTRIC BRAKE TROUBLESHOOTING
Troubleshooting and fault elimination

Fault Cause Remedy
2
Brake not - Power supply is too low - Adjust power supply
release - Power supply is interrupted - Reconnect power supply
2
- Airgap too large - Re-adjust the airgap
- Worn disc - Change the disc and re-adjust the airgap 2
- Coil is damaged - Replace the brake
- Airgap too small - Re-adjust the airgap 3
Brake does - Enabling the brake: power on - Adjust power supply
not brake - Grease on friction faces - Change the disc and re-adjust the airgap 4
Nuisance - Power supply is too low - Adjust power supply
braking 5
6
7
9
9
10
11
12
13
14
15
16
17
18
18
18
18
18
18
9-28
10-1
BODY & FRAME

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

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

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

Page
HYDRAULIC CIRCUIT ............................................... 11-2
0
HYDRAULIC SYSTEM............................................... 11-6
1
PUMP SYSTEM .....................................................................11-6
STEERING SYSTEM .............................................................11-7 2
TILTING SYSTEM..................................................................11-7 3
BRAKES SYSTEM ................................................................11-8 4
COMPONENTS .......................................................... 11-9
5
HYDRAULIC OIL TANK ........................................................11-9
6
HYDRAULIC SYSTEM OIL FILTER ........................ 11-10
HYDRAULIC OIL...................................................... 11-11
7
LIFTING LOAD DOWN TEST .................................. 11-12 8
OIL LEAK TEST....................................................... 11-13 9
LIFTING CYLINDERS .........................................................11-13 10
TILTING CYLINDERS..........................................................11-13
11
12
13
14
15
16
17
18
19
20
21
E
11-2
HYDRAULIC CIRCUIT
11-3
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
11-4

11-5
2
2
2
3
4
5
6
6
8
9
9
11
12
13
14
15
16
17
18
18
18
18
18
18
11-6
HYDRAULIC SYSTEM
PUMP SYSTEM
11-7
STEERING SYSTEM
2
2
2
3
4
5
6
6
8
9
9
TILTING SYSTEM 11
12
13
14
15
16
17
18
18
18
18
18
18
11-8
BRAKES SYSTEM
11-9
COMPONENTS
HYDRAULIC OIL TANK
The tank filter plug is positioned under the footboard, on the left side. 2
The tank capacity is 18.5 litres.
2
Parachute
cylinders 2
breather
3
4
5
6
6
8
9
9
Pump suction
Drain plug
11
12
Oil drain from
Plug drain
13
Oil drain from
control valve
14
15
Ventilation
filter 16
17
18
18
18
18
18
18
11-10
HYDRAULIC SYSTEM OIL FILTER

B
A
4.Remove the footboard and the tank plug (A)
5.Remove the filter
6.Loose and remove all oil drain pipes from the filter
7.Unscrew the oil filter fixing screw (B) (T = 15 Nm)
8.Remove the oil filter group
Assembly procedure
11-11
HYDRAULIC OIL
REPLACEMENT
Tightening torque T =Nm 2
2
2
3
4
5
B
6
A T= 20-25Nm
6
8
Replacement Procedure
4.Remove the footboard and the tank plug
9
5.Remove the filter
6.Lift the truck 11
7.Loosen and remove the oil drain plug (A)
8.Let flow all the oil in a suitable recipient 12
9.Check the oil level using the oil dipstick
10.Reposition the oil drain plug (A)
11.Introduce new oil
13
12.Reinsert the filter
13.Reposition the plug and the footboard 14
Remarks:
• Check the state of seals and if there are no oil leakages;
15
• Check the oil level in the tank, using the dip-stick (B) with mast in vertical position and forks
lowered. 16
Oil/filter changing: 17
After the first 40 hours of operation
• first changing of the filter 18
Every 1000 hours
• check the oil level in the tank using the dipstick (B)
18
Every 2000 hours 18
• change the oil of the system and the filter
18
18
18
11-12
LIFTING LOAD DOWN TEST

1.Set the mast in the vertical position with the standard load
on the fork
2.Lift the forks 1.5 m and leave the key switch ON
3.Take the measure between forks and ground with a meter
or draw datum lines on the inner and outer masts
4.After 10 minutes take the measure between forks and

ground or between the datum lines on the inner and
outer masts
Limit: A = 100 mm
11-13
OIL LEAK TEST

