SB4177E02

Specifications
Systems Operation
Testing & Adjusting
MicroController Control Systems
B15T-5, B18T-5, B20T-5 (AC 36V/48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
for Electric Lift Truck
 Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING” as
shown below.

The meaning of this safety alert symbol is as follows:

Attention ! Become Alert ! Your Safety is Involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DOOSAN dealers have the most current information
available.

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Index
Specifications Instrument Panel

Assembly Layout of Controller (4 Wheel) ..................9 Accessing Stored Error Codes ...............................118
Assembly Layout of Motors........................................9 Default Setting........................................................114
Component Measurements........................................5 Diagnostic Mode.....................................................115
Control Panel Layout................................................10 Display Keys Utilization ..........................................107
Controller AS Specification.........................................6 Instrument Panel ....................................................105
Drive Motor Specification ...........................................7 LED Indicators........................................................107
Fuses .........................................................................9 Lift truck operation mode........................................106
Instrument Panel Layout ............................................8 List of diagnostic.....................................................116
Pump Motor Specification ..........................................7 Parameter Calibration ............................................109
Sensor Initial Setting ..............................................114

Systems Operation
Eye Software Interface
General Information .................................................13
Advantage of AC motor.........................................13 Features .................................................................123
Basic ITC ..............................................................16 General Information................................................121
Comparison between AC and DC motor...............13 Installation ..............................................................122
ITC system characteristics....................................16 Main Menu..............................................................124
Main ITC(Intelligent Torque Control) features .......15 Calibration ...........................................................133
Glossary ................................................................... 11 Configuration Menu (Setup) ................................128
Installation and Wiring..............................................17 Data Logging.......................................................153
Accessory Circuits ................................................26 Flash ...................................................................155
General .................................................................17 Not Actual Software / Eeprom Crc Fault .............127
Hydraulic Pump Motor Circuit ...............................25 Password Insertion..............................................125
K1 connector: list of all terminals ..........................19 Submenus ...........................................................127
System Circuit.......................................................23 Test......................................................................129
Thermal protection circuit .....................................26

Troubleshooting of Eye Program

Testing and Adjusting
Flash Programmation .............................................156
Preparation Tests and Check ...................................27 Generality ...............................................................156
Programmable Parameters ......................................30 Other Problems ......................................................156
Adjustable Parameters Description.......................30 Serial Communication ............................................156
E-S-H Energetic Modes Parameters ....................39 Software Installation ...............................................156
Some Functions Management .................................40
B.D.I. Measure Management ................................40
Buzzer Management.............................................40 Appendix
Pump Motor Modes ..............................................40
Static Return to Off................................................40 Appendix A : 48[V] Parameter List..........................157
Appendix B : 36[V] Parameter List .........................160
Appendix C : Error Code List..................................163
Diagnostic and Troubleshooting Appendix D : Contraction for dot matrix display. ....171
1. Alarm Code .....................................................171
Alarm List .................................................................41 2. Calibration Code .............................................172
Electrical System Adjustment.................................101 3. Diagnostic Code..............................................173
General Description .................................................41
System Tests and Adjustments ..............................100
Troubleshooting Problem List ..................................50

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Specifications
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Component Measurements

SPECIFICATIONS
Multimeter Setting (+) Test Lead (-) Test Lead Results
Resistance +BATT Each U,V,W Over 1.4 Mohms
Resistance -BATT Each U,V,W Over 1.4 Mohms
Resistance U Termina V Terminal Below 0.5 ohms
Resistance U Termina W Terminal Below 0.5 ohms
Resistance V Termina W Terminal Below 0.5 ohms

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Controller AS Specification

BATTERY VOLTAGE 24-60 V

MAXIMUM IMPULSIVE DRIVE INVERTER CURRENT 325 A
MAXIMUM IMPULSIVE PUMP INVERTER CURRENT 400 A
SWITCHING FREQUENCY 3-6-9 KHz
EFFICIENCY 95 %
PROTECTION LEVEL IP54
MECHANICAL SIZE 580x248x187
WEIGHT 24 Kg
VIBRATION 5g 10-500Hz in X,Y,Z axis
TEMPERATURE RANGE - 30 °C ¸ + 40 °C
MAXIMUM MODULE TEMPERATURE 100°C
CONTROLLER Complies with EN 1175-1 EN 12895-1
MAIN CONTACTOR 250A
MAIN FUSE 700A
KEY FUSE 10A

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Drive Motor Specification Pump Motor Specification

POWER 5 KW POWER 12 KW
VOLTAGE 32 V VOLTAGE 30.5 V
CURRENT 157 A CURRENT 335 A
RATED SPEED 1500 RPM RATED SPEED 2200 RPM
MAXIMUM SPEED 4500 RPM MAXIMUM SPEED 4500 RPM
FREQUENCY 75 Hz FREQUENCY 73 Hz
Cos G 0,72 Cos G 0.84G
SERVICE S2 60' SERVICE S3 15%
INSULATION CLASS F INSULATION CLASS F
PROTECTION DEGREE IP 10 PROTECTION DEGREE IP 20
BEARINGS 6206 2RS BEARINGS 6206 2RS
WEIGHT 38.5 Kg WEIGHT 43.5 Kg

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Instrument Panel Layout

TYPE A

TYPE B

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Fuses Assembly Layout of Motors

Line ..................................................................... 700A
Key ........................................................................ 10A
Horn ...................................................................... 10A
DC / DC Converter ................................................ 10A
Light ..................................................................... 10A
Option light ............................................................ 10A

Assembly Layout of Controller

(4 Wheel)

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Control Panel Layout

NOTE: Apply a small amount of D557047 Thermal Joint Compound on control panel plate and mating surface
prior to assembly. Communication cable’s assembly with power units and logic control unit uses the micro
screw driver(2.5*100mm)

Communication cable's assembly with Power Unit and Logic Control Unit uses Micro Screw Driver

(1) Logic Control Unit. Use a socket wrench(7mm) to hold bolts

(2) Left Drive Motor Power Unit. Use a hex bit socket(5mm) wrench(100mm) or L-wrench to hold bolts
(3) Pump Motor Power Unit
(4) Right Drive Motor Power Unit
(5) FUSE. Use a socket wrench(13mm) and a wrench(13mm) to hold bolts
(6) Line Contactor
(7) Bus Bar. Use a socket wrench(13mm) and a socket wrench(17mm) to hold bolts

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Systems Operation
Glossary
NAME DESCRIPTION

Accelerator A device that converts mechanical movement into a analog voltage pattern to the
logics for variable drive motor speed.
Ampere (or Amp) The unit of measurement of current flow. The amount of current that one volt can
push through a resistance of one ohm.
Analog to Digital A device that converts an analog voltage into a pattern of digital HIGH and LOW
Converter voltage signals.
Battery Two or more cells connected together for a supply of electric current.
BDI Battery Discharge Indicator - An electrically controlled display showing the operator
the state of batter y charge.
Bus Bar A heavy electrical conductor to which other smaller wires are connected.
Capacitor Device used to store electrical energy for short periods of time.
Circuit A way for current to go from the positive (+) side of an electrical power source to the
negative (-) side of an electrical power source. This can be through wires and
electrical components.
Coil A component made from many circles or turns of wire used to concentrate a
magnetic field.
Connector Part of a wire assembly or harness that connects with another wire assembly or
harness. Used for ease of assembly and disassembly.
Contactor Assembly An electrical component consisting of an electromagnetic coil and a set of heavy
contact tips. Control current passes through the coil, building a magnetic field which
closes or opens the contact tips.
Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly.
Contact Tips or Contacts The portion of a switch, relay or contactor where the circuit can be opened or closed.
Current The movement or flow of electricity through a conductor. A circuit must be complete
for current to flow.
Current Limit The maximum allowable armature current of a stalled drive motor during pulsing.
Digital Signal A signal in which the elements may be either of two distinct values.
For example high voltage, low voltage.
Diode A semiconductor device that allows current to flow in one direction, from the anode to
the cathode.
Display An electrical device that converts voltage inputs to a visual output.
Electrical Assist Braking Electrically trying to rotate the drive motor opposite to the direction of truck
(EAB) movement.
Fuse A component in an electrical circuit that will open the circuit if too much current goes
through it.
Harness An assembly made of two or more wires that are held together.
Heat Sink A mounting frame used for semiconductor cooling.
Indicator LCD that gives an indication of some vehicle condition when it turns on or flashes.
LCD Liquid Crystal Display.
Logic Control Unit The main printed circuit board containing a microprocessor and circuits to condition
the voltage signals that go into or come out of the logics. It electronically monitors
and controls the truck's functions.

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NAME DESCRIPTION

Microprocessor A small computer chip preprogrammed to control the various electrical functions on a
lift truck.
Normal Condition Words used with a switch or relay. Their normal condition is their condition when they
are not controlled by the application of force, temperature, pressure, or electricity.
MOSFET A semiconductor component used in electric lift trucks as an electronic switch. A
MOSFET most often has three terminals, a GATE(G), a DRAIN(D), a SOURCE(S). A
MOSFET is a voltage-controlled device and required only a small input current. The
switching speed is very high.
Ohm The unit of measurement of resistance. The amount of resistance that will let one volt
push only one ampere of current through it.
ON-Time The amount of time current flows through a transistor.
Open Circuit Wiring or components of a circuit that have no continuity.
Overload The presence of voltage or current which is greater than an electrical circuit or
component is designed to handle.
Plugging A portion of electrical braking where the generated current is directed back through
the armature.
Relay An electrical component consisting of an electromagnetic coil and a set of small
contact tips. Control current passes through the coil, building a magnetic field which
closes or opens the contact tips. When the contact tips are closed, low current can
flow in a separate isolated circuit.
Resistor A component made of a material that has a specific resistance to the flow of current.
Rotor Part that rotate of motor
Schematic A line drawing of an electrical or electronic assembly which uses symbols to show
individual components. It shows how the components, wires and connectors function
electrically.
Short Circuit An electrical connection between two or more components that is not desired.
Socket The female contact of a connector that slips over a male contact (pin) of another
connector.
Solid State Reference to semiconductor components or circuits that use semiconductor
components that have no moving parts, such as diodes and transistors.
Stator Fixed part in driving state of motor
Switch A component used to control an electric circuit. It can close or open a circuit.
Systems The electrical components, circuits, and connections that deliver power to perform
specific tasks.
Terminal An electrical connection point on an electrical component.
Thermal Sensor A sensor that activates at a set temperature.
Volt The unit of measurement of electromotive force. One volt is the force needed to
make one ampere of current flow through one ohm of resistance in a circuit.
Watt The unit of measurement of power. The amount of power used when one volt pushes
one ampere of current through a resistance of one ohm. The result of amperes
(current) multiplied by volts (voltage) is watts (power).
Wire A conductor used to provide a path for current to flow to and from electrical
components.
Wiring Diagram A drawing using visual representation of components the way they actually look. It is
used to show the locations of components and the connections between them.
Zener Diode A special diode used to regulate voltage or as an over-voltage (too high a voltage)
protector.

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General Information
Advantage of AC motor Comparison between AC and DC
motor

Motor Characteristics

AC Motor systems DC Motor system

1 Little components More complex
2 Decreasing price Increasing price
3 More reliable Less reliable

Practically Continuous
4
maintenance free maintenance to brushes

AC induction motors are the most diffused for power 5 High speed Low speed
conversion in industrial application. In the battery- High torque Low torque
fed lift-truck applications DC motors are more used, 6 performance at high performance at high
because they are easy to control in torque with a
speed speed
simple chopper drive with a current limitation.
High braking Poor braking
To reach the traction requirements the AC control 7 performance at high performance at high
has to be very advanced and the motor parameters speed speed
have to be known by the control algorithms.
8 Safer Less safe
The reason of their recent diffusion are related to
the technological development and to deeper
studies about this matter.
Controller Characteristics
The advantages of using AC motors instead of
DC motors are many: AC Motor systems DC Motor system
1. More robust and easy to build 9 Complex controller Simple controller
2. Less complex and more reliable
3. Practically maintenance free (no continuous Presence of auxiliary
10 No auxiliary contactor
brush maintenance) contactors
4. Higher speed 4 quadrants Torque discontinuity and
5. More performance at high speed especially in 11
continuous transition delay
regeneration
6. Absence of contactors for speed inversion Precise and smooth
12 Poor regulation
7. Continuous torque control during inversion (no regulation
delay with zero torque)
8. Safer because AC motor is not supplied and it
doesn’t work in case of short circuit

See following tables and relative explanation for a

comparison between AC and DC motor systems.

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AC and DC Motors Difference Explanation

DC motor is made with a rotor with power windings

and a stator with excitation windings and brushes.
The AC motor is composed by a rotor and a stator
with windings.

Because of great diffusion of AC motors and the

automatic industrial production process, their prices
continue to decrease.

Because of DC motor more complexity, brush

presence and poor environmental protection, the life
of DC motor is greatly reduced, compared with AC
motor.

The maintenance of DC motor must be continuous

because of consumption of brushes.
The most critical component for AC motor are the
bearings. AC motor reaches higher speed because
of DC sparkling limitation of brushes.

AC motor has higher torque at high speed because

of DC sparkling limitation of brushes. AC motor has
much more regenerative braking torque at high
speed because of DC sparkling limitation of brushes.

AC motor is safer than DC because if a short circuit

happens in armature, DC motor accelerates. The
AC motor needs an AC voltage to accelerate.

The AC controller is much more complex of a DC

one. The reason why is the AC control algorithms
requires the use of a very powerful microprocessor
which performs a fast real time control.

In most of DC controllers are present auxiliary

breakers which operate every drive inversion,
introducing delays and compromising the controller
life.

Most of DC controller systems has zero torque

delays during inversion causing a poor driving
performance. In AC the transition between forward
and reverse and acceleration and braking is
continuous giving an optimum performance even at
very low speed and in sharp ramp.

Because of 4 quadrants continuous transition and

the presence of a sophisticated controller the
regulation of AC system is superior in precision,
stability, smoothness and safety to DC one.

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Main ITC(Intelligent Torque Control) Software control algorithm is customised in order to

features best fit lift truck characteristics; you can set the
value of a wide range of parameters, in order to
Most important features of Intelligent Torque optimise system performance and to adjust the
Control system developed by DHIM the settings of main functions in compliance with user’s
following: needs.

1. Control unit: One panel assembly containing User can interact with control board making use of a
three power inverters for drive and pump and a software application (named EYE) developed by
control board; main board, wired directly to the DHIM, or with COMPACT display. In both cases, it’s
power modules, could manage up to 4 inverters. possible to obtain an exhaustive “on line” diagnostic
The presence of 2 DSP (Digital Signal for all lift truck functional parameters and also to
Processors), working in mutual redundant adjust them.
control, guarantees powerful software
performance: in case of such a system, You can upgrade control board internal software
managing both drive and pump motors, high connecting a PC via serial port (or via USB 1.x or
dynamic performance in vectorial torque control higher, inserting the appropriate serial port-USB
can be obtained. adapter); in fact, working with RS232
communication standard, EYE application permit to
2. Two asynchronous three-phase drive motors load and upgrade panel software in any working
equipped with magnetic sensors(64 impulses/ conditions, if only control board is correctly fed on .
rotation).

3. An asynchronous three-phase pump motor for

lifting equipped with magnetic sensor (64
impulses/ rotation).

4. Instrument Panel.

Instrument Panel

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Basic ITC ITC system characteristics

Following basic hardware and software You can obtain high performance for the lift
functions characterize DHIM Company system: truck with DHIM system, thanks to following
specific features:
1. Protection against reverse battery polarity
2. Anti-roll-back, with adjustable ramp stop time 1. DSPs(Digital Signal Processor) high
3. Anti-roll-down performance control with custom software: this
4. Regenerative braking is resident in the internal FLASH memory, and
5. Electrically assisted braking allows to control 3 independent AC motors.
6. Management of static return to off function 2. One serial asynchronous RS232 interface for
(SRO) PC communication in order to obtain:
7. Drive speed compensation (load/unload) a. Software update
8. Drive speed acceleration/deceleration b. Diagnosis of truck functionalities
9. Drive speed reduction c. Parameters modification, in order to
10. Redundant control of acceleration pedal custommize the system
(applying a control switch or a double 3. One accelerator (0 - 5 V) and all on/off
potentiometer) emergency micro-switches interface.
11. Continuous lift speed control 4. One encoder (0 - 5 V) interface for traction and
12. Pump speed compensation (load/unload) pump motors.
13. Lift speed acceleration/deceleration 5. Motor torque control by speed and current loop.
14. Continuous control of main contactor applied to 6. Controlled acceleration and deceleration ramps
DC power line of drive and pump motors in order to avoid
15. Seat switch open check with delay time uncontrolled jolts of the load due to oversights
16. Battery discharged indicator with adjustable of the operator.
reset value 7. Automatic truck speed limitation depending on
17. Overtemperature protection for inverters and steering angle.
motors 8. Ramp stop of the lift truck.
18. Low and high battery voltage limit 9. Automatic energy recovery at each truck
19. Drive/pump speed feedback braking.
20. Zero speed drive in ramp 10. LIN (Local Interconnect Network) display
21. Standby for supply interface.
22. Diagnostics and stored error code 11. Automatic truck speed limitation, depending on
23. Power line fault detection (fuse/contactor) the height of the load lifted(option).
24. Continuous temperature measuring (Controller, 12. Automatic truck maximum speed limitation, in
drive/pump motor) function of:
13. Weight present on the forks(option)
a. Fork height
b. Battery voltage level
c. Any thermal alarm
d. Full protection of drives against overcurrent
of the motors, overheating of the power
transistors and both maximum and minimum
battery voltage.
14. Low maintenance costs by using A.C induction
motors

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Installation and Wiring

General

1. A metallic container encloses control board (Fig.

1).

2. There are three power modules (see fig 2 for

single module) assembled to main board as
shown in Fig. 3 and Fig. 4.

3. A 68 ways AMP connector (named K1), permits

Fig. 1: Logic control board
to interface control board to lift truck
electrical/electronic sub-devices. See Fig. 4 for
a view of K1- 68 ways connector.

4. Three 26 ways connectors (named C1 C2 C4)

permit to wire and control 3 power inverters. No
details are given about the pin-out of these
connectors t, because they are not user
accessible for maintenance or diagnostic
operations. Power modules shall be connected
also to battery supply (wire named +B and -B)
and to corresponding motor phases.

Fig. 2: Single power module

Working on electrical systems is potentially

dangerous; you should protect yourself
against :
Uncontrolled operation: some conditions could
cause the motor to run out of control:
disconnect the motor or jack up the vehicle and
get the drive wheels off the ground before
attempting any work on motor control circuitry.
High current arcs: batteries can supply very
high power, and arcs can occur if they are short
circuited. Always open the battery circuit
ground before working on motor control circuit.
Fig. 3: Power modules assembly with main contactor and
Wear safety glasses and use properly insulated fuses
tools to prevent shorts.
Lead acid batteries: charging or discharging
generates hydrogen gas, which can build up
and go around the batteries. Follow the battery
manufacturer’s safety

Fig. 4: Power modules assembly with control board mounted

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Fig. 4: View of accessible terminals on 68 ways connector

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K1 connector: list of all terminals

Pin
Use Name Function
number
K1 – 1 IN -Battery Negative supply voltage of control board
K1 – 2 OUT + 24 V supply
IN Lift pressure (optional) Proportional voltage signal (0-5V); you can connect a
K1 – 3 A pressure linear sensor, made by SME cod B00ID160
working correctly in 0¸250 bar pressure range
IN start switch for accelerator START signal
K1 – 4
D pedal N.O. with internal pull-up and Vmax(in)=24V
IN accelerator pedal 2° Proportional voltage signal (0-5V) or (0-12V) managed as
K1 – 5
A potentiometer accelerator pedal input
IN park brake switch Park brake signal
K1 – 6
D N.C., with internal pull-up and Vmax(in)=24V
IN seat switch Seat switch signal
K1 – 7
D N.O., with internal pull-up and Vmax(in)=24V
IN reverse drive direction switch reverse drive direction di selezione signal
K1 – 8
D N.O., with internal pull-up and Vmax(in)=24V
IN forward drive direction switch forward drive direction signal
K1 – 9
D N.O., with internal pull-up and Vmax(in)=24V
IN accelerator pedal 1° Proportional voltage signal (0-5V) or (0-12V) managed as
K1 – 10
A potentiometer accelerator pedal input
OUT + 12 V supply +12V supply voltage (self-protected electronic
K1 – 11
component) with: Idc (nominal) =500mA; Imax = 1Adc
IN/OUT LIN data line (Display I/0)
K1 – 12 Data line of LIN interface for COMPACT display
D
IN not used - Digital input, for an optional encoder, Vmax(in) =5V
K1 – 13
A/D - Analogue input (0-12V)
OUT + 5 V encoder supply +5V supply voltage (self-protected electronic component)
K1 – 14
with: Idc (nominal) =500mA; Imax = 1Adc
OUT GND Negative supply voltage for data type signals, with self
K1 – 15 protection against noises coming from DC power line;
Imax=500mA
IN PHASE B of left drive motor PHASE B signal of the sensor bearing mounted into the
K1 – 16
D encoder left drive motor; internal pull-up; Vin:(0 – 5V)
IN PHASE A of left drive PHASE A signal of the sensor bearing mounted into the
K1 – 17
D motor encoder left drive motor; internal pull-up; Vin:(0 – 5V)
K1 – 18 OUT + coil main breaker Positive command of contactor coil; Inom=1A; Imax = 5A
K1 –19 OUT - coil main breaker Main breaker coil reference signal; Inom=1A; Imax = 5A
OUT not used Self-protected open collector power output, you can
K1 – 20 A apply it to an ON/OFF or proportional electrovalve coil;
Vmax =Vali; Inom=2A; Imax=6A

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Pin
Use Name Function
number
OUT not used Self-protected open collector power output, you can
K1 – 21 D apply it to an ON/OFF or proportional electrovalve
coil; Vmax =Vali; Inom=2A; Imax=6A
K1 – 22 IN + battery Control board supply voltage; V = Vsupply
K1 – 23 IN + battery key input Supply voltage of key and coils ; Vkey=Vsupply
IN not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;
K1 – 24
A/D - Analogue input (0-12V)
IN not used Digital input , N.O., internal pull-up, Vmax(in)=24V
K1 – 25
D
IN not used Analogue input (0-12V)
K1 – 26
A
IN lift pressure Analogue input (0-5V)
K1 – 27
A
IN PHASE B of pump PHASE B signal of the sensor bearing mounted into
K1 – 28
D motor encoder the pump motor; internal pull-up; Vin:(0 – 5V)
IN PHASE A of pump PHASE A signal of the sensor bearing mounted into
K1 – 29
D motor encoder the pump motor; internal pull-up; Vin:(0 – 5V)
IN Not used; Digital input for an optional encoder, motor; internal
K1 – 30
D PHASE A of an optional encoder pullup; Vmax(in)=5V;
IN/OUT Not used; - Digital input for an optional encoder, Vmax(in)=5V;
A/D PHASE B of an optional encoder - Open Collector power output, to command an
K1 – 31
ON/OFF electrovalve coil; Vmax =Vsupply; Inom=2A;
Imax=6A
IN Asynchronous RS232 RX input for asynchronous RS232 serial
K1 – 32
D serial RX input communication standard
IN PHASE A of left drive TX output for asynchronous RS232 serial
K1 – 33
D motor encoder communication standard
OUT + coil main breaker H line input for CAN (Controller Area Network )
K1 – 34 component; presence of internal termination
resistance
OUT - coil main breaker L line input for CAN component; presence of internal
K1 – 35
termination resistance
OUT not used PHASE B signal of the sensor bearing mounted into
K1 – 36
A the right drive motor; internal pull-up; Vin:(0 – 5V)
OUT not used PHASE A signal of the sensor bearing mounted into
K1 – 37
D the right drive motor; internal pull-up; Vin:(0 – 5V)
IN AUX 2 Digital input to activate pump motor auxiliary function
K1 – 38
AUX2; N.O., internal pull-up, Vmax(in)=24V
IN FANS Command (optional) Open Collector power output, to command fans (or
K1 – 39
other devices) Inom = 1A, Imax=3A; Vmax=60V;
IN not used Open Collector power output, to command an
K1 – 40 A/D ON/OFF
electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A

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Pin
Use Name Function
number
IN not used Open Collector power output, to command an ON/OFF
K1 – 41
D electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
IN not used Open Collector power output, to command an ON/OFF
K1 – 42
A electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
IN not used Open Collector power output, to command an ON/OFF
K1 – 43
A electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
IN not used Open Collector power output, to command an ON/OFF
K1 – 44
D electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
IN not used PWM supply voltage for electrovalve coils (or similar
K1 – 45
D devices)
IN lift high 1 switch(optional) Voltage signal of lift critical high switch, N.O., internal
K1 – 46
D pull-up, Vmax(in)=24V
IN Not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;
K1 – 47
A/D - Analogue input (0-12V)

IN Pedal brake switch Activation signal for park brake, N.O., internal pull-up,
K1 – 48
D Vmax(in)=24V

IN Not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;

K1 – 49
A/D - Analogue input (0-12V)

IN lift lever potentiometer voltage Proportional voltage signal (0-12V), input of lift lever
K1 – 50
A potentiometer
IN Not used Proportional voltage signal (0-12V)
K1 – 51
A
IN Not used Proportional voltage signal (0-12V)
K1 – 52
A
OUT buzzer command Open Collector power output, to command buzzer
K1 – 53
D activation; Vmax =24V; Inom=30mA; Imax=100mA.
IN tilt switch Request of tilting, N.O., internal pull-up, Vmax(in)=24V
K1 – 54
D
IN lift high 2 switch(option) Voltage signal of lift critical high switch, N.O., internal
K1 – 55
D pull-up, Vmax(in)=24V
IN digital input for 3 / 4 wheels - Digital input to select a lift truck with 3 wheels (Closed )
D choice; or 4 wheels (Open);
K1 – 56
PHASE A of an optional - PHASE A signal for an optional encoder; internal pull
encoder up; Vin:(0 – 5V)
IN AUX1 Digital input to activate pump motor auxiliary function
K1 – 57
D AUX1; N.O., internal pull-up, Vmax(in)=24V
IN right drive motor thermal Analogue input (or digital as optional) used for right drive
K1 - 58
A/D sensor/ switch motor thermal sensor (0-5V); internal pull-up;
IN left drive motor thermal sensor/ Analogue input (or digital as optional) used for left drive
K1 – 59
A/D switch motor thermal sensor (0-5V); internal pull-up;
IN pump motor thermal sensor/ Analogue input (or digital as optional) used for pump
K1 - 60
A/D switch motor thermal sensor (0-5V)

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Pin
Use Name Function
number
IN Not in use - Digital input , N.O., internal pull-up, Vmax(in)=5V;
K1 - 61
A/D - Analogue input (0-5V)
IN steering angle sensor voltage Proportional voltage signal (0-12V) or (0-5V), used as input
K1 – 62
A to steering sensor circuit
OUT Not used; Open Collector power output, to command an ON/OFF
K1 – 63
D Electrovalve (or alike) command electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
OUT Not used;
Open Collector power output, to command an ON/OFF
K1 – 64 D Electrovalve (or alike)
electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
command
OUT Not used; Open Collector power output, to command an ON/OFF
K1 – 65
D Electrovalve (or alike) electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
OUT Not used; Open Collector power output, to command an ON/OFF
K1 – 66
D Electrovalve (or alike) electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
OUT Not used Power output, to command a proportional electrovalve coil;
K1 – 67
A Vmax =Vsupply; Inom=2A; Imax=6A
OUT Not used; Open Collector power output, to command an ON/OFF
K1 – 68
D Electrovalve (or alike) electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A

NOTES:
D : digital signal, with boolean values (ON/OFF)
A : analogue signal, assuming values in
[Vground -Vmax] range
A/D : signal that could be both analogue and digital
NO : normally open
NC : normally close
IN : signal used as input
OUT : signal used as output

NOTICE
Remember the controller contains ESD(Electro
Static dischange) sensitive components.
Use appropriate precautions in connecting,
disconnecting and handling it.

