Toyota 8fbe15-20t, 8fbek16-18t, 8fbm16-20t, 8fbmk16-20t Pub - Ce375 Repair Manual

EPAIR
ANUAL
8FBE15, 16, 18, 20 T
8FBEK16, 18 T
8FBM16, 18, 20 T
8FBMK16, 20 T
Pub. No. CE375

INDEX
GENERAL ................................................................................................ 0
BATTERY................................................................................................. 1
CONTROL SYSTEM ................................................................................ 2
MULTI-FUNCTION DISPLAY .................................................................. 3
TROUBLESHOOTING ............................................................................. 4
ENGINE.................................................................................................... 5
DRIVE UNIT & FRONT AXLE.................................................................. 6
REAR AXLE............................................................................................. 7
HYDRAULIC STEERING ......................................................................... 8
BRAKE..................................................................................................... 9
FRAME................................................................................................... 10
MATERIAL HANDLING SYSTEM ......................................................... 11
MASTS ................................................................................................... 12
CYLINDERS........................................................................................... 13
OIL PUMP .............................................................................................. 14
DISTRIBUTOR ....................................................................................... 15
SAS FUNCTION..................................................................................... 16
MAIN OPTIONS ..................................................................................... 17
APPENDIX ............................................................................................. 18
GENERAL 0-1
0
GENERAL
VEHICLE EXTERIOR VIEW .................................................................................. 2
0
VEHICLE MODELS ............................................................................................... 2
CHASSIS NUMBER............................................................................................... 3
HOW TO USE THIS MANUAL............................................................................... 3
OPERATING TIPS................................................................................................. 5
LIST OF SUSPENSION ROPE ANGLES .............................................................. 7
SAFETY LOAD FOR EACH SUSPENSION ROPE ANGLE.................................. 7
COMPONENT WEIGHTS...................................................................................... 8
TOWING THE TRUCK........................................................................................... 8
ELECTRICAL COMPONENTS INSPECTION ....................................................... 9
NOTES ON SAS .................................................................................................. 10
TIGHTENING TORQUE TABLE .......................................................................... 10
0-2 GENERAL
VEHICLE EXTERIOR VIEW

GENERAL 0-3
VEHICLE MODELS
Model
8FBE15T
Load capacity
1.5 ton
Control method
AC Microcomputer Controller
Supply voltage (V)
48
0
8FBEK16T 1.6 ton ↑ ↑
8FBE16T 1.6 ton ↑ ↑
8FBEK18T 1.8 ton ↑ ↑
8FBE18T 1.8 ton ↑ ↑
8FBE20T 2.0 ton ↑ ↑
8FBMK16T 1.6 ton ↑ ↑
8FBM16T 1.6 ton ↑ ↑
8FBM18T 1.8 ton ↑ ↑
8FBMK20T 2.0 ton ↑ ↑
8FBM20T 2.0 ton ↑ ↑
CHASSIS NUMBER
Model Punch shape Punching position
8FBE15T 8FBE15T 10011
8FBEK16T 8FBEK16T 10011
8FBE16T 8FBE16T 10011
8FBEK18T 8FBEK18T 10011
8FBE18T 8FBE18T 10011
8FBE20T 8FBE20T 10011
8FBMK16T 8FBMK16T 10011
8FBM16T 8FBM16T 10011
Punch position
8FBM18T 8FBM18T 10011
8FBMK20T 8FBMK20T 10011
8FBM20T 8FBM20T 10011
HOW TO USE THIS MANUAL
EXPLANATION METHOD
Operating procedure
Operating procedures are described using either pattern A or pattern B.
Pattern A: Each step of the operation is explained with its own illustration.
Pattern B: The entire operation is indicated by step numbers in one illustration, followed by cautions, notes, and
point operations.
Example of pattern B
0-4 GENERAL
DISASSEMBLY·INSPECTION·ASSEMBLY
Tightening torque unit T = Nm
Some step numbers may be omitted in some illustrations.
When a part requiring tightening torque instruction is not

indicated in the illustration, the part name is described in the
illustration frame.
T = 12 ÷ 13 Nm
Dismantling procedure.
1 Remove the cover. [Point 1] Operation to be explained
2 Remove the bushing.
Remove the gear.
Point Operation
Explanation of operation point with illustration
[Point 1]
Disassembly:
Make match marks before removing the pump cover.
Matters omitted in this manual

This manual omits descriptions of the following jobs, but they should actually be performed in practice:
▪ Cleaning and washing of removed parts as required
▪ Visual inspection (partially described)
TERMINOLOGY
CAUTION!
Important matters whose negligence may cause accidents. Be sure to observe them.
NOTICE!
Important items, whose negligence may cause accidents or matters during operating so it is required
special attention.
Standard value: Value showing the allowable range in inspection and adjustment.
Limit: The maximum or minimum value allowed in inspection or adjustment.
ABBREVIATIONS
Abbreviation Meaning Abbreviation Meaning
ASSY Unit / Assembly SAE Society of Automotive Engineers
ATT Attachment SAS System of active stability
LH Left hand SST Special service tool
L/ Less STD Standard
OPTIONAL Option T= Tightening torque
O/S Oversize OOT Number of teeth (OOT)
PS Power steering U/S Undersize
RH Right hand W/ With
GENERAL 0-5
SI UNITS
Meaning of SI
This manual uses SI units. SI represents the International System of Units, which was established to unify the 0
various systems of units used in the past for simpler international technical communication.
New SI units
Item New unit Conventional unit Conversion ratio*1 (1 [conventional

unit] = X [SI unit])
Force*2 N (newton) kgf 1 kgf = 9.80665 N
Torque*2 (Moment) N·m kgf·cm 1 kgf·m = 9.80665 N·m
Pressure*2 Pa (pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665
MPa
↑ ↑ mmHg 1 mmHg = 0.133322 kPa
Revolving speed rpm rpm 1 rpm = 1 r/min
Spring constant*2 N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
Volume l cc 1 cc = 1 ml
Power W PS system 1 PS = 0.735499 kW
Heat quantity W·h cal 1 kcal = 1.16279 W·h
Specific fuel consumption g/W·h g/PS·h 1 g/PS·h = 1.3596 g/kW·h
<Reference>
* 1: X represents the value in SI units as converted from 1 [in conventional units], which can be used as
the conversion ratio between conventional and SI units.
* 2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], which
should be used as the unit of force.
Conversion between Conventional and SI Units
Equation for conversion
Value in SI unit = Conversion rate x Value in conven- Conversion rate: Figure corresponding to X in the con-
tional unit version ratio column in the table illustrated above
Value in conventional unit = Value in SI unit ÷ Conver-
sion rate
When converting, change the unit of the value in conventional or SI units to the one in the conversion
rate column in the table above before calculation. For example, when converting 100 W to the value in
conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499.
OPERATING TIPS
1. Operations to be carried out in safe conditions
(1) After jacking up the vehicle, always rest it on wooden blocks or sturdy supports
(2) Use a rope with suitable capacity to jack up the vehicle or any heavy part of it
2. Practical operations
(1) Make sure the tools, required measurement instruments (circuit tester, ohmmeter, oil manometer, etc.)
and specific tools are available before starting work.
(2) Before disconnecting any electrical wire, check its color and condition.
(3) When reviewing the functional components, complex parts or corresponding mechanisms, arrange the
components in the right order to avoid confusion.
(4) When dismantling and inspecting precision components such as the control valve, use clean tools and
work in a clean environment.
(5) Follow the specified dismantling, checking and reassembling procedures.
(6) When removing gaskets, joints, O-rings, self-locking nuts and split pins, always replace them with new
ones during reassembly.
(7) When replacing them, only use original Toyota spare parts.
(8) During reassembly, use the specified bolts and nuts and observe the specified tightening torque (tighten
to the middle value in the specified tightening torque). If no tightening torque is specified, adopt the value
given in the “table of standard tightening torques”.
3. Fault status check.
Do not dismantle and/or replace any components immediately; first check whether this is necessary.
0-6 GENERAL
4. Disposal of exhausted liquids, etc.

Always use a suitable recipient to collect exhausted liquids when draining them. The disposal of oil, fuel,
coolant, the oil filter, electrolytic fluid from the battery or any other harmful substance may have toxic effects
on health or the environment. These substances should therefore be kept separate and given to an organiz-
ation authorized to handle them.
5. Lubrication of sliding parts
In addition to the regular lubrication specified in the maintenance table, MP grease (or molybdenum disulfide
grease) should be applied after repairs to all parts or surfaces involved in sliding actions (pedal articulated
joints, for example).
6. Disconnect the battery connector
Use the grip when disconnecting the battery connector. Do not touch the wiring.
JACK-UP POINTS
Always observe the following instructions when jacking up the vehicle:
Front
▪ Jack up the vehicle by positioning the cylinder at the bottom of the frame, behind the front wheel.
▪ The cylinder should be positioned 150 mm away from the end of the chassis, on the lower panel.
Rear
▪ When jacking up with a cylinder, position it as illustrated in the figure below
Front
Rear
LIFTING THE VEHICLE

When jacking up the vehicle, use the lifting holes near the top of the mast for the front and the indicated anchor-
ing parts for the rear, as illustrated in the figure.
NOTICE! Before jacking up the vehicle, tilt the mast backwards as far as possible.
NOTICE! Use protective ball bearings on the corners of the roof.
NOTICE! Make sure you do not place the driver's overhead guard under stress.
NOTICE! The figure illustrates a STD mast.
GENERAL 0-7
CAUTION! To jack up the vehicle, use belts or ropes of suitable strength.
LIST OF SUSPENSION ROPE ANGLES

Suspension Tension Compression Suspension Suspension Tension Compression Suspension
angle method angle method
0° 1.00 times 0 times 90° 1.41 times 1.00 times
90°
tf
1.0 tf
41
1.
2t
2t
30° 1.04 times 0.27 times 120° 2.00 times 1.73 times
30°
120°
tf
f
2t
1.04
2t
2t
60° 1.16 times 0.58 times
60°
f
6t
1.1
2t
SAFETY LOAD FOR EACH SUSPENSION ROPE ANGLE

Unit: N
0-8 GENERAL
Rope dia- Slant load Single rope Double rope suspension Four-rope suspension
meter 0° 0° 30° 60° 90° 0° 30° 60° 90°
6 mm 21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
8 mm 31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
10 mm 49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
12.5 mm 76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
14 mm 96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
COMPONENT WEIGHTS
Component Vehicle model Minimum / maximum weight
Battery All models 2069 / 2287 Kg
All models (fork pocket version) 1635 / 1807 Kg
Gear motor unit All models ~ 72 Kg
Pump motor unit All models ~ 45 Kg
Rear axle assembly 8FBE(K)T ~ 51 Kg
8FBM(K)T ~ 80 Kg
Counterweight 8FBE15T ~ 750 Kg
8FBEK16T ~ 565 Kg
8FBE16T ~ 395 Kg
8FBEK18T ~ 750 Kg
8FBE18T ~ 565 Kg
8FBE20T ~ 750 Kg
8FBMK16T ~ 575 Kg
8FBM16T ~ 400 Kg
8FBM18T ~ 435 Kg
8FBMK20T ~ 860 Kg
8FBM20T ~ 575 Kg
Mast assembly (type V height 3300 8FBE15T 365 ÷ 440 Kg
without forks) 8FBEK16T
8FBE16T
8FBMK16T
8FBM16T
8FBEK18T ~ 445 Kg
8FBE18T
8FBE20T
8FBM18T
8FBMK20T
8FBM20T
TOWING THE TRUCK

Bear the following warnings in mind when towing a vehicle.
1. Lift the rear wheels for towing.
2. The traveling speed when towing must not exceed the max-
imum traveling speed of the forklift.
3. Before starting towing, always set the key switch to OFF and
the direction switch to the neutral position.
GENERAL 0-9
4. Before towing, either remove the fork or take action to prevent

the fork from coming into contact with the ground due to boun-
cing.
NOTICE! If the vehicle has a negative braking traction axle, the
0
brakes must be deactivated for towing.
ELECTRICAL COMPONENTS INSPECTION

1. Always disconnect the battery connector before performing any
checks or work on the electrical components
2. Take care when handling electrical components
▪ Do not knock electronic components such as computers and
relays.
▪ Do not expose electronic components to high temperatures or
humidity.
▪ Avoid touching connector cable terminals as they could be-
come damaged or warped as a result of static electricity.
Use a tester which is suited to the object and the type of measure-
ment to be carried out.
Analog type: Suitable for observing movements interfering with the
operating process. The value recorded may only be used for refer-
ence.
Digital type: Takes very precise readings. However, it cannot be
used to observe variations or movements.
* The results of measurements carried out using digital or analog
testers may differ. Differences between the polarities of the analog
type and the digital type are described below.
1) Analog tester
Direct connection Reverse connection
Example of measurement results
Tester measurement scale: scale kΩ
Analog type
Forward Continuity
11 kΩ
Reverse No continuity
∞
2) Digital tester
Direct connection Reverse connection
Example of measurement results
Tester measurement scale: scale 2 MΩ
0-10 GENERAL
Digital type
Forward No continuity
1
Reverse Continuity
2 MΩ
NOTES ON SAS
1. If repair or replacement is performed in any section of the vehicle that relates to SAS function, perform ne-
cessary matching to ensure proper SAS function.
2. Always be sure to operate the vehicle carefully. Be aware of the difference in control features between with
and without SAS.
3. Many precision valves are used in the SAS oil control valves. When disassembling or replacing hydraulic
parts (valves, piping, etc.), be sure to clean the parts before installation. Periodic change of the hydraulic oil
is also very important.
4. As the vehicle is equipped with high-precision electronic devices, modification of electrical parts may cause
vehicle failure. Be sure to use genuine Toyota parts for replacement and installation of the electrical parts
(auxiliary equipment, optional parts, etc.).
TIGHTENING TORQUE TABLE

The tables here below are valid for screws and nuts without superficial covering.
SCREWS WITH “ISO” METRIC COARSE THREAD
Nominal diameter PRELOADING V (N) TORQUE Max (Nm)

(mm) 6 D* 8 G* 10 K* 12 K* 6 D* 8 G* 10 K* 12 K*
6.6* 8.8* 10.9* 12.9* 6.6* 8.8* 10.9* 12.9*
M4 x 0,7 21781 3865 5435 6524 1,7 3 4,2 5,1
M6 x 1 4974 8849 12459 14911 5,7 10 14,3 17,1
M7 x 1 7142 12753 17854 21386 9,2 16,6 23 27,8
M8 x 1,25 9025 16088 22661 27174 13,6 24,3 34 41,1
M9 x 1,25 11870 21190 29921 35610 20,1 36 50,8 60,5
M10 x 1,5 14519 25506 35905 42968 27,8 49 69 82
M12 x 1,75 20797 37082 52189 62588 46,5 83 117 140
M14 x 2 28351 50620 71123 85347 74 132 186 223
M16 x 2 38750 68866 97119 116739 113 200 283 339
M18 x 2,5 47480 84366 118701 142245 157 279 392 471
M20 x 2,5 60430 107910 151565 181485 218 388 545 653
M24 x 3 87309 155979 218763 261927 383 687 961 1148
M27 x 3 112815 202086 283509 340407 549 991 1393 1668
M30 x 3 138321 247212 347274 415944 755 1354 1893 2276
SCREWS WITH “ISO” METRIC FINE THREAD

(mm) 6 D* 8 G* 10 K* 12 K* 6 D* 8 G* 10 K* 12 K*
6.6* 8.8* 10.9* 12.9* 6.6* 8.8* 10.9* 12.9*
M8 x 1 9761 17168 24231 29038 14,5 25,5 36,2 43
M10 x 1,25 15107 26879 37867 45420 28,4 51 72 85
M12 x 1,25 23740 40613 56898 68474 52 89 126 151
M12 x 1,5 21778 38848 54642 65531 49 87 123 147
M14 x 1.5 30902 54936 77303 92705 78 140 196 235
M16 x 1.5 41202 73575 103005 123606 118 211 294 353
M18 x 1.5 53268 95157 133416 159903 171 304 422 510
GENERAL 0-11

(mm) 6 D* 8 G* 10 K* 12 K* 6 D* 8 G* 10 K* 12 K*
6.6* 8.8* 10.9* 12.9* 6.6* 8.8* 10.9* 12.9* 0
M20 x 1.5 67689 118701 168242 202086 239 422 598 716
M24 x 2 94667 168732 237402 284490 402 721 1010 1216
M27 x 2 122625 218763 307053 367875 589 1050 1472 1766
M30 x 2 154017 272718 384552 461070 814 1442 2040 2453
* = screw class
0-12 GENERAL
BATTERY 1-1
1
BATTERY
BATTERY COMPARTMENT AND REQUIRED WEIGHT ..................................... 2 1
STANDARD SERVICE VALUES ........................................................................... 2
MULTI-DISPLAY FUNCTIONS.............................................................................. 2
STATE OF BATTERY CHARGE INDICATOR....................................................... 3
BATTERY MANAGEMENT PARAMETERS.......................................................... 4
BATTERY INDICATOR TROUBLESHOOTING .................................................... 6
TROUBLESHOOTING........................................................................................... 7
BATTERY UNIT ..................................................................................................... 9
INSPECTION ....................................................................................................... 10
STATE OF BATTERY CHARGE ......................................................................... 12
BATTERY CAPACITY ......................................................................................... 13
GEL BATTERIES................................................................................................. 13
REPLACING BATTERY PLUG TERMINALS ...................................................... 14
1-2 BATTERY
BATTERY COMPARTMENT AND REQUIRED WEIGHT

If you purchase the battery locally, it must be adjusted to meet the minimum required weight, as shown in the
table below:
Vehicle model Battery compartment dimensions [mm] Battery min- Capacity [Ah/5h]
Length a Width b Height h imum / max-
imum
weight(with
case) - kg
8FBE15T 522 830 627 708 420
460
500
8FBEK16T 630 830 627 856 525
8FBEK18T 575
8FBMK16T 625
8FBMK18T
8FBE16T 738 830 627 962 630
8FBE18T 690
8FBE20T 750
8FBM16T
8FBM18T
8FBM20T
Left hand
320A connector
b
Rear
+ pole - pole
a
STANDARD SERVICE VALUES

Specific gravity (battery charged) 1.290 [20 °C]
Specific gravity (battery fully discharged) 1.140 [20 °C)]
Discharge end voltage 48 V 47.28 V *
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled water
Insulation resistance 1 MΩ or higher
* Battery value on standby (only with key ON and no power consumption).
BATTERY 1-3
MULTI-DISPLAY FUNCTIONS
Battery charge indicator 1

The battery charge indicates 10 battery charge levels via the display.
(A) Diagnostic LED
(B) (A) (B) Battery charge status indicator
Insufficient battery charge alarm

Percentage Description Notes
10 to 3 residual charge LEDs on; No performance drop
▪ Normal working
2 residual charge LEDs on; First reduction in traction and lifting

▪ Indicator (B) flashes speed, adjustable via the parameters:
▪ 20 BDI CUTB (TUNING - TRACTION)
for traction
▪ 20 BDI CUTB (TUNING - M. HAND-
LING) for lifting
1 residual charge LED on; Second reduction in traction and lifting
▪ Blinking (A) Led, speed, adjustable via the parameters:
▪ Indicator (B) flashes ▪ 10 BDI CUTB (TUNING - TRACTION)

for traction
▪ 10 BDI CUTB (TUNING - M. HAND-
LING) for lifting
0 residual charge LEDs; Traction + lifting double function disabled;

▪ Blinking (A) Led, the two functions can be used individually
and maintain the previous speed reduc-
▪ Indicator (B) flashes tions.
▪ Horn Specific gravity must not fall below:
▪ 1.140 kg/l
If the electrolyte falls below the above
value, use the BDI MIN (OPTION MENU -
BATTERY) parameter to reduce the max-
imum battery discharge
1-4 BATTERY
STATE OF BATTERY CHARGE INDICATOR

The battery charge status indicator is controlled by the traction logic unit. The display can be used to edit the
battery discharge and charge curves to bring the charge status indicator into line with the battery installed in the
vehicle.
NOTICE! The battery indicator must be adjusted according to the characteristics and type of the battery
installed in the truck. Incorrect indicator setting may lead to the non-reset of the indicator and/or the in-
correct discharge of the battery, causing damage in the long term.
BATTERY MANAGEMENT PARAMETERS

The battery management parameters are located in MASK MENU -> OPTION SET MENU -> BATTERY. The
battery management parameters can be used to adjust the battery indicator charge and discharge curves.
LI-ION BATT
The parameter LI-ION BATT enables / disables the discharge and
charge curve for lithium batteries.
▪ ON = enabled
▪ OFF = disabled
BDI TO 100%
The BDI TO 100% parameter is used to instantly reset the battery
indicator to 100%.
Press → to reset the battery indicator to 100%.
BATTERY 1-5
BDI RESET
The parameter BDI RESET sets the minimum charge / discharge
that the battery needs to receive / sustain for a partial or full battery
charge status indicator reset to take place. It is expressed as a per-
centage of the battery indicator. 1
▪ the value 10% is equivalent to 1 battery charge status indicator
LEDs
▪ the value 100% is equivalent to 10 battery charge status indic-
ator LEDs
BDI GEL
The parameter BDI GEL enables / disables the discharge and
charge curve for gel batteries.
▪ ON = enabled
▪ OFF = disabled
BDI MAX
The parameter DBI MAX outlines the battery indicator discharge
curve.
BDI MIN
The parameter DBI MIN outlines the battery indicator discharge
curve. Reducing the parameter value, the battery is discharged
more.
NOTICE! When the battery indicator shows 0% (0 led) check
the battery density. The electrolyte density must not fall below
1.14 Kg/dm³
DISCHARGE CURVE
1-6 BATTERY
RESET VOLT MAX

The parameter RESET VOLT MAX outlines the battery indicator
charge curve. Reducing the parameter value you will reduce the
battery voltage needed for a total or partial reset of the indicator.
RESET VOLT MIN

The parameter RESET VOLT MIN outlines the battery indicator re-
set curve.
RESET CURVE
BATTERY 1-7
BATTERY INDICATOR TROUBLESHOOTING

ERROR CAUSE REMEDY
Battery indicator does not reset after The BDI RESET rule is not respec-
partial battery charge. ted.
▪ Make sure you have discharged
the battery indicator at the value
1
Standard BDI RESET = 30% (3 led) set by BDI RESET before char-
ging the battery.
▪ Lower the BDI RESET value.
▪ Battery charge duration too
short for the value set in BDI
RESET.
Battery indicator does not shown The BDI RESET rule is not respec- ▪ Make sure you have discharged
100% after complete battery charge. ted. the battery indicator at the value
ging the battery.
After charging the battery does not ▪ Check the battery conditions
exceed the voltage set in RESET (old or damaged battery). Elec-
VOLT MAX. trolyte density after charging
1.29 Kg/dm³.
▪ Lower the RESET VOLT value.
Battery indicator does not shown The BDI RESET rule is not respec- ▪ Make sure you have discharged
100% after changing the battery. ted. the battery indicator at the value
ging the battery.
After charging the battery does not ▪ Check the battery conditions
exceed the voltage set in RESET (old or damaged battery, or un-
VOLT MAX. used for too much time has
passed between end of charging
and use). Electrolyte density
after charging 1.29 Kg/dm³.
▪ Lower the RESET VOLT value
using the battery with a lower fi-
nal charge voltage.
When the battery indicator shows BDI MIN value too high. ▪ Lower the BDI MIN value.
0% the electrolyte density is greater
than 1.14 Kg/dm³
When the battery indicator shows BDI MIN value too low ▪ Increase the BDI MIN value.
0% the electrolyte density is less
than 1.14 Kg/dm³
1-8 BATTERY
TROUBLESHOOTING
plate corrosion sulfation plate warpage and active substance freeing

improper
charging
Repeated overdischarge procedures
short circuit to Long time in storage
and overdischarge
end of life
battery
in the battery cells defect of electrolyte excessive charging
defect of electrolyte
defect of electrolyte
battery Overdischarge excessive enviroment temp.
battery defect
broken or chipping of cells
defect separator wrong water power
overcharge imperfect terminal connectiom
deposit of free substances at plug terminal and/or

bottom of cells connecting plug
short circuit electrolyte leakage end reduction loosened or corroded connection

BATTERY 1-9
DEFECT CAUSE REMEDY

▪ Battery runs down rapidly during ▪ Battery does not have an ad- ▪ Moderate current consumption
the work period equate capacity for the type of or charge more frequently
work
▪ Battery is very old
▪ If necessary, replace the battery 1
▪ Check the battery charger
▪ Battery not completely charged
▪ Battery runs down rapidly ▪ Excessive current consumption ▪ Check the load lifted by the
▪ Low voltage, truck goes slowly ▪ Truck motor overloaded, espe- truck
during work cially when going up a slope ▪ Lubricate and check the motor
▪ Electrolyte heats up ▪ Battery charger with high current mechanical parts
at end of charge ▪ If necessary, fit a battery with a
higher capacity
▪ Check the battery charger
▪ Density not the same ▪ Faulty insulation of some elec- ▪ Examine the insulation
▪ Contacts shorting to earth tric device in the truck or battery ▪ Clean the case and the ele-
▪ Current leakage ▪ Battery has cracked cells or dirty ments • Renew the insulating
elements coating
▪ Metal case has faulty insulation ▪ Repeat the final charge
▪ Intermediate current sockets ▪ Eliminate too high and/or con-
tinuous intermediate current
sockets
▪ Battery runs down rapidly ▪ Plates short circuiting in some ▪ Replace faulty elements
▪ Truck slow, low voltage battery elements
▪ Acid heats up
▪ Density not the same
▪ Density too low while charging
▪ Charge voltage too low
▪ High water consumption
▪ Battery runs down rapidly ▪ Electrolyte density too low due ▪ If the density does not increase
▪ Electrolyte density too low dur- to acid leakage with a trickle charge, the electro-
ing the charge ▪ Frequent and excessive top-ups lyte density must be restored by
adding acid.
▪ Battery runs down rapidly ▪ Poles loose or oxidized ▪ Tighten the contacts of the poles
▪ Truck slow, poor performance and clean them accurately
▪ Charge voltage too high

▪ Charge current too low
▪ Acid heats up ▪ Charge time set too long The ▪ Adjust the point of intervention
▪ Charge time too long timer comes on late and extends of the timer
the charge
▪ High water consumption
▪ Battery runs down rapidly ▪ Charge time set too short The ▪ Adjust the point of intervention
▪ Density not the same timer intervenes early of the timer
▪ Density too low during charging ▪ Insufficient time for recharging ▪ Increase the recharging time
▪ Replace the battery charger with
a more powerful one
1-10 BATTERY
BATTERY UNIT
DISASSEMBLY-ASSEMBLY
Dismantling procedure
1) Release the steering lock lever.
2) Move the steering column forward.
3) Open the battery cover and remove the side plate.
4) Disconnect the battery connector.
5) Remove the battery unit.
Assembly procedure
The assembly procedure is the reverse of the disassembly proced-
ure.
INSPECTION
1. Electrolyte level inspection:
Open the cover of each battery element and, if the white line on the
red float has dropped and disappeared, add water. Add water until
Cap
the white line reappears. Stop topping the water up when the white
White line line appears; if the top of the float comes into contact with the re-
tainer, the recipient has been overfilled.
Float
There is a level gauge on the front of the battery box, which usually
allows quick visual checking of the electrolyte level; nevertheless,
inspection involving actual opening of the plugs should be carried
out regularly. The green level indicator lights up to indicate level
sensor activation; the red indicator flashes to indicate that a top-up
is required.
Red light Green light

Normal level Off On
Level insufficient Flashing On
NOTICE! Never change the location in which the sensor is installed.
Reference: Electrolyte consumption can be calculated using the following equation:
Consumption (cc) = 5 hours of capacity x 0.0336 x number of cells x number of charges
BATTERY 1-11
2. Electrolyte inspection:
The battery fluid should be transparent. Check for clouding during
the specific gravity check. In case of difficulty, put it in a cup for the
inspection.
1
3. Battery electrolyte specific gravity check. Use a hydrometer to

measure the specific gravity of the electrolyte.
Specific gravity in full charge status .... 1.290 [20°C (86°F)]
Specific gravity when completely discharged.... 1.140 [20°C
(86°F)]
The specific gravity of the electrolyte refers to a temperature of

30°C (86°F).
Equation for converting specific gravity
S30=St+0.0007 (t-30)
S30: Specific gravity at 30°C
St: Specific gravity at t°C
t: Electrolyte temperature upon measurement (°C)
How to use the hydrometer:

▪ Insert the hydrometer nozzle into the electrolyte opening and
let the fluid flow into the external pipe.
Hydrometer
▪ Allow the hydrometer to float without touching the external
Rubber tube, or top or bottom, and when the bubbles in the fluid disap-
deposit pear, read the highest value of the scale on the fluid's surface,
Outlet pipe as shown in the figure.
▪ After the measurement, carefully wash the inside and outside
Nozzle of the hydrometer with water and put it away after drying with a
clean cloth.
4. Insulation resistance measurement:

Measure the resistance between battery and box with an insulation
resistance meter (mega-ohmmeter).
Insulation resistance... 1 MΩ or higher
NOTICE! When the insulation resistance is less than 1 MW,
wash the battery with water after removing it from the vehicle.
Fully dry the washed battery and measure the insulation resist-
ance again. Install the battery on the vehicle after confirming
that the insulation resistance is 1 MW or more.
1-12 BATTERY
* Battery control table

Prepare a control table for each battery, to record and process the inspection results.
Electrolyte
Inspection time Time
Inspected element Nr. specific Added water Notes Inspector
and date electrolyte
gravity
STATE OF BATTERY CHARGE

The state of charge of a battery is measured by means of the electrolyte density. Before measuring the electro-
lyte, ensure that the battery has been at rest for at least 30 minutes (see previous paragraph).
NOTICE! Notes:The tables below represent ideal discharge values of lead-acid batteries.
Electrolyte density vs Discharged capacity
Recommended
Electrolyte density (kg/l)
discharge
Discharged capacity (%)
Formula: Density = (Volt / n° cells) - 0.84

It is possible to convert the density (kg/l) approximately into voltage (V) for an indication of the state of charge.
Cell voltage vs Discharged capacity
Recommended
discharge
Cell voltage (kg/l)
Discharged capacity (%)
Battery discharge limits

Discharge protracted beyond the established limits makes recharging more difficult, as a longer time is required.
This happens on batteries that are removed from charging before they have been completely charged. At the
next discharge they may be discharged to an even lower point, triggering an incorrect charge-discharge cycle
which, with time, will cause permanent damage.
NOTICE! The acid density limit below which it is not advisable to discharge the battery may be roughly
BATTERY 1-13
considered as 1.13 Kg/l. When the battery has run a long way down, it is important to recharge it as soon
as possible. It is advisable not to leave it completely discharged for more than one day. Discharging the
battery by more than 80% of its capacity means considerably reducing its life cycle.
1
BATTERY CAPACITY
The capacity of a battery is the amount of electricity that it can supply to an external circuit before the voltage
falls below the final limit value; it is expressed in Ah (Ampere-hour).
The main factors that influence the capacity of lead-acid batteries are:
Discharge rate
The capacity supplied at high discharge rates (high current intensity) is lower than that supplied at low discharge
rates (low current intensity). The causes of the decrease in the capacity supplied at high rates are the following:
▪ Sulphation of the plate surface, which closes the pores of the active material;
▪ Limited time for electrolyte diffusion;
▪ Loss of voltage due to the accumulator internal resistance.
Electrolyte specific gravity

The specific gravity of the electrolyte influences the voltage and the capacity for the following reasons:
▪ It determines the potential of the plates;
▪ It influences the electrolyte viscosity and therefore its diffusion speed.
Electrolyte temperature
Batteries operating in environments at low temperature undergo a temporary decrease of the capacity available
and of the voltage (the rated capacity and voltage values are restored when the temperature returns to normal).
An increase in the battery temperature leads to an increase in its capacity. The effect of the temperature on the
capacity is due to the variations of the viscosity and resistance of the electrolyte. At low temperatures the vis-
cosity increases and this reduces the rate of diffusion of the acid in the pores of the active material. The temper-
ature effect is more sensitive at high discharge rates. Due to the effect of the electrolyte temperature, the battery
capacity varies as shown in the diagram below.
CAPACITY ACCORDING TO ELECTROLYTE TEMPERATURE

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

CAUTION! Disconnect the battery cables one by one.
CAUTION! Never disconnect more than one cable at a time. A short circuit could cause a fatal accident.
BATTERY 1-15
1. Remove the self-threading screws and the clamp cable.
2. Remove the contact holder unit from the connector box with a
screwdriver, pulling the cables at the same time.
3. Remove the contacts from the contact holder and cut the old
ones.
4. Peel the cables to the required lengths:

Main contacts: 20.0 mm for 10 mm² to 70 mm² cables. Insert
the cable into the hole right to the bottom. Weld or crimp the
contacts. Insert the contacts in the contact holder. Pay atten-
tion to the polarity of the contacts during assembly. The main
contacts must be inserted in the special support on the oppos-
ite sides with an inwards movement.
5. Slide the contact holder inside the connector box until it locks
into position, protect the cables using the special clamps with
the self-threading screws.
1-16 BATTERY
6. Insert the voltage key into the hex shaped opening in the front
of the connector. Check that the battery voltage can be seen in
the window. Apply force to the key to make sure it is fully inser-
ted and locked in its seat.
CONTROL SYSTEM 2-1
2
CONTROL SYSTEM
GENERAL.............................................................................................................. 2
REAR COMPARTMENT FUSES........................................................................... 2 2
FUSES UNDER DASHBOARD ............................................................................. 3
CONTACTORS...................................................................................................... 4
DC/DC CONVERTERS.......................................................................................... 5
LOGIC UNITS ........................................................................................................ 7
MCB CARD............................................................................................................ 8
MULTI-DISPLAY FUNCTIONS.............................................................................. 8
ARMREST CARD .................................................................................................. 9
ARMREST CARD POTENTIOMETERS.............................................................. 10
ACCELERATOR AND BRAKE POTENTIOMETERS.......................................... 11
STEERING SENSOR - 3 WHEEL VERSION ...................................................... 13
STEERING SENSOR - 4 WHEEL VERSION ...................................................... 14
TILT ANGLE POTENTIOMETER ........................................................................ 15
MAST PRESSURE SENSOR .............................................................................. 16
MAST HEIGHT SWITCH ..................................................................................... 17
CALIBRATIONS................................................................................................... 17
2-2 CONTROL SYSTEM
GENERAL
Models in the 8FBM series are equipped with special systems to control traveling speed and material handling.
They are multi-functional cards or control units equipped with microprocessors. The traveling/material handling
controller carries out a wide range of high-performance functions and procedures by regulating the AC motor
control system. The main controller has a self-diagnosis function that automatically detects any abnormality of
the main activation/pump circuits, the SAS function or any other sensor, and displays the corresponding error
code together while a warning beep sounds. At the same time, actions such as traveling disabling, material
handling disabling or restriction of traveling speed are automatically taken to ensure safety. In addition, by set-
ting the display in analyzer mode (fault analysis) it is possible to identify faulty portions and test operation of the
main traction/pump circuits, each operating system and the sensors.
24-12v fuse card
Display
Traction and lifting
logic units
EPS
MCB
Armrest card
Contactor Group
CONTROL SYSTEM 2-3
REAR COMPARTMENT FUSES
Fuse Function Capacity

F1 T2 and T3 converter output 30A - 24V
F2 T2 and T3 converter input 15A - 48V
F3 Heater unit 30A - 48V
F4 MCB auxiliaries 10A - 48V
F5 Horn 5A - 48V
F6 Electronic card power supply 5A - 48V
F7 Pneumatic seat 15A - 24V
FP Pump control power 300A
FS EPS control power 40A
FT1 Right traction control unit power 250A
FT2 Left traction control unit power 250A
2-4 CONTROL SYSTEM
FUSES UNDER DASHBOARD

F12 Heater unit 7,5A - 24V
F13 Work spotlights 7,5A - 24V
F14 +24V auxiliary output 5A - 24V
F15 Courtesy light 5A - 24V
F16 Rear window 10A - 24V
F17 Radio 7,5A - 12V
F18 +12V auxiliary output 7,5A - 12V
F19 +12V auxiliary output 7,5A - 12V
F20 Heated seat 7,5A - 12V
F21 Rear wiper motor 7,5A - 24V
F22 Front wiper motor 7,5A - 24V
F23 Work spotlights 7,5A - 24V
CONTROL SYSTEM 2-5
CONTACTORS
Fuse Description Function Coil resistance (at 20°C)

K1 SU280B-1166 48V IO Master, slave and pump ~100 Ω
control power switch
K2 SW60B-258 48V CO EPS steering control ~420 Ω
power switch
K7 SW60B-258 48V CO Key line switch ~420 Ω
2-6 CONTROL SYSTEM
DC/DC CONVERTERS
DC/DC converters Power Connected systems Maximum system con-

sumption
T1 144W 2 front working lights (LED) 140 W (70W)
Converter / 2 rear working lights (LED) 140 W (70W)
48V / 24V 360W Rear lights (stop/tail + re- 140 W
versing)
/
Rear LED lights (stop/tail + 7W
720W reversing)
2 washer pumps 72 W
Combined front lights 192 W
(dipped + tail + direction in-
dicators)
Combined front LED lights 26 W
(dipped + tail + direction in-
dicators)
2 additional LED working 70 W
lights
Height selector 6W
T2 360W 2 wiper motors 200 W
Converter 24V auxiliary output 80 W
48V / 24V Heater 40 W
Courtesy light 5W
2 additional LED working 29 W
lights on the mast
T3 360W Heated rear window 115 W
Converter Pneumatic seat (+ heated 120 W (96W)
48V / 24V seat)
Blue LED light 7,2 W
Reading light 2,5 W
T4 300W Radio 80 W
Converter 12V auxiliary output 60 W
48V / 12V Heated seat 40 W
CONTROL SYSTEM 2-7
NOTICE! It is necessary to calculate the total absorption of the optional systems adding +10% of the total
in order to select the correct converter.
LOGIC UNITS 2
CAUTION! Before starting work, disconnect the battery connector and measure the voltage between +
and GND on the logic unit; if any voltage is present, insert a resistance of approx. 100Ω 50W between +
and GND in order to discharge the condenser.
Disassembly Procedure
1) Open the rear cover and the battery hood.
3) Remove the rear metal brackets.
4) Remove the back plastic cover.
5) Disconnect the power cables and the electrical wiring.
6) Remove the the traction logic unit.
7) Remove the lift assembly.
Reassembly Procedure
The assembly procedure is the reverse of the disassembly procedure.
Whenever one of the logic units has been disassembled, remember to restore the layer of the thermo conduct-
ive paste whose purpose is to favour the thermic transmission between the logic unit and the heat radiant struc-
ture: the counterweight. Spread approx. 40 grams of paste in a thin and even layer over the surface in contact
with the logic unit. After replacing the card, the vehicle settings must be repeated (see heading CALIBRA-
TIONS).
2-8 CONTROL SYSTEM
SST 0991269
Spread approx. 40 grams of paste in a thin and even layer over the
surface in contact with the logic unit.
MCB CARD
1) Open the battery cover.
3) Remove the footboards and the accelerator pedal.
4) Disconnect the electrical wiring.
5) Remove the MCB card.
After replacing the card, the vehicle settings must be repeated (see heading CALIBRATIONS).
CONTROL SYSTEM 2-9
2
3) Remove the dashboard.
5) Remove the display.
Assembly procedure
2-10 CONTROL SYSTEM
ARMREST CARD
3) Remove the cover card bracket.
5) Remove the armrest card.
Assembly procedure
CONTROL SYSTEM 2-11
ARMREST CARD POTENTIOMETERS
2
3) Remove the armrest covers.
5) Remove the potentiometers.
Assembly procedure
After replacing the potentiometer, the vehicle settings must be repeated (see heading CALIBRATIONS).
2-12 CONTROL SYSTEM
ACCELERATOR AND BRAKE POTENTIOMETERS
1. Remove the potentiometer.
2. Check the resistance between the terminals:
Terminal 5 - 6 = 1.8 at 3.4 kΩ
Terminal 4 - 6 = When the potentiometer is rotated, the resistance
must increase in proportion to its angle
Terminal 1 - 2 = 1.8 at 3.4 kΩ
Terminal 2 - 3 = When the potentiometer is rotated, the resistance
must increase in proportion to its angle
3. Fit the potentiometer temporarily.
NOTICE! Incline the accelerator potentiometer, turning it 10
degrees clockwise using the fixing holes, then proceed with in-
stallation.
4. View ANL -> I/O TRAVELING and check the output voltage of
the accelerator potentiometer with the pedal released.
Standard accelerator potentiometer values: POT ACC R3 = 2.00 ±
0.1 V
Standard brake potentiometer values: POT BRK R1 = 2.90 ± 0.1 V
If the voltage is within the standard range, proceed with the poten-
tiometer acquisition.
If the voltage is outside the standard range:
▪ Loosen the screw and adjust the potentiometer through the fix-
ing holes to obtain the standard value shown above;
▪ Tighten the screws:
▪ Proceed with the potentiometer acquisition.
CONTROL SYSTEM 2-13
5. After adjustment, having tightened the screw, mark the screw

head with the symbol “I” with yellow paint.
STEERING SENSOR - 3 WHEEL VERSION

2
2) Disconnect the connector from the steering sensor.
3) Remove the steering sensor. [Point 1]
WARNING! The sensor wiring harness must face the EPS steering logic unit.
2-14 CONTROL SYSTEM
Point Operations
[Point 1]
Assembly:
Position the steering sensor with the label facing upwards.
STEERING SENSOR - 4 WHEEL VERSION
2) Disconnect the connector from the steering sensor.
3) Remove the steering sensor cover.
4) Remove the steering sensor. [Point 1]
CONTROL SYSTEM 2-15

After replacing the steering sensor, the vehicle settings must be repeated (see heading CALIBRATIONS).
WARNING! Place the wheels straight before installing the steering potentiometer.
Point Operations 2
[Point 1]
Inspection:
View ANL -> I/O STEERING and check the output voltage of the
steering sensor.
Standard values:
Fully to the left: ~ 2,40 V
Central position: ~ 4,70 V
Fully to the right: ~ 8,10 V
TILT ANGLE POTENTIOMETER
2) Remove the footboard and the accelerator pedal.
3) Disconnect the tilt angle potentiometer rod. [Point 1]
4) Disconnect the wiring harness.
5) Remove the tilt angle potentiometer.
After replacing the potentiometer, the vehicle settings must be repeated (see heading CALIBRATIONS).
2-16 CONTROL SYSTEM
NOTICE! For installation, apply MP grease to the ends of the rod.
Point Operations
[Point 1]
Assembly:
1) View ANL -> I/O M. HANDLING and record the length of the
rod for a voltage of 1.50V ± 0.10 with the mast tilted fully for-
wards (5.0 degrees forward);
2) Apply thread lock 08833-76002-71 (08833-00080), or equival-
ent, on the threaded part of the shaft;
3) Before tightening the nut, lock the rod to prevent rotation.
MAST PRESSURE SENSOR
1) Lower the forks to the ground, tilt the mast forwards and switch off the machine.
3) Remove the footboard.
4) Disconnect the mast pressure sensor wiring harness.
5) Remove the mast pressure sensor (tightening torque T = 26 Nm).
CONTROL SYSTEM 2-17
After replacing the sensor, the vehicle settings must be repeated (see heading CALIBRATIONS).
MAST HEIGHT SWITCH

2
1) Remove the cover. (FV, FW, FSV, FSW mast)
2) Disconnect the wiring harness.
3) Remove the mast height switch.
2-18 CONTROL SYSTEM
CALIBRATIONS
Menu Name Description Requirement for ex-
ecution
MAT FW/BW SELECTOR Selecting the type of reverse drive *1, *5
FW/BW SELECTOR
MAT ACCEL Calibration of the forward/backward move- *1,* 3, *7
DRIVE ment accelerator potentiometer
BRAKE Brake potentiometer calibration *1,* 3, *8
STEER RANGE Steering sensor calibration *2,* 3, *12, *21
KNOB REST TFD sensor calibration *2, *12, *21
ZERO POT Steering sensor calibration *2, *12, *21
MAT MULTIF. Enable the multifunction joystick configura- *5
MAT. HANDLING tion
LEVER 1 Calibration of the lifting minilever/joystick *5, *16
potentiometer
LEVER 2 Calibration of the tilting minilever/joystick *5, *17
potentiometer
PB 3WAY Configure the 3rd way button (ATT1) *5
LEVER 3 Calibration of the 3rd way minilever/joystick *5, *18
(ATT1) potentiometer
PB 4WAY Configure the 4th way button (ATT2) *5
LEVER 4 Calibration of the 4th way minilever/joystick *5, *19
(ATT2) potentiometer
MAT TILT LEVEL Calibration of mast tilt angle potentiometer, *1, *9, *10, *14, *15
SAS vertical position
TILT FW Calibration of mast tilt angle potentiometer, *1, *9, *10, *14, *15
forward end of stroke
TILT BW Calibration of mast tilt angle potentiometer, *1, *9, *10, *14, *15
backward end of stroke
LOAD SENSOR Calibration of open mast pressure sensor *1, *11, *13, *14
MAT MAST TYPE Type of mast fitted to the vehicle *1, *14
LOAD METER (de- ZERO SET Calibration of the pressure switch with the *1, *11, *13, *14
luxe display version) forks 500 mm from the ground (V masts
only)
ZERO SET 1 Calibration of the pressure switch with the *1, *11, *13, *14
forks 500 mm from the ground (FV, FW,
FSV, FSW masts only)
ZERO SET 2 Calibration of the pressure switch with the *1, *11, *13, *14
side cylinders opened by 100 mm (FV, FW,
FSV, FSW masts only)
COMPENSATION Compensation of the load measuring *1, *11, *13, *14
device
MAT ENABLE Enabling of the height selector option *1, *20
H-SELECTOR MIN HEIGHT Calibration of the fork height sensor, forks *1, *20
on the ground
MAX HEIGHT Calibration of the fork height sensor, forks *1, *20
at maximum height
TUNING ANGLE FW Front tilt angle control *1, *9, *10, *14, *15
M. HANDLING ANGLE BW Rear tilt angle control *1, *9, *10, *14, *15
Content required for execution:
*1: When the MCB is replaced
*2: When the drive logic unit is replaced
*3: When the drive logic unit is replaced
*4: When the lifting logic unit is replaced
CONTROL SYSTEM 2-19
*5: When the armrest card is replaced

*6: When the multifunctional display is replaced
*7: When the accelerator potentiometer is removed/installed or replaced
*8: When the brake potentiometer is removed/installed or replaced
*9: When the tilt angle potentiometer is removed/installed or replaced
*10: When the tilt angle potentiometer rod is replaced
*11: When the mast pressure sensor is removed/installed or replaced
2
*12: When the steering sensor is removed/installed or replaced
*13: When the equipment or fork is installed or replaced
*14: When the mast is removed/installed or replaced
*15: When the tilting cylinder is removed/installed or replaced
*16: When the lifting lever potentiometer is replaced
*17: When the tilting lever potentiometer is replaced
*18: When the optional system (1) lever potentiometer is replaced
*19: When the optional system (2) lever potentiometer is replaced
*20: When the fork height sensor is removed/installed or replaced
*21: When the TFD sensor is removed/installed or replaced
2-20 CONTROL SYSTEM
MULTI-FUNCTION DISPLAY 3-1
3
MULTI-FUNCTION DISPLAY
GENERAL.............................................................................................................. 2
MENU MAP............................................................................................................ 3
OPERATOR MENU ............................................................................................... 4 3
ADMINISTRATOR MENU...................................................................................... 5
ADMINISTRATOR menu screen (with vehicle startup using key) ......................... 7
ADMINISTRATOR menu screen (with vehicle startup using pin code via keypad) ...
17
MASK MENU ....................................................................................................... 25
ANALYZER .......................................................................................................... 26
TUNING ............................................................................................................... 32
OPTION SET ....................................................................................................... 42
MATCHING.......................................................................................................... 51
OTHERS MENU .................................................................................................. 59
3-2 MULTI-FUNCTION DISPLAY
GENERAL
The multifunctional display indicates various types of vehicle information by switching the screen according to
requirements.
Display and buttons
No. Description Multi-function Multi-function

display display deluxe
(1) Button (1): Set Speed reduction / Scroll down o o
(2) Button (2): Select Power / Scroll left o o
(3) Button (3): Select Date and time / Scroll right o o
(4) Button (4): Display Hour meter / Scroll up o o
(5) Multi-screen display area o o
(6) Button (6): Enter / ok o o
(7) Button (7): Out o o
(8) Button (8): Rotating / Flashing light o o
(9) Button (9): Hazard lights o o
(10) Button (10): Rear working lights o o
(11) Button (11): Front wind-screen wiper / Front wind-screen washer o o
(12) Button (12): Rear wind-screen wiper / Rear wind-screen washer o o
(13) Button (13): Heated rear window / heated seat o o
(14) Battery charge indicator o o
(15) OPS indicator o o
(16) Wheel direction indicator o o
(17) Mast tilt indicator x o
(18) Time / Date o o
(19) Parking brake indicator o o
(20) Traveling direction indicator o o
(21) Selected power indicator o o
(22) Low speed selected indicator o o
(23) Hire period expiry indicator o o
No. Description Multi-function Multi-function

display display deluxe
(24) Start maintenance indicator o o
(25) Over load indicator x o
(26) Shock indicator OPT OPT
(27) Overheat indicator o o 3
(28) Height limit selected indicator OPT OPT
(29) Traveling speed o o
o: Standard
x: Not available
OPT: Option
Initializing screen
This screen is displayed for 2 seconds after the key is turned to
ON. However, if vehicle speed is detected for 1 second or more af-
terwards, the display switches to the TRAVELING screen.
Display Description
12/7/2013 (FRI) Displays the date
Traction speed limiter indicator enabled
Speeding alarm indicator enabled
Automatic speed control indicator enabled
Maximum height limiter indicator enabled
Integrated shock sensor indicator enabled
Mast active front tilt control indicator disabled
Height limiter indicator enabled
Overload indicator enabled

MENU MAP
OPERATOR MENU
Operators can set several vehicle services. Function adjustment can be disabled via the ADMINISTRATOR
menu.
POWER CONTROL MENU TRAVEL SETTING MENU

This menu only appears if the parameter MENU LOCK This menu only appears if the parameter MENU LOCK
= OFF = OFF
3
Press and hold the
Press and hold the button for at least two
button for at least two seconds
seconds
Parameters: HEIGHT SET - HEIGHT SET CLR -

HEIGHT LIM appear only if the option selector height
is present and enabled on the truck
METER MENU DATE / TIME SETTING MENU
Press and hold the

button for at least two
seconds
ADMINISTRATOR MENU
Administrators can set vehicle services and their functions. The functions are password-protected to prevent
damage due to unintentional operation by users.
Password menu
NOTICE! Always use your fingertips to operate the switches on the display. Sharp objects may damage
the switch.
NOTICE! If an error occurs during the startup procedure, turn the key switch to OFF and start again from
the beginning.
Password entry procedure

Step Display Operation Vehicle response
(1) When you first press the
Press and hold the ( ) buttons, a short beep will
and ( ) buttons simul- sound, followed by another
taneously for at least 2 short beep after 2
seconds. seconds.
(2) Short acoustic warning.