LIFTING CYLINDERS
2
on the fork
2.Lift the forks 1.5 m, measure the distance between the
2
forks and the ground and leave the key switch ON
3.After 10 minutes take the measurement between the 2
forks and the ground again
Limit: A = 100 mm 3
4.If there are oil leakages on the body of the lifting
cylinders, check if cylinder connections are well tight. 4
Replace the cylinder if necessary.
5
6
TILTING CYLINDERS
6
on the fork, lift the fork to 1.5 m and leave the key 8
switch ON
9
9
11
12
13
2.Secure the lead rope on the front edge of the top of the
mast; measure the distance between the rope and the
mast 1 m lower
14
3.Perform the same measurement 10 minutes after.
(1° = 17,5 mm) 15
Límite: Maximum forward angle (°) <= 0.5 (°/min)
Time (10 min)
16
4.If the truck is out of the above limit lower completely the
mast and turn the key switch OFF 17
5.Invert the tilting hoses with the sideshift hoses (if present)
on the control valve. This operation is necessary to 18
understand if there is any internal leakage inside the
tilting cylinder or inside the control valve.
6.Turn the key switch ON and repeat the test from point 1
18
to 3.
(a)a) The test result is within the set limits: 18
replace the control valve.
(b)b) The test result is not within the set limits: 18
replace the tilting cylinders.
18
18
11-14
12-1
MAST
Page
MAST..........................................................................12-2
GENERAL............................................................................. 12-2
0
MAST SECTION ................................................................... 12-3 1
MAST GROUP ...........................................................12-4 2
COMPONENTS .................................................................... 12-4 3
T.V. - F.F.L. MAST, MAST CHAIN AND CHAIN WHEEL
GROUP.............................................................................. 12-4
4
MAST FORK CARRIAGE (ALL MODELS).......................... 12-5 5
FORKS (ALL MODELS)....................................................... 12-6 6
FORK CARRIAGE GROUP AND MAST REMOVAL ........... 12-7
7
MAST GROUP (WITH FORK CARRIAGE).......................... 12-9
8
T.V. MAST GROUP ..................................................12-10
9
2M F.F.L. MAST GROUP.......................................... 12-11
3M F.F.L. MAST GROUP..........................................12-12 10
FORK CARRIAGE ...................................................12-13 11
FORK CARRIAGE GUIDE SHOES 12
REPLACING..........................................................12-16
13
MAST CHAINS CHECK ..................................................... 12-19
POSITION OF THE FORK CARRIAGE ............................. 12-20
14
FORKS................................................................................ 12-21 15
MAST LUBRICATION ..............................................12-22 16
MAST .................................................................................. 12-22 17
SAFETY FORK CARRIAGE LIMIT STOPS ....................... 12-23
18
MAST UNIT TILTING SETTING............................... 12-24
19
20
21
E
12-2
MAST
GENERAL
The profile of the mast has a double strengthening wing having great rigidity to bending and twisting.
It allows wide visibility thanks to reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside profiles.
The mast group is roller type with a variable center distance (i.e. a fixed roller is fitted on the outer mast
and a mobile one on the inner mast). This solution ensures better grip and stability during operation.
Others: side clearance adjustable from outside. Plastic guide shoes.
Lifting cylinders:
Double mast T.V. No. 2 rear cylinders

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

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

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

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

12-7
FORK CARRIAGE GROUP AND MAST REMOVAL

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

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

2
2
2
3
4
5
6
6
8
9
9
1. Set mast in vertical position and lower forks completly
2. Remove the forks
9
3. Disconnect the overflow hose and high pressure hoses (before hose disconnection, fully lower the
inner mast) 12
4. Tie the fork carriage and outer mast with a wire rope
5. Slightly hoist the mast [Point 1] 13
6. Remove the tilt cylinder front pin
7. Remove the mast support cap 14
8. Remove the mast group with the fork carriage
Reassembly Procedure 15
The reassambly procedure is the reverse of the disassembly procedure.
Note:
16
• Apply chassis special grease to the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin 17
• Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced 18
• Adjust the chain tension after installation
Point Operations
18
[Point 1] 18
Disassembly:
To remove the mast, use the eyebolt at the top of fix 18
mast
18
18
12-10
T.V. MAST GROUP

