CESAB BT BLITZ 318-416-418-320-420-C3E120 Service Manual

SERVICE MANUAL
C3E120 C4E120
C3E150 C4E150
C3E160 C4E160
C3E160L C4E160L
C3E180 C4E180
C3E180L C4E180L
C3E200 C4E200
036-0410-07 04/2005
PAGINA INTENZIONALMENTE BIANCA
INTENTIONALLY LEFT BLANK
PAGE INTENTIONNELLEMENT BLANCHE
ABSICHTLICH FREIGELASSENE SEITE
PÁGINA INTENCIONALMENTE BLANCA

Electric 1,2 - 2,0 t A.C.
036-0410-07
SERVICE MANUAL index
page 1
CESAB S.p.a. reserves all rights of

reproduction of this handbook
The text and the numbering system

may not be used in other printed matter,
reprinted or translated, whether entirely
or in part, without written authorization
from
CESAB reserves the right to make any

necessary modifications without obligation
to promptly update this handbook.
Copyright by
CESAB S.p.A
via Persicetana Vecchia, 10
40132 Bologna - Italy
Tel. (0039) 051.20 54 11
Fax (0039) 051.72 80 07
E-mail: [email protected]
BOLOGNA’S FACTORY, AFTER SALES SERVICE

1,2 - 2,0 t A.C. Electric
index SERVICE MANUAL 036-0410-07
page 2
INDEX
GENERAL INFORMATION chapter A
CHASSIS chapter 0000
MOTORS / ENGINES chapter 1000
TRANSMISSION / DRIVE GEAR chapter 2000
BRAKE / WHEEL chapter 3000
STEERING SYSTEM chapter 4000
ELECTRICAL SYSTEM chapter 5000
HYDRAULIC / PNEUMATIC SYSTEM chapter 6000
MAST GROUP chapter 7000
ATTACHEMENT chapter 8000
OPTIONS chapter 9000
MAINTENANCE TABLES chapter B
SAFETY INFORMATION chapter C

036-0410-07
SERVICE MANUAL chapter A
page 1
CHAPTER A
GENERAL INFORMATION
chapter A SERVICE MANUAL 036-0410-07
page 2
GENERAL INFORMATION INDEX
TECHNICAL DATA page3

036-0410-07
page 3
TECHNICAL DATA
page 4
036-0410-07
page 5
page 6

036-0410-07
SERVICE MANUAL chapter 0000
page 1
CHAPTER 0000
CHASSIS
chapter 0000 SERVICE MANUAL 036-0410-07
page 2
CHASSIS INDEX
TRUCK’S LAY OUT page 3
PEDALS page 4
DRIVE DIRECTION LEVER ON STEERING COLUMN page 4
STEERING COLUMN PUSH BUTTONS page 5
LOAD HANDLING COMMANDS page 6
DASHBOARD page7
DASHBOARD CONTROLS page 8
PLATES page 9
LIFTING OF THE TRUCK page 10

036-0410-07
page 3
TRUCK’S LAY OUT
B A
J
H
C DESCRIPTION OF MAIN PARTS
K
D
A) Mast frame
B) Opening for lifting battery
I
E F C) Seat
D) Electronic control unit compartment
G
E) Counterweight
F) Hydraulic valve commands
N M Q G) Control valve cover
H) Lifting jack
I) Lifting fork carriage
B J) Overhead guard
J A K) Present man device
M) Driven wheels
N) Steered wheels
C
K H Q) Forks
D
E
F
I
G
N M Q
page 4
OPERATOR'S SEAT
FOOT PEDALS VERSION
FOOT DRIVE DIRECTION

(Standard version)
- Forward direction (D)
- Backward direction (E)
B - Service brake pedal (B)
D E
DRIVE DIRECTION LEVER ON STEERING

COLUMN (Alternative version)
1 Direction selector lever (F)

o é 1 Forward direction
2 o 0 Neutral
F
H ê 2 Backward direction
A
Parking brake lever (A)
Emergency push button (H)
Single drive pedal (G)
B
G
Horn push button (O)

O
Ignition key (P)
P
The steering column position can be adjusted forward or backward.
In order to do it, unloose the lever (Q) then secure the steering
Q column in the desired position. Do not adjust the steering column
while the truck is moving.
036-0410-07
page 5
M
STEERING COLUMN PUSH BUTTONS
N
It is strongly recommended to avoid operating
both push buttons when the truck is running.
Selected setting push button (M):

P (programmable), H (high), L (low)
Speed reduction push button (N) (turtle function)
M
N
M) Selected setting push button:

at the start up, the truck is setted in the same condition as it was turned off. The available settings are:
P (programmable), H (high) or L (low).
Settings can be selected pulling the push button several times.Three leds will show the selected program
as indicated at the dashboard description page, item 11.
P: - Maximum drive speed.

- Acceleration and braking action are optimised for low energy consumption.
- Parameter change function enabled.
H: - High drive speed.

- Strong action of the traction parameters.
- Parameter change function disabled.
L: - Low drive speed.

- Soft action of the traction parameters.
- Parameter change function disabled.
N) Speed reduction push putton:

it limits the maximum drive speed of the truck by the set percentage ( from 10% up to 90% ). See
chapter 5000 (Parameter change function, DualAC2 traction unit) paragraph “CUTBACK SPEED”.
page 6
LOAD HANDLING COMMANDS

The truck can be equipped with three types of commands for load handling
CONTROL VALVE VERSION (A)
JOYSTICK VERSION (B)
FINGERTIPS VERSION (C)
H K J
Levers unit
A
H) Lifting control lever (yellow cap)
K) Tilting control lever (green cap)
L
J) Sideshift control lever (red cap)
L) Device control lever (optional) (black cap)
Functions
BATTERY COVER
- Handle for a better opening / closing (1)
- Hook with opening button(2)
2 1
Battery plug fixing position
- Battery Plug (3)

3
036-0410-07
page 7
DASHBOARD
The dashboard consists of a series of instruments and warning lights to check the correct operation of
the truck.
15 1 6 2 3 4 5 14
9 10 11 12 8 7 13
1) Battery charge status indicator.

2) Parking brake ON warning light.
3) Brake fluid low level warning light.
4) Lifting speed reduction due to flat battery.
5) “Present man device” warning light.
6) Drive left motor temperature warning light.
7) Drive right motor temperature warning light.
8) Lifting motor temperature warning light.
9) Electronic hour meter.
10) Diagnostic code alphanumeric display.
11) Selected setting display.
12) Speed reduction indication light
13) Forward/backward indication lights
14) Steeringindicationdisplay
15) Light sensor
page 8
DASHBOARD CONTROLS
1 1) Battery charge status indicator:
This bar consists of 3 green LEDS on the right side, 4 orange LEDS in the
middle and 3 red LEDS on the left side; when the battery is charged the
first green LED on the right is On; while the battery discharges, the LEDS
2 turn On or Off, one per time, from the right to the left according with the
battery charging status. When the battery is 80% discharged, the first red
LED on the left is On, the display (10) shows the alarm code 1C so the
battery must be recharged (reserve). There is an indication on the dashboard
3 (4) and the lifting speed is reduced because there is a current cutback by
50%. The battery charge indicator does not rearm if the battery charging
status is between 70% and 100%. It can be adjusted (see at chapter 5000).
4 2) Parking brake ON warning light
3) Brake fluid low level warning light:

This warning light comes ON when the level of brake fluid in the tank has
5 reached the minimum level.
4) Lifting speed reduction due to flat battery
6 5) ”Present man device” warning light:

The pilot light comes ON when the driver leaves the driving seat without
switching OFF the truck; under these conditions, the traction and the lifting
movement are disabled.
7
6) Drive left motor temperature warning light:
lights up when the temperature is 140°C.
8 7) Drive right motor temperature warning light:

lights up when the temperature is 140°C.
8) Lifting motor temperature warning light:

9 lights up when the temperature is 140°C.
9) Electronic hour meter:

It is activated by insertion of the ignition key and it conts the real working
10 time of the truck. It shows the working hoursand hours fractions (in tenth).
It can be adjusted (see chapter 5000, dashboard map)
10) Diagnostic code alphanumeric display:

11 When a malfunction occurs in the truck, this display identifies the error
through a corresponding code (see Alarm function chapter 5000).
11) Selected setting display:

12 Indicates the running setting selected: L (low), P (programmable), H (high):
12) Speed reduction indication light:

When the reduction speed is selected the blue light is on.
13
13) Forward/backward indication lights.
14) Steering indication display.

14
15) Light sensor:
1234 It changes automatically the light intensity of the LEDS in the dashboard
1234 according to the light of the environment.
1234 15
036-0410-07
page 9
PLATES
A IDENTIFICATION PLATE
B CAPACITY PLATE
The plates positions, as shown in the picture, are refered to the standard fork lift trucks; those positions
can be modified in case of special truck configuration.
B (1,2 - 1,5 t)
B (1,6 - 2,0 t)
ATTACHMENT OR SPECIAL CONDITION OF USE
MODEL Type MOTOR RATED CAPACITY

kW kg TYRES SERIAL N°
SERIAL N° DRAW-BAR PULL (1h) CENTER OF LOAD DISTANCE mm

LIFT HEIGHT
N mm
BATTERY MASS SERVICE MASS

kg kg Without
min. max. Battery kg A B
MANUFACT. YEAR TENSION
V
Cod. 0312005
Cod. 0312004
DERATED CAPACITY Kg
CARRELLI ELEVATORI S.p.A. CESAB LDT

via Persicetana vecchia, 10 Bevan Way
40132 - Bologna - Italia Smethwick - Warley CAPACITY PLATE
West Midla 1ds B66 1BZ
IDENTIFICATION PLATE LOAD PLATE

It identifies the lift truck technical data It identifies the load capacity with a load center
of 500 mm (except for different indications)
page 10
LIFTING OF THE TRUCK
If the truck is equipped with mudguard extensions, the chains can
be hooked only after the extensions disassembling.
HOOK ATTACHMENT POINTS FOR LIFTING THE TRUCK

The hooking points are shown on the carriage with the symbol shown on
the side (see picture).
LIFTING OF THE FORKLIFT TRUCK WITH OVERHEAD

GUARD
The following equipments must be used to lift the forklift truck with
A overhead guard (standard):
- N° 2 slings (A): in accordance with DIN B2N -UNI 9531,

B minimum length 9 m and capacity of 2800 kg.
LIFTING OF THE FORKLIFT TRUCK WITH CABIN

The following equipments must be used to lift the forklift truck with
cabin:
A - N° 2 slings (A): in accordance with DIN B2N -UNI 9531,
minimum length 9 m and capacity of 2800 kg.
- N° 2 upper brackets (B) to hold the chains.
It is important to remember that the chains or slings length must be

sufficient to lift the truck in a horizontal position, with the lifting angles
(ß) ≤ 45° with respect to the vertical lifting line. Ensure that the chains
or slings are protected where it comes into contact with edges, then
arrange the chains or slings on the truck so that it remains in a horizontal
position during the entire lifting operation.
Make sure that there are no personnel in the vicinity of the truck, before
carrying out the lifting operation.
If any maintenance operations need to be performed on the truck in a
raised position, the vehicle must be rested on appropriate
supports, sufficient to bear the overall weight of the vehicle, keeping the
chains or slings taut.
TYPE WHEELS TRUCK WEIGHT WITH WEIGHT ON AXLES WITHOUT LOAD

t. STANDARD BATTERY (FRONT / REAR)
1.2 3 2960 kg 1675 / 1285 kg

1.5 3 3190 kg 1680 / 1510 kg
1.6 3 3230 kg 1740 / 1490 kg
1.8 3 3375 kg 1770 / 1605 kg
2.0 3 3565 kg 1850 / 1715 kg
1.6L 3 3335 kg 1845 / 1490 kg
1.8L 3 3440 kg 1860 / 1580 kg
1.2 4 2950 kg 1665 / 1285 kg
1.5 4 3140 kg 1670 / 1470 kg
1.6 4 3180 kg 1650 / 1530 kg
1.8 4 3320 kg 1630 / 1690 kg
2.0 4 3520 kg 1820 / 1700 kg
1.6L 4 3300 kg 1820 / 1480 kg
1.8L 4 3380 kg 1830 / 1550 kg
036-0410-07
page 1
CHAPTER 1000
MOTORS/ ENGINES
page 2
MOTORS / ENGINES INDEX
ELECTRICAL MOTORS CHARACTERISTICS page 3
ELECTRICAL MOTORS ARRANGEMENT page 5

036-0410-07
page 3
ELECTRICAL MOTORS CHARACTERISTICS
TRACTION MOTORS
MANUFACTURER SAUER DANFOSS (SCHABMÜLLER)

POWER 4,5 KW f=80 Hz
POLES NUMBER 4
FREQUENCY 80 Hz
NOMINAL VOLTAGE 27 V (AC)
POWER FACTOR (cos f) 0,915
SERVICE S2 60’
INSULATION CLASS F
R.P.M. 2295 rpm
page 4
LIFTING MOTOR
MANUFACTURER SAUER DANFOSS (SCHABMÜLLER)

POWER 10 KW
POLES NUMBER 4
FREQUENCY 80 Hz
SERVICE S3 = 26%
INSULATION CLASS F
R.P.M. 2314 rpm
PUMP CAPACITY 11 l/m’

036-0410-07
page 5
ELECTRICAL MOTORS ARRANGEMENT
TRACTION MOTORS
LIFTING MOTOR
page 6

036-0410-07
page 1
CHAPTER 2000
TRANSMISSION / DRIVE GEAR

page 2
TRANSMISSION / DRIVE GEAR INDEX
REDUCTION GEAR VIEW page 3
REDUCTION GEAR MAINTENANCE page 4
REPLACEMENT OF THE REDUCTION GEAR page 5

036-0410-07
page 3
REDUCTION GEAR VIEW
Reduction ratio of the reduction gear: 1 : 18,2

page 4
REDUCTION GEAR MAINTENANCE

DRIVE UNIT
The drive unit, one for each driven wheel, consists of an electric motor and a reduction gear, complete
with oil-bathed brake discs inside.
To top up or drain oil remove the magnetic plugs.
- PLUG FOR OIL LEVEL CHECK

A AND TOPPING UP
B - OIL DRAIN PLUG
After the first 50-100 hours

- replace the oil.
Every 500 hours
- check the oil level, when cold, with the truck on a flat surface, and if necessary top up. Use transmission
oil such as AGIP-ATF II D or equivalent. The correct level is obtained when the oil starts to come
out from the hole (A).
- check that there are no oil leaks.
Every 1000 hours
- check that all the screws on the unit are tight.
- change the oil; in any case, for occasional use change the oil at least every 12 months
Changing the oil in the reduction gears:

- clean carefully the area around the oil topping up and
draining plugs; place a suitable container below the drain
plug and then remove both the topping up and the draining
0,2 plug and allow the oil to drain out completely;
2L - clean the magnetic plug (B) from any ferrous residues
and replace it;
- pour fresh oil into the hole (A) until it begins to overflow
(approximately 0.22 litre) then replace the plug;
- when the topping up is complete, remove any trace of
overflowing. After a short period of operation, check
the oil level again.
To improve the oil flow, it is advisable to empty the

reduction gears after running the truck for a few minutes
to warm them up.
For a correct operation of the reduction gears do not

fill with more oil than necessary.
036-0410-07
page 5
REPLACEMENT OF THE REDUCTION GEAR
- Lift the truck

- Remove the wheel from the reduction gear.
- Remove the cable for the parking brake and
the tube for the oil brake system.
- Put a shim under the electric motor.
Tube for the oil brake system.
Cable for the parking brake.
- Remove the screws for fixing the group (gear-

motor).
After replacing the reduction gear it is necessary

to replace also the pinion.
Pignon
page 6

036-0410-07
page 1
CHAPTER 3000
BRAKES / WHEELS
page 2
BRAKES / WHEELS INDEX
SERVICE BRAKES page 3
PARKING BRAKE page 4
BRAKE OPERATING SYSTEM DESCRIPTION page 5
BRAKE DISKS page 6
REPLACEMENT OF THE WHEEL BRAKE CYLINDER page 7
WHEELS / TYRES page 9

036-0410-07
page 3
BRAKE SYSTEM
M N O P SERVICE BRAKE
Oil-bath brakes are inside the reduction gear box and use
the same oil.
SERVICE BRAKE SYSTEM

U DIAGRAM
M)Reduction gears and braking unit
N) Parking brake command
O) Bleeding screw
Q P) Electric drive motor
Q) Distribution block
R) Tank
S) Service brake pedal
R T) Command pump
S U) Brake pipes
BRAKE PEDAL approximately 1 mm

T
Clearance of the brake pedal in neutral position
BRAKE PIPES SERVICE BRAKE CONTROL

Every 1000 hours
- check that the braking system liquid level in the tank has not dropped;
if it has, check the system.
- control functioning of the service brake pedal and the parking brake
pedal or lever , they must be smooth and with no jamming;
Every 2000 hours
- change the braking system liquid.
U
Every 5000 hours
- replace brake hoses.
BRAKE OIL TANK
The brake system uses the
AGIP BRAKE FLUID DOT 4
This is used only in the brake system and not in the reduction gear.
The brake oil tank is located in the front side of the machine below the
dashboard. After pressing the brake pedal the oil pressure moves the
brake cylinder, which, acting on the brakes, creates the brake effect.
Warning light (3) on the dashboard

When the liquid in the brake tank is too low, the warning light comes
R ON. If the warning light (3) comes ON, check that there are no
leaks in the system.
page 4
PARKING BRAKE
The hand parking brake operates by means of the same disks as the service brake.
J) Release system
K) Parking brake lever
V) Microswitch
W)Brake block anchor
X) Parking brake lever adjusting screw
PARKING BRAKE CONTROL AND ADJUSTMENT
Every 1000 hours

- check the parking brake travel which should correspond to
V 3 notches. If necessary, adjust the appropriate screws (X);
- check the condition of the stay bolt cables and the anchors.
J
K
V
W
X
W
036-0410-07
page 5
BRAKE OPERATING SYSTEM DESCRIPTION
Main piston
Pad
Brake pin
Fulcrum
Brake cylinder
Oil brake tube

Parking brake cable
Wheel cylinder
Oil area
Spring
Disks group
The brake effect is activated when the brake cylinder of the reduction gear is moving. It moves when the
parking brake pedal or the brake pedal is pressed.
When the brake pedal is pressed the oil moves the wheel cylinder which, by pressing against the side surface
of the reduction gear, moves the wheel brake cylinder. This turns around the fulcrum and presses against the
brake pin that pushes the pad. The pad pushes the main piston that closes the brake disks, obtaining the
braking effect.
When the brake pedal is released the springs push the main piston in the neutral position, freeing the disks.
The same movement around the fulcrum is obtained by pulling the parking brake lever that moves the brake
cylinder mechanically.
page 6
BRAKE DISKS
Reduction gear body
Gear group 1
Plate disk
Gear group 2
Pinion
The brake effect starts when the wheel brake cylinder

is moving. The brake cylinder presses the free cylinder
and the pad. The pin is used in order to block the pad
that otherwise would turn with the brake disks.
The pinion turns on gear group 2 where gear group 1
and the brake disks are fixed.
Wheel brake
The brake disks have a tooted shape on the external
cylinder
diameter in order to block them on the reduction gear
body. The counter disks have a tooted shape on the
internal diameter in order to block gear group 1.
Consequently, after pressing the brake pedal all the
Free rod pin disks are pressed and gear group 1 is stopped by
Pad
means of the counter disks. The springs are used to
Pin retrieve the neutral position of gear group 1.
036-0410-07
page 7
REPLACEMENT OF THE WHEEL BRAKE CYLINDER
A: Wheel
A B: Reduction gear
D
C: Electric motor
D: Wheel brake cylinder
E: Metal parking brake cable
C
F: Oil brake hose
B
G: Threaded bar M8
H: Threaded bar M14 (see next page)
In order to replace the wheel brake cylinder D it is possible to proceed in two different ways:
1st WAY
1) Lift the truck
E F D
2) Remove cable E and hose F
3) Remove wheel A
4) Replace the three screws used for fixing the

reduction gear to the electric motor with three
threaded bar M8 or three longer screws (G).
5) Move the electric motor C in order to create enough

G space between the two components (reduction gear
and electric motor).
6) Replace the wheel brake cylinder by dismounting the

clip of the pin.
7) Reassemble the parts.
Be careful not to damage the pinion during the

coupling of the motor with the reduction gear.
page 8
2nd WAY
1) Lift the truck

E F D
2) Remove cable E and hose F
3) Remove wheel A (see previous page)
4) Remove the screws that fixed the gear box to the

frame
5) Fix bar G (of 40 cm) into the upmost hole in the

frame using it as a guide to keep the reduction gear
(5-10 cm) off the frame, therefore having enough
H space to change the brake cylinder.
6) Repeat the procedure backwards to fit the

components again.
036-0410-07
page 9
STANDARD TYRES
SAFETY OF RIMS AND WHEELS FOR FORKLIFT TRUCKS

