Electrical System

SERVICE ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
WIRING DIAGRAMS...............................................................................................................................................4
MODELS WITH MECHANICAL STEERING..........................................................................................................4
MODELS WITH MECHANICAL STEERING AND INITIAL LIFT OPTION............................................................ 1.2
MODELS WITH ELECTRIC STEERING................................................................................................................. 20
MODELS WITH ELECTRIC STEERING AND INITIAL LIFT OPTION................................................................. 28
ELECTRICAL COMPONENTS............................................................................................................................... 37
TILLER BOARD........................................................................................................................................................ 40
CONTROLS.............................................................................................................................................................. 42
KEY TO TILLER CONTROLS AND MAIN PANEL.................................................................................................. 42
MDI DISPLAY .......................................................................................................................................................... 44
BATTERY CHARGE LEVEL INDICATOR............................................................................................................... 45
MAINTENANCE AND WARNINGS INDICATOR.................................................................................................... 45
TRUCK FUNCTIONS............................................................................................................................................... 46
FORWARD/REVERSE TRACTION......................................................................................................................... 46
ACTUATION CONTROLS........................................................................................................................................ 46
CONFIGURATION PARAMETERS......................................................................................................................... 47
SPEED REDUCTION............................................................................................................................................... 48
SPEED REDUCTIONS AND TRACTION BLOCK WITH “CHECK UP NEEDED” ALARM........................................ 48
BRAKING.................................................................................................................................................................. 49
EMERGENCY REVERSE MANOEUVRE............................................................................................................... 50
SNAIL FUNCTION.................................................................................................................................................... 50
MECHANICAL STEERING...................................................................................................................................... 51
ELECTRIC STEERING............................................................................................................................................ 52
CONFIGURATION PARAMETERS......................................................................................................................... 52
FORK LIFTING/LOWERING................................................................................................................................... 53
ACTUATION CONTROLS................................................................................................................................................53
CONFIGURATION PARAMETERS........................................................................................................................... 54
ACCELERATION / DECELERATION RAMPS........................................................................................................ 55
CLAMP AND LIFTING POSITION READING......................................................................................................... 56
PROCEDURE FOR ACCESS TO CONFIGURATION PARAMETERS................................................................ 57
CONFIGURATION OF STANDARD MODULE PARAMETERS........................................................................... 57
DESCRIPTION OF MODULE PARAMETERS ......................................................................................................... 59
“COMBI” MODULE.................................................................................................................................................... 59
“EPS” MODULE........................................................................................................................................................ 64
INTRODUCTION MODULES................................................................................................................................... 66
POSITIONING OF THE "PC TOOL" CONNECTORS............................................................................................ 66
“COMBI ACX” MODULE............................................................................................................................................. 67
“COMBI AC0” MODULE........................................................................................................................................... 68
“EPS-BLI” MODULE................................................................................................................................................. 69
REPLACEMENT OF THE COMBI MODULES...................................................................................................... 70
1
ELECTRICAL SYSTEM SERVICE
CDF FILE LOADING PROCEDURE.......................................................................................................................7 2

ELECTRICAL COMPONENT DISMANTLING.......................................................................................................7 4
REPLACEMENT OF THE GENERAL EMERGENCY SWITCH............................................................................7 4
REPLACEMENT OF THE DISPLAY........................................................................................................................7 5
REPLACEMENT OF THE KEY SWITCH................................................................................................................7 6
REPLACEMENT OF THE KEY-PAD (OPTIONAL).................................................................................................7 7
REPLACEMENT OF THE WARNING BUZZER.....................................................................................................7 8
FUSE REPLACEMENT............................................................................................................................................7 9
REPLACEMENT OF THE POWER FUSE..............................................................................................................8 0
REPLACEMENT OF HORN RELAY........................................................................................................................8 1
REPLACEMENT OF THE GENERAL REMOTE SWITCH....................................................................................8 2
REPLACEMENT OF THE BATTERY CHARGER (OPTIONAL) ...........................................................................8 3
CHARGE CURVE CHARGING PROCEDURE.......................................................................................................8 4
REPLACEMENT OF REVERSING BUZZER (OPTIONAL)...................................................................................8 6
REPLACEMENT OF TILLER SENSOR..................................................................................................................8 7
REPLACEMENT OF TILLER BOARD.....................................................................................................................8 9
REPLACEMENT OF TILLER BUTTONS................................................................................................................9 0
REPLACEMENT OF TILLER CONTROL SPRINGS..............................................................................................9 1
REPLACEMENT OF SENSOR ASSEMBLY FOR INITIAL LIFT MODELS ONLY..............................................9 3
FORK UPPER AND LOWER SENSOR OVER 1800 MM......................................................................................95
REPLACEMENT OF THE CENTRED WHEEL SENSOR.....................................................................................96
ONLY VERSIONS WITH ELECTRIC STEERING..................................................................................................96
2
3
WIRING DIAGRAMS
MODELS WITH MECHANICAL STEERING WITHOUT INITIAL LIFT
COMPONENTS
Ref Description
A1 Traction control
A2 Tiller board
A3 MDI display
A6 Battery charger internal circuit
A7 Optional keypad
B1 Encoder
B2 Traction motor heat sensor
B4 Heat sensor
C Capacitors
C1 Battery 24V
F1 Power fuse
F2 Fuse 3A
F3 Fuse 5A
F4 Fuse 3A
K1 Main remote control coil
K3 Horn relay
M Complete traction motor
M1 Traction motor
M2 Pump motor
P1 Horn
P2 Optional buzzer
P3 Battery charger led
Q_D Fork lowering proportional solenoid valve
Q_E Fork lifting solenoid valve
R1 Horn Varistore
R3 Electromagnetic brake
R22 Tiller sensor heating element
S1 Emergency button
S2 Key switch
S5 Lifting proportional button
S6 Lowering proportional button
S7 Lifting on-off button
S8 Lowering on-off button
S9 Horn button
S10 Belly switch
S11 Snail button
S12 Tiller sensor
T1 Optional battery charger
4
BATTERY CHARGER ON THE MACHINE WIRING DIAGRAM

BUZZER (OPTIONAL)
KEYPAD WIRING DIAGRAM (OPTIONAL) REVERSING BUZZER WIRING DIAGRAM (OPTIONAL)

11
MODELS WITH MECHANICAL STEERING AND INITIAL LIFT OPTION

COMPONENTS
S2 Key switch
Ref Description S5 Lifting proportional button
A1 Traction control
A2 Tiller board
A3 MDI display
S9 Horn button
S10 Belly switch
A7 Optional keypad
S11 Snail button
B1 Encoder
S12 Tiller sensor
B4 Heat sensor
B11 Forks above 1800 mm upper sensor (Initial
Lift only)
B12 Forks above 1800 mm lower sensor (Initial
Lift only)
B15 Clamps down REED sensor
(Initial Lift only)
B16 Clamp lifting limit stop sensor(
Initial Lift only)
C Capacitors
C1 Battery 24 V
F1 Power fuse 200-250A
F2 Fuse 3A
F3 Fuse 5A
F4 Fuse 3A
K3 Horn relay
M1 Traction motor
M2 Pump motor
P1 Horn
P2 Optional buzzer
P3 Battery charger led
Q_D Lowering solenoid valve
Q_E Lifting solenoid valve
Q_B Fork on/off lifting/lowering solenoid valve
Q_C Fork on/off lifting/lowering solenoid valve IL
R1 Horn Varistore
S1 Emergency button
12
WIRING DIAGRAM FORK SENSORS DIAGRAM

2STG FFL HI >=2150 & 3STG FFL HI >=2250 A H.600MM (OPTIONAL)
(OPTIONAL) (2STG FFL HI >=2050 & 3STG FFL HI >=2150 & 2STG NFL)

BUZZER (OPTIONAL)

MODELS WITH ELECTRIC STEERING

COMPONENTS
S2 Key switch
Ref Description S5 Lifting proportional button
A1 Traction control
A2 Tiller board
A3 MDI display
S9 Horn button
A4 Steering control
S10 Belly switch
S11 Snail button
A7 Optional keypad
S12 Tiller sensor
B1 Encoder
B4 Encoder
B5 Encoder
B6 Steer motor heat sensor
B7 Steering angular position sensor
B8 Centred wheel sensor
C1 Battery
C2 Drive control capacitors
C3 Steering control capacitors
F1 Power fuse 250A
F2 Fuse 3A
F3 Fuse 5A
F4 Fuse 3A
F5 Fuse 30A
K3 Horn relay
M1 Traction motor
M2 Pump motor
M3 Steering motor
P1 Horn
P2 Optional buzzer
P3 Battery charger charge phase indicator LED
R1 Horn Varistore
S1 Emergency button
20