Press the ( ) button
within 10 seconds.
(3) Short acoustic warning.

Press the ( ) button
within 10 seconds.
(4) Within 10 seconds, press When you first press the

buttons, a short beep will
and hold the ( ) and sound, followed by another
( ) buttons simultan- short beep after 2
eously for at least 2 seconds.
seconds.
(5) Entry of the second password:

The second password screen appears, enter the
second password.
Or:
If it has not been set beforehand, this screen will be
skipped.
(6) The menu screen is displayed automatically.
ADMINISTRATOR menu screen
With vehicle startup using pin code via

With vehicle startup using key
keypad
Symbols
Symbol Description Symbol Description
This icon enables the trac- This icon enables the
tion and lifting power con- shock sensor function
trol function. (models with shock sensor
only).
This icon enables the trac- This icon enables the PIN
tion control function. code entry system function
(models with PIN code
entry system only).
This icon enables the ma- Return to main screen.

terial handling control func-
tions (models with height
selector or deluxe multi-
functional operation only).
This icon enables the
vehicle management func-
tion
ADMINISTRATOR menu screen (with vehicle startup

using key)
General screen.
ü Operating procedure
1) Enter the password on the general screen to display the AD-
MINISTRATOR menu.
2) Press the ( ) or ( ) button to select the desired menu.
3) Press the ( ) or ( ) button to select the option, and press

the (I) button to view the menu
NOTICE! Press the (O) switch to return to the general screen
POWER CONTROL (SPH)

PROFILE SETTING (selection of profile 0-1-2-3)
POWER MODE (selection of program S-P-H)
DRIVE POWER (setting of drive motor torque for SPH mode)
LIFT POWER (setting of lifting motor torque for SPH mode)
TRACTION SETTING
LOW SPEED (setting of low speed)
SPEED LIMIT (setting of maximum speed limiter)
SPEED ALARM (setting of over speed alarm)
MATERIAL HANDLING (optional)

LOAD METER 0 SET *1 (load meter reset)
LOAD ALARM SET *1 (setting of overload alarm)
HEIGHT SET *2 (setting of automatic height control)
HEIGHT SET CLR *2 (reset of automatic height control)
HEIGHT LIM *2 (setting of height limiter)
MAX HEIGHT LIM *2 (setting of maximum height limiter)
*1: With Deluxe multi-function display

*2: With height selector
3
TRUCK MANAGEMENT
AUTO POWER OFF (setting of auto power off)
PASSWORD (setting of second password)
MENU LOCK (switching of operator menu lock)
HR COUNTER CLR (reset partial hour counter)
SHOCK SENSOR (optional)

CUTBACK SPEED (reduction of shock speed)
DAMAGE MEMORY (control of shock memorization) *
ALARM RESET (reset shock alarm) *
MEAS. / SETTING (monitoring and setting of shock detection level)
*
MEMORY CLR (reset of shock memory) *
* Parameter not available with I_Site
POWER CONTROL
This menu can be used to set the traction and lifting control func-
tions.
1. PROFILE SETTING
Can be used to select the operator profile:
Profile: 0 - 1 - 2 - 3
The ( ) or ( ) button can be used to select the desired profile.

Press the (I) button to return to the menu screen.
2. POWER MODE
Can be used to select one of the programs: S - P - H - SPH

3. DRIVE POWER
Can be used to select the drive motor torque for the SPH program:
Value 1: lower motor torque - Value 5: higher motor torque

4. LIFT POWER
Can be used to select the lifting motor torque for the SPH program:

TRACTION SETTING
This menu can be used to set the traction control functions.
1. LOW SPEED
Can be used to select the maximum traction speed when the low
speed function is enabled.
Button ( ): Reduces the traveling speed.
Button ( ): Increases the traveling speed.

Button (I): Return to the menu screen.

The limit can be adjusted from 2 to 50 km/h in steps of 1 km/h. If
the operator sets the speed to over 50km/h, the low speed function
is disabled. In that case “OFF” is displayed.
2. SPEED LIMIT
Can be used to select the maximum traction speed.
3

the operator sets the speed to over 50km/h, the maximum speed
limit function is disabled. In that case “OFF” is displayed.
3. SPEED ALARM
Can be used to enable an alarm (acoustic and visual) when the set
speed is reached.

the operator sets the speed to over 50km/h, the speeding alarm
function is disabled. In that case “OFF” is displayed.
MATERIAL HANDLING
This menu can be used to set the material handling control func-
tions.
LOADMETER 0 SET (V mast version)

Can be used to adjust the load measuring device (deluxe multi-
functional display only)
ZERO SET procedure: Position the mast vertically and lift the forks
to a height of 500 mm above the ground.
Press and hold the (I) button for at least 2 seconds to reset the
value to 0. In that case “OK” is displayed.
Press button ( O ) to return to the MATERIAL HANDLING screen.
LOADMETER 0 SET (FV and FSV mast version)

Can be used to adjust the load measuring device (deluxe multi-
functional display only)
ZERO SET 1 procedure: Position the mast vertically and lift the
forks to a height of 500 mm above the ground.
Press the ( ) button to continue to the next screen
Procedure: ZERO SET 2: Position the mast vertically and lift the
forks until the side cylinders open by 100 mm.
LOAD ALARM SET

Can be used to set the overload alarm (deluxe multifunctional dis-
play only)
Button ( ): Decreases the load value.
Button ( ): Increases the load value.

Button (O): Return to the menu screen.
Press and hold the (I) button for at least 2 seconds to save the in-
dicated value. In that case “OK” is displayed.
HEIGHT SET
Can be used to set the three height levels (with height selector op-
tion only)
Procedure: Use the ( ) or ( ) button to select the level (A or B

or C) you wish to set.
Set the mast in a vertical position and lift the forks until they reach
the desired height.
Press and hold the (I) button for at least 2 seconds to save the
mast height. In that case “OK” is displayed.
Repeat the procedure for the remaining levels.
HEIGHT SET CLR

Can be used to delete all memorized height levels in the height se-
lector option
Press and hold the (I) button for at least 2 seconds to delete all
memorized height levels. In that case “OK” is displayed.
3
HEIGHT LIM
Can be used to enable/disable height limitation via the height lim-
iter button (S15).
Procedure (SET): Use the ( ) or ( ) button to select the "SET"

option.
the desired height.
mast height. In that case “OK” is displayed.
Procedure (CLR): Use the ( ) or ( ) button to select the

"CLR" option.
Press and hold the (I) button for at least 2 seconds to delete the
memorized height limit. In that case “OK” is displayed.
MAX HEIGHT LIM

Can be used to set the maximum lifting height.
Procedure (SET): Use the ( ) or ( ) button to select the "SET"

option.
the desired height.
maximum lifting height. In that case “OK” is displayed.
Procedure (CLR): Use the ( ) or ( ) button to select the

"CLR" option.
Press and hold the (I) button for at least 2 seconds to delete the
memorized mast height. In that case “OK” is displayed.
TRUCK MANAGEMENT
This menu can be used to set the vehicle management functions.
AUTO POWER OFF

Can be used to enable and set automatic switching off of the
vehicle.
Button ( ): decreases the set time.
Button ( ): increases the set time.

Button (I): return to the menu screen.
The time can be adjusted from 2 to 60 minutes in steps of 1
minute. The automatic switch-off function can be disabled by se-
lecting "OFF", which comes after "60 min".
PASSWORD
Can be used to enable a secondary password for accessing the
ADMINISTRATOR menu.
ENABLE
Press the ( ) or ( ) button to enable/disable the second pass-

word for the ADMINISTRATOR menu.
ON: enabled
OFF: disabled
Press the ( ) button to start the password change procedure.

Press the (O) button to return to the TRUCK MANAGEMENT
screen.
3
Procedure:
Use the numeric buttons on the display to enter the password.
Press the (I) button to save the entered password;
screen.
MENU LOCK *
Can be used to enable/disable operator access to the menus:
POWER CONTROL MENU
TRAVEL SETTING MENU
and selection of the power mode (S-P-H).
Button ( ) or ( ): to select ON / OFF.

screen.
When "MENU LOCK" is set to “YES”, the operator cannot change
the power mode (S-P-H) and the operator menus are not shown.
* Not active with PIN CODE version
HR COUNTER CLR
Can be used to reset the partial hour meters which can be seen
from the operator menu.
Press the ( ) or ( ) button to select the hour meter you wish

to reset.
Press the ( ) or ( ) button to enter the reset hour meter sub-

menu.**
Press the ( O ) button to return to the menu screen.
PUMP HM: Reset pump motor hour meter
TRAC HM: Reset drive motor hour meter
KEY HM: Reset key hour meter
TRAC + PUMP HM: Reset drive motor + pump motor hour meter
** Reset hour meter sub-menu: Press and hold the (I) button for at
least two seconds to reset the hour meter. In that case “OK” is dis-
played.
SHOCK SENSOR
This screen can be used to select the shock sensor function.
CUTBACK SPEED
Can be used to select the maximum traction speed when the
vehicle is subjected to a shock with a greater intensity than the set
value.

DAMAGE MEMORY
Can be used to view the last 10 shocks recorded
Button ( ): Selects the option within the menu.
Button ( ): Selects the option within the menu.

Button (I): Enters the alarm.
Within each alarm you will see:
F/R: intensity of the front or rear shock.
L/R: intensity of the side shock.
PIN: Operator code enabled when the shock occurred.
ALARM RESET
Allows the vehicle administrator to restore standard machine func-
tions after it has been subjected to a shock.
Press and hold the ( I ) button for at least 2 seconds to delete the
shock alarm.
Press the ( O ) button to return to the SHOCK SENSOR screen.
MEAS./SETTING
3
Can be used to view the intensity of the shock in real time and the
maximum peaks memorized, and to set the acceleration value
which activates the speed reduction set via the CUTBACK SPEED
menu.
Values in real time Maximum peaks memorized

Front/rear acceleration value
above the shock alarm trigger threshold
Press button ( tartaruga ) to

continue to the alarm setting
screen
Press and hold the ( I ) button for at

least 2 seconds to delete the
memorized mast height.
Press button ( tartaruga ) to continue to the
next alarm setting screen
Side acceleration value

above the shock alarm trigger threshold
MEMORY CLR
Can be used to delete all shock alarms memorized.
Press and hold the ( I ) button for at least 2 seconds to delete all
shock alarms. In that case “OK” is displayed.
Press the ( O ) button: Return to menu screen
ADMINISTRATOR menu screen (with vehicle startup

using pin code via keypad)
General screen.
ü Operating procedure
1) Enter the password on the general screen to display the AD-
MINISTRATOR menu.
2) Press the ( ) or ( ) button to select the desired menu.
3) Press the ( ) or ( ) button to select the option, and press

the (I) button to view the menu
NOTICE! Press the (O) switch to return to the general screen
PIN ENTRY
▪ REGISTRY (setting of the number of pin codes enabled)
▪ MODIFY (changing of pin codes)
▪ CHANGE CLR (reset of pin codes to the default values)
▪ PROFILE SETTING (selection of operator profile to edit)
3
MATERIAL HANDLING (optional)
▪ LOAD METER 0 SET *1 (load meter reset)
▪ LOAD ALARM SET *1 (setting of overload alarm)
▪ HEIGHT SET *2 (setting of automatic height control)
▪ HEIGHT SET CLR *2 (reset of automatic height control)
▪ HEIGHT LIM *2 (setting of height limiter)
▪ MAX HEIGHT LIM *2 (setting of maximum height limiter)
*1: With Deluxe multi-function display
*2: With height selector
TRUCK MANAGEMENT
▪ AUTO POWER OFF (setting of auto power off)
▪ PASSWORD (setting of second password)
▪ MENU LOCK (switching of operator menu lock)
▪ HR COUNTER CLR (reset partial hour counter)
SHOCK SENSOR (optional)

▪ CUTBACK SPEED (reduction of shock speed)
▪ DAMAGE MEMORY (control of shock memorization)
▪ ALARM RESET (reset shock alarm)
▪ MEAS. / SETTING (monitoring and setting of shock detection
level)
▪ MEMORY CLR (reset of shock memory)
PIN ENTRY
This menu can be used to change the pin codes and set the trac-
tion and lifting control functions.
1) REGISTRY
Can be used to enable 1 to 40 startup pin codes:
Use the ( ) or ( ) button to adjust the value. Press the ( O )
button to return to the menu screen.
2) MODIFY
Can be used to change the startup in codes, associate each code
with an operator profile and enable/disable power modes (S - P - H
- SPH).
The ( ) or ( ) button can be used to select the code you wish
to change.
Use the ( ) button to enter the sub-menu for changing the selec-
ted code*.
*Sub-menu screen.
The ( ) or ( ) button can be used to select the field you wish
to change.
The ( ) or ( ) button can be used to change or enable/disable
the selected field.
Press the ( I ) button to enter the save screen.
changes. In that case “OK” is displayed.
3) CHANGE CLR
Can be used to restore the default configuration of all startup pin
codes.
Press and hold the ( I ) button for at least 2 seconds to restore the
original configuration of all pins. In that case “OK” is displayed.
3
List of pin codes
Pin Middle Pin Middle Pin Middle Pin Middle Pin Middle
00323 0 10043 3 20102 1 30001 0 40010 2
01034 1 11020 0 21020 2 30204 0 40143 3
02021 2 11404 0 22010 3 32040 1 41342 0
02102 3 12403 1 22344 0 33300 2 41414 0
03033 0 13042 2 22433 0 33410 3 42231 1
03421 0 14143 3 23013 1 34010 0 43001 2
04031 1 14021 0 23401 2 34132 0 43203 3
04432 2 14322 0 24431 3 34343 1 44044 0
4) PROFILE SETTING
Can be used to set the POWER CONTROL, TRACTION SETTING and MATERIAL HANDLING SETTING func-
tions for the operator profiles.
The ( SPH) or ( clock) button can be used to select the desired

profile.
The (I) button can be used to enter the setting menu for
services within the selected profile
Refer to the selected profile

on the SETTING screen
POWER CONTROL TRACTION SETTING MATERIAL HANDLING SETTING
PROFILE SETTING - POWER CONTROL

This menu can be used to set the traction and lifting control func-
tions for the profile selected previously.
1. POWER MODE
Can be used to select one of the programs: S - P - H - SPH
The ( ) or ( ) button can be used to select the desired pro-

gram.
2. DRIVE POWER
Can be used to select the drive motor torque for the SPH program

gram.
3. LIFT POWER
Can be used to select the lifting motor torque for the SPH program

gram.
PROFILE SETTING - TRACTION SETTING

This menu can be used to set the traction control functions for the
profile selected previously.
LOW SPEED
Can be used to select the maximum traction speed when the low
the operator sets the speed to over 50km/h, the low speed function
is disabled. In that case “OFF” is displayed.
SPEED LIMIT
Can be used to select the maximum traction speed.
The limit can be adjusted from 2 to 50 km/h in steps of 1 km/h. If 3
the operator sets the speed to over 50km/h, the maximum speed
limit function is disabled. In that case “OFF” is displayed.
SPEED ALARM
Can be used to enable an acoustic and visual alarm when the set
speed is reached.
the operator sets the speed to over 50km/h, the speeding alarm
function is disabled. In that case “OFF” is displayed.
DRIVE TUNE
Can be used to modify the traction parameters.
Button ( ) and button ( ): Select the parameter
Button ( ): Decreases the parameter value.
Button ( ): Increases the parameter value.
▪ T ACC DELAY: adjusts the traction acceleration
Minimum value: sharp acceleration
Maximum value: gentle acceleration
▪ INV BRK: adjusts deceleration while reversing
Minimum value: sharp deceleration
Maximum value: gentle deceleration
▪ RELEASE BRK: adjusts deceleration when the accelerator
pedal is released (regenerative braking or release braking)
Minimum value: sharp deceleration
Maximum value: gentle deceleration
PROFILE SETTING - MATERIAL HANDLING SETTING

tions for the profile selected previously.
LOW SPEED
Can be used to select the maximum lifting speed when the low
Button ( ): Reduces the lifting speed
Button ( ): Increases the lifting speed
MATERIAL HANDLING
tion.
Please refer to the specific section.
TRUCK MANAGEMENT
This menu can be used to set the vehicle management functions.
SHOCK SENSOR
This menu can be used to set the shock sensor functions.
MASK MENU
GENERAL
Besides the general functions normally used by the operator, the multifunctional display also offers the following
hidden functions, for use by servicing and maintenance personnel. The service functions are password-protec-
ted so that important data cannot be damaged by misuse or errors on the part of users.
3
List of functions
Function menu Sub-menu

ANALYZER Diag memory I/O steering
I/O temp/volt I/O others
I/O traveling Active test (4 wheels version only)
I/O material handling Software version
TUNING Traction Tilt valve
Material handling ATT1 valve
Steering (3 wheels version only) ATT2 Valve
Valve SAS ATT3 valve
Lift valve
OPTION SETTING Optionset Dipped light
Maintenance Work lamp
Rent time Wipers/washer
Battery Dir lights
Twis flag Heater
Rot lamp Opt out
Flash lamp
MATCHING Serial number SAS
Fw/Bw selector Load meter (deluxe display only)
Drive H-selector
Mat. Handling Tire data
OTHERS MENU Meter start Manager pass
Demo mode Contrast
To default set Deluxe mode
Mask password
Mask menu password

Password entry procedure
NOTICE! Always use your fingertips to operate the switches on the display. Sharp objects may damage
the switch.
NOTICE! If an error occurs during the startup procedure, turn the key to OFF and start again from the
beginning. If the MASK MENU does not appear after several attempts, the system may be faulty.
Step Display Operation Vehicle response
1 When you press the but-
Press and hold the ( ) and ( ) tons, a short beep will
buttons simultaneously for at least 2 sound, followed by another
seconds 2 short beeps after 2
seconds.
2 Short acoustic warning.
Press the ( ) button within 10
seconds.
3 Short acoustic warning.

Press the ( ) button within 10
seconds.
4 Within 10 seconds, press and hold the When you press the but-
tons, a short beep will
( ) and ( ) buttons simultan- sound, followed by another
eously for at least 2 seconds. 2 short beeps after 2
seconds.
5 When the second hidden password has been set: The second
password screen is displayed. Enter the second password. Or: If it
has not been set beforehand, this screen will be skipped.
6 The ANALYZER menu screen is displayed automatically.
ANALYZER
GENERAL
The ANALYZER function can be used to view information relating to the sensors and machine fault error codes.
Button ( ): Indicates the selected option
Button ( ): Selects the previous option
Button ( ): Selects the next option
Button ( ): Selects the next folder
Button ( ): Selects the previous folder

Button (I): Confirm
Button (O): Output
DIAG MEMORY
The DIAG MEMORY menu is used to display the alarms in real time and view/delete the alarms stored in the
memory.
Button ( ): Selects the previous parameter 3

Button ( ): Selects the next parameter
Button ( ): Enters the selected option

Button (O): Return to menu screen
Display option Description Unit of measure

CURRENT ALR Displays the error codes in real time /
READ LOG Displays the error codes in memory /
CLEAR LOG Deletes the list of error codes in memory /
I/O TEMP/VOLT
The I/O TEMP/VOLT menu is used to display the temperatures of the motors, logic units and battery voltage.
Button ( ): Selects the previous screen
Button ( ): Selects the next screen


TR MOTOR T Displays the right drive motor temperature °C
TR CONTR T Displays the right drive logic unit temperature °C
TL MOTOR T Displays the left drive motor temperature °C
TL CONTR T Displays the left drive logic unit temperature °C
P MOTOR T Displays the pump motor temperature °C
P CONTR T Displays the lifting logic unit temperature °C
S CONTR T Displays the EPS steering logic unit temperature °C
S MOTOR T Displays the steering motor temperature °C
CAPACITOR V Displays the battery voltage measured between +VBATT and Volt
GND
KEY VOLTAGE Displays the battery voltage measured between pin 1 connector Volt
J1 and GND
BATTERY % Displays the residual battery charge as a percentage %
I/O TRAVELING
The I/O TRAVELING menu is used to display the drive motor frequencies, potentiometer and other component
signals linked to the drive function.


SPEED SET Frequency supplied by the MCB to the right drive logic unit Hz
SPEED TRAC Frequency read by the drive motor rpm sensors Hz
TRAC ACC Difference between the “SPEED SET” and “SPEED TRAC” fre- Seconds
quencies.
FREQ RIGHT Frequency supplied by the right drive logic unit to the right drive Hz
motor.
ENC RIGHT Frequency read by the right drive motor rpm sensor Hz
SLIP RIGHT Difference between the “FREQ RIGHT” and “ENC RIGHT” fre- Hz
quencies
FREQ LEFT Frequency supplied by the left drive logic unit to the left drive mo- Hz
tor
ENC LEFT Frequency read by the left drive motor rpm sensor Hz
SLIP LEFT Difference between the “FREQ LEFT” and “ENC LEFT” frequen- Hz
cies
CURRENT R Current supplied by the right drive logic unit to the right drive mo- Ampere
tor.
ID RIGHT Current supplied by the right drive logic unit to the right drive mo- Ampere
tor.
IQ RIGHT Current supplied by the right drive logic unit to the right drive mo- Ampere
tor.
CURRENT L Current supplied by the right drive logic unit to the left drive motor. Ampere
ID LEFT Current supplied by the right drive logic unit to the left drive motor. Ampere
IQ LEFT Current supplied by the right drive logic unit to the left drive motor. Ampere
POT ACC R3 Accelerator potentiometer signal R3 Volt
POT ACC R2 Accelerator potentiometer signal R2 Volt
POT BRK R1 Brake potentiometer signal R1 Volt
POT BRK R4 Brake potentiometer signal R4 Volt
FORWARD Microswitch forward drive signal N.O. ON/OFF
NOT FW Microswitch forward drive signal N.C. ON/OFF
BACKWARD Microswitch reverse drive signal N.O. ON/OFF
NOT BW Microswitch reverse drive signal N.C. ON/OFF
CFG Accelerator foot board configuration No. Pedals
FW JOY Forward drive signal of arm rest inverter ON/OFF
BW JOY Reverse drive signal of arm rest inverter ON/OFF
SEAT Seat microswitch signal ON/OFF
ELT SWING Oscillation lock cylinder valve on ON/OFF
ELT SWING Current supplied to oscillation lock cylinder valve Ampere
PARK BRK Parking brake selector signal ON/OFF
ELT BRK R Voltage supplied to the right parking brake Vbatt %
ELT BRK L Voltage supplied to the left parking brake Vbatt %
TURTLE Speed reduction of the turtle function on ON/OFF
SPEED LIMIT Speed reduction of the SPEED LIMIT function on ON/OFF
TRAC OVERTEMP Speed reduction in the case of drive motor overheating ON/OFF

PUMP OVERTEMP Speed reduction with pump motor overheating ON/OFF
PUMP IN ALARM Speed reduction with lifting logic unit malfunction ON/OFF
AUX RED 1 T CUTB SP1 function speed reduction ON/OFF
AUX RED 2 T CUTB SP2 function speed reduction ON/OFF
OIL BRAKE Speed reduction with low brake oil level ON/OFF 3
SHOCK ALARM Speed reduction with shocks ON/OFF
MAINTENANCE Speed reduction with maintenance hour meter expiry ON/OFF
RENTAL Speed reduction with hire hour meter expiry ON/OFF
FORCED P. ON Speed reduction with forced display on ON/OFF
BATTERY LOW Speed reduction with flat battery ON/OFF
I/O M. HANDLING
The I/O M.HANDLING is used to display the pump motor frequencies, the potentiometer signals of the hydraulic
functions and the remaining materials handling components.


SPEED SET Frequency supplied by the MCB to the lifting logic unit Hz
FREQ PUMP Frequency supplied by the lift logic unit to the pump motor. Hz
ENC PUMP Frequency read by the pump motor rpm sensor. Hz
PUMP SLIP Difference between the “FREQ PUMP” and “ENC PUMP” frequen- Hz
cies
CURRENT Current supplied by the lift logic unit to the pump motor. Ampere
ID PUMP Current supplied by the lift logic unit to the pump motor. Ampere
IQ PUMP Current supplied by the lift logic unit to the pump motor. Ampere
PRESSURE Pressure read by pressure sensor Bar
PRESSURE V Pressure sensor signal Volt
POT LIFT Lifting potentiometer signal Volt
/POT LIFT Lifting potentiometer signal Volt
EVP LIFT Current supplied to the lifting and lowering valve Ampere
POT TILT Tilt potentiometer signal Volt
/POT TILT Tilt potentiometer signal Volt
EVP TILT Current supplied to the tilt valve Ampere
POT ATT1 ATT1 function potentiometer signal Volt
/POT ATT1 ATT1 function potentiometer signal Volt
EVP ATT1 Current supplied to the ATT1 function valves Ampere
POT ATT2 ATT2 function potentiometer signal Volt
/POT ATT2 ATT2 function potentiometer signal Volt
EVP ATT2 Current supplied to the ATT2 function valves Ampere
ATT3 SW ATT3 function button on ON/OFF
ATT3 ELT ATT3 function button on ON/OFF
% CAPACITY Percentage of nominal lifted capacity %
HEIGHT SW Height selector button on ON/OFF

H SENSOR Fork height sensor signal Volt
MAX H REQ Maximum height limit button on ON/OFF
FORK LEVEL Fork auto-leveling button on ON/OFF
TILT ANGLE Tilt angle read by tilt angle potentiometer Degrees
TILT POT Tilt angle potentiometer signal Volt
MAST H NO Mast height microswitch signal N.O. ON/OFF
MAST H NC Mast height microswitch signal N.C. ON/OFF
TURTLE Speed reduction of the turtle function on ON/OFF
BATTERY LOW Speed reduction with flat battery ON/OFF
PUMP OVERTEMP Speed reduction with pump motor overheating ON/OFF
MAINTENANCE Speed reduction with maintenance hour meter expiry ON/OFF
RENTAL Speed reduction with hire hour meter expiry ON/OFF
LIFT LOCK Lifting lock valve L27 on ON/OFF
TILT LOCK Tilt control valve L25 on ON/OFF
I/O STEERING
The I/O STEERING menu is used to display the steering motor frequencies, sensor and other component sig-
nals linked to the steering function.

3 wheels version

STEER POT1 TFD sensor 1 signal /
STEER POT2 TFD sensor 2 signal /
T ST POT1 Steering sensor signal 1 mVolt
T ST POT2 Steering sensor signal 2 mVolt
POS SETP Position of wheels read by the steering sensor Volt
MOTOR SPEED Frequency read by the steering motor encoder Hz
MOTOR FREQ Frequency supplied by the EPS steering logic unit to the steering Hz
motor
CURRENT Current supplied by the EPS steering logic unit to the steering mo- Ampere
tor
STEER IQ Current supplied by the EPS steering logic unit to the steering mo- Ampere
tor
STEER ID Current supplied by the EPS steering logic unit to the steering mo- Ampere
tor
STEER ANG Steering angle read by the steering sensor Degrees
4 wheels version

EVP STEER Steering wheel knob synchronizer valve on ON/OFF
DC STEER Current supplied to the steering wheel knob synchronizer valve Ampere
TIRE ST POT Steering angle read by the steering sensor Degrees
TIRE ST POT Steering sensor signal Volt 3
COMP Steering wheel knob position compensation /
KNOB ANGLE Knob position read by the steering encoder /
I/O OTHERS
The I/O OTHERS menu is used to display the working hours. These hour/trip meters are not resettable, in con-
trast to the other hour meters on the truck, and act as a reference for the warranty.


LIFE WORK HM Displays the combined pump + drive working hours Hours
LIFE KEY HM Displays the key working hours Hours
DHU CONN DHU card connected ON/OFF
KEY PAD CONN Keypad connected ON/OFF
SHOCK SENS Shock sensor connected ON/OFF
SMART ACCESS Smart Access connected ON/OFF
ACTIVE TEST
The ACTIVE TEST menu is used to enable or disable some functions in the steering systems on the 4 wheel
version, to check some functions.
Button ( ): Selects the previous parameter
Button ( ): Modifies the parameter value


STEER COMP Enables/disables the steering wheel knob synchronizer function ON/OFF
STEER EV Enables the steering wheel synchronization valve ON/OFF
SWING CONTR Enables/disables the oscillation lock cylinder valve function ON/OFF
SWING EV Enables the oscillation lock cylinder valve ON/OFF
SW VERSION
The SW VERSION menu is used to view the software versions of the various cards installed on the machine.


DISPLAY Displays the software version of the display /
TRCB Displays the software version of the TRCB section MCB card /
RH DR DRV Displays the software version of the right drive logic unit /
LH DR DRV Displays the software version of the left drive logic unit /
PM DRIVER Displays the software version of the lifting logic unit /
ARMREST M Displays the software version of the master armrest card /
ARMREST S Displays the software version of the slave armrest card /
EVCB Displays the software version of the EVCB section MCB card /
EPS Displays the software version of the EPS lifting logic unit /
TUNING
GENERAL
The TUNING function accurately controls the traction and material handling control systems. When a user re-
quest is received, such as a request to soften acceleration for the regenerative braking force, the various setting
levels can be changed.

Button (I): Confirm
Button (O): Output
TRACTION
The TRACTION menu is used to control the traction parameters.

Button ( ): Selects the POWER MODE (S-P-H-SPH)
Button ( ): Selects the operator profile (0-1-2-3)

MAX SPD FW Controls the maximum speed in forward drive Hz
See GRAPHIC A
MAX SPD BW Controls the maximum speed in backward drive Hz
See GRAPHIC A
T ACC DELAY Controls the forward and reverse acceleration Seconds 3
See GRAPHIC B
THROTTLE 0 Determines point 0 on the accelerator pedal % potentiometer
See GRAPHIC A stroke
FREQ CREEP Controls the speed at point 0 on the accelerator pedal Hz
See GRAPHIC A
THROTTLE X1 Determines point 1 on the accelerator pedal % potentiometer
THROTTLE Y1 Controls the speed at point 1 on the accelerator pedal % max. speed
See GRAPHIC A
See GRAPHIC A
See GRAPHIC A
TORQUE PROF Selects the drive motor torque /
See GRAPHIC D
PEDAL BRK Controls the braking time pressing on the brake pedal and Seconds
releasing the accelerator pedal
See GRAPHIC F
SPD LIM BRK Controls the braking time when the accelerator pedal is par- Seconds
tially released
See GRAPHIC I
INV BRAKE Controls the reverse drive braking time Seconds
See GRAPHIC J
F THROTTLE 0 Controls point 0 on the brake pedal % potentiometer
See GRAPHIC E stroke
F THROTTLE X Controls point 1 on the brake pedal % potentiometer
See GRAPHIC E stroke
RELEASE BRK Controls the braking time when the accelerator pedal is fully Seconds
released
See GRAPHIC H
BRAKE DELAY Controls the braking time pressing on the brake pedal and Seconds
holding down the accelerator pedal
See GRAPHIC G
ACC SMOOTH Controls the initial forward and reverse acceleration Seconds
See GRAPHIC B
ACC SM SP Controls the speed at which the ACC SMOOTH effect ends Hz
See GRAPHIC B
REL SMOOTH Controls the braking time at low speed Seconds
See GRAPHIC H

LOW SPEED BRK Controls the speed at which the REL SMOOTH effect starts % max. speed
See GRAPHIC H
CONST SP ACC Controls the acceleration when partially pressing the accel- Seconds
erator pedal
See GRAPHIC C
EMERG ACC Controls the braking time if the emergency button is enabled Seconds
See GRAPHIC K
20 BDI CUTB Controls the maximum speed when the battery indicator % max. speed
shows 20% residual charge
TURTLE CUTB Controls the maximum speed when selecting the tortoise Km/h
function
T CUTB SP1 Controls the maximum speed when there is no continuity % max. speed
between pin 1 and pin 2 on connector J23
T CUTB SP2 Controls the maximum speed when the body guard gates % max. speed
are open
STOP RAMP T Determines after how long the parking brakes are enabled Seconds
when the truck is stopped
PK BRK MODE Disables the automatic parking brake function ON/OFF
TUNING - TRACTION PARAMETER GRAPHICS

M. HANDLING
The M. HANDLING menu is used to control the materials handling parameters.


MIN SPEED UP Controls the minimum speed of the hydraulic functions Hz
See GRAPHIC M
MAX SPEED UP Controls the maximum speed of the hydraulic functions Hz
See GRAPHIC M
TILT SPEED Controls the maximum tilt speed Hz
ATT1 SPEED Controls the maximum speed of the ATT1 functions Hz
HYDRO SPEED Controls the hydraulic steering speed for the 4 wheel version Hz
LIFT SMOOTH Controls the lifting valve closing time /
See GRAPHIC O
LOWER SMOOTH Controls the lowering valve closing time /
See GRAPHIC O
P ACC DELAY Controls the lift acceleration Seconds
P DEC DELAY Controls the lift deceleration Seconds
CURVE MODE Selects the potentiometer sensitivity /
See GRAPHIC L
P THROTTLE 0 Determines point 0 on the lifting lever % potentiometer
See GRAPHIC M stroke
P THROTTLE X Determines point 1 on the lifting lever % potentiometer
See GRAPHIC M stroke
P THROTTLE Y Controls the speed at point 1 on the lifting lever Hz
See GRAPHIC M
TORQUE PROF Selects the pump motor torque /
See GRAPHIC N
TURTLE CUTB Controls the maximum speed when selecting the tortoise % max. speed
function
P CUTB SP1 Unused. % max. speed
P CUTB SP2 Unused. % max. speed
ANGLE FW Determines the forward tilting in degrees to calculate the tilt- Degrees
ing degrees indicated on the display
ANGLE BW Determines the backward tilting in degrees to calculate the Degrees
tilting degrees indicated on the display
TUNING - M. HANDLING PARAMETER GRAPHICS
STEERING
The STEERING menu is used to control the steering parameters on the 3 wheel version.


I_STEER_L Controls the steering hardness at low speed Ampere
See GRAPHIC P
I_STEER_H Controls the steering hardness at high speed Ampere
See GRAPHIC P
STEER_L_F Defines the low speed range % max. speed
See GRAPHIC P
STEER_H_F Defines the high speed range % max. speed
See GRAPHIC P
STEER_REV Controls the number of steering wheel turns from full right to Hz
full left
TUNING - STEERING PARAMETER GRAPHIC
VALVE SAS
The VALVE SAS menu is used to control the SAS function parameters on the mast.


2ND COIL I Controls the spool capacity of the tilt function when the mast % maximum current
height microswitch is open
2ND SPEED Controls the pump motor rpm of the tilt function when the % max. speed
mast height microswitch is open
LIFT VALVE
The LIFT VALVE menu is used to control the lowering and lifting valve currents.


IMIN LOW Minimum current supplied to the lowering valve Ampere
See GRAPHIC Q
IMIN LIFT Minimum current supplied to the lifting valve Ampere
See GRAPHIC Q
IMAX LOW Maximum current supplied to the lowering valve Ampere 3
See GRAPHIC Q
IMAX LIFT Maximum current supplied to the lifting valve Ampere
See GRAPHIC Q
TUNING - LIFT VALVE PARAMETER GRAPHIC
TILT VALVE
The TILT VALVE menu is used to control the tilt valve currents.


IMIN TILT FW Minimum current supplied to the forward tilt valve Ampere
See GRAPHIC Q
IMIN TILT BW Minimum current supplied to the backward tilt valve Ampere
See GRAPHIC Q
IMAX TILT FW Maximum current supplied to the forward tilt valve Ampere
See GRAPHIC Q
IMAX TILT BW Maximum current supplied to the backward tilt valve Ampere
See GRAPHIC Q
TUNING - TILT VALVE PARAMETER GRAPHIC
ATT1 VALVE
The ATT1 VALVE menu is used to control the valve currents of the ATT1 function.


IMIN ATT1 1 Minimum current supplied to the ATT1 1 function valve Ampere
See GRAPHIC Q
See GRAPHIC Q
IMAX ATT1 1 Maximum current supplied to the ATT1 1 function valve Ampere
See GRAPHIC Q
See GRAPHIC Q
TUNING - ATT1 VALVE PARAMETER GRAPHIC
ATT2 valve
The ATT2 VALVE menu is used to control the valve currents of the ATT2 function.


See GRAPHIC Q
See GRAPHIC Q
See GRAPHIC Q
See GRAPHIC Q
TUNING - ATT2 VALVE PARAMETER GRAPHIC
ATT3 VALVE
The ATT3 VALVE menu is used to enable the ATT3 function valve.


ATT3 EN Enables the 5th way valve pilot. ON/OFF
Flow exchanger valve at 48V between the 4th and 5th way
OPTION SET
GENERAL
The OPTION SET function is used to adapt the specifications of the controller and the multifunctional display to
the options currently applied to the vehicle. The functions are not available on the vehicle if they are not in-
stalled, even if they have been enabled via OPTION SET.
NOTICE! If the main controller or the multifunctional display is replaced, the option set function must be
reset in line with vehicle specifications.

Button (I): Confirm
Button (O): Output
OPTIONSET
The OPTIONSET menu is used to disable the truck options.

3


SPEED FORMAT Selects the unit of the speedometer Mph/Kmh
DATE TYPE Selects the date format in the DIAG MEMORY menu D-M / M-D
TILT IND Enables the tilt degree indication on the display (DELUXE ON/OFF
version only
LOAD ALM Selects the automatic or on request function of the overload AUT/REQ
alarm (DELUXE version only)
KNOB COMP Disables the steering wheel synchronization function ON/OFF
SAS TILT EN Disables the mast SAS function ON/OFF
AUTO SPEED Enables the AUTO SPEED CONTROL function /
LIFE HM MODE Selects the hour meter format in the DIAG MEMORY menu KH/WH
HYDRO DEL ACC Controls after how long the pump motor switches off after re- Seconds
leasing the accelerator pedal (4 wheel version only)
HYDRO DEL BRK Controls after how long the pump motor switches off after re- Seconds
leasing the brake pedal (4 wheel version only)
BELT SWITCH Enables the ZLOC function ON/OFF
HIMAST RED Enables the speed reduction (12Km/h) when the truck is fit- ON/OFF
ted with a mast > 6300 mm
CRV REDUCTION Enables the speed reduction in the curve (DELUXE 4 wheel ON/OFF
version only)
ANGLE START Defines the starting steering angle of speed reduction in the Degrees
curve
See GRAPHIC R / GRAPHIC S
ANGLE INC Defines the second steering angle of speed reduction in the Degrees
curve
ANGLE MAX Defines the third steering angle of speed reduction in the Degrees
curve
CRV CUTB OUT Controls the speed reduction in the curve at the angle % max. speed
ANGLE INC. Parameter valid when steering from straight
wheels to turned wheels
See GRAPHIC R
CRV CUTB IN Controls the speed reduction in the curve at the angle % max. speed
ANGLE INC. Parameter valid when steering from turned
wheels to straight wheels
See GRAPHIC S
CRV CUTB MAX Controls the speed reduction in the curve at the angle % max. speed
ANGLE MAX

ANGLE MAX 2 Defines the fourth steering angle of speed reduction in the Degrees
curve
See GRAPHIC R
ANGLE STOP Defines the fifth steering angle of speed reduction in the Degrees
curve
See GRAPHIC R
MAX CURV CB Controls the speed reduction in the curve at the angle %
ANGLE STOP
See GRAPHIC R
OPTIONSET - SPEED REDUCTION IN THE CURVE PARAMETER GRAPHICS

▪ GRAPHIC R valid when steering goes from straight wheels to turned wheels
▪ GRAPHIC S valid when steering goes from turned wheels to straight wheels
MAINTENANCE
The MAINTENANCE menu is used to enable and set the hour meter and maintenance meter.