“PNEUMATIC” tyres must be replaced when the tread is less than 1.6 mm. “SUPERELASTIC” tyres
must be replaced when the tread reaches the “60J” indication printed on the side.
The replacement of “CUSHION” tyres is recommended when they reach a thickness of 20 or 30 mm.
C
CUSHION
→ →
SE
SUPERELASTICHE
→
PN
PNEUMATICHE
→
STANDARD TYRES
Type Size Air Truck
Pressure
(C)
FRONT 432x152 1,2-1,6L t
FRONT 457x178 1,8-2,0 t
REAR 381x127 ALL
(SE)
FRONT 18x7-8 1,2-1,6L t
FRONT 200/50-15 1,8-2,0 t
REAR 16x6-8 ALL
(PN)
FRONT 18x7-8 10 bar ALL
TIGHTENING TORQUES
WHEEL TORQUE
14 daNm steering wheels
14 daNm driving wheels
DRIVE UNIT TORQUE
2,3 daNm electric motor securing
13,5 daNm unit securing to frame
5 daNm service brake delivery pipes screw
5 daNm parking brake cable fixing screw
2,2 daNm oil filling and draining cap
VARIOUS TORQUES
4,9 daNm mast-securing U-bolts
0,8÷1,2 daNm jack collar self-locking nuts
20 daNm counterweight locking screws
page 10

036-0410-07
page 1
CHAPTER 4000
STEERING SYSTEM
page 2
STEERING SYSTEM INDEX
STEERING CONTROL page 3
POWER STEERING HYDRAULIC DIAGRAM page4
POWER STEERING HYDRAULIC LAYOUT page5
POWER STEERING SETTING page 6
STEERING AXLE 3 WHEELS page 8
STEERING AXLE 3 WHEELS page 9
BEARING ADJUSTMENT page 10

036-0410-07
page 3
STEERING CONTROL
The steering uses the same oil as the lifting by means of a priority valve, which guarantees a sufficient
oil flow to the power steering.
The oil capacity is checked by the Ls signal (load - sensing), coming from the steering unit so that the
oil quantity sent to the power steering is equal to its real request.
The exceeding oil is sent to the control valve for other functions.
When the steering wheel is turned, proportionally to the above rotation, the steering unit “measures” a
volume of oil and sends it into the steering cylinder.
Every 1000 hours

- check the entire system to identify any leak;
any intervention must be carried out without
B pressure in the system.
Every 5000 working hours

- replace hoses (G) connecting the orbitrol
device to the steering jack.
G
Every 10000 hours

- replace the hydraulic pipe system.
Power steering pressure setting

The max power steering pressure must be
100 Bar
In order to set the power steering pressure, the following operation are necessary:
1 - Fit a manometer on the pressure access point (A) on the punp;
2 - In order reach the adjusting screw (B) remove the cap (by means of an Allen wrench) positioned
on the upper side of the orbitrol (power steering unit);
- screw in to increase the pressure
- screw out to decrease the pressure
A
page 4
POWER STEERING HYDRAULIC DIAGRAM
STEERING CYLINDER
ORBITROL
TO THE CONTROL VALVES
PRIORITY
VALVE
A A
PUMP
FILTER
036-0410-07
page 5
3 AND 4 WHEELS VERSION
3 WHEELS
R
L
LOAD
SENSOR R L
R
è
L 4 WHEELS
LOAD
è è R
SENSOR
L
è
ORBITROL
Oil inlet Drain

Load sensor and
Valve for the
maximum
pressure
page 6
POWER STEERING SETTING

In order to set the pressure remove the cap and adjust the Allen screw
PRESSURE SETTING
90-100 BAR
The same pressure is used for both

versions (3 and 4 wheels)
Adjusting:
Screw in = highter pressure
Screw out = lower pressure
036-0410-07
page 7
3 WHEELS VERSION
The 3 wheels uses a static system. It means that the oil reaches the load sensor on the priority valve only when the
steering is moving.
PRIORITY VALVE
OSPC 50 LS STATIC ORBITROL
4 WHEELS VERSION
The 4 wheels uses a dinamic system. It means that the oil always reaches the load sensor on the priority valve.
On the priority valve there is a channel that connect LS to PP in order to guarantee always a flow of oil for a prompt
replay of the steering. The increasing of the pressure on the system can create a return pressure on the line LS (that
is connected to PP) and a conseguent kickback on the steering. Another no return valve is used on the line LS to
avoid this situation.
PRIORITY VALVE
OSPF 80 LS DINAMIC ORBITROL

page 8
3-WHEEL STEERING AXLE
Control of steering unit

The steering unit (D) does not require greasing or lubrication.
Every 1000 hours
- check and if necessary adjust the wheel hub bearings.
24 daNm
Steering potentiometer fixing

036-0410-07
page 9
4-WHEEL STEERING AXLE

Steering axle check
Every 1000 hours
- lubricate the steering gear joints using the appropriate grease nipples (I);
- check the steering angles.
- check and if it is necessary, adjust the wheel hub bearings.
Max steering angle (internal wheel B = 80°)

End stroke setting (adjustment):
make the cylinder reach the internal end stroke, then operate on the special screws fixing
them on the spindles. Then screw in the adjust screws until you obtain the desired steering
angle B = 80°
If any abnormal consumption of the wheel tread is observed, the following controls should be
performed:
- check the parallelism of the steered wheels;
- check that the steering angle of the wheels is the same in both directions.
I
B = 80° Standard
ANGLE MEASURED FROM THE
AXLE FRAME TO THE INTERNAL
WHEEL THROUGH A SPECIAL
I
DEVICE
I
6 daNm
12 daNm
page 10
BEARING ADJUSTMENT
Steering wheel bearings require an adjustment once a year.
Steering wheels
- lift the steering wheels
- remove cap (1);
- fasten the nut with a torque setting of 6 dNm;
- turn the hub of 2-3 turns in both senses;
- unfasten nut (3) and retighten with a 2-1 daNm torque;
- check that the wheels slide correctly (max. rolling final torque: 0.2 dNm) and that there is no side play
(maximum axial play of 0.05 mm);
- reassemble the cap (1);
- lower the wheels again and check that all bolts fixing the wheel disk (5) to hub (2) are well tightened.
3
036-0410-07
page 1
CHAPTER 5000
ELECTRIC & ELECTRONIC SYSTEM

page 2
ELECTRIC & ELECTRONIC SYSTEM INDEX
BATTERY AND BATTERY CHARGER page3

ELECTRICAL MOTOR CHARACTERISTIC page 4
ENCODER page 5
MAIN ELECTRICAL COMPONENTS DESCRIPTION page7
ACCELERATOR PEDAL page7
FUSE BOX page8
24 VOLT FUSES page8
DC/DC CONVERTER page9
ELECTRONIC PANELS (TECHNICAL SPECIFICATIONS) page 10
OPERATIONAL FEATURES page11
DIAGNOSI page11
GENERAL PRECAUTIONS page12
PROTECTIONS page12
CONNECTION OF THE AUXILIARY CIRCUIT: TRACTION page13
TRACTION ELECTRIC BLOCK DIAGRAM page 15
STEERING SYSTEM page16
CONNECTION OF THE AUXILIARY CIRCUIT: LIFTING page18
LIFTING ELECTRIC BLOCK DIAGRAM page20
ELECTRICAL CIRCUIT CONNECTION TRACTION AND LIFTING page 21
CAN-BUS AND ONBOARD COMMANDS DIAGRAM page23
CAN - BUS DESCRIPTION page 25
ARM CARD page26
LIGHT CARD page28
I/O CARD page30
MHYRIO CARD page 31
POTENTIOMETER CONFIGURATION page 32
CONSOLE FUNCTION GENERAL DESCRIPTION page36
GENERAL DESCRIPTION page38
KEYBOARD page 38
CONSOLE CONNECTION page 39
PARAMETER CHANGE page 40
TESTER page44
ALARM FUNCTIONS page50
PARAMETER SETTING TABLE page66
MAPS FOR USING THE CONSOLE
TRACTION page 69
LIFTING page95
MHYRIO page109
DASHBOARD page119
WIRING DIAGRAM page123
036-0410-07
page 3
BATTERY AND BATTERY CHARGER
General indications for battery maintenance

Every 50 working hours - measure electrolyte density.
Approximate density data

For a temperature of 15° C
- a density of 1.12 to 1.13+
kg/dm3 indicates that the battery is flat;
- a density of 1.25 to 1.26 kg/dm3 indicates that the battery is charged (battery capacity increased: 1.29 to 1.30
kg/dm3).
BATTERY CHARGING WARNINGS

Before charging the battery, verify that the room is well aerated. Open the battery compartment door.
Make sure that all electrical connections (electrical cable terminals, battery terminals, plugs-sockets, etc.) are well
attached and in good condition.
- Do not open either remove battery filling caps.
- Never top up before and while charging the battery.
- Do not smoke, do not stay close to naked flames and do not cause sparks next to batteries
- Do not use the battery while it is being charged
- Do not lean metal tools on the battery while under charge
- Never repair the battery while under charge
- Check that during the charging phase, the electrolyte temperature is kept below 50°C.
Warning
The battery normal working range is from 100% to 20% of the capacity. For the battery protection,
don’t let the residual capacity to drop down under 20% of the charge. Under this limit you can have
possible battery damages and, above all, logic units malfunctions and stops that could invalidate the
truck safe use.
BATTERY WEIGHTS AND CAPACITY
TRUCK WHEELS WEIGHT WITH BATTERY BATTERY

t. STANDARD BATTERY WEIGHT CAPACITY
1.2 3 2960 kg 775 kg 420-500 Ah
1.5 3 3190 kg 775 kg 420-500 Ah
1.6 3 3230 kg 920 kg 525-625 Ah
1.8 3 3375 kg 920 kg 525-625 Ah
2.0 3 3565 kg 1090 kg 630-750 Ah
1.6L 3 3335 kg 1090 kg 630-750 Ah
1.8L 3 3440 kg 1090 kg 630-750 Ah
1.2 4 2950 kg 775 kg 420-500 Ah
1.5 4 3140 kg 775 kg 420-500 Ah
1.6 4 3180 kg 920 kg 525-625 Ah
1.8 4 3320 kg 920 kg 525-625 Ah
2.0 4 3520 kg 1090 kg 630-750 Ah
1.6L 4 3300 kg 1090 kg 630-750 Ah
1.8L 4 3380 kg 1090 kg 630-750 Ah
page 4
ELECTRICAL MOTORS CHARACTERISTICS

TRACTION MOTORS
MANIFACTURER SAUER DANFOSS (SCHABMÜLLER)

POWER 4,5 KW f=80 Hz
POLES NUMBER 4
FREQUENCY 80 Hz
SERVICE S2 60’
INSULATION CLASS F
R.P.M. 2295 rpm
LIFTING MOTOR
MANIFACTURER SAUER DANFOSS (SCHABMÜLLER)

POWER 10 KW
POLES NUMBER 4
FREQUENCY 80 Hz
SERVICE S3 = 26%
INSULATION CLASS F
R.P.M. 2314 rpm
PUMP CAPACITY 11 l/m’

036-0410-07
page 5
ENCODER
The encoder function is to generate motors feed-back signals to
the logic unitis (motor running; R.P.M.; rotation direction). It is
Encoder built-in the bearing placed on the opposite side of the motor drive
shaft
Motor signals connector
pin cable color destination function
1 red encoder +12 V

2 black encoder -
3 blue encoder signal B
4 white encoder signal A
5 white thermo sensor
Motor 6 white thermo sensor
signals 7 not used
connector 8 not used
9 not used
wire side view
12V !
Critical damage if:
_ +V > 13Volts
_ Short circuit between signal and supplay
_ Induction heating
_ Hammer mounting
The signal is connected to the power supplay to 12

Volt. It is brought down with the internal transistor for
creating to output impulse.
Signals view on the oscilloscope screen.

page 6
Disassembly
Disconnect the motor electrically and remove it.

Open and remove the 4 cylinder head screws
LIFTING MOTOR (M8x250 for the lifting motor, M8x130 for the
traction motor) Pos. 1 between non drive end
4 plate Pos. 2 and drive end plate Pos. 3. For the
5 lifting motor: take off the metal cover Pos. 4
2 after loosening the cylinder head screws Pos. 5
of the aluminium non drive end plate Pos. 2.
7 Take off the aluminium non drive end plate Pos.
2 with slight punches by means of a rubber
6 mallet. Remove the cable strap (which fastens
the sensor bearing cable).
8 Carefully remove the 2 clamping pins of the
temperature sensor from the 9-pin plug (pin
5+6). Remove the sensor bearing Pos. 6 by
means of an extractor (caution! do not damage
3 the centering of the shaft).
1
TRACTION MOTOR Assembly
Put the motor shaft with drive end side against

the plate (Pos 9); there should be no pressure
3 to the drive end bearing ! Put the sensor
bearing on the shaft (Pos 6). Put the press on
2 device (Pos 10) on the inner ring of the sensor
bearing as shown in the drawing and fix the
7 device with the two longer screws. Press on the
6 sensor bearing with the screw (Pos 11):
Be shure to press only the inner (!) ring of
8 the sensor bearing.
Put the connection of the temperature sensor in
the 9-pin plug (pin 5+6) again. Secure the cable
of the temperature sensor and the sensor cable
by means of a cable strap at the motor
connecting cables. Examine the o-ring (62x2,0)
Pos. 7 inside the non drive end plate Pos. 2
1 regarding damages, if necessary exchange it.
LIFTING MOTOR TRACTION MOTOR Put in the wavy washer Pos. 8 inside the
11 aluminium non drive end plate Pos. 2 again. Put
10 the aluminium non drive end plate Pos..2 on the
6 motor again, pay attention to the position of the
cable of the sensor bearing. (Attention! Risk of
damaging the cable insulation). For the lifting
motor: put the metal cover on the aluminium
non drive end plate Pos. 2 again and fix it by
means of the cylinder head screws Pos. 5 with
a torque of 7 Nm. For the traction and lifting
motors: clamp the complete terminal between
the drive end plate Pos. 3 and the aluminium
non drive end plate Pos. 2 again. Put in the 4
cylinder head screws (M8x250 for the lifting
motor, M8x130 for the traction motor) Pos. 1
and tighten them with 11 Nm. torque for the
lifting motor or with 20 Nm. torque for the
traction motor
9
036-0410-07
page 7
MAIN ELECTRICAL COMPONENTS DESCRIPTION
D G F C
A) Traction module
B) Lifting module
C) Contactors
D) Panel cooling fan
E) Power fuses
F) Fuses (covered by the light board)
G) Light card
ACCELERATOR PEDAL
Set the potentiometer

Position the tester set in OHM between the green and the red wire.
Set the potentiometer
from 5.13 to 6.27 KOHM (pedal released)
from 1.087 to 1.32 KOHM (pedal pressed)
180 mm
Height adjustment screw

page 8
FUSE BOX
The fuse box is located next to the battery connector, covered by the light card.
1 3
4 FUSE DESCRIPTION
1. F1 key fuse 10 Amp
2. F2 horn fuse 5 Amp
3. F3 DC/DC converter fuse 20 Amp
4. Diode
LIGHT CARD 2 1 3
CONTACTORS
24 VOLT FUSES
This box is located under the dashboard and it is used for all the
24 V fuses only.
5 Connector for the wiring.
6 Connection bars transfer the positive pole to all fuses.
7 Direction lights intermittence connector.
This box is present on the truck only if optional equipments are
foreseen
5 6 7
036-0410-07
page 9
DC/DC CONVERTER
140 W DC/DC converter (STD)
The DC/DC converter is located on the truck front side, under the I/O card fixed on the same plate. The STD
machines use a converter to 140 Watt. It is under contactor (see electrical diagram).
CONVERTER
P/N Power
2773040 140W
2773041 240W
2773042 360W
2773043 720W
2773044 960W
EQUIPMENT CONSUPTION OF THE EQUIPMENT

CONNECTED TO 24 V
STD. MACHINE 86 W
REVERCE ACUSTIC WARNING 05 W
FLASH BEACON 03 W
ROTARY BEACON 70 W
WIPER 100W
2 WORKING LIGHTS 140W
LIGHTENING EQUPIMENT (STREET LIGHT) 200W
HEATER 150W
Choose the right converter rounding up the calculation of the maximum power used and considering a margin
of 10%.
A std machine uses a converter of 140W and the maximum power used is 86W.
It means that there are 40W still available.
page 10
ELECTRONIC PANELS
TECHNICAL SPECIFICATIONS
“DUALAC2” TRACTION
Inverter for pairs of AC asynchronous 3-phase motors

Regenerative braking functions
Can-bus interface
Digital control based upon a microcontroller (one per each motor)
Voltage: 48V
Maximum current 2 x 275A (RMS) for 3'
Operating frequency 8kHz
External temperature range -30°C ÷ 40°C
Maximum inverter temperature (at full power) 75°C
“AC2” LIFTING
Inverter for AC asyncronous 3-phase motors

Regenerative braking functions
Can-bus interface
Digital control based upon a microcontroller
Voltage 48V
Maximum current 350A (RMS) for 3'
Operating frequency 8kHz
External temperature range -30°C ÷ 40°C
Maximum inverter temperature (at full power) 75°C
036-0410-07
page 11
OPERATIONAL FEATURES
- Speed control.
- Very good behaviour on a slope due to the speed feedback.
- The motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed
set point.
- Stable speed in every position of the accelerator.
- Regenerative release braking based upon deceleration ramps.
- Regenerative braking when the accelerator pedal is partially released (deceleration).
- Direction inversion with regenerative braking based upon deceleration ramp.
- Regenerative braking and direction inversion without contactors: only the two main
contactors are present.
- The release braking ramp can be modulated by an analog input, so that a proportional brake feature is obtained.
- Very good sensitivity at low speeds.
- Voltage boost at the start and with overload to obtain more torque (with current control).
- High efficiency of motor and battery due to high frequency commutations.
- Self diagnosis with indication of the fault shown by numeric display.
- Modification of parameters through the programming console.
- Internal hour-meter with values that can be displayed on the console.
- Memory of the last five alarms with relative hour-meter and temperature displayed on the console.
- Test function within console for checking main parameters.
- Hydraulic steering function:
1) traction inverter
- the traction inverter sends a "hydraulic steering function" request to the pump inverter on the can-bus line
2) pump inverter
- the pump inverter manages a "hydraulic steering function". That is, it drives the pump motor at the
programmed speed for the programmed time.
DIAGNOSIS
The microprocessor continually monitors the inverter and carries out a diagnostic procedure on the main
functions. The diagnosis is made in 4 points:
1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging, phases’
voltages, contactor drives, can-bus interface, if the switch sequence for operation is correct and if the
output of the accelerator unit is correct.
2) Standby diagnosis at rest that checks: watchdog circuit, phases’ voltages, contactor driver, current sensor,
can-bus interface.
3) Diagnosis during operation that checks: watchdog circuits, contactor driver, current sensors, can-bus
interface.
4) Continuous diagnosis that checks: temperature of the inverter.
Diagnosis is provided in two ways.

- the diagnostic ERROR DISPLAY placed to the dashboard that shows the code number for a
given alarm (see the chapter 5000 Alarm description).
- the digital console, which gives more detailed information about the failure.
page 12
GENERAL PRECAUTIONS
- Do not connect the inverter to a battery with a nominal value different from the value indicated on the
chopper plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit does not
"power up".
- During the battery charge, disconnect the INVERTER from the battery.
- Supply the INVERTER only with battery for traction; do not use a power supply.
- When the chopper is installed, make tests with the wheels raised from the ground, in order to avoid danger-
ous situations due to connection errors.
- After the chopper is switched off (key off), the filter capacitors remain charged for some minutes; if you
need to work on the inverter, discharge them using a
10W ÷ 100W resistance connected from the +Batt to the -Batt.
- Before carrying out any arc-welding on the trucks, disconnect the battery and short-circuit the unit between
positive (+) and negative (-).
PROTECTIONS
- Connection Errors:
All inputs are protected against connection errors.
- Thermal protection:
If the chopper temperature exceeds 75°C, the maximum current is reduced in
proportion to the thermal increase. The temperature can never exceeds 100°C.
- External agents:
The inverter is protected against dust and the spray of liquid to a degree of
protection meeting IP54.
- Protection against uncontrolled movements:
The main contactor will not close if:
- the Power unit is not functioning.
- the Logic is not functioning perfectly.
- the output voltage of the accelerator does not fall below the minimum voltage value stored, with 1V
added.
- running microswitch in closed position.
- Protection against accidental Start up
A precise sequence of operations are necessary before the machine starts.
Operation cannot begin if these operations are not carried out correctly.
Drive requests must be made after closing the key switch.
036-0410-07
page 13
CONNECTION OF THE AUXILIARY CIRCUIT - DUAL AC2 UNIT TRACTION
CABLES ASSEMBLY INSTRUCTIONS

page 14
CONNECTORS
A1 CAN_H High level CANBUS.

A4 CANL_OUT Low level CANBUS: to be used as repetition for CAN_L line.
A6 CAN_L Low level CANBUS.
A7 CAN_H_OUT High level CANBUS: to be used as repetition for CAN_H line or to be connected to
CANT_L to insert termination resistance.
B1 PCLRXD
B2 NCLRXD
B3 PCLTXD
B4 NCLTXD console connecto
B5 GND
B6 +12
B7 FLASH
B8 FLASH
C1 PENC_R Positive of right motor encoder power supply (+12V).