BUZZER (OPTIONAL)

MODELS WITH ELECTRIC STEERING AND INITIAL LIFT OPTION

COMPONENTS
Ref Description R22 Tiller sensor heating element
S1 Emergency button
A1 Traction control
S2 Key switch
A2 Tiller board
S5 Lifting proportional button
A3 MDI display
A4 Steering control
A7 Optional keypad
S9 Horn button
B1 Encoder
S10 Belly switch
S11 Snail button
B4 Sine-cosine 1/Sin-cos1
S12 Tiller sensor
B5 Encoder
B6 Encoder
B7 Steering angular position sensor
B8 Centred wheel sensor
B11 Fork upper sensor over 1800 mm
B12 Fork lower sensor over 1800 mm
B15 Clamps lowered REED sensor
B16 Clamp lifting limit stop sensor
C1 Battery
C2 Drive control capacitors
C3 Steering control capacitors
F1 Power fuse 250A
F2 Fuse 3A
F3 Fuse 5A
F4 Fuse 3A
F5 Fuse 30A
K3 Horn relay
M1 Traction motor
M2 Pump motor
M3 Steering motor
P1 Horn
P2 Optional buzzer
P3 Battery charger charge phase indicator LED
Q_B Fork on/off lifting/lowering solenoid valve
Q_C Fork on/off lifting/lowering solenoid valve IL
R1 Horn Varistore
28

BUZZER (OPTIONAL)

ELECTRICAL COMPONENTS
IDENTIFICATION OF ELECTRICAL COMPONENTS
Wiring diagram
Ref. Description
ref.
1 Traction motor M1
2 Pump motor M2
3 Electromagnetic brake R3
4 Tiller control sensor S12
5 Battery C1
6 Tiller board A2
7 Horn P1
8 PC connector X30
9 Horn relay K3
10 Fuse 3 A F2
11 Fuse 3A F4
12 Fuse 5 A F3
13 Power fuse 200-250 A F1
14 Main contactor K1
15 COMBI AC0/COMBI ACX MODULE A1
16 Battery charger (optional) T1
17 Key pad (optional) A7
18 Battery charge level indicator P3
19 Emergency button S1
20 Wrench S2
21 Buzzer (optional) P2
22 Battery connector
23 Forks above 1800 mm upper sensor (Initial Lift only) B11
24 Forks above 1800 mm lower sensor (Initial Lift only) B12
25 Clamp lifting limit stop sensor (Initial Lift only) B15
26 Clamps down REED sensor (Initial Lift only) B16
37
20 23
24
25
17
18
26
19
13
8 5
10 22
11
12
14
16 2
1
21
4
15
9
7
3
KEY TO ELECTRIC COMPONENTSELECTRIC STEERING VERSION ONLY
Wiring
Ref. Description
diagram ref.
1 Electric steering motor A4
2 Centred wheel sensor B8
2
TILLER BOARD
Ref. Description
1 Rapid reverse microswitch

2 Enabling microswitch for slow travel with tiller vertical
3 Tiller control cable connection connector
4 Tiller sensor connection connector
5 Connector not used
6 Lifting proportional button connector
7 Lowering proportional button connector
Lifting ON/OFF button connector
8
Clamps lifting ON/OFF button wiring connector (Initial Lift only)
Lowering ON/OFF button connector
9
Clamps lowering ON/OFF button wiring connector (Initial Lift only)
14 Horn microswitch
40
14
13
12
11
10
4
5
41
CONTROLS
KEY TO TILLER CONTROLS AND MAIN PANEL
4 5 6 7
3
1
42
10
11
Ref. Description Wiring diagram ref.
1 Rapid reverse button S10

2 Horn button S9
3 Forward/reverse traction control throttle
Slow fork lowering button
4 S8
Clamps lowering button (initial lift only)
Slow fork lifting button
5 S7
Clamps lifting button (initial lift only)
6 Proportional* fork lifting button S5
7 Proportional* fork lowering button S6
8 Slow travel enabling button with tiller in rest position S11
9 Emergency button S1
10 Key switch S2
11 Key-Pad A7
43
MDI DISPLAY
2 3 4
Ref. Description
1 Total worked hours and alarms indicator

2 Green LED - hour meter ON
3 Yellow LED - battery low
4 Red LED - alarm and maintenance warning
When starting the truck (key-on) the MDI performs a number of tests, and each element will illuminate
for one second. On completion of the tests, the display will show the total truck operating hours for a few
seconds, followed by the battery charge status. The green operating LED will illuminate.
44
When the tiller is lowered or a traction command is given, the total number of traction hours are displayed
for a few seconds.
When a lifting or lowering command is given, the total operating hours of the truck pump appear on the
display for a few seconds.
BATTERY CHARGE STATUS INDICATOR

The battery charge status is indicated on the display.
When the battery charge state reaches 20% the fork lifting is inhibited.
The "battery low" indicator LED illuminates.
To reset the low battery charge indicator, recharge the battery. When
the charge level reaches 75%% the "battery low" indicator it resets
and fork lifting is enabled.
ALARMS AND MAINTENANCE INDICATOR

The MDI provides an indication of the truck alarm status. When an
alarm signal is generated, the red LED will start flashing.
The error code that has generated the warning appears on the display
(XXXAYY or XXXBYY), comprised of a number that identifies the
alarm (XXX) and one (YY) that identifies the node (YY) where O2
is the Traction node and 06 is the Eps node. The letter indicates the
concerned microcontroller, MASTER (A) or SLAVE (B).
On reaching the number of hours of operation after which maintenance
is required, the red LED lights up. After carrying out the necessary
maintenance, reset the parameters MAIN MENU PROGRAM / display
functions / maintenance timers / reset total maintenance - reset traction
maintenance - reset pump maintenance (see “DESCRIPTION OF
MODULE PARAMETERS”).
for example: the error code 79A02 corresponds to the

INCORRECT START alarm, on the Master microcontroller
of the Traction node.
45
TRUCK FUNCTIONS
FORWARD/BACKWARD TRACTION
ACTUATION CONTROLS
Forward travel (operator side) Reverse travel (fork side)
Wiring diagram
Actuators involved Status
ref.
Key switch ON S2
Emergency switch ON S1
Tiller tilt sensor ON* S12
Forward/reverse traction control throttle forward/reverse rotation
* OFF when the button (S11) "snail" is pressed
46
CONFIGURATION PARAMETERS
parameter change menu adjustment menu
Acceler delay Adjust key volt

Release braking Adjust battery
Inverse braking Throttle X0 zone
Decel. braking Throttle X1 map
Speed limit brk Throttle Y1 map
Max speed forw Throttle X2 map
Max speed back Throttle Y2 point
Ctb. spd 600 Throttle X3 point
Ctb. spd diag. Throttle Y3 point
Frequency creep Check up time
Acc. smooth Check up done
Stop smooth Check up hours
Brk smooth
Stop brk smooth
Auxiliary time
Emb ins delay
For the standard values of each individual parameter, see the paragraph "STANDARD CON-
FIGURATION OF MODULE PARAMETERS". For a description of each individual parameter
see "DESCRIPTION OF MODULE PARAMETERS".
The acceleration ramp can be set with the programmer.