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System Circuit

Power Circuit

If divide greatly composition of electric controller

system of this vehicles, is consisted of 1 Logic
control board, Power Unit (Left Drive, Right Drive,
Pump) 3, Line Contactor 1.

Each power unit controls each motor's speed, logic

control board vehicles situation and driver's select
receiving feedback vehicles control.

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Actuation Circuit

This circuit supplies power to the Logic Control When the seat switch is closed, current will flow
Board and the Instrument Panel(Display). It must be from the logic K1-7 through the seat switch to
activated before power steering, hydraulics or drive controller negative. The logics then activates the
will operate. line contactor by allowing current to flow from K1-18
through the line contactor coil (+) and K1-19 the line
When the battery is connected and the key switch is contactor coil (-).
closed, current flows from battery positive through
the key fuse, key switch, wire #23 to the logic With the line contactor tips closed the logics
control board (logic) contactor K1-23. continues its checks for any “Run Time” faults. If no
The logic connection to battery negative is at K1-1. faults are detected the display will indicate the
The logic circuits are powered up to accept voltage battery charge level, the power steering (IDLE)
inputs and create voltage outputs whenever the system operates, the pump and drive power circuits
battery is connected and the key is turned to ON. receive battery voltage and the logics receives
battery voltage.

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Hydraulic Pump Motor Circuit

Only one hydraulic pump motor is used for all power

steering, lift, tilt and auxiliary hydraulic functions. To
activate the pump circuit, the seat switch, key switch
and line contactor must be closed first as explained
in the topic, Actuation Circuit.

Power Steering Circuit

The power steering speed of this vehicles operate

by speed (default 500 rpm) that specify in pump
motor calibration.

Lift Control Circuit Location Components

(2) Lift Sensor. (3) Magnet.

When the operator pulls the lift lever, magnet (3)

moves closer to the lift sensor (2). The sensor
detects the increasing magnetic field and sends an
increasing voltage to the valve control card. The
input to the logics at K1-50. The logics uses these
changing voltages to determine what speed to
operate the pump motor. The logics then controls
the pump power unit.

Location Components
(1) Valve control card.

This control panel accept a linear speed lift signals

and tilt/aux lever signals. The lift control system is
controlled by valve control card (1) mounted at the
top of the control valve.

The drive control card uses a hall-effect transducer

(Lift Sensor) and magnet to sense lift lever
movement. The closer the magnet is to the
transducer the greater the hydraulic pump motor
speed.

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Thermal protection circuit Accessory Circuits

Control Panel Horn Circuit

If the Power Unit’s MOSFETs overheat, a thermal The horn will operate when the battery is connected
senders mounted in the MOSFET heatsink will give and the horn button is pushed. Current flows from
a voltage signal to logic. If the temperature is over battery positive through horn fuse, horn switch and
than preset value(100°C), the Instrument Panel will horn, back to battery negative.
display a “Run Time” diagnostic symbol and E1, E2,
E3. The logics will decrease the speed of the drive
motors and the pump motor. The amount of current DC-DC Converter Circuit
allowed to flow through the MOSFETs is decreased
to permit them to cool. When the heatsink cools off
the truck will return to normal operation. But due to
the reduced speed, acceleration performance will
be decreased. Each error code is stored in memory.

Drive Motor

If the drive motor overheats a thermal sensor

mounted in the stator coil of drive motor will warn at
a predetermined temperature (155°C). If reach in
overheating temperature, the Instrument Panel will
display a “Run Time” diagnostic symbol and E4, E5.
To decrease the amount of current allowed to flow
through the drive motor, the logics will reduce the
speed. When the drive motor cools off, the truck will
return to normal operation. Drive system
acceleration performance and top travel speed is
affected by an overheated drive motor. “MOTOR
TEMPERATURE” will be stored for Drive Motor
overheating in memory.

The 12 volt output of the converter is protected

Hydraulic Pump Motor against short circuits and overloading by an internal
15 amp current limit circuit. A fuse on the converter
If the drive motor overheats a thermal sensor protects it from reverse connection of the battery
mounted in the stator coil of drive motor will warn at voltage.
a predetermined temperature (155°C). If reach in
overheating temperature, the Instrument Panel will Notice: Do not connect the 12 volt negative output
display a “Run Time” diagnostic symbol and E6. To of the DC-DC converter to battery negative.
decrease the amount of current allowed to flow Damage to system components could
through the pump motor, the logics will reduce the occur.
speed. When the pump motor cools off, the truck
will return to normal operation. “MOTOR The DC-DC converter changes the lift truck battery
TEMPERATURE” will be stored for Pump Motor voltage to 12 volts. This 12 volts is used to power
overheating in memory. accessories such as floodlights, brakes/side lights
and backup alarms.

The positive of the 12 volt output is common to the

positive of the batter y voltage. The negative of the
12 volt output is pulsed to maintain a steady 12 volt
supply.

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Testing and Adjusting Cell Voltage Test

With the truck powered up and the pump(Idle) motor

Preparation Tests and Check running, measure the voltage at each cell. Normal
voltage should be between 1.95V and 2.12V per cell.
Battery Tests If the voltage on each cell is below 1.95V the battery
must be charged or repaired before continuing to
A weak battery can cause or contribute to problems troubleshoot.
in the Logic Control Board and power circuits. Verify
the battery is good before investigating other NOTE: The indication between cells should not
possibilities. differ more than 0.05 volts. If it does, the
battery must have an equalizing charge or
1. Verify proper polarity at the battery connector
be repaired.
and the control panel. Positive cable should be
at the line fuse and negative at the negative on
control panel.
Hydrometer Test
2. If the lift truck is operational, perform a battery
load test. Test each cell of the battery with a hydrometer. If the
specific gravity indication is below 1.140, the battery
3. If the truck is not operational and the battery is must be charged. The battery is fully charged if the
suspected, perform a cell voltage or specific indication is 1.265 to 1.285.
gravity test.
NOTE: The indication between cells should not
differ more than 1.020 If it does, the battery
Battery Load Test needs an equalizing charge or needs to be
repaired.
1. Turn the range switch on the multimeter to read
battery voltage.

2. Connect the battery.

2
1

Battery Voltage Test.

(1) Positive cable connection. (2) Negative cable connection.

3. Connect the multimeter leads between positive

(+) cable connection (1), and negative (-) cable
connection (2).

4. In a safe area, operate the hydraulic system,

(hold tilt lever to maximum position
momentarily) while reading the voltage indicated
on the multimeter.

5. If the indication is less than 45.6V(48V truck),

34.5V(36V truck), the battery needs to be
charged or repaired before continuing to
troubleshoot.

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Battery Maintenance 6. Keep accurate battery records. Regular battery

readings should be taken with a battery tester or
NOTE: It is important that all batteries be charged voltmeter and a written record kept. Specific
and maintained according to the battery gravity and voltage of each cell should be
manufacturers instructions. checked and recorded at least once each month.
This inspection should be made after an
The care and maintenance of batteries is most equalizing charge. Readings should never be
important to maximize battery life and efficient truck taken directly after water has been added.
operation. Periodic inspection and service will Records of all battery maintenance should be
increase the life of batteries. Special attention made and filed so it will be known which
should be given to the rules that follow: batteries are being abused or wearing out.

1. Keep batteries clean at all times. Cleaning will Repairs should be made immediately otherwise the
prevent corrosion, current leakage and shorts to battery may become damaged. Batteries stored in a
chassis. Tighten all vent plugs, wash the battery discharged condition may be difficult to recharge
with water and a brush, then dry with an air due to sulfate formation.
hose. It may be necessary to use a baking soda
solution if water alone will not clean the top of
the battery. Visual Checks

2. Add enough water to cover the plates before 1. Verify all components and wires are in their
charging. This will ensure the proper chemical proper place. Check fuses, components,
reaction over the entire plate surface. After contactor tips, wires and connections. Verify that
charging is complete, add water until it is about they are not burned, broken or loose.
12.7 mm (.50 in) above the plates. Use distilled
water or water that has tested free from 2. Verify there is no mechanical binding or
minerals. interference in the contactor.

3. Charge the battery correctly. A battery should be 3. Visually check the parking brake switch, the
discharged to 80% of its capacity then fully hydraulic switches and accelerator linkage for
recharged. It should cool four to eight hours to adjustment or interference problems.
allow the voltage to stabilize before being put
back in use. The battery should have an
equalizing charge (an extra three or four hour
charge at a low finish rate) once a month to
make sure all cells are in a fully charged
condition. Properly charged batteries should be
identified to prevent low batteries from being
installed in trucks.

4. Operation with a low battery must be prevented.

Low battery operation may damage the battery
and will cause higher than normal current in the
electrical system. High current draw due to a
low battery will damage contactor tips and
shorten motor brush life.

5. The battery's maximum temperature is critical.

The electrolyte temperature should never
exceed 43°C (110ȋF) either while operating or
charging. Overcharging a battery will cause
over heating and warp the batter y plates.
Maximum battery life will result from maintaining
25ȋC (77ȋF) electrolyte temperature. Most of the
charging equipment is fully automatic but should
be checked periodically to assure proper
working order.

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Resistance to Chassis Checks

Resistance between any point in the truck wiring

and the chassis should be a minimum of 10,000
ohms or more.

Many malfunctions are caused by shorts to chassis.

Usually, two shorts must exist before a malfunction
will occur. But, since batteries can have chassis
leakage, only one short to chassis in the truck wiring
can cause problems. To prevent problems because
of shorts, do the following:

1. Disconnect the battery and discharge the Power

Uint.

2. Randomly measure any component connection

or wiring connection in respect to the lift truck
chassis for a minimum resistance of 10,000
ohms. Any test point with low resistance must
have the short to chassis removed.

3. Always keep batteries clean to minimize current

leakage to the chassis.

4. Routinely clean the brush dust from the motors.

5. Be sure that all attachments, such as horns and

lights are designed for no chassis connection (a
two wire system).

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Programmable Parameters
Adjustable Parameters Description

The possibility of interfacing by PC with the system

allows to have an exhaustive real time analysis of
the system working and of the condition of its
components; moreover, you can choose among a
wide range of parameters in order to reach the
optimum operating of the system in compliance with
your needs.

Adjustable parameters are listed below, divided by

functional groups, both for a 36 V and a 48 V
system. We briefly explain what’s the meaning of
each programmable parameter, and which is the
effect of its changes in lift truck performance.

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<48V SYSTEM>

Drive Motor

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
as high it is as quickly the truck decreases
Deceleration
5 its speed if the truck driver is turning the rpm/s 0 800 5,000
steering ramp 1
wheel quickly
as high it is as quickly the truck decreases
its speed in relation to the drive speed of
Deceleration
6 truck. This parameter increases the rpm/s 0 6 10
steering ramp 2
deceleration ramp while the driver is steering
at high speed
Buzzer on If it’s ON, the buzzer will be alarmed when OFF = 0 (Default)
30 digit
forward direction the direction switch is moved to forward ON = 1
Buzzer on If it’s ON, the buzzer will be alarmed when OFF = 0 (Default)
31 digit
reverse direction the direction switch is moved to reverse ON = 1
The cooling Fan runs when the temperature
Starting of motors reaches to set value. And the
35 temperature of cooling Fan stops when the motors cools ଇ 55 85 155
motor's Fans down below 60ଇ from set value(The
minimum of stop temperature is 25ଇ)
Maximum forward lift truck speed with no
Forward
42 speed limitation rpm 1,000 4,500 4,500
maximum speed
(no alarms present and turtle not active)
Maximum reverse lift truck speed with no
Reverse
43 speed limitation rpm 1,000 4,500 4,500
maximum speed
(no alarms present and turtle not active)
Drive limitation Maximum lift truck speed with speed
44 rpm 500 2,000 2,500
maximum speed limitation (turtle active)
High lift switch 1 Maximum travel speed when switch 1 was
46 rpm 0 1,000 4,500 option
drive max speed "ON"
Steer limitation
Maximum speed reference in the angle in
47 drive maximum rpm 400 1,500 2,000
which the internal wheel is mechanically still
speed
Acceleration Lift truck acceleration with accelerator pedal
48 rpm/s 400 1,100 2,000
ramp pressed
49 Inversion ramp Lift truck deceleration in inversion rpm/s 400 1,300 2,000
Lift truck deceleration with accelerator pedal
50 Release ramp rpm/s 400 1,000 2,000
released
Lift truck deceleration with pedal brake
51 Pedal brake ramp rpm/s 400 1,200 2,000
pressed
If the truck speed is greater then this
threshold, the speed
52 Creep speed rpm 100 300 2,000
reference becomes a parabolic function of
the accelerator potentiometer voltage.
Diameter of drive
53 Drive tyre's diameter mm 300 451 700
tyres
High lift switch 2 Maximum travel speed when switch 1 and
54 rpm 0 1,000 4,500 option
drive max speed switch 2 was "ON"
Parameter that softens the drive inversion
Partial release
59 ramp if the traction motors are working with rpm 10 50 500
ramp
low rpm
If parameter is set to1, speed limitation is
Disable = 0(Default)
94 Slow speed active; otherwise lift truck speed is managed digit
Enable = 1
as usual
If parameter is set to 1, values are
Normal = 0(Default)
95 British unit expressed in British unit, otherwise in digit
British unit = 1
international ones
Display
96 Display's brightness adjustment digit 0 5 8
brightness
If this parameter is set to 1, it is possible to
Disable = 0
97 E-S-H enable change the value of the power mode with digit
Enable = 1(Default)
the display

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Time meter / If parameter is set to 1, odometer indication

Timer meter = 0(Default)
98 Odometer on appears on display ; otherwise display digit
Odometer = 1
display shows the hour meter
99 Maintenance time Can set truck's maintenance period h 0 0 10,000

Sensors and Potentiometers

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Steering Steering sensor voltage with wheels turned on
18 mV 500 10,300 11.500
anticlockwise right
Steering sensor voltage with wheels turned on
19 Steering clockwise mV 500 1,200 11.500
left
20 Steering middle Steering voltage with wheels straight ahead mV 500 6,300 11,500
Minimum
23 Accelerator sensor voltage with pedal released mV 200 1,000 4,500
accelerator
Maximum Accelerator sensor voltage with pedal
24 mV 2,000 3,600 5,000
accelerator completely pressed
Lift sensor voltage with lift lever completely
32 Maximum lift mV 3,000 11,500 12,000
pressed
33 Minimum lift Lift sensor voltage with lift lever released mV 0 2,300 12,000
Lift lever potentiometer voltage to which the
34 Middle lift lifting becomes proportional to the shift of the mV 1,000 2,750 12,000
lever

Pump Motor

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Lift priority for if it's OFF, the pump motor works like it does now,
speed reference that is, the reference speed of pump motor, in case
of many simultaneous commands (LIFT + TILT, LIFT
+ AUX1, TILT + AUX1.......), will be the highest of OFF = 0 (Default)
27 digit
every single command; if it's ON the reference ON = 1
speed of pump motor, in case of many simultaneous
commands, will be the lowest of those reference
speed required by every single command
Weight of the load Load mesurement
36 kg 0 0
on the forks future
37 No load pressure Load mesurement bar·10 0 0 2,200 option
38 Load pressure Load mesurement bar·10 0 0 2,200
Limitation
39 Start temperature of performance reduction ଇ 100
temperature
Lift maximum Pump motor maximum current with lift
61 % 20 100 100
current function active
Auxiliary Pump motor maximum current with lift lever
62 % 10 65 100
maximum current released
Lift maximum
63 Maximum lift speed rpm 1,500 2,950 4,500
speed
64 Tilt speed Pump motor speed with lift function active rpm 500 900 2,000
Auxiliary 1
65 Pump motor speed with 1st auxiliary function active rpm 500 900 2,800
function speed
Auxiliary 2 Pump motor speed with 2nd auxiliary function
66 rpm 500 900 2,800
function speed active
Auxiliary 3 Pump motor speed with 3rd auxiliary function
67 rpm 500 900 2,800
function speed active

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Lift minimum
68 Minimum lift speed rpm 500 700 1,500
speed
High lift 1 switch Maximum pump motor speed with forks above the
69 rpm 0 1,500 3,500 Opion
lift max speed critical height
70 Hydro speed Pump motor speed when steering rpm 400 500 800
Hydro idle speed Pump motor speed with direction command lever
71 not in neutral, acceleration pressed and no pump rpm 200 300 500
command active
Pump
72 Lift acceleration rpm/s 1,000 7,000 10,000
acceleration ramp
Pump Pump motor deceleration after the end of a
73 rpm 1,000 7,000 10,000
deceleration ramp command
High lift 2 switch Maximum lift speed when switch 1 and switch
74 rpm 0 1,500 3,500 Opion
lift max speed 2 was "ON"
High lift 1 switch
75 Maximum tilt speed when switch 1 was "ON" rpm 0 500 2,000 Opion
tilt max speed
High lift 2 switch Maximum tilt speed when switch 1 and switch
76 rpm 0 500 2,000 Opion
tilt max speed 2 was "ON"
High lift 1 switch
Maximum auxiliary 1 speed when switch 1
77 auxiliary 1 max rpm 0 500 2,800 Opion
was "ON"
speed
High lift 2 switch
Maximum auxiliary 1 speedwhen switch 1
78 auxiliary 1 max rpm 0 500 2,800 Opion
and switch 2 was "ON"
speed
High lift 1 switch
Maximum auxiliary 2 speed when switch 1
79 auxiliary 2 function rpm 0 500 2,800 Opion
was "ON"
max speed
High lift 2 switch
Maximum auxiliary 2 speed when switch 1
80 auxiliary 2 function rpm 0 500 2,800 Opion
and switch 2 was "ON"
max speed
High lift 1 switch
Maximum auxiliary 3 speed when switch 1
83 auxiliary 3 function rpm 0 500 2,800 Opion
was "ON"
max speed
High lift 2 switch
Maximum auxiliary 3 speed when switch 1
84 auxiliary 3 function rpm 0 500 2,800 Opion
and switch 2 was "ON"
max speed

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Timers

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Time interval between seat switch opening
11 Seat switch delay s 1 3 9
and drive and pump motors stopping
Time delay between last command given to
12 Chat time a drive or pump motor and chat mode s 3 6 9
signalling
Time interval when pump motor works (with
13 Hydro time s 10 10 20
hydro speed) after the end of a command
Stop on slop Without stepping on pedal brake, time that is
26 s 1 5 10
timer doing stop in slope

Battery

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Battery reset Minimum battery voltage necessary to reset
9 V*10 464 470 501
value battery discharged voltage alarm

Program Service

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
99 Maintenance time Maintenance period decision h 0 0 10,000
Maintenance time Disable = 0 (Default)
14 Maintenance time inserting enable digit
inserting enable Enable = 1

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<36V SYSTEM>

Drive Motor

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
as high it is as quickly the truck decreases
Deceleration
5 its speed if the truck driver is turning the rpm/s 0 800 5000
steering ramp 1
wheel quickly
as high it is as quickly the truck decreases
its speed in relation to the drive speed of
Deceleration
6 truck. This parameter increases the rpm/s 0 6 10
steering ramp 2
deceleration ramp while the driver is steering
at high speed.
Buzzer on If it’s ON, the buzzer will be alarmed when OFF = 0 (Default)
30 digit
forward direction the direction switch is moved to forward. ON = 1
Buzzer on f it’s ON, the buzzer will be alarmed when OFF = 0 (Default)
31 digit
reverse direction the direction switch is moved to reverse. ON = 1
The cooling Fan runs when the temperature
Starting of motors reaches to set value. And the
35 temperature of cooling Fan stops when the motors cools ଇ 55 85 155
motor's Fans down below 60ଇ from set value(The
minimum of stop temperature is 25ଇ).
Drive maximum Drive motors maximum current (expressed
41 % 20 100 100
current in per cent of high energetic mode value)
Maximum forward lift truck speed with no
Forward
42 speed limitation rpm 1,000 3,800 3,800
maximum speed
(no alarms present and turtle not active)
Maximum reverse lift truck speed with no
Reverse
43 speed limitation rpm 1,000 3,800 3,800
maximum speed
(no alarms present and turtle not active)
Drive limitation Maximum lift truck speed with speed
44 rpm 500 2,000 2,500
maximum speed limitation (turtle active)
High lift switch 1 Maximum travel speed when switch 1 was
46 rpm 0 1,000 3,800 option
drive max speed "ON"
Steer limitation drive Maximum speed reference in the angle in
47 rpm 400 1,200 2,000
maximum speed which the internal wheel is mechanically still.
Lift truck acceleration with accelerator pedal
48 Acceleration ramp rpm/s 400 1,100 2,000
pressed
49 Inversion ramp Lift truck deceleration in inversion rpm/s 400 1,300 2,000
Lift truck deceleration with accelerator pedal
50 Release ramp rpm/s 400 900 2,000
released
Lift truck deceleration with pedal brake
51 Pedal brake ramp rpm/s 400 1,200 2,000
pressed
If the truck speed is greater then this
threshold, the speed reference becomes a
52 Creep speed rpm 100 300 2,000
parabolic function of the accelerator
potentiometer voltage.
Diameter of drive
53 Drive tyre's diameter mm 300 451 600
tyres
High lift switch 2 Maximum travel speed when switch 1 and
54 rpm 0 1,000 3,800 option
drive max speed switch 2 was "ON"
Parameter that softens the drive inversion
59 Partial release ramp ramp if the traction motors are working with rpm/s 10 50 500
low rpm
If parameter is set to1, speed limitation is
Disable = 0 (Default)
94 Slow speed active; otherwise lift truck speed is managed digit
Enable = 1
as usual.
If parameter is set to 1, values are
Normal = 0
95 British unit expressed in British unit, otherwise in digit
British unit = 1 (Default)
international ones.
Display
96 Display's brightness adjustment digit 0 5 8
brightness

G 35
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If this parameter is set to 1, it is possible to

Disable = 0
97 E-S-H enable change the value of the power mode with digit
Enable = 1 (Default)
the display
Time meter / If parameter is set to 1, odometer indication
Timer meter = 0 (Default)
98 Odometer on appears on display ; otherwise display digit
Odometer = 1
display shows the hour meter.
99 Maintenance time Can set truck's maintenance period. h 0 0 10,000

