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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

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GENERAL VEHICLE EXTERIOR VIEW .................................................................................. 2 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

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VEHICLE EXTERIOR VIEW

GENERAL

GENERAL

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VEHICLE MODELS Model 8FBE15T 8FBEK16T 8FBE16T 8FBEK18T 8FBE18T 8FBE20T 8FBMK16T 8FBM16T 8FBM18T 8FBMK20T 8FBM20T

Load capacity 1.5 ton 1.6 ton 1.6 ton 1.8 ton 1.8 ton 2.0 ton 1.6 ton 1.6 ton 1.8 ton 2.0 ton 2.0 ton

Control method AC Microcomputer Controller ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑

Supply voltage (V) 48 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑

CHASSIS NUMBER Model 8FBE15T 8FBEK16T 8FBE16T 8FBEK18T 8FBE18T 8FBE20T 8FBMK16T 8FBM16T 8FBM18T 8FBMK20T 8FBM20T

Punch shape 8FBE15T 10011 8FBEK16T 10011 8FBE16T 10011 8FBEK18T 10011 8FBE18T 10011 8FBE20T 10011 8FBMK16T 10011 8FBM16T 10011 8FBM18T 10011 8FBMK20T 10011 8FBM20T 10011

Punching position

Punch position

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

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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.

Operation to be explained 1 Remove the cover. [Point 1] 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 ASSY ATT LH L/ OPTIONAL O/S PS RH

Meaning Unit / Assembly Attachment Left hand Less Option Oversize Power steering Right hand

Abbreviation SAE SAS SST STD T= OOT U/S W/

Meaning Society of Automotive Engineers System of active stability Special service tool Standard Tightening torque Number of teeth (OOT) Undersize With

GENERAL

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SI UNITS Meaning of SI This manual uses SI units. SI represents the International System of Units, which was established to unify the various systems of units used in the past for simpler international technical communication.

New SI units

Item

New unit

Conventional unit

Force*2 Torque*2 (Moment) Pressure*2

N (newton) N·m Pa (pascal)

kgf kgf·cm kgf/cm2

↑ Revolving speed Spring constant*2 Volume Power Heat quantity Specific fuel consumption

↑ rpm N/mm l W W·h g/W·h

mmHg rpm kgf/mm cc PS system cal g/PS·h

Conversion ratio*1 (1 [conventional unit] = X [SI unit]) 1 kgf = 9.80665 N 1 kgf·m = 9.80665 N·m 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa 1 mmHg = 0.133322 kPa 1 rpm = 1 r/min 1 kgf/mm = 9.80665 N/mm 1 cc = 1 ml 1 PS = 0.735499 kW 1 kcal = 1.16279 W·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 contional unit version ratio column in the table illustrated above Value in conventional unit = Value in SI unit ÷ Conversion 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.

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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 organization 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 anchoring 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

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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 angle method angle 0° 1.00 times 0 times 90° 1.41 times 1.00 times

Suspension method

1.

41

1.0 tf

tf

90°

2t

2t

1.04 times

0.27 times

30°

120°

2.00 times

1.73 times

120°

tf

30°

f

1.04

2t 2t

2t

60°

1.16 times

0.58 times

1.1

6t

f

60°

2t

SAFETY LOAD FOR EACH SUSPENSION ROPE ANGLE Unit: N

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GENERAL

Rope diameter

Slant load

6 mm 8 mm 10 mm 12.5 mm 14 mm

21380 31480 49230 76880 96400

Single rope 0° 3040 4410 6960 10980 13730

Double rope suspension 0° 30° 60° 90° 6080 5880 5200 4310 8830 8530 7650 6280 14020 13440 11770 9810 21570 21280 18630 14710 27460 26480 23540 18630

Four-rope suspension 0° 30° 60° 90° 12160 11770 10400 8630 17650 17060 15300 12550 27460 26480 23540 19610 43150 41190 37270 29420 54920 52960 47070 37270

COMPONENT WEIGHTS Component

Vehicle model All models All models (fork pocket version) Gear motor unit All models Pump motor unit All models Rear axle assembly 8FBE(K)T 8FBM(K)T Counterweight 8FBE15T 8FBEK16T 8FBE16T 8FBEK18T 8FBE18T 8FBE20T 8FBMK16T 8FBM16T 8FBM18T 8FBMK20T 8FBM20T Mast assembly (type V height 3300 8FBE15T without forks) 8FBEK16T Battery

Minimum / maximum weight 2069 / 2287 Kg 1635 / 1807 Kg ~ 72 Kg ~ 45 Kg ~ 51 Kg ~ 80 Kg ~ 750 Kg ~ 565 Kg ~ 395 Kg ~ 750 Kg ~ 565 Kg ~ 750 Kg ~ 575 Kg ~ 400 Kg ~ 435 Kg ~ 860 Kg ~ 575 Kg 365 ÷ 440 Kg

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 maximum 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 bouncing.

NOTICE! If the vehicle has a negative braking traction axle, the 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 become damaged or warped as a result of static electricity.

Use a tester which is suited to the object and the type of measurement to be carried out.

Analog type: Suitable for observing movements interfering with the operating process. The value recorded may only be used for reference.

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 Continuity 11 kΩ No continuity ∞

Forward Reverse 2) Digital tester Direct connection

Reverse connection

Example of measurement results Tester measurement scale: scale 2 MΩ

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GENERAL Digital type No continuity 1 Continuity 2 MΩ

Forward Reverse

NOTES ON SAS 1. If repair or replacement is performed in any section of the vehicle that relates to SAS function, perform necessary 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 (mm) M4 x 0,7 M6 x 1 M7 x 1 M8 x 1,25 M9 x 1,25 M10 x 1,5 M12 x 1,75 M14 x 2 M16 x 2 M18 x 2,5 M20 x 2,5 M24 x 3 M27 x 3 M30 x 3

PRELOADING V (N) TORQUE Max (Nm) 6 D* 8 G* 10 K* 12 K* 6 D* 8 G* 10 K* 6.6* 8.8* 10.9* 12.9* 6.6* 8.8* 10.9* 21781 3865 5435 6524 1,7 3 4,2 4974 8849 12459 14911 5,7 10 14,3 7142 12753 17854 21386 9,2 16,6 23 9025 16088 22661 27174 13,6 24,3 34 11870 21190 29921 35610 20,1 36 50,8 14519 25506 35905 42968 27,8 49 69 20797 37082 52189 62588 46,5 83 117 28351 50620 71123 85347 74 132 186 38750 68866 97119 116739 113 200 283 47480 84366 118701 142245 157 279 392 60430 107910 151565 181485 218 388 545 87309 155979 218763 261927 383 687 961 112815 202086 283509 340407 549 991 1393 138321 247212 347274 415944 755 1354 1893

12 K* 12.9* 5,1 17,1 27,8 41,1 60,5 82 140 223 339 471 653 1148 1668 2276

SCREWS WITH “ISO” METRIC FINE THREAD

Nominal diameter (mm) M8 x 1 M10 x 1,25 M12 x 1,25 M12 x 1,5 M14 x 1.5 M16 x 1.5 M18 x 1.5

PRELOADING V (N) TORQUE Max (Nm) 6 D* 8 G* 10 K* 12 K* 6 D* 8 G* 10 K* 6.6* 8.8* 10.9* 12.9* 6.6* 8.8* 10.9* 9761 17168 24231 29038 14,5 25,5 36,2 15107 26879 37867 45420 28,4 51 72 23740 40613 56898 68474 52 89 126 21778 38848 54642 65531 49 87 123 30902 54936 77303 92705 78 140 196 41202 73575 103005 123606 118 211 294 53268 95157 133416 159903 171 304 422

12 K* 12.9* 43 85 151 147 235 353 510

GENERAL Nominal diameter (mm) M20 x 1.5 M24 x 2 M27 x 2 M30 x 2 * = screw class

0-11 PRELOADING V (N) TORQUE Max (Nm) 6 D* 8 G* 10 K* 12 K* 6 D* 8 G* 10 K* 6.6* 8.8* 10.9* 12.9* 6.6* 8.8* 10.9* 67689 118701 168242 202086 239 422 598 94667 168732 237402 284490 402 721 1010 122625 218763 307053 367875 589 1050 1472 154017 272718 384552 461070 814 1442 2040

12 K* 12.9* 716 1216 1766 2453

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GENERAL

BATTERY

1-1 1

BATTERY BATTERY COMPARTMENT AND REQUIRED WEIGHT ..................................... 2 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

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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

8FBE15T

Battery compartment dimensions [mm] Length a Width b Height h

522

830

Battery minimum / maximum weight(with case) - kg 708

627

Capacity [Ah/5h]

420 460

8FBEK16T

630

830

627

500 525

856

8FBEK18T

575

8FBMK16T

625

8FBMK18T 8FBE16T

738

830

627

962

630

8FBE18T

690

8FBE20T

750

8FBM16T 8FBM18T 8FBM20T

Left hand 320A connector

Rear

b h

- pole

+ pole a

STANDARD SERVICE VALUES Specific gravity (battery charged) Specific gravity (battery fully discharged) Discharge end voltage Electrolyte Fluid to be added Insulation resistance

48 V

1.290 [20 °C] 1.140 [20 °C)] 47.28 V * Refined dilute sulfuric acid Distilled water 1 MΩ or higher

* Battery value on standby (only with key ON and no power consumption).

BATTERY

1-3

MULTI-DISPLAY FUNCTIONS

1

Battery charge indicator 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 10 to 3 residual charge LEDs on;

Notes No performance drop

▪ Normal working

2 residual charge LEDs on; ▪ Indicator (B) flashes

First reduction in traction and lifting speed, adjustable via the parameters: ▪ 20 BDI CUTB (TUNING - TRACTION) for traction ▪ 20 BDI CUTB (TUNING - M. HANDLING) for lifting

1 residual charge LED on; ▪ Blinking (A) Led, ▪ Indicator (B) flashes

Second reduction in traction and lifting speed, adjustable via the parameters: ▪ 10 BDI CUTB (TUNING - TRACTION) for traction ▪ 10 BDI CUTB (TUNING - M. HANDLING) for lifting

0 residual charge LEDs; ▪ Indicator (B) flashes

Traction + lifting double function disabled; the two functions can be used individually and maintain the previous speed reductions.

▪ Horn

Specific gravity must not fall below:

▪ Blinking (A) Led,

▪ 1.140 kg/l If the electrolyte falls below the above value, use the BDI MIN (OPTION MENU BATTERY) parameter to reduce the maximum battery discharge

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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 incorrect 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 percentage of the battery indicator.

▪ the value 10% is equivalent to 1 battery charge status indicator LEDs ▪ the value 100% is equivalent to 10 battery charge status indicator 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

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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 reset curve.

RESET CURVE

BATTERY

1-7

BATTERY INDICATOR TROUBLESHOOTING ERROR CAUSE Battery indicator does not reset after The BDI RESET rule is not respecpartial battery charge. ted.

REMEDY ▪ Make sure you have discharged the battery indicator at the value set by BDI RESET before charStandard BDI RESET = 30% (3 led) 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 respec100% after complete battery charge. ted.

Standard BDI RESET = 30% (3 led)

Battery indicator does not shown 100% after changing the battery.

▪ Lower the BDI RESET value.

▪ Make sure you have discharged the battery indicator at the value set by BDI RESET before charging the battery.

After charging the battery does not exceed the voltage set in RESET VOLT MAX.

▪ Lower the BDI RESET value.

▪ Check the battery conditions (old or damaged battery). Electrolyte density after charging 1.29 Kg/dm³.

The BDI RESET rule is not respected.

▪ Lower the RESET VOLT value.

▪ Make sure you have discharged the battery indicator at the value set by BDI RESET before charging the battery.

Standard BDI RESET = 30% (3 led)

After charging the battery does not exceed the voltage set in RESET VOLT MAX.

When the battery indicator shows BDI MIN value too high.

0% the electrolyte density is greater than 1.14 Kg/dm³ When the battery indicator shows BDI MIN value too low 0% the electrolyte density is less than 1.14 Kg/dm³

▪ Lower the BDI RESET value.

▪ Check the battery conditions (old or damaged battery, or unused 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 final charge voltage.

▪ Lower the BDI MIN value.

▪ Increase the BDI MIN value.

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1-8

BATTERY

TROUBLESHOOTING sulfation

plate corrosion

plate warpage and active substance freeing

improper charging short circuit to end of life

Repeated overdischarge procedures Long time in storage

and overdischarge

battery in the battery cells

excessive charging

battery Overdischarge

excessive enviroment temp. battery defect

defect of electrolyte

defect of electrolyte

defect of electrolyte

broken or chipping of cells defect separator

wrong water power

imperfect terminal connectiom

overcharge

short circuit

deposit of free substances at

plug terminal and/or

bottom of cells

connecting plug

electrolyte leakage end reduction

loosened or corroded connection

BATTERY

1-9

DEFECT CAUSE ▪ Battery runs down rapidly during ▪ Battery does not have an adthe work period equate capacity for the type of work ▪ Battery is very old ▪ Battery runs down rapidly

▪ Battery not completely charged ▪ Excessive current consumption

▪ Low voltage, truck goes slowly during work

▪ Truck motor overloaded, especially when going up a slope

▪ Electrolyte heats up

▪ Battery charger with high current at end of charge

▪ Density not the same ▪ Contacts shorting to earth ▪ Current leakage

▪ Battery runs down rapidly ▪ Truck slow, low voltage

▪ Faulty insulation of some electric device in the truck or battery

REMEDY ▪ Moderate current consumption or charge more frequently ▪ If necessary, replace the battery ▪ Check the battery charger ▪ Check the load lifted by the truck ▪ Lubricate and check the motor mechanical parts ▪ If necessary, fit a battery with a higher capacity ▪ Check the battery charger ▪ Examine the insulation

▪ Battery has cracked cells or dirty elements

▪ Clean the case and the elements • Renew the insulating coating

▪ Metal case has faulty insulation

▪ Repeat the final charge

▪ Intermediate current sockets

▪ Eliminate too high and/or continuous intermediate current sockets ▪ Replace faulty elements

▪ Plates short circuiting in some 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 during the charge ▪ Battery runs down rapidly

▪ Electrolyte density too low due to acid leakage ▪ Frequent and excessive top-ups ▪ Poles loose or oxidized

▪ Truck slow, poor performance

▪ If the density does not increase with a trickle charge, the electrolyte density must be restored by adding acid.

▪ Tighten the contacts of the poles and clean them accurately

▪ Charge voltage too high ▪ Charge current too low ▪ Acid heats up

▪ Charge time set too long The timer comes on late and extends the charge

▪ Adjust the point of intervention of the timer

▪ Density not the same

▪ Charge time set too short The timer intervenes early

▪ Adjust the point of intervention of the timer

▪ Density too low during charging

▪ Insufficient time for recharging

▪ Increase the recharging time

▪ Charge time too long ▪ High water consumption ▪ Battery runs down rapidly

▪ Replace the battery charger with a more powerful one

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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 procedure.

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 the white line reappears. Stop topping the water up when the white line appears; if the top of the float comes into contact with the retainer, the recipient has been overfilled.

Cap White line

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.

Normal level Level insufficient

Red light Off Flashing

Green light On 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.

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:

Hydrometer Rubber deposit

Outlet pipe

Nozzle

▪ Insert the hydrometer nozzle into the electrolyte opening and let the fluid flow into the external pipe.

▪ Allow the hydrometer to float without touching the external tube, or top or bottom, and when the bubbles in the fluid disappear, read the highest value of the scale on the fluid's surface, as shown in the figure.

▪ After the measurement, carefully wash the inside and outside of the hydrometer with water and put it away after drying with a clean cloth.

4. Insulation resistance measurement: Measure the resistance between battery and 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 resistance again. Install the battery on the vehicle after confirming that the insulation resistance is 1 MW or more.

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1-12

BATTERY

* Battery control table Prepare a control table for each battery, to record and process the inspection results.

Inspection time and date

Inspected element Nr.

Electrolyte specific gravity

Time electrolyte

Added water

Notes

Inspector

STATE OF BATTERY CHARGE The state of charge of a battery is measured by means of the electrolyte density. Before measuring the electrolyte, ensure that the battery has been at rest for at least 30 minutes (see previous paragraph).

NOTICE! Notes:The tables below represent ideal discharge values of lead-acid batteries.

Electrolyte density (kg/l)

Electrolyte density vs Discharged capacity

Recommended 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

Cell voltage (kg/l)

Recommended discharge

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 viscosity increases and this reduces the rate of diffusion of the acid in the pores of the active material. The temperature effect is more sensitive at high discharge rates. Due to the effect of the electrolyte temperature, the battery capacity varies as shown in the diagram below.

Capacity (%)

CAPACITY ACCORDING TO ELECTROLYTE TEMPERATURE

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 elements, 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 replaced.

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 battery voltage and the voltage of every single element, recording it on a special chart. If a significant variation is found with respect to the previous record, carry out a new series of checks on 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 discharged 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.

1

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 attention to the polarity of the contacts during assembly. The main contacts must be inserted in the special support on the opposite 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 inserted and locked in its seat.

CONTROL SYSTEM

2-1 2

CONTROL SYSTEM GENERAL.............................................................................................................. 2 REAR COMPARTMENT FUSES........................................................................... 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

2-2

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 setting 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

2

Fuse F1 F2 F3 F4 F5 F6 F7 FP FP FS FT1 FT2

Function T2 and T3 converter output T2 and T3 converter input Heater unit MCB auxiliaries Horn Electronic card power supply Pneumatic seat Pump control power Pump control power EPS control power Right traction control unit power Left traction control unit power

Capacity 30A - 24V 15A - 48V 30A - 48V 10A - 48V 5A - 48V 5A - 48V 15A - 24V 300A 350A 40A 250A 250A

2-4

CONTROL SYSTEM

FUSES UNDER DASHBOARD

Fuse F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23

Function MCB auxiliaries Heater unit Work spotlights +24V auxiliary output Courtesy light Rear window Radio +12V auxiliary output +12V auxiliary output Heated seat Rear wiper motor Front wiper motor Work spotlights

Capacity 10A - 24V 7,5A - 24V 7,5A - 24V 5A - 24V 5A - 24V 10A - 24V 7,5A - 12V 7,5A - 12V 7,5A - 12V 7,5A - 12V 7,5A - 24V 7,5A - 24V 7,5A - 24V

CONTROL SYSTEM

2-5

CONTACTORS

2

Fuse K1

Description SU280B-1166 48V IO

K2

SW60B-258 48V CO

K7

SW60B-258 48V CO

Function Master, slave and pump control power switch EPS steering control power switch Key line switch

Coil resistance (at 20°C) ~100 Ω ~420 Ω ~420 Ω

2-6

CONTROL SYSTEM

DC/DC CONVERTERS

DC/DC converters

Power

Connected systems

T1

144W

Converter 48V / 24V

/

2 front working lights (LED) 2 rear working lights (LED) Rear lights (stop/tail + reversing) Rear LED lights (stop/tail + reversing) 2 washer pumps Combined front lights (dipped + tail + direction indicators) Combined front LED lights (dipped + tail + direction indicators) 2 additional LED working lights Height selector 2 wiper motors 24V auxiliary output Heater Courtesy light 2 additional LED working lights on the mast Heated rear window Pneumatic seat (+ heated seat) Blue LED light Reading light Radio 12V auxiliary output Heated seat

360W / 720W

T2

360W

Converter 48V / 24V

T3

360W

Converter 48V / 24V

T4 Converter 48V / 12V

300W

Maximum system consumption 140 W (70W) 140 W (70W) 140 W 7W 72 W 192 W

26 W

70 W 6W 200 W 80 W 40 W 5W 29 W 115 W 120 W (96W) 7,2 W 2,5 W 80 W 60 W 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 DISASSEMBLY-ASSEMBLY 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.

2) Disconnect the battery connector.

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 conductive paste whose purpose is to favour the thermic transmission between the logic unit and the heat radiant structure: 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 CALIBRATIONS).

2

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 DISASSEMBLY-ASSEMBLY

Disassembly Procedure 1) Open the battery cover.

2) Disconnect the battery connector.

3) Remove the footboards and the accelerator pedal.

4) Disconnect the electrical wiring.

5) Remove the MCB card.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

After replacing the card, the vehicle settings must be repeated (see heading CALIBRATIONS).

CONTROL SYSTEM

2-9

MULTI-DISPLAY FUNCTIONS DISASSEMBLY-ASSEMBLY

Dismantling procedure 1) Open the battery cover.

2) Disconnect the battery connector.

3) Remove the dashboard.

4) Disconnect the electrical wiring.

5) Remove the display.

Assembly procedure The assembly procedure is the reverse of the disassembly procedure.

After replacing the card, the vehicle settings must be repeated (see heading CALIBRATIONS).

2

2-10

CONTROL SYSTEM

ARMREST CARD DISASSEMBLY-ASSEMBLY

Dismantling procedure 1) Open the battery cover.

2) Disconnect the battery connector.

3) Remove the cover card bracket.

4) Disconnect the electrical wiring.

5) Remove the armrest card.

Assembly procedure The assembly procedure is the reverse of the disassembly procedure.

After replacing the card, the vehicle settings must be repeated (see heading CALIBRATIONS).

CONTROL SYSTEM

2-11

ARMREST CARD POTENTIOMETERS DISASSEMBLY-ASSEMBLY

Dismantling procedure 1) Open the battery cover.

2) Disconnect the battery connector.

3) Remove the armrest covers.

4) Disconnect the electrical wiring.

5) Remove the potentiometers.

Assembly procedure The assembly procedure is the reverse of the disassembly procedure.

After replacing the potentiometer, the vehicle settings must be repeated (see heading CALIBRATIONS).

2

2-12

CONTROL SYSTEM

ACCELERATOR AND BRAKE POTENTIOMETERS DISASSEMBLY-ASSEMBLY

Disassembly Procedure 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 installation.

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 potentiometer acquisition.

If the voltage is outside the standard range: ▪ Loosen the screw and adjust the potentiometer through the fixing 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 DISASSEMBLY-ASSEMBLY

Disassembly Procedure 1) Disconnect the battery connector.

2) Disconnect the connector from the steering sensor.

3) Remove the steering sensor. [Point 1] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

WARNING! The sensor wiring harness must face the EPS steering logic unit.

2

2-14

CONTROL SYSTEM

Point Operations [Point 1] Assembly: Position the steering sensor with the label facing upwards.

STEERING SENSOR - 4 WHEEL VERSION DISASSEMBLY-ASSEMBLY

Disassembly Procedure 1) Disconnect the battery connector.

2) Disconnect the connector from the steering sensor.

3) Remove the steering sensor cover.

4) Remove the steering sensor. [Point 1] Reassembly Procedure

CONTROL SYSTEM

2-15

The assembly procedure is the reverse of the disassembly procedure.

After replacing the steering sensor, the vehicle settings must be repeated (see heading CALIBRATIONS).

WARNING! Place the wheels straight before installing the steering potentiometer.

2

Point Operations [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 DISASSEMBLY-ASSEMBLY

Disassembly Procedure 1) Disconnect the battery connector.

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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 forwards (5.0 degrees forward); 2) Apply thread lock 08833-76002-71 (08833-00080), or equivalent, on the threaded part of the shaft; 3) Before tightening the nut, lock the rod to prevent rotation.

MAST PRESSURE SENSOR DISASSEMBLY-ASSEMBLY

Disassembly Procedure 1) Lower the forks to the ground, tilt the mast forwards and switch off the machine.

2) Disconnect the battery connector.

3) Remove the footboard.

4) Disconnect the mast pressure sensor wiring harness.

5) Remove the mast pressure sensor (tightening torque T = 26 Nm).

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

CONTROL SYSTEM

2-17

After replacing the sensor, the vehicle settings must be repeated (see heading CALIBRATIONS).

MAST HEIGHT SWITCH DISASSEMBLY-ASSEMBLY

Disassembly Procedure 1) Remove the cover. (FV, FW, FSV, FSW mast) 2) Disconnect the wiring harness.

3) Remove the mast height switch.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

2

2-18

CONTROL SYSTEM

CALIBRATIONS Menu

Name

MAT FW/BW SELECTOR FW/BW SELECTOR MAT ACCEL DRIVE BRAKE STEER RANGE KNOB REST ZERO POT MAT MULTIF. MAT. HANDLING LEVER 1 LEVER 2 PB 3WAY LEVER 3 PB 4WAY LEVER 4 MAT SAS

TILT LEVEL TILT FW TILT BW

LOAD SENSOR MAT MAST TYPE LOAD METER (de- ZERO SET luxe display version) ZERO SET 1

ZERO SET 2

COMPENSATION MAT H-SELECTOR

ENABLE MIN HEIGHT MAX HEIGHT

TUNING M. HANDLING

ANGLE FW ANGLE BW

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

Description Selecting the type of reverse drive

Requirement for execution *1, *5

Calibration of the forward/backward move- *1,* 3, *7 ment accelerator potentiometer Brake potentiometer calibration *1,* 3, *8 Steering sensor calibration *2,* 3, *12, *21 TFD sensor calibration *2, *12, *21 Steering sensor calibration *2, *12, *21 Enable the multifunction joystick configura- *5 tion Calibration of the lifting minilever/joystick *5, *16 potentiometer Calibration of the tilting minilever/joystick *5, *17 potentiometer Configure the 3rd way button (ATT1) *5 Calibration of the 3rd way minilever/joystick *5, *18 (ATT1) potentiometer Configure the 4th way button (ATT2) *5 Calibration of the 4th way minilever/joystick *5, *19 (ATT2) potentiometer Calibration of mast tilt angle potentiometer, *1, *9, *10, *14, *15 vertical position Calibration of mast tilt angle potentiometer, *1, *9, *10, *14, *15 forward end of stroke Calibration of mast tilt angle potentiometer, *1, *9, *10, *14, *15 backward end of stroke Calibration of open mast pressure sensor *1, *11, *13, *14 Type of mast fitted to the vehicle *1, *14 Calibration of the pressure switch with the *1, *11, *13, *14 forks 500 mm from the ground (V masts only) Calibration of the pressure switch with the *1, *11, *13, *14 forks 500 mm from the ground (FV, FW, FSV, FSW masts only) Calibration of the pressure switch with the *1, *11, *13, *14 side cylinders opened by 100 mm (FV, FW, FSV, FSW masts only) Compensation of the load measuring *1, *11, *13, *14 device Enabling of the height selector option *1, *20 Calibration of the fork height sensor, forks *1, *20 on the ground Calibration of the fork height sensor, forks *1, *20 at maximum height Front tilt angle control *1, *9, *10, *14, *15 Rear tilt angle control *1, *9, *10, *14, *15

CONTROL SYSTEM *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 *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

2-19

2

2-20

CONTROL SYSTEM

MULTI-FUNCTION DISPLAY

3-1 3

MULTI-FUNCTION DISPLAY GENERAL.............................................................................................................. 2 MENU MAP............................................................................................................ 3 OPERATOR MENU ............................................................................................... 4 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

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. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)

Description Button (1): Set Speed reduction / Scroll down Button (2): Select Power / Scroll left Button (3): Select Date and time / Scroll right Button (4): Display Hour meter / Scroll up Multi-screen display area Button (6): Enter / ok Button (7): Out Button (8): Rotating / Flashing light Button (9): Hazard lights Button (10): Rear working lights Button (11): Front wind-screen wiper / Front wind-screen washer Button (12): Rear wind-screen wiper / Rear wind-screen washer Button (13): Heated rear window / heated seat Battery charge indicator OPS indicator Wheel direction indicator Mast tilt indicator Time / Date Parking brake indicator Traveling direction indicator Selected power indicator Low speed selected indicator Hire period expiry indicator

Multi-function Multi-function display display deluxe o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o x o o o o o o o o o o o o o

MULTI-FUNCTION DISPLAY No. (24) (25) (26) (27) (28) (29)

3-3 Description

Start maintenance indicator Over load indicator Shock indicator Overheat indicator Height limit selected indicator Traveling speed

Multi-function Multi-function display display deluxe o o x o OPT OPT o o OPT OPT 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 afterwards, the display switches to the TRAVELING screen.

Display 12/7/2013 (FRI)

Description 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

3

3-4

MULTI-FUNCTION DISPLAY

MENU MAP

OPERATOR MENU Operators can set several vehicle services. Function adjustment can be disabled via the ADMINISTRATOR menu.

MULTI-FUNCTION DISPLAY POWER CONTROL MENU

3-5 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

METER MENU

Parameters: HEIGHT SET - HEIGHT SET CLR HEIGHT LIM appear only if the option selector height is present and enabled on the truck 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.

3-6

MULTI-FUNCTION DISPLAY

Password entry procedure Step (1)

Display

Operation Press and hold the (

)

and ( ) buttons simultaneously for at least 2 seconds.

(2)

(3)

(4)

Press the ( ) button within 10 seconds.

Press the ( ) button within 10 seconds.

Within 10 seconds, press and hold the (

) and

( ) buttons simultaneously for at least 2 seconds.

(5)

(6)

Vehicle response When you first press the buttons, a short beep will sound, followed by another short beep after 2 seconds.

Short acoustic warning.

Short acoustic warning.

When you first press the buttons, a short beep will sound, followed by another short beep after 2 seconds.

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.

The menu screen is displayed automatically.

MULTI-FUNCTION DISPLAY

3-7

ADMINISTRATOR menu screen With vehicle startup using pin code via With vehicle startup using key

keypad

3

Symbols Symbol

Description This icon enables the traction and lifting power control function.

Symbol

Description This icon enables the shock sensor function (models with shock sensor only).

This icon enables the traction control function.

This icon enables the PIN code entry system function (models with PIN code entry system only).

This icon enables the material handling control functions (models with height selector or deluxe multifunctional operation only).

This icon enables the vehicle management function

Return to main screen.

ADMINISTRATOR menu screen (with vehicle startup using key) General screen.

ü Operating procedure 1) Enter the password on the general screen to display the ADMINISTRATOR menu.

3-8

MULTI-FUNCTION DISPLAY

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)

MULTI-FUNCTION DISPLAY

3-9 *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 functions.

3-10

MULTI-FUNCTION DISPLAY

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 The ( ) or ( ) button can be used to select the desired profile.

Press the (I) button to return to the menu screen.

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 The ( ) or ( ) button can be used to select the desired profile.

Press the (I) button to return to the menu screen.

4. LIFT POWER Can be used to select the lifting motor torque for the SPH program: Value 1: lower motor torque - Value 5: higher motor torque The ( ) or ( ) button can be used to select the desired profile.

Press the (I) button to return to the menu screen.

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.

MULTI-FUNCTION DISPLAY

3-11 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.

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 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.

Button (

): Reduces the traveling speed.

Button (

): Increases the traveling speed.

Button (I): Return to the menu screen.

The limit can be adjusted from 5 to 50 km/h in steps of 1 km/h. If 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 functions.

LOADMETER 0 SET (V mast version) Can be used to adjust the load measuring device (deluxe multifunctional 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.

3

3-12

MULTI-FUNCTION DISPLAY LOADMETER 0 SET (FV and FSV mast version) Can be used to adjust the load measuring device (deluxe multifunctional display only) ZERO SET 1 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 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.

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.

LOAD ALARM SET Can be used to set the overload alarm (deluxe multifunctional display 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 indicated value. In that case “OK” is displayed.

Press button ( O ) to return to the MATERIAL HANDLING screen.

HEIGHT SET Can be used to set the three height levels (with height selector option only) Procedure: Use the ( or C) you wish to set.

) or (

) button to select the level (A or B

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.

Press button ( O ) to return to the MATERIAL HANDLING screen.

Repeat the procedure for the remaining levels.

HEIGHT SET CLR Can be used to delete all memorized height levels in the height selector option Press and hold the (I) button for at least 2 seconds to delete all memorized height levels. In that case “OK” is displayed.

Press button ( O ) to return to the MATERIAL HANDLING screen.

MULTI-FUNCTION DISPLAY

3-13

3 HEIGHT LIM Can be used to enable/disable height limitation via the height limiter button (S15).

Procedure (SET): Use the ( option.

) or (

) button to select the "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.

Press button ( O ) to return to the MATERIAL HANDLING screen.

Procedure (CLR): Use the ( "CLR" option.

) or (

) button to select the

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

Press button ( O ) to return to the MATERIAL HANDLING screen.

MAX HEIGHT LIM Can be used to set the maximum lifting height.

Procedure (SET): Use the ( option.

) or (

) button to select the "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 maximum lifting height. In that case “OK” is displayed.

Press button ( O ) to return to the MATERIAL HANDLING screen.

3-14

MULTI-FUNCTION DISPLAY

Procedure (CLR): Use the ( "CLR" option.

) or (

) button to select the

Press and hold the (I) button for at least 2 seconds to delete the memorized mast height. In that case “OK” is displayed.

Press button ( O ) to return to the MATERIAL HANDLING screen.

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 selecting "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 password for the ADMINISTRATOR menu.

ON: enabled OFF: disabled

MULTI-FUNCTION DISPLAY

3-15

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; Press the (O) button to return to the TRUCK MANAGEMENT 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.

Press the (O) button to return to the TRUCK MANAGEMENT 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 ( to reset.

) or (

) button to select the hour meter you wish

Press the ( menu.**

) or (

) button to enter the reset hour meter sub-

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 displayed.

3-16

MULTI-FUNCTION DISPLAY

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.

Button (

): Reduces the traveling speed.

Button (

): Increases the traveling speed.

Button (I): Return to the menu screen.

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 (O): Return to the menu screen.

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.

MULTI-FUNCTION DISPLAY

3-17 ALARM RESET Allows the vehicle administrator to restore standard machine functions 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 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

3

3-18

MULTI-FUNCTION DISPLAY

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 ADMINISTRATOR 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)

MULTI-FUNCTION DISPLAY

3-19

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)

3-20

MULTI-FUNCTION DISPLAY

PIN ENTRY This menu can be used to change the pin codes and set the traction 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 ( to change.

) button can be used to select the code you wish

Use the ( ) button to enter the sub-menu for changing the selected code*.

Press the ( O ) button to return to the menu screen. *Sub-menu screen.

The ( ) or ( to change.

) button can be used to select the field you wish

The ( ) or ( ) button can be used to change or enable/disable the selected field.

Press the ( I ) button to enter the save screen.

Press and hold the (I) button for at least 2 seconds to save the changes. In that case “OK” is displayed.

Press the ( O ) button to return to the menu screen.

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.

Press the ( O ) button to return to the menu screen.

