SERVICE DIAGNOSTICS

DIAGNOSTICS
1.00 ALARMS DERIVED FROM “COMBI” CONTROLLER ..................................................................................... 2
2.00 ALARMS DERIVED FROM “EPAS” CONTROLLER ..................................................................................... 27
3.00 ALARMS DERIVED FROM “TILLER” CONTROLLER .................................................................................. 28
4.00 ALARMS DERIVED FROM “DDI” CONTROLLER ......................................................................................... 28

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 DIAGNOSTICS SERVICE

1.00 ALARMS DERIVED FROM “COMBI” CONTROLLER

The alarms which block the machine are displayed on “DDI” with a nume-
rical alarm code preceded by two letters identifying the module in alarm,
the LED becomes red as well.
“Co” followed by the alarm number corresponds to the “COMBI” con-
troller.

ERROR CODE: 8000 (Only COMBI 200A)

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

8000 Current sensor The current sensor is 1 Switch off the key switch and switch it on
failure, phase W no longer supplied after few seconds
2 If the error code is repeated, an internal
controller failure occurred, replace the
controller
* NO MEASURES NEEDED

ERROR CODE: 8001 (Only COMBI 200A)

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

8001 Current sensor The current sensor is 1 Switch off the key switch and switch it on
failure, phase V no longer supplied after few seconds
2 If the error code is repeated, an internal
controller failure occurred, replace the
controller
* NO MEASURES NEEDED

ERROR CODE: 8002 (Only COMBI 200A)

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

8002 Current sensor The current sensor is 1 Switch off the key switch and switch it on
failure, phase U no longer supplied after few seconds
2 If the error code is repeated, an internal
controller failure occurred, replace the
controller
* NO MEASURES NEEDED

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ERROR CODE: 9024

Truck behaviour: traction and hydraulics disabled, main contactor open

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

9024 Short-circuit on the Traction motor phase 1. Turn the key to the OFF position and
traction motor or on U, V or W shorted to disconnect the battery connector
a controller part B+ or B-, two phases 2. Visually check if there is a short-circuit between
shorted with each the motor phase cable terminals and the
other, controller power controller power terminals B+ or B- (as phase
stage shorted terminals and B+ and B- terminals are close, the
cables could be turned in such a way to cause
short-circuits with each other)
- if there is a short-circuit, remove it and fix
the controller terminals by means of screws
- if there is not a short-circuit, proceed to
point 3
3. Disconnect the motor cables to the controller
4. Check the motor insulation by using a multimeter
- the resistance should measure minimum 1
MΩ
- if it does not, replace the traction motor
- if it does, proceed to point 5
5. Check if the controller phase B+ or B- is short-
circuited by using a multimeter (the controller
capacitors should be discharged)
- if the resistance between the phase
terminal and B+ or B- terminal
(all three phase terminals should
be checked) is lower than
5 kΩ, replace the controller
- if the resistance is higher, replace the
traction motor after carrying out any
check concerning possible mechanical
failures of the cables or short-circuits due
to these faults and/or short-circuits of the
earthing cable of the truck

ERROR CODE: 9088

Truck behaviour: traction and hydraulics disabled, main contactor open

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

9088 Short-circuit of the Internal short-circuit 1. Switch off the key switch and switch it on
pump motor of the pump motor or after few seconds and check if the alarm
external short-circuit appears again
between the pump 2. Turn the key to OFF position and
motor cable and B+ disconnect the battery
3. Disconnect the pump motor cables from the
controller
4. Visually check if there are any motor cable
faults or possible short-circuit to B+
- if possible, replace the cable and all
other damaged truck leads
5. Check if the P- terminal in the controller is
shorted to B+
- if the resistance between P- and
B+ terminals measured by using
a multimeter is lower than 40 kΩ,
replace the controller
If the controller and the pump motor cables
are OK, replace the pump motor

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ERROR CODE: 9089

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

9089 Pump motor The pump motor is 1. Tighten the screws on the controller and
connection opened not connected to the on the motor side and switch off and on the
Pump motor short- controller terminal key switch at intervals of few seconds to
circuited with B- P- because of a motor see if the error code appears again
internal failure or a 2. Turn the key to OFF position and
loss of power wire disconnect the battery
connection of the 3. Check if there is a short-circuit between
motor or the controller the motor cable and the controller terminal
The pump motor cable B-.
is short-circuited with - If there is, disconnect the pump motor
B- leads from the controller
4. Visually check if the pump motor leads are
not interrupted and if the cable and the
pump motor terminals are without evidence
of arcing or oxidation.
- If there is an anomaly, replace the
motor leads or just clean the leads,
the motor and the controller terminals
5. Visually check the motor lead for any
damage and possible short-circuit to
B-
- If there is an anomaly, replace the
lead and all other damaged truck
leads
6. Check if the P- terminal in the controller is
short-circuited with B-
- if the resistance measured between
P- and B- terminals by using a
multimeter is lower than 40 kΩ
replace the controller
7. Check if the pump motor is in open
condition. If the resistance measured
between the two motor terminals
disconnected from the cables is higher than
0,5Ω, replace the pump motor

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ERROR CODE: 9090

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

9090 Pump overcurrent The pump current 1. Switch off the key switch and switch it on
sensor detects a higher after few seconds and check if the alarm
current than the one appears again
set according to the 2. Check if the pump motor is running
parameter “maximum - check the value of the Par-
pump current” PumpMaxCurr parameter
- set it to the default value (see
By pressing the service manual)
lowering push button, - adjust the maximum pressure to
the error is cleared and the correct value
the truck continues its 3. Check if the pump motor is mechanically
normal operation blocked, verify there is no binding in the
lifting mechanism
- verify that the weight of the load does
not exceed the truck lift capacity listed
on the nameplate
- reduce the load weight
- replace the maximum pressure valve
if it is not working properly
or
- replace the pump motor if blocked
or
- replace the controller

ERROR CODE: 12816

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

12816 Battery overvoltage The controller detects 1. Check the battery voltage in the controller
a voltage higher than between B+ and B- terminals
36V 2. Verify if the battery voltage matches
with the voltage listed on the lift truck
nameplate
- if it does not, install the correct battery
3. Tighten the screws on the controller B+
and + battery terminals as on the main
contactor side
4. Check the voltage drop across the main
contactor contacts
- if the voltage drop is higher than
0,5V at full system current
replace the main contactor
5. Check the voltage drop across the fuse on
the controller
- if the voltage drop is higher than
0,5V at full system current,
replace the fuse
6. Check possible damage on the truck
leads from the battery to the main
contactor and from the main contactor to
the controller B+ terminal
- if there is a damage, replace the leads
7. Check if main contactor contacts are loose
due to vibrations
- if possibility exists, replace that
part of wiring
7. Clean all the contacts from the battery to
the controller B+ terminal
8. Replace the controller

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ERROR CODE: 12832

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

12832 Battery low voltage The controller detects 1. Check the battery voltage in the controller
a voltage lower than between B+ and B- terminals
16V 2. Verify if the battery voltage matches
with the voltage listed on the lift truck
nameplate
- If it does not, install the correct battery
3. Tighten the screws on the controller B+
and + battery terminals as on the main
contactor side
4. Check the voltage drop over the main
contactor contacts
- if the voltage drop is higher than
0,5V at full system current,
replace the main contactor
5. Check the voltage drop across the fuse
on the controller
- if the voltage drop is higher than
0,5V at full system current,
replace the fuse
6. Check possible damage on the truck
leads from the battery to the main
contactor and from the main contactor to
the controller B+ terminal
- if there is a damage, replace the leads
7. Clean all the contacts from the battery to
the controller B+ terminal
8. Check the battery state of charge on the
DDI
- recharge the battery
- install a fully charged battery
9. Check the battery condition (what is its real
capacity)
- install a new battery
10. Replace the controller