Sensors and Potentiometers

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Steering Steering sensor voltage with wheels turned
18 mV 500 10,300 11,500
anticlockwise on right
Steering Steering sensor voltage with wheels turned
19 mV 500 1,200 11,500
clockwise on left
20 Steering middle Steering voltage with wheels straight ahead mV 500 6,300 11,500
Minimum Accelerator sensor voltage with pedal
23 mV 200 1,000 4,500
accelerator released
Maximum Accelerator sensor voltage with pedal
24 mV 2,000 3,600 5,000
accelerator completely pressed
Lift sensor voltage with lift lever completely
32 Maximum lift mV 3,000 11,500 12,000
pressed
33 Minimum lift Lift sensor voltage with lift lever released mV 0 2,300 12,000
Lift lever potentiometer voltage to which the
34 Middle lift lifting becomes proportional to the shift of the mV 1,000 2,750 12,000
lever

Pump Motor

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
if it's OFF, the pump motor works like it does now,
that is, the reference speed of pump motor, in
case of many simultaneous commands (LIFT +
TILT, LIFT + AUX1, TILT + AUX1.......), will be the
Lift priority for OFF = 0
27 highest of every single command; if it's ON the digit
speed reference ON = 1 (Default)
reference speed of pump motor, in case of many
simultaneous commands, will be the lowest of
those reference speed required by every single
command.
Weight of the
36 Load mesurement kg 0 0
load on the forks future
37 No load pressure Load mesurement bar·10 0 0 2,200 option
38 Load pressure Load mesurement bar·10 0 0 2,200
Limitation
39 Start temperature of performance reduction ൓ 212
temperature
Lift maximum Pump motor maximum current with lift
61 % 20 100 100
current function active
Auxiliary Pump motor maximum current with lift lever
62 % 10 65 100
maximum current released
Lift maximum
63 Maximum lift speed rpm 1,500 2,950 4,500
speed
64 Tilt speed Pump motor speed with lift function active rpm 500 900 2,000
Auxiliary 1
65 Pump motor speed with 1st auxiliary function active rpm 500 900 2,800
function speed
Auxiliary 2 Pump motor speed with 2nd auxiliary function
66 rpm 500 900 2,800
function speed active
Auxiliary 3 Pump motor speed with 3rd auxiliary function
67 rpm 500 900 2,800
function speed active
Lift minimum
68 Minimum lift speed rpm 500 700 1,500
speed

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High lift 1 switch Maximum pump motor speed with forks above the
69 rpm 0 1,500 3,500 option
lift max speed critical height
70 Hydro speed Pump motor speed when steering rpm 400 500 800
Pump motor speed with direction command lever
71 Hydro idle speed not in neutral, acceleration pressed and no pump rpm 200 300 500
command active
Pump
72 Lift acceleration rpm/s 1,000 7,000 10,000
acceleration ramp
Pump Pump motor deceleration after the end of a
73 rpm 1,000 7,000 10,000
deceleration ramp command
High lift 2 switch Maximum lift speed when switch 1 and switch 2
74 rpm 0 1,500 3,500 option
lift max speed was "ON"
High lift 1 switch
75 Maximum tilt speed when switch 1 was "ON" rpm 0 500 2,000 option
tilt max speed
High lift 2 switch Maximum tilt speed when switch 1 and switch 2
76 rpm 0 500 2,000 option
tilt max speed was "ON"
High lift 1 switch
Maximum auxiliary 1 speed when switch 1 was
77 auxiliary 1 max rpm 0 500 2,800 option
"ON"
speed
High lift 2 switch
Maximum auxiliary 1 speedwhen switch 1 and
78 auxiliary 1 max rpm 0 500 2,800 option
switch 2 was "ON"
speed
High lift 1 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1 was
79 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1 and
80 rpm 0 500 2,800 option
function max switch 2 was "ON"
speed
High lift 1 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1 was
83 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1 and
84 rpm 0 500 2,800 option
function max switch 2 was "ON"
speed

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Timers

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Time interval between seat switch opening
11 Seat switch delay s 1 3 9
and drive and pump motors stopping
Time delay between last command given to
12 Chat time a drive or pump motor and chat mode s 3 6 9
signalling
Time interval when pump motor works (with
13 Hydro time s 10 10 20
hydro speed) after the end of a command
Stop on slop Without stepping on pedal brake, time that is
26 s 1 5 10
timer doing stop in slope

Battery

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Battery reset Minimum battery voltage necessary to reset
9 V*10 344 356 373
value battery discharged voltage alarm

Program Service

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
99 Maintenance time Maintenance period decision h 0 0 10,000
Maintenance time Disable = 0 (Default)
14 Maintenance time inserting enable digit
inserting enable Enable = 1

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E-S-H Energetic Modes Parameters

Some parameters value depend on selected energetic mode: in following tables are listed parameter default
values for each operating mode (Economic, Standard and High)

In case of 48 V system:

PARAMETER ECONOMIC MODE STANDARD MODE HIGH MODE

Maximum drive current 62 76 100
Maximum forward speed [rpm] 3000 3500 4500
Maximum reverse speed [rpm] 3000 3500 4500
Acceleration proportional to load 20 20 20
Drive acceleration ramp [rpm/s] 700 800 1150
Drive inversion ramp [rpm/s] 600 900 1200
Drive release ramp [rpm/s] 600 850 1000
Lift maximum current 75 80 100
Maximum lift speed [rpm]v 2500 2750 2950

In case of 36 V system:

PARAMETER ECONOMIC MODE STANDARD MODE HIGH MODE

Maximum drive current 62 76 100
Maximum forward speed [rpm] 2800 3300 3800
Maximum reverse speed [rpm] 2800 3300 3800
Acceleration proportional to load 20 20 20
Drive acceleration ramp [rpm/s] 700 900 1100
Drive inversion ramp [rpm/s] 700 900 1100
Drive release ramp [rpm/s] 700 900 1200
Lift maximum current 75 80 100
Maximum lift speed [rpm]v 1600 2500 2950

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Some Functions Management

Static Return to Off Buzzer Management

To ensure operator safety, when switching on the lift The buzzer is activated in the following cases:
truck, a number of inputs are analysed; if one of 1. Alarm condition
these signals indicates a wrong start condition or 2. Switching your device on you find wrong start
any likely danger situation, main breaker is not conditions:
closed and all system modes are disabled. a. Accelerator pedal pressed or directional
(forward or reverse) switch inserted.
If the anomalous input assumes the correct value, b. One of pump motor command levers not
main breaker is closed and it’s now possible go on released.
with usual truck management. 3. Parhig lever is pot pulling and no one is in the
seat.
The analysed inputs are the followings:
1. Seat switch (the closing is checked)
2. Directional switch (the insertion of a selected B.D.I. Measure Management
direction is checked)
3. Accelerator (the system controls if the pedal is To measure battery voltage one of the following
pressed) conditions must be true :
1. Chat mode
2. Lift with drive and pump motors still
Pump Motor Modes 3. Drive motors still and pump motor working to its
minimum speed (idle speed)
Control of a command lever moving when
starting If this conditions are fulfilled for at least 2 seconds,
G battery voltage begins to be evaluated, using a low–
When switching on the key, in case an hydraulic pass filtering. After 15 seconds of voltage
command is active, the lift, lateral shift, tilt and processing, the filter output signal is uses to
auxiliary functions are disabled. evaluate the battery charge level.

Only when the activated lever and/or the requested If the battery is discharged for at least two
command assumes the released position, operator consecutive sampling periods, low battery voltage
can return to the usual operative condition. alarm is signalled and following limitations are
activated:
Pump motor commands management Switching on 1. Limitation of drive motor speed and maximum
the key, the motor works at minimum speed (idle torque
speed, adjustable by PC). 2. Limitation of maximum pump motor speed
3. Lift, tilt and auxiliary functions are disabled
If the operator moves a command lever or the
steering wheel, the speed takes on a value that can If the alarm is observed switching on the key, the
be adjusted, depending on the type of the active first received pump command is keep active for 3
command and on the possible presence of seconds and then is disabled. Battery voltage must
limitations (caused by thermal or low battery alarms). exceed an adjustable limit value (Battery reset value,
see Chapter4) to return to normal operative
After the active command is switched off, motor condition after a low battery voltage alarm.
speed assumes idle speed value for an adjustable
time (idle time), relating to the start of hydro guide; if
no command is activated during this period of time, the
speed returns to no operation value (0 rpm)

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Diagnostic and Troubleshooting

General Description Alarm List
Diagnostic information about anomalous working Maximum battery voltage
condition is provided by COMPACT display or by
PC (using EYE software utility). 1. Eye alarm code: 1
This chapter explains how to manage any detected 2. Display alarm code: F0
fault and how to return to a normal working 3. Alarm level: 1
situation; suggestions to be applied in case of each 4. Alarm cause: battery voltage, measured by a
possible alarm are listed in a growing order, i.e. circuit inside control unit, exceeds following
from the least to the most serious one. levels:
a. 63 V, in case of systems working at 36 V
If an alarm condition is detected by main board, b. 63 V, in case of systems working at 48 V
software control inhibits some lift truck functions, to
guarantee operator safety. If the controller detects such a fault, refer to
Anomalous working conditions are indicated by following troubleshooting procedure:
different alarm levels, classified as follows, 1. Such an alarm can be caused also by the
depending on their effects on the system: presence of regeneration currents; when lift
1. Main breaker is opened and both pump and truck is on release or reverse braking ramp,
drive motors are stopped; buzzer and red led on motors work as generators, and battery voltage
the upper right corner of COMPACT display, can exceed overvoltage limit. In a case like that,
signal the presence of such an alarm. the battery condition should be verified ( if the
2. Pump and drive motors are stopped. battery is new it is necessary to do some
3. Drive motors speed is limited to 2000 rpm. charge-discharge cycles before reaching the
Moreover, in presence of such an alarm, first rating declared by the constructor) or has a high
command given to pump motor is inhibited 3 internal resistance. If the case is the second
seconds after activation, together with all pump and it is not possible to change the battery, the
motor functions (except hydro functions). solution may be to reduce the release and
4. Drive and pump motors speed is limited to 800 reverse braking ramp.
rpm; buzzer signals the presence of such an 2. Incorrect wiring to battery positive or negative
alarm. terminals.
5. Drive motors speed is limited to 800; over 3. Verify if battery is still in good conditions.
temperature alarms are signalled by. buzzer 4. Replace the logic.
activation.
6. Pump motor speed is limited to 800; buzzer Minimum battery voltage
signals the presence of such an alarm.
7. No effects on system performance. 1. Eye alarm code: 2
2. Display alarm code: F1
3. Alarm level: 1
NOTICE 4. Alarm cause: battery voltage, measured by an
If more than one faulty condition is detected, internal circuit, is lower than following levels :
Compact displays shows alarm code referring to a. 24 V , in case of systems working at 36 V
the most serious one (the one characterized by b. 24 V , in case of systems working at 48V
lower alarm level).

Following section gives useful suggestions covering

a wide range of possible faults, listing
corresponding alarm cause identified by its alarm
code.

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In case of minimum battery voltage alarm, follow Eeprom alarm

these steps:
1. Incorrect wiring to battery, or corroded positive 1. Eye alarm code: 5
or negative terminals; 2. Display alarm code: F
2. Verify battery conditions: if the electrolyte inside 3. Alarm level: 1
is partially exhausted, an under voltage alarm 4. Alarm cause: eeprom does not work properly, or
can sometimes be detected from the controller; one of memorised values is out of correct limits.
even in case of low battery charge (<10%), high
current rates (i.e. both pump and drive motors In case of alarm follow this procedure:
working in full load conditions) could cause an 1. Load default values for eeprom variables, both
under voltage alarm, in particular in presence of using PC with serial communication software
an exhausted battery. and Instrument;
3. Replace the logic. 2. Replace the logic.

Pedal trimmer fault Pre-charge capacitors low voltage

alarm (Capacitors not charged)
1. Eye alarm code: 3
2. Display alarm code: F2 1. Eye alarm code: 6
3. Alarm level: 2 2. Display alarm code: A
4. Alarm cause: voltage measured on accelerator 3. Alarm level: 1
circuit exceeds the value calculated averaging 4. Alarm cause: voltage level of pre-charge
calibration and reachable voltages; moreover, capacitors is less then 70 % of nominal battery
start switch seems to be open. level.
It could happen, in example, if the inverter is
In case of such an alarm, follow these working with main breaker open.
troubleshooting steps : Capacitors voltage decreases cause energy spent
1. Verify if the potentiometer initial set-up is to keep motors in motion.
correct; if not, repeat calibration procedure. (You
can use both PC with serial com-munication In case of alarm follow this procedure:
software and Instrument). 1. Verify if main breaker coil and power terminals
2. Verify if the following 68 ways connector are in good conditions;
terminals are correctly wired to their 2. Verify if supply lines power fuse is damaged;
correspondent inputs in potentiometer circuit: 3. Verify if main breaker coils are correctly wired to
a. K1-14 (5 V) their correspondent inputs :
b. K1-15 (ground) a. K1-18 (positive terminal)
c. K1-10 (pedal input A) b. K1-19 (negative terminal)
d. K1-5 (pedal input B) 4. Replace main breaker;
3. In case of correct wiring, replace the 5. Replace logic.
potentiometer itself.
4. Replace logic

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Inverter desaturation or overcurrent Pump motor inverter overtemperature

alarm
1. Eye alarm code: 10
1. Eye alarm code: 2. Display alarm code E3:
8 for right drive motor power module 3. Alarm level: 6
24 for pump motor power module 4. Alarm cause: the inverter temperature
25 for left drive motor power module (measured with a temperature probe), exceeds
2. Display alarm code: 100 °C
F3 for right drive motor power module
F4 for pump motor power module In case of alarm follow this procedure:
F5 for left drive motor power module 1. Alarm could be caused by ineffective tem-
3. Alarm level: 1 perature dissipation. Verify thermal coupling
4. Alarm cause: actual current exceeds limits between inverter block and aluminium plate,
929A and between aluminium plate and truck ballast.
The presence of a correct amount of thermal
In case of alarm follow this procedure: grease in the coupling is essential to ensure an
1. With such an alarm present when you turn on efficient heat exchange;
lift truck, disconnect the power cable between 2. Replace cable connecting the output CN4 of the
the malfunctioning inverter and the logic to the pump inverter;
corresponding motor (first, turn off the system, 3. If temperature readings seem too high in
of course). function of total time interval of lift truck using,
replace pump inverter causing the alarm. You
If turning lift truck on again, alarm is not active, can read temperature measures using
then: “Instrument Panel” display or “EYE”
1. Replace the cable connecting logic and inverter. communication software.
2. Replace the inverter; 4. Replace logic.
3. Replace logic.

If turning lift truck on again, alarm is active,

then :
1. Replace the inverter;
2. Replace the motor.

Inverter capacitors pre-charge too fast

1. Eye alarm code: 9

2. Display alarm code: A
3. Alarm level: 1
4. Alarm cause: pre-charge capacitors voltage
increases too fast when you turn the system on.

In case of too fast pre-charge alarm, follow this

procedure:
1. Replace main breaker.
2. Replace cable connecting the CN1 output of the
logic with the corresponding
3. Inverter;
4. Replace the inverter connected with the
CN1output of control board replace logic

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Capacitors too charged on start Drive motor overtemperature

1. Eye alarm code: 11 1. Eye alarm code: 13 for right drive motor
2. Display alarm code: A 19 for left drive motor
3. Alarm level: 1 2. Display alarm code: E4 for right drive motor
4. Alarm cause: when you turn on the system, E5 for left drive motor
capacitors are not completely discharged by 3. Alarm level: 5
pump motor. In fact, if you turn suddenly on the 4. Alarm cause: The measure of drive motor
lift truck, after a turning off, capacitors voltage temperature exceeds 155 °C.
level is too high. You have to discharge them
before checking the presence of any fault (both In case of alarm, follow this procedure:
of capacitors and of logic) Presence of alarm with cold motors:
5. With a handheld multimeter (in resistance
In case of alarm follow this procedure: operating mode) you have to measure a
1. Verify the correctness of wiring from pump resistance of about 10 kohm between the two
motor and relative inverter; wires of the temperature sensor (execute the
2. Replace cable connecting the output CN4 of the measure at ambient temperature of 25°C). If the
logic with the corresponding inverter; measure is not correct it is necessary to replace
3. Replace the inverter connected to CN4 output the temperature sensor.
of the logic; 6. Disconnect the temperature sensor and check
4. Verify if main breaker has stuck closed the wiring insulation between signal wire and
terminals: in such a case replace it; ground wire (towards logic);
5. Replace the cable connecting the output CN1 of 7. Replace logic.
the logic to the right drive motor inverter: a
defective cable could give a wrong measure for Presence of alarm with hot motors:
capacitors voltage; 1. If temperature value (you can read it from
6. Replace the right drive inverter; Instrument or via PC) seems correct, verify if
7. Replace logic. fans (if present) work properly; fault is caused
by on inefficient motor refreshing, or by
Low battery alarm operating out of nominal maximum ranges.

1. Eye alarm code: 12

2. Display alarm code: EL
3. Alarm level: 3
4. Alarm cause: battery voltage level is lower than
minimum charge value expected, referred to
table 2 (for 36V system) and table 3 (for 48V
system) in Instrument user manual.

In case of low battery alarm, follow this

procedure:
1. Measure battery voltage with a tester and, if
different from the value reported on Instrument,
replace logic;
2. Otherwise recharge battery.

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Pump motor overtemperature Main breaker fault

1. Eye alarm code: 14 1. Eye alarm code: 17

2. Display alarm code: E6 2. Display alarm code: 17
3. Alarm level: 6 3. Alarm level: 1
4. Alarm cause: The measure of pump motor 4. Alarm cause: overcurrent on main breaker coil.
temperature exceeds 155 °C.
In case of alarm follow this procedure:
In case of alarm follow this procedure: 1. Replace main breaker
Presence of alarm with cold motors: 2. Replace logic.
1. With a handheld multimeter in resistance
operating mode, you have to measure about Watchdog timer alarm
10kohm at ambient temperature of 25°C
between the two wires of the temperature 1. Eye alarm code: 18
connector. If the measure is not correct it is 2. Display alarm code: F
necessary to replace the temperature sensor. 3. Alarm level: 1
2. Disconnect the temperature sensor and check 4. Alarm cause: improper communication between
the wiring insulation between signal wire and DSPs present on logic, or/and defective logic.
ground wire (towards logic);
3. Replace logic. In case of alarm follow this procedure:
1. Using EYE program interface, try to program
Presence of alarm with hot motors: control board flash memory;
1. If temperature value (you can read it from 2. Replace logic.
Instrument panel or via PC) seems correct,
verify if the motor stator case are clean

Motor current offset alarm

1. Eye alarm code: 15 for right drive motor

16 for left drive motor
36 for pump motor
2. Display alarm code: F6 for right drive motor
F7 for left drive motor
F8 for pump motor
3. Alarm level: 1
4. Alarm cause: non-zero phase currents when
you turn lift truck on.

In case of motor current offset alarm, follow this

procedure:
1. Replace the cable connecting the
malfunctioning inverter to logic.
2. Replace inverter.
3. Replace logic.

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Drive motor inverter overtemperature Alarm on 5 V encoder voltage

1. Eye alarm code: 20 for right drive motor 1. Eye alarm code: 37
22 for left drive motor 2. Display alarm code: FH
2. Display alarm code: E1 for right drive motor 3. Alarm level: 1
E2 for left drive motor 4. Alarm cause: K1-14 terminal (5 V output)
3. Alarm level: 5 voltage is lower than 4.3 V.
4. Alarm cause: inverter temperature, measured
with a probe, exceed 100 °C. In case of alarm follow this procedure:
1. Verify if 5 V output is grounded, cause an
In case of alarm follow this procedure: incorrect encoder wiring.
1. Alarm could be caused by ineffective tem- 2. Verify if 5 V output is grounded, cause any
perature dissipation; verify thermal coupling encoder malfunction. In that case, replace the
between inverter block and aluminium plate and defective one.
between aluminium plate and truck ballast. The 3. Replace logic.
presence of the correct amount of thermal
grease in the coupling are essential to ensure a Alarm on 12 V output voltage
correct heat exchange;
2. Replace cable connecting the output CN1 ( for 1. Eye alarm code: 38
right drive motor) or CN2 ( for left drive motor) 2. Display alarm code: FA
of the logic to the corresponding inverter; 3. Alarm level: 1
3. If temperature readings seem too high in 4. Alarm cause: K1-11 terminal (12 V output)
function of total time interval of lift truck using, voltage is lower than 10.5 V.
replace inverter unit causing the alarm. You can
read temperature measures using ˈInstrument In case of an alarm on 12 V output voltage,
Panel” display or “EYE” communication follow this procedure:
software. 1. Verify if 12 V output is grounded, cause an
4. Replace logic. incorrect wiring to:
a. Steering sensor
Serial communication alarm b. Buzzer
c. Display
1. Eye alarm code: 21 2. Replace defective device;
2. Display alarm code: F 3. Replace logic.
3. Alarm level: 1
4. Alarm cause: error in serial communication Pump motor commands active on
between the two DSP; DSP present on main
start
board make a mutual software control, to insure
fast diagnosis of such a fault.
1. Eye alarm code: 50
2. Display alarm code: FL
In case of alarm follow this procedure:
3. Alarm level: warning; while the fault condition is
1. Program pump and drive DSP again; maybe
active, all pump motor functions (except hydro
software present in flash memory was corrupted.
functions) are inhibited.
2. Replace logic.
4. Alarm cause: you find a pump motor command
active when you turn your system on.

In case of alarm follow this procedure:

1. Before starting to operate, turn off any active
command (both levers and switches);
2. Be sure that lift, tilt and auxiliary command
switches, are not active;
3. Replace logic.

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Alarm of over temperature of motors Wrong start

1. Eye alarm code: 1. Eye alarm code: 64

61 (overtemperature of right motor) 2. Eye alarm code: EE
62 (overtemperature of left motor) 3. Alarm level: warning; main breaker is opened
65 (overtemperature of pump motor) and pump and drive motors are stopped.
4. Alarm cause: when you start working, you find
2. Display alarm code: accelerator pedal pressed or a forward/ reverse
61 (overtemperature of right motor) switch active.
62 (overtemperature of left motor)
65 (overtemperature of pump motor) In case of alarm follow this procedure:
3. Alarm level: 1 1. Verify if a switch was active or the pedal
4. Alarm cause: The motors temperature pressed, when you turn on the lift truck;
(measured with a temperature probe) exceeds 2. Verify if start, forward or reverse switches are
165 °C stuck close;
3. Verify if pedal circuit voltage exceeds 1/3 its
In case of alarm, follow this procedure: maximum range (measured in Volt);
Presence of alarm with cold motors: 4. Replace logic.
1. With a handheld multimeter (in resistance
operating mode) you have to measure a Encoder alarm
resistance of about 10 kohm between the two
wires of the temperature sensor (execute the 1. Eye alarm code:
measure at ambient temperature of 25°C). If the 74 (for right drive motor encoder)
measure is not correct it is necessary to replace 75 (for left drive motor encoder)
the temperature sensor. 2. Display alarm code:
2. Disconnect the temperature sensor and check Fc (for right drive motor encoder)
the wiring insulation between signal wire and Fd (for left drive motor encoder)
ground wire (towards logic); 3. Alarm level: 1
3. Replace logic. 4. Alarm cause: an encoder channel is
disconected, and motor is working.
Presence of alarm with hot motors:
4. If temperature value (you can read it from In case of alarm follow this procedure:
Instrument or via PC) seems correct, verify if 1. Verify if the encoder is correctly connected to:
fans (if present) work properly; fault is caused a. Motor itself
by on inefficient motor refreshing, or by b. Ground : K1- 15 terminal
operating out of nominal maximum ranges. c. + 5 V: K1- 14 terminal
d. A channel:
Seat switch open on start K1- 37 terminal (for right drive motor
encoder)
1. Eye alarm code: 63 K1- 17 terminal (for left drive motor encoder)
2. Display alarm code: EE (flashing) e. B channel:
3. Alarm level: warning; main breaker is opened K1- 36 terminal (for right drive motor
and pump and drive motors are stopped. encoder)
4. Alarm cause: when you start working, you find K1- 16 terminal (for left drive motor
seat switch open, or, after the main breaker is encoder);
closed, the seat switch remains opened for at 2. If correctly wired, replace the encoder;
least “seat switch delay” s. 3. Replace logic.

In case of alarm follow this procedure:

1. Verify if seat switch is defective;
2. Replace logic.

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Alarm of motor thermal sensor CRC(Cyclic Redundancy Check) fault

alarm
1. Eye alarm code:
77 (for right drive motor thermal sensor) 1. Eye alarm code: 83
78 (for left drive motor thermal sensor) 2. Display alarm code: 83
79 (for pump motor thermal sensor). 3. Alarm level: 1
2. Display alarm code: 4. Alarm cause: Faulty eeprom or mismatching
77 (for right drive motor thermal sensor) software release.
78 (for left drive motor thermal sensor)
79 (for pump motor thermal sensor). In case of alarm follow this procedure:
3. Alarm level: 7 1. Restore eeprom with EYE application software,
4. Alarm cause: Temperature difference between using the “RESTORE” item present in main
any two of the 3 motors results greater than page
70 °C 2. If alarm is still present, replace logic.

