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SERVICE MANUAL CHAPTER 5000
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CHAPTER 5000
ELECTRIC SYSTEM
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SERVICE MANUAL 036-0428-00
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ELECTRIC SYSTEM
BATTERY COMPARTMENT AND REQUIRED WEIGHT ................................... 7

GUIDELINES FOR ASSISTANCE ........................................................................ 8
DISPLAY ............................................................................................................... 8
TROUBLESHOOTING ON THE BATTERY.......................................................... 9
BATTERY .............................................................................................................10
INSPECTION .......................................................................................................12
GENERAL............................................................................................................. 14
SPECIFICATIONS ................................................................................................ 15
COMPONENTS ....................................................................................................16
DRIVE LOGIC UNIT.............................................................................................. 16
LIFTING LOGIC UNIT........................................................................................... 16
MHYRIO LOGIC UNIT (optional)......................................................................... 17
ARMREST BOARD (optional) ............................................................................. 17
I/O CARD .............................................................................................................. 18
LIGHT CARD ........................................................................................................ 18
BATTERY PIN UNIT ............................................................................................. 19
BEFORE REPAIR ................................................................................................. 20
CONNECTOR INSPECTION ............................................................................... 21
DRIVE LOGIC UNIT.............................................................................................. 23
I/O CONTROL BOARD......................................................................................... 28
MHYRIO LOGIC UNIT .......................................................................................... 31
ARMREST BOARD ............................................................................................. 32
LIGHT CARD ........................................................................................................ 35
MAIN CONTROL UNIT ......................................................................................... 37
OPERATIONAL FEATURES ................................................................................ 37
DIAGNOSIS .......................................................................................................... 38
GENERAL PRECAUTIONS.................................................................................. 38
PROTECTIONS .................................................................................................... 38
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ELECTRIC CIRCUIT CONNECTION.................................................................... 39

CHECK DRIVE MOTOR PHASES
BALANCING........................................................................................................ 40
CHECK LIFTING MOTOR PHASES
BALANCING........................................................................................................ 41
ARMREST BOARD .............................................................................................44
ARMREST BOARD ADJUSTMENT..................................................................... 45
VOLTAGES ON ARMREST POTENTIOMETERS................................................ 46
MHYRIO LOGIC UNIT .........................................................................................49
OPERATIONAL FEATURES ................................................................................ 49
I/O CONTROL BOARD......................................................................................... 51
INPUT / OUTPUT CARD .....................................................................................51
CONNECTORS DESCRIPTION ........................................................................... 52
LIGHT CARD UNIT............................................................................................... 55
VERSION 1 ........................................................................................................... 55
VERSION 2 ........................................................................................................... 56
LIGHT CARD ........................................................................................................ 57
VERSION 1 ........................................................................................................... 58
VERSION 2 ........................................................................................................... 58
MATERIALS HANDLING AC DRIVER, CONTACTOR PANEL ........................... 61
DISPLAY ............................................................................................................... 65
ACCELERATOR POTENTIOMETER ADJUSTMENT.......................................... 67
LIFTING POTENTIOMETER ADJUSTMENT....................................................... 68
CONNECTOR CHECK ......................................................................................... 69
WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE................... 70
SYSTEM CONFIGURATION WITH MECHANICAL VALVE................................. 72
SYSTEM CONFIGURATION WITH ELECTRIC VALVE....................................... 73
DIAGNOSIS CODE LIST ..................................................................................... 74
WHEN AN ERROR CODE IS DISPLAYED .......................................................... 79
DRIVE LOGIC UNIT.............................................................................................. 79
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MHYRIO LOGIC UNIT .........................................................................................107
DASHBOARD ......................................................................................................109
I/O CONTROL BOARD......................................................................................... 112
LIGHT CARD ........................................................................................................ 113
ARMREST BOARD .............................................................................................114
CONSOLE............................................................................................................. 117
CONSOLE FUNCTION GENERAL DESCRIPTION............................................. 118
PARAMETER CHANGE DESCRIPTION.............................................................. 119
DRIVE MODULE................................................................................................... 119
PUMP MODULE ................................................................................................... 121
DASHBOARD ......................................................................................................124
TESTER PARAMETER DESCRIPTION ............................................................... 125
DRIVE MODULE................................................................................................... 125
PUMP MODULE ................................................................................................... 127
MHYRIO MODULE ............................................................................................... 128
MAPS FOR USING THE DRIVE CONSOLE ....................................................... 129
NECESSARY ADJUSTMENTS AFTER REPLACING THE
DRIVE LOGIC UNIT.............................................................................................. 130
DRIVE UNIT CONSOLE MENU STANDARD DESCRIPTION ............................ 131
BLOCK DIAGRAM ............................................................................................... 132
MAIN MENU: PARAMETER CHANGE ................................................................ 133
MAIN MENU: TESTER ......................................................................................... 134
MAIN MENU: SAVE PARAMETER ...................................................................... 135
MAIN MENU: RESTORE PARAMETER............................................................... 136
MAIN MENU: ALARM .......................................................................................... 137
MAIN MENU: PROGRAM VACC.......................................................................... 138
STOP ON RAMP................................................................................................... 139
SLIP CONTROL.................................................................................................... 140
BATTERY INDICATOR ......................................................................................... 141
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BATTERY SETTING ............................................................................................. 141

RESETTING BATTERY INDICATOR.................................................................... 142
BATTERY .............................................................................................................143
TRACTION ACQUISITION ................................................................................... 145
MAPS FOR USING THE LIFTING CONSOLE ..................................................... 146
NECESSARY ADJUSTMENTS AFTER REPLACING THE
LIFTING LOGIC UNIT.......................................................................................... 147
LIFTING UNIT CONSOLE MENU STANDARD DESCRIPTION ......................... 148
BLOCK DIAGRAM ............................................................................................... 149
MAIN MENU: TESTER ......................................................................................... 151
MAIN MENU: ALARM .......................................................................................... 154
SLIP CONTROL.................................................................................................... 156
BATTERY .............................................................................................................157
PUMP DATA ACQUISITION ................................................................................. 158
MAPS FOR USING THE MHYRIO CONSOLE..................................................... 159
MHYRIO CONSOLE MENU STANDARD DESCRIPTION .................................. 160
BLOCK DIAGRAM ............................................................................................... 161
MAIN MENU: PARAMETER CHANGE ............................................................... 162
MAIN MENU: TESTER ......................................................................................... 163
MAIN MENU: ALARM .......................................................................................... 166
MAPS FOR USING THE DASHBOARD CONSOLE ........................................... 168
WIRING DIAGRAMS ............................................................................................ 171
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PAGINA INTENZIONALMENTE BIANCA
INTENTIONALLY LEFT BLANK
PAGE INTENTIONNELLEMENT BLANCHE
WEIß SEITE
PÀGINA INTENCIONALMENTE BLANCA

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BATTERY COMPARTMENT AND REQUIRED WEIGHT

When the battery is purchased locally, always adjust the weight to satisfy the minimum required weight.
Batteries to DIN standards (DIN 43531 / 35 / 36 A, B, C, No)

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SERVICE STANDARDS
Specific gravity (battery charged) 1.280 [20 °C]
Specific gravity (battery discharged) 1.150 [20 °C]
Discharge end voltage 80 V 78.2 V *
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled water
Insulation resistance 10MΩ or more
* Value of battery on standby (only with key ON and no power consumption)
DISPLAY
Battery Charge Indicator
The battery charge indicator indicates 10 levels of battery
charge on the LCD.
Low Remaining Battery Charge Warning
Battery Indicate level This bar consists of 3 green LEDS on the right side, 4
% charged orange LEDS in the middle and 3 red LEDS on the left
1 2 3 4 5 6 7 8 9 10
state side. when the battery is charged the first green LED on
E F
the right is On; while the battery discharges, the LEDS
0 to 10 turn On or Off, one per time, from the right to the left
(exclusive) according to the battery charging status. When the battery
10 to 20 is 80% discharged, the first red LED on the left is On, the
o
(exclusive) display shows the alarm code 1C so the battery must be
20 to 30 recharged (reserve). There is an indication on the
o dashboard and the lifting speed is reduced. The battery
(exclusive)
30 to 40 charge indicator does not reset if the battery charge is
o between 70% and 100%.
(exclusive)
40 to 50
o
(exclusive)
50 to 60
o
(exclusive)
60 to 70
o
(exclusive)
70 to 80
o
(exclusive)
80 to 90
o
(exclusive)
90 to 100
o
(exclusive)
100 or more o
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TROUBLESHOOTING ON THE BATTERY
Plate corrosion Sulfation Plate warpage and active substance freeing
Improper charging
Long storage Repeated overdischarge
procedures in warehouse
End of life without operation overcharge
Short circuit
of battery between cells
of the battery Charging current
Defect of electrolyte
Excessive
Electrolyte
Electrolyte Insufficient
Defective
Ambient Temperature
overdischarge capacity
Battery defect
of the battery excessive
Crack or
Improper chipping of cell
Separator of the cells
defective supply
water Imperfect
Overcharge connection
of the terminal
Deposition of free Fouled terminal or

active substance connecting plug
at bottom of cell
Short circuit Electrolyte leakage end reduction Loosened or corroded connection

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BATTERY
REMOVAL • INSTALLATION
Disassembly Procedure
1. Park the truck on a level surface and apply the parking brake
2. Switch off the truck
3. Open the compartment and disconnect the battery
4. Remove the battery safety retainers [Point 1]
5. Remove the battery [Point 2]
Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.
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Points of Operation
[Point 1]
Removal:
Remove the battery safety retainers
[POINT 2]
Removal:
Remove the battery from the truck
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INSPECTION
1. Electrolyte inspection:
The battery electrolyte is normal when it is
transparent. Check turbidity when inspecting the
specific gravity. If it cannot be checked clearly, put the
electrolyte in a beaker for inspection
2. Battery electrolyte specific gravity inspection.

Use a hydrometer to measure the specific gravity of
the electrolyte
Specific gravity upon complete charging....
1.280 [20 °C ]
Specific gravity upon end of discharge....
1.150 [20 °C]
The specific gravity of the electrolyte at 20 °C (68 °F)

is used.
Equation for converting specific gravity
S20=St+[0.0007 x (t-20)]
S20: Specific gravity at 20 °C
St: Specific gravity at t °C
t: Electrolyte temperature upon measurement (°C)
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How to use the hydrometer

• Squeeze the rubber bulb, insert the hydrometer nozzle
into the battery element plug orifice and, releasing the
HYDROMETER rubber bulb, let the electrolyte be sucked into its outer
pipe
BULB • Let the hydrometer float correctly without contact with
OF RUBBER EXTERNAL the outer tube, top or bottom. When the bubbles in the
TUBE electrolyte disappear, read the scale at the highest point
of the electrolyte surface, as shown at left
• After the measurement, wash carefully with clear water
SUCTION NOZZLE the inside and outside of the hydrometer and store it
after wiping off the water with clean cloth
3. Insulation resistance inspection

Measure the resistance between the battery and
battery case with an insulation resistance meter
(megohmmeter)
Insulation resistance .... 1 MΩ or higher
Notes:
When the insulation resistance is less than 1 MΩ,
wash the battery with water after removing it from the
vehicle.
Fully dry the washed battery and measure the
insulation resistance again. Install the battery on the
vehicle after confirming that the insulation resistance
is 1 MΩ or more.
* Battery control table

Prepare a control table for each battery to record and maintain the inspection results
Time and date Specific gravity Temperature Capacity

Inspection Inspected element Nr. Electrolyte Electrolyte added water Notes Inspector
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GENERAL
It is equipped with traction & pump logic units that control traveling and material handling system. They
are multi-functional controllers that utilize microcomputers.
The traction & pump logic units provide high performance in a wide range by means of inverter control
of the AC motor drive system.
The main controllers have a self-diagnosis function that automatically detects any abnormality of the
traction/lifting circuits, accelerator or any other sensor and displays the corresponding error code
together with a warning beep. At the same time, an action such as disabling traveling, disabling material
handling or restriction of traveling speed is automatically taken to ensure safety. Identification of faulty
portion and functional inspection of the main traction/lifting circuits, each operating system and sensors
are also possible by setting the display to the analyzer (fault analysis) mode.
I/O CARD LOGIC UNIT

LIFTING
LIGHT CARD
LOGIC UNIT
MHYRIO UNIT TRACTION
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SPECIFICATIONS
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FT (traction logic unit) 355A
FP (lifting logic unit) 355A
F1 (key switch) 5A
FUSES F2 (DC/DC power supply) 20A
F3 (heating) 20A
F4 (audible warning) 1A
F5 (cooling fan) 5A
K1 (traction logic unit) SW280B-107 80V
CONTACTORS K2 (lifting logic unit) SW280B-107 80V
K3 (key power supply) SW60B-238 80V
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COMPONENTS
DRIVE LOGIC UNIT
LIFTING LOGIC UNIT

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MHYRIO LOGIC UNIT (optional)
ARMREST BOARD (optional)

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I/O CARD
LIGHT CARD
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BATTERY PLUG UNIT

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BEFORE REPAIR
INSPECTION
1. Insulation resistance measurement

Notes:
Always measure before inspecting the traction/
materials handling units.
(1) Disconnect the battery plug and measure the
resistance between the plug and the body of the
battery
Measurement terminals Controller side of battery plug-body

Resistance value depends greatly on the vehicle operating state, place
Standard: and weather
(Approx. 10MΩ or more)
Some components can be inspected after they are removed from the vehicle, while others can only be
inspected as installed on the vehicle
The logic unit must be inspected on the vehicle since the battery voltage must be applied
The explanation here is mainly for inspection of the controller as removed from the vehicle
• Overhauling the control panel is rarely necessary. In most cases, failed parts is replaced after finding
out the cause of the failure from inspection. Therefore, make sure to repair correctly by referring to
the figures of configuration
Caution for part replacement
• Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of
tightening may cause other failure
• When disconnecting the bars and harness, record the connecting location and place tags. When
connecting them again, be sure to confirm with the record and tags to prevent incorrect connection.
Incorrect connection may cause other failure
• Always apply new silicon grease when reassembling parts originally coated with silicon grease.
Otherwise, overheating may occur
• After installation, check that there is no interference of the bar and harness connection with other
portion
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CONNECTOR INSPECTION
When inspecting each board and the cause of the trouble is found, do not immediately replace the
board but check the following items.
• Abnormality in related harnesses
• Looseness of the related connectors
• Bending or damage of connector pin and defective contact of any related connector pin
If any of the above is the cause of the trouble and the board is replaced with a new one, the new board
will be damaged.
Always replace the board after careful inspection.
When the cause of trouble is determined to be in the logic unit or another board measure the applied
voltage and resistance. Always disconnect the battery plug before measuring the resistance.
Warning:
Disconnect the battery plug before connecting or disconnecting the logic unit.
Notes:
When a logic unit is determined to be the cause of trouble as the result of troubleshooting,
always measure the applied voltage and resistance of each related portion when replacing.
(1) Setting Method
(a) Key switch OFF and battery plug disconnected
(b) Connect the multimeter to the corresponding connector pin
Warning:
As connection of the wrong connector pin may damage normal portions, make sure to confirm
the connector pin number.
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(2) Measurement method and standard list

How to read the list
CN (pin-colour) ⇔ CN (pin-colour)
Description Standard Notes
From ⇔ To
Arriving point
Starting point
JDT (1-BS) J15 (1-BS) Positive output 12V
Colour Value of the

No. connector pin measurement
No. connector
COLOUR CODING
COLORI COLOURS FARBEN COULEURS COLORES

C arancio orange orange orange naranja
A azzurro blue blau bleu azul
B bianco white weiß blanc blanco
L blu dark blue dunkelblau bleu marine azul intenso
G giallo yellow gelb jaune amarillo
H grigio grey grau gris gris
M marrone brown braun marron castaño
N nero black schwarz noir negro
S rosa pink pink rose rosa
R rosso red rot rouge rojo
V verde green grün vert verde
Z viola/porpora purple violett violet púrpura
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DRIVE LOGIC UNIT

Basic conditions (battery plug connected, key switch ON) [Standard vehicle and Mini-lever specification
vehicle]
See the reference names of the connectors in the electrical diagram.
CN (wire pin) ⇔ CN (wire pin)
From ⇔ To
S1 (1-102) Key
B (1-102) K3 (1-102) DC/DC power supply +VB
B (1-102) Pump AC3 module
B (2-125) K1 (2-125) Traction line contactor K1 80V
B (3-145) J97 (1-145) Clamp 80V
SW4 (4-117) Deadman device
B (4-117) 80V
B (4-117) Pump AC3 module
B (5-150) B (9-150) Pump AC3 module GND
B (6) ⎯ Unused 80V
B (7-152) B (10-152) Traction AC3 module 80V
B (8-129) K1 (8-129) Traction line 30V
B (9-149) J97 (2-149) Clamp ~5.5V
B (11) ⎯ Unused ⎯
JC (3-156) Mhyrio
J130 (1-156)
J2 (1-156) Light card
J132 (1-156)
J131 (1-156)
C (1-156) Low Signal
J130 (2-156)
J13 (1-156) I/O card
C (1-156) Pump AC3 module
JC (3-156) Mhyrio unit
J130 (1-156)
J132 (1-156)
J131 (1-156)
J130 (2-156)
J13 (1-156) I/O card
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CN (wire pin) ⇔ CN (wire pin)

From ⇔ To
J132 (2-157)
C (3-157) High Signal
J131 (2-157)
J130 (3-157)
J13 (2-157) I/O card
J132 (2-157)
J131 (2-157)
J130 (4-157)
J13 (2-157) I/O card
E (1-M) J12 (1-M) Rev sensor 12V
E (2-B) E (2-B) Rev sensor GND
E (3-V) E (3-V) Rev sensor Signal B
E (4) ⎯ Unused ⎯
E (5-G) J12 (5-G) Rev sensor Signal A
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LIFTING LOGIC UNIT

Basic conditions (battery plug connected, key switch ON) [Standard vehicle & Mini-lever specification
vehicle]
See the reference name of the connector in the electrical diagram].
Connector ⇔ Connector
From ⇔ To
A (1) ⎯ Unused ⎯
J86 (1-151)
A (4-151) 80 V
A (13-151) Pump AC3 module
Jumper for the electronic
A (12-124) J86 (2-124) 80V
control valve
A (13-151) J86 (1-124) Pump AC3 module 80V
B (2-120) K2 (2-120) Pump line 80V
B (4-117) Traction AC3 module
B (4-117) 80V
SW4 (4-117) Deadman device
B (7-143) SW4 (7-143) Deadman device 80V
B (8-164) K2 (8-164) Pump line GND
B (9-150) B (5-150) Traction AC3 module GND
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From ⇔ To
JC3 (1-156) Mhyrio unit
J130 (1-156)
J130 (2-156)
J132 (1-156)
J131 (1-156)
J13 (1-156) I/O card
C (1-156) Traction AC3 module
J130 (1-156)
J130 (2-156)
J132 (1-156)
J131 (1-156)
J13 (1-156) I/O card
J130 (3-157)
J130 (4-157)
J132 (2-157)
J131 (2-157)
J13 (2-157) I/O card
J130 (3-157)
J130 (4-157)
J132 (2-157)
J131 (2-157)
J13 (2-157) I/O card
Disconnect
D (1-159) D (2-159) Jumper on logic GND ed
0V
Disconnect
D (2-159) D (1-159) Jumper on logic GND ed
5V
E (1-M) J13 (1-M) Pump speed sensor +12V
E (2-B) J13 (2-B) Pump speed sensor GND
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From ⇔ To
E (3-G) J13 (3-G) Pump speed sensor Signal B
E (5-V) J13 (5-V) Pump speed sensor Signal A
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I/O CONTROL BOARD

vehicle]
See the reference names of the connectors in the electrical diagram].
From ⇔ To
J38 (1-126) SW1 (1-126) Brake fluid tank 5V
J38 (2-154) P2 (2-154) Setting selector 5V
J38 (3-158) P3 (3-158) Speed reduction 5V
J38 (4) ⎯ Unused 5V
J38 (6-925) ALL GND Negative GND
J1 (1-121) J8 (2-121) Pump motor thermal detector 0V open 5V closed
Traction motor thermal
J1 (3-127) J9(2-127) 0V open 5V closed
detector
J5 (1-104) LS1 (1-104) Horn input 24V 0V
J5 (3) ⎯ Unused ⎯
J6 (2-114)
J34 (1-114) Forward speed signal (central) 5V
J33 (2-114)
J7 (2-115)
J34 (2-115) Reverse speed signal (central) 5V
J33 (8-115)
J34 (3-113) J32 (5-113) Unused 5V
J34 (4-107) SW3 (4-107) Parking brake 5V
J34 (5-116) SW2 (5-116) Service brake 5V
J34 (6-103) P1 (6-103) Horn button 5V
J34 (7-170) J33 (5-170) GND
J34 (8-160) J3 (6-160) Unused ⎯
J7 (3-161)
J34 (9-161) Reverse speed signal 0V 5V
J33 (9-161)
J33 (3-162)
J34 (10-162) Forward speed signal 0V 5V
J6 (3-162)
J34 (11) ⎯ Unused ⎯
J34 (12-925) ALL GND GND
Accelerator potentiometer
J34 (13-111) J32 (3-111) 5V
output
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From ⇔ To
Accelerator potentiometer
J34 (14-109) J32 (1-109) 0.8V 1.8V
input
J34 (15-110) J32 (2-110) Potentiometer GND GND
J135 (1-M) J132 (1-M) Can-bus lights card Low Signal
J135 (2-B) J132 (2-B) Can-bus lights card High Signal
J135 (3-V) J132 (3-V) Can-bus lights card GND
J135 (4-screen) J132 (4-screen) Can-bus lights card ⎯
J135 (5-G) J132 (5-G) Can-bus lights card 12V
J135 (6) ⎯ Unused ⎯
J136 (1-M) J1 (1-M) Can-bus dashboard Low Signal
J136 (2-B) J1 (2-B) Can-bus dashboard High Signal
J136 (3-V) J1 (3-V) Can-bus dashboard GND
J136 (4-screen) J1 (4-screen) Can-bus dashboard
J136 (5-G) J6 (5-G) Can-bus dashboard 12V
J136 (6) ⎯ Unused ⎯
U1 (1-202) DC-DC converter
J98 (1-202) J4 (1-202) Light card 24V
J98 (2-924) ALL negative Negative GND
J40 (1-131) J42 (3-131) Lifting microswitch (S1) 5V
J40 (2-134) J43 (3-134) Tilt microswitch (S2) 5V
J40 (3-133) J44 (3-133) Sideshift microswitch (S3) 5V
J40 (4-132) J45 (3-132) 4th-way microswitch 5V
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From ⇔ To
J40 (10-137) RP1 (1-137) Lifting potentiometer output 1.3V 5V
J40 (11-135) RP1 (2-135) Lifting potentiometer input 5V
J40 (12-136) RP1 (3-136) Lifting potentiometer GND GND
J139 (1-156) JC (3-156) Can-bus Mhyrio Low Signal
J139 (2-157) JC (5-157) Can-bus Mhyrio High Signal
J139 (4) ⎯ Unused ⎯
J139 (5-254) 5V
J139 (6-254) 5V
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MHYRIO LOGIC UNIT

Basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle]
From ⇔ To
JA (1-A) EV3 (2-A) GND EV3 GND
JA (3-NL) EVP (3-NL) GND EVP GND
JA (4-R) EV3 (1-R) EV3 24V
JA (15-S) EV6 (2-S) GND EV6 GND
JA (16-ZN) EV11 (2-ZN) GND EV11 GND
JA (17-R) EVP (1-R) EVP 19V
JA (20-R) EV6 (1-R) EV6 24V
JA (22-R) EV11 (1-R) EV11 24V
JA (27-R) EV4 (1-R) EV4 19V
JA (29-Z) GND GND EV5 GND
JA(30-H) GND GND EV4 GND
JA (31-C) GND GND EV3 GND
JA (33-R) EV5 (1-R) EV5 19V
J13 (5-254) I/O card
JC (1-254) 80V
J13 (6-254) I/O card
JC (2) ⎯ Unused ⎯
JC (3-156) J139 (1-156) Can-bus Mhyrio Low Signal
J13 (5-254) I/O card
JC (4-254) 80V
J13 (6-254) I/O card
JC (5-157) J139 (2-157) Can-bus Mhyrio High Signal
JC (6-924) ALL GND GND
JD (1) ⎯ Unused ⎯
JD (5) ⎯ Unused GND
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ARMREST BOARD
Basic conditions (battery plug connected, key switch ON)
[Mini-lever specification vehicle]
From ⇔ To
J1 (1) ⎯ Unused GND
J1 (10) ⎯ Unused ⎯
P1 (R) joystick
J2 (1) Potentiometer GND GND
P1 (N) fingertips
P1 (4)
J2 (2) Potentiometer input
P1 (V)
P1 (C)
J2 (3) +5V 5V
P1 (R)
S1 (N)
J2 (4) 4th-way input 5V
S1 (G)
S1 (R/N)
S1 (E/L)
J2 (6) S1 (G-M) +5V 5V
J2 (7) J2 (8-H) Unused ⎯
J2 (8) J2 (7-M) joystick Unused ⎯
P1 (R) joystick
P1 (N) fingertips
P1 (4)
P1 (V)
P1 (C)
J4 (3) +5V 5V
P1 (R)
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From ⇔ To
S1 (N)
S1 (G)
S1 (R/N)
S1 (E/L)
J4 (6) S1 (G-M) +5V 5V
J4 (7) J2 (8-H) Unused ⎯
P1 (R) joystick
P1 (N) fingertips
P1 (4)
P1 (V)
P1 (C)
J5 (3) +5V 5V
P1 (R)
S1 (N)
S1 (G)
S1 (R/N)
S1 (E/L)
J5 (6) S1 (G-M) +5V 5V
J5 (7) J2 (8-H) Unused ⎯
P1 (R) joystick
P1 (N) fingertips
P1 (4)
P1 (V)
P1 (C)
J6 (3) +5V 5V
P1 (R)
S1 (N)
S1 (G)
S1 (R/N)
S1 (E/L)
J6 (6) S1 (G-M) +5V 5V
J6 (7) J2 (8-H) Unused ⎯
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From ⇔ To
J7 (3-R) PB2 (3-R) Horn button 5V
J7 (4-R) PB2 (4-R) Horn button 0V
J7 (5-G) J33 (1-G) Enabling button 5V
J7 (6-G) J33 (3-G) Enabling button 5V
J7 (7-L) PB3 (7-L) Reverse button 5V
J7 (8-L) PB3 (8-L) Reverse button 0V
J7 (9-B) PB1 (9-B) Forward button 5V
J7 (10-B) PB1 (10-B) Forward button 0V
J138 (1-V)
J8 (1-V) Can-bus armrest GND
J131 (3-V)
J138 (2-M)
J8 (2-M) Can-bus armrest High Signal
J131 (1-M)
J8 (3-N) J138 (3-N) Can-bus armrest GND
J138 (4-B)
J8 (4-B) Can-bus armrest Low Signal
J131 (2-B)
J138 (5-G)
J8 (5-G) Can-bus armrest 80V
J131 (5-G)
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LIGHT CARD
vehicle]
See the reference names of the connectors in the electrical diagram].
From ⇔ To
J130 (1-156) J131 (1-156) Can-bus armrest Low Signal
J130 (2-157) J131 (2-157) Can-bus armrest High Signal
J130 (3-924) ALL GND Can-bus armrest GND
J130 (4-155) J131 (4-155) Can-bus armrest ⎯
J130 (5-210) J131 (5-210) Can-bus armrest 80V
J130 (6) ⎯ Unused ⎯
J130 (1-156)
J131 (1-156) Can-bus modules Low Signal
J130 (2-156)
J130 (3-157)
J131 (2-157) Can-bus modules High Signal
J130 (4-157)
J131 (3-924) ALL GND Can-bus modules GND
J1 (4-155)
J131 (4-155) J132 (4-155) Shielded cable ⎯
J131 (4-155)
J131 (5-202) J131 Light card 80V
J131 (6) ⎯ Unused ⎯
J132 (1) ⎯ Unused ⎯
J132 (2) ⎯ Unused ⎯
J132 (3) ⎯ Unused ⎯
J132 (4) ⎯ Unused ⎯
J132 (5) ⎯ Unused ⎯
J132 (6) ⎯ Unused ⎯
J94 (1-202) 24V
U1 (1-202)
J94 (2-200) LP1 (2-200) LP1 24V
LP2 (2-200) LP2
LP3 (3-201) LP3
LP4 (3-201) LP4
J94 (3-201) 24V
J70 (1-201) Reverse gear
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From ⇔ To
J94 (5-202) 24V
U1 (1-202)
J94 (6-200) LP1 (2-200) LP1 24V
LP2 (2-200) LP2
LP3 (3-201) LP3
LP4 (3-201) LP4
J94 (7-201) 24V
J70 (1-201) Reverse gear
J94 (8-202) 24V
U1 (1-202)
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CONTROL UNIT
MAIN CONTROL UNIT
ELECTRONIC PANEL Traction unit Pump unit
AC3T AC3P
Inverter for AC asynchronous 3-phase motors
Regenerative braking functions
Can-bus interface
Digital control based upon a microcontroller
Voltage 80 V 80 V
Maximum current 450 A (RMS) 450 A (RMS)
Operating frequency 8 Khz 8 Khz
External temperature range - 30° C + 40° C - 30° C + 40° C
Maximum inverter temperature 75° C 75° C
OPERATIONAL FEATURES
• Speed control
• Very good behaviour on a slope due to the speed feedback
• The motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the
set point of operation
• Stable speed in every position of the accelerator
• Regenerative release braking based upon deceleration ramps
• Regenerative braking when the accelerator pedal is partially released (deceleration)
• Direction inversion with regenerative braking based upon deceleration ramp
• Regenerative braking and direction inversion without contactors: only the two main contactors are
present
• The release braking ramp can be modulated by an analog input, so that a proportional brake feature
is obtained
• Very good sensitivity at low speeds
• Voltage boost at the start and with overload to obtain more torque (with current control)
• High efficiency of motor and battery due to high frequency commutations
• Self diagnosis with indication of the fault shown by numeric display
• Modification of parameters through the programming instrument panel interface
• Internal hour-meter with values that can be displayed on the console
• Memory of the last five alarms with relative hour-meter and temperature displayed on the console
• Test function within console for checking main parameters
• Hydraulic steering function:
1) truck stopped: the power steering starts only if the steering is moved
2) truck in movement: the power steering starts after 1km/h and the RpM of the lifting motor are
proportional to the speed of the steering rotation
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DIAGNOSIS
The microprocessor continually monitors the inverter and carries out a diagnostic procedure on the
main functions. The diagnosis is made in 4 points:
1 Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging,
phases’ voltages, contactor drives, can-bus interface, if the switch sequence for operation is correct
and if the output of the accelerator unit is correct
2 Standby diagnosis at rest that checks: watchdog circuit, phases’ voltages, contactor driver, current
sensor, can-bus interface
3 Diagnosis during operation that checks: watchdog circuits, contactor driver, current sensors, can-
bus interface
4 Continuous diagnosis that checks: temperature of the inverter
Diagnosis is provided in two ways:
• the diagnostic ERROR DISPLAY placed to the dashboard that shows the code number for a given
alarm
• the digital console, which gives more detailed information about the failure
GENERAL PRECAUTIONS
• Do not connect the inverter to a battery with a nominal value different from the value indicated on the
chopper plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit does not
"power up"
• During the battery charge, disconnect the INVERTER from the battery
• Supply the INVERTER only with battery for traction; do not use a power supply
• When the chopper is installed, make tests with the wheels raised from the ground, in order to avoid
dangerous situations due to connection errors
• After the chopper is switched off (key off), the filter capacitors remain charged for some minutes; if
you need to work on the inverter, discharge them using a 10W -- 100W resistance connected from
the +Batt to the -Batt
• Before carrying out any arc-welding on the trucks, disconnect the battery and short-circuit the unit
between positive (+) and negative (-)
PROTECTIONS
• Connection Errors:
All inputs are protected against connection errors.
• Thermal protection:
If the chopper temperature exceeds 75°C, the maximum current is reduced in proportion to the thermal
increase. The temperature can never exceeds 100°C.
• External agents:
The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP54.
• Protection against uncontrolled movements:
The main contactor is not closed if:
• the Power unit is not functioning.
• the Logic is not functioning perfectly.
• the output voltage of the accelerator does not fall below the minimum voltage value stored, with 1V
added
• running microswitch in closed position
• protection against accidental starting
A precise sequence of operations are necessary before the machine starts.
Operation cannot begin if these operations are not carried out correctly.
Drive requests must be made after closing the key switch.
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ELECTRIC CIRCUIT CONNECTION
DRIVE
MOTOR DRIVE
152
MODULE CUTBACK SPEED 3
CAN / BUS
PUMP
MOTOR PUMP
MODULE
DISCONNECT IN THE HYDRAULIC

CONTROL VALVE VERSION
CUTBACK SPEED 3 (enabling for further speed reduction)

microswitch closed = reduction off
microswitch open = reduction on
PUMP MODE ENABLING = Module enabling in pump version
LEGEND
FUSE AUX = Auxiliary circuit fuse MC COIL T = Drive contactor coil
KEI = Key switch MCP = Pump contactor
MCT = Drive contactor FUSE P = Pump power fuse
FUSE T = Drive power fuse MC COIL P = Pump contactor coil
SEAT = Seat microswitch
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CHECK TRACTION MOTOR PHASES BALANCING

When traveling or material handling operation seems abnormal, it is possible to accurately
judge if the controller is functioning correctly or not by measuring the motor phase balancing.
Measuring method Procedure using a clamp amperometer
(1) Remove the rear platic
(2) Jack up the front wheels
(3) Connect a clamp amperometer
(4) Selct a direction,shift the direction switch to the forward (or backward) position, and start the
machine with low speed
(5) Check the value of the current of each phase
(6) If the value of one phase is higher or lower respect the others it means that the system is not
balanced and the motor goes jerkling. In this situation the logic unit must be replace.
Measuring method Procedure using a multemeter
(3) Set the multemeter on V~
(4) Connect the negative of the multemeter on the battery negative
(5) Connect the positive on one of the phase of the logic unit
(6) Check the value of the voltage of each phase
In order to compere the value of the phases it is necessary to use the same tool and not
different type of multemeters or clamp amperometers for each phases. This because the tool
have different tollerance respect each others.
Measuring method Procedure using a Measuring method Procedure using a

multemeter clamp amperometer
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CHECK LIFTING MOTOR PHASES BALANCING

Measuring method Procedure using a clamp amperometer
(3) Connect a clamp amperometer
(4) Selct a direction,shift the direction switch to the forward (or backward) position, and start the
machine with low speed
(5) Check the value of the current of each phase
Measuring method Procedure using a multemeter
(3) Set the multemeter on V~
(4) Connect the negative of the multemeter on the battery negative
(5) Connect the positive on one of the phase of the logic unit
(6) Check the value of the voltage of each phase
In order to compere the value of the phases it is necessary to use the same tool and not
different type of multemeters or clamp amperometers for each phases. This because the tool
have different tollerance respect each others.
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Before starting the job, measure the voltage between (+) and GND; if there is any voltage, insert
a resistor at approx. 100Ω between (+) and GND to discharge the capacitor.
DRIVE LOGIC UNIT LIFTING LOGIC UNIT
4. Remove the boot [Point 1]
5. Remove the DC/DC converter [Point 2]
6. Remove the lights card unit [Point 3]
7. Remove the lifting logic unit and the drive logic unit [Point 4]
Notes:
For the necessary adjustments to be made after the logic change, see the dedicated section.
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Points of Operation
[Point 1]
Removal:
Remove the boot
[Point 2]
Removal:
Remove the DC/DC converter
[Point 3]
Removal:
Remove the lights card unit
[Point 4]
Removal:
Remove the lifting logic unit and/or drive logic unit
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ARMREST BOARD
8 7 COMPONENT DESCRIPTION
1. Connector for the lifting joystick
2. Connector for the tilting joystick
3. Connector for the sideshift joystick
4. Connector for the 4th-way joystick
5. Connector for the 5th-way joystick
6. Connector for auxiliary commands: forward/reverse
gear button, horn button
7. Connector for the CAN-BUS
8. SWITCH
1 2 3 4 5 6
The purpose of this card is to pilot the horn button, forward and reverse speed buttons (FW/BW button
version) and the fingertip and joystick signals.
Operating a lever on the armrest converts the analog signal into a digital signal that is then transferred
to the lights card via the CAN-BUS. From here the signal goes to the pump module that sends the
information to the MHYRIO unit that, in its turn, converts it from digital to analog.
The card uses printed circuits that must be powered to decode the CAN-BUS signals. To supply the
card we use a DC-DC converter, 80/24, that by powering an internal circuit creates a voltage of 5 volts
to power the potentiometers of the joysticks or fingertips.
The card is used in both the fingertip configuration and in the mini-joystick configuration.
This interface is possible thanks to the SWITCHES (pos.8 in the figure).
JOYSTICKS all the dip switchs must be in the OFF position
FINGERTIP switch 2 is ON
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ARMREST BOARD ADJUSTMENT

(JOYSTICK/FINGERTIP version)
PB1 = Forward speed button
PB2 = Horn button
PB3 = Reverse button
FINGERTIP = switch 2 ON JOYSTICK = All the switches are OFF
PB3
PB2
PB1
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VOLTAGES ON ARMREST POTENTIOMETERS

FINGERTIP version
RED: 5V
GREEN: 0 -- 5 (AT REST 2.5 V)
BLACK: 0
JOYSTICK version
ORANGE: 5V GREEN: 5V
YELLOW: 0 -- 5 (AT REST 2.5 V) BLACK: 0 -- 5 (AT REST 2.5 V)
RED: 0V WHITE: 0V
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4. Disconnect the wiring of the armrest [Point 1]
5. Remove the armrest padding
6. Remove the fixing screws located on the armrest [Point 2]
7. Remove the fixing screws located in the side of the armrest [Point 3]
8. Open the armrest
9. Disconnect the wirings of the armrest card [Point 4]
10. Remove the armrest card
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Points of Operation
[Point 1]
Removal:
Disconnect the wiring in the bottom of the armrest
[Point 2]
Removal:
Screw out the 4 screws (A) on the armrest
[Point 3]
Removal:
Screw out the 4 screws (B) at the sides of the armrest
B
B
[Point 4]
Removal:
Disconnect all the wirings of the armrest card
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MHYRIO LOGIC UNIT

OPERATIONAL FEATURES
It works at 24 V and it is located on the left side of the truck below the footboard. The Mhyrio card
receives the digital inputs from the CAN and it converts them in analogic signals to control the solenoid
valves with.
JC
JA
JD
In the front it has three connectors:

- connector JA is used to control the solenoid valves.
- connector JC is used for the CAN and the power supply.
Cable 254 positive (pin 1;4 connector JC)
Cable 924 negative (pin 6 connector JC )
Cable 157 CAN H (high) (pin 5 connector JC)
Cable 156 CAN L (low) (pin 3 connector JC)
Voltage supplied to the ON-OFF valve coil: battery voltage

Voltage supplied to the proportional valve coil: aproximatelly 12 V
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4. Remove the footboard
5. Disconnect the wirings [Point 1]
6. Remove the fixing screws
7. Remove the Mhyrio logic unit
Points of Operation
[Point 1]
Removal:
Remove the 2 connectors as shown in the figure
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I/O CONTROL BOARD

INPUT / OUTPUT CARD
The card is located on the left side of the truck under the
footboard. It controls and converts analogical signals to
digital signals and vice versa.
1. Connector J1 for temperature sensors of traction and lifting motors

2. Connector J5
2a) pin 1. horn command signal (B white cable)
2b) pin 2. horn negative (L blue cable)
3. Connector J136 CAN-BUS (dashboard)
4. Connector J135 CAN-BUS (light card)
5. Connector not used
6. Connector J139 for the Mhyrio card supply and to connect it to CAN-BUS
7. Connector J34 for the pedals: accelerator pedal, brake pedal, parking brake lever. It is also an input
for the horn on trucks with a mechanical control valve
8. Connector J38 for input of the brake oil tank LED, button for speed reduction and button for
programmed performance,
9. Connector J40 for the mechanical control valve (in this case the voltage on the micro is 5 volt)
10. Connector for programming the card via PC
2 3 4 5
HORN ELECTRIC CONNECTION
The horn is electronic and needs a signal to work. It is
continually supplied by the following cables: 203, cable
positive + 24 V ["+" on the horn] and 924, cable negative
2b 6 ["-" on the horn). The command signal on cable 104 [IN on
2a the horn] is a high signal, when the horn push button is
pressed the signal goes to the negative and the horn
7 begins to sound.
1 8
10 9
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CONNECTOR DESCRIPTION
J2 connector for the drive / lifting motor temperature
sensor
wire nr./colour
Pin 1: lifting motor 121
Pin 2: pump (GND) 925
Pin 3: drive motor 127
Pin 4: drive (GND) 925
J3 connector for the horn
Pin 1: signal output 104
Pin 2: GND 924
Pin 3: not connected
J6 CAN BUS light card
Pin 1: CAN L M
Pin 2: CAN H B
Pin 3: GND V
Pin 4: CAN SH
Pin 5: +V CAN G
J5 CAN BUS dashboard
Pin 1: CAN L M
Pin 2: CAN H B
Pin 3: GND V
Pin 4: CAN SH
Pin 5: +V CAN G
J13 CAN BUS mhyrio
Pin 1: CAN L 156
Pin 2: CAN H 157
Pin 3: GND 924
Pin 5: +V 254
Pin 6: +V 254
J1 connector for brake fluid level
Pin 1: SW5 brake fluid 126
Pin 2: P2 speed select. 154
Pin 3: P3 red. speed 158
Pin 6: GND 925
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J4 microswitch connector
Pin 1: S10 forward 114
Pin 2: S11 reverse 115
Pin 3: S14 not working 113
Pin 4: S13 parking brake 107
Pin 5: S12 brake pedal 116
Pin 6: Pb4 horn 103
Pin 7: configuration 170
Pin 8: S14 normally closed 160
Pin 9: normally closed 161
Pin 10: normally closed 162
Pin 12: GND of all push-buttons 925
Pin 13: +5 V of potentiometer 111
Pin 14: slider 109
Pin 15: GND of potentiometer 110
J8
Pin 1: +V 202
Pin 2: GND 924
J10 connector of the mechanical control valve
Pin 1: S3 lifting 131
Pin 2: S4 tilting 134
Pin 3: S5 sideshift 133
Pin 4: fourth lever 132
Pin 5: fifth lever
Pin 6: GND 925
Pin 7: GND 925
Pin 8: GND 925
Pin 9: GND 925
Pin 10: RP1 +5 V potentiometer 137
Pin 11: RP1 slider 135
Pin 12: GND potentiometer 136
J7
Connector for programming the card
COLOUR CODING
COLORI COLOURS FARBEN COULEURS COLORES

C arancio orange orange orange naranja
A azzurro blue blau bleu azul
B bianco white weiß blanc blanco
L blu dark blue dunkelblau bleu marine azul intenso
G giallo yellow gelb jaune amarillo
H grigio grey grau gris gris
M marrone brown braun marron castaño
N nero black schwarz noir negro
S rosa pink pink rose rosa
R rosso red rot rouge rojo
V verde green grün vert verde
Z viola/porpora purple violett violet púrpura
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1. Park the truck on a level surface and apply the
parking brake
4. Remove the footboard
5. Disconnect the connectors of the I/O card
6. Remove the fixing screws
7. Replace the card
The reassembly procedure is the reverse of the
disassembly procedure, taking care that when fitting the
wirings connections J5 and J6 can get reversed with each
other, but they must not get reversed with J13.
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LIGHT CARD UNIT

VERSION 1
14 13 12 11
1 2 3 4 5 6 7 8 9 10
Description
1. J132 can-bus wiring
4. Light card (see light card section)
5. Single connector (J134 - J133 - J99)
6. F1 key fuse (5A)
7. F2 DC DC converter fuse (20A)
8. FA optional systems fuse
9. Diode D1 + 80V (protection against battery polarity reversal
10. Battery connector
11. + 24V
12. GND
13. J95 auxiliary wiring
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VERSION 2
16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10
Description
4. J133
5. J132 armrest can-bus wiring
6. Light card (see light card section)
7. F1 key fuse (5A)
8. F2 DC DC converter fuse (20A)
9. FA optional systems fuse
10. Battery connector
11. + 24V
12. GND
13. J134
14. J99
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LIGHT CARD
The light card is located at the back of the truck in a

protective compartment (A).
The card is equipped with 4 connectors:
1 power supply and rear lights control: brakes and reverse
2-3-4 are connected in parallel, they distribute the canbus
signal and the power supply to the other cards: I/O card
and armrest card
A
The lights are controlled with a signal from the speed sensor of the drive motor.
The brake lights are automatically turned on whenever the truck reduces speed.
The reverse lights are turned on automatically whenever the motor works in reverse gear.
Notes:
Checking the light bulbs work properly requires operating the drive motor
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VERSION 1
1. Connector for lights (J2D)

2. Connector not used (J2C)
3. CAN-BUS (J2A)
4. CAN-BUS (J2B)
1 2 3 4
VERSION 2
FUNCTIONS
• rear lights control
• bridge for signals and power supply (24 V)
5
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Connector 1 (J4)
5 1 Connector with 8 Pins used to control the lights.
PINS 1-5-8 are connected together = 24 Volt
6 2 PINS 2-6 are connected together = BRAKE lights output
0-24 Volt. It is a proportional value given that
7 3 the voltage depends on the temperature of the
8 4 lamp bulb
PINS 3-7 are connected together = reverse lights output
0-24 Volt. It is a proportional value given that
the voltage depends on the temperature of the
lamp bulb.
PIN 4 GND
Connector 2
4 1 Connector with 6 Pins
PIN 1 CAN L
5 2 PIN 2 CAN H
PIN 3 GND
6 3 PIN 4 CAN SH
PIN 5 Output 24 Volt
PIN 6 Not used
Connector 3
PIN 1 CAN L
5 2 PIN 2 CAN H
PIN 3 GND
6 3 PIN 4 CAN SH
PIN 6 Not used
Connector 4
PIN 1 CAN L
5 2 PIN 2 CAN H
PIN 3 GND
6 3 PIN 4 CAN SH
PIN 6 Not used
LED 5
Shows that the light card is powered but is not receiving
the CAN-BUS input
Resistor R17
Resistor input. R17 = 100 Ohm 3 Watt
See wiring diagram.

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1. Park the truck on a level surface and apply the
parking brake
4. Remove the boot
5. Remove the cover [Point 1]
6. Disconnect the connectors of the card
7. Remove the card
Points of Operation
[Point 1]
Removal:
Remove the 2 Allen screws
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MATERIALS HANDLING AC DRIVER, CONTACTOR PANEL

Warning:
Before starting the job, measure the voltage between (+) and GND; if there is any voltage, insert
a resistor at approx. 100Ω between (+) and GND to discharge the capacitor.
4. Remove the boot
5. Disconnect the power cables of the contactors
6. Remove the two fixing screws on the contactor unit [Point 1]
7. Remove the contactors
Points of operation
[Point 1]
Remove the two fixing screws (A) on the contactor unit
A
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INSPECTION
1. CONTACTOR
Inspection method
Disconnect the connector from the wiring harness
and measure the resistance of the coil.
Portion
Measurement
to be Standard Tester range
terminals
inspected
Both Approx.
Coil K1 terminals of the 260 Ω (at Ω×1
coil 20°C)
Both Approx.
coil 20°C)
Both Approx.
coil 20°C)
2. FUSE
Inspection method
Disconnect the fuse and measure the insulation
resistance
Portion
Measurement Tester
to be Standard
terminals range
inspected
Both
Fuses terminals of the 0Ω Ω ×1
fuse
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Contactor unit assembly drawing

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DESCRIPTION OF CONTACTORS
K1 = Drive contactor
Drive logic Contactor Description Standard
B(8-129) K1 Coil power supply + 50V
B(2-125) K1 Coil negative Negative
K2 = Lifting contactor
Lifting logic Contactor Description Standard
B(2-120) K2 Coil power supply + Vb
B(8-164) K2 Coil negative Negative
K3 = Line contactor
Key Contactor Description Standard
+ Vb K3 Coil power supply + Vb
140 K3 Negative Negative
B1 = Connector
Pin Wire Description V V holding
1 125 Drive contactor K1(pin 1) GND GND
2 129 Drive contactor K1(pin 2) 80 V 50 V
3 120 Lifting contactor K2(pin 1) 80 V 80 V
4 164 Lifting contactor K2(pin 2) GND GND
5 102 Key contactor K3(pin 1) +Vb +Vb
6 900 Key contactor K3(pin 2) GND GND
7 100A Drive contactor input +Vb +Vb
8 140A Key contactor output +Vb +Vb

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DISPLAY
If the cause of trouble is judged to exist in the display, measure the voltage at the connector to which
voltage is applied.
No. connector ⇔ N. connector Conditions Standard Notes

J131 (4-CR) J137 (5-CR) Power supply 24V
Parking brake ON warning light
Brake fluid low level warning light

This warning light comes ON when the level of brake fluid in the tank has
reached the minimum level
Lifting speed reduction due to flat battery
Deadman device warning light:

The pilot light comes on when the driver leaves the driving seat without switching off the
truck: under these conditions, the traction and the material handling movement are disabled
Drive motor temperature warning light:

- lights up when the temperature is 130°C
Lifting motor temperature warning light:

- lights up when the temperature is 130°C
Diagnostic code alphanumeric display:

When a malfunction occurs in the truck, this display identifies the error through a
corresponding code
Forward/backward indication lights

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Speed reduction indication light:

When the reduction speed is selected the blue light is on
Adjustable electronic hour meter:

It is activated by insertion of the ignition key and it conts the real working
time of the truck. It shows the working hoursand hours fractions (in tenth)
Selected setting display:

Indicates the running setting selected
This bar consists of 3 green LEDS on the right side, 4 orange LEDS in the middle and 3 red
LEDS on the left side. when the battery is charged the first green LED on the right is On;
while the battery discharges, the LEDS turn On or Off, one per time, from the right to the left
according to the battery charging status. When the battery is 80% discharged, the first red
LED on the left side is On, the display shows the alarm code 1C, the lifting speed is reduced
Note: The battery charge indicator does not rearm if the battery charging status is between
70% and 100%
Light sensor:
automatically changes the brightness of the LEDs on the dashboard according to the ambient
light
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ACCELERATOR POTENTIOMETER ADJUSTMENT
1. Check the ON/OFF condition of the switch

2. SW16 (single pedal)
3. SW5 - SW6 (double pedal)
Measurement terminals Status
Pedal not
∞Ω
Standard operated
Pedal operated Continuity
4. Adjustment of accelerator potentiometer (RP1)

Installation
(1) Before installing a new traction potentiometer it is
suggest to check it with an anlalogical multemeter.
Move slowly the wiper until the maximum stroke
and in the same time check if the multemeter
increases or decreases the value proportionally
with the movement.
(2) Install the potentiometer and connect it to the
wiring harness of the machine
(3) After turning on the microswitch the voltage on the
potentiometer slider has to be aproximately 0.5V
and 1.6V at the maximum travel. This
measurement is referred to its negative
(4) After installing the potentiometer, do the Vacc
setting
Values obtained with the multimeter
Yellow 111
4.5KOhm 1.2KOhm J32 (3-111) 5V

Red 109
Standard J32 (2-110) GND
Green 110 J32 (1-109) 0.7 V ÷ 1.8 V
Values obtained with the console

MENU TESTER - ACCELERATOR
0.7 V ÷ 1.7 V with pedal pressed
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LIFTING POTENTIOMETER ADJUSTMENT

The test of the potentiometer can be carried out in two different ways:
Values obtained with the console

MENU TESTER - ACCELERATOR
1.1 V ÷ 4.6 V with lever operated
Values obtained with the multimeter

1.1 V ÷ 4.6 V
With microswitch closed: 0.46 V
There is a difference between the values obtained with the two methods. When measuring voltage, the
console display shows a value 0.4 Volt greater than the actual one and this is a constant condition.
135
2 RP1 (137) 5V
1
137
3 Standard RP1 (135) 0.46 V ÷ 4.6 V
RP1 (136) GND
136
Yellow 137
4.5KOhm 1.2KOhm
Red 135
Green 136
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CONNECTOR CHECK
BEFORE TROUBLESHOOTING
1. Disconnect the battery plug before connecting or

disconnecting each connector or terminal
2. When disconnecting a connector, do not pull it at the
harness but hold the connector itself and pull it after
unlocking it. To connect, push the connector fully until
it is locked in position
3. Bring a tester probe into contact with a connector

terminal from the rear side of the coupler (harness
side)
4. If insertion from the rear side is impossible, as in the
case of a waterproof connector, bring the tester probe
carefully into contact with the terminal so as not to
cause deformation of the connector terminal
5. Do not touch connector terminals directly with your
hand
6. When bringing tester probes into contact with live
terminals, prevent two tester probes from coming into
contact with each other
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WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE

When any trouble occurs, first inspect the connectors and wire harness of the related circuit according
to the following procedure:
Continuity check
1. Disconnect the connectors at both ends of the
corresponding harness
2. Measure the resistance between corresponding
terminals of the connectors at both ends
Standard:10 W or less
Notes:
Measure while lightly shaking the wire harness up and
down and sideways.
Reference:
Open circuit at the wire harness occurs rarely partway
through a vehicle wiring but mostly at connectors.
Inspect especially the sensor connectors with sufficient
care
Short circuit check

3. Disconnect the connectors at both ends of the
4. Measure the resistance between the corresponding
connector terminal and negative. Always inspect the
connectors at both ends
Standard: 1 MΩ or more
Notes:
Measure while lightly shaking the wire harness up and
down and sideways.
5. Measure the resistance between a terminal

corresponding to the connector terminal and N1.
Always inspect the connectors at both ends
Standard: 1 MΩ or more
Notes:
The wiring may short-circuit due to pinching by the
body or defective clamping.
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Visual and contact pressure checks

• Disconnect the connectors at both ends of the
• Visually inspect that there is neither rust nor foreign
matter trapped at connector terminals
• Inspect that there is no loosening or damage at the
locked portion. Also, lightly pull the wire harness from
the connector to check that it does not come off
• Insert a male terminal the same as that of the terminal
to check into a female connector and check the force if
extraction.
Defective contact may exist at a terminal where the
extracting force is less than that of other terminals
Notes:
Even if there is rust or foreign matter trapped at the
terminal, or the contact pressure between male and
female terminals is low, abnormal contact condition
may be changed to normal by disconnecting and
reconnecting the connector. In that case, repeat
connector connection and disconnection several
times. If defect is perceived even once, terminal
contact may be defective.
The above information, concerning the inspection of the connectors, are referred to specific type as
shown in the drawing. The same procedure must be apply for all type found on the machines.
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SYSTEM CONFIGURATION WITH MECHANICAL VALVE
DASHBOARD
Potentiometer,
microswitches, I/O CARD
mechanical control
Potentiometer,
microswitches,
pedal system.
LIGHT CARD
Lights
LOGIC UNIT LOGIC UNIT

FOR DRIVE FOR LIFTING
Encoder Encoder
CAN BUS ANALOG

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SYSTEM CONFIGURATION WITH ELECTRIC VALVE
DASHBOARD
LOGIC UNIT
MHYRIO UNIT
I/O CARD
Coils
electric control valve ARMREST
BOARD
Potentiometers,
microswitches,
pedal system
LIGHT CARD
Lights

FOR DRIVE FOR LIFTING
Encoder Encoder
CAN BUS ANALOG

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DIAGNOSIS CODE LIST

When an Error Code is Displayed
Displayed
Alarm specification Error mode Page
code
01 WATCHDOG DRIVE LOGIC UNIT: Self-diagnostic test 79
02 EEPROM KO DRIVE LOGIC UNIT: Fault in the memory area 79
03 LOGIC FAILURE #3 DRIVE LOGIC UNIT: Logic defect 79
DRIVE LOGIC UNIT: Fault in the hardware section which
04 LOGIC FAILURE #2 80
manages the voltage of the 3 phases
DRIVE LOGIC UNIT: Protection from
undervoltage/overvoltage
06 VMN LOW DRIVE LOGIC UNIT: Failure in the VMN test 82
07 VMN HIGH DRIVE LOGIC UNIT: Failure in the VMN test 83
DRIVE LOGIC UNIT: Failure on the contactor
08 CONTACTOR OPEN 84
driver
DRIVE LOGIC UNIT: Failure on the current
09 STBY I HIGH 84
sensor
CAPACITOR
10 DRIVE LOGIC UNIT: Capacitors not charged 84
CHARGE
HIGH DRIVE LOGIC UNIT: Logic unit’s temperature higher than
11 85
TEMPERATURE 75°C
MOTOR DRIVE LOGIC UNIT: Drive motor
12 85
TEMPERATURE sensor open
13 ENCODER ERROR DRIVE LOGIC UNIT: Fault of the encoder’s circuit 86
THERMIC DRIVE LOGIC UNIT: Logic unit’s internal sensor out of
14 87
SENSOR KO range
15 SAFETY DRIVE LOGIC UNIT: Protection activated 87
DRIVE LOGIC UNIT: It is detecting comunication of
16 CAN BUS KO 88
another card
WAITING FOR DRIVE LOGIC UNIT: It is detecting a delay in
17 88
NODES data transmission
18 AUX OUTPUT KO 89
driver
19 DRIVER SHORTED 89
driver
CONTACTOR DRIVE LOGIC UNIT: Failure on the contactor
20 89
DRIVER driver
21 COIL SHORTED 89
driver
DRIVE LOGIC UNIT: Failure on the acceleration
22 VACC NOT OK 89
potentiometer signal
23 INCORRECT START DRIVE LOGIC UNIT: Change the command 90
24 PEDAL WIRE KO DRIVE LOGIC UNIT: Change the command 90
WRONG SET
25 DRIVE LOGIC UNIT: Battery voltage out of range 90
BATTERY
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Displayed
code
26 REMOTE INPUT DRIVE LOGIC UNIT: General incorrect starting procedure 90
27 UNUSED UNUSED 90
28 UNUSED UNUSED 90
29 FORW + BACK DRIVE LOGIC UNIT: Incorrect starting procedure 90
30 UNUSED UNUSED 90
LIFTING LOGIC UNIT: Self-diagnostic
31 WATCHDOG 93
test
32 EEPROM KO LIFTING LOGIC UNIT: Fault in the memory area 93
33 LOGIC FAILURE #3 LIFTING LOGIC UNIT: Logic defect 93
34 LOGIC FAILURE #2 LIFTING LOGIC UNIT: Fault in the hardware section 94
LIFTING LOGIC UNIT: Protection from
undervoltage/overvoltage
36 VMN LOW LIFTING LOGIC UNIT: VMN test failure 96
37 VMN HIGH LIFTING LOGIC UNIT: VMN test failure 97
LIFTING LOGIC UNIT: Failure on the
38 CONTACTOR OPEN 98
main contactor
39 STBY I HIGH LIFTING LOGIC UNIT: Failure on the current sensor 98
CAPACITOR
40 LIFTING LOGIC UNIT: Capacitors not charged 98
CHARGE
HIGH LIFTING LOGIC UNIT: Logic unit’s temperature higher
41 99
TEMPERAURE than 75°C
MOTOR
42 LIFTING LOGIC UNIT: Sensor of lifting motor opened 99
TEMPERATURE
LIFTING LOGIC UNIT: Failure on the
43 ENCODER ERROR 100
encoder circuit
THERMIC LIFTING LOGIC UNIT: Logic unit’s internal sensor out of
44 101
SENSOR KO range
45 SAFETY LIFTING LOGIC UNIT: Protection activated 101
LIFTING LOGIC UNIT: It is detecting
46 CAN BUS KO 102
comunication of another card
WAITING FOR LIFTING LOGIC UNIT: it is detecting a delay in data
47 102
NODES transfer
48 AUX OUTPUT KO LIFTING LOGIC UNIT: Failure on the contactor driver 103
49 DRIVER SHORTED LIFTING LOGIC UNIT: Failure on the contactor driver 103
CONTACTOR
50 LIFTING LOGIC UNIT: Failure on the contactor driver 103
DRIVER
51 COIL SHORTED LIFTING LOGIC UNIT: Failure on the contactor driver 103
LIFTING LOGIC UNIT: Failure on the lifting potentiometer
52 VACC NOT OK 103
signal
53 INCORRECT START LIFTING LOGIC UNIT: Incorrect starting procedure 103
54 UNUSED UNUSED 104
55 WRONG BATTERY LIFTING LOGIC UNIT: Battery voltage out of range 104
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Displayed
code
56 REMOTE INPUT XX LIFTING LOGIC UNIT: Incorrect starting procedure 104
LIFTING LOGIC UNIT: It is detecting a delay in data
57 WAITING MHYRIO 104
transfer of Mhyrio logic unit
58 I=0 EVER LIFTING LOGIC UNIT: Failure on the current sensor 104
LIFTING LOGIC UNIT: The lifting logic unit fails to detect
59 SEAT KO 105
the microswitch is on
81 INCORRECT START I/O CARD: Incorrect starting procedure 112
82 LOGIC FAILURE I/O CARD: Logic defect 112
I/O CARD: Failure on the acceleration potentiometer
83 PEDAL WIRE KO 112
signal at rest
84 BAD MICROSWITCH I/O CARD: General alarm of broken microswitch 112
85 UNUSED UNUSED. 112
PUMP INCORRECT
88 I/O CARD: Incorrect starting procedure 112
START
1A I=0 EVER DRIVE LOGIC UNIT: Failure on the current sensor 91
1C BATTERY LOW DRIVE LOGIC UNIT: Battery discharged 91
CONTACTOR
1E DRIVE LOGIC UNIT: Failure on the contactor driver 91
CLOSED
CHOPPER NOT
2A DRIVE LOGIC UNIT: Incorrect configuration 91
CONFIG.
DRIVE LOGIC UNIT: The logic unit is during the data
2C GAIN ACQUISITION 91
acquisition phase
2E HANDBRAKE DRIVE LOGIC UNIT: Parking brake switch failure 92
RAM MEMORY NOT
2F DRIVE LOGIC UNIT: Electrostatic protection 92
OK
4A UNUSED UNUSED 105
4C BATTERY LOW LIFTING LOGIC UNIT: Battery discharged 105
4E UNUSED UNUSED 105
CHOPPER NOT
5A LIFTING LOGIC UNIT: Incorrect configuration 106
CONFIG.
LIFTING LOGIC UNIT: The logic unit is during the data
5C GAIN ACQUISITION 106
acquisition phase
5E UNUSED UNUSED 106
RAM MEMORY NOT
5F LIFTING LOGIC UNIT: Electrostatic protection 106
OK
MHYRIO LOGIC UNIT: Fault in the area of memory in
A1 EEPROM KO 107
which the adjustment parameters are stored
MHYRIO LOGIC UNIT: The transistor that controls the
A2 DRIVER SHORTED lifting valves supply positive is closed when it should be 107
open
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Displayed
code
A3 CAN BUS KO MHYRIO LOGIC UNIT: Failure of the can bus comunication 107
A4 FF VALVES MHYRIO LOGIC UNIT: Problem in the hardware circuit 108
MHYRIO LOGIC UNIT: The transistor that controls the
A5 DRIVER OPENED lifting valves supply positive is open when it should be 108
closed
MHYRIO LOGIC UNIT: One or more MOS controlling the
A6 DRIVER EPV GR1 108
valves are in short-circuit
C1 STOP OPEN LIGHT CARD: Failure on the stop lights 113
C2 UNUSED UNUSED 113
C4 RETRO OPEN LIGHT CARD: Failure on the reverse lights 113
C5 C1 + C4 LIGHT CARD: C1 + C4 113
b1 IO COMMUNIC KO DASHBOARD: The dashboard doesn't see the I/O card 109
MHY COMMUNIC DASHBOARD: The dashboard doesn't see the Mhyrio
b2 109
KO logic
b3 b1 + b2 DASHBOARD: Alarm b1 + Alarm b2 109
LIGHTS COMMUNIC
b4 DASHBOARD: The dashboard doesn't see the lights card 109
KO
b7 b4 + b2 + b1 DASHBOARD: Alarm b1 + Alarm b2 + Alarm b4 109
TRAC COMMUNIC DASHBOARD: The dashboard doesn't see the traction
d1 110
KO logic unit
PUMP COMMUNIC DASHBOARD: The dashboard does not see the lifting
d2 110
KO card
d3 d1 + d2 DASHBOARD: Alarm d1 + Alarm d2 110
d4 UNUSED UNUSED 110
DASHBOARD: The dashboard does not see the armrest
d8 JOY COMMUNIC KO 110
board
d9 d8 + d1 DASHBOARD: Alarm d8 + Alarm d1 110
dA d8 + d2 DASHBOARD: Alarm d2 + Alarm d8 111
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Displayed
code
db d8 + d2 + d1 DASHBOARD: Alarm d1 + Alarm d2 + Alarm d8 111
dC UNUSED UNUSED 111
dd UNUSED UNUSED 111
dE UNUSED UNUSED 111
dF UNUSED UNUSED 111
E1 UNUSED UNUSED 112
E2 BAD LIFT POT ARMREST BOARD: Failure on the lifting potentiometer 114
E3 BAD TILT POT ARMREST BOARD: Failure on the tilting potentiometer 114
ARMREST BOARD: Failure on the sideshift potentiometer
E4 BAD SIDESH. POT 115
signal
ARMREST BOARD: Failure on the 4th way potentiometer
E5 BAD IV POT 115
signal
ARMREST BOARD: Failure on the 5th way potentiometer
E6 UNUSED 115
signal
E7 INCORRECT START ARMREST BOARD: Incorrect start sequence 116
BAD ARMREST BOARD: General alarm for one of the
E8 116
POTENTIOMETER potentiometers malfunctioning
bF FW + BW ARMREST BOARD: Incorrect starting procedure. 116
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WHEN AN ERROR CODE IS DISPLAYED

DRIVE LOGIC UNIT
01 WATCHDOG
Condition for error detection

The test is made in both running and standby. It is a self-diagnosing test within the logic.
This alarm could also be caused by the canbus malfunctioning.
Therefore, before replacing the controller check the canbus.
02 EEPROM KO

Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibits the truck
operation, but the unit will load the default parameters.
If the defect persists when the machine is switched back on again, replace the module.
If the alarm disappears then the previously saved parameters will be deleted and the default
parameters of the electronic control unit will automatically be loaded.
03 LOGIC FAILURE #3

Logic defect. Replace the logic unit.
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04 LOGIC FAILURE #2

Fault in the hardware section of the logic board which manages the phase voltage feedback.
The alarm appears even if the contactor K1 (drive line) opens with the coil still powered.
Output voltage of the logic for coil power supply:
connector B: pin 2 wire 125 (+80V) - pin 8 wire 129 (-)
Check:
- connector present on the contactor unit: possible false contacts
(see Contactor Unit Assembly Drawing paragraph)
- coil resistance of contactor K1 = 260 ohm
- the status of the power cables connected to the motor
- replace the logic unit
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05 LOGIC FAILURE #1

This alarm signals that the low or high voltage protection cut-out has tripped.
- low voltage: the logic unit keeps the key input voltage under control (connector B1 wire 102). If the
voltage has a peak down the alarm trips.
- high voltage: the logic unit keeps the key input voltage under control (connector B1 wire 102). If the
voltage has a peak up the alarm trips.
The possible reasons are:
a. Battery voltage too low/too high or loss of voltage after key switch or after battery connector.
b. If the alarm is signalled when the vehicle is switched on and it appears in combination with alarm 35
of the lifting logic, check:
- the key switch connections (there must not be a drop in voltage between the input and output)
- the battery connector is well connected and the contacts are neither damaged nor oxidized
- the state of the battery. One of the elements could leaking or shorted
c. If the alarm appears when switching on and there is no loss of voltage on the key switch: fault in the
hardware section of the logic unit which controls this type of protection.
Replace the drive module.
d. The alarm appears when driving is required, one or more phases of the motor do not have proper
insulation. Check the motor insulation (with battery disconnected): the measurement must be made in
the order of Mohm. To check the insulation, check the resistance between the motor power cables and
a screw fixed to the chassis. After identifying a low resistance, disconnect the components so as to
find the component that has lost its insulation.
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06 VMN LOW

Failure in the VMN test.
This test starts when the ignition key is turned ON and there is no current consumption (machine
stationary). The alarm appears if there is a leakage of current on one or more phases with respect to
battery negative; check the connections of the 3 power cables from the logic unit to the traction motor
and the cables condition. In order to point out if the fault is produced by an internal or external cause
proceed as follows:
- The alarm appears when driving is required, one or more phases of the motor do not have proper
- Switch off the machine and reverse the drive and lifting motor connections on the logic units.
- Check the state of the coil of contactor K1 (260 ohm).
- Switch on the machine and wait for the logic unit to run the test. Important: With the motors reversed
do not give any driving or lifting signals.
- If the alarm persists replace the drive logic unit.
- If the alarm is detected by the lifting logic unit, check and if necessary replace the drive motor
Two of the three phases are

controlled by a shunt. If the
logic unit detects a leakage of
current it keeps the truck
stopped.
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07 VMN HIGH

stationary). The alarm appears if the power circuit is open; check the connections of the 3 power
cables from the logic unit to the traction motor and the cables condition.
Check the state of the coil of contactor K1 (260 ohm).
Note: Two of the three phases are controlled by a shunt. If the logic unit detects a leakage of current it
keeps the truck stopped.
To determine the cause of the fault, proceed by running one of the tