SERVICE Section: ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
ELECTRICAL
SYSTEM

D KEY TO ELECTRICAL DIAGRAMS ...................................................14

D KEY TO POSITION OF ELECTRICAL COMPONENTS ........................16

D FUNCTION INPUTS TABLE ................................................................ 18

D PARAMETER TABLES....................................................................... 20

D ACCESS PROCEDURE FOR CALIBRATION OF THE VARIOUS M ... 24

D TRACTION START SEQUENCE ......................................................... 27

D SPEED CUTBACK ............................................................................. 29

D MODULES REPLACEMENT PROCEDURE ....................................... 30

D SICOS DISPLAY ................................................................................ 36

D DISPLAY MENUS .............................................................................. 42

D PRE-HEIGHT SELECTOR .................................................................. 48

D ALARMS ............................................................................................ 54
D DIAGNOSTICS ................................................................................... 55

D TROUBLESHOOTING GUIDE ............................................................ 55

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 Section: ELECTRICAL SYSTEM SERVICE
1.0 KEY TO ELECTRICAL DIAGRAMS
MODEL ALL MODELS
ELECTRICAL SYSTEM

D i a g ra m D ia g r a m
D e sc ri p ti o n o f C o m p o n e n t
S y m b o l R e f. P a g e R e f.
SW 1 1/7 E m e rg e n c y p u s h b u t t o n
SW 2 1/7 K e y s w it c h
SW 3 2/7 O p e ra t o r p re s e n c e in d u c t ive s e n s o r
SW 4 2/7 S t e e r w h e e l c e n t re d in d u c t ive s e n s o r
SW 5 3/7 S p e e d re d u c t io n a n d h e ig h t in d ic a t o r z e ro in d u c t ive s e n s o r
SW 6 3/7 S p e e d re d u c t io n in h e ig h t in d u c t ive s e n s o r
SW 7 3/7 In d u c t ive s e n s o r - R e a c h c a rria g e fo rw a rd s t o p - R e a c h c a rria g e re tra c t d e c e le ra t io n
SW 8 3/7 In d u c t ive s e n s o r - R e a c h c a rria g e re tra c tio n s to p - R e a c h c a rria g e fo rw a rd d e c e le ra t io n
SW 9 3/7 F o rk s lo w e rin g d e c e le ra t io n in d u c t ive s e n s o r
S W 10 3/7 F o rk s lo w e rin g in t e rlo c k in d u c t ive s e n s o r
S W 11 3/7 L o a d p re s e n c e o n fo rk s in d u c t ive s e n s o r
S W 12 4/7 F o rw a rd t ra ve l c o m m a n d o n p e d a l in d u c tive s e n s o r
S W 13 4/7 R e ve rs e t ra ve l c o m m a n d o n p e d a l in d u c tive s e n s o r
S W 14 4/7 F o rw a rd /re ve rs e t ra ve l S t a rt in d u c t ive s e n s o r
S W 15 4/7 P e d a l b ra k e c o n tro l in d u c t ive b ra k in g s e n s o r
S W 16 4/7 B a t te ry o u t o f p o s it io n in d u c tive s e n s o r
S W 17 4/7 O p e ra t o r p re s e n c e m ic ro s w itc h lo c a t e d u n d e r s e a t (o p tio n a l)
S W 18 5/7 Tra c t io n p e rm is s ive p u s h b u t t o n w it h b a t t e ry o u t
S W 19 5/7 P a rk in g p e rm is s ive p u s h b u tt o n