In case of alarm, follow this procedure: Bank CRC(Cyclic Redundancy Check)

1. Verify if the wiring is correct;
restored
2. Replace the sensor;
3. Replace logic.
1. Eye alarm code: 84
2. Display alarm code: 84
Alarm of a inverter temperature 3. Alarm level: warning
thermal sensor 4. Alarm cause: there was an eeprom restore,
caused by a CRC(Cyclic Redundancy Check)
1. Eye alarm code: alarm.
80 (for right drive motor power module thermal
sensor) In case of alarm follow this procedure:
81 (for left drive motor power module thermal 1. Switch on the system and the turn it on again
sensor)
82 (for pump motor power module thermal Steering sensor alarm
sensor)
2. Display alarm code: 1. Eye alarm code: 91
80 (for right drive motor power module thermal 2. Display alarm code: F9
sensor) 3. Alarm level: 5
81 (for left drive motor power module thermal 4. Alarm cause: steer circuit voltage is out of
sensor) nominal range.
82 (for pump motor power module thermal
sensor) In case of a steering sensor alarm follow this
3. Alarm level: 7 procedure:
4. Alarm cause: Temperature difference between 1. Verify correctness of wiring with :
any two of the 3 inverters is greater than 70¶C. a. K1-11 (12 V),
b. K1-15 (ground)
In case of alarm follow this procedure: c. K1- 62 (steering sensor input);
1. Check the wiring connecting logic and inverter; 2. If correctly wired, replace steering sensor;
2. Replace the inverter; 3. Replace logic.
3. If alarm is still present, replace logic.

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Capacitors pre-charge too slow

1. Eye alarm code: 98

2. Display alarm code: A
3. Alarm level: 1
4. Alarm cause: pre-charge capacitor voltage
grows too slowly, when you turn on the system.

In case of alarm follow this procedure:

1. Replace cable connecting the CN1 output of the
logic with the corresponding inverter
2. Replace the inverter connected with CN1 output
of the logic;
3. Replace logic;

Capacitors pre-charge timeout

1. Eye alarm code: 99

2. Display alarm code: A
3. Alarm level: 1
4. Alarm cause: pre-charge capacitor voltage
grows too slowly, when you turn on the system.

In case of alarm follow this procedure:

1. Replace cable connecting the CN1 output of the
logic with the corresponding inverter
2. Replace the inverter connected with CN1 output
of the logic;
3. Replace logic;

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Troubleshooting Problem List

Problem # TROUBLESHOOTING PROBLEM LIST EYE Abrm code
1 CVMS does not work, with no lift truck operation. -
2 CVMS does not work at all, lift truck operation normal. -
Display protion of CVMS seems random or wrong.
3 -
Lift truck operation normal.
4 Direction switch circuit defect. -
5 Lift sensor circuit defect. -
6 Tilt switch circuit defect. -
7 Auxiliary switch circuit defect. -
8 Park brake switch circuit defect. -
9 Pedal brake switch circuit defect. -
10 Display="E1", The max speed of drive motor is reduced. 20
11 Display="E2", The max speed of drive motor is reduced. 22
12 Display="E3", The max speed of pump motor is reduced. 10
13 Display="E4", The max speed of drive motor is reduced. 13
14 Display="E5", The max speed of drive motor is reduced. 19
15 Display="E6", The max speed of pump motor is reduced. 14
Display="EL", The max speed and max torque of drive &pump motor is reduced
16 12
to minimum value
17 Display="EE", No left truck operation 64
18 Display="EE(Flash)", No left truck operation 63
19 Display="F", No lift truck operation 5, 18, 21
20 Display="F0", No Left truck operation 1
21 Display="F1", No Left truck operation 2
22 Display="F2", No left truck operation 3
23 Display="F3", No left truck operation 8
24 Display="F4", No left truck operation 24
25 Display="F5", No left truck operation 25
26 Display="F6", No left truck operation 15
27 Display="F7", No left truck operation 16
28 Display="F8", No left truck operation 36
29 Display="F9",The max speed of pump motor is reduced. 91
30 Display="FH", No left truck operation 21, 37
31 Display="Fc", No left truck operation 74
32 Display="Fd", No left truck operation 75
33 Display="FA", No Left truck operation 38
34 Display="FL", No left truck operation 50
35 Display="A", No lift truck operation 6, 9, 11, 98, 99
36 Display="60", Lift truck operation 60
37 Display="61", No lift truck operation 61
38 Display="62", No lift truck operation 62
39 Display="65", No lift truck operation 65
40 Display="77", Lift truck operation 77
41 Display="78", Lift truck operation 78
42 Display="79", Lift truck operation 79
43 Display="80", Lift truck operation 80
44 Display="81", Lift truck operation 81
45 Display="82", Lift truck operation 82
46 Display="83", No lift truck operation 83
47 Display="84", No lift truck operation 84
48 Display does work normal,Lift truck operation abnormal. -

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PROBLEM 1

Central Vehicle Monitoring System (CVMS) does not work,

with no lift truck operation.

POSSIBLE CAUSE

Battery polarity not correct on control panel;

Key fuse open circuit; Key switch defect; Logics

CHECKS

With battery connected, check control panel battery connections for correct polarity.
Positive battery connected to line fuse and negative battery connected to B - on controller.
If correct If not correct

Push horn button to close horn switch. Make correction to cables.

Horn work Horn does not work

Disconnnect battery and check the horn

fuse for continuity.

Continuity No continuity

Check for shorts and

replace fuse.

Close key switch. Measure voltage on K1-23 Measure voltage on horn (wire #90) with
depressing the horn switch.
Battery Less than Check continuity the negative wire of horn
Voltage Battery voltage
Battery Less than
Voltage Battery voltage
Replace logics.

Replace horn or Repair or replace

check the battery. open wire
Replace key switch or repair broken wire
#23 between key switch and K1-23.

G 51
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PROBLEM 2

CVMS does not work at all, lift truck operation normal.

If only part of CVMS works.

POSSIBLE CAUSE

Open circuit from K1-11 to CVMS connector PIN 8;

Open circuit from K1-15 to CVMS connector PIN 7;
CVMS defect.

CHECKS

Make sure CVMS connector is connected to CVMS.

If connected If not connected

Connect multimeter positive lead to K1-11 Connect CVMS connector.

and negative lead to K1-15.
Measure the voltage.

12 volts 0 volts

Replace the CVMS module. Repair or replace open circuit between 5 wires
from controller to CVMS.

G 52
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PROBLEM 3

Display portion of the CVMS seems random or wrong.

Lift truck operation normal.

POSSIBLE CAUSE

Connection defect; Wiring defect; Logics defect;

Display defect.

CHECKS

Check continuity from logics to CVMS connector

Continuity No continuity

Check for shorts to battery negative from Repair or replace open wire.
PIN 1 to PIN 8 on CVMS connector.

No shorts found Shorted

Replace logics. Repair or replace shorted wire.

G 53
G

PROBLEM 4

Direction switch circuit defect.

POSSIBLE CAUSE

Direction switch defect; Wiring to direction

switch defect;

CHECKS

Disconnect the battery.

Disconnect K-1 connector.
Check continuity from K1-15 to K1-9 harness connector;
With direction lever in forward should have a closed circuit,
in neutral should be open.

Check OK Check failed

Check continuity from K1-15 to K1-8. Disconnect direction switch connector.

With direction lever in reverse should have a Check continuity between Pin2 and Pin3.
closed circuit, in neutral should be open.
Check OK Check failed
Check OK Check failed

Replace logics. Repair or replace direction switch.

Check wiring for open/short circuits Check wiring for open/short circuits
between harness connector K1-15 and K1-8. between harness connector K1-15 and K1-9.
Repair any open/short circuit found. Repair any open/short circuit found.

Replace direction switch.

G 54
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PROBLEM 5

Lift sensor circuit defect.

POSSIBLE CAUSE

Lift sensor not adjusted properly or defective;

Lift sensor wiring defect; Valve control card (board)
defect; Logics defect.

CHECKS

Retest lift sensor circuit in self diagnostics.

Circuit passes Circuit fails

ˈDiagnostics” “Diagnostics”

Perform Problem 11,12 Tilt or Key switch ON.

auxiliary circuit defect. Connect multimeter negative lead to Pin5
and the positive lead to Pin2 and Pin7.
Measure the voltage.

Battery Voltage 0 Volt

Measure voltage from Pin7 to Pin5 battery Repair or replace broken wire
negative as the lever is pulled and released. between Pin1 and Pin5(wire #15)
or between Pin5 and battery
9.0 to 11.0 and .2v 9.0 to 11.0 and .2V negative(-).
Measured NOT measured

Replace logics. Replace Valve Control Card.

NOTE: Before lift truck is placed into operation, connect tilt and auxliary switches and verify proper adjustment.
Refer to Valve Control Card Adjustments.

G 55
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PROBLEM 6

Tilt switch circuit defect.

POSSIBLE CAUSE

Tilt switch defect; Wiring defect; Logics defect.

CHECKS

Disconnect K1 connector. Pull tilt lever to maximum.

Check continuity from K1-54 to K1-15.
Continuity No continuity

Replace logics. Check continuity of wire #54.

Continuity No continuity

Check continuity from K1-54 of wire #54 to Repair or replace wire.

Pin5 of valve board connector.

Continuity No continuity

Replace tilt switch. Repair or replace wire.

G 56
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PROBLEM 7

Auxiliary switch circuit defect.

POSSIBLE CAUSE

Wiring defect; Auxiliary switch defect; Logics defect.

CHECKS

Disconnect K1 connector. Pull auxiliary lever to maximum.

Check continuity from K1-15 to K1-38 or K1-57.

Continuity No continuity

Replace logics. Check continuity of wire #38 or #57.

Continuity No continuity

Check continuity from K1-15 of wire #15 to Repair or replace wire.

Pin1 of valve board connector.

Continuity No continuity

Replace AUX switch. Repair or replace wire.

G 57
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PROBLEM 8

Park brake switch circuit defect.

POSSIBLE CAUSE

Wiring defect; Park brake switch defect; Logics defect.

CHECKS

Disconnect K1 connector. Release park brake lever.

Check continuity from K1-6 to K1-15.

Continuity No continuity

Replace logics. Check continuity of wire #6.

Continuity No continuity

Check continuity from K1-6 of wire #6 Repair or replace wire.

to terminal of park brake switch.

Continuity No continuity

Replace park brake switch. Repair or replace wire.

G 58
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PROBLEM 9

Pedal brake switch circuit defect.

POSSIBLE CAUSE

Wiring defect; Pedal brake switch defect; Logics defect.

CHECKS

Disconnect K1 connector. Push down the brake pedal.

Check continuity from K1-15 to K1-48.

Continuity No continuity

Replace logics. Check continuity of wire #48.

Continuity No continuity

Check continuity from K1-15 of wire Repair or replace wire.

#15 to Pin2 of pedal brake switch.

Continuity No continuity

Replace park brake switch. Repair or replace wire.

G 59
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PROBLEM 10

Display=“E1”
The max speed of drive motor is reduced.

POSSIBLE CAUSE

Right drive inverter overtemperature.

Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

Check temperature of right If repeat occur, check right drive

inverter seem too high motor current draw or operating
cycle for excessive ramp climbing
You can read temperature or towing
measures using “COMPACT”
display or “EYE” software.

Yes No

Replace right inverter Repair logic board

G 60
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PROBLEM 11

Display=“E2”
The max speed of drive motor is reduced.

POSSIBLE CAUSE

Left drive module overtemperature.

Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

Check temperature of left If repeat occur, check right drive

inverter seem too high motor current draw or operating
cycle for excessive ramp climbing
You can read temperature or towing
measures using ”COMPACT”
display or “EYE” software.

Yes No

Replace right inverter Repair logic board

G 61
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PROBLEM 12

Display=“E3”
The max speed of pump motor is reduced.

POSSIBLE CAUSE

Pump module overtemperature.

Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

Check temperature of pump

inverter seem too high

You can read temperature

measures using “COMPACT”
display or “EYE” software.

Yes No

Replace pump inverter Repair logic board

G 62
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PROBLEM 13

Display=“E4”
The max speed of drive motor is reduced.

POSSIBLE CAUSE

Right drive motor overtemperature.; Drive

motor thermal sensor defect;
Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a If repeat occur, check right drive

resistance about 10kohm motor current draw or operating
between two wires of the cycle for excessive ramp climbing
thermal sensor of right drive. or towing

Yes No

Replace control board. Replace thermal sensor.

G 63
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PROBLEM 14

Display=“E5”
The max speed of drive motor is reduced.

POSSIBLE CAUSE

Left drive motor overtemperature.; Drive

motor thermal sensor defect;
Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a If repeat occur, check left drive

resistance about 10kohm motor current draw or operating
between two wires of the cycle for excessive ramp climbing
thermal sensor of left drive. or towing

Yes No

Replace control board. Replace thermal sensor.

G 64
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PROBLEM 15

Display=“E6”
The max speed of pump motor is reduced.

POSSIBLE CAUSE

Pump motor overtemperature.;

Pump motor thermal sensor defect;
Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a

resistance about 10kohm
between two wires of the
thermal sensor of pump motor.

Yes No

Replace control board. Replace thermal sensor.

G 65
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PROBLEM 16

Display=“EL”
The max speed and max torque of drive &
pump motor is reduced to minimum value.

POSSIBLE CAUSE

Battery discharged; Logic defect

CHECKS

Connect battery, turn on the key switch, close seat switch

And measure voltage from B+ to B- on controller.
Voltage must be greater than 34.5V at 36V system.
Voltage must be greater than 45V at 48V system.

Voltage OK Voltage low

With key on, seat switch and main Check battery

contactor closed, measure voltage connection ;
at BATT+ on controller.
Charge or replace battery
Battery voltage

Replace logic

G 66
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PROBLEM 17

Display=“EE”
No left truck operation

POSSIBLE CAUSE

Static Return to Off(SRO) circuit activated by

Improper operation sequence; Direction switch defect
Accelerator linkage not fully release.
Accelerator control defect; Logic defect.

CHECKS

Check SRO by release of accelerator, release park brake

Move the direction lever to neutral, reselect direction and
Press the accelerator.

No change Lift truck operation ok

Check accelerator, Inform operator of correct start-up

F/R switch. procedure. Also, that the direction lever
must be left in neutral when leaving the
truck.

If no faulty component is
found, replace logics.

G 67
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PROBLEM 18

Display=“EE(Flashing)”
No left truck operation

POSSIBLE CAUSE

No operator in seat; Seat switch defect;

Open wire.

CHECKS

Disconnect K1 connector Check continuity from wire #7

to wire #15 .Should be closed circuit when seat is
pressed on and open circuit when seat release.

No continuity Check OK

Disconnect seat switch connector. Replace logics

Push on the seat and check the
continuity across the seat switch.

Continuity No continuity

Replace seat switch

Check wiring for open circuits

Between harness #7 and #15.
Repair any open circuit found.

G 68
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PROBLEM 19

Display=“F”
No lift truck operation

POSSIBLE CAUSE

Improper communication between DSP,

Logic board defect.

CHECKS

Install eye software; pedal, steering, lift resetting.

OK If not ok

Normal operating. Replace logic board

G 69
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PROBLEM 20

Display=“F0”,
No Lift truck operation.

POSSIBLE CAUSE

Battery voltage exceeds 63V.

Failed logic

CHECKS

Disconnect battery, measure voltage at battery

connector terminal.

More than 63V Not

Battery discharge Replace logic board

G 70
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PROBLEM 21

Display=“F1”
No Lift truck operation.

POSSIBLE CAUSE

Battery voltage is lower than 24V.

Failed logic

CHECKS

Disconnect battery, measure voltage at battery

connector terminal.

Lower than 24V Not

Battery charge Replace logic board

G 71
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PROBLEM 22

Display=“F2”
No lift truck operation.

POSSIBLE CAUSE

Accelerator sensor failure. Accelerator

connector disconnect. Failed logic.

CHECKS

Check Accelerator connector.

Connector Disconnector

Accelerator resetting; value must be lower Connect Accelerator

than Min 0.2V and higher than Max 3.0V connector.
(You can read temperature measures
using “COMPACT” display or “EYE”
software.)

Continuity No continuity

Replace logic board

G 72
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PROBLEM 23

Display=“F3”
No lift truck operation.

POSSIBLE CAUSE

Right drive inverter overcurrent.

(Actual current exceeds limit 340A)
Failed logic board or inverter.

CHECKS

Key switch off and on again.

Display=F3 Drive operation normal

Measure the resistance between U,V,W terminals and

shell on the right motor

Open 0 ohm

Replace right drive motor

Measure the resistance between U,V,W terminals on

the right inverter.

About 4.4 Mohm 0 ohm or open

Replace logic board Replace right inverter

G 73
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PROBLEM 24

Display=“F4”
No lift truck operation.

POSSIBLE CAUSE

Left drive inverter overcurrent.

(Actual current exceeds limit 340A)
Failed logic board or inverter.

CHECKS

Key switch off and on again.

Display=F4 Drive operation normal

Measure the resistance between U,V,W terminals and

shell on the left motor

Open 0 ohm

Replace left drive motor

Measure the resistance between U,V,W terminals on

the left inverter.

About 4.4 Mohm 0 ohm or open

Replace logic board Replace left inverter

G 74
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PROBLEM 25

Display=“F5”
No lift truck operation.

POSSIBLE CAUSE

Pump inverter overcurrent.

(Actual current exceeds limit 410A)
Failed logic board or inverter.

CHECKS

Key switch off and on again.

Display=F5 Drive operation normal

Measure the resistance between U,V,W terminals and

shell on the pump motor

Open 0 ohm

Replace pump motor

Measure the resistance between U,V,W terminals on

the pump inverter.

About 4.4 Mohm 0 ohm or open

Replace logic board Replace pump inverter

G 75
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PROBLEM 26

Display=“F6”
No lift truck operation.

POSSIBLE CAUSE

Disconnect cable(CN1) from right inverter to

right drive motor; Right inverter defect.
Logic board defect.

CHECKS

Check the cable connecting from right invert to right drive motor.

Connection Disconnection

Connect cable (CN1)

Check current of right inverter when you turn on the lift truck.
(You can read temperature measures using ”COMPACT”
display or “EYE” software.)

Zero current Non zero current

Replace logic board Replace right inverter

G 76
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PROBLEM 27

Display=“F7”
No lift truck operation.

POSSIBLE CAUSE

Disconnect cable(CN2) from left inverter to

Left drive motor; Left inverter defect.
Logic board defect.

CHECKS

Check the cable connecting from left inverter to left drive motor.

Connection Disconnection

Connect cable (CN2)

Check current of left inverter when you turn on the lift truck.
(You can read temperature measures using ”COMPACT”
display or “EYE” software.)

Zero current Non zero current

Replace logic board. Replace left inverter.

G 77
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PROBLEM 28

Display=“F8”
No lift truck operation.

POSSIBLE CAUSE

Disconnect cable(CN4) from pump inverter to

Pump motor; Pump inverter defect;
Logic board defect.

CHECKS

Check the cable connecting from pump inverter to Pump motor.

Connection Disconnection

Connect cable (CN4)

Check current of pump inverter when you turn on the lift truck.
(You can read temperature measures using ”COMPACT”
display or “EYE” software.)

Zero current Non zero current

Replace logic board. Replace pump inverter

G 78
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PROBLEM 29

Display=“F9”
The max speed of pump motor is reduced.

POSSIBLE CAUSE

Steering angle sensor fault.

Wiring defect.

CHECKS

Check continuity from K-11(12V) to pin3.; Check continuity from

K-15(Gnd) to pin1.; Check continuity from K-62(out) to pin2.
Check the housing.

No continuity Continuity

Repair or replace wire Replace angle sensor

G 79
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PROBLEM 30

Display=“FH”
No lift truck operation.

POSSIBLE CAUSE

5V Encoder not ok.

Voltage of K1-14 terminal is lower than 4.3V

CHECKS

Measure voltage from K1-14 terminal of encoder to

K1-15(GND) terminal of encoder.

5 voltage Lower than 4.3 voltage

Replace logic board Replace defective one

(Right/left, pump encoder)

G 80
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PROBLEM 31

Display=“Fc”
No lift truck operation.

POSSIBLE CAUSE

Right drive motor encoder defect.

An encoder channel is disconnected and
motor is working.

CHECKS

Check right drive motor encoder connection.

If correct If not correct

Check continuity from K1-36 to Connect correctly encoder

encoder (pin 4) and from K1-36 connector
to encoder (pin 3).

If correct If no correct

Replace logic board Repair or replace wire

G 81
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PROBLEM 32

Display=“Fd”
No lift truck operation.

POSSIBLE CAUSE

Left drive motor encoder fail.

An encoder channel is disconnected and
motor is working.

CHECKS

Check left drive motor encoder connection.

If correct If not correct

Check continuity from K1-16 to Connect correctly encoder

encoder (pin 4) and from K1-17 connector
to encoder (pin 3).

If correct If no correct

Replace logic board Repair or replace wire

G 82
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PROBLEM 33

Display=“FA”
No Lift truck operation.

POSSIBLE CAUSE

12V output not ok.

Voltage of K1-11 terminal is lower than 10.5V.

CHECKS

Measure voltage from K1-11 to K1-15.

12 voltage Lower than 10.5 voltage

Replace logic board Replace defective device one

(Instrument, steering sensor)

G 83
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PROBLEM 34

Display=“FL”
No lift truck operation.

POSSIBLE CAUSE

Valve control card defect, Lift setting fault.

Tilt and Auxiliary switchs
Closed before key switch on.

CHECKS

Key switch on. Seat switch on.

Measure voltage at K1-50

Over minimum setting voltage No voltage

Resetting lift calibration. Replace logic board

Ok If not ok

Adjust valve board

Ok If not ok

Replace valve board

G 84
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PROBLEM 35

Display=“A”
No lift truck operation

POSSIBLE CAUSE

Capacitor discharge; Main contactor fail,

Logic board fail

CHECKS

Key switch off and on again. Key switch off and

measure resistance of the main contactor.

About 85~90˟ Other resistance

Check continuity from K-18 to Replace main contactor

main contactor terminal.

Check continuity from K-19 to

main contactor terminal.

Continuity No continuity

Check power fuse Repair or replace wire

Normal Open

Replace logic board Replace logic board

G 85
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PROBLEM 36

Display=“60”
Lift truck operation

POSSIBLE CAUSE

Battery miss matching;

Logic board fail

CHECKS

Check battery voltage at the each system.

(36V system must use 36V battery, 48V system must
use 48V battery)

OK If not ok

Replace logic board Replace battery

G 86
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PROBLEM 37

Display=“61”
No lift truck operation

POSSIBLE CAUSE

Right drive motor overtemperature (over 165°C);

Drive motor thermal sensor defect ;
Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a If repeat occur, check right

resistance about 10kohm drive motor current draw or
between two wires of the operating cycle for
thermal sensor of right drive. excessive ramp climbing
Yes No or towing

Replace control board Replace thermal sensor

G 87
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PROBLEM 38

Display=“62”
No lift truck operation

POSSIBLE CAUSE

Left drive motor overtemperature (over 165°C);

Drive motor thermal sensor defect ;
Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a If repeat occur, check left

resistance about 10kohm drive motor current draw or
between two wires of the operating cycle for
thermal sensor of right drive. excessive ramp climbing
Yes No or towing

Replace control board Replace thermal sensor

G 88
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PROBLEM 39

Display=“65”
No lift truck operation

POSSIBLE CAUSE

Pump motor overtemperature (over 165°C);

Pump motor thermal sensor defect ;
Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a If repeat occur, check

resistance about 10kohm pump motor current draw
between two wires of the or operating cycle for
thermal sensor of right drive. excessive ramp climbing
Yes No or towing

Replace control board Replace thermal sensor

G 89
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PROBLEM 40

Display=“77”
Lift truck operation

POSSIBLE CAUSE

Thermal sensor wire of right drive motor open.

Logic board fail

CHECKS

Check continuity from K1-15 to thermal sensor pin1.

Check continuity from K1-58 to thermal sensor pin2.

Continuity No continuity

Replace thermal sensor. Repair or replace wire.

G 90
G

PROBLEM 41

Display=“78”
Lift truck operation

POSSIBLE CAUSE

Thermal sensor wire of right drive motor open.

Logic board fail

CHECKS

Check continuity from K1-15 to thermal sensor pin1.

Check continuity from K1-59 to thermal sensor pin2.

Continuity No continuity

Replace thermal sensor. Repair or replace wire.

G 91
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PROBLEM 42

Display=“79”
Lift truck operation

POSSIBLE CAUSE

Thermal sensor wire of right drive motor open.

Logic board fail

CHECKS

Check continuity from K1-15 to thermal sensor pin1.

Check continuity from K1-60 to thermal sensor pin2.

Continuity No continuity

Replace thermal sensor. Repair or replace wire.

G 92
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PROBLEM 43

Display=“80”
Lift truck operation

POSSIBLE CAUSE

Wrong right drive inverter Thermal sensor.

Logic board fail

CHECKS

Check temperature of right drive power unit.

(You can read temperature measures using ”COMPACT”
display or “EYE” software)

Normal Abnormal

Replace logic board. Replace right drive inverter

G 93
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PROBLEM 44

Display=“81”
Lift truck operation

POSSIBLE CAUSE

Wrong left drive inverter thermal sensor

Logic board fail

CHECKS

Check temperature of left drive inverter.