TIMER EN Enables the maintenance hour meter ON/OFF
COUNT MODE Selects the maintenance hour meter unit of measurement KH/WH
SETTING Selects the maintenance hour meter time interval KH/WH
RESET CURR Resets the maintenance hour meter time /
CUT TIME Time which elapses between the alarm and the maintenance KH/WH
hour meter speed reductions
T SPEED CUT Traction speed reduction when CUT TIME has elapsed % max. speed
P SPEED CUT Lifting speed reduction when CUT TIME has elapsed % max. speed
BLINK TIME Defines the activation time of the maintenance indication KH/WH
MAINTENANCE PARAMETER GRAPHICS
Speed
Speed
3
Time Time
1 = when the key is switched on, the icon and the diagnostics LED flash 5 times
2 = Diagnostics LED lit steadily
3 = Speed reductions enabled
RENT TIME
The RENT TIME menu is used to enable and set the rent hour meter.


TIMER EN Enables the rental hour meter ON/OFF
COUNT MODE Selects the rental hour meter unit of measurement KM/WH/DD
SETTING TIME Selects the rental hour meter time interval KM/WH/DD
RESET CURR Resets the rental hour meter time /
CUT TIME Time which elapses between the alarm and the rental hour KM/WH/DD
meter speed reductions
T SPEED CUT Traction speed reduction when CUT TIME has elapsed % max. speed
P SPEED CUT Lifting speed reduction when CUT TIME has elapsed % max. speed
BLINK TIME Defines the activation time of the rental indication KM/WH/DD
RENT TIME PARAMETER GRAPHICS
Speed
Speed
Time Time
1 = when the key is switched on, the icon and the diagnostics LED flash 5 times
2 = Diagnostics LED lit steadily
3 = Speed reductions enabled
BATTERY
The BATTERY menu is used to control the battery indicator.


Li-ION BATT Enables the battery indicator for the lithium batteries ON/OFF
BDI TO 100% Instant reset of battery indicator to 100% %
BDI RESET Defines the minimum charge/discharge the battery must re- %
ceive/undergo for a total or partial reset of the battery indic-
ator
BDI GEL Enables the battery indicator for the gel batteries ON/OFF
BDI MAX Defines the battery indicator discharge curve /
See GRAPHIC T
BDI MIN Defines the battery indicator discharge curve /
See GRAPHIC T
RST VOLT MAX Defines the battery indicator reset curve /
See GRAPHIC U
RST VOLT MIN Defines the battery indicator reset curve /
See GRAPHIC U
BATTERY PARAMETER GRAPHICS
TWIS FLAG
The TWIS FLAG menu is used to reset the truck configuration after removal of one or more components of the
I_Site system.


DHU FLAG Reset DHU card ON/OFF
KEY PAD FLAG Reset pin code keypad ON/OFF
SHOCK SENSOR Reset shock sensor ON/OFF
SMART ACCESS Reset Smart Access ON/OFF
ROT LAMP
The ROT LAMP menu is used to enable the rotating lamp control.


LAMP Enables the rotating lamp ON/OFF
WITH TURTLE Enables the automatic rotating lamp switch-on when the ON/OFF
turtle function is enabled
TRACTION Enables the automatic rotating lamp switch-on when move- ON/OFF
ment is requested
ANY PUMP Enables the automatic rotating lamp switch-on when mater- ON/OFF
ial handling functions are requested
SEAT Enables the automatic rotating lamp switch-on when the ON/OFF
seat microswitch is closed
JOY1 Enables the automatic rotating lamp switch-on when the 5th ON/OFF
way function is enabled
JOY2 Unused. ON/OFF
JOY3 Unused. ON/OFF
JOY4 Unused. ON/OFF
SPEED Enables the automatic rotating lamp switch-on when the ON/OFF
speed set via SPEED VALUE is reached
SPEED VALUE Speed of SPEED parameter Km/h
REVERSE Enables the automatic rotating lamp switch-on when reverse ON/OFF
drive is requested
PB ENABLED Enables the rotating lamp ignition button on the display ON/OFF
FLASH LAMP
The FLASH LAMP menu is used to enable the flash lamp control.


LAMP Enables the flash lamp ON/OFF
WITH TURTLE Enables the automatic flash lamp switch-on when the turtle ON/OFF
function is enabled
TRACTION Enables the automatic flash lamp switch-on when movement ON/OFF
is requested
ANY PUMP Enables the automatic flash lamp switch-on when material ON/OFF
handling functions are requested
SEAT Enables the automatic flash lamp switch-on when the seat ON/OFF
microswitch is closed
JOY1 Enables the automatic flash lamp switch-on when the 5th ON/OFF
way function is enabled
JOY2 Unused. ON/OFF
JOY3 Unused. ON/OFF
JOY4 Unused. ON/OFF
SPEED Enables the automatic flash lamp switch-on when the speed ON/OFF
set via SPEED VALUE is reached
SPEED VALUE Speed of SPEED parameter Km/h

REVERSE Enables the automatic flash lamp switch-on when reverse ON/OFF
drive is requested
PB ENABLED Enables the flash lamp ignition button on the display ON/OFF
DIPPED LIGHT 3
The DIPPED LIGHT menu is used to enable the combined front light control.


LAMP Enables the combined front lights ON/OFF
WORK LAMP
The WORK LAMP menu is used to enable the work lights control.


LAMP FW R Enables the right front working light ON/OFF
LAMP FW L Enables the left front working light ON/OFF
LAMP ADD Enables the additional front working lights ON/OFF
LAMP MAST Enables the additional front working lights on the mast ON/OFF
LAMP BW Enables the rear working lights ON/OFF
MOTION Enables the automatic rear working light switch-on and front ON/OFF
working light switch-off when reverse drive is requested
AUTO BW Enables the automatic rear working light switch-on when re- ON/OFF
verse drive is requested
WIPERS/WASHER
The WIPERS/WASHER menu is used to enable the wind-screen wiper and washer pump control.


FW Enables the front wind-screen wiper ON/OFF
BW Enables the rear wind-screen wiper ON/OFF
MOTION Enables the automatic rear wind-screen wiper switch-on and ON/OFF
front wind-screen wiper switch-off when reverse drive is re-
quested
AUTO BW Enables the automatic rear wind-screen wiper switch-on ON/OFF
when reverse drive is requested
WASHER FW Enables the front washer reservoir ON/OFF
WASHER BW Enables the rear washer reservoir ON/OFF
DIR LIGHTS
The DIR LIGHT menu is used to enable the direction indicator control.


LIGHT Enables the direction indicators ON/OFF
HEATER
The HEATER menu is used to enable the heated rear window and heated seat control.


REAR W HEATER Enables the heated rear window ON/OFF
HEATED SEAT Enables the heated seat ON/OFF
OPT OUT
The OPT OUT menu is used to enable the optional light control.

3


LAMP Enables the optional lights ON/OFF
FW Enables the automatic rotating lamp switch-on when forward ON/OFF
drive is requested
BW Enables the automatic rotating lamp switch-on when reverse ON/OFF
drive is requested
MATCHING
GENERAL
The MATCHING function is used to calibrate the potentiometers, sensors and cards fitted in the vehicle.
NOTICE! After replacing a card, potentiometer or sensor, the replaced component must undergo all the
necessary calibration procedures.

Button (I): Confirm
Button (O): Output
SERIAL NUMBER
The SERIAL NUMBER menu is used for the acquisition of the truck model and serial number. This procedure
can be run if the truck hour counters have not been enabled.
Button (I): Reset
Button ( ): Selects the next field
Button ( ): Selects the previous field

Press ( I ) for 3
seconds
Disconnect and reconnect the

battery
Press ( ) or ( )
to edit the value of
the flashing field
Press ( ) to move
to the next field
Press ( I )
Press ( I )

battery

battery
Press ( O )
FW/BW SELECTOR
The FW/BW SELECTOR menu is used to select the type of drive direction control.

3
Display option Value Description
GEAR MODE DBPEDAL Double pedal
SWPEDAL Swaying pedal
STEERCOL Drive direction control on steering column
ARMREST Drive direction control on armrest
MULTIJOY Multifunction Joystick version drive direction control
DRIVE
The DRIVE menu is used to acquire the accelerator, brake and steering potentiometer.

ACCEL
Used to acquire the accelerator potentiometer.
Press ( )
Press ( I ) for 2 seconds

Press the accelerator
pedal (forward) to
end stroke and re-
lease it slowly. Re-
peat the operation
with the reverse
pedal (if fitted on the
truck)
Press ( I )
OK: acquisition suc-
cessful
NG: acquisition failed
Press ( )
BRAKE
Used to acquire the brake potentiometer.
Press ( )

Press the brake
pedal fully down and
release slowly
Press ( I )
cessful
Press ( )
KNOB REST
Used to acquire the steering wheel knob position (3 wheel version only).
Press ( )

3
Position the steering
wheel with the
TOYOTA logo
straight
Press ( I )
ZERO POT
Used to acquire the steering sensor (3 wheel version only).
Press ( )

Jack up the rear of
the vehicle and posi-
tion the wheels
straight by hand.
Read the sensor
value in the ANL - I/O
STEERING - POS
SETP menu and
enter it in the ZERO
POT screen
ANL - I/O STEERING - POS Press ( I )
SETP
cessful
Press ( )
STEER RANGE (3 wheel version)

Used to acquire the steering sensor.
Press ( )

Turn the wheels fully
right and then fully
left
Press ( I )
STEER RANGE (4 wheel version)

Used to acquire the steering sensor.
Press ( )

Turn the wheels fully
right and then fully
left
Press ( I )
Press ( I )
MAT. HANDLING
The MAT. HANDLING menu is used to acquire the materials handling functions potentiometers.

Standard version

MULTIF. ON Configures the truck in multifunction Joystick mode
OFF Configures the truck in mini lever or mini joystick mode
LEVER 1 / Used to acquire the lifting potentiometer
Actions: 3
▪ Push the lever fully forwards and then fully backwards
and press ( I )
LEVER 2 / Used to acquire the tilting potentiometer
Actions:
and press ( I )
PB 3WAY ATT1 Configures the third lever without button
ATT1+PB Configures the third lever with safety button
LEVER 3 / Used to acquire the third lever potentiometer
Actions:
and press ( I )
PB 4WAY ATT2 Configures the fourth lever without safety button
ATT2+PB Configures the fourth lever with safety button
ATT2/ATT3 Configures the fourth lever with safety button to enable the
ATT3 function
LEVER 4 / Used to acquire the fourth lever potentiometer
Actions:
and press ( I )
RESET ALL / Deletes all lever acquisitions
Multifunction Joystick version

MULTIF. ON Configures the truck in multifunction Joystick mode
OFF Configures the truck in mini lever or mini joystick mode
NUM WAY 3 Configures the truck with 3 hydraulic functions
4 Configures the truck with 4 hydraulic functions
5 Configures the truck with 5 hydraulic functions
WAY WITH EN NONE No hydraulic function is enabled with the safety button
3 Configures the third way with safety button
4 Configures the fourth way with safety button
5 Configures the fifth way with safety button
SAS
The SAS menu is used to acquire the pressure sensor and tilt angle potentiometer.

Display option Description

TILT LEVEL Used to acquire the tilting angle potentiometer (mast in the vertical position)
Actions:
▪ Set the mast in vertical position and press (I)
TILT FW Used to acquire the tilting angle potentiometer (mast tilted fully forward)
Actions:
▪ Tilt the mast fully forward and press (I)
TILT BW Used to acquire the tilting angle potentiometer (mast tilted fully backward)
Actions:
▪ Tilt the mast fully backward and press (I)
LOAD SENSOR Used to acquire the pressure sensor (mast height microswitch open)
Actions:
▪ Lift the forks without load until the mast height microswitch opens and press
(I)
RESET SAS Deletes all the pressure sensor and tilt angle potentiometer acquisitions
LOAD METER
The LOAD METER menu is used to acquire the load indicator (DELUXE version only).


MAST TYPE Selects the type of mast installed (V - FV - FSV - FW - FSW)
ZERO SET 1 Used to acquire the pressure sensor with the mast closed
Actions:
▪ Position the mast in the vertical position, lift the forks 500mm off the ground
without load and press ( I ) for 2 seconds
ZERO SET 2 Used to acquire the tilting angle potentiometer (mast tilted fully forward)
Actions:
▪ Position the mast in the vertical position, lift the forks without load until the mast
height microswitch opens and press ( I ) for 2 seconds
COMPENSATION Used to acquire the tilting angle potentiometer (mast tilted fully backward)
Actions:
▪ Place a sample weight on the forks, control the load weight reading and press
(I)
H-SELECTOR
The H-SELECTOR menu is used to acquire the height meter.

3

ENABLE Enables the H-SELECTOR option
MIN HEIGHT Used to acquire the height meter with the forks on the ground
Actions:
▪ Tilt the mast fully backward, completely lower the forks and press (I)
MAX HEIGHT Used to acquire the height meter with the forks at maximum height
Actions:
▪ Lift the forks to their full lifting height and press ( I )
TYRE DATA
The TYRE DATA menu is used to modify the speed calculation constant.


TYRE DATA Used to modify the speed calculation constant
OTHERS MENU
NOTICE! After completing the hour meter startup settings, “METER START” and “DEMO MODE” will no
longer be available for selection.

Button (I): Confirm
Button (O): Output
METER START
The METER START menu enables the truck hour meter.
Button (I): Confirm


METER START Enables the truck hour meter /
DEMO MODE
The DEMO MODE menu enables the demo mode


ENABLE Enables the demo mode ON/OFF
TO DEFAULT SET
The TO DEFAULT TEST menu is used to reset the card parameters.


DISPLAY Resetting of display parameters to their default values /
EVCB Resetting of EVCB card parameters to their default values /
TRCB Resetting of TRCB card parameters to their default values /
TR DRV Resetting of right traction logic unit parameters to their de- /
fault values
TL DRV Resetting of left traction logic unit parameters to their default /
values
PM DRV Resetting of lifting logic unit parameters to their default val- /
ues
ARM M Resetting of Master armrest card parameters to their default /
values
ARM S Resetting of Slave armrest card parameters to their default /
values
EPS Resetting of EPS steering logic unit parameters to their de- /
fault values
MASK PASSWORD
The MASK PASSWORD menu enables the numeric password to access the MASK menu.

3


ENABLE Enables the MASK menu password ON/OFF
CHANGE Edits the password (standard: 0000) /
MANAGER PASS
The MANAGER PASS menu enables the numeric password to access the MASK menu.


ENABLE Disables the secondary password in the Administrator menu ON/OFF
CONTRAST
The CONTRAST menu sets the display contrast.


CONTRAST Controls the display contrast /
DELUXE MODE
The DELUXE MODE menu enables the deluxe version of the display.
Button ( ): Selects the next field

Button (I): Confirm

DELUXE MODE Enables the deluxe version of the display ON/OFF
TROUBLESHOOTING 4-1
4
TROUBLESHOOTING
CONNECTOR CHECK .......................................................................................... 2
WIRE HARNESS AND CONNECTORS INSPECTION PROCEDURE ................. 2
INSULATION CHECK PROCEDURE.................................................................... 3
MOTOR WINDING CHECK PROCEDURE ........................................................... 4
4
TEMPERATURE SENSOR CHECK PROCEDURE .............................................. 5
CAN-BUS CHECK PROCEDURE ......................................................................... 5
DIAGNOSTIC CODES LIST .................................................................................. 7
WHEN AN ERROR CODE IS DISPLAYED ......................................................... 23
4-2 TROUBLESHOOTING
CONNECTOR CHECK
BEFORE TROUBLESHOOTING
1) Disconnect the battery plug before connecting or disconnecting
each connector or terminal.
2) When disconnecting a connector, do not pull it at the harness
but hold the connector itself and pull it after unlocking it. To
connect, push the connector fully until it is locked in position.
3) Bring a tester probe into contact with a connector terminal from

the rear side of the coupler (harness side).
4) If insertion from the rear side is impossible, as in the case of a
waterproof connector, bring the tester probe carefully into con-
tact with the terminal so as not to cause deformation of the
connector terminal.
5) Do not touch connector terminals directly with your hand.
6) When bringing tester probes into contact with live terminals,
ensure the two probes do not come into contact with each
other.
7) Remove the fuse from its holder and check its condition:
Standard: 10 Ω or less
WIRE HARNESS AND CONNECTORS INSPECTION

PROCEDURE
When any trouble occurs, first inspect the connectors and wire harness of the related circuit according to the fol-
lowing procedure:
Continuity check
1. Disconnect the connectors at both ends of the corresponding
harness.
2. Measure the resistance between corresponding terminals of
the connectors at both ends.
Standard: 10 Ω or less
NOTICE! Measure while lightly shaking the wire harness up
and down and sideways.
Reference: Breaks in the circuit rarely occur along the wiring
harness, but more typically between connectors. Make a care-
ful inspection especially of the sensor connectors
TROUBLESHOOTING 4-3
Short circuit check

1) Disconnect the connectors at both ends of the corresponding
harness.
2) Measure the resistance between the corresponding connector
terminal and GND. Always inspect the connectors at both
ends.
Standard: 1 MΩ or higher
NOTICE! Measure while lightly shaking the wire harness up
4
and down and sideways.
3) Measure the resistance between a terminal corresponding to

the connector terminal and N1. Always inspect the connectors
at both ends.
CAUTION! Wires can short-circuit if tugged by structural
parts or connected with defective terminals.
Visual and contact pressure checks

▪ Disconnect the connectors at both ends of the corresponding
harness.
▪ Visually inspect that there is neither rust nor foreign matter
trapped at connector terminals
▪ Inspect that there is no loosening or damage at the locked por-
tion. Also, lightly pull the wire harness from the connector to
check that it does not come off
▪ Insert a male terminal the same as that of the terminal to check
into a female connector and check the force of extraction.
Defective contact may exist at a terminal where the extracting
force is less than that of other terminals
NOTICE! Even if there is rust or foreign matter trapped at the

terminal, or the contact pressure between male and female ter-
minals is low, abnormal contact condition may be changed to
normal by disconnecting and reconnecting the connector. In
that case, repeat connector connection and disconnection sev-
eral times. If defect is perceived even once, terminal contact
may be defective.
The above information, concerning the inspection of the connect-
ors, are referred to specific type as shown in the drawing. The
same procedure must be apply for all type found on the machines.
INSULATION CHECK PROCEDURE

When any trouble occurs, first inspect the truck insulation and its components, according to the following pro-
cedure:
4-4 TROUBLESHOOTING
Truck insulation check

1. Disconnect the battery from the truck
2. Measure the resistance between the truck plug positive and the
chassis (unpainted surface)
3. Measure the resistance between the truck plug negative and
the chassis (unpainted surface)
4. Measure the resistance between the contactor contacts and
the chassis (unpainted surface)
Battery insulation check

2. Measure the resistance between the battery plug positive and
the case (unpainted surface)
3. Measure the resistance between the battery plug negative and
the case (unpainted surface)
Motor insulation check

2. Measure the resistance between a phase and the motor body
(unpainted surface)
3. Turning the rotor slowly by hand, measure the resistance
between a phase and the motor body (unpainted surface)
Card insulation check

2. Measure the resistance between a phase and the card body
(unpainted surface)
3. Measure the resistance between the connector pins and the
card body (unpainted surface)
MOTOR WINDING CHECK PROCEDURE

When trouble occurs, check the state of the motors, following the procedure described below:
TROUBLESHOOTING 4-5
Motor phase continuity check

2. Disconnect the three power cables
3. Check the continuity between the motor cables
Standard: U-V 0 Ω
V-W 0 Ω
U-W 0 Ω 4
TEMPERATURE SENSOR CHECK PROCEDURE

When trouble occurs, check the state of the temperature sensor, following the procedure described below:
Sensor integrity check

2. Disconnect the sensor connector
3. Check the resistance value of the sensor
Temperature 25 °C = 600 Ω
Sensor insulation check

2. Disconnect the sensor connector
3. Measure the resistance between the sensor and the motor
body (unpainted surface)
CAN-BUS CHECK PROCEDURE

If fault codes associated with the Can-bus appear, follow the procedure described below:
4-6 TROUBLESHOOTING
Software version check

If there are any cards not communicating on the Can-bus line, the display will not be able to identify the version
of the relative software.
1. Access the SERVICE MENU
2. Select the SW VERSION menu
3. Identify which cards are not communicating
NOTICE! When a card is not communicating on the Can-
bus, the number of the software version will be replaced by
the message: NOT CONNECTED
Having identified which card is not communicating on the Can-
bus line, proceed to check the wiring and connections
Wiring harness and connections check

Having identified which card is not communicating on the Can-bus line:
1. Check that the connector is plugged into the card.
2. Check that the pins are correctly set and inserted in the sockets of the card-edge connector.
3. Check that the card is powered up (refer to the diagram below).
4. Check the continuity of the CAN L and CAN H wires (refer to the diagram below).
TROUBLESHOOTING 4-7
DIAGNOSTIC CODES LIST

Current Card Alarm Description
108 [P 24] EPS STEERING LOGIC WATCHDOG Internal communication problem
UNIT between the MASTER and SLAVE mi-
crocontrollers on the EPS steering logic
unit
10D [P 24] EPS STEERING LOGIC EEPROM KO Problem with the memory in the EPS
UNIT steering logic unit: the EPS steering lo-
gic unit has reloaded the default para-
meters
110 [P 24] EPS STEERING LOGIC LOGIC FAILURE #4 Problem with the EPS steering logic unit
UNIT power circuit
UNIT power circuit
120 [P 25] EPS STEERING LOGIC VMN NOT OK Problem with the EPS steering logic unit
UNIT power circuit
130 [P 25] EPS STEERING LOGIC MAIN CONT OPEN Contactor K7 detected open despite be-
UNIT ing piloted by the EPS steering logic unit
135 [P 26] EPS STEERING LOGIC STBY I HIGH Problem with the EPS steering logic unit
UNIT power circuit
13C [P 26] EPS STEERING LOGIC CAPACITOR CHARGE Problem with EPS steering unit power
UNIT capacitor - no increase in capacitor
voltage
13D [P 27] EPS STEERING LOGIC HIGH TEMPERATURE EPS steering logic unit overheating
UNIT alarm - t > 80°C detected
141 [P 28] EPS STEERING LOGIC MOTOR TEMPERATURE Steering motor overheating alarm - t >
UNIT 120°C detected
4-8 TROUBLESHOOTING

146 [P 28] EPS STEERING LOGIC HIGH CURRENT Problem with the EPS steering logic unit
UNIT power circuit
147 [P 28] EPS STEERING LOGIC POWER FAILURE #3 Low current detected on the W phase of
UNIT the EPS steering logic unit
148 [P 29] EPS STEERING LOGIC POWER FAILURE #2 Low current detected on the V phase of
149 [P 29] EPS STEERING LOGIC POWER FAILURE #1 Low current detected on the U phase of
162 [P 29] EPS STEERING LOGIC INPUT ERROR #1 Problem on the TFD sensor signals
UNIT
1D2 [P 30] EPS STEERING LOGIC WRONG SLAVE VER Incorrect software version of the EPS
UNIT SLAVE steering logic unit detected
1D3 [P 30] EPS STEERING LOGIC TFD FEEDB ERROR Problem on the TFD sensor signals
UNIT
1D4 [P 31] EPS STEERING LOGIC WRONG RAM MEMORY Problem with the memory of the EPS
UNIT steering logic unit
1D5 [P 31] EPS STEERING LOGIC PARAM RESTORE The EPS steering logic unit has run the
UNIT reset
1D6 [P 31] EPS STEERING LOGIC SP JERK Problem on the TFD sensor signals
UNIT
1D7 [P 32] EPS STEERING LOGIC CAN BUS KO M/S Internal communication problem
unit
1D8 [P 32] EPS STEERING LOGIC TFD WRONG RESIST Problem with the TFD sensor configura-
UNIT tion
1DA [P 33] EPS STEERING LOGIC CONTROLLER MIS- Incorrect software detected
UNIT MATCH
1DC [P 33] EPS STEERING LOGIC MOTOR LOCKED Locked steering motor detected
UNIT
1DD [P 33] EPS STEERING LOGIC M/S PAR CHK MISM Problem with the parameters memory of
1DF [P 34] EPS STEERING LOGIC FB JERK Steering motor encoder problem
UNIT
1E1 [P 34] EPS STEERING LOGIC CURRENT GAIN Problem with the EPS steering logic unit
UNIT power circuit
1E4 [P 34] EPS STEERING LOGIC POSITION ERROR Incorrect steering axle position detected
UNIT
1EB [P 34] EPS STEERING LOGIC TFD SHRT/VOLT KO TFD sensor problem
UNIT
1EC [P 35] EPS STEERING LOGIC TFD STB I HIGH TFD sensor problem
UNIT
1ED [P 36] EPS STEERING LOGIC SLAVE ALARM XX Problem inside the SLAVE microcontrol-
UNIT ler of the EPS steering logic unit
1F1 [P 36] EPS STEERING LOGIC FB SENSOR LOCKED Steering motor encoder problem
UNIT
1F4 [P 36] EPS STEERING LOGIC PARAM TRANSFER Problem with the parameters memory of
1F5 [P 37] EPS STEERING LOGIC DATA ACQUISITION Problem with the steering motor value
UNIT acquisition
1F7 [P 37] EPS STEERING LOGIC CAN BUS KO Problem with communication on Can-
UNIT bus line - EPS steering logic unit not re-
ceiving messages from other cards
1F8 [P 37] EPS STEERING LOGIC SP OUT OF RANGE TFD sensor problem
UNIT
TROUBLESHOOTING 4-9

1FB [P 38] EPS STEERING LOGIC INIT VMN NOT OK Problem with the EPS steering logic unit
UNIT power circuit
1FC [P 38] EPS STEERING LOGIC TWIN POT MISMAT Steering sensor problem
UNIT
1FD [P 39] EPS STEERING LOGIC ANALOG Problem with the analog signals of the
UNIT EPS steering logic unit
1FE [P 39] EPS STEERING LOGIC NO SP REFRESH TFD sensor problem
4
UNIT
201 [P 40] RIGHT TRACTION LO- WATCHDOG Problem during right traction logic unit
GIC UNIT self-test routine
202 [P 40] RIGHT TRACTION LO- BATTERY LOW Incorrect battery voltage value
GIC UNIT
203 [P 40] RIGHT TRACTION LO- LOGIC FAILURE #3 Problem with right traction logic unit
GIC UNIT power circuit - high current overload pro-
tection
204 [P 41] RIGHT TRACTION LO- LOGIC FAILURE #2 Problem with section of right traction lo-
GIC UNIT gic unit hardware monitoring voltage
feedback signal from right drive motor
phases
GIC UNIT power circuit - low voltage condition de-
tected
206 [P 43] RIGHT TRACTION LO- VMN LOW Problem with right traction logic unit
GIC UNIT power circuit - low right drive motor
voltage condition detected
207 [P 44] RIGHT TRACTION LO- VMN HIGH Problem with right traction logic unit
GIC UNIT power circuit - right drive motor over-
208 [P 45] RIGHT TRACTION LO- CONTACTOR OPEN Contactor K7 detected open despite be-
GIC UNIT ing piloted by right traction logic unit
209 [P 45] RIGHT TRACTION LO- STBY I HIGH Abnormal level of current detected at rigt
GIC UNIT drive motor in stand-by status
20A [P 46] RIGHT TRACTION LO- INCORRECT START Start sequence incorrect
GIC UNIT
20C [P 46] RIGHT TRACTION LO- FORW+BACK Incorrect start: forward drive and reverse
GIC UNIT drive directions selected simultaneously
20D [P 46] RIGHT TRACTION LO- HARDWARE FAULT Problem with right traction logic unit
GIC UNIT power circuit
20E [P 47] RIGHT TRACTION LO- POWER MOS SHORTED Problem with right traction logic unit
GIC UNIT power circuit
210 [P 48] RIGHT TRACTION LO- CAPACITOR CHARGE Problem with right traction logic unit
GIC UNIT power capacitor - no increase in capa-
citor charge voltage.
211 [P 49] RIGHT TRACTION LO- THERMIC PROTECTION Right traction logic unit temperature rise
GIC UNIT alarm - t > 85°C detected
212 [P 50] RIGHT TRACTION LO- MOTOR TEMPERATURE Right drive motor temperature rise alarm
GIC UNIT - t > 150°C detected
213 [P 50] RIGHT TRACTION LO- ENCODER ERROR Problem with signals generated by right
GIC UNIT drive motor rpm sensor
214 [P 51] RIGHT TRACTION LO- THERMIC SENS. KO Right drive motor temperature sensor
GIC UNIT generating values out of range
216 [P 51] RIGHT TRACTION LO- NO CAN MSG Problem with communication on Can-
GIC UNIT bus line - right traction logic unit not re-
4-10 TROUBLESHOOTING

219 [P 51] RIGHT TRACTION LO- DRIVER SHORTED Problem with driver circuit controlling
GIC UNIT contactor K1
21B [P 52] RIGHT TRACTION LO- SENS MOT TEMP KO Right drive motor temperature sensor
GIC UNIT generating values out of range
21C [P 52] RIGHT TRACTION LO- VDC OFF SHORTED Low voltage detected
GIC UNIT
21D [P 53] RIGHT TRACTION LO- STALL ROTOR Problem with signals generated by rpm
GIC UNIT sensor, or rotor of right drive motor
stalled
21E [P 54] RIGHT TRACTION LO- CONTACTOR CLOSED Right traction logic unit detects contactor
GIC UNIT K1 closed at power up
21F [P 54] RIGHT TRACTION LO- MIS. SETPOINT Inconsistency between the right traction
GIC UNIT logic unit and the TRCB card detected
on the drive motor phase frequency
220 [P 55] RIGHT TRACTION LO- CONTACTOR DRIVER Problem with driver circuit controlling
GIC UNIT contactor K1
221 [P 55] RIGHT TRACTION LO- MC COIL SHORTED Problem with coil of contactor K1
GIC UNIT
224 [P 56] RIGHT TRACTION LO- INIT VMN HIGH Problem with right traction logic unit
GIC UNIT power circuit - right drive motor over-
225 [P 57] RIGHT TRACTION LO- WRONG SET BATTERY Detection of battery voltage 20% higher
GIC UNIT than nominal value
[P 57] RIGHT TRACTION LO- INIT VMN LOW Problem with right traction logic unit
GIC UNIT power circuit - low right drive motor
227 [P 58] RIGHT TRACTION LO- EEPROM KO Problem with the memory in the right
GIC UNIT traction logic unit: the right traction logic
unit has reloaded the default parameters
228 [P 58] RIGHT TRACTION LO- VDC LINK OVERV Overvoltage detected
GIC UNIT
22C [P 59] RIGHT TRACTION LO- CURRENT GAIN Problem with current monitoring circuit
GIC UNIT of right traction logic unit
22F [P 59] RIGHT TRACTION LO- NO SLAVE ENABLE Communication problem between the
GIC UNIT MASTER and SLAVE microcontrollers
on the right traction logic unit
230 [P 60] RIGHT TRACTION LO- PEV NOT OK The right traction logic unit does not re-
GIC UNIT ceive +48V.
231 [P 60] RIGHT TRACTION LO- VKEY OFF SHORTED Problem with power up circuit: key line
GIC UNIT
232 [P 61] RIGHT TRACTION LO- TEACH VACC POT Right traction logic circuit has no acquis-
GIC UNIT ition values from accelerator poten-
tiometer stored in memory
233 [P 61] RIGHT TRACTION LO- STEER ACQ Traction logic unit has no steering
GIC UNIT sensor acquisition values stored in
memory
234 [P 62] RIGHT TRACTION LO- WRONG RAM MEM Incorrect values detected in right traction
GIC UNIT logic unit RAM memory
235 [P 62] RIGHT TRACTION LO- STEER OUT OF RANGE Steering sensor generating values differ-
GIC UNIT ent from those stored in memory
236 [P 62] RIGHT TRACTION LO- HANDBRAKE Incorrect starting procedure: drive con-
GIC UNIT trol selected with parking brake on
23A [P 62] RIGHT TRACTION LO- COIL SHOR. EB Problem with the right parking brake coil
GIC UNIT
TROUBLESHOOTING 4-11

23C [P 63] RIGHT TRACTION LO- ANALOG INPUT Problem with signal monitoring circuit of
GIC UNIT right traction logic unit
23D [P 63] RIGHT TRACTION LO- CONTROLLER MIS- Problem with software of right traction
GIC UNIT MATCH logic unit
241 [P 63] RIGHT TRACTION LO- IQ MISMATCHED Detection of inconsistency between cur-
GIC UNIT rent values of right traction logic unit
242 [P 64] RIGHT TRACTION LO- AUX DRIV. OPEN Problem in the right parking brake coil
4
GIC UNIT control
243 [P 64] RIGHT TRACTION LO- CHECK UP NEEDED Maintenance hour counter warning
GIC UNIT
244 [P 64] RIGHT TRACTION LO- FIELD ORIENT. KOProblem with right drive motor field ori-
GIC UNIT entation circuit
245 [P 65] RIGHT TRACTION LO- AUX DRIV. SHRT Problem in the right parking brake coil
GIC UNIT control
248 [P 65] RIGHT TRACTION LO- WRONG ENCODER SET Incorrect setting of the right drive motor
GIC UNIT speed sensor detected
24C [P 66] RIGHT TRACTION LO- PARAM TRANSFERT Problem with the parameters memory of
GIC UNIT the right traction logic unit
24D [P 66] RIGHT TRACTION LO- EMERGENCY SWITCH Incorrect ignition sequence: emergency
GIC UNIT button on
24E [P 66] RIGHT TRACTION LO- STOP RQ FROM EPS EPS steering unit has detected a prob-
GIC UNIT lem and has inhibited the traction
24F [P 66] RIGHT TRACTION LO- WRONG SLAVE VER- Incorrect software version of the SLAVE
GIC UNIT SION right traction logic unit detected
250 [P 66] RIGHT TRACTION LO- NO CAN MSG EPS Problem with communication on Can-
GIC UNIT bus line: right traction logic unit not re-
ceiving messages from EPS steering lo-
gic unit
251 [P 67] RIGHT TRACTION LO- STOP FROM EPS EPS steering unit has detected a prob-
GIC UNIT lem and has inhibited the traction
252 [P 67] RIGHT TRACTION LO- EPS IS ONLINE Incorrect configuration between 3 wheel
GIC UNIT and 4 wheel version detected
253 [P 67] RIGHT TRACTION LO- TEACH BRK POT Right traction logic circuit has no acquis-
GIC UNIT ition values from brake potentiometer
stored in memory
25B [P 67] RIGHT TRACTION LO- M/S PAR CHK MISM Problem with the parameters memory of
GIC UNIT the right traction logic unit
301 [P 68] LEFT TRACTION LOGIC WATCHDOG Problem during left traction logic unit
UNIT self-test routine
302 [P 68] LEFT TRACTION LOGIC BATTERY LOW Incorrect battery voltage value
UNIT
303 [P 68] LEFT TRACTION LOGIC LOGIC FAILURE #3 Problem with left traction logic unit
UNIT power circuit - high current overload pro-
tection
304 [P 69] LEFT TRACTION LOGIC LOGIC FAILURE #2 Problem with section of left traction logic
UNIT unit hardware monitoring voltage feed-
back signal from left drive motor phases
UNIT power circuit - low voltage condition de-
tected
306 [P 71] LEFT TRACTION LOGIC VMN LOW Problem with left traction logic unit
UNIT power circuit - low left drive motor

307 [P 72] LEFT TRACTION LOGIC VMN HIGH Problem with left traction logic unit
UNIT power circuit - left drive motor over-
308 [P 73] LEFT TRACTION LOGIC CONTACTOR OPEN Contactor K7 detected open despite be-
UNIT ing piloted by left traction logic unit
309 [P 73] LEFT TRACTION LOGIC STBY I HIGH Abnormal level of current detected at left
UNIT drive motor in stand-by status
30A [P 74] LEFT TRACTION LOGIC INCORRECT START Start sequence incorrect
UNIT
30C [P 74] LEFT TRACTION LOGIC FORW+BACK Incorrect start: forward drive and reverse
UNIT drive directions selected simultaneously
30D [P 74] LEFT TRACTION LOGIC HARDWARE FAULT Problem with left traction logic unit
UNIT power circuit
30E [P 75] LEFT TRACTION LOGIC POWER MOS SHORTED Problem with left traction logic unit
UNIT power circuit
310 [P 76] LEFT TRACTION LOGIC CAPACITOR CHARGE Problem with left traction logic unit
UNIT power capacitor - no increase in capa-
citor charge voltage
311 [P 77] LEFT TRACTION LOGIC THERMIC PROTECTION Left traction logic unit temperature rise
UNIT alarm - t > 85°C detected
312 [P 78] LEFT TRACTION LOGIC MOTOR TEMPERATURE Left drive motor temperature rise alarm -
UNIT t > 150°C detected
313 [P 78] LEFT TRACTION LOGIC ENCODER ERROR Problem with signals generated by left
UNIT drive motor rpm sensor
314 [P 79] LEFT TRACTION LOGIC THERMIC SENS. KO Left drive motor temperature sensor
UNIT generating values out of range
316 [P 79] LEFT TRACTION LOGIC NO CAN MSG Problem with communication on Can-
UNIT bus line - left traction logic unit not re-
319 [P 79] LEFT TRACTION LOGIC DRIVER SHORTED Problem with driver circuit controlling
UNIT contactor K1
31B [P 80] LEFT TRACTION LOGIC SENS MOT TEMP KO Left drive motor temperature sensor
UNIT generating values out of range
31C [P 80] LEFT TRACTION LOGIC VDC OFF SHORTED Low voltage detected
UNIT
31D [P 81] LEFT TRACTION LOGIC STALL ROTOR Problem with signals generated by rpm
UNIT sensor, or rotor of left drive motor stalled
31E [P 82] LEFT TRACTION LOGIC CONTACTOR CLOSED Left traction logic unit detects contactor
UNIT K1 closed at power up
31F [P 82] LEFT TRACTION LOGIC MIS. SETPOINT Inconsistency between the left traction
UNIT logic unit and the TRCB card detected
on the drive motor phase frequency
320 [P 83] LEFT TRACTION LOGIC CONTACTOR DRIVER Problem with driver circuit controlling
UNIT contactor K1
321 [P 83] LEFT TRACTION LOGIC MC COIL SHORTED Problem with coil of contactor K1
UNIT
324 [P 84] LEFT TRACTION LOGIC INIT VMN HIGH Problem with left traction logic unit
UNIT power circuit - left drive motor over-
325 [P 85] LEFT TRACTION LOGIC WRONG SET BATTERY Detection of battery voltage 20% higher
UNIT than nominal value
326 [P 85] LEFT TRACTION LOGIC INIT VMN LOW Problem with left traction logic unit
UNIT power circuit - low left drive motor

327 [P 86] LEFT TRACTION LOGIC EEPROM KO Problem with the memory in the left trac-
UNIT tion logic unit: the left traction logic unit
has reloaded the default parameters
328 [P 86] LEFT TRACTION LOGIC VDC LINK OVERV Overvoltage detected
UNIT
32C [P 87] LEFT TRACTION LOGIC CURRENT GAIN Problem with current monitoring circuit
UNIT of left traction logic unit 4
32F [P 87] LEFT TRACTION LOGIC NO SLAVE ENABLE Communication problem between the
UNIT MASTER and SLAVE microcontrollers
on the left traction logic unit
330 [P 88] LEFT TRACTION LOGIC PEV NOT OK The left traction logic unit does not re-
UNIT ceive +48V.
331 [P 88] LEFT TRACTION LOGIC VKEY OFF SHORTED Problem with power up circuit: key line
UNIT
332 [P 89] LEFT TRACTION LOGIC TEACH VACC POT Left traction logic circuit has no acquisi-
UNIT tion values from accelerator poten-
tiometer stored in memory
333 [P 89] LEFT TRACTION LOGIC STEER ACQ Traction logic unit has no steering
UNIT sensor acquisition values stored in
memory
334 [P 90] LEFT TRACTION LOGIC WRONG RAM MEM Incorrect values detected in left traction
UNIT logic unit RAM memory
335 [P 90] LEFT TRACTION LOGIC STEER OUT OF RANGE Steering sensor generating values differ-
UNIT ent from those stored in memory
336 [P 90] LEFT TRACTION LOGIC HANDBRAKE Incorrect starting procedure: drive con-
UNIT trol selected with parking brake on
33A [P 90] LEFT TRACTION LOGIC COIL SHOR. EB Problem with the left parking brake coil
UNIT
33C [P 91] LEFT TRACTION LOGIC ANALOG INPUT Problem with signal monitoring circuit of
UNIT left traction logic unit
33D [P 91] LEFT TRACTION LOGIC CONTROLLER MIS- Problem with software of left traction lo-
UNIT MATCH gic unit
341 [P 91] LEFT TRACTION LOGIC IQ MISMATCHED Detection of inconsistency between cur-
UNIT rent values of left traction logic unit
342 [P 92] LEFT TRACTION LOGIC AUX DRIV. OPEN Problem in the left parking brake coil
UNIT control
343 [P 92] LEFT TRACTION LOGIC CHECK UP NEEDED Maintenance hour counter warning
UNIT
344 [P 92] LEFT TRACTION LOGIC FIELD ORIENT. KO Problem with left drive motor field orient-
UNIT ation circuit
345 [P 93] LEFT TRACTION LOGIC AUX DRIV. SHRT Problem in the left parking brake coil
UNIT control
348 [P 93] LEFT TRACTION LOGIC WRONG ENCODER SET Incorrect setting of the left drive motor
UNIT speed sensor detected
34C [P 94] LEFT TRACTION LOGIC PARAM TRANSFERT Problem with the parameters memory of
UNIT the left traction logic unit
34D [P 94] LEFT TRACTION LOGIC EMERGENCY SWITCH Incorrect ignition sequence: emergency
UNIT button on
34E [P 94] LEFT TRACTION LOGIC STOP RQ FROM EPS EPS steering unit has detected a prob-
UNIT lem and has inhibited the traction
34F [P 94] LEFT TRACTION LOGIC WRONG SLAVE VER- Incorrect software version of the SLAVE
UNIT SION left traction logic unit detected

350 [P 94] LEFT TRACTION LOGIC NO CAN MSG EPS Problem with communication on Can-
UNIT bus line: left traction logic unit not re-
ceiving messages from EPS steering lo-
gic unit
351 [P 95] LEFT TRACTION LOGIC STOP FROM EPS EPS steering unit has detected a prob-
UNIT lem and has inhibited the traction
352 [P 95] LEFT TRACTION LOGIC EPS IS ONLINE Incorrect configuration between 3 wheel
UNIT and 4 wheel version detected
353 [P 95] LEFT TRACTION LOGIC TEACH BRK POT Left traction logic circuit has no acquisi-
UNIT tion values from brake potentiometer
stored in memory
35B [P 95] LEFT TRACTION LOGIC M/S PAR CHK MISM Problem with the parameters memory of
UNIT the left traction logic unit
430 [P 96] MCB - TRCB CARD WRONG BATTERY Incorrect battery configuration detected
450 [P 96] MCB - TRCB CARD ACC WRONG PARA- Incorrect traction parameter values de-
METER tected
452 [P 96] MCB - TRCB CARD BAD EMERGENCY Problem with the emergency button
SWITCH
453 [P 96] MCB - TRCB CARD ACC ZAPI MISMATCH Inconsistency detected between the ac-
celerator potentiometer readings of the
right traction logic unit and the MCB
card
454 [P 96] MCB - TRCB CARD BRAKE ZAPI MISMATCH Inconsistency detected between the ac-
celerator potentiometer readings of the
right traction logic unit and the MCB
card
45A [P 96] MCB - TRCB CARD LHS ERR Problem with signal generated by mast
height switch K4
494 [P 97] MCB - TRCB CARD CHKSUM ERROR Problem with memory of TRCB card
496 [P 97] MCB - TRCB CARD RELOAD PARAM WARN Problem with memory of TRCB card
4A7 [P 97] MCB - TRCB CARD EVP CURR MISMATCH Problem with the distributor valve control
4B6 [P 97] MCB - TRCB CARD DASH KO Problem with communication on Can-
bus line: TRCB card not receiving mes-
sages from display
4C1 [P 98] MCB - TRCB CARD INCORRECT START Incorrect starting procedure.
4C2 [P 98] MCB - TRCB CARD BRAKE WIRE KO Problem with signal generated by brake
potentiometer
4C3 [P 98] MCB - TRCB CARD BAD MICROSWITCH Problem with microswitches of acceler-
ator pedal or hand direction lever
4C4 [P 98] MCB - TRCB CARD BAD MICROSWITCH Problem with microswitches accelerator
pedal or hand direction lever or direction
control configuration
4C6 [P 99] MCB - TRCB CARD BAD VACC Accelerator potentiometer generating
values different from those stored in
memory
4C7 [P 99] MCB - TRCB CARD ERR SEAT Incorrect starting procedure: seat or seat
belt microswitch open
4C8 [P 100] MCB - TRCB CARD TRACTION LOCK Detection of inconsistency in signals as-
sociated with drive direction
4C9 [P 100] MCB - TRCB CARD PARKING SELECTED Incorrect starting procedure: parking
brake microswitch open
4CA [P 100] MCB - TRCB CARD PAR LOAD ERROR Problem with TRCB card parameters
memory
4CB [P 101] MCB - TRCB CARD TRAC IN ALARM Traction logic alarm detected