Acceleration ramp setting
COMBI / main menu parameter change / acceler. Delay
47
SPEED REDUCTION
There are several levels of speed reduction available on the machine:
• ctb. spd 600 speed reduction for forks lifted over 600mm , available only in
SPED version.
• ctb. spd diag. drive speed reduction during an hydraulic function
Setting the speed reduction

COMBI / main menu parameter change / ctb. spd 600
COMBI / main menu parameter change / ctb. spd diag
Furthermore, only for INITIAL LIFT versions, when the forks exceed 1800 mm, a speed reduction to 2.5
km/h occurs.
SPEED REDUCTIONS AND TRACTION BLOCK WITH “CHECK UP NEEDED” WARNING

When the programmed maintenance control is enabled, if it is not performed, depending on the parameter
values it is possible that the truck may first be subject to a reduction in speed and then to a traction block.
Various truck operating parameters can be set via the programmer.
Setting the action that follows a maintenance warning

COMBI / config menu adjustment / check up typeu
NONE: no alarm
OPTION #1: the alarm appears when reaching the hours set by the parameter
COMBI/config menu adjustment/check up hours
OPTION #2: the alarm appears when reaching the hours set by the parameter
The drive speed is reduced when reaching check up hours + 40 hours
OPTION#3: the alarm appears when reaching the hours set by the parameter
The drive speed is reduced when reaching check up hours + 40 hours. The truck blocks when reach-
ing check up hours + 80 hours
Once the programmed maintenance is performed, to reset the "check up needed" warming, it is necessary to
set the parameter:
Reset the hourmeter of the maintenance hours

COMBI AC1 TRACTION/ menu adjustment / check up doneuON
48
BRAKING
The truck is equipped with four braking systems:
• Release braking.
• Braking on direction reversal.
• Emergency braking.
• Parking brake.
Truck braking will be performed in different ways according to which one of the above systems is implemented.
For further information on the braking systems see "BRAKING SYSTEMS" “BRAKING SYSTEM” section.
BRAKING SYSTEM WHEN DOES IT COME INTO OPERATION?
Release braking Release of the butterfly drive control

Braking on direction reversal Inversion of the direction of travel using the drive control
Emergency brake button operation.
Emergency braking AN alarm has been generated that requires traction to be hal-
ted immediately
The tiller is released in the rest position. Drive motor electrical
Parking brake braking with subsequent engagement of the electromagnetic
brake
Through the programmer one can set the deceleration slope of the release braking, of the partial release
braking and of the reverse braking.
Setting of release braking deceleration ramp

COMBI / main menu parameter change / release braking
Setting of partial release braking deceleration ramp
COMBI / main menu parameter change / decel. braking
Setting of inverse braking deceleration ramp
COMBI / main menu parameter change / inverse braking
SPEED REDUCTIONS AND BRAKING

When the truck speed is reduced this causes a gradual deceleration of the truck through a braking pro-
cess that can be set by the programmer.
Setting of deceleration ramp speed reduction intervention
COMBI / main menu parameter change / speed limit braking
49
EMERGENCY REVERSE MANOEUVRE

The emergency reverse manoeuvre is a safety function that is applied in
the event that the operator, when driving forwards (direction of the traction
wheel), hits an object. In this event, pressing the “BELLY SWITCH” S10
button causes the truck to immediately reverse, thereby preventing the
operator from being crushed.
The emergency reverse procedure is activated with the truck in forward
gear, the tiller in driving position (tiller sensor S12 active) and the "BELLY
SWITCH" button pressed. emergency reverse
function activation button
After reversing, if the belly is held down, the truck continues the travel
for a maximum of 5 seconds at low speed.
SNAIL FUNCTION snail function activation potentiometric throttle

button
The "snail" function enables the traction even when the tiller is in the rest
position (tiller sensor S12 is not active). This allows the operator to drive
the truck even when there is not enough room to lower the tiller. The
"snail" function is activated by pressing the button on the tiller head (S11).
Once the "snail" button is pressed, the traction request is performed by
the potentiometric throttle
50
MECHANICAL STEERING
ACTUATION CONTROLS
To steer to the right or to the left rotate the tiller to the right or left.
Wiring diagram
Actuators involved status
ref.
Key switch ON S2
Tiller sensor ON S12
Tiller rotation right/left rotation
51
ELECTRIC STEERING
ACTUATION CONTROLS
To steer to the right or to the left rotate the tiller to the right or left.
Wiring diagram
ref.
Key switch ON S2
Tiller sensor ON S12
Tiller rotation right/left rotation
adjustment menu
Zero SP POT 1
Zero SP POT 2
Set Steer 0-POS
The steering 0 position can be adjusted via the programmer:

Steering 0 position adjustment
EPS / main menu adjustment / Set Steer 0-POS
52
FORK LIFTING/LOWERING
ACTUATION CONTROLS
D C
A B
STANDARD VERSION
To lift the forks quickly press the potentiometric button“A”.
To lower the forks quickly press the potentiometric button “B”.
To lift the forks slowly press the on/off button “C”.
To lower the forks slowly press the on/off button “D”
VERSION WITH INITIAL LIFT

To lift the forks quickly press the potentiometric button“A”.
To lower the forks quickly press the potentiometric button “B”.
To lift the clamps, press the on/off button “C”.
To lower the clamps, press the on/off button “D”.
Wiring diagram
ref.
Key switch ON S2
proportional button
Quick fork lifting/lowering
lifting/lowering S5 - S6
Clamp lifting/lowering
active
Slow fork lifting/lowering ON-OFF button lifting/
S7 - S8
clamp lifting/lowering lowering active
Tiller sensor ON* S12
* Only where the forks are being lowered (OFF if the (S11) "snail" button is pressed)
53
parameter change menu adjustment menu
Min evp Adjust key volt.

Max evp Adjust battery
Evp open delay Throt 0 prop
Evp close delay Throt X prop
Lift max time Throt Y prop
The legs max time Throt X1 prop
Pu acceler. del Throttle Y1 prop
Pu deceler. del Hydraulic delay 1
Max speed liftdc Hydraulic delay 2
Speed lift 2 Hydraulic delay 3
Speed lower 2 Hydraulic delay 4
Pu. dc creep speed Hydraulic delay 5
Aux. hydraulic 1 Hydraulic delay 6
Aux hydraulic 2 Hydraulic delay 7
Hydraulic delay 8
Hydraulic delay 9
Hydraulic delay 10
Hydraulic delay 11
For the standard values of each individual parameter, see the paragraph "STANDARD
MODULE PARAMETERS CONFIGURATION".
For a description of each individual parameter see "DESCRIPTION OF MODULE
PARAMETERS".
Via the programmer it is possible to set the maximum lifting/lowering speed.

Setting of the forks maximum proportional lifting speed
COMBI / main menu parameter change / max speed liftdc
Setting of the forks maximum proportional lowering speed
COMBI / main menu parameter change / min evp
COMBI / main menu parameter change / max evp
Setting of on/off maximum lifting/lowering speed
COMBI / main menu parameter change / speed lift 2
COMBI / main menu parameter change / speed lower 2
FOR INITIAL LIFT MODELS ONLY

Setting of clamp maximum lifting/lowering speed
COMBI / main menu parameter change / speed lift 2
COMBI / main menu parameter change / speed lower 2
54
ACCELERATION/DECELERATION RAMPS
By activating the proportional lift button (S5), the forks begin to rise with an acceleration ramp that can
be set via the programmer.
Setting of the forks lifting acceleration ramp
COMBI / main menu parameter change / pu. acceler delay
By releasing the proportional lift button (S5), the forks start to stop with a deceleration ramp that can be
set via the programmer.
Setting of the forks lifting potentiometer release deceleration ramp
COMBI / main menu parameter change / pu deceler delay
By activating the proportional descent button (S6), the forks begin to descend with an acceleration ramp
that depends on the opening ramp of the solenoid valve Q_D.
Setting of the forks lowering acceleration ramp
COMBI / main menu parameter change / evp open delay
By releasing the proportional descent button (S6), the forks begin to stop with a deceleration ramp that
depends on the closing ramp of the solenoid valve Q_D.
Setting of the forks lowering potentiometer release deceleration ramp
COMBI / main menu parameter change / evp close delay
FORK LOWERING AND FORK LIFT AND BUTTON

BUTTON RELEASE RELEASE
button “ “ON”” stop
settable acceleration ramp: “evp settable deceleration ramp:

open delay” “pu.deceler delay”
button release
maximum lowering speed maximum settable lifting speed:

settable:“min evp” “max evp” “max speed liftdc”
button release
settable deceleration ramp: settable acceleration ramp:

“evp close delay” “pu. acceler delay open delay”
stop button “ “ON””
55
CLAMP AND LIFTING POSITION READING