(You can read temperature measures using “COMPACT”
display or “EYE” software)

Normal Abnormal

Replace logic board. Replace left drive inverter

G 94
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PROBLEM 45

Display=“82”
Lift truck operation

POSSIBLE CAUSE

Wrong pump inverter thermal sensor

Logic board fail

CHECKS

Check temperature of pump inverter.

(You can read temperature measures using “COMPACT”
display or “EYE” software)

Normal Abnormal

Replace logic board. Replace pump inverter

G 95
G

PROBLEM 46

Display=“83”
No lift truck operation

POSSIBLE CAUSE

Faulty eeprom or mismatching software release

Logic board fail

CHECKS

Restore eeprom with EYE application, Eye software install

Normal Still problem

Replace logic board.

G 96
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PROBLEM 47

Display=“84”
No lift truck operation

POSSIBLE CAUSE

CRC alarm

CHECKS

System turn off/on again.

Eye software reinstall.

Normal Still problem

Replace logic board.

G 97
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PROBLEM 48

Display does work normal

Lift truck operation abnormal.

POSSIBLE CAUSE

Encoder defect;
Logic board fall; Wiring or cable defect’

CHECKS

In case detected motor is operating, RPM of defected motor

is about zero(0) rpm and current of defected motor is waving
from 100A to 400A.
You can see diagnostic mode of display panel.
Parameter No.
15, 16, 17 : Right drive motor current,
18, 19, 20 : Left drive motor current,
21, 22, 23 : Pump motor current
2 : Right drive motor rpm
4 : Left drive motor rpm
9 : Pump motor rpm
Or you can see test mode of eye program by Pc.

OK If not ok

Check cables (U, V, W) connecting

from motor to inverter.

Connection Disconnection

Replace logic board Connect cable

Check wiring for open circuit.

Wiring No.#14, #15, #36, #37 of right motor and #14, #15, #16, #17 of
left motor and #14, #15, #28, #29 of pump motor.
Check connection of encoder connector.

Connection Disconnection

Replace encoder Replace harness or repair

OK If not ok

Replace logic board

G 98
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PROBLEM 49

Display does work normal

Lift truck operation abnormal.

POSSIBLE CAUSE

Encoder defect;
Logic board defect’

CHECKS

RPM of defected motor is reducing and current of defected

motor is increasing.
(You can see diagnostic mode of display panel and eye
software.)

OK If not ok

Replace encoder Replace logic board

G 99
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System Tests and Adjustments Hydrometer

Test Equipments Hydrometers are usually available from any battery

supplier. Battery maintenance is a crucial par t of
maintaining the electric vehicle. The ability to
measure specific gravity and adjust the battery
discharge indicator to match battery manufacturers
specifications is an important part in the total
maintenance of the electric vehicle.
There are various pieces of electric truck test
equipment that DOOSAN recommends for all
service personnel. This equipment is available from
a number of world wide manufacturers and local
electronic suppliers. Contact your DOOSAN dealer
or the factory for further recommendations.

Handheld Multimeter
There are various pieces of electric truck test
equipment that DOOSAN recommends for all A digital multimeter that measures DC voltage,
service personnel. This equipments are available resistance, and has a diode tester, is required. It is
from a number of world wide manufactures and recommended that a high quality meter that is drop
local electronic suppliers. Contact your DOOSAN protected, or comes with a drop proof case, be
dealer or the factory for further recommendations. purchased. Autoranging features, fast becoming an
industry standard, are convenient for the service
personnel, but are not required for servicing the lift
truck. A variety of miniature test leads, alligator clips,
and needle probes are also useful, and some of
these usually come with the multimeter.

Clamp-on Current Probe

The electric lift truck testing and adjusting

procedures require the measurement of average
DC currents. Currents in excess of 600 amps may
be present, so a clamp-on meter that will exceed
this level is required. It is also highly recommeded
that a device that has a voltage output, as well as a
visible display, be used. This makes viewing and
adjusting currents from the operator's seat possible.
The jaws of the current probe should be able to
accept at least a 19mm (.75 inch) cable diameter.

G 100
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Electrical System Adjustment Lift Sensor

Parking Brake Switch 1. Disconnect the battery and discharge the head
capacitor.

The lift truck can move suddenly. Injury to

personnel or damage to the lift truck is possible. 1
Safely lift the drive wheels off the floor. Put 3
blocks of wood under the frame so both drive
wheels are free to turn. Keep away from drive
wheels that turn.

4
2

Lift Sensor Adjustment

(1) Lift Sensor(transducer) (2) Magnet. (3) Screw.
(4) Setscrew. (A) 1.0 mm (.039 in) Clearance.

NOTICE
Lift sensor may be damaged. Do not allow the
magnet (2) to make contact with the plastic
bracket when the lift lever is activated.
Parking Brake Switch Adjustment
(1) Switch. (2) Plate. (3) Bolts.
2. Loosen setscrew (4).
1. Close the seat switch and turn the key to ON.
3. Adjust screw (3) to make clearance (A) 1.0mm
2. Release the parking brake and put the truck in (.039 in) between lift sensor (1) and magnet (2)
forward. when the lift lever is activated fully (pulled all the
way back).
3. Reposition plate (2) so the switch (1) actuator is
against the bracket. Tighten bolts (3). 4. Tighten setscrew (4). Check lift sensor circuit.
The valve control card may need adjusting.
4. Engage the parking brake and the park brake
symbol will be displayed. Repeat the procedure 5. Set lift sensor initial setting.
until adjustment is correct. Refer to “Sensor Initial Setting”.

G 101
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Valve Control Card Adjustment

The lift truck can more suddenly. Injury to

personnel or damage to the lift truck is possible.
Safety lift the drive wheels off the floor. Put
blocks of wood under the frame so both drive
wheels are free to turn. Keep away from drive
wheels that turn.

1. Verify the lift sensor clearance is adjusted

correctly..

2. Disconnect all tilt and auxiliary switch 6. Pull the lift lever all the way back. More than
connectors. “10V (10000mV)” must be displayed..

3. Confirm and control the lift sensor's value using 7. If is not more than “10V (10000mV)”, adjust P2
the lift command value of the eye program's (2) clockwise until it is.
"test-pump" menu or parameter No.5 of
Instrument panel's diagnostic mode. 8. Release the lift lever and adjust P1
counterclockwise until less than “1V (1000mV)”
is displayed.

9. Repeat steps 9 and 10 until the lift sensor value

correct.

10. Set the lift sensor’s initial setting. Refer to

“Sensor Initial Setting”.

4. When lift lever is neutrality, the lift sensor's

value must be less than 1V (1000mV). And
when pulled lift lever by maximum, the lift
sensor's value must be more than 10V
(10000mV).

5. If lift sensor's value is not correct, regulate valve

control card's potentiometer according to next
time order.

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Tilt and Auxiliary Switches

Because each tilt and auxiliary switch can turn on

the pump motor, it is recommended that only one be
connected to start with. After adjusting the first
switch proceed with the next one.

1. Disconnect the battery and discharge the head

capacitor. Disconnect all but one switch
connector.

Tilt and Auxiliary Switch Adjustment

(1) Screw. (2) Screws.

2. With valve spool in neutral position, loosen

screws (2) and adjust screw (1) to center the
switch roller on cam.

3. After adjusting switch in or out to obtain correct

switch point, tighten screws (1) and (2) to lock
switch into position.

4. Connect the battery, close the seat switch and

turn the key to on. Readjust switch if needed, so
that the pump motor turns on before the control
valve opens.
This must be adjusted for each lever direction
(pushed or pulled).

5. Connect the next switch and repeat this

proccdure.

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Instrument Panel
LCD Instrument panel shows information about
system main analogue and digital parameters,
as follows:
1. Truck speed
2. Park brake insertion
3. Steering angle
4. Seat switch closure
5. Maintenance period expiry
6. Low speed insertion
7. Battery charge level
8. Energetic operating mode

To find further technical data and useful information

about Compact display refer its own user manual.

We briefly mention two important functions:

Diagnostic Mode
This operating mode enables you to test main
analogical and digital signals managed by your
system.

Parameter Calibration
This procedure allows to adjust the main operating
parameters of the system.
You can enter calibration mode before working as
usual with your lift truck.
It is also possible to update the parameters with
default values.
(Notice this way you loose calibration values).

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Instrument Panel Relation between battery charge level and

number of visualized bars

BATTERY CHARGE
DISPLAY INDICATION
LEVEL
No segments Discharged battery
1 flashing segment 10 %
1 segment 20 %
2 segments 30 %
3 segments 40 %
4 segments 50 %
5 segments 60 %
6 segments 70 %
7 segments 80 %
8 segments 90 %
The display gives the following information about 9 segments Full charged battery
the operating state of the system:
Table 1 : Case of a generic system

Lift truck speed (expressed in kmh or

mph)
BATTERY CHARGE BATTERY VOLTAGE
LEVEL [V]
Handbrake active, indicated by the Discharged battery Voltage < 34.5 V
warning symbol 10 % 34.5 V ~ 35.1 V
20 % 35.1 V ~ 35.5 V
Safety contact open, indicated both by 30 % 35.5 V ~ 35.9 V
EE blinking message visualized in 40 % 35.9 V ~ 36.2 V
timemeter area and by relative symbol 50 % 36.2 V ~ 36.5 V
60 % 36.5 V ~ 36.8 V
With any directional switch active and safety contact 70 % 36.8 V ~ 37.1 V
still open, lift truck can’t be moved, even after seat 80 % 37.1 V ~ 37.4 V
switch is closed; in such a case, after safety contact 90 % 37.4 V ~ 37.6 V
is closed, the symbol disappears. Full charged battery Voltage > 37.6 V
Table 2 : Case of an 36V system
EE code disappears only after active directional
switch is turned off.
BATTERY CHARGE BATTERY VOLTAGE
Time meter or, otherwise, odometer
LEVEL [V]
Steering angle Discharged battery Voltage < 45.6 V
10 % 45.6 V ~ 46.4 V
Maintenance time expiry, indicated by 20 % 46.4 V ~ 47.0 V
warning symbol 30 % 47.0 V ~ 47.6 V
40 % 47.6 V ~ 48.2 V
Slow speed operation, indicated by 50 % 48.2 V ~ 48.7 V
60 % 48.7 V ~ 49.2 V
Lift truck speed level, range from 0 70 % 49.2 V ~ 49.7 V
(NO speed) to 9 (MAXIMUM speed) 80 % 49.7 V ~ 50.1 V
segment, as in symbol 90 % 50.1 V ~ 50.4 V
Full charged battery Voltage > 50.4 V
Battery level, indicated by a 9
Table 3: Case of a 48V system
segments symbol.

In following Table 1, you can read the generic

relation between battery charge level and number of
visualized bars . See Table 2 in case of an 36V
system and Table 3 in case of a 48V system.
Display signals with alarm code EL the fact battery
is completely discharged.

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Lift truck operation mode Otherwise symbol indicates, as usual,

selected operating mode.
Pressing E-S-H button, you can set
energetic operating mode for your system. Notice:As usual, if lift truck is moving,
symbol indicates speed level.
This function is enabled using EYE menu named
Calibration – ESH, to select desired operating mode. Notice: If active mode is one of L1, L2 or L3
In particular you can choose between E-S-H or limitations and you change operating mode
PROGRAMMABLE WORKING : (from PROGRAMMABLE WORKING to E-
S-H), software automatically sets operating
- Pressing E-S-H (economic, standard, high) button, mode to economic one.
you change energetic mode and update related
parameters with a value, corresponding to Alarm message, indicated by an alpha-numerical
selected operating mode, that operator can’t code in the display area where usually lift truck
modify. speed appears.
- Pressing PROGRAMMABLE WORKING you can See Table 5 for the meaning of alarm codes.
manage 3 further options (limit 1, limit 2, and limit
3). You can set parameters value, that are Over-temperature alarm, indicated by the
expressed in per cent of high energetic mode; warning light In case the temperature of
changing active limitation (among L1, L2 or L3), power transistors exceeds the warning limit, alarm
related per cent data are used to calculate actual code and relative light blink.
parameters value. Moreover, in case temperature exceeds the alarm
limit, (or it stays between the two thresholds for 30 s
Notice:Percent values can be modified only with or more), the symbols stop blinking and became still.
EYE Calibration – E-S-H menu.
Hour meter separation point, usually blinking, stops
Notice:Pressing PROGRAMMABLE WORKING in following cases:
you can manage economic, standard or - Seat switch open.
high operating mode too. - Serial communication between display and control
unit not active
COMPACT display shows different symbols in - Main breaker open
function of selected energetic mode:
Turning your lift truck on, some alphanumeric codes,
- E-S-H management disabled: no symbol visible for 3 seconds, appear where usually is
visualised. visualized speed indicator symbol; those codes help
- E-S-H management enabled: active to identify system in use (see Table 6).
mode is indicated by symbol Where usually is visualized hour meter, on left side
- PROGRAMMABLE WORKING appears feed voltage in VDC, and on right side,
management enabled: in case you have chosen maximum weight industrial truck can lift, expressed
one of L1, L2 or L3 operating modes, and lift truck in quintals.
is stopped, one of the segments of speed indicator
symbol (see Table 4 ) blinks to show selected SYSTEM IN USE CODE
energetic mode 4 Wheels (BX) C0
3 Wheels (BT) C1
DISPLAY Table 6
VISUALISATION OPERATINGMODE
(from symbol left side)
1st segment L1 (Limit 1)
5th segment L2 (Limit 2)
9th segment L3 (Limit 3)
Table 4 : selected energetic mode

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ALARM
ALARM DESCRIPTION LED Indicators
CODE
F Wrong eeprom + watch dog timer On left side, COMPACT display has four LED
F0 Maximum battery voltage indicators which, when switched on, give
F1 Minimum battery voltage information as follows:
F2 Pedal trimmer fault
F3 Drive right module desat/overcurrent Alarm message; red colour LED
F4 Drive left module desat/overcurrent
F5 Pump module Desat/overcurrent Message of lamps; green colour LED
F6 Drive right motor current offset (future)
F7 Drive left motor current offset
F8 Pump motor current offset Indicator lights activated; green colour
F9 Steer sensor fault LED (future)
FH 5V encoders not ok
Fc Drive right motor Encoder Warning of seat belt ; red colour LED (future)
Fd Left right motor Encoder
FE 24V out not ok
FA 12V out not ok
Notice: Alarm LED is managed as follows:
FL Pump inputs on at start
- Display normally working: LED lights up
E1 Drive right module Overtemperature
briefly switching on /off your system
E2 Drive left module Overtemperature
E3 Pump module overtemperature - Display not communicating with control
E4 Drive right motor Overtemperature board: after 3 seconds from the moment in
which the communication stops, alarm
E5 Drive left motor Overtemperature
LED brightens
E6 Pump motor Overtemperature
EE Wrong start - Display board microprocessor not working:
EL Low battery voltage alarm LED brightens.
EE (flashing) Seat switch opened
Alarm on pre-charge circuit of
A
internal capacitors G
AL Key retention G
17 Main breaker fault G
60 Battery / inverter mismatch G
Drive Right Motor G
61
Overtemperature(over 165°C) G
Drive Left Motor G
62
Overtemperature(over 165°C) G
65
Pump Motor Overtemperature(over G
165°C) G
77
Wrong right traction motor thermal G
probe G
Wrong left traction motor thermal G
78
probe G
79 Wrong pump motor thermal probe G
Wrong right traction module thermal G
80
probe G
Wrong left traction module thermal G
81
probe G
82 Wrong pump module thermal probe G
83 CRC fault G
84 Bank CRC restored G
Table 5 : Meaning of alarm codes
G
G
G
G
G
G

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Display Keys Utilization

As you can see in Fig.1, on right side of display front there are four keys: E-S-H, UP (TURTLE), DOWN and
ENTER.

The function of each of them is described as E-S-H key

follows: With this key, you can modify the device operating
condition, in a circular sequence, as described in
ENTER key Table 7 :
1. When you switch your device on, this key,
pressed for 3 consecutive seconds, allows Current Working Working Condition After
entering both to parameter calibration and to Condition the Key Pressure
diagnostic mode.
Economic (E) Standard (S)
2. During usual operations, this key, pressed for 3
consecutive s, allows you to access merely to Standard (S) High (H)
diagnostic mode. High (H) Limitation 1 (L1)
Limitation 1 (L1) Limitation 2 (L2)
Remember that if the display is operating in Limitation 2 (L2) Limitation 3 (L3)
diagnostic mode during typical operations, you can
Limitation 3 (L3) Economic (E)
exit this procedure pressing once ENTER key.
Moreover, ENTER key is used to confirm the new Table 7
value of the parameter in calibration procedure.
Notice: You can modify system operating modes
only after enabling their management with
UP key EYE applicative software.
1. Pressing of this key, in calibration and
diagnostic mode, you increase the number of Notice: Pressing this key when you are in
the parameter displayed. diagnostic mode you can see a circular list
2. In calibration phase, you increase the numeric of 10 latest alarms.
value of the parameter displayed.

TURTLE key
Remember that pressing this key you can toggle
between slow running and normal working condition
(if the lift truck is already in speed limitation mode).

DOWN key
1. Pressing of this key, in calibration and
diagnostic mode, you decrease the number of
the parameter displayed.
2. In calibration phase, you decrease the numeric
value of the parameter displayed.

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Parameter Calibration The parameter number (blinking) appears on the

display area usually reserved to lift truck speed and
This chapter describes the way to adjust the main alarm codes, and its value is shown in the time-
operating parameters of the system. meter area.
You inhibit the access to this menu with EYE Moreover, appear a number of segments
submenu named “Lift truck setup”. proportional to the parameter value.
To calibrate your parameters, read following
instructions: If you see that the numeric data have been modified
in the time meter area, it means that the value of the
To enter calibration mode: chosen parameter has really been updated into
1. Switching on your system, press ENTER key control board memory.
until a blinking “0” (zero) appears.
2. Press UP key: the entry to the chosen Notice: Remember that parameter values can be
calibration mode is indicated by “C”; this symbol modified only by discrete increments.
persists until the first parameter will be selected. See Table 8 for the list of all adjustable
parameters and relative minimum available
Notice: If calibration procedure is not enabled variations.
using EYE “Lift truck setup” menu, UP key
pressure has no effect.

Notice: You can exit this operating mode only

switching off your system.

To execute the calibration:

1. Select parameter 10 using UP and DOWN keys,
and confirm your choice pressing ENTER key.
2. Use UP and DOWN keys to set at 4 the value of
this parameter, and confirm with ENTER key.
3. Repeat the above operations to fix parameter
17 value at 6 Notice: it doesn’t matter if you first
modify parameter 10 and then 17, or vice versa.

Only after this procedure, you allow operator to

change the value of other parameters:
1. Select the parameter to change, using UP or
DOWN key; press ENTER to confirm.
2. Now adjust the value of the selected parameter
with UP and DOWN keys; confirm your choice
typing ENTER key.

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<48V>

No Parameter Unit Minimum Default Maximum Remark

5 Deceleration steering ramp 1 rpm/s 0 800 5000
6 Deceleration steering ramp 2 rpm/s 0 6 10
9 Battery reset value V*10 464 470 501
10 First parameter for calibration enable
11 Seat switch delay s 1 3 9
12 Chat time s 3 6 9
13 Hydro time s 10 10 20
Disable = 0 (Default)
14 Maintenance time inserting enable digit
Enable = 1
17 Second parameter for calibration enable
18 Steering clockwise mV 500 10,300 11,500
19 Steering anticlockwise mV 500 1,200 11,500
20 Steering middle mV 500 6,300 11,500
23 Minimum accelerator mV 200 1,000 4,500
24 Maximum accelerator mV 2,000 3,600 5,000
26 Stop on slop timer s 1 5 10
OFF = 0 (Default)
27 Lift priority for speed reference digit
ON = 1
OFF = 0 (Default)
30 Buzzer on forward direction digit
ON = 1
OFF = 0 (Default)
31 Buzzer on reverse direction digit
ON = 1
32 Maximum lift mV 3,000 11,500 12,000
33 Minimum lift mV 0 2,300 12,000
34 Middle lift mV 1,000 2,750 12,000
35 Starting temperature of motor's Fans ଇ 55 85 155
36 Weight of the load on the forks kg 0 0
Future
37 No load pressure bar·10 0 0 2200 option
38 Load pressure bar·10 0 0 2200
39 Limitation temperature ଇ 100
41 Drive maximum current % 20 100 100
42 Forward maximum speed rpm 1,000 4,500 4,500
43 Reverse maximum speed rpm 1,000 4,500 4,500
44 Drive limitation maximum speed rpm 500 2,000 2,500
46 High lift switch 1 drive max speed rpm 0 1,000 4,500 Option
47 Steer limitation drive maximum speed rpm 400 1,000 2,000
48 Acceleration ramp rpm/s 400 1,100 2,000
49 Inversion ramp rpm/s 400 1,300 2,000
50 Release ramp rpm/s 400 900 2,000
51 Pedal brake ramp rpm/s 400 1,200 2,000
52 Creep speed rpm/s 100 300 2,000
53 Diameter of drive tyres mm 300 451 600
54 High lift switch 2 drive max speed rpm 0 1,000 4,500 Option
59 Partial release ramp rpm/s 10 50 500
61 Lift maximum current % 20 100 100
62 Auxiliary maximum current % 10 65 100
63 Lift maximum speed rpm 1,500 2,950 4,500

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64 Tilt speed rpm 500 900 2,000

65 Auxiliary 1 function speed rpm 500 900 2,800
66 Auxiliary 2 function speed rpm 500 900 2,800
67 Auxiliary 3 function speed rpm 500 900 2,800
68 Lift minimum speed rpm 500 700 1,500
69 High lift 1 switch lift max speed rpm 0 1,500 3,500 Option
70 Hydro speed rpm 400 500 800
71 Hydro idle speed rpm 200 300 500
72 Pump acceleration ramp rpm/s 1,000 7,000 10,000
73 Pump deceleration ramp rpm/s 1,000 7,000 10,000
74 High lift 2 switch lift max speed rpm 0 1,500 3,500 Option
75 High lift 1 switch tilt max speed rpm 0 500 2,000 Option
76 High lift 2 switch tilt max speed rpm 0 500 2,000 Option
77 High lift 1 switch side shift max speed rpm 0 500 2,800 Option
78 High lift 2 switch side shift max speed rpm 0 500 2,800 Option
79 High lift 1 switch auxiliary 2 function max speed rpm 0 500 2,800 Option
80 High lift 2 switch auxiliary 2 function max speed rpm 0 500 2,800 Option
83 High lift 1 switch auxiliary 3 function max speed rpm 0 500 2,800 Option
84 High lift 2 switch auxiliary 3 function max speed rpm 0 500 2,800 Option
Disable = 0 (Default)
94 Slow speed digit
Enable = 1
Normal = 0 (Default)
95 British unit digit
British unit = 1
96 Display brightness digit 0 5 8
Disable = 0
97 E-S-H enable digit
Enable = 1 (Default)
Timer meter = 0 (Default)
98 Time meter / Odometer on display digit
Odometer = 1
99 Maintenance time h 0 0 10,000

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<36V>

No Parameter Unit Minimum Default Maximum Remark

5 Deceleration steering ramp 1 rpm/s 0 800 5,000
6 Deceleration steering ramp 2 rpm/s 0 6 10
9 Battery reset value V*10 344 356 373
10 First parameter for calibration enable
11 Seat switch delay s 1 3 9
12 Chat time s 3 6 9
13 Hydro time s 10 10 20
Disable = 0 (Default)
14 Maintenance time inserting enable digit
Enable = 1
17 Second parameter for calibration enable
18 Steering anticlockwise mV 500 10,300 11,500
19 Steering clockwise mV 500 1,200 11,500
20 Steering middle mV 500 6,300 11,500
23 Minimum accelerator mV 200 1,000 4,500
24 Maximum accelerator mV 2,000 3,600 5,000
26 Stop on slop timer s 1 5 10
OFF = 0
27 Lift priority for speed reference digit
ON = 1 (Default)
OFF = 0 (Default)
30 Buzzer on forward direction digit
ON = 1
OFF = 0 (Default)
31 Buzzer on reverse direction digit
ON = 1
32 Maximum lift mV 3,000 11,500 12,000
33 Minimum lift mV 0 2,300 12,000
34 Middle lift mV 1,000 2,750 12,000
35 Starting temperature of motor's Fans ଇ 55 85 155
36 Weight of the load on the forks (option) kg 0 0
Future
37 No load pressure (option) bar·10 0 0 2,200
option
38 Load pressure (option) bar·10 0 0 2,200
39 Limitation temperature ଇ 100
41 Drive maximum current % 20 100 100
42 Forward maximum speed rpm 1,000 3,800 3,800
43 Reverse maximum speed rpm 1,000 3,800 3,800
44 Drive limitation maximum speed rpm 500 2,000 2,500
46 High lift switch 1 drive max speed rpm 0 1,000 3,800 Option
47 Steer limitation drive maximum speed rpm 400 1,000 2,000
48 Acceleration ramp rpm/s 400 1,100 2,000
49 Inversion ramp rpm/s 400 1,300 2,000
50 Release ramp rpm/s 400 900 2,000
51 Pedal brake ramp rpm/s 400 1,200 2,000
52 Creep speed rpm/s 100 300 2,000
53 Diameter of drive tyres mm 300 451 600
54 High lift switch 2 drive max speed rpm 0 1,000 3,800 Option
59 Partial release ramp rpm/s 10 50 500
61 Lift maximum current % 20 100 100
62 Auxiliary maximum current % 10 65 100
63 Lift maximum speed rpm 1,500 2,950 4,500