C2 NENC_R Negative of right motor encoder power supply.
C3 KEY Connected to +Batt through the series costituited by the key switch, the protection
diode and a 10A fuse.
C4 CM Common of FW / REV / HB / PB / SEAT / ENABLE microswitches.
C5 SEAT Seat presence signal; active high.
C11 PENC_L Positive of left motor encoder power supply (+12V).
C12 NENC_L Negative of left motor encoder power supply.
C13 PHA_R Right motor encoder phase A.
C14 PHB_R Right motor encoder phase B.
C15 NPOTST Negative of steering potentiometer (-BATT).
C16 PPOTST Positive of steering potentiometer (+12V).
C17 CPOTST Steering potentiometer wiper signal.
C22 PHB_H Left motor encoder phase A.
C23 PHB_L Left motor encoder phase B.
C26 NLC Output of main contactor coil driver (drives to -BATT).
C27 PLC Positive of main contactor coil.
036-0410-07
page 15
ENABLING OF C10 SPEED REDUCTION
By connecting a wire between the pin C10 and the positive (+Vb) from the seat switch, it is possible to disable
the reduction of speed (CUTBACK SPEED 3) normally on.
By connecting a microswitch on the wire between the pin C10 and the seat switch, it is possible to set ON or
OFF the CUTBACK SPEED 3 (parameter located in the menu PARAMETER CHANGE).
Disconnect the connector from the logic unit and and remove the red part
that is fixed inside by means of two tongues on the external side.
Type of PINS used:
AMP770854 - 3.
TRACTION ELECTRIC BLOCK DIAGRAM
CONTROL LOGIC
page 16
STEERING SYSTEM
3 WHEELS
When the potentiometer reaches approximately
70° the traction logic unit controls the motor in
order to stop one motor completely according
to the direction. In this case the truck turns
around point A. If the stroke of the potentiometer
increases the motor that was stopped starts
running in the opposite direction and the truck
starts turning around point B.
4 WHEELS
When the potentiometer reaches the maximum
stroke the traction logic unit controls the motor
in order to stop one motor completely according
to the direction. In this case the truck turns
around point A.
3 WHEELS
Transducer steering-wheel with potentiometer
The potentiometer has the following characteristics:
- Resistance 2,2 Kohm.
- The potentiometer supply is 12 V (5 V on the console). The
potentiometer should be installed so that in the "zero position"
(straightened wheels) the output voltage is 2,5 V. The
potentiometer has to be fitted so that when the trolley turns
clockwise the voltage decreases.
4 WHEELS
RIGHT
STEERING
POTENTIOMETER
LEFT
036-0410-07
page 17
3 WHEELS
-90° +90°
Steering potentiometer (3 wheels)
Yellow : ~ 12 V
Green : ~ 0,7 V with max. steering angle right hand + 90°
2,5 V with straight wheel
~ 4,3 V with max. steering angle left hand - 90°
Black : 0V
Grey
) Black
Red
2,2 KOhm Í ) Green
Black
) Yellow
4 WHEELS
-58° +80°
Steering potentiometer (4 wheels)
Yellow : ~ 12 V
Green : ~ 0,9V with max. steering angle right hand + 80°
2,5 V with straight wheel
~ 3,8 V with max. steering angle left hand - 58°
Black : 0V
Grey
) Black
Red
2,2 KOhm Í ) Green
Black
) Yellow
page 18
CONNECTION OF THE ELECTRIC CIRCUIT - AC2 UNIT LIFTING

036-0410-07
page 19
CONNECTORS
A1 PCLRXD
A2 NCLRXD
A3 PCLTXD
A4 NCLTXD Console connector
A5 GND
A5 GND
A6 +12
A7 FLASH
A8 FLASH
C1 CAN-L Low level CAN-BUS voltage I/O.

C3 CAN-H High level CAN-BUS voltage I/O.
D1 Positive of lifting motor encoder power supply (+12V).

D2 Negative of lifting motor encoder power supply.
D3 Lifting motor encoder phase A.
D5 Lifting motor encoder phase B.
E4 CM Common of LIFT ENABLE / 1st SPEED / 2nd SPEED/ 3rd SPEED /4th SPEED /
HYDRO / SR microswitches.
E12 HYDRO REQ. Input for hydraulic steering request. Active high.
F1 KEY Connected to +Batt through the series costituited by the key switch, the protection
diode and a 10A fuse
F5 SAFETY If not connected to -Batt the MC coil power output will be disabled.
Can also be used as a general purpose input.
F6 PTHERM Input for motor temperature sensor.
F11 GND -Batt.
F12 NTHERM -Batt.
page 20
LIFTING ELECTRIC BLOCK DIAGRAM
KEY
CONTROL LOGIC
POTENTIOMETER
MICROSWITCHES
PROGRAMMING
CONSOLE
KEY
036-0410-07
page 21
ELECTRICAL CIRCUIT CONNECTION
DUAL AC2 TRACTION UNIT AND AC2 LIFTING UNIT
355 A FUSE
SEGNALI
CAN-BUS
300 A FUSE
page 22
NECESSARY SETTING AFTER REPLACING THE TRACTION LOGIC UNIT
1. TRACTION ACQUISITION
2. ADJUST BATTERY
3. STEERING POTENTIOMETER
4. Vacc PROGRAM
5. STEER TABLE
for all references see “MAPS FOR USING THE CONSOLE - TRACTION” in the following pages
NECESSARY SETTING AFTER REPLACING THE LIFTING LOGIC UNIT
1. LIFTING ACQUSITION
2. Vacc PROGRAM (with mechanic distributor only)
for all references see “MAPS FOR USING THE CONSOLE - LIFTING” in the following pages
036-0410-07
page 23
CAN-BUS AND ONBOARD COMMANDS DIAGRAM
ARM
COMMANDS
ARM CARD DASHBOARD
LIFTING ON BOARD
COMMAND
LIGHT CARD I / O CARD
TRACTION ON
BOARD COMMAND
MHYRIO ELECTRO
CONTROL VALVE
DUAL AC2 AC2

TRACTION LIFTING
UNIT UNIT
= CAN-BUS CONNECTION (4 WIRES)

= ANALOGIC CONNECTION (SEVERAL WIRES)
see legend at the next page

page 24
LEGEND
ARM COMMANDS - forward switch

- backward switch
- horn switch
joystick - 5° way (opt)
- lifting-tilt joystick
- sideshift / 4° way (opt) joystick
- forward switch
- backward switch
- horn switch
- lifting fingertip
- tilt fingertip
fingertip - sideshift fingertip
- 4° way fingertip (opt)
- 5° way fingertip (opt)
ARM CARD *
LIGHT CARD *
I / O CARD *
AC2 = lifting logic unit
DUAL AC2 = traction logic unit
LIFTING ON BOARD COMMAND = lift reduction speed (FFL only)
TRACTION ON BOARD COMMAND = park brake switch

accelerator switch
traction potentiometer
seat switch
pedal brake switch
MHYRIO *
CONTROL VALVES *
* for all references see following pages

036-0410-07
page 25
CAN - BUS DESCRIPTION
Controller Area Network
The CAN BUS technology is a way to assemble the electronic parts of the machines. It has been designed to avoid
the enormous quantity of cables that normally are used to connect two or more electric components. For example,
in case you want to connect all potentiometers to control the distributor, it is necessary to fix a lot of wires with
consequent reduction of space. Normally a cable in an electric installation is used for only one function: either
positive, or negative, or signal.
In order to avoid the above problem the NEW TECHNOLOGY is used for saving in space given that all the
information go only through two cables and they are decoded by microchips located in different parts of the truck.
One of the greatest advantages is that all microchips can communicate with each other and control functions which
work contemporaneously in a short time.
The CAN transfers all data giving priority to the most important signals.
The CAN is composed of four cables: two for the feeding and two for the signals.
R (red cable) +24Volt

L (blue cable) Negative
AN (light blue/ black cable) CAN H (high)
HG (grey/ yellow cable) CAN L (low)
It is necessary to have two cables for the feeding given that the microchips are not fed.
BUS: In electronics and computer science it indicates a set of wires connecting several microchips,
thus allowing information exchange within the circuit.
BIT: Figure of the binary numeration that can have only two values: 1 (high) - 0 (low).
In computer science it defines the information unit. The bit/sec. defines the capacity of a channel,
that is the quantity of information which can be transmitted through the channel in one second.
page 26
ARM CARD
The arm card, located inside the seat arm is present in fingertips /
joysticks truck version. It is supplied by the dc / dc converter with
24 V.
The fingertips /joysticks version requires also the use of an
additional logic unit (Mhyrio)
FUNCTIONS
It controls and converts from analogic to digital the fingertips /
joysticks potentiometers signals in order to drive, via Mhyrio, the
electric distibutor, equipped with solenoid valves.
It also controls the push buttons signals of the forward / backward
directions and of the horn.
CONNECTIONS
The card is connected by the cab-bus wiring to the light card
SETTINGS
In order to inform the card about the potentiometers type used, the
following setting is required:
JOYSTICKS all the dip switches (layout, pos. 9) are

9 setted on OFF position.
7 FINGERTIPS the dip switch n° 2 (layout, pos. 9) is setted
on ON position
8 (In case this is not enabled the logic unit
shows the alarm INCORRECT START)
The potentiometres replacement does not require any calibration

by the console
LAY-OUT
1. Connector for the lifting potentiometer (finger/joystick)

2. Connector for the tilt potentiometer (finger/joystick)
1 2 3 4 5 6
3. Connector for the sideshift potentiometer (finger/joystick)
4. Connector for the 4th way potentiometer (finger/joystick)
5. Connector for the 5th way potentiometer (finger/joystick)
6. Connector for the auxiliary funtions: push buttons for the
horn and for the directions.
7. Connector for the CAN-BUS
8. Connector for the programming of the microchip.
9. Dip switches
see wiring diagram

036-0410-07
page 27
FINGERTIP
JOYSTICK
PB1=Horn pushbutton
PB2=Backward pushbutton
PB3=Forward pushbutton
PB1
PB2
PB3
page 28
LIGHT CARD
The light card is located in the compartment on the left

side of the truck. The 24 V supplied by the converter
arrive at the card. It is used as a bridge so that the
voltage is supplied to all the other cards.
FUNCTIONS
- Controlling of the back lights.
1 The light card permits the automatic control of the back

lights according to the operation of the traction motors.
The card is controlled by the traction logic unit that
receives the signals of the external motor (in a curve).
2 The light card works thanks to the signals put out by
7 the encoder, therefore the back lights are not operative
6 when the machine stands still.
3
5
036-0410-07
page 29
CONNECTOR DESCRIPTION
Connector 1
5 1 It is a connector to 8 Pins used for controlling the lights.
PINS 1-5 are connected together = 24 Volt.
6 2
PINS 2-6 are connected together = output of the stop lights 0-24 Volt. It is a proportional
7 3 value given that the voltage depends on the temperature of the lamp bulbs
PINS 3-7 are connected together = output of the reverse lights 0-24 Volt.
8 4 It is a proportional value given that the voltage depends on the temperature of the
lamp bulbs
PINS 4 negative signal
PIN 8 24 Volt input for the converter 24-5 Volt located on the card.
Connector 2
4 1 It is a connector to 6 Pins.
5 2 PIN 1 CAN L
PIN 2 CAN H
6 3 PIN 3 GND
PIN 4 Not used
PIN 5 Out put 24 Volt
PIN 6 Not used
Connector 3
5 2 PIN 1 CAN L
PIN 2 CAN H
6 3 PIN 3 GND
PIN 4 Not used
PIN 6 Not used
Connector 4
5 2 PIN 1 CAN L
PIN 2 CAN H
6 3 PIN 3 GND
PIN 4 Not used
PIN 6 Not used
Led 5
shows that the light card is fed but is not receiving the CAN-BUS input
C B A Converter 6
PIN A 24 Volt
PIN B GND
PIN C 5 Volt
24 V / 5 V
Resistance 7
It is the input resistance. R17 = 100 Ohm 3 Watt.
The connectors 2-3-4 are connectors for the CAN-BUS and they can be inverted without
problem
See wiring diagram

page 30
I/O CARD
INPUT / OUTPUT CARD
The card is located on the left side of the truck under the footboard. controls and
converts analogic signals to digital signals and vice versa
Connector J1 (J38*) for input of the brake oil tank LED, button for the
programmed performance, button for the speed reduction.
Connector J2 not used
Connector J3 (J5*) to control the electric horn. The horn is electronic and this is
the electric connection on the card:
J3/1 command signal (B white cable) from Arm Card
via CAN-BUS
J3/2 negative (N black cable)
Connector J4 (J34*) for the pedals: accelerator pedal, brake pedal, parking
brake lever, horn.
Connector J5 (J135*) CAN-BUS (light card) and feeding to 24V
Connector J6 (J136*) CAN-BUS (dashboard) and feeding to 24V
Connector J7 (J1*) for traction motors temperature sensors.
Connector J8 (J98*)(+BV) feeding for Mhyrio logic unit
Connector J10 (J40*) for the mechanic distributor (in this case the voltage on the
micro is 5 volt).
Connector J13 (J139*) CAN-BUS signals and feeding to 48V for Mhyrio logic
unit
NOTE: (Jxxx*) WIRING DIAGRAM CONNECTORS
J3/1 J3/2
HORN ELECTRIC CONNECTION
J7 J3 ( horn side)
The horn is electronic and needs a signal to
J2 J5 work. It is continually supplied by the following
10
cables: A, light blue, positive cable + 48 V
["+" on the horn] and N black cable negative
["-" on the horn]. The command signal on cable
J6 B white cable ["IN" on the horn] is a high signal,
J10 when the horn push button is pressed the signal
J8 goes to the negative and the horn begins to beep.
J1 J4 J13
On the I/O card there is another resistance of pull up for the CAN BUS. It
could be connected in case of disconnection of the dashboard. To perform
this operation it is enough to connect the two free PINS circled in the
picture by means of a brigde.
PINS for connecting the extra resistance for the CAN BUS
036-0410-07
page 31
MHYRIO CARD
It works to 48 V and it is located on the upper side of the

truck over the electro control valve group. The Mhyrio card
receives the digital inputs from the CAN and it converts them
in analogic signals to control the solenoid valves with.
In the front it has three connectors:

- connector 1 is used for the console
- connector 2 is used for the CAN
- connector 3 is used to control the solenoid valves.
The feeding reaches the card through three cables:

N (black cable) negative (pin 3 connector 2)
M (brown cable) positive (pin 1 connector 2)
M (brown cable) positive (pin 2 connector 2)
The cables for the CAN-BUS (it means for digital input) arrive
to the same connector used for the feeding:
AN (light blu/black cable) CAN H (high)

(pin 13 connector 2)
HG (grey/yellow cable) CAN L (low)

(pin 4 connector 2)
Voltage supplied to the ON-OFF valve coil ≅ battery voltage

3 Voltage supplied to the proportional valve coil ≅ 12 V
2
COLORI COLOURS FARBEN COULEURS COLORES
1 C arancio orange orange orange naranja
A azzurro blue blau bleu azul
B bianco white weiß blanc blanco
L blu dark blue dunkelblau bleu marine azul intenso
G giallo yellow gelb jaune amarillo
H grigio grey grau gris gris
M marrone brown braun marron castaño
N nero black schwarz noir negro
S rosa pink pink rose rosa
R rosso red rot rouge rojo
V verde green grün vert verde
Z viola/porpora purple violett violet púrpura
page 32
POTENTIOMETER CONFIGURATION
ARM COMMAND (JOYSTICKS / FINGERTIPS VERSION)
è
è
è
è
HORN PUSHBUTTON (PB1)

è
è
BACKWARD PUSHBUTTON (PB2)
FORWARD PUSHBUTTON (PB3)

036-0410-07
page 33
FINGERTIPS
RED : 5V
GREEN : 0 ÷ 5(AT REST 2,5 V)
S1 - S3 - S5 - S7
BLACK : 0V
S2 - S4 - S6 - S8
JOYSTICK
(FORWARD-BACKWARD MOV.)
S1 - S5
ORANGE : 5 V
S2 - S6 YELLOW : 0 ÷ 5 (AT REST 2,5 V)
PB4 - PB5
RED : 0V
JOYSTICK
S3 - S7 (LEFT-RIGHT MOV.)
S4 - S8
GREEN : 5V
BLACK : 0 ÷ 5 (AT REST 2,5 V)
WHITE : 0V
COLORI COLOURS FARBEN COULEURS COLORES

C arancio orange orange orange naranja
A azzurro blue blau bleu azul
B bianco white weiß blanc blanco
L blu dark blue dunkelblau bleu marine azul intenso
G giallo yellow gelb jaune amarillo
H grigio grey grau gris gris
M marrone brown braun marron castaño
N nero black schwarz noir negro
S rosa pink pink rose rosa
R rosso red rot rouge rojo
V verde green grün vert verde
Z viola/porpora purple violett violet púrpura
page 34
ACCELERATOR POTENTIOMETER CONFIGURATION
The test of the potentiometer can be carried out in two different ways:
Values optained by the console

Yellow : 1,6 V
Green : 0,6 ÷1,6 V with pedal pressed
Black : 0,6 V
Values optained by the multimeter

Yellow : 1,2 V
Green : 0,2 ÷1,2 V with pedal pressed
Black : 0,2 V
There is a difference between the values obtained in the two methods because, in case of voltage
measurement, the console increases the real value of 0.4 volt and it is a default condition
Yellow Yellow
)
1,2 KOhm Red Green
ç )
4,5 KOhm
é
Green Black
)
DOUBLE PEDAL VERSION SINGLE PEDAL VERSION

036-0410-07
page 35
LIFTING POTENTIOMETER CONFIGURATION
(CONTROL VALVE VERSION)
The test of the potentiometer can be carried out in two different ways:
Values optained by the console

137 : 5V
135 : 1,5 ÷ 5 V with lifting lever pulled
136 : 1,5 V
Values optained by the multimeter

137 : 4,6 V
135 : 1,1 ÷ 4,6 V with lifting lever pulled
136 : 1,1 V
There is a difference between the values obtained in the two methods because, in case of voltage
measurement, the console increases the real value of 0.4 volt and it is a default condition
137 Yellow
)
1
é 5 KOhm
2 135 Green
ç )
3 136 Black
)
136
137
3
135
page 36
CONSOLE FUNCTION
GENERAL DESCRIPTION
036-0410-07
page 37
CONSOLE FUNCTION GENERAL DESCRIPTION
HOUR METER
The hour meter appears in the second line of the display when the chopper is connected. It shows the real working
hours.
PARAMETER CHANGE
The chopper parameters can be displayed and programmed via the keyboard, in real time and with operating
machine, thereby making it possible to set the chopper easily.
TESTER
It makes it possible to display the state of the chopper analogue and digital values and thereby to have a useful tool
for the analysis of chopper operation and external cables.
SAVE PARAMETER
It makes it possible to store all values relating to the parameters and the chopper hardware configuration into the
console with a program which can be selected from the keyboard.
RESTORE PARAMETER
It makes it possible to program a chopper with the parameters contained in a program generated by a SAVE.
ALARMS
The console features the possibility to read the last five alarm messages stored in the chopper and displayed together
with the time of occurrence, the number of times the alarm was sent and the temperature value at the time of the
alarm.
PROGRAM VACC
It allows to program the accelerator max. stroke.
CONSOLE DESCRIPTION
KEYBOARD
Description of key functions:
ROLL 1 = Allows selection of an option or the next menu item
1 PROGRAM I MAX B.REVERSE ROLL 2 = Allows selection of an option or the previous menu
BRAKING COMPENS.
2 TESTER
ACCEL. R.BRAKE item
MAX SP. SPEED I
S.P. I SPEED II
3 SAVE S.P. II SPEED III
BYPASS FIELD WEAK... ENTER = Allow confirmation of selected options
4 RESTORE I MOT V.POT.
TEMP. V.BATT.
5 ALARMS TEMP. VMN.MOT.
M.SW.TEST OUT = Retains the current function
6 PROGRAM PEDAL
7 MOTOR DATA
PARAM = Allows an increase in the parameters or selects the
1 3 5 type of connected I/O
ROLL ENTER PARAM.
ROLL OUT SET SET = Allows a reduction in the parameters or selects the
2 4 6 type of connected I/O
page 38
CONSOLE CONNECTION
LIFTING UNIT
TRACTION UNIT
MHYRIO UNIT
The connection has to be made with the machine at rest.

036-0410-07
page 39
PARAMETER CHANGE
DUAL AC2 MASTER TRACTION UNIT
ACCELER/DELAY determines the acceleration ramp.

RELEASE BRAKING controls the deceleration ramp when the travel pedal is released.
INVERSION BRAKING controls the deceleration ramp when the direction switch is inverted
during the travel.
PEDAL BRAKING determines the deceleration ramp when the travel pedal is released and
thebrake pedal switch is closed.
SPEED LIMIT BRAKING deceleration ramp when the pedal position is partly released, not
completely.
BRAKE CUTBACK determines the deceleration ramp when the speed reduction input
becomes active and the motor slows down.
MAX SPEED FORWARD determines the maximum speed in forward direction.
MAX SPEED BACKWARD determines the maximum speed in backward direction.
CUTBACK SPEED 1 speed reduction when the cutback switch is active. Turtle function.
CUTBACK SPEED 2 speed reduction with brake pedal pressed.
CUTBACK SPEED 3 speed reduction enabled when the C10 signal is low.
CURVE CUT BACK speed reduction in curve.
FREQUENCY CREEP minimum speed when the forward or reverse switch is closed, but the
accelerator is slightly pressed.
MAXIMUM CURRENT this changes the maximum current of the inverter.
ACC. SMOOTH this delays the acceleration ramp from 0 hz to “stop smooth” value.
INV. SMOOTH this delays the deceleration ramp of the inversion from “stop smooth”
value to 0 hz.
STOP SMOOTH reference speed for the parameters ACC. SMOOTH and INV. SMOOTH
AUXILIARY TIME time delay when an hydraulic steering function request is switched off.
page 40
PARAMETER CHANGE
DUAL AC2 SLAVE TRACTION UNIT
NOT AVAILABLE.
036-0410-07
page 41
PARAMETER CHANGE
AC2 LIFTING UNIT
ACCELER/DELAY acceleration ramp.