S W 20 5/7 L o w s p e e d t ra ve l p e rm is s ive b u t t o n a n d p e rfo rm a n c e c h a n g e (S L O W - S TD - H A R D -
S W 21 4/7 H o rn b u t to n
S W 22 5/7 F ifth h y d ra u lic c irc u it c o n t ro l p u s h b u t to n
S W 23 5/7 A u t o m a t ic s c a le s c o n tro l p u s h b u t to n
S W 24 4/7 W o rk lig h t s p o w e r O N p u s h b u t t o n
S W 25 4c /7 F o rw a rd t ra ve l s e le c t o r b u t to n o n d a s h b o a rd
S W 26 4c /7 R e ve rs e t ra ve l s e le c t o r b u t to n o n d a s h b o a rd
FU1 1/7 A C 2 t ra c t io n c o n tro lle r 3 0 0 A p o w e r fu s e
FU2 1/7 A C 2 p u m p c o n t ro lle r 3 0 0 A p o w e r fu s e
FU3 1/7 E P S A C c o n t ro lle r 3 2 A p o w e r fu s e
FU4 1/7 A u x ilia ry lin e 1 0 A fu s e
FU5 2/7 A u x ilia ry lin e 1 0 A fu s e
FU6 2/7 A u x ilia ry lin e 1 0 A fu s e
FU7 2/7 A u x ilia ry lin e 6 A fu s e
EM B 2/7 E le c t ro m a g n e t ic b ra k e
ENC. M T R 2/7 Tra c t io n m o t o r e n c o d e r
EN C . M S 2/7 S t e e rin g m o t o r e n c o d e r
EN C . M P 3/7 P um p m otor enc oder
EN C . H .I 3/7 H e ig h t in d ic a tio n e n c o d e r
EV I 3/7 P ro p o rt io n a l lo w e rin g s o le n o id va lve
EV 2 3/7 P ro p o rt io n a l lift in g s o le n o id va lve
EV 3 3/7 R e a c h c a rria g e re t ra c t io n p ro p o rt io n a l s o le n o id va lve
EV 4 3/7 R e a c h c a rria g e e x t e n s io n p ro p o rt io n a l s o le n o id va lve
EV 5 3/7 Tilt B a c k s o le n o id va lve
EV 6 3/7 Tilt F W D s o le n o id va lve
EV 7 3/7 F o rk s rig h t -h a n d s id e s h ift s o le n o id va lve
EV 8 3/7 F o rk s le ft -h a n d s id e s h ift s o le n o id va lve
OPT. 1 3/7 O p tio n s s o le n o id va lve w irin g c o n n e c t o r
OPT. 2 3/7 O p tio n s s o le n o id va lve w irin g c o n n e c t o r
H1 4/7 H o rn
H2 4/7 R e ve rs e t ra ve l w a rn in g s o u n d e r
H3 4/7 W o rk lig h t s
H4 3/7 Tru c k in m o t io n fla s h in g w a rn in g b e a c o n
M1 2/7 M o t o r c o m p a rt m e n t c o o lin g fa n
M2 3/7 M o t o r c o m p a rt m e n t c o o lin g fa n
L O A D C EL L 3/7 L o a d c e ll fo r d e te c t in g w e ig h t o f lo a d o n fo rk s
M TR 1/7 A C t ra c t io n m o t o r
MP 1/7 A C pum p m otor
MS 1/7 A C s t e e rin g m o t o r
POT. 1 4/7 Tra c t io n s p e e d va ria t io n p o t e n t io m e t e r
S 1/7 B a t te ry to m a c h in e e le c t ric a l s y s te m c o n n e c t o r p lu g
S .S . 2/7 S t e e rin g s te p p e r m o to r
T. M TR 2/7 Tra c t io n m o t o r t e m p e ra t u re p ro b e
T. M P 3/7 P u m p m o t o r te m p e ra t u re p ro b e
T. M S 2/7 S t e e rin g m o t o r t e m p e ra tu re p ro b e
J 1 (2 a x i x ) 4 -4 c / 7 F o rk s lift/ lo w e r c o n t ro l a n d re a c h c a rria g e e x t e n d /re t ra c t c o n t ro l jo y s tic k
J 2 (2 a x i x ) 4 -4 c / 7 F o rk s B a c k / F w d t ilt a n d rig h t / le ft s id e s h ift c o n t ro l jo y s t ic k
J1 4 a -4 d /7 F o rk s lift/ lo w e r c o n t ro l jo y s tic k
J2 4 a -4 d /7 R e a c h c a rria g e e x t e n d / re t ra c t c o n t ro l jo y s tic k
J3 4 a -4 d /7 F o rk s b a c k /fw d t ilt c o n t ro l jo y s t ic k
J4 4 a -4 d /7 F o rk s rig h t /le ft s id e s h ift c o n t ro l jo y s t ic k