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64 Tilt speed rpm 500 900 2,000

65 Auxiliary 1 function speed rpm 500 900 2,800
66 Auxiliary 2 function speed rpm 500 900 2,800
67 Auxiliary 3 function speed rpm 500 900 2,800
68 Lift minimum speed rpm 500 700 1,500
69 High lift 1 switch lift max speed rpm 500 500 4,500 Option
70 Hydro speed rpm 400 500 800
71 Hydro idle speed rpm 200 300 500
72 Pump acceleration ramp rpm/s 1,000 7,000 10,000
73 Pump deceleration ramp rpm/s 1,000 7,000 10,000
74 High lift 2 switch lift max speed rpm 0 1,500 3,500 Option
75 High lift 1 switch tilt max speed rpm 0 500 2,000 Option
76 High lift 2 switch tilt max speed rpm 0 500 2,000 Option
77 High lift 1 switch side shift max speed rpm 0 500 2,800 Option
78 High lift 2 switch side shift max speed rpm 0 500 2,800 Option
79 High lift 1 switch auxiliary 2 function max speed rpm 0 500 2,800 Option
80 High lift 2 switch auxiliary 2 function max speed rpm 0 500 2,800 Option
83 High lift 1 switch auxiliary 3 function max speed rpm 0 500 2,800 Option
84 High lift 2 switch auxiliary 3 function max speed rpm 0 500 2,800 Option
Disable = 0 (Default)
94 Slow speed digit
Enable = 1
Normal = 0
95 British unit digit
British unit = 1 (Default)
96 Display brightness digit 0 5 8
Disable = 0
97 E-S-H enable digit
Enable = 1 (Default)
Timer meter = 0 (Default)
98 Time meter / Odometer on display digit
Odometer = 1
99 Maintenance time h 0 0 10,000

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Sensor Initial Setting Default Setting

In case that initial settings of sensors are not It is also possible to update the parameters with
performed accordingly, the machine performance default values.
can be lowered.
So, in the following cases, initial setting for each As for the procedure explained below, use UP,
sensor should be done to secure the correct DOWN and ENTER keys to set parameter 10 value
machine performance. to 5 and parameter 17 value to 2. Once more, the
order you adopt to change the two parameters is
- Replacing Logic not important.
- Updating flash memory(Update EEPROM) or The loading of default data is indicated by the
Resetting EEPROM symbols d S (default set);
- Replacing or adjusting Sensor
- Default Setting Notice: All parameters whose value is related to
selected energetic operating mode
STEERING SENSOR (parameter 13): (economic, standard, high, limitation 1,
Enter diagnostic mode to visualize steering sensor limitation 2, limitation 3) are updated with
voltage. default values corresponding to the active
Minimum value calibration: turn wheels completely one.
on left and read sensor voltage value from display; Pressing E-S-H key on display, and
enter calibration mode and set parameter 19 to the selecting a different working mode, you
value measured. immediately change the value of all
parameters related. Such parameters, as
Maximum value calibration: turn wheels completely well as their default values, are listed in
on right and read sensor voltage value from display; Table 10 (*)
enter calibration mode and set parameter 18 to the
value measured.
Econom Standar Hige
Parameter
ic Mode d Mode Mode
Central value calibration: put wheels straight and
Maximum drive
read sensor voltage value from display; enter 62 76 100
current
calibration mode and set parameter 20 to the value
Maximum forward
measured. 3000 3500 4500
speed [rpm]
ACCELERATOR SENSOR (parameter 11): Maximum reverse
3000 3500 4500
Enter diagnostic mode to visualize speed sensor speed [rpm]
voltage. Acceleration
20 20 20
Minimum value calibration: read from display sensor proportional to load
voltage corresponding to start switch closure (when Drive acceleration
700 800 1150
all segments dedicated to speed level visualisation ramp [rpm/s]
are active); enter calibration mode and set Lift maximum
70 80 100
parameter 23 to the value measured. current
Maximum lift speed
2500 2750 2950
Maximum value calibration: read sensor voltage [rpm]
value from display, with pedal completely pressed; Drive inversion ramp
600 900 1200
enter calibration mode and set parameter 24 to the [rpm/s]
value measured. Drive release ramp
600 850 1000
[rpm/s]
LIFT LEVER SENSOR (parameter 5): Table 10 (*) Its values are actually implemented into the
Enter diagnostic mode to visualize lift lever voltage. software of BX20 48 V lift truck
Minimum value calibration: read from display sensor
voltage with lift lever released; enter calibration Notice: Once default data have been loaded, if you
mode and set parameter 33 to the value read. further need to modify parameters value,
you have to switch your system off, before
Maximum value calibration: read from display entering calibration mode again.
sensor voltage with lift lever completely pressed;
enter calibration mode and set parameter 32 to the Notice: Parameter 94 is visualized only in case E-
value measured. S-H management procedure is enabled
Central value calibration: enter calibration mode and with relative EYE software calibration menu.
modify parameter 34.

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Diagnostic Mode
This operating mode enables you to test main
analogical and digital signals managed by your
system.

Enter diagnostic mode if you are switching on

your lift truck:
1. Press ENTER key (for 3 consecutive seconds)
until the symbol “0” lights up.

2. Press DOWN key to enter diagnostic mode; the

symbol “d” is visualized and it persists until the
first parameter has been selected.

Enter diagnostic mode if you are working as

usual with your lift truck:
1. Press ENTER key (for 3 consecutive seconds)
until symbol “d” appears; it will persist as long
as the first parameter has been selected.

After diagnostic operation mode has been enabled,

you can choose the parameter you want to analyse
using UP and DOWN keys (parameter number
increases using UP key and decreases with DOWN
key).

Here, in Table 11, you have a list of the parameters

you can analyze with their respective displaying
order :

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List of diagnostic

Parameter No. Description Unit

1 Right traction motor speed [rpm]
2 Right traction motor speed reference [rpm]
3 Left traction motor speed [rpm]
4 Left traction motor speed reference [rpm]
5 Lift voltage [mV]
6 Battery voltage [V·10]
7 Right traction motor power module temperature [ºC / °F]
8 Pump motor power module temperature [ºC / °F]
9 Pump motor speed [rpm]
10 Pump motor speed reference [rpm]
11 Accelerator potentiometer voltage [mV]
12 Accelerator second potentiometer voltage [mV]
13 Steering sensor voltage [mV]
14 Left traction motor power module temperature [ºC / °F]
15 Right traction motor phase current U [A rms]
16 Right traction motor phase current V [A rms]
17 Right traction motor phase current W [A rms]
18 Left traction motor phase current U [A rms]
19 Left traction motor phase current V [A rms]
20 Left traction motor phase current W [A rms]
21 Pump motor phase current U [A rms]
22 Pump motor phase current V [A rms]
23 Pump motor phase current W [A rms]
24 Right traction motor temperature [ºC / °F]
25 Left traction motor temperature [ºC / °F]
26 Pump motor temperature [ºC / °F]
27 Seat switch hour meter [h]
28 Drive motor hour meter [h]
29 Pump motor hour meter [h]
30 Seat switch [digit]
31 Park brake switch [digit]
32 Start switch [digit]
33 Reverse traction direction switch [digit]
34 Forward traction direction switch [digit]
35 Pedal brake switch [digit]
36 3 / 4 wheels selection switch [digit]
37 Side shift switch [digit]
38 Auxiliary 2 function switch [digit]
39 Auxiliary 3 function switch [digit]
40 High lift switch 1 [digit]
41 Tilt switch [digit]
42 High lift switch 2 [digit]
43 Main breaker command [digit]

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44 5V out [digit] [digit]

45 12V out [mV] [mV]
46 24V out [digit] [digit]
47 Buzzer command [digit] [digit]
48 Fans command [digit] [digit]
49 Drive right motor encoder channels -
50 Drive left motor encoder channels -
51 Drive pump motor encoder channels -
52 Lift pressure [bar · 10] [bar • 10]
53 Pressure sensor voltage [mV] [mV]
54 Weight of the load on the forks [kg] [kg]

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In diagnostic mode selected parameter is Accessing Stored Error Codes

visualized as follows:
1. In the area dedicated to speed and alarm The B15X-5/B16X-5 series of remembers the last
signals, appears parameter number ( flashing) 10 error codes. This is case the truck has had an
2. Its actual value is displayed in the area reserved intermittent problem, but the operator cannot
to the time meter. remember which code appeared on the display. Also
by analyzing the contents of the last 10 error codes,
In particular, if the selected parameter is: it may be possible to determine what sort of
Analogue input: Instrument panel shows the application the truck has been working in.
parameter value, expressed in the unit of Table 11
The stored error codes are accessed at diagnostic
Digital input: if the command activated by the mode by using E-S-H button.
operator corresponds to the parameter selected, the
value of the quantity is visualized. 1. Access the diagnostic mode.

Other way the symbol E (error) appears, except 2. Press E-S-H button. And then, the stored error
in following case: code will be shown with SMU hours, if any.
1. Seat switch active, for any selected digital input.
3. By pressing UP or DOWN key, more error
To exit diagnostic mode, press ENTER key again. codes can be shown.

Notice: If an alarm occurs when diagnostic mode is 4. Pressing again E-S-H key, you return to
enabled, and the system is working as diagnostic mode.
usual, display returns automatically to its
typical visualization mode.
However you can enter diagnostic mode
again, pressing ENTER key (for 3
consecutive s), until the last parameter
displayed before exiting is visualized.

If the selected parameter is a temperature, also

thermal alarm symbol is visualized.

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Eye Software Interface

EYE is a diagnostic software environment designed
to communicate with the forklift truck.

It can be run from a PC with serial or USB (1.x o2.x)

port. Connection between PC and Main harness’s
Serial Communication connector is characterized by
a 38,4 kBaud/s Baud-rate.

User can communicate with lift truck during working

operations, and can analyse on line main electrical
variables value/ status.

EYE software interface is user friendly and intuitive:

it guides the operator through the process of
parameter setting and is an effective data analysis
instrument, helping to identify faults and causes of
malfunctioning.

Following functions are in particular very useful:

1. Diagnostic: User can receive relevant control
data from the main board (such as current,
voltage, rpm, temperatures etc ) evaluating lift
truck performance and detecting any faulty
circuit
2. Calibration: User can transmit parameters and
settings to the truck in order to tune its
performance.
3. Flash memory software update

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To find further technical data and useful information about EYE software, refer its own user manual.

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General Information PC-Controller Communication

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Minimum Requirements Connect serial port of PC and harness with picture
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1. 350MHz Pentium class or higher
microprocessor
2. 128Mb or greater of RAM
3. Serial port or USB port

Serial port

USB port

4. Graphic card 1Mb

5. Windows 98SE/NT/XP/ME/2000
6. 1024x768 resolution video adapter
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Recommended Requirements
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1. 1GHz Pentium class or higher microprocessor
2. 512Mb of RAM
3. Serial port or USB port
4. Graphic card 2Mb
5. Windows 98SE/NT/XP/ME/2000
6. 1024x768 resolution video adapter
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Installation
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To install EYE software, complete following
steps:
1. Check computer requirements
2. Start Setup.exe application
3. Select destination path then press FINISH
4. At the end press OK and then reboot
5. You can create a short-cut of EYE.exe on
desktop

If there is an old release installed, you must uninstall

it.
To uninstall you must execute Setup.exe application
from CD and confirm any step

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Features
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If EYE software installation is successful, starting the application from Windows “Programs” Menu, or using short-
cut on desktop (Fig.1), you can access main menu (Fig.2).

Fig.1: Short-cut

Date: xx-xx-xx (Software version)

Fig.2: Main menu – operator mode

To quit application or exit a submenu, press ESC key or select Exit menu.
In case of any problems, refer to section 4 “TROUBLESHOOTING”.

WARNING
Some menus, items or calibration parameters described in this manual are optional lift truck functions: so
they could be not implemented.

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Main Menu
On left side, there are some notes about software release, operating mode and serial communication setting.
Below lift-truck picture, there are actual active alarms (code level and description);
In case of more alarms with the same priority level, the first occurred is visualized.

In operator mode, you can access following menus:

1. “Setup”
2. “Test”
3. “Data logging”
4. “Password”
5. “About”

Even before starting of serial communication between lift truck and PC (Fig.3), you can access “Setup”,
“Password” and “About” menus (Fig.4). In such a case some data field are missing.
In case of faults during a serial communication data flow, any submenu is aborted and main menu front panel is
reinitialized.

Fig.3: operator mode – serial communication faulty

Fig.4: About menu

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Password Insertion
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Fig.5: Password insertion

Selecting Password mode from menu-bar, you can access Supervisor mode (Fig.6) inserting the correct password
(Fig.5).
Contact EYE software developer to know correct password.

Fig.6: main menu – supervisor mode

In case wrong password insertion (Fig.7), following message becomes visible:

Fig.7: unauthorized user

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In Supervisor mode, you can access these further menus:

1. “Calibration”
2. “Flash”

“Password” menu disappears from menu-bar.

In case of faulty serial communication, main menu front panel is reinitialized as follows (Fig.8):

WARNING
“PANEL BLANK” message is used to distinguish case of not programmed flash memory, so Flash menu is
obviously active.

Fig.8: supervisor mode – communication faulty

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You can select active menus directly from main panel menu bar (any greyed menu is not accessible in that
moment); you can also access present sub panels with a further selection by a pop-up menu (Fig.9)

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Fig.9: Submenu selection

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Not Actual Software / Eeprom Crc Fault

A CRC alarm message is visualized both in case of failed EEPROM memory writing and of using a software
version without the CRC control procedure.
Pressing the visualized button, you can load in EEPROM default values: if you don’t execute this procedure,
calibration functions are inhibited. You have now to execute calibration procedure (see inverter manual).
A message signals also the presence of not actual software loaded on inverter panel.
In such a case you can access only basic EYE functions: some menus, for compatibility reasons, will be inhibited.

Submenus

Print function is accessible from many of listed submenus: you can send active front panel image to printer or
save it on file; in that case destination directory is <EYE PATH>\EYE\ images.

BEWARE: if more than one window is in use, only the one relative to the inner submenu is active and all others
work in background.
If you select a non active window, you can’t communicate\ interact with inverter panel.

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Configuration Menu (Setup)

Fig.10: Setup menu

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From setup menu (Fig.10) you can select communication serial port and image file format used by Print function.

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Test

This pop-up menu includes of following subjects:

1. “Drive” (Fig.11)
2. “Pump” (Fig.12)
3. “Battery” (Fig.13)
4. “Timers” (Fig.14)

Drive (Traction)

Fig.11: Drive menu

Following items appear in Drive menu front panel:

1. Accelerator pedal voltage
2. Pedal brake pressure (in bar)
3. Drive motors phase currents: you can select current phase from pop-up menu
4. Both modules temperature: you can select measure unit between °C and °F.
Temperature above 60°C is signalled by a red colour; temperature above 90°C is signalled by a flashing
display.
5. Steering angle in percent, using following criteria:
6. 0% steering completely on left
7. 50% straight wheels
8. 100% steering completely on right
9. Steering sensor voltage
10. Request RPM and motor speed for both motors, with an arrow signalling direction
11. Both motors temperature: you can select measure unit between °C and °F.
In case of an overheating alarm, the corresponding green led becomes red.
12. Active output command status
13. Steering switch status
14. Customizable input switch status
15. Start, forward and reverse switches status
16. Drive motors encoder diagnostic leds, both for A and B channel
17. Pedal brake, hand brake and seat switches status

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Pump

Fig.12: Pump menu

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Following items appear in Pump menu front panel:
1. Voltage on lift command circuit
2. Hydraulic lift circuit pressure
3. Pump motor current : you can select current phase from pop-up menu
4. Module temperature: you can select measure unit between °C and °F.
Temperature above 60°C is signalled by a red colour; temperature above 90°C is signalled by a flashing
display.
5. Request RPM and motor speed, with an arrow signalling direction
6. Motor temperature: you can select measure unit between °C and °F. In case of an overheating alarm, the
green led becomes red
7. Electrovalves output status
8. Customizable input switches status
9. Tilt, lift and high lift digital input status
10. Encoder diagnostic leds, both for A and B

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Battery

Fig.13: Battery menu

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Following items appear in Battery menu front panel:
1. Battery and inverter voltages
2. Battery charge level
3. Code, description and level of active more serious alarm for both microprocessors; if there is more than one
alarm of same level, the latest is visualized.
4. There is a chronological list of latest 10 alarms, with code, description, time and temperature. First listed alarm
is the first occurred.
Temperature value is obviously referred to faulty module or faulty motor (if there are no faulty modules or
motors, this is a no meaning data field).

With “Reset alarms” menu, you can reset alarm list.

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Timers

Fig.14: Timers menu

Following items appear in Timers menu front panel: total inverter working hours, drive motor and pump motor hour
meter.

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Calibration
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For safety, you can access all calibration menus only in Supervisor mode and with park brake on.
A confirmation is asked to quit a calibration menu without saving changes.
You can’t set a value out of fixed limits: the message “OUT OF LIMIT” signals a case like that.

By a pop-up menu, you can access following calibration functions:

1. “Battery“: Battery reset voltage calibration (Refer to page 125)
2. “Timers“: Timers calibration (Refer to page 126)
3. “Steering“: Steering sensor (Refer to page 127)
4. “Pedal“: Pedal accelerator calibration (Refer to page 128) (**)
5. “Lift“: Lift calibration (Refer to page 129)
6. “ESH“: E/S/H parameters calibration and limits (Refer to page 130)
7. “Steering parameters“: Steering parameters calibration (Refer to page 132)
8. “Program service“: Program service interval setting (Refer to page 133)
9. “Drive motor“: Drive motors parameters calibration (Refer to page 134)
10. “Pump motor“: Pump motors parameters calibration (Refer to page 135)
11. “Critical height switches“: Speed limits calibration in case of critical height (Refer to page 136)
12. “Weight sensor“: Weight sensor calibration (Refer to page 137) (*)
13. “Cab lift“: Cab lift speed calibration (Refer to page 138) (*)
14. “Timer reset“: Timers meters reset (Refer to page 139)
15. “Truck setup“: Some lift truck parameters setup (Refer to page 140) (*)
16. “Backing mode“: Slow mode calibration (Refer to page 141) (*)
17. “Load eeprom default“: EEPROM configuration (Refer to page 142)
18. “Paramters image”: Parameter store or Restore. (Refer to page 143)

(*): Optional menu

(**): Menu present in standard or optional version

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Battery calibration

Fig.15: Battery menu

In that menu front panel, you can find following data about battery reset voltage and discharged voltage:
description, actual value, new value you want to set, measure unit, default value, minimum and maximum settable
values.
You can execute following operations:

Load default value:

1. Press DEFAULT button ; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field too will be updated

Change actual value:

1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.

Discard changes:
1. Press CANCEL button; initial value will be restored in NEW data field
2. Press SAVE button and confirm; OLD data field too is restored with initial value
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Timers calibration

Fig.16: Timers calibration menu

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In that menu front panel, you can find following data about timer parameters: description, actual value, new value
you want to set, measure unit, default value, minimum and maximum settable values.
You can execute following operations:

Load default value:

1. Press DEFAULT button ; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields too will be updated

Change actual value:

1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.

Discard changes:
1. Press CANCEL button; initial values will be restored in NEW data fields
2. Press SAVE button and confirm; OLD data fields too are restored with initial values

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Steering sensor calibration

Fig.17: Steering calibration menu

There are following data about steering parameters: description, actual value, measure unit, default values,
minimum and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with steering sensor actual voltage.
You can execute following operations:

Load default value:

1. Press DEFAULT button; VALUE data fields will be automatically updated with default values

Change parameters value:

1. Select ANTICLOCK parameter
2. Turn steering completely anticlockwise
3. Press SAVE button and confirm
4. Select CLOCK parameter
5. Turn steering completely clockwise
6. Press SAVE button and confirm
7. Select MIDDLE parameter
8. Put wheels straight ahead
9. Press SAVE button and confirm

Discard changes:
1. Press CANCEL button; initial value will be restored in VALUE data fields

If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any
lift truck fault.

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Accelerator pedal calibration

Standard version

Fig.18: Menù di calibrazione del pedale

There are following data about accelerator parameters: description, actual value, measure unit, default values,
minimum and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with pedal sensor actual voltage.
You can execute following operations:

Load default value:

1. Press DEFAULT button; VALUE data field will be automatically updated with default value

Change parameters value:

1. Select MIN ACCELERATOR parameter
2. Slowly press accelerator pedal until START switch turns on
3. Press SAVE button and confirm
4. Select MAX ACCELERATOR parameter
5. Press completely accelerator pedal
6. Press SAVE button and confirm

Discard changes:
1. Press CANCEL button; initial value will be restored in VALUE data fields

If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any
lift truck fault.
In this window front panel there are 3 green leds, expressing actual state of forward, reverse and start switches.

Optional version

There is a second pedal sensor.

Calibration procedure is like standard one, except that START led present (Fig.18) turns ON only after software
verifies that the voltages on both pedal sensors are equal to Vmin + 0,5 V voltage, obtained slowly pressing
accelerator pedal.

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Lift calibration

Fig.19: Lift sensor calibration menu

There are following data about lift parameters: description, actual value, measure unit, default values, minimum
and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with lift sensor actual voltage.
You can execute following operations:

Load default value:

1. Press DEFAULT button; VALUE data fields will be automatically updated with default values

Change parameters value:

1. Select MIN LIFT parameter
2. Release lift command lever
3. Press SAVE button and confirm
4. Select MAX LIFT parameter
5. Press completely lift command lever
6. Press SAVE button and confirm
7. Select MIDDLE LIFT parameter
8. Press lift command lever to select start acceleration point for pump motor
9. If lift sensor actual value is inside permitted range, press SAVE button and confirm

Discard changes:
1. Press CANCEL button; VALUE data fields will be restored with initial values

If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any
lift truck fault.

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E/S/H parameters and L1, L2, L3 limits calibration

Fig.20: E/S/H calibration menu

In that menu front panel, you can find following data about E/S/H parameters: description, actual value, new value
you want to set, measure unit, default values for E, S, and H operating mode, settable per cent values for
parameters in L1,L2,L3 operating mode
You can execute following operations:

Select default value:

1. Press DEFAULT button ; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field too will be updated

Change actual value:

1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.

Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields too are restored with initial values

This calibration procedure is optional, and you can enable/disable it with the ESH button.
In any case, you can disable limits calibration section (L1, L2 and L3 parameters) with PROGRAMMABLE
WORKING button.

N.B.: if “programmable working” section is disabled, and you select one of L1, L2 or L3 operating modes,
a message will advise user and E operating mode will be forced .

With E_S_H, pop-up menu you can select one of lift truck possible energetic operating modes (Economic,
Standard and High); selected operating mode default values are so loaded on characteristic parameters.
The message in Fig. 21 appears if you have selected a different energetic mode using Compact display; pressing
OK button, parameters are updated loading new values from control board.

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Fig.21: Parameters externally changed
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If PROGRAMMABLE WORKING section is enabled, pressing MODIFY LIMITS button you enter Fig. 22 window;
you can now modify per cent values for L1, L2 and L3 limits, remembering that every single data change require
to be confirmed.

Fig.22: Percent parameters menu

In that menu front panel, there are data about L1, L2 and L3 parameters: description, measure unit, modifiable
values expressed in per cent, minimum and maximum settable values.
You can execute following operations:

Change actual value:

1. Insert new value
2. Confirm

If actually selected operating mode percent values are now modified, exiting to ESH calibration menu, user can
load new default values. Every parameter per cent value is referred to High mode data.

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Steering parameters calibration

Fig.23: Steering parameters calibration menu

In that menu front panel, you can find following data about steering parameters: description, actual value, new
value you want to set, measure unit, default values minimum and maximum settable values.
You can execute following operations:

Select default value:

1. Press DEFAULT button ; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields too will be updated

Change actual value:

1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.

Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields too are restored with initial values

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Program service calibration

Fig. 24: "Program service" menu

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To modify assistance interval, you have to enable apposite function.

Change actual value:

1. Set button INCREASE properly to select if increase or decrease service interval
2. Change assistance interval value using HOURS INCREASE pop-up menu
3. Press SAVE AND EXIT button and confirm

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Drive motor parameters calibration

Fig.25: Drive motors calibration

In that menu front panel, you can find following data about drive motor parameters: description, actual value, new
value you want to set, measure unit, default values minimum and maximum settable values, actual value in
percent.
You can execute following operations:

Select default value:

1. Press DEFAULT button; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; both OLD data fields and first 3 parameters will be updated

Change actual value:

1. Insert changed value in NEW data field (or modify one of first 3 parameters)
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field (or one of first 3 parameters) initial value is restored.

Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields and first 3 parameters are restored with initial values

First 3 parameters, for their particular meaning, are visualized and managed in a more user friendly way.