The clamps position is read by two sensors placed on the truck.
A proximity sensor on the upper part is used to read the presence or absence of the metallic cam. On the
bottom, instead, a dual-contact magnetic sensor is used, one normally closed (NC) and one normally open
(NO).
The behaviour of the sensor is shown in the table below.
If it is necessary to replace the sensor also the magnet fixed to the truck must be replaced, in fact every
sensor can operate only with its related magnet.
With forks raised off the ground above the height specified in the table above, the clamp lifting function is
inhibited.
With clamps raised, the fork lifting stops once it reaches the height from the ground indicated in the table
and the clamps are lowered with assisted movement (it is in fact always possible to stop the descent of the
forks releasing the forks lifting button).
After the descent of the clamps, it is possible to resume fork lifting.
56
PROCEDURE FOR ACCESS TO CONFIGURATION PARAMETERS

Thanks to the CAN BUS connection, it is possible to configure the module parameters using the software
PC Service Tool and the third party Control Software CAN PC Console. The software is used by connecting
the Ifak cable to the diagnosis connector (X30 reference on the wiring diagram). The manual console is
connected to the connector on the EPS BLI module.
Before connecting the Ifak cable to the diagnostic connector, turn the keyswitch to “OFF”
Before selecting the module to be configured with the console
The COMBI is equipped with two microcontrollers: each microcontroller is identified by a number (node)
The EPS is equipped with two microcontrollers: each microcontroller is identified by a number (node)
Module Microcontoller Node

COMBI Master 2.0
COMBI Slave 2.1
EPS Master 6.0
EPS Slave 6.1
STANDARD CONFIGURATION OF MODULE PARAMETERS

It is always advisable to keep the factory settings as designed in order to have the best compromise
between performance and component wear. It is however possible to customise the performance to suit
the customer's requirements, the characteristics of the warehouse and the materials to be moved, but no
parameters must be changed if this jeopardises the safety of the truck.
57
“COMBI” MODULE ADJUSTMENT MENU

COMBI / menu parameter change /
COMBI / menu set options / PARAMETER Default
COMBI / menu adjustment /
COMBI / special adjustment ADJUST KEY VOL. 25.87 V
COMBI / Hardware settings ADJUST BATTERY 25.82 V
THROTTLE X0 ZONE 4%
PARAMETER CHANGE MENU
THROTTLE X1 MAP 15%
THROTTLE Y1 MAP 3%
PARAMETER Default
THROTTLE X2 MAP 40%
ACCELER DELAY 2.6 sec THROTTLE Y2 POINT 17%
RELEASE BRAKING 1.1 sec THROTTLE X3 POINT 60%
INVERSE BRAKING 1.5 sec THROTTLE Y3 POINT 40%
DECEL. BRAKING 1 sec THROT 0 PROP 4%
SPEED LIMIT BRK 1.8 sec THROT X PROP 30%
MAX SPEED FORW 6 Km/h THROT Y PROP 40%
MAX SPEED BACK 6 Km/h THROT X1 PROP 50%
CTB. SPD 600 5 Km/h THROT Y1 PROP 69%
CTB. SPD DIAG. 6 Km/h HYDRAULIC DELAY 1 32 millisec
FREQUENCY CREEP 2 Hz HYDRAULIC DELAY 2 0 millisec
MIN EVP 30.20% HYDRAULIC DELAY 3 160 millisec
MAX EVP 72.20% 160 millisec
HYDRAULIC DELAY 4
EVP OPEN DELAY 0.55 sec
HYDRAULIC DELAY 5 160 millisec
EVP CLOSE DELAY 0.4 sec
EMB INS DELAY 0.2 sec HYDRAULIC DELAY 6 160 millisec
LIFT MAX TIME 40 sec HYDRAULIC DELAY 7 160 millisec
THE LEGS MAX TIME 10 sec HYDRAULIC DELAY 8 160 millisec
PU. ACCELER. DEL 1 sec
PU. DECELER. DEL 0.1 sec
MAX SPEED LIFTDC 100%
SPEED LIFT 2 50% HYDRAULIC DELAY 11 160 millisec
SPEED LOWER 2 30% BAT. MIN ADJ. 0%
PU. DC CREEP SPEED 10% BAT. MAX ADJ. -1.1%
AUX HYDRAULIC 1 30% BDI ADJ STARTUP 1%
AUX HYDRAULIC 2 30% BDI RESET 20%
CHECK UP DONE OFF
CHECK UP TYPE NONE
MENU SET OPTIONS CHECK UP HOURS 1000 h
PLATFORM POT. UP 0
PARAMETER Default PLATFORM POT. DW 0
HOUR COUNTER RUNNING
TRANSFER HOURS NONE
HARDWARE SETTINGS MENU
PARAMETER Default
MENU SPECIAL ADJUSTMENT
SET CONFIGURAT LEVEL=0
PARAMETER Default
DEBUG MESSAGE OFF
58
DESCRIPTION OF MODULES PARAMETERS

“COMBI” MODULE
COMBI / main menu parameter change /

COMBI / menu set options /
COMBI / menu adjustment /
COMBI / special adjustment /
COMBI / Hardware settings
PARAMETER CHANGE MENU
PARAMETER min. max.
ACCELER. DELAY 1 sec 5 sec

Traction acceleration ramp
RELEASE BRAKING 1 sec 5 sec

Throttle release braking deceleration ramp.
INVERS. BRAKING 0.1 sec 5 sec

Direction reversal braking deceleration ramp
DECEL. BRAKING 0.1 sec 10 sec

Deceleration slope with throttle released but not completely at 0
SPEED LIMIT BRK. 0.1 sec 5 sec

Deceleration ramp when a speed limit is active.
MAX SPEED FORW 0 Km/h 6 Km/h

Maximum forward traction speed
MAX SPEED BACK 0 Km/h 6 Km/h

Maximum backward traction speed.
CTB. SPD 600 0 Km/h 6 Km/h

Speed reduction for forks lifted over 600mm (option, available only in SPED configuration).
CTB. SPD DIAG. 0 Km/h 6 Km/h

Drive speed reduction during the combined functions (hydraulic function + active traction simultaneously)
FREQUENCY CREEP 0.6 Hz 10Hz

It determines the frequency applied to the motor when the traction control is in the minimum position.
MIN EVP 0% 100%

Minimum current present on the lowering proportional solenoid valve coil Q_D
MAX EVP 0% 100%

Maximum current present on the lowering proportional solenoid valve coil Q_D.
59
PARAMETER min. max.

EVP OPEN DELAY 0 sec 5 sec
Ramp for opening of proportional descent solenoid valve Q_D
EVP CLOSE DELAY 0 sec 5 sec

Lowering proportional solenoid valve closing ramp Q_D
EMB INS DELAY 0 sec 2 sec

It is the time that elapses before the electromagnetic brake is triggered when the tiller and the throttle are released
LIFT MAX TIME 3 sec 100 sec

Defines the maximum time for which continuous fork lifting is possible before the lifting block
THE LEGS MAX TIME 3 sec 100 sec

If "Initial Lift = ON" it is the maximum time of the clamp lift before the electric lifting block
PU. ACCELER. DEL 0.1 sec 5 sec

Fork lifting acceleration ramp
PU. DECELER. DEL 0.1 sec 5 sec

Fork lifting deceleration ramp
MAX SPEED LIFTDC 0% 100%

Sets the forks fast lifting speed as percentage of the maximum speed
SPEED LIFT 2 5% 100%

Sets the forks slow lifting speed as percentage of the maximum speed
SPEED LOWER 2 5% 100%

Sets the forks slow lowering speed as percentage of the maximum speed
PU. DC CREEP SPEED 0% 100%

Pump minimum speed
AUX HYDRAULIC 1 5% 100%

Percentage of the maximum speed of the additional hydraulic functions during forward gear traction (only if the ad-
ditional hydraulic functions are enabled).
AUX HYDRAULIC 2 5% 100%

Percentage of the maximum speed of the additional hydraulic functions during backward gear traction (only if the
additional hydraulic functions are enabled).
60
ADJUSTMENT MENU
PARAMETER min. max.
ADJUST KEY VOLT. 0V 255 V

Exact battery voltage value measured at the inverter (pin 10).
ADJUST BATTERY 0V 255 V

Exact battery voltage value measured on the control
THROTTLE X0 ZONE 0% 100%

Breadth of the throttle dead zone corresponding to the drive speed equal to "Frequency Creep"
THROTTLE X1 MAP 0% 100%