4CC [P 101] MCB - TRCB CARD TRAC STUFFING ERR Problem with communication on Can-
sages from traction logic unit
4CD [P 101] MCB - TRCB CARD JOY MSG LOST Problem with communication on Can-
sages from armrest card
4CE [P 101] MCB - TRCB CARD BRAKE BAD VACC Brake potentiometer generating values 4
different from those stored in memory
4CF [P 101] MCB - TRCB CARD STEER ENCODER KO Problem with signal from steering en-
coder
4F1 [P 101] MCB - TRCB CARD STEER SENSOR KO Problem with signal from steering en-
coder
4F2 [P 102] MCB - TRCB CARD INT INDEX ERROR Problem with signal from steering en-
coder
4F5 [P 102] MCB - TRCB CARD STEER LOAD OPEN Problem with knob synchronizer valve
coil
4FA [P 103] MCB - TRCB CARD STEER LOAD SHORTED Problem with knob synchronizer valve
coil
4FB [P 103] MCB - TRCB CARD SWING LOAD OPEN Problem with oscillation lock cylinder
valve coil
4FC [P 103] MCB - TRCB CARD SWING LOAD SHORTED Problem with oscillation lock cylinder
valve coil
4FD [P 104] MCB - TRCB CARD V BAT KO The TRCB card does not receive +48V
5A0 [P 105] LIFT LOGIC UNIT ANALOG INPUT Problem with signal monitoring circuit of
lift logic unit
5A1 [P 105] LIFT LOGIC UNIT COIL SHORT HW KO Problem with coils connected to auxiliary
outputs of lift logic unit
5A2 [P 105] LIFT LOGIC UNIT LOGIC FAILURE #3 Problem with lift logic unit power circuit:
high current overload protection
5A3 [P 106] LIFT LOGIC UNIT CAPACITOR CHARGE Problem with lift logic unit power capa-
citor: no increase in capacitor charge
voltage
5A4 [P 107] LIFT LOGIC UNIT VMN LOW Problem with lift logic unit power circuit:
low motor voltage condition detected
5A5 [P 108] LIFT LOGIC UNIT DRIVER SHORTED Problem with driver circuit controlling
contactor K1
5A6 [P 109] LIFT LOGIC UNIT MC COIL SHORT Problem with coil of contactor K1
5A7 [P 110] LIFT LOGIC UNIT VMN HIGH Problem with lift logic unit power circuit:
motor overvoltage condition detected
5A8 [P 110] LIFT LOGIC UNIT STBY I HIGH Abnormal level of current detected at
pump motor in stand-by status
5A9 [P 111] LIFT LOGIC UNIT CONTACTOR OPEN Contactor K7 detected open despite be-
ing piloted by right traction logic unit
5AA [P 111] LIFT LOGIC UNIT AUX DRIV. SHRT Problem with driver circuit controlling
coil connected to auxiliary output of lift
logic unit
5AB [P 112] LIFT LOGIC UNIT LOGIC FAILURE #1 Problem with lift logic unit power circuit:
low voltage condition detected
5AC [P 113] LIFT LOGIC UNIT LOGIC FAILURE #2 Problem with hardware section of lift lo-
gic unit monitoring voltage feedback sig-
nal from motor phases
5AD [P 114] LIFT LOGIC UNIT SAFETY INPUT Problem with SAFETY signal on input
side
5AE [P 114] LIFT LOGIC UNIT CONTACTOR DRIVER Problem with driver circuit controlling
contactor K1

5AF [P 115] LIFT LOGIC UNIT THERMIC PROTECTIONLift logic unit overheating alarm: t >
85°C detected
5B0 [P 115] LIFT LOGIC UNIT EEPROM KO Problem with memory of lift logic unit
5B1 [P 116] LIFT LOGIC UNIT MOTOR TEMPERATURE Pump motor overheating alarm: t >
150°C detected
5B2 [P 116] LIFT LOGIC UNIT WRONG SET BAT Detection of battery voltage 20% higher
than nominal value
5B3 [P 116] LIFT LOGIC UNIT THERMIC SENS. KO Pump motor temperature sensor gener-
ating values out of range
5B4 [P 117] LIFT LOGIC UNIT AUX COIL SHORT Problem with coil connected to auxiliary
output of lift logic unit
5B5 [P 117] LIFT LOGIC UNIT CHECK UP NEEDED Maintenance hour counter warning
5B6 [P 118] LIFT LOGIC UNIT NO CAN MSG Problem with communication on Can-
bus line: lift logic unit not receiving mes-
sages from other cards
5B7 [P 118] LIFT LOGIC UNIT AUX DRIV. OPEN Problem with driver circuit controlling
coil connected to auxiliary output of lift
logic unit
5B8 [P 118] LIFT LOGIC UNIT SAFETY OUTPUT Problem with SAFETY signal on output
side
5B9 [P 119] LIFT LOGIC UNIT KEY OFF SHORT Problem with power up circuit: key line
5BA [P 119] LIFT LOGIC UNIT HARDWARE FAULT Problem with lift logic unit power circuit
5BB [P 120] LIFT LOGIC UNIT POWER MOS SHORT Problem with lift logic unit power circuit
5BC [P 121] LIFT LOGIC UNIT CONTACTOR CLOSED Lift logic unit detects contactor K1
closed at power up
5BD [P 121] LIFT LOGIC UNIT ENCODER ERROR Problem with signals generated by
pump motor rpm sensor
5BE [P 122] LIFT LOGIC UNIT WATCHDOG #1 Problem during lift logic unit self-test
routine
5BF [P 122] LIFT LOGIC UNIT WATCHDOG #2 Problem during lift logic unit self-test
routine
5C1 [P 123] LIFT LOGIC UNIT WRONG RAM MEMORY Incorrect values detected in lift logic unit
RAM
5C2 [P 123] LIFT LOGIC UNIT SENS MOT TEMP KO Pump motor temperature sensor gener-
ating values out of range
5C3 [P 124] LIFT LOGIC UNIT CURRENT GAIN Problem with current monitoring circuit
of lift logic unit
5C4 [P 124] LIFT LOGIC UNIT WRONG 0 VOLTAGE Problem with hardware section of lift lo-
gic unit monitoring voltage feedback sig-
nal from motor phases
5C5 [P 125] LIFT LOGIC UNIT TORQUE PROFILE Detection of inconsistencies in torque
values saved to memory
5C7 [P 125] LIFT LOGIC UNIT ENCODER LOCKED Problem with signals generated by
pump motor rpm sensor
5C8 [P 126] LIFT LOGIC UNIT FOC LOST Problem with pump motor field orienta-
tion circuit
5C9 [P 126] LIFT LOGIC UNIT IQ MISMATCHED Detection of inconsistency between cur-
rent values of lift logic unit
5CA [P 126] LIFT LOGIC UNIT PROG VACC NOT OK Fault code not utilized
5CB [P 127] LIFT LOGIC UNIT TEACH SWING POT Fault code not utilized
5CC [P 127] LIFT LOGIC UNIT STEER OUT RANGE Fault code not utilized
5CD [P 127] LIFT LOGIC UNIT TEACH STEER POT Fault code not utilized
659 [P 128] MCB - EVCB CARD PSV ERR Problem with mast pressure sensor

65A [P 128] MCB - EVCB CARD LHS ERR Problem with signal at mast height
switch
65B [P 128] MCB - EVCB CARD TAS ERR Problem with tilt angle potentiometer
65D [P 129] MCB - EVCB CARD WMV ERR Problem with tilt angle potentiometer or
pressure sensor
65E [P 129]
6A1 [P 129]
MCB - EVCB CARD
MCB - EVCB CARD
LHP ERR
DOUBLE REQUEST
Problem with fork height potentiometer
Selection of two commands attempted
4
on the same way
6A2 [P 130] MCB - EVCB CARD RELOAD PARAM WARN Default parameters reloaded by EVCB
card at power up
6A3 [P 130] MCB - EVCB CARD PAR LOAD ERROR Problem with memory of EVCB card
6A4 [P 130] MCB - EVCB CARD NOT REP ERROR Problem with communication on Can-
bus line: EVCB card not receiving mes-
sages
6A7 [P 130] MCB - EVCB CARD P SHORT ERR Problem with circuit piloting solenoid
valves
6A8 [P 130] MCB - EVCB CARD EV1 1 OPEN Descent valve coil disconnected: EVCB
card detects no load at the coil
6A9 [P 131] MCB - EVCB CARD EV2 1 OPEN Lift valve coil disconnected: EVCB card
detects no load at the coil
6AA [P 131] MCB - EVCB CARD EV1 2 OPEN Tilt valve coil disconnected: EVCB card
6AB [P 131] MCB - EVCB CARD EV2 2 OPEN Tilt valve coil disconnected: EVCB card
6AC [P 132] MCB - EVCB CARD EV1 3 OPEN Sideshift valve coil disconnected: EVCB
6AD [P 132] MCB - EVCB CARD EV2 3 OPEN Sideshift valve coil disconnected: EVCB
6AE [P 132] MCB - EVCB CARD EV1 4 OPEN 4th way valve coil disconnected: EVCB
6AF [P 133] MCB - EVCB CARD EV2 4 OPEN 4th way valve coil disconnected: EVCB
6B1 [P 133] MCB - EVCB CARD DRIVER EV1 SHORTED Problem with circuit piloting descent and
lift solenoid valves
6B2 [P 133] MCB - EVCB CARD DRIVER EV2 SHORTED Problem with circuit piloting tilt solenoid
valves
6B3 [P 134] MCB - EVCB CARD DRIVER EV3 SHORTED Problem with circuit piloting sideshift
solenoid valves
6B4 [P 134] MCB - EVCB CARD DRIVER EV4 SHORTED Problem with driver circuit piloting valves
of 4th way
6B6 [P 135] MCB - EVCB CARD DASH KO Problem with communication on Can-
sages from DISPLAY
6B7 [P 135] MCB - EVCB CARD SEAT ERR Incorrect starting procedure.
6B8 [P 135] MCB - EVCB CARD JOY STUFFING ERR Problem with communication on Can-
sages from armrest card
6BA [P 135] MCB - EVCB CARD DR PMOS LOCK Internal fault in the EVCB card
6BB [P 136] MCB - EVCB CARD LOAD 1 SHORTED Problem with circuit piloting descent and
lift solenoid valves: coil short-circuiting
6BC [P 136] MCB - EVCB CARD LOAD 2 SHORTED Problem with circuit piloting tilt solenoid
valves: coil short-circuiting
6BD [P 136] MCB - EVCB CARD LOAD 3 SHORTED Problem with circuit piloting sideshift
solenoid valves: coil short-circuiting

6BE [P 137] MCB - EVCB CARD LOAD 4 SHORTED Problem with circuit piloting valves of 4th
way: coil short-circuiting
6E1 [P 137] MCB - EVCB CARD PUMP INCORRECT Incorrect starting procedure.
START
6EE [P 137] MCB - EVCB CARD PUMP STUFFING ERR Problem with communication on Can-
sages from lift logic unit
6F3 [P 137] MCB - EVCB CARD NYM ERR The EVCB card has no acquisition val-
ues for tilt angle potentiometer or pres-
sure sensor stored in memory
6F4 [P 138] MCB - EVCB CARD INCORRECT START Incorrect starting procedure.
8E1 [P 138] MASTER ARMREST INCORRECT START Incorrect starting procedure.
CARD
8E2 [P 138] MASTER ARMREST BAD LIFT POT Lift potentiometer voltage detected out
CARD of range
8E3 [P 138] MASTER ARMREST BAD TILT POT Tilt potentiometer voltage detected out
CARD of range
8E4 [P 138] MASTER ARMREST BAD SIDESHIFT POT Sideshift potentiometer voltage detected
CARD out of range
8E5 [P 139] MASTER ARMREST BAD IV POT 4th way potentiometer voltage detected
CARD out of range
8E6 [P 139] MASTER ARMREST BAD V POT 5th way potentiometer voltage detected
CARD out of range
8E7 [P 139] MASTER ARMREST ERROR SEAT Incorrect starting procedure.
CARD
8E8 [P 139] MASTER ARMREST INVALID RESTORE Problem with memory of armrest card
CARD STATE
8E9 [P 140] MASTER ARMREST EEPROM INC ERROR Problem with memory of armrest card
CARD
8EA [P 140] MASTER ARMREST DEFAULT RESTORE The armrest card has loaded the default
CARD parameters
8EB [P 140] MASTER ARMREST MATCHING REQUIRED No potentiometer acquisition values
CARD stored in memory of armrest card
8EC [P 140] MASTER ARMREST PDO CHKSUM ERROR Problem with memory of armrest card
CARD
8ED [P 141] MASTER ARMREST BAD COMM EVCB Problem with communication on Can-
CARD bus line: armrest card not receiving
messages from EVCB card
8EE [P 141] MASTER ARMREST INCORRECT START Incorrect starting procedure.
CARD TRAC
8EF [P 141] MASTER ARMREST FW BW Reverse drive problem on arm rest
CARD
A01 [P 142] LITHIUM BATTERY CAN COMUNICATION Communication problem with the Can-
bus line
A02 [P 142] LITHIUM BATTERY HW FAIL 1 Battery internal problem
A03 [P 142] LITHIUM BATTERY OVER VOLTAGE Problem with the battery voltage
A04 [P 142] LITHIUM BATTERY UNDER VOLTAGE Problem with the battery voltage
A06 [P 142] LITHIUM BATTERY OVER TEMPERATURE 1 Problem with the battery temperature
A07 [P 143] LITHIUM BATTERY UNDER TEMPERATURE Problem with the battery temperature
1
A08 [P 143] LITHIUM BATTERY UNDER TEMPERATURE Problem with the battery temperature
2
A09 [P 143] LITHIUM BATTERY OVER TEMPERATURE 2 Problem with the battery temperature

A0A [P 143] LITHIUM BATTERY HW FAIL 3 Battery internal problem
A0B [P 143] LITHIUM BATTERY OVER CURRENT 1 Problem with the battery current
A0C [P 144] LITHIUM BATTERY OVER CURRENT 2 Problem with the battery current
A0D [P 144] LITHIUM BATTERY OVER CURRENT 3 Problem with the battery current
A0E [P 144] LITHIUM BATTERY OVER CURRENT 4 Problem with the battery current
A0F [P 144] LITHIUM BATTERY PROTECTION CIRCUIT 1Battery internal problem 4
A10 [P 144] LITHIUM BATTERY PROTECTION CIRCUIT 2Battery internal problem
C01 [P 146] DISPLAY EPS KO Problem with communication on Can-
bus line: DISPLAY not receiving mes-
sages from EPS steering logic unit
C02 [P 146] DISPLAY TRAC KO Problem with communication on Can-
bus line: display not receiving messages
from right traction logic unit
C03 [P 146] DISPLAY TRAC SLAVE KO Problem with communication on Can-
from left traction logic unit
C04 [P 146] DISPLAY MCB TRAC KO Problem with communication on Can-
sages from TRCB card
C05 [P 146] DISPLAY PUMP KO Problem with communication on Can-
sages from lift logic unit
C06 [P 147] DISPLAY MCB MHY KO Problem with communication on Can-
from EVCB card
C08 [P 147] DISPLAY JOY KO Problem with communication on Can-
sages from MASTER armrest card
C0B [P 147] DISPLAY JOY SLAVE KO Problem with communication on Can-
sages from SLAVE armrest card
CA1 [P 147] DISPLAY BOARD MISMATCH Inconsistency detected between soft-
ware installed on different cards
CA2 [P 148] DISPLAY NUM WHEELS MIS- Incorrect configuration between 3 wheel
MATCH and 4 wheel version detected
CA3 [P 148] DISPLAY BRAKE LEVEL ALARM Low level of brake oil detected
CA4 [P 148] DISPLAY CANNOT READ SN The DISPLAY cannot read the serial
number from a card
CA5 [P 148] DISPLAY CANNOT RESET LEARN The DISPLAY cannot reset the acquisi-
FLAG tions of a logic unit
CB9 [P 148] DISPLAY DHU KO Problem with communication on Can-
from DHU card
CDA [P 149] DISPLAY SHOCK LOCKOUT The shock sensor has detected a bump
CDC [P 149] DISPLAY CAP DISCHARGE ALARM Incomplete discharge of capacitors de-
tected following last machine shutdown
CDD [P 149] DISPLAY LIGHT ERROR Problem with outputs piloting operation
of optionals
CDE [P 149] DISPLAY KEY ERROR Problem with the truck ignition signal
CDF [P 149] DISPLAY EEPROM ERROR Problem with the memory

CF1 [P 150] DISPLAY SHOCK SENSOR KO Problem with communication on Can-
sages from shock sensor
CF2 [P 150] DISPLAY IMMOBILIZE The P.O.C. system has enabled the IM-
MOBILIZE function
CF3 [P 150] DISPLAY SMART ACCESS KO Problem with communication on Can-
sages from SMART ACCESS card
BE6 [P 151] SLAVE ARMREST CARD LIFT POT ERROR Detection of inconsistency between lift
potentiometer values read by MASTER
and SLAVE sections of the armrest card
BE7 [P 151] SLAVE ARMREST CARD TILT POT ERROR Detection of inconsistency between tilt
potentiometer values read by MASTER
BE8 [P 151] SLAVE ARMREST CARD SIDESHIFT POT ERROR Detection of inconsistency between
sideshift potentiometer values read by
MASTER and SLAVE sections of the
armrest card
BE9 [P 151] SLAVE ARMREST CARD IV POT ERROR Detection of inconsistency between 4th
way potentiometer values read by MAS-
TER and SLAVE sections of the armrest
card
BEA [P 152] SLAVE ARMREST CARD V POT ERROR Detection of inconsistency between 5°
oil line button values read by MASTER
BEC [P 152] SLAVE ARMREST CARD DIGITAL ERROR Detection of inconsistency between di-
gital values read by MASTER and
SLAVE sections of the armrest card
BED [P 152] SLAVE ARMREST CARD FIRMWARE TYPE ER- Incorrect software version detected on
ROR the arm rest card
BEF [P 152] SLAVE ARMREST CARD JOY MASTER KO Communication problem between the
MASTER and SLAVE microcontrollers
on the arm rest card
BF8 [P 153] SLAVE ARMREST CARD INVALID RESTORE Problem with the arm rest card memory:
STATE the default parameters have been
loaded
BF9 [P 153] SLAVE ARMREST CARD EEPROM INCOSIS ER- Problem with the arm rest card memory:
ROR the default parameters have been
loaded
BFA [P 153] SLAVE ARMREST CARD DEFAULT RESTORED Default parameters reloaded by arm rest
card at power up
4108 [P 154] EPS STEERING LOGIC WATCHDOG Internal communication problem
unit
410D [P 154] EPS STEERING LOGIC EEPROM KO Problem with the memory in the EPS
UNIT steering logic unit: the EPS steering lo-
gic unit has reloaded the default para-
meters
UNIT power circuit
UNIT power circuit
4120 [P 155] EPS STEERING LOGIC VMN NOT OK Problem with the EPS steering logic unit
UNIT power circuit
4130 [P 155] EPS STEERING LOGIC MAIN CONT OPEN Contactor K7 detected open despite be-
UNIT ing piloted by the EPS steering logic unit

4135 [P 156] EPS STEERING LOGIC STBY I HIGH Problem with the EPS steering logic unit
UNIT power circuit
4146 [P 156] EPS STEERING LOGIC HIGH CURRENT Problem with the EPS steering logic unit
UNIT power circuit
4147 [P 156] EPS STEERING LOGIC POWER FAILURE #3 Low current detected on the W phase of
4148 [P 157] EPS STEERING LOGIC POWER FAILURE #2 Low current detected on the V phase of
4
4149 [P 157] EPS STEERING LOGIC POWER FAILURE #1 Low current detected on the U phase of
4162 [P 157] EPS STEERING LOGIC INPUT ERROR #2 Problem on the TFD sensor signal
UNIT
41CF [P 158] EPS STEERING LOGIC SP MISMATCH Problem reading the TFD sensor values
unit
41D0 [P 158] EPS STEERING LOGIC OUTPUT MISMATCH Problem reading the steering sensor val-
UNIT ues between the MASTER and SLAVE
microcontrollers on the EPS steering lo-
gic unit
41D1 [P 159] EPS STEERING LOGIC WD SYNCHRO Internal communication problem
unit
41D4 [P 159] EPS STEERING LOGIC WRONG RAM MEMORY Problem with the memory of the EPS
UNIT steering logic unit
41D5 [P 159] EPS STEERING LOGIC PARAM RESTORE The EPS steering logic unit has run the
UNIT reset
41D6 [P 159] EPS STEERING LOGIC SP JERK Problem on the TFD sensor signals
UNIT
41D7 [P 160] EPS STEERING LOGIC CAN BUS KO M/S Internal communication problem
unit
41D8 [P 160] EPS STEERING LOGIC TFD CURRENT MIS- Problem with the TFD sensor power
UNIT MATCH supply circuit
41DA [P 161] EPS STEERING LOGIC CONTROLLER MIS- Incorrect software detected
UNIT MATCH
41DC [P 161] EPS STEERING LOGIC MOTOR LOCKED Locked steering motor detected
UNIT
41DF [P 161] EPS STEERING LOGIC FB JERK Steering motor encoder problem
UNIT
41E1 [P 162] EPS STEERING LOGIC CURRENT GAIN Problem with the EPS steering logic unit
UNIT power circuit
41E4 [P 162] EPS STEERING LOGIC POSITION ERROR Steering motor encoder problem
UNIT
41EB [P 162] EPS STEERING LOGIC TFD SHRT/VOLT KO TFD sensor problem
UNIT
41EC [P 163] EPS STEERING LOGIC TFD STB I HIGH TFD sensor problem
UNIT
41ED [P 164] EPS STEERING LOGIC WAITING MASTER Internal communication problem
unit
41F0 [P 164] EPS STEERING LOGIC LOGIC SUPPLY ERR Problem with the EPS steering logic unit
UNIT power supply line

41F1 [P 164] EPS STEERING LOGIC FB SENSOR LOCKED Steering motor encoder problem
UNIT
41F7 [P 165] EPS STEERING LOGIC CAN BUS KO Problem with communication on Can-
UNIT bus line - EPS steering logic unit not re-
41F8 [P 165] EPS STEERING LOGIC SP OUT OF RANGE TFD sensor problem
UNIT
41FA [P 165] EPS STEERING LOGIC INPUT MISMATCH Problem with the input readings
crocontroller on the EPS steering logic
unit
41FC [P 166] EPS STEERING LOGIC TWIN POT MISMAT Steering sensor problem
UNIT
41FD [P 166] EPS STEERING LOGIC ANALOG Problem with the analog signals of the
UNIT EPS steering logic unit
41FE [P 166] EPS STEERING LOGIC NO SP REFRESH TFD sensor problem
UNIT
4201 [P 167] RIGHT TRACTION LO- WATCHDOG Problem during right traction logic unit
GIC UNIT self-test routine
GIC UNIT power circuit - low voltage condition de-
tected
4208 [P 168] RIGHT TRACTION LO- CONTACTOR OPEN Contactor K7 detected open despite be-
GIC UNIT ing piloted by right traction logic unit
4213 [P 169] RIGHT TRACTION LO- ENCODER ERROR Problem with signals generated by right
GIC UNIT drive motor rpm sensor
4216 [P 169] RIGHT TRACTION LO- NO CAN MSG Problem with communication on Can-
GIC UNIT bus line - right traction logic unit not re-
4219 [P 170] RIGHT TRACTION LO- AUX DRV SHORTED Problem with driver circuit controlling
GIC UNIT coil connected to auxiliary output of right
traction logic unit
421C [P 170] RIGHT TRACTION LO- VDC OFF SHORTED Low voltage detected
GIC UNIT
4225 [P 171] RIGHT TRACTION LO- WRONG SET BAT Detection of battery voltage 20% higher
GIC UNIT than nominal value
4227 [P 172] RIGHT TRACTION LO- EEPROM KO Problem with the memory in the right
GIC UNIT traction logic unit: the right traction logic
4228 [P 172] RIGHT TRACTION LO- VDC LINK OVERV. Overvoltage detected
GIC UNIT
422C [P 173] RIGHT TRACTION LO- CURRENT GAIN Problem with current monitoring circuit
GIC UNIT of right traction logic unit
4231 [P 173] RIGHT TRACTION LO- VKEY OFF SHORTED Problem with power up circuit: key line
GIC UNIT
4234 [P 174] RIGHT TRACTION LO- WRONG RAM MEM Incorrect values detected in right traction
GIC UNIT logic unit RAM memory
423C [P 174] RIGHT TRACTION LO- ANALOG INPUT Problem with signal monitoring circuit of
GIC UNIT right traction logic unit
423D [P 175] RIGHT TRACTION LO- CONTROLLER MIS- Problem with software of right traction
GIC UNIT MATCH logic unit
4242 [P 175] RIGHT TRACTION LO- AUX DRV OPEN Problem with driver circuit controlling
GIC UNIT coil connected to auxiliary output of right
traction logic unit

424A [P 176] RIGHT TRACTION LO- WD SYNCRO Internal communication problem
GIC UNIT between the MASTER and SLAVE mi-
crocontrollers on the right traction logic
unit
4252 [P 176] RIGHT TRACTION LO- OUTPUT MISMATCH Problem reading the output values con-
GIC UNIT nected to the right traction logic unit
425B [P 177] RIGHT TRACTION LO- INPUT MISMATCH Problem reading the input values con- 4
GIC UNIT nected to the right traction logic unit
4301 [P 177] LEFT TRACTION LOGIC WATCHDOG Problem during left traction logic unit
UNIT self-test routine
UNIT power circuit - low voltage condition de-
tected
4308 [P 178] LEFT TRACTION LOGIC CONTACTOR OPEN Contactor K7 detected open despite be-
UNIT ing piloted by left traction logic unit
4313 [P 179] LEFT TRACTION LOGIC ENCODER ERROR Problem with signals generated by left
UNIT drive motor rpm sensor
4316 [P 179] LEFT TRACTION LOGIC NO CAN MSG Problem with communication on Can-
UNIT bus line - left traction logic unit not re-
4319 [P 180] LEFT TRACTION LOGIC AUX. DRV.SHORTED Problem with driver circuit controlling
UNIT coil connected to auxiliary output of left
traction logic unit
431C [P 180] LEFT TRACTION LOGIC VDC OFF SHORTED Low voltage detected
UNIT
4325 [P 181] LEFT TRACTION LOGIC WRONG SET BAT Detection of battery voltage 20% higher
UNIT than nominal value
4327 [P 182] LEFT TRACTION LOGIC EEPROM KO Problem with the memory in the right
UNIT traction logic unit: the right traction logic
4328 [P 182] LEFT TRACTION LOGIC VDC LINK OVERV. Overvoltage detected
UNIT
432C [P 183] LEFT TRACTION LOGIC CURRENT GAIN Problem with current monitoring circuit
UNIT of left traction logic unit
4331 [P 183] LEFT TRACTION LOGIC VKEY OFF SHORTED Problem with power up circuit: key line
UNIT
4334 [P 184] LEFT TRACTION LOGIC WRONG RAM MEM Incorrect values detected in left traction
UNIT logic unit RAM memory
433C [P 184] LEFT TRACTION LOGIC ANALOG INPUT Problem with signal monitoring circuit of
UNIT left traction logic unit
433D [P 185] LEFT TRACTION LOGIC CONTROLLER MIS- Problem with software of left traction lo-
UNIT MATCH gic unit
4342 [P 185] LEFT TRACTION LOGIC AUX DRV OPEN Problem with driver circuit controlling
UNIT coil connected to auxiliary output of left
traction logic unit
434A [P 186] LEFT TRACTION LOGIC WD SYNCRO Internal communication problem
crocontrollers on the left traction logic
unit
4352 [P 186] LEFT TRACTION LOGIC OUTPUT MISMATCH Problem reading the output values con-
UNIT nected to the left traction logic unit
435B [P 187] LEFT TRACTION LOGIC INPUT MISMATCH Problem reading the input values con-
UNIT nected to the left traction logic unit
WHEN AN ERROR CODE IS DISPLAYED
EPS STEERING LOGIC UNIT - MASTER MICROCONTROLLER
108
WATCHDOG (steering logic unit EPS - master microcontroller)
Circumstances of error detection
The steering logic unit EPS (AU4) has detected an internal communication problem between the MASTER and
SLAVE microcontrollers.
Actions:
▪ Run a key reset
▪ Reset the steering logic unit EPS using the function TO DEFAULT SET
▪ If the fault code is repeated, replace the steering logic unit EPS
10D
EEPROM KO (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the memory and has reloaded the default para-
meters.
Actions:
▪ Run a key reset and check the correct value of the steering parameters on the display
110
LOGIC FAILURE #4 (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem with the power circuit.
Actions:
▪ Check the tightening torque of the screws in phases U-V-W on the steering motor (0.8 Nm ÷ 1.2 Nm)
▪ Check the insulation of the steering motor (see paragraph INSULATION CHECK PROCEDURE):
If the measured value is less than 1MΩ replace the steering motor
▪ Check the windings of the steering motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE):
If the measured value is greater than 1Ω replace the steering motor
▪ Check the insulation of the steering logic unit (see paragraph INSULATION CHECK PROCEDURE):
If the measured value is less than 1MΩ replace the steering logic unit EPS
▪ Replace the steering logic unit EPS
111
LOGIC FAILURE #3 (steering logic unit EPS - master microcontroller)
Actions:
4
120
VMN NOT OK (steering logic unit EPS - master microcontroller)
Actions:
▪ Check the tightening torque of nuts on the power contactor K2 (3.6 Nm – 3.9 Nm)
▪ Check the output voltage on contactor K2:
If the value measured is different from that measured directly from the battery replace contactor K2
130
MAIN CONT OPEN (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected open status at power contactor K2.
Actions:
▪ Check that power contactor K2 is correctly plugged in
▪ Check that the wiring harness between the EPS steering logic and contactor K2 is not crushed or damaged
▪ Check the state of the connections:
▪ Crimping of wires and insertion of the pins in connectors J42, J4, J202, J203
▪ Continuity of the wiring harness between connector J4 pin 14 and connector J202 of contactor K2
▪ Check the state of the power contactor K2:
▪ The resistance value of the coil K2 (standard 420Ω at 20°C)
▪ Insulation of the coil from the body (standard greater than 1MΩ)
▪ The condition of the plate and contacts of contactor K2 (oxidation or dirt)
▪ The tightening torque of nuts on the contacts of contactor K2 (3.6 Nm – 3.9 Nm)
135
STBY I HIGH (steering logic unit EPS - master microcontroller)
Actions:
13C
CAPACITOR CHARGE (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem with the condenser charge.
Actions:
▪ If the alarm 13C appears alone check:
▪ The EPS steering logic power supply must have battery voltage on pin 15 connector J4
4
▪ If the alarm 13C appears together with 210, 310, 5A3:
▪ Disconnect cable (+T) from the right drive unit
▪ Disconnect cable (+P) from the lift logic unit
▪ Disconnect the copper bar from the right and left traction logic unit
▪ Disconnect the red cable WT11 from fuse FS on the EPS steering logic unit
▪ Connect the battery and turn on the truck

▪ Measure the voltage between +BF and -B on the right traction logic unit
▪ Measure the voltage between +BF and -B on the left traction logic unit
▪ Measure the voltage between +BF and -B on the lift logic unit
▪ Measure the voltage between the red cable WT2 and the battery negative
▪ Replace the logic unit where the lowest value was measured in the previous points
13D
HIGH TEMPERATURE (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a temperature above 80°C tripping thermal overload protection.
Actions:
▪ If the steering logic unit is really overheated, wait for it to cool down and check that the steering axle is not
mechanically locked
▪ If the alarm appears when the logic unit is cold, replace the EPS steering logic unit
141
MOTOR TEMPERATURE (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a temperature higher than 120°C at the steering motor.
Actions:
▪ If the steering motor is really overheated, wait for it to cool down and check that the steering axle is not
mechanically locked
▪ If the alarm appears when the steering motor is cold:
▪ Check the resistance value of the steering motor temperature sensor (standard 629Ω at 25°C)
▪ Check the connector and pins on the electrical connection between the motor and the steering logic unit
Self-diagnostic
▪ Connect an external resistance (500 ohm ÷ 1000 ohm) to the temperature sensor connector:
▪ If the fault code disappears replace the steering motor
▪ If the fault code persists, replace the steering logic unitEPS
146
HIGH CURRENT (steering logic unit EPS - master microcontroller)
Actions:
147
POWER FAILURE #3 (steering logic unit EPS - master microcontroller)
The EPS (AU4) steering logic unit has detected a low current on phase W.
Actions:
4
148
The EPS (AU4) steering logic unit has detected a low current on phase V.
Actions:
▪ Check the insulation of the steering logic unit. (see paragraph INSULATION CHECK PROCEDURE):
149
The EPS (AU4) steering logic unit has detected a low current on phase u.
Actions:
162
INPUT ERROR #1 (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem with the TFD sensor signals.
Actions:
▪ Check that the TFD sensor is correctly plugged in
▪ Crimping of wires and insertion of the pins in connectors J4 and J11
▪ Continuity of the wiring harness between connector J4 pin 21 and connector J11 pin 1 on the TFD
sensor
sensor
sensor
sensor
▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor
sensor
▪ Check the state of the TFD sensor:
▪ The resistance value of the TFD sensor coil (standard 10Ω between pins 5-6 on connector P11)
▪ The insulation of connector P11 pins on the TFD sensor body (standard greater than 1MΩ)
1D2
WRONG SLAVE VER (steering logic unit EPS - master microcontroller)
The EPS (AU4) steering logic unit has detected an incorrect software version.
Actions:
▪ Update the software version of the MASTER and SLAVE microcontroller on the EPS steering logic unit
1D3
TFD FEEDB ERROR (steering logic unit EPS - master microcontroller)
Actions:
▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged
4
sensor
sensor
sensor
sensor
sensor
1D4
WRONG RAM MEMORY (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the memory.
Actions:
▪ Run a key reset
1D5
PARAM RESTORE (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has reloaded the default parameters.
Actions:
▪ Run a key reset
1D6
SP JERK (steering logic unit EPS - master microcontroller)
Actions:
sensor
sensor
sensor
sensor
sensor
▪ Check the power supply from the EPS steering logic unit:
▪ Measure the voltage between pin 1 and pin 2 on connector J11 (standard +5V)
1D7
CAN BUS KO M/S (steering logic unit EPS - master microcontroller)
The EPS (AU4) steering logic unit has detected a communication problem between the MASTER and SLAVE
microcontrollers.
Actions:
1D8
TFD WRONG RESIST (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem with the TFD sensor resistance.
Actions:
4
sensor
sensor
sensor
sensor
sensor
1DA
CONTROLLER MISMATCH (steering logic unit EPS - master microcontroller)
The EPS (AU4) steering logic unit has detected an incorrect software version.
Actions:
1DC
MOTOR LOCKED (steering logic unit EPS - master microcontroller)
The EPS (AU4) steering logic unit has detected that the steering motor is blocked.
Actions:
▪ Check that the steering axle and/or the steering motor are not mechanically locked
▪ Check that the wiring harness between the EPS steering logic and the steering motor encoder is not
crushed/damaged/disconnected
▪ Use the ANALYZER menu to check the steering motor encoder functions
1DD
M/S PAR CHK MISM (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the memory.
Actions:
▪ Run a key reset
1DF
FB JERK (steering logic unit EPS - master microcontroller)
The EPS (AU4) steering logic unit has detected a problem with the steering motor encoder.
Actions:
▪ Use the ANALAYZER menu to check the steering motor encoder functions
1E1
CURRENT GAIN (steering logic unit EPS - master microcontroller)
Actions:
▪ Run a key reset
1E4
POSITION ERROR (steering logic unit EPS - master microcontroller)
The EPS (AU4) steering logic unit has detected an incorrect steering axle position.
Actions:
▪ Run several key reserts to recover the correct position of the steering axle
▪ Use the ANALYZER menu to check the steering motor encoder and steering sensor functions
1EB
TFD SHRT/VOLT KO (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the sensor TFD.
Actions:
4
sensor
sensor
sensor
sensor
sensor
▪ The resistance value of the TFDsensor coil (standard 10Ω between pins 5-6 on connector P11)
▪ Measure the voltage between pin 5 and pin 6 on connector J11 (standard battery voltage)
1EC
TFD STB I HIGH (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the sensor TFD.
Actions:
sensor
sensor
sensor
sensor
sensor
1ED
SLAVE ALARM XX (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the SLAVE microcontroller.
Actions:
▪ Run a key reset
1F1
FB SENSOR LOCKED (steering logic unit EPS - master microcontroller)
The EPS (AU4) steering logic unit has detected a problem with the steering motor encoder.
Actions:
1F4
PARAM TRANSFER (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the parameters memory.
Actions:
▪ Run a key reset
4
▪ Edit one or more parameters on the EPS steering logic unit
1F5
DATA ACQUISITION (steering logic unit EPS - master microcontroller)
Actions:
▪ Run a key reset
1F7
CAN BUS KO (steering logic unit EPS - master microcontroller)
The EPS (AU4) steering logic unit has detected a communication problem on the CAN-BUS line.
Actions:
▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)
1F8
SP OUT OF RANGE (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the TFD sensor.
Actions:
▪ Check that the steering wheel column is not mechanically locked
sensor
sensor
sensor
sensor
sensor
1FB
INIT VMN NOT OK (steering logic unit EPS - master microcontroller)
Actions:
1FC
TWIN POT MISMAT (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the steering sensor.
Actions:
▪ Check that the steering sensor is correctly plugged in
▪ Check that the steering sensor is correctly mounted (upside down or turned 180°)
4
▪ Check the steering sensor operation using the ANALYZER function
▪ Repeat the steering sensor calibration
▪ Replace the steering sensor
1FD
ANALOG (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the analog signals.
Actions:
▪ Run a key reset
1FE
NO SP REFRESH (steering logic unit EPS - master microcontroller)
The steering logic unit EPS (AU4) has detected a problem in the TFD sensor.
Actions:
sensor
sensor
sensor
sensor
sensor
RIGHT TRACTION LOGIC UNIT - MASTER MICROCONTROLLER
201
WATCHDOG (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected an internal communication problem between the MASTER and
Actions:
▪ Run a key reset
▪ Reset the right traction logic unit using the function TO DEFAULT SET
Self-diagnostic
▪ Invert the right traction logic unit and the left traction logic unit
▪ If the fault code changes from 201 to 301, replace the traction logic unit originally on the right
▪ If the fault code remains 201, the cause of the fault is outside the right traction logic unit
202
BATTERY LOW (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has measured a battery voltage less than or equal to 10% of nominal battery
value.
Actions:
▪ Discharged battery
▪ Check the density of the battery electrolyte (see paragraph INSPECTION, chapter 01)
▪ Check the battery voltage (see paragraph BATTERY CHARGE STATUS, chapter 01)
▪ The value read by the right traction logic unit is wrong
▪ Calibrate the battery indicator (see paragraph BATTERY VOLTAGE READING ADJUSTMENT PRO-
CEDURE, chapter 01)
▪ Battery damaged
▪ Replace the battery
203
LOGIC FAILURE #3 (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the power circuit - high current overload protec-
tion.
Actions:
▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)
4
▪ Check the state of the right drive motor power cables:
▪ The tightening torque of nuts on the right traction logic unit (13 Nm – 15 Nm)
▪ The tightening torque of nuts on the right drive motor (13 Nm – 15 Nm)
▪ The crimping of terminals
▪ That cable sheaths are not worn or damaged (possible current leakage to chassis)
▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE):
▪ If the measured value is less than 1MΩ replace the motor
▪ Check the windings of the right motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE):
▪ If the measured value is greater than 1Ω replace the motor
▪ Check the insulation of the right traction logic unit (see paragraph INSULATION CHECK PROCEDURE):
▪ If the measured value is less than 1MΩ replace the right traction logic unit
Self-diagnostic
▪ Invert the right traction logic unit and the left traction logic unit.
204
The right traction logic unit (AU1) has detected a problem with the hardware section controlling voltage feed-
back from the drive motor phases.
Actions:
If the measured value is less than 1MΩ replace the motor
If the measured value is greater than 1Ω replace the motor
If the measured value is less than 1MΩ replace the right traction logic unit
▪ Check the K1 contactor coil status:
Self-diagnostic
▪ Invert the right traction logic unit and the left traction logic unit:
205
The right traction logic unit (AU1) has detected a problem with the power circuit - low voltage.
Actions:
▪ Check for the correct battery voltage between pin 1 of connector J1 and negative - BATT when the truck is
powered up
4
▪ Check the state of the battery
▪ The state of the battery elements (one or more elements of the battery could be damaged)
▪ The state of the battery plug contacts (oxidation, defective crimping or damage)
▪ That the battery voltage does not drop below 30V with the drive motor in operation or when handling
materials
Self-diagnostic
206
VMN LOW (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the power circuit - low voltage at drive motor.
Actions:
▪ Insulation of the coil from the body (standard greater than 1M1MΩ)
Self-diagnostic
207
VMN HIGH (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the power circuit - overvoltage at drive motor.
Actions:
▪ Check the state of the right drive motor power cables
4
Self-diagnostic
208
CONTACTOR OPEN (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with contactor K1 - power is applied to the contactor,
but the contacts do not close.
Actions:
▪ Check the other fault codes, fault code 208 may simply be a consequence
▪ The crimping of wires to contacts and insertion of the contacts into connectors J204, J205, J1, J42 and
P42 (possible false contact/dilated pin)
▪ Continuity of the wiring between connector J1 pin 16 and connector J205
▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors
209
STBY I HIGH (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected an abnormal level of current at the drive motor when in stand-by
status.
Actions:
Self-diagnostic
20A
INCORRECT START (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected an incorrect start sequence.
20C
FORW+BACK (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected an incorrect start sequence - forward drive and reverse drive
selected simultaneously.
20D
HW FAULT (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the power circuit.
Actions:
4
Self-diagnostic
▪ If the fault code changes from 20D to 30D, replace the traction logic unit originally on the right
▪ If the fault code remains 20D, the cause of the fault is outside the right traction logic unit
20E
POWER MOS SHORT (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the power circuit.
Actions:
Self-diagnostic
▪ If the fault code changes from 20E to 30E, replace the traction logic unit originally on the right
▪ If the fault code remains 20E, the cause of the fault is outside the right traction logic unit
210
CAPACITOR CHARGE (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the power capacitor charging step.
Actions:
▪ If the alarm 210 appears alone check:
▪ The right traction logic power supply must have battery voltage on pin 1 connector J1
4
▪ Replace the right traction logic unit
▪ If the alarm 210 appears together with 310, 5A3, 13C:

211
TH PROTECTION (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has reached a temperature above 85°C tripping thermal overload protection.
Actions:
▪ If the right traction logic unit is really overheated:
▪ Wait for the traction logic unit to cool down
▪ Check that the right parking brake is working correctly (worn/faulty brake)
▪ Check that the reduction gear and right drive motor are not mechanically locked (release the right park-
ing brake to do this test)
▪ Check the presence and state of the heat dissipation paste between the right traction logic unit and
counterweight
▪ If the alarm appears when the logic unit is cold, replace the right traction logic unit.
212
MOTOR TEMP (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a temperature higher than 150°C at the right drive motor.
Actions:
▪ If the right drive motor is really overheated:
▪ Wait for the right drive motor to cool down
▪ If the alarm appears when the right drive motor is cold:
▪ Check that connector J7 is correctly plugged in
▪ Check the resistance value of the right drive motor temperature sensor (standard 629Ω at 25°C)
▪ Check for continuity between pin 1 of connector J7 and pin 23 of connector J1
▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the
connectors J1 and J7
Self-diagnostic
▪ Connect an external resistance (500 ohm ÷ 1000 ohm) to the temperature sensor connector J7:
▪ If the fault code disappears replace the right drive motor
▪ If the fault code persists, replace the right traction logic unit
213
ENCODER ERROR (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with signals generated by the right drive motor rpm
sensor.
Actions:
4
▪ Check the rpm sensor operation using the ANALYZER function
▪ Check the rpm sensor connections:
▪ Check that the rpm sensor is not damaged:
▪ Check that the rpm sensor is clean, and correctly positioned and secured in its socket
▪ Check the power input to the rpm sensor (10.5V – 11.5 V) between pin 1 and pin 4 of connector J12
▪ The insulation of the rpm sensor relative to the body of the drive axle (must be > 1MΩ)
214
THERMIC SENSOR KO (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a value generated by the right drive motor temperature sensor
that is out of range.
Actions:
▪ Check that the temperature sensor is not damaged:
Self-diagnostic
216
NO CAN MSG (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) receives no messages from other cards connected to the Can-bus line.
Actions:
219
DRIVER SHORTED (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the driver circuit controlling contactor K1.
Actions:
Self-diagnostic
21B
SENS MOT TEMP KO (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a value generated by the right drive motor temperature sensor
that is out of range.
Actions:
Self-diagnostic
21C
VDC OFF SHORTED (right traction logic unit - master microcontroller)
Actions:
powered up
4
▪ Check the state of the battery:
materials
Self-diagnostic
▪ If the fault code changes from 21C to 31C, replace the traction logic unit originally on the right
▪ If the fault code remains 21C, the cause of the fault is outside the right traction logic unit
21D
STALL ROTOR (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with signals from the motor rpm sensor, or the rotor
is stuck.
Actions:
▪ Check the operation of the right drive motor:
21E
CONTACT CLOSED (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected the contact of contactor K1 already closed when the machine is
switched on.
Actions:
▪ Release the contactor:
Check the condition of the plate and contacts of contactor K1 (oxidation or dirt)
21F
MIS. SETPOINT (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected an incorrect accelerator potentiometer voltage reading between
TRCB card and right traction logic unit.
Actions:
▪ Check the correct installation of the accelerator potentiometer (see paragraph ACCELERATOR POTEN-
4
TIOMETER, chapter 02)
▪ Check the correct configuration of the accelerator pedal, parameter SWAYING PEDAL
▪ Repeat the calibration of the accelerator potentiometer
▪ Restore all the drive parameters (MENU TUNING) to the default value
220
CONTACTOR DRIVER (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the driver circuit controlling contactor K1.
Actions:
Self-diagnostic
221
MC COIL SHORTED (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the coil of contactor K1.
Actions:
Self-diagnostic
224
INIT VMN HIGH (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the power circuit - overvoltage at drive motor.
Actions:
4
Self-diagnostic
225
WRONG SET BATT (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a battery voltage 20% higher than the nominal value.
Actions:
▪ Check the battery voltage:
▪ The density of the battery electrolyte (see paragraph INSPECTION, chapter 01)
▪ The battery voltage (see paragraph BATTERY CHARGE STATUS, chapter 01)
▪ Calibrate battery indicator (see paragraph BATTERY VOLTAGE READING ADJUSTMENT PROCEDURE,
chapter 01)
▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit
226
INIT VMN LOW (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the power circuit - low voltage at drive motor.
Actions:
Self-diagnostic
227
EEPROM KO (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem in the memory and has reloaded the default paramet-
ers.
Actions:
▪ Run a key reset and check the correct value of the drive parameters on the display
▪ If the fault code is repeated, replace the right traction logic unit
228
VDC LINK OVERV. (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the power circuit - overvoltage.
Actions:
powered up
4
materials
Self-diagnostic
22C
CURRENT GAIN (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with acquisition of electric current values.
Actions:
22F
NO SLAVE ENABLE (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected an communication problem between the MASTER and SLAVE
microcontrollers.
Actions:
▪ If the fault code is repeated and appears on its own, replace the right traction logic unit
230
PEB-PEVP NOT OK (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) does not receive +48V.
Actions:
▪ Check the correct battery voltage between pin 17 of connector J1 and negative - BATT
connectors
231
VKEY OFF SHORTED (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the ignition circuit.
Actions:
powered up
4
materials
Insulation of the coil from the body (standard greater than 1MΩ)
The condition of the plate and contacts of contactor K1 (oxidation or dirt)
The tightening torque of nuts on the contacts of contactor K1 (15.3 Nm – 16.4 Nm)
Self-diagnostic
232
TEACH VACC POT (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) prompts for acquisition of the accelerator potentiometer.
Actions:
233
STEER ACQ (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) prompts for acquisition of the steering sensor.
Actions:
▪ Check the correct installation of the steering sensor (see paragraph STEERING SENSOR, chapter 02)
234
WRONG RAM MEM. (right traction logic unit - master microcontroller)
The RIGHT traction logic unit (AU1) has encountered a problem in the RAM.
Actions:
235
STEER OUT RANGE (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has encountered a problem in the steering sensor.
Actions:
236
HANDBRAKE (right traction logic unit - master microcontroller)
23A
COIL SHORT. EB (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the right parking brake coil.
Actions:
▪ Check the state of the right parking brake:
▪ The resistance value of the right parking brake coil (standard 30Ω at 20°C)
4
▪ The crimping of wires to contacts and insertion of the contacts into connectors J1 and J13 (possible
false contact/dilated pin)
▪ Continuity of the wiring between connector J1 pin 18 and connector J13 pin 1
Self-diagnostic
▪ If the fault code changes from 23A to 33A, replace the traction logic unit originally on the right
▪ If the fault code remains 23A, the cause of the fault is outside the right traction logic unit
23C
ANALOG INPUT (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with input signals.
Actions:
Self-diagnostic
23D
CONTROLLER MISMATCH (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the configuration of parameters stored in
memory.
Actions:
241
IQ MISMATCHED (right traction logic unit - master microcontroller)
memory.
Actions:
Self-diagnostic
242
EB. DRIV. OPEN (right traction logic unit - master microcontroller)
Actions:
Self-diagnostic
243
CHECK UP NEEDED (right traction logic unit - master microcontroller)
Maintenance hour counter warning.
Actions:
244
FIELD ORIENT. KO (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the drive motor field orientation circuit.
Actions:
4
Self-diagnostic
245
EB. DRIV. SHRT (right traction logic unit - master microcontroller)
Actions:
Self-diagnostic
248
WRONG ENC SET (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a problem with the configuration of the right drive motor rpm
sensor.
Actions:
24C
PARAM TRANSFERT (right traction logic unit - master microcontroller)
The traction logic unit (AU1) has detected a problem with the parameters memory.
Actions:
▪ Run a key reset
24D
EMERGENCY SW (right traction logic unit - master microcontroller)
Actions:
▪ Check the emergency button
24E
STOP RQ FROM EPS (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) had received a stop message from the EPS. steering logic unit
Actions:
▪ Check the other fault codes
24F
WRONG SLAVE VERS (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected an incorrect software version.
Actions:
250
NO CAN MSG EPS (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected a communication problem on the CAN-BUS line.
Actions:
4
251
STOP FROM EPS (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) had received a stop message from the EPS. steering logic unit
Actions:
252
EPS IS ONLINE (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected the EPS steering logic unit but the truck is configured to the 4
wheel version.
Actions:
▪ Check the truck serial number in the MATCHING menu
253
TEACH BRK POT (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) prompts for acquisition of the brake potentiometer.
Actions:
▪ Check the correct installation of the brake potentiometer (see paragraph BRAKE POTENTIOMETER,
chapter 02)
▪ Repeat the calibration of the brake potentiometer
25B
M/S PAR CHK MISM (right traction logic unit - master microcontroller)
The right traction logic unit (AU1) has detected an communication problem between the MASTER and SLAVE
microcontrollers.
Actions:
LEFT TRACTION LOGIC UNIT - MASTER MICROCONTROLLER
301
WATCHDOG (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected an internal communication problem between the MASTER and
Actions:
▪ Run a key reset
▪ Reset the left traction logic unit using the function TO DEFAULT SET
Self-diagnostic
▪ If the fault code changes from 301 to 201, replace the left traction logic unit
▪ If the fault code remains 301, the cause of the fault is outside the left traction logic unit
302
BATTERY LOW (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has measured a battery voltage less than or equal to 10% of nominal battery
value.
Actions:
▪ Discharged battery
▪ Check the density of the battery electrolyte (see paragraph INSPECTION, chapter 01)
▪ Check the battery voltage (see paragraph BATTERY CHARGE STATUS, chapter 01)
▪ The value read by the left traction logic unit is wrong
▪ Calibrate the battery indicator (see paragraph BATTERY VOLTAGE READING ADJUSTMENT PRO-
CEDURE, chapter 01)
▪ Battery damaged
▪ Replace the battery
303
LOGIC FAILURE #3 (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the power circuit - high current overload protec-
tion.
Actions:
4
▪ Check the state of the left drive motor power cables:
▪ The tightening torque of nuts on the left traction logic unit (13 Nm – 15 Nm)
▪ The tightening torque of nuts on the left drive motor (13 Nm – 15 Nm)
▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE):
▪ If the measured value is less than 1MΩ replace the motor
▪ Check the windings of the left motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE):
▪ If the measured value is greater than 1Ω replace the motor
▪ Check the insulation of the left traction logic unit (see paragraph INSULATION CHECK PROCEDURE):
▪ If the measured value is less than 1MΩ replace the left traction logic unit
Self-diagnostic
▪ If the fault code changes from 203 to 303, replace the traction logic unit originally on the left
304
The left traction logic unit (AU2) has detected a problem with the hardware section controlling voltage feedback
from the drive motor phases.
Actions:
If the measured value is less than 1MΩ replace the left traction logic unit
Self-diagnostic
305
The left traction logic unit (AU2) has detected a problem with the power circuit - low voltage.
Actions:
powered up
4
materials
Self-diagnostic
306
VMN LOW (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the power circuit - low voltage at drive motor.
Actions:
▪ Insulation of the coil from the body (standard greater than 1M1MΩ)
Self-diagnostic
307
VMN HIGH (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the power circuit - overvoltage at drive motor.
Actions:
▪ Check the state of the left drive motor power cables
4
Self-diagnostic
308
CONTACTOR OPEN (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with contactor K1 - power is applied to the contactor,
Actions:
309
STBY I HIGH (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected an abnormal level of current at the drive motor when in stand-by
status.
Actions:
Self-diagnostic
30A
INCORRECT START (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected an incorrect start sequence.
30C
FORW+BACK (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected an incorrect start sequence - forward drive and reverse drive se-
lected simultaneously.
30D
HW FAULT (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the power circuit.
Actions:
4
Self-diagnostic
▪ If the fault code changes from 30D to 20D, replace the traction logic unit originally on the left
▪ If the fault code remains 30D, the cause of the fault is outside the left traction logic unit
30E
POWER MOS SHORT (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the power circuit.
Actions:
Self-diagnostic
▪ If the fault code changes from 30E to 20E, replace the traction logic unit originally on the left
▪ If the fault code remains 30E, the cause of the fault is outside the left traction logic unit
310
CAPACITOR CHARGE (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the power capacitor charging step.
Actions:
▪ If the alarm 310 appears alone check:
▪ The left traction logic power supply must have battery voltage on pin 1 connector J2
4
▪ Replace the left traction logic unit
▪ If the alarm 310 appears together with 310, 5A3, 13C:

311
TH PROTECTION (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has reached a temperature above 85°C tripping thermal overload protection.
Actions:
▪ If the left traction logic unit is really overheated:
▪ Wait for the traction logic unit to cool down
▪ Check that the left parking brake is working correctly (worn/faulty brake)
▪ Check that the reduction gear and left drive motor are not mechanically locked (release the left parking
brake to do this test)
▪ Check the presence and state of the heat dissipation paste between the left traction logic unit and coun-
terweight
▪ If the alarm appears when the logic unit is cold, replace the left traction logic unit
312
MOTOR TEMP (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a temperature higher than 150°C at the left drive motor.
Actions:
▪ If the left drive motor is really overheated:
▪ Wait for the left drive motor to cool down
▪ If the alarm appears when the left drive motor is cold:
▪ Check the resistance value of the left drive motor temperature sensor (standard 629Ω at 25°C)
Self-diagnostic
▪ If the fault code disappears replace the left drive motor
▪ If the fault code persists, replace the left traction logic unit
313
ENCODER ERROR (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with signals generated by the left drive motor rpm
sensor.
Actions:
4
314
THERMIC SENS KO (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a value generated by the left drive motor temperature sensor that
is out of range.
Actions:
▪ Check the resistance value of the left drive motor temperature sensor (standard 629Ω at 25°C)
Self-diagnostic
316
NO CAN MSG (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) receives no messages from other cards connected to the Can-bus line.
Actions:
319
DRIVER SHORTED (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the driver circuit controlling contactor K1.
Actions:
Self-diagnostic
31B
SENS MOT TEMP KO (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a value generated by the left drive motor temperature sensor that
is out of range.
Actions:
Self-diagnostic
31C
VDC OFF SHORTED (left traction logic unit - master microcontroller)
Actions:
powered up
4
materials
Self-diagnostic
▪ If the fault code changes from 31C to 21C, replace the traction logic unit originally on the left
▪ If the fault code remains 31C, the cause of the fault is outside the left traction logic unit
31D
STALL ROTOR (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with signals from the motor rpm sensor, or the rotor is
stuck.
Actions:
▪ Check the operation of the left drive motor:
31E
CONTACT CLOSED (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected the contact of contactor K1 already closed when the machine is
switched on.
Actions:
Check the condition of the plate and contacts of contactor K1 (oxidation or dirt)
31F
MIS. SETPOINT (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected an incorrect accelerator potentiometer voltage reading between
TRCB card and left traction logic unit.
Actions:
4
320
CONTACT DRIVER (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the driver circuit controlling contactor K1.
Actions:
Self-diagnostic
321
MC COIL SHORTED (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the coil of contactor K1.
Actions:
Self-diagnostic
324
INIT VMN HIGH (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the power circuit - overvoltage at drive motor.
Actions:
4
Self-diagnostic
325
WRONG SET BATT (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a battery voltage 20% higher than the nominal value.
Actions:
chapter 01)
▪ Reset the left traction logic unit using the TO DEFAULT SET function
▪ Update the software version of the MASTER and SLAVE microcontroller on the left traction logic unit
326
INIT VMN LOW (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the power circuit - low voltage at drive motor.
Actions:
Self-diagnostic
327
EEPROM KO (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem in the memory and has reloaded the default paramet-
ers.
Actions:
▪ If the fault code is repeated, replace the left traction logic unit
328
VDC LINK OVERV. (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the power circuit - overvoltage.
Actions:
powered up
4
materials
Self-diagnostic
32C
CURRENT GAIN (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with acquisition of electric current values.
Actions:
32F
NO SLAVE ENABLE (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected an communication problem between the MASTER and SLAVE
microcontrollers.
Actions:
▪ If the fault code is repeated and appears on its own, replace the left traction logic unit
330
PEB-PEVP NOT OK (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) does not receive +48V.
Actions:
▪ Check the correct battery voltage between pin 17 of connector J2 and negative - BATT
connectors
331
VKEY OFF SHORTED (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the ignition circuit.
Actions:
powered up
4
materials
Self-diagnostic
332
TEACH VACC POT (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) prompts for acquisition of the accelerator potentiometer.
Actions:
333
STEER ACQ (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) prompts for acquisition of the steering sensor.
Actions:
334
WRONG RAM MEM. (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem in the RAM.
Actions:
335
STEER OUT RANGE (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has encountered a problem in the steering sensor.
Actions:
336
HANDBRAKE (left traction logic unit - master microcontroller)
33A
COIL SHORT. EB (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the left parking brake coil.
Actions:
▪ Check the state of the left parking brake:
▪ The resistance value of the left parking brake coil (standard 30Ω at 20°C)
4
Self-diagnostic
▪ If the fault code changes from 33A to 23A, replace the traction logic unit originally on the left
▪ If the fault code remains 33A, the cause of the fault is outside the left traction logic unit
33C
ANALOG INPUT (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with input signals.
Actions:
Self-diagnostic
33D
CONTROLLER MISMATCH (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the configuration of parameters stored in memory.
Actions:
341
IQ MISMATCHED (left traction logic unit - master microcontroller)
Actions:
Self-diagnostic
342
EB. DRIV. OPEN (left traction logic unit - master microcontroller)
Actions:
Self-diagnostic
343
CHECK UP NEEDED (left traction logic unit - master microcontroller)
Actions:
344
FIELD ORIENT. KO (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the drive motor field orientation circuit
Actions:
4
Self-diagnostic
345
EB. DRIV. SHRT (left traction logic unit - master microcontroller)
Actions:
Self-diagnostic
348
WRONG ENC SET (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with configuration generated by the left drive motor
rpm sensor.
Actions:
34C
PARAM TRANSFERT (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a problem with the parameters memory.
Actions:
▪ Run a key reset
34D
EMERGENCY SW (left traction logic unit - master microcontroller)
Actions:
34E
STOP RQ FROM EPS (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) had received a stop message from the EPS steering logic unit
Actions:
34F
WRONG SLAVE V. (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected an incorrect software version.
Actions:
350
NO CAN MSG EPS (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected a communication problem on the CAN-BUS line.
Actions:
4
351
STOP FROM EPS (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) had received a stop message from the EPS steering logic unit
Actions:
352
EPS IS ONLINE (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected the EPS steering logic unit but the truck is configured to the 4
wheel version.
Actions:
353
TEACH BRK POT (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) prompts for acquisition of the brake potentiometer.
Actions:
chapter 02)
35B
M/S PAR CHK MISM (left traction logic unit - master microcontroller)
The left traction logic unit (AU2) has detected an communication problem between the MASTER and SLAVE
microcontrollers.
Actions:
MCB CARD (TRCB section)
430
WRONG BATTERY (MCB card - TRCB section)
The MCB (AE5) card has detected an incorrect battery configuration.
Actions:
▪ Check the settings of the Li-ION BATT parameter in the OPT - BATTERY menu
450
ACC WRONG PARAMETER (MCB card - TRCB section)
The MCB (AE5) card has detected a problem on the drive parameter values.
Actions:
▪ Run a key reset
▪ Reset the TRCB card using the function TO DEFAULT SET
452
BAD EMERGENCY SWITCH (MCB card - TRCB section)
The MCB (AE5) card has detected a problem on the emergency button.
Actions:
453
ACC ZAPI MISMATCH (MCB card - TRCB section)
The MCB (AE5) card has detected an inconsistency with the accelerator potentiometer values.
Actions:
454
BRAKE ZAPI MISMATCH (MCB card - TRCB section)
The MCB (AE5) card has detected an inconsistency with the brake potentiometer values.
Actions:
chapter 02)
45A
LHS ERR (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with signals from the mast height switch K4.
Actions:
▪ Check the mast height switch operation using the ANALYZER function
▪ Check the mast height switch connections
4
494
CHKSUM ERROR (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with the TRCB memory.
Actions:
▪ Check that an antistatic ground strap is fitted to the machine, if equipped with non-marking tyres
▪ Reset the TRCB card using the TO DEFAULT SET function
▪ Update the software version of the TRCB card
▪ If the fault code is repeated, replace the MCB card
496
RELOAD PARAM WARN (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with the TRCB memory.
Actions:
4A7
EVP CURR MISMATCH (MCB card - TRCB section)
The MCB (AE5) card has detected a problem in the distributor valve pilot.
Actions:
▪ Update the software version of the TRCB and EVCB cards
4B6
DASH KO (MCB card - TRCB section)
The MCB (AE5) card does not receive messages from the DISPLAY.
Actions:
▪ Run a key reset
▪ Update the software version of the DISPLAY
4C1
INCORRECT START (MCB card - TRCB section)
The MCB (AE5) card has detected an incorrect start sequence.
4C2
BRAKE WIRE KO (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with signals from brake potentiometer.
Actions:
▪ Check the brake potentiometer operation using the ANALYZER function
▪ Check the brake potentiometer connections
▪ Check for continuity between pin 1 of connector P15 and pin 16 of connector J5
connectors P15 and J5
4C3
PEDAL WIRE KO (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with signals from accelerator potentiometer.
Actions:
▪ Check the brake potentiometer operation using the ANALYZER function
▪ Check the brake potentiometer connections
connectors P32 and J5
4C4
BAD MICROSWITCH (MCB card - TRCB section)
The MCB (AE5) card has detected a problem on the accelerator pedal microswitch signals or the drive direction
control on the steering wheel column or in the reverse drive configuration.
Actions:
▪ Check the correct setting of the GEAR MODE parameter in the MAT - FW/BW SELECTOR menu
4
▪ Check the accelerator pedal microswitch operation or the drive direction control on the steering wheel
column using the ANALYZER function
▪ Check that the accelerator pedal microswitches or the drive direction control on the steering wheel column
are not mechanically locked or broken
▪ Check the connections on the accelerator pedal microswitches
▪ Check that connector P33 is correctly plugged in
connectors P33, J33 and J5
▪ Check the connections on the drive direction control on the steering wheel column
connectors J29, J61, P61 and J5
4C6
BAD VACC (MCB card - TRCB section)
The MCB (AE5) card requires the acquisition of the accelerator potentiometer.
Actions:
4C7
ERR SEAT (MCB card - TRCB section)
4C8
TRACTION LOCK (MCB card - TRCB section)
The MCB (AE5) card has detected an inconsistency between drive direction signals.
Actions:
▪ Check the accelerator pedal microswitch operation or the drive direction control on the steering wheel
column using the ANALYZER function
▪ Check that the accelerator pedal microswitches or the drive direction control on the steering wheel column
are not mechanically locked or broken
▪ Check the connections on the accelerator pedal microswitches
connectors P33, J33 and J5
▪ Check the connections on the drive direction control on the steering wheel column
4C9
PARKING SELECTED (MCB card - TRCB section)
4CA
PAR LOAD ERROR (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with the TRCB. memory
Actions:
4
4CB
TRAC IN ALARM (MCB card - TRCB section)
The MCB (AE5) card has detected a faulty traction logic unit.
Actions:
4CC
TRUC STUFFING ERR (MCB card - TRCB section)
The MCB (AE5) card receives no messages from other cards connected to the Can-bus line.
Actions:
4CD
JOY MSG LOST (MCB card - TRCB section)
The MCB (AE5) card receives no messages from other cards connected to the Can-bus line.
Actions:
4CE
BRAKE BAD VACC (MCB card - TRCB section)
The MCB (AE5) card requires the acquisition of the brake potentiometer.
Actions:
chapter 02)
4CF
FW PLUS BW (MCB card - TRCB section)
4F1
STEER ENCODER KO (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with signals from steering encoder E1.
Actions:
▪ Check the steering encoder operation using the ANALYZER function
▪ Check the steering encoder connections
▪ That a measurement between pin 1 and pin 2 of connector J14 gives a reading of 12V
4F2
STEER SENSOR KO (MCB card - TRCB section)
Actions:
▪ Check that a measurement between pin 1 and pin 2 of connector J14 gives a reading of 12V
4F5
INT INDEX ERROR (MCB card - TRCB section)
Actions:
4
▪ Check that a measurement between pin 1 and pin 2 of connector J14 gives a reading of 12V
4FA
STEER LOAD OPEN (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with the coil of the synchronization valve of steering wheel knob.
Actions:
▪ Check the that the steering wheel knob synchronizer value is working using the ANALYZER function
▪ Check the connections with the steering wheel knob synchronizer valve
▪ The resistance value of the valve (standard 10Ω at 20°C)
connectors J98, P98 and J6
4FB
STEER LOAD SHORTED (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with the coil of the synchronization valve of steering wheel knob.
Actions:
▪ Check the that the steering wheel knob synchronizer value is working using the ANALYZER function
▪ Check the connections with the steering wheel knob synchronizer valve
▪ The resistance value of the valve (standard 10Ω at 20°C)
4FC
SWING LOAD OPEN (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with the coil of the oscillation lock cylinder valve.
Actions:
▪ Check the oscillation lock cylinder valve is working using the ANALYZER function
▪ Check the oscillation lock cylinder valve connections
4FD
SWING LOAD SHORTED (MCB card - TRCB section)
The MCB (AE5) card has detected a problem with the coil of the oscillation lock cylinder valve.
Actions:
▪ Check the oscillation lock cylinder valve is working using the ANALYZER function
▪ Check the oscillation lock cylinder valve connections
4FE
V BATT KO (MCB card - TRCB section)
The MCB (AE5) card does not receive 48V from the battery.
Actions:
▪ Check the connections on the MCB card
▪ Check that 48V registers between pin 17 of connector J6 and battery negative
▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in
connector J6
LIFT LOGIC UNIT
5A0
ANALOG INPUT (lift logic unit)
The lift logic unit (AU3) has detected a problem with input signals. 4
Actions:
▪ Check the insulation of the lift logic unit (see paragraph INSULATION CHECK PROCEDURE)
Self-diagnostic
▪ Disconnect the rpm sensor and the pump motor temperature sensor and the connectors from the hydraulic
distributor
▪ If the fault code disappears, the cause of the fault is outside the lift logic unit
▪ If the fault code 5A0 persists, replace the lift logic unit
5A1
COIL SHORT HW KO (lift logic unit)
The lift logic unit (AU3) has detected a problem with the coils connected to the auxiliary outputs.
Actions:
▪ Check the state of the pump motor power cables
▪ The tightening torque of nuts on the lift logic unit (13 Nm – 15 Nm)
▪ The tightening torque of nuts on the pump motor (13 Nm – 15 Nm)
▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE):
▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE):
▪ Check the insulation of the lift logic unit (see paragraph INSULATION CHECK PROCEDURE):
If the measured value is less than 1MΩ replace the lift logic unit
▪ Check the status of the coils on valves L27 and L25:
▪ The resistance value of the coils on valves L27 and L25 (standard 10Ω at 20°C)
▪ Insulation of the coils from the body (standard greater than 1MΩ)
J3 and J30
▪ Replace the lift logic unit
5A2
LOGIC FAILURE #3 (lift logic unit)
The lift logic unit (AU3) has detected a problem with the power circuit - high current overload protection.
Actions:
5A3
CAPACITOR CHARGE (lift logic unit)
The lift logic unit (AU3) has detected a problem with the power capacitor charging step.
Actions:
▪ If the alarm 5A3 appears alone check:
▪ The right traction logic power supply must have battery voltage on pin 1 connector J1
4
▪ If the alarm 5A3 appears together with 310, 210, 13C:

5A4
VMN LOW (lift logic unit)
The lift logic unit (AU3) has detected a problem with the power circuit - low voltage at pump motor.
Actions:
5A5
DRIVER SHORTED (lift logic unit)
The lift logic unit (AU3) has detected a problem with the driver circuit of valve L27.
Actions:
4
J3 and J30
5A6
MC COIL SHORTED (lift logic unit)
The lift logic unit (AU3) has detected a problem with the coil of contactor K1.
Actions:
▪ Continuity of the wiring between connector J44 pin 3 and connector J204.
5A7
VMN HIGH (lift logic unit)
The lift logic unit (AU3) has detected a problem with the power circuit - overvoltage at pump motor.
Actions:
▪ Check the state of the pump motor power cables:
▪ Check the windings of the pump (see paragraph MOTOR WINDINGS CHECK PROCEDURE):
- If the measured value is greater than 1Ω replace the motor
5A8
STBY I HIGH (lift logic unit)
The lift logic unit (AU3) has detected an abnormal level of current at the drive motor when in stand-by status.
Actions:
4
5A9
CONTACTOR OPEN (lift logic unit)
The lift logic unit (AU3) has detected a problem with contactor K1 - power is applied to the contactor, but the
contacts do not close.
Actions:
▪ Check the other fault codes, fault code 5A9 may simply be a consequence
5AA
AUX DRIV. SHRT (lift logic unit)
Actions:
J3 and J30
5AB
The lift logic unit (AU3) has detected a problem with the power circuit - low voltage.
Actions:
powered up
4
materials
▪ - The resistance value of the coil K1 (standard 100Ω at 20°C)
5AC
The lift logic unit (AU3) has detected a problem with the hardware section controlling voltage feedback from the
pump motor phases.
Actions:
▪ The tightening torque of nuts on the pump logic unit (13 Nm – 15 Nm)
5AD
SAFETY INPUT (lift logic unit)
The lift logic unit (AU3) does not receive the SAFETY signal.
Actions:
▪ Check the status of connector J3:
▪ Continuity of the wiring harness between pin 9 and pin 11 on connector J3
▪ The crimping of wires to contacts and insertion of the contacts into connectors J3 (possible false con-
tact/dilated pin)
5AE
CONTACTOR DRIVER (lift logic unit)
The lift logic unit (AU3) has detected a problem with the driver circuit of valve L27.
Actions:
4
J3 and J30
5AF
THERMIC PROTECTION (lift logic unit)
The lift logic unit (AU3) has reached a temperature above 85°C tripping thermal overload protection
Actions:
▪ If the lift logic unit is really overheated
▪ Wait for the lift logic unit to cool down
▪ Check that the hydraulic system pressure complies with the model specifications
▪ Check the presence and state of the heat dissipation paste between the right traction logic unit and
counterweight
▪ If the alarm appears when the lift logic unit is cold, replace the lift logic unit.
5B0
EEPROM KO (lift logic unit)
The lift logic unit (AU3) has detected a problem in the memory and has reloaded the default parameters.
Actions:
▪ Run a key reset and check the correct value of the hydraulic function parameters on the display
▪ Reset the lift logic unit using the TO DEFAULT SET function
▪ If the fault code is repeated, replace the lift logic unit
5B1
MOTOR TEMPERATURE (lift logic unit)
The lift logic unit (AU3) has detected a temperature higher than 150°C at the pump motor.
Actions:
▪ If the pump motor is really overheated:
▪ Wait for the pump motor to cool down
▪ Check that the hydraulic system pressure complies with the model specifications
▪ Check that the pump and the motor are not mechanically locked
▪ If the alarm appears when the pump motor is cold:
▪ Check the resistance value of the pump motor temperature sensor (standard 629Ω at 25°C)
5B2
WRONG SET BATTERY (lift logic unit)
The lift logic unit (AU3) has detected a battery voltage 20% higher than the nominal value.
Actions:
chapter 01)
▪ Update the software version of the lifting logic unit
5B3
THERMIC SENS KO (lift logic unit)
The lift logic unit (AU3) has detected a value generated by the drive motor temperature sensor that is out of
range.
Actions:
4
▪ Check the resistance value of the pump motor temperature sensor (standard 629Ω at 25°C)
Self-diagnostic
▪ If the fault code disappears replace the pump motor
▪ If the fault code persists, replace the lift logic unit
5B4
AUX COIL SHORT (lift logic unit)
Actions:
J3 and J30
5B5
CHECK UP NEEDED (lift logic unit)
Actions:
5B6
NO CAN MSG. (lift logic unit)
The lift logic unit (AU3) receives no messages from other cards connected to the Can-bus line.
Actions:
5B7
AUX DRIV. OPEN (lift logic unit)
Actions:
J3 and J30
5B8
SAFETY OUTPUT (lift logic unit)
The lift logic unit (AU3) does not send the SAFETY signal.
Actions:
▪ Check the status of connector J3:
▪ Continuity of the wiring harness between pin 9 and pin 11 on connector J3
4
▪ The crimping of wires to contacts and insertion of the contacts into connectors J3 (possible false con-
tact/dilated pin)
5B9
KEY OFF SHORT (lift logic unit)
The lift logic unit (AU3) has detected a problem with the power-up circuit.
Actions:
powered up
materials
5BA
HARDWARE FAULT (lift logic unit)
The lift logic unit (AU3) has detected a problem with the power circuit.
Actions:
5BB
POWER MOS SHORT (lift logic unit)
The lift logic unit (AU3) has detected a problem with the power circuit.
Actions:
4
5BC
CONTACTOR CLOSED (lift logic unit)
The lift logic unit (AU3) has detected the contact of contactor K1 already closed when the machine is switched
on.
Actions:
▪ Check the condition of the plate and contacts of contactor K1 (oxidation or dirt)
▪ - The integrity of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the
connectors
5BD
ENCODER ERROR (lift logic unit)
The lift logic unit (AU3) has detected a problem with signals generated by the pump motor rpm sensor
Actions:
5BE
WATCHDOG #1 (lift logic unit)
The lift logic unit (AU3) has detected an internal problem.
Actions:
5BF
WATCHDOG #2 (lift logic unit)
The lift logic unit (AU3) has detected an internal problem.
Actions:
4
5C1
WRONG RAM MEMORY (lift logic unit)
The lift logic unit (AU3) has detected a problem in the memory.
Actions:
▪ Run a key reset
5C2
SENS MOT TEMP KO (lift logic unit)
The lift logic unit (AU3) has detected a value generated by the drive motor temperature sensor that is out of
range.
Actions:
Self-diagnostic
▪ If the fault code disappears replace the pump motor
▪ If the fault code persists, replace the lift logic unit
5C3
CURRENT GAIN (lift logic unit)
The lift logic unit (AU3) has detected a problem with acquisition of electric current values
Actions:
▪ Reset the pump logic unit using the TO DEFAULT SET function
5C4
WRONG 0 VOLTAGE (lift logic unit)
The lift logic unit (AU3) has detected a problem with the hardware section controlling voltage feedback from the
pump motor phases.
Actions:
4
powered up
materials
5C5
TORQUE PROFILE (lift logic unit)
The lift logic unit (AU3) has detected inconsistent torque values given by the profiles stored in its memory.
Actions:
▪ Reset the EVCB, TRCB cards, the MASTER and SLAVE arm rests using the TO DEFAULT SET function
▪ Restore all the drive and material handling parameters (MENU TUNING) to the default value
▪ Update the software version on all cards on the truck
5C7
ENCODER LOCKED (lift logic unit)
The lift logic unit (AU3) has detected a problem with signals from the motor rpm sensor, or the rotor is stuck
Actions:
5C8
FOC LOST (lift logic unit)
The lift logic unit (AU3) has detected a problem with the pump motor field orientation circuit.
Actions:
5C9
IQ MISMATCHED (lift logic unit)
The lift logic unit (AU3) has detected a problem with the configuration of parameters stored in memory
Actions:
▪ Run a key reset and check the correct value of the drive parameters on the display.
5CA
PROG VACC NOT OK (lift logic unit)
Fault code not utilized.
Actions:
4
5CB
TEACH SWING POT (lift logic unit)
Actions:
5CC
STEER OUT RANGE (lift logic unit)
Actions:
5CD
TEACH STEER POT (lift logic unit)
Actions:
MCB CARD (EVCB section)
659
PSV ERR (MCB card - EVCB section)
The MCB (AU5) card has detected a problem with the signal from the mast pressure sensor R7.
Actions:
▪ Check the pressure sensor connections:
▪ Check the steering sensor operation using the ANALYZER function:
▪ The value must be between 0.1V and 4.9V
▪ Repeat the pressure sensor calibration
65A
LHS ERR (MCB card - EVCB section)
The MCB (AU5) card has detected a problem with signals from the mast height switch K4.
Actions:
▪ Check the mast height switch operation using the ANALYZER function:
The values of the switch signals, using the ANL function of display (MAST H NO and MAST H NC must
never be both ON or both OFF, but always one ON and the other OFF, depending on the position of the
mast height switch)
▪ :Check the mast height switch connections
65B
TAS ERR (MCB card - EVCB section)
The MCB (AU5) card has detected a problem with the signal from tilt angle potentiometer R6.
Actions:
▪ Check the tilt angle potentiometer operation using the ANALYZER function:
The value of the tilt angle potentiometer, using the ANL function of the display (parameter TILT POT); the
4
value must read between 0.1V and 4.9V.
▪ Check the connections of the tilt angle potentiometer:
▪ Adjust the potentiometer rod (see paragraph TILT ANGLE POTENTIOMETER, chapter 02)
▪ Repeat the calibration of the tilt angle potentiometer
65D
WMV ERR (MCB card - TRCB section)
The MCB (AU5) card has detected values for tilt angle potentiometer R6 or mast pressure sensor R7 different
from those stored in memory.
Actions:
▪ Repeat the calibration of the tilt angle potentiometer and the mast pressure sensor
65E
LPH ERR (MCB card - EVCB section)
The MCB (AU5) card has detected a problem with the signal from the mast height sensor R24.
Actions:
▪ Check the configuration parameters of the option and repeat the acquisitions of the mast height sensor R24
▪ Check the tilt angle potentiometer operation using the ANALYZER function:
The value of the mast height sensor, using the ANL function of the display (parameter H SENSOR); the
value must read between 0.1V and 23.9V
▪ Check the mast height sensor connections:
▪ Check that connectors J411 and J409 are correctly plugged in
connectors J5, J6, P409, P411 and J411
6A1
DOUBLE REQUEST (MCB card - EVCB section)
The MCB (AU5) card has detected an attempt to select two operations on the same oil line.
6A2
RELOAD PARAM WARN (MCB card - EVCB section)
The MCB (AE5) card has detected a problem with the EVCB memory.
Actions:
▪ Reset the EVCB card using the TO DEFAULT SET function
▪ Update the software version of the EVCB card
6A3
PAR LOAD ERROR (MCB card - EVCB section)
The MCB (AE5) card has detected a problem with the MCB memory.
Actions:
▪ Reset the EVCB card using the TO DEFAULT SET function
6A4
NOT REP ERROR (MCB card - EVCB section)
The MCB (AU5) card does not receive Can-bus messages.
Actions:
6A7
P SHORT ERR (MCB card - EVCB section)
The MCB (AU5) card has detected a problem with the circuit piloting the valves.
Actions:
▪ Disconnect the distributor valves and the rear lights:
▪ If the alarm condition disappears on disconnecting one of the components listed above, proceed to
check the state of the component
▪ If the alarm persists replace the MCB card
6A8
EV1 1 OPEN (MCB card - EVCB section)
The MCB (AU5) card has detected a problem with descent valve L21.
Actions:
▪ Check the lowering valve connections:
▪ That connector P31 is correctly plugged in
4
▪ For continuity between pin 1 of connector J31 and pin 3 of connector J6
▪ The resistance value of the valve coil (standard 7.2Ω at 20°C)
▪ Insulation of the valve coil from the body (standard greater than 1MΩ)
6A9
The MCB (AU5) card has detected a problem with lift valve L28.
Actions:
▪ Check the lift valve connections:
6AA
The MCB (AU5) card has detected a problem with backward tilt valve L26.
Actions:
▪ Check the backward tilt valve connections:
6AB
The MCB (AU5) card has detected a problem with forward tilt valve L20.
Actions:
▪ Check the forward tilt valve connections:
6AC
The MCB (AU5) card has detected a problem with the right sideshift valve L24.
Actions:
▪ Check the right sideshift valve connections:
6AD
The MCB (AU5) card has detected a problem with the left sideshift valve L19.
Actions:
▪ Check the left sideshift valve connections:
6AE
The MCB (AU5) card has detected a problem with the ATT2 valve L23.
Actions:
▪ Check the ATT2 valve connections:
4
6AF
The MCB (AU5) card has detected a problem with the ATT2 valve L18.
Actions:
▪ Check the ATT2 valve connections:
6B1
DRIVER EV1 SHORTED (MCB card - EVCB section)
The MCB (AU5) card has detected a problem with descent valve L21 or with lift valve L28.
Actions:
▪ Check the lift and lowering valve connections:
▪ That connector P31 and P30 are correctly plugged in
▪ The resistance value of the valve coils (standard 7.2Ω at 20°C)
▪ Insulation of the valve coils from the body (standard greater than 1MΩ)
connectors J6, P31, J31, P30 and J30
▪ Replace the MCB card
6B2
The MCB (AU5) card has detected a problem with tilt valves L26 or L20.
Actions:
6B3
The MCB (AU5) card has detected a problem with the sideshift valve L19 or L24.
Actions:
6B4
The MCB (AU5) card has detected a problem with the ATT2 valves L23 or L18.
Actions:
4
6B6
DASH KO (MCB card - EVCB section)
The MCB (AE5) card does not receive messages from the DISPLAY.
Actions:
▪ Run a key reset
▪ Update the software version of the DISPLAY
6B7
ERR SEAT (MCB card - EVCB section)
The MCB (AU5) card has detected an attempt to handle materials while the seat microswitch is open.
6B8
JOY STUFFING ERR (MCB card - EVCB section)
The MCB (AU5) card is not receiving Can-bus messages from the armrest card (AU6).
Actions:
6BA
DR PMOS LOCK (MCB card - EVCB section)
The MCB (AU5) card has detected a problem with the circuit piloting the valves.
Actions:
▪ Disconnect the distributor valves and the rear lights:
▪ If the alarm persists, replace the MCB card
6BB
LOAD 1 SHORTED (MCB card - EVCB section)
The MCB (AU5) card has detected a problem with descent valve L21 or with lift valve L28.
Actions:
6BC
The MCB (AU5) card has detected a problem with tilt valves L26 or L20.
Actions:
6BD
The MCB (AU5) card has detected a problem with the sideshift valve L19 or L24.
Actions:
4
6BE
The MCB (AU5) card has detected a problem with the ATT2 valves L23 or L18.
Actions:
6E1
PUMP INCORR. START (MCB card - EVCB section)
The MCB (AU5) card has detected an incorrect start procedure.
6EE
PUMP STUFFING ERR (MCB card - EVCB section)
The MCB (AU5) card is not receiving Can-bus messages from the lift logic unit (AU2).
Actions:
6F3
NYM ERR (MCB card - TRCB section)
The MCB (AU5) card has no acquisition values for tilt angle potentiometer R6 or mast pressure sensor R7
stored in memory.
Actions:
6F4
INCORRECT START (MCB card - EVCB section)
The MCB (AU5) card has detected an incorrect start procedure.
ARM REST CARD - MASTER MICROCONTROLLER
8E1
INCORRECT START MH (arm rest card - master microcontroller)
The armrest card (AU6) has detected an incorrect start procedure.
8E2
BAD LIFT POT (arm rest card - master microcontroller)
The armrest card (AU6) has detected a problem with the lift potentiometer R8 / R9.
Actions:
▪ Repeat the calibration of the lift potentiometer
Self-diagnostic
▪ Invert the lift and tilt potentiometers and repeat the calibrations:
▪ If the fault code changes from 8E2 to 8E3, replace the potentiometer that was originally for the lift
▪ If the fault code remains 8E2, the cause of the fault is in the arm rest wiring harness or the arm rest card
is faulty
8E3
BAD TILT POT (arm rest card - master microcontroller)
The armrest card (AU6) has detected a problem with the tilt potentiometer R10 / R11.
Actions:
▪ Repeat the calibration of the tilt potentiometer
Self-diagnostic
▪ If the fault code changes from 8E3 to 8E2, replace the potentiometer that was originally for the tilt
is faulty
8E4
BAD SIDESHIFT POT (arm rest card - master microcontroller)
The armrest card (AU6) has detected a problem with the ATT1 function potentiometer R12 / R13.
Actions:
▪ Repeat the calibration of the ATT1 function potentiometer
Self-diagnostic
4
▪ Invert the ATT1 function and tilt potentiometers and repeat the calibrations:
▪ If the fault code changes from 8E4 to 8E3, replace the potentiometer that was originally for ATT1
is faulty
8E5
BAD IV POT (arm rest card - master microcontroller)
Actions:
Self-diagnostic
▪ Invert the ATT2 and ATT1 function potentiometers and repeat the calibration:
is faulty
8E6
BAD V POT (arm rest card - master microcontroller)
The armrest card (AU6) has detected a problem with the ATT2 function potentiometer R14 / R15 when it is
used along with the 5th way button.
Actions:
Self-diagnostic
▪ Invert the ATT2 and ATT1 function potentiometers and repeat the calibrations
is faulty
8E7
ERROR SEAT (arm rest card - master microcontroller)
The armrest card (AU6) has detected an incorrect start procedure.
8E8
INV RESTORE STATE (arm rest card - master microcontroller)
The armrest card (AU6) has detected a memory problem.
Actions:
▪ Reset the MASTER and SLAVE arm rest cards using the TO DEFAULT SET function
▪ Update the software version of the MASTER and SLAVE arm rest card
▪ If the fault code is repeated, replace the arm rest card
8E9
EEPROM INC ERROR (arm rest card - master microcontroller)
Actions:
8EA
DEFAULT RESTORE (arm rest card - master microcontroller)
The armrest card (AU6) has detected a problem in the memory and has reloaded the parameter default values.
Actions:
8EB
MATCHING REQUIRED (arm rest card - master microcontroller)
No potentiometer acquisition values stored in memory of armrest card (AU6).
Actions:
8EC
PDO CHKSUM ERROR (arm rest card - master microcontroller)
Actions:
4
8ED
BAD COMM EVCB (arm rest card - master microcontroller)
The armrest card (AU6) is not receiving Can-bus messages from the MCB (AU5) card.
Actions:
8EE
BAD COMM PUMP (arm rest card - master microcontroller)
The armrest card (AU6) is not receiving Can-bus messages from the lift logic unit (AU3).
Actions:
8EF
FW BW (arm rest card - master microcontroller)
The arm rest card (AU6) has detected a problem with the driver selector on the arm rest.
Actions:
▪ Check that the drive selector on the arm rest is working correcting using the ANALYZER function
▪ Check the drive selector connections on the arm rest:
LITHIUM BATTERY
A01
CAN COMUNICATION (Li-ION BATTERY)
The lithium battery has detected a communication problem on the CAN-BUS line.
Actions:
▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu
▪ Check the connections on the Can-Bus line of the battery
A02
HW FAIL 1 (Li-ION BATTERY)
The lithium battery has detected an internal problem.
Actions:
▪ Contact the battery supplier
A03
OVER VOLTAGE (Li-ION BATTERY)
The lithium battery has detected a problem with the battery voltage.
Actions:
A04
UNDER VOLTAGE (Li-ION BATTERY)
The lithium battery has detected a problem with the battery voltage.
Actions:
▪ Charge the battery
A05
Actions:
A06
OVER TEMPERATURE 1 (Li-ION BATTERY)
The lithium battery has detected a problem with the battery temperature.
Actions:
▪ Check the settings of the Li-ION BATT parameter in the OPT - BATTERY menu
▪ Wait for the battery temperature to fall below 55°C
4
A07
UNDER TEMPERATURE 1 (Li-ION BATTERY)
Actions:
▪ Wait for the battery temperature to rise above 0°C
A08
UNDER TEMPERATURE 2 (Li-ION BATTERY)
Actions:
▪ Wait for the battery temperature to rise above 0°C
A09
OVER TEMPERATURE 2 (Li-ION BATTERY)
Actions:
▪ Wait for the battery temperature to fall below 55°C
A0A
Actions:
A0B
OVER CURRENT 1 (Li-ION BATTERY)
The lithium battery has detected a problem with the battery current.
Actions:
A0C
Actions:
A0D
Actions:
A0E
Actions:
A0F
PROTECTION CIRCUIT 1 (Li-ION BATTERY)
Actions:
A10
PROTECTION CIRCUIT 2 (Li-ION BATTERY)
Actions:
4
A11
Actions:
A12
Actions:
A13
Actions:
A14
Actions:
C01
EPS KO (display)
The display (AE1) is not receiving Can-bus messages from the EPS (AU4) logic unit.
Actions:
▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE)
powered up
C02
TRAC KO (display)
The display (AE1) is not receiving Can-bus messages from the right traction logic unit (AU1).
Actions:
powered up
C03
TRAC SLAVE KO (display)
The display (AE1) is not receiving Can-bus messages from the left traction logic unit (AU2).
Actions:
powered up
C04
MCB TRAC KO (display)
The display (AE1) is not receiving Can-bus messages from the TRCB section of the MCB (AU5) card.
Actions:
powered up
C05
PUMP KO (display)
The display (AE1) is not receiving Can-bus messages from the lift logic unit (AU3).
Actions:
4
powered up
C06
MCB MHY KO (display)
The display (AE1) is not receiving Can-bus messages from the EVCB section of the MCB card (AU5).
Actions:
powered up
C08
JOY KO (display)
The display (AE1) is not receiving Can-bus messages from the MASTER microcontroller of the armrest card
(AU6).
Actions:
▪ Check for the correct battery voltage between pin 5 and pin 6 / pin 3 of connector J138 when the truck is
powered up
▪ Replace the Armrest Board
C0B
JOY SLAVE KO (display)
The display (AE1) is not receiving Can-bus messages from the SLAVE microcontroller of the armrest card
(AU6).
Actions:
▪ Check for the correct battery voltage between pin 5 and pin 6 / pin 3 of connector J138 when the truck is
powered up
CA1
BOARD MISMATCH (display)
The display (AE1) has detected one or more incorrect software items on the cards of the truck.
Actions:
▪ Wrong software installed one or more cards:
▪ Update the software on all cards on the truck
CA2
NUM WHEELS MISMATCH (display)
The display (AE1) has detected that the truck was incorrectly configured.
Actions:
CA3
BRAKE LEVEL ALARM (display)
The display (AE1) has detected a low brake oil level.
Actions:
▪ Check the brakes oil level
CA4
CANNOT READ SN (display)
The display (AE1) cannot read the truck serial number saved in the other cards.
Actions:
CA5
CANNOT RESET LEARN FLAG (display)
The display (AE1) cannot reset the calibrations of one or more cards.
Actions:
CB9
DHU KO (display)
The display (AE1) is not receiving Can-bus messages from the DHU (AU7) card.
Actions:
▪ Check for the correct battery voltage between pin 1 and pin 8 of connector J142 when the truck is powered
4
up
▪ Reset the DHU configuration
▪ Replace the DHU card
CDA
SHOCK LOCKOUT (display)
The shock sensor SH1 has detected a bump and the machine has reduced speed. The truck supervisor must
restore normal operation.
CDC
CAP DISCHARGE ALARM (display)
The display (AE1) has detected that the truck was not shut down correctly.
Actions:
▪ Truck switched off using the emergency button
CDD
LIGHT ALARM (display)
The display (AE1) has detected a problem with the outputs piloting optionals.
Actions:
▪ Disconnect the optional systems (sidelights, headlights, hazard lights, beacons, screenwasher, heated rear
window, heated seat):
▪ Check the state and operation of the relays mounted on the 12-24V fuse card
▪ Replace the display
CDE
KEY ERROR (display)
The display (AE1) has detected a problem with the key circuit.
Actions:
powered up
▪ Replace the display
CDF
EEPROM ERROR (display)
The display (AE1) has detected a memory problem.
Actions:
▪ Run a CLEAR LOG in the fault code logbook
▪ Update the display software
CF1
SHOCK SENSOR KO (display)
The display (AE1) is not receiving Can-bus messages from the shock sensor (SH1).
Actions:
up
▪ Reset the shock sensor configuration
▪ Replace the shock sensor
CF2
IMMOBILIZED POC (display)
P.O.C. card has blocked the machine. The truck supervisor must restore normal operation.
CF3
SMART ACCESS KO (display)
The display (AE1) is not receiving Can-bus messages from the SMART ACCESS card.
Actions:
up
▪ Reset the SMART ACCESS card configuration
▪ Replace the SMART ACCESS card
ARM REST CARD - SLAVE MICROCONTROLLER
BE6
LIFT POT ERROR (arm rest card - slave microcontroller)
The armrest card (AU6) has detected a problem with the lift potentiometer R8 / R9. 4
Actions:
▪ Repeat the calibration of the lift potentiometer
Self-diagnostic
▪ If the fault code changes from BE6 to BE7, replace the potentiometer that was originally for the lift
▪ If the fault code remains BE6, the cause of the fault is in the arm rest wiring harness or the arm rest card
is faulty
BE7
TILT POT ERROR (arm rest card - slave microcontroller)
The armrest card (AU6) has detected a problem with the tilt potentiometer R10 / R11.
Actions:
▪ Repeat the calibration of the tilt potentiometer
Self-diagnostic
▪ If the fault code changes from BE7 to BE6, replace the potentiometer that was originally for the tilt
is faulty
BE8
SIDESHIFT POT ERROR (arm rest card - slave microcontroller)
Actions:
Self-diagnostic
▪ Invert the ATT1 function and tilt potentiometers and repeat the calibrations:
▪ If the fault code changes from BE8 to BE7, replace the potentiometer that was originally for ATT1
is faulty
BE9
IV POT ERROR (arm rest card - slave microcontroller)
Actions:
Self-diagnostic
▪ Invert the ATT2 and ATT1 function potentiometers and repeat the calibration:
▪ If the fault code changes from BE9 to BE8, replace the potentiometer that was originally for ATT2
is faulty
BEA
BAD V POT (arm rest card - slave microcontroller)
The armrest card (AU6) has detected a problem with the ATT2 function potentiometer R14 / R15 when it is
used along with the 5th way button.
Actions:
Self-diagnostic
▪ Invert the ATT2 and ATT1 function potentiometers and repeat the calibrations
▪ If the fault code changes from BEA to BE8, replace the potentiometer that was originally for ATT2
▪ If the fault code remains BEA, the cause of the fault is in the arm rest wiring harness or the arm rest
card is faulty
BEC
DIGITAL ERROR (arm rest card - slave microcontroller)
The armrest card (AU6) has detected an inconsistency between digital values read by its MASTER and SLAVE
sections.
Actions:
▪ Check if the fault code BEC appears at the same time as pressing an armrest button.
▪ Update the software of the MASTER and SLAVE armrest card
BED
FIRMWARE TYPE ERROR (arm rest card - slave microcontroller)
The armrest card (AU6) has detected a software problem.
Actions:
▪ Update the software of the MASTER and SLAVE armrest card
BEF
JOY MASTER KO (arm rest card - slave microcontroller)
The arm rest card (AU6) has detected an internal communication problem between the MASTER and SLAVE
microcontrollers.
Actions:
4
BF8
INVALID RESTORE STATE (arm rest card - slave microcontroller)
Actions:
BF9
EEPROM INCOSIS ERROR (arm rest card - slave microcontroller)
Actions:
BFA
DEFAULT RESTORED (arm rest card - slave microcontroller)
Actions:
EPS STEERING LOGIC UNIT - SLAVE MICROCONTROLLER
4108
WATCHDOG (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected an internal communication problem between the MASTER and
Actions:
▪ Run a key reset
▪ Reset the EPS steering logic unit using the TO DEFAULT SET function
410D
EEPROM KO (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem in the memory and has reloaded the default para-
meters.
Actions:
▪ Run a key reset and check the correct value of the steering parameters on the display
4110
LOGIC FAILURE #4 (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the power circuit.
Actions:
4111
LOGIC FAILURE #3 (EPS steering logic unit - slave microcontroller)
Actions:
4
4120
VMN NOT OK (EPS steering logic unit - slave microcontroller)
Actions:
4130
MAIN CONT OPEN (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected open status at power contactor K2.
Actions:
▪ Check that power contactor K2 is correctly plugged in
▪ Check that the wiring harness between the EPS steering logic and contactor K2 is not crushed or damaged
▪ Crimping of wires and insertion of the pins in connectors J42, J4, J202, J203
▪ Check the state of the power contactor K2:
4135
STBY I HIGH (EPS steering logic unit - slave microcontroller)
Actions:
4146
HIGH CURRENT (EPS steering logic unit - slave microcontroller)
Actions:
4147
POWER FAILURE #3 (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a low current on phase W.
Actions:
4
4148
The EPS steering logic unit (AU4) has detected a low current on phase V.
Actions:
4149
The EPS steering logic unit (AU4) has detected a low current on phase U.
Actions:
4162
INPUT ERROR #2 (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the TFD sensor signals.
Actions:
sensor
sensor
sensor
sensor
sensor
41CF
SP MISMATCH (EPS steering logic unit - slave microcontroller)
Actions:
▪ Restore all the steering parameters to the default value
sensor
sensor
sensor
sensor
sensor
41D0
OUTPUT MISMATCH (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the steering sensor.
Actions:
4
41D1
WD SYNCHRO (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected an internal communication problem between the MASTER and
Actions:
▪ Run a key reset
41D4
WRONG RAM MEMORY (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the memory.
Actions:
▪ Run a key reset
41D5
PARAM RESTORE (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has reloaded the default parameters.
Actions:
▪ Run a key reset
41D6
SP JERK (EPS steering logic unit - slave microcontroller)
Actions:
sensor
sensor
sensor
sensor
sensor
41D7
CAN BUS KO M/S (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected an communication problem between the MASTER and SLAVE
microcontrollers.
Actions:
41D8
TFD WRONG RESIST (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the TFD sensor resistance.
Actions:
4
sensor
sensor
sensor
sensor
sensor
41DA
CONTROLLER MISMATCH (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected an incorrect software version.
Actions:
41DC
MOTOR LOCKED (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected that the steering motor is blocked.
Actions:
41DF
FB JERK (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the steering motor encoder.
Actions:
41E1
CURRENT GAIN (EPS steering logic unit - slave microcontroller)
Actions:
▪ Run a key reset
41E4
POSITION ERROR (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected an incorrect steering axle position.
Actions:
▪ Run several key reserts to recover the correct position of the steering axle
▪ Use the ANALYZER menu to check the steering motor encoder and steering sensor functions
41EB
TFD SHRT/VOLT KO (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the TFD sensor.
Actions:
4
sensor
sensor
sensor
sensor
sensor
41EC
TFD STB I HIGH (EPS steering logic unit - slave microcontroller)
Actions:
sensor
sensor
sensor
sensor
sensor
41ED
SLAVE ALARM XX (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the SLAVE microcontroller.
Actions:
▪ Run a key reset
41F0
LOGIC SUPPLY ERR (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the key line.
Actions:
▪ Check the power supply on the EPS steering logic, there must be battery voltage between pin 15 and pins
6, 7 and 8 on connector J4
41F1
FB SENSOR LOCKED (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the steering motor encoder.
Actions:
4
41F7
CAN BUS KO (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a communication problem on the CAN-BUS line.
Actions:
41F8
SP OUT OF RANGE (EPS steering logic unit - slave microcontroller)
Actions:
sensor
sensor
sensor
sensor
sensor
41FA
INPUT MISMATCH (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected an internal problem between the MASTER and SLAVE micro-
controllers.
Actions:
▪ Run a key reset
41FC
TWIN POT MISMAT (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the steering sensor.
Actions:
41FD
ANALOG (EPS steering logic unit - slave microcontroller)
The EPS steering logic unit (AU4) has detected a problem with the analog signals.
Actions:
▪ Run a key reset
41FE
NO SP REFRESH (EPS steering logic unit - slave microcontroller)
Actions:
4
sensor
sensor
sensor
sensor
sensor
RIGHT TRACTION LOGIC UNIT - SLAVE MICROCONTROLLER
4201
WATCHDOG (right traction logic unit - slave microcontroller)
Actions:
▪ Run a key reset
Self-diagnostic
4205
LOGIC FAILURE #1 (right traction logic unit - slave microcontroller)
Actions:
powered up
materials
Self-diagnostic
4208
CONTACTOR OPEN (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a problem with contactor K1 - power is applied to the contactor,
Actions:
4
4213
ENCODER ERROR (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a problem with signals generated by the right drive motor rpm
sensor.
Actions:
4216
NO CAN MSG (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) receives no messages from other cards connected to the Can-bus line.
Actions:
4219
AUX DRIV. SHORTED (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a problem with the coils connected to the auxiliary outputs.
Actions:
▪ Check that the ATT3 valve enabling parameter has been correctly configured
▪ Check the windings of the right drive motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE):
▪ Check the state of the coils on valves L1, L3 and K1:
▪ The resistance value of the coils on valves L1 (standard 30Ω at 20°C)
▪ The resistance value of the coils on valves K1 (standard 100Ω at 20°C)
▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the coil con-
nectors
Self-diagnostic
421C
VDC OFF SHORTED (right traction logic unit - slave microcontroller)
Actions:
powered up
4
materials
Self-diagnostic
4225
WRONG SET BATT (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a battery voltage 20% higher than the nominal value.
Actions:
chapter 01)
4227
EEPROM KO (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a problem in the memory and has reloaded the default paramet-
ers.
Actions:
4228
VDC LINK OVERV. (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a problem with the power circuit - overvoltage.
Actions:
powered up
4
materials
Self-diagnostic
422C
CURRENT GAIN (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a problem with acquisition of electric current values.
Actions:
4231
VKEY OFF SHORTED (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a problem with the ignition circuit.
Actions:
powered up
materials
Self-diagnostic
4234
WRONG RAM MEM. (right traction logic unit - slave microcontroller)
The RIGHT traction logic unit (AU1) has encountered a problem in the RAM.
Actions:
423C
ANALOG INPUT (right traction logic unit - slave microcontroller)
Actions:
4
Self-diagnostic
423D
CONTROLLER MISMATCH (right traction logic unit - slave microcontroller)
memory.
Actions:
4242
AUX DRV OPEN (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a problem with the coils connected to the auxiliary outputs.
Actions:
▪ Check the windings of the right drive motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE):
nectors
Self-diagnostic
424A
WD SYNCHRO (right traction logic unit - slave microcontroller)
Actions:
▪ Run a key reset
Self-diagnostic
▪ If the fault code changes from 984A to 994A, replace the traction logic unit originally on the right
▪ If the fault code remains 984A, the cause of the fault is outside the right traction logic unit
4252
OUTPUT MISMATCH (right traction logic unit - slave microcontroller)
The right traction logic unit (AU1) has detected a problem with output signals.
Actions:
▪ Run a key reset
4
Self-diagnostic
425B
INPUT MISMATCH (right traction logic unit - slave microcontroller)
Actions:
▪ Run a key reset
Self-diagnostic
▪ If the fault code changes from 985B to 995B, replace the traction logic unit originally on the right
▪ If the fault code remains 985B, the cause of the fault is outside the right traction logic unit
LEFT TRACTION LOGIC UNIT - SLAVE MICROCONTROLLER
4301
WATCHDOG (left traction logic unit - slave microcontroller)
Actions:
▪ Run a key reset
Self-diagnostic
4305
LOGIC FAILURE #1 (left traction logic unit - slave microcontroller)
Actions:
powered up
materials
Self-diagnostic
4308
CONTACTOR OPEN (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem with contactor K1 - power is applied to the contactor,
Actions:
4
4313
ENCODER ERROR (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem with signals generated by the left drive motor rpm
sensor.
Actions:
4316
NO CAN MSG (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) receives no messages from other cards connected to the Can-bus line.
Actions:
4319
AUX DRIV. SHORTED (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem with the coils connected to the auxiliary outputs.
Actions:
▪ Check the windings of the left drive motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE):
nectors
Self-diagnostic
431C
VDC OFF SHORTED (left traction logic unit - slave microcontroller)
Actions:
powered up
4
materials
Self-diagnostic
4325
WRONG SET BATT (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a battery voltage 20% higher than the nominal value.
Actions:
chapter 01)
4327
EEPROM KO (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem in the memory and has reloaded the default paramet-
ers.
Actions:
4328
VDC LINK OVERV. (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem with the power circuit - overvoltage.
Actions:
powered up
4
materials
Self-diagnostic
432C
CURRENT GAIN (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem with acquisition of electric current values.
Actions:
4331
VKEY OFF SHORTED (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem with the ignition circuit.
Actions:
powered up
materials
Self-diagnostic
4334
WRONG RAM MEM. (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem in the RAM.
Actions:
433C
ANALOG INPUT (left traction logic unit - slave microcontroller)
Actions:
4
Self-diagnostic
433D
CONTROLLER MISMATCH (left traction logic unit - slave microcontroller)
Actions:
4342
AUX DRV OPEN (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem with the coils connected to the auxiliary outputs.
Actions:
▪ Check the windings of the left drive motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE):
nectors
Self-diagnostic
434A
WD SYNCHRO (left traction logic unit - slave microcontroller)
Actions:
▪ Run a key reset
Self-diagnostic
▪ If the fault code changes from 994A to 984A, replace the traction logic unit originally on the left
▪ If the fault code remains 994A, the cause of the fault is outside the left traction logic unit
4352
OUTPUT MISMATCH (left traction logic unit - slave microcontroller)
The left traction logic unit (AU2) has detected a problem with output signals.
Actions:
▪ Run a key reset
4
Self-diagnostic
435B
INPUT MISMATCH (left traction logic unit - slave microcontroller)
Actions:
▪ Run a key reset
Self-diagnostic
▪ If the fault code changes from 995B to 985B, replace the traction logic unit originally on the left
▪ If the fault code remains 995B, the cause of the fault is outside the left traction logic unit
ENGINE 5-1
5
ENGINE
SENSOR................................................................................................................ 2
PUMP MOTOR: ..................................................................................................... 4
5
5-2 ENGINE
SENSOR
GENERAL
TT = 15Nm ± 5%
TT = 55Nm ± 5%
TT = 24Nm ± 5%
DISASSEMBLY·INSPECTION·REASSEMBLY
1) Remove the gear motor unit. (See section 6)
2) Remover the magnetic brake cover (380), the circlip (340) and the bolts (330).
3) Remove the magnetic brake (390) with the terminal (370) and the key (350).
4) Remove the upper base of the terminal (40).
5) Remove the lower base of the terminal (50).
6) Remove the sensor bracket (120).
7) Remove the plate (100).
ENGINE 5-3
8) Remove the nuts (200), washers (210) and supports (150).