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Pump motor parameters calibration

Fig.26: Pump motor calibration menu

In that menu front panel, you can find following data about pump motor parameters: description, actual value, new
value you want to set, measure unit, default values minimum and maximum settable values, actual value in
percent.
You can execute following operations:

Select default value:

1. Press DEFAULT button; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields will be updated

Change actual value:

1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.

Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields are restored with initial values

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Critical height: speed limits calibration(Optional Menu)

Fig.27: Maximum speed calibration menu

You can set maximum speed of pump and drive motors in case of a fork height superior to critical one (that
condition is signalled by two switches present on lift truck forks)
In that menu front panel, you can find following data about critical maximum speeds: description, actual value,
new value you want to set, measure unit, default values minimum and maximum settable values, actual value in
percent.
You can execute following operations:

Select default value:

1. Press DEFAULT button; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields will be updated

Change actual value:

1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.

Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields are restored with initial values

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Weight sensor calibration (Optional Menu)

Fig.28: Fork weight calibration menu

In that menu front panel, you can find following data about parameters: description, actual value, measure unit,
default values, minimum and maximum settable values. Pressing SAVE button, visualized pressure value is saved
on actually selected parameter.
You can execute following operations:

Select default value:

1. Press DEFAULT button; VALUE data fields will be automatically updated with default value

Calibrate weight sensor:

1. Select NO LOAD parameter
2. Hoist lift truck forks till 50 cm height
3. Wait for 5 s
4. Press SAVE button and confirm to record weight sensor reading in case of no load on forks
5. Put on lift truck forks a known value load
6. Select LOAD parameter
7. Set, in weight data field, lifted load value
8. Hoist lift truck forks till 50 cm height
9. Wait for 5 s
10. Press SAVE button and confirm to record weight sensor reading in case of known load on forks

Discard changes:
1. Press CANCEL button; VALUE data fields will be restored with initial values

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Cab lift speed calibration (Optional Menu)

Fig.29: Cab lift calibration menu

In that menu front panel, you can find following data about cab lift speed: description, actual value, new value you
want to set, measure unit, default values minimum and maximum settable values.
You can execute following operations:

Select default value:

1. Press DEFAULT button; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field will be updated

Change actual value:

1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.

Discard changes:
1. Press CANCEL button; NEW data field will be restored with initial values
2. Press SAVE button and confirm; OLD data field are restored with initial values

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Timers reset

Fig.30: Timers reset menu

In that menu you can reset timers signalling lift truck working hours; remember that if you press that button, a
double confirmation is necessary.

This menu is use possibility developer.

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Lift truck setup (Optional Menu)

Fig.31: Lift truck setup menu

In that menu front panel, you can find following data: parameters description, actual status (ON or OFF), new
status you want to set, and default status.
You can execute following operations:

Select default value:

1. Press DEFAULT button; NEW data fields will be automatically updated with default status
2. Press SAVE button and confirm; OLD data fields will be updated

Change actual value:

1. Insert changed status in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial status is restored.

Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial status
2. Press SAVE button and confirm; OLD data fields are restored with initial status

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Backing mode parameters calibration (Optional Menu)

Fig.32: Backing mode calibration menu

In that menu front panel, you can find following data about backing mode parameters: description, actual value,
new value you want to set, measure unit, default values minimum and maximum settable values.
You can execute following operations:

Select default value:

1. Press DEFAULT button; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field will be updated

Change actual value:

1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.

Discard changes:
1. Press CANCEL button; NEW data field will be restored with initial values
2. Press SAVE button and confirm; OLD data field are restored with initial values

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Eeprom reset menu

That menu has two important functions:

1. In case of Eeprom alarm, you have to use complete EEPROM reset procedure.
2. If you have updated flash memory software, and you want to load default Eeprom configuration, you have to
use complete Eeprom reset; to maintain already calibrated values you can use partial EEPROM reset
procedure.

Pay attention that using complete reset procedure you loose already calibrated values.
Both procedures, in any case, don’t modify timers value and alarm history.

Partial EEPROM reset:

1. Press PARTIAL LOAD EEPROM button
2. Give a confirmation to load default values

Fig. 33: Eeprom configuration menu

Complete EEPROM reset:

1. Press TOTAL LOAD EEPROM button
2. Give a confirmation to load default values
3. Give a further confirmation (Fig. 34)

Fig. 34: Further confirmation

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Parameters Image menu

Fig 35: Parameters image menu

In that menu, You can store and restor about calibration parameters except Lift, pedal, steering setting valure.

Parameter Store
1. Press Export button
2. Store calibration parameters

Parameter Restore (other trucks)

1. Press Import button
2. Restore calibration parameters

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Data Logging

With that menu (Fig. 36) you can save on file the values of a certain number of variables with a certain frequency;
the resulting file is logging.out, saved in <EYE PATH>\EYE\out directory.

Fig. 36: Data logging menu

Data acquisition procedure is following:

1. Select Nmax, the number of variables you want to save
2. Select the variables whose value you want to record, with apposite pop-up menu
3. You can modify sampling period, expressed in seconds.
4. Pressing START button, saving procedure begins; in that phase you can’t modify acquisition parameters

During acquisition procedure (Fig. 37), following data are visualized:

1. A led signals saving instant
2. A gauge scans time between 2 saving instants
3. Indication of number of saved frames
4. Flashing message SAVING…

To stop saving procedure you can press START button, or simply exiting the menu.

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Fig. 37: Data logging menu – saving mode

Logging.out file format is:

FIRST ROW: name of NMAX variables to be saved followed by saving date and time;
SUCCESSIVE ROWS: NMAX recorded values separated by space.

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Flash

Fig. 38: Flash programming phase

To upgrade main controller software, with Flash menu (Fig. 36) follow these steps:
1. Disable all commands
2. Verify if C:\SOURCE_FILE directory exists (otherwise create it)
3. Source directory must contain only 2 source files
4. Select FLASH item from menu-bar
5. Give confirmation to start programming phase
6. In case of troubles with source files, (missing files, wrong version,...) there will be an error message and flash
memory will not programmed .
7. After a synchronization phase, flash programming will start; a bar gives the percent indication of already
programmed memory.
8. In case of problems with serial communication, there will be an error message and flash programming phase
will be stopped.
9. After traction micro successful programming, begins pump micro programming phase (step 7 and 8)
10. A message will signal the end of programming phase, and its result; give confirmation to exit the menu.

See troubleshooting section in case of any error.

NOTE: If programming phase fails after synchronization, panel has to be programmed with correct software
before being used.

Enforce necessarily following item after Flash.

1. Click the total load EEPROM of LOAD EEPROM DEFAULT MENU
2. Re-set the lift, pedal, steering sensor

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Troubleshooting of Eye Program

Generality Flash Programmation
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Often you can solve problems reading error If panel programming phase fails, when you try
messages and following suggestions. to load source files:
1. Verify if c:\source_file directory exists
2. Verify if c:\source_file directory contains only 2
Software Installation source files
3. Be sure that source files are the ones provided
In case of failed EYE software installation, follow by DHIM’s Homepage.
these steps:
1. Verify if your PC complies minimal requirements If you program memory successfully, but
2. Be sure of having PC administrator rights inverter doesn’t work correctly:
3. Close all active applications and disable 1. Be sure that source files are the ones provided
antivirus before installation by S.M.E
4. Verify installation, step by step
In case of transmission error:
In case of successful installation, if application 1. Verify system ground connections
has a runtime error: 2. Control serial connection cable: you must use a
1. Verify if your PC complies minimal requirements shielded one
2. Turn off PC and try again after turning it on 3. Verify if serial port works correctly
3. Uninstall and install again EYE software 4. Verify if there are any active commands

Serial Communication Other Problems

If application doesn’t work and message “not Application works slowly:

connected” appears: 1. Verify if your PC complies minimal requirements
1. Verify system ground connections
2. Verify if inverter panel works correctly Application doesn’t work properly:
3. Control serial connection cable: you must use a 1. Verify if your PC complies minimal requirements
shielded one
4. Verify if serial port works correctly Text and ”objects” on main panel are not centred:
5. Use Setup menu to verify serial port 1. Verify if your PC complies minimal requirements
configuration 2. Don’t modify window size
6. Verify no other applications serial port
Monitor doesn’t display correctly text and
“objects”
1. Verify if monitor refresh frequency is at least
75Hz
2. Verify if your PC complies minimal requirements

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Appendix A : 48[V] Parameter List

Parameter Mini Def Maxi Re
Parameter Parameter Description Unit
No mum ault mum mark
as high it is as quickly the truck decreases
Deceleration
5 its speed if the truck driver is turning the rpm/s 0 800 5,000
steering ramp 1 wheel quickly
as high it is as quickly the truck decreases its
speed in relation to the drive speed of truck.
Deceleration
6 This parameter increases the deceleration rpm/s 0 6 10
steering ramp 2 ramp while the driver is steering at high
speed
Battery reset Minimum battery voltage necessary to reset
9 V*10 464 470 501
value battery discharged voltage alarm
Seat switch Time interval between seat switch opening
11 s 1 3 9
delay and drive and pump motors stopping
Time delay between last command given to a
12 Chat time s 3 6 9
drive or pump motor and chat mode signalling
Time interval when pump motor works (with
13 Hydro time s 10 10 20
hydro speed) after the end of a command
Maintenance
Disable = 0 (Default)
14 time inserting Maintenance time inserting enable digit
Enable = 1
enable
Steering Steering sensor voltage with wheels turned
18 on right mV 500 10,300 11,500
anticlockwise
Steering Steering sensor voltage with wheels turned
19 on left mV 500 1,200 11,500
clockwise
20 Steering middle Steering voltage with wheels straight ahead mV 500 6,300 11,500
Minimum Accelerator sensor voltage with pedal
23 released mV 200 1,000 4,500
accelerator
Maximum Accelerator sensor voltage with pedal
24 completely pressed mV 2,000 3,600 5,000
accelerator
Stop on slop Without stepping on pedal brake, time that is
26 doing stop in slope s 1 5 10
timer
if it's OFF, the pump motor works like it does
now, that is, the reference speed of pump
motor, in case of many simultaneous
commands (LIFT + TILT, LIFT + AUX1, TILT +
Lift priority for AUX1.......), will be the highest of every OFF = 0 (Default)
27 digit
speed reference single command; if it's ON the reference ON = 1
speed of pump motor, in case of many
simultaneous commands, will be the lowest of
those reference speed required by every
single command
Buzzer on If it’s ON, the buzzer will be alarmed when the OFF = 0 (Default)
30 digit
forward direction direction switch is moved to forward ON = 1
Buzzer on If it’s ON, the buzzer will be alarmed when the OFF = 0 (Default)
31 digit
reverse direction direction switch is moved to reverse ON = 1
Lift sensor voltage with lift lever completely
32 Maximum lift mV 3,000 11,500 12,000
pressed
33 Minimum lift Lift sensor voltage with lift lever released mV 0 2,300 12,000
Lift lever potentiometer voltage to which the
34 Middle lift lifting becomes proportional to the shift of the mV 1,000 2,750 12,000
lever
The cooling Fan runs when the temperature
Starting of motors reaches to set value. And the
35 temperature of cooling Fan stops when the motors cools ଇ 55 85 155
motor's Fans down below 60ଇ from set value(The
minimum of stop temperature is 25ଇ)
Weight of the future
36 Load measurement kg 0 0 0
load on the forks option

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Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
No load
37 Load measurement bar·10 0 0 2,200 future
pressure
option
38 Load pressure Load measurement bar·10 0 0 2,200
Limitation
39 Start temperature of performance reduction ଇ 100
temperature
Drive maximum Drive motors maximum current (expressed in
41 % 20 100 100
current per cent of high energetic mode value)
Maximum forward lift truck speed with no
Forward
42 speed limitation rpm 1,000 4,500 4,500 Option
maximum speed (no alarms present and turtle not active)
Maximum reverse lift truck speed with no
Reverse
43 speed limitation rpm 1,000 4,500 4,500
maximum speed (no alarms present and turtle not active)
Drive limitation Maximum lift truck speed with speed
44 rpm 500 2,000 2,500
maximum speed limitation (turtle active)
High lift switch 1 Maximum travel speed when switch 1 was
46 rpm 0 1,000 4,500 Option
drive max speed "ON"
Steer limitation
Maximum speed reference in the angle in
47 drive maximum rpm 400 1,500 2,000
which the internal wheel is mechanically still.
speed
Acceleration Lift truck acceleration with accelerator pedal
48 rpm/s 400 1,100 2,000
ramp pressed
49 Inversion ramp Lift truck deceleration in inversion rpm/s 400 1,300 2,000
Lift truck deceleration with accelerator pedal
50 Release ramp rpm/s 400 1,000 2,000
released
Pedal brake Lift truck deceleration with pedal brake
51 rpm/s 400 1,200 2,000
ramp pressed
If the truck speed is greater then this
threshold, the speed reference becomes a
52 Creep speed rpm 100 300 2,000
parabolic function of the accelerator
potentiometer voltage
Diameter of drive
53 Drive tyre's diameter mm 300 451 700
tyres
High lift switch 2 Maximum travel speed when switch 1 and
54 rpm 0 1,000 4,500 Option
drive max speed switch 2 was "ON"
Parameter that softens the drive inversion
Partial release
59 ramp if the traction motors are working with rpm/s 10 50 500
ramp low rpm
Lift maximum Pump motor maximum current with lift
61 % 20 100 100
current function active
Auxiliary
Pump motor maximum current with lift lever
62 maximum % 10 65 100
released
current
Lift maximum
63 Maximum lift speed rpm 1,500 2,950 4,500
speed
64 Tilt speed Pump motor speed with lift function active rpm 500 900 2,000
Auxiliary 1 Pump motor speed with 1st auxiliary function
65 rpm 500 900 2,800
function speed active
Auxiliary 2 Pump motor speed with 2nd auxiliary function
66 rpm 500 900 2,800
function speed active
Auxiliary 3 Pump motor speed with 3rd auxiliary function
67 rpm 500 900 2,800
function speed active
Lift minimum
68 Minimum lift speed rpm 500 700 1,500
speed
High lift 1 switch Maximum pump motor speed with forks
69 rpm 0 1,500 3,500 Option
lift max speed above the critical height

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Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
70 Hydro speed Pump motor speed when steering rpm 400 500 800
Pump motor speed with direction command
71 Hydro idle speed lever not in neutral, acceleration pressed and rpm 200 300 500
no pump command active
Pump
72 acceleration Lift acceleration rpm/s 1,000 7,000 10,000
ramp
Pump
Pump motor deceleration after the end of a
73 deceleration rpm 1,000 7,000 10,000
command
ramp
High lift 2 switch Maximum lift speed when switch 1 and
74 rpm 0 1,500 3,500 Option
lift max speed switch 2 was "ON"
High lift 1 switch Maximum tilt speed when switch 1 was
75 rpm 0 500 2,000 Option
tilt max speed "ON"
High lift 2 switch Maximum tilt speed when switch 1 and
76 rpm 0 500 2,000 Option
tilt max speed switch 2 was "ON"
High lift 1 switch
Maximum auxiliary 1 speed when switch 1
77 auxiliary 1 max rpm 0 500 2,800 Option
was "ON"
speed
High lift 2 switch
Maximum auxiliary 1 speedwhen switch 1
78 auxiliary 1 max rpm 0 500 2,800 Option
and switch 2 was "ON"
speed
High lift 1 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1
79 rpm 0 500 2,800 Option
function max was "ON"
speed
High lift 2 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1
80 rpm 0 500 2,800 Option
function max and switch 2 was "ON"
speed
High lift 1 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1
83 rpm 0 500 2,800 Option
function max was "ON"
speed
High lift 2 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1
84 rpm 0 500 2,800 Option
function max and switch 2 was "ON"
speed
If parameter is set to1, speed limitation is
Disable = 0 (Default)
94 Slow speed active; otherwise lift truck speed is managed Digit
Enable = 1
as usual.
If parameter is set to 1, values are expressed Normal = 0 (Default)
95 British unit Digit
in British unit, otherwise in international ones British unit = 1
Display
96 Display's brightness adjustment digit 0 5 8
brightness
If this parameter is set to 1, it is possible to
Disable = 0
97 E-S-H enable change the value of the power mode with the digit
Enable = 1 (Default)
display
Time meter / If parameter is set to 1, odometer indication
Timer meter = 0 (Default)
98 Odometer on appears on display ; otherwise display shows Digit
Odometer = 1
display the hour meter
Maintenance
99 Can set truck's maintenance period h 0 0 10,000
time
Maintenance
99 Maintenance period decision h 0 0 10,000
time

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Appendix B : 36[V] Parameter List

Parameter Mini Def Maxi Re
Parameter Parameter Description Unit
No mum ault mum mark
Deceleration as high it is as quickly the truck decreases
5 steering ramp its speed if the truck driver is turning the rpm/s 0 800 5,000
1 wheel quickly
as high it is as quickly the truck decreases its
Deceleration speed in relation to the drive speed of truck.
6 steering ramp This parameter increases the deceleration rpm/s 0 6 10
2 ramp while the driver is steering at high
speed.
Battery reset Minimum battery voltage necessary to reset
9 V*10 344 356 373
value battery discharged voltage alarm
Seat switch Time interval between seat switch opening
11 s 1 3 9
delay and drive and pump motors stopping
Time delay between last command given to a
12 Chat time s 3 6 9
drive or pump motor and chat mode signalling
Time interval when pump motor works (with
13 Hydro time s 10 10 20
hydro speed) after the end of a command
Maintenance
Disable = 0 (Default)
14 time inserting Maintenance time inserting enable digit
Enable = 1
enable
Steering Steering sensor voltage with wheels turned
18 mV 500 10,300 11,500
anticlockwise on right
Steering Steering sensor voltage with wheels turned
19 mV 500 1,200 11,500
clockwise on left
Steering
20 Steering voltage with wheels straight ahead mV 500 6,300 11,500
middle
Minimum Accelerator sensor voltage with pedal
23 mV 200 1,000 4,500
accelerator released
Maximum Accelerator sensor voltage with pedal
24 mV 2,000 3,600 5,000
accelerator completely pressed
Stop on slop Without stepping on pedal brake, time that is
26 s 1 5 10
timer doing stop in slope
if it's OFF, the pump motor works like it does now, that is,
the reference speed of pump motor, in case of many
simultaneous commands (LIFT + TILT, LIFT + AUX1,
Lift priority for
TILT + AUX1.......), will be the highest of every single OFF = 0
27 speed digit
command; if it's ON the reference speed of pump motor, ON = 1 (Default)
reference
in case of many simultaneous commands, will be the
lowest of those reference speed required by every single
command.
Buzzer on
If it’s ON, the buzzer will be alarmed when the OFF = 0 (Default)
30 forward digit
direction switch is moved to forward. ON = 1
direction
Buzzer on
If it’s ON, the buzzer will be alarmed when the OFF = 0 (Default)
31 reverse digit
direction switch is moved to reverse. ON = 1
direction
Lift sensor voltage with lift lever completely
32 Maximum lift mV 3,000 11,500 12,000
pressed
33 Minimum lift Lift sensor voltage with lift lever released mV 0 2,300 12,000
Lift lever potentiometer voltage to which the
34 Middle lift lifting becomes proportional to the shift of the mV 1,000 2,750 12,000
lever
The cooling Fan runs when the temperature
Starting of motors reaches to set value. And the
35 temperature of cooling Fan stops when the motors cools ଇ 55 85 155
motor's Fans down below 60ଇ from set value(The
minimum of stop temperature is 25ଇ).
Weight of the
36 Load mesurement kg 0 0
load on the forks
future
No load
37 Load mesurement bar·10 0 0 2,200 option
pressure
38 Load pressure Load mesurement bar·10 0 0 2,200

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Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Limitation
39 Start temperature of performance reduction ൓ 212
temperature
Drive
Drive motors maximum current (expressed in
41 maximum % 20 100 100
per cent of high energetic mode value)
current
Reverse Maximum reverse lift truck speed with no
43 maximum speed limitation rpm 1,000 3,800 3,800
speed (no alarms present and turtle not active)
Drive limitation
Maximum lift truck speed with speed
44 maximum rpm 500 2,000 2,500
limitation (turtle active)
speed
High lift switch
Maximum travel speed when switch 1 was
46 1 drive max rpm 0 1,000 3,800 Option
"ON"
speed
Steer limitation
Maximum speed reference in the angle in
47 drive maximum rpm 400 1,200 2,000
which the internal wheel is mechanically still.
speed
Acceleration Lift truck acceleration with accelerator pedal
48 rpm/s 400 1,100 2,000
ramp pressed
Inversion
49 Lift truck deceleration in inversion rpm/s 400 1,300 2,000
ramp
Lift truck deceleration with accelerator pedal
50 Release ramp rpm/s 400 900 2,000
released
Pedal brake Lift truck deceleration with pedal brake
51 rpm/s 400 1,200 2,000
ramp pressed
If the truck speed is greater then this
threshold, the speed reference becomes a
52 Creep speed rpm 100 300 2,000
parabolic function of the accelerator
potentiometer voltage.
Diameter of
53 Drive tyre's diameter mm 300 451 600
drive tyres
High lift switch
Maximum travel speed when switch 1 and
54 2 drive max rpm 0 1,000 3,800 Option
switch 2 was "ON"
speed
Parameter that softens the drive inversion
Partial release
59 ramp if the traction motors are working with rpm/s 10 50 500
ramp
low rpm
Lift maximum Pump motor maximum current with lift
61 % 20 100 100
current function active
Auxiliary
Pump motor maximum current with lift lever
62 maximum % 10 65 100
released
current
Lift maximum
63 Maximum lift speed rpm 1,500 2,950 4,500
speed
64 Tilt speed Pump motor speed with lift function active rpm 500 900 2,000
Auxiliary 1 Pump motor speed with 1st auxiliary function
65 rpm 500 900 2,800
function speed active
Auxiliary 2 Pump motor speed with 2nd auxiliary function
66 rpm 500 900 2,800
function speed active
Auxiliary 3 Pump motor speed with 3rd auxiliary function
67 rpm 500 900 2,800
function speed active
Lift minimum
68 Minimum lift speed rpm 500 700 1,500
speed
High lift 1
Maximum pump motor speed with forks
69 switch lift max rpm 0 1,500 3,500 Option
above the critical height
speed
70 Hydro speed Pump motor speed when steering rpm 400 500 800
Pump motor speed with direction command
Hydro idle
71 lever not in neutral, acceleration pressed and rpm 200 300 500
speed
no pump command active

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Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Pump
72 Lift acceleration rpm/s 1,000 7,000 10,000
acceleration ramp
Pump Pump motor deceleration after the end of a
73 rpm 1,000 7,000 10,000
deceleration ramp command
High lift 2 switch Maximum lift speed when switch 1 and
74 rpm 0 1,500 3,500 Option
lift max speed switch 2 was "ON"
High lift 1 switch Maximum tilt speed when switch 1 was
75 rpm 0 500 2,000 Option
tilt max speed "ON"
High lift 2 switch Maximum tilt speed when switch 1 and
76 rpm 0 500 2,000 Option
tilt max speed switch 2 was "ON"
High lift 1 switch
Maximum auxiliary 1 speed when switch 1
77 auxiliary 1 max rpm 0 500 2,800 Option
was "ON"
speed
High lift 2 switch
Maximum auxiliary 1 speedwhen switch 1
78 auxiliary 1 max rpm 0 500 2,800 Option
and switch 2 was "ON"
speed
High lift 1 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1
79 rpm 0 500 2,800 Option
function max was "ON"
speed
High lift 2 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1
80 rpm 0 500 2,800 Option
function max and switch 2 was "ON"
speed
High lift 1 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1
83 rpm 0 500 2,800 Option
function max was "ON"
speed
High lift 2 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1
84 rpm 0 500 2,800 Option
function max and switch 2 was "ON"
speed
If parameter is set to1, speed limitation is
Disable = 0 (Default)
94 Slow speed active; otherwise lift truck speed is managed digit
Enable = 1
as usual.
If parameter is set to 1, values are expressed Normal = 0
95 British unit digit
in British unit, otherwise in international ones. British unit = 1 (Default)
Display
96 Display's brightness adjustment digit 0 5 8
brightness
If this parameter is set to 1, it is possible to
Disable = 0
97 E-S-H enable change the value of the power mode with the digit
Enable = 1 (Default)
display
Time meter / If parameter is set to 1, odometer indication
Timer meter = 0 (Default)
98 Odometer on appears on display ; otherwise display shows digit
Odometer = 1
display the hour meter.
Maintenance
99 Can set truck's maintenance period. h 0 0 10,000
time
Maintenance
99 Maintenance period decision h 0 0 10,000
time

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Appendix C : Error Code List

EYE Error
Description Level Cause Trohbleshooting
Code Code
1. Such an alarm can be caused also by the
presence of regeneration currents; when lift
truck is on release or reverse braking ramp,
motors work as generators, and battery voltage
can exceed overvoltage limit. In a case like
Battery voltage, measured that, the battery condition should be verified ( if
by a circuit inside logic, the battery is new it is necessary to do some
Maximum exceeds following levels: charge-discharge cycles before reaching the
1 F0 battery 1 63 V, in case of systems rating declared by the constructor) or has a
voltage working at 36 V high internal resistance.
63 V, in case of systems If the case is the second and it is not possible
working at 48 V to change the battery, the solution may be to
reduce the release and reverse braking ramp.
2. Incorrect wiring to battery positive or negative
terminals.
3. Verify if battery is still in good conditions.
4. Replace the logic.
1. Incorrect wiring to battery, or corroded positive
or negative terminals;
2. Verify battery conditions: if the electrolyte
Battery voltage, measured inside is partially exhausted, an under voltage
Minimum by an internal circuit, is alarm can sometimes be detected from the
2 F1 battery 1 lower than following controller; even in case of low battery charge
voltage levels : 24 V , in case of (<10%), high current rates (i.e. both pump and
systems working at 36 V drive motors working in full load conditions)
could cause an under voltage alarm, in
particular in presence of an exhausted battery.
3. Replace the logic.
1. Verify if the potentiometer initial set-up is
correct; if not, repeat calibration
procedure.(You can use both PC with serial
communication software and Instrument
Voltage measured on
panel).
accelerator circuit exceeds
2. Verify if the following 68 ways connector
the value calculated
Pedal terminals are correctly wired to their
3 F2 2 averaging calibration and
trimmer fault correspondent inputs in potentiometer circuit:
reachable voltages;
- K1-11 (12 V)
moreover, start switch
- K1-15 (ground)
seems to be open.
- K1-10 (pedal input)
3. In case of correct wiring, replace the
potentiometer itself.
4. Replace logic
Eeprom does not work 1. Load default values for eeprom variables, both
Eeprom properly, or one of using PC with serial communication software
5 F 1
alarm memorised values is out of and Instrument panel;
correct limits. 2. Replace the logic.
Voltage level of pre -
charge capacitors is less
1. Verify if main breaker coil and power terminals
then 70 % of nominal
Pre -charge are in good conditions;
battery level.
capacitors 2. Verify if supply lines power fuse is damaged;
It could happen, in
low voltage 3. Verify if main breaker coils are correctly wired
example, if the inverter is
6 A alarm 6 to their correspondent inputs :
working with main breaker
(Capacitors - K1-18 (positive terminal)
open.
not - K1-19 (negative terminal)
Capacitors voltage
charged) 4. Replace main breaker;
decreases cause energy
5. Replace logic.
spent to keep motors in
motion.