DECELER/DELAY deceleration ramp.
MAX SPEED UP determines the maximum lifting speed controlled by a potentiometer.
MIN SPEED UP determines the minimum lifting speed controlled by a potentiometer when the
lift enabling switch is closed.
CUTBACK SPEED speed reduction when the cutback switch is active.
(+V =E4; input E13) if E13 is open the Cutbackspeed is on,
is the E13 is closed the Cutbackspeed is off.
CUTBACK SPEED 2 speed reduction when the cutback switch is active.
(+V =E4; input E14); if E14 is open the Cutbackspeed is off,
if E14 is closed the Cutbackspeed is on.
1ST SPEED FINE tilt speed, fine regulation.
2ND SPEED FINE side-shift speed, fine regulation.
th
3RD SPEED FINE 4th lever speed, fine regulation.
th
4TH SPEED FINE 5th lever speed, fine regulation.
AUX FUNCTION 1 pot. value increasing the motor RPM.
HYD SPEED FINE hydro speed, fine regulation.
MAXIMUM CURRENT maximum current of the inverter.
AUXILIARY TIME time delay when a hydraulic steering function request is switched off.
page 42
PARAMETER CHANGE
MHYRIO UNIT
MIN EVP Min voltage on the draining solenoid valve

MAX EVP Max voltage on the draining solenoid valve
MIN EVP1 Min. voltage on the lowering solenoid valve
MAX EVP1 Max voltage on the lowering solenoid valve
MIN EVP2 Min. voltage on the lifting solenoid valve
MAX EVP2 Max voltage on the lifting solenoid valve
MIN EVP3 Min voltage on the backward tilt solenoid valve
MAX EVP3 Max voltage on the backward tilt solenoid valve
MIN EVP4 Min voltage on the forward tilt solenoid valve
MAX EVP4 Max voltage on the forward tilt solenoid valve
MIN EVP5 Min voltage on the sideshift right solenoid valve
MAX EVP5 Max voltage on the sideshift right solenoid valve
MIN EVP6 Min voltage on the sideshift left solenoid valve
MAX EVP6 Max voltage on the sideshift left solenoid valve
MIN EVP7 Min voltage on the 4th way forward solenoid valve
MAX EVP7 Max voltage on the 4th way backward solenoid valve
EVP OPEN DELAY Delay of the EVP in opening
EVP CLOSE DELAY Delay of the EVP in closing
EVP1 OPEN DELAY Delay of the EVP1 in opening
EVP1 CLOSE DELAY Delay of the EVP1 in closing
036-0410-07
page 43
PARAMETER CHANGE
DASHBOARD UNIT
HOURS COUNTER RUNNING/KEY: key on / lifting unit working hours counter switch
DISPLAY ON/OFF: displaied speed switch
SPEED RATIO 0-5 12: speed calculation ratio
page 44
TESTER
MOTOR VOLTAGE: voltage supplied to the motor by the inverter; it is expressed as a

percentage of the full voltage (which depends on the battery voltage).
FREQUENCY: frequency of the voltage and current supplied to the motor.
ENCODER: motor speed, expressed in the same unit as the frequency; this
information comes from the speed sensor.
SLIP VALUE: difference between the rotating field frequency and the motor shaft
frequency (measured by the encoder)
CURRENT RMS: Root Mean Square value of the motor current.
TEMPERATURE: temperature measured on the aluminum heat sink holding the MOSFET
devices.
TEMPERATURE #1: not used.
TEMPERATURE #2: not used.
ACCELERATOR: voltage of the accelerator potentiometer’s wiper (CPOT). The voltage
level is shown on the left hand side of the Console Display and the
value in percentage is shown on the right hand side.
STEER ANGLE: indication of the angular displacement of the steered wheel.
BRAKE PEDAL POTI: not used.
INTERNAL WHEEL CUTBACK: indication of the speed reduction applied to the internal wheel; in other
words, it shows the ratio of the two speeds.
SEAT SWITCH: state of the Seat Microswitch digital input.
ON / +VB* = active input, closed switch.
OFF / GND = non-active input, open switch.
FORWARD SWITCH: state of the Forward direction digital input FW.
BACKWARD SWITCH: state of the Reverse direction digital input BW.
ENABLE SWITCH: state of the Enable digital input:
ON / +VB*= active input, closed switch.
BRAKE SWITCH: state of the Brake Pedal Microswitch.
CUTBACK SWITCH: state of the Speed Reduction Microswitch.
ON / GND = active input, opened switch.
OFF / +VB* = non-active input, closed switch.
EXCLUSIVE HYDRO: state of the exclusive hydro switch.
HAND BRAKE: state of the Handbrake Microswitch.
VOLTAGE BOOSTER: voltage booster supplied to the motor in load condition; it is expressed
as a percentage of the full voltage.
BATTERY VOLTAGE: level of battery voltage measured with the key switch ON.
BATTERY CHARGE: percentage of battery charge.
* = The console shows “ + VB “, but the real voltage is +5V

036-0410-07
page 45
TESTER
DUAL AC2 SLAVE TRACTION UNIT

ENCODER: speed of the motor, expressed in the same unit as the frequency; this
devices.
FORWARD SWITCH: state of the Forward direction digital input FW.
BACKWARD SWITCH: state of the Reverse direction digital input BW.
ENABLE SWITCH: state of the Enable digital input:

page 46
TESTER
AC2 LIFTING UNIT

ENCODER: speed of the motor, expressed in the same unit as the frequency; this
devices.
MOTOR TEMPERATURE: temperature of the motor; if the option is programmed "None"
it shows 0°.
ACCELERATOR: voltage of the accelerator potentiometer’s wiper (CPOT). The voltage
level is shown on the Left Hand Side of the Console Display and the
value in percentage is shown on the Right Hand Side.
LIFTING SWITCH: state of the lifting switch.
1 ST SPEED SWITCH: state of the tilt switch of the pump (%).
2 ND SPEED SWITCH: state of the side-shift switch of the pump (%).
3 RD SPEED SWITCH: state of the 4th lever switch of the pump (%).
4 TH SPEED SWITCH: state of the 5th speed switch of the pump (%).
HYDRO SPEED REQ.: state of the hydro speed request of the pump.
CUTBACK SWITCH: state of the Speed Reduction Microswitch.
CUTBACK SWITCH 2: state of the Speed Reduction Microswitch.
ON / +VB* = active input, opened switch.
OFF / GND = non-active input, closed switch.
COS FI: cos ϕ (real time calculated) of the motor.
BATTERY CURRENT: battery current (not measured but calculated).
BATTERY CHARGE: percentage of battery charge.

036-0410-07
page 47
TESTER
MHYRIO UNIT
VALVES SUPPLY: level of voltage at the positive valve supply (0-VB).
CAN POT EVP: single proportional valve current setpoint, received by the canbus
(% of the current supplied to the valve).
CAN POT GROUP 1: group 1 proportional valves current setpoint, received by canbus
(0-100 % of the current supplied to the lifting, proportional % for the
lowering valve).
CAN POT GROUP 2: group 2 proportional valves current setpoint, received by the canbus
(0-100 % of the current supplied to the tilt box)
(0-100 % of the current supplied to the side-shift box)
(0-100 % of the current supplied to the 4° Way box)
INPUT 0: state of DIGITAL INPUT 0:

ON / +VB : active input, closed switch
OFF / COND : non-active input, open switch

OFF / COND : non-active input, open switch not used
OFF / COND : non-active input, open switch
ANALOG INPUT 1: voltage of the analog input.
*: ON= active when the switch is closed (+ BATT)

OFF= not active when the switch is opened (GND)
page 48
TESTER
MHYRIO UNIT
NOT AVAILABLE.
036-0410-07
page 49
TESTER
DASHBOARD UNIT
NOT AVAILABLE.
page 50
ALARMS FUNCTIONS
DUAL AC2 TRACTION MASTER UNIT
CODE ALARM DESCRIPTION
1 WATCH - DOG It is a self-diagnostic test within the logic between the Master and Slave
µcontrollers. This alarm could also be caused by the canbus malfunctioning
or data transmission interferences.Therefore, before replacing the Dual AC2
unit check the correct canbus functioning and the general turck insulation.
2 EEPROM KO Fault in the area of memory in which the adjustment parameters are stored;
this alarm inhibits the truck operation, but the controller will use default
parameters. If the defect persists when the key is switched OFF and ON
again, replace the logic. If the alarm disappears, remember that the
parameters previously stored have been deleted and replaced by the default
values (see adjustin tables).
3 LOGIC FAILURE #3 Logic defect. Replace the traction unit.
4 LOGIC FAILURE #2 Fault in the hardware section of the logic boardwhich manages the phase
voltage feedback. Check the 3 power cables connected to the right traction
motor. If the fault is not caused by external reasons, replace the traction unit.
5 LOGIC FAILURE #1 This alarm signals that the interruption of protection against undervoltage /
overvoltage has been triggered. The possible reasons are:
a. Real battery undervoltage / overvoltage, or voltage loss after tht ignition
key or after the battery connector
b. Fault in the hardware section of the logic board which controls the
overvoltage protection. Logic defect. Replace the traction unit.
c. The alarm appears also when one or more phases of the right traction
motor doesn't present a correct insulation. Check the motor insulation
(with deconnected battery): it must be higher than 1 Mohm. Otherwise
check the insulation of the power cables to the motor.
6 VMN LOW Failure in the VMN test. This test starts when the ignition key is turned ON.
The alarm appears if there is a creepage on one or more phases; check
the connections of the 3 power cables from the Master unit to the right
traction motor and the cables condition also. In order to point out if the
fault is produced by an internal or external cause invert the connection of the
traction motors. It means Slave to right motor and Master to left motor.
If the problem jumps on the Slave it means that the right traction motor is
demaged, otherwise replace the traction unit.
7 VMN HIGH Failure in the VMN test. This test starts when the ignition key is turned on.
The alarm appears if one or more pover cables are not connected; check
the connections of the 3 power cables from the Master unit to the right
traction motor and the cables condition also. In order to point out if the
fault is produced by an internal or external cause invert the connection of the
traction motors. It means Slave to right motor and Master to left motor.
demaged, otherwise replace the traction unit
8 CONTACTOR OPEN Failure on the contactor driver.
- Check main contactors coils and relevant wirings.
9 STBY I HIGH Failure on the current sensor.
- Replace the traction unit.
036-0410-07
page 51
10 CAPACITOR When the key is switch ON, the inverter tries to charge the capacitor
CHARGE through a power resistance, and check if the capitor are charged within a
timout. If they do not charge, an alarm is signalled;
the main contactor is not closed.
- Check the negative connection.
- Check voltage in the input of the key. Battery voltage must be present.
- Execute a short circuit between the key terminals.
Traction
Vb D1 F1 PB1 S1 power
capacitor
11 HIGH Master or Slave or both temperatures are higher than 75°C. The maximum
TEMPERATURE current is reduced proportionally to the temperature increase. At 100°C the
max current of both inverters is reduced to zero. If the alarm is signalled
when the controller is cold:
12 MOTOR This warning is signalled if the sensor of the right motor is opened (digital
TEMPERATURE sensor)
- identify the on wiring diagram the connector J1 (J7 on I/O card):
- If between the positive pin (1) and negative pin (2) there is 5V = the
sensor is open
sensor is closed
If it occurs when the motor is cold, check:

a: the sensor is closed
b: between the positive pin (1) and negative pin (2) of the connector J1 (J7
on I/O card) there is 0V
- if "a" and "b" conditions take place replace the logic unit .
- 5V must be present on the positive pin (1) and negative pin (2) in the I/O
card connector J7 (with the wiring diagram J1 connector disconnected).
In the opposite case, replace the I/O card.
page 52
13 ENCODER ERROR Encoder failure.

This alarm indicates that the encoder information is not correct or is not
present.
The encoder transmits signals only when the motor is running. The alarm is
detected by the logics when it exceeds 20Hz.
Therefore, if an error signal appears on the dashboard and the operator
uses the reset key with the machine stopped, the alarm disappears -
however, it remains stored in the logic.
If the alarm signal starts before reaching 20Hz, the problem can be
attributed to a possible wrong insulation of a power cable on the frame.
without the encoder correct signals, the machine remains still or moves very
slowly. To determine whether the problem is to be attributed to the encoder
or to the logic,proceed as follow.
Set the SLIP CONTROL on OFF and speeding up slowly.
Please note that the engine speed increase does not necessary mean that the
problem is linked to the encoder. Any of the following components may
have a fault:
- The logic internal circuit
- The encoder
- The wiring
You may use a digital or analogue multemeter to determine where the
problem is located.
Speed sensor basic electric diagram.

The figure shows only one signal (A).
The encoders used have two equal signals, with a
phase difference of 90°(A-B).
1. Connect the multemeter positive point (red) to
theencoder positive terminal.
sensor
2. Connect the multemeter COM point (black)

to the encoder signal (A).
According to the engine position, the following
values will be displayed:
low signal: 0.5-1.5 Volt
high signal: 10.5-11.5 Volt
Intermediate values cannot be read as the motor
is stopped.
If the motor is running, the multemeter will

automatically read the Mv (medium value)
Mv= 5.5-6.5 Volt
Carrying out this test directly on the logic
connector, you can determine if the signals are
good (see above-mentioned description) or if the
channels are open or in short circuit
If the signals are good, the problem should be

attributed to the electronic control.
In the contrary case repeat the test directly on the

encoder connector. If the problem persists to
replace the encoder.
036-0410-07
page 53
14 THERMIC SENS KO The values indicated by the temperature sensor of the inverter are always
checked and if they are out of range this warning appears.
- Replace the logic unit.
15 SAFETY Replace the logic unit.
16 CAN BUS KO Comunication failure between the logic units: traction (Master & Slave),
lifting, Mhyrio and all the cards. The alarm appears if:
- CAN H and / or CAN L signals deconnected
- there is no comunication from one logic unit.
If the problem starts from one card the system recognizes in which one:
CAN BUS KO 0A : I/O card
CAN BUS KO 05 : Lifting logic unit
CAN BUS KO 04 : Slave logic unit
CAN BUS KO : Master logic unit (no suffix after the alarm message)
- Before replacing any logic unit it is suggested a preliminary check of the
CAN BUS connections.
Using the console, through connection numbersand selecting the
TESTER function, try to carry out a link with all the junction knots
toward the different logic units. Verify the links by, at least, one of the
signals from the field, i.e. microswitches, potentiometers. Where you
don’t reach the link, there is a line interruption.
17 WAITING Time lag fault on the CAN BUS comunication. The Master logic unit detects
FOR NODE wich logic unit has generated the problem
#4 The Master logic unit receives the informations caming from the Slave
logic unitwith a time lag fault.
The fault can be caused by
- interference on the can bus. Check the CAN-BUS comunication.
- broken logic. Replace the traction logic unit.
#5 The Master logic unit receives the informations caming from the
Lifting logic unit with a time lag fault.
- false contact. Check the connections of CAN H and CAN L wires.
- broken logic. Replace the lifting logic unit.
#9 The Master logic unit receives the informations caming from the
Mhyrio logic unit with a time lag fault.
- interference on the CAN-BUS. Check the CAN-BUS comunication.
- broken logic. Replace the Mhyrio logic unit.
18 AUX OUTPUT KO Failure on the contactor driver.
19 DRIVER SHORTED Failure on the contactor driver.
Check the main contactors coils and relevant wirings.
If the failure is not due to external causes, replace the traction logic unit.
20 CONTACTOR Failure on the contactor driver.
DRIVER - Replace the traction unit.
21 COIL SHORTED Failure on the contactor driver. Check the main contactors coils and
relevant wirings. Control that there are no short-circuits in the wiring and
that the coil resistance value is correct. If the failure is not due to external
causes replace the logic unit.
page 54
22 VACC NOT OK Failure on the acceleration potentiometer signal at rest. The alarm points out
that the voltage value detected on the accelerator potentiometer is 1Volt
higher than the least value programmed with the Vacc function. Check:
- The traction potentiometer (it could be damaged or not correctly
calibrated)
- The traction potentiometer wiring.
- Carry out the Vacc setting again.
23 INCORRECT START replace the traction logic unit.
24 PEDAL WIRE KO Not used
25 WRONG BATTERY When the key is turned ON, the controller checks the battery voltage and
compares it with the “SET BATTERY” parameter setting. If the actual value
is 20% higher or lower than the nominal value, there is a fault. Replace the
battery with a correct one.
26 REMOTE IMPUT incorrect starting procedure.
28 STEER SENSOR KO This alarm signals that the steering potentiometer is out of range. There is a
fault in the following conditions:
- the “Set steer 0 pos” (straight wheels programmation) parameter is
wrong (lower than “Set steer min” or higher than “Set steer max”).
- the feedback signal of the steering potentiometer is outside the window
defined by the “Set steer min” and the “Set steer max” parameters.
In the first case, repeat the steering potentiometer acquisition. In the second
case, check the steering potentiometer and its wiring again. In case, repeat
once again the steering potentiometer acquisition .
29 FORW + BACK Incorrect sequce by starting. Check:
- Microswitch for forward/backward directions and relevant wires.
- Microswitch for parking brake and relevant wires.
1A SLAVE KO Failure on the slave module.
1C BATTERY_LOW Discharged battery. If the “battery check” option is ON, a battery discharge
algorithm is carried out. When the charge level is 10% , this alarm is
ignalled and the current is reduced to the half of the programmed level.
2A CHOPPER The Dual AC2 traction unit has an erroneous configuration. Using the
NOT CONF. programming console it is possible to set the unit correctly according to the
truck configuration:
(0)double pedal version;
(1)manual inversor version;
(2)with inversor on the armrest.
(3)arm comand + direction selector on the steering column
1E CONTACTOR Failure on the contactor driver. Check the main contactors coils
CLOSED and the relevant wirings.
2C GAIN ACQUISITION This warning communicates that the logic is in phase of input acquisition. In
this phase the logic doesn't start.
2E HANDBRAKE Failure on parking brake. Check: the parking brake microswitch and the
relevant cables.
036-0410-07
page 55
DUAL AC2 TRACTION SLAVE UNIT
61 WATCH - DOG It is a self-diagnostic test within the logic between the Master and Slave
µcontrollers. This alarm could also be caused by the canbus malfunctioning
or data transmission interferences.Therefore, before replacing the Dual AC2
unit check the correct canbus functioning and the general turck insulation.
values (see adjusting tables).
63 LOGIC FAILURE #3 Logic defect. Replace the traction unit.
voltage feedback. Check the power cables connected to the left traction
motor. If the fault is not caused by external reasons, replace the Dual AC2
traction unit.
overvoltage protection. Logic defect. Replace the traction unit.
c. The alarm appears also when one or more phases of the left traction
motor doesn't present a correct insulation. Check the motor insulation
(with deconnected battery): it must be higher than 1 Mohm. Otherwise
check the power cables insulation to the motor.
the connections of the 3 power cables from the Slave unit to the left traction
motor and the cables condition also. In order to point out if the fault is
produced by an internal or external cause invert the connection of the
traction motors. It means Slaveto right motor and Master to left motor.
If the problem jumps on the Master it means that the left traction motor is
the connections of the 3 power cables from the Slave unit to the left traction
produced by an internal or external cause invert the connection of the
traction motors. It means Slaveto right motor and Master to left motor.
- Check main contactor coil and relevant wirings.
page 56
Traction
capacitor
71 HIGH Master or Slave or both temperatures are higher than 75°C. The maximum
TEMPERATURE current is reduced proportionally to the temperature increase. At 100°C the
max current of both inverters is reduced to zero. If the alarm is signalled
when the controller is cold:
TEMPERATURE sensor)
- identify the on wiring diagram the connector J1 (J7 on I/O card):
sensor is open
sensor is closed
If it occurs when the motor is cold, check:

a: the sensor is closed
b: between the positive pin (3) and negative pin (4) of the connector J1 (J7
on I/O card) there is 0V
- if "a" and "b" conditions take place replace the logic unit .
- 5V must be present on the positive pin (1) and negative pin (2) in the I/O
card connector J7 (with the wiring diagram J1 connector disconnected).
In the opposite case, replace the I/O card.
036-0410-07
page 57

present.
have a fault:
- The encoder
- The wiring
problem is located.

the encoder positive terminal.
sensor

is stopped.