9) Remove the final support (160). [Point 1]
10) Remove the stator (10) and the stud bolts (190).
11) Remove the circlip (280) and the bolts (270) having removed the oil guard (100). Make sure not to damage
the final support when removing the oil guard.
12) Remove the ball bearing cover (300) having removed the ball bearings (220, 230) from the rotor (20). [Point
2]
NOTICE! The phonic wheel and rotor must always be supplied complete 5
Point Operations
[Point 1]
Disassembly:
SST (1) Use the specific tools (SST) to remove the end of the chassis.
SST: 09950-76014-71(09950-40011) (1)
SST (2)
SST: 09140-10920-71 (2)
[Point 2]
Disassembly:
Use the specific tools (SST) to remove the ball bearing.
SST (1)
SST: 09950-76014-71(09950-40011) (1)
SST: 09950-76018-71(09950-60010) (2)
SST (2)
Inspection:
Measure the insulation resistance on the stator unit.
Measuring terminals: between the motor cables and the body
Standard: 1 MW or higher
5-4 ENGINE
Check the continuity between the motor cables.

Terminal measurement: U-V, V-W, W-U
Standard: 0 ohm
Measure the resistance of the temperature sensor.

Terminal measurement: Both terminals of the temperature
sensor connector
Standard: From 555 to 607 ohm (at 20 °C)
PUMP MOTOR:
GENERAL
TT = 15Nm
TT = 61Nm
ENGINE 5-5
1) Remove the battery.
2) Remove the hydraulic oil from the tank.
3) Disconnect the power cables and the wiring from the pump motor.
4) Disconnect the piping from the priority valve (4 wheel version).
5) Disconnect the hoses from the pump.
6) Unscrew the pump motor fixing nuts.
7) Remove the pump motor.
8) Remove the speed sensor (150).
9) Remove the sensor cover (240).
10) Remove the upper base of the terminal (40).
11) Remove the lower base of the terminal (50).
12) Remove the plate (100).
13) Remove the bolts (160) and washers (170).
14) Remove the rotor (20) with the support (110), the ball bearings (180, 190) and circlip (230). [Point 1]
15) Remove the nut (140) and phonic wheel (130). Make sure the shaft does not turn and loosen the nut.
16) Remove the ball bearing (180) and the support (110) with ball bearing (190) and circlip (230) from the rotor
(20).
17) Remove the ball bearing (190) and circlip (230) from the support (110).
18) Remove the stator (10). [Point 2]
NOTICE! Apply CASTROL OPTIMOL T WHITE type paste in the spline section of the pump before assem-
bling.
5-6 ENGINE
Point Operations
[Point 1]
Disassembly:
SST (1) Use the specific tools (SST) to remove the end of the chassis.
SST: 09950-76014-71(09950-40011) (1)
SST (2)
SST: 09140-10920-71 (2)
[Point 2]
Disassembly:
Use the specific tools (SST) to remove the ball bearing.
SST (1)
SST: 09950-76014-71(09950-40011) (1)
SST: 09950-76018-71(09950-60010) (2)
SST (2)
Inspection:
Measure the insulation resistance on the stator unit.
Measuring terminals: between the motor cables and the body
Standard: 1 MW or higher
Check the continuity between the motor cables.

Terminal measurement: U-V, V-W, W-U
Standard: 0 ohm
ENGINE 5-7
Measure the resistance of the temperature sensor.

Terminal measurement: Both terminals of the temperature
sensor connector
Standard: From 555 to 607 ohm (at 20 °C)
5
5-8 ENGINE
DRIVE UNIT & FRONT AXLE 6-1
6
DRIVE UNIT & FRONT AXLE

GENERAL.............................................................................................................. 2
DISASSEMBLY•ASSEMBLY ................................................................................. 2
MAINTENANCE..................................................................................................... 3
6
6-2 DRIVE UNIT & FRONT AXLE
GENERAL
DISASSEMBLY•ASSEMBLY
Nord-Lock washer Bolt
Reference pin
Nord-Lock washer
Bolt
Left drive unit
ASSEMBLY SEQUENCE
Reference pin
Right drive unit
Lightly tighten all screws then

tighten in the following order:
V1 - V2 - V3 - V4
2) Remove the mast group.
3) Jack up the vehicle and remove the front wheels. [Point 1]
5) Remove the accelerator pedal and the brake pedal and relative wiring harnesses and hoses.
6) Disconnect power cables from the gear motor units.
DRIVE UNIT & FRONT AXLE 6-3
7) Disconnect the rpm sensor, temperature sensor and parking brake connectors.
8) Disconnect the pipes of the braking system.
9) Remove the gear motor units. [Point 2]
10) Remove the motors.
CAUTION! Bleed the service brake system and check it is working correctly.
NOTICE! When replacing the reduction gear, also replace the pinion. 6
Point Operations
[Point 1]
Disassembly:
Unscrew the fixing bolts and remove the wheel.
CAUTION! Always jack up the vehicle near the lifting points.
Jacking up at any other point is very dangerous. Always sup-
port the load of the jacked-up vehicle using wooden blocks at
the specified points.
Assembly:
During installation, tightening torque of the wheel fixing nuts = 159
Nm (±39Nm)
[Point 2]
Disassembly:
Use two threaded bars to remove the gear motor.
6-4 DRIVE UNIT & FRONT AXLE
MAINTENANCE
DRAINING AND CHANGING THE OIL
1) Unscrew the top-up plug (A), the oil level plug (B) and drain plug (C) and let the oil flow out into a sufficiently
large recipient (to make drainage easier, we recommend you do so while the oil is warm).
2) Wait a few minutes until all the oil has drained out, then screw on the drain plug (C).
3) Pour ATF Dexron III lubricating oil into opening (A) until it comes out of the oil level opening (B).
4) Screw on the top-up plug (A) and the oil level plug (B).
5) Work the axle; wait for a few minutes, then check the oil level again.
6) Add oil if necessary.
CAUTION! Remove the oil plugs with extreme care, as any excessive pressure inside the product could
cause them to be expelled violently outwards.
REAR AXLE 7-1
7
REAR AXLE
REAR AXLE UNIT - 3 WHEEL VERSION ............................................................. 2
REAR AXLE UNIT - 4 WHEEL VERSION ............................................................. 3
REAR AXLE HUB - CAST ARTICULATED JOINT ................................................ 7
REAR AXLE CYLINDER...................................................................................... 10
WHEELS.............................................................................................................. 11
7
7-2 REAR AXLE
REAR AXLE UNIT - 3 WHEEL VERSION
GENERAL
REAR AXLE 7-3
TT = 205 Nm ±10%
1) Lock the front wheels with wooden blocks.
2) Jack up the rear of the vehicle and remove the rear wheels.
3) Disconnect the wiring harness and power cables from the logic unit.
4) Remove the counterweight.
5) Remove the rear axle.
7-4 REAR AXLE
REAR AXLE UNIT - 4 WHEEL VERSION
GENERAL
COMPONENTS
REAR AXLE 7-5
TT = 29 Nm ±10%
TT = 151Nm±10%
TT = 140Nm±10%
1) Lock the front wheels with wooden blocks.
2) Jack up the vehicle and remove the rear wheels.
3) Remove the pin from the (bottom) oscillation crank rod on the oscillation lock cylinder. [Point 1]
4) Disconnect the rear axle cylinder pipes.
5) Disconnect the wheel angle sensor connector.
6) Support the rear axle unit with a jack.
7) Remove the rear axle assembly. [Point 2]
8) Remove the center pin bushing. [Point 3]
NOTICE! When the wheel angle sensor is removed and re-assembled or replaced, perform calibration.
NOTICE! After installation, add grease through the grease nipples. Add molybdenum disulfide grease in
the pins (2 points) on the rear axle and in the oscillation lock cylinder rod pin. Use MP grease for all other
greasing points.
7-6 REAR AXLE
Point Operations
[Point 1]
Assembly:
Dust shield direction
Install the rod with the grooves facing downwards.
Dust shield
Make sure that the upper and lower sides of the rod are correctly
positioned. Measure the rear axle clearance from front to back.
[Point 2]
Inspection:
Measure the rear axle clearance from front to back.
1. Before removing the rear axle unit, measure the rear axle
clearance from front to back.
Standard clearance: 0.3 mm or less
2. If the value measured does not meet the standard values, re-
move the rear axle unit and adjust, by adding or removing
shims.
Shim thickness: 0.3 - 0.5 - 1.2 - 2.3 - 3.0 - 3.5 - 4.0 - 4.5 - 5.0
mm
Disassembly:
Mark the front and rear covers on the rear axle to avoid confusion.
Inspection:
Install after aligning the marks.
Mark
REAR AXLE 7-7
[Point 3]
Inspection:
Inspect the inside diameter of the rear axle center pin bushing.
Limit: 52 mm
Assembly:
Apply molybdenum disulfide grease to the bushing installation
hole.
Assembly:
7
Assemble the bushing aligning the greasing groove in the bushing
with the greasing tool position.
REAR AXLE HUB - CAST ARTICULATED JOINT
1) Raise the rear of the vehicle.
2) Remove the rear wheels.
3) Remove the hub cap. [Point 1]
4) Remove the castellated nut and self-locking washer.
5) Remove the hub with the outer bearing. [Point 2]
6) Remove the hub.
7) Remove the inner ball bearing and oil gasket. [Point 3]
8) Disconnect the tension rod (on the cast articulated joint side).
9) Remove the steering pin. [Point 4]
10) Remove the articulated joint.
11) Remove the joint pin oil seals and needle bearings. [Point 5]
7-8 REAR AXLE

NOTICE! After installation, add MP grease through the grease nipples.
NOTICE! The hub rolling torque must be 2Nm ±1Nm.
Point Operations
[Point 1]
Assembly:
Apply MP grease to the hub cap and assemble it by tapping the
flange portion. (Instead of MP grease filling, spraying grease over
the castle nut is also available)
[Point 2]
Assembly:
SST 09950-76014-71 (09950-40011)
SST
Assembly:
Fit the outer ball bearing.
SST 09370-20270-71
SST
[Point 3]
Disassembly:
SST 09950-76014-71 (09950-40011)
SST
REAR AXLE 7-9
Assembly:
Fit the oil gasket and inner ball bearing.
▪ Use the special tool (SST) to install the oil gasket.
SST 09370-10140-71
SST
Use the special tool (SST) to install the inner ball bearing.
7
▪ Use the special tool (SST) to install the inner ball bearing.
SST 09370-20270-71
SST
[Point 4]
Inspection:
Measure the outer diameter of the steering pin.
Limit: 27.8 mm
Assembly:
Before assembly, check the position ratios between the punch
mark on the top of the steering pin and the steering pin lock.
Assembly:
Adjust the clearance.
▪ Assemble the thrust ball bearing with the sealed face upwards.
▪ Temporarily assemble the steering pin and the steering pin
lock bolt. Choose a spacer that minimizes the vertical clear-
ance of the articulated joint and install it on the upper side of
the thrust ball bearing.
Shim thickness: 3.0 - 3.5 - 4.0 - 4.5 mm
Standard clearance: 0.5 mm or less
7-10 REAR AXLE
[Point 5]
Disassembly:
Remove the articulated joint pin oil seals and needle bearings.
▪ Use a slotted screwdriver to remove the dust shield and oil
gasket.
▪ Use the specific tool (SST), to remove the needle bearings.
SST (2)
SST (1) SST 09950-76018-71.....(1)
SST (09950-60010)
SST 09950-76020-71.....(2)
SST (09950-70010)
Assembly:
4.5 mm Install the needle roller bearings and articulated joint pin oil seals.
(0.177 in)
▪ Use the special tool (SST) to install the needle bearings.
Check the ball bearing press-fitting surface, pressing direction
1.0 mm and depth.
(0.039 in)
SST 09950-76018-71.....(1)
SST (09950-60010)
8.2 mm
(0.323 in) SST 09950-76020-71.....(2)
SST (09950-70010)
1.8 mm ▪ Fit the dust protection element.
(0.071 in)
▪ Use the special tool (SST) to install the oil gasket.
SST 09950-76018-71.....(1)
SST (09950-60010)
SST 09950-76020-71.....(2)
SST (09950-70010)
Press-fitting direction
REAR AXLE CYLINDER
DISASSEMBLY-ASSEMBLY-INSPECTION
1) Remove the steering cylinder from the axle.
REAR AXLE 7-11
2) Remove the piston rod guide.

3) Remove the piston rod. [Point 1]
4) Inspect the cylinder. [Point 2]
NOTICE! Before assembly, coat with hydraulic oil.
Point Operations
7
[Point 1]
Inspection:
Measure the external diameter of the piston rod.
Limit: 49.92 mm
Inspection:
Measure the curve of the piston rod.
Limit: 0.5 mm
Assembly:
Before assembly, heat the sealing ring to a temperature just below
80°C in oil or hot water. Do not pull excessively.
WARNING! Proceed with caution, to avoid burns.
[Point 2]
Inspection:
Measure the rear axle jack.
Limit: 68.20 mm
7-12 REAR AXLE
WHEELS
TT = 159 Nm ±39Nm
TT = 159 Nm ±39Nm
SPECIFICATIONS
Model Front tyre size Rear tyre size
8FBE15T 18 x 7-8 15 x 4.1/2-8
8FBEK16T 18 x 7-8 15 x 4.1/2-8
8FBE16T 18 x 7-8 15 x 4.1/2-8
8FBEK18T 18 x 7-8 140/55-9
8FBE18T 18 x 7-8 140/55-9
8FBE20T 200/50-10 140/55-9
8FBMK16T 18 x 7-8 16 x 6-8
8FBM16T 18 x 7-8 16 x 6-8
8FBM18T 18 x 7-8 16 x 6-8
REAR AXLE 7-13
Model Front tyre size Rear tyre size

8FBMK20T 200/50-10 16 x 6-8
8FBM20T 200/50-10 16 x 6-8
7
7-14 REAR AXLE
HYDRAULIC STEERING 8-1
8
HYDRAULIC STEERING
SCRAPER.............................................................................................................. 2
STEERING COLUMN ............................................................................................ 2
TFD SENSOR - 3 WHEEL VERSION.................................................................... 4
ORBITROL - 4 WHEEL VERSION ........................................................................ 5
INSPECTION AND ADJUSTMENT OF MAXIMUM PRESSURE .......................... 5
PRIORITY VALVE - 4 WHEEL VERSION ............................................................. 6
8
8-2 HYDRAULIC STEERING
SCRAPER
STEERING COLUMN
TT = 25-45 Nm
TT = 1 Nm
2) Remove the steering wheel. [Point 1]
3) Remove the column cover (front and rear).
4) Disconnect the connectors around the direction switch.
5) Remove the direction switch.
6) Remove the return spring.
7) Remove the tilt lock mechanism and the column tilt lock release lever.
8) Disconnect and remove the TFD sensor (3 wheel version).
9) Remove the orbitrol hydraulic connections (4 wheel versions).
10) Remove the orbitrol bolt assembly (4 wheel versions).
NOTICE! Apply MP grease to every sliding part of the tilt lock mechanism and the column tilt lock release
lever.
NOTICE! Apply “Mobil grease special” to the coupling between the steering column shaft and the orbit-
rol.
Point Operations
[Point 1]
Disassembly:
SST: 09609-76002-71 (09609-20011)
SST
Steering wheel assembly:

1. Before removing the steering wheel, make a reference mark at
the top of the steering wheel shaft.
2. Apply grease for rubber to the sliding parts of the curve signal
microswitch.
3. Fit the steering wheel, referring to the mark you made in point
(1).
4. After fitting, turn the steering wheel. As you turn the steering
wheel, the three curve signal microswitch pins will automatic-
ally align themselves with the steering wheel pin holes.
TFD SENSOR - 3 WHEEL VERSION
TT = 10Nm ±10% + Loctite 222
TT = 10Nm ±10% + Loctite 222
2) Remove the parking brake cover.

4) Disconnect the connectors.
6) Remove the tilt lock mechanism and the steering mast lock release lever.
7) Remove the TFD sensor.
NOTICE! Apply “Mobil grease special” to the coupling between the steering shaft and the steering valve.
8
ORBITROL - 4 WHEEL VERSION
TT = 39±6 Nm
2) Remove the parking brake cover.
4) Disconnect the connectors around the mast cover.
7) Remove the hydraulic steering pipes.
8) Remove the hydraulic steering fixing bolts.
9) Remove the hydraulic steering unit.
10) Remove the connections.
NOTICE! Apply “Mobil grease special” to the coupling between the steering shaft and the steering valve.
INSPECTION AND ADJUSTMENT OF MAXIMUM

PRESSURE
1) Install an oil pressure gauge.
Disconnect the hose from the steering valve port and connect
the adapter (SST).
SST SST 09450-23610-71
Install the oil pressure gauge. Plug size: PT1/8
2) Start the motor and turn the steering wheel slowly clockwise
and then anti-clockwise.
3) Start the motor, turn the steering wheel and measure the pres-
sure at the time of discharge.
Standard: 9.1 to 9.6 MPa
4) If the standard value is not obtained, remove the steering valve
and perform adjustment by turning the maximum pressure
valve adjustment screw.
PRIORITY VALVE - 4 WHEEL VERSION
TT = 11±2Nm
2) Remove the battery.

3) Remove the battery front panel.
4) Remove the lower battery cover.
5) Disconnect the connections. [Point 1]
6) Remove the priority valve.
Point Operations
8
[Point 1]
Assembly:
Install the connections with the corner shown in the figure.
A: TT = 56 ÷ 62 Nm
B: TT = 32 ÷ 36 Nm
C: TT = 24 ÷ 26 Nm
BRAKE 9-1
9
BRAKE
GENERAL.............................................................................................................. 2
SERVICE BRAKE PEDAL ..................................................................................... 2
PARKING BRAKE.................................................................................................. 4
9
9-2 BRAKE
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 III. 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).
Parking brake selector
Service master brake

cylinder
Service brake potentiometer
Service brake piston

Parking brake
BRAKE 9-3
SERVICE BRAKE PEDAL
1) Park the vehicle on a level surface and apply the parking brake.
2) Switch off the truck.
3) Open the compartment and disconnect the battery.
5) Disconnect the brake potentiometer.
6) Empty the brake oil circuit, disconnecting the rigid pipe from the master brake cylinder.
7) Remove the 3 screws fastening the pedal to the chassis.
8) Remove the brake pedal system.
9-4 BRAKE
Inspection:
0,2 ÷ 0,5 mm Make sure that there is a gap of 0.2-0.5 mm between the cap and
pump piston, otherwise there is the risk of the truck remaining
braked which would cause early brake disc wear.
Service brake bleeding procedure

The bleeding procedure is necessary to take out completely the air from the system. The oil used in this braking
system is: ATF Dexron III.
1. Fill the brake fluid tank (ATF Dexron III)
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
6. Repeat the procedure on the other reduction gear
PARKING BRAKE
BRAKE 9-5

3) Jack up the vehicle and remove the front wheels.
4) Remove the gear motor unit.
5) Remove the parking brake.
Inspection:
Use a feeler gauge to check the nominal clearance of the brake
with the machine switched off.
The parking brake must be replaced if the nominal clearance is
greater than or equal to 0.35 mm. 9
9-6 BRAKE
FRAME 10-1
10
FRAME
COMPONENTS ..................................................................................................... 2
OPERATOR’S SEAT ............................................................................................. 6
BATTERY COVER UNIT ....................................................................................... 7
OVERHEAD GUARD............................................................................................. 8
10
10-2 FRAME
COMPONENTS
FRAME 10-3
10
10-4 FRAME
FRAME 10-5
10
10-6 FRAME
FRAME 10-7
OPERATOR’S SEAT
10
1) Tilt the steering column forward (or release it).

4) Disconnect the arm rest and seat connector and slide out from the hood.
5) Loosen the 4 seat fixing nuts, then remove it.
6) Remove the seat with the arm rest assembly, do not use the safety belt as an anchoring point.
7) Remove the arm rest assembly from the seat.
10-8 FRAME
BATTERY COVER UNIT
1) Tilt the steering column forward (or release it).
2) Remove the back plastic cover.
5) Remove the side plates.
6) Disconnect the seat and arm rest connector.
7) Loosen the 4 nuts fixing the seat in place, then remove it. (See Operator's Seat section)
8) Disconnect the battery cover gas spring (chassis side).
9) Close the battery cover.
10) Remove the battery cover hinge bolts.
11) Remove the battery cover unit.
FRAME 10-9
OVERHEAD GUARD
10
3) Remove the side plates and the front footboard.
4) Remove the battery cover.
5) Remove the pedals.
6) Remove the dashboard, the steering column covers and the metal cable cover plate.
8) Disconnect the hydraulic connectors from the steering valve (4 wheel version only).
9) Remove the overhead guard.
10-10 FRAME
MATERIAL HANDLING SYSTEM 11-1
11
MATERIAL HANDLING SYSTEM

HYDRAULIC CIRCUIT - 3 WHEEL VERSION ...................................................... 2
HYDRAULIC CIRCUIT - 4 WHEEL VERSION ...................................................... 2
OIL FILTER............................................................................................................ 3
LIFTING LOAD DOWN TEST................................................................................ 5
NATURAL FORWARD TILTING TEST.................................................................. 5
OIL LEAK TEST..................................................................................................... 6
11
11-2 MATERIAL HANDLING SYSTEM
HYDRAULIC CIRCUIT - 3 WHEEL VERSION

HYDRAULIC CIRCUIT - 4 WHEEL VERSION
11
OIL FILTER
REMOVAL• INSTALLATION
2) Remove the footboard (FR RR) and the tilting cylinder cover.
3) Open the tank plug.
4) Remove the return filter. [Point 1]
Point Operations
[Point 1]
Disassembly:
(B) 1. Remove the ring (A) mounted on the base of the level, insert-
(A) ing a screwdriver in the opening.
2. Remove the dipstick (B).
(C) 3. Remove the filter (C).
Assembly:
Reassemble in reverse order. When installing the ring (A) fit the
ring tabs in the grooves between the filter and the tank. 11
NOTICE! Holding the filter by the handle, insert it into the
tank.
LIFTING LOAD DOWN TEST

1) Place the mast in the vertical position with a nominal load on
the forks, raise the forks to 3 m and switch off the truck.
2) Mark reference lines on the inner and outer sections of the

mast and measure any drop after 110 minutes.
Limit: A= 100 mm or less
NATURAL FORWARD TILTING TEST

the forks, raise the forks 500 mm and switch off the truck.
2) Measure the tilting cylinder rod dilation after 110 minutes.