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EYE Error
Description Level Cause Trohbleshooting
Code Code
right drive 1. With such an alarm present when you turn on
8 F3 motor power 1 lift truck, disconnect the power cable between
module the malfunctioning inverter and the
left drive corresponding motor (first, turn off the system,
24 F4 motor power 1 of course).
module If turning lift truck on again, alarm is not active,
then:
Actual current exceeds
1. Replace the cable connecting logic and
limits 929 A
inverter.
pump motor 2. Replace the inverter;
25 F5 power 1 3. Replace logic.
module If turning lift truck on again, alarm is active,
then :
1. Replace the inverter;
2. Replace the motor.
1. Replace main breaker.
Inverter Pre -charge capacitors 2. Replace cable connecting the CN1 output of
capacitors voltage increases too fast the logic with the corresponding inverter;
9 A 1
pre -charge when you turn the system 3. Replace the inverter connected with the
too fast on. CN1output of logic
4. Replace logic
1. Alarm could be caused by ineffective
temperature dissipation.
Verify thermal coupling between inverter block
and aluminium plate, and between aluminium
plate and truck ballast.
The presence of a correct amount of thermal
The inverter temperature
grease in the coupling is essential to ensure an
Pump motor (measured with a
efficient heat exchange;
inverter temperature connector),
10 E3 6 2. Replace cable connecting the output CN4 of
overtemper exceeds 100 º C, or is
the logic to the pump inverter;
ature inside [95 ºC, 100 ºC]
3. If temperature readings seem too high in
range at least 30 s.
function of total time interval of lift truck using,
replace pump inverter causing the alarm.
You can read temperature measures using
Instrument panel or “EYE” communication
software.
4. Replace logic.
1. Verify the correctness of wiring from pump
When you turn on the
motor and relative inverter;
system, capacitors are not
2. Replace wire connecting CN3 with the
completely discharged by
corresponding inverter or if not possible
pump motor.
because the pump motor inverter box
In fact, if you turn
integrates the outlet wire, substitute the
Capacitors suddenly on the lift truck,
inverter box;
11 A too charged 1 after a turning off,
3. Verify if main breaker has stuck closed
on start capacitors voltage level is
terminals: in such a case replace it;
too high. You have to
4. Replace the wire connecting CN1 in logic to
discharge them before
right drive motor inverter: a defective wire
checking the presence of
could give a wrong measure for capacitors
any fault (both of
voltage;
capacitors and of logic)
5. Replace logic.

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EYE Error
Description Level Cause Trohbleshooting
Code Code
Battery voltage level is
lower than minimum
charge value expected, 1. Measure battery voltage with a tester and, if
Low battery referred to table 2 (for 36V different from the value reported on Instrument
12 EL 3
alarm system) and table 3(for panel, replace logic;
48V system) in Instrument 2. Otherwise recharge battery.
panel technical
documentation.
Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
operating mode) you have to measure a
resistance of about 10 kohm between the two
wires of the temperature connector ( execute
the measure at ambient temperature of 25°C) .
If the measure is not correct it is necessary to
replace the temperature connector;
Drive motor The measure of drive 2. Disconnect the temperature connector and
13 E4 over 5 motor temperature check the wiring insulation between signal
temperature exceeds 155 ºC. wire an ground wire ( towards logic);
3. replace logic.

Presence of alarm with hot motors :

1. If temperature value (you can read it from
Instrument panel or via PC) seems correct,
verify if fans (if present) work properly; fault is
caused by an inefficient motor refreshing, or by
operating out of nominal maximum ranges.
Presence of alarm with cold motors:
1. With a handheld multimeter in resistance
operating mode, you have to measure about
10kohm at ambient temperature of 25°C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor The measure of pump 2. Disconnect the temperature connector and
14 E6 over 6 motor temperature check the wiring insulation between signal
temperature exceeds 155 ºC . wire and ground wire ( towards logic);
3. replace logic.

Presence of alarm with hot motors:

1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
Motor 1. Replace the wire connecting inverter to logic.
Non-zero phase currents
15 F6 current 1 2. Replace inverter.
when you turn lift truck on.
offset alarm 3. Replace logic.
Motor 1. Replace the wire connecting inverter to logic.
Non-zero phase currents
16 F7 current 1 2. Replace inverter.
when you turn lift truck on.
offset alarm 3. Replace logic.
Main Overcurrent on main 1. Replace main breaker
17 17 1
breaker fault breaker coil. 2. If alarm is still present, replace logic
Improper communication
1. Using EYE program interface, try to program
Watchdog between DSPs present on
18 F 1 logic flash memory;
timer alarm logic, or/and defective
2. Replace logic .
logic.

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EYE Error
Description Level Cause Trohbleshooting
Code Code
Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
operating mode) you have to measure a
resistance of about 10 kohm between the two
wires of the temperature connector ( execute
the measure at ambient temperature of 25°C) .
If the measure is not correct it is necessary to
replace the temperature connector;
Drive motor The measure of drive 2. Disconnect the temperature connector and
19 E5 over 5 motor temperature check the wiring insulation between signal
temperature exceeds 155 ºC.. wire an ground wire ( towards logic);
3. replace logic.

Presence of alarm with hot motors :

1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
1. Alarm could be caused by ineffective
temperature dissipation; verify thermal coupling
between inverter block and aluminium plate
and between aluminium plate and truck ballast.
The presence of the correct amount of thermal
grease in the coupling are essential to ensure
Right drive Inverter temperature,
a correct heat exchange;
motor measured with a
2. Replace cable connecting the output CN1 of
20 E1 inverter 5 connector, exceed 100 ºC ,
the logic to the corresponding inverter;
overtemper or is inside [100 ºC] range
3. If temperature readings seem too high in
ature at least 30 s.
function of total time interval of lift truck using,
replace inverter unit causing the alarm. You
can read temperature measures using
“Instrument panel” or “EYE” communication
software.
4. Replace logic.
Error in serial
communication between
1. Program pump and drive DSP again; maybe
Serial the two DSP; DSP present
software present in flash memory was
21 F communicat 1 on logic make a mutual
corrupted.
ion alarm software control, to insure
2. Replace logic.
fast diagnosis of such a
fault.
1. Alarm could be caused by ineffective
temperature dissipation; verify thermal coupling
between inverter block and aluminium plate
and between aluminium plate and truck ballast.
The presence of the correct amount of thermal
grease in the coupling are essential to ensure
Left drive
Inverter temperature, a correct heat exchange;
motor
measured with a connector, 2. Replace cable connecting the output CN2 of
22 E2 inverter 5
exceed 100 ºC , or is inside the logic to the corresponding inverter;
overtemper
[100 ºC] range at least 30 s. 3. If temperature readings seem too high in
ature
function of total time interval of lift truck using,
replace inverter unit causing the alarm. You
can read temperature measures using
“Instrument panel” or “EYE” communication
software.
4. Replace logic.

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G
EYE Error
Description Level Cause Trohbleshooting
Code Code
Motor 1. Replace the wire connecting inverter to logic.
Non-zero phase currents
36 F8 current 1 2. Replace inverter.
when you turn lift truck on.
offset alarm 3. Replace logic.
1. Verify if 5 V output is grounded, cause an
incorrect encoder wiring.
Alarm on 5 logic K1-14 terminal (5 V
2. Verify if 5 V output is grounded, cause any
37 FH V encoder 1 output) voltage is lower
encoder malfunction. In that case, replace the
voltage than 4.3 V.
defective one.
3. Replace logic.
1. Verify if 12 V output is grounded, cause an
incorrect wiring to:
- Accelerator potentiometer
Alarm on 12 logic K1-12 terminal (12 V
- Steering sensor
38 FA V output 1 output) voltage is lower
- Buzzer
voltage than 10.5 V.
- Display
2. Replace defective device;
3. Replace logic.
1. Before starting to operate, turn off any active
Pump motor
You find a pump motor command (both levers and switches);
commands
50 FL 1 command active when you 2. Be sure that lift, tilt and auxiliary command
active on
turn your system on. switches, are not active;
start
3. Replace valve board.
Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
operating mode) you have to measure a
resistance of about 10 kohm between the two
wires of the temperature connector ( execute
the measure at ambient temperature of 25°C) .
If the measure is not correct it is necessary to
replace the temperature connector;
Right drive
The measure of right drive 2. Disconnect the temperature connector and
motor
61 61 1 motor temperature check the wiring insulation between signal
overtemper
exceeds 165 ºC. wire an ground wire ( towards logic);
ature
3. replace logic.

Presence of alarm with hot motors :

1. If temperature value (you can read it from
Instrument panel or via PC) seems correct,
verify if fans (if present) work properly; fault is
caused by an inefficient motor refreshing, or by
operating out of nominal maximum ranges.

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EYE Error
Description Level Cause Trohbleshooting
Code Code
Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
operating mode) you have to measure a
resistance of about 10 kohm between the two
wires of the temperature connector ( execute
the measure at ambient temperature of 25°C) .
If the measure is not correct it is necessary to
replace the temperature connector;
Left drive
The measure of left drive 2. Disconnect the temperature connector and
motor
62 62 1 motor temperature check the wiring insulation between signal
overtemper
exceeds 165 ºC. wire an ground wire ( towards logic);
ature
3. replace logic.

Presence of alarm with hot motors :

1. If temperature value (you can read it from
Instrument panel or via PC) seems correct,
verify if fans (if present) work properly; fault is
caused by an inefficient motor refreshing, or by
operating out of nominal maximum ranges.
Presence of alarm with cold motors:
1. With a handheld multimeter in resistance
operating mode, you have to measure about
10kohm at ambient temperature of 25¶C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor 2. Disconnect the temperature connector and
63 63 Overtemper 1 The measure of pump check the wiring insulation between signal wire
ature and ground wire ( towards logic);
3. replace logic.

Presence of alarm with hot motors:

1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
When you start working,
you find seat switch open,
Seat switch
EE or, after the main breaker is 1. Verify if seat switch is defective;
63 open on 1
(flash) closed, the seat switch 2. Replace logic.
start
remains opened for at least
ˈseat switch delayˉ s.
1. verify if a switch was active or the pedal
pressed, when you turn on the lift truck;
When you start working,
2. verify if start, forward or reverse switches are
you find accelerator pedal
64 EE Wrong start 1 stuck close;
pressed or a forward/
3. verify if pedal circuit voltage exceeds 1/3 its
reverse switch active.
maximum range (measured in Volt);
4. replace logic.

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EYE Error
Description Level Cause Trohbleshooting
Code Code
Presence of alarm with cold motors:
1. With a handheld multimeter in resistance
operating mode, you have to measure about
10kohm at ambient temperature of 25°C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor The measure of pump 2. Disconnect the temperature connector and
65 65 overtemper 1 motor temperature check the wiring insulation between signal
ature exceeds 165 ºC . wire and ground wire ( towards logic);
3. replace logic.

Presence of alarm with hot motors:

1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K1- 15 terminal
An encoder channel is
Encoder - + 5 V: K1- 14 terminal
74 Fc 1 disconnected, and motor
alarm - A channel: K1- 37 terminal
is working.
- B channel: K1- 36 terminal
2. If correctly wired, replace the encoder;
3. Replace logic.
1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K1- 15 terminal
An encoder channel is
Encoder - + 5 V: K1- 14 terminal
75 Fd 1 disconnected, and motor
alarm - A channel: K1- 17 terminal
is working.
- B channel: K1- 16 terminal
2. If correctly wired, replace the encoder;
3. Replace logic.
Alarm of
right drive
77 77 motor
thermal
connector
Temperature difference
Alarm of left 1. Verify if the wiring is correct;
between any two of the 3
drive motor 7 2. Replace the connector;
78 78 motors results greater
thermal 3. Replace logic.
than 70 ºC.
connector
Alarm of
pump motor
79 79
thermal
connector

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EYE Error
Description Level Cause Trohbleshooting
Code Code
Alarm of
right drive
80 80 motor 7
module
connector
Temperature difference 1. Check the wiring connecting control unit and
Alarm of left
between any two of the 3 inverter;
drive motor
81 81 7 inverters results greater 2. Replace the inverter;
module
than 70 ºC. 3. If alarm is still present, replace logic.
connector
Alarm of
pump motor
82 82 7
module
connector
1. restore eeprom with EYE application software,
Faulty eeprom or using the “RESTORE” item present in main
CRC fault
83 83 1 mismatching software page
alarm
release. 2. if alarm is still present, replace logic.
CRC : Cyclic Redundancy Checking error.
There was an eeprom
Bank CRC
84 84 1 restore, caused by a CRC 1. Switch on the system and the turn it on again
restored
alarm.
1. verify correctness of wiring with :
- K1-11 (12 V),
Steering
Steer circuit voltage is out - K1-15 (ground)
91 F9 sensor 5
of nominal range. - K1-10 (steering sensor input);
alarm
2. if correctly wired, replace steering sensor;
3. replace logic.
1. Replace cable connecting the CN1 output of
Pre -charge capacitor
Capacitors the logic with the corresponding inverter
voltage grows too slowly,
98 A pre -charge 1 2. Replace the inverter connected with CN1
when you turn on the
too slow output of the logic;
system.
3. Replace logic
Pre-charge capacitors 1. Replace cable connecting the CN1 output of
Capacitors voltage does not reach the the logic with the corresponding inverter
99 A pre-charge 1 rated battery voltage 2. Replace the inverter connected with CN1
too slow within a limit time, when output of the logic;
you turn on the system. 3. Replace logic

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Appendix D : Contraction for dot matrix display.

1. Alarm Code

[Display Code] [Description] [Contraction]

17 Main breaker fault CONTACTOR FAULT
60 Battery/inverter mismatch BATT MISMATCH
61 Right Motor Overtemperature R-MOTOR SHUTDOWN
62 Left Motor Overtemperature L-MOTOR SHUTDOWN
65 Pump Motor Overtemperature P-MOTOR SHUTDOWN
76 Pump motor Encoder P-MOTOR ENCODER
77 Wrong right traction motor thermal switch R-M TEMP SENSOR
78 Wrong left traction motor thermal switch L-M TEMP SENSOR
79 Wrong pump motor thermal probe P-M TEMP SENSOR
80 Wrong right traction module thermal probe R-INV T SENSOR
81 Wrong left traction module thermal probe L-INV T SENSOR
82 Wrong pump module thermal probe P-INV T SENSOR
83 CRC fault CRC FAULT
84 Bank CRC restored CRC RESTORED
A Capacitors not charged : fast charge FAST CHARGE
A Trans.precharge in short/Cap. too charged TOO CHARGED
A Capacitors not charged : slow charge CAP SLOW CHARGE
A Capacitors not charged : time out TIME OUT CHARGE
A Capacitors not charged CAP NOT CHARGED
E1 Drive right module Overtemperature R-INV OVERTEMP
E2 Drive left module Overtemperature L-INV OVERTEMP
E3 Pump module Overtemperature P-INV OVERTEMP
E4 Drive right motor Overtemperature R-MOTOR OVERTEMP
E5 Drive left motor Overtemperature L-MOTOR OVERTEMP
E6 Pump motor Overtemperature P-MOTOR OVERTEMP
EE Wrong start WRONG START
EE(FLASING) Seat switch SEAT SW OPEN
EL Low battery voltage LOW BATT VOLT
F Eeprom EEPROM FAULT
F WD Timer/Enable micro signals WD TIMER FAULT
F Serial communication COMM FAULT
F0 Maximum battery voltage MAX BATT VOLT
F1 Minimum battery voltage MIN BATT VOLT
F2 Pedal trimmer fault ACCEL FAULT
F3 Drive right module Desat/overcurrent R-INVERTER FAULT
F4 Drive left module Desat/overcurrent L-INVERTER FAULT
F5 Pump module Desat/overcurrent P-INVERTER FAULT
F6 Drive right motor current Offset R-MOTOR I OFFSET
F7 Drive left motor current Offset L-MOTOR I OFFSET
F8 Pump motor current Offset P-MOTOR I OFFSET
F9 Steer sensor fault STEER SENSOR OUT
FH 5V encoders not ok 5V NOT OK
Fc Drive right motor Encoder R-MOTOR ENCODER
Fd Drive left motor Encoder L-MOTOR ENCODER
FE 24V out 24V NOT OK
FA 12V out not ok 12V NOT OK
FL Pump input on at the start PUMP SIGN ON

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2. Calibration Code

[Display Code] [Description] [Contraction]

5 Deceleration steering ramp 1 STEERING DECEL1
6 Deceleration steering ramp 2 STEERING DECEL2
9 Battery reset value BATT RESET VALUE
10 First parameter for calibration enable 1ST PASSWARD
11 Seat switch delay SEAT SW DELAY
12 Chat time CHAT TIME
13 Hydro time HYDRO TIME
14 Maintenance time inserting enable SERVICE TIME ON
17 Second parameter for calibration enable 2ND PASSWARD
18 Steering sensor value : wheels turned on the right WHEEL TURN RIGHT
19 Steering sensor value : wheels turned on the left WHEEL TURN LEFT
20 Steering sensor value : wheels on straight position WHEEL STRAIGHT
23 Accelerator pedal minimum value ACCEL MIN VALUE
24 Accelerator pedal maximum value ACCEL MAX VALUE
26 Stop on slop timer SLOP TIMER
27 Lift priority for speed reference LIFT PRI SPEED
30 Buzzer on forward direction FORWARD ALARM
31 Buzzer on reverse direction BACK UP ALARM
32 Lift sensor maximum value LIFT MAX VALUE
33 Lift sensor minimum value LIFT MIN VALUE
34 Lift sensor middle value LIFT START VALUE
35 Starting temperature of motor's Fans START MOTOR FAN
36 Weight of the load on the forks LOAD WEIGHT
37 No load pressure NO LOAD PRESSURE
38 Load pressure LOAD PRESSURE
39 Limitation temperature LIMIT TEMP
41 Drive maximum current DRIVE MAX I
42 Forward maximum speed FWD MAX SPEED
43 Reverse maximum speed REV MAX SPEED
44 Drive limitation max speed D LIMIT MAX SPD
46 High lift switch 1 drive max speed DIGH1 D-LIMIT
47 Steer limitation drive max speed STEER LIMIT SPD
48 Drive acceleration ramp D ACCEL RAMP
49 Drive inversion ramp D INVERSION RAMP
50 Drive release ramp D RELEASE RAMP
51 Pedal brake ramp PEDAL BRAKE RAMP
52 Creep speed CREEP SPEED
53 Diameter of drive tyres TIRES DIA
54 High lift switch 2 drive max speed HIGH2 D-LIMIT
59 Partial release ramp PARTIAL RELEASE
61 Lift max current LIFT MAX I
62 Auxiliary max current AUX MAX I
63 Lift max speed LIFT MAX SPEED
64 Tilt speed TILT SPEED
65 Auxiliary 1 function speed AUX 1 SPEED
66 Auxiliary 2 function speed AUX 2 SPEED
67 Auxiliary 3 function speed AUX 3 SPEED
68 Lift min speed LIFT MIN SPEED
69 Pump max speed in limiting PUMP LIMIT MAX
70 Hydro speed HYDRO SPEED
71 Hydro idle speed IDLE SPEED
72 Pump acceleration ramp PUMP ACCEL RAMP
73 Pump deceleration ramp PUMP DECEL RAMP
74 High lift 2 switch lift max speed HIGH2 L-LIMIT
75 High lift 1 switch tilt max speed HIGH1 L-LIMIT
76 High lift 2 switch tilt max speed HIGH2 T-LIMIT
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77 High lift 1 switch auxiliary 1 max speed HIGH1 AUX1 LIMIT

78 High lift 2 switch auxiliary 1 max speed HIGH2 AUX1 LIMIT
79 High lift 1 switch auxiliary 2 function max speed HIGH1 AUX2 LIMIT
80 High lift 2 switch auxiliary 2 function max speed HIGH2 AUX2 LIMIT
83 High lift 1 switch auxiliary 3 function max speed HIGH1 AUX3 LIMIT
84 High lift 2 switch auxiliary 3 function max speed HIGH2 AUX3 LIMIT
94 Slow speed SLOW SPEED
95 British unit BRITISH UNIT
96 Display brightness LCD BRIGHTNESS
97 E-S-H enable E-S-H
98 Time meter / Odometer on display TIMER-ODOMETER
99 Maintenance time SERVICE PERIOD

3. Diagnostic Code

[Display Code] [Description] [Contraction]

1 Right traction motor speed RIGHT MOTOR SPD
2 Right traction motor speed reference R-MOTOR REF SPD
3 Left traction motor speed LEFT MOTOR SPD
4 Left traction motor speed reference L-MOTOR REF SPD
5 Lift lever voltage LIFT SENSOR OUT
6 Battery voltage BATT VOLTAGE
7 Right traction motor power module temperature R-INVERTER TEMP
8 Pump motor power module temperature P-INVERTER TEMP
9 Pump motor speed PUMP MOTOR SPD
10 Pump motor speed reference P-MOTOR REF SPD
11 Accelerator potentiometer voltage ACCEL 1ST OUT
12 Accelerator second Potentiometer voltage ACCEL 2ND OUT
13 Steering sensor voltage STEER SENSOR OUT
14 Left traction motor power module temperature L-INVERTER TEMP
15 Right traction motor phase current R-MOTOR I-U
16 Right traction motor phase current R-MOTOR I-V
17 Right traction motor phase current R-MOTOR I-W
18 Left traction motor phase current L-MOTOR I-U
19 Left traction motor phase current L-MOTOR I-V
20 Left traction motor phase current L-MOTOR I-W
21 Pump motor phase current P-MOTOR I-U
22 Pump motor phase current P-MOTOR I-V
23 Pump motor phase current P-MOTOR I-W
24 Right traction motor temperature R-MOTOR TEMP
25 Left traction motor temperature L-MOTOR TEMP
26 Pump motor temperature P-MOTOR TEMP
27 Seat switch hour meter SEAT H METER
28 Drive motor hour meter DRIVE H METER
29 Pump motor hour meter PUMP H METER
30 Seat switch SEAT SWITCH
31 Park brake switch PARK SWITCH
32 Start switch SRART SWITCH
33 Reverse traction direction switch REV SELECT SW
34 Forward traction direction switch FWD SELECT SW
35 Pedal brake switch PEDAL BRAKE SW
36 3/4 wheels selection switch 3 OR 4 WHEEL
37 Auxiliary 1 switch AUX 1 OUTPUT
38 Auxiliary 2 switch AUX 2 OUTPUT
39 Auxiliary 3 switch AUX 3 OUTPUT
40 High lift switch HIGH LIFT SWITCH
41 Tilt switch TILT SWITCH OUT
42 High lift 2 switch HIGH LIFT 2 SWITCH
43 Main breaker command CONTACTOR
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44 5V out 5V OUT
45 12V out 12V OUT
46 24V out 24V OUT
47 Buzzer command BUZZER
48 Fans command FAN
49 Drive right motor encoder channels R-MOTOR ENCODER
50 Drive left motor encoder channels L-MOTOR ENCODER
51 Pump motor encoder channels P-MOTOR ENCODER
52 lift pressure LIFT PRESSURE
53 Pressure sensor voltage PRESSURE OUTPUT
54 Weight of the load on the forks LOAD WIGHT

G 174