Throttle angle of rotation value corresponding to the drive speed Y1
THROTTLE Y1 MAP 0% 100%

Drive speed for angle of rotation of the throttle X1
THROTTLE X2 MAP 0% 100%

THROTTLE Y2 POINT 0% 100%

THROTTLE X3 POINT 0% 100%

THROTTLE Y3 POINT 0% 100%

THROT 0 PROP 0% 100%

Breadth of the proportional button dead zone
THROT X PROP 0% 100%

Value of the proportional button stroke corresponding to the current Y (THROT Y PROP) applied to the proportional
valve coil
THROT Y PROP 0% 100%

Current set point (0% = 0 A, 100% = 2 A) applied to the proportional valve coil corresponding to the value of the
stroke X (THROT X PROP) of the proportional button
THROT X1 PROP 0% 100%

Value of the proportional button stroke corresponding to the current Y1 (THROT Y1 PROP) applied to the propor-
tional valve coil
THROT Y1 PROP 0% 100%

Current set point (0% = 0 A, 100% = 2 A) applied to the proportional valve coil corresponding to the value of the
stroke X1 (THROT X1 PROP) of the proportional button
61
PARAMETER min. max.
HYDRAULIC DELAY 1 0 millisec 4080 millisec

Pump motor start delay.

Q_E solenoid valve closing delay compared to the pump ramp

On/off solenoid valve closing delay after the complete stop of the pump motor

On/off solenoid valve closing delay after the complete closing of the proportional solenoid valve

On/off solenoid valve closing delay after the complete stop of the pump motor
BAT. MIN ADJ. -12.7% 12.7%

It adjusts the lower value of the battery charge status table
BAT. MAX ADJ. -12.7% 12.7%

It adjusts the upper value of the battery charge status table
BDI ADJ STARTUP 0% 100%

At the start up it alters the battery reading voltage
BDI RESET 0% 100%

Minimum difference value between the BDI to the last power off and power on for which the machine BDI is up-
dated. Under this difference the BDI evaluated before shutdown is maintained.
62
PARAMETER
ON = scheduled maintenance carried out.
CHECK UP DONE OFF = scheduled maintenance not carried
out.
It defines if scheduled maintenance has been carried out
CHECK UP TYPE NONE OPTION #3

Enables/disables the start and scheduled maintenance mode: None alarm disabled; Option#1=alarm after reaching
the value set in the CHECK UP HOURS parameter; Option#2: alarm after reaching the value set in the CHECK UP
HOURS parameter and speed reduction after another 40 hours; Option#3=alarm after reaching the value set in the
CHECK UP HOURS parameter, speed reduction after another 40 hours, truck block after another 80 hours
CHECK UP HOURS 1000 h 2000 h

Value of the hours at which the alarm triggers for maintenance
PLATFORM POT. UP 0V 10 V
Not used
PLATFORM POT. DW 0V 10 V
Not used
SET OPTIONS MENU
PARAMETER min. max.
HOUR COUNTER KEY ON RUNNING

Selects the hourmeter mode: KEY ON= hourmeter active at start up; RUNNING = during a request for traction,
pump activation or valves activation.
TRANSFER HOURS NONE OPTION #2

Enables/disables the transfer of the “total hours”, “traction hours”, “pump hours” of the truck.
NONE: no action, OPTION#1: transfer of hours from COMBI to EPS; OPTION#2: transfer of hours from EPS to
COMBI.
SPECIAL ADJUSTMENT MENU
PARAMETER min. max.
DEBUG MESSAGE ON OFF

Enables/disables the debug messages.

PARAMETER min. max.
SET CONFIGURAT ON OFF

CDF recovery parameter from other CAN nodes.
LEVEL 0: no CDF copy request.
LEVEL 1: The CDF is copied from EPS/Combi to the node in which the CDF is not present.
LEVEL 2: The CDF is copied from the Combi to the EPS.
LEVEL 3: The CDF is copied from the EPS to the Combi.
63
“EPS” MODULE
EPS / menu adjustment /

EPS / set options
EPS / hardware settings
ADJUSTMENT MENU
PARAMETER Default
ZERO SP POT 1 0
ZERO SP POT 2 2.5
SET STEER 0-POS 0
MENU SET OPTIONS
PARAMETER Default
HOUR COUNTER RUNNING
PARAMETER Default
MST DEBUG MSG 0
SLV_DEBUG_MSG 0
64
ADJUSTMENT MENU
PARAMETER min. max.
ZERO SP POT 1 0V 5V
Set point 1 zero acquisition value
ZERO SP POT 2 0V 5V
Set point 2 zero acquisition value
SET STEER 0-POS -44 V 44V

Zero offset acquired from the home switch. Changes the 0 position of the wheel.
SET OPTIONS MENU
PARAMETER min. max.
HOUR COUNTER KEY ON RUNNING

Selects the hourmeter mode: KEY ON= hourmeter active at start up; RUNNING = during an effective steering
movement.
PARAMETER min. max.
MST DEBUG MSG 0 255

Debug messages from the micro master
SLV_DEBUG_MSG 0 255
Debug messages from the micro slave
65
MODULES: INTRODUCTION
“COMBI ACX” module for MS10 - MS12 models
For models MS14 - MS16 - MS20 - and MS10 and MS12 in the EL version, the module “COMBI AC0” is
provided
POSITIONING OF THE "PC TOOL" CONNECTORS
The module is connected and communicates through the CANBUS network, which allows access to truck
diagnostics or programming by using a PC (or laptop) or keyboard.
The connector for the cable kit interface connection ("PC CONSOLE") is connected to the “COMBI" module
and can be accessed from the engine compartment.
The module is equipped with a flash memory, which enables the software to be updated by connecting a
PC to the CANBUS network (Can flash).
PC connector
kit cavo interfaccia PC

cod.580039670
66
COMBI ACX MODULE

The “COMBI ACX INVERTER" is used on MS10 and MS12 models with mechanical steering.
It has been designed to perform all the electrical functions normally present on the truck:
• control for the 1.27 Kw AC motor • control for the 2.2 - 3 kW hydraulic pump
• driver for the proportional solenoid valve • CanBus interface
• interface with the tiller Can Bus • alarms
• performance
Technical specifications:
Inverter for asynchronous three phase AC motors and chopper for DC pump motors
Regenerative braking functions
Digital control via two redundant microcontrollers.
Voltage:................................................................................................................... 24V - 36V - 48V
Maximum inverter current (24V):................................................................................. 165A (RMS) for 2’
Output direct current (24V):........................................................................................... 70A (RMS) continuous.
Inverter operating frequency:...................................................................................................8 kHz
Maximum chopper current (24V):........................................................................ 280A (RMS) for 2’
Chopper operating frequency:.......................................................................16 kHz
External temperature limits................................................................................................ -40°C to 40°C
Maximum inverter temperature (at maximum power):.............................................. 85°C
The COMBI module is connected and communicates through the CANBUS network, which allows
access to truck diagnostics or programming via PC (or laptop).
The connector for the X30 diagnostics can be accessed from the engine compartment.
The module is equipped with a flash memory, which enables the software to be updated by connecting a
PC to the CANBUS network (Can flash).
67
COMBI AC0 MODULE

The “COMBI AC0 INVERTER” module is used on models MS14 - MS16 - MS20 mechanical steering
version, on all models with the initial lift option and all models with the electric steering version.
It has been designed to perform all the electrical functions normally present on the truck:
• control for the 1.27 Kw AC motor • control for the 3Kw hydraulic pump
• driver for the proportional solenoid valve • CanBus interface
• Interface with the tiller Can Bus • alarms
• performance
Inverter for asynchronous three phase AC motors and chopper for DC pump motors
Regenerative braking functions
Digital control via two redundant microcontrollers.
Voltage:..................................................................................................................................... 24V - 36V - 48V
Maximum inverter current (24V):........................................................................................... 200A (RMS) for 2’
Output direct current (24V):...................................................................................... 70A (RMS) for 2’
Inverter operating frequency:.........................................................................................................................8 kHz
Maximum chopper current (24V):....................................................................... 270A (RMS) for 2’
Chopper operating frequency:.........................................................................................................16 kHz
External temperature limits............................................................................................................... -40°C to 40°C
Maximum inverter temperature (at maximum power):.......................................................... 85°C
68
EPS BLI MODULE