MULTI-FUNCTION DISPLAY

3-21

3 List of pin codes

Pin 00323 01034 02021 02102 03033 03421 04031 04432

Middle 0 1 2 3 0 0 1 2

Pin 10043 11020 11404 12403 13042 14143 14021 14322

Middle 3 0 0 1 2 3 0 0

Pin 20102 21020 22010 22344 22433 23013 23401 24431

Middle 1 2 3 0 0 1 2 3

Pin 30001 30204 32040 33300 33410 34010 34132 34343

Middle 0 0 1 2 3 0 0 1

Pin 40010 40143 41342 41414 42231 43001 43203 44044

Middle 2 3 0 0 1 2 3 0

4) PROFILE SETTING Can be used to set the POWER CONTROL, TRACTION SETTING and MATERIAL HANDLING SETTING functions 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 functions for the profile selected previously.

3-22

MULTI-FUNCTION DISPLAY 1. POWER MODE Can be used to select one of the programs: S - P - H - SPH The ( gram.

) or (

) button can be used to select the desired pro-

Press the (I) button to return to the menu screen.

2. 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 The ( gram.

) or (

) button can be used to select the desired pro-

Press the (I) button to return to the menu screen.

3. LIFT POWER Can be used to select the lifting motor torque for the SPH program Value 1: lower motor torque - Value 5: higher motor torque The ( gram.

) or (

) button can be used to select the desired pro-

Press the (I) button to return to the menu screen.

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 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.

MULTI-FUNCTION DISPLAY

3-23 SPEED LIMIT Can be used to select the maximum traction speed.

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 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.

Button (

): Reduces the traveling speed.

Button ( ): Increases the traveling speed.

Button (I): Return to the menu screen.

The limit can be adjusted from 5 to 50 km/h in steps of 1 km/h. If 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.

Button (O): Return to the menu screen.

▪ 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 This menu can be used to set the material handling control functions for the profile selected previously.

LOW SPEED Can be used to select the maximum lifting speed when the low speed function is enabled.

Button (

): Reduces the lifting speed

Button ( ): Increases the lifting speed Button (I): Return to the menu screen.

3

3-24

MULTI-FUNCTION DISPLAY

MATERIAL HANDLING This menu can be used to set the material handling control function.

Please refer to the specific section.

TRUCK MANAGEMENT This menu can be used to set the vehicle management functions.

Please refer to the specific section.

SHOCK SENSOR This menu can be used to set the shock sensor functions.

Please refer to the specific section.

MULTI-FUNCTION DISPLAY

3-25

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-protected so that important data cannot be damaged by misuse or errors on the part of users.

List of functions

Function menu ANALYZER

TUNING

OPTION SETTING

MATCHING

OTHERS MENU

Sub-menu 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 Traction Tilt valve Material handling ATT1 valve Steering (3 wheels version only) ATT2 Valve Valve SAS ATT3 valve Lift valve Optionset Dipped light Maintenance Work lamp Rent time Wipers/washer Battery Dir lights Twis flag Heater Rot lamp Opt out Flash lamp Serial number SAS Fw/Bw selector Load meter (deluxe display only) Drive H-selector Mat. Handling Tire data Meter start Manager pass Demo mode Contrast To default set Deluxe mode Mask password

3

3-26

MULTI-FUNCTION DISPLAY

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 1

2

3

Display

Operation Press and hold the ( ) and ( ) buttons simultaneously for at least 2 seconds

Press the ( seconds.

) button within 10

Press the ( seconds.

) button within 10

Vehicle response When you press the buttons, a short beep will sound, followed by another 2 short beeps after 2 seconds.

Short acoustic warning.

Short acoustic warning.

4

Within 10 seconds, press and hold the When you press the buttons, a short beep will ( ) and ( ) buttons simultansound, 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

MULTI-FUNCTION DISPLAY

3-27

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 (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Enters the selected option

Button ( ): Enters the selected option Button (O): Return to menu screen Display option CURRENT ALR READ LOG CLEAR LOG

Description Displays the error codes in real time Displays the error codes in memory Deletes the list of error codes in memory

Unit of measure / / /

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 (

): Indicates the selected option

Button (

): Selects the previous screen

Button ( ): Selects the next screen Button (O): Return to menu screen

Display option TR MOTOR T TR CONTR T TL MOTOR T TL CONTR T P MOTOR T P CONTR T S CONTR T S MOTOR T CAPACITOR V KEY VOLTAGE BATTERY %

Description Displays the right drive motor temperature Displays the right drive logic unit temperature Displays the left drive motor temperature Displays the left drive logic unit temperature Displays the pump motor temperature Displays the lifting logic unit temperature Displays the EPS steering logic unit temperature Displays the steering motor temperature Displays the battery voltage measured between +VBATT and GND Displays the battery voltage measured between pin 1 connector J1 and GND Displays the residual battery charge as a percentage

Unit of measure °C °C °C °C °C °C °C °C Volt Volt %

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.

3

3-28

MULTI-FUNCTION DISPLAY Button (

): Indicates the selected option

Button (

): Selects the previous screen

Button ( ): Selects the next screen Button (O): Return to menu screen

Display option SPEED SET SPEED TRAC TRAC ACC FREQ RIGHT ENC RIGHT SLIP RIGHT FREQ LEFT ENC LEFT SLIP LEFT CURRENT R ID RIGHT IQ RIGHT CURRENT L ID LEFT IQ LEFT POT ACC R3 POT ACC R2 POT BRK R1 POT BRK R4 FORWARD NOT FW BACKWARD NOT BW CFG FW JOY BW JOY SEAT ELT SWING ELT SWING PARK BRK ELT BRK R ELT BRK L TURTLE SPEED LIMIT TRAC OVERTEMP

Description Frequency supplied by the MCB to the right drive logic unit Frequency read by the drive motor rpm sensors Difference between the “SPEED SET” and “SPEED TRAC” frequencies.

Frequency supplied by the right drive logic unit to the right drive motor.

Frequency read by the right drive motor rpm sensor Difference between the “FREQ RIGHT” and “ENC RIGHT” frequencies Frequency supplied by the left drive logic unit to the left drive motor Frequency read by the left drive motor rpm sensor Difference between the “FREQ LEFT” and “ENC LEFT” frequencies Current supplied by the right drive logic unit to the right drive motor.

Current supplied by the right drive logic unit to the right drive motor.

Current supplied by the right drive logic unit to the right drive motor.

Current supplied by the right drive logic unit to the left drive motor.

Current supplied by the right drive logic unit to the left drive motor.

Current supplied by the right drive logic unit to the left drive motor.

Accelerator potentiometer signal R3 Accelerator potentiometer signal R2 Brake potentiometer signal R1 Brake potentiometer signal R4 Microswitch forward drive signal N.O. Microswitch forward drive signal N.C. Microswitch reverse drive signal N.O. Microswitch reverse drive signal N.C. Accelerator foot board configuration Forward drive signal of arm rest inverter Reverse drive signal of arm rest inverter Seat microswitch signal Oscillation lock cylinder valve on Current supplied to oscillation lock cylinder valve Parking brake selector signal Voltage supplied to the right parking brake Voltage supplied to the left parking brake Speed reduction of the turtle function on Speed reduction of the SPEED LIMIT function on Speed reduction in the case of drive motor overheating

Unit of measure Hz Hz Seconds Hz Hz Hz Hz Hz Hz Ampere Ampere Ampere Ampere Ampere Ampere Volt Volt Volt Volt ON/OFF ON/OFF ON/OFF ON/OFF No. Pedals ON/OFF ON/OFF ON/OFF ON/OFF Ampere ON/OFF Vbatt % Vbatt % ON/OFF ON/OFF ON/OFF

MULTI-FUNCTION DISPLAY Display option PUMP OVERTEMP PUMP IN ALARM AUX RED 1 AUX RED 2 OIL BRAKE SHOCK ALARM MAINTENANCE RENTAL FORCED P. ON BATTERY LOW

3-29

Description Speed reduction with pump motor overheating Speed reduction with lifting logic unit malfunction T CUTB SP1 function speed reduction T CUTB SP2 function speed reduction Speed reduction with low brake oil level Speed reduction with shocks Speed reduction with maintenance hour meter expiry Speed reduction with hire hour meter expiry Speed reduction with forced display on Speed reduction with flat battery

Unit of measure ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF 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.

Button (

): Indicates the selected option

Button (

): Selects the previous screen

Button ( ): Selects the next screen Button (O): Return to menu screen

Display option SPEED SET FREQ PUMP ENC PUMP PUMP SLIP CURRENT ID PUMP IQ PUMP PRESSURE PRESSURE V POT LIFT /POT LIFT EVP LIFT POT TILT /POT TILT EVP TILT POT ATT1 /POT ATT1 EVP ATT1 POT ATT2 /POT ATT2 EVP ATT2 ATT3 SW ATT3 ELT % CAPACITY HEIGHT SW

Description Frequency supplied by the MCB to the lifting logic unit Frequency supplied by the lift logic unit to the pump motor.

Frequency read by the pump motor rpm sensor.

Difference between the “FREQ PUMP” and “ENC PUMP” frequencies Current supplied by the lift logic unit to the pump motor.

Current supplied by the lift logic unit to the pump motor.

Current supplied by the lift logic unit to the pump motor.

Pressure read by pressure sensor Pressure sensor signal Lifting potentiometer signal Lifting potentiometer signal Current supplied to the lifting and lowering valve Tilt potentiometer signal Tilt potentiometer signal Current supplied to the tilt valve ATT1 function potentiometer signal ATT1 function potentiometer signal Current supplied to the ATT1 function valves ATT2 function potentiometer signal ATT2 function potentiometer signal Current supplied to the ATT2 function valves ATT3 function button on ATT3 function button on Percentage of nominal lifted capacity Height selector button on

Unit of measure Hz Hz Hz Hz Ampere Ampere Ampere Bar Volt Volt Volt Ampere Volt Volt Ampere Volt Volt Ampere Volt Volt Ampere ON/OFF ON/OFF % ON/OFF

3

3-30 Display option H SENSOR MAX H REQ FORK LEVEL TILT ANGLE TILT POT MAST H NO MAST H NC TURTLE BATTERY LOW PUMP OVERTEMP MAINTENANCE RENTAL LIFT LOCK TILT LOCK

MULTI-FUNCTION DISPLAY Description Fork height sensor signal Maximum height limit button on Fork auto-leveling button on Tilt angle read by tilt angle potentiometer Tilt angle potentiometer signal Mast height microswitch signal N.O. Mast height microswitch signal N.C. Speed reduction of the turtle function on Speed reduction with flat battery Speed reduction with pump motor overheating Speed reduction with maintenance hour meter expiry Speed reduction with hire hour meter expiry Lifting lock valve L27 on Tilt control valve L25 on

Unit of measure Volt ON/OFF ON/OFF Degrees Volt ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF

I/O STEERING The I/O STEERING menu is used to display the steering motor frequencies, sensor and other component signals linked to the steering function.

Button (

): Indicates the selected option

Button (

): Selects the previous screen

Button ( ): Selects the next screen Button (O): Return to menu screen

3 wheels version

Display option STEER POT1 STEER POT2 T ST POT1 T ST POT2 POS SETP MOTOR SPEED MOTOR FREQ CURRENT STEER IQ STEER ID STEER ANG

Description TFD sensor 1 signal TFD sensor 2 signal Steering sensor signal 1 Steering sensor signal 2 Position of wheels read by the steering sensor Frequency read by the steering motor encoder Frequency supplied by the EPS steering logic unit to the steering motor Current supplied by the EPS steering logic unit to the steering motor Current supplied by the EPS steering logic unit to the steering motor Current supplied by the EPS steering logic unit to the steering motor Steering angle read by the steering sensor

Unit of measure / / mVolt mVolt Volt Hz Hz Ampere Ampere Ampere Degrees

MULTI-FUNCTION DISPLAY

3-31

4 wheels version

Display option EVP STEER DC STEER TIRE ST POT TIRE ST POT COMP KNOB ANGLE

Description Steering wheel knob synchronizer valve on Current supplied to the steering wheel knob synchronizer valve Steering angle read by the steering sensor Steering sensor signal Steering wheel knob position compensation Knob position read by the steering encoder

Unit of measure ON/OFF Ampere Degrees Volt / /

I/O OTHERS The I/O OTHERS menu is used to display the working hours. These hour/trip meters are not resettable, in contrast to the other hour meters on the truck, and act as a reference for the warranty.

Button (

): Indicates the selected option

Button (

): Selects the previous screen

Button ( ): Selects the next screen Button (O): Return to menu screen

Display option LIFE WORK HM LIFE KEY HM DHU CONN KEY PAD CONN SHOCK SENS SMART ACCESS

Description Displays the combined pump + drive working hours Displays the key working hours DHU card connected Keypad connected Shock sensor connected Smart Access connected

Unit of measure Hours Hours ON/OFF ON/OFF ON/OFF 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 (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option STEER COMP STEER EV SWING CONTR SWING EV

Description Enables/disables the steering wheel knob synchronizer function Enables the steering wheel synchronization valve Enables/disables the oscillation lock cylinder valve function Enables the oscillation lock cylinder valve

Unit of measure ON/OFF ON/OFF ON/OFF ON/OFF

SW VERSION The SW VERSION menu is used to view the software versions of the various cards installed on the machine.

3

3-32

MULTI-FUNCTION DISPLAY Button (

): Indicates the selected option

Button (

): Selects the previous screen

Button ( ): Selects the next screen Button (O): Return to menu screen

Display option DISPLAY TRCB RH DR DRV LH DR DRV PM DRIVER ARMREST M ARMREST S EVCB EPS

Description Displays the software version of the display Displays the software version of the TRCB section MCB card Displays the software version of the right drive logic unit Displays the software version of the left drive logic unit Displays the software version of the lifting logic unit Displays the software version of the master armrest card Displays the software version of the slave armrest card Displays the software version of the EVCB section MCB card Displays the software version of the EPS lifting logic unit

Unit of measure / / / / / / / / /

TUNING GENERAL The TUNING function accurately controls the traction and material handling control systems. When a user request is received, such as a request to soften acceleration for the regenerative braking force, the various setting levels can be changed.

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

TRACTION The TRACTION menu is used to control the traction parameters.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button (

): Modifies the parameter value

Button (

): Selects the POWER MODE (S-P-H-SPH)

Button ( ): Selects the operator profile (0-1-2-3) Button (O): Return to menu screen

MULTI-FUNCTION DISPLAY

3-33

Display option MAX SPD FW

Description Controls the maximum speed in forward drive

Unit of measure Hz

MAX SPD BW

See GRAPHIC A Controls the maximum speed in backward drive

Hz

T ACC DELAY

See GRAPHIC A Controls the forward and reverse acceleration

Seconds

THROTTLE 0

See GRAPHIC B Determines point 0 on the accelerator pedal

FREQ CREEP

See GRAPHIC A Controls the speed at point 0 on the accelerator pedal

THROTTLE X1

See GRAPHIC A Determines point 1 on the accelerator pedal

THROTTLE X2

See GRAPHIC A Determines point 2 on the accelerator pedal

THROTTLE X3

See GRAPHIC A Determines point 3 on the accelerator pedal

THROTTLE Y1

See GRAPHIC A Controls the speed at point 1 on the accelerator pedal

THROTTLE Y2

See GRAPHIC A Controls the speed at point 2 on the accelerator pedal

% max. speed

THROTTLE Y3

See GRAPHIC A Controls the speed at point 3 on the accelerator pedal

% max. speed

TORQUE PROF

See GRAPHIC A Selects the drive motor torque

% potentiometer stroke Hz % potentiometer stroke % potentiometer stroke % potentiometer stroke % max. speed

/

PEDAL BRK

See GRAPHIC D Controls the braking time pressing on the brake pedal and releasing the accelerator pedal

Seconds

SPD LIM BRK

See GRAPHIC F Controls the braking time when the accelerator pedal is partially released

Seconds

INV BRAKE

See GRAPHIC I Controls the reverse drive braking time

F THROTTLE 0

See GRAPHIC J Controls point 0 on the brake pedal

F THROTTLE X

See GRAPHIC E Controls point 1 on the brake pedal

RELEASE BRK

See GRAPHIC E Controls the braking time when the accelerator pedal is fully released

BRAKE DELAY

See GRAPHIC H Controls the braking time pressing on the brake pedal and holding down the accelerator pedal

ACC SMOOTH

See GRAPHIC G Controls the initial forward and reverse acceleration

ACC SM SP

See GRAPHIC B Controls the speed at which the ACC SMOOTH effect ends

REL SMOOTH

See GRAPHIC B Controls the braking time at low speed See GRAPHIC H

Seconds % potentiometer stroke % potentiometer stroke Seconds

Seconds

Seconds Hz Seconds

3

3-34

MULTI-FUNCTION DISPLAY

Display option LOW SPEED BRK

Description Controls the speed at which the REL SMOOTH effect starts

Unit of measure % max. speed

CONST SP ACC

See GRAPHIC H Controls the acceleration when partially pressing the accelerator pedal

Seconds

EMERG ACC 20 BDI CUTB 10 BDI CUTB TURTLE CUTB T CUTB SP1 T CUTB SP2 STOP RAMP T PK BRK MODE

See GRAPHIC C Controls the braking time if the emergency button is enabled See GRAPHIC K Controls the maximum speed when the battery indicator shows 20% residual charge Controls the maximum speed when the battery indicator shows 10% residual charge Controls the maximum speed when selecting the tortoise function Controls the maximum speed when there is no continuity between pin 1 and pin 2 on connector J23 Controls the maximum speed when the body guard gates are open Determines after how long the parking brakes are enabled when the truck is stopped Disables the automatic parking brake function

TUNING - TRACTION PARAMETER GRAPHICS

Seconds % max. speed % max. speed Km/h % max. speed % max. speed Seconds ON/OFF

MULTI-FUNCTION DISPLAY

3-35

3

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

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button (

): Modifies the parameter value

Button (

): Selects the POWER MODE (S-P-H-SPH)

Button ( ): Selects the operator profile (0-1-2-3) Button (O): Return to menu screen

3-36

MULTI-FUNCTION DISPLAY

Display option MIN SPEED UP

Description Controls the minimum speed of the hydraulic functions

Unit of measure Hz

MAX SPEED UP

See GRAPHIC M Controls the maximum speed of the hydraulic functions

Hz

TILT SPEED ATT1 SPEED ATT2 SPEED ATT3 SPEED HYDRO SPEED LIFT SMOOTH

See GRAPHIC M Controls the maximum tilt speed Controls the maximum speed of the ATT1 functions Controls the maximum speed of the ATT2 functions Controls the maximum speed of the ATT3 functions Controls the hydraulic steering speed for the 4 wheel version Controls the lifting valve closing time

Hz Hz Hz Hz Hz /

LOWER SMOOTH

See GRAPHIC O Controls the lowering valve closing time

/

P ACC DELAY P DEC DELAY CURVE MODE

See GRAPHIC O Controls the lift acceleration Controls the lift deceleration Selects the potentiometer sensitivity

P THROTTLE 0

See GRAPHIC L Determines point 0 on the lifting lever

P THROTTLE X

See GRAPHIC M Determines point 1 on the lifting lever

P THROTTLE Y

See GRAPHIC M Controls the speed at point 1 on the lifting lever

TORQUE PROF

See GRAPHIC M Selects the pump motor torque

20 BDI CUTB 10 BDI CUTB TURTLE CUTB P CUTB SP1 P CUTB SP2 ANGLE FW ANGLE BW

See GRAPHIC N Controls the maximum speed when the battery indicator shows 20% residual charge Controls the maximum speed when the battery indicator shows 10% residual charge Controls the maximum speed when selecting the tortoise function Unused.

Unused.

Determines the forward tilting in degrees to calculate the tilting degrees indicated on the display Determines the backward tilting in degrees to calculate the tilting degrees indicated on the display

Seconds Seconds / % potentiometer stroke % potentiometer stroke Hz / % max. speed % max. speed % max. speed % max. speed % max. speed Degrees Degrees

MULTI-FUNCTION DISPLAY

3-37

TUNING - M. HANDLING PARAMETER GRAPHICS

3

STEERING The STEERING menu is used to control the steering parameters on the 3 wheel version.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button (

): Modifies the parameter value

Button (

): Selects the POWER MODE (S-P-H-SPH)

Button ( ): Selects the operator profile (0-1-2-3) Button (O): Return to menu screen Display option I_STEER_L

Description Controls the steering hardness at low speed

Unit of measure Ampere

I_STEER_H

See GRAPHIC P Controls the steering hardness at high speed

Ampere

STEER_L_F

See GRAPHIC P Defines the low speed range

% max. speed

STEER_H_F

See GRAPHIC P Defines the high speed range

% max. speed

STEER_REV

See GRAPHIC P Controls the number of steering wheel turns from full right to full left

Hz

3-38

MULTI-FUNCTION DISPLAY

TUNING - STEERING PARAMETER GRAPHIC

VALVE SAS The VALVE SAS menu is used to control the SAS function parameters on the mast.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option 2ND COIL I 2ND SPEED

Description Controls the spool capacity of the tilt function when the mast height microswitch is open Controls the pump motor rpm of the tilt function when the mast height microswitch is open

Unit of measure % maximum current % max. speed

LIFT VALVE The LIFT VALVE menu is used to control the lowering and lifting valve currents.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen

MULTI-FUNCTION DISPLAY

3-39

Display option IMIN LOW

Description Minimum current supplied to the lowering valve

Unit of measure Ampere

IMIN LIFT

See GRAPHIC Q Minimum current supplied to the lifting valve

Ampere

IMAX LOW

See GRAPHIC Q Maximum current supplied to the lowering valve

Ampere

IMAX LIFT

See GRAPHIC Q 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.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option IMIN TILT FW

Description Minimum current supplied to the forward tilt valve

Unit of measure Ampere

IMIN TILT BW

See GRAPHIC Q Minimum current supplied to the backward tilt valve

Ampere

IMAX TILT FW

See GRAPHIC Q Maximum current supplied to the forward tilt valve

Ampere

IMAX TILT BW

See GRAPHIC Q Maximum current supplied to the backward tilt valve

Ampere

See GRAPHIC Q

3

3-40

MULTI-FUNCTION DISPLAY

TUNING - TILT VALVE PARAMETER GRAPHIC

ATT1 VALVE The ATT1 VALVE menu is used to control the valve currents of the ATT1 function.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option IMIN ATT1 1

Description Minimum current supplied to the ATT1 1 function valve

Unit of measure Ampere

IMIN ATT1 2

See GRAPHIC Q Minimum current supplied to the ATT1 2 function valve

Ampere

IMAX ATT1 1

See GRAPHIC Q Maximum current supplied to the ATT1 1 function valve

Ampere

IMAX ATT1 2

See GRAPHIC Q Maximum current supplied to the ATT1 2 function valve

Ampere

See GRAPHIC Q

MULTI-FUNCTION DISPLAY

3-41

TUNING - ATT1 VALVE PARAMETER GRAPHIC

3

ATT2 valve The ATT2 VALVE menu is used to control the valve currents of the ATT2 function.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option IMIN ATT2 1

Description Minimum current supplied to the ATT2 1 function valve

Unit of measure Ampere

IMIN ATT2 2

See GRAPHIC Q Minimum current supplied to the ATT2 2 function valve

Ampere

IMAX ATT2 1

See GRAPHIC Q Maximum current supplied to the ATT2 1 function valve

Ampere

IMAX ATT2 2

See GRAPHIC Q Maximum current supplied to the ATT2 2 function valve

Ampere

See GRAPHIC Q

3-42

MULTI-FUNCTION DISPLAY

TUNING - ATT2 VALVE PARAMETER GRAPHIC

ATT3 VALVE The ATT3 VALVE menu is used to enable the ATT3 function valve.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option ATT3 EN

Description Enables the 5th way valve pilot.

Unit of measure 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 installed, 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 (

): 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

MULTI-FUNCTION DISPLAY

3-43

OPTIONSET The OPTIONSET menu is used to disable the truck options.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option SPEED FORMAT DATE TYPE TILT IND LOAD ALM KNOB COMP SAS TILT EN AUTO SPEED LIFE HM MODE HYDRO DEL ACC HYDRO DEL BRK BELT SWITCH HIMAST RED CRV REDUCTION ANGLE START

Description Selects the unit of the speedometer Selects the date format in the DIAG MEMORY menu Enables the tilt degree indication on the display (DELUXE version only Selects the automatic or on request function of the overload alarm (DELUXE version only) Disables the steering wheel synchronization function Disables the mast SAS function Enables the AUTO SPEED CONTROL function Selects the hour meter format in the DIAG MEMORY menu Controls after how long the pump motor switches off after releasing the accelerator pedal (4 wheel version only) Controls after how long the pump motor switches off after releasing the brake pedal (4 wheel version only) Enables the ZLOC function Enables the speed reduction (12Km/h) when the truck is fitted with a mast > 6300 mm Enables the speed reduction in the curve (DELUXE 4 wheel version only) Defines the starting steering angle of speed reduction in the curve

Unit of measure Mph/Kmh D-M / M-D ON/OFF AUT/REQ ON/OFF ON/OFF / KH/WH Seconds Seconds ON/OFF ON/OFF ON/OFF Degrees

ANGLE INC

See GRAPHIC R / GRAPHIC S Defines the second steering angle of speed reduction in the curve

Degrees

ANGLE MAX

See GRAPHIC R / GRAPHIC S Defines the third steering angle of speed reduction in the curve

Degrees

CRV CUTB OUT

See GRAPHIC R / GRAPHIC S Controls the speed reduction in the curve at the angle ANGLE INC. Parameter valid when steering from straight wheels to turned wheels

% max. speed

CRV CUTB IN

See GRAPHIC R Controls the speed reduction in the curve at the angle ANGLE INC. Parameter valid when steering from turned wheels to straight wheels

% max. speed

CRV CUTB MAX

See GRAPHIC S Controls the speed reduction in the curve at the angle ANGLE MAX

% max. speed

See GRAPHIC R / GRAPHIC S

3

3-44 Display option ANGLE MAX 2

MULTI-FUNCTION DISPLAY Description Defines the fourth steering angle of speed reduction in the curve

Unit of measure Degrees

ANGLE STOP

See GRAPHIC R Defines the fifth steering angle of speed reduction in the curve

Degrees

MAX CURV CB

See GRAPHIC R 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.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option TIMER EN COUNT MODE SETTING RESET CURR CUT TIME T SPEED CUT P SPEED CUT BLINK TIME

Description Enables the maintenance hour meter Selects the maintenance hour meter unit of measurement Selects the maintenance hour meter time interval Resets the maintenance hour meter time Time which elapses between the alarm and the maintenance hour meter speed reductions Traction speed reduction when CUT TIME has elapsed Lifting speed reduction when CUT TIME has elapsed Defines the activation time of the maintenance indication

Unit of measure ON/OFF KH/WH KH/WH / KH/WH % max. speed % max. speed KH/WH

MULTI-FUNCTION DISPLAY

3-45

Speed

Speed

MAINTENANCE PARAMETER GRAPHICS

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.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option TIMER EN COUNT MODE SETTING TIME RESET CURR CUT TIME T SPEED CUT P SPEED CUT BLINK TIME

Description Enables the rental hour meter Selects the rental hour meter unit of measurement Selects the rental hour meter time interval Resets the rental hour meter time Time which elapses between the alarm and the rental hour meter speed reductions Traction speed reduction when CUT TIME has elapsed Lifting speed reduction when CUT TIME has elapsed Defines the activation time of the rental indication

Unit of measure ON/OFF KM/WH/DD KM/WH/DD / KM/WH/DD % max. speed % max. speed KM/WH/DD

3-46

MULTI-FUNCTION DISPLAY

Speed

Speed

RENT TIME PARAMETER GRAPHICS

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.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option Li-ION BATT BDI TO 100% BDI RESET

BDI GEL BDI MAX

Description Enables the battery indicator for the lithium batteries Instant reset of battery indicator to 100% Defines the minimum charge/discharge the battery must receive/undergo for a total or partial reset of the battery indicator Enables the battery indicator for the gel batteries Defines the battery indicator discharge curve

BDI MIN

See GRAPHIC T Defines the battery indicator discharge curve

/

RST VOLT MAX

See GRAPHIC T Defines the battery indicator reset curve

/

RST VOLT MIN

See GRAPHIC U Defines the battery indicator reset curve

/

See GRAPHIC U

Unit of measure ON/OFF % %

ON/OFF /

MULTI-FUNCTION DISPLAY

3-47

BATTERY PARAMETER GRAPHICS

3

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.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option DHU FLAG KEY PAD FLAG SHOCK SENSOR SMART ACCESS

Description Reset DHU card Reset pin code keypad Reset shock sensor Reset Smart Access

Unit of measure ON/OFF ON/OFF ON/OFF ON/OFF

ROT LAMP The ROT LAMP menu is used to enable the rotating lamp control.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen

3-48 Display option LAMP WITH TURTLE TRACTION ANY PUMP SEAT JOY1 JOY2 JOY3 JOY4 SPEED SPEED VALUE REVERSE PB ENABLED

MULTI-FUNCTION DISPLAY Description Enables the rotating lamp Enables the automatic rotating lamp switch-on when the turtle function is enabled Enables the automatic rotating lamp switch-on when movement is requested Enables the automatic rotating lamp switch-on when material handling functions are requested Enables the automatic rotating lamp switch-on when the seat microswitch is closed Enables the automatic rotating lamp switch-on when the 5th way function is enabled Unused.

Unused.

Unused.

Enables the automatic rotating lamp switch-on when the speed set via SPEED VALUE is reached Speed of SPEED parameter Enables the automatic rotating lamp switch-on when reverse drive is requested Enables the rotating lamp ignition button on the display

Unit of measure ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF Km/h ON/OFF ON/OFF

FLASH LAMP The FLASH LAMP menu is used to enable the flash lamp control.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option LAMP WITH TURTLE TRACTION ANY PUMP SEAT JOY1 JOY2 JOY3 JOY4 SPEED SPEED VALUE

Description Enables the flash lamp Enables the automatic flash lamp switch-on when the turtle function is enabled Enables the automatic flash lamp switch-on when movement is requested Enables the automatic flash lamp switch-on when material handling functions are requested Enables the automatic flash lamp switch-on when the seat microswitch is closed Enables the automatic flash lamp switch-on when the 5th way function is enabled Unused.

Unused.

Unused.

Enables the automatic flash lamp switch-on when the speed set via SPEED VALUE is reached Speed of SPEED parameter

Unit of measure ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF Km/h

MULTI-FUNCTION DISPLAY Display option REVERSE PB ENABLED

3-49

Description Enables the automatic flash lamp switch-on when reverse drive is requested Enables the flash lamp ignition button on the display

Unit of measure ON/OFF ON/OFF

3

DIPPED LIGHT The DIPPED LIGHT menu is used to enable the combined front light control.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option LAMP

Description Enables the combined front lights

Unit of measure ON/OFF

WORK LAMP The WORK LAMP menu is used to enable the work lights control.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option LAMP FW R LAMP FW L LAMP ADD LAMP MAST LAMP BW MOTION AUTO BW

Description Enables the right front working light Enables the left front working light Enables the additional front working lights Enables the additional front working lights on the mast Enables the rear working lights Enables the automatic rear working light switch-on and front working light switch-off when reverse drive is requested Enables the automatic rear working light switch-on when reverse drive is requested

Unit of measure ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF

WIPERS/WASHER The WIPERS/WASHER menu is used to enable the wind-screen wiper and washer pump control.

3-50

MULTI-FUNCTION DISPLAY Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option FW BW MOTION

AUTO BW WASHER FW WASHER BW

Description Enables the front wind-screen wiper Enables the rear wind-screen wiper Enables the automatic rear wind-screen wiper switch-on and front wind-screen wiper switch-off when reverse drive is requested Enables the automatic rear wind-screen wiper switch-on when reverse drive is requested Enables the front washer reservoir Enables the rear washer reservoir

Unit of measure ON/OFF ON/OFF ON/OFF

ON/OFF ON/OFF ON/OFF

DIR LIGHTS The DIR LIGHT menu is used to enable the direction indicator control.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option LIGHT

Description Enables the direction indicators

Unit of measure ON/OFF

HEATER The HEATER menu is used to enable the heated rear window and heated seat control.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option REAR W HEATER HEATED SEAT

Description Enables the heated rear window Enables the heated seat

Unit of measure ON/OFF ON/OFF

MULTI-FUNCTION DISPLAY

3-51

OPT OUT The OPT OUT menu is used to enable the optional light control.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option LAMP FW BW

Description Enables the optional lights Enables the automatic rotating lamp switch-on when forward drive is requested Enables the automatic rotating lamp switch-on when reverse drive is requested

Unit of measure ON/OFF ON/OFF ON/OFF

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 (

): 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

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 ( ): Indicates the selected option Button (I): Reset Button (

): Modifies the parameter value

Button (

): Modifies the parameter value

Button (

): Selects the next field

Button ( ): Selects the previous field Button (O): Return to menu screen

3

3-52

MULTI-FUNCTION DISPLAY 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 )

Disconnect and reconnect the battery

Disconnect and reconnect the battery

Press ( O )

FW/BW SELECTOR The FW/BW SELECTOR menu is used to select the type of drive direction control.

MULTI-FUNCTION DISPLAY

3-53 Button (

): Indicates the selected option

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen

Display option GEAR MODE

Value DBPEDAL SWPEDAL STEERCOL ARMREST MULTIJOY

Description Double pedal Swaying pedal Drive direction control on steering column Drive direction control on armrest Multifunction Joystick version drive direction control

DRIVE The DRIVE menu is used to acquire the accelerator, brake and steering potentiometer.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Enters the selected option

Button ( ): Enters the selected option Button (O): Return to menu screen

ACCEL Used to acquire the accelerator potentiometer.

3

3-54

MULTI-FUNCTION DISPLAY

Press (

)

Press ( I ) for 2 seconds Press the accelerator pedal (forward) to end stroke and release it slowly. Repeat the operation with the reverse pedal (if fitted on the truck) Press ( I ) OK: acquisition successful NG: acquisition failed

Press (

)

BRAKE Used to acquire the brake potentiometer.

Press (

)

Press ( I ) for 2 seconds Press the brake pedal fully down and release slowly

Press ( I ) OK: acquisition successful NG: acquisition failed

Press (

KNOB REST Used to acquire the steering wheel knob position (3 wheel version only).

)

MULTI-FUNCTION DISPLAY

3-55

Press (

)

3

Press ( I ) for 2 seconds Position the steering wheel with the TOYOTA logo straight

Press ( I )

ZERO POT Used to acquire the steering sensor (3 wheel version only).

Press (

)

Press ( I ) for 2 seconds Jack up the rear of the vehicle and position 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 SETP

Press ( I ) OK: acquisition successful NG: acquisition failed

Press (

STEER RANGE (3 wheel version) Used to acquire the steering sensor.