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

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

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

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

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

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

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

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

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

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

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

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

Every 1000 hours
• Check the tilting of the mast; standard values are:
α = 5° FORWARD
FORWARD - BACKWARD
β = 7° BACKWARD (standard)
β = 5° BACKWARD (optional)
The tilt angle can easily be checked using a plumb-line

dropped from the front outside edge of the top of the fixed
masts and measuring the distance between the line and the
front edge at a metre from the top of masts.
NB. 1 tilting degree corresponds to a 17.4 mm movement
on 1 m
α = 5° FORWARD = 87,5 mm
β = 7° BACKWARD (standard) = 122,7 mm
β = 5° BACKWARD (optional) = 87,5 mm
1° = 17,4 mm
13-1
CYLINDER
Page
LIFT CYLINDER ...................................................13-2
0
GENERAL ...................................................................... 13-2
1
LIFTING CYLINDERS SPECIFICATIONS ...........13-4
REAR LIFTING CYLINDERS (T.V.)................................ 13-4
2
FRONT LIFTING CYLINDERS 3
(2M F.F.L. / 3M F.F.L.)................................................... 13-4
4
REAR LIFTING CYLINDERS (2M F.F.L.)....................... 13-4
5
REAR LIFTING CYLINDERS (3M F.F.L.)....................... 13-4
PARACHUTE VALVE (SAFETY DOWN VALVE)........... 13-5 6
FRONT DISPLACEMENT CYLINDER WITH 7
BRAKING EFFECT ON LIFTING .......................13-6
8
REAR TELESCOPIC CYLINDER WITH
BRAKING EFFECT ON LOWERING .................13-7 9
FRONT DISPLACEMENT CYLINDER WITH 10
BRAKING EFFECT ON LIFTING AND 11
LOWERING ........................................................13-8
12
REAR TELESCOPIC CYLINDER WITHOUT
BRAKING EFFECT ............................................13-9 13
REAR DISPLACEMENT CYLINDER WITH 14
BRAKING EFFECT ON LOWERING ...............13-10
15
CYLINDER CHECKING METHODS...................13-13
16
UPPER FIXING SCREW ADJUSTMENT .................... 13-14
LOWERING VALVE ............................................13-15 17
SPECIFICATIONS ........................................................ 13-15 18
TILTING CYLINDER ...........................................13-16 19
GENERAL .................................................................... 13-16 20
ADJUSTMENT ............................................................. 13-18
21
E
13-2
LIFT CYLINDER
GENERAL
FRONT CYLINDER
1.5 to 1.8 t 2.0 t
T.V.
2 displacement cylinders with brake effect on the lifting 2 displacement cylinders with brake effect on the lifting
(standard) (standard)
2-3M
2 displacement cylinders with brake effect on the 2 displacement cylinders with brake effect on the
lowering (optional) lowering ( optional) F.F.L.

BT Forklift C3E150 C3E200 C4E150 C4E200 Repair Manual 036 0437 00 (251 400)

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4-63

3A SAFETY OUTPUT - NOT USED

Condition for error detection

3E POWER MOS SHORTED

Condition for error detection

Values on control with disconnected motor

If an open circuit is detected, replace the logic unit

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

5A CHOPPER NOT CONF - UNUSED

5B STEER WIRE KO - NOT USED

Condition for error detection

Condition for error detection

MCB CONTROL BOARD (section EVCB)

Condition for error detection

A3 PARAM LOAD ERROR

Condition for error detection

Condition for error detection

A5 CHKSUM_ERROR - NOT USED

Condition for error detection

A7 HI SIDE DRIVER SHORT

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

B3 GROUP3 DRIVER SHORT

Condition for error detection

B4 GROUP4 DRIVER SHORT

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

E2 BAD LIFT POT

Condition for error detection

EB POT NOT ACQUIRED

Condition for error detection

EE PUMP STUFFING ERROR

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

Condition for error detection

MCB CONTROL BOARD (section TRCB)

Condition for error detection

Condition for error detection

Condition for error detection

C8 BAD BRAKE MICRO SWITCH

Condition for error detection

Condition for error detection

CA PARAM LOAD ERROR

Condition for error detection