The “EPS BLI" module is used on MS10 and MS12 models. - MS14 - MS16 - MS20 version with standard
electric steering and with Initial Lift option.
It is an integrated module for controlling the electric steering, designed to be mounted axially on the
steering motor, developed for performing the following functions:
• controlling the 600 Kw AC motor • CanBus interface

• alarms • performance
Nominal voltage:................................................................................... 24V
Maximum nominal current: ............................................................................... 50 Arms
Maximum time at maximum current:......................................................... 2 min (alarm after 5”)
Minimum battery voltage:...........................................................................12,5 V
Maximum battery voltage: .................................................................................... 35 V
Operating frequency:......................................................................................8 kHz
Maximum inverter temperature: ..................................................................... 90°
External temperature limits.................................................................................. -30°C to 40°C
69
COMBI MODULES REPLACEMENT

Equipment and tools
5 mm T 100Ohm resi-
handle hex stor socket wrench
spanner 25W insulated
Procedure
Before starting work, ensure that you are wearing suitable A
protective clothing. Move the truck to a safe place, away
from areas of transit of other vehicles and all pedestrians.
Turn the keyswitch to OFF and disconnect the battery.
A
Fig. 1
Phase 1
5 mm T-handle hex spanner
Using the T-handle hex spanner remove the 6 screws that secure the
truck front cover (ref.A fig.1). Then remove it.
Phase 2
Then remove the motor and brake cover (fig.2)
Fig. 2
Phase 3
RESISTANCE 100 Ohm 25 W
Connect the resistance between the positive (B+) and negative (B-) of the
module (fig.3). Wait approximately 10 seconds for the internal capacitors
to lose their charge and then disconnect the resistance.
To avoid short circuits, it is important that

the resistance is isolated.
If it is not possible to have an external resistance to

run down the capacitors, it will be necessary to wait at
least 90 seconds before disconnecting the power cables.
Fig. 3
70
Phase 4
10 mm HEX SOCKET WRENCH
Using the hex socket wrench, unscrew and remove the power cables
fastening screws (ref.B fig.4).
Disconnect the connector for the module connection (ref.C fig.4). B
Mark the power cables for reassembling and then disconnect them.
C
Phase 5
10 mm HEX SOCKET WRENCH
Using the hex socket wrench, unscrew and remove the fastening screws
of the
module to the base truck (ref.D fig.5), recover the washers and the cable
fasteners (ref.E fig.5).
Remove the module and proceed with the replacement.
Fig. 4
Only for trucks with mechanical steering, or if replacing

both modules in the configuration with electric steering:
after replacing the Combi module, the CDF file loading
procedure must be carried out E
If replacing only one of the two modules in the electric

steering version, refer to the SET CONFIGURAT parameter D
in the hardware settings menu of the COMBI control.
REPLACEMENT OF THE EPS MODULE Fig.5
In the case of an EPS control fault, as it is integrated with

the steering motor, it will also be necessary to replace the
latter, according to the procedure in section “BASE TRUCK
MECHANICS”
71
CDF FILE LOADING PROCEDURE

Requirements:
• Windows XP 32-64 bit, Windows 7 32-64 bit, not tested for Windows 8 and Windows 10.
Installation:
• Create a folder on your C: drive called C:\cdf_program
• Create a folder on your C: drive called C:\temp_cdf
• Extract the files from the .zip file in the folder C:\cdf_program
• The folder C:\cdf_program should contain two files:
1. ZAPI.EXE
2. cdf_upload_tool.exe
Use:
• Copy the CDF file, previously downloaded from
the AxcessOnline website, in the folder C:\
temp_cdf. Å
• Connect the IFAK cable to the connector of the
truck (X40).
• Run the file C:\cdf_program\cdf_upload_tool.
exe.
• Enter the serial number of the truck into the
window and press "Enter" (Fig.1).
Fig. 1
• The program looks for the CDF file in the folder C:\
temp_cdf (DXXXT01406P_01.txt in this example).
If the file is found correctly, the CHK button is
enabled.
• Press the CHK button to continue (Fig.2).
Å
Fig. 2
72
• The program checks the syntax of the CDF file

and the CAN communication.
Each error is reported and the update execution
is stopped (see error list).
Correct the problem or exit.
• If all checks are successful, the GO button is
enabled (Fig.3)
Å
Fig. 3
• Press the GO button to start loading the CDF file.
Error code Description Corrective action

0 OK No action is required
1 Parameters not correct Contact the Service
Check that the file was saved in the

2 CDF file not found folder C.\temp_cdf. If it is not present
ask for assistance by the Service
The CDF file may be corrupt, report the

3 CheckSum Error
problem to the Service
Check the configuration of the IFAK and
4 Wrong IFAK configuration
tray again
Check the CANbus connection and
5 Wrong CANbus configuration
switch on the truck.
Check the CANbus connection and
6 CAN Master communication setting error
switch on the truck.
7-8-9 CDF file loading error Report the problem to the Service
The CDF file refers to another truck,
100 Serial number not matching
loading is forbidden
Software running on the truck is not valid Check the software version on the truck,
200
for the CDF file contact the Service
211 Parameters not found Contact the Service
73
DISMANTLING THE ELECTRICAL COMPONENTS

REPLACEMENT OF THE GENERAL EMERGENCY SWITCH
Equipment and tools
A
5 mm T
handle hex
spanner
Fig. 1
Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and all pedestrians. Lower the forks to
the ground, turn the keyswitch to OFF and disconnect
the battery.
Phase 1
5 mm T-handle hex spanner
B
Fig. 2
Fig. 3
Phase 2
Disconnect the connectors.
Unscrew the nut on the back of the panel that blocks the main switch
(ref.B fig.2).
Phase 3
Pull out the switch from the top and replace it (fig.3) .
74
REPLACEMENT OF THE DISPLAY

Equipment and tools
5 mm T A
handle hex
spanner
Fig. 1
Procedure
the battery.
Fig. 2 B
Phase 1
5 MM T HANDLE HEX SPANNER
D
C Fig. 3
Phase 2
Disconnect the connector of the electrical connection (ref. B fig.2).
Loosen the nuts securing the retaining bracket (ref.C fig.3). Remove the
bracket (ref.D fig.3).
Remove the display (fig.4) and proceed with replacement.
Fig. 4
75
REPLACEMENT OF THE KEY SWITCH

Equipment and tools
5 mm T
handle hex
spanner
Procedure
the ground, turn the keyswitch to OFF and disconnect A
the battery.
Phase 1 Fig. 1
truck front cover (ref.A fig.1). Then remove it. B
Phase 2
Remove the ignition key (fig.2).
Unscrew the nut (ref. B fig.2), remove the switch block from the dash-
board (ref.C fig.3).
Disconnect the connectors and proceed with replacement.
Fig. 2
INSTALLATION
Before reconnecting them, check that the faston clamps

are properly secure. If not, tighten the connectors with
pliers for faston clamp.
C
Fig. 3
76
REPLACEMENT OF THE KEY-PAD (OPTIONAL)

Equipment and tools
5 mm T
handle hex
spanner
Procedure
the battery.
Fig. 1
Phase 1
C
Fig. 2 B
Phase 2
Disconnect the connector of the electrical connection (ref. B fig.2-3).
Loosen the nuts securing the retaining bracket (ref.C fig.2-3). Remove
the bracket (ref.D fig.3).
Remove the display and proceed with replacement.
Fig. 3 C
77
REPLACEMENT OF THE HORN

Equipment and tools
5 mm T 10 mm open
handle hex ended span-
spanner ner
Procedure
the battery.
Phase 1 Fig. 1
Phase 2
10 MM OPEN ENDED SPANNER
Using the open ended spanner, unscrew the nut securing the horn to the
bracket (ref.B fig.3).
Disconnect the connectors, remove the horn and proceed with the re-
Fig. 2
placement.
Fig. 3
INSTALLATION
Before reconnecting them, check that the faston clamps

are properly secure. If not, tighten the connectors with
pliers for faston clamp.
78
REPLACEMENT OF THE FUSES

Equipment and tools
5 mm T small flat
handle hex head
spanner screwdriver
Procedure
Move the truck to a safe place, away from areas of transit A
the battery.
A
Fig. 1
Phase 1
Fig. 2
F2
Phase 2
F3
F4
SMALL FLAT HEAD SCREWDRIVER