ERROR CODE: 16912

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

16912 Controller The controller detects 1. Check the air temperature inside the truck
overtemperature a temperature on the - if the air temperature is higher
power stage higher than 45°C, increase the cooling of the
than 85°C (25°C higher motor compartment
than the one set by 2. Check the difference between the
means of “Twarning” temperature on the controller base plate
parameter) and on the plate with the cooling ribs
- if the difference is higher than 5°C,
check if some silicone grease is
present between the base plate and
the cooling ribs and if the controller is
well fixed to the cooling ribs
3. Reduce the truck use and allow the
controller to cool
4. Switch off the key switch and switch it on
after 5 minutes. In case the same error
code appears again check the temperature
on the controller base plate
- if the temperature is lower than 60°C
replace the controller

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ERROR CODE: 16944

Truck behaviour: traction reduced, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

16944 Controller The controller detects 1. Check the “Twarning” parameter and
overtemperature a temperature on the verify that the value corresponds to the
power stage higher parameter default value
than 60°C (higher than 2. Check the air temperature inside the truck
the temperature set by - if the air temperature is higher
means of “Twarning” than 45°C, increase the cooling of the
parameter) motor compartment
3. Check the difference between the
temperature on the controller base plate
and on the plate with the cooling ribs
- if the difference is higher than 5°C
check if some silicone grease is
present between the base plate and
the cooling ribs and if the controller is
well fixed to the cooling ribs
4. Reduce the truck use and allow the
controller to cool
5. Switch off the key switch and switch it on
after 5 minutes. In case the same error
code immediately appears again check the
temperature on the controller base plate
- if the temperature is lower than 45°C
replace the controller

ERROR CODE:16976

Truck behaviour: traction and hydraulic disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

16976 Excess of Controller detects an 1. Check the air temperature inside the
temperature of excess of temperature truck
power output cables in the output power - if the air temperature is greater
cables than 45°C increase the compartment
cooling
2. Reduce the truck usage and allow the
motor to cool
3. Check if the truck is overloaded or the
motor is partially blocked
4. Switch off the key switch and switch it on
after 10 minutes. In case that the same
error code immediately appears again
check the resistance of the temperature
sensor
- if the resitance is zero, replace
the temperature sensor
5. Check if the power cables are well fixed
to the controller and motor terminals
- otherwise fix them with the prescribed
driving torque
6. Check if the terminals of power wires are
clean and without consequence of voltaic
arcs
- otherwise replace wiring
7. Check if the power terminals of the
controller and of the motor are without
consequence of voltaic arcs
- otherwise brush them

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ERROR CODE: 17168

Truck behaviour: traction disabled, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

17168 Traction motor The controller detects 1. Check the air temperature inside the truck
overtemperature a temperature of the - if the air temperature is higher than
traction motor higher 45°C, increase the cooling of the
than 155°C motor compartment
2. Reduce the truck use and allow the
controller to cool
3. Turn the key to OFF position and
disconnect the battery
- check the resistance between the
pins on the motor temperature sensor
connector
- if the resistance is higher than
1450 Ohms and the motor stack
temperature is lower than
130 °C, replace the sensor
- check if the truck wiring is OK
- if it is not, replace it
4. Check if the truck is overloaded or if the
motor is partially blocked
5. Switch off the key switch and switch it on
after 10 minutes. In case the same error
code immediately appears again, check the
temperature of the motor
- if the temperature is lower than 130°C,
replace the controller

ERROR CODE:17169

Truck behaviour: traction reduced, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

17169 Traction motor The controller detects 1. Check the air temperature inside the truck
overtemperature a temperature of the - if the air temperature is higher than
traction motor higher 45°C, increase the cooling of the
than 120°C motor compartment
2. Reduce the truck use and allow the
controller to cool
3. Turn the key to OFF position and
disconnect the battery
- check the resistance between the
pins on the motor temperature sensor
connector
- if the resistance is higher than
1250 Ohms and the motor
temperature is lower than
95 °C, replace the sensor
- check if the truck wiring is OK
- if it is not, replace it
4. Check if the truck is overloaded or if the
motor is partially blocked
5. Switch off the key switch and switch it on
after 10 minutes. In case the same error
code immediately appears again, check
the temperature on the motor
- if the temperature is lower than 90°C,
replace the controller

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ERROR CODE: 20756

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

20756 Pin 1 on 35 pin The controller doesn’t 1. Switch off the key switch and switch it on
connector not detect any voltage at after few seconds and check if the alarm
connected pin 1 appears again
2. Switch off the key switch and disconnect
the truck 35 pin connector from the
controller
- switch on the key switch and measure
the voltage between pin 1 and B- on
the truck connector
- if there is no voltage, there should
be some problem with the truck
wiring or the key switch
- if battery voltage is measured on
pin 1, switch off the key switch,
connect the connector to the
controller and after 10 minutes
switch on the key switch again
- if the same alarm appears
immediately, replace the
controller
- if the alarm appears at
intervals of few seconds,
check again the state of the
key switch and the main
contactor

ERROR CODE: 21376

Truck behaviour: traction disabled, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21376 Belly switch failure The controller has 1. Check that the belly switch contact on the
detected the belly tiller handle has not been held closed at the
switch contact is start-up
closed, but the tiller 2. Verify if all the tiller handle wiring
has detected that connections are tight and safe
it is open (problem 3. Check the resistance across the switch
in the CANopen terminals to see if the belly switch is short-
communication) circuited
- replace the belly switch

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ERROR CODE: 21378

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21378 No tiller present The Combi controller 1. Make sure that all the wiring connections
does not detect Tiller between the tiller board and the controller
through CANopen are tight and safe
communication at the - check if pins 1 and 2 of K3 on the tiller
system start-up board are connected
- check if pins 27 and 28 of the signal
connector on the controller are
connected
- measure the resistance between pin 1
of K3 on the tiller board and pin 28 on
the controller
- if the resistance is higher than
0.5Ω, replace the wiring
- measure the resistance between pin 2
of K3 on the tiller board and pin 27 on
the controller
- if the resistance is higher than
0.5Ω, replace the wiring
- if the error code appears when
vibrations are active, replace the
wiring

ERROR CODE: 21379

Truck behaviour: traction disabled, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21379 Tiller switch failure The CANopen 1. Make sure that all wiring connections
communication between the tiller board and the controller
between the controller are tight and safe
and the tiller board - check if pins 1 and 2 of K3 and pin 3
does not operate of K1 on the tiller board are connected
well; the controller - check if pins 7, 27 and 28 of the
has detected that signal connector on the controller are
the tiller switch has connected
been closed, but the - measure the resistance between pin 1
tiller has detected the of K3 on the tiller board and pin 28 on
tiller switch has been the controller
opened - if the resistance is higher than
0.5Ω, replace the wiring
- measure the resistance between pin 2
of K3 on the tiller board and pin 27 on
the controller
- if the resistance is higher than
0.5Ω, replace the wiring
- measure the resistance between pin 3
of K1 on the tiller board and pin 7 on
the controller
- if the resistance is higher than
0.5Ω, replace the wiring

2. If the error code appears when vibrations

are active, replace the wiring

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ERROR CODE: 21380

Truck behaviour: traction disabled, hydraulic enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21380 Dig. In. 7 problem The controller detects 1. Check if the wiring is used
no voltage on Dig. in. 7 - otherwise replace wiring
2. Disconnect the battery and check if the
wire to Dig. In. 7 is OK
- if the wire is damaged, replace wiring
- If the contact on Dig. In 7 is not OK
replace wiring

ERROR CODE: 21392

Truck behaviour: traction disabled, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21392 Throttle problem The throttle is pressed 1. Switch off the key switch and switch it on
before the tiller is after few seconds
lowered; by releasing 2. Release the throttle, lower the tiller and
the throttle, the error check if the same error code appears
disappears from DDI - if it does, check if the throttle is
and the truck continues mechanically blocked on the tiller
its normal operation. handle
- if it is, remove the reason of the
blocking or replace the tiller
handle
- if it is not, replace the tiller board
Otherwise there was an operator
mistake.