Outer mast Limit: 0.10° or less
Inclinometer
NOTICE! The above tests must be carried out with the hy-
draulic oil at 50°C.
OIL LEAK TEST
LIFT CYLINDER
the forks, raise the forks to between 1 and 1.5 m.
2) Tilt the mast forwards slightly. After 5 minutes, with the truck
switched off, disconnect the hose from the distributor to the oil
tank and measure the oil loss.
[Measurement method]
Distributor If the oil level exceeds the standard specified, before replacing the
distributor, check the following:
▪ the lifting cylinder assembly
Tank drain ▪ the flow setting valve on the mast
▪ the distributor manual lowering valve
Standard: 7.5 cc (7.5 ml) or less
TILTING CYLINDERS
the forks, raise the forks 500 mm and switch off the truck.
2) After 5 minutes, with the truck switched off, disconnect the
hose from the distributor to the oil tank.
[Measurement method]
Distributor If the oil level exceeds the standard specified, before replacing the
distributor, check the tilting cylinder assembly or the tilting valve.
Standard: 7.5 cc (7.5 ml) or less
11
Tank drain
NOTICE! The above tests must be carried out with the hy-
draulic oil at 50°C.
MASTS 12-1
12
MASTS
MAST ..................................................................................................................... 2
FORK CARRIAGE ASSEMBLY AND MAST REMOVAL..................................... 14
MAST GROUP (WITH FORK CARRIAGE) ......................................................... 19
MAST ASSEMBLY V ........................................................................................... 21
MAST GROUP FV ............................................................................................... 23
MAST GROUP FSV............................................................................................. 25
FW MAST GROUP .............................................................................................. 27
FSW MAST GROUP............................................................................................ 29
FORK CARRIAGE (V - FV - FSV) ....................................................................... 31
12
REPLACING THE FORK CARRIAGE GUIDE SHOES (V - FV - FSV) (NISS).... 33
MAST ADJUSTMENT (V - FV - FSV) .................................................................. 35
STANDARD FOR SELECTING AN OVERSIZE ROLLER................................... 39
MAST ROLLER.................................................................................................... 40
FORK CARRIAGE (FW - FSW) ........................................................................... 40
SIDESHIFT FORK CARRIAGE (FW - FSW) (ISS) .............................................. 41
REPLACING THE FORK CARRIAGE GUIDE SHOES (FW - FSW) (ISS).......... 42
MAST ADJUSTMENT (FW - FSW)...................................................................... 44
CHAINS ............................................................................................................... 45
FORK ................................................................................................................... 49
ADJUSTING THE ADJUSTING RINGS ON THE LIFT CYLINDER ROD (TO
AVOID IRREGULAR LIFTING)............................................................................ 51
12-2 MASTS
MAST
GENERAL
V mast
Double mast: 2 rear cylinders
MASTS 12-3
FV mast
Double mast: 2 rear cylinders and 1 front cylinder
12
FSV mast
Triple mast: 2 rear cylinders and 1 front cylinder
12-4 MASTS
FW mast
Double mast: 2 rear cylinders and 2 front cylinders
FSW mast
Triple mast: 2 rear cylinders and 2 front cylinders
MASTS 12-5
MAST SECTION (V - FV - FSV)
Internal profile
Intermediate External profile
profile 12
Internal profile Intermediate profile External profile
A B C
CENTRAL MFH (mm) 1.5 - 2.0 t

V 3000 ÷ 5000 A+C
FV 3000÷ 3700 A+C
FSV 4300 ÷ 6000 A+B+C
12-6 MASTS
MAST SECTION (FW - FSW)
Internal
profile External profile
Intermediate
profile
Internal profile Intermediate profile External profile

A
CENTRAL MFH (mm) 1.5 - 1.6 t 1.8 - 2.0 t

FW 3000 ÷ 4000 A B
FSW ALL B B
MASTS 12-7
COMPONENTS
MAST GROUP (V) (1.5 - 2.0 t)
12
MAST GROUP (FV) (1.5 - 2.0 t)

12-8 MASTS
MAST GROUP (FSV) (1.5 - 2.0 t)
MAST GROUP (FW) (1.5 - 2.0 t)
MAST GROUP (FSW) (1.5 - 2.0 t)

MASTS 12-9
LIFTING BRACKET GROUP (V - FV) (1.5 - 2.0 t)
12
LIFTING BRACKET GROUP (FSV) (1.5 - 2.0 t)

12-10 MASTS
LIFTING BRACKET GROUP (FW) (1.5 - 2.0 t)
LIFTING BRACKET GROUP (FSW) (1.5 - 2.0 t)

MASTS 12-11
SIDESHIFT FORK CARRIAGE GROUP (V) (1.5 - 2.0 t)
12
SIDESHIFT FORK CARRIAGE GROUP (FV) (1.5 - 2.0 t)

12-12 MASTS
SIDESHIFT FORK CARRIAGE GROUP (FSV) (1.5 - 2.0 t)
SIDESHIFT FORK CARRIAGE GROUP (FW) (1.5 - 2.0 t)

MASTS 12-13
SIDESHIFT FORK CARRIAGE GROUP (FSW) (1.5 - 2.0 t)
12
CHAIN AND CHAIN PULLEY GROUP (V) (1.5 - 2.0 t)
CHAIN AND CHAIN PULLEY GROUP (FV) (1.5 - 2.0 t)

12-14 MASTS
CHAIN AND CHAIN PULLEY GROUP (FSV) (1.5 - 2.0 t)
CHAIN AND CHAIN PULLEY GROUP (FW) (1.5 - 2.0 t)
CHAIN AND CHAIN PULLEY GROUP (FSW) (1.5 - 2.0 t)

MASTS 12-15
FORK CARRIAGE ASSEMBLY AND MAST REMOVAL
T=110Nm±10%
8
12
T=83Nm±10%
T=27Nm
±10%
1) Set the mast in the vertical position and fully lower the forks.
2) Disconnect the chain from the mast side. [Point 1]
3) Remove the chain winder, if needed. [Point 2]
4) Remove the fork carriage assembly. (Lift the inner mast until it comes out of the fork carriage, and move the
vehicle slowly backwards to detach from the fork carriage.)
5) Disconnect the lifting height switch wiring.
6) Disconnect the overflow hose and high pressure hoses. (Before disconnecting the hoses, fully lower the in-
ner mast.)
7) Slightly lift the mast group. [Point 3]
8) Remove the tilting cylinder front pin from the mast side. [Point 4]
9) Remove the mast support cap.
11) Check the condition of the mast support bushing. [Point 5]
NOTICE! Apply molybdenum bisulphite grease to the inside of the mast support bushing and the mast
support cap. Apply MP grease to the tilting cylinder front pin.
NOTICE! Shim the lift cylinder rod when the mast assembly, outer mast, inner mast or either lift cylinder
is replaced.
NOTICE! After assembly, adjust the chain tension.
NOTICE! When replacing the mast, calibrate the SAS system. (See Chapter 16.)
12-16 MASTS
Point Operations
[Point 1]
Disassembly:
After removing the hoses. Tightening torque of the chain adjust-
ment nut: 70 Nm ± 5%.
Mast V
Mast FV
Mast FSV
MASTS 12-17
Mast FW (1.5 - 1.6 t)
Mast FW (1.8 - 2.0 t)

12
Mast FSW
12-18 MASTS
Inspection:
Remove the forks, lower the fork carriage completely and measure
the height X: Standard size X = 76 mm (2.99 in). If the height has a
different measure, set the chain adjustment nuts.
Inspection: (only for masts FW and FSW)

Check the removal between the inner mast and the fork yoke pad.
Fork carriage Standard clearance: 0.2 - 0.4 mm
0.2-0.4 mm
External profile Internal profile

0.2-0.4 mm
[Point 2]
Disassembly:
For rigid fixings, use the special tool for removal.
SST SST 09950-76014-71 (09950-40011)
[Point 3]
Disassembly:
To remove the mast, use the lifting rings at the top of fixed mast.
MASTS 12-19
[Point 4]
Disassembly:
SST1 09810-20172-71
SST2 09820-31040-71
SST 2
SST 1
[Point 5]
Inspection:
12
Measure the thickness of the mast support bushing.
Standard measure: 5 mm
Limit: 4 mm
Having installed the mast, apply Shell Mobil Grease Special or
equivalent to the grease nipples.
12-20 MASTS
MAST GROUP (WITH FORK CARRIAGE)
T=110Nm±10%
8
T=83Nm±10%
T=27Nm
±10%
1) Arrange the mast in the vertical position.
2) Remove the fork.
3) Disconnect the lifting height switch wiring.
4) Disconnect the overflow hose and high pressure hoses. (Before disconnecting the hoses, fully lower the in-
ner mast.)
5) Tie the fork carriage and outer mast with a rope.
6) Slightly lift the mast group. [Point 1]
7) Remove the tilting cylinder front pin. [Point 2]
8) Remove the mast support screws.
9) Remove the mast assembly with the fork carriage.
NOTICE! Apply molybdenum bisulphite grease to the inside of the mast support bushing and the mast
support cap. Apply MP grease to the tilting cylinder front pin.
NOTICE! Shim the lift cylinder rod when the mast assembly, outer mast, inner mast or either lift cylinder
is replaced.
NOTICE! After assembly, adjust the chain tension.
NOTICE! When replacing the mast, calibrate the SAS system. (See Chapter 16.)
MASTS 12-21
Point Operations
[Point 1]
Disassembly:
To remove the mast, use the lifting rings at the top of fixed mast.
12
[Point 2]
Disassembly:
SST1 09810-20172-71
SST2 09820-31040-71
SST 2
SST 1
Inspection:
Measure the thickness of the mast support bushing.
Standard measure: 5 mm
Limit: 4 mm
12-22 MASTS
MAST ASSEMBLY V
STD OIL FULL
4 7
1) Remove the mast lifting height switch.
2) Disconnect the overflow hose and high pressure pipe.
3) Remove the lock nut set at the end of the cylinder rod. [Point 1]
4) Remove the cylinder supports.
5) Remove the lock nut set on the lower part of the cylinder and remove all the lifting cylinders.
6) Slide the inner mast downward and remove the lift rollers.
7) Remove the mast tab. [Point 2]
8) Remove the outer mast.
MASTS 12-23
Point Operations
[Point 1]
Disassembly:
x
Adjustment must be done using shims on the end of the lifting cyl-
y inder rod to prevent uneven lifting of the right and left lifting cylin-
ders. Keep a record of how the adjustment is done and how many
shims are used.
Assembly:
Tighten the screw and leave some play, as shown in the figure.
Maximum play (x): 1.5 mm
Spacer thickness (y): 0.8 mm
12
[Point 2]
Inspection:
Measure the thickness of the mast tab.
Limit: 1.5 mm
12-24 MASTS
MAST GROUP FV
2
3
4
7
MASTS 12-25
Point Operations
[Point 1]
Disassembly:
x
inder rod to prevent uneven lifting of the right and left lifting cylin-
shims are used.
Assembly:
Maximum play (x): 1.5 ~ 3.5 mm
12
[Point 2]
Inspection:
Limit: 1.5 mm
12-26 MASTS
MAST GROUP FSV
2
2
1
OIL FULL
2
MASTS 12-27
Point Operations
[Point 1]
Disassembly:
x
y shims are used.
Assembly:
12
[Point 2]
Inspection:
Limit: 1.5 mm
12-28 MASTS
FW MAST GROUP
2) Disconnect the overflow hose and high pressure hoses.
3) Disconnect the chains.
4) Remove the fork carriage assembly.
5) Remove the pulley support (chain and hydraulic pipes).
6) Remove the central lift cylinder support and the bolt set from the bottom of each cylinder.
7) Remove the central lift cylinders.
8) Remove the bolt set from the ends of the rods on each cylinder and remove the end parts of the rods.
[Point 1]
9) Remove all the cylinder supports.
10) Remove the bolt set from the bottom of each cylinder and remove the side lifting cylinders.
11) Remove the swivel joints from the internal and external master.
MASTS 12-29
Point Operations
[Point 1]
Disassembly:
x
y
shims are used.
Assembly:
12
12-30 MASTS
FSW MAST GROUP
1 2
10
2) Disconnect the overflow hose and high pressure hoses.
3) Disconnect the chains.
4) Remove the fork carriage assembly.
5) Remove the pulley support.
6) Remove the bolt set from the ends of the rods on each central lifting cylinder and remove the end parts of
the rods.
7) Remove the central lift cylinder support and the bolt set from the bottom of each cylinder.
8) Remove the central lift cylinders.
9) Remove central profile chains.
10) Remove the bolt set from the ends of the rods on each side lifting cylinder and remove the end parts of the
rods. [Point 1]
11) Remove the side lift cylinder support and the bolt set from the bottom of each cylinder.
12) Remove the side lift cylinder support.
13) Slide the inner mast downward and remove the lift rollers and shoes.
MASTS 12-31
14) Remove the inner profile.

15) Slide the central mast downward and remove the lift rollers and shoes.
16) Remove the central profile.
Point Operations
[Point 1]
Disassembly:
x
y
shims are used.
Assembly:
12
12-32 MASTS
FORK CARRIAGE (V - FV - FSV)
V - FV FSV
1) Remove the lifting rollers. [Point 1]
2) Remove the support.
Point Operations
[Point 1]
Disassembly:
SST 09950-76014-71 (09950-40011)
Assembly:
Install the rollers making sure they face the right direction.
SST
MASTS 12-33
12
REPLACING THE FORK CARRIAGE GUIDE SHOES (V - FV
- FSV) (NISS)
DISASSEMBLY·REASSEMBLY
V FSV
7 7
8
8
5 5
6
6
FV
7
9 8 9
5
2) Turn off the truck.
4) Remove the two forks from the carriage.
5) Replace the 2 screws with appropriate eyebolts and fix them to the bridge crane.
6) Remove the 2 stop hooks. [Point 1]
7) Remove the fork plate by sliding upwards with the bridge crane.
8) Replace the upper guide shoes.[Point 2]
12-34 MASTS
9) Replace the rollers. [Point 3]

10) Replace the gaskets. [Point 4]
Point Operations
[Point 1]
Assembly:
[Point 2]
Assembly:
Limit: 4.5 mm
[Point 3]
Disassembly:
Remove the dowel (A) and then remove the pin (B) sliding up-
wards.
A
B
MASTS 12-35
[Point 4]
Disassembly:
▪ Remove the rod (C)
C
▪ Remove the dust shield (D)
▪ Remove the seeger (E) (insert the drive pin punch in the hole
on the lower side (F))
D
E
F
Disassembly:
▪ Remove the bushing (using an extractor with washer Z = Ø 34
Z x 4 mm)
12
MAST ADJUSTMENT (V - FV - FSV)
Adjusting the lifting roller on the mast
Adjusting the play on the inner mast roller (V - FV - FSV) and central mast lower roller
(FSV)
Bring into contact
V - FV MAST FSV MAST
Inner mast Inner mast

Outer mast
External mast
Middle mast
These rollers These rollers

12-36 MASTS
▪ Adjust the part overlapping the mast by approximately 450 mm

▪ Move the inner mast to one side to bring the roller into contact
with the outer mast, and on the opposite side measure the play
between the side surface of the roller and the mast at their
nearest point.
Standard value: A = 0 ~ 0.6 mm
If it is not to standard, change the thickness of the inner mast
roller adjusting ring (see paragraph on Mast roller).
Thickness of adjusting ring: 0.5 - 1.0 mm
▪ Distribute the adjusting rings equally on the right and left rollers
▪ After adjustment, check that the inner mast slides smoothly on
the outer mast
Shims
Adjusting the play on the outer mast roller (V - FV - FSV) and central mast upper roller
(FSV)
Bring into contact
Bring into contact
V - FV MAST FSV MAST

These rollers
These rollers
External mast
External mast
Middle mast
Inner mast
Inner mast
MASTS 12-37
▪ Adjust the part overlapping the mast by approximately 450 mm

▪ Move the inner mast to one side to bring the roller into contact
with the outer mast, and on the opposite side measure the play
between the side surface of the roller and the mast at their
nearest point.
Standard value: B = 0 ~ 0.6 mm
If it is not to standard, change the thickness of the inner mast
▪ Distribute the adjusting rings equally on the right and left rollers
▪ After adjustment, check that the inner mast slides smoothly on
the outer mast
Shims
12
Adjusting the roller on the fork plate
Adjusting the play on the lower/central/upper lifting roller
Outer mast
C
Bring into contact
Inner mast
Lifting rod
▪ Bring the center of the upper lifting roller on the fork plate 100
mm from the upper end of the inner mast.
12-38 MASTS
▪ Push the fork plate on one side to bring the roller into contact
with the mast and measure the play of the central and lower
lifting rollers when the play between the opposite rollers and
the mast is at a minimum.
NOTICE! Adjust the RH pads (upper and lower) for half the
play (considering that for each turn, the screw moves 1.25
mm: 1/4=0.3mm). Put shim (0.3 mm) on the LH side and
tighten the adjustment screw until the shim does not
move. Remove the shim.
Standard value: C=0.2 ~ 0.4 mm
If the standard is not satisfied, make adjustment by changing
the lift roller shim thickness.
▪ Distribute the adjusting rings equally on the right and left
rollers.
▪ If the fork carriage is equipped with 3 rollers on each side, shim
the upper pad (in bronze) in order to assure a maximum clear-
ance of 0.5 mm with both inner mast profiles.
Shims
Adjusting the lifting roller on the mast
Adjusting the clearance of the inner mast roller
V - FV MAST
Upper side roller
Bring into contact
Inner mast
External mast
FSV MAST Middle mast
Top roller
Bring into contact
Inner mast
Outer mast
MASTS 12-39
▪ Lower the inner mast completely.

▪ With the inner mast in contact with the outer mast roller, meas-
ure the play between the mast tab and the inner mast.
Standard value: E = 0 ~ 0.6 mm
If it is not to standard, change the thickness of the mast tab
▪ After adjustment, check that the mast slides smoothly
Shims
12
STANDARD FOR SELECTING AN OVERSIZE ROLLER

▪ Select the lifting rollers of the mast and of the lifting bracket.
The clearance is on one side Select the appropriate rollers from the table below so that the
minimum clearance between the mast or the lift rod and the
roller is from 0 to 1.0 mm.
No clearance
Minimum clearance = A
Outside diameter of the roller

107,7 108,7
▪ Select the lift rod central lift rollers. Select the central lift rollers
from the following table that correspond to the lift rollers selec-
Upper lift rollers
ted in the previous point; if it is not possible to maintain clear-
ance below 1 mm even with a larger roller, it is possible to use
a greater clearance as indicated below.
Lift rod roller: equal to or less than 1.2 mm
Central lift rollers

12-40 MASTS
Outside diameter of the roller

Upper lift rollers Central lift rollers
107,7 107,7
108,7 107,7
NOTICE! It is not possible to select the outer and central mast lift rollers.
NOTICE! The LH and RH outer diameter of the selected rollers may differ.
MAST ROLLER
ü Disassembly Procedure
1) Remove the fork yoke plate (see mast assembly removal pro-
cedure).
2) Lift the vehicle and support it with wooden blocks under the
tires. Block the wheels with wedges.
3) Remove the lift cylinders.
4) Remove the mast rollers:

Remove the wooden blocks under the internal mast, and slowly
Shims lower the raised internal mast until the mast rollers are no
longer visible; raise the lower part of the internal mast using
wooden blocks; remove the rollers and adjuster rings from the
internal mast.
Remove the inner mast rollers and adjusting rings.

Shims
ure.
MASTS 12-41
FORK CARRIAGE (FW - FSW)
FW FSW
12
1) Remove the guide shoes.
2) Slacken the adjustment screw.
3) Remove the snap ring. [Point 1]
4) Remove the roller. [Point 1]
Point Operations
[Point 1]
Disassembly:
SST 09950-76014-71 (09950-40011)
SST
12-42 MASTS
SIDESHIFT FORK CARRIAGE (FW - FSW) (ISS)
FW FSW
2 2
1 1
3
3
5 5
1) Remove one of the two side panels from the side shift.
2) Remove the fork carriage.
3) Remove the head of cylinder.
4) Remove the piston rod guide.
5) Remove the piston rod.
6) Inspect the rod.[Point 1]
Point Operations
[Point 1]
Inspection:
Limit: 29.92 mm
Inspection:
Measure the bend of the piston rod.
Limit: 0.1 mm
MASTS 12-43
REPLACING THE FORK CARRIAGE GUIDE SHOES (FW -

FSW) (ISS)
DISASSEMBLY·REASSEMBLY
5
12
upper shim
7
8
lower shim
2) Turn off the truck.
4) Remove the two forks from the carriage.
5) Remove one of the two side panels (B) from the fork carriage.
6) Remove the fork plate sliding it to RH or LH side.
7) Replace the upper and lower guide shoes.
8) Adjust the shims as required for the lower shoes. [Point 1]
Point Operations
[Point 1]
Assembly:
Shim thickness: 0.5 - 0.8 mm
Thickness
Shim wear limit: 2 mm
12-44 MASTS
Max clearence: 0.5 ~ 2.0 mm
MAST ADJUSTMENT (FW - FSW)
Adjusting the mast and fork carriage shoes
MAST LIFT BRACKET
Fork yoke
Internal Clearance
profile 0.2-0.4 mm
50 mm
Clearance
0.2-0.4 mm
350 mm Clearance
Push 0.2-0.4 mm
Clearanc
Inner profile e
0.2-0.4 mm
External
profile
MASTS 12-45
1. Unscrew the adjustment screw.

Standard clearance: 0.2-0.4 mm 2. Assemble the chassis (mast or fork carriage) as shown in the
External profile
image to the side.
Fork yoke
3. Put the chassis (mast or fork carriage) to one side.
0.2-0.5mm
4. Measure the clearance between the chassis and the shoes.
5. Adjust the RH pads (upper and lower) for half the play (consid-
Setting ering that for each turn, the screw moves 1.25 mm: 1/4 = 0.3
screw
mm).
Roller 6. Put shim (0.3 mm) on the LH side and tighten the adjustment
Pad
screw until the shim does not move.
Internal profile
0.2-0.5 mm 7. Remove the shim.
CHAINS
12
INSPECTIONS - INSTALLATION - TUNING
Inspection:
To lengthen the chain following the procedure below:
As the measuring scale (SST) varies according to the type of
chain, position the relative scale on the chain as shown in the fig-
ure.
SST 09631-22000-71
Check the number of the chain to be checked and check if the pin
is in the central position. If the pin is in the point shown by the ar-
row on the measuring tool, this means that it has reached the limit
and the chain must be replaced.
The chains must be replaced when, in a portion correspond-
ing to 34 pitches, only 33 pitches are found.
Standard values of the chain pitch distance

Mast Vehicle Distance (mm) Type
V 1.5 - 2.0 t 15,875 * BL534
FV 1.5 - 2.0 t 15,875 * BL534
FSV 1.5 - 2.0 t 15,875 * BL534 (primary)
15,875 * BL534 (secondary)
FW 1.5 - 2.0 t 15,96 * BL544
FSW 1.5 - 2.0 t 15,96 * BL544 (primary)
15,875 * BL544 (secondary)
* Measure using a caliber.
NOTICE! Take the measurement without removing the chain from the vehicle
NOTICE! Check for any localized stretching along the chain
12-46 MASTS
Assembly
Installation direction
V: Lift bracket FV: Lift bracket FSV: Inner mast

FSV: Lift bracket
V: Lift bracket FW: Lift bracket FSW: Inner mast

FSW: Lift bracket
/
MASTS 12-47
Procedure for tightening the chain adjusting nut (tightening torque = 70 Nm ± 5%)
V: External mast FSV: External mast FV: Front cylinder

FSV: Front cylinder
12
V: Lift bracket FSW: External mast FW: Front cylinder

FSW: Front cylinder
/
12-48 MASTS
Adjustment
1) Park the vehicle on a flat surface and set the mast in vertical
position (pull on the parking brake).
2) Lower the forks to the ground and adjust the adjusting nut to
eliminate any bends in the chain (side opposite the carriage).
3) Remove the fork.
4) Check that the chain tension is the same on both sides.
5) Check the X measurement against the standard measure:

Standard size X = 76 mm (2.99 in).
6) Adjust to eliminate any chain sag by turning the nylon adjusting
nut.
7) Check that the chain is not twisted.
8) Check that the lifting height meets the standard.
9) In the upper position, check that the lifting rod stop plate on the
inner mast is not in contact with the lifting rod.
MASTS 12-49
TABLE 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)
IA 0 ÷ 999 114 mm
II A 1000 ÷ 2500 152 mm
III A 2500 ÷ 4999 203 mm
IV A 5000 ÷ 8000 254 mm
VA 8001 ÷ 10999 257 mm
12
FORK
1) Lift the forks to approx. 20 cm (7.87 in) from the floor.
2) Place a wooden block under the notched part of the fork guide.
3) Release the fork lifting the stop pin and move the fork blades,
one at a time, to the center.
4) Slowly lower the forks to remove them.
Assembly procedure
ure.
Inspection:
▪ Check that the ends of the forks are not irregularly aligned.
Limit value: 10 mm
If the limit is exceeded, check the curvature of each fork, the
clearance of the forks and the deformation of the lifting rod
comb-holders
12-50 MASTS
1. Surface cracks:
The fork arm must be thoroughly examined visually for cracks
giving special attention to the heel (D) and top (E) and bottom
(F) hooks. If necessary, the forks may be subjected to a non-
destructive test.
2. Difference in height of fork tips:
Check the difference in height between the blade tips on each
pair of forks, this must not be more than 3% of blade length
with the forks fitted on the fork plate
3. Positioning lock:
Check that the fork positioning lock (G) is in good order
4. Clear reading of the fork punching:
If the fork arm marking is not clearly readable, it must be re-
newed by the original fork supplier.
5. Fork wear control:
The fork arm blade and shank must be thoroughly checked for
wear, paying special attention to the area around the heel (D).
When maximum wear is detected, with thickness reduced to
10% of the original, the fork arm must be replaced.
6. Fork mounting wear control:
The horizontal supporting surface of the top hook (E) and the
contact surfaces of both hooks (E) and (F) must be checked for
wear and any damage.
7. Withdrawal of the forks from service:
Any fork with defects revealed during the above controls must
be withdrawn from service.
NOTICE! Tampering with the system or the components may
compromise the safety of the vehicle. All repairs and replace-
ments must be done by trained and authorized staff.
MASTS 12-51
ADJUSTING THE ADJUSTING RINGS ON THE LIFT

CYLINDER ROD (TO AVOID IRREGULAR LIFTING)
NOTICE! For double lift cylinders, check and adjust in order to prevent the irregular lifting on the right
and left sides caused by loads beyond the permitted limits, etc.
NOTICE! Check and adjust where required when replacing any of the following elements: Lift cylinder
ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY and inner
mast SUB-ASSY
NOTICE! Having completed the adjustments, align the SAS system.
1. Inspection method.
Slowly lift the inner mast and check that the right and left cylinder
rod stop when the inner mast reaches maximum height.
▪ Normal conditions:
The right and left rods stop more or less simultaneously with al-
12
most no vibrations on the inner mast.
▪ Abnormal condition:
The rods stop at a slightly different time and the upper part of
the inner mast vibrates as they stop. To correct the defect, add
adjustment rings to the cylinder which stops first.
2. Adjustment method:
▪ Lift the inner mast, connect the SST to the outer mast and
lower the inner mast until it comes into contact with the SST.
SST 09610-22000-71
▪ Remove the end stop nut from the cylinder on the side on
which the adjusting rings need adjustment.
▪ Slowly lower the lift cylinder rod and disconnect the end.
▪ Place the adjusting rings on the end of the cylinder rod and lift
it slowly in the inner mast.
▪ Replace the end stop nut on the cylinder.
▪ Lift the inner mast again for a final check.
Shims
▪ Repeat the control and adjustments until the number of adjust-
ing rings is defined.
Thickness of adjusting ring: 0.5·1.0 mm
12-52 MASTS
CYLINDERS 13-1
13
CYLINDERS
LIFTING CYLINDERS............................................................................................ 2
TILTING CYLINDERS.......................................................................................... 32
13
13-2 CYLINDERS
LIFTING CYLINDERS
GENERAL
CENTRAL CYLINDERS
1.5 - 1.8 t 2.0 t
/ / V
1 telescopic cylinder with braking effect on lifting 1 telescopic cylinder with braking effect on lifting FV
(standard) (standard)
1 telescopic cylinder with braking effect on lifting

& lowering (optional) 1 telescopic cylinder with braking effect on lifting
& lowering (optional)
1 telescopic cylinder with braking effect on lifting 1 telescopic cylinder with braking effect on lifting FSV
1 telescopic cylinder with braking effect on lifting

& lowering (optional) 1 telescopic cylinder with braking effect on lifting
& lowering (optional)
CYLINDERS 13-3
CENTRAL CYLINDERS
1.5 - 1.8 t 2.0 t
2 telescopic cylinders with braking effect on lifting 2 telescopic cylinders with braking effect on lifting FW
2 telescopic cylinders with braking effect on lifting 2 telescopic cylinders with braking effect on lifting
& lowering (optional) & lowering (optional)
2 telescopic cylinders with braking effect on lifting 2 telescopic cylinders with braking effect on lifting FSW
2 telescopic cylinders with braking effect on lifting 2 telescopic cylinders with braking effect on lifting
& lowering (optional) & lowering (optional) 13
SIDE CYLINDERS
1.5 - 1.8 t 2.0 t
2 telescopic cylinders with braking effect on 2 telescopic cylinders with braking effect on V
lowering (standard) lowering (standard)
2 displacement cylinders with brake effect on the 2 displacement cylinders with brake effect on the FV
lifting and lowering (standard) lifting and lowering (standard)
2 telescopic cylinders with braking effect on 2 telescopic cylinders with braking effect on FSV
2 displacement cylinders with brake effect on the 2 displacement cylinders with brake effect on the FW
lifting and lowering (standard) lifting and lowering (standard)
2 telescopic cylinders with braking effect on 2 telescopic cylinders with braking effect on FSW
2 telescopic cylinders with braking effect on 2 telescopic cylinders with braking effect on
lowering, OIL FULL version (optional) lowering, OIL FULL version (optional)
13-4 CYLINDERS
SPECIFICATIONS
V MAST SIDE LIFTING CYLINDER
1.5 - 1.8 t 2.0 t

Cylinder type Single effect
Cylinder bore mm 45 48
Piston rod external diameter 36 36
Parachute valve R mm 1.2 1.8
Opening mm 0.6 0.6
FV MAST SIDE LIFTING CYLINDER
1.5 - 1.8 t 2.0 t

Opening mm 0.6 0.6
FSV MAST SIDE LIFTING CYLINDER
1.5 - 1.8 t 2.0 t

Opening mm 0.6 0.6
FW MAST SIDE LIFTING CYLINDER
1.5 - 1.8 t 2.0 t

Opening mm 0.6 0.6
FSW MAST SIDE LIFTING CYLINDER
1.5 - 1.8 t 2.0 t

Opening mm 0.6 0.6
FV MAST CENTRAL LIFTING CYLINDER
1.5 - 1.8 t 2.0 t

Opening mm 0.6 0.6
CYLINDERS 13-5
FSV MAST CENTRAL LIFTING CYLINDER
1.5 - 1.8 t 2.0 t

Opening mm 0.6 0.6
FW MAST CENTRAL LIFTING CYLINDER
1.5 - 1.8 t 2.0 t

Opening mm 0.6 0.6
FSW MAST CENTRAL LIFTING CYLINDER
13
1.5 - 1.8 t 2.0 t
Opening mm 0.6 0.6
PARACHUTE VALVE (LOWERING SAFETY VALVE)

The parachute valve enables the load descent speed reduction if
the actuator is in the moment of failure (as might happen in the
event of hose failure, the flow is slowed).
R
NOTICE! We advise you to check the integrity of the valve and

replace it if the pressure spike generated by hose failure is
such to damage some valve components permanently.
opening
R= valve setting
LOWERING VALVE
SPECIFICATIONS
Valve settings
Mast type Valve type s (mm)
V Integrated in the control valve /
FV Integrated in the control valve /
FSV Integrated in the control valve /
FW Integrated in the control valve /
FSW Integrated in the control valve /
13-6 CYLINDERS
COMPONENTS
SIDE LIFTING CYLINDERS V - FSV MAST (1.5 - 1.8 t)
SIDE LIFTING CYLINDERS V - FSV MAST (2.0 t)

CYLINDERS 13-7
SIDE LIFTING CYLINDERS FV MAST (1.5 - 1.8 t)
13
CENTRAL LIFTING CYLINDERS FV - FSV MAST (1.5 - 1.8 t)

13-8 CYLINDERS
SIDE LIFTING CYLINDERS FV MAST (2.0 t)
CENTRAL LIFTING CYLINDERS FV - FSV MAST (2.0 t)

CYLINDERS 13-9
FW MAST SIDE LIFTING CYLINDERS (1.5 - 1.8 t)
13
CENTRAL LIFTING CYLINDERS FW - FSW MAST (1.5 - 1.8 t)

13-10 CYLINDERS
FW MAST SIDE LIFTING CYLINDERS (2.0 t)
CENTRAL LIFTING CYLINDERS FW - FSW MAST (2.0 t)

CYLINDERS 13-11
FSW MAST SIDE LIFTING CYLINDER (1.5 - 1.8 t)
13
FSW MAST SIDE LIFTING CYLINDERS (2.0 t)

13-12 CYLINDERS
SIDE LIFTING CYLINDER ASSEMBLY
V - FSV
FV FW - FSW
1) Set the mast in the vertical position and fully lower the forks.
2) Remove the upper hose (V - FSV - FSW); Remove the upper rigid pipe (FV - FW).
3) Remove the upper locking nut from the lifting cylinder. [Point 1]
4) Lift the inner mast, harnessing it with a metal wire until the lifting cylinder assembly can be removed from
the front of the vehicle.
5) Support the lower part of the inner mast with wooden blocks and fix the external mast with a cord.
6) Detach the rigid pipe.
7) Remove the upper locking nut from the lower part of the lifting cylinder.
8) Remove the system guides and collars.
9) Remove the lifting cylinder assembly.
WARNING! Having installed the lifting cylinder, proceed as follows:
1. Repeatedly lift and lower the cylinder along the full stroke to bleed the air and make sure that it is
working correctly;
2. Check the hydraulic oil level and top up if insufficient.
3. Check that the lifting cylinder movement is regular and adjust if required.
CYLINDERS 13-13
Point Operations
[Point 1]
Disassembly (V mast):
shims are used.
Assembly:
Tighten the nut and leave some play, as shown in the figure.
13
Disassembly (FV mast):

shims are used.
Assembly:
13-14 CYLINDERS
Disassembly (FSV mast):

shims are used.
Assembly:
Tighten the nut and leave some play, as shown in the figure.
Disassembly (FW mast):

shims are used.
Assembly:
Tighten the screw onto the cover as illustrated in the figure.
Disassembly (FSW mast):

shims are used.
Assembly:
CYLINDERS 13-15
CYLINDER (V - FSV - FSW)
REMOVAL - INSPECTION - INSTALLATION
V - FSV FSW
T= 450 ±5% Nm
4
3
4
13
7
T= 3Nm
1) Lock the cylinder in the vice.
2) Position a container to collect the oil.
3) Remove the bushing from the cylinder (upper side). [Point 1]
5) Remove the seals from the piston rod. [Point 3]
6) Remove the descent braking device. [Point 4]
7) Remove the parachute valve (descent safety valve). [Point 5]
8) Remove the cylinder. [Point 6]
NOTICE! Apply hydraulic oil to packings, O-rings and dust seal lips;
NOTICE! Apply sealant (Loctite 222) to the threaded parts of the cylinder covers (upper side: V - FSV -
FSW and lower side: FSW).
13-16 CYLINDERS
Point Operations
[Point 1]
Disassembly:
Slide out the piston rod.
Unscrew the bushing as shown in the figure.
NOTICE! Touch up the cover with paint if it has been damaged
during disassembly; do not contaminate the rod.
Disassembly:
Unscrew the bushing as shown in the figure (if the previous one is
not available).
V - FSV assembly (1.5 - 1.8 t)

CYLINDERS 13-17
V - FSV assembly (2.0 t)
Assembly:
Clean the housing seats with compressed air; lubricate the gasket
with hydraulic oil before installation and twist slightly when insert-
ing.
NOTICE! Check that the gasket is correctly in its seat and is not
damaged or twisted. Gaskets may be more elastic if heated to
a max. temperature of 50°C.
13
Assembly:
ing.
NOTICE! Clean the housing seat with compressed air; insert the
seeger
Assembly:
Before inserting the ring, clean the housing seats with compressed
air.
NOTICE! Check that the scraper is correctly in its seat and is not
damaged or twisted Gaskets may be more elastic if heated to a
max. temperature of 50°C.
Assembly:
Lubricate the o-ring with hydraulic oil before mounting in order to
facilitate its positioning.
NOTICE! Check that the o-ring is correctly in its seat and is not
damaged or twisted.
13-18 CYLINDERS
Assembly:
Lubricate the bushing with oil before inserting the rod.
Assembly:
Insert the bushing slightly twisting it on the chrome rod.
NOTICE! Check that the rod protrudes 150mm from the bush-
ing so as to avoid deforming the bottom of the cylinder.
[Point 2]
Disassembly:
Remove the rod from the cylinder without damaging it.
Inspection:
Measure the external diameter of the piston rod; measure the
curvature of the piston rod
Limit: 2.0 mm (0.079 in)
[Point 3]
Disassembly:
Remove the gasket without damaging the seat.
Assembly:
1) Clean the housing seat with compressed air; insert the seeger
2) Lubricate the gasket with hydraulic oil before mounting in order
to facilitate its positioning
NOTICE! Avoid twisting the gasket in the seat.
2
1
CYLINDERS 13-19
[Point 4]
Assembly:
Insert the bushing as shown in the figure, otherwise it will not be
possible to apply the seeger.
Assembly:
Insert the pliers and twist slightly to insert.
13
[Point 5]
Disassembly:
SST 09610-T1000-71
T = 3 Nm
[Point 6]
Inspection:
Measure the internal diameter of the lifting cylinder and check that
it is in good condition.
13-20 CYLINDERS
CYLINDER (FV - FW)
FV FW
T= 300 ±5% Nm
4 4
3
7
T= 3 Nm
4) Remove the piston rod.
6) Remove the descent braking device. [Point 3]
7) Remove the parachute valve (descent safety valve). [Point 4]
NOTICE! Apply hydraulic oil to the gaskets, O-rings and dust seal edges.
NOTICE! Apply sealant (Loctite 222) to the threaded parts of the cylinder covers (upper and lower sides).
CYLINDERS 13-21
Point Operations
[Point 1]
Disassembly:
Disassembly:
13
Unscrew the bushing as shown in the figure (if the previous one is
not available).
Disassembly:
Disassemble using a pneumatic percussion screwdriver (or electric
equivalent).
NOTICE! Block the rotation of the chrome rod using a drive pin
punch.
Assembly:
ing.
Assembly:
Clean the housing seats with compressed air; lubricate the scraper
with hydraulic oil before installation to facilitate positioning.
13-22 CYLINDERS
Assembly:
air.
NOTICE! Check that the ring is correctly in its seat and is not
damaged or twisted. The ring may be more elastic if heated to
Assembly:
damaged or twisted.
Assembly:
Assembly:
Use a spacer (X) if required.
- For FV mast:
Mast height 1.5 - 1.8 t 2.0 t

3000 no no
3300 no no
3500 no no
3700 yes (120 mm) yes (120 mm)
CYLINDERS 13-23
- For FW mast:
Mast height 1.5 - 1.8 t 2.0 t

1760 yes (40 mm) no
2600 no no
2900 no no
3000 no no
3300 no no
3500 no no
3700 no no
4000 yes (100 mm) yes (100 mm)
Assembly:
13
Assembly:
Clean the housing seats with compressed air. Manual tightening.
Assembly:
Make a diagonal cut to facilitate insertion.
13-24 CYLINDERS
Assembly:
Use the inserter and lubricate to facilitate insertion.
Inserter: M24 x 1,5 (1,5 - 1,8 t) (FV - FW)
Inserter: M28 x 1,5 (2,0 t) (FV - FW)
damaged or twisted.
NOTICE! Use Loctite 222 on the upper end.
Assembly:
Insert the upper bushing. Insert the washer between the chrome
rod and the upper end. Place the upper end near the pipe and
tighten with a pneumatic percussion screwdriver (or electrical equi-
valent).
NOTICE! Block the rotation of the chrome rod using a drive pin
punch.
[Point 2]
Disassembly:
Assembly:
▪ Clean the housing seat with compressed air; insert the seeger.
▪ Lubricate the gasket with hydraulic oil before mounting in order
2
to facilitate its positioning.
1
CYLINDERS 13-25
[Point 3]
Assembly:
Insert the bushing as shown in the figure, otherwise it will not be
possible to apply the seeger.
Assembly:
Insert the pliers and twist slightly to insert.
13
[Point 4]
Disassembly:
SST 09610-T1000-71
T = 3 Nm
Assembly (FW):
NOTICE! Check that the O-ring is correctly in its seat and is not
damaged or twisted.
13-26 CYLINDERS
Assembly (FW):
air.
NOTICE! Check that the ring is correctly in its seat and is not
damaged or twisted. The ring may be more elastic if heated to
[Point 5]
Disassembly:
Inspection:
Limit: 2.0 mm
Inspection:
CYLINDERS 13-27
CENTRAL LIFTING CYLINDER ASSEMBLY
FV FSV
13
FW FSW
1) Remove the fork holder plate.
2) Disconnect all the piping.
3) Remove the front lifting cylinder.
NOTICE! Having installed the lifting cylinder, proceed as follows:
1. Repeatedly lift and lower the cylinder along the full stroke to bleed the air and make sure that it is
working correctly;
2. Check the hydraulic oil level and top up if insufficient.
3. Check that the lifting cylinder movement is regular and adjust if required.
13-28 CYLINDERS
CYLINDER (FV - FSV - FW - FSW)
FV - FSV FW - FSW
T= 450 ±5% Nm
6) Remove the lifting braking device. [Point 4]
NOTICE! Apply sealant (Loctite 222) to the threaded parts of the cylinder covers (upper sides).
NOTICE! Add 50-80 ml of hydraulic oil to the cylinder from its top, before installing the cylinder cup.
CYLINDERS 13-29
Point Operations
[Point 1]
Disassembly:
Disassembly: 13
Slide out the piston rod. Unscrew the bushing as shown in the fig-
ure (if the previous one is not available).
Assembly:
ing.
Assembly:
Clean the housing seats with compressed air; lubricate the scraper
13-30 CYLINDERS
Assembly:
Assembly:
damaged or twisted.
Assembly:
Assembly:
NOTICE! Check that the rod protrudes 150mm from the bush-
ing so as to avoid deforming the bottom of the cylinder.
CYLINDERS 13-31
[Point 2]
Disassembly:
Inspection:
Limit: 2.0 mm (0.079 in)
[Point 3]
Disassembly:
Assembly (FV - FSV):
1) Insert the gasket.
13
2) Insert the seeger.
3
NOTICE! Before assembly, clean the housing with compressed
air and lubricate the gasket with hydraulic oil;
2
1
Disassembly:
Assembly (FW - FSW):
NOTICE! Before assembly, clean the housing with compressed
air and lubricate the gasket with hydraulic oil;
3
2
1
[Point 4]
Disassembly: (only for version with braking effect on lowering):
Remove the seeger and the unidirectional valve.
13-32 CYLINDERS
Assembly (version FW - FSW only):

a max. temperature of 50°C
Assembly:
damaged or twisted
[Point 5]
Inspection:
CYLINDERS 13-33
TILTING CYLINDERS
GENERAL
V - FV - FSV
5° - 7°
13
5° - 5°
13-34 CYLINDERS
FW - FSW
5° - 7°
5° - 5°
SPECIFICATIONS
Cylinder model Double action
Cylinder bore mm 70
Piston rod outside diameter mm 30
Piston gasket U gasket
Rod gasket U gasket
Tilting degrees Stroke mm

5° forwards - 7° backwards 82 *
5° forwards - 5° backwards 69 **
* without roof / without front panel or ≤ 6000mm
* with roof / with front panel or > 6000mm
COMPONENTS
CYLINDERS 13-35
13
INSTALLING THE REAR BUSHING ON THE TILTING CYLINDER FRAME
Notes:
1) The bushing can be installed either facing the inside or the outside of the truck.
FRONT FRAME 2) The bushing must be assembled using specific lithium-based grease (Microlube GL 261
or similar).
BUSHING 3) After assembly, check that the bushing is not damaged and that the internal diameter
has not changed.
4) After assembly, the space between the frame and the bushing must be 2mm (both
sides).
FRAME BUSHING
TRUCK INTERIOR TRUCK EXTERIOR
2) Remove the tilt cover.
3) Set the mast in vertical position and disconnect the hose.
4) Remove the tilting cylinder front pin.
5) Remove the tilting cylinder rear pin.
6) Remove the tilting cylinder.
NOTICE! If both tilting cylinders are removed fix the mast with a chain in order to avoid the mast over-
turning.
NOTICE! Before installation, apply grease to the front and rear pin seats on the tilting cylinder (Shell Mo-
bil Grease special or equivalent).
NOTICE! Do not tilt the mast fully backwards before having adjusted the mast tilting angle.
NOTICE! Check the hydraulic oil level and top up if necessary.
NOTICE! After installation, slowly tilt the mast forwards and backwards a few times without load to bleed
the air from the hydraulic circuit and check that it is working correctly.
NOTICE! After installation, if the tilt sensor has been removed, calibrate the SAS system.
13-36 CYLINDERS
Adjusting
To adjust the length of the internal lock on the screw between the rod and the gasket, adjust the tilting angle of
the mast by rotating the rod.
The tolerance range of the tilting angle of the mast:
4 wheels
Forwards 0° - 0.4°
Reverse 0.6° - 0°
The stroke difference between the tilting cylinders is not more than 1 mm.
NOTICE! Adjust the forwards and backwards tilting angle of the mast (to prevent unwanted tilting) when
the tilting cylinder and/or mast are replaced or disassembled;
NOTICE! After adjustment, calibrate the SAS system.
NOTICE! When adjusting the rod joint by loosening it, make sure that the remaining thread is max. 18
mm long.
DISASSEMBLY•INSPECTION•ASSEMBLY
1
T= 500 ±20 Nm
5
T= 300 ±20 Nm
6
CYLINDERS 13-37
1) Remove the rod connection.
2) Loosen the rod guide. [Point 1]
3) Extract the piston rod with the piston.
4) Loosen the piston nuts.
5) Inspect the cylinder. [Point 2]
6) Inspect the piston rod. [Point 3]
NOTICE! Apply antioxidant to the rod eye threads.
NOTICE! Replace the piston nut after each removal procedure.
Point Operations
13
[Point 1]
Disassembly:
Loosen the rod guide.
SST 92741T899071 (or equivalent)
[Point 2]
Inspection:
Measure the cylinder bore.
Standard: 70.0 mm
Limit: 70.35 mm
13-38 CYLINDERS
Disassembly:
Remove the internal and external piston gaskets using a screw-
driver; remove the guide ring by hand.
NOTICE! Use the screwdriver carefully taking care not to
scratch the gasket seat.
Assembly:
Insert the internal/external gaskets or o-rings as shown to the side,
using the SST.
Disassembly:
Remove the internal and external gaskets from the cylinder head
using a screwdriver.
NOTICE! Use the screwdriver carefully taking care not to
scratch the gasket seat.
Assembly:
Insert the internal/external gaskets or o-rings as shown to the side.
NOTICE! Before installing the new gaskets, clean the seat care-
fully (A).
(A)
Assembly:
Before re-installing, lubricate the gaskets and o-rings with Vasel-
ine.
CYLINDERS 13-39
[Point 3]
Inspection:
Standard: 30.0 mm
Limit: 29.92 mm
Inspection:
Measure the curve of the piston rod.
Limit: 0.2 mm
13
13-40 CYLINDERS
OIL PUMP 14-1
14
OIL PUMP
SCRAPER.............................................................................................................. 2
COMPONENTS ..................................................................................................... 2
DISASSEMBLY·INSPECTION·REASSEMBLY..................................................... 3
TEST METHOD ..................................................................................................... 6
14
14-2 OIL PUMP
SCRAPER
Oil pump name Gear pump