Mv= 5.5-6.5 Volt


page 58
74 THERMIC SENS KO The values indicated by the temperature sensor of the inverter are always
checked and if they are out of range this warning appears.
75 SAFETY Replace the logic unit.
CAN BUS KO 0A : I/O card
CAN BUS KO 05 : Lifting logic unit
CAN BUS KO 03 : Master logic unit
CAN BUS KO : Slave logic unit (no suffix after the alarm message)
77 WAITING Time lag fault on the CAN BUS comunication. The Slavelogic unit detects
#4 The Slave logic unit receives the informations caming from the Master
#5 The Slave logic unit receives the informations caming from the
Lifting logic unit with a time lag fault.
- broken logic. Replace the lifting logic unit.
#9 The Slave logic unit receives the informations caming from the
If the failure is not due to external causes, replace the traction logic unit.
DRIVER - Replace the traction unit.
82 VACC NOT OK Not used.
036-0410-07
page 59
84 PEDAL WIRE KO Failure on the acceleration potentiometer signal at rest. This alarm appears
when there is an interruption on the potentiometer positive (PPOT) or the
negative (NPOT). Check:
- Traction potentiometer (could be damaged)
- Traction potentiometer wiring.
89 Not used.
7C Not used.
7A MASTER KO Failure on the Master module. Replace the Dual AC2 traction unit.
8E Not used.
8A Not used.
8C GAIN ACQUISITION This warning communicates that the logic is in phase of input acquisition.
In this phase the logic doesn't start.
AC2 LIFTING UNIT
31 WATCH - DOG It is a self-diagnostic test of logic lifting µcontroller . This alarm could also be
caused by the canbus malfunctioning or data transmission
interferences.Therefore, before replacing the AC2 lifting unit check the
correct canbus functioning and the general turck insulation.
values (see adjustin tables).
33 LOGIC FAILURE #3 Logic defect. Replace the lifting unit.
voltage feedback. Check the 3 power cables connected to the liftilg motor.
If the fault is not caused by external reasons, replace the traction unit.
overvoltage protection. Logic defect. Replace the lifting unit.
c. The alarm appears also when one or more phases of the lifting motor
doesn't present a correct insulation. Check the motor insulation(with
deconnected battery): it must be higher than 1 Mohm. Otherwise check
the insulation of the power cables to the motor.
the connections of the 3 power cables from the Lifting unit to the lifting
produced by an internal or external cause connect the lifting motor.to one of
the traction logic units: Slave or Master. If the problem jumps on the traction
unit connected it means that the lifting motor is demaged, otherwise replace
the lifting unit.
page 60
the connections of the 3 power cables from the Lifting unit to the lifting
produced by an internal or external cause connect the lifting motor.to one of
the traction logic units: Slave or Master. If the problem jumps on the traction
unit connected it means that the lifting motor is demaged, otherwise replace
the lifting unit.
- Check main contactors coils and relevant wirings.
- Replace the lifting unit.
Lifting
capacitor
41 HIGH Logic unit temperature is higher than 75°C. The maximum current is
TEMPERATURE reduced proportionally to the temperature increase. The logic unit stops at
100°C. If the alarm is signalled when the chopper is cold replace the lifting
unit.
TEMPERATURE sensor). If it occurs when the motor is cold, check
- the sensor (it should be closed) and the relevant wiring loop.
- If everything is OK replace the logic unit.
036-0410-07
page 61

present.
have a fault:
- The encoder
- The wiring
problem is located.

sensor
the encoder positive terminal.

is stopped.

Mv= 5.5-6.5 Volt


page 62
44 THERMIC SENS KO The values indicated by the temperature sensor of theinverter are always
checked and if they are out of range there is a warning.
45 SAFETY This alarm appears if the connection between the pins 5 and 11 on the JFP
connector is open.
- CAN BUS KO 0A: I/O
- CAN BUS KO 00: arm card
- CAN BUS KO 03: Master
- CAN BUS KO 04: Slave
- CAN BUS KO : Lifting logic unit (no suffix after the alarm message)
47 WAITING Time lag fault on the CAN BUS comunication. The Lifting logic unit detects
#4 The Lifting logic unit receives the informations caming from the Slave
#3 The Lifting logic unit receives the informations caming from the Master
#9 The Lifting logic unit receives the informations caming from the
If the failure is not due to external causes, replace the lifting logic unit.
DRIVER - Replace the lifting unit.
036-0410-07
page 63
52 VACC NOT OK Failure on the lifting potentiometer signal at rest. The alarm points out
that the voltage value detected on the lifting potentiometer is 1Volt
higher than the least value programmed with the Vacc function. Check:
- The tlifting potentiometer (it could be damaged or not correctly
calibrated)
- The lifting potentiometer wiring.
- Carry out the Vacc setting again.
53 INCORRECT START Incorrect sequence from the start. Check:
- Control valve microswitcheis and relevant wires.
If the failure is not due to external causes replace the traction logic unit.
54 PEDAL WIRE KO Failure on the lifting potentiometer signal at rest. This alarm appears
when there is an interruption on the potentiometer positive (PPOT) or the
negative (NPOT). Check:
- lifting potentiometer (could be damaged)
- lifting potentiometer wiring.
56 REMOTE INPUT Incorrect starting procedure.
57 WAITING The Lifting logic unit receives the informations caming from the
58 I= 0 EVER Failure on the current sensor. Replace the lifting unit.
59 Not used.
4A Not used
4C BATTERY_LOW Discharged battery. If the “battery check” option is ON, a battery discharge
algorithm is carried out. When the charge level is 10% , this alarm is
signalled and the current is reduced to the half of the programmed level.
5A CHOPPER The lifting unit has an erroneous configuration. Using the programming
NOT CONF. console it is possible to set the unitcorrectly according to the truck
configuration:
a. (joystick ON) control valve version
b. (joystick OFF) fingertip - joystick version.
4E Not used.
5C GAIN ACQUISITION This warning communicates that the logic is in phase of input acquisition. In
this phase the logic doesn't start.
5E Not used.
MHYRIO UNIT
A1 EEPROM KO Fault in the area of memory in which the adjustment parameters are stored;
parameters previously stored have been deleted and replaced by
the default values.
A2 DRIVER SHORTED The transistor that controls the lifting and lowering valvespositive supply is
closed when it should be open. Replace the logic unit.
page 64
A3 CAN BUS KO Failure wires connecting the logic units: traction (Master & Slave), lifting,
Mhyrio and all the cards.
A4 FF VALVES Replace the logic unit.
A5 DRIVER OPEN The transistor that controls the lifting and lowering valvespositive supply is
open when it should be closed. Replace the logic unit.
A6 DRIVER EPV GR1 One or more MOS controlling the valves are inshort-circuit.
Replace the logic unit.
DASHBOARD
d1 the dashboard doesn't receive information from the traction Master unit.
d2 the dashboard doesn't receive information from lifting logic unit.
d4 the dashboard doesn't receive information from traction Slave unit
d8 the dashboard doesn't receive information from joystick card.
b1 the dashboard doesn't receive information from I/O card (Input output)
b2 the dashboard doesn't receive information from Mhyrio unit
b4 the dashboard doesn't receive information from lights card
Combinations of the above alarms as follows:
d3 d1+d2
d5 d1+d4
d6 d2+d4
d7 d1+d2+d4
dA d2+d8
dB d1+d2+d8
dC d4+d8
dD d1+d4+d8
dE d2+d4+d8
dF d1+d2+d4+d8
b3 b1+b2
b5 b1+b4
b6 b2+b4
b7 b1+b2+b4
FINGERTIPS/JOYSTICKS (NOT SHOWN BY THE CONSOLE)
E1 Not used.
E2 BAD LIFT POT Failure on the lifting potentiometer in the fingertips / joysticks group.
Check, and if necessary replace the relevant fingertip / joystick.
E3 BAD TILT POT Failure on the tilting potentiometer in the fingertips / joysticks group.
Check, and if necessary replace the relevant fingertip / joystick
E4 BAD SIDESH. POT Failure on the sideshift potentiometer in the fingertips / joysticks group.
E5 BAD IV POT Failure on the 4th way potentiometer in the fingertips / joysticks group.
E6 BAD V POT Failure on the 5th way potentiometer in the fingertips / joysticks group.
E7 INCORRECT START Incorrect start sequence.
E8 BAD POTENTIOMETER
BF FW+BW Incorrect start sequence. Check, and if necessary replace the forward
pushbutton (PB3), the backward pushbutton (PB2) and the relevant
cables on the arm.
036-0410-07
page 65
LIGHTS CARD (NOT SHOWN BY THE CONSOLE)
C1 STOP-OPEN Failure on the stop lights. Check the bulbs of the stopstreetlights and the
relevant cables.
C2 Not used.
C3 Not used.
C4 RETRO-OPEN Failure on the backup lights. Check the bulbs of the backup streetlights and
the relevant cables.
C5 C1+C4 Failure on the stop and the backup lights. Check the relevant bulbs and the
cables of both light types.
C6 Not used.
C7 Not used.
C8 Not used.
I / O CARD (NOT SHOWN BY THE CONSOLE)
81 TRACTION Incorrect start sequence (control valve version). Check:

INCORRECT START - forward, backward microswitches and relevant cables;
- parking brake micro and relevant cables.
82 LOGIC FAILURE Logic defect (control valve version).
83 PEDAL WIRE KO Failure on the acceleration potentiometer signal at rest. Check:
- traction potentiometer (could be damaged or not correctly calibrated);
- traction potentiometer wiring.
84 BAD MICROSWITCH
85 Not used.
86 Not used.
87 Not used.
88 PUMP INCORRECT START
89 TRACTION Alarm 81 + alarm 88
AND PUMP
INCORRECT START
ALARM COMBINATION
81-26 INCORRECT START traction pedal

56-88 INCORRECT START mechanic distributor
page 66
PARAMETER SETTING TABLE

DUAL AC2 TRACTION UNIT
PROGRAMMEDLEVEL
PARAMETER
UNIT 0 1 2 3 4 5 6 7 8 9
ACCELERATION DELAY (*) SEC 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5
RELEASE BRAKING (**) SEC 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
INVERS BRAKING (**) SEC 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
PEDAL BRAKING (**) SEC 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
SPEED LIMIT BRAKING (**) SEC 8.9 8.3 7.7 7.1 6.6 6.0 5.5 4.9 4.4 3.8
BRAKE CUTBACK (**) SEC 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
MAX SPEED FW HZ 65 80 95 110 125 140 155 170 185 200
MAX SPEED BW HZ 65 80 95 110 125 140 155 170 185 200
CURVE CUTBACK % 10 20 30 40 50 60 70 80 90 100
CUTBACK SPEED % MAX SPEED 10 20 30 40 50 60 70 80 90 100
FREQUENCY CREEP HZ 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3.0
MAXIMUM CURRENT % IMAX 47 53 58 64 70 76 82 88 94 100
ACC. SMOOTH
INV. SMOOTH
STOP SMOOTH HZ
AUXILIARY TIME SEC 0 0.2 0.4 0.8 1 1.5 2 3 4 5
(*) The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp calculated by the
software; the real ramp could change according to the motor parameters setting and, obviously, according
to the load.
(**) The braking feature is based upon deceleration ramps. The value shown in the table is the time to
decrease the speed from 100 Hz to 0 Hz. This is the ideal ramp calculated by the software; the real ramp
could change according to the motor parameters setting and, obviously, according to the load.
036-0410-07
page 67
PARAMETER SETTING TABLE
AC2 LIFTING UNIT
PROGRAMMEDLEVEL
PARAMETER
UNIT 0 1 2 3 4 5 6 7 8 9
ACCELERATION DELAY (*) SEC 0.5 0.7 1.0 1.4 1.9 2.5 3.2 4.0 4.8 5.5
DELERATION DELAY (**) SEC 0.5 0.7 1.0 1.4 1.9 2.5 3.2 4.0 4.8 5.5
MAX SPEED UP HZ 65 80 95 110 125 140 155 170 185 200
MIN SPEED UP HZ 12.0 13.5 15.0 16.5 18.0 19.5 21.0 22.5 24.0 25.5
SPEED FINE (ALL) (***) HZ - - - - - - - - - -
MAXIMUM CURRENT % IMAX 47 53 58 64 70 76 82 88 94 100
AUXILIARY TIME SEC 0 0.2 0.4 0.8 1.0 1.5 2.0 3.0 4.0 5.0
(*) The acceleration time shown is the time from 0 Hz to 100 Hz (maximum selectable speed). This is the ideal
ramp calculated by the software; the real ramp could change according to the motor parameters setting and,
obviously, according to the load.
(**) The deceleration time shown in the table is the time from 100 Hz to 0 Hz. This is the ideal ramp calculated
by the software; the real ramp could change according to the motor parameters setting and, obviously,
according to the load.
(***) Adjustable with a 1Hz resolution in the 0 to 200 Hz range.
page 68

036-0410-07
page 69
MAPS FOR USING

THE CONSOLE
TRACTION
page 70
NECESSARY SETTING AFTER REPLACING THE TRACTION LOGIC UNIT
1. TRACTION ACQUISITION see following pages

2. ADJUST BATTERY see following pages
3. STEERING POTENTIOMETER see following pages
4. Vacc PROGRAM see following pages
5. STEER TABLE see following pages
036-0410-07
page 71
DESCRIPTION OF THE CONSOLE STANDARD MENU

The console can be connected to the traction logic unit in two different ways:
1. Directly, by means of an interface cable in the concerned connector of the traction logic unit.
2. By connecting the console in another logic unit (pump or Mhyrio) and selecting the relevant connection
number as shown in the map here below.
AC2P2B D CE 1.06 In case the console is connected to the lifting logic unit
48V 350A 00000
Press ROLL and PARAM together
* CONFIG. MENU *
SET MODEL
Press ENTER
CONNECTED TO It is the connection number of the lifting logic unit.

5
Press SET and select the connection number of the traction logic unit
CONNECTED TO It is the connection number of the MASTER traction logic unit

3
Press OUT
ARE YOU SURE? CONNECTION NUMBERS

YES=ENTER NO=OUT
3 TRACTION MASTER
Press ENTER
to confirm
4 TRACTION SLAVE
5 PUMP
* CONFIG. MENU * 9 MHYRIO
SET MODEL
11 DASHBOARD
Press ROLL, OUT and SET together
DA2M2B C CE 1.13 Connected to the MASTER traction logic unit

48V 280A 00000
page 72

DUAL AC2 TRACTION UNIT MASTER MENU
HEADING
MAIN MENU
ACCELERATION DELAY 0-9

RELEASE BRAKING 0-9
INVERS. BRAKING 0-9
PARAMETER PEDAL BRAKING 0-9
CHANGE SPEED LIMIT BRAK. 0-9 SET MODEL CONNECTED TO 3
BRAKE CUTBACK 0-9
MAX SPEED FORW Hz
MAX SPEED BACK Hz
CUTBACK SPEED Hz
CUTBACK SPEED 2 Hz
CUTBACK SPEED 3 Hz
FREQUENCY CREEP Hz
MAXIMUM CURRENT 0-9 HOUR COUNTER RUNNING/ KEY ON
ACC. SMOOTH 1-1.5 Hz BATTERY CHECK ON/OFF
INV. SMOOTH 0.4-1.5 Hz HYDRO KEY ON ON/OFF
STOP SMOOTH 5-20 Hz STOP ON RAMP ON/OFF
AUXILIARY TIME Sec AUX INPUT #1 EXCLUSIVE HYDRO
SET OPTIONS OPTION #1
CUT BACK SPEED
MOTOR VOLTAGE %
PEDAL BRAKING ANALOG/DIGITAL
FREQUENCY Hz
SET TEMPERATURE ANALOG/DIGITAL/
ENCODER Hz
NONE
SLIP VALUE Hz
STEER TABLE OPTION #1
CURRENT RMS A
TEMPERATURE °C
TEMPERATURE #1 not used
TEMPERATURE #2 not used
ACCELERATOR V
TESTER
STEER ANGLE °
INTERNAL WHEEL CUTBACK % SET POT BRK MIN ....V
ADJUSTMENTS SET POT BRK MAX ....V
FORWARD SWITCH ON-OFF
BACKWARD SWITCH ON-OFF SET BATTERY TYPE 48/72/80/96
ENABLE SWITCH ON-OFF ADJUST BATTERY ....V
SEAT SWITCH ON-OFF MAX STEER RIGHT ....V
CUTBACK SWITCH ON-OFF MAX STEER LEFT ....V
CUTBACK SWITCH 3 ON-OFF SET STEER 0-POS 2.5V
BRAKE SWITCH ON-OFF SET STEER RIGHT ....V
EXCLUSIVE HYDRO ON-OFF SET STEER LEFT ....V
BRAKE PEDAL POT. not used THROTTLE 0 ZONE ....%
HAND BRAKE ON-OFF THROTTLE X ZONE ....%
VOLTAGE BOOSTER V THROTTLE Y ZONE ....%
BATTERY VOLTAGE V ADJUSTMENT #02 1-9
BATTERY CHARGE % ADJUSTMENT #01 1-9
MAIN CONT VOLT ....V
AUX OUTPUT VOLT ....V
SAVE
PARAMETER
RESTORE
PARAMETER
CODE
ALARMS
h, N°, C°
PROGRAM
VACC SETTING MIN/MAX
VACC
STEER
NOT AVAIBLE
TABLE
036-0410-07
page 73

DUAL AC2 TRACTION UNIT SLAVE MENU
HEADING
MAIN MENU
PARAMETER NOT AVAILABLE

CHANGE SET MODEL CONNECTED TO
SET OPTIONS NOT AVAILABLE
MOTOR VOLTAGE %
FREQUENCY Hz
ENCODER Hz
SLIP VALUE Hz
CURRENT RMS A
TESTER TEMPERATURE °C SET BATTERY TYPE 48/72/80/96
SEAT SWITCH ON-OFF ADJUST BATTERY ....V
ADJUSTMENTS
FORW. SWITCH ON-OFF AUX OUTPUT VOLT ....V
BACK. SWITCH ON-OFF
ENABLE SWITCH ON-OFF
VOLTAGE BOOSTER %
BATTERY VOLTAGE V
SAVE
PARAMETER
RESTORE
PARAMETER
CODE
ALARMS
h, N°, C°
PROGRAM
VACC
STEER
NOT AVAILABLE
TABLE
page 74
MAIN MENU: PARAMETER CHANGE (MASTER connection number 3)

Select the program P on the dashboard before working with the main menu PARAMETER CHANGE.
DA2M2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ENTER
ACCELER/DELAY determines the acceleration ramp.

RELEASE BRAKING controls the deceleration ramp when the travel pedal is released.
INVERSION BRAKING controls the deceleration ramp when the direction switch is inverted
during the travel.
PEDAL BRAKING determines the deceleration ramp when the travel pedal is released and
thebrake pedal switch is closed.
SPEED LIMIT BRAKING deceleration ramp when the pedal position is partly released, not
completely.
BRAKE CUTBACK determines the deceleration ramp when the speed reduction input
becomes active and the motor slows down.
MAX SPEED FORWARD determines the maximum speed in forward direction.
MAX SPEED BACKWARD determines the maximum speed in backward direction.
CUTBACK SPEED 1 speed reduction when the cutback switch is active. Turtle function.
CUTBACK SPEED 2 speed reduction with brake pedal pressed.
CUTBACK SPEED 3 speed reduction enabled when the C10 signal is low.
CURVE CUT BACK speed reduction in curve.
FREQUENCY CREEP minimum speed when the forward or reverse switch is closed, but the
accelerator is slightly pressed.
MAXIMUM CURRENT this changes the maximum current of the inverter.
ACC. SMOOTH this delays the acceleration ramp from 0 hz to “stop smooth” value.
INV. SMOOTH this delays the deceleration ramp of the inversion from “stop smooth”
value to 0 hz.
STOP SMOOTH reference speed for the parameters ACC. SMOOTH and INV. SMOOTH
AUXILIARY TIME time delay when an hydraulic steering function request is switched off.
Scroll the parameters using ROLL and save the new values pressing OUT and after ENTER
036-0410-07
page 75
MAIN MENU: TESTER (MASTER connection number 3)
DA2M2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ENTER
MOTOR VOLTAGE
FREQUENCY
ENCODER
SLIP VALUE
CURRENT RMS
TEMPERATURE
TEMPERATURE #1
TEMPERATURE #2
ACCELERATOR
STEER ANGLE
BRAKE PEDAL POTI
INTERNAL WHEEL CUTBACK Scroll the parameters using ROLL.
SEAT SWITCH
FORWARD SWITCH Press OUT to escape.
BACKWARD SWITCH
ENABLE SWITCH
BRAKE SWITCH
CUTBACK SWITCH
EXCLUSIVE HYDRO
HAND BRAKE
VOLTAGE BOOSTER
BATTERY VOLTAGE
BATTERY CHARGE
page 76
MAIN MENU : SAVE PARAMETER (MASTER connection number 3)

DA2M2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ENTER
Select the box (0-31) where you want to save the program:
SELECT Mod 00 = Program number
FREE/DA2M2B C = Program version stored
SELECT Mod 00 SELECT Mod 00

FREE DA2M2B C
Press ENTER Press ENTER
OVERWRITE DATA?
READING........
RUN ALL PARAMETERS YES=ENTER NO=OUT
MAIN MENU
SAVE PARAM
Press ENTER Press OUT
to confirm to escape
READING........ MAIN MENU

RUN ALL PARAMETERS SAVE PARAM
MAIN MENU
SAVE PARAM
036-0410-07
page 77
MAIN MENU : RESTORE PARAMETER (MASTER connection number 3)
DA2M2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ROLL
MAIN MENU
RESTORE PARAM
Press ENTER
SELECT Mod 00 SELECT Mod 00 = Program number

DA2M2B C FREE/DA2M2B C = Program version stored
Press ROLL to select the box (0-31) where you

want to save the program
OVERWRITE DATA?
YES=ENTER NO=OUT

STORING........ MAIN MENU

RUN ALL PARAMETERS RESTORE PARAM
MAIN MENU
RESTORE PARAM
page 78
MAIN MENU : ALARM (MASTER connection number 3)
DA2M2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN. MENU
PARAM. CHANGE
Press ROLL until reaching MAIN

MENU ALARM
MAIN. MENU
ALARM
Press ENTER
no alarms stored max 5 alarms stored
NONE ALARM CODE

00000h #00 0°C 23h 2 25°C
hour meter no. alarms temperature

Press OUT Press ENTER
CLEAR LOGBOOK
YES=ENTER NO=OUT

ARE YOU SURE?

YES=ENTER NO=OUT

LOGBOOK CLEARED
(PRESS OUT)
036-0410-07
page 79
MAIN MENU: PROGRAM VACC. (MASTER connection number 3)
This setting must be made with the parking brake released
DA2M2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL until reaching the program VACC
MAIN MENU
PROGRAM VACC
Press ENTER
VACC SETTING These are the old parameters stored

0.6 1.6
Press ENTER
VACC SETTING Reset of the parameters

0.0 0.0
Select the forward direction

Press the accelerator pedal slowly until the maximum stroke
VACC SETTING
0.6 1.6
Press OUT keeping the acc. pedal pressed
ARE YOU SURE?

YES=ENTER NO=OUT
Press ENTER to confirm and release the pedal
Repeat the same operation selecting the backward direction.

page 80
STEERING POTENTIOMETER ADJUSTMENT (MASTER connection

number 3)
The setting of the steering potentiometer is made in the MASTER (connection number 3) of the traction logic
unit, that is automatically selected when the console is fisically connected to the MASTER unit.
DA2M2B C CE 1.13
48V 280A 00000
* CONFIG. MENU *
SET MODEL
Press ROLL
* CONFIG. MENU *
SET OPTIONS
Press ROLL
* CONFIG. MENU *
ADJUSTMENTS
Press ENTER
SET POT BRK MIN ....V Scroll the parameters using ROLL
SET POT BRK MAX ....V
SET BATTERY TYPE 48/72/80/96 1. Select MAX STEER RIGHT (pressing ENTER
ADJUST BATTERY ....V to delete the old parameter) with the wheels turned
completely right and store the parameter pressing
MAX STEER RIGHT ....V OUT and then ENTER to confirm. (This value
MAX STEER LEFT ....V corresponds to the min. voltage)
SET STEER 0-POS 2.5V
2. Select MAX STEER LEFT (pressing ENTER to
SET STEER RIGHT ....° delete the old parameter) with the wheels turned
SET STEER LEFT ....° completely left and store the parameter pressing
THROTTLE 0 ZONE ....% OUT and then ENTER to confirm. (This value
THROTTLE X ZONE ....% corresponds to the max. voltage)
THROTTLE Y ZONE ....%
ADJUSTMENT #02 1-9 3. Select SET STEER 0-POS (pressing ENTER to
ADJUSTMENT #01 1-9 delete the old parameter) with straight wheels and
MAIN CONT VOLT ....V store the parameter pressing OUT and then ENTER
AUX OUTPUT VOLT ....V to confirm the new value.
036-0410-07
page 81
STEER TABLE (MASTER connection number 3)
Select the type of truck according to the 3 wheels or 4 wheels configuration.
OPTION #1 3 WHEELS 1,2-2,0 t AC

OPTION #2 4 WHEELS 1,2-2,0 t AC
OPTION #3 cenTAURO 160-200 L AC/C4E 160-200 NL AC
DA2M2B C CE 1.13
48V 280A 00000
* CONFIG. MENU *
SET MODEL
Press ROLL
* CONFIG. MENU *
SET OPTIONS
Press ENTER
HOUR COUNTER RUNNING/ KEY ON

BATTERY CHECK ON/OFF
HYDRO KEY ON ON/OFF
STOP ON RAMP ON/OFF
AUX INPUT #1 EXCLUSIVE HYDRO
OPTION #1 Scroll the parameters using ROLL
CUT BACK SPEED
SET TEMPERATURE ANALOG/DIGITAL/NONE
OPTION #2
OPTION #3
Select OPTION #1 for the 3 wheels and store the parameter pressing OUT and then ENTER to
confirm.
Select OPTION #2 for the 4 wheels and store the parameter pressing OUT and then ENTER to
confirm.
Select OPTION #3 for the cenTAURO 160-200 L AC/C4E 160-200 NL AC and store the parameter
pressing OUT and then ENTER to confirm.
page 82
STOP ON RAMP (MASTER connection number 3)
DA2M2B C CE 1.13
48V 280A 00000
* CONFIG. MENU *
SET MODEL
Press ROLL
* CONFIG. MENU *
SET OPTIONS
Press ENTER

HYDRO KEY ON ON/OFF
STOP ON RAMP ON/OFF

Scroll the parameters using ROLL
OPTION #1
CUT BACK SPEED
OPTION #2
Select STOP ON RAMP and change the status using PARAM or SET
ON ACTIVATED
OFF DEACTIVATED
and store the parameter pressing OUT and then ENTER to confirm.
After releasing the pedals the truck can stay still on a ramp for about 1 second.
This parameter activates/deactivates this function.
036-0410-07
page 83
SLIP CONTROL (MASTER connection number 3)
This function is useful to understand if a traction problem is due to the encoder or not.
In case the truck stops or works with low speed with high consumption of current (and relevant alarm code shown
on the dashboard) it is possible to disable the encoder for some seconds, no longer, given that the logic unit cannot
control the motor any longer.
Do not work with this configuration.
DA2M2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
until reaching ALARM menu
MAIN MENU
ALARM
With the SLIP CONTROL OFF push the
Press ENTER accelerator pedal slowly otherwise the motor
stands still.
DESCRIPTION OF THE
ALARM CODE
Press PARAM and SET

together
* MENU *
SPECIAL ADJUST
Press ROLL
* MENU *
HARDWARE SETTING
Press ENTER
Select SLIP CONTROL ON or OFF and store the

COMPENSATION
parameter pressing OUT and then ENTER to confirm.
SLIP CONTROL ON/OFF
After that switch the truck OFF and ON.
page 84
BATTERY INDICATOR
The control of the battery LED indication on the dashboard and the relevant reduction of the speed are
managed by the traction logic unit.
The dashboard reads only the information coming from the logic unit and shows, using the led battery indicator,
the status of the battery.
In order to have a precise reading of the logic unit it is necessary to set the parameter ADJUST
BATTERY everytime the traction logic unit is replaced or you received a new truck without battery.
ADJUST BATTERY SETTING
- Connect the analyser

- Switch the truck on
In order to have a pricise measure of the battery voltage you have to set the parameter ADJUST BATTERY
with the same value read directly on the battery by a multimeter.
Note that the logic uses as refernce voltage the key input which is not at the same potential of the positive pole
of the battery due to the fact that between them different devices are locatet (connectors, the fuse F1 the push
button PB1).
M S Z M
F1 PB1 S1
BATTERY LOGIC UNIT
Once taken the measure of the voltage set the parameter adjust battery following the instruction
explained in the BATTERY SETTING MAP.
ADVICE
Set the multimeter in volt and join the two terminal togheter. On the display you have to read zero.
If you read other value that it in consideration during the measure of the battery voltage.
036-0410-07
page 85
REARM OF THE BATTERY INDICATOR
0% 100 % The battery indicator rearms only

below the 70% of the full charge.
With highter value there is not the rearm

of the indicator. It means that it does
not come back to 100%.
The battery indicator is adjustable by the console in order to change the
the reset value ADJUSTMENT #01

the discharge value ADJUSTMENT #02
>
V
ADJUSTMENT
DISCHARGE CURVE
ADJUSTMENT
>
t
To modify the above parameter see the BATTERY SETTING MAP

page 86
BATTERY (MASTER connection number 3)
The control of the battery LED indication on the dashboard and the relevant reduction of speed are performed
by the MASTER of the traction logic unit.
DA2M2B C CE 1.13
48V 280A 00000 Scroll the parameters using ROLL and
save the new values pressing OUT and
then ENTER
Press ROLL and
PARAM together
* CONFIG. MENU *
SET MODEL
BATTERY CHECK ON
Press ROLL HYDRO KEY ON ON/OFF

STOP ON RAMP ON/OFF
* CONFIG. MANU *
SET OPTIONS OPTION #1
CUT BACK SPEED
Press ENTER
OPTION #2
ARE YOU SURE?

YES=ENTER NO=OUT
Press OUT
Press ENTER SET POT BRK MIN ....V

SET POT BRK MAX ....V
SET BATTERY TYPE 48
* CONFIG. MANU * ADJUST BATTERY ....V
SET OPTIONS MAX STEER RIGHT ....V
MAX STEER LEFT ....V
Press ROLL SET STEER 0-POS 2.5V
SET STEER RIGHT ....V
SET STEER LEFT ....V
* CONFIG. MANU * THROTTLE 0 ZONE ....%
ADJUSTMENTS
THROTTLE X ZONE ....%
Press ENTER ADJUSTMENT #02 1-9
ADJUSTMENT #01 1-9
MAIN CONT VOLT ....V
AUX OUTPUT VOLT ....V
ARE YOU SURE?

YES=ENTER NO=OUT
Press OUT
Press ENTER
036-0410-07
page 87
SET BATTERY TYPE: selects the nominal battery voltage

ADJUST BATTERY: adjusts the value displayed in the console to adapt it to the real value of the
battery (measured with a multimeter)
ADJUSTMENT #02 adjustment of the lowest value of charge of the battery
ADJUSTMENT #01 adjustment of the reset value of the battery indicator
ADJUSTMENT #01
CONSOLE VALUE VOLT RESETTING
indicatore della batteria
0 49.20 49.10
1 49.48 49.39
2 49.73 49.58
3 50.02 49.87
4 50.26 50.11
5 50.54 50.35
6 50.83 50.64
7 51.02 50.83
8 51.26 51.27
9 51.80 51.55
ADJUSTMENT #02
CONSOLE VALUE VOLT

0 45.70
1 45.98
2 46.22
3 46.51
4 46.75
5 47.04
6 47.33
7 47.57
8 47.81
9 48.38
page 88
MAIN MENU: PARAMETER CHANGE (SLAVE connection number 4)
DUAL AC2 - SLAVE
By means of the config menu of the programming console, the user can configure the following
functions.
SUBMENU “SET OPTIONS”

Not available.
SUBMENU “ADJUSTMENT”
1 SET BATTERY TYPE: selects the battery nominal voltage;

2 ADJUST BATTERY: fine adjustment of the battery voltage measured by the controller.
3 AUX OUPUT VOLTAGE: this parameter adjusts the voltage of the auxiliary output coil
(hydraulic steering contactor coil), PWM output A31.
DA2S2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ENTER
NOT AVAILABLE
Press OUT to escape

036-0410-07
page 89
MAIN MENU: TESTER (SLAVE connection number 4)
DA2S2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ENTER
MOTOR VOLTAGE
FREQUENCY Scroll the parameters using ROLL.
ENCODER
SLIP VALUE Press OUT to escape
CURRENT RMS
TEMPERATURE
SEAT SWITCH
FORWARD SWITCH
BACKWARD SWITCH
ENABLE SWITCH
VOLTAGE BOOSTER
BATTERY VOLTAGE
page 90
MAIN MENU : SAVE PARAMETER (SLAVE connection number 4)

DA2S2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ENTER
Select a box (0-31) where you want to save the program:

FREE/DA2S2B C = Program version stored

FREE DA2S2B C
READING........ OVERWRITE DATA?

MAIN MENU
SAVE PARAM


MAIN MENU
SAVE PARAM
036-0410-07
page 91
MAIN MENU : RESTORE PARAMETER (SLAVE connection number 4)
DA2S2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ROLL
MAIN MENU
RESTORE PARAM
Press ENTER

DA2S2B C FREE/DA2S2B C = Program version stored

OVERWRITE DATA?
YES=ENTER NO=OUT


MAIN MENU
RESTORE PARAM
page 92
MAIN MENU : ALARM (SLAVE connection number 4)
DA2S2B C CE 1.13
48V 280A 00000
Press ENTER
MAIN. MENU
PARAM. CHANGE

MENU ALARM
MAIN. MENU
ALARM
Press ENTER
NONE ALARM CODE

00000h #00 0°C 23h 2 25°C

CLEAR LOGBOOK
YES=ENTER NO=OUT

ARE YOU SURE?

YES=ENTER NO=OUT

LOGBOOK CLEARED
(PRESS OUT)
036-0410-07
page 93
MAIN MENU: PROGRAM VACC. (SLAVE connection number 4)
It must be carried out in the MASTER traction logic unit.

page 94
TRACTION ACQUISITION (MASTER connection number 3)
Connect the console to the TRACTION logic unit
DA2M2B C CE 1.13
48V 280A 00000
* CONFIG MENU *
SET MODEL
Press ENTER
CONNECTED TO 3
Press ROLL
LEVEL 0 0 with double pedal version
LEVEL 1 1 with hand inversor version
LEVEL 2 2 with inversor on the arm
Press OUT
ARE YOU SURE?

YES=ENTER NO=OUT
Press ENTER to confirm

036-0410-07
page 95
MAPS FOR USING

THE CONSOLE
LIFTING
page 96
NECESSARY SETTING AFTER REPLACING THE LIFTING LOGIC UNIT
1. LIFTING ACQUSITION see following pages

2. Vacc PROGRAM (with mechanic distributor only) see following pages
036-0410-07
page 97

AC2 LIFTING UNIT
The console can be connected to the lifting logic unit in two different ways:
1. Directly by means of an interface cable on the logic unit.

2. By connecting the console to another logic unit (traction or Mhyrio) and selecting the relevant connection
DA2M2B C CE 1.13 In case the console is connected to the traction logic unit
48V 280A 00000
* CONFIG. MENU *
SET MODEL
Press ENTER
CONNECTED TO It is the connection number of the traction logic unit.

3
Press SET and select the connection number of the lifting logic unit
CONNECTED TO It is the connection number of the lifting unit.

5
Press OUT
CONNECTION NUMBERS
ARE YOU SURE?
YES=ENTER NO=OUT 3 TRACTION MASTER
4 TRACTION SLAVE
Press ENTER 5 PUMP
to confirm 9 MHYRIO
11 DASHBOARD
* CONFIG MENU *
SET MODEL
AC2P2B D CE 1.06
48V 350A 00000 Connected to the lifting logic unit
page 98
AC2 LIFTING UNIT MENU
HEADING
MAIN MENU
PARAMETER ACCELER/DELAY 0-9

CHANGE DECELER/DELAY 0-9 SET MODEL CONNECTED TO 5
MAX SPEED UP Hz
MIN SPEED UP Hz
HzCUTBACK SPEED %
CUTBACK SPEED 2 %
1ST SPEED FINE Hz
2ND SPEED FINE Hz
3RD SPEED FINE Hz
4TH SPEED FINE Hz
AUX FUNCTION 1 %
HYD SPEED FINE Hz
MAXIMUM CURRENT A
AUXILIARY TIME sec
HOUR COUNTER RUNNING/KEY ON
SET OPTIONS
SET TEMPERATURE DIGITAL/ANALOG/
NONE
MOTOR VOLTAGE %
FREQUENCY Hz
ENCODER Hz
SLIP VALUE Hz
CURRENT RMS A
TEMPERATURE °C
MOTOR TEMPERATURE °C
TESTER ACCELERATOR V SET BATTERY TYPE 48/72/80/96
SEAT SWITCH ON-OFF ADJUSTMENTS ADJUST BATTERY ....V
CUTBACK SWITCH ON-OFF THROTTLE 0 ZONE ....%
CUTBACK SWITCH 2 ON-OFF THROTTLE X POINT ....%
LIFTING SWITCH % THROTTLE Y POINT ....%
1ST SPEED SWITCH % ADJUSTMENT #04 ....°C
2ND SPEED SWITCH % ADJUSTMENT #03 ....°C
3RD SPEED SWITCH % ADJUSTMENT #02 1-9
4TH SPEED SWITCH % ADJUSTMENT #01 1-9
HYDRO SPEED REQ. %
VOLTAGE BOOSTER %
BATTERY VOLTAGE V
COS FI
BATTERY CURRENT A
BATTERY CHARGE %
SAVE
PARAMETER
RESTORE
PARAMETER
CODE
ALARMS
h, N°, C°
PROGRAM
VACC
STEER
NOT AVAILABLE
TABLE
036-0410-07
page 99
MAIN MENU: PARAMETER CHANGE (PUMP connection number 5)
AC2P2B D CE 1.06
48V 350A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ENTER
ACCELER/DELAY acceleration ramp.

DECELER/DELAY deceleration ramp.
MAX SPEED UP determines the maximum lifting speed controlled by a potentiometer.
MIN SPEED UP determines the minimum lifting speed controlled by a potentiometer when the
lift enabling switch is closed.
CUTBACK SPEED speed reduction when the cutback switch is active.
(+V =E4; input E13) if E13 is open the Cutbackspeed is on,
is the E13 is closed the Cutbackspeed is off.
CUTBACK SPEED 2 speed reduction when the cutback switch is active.
(+V =E4; input E14); if E14 is open the Cutbackspeed is off,
if E14 is closed the Cutbackspeed is on.
1ST SPEED FINE tilt speed, fine regulation.
2ND SPEED FINE side-shift speed, fine regulation.
th
3RD SPEED FINE 4th lever speed, fine regulation.
th
4TH SPEED FINE 5th lever speed, fine regulation.
AUX FUNCTION 1 pot. value increasing the motor RPM.
HYD SPEED FINE hydro speed, fine regulation.
MAXIMUM CURRENT maximum current of the inverter.
AUXILIARY TIME time delay when a hydraulic steering function request is switched off.
Scroll the parameters using ROLL and save the new values pressing OUT and then ENTER
page 100
MAIN MENU: TESTER (PUMP connection number 5)
AC2P2B D CE 1.06
48V 350A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ENTER
MOTOR VOLTAGE
FREQUENCY
ENCODER
SLIP VALUE
CURRENT RMS
TEMPERATURE
MOTOR TEMPERATURE
SEAT SWITCH
ACCELERATOR
LIFTING SWITCH Scroll the parameters using ROLL.
1 ST SPEED SWITCH
2 ND SPEED SWITCH Press OUT to escape.
3 RD SPEED SWITCH
4 TH SPEED SWITCH
HYDRO SPEED REQ.
CUTBACK SWITCH
CUTBACK SWITCH 1
VOLTAGE BOOSTER
BATTERY VOLTAGE
COS FI
BATTERY CURRENT
BATTERY CHARGE
036-0410-07
page 101
MAIN MENU : SAVE PARAMETER (PUMP connection number 5)
AC2P2B D CE 1.06
48V 350A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ENTER
FREE/AC2P2B D = Program version stored

FREE AC2P2B D

MAIN MENU
SAVE PARAM


MAIN MENU
SAVE PARAM
page 102
MAIN MENU : RESTORE PARAMETER (PUMP connection number 5)

AC2P2B D CE 1.06
48V 350A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ROLL
MAIN MENU
RESTORE PARAM
Press ENTER

AC2P2B D FREE/AC2P2B D = Program version stored

OVERWRITE DATA?
YES=ENTER NO=OUT


MAIN MENU
RESTORE PARAM
036-0410-07
page 103
MAIN MENU : ALARM (PUMP connection number 5)
AC2P2B D CE 1.06
48V 350A 00000
Press ENTER
MAIN. MENU
PARAM. CHANGE

MENU ALARM
MAIN. MENU
ALARM
Press ENTER
NONE ALARM CODE

00000h #00 0°C 23h 2 25°C

CLEAR LOGBOOK
YES=ENTER NO=OUT

ARE YOU SURE?

YES=ENTER NO=OUT

LOGBOOK CLEARED
(PRESS OUT)
page 104
MAIN MENU: PROGRAM VACC. (PUMP connection number 5)
This setting must be made with the parking brake released
AC2P2B D CE 1.06
48V 350A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL until reaching the program VACC
MAIN MENU
PROGRAM VACC
Press ENTER
VACC SETTING
These are the old parameters stored
0.2 4.8
Press ENTER
VACC SETTING Reset of the parameters

0.0 0.0
Pull the lifting lever slowly until the maximun stroke
VACC SETTING
0.2 4.8
Press OUT keeping the lever pulled
ARE YOU SURE?

YES=ENTER NO=OUT
Press ENTER to confirm and release the lever

036-0410-07
page 105
SLIP CONTROL (PUMP connection number 5)
This functions is useful to understand if a lifting problem is due to the encoder or not.
In case the truck stops or works with low speed with high consumption of current (and relevant alarm code
displayed on the dashboard) it is possible to disable the encoder for some seconds, no longer, given that the logic
unit cannot control the motor any longer.
Do not work with this configuration.
AC2P2B D CE 1.06
48V 350A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
until reaching ALARM menu
MAIN MENU
ALARM
With the SLIP CONTROL OFF pull the lever of
the potentiometer slowly otherwise the motor
Press ENTER stands still.
DESCRIPTION OF THE
ALARM CODE
Press PARAM and SET

together
* MENU *
SPECIAL ADJUST
Press ROLL
* MENU *
HARDWAR E SETTING
Press ENTER
Select SLIP CONTROL ON or OFF and store the

COMPENSATION
parameter pressing OUT and then ENTER to confirm.
SLIP CONTROL ON/OFF
After that switch the truck OFF and ON.
page 106
BATTERY (PUMP connection number 5)

The control of the battery LED indication on the dashboard and the relevant reduction of speed are performed
by the MASTER of the traction logic unit.
Scroll the parameters using ROLL and
AC2P2B D CE 1.06 save the new values pressing OUT and
48V 350A 00000
then ENTER

* CONFIG. MENU *
SET MODEL BATTERY CHECK OFF
Press ROLL HYDRO KEY ON ON/OFF

STOP ON RAMP ON/OFF
* CONFIG. MENU *
SET OPTIONS
OPTION #1
CUT BACK SPEED
Press ENTER SET TEMPERATURE ANALOG/DIGITAL/NONE
OPTION #2
ARE YOU SURE?

Press OUT
YES=ENTER NO=OUT
Press ENTER
* CONFIG. MENU *
SET OPTIONS
Press ROLL SET BATTERY TYPE 48

ADJUST BATTERY ....V
* CONFIG. MENU * ADJUSTMENT #03 ....°C

ADJUSTMENTS
ADJUSTMENT #04 ....°C
THROTTLE 0 ZONE ....%
Press ENTER THROTTLE X ZONE ....%
ADJUSTMENT #02 1-9
ADJUSTMENT #01 1-9
ARE YOU SURE?

YES=ENTER NO=OUT Press OUT
Press ENTER
036-0410-07
page 107
LIFTING ACQUISITION (Lifting connection number 5)
Connect the console to the LIFTING logic unit
AC2P2B D CE 1.06
48V 350A 00000
* CONFIG. MENU *
SET MODEL
Press ENTER
CONNECTED TO 5
Press ROLL
JOYSTICK ON with electric distributor
JOYSTICK OFF with mechanic distributor
Press OUT
ARE YOU SURE?

YES=ENTER NO=OUT
Press ENTER to confirm

page 108

036-0410-07
page 109
MAPS FOR USING

THE CONSOLE
MHIRIO
page 110

036-0410-07
page 111
DESCRIPTION OF THE CONSOLE STANDARD MENU OF THE MHYRIO

UNIT
The console can be connected to the MHYRIO logic unit in two different ways:
1. Directly by means of an interface cable on the logic unit.

2. By connecting the console to another logic unit (pump or traction) and selecting the relevant connection
48V 280A 00000
* CONFIG. MENU *
SET MODEL
Press ENTER

3
Press SET and select the connection number of the Mhyrio logic unit
CONNECTED TO It is the connection number of the mhyrio unit.

9
Press OUT
CONNECTION NUMBERS
ARE YOU SURE?
4 TRACTION SLAVE
Press ENTER to 5 PUMP
confirm 9 MHYRIO
* CONFIG. MENU *
11 DASHBOARD
SET MODEL
MHY CB ZP 0.11 Connected to the MHYRIO logic unit

48V 0A 00000
page 112

MHYRIO UNIT
HEADING
MAIN MENU
MIN EVP EVP OPEN DELAY

MAX EVP EVP CLOSE DELAY
PARAMETER
MIN EVP1 EVP1 OPEN DELAY
CHANGE SET MODEL CONNECTED TO 9
MAX EVP1 EVP1 CLOSE DELAY
MIN EVP5 EVP5 OPEN DELAY SET BATTERY TYPE 12/24/36/48/72/80V
MAX EVP5 EVP5 CLOSE DELAY V VALVES COIL 12/24/36/48/72/80V
MIN EVP6 EVP6 OPEN DELAY VALVES SUPPLAY 12/24/36/48/72/80V
MAX EVP6 EVP6 CLOSE DELAY EVP TYPE Analogic/digital
MIN EVP7 EVP7 OPEN DELAY EVP1 TYPE Analogic/digital
MAX EVP7 EVP7 CLOSE DELAY EVP2 TYPE Analogic/digital
SET OPTIONS
MIN EVP8 EVP8 OPEN DELAY EVP3 TYPE Analogic/digital
MAXEVP8 EVP8 CLOSE DELAY EVP4 TYPE Analogic/digital
EVP5 TYPE Analogic/digital
TESTER BATTERY VOLTAGE V

VALVES SUPPLY V
CAN POT EVP % ADJUSTMENTS ADJUST BATTERY ....V
CAN POT GROUP 1 %
CAN POT GROUP %
CAN POT GROUP %
CAN POT GROUP %
INPUT 0 ON/OFF
INPUT 1 ON/OFF
INPUT 2 ON/OFF
ANALOG INPUT 1 0/256
SAVE
PARAMETER
RESTORE
PARAMETER
CODE
ALARMS
h, N°, C°
PROGRAM
VACC
STEER
NOT AVAILABLE
TABLE
036-0410-07
page 113
MAIN MENU: PARAMETER CHANGE (Mhyrio connection number 9)
MHY CB ZP 0.11
48V 0A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ENTER
MIN EVP Min voltage on the draining solenoid valve

MAX EVP Max voltage on the draining solenoid valve
MIN EVP1 Min. voltage on the lowering solenoid valve
MAX EVP1 Max voltage on the lowering solenoid valve
MIN EVP2 Min. voltage on the lifting solenoid valve
MAX EVP2 Max voltage on the lifting solenoid valve
MIN EVP3 Min voltage on the backward tilt solenoid valve
MAX EVP3 Max voltage on the backward tilt solenoid valve
MIN EVP4 Min voltage on the forward tilt solenoid valve
MAX EVP4 Max voltage on the forward tilt solenoid valve
MIN EVP5 Min voltage on the sideshift right solenoid valve
MAX EVP5 Max voltage on the sideshift right solenoid valve
MIN EVP6 Min voltage on the sideshift left solenoid valve
MAX EVP6 Max voltage on the sideshift left solenoid valve
EVP OPEN DELAY Delay of the EVP in opening
EVP CLOSE DELAY Delay of the EVP in closing
Scroll the parameters using ROLL and save the new values pressing OUT and then ENTER
page 114
MAIN MENU: TESTER (Mhyrio connection number 9)
MHY CB ZP 0.11
48V 0A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ENTER
BATTERY VOLTAGE V
VALVES SUPPLY V
CAN POT EVP %
CAN POT GROUP 1 %
CAN POT GROUP 2 % Scroll the parameters using ROLL.
CAN POT GROUP 3 %
CAN POT GROUP 4 % Press OUT to escape.
INPUT 0 ON/OFF
INPUT 1 ON/OFF
INPUT 2 ON/OFF
ANALOG INPUT 1 0/256
036-0410-07
page 115
MAIN MENU : SAVE PARAMETER (Mhyrio connection number 9)
MHY CB ZP 0.11
48V 0A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ENTER
FREE/MHY CB = Program version stored

FREE MHY CB

MAIN MENU
SAVE PARAM


MAIN MENU
SAVE PARAM
page 116
MAIN MENU : RESTORE PARAMETER (Mhyrio connection number 9)
MHY CB ZP 0.11
48V 0A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ROLL
MAIN MENU
RESTORE PARAM
Press ENTER

MHY CB FREE/MHY CB = Program version stored
Press ROLL to Select the box (0-31) where

you want to save the program
OVERWRITE DATA?
YES=ENTER NO=OUT

MAIN MENU
RESTORE PARAM
036-0410-07
page 117
MAIN MENU : ALARM (Mhyrio connection number 9)
MHY CB ZP 0.11
48V 0A 00000
Press ENTER
MAIN. MENU
PARAM. CHANGE

MENU ALARM
MAIN. MENU
ALARM
Press ENTER
NONE ALARM CODE

00000h #00 0°C 23h 2 25°C

CLEAR LOGBOOK
YES=ENTER NO=OUT

ARE YOU SURE?

YES=ENTER NO=OUT

LOGBOOK CLEARED
(PRESS OUT)
page 118
MAIN MENU : PROGRAM VACC. (Mhyrio connection number 9)
Not available
036-0410-07
page 119
MAPS FOR USING

THE CONSOLE
DASHBOARD
page 120

036-0410-07
page 121

DASHBOARD
The console can be connected to the dashboard unit in the following way:
By connecting the console to another logic unit (traction, lifting or mhyrio) and selecting the relevant connection
48V 280A 00000
* CONFIG. MENU *
SET MODEL
Press ENTER

3
Press SET and select the connection number of the lifting logic unit
CONNECTED TO It is the connection number of the dashboard unit.

11
Press OUT
CONNECTION NUMBERS
ARE YOU SURE?
4 TRACTION SLAVE
Press ENTER 5 PUMP
to confirm 9 MHYRIO
11 DASHBOARD
* CONFIG MENU *
SET MODEL
DASH CE V 1.00
24 0A 00000
Connected to the dashboard unit
page 122
MAIN MENU : PARAMETER CHANGE (Dashboerd connection number 11)

Parameters shown in the adjusting table wich can be modified in a fixed range.
DASH CE V 1.00
24 0A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ENTER
HOURS COUNTER RUNNING/KEY: key on / lifting unit working hours counter switch
DISPLAY ON/OFF: displaied speed switch
SPEED RATIO 0-5 12: speed calculation ratio
Scroll the parameters using ROLL, store the new parameters pressing OUT and then ENTER.
Reset by ignition key whenever a modification is carryed out.
If the parameter HOURS COUNTER is switched in KEY ON option the hourglass will start to blink
whenever the ignition key will be tourned on (=key workhours count).
If the parameter DISPLAY SPEED is switched ON on the display used to point off the alarm codes, will
appear two zeros (=truck speed displayed).
In case of folt the speed indication disappears and the alarm code appears.
036-0410-07
page 123
WIRING DIAGRAMS
page 124
036-0410-07
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page 126
036-0410-07
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page 128
036-0410-07
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page 130
036-0410-07
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page 132
036-0410-07
page 1
CHAPTER 6000
HYDRAULIC / PNEUMATIC SYSTEM

page 2
HYDRAULIC / PNEUMATIC SYSTEM INDEX
CONTROL VALVE SYSTEM (CONTROL VALVE VERSION) page 3
CONTROL VALVE SYSTEM (JOYSTICKS/FINGERTIPS VERSION) page 9
POWER STEERING HYDRAULIC DIAGRAM page 13
OIL AND OIL FILTER page 14
PUMP REPLACEMENT page 15

036-0410-07
page 3
HYDRAULIC DIAGRAM
Control valve version
STEERIG AXLE
ORBITROL
SIDESHIFT
TILTING
LIFTING
page 4
CONTROL VALVE HYDRAULIC SYSTEM

3 AND 4 WHEELS
Control valve
Manometer connection
Priority valve
Drain hose
Hydraulic oil filter
Hydraulic oil tank

Lowering valve
AGIP ARNICA 46
~20 litres
The correct position of the valve is shown

in the picture
control valve tank
0,5 Bar
036-0410-07
page 5
HYDRAULIC CONTROL VALVES

Tilting
Lifting
Sideshift
4th way
Lifting max pressure valve *
Tilting max pressure valve *

Sideshift max pressure valve *
4th way max pressure valve *
*: screw in to increase pressure, screw out to decrease pressure
MANOMETER CONNECTION POINT FOR HYDRAULIC PRESSURE CONTROL

page 6
CONTROL VALVE
Tilting Lifting
4th way Sideshift
4th way max pressure valve

Lifting max pressure valve
Tilting max pressure valve

Sideshift max pressure valve
036-0410-07
page 7
LIFTING PERFORMANCE
Here below the table with the performance of a STD machine.
Q1 = It corresponds to the maximum load of the machine at 3mt. (See capacity plate).
Q2 = It corresponds to the maximum load of the machine at maximum load.
FFL = Full free loft mast
TV = Total visibility mast
m/sec = Lifting speed: min 0.30 m/sec = it means 3.3 sec to cover 1 meter.
max 0.50 m/sec = it means 2 sec to cover 1 meter.
max 0.60 m/sec = it means 1.7 sec to cover 1 meter
Amp = Consuption of Ampere
P = Pressure
LIFTING
*
* = Max pressure to max high
For fingertips / mini joysticks version the maximum pressure valve is set to 240 Bar
page 8
TILTING AND SIDESHIFT PERFORMANCE
Here below the table with the performance of a STD machine.
Q1 = It corresponds to the maximum load of the machine at 3mt. (See capacity plate).
Exercise = It means mast in movement.
End stroke= It corresponds to the maximum stroke in forward or backward
bw = Backward
fw = Forward
TILTING AND SIDESHIFT

036-0410-07
page 9
HYDRAULIC DIAGRAM
STEERIG AXLE
Joysticks / fingertips version
ORBITROL
4th WAY
SIDESHIFT
TILTING
LIFTING
page 10
ELECTRIC CONTROL VALVE HYDRAULIC SYSTEM

3 AND 4 WHEELS
Electric
Control valve
Manometer connection
Priority valve
Drain hose
Hydraulic oil filter
Hydraulic oil tank

Lowering valve
AGIP ARNICA 46
~20 litres
036-0410-07
page 11
HYDRAULIC ELECTRIC CONTROL VALVES

Proportional valve
4th way
Sideshift
Lifting
Tilting
Drain line
Plug
6
5
4
3 9
1. Safety valve for load lowering in case of failure

of the lifting solenoid valve.
2. Maximum pressure valve.
3. Lifting box.
4. Tilt box.
1 5. Sideshift box.
6. 4° Way box.
2 7. Proportional valve (EVP).
8. Drain pipe connection.
9. Main lifting pipe connection.
page 12
Version with fingertips control and joysticks

It consists of:
1. One 48 V lifting ON/OFF solenoid valve
One 24 V proportional solenoid valve for the lowering
2. Two 48 V ON/OFF tilt control solenoid valves
3. Two 48 V ON/OFF sideshift control solenoid valves
4. One 24 Vproportinonal valve for the drain.
The solenoid valve EVP has been integrated in the circuit given that there is only one motor for both functions,
lifting and power steering. It allows the oil in excess to return into the tank, thus reducing the pressure in the
hydraulic control valve circuit.
By means of this valve it is possible to increase or decrease the sensitivity of the lifting by acting on control of
the valve (SEE MHYRIO setting funtion).
DESCRIPTION OF THE CONTROL VALVE BOX
Lifting box uses a solenoid valve EV2 ON/OFF for the lifting, a proportional solenoid valve for
the drain EVP1 and a valve for the maximum pressure.
Tilting box has a governor of oil capacity (12 l/m’). In this way the oil quantity is reduced when using
the double function: lifting-tilt. In this box there is also an OVER CENTER valve to avoid
any forward movement of the mast with load on the forks and the emptying of the tilt
cylinders in case of min. rpm of the motor.
Sideshift box has a governor of oil capacity (12 l/m’). In this way the oil quantity is reduced when using
the double function: lifting-sideshift. For safety reason the logic unit is set to the lower
speed.
4th WAY has two valves already set to 150 Bar. Shims are used in order to increase or decrease the
pressure. Each shim corresponds to 17 bar.
036-0410-07
page 13
POWER STEERING HYDRAULIC DIAGRAM
STEERING CYLINDER
ORBITROL
TO THE CONTROL VALVES
PRIORITY
VALVE
PUMP FILTER
page 14
LIFTING EQUIPMENT OIL AND OIL FILTER
C
A The hydraulic oil tank is located under the
platform.
The filter cartridge (A) is beneath the screw
D cap (C).
To check and change the oil, place and

stop the truck on a flat surface, with the
mast tilted backwards and the forks
lowered.
After the first 50 hours

B - filter change
Every 500 hours

- check the oil level in the tank using
E the dip-stick (D);
Every 2000 hours

- replace the oil and the filter.
- check and clean the tank breather valve
filter (B).
To change the filter:
- remove the tank cap (C) and the filter

- fit a new filter after checking the state of
the seals
- after testing, check that there are no oil
leaks
C
D
HYDRAULIC OIL: AGIP type ARNICA 46

036-0410-07
page 15
To change oil and filter:

D
The tank does not have the drain plug. Place and stop the
truck on a flat surface, with the mast tilted backwards and
the forks lowered. Two different procedures can be
followed to replace the hydraulic oil:
C 1) To drain the tank it is possible to use a pump to such

up the hydraulic oil
B
2) It is also possible to remove the drain hose of the
A control valve from the tank and place it on an
external case. By pressing the brake pedal
(at the minimum RPM of the lifting pump) the oil
flows out. When the tank is nearly empty switch the
D the truck off by the key
Be careful! The pump must not work without oil.
B
A
PUMP REPLACEMENT
Before fitting the new pump to the motor pay attention to the gasket right
positioning.
page 16
clean carefully the motor coupling surface
insert the shaft in the tootded seating

Before insert the motor shaft be sure that in the toothed seating
there is a thin layer of "CASTROL OPTIMOL T. WHITE" (paste
or spray). If not, restore the layer with the product before
mentioned.
D screw in and tight the two bolts
Tightening torque 45 +/- 5 Nm
After the pump replacement it is suggested to fill the suction hose C (see previous page). It is also
possible to use the manometer connection point D (see previous page) to fill the main hose C with oil in order
to avoid that the pump turns without oil during the first working period. Once ending the assembling operation
switchthe truck on and wait for the lifting motor automatic stop.
036-0410-07
page 1
CHAPTER 7000
MAST GROUP
page 2
MAST GROUP INDEX
MAST GROUP page 3
TRIPLE MAST SECTION page 4
LIFTING CYLINDERS ON THE MAST page 5
CENTRAL DISPLACEMENT CYLINDER WITH BRAKING EFFECT page 6
SIDE DISPLACEMENT CYLINDER WITH BRAKING EFFECT page 7
SIDE TELESCOPIC CYLINDER WITH BRAKING EFFECT page 8
TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT page 9
CYLINDER CHECKING METHODS page 10
LUBRICATION OF THE LIFTING EQUIPMENT page 11
GUIDE ROLLERS AND GUIDE SHOES REPLACING page 13
GUIDE SHOES FORK CARRIAGE REPLACING page 14
MAST CHAINS INSPECTION page 15
FORK INSPECTION page 16

036-0410-07
page 3
MAST GROUPS
The mast profile with double stiffening flange is characterised by a high flexural and torsional strength.
It allows wide visibility thanks to the reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside the profiles.
The mast group is a roller type with a variable centre distance (i.e. a fixed roller is fitted on the outer mast and a
mobile one on the inner mast, instead of a number of mobile rollers only on the inner mast). This solution ensures
better grip and stability on operation.
Other features: side plays adjustable from outside. Plastic guide shoes. Roller bearings with grease nipples, ball
joints on axle couplings and tilt cylinders.
Grease nipple Adjusting screw Shoe Roller

page 4
TRIPLE MAST SECTION
Fork carriage
Internal
section bar
Intermediate
section bar
External
section bar
036-0410-07
page 5
LIFTING CYLINDERS ON THE MAST
page 6
CENTRAL DISPLACEMENT CYLINDER WITH BRAKING EFFECT

ON THE LIFTING
The oil flows into the cylinder from the

“Oil inlet” when the control valve is
Rod operated.
Flowing through channels 1, 2 and 3, it fills
Cap chamber A until the inner oil pressure
Bleeder exerts an upward force against the surface
screw C. The outward sliding of the rod is, thus,
set off. This movement is enacted by the
oil flow from chamber A to chamber B
through the above mentioned channels.
At the end of the expanding process
channels 1 and 2 are plugged by the cap.
Therefore, since the oil flowing between
the two chambers passes only through
Chamber A
channel 3, it has a lower capacity. The
outcome is a slowing-down or “Braking
effect”.
The downward sliding of the rod is
allowed by the opening of the “Oil inlet”
circuit, so that the oil can be retrieved
Channels 1-2 into the tank by means of the control
valve.
Unidirectional
At the beginning of this phase chamber
valves D-E
A contains no oil. A more constant
Channels 3
filling is allowed by the two
unidirectional valves D and E that,
when open, permit avoiding jolts.
Once beyond the cap, the oil flow
Chamber B between the two chambers passes
through channels 1 and 2, which are
now open.
Surface C
Oil inlet
>
Unidirectional
valves D-E
Safety valve
036-0410-07
page 7
SIDE DISPLACEMENT CYLINDER WITH BRAKING EFFECT

ON THE LOWERING
Channel A The oil flows into the cylinder from the

(to the central “Oil inlet” when the control valve is
cylinder) Chamber B
bleeder operated.
screw Flowing through chamber B and channel
A it fills first the central cylinders, then
chamber A through hole F and the
unidirectional valve C.
The oil exerts thus an upward force against
Rod the surface D, which sets off the outward
sliding of the rod.
This movement is allowed by the oil flow
from chamber A to chamber B through
hole F and the guide ring.
The downward sliding of the rod is
allowed by the opening of the “Oil inlet”
Chamber A
circuit, so that the oil can be retrieved
blender
into the tank by means of the control
screw
valve.
In this phase the oil flows between the two
chambers only through the hole F, as
valve C is closed.
The downward speed of the rod remains
constant until hole F is closed by profile E.
The remarkable reduction of oil flow has
a slowing-down or “Braking effect”.
Chamber A
Surface D
Hole F
Profile E
Guide ring Chamber B
Safety valve
Unidirectional
valve C
>
Oil inlet
page 8
SIDE TELESCOPIC CYLINDER WITH BRAKING EFFECT

IN THE LOWERING (WITH SPHERE)
The oil flows into the cylinder from the

“Oil inlet” when the control valve is
operated.
Flowing through channels 1 and 2 and
Rod thanks to the upward movement of the
sphere, the oil fills chamber A until the
inner oil pressure exerts an upward force
against surface C, obtaining the outward
sliding of the rod.
The snap ring is used to prevent the sphere
Cylinder from sliding out of channel 2 while the rod
is moving, but freeing, all the same, the
passage of the oil between channel 2 and
chamber A.
The downward sliding of the rod is allowed
by the opening of the “Oil inlet” circuit, so
that the oil can be retrieved into the tank
by means of the control valve.
Sphere The drop of oil pressure in chamber A
causes the sphere to move to the
Hole F bottom of channel 2 and stop on the
snap ring.
In the beginning of this phase the oil
Channel 2
Seals from chamber A flows all the way
through channel 1.
Only toward the end of its down-stroke
Snap ring
Surface C the sphere closes the top of channel 1,
thus directing the oil flow uniquely
Chamber A Channel 1 through hole F.
This produces the hydraulic braking
effect in the lowering.
Oil inlet
<
Cap
Safety valve
036-0410-07
page 9
TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT

DESCRIPTION OF THE CYLINDER COMPONENTS
The cylinder pistons are single-acting types (fig. A).
Dust control ring (6)
In these cylinders a seal (1) has been fitted on the

Anti-friction
piston (2) that works on the inner surface of the
ring (5) Top cap (4) cylinder liner (3).
The rod guide is made by the plug (4) and by the

piston through anti-friction rings (5).
Drain hole (7)
The dust control ring (6) prevents any dirt and water
from penetrating the cylinder.
Slight leakages that may occur are directed to the

tank through the drain pipe connected to the pipe
coupling (7).
The drain pipe shall reach the oil tank (fig. B)
A small quantity of oil will always remain in the loop

formed by the pipe before connecting to the tank. It
acts as a trap and constantly moisturizes the cylinder
Inner cylinderliner, when it is completely closed (fig. B).
surface (3)
Piston (2)
Seal (1)
Chamber
Low cap Fig. B

Safety valve
>
Fig. A Oil inlet

page 10
CYLINDER CHECKING METHODS
1ST CHECK
Remove the drain pipe from the cylinder (fig. C)
Lift the cylinder some times to end stroke, so as to discharge any oil
residual.
Put a load on the forks and lift it by at least 200 mm.
After 10 minutes, measure the amount by which the load has lowered.
A drop of a few millimetres is quite normal, as in the distributor there
are always some leakages.
Now, lift the cylinder to its end stroke, if no oil leaks from the drain
pipe coupling, it means that the load lowering is only due to the leakages
on the distributor.
Fig. C
In the presence of leakages, it will be necessary to replace the seal.

Should this be the case, inspect the cylinder liner.
2nd CHECK
(To be carried out if the 1st inspection has been successful and after
seal replacement).
Remove the drain pipe from the cylinder.
Lift the cylinder some times to end stroke, so that all the possible
remaining oil is discharged.
Put a load on the forks. Lift and lower it for 10 minutes, making sure
that the limit stop is never reached.
Lift the cylinder to end stroke.
If any leakages should be still present, the cylinder is damaged and

then it must be replaced.
036-0410-07
page 11
LUBRICATION OF LIFTING EQUIPMENT
MASTS
D
- adjust the guide shoes through socket head (Allen) screw (D)
E For this purpose use a 0.2-0.5 mm thickness gauge, inserting it
from below upwards to the centre of the Allen screw (D) passing
behind the roller (F) and sliding on the outer mast..
Every 500 hours

- check the mast tilting
- check the mast guide pads
A
- adjust the mast fixing
- adjust the lifting jacks collars and tilting jacks nuts
Every 1000 hours

- check the mast sliding guides, mast and mast jacks fixing
- lubricate the tilting jacks and the mast connections.
- inspect the mast guide rollers (E); they have to rotate freely and
not to be too worn out.
A) Tilting jacks 2+2 grease nipples

A B) Mast connections 1+1 grease nipples
- adjust the guide shoes;
- grease the mast guide rollers (E)
FORK CARRIAGE AND SIDESHIFT UNIT

- adjust the guide shoes through socket head (Allen) screw (G)
B For this purpose use a 0.2-0.5 mm thickness gauge, inserting it
from below upwards to the centre of the Allen screw (G) passing
behind the roller (H) and sliding on the outer mast.
Every 500 hours

- check the fork carriage position
F
G Every 1000 hours
- check and adjust the the sideshift guide shoes
- check and lubricate the fork positioning pins and notches.
- inspect and grease the fork carriage guide rollers (F); they have to
H rotate freely and not to be too worn out.
page 12
P Sideshift unit
upper par 3 grease nipples (P)
lower part without grease nipples excessive wear.
SECURITY INSTALLATIONS CONTROL
C Make sure that:
- the lifting chain stay bolts are free of defects and the adjusting
nuts are locked by the appropriate cotter pins (A);
E - the fork carriage safety end stops (G) are present and tightly
E
fixed.
- the collars (C) are present and tightly fixed.
Every 500 hours

- check that there is a clearance (D); of 0.5 to 3 mm between
D the collar and external lifting jack cylinder.
- check that the self-locking nuts (E) are tight.
Locking torques:
- collar self-locking nuts 0.8-1.2 daNm
SAFETY FORK CARRIAGE END STOP
The lifting unit is equipped with a mechanical safety end stop,

to avoid the accidental escape of the fork carriage from the botton
of the mast.
The end stops (G) consists of two Allen bolts. To remove the
fork carriage, first of all unscrew the end stops.
G
036-0410-07
page 13
GUIDE ROLLERS AND GUIDE SHOES REPLACING
Mast-Fork carriage guide rollers and guide shoes replacing
In order to carry out the job proceed as follows:
1) remove the two forks from the carriage

Picture 1
Picture 1
2) disconnect the two sideshift hoses on the fork carriage
(Picture 1)
3) tie the fork carriage with a belt (Picture 2)
4) remove the safety clip of the chain pin on the carriage (Picture 3)
5) remove the nut stopping the chain pin with a tool as shown in
Picture 2 Picture 4. After that move the two chains to the opposite side in
order to have more space.
6) remove the two Allen screws (Picture 5)
7) remove the complete fork carriage from the bottom
8) remove the guide shoes with two screw drivers (Picture 6) and
screw out the Allen screw G (see page 12) in the opposite
Picture 3 side, in order to let the new guide shoes go inside completely.
9) remove the snap ring A and take out the guide roller (Picture 7)
10) reassemble all parts in reverse order and adjust the guide shoes.
Picture 4
A
Picture 5 Picture 6 Picture 7
page 14
FORK CARRIAGE GUIDE SHOES REPLACING
In order to carry out the job proceed as follows:

C
1) remove one of the two side bars B from the fork carriage
(Picture 8)
2) take out the mobile plate C (Picture 8)

B
Picture 8
3) replace the upper and lower guide shoes D-E (Picture 9)
4) fit the shims F properly in order to have a correct clearence of the

D mobile plate C on the fork carriage
5) reassemble all parts in reverse order and adjust the guide shoes.
E
Picture
Picture 7
9
Picture 10
B C
D
E
A
036-0410-07
page 15
MAST CHAINS INSPECTION
CHECKING THE CHAINS:
Every 1000 hours

- Check the condition of the chains which in any case must not be faulty, worn out or
damaged. To check the links for wear, use the appropriate gauge
- Remove the chains, clean them thoroughly, refit them inverting the original working position and
lubricate them.
Every 10000 hours

- Replace the chains and the fixing tie rods
Replacing the chains use original spare parts which will guarantee that the safety
requirements stated by the regulations in force are complied with.
POSITIONING THE FORK MOUNTING CARRIAGE
Every 500 hours

After testing the chains as described above, with the truck on an even surface and the mast in a vertical
position, check the position of the fork carriage plate, as follows:
- remove the forks, lower the fork carriage completely and measure the height (X), comparing it with
the value shown in the table, corresponding to the capacity in kg of the truck.
(e.g. the correct value of (X) for a truck with a capacity of 2000 kg (class II B), must be
152 ±5 mm).
TABLE ISO 2328 - 1993

Rate Lifting load (kg) "X" (± 5)
I A 0 ÷ 999 76 mm
II A 1000 ÷ 2500 76 mm
III A 2500 ÷ 4999 76 mm
IV A 5000 ÷ 8000 127 mm
V A 8001 ÷ 10999 127 mm
TABLE ISO 2328 - 1993

Rate Lifting load (kg) "X" (± 5)
I B 0 ÷ 999 114 mm
X = 76 mm (A)
II B 1000 ÷ 2500 152 mm
X = 152 mm (B) OPTIONAL III B 2500 ÷ 4999 203 mm
IV B 5000 ÷ 8000 254 mm
V B 8001 ÷ 10999 257 mm
page 16
FORK INSPECTIONS
General criteria
Fork arms in use must be inspected at intervals of not
more than 1000 hours, and whenever a defect or permanent
deformation is detected. If the truck is subject to intensive use,
more frequent inspections may be required.
Inspection
Fork arm inspection must be carried out carefully by trained
personnel to detect any damage, failure, deformation, etc., which
may impair safe use.
Surface cracks
G G
The fork arm must be thoroughly examined visually for cracks
giving special attention to the heel (D) and top (E) and bottom
E E (F) hooks. If necessary, the forks may be subjected to a non-
destructive crack detection process.
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
F F with the forks fitted on the fork plate.
D D Positioning lock
Check that the fork positioning lock (G) is in good working
order.
Legibility of marking
If the fork arm marking is not clearly legible, it must be
renewed by the original fork supplier.
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
90% of the original, the fork arm must be replaced.
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.
Withdrawal of the forks from the service
Any fork with defects revealed during the above controls must
be withdrawn from service.
<= FORWARD - BACKWARD=>
MAST GROUP TILTING SETTING
Every 500 hours

- control the tilting of the masts; the standard values (β) (α)
are the following:
α =2°30’ FORWARD = 43,7mm

β = 6° BACKWARD = 105,1 mm
The tilt angle can easily be checked using a plumb-line dropped from
the front outside edge of the top of the fixed masts and measuring the
distance between the line and the front edge at a metre from the top of
the masts.
N.B. 1 tilting degree corresponds to a 17.4 mm movement on 1 mt.
1° = 17,4 mm
036-0410-07
page 1
CHAPTER 8000
ATTACHEMENT
page 2

036-0410-07
page 1
CHAPTER 9000
OPTIONS
page 2

036-0410-07
SERVICE MANUAL chapter B
page 1
CHAPTER B
MAINTENANCE TABLES
chapter B SERVICE MANUAL 036-0410-07
page 2
MAINTENANCE TABLES INDEX
OIL AND GREASE SPECIFICATION page 3
TYRE TIGHTENING TORQUES page 3
RUNNING-IN MAINTENANCE TIMES TABLE page 4
MAINTENANCE TIMES page 5

036-0410-07
page 3
OIL AND GREASE SPECIFICATIONS
FOR NORMAL ENVIRONMENTS

type specifications q.ty PARTS INVOLVED
AGIP ARNICA 46 ISO-L-HV FZG 20 L Hydraulic system, lifting and power
tests to stage 11 steering
AGIP ATF II D GM DEXRON II 6137-M 0,22 L Transmission reduction gears
GM DEXRON 6032-M
GM DEXRON ATF type A suffix A
AGIP BRAKE FLUID DOT 4 SAE J 1730-JAN 80 --------- Hydraulic brake system
DOT 4 TYPE
MOBILGREASE SPECIAL Lithium base ASTM --------- Mast securing joints - sideshift unit -
275-305 NLGI Nr.2 steering joint - general lubrication
Dropping point 180° with grease nipples - Mast guides
FOR COLD CLIMATES AND
COLD-STORAGE CELLS
type specifications q.ty PARTS INVOLVED
AGIP ARNICA 22 ISO-L-HV FZG 20 L Hydraulic system, lifting and power
tests to stage 10 steering
MOBILTEMP SHC 100 Thickening Infusible ASTM --------- Mast securing joints - sideshift unit -
265-295 NLGI Nr.2 steering joint - general lubrication
Dropping point >260° with grease nipples - Mast guides
STANDARD TYRES
Type Size Air Truck

Pressure
(C)
FRONT 432x152 1,2-1,6L t
REAR 457x178 1,8-2,0 t
REAR 381x127 ALL
(SE)
FRONT 18x7-8 1,2-1,6L t
FRONT 200/50-15 1,8-2,0 t
REAR 16x6-8 ALL
(PN)
FRONT 18x7-8 10 bar ALL
TIGHTENING TORQUES
WHEEL TORQUE
14 daNm steering wheels
14 daNm driving wheels
DRIVE UNIT TORQUE
2,3 daNm electric motor securing
13,5 daNm unit securing to frame
5 daNm service brake delivery pipes screw
5 daNm parking brake cable fixing screw
2,2 daNm oil filling and draining cap
VARIOUS TORQUES
4,9 daNm mast-securing U-bolts
0,8÷1,2 daNm jack collar self-locking nuts
20 daNm counterweight locking screws
page 4
RUNNING-IN MAINTENANCE TIMES TABLE
50 at # hours for MEDIUM/INTENSE USE

7/- at # days/months FOR OCCASIONAL USE
LIFTING UNIT - MASTS
', guide pads - masts and sideshift unit slides
& lifting oil filter
' chain security bolts
DRIVE UNIT
& transmission reduction gears oil - differential oil
CHASSIS AND COMMANDS
, bolts in general
, wheel tightness
LEGEND
In the maintenance table showing a visual control
'
and cleaning of the parts indicated; replacement
/ lubrification / clamping according to necessity.
&
In the maintenance table showing the
replacement of the parts indicated.
"
In the maintenance table showing lubrification
of the parts indicated.
,
In the maintenance table showing tightening
or adjustment of the parts indicated.
The servicing periods are divided into hours, considering an average working day of 8 hours
of effective operation.
If the truck is used on average for less than 8 hours per day, refer to the schedules expressed
in days/months
036-0410-07
page 5
MAINTENANCE TIMES TABLES
8 50 250 500 1000 2000 5000 10000 after # hours FOR MEDIUM/INTENSE USE
1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 after # days/months FOR OCCASIONAL USE
LIFTING EQUIPMENT - MASTS
- - - - ', - - - carriage - sideshift unit
- - - - '" - - - forks positioning pins
- - - ' - - - - mast guide pads
- - - - ' - - - mast, carriage and chain rollers
- - - - - - & - tilting jacks supply pipes
- - - - - & - - lifting oil filter
- - - ' - & - - lifting system oil
- - - - ' - - - mast guides, mast and jack fixing
- - - , - - - - lifting jack retaining collars
- - - ' - - - - fork carriage position
- - - - ' - - - forks
- - - ' - - - - mast inclination
- - - , " - - - mast fixing to the frame
- - - - '" - - & lifting chains
- - - - '" - - & chain stay bolts
- - - - - - - & high pressure hydraulic pipe system
- - - - ' - - - hydraulic seals and connection
- - - , - - - - tilting jacks nuts
DRIVE UNIT(S)
- - - - ' - - - system seal
- - - ' - & - - transmission reduction gear oil - differential gear oil
- - - - , - - - transmission complete unit
page 6
MAINTENANCE TIMES TABLES
8 50 250 500 1000 2000 5000 10000 after # hours FOR MEDIUM/INTENSE USE
1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 after # days/months FOR OCCASIONAL USE
ELECTRICAL SYSTEM
- - - - ' - - - electronic control
- - - ' - - - - contactors, pushbuttons, pedals and control valves
microswitches
- - - ' - - - - safety control circuit
- - - - ' - - - lead terminals - lead insulation
- ' - - - - - - BATTERY - specific gravity and charge level
- - - ' - - - - ELECTRIC MOTORS - external cleaning
- - - ' - - - - electric fans
- - - - ' - - & motor bearings
- - - - ', - - - motor supports
CHASSIS AND CONTROLS
- - - - ' - - & steering and pipe systems seal
- - - - ' - & - hoses from orbitrol to steering jack
- - - - ' - - - steering axle and wheel hub bearing
- - - - ' - - - steering lock pedals in general - linkage
- - - - ' - - - parking brake pedal or lever
- - - - ' - - - service brake pedal
- - - - ' - & - service brake hoses
- - - - ' & - - brake fluid
- - - - - ' - - brake fluid low level warning light
- - - - ' - - - chassis cleaning - bolts in general
- - - ' - - - - driver’s seat
- - - - ' - - - wheel tyres
- ' - - - - - - tyre pressure and completeness - wheels tightness
036-0410-07
SERVICE MANUAL chapter C
page 1
CHAPTER C
SAFETY INFORMATION
chapter C SERVICE MANUAL 036-0410-07
page 2
SAFETY INFORMATION INDEX
WORK CLOTHES page 3
WORK PLACE page 3
LIFTING THE TRUCK page 3
ELECTRIC PART page 4
WELDING page 5
TRUCK WASHING page 5

036-0410-07
page 3
SAFETY INFORMATION
Work clothes
1 protective gloves
2 overalls
3 safety boots
4 protective goggles
Work place
The work place must be lighted and aired.

The area around the truck must be obstacles free
Oil signs or grease substances must not be presents on the pavement (danger of sliding).
Lifting the truck

Before doing any job, it is obligatory to lift the front wheels with blocks
to avoid the risk of accident.
B
1. Block the steered wheels with chocks (A).
2. Tilt the mast back and place blocks (B) under their base.
3. Tilt the mast forwards: the direction wheels must be lifted and
free to rotate
To carry out correctly all the lifting operation of the truck it is necessary to have the following tools:
. a hydraulic jack with up to 5 ton capacity

. metal or hard wood blocks
before putting the blocks under the must, check the inclination of the floor, the truck must be parked on a flat,
horizontal surface.
page 4
ELECTRIC PART
It is obligatory to disconnect the battery before doing any job to avoid the risk of accident.
- Do not connect the chopper to a battery with a nominal voltage different from the voltage stated on the unit plate.
If the battery voltage is higher, it may cause the MOS failure.
If the battery voltage is lower, the unit does not run.
- During the battery recharging no units must be connected to the battery as the unit can be
damaged by the overvoltage generated by the battery charger.
- Supply the unit only with the traction battery, do not use any output rectifiers or power supplies.
- With the key switched off, the filter capacitors could remain charged for some minutes. To ensure safe working
conditions, we advise:
. To wait some seconds with the machine stopped and the key inserted until the display turns
completely off to disconnect the battery.
Or
. To short-circuit the capacitors through a resistor (56 Ohm 1W) between the B+ and B- chopper
power connections.
Do not wear jewellery, necklaces, watches, etc because they can be causes of short circuit.
Charging of the battery
Do not smoke (danger of explosion).

It is necessary to switch the battery charger off before disconnecting the battery.
Also little sparks can cause the battery to explode.
In order to fill in the battery or control the level of the acid it is necessary to wear gloves and glasses.
It is prohibited to smoke.
036-0410-07
page 5
Welding
Wear a leather overall, gloves and a welding mask.
It is obligatory to wear gloves and protective goggles during the grinding operations because they could cause
the projection of metallic particles.
Make sure that these two operations are performable inside the working area where you are.
When these operations are carried out on a truck, in order to avoid the danger of explosion, cover and protect
the battery and the parts in contact with fuel carefully.
Make sure that around the working area there are not any inflammable products.
Disconnect the battery and short-circuit the logic units through a resistor (56 Ohm 1W) between the positive
(+) and the negative (-) before carrying out any arc-weldings on the truck.
Truck washing
During this operation be careful when using water on electric components.

page 6


Cargo Range
CESAB S.p.A
via Persicetana Vecchia, 10 40132 Bologna - Italy
Tel. (0039) 051.20 54 11
Fax (0039) 051.72 80 07
E-mail: [email protected]

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What are the main components of the truck described in the manual?

What are the main components of the truck described in the manual?

What safety precautions should be taken when working on the truck?

What safety precautions should be taken when working on the truck?

SERVICE MANUAL

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PAGE INTENTIONNELLEMENT BLANCHE

ABSICHTLICH FREIGELASSENE SEITE

PÁGINA INTENCIONALMENTE BLANCA

CESAB S.p.a. reserves all rights of

The text and the numbering system

CESAB reserves the right to make any

BOLOGNA’S FACTORY, AFTER SALES SERVICE

GENERAL INFORMATION chapter A

CHASSIS chapter 0000

MOTORS / ENGINES chapter 1000

TRANSMISSION / DRIVE GEAR chapter 2000

BRAKE / WHEEL chapter 3000

STEERING SYSTEM chapter 4000

ELECTRICAL SYSTEM chapter 5000

HYDRAULIC / PNEUMATIC SYSTEM chapter 6000

MAST GROUP chapter 7000

ATTACHEMENT chapter 8000

OPTIONS chapter 9000

MAINTENANCE TABLES chapter B

SAFETY INFORMATION chapter C

GENERAL INFORMATION INDEX

TECHNICAL DATA page3

PAGINA INTENZIONALMENTE BIANCA

INTENTIONALLY LEFT BLANK

PAGE INTENTIONNELLEMENT BLANCHE

ABSICHTLICH FREIGELASSENE SEITE

PÁGINA INTENCIONALMENTE BLANCA

TRUCK’S LAY OUT page 3

DRIVE DIRECTION LEVER ON STEERING COLUMN page 4

STEERING COLUMN PUSH BUTTONS page 5

LOAD HANDLING COMMANDS page 6

DASHBOARD CONTROLS page 8

LIFTING OF THE TRUCK page 10

TRUCK’S LAY OUT

FOOT PEDALS VERSION

FOOT DRIVE DIRECTION

DRIVE DIRECTION LEVER ON STEERING

1 Direction selector lever (F)

Emergency push button (H)

Single drive pedal (G)

Horn push button (O)

Selected setting push button (M):

M) Selected setting push button:

P: - Maximum drive speed.

H: - High drive speed.

L: - Low drive speed.

N) Speed reduction push putton:

LOAD HANDLING COMMANDS

Battery plug fixing position

- Battery Plug (3)

1) Battery charge status indicator.

4 2) Parking brake ON warning light

3) Brake fluid low level warning light:

4) Lifting speed reduction due to flat battery