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 1/7

MOTORS AND CONTROLLERS CONNECTION
CONTROL CIRCUITS POWER SUPPLY

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 2/7

AC TRACTION MODULE CONNECTION
Reference to diagram number at top right EPS AC MODULE CONNECTION
Fuse after Solenoid valves power Auxiliary services 4a -4d,/7 joysticks R1 power supply positi- DC-DC CONVERTER FOR 12/24V
keyswitch supply fuse power supply fuse ve (Resistor for cold store version) POWER SUPPLY (OPTIONAL

M 1

1B - 2B PONTE CONFIGURAZIONE INVERTER

24V ALL’INSERZIONE - 19V DI ALIMENTAZIONE PRESENTE = POMPA / NON PRESENTE = TRAZIONE
1 24V ON THE START UP - 19V TO KEEP EMB OPEN 2 1B - 2B INVERTER JUMPER CONFIGURATION 1501469-2
CLOSED = PUMP / OPEN = TRACTION

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 3/7

AC PUMP MODULE CONNECTION
MHYRIO MODULE CONNECTION

1B - 2B PONTE CONFIGURAZIONE INVERTER

1
PRESENTE = POMPA / NON PRESENTE = TRAZIONE
1B - 2B INVERTER JUMPER CONFIGURATION 2 24V ALL’INSERZIONE - 19V DI ALIMENTAZIONE
24V ON THE START UP - 19V TO KEEP EMB OPEN 3 SE SW5 NON E’ PRESENTE PONTICELLARE 15A CON 12A
IF SW5 IS NOT MOUNTED JUMPER 15A WITH 12A
CLOSED = PUMP / OPEN = TRACTION

1501469-3

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 4/7

CAN I/O MODULE CONNECTION
2-JOYSTICK HYDRAULIC CONTROL
FWD/REV TRAVEL CONTROL ON PEDALS

Function Range Function Ra nge

Lift 2,6V - 4,5V Tilt Up 2,6V - 4,5V
Low 2,4V - 0.5V Tilt Down 2,4V - 0.5V
POT. J1 POT. J2
Forw. Carr. 2,4V - 0,5V Side Shift rh. 2,6V - 4,5V
Rev. Carr. 2,6V - 4.5V Side Shift sh 2,4V - 0.5V

SW13

SW12

DUAL FUNCTION PEDAL WITH DIRECTIONAL NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS
CONTROL FORW/REV NOT PRESENT WHEN THE TRAVEL DIRECTION CONTROL
AND TWO JOYSTICKS HYDRAULIC CONTROL ON THE PEDALS IS UTILIZED

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 4a/7

CAN I/O MODULE CONNECTION
4-JOYSTICK HYDRAULIC CONTROL
FWD/REV TRAVEL CONTROL ON PEDALS

Function Range Function Ra nge

Lift 2,6V - 4,5V Tilt Up 2,6V - 4,5V
POT. J1 POT. J3
B Low 2,4V - 0.5V Tilt Down 2,4V - 0.5V
Forw. Carr. 2,4V - 0,5V Side Shift rh. 2,6V - 4,5V
POT. J2 POT. J4
Rev. Carr. 2,6V - 4.5V Side Shift sh 2,4V - 0.5V

SW13

SW12

DUAL FUNCTION PEDAL WITH DIRECTIONAL NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS
CONTROL FORW/REV NOT PRESENT WHEN THE TRAVEL DIRECTION CONTROL R1 RESITOR FOR COLD STORE VERSION
AND FOUR JOYSTICKS HYDRAULIC CONTROL ON THE PEDALS IS UTILIZED

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 4b/7

CAN I/O MODULE CONNECTION
SINGLE JOYSTICK HYDRAULIC CONTROL
FWD/REV TRAVEL CONTROL ON PEDALS

SW13

SW12

CON PEDALIERA DOPPIA IN FUNZIONE, IL COMANDO SUL JOYSTICK E’ DISATTIVATO

WITH DUAL FUNCTION PEDAL, THE SPEED CONTROL IS DISABILITY

DUAL FUNCTION PEDAL WITH DIRECTIONAL NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A
CONTROL FORW/REV IS NOT PRESENT WHEN THE TRAVEL DIRECTION
AND ONLY ONE JOYSTICKS HYDRAULIC CONTROL CONTROL ON THE PEDALS IS UTILIZED

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 4c/7

CAN I/O MODULE CONNECTION
2-JOYSTICK HYDRAULIC CONTROL
FWD/REV TRAVEL CONTROL
ON INSTRUMENT PANEL

Function Range Function Range

Lift 2,6V - 4,5V Tilt Up 2,6V - 4,5V
Low 2,4V - 0.5V Tilt Down 2,4V - 0.5V
POT. J1 POT. J2
Forw. Carr. 2,4V - 0,5V Side Shift rh. 2,6V - 4,5V
Rev. Carr. 2,6V - 4.5V Side Shift sh 2,4V - 0.5V

SW26 SW25

FORWARD BACKWARD WITH SWITCH NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS
AND TWO JOYSTICKS FOR IDRAULIC CONTROL PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE
INSTRUMENT PANEL IS UTILIZED

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 4d/7

CAN I/O MODULE CONNECTION
4-JOYSTICK HYDRAULIC CONTROL
TRAVEL CONTROL ON INSTRUMENT PANEL

Function Range Function Ra nge

Lift 2,6V - 4,5V Tilt Up 2,6V - 4,5V
POT. J1 POT. J3
Low 2,4V - 0.5V Tilt Down 2,4V - 0.5V
Forw. Carr. 2,4V - 0,5V Side Shift rh. 2,6V - 4,5V
B POT. J2 POT. J4
Rev. Carr. 2,6V - 4.5V Side Shift sh 2,4V - 0.5V

SW26 SW25

FORWARD BACKWARD WITH SWITCH NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS
PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE R1 RESITOR FOR COLD STORE VERSION
AND FOUR JOYSTICKS FOR IDRAULIC CONTROL
INSTRUMENT PANEL IS UTILIZED