Oil pump type TMG1A21A3H5-L (Shimadzu)
Engine system Direct motor activation
Delivery (pump at 1500 rpm) 30.8 l/min
Nominal leakage 21.9 cm3 / rev
OIL PUMP 14-3
COMPONENTS
14
TT = 61Nm
14-4 OIL PUMP
5
TT = 88 ÷ 98 Nm
1
6
4
1) Remove the oil pump group.
2) Mark the positions of the front and rear covers on the casing. [Point 1]
3) Position the front cover facing downwards, and remove the bolts (4 pieces)
4) Remove the rear cover assembly (cover, bushing, gasket, fig. 3). [Point 2]
5) Remove the guide gear, driven gear and side plate. [Point 3]
6) Remove the drive gear, driven gear and side plate. [Point 4]
7) Remove the oil seal. [Point 5]
Lubricate the shaft and the motor seat with paste such as: CASTROL OPTIMOLT T WHITE.
NOTICE! Wash each part, blow compressed air and apply hydraulic oil before installation
NOTICE! Always use new seals for reassembly
OIL PUMP 14-5
Point Operations
[Point 1]
Disassembly:
Match mark between Match mark between
rear cover and front cover and Mark the positions of the front and rear covers on the casing.
casing casing
Assembly:
Align match marks when installing.
Front cover Rear cover
Casing
14
[Point 2]
Inspection:
Bush
The inner surface of the bushing must not be scratched or worn on
Lubrication Rear cover the outside, the metal on the rear side must be visible.
groove
[Point 3]
Inspection:
The side surface of the place (LBC surface) in contact with the
Limit of wear: 0.15mm or less gears must not be worn beyond the limit shown in the picture on
the left.
LBC surface
(yellow)
Outlet opening
Rigid contacts
Cavitation wear
14-6 OIL PUMP
Inspection:
Scratch depth from 0.01 to
Outlet opening
0.06mm
Inspect the inner surface of the casing, checking for friction
scratches.
Normal friction depth: from 0.01 to 0.06 mm
Intake opening Friction scratching
[Point 4]
Inspection:
Make marks on the toothed side of the driving and driven gears.
Assembly:
Align match marks when installing.
Drive gear
Driven gear
Front cover
[Point 5]
Inspection:
Oil seal
1. Check that the oil seal lip is not worn (you cannot see the roun-
ded part of the edge) or damaged.
2. Check that the gasket in figure 3 is undamaged.
3. Check that the external gasket is undamaged.
4. Check that the seals are not swollen.
Gasket
gasket figure 3
TEST METHOD
For correct testing a test bench should be used; however, as this is usually impossible during maintenance, in-
stall the oil pump on the vehicle and check the oil pump drain performance according to the cylinder operation.
▪ Check the specific indicators to see if the battery is sufficiently charged.
▪ Check that the maximum pressure setting of the distributor is as specified.
▪ Measure the time of full stroke of the lift cylinder, with the hydraulic oil temperature at 50~55°C and calculate
the lifting speed. However, due to the slow start on the material handling chopper circuit, the lifting speed is
between 10~20 mm/sec less than the value taken from the table. The lifting speed can be calculated pre-
OIL PUMP 14-7
cisely by measuring the time taken to complete the full stroke, excluding the slow start period. The lifting
speed may differ depending on the battery state, the hydraulic oil temperature and mast adjustment. The fol-
lowing values are based on certain conditions.
Lifting speed reference value
mm/sec
Model 1.5 t 1.6 t 1.8 t 2.0 t
Empty Shear Empty Shear Empty Shear Empty Shear
V Lifting H 610 440 610 430 610 420 540 380
P 550 350 550 340 540 310 480 280
S 480 260 480 250 480 240 420 200
Lowering All 550 530 550 530 550 530 500 520
FS Lifting H 570 390 570 390 570 380 500 340
W P 500 320 500 310 500 280 440 260
S 440 240 440 230 440 200 380 180
Lowering All 450 510 450 510 450 510 390 490
FW Lifting H 570 400 570 400 570 390 490 340
P 510 330 510 310 510 290 430 260 14
S 440 250 440 230 450 210 380 190
Lowering All 420 500 420 500 420 500 340 470
14-8 OIL PUMP
DISTRIBUTOR 15-1
15
DISTRIBUTOR
HYDRAULIC DIAGRAM ........................................................................................ 2
COMPONENTS ..................................................................................................... 2
SPECIFICATIONS ................................................................................................. 5
DISASSEMBLY-ASSEMBLY ................................................................................. 6
DISASSEMBLY·INSPECTION·REASSEMBLY..................................................... 6
MAXIMUM PRESSURE ADJUSTMENT.............................................................. 10
MANUAL LOWERING VALVE............................................................................. 11
15
15-2 DISTRIBUTOR
HYDRAULIC DIAGRAM
DISTRIBUTOR 15-3
COMPONENTS
15
15-4 DISTRIBUTOR
DISTRIBUTOR 15-5
15
SPECIFICATIONS
Model 8FBE15T 8FBEK16T 8FBE16T 8FBEK18T 8FBE18T 8FBE20T
Type Additional type
Relief pressure (MPa) Lifting 18,3 ← ← ← ← ←
Tilting 18,3 ← ← ← ← ←
Flow regulator flow rate (ℓ/min) 50 ← ← ← ← 55
Lowering speed V Empty 520 ← ← ← ← 500
specifications Loaded 520 ← ← ← ← 510
(mm/sec)
FSW Empty 400 ← ← ← ← 370
Loaded 500 ← ← ← ← 480
FW Empty 360 ← ← ← ← 320
Loaded 490 ← ← ← ← 450
Model 8FBMK16T 8FBM16T 8FBM18T 8FBMK20T 8FBM20T

Type Additional type
Relief pressure (MPa) Lifting 18,3 ← ← ← ←
Tilting 18,3 ← ← ← ←
Flow regulator flow rate (ℓ/min) 50 ← ← 55 ←
Lowering speed spe- V Empty 550 ← ← 500 ←
cifications (mm/sec) Loaded 530 ← ← 520 ←
FSW Empty 450 ← ← 390 ←
Loaded 510 ← ← 490 ←
FW Empty 420 ← ← 340 ←
Loaded 500 ← ← 470 ←
15-6 DISTRIBUTOR
Solenoid valve Function Coil value COIL VOLTAGE Maximum flow rate
L28 Lifting 7.2 ohm 0÷12 V 79 lt
L21 Lowering 7.2 ohm 0÷12 V 79 lt
L27 Lift lock 9.9 ohm 0÷12 V /
L26 Tilting Backward 7.2 ohm 0÷12 V 16 lt
L20 Tilting Forward 7.2 ohm 0÷12 V 13 lt
L25 Tilting control 9.9 ohm 0÷12 V /
L24 ATT1 7.2 ohm 0÷12 V 43 lt
L19 ATT1 7.2 ohm 0÷12 V 43 lt
L23 ATT2 7.2 ohm 0÷12 V 43 lt
L28 ATT2 7.2 ohm 0÷12 V 43 lt
NOTICE! Move the mast into a vertical position and the forks into their lowest position, then lower the
residual pressure in the material handling system before beginning any disassembly procedures.
2) Remove the accelerator pedal and the brake pedal and relative wiring harnesses.
3) Disconnect the distributor wiring harness.
4) Remove the distributor supports and flexible pipes / rigid pipes.
5) Remove the distributor.
NOTICE! Check the hydraulic oil level and add more if insufficient.
DISTRIBUTOR 15-7
NOTICE! Work in a clean environment.
NOTICE! Since individual parts are finished with high precision, carefully operate so as not to damage
them.
6
3
3
1
15
5
2
4 3
4
5
1) Remove the lift lock valve and flow regulator valve. [Point 1]
2) Remove the tilting check valve. [Point 2]
3) Remove the proportional valve (a). [Point 3]
4) Remove the proportional valve (b). [Point 4]
5) Remove the lifting spool, the tilting spool and the optional equipment spool.
6) Remove the relief valve.
7) Remove the threaded bar and then remove the housing.
NOTICE! Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before re-
assembling.
15-8 DISTRIBUTOR
Point Operations
[Point 1]
Disassembly:
Trace reference lines to avoid installing the solenoid in the incor-
rect position.
Assembly:
Align the reference lines for installation.
Inspection:
Check the lift lock solenoid resistance.
Terminal 3 - 4 measurement: Continuity ok
Standard: 7 to 17 ohm
Inspection:
Check and clean the filters if blocked.
Assembly:
Carefully reassemble to avoid any incorrect installation of the
spools, solenoid valves etc.
[Point 2]
Inspection:
Check the tilting solenoid resistance.
DISTRIBUTOR 15-9
Inspection:
Check and clean the filters if blocked.
Inspection:
Check and clean all openings, if blocked.
Assembly:
Carefully reassemble to avoid any incorrect installation of the
spools, solenoid valves etc.
15
[Point 3]
Inspection:
Check the continuity of the proportional solenoid valve solenoid (a).
Check the resistance of the proportional solenoid valve solenoid
(a).
Disassembly:
Setting screw A Before disassembly, measure the installation position (dimension
A) of the material handling adjusting screw.
Assembly:
Reassemble respecting the dimension A measured before disas-
sembly.
Adjustment:
Having installed the distributor on the vehicle, check that there are
no material handling abnormalities, starting the timing by slowly
moving the levers. If there are any abnormalities, perform tuning
with the display.
15-10 DISTRIBUTOR
[Point 4]
Inspection:
Check the continuity of the proportional solenoid valve solenoid (b).
Check the resistance of the proportional solenoid valve solenoid
(b).
Disassembly:
Setting screw A Before disassembly, measure the installation position (dimension
A) of the material handling adjusting screw.
Assembly:
Reassemble respecting the dimension A measured before disas-
sembly.
Adjustment:
Having installed the distributor on the vehicle, check that there are
no material handling abnormalities, starting the timing by slowly
moving the levers. If there are any abnormalities, perform tuning
with the display.
MAXIMUM PRESSURE ADJUSTMENT

NOTICE! Always adjust the maximum pressure as described below. Avoid hasty adjustments as they can
generate such high pressures as to damage the oil pump and other hydraulic equipment.
NOTICE! Before starting adjustment, check that the maximum number of revolutions [rpm] in no-load
conditions is as specified.
Connection 3) Install an oil pressure gauge. Remove the oil pressure sensor
socket on the left side of the distributor (connection) and install
the oil manometer. Connection: 90407-13469-71
4) Loosen the lock nut.

DISTRIBUTOR 15-11
5) Adjust the maximum pressure, turning the adjustment screw.

Standard: 18.3 MPa
6) Tighten the lock nut.
7) Disconnect the oil pressure gauge.
MANUAL LOWERING VALVE
Manual lowering valve
15
If the forks do not lower due to a malfunction, or other reason, loosen the manual lowering valve as an emer-
gency procedure. When loosening the manual lowering value, do not turn more than one full rotation. After the
repairs, tighten it securely.
15-12 DISTRIBUTOR
SAS FUNCTION 16-1
16
SAS FUNCTION
GENERAL.............................................................................................................. 2
FOR REPAIR WORK............................................................................................. 3
HAND GRIP POSITION CORRECTION VALVE ................................................... 3
OSCILLATION LOCK CYLINDER ......................................................................... 5
16
16-2 SAS FUNCTION
GENERAL
SAS system (System of active stability)
The sensors and microswitches installed in each part of the vehicle detect vehicle movements and output sig-
nals sent to the controllers. These signals are processed by the controllers, to control each actuator for active
mast function control (T), for the active hydraulic steering synchronizer (K) and for active control of the rear sta-
bilizer (S).
S: Active control of rear stabilizer
T: Active mast function control
K: Active hydraulic steering synchronizer
Control IN MCB Card OUT Control
Sensor/Switch S T K S T K Actuator
1 Mast height O O → → O 9 Oscillation lock
switch cylinder
2 Tilt angle poten- O → → O 10 Tilt control valve
tiometer
3 Tilt potentiometer O → → O 11 Electric tilting
proportional
valve
4 Lifting Poten- O → → O 12 Lift lock valve
tiometer
5 Mast pressure O O → → O 13 Hand grip posi-
sensor tion correction
valve
6 Automatic fork O → - - - -
level control
switch
7 Steering wheel O → - - - -
angle sensor
8 MASTER OF O → - - - -
THE PUMP LO-
GIC UNIT
SAS FUNCTION 16-3
FOR REPAIR WORK

CAUTION! Before repairing the system of active stability (SAS), make sure you fully understand its func-
tions.
1. Preparation for repair:
▪ If possible, avoid washing the vehicle; use a jet of compressed air for cleaning purposes. If washing with wa-
ter is necessary, do not use a jet. Always use compressed air to remove water after washing.
▪ Transport the SAS control unit in its packaging and keep it packaged until installation begins. Never trans-
port it in an exposed state. Take care not to drop or knock the control unit.
▪ If it needs to be aligned after the repair process, first you should park the vehicle on a flat surface.
▪ Prepare the necessary tools: tester (analog) and special tool SST 09580-10920-71.
2. During repair:
▪ Do not switch the key-microswitch to ON or OFF when the sensor wires are disconnected. In this case, with
the key-microswitch set to ON, an error could occur and the error code memorized in the control unit. Error
codes cannot be deleted. When the number of codes exceeds ten, they will begin to be deleted, starting
with the oldest. This means the information required for repairs will be lost.
▪ If the hydraulic piping is disconnected, fit a plug to all connections and flexible pipes so that they do not
come into contact with dirt.
▪ If the distributor manual descent valve is loose, tighten it to the specified torque and restore the bolt to the
16
state it was in before repairs took place.
▪ Tighten the retainer bolts for the respective functional parts to the specified torque.
▪ No adjustment is required for each sensor during installation, but make sure alignment takes place after in-
stallation.
▪ When a connector is disconnected, do not pull the wiring harness.
▪ When inspecting the harness, carefully operate so as not to damage connector terminals.
▪ The oscillation lock cylinder cannot be removed. If removed, air will get in and it will be unusable.
▪ Do not switch the key-microswitch to ON while one side (either right or left) of the vehicle is raised. The act
of switching the key-microswitch to ON jams the lock cylinder and causes sudden tilting of the vehicle, which
is very dangerous.
▪ Never use a hammer drill to remove or install the controllers. Every care must be taken to ensure that the
controllers are not allowed to fall accidentally, preventing impacts which could damage internal parts.
▪ The high and low fork heights in the error search section can be interpreted as follows:
▪ Low fork height: position below which the fork height microswitch is activated
▪ High fork height: position above which the fork height microswitch is activated
3. Emergency action:
Manual lowering valve
If the mast cannot be lowered due to a problem when the lifting
switch is in the bottom position, it can be lowered with the following
emergency action: loosen the lifting unlock bolt and shift the lifting
lever downwards.
NOTICE! After the repairs, remember to re-tighten the lifting
unlock bolt. If the lifting unlock bolt is loose, the lifting speed
will be significantly reduced.
16-4 SAS FUNCTION
HAND GRIP POSITION CORRECTION VALVE
2) Remove the column cover (front).
3) Remove the direction unit cover (front and rear).
4) Disconnect the connectors around the mast cover.
7) Remove the hydraulic steering fixing bolts. [Point 1]
8) Remove the mast cover.
9) Remove the front panel.
10) Remove the seals. [Point 2]
11) Remove the hydraulic steering unit with the hand grip position correction valve.
12) Remove the position correction valve from the hydraulic steering hand grip.
NOTICE! Add MP grease to the coupling between the steering shaft and the steering valve.
SAS FUNCTION 16-5
Point Operations
[Point 1]
Disassembly-Assembly:
Hook up the hydraulic steering with a rope or similar.
[Point 2]
Inspection:
Install the seals with the corner shown in the figure.
TT = 32 to 36 Nm
16
Disassembly-Assembly (models with steel can or windshield):

Use the specific tool (SST), to remove the hydraulic steering seals.
SST 09451-13240-71
16-6 SAS FUNCTION
OSCILLATION LOCK CYLINDER
1) Remove the counterweight.
2) Hoist the vehicle until the rear wheels are lifted.
3) Disconnect the oscillation lock solenoid valve connector.
4) Remove the oscillation lock cylinder crank pin.
5) Remove the oscillation lock cylinder pin.
6) Remove the oscillation lock cylinder assembly including the crank. [Point 1]
7) Remove the oscillation lock cylinder crank.
NOTICE!
1) Apply molybdenum bisulphite grease to the spherical part of the cylinder pin before installation.
2) Apply thread tightener 08833-76001-71 (08833-00070) to the threaded parts of the cylinder pin and
crank pin bolt assembly before tightening them.
3) Apply molybdenum bisulphite grease to the grease nipples after installation.
SAS FUNCTION 16-7
Point Operations
[Point 1]
Accumulator inspection:
▪ Remove the socket from the end of the accumulator.
▪ Check the accumulator depth using calipers.
▪ Measure the accumulator depth L.

Standard: L = 46 mm (20°C)
Limit: L = 52 mm (20°C)
If the limit value is greater, replace the oscillation lock cylinder
assembly.
L
▪ After inspection, tighten the socket so that it is aligned with the 16
end of the accumulator (do not over-tighten).
16-8 SAS FUNCTION
MAIN OPTIONS 17-1
17
MAIN OPTIONS
DC/DC CONVERTERS.......................................................................................... 2
REAR COMPARTMENT FUSES........................................................................... 2
FUSES UNDER DASHBOARD ............................................................................. 3
HEIGHT SELECTOR ............................................................................................. 4
I-SITE..................................................................................................................... 9
FLASH - ROTATING LAMP................................................................................. 10
WORK SPOTLIGHTS .......................................................................................... 11
COMBINED LIGHTS............................................................................................ 12
HEATER - HEATED REAR WINDOW - RADIO - WIND-SCREEN WIPER - COUR-
TESY LIGHT ........................................................................................................ 13
MULTIFUNCTION JOYSTICK ............................................................................. 14
17
17-2 MAIN OPTIONS
DC/DC CONVERTERS
DC/DC con- Power Connected systems Maximum system

verters consumption
T1 144 W 2 front working lights (LED version) 140 W (70 W)
48V / 24V con- / 2 rear working lights (LED version) 140 W (70 W)
verter 360 W
/ Rear lights (stop/tail + reversing) 140 W
720 W Rear LED lights (stop/tail + reversing) 7W
2 washer pumps 72 W
Combined front lights (dipped + tail + direction in- 192 W
dicators)
Combined front LED lights (dipped + tail + direc- 26 W
tion indicators)
2 additional LED working lights 70 W
Height selector 6W
T2 360 W 2 wiper motors 200 W
48V / 24V con- 24V auxiliary output 80 W
verter Heater 40 W
Courtesy light 5W
2 additional LED working lights on the mast 29 W
T3 360 W Heated rear window 115 W
48V / 24V con- Pneumatic seat (+ heated seat) 120 W (96 W)
verter Blue LED light 7.2 W
Reading light 2.5 W
T4 300 W Radio 80 W
48V / 12V con- 12V auxiliary output 60 W
verter Heated seat 40 W
NOTICE! It is necessary to calculate the total absorption of the optional systems adding +10% of the total
in order to select the correct converter.
MAIN OPTIONS 17-3
REAR COMPARTMENT FUSES
17
F1 T1 and T2 converter output 30A - 24V
F2 T1 and T2 converter input 15A - 48V
F3 Heater unit 30A - 48V
F5 Horn 5A - 48V
F6 Electronic card power supply 5A - 48V
F7 Pneumatic seat 15A - 24V
FP Pump control power (8FBE18T-18K) 300A
FS EPS control power 40A
FT1 Master traction control unit power 250A
FT2 Slave traction control unit power 250A
17-4 MAIN OPTIONS
FUSES UNDER DASHBOARD

F12 Heater unit 7.5A - 24V
F13 Work spotlights 7.5A - 24V
F14 +24V auxiliary output 5A - 24V
F15 Courtesy light 5A - 24V
F16 Rear window 10A - 24V
F17 Radio 7.5A - 12V
F18 +12V auxiliary output 7.5A - 12V
F19 +12V auxiliary output 7.5A - 12V
F20 Heated seat 7.5A - 12V
F21 Rear wiper motor 7.5A - 24V
F22 Front wiper motor 7.5A - 24V
F23 Work spotlights 7.5A - 24V
MAIN OPTIONS 17-5
HEIGHT SELECTOR
COMPONENTS
17
NOTICE! After the option is installed, calibration procedures must be carried out via the display; for pro-
cedure details please refer to chapter 03 (MASK MENU -> MATCHING MENU -> H-SELECTOR)
17-6 MAIN OPTIONS
FUNCTIONS
The height selector option consists of three different functions:
▪ Maximum height limiter
▪ Height limiter
▪ Automatic height control
MAXIMUM HEIGHT LIMITER

ü The administrator can set a maximum height limit value. Sub-
sequently, forks can never be raised over the set height.
1) To enable the "Maximum height limiter" function, you will need
to access the ADMINISTRATOR menu. Please refer to the pro-
cedure in chapter 03.
2) Select the MATERIAL HANDLING folder.

3) Enter the MAX HEIGHT LIM option.
4) Select SET.
5) Set the mast in a vertical position and lift the forks until they
reach the desired height.
6) Press and hold the (I) button for at least 2 seconds to save the
maximum lifting height. In that case “OK” is displayed.
7) Press button (O) to return to the MATERIAL HANDLING folder.
8) To disable the "maximum height limiter" function select the

CLR value under the MAX HEIGHT LIM option in the MATER-
IAL HANDLING folder.
9) Press and hold the ( I ) button for at least 2 seconds to disable
the function. In that case “OK” is displayed.
MAIN OPTIONS 17-7
HEIGHT LIMITER
The administrator can set a height limit value which can be en-
S15 abled/disabled by the operator via the height limiter button (S15).
When the function is enabled, the forks cannot be raised over the
set height.
NOTICE! The operator can set the height value for the height
limit function if the parameter MENU LOCK = OFF
ü Enable procedure via menu ADMINISTRATOR, if the para-

meter MENU LOCK = OFF the operator will have the same 17
parameters in the TRAVEL SETTING menu.
1) To enable the "height limiter" function enter the ADMINIS-
TRATOR menu. Please refer to the procedure in chapter 03.

3) Enter the HEIGHT LIM option.
4) Select SET.
reach the desired height.
6) Press and hold the ( I ) button for at least 2 seconds to save
the height. In that case “OK” is displayed.
8) To disable the "maximum height limiter" function select the

CLR value under the HEIGHT LIM option in the MATERIAL
HANDLING folder.
9) Press and hold the ( I ) button for at least 2 seconds to disable
the function. In that case “OK” is displayed. Press button (O) to
return to the MATERIAL HANDLING folder.
17-8 MAIN OPTIONS
AUTOMATIC HEIGHT CONTROL

The administrator can set up to three favorite height positions. By
pressing the automatic height control button (S17 or S14), the op-
erator can enable one of the favorite height positions, meaning the
forks cannot be raised above this limit.
S14
NOTICE! The operator can set the value for the automatic
height control function if the parameter MENU LOCK = OFF
Target selection before lift-up operation

Target height memory can be selected by click operation of the load display switch while the lift lever is at neut-
ral.
The click operation is defined as the brief push operation of the load display button (S14) within one second.
The long push operation over one second will be ignored. The controller takes it as the operation to display the
load meter on models with the Deluxe multi-function display.
Counts of clicks and the selected target memory are indicated as follows:
0 : This feature will not be activated.
1 : The lowest target is selected.
2 : The middle target is selected.
3 : The highest target is selected.
When the highest target has been selected, one extra click returns to the original situation of the count zero.
When the operator is selecting the target, the assistant screen is displayed as follows. The order of the height
memories is always displayed on the screen in low order.
NOTICE! The first click always select the lowest target even if the forks height has already been over the
lowest target position. This is to keep the constant relation between the number of clicks and the
memory to be selected.
NOTICE! No assistant screen is displayed when no position has been memorized.
Restriction on joystick models
On joystick models, favorite height can’t be selected during tilting operations. Doing so activates the auto-level-
ing function.
Cancel of the target and activation
Displaying the general screen by clicks can cancel the target before lift-up operation. The target and the assist-
ant screen are canceled if neither click nor lift-up operation is done over 10 seconds. Operating the lift lever
downward, or returning it to the neutral position while this feature is activating also cancels them.
Operation to stop the selected target
Operating the lift lever upward within 10 seconds with the target height selected and keeping the lever upward
will stop forks automatically at the selected target. At that time, the number of the short buzzer sounds informs
the operator of the selected target height as follows while the lift lever is operated upward.
The lowest target position: a single brief buzzer sound repeats at intervals of 1 second (pip..pip..pip..). The
middle target position: two brief buzzer sounds repeat at intervals of 1 second (pipip..pipip..pipip..).
The highest target position: three brief buzzer sounds repeat at intervals of 1 second (pipipip..pipipip..pipipip..).
NOTICE! Returning the lifting lever to the neutral position of course stops the lifting up immediately
while this feature is enabled.
MAIN OPTIONS 17-9
NOTICE! When a limitation function of the material handling or the OPS function activates, all the func-
tion of the Height Selector (including the screen) are canceled. The movement of the mast is halted.
NOTICE! When selecting a favorite height position lower than the current height, this feature prevent
forks from moving upward. In this case, the buzzer sounds for a second, and the screen informs the oper-
ator of the invalid operation.
ü Enable procedure via menu ADMINISTRATOR, if the para-
meter MENU LOCK = OFF the operator will have the same
parameters in the TRAVEL SETTING menu.
1) To enable the "height limiter" function enter the ADMINIS-
TRATOR menu. Please refer to the procedure in chapter 03.

3) Enter the HEIGHT SET option.
4) Select the level to be set (A-B-C). 17

reach the desired height for the selected level (A-B-C).
6) Press and hold the ( I ) button for at least 2 seconds to save
the height. In that case “OK” is displayed.
7) Press the (O ) button to exit and repeat the same procedure for
the remaining levels.
8) To disable the "height limiter" function enter the ADMINIS-
TRATOR menu.
10) Enter the HEIGHT SET CLR option.
11) Press and hold the ( I ) button for at least 2 seconds to delete
all memorized height levels. In that case “OK” is displayed.
17-10 MAIN OPTIONS
I-SITE
COMPONENTS
NOTICE! When removing one or more components, the configuration must be reset, see procedure in
chapter 03.
MAIN OPTIONS 17-11
FLASH - ROTATING LAMP
COMPONENTS
17
cedure details please refer to chapter 03.
17-12 MAIN OPTIONS
WORK SPOTLIGHTS
COMPONENTS
NOTICE! The working lights are powered by converter T1 (see DC/DC CONVERTER paragraph to calculate
absorption).
MAIN OPTIONS 17-13
COMBINED LIGHTS
COMPONENTS
17
NOTICE! The combined lights are powered by converter T1 (see DC/DC CONVERTER paragraph to calcu-
late absorption).
NOTICE! The blue light is powered by converters T2/T3 (see DC/DC CONVERTER paragraph to calculate
absorption).
cedure see chapter 03 (MASK MENU -> OPTION SET MENU -> DIPPED LIGHT, DIR LIGHTS).
17-14 MAIN OPTIONS
HEATER - HEATED REAR WINDOW - RADIO - WIND-

SCREEN WIPER - COURTESY LIGHT
COMPONENTS
NOTICE! The washer pumps are powered by converter T1 (see DC/DC CONVERTER paragraph to calculate
absorption).
NOTICE! The heater, wind-screen wipers, courtesy light and heated rear window are powered by convert-
ers T2/T3 (see DC/DC CONVERTER paragraph to calculate absorption).
NOTICE! The radio is powered by converter T4 (see DC/DC CONVERTER paragraph to calculate absorp-
tion).
MAIN OPTIONS 17-15
MULTIFUNCTION JOYSTICK
CONFIGURATIONS
PERSON PRESENT SWITCH AUTO LEVEL HEIGHT SELECTOR LOAD INDICATOR
LIFTING / LOWERING 3RD WAY +

PARAMETERS SETTING LIFTING / LOWERING TILTING 3RD WAY LIFTING / LOWERING
+ TILTING LIFTING / LOWERING
LOWERING LOWERING LOWERING LOWERING
MAT. HANDLING
MULTIF. ON
NUM WAY 3
WAY WITH EN None TILTING BW TILTING FW TILTING BW TILTING FW SIDESHIFT SIDESHIFT SIDESHIFT SIDESHIFT
OUT LH RH LH RH
LIFTING LIFTING LIFTING LIFTING

PARAMETERS SETTING LIFTING / LOWERING TILTING 3RD WAY LIFTING / LOWERING
MAT. HANDLING
MULTIF. ON
NUM WAY 3
WAY WITH EN 3 TILTING BW TILTING FW TILTING BW TILTING FW SIDESHIFT SIDESHIFT SIDESHIFT SIDESHIFT
LH RH LH RH
17
OUT
LIFTING / LOWERING
PARAMETERS SETTING LIFTING / LOWERING TILTING 3RD WAY 4TH WAY
+ TILTING
LOWERING LOWERING POSITIONING
FORKS CLOSER
MAT. HANDLING
MULTIF. ON
NUM WAY 4
WAY WITH EN None TILTING BW TILTING FW TILTING BW TILTING FW SIDESHIFT SIDESHIFT
OUT LH RH
LIFTING LIFTING POSITIONING

FORKS FARTHEST

PARAMETERS SETTING LIFTING / LOWERING TILTING 3RD WAY 4TH WAY LIFTING / LOWERING
MAT. HANDLING
MULTIF. ON
NUM WAY 4
WAY WITH EN 3 TILTING BW TILTING FW TILTING BW TILTING FW SIDESHIFT SIDESHIFT SIDESHIFT SIDESHIFT
OUT LH RH LH RH
LIFTING / LOWERING 4TH WAY +

PARAMETERS SETTING LIFTING / LOWERING TILTING 3RD WAY 4TH WAY LIFTING / LOWERING
MAT. HANDLING
MULTIF. ON
NUM WAY 4
WAY WITH EN 4 TILTING BW TILTING FW TILTING BW TILTING FW SIDESHIFT SIDESHIFT OPENING CLOSING OPENING CLOSING
OUT LH RH CLAMP CLAMP CLAMP CLAMP
LIFTING / LOWERING 5TH WAY +

PARAMETERS SETTING LIFTING / LOWERING TILTING 3RD WAY 4TH WAY 5TH WAY LIFTING / LOWERING
LOWERING LOWERING POSITIONING LOWERING LOWERING
FORKS CLOSER
MAT. HANDLING
MULTIF. ON
NUM WAY 5
WAY WITH EN 5 TILTING BW TILTING FW TILTING BW TILTING FW SIDESHIFT SIDESHIFT
OUT LH RH
LIFTING LIFTING POSITIONING LIFTING LIFTING

FORKS FARTHEST
NOTICE! To modify the multifunction joystick functions configuration see chapter 03.
17-16 MAIN OPTIONS
APPENDIX 18-1
18
APPENDIX
COMPONENTS ..................................................................................................... 2
MAIN HARNESS.................................................................................................... 9
WIRING DIAGRAM - 3 WHEEL VERSION.......................................................... 11
WIRING DIAGRAM - 4 WHEEL VERSION.......................................................... 23
18
18-2 APPENDIX
COMPONENTS
Ref. Description Wiring diagram
page
AE1 Display 03/11
AE4 12-24 V fuse card 06/11 - 09/11
AU1 Traction logic unit - MASTER 01/11
AU2 Traction logic unit - SLAVE 01/11
AU3 Lift logic unit 01/11
AU4 Steering logic unit - EPS 01/11
AU5 MCB Card 02/11
AU6 Armrest card 04/11
AU7 DHU Card 11/11
AU8 Rear fuses unit 01/11
B1 Right drive motor 01/11
B2 Left drive motor 01/11
B3 Motor pump 01/11
BT1 Battery 01/11
CN1 Heater unit electronic card connector UT1 10/11
CR1 Front left LED working light 07/11
CR2 Front right LED working light 07/11
CR3 Rear left LED working light 07/11
CR4 Additional front left LED working light 07/11
CR5 Additional front right LED working light 07/11
CR6 Rear blue light 07/11
CR7 Front left LED direction indicator 07/11
CR8 Front left LED dipped beam 07/11
CR9 Front right LED direction indicator 07/11
CR10 Front right LED dipped beam 07/11
CR11 Left LED working light on mast 07/11
CR12 Right LED working light on mast 07/11
CR13 Front rear LED working light 07/11
D1 Diode for 12-24 V fuse card AE4 09/11
D9 Diode for 5th way valve L3 05/11
DA1 Flash lamp 07/11
DA2 Rotating lamp 07/11
DA3 Front right direction indicator 07/11
DA4 Front right dipped beam 07/11
DA5 Right headlight 07/11
DA6 Left right direction indicator 07/11
DA7 Front left dipped beam 07/11
DA8 Left headlight 07/11
APPENDIX 18-3

page
DA9 Left-hand front working light 07/11
DA10 Right-hand front working light 07/11
DA11 Left-hand rear working light 07/11
DA12 Left rear direction indicator 07/11
DA13 Left reversing light 07/11
DA14 Left stop light 07/11
DA15 Left rear side light 07/11
DA16 Right rear direction indicator 07/11
DA17 Right reversing light 07/11
DA18 Right stop light 07/11
DA19 Right rear side light 07/11
DA20 Courtesy light 06/11
E1 Steering encoder 02/11
E2 TFD sensor 03/11
F1 Fuse on T2 and T3 output 08/11
F2 Fuse on T2 and T3 input 08/11
F3 Heater unit fuse UT3 08/11
F4 MCB CARD AU5 fuse 08/11
F5 Horn fuse HT1 08/11 18
F6 Fuse for electronic cards 08/11
F7 Fuse for pneumatic seat 08/11
F11 Distributor valve fuse 06/11 - 09/11
F12 Heater unit fuse UT3 06/11 - 09/11
F13 Fuse for working lights 06/11 - 09/11
F14 +24V output fuse 06/11 - 09/11
F15 Fuse for courtesy light DA20 06/11 - 09/11
F16 Fuse for heated rear window R16 06/11 - 09/11
F17 Fuse for radio UT5 06/11 - 09/11
F18 +12V output fuse 06/11 - 09/11
F19 +12V output fuse 06/11 - 09/11
F20 Fuse for heated seat 06/11 - 09/11
F21 Fuse for rear wiper motor M2 06/11 - 09/11
F22 Fuse for front wiper motor M1 06/11 - 09/11
F23 Fuse for working lights 06/11 - 09/11
FP Fuse for lift logic unit AU3 01/11
FS Steering logic unit fuse - EPS AU4 01/11
FT1 Traction logic unit fuse - MASTER 01/11
FT2 Traction logic unit fuse - SLAVE 01/11
HT1 Horn 02/11
J1 Connector 01/11
J2 Connector 01/11
J3 Connector 01/11
J4 Connector 01/11
J5 Connector 02/11
J6 Connector 02/11
J7 Connector 01/11
J8 Connector 01/11
18-4 APPENDIX

page
J9 Connector 04/11
J10 Connector 03/11
J11 Connector 01/11 - 03/11
J12 Connector 01/11
J13 Connector 01/11
J14 Connector 02/11
J15 Connector 01/11 - 02/11
J16 Connector 01/11
J17 Connector 01/11
J18 Connector 03/11
J19 Connector 03/11
J20 Connector 01/11
J21 Connector 07/11
J22 Connector 01/11
J23 Connector 02/11
J24 Connector 03/11
J25 Connector 06/11
J26 Connector 07/11
J27 Connector 04/11
J28 Connector 04/11
J29 Connector 01/11
J30 Connector 05/11
J31 Connector 05/11
J32 Connector 02/11
J33 Connector 02/11
J34 Connector 06/11
J35 Connector 07/11
J36 Connector 07/11
J37 Connector 07/11
J38 Connector 03/11
J39 Connector 03/11
J40 Connector 03/11
J41 Connector 07/11
J42 Connector 01/11
J43 Connector 01/11
J44 Connector 01/11
J45 Connector 03/11
J46 Connector 03/11
J47 Connector 10/11
J48 Connector 02/11
J49 Connector 02/11
J50 Connector 02/11
J51 Connector 05/11 - 10/11
J52 Connector 07/11
J53 Connector 07/11
J56 Connector 07/11
J57 Connector 02/11
APPENDIX 18-5

page
J58 Connector 07/11
J59 Connector 07/11
J60 Connector 06/11
J61 Connector 03/11
J62 Connector 02/11
J64 Connector 02/11
J65 Connector 06/11
J71 Connector 05/11
J75 Connector 04/11
J84 Connector 02/11
J86 Connector 02/11
J87 Connector 04/11
J88 Connector 02/11
J89 Connector 06/11
J90 Connector 06/11
J91 Connector 06/11
J93 Connector 04/11
J94 Connector 03/11
J95 Connector 08/11 18
J97 Connector 06/11
J98 Connector 02/11
J99 Connector 02/11
J100 Connector 01/11
18-6 APPENDIX

page
JR1 Connector 06/11
JR2 Connector 06/11
K1 Logic unit switch AU1 AU3 AU3 01/11
K2 Steering logic unit switch - EPS AU4 01/11
K4 Mast height switch 02/11
K7 Key switch 01/11
KP1 Keypad 11/11
L1 Right motor brake 01/11
L2 Left motor brake 01/11
L3 5th way function valve 05/11
L4 Oscillation lock cylinder valve 02/11
L5 Hand grip position correction valve 02/11
L18 Valve ATT2 05/11
L20 Forward tilt valve 05/11
L21 Emergency lowering 05/11
L25 Tilt control valve 05/11
L26 Backward tilt valve 05/11
L27 Lift lock valve 05/11
APPENDIX 18-7

page
L28 Lift valve 05/11
LS1 Back-up buzzer 02/11
M1 Front wiper motor 06/11
M2 Rear wiper motor 06/11
M3 Front washer motor 06/11
M4 Rear washer motor 06/11
P4 Connector 04/11
P9 Connector 04/11
P11 Connector 01/11 - 03/11
P15 Connector 01/11
P18 Connector 03/11
P21 Connector 04/11
P24 Connector 03/11
P25 Connector 06/11
P26 Connector 07/11
P27 Connector 04/11
P28 Connector 04/11
P29 Connector 08/11
P30 Connector 05/11 18
P31 Connector 05/11
P32 Connector 02/11
P33 Connector 02/11
P35 Connector 07/11
P37 Connector 07/11
P41 Connector 07/11
P42 Connector 07/11
P43 Connector 01/11
P44 Connector 08/11
P47 Connector 06/11
P51 Connector 06/11
P52 Connector 07/11
P53 Connector 07/11
P56 Connector 07/11
P58 Connector 07/11
P59 Connector 07/11
P60 Connector 06/11 - 09/11
P61 Connector 03/11
P62 Connector 02/11
P64 Connector 11/11
P71 Connector 05/11
P84 Connector 02/11
P86 Connector 02/11
P87 Connector 04/11
P88 Connector 02/11
P89 Connector 09/11
P90 Connector 09/11
P91 Connector 09/11
18-8 APPENDIX

page
P98 Connector 02/11
P100 Connector 01/11
P122 Connector 06/11 - 09/11
P330 Connector 06/11 - 09/11
P343 Connector 06/11 - 09/11
P344 Connector 06/11 - 09/11
P346 Connector 06/11 - 09/11
P347 Connector 06/11 - 09/11
P348 Connector 06/11 - 09/11
P349 Connector 06/11 - 09/11
R1 Brake pedal potentiometer 01/11 - 02/11
R2 Accelerator pedal potentiometer 02/11
R3 Accelerator pedal potentiometer 02/11
R4 Brake pedal potentiometer 01/11 - 02/11
R6 Tilt angle potentiometer 02/11
R7 Mast pressure sensor 02/11
R8 Lifting lever potentiometer 04/11
R9 Lifting lever potentiometer 04/11
R10 Tilt lever potentiometer 04/11
R11 Tilt lever potentiometer 04/11
R12 Lever ATT1 potentiometer 04/11
R16 Heated rear window 06/11
R24 Mast height sensor 02/11
RL1 Wind-screen wiper relay 09/11
APPENDIX 18-9

page
S1 Emergency button 04/11
S2 Seat microswitch 04/11
S3 Key switch 03/11
S4 Horn push 03/11
S5 Reverse selector on steering column 03/11
S6 Brake oil tank microswitch 03/11
S7 Tilt SAS button 04/11
S8 Reverse drive microswitch 02/11
S9 Forward drive microswitch 02/11
S10 Lever ATT2 button 04/11
S11 Reverse selector on armrest 04/11
S12 Light switch 03/11
S13 Horn button on armrest 04/11
S14 Lift mini-lever button 04/11
S15 Height limiter button 04/11
S16 Horn button on rear lever 03/11
S17 ATT1 mini-lever button 04/11
S19 Bodyguard gate sensor 07/11 18
S20 Bodyguard gate sensor 07/11
S21 Steering sensor 01/11
S23 Parking brake selector 03/11
SA1 Smart access 11/11
SH1 Bump sensor 11/11
T1 DC/DC 48V/24V converter 06/11
TN1 Connector on driver's overhead guard 06/11
TN2 Connector on arm rest 04/11
UT1 Heater unit 06/11 - 10/11
UT5 Radio 06/11
WT1 Connection 01/11
18-10 APPENDIX
MAIN HARNESS
J90 J91 J89

J349 J98
P61
J53A J11
J35A
J26 J38 J410
J40
P24 P51
P47
J46 J53B
P71 J45 J35B
J52
P56 J132
J8
P84
J16 P15
J20 P409
P32
J48
J49
J50
J99 J31
J30 P86
J13
J12
J7
J17 J22
J33
J64
J23 J500
J5 J6
APPENDIX 18-11
J1
J18 WT12 J2
J27
J53D
P87 WT9
WT11
J42 J3
J43
P58
J97
J4
P41
J29
J34
J57
18
P62 J53C P320
J34
J65
J25
18-12 APPENDIX
WIRING DIAGRAM - 3 WHEEL VERSION

APPENDIX 18-13
18
18-14 APPENDIX
APPENDIX 18-15
18
18-16 APPENDIX
APPENDIX 18-17
18
18-18 APPENDIX
APPENDIX 18-19
18
18-20 APPENDIX
APPENDIX 18-21
18
18-22 APPENDIX
APPENDIX 18-23
18
18-24 APPENDIX
WIRING DIAGRAM - 4 WHEEL VERSION

APPENDIX 18-25
18
18-26 APPENDIX
APPENDIX 18-27
18
18-28 APPENDIX
APPENDIX 18-29
18
18-30 APPENDIX
APPENDIX 18-31
18
18-32 APPENDIX
APPENDIX 18-33
18
18-34 APPENDIX
APPENDIX 18-35
18
Published by
1st Printing: January 2016
Pub. No. CE375
Printed in Italy
C
PRINTED IN ITALY Pub. No. CE375

Toyota 8fbe15-20t, 8fbek16-18t, 8fbm16-20t, 8fbmk16-20t Pub - Ce375 Repair Manual

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EPAIR

Pub. No. CE375

VEHICLE EXTERIOR VIEW

HOW TO USE THIS MANUAL

Some step numbers may be omitted in some illustrations.

When a part requiring tightening torque instruction is not

Matters omitted in this manual

Item New unit Conventional unit Conversion ratio*1 (1 [conventional

4. Disposal of exhausted liquids, etc.

LIFTING THE VEHICLE

CAUTION! To jack up the vehicle, use belts or ropes of suitable strength.

LIST OF SUSPENSION ROPE ANGLES

60° 1.16 times 0.58 times

SAFETY LOAD FOR EACH SUSPENSION ROPE ANGLE

TOWING THE TRUCK

4. Before towing, either remove the fork or take action to prevent

ELECTRICAL COMPONENTS INSPECTION

TIGHTENING TORQUE TABLE

Nominal diameter PRELOADING V (N) TORQUE Max (Nm)

Nominal diameter PRELOADING V (N) TORQUE Max (Nm)

Nominal diameter PRELOADING V (N) TORQUE Max (Nm)

BATTERY COMPARTMENT AND REQUIRED WEIGHT

STANDARD SERVICE VALUES

Battery charge indicator 1

Insufficient battery charge alarm

2 residual charge LEDs on; First reduction in traction and lifting

▪ Indicator (B) flashes ▪ 10 BDI CUTB (TUNING - TRACTION)

0 residual charge LEDs; Traction + lifting double function disabled;

STATE OF BATTERY CHARGE INDICATOR

BATTERY MANAGEMENT PARAMETERS

RESET VOLT MAX

RESET VOLT MIN

BATTERY INDICATOR TROUBLESHOOTING

plate corrosion sulfation plate warpage and active substance freeing

battery Overdischarge excessive enviroment temp.

overcharge imperfect terminal connectiom

deposit of free substances at plug terminal and/or

short circuit electrolyte leakage end reduction loosened or corroded connection

DEFECT CAUSE REMEDY

▪ Charge voltage too high

Red light Green light

3. Battery electrolyte specific gravity check. Use a hydrometer to

The specific gravity of the electrolyte refers to a temperature of

How to use the hydrometer:

4. Insulation resistance measurement:

* Battery control table

STATE OF BATTERY CHARGE

Electrolyte density vs Discharged capacity

Discharged capacity (%)

Formula: Density = (Volt / n° cells) - 0.84

Cell voltage vs Discharged capacity

Discharged capacity (%)

Battery discharge limits

Electrolyte specific gravity

CAPACITY ACCORDING TO ELECTROLYTE TEMPERATURE

REPLACING BATTERY PLUG TERMINALS

1. Remove the self-threading screws and the clamp cable.

4. Peel the cables to the required lengths:

24-12v fuse card

REAR COMPARTMENT FUSES

Fuse Function Capacity

FUSES UNDER DASHBOARD

Fuse Function Capacity