)

3-56

MULTI-FUNCTION DISPLAY

Press (

)

Press ( I ) for 2 seconds Turn the wheels fully right and then fully left

Press ( I )

STEER RANGE (4 wheel version) Used to acquire the steering sensor.

Press (

)

Press ( I ) for 2 seconds 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.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Enters the selected option

Button ( ): Enters the selected option Button (O): Return to menu screen

MULTI-FUNCTION DISPLAY

3-57

Standard version

Display option MULTIF. LEVER 1

Value ON OFF /

Description Configures the truck in multifunction Joystick mode Configures the truck in mini lever or mini joystick mode Used to acquire the lifting potentiometer Actions:

LEVER 2

/

▪ Push the lever fully forwards and then fully backwards and press ( I ) Used to acquire the tilting potentiometer Actions:

PB 3WAY LEVER 3

ATT1 ATT1+PB /

▪ Push the lever fully forwards and then fully backwards and press ( I ) Configures the third lever without button Configures the third lever with safety button Used to acquire the third lever potentiometer Actions:

PB 4WAY

ATT2 ATT2+PB ATT2/ATT3

LEVER 4

/

▪ Push the lever fully forwards and then fully backwards and press ( I ) Configures the fourth lever without safety button Configures the fourth lever with safety button Configures the fourth lever with safety button to enable the ATT3 function Used to acquire the fourth lever potentiometer Actions:

RESET ALL

/

▪ Push the lever fully forwards and then fully backwards and press ( I ) Deletes all lever acquisitions

Value ON OFF 3 4 5 NONE 3 4 5

Description Configures the truck in multifunction Joystick mode Configures the truck in mini lever or mini joystick mode Configures the truck with 3 hydraulic functions Configures the truck with 4 hydraulic functions Configures the truck with 5 hydraulic functions No hydraulic function is enabled with the safety button Configures the third way with safety button Configures the fourth way with safety button Configures the fifth way with safety button

Multifunction Joystick version

Display option MULTIF. NUM WAY

WAY WITH EN

SAS The SAS menu is used to acquire the pressure sensor and tilt angle potentiometer.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Enters the selected option

Button ( ): Enters the selected option Button (O): Return to menu screen

3

3-58 Display option TILT LEVEL

MULTI-FUNCTION DISPLAY Description Used to acquire the tilting angle potentiometer (mast in the vertical position) Actions:

TILT FW

▪ Set the mast in vertical position and press (I) Used to acquire the tilting angle potentiometer (mast tilted fully forward) Actions:

TILT BW

▪ Tilt the mast fully forward and press (I) Used to acquire the tilting angle potentiometer (mast tilted fully backward) Actions:

LOAD SENSOR

▪ Tilt the mast fully backward and press (I) Used to acquire the pressure sensor (mast height microswitch open) Actions:

RESET SAS

▪ Lift the forks without load until the mast height microswitch opens and press (I) 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).

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Enters the selected option

Button ( ): Enters the selected option Button (O): Return to menu screen Display option MAST TYPE ZERO SET 1

Description Selects the type of mast installed (V - FV - FSV - FW - FSW) Used to acquire the pressure sensor with the mast closed Actions:

ZERO SET 2

▪ Position the mast in the vertical position, lift the forks 500mm off the ground without load and press ( I ) for 2 seconds Used to acquire the tilting angle potentiometer (mast tilted fully forward) Actions:

COMPENSATION

▪ Position the mast in the vertical position, lift the forks without load until the mast height microswitch opens and press ( I ) for 2 seconds 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.

MULTI-FUNCTION DISPLAY

3-59 Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Enters the selected option

Button ( ): Enters the selected option Button (O): Return to menu screen Display option ENABLE MIN HEIGHT

Description Enables the H-SELECTOR option Used to acquire the height meter with the forks on the ground Actions:

MAX HEIGHT

▪ Tilt the mast fully backward, completely lower the forks and press (I) 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.

Button (

): Indicates the selected option

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen

Display option TYRE DATA

Description 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 (

): 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

METER START The METER START menu enables the truck hour meter.

3

3-60

MULTI-FUNCTION DISPLAY Button (I): Confirm Button (O): Return to menu screen

Display option METER START

Description Enables the truck hour meter

Unit of measure /

DEMO MODE The DEMO MODE menu enables the demo mode Button (

): Indicates the selected option

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen

Display option ENABLE

Description Enables the demo mode

Unit of measure ON/OFF

TO DEFAULT SET The TO DEFAULT TEST menu is used to reset the card parameters.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Enters the selected option

Button ( ): Enters the selected option Button (O): Return to menu screen Display option DISPLAY EVCB TRCB TR DRV TL DRV PM DRV ARM M ARM S EPS

Description Resetting of display parameters to their default values Resetting of EVCB card parameters to their default values Resetting of TRCB card parameters to their default values Resetting of right traction logic unit parameters to their default values Resetting of left traction logic unit parameters to their default values Resetting of lifting logic unit parameters to their default values Resetting of Master armrest card parameters to their default values Resetting of Slave armrest card parameters to their default values Resetting of EPS steering logic unit parameters to their default values

Unit of measure / / / / / / / / /

MULTI-FUNCTION DISPLAY

3-61

MASK PASSWORD The MASK PASSWORD menu enables the numeric password to access the MASK menu.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option ENABLE CHANGE

Description Enables the MASK menu password Edits the password (standard: 0000)

Unit of measure ON/OFF /

MANAGER PASS The MANAGER PASS menu enables the numeric password to access the MASK menu.

Button (

): Indicates the selected option

Button (

): Selects the previous parameter

Button (

): Selects the next parameter

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen Display option ENABLE

Description Disables the secondary password in the Administrator menu

Unit of measure ON/OFF

CONTRAST The CONTRAST menu sets the display contrast.

Button (

): Indicates the selected option

Button (

): Modifies the parameter value

Button ( ): Modifies the parameter value Button (O): Return to menu screen

Display option CONTRAST

Description Controls the display contrast

DELUXE MODE The DELUXE MODE menu enables the deluxe version of the display.

Unit of measure /

3

3-62

MULTI-FUNCTION DISPLAY Button (

): Indicates the selected option

Button (

): Modifies the parameter value

Button (

): Modifies the parameter value

Button ( ): Selects the next field Button (I): Confirm Button (O): Return to menu screen Display option DELUXE MODE

Description Enables the deluxe version of the display

Unit of measure 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 TEMPERATURE SENSOR CHECK PROCEDURE .............................................. 5 CAN-BUS CHECK PROCEDURE ......................................................................... 5 DIAGNOSTIC CODES LIST .................................................................................. 7 WHEN AN ERROR CODE IS DISPLAYED ......................................................... 23

4

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 contact with the terminal so as not to cause deformation of the connector terminal.

5) Do not touch connector terminals directly with your hand.

6) When bringing tester probes into contact with live terminals, 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 following procedure:

Continuity check 1. Disconnect the connectors at both ends of the corresponding harness.

2. Measure the resistance between corresponding terminals of the connectors at both ends.

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 careful 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 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.

Standard: 1 MΩ or higher 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 portion. Also, lightly pull the wire harness from the connector to check that it does not come off ▪ Insert a male terminal the same as that of the terminal to check into a female connector and check the force of extraction.

Defective contact may exist at a terminal where the extracting force is less than that of other terminals

NOTICE! Even if there is rust or foreign matter trapped at the terminal, or the contact pressure between male and female terminals is low, abnormal contact condition may be changed to normal by disconnecting and reconnecting the connector. In that case, repeat connector connection and disconnection several times. If defect is perceived even once, terminal contact may be defective.

The above information, concerning the inspection of the connectors, are referred to specific type as shown in the drawing. The same procedure must be apply for all type found on the machines.

INSULATION CHECK PROCEDURE When any trouble occurs, first inspect the truck insulation and its components, according to the following procedure:

4

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) Standard: 1 MΩ or higher 3. Measure the resistance between the truck plug negative and the chassis (unpainted surface) Standard: 1 MΩ or higher 4. Measure the resistance between the contactor contacts and the chassis (unpainted surface) Standard: 1 MΩ or higher

Battery insulation check 1. Disconnect the battery from the truck 2. Measure the resistance between the battery plug positive and the case (unpainted surface) Standard: 1 MΩ or higher 3. Measure the resistance between the battery plug negative and the case (unpainted surface) Standard: 1 MΩ or higher

Motor insulation check 1. Disconnect the battery from the truck 2. Measure the resistance between a phase and the motor body (unpainted surface) Standard: 1 MΩ or higher 3. Turning the rotor slowly by hand, measure the resistance between a phase and the motor body (unpainted surface) Standard: 1 MΩ or higher

Card insulation check 1. Disconnect the battery from the truck 2. Measure the resistance between a phase and the card body (unpainted surface) Standard: 1 MΩ or higher 3. Measure the resistance between the connector pins and the card body (unpainted surface) Standard: 1 MΩ or higher

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 1. Disconnect the battery from the truck 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

TEMPERATURE SENSOR CHECK PROCEDURE When trouble occurs, check the state of the temperature sensor, following the procedure described below:

Sensor integrity check 1. Disconnect the battery from the truck 2. Disconnect the sensor connector 3. Check the resistance value of the sensor Temperature 25 °C = 600 Ω

Sensor insulation check 1. Disconnect the battery from the truck 2. Disconnect the sensor connector 3. Measure the resistance between the sensor and the motor body (unpainted surface) Standard: 1 MΩ or higher

CAN-BUS CHECK PROCEDURE If fault codes associated with the Can-bus appear, follow the procedure described below:

4

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 Canbus, the number of the software version will be replaced by the message: NOT CONNECTED Having identified which card is not communicating on the Canbus 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

4

DIAGNOSTIC CODES LIST Current 108 [P 24]

Card EPS STEERING LOGIC UNIT

10D [P 24]

EPS STEERING LOGIC UNIT

110 [P 24]

EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT

111 [P 24] 120 [P 25] 130 [P 25] 135 [P 26] 13C [P 26]

13D [P 27] 141 [P 28]

EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT

Alarm WATCHDOG

Description Internal communication problem between the MASTER and SLAVE microcontrollers on the EPS steering logic unit EEPROM KO Problem with the memory in the EPS steering logic unit: the EPS steering logic unit has reloaded the default parameters LOGIC FAILURE #4 Problem with the EPS steering logic unit power circuit LOGIC FAILURE #3 Problem with the EPS steering logic unit power circuit VMN NOT OK Problem with the EPS steering logic unit power circuit MAIN CONT OPEN Contactor K7 detected open despite being piloted by the EPS steering logic unit STBY I HIGH Problem with the EPS steering logic unit power circuit CAPACITOR CHARGE Problem with EPS steering unit power capacitor - no increase in capacitor voltage HIGH TEMPERATURE EPS steering logic unit overheating alarm - t > 80°C detected MOTOR TEMPERATURE Steering motor overheating alarm - t > 120°C detected

4-8 Current 146 [P 28] 147 [P 28] 148 [P 29] 149 [P 29] 162 [P 29] 1D2 [P 30] 1D3 [P 30] 1D4 [P 31] 1D5 [P 31] 1D6 [P 31] 1D7 [P 32]

1D8 [P 32] 1DA [P 33] 1DC [P 33] 1DD [P 33] 1DF [P 34] 1E1 [P 34] 1E4 [P 34] 1EB [P 34] 1EC [P 35] 1ED [P 36] 1F1 [P 36] 1F4 [P 36] 1F5 [P 37] 1F7 [P 37]

1F8 [P 37]

TROUBLESHOOTING Card EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT

Alarm HIGH CURRENT

EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT

TFD WRONG RESIST

EPS STEERING LOGIC UNIT

SP OUT OF RANGE

POWER FAILURE #3 POWER FAILURE #2 POWER FAILURE #1 INPUT ERROR #1 WRONG SLAVE VER TFD FEEDB ERROR WRONG RAM MEMORY PARAM RESTORE SP JERK CAN BUS KO M/S

CONTROLLER MISMATCH MOTOR LOCKED M/S PAR CHK MISM FB JERK CURRENT GAIN

Description Problem with the EPS steering logic unit power circuit Low current detected on the W phase of the EPS steering logic unit Low current detected on the V phase of the EPS steering logic unit Low current detected on the U phase of the EPS steering logic unit Problem on the TFD sensor signals Incorrect software version of the EPS SLAVE steering logic unit detected Problem on the TFD sensor signals Problem with the memory of the EPS steering logic unit The EPS steering logic unit has run the reset Problem on the TFD sensor signals Internal communication problem between the MASTER and SLAVE microcontrollers on the EPS steering logic unit Problem with the TFD sensor configuration Incorrect software detected Locked steering motor detected Problem with the parameters memory of the EPS steering logic unit Steering motor encoder problem

POSITION ERROR

Problem with the EPS steering logic unit power circuit Incorrect steering axle position detected

TFD SHRT/VOLT KO

TFD sensor problem

TFD STB I HIGH

TFD sensor problem

SLAVE ALARM XX

Problem inside the SLAVE microcontroller of the EPS steering logic unit Steering motor encoder problem

FB SENSOR LOCKED PARAM TRANSFER DATA ACQUISITION CAN BUS KO

Problem with the parameters memory of the EPS steering logic unit Problem with the steering motor value acquisition Problem with communication on Canbus line - EPS steering logic unit not receiving messages from other cards TFD sensor problem

TROUBLESHOOTING Current 1FB [P 38]

4-9

Card EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT EPS STEERING LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

Alarm INIT VMN NOT OK

204 [P 41]

RIGHT TRACTION LOGIC UNIT

LOGIC FAILURE #2

205 [P 42]

RIGHT TRACTION LOGIC UNIT

LOGIC FAILURE #1

206 [P 43]

RIGHT TRACTION LOGIC UNIT

VMN LOW

207 [P 44]

RIGHT TRACTION LOGIC UNIT

VMN HIGH

208 [P 45]

RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

CONTACTOR OPEN

1FC [P 38] 1FD [P 39] 1FE [P 39] 201 [P 40] 202 [P 40] 203 [P 40]

209 [P 45] 20A [P 46] 20C [P 46] 20D [P 46] 20E [P 47] 210 [P 48]

211 [P 49] 212 [P 50] 213 [P 50] 214 [P 51] 216 [P 51]

RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

TWIN POT MISMAT ANALOG NO SP REFRESH WATCHDOG BATTERY LOW LOGIC FAILURE #3

STBY I HIGH INCORRECT START FORW+BACK

Description Problem with the EPS steering logic unit power circuit Steering sensor problem Problem with the analog signals of the EPS steering logic unit TFD sensor problem Problem during right traction logic unit self-test routine Incorrect battery voltage value Problem with right traction logic unit power circuit - high current overload protection Problem with section of right traction logic unit hardware monitoring voltage feedback signal from right drive motor phases Problem with right traction logic unit power circuit - low voltage condition detected Problem with right traction logic unit power circuit - low right drive motor voltage condition detected Problem with right traction logic unit power circuit - right drive motor overvoltage condition detected Contactor K7 detected open despite being piloted by right traction logic unit Abnormal level of current detected at rigt drive motor in stand-by status Start sequence incorrect

Incorrect start: forward drive and reverse drive directions selected simultaneously HARDWARE FAULT Problem with right traction logic unit power circuit POWER MOS SHORTED Problem with right traction logic unit power circuit CAPACITOR CHARGE Problem with right traction logic unit power capacitor - no increase in capacitor charge voltage.

THERMIC PROTECTION Right traction logic unit temperature rise alarm - t > 85°C detected MOTOR TEMPERATURE Right drive motor temperature rise alarm - t > 150°C detected ENCODER ERROR Problem with signals generated by right drive motor rpm sensor THERMIC SENS. KO Right drive motor temperature sensor generating values out of range NO CAN MSG Problem with communication on Canbus line - right traction logic unit not receiving messages from other cards

4

4-10

TROUBLESHOOTING

Current 219 [P 51]

Card RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

Alarm DRIVER SHORTED

RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

CONTACTOR CLOSED

RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

CONTACTOR DRIVER

RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

WRONG SET BATTERY

227 [P 58]

RIGHT TRACTION LOGIC UNIT

EEPROM KO

228 [P 58]

RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

VDC LINK OVERV

RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

PEV NOT OK

233 [P 61]

RIGHT TRACTION LOGIC UNIT

STEER ACQ

234 [P 62]

RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

WRONG RAM MEM

21B [P 52] 21C [P 52] 21D [P 53]

21E [P 54] 21F [P 54]

220 [P 55] 221 [P 55] 224 [P 56]

225 [P 57] [P 57]

22C [P 59] 22F [P 59]

230 [P 60] 231 [P 60] 232 [P 61]

235 [P 62] 236 [P 62] 23A [P 62]

SENS MOT TEMP KO VDC OFF SHORTED STALL ROTOR

MIS. SETPOINT

MC COIL SHORTED INIT VMN HIGH

INIT VMN LOW

CURRENT GAIN NO SLAVE ENABLE

VKEY OFF SHORTED TEACH VACC POT

STEER OUT OF RANGE HANDBRAKE COIL SHOR. EB

Description Problem with driver circuit controlling contactor K1 Right drive motor temperature sensor generating values out of range Low voltage detected Problem with signals generated by rpm sensor, or rotor of right drive motor stalled Right traction logic unit detects contactor K1 closed at power up Inconsistency between the right traction logic unit and the TRCB card detected on the drive motor phase frequency Problem with driver circuit controlling contactor K1 Problem with coil of contactor K1 Problem with right traction logic unit power circuit - right drive motor overvoltage condition detected Detection of battery voltage 20% higher than nominal value Problem with right traction logic unit power circuit - low right drive motor voltage condition detected Problem with the memory in the right traction logic unit: the right traction logic unit has reloaded the default parameters Overvoltage detected Problem with current monitoring circuit of right traction logic unit Communication problem between the MASTER and SLAVE microcontrollers on the right traction logic unit The right traction logic unit does not receive +48V. Problem with power up circuit: key line Right traction logic circuit has no acquisition values from accelerator potentiometer stored in memory Traction logic unit has no steering sensor acquisition values stored in memory Incorrect values detected in right traction logic unit RAM memory Steering sensor generating values different from those stored in memory Incorrect starting procedure: drive control selected with parking brake on Problem with the right parking brake coil

TROUBLESHOOTING Current 23C [P 63] 23D [P 63] 241 [P 63] 242 [P 64] 243 [P 64] 244 [P 64] 245 [P 65] 248 [P 65] 24C [P 66] 24D [P 66] 24E [P 66] 24F [P 66] 250 [P 66]

251 [P 67] 252 [P 67] 253 [P 67]

25B [P 67] 301 [P 68] 302 [P 68] 303 [P 68]

304 [P 69]

305 [P 70]

306 [P 71]

Card RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT RIGHT TRACTION LOGIC UNIT

4-11 Alarm ANALOG INPUT CONTROLLER MISMATCH IQ MISMATCHED AUX DRIV. OPEN CHECK UP NEEDED FIELD ORIENT. KO

Description Problem with signal monitoring circuit of right traction logic unit Problem with software of right traction logic unit Detection of inconsistency between current values of right traction logic unit Problem in the right parking brake coil control Maintenance hour counter warning

Problem with right drive motor field orientation circuit AUX DRIV. SHRT Problem in the right parking brake coil control WRONG ENCODER SET Incorrect setting of the right drive motor speed sensor detected PARAM TRANSFERT Problem with the parameters memory of the right traction logic unit EMERGENCY SWITCH Incorrect ignition sequence: emergency button on STOP RQ FROM EPS EPS steering unit has detected a problem and has inhibited the traction WRONG SLAVE VERIncorrect software version of the SLAVE SION right traction logic unit detected NO CAN MSG EPS Problem with communication on Canbus line: right traction logic unit not receiving messages from EPS steering logic unit RIGHT TRACTION LO- STOP FROM EPS EPS steering unit has detected a probGIC UNIT lem and has inhibited the traction RIGHT TRACTION LO- EPS IS ONLINE Incorrect configuration between 3 wheel GIC UNIT and 4 wheel version detected RIGHT TRACTION LO- TEACH BRK POT Right traction logic circuit has no acquisGIC UNIT ition values from brake potentiometer stored in memory RIGHT TRACTION LO- M/S PAR CHK MISM Problem with the parameters memory of GIC UNIT the right traction logic unit LEFT TRACTION LOGIC WATCHDOG Problem during left traction logic unit UNIT self-test routine LEFT TRACTION LOGIC BATTERY LOW Incorrect battery voltage value UNIT LEFT TRACTION LOGIC LOGIC FAILURE #3 Problem with left traction logic unit UNIT power circuit - high current overload protection LEFT TRACTION LOGIC LOGIC FAILURE #2 Problem with section of left traction logic UNIT unit hardware monitoring voltage feedback signal from left drive motor phases LEFT TRACTION LOGIC LOGIC FAILURE #1 Problem with left traction logic unit UNIT power circuit - low voltage condition detected LEFT TRACTION LOGIC VMN LOW Problem with left traction logic unit UNIT power circuit - low left drive motor voltage condition detected

4

4-12 Current 307 [P 72]

308 [P 73] 309 [P 73] 30A [P 74] 30C [P 74] 30D [P 74] 30E [P 75] 310 [P 76]

311 [P 77] 312 [P 78] 313 [P 78] 314 [P 79] 316 [P 79]

319 [P 79] 31B [P 80] 31C [P 80] 31D [P 81] 31E [P 82] 31F [P 82]

320 [P 83] 321 [P 83] 324 [P 84]

325 [P 85] 326 [P 85]

TROUBLESHOOTING Card Alarm LEFT TRACTION LOGIC VMN HIGH UNIT LEFT TRACTION LOGIC CONTACTOR OPEN UNIT LEFT TRACTION LOGIC STBY I HIGH UNIT LEFT TRACTION LOGIC INCORRECT START UNIT LEFT TRACTION LOGIC FORW+BACK UNIT LEFT TRACTION LOGIC HARDWARE FAULT UNIT LEFT TRACTION LOGIC POWER MOS SHORTED UNIT LEFT TRACTION LOGIC CAPACITOR CHARGE UNIT

Description Problem with left traction logic unit power circuit - left drive motor overvoltage condition detected Contactor K7 detected open despite being piloted by left traction logic unit Abnormal level of current detected at left drive motor in stand-by status Start sequence incorrect

Incorrect start: forward drive and reverse drive directions selected simultaneously Problem with left traction logic unit power circuit Problem with left traction logic unit power circuit Problem with left traction logic unit power capacitor - no increase in capacitor charge voltage LEFT TRACTION LOGIC THERMIC PROTECTION Left traction logic unit temperature rise UNIT alarm - t > 85°C detected LEFT TRACTION LOGIC MOTOR TEMPERATURE Left drive motor temperature rise alarm UNIT t > 150°C detected LEFT TRACTION LOGIC ENCODER ERROR Problem with signals generated by left UNIT drive motor rpm sensor LEFT TRACTION LOGIC THERMIC SENS. KO Left drive motor temperature sensor UNIT generating values out of range LEFT TRACTION LOGIC NO CAN MSG Problem with communication on CanUNIT bus line - left traction logic unit not receiving messages from other cards LEFT TRACTION LOGIC DRIVER SHORTED Problem with driver circuit controlling UNIT contactor K1 LEFT TRACTION LOGIC SENS MOT TEMP KO Left drive motor temperature sensor UNIT generating values out of range LEFT TRACTION LOGIC VDC OFF SHORTED Low voltage detected UNIT LEFT TRACTION LOGIC STALL ROTOR Problem with signals generated by rpm UNIT sensor, or rotor of left drive motor stalled LEFT TRACTION LOGIC CONTACTOR CLOSED Left traction logic unit detects contactor UNIT K1 closed at power up LEFT TRACTION LOGIC MIS. SETPOINT Inconsistency between the left traction UNIT logic unit and the TRCB card detected on the drive motor phase frequency LEFT TRACTION LOGIC CONTACTOR DRIVER Problem with driver circuit controlling UNIT contactor K1 LEFT TRACTION LOGIC MC COIL SHORTED Problem with coil of contactor K1 UNIT LEFT TRACTION LOGIC INIT VMN HIGH Problem with left traction logic unit UNIT power circuit - left drive motor overvoltage condition detected LEFT TRACTION LOGIC WRONG SET BATTERY Detection of battery voltage 20% higher UNIT than nominal value LEFT TRACTION LOGIC INIT VMN LOW Problem with left traction logic unit UNIT power circuit - low left drive motor voltage condition detected

TROUBLESHOOTING Current 327 [P 86]

328 [P 86] 32C [P 87] 32F [P 87]

330 [P 88] 331 [P 88] 332 [P 89]

Card Alarm LEFT TRACTION LOGIC EEPROM KO UNIT LEFT TRACTION LOGIC VDC LINK OVERV UNIT LEFT TRACTION LOGIC CURRENT GAIN UNIT LEFT TRACTION LOGIC NO SLAVE ENABLE UNIT LEFT TRACTION LOGIC PEV NOT OK UNIT LEFT TRACTION LOGIC VKEY OFF SHORTED UNIT LEFT TRACTION LOGIC TEACH VACC POT UNIT

333 [P 89]

LEFT TRACTION LOGIC STEER ACQ UNIT

334 [P 90]

LEFT TRACTION LOGIC WRONG RAM MEM UNIT LEFT TRACTION LOGIC STEER OUT OF RANGE UNIT LEFT TRACTION LOGIC HANDBRAKE UNIT LEFT TRACTION LOGIC COIL SHOR. EB UNIT LEFT TRACTION LOGIC ANALOG INPUT UNIT LEFT TRACTION LOGIC CONTROLLER MISUNIT MATCH LEFT TRACTION LOGIC IQ MISMATCHED UNIT LEFT TRACTION LOGIC AUX DRIV. OPEN UNIT LEFT TRACTION LOGIC CHECK UP NEEDED UNIT LEFT TRACTION LOGIC FIELD ORIENT. KO UNIT LEFT TRACTION LOGIC AUX DRIV. SHRT UNIT LEFT TRACTION LOGIC WRONG ENCODER SET UNIT LEFT TRACTION LOGIC PARAM TRANSFERT UNIT LEFT TRACTION LOGIC EMERGENCY SWITCH UNIT LEFT TRACTION LOGIC STOP RQ FROM EPS UNIT LEFT TRACTION LOGIC WRONG SLAVE VERUNIT SION

335 [P 90] 336 [P 90] 33A [P 90] 33C [P 91] 33D [P 91] 341 [P 91] 342 [P 92] 343 [P 92] 344 [P 92] 345 [P 93] 348 [P 93] 34C [P 94] 34D [P 94] 34E [P 94] 34F [P 94]

4-13 Description Problem with the memory in the left traction logic unit: the left traction logic unit has reloaded the default parameters Overvoltage detected Problem with current monitoring circuit of left traction logic unit Communication problem between the MASTER and SLAVE microcontrollers on the left traction logic unit The left traction logic unit does not receive +48V. Problem with power up circuit: key line Left traction logic circuit has no acquisition values from accelerator potentiometer stored in memory Traction logic unit has no steering sensor acquisition values stored in memory Incorrect values detected in left traction logic unit RAM memory Steering sensor generating values different from those stored in memory Incorrect starting procedure: drive control selected with parking brake on Problem with the left parking brake coil Problem with signal monitoring circuit of left traction logic unit Problem with software of left traction logic unit Detection of inconsistency between current values of left traction logic unit Problem in the left parking brake coil control Maintenance hour counter warning Problem with left drive motor field orientation circuit Problem in the left parking brake coil control Incorrect setting of the left drive motor speed sensor detected Problem with the parameters memory of the left traction logic unit Incorrect ignition sequence: emergency button on EPS steering unit has detected a problem and has inhibited the traction Incorrect software version of the SLAVE left traction logic unit detected

4

4-14

TROUBLESHOOTING

Current 350 [P 94]

Card Alarm LEFT TRACTION LOGIC NO CAN MSG EPS UNIT

351 [P 95]

LEFT TRACTION LOGIC STOP FROM EPS UNIT LEFT TRACTION LOGIC EPS IS ONLINE UNIT LEFT TRACTION LOGIC TEACH BRK POT UNIT

352 [P 95] 353 [P 95]

35B [P 95]

453 [P 96]

LEFT TRACTION LOGIC M/S PAR CHK MISM UNIT MCB - TRCB CARD WRONG BATTERY MCB - TRCB CARD ACC WRONG PARAMETER MCB - TRCB CARD BAD EMERGENCY SWITCH MCB - TRCB CARD ACC ZAPI MISMATCH

454 [P 96]

MCB - TRCB CARD

45A [P 96]

MCB - TRCB CARD

494 [P 97] 496 [P 97] 4A7 [P 97] 4B6 [P 97]

MCB - TRCB CARD MCB - TRCB CARD MCB - TRCB CARD MCB - TRCB CARD

4C1 [P 98] 4C2 [P 98]

MCB - TRCB CARD MCB - TRCB CARD

4C3 [P 98]

MCB - TRCB CARD

4C4 [P 98]

MCB - TRCB CARD

4C6 [P 99]

MCB - TRCB CARD

4C7 [P 99]

MCB - TRCB CARD

430 [P 96] 450 [P 96] 452 [P 96]

4C8 [P 100] MCB - TRCB CARD 4C9 [P 100] MCB - TRCB CARD 4CA [P 100] MCB - TRCB CARD 4CB [P 101] MCB - TRCB CARD

Description Problem with communication on Canbus line: left traction logic unit not receiving messages from EPS steering logic unit EPS steering unit has detected a problem and has inhibited the traction Incorrect configuration between 3 wheel and 4 wheel version detected Left traction logic circuit has no acquisition values from brake potentiometer stored in memory Problem with the parameters memory of the left traction logic unit Incorrect battery configuration detected Incorrect traction parameter values detected Problem with the emergency button

Inconsistency detected between the accelerator potentiometer readings of the right traction logic unit and the MCB card BRAKE ZAPI MISMATCH Inconsistency detected between the accelerator potentiometer readings of the right traction logic unit and the MCB card LHS ERR Problem with signal generated by mast height switch K4 CHKSUM ERROR Problem with memory of TRCB card RELOAD PARAM WARN Problem with memory of TRCB card EVP CURR MISMATCH Problem with the distributor valve control DASH KO Problem with communication on Canbus line: TRCB card not receiving messages from display INCORRECT START Incorrect starting procedure.

BRAKE WIRE KO Problem with signal generated by brake potentiometer BAD MICROSWITCH Problem with microswitches of accelerator pedal or hand direction lever BAD MICROSWITCH Problem with microswitches accelerator pedal or hand direction lever or direction control configuration BAD VACC Accelerator potentiometer generating values different from those stored in memory ERR SEAT Incorrect starting procedure: seat or seat belt microswitch open TRACTION LOCK Detection of inconsistency in signals associated with drive direction PARKING SELECTED Incorrect starting procedure: parking brake microswitch open PAR LOAD ERROR Problem with TRCB card parameters memory TRAC IN ALARM Traction logic alarm detected

TROUBLESHOOTING Current Card 4CC [P 101] MCB - TRCB CARD

4CD [P 101] MCB - TRCB CARD

4CE [P 101] MCB - TRCB CARD 4CF [P 101] MCB - TRCB CARD 4F1 [P 101]

MCB - TRCB CARD

4F2 [P 102]

MCB - TRCB CARD

4F5 [P 102]

MCB - TRCB CARD

4FA [P 103] MCB - TRCB CARD 4FB [P 103] MCB - TRCB CARD 4FC [P 103] MCB - TRCB CARD 4FD [P 104] MCB - TRCB CARD 5A0 [P 105] LIFT LOGIC UNIT 5A1 [P 105]

LIFT LOGIC UNIT

5A2 [P 105]

LIFT LOGIC UNIT

5A3 [P 106]

LIFT LOGIC UNIT

5A4 [P 107]

LIFT LOGIC UNIT

5A5 [P 108]

LIFT LOGIC UNIT

5A6 [P 109] 5A7 [P 110]

LIFT LOGIC UNIT LIFT LOGIC UNIT

5A8 [P 110]

LIFT LOGIC UNIT

5A9 [P 111]

LIFT LOGIC UNIT

5AA [P 111] LIFT LOGIC UNIT

5AB [P 112] LIFT LOGIC UNIT 5AC [P 113] LIFT LOGIC UNIT

5AD [P 114] LIFT LOGIC UNIT 5AE [P 114] LIFT LOGIC UNIT

4-15 Alarm TRAC STUFFING ERR

Description Problem with communication on Canbus line: TRCB card not receiving messages from traction logic unit JOY MSG LOST Problem with communication on Canbus line: TRCB card not receiving messages from armrest card BRAKE BAD VACC Brake potentiometer generating values different from those stored in memory STEER ENCODER KO Problem with signal from steering encoder STEER SENSOR KO Problem with signal from steering encoder INT INDEX ERROR Problem with signal from steering encoder STEER LOAD OPEN Problem with knob synchronizer valve coil STEER LOAD SHORTED Problem with knob synchronizer valve coil SWING LOAD OPEN Problem with oscillation lock cylinder valve coil SWING LOAD SHORTED Problem with oscillation lock cylinder valve coil V BAT KO The TRCB card does not receive +48V ANALOG INPUT Problem with signal monitoring circuit of lift logic unit COIL SHORT HW KO Problem with coils connected to auxiliary outputs of lift logic unit LOGIC FAILURE #3 Problem with lift logic unit power circuit: high current overload protection CAPACITOR CHARGE Problem with lift logic unit power capacitor: no increase in capacitor charge voltage VMN LOW Problem with lift logic unit power circuit: low motor voltage condition detected DRIVER SHORTED Problem with driver circuit controlling contactor K1 MC COIL SHORT Problem with coil of contactor K1 VMN HIGH Problem with lift logic unit power circuit: motor overvoltage condition detected STBY I HIGH Abnormal level of current detected at pump motor in stand-by status CONTACTOR OPEN Contactor K7 detected open despite being piloted by right traction logic unit AUX DRIV. SHRT Problem with driver circuit controlling coil connected to auxiliary output of lift logic unit LOGIC FAILURE #1 Problem with lift logic unit power circuit: low voltage condition detected LOGIC FAILURE #2 Problem with hardware section of lift logic unit monitoring voltage feedback signal from motor phases SAFETY INPUT Problem with SAFETY signal on input side CONTACTOR DRIVER Problem with driver circuit controlling contactor K1

4

4-16

TROUBLESHOOTING

Current Card 5AF [P 115] LIFT LOGIC UNIT 5B0 [P 115] 5B1 [P 116]

LIFT LOGIC UNIT LIFT LOGIC UNIT

5B2 [P 116]

LIFT LOGIC UNIT

5B3 [P 116]

LIFT LOGIC UNIT

5B4 [P 117]

LIFT LOGIC UNIT

5B5 [P 117] 5B6 [P 118]

LIFT LOGIC UNIT LIFT LOGIC UNIT

5B7 [P 118]

LIFT LOGIC UNIT

5B8 [P 118]

LIFT LOGIC UNIT

5B9 [P 119] 5BA [P 119] 5BB [P 120] 5BC [P 121]

LIFT LOGIC UNIT LIFT LOGIC UNIT LIFT LOGIC UNIT LIFT LOGIC UNIT

5BD [P 121] LIFT LOGIC UNIT 5BE [P 122] LIFT LOGIC UNIT 5BF [P 122] LIFT LOGIC UNIT 5C1 [P 123] LIFT LOGIC UNIT 5C2 [P 123] LIFT LOGIC UNIT 5C3 [P 124] LIFT LOGIC UNIT 5C4 [P 124] LIFT LOGIC UNIT

5C5 [P 125] LIFT LOGIC UNIT 5C7 [P 125] LIFT LOGIC UNIT 5C8 [P 126] LIFT LOGIC UNIT 5C9 [P 126] LIFT LOGIC UNIT 5CA [P 126] 5CB [P 127] 5CC [P 127] 5CD [P 127] 659 [P 128]

LIFT LOGIC UNIT LIFT LOGIC UNIT LIFT LOGIC UNIT LIFT LOGIC UNIT MCB - EVCB CARD

Alarm THERMIC PROTECTION

Description Lift logic unit overheating alarm: t > 85°C detected EEPROM KO Problem with memory of lift logic unit MOTOR TEMPERATURE Pump motor overheating alarm: t > 150°C detected WRONG SET BAT Detection of battery voltage 20% higher than nominal value THERMIC SENS. KO Pump motor temperature sensor generating values out of range AUX COIL SHORT Problem with coil connected to auxiliary output of lift logic unit CHECK UP NEEDED Maintenance hour counter warning NO CAN MSG Problem with communication on Canbus line: lift logic unit not receiving messages from other cards AUX DRIV. OPEN Problem with driver circuit controlling coil connected to auxiliary output of lift logic unit SAFETY OUTPUT Problem with SAFETY signal on output side KEY OFF SHORT Problem with power up circuit: key line HARDWARE FAULT Problem with lift logic unit power circuit POWER MOS SHORT Problem with lift logic unit power circuit CONTACTOR CLOSED Lift logic unit detects contactor K1 closed at power up ENCODER ERROR Problem with signals generated by pump motor rpm sensor WATCHDOG #1 Problem during lift logic unit self-test routine WATCHDOG #2 Problem during lift logic unit self-test routine WRONG RAM MEMORY Incorrect values detected in lift logic unit RAM SENS MOT TEMP KO Pump motor temperature sensor generating values out of range CURRENT GAIN Problem with current monitoring circuit of lift logic unit WRONG 0 VOLTAGE Problem with hardware section of lift logic unit monitoring voltage feedback signal from motor phases TORQUE PROFILE Detection of inconsistencies in torque values saved to memory ENCODER LOCKED Problem with signals generated by pump motor rpm sensor FOC LOST Problem with pump motor field orientation circuit IQ MISMATCHED Detection of inconsistency between current values of lift logic unit PROG VACC NOT OK Fault code not utilized TEACH SWING POT Fault code not utilized STEER OUT RANGE Fault code not utilized TEACH STEER POT Fault code not utilized PSV ERR Problem with mast pressure sensor

TROUBLESHOOTING Current 65A [P 128]

4-17

Card MCB - EVCB CARD

Alarm LHS ERR

65B [P 128] MCB - EVCB CARD 65D [P 129] MCB - EVCB CARD

TAS ERR WMV ERR

65E [P 129] 6A1 [P 129]

MCB - EVCB CARD MCB - EVCB CARD

LHP ERR DOUBLE REQUEST

6A2 [P 130]

MCB - EVCB CARD

RELOAD PARAM WARN

6A3 [P 130] 6A4 [P 130]

MCB - EVCB CARD MCB - EVCB CARD

PAR LOAD ERROR NOT REP ERROR

6A7 [P 130]

MCB - EVCB CARD

P SHORT ERR

6A8 [P 130]

MCB - EVCB CARD

EV1 1 OPEN

6A9 [P 131]

MCB - EVCB CARD

EV2 1 OPEN

6AA [P 131] MCB - EVCB CARD

EV1 2 OPEN

6AB [P 131] MCB - EVCB CARD

EV2 2 OPEN

6AC [P 132] MCB - EVCB CARD

EV1 3 OPEN

6AD [P 132] MCB - EVCB CARD

EV2 3 OPEN

6AE [P 132] MCB - EVCB CARD

EV1 4 OPEN

6AF [P 133] MCB - EVCB CARD

EV2 4 OPEN

6B1 [P 133]

MCB - EVCB CARD

DRIVER EV1 SHORTED

6B2 [P 133]

MCB - EVCB CARD

DRIVER EV2 SHORTED

6B3 [P 134]

MCB - EVCB CARD

DRIVER EV3 SHORTED

6B4 [P 134]

MCB - EVCB CARD

DRIVER EV4 SHORTED

6B6 [P 135]

MCB - EVCB CARD

DASH KO

6B7 [P 135] 6B8 [P 135]

MCB - EVCB CARD MCB - EVCB CARD

SEAT ERR JOY STUFFING ERR

6BA [P 135] MCB - EVCB CARD 6BB [P 136] MCB - EVCB CARD

DR PMOS LOCK LOAD 1 SHORTED

6BC [P 136] MCB - EVCB CARD

LOAD 2 SHORTED

6BD [P 136] MCB - EVCB CARD

LOAD 3 SHORTED

Description Problem with signal at mast height switch Problem with tilt angle potentiometer Problem with tilt angle potentiometer or pressure sensor Problem with fork height potentiometer Selection of two commands attempted on the same way Default parameters reloaded by EVCB card at power up Problem with memory of EVCB card Problem with communication on Canbus line: EVCB card not receiving messages Problem with circuit piloting solenoid valves Descent valve coil disconnected: EVCB card detects no load at the coil Lift valve coil disconnected: EVCB card detects no load at the coil Tilt valve coil disconnected: EVCB card detects no load at the coil Tilt valve coil disconnected: EVCB card detects no load at the coil Sideshift valve coil disconnected: EVCB card detects no load at the coil Sideshift valve coil disconnected: EVCB card detects no load at the coil 4th way valve coil disconnected: EVCB card detects no load at the coil 4th way valve coil disconnected: EVCB card detects no load at the coil Problem with circuit piloting descent and lift solenoid valves Problem with circuit piloting tilt solenoid valves Problem with circuit piloting sideshift solenoid valves Problem with driver circuit piloting valves of 4th way Problem with communication on Canbus line: EVCB card not receiving messages from DISPLAY Incorrect starting procedure.

Problem with communication on Canbus line: EVCB card not receiving messages from armrest card Internal fault in the EVCB card Problem with circuit piloting descent and lift solenoid valves: coil short-circuiting Problem with circuit piloting tilt solenoid valves: coil short-circuiting Problem with circuit piloting sideshift solenoid valves: coil short-circuiting

4

4-18

TROUBLESHOOTING

Current Card 6BE [P 137] MCB - EVCB CARD

Alarm LOAD 4 SHORTED

6E1 [P 137]

6EE [P 137] MCB - EVCB CARD

PUMP INCORRECT START PUMP STUFFING ERR

6F3 [P 137]

MCB - EVCB CARD

NYM ERR

6F4 [P 138] 8E1 [P 138]

MCB - EVCB CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD MASTER ARMREST CARD

INCORRECT START INCORRECT START

8EE [P 141] MASTER ARMREST CARD 8EF [P 141] MASTER ARMREST CARD A01 [P 142] LITHIUM BATTERY

INCORRECT START TRAC FW BW

8E2 [P 138] 8E3 [P 138] 8E4 [P 138] 8E5 [P 139] 8E6 [P 139] 8E7 [P 139] 8E8 [P 139] 8E9 [P 140] 8EA [P 140] 8EB [P 140] 8EC [P 140] 8ED [P 141]

MCB - EVCB CARD

A02 [P 142] A03 [P 142] A04 [P 142] A05 [P 142] A06 [P 142] A07 [P 143]

LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY

A08 [P 143]

LITHIUM BATTERY

A09 [P 143]

LITHIUM BATTERY

BAD LIFT POT BAD TILT POT BAD SIDESHIFT POT BAD IV POT BAD V POT ERROR SEAT

Description Problem with circuit piloting valves of 4th way: coil short-circuiting Incorrect starting procedure.

Problem with communication on Canbus line: EVCB card not receiving messages from lift logic unit The EVCB card has no acquisition values for tilt angle potentiometer or pressure sensor stored in memory Incorrect starting procedure.

Incorrect starting procedure.

Lift potentiometer voltage detected out of range Tilt potentiometer voltage detected out of range Sideshift potentiometer voltage detected out of range 4th way potentiometer voltage detected out of range 5th way potentiometer voltage detected out of range Incorrect starting procedure.

INVALID RESTORE STATE EEPROM INC ERROR

Problem with memory of armrest card

DEFAULT RESTORE

The armrest card has loaded the default parameters No potentiometer acquisition values stored in memory of armrest card Problem with memory of armrest card

MATCHING REQUIRED PDO CHKSUM ERROR BAD COMM EVCB

CAN COMUNICATION

Problem with memory of armrest card

Problem with communication on Canbus line: armrest card not receiving messages from EVCB card Incorrect starting procedure.

Reverse drive problem on arm rest

Communication problem with the Canbus line HW FAIL 1 Battery internal problem OVER VOLTAGE Problem with the battery voltage UNDER VOLTAGE Problem with the battery voltage HW FAIL 2 Battery internal problem OVER TEMPERATURE 1 Problem with the battery temperature UNDER TEMPERATURE Problem with the battery temperature 1 UNDER TEMPERATURE Problem with the battery temperature 2 OVER TEMPERATURE 2 Problem with the battery temperature

TROUBLESHOOTING Current A0A [P 143] A0B [P 143] A0C [P 144] A0D [P 144] A0E [P 144] A0F [P 144] A10 [P 144] A11 [P 145] A12 [P 145] A13 [P 145] A14 [P 145] C01 [P 146]

Card LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY LITHIUM BATTERY DISPLAY

C02 [P 146] DISPLAY

C03 [P 146] DISPLAY

C04 [P 146] DISPLAY

C05 [P 146] DISPLAY

C06 [P 147] DISPLAY

C08 [P 147] DISPLAY

C0B [P 147] DISPLAY

CA1 [P 147] DISPLAY CA2 [P 148] DISPLAY CA3 [P 148] DISPLAY CA4 [P 148] DISPLAY CA5 [P 148] DISPLAY CB9 [P 148] DISPLAY

CDA [P 149] DISPLAY CDC [P 149] DISPLAY CDD [P 149] DISPLAY CDE [P 149] DISPLAY CDF [P 149] DISPLAY

4-19 Alarm Description HW FAIL 3 Battery internal problem OVER CURRENT 1 Problem with the battery current OVER CURRENT 2 Problem with the battery current OVER CURRENT 3 Problem with the battery current OVER CURRENT 4 Problem with the battery current PROTECTION CIRCUIT 1 Battery internal problem PROTECTION CIRCUIT 2 Battery internal problem HW FAIL 4 Battery internal problem HW FAIL 5 Battery internal problem HW FAIL 6 Battery internal problem HW FAIL 7 Battery internal problem EPS KO Problem with communication on Canbus line: DISPLAY not receiving messages from EPS steering logic unit TRAC KO Problem with communication on Canbus line: display not receiving messages from right traction logic unit TRAC SLAVE KO Problem with communication on Canbus line: display not receiving messages from left traction logic unit MCB TRAC KO Problem with communication on Canbus line: DISPLAY not receiving messages from TRCB card PUMP KO Problem with communication on Canbus line: DISPLAY not receiving messages from lift logic unit MCB MHY KO Problem with communication on Canbus line: display not receiving messages from EVCB card JOY KO Problem with communication on Canbus line: DISPLAY not receiving messages from MASTER armrest card JOY SLAVE KO Problem with communication on Canbus line: DISPLAY not receiving messages from SLAVE armrest card BOARD MISMATCH Inconsistency detected between software installed on different cards NUM WHEELS MISIncorrect configuration between 3 wheel MATCH and 4 wheel version detected BRAKE LEVEL ALARM Low level of brake oil detected CANNOT READ SN The DISPLAY cannot read the serial number from a card CANNOT RESET LEARN The DISPLAY cannot reset the acquisiFLAG tions of a logic unit DHU KO Problem with communication on Canbus line: display not receiving messages from DHU card SHOCK LOCKOUT The shock sensor has detected a bump CAP DISCHARGE ALARM Incomplete discharge of capacitors detected following last machine shutdown LIGHT ERROR Problem with outputs piloting operation of optionals KEY ERROR Problem with the truck ignition signal EEPROM ERROR Problem with the memory

4

4-20

TROUBLESHOOTING

Current Card CF1 [P 150] DISPLAY

CF2 [P 150] CF3 [P 150]

BE6 [P 151]

BE7 [P 151]

BE8 [P 151]

BE9 [P 151]

BEA [P 152]

BEC [P 152]

BED [P 152] BEF [P 152]

BF8 [P 153]

BF9 [P 153]

BFA [P 153] 4108 [P 154]

410D [P 154]

4110 [P 154] 4111 [P 154] 4120 [P 155] 4130 [P 155]

Alarm SHOCK SENSOR KO

Description Problem with communication on Canbus line: DISPLAY not receiving messages from shock sensor DISPLAY IMMOBILIZE The P.O.C. system has enabled the IMMOBILIZE function DISPLAY SMART ACCESS KO Problem with communication on Canbus line: DISPLAY not receiving messages from SMART ACCESS card SLAVE ARMREST CARD LIFT POT ERROR Detection of inconsistency between lift potentiometer values read by MASTER and SLAVE sections of the armrest card SLAVE ARMREST CARD TILT POT ERROR Detection of inconsistency between tilt potentiometer values read by MASTER and SLAVE sections of the armrest card SLAVE ARMREST CARD SIDESHIFT POT ERROR Detection of inconsistency between sideshift potentiometer values read by MASTER and SLAVE sections of the armrest card SLAVE ARMREST CARD IV POT ERROR Detection of inconsistency between 4th way potentiometer values read by MASTER and SLAVE sections of the armrest card SLAVE ARMREST CARD V POT ERROR Detection of inconsistency between 5° oil line button values read by MASTER and SLAVE sections of the armrest card SLAVE ARMREST CARD DIGITAL ERROR Detection of inconsistency between digital values read by MASTER and SLAVE sections of the armrest card SLAVE ARMREST CARD FIRMWARE TYPE ERIncorrect software version detected on ROR the arm rest card SLAVE ARMREST CARD JOY MASTER KO Communication problem between the MASTER and SLAVE microcontrollers on the arm rest card SLAVE ARMREST CARD INVALID RESTORE Problem with the arm rest card memory: STATE the default parameters have been loaded SLAVE ARMREST CARD EEPROM INCOSIS ERProblem with the arm rest card memory: ROR the default parameters have been loaded SLAVE ARMREST CARD DEFAULT RESTORED Default parameters reloaded by arm rest card at power up EPS STEERING LOGIC WATCHDOG Internal communication problem UNIT between the MASTER and SLAVE microcontrollers on the EPS steering logic unit EPS STEERING LOGIC EEPROM KO Problem with the memory in the EPS UNIT steering logic unit: the EPS steering logic unit has reloaded the default parameters EPS STEERING LOGIC LOGIC FAILURE #4 Problem with the EPS steering logic unit UNIT power circuit EPS STEERING LOGIC LOGIC FAILURE #3 Problem with the EPS steering logic unit UNIT power circuit EPS STEERING LOGIC VMN NOT OK Problem with the EPS steering logic unit UNIT power circuit EPS STEERING LOGIC MAIN CONT OPEN Contactor K7 detected open despite beUNIT ing piloted by the EPS steering logic unit

TROUBLESHOOTING

4-21

Current Card 4135 [P 156] EPS STEERING LOGIC UNIT 4146 [P 156] EPS STEERING LOGIC UNIT 4147 [P 156] EPS STEERING LOGIC UNIT 4148 [P 157] EPS STEERING LOGIC UNIT 4149 [P 157] EPS STEERING LOGIC UNIT 4162 [P 157] EPS STEERING LOGIC UNIT 41CF [P 158] EPS STEERING LOGIC UNIT

Alarm STBY I HIGH

41D0 [P 158] EPS STEERING LOGIC UNIT

OUTPUT MISMATCH

41D1 [P 159] EPS STEERING LOGIC UNIT

WD SYNCHRO

41D4 [P 159] EPS STEERING LOGIC UNIT 41D5 [P 159] EPS STEERING LOGIC UNIT 41D6 [P 159] EPS STEERING LOGIC UNIT 41D7 [P 160] EPS STEERING LOGIC UNIT

WRONG RAM MEMORY

41D8 [P 160] EPS STEERING LOGIC UNIT 41DA [P 161] EPS STEERING LOGIC UNIT 41DC [P 161] EPS STEERING LOGIC UNIT 41DF [P 161] EPS STEERING LOGIC UNIT 41E1 [P 162] EPS STEERING LOGIC UNIT 41E4 [P 162] EPS STEERING LOGIC UNIT 41EB [P 162] EPS STEERING LOGIC UNIT 41EC [P 163] EPS STEERING LOGIC UNIT 41ED [P 164] EPS STEERING LOGIC UNIT

TFD CURRENT MISMATCH CONTROLLER MISMATCH MOTOR LOCKED

41F0 [P 164] EPS STEERING LOGIC UNIT

LOGIC SUPPLY ERR

HIGH CURRENT POWER FAILURE #3 POWER FAILURE #2 POWER FAILURE #1 INPUT ERROR #2 SP MISMATCH

PARAM RESTORE SP JERK CAN BUS KO M/S

Description Problem with the EPS steering logic unit power circuit Problem with the EPS steering logic unit power circuit Low current detected on the W phase of the EPS steering logic unit Low current detected on the V phase of the EPS steering logic unit Low current detected on the U phase of the EPS steering logic unit Problem on the TFD sensor signal Problem reading the TFD sensor values between the MASTER and SLAVE microcontrollers on the EPS steering logic unit Problem reading the steering sensor values between the MASTER and SLAVE microcontrollers on the EPS steering logic unit Internal communication problem between the MASTER and SLAVE microcontrollers on the EPS steering logic unit Problem with the memory of the EPS steering logic unit The EPS steering logic unit has run the reset Problem on the TFD sensor signals Internal communication problem between the MASTER and SLAVE microcontrollers on the EPS steering logic unit Problem with the TFD sensor power supply circuit Incorrect software detected Locked steering motor detected

FB JERK

Steering motor encoder problem

CURRENT GAIN POSITION ERROR

Problem with the EPS steering logic unit power circuit Steering motor encoder problem

TFD SHRT/VOLT KO

TFD sensor problem

TFD STB I HIGH

TFD sensor problem

WAITING MASTER

Internal communication problem between the MASTER and SLAVE microcontrollers on the EPS steering logic unit Problem with the EPS steering logic unit power supply line

4

4-22

TROUBLESHOOTING

Current Card 41F1 [P 164] EPS STEERING LOGIC UNIT 41F7 [P 165] EPS STEERING LOGIC UNIT

Alarm FB SENSOR LOCKED

Description Steering motor encoder problem

CAN BUS KO

41F8 [P 165] EPS STEERING LOGIC UNIT 41FA [P 165] EPS STEERING LOGIC UNIT

SP OUT OF RANGE

Problem with communication on Canbus line - EPS steering logic unit not receiving messages from other cards TFD sensor problem

41FC [P 166] EPS STEERING LOGIC UNIT 41FD [P 166] EPS STEERING LOGIC UNIT 41FE [P 166] EPS STEERING LOGIC UNIT 4201 [P 167] RIGHT TRACTION LOGIC UNIT 4205 [P 167] RIGHT TRACTION LOGIC UNIT

TWIN POT MISMAT

4208 [P 168] RIGHT TRACTION LOGIC UNIT 4213 [P 169] RIGHT TRACTION LOGIC UNIT 4216 [P 169] RIGHT TRACTION LOGIC UNIT

CONTACTOR OPEN

4219 [P 170] RIGHT TRACTION LOGIC UNIT

AUX DRV SHORTED

421C [P 170] RIGHT TRACTION LOGIC UNIT 4225 [P 171] RIGHT TRACTION LOGIC UNIT 4227 [P 172] RIGHT TRACTION LOGIC UNIT

VDC OFF SHORTED

4228 [P 172] RIGHT TRACTION LOGIC UNIT 422C [P 173] RIGHT TRACTION LOGIC UNIT 4231 [P 173] RIGHT TRACTION LOGIC UNIT 4234 [P 174] RIGHT TRACTION LOGIC UNIT 423C [P 174] RIGHT TRACTION LOGIC UNIT 423D [P 175] RIGHT TRACTION LOGIC UNIT 4242 [P 175] RIGHT TRACTION LOGIC UNIT

VDC LINK OVERV.

INPUT MISMATCH

ANALOG NO SP REFRESH WATCHDOG LOGIC FAILURE #1

ENCODER ERROR NO CAN MSG

WRONG SET BAT EEPROM KO

CURRENT GAIN VKEY OFF SHORTED WRONG RAM MEM ANALOG INPUT CONTROLLER MISMATCH AUX DRV OPEN

Problem with the input readings between the MASTER and SLAVE microcontroller on the EPS steering logic unit Steering sensor problem Problem with the analog signals of the EPS steering logic unit TFD sensor problem Problem during right traction logic unit self-test routine Problem with right traction logic unit power circuit - low voltage condition detected Contactor K7 detected open despite being piloted by right traction logic unit Problem with signals generated by right drive motor rpm sensor Problem with communication on Canbus line - right traction logic unit not receiving messages from other cards Problem with driver circuit controlling coil connected to auxiliary output of right traction logic unit Low voltage detected Detection of battery voltage 20% higher than nominal value Problem with the memory in the right traction logic unit: the right traction logic unit has reloaded the default parameters Overvoltage detected Problem with current monitoring circuit of right traction logic unit Problem with power up circuit: key line Incorrect values detected in right traction logic unit RAM memory Problem with signal monitoring circuit of right traction logic unit Problem with software of right traction logic unit Problem with driver circuit controlling coil connected to auxiliary output of right traction logic unit

TROUBLESHOOTING Current Card 424A [P 176] RIGHT TRACTION LOGIC UNIT

4-23 Alarm WD SYNCRO

4252 [P 176] RIGHT TRACTION LO- OUTPUT MISMATCH GIC UNIT 425B [P 177] RIGHT TRACTION LO- INPUT MISMATCH GIC UNIT 4301 [P 177] LEFT TRACTION LOGIC WATCHDOG UNIT 4305 [P 177] LEFT TRACTION LOGIC LOGIC FAILURE #1 UNIT 4308 [P 178] LEFT TRACTION LOGIC CONTACTOR OPEN UNIT 4313 [P 179] LEFT TRACTION LOGIC ENCODER ERROR UNIT 4316 [P 179] LEFT TRACTION LOGIC NO CAN MSG UNIT 4319 [P 180] LEFT TRACTION LOGIC AUX. DRV.SHORTED UNIT 431C [P 180] LEFT TRACTION LOGIC VDC OFF SHORTED UNIT 4325 [P 181] LEFT TRACTION LOGIC WRONG SET BAT UNIT 4327 [P 182] LEFT TRACTION LOGIC EEPROM KO UNIT 4328 [P 182] LEFT TRACTION LOGIC VDC LINK OVERV. UNIT 432C [P 183] LEFT TRACTION LOGIC CURRENT GAIN UNIT 4331 [P 183] LEFT TRACTION LOGIC VKEY OFF SHORTED UNIT 4334 [P 184] LEFT TRACTION LOGIC WRONG RAM MEM UNIT 433C [P 184] LEFT TRACTION LOGIC ANALOG INPUT UNIT 433D [P 185] LEFT TRACTION LOGIC CONTROLLER MISUNIT MATCH 4342 [P 185] LEFT TRACTION LOGIC AUX DRV OPEN UNIT 434A [P 186] LEFT TRACTION LOGIC WD SYNCRO UNIT

4352 [P 186] LEFT TRACTION LOGIC OUTPUT MISMATCH UNIT 435B [P 187] LEFT TRACTION LOGIC INPUT MISMATCH UNIT

Description Internal communication problem between the MASTER and SLAVE microcontrollers on the right traction logic unit Problem reading the output values connected to the right traction logic unit Problem reading the input values connected to the right traction logic unit Problem during left traction logic unit self-test routine Problem with left traction logic unit power circuit - low voltage condition detected Contactor K7 detected open despite being piloted by left traction logic unit Problem with signals generated by left drive motor rpm sensor Problem with communication on Canbus line - left traction logic unit not receiving messages from other cards Problem with driver circuit controlling coil connected to auxiliary output of left traction logic unit Low voltage detected Detection of battery voltage 20% higher than nominal value Problem with the memory in the right traction logic unit: the right traction logic unit has reloaded the default parameters Overvoltage detected Problem with current monitoring circuit of left traction logic unit Problem with power up circuit: key line Incorrect values detected in left traction logic unit RAM memory Problem with signal monitoring circuit of left traction logic unit Problem with software of left traction logic unit Problem with driver circuit controlling coil connected to auxiliary output of left traction logic unit Internal communication problem between the MASTER and SLAVE microcontrollers on the left traction logic unit Problem reading the output values connected to the left traction logic unit Problem reading the input values connected to the left traction logic unit

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TROUBLESHOOTING

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) Circumstances of error detection The steering logic unit EPS (AU4) 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 steering parameters on the display ▪ Reset the steering logic unit EPS using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the steering logic unit EPS

110 LOGIC FAILURE #4 (steering logic unit EPS - master microcontroller) Circumstances of error detection 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

TROUBLESHOOTING

4-25

111 LOGIC FAILURE #3 (steering logic unit EPS - master microcontroller) Circumstances of error detection 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

120 VMN NOT OK (steering logic unit EPS - master microcontroller) Circumstances of error detection 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 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 ▪ 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

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TROUBLESHOOTING

130 MAIN CONT OPEN (steering logic unit EPS - master microcontroller) Circumstances of error detection 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 ▪ Continuity of the wiring harness between connector J4 pin 16 and connector J203 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) Circumstances of error detection 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

TROUBLESHOOTING

4-27

13C CAPACITOR CHARGE (steering logic unit EPS - master microcontroller) Circumstances of error detection 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 ▪ The condition of the plate and contacts of contactor K2 (oxidation or dirt) ▪ Replace the steering logic unit EPS ▪ 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

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TROUBLESHOOTING

13D HIGH TEMPERATURE (steering logic unit EPS - master microcontroller) Circumstances of error detection 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) Circumstances of error detection 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) Circumstances of error detection 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

TROUBLESHOOTING

4-29

147 POWER FAILURE #3 (steering logic unit EPS - master microcontroller) Circumstances of error detection The EPS (AU4) steering logic unit has detected a low current on phase W. 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

148 POWER FAILURE #2 (steering logic unit EPS - master microcontroller) Circumstances of error detection The EPS (AU4) steering logic unit has detected a low current on phase V. 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

149 POWER FAILURE #1 (steering logic unit EPS - master microcontroller) Circumstances of error detection The EPS (AU4) steering logic unit has detected a low current on phase u.

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

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TROUBLESHOOTING

162 INPUT ERROR #1 (steering logic unit EPS - master microcontroller) Circumstances of error detection 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 ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD 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) Circumstances of error detection 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

TROUBLESHOOTING

4-31

1D3 TFD FEEDB ERROR (steering logic unit EPS - master microcontroller) Circumstances of error detection 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 ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD 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)

1D4 WRONG RAM MEMORY (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem in the memory.

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

1D5 PARAM RESTORE (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has reloaded the default parameters.

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

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TROUBLESHOOTING

1D6 SP JERK (steering logic unit EPS - master microcontroller) Circumstances of error detection 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 ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD 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) ▪ 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) Circumstances of error detection The EPS (AU4) steering logic unit has detected a communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Update the software version of the MASTER and SLAVE microcontroller on the EPS steering logic unit ▪ Replace the steering logic unit EPS

TROUBLESHOOTING

4-33

1D8 TFD WRONG RESIST (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem with the TFD sensor resistance.

Actions: ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD 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) ▪ Reset the steering logic unit EPS using the function TO DEFAULT SET

1DA CONTROLLER MISMATCH (steering logic unit EPS - master microcontroller) Circumstances of error detection 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

1DC MOTOR LOCKED (steering logic unit EPS - master microcontroller) Circumstances of error detection 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

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TROUBLESHOOTING

1DD M/S PAR CHK MISM (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem in the memory.

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

1DF FB JERK (steering logic unit EPS - master microcontroller) Circumstances of error detection The EPS (AU4) steering logic unit has detected a problem with the steering motor encoder.

Actions: ▪ Check that the wiring harness between the EPS steering logic and the steering motor encoder is not crushed/damaged/disconnected ▪ Check that the steering axle and/or the steering motor are not mechanically locked ▪ Use the ANALAYZER menu to check the steering motor encoder functions

1E1 CURRENT GAIN (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem with the power circuit.

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

1E4 POSITION ERROR (steering logic unit EPS - master microcontroller) Circumstances of error detection 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

TROUBLESHOOTING

4-35

1EB TFD SHRT/VOLT KO (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem in the sensor TFD. Actions: ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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) ▪ Check the power supply from the EPS steering logic unit: ▪ Measure the voltage between pin 5 and pin 6 on connector J11 (standard battery voltage)

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TROUBLESHOOTING

1EC TFD STB I HIGH (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem in the sensor TFD. Actions: ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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) ▪ Check the power supply from the EPS steering logic unit: ▪ Measure the voltage between pin 5 and pin 6 on connector J11 (standard battery voltage)

1ED SLAVE ALARM XX (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem in the SLAVE microcontroller.

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

1F1 FB SENSOR LOCKED (steering logic unit EPS - master microcontroller) Circumstances of error detection The EPS (AU4) steering logic unit has detected a problem with the steering motor encoder.

Actions: ▪ Check that the wiring harness between the EPS steering logic and the steering motor encoder is not crushed/damaged/disconnected ▪ Check that the steering axle and/or the steering motor are not mechanically locked ▪ Use the ANALYZER menu to check the steering motor encoder functions

TROUBLESHOOTING

4-37

1F4 PARAM TRANSFER (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem in the parameters memory.

Actions: ▪ Run a key reset ▪ Reset the steering logic unit EPS using the function TO DEFAULT SET ▪ Edit one or more parameters on the EPS steering logic unit ▪ If the fault code is repeated, replace the steering logic unit EPS

1F5 DATA ACQUISITION (steering logic unit EPS - master microcontroller) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem with the power circuit.

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

1F7 CAN BUS KO (steering logic unit EPS - master microcontroller) Circumstances of error detection 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)

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TROUBLESHOOTING

1F8 SP OUT OF RANGE (steering logic unit EPS - master microcontroller) Circumstances of error detection 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 ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD 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) ▪ Check the power supply from the EPS steering logic unit: ▪ Measure the voltage between pin 1 and pin 2 on connector J11 (standard +5V)

1FB INIT VMN NOT OK (steering logic unit EPS - master microcontroller) Circumstances of error detection 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 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 ▪ 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

TROUBLESHOOTING

4-39

1FC TWIN POT MISMAT (steering logic unit EPS - master microcontroller) Circumstances of error detection 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°) ▪ 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) Circumstances of error detection The steering logic unit EPS (AU4) has detected a problem in the analog signals.

Actions: ▪ Run a key reset ▪ If the fault code is repeated, replace the steering logic unit EPS

1FE NO SP REFRESH (steering logic unit EPS - master microcontroller) Circumstances of error detection 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 ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD 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) ▪ Check the power supply from the EPS steering logic unit: ▪ Measure the voltage between pin 1 and pin 2 on connector J11 (standard +5V)

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TROUBLESHOOTING

RIGHT TRACTION LOGIC UNIT - MASTER MICROCONTROLLER 201 WATCHDOG (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected an internal communication problem between the MASTER and SLAVE microcontrollers.

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) Circumstances of error detection 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 PROCEDURE, chapter 01) ▪ Battery damaged ▪ Replace the battery

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203 LOGIC FAILURE #3 (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the power circuit - high current overload protection.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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.

▪ If the fault code changes from 203 to 303, replace the traction logic unit originally on the right ▪ If the fault code remains 203, the cause of the fault is outside the right traction logic unit

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204 LOGIC FAILURE #2 (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the hardware section controlling voltage feedback from the drive motor phases.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 204 to 304, replace the traction logic unit originally on the right ▪ If the fault code remains 204, the cause of the fault is outside the right traction logic unit

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205 LOGIC FAILURE #1 (right traction logic unit - master microcontroller) Circumstances of error detection 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 ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit ▪ If the fault code changes from 205 to 305, replace the traction logic unit originally on the right ▪ If the fault code remains 205, the cause of the fault is outside the right traction logic unit

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206 VMN LOW (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the power circuit - low voltage at drive motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ Insulation of the coil from the body (standard greater than 1M1MΩ) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit ▪ If the fault code changes from 206 to 306, replace the traction logic unit originally on the right ▪ If the fault code remains 206, the cause of the fault is outside the right traction logic unit

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207 VMN HIGH (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the power circuit - overvoltage at drive motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit ▪ If the fault code changes from 207 to 307, replace the traction logic unit originally on the right ▪ If the fault code remains 207, the cause of the fault is outside the right traction logic unit

208 CONTACTOR OPEN (right traction logic unit - master microcontroller) Circumstances of error detection 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors

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209 STBY I HIGH (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected an abnormal level of current at the drive motor when in stand-by status.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit ▪ If the fault code changes from 209 to 309, replace the traction logic unit originally on the right ▪ If the fault code remains 209, the cause of the fault is outside the right traction logic unit

20A INCORRECT START (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected an incorrect start sequence.

20C FORW+BACK (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected an incorrect start sequence - forward drive and reverse drive selected simultaneously.

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20D HW FAULT (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the power circuit.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit ▪ 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

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20E POWER MOS SHORT (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the power circuit.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit ▪ 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

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210 CAPACITOR CHARGE (right traction logic unit - master microcontroller) Circumstances of error detection 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 ▪ The condition of the plate and contacts of contactor K1 (oxidation or dirt) ▪ Replace the right traction logic unit ▪ If the alarm 210 appears together with 310, 5A3, 13C: ▪ 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

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211 TH PROTECTION (right traction logic unit - master microcontroller) Circumstances of error detection 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 parking 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) Circumstances of error detection 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 ▪ 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 parking brake to do this test) ▪ 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 for continuity between pin 2 of connector J7 and pin 22 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

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213 ENCODER ERROR (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with signals generated by the right drive motor rpm sensor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 rpm sensor operation using the ANALYZER function ▪ Check the rpm sensor connections: ▪ Check that connector J12 is correctly plugged in ▪ Check for continuity between pin 1 of connector J12 and pin 8 of connector J1 ▪ Check for continuity between pin 2 of connector J12 and pin 14 of connector J1 ▪ Check for continuity between pin 3 of connector J12 and pin 7 of connector J1 ▪ Check for continuity between pin 4 of connector J12 and pin 15 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 J12 ▪ 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) Circumstances of error detection 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: ▪ 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 for continuity between pin 2 of connector J7 and pin 22 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

216 NO CAN MSG (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) receives no messages from other cards connected to the Can-bus line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

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219 DRIVER SHORTED (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the driver circuit controlling contactor K1.

Actions: ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 219 to 319, replace the traction logic unit originally on the right ▪ If the fault code remains 219, the cause of the fault is outside the right traction logic unit

21B SENS MOT TEMP KO (right traction logic unit - master microcontroller) Circumstances of error detection 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: ▪ 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 for continuity between pin 2 of connector J7 and pin 22 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 ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor 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

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21C VDC OFF SHORTED (right traction logic unit - master microcontroller) Circumstances of error detection 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 ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ 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

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21D STALL ROTOR (right traction logic unit - master microcontroller) Circumstances of error detection 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 truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the rpm sensor operation using the ANALYZER function ▪ Check the rpm sensor connections: ▪ Check that connector J12 is correctly plugged in ▪ Check for continuity between pin 1 of connector J12 and pin 8 of connector J1 ▪ Check for continuity between pin 2 of connector J12 and pin 14 of connector J1 ▪ Check for continuity between pin 3 of connector J12 and pin 7 of connector J1 ▪ Check for continuity between pin 4 of connector J12 and pin 15 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 J12 ▪ 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) ▪ Check the operation of the right drive motor: ▪ 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 parking brake to do this test)

21E CONTACT CLOSED (right traction logic unit - master microcontroller) Circumstances of error detection 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) ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ Insulation of the coil from the body (standard greater than 1MΩ) ▪ The tightening torque of nuts on the contacts of contactor K1 (15.3 Nm – 16.4 Nm) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors

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21F MIS. SETPOINT (right traction logic unit - master microcontroller) Circumstances of error detection 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 POTENTIOMETER, 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) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the driver circuit controlling contactor K1.

Actions: ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 220 to 320, replace the traction logic unit originally on the right ▪ If the fault code remains 220, the cause of the fault is outside the right traction logic unit

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221 MC COIL SHORTED (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the coil of contactor K1.

Actions: ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 220 to 320, replace the traction logic unit originally on the right ▪ If the fault code remains 220, the cause of the fault is outside the right traction logic unit

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224 INIT VMN HIGH (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the power circuit - overvoltage at drive motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 224 to 324, replace the traction logic unit originally on the right ▪ If the fault code remains 224, the cause of the fault is outside the right traction logic unit

225 WRONG SET BATT (right traction logic unit - master microcontroller) Circumstances of error detection 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) ▪ 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) ▪ Calibrate battery indicator (see paragraph BATTERY VOLTAGE READING ADJUSTMENT PROCEDURE, chapter 01) ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit

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226 INIT VMN LOW (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the power circuit - low voltage at drive motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 226 to 326, replace the traction logic unit originally on the right ▪ If the fault code remains 226, the cause of the fault is outside the right traction logic unit

227 EEPROM KO (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) 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 drive parameters on the display ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the right traction logic unit

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228 VDC LINK OVERV. (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the power circuit - overvoltage.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J1 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ 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 ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 228 to 328, replace the traction logic unit originally on the right ▪ If the fault code remains 228, the cause of the fault is outside the right traction logic unit

22C CURRENT GAIN (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with acquisition of electric current values.

Actions: ▪ Run a key reset and check the correct value of the drive parameters on the display ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the right traction logic unit

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22F NO SLAVE ENABLE (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected an communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE) ▪ 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) Circumstances of error detection The right traction logic unit (AU1) does not receive +48V. Actions: ▪ 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 correct battery voltage between pin 17 of connector J1 and negative - BATT ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors

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231 VKEY OFF SHORTED (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the ignition circuit.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J1 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 231 to 331, replace the traction logic unit originally on the right ▪ If the fault code remains 231, the cause of the fault is outside the right traction logic unit

232 TEACH VACC POT (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) prompts for acquisition of the accelerator potentiometer.

Actions: ▪ Check the correct installation of the accelerator potentiometer (see paragraph ACCELERATOR POTENTIOMETER, chapter 02) ▪ Check the correct configuration of the accelerator pedal, parameter SWAYING PEDAL ▪ Repeat the calibration of the accelerator potentiometer

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233 STEER ACQ (right traction logic unit - master microcontroller) Circumstances of error detection 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) ▪ Repeat the steering sensor calibration

234 WRONG RAM MEM. (right traction logic unit - master microcontroller) Circumstances of error detection The RIGHT traction logic unit (AU1) has encountered a problem in the RAM. Actions: ▪ Run a key reset and check the correct value of the drive parameters on the display ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the right traction logic unit

235 STEER OUT RANGE (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has encountered a problem in the steering sensor.

Actions: ▪ Check the correct installation of the steering sensor (see paragraph STEERING SENSOR, chapter 02) ▪ Repeat the steering sensor calibration

236 HANDBRAKE (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected an incorrect start sequence.

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23A COIL SHORT. EB (right traction logic unit - master microcontroller) Circumstances of error detection 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) ▪ 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 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J13 pin 2 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ 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) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with input signals.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 23C to 33C, replace the traction logic unit originally on the right ▪ If the fault code remains 23C, the cause of the fault is outside the right traction logic unit

23D CONTROLLER MISMATCH (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) 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 ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit ▪ If the fault code is repeated, replace the right traction logic unit

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241 IQ MISMATCHED (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) 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 ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 241 to 341, replace the traction logic unit originally on the right ▪ If the fault code remains 241, the cause of the fault is outside the right traction logic unit

242 EB. DRIV. OPEN (right traction logic unit - master microcontroller) Circumstances of error detection 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) 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 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J13 pin 2 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 242 to 342, replace the traction logic unit originally on the right ▪ If the fault code remains 242, the cause of the fault is outside the right traction logic unit

243 CHECK UP NEEDED (right traction logic unit - master microcontroller) Circumstances of error detection Maintenance hour counter warning.

Actions: ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit

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244 FIELD ORIENT. KO (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the drive motor field orientation circuit.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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: ▪ If the fault code changes from 244 to 344, replace the traction logic unit originally on the right ▪ If the fault code remains 244, the cause of the fault is outside the right traction logic unit

245 EB. DRIV. SHRT (right traction logic unit - master microcontroller) Circumstances of error detection 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) ▪ 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 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J13 pin 2 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 245 to 345, replace the traction logic unit originally on the right ▪ If the fault code remains 245, the cause of the fault is outside the right traction logic unit

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248 WRONG ENC SET (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the configuration of the right drive motor rpm sensor.

Actions: ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit

24C PARAM TRANSFERT (right traction logic unit - master microcontroller) Circumstances of error detection The traction logic unit (AU1) has detected a problem with the parameters memory.

Actions: ▪ Run a key reset ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ Restore all the drive parameters (MENU TUNING) to the default value ▪ If the fault code is repeated, replace the right traction logic unit

24D EMERGENCY SW (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected an incorrect start sequence.

Actions: ▪ Check the emergency button

24E STOP RQ FROM EPS (right traction logic unit - master microcontroller) Circumstances of error detection 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) Circumstances of error detection The right traction logic unit (AU1) has detected an incorrect software version.

Actions: ▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit

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250 NO CAN MSG EPS (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a communication problem on the CAN-BUS line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

251 STOP FROM EPS (right traction logic unit - master microcontroller) Circumstances of error detection The right traction logic unit (AU1) had received a stop message from the EPS. steering logic unit Actions: ▪ Check the other fault codes

252 EPS IS ONLINE (right traction logic unit - master microcontroller) Circumstances of error detection 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) Circumstances of error detection 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) Circumstances of error detection The right traction logic unit (AU1) has detected an communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit ▪ Replace the right traction logic unit

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LEFT TRACTION LOGIC UNIT - MASTER MICROCONTROLLER 301 WATCHDOG (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an internal communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Run a key reset ▪ Reset the left 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 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) Circumstances of error detection 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 PROCEDURE, chapter 01) ▪ Battery damaged ▪ Replace the battery

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303 LOGIC FAILURE #3 (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - high current overload protection.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 203 to 303, replace the traction logic unit originally on the left ▪ If the fault code remains 203, the cause of the fault is outside the left traction logic unit

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304 LOGIC FAILURE #2 (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the hardware section controlling voltage feedback from the drive motor phases.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 304 to 204, replace the traction logic unit originally on the left ▪ If the fault code remains 304, the cause of the fault is outside the left traction logic unit

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305 LOGIC FAILURE #1 (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - low voltage.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J2 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 305 to 205, replace the traction logic unit originally on the left ▪ If the fault code remains 305, the cause of the fault is outside the left traction logic unit

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306 VMN LOW (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - low voltage at drive motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ Insulation of the coil from the body (standard greater than 1M1MΩ) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 306 to 206, replace the traction logic unit originally on the left ▪ If the fault code remains 306, the cause of the fault is outside the left traction logic unit

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307 VMN HIGH (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - overvoltage at drive motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 307 to 207, replace the traction logic unit originally on the left ▪ If the fault code remains 307, the cause of the fault is outside the left traction logic unit

308 CONTACTOR OPEN (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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 308 may simply be a consequence ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors

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309 STBY I HIGH (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an abnormal level of current at the drive motor when in stand-by status.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 309 to 209, replace the traction logic unit originally on the left ▪ If the fault code remains 309, the cause of the fault is outside the left traction logic unit

30A INCORRECT START (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an incorrect start sequence.

30C FORW+BACK (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an incorrect start sequence - forward drive and reverse drive selected simultaneously.

TROUBLESHOOTING

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30D HW FAULT (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ 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

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30E POWER MOS SHORT (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ 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

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310 CAPACITOR CHARGE (left traction logic unit - master microcontroller) Circumstances of error detection 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 ▪ The condition of the plate and contacts of contactor K1 (oxidation or dirt) ▪ Replace the left traction logic unit ▪ If the alarm 310 appears together with 310, 5A3, 13C: ▪ 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

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311 TH PROTECTION (left traction logic unit - master microcontroller) Circumstances of error detection 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 counterweight ▪ 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) Circumstances of error detection 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 ▪ 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) ▪ If the alarm appears when the left drive motor is cold: ▪ Check that connector J8 is correctly plugged in ▪ Check the resistance value of the left drive motor temperature sensor (standard 629Ω at 25°C) ▪ Check for continuity between pin 1 of connector J8 and pin 23 of connector J1 ▪ Check for continuity between pin 2 of connector J8 and pin 22 of connector J1 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J2 and J8 Self-diagnostic ▪ Connect an external resistance (500 ohm ÷ 1000 ohm) to the temperature sensor connector J8: ▪ If the fault code disappears replace the left drive motor ▪ If the fault code persists, replace the left traction logic unit

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313 ENCODER ERROR (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with signals generated by the left drive motor rpm sensor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 rpm sensor operation using the ANALYZER function ▪ Check the rpm sensor connections: ▪ Check that connector J12 is correctly plugged in ▪ Check for continuity between pin 1 of connector J16 and pin 8 of connector J2 ▪ Check for continuity between pin 2 of connector J16 and pin 14 of connector J2 ▪ Check for continuity between pin 3 of connector J16 and pin 7 of connector J2 ▪ Check for continuity between pin 4 of connector J16 and pin 15 of connector J2 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J2 and J16 ▪ 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 J16 ▪ The insulation of the rpm sensor relative to the body of the drive axle (must be > 1MΩ)

314 THERMIC SENS KO (left traction logic unit - master microcontroller) Circumstances of error detection 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 that the temperature sensor is not damaged: ▪ Check that connector J8 is correctly plugged in ▪ Check the resistance value of the left drive motor temperature sensor (standard 629Ω at 25°C) ▪ Check for continuity between pin 1 of connector J8 and pin 23 of connector J2 ▪ Check for continuity between pin 2 of connector J8 and pin 22 of connector J2 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J2 and J8 Self-diagnostic ▪ Connect an external resistance (500 ohm ÷ 1000 ohm) to the temperature sensor connector J8: ▪ If the fault code disappears replace the left drive motor ▪ If the fault code persists, replace the left traction logic unit

316 NO CAN MSG (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) receives no messages from other cards connected to the Can-bus line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

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319 DRIVER SHORTED (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the driver circuit controlling contactor K1.

Actions: ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 319 to 219, replace the traction logic unit originally on the left ▪ If the fault code remains 319, the cause of the fault is outside the left traction logic unit

31B SENS MOT TEMP KO (left traction logic unit - master microcontroller) Circumstances of error detection 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 that the temperature sensor is not damaged: ▪ Check that connector J8 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 J8 and pin 23 of connector J2 ▪ Check for continuity between pin 2 of connector J8 and pin 22 of connector J2 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J2 and J8 ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Connect an external resistance (500 ohm ÷ 1000 ohm) to the temperature sensor connector J8: ▪ If the fault code disappears replace the left drive motor ▪ If the fault code persists, replace the left traction logic unit

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31C VDC OFF SHORTED (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - low voltage.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J2 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ 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

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31D STALL ROTOR (left traction logic unit - master microcontroller) Circumstances of error detection 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 truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the rpm sensor operation using the ANALYZER function ▪ Check the rpm sensor connections: ▪ Check that connector J16 is correctly plugged in ▪ Check for continuity between pin 1 of connector J16 and pin 8 of connector J2 ▪ Check for continuity between pin 2 of connector J16 and pin 14 of connector J2 ▪ Check for continuity between pin 3 of connector J16 and pin 7 of connector J2 ▪ Check for continuity between pin 4 of connector J16 and pin 15 of connector J2 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J2 and J16 ▪ 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 J16 ▪ The insulation of the rpm sensor relative to the body of the drive axle (must be > 1MΩ) ▪ Check the operation of the left drive motor: ▪ 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)

31E CONTACT CLOSED (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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) ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ Insulation of the coil from the body (standard greater than 1MΩ) ▪ The tightening torque of nuts on the contacts of contactor K1 (15.3 Nm – 16.4 Nm) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors

TROUBLESHOOTING

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31F MIS. SETPOINT (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an incorrect accelerator potentiometer voltage reading between TRCB card and left traction logic unit.

Actions: ▪ Check the correct installation of the accelerator potentiometer (see paragraph ACCELERATOR POTENTIOMETER, 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

320 CONTACT DRIVER (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the driver circuit controlling contactor K1.

Actions: ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 320 to 220, replace the traction logic unit originally on the left ▪ If the fault code remains 320, the cause of the fault is outside the left traction logic unit

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321 MC COIL SHORTED (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the coil of contactor K1.

Actions: ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 320 to 220, replace the traction logic unit originally on the left ▪ If the fault code remains 320, the cause of the fault is outside the left traction logic unit

TROUBLESHOOTING

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324 INIT VMN HIGH (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - overvoltage at drive motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 324 to 224, replace the traction logic unit originally on the left ▪ If the fault code remains 324, the cause of the fault is outside the left traction logic unit

325 WRONG SET BATT (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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) ▪ 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) ▪ Calibrate battery indicator (see paragraph BATTERY VOLTAGE READING ADJUSTMENT PROCEDURE, 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

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326 INIT VMN LOW (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - low voltage at drive motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 326 to 226, replace the traction logic unit originally on the left ▪ If the fault code remains 326, the cause of the fault is outside the left traction logic unit

327 EEPROM KO (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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 drive parameters on the display ▪ Reset the left traction logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the left traction logic unit

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328 VDC LINK OVERV. (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - overvoltage.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J2 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ 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 right traction logic unit ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 328 to 228, replace the traction logic unit originally on the left ▪ If the fault code remains 328, the cause of the fault is outside the left traction logic unit

32C CURRENT GAIN (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with acquisition of electric current values.

Actions: ▪ Run a key reset and check the correct value of the drive parameters on the display ▪ Reset the left traction logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the left traction logic unit

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32F NO SLAVE ENABLE (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE) ▪ 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) Circumstances of error detection The left traction logic unit (AU2) does not receive +48V. Actions: ▪ 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 correct battery voltage between pin 17 of connector J2 and negative - BATT ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors

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331 VKEY OFF SHORTED (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the ignition circuit.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J2 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 331 to 231, replace the traction logic unit originally on the left ▪ If the fault code remains 331, the cause of the fault is outside the left traction logic unit

332 TEACH VACC POT (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) prompts for acquisition of the accelerator potentiometer.

Actions: ▪ Check the correct installation of the accelerator potentiometer (see paragraph ACCELERATOR POTENTIOMETER, chapter 02) ▪ Check the correct configuration of the accelerator pedal, parameter SWAYING PEDAL ▪ Repeat the calibration of the accelerator potentiometer

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333 STEER ACQ (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) prompts for acquisition of the steering sensor.

Actions: ▪ Check the correct installation of the steering sensor (see paragraph STEERING SENSOR, chapter 02) ▪ Repeat the steering sensor calibration

334 WRONG RAM MEM. (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem in the RAM. Actions: ▪ Run a key reset and check the correct value of the drive parameters on the display ▪ Reset the left traction logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the left traction logic unit

335 STEER OUT RANGE (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has encountered a problem in the steering sensor.

Actions: ▪ Check the correct installation of the steering sensor (see paragraph STEERING SENSOR, chapter 02) ▪ Repeat the steering sensor calibration

336 HANDBRAKE (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an incorrect start sequence.

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33A COIL SHORT. EB (left traction logic unit - master microcontroller) Circumstances of error detection 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) ▪ 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 crimping of wires to contacts and insertion of the contacts into connectors J2 and J20 (possible false contact/dilated pin) ▪ Continuity of the wiring between connector J2 pin 18 and connector J20 pin 1 ▪ Continuity of the wiring between connector J44 pin 3 and connector J20 pin 2 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ 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) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with input signals.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 33C to 23C, replace the traction logic unit originally on the left ▪ If the fault code remains 33C, the cause of the fault is outside the left traction logic unit

33D CONTROLLER MISMATCH (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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 ▪ 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 ▪ If the fault code is repeated, replace the left traction logic unit

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341 IQ MISMATCHED (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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 ▪ 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 ▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 341 to 241, replace the traction logic unit originally on the left ▪ If the fault code remains 341, the cause of the fault is outside the left traction logic unit

342 EB. DRIV. OPEN (left traction logic unit - master microcontroller) Circumstances of error detection 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) 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 crimping of wires to contacts and insertion of the contacts into connectors J2 and J20 (possible false contact/dilated pin) ▪ Continuity of the wiring between connector J2 pin 18 and connector J20 pin 1 ▪ Continuity of the wiring between connector J44 pin 3 and connector J20 pin 2 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 342 to 242, replace the traction logic unit originally on the left ▪ If the fault code remains 342, the cause of the fault is outside the left traction logic unit

343 CHECK UP NEEDED (left traction logic unit - master microcontroller) Circumstances of error detection Maintenance hour counter warning.

Actions: ▪ 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

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344 FIELD ORIENT. KO (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the drive motor field orientation circuit Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 344 to 244, replace the traction logic unit originally on the left ▪ If the fault code remains 344, the cause of the fault is outside the left traction logic unit

345 EB. DRIV. SHRT (left traction logic unit - master microcontroller) Circumstances of error detection 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) ▪ 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 crimping of wires to contacts and insertion of the contacts into connectors J2 and J20 (possible false contact/dilated pin) ▪ Continuity of the wiring between connector J2 pin 18 and connector J20 pin 1 ▪ Continuity of the wiring between connector J44 pin 3 and connector J20 pin 2 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 345 to 245, replace the traction logic unit originally on the left ▪ If the fault code remains 345, the cause of the fault is outside the left traction logic unit

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348 WRONG ENC SET (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with configuration generated by the left drive motor rpm sensor.

Actions: ▪ Reset the left traction logic unit using the TO DEFAULT SET function ▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Update the software version of the MASTER and SLAVE microcontroller on the left traction logic unit

34C PARAM TRANSFERT (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the parameters memory.

Actions: ▪ Run a key reset ▪ Reset the left traction logic unit using the TO DEFAULT SET function ▪ Restore all the drive parameters (MENU TUNING) to the default value ▪ If the fault code is repeated, replace the left traction logic unit

34D EMERGENCY SW (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an incorrect start sequence.

Actions: ▪ Check the emergency button

34E STOP RQ FROM EPS (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) had received a stop message from the EPS steering logic unit Actions: ▪ Check the other fault codes

34F WRONG SLAVE V. (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an incorrect software version.

Actions: ▪ Update the software version of the MASTER and SLAVE microcontroller on the left traction logic unit

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350 NO CAN MSG EPS (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a communication problem on the CAN-BUS line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

351 STOP FROM EPS (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) had received a stop message from the EPS steering logic unit Actions: ▪ Check the other fault codes

352 EPS IS ONLINE (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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

353 TEACH BRK POT (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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

35B M/S PAR CHK MISM (left traction logic unit - master microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Update the software version of the MASTER and SLAVE microcontroller on the left traction logic unit ▪ Replace the left traction logic unit

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MCB CARD (TRCB section) 430 WRONG BATTERY (MCB card - TRCB section) Circumstances of error detection 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) Circumstances of error detection 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 ▪ Restore all the drive parameters (MENU TUNING) to the default value

452 BAD EMERGENCY SWITCH (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card has detected a problem on the emergency button.

Actions: ▪ Check the emergency button

453 ACC ZAPI MISMATCH (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card has detected an inconsistency with the accelerator potentiometer values.

Actions: ▪ Check the correct installation of the accelerator potentiometer (see paragraph ACCELERATOR POTENTIOMETER, chapter 02) ▪ Check the correct configuration of the accelerator pedal, parameter SWAYING PEDAL ▪ Repeat the calibration of the accelerator potentiometer

454 BRAKE ZAPI MISMATCH (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card has detected an inconsistency with the brake potentiometer values.

Actions: ▪ Check the correct installation of the brake potentiometer (see paragraph BRAKE POTENTIOMETER, chapter 02) ▪ Repeat the calibration of the brake potentiometer

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45A LHS ERR (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector J84 is correctly plugged in ▪ Check for continuity between pin 1 of connector J84 and pin 33 of connector J5 ▪ Check for continuity between pin 2 of connector J84 and pin 34 of connector J5 ▪ Check for continuity between pin 3 of connector J84 and pin 32 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J84 and J5

494 CHKSUM ERROR (MCB card - TRCB section) Circumstances of error detection 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) Circumstances of error detection 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

4A7 EVP CURR MISMATCH (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card has detected a problem in the distributor valve pilot.

Actions: ▪ Update the software version of the TRCB and EVCB cards ▪ If the fault code is repeated, replace the MCB card

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4B6 DASH KO (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card does not receive messages from the DISPLAY. Actions: ▪ Run a key reset ▪ Update the software version of the TRCB card ▪ Update the software version of the DISPLAY

4C1 INCORRECT START (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card has detected an incorrect start sequence.

4C2 BRAKE WIRE KO (MCB card - TRCB section) Circumstances of error detection 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 that connector J15 is correctly plugged in ▪ Check for continuity between pin 1 of connector P15 and pin 16 of connector J5 ▪ Check for continuity between pin 2 of connector P15 and pin 30 of connector J5 ▪ Check for continuity between pin 3 of connector P15 and pin 27 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors P15 and J5

4C3 PEDAL WIRE KO (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector J32 is correctly plugged in ▪ Check for continuity between pin 1 of connector P32 and pin 30 of connector J5 ▪ Check for continuity between pin 2 of connector P32 and pin 28 of connector J5 ▪ Check for continuity between pin 3 of connector P32 and pin 25 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors P32 and J5

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4C4 BAD MICROSWITCH (MCB card - TRCB section) Circumstances of error detection 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 ▪ 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 ▪ Check for continuity between pin 1 of connector J33 and pin 32 of connector J5 ▪ Check for continuity between pin 2 of connector J33 and pin 4 of connector J5 ▪ Check for continuity between pin 3 of connector J33 and pin 5 of connector J5 ▪ Check for continuity between pin 4 of connector J33 and pin 32 of connector J5 ▪ Check for continuity between pin 5 of connector J33 and pin 1 of connector J5 ▪ Check for continuity between pin 7 of connector J33 and pin 32 of connector J5 ▪ Check for continuity between pin 8 of connector J33 and pin 6 of connector J5 ▪ Check for continuity between pin 9 of connector J33 and pin 7 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors P33, J33 and J5 ▪ Check the connections on the drive direction control on the steering wheel column ▪ Check that connector J39 is correctly plugged in ▪ Check for continuity between pin 2 of connector J39 and pin 32 of connector J5 ▪ Check for continuity between pin 3 of connector J39 and pin 32 of connector J5 ▪ Check for continuity between pin 4 of connector J39 and pin 7 of connector J5 ▪ Check for continuity between pin 5 of connector J39 and pin 5 of connector J5 ▪ Check for continuity between pin 6 of connector J39 and pin 32 of connector J5 ▪ Check for continuity between pin 7 of connector J39 and pin 4 of connector J5 ▪ Check for continuity between pin 8 of connector J39 and pin 6 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J29, J61, P61 and J5

4C6 BAD VACC (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card requires the acquisition of the accelerator potentiometer.

Actions: ▪ Check the correct installation of the accelerator potentiometer (see paragraph ACCELERATOR POTENTIOMETER, chapter 02) ▪ Check the correct configuration of the accelerator pedal, parameter SWAYING PEDAL ▪ Repeat the calibration of the accelerator potentiometer

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4C7 ERR SEAT (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card has detected an incorrect start sequence.

4C8 TRACTION LOCK (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector P33 is correctly plugged in ▪ Check for continuity between pin 1 of connector J33 and pin 32 of connector J5 ▪ Check for continuity between pin 2 of connector J33 and pin 4 of connector J5 ▪ Check for continuity between pin 3 of connector J33 and pin 5 of connector J5 ▪ Check for continuity between pin 4 of connector J33 and pin 32 of connector J5 ▪ Check for continuity between pin 5 of connector J33 and pin 1 of connector J5 ▪ Check for continuity between pin 7 of connector J33 and pin 32 of connector J5 ▪ Check for continuity between pin 8 of connector J33 and pin 6 of connector J5 ▪ Check for continuity between pin 9 of connector J33 and pin 7 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors P33, J33 and J5 ▪ Check the connections on the drive direction control on the steering wheel column ▪ Check that connector J39 is correctly plugged in ▪ Check for continuity between pin 2 of connector J39 and pin 32 of connector J5 ▪ Check for continuity between pin 3 of connector J39 and pin 32 of connector J5 ▪ Check for continuity between pin 4 of connector J39 and pin 7 of connector J5 ▪ Check for continuity between pin 5 of connector J39 and pin 5 of connector J5 ▪ Check for continuity between pin 6 of connector J39 and pin 32 of connector J5 ▪ Check for continuity between pin 7 of connector J39 and pin 4 of connector J5 ▪ Check for continuity between pin 8 of connector J39 and pin 6 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J29, J61, P61 and J5

4C9 PARKING SELECTED (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card has detected an incorrect start sequence.

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4CA PAR LOAD ERROR (MCB card - TRCB section) Circumstances of error detection 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

4CB TRAC IN ALARM (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card has detected a faulty traction logic unit.

Actions: ▪ Check the other fault codes

4CC TRUC STUFFING ERR (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card receives no messages from other cards connected to the Can-bus line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

4CD JOY MSG LOST (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card receives no messages from other cards connected to the Can-bus line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

4CE BRAKE BAD VACC (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card requires the 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 accelerator potentiometer

4CF FW PLUS BW (MCB card - TRCB section) Circumstances of error detection The MCB (AE5) card has detected an incorrect start sequence.

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4F1 STEER ENCODER KO (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector J14 is correctly plugged in ▪ Check for continuity between pin 1 of connector J14 and pin 13 of connector J5 ▪ Check for continuity between pin 2 of connector J14 and pin 14 of connector J5 ▪ Check for continuity between pin 3 of connector J14 and pin 11 of connector J5 ▪ Check for continuity between pin 4 of connector J14 and pin 12 of connector J5 ▪ Check for continuity between pin 5 of connector J14 and pin 10 of connector J5 ▪ That a measurement between pin 1 and pin 2 of connector J14 gives a reading of 12V ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J14, J88, P88 and J5

4F2 STEER SENSOR KO (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector J14 is correctly plugged in ▪ Check for continuity between pin 1 of connector J14 and pin 13 of connector J5 ▪ Check for continuity between pin 2 of connector J14 and pin 14 of connector J5 ▪ Check for continuity between pin 3 of connector J14 and pin 11 of connector J5 ▪ Check for continuity between pin 4 of connector J14 and pin 12 of connector J5 ▪ Check for continuity between pin 5 of connector J14 and pin 10 of connector J5 ▪ Check that a measurement between pin 1 and pin 2 of connector J14 gives a reading of 12V ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J14, J88, P88 and J5

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4F5 INT INDEX ERROR (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector J14 is correctly plugged in ▪ Check for continuity between pin 1 of connector J14 and pin 13 of connector J5 ▪ Check for continuity between pin 2 of connector J14 and pin 14 of connector J5 ▪ Check for continuity between pin 3 of connector J14 and pin 11 of connector J5 ▪ Check for continuity between pin 4 of connector J14 and pin 12 of connector J5 ▪ Check for continuity between pin 5 of connector J14 and pin 10 of connector J5 ▪ Check that a measurement between pin 1 and pin 2 of connector J14 gives a reading of 12V ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J14, J88, P88 and J5

4FA STEER LOAD OPEN (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector P98 is correctly plugged in ▪ The resistance value of the valve (standard 10Ω at 20°C) ▪ Check for continuity between pin 1 of connector J98 and pin 33 of connector J6 ▪ Check for continuity between pin 2 of connector J98 and pin 32 of connector J6 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J98, P98 and J6

4FB STEER LOAD SHORTED (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector P98 is correctly plugged in ▪ The resistance value of the valve (standard 10Ω at 20°C) ▪ Check for continuity between pin 1 of connector J98 and pin 33 of connector J6 ▪ Check for continuity between pin 2 of connector J98 and pin 32 of connector J6 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J98, P98 and J6

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4FC SWING LOAD OPEN (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector J62 is correctly plugged in ▪ The resistance value of the coil K1 (standard 6Ω at 20°C) ▪ Check for continuity between pin 1 of connector P62 and pin 35 of connector J6 ▪ Check for continuity between pin 2 of connector P62 and pin 34 of connector J6 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J62, P62 and J6

4FD SWING LOAD SHORTED (MCB card - TRCB section) Circumstances of error detection 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 ▪ Check that connector J62 is correctly plugged in ▪ The resistance value of the coil K1 (standard 6Ω at 20°C) ▪ Check for continuity between pin 1 of connector P62 and pin 35 of connector J6 ▪ Check for continuity between pin 2 of connector P62 and pin 34 of connector J6 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J62, P62 and J6

4FE V BATT KO (MCB card - TRCB section) Circumstances of error detection 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 that 48V registers between pin 18 of connector J6 and battery negative ▪ Check that 48V registers between pin 28 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

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LIFT LOGIC UNIT 5A0 ANALOG INPUT (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with input signals.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the coils connected to the auxiliary outputs.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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) ▪ The crimping of wires to contacts and insertion of the contacts into connectors J3 and J30 (possible false contact/dilated pin) ▪ Continuity of the wiring between connector J3 pin 16 and connector J30 pin 4 ▪ Continuity of the wiring between connector J3 pin 18 and connector J30 pin 8 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors J3 and J30 ▪ Replace the lift logic unit

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5A2 LOGIC FAILURE #3 (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the power circuit - high current overload protection.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 ▪ Replace the lift logic unit

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5A3 CAPACITOR CHARGE (lift logic unit) Circumstances of error detection 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 ▪ The condition of the plate and contacts of contactor K1 (oxidation or dirt) ▪ Replace the right traction logic unit ▪ If the alarm 5A3 appears together with 310, 210, 13C: ▪ 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

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5A4 VMN LOW (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the power circuit - low voltage at pump motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ Replace the lift logic unit

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5A5 DRIVER SHORTED (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the driver circuit of valve L27.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL 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 insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ Insulation of the coil from the body (standard greater than 1MΩ) ▪ The condition of the plate and contacts of contactor K7 (oxidation or dirt) ▪ The tightening torque of nuts on the contacts of contactor K1 (15.3 Nm – 16.4 Nm) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ 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) ▪ The crimping of wires to contacts and insertion of the contacts into connectors J3 and J30 (possible false contact/dilated pin) ▪ Continuity of the wiring between connector J3 pin 16 and connector J30 pin 4 ▪ Continuity of the wiring between connector J3 pin 18 and connector J30 pin 8 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors J3 and J30 ▪ Replace the lift logic unit

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5A6 MC COIL SHORTED (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the coil of contactor K1.

Actions: ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204.

▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor

5A7 VMN HIGH (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the power circuit - overvoltage at pump motor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump (see paragraph MOTOR WINDINGS CHECK PROCEDURE): - If the measured value is greater than 1Ω replace the motor ▪ 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 K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ Replace the lift logic unit

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5A8 STBY I HIGH (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected an abnormal level of current at the drive motor when in stand-by status.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ Replace the lift logic unit

5A9 CONTACTOR OPEN (lift logic unit) Circumstances of error detection 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors

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5AA AUX DRIV. SHRT (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the coils connected to the auxiliary outputs.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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) ▪ The crimping of wires to contacts and insertion of the contacts into connectors J3 and J30 (possible false contact/dilated pin) ▪ Continuity of the wiring between connector J3 pin 16 and connector J30 pin 4 ▪ Continuity of the wiring between connector J3 pin 18 and connector J30 pin 8 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors J3 and J30 ▪ Replace the lift logic unit

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5AB LOGIC FAILURE #1 (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the power circuit - low voltage.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J3 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 K1 contactor coil status: ▪ - The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ Replace the lift logic unit

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5AC LOGIC FAILURE #2 (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the hardware section controlling voltage feedback from the pump motor phases.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the state of the pump motor power cables ▪ The tightening torque of nuts on the pump logic unit (13 Nm – 15 Nm) ▪ The tightening torque of nuts on the pump motor (13 Nm – 15 Nm) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ Replace the lift logic unit

5AD SAFETY INPUT (lift logic unit) Circumstances of error detection 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 contact/dilated pin) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor

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5AE CONTACTOR DRIVER (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the driver circuit of valve L27.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL 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 insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors ▪ 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) ▪ The crimping of wires to contacts and insertion of the contacts into connectors J3 and J30 (possible false contact/dilated pin) ▪ Continuity of the wiring between connector J3 pin 16 and connector J30 pin 4 ▪ Continuity of the wiring between connector J3 pin 18 and connector J30 pin 8 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors J3 and J30 ▪ Replace the lift logic unit

5AF THERMIC PROTECTION (lift logic unit) Circumstances of error detection 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.

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5B0 EEPROM KO (lift logic unit) Circumstances of error detection 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) Circumstances of error detection 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 that connector J22 is correctly plugged in ▪ Check the resistance value of the pump motor temperature sensor (standard 629Ω at 25°C) ▪ Check for continuity between pin 1 of connector J22 and pin 23 of connector J3 ▪ Check for continuity between pin 2 of connector J22 and pin 22 of connector J3 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J3 and J22

5B2 WRONG SET BATTERY (lift logic unit) Circumstances of error detection The lift logic unit (AU3) 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) ▪ 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) ▪ Calibrate battery indicator (see paragraph BATTERY VOLTAGE READING ADJUSTMENT PROCEDURE, chapter 01) ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ Update the software version of the lifting logic unit

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5B3 THERMIC SENS KO (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a value generated by the drive motor temperature sensor that is out of range.

Actions: ▪ Check that the temperature sensor is not damaged: ▪ Check that connector J22 is correctly plugged in ▪ Check the resistance value of the pump motor temperature sensor (standard 629Ω at 25°C) ▪ Check for continuity between pin 1 of connector J22 and pin 23 of connector J3 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J3 and J22 ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Connect an external resistance (500 ohm ÷ 1000 ohm) to the temperature sensor connector J22: ▪ 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) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the coils connected to the auxiliary outputs.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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) ▪ The crimping of wires to contacts and insertion of the contacts into connectors J3 and J30 (possible false contact/dilated pin) ▪ Continuity of the wiring between connector J3 pin 16 and connector J30 pin 4 ▪ Continuity of the wiring between connector J3 pin 18 and connector J30 pin 8 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors J3 and J30 ▪ Replace the lift logic unit

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5B5 CHECK UP NEEDED (lift logic unit) Circumstances of error detection Maintenance hour counter warning.

Actions: ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ Update the software version of the lifting logic unit

5B6 NO CAN MSG. (lift logic unit) Circumstances of error detection The lift logic unit (AU3) receives no messages from other cards connected to the Can-bus line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

5B7 AUX DRIV. OPEN (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the coils connected to the auxiliary outputs.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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) ▪ The crimping of wires to contacts and insertion of the contacts into connectors J3 and J30 (possible false contact/dilated pin) ▪ Continuity of the wiring between connector J3 pin 16 and connector J30 pin 4 ▪ Continuity of the wiring between connector J3 pin 18 and connector J30 pin 8 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors J3 and J30 ▪ Replace the lift logic unit

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5B8 SAFETY OUTPUT (lift logic unit) Circumstances of error detection 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 ▪ The crimping of wires to contacts and insertion of the contacts into connectors J3 (possible false contact/dilated pin) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor

5B9 KEY OFF SHORT (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the power-up circuit.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J3 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) 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) ▪ Replace the lift logic unit

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5BA HARDWARE FAULT (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the power circuit.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ Replace the lift logic unit

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5BB POWER MOS SHORT (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the power circuit.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ Replace the lift logic unit

5BC CONTACTOR CLOSED (lift logic unit) Circumstances of error detection The lift logic unit (AU3) 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) ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ Insulation of the coil from the body (standard greater than 1MΩ) ▪ The tightening torque of nuts on the contacts of contactor K1 (15.3 Nm – 16.4 Nm) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ - The integrity of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors

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5BD ENCODER ERROR (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with signals generated by the pump motor rpm sensor Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the rpm sensor operation using the ANALYZER function ▪ Check the rpm sensor connections: ▪ Check that connector J17 is correctly plugged in ▪ Check for continuity between pin 1 of connector J17 and pin 8 of connector J3 ▪ Check for continuity between pin 2 of connector J17 and pin 14 of connector J3 ▪ Check for continuity between pin 3 of connector J17 and pin 7 of connector J3 ▪ Check for continuity between pin 4 of connector J17 and pin 15 of connector J3 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J3 and J17 ▪ 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 J17 ▪ The insulation of the rpm sensor relative to the body of the drive axle (must be > 1MΩ)

5BE WATCHDOG #1 (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected an internal problem.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the lift logic unit

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5BF WATCHDOG #2 (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected an internal problem.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the lift logic unit

5C1 WRONG RAM MEMORY (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem in the memory.

Actions: ▪ Run a key reset ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the lift logic unit

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5C2 SENS MOT TEMP KO (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a value generated by the drive motor temperature sensor that is out of range.

Actions: ▪ Check that the temperature sensor is not damaged: ▪ 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 J22 and pin 23 of connector J3 ▪ Check for continuity between pin 2 of connector J22 and pin 22 of connector J3 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J3 and J17 ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Connect an external resistance (500 ohm ÷ 1000 ohm) to the temperature sensor connector J17: ▪ 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) Circumstances of error detection The lift logic unit (AU3) has detected a problem with acquisition of electric current values Actions: ▪ Run a key reset and check the correct value of the drive parameters on the display ▪ Reset the pump logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the lift logic unit

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5C4 WRONG 0 VOLTAGE (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the hardware section controlling voltage feedback from the pump motor phases.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J3 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ The crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ Replace the lift logic unit

5C5 TORQUE PROFILE (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected inconsistent torque values given by the profiles stored in its memory.

Actions: ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ 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 ▪ Replace the lift logic unit

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5C7 ENCODER LOCKED (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with signals from the motor rpm sensor, or the rotor is stuck Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the rpm sensor operation using the ANALYZER function ▪ Check the rpm sensor connections: ▪ Check that connector J17 is correctly plugged in ▪ Check for continuity between pin 1 of connector J17 and pin 8 of connector J3 ▪ Check for continuity between pin 2 of connector J17 and pin 14 of connector J3 ▪ Check for continuity between pin 3 of connector J17 and pin 7 of connector J3 ▪ Check for continuity between pin 4 of connector J17 and pin 15 of connector J3 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J3 and J17 ▪ 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 J17 ▪ The insulation of the rpm sensor relative to the body of the drive axle (must be > 1MΩ)

5C8 FOC LOST (lift logic unit) Circumstances of error detection The lift logic unit (AU3) has detected a problem with the pump motor field orientation circuit.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor ▪ Check the windings of the pump motor (see paragraph MOTOR WINDINGS CHECK PROCEDURE): If the measured value is greater than 1Ω replace the motor ▪ 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 ▪ Replace the lift logic unit

5C9 IQ MISMATCHED (lift logic unit) Circumstances of error detection 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.

▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ Update the software version of the lifting logic unit ▪ Check the insulation of the pump motor (see heading INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor

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5CA PROG VACC NOT OK (lift logic unit) Circumstances of error detection Fault code not utilized.

Actions: ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ Update the software version of the lifting logic unit

5CB TEACH SWING POT (lift logic unit) Circumstances of error detection Fault code not utilized.

Actions: ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ Update the software version of the lifting logic unit

5CC STEER OUT RANGE (lift logic unit) Circumstances of error detection Fault code not utilized.

Actions: ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ Update the software version of the lifting logic unit

5CD TEACH STEER POT (lift logic unit) Circumstances of error detection Fault code not utilized.

Actions: ▪ Reset the lift logic unit using the TO DEFAULT SET function ▪ Update the software version of the lifting logic unit

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MCB CARD (EVCB section) 659 PSV ERR (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with the signal from the mast pressure sensor R7.

Actions: ▪ Check the pressure sensor connections: ▪ Check that connector J99 is correctly plugged in ▪ Check for continuity between pin 1 of connector J99 and pin 26 of connector J6 ▪ Check for continuity between pin 2 of connector J99 and pin 15 of connector J6 ▪ Check for continuity between pin 3 of connector J99 and pin 24 of connector J6 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6 and J99 ▪ 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) Circumstances of error detection 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 ▪ Check that connector J84 is correctly plugged in ▪ Check for continuity between pin 1 of connector J84 and pin 33 of connector J5 ▪ Check for continuity between pin 2 of connector J84 and pin 34 of connector J5 ▪ Check for continuity between pin 3 of connector J84 and pin 32 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J5 and J84

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65B TAS ERR (MCB card - EVCB section) Circumstances of error detection 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 value must read between 0.1V and 4.9V. ▪ Check the connections of the tilt angle potentiometer: ▪ Check that connector P86 is correctly plugged in ▪ Check for continuity between pin 1 of connector P86 and pin 30 of connector J5 ▪ Check for continuity between pin 2 of connector P86 and pin 24 of connector J5 ▪ Check for continuity between pin 3 of connector P86 and pin 31 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J5 and J86 ▪ 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) Circumstances of error detection The MCB (AU5) card has detected values for tilt angle potentiometer R6 or mast pressure sensor R7 different from those stored in memory.

Actions: ▪ Adjust the potentiometer rod (see paragraph TILT ANGLE POTENTIOMETER, chapter 02) ▪ Repeat the calibration of the tilt angle potentiometer and the mast pressure sensor

65E LPH ERR (MCB card - EVCB section) Circumstances of error detection 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 ▪ Check for continuity between pin 1 of connector P411 and pin 30 of connector J6 ▪ Check for continuity between pin 2 of connector P411 and pin 26 of connector J5 ▪ Check for continuity between pin 3 of connector P411 and pin 31 of connector J5 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J5, J6, P409, P411 and J411

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6A1 DOUBLE REQUEST (MCB card - EVCB section) Circumstances of error detection 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) Circumstances of error detection The MCB (AE5) card has detected a problem with the EVCB memory.

Actions: ▪ Check that an antistatic ground strap is fitted to the machine, if equipped with non-marking tyres ▪ Reset the EVCB card using the TO DEFAULT SET function ▪ Update the software version of the EVCB card ▪ If the fault code is repeated, replace the MCB card

6A3 PAR LOAD ERROR (MCB card - EVCB section) Circumstances of error detection The MCB (AE5) card has detected a problem with the MCB memory.

Actions: ▪ Check that an antistatic ground strap is fitted to the machine, if equipped with non-marking tyres ▪ Reset the EVCB card using the TO DEFAULT SET function ▪ Update the software version of the EVCB card ▪ If the fault code is repeated, replace the MCB card

6A4 NOT REP ERROR (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card does not receive Can-bus messages.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)

6A7 P SHORT ERR (MCB card - EVCB section) Circumstances of error detection 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

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6A8 EV1 1 OPEN (MCB card - EVCB section) Circumstances of error detection 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 ▪ For continuity between pin 1 of connector J31 and pin 3 of connector J6 ▪ For continuity between pin 2 of connector J31 and pin 2 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31 and J31

6A9 EV2 1 OPEN (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with lift valve L28.

Actions: ▪ Check the lift valve connections: ▪ That connector P30 is correctly plugged in ▪ For continuity between pin 1 of connector J30 and pin 3 of connector J6 ▪ For continuity between pin 2 of connector J30 and pin 1 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P30 and J30

6AA EV1 2 OPEN (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with backward tilt valve L26.

Actions: ▪ Check the backward tilt valve connections: ▪ That connector P30 is correctly plugged in ▪ For continuity between pin 5 of connector J30 and pin 6 of connector J6 ▪ For continuity between pin 6 of connector J30 and pin 4 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P30 and J30

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6AB EV2 2 OPEN (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with forward tilt valve L20.

Actions: ▪ Check the forward tilt valve connections: ▪ That connector P31 is correctly plugged in ▪ For continuity between pin 3 of connector J31 and pin 6 of connector J6 ▪ For continuity between pin 4 of connector J31 and pin 5 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31 and J31

6AC EV1 3 OPEN (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with the right sideshift valve L24.

Actions: ▪ Check the right sideshift valve connections: ▪ That connector P30 is correctly plugged in ▪ For continuity between pin 9 of connector J30 and pin 9 of connector J6 ▪ For continuity between pin 10 of connector J30 and pin 8 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P30 and J30

6AD EV2 3 OPEN (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with the left sideshift valve L19.

Actions: ▪ Check the left sideshift valve connections: ▪ That connector P31 is correctly plugged in ▪ For continuity between pin 5 of connector J31 and pin 9 of connector J6 ▪ For continuity between pin 6 of connector J31 and pin 7 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31 and J31

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6AE EV1 4 OPEN (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with the ATT2 valve L23.

Actions: ▪ Check the ATT2 valve connections: ▪ That connector P30 is correctly plugged in ▪ For continuity between pin 11 of connector J30 and pin 12 of connector J6 ▪ For continuity between pin 12 of connector J30 and pin 11 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P30 and J30

6AF EV2 4 OPEN (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with the ATT2 valve L18.

Actions: ▪ Check the ATT2 valve connections: ▪ That connector P31 is correctly plugged in ▪ For continuity between pin 7 of connector J31 and pin 12 of connector J6 ▪ For continuity between pin 8 of connector J31 and pin 10 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31 and J31

6B1 DRIVER EV1 SHORTED (MCB card - EVCB section) Circumstances of error detection 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 ▪ For continuity between pin 1 of connector J31 and pin 3 of connector J6 ▪ For continuity between pin 2 of connector J31 and pin 2 of connector J6 ▪ For continuity between pin 1 of connector J30 and pin 3 of connector J6 ▪ For continuity between pin 2 of connector J30 and pin 1 of connector J6 ▪ 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31, J31, P30 and J30 ▪ Replace the MCB card

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6B2 DRIVER EV2 SHORTED (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with tilt valves L26 or L20.

Actions: ▪ Check the lift and lowering valve connections: ▪ That connector P31 and P30 are correctly plugged in ▪ For continuity between pin 5 of connector J30 and pin 6 of connector J6 ▪ For continuity between pin 6 of connector J30 and pin 4 of connector J6 ▪ For continuity between pin 3 of connector J31 and pin 6 of connector J6 ▪ For continuity between pin 4 of connector J31 and pin 5 of connector J6 ▪ 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31, J31, P30 and J30 ▪ Replace the MCB card

6B3 DRIVER EV3 SHORTED (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with the sideshift valve L19 or L24.

Actions: ▪ Check the lift and lowering valve connections: ▪ That connector P31 and P30 are correctly plugged in ▪ For continuity between pin 9 of connector J30 and pin 9 of connector J6 ▪ For continuity between pin 10 of connector J30 and pin 8 of connector J6 ▪ For continuity between pin 5 of connector J31 and pin 9 of connector J6 ▪ For continuity between pin 6 of connector J31 and pin 7 of connector J6 ▪ 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31, J31, P30 and J30 ▪ Replace the MCB card

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6B4 DRIVER EV4 SHORTED (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with the ATT2 valves L23 or L18.

Actions: ▪ Check the lift and lowering valve connections: ▪ That connector P31 and P30 are correctly plugged in ▪ For continuity between pin 11 of connector J30 and pin 12 of connector J6 ▪ For continuity between pin 12 of connector J30 and pin 11 of connector J6 ▪ For continuity between pin 7 of connector J31 and pin 12 of connector J6 ▪ For continuity between pin 8 of connector J31 and pin 10 of connector J6 ▪ 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31, J31, P30 and J30 ▪ Replace the MCB card

6B6 DASH KO (MCB card - EVCB section) Circumstances of error detection The MCB (AE5) card does not receive messages from the DISPLAY. Actions: ▪ Run a key reset ▪ Update the software version of the EVCB card ▪ Update the software version of the DISPLAY

6B7 ERR SEAT (MCB card - EVCB section) Circumstances of error detection 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) Circumstances of error detection The MCB (AU5) card is not receiving Can-bus messages from the armrest card (AU6).

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)

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6BA DR PMOS LOCK (MCB card - EVCB section) Circumstances of error detection 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

6BB LOAD 1 SHORTED (MCB card - EVCB section) Circumstances of error detection 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 ▪ For continuity between pin 1 of connector J31 and pin 3 of connector J6 ▪ For continuity between pin 2 of connector J31 and pin 2 of connector J6 ▪ For continuity between pin 1 of connector J30 and pin 3 of connector J6 ▪ For continuity between pin 2 of connector J30 and pin 1 of connector J6 ▪ 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31, J31, P30 and J30 ▪ Replace the MCB card

6BC LOAD 2 SHORTED (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with tilt valves L26 or L20.

Actions: ▪ Check the lift and lowering valve connections: ▪ That connector P31 and P30 are correctly plugged in ▪ For continuity between pin 5 of connector J30 and pin 6 of connector J6 ▪ For continuity between pin 6 of connector J30 and pin 4 of connector J6 ▪ For continuity between pin 3 of connector J31 and pin 6 of connector J6 ▪ For continuity between pin 4 of connector J31 and pin 5 of connector J6 ▪ 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31, J31, P30 and J30 ▪ Replace the MCB card

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6BD LOAD 3 SHORTED (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with the sideshift valve L19 or L24.

Actions: ▪ Check the lift and lowering valve connections: ▪ That connector P31 and P30 are correctly plugged in ▪ For continuity between pin 9 of connector J30 and pin 9 of connector J6 ▪ For continuity between pin 10 of connector J30 and pin 8 of connector J6 ▪ For continuity between pin 5 of connector J31 and pin 9 of connector J6 ▪ For continuity between pin 6 of connector J31 and pin 7 of connector J6 ▪ 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31, J31, P30 and J30 ▪ Replace the MCB card

6BE LOAD 4 SHORTED (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected a problem with the ATT2 valves L23 or L18.

Actions: ▪ Check the lift and lowering valve connections: ▪ That connector P31 and P30 are correctly plugged in ▪ For continuity between pin 11 of connector J30 and pin 12 of connector J6 ▪ For continuity between pin 12 of connector J30 and pin 11 of connector J6 ▪ For continuity between pin 7 of connector J31 and pin 12 of connector J6 ▪ For continuity between pin 8 of connector J31 and pin 10 of connector J6 ▪ 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) ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J6, P31, J31, P30 and J30 ▪ Replace the MCB card

6E1 PUMP INCORR. START (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected an incorrect start procedure.

6EE PUMP STUFFING ERR (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card is not receiving Can-bus messages from the lift logic unit (AU2).

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)

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6F3 NYM ERR (MCB card - TRCB section) Circumstances of error detection The MCB (AU5) card has no acquisition values for tilt angle potentiometer R6 or mast pressure sensor R7 stored in memory.

Actions: ▪ Adjust the potentiometer rod (see paragraph TILT ANGLE POTENTIOMETER, chapter 02)

6F4 INCORRECT START (MCB card - EVCB section) Circumstances of error detection The MCB (AU5) card has detected an incorrect start procedure.

ARM REST CARD - MASTER MICROCONTROLLER 8E1 INCORRECT START MH (arm rest card - master microcontroller) Circumstances of error detection The armrest card (AU6) has detected an incorrect start procedure.

8E2 BAD LIFT POT (arm rest card - master microcontroller) Circumstances of error detection 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) Circumstances of error detection The armrest card (AU6) has detected a problem with the tilt potentiometer R10 / R11.

Actions: ▪ Repeat the calibration of the tilt potentiometer Self-diagnostic ▪ Invert the lift and tilt potentiometers and repeat the calibrations: ▪ If the fault code changes from 8E3 to 8E2, replace the potentiometer that was originally for the tilt ▪ If the fault code remains 8E3, the cause of the fault is in the arm rest wiring harness or the arm rest card is faulty

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8E4 BAD SIDESHIFT POT (arm rest card - master microcontroller) Circumstances of error detection 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 ▪ 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 ▪ If the fault code remains 8E4, the cause of the fault is in the arm rest wiring harness or the arm rest card is faulty

8E5 BAD IV POT (arm rest card - master microcontroller) Circumstances of error detection The armrest card (AU6) has detected a problem with the ATT2 function potentiometer R14 / R15.

Actions: ▪ Repeat the calibration of the ATT2 function potentiometer Self-diagnostic ▪ Invert the ATT2 and ATT1 function potentiometers and repeat the calibration: ▪ If the fault code changes from 8E5 to 8E4, replace the potentiometer that was originally for ATT2 ▪ If the fault code remains 8E5, the cause of the fault is in the arm rest wiring harness or the arm rest card is faulty

8E6 BAD V POT (arm rest card - master microcontroller) Circumstances of error detection 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: ▪ Repeat the calibration of the ATT2 function potentiometer Self-diagnostic ▪ Invert the ATT2 and ATT1 function potentiometers and repeat the calibrations ▪ If the fault code changes from 8E6 to 8E4, replace the potentiometer that was originally for ATT2 ▪ If the fault code remains 8E6, the cause of the fault is in the arm rest wiring harness or the arm rest card is faulty

8E7 ERROR SEAT (arm rest card - master microcontroller) Circumstances of error detection The armrest card (AU6) has detected an incorrect start procedure.

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8E8 INV RESTORE STATE (arm rest card - master microcontroller) Circumstances of error detection The armrest card (AU6) has detected a memory problem.

Actions: ▪ Check that an antistatic ground strap is fitted to the machine, if equipped with non-marking tyres ▪ 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) Circumstances of error detection The armrest card (AU6) has detected a memory problem.

Actions: ▪ Check that an antistatic ground strap is fitted to the machine, if equipped with non-marking tyres ▪ 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

8EA DEFAULT RESTORE (arm rest card - master microcontroller) Circumstances of error detection The armrest card (AU6) has detected a problem in the memory and has reloaded the parameter default values.

Actions: ▪ Check that an antistatic ground strap is fitted to the machine, if equipped with non-marking tyres ▪ 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

8EB MATCHING REQUIRED (arm rest card - master microcontroller) Circumstances of error detection No potentiometer acquisition values stored in memory of armrest card (AU6).

Actions: ▪ Repeat the calibration of the ATT2 function potentiometer

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4-141

8EC PDO CHKSUM ERROR (arm rest card - master microcontroller) Circumstances of error detection The armrest card (AU6) has detected a memory problem.

Actions: ▪ Check that an antistatic ground strap is fitted to the machine, if equipped with non-marking tyres ▪ 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

8ED BAD COMM EVCB (arm rest card - master microcontroller) Circumstances of error detection The armrest card (AU6) is not receiving Can-bus messages from the MCB (AU5) card.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)

8EE BAD COMM PUMP (arm rest card - master microcontroller) Circumstances of error detection The armrest card (AU6) is not receiving Can-bus messages from the lift logic unit (AU3).

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE)

8EF FW BW (arm rest card - master microcontroller) Circumstances of error detection 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: ▪ Check that connector J390 is correctly plugged in ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J390 and J139

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LITHIUM BATTERY A01 CAN COMUNICATION (Li-ION BATTERY) Circumstances of error detection 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) Circumstances of error detection The lithium battery has detected an internal problem.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

A03 OVER VOLTAGE (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected a problem with the battery voltage.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

A04 UNDER VOLTAGE (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected a problem with the battery voltage.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Charge the battery ▪ Contact the battery supplier

A05 HW FAIL 2 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected an internal problem.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

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A06 OVER TEMPERATURE 1 (Li-ION BATTERY) Circumstances of error detection 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

A07 UNDER TEMPERATURE 1 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected a problem with the battery temperature.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Wait for the battery temperature to rise above 0°C

A08 UNDER TEMPERATURE 2 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected a problem with the battery temperature.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Wait for the battery temperature to rise above 0°C

A09 OVER TEMPERATURE 2 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected a problem with the battery temperature.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Wait for the battery temperature to fall below 55°C

A0A HW FAIL 3 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected an internal problem.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

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A0B OVER CURRENT 1 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected a problem with the battery current.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

A0C OVER CURRENT 2 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected a problem with the battery current.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

A0D OVER CURRENT 3 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected a problem with the battery current.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

A0E OVER CURRENT 4 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected a problem with the battery current.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

A0F PROTECTION CIRCUIT 1 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected an internal problem.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Charge the battery ▪ Contact the battery supplier

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A10 PROTECTION CIRCUIT 2 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected an internal problem.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Charge the battery ▪ Contact the battery supplier

A11 HW FAIL 4 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected an internal problem.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

A12 HW FAIL 5 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected an internal problem.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

A13 HW FAIL 6 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected an internal problem.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

A14 HW FAIL 7 (Li-ION BATTERY) Circumstances of error detection The lithium battery has detected an internal problem.

Actions: ▪ Check the setting of the Li-ION BATT parameter in the OPT - BATTERY menu ▪ Contact the battery supplier

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MULTI-DISPLAY FUNCTIONS C01 EPS KO (display) Circumstances of error detection 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) ▪ Check for the correct battery voltage between pin 15 of connector J4 and negative - BATT when the truck is powered up ▪ Replace the steering logic unit EPS

C02 TRAC KO (display) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the right traction logic unit (AU1).

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check for the correct battery voltage between pin 1 of connector J1 and negative - BATT when the truck is powered up ▪ Replace the right traction logic unit

C03 TRAC SLAVE KO (display) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the left traction logic unit (AU2).

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check for the correct battery voltage between pin 1 of connector J2 and negative - BATT when the truck is powered up ▪ Replace the left traction logic unit

C04 MCB TRAC KO (display) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the TRCB section of the MCB (AU5) card.

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check for the correct battery voltage between pin 13 of connector J6 and negative - BATT when the truck is powered up ▪ Replace the MCB card

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C05 PUMP KO (display) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the lift logic unit (AU3).

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check for the correct battery voltage between pin 1 of connector J3 and negative - BATT when the truck is powered up ▪ Replace the lift logic unit

C06 MCB MHY KO (display) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the EVCB section of the MCB card (AU5).

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check for the correct battery voltage between pin 13 of connector J6 and negative - BATT when the truck is powered up ▪ Replace the MCB card

C08 JOY KO (display) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the MASTER microcontroller of the armrest card (AU6).

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ 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) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the SLAVE microcontroller of the armrest card (AU6).

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ 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

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CA1 BOARD MISMATCH (display) Circumstances of error detection 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) Circumstances of error detection The display (AE1) has detected that the truck was incorrectly configured.

Actions: ▪ Check the truck serial number in the MATCHING menu

CA3 BRAKE LEVEL ALARM (display) Circumstances of error detection The display (AE1) has detected a low brake oil level.

Actions: ▪ Check the brakes oil level

CA4 CANNOT READ SN (display) Circumstances of error detection The display (AE1) cannot read the truck serial number saved in the other cards.

Actions: ▪ Update the software on all cards on the truck ▪ Check the truck serial number in the MATCHING menu

CA5 CANNOT RESET LEARN FLAG (display) Circumstances of error detection The display (AE1) cannot reset the calibrations of one or more cards.

Actions: ▪ Update the software on all cards on the truck

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CB9 DHU KO (display) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the DHU (AU7) card.

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check for the correct battery voltage between pin 1 and pin 8 of connector J142 when the truck is powered up ▪ Reset the DHU configuration ▪ Replace the DHU card

CDA SHOCK LOCKOUT (display) Circumstances of error detection 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) Circumstances of error detection 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) Circumstances of error detection 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): ▪ If the alarm condition disappears on disconnecting one of the components listed above, proceed to check the state of the component ▪ Check the state and operation of the relays mounted on the 12-24V fuse card ▪ Replace the display

CDE KEY ERROR (display) Circumstances of error detection The display (AE1) has detected a problem with the key circuit.

Actions: ▪ Check for the correct battery voltage between pin 29 of connector J5 and negative - BATT when the truck is powered up ▪ Replace the MCB card ▪ Replace the display

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CDF EEPROM ERROR (display) Circumstances of error detection The display (AE1) has detected a memory problem.

Actions: ▪ Check that an antistatic ground strap is fitted to the machine, if equipped with non-marking tyres ▪ Run a CLEAR LOG in the fault code logbook ▪ Update the display software

CF1 SHOCK SENSOR KO (display) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the shock sensor (SH1).

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check for the correct battery voltage between pin 1 and pin 2 of connector J145 when the truck is powered up ▪ Reset the shock sensor configuration ▪ Replace the shock sensor

CF2 IMMOBILIZED POC (display) Circumstances of error detection P.O.C. card has blocked the machine. The truck supervisor must restore normal operation.

CF3 SMART ACCESS KO (display) Circumstances of error detection The display (AE1) is not receiving Can-bus messages from the SMART ACCESS card.

Actions: ▪ Check the Can-bus connections (see paragraph CAN-BUS CHECK PROCEDURE) ▪ Check for the correct battery voltage between pin 1 and pin 2 of connector J146 when the truck is powered up ▪ Reset the SMART ACCESS card configuration ▪ Replace the SMART ACCESS card

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ARM REST CARD - SLAVE MICROCONTROLLER BE6 LIFT POT ERROR (arm rest card - slave microcontroller) Circumstances of error detection 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 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) Circumstances of error detection The armrest card (AU6) has detected a problem with the tilt potentiometer R10 / R11.

Actions: ▪ Repeat the calibration of the tilt potentiometer Self-diagnostic ▪ Invert the lift and tilt potentiometers and repeat the calibrations: ▪ If the fault code changes from BE7 to BE6, replace the potentiometer that was originally for the tilt ▪ If the fault code remains BE7, the cause of the fault is in the arm rest wiring harness or the arm rest card is faulty

BE8 SIDESHIFT POT ERROR (arm rest card - slave microcontroller) Circumstances of error detection 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 ▪ 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 ▪ If the fault code remains BE8, the cause of the fault is in the arm rest wiring harness or the arm rest card is faulty

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BE9 IV POT ERROR (arm rest card - slave microcontroller) Circumstances of error detection The armrest card (AU6) has detected a problem with the ATT2 function potentiometer R14 / R15.

Actions: ▪ Repeat the calibration of the ATT2 function potentiometer 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 ▪ If the fault code remains BE9, the cause of the fault is in the arm rest wiring harness or the arm rest card is faulty

BEA BAD V POT (arm rest card - slave microcontroller) Circumstances of error detection 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: ▪ Repeat the calibration of the ATT2 function potentiometer 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) Circumstances of error detection 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 ▪ Replace the Armrest Board

BED FIRMWARE TYPE ERROR (arm rest card - slave microcontroller) Circumstances of error detection The armrest card (AU6) has detected a software problem.

Actions: ▪ Update the software of the MASTER and SLAVE armrest card

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BEF JOY MASTER KO (arm rest card - slave microcontroller) Circumstances of error detection The arm rest card (AU6) has detected an internal communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Replace the Armrest Board

BF8 INVALID RESTORE STATE (arm rest card - slave microcontroller) Circumstances of error detection 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

BF9 EEPROM INCOSIS ERROR (arm rest card - slave microcontroller) Circumstances of error detection 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

BFA DEFAULT RESTORED (arm rest card - slave microcontroller) Circumstances of error detection 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

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EPS STEERING LOGIC UNIT - SLAVE MICROCONTROLLER 4108 WATCHDOG (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected an internal communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Run a key reset ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the steering logic unit EPS

410D EEPROM KO (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) 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 steering parameters on the display ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the steering logic unit EPS

4110 LOGIC FAILURE #4 (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (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

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4111 LOGIC FAILURE #3 (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (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

4120 VMN NOT OK (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (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 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 ▪ 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

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4130 MAIN CONT OPEN (EPS steering logic unit - slave microcontroller) Circumstances of error detection 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 ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 16 and connector J203 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)

4135 STBY I HIGH (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (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

4146 HIGH CURRENT (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (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

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4147 POWER FAILURE #3 (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a low current on phase W. 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

4148 POWER FAILURE #2 (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a low current on phase V. 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

4149 POWER FAILURE #1 (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a low current on phase U. 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

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4162 INPUT ERROR #2 (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the TFD sensor signals.

Actions: ▪ Check that the TFD sensor is correctly plugged in ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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)

41CF SP MISMATCH (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the TFD sensor signals.

Actions: ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function ▪ Restore all the steering parameters to the default value ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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)

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41D0 OUTPUT MISMATCH (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with 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°) ▪ Check the steering sensor operation using the ANALYZER function ▪ Repeat the steering sensor calibration ▪ Replace the steering sensor

41D1 WD SYNCHRO (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected an internal communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Run a key reset ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the steering logic unit EPS

41D4 WRONG RAM MEMORY (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the memory.

Actions: ▪ Run a key reset ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the steering logic unit EPS

41D5 PARAM RESTORE (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has reloaded the default parameters.

Actions: ▪ Run a key reset ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the steering logic unit EPS

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41D6 SP JERK (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the TFD sensor signals.

Actions: ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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) ▪ Check the power supply from the EPS steering logic unit: ▪ Measure the voltage between pin 1 and pin 2 on connector J11 (standard +5V)

41D7 CAN BUS KO M/S (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected an communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Update the software version of the MASTER and SLAVE microcontroller on the EPS steering logic unit ▪ Replace the steering logic unit EPS

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41D8 TFD WRONG RESIST (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the TFD sensor resistance.

Actions: ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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) ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function

41DA CONTROLLER MISMATCH (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected an incorrect software version.

Actions: ▪ Update the software version of the MASTER and SLAVE microcontroller on the EPS steering logic unit

41DC MOTOR LOCKED (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) 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

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41DF FB JERK (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the steering motor encoder.

Actions: ▪ Check that the wiring harness between the EPS steering logic and the steering motor encoder is not crushed/damaged/disconnected ▪ Check that the steering axle and/or the steering motor are not mechanically locked ▪ Use the ANALYZER menu to check the steering motor encoder functions

41E1 CURRENT GAIN (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the power circuit.

Actions: ▪ Run a key reset ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the steering logic unit EPS

41E4 POSITION ERROR (EPS steering logic unit - slave microcontroller) Circumstances of error detection 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

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41EB TFD SHRT/VOLT KO (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the TFD sensor.

Actions: ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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) ▪ Check the power supply from the EPS steering logic unit: ▪ Measure the voltage between pin 5 and pin 6 on connector J11 (standard battery voltage)

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41EC TFD STB I HIGH (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the TFD sensor.

Actions: ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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) ▪ Check the power supply from the EPS steering logic unit: ▪ Measure the voltage between pin 5 and pin 6 on connector J11 (standard battery voltage)

41ED SLAVE ALARM XX (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the SLAVE microcontroller.

Actions: ▪ Run a key reset ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the steering logic unit EPS

41F0 LOGIC SUPPLY ERR (EPS steering logic unit - slave microcontroller) Circumstances of error detection 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

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41F1 FB SENSOR LOCKED (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the steering motor encoder.

Actions: ▪ Check that the wiring harness between the EPS steering logic and the steering motor encoder is not crushed/damaged/disconnected ▪ Check that the steering axle and/or the steering motor are not mechanically locked ▪ Use the ANALYZER menu to check the steering motor encoder functions

41F7 CAN BUS KO (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a communication problem on the CAN-BUS line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

41F8 SP OUT OF RANGE (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the TFD sensor.

Actions: ▪ Check that the steering wheel column is not mechanically locked ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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) ▪ Check the power supply from the EPS steering logic unit: ▪ Measure the voltage between pin 1 and pin 2 on connector J11 (standard +5V)

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41FA INPUT MISMATCH (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected an internal problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Run a key reset ▪ Reset the EPS steering logic unit using the TO DEFAULT SET function ▪ If the fault code is repeated, replace the steering logic unit EPS

41FC TWIN POT MISMAT (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with 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°) ▪ Check the steering sensor operation using the ANALYZER function ▪ Repeat the steering sensor calibration ▪ Replace the steering sensor

41FD ANALOG (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the analog signals.

Actions: ▪ Run a key reset ▪ If the fault code is repeated, replace the steering logic unit EPS

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41FE NO SP REFRESH (EPS steering logic unit - slave microcontroller) Circumstances of error detection The EPS steering logic unit (AU4) has detected a problem with the TFD sensor.

Actions: ▪ Check that the steering wheel column is not mechanically locked ▪ Check that the TFD sensor is correctly plugged in ▪ Check that the wiring harness between the EPS steering logic and TFD sensor is not crushed or damaged ▪ Check the state of the connections: ▪ 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 ▪ Continuity of the wiring harness between connector J4 pin 19 and connector J11 pin 2 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 17 and connector J11 pin 3 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 20 and connector J11 pin 4 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 9 and connector J11 pin 5 on the TFD sensor ▪ Continuity of the wiring harness between connector J4 pin 10 and connector J11 pin 6 on the TFD sensor ▪ Check the state of the TFD sensor: ▪ The resistance value of the TFDsensor 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) ▪ Check the power supply from the EPS steering logic unit: ▪ Measure the voltage between pin 1 and pin 2 on connector J11 (standard +5V)

RIGHT TRACTION LOGIC UNIT - SLAVE MICROCONTROLLER 4201 WATCHDOG (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected an internal communication problem between the MASTER and SLAVE microcontrollers.

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 9801 to 9901, replace the traction logic unit originally on the right ▪ If the fault code remains 9801, the cause of the fault is outside the right traction logic unit

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4205 LOGIC FAILURE #1 (right traction logic unit - slave microcontroller) Circumstances of error detection 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 ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9805 to 9905, replace the traction logic unit originally on the right ▪ If the fault code remains 9805, the cause of the fault is outside the right traction logic unit

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4208 CONTACTOR OPEN (right traction logic unit - slave microcontroller) Circumstances of error detection 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors

4213 ENCODER ERROR (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with signals generated by the right drive motor rpm sensor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 rpm sensor operation using the ANALYZER function ▪ Check the rpm sensor connections: ▪ Check that connector J12 is correctly plugged in ▪ Check for continuity between pin 1 of connector J12 and pin 8 of connector J1 ▪ Check for continuity between pin 2 of connector J12 and pin 14 of connector J1 ▪ Check for continuity between pin 3 of connector J12 and pin 7 of connector J1 ▪ Check for continuity between pin 4 of connector J12 and pin 15 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 J12 ▪ 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)

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4216 NO CAN MSG (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) receives no messages from other cards connected to the Can-bus line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

4219 AUX DRIV. SHORTED (right traction logic unit - slave microcontroller) Circumstances of error detection 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 truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 drive 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 ▪ 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 L3 (standard 30Ω at 20°C) ▪ The resistance value of the coils on valves K1 (standard 100Ω at 20°C) ▪ Insulation of the coils from the body (standard greater than 1MΩ) ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the coil connectors Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9819 to 9919, replace the traction logic unit originally on the right ▪ If the fault code remains 9819, the cause of the fault is outside the right traction logic unit

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421C VDC OFF SHORTED (right traction logic unit - slave microcontroller) Circumstances of error detection 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 ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 981C to 991C, replace the traction logic unit originally on the right ▪ If the fault code remains 981C, the cause of the fault is outside the right traction logic unit

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4225 WRONG SET BATT (right traction logic unit - slave microcontroller) Circumstances of error detection 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) ▪ 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) ▪ Calibrate battery indicator (see paragraph BATTERY VOLTAGE READING ADJUSTMENT PROCEDURE, chapter 01) ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit

4227 EEPROM KO (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) 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 drive parameters on the display ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the right traction logic unit

TROUBLESHOOTING

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4228 VDC LINK OVERV. (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the power circuit - overvoltage.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J1 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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) ▪ 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 ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9828 to 9928, replace the traction logic unit originally on the right ▪ If the fault code remains 9828, the cause of the fault is outside the right traction logic unit

422C CURRENT GAIN (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with acquisition of electric current values.

Actions: ▪ Run a key reset and check the correct value of the drive parameters on the display ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the right traction logic unit

4

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TROUBLESHOOTING

4231 VKEY OFF SHORTED (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with the ignition circuit.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J1 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9831 to 9931, replace the traction logic unit originally on the right ▪ If the fault code remains 9831, the cause of the fault is outside the right traction logic unit

4234 WRONG RAM MEM. (right traction logic unit - slave microcontroller) Circumstances of error detection The RIGHT traction logic unit (AU1) has encountered a problem in the RAM. Actions: ▪ Run a key reset and check the correct value of the drive parameters on the display ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the right traction logic unit

TROUBLESHOOTING

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423C ANALOG INPUT (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with input signals.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the right drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 983C to 993C, replace the traction logic unit originally on the right ▪ If the fault code remains 983C, the cause of the fault is outside the right traction logic unit

423D CONTROLLER MISMATCH (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) 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 ▪ Reset the right traction logic unit using the function TO DEFAULT SET ▪ Update the software version of the MASTER and SLAVE microcontroller on the right traction logic unit ▪ If the fault code is repeated, replace the right traction logic unit

4

4-176

TROUBLESHOOTING

4242 AUX DRV OPEN (right traction logic unit - slave microcontroller) Circumstances of error detection 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 truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 drive 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 lift logic unit ▪ 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 L3 (standard 30Ω at 20°C) ▪ The resistance value of the coils on valves K1 (standard 100Ω at 20°C) ▪ Insulation of the coils from the body (standard greater than 1MΩ) ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the coil connectors Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9842 to 9942, replace the traction logic unit originally on the right ▪ If the fault code remains 9842, the cause of the fault is outside the right traction logic unit

424A WD SYNCHRO (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected an internal communication problem between the MASTER and SLAVE microcontrollers.

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 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

TROUBLESHOOTING

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4252 OUTPUT MISMATCH (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with output signals.

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 9852 to 9952, replace the traction logic unit originally on the right ▪ If the fault code remains 9852, the cause of the fault is outside the right traction logic unit

425B INPUT MISMATCH (right traction logic unit - slave microcontroller) Circumstances of error detection The right traction logic unit (AU1) has detected a problem with input signals.

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 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) Circumstances of error detection The left traction logic unit (AU2) has detected an internal communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Run a key reset ▪ Reset the left 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 9901 to 9801, replace the traction logic unit originally on the left ▪ If the fault code remains 9901, the cause of the fault is outside the left traction logic unit

4

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TROUBLESHOOTING

4305 LOGIC FAILURE #1 (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - low voltage.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J2 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9905 to 9805, replace the traction logic unit originally on the left ▪ If the fault code remains 9905, the cause of the fault is outside the left traction logic unit

TROUBLESHOOTING

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4308 CONTACTOR OPEN (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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 308 may simply be a consequence ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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) ▪ 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 ▪ Continuity of the wiring between connector J44 pin 3 and connector J204 ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the connectors

4313 ENCODER ERROR (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with signals generated by the left drive motor rpm sensor.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 rpm sensor operation using the ANALYZER function ▪ Check the rpm sensor connections: ▪ Check that connector J12 is correctly plugged in ▪ Check for continuity between pin 1 of connector J16 and pin 8 of connector J2 ▪ Check for continuity between pin 2 of connector J16 and pin 14 of connector J2 ▪ Check for continuity between pin 3 of connector J16 and pin 7 of connector J2 ▪ Check for continuity between pin 4 of connector J16 and pin 15 of connector J2 ▪ Check the state of the wiring (no pinch points), with wires securely crimped, and pins seated firmly in the connectors J2 and J16 ▪ 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 J16 ▪ The insulation of the rpm sensor relative to the body of the drive axle (must be > 1MΩ)

4

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TROUBLESHOOTING

4316 NO CAN MSG (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) receives no messages from other cards connected to the Can-bus line.

Actions: ▪ Check the other fault codes (see paragraph CAN-BUS CHECK PROCEDURE)

4319 AUX DRIV. SHORTED (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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 truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 drive 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 ▪ Check the state of the coils on valves L2, L3 and K1: ▪ The resistance value of the coils on valves L2 (standard 30Ω at 20°C) ▪ The resistance value of the coils on valves L3 (standard 30Ω at 20°C) ▪ The resistance value of the coils on valves K1 (standard 100Ω at 20°C) ▪ Insulation of the coils from the body (standard greater than 1MΩ) ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the coil connectors Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9919 to 9819, replace the traction logic unit originally on the left ▪ If the fault code remains 9919, the cause of the fault is outside the left traction logic unit

TROUBLESHOOTING

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431C VDC OFF SHORTED (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - low voltage.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J2 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 991C to 981C, replace the traction logic unit originally on the left ▪ If the fault code remains 991C, the cause of the fault is outside the left traction logic unit

4

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TROUBLESHOOTING

4325 WRONG SET BATT (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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) ▪ 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) ▪ Calibrate battery indicator (see paragraph BATTERY VOLTAGE READING ADJUSTMENT PROCEDURE, chapter 01) ▪ Reset the left traction logic unit using the function TO DEFAULT SET ▪ Update the software version of the MASTER and SLAVE microcontroller on the left traction logic unit

4327 EEPROM KO (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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 drive parameters on the display ▪ Reset the left traction logic unit using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the left traction logic unit

TROUBLESHOOTING

4-183

4328 VDC LINK OVERV. (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the power circuit - overvoltage.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J2 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ 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 right traction logic unit ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) ▪ 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9928 to 9828, replace the traction logic unit originally on the left ▪ If the fault code remains 9928, the cause of the fault is outside the left traction logic unit

432C CURRENT GAIN (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with acquisition of electric current values.

Actions: ▪ Run a key reset and check the correct value of the drive parameters on the display ▪ Reset the left traction logic unit using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the left traction logic unit

4

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TROUBLESHOOTING

4331 VKEY OFF SHORTED (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with the ignition circuit.

Actions: ▪ Check for the correct battery voltage between pin 1 of connector J2 and negative - BATT when the truck is powered up ▪ 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 ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 ▪ Check the K1 contactor coil status: ▪ The resistance value of the coil K1 (standard 100Ω at 20°C) 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 ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9931 to 9831, replace the traction logic unit originally on the left ▪ If the fault code remains 9931, the cause of the fault is outside the left traction logic unit

4334 WRONG RAM MEM. (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem in the RAM. Actions: ▪ Run a key reset and check the correct value of the drive parameters on the display ▪ Reset the left traction logic unit using the function TO DEFAULT SET ▪ If the fault code is repeated, replace the left traction logic unit

TROUBLESHOOTING

4-185

433C ANALOG INPUT (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with input signals.

Actions: ▪ Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ The insulation of the left drive motor (see paragraph INSULATION CHECK PROCEDURE): If the measured value is less than 1MΩ replace the motor Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 993C to 983C, replace the traction logic unit originally on the left ▪ If the fault code remains 993C, the cause of the fault is outside the left traction logic unit

433D CONTROLLER MISMATCH (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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 ▪ Reset the left traction logic unit using the function TO DEFAULT SET ▪ Update the software version of the MASTER and SLAVE microcontroller on the left traction logic unit ▪ If the fault code is repeated, replace the left traction logic unit

4

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TROUBLESHOOTING

4342 AUX DRV OPEN (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) 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 truck insulation (see paragraph INSULATION CONTROL PROCEDURE) ▪ 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 crimping of terminals ▪ That cable sheaths are not worn or damaged (possible current leakage to chassis) ▪ 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 drive 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 ▪ Check the state of the coils on valves L2, L3 and K1: ▪ The resistance value of the coils on valves L2 (standard 30Ω at 20°C) ▪ The resistance value of the coils on valves L3 (standard 30Ω at 20°C) ▪ The resistance value of the coils on valves K1 (standard 100Ω at 20°C) ▪ Insulation of the coils from the body (standard greater than 1MΩ) ▪ The state of the wiring (pinched wire), crimping of the wires, and insertion of the pins into the coil connectors Self-diagnostic ▪ Invert the right traction logic unit and the left traction logic unit: ▪ If the fault code changes from 9942 to 9842, replace the traction logic unit originally on the left ▪ If the fault code remains 9942, the cause of the fault is outside the left traction logic unit

434A WD SYNCHRO (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected an internal communication problem between the MASTER and SLAVE microcontrollers.

Actions: ▪ Run a key reset ▪ Reset the left 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 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

TROUBLESHOOTING

4-187

4352 OUTPUT MISMATCH (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with output signals.

Actions: ▪ Run a key reset ▪ Reset the left 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 9952 to 9852, replace the traction logic unit originally on the left ▪ If the fault code remains 9952, the cause of the fault is outside the left traction logic unit

435B INPUT MISMATCH (left traction logic unit - slave microcontroller) Circumstances of error detection The left traction logic unit (AU2) has detected a problem with input signals.

Actions: ▪ Run a key reset ▪ Reset the left 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 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

4

4-188

TROUBLESHOOTING

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

Disassembly Procedure 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 Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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

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

DISASSEMBLY·INSPECTION·REASSEMBLY

5

Disassembly Procedure 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] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

NOTICE! Apply CASTROL OPTIMOL T WHITE type paste in the spline section of the pump before assembling.

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

Disassembly Procedure 1) Disconnect the battery connector.

2) Remove the mast group.

3) Jack up the vehicle and remove the front wheels. [Point 1] 4) Remove the footboard.

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

CAUTION! Bleed the service brake system and check it is working correctly.

NOTICE! When replacing the reduction gear, also replace the pinion.

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 support 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

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 UNIT - 3 WHEEL VERSION GENERAL

REAR AXLE

REAR AXLE

7-3

DISASSEMBLY-ASSEMBLY TT = 205 Nm ±10%

7

Disassembly Procedure 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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

7-4

REAR AXLE UNIT - 4 WHEEL VERSION GENERAL

COMPONENTS

REAR AXLE

REAR AXLE

7-5

7

DISASSEMBLY-ASSEMBLY

TT = 29 Nm ±10%

TT = 151Nm±10% TT = 140Nm±10%

Disassembly Procedure 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] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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, remove 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: Assemble the bushing aligning the greasing groove in the bushing with the greasing tool position.

REAR AXLE HUB - CAST ARTICULATED JOINT DISASSEMBLY-ASSEMBLY

Disassembly Procedure 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] Reassembly Procedure

7

7-8

REAR AXLE

The assembly procedure is the reverse of the disassembly procedure.

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.

▪ 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 clearance 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

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 (0.177 in)

Install the needle roller bearings and articulated joint pin oil seals.

▪ Use the special tool (SST) to install the needle bearings.

Check the ball bearing press-fitting surface, pressing direction and depth.

1.0 mm (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 (0.071 in)

▪ Fit the dust protection element.

▪ 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

Disassembly Procedure 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] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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 8FBE15T 8FBEK16T 8FBE16T 8FBEK18T 8FBE18T 8FBE20T 8FBMK16T 8FBM16T 8FBM18T

Front tyre size 18 x 7-8 18 x 7-8 18 x 7-8 18 x 7-8 18 x 7-8 200/50-10 18 x 7-8 18 x 7-8 18 x 7-8

Rear tyre size 15 x 4.1/2-8 15 x 4.1/2-8 15 x 4.1/2-8 140/55-9 140/55-9 140/55-9 16 x 6-8 16 x 6-8 16 x 6-8

REAR AXLE Model 8FBMK20T 8FBM20T

7-13 Front tyre size 200/50-10 200/50-10

Rear tyre size 16 x 6-8 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

SCRAPER

HYDRAULIC STEERING

HYDRAULIC STEERING

8-3

STEERING COLUMN DISASSEMBLY•ASSEMBLY TT = 25-45 Nm

8

TT = 1 Nm

Disassembly Procedure 1) Disconnect the battery connector.

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).

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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 orbitrol.

8-4

HYDRAULIC STEERING

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 automatically align themselves with the steering wheel pin holes.

TFD SENSOR - 3 WHEEL VERSION DISASSEMBLY•ASSEMBLY

TT = 10Nm ±10% + Loctite 222

TT = 10Nm ±10% + Loctite 222

Disassembly Procedure 1) Disconnect the battery connector.

HYDRAULIC STEERING

8-5

2) Remove the parking brake cover.

3) Remove the column cover (front and rear).

4) Disconnect the connectors.

5) Remove the return spring.

6) Remove the tilt lock mechanism and the steering mast lock release lever.

7) Remove the TFD sensor.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

NOTICE! Apply “Mobil grease special” to the coupling between the steering shaft and the steering valve.

8 ORBITROL - 4 WHEEL VERSION DISASSEMBLY•ASSEMBLY

TT = 39±6 Nm

Disassembly Procedure 1) Disconnect the battery connector.

2) Remove the parking brake cover.

3) Remove the column cover (front and rear).

4) Disconnect the connectors around the mast cover.

5) Remove the return spring.

6) Remove the tilt lock mechanism and the steering mast lock release lever.

7) Remove the hydraulic steering pipes.

8) Remove the hydraulic steering fixing bolts.

9) Remove the hydraulic steering unit.

10) Remove the connections.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

NOTICE! Apply “Mobil grease special” to the coupling between the steering shaft and the steering valve.

8-6

HYDRAULIC STEERING

INSPECTION AND ADJUSTMENT OF MAXIMUM PRESSURE SST

1) Install an oil pressure gauge.

Disconnect the hose from the steering valve port and connect the adapter (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 pressure 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 DISASSEMBLY•ASSEMBLY

TT = 11±2Nm

Disassembly Procedure 1) Disconnect the battery connector.

HYDRAULIC STEERING

8-7

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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

8-8

HYDRAULIC STEERING

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 DISASSEMBLY·INSPECTION·ASSEMBLY

9

Disassembly Procedure 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.

4) Remove the footboard.

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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 DISASSEMBLY·INSPECTION·ASSEMBLY

Disassembly Procedure

BRAKE

9-5

1) Disconnect the battery connector.

2) Remove the mast group.

3) Jack up the vehicle and remove the front wheels.

4) Remove the gear motor unit.

5) Remove the parking brake.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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

COMPONENTS

FRAME

FRAME

10-3

10

10-4

FRAME

FRAME

10-5

10

10-6

FRAME

FRAME

10-7

OPERATOR’S SEAT DISASSEMBLY-ASSEMBLY

10

1) Tilt the steering column forward (or release it).

2) Open the battery cover.

3) Disconnect the battery connector.

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

10-8

BATTERY COVER UNIT DISASSEMBLY-ASSEMBLY

Disassembly Procedure 1) Tilt the steering column forward (or release it).

2) Remove the back plastic cover.

3) Open the battery cover.

4) Disconnect the battery connector.

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

FRAME

FRAME

10-9

OVERHEAD GUARD DISASSEMBLY-ASSEMBLY

10

Disassembly Procedure 1) Open the battery cover.

2) Disconnect the battery connector.

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.

7) Disconnect the electrical wiring.

8) Disconnect the hydraulic connectors from the steering valve (4 wheel version only).

9) Remove the overhead guard.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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

MATERIAL HANDLING SYSTEM

11-3

HYDRAULIC CIRCUIT - 4 WHEEL VERSION

11

11-4

OIL FILTER REMOVAL• INSTALLATION

Disassembly Procedure 1) Disconnect the battery connector.

2) Remove the footboard (FR RR) and the tilting cylinder cover.

3) Open the tank plug.

4) Remove the return filter. [Point 1] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

MATERIAL HANDLING SYSTEM

MATERIAL HANDLING SYSTEM

11-5

Point Operations [Point 1] Disassembly: (B) (A)

1. Remove the ring (A) mounted on the base of the level, inserting 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.

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

11

11-6

MATERIAL HANDLING SYSTEM

NATURAL FORWARD TILTING TEST 1) Place the mast in the vertical position with a nominal load on the forks, raise the forks 500 mm and switch off the truck.

2) Measure the tilting cylinder rod dilation after 110 minutes.

Limit: 0.10° or less

Outer mast Inclinometer

NOTICE! The above tests must be carried out with the hydraulic oil at 50°C.

OIL LEAK TEST LIFT CYLINDER 1) Place the mast in the vertical position with a nominal load on 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

MATERIAL HANDLING SYSTEM

11-7

TILTING CYLINDERS 1) Place the mast in the vertical position with a nominal load on 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

Tank drain

NOTICE! The above tests must be carried out with the hydraulic oil at 50°C.

11

11-8

MATERIAL HANDLING SYSTEM

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 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

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 profile

Internal profile A

V FV FSV

External profile

12

Intermediate profile B

External profile C

CENTRAL MFH (mm) 3000 ÷ 5000 3000÷ 3700 4300 ÷ 6000

1.5 - 2.0 t A+C A+C A+B+C

12-6

MASTS

MAST SECTION (FW - FSW)

Internal profile

Internal profile

Intermediate profile

Intermediate profile

External profile

External profile A

B

FW FSW

CENTRAL MFH (mm) 3000 ÷ 4000 ALL

1.5 - 1.6 t A B

1.8 - 2.0 t 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

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

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

LIFTING BRACKET GROUP (FW) (1.5 - 2.0 t)

LIFTING BRACKET GROUP (FSW) (1.5 - 2.0 t)

MASTS

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

SIDESHIFT FORK CARRIAGE GROUP (FSV) (1.5 - 2.0 t)

SIDESHIFT FORK CARRIAGE GROUP (FW) (1.5 - 2.0 t)

MASTS

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

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

MASTS

12-15

FORK CARRIAGE ASSEMBLY AND MAST REMOVAL DISASSEMBLY-ASSEMBLY

3

T=110Nm±10%

12

8

T=83Nm±10%

9 T=27Nm ±10%

4 2

Disassembly Procedure 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 inner 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.

10) Remove the mast group.

11) Check the condition of the mast support bushing. [Point 5] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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 adjustment 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)

Mast FSW

12

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

0.2-0.4 mm

Internal profile

[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: For rigid fixings, use the special tool for removal.

SST1 09810-20172-71 SST2 09820-31040-71

SST 2 SST 1

[Point 5] Inspection: 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

12-20

MASTS

MAST GROUP (WITH FORK CARRIAGE) DISASSEMBLY-ASSEMBLY

3

T=110Nm±10% 8

T=83Nm±10%

9 T=27Nm ±10%

4 2

Disassembly Procedure 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 inner 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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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: For rigid fixings, use the special tool for removal.

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 DISASSEMBLY·INSPECTION·ASSEMBLY

OIL FULL

STD 2 1

2 3

4

7

5

Disassembly Procedure 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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

MASTS

12-23

Point Operations [Point 1] Disassembly: x y

Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. 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 DISASSEMBLY·INSPECTION·ASSEMBLY

1

2 2 3 4

7

5

Disassembly Procedure 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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

MASTS

12-25

Point Operations [Point 1] Disassembly: x

Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. Keep a record of how the adjustment is done and how many shims are used.

Assembly: Maximum play (x): 1.5 ~ 3.5 mm

12 [Point 2] Inspection: Measure the thickness of the mast tab.

Limit: 1.5 mm

12-26

MASTS

MAST GROUP FSV DISASSEMBLY·INSPECTION·ASSEMBLY

2

2

1 OIL FULL 2

3

4

7

5

Disassembly Procedure 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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

MASTS

12-27

Point Operations [Point 1] Disassembly:

x y

Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. 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

12-28

MASTS

FW MAST GROUP DISASSEMBLY·INSPECTION·ASSEMBLY

1

2 2

8

Disassembly Procedure 1) Remove the mast lifting height switch.

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

MASTS

12-29

Point Operations [Point 1] Disassembly: x y

Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. 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 ~ 3.5 mm Spacer thickness (y): 0.8 mm

12

12-30

MASTS

FSW MAST GROUP DISASSEMBLY·INSPECTION·ASSEMBLY

1

2

2

10

Disassembly Procedure 1) Remove the mast lifting height switch.

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

Point Operations [Point 1] Disassembly: x y

Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. 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 ~ 3.5 mm Spacer thickness (y): 0.8 mm

12

12-32

MASTS

FORK CARRIAGE (V - FV - FSV) DISASSEMBLY·INSPECTION·ASSEMBLY

V - FV

FSV

Disassembly Procedure 1) Remove the lifting rollers. [Point 1] 2) Remove the support.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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

6

9

Disassembly Procedure 1) Park the vehicle on a level surface and apply the parking brake.

2) Turn off the truck.

3) Disconnect the battery connector.

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] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

Point Operations [Point 1] Assembly: Spacer thickness (y): 0.5 mm Maximum play (x): 0.5 ~ 1.0 mm

y

x

[Point 2] Assembly: Limit: 4.5 mm

[Point 3] Disassembly: Remove the dowel (A) and then remove the pin (B) sliding upwards.

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 x 4 mm)

Z

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

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 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

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.

Thickness of adjusting ring: 0.5 - 1.0 mm ▪ 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 clearance 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, measure 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 roller adjusting ring (see paragraph on Mast roller).

Thickness of adjusting ring: 0.5 - 1.0 mm

▪ 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.

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.

The clearance is on one side

No clearance

Minimum clearance = A

Outside diameter of the roller 107,7

Upper lift rollers

108,7 ▪ Select the lift rod central lift rollers. Select the central lift rollers from the following table that correspond to the lift rollers selected in the previous point; if it is not possible to maintain clearance 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 107,7 108,7

Central lift rollers 107,7 107,7

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 DISASSEMBLY-ASSEMBLY ü Disassembly Procedure 1) Remove the fork yoke plate (see mast assembly removal procedure).

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 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.

Shims

Remove the inner mast rollers and adjusting rings.

Reassembly Procedure Shims

The assembly procedure is the reverse of the disassembly procedure.

MASTS

12-41

FORK CARRIAGE (FW - FSW) DISASSEMBLY·INSPECTION·ASSEMBLY FW

FSW

12

Disassembly Procedure 1) Remove the guide shoes.

2) Slacken the adjustment screw.

3) Remove the snap ring. [Point 1] 4) Remove the roller. [Point 1] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

Point Operations [Point 1] Disassembly: SST 09950-76014-71 (09950-40011)

SST

12-42

MASTS

SIDESHIFT FORK CARRIAGE (FW - FSW) (ISS) DISASSEMBLY·INSPECTION·REASSEMBLY

FW

FSW 2

2

1

1

3

3

5

5

Disassembly Procedure 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] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

Point Operations [Point 1] Inspection: Measure the external diameter of the piston rod.

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 6

7

12

5

upper shim 8

7

lower shim

Disassembly Procedure 1) Park the vehicle on a level surface and apply the parking brake.

2) Turn off the truck.

3) Disconnect the battery connector.

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] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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

Internal profile

Clearance 0.2-0.4 mm

50 mm

Clearance 0.2-0.4 mm

350 mm Push

Fork yoke

Clearance 0.2-0.4 mm

Clearanc e

Inner profile 0.2-0.4 mm External profile

MASTS

12-45 1. Unscrew the adjustment screw.

2. Assemble the chassis (mast or fork carriage) as shown in the image to the side.

Standard clearance: 0.2-0.4 mm External profile

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.

Setting screw

Roller Pad

Internal profile 0.2-0.5 mm

5. Adjust the RH pads (upper and lower) for half the play (considering that for each turn, the screw moves 1.25 mm: 1/4 = 0.3 mm).

6. Put shim (0.3 mm) on the LH side and tighten the adjustment screw until the shim does not move.

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 figure.

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 arrow 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 corresponding to 34 pitches, only 33 pitches are found.

Standard values of the chain pitch distance Mast V FV FSV

Vehicle 1.5 - 2.0 t 1.5 - 2.0 t 1.5 - 2.0 t

FW FSW

1.5 - 2.0 t 1.5 - 2.0 t

Distance (mm) 15,875 * 15,875 * 15,875 * 15,875 * 15,96 * 15,96 * 15,875 *

* Measure using a caliber.

NOTICE! Take the measurement without removing the chain from the vehicle NOTICE! Check for any localized stretching along the chain

Type BL534 BL534 BL534 (primary) BL534 (secondary) BL544 BL544 (primary) BL544 (secondary)

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: Lift bracket

/

FSW: Inner mast

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

Class IA II A III A IV A VA Class IA II A III A IV A VA

TABLE ISO 2328 - 1993 Capacity (kg) 0 ÷ 999 1000 ÷ 2500 2500 ÷ 4999 5000 ÷ 8000 8001 ÷ 10999 Capacity (kg) 0 ÷ 999 1000 ÷ 2500 2500 ÷ 4999 5000 ÷ 8000 8001 ÷ 10999

“X” (± 5) 76 mm 76 mm 76 mm 127 mm 127 mm “X” (± 5) 114 mm 152 mm 203 mm 254 mm 257 mm

12

FORK DISASSEMBLY·INSPECTION·ASSEMBLY Dismantling procedure 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 The assembly procedure is the reverse of the disassembly procedure.

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 nondestructive 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 renewed by the original fork supplier.

5. Fork wear control: The fork arm blade and shank must be thoroughly checked for wear, paying special attention to the area around the heel (D).

When maximum wear is detected, with thickness reduced to 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 replacements 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 almost 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.

Shims

▪ Lift the inner mast again for a final check.

▪ Repeat the control and adjustments until the number of adjusting rings is defined.

Thickness of adjusting ring: 0.5·1.0 mm

12

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 / / 1 telescopic cylinder with braking effect on lifting 1 telescopic cylinder with braking effect on lifting (standard) (standard)

V FV

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

1 telescopic cylinder with braking effect on lifting 1 telescopic cylinder with braking effect on lifting (standard) (standard)

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

FSV

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 (standard) (standard)

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 (standard) (standard)

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 telescopic cylinders with braking effect on lowering (standard)

2.0 t 2 telescopic cylinders with braking effect on lowering (standard)

V

2 displacement cylinders with brake effect on the 2 displacement cylinders with brake effect on the lifting and lowering (standard) lifting and lowering (standard)

FV

2 telescopic cylinders with braking effect on lowering (standard)

FSV

2 telescopic cylinders with braking effect on lowering (standard)

2 displacement cylinders with brake effect on the 2 displacement cylinders with brake effect on the lifting and lowering (standard) lifting and lowering (standard)

FW

2 telescopic cylinders with braking effect on lowering (standard)

2 telescopic cylinders with braking effect on lowering (standard)

FSW

2 telescopic cylinders with braking effect on lowering, OIL FULL version (optional)

2 telescopic cylinders with braking effect on lowering, OIL FULL version (optional)

13-4

CYLINDERS

SPECIFICATIONS V MAST SIDE LIFTING CYLINDER

1.5 - 1.8 t Cylinder type Cylinder bore mm Piston rod external diameter Parachute valve R mm Opening mm

2.0 t Single effect

45 36 1.2 0.6

48 36 1.8 0.6

1.5 - 1.8 t

2.0 t

FV MAST SIDE LIFTING CYLINDER

Cylinder type Cylinder bore mm Piston rod external diameter Parachute valve R mm Opening mm

Single effect 40 32 1.2 0.6

45 35 1.8 0.6

1.5 - 1.8 t

2.0 t

FSV MAST SIDE LIFTING CYLINDER

Cylinder type Cylinder bore mm Piston rod external diameter Parachute valve R mm Opening mm

Single effect 45 36 1.2 0.6

48 36 1.8 0.6

1.5 - 1.8 t

2.0 t

FW MAST SIDE LIFTING CYLINDER

Cylinder type Cylinder bore mm Piston rod external diameter Parachute valve R mm Opening mm

Single effect 32 40 1.2 0.6

45 35 1.8 0.6

FSW MAST SIDE LIFTING CYLINDER

1.5 - 1.8 t Cylinder type Cylinder bore mm Piston rod external diameter Parachute valve R mm Opening mm

2.0 t Single effect

45 38 1.2 0.6

48 40 1.2 0.6

1.5 - 1.8 t

2.0 t

FV MAST CENTRAL LIFTING CYLINDER

Cylinder type Cylinder bore mm Piston rod external diameter Parachute valve R mm Opening mm

Single effect 70 55 1.6 0.6

75 55 1.8 0.6

CYLINDERS

13-5

FSV MAST CENTRAL LIFTING CYLINDER

1.5 - 1.8 t Cylinder type Cylinder bore mm Piston rod external diameter Parachute valve R mm Opening mm

2.0 t Single effect

70 55 1.6 0.6

75 55 1.8 0.6

1.5 - 1.8 t

2.0 t

FW MAST CENTRAL LIFTING CYLINDER

Cylinder type Cylinder bore mm Piston rod external diameter Parachute valve R mm Opening mm

Single effect 48 40 1.2 0.6

52 42 1.8 0.6

1.5 - 1.8 t

2.0 t

FSW MAST CENTRAL LIFTING CYLINDER

Cylinder type Cylinder bore mm Piston rod external diameter Parachute valve R mm Opening mm

Single effect 48 40 1.2 0.6

52 42 1.8 0.6

PARACHUTE VALVE (LOWERING SAFETY VALVE)

R

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).

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

Mast type V FV FSV FW FSW

Valve settings Valve type Integrated in the control valve Integrated in the control valve Integrated in the control valve Integrated in the control valve Integrated in the control valve

s (mm) / / / / /

13

13-6

COMPONENTS SIDE LIFTING CYLINDERS V - FSV MAST (1.5 - 1.8 t)

SIDE LIFTING CYLINDERS V - FSV MAST (2.0 t)

CYLINDERS

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

SIDE LIFTING CYLINDERS FV MAST (2.0 t)

CENTRAL LIFTING CYLINDERS FV - FSV MAST (2.0 t)

CYLINDERS

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

FW MAST SIDE LIFTING CYLINDERS (2.0 t)

CENTRAL LIFTING CYLINDERS FW - FSW MAST (2.0 t)

CYLINDERS

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 DISASSEMBLY•ASSEMBLY V - FSV 2

6

FW - FSW

FV 2

6

6

Disassembly Procedure 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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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): Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. Keep a record of how the adjustment is done and how many shims are used.