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 4e/7

CAN I/O MODULE CONNECTION
SINGLE JOYSTICK HYDRAULIC CONTROL
TRAVEL CONTROL ON JOYSTICK

SW25

SW26

FORWARD BACKWARD AND HYDRAULIC NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS PRESENT
CONTROL WITH ONLY JOYSTICK WHEN THE ITT JOYSTICK IS UTILIZED WITH INTEGRAL TRAVEL
CONTROL

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 5/7

SICOS MODULE CONNECTIONS

1501469 - 10

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 6/7

CAN BUS MODULES CONNECTION

1501469 - 11

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SERVICE Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 7/7

CONNECTION DIAGRAM
POWER CABLES

1501486

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SERVICE Sezione: ELECTRICAL SYSTEM

INPUT / OUTPUT CONNECTORS

MODULES AC2 T, AC2 P

Input / output connectors module AC2 TRAZIONE Input / output connectors module AC2 POMPA

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SERVICE Sezione: ELECTRICAL SYSTEM

INPUT / OUTPUT CONNECTORS

MODULES EPS AC, MHYRIO

Input / output connectors module EPS AC Input / output connectors module MHYRIO

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SERVICE Sezione: ELECTRICAL SYSTEM

INPUT / OUTPUT CONNECTORS

MODULES CAN I/O, SICOS
(display)

Input / output connectors module CAN I/O Input / output connectors module SICOS

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SERVICE Section: ELECTRICAL SYSTEM

NOTES:

ELECTRICAL SYSTEM

UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 15

 Section: ELECTRICAL SYSTEM SERVICE

2.0 KEY TO POSITION OF ELECTRICAL COMPONENTS

ELECTRICAL SYSTEM

MODEL ALL MODELS

Diagram Diagram
Ref. Description of Component
Symbol Ref. Page Ref.
1 MTR 1/7 AC traction motor - 6.4 kW 70 Hz
2 MP 1/7 AC pump motor - 11 kW 8 Hz
3 MS 1/7 AC steering motor - 0.4 kW 95 Hz
4 SW3 2/7 Operator presence inductive sensor
5 Pot 1 4/7 Acceleration traction potentiometer
6 SW14 4/7 Forward/reverse travel start inductive sensor
7 SW12 4/7 Forward travel selection inductive sensor on pedal
8 SW13 4/7 Reverse travel selection inductive sensor on pedal
9 SW15 4/7 Brake pedal control braking inductive sensor
10 H1 4/7 Horn
11 SW16 4/7 Battery out of position inductive sensor
12 SW4 2/7 Steer wheel centred inductive sensor
13 SW8 3/7 Inductive sensor - reach carriage forward deceleration and retraction stop
14 SW7 3/7 Inductive sensor - reach carriage retraction deceleration and forward stop
15 M1 2/7 Motor compartment cooling fan
16 S.S. 2/7 Steering stepper motor
17 EPS AC Logic 2/7 AC steering motor control module
18 SW25 4c/7 Forward travel selection switch on dashboard
19 SW26 4c/7 Reverse travel selection switch on dashboard
20 SW21 4/7 Horn button
AC2 Traction
21 2/7 AC traction motor control module
Logic
AC2 Pump
22 3/7 AC pump motor control module
Logic
23 CAN I/O 4/7 CAN I/O control module
24 Mhyrio 3/7 Mhyrio control module for valves bank management
25 Sicos 5/7 Sicos (display) control module for alarms and test information
26 M2 3/7 Panels cooling fan
27 Enc Height Ind 3/7 Height indication encoder
28 SW5 3/7 Height encoder, speed reduction inductive zero sensor
29 SW1 1/7 Emergency circuit breaker
30 SW2 1/7 Keyswitch
31 FU7 2/7 Auxiliary line fuse
32 FU6 2/7 Auxiliary line fuse
33 FU5 2/7 Auxiliary line fuse
34 FU4 1/7 Auxiliary line fuse
35 J1 (2axix) 4-4c/7 Joystick - forks Up/Down control, reach carriage extend/retract
36 J2 (2axix) 4-4c/7 Joystick - forks tilt back/fwd control and forks left/right sideshift control
37 J1 4a-4d/7 Joystick - forks lift/lower
38 J2 4a-4d/7 Joystick - reach carriage forward/back control
39 J3 4a-4d/7 Joystick - forks tilt Fwd/Back control
40 J4 4a-4d/7 Joystick - forks left/right sideshift control
Multifunction Joystick. Displace lever up and down for lift and lower, displace right
41 J ITT 4b-4e/7
and left for reach carriage movements
42 Travel forward / reverse control pushbutton
43 Forks tilt Fwd / Back control pushbutton
44 Forks right and left sideshift control pushbutton
45 Horn button

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SERVICE Section: ELECTRICAL SYSTEM

MOTORS COMPARTMENT ELECTRICAL COMPONENTS WITH

FORWARD/REVERSE TRAVEL PUSHBUTTONS ON PEDALS
MODEL ALL MODELS

16

15

3
17
1

5
6

12
9 5 11

13 14
6

10

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SERVICE Section: ELECTRICAL SYSTEM

MOTORS COMPARTMENT ELECTRICAL COMPONENTS

FORWARD/REVERSE TRAVEL CONTROL WITH DIRECTION
CHANGE CONTROL ON INSTRUMENT PANEL
MODEL ALL MODELS

16

15

3
17
1
19 18
4

20

12
9 5 11

13 14
6

10

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SERVICE 4 Section: ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS AND

POSITION OF CONTROL MODULES
MODEL ALL MODELS

25

44 30 29 30 29 30 29
43

42 37 38 39
35 40
36
28 45

41

19 19 18
27 18
20
20

23
22
21

30

26
32
31 24

34 29
33

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SERVICE Section: ELECTRICAL SYSTEM

POSITIONING OF DECELERATION
SENSORS ON REACH CARRIAGE
MODEL ALL MODELS

140-150mm

3
1

2
4
3
STANDARD AND PLUS REACH CARRIAGE WITH
4 SENSOR POSITIONING ACCORDING TO
BASIC TRUCK BATTERY SIZE
STANDARD AND PLUS REACH CARRIAGE
WITH FOUR SENSOR HOLDER SLOTS
BASIC TRUCK WITH THREE
BASIC TRUCK WITH THREE POSITIONS OF SENSORS WITH REFERENCE TO BASIC TRUCK AND BATTERY DIMENSIONS
R1.4 R1.4H R1.6 R1.6H R1.6N R2.0 R2.0H R2.0W R2.5
1 Slot Ref. Battery Dimensions
"A" "A" "A" "A" "A" "A" "A" "A" "A"
Read distance between the two sensors 140-150mm
1 Din C 420A (1220x280x784) 127 109 39
2 Din C 560A (1220x352x784) 127 109 39 39 51
3 Din C 700A (1220x424x784) 127 109 39 39 51 51 22 23
2 4 Din C 840A (1220x496x784) 51 51 22 23

1 Din B 420A (1032x350x784) 39

BASIC TRUCK WITH TWO NARROW REACH CARRIAGE
2 Din B 560A (1032x440x784) 39
SENSOR READING CAMS WITH TWO SENSOR HOLDER SLOTS

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SERVICE Section: ELECTRICAL SYSTEM

NOTES:

ELECTRICAL SYSTEM

UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 17

 Section: ELECTRICAL SYSTEM SERVICE

3.0 TABLE OF FUNCTION INPUTS

ELECTRICAL SYSTEM

MODEL ALL MODELS

The tables show all the sensors and microswitches that are activated in accordance with the requested
functions.

Key

Input = List of sensor inputs in the modules with specification of pins and
access connector.
Description of Functions = Description of the function to be executed

Enabled function = Description of the requested enabled function

Control = Controller involved

Pin = Pin corresponding to signal output

Status = State of the sensor at the time of the function request

SW4 - SW23 = Sensors activated on the basis of the requested function

NOTES:

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 SERVICE Sezione: IMPIANTO ELETTRICO

INPUT TABLE OF THE

FUNCTIONS (Sheet 1/3)
Inputs
AC2-TR EPS-AC AC2-PU MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS
= INPUT ACTIVITY 4/F 12/B 2/B 12/A 1/A 2/A 3/A 5/A 7/A 8/A 3/G 4/G 1/G 2/G 9/A 14/A 5/G 6/G 1/B 4/B 1/C 4/C 13/A 8/A 1/A 6/A 2/A 3/A 15/A

SLOW D.
REV. SLOW D.
RESET ENCODER

WEIGHT BUTTON
CUT OUT FORW.

BATTERY OUT
BATTERY OUT

OPTIONAL 1-2
SLOW SPEED
PEDAL MODE
EMERGENCY
PUMP MODE

ENABLE TILT
REDUCTION

REDUCTION

REDUCTION

SEAT SWITC

AUTOMATIC
STOP

LOW FORKS
SPEED LOW
SPEED AND

INTERLOCK

BACKWARD

(OPTIONAL)
SPEED LIFT

CARRIAGE

PRESENCE
CARRIAGE
REV. STOP

SIDE SHIFT
DEAD MAN

DEAD MAN
CARRIAGE

CARRIAGE

CARRIAGE

IDR.VALVE
FORWARD

CLACSON
REVERSE
POSITION

LIFT/LOW

PARKING
CUT OUT

BUTTON

BUTTON

BUTTON

BUTTON

BUTTON
ENABLE

ENABLE

ENABLE
ENABLE

BRAKE
STEER

LOAD
FOR.
FOR.
STATU
FUNCTION DESCRIPTION FUNCTION OPERATED CONTROL PIN SW3 SW4 SW5 SW6 SW7 SW8 SW9 SW10 SW11 SW12/25 SW13/26 SW14 SW15 SW16 SW17 SW3 SW1 J1/J1 J1/J2 J3 J4 SW21 SW18 SW20 SW19 SW22 SW23
S
TRACTION MAX SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l
TRACTION MAX SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l
TRACTION MAX SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l l
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
TRACTION MAX SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l l
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l l
WITH SLOW DOWN BUTTON ACTIVITY
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l l
WITH SLOW DOWN BUTTON ACTIVITY
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l l l
WITH SLOW DOWN BUTTON ACTIVITY
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l l l
WITH SLOW DOWN BUTTON ACTIVITY
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l
WITH FORKS OVER FREE LIFT
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l
WITH FORKS OVER FREE LIFT
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l
WITH FORKS OVER FREE LIFT
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l
WITH FORKS OVER FREE LIFT
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
TRACTION SPEED REDUCTION FORWARD SPEED AC2-TR ON l l l l l l l l
WITH CARRIAGE ALL OUT
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l
WITH CARRIAGE ALL OUT
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l
WITH CARRIAGE ALL OUT
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l
WITH CARRIAGE ALL OUT
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l

AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517320 Page 18a

 SERVICE Sezione: IMPIANTO ELETTRICO

INPUT TABLE OF THE

FUNCTIONS (Sheet 2/3)
Inputs
AC2-TR EPS-AC AC2-PU MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS
= INPUT ACTIVITY 4/F 12/B 2/B 12/A 1/A 2/A 3/A 5/A 7/A 8/A 3/G 4/G 1/G 2/G 9/A 14/A 5/G 6/G 1/B 4/B 1/C 4/C 13/A 8/A 1/A 6/A 2/A 3/A 15/A

RESET ENCODER

WEIGHT BUTTON
SLOW D.
FORW.
REV. SLOW D.

BATTERY OUT

BATTERY OUT

OPTIONAL 1-2
SLOW SPEED
EMERGENCY

PEDAL MODE
PUMP MODE

ENABLE TILT
SEAT SWITC
REDUCTION

REDUCTION

REDUCTION

LOW FORKS
SPEED LOW

AUTOMATIC
(OPTIONAL)
INTERLOCK
SPEED AND

SPEED LIFT

BACKWARD
PRESENCE

SIDE SHIFT
DEAD MAN
DEAD MAN

CARRIAGE

CARRIAGE

CARRIAGE
FORWARD

IDR.VALVE
POSITION

REVERSE

CLACSON
LIFT/LOW
CUT OUT

PARKING
STOP

BUTTON

BUTTON

BUTTON

BUTTON

BUTTON
ENABLE

ENABLE

ENABLE
CARRIAGE

CARRIAGE
STOP

ENABLE
BRAKE
STEER

LOAD
CUT OUT

FOR.
FOR.

REV.
FUNCTION DESCRIPTION FUNCTION OPERATED CONTROL PIN STATUS SW3 SW4 SW5 SW6 SW7 SW8 SW9 SW10 SW11 SW12/25 SW13/26 SW14 SW15 SW16 SW17 SW3 SW1 J1/J1 J1/J2 J3 J4 SW21 SW18 SW20 SW19 SW22 SW23
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l
WITH BATTERY OUT
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l
WITH BATTERY OUT
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l l
WITH BATTERY OUT
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l l
WITH BATTERY OUT
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
PARKING BRAKE ACTIVITY FORWARD SPEED AC2-TR OFF l l l l l l l
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW
OR SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F OFF l l l l l l l
PARKING BRAKE ACTIVITY BACKWARD SPEED AC2-TR OFF l l l l l l l
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW
OR SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F OFF l l l l l l l
STRIGHT WELL ELECTIRC STEERING EPS-AC ON l l
MOTOR PUMP AC2-PU ON
LIFT FORKS MAX SPEED
EV2 MHYRIO 7/G ON l l l l l l l
MOTOR PUMP AC2-PU ON
LIFT FORKS REDUCTION SPEED
EV2 MHYRIO 7/G ON l l l l l l l l
LOWER FORKS MAX SPEED EV1 MHYRIO 8/G ON l l l l l l
LOWER FORKS REDUCTION SPEED EV1 MHYRIO 8/G ON l l l l l l l
MOTOR PUMP AC2-PU ON
CARRIAGE FORWARD MAX SPEED
EV4 MHYRIO 5/G ON l l l l l l l l
MOTOR PUMP AC2-PU ON
CARRIAGE FORWARD REDUCTION SPEED
EV4 MHYRIO 5/G ON l l l l l l l
MOTOR PUMP AC2-PU OFF
CARRIAGE FORWARD STOP
EV4 MHYRIO 5/G OFF l l l l l l
MOTOR PUMP AC2-PU ON
CARRIAGE REVERSE MAX SPEED
EV3 MHYRIO 6/G ON l l l l l l l l
MOTOR PUMP AC2-PU ON
CARRIAGE REVERSE REDUCTION SPEED
EV3 MHYRIO ON l l l l l l l
MOTOR PUMP AC2-PU OFF
CARRIAGE REVERSE STOP
EV3 MHYRIO 6/G OFF l l l l l l
MOTOR PUMP AC2-PU ON
TILT UP
EV5 MHYRIO 4/G ON l l l l l l l
MOTOR PUMP AC2-PU ON
TILT DOWN
EV6 MHYRIO ON l l l l l l l
MOTOR PUMP AC2-PU ON
SIDE SHIFT RIGHT
EV7 MHYRIO 2/G ON l l l l l l l
MOTOR PUMP AC2-PU ON
SIDE SHIFT LEFT
EV8 MHYRIO 1/G ON l l l l l l l
MOTOR PUMP AC2-PU ON
OPTIONAL 1
OPT.1 MHYRIO 3/F ON l l l l l l l l

AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517320 Page 18b

 SERVICE Sezione: IMPIANTO ELETTRICO

INPUT TABLE OF THE

FUNCTIONS (Sheet 3/3)
Inputs
AC2-TR EPS-AC AC2-PU MHYRIOMHYRIOMHYRIOMHYRIOMHYRIOMHYRIOMHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS
= INPUTACTIVITY 4/F 12/B 2/B 12/A 1/A 2/A 3/A 5/A 7/A 8/A 3/G 4/G 1/G 2/G 9/A 14/A 5/G 6/G 1/B 4/B 1/C 4/C 13/A 8/A 1/A 6/A 2/A 3/A 15/A

OPTIONAL 1-2 IDR

RESET ENCODER

WEIGHT BUTTON
FORW.

.VALVE BUTTON
BATTERY OUT
BATTERY OUT

SLOW SPEED
ENABLE SIDE

PEDAL MODE
EMERGENCY

ENABLE TILT
SLOW D.
PUMP MODE

SLOW D.

SEAT SWITC
REDUCTION

REDUCTION

REDUCTION

LOW FORKS
SPEED LOW

AUTOMATIC
SPEED AND

BACKWARD

(OPTIONAL)
INTERLOCK
SPEED LIFT

PRESENCE

DEAD MAN
DEAD MAN

CARRIAGE

CARRIAGE

CARRIAGE
FORWARD

CLACSON
REVERSE
POSITION

PARKING
LIFT/LOW
CUT OUT

BUTTON

BUTTON

BUTTON

BUTTON
ENABLE

ENABLE

ENABLE
BRAKE
STEER

STOP

SHIFT
LOAD
CARRIAGE

CARRIAGE
STOP
FOR.OUT

FOR.
REV.

REV.
CUT
FUNCTIONDESCRIPTION FUNCTIONOPERATED CONTROL PIN STATUS SW3 SW4 SW5 SW6 SW7 SW8 SW9 SW10 SW11 SW12/25 SW13/26 SW14 SW15 SW16 SW17 SW3 SW1 J1/J1 J1/J2 J3 J4 SW21 SW18 SW20 SW19 SW22 SW23
MOTORPUMP AC2-PU ON
OPTIONAL 2
OPT.2 MHYRIO 2/F ON l l l l l l l l
MOTORPUMP AC2-PU ON
LIFTANDCARRIAGEFORWARDMAXSPEED
EV2-EV4 MHYRIO 7/G-5/G ON l l l l l l l l l l
LIFTANDCARRIAGEFORWARDREDUCTION MOTORPUMP AC2-PU ON
SPEED EV2-EV4 MHYRIO 7/G-5/G ON l l l l l l l l l
MOTORPUMP AC2-PU OFF
LIFTANDCARRIAGEFORWARDSTOP
EV2-EV4 MHYRIO 7/G-5/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
LIFTANDCARRIAGEREVERSEMAXSPEED
EV2-EV3 MHYRIO 7/G-6/G ON l l l l l l l l l l
LIFTANDCARRIAGEREVERSEREDUCTION MOTORPUMP AC2-PU ON
SPEED EV2-EV3 MHYRIO 7/G-6/G ON l l l l l l l l l
MOTORPUMP AC2-PU OFF
LIFTANDCARRIAGEREVERSESTOP
EV2-EV3 MHYRIO 7/G-6/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
LOWERANDCARRIAGEFORWARDMAXSPEED
EV2-EV4-EV1 MHYRIO 7/G-5/G-8/G ON l l l l l l l l l l
LOWERANDCARRIAGEFORWARDREDUCTION MOTORPUMP AC2-PU ON
SPEED EV2-EV4-EV1 MHYRIO 7/G-5/G-8/G ON l l l l l l l l l
MOTORPUMP AC2-PU OFF
LOWERANDCARRIGAFORWARDSTOP
EV2-EV4-EV1 MHYRIO 7/G-5/G-8/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
LOWERANDCARRIAGEREVERSEMAXSPEED
EV2-EV3-EV1 MHYRIO 7/G-6/G-8/G ON l l l l l l l l l l
LOWERANDCARRIAGEREVERSE REDUCTION MOTORPUMP AC2-PU ON
SPEED EV2-EV3-EV1 MHYRIO 7/G-6/G-8/G ON l l l l l l l l l
MOTORPUMP AC2-PU OFF
LOWERANDCARRIAGEREVERSESTOP
EV2-EV3-EV1 MHYRIO 7/G-6/G-8/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
LOWERANDSIDESHIFTRIGHT
EV7-EV1 MHYRIO 2/G-8/G ON l l l l l l l l
MOTORPUMP AC2-PU
LOWERANDSIDESHIFTLEFT
EV8-EV1 MHYRIO 1/G-8/G ON l l l l l l l l
LOWERWITHCARRIAGEALLREVERSE
EV1 MHYRIO 8/G OFF l l l l l l l
ANDINTERLOKFORKSDEVICEACTIVITY
CARRIAGEREVERSEWITHFORKSALLDOWN MOTORPUMP AC2-PU OFF
ANDINTERLOKFORKSDEVICEACTIVITY EV3 MHYRIO 6/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
AUTOMATICWEIGHTLOAD
EV2 MHYRIO 7/G ON l l l l l l l
CLACSON H2 CANI/O 8/G ON l l
BACKUPALARMDUALFUNCTIONPEDAL REVERSESPEED AC2-TR ON
WITHDIRECTIONALCONTROLFW/BACKW H3 CANI/O 7/G ON l l l l l l
BACKUPALARMFORWARDBACWARD REVERSESPEED AC2-TR ON
WITHSWITH H3 CANI/O 7/G ON l l l l l l l
OR OR OR OR OR OR
FLSHINGBEACON
H1 AC2-PU 8/F ON l l l l l l l l l l l
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517320 Page 18c
SERVICE Section: ELECTRICAL SYSTEM

NOTES:

ELECTRICAL SYSTEM

UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 19

 Section: ELECTRICAL SYSTEM SERVICE
4.0 PARAMETERS TABLE
MODULE 2 AC2 TRACTION
ELECTRICAL SYSTEM

The values of certain levels programmed in the “PARAMETER CHANGE” main menu are displayed in
different ways depending on how the “PERFORMANCE TYPE” parameter in the config. menu “SET
OPTIONS” is set on the SICOS display module.
“PERFORMANCE TYPE” can be set in four different modes by means of the console (see following
numbers) or directly by means of the button on the display (see description):

0) “SLOW” = Cutback speed 1 activation

1) “SOFT” = Reduction of parameters “ACCELERATION DELAY”, “RELEASE BRAKING”,
“INVERSION BRAKING” and “MAX SPEED” by one level.
2) “STDN” = Parameters programmed from the console
3) “HARD” = Increase of parameters “ACCELERATION DELAY”, “RELEASE BRAKING”,
“INVERSION BRAKING” and “MAX SPEED” by one level.

NOTE: In order to change the value of the parameters in the “PARAMETER CHANGE” of the AC2
traction inverter you must have the parameter “PERFORMANCE TYPE” of the SICOS 2 (the display
must indicate the letters STDN).

MODULE (DISPLAY) PARAMETERS AC2 TRACTION

HOUR COUNTER RUNNING KEYON
SET OPTIONS

BATTERY CHECK ON OFF

CONFIG MENU'

STOP ON RAMP ON OFF

AUX OUTPUT Brake
PEDAL BRAKING Digital Analog
SET BATTERY TYPE 48V
ADJUST

ADJUST BATTERY 51,6V

ADJUSTMENT # 1 LEVEL 3
ADJUSTMENT # 2 LEVEL 5
ACCELER. DELAY 1 Max = 9
RELEASE BRAKING 7 Max = 9
PARAMETER CHANGE

INVERS. BRAKING 8 Max = 9

PEDAL BRAKING 9 Max = 9
MAIN MENU'

MAX SPEED FORW . 105 Hz Min 95Hz - Mx 114Hz

MAX SPEED BACK 105 Hz Min 95Hz - Mx 114Hz
CURVE CUTBACK 44%
STEER DEAD ANGLE 6%
FREQUENCY CREEP 1,20 Hz
MAXIMUN CURRENT 7 Max = 9
AUXILIARY TIME 1.5 Min 0sec - Max 5sec

Page: 20 Part No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 UPDATE