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ERROR CODE: 21409

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21409 Proportional valve The controller detects 1. Switch off the key switch and switch it on
failure that the proportional after few seconds. Check if the same error
valve circuit is open code is repeated
- if it is, disconnect the battery and
check the resistance between one
side of the proportional valve and
pin 22 on the controller and the
resistance between the second side
of the proportional valve and pin 23
on the controller
- if the wires are damaged
(interrupted) or the contacts to
pins 22, 23 are not OK, replace
the wiring
- if it is repeated, disconnect the battery
and check the resistance of the
proportional valve not connected in
the truck system
- if the resistance is higher than
50Ω, replace the proportional
valve
- if yes, check if voltage exists on
prop. valve outlet pin during the fork
lowering
- otherwise replace controller
- if yes, check if voltage exists on
prop. valve return pin
- if the measured voltage is
close to the battery voltage,
replace the controller

ERROR CODE: 21410

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21410 Proportional valve The controller detects 1. Switch off the key switch and switch it on
failure a short-circuit in the after few seconds and check if the same
proportional valve error code is repeated
circuit - if it is, disconnect the battery and the
35 pin connector from the controller.
Check the resistance between pins
22, 23 on the truck connector
- measure the resistance of
the proportional valve circuit
and replace the proportional
valve if the resistance is lower
than 8Ω, if it is higher
replace the wiring

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ERROR CODE: 21521

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21521 EV2 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit with B+ after few seconds and check if the same
error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 15 and
pin 1 on the truck 35 pin connector
- If the resistance is lower than 20Ω
- replace EV2
- replace the wiring
4. Check the resistance between pin 15 and
pin 1 on the controller connector
- if the resistance is lower than 100kΩ,
replace the controller

ERROR CODE: 21522

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21522 EV2 failure The controller detects 1. Switch off the key switch and switch it on
that the circuit of EV2 after few seconds and check if the same
coil is open error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 15 on the
truck connector and the key switch
- If the resistance is higher than 50Ω
- replace EV2
- replace the wiring

ERROR CODE: 21523

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21523 EV2 failure The controller detects 1. Switch off the key switch and switch it on
a shor-circuit between after few seconds and check if the same
EV2 and B- error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 15 on the
truck connector and the controller power
terminal B-.
4. If the resistance is lower than 1000Ω
- replace EV2
- replace the wiring
5. Check the resistance between pin 15 and
pin 29 on the controller connector
- if the resistance is lower than 100kΩ
replace the controller

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ERROR CODE: 21524

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21524 EV3 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit to B+ after few seconds and check if the same
error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 16 on the
truck connector and the key switch
- If the resistance is lower than 20Ω
- replace EV3
- replace the wiring
4. Check the resistance between pin 16 and
pin 1 on the controller connector
- if the resistance is lower than 100kΩ,
replace the controller

ERRROR CODE: 21525

Truck behaviour: traction enabled, hydraulics disabled
LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21525 EV3 failure The controller detects 1. Switch off the key switch and switch it on
that the circuit of EV3 after few seconds and check if the same
coil is open error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 16 on the
truck connector and the key switch
- If the resistance is higher than 50Ω
- replace EV3
- replace the wiring

ERROR CODE: 21526

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21526 EV3 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit between after few seconds and check if the same
EV3 and B- error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 16 on the
truck connector and the controller power
terminal B-.
4. If the resistance is lower than 1000Ω
- replace EV3
- replace the wiring
5. Check the resistance between pin 16 and
pin 29 on the controller connector
- if the resistance is lower than 100kΩ,
replace the controller

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ERROR CODE: 21527

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21527 EV4 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit to B+ after few seconds and check if the same
error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 17 on the
truck connector and the key switch
- If the resistance is lower than 20Ω
- replace EV4
- replace the wiring
4. Check the resistance between pin 17 and
pin 1 on the controller connector
- if the resistance is lower than 100kΩ ,
replace the controller

ERROR CODE: 21528

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21528 EV4 failure The controller detects 1. Switch off the key switch and switch it on
that the circuit of EV4 after few seconds and check if the same
coil is open error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 17 on the
truck connector and the key switch
- If the resistance is higher than 50Ω
- replace EV4
- replace the wiring

ERROR CODE: 21529

Truck behaviour: traction enabled, hydraulic disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21529 EV4 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit between after few seconds and check if the same
EV4 and B- error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 17 on the
truck connector and the controller power
terminal B-.
4. If the resistance is lower than 1000Ω
- replace EV4
- replace the wiring
5. Check the resistance between pin 17 and
pin 29 on the controller connector
- if the resistance is lower than 100kΩ
replace the controller

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ERROR CODE: 21533

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21533 Horn failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit to B+ after few seconds and check if the same
error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 20 on the
truck connector and the key switch
- If the resistance is lower than 20Ω
- replace the horn
- replace the wiring
4. Check the resistance between pin 20 and
pin 1 on the controller connector
- if the resistance is lower than 100kΩ
replace the controller

ERROR CODE: 21534

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21534 Horn failure The controller detects 1. Switch off the key switch and switch it on
that the circuit of the after few seconds and check if the same
horn coil is open error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 20 on the
truck connector and the key switch
- If the resistance is higher than 50Ω
- replace the horn
- replace the wiring

ERROR CODE:21535

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21535 Horn failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit between after few seconds and check if the same
the horn and B- error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 20 on the
truck connector and the controller power
terminal B-.
4. If the resistance is lower than 1000Ω
- replace the horn
- replace the wiring
5. Check the resistance between pin 20 and
pin 29 on the controller connector
- if the resistance is lower than 100kΩ,
replace the controller

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ERROR CODE: 21540

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21540 EV5 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit to B+ after few seconds and check if the same
error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 19 on the
truck connector and the key switch
- If the resistance is lower than 20Ω
- replace EV5
- replace the wiring
4. Check the resistance between pin 19 and
pin 1 on the controller connector
- if the resistance is lower than 100kΩ,
replace the controller

ERROR CODE: 21541

Truck behaviour: traction enabled, hydraulic disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21541 EV5 failure The controller detects 1. Switch off the key switch and switch it on
that the circuit of EV5 after few seconds and check if the same
coil is open error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 19 on the
truck connector and the key switch
- If the resistance is higher than 50Ω
- replace EV5
- replace the wiring

ERROR CODE: 21542

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21542 EV5 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit between after few seconds and check if the same
EV5 and GND error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 19 on the
truck connector and the controller power
terminal B-.
4. If the resistance is lower than 1000Ω
- replace EV5
- replace the wiring
5. Check the resistance between pin 19 and
pin 29 on the controller connector
- if the resistance is lower than 100kΩ
replace the controller

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 DIAGNOSTICS SERVICE

ERROR CODE: 21543

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21543 EV6 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit to B+ after few seconds and check if the same
error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 21 on the
truck connector and the key switch
- If the resistance is lower than 20Ω
- replace EV6
- replace the wiring
4. Check the resistance between pin 21 and
pin 1 on the controller connector
- if the resistance is lower than 100kΩ
replace the controller

ERROR CODE: 21544

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21544 EV6 failure The controller detects 1. Switch off the key switch and switch it on
that the circuit of EV6 after few seconds and check if the same
coil is open error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 21 on the
truck connector and the key switch
- If the resistance is higher than 50Ω
- replace EV6
- replace the wiring

ERROR CODE: 21545

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21545 EV6 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit between after few seconds and check if the same
EV6 and B- error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 21 on the
truck connector and the controller power
terminal B-.
4. If the resistance is lower than 1000Ω
- replace EV6
- replace the wiring
5. Check the resistance between pin 21 and
pin 29 on the controller connector
- if the resistance is lower than 100kΩ
replace the controller

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 SERVICE DIAGNOSTICS

ERROR CODE: 21546 (Only COMBI 200A)

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21546 EV7 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit to B+ after few seconds and check if the same
error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 33 on the
truck connector and the key switch
- If the resistance is lower than 20Ω
- replace EV7
- replace the wiring
4. Check the resistance between pin 33 and
pin 1 on the controller connector
- if the resistance is lower than 100kΩ
replace the controller

ERROR CODE: 21547 (Only Combi 200A)

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21547 EV7 failure The controller detects 1. Switch off the key switch and switch it on
that the circuit of EV7 after few seconds and check if the same
coil is open error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 33 on the
truck connector and the key switch
- If the resistance is higher than 50Ω
- replace EV7
- replace the wiring

ERROR CODE: 21548 (Only Combi 200A)

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21548 EV7 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit between after few seconds and check if the same
EV7 and B- error code is repeated
2. Disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 33 on the
truck connector and the controller power
terminal B-.
4. If the resistance is lower than 1000Ω
- replace EV7
- replace the wiring
5. Check the resistance between pin 33 and
pin 29 on the controller connector
- if the resistance is lower than 100kΩ
replace the controller

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 DIAGNOSTICS SERVICE

ERROR CODE: 21549 (Only COMBI 200A)

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21549 EV8 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit to B+ after few seconds and check if the same
error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 34 on the
truck connector and the key switch
- If the resistance is lower than 20Ω
- replace EV8
- replace the wiring
4. Check the resistance between pin 34 and
pin 1 on the controller connector
- if the resistance is lower than 100kΩ,
replace the controller

ERROR CODE:21550 (Only Combi 200A)

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21550 EV8 failure The controller detects 1. Switch off the key switch and switch it on
that the circuit of EV8 after few seconds and check if the same
coil is open error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 34 on the
truck connector and the key switch
- If the resistance is higher than 50Ω
- replace EV8
- replace the wiring

ERROR CODE: 21551 (Only COMBI 200A)

Truck behaviour: traction enabled, hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21551 EV8 failure The controller detects 1. Switch off the key switch and switch it on
a short-circuit between after few seconds and check if the same
EV8 and B- error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 34 on the
truck connector and the controller power
terminal B-.
4. If the resistance is lower than 1000Ω
- replace EV8
- replace the wiring
5. Check the resistance between pin 34 and
pin 29 on the controller connector
- if the resistance is lower than 100kΩ
replace the controller

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 SERVICE DIAGNOSTICS

ERROR CODE: 21554

Truck behaviour: traction disabled, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21554 Dig. Input problem The controller detects 1. Switch off the key switch and switch it on
that the 1500mm after few seconds and check if the same
sensor is not open and error code is repeated
the 500mm sensor is 2. If it is, disconnect the battery
on 3. Check the truck wiring to see if it is
damaged
- replace the truck wiring
4. Check the 1500mm and 500mm
sensors
- replace the damaged sensor

ERROR CODE:21555

Truck behaviour: traction disabled, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21555 Dig. Input problem The controller detects 1. Switch off the key switch and switch it on
a problem or an after few seconds and check if the same
inappropriate state of error code is repeated
the side gates 2. If it is, check if both side gates are open or
closed
3. Disconnect the battery
4. Check the truck wiring to see if it is
damaged
- replace the truck wiring
5. Check if the contacts between the truck
wiring and the controller are OK
- replace the truck wiring
6. Check the sensors for detecting the side
gate state
- replace the damaged sensor

ERROR CODE: 21568

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21568 Main contactor The controller detects 1. Switch off the key switch and switch it on
problem that the main contactor after few seconds and check if the same
is not switched on error code is repeated
2. If it is, check the voltage drop across the
contacts of the main contactor
- if the voltage drop is higher than 2V,
replace the main contactor
3. Disconnect the battery
4. Check the fuse on the controller
- replace the fuse
5. Check the power wires that come to and
from the main contactor contacts
- replace the wires
6. Check if the wires are well tight on the main
contactor
- tighten the wires
7. Check if the wire from the main contactor is
well tight on the controller power terminal
B+
- tighten the wire

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 DIAGNOSTICS SERVICE

ERROR CODE: 21569

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21569 Main contactor The controller detects 1. Switch off the key switch and switch it on
problem that the main contactor after few seconds and check if the same
coil is shorted to B+ error code is repeated
2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 18 on the
truck connector and the key switch
- If the resistance is lower than 10Ω
- replace the main contactor
- check if the truck wiring is
damaged and if the wire of the main
contactor coil is shorted to B+
- Replace the wiring

ERROR CODE: 21570

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21570 Main contactor The controller detects 1. Switch off the key switch and switch it
problem that main remote on after a few seconds and check if the
control switch coil is same error code is repeated
opened 2. If yes, disconnect the battery
3. Measure the resistance of the main
remote control switch coil on the truck
connector
- If the resistance is higher than
50Ω replace the main remote
control switch
- If the error is repeated after
the main remote control switch
replacement, replace the wiring

ERROR CODE: 21571

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

21571 Main contactor The controller detects 1. Switch off the key switch and switch it
problem that there is a short on after a few seconds and check if the
circuit between the same error code is repeated
main remote control 2. If yes, disconnect the battery
switch and B -
3. Measure the resistance of the main
remote control switch coil on the truck
connector towards B -
- If the resistance is lower than
100Ω, replace the wiring and if the
still appears, replace the controller

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 SERVICE DIAGNOSTICS

ERROR CODE: 25088 (Only COMBI 200A)

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

25088 Software version The controller detects 1. Check the traction motor code No.
problem that the software 2. Check the software version that was
installed is not correct installed
for a motor with a 32 3. Install the correct software version
pulse encoder

ERROR CODE: 25089

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

25089 Software version The controller detects 1. Check the traction motor code No.
problem that the software 2. Check the software version that was
installed is not correct installed
for a motor with a 48 3. Install the correct software version
pulse encoder

ERROR CODE: 25090

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

25090 Software version The controller detects 1. Check the traction motor code No.
problem that the software 2. Check the software version that was
installed is not correct installed
for a motor with a 64 or 3. Install the correct software version
32 pulse encoder

ERROR CODE: 28945

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

28945 Electromagnetic The controller 1. Switch off the key switch and switch it on
brake problem detects that the after few seconds and check if the same
electromagnetic brake error code is repeated
coil is shorted to B+ 2. If it is, disconnect the battery
3. Disconnect the controller connector and
check the resistance between pin 14 on the
truck connector and the key switch
- If the resistance is lower than 15Ω
- replace the electromagnetic
brake
- replace the wiring
4. Check the resistance between pin 14 and
pin 1 on the controller connector
- if the resistance is lower than 100kΩ,
replace the controller

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 DIAGNOSTICS SERVICE

ERROR CODE: 28946

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

28946 Electromagnetic The controller 1. Switch off the key switch and switch it on
brake problem detects that the after few seconds and check if the same
electromagnetic brake error code is repeated
coil is shorted to B- or 2. If it is, disconnect the battery
open 3. Measure the resistance of the
electromagnetic brake coil
- If the resistance is higher than 50Ω,
replace the electromagnetic brake

ERROR CODE: 28947

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

28947 Electromagnetic The controller detects 1. Switch off the key switch and switch it
brake problem that there is a short on after few seconds and check if the
circuit between the same error code is repeated
electromagnetic brake 2. If yes, disconnect the battery
and B -
3. Measure the resistance of the
electromagnetic brake coil between pin
14 on the truck connector and B -
- If the resistance is lower than
100Ω replace the wiring
- If the error is repeated after the
wiring replacement, replace the
controller

ERROR CODE: 29445

Truck behaviour: traction and hydraulics disabled, main contactor switched off
LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

29445 Encoder problem The controller detects 1. Switch off the key switch and switch it on
that the signals or just after few seconds and check if the same
one signal from the error code is repeated
encoder are missing 2. If it is, check if the encoder connector is
disconnected
3. Measure the voltage at pin 30 of the
controller connector
- if the voltage is lower than 12V,
replace the controller
4. Turn the truck driving wheel and check with
an oscilloscope if the encoder signals exist.
If they do not, replace the encoder
5. Disconnect the battery
6. Check the wires between the encoder and
the controller
- if no short-circuit is present, replace
the wiring

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 SERVICE DIAGNOSTICS

ERROR CODE: 33056

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

33056 CAN open The controller cannot 1. Switch off the key switch and switch it on
communication reestablish the CAN after few seconds and check if the alarm
problem communication with appears again
the tiller board 2. Make sure all wiring connections between
the tiller board and the controller are tight
and safe
3. Check for the continuity of the wires that
serve for the CAN communication between
the tiller board and the controller
- replace the wiring
4. Internal failure in the tiller board
- replace the tiller board
5. Internal failure of the controller
- replace the controller

ERROR CODE: 33057

Truck behaviour: traction and hydraulics disabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

33057 CAN open The controller cannot 1. Reset the controller to see if the same error
communication reestablish the CAN code appears again
problem communication with 2. Make sure all wiring connections between
the EPAS controller the tiller board and the controller are tight
and safe
3. Check for the continuity of the wires that
serve for the CAN communication between
the EPAS controller and the controller
- replace the wiring
4. Internal failure in the EPAS controller
- replace the tiller board
5. Internal failure of the controller
- replace the controller

ERROR CODE: 36864

Truck behaviour: traction disabled, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

36864 EPAS problem The controller detects 1. Switch off the key switch and switch it on
that the security line after few seconds and check if the same
of EPAS has a too low error code is repeated
value 2. Make sure that the EPAS security line
connections between the EPAS controller
and the Combi controller are tight and safe
3. Check for the continuity of the EPAS
security line
- replace the wiring
4. Check if the EPAS controller fuse is burnt
- replace the fuse
5. Internal failure in the EPAS steering
system
- replace the failed component in the
EPAS system
6. Internal failure of the controller
- replace the controller

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 DIAGNOSTICS SERVICE

ERROR CODE: 65281

Truck behaviour: traction reduced, hydraulics enabled

LED on DDI: red

Error code Type of failure Failure explanation Troubleshooting

65281 Service The truck has reached 1. Carry out the scheduled service
the working hours 2. Update the service hours
set for the scheduled
service

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 SERVICE DIAGNOSTICS

2.00 ALARMS DERIVED FROM “EPAS” CONTROLLER

The alarms which block the machine are displayed on “DDI” with a nume-
rical alarm code preceded by two letters identifying the module in alarm,
the LED becomes red as well.
“Ep” followed by the alarm number corresponds to the “EPAS” steering
motor control.

CODE DESCRIPTION SYMPTOMS POSSIBLE CAUSES TEST PROCEDURES

Check if +24V is present on motor B+ terminal.

Ep 21588
No assistance, Lack of power supply, error on the If it is not present, check the fuse and the power
Co 36864 Power stage, fuse
the truck stops power MOSFET, fuse burnt connections. If the power supply is OK, there
might be a failure in the motor - replace the motor.
Bad electrical connection, not Check if the inductive sensor signal changes
Ep 29472
Straight wheel inductive No assistance, correctly installed (the distance condition (from 0 to +24V or vice versa) when the
Co 36864
sensor the truck stops between the sensor and the metal wheel passes to the neutral position. Check the
surface is too small or too big) assembly distance and the connections.
Ep 65281 Sensor broken, sensor features not Check the connections and verify that there
No assistance,
Co 36864 Torque sensor specified, bad electrical connection on are no short-circuits on the sensor connector. If
the truck stops
one of the six sensors everything is OK, replace the sensor.

Ep 65282 Torque bar broken, reducer broken, Check the trasmission between tiller and EPAS
No assistance,
Co 36864 Mechanical connection mechanical connection lost, bad motor, check the torque bar, check the torque
the truck stops
electrical connection on P1 sensor sensor connection on pin 5

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 DIAGNOSTICS SERVICE

3.00 ALARMS DERIVED FROM “TILLER” CONTROLLER

The alarms which block the machine are displayed on “DDI” with a nume-
rical alarm code preceded by two letters identifying the module in alarm,
the LED becomes red as well.
“Ti” followed by the alarm number corresponds to the tiller box board
“TILLER”.

CODE DESCRIPTION SYMPTOMS POSSIBLE CAUSES TEST PROCEDURES

The permanent memory The eeprom does

Ti 21024 The truck does not work Replace the tiller board
does not work not communicate

One or more tiller inputs are not on Switch off all the switches and put the throttle in
Start the control procedure The truck is 0. Caused by an operator or by the neutral position, release the proportional switches.
Ti 21552
of truck inputs waiting bad operation of an input (or of more If an alarm is still present, check the inputs and
inputs) replace them if they are broken or not operating.

Repeat potentiometer acquisition. Try to move

Procedure of potentiometer the throttle. If the error repeats itself, the neutral
Proportional
Ti 29456 Error in the throttle sensor acquisition not carried out, or throttle sensor or the throttle sensor are not working
switches disabled
sensor or neutral switch not working correctly. Check if the neutral switch changes its
condition correctly.

Error in the proportional One or both proportional switches are

Ti 29457 Replace the damaged switch
switches not working correctly

Bad operation
The Combi is not connected CAN connection broken or bad Check CAN connection between Combi and Tiller,
Ti 33072 of the Combi
or does not answer operation of the Combi controller check the Combi
controller
Bad operation
The Epas is not connected CAN connection interrupted or bad Check CAN connection between Epas and Tiller,
Ti 33073 of the Epas
or does not answer operation of the Epas controller check the Epas
controller
Inconsistency between Tiller method parameter in the tiller
the parameter in the tiller is not set for the truck provided with
Ti 33074 Key On Internal problem in the tiller (Change Ramtron).
and the truck hardware a numeric keypad, but the numeric
configuration keypad is present
Inconsistency between Tiller method parameter in the tiller
the parameter in the tiller is set for the truck provided with a
Ti 33075 Key On Internal problem in the tiller (Change Ramtron).
and the truck hardware numeric keypad, but the numeric
configuration keypad is not present

4.00 ALARMS DERIVED FROM “DDI” CONTROLER

The alarms which block the machine are displayed on “DDI” with a nume-
rical alarm code preceded by two letters identifying the module in alarm,
the LED becomes red as well.
“Dd” followed by the alarm number corresponds to the “DDI” display
control.

CODE DESCRIPTION SYMPTOMS POSSIBLE CAUSES TEST PROCEDURES

The hours stored in DDI The COMBI

The alarm automatically disappears Carry out the working hour passage procedure
DDI 21008 do not correspond to the controller has
10 minutes after the machine ignition from DDI to COMBI
Combi ones been replaced
The permanent memory The eeprom does
DDI 21024 The truck does not work Replace the “DDI” display
does not work not communicate

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SERVICE DIAGNOSTICS

DESCRIPTION OF COMBI CONTROL INPUTS/OUTPUTS

COMBI 200A COMBI 400A

Number of connector pin
P2.0SE P2.0S S1.2/1.5S P2.0SD S1.2/1.5S I.L.
1 Key-in Key-in Key-in Key-in Key-in
2 Digital Input 1 Connected to pin 6 Right guard rail sensor SW6, active input, high B+ Right guard rail sensor SW6, active input, high B+ Right guard rail sensor SW6, active input, high B+
Platform sensor SW3 open (down) - operator Open platform sensor SW3 (Down) - operator Open platform sensor SW3 (down) - operator Open platform sensor SW3 (down) - operator
3 Digital Input 2
presence - active input, high (B+) presence - activee input, high (B+) presence - active input, high (B+) presence - active input, high (B+)
Platform sensor SW4 closed (Su') - active input, Closed platform sensor SW4 (Up') - activee input, Closed platform sensor SW4 (Up') - active input, Closed platform sensor SW4 (Up') - active input,
4 Digital Input 3
high (B+) high (B+) high (B+) high (B+)
Push button for the Belly Switch enabling -
Push button for the Belly Switch enabling - Push button for the Belly Switch enabling - Push button for the Belly Switch enabling -
5 Digital Input 4 emergency reverse travel - activee input, high
emergency reverse travel - active input, high (B+) emergency reverse travel - active input, high (B+) emergency reverse travel - active input, high (B+)
(B+)
Left guard rail sensor SW5 - active input, high Left guard rail sensor SW5 - active input, high Left guard rail sensor SW5 - active input, high
6 Digital Input 5
(B+) (B+) (B+)
Tiller enabling sensor (Tiller Sensor) - active input, Tiller enabling sensor (Tiller Sensor) - active input, Tiller enabling sensor (Tiller Sensor) - active input, Tiller enabling sensor (Tiller Sensor) - active input,
7 Digital Input 6
high (B+) high (B+) high (B+) high (B+)
8 Digital Input 7 Optional Input Optional Input Optional Input Optional Input
9 Digital Input 8 Optional Input Optional Input Optional Input Optional Input
10 Digital Input 9 Jumpers Safety input "EPAS" - steering board Safety input "EPAS" - steering board Safety input "EPAS" - steering board
Sensor for the fork lifting at 500 mm "SW9" - high
11 Digital Input 10 Jumpers Jumpers Jumpers
active input (B+)
Deceleration sensor SW13 with the tiller rotated of Sensor for the fork lifting at 1500mm "SW8" - Sensor for the base arm lifting SW7 - active Input,
12 Digital Input 11 Jumpers
15° active Input, high (B+) high (B+)
Sensor for the fork lifting at 500mm "SW7" - Sensor for the fork lifting at 1500 mm "SW8" -
13 Digital Input 12 Connected to pin 12 Jumpers
active Input, high (B+) active Input, high (B+)
14 Digital output 1 Electromagnetic brake control output Electromagnetic brake control output Electromagnetic brake control output Electromagnetic brake control output
Power supply output of solenoid valve "EV2" for
15 Digital output 2 Not used
the fork lowering
Power supply output of solenoid valve "EV3" for
16 Digital output 3 Not used
the base arm lifting and lowering
Power supply output of solenoid valve "EV4" for
17 Digital output 4 Not used
the fork lifting
18 Digital output 5 Main contactor coil control output Main contactor coil control output Main contactor coil control output Main contactor coil control output
19 Digital output 6 Not used Main contactor coil control output Main contactor coil control output Main contactor coil control output
20 Digital output 7 Horn Main contactor coil control output Main contactor coil control output Main contactor coil control output
21 Digital output 8 Not used
Positive pole (B+) output of proportional solenoid Positive pole (B+) output of proportional solenoid Positive pole (B+) output of proportional solenoid Positive pole (B+) output of proportional solenoid
22 B+
valve "EV1" power supply (ON-OFF) valve "EV1" power supply (ON-OFF) valve "EV1" power supply (ON-OFF) valve "EV1" power supply (ON-OFF)
Negative pole (B-) output of solenoid valve "EV1" Negative pole (B-) output of solenoid valve "EV1" Negative pole (B-) output of solenoid valve "EV1" Negative pole (B-) output of solenoid valve "EV1"
23 B-
power supply (ON-OFF) power supply (ON-OFF) power supply (ON-OFF) power supply (ON-OFF)
24 Digital Input 14 Battery charger on board Accelerator signal from 0:+ 4,7V Accelerator signal from 0:+ 4.7V Accelerator signal from 0:+ 4,7V
25 Analogue input Drive motor thermal sensor Drive motor thermal sensor Drive motor thermal sensor Drive motor thermal sensor
26 Analogue input Optional Input Optional Input Optional Input Optional Input
27 Can High Can High Can High Can High
Can bus
28 Can Low Can Low Can Low Can Low
29 GND Drive motor encoder power supply negative pole Drive motor encoder power supply negative pole Drive motor encoder power supply negative pole Drive motor encoder power supply negative pole
30 +12 V Drive motor encoder power supply positive pole Drive motor encoder power supply positive pole Drive motor encoder power supply positive pole Drive motor encoder power supply positive pole
31 Phase A Drive motor encoder phase A Drive motor encoder phase A Drive motor encoder phase A Drive motor encoder phase A
32 Phase B Drive motor encoder phase B Drive motor encoder phase B Drive motor encoder phase B Drive motor encoder phase B
33 Digital output Available
34 Digital output Available
35 Digital output Available

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SERVICE ELECTRIC SYSTEM

WIRING DIAGRAM
MOD. P2.0S

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SERVICE ELECTRIC SYSTEM

SHEATH CONNECTING DIAGRAM

Ref Connector description
MOD.P2,0S
CPS1 COMBI control connector
CPS2 General contactor connector
CPS3 Tiller sheath connector
CPS4 Drive motor encoder connector
CPS6 Drive motor temperature sensor connector
CPS7 Electromagnetic brake connector
CPS8 Man on board sensor connector (SW3)
CPS9 Closed board sensor connector (SW4)
CPS10 Right guard rail sensor connector (SW5)
CPS11 Left guard rail sensor connector (SW6)
CPS12 Cooling fan connector (if any)
CPS13 Electromagnetic brake direct connector (override brake)
CPS14 Proportional solenoid valve EV1 connector
T6-T7-T8 Horn and electronic buzzer Faston connector
T3-T4-T5 Steering calibration switch Faston connector (EPAS)
CPS18 Solenoid valve connector
CPS19 Mast sensor connector
CPS19A Lifted outrigger sensor connector (SW9)
CPS19B Connector of fork sensor below 1500mm (SW8)
CPS19C Connector of fork sensor below 500mm (SW7)
CPS21 Connector of "computer for parameter adjustment"
CPS22 "DDI" display diagnostic connector
CPS23 Connector (Stacker lifting block, backing push button)
CPS30 "ETAC" interface connector
CPS31 Serial interface connector (Only for Iskra technicians)
CPS33 Connector of auxiliary function solenoid valves
CPSK Key switch connector
CPSTS Connector of "Torque Sensor" steering potentiometer

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2
SERVICE ELECTRIC SYSTEM

POWER WIRE CONNECTING DIAGRAM

MOD. P2.0S - P2.0SD - S1.2/1.5S - S1.2/1,5S I. L.

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3
SERVICE ELECTRIC SYSTEM

WIRING DIAGRAM
MOD. P2.0S Mechanical steering

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6a
SERVICE ELECTRIC SYSTEM

Ref Connector description

SHEATH CONNECTING DIAGRAM
MOD.P2,0S Mechanical Steering
CPS1 COMBI control connector
CPS2 General contactor connector
CPS3 Tiller sheath connector
CPS4 Drive motor encoder connector
CPS6 Drive motor temperature sensor connector
CPS7 Electromagnetic brake connector
CPS8 Man on board sensor connector (SW3)
CPS9 Closed board sensor connector (SW4)
CPS10 Right guard rail sensor connector (SW5)
CPS11 Left guard rail sensor connector (SW6)
CPS12 Cooling fan connector (if any)
CPS13 Electromagnetic brake direct connector (override brake)
CPS14 Proportional solenoid valve EV1 connector
T6-T7-T8 Horn and electronic buzzer Faston connector
T3-T4-T5 Steering calibration switch Faston connector (EPAS)
CPS18 Solenoid valve connector
CPS19 Mast sensor connector
CPS19A Lifted outrigger sensor connector (SW9)
CPS19B Connector of fork sensor below 1500mm (SW8)
CPS19C Connector of fork sensor below 500mm (SW7)
CPS21 Connector of "computer for parameter adjustment"
CPS22 "DDI" display diagnostic connector
CPS23 Connector (Stacker lifting block, backing push button)
CPS30 "ETAC" interface connector
CPS31 Serial interface connector (Only for Iskra technicians)
CPS33 Connector of auxiliary function solenoid valves
CPSK Key switch connector
CPSTS Connector of "Torque Sensor" steering potentiometer

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6b
SERVICE ELECTRIC SYSTEM

POWER WIRE CONNECTING DIAGRAM

MOD. P2.0S Mechanical Steering

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SERVICE ELECTRIC SYSTEM

WIRING DIAGRAM
MOD. P2.0SD

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1
SERVICE ELECTRIC SYSTEM

Ref Connector description

SHEATH CONNECTING DIAGRAM
MOD. P2.0SD
CPS1 COMBI control connector
CPS2 General contactor connector
CPS3 Tiller sheath connector
CPS4 Drive motor encoder connector
CPS6 Drive motor temperature sensor connector
CPS7 Electromagnetic brake connector
CPS8 Man on board sensor connector (SW3)
CPS9 Closed board sensor connector (SW4)
CPS10 Right guard rail sensor connector (SW5)
CPS11 Left guard rail sensor connector (SW6)
CPS12 Cooling fan connector (if any)
CPS13 Electromagnetic brake direct connector (override brake)
CPS14 Proportional solenoid valve EV1 connector
T6-T7-T8 Horn and electronic buzzer Faston connector
T3-T4-T5 Steering calibration switch Faston connector (EPAS)
CPS18 Solenoid valve connector
CPS19 Mast sensor connector
CPS19A Lifted outrigger sensor connector (SW9)
CPS19B Connector of fork sensor below 1500mm (SW8)
CPS19C Connector of fork sensor below 500mm (SW7)
CPS21 Connector of "computer for parameter adjustment"
CPS22 "DDI" display diagnostic connector
CPS23 Connector (Stacker lifting block, backing push button)
CPS30 "ETAC" interface connector
CPS31 Serial interface connector (Only for Iskra technicians)
CPS33 Connector of auxiliary function solenoid valves
CPSK Key switch connector
CPSTS Connector of "Torque Sensor" steering potentiometer

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2
SERVICE IMPIANTO ELETTRICO

WIRING DIAGRAM
MOD. S1.2S - S1.5S

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1
SERVICE IMPIANTO ELETTRICO
Ref Connector description SHEATH CONNECTING DIAGRAM
MOD. S1.2S - S1.5S
CPS1 COMBI control connector
CPS2 General contactor connector
CPS3 Tiller sheath connector
CPS4 Drive motor encoder connector
CPS6 Drive motor temperature sensor connector
CPS7 Electromagnetic brake connector
CPS8 Man on board sensor connector (SW3)
CPS9 Closed board sensor connector (SW4)
CPS10 Right guard rail sensor connector (SW5)
CPS11 Left guard rail sensor connector (SW6)
CPS12 Cooling fan connector (if any)
CPS13 Electromagnetic brake direct connector (override brake)
CPS14 Proportional solenoid valve EV1 connector
T6-T7-T8 Horn and electronic buzzer Faston connector
T3-T4-T5 Steering calibration switch Faston connector (EPAS)
CPS18 Solenoid valve connector
CPS19 Mast sensor connector
CPS19A Lifted outrigger sensor connector (SW9)
CPS19B Connector of fork sensor below 1500mm (SW8)
CPS19C Connector of fork sensor below 500mm (SW7)
CPS21 Connector of "computer for parameter adjustment"
CPS22 "DDI" display diagnostic connector
CPS23 Connector (Stacker lifting block, backing push button)
CPS30 "ETAC" interface connector
CPS31 Serial interface connector (Only for Iskra technicians)
CPS33 Connector of auxiliary function solenoid valves
CPSK Key switch connector
CPSTS Connector of "Torque Sensor" steering potentiometer

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2
SERVICE ELECTRIC SYSTEM

WIRING DIAGRAM
MOD. S1.2S - S1.5S Mechanical steering

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12a
SERVICE ELECTRIC SYSTEM

Ref Connector description

SHEATH CONNECTING DIAGRAM
MOD.S1.2S - S1.5S Mechanical Steering
CPS1 COMBI control connector
CPS2 General contactor connector
CPS3 Tiller sheath connector
CPS4 Drive motor encoder connector
CPS6 Drive motor temperature sensor connector
CPS7 Electromagnetic brake connector
CPS8 Man on board sensor connector (SW3)
CPS9 Closed board sensor connector (SW4)
CPS10 Right guard rail sensor connector (SW5)
CPS11 Left guard rail sensor connector (SW6)
CPS12 Cooling fan connector (if any)
CPS13 Electromagnetic brake direct connector (override brake)
CPS14 Proportional solenoid valve EV1 connector
T6-T7-T8 Horn and electronic buzzer Faston connector
T3-T4-T5 Steering calibration switch Faston connector (EPAS)
CPS18 Solenoid valve connector
CPS19 Mast sensor connector
CPS19A Lifted outrigger sensor connector (SW9)
CPS19B Connector of fork sensor below 1500mm (SW8)
CPS19C Connector of fork sensor below 500mm (SW7)
CPS21 Connector of "computer for parameter adjustment"
CPS22 "DDI" display diagnostic connector
CPS23 Connector (Stacker lifting block, backing push button)
CPS30 "ETAC" interface connector
CPS31 Serial interface connector (Only for Iskra technicians)
CPS33 Connector of auxiliary function solenoid valves
CPSK Key switch connector
CPSTS Connector of "Torque Sensor" steering potentiometer

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SERVICE ELECTRIC SYSTEM

POWER CABLE CONNECTION SCHEME

MOD. S1.2/1.5S Mechanical steering

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3
SERVICE ELECTRIC SYSTEM

WIRING DIAGRAM
MOD. S1.2S I. L. - S1.5S I. L.

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1
SERVICE ELECTRIC SYSTEM

Ref Connector description

SHEATH CONNECTING DIAGRAM
MOD. S1.2S I. L. -S1.5S I. L.
CPS1 COMBI control connector
CPS2 General contactor connector
CPS3 Tiller sheath connector
CPS4 Drive motor encoder connector
CPS6 Drive motor temperature sensor connector
CPS7 Electromagnetic brake connector
CPS8 Man on board sensor connector (SW3)
CPS9 Closed board sensor connector (SW4)
CPS10 Right guard rail sensor connector (SW5)
CPS11 Left guard rail sensor connector (SW6)
CPS12 Cooling fan connector (if any)
CPS13 Electromagnetic brake direct connector (override brake)
CPS14 Proportional solenoid valve EV1 connector
T6-T7-T8 Horn and electronic buzzer Faston connector
T3-T4-T5 Steering calibration switch Faston connector (EPAS)
CPS18 Solenoid valve connector
CPS19 Mast sensor connector
CPS19A Lifted outrigger sensor connector (SW9)
CPS19B Connector of fork sensor below 1500mm (SW8)
CPS19C Connector of fork sensor below 500mm (SW7)
CPS21 Connector of "computer for parameter adjustment"
CPS22 "DDI" display diagnostic connector
CPS23 Connector (Stacker lifting block, backing push button)
CPS30 "ETAC" interface connector
CPS31 Serial interface connector (Only for Iskra technicians)
CPS33 Connector of auxiliary function solenoid valves
CPSK Key switch connector
CPSTS Connector of "Torque Sensor" steering potentiometer

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2
SERVICE ELECTRIC SYSTEM

1.06 WIRING DIAGRAM

MOD. LO2.0M

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SERVICE ELECTRIC SYSTEM

Re f Conne ctor de scription

SHEATH CONNECTING DIAGRAM
MOD. LO2.0M
CPS1 COMBI control connector
CPS2 General contactor connector
CPS3 Tiller sheath connector
CPS4 Drive motor encoder connector
CPS6 Drive motor temperature sensor connector
CPS7 Electromagnetic brake connector
CPS8 Man on board sensor connector (SW 3)
CPS9 Closed board sensor connector (SW 4)
CPS12 Cooling fan connector
CPS13 Electromagnetic brake direct connector (override brake)
CPS14 Proportional solenoid valve EV1 connector
CPS18 Solenoid valve connector (EV2, EV3,EV4)
CPS19 Mast sensor connector (SW 6 - SW 7 - SW 8)
CPS21 Connector of "computer for parameter adjustment"
CPS22 "DDI" display diagnostic connector
CPS24 Steering sensor connector (SW 5)
CPS28 Sensor connector (SW 3 - SW 4 - SW 10 - SW 11 - SW 12)
CPS29 Forward/reverse push button P6 - P7 connector with operator on the ground
CPS30 "ETAC" interface connector
CPS31 Serial interface connector (Only for Iskra technicians)
CPS32 Emergency push button T2, T3 connector
CPS33 Connector of auxiliary function solenoid valves
CPSK Key switch connector
CPSTS Connector of "Torque Sensor" steering potentiometer
T6-T7-T8 Horn and electronic buzzer Faston connector

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2
SERVICE ELECTRIC SYSTEM

WIRING DIAGRAM
MOD. LO2.0M Mechanical steering

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1
SERVICE ELECTRIC SYSTEM

SHEATH CONNECTING WIRING

Ref Connector description
MOD. LO2.0M Mechanical steering
CPS1 COMBI control connector
CPS2 General contactor connector
CPS3 Tiller sheath connector
CPS4 Drive motor encoder connector
CPS6 Drive motor temperature sensor connector
CPS7 Electromagnetic brake connector
CPS8 Man on board sensor connector (SW3)
CPS9 Closed board sensor connector (SW4)
CPS12 Cooling fan connector
CPS13 Electromagnetic brake direct connector (override brake)
CPS14 Proportional solenoid valve EV1 connector
CPS18 Solenoid valve connector (EV2, EV3,EV4)
CPS19 Mast sensor connector (SW6 - SW7 - SW8)
CPS21 Connector of "computer for parameter adjustment"
CPS22 "DDI" display diagnostic connector
CPS24 Steering sensor connector (SW5)
CPS28 Sensor connector (SW3 - SW4 - SW10 - SW11 - SW12)
CPS29 Forward/reverse push button P6 - P7 connector with operator on the ground
CPS30 "ETAC" interface connector
CPS31 Serial interface connector (Only for Iskra technicians)
CPS32 Emergency push button T2, T3 connector
CPS33 Connector of auxiliary function solenoid valves
CPSK Key switch connector
CPSTS Connector of "Torque Sensor" steering potentiometer
T6-T7-T8 Horn and electronic buzzer Faston connector

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2
SERVICE ELECTRIC SYSTEM

POWER CABLE CONNECTING DIAGRAM

MOD. LO2.0M Mechanical steering

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3
SERVICE ELECTRIC SYYSTEM

1.08 WIRING DIAGRAM

MODEL P2.0SE

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SERVICE ELECTRIC SYSTEM 24

ELECTRIC COMPONENTS
MOD. P2.0SD
11

10

23

12

9
15
8

13

6 22
14 5
1
2
4
19 7 20
16 3

18 17 21

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SERVICE ELECTRIC SYSTEM

ELECTRIC COMPONENTS
MOD. S1.2-1.5S
11

10

23

15 9 22

8
13 12

2
14 6

4 7
19 16 20
1

18 17 21

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SERVICE ELECTRIC SYSTEM

ELECTRIC COMPONENTS
MOD. S1.2-1.5S I.L.

11

10

24

12
23
15

13 9

14 5
6
2
19 16 4 20
7
1 22

18 17 21

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1
 ELECTRIC SYSTEM SERVICE

22.00 REPLACEMENT OF THE DRIVE DECELERATION SENSOR LOCATED ON THE FORKS

MOD. P2.0SD - S1.2S - S1.5S - S1.2S I.L. - S1.5S I.L.

Necessary tools

small cross-head 4 mm scissors

screwdriver Allen wrench

Procedure
Before starting to work wear suitable safety clothes.
Fig. 1
Park the truck in a safe area,away from the transit of other
motor vehicles and from the passage of pedestrians.
Lower the forks to the ground, turn the key switch OFF
and disconnect the battery.

Step 1
Lift the forks up to a height allowing working in safe and seeing the sensor
located at the mast base. Turn the key switch OFF and disconnect the
battery

Step 2
4mm ALLEN WRENCH, SCISSORS
By using the Allen wrench loosen and remove the clamp fastening screws B
(ref A fig.2).
By using the scittors remove the cable clamp, disconnect the connector
located on the battery compartment and remove the sensor complete
with clamp.

Step 3
A
SCREWDRIVER
Fig. 2
Loosen the screw locking the sensor in the clamp by means of the
screwdriver (ref.B fig.2). Remove the sensor and replace it.

To assemble carry out the procedure in the reverse order.

The optimum sensor reading distance from the cam s 4 mm.

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