Assembly: Tighten the nut and leave some play, as shown in the figure.

Maximum play (x): 1.5 mm Spacer thickness (y): 0.8 mm

13

Disassembly (FV mast): Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. 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 ~ 3.5 mm

13-14

CYLINDERS Disassembly (FSV mast): Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. Keep a record of how the adjustment is done and how many shims are used.

Assembly: Tighten the nut and leave some play, as shown in the figure.

Maximum play (x): 1.5 mm Spacer thickness (y): 0.8 mm

Disassembly (FW mast): Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. Keep a record of how the adjustment is done and how many shims are used.

Assembly: Tighten the screw onto the cover as illustrated in the figure.

Maximum play (x): 1.5 ~ 3.5 mm Spacer thickness (y): 0.8 mm

Disassembly (FSW mast): Adjustment must be done using shims on the end of the lifting cylinder rod to prevent uneven lifting of the right and left lifting cylinders. 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 ~ 3.5 mm Spacer thickness (y): 0.8 mm

CYLINDERS

13-15

CYLINDER (V - FSV - FSW) REMOVAL - INSPECTION - INSTALLATION V - FSV

FSW T= 450 ±5% Nm

4

3

4

3

8

13 7 T= 3Nm

Disassembly Procedure 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] 4) Remove the piston rod. [Point 2] 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] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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: Slide out the piston rod.

Unscrew the bushing as shown in the figure (if the previous one is not available).

NOTICE! Touch up the cover with paint if it has been damaged during disassembly; do not contaminate the rod.

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 inserting.

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.

Assembly: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation and twist slightly when inserting.

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. 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

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 bushing 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) REMOVAL - INSPECTION - INSTALLATION FV

FW T= 300 ±5% Nm

4

4 3

3

8

7 T= 3 Nm

Disassembly Procedure 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] 4) Remove the piston rod.

5) Remove the seals from the piston rod. [Point 2] 6) Remove the descent braking device. [Point 3] 7) Remove the parachute valve (descent safety valve). [Point 4] 8) Remove the cylinder. [Point 5] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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: 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: Slide out the piston rod.

Unscrew the bushing as shown in the figure (if the previous one is not available).

NOTICE! Touch up the cover with paint if it has been damaged during disassembly; do not contaminate the rod.

Disassembly: Disassemble using a pneumatic percussion screwdriver (or electric equivalent).

NOTICE! Block the rotation of the chrome rod using a drive pin punch.

Assembly: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation and twist slightly when inserting.

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. Assembly: Clean the housing seats with compressed air; lubricate the scraper with hydraulic oil before installation to facilitate positioning.

13

13-22

CYLINDERS 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: Before inserting the ring, clean the housing seats with compressed 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 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.

Assembly: Lubricate the bushing with oil before inserting the rod.

Assembly: Use a spacer (X) if required.

X

- For FV mast:

Mast height 3000 3300 3500 3700

1.5 - 1.8 t no no no yes (120 mm)

2.0 t no no no yes (120 mm)

CYLINDERS

13-23

- For FW mast:

Mast height 1760 2600 2900 3000 3300 3500 3700 4000

1.5 - 1.8 t yes (40 mm) no no no no no no yes (100 mm)

2.0 t no no no no no no no yes (100 mm)

Assembly: Insert the bushing slightly twisting it on the chrome rod.

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) NOTICE! Check that the o-ring is correctly in its seat and is not 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 equivalent).

NOTICE! Block the rotation of the chrome rod using a drive pin punch.

[Point 2] Disassembly: Remove the gasket without damaging the seat.

Assembly: ▪ Clean the housing seat with compressed air; insert the seeger.

2

1

▪ Lubricate the gasket with hydraulic oil before mounting in order to facilitate its positioning.

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): 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.

13-26

CYLINDERS Assembly (FW): Before inserting the ring, clean the housing seats with compressed 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 a max. temperature of 50°C.

[Point 5] 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

Inspection: Measure the internal diameter of the lifting cylinder and check that it is in good condition.

CYLINDERS

13-27

CENTRAL LIFTING CYLINDER ASSEMBLY DISASSEMBLY•ASSEMBLY FV

FSV

13 FW

FSW

Disassembly Procedure 1) Remove the fork holder plate.

2) Disconnect all the piping.

3) Remove the front lifting cylinder.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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) REMOVAL - INSPECTION - INSTALLATION FW - FSW

FV - FSV

T= 450 ±5% Nm 3

4

7

Disassembly Procedure 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] 4) Remove the piston rod. [Point 2] 5) Remove the seals from the piston rod. [Point 3] 6) Remove the lifting braking device. [Point 4] 7) Remove the cylinder. [Point 5] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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 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: 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: Slide out the piston rod. Unscrew the bushing as shown in the figure (if the previous one is not available).

NOTICE! Touch up the cover with paint if it has been damaged during disassembly; do not contaminate the rod.

Assembly: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation and twist slightly when inserting.

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.

Assembly: Clean the housing seats with compressed air; lubricate the scraper with hydraulic oil before installation to facilitate positioning.

13

13-30

CYLINDERS 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: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning.

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.

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.

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 bushing so as to avoid deforming the bottom of the cylinder.

CYLINDERS

13-31

[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 (FV - FSV): 1) Insert the gasket.

2) Insert the seeger.

3) Insert the gasket.

NOTICE! Before assembly, clean the housing with compressed air and lubricate the gasket with hydraulic oil;

3

NOTICE! Avoid twisting the gasket in the seat.

2 1

Disassembly: Remove the gasket without damaging the seat.

Assembly (FW - FSW): 1) Insert the seeger.

2) Insert the gasket.

3) Insert the seeger.

NOTICE! Before assembly, clean the housing with compressed air and lubricate the gasket with hydraulic oil;

3

NOTICE! Avoid twisting the gasket in the seat.

2 1

[Point 4] Disassembly: (only for version with braking effect on lowering): Remove the seeger and the unidirectional valve.

13

13-32

CYLINDERS Assembly (version FW - FSW only): Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning.

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

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

[Point 5] Inspection: Measure the internal diameter of the lifting cylinder and check that it is in good condition.

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 Cylinder bore mm Piston rod outside diameter mm Piston gasket Rod gasket Tilting degrees 5° forwards - 7° backwards 5° forwards - 5° backwards * without roof / without front panel or ≤ 6000mm * with roof / with front panel or > 6000mm

COMPONENTS

Double action 70 30 U gasket U gasket Stroke mm 82 * 69 **

CYLINDERS

13-35

DISASSEMBLY•ASSEMBLY

13

INSTALLING THE REAR BUSHING ON THE TILTING CYLINDER FRAME

FRONT

FRAME BUSHING

Notes: 1) The bushing can be installed either facing the inside or the outside of the truck.

2) The bushing must be assembled using specific lithium-based grease (Microlube GL 261 or similar).

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

TRUCK INTERIOR

BUSHING

TRUCK EXTERIOR

Disassembly Procedure 1) Remove the footboard.

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 overturning.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

NOTICE! Before installation, apply grease to the front and rear pin seats on the tilting cylinder (Shell Mobil 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 0° - 0.4° 0.6° - 0°

Forwards Reverse 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

4

5

T= 300 ±20 Nm 6

T= 500 ±20 Nm

CYLINDERS

13-37

Disassembly Procedure 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] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

NOTICE! Apply hydraulic oil to the gaskets, O-rings and dust seal edges.

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 screwdriver; 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 carefully (A).

(A)

Assembly: Before re-installing, lubricate the gaskets and o-rings with Vaseline.

CYLINDERS

13-39

[Point 3] Inspection: Measure the external diameter of the piston rod.

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 Oil pump type Engine system Delivery (pump at 1500 rpm) Nominal leakage

Gear pump TMG1A21A3H5-L (Shimadzu) Direct motor activation 30.8 l/min 21.9 cm3 / rev

OIL PUMP

14-3

COMPONENTS

14 TT = 61Nm

14-4

OIL PUMP

DISASSEMBLY·INSPECTION·REASSEMBLY 5

TT = 88 ÷ 98 Nm 1 6

3

4

Disassembly Procedure 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] Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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] Match mark between front cover and casing

Match mark between rear cover and casing

Disassembly: Mark the positions of the front and rear covers on the casing.

Assembly: Align match marks when installing.

Rear cover

Front cover

Casing

14

[Point 2] Inspection: Bush Rear cover

Lubrication groove

The inner surface of the bushing must not be scratched or worn on the outside, the metal on the rear side must be visible.

[Point 3] Inspection: Limit of wear: 0.15mm or less LBC surface (yellow)

Outlet opening

Rigid contacts Cavitation wear

The side surface of the place (LBC surface) in contact with the gears must not be worn beyond the limit shown in the picture on the left.

14-6

OIL PUMP Inspection:

Outlet opening

Scratch depth from 0.01 to 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 rounded 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, install 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 following values are based on certain conditions.

Lifting speed reference value mm/sec Model V

FS W

FW

Lifting

Lowering Lifting

Lowering Lifting

Lowering

H P S All H P S All H P S All

1.5 t Empty Shear 610 440 550 350 480 260 550 530 570 390 500 320 440 240 450 510 570 400 510 330 440 250 420 500

1.6 t Empty Shear 610 430 550 340 480 250 550 530 570 390 500 310 440 230 450 510 570 400 510 310 440 230 420 500

1.8 t Empty Shear 610 420 540 310 480 240 550 530 570 380 500 280 440 200 450 510 570 390 510 290 450 210 420 500

2.0 t Empty Shear 540 380 480 280 420 200 500 520 500 340 440 260 380 180 390 490 490 340 430 260 380 190 340 470

14

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

HYDRAULIC DIAGRAM

DISTRIBUTOR

DISTRIBUTOR

15-3

COMPONENTS

15

15-4

DISTRIBUTOR

DISTRIBUTOR

15-5

15

SPECIFICATIONS Model Type Relief pressure (MPa)

8FBE15T 8FBEK16T 8FBE16T 8FBEK18T 8FBE18T 8FBE20T Additional type 18,3 ← ← ← ← ← 18,3 ← ← ← ← ← 50 ← ← ← ← 55 520 ← ← ← ← 500 520 ← ← ← ← 510 400 ← ← ← ← 370 500 ← ← ← ← 480 360 ← ← ← ← 320 490 ← ← ← ← 450

Model Type Relief pressure (MPa)

8FBMK16T 8FBM16T 8FBM18T 8FBMK20T 8FBM20T Additional type 18,3 ← ← ← ← 18,3 ← ← ← ← 50 ← ← 55 ← 550 ← ← 500 ← 530 ← ← 520 ← 450 ← ← 390 ← 510 ← ← 490 ← 420 ← ← 340 ← 500 ← ← 470 ←

Lifting Tilting Flow regulator flow rate (ℓ/min) Lowering speed V Empty specifications Loaded (mm/sec) FSW Empty Loaded FW Empty Loaded

Lifting Tilting

Flow regulator flow rate (ℓ/min) Lowering speed speV cifications (mm/sec) FSW FW

Empty Loaded Empty Loaded Empty Loaded

15-6 Solenoid valve L28 L21 L27 L26 L20 L25 L24 L19 L23 L28

DISTRIBUTOR Function Lifting Lowering Lift lock Tilting Backward Tilting Forward Tilting control ATT1 ATT1 ATT2 ATT2

Coil value 7.2 ohm 7.2 ohm 9.9 ohm 7.2 ohm 7.2 ohm 9.9 ohm 7.2 ohm 7.2 ohm 7.2 ohm 7.2 ohm

COIL VOLTAGE 0÷12 V 0÷12 V 0÷12 V 0÷12 V 0÷12 V 0÷12 V 0÷12 V 0÷12 V 0÷12 V 0÷12 V

Maximum flow rate 79 lt 79 lt / 16 lt 13 lt / 43 lt 43 lt 43 lt 43 lt

DISASSEMBLY-ASSEMBLY 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.

Disassembly Procedure 1) Remove the footboard.

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

NOTICE! Check the hydraulic oil level and add more if insufficient.

DISTRIBUTOR

15-7

DISASSEMBLY·INSPECTION·REASSEMBLY NOTICE! Work in a clean environment.

NOTICE! Since individual parts are finished with high precision, carefully operate so as not to damage them.

7

6

3

3

1

15

5 2 4

3

5

4 5 4

8

Disassembly Procedure 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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

NOTICE! Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembling.

15-8

DISTRIBUTOR

Point Operations [Point 1] Disassembly: Trace reference lines to avoid installing the solenoid in the incorrect 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.

Terminal 7 - 8 measurement: Continuity ok Standard: 7 to 17 ohm

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).

Terminal 1 - 2 measurement: Continuity ok Terminal 3 - 4 measurement: Continuity ok Terminal 5 - 6 measurement: Continuity ok Terminal 7 - 8 measurement: Continuity ok Check the resistance of the proportional solenoid valve solenoid (a).

Standard: 5 to 12 ohm 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 disassembly.

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).

Terminal 1 - 2 measurement: Continuity ok Terminal 3 - 4 measurement: Continuity ok Terminal 5 - 6 measurement: Continuity ok Terminal 7 - 8 measurement: Continuity ok Check the resistance of the proportional solenoid valve solenoid (b).

Standard: 5 to 12 ohm 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 disassembly.

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.

1) Open the battery cover.

2) Remove the footboard.

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 emergency 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 signals 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 stabilizer (S).

S: Active control of rear stabilizer T: Active mast function control K: Active hydraulic steering synchronizer Sensor/Switch 1 Mast height switch 2 Tilt angle potentiometer 3 Tilt potentiometer

4 5

6

7 8

Lifting Potentiometer Mast pressure sensor Automatic fork level control switch Steering wheel angle sensor MASTER OF THE PUMP LOGIC UNIT

Control S T K O O

IN →

O

O

MCB Card

OUT →

Control S T K O

9

→

→

O

10

O

→

→

O

11

O

→

→

O

12

O

→

→

O

→

-

-

-

-

O

→

-

-

-

-

O

→

-

-

-

-

O

13

Actuator Oscillation lock cylinder Tilt control valve Electric tilting proportional valve Lift lock valve Hand grip position correction valve

SAS FUNCTION

16-3

FOR REPAIR WORK CAUTION! Before repairing the system of active stability (SAS), make sure you fully understand its functions.

1. Preparation for repair: ▪ If possible, avoid washing the vehicle; use a jet of compressed air for cleaning purposes. If washing with water 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 transport 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 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 installation.

▪ 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

16-4

SAS FUNCTION

HAND GRIP POSITION CORRECTION VALVE DISASSEMBLY-ASSEMBLY

Disassembly Procedure 1) Disconnect the battery connector.

2) Remove the column cover (front).

3) Remove the direction unit cover (front and rear).

4) Disconnect the connectors around the mast cover.

5) Remove the return spring.

6) Remove the tilt lock mechanism and the steering mast lock release lever.

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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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

Disassembly-Assembly (models with steel can or windshield): Use the specific tool (SST), to remove the hydraulic steering seals.

SST 09451-13240-71

16

16-6

SAS FUNCTION

OSCILLATION LOCK CYLINDER DISASSEMBLY-ASSEMBLY

Disassembly Procedure 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.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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 end of the accumulator (do not over-tighten).

16

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 - COURTESY LIGHT ........................................................................................................ 13 MULTIFUNCTION JOYSTICK ............................................................................. 14

17

17-2

MAIN OPTIONS

DC/DC CONVERTERS

DC/DC converters T1 48V / 24V converter

T2

Power

Connected systems

144 W / 360 W / 720 W

2 front working lights (LED version) 2 rear working lights (LED version) Rear lights (stop/tail + reversing) Rear LED lights (stop/tail + reversing) 2 washer pumps Combined front lights (dipped + tail + direction indicators) Combined front LED lights (dipped + tail + direction indicators) 2 additional LED working lights Height selector 2 wiper motors 24V auxiliary output Heater Courtesy light 2 additional LED working lights on the mast Heated rear window Pneumatic seat (+ heated seat) Blue LED light Reading light Radio 12V auxiliary output Heated seat

360 W

48V / 24V converter

T3

360 W

48V / 24V converter T4 48V / 12V converter

300 W

Maximum system consumption 140 W (70 W) 140 W (70 W) 140 W 7W 72 W 192 W 26 W 70 W 6W 200 W 80 W 40 W 5W 29 W 115 W 120 W (96 W) 7.2 W 2.5 W 80 W 60 W 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 Fuse F1 F2 F3 F4 F5 F6 F7 FP FP FS FT1 FT2

Function T1 and T2 converter output T1 and T2 converter input Heater unit MCB auxiliaries Horn Electronic card power supply Pneumatic seat Pump control power (8FBE18T-18K) Pump control power EPS control power Master traction control unit power Slave traction control unit power

Capacity 30A - 24V 15A - 48V 30A - 48V 10A - 48V 5A - 48V 5A - 48V 15A - 24V 300A 350A 40A 250A 250A

17-4

MAIN OPTIONS

FUSES UNDER DASHBOARD

Fuse F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23

Function MCB auxiliaries Heater unit Work spotlights +24V auxiliary output Courtesy light Rear window Radio +12V auxiliary output +12V auxiliary output Heated seat Rear wiper motor Front wiper motor Work spotlights

Capacity 10A - 24V 7.5A - 24V 7.5A - 24V 5A - 24V 5A - 24V 10A - 24V 7.5A - 12V 7.5A - 12V 7.5A - 12V 7.5A - 12V 7.5A - 24V 7.5A - 24V 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 procedure 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. Subsequently, 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 procedure 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 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.

10) Press button (O) to return to the MATERIAL HANDLING folder.

MAIN OPTIONS

17-7

HEIGHT LIMITER S15

The administrator can set a height limit value which can be enabled/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 parameter MENU LOCK = OFF the operator will have the same parameters in the TRAVEL SETTING menu.

1) To enable the "height limiter" function enter the ADMINISTRATOR menu. Please refer to the procedure in chapter 03.

2) Select the MATERIAL HANDLING folder.

3) Enter the 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 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 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

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 operator 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 neutral.

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-leveling 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 assistant 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 function 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 operator of the invalid operation. ü Enable procedure via menu ADMINISTRATOR, if the parameter MENU LOCK = OFF the operator will have the same parameters in the TRAVEL SETTING menu.

1) To enable the "height limiter" function enter the ADMINISTRATOR menu. Please refer to the procedure in chapter 03.

2) Select the MATERIAL HANDLING folder.

3) Enter the HEIGHT SET option.

4) Select the level to be set (A-B-C).

5) Set the mast in a vertical position and lift the forks until they 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 ADMINISTRATOR menu.

9) Select the MATERIAL HANDLING folder.

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.

12) Press button (O) to return to the MATERIAL HANDLING folder.

17

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

NOTICE! After the option is installed, calibration procedures must be carried out via the display; for procedure 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).

NOTICE! After the option is installed, calibration procedures must be carried out via the display; for procedure details please refer to chapter 03.

MAIN OPTIONS

17-13

COMBINED LIGHTS COMPONENTS

17

NOTICE! The combined lights are powered by converter T1 (see DC/DC CONVERTER paragraph to calculate absorption).

NOTICE! The blue light is powered by converters T2/T3 (see DC/DC CONVERTER paragraph to calculate absorption).

NOTICE! After the option is installed, calibration procedures must be carried out via the display; for procedure see chapter 03 (MASK MENU -> OPTION SET MENU -> DIPPED LIGHT, DIR LIGHTS).

17-14

MAIN OPTIONS

HEATER - HEATED REAR WINDOW - RADIO - WINDSCREEN 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 converters 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 absorption).

NOTICE! After the option is installed, calibration procedures must be carried out via the display; for procedure details please refer to chapter 03.

MAIN OPTIONS

17-15

MULTIFUNCTION JOYSTICK CONFIGURATIONS PERSON PRESENT SWITCH

PARAMETERS SETTING

AUTO LEVEL

LIFTING / LOWERING + TILTING

TILTING

LIFTING / LOWERING LOWERING

MAT. HANDLING MULTIF. NUM WAY WAY WITH EN

ON 3 None

HEIGHT SELECTOR

TILTING FW

TILTING BW

TILTING BW

TILTING FW

OUT

LIFTING

PARAMETERS SETTING

LIFTING / LOWERING

ON 3 3

LIFTING / LOWERING + TILTING

TILTING

TILTING FW

TILTING BW

LIFTING

MAT. HANDLING MULTIF. NUM WAY WAY WITH EN

TILTING FW

TILTING FW

TILTING BW

PARAMETERS SETTING

TILTING FW

MAT. HANDLING MULTIF. NUM WAY WAY WITH EN

ON 4 3

TILTING FW

TILTING BW

PARAMETERS SETTING

TILTING FW

TILTING FW

TILTING BW

TILTING FW

ON 5 5

3RD WAY

4TH WAY POSITIONING FORKS CLOSER

TILTING BW

TILTING FW

TILTING BW

LIFTING

TILTING FW

SIDESHIFT LH

LIFTING

LIFTING / LOWERING

4TH WAY + LIFTING / LOWERING LOWERING

CLOSING CLAMP

OPENING CLAMP

SIDESHIFT RH

LOWERING

OPENING CLAMP

LIFTING

LOWERING

OUT

LIFTING

4TH WAY

SIDESHIFT RH

SIDESHIFT LH

LIFTING / LOWERING + TILTING

TILTING

LIFTING / LOWERING LOWERING

MAT. HANDLING MULTIF. NUM WAY WAY WITH EN

3RD WAY

LIFTING

LIFTING

3RD WAY + LIFTING / LOWERING LOWERING

SIDESHIFT LH

LOWERING

TILTING BW

LIFTING / LOWERING LOWERING

LIFTING

OUT

PARAMETERS SETTING

4TH WAY

SIDESHIFT RH

SIDESHIFT LH

LIFTING / LOWERING + TILTING

TILTING

LIFTING / LOWERING

ON 4 4

3RD WAY

LIFTING

LOWERING

MAT. HANDLING MULTIF. NUM WAY WAY WITH EN

4TH WAY

POSITIONING FORKS FARTHEST

OUT

LIFTING

17

LIFTING

LOWERING

TILTING BW

SIDESHIFT RH

SIDESHIFT LH

SIDESHIFT RH

SIDESHIFT LH

LIFTING / LOWERING + TILTING

TILTING

LIFTING / LOWERING

3RD WAY + LIFTING / LOWERING LOWERING

3RD WAY

LIFTING

LOWERING

LIFTING / LOWERING LOWERING

POSITIONING FORKS CLOSER

OUT

LIFTING

SIDESHIFT RH

LIFTING

LIFTING

LOWERING

TILTING BW

SIDESHIFT LH

SIDESHIFT RH

SIDESHIFT LH

LIFTING / LOWERING + TILTING

TILTING

LIFTING / LOWERING

ON 4 None

3RD WAY

LIFTING

LOWERING

3RD WAY + LIFTING / LOWERING LOWERING

SIDESHIFT RH

LOWERING

TILTING BW

LIFTING / LOWERING LOWERING

LIFTING

OUT

PARAMETERS SETTING

SIDESHIFT LH

LIFTING

LOWERING

MAT. HANDLING MULTIF. NUM WAY WAY WITH EN

3RD WAY

LOWERING

LOAD INDICATOR

5TH WAY

CLOSING CLAMP

LIFTING

LIFTING / LOWERING

5TH WAY + LIFTING / LOWERING

LOWERING

LOWERING

LIFTING

LIFTING

SIDESHIFT RH

POSITIONING 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. AE1 AE4 AU1 AU2 AU3 AU4 AU5 AU6 AU7 AU8 B1 B2 B3 BT1 CN1 CN3 CN4 CR1 CR2 CR3 CR4 CR5 CR6 CR7 CR8 CR9 CR10 CR11 CR12 CR13 D1 D2 D3 D7 D8 D9 DA1 DA2 DA3 DA4 DA5 DA6 DA7 DA8

Description Display 12-24 V fuse card Traction logic unit - MASTER Traction logic unit - SLAVE Lift logic unit Steering logic unit - EPS MCB Card Armrest card DHU Card Rear fuses unit Right drive motor Left drive motor Motor pump Battery Heater unit electronic card connector UT1 Heater unit electronic card connector UT1 Heater unit electronic card connector UT1 Front left LED working light Front right LED working light Rear left LED working light Additional front left LED working light Additional front right LED working light Rear blue light Front left LED direction indicator Front left LED dipped beam Front right LED direction indicator Front right LED dipped beam Left LED working light on mast Right LED working light on mast Front rear LED working light Diode for 12-24 V fuse card AE4 Diode for 12-24 V fuse card AE4 Diode for 12-24 V fuse card AE4 Diode for 12-24 V fuse card AE4 Diode for 12-24 V fuse card AE4 Diode for 5th way valve L3 Flash lamp Rotating lamp Front right direction indicator Front right dipped beam Right headlight Left right direction indicator Front left dipped beam Left headlight

Wiring diagram page 03/11 06/11 - 09/11 01/11 01/11 01/11 01/11 02/11 04/11 11/11 01/11 01/11 01/11 01/11 01/11 10/11 10/11 10/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 09/11 09/11 09/11 09/11 09/11 05/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11

APPENDIX Ref. DA9 DA10 DA11 DA12 DA13 DA14 DA15 DA16 DA17 DA18 DA19 DA20 E1 E2 F1 F2 F3 F4 F5 F6 F7 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 FP FS FT1 FT2 HT1 J1 J2 J3 J4 J5 J6 J7 J8

18-3 Description Left-hand front working light Right-hand front working light Left-hand rear working light Left rear direction indicator Left reversing light Left stop light Left rear side light Right rear direction indicator Right reversing light Right stop light Right rear side light Courtesy light Steering encoder TFD sensor Fuse on T2 and T3 output Fuse on T2 and T3 input Heater unit fuse UT3 MCB CARD AU5 fuse Horn fuse HT1 Fuse for electronic cards Fuse for pneumatic seat Distributor valve fuse Heater unit fuse UT3 Fuse for working lights +24V output fuse Fuse for courtesy light DA20 Fuse for heated rear window R16 Fuse for radio UT5 +12V output fuse +12V output fuse Fuse for heated seat Fuse for rear wiper motor M2 Fuse for front wiper motor M1 Fuse for working lights Fuse for lift logic unit AU3 Steering logic unit fuse - EPS AU4 Traction logic unit fuse - MASTER Traction logic unit fuse - SLAVE Horn Connector Connector Connector Connector Connector Connector Connector Connector

Wiring diagram page 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 07/11 06/11 02/11 03/11 08/11 08/11 08/11 08/11 08/11 08/11 08/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 01/11 01/11 01/11 01/11 02/11 01/11 01/11 01/11 01/11 02/11 02/11 01/11 01/11

18

18-4

APPENDIX

Ref. J9 J10 J11 J12 J13 J14 J15 J16 J17 J18 J19 J20 J21 J22 J23 J24 J25 J26 J27 J28 J29 J30 J31 J32 J33 J34 J35 J36 J37 J38 J39 J40 J41 J42 J43 J44 J45 J46 J47 J48 J49 J50 J51 J52 J53 J56 J57

Description Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

Wiring diagram page 04/11 03/11 01/11 - 03/11 01/11 01/11 02/11 01/11 - 02/11 01/11 01/11 03/11 03/11 01/11 07/11 01/11 02/11 03/11 06/11 07/11 04/11 04/11 01/11 05/11 05/11 02/11 02/11 06/11 07/11 07/11 07/11 03/11 03/11 03/11 07/11 01/11 01/11 01/11 03/11 03/11 10/11 02/11 02/11 02/11 05/11 - 10/11 07/11 07/11 07/11 02/11

APPENDIX

18-5

Ref. J58 J59 J60 J61 J62 J64 J65 J71 J75 J84 J86 J87 J88 J89 J90 J91 J93 J94 J95 J97 J98 J99 J100 J122 J126 J127 J128 J129 J132 J133 J138 J139 J142 J143 J144 J145 J146 J147 J148 J150 J151 J152 J153 J154 J155 J156 J157

Description Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

Wiring diagram page 07/11 07/11 06/11 03/11 02/11 02/11 06/11 05/11 04/11 02/11 02/11 04/11 02/11 06/11 06/11 06/11 04/11 03/11 08/11 06/11 02/11 02/11 01/11 06/11 06/11 06/11 06/11 06/11 03/11 11/11 04/11 04/11 11/11 11/11 11/11 11/11 11/11 07/11 07/11 08/11 08/11 08/11 08/11 08/11 08/11 08/11 08/11

18

18-6 Ref. J158 J159 J160 J161 J320 J330 J343 J344 J347 J348 J349 J390 J400 J401 J402 J403 J404 J405 J406 J407 J408 J409 J410 J411 J412 J500 JR1 JR2 K1 K2 K4 K7 KP1 L1 L2 L3 L4 L5 L18 L19 L20 L21 L23 L24 L25 L26 L27

APPENDIX Description Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Logic unit switch AU1 AU3 AU3 Steering logic unit switch - EPS AU4 Mast height switch Key switch Keypad Right motor brake Left motor brake 5th way function valve Oscillation lock cylinder valve Hand grip position correction valve Valve ATT2 Valve ATT1 Forward tilt valve Emergency lowering Valve ATT2 Valve ATT1 Tilt control valve Backward tilt valve Lift lock valve

Wiring diagram page 08/11 08/11 08/11 08/11 07/11 07/11 06/11 06/11 06/11 06/11 06/11 04/11 04/11 04/11 04/11 04/11 04/11 04/11 04/11 04/11 04/11 02/11 03/11 02/11 04/11 02/11 06/11 06/11 01/11 01/11 02/11 01/11 11/11 01/11 01/11 05/11 02/11 02/11 05/11 05/11 05/11 05/11 05/11 05/11 05/11 05/11 05/11

APPENDIX

18-7

Ref. L28 LS1 M1 M2 M3 M4 P4 P9 P11 P15 P18 P21 P24 P25 P26 P27 P28 P29 P30 P31 P32 P33 P35 P37 P41 P42 P43 P44 P47 P51 P52 P53 P56 P58 P59 P60 P61 P62 P64 P71 P84 P86 P87 P88 P89 P90 P91

Description Lift valve Back-up buzzer Front wiper motor Rear wiper motor Front washer motor Rear washer motor Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

Wiring diagram page 05/11 02/11 06/11 06/11 06/11 06/11 04/11 04/11 01/11 - 03/11 01/11 03/11 04/11 03/11 06/11 07/11 04/11 04/11 08/11 05/11 05/11 02/11 02/11 07/11 07/11 07/11 07/11 01/11 08/11 06/11 06/11 07/11 07/11 07/11 07/11 07/11 06/11 - 09/11 03/11 02/11 11/11 05/11 02/11 02/11 04/11 02/11 09/11 09/11 09/11

18

18-8 Ref. P98 P100 P122 P126 P127 P128 P129 P320 P330 P343 P344 P346 P347 P348 P349 P350 P351 P400 P401 P402 P403 P404 P405 P407 P409 P410 P411 P412 P500 R1 R2 R3 R4 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R24 RL1 RL2

APPENDIX Description Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Brake pedal potentiometer Accelerator pedal potentiometer Accelerator pedal potentiometer Brake pedal potentiometer Tilt angle potentiometer Mast pressure sensor Lifting lever potentiometer Lifting lever potentiometer Tilt lever potentiometer Tilt lever potentiometer Lever ATT1 potentiometer Lever ATT1 potentiometer Lever ATT2 potentiometer Lever ATT2 potentiometer Heated rear window Mast height sensor Wind-screen wiper relay Wind-screen wiper relay

Wiring diagram page 02/11 01/11 06/11 - 09/11 06/11 06/11 06/11 06/11 06/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 06/11 - 09/11 07/11 07/11 04/11 04/11 04/11 04/11 04/11 04/11 04/11 02/11 11/11 02/11 04/11 02/11 01/11 - 02/11 02/11 02/11 01/11 - 02/11 02/11 02/11 04/11 04/11 04/11 04/11 04/11 04/11 04/11 04/11 06/11 02/11 09/11 09/11

APPENDIX Ref. RL3 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S19 S20 S21 S23 SA1 SH1 T1 T2 T3 T4 TN1 TN2 UT1 UT5 WT1 WT2 WT6 WT7 WT8 WT9 WT10 WT11 WT12

18-9 Description Wind-screen wiper relay Emergency button Seat microswitch Key switch Horn push Reverse selector on steering column Brake oil tank microswitch Tilt SAS button Reverse drive microswitch Forward drive microswitch Lever ATT2 button Reverse selector on armrest Light switch Horn button on armrest Lift mini-lever button Height limiter button Horn button on rear lever ATT1 mini-lever button Bodyguard gate sensor Bodyguard gate sensor Steering sensor Parking brake selector Smart access Bump sensor DC/DC 48V/24V converter DC/DC 48V/24V converter DC/DC 48V/24V converter DC/DC 48V/12V converter Connector on driver's overhead guard Connector on arm rest Heater unit Radio Connection Connection Connection Connection Connection Connection Connection Connection Connection

Wiring diagram page 09/11 04/11 04/11 03/11 03/11 03/11 03/11 04/11 02/11 02/11 04/11 04/11 03/11 04/11 04/11 04/11 03/11 04/11 07/11 07/11 01/11 03/11 11/11 11/11 06/11 06/11 06/11 08/11 06/11 04/11 06/11 - 10/11 06/11 01/11 01/11 01/11 04/11 04/11 01/11 04/11 01/11 01/11

18

18-10

APPENDIX

MAIN HARNESS J89 J91 J349 P61

J90 J53A J35A J26

J98 J11 J38

J410

J40

P51

P24

P47 J53B J35B J52

J46 J45 P56

P71 J8 J16 J20

J132

P84 P15 P32

P409

J48 J49 J50 J99

J31 J30

P86 J13 J12 J7

J17

J22 J33 J23

J64 J5

J6

J500

APPENDIX

18-11

J1 J18

WT12 J2

J27 J53D P87

WT9 J42

WT11

J3

J43 P58

J97 J4

P41

J29 J34

18

J57 P62 J53C

P320

J34

J65 J25

18-12

WIRING DIAGRAM - 3 WHEEL VERSION

APPENDIX

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

WIRING DIAGRAM - 4 WHEEL VERSION

APPENDIX

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