MAINTENANCE AND REPAIR

INTERVENTIONS ON
MERLO REMOTE CONTROL UNITS

MARIRAD.01
 INDEX

SAFETY STANDARDS................................................................................................................ 1
COMPONENTS ........................................................................................................................... 2
FEATURES.................................................................................................................................. 3
DIAGNOSTICS - FAULTS - ANOMALIES................................................................................... 4
TROUBLESHOOTING ................................................................................................................ 5
BATTERY CHARGE LEVEL CHECK ......................................................................................... 6
REPLACEMENT OF RADIO CONTROL COMPONENTS .......................................................... 7
 1 - SAFETY STANDARDS

WARNING!!!
The present manual contains an extensive description of the procedures to be applied to MERLO RADIO CONTROLS in case of
malfunctioning which are not contained in the REMOTE CONTROL UNIT INSTRUCTION MANUAL. It is therefore aimed at
skilled personnel with a sufficiently deep knowledge of the mechanical components and electric and electronic systems of
the vehicle on which they are operating.
The repair workshop manager is responsible for the application of all accident prevention and environmental standards and
he shall implement all the measures he deems necessary to prevent accidents during maintenance operations (some
suggestions are listed in the OPERATION AND MAINTENANCE MANUAL).

NOTES!!!
This manual only provides information on the "MERLO" REMOTE CONTROL UNIT and the possibile replacement and /or
calibration of its component. Therefore:

- For information on the proper operation of the machine components and controls mentioned in the following pages,
please refer to the relevant OPERATION AND MAINTENANCE MANUAL.
- For any reference to electric diagrams, connections and terminals mentioned in the following pages, please reger to
the ELECTRIC SYSTEM MANUAL of the relevant machine.
- For any reference to the hydraulic system please refer to the HYDROSTATIC TRANSMISSION MANUALE of the relevant
machine.

IMPORTANT!!!
The REMOTE CONTROL UNIT is designed and manufactured according to Merlo specifications. In order to prevent accidents
and ensure maximum performance, the equipment shall not be changed or modified in any way which is not approved by
Merlo S.p.A. and shall not be used in conditions or for purposes which are not explicitely indicated.

WARNING!
This safety alert symbol indicates important safety messages in this manual. When you see this symbol, pay particular
attention and carefully read the text that follows.

All information, illustrations and specifications contained in this manual are based on the product available at the time of publication.
Merlo S.p.A. reserves the right to make any necessary changes without previous notice.

PROTECTION DEVICES

All radio controls have been fitted with a stop push-button on the control panel of the transmitting unit.
The radio control system has further protection which are automatically activated in the following cases:
- There is a radio interference in the working area that affects the frequency range of the radio control;
- The action range of the transmitting unit is exceeded.
In such situations, the radio control immediately activates the Emergency Stop and interrupts any outgoing signal from the
receiving unit whilst maintaining continuous radio contact between the transmitter and receiver.

IMPORTANT!!!
Always review the operating instructions of your machine in order to be aware of any further important information to be
observed. When placing the transmitter away during breaks, the user must make sure that no unauthorized people can use it
by turning the switch off or removing the key and locking it in a safe place. This will prevent any illicit operation by
unauthorised third parties.
The user must be able to access all operating instructions necessary for the smooth operation of the machine he is
controlling. Before using the radio control, the user shall also read and fully understand each section of this manual.

1-1
 2 - COMPONENTS

IMPORTANT!!!
The table below contains the description and code number of the material required to repair the REMOTE CONTROL UNITS
manufactured by Merlo S.p.A.
Before placing any order for the following material, always check its availability and make sure you have included the
correct details.

DESCRIPTION
Radio control lower box

p/n: 048424

01

Radio control battery

p/n: 045645

02

APD connector

p/n: 060948

03

2-1
 2 - COMPONENTS

DESCRIPTION

APD connector cap

p/n: 047831

04

NEW emergency push-button with key

p/n: 060946

05

Key for NEW emergency push-button

p/n: 061943

06

2-2
 2 - COMPONENTS

DESCRIPTION

OLD Joystick

p/n: 045649

07

Key for OLD emergency push-button

p/n: 055897

08

WARNING!!!
If the old emergency stop key button needs replacing (see
picture), order component 05 in the table (code 060946),
as it is interchangeable with the previous model.

2-3
 2 - COMPONENTS

DESCRIPTION

NEW joystick for radio control

p/n: 060947

09

Sticker for radio control

p/n: 051981

10

Sticker for radio control multi-function

p/n: 055275

11

2-4
 2 - COMPONENTS

DESCRIPTION

Belt for radio control

p/n: 049378

12

Warning horn for radio control

p/n: 045646

13

Seal between the upper and the lower

radio control box

p/n: 048436

14

2-5
 2 - COMPONENTS

DESCRIPTION

Button for radio control monitor

p/n: 045339 (BLUE button)

p/n: 045766 (RED button)

15

Emergency button without key (only for

the radio control STEP 2)

p/n: 048440

16

WARNING!!!
The quantity of each component listed in the previous tables is to be considered as one unit. For each order, it will therefore
be necessary to specify the quantity of each component you wish to receive.

2-6
 3 - FEATURES

This chapter describes the features of MERLO radio controls so as to facilitate the identification of the radio control model you own
and any necessary maintenance operation which is appropriate to that specific type.

The radio controls manufactured by MERLO s.p.A. can be subdivided into two categories:

(A) RADIO CONTROL "STEP2" (old generation)

(B) RADIO CONTROL "STEP3" (new generation)

The new "STEP3" model differs from the previous version in terms of internal components and updated software.
Externally, you can identify the two versions by looking at:

(a) presence of the movement enable lever (only on version

"STEP2")
(b) type of emergency button (differs according to radio
control)

This manual refers to the following radio controls:

RADIO CONTROL "STEP2" for operation from the platform (code 049370)

3-1
 3 - FEATURES

RADIO CONTROL "STEP3" for operation from the platform (code 053348)
RADIO CONTROL "STEP3" for operation from the platform and radio (code 050706)

Multifuction RADIO CONTROL "STEP3" for operation from the platform (code 054990)
Multifuction RADIO CONTROL "STEP3" for operation from the platform and radio (code 055800)

The multifunction radio control supports the use of the MERLO handler and any accessories attached to it (i.e. SPACE)

3-2
 4 - DIAGNOSTICS - FAULTS - ANOMALIES

IMPORTANT !!!
The diagnostic system this manual refers to is available only on "STEP3" radio controls.

Any misfunction or component anomaly of the MERLO radio control owned is signalled to the operator by the radio control itself every
time it is switched on and for a period of about 4-5 seconds.

Example: on STEP 3 radio controls, in case of fault, the display

shows the text FAULT with the identification of the relevant
component.

WARNING!!!
Before replacing any component, carefully check its status. If you are using a "STEP 3" radio control, plase access the radio
control diagnostic system to better carry out such check.

WARNING!!!
The diagnostic system is available only on STEP 3 radio controls.

The diagnostic system on MERLO SpA radio controls allows to view, on the diagnostic screen, the anomaly currently detected on the
radio control. The user can therefore intervene on the relevant component without further investigate where the problem comes from.

ACCESS TO THE DIAGNOSTIC SYSTEM

To access the diagnostic system, proceed as follows:

a) Switch on the radio control by rotating the key on the side
emergency button.
b) Press and hold the blue button MODE until the radio
control emits a triple sound signal.
c) After the sound signal, while still keeping the blue button
MODE pressed, press the red button on the right side of
the display (under button MODE). The diagnostic screen
will appear.

The screen contains two lines, each made of a series of dots.

Each possible radio control anomaly corresponds to a specific
number or letter which replaces a dot.

IMPORTANT!!!
The absence of numbers or letters in the diagnostic display lines indicates the radio control correct operation.

4-1
 4 - DIAGNOSTICS - FAULTS - ANOMALIES

The table below shows the correspondence between numbers or letters and the radio control anomaly detected.

FIRST LINE SECOND LINE

0 Joystick 1 center position switch error 0 ERROR on the electrical cards inside the Radio Control
1 Joystick 2 center position switch error 1 ERROR on the electrical cards inside the Radio Control
2 Joystick 3 center position switch error 2 Joysticks not calibrated
3 Joystick 4 center position switch error 3 Battery ERROR; both discharged
4 Joystick 5 center position switch error 4 “A” battery ERROR
5 ERROR on the electrical cards inside the Radio Control 5 “B” battery ERROR
Battery ERROR; necessary replace both the battery after 500
6 ERROR on the electrical cards inside the Radio Control 6
recharge cycle
7 ERROR on the electrical cards inside the Radio Control 7 ERROR on the electrical cards inside the Radio Control
8 Joystick 1 center position switch error 8 ERROR on the electrical cards inside the Radio Control
9 Joystick 2 center position switch error 9 ERROR on the electrical cards inside the Radio Control
a Joystick 3 center position switch error a ERROR on the electrical cards inside the Radio Control
b Joystick 4 center position switch error b ERROR on the electrical cards inside the Radio Control
c Joystick 5 center position switch error c ERROR on the electrical cards inside the Radio Control
d ERROR on the electrical cards inside the Radio Control d ERROR on the electrical cards inside the Radio Control
e ERROR on the electrical cards inside the Radio Control e ERROR on the electrical cards inside the Radio Control
f ERROR on the electrical cards inside the Radio Control

WARNING !!!
The anomaly corresponding to number 0, if present, is shown on the first or second line, on the first dot on the left side of
the display.

4-2
 5 - TROUBLESHOOTING

This Chapter describes the procedures required to solve any problem detected during the diagnostic control.

WARNING !!!
All faults - displayed both on the first and second line of the diplay and in the lists above - which correspond to the
description "Fault on internal interface boards" CANNOT BE CHECKED/CORRECTED BY THE USER.
For this type of fault, please follow the instructions provided directly by the Merlo SpA Support Service.
In such cases, the radio control shall be sent to MERLO SpA for the necessary check and repair operations.

FIRST LINE

ERROR reported Problem Intervention necessary:

0 Problem on the Joystick 1 Replace the Joystick 1

1 Problem on the Joystick 2 Replace the Joystick 2
2 Problem on the Joystick 3 Replace the Joystick 3
3 Problem on the Joystick 4 Replace the Joystick 4
4 Problem on the Joystick 5 Replace the Joystick 5
5 Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
6 Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
7 Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
8 Problem on the Joystick 1 Replace the Joystick 1
9 Problem on the Joystick 2 Replace the Joystick 2
a Problem on the Joystick 3 Replace the Joystick 3
b Problem on the Joystick 4 Replace the Joystick 4
c Problem on the Joystick 5 Replace the Joystick 5
d Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
e Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
f Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance

5-1
 5 - TROUBLESHOOTING

SECOND LINE

ERROR reported Problem Intervention Necessary

0 Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
1 Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
2 Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
3 Battery discharged Recharge both the battery
1. Verify the loading of the battery in subject and
the connetion of this connector inside the
radiocontrol.
4 Problem on the “A” battery
2. If the problemi s not solved aftre the
verificationo n the point (1), replace the
battery
1. Verify the loading of the battery in subject and
the connetion of this connector inside the
radiocontrol.
5 Problem on the “B” battery
2. If the problemi s not solved aftre the
verificationo n the point (1), replace the
battery
6 Battery discharged Replace both the battery
7 Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
8 Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
9 Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
a Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
b Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
c Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
d Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance
e Error on the electrical cards inside the radio control Contact the MERLO SpA Service Assistance

WARNING !!!
In the case are present in the same time two error code between the number "0" and the number "4" (for example; the
number "1" and the number "3") or between the number "8" and the letter "c" (for example; the number "9" and the letter "b"),
it's probabile the problem on the radio control was caused from the electrical cards inside the Radio Control; in this case
will be necessary contact directly the MERLO SpA Assistance Service.

5-2
 5 - TROUBLESHOOTING

JOYSTICK CALIBRATION

Should it be necessary to calibrate one or more joysticks, please follow the instructions below. They differ according to the type of
radio control being calibrated.

RADIO CONTROL STEP 3 (includine the multifunction model)

1] Switch on the radio control by rotating the key located on the side emergency button.
2] Press the blue MODE button and hold it until the radio control emits a triple sound signal.
3] After such signal, while still pressing the blue MODE button, press the red button on the right of the display (under the MODE
button) and access the radio control diagnostics.
4] Press the same red button twice to access the screen
illustraded here.
5] Keep pressing the blue button shown in the picture until
the radio control emits a triple sound signal.

6] Bring all joysticks to their end stops, first up and then

down, and check how values vary on the display.

ATTENTION !!!
aftre the joysticks control, verify that is present "OK" at the
side of the value reported.

Verify also that the value on the brackets at the right of

the display, is bigger than 10; otherwise will be necessari
replace the joystick in subject.

5-3
 5 - TROUBLESHOOTING

Once the joystick sequence has been completed, press

the blue AUX1 button, and make sure that the screen
illustrated here appears on the display.

Verify that the values present are inside the maximun

value 543 and the minimun value 477. Otherwise on the
display will appear the image below, and will be necessari
replace the interested joystick.

For individualize the joystick needing the replacement,

follow the instruction from the point 1 to point 3, and
push one time the red button.

NOTE !!!
If working on a multifuction radio control, act on the right
selector: bring it to a vertical position and then rotate it
back to a horizontal position. Also in this case, the screen
illustrated here shall appear.

5-4
 5 - TROUBLESHOOTING

7) To save the completed calibration, press the buttons

indicated in the picture simultaneoulsy until the SAVE OK
screen appears.

8) To confirm the calibration saving operation, switch off the radio control with the side mushroom button.

RADIO CONTROL STEP 2

1] Press the red MODE button and, at the same time, switch
on the radio control by rotating the side emergency
button.

2] Press the left blue button and follow the instructions on the display.

5-5
 5 - TROUBLESHOOTING

3] Bring all joysticks to their end stops, first up and then

down.

4] Release the joysticks and the blue button and wait for the
radio control to save the calibration, until the illustrated
screen appears.

5] Press the red MODE button to conclude the operation.

If, after the calibration procedure, anomalies are still detected on the joystick and faults are shown in the radio control diagnostic
system, the faulted joysticks shall be replaced.

WARNING !!!
For operations involving the replacement of the radio control components, carefully read the instructions found in Chapter 7
of the present manual "REPLACEMENT OF RADIO CONTROL COMPONENTS".

5-6
 6 - BATTERY CHARGE LEVEL CHECK

If any anomaly regarding the radio control battery charge level is detected, first make sure that the batteries have been charged on the
MERLO handler following the right procedure.
For information on such procedure, refer to the radio control operation and maintenance manual, provided with the relevant MERLO
handler at the time of delivery.

IMPORTANT!!!
The battery recharge operation MUST NOT BE
INTERRUPTED before the green led (see picture) has come
off. This ensures the battery correct conservation
condition and its correct recharging.

If you still encounter problems with the charging level of the radio control battery, check the charge status by accessing the diagnostic
menu and proceed as follows:
1] Switch on the radio control by rotating the key on the side emergency button
b) Press and hold the blue button MODE until the radio control emits a triple sound signal.
c) After the sound signal, while still keeping the blue button MODE pressed, press the red button on the right side of the display and
access the radio control diangostics.
4] Press the same red button five times to access the screen
shown here.

5] Check the letters on the right, which indicate the two batteries charge status.
According to the letter which appears, the battery is:
F = Load battery
D = Battery used by radio control
C = Battery now in reloading
E = Unload battery, reload now.

If, after carrying out the correct charging procedure, you still detect an anomaly in the batteries and the radio control diagnostic system
shows a fault, the batteries shall be replaced.

WARNING!!!
When replacing the radio control components, carefully read the istructions container in chapter 7 "REPLACEMENT OF
RADIO CONTROL COMPONENTS".

6-1
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

This chapter provides the correct description of the different procedures for the replacement of the components mounted on MERLO
S.p.A. radio controls; in particular:
A] Radio control lower protection
B] Radio control batteries
C] Wired APD connector
D] Emergency button
E] Joystick lever
F] Radio control top sticker
G] Radio control buzzer
H] Lower protection seal
I] Radio control monitor buttons

IMPORTANT !!!
Please, carefully follow the instructions provided and their sequence in order to prevent malfunctioning of the component
and the radio control.

[A] REPLACEMENT OF LOWER PROTECTION

1] Unscrew the four fastening screws on the side using a

suitable Allen wrench.

2] Remove the batteries and the APD connector from the bottom part to be replaced. For further information on these operations,
please refer to the section on component replacement.

3] Before fitting the new lower protection, apply a strip of

insulating silicone along its edge. This is required to
prevent water or any other fluid from penetratine into the
radio control during its operation.

4] Fit the new protection and secure it to the radio control through the four fastening screws.

7-1
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

[B] BATTERIES

1] To access the battery compartment, lift the lower protection and place it on a support at the side of the radio control, so as to
work on it without damaging the APD connector wiring.

IMPORTANT !!!
Should it be necessary to replace only one battery of your
radio control, first check whether letter "A" or letter "B"
appears on the display.
After opening the radio control as illustrated in the picture
above, you will see that battery "A" is always the one
connected to the connector on the right, closer to the
radio control edge and to the emergency button.

(1) = Connector of battery "A"

(2) = Connector of battery "B"

2] Disconnect all connectors on the radio control inner board in order to work on the batteries applied to the lower protection.

7-2
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

3] Unscrew the fastening screws of the brackets securing

the lower protection and procede with the replacement.

To mount the component back, carry out the above mentioned

operations in riverse order. Make sure that the battery and APD
connector wiring is positioned correctly before closing the
lower protection.

NOTE !!!
Before closing the lower protection, apply some insulating
silicone as mentioned in Paragraph "[A] RADIO CONTROL
LOWER PROTECTION".

[C] WIRED "APD" CONNECTOR

1] To access the APD connector compartment, lift the lower protection. Place the protection on a support, at the side of the radio
control, so as to work on it without damaging the battery wiring.

7-3
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

2] Disconnect the connector wiring from the radio control

inner board and unscrew the connector from the lower
protection.

3] Remove the APD connector from the lower protection

from one side.

4] While replacing the component, make sure not to damage

the seal between the component and the lower protection.

7-4
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

To mount back the component, carry out the above mentioned

operations in riverse order. Make sure to position correctly the
connectors wirings and APD connector wiring.

NOTE !!!
Before closing the lower protection, apply some insulating silicone as mentioned in Paragraph "[A] RADIO CONTROL LOWER
PROTECTION".

[D] EMERGENCY BUTTON

1] Open the radio control and remove the lower protection,

after disconnecting the central board connectors.

2] Release the inner board by unscrewing the two fastening

screws on the sides.

7-5
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

3] Vertically lift the board making sure not to damage the connector close to the emergency button.

4] Position the electric board so that it is possible to work

inside the radio control. Handle it carefully to prevent any
damage to the board itself or to the connectors inside the
radio control.

5] Disconnect the emergency button connector from the

electric board.

Replace the emergency button after removing the old one. This procedure varies according to the type of button fitted:

7-6
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

a] OLD GENERATION BUTTON

a1] Disconnect the connector on the button section which is

located inside the radio control.

a2] Unscrew the fastening ring nut close to the radio control
wall.

a3] Remove the damaged button and replace it with the new one.

7-7
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

b] NEW GENERATION BUTTON

b1] Disconnect the connector on the button section located inside the radio control. For this operation, use a screwdriver to open the
locking key.

b2] Unscrew the fastening ring nut close to the radio control
wall.

b3] Remove the damaged button and replace it with the new
one.

WARNING !!!
Even when replacing an old generation button, please
order the new one.

7-8
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

b4] Reconnect the wires to the new connector according to the tables below.

CONNECTOR LINE CONNECTOR LINE

2 RED 22 GREEN

3+ GREEN 12 RED

3- BLACK 11 WHITE

2 WHITE 21 BLACK

[E] JOYSTICK LEVER

The joystick replacement is required if calibration alone (See Chapter 5 "TROUBLESHOOTING") does not solve the radio control faults.
The operations needed for replacement vary according to the type of joystick:
a] JOYSTICK LEVER (OLD GENERATION)
b] JOYSTICK FOR RADIO CONTROL (NEW GENERATION)

a1] In this case, replacement is simply carried out by

unscrewing the four fastening screws and removing the
joystick. When pulling out the joystick to be replaced and
fitting the new one, make sure not to damage the inside
of the connector.

7-9
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

b1] In this case it is necessary to open the radio control.

b2] Inside the radio control, unscrew the two fastening screws of the joystick to be replaced.

b3] Remove the joystick making sure not to damage the

inside of the connector.

7 - 10
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

NOTE !!!
During replacement, make sure to properly fit the seal
between the radio control surface and the joystick.

[F] RADIO CONTROL TOP STICKER

Should it be necessary to replace this component, before applying the new sticker, take out all the button on the display. The tightness
on the radiocontrol of the sticker, is guarantie from the glue on the lower surface.

WARNING !!!
Make sure not to let any silicone penetrate inside the radio control and apply the sticker in the correct position.

[G] RADIO CONTROL BUZZER

1] For the replacement of this component, it is necessary to

open the radio control.

2] Disconnect the connector from the lower board.

7 - 11
 7 - REPLACEMENT OF RADIO CONTROL COMPONENTS

3] Loosen the buzzer fastening plastic ring nut.

4] Remove the component to be replaced and fit the new

one making sure to insert the seal correctly.

[H] LOWER PROTECTION SEAL

For the replacement of this componentn it is necessary to observe the instructions in Paragraph "[A] REPLACEMENT OF LOWER
PROTECTION" of this Chapter.
After replacing this component, it is extremely important to apply a layer of insulating silicone on it.

[I] RADIO CONTROL MONITOR BUTTONS

WARNING !!!
During the button replacement procedure, make sure that
no foreign body gets inside the radio control, and that the
spacer inside the button, doesn't lost durino the
replacement.

7 - 12