Using the small flat head screwdriver press the flaps (ref. B Fig.3) and
remove the fuse holder cover.
Remove the fuse and proceed with the replacement.
Fig. 3
B
79
REPLACEMENT OF THE POWER FUSE

Equipment and tools
5 mm T 13 mm open
handle hex ended span-
spanner ner A
Procedure
Fig. 1
the battery.
Phase 1
Fig. 2
truck front cover (ref.A fig.1). Then remove it. Fig. 3
Phase 2
Using the open ended spanner, unscrew and remove the power cables
retaining screws (ref.B fig.2). B
Phase 3
Remove the power fuse (ref.C fig.3) and replace it.
Fig. 4
80
REPLACEMENT OF THE HORN RELAY

Equipment and tools
5 mm T
8 mm hex socket
handle hex
wrench
spanner
Procedure
Move the truck to a safe place, away from areas of transit A
the battery.
A
Fig. 1
Phase 1
Fig. 2
B
Phase 2
8 MM HEX SOCKET WRENCH
Disconnect the connector from the horn relay.
Using the socket wrench, unscrew and remove the relay fastening screw.
Proceed with replacement.
Fig. 3
81
REPLACEMENT OF THE GENERAL REMOTE SWITCH

Equipment and tools
4-5 mm T 13 mm open
handle ended span-
hex spanner ner A
Procedure
Fig. 1
the battery.
Phase 1
Fig. 2
truck front cover (ref.A fig.1). Then remove it. Fig. 3
Phase 2
13 MM OPEN ENDED SPANNER B
Using the open ended spanner, unscrew and remove the power cables
retaining screws (ref.B fig.3).
Phase 3
Using the T wrench, unscrew and remove the remote control switch
fastening screws
to the support plate (ref.C fig. 4)
Remove the remote switch and proceed with the replacement.
C
Fig. 4
82
REPLACEMENT OF THE BATTERY CHARGER (OPTIONAL)

Equipment and tools
5 mm T
13 mm hex socket
handle hex
spanner
wrench A
Procedure
A
Move the truck to a safe place, away from areas of transit Fig. 1
the battery.
Fig. 2
Phase 1
Phase 2
13 MM HEX SOCKET WRENCH Fig. 3
Disconnect all the electrical cables (ref.B fig.3).
Using the socket wrench loosen and remove the 2 screws fastening the
battery charger to the truck (ref.C fig.4). Then proceed with replacement.
After replacing the battery charger it is necessary to make

the charger curve loading procedure. C
Fig. 4
83
CHARGE CURVE CHARGING PROCEDURE
Perform this procedure in the case of the battery charger

replacement or in the case of battery charger installation
on a truck which initially was not provided with it. When
the installation is complete, affix the label on the truck
showing the characteristics of the charge curve and the
battery to use, at the point shown in Figure 1.
Requirements:
• Windows XP 32-64 bit, Windows 7 32-64 bit, not tested for Windows
8 and Windows 10.
Fig. 1
Installation:
• Create a folder on your C: drive called C:\charger_program
• Extract the files from the .zip file in the folder C:\charger_program
Use:
• Switch off the truck.
• Connect the IFAK cable to the connector of the
battery charger (X32)
• Connect the battery charger to the mains Å
• Run the file C:\charger_program\upload_tool_
charger.exe
• Enter the number of the charging curve suited to
the battery used on the truck (Fig.2)
CURVE 1 = Lead Acid Battery 150Ah-325Ah
CURVE 2 = Lead Acid Battery 375A
Fig. 2
• If the curve number entered is valid, the CHK

button is enabled. Press the CHK button to
continue (Fig.3).
Å
Fig. 3
84
• The program checks the CAN communication.

If all checks are successful, the GO button is
enabled.
• Press the GO button to start loading the charging
curve (Fig. 4).
Å
Fig. 4
• After the procedure, exit the program, disconnect the battery charger
and unplug the IFAK cable.
Error code Description Corrective action

1 Parameter out of range Contact the Service
2 Parameter in range but not valid Contact the Service
Wrong IFAK configuration or CAN bus

connection error.
3 CAN configuration error
Check the configuration of the IFAK
cable and tray again.
Wrong IFAK configuration or CAN bus
connection error.
4 CAN communication error
Check the configuration of the IFAK
cable and tray again.
5 Eeprom saving failed Contact the Service
85
REPLACEMENT OF REVERSING BUZZER (OPTIONAL)

Equipment and tools
5 mm T
handle hex
spanner
Procedure
the battery.
Fig. 1
Phase 1
Phase 2
Manually unscrew the buzzer ring and remove it from its seat (ref.B fig.3). Fig. 2
B
Fig. 3
86
REPLACEMENT OF THE TILLER SENSOR

Equipment and tools
3-4-5 mm T
handle
hex spanner
Procedure
Before starting work, ensure that you are wearing suit-
able protective clothing.
the battery.
Phase 1
Fig. 1
Phase 2
Then remove the engine and brake cover (fig.2).
Fig. 2
Phase 3 Fig. 3
Disconnect the tiller connector X3 (ref.B fig.3).
Carry out the tiller spring disassembly procedure (see "REPLACEMENT

OF THE TILLER SPRING" described in the MECHANICS section.
87
Phase 4
Using the T-handle hex wrench, unscrew the bolts securing the upper
casing (ref.C-D-E fig.4).
Phase 5
C
Lift the upper casing and detach it from the lower casing (fig.5). Discon-
nect the serial cable connector (ref.Ffig.5) and place the cover on a D E
Fig. 4
clean work bench.
Fig.5
Phase 6
Using the T-handle hex spanner loosen the F
2 screws that secure the sensor to the tiller
F
arm (ref.G fig.6). Then proceed with the
replacement (fig.7).
Fig.6
Fig. 7
88
REPLACEMENT OF TILLER BOARD

Equipment and tools
2.5-5 mm T small flat

handle head
hex spanner screwdriver
A
Procedure
B C
Fig. 1
Before starting work, ensure that you are wearing suit-
able protective clothing.
Move the truck to a safe place, away from areas of transit Fig.2
the battery.
Phase 1
Unscrew the nuts holding the upper frame housing in place (ref. A,B,C
fig.1). E G H
F
Phase 2
Lift the upper casing and detach it from the lower casing (fig.2). Discon-
nect the connector connecting the serial cable (ref. D fig.2) and place
the cover on a clean work bench.
Fig.3
Phase 3
2.5 MM “T” HANDLE HEX SPANNER
Loosen the screw holding one of the two throttle valves (ref. E fig.3) and
retrieve the washer (ref. F fig.3). Remove the throttle from the pin (ref.G
fig.3). Remove the other throttle complete with the guide pin (ref.H fig.3).
Phase 4
SMALL FLAT HEAD SCREWDRIVER K I
Unscrew the tiller board latch fastening screw (ref. I fig.4). Remove the
latch (ref. J fig.4) and the card from its seat (ref. K fig.4), disconnect the
connectors of the various micro commands. J
Proceed with replacement. Fig.4
89
REPLACEMENT OF TILLER BUTTONS

Equipment and tools
A B
Fig. 1 C
4 mm T small flat
handle hex head
spanner screwdriver Fig.2
Procedure
the ground, turn the keyswitch to OFF and disconnect D
the battery.
Fig. 3
Phase 1
4 MM “T” HANDLE HEX SPANNER
fig.1).
Phase 2
Lift the frame of the upper housing and remove it from the lower frame
housing (fig.2). Disconnect the connector connecting the serial cable
(ref. D fig.2) and place the cover on a clean work bench.
Phase 3
Using the screwdriver, prise open the clips (fig.4) and push the button Fig. 4
out of its seat (fig.4-5).
Fig. 5
90
REPLACEMENT OF THE TILLER CONTROL SPRINGS

Equipment and tools
2.5-4 mm T small flat

handle head
hex spanner screwdriver
Procedure
the battery.
A B
Phase 1
Fig. 1 C
4 MM “T” HANDLE HEX SPANNER
fig.1). Fig.2
Phase 2
Lift the frame of the upper housing and remove it from the lower frame
housing (fig.2). Disconnect the connector connecting the serial cable
(ref. D fig.2) and place the cover on a clean work bench. D
Phase 3
2.5 MM “T” HANDLE HEX SPANNER E G H
Loosen the screw holding one of the two throttle valves (ref. E fig.3) and
retrieve the washer (ref. F fig.3). Remove the throttle from the pin (ref.G
fig.3). Remove the other throttle complete with the guide pin (ref.H fig.3). F
Fig.3
91
BUTTERFLY CONTROL SPRING

Fig. 4
Phase 4
SMALL FLAT HEAD SCREWDRIVER J
With the screwdriver, prise out the throttle control guide bush (ref.I
fig.4). In the same way, prise out the throttle control spring (ref.J fig.4)
.
I
BELLY AND HORN BUTTON SPRINGS Fig. 5
Phase 5
With the screwdriver, prise under the belly button at the locking pin (fig.5).
Take out the button (ref.K fig.6) and remove the spring (ref.L fig.6).
In the same way, apply leverage under the horn button in correspondence
with the locking pin (fig.5). Take out the button (ref.M fig.6) and remove
the spring (ref.N fig.6).
Proceed with replacement. Fig. 6
K
L
N
92
REPLACEMENT OF SENSORS ASSEMBLY

FOR INITIAL LIFT VERSION ONLY
Equipment and tools
3-7-10 mm 5 mm T
wooden blocks open ended handle hex
spanner spanner
Procedure
the battery.
Fig. 1
The sensor assembly for the initial lift version consists of 4

sensors, it should be noted that to replace even only one
sensor it is necessary to replace the entire sensor assembly.
CLAMPS LOWERED REED SENSOR
Phase 1 Fig. 2
Using the open ended spanner unscrew the screws securing the sensors
protection plate. (ref.A fig.2). Retrieve the washer and remove the plate, Fig.3
so that the two hidden sensors are accessible:
B
Clamp lifting limit stop sensor (ref.B fig.3)
Lowered clamps REED sensor (ref.C fig.3)
93
Phase 2
Fig.4
NO. 2 WOODEN BLOCKS - 7 MM AND 3 MM OPEN ENDED SPAN-
NER
Lift the clamps and rest them on the blocks, to separate the magnet from
the REED SENSOR in order to disassemble it (ref. 4).
Using the 3 mm open ended spanner, loosen the screws that secure the
magnet (ref.D fig.5), while with the 7 mm one loosen the lock nuts (ref.E
fig.5). Retrieve the washers and the magnet (ref.F fig.5).
Phase 3
Unscrew the upper nut of the sensor (ref.G fig.6), remove the sensor E
from the bottom (ref.H fig.6).
The REED sensor must be changed together with its magnet D

as they are encoded in pairs.
Fig.5
During the assembly stage make sure that the REED sensor
and the encoded magnet are at a distance of 2-3 mm. Fig.6
G
CLAMP LIFTING LIMIT STOP SENSOR

H
Phase 4
24 MM OPEN ENDED SPANNERS
Use an open ended spanner to lock a nut of the sensor (ref.I fig.7) while I L
with the other loosen the other nut (ref.L fig.7), then remove the sensor.
Fig.7
94
FORK UPPER AND LOWER SENSOR OVER 1800 MM
Phase 5
With the T handle spanner unscrew the screw and remove the cover
(ref.M-N fig.9) that protects the 2 sensors:
Fork upper sensor over 1800 mm (ref.O fig.9)

Fig. 8
Fork upper sensor over 1800 mm (ref.P fig.9)
O
P
Phase 6
24 MM OPEN ENDED SPANNERS
Fork LOWER SENSOR OVER 1800 MM
N
Use an open ended spanner to lock a nut of the sensor (ref.Q fig.10) while
with the other loosen the other nut (ref.R fig.10), then remove the sensor.
Fig. 9
M
FORK UPPER SENSOR OVER 1800 M
Repeat the same operations carried out to disassemble the lower sensor.
Fig. 10 P N
95
REPLACEMENT OF CENTRED WHEEL SENSOR

ONLY FOR THE VERSION WITH ELECTRIC STEERING
Equipment and tools
5 mm T
hydraulic jack wooden blocks handle hex
spanner
Procedure
A
the battery. A
Fig. 1
Phase 1
Phase 2
Then remove the engine and brake cover (fig.2). Fig. 2
Fig. 3
Phase 3
HYDRAULIC JACK - WOODEN BLOCK
Position the hydraulic jack beside the tiller and lift until the wooden block
is able to pass. Position the wooden stock, lower the jack and rest the
truck on the block (fig.3).
96
Phase 4
Disconnect the connector (ref.B fig.4). Then loosen the ring nut from
below the truck and remove the sensor from above (ref.C fig.4).
Replace the sensor.

C
Fig. 4
B
C B
97

Electrical System

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Electrical System

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SERVICE ELECTRICAL SYSTEM

CDF FILE LOADING PROCEDURE.......................................................................................................................7 2

BATTERY CHARGER ON THE MACHINE WIRING DIAGRAM

KEYPAD WIRING DIAGRAM (OPTIONAL) REVERSING BUZZER WIRING DIAGRAM (OPTIONAL)

MODELS WITH MECHANICAL STEERING AND INITIAL LIFT OPTION

WIRING DIAGRAM FORK SENSORS DIAGRAM

BATTERY CHARGER ON THE MACHINE WIRING DIAGRAM

KEYPAD WIRING DIAGRAM (OPTIONAL) REVERSING BUZZER WIRING DIAGRAM (OPTIONAL)

MODELS WITH ELECTRIC STEERING

BATTERY CHARGER ON THE MACHINE WIRING DIAGRAM

KEYPAD WIRING DIAGRAM (OPTIONAL) REVERSING BUZZER WIRING DIAGRAM (OPTIONAL)

MODELS WITH ELECTRIC STEERING AND INITIAL LIFT OPTION

BATTERY CHARGER ON THE MACHINE WIRING DIAGRAM

KEYPAD WIRING DIAGRAM (OPTIONAL) REVERSING BUZZER WIRING DIAGRAM (OPTIONAL)

KEY TO ELECTRIC COMPONENTSELECTRIC STEERING VERSION ONLY

1 Rapid reverse microswitch

Ref. Description Wiring diagram ref.

1 Rapid reverse button S10

1 Total worked hours and alarms indicator

BATTERY CHARGE STATUS INDICATOR

ALARMS AND MAINTENANCE INDICATOR

for example: the error code 79A02 corresponds to the

Forward travel (operator side) Reverse travel (fork side)

* OFF when the button (S11) "snail" is pressed

parameter change menu adjustment menu

Acceler delay Adjust key volt

The acceleration ramp can be set with the programmer.

Setting the speed reduction

SPEED REDUCTIONS AND TRACTION BLOCK WITH “CHECK UP NEEDED” WARNING

Setting the action that follows a maintenance warning

Reset the hourmeter of the maintenance hours

BRAKING SYSTEM WHEN DOES IT COME INTO OPERATION?

Release braking Release of the butterfly drive control

Setting of release braking deceleration ramp

SPEED REDUCTIONS AND BRAKING

EMERGENCY REVERSE MANOEUVRE

SNAIL FUNCTION snail function activation potentiometric throttle

The steering 0 position can be adjusted via the programmer:

VERSION WITH INITIAL LIFT

parameter change menu adjustment menu

Min evp Adjust key volt.

Via the programmer it is possible to set the maximum lifting/lowering speed.

FOR INITIAL LIFT MODELS ONLY

FORK LOWERING AND FORK LIFT AND BUTTON

button “ “ON”” stop

settable acceleration ramp: “evp settable deceleration ramp:

maximum lowering speed maximum settable lifting speed:

settable deceleration ramp: settable acceleration ramp:

stop button “ “ON””

CLAMP AND LIFTING POSITION READING

PROCEDURE FOR ACCESS TO CONFIGURATION PARAMETERS

Before selecting the module to be configured with the console

Module Microcontoller Node

STANDARD CONFIGURATION OF MODULE PARAMETERS

“COMBI” MODULE ADJUSTMENT MENU

DESCRIPTION OF MODULES PARAMETERS

COMBI / main menu parameter change /

PARAMETER CHANGE MENU

PARAMETER min. max.

ACCELER. DELAY 1 sec 5 sec

RELEASE BRAKING 1 sec 5 sec

INVERS. BRAKING 0.1 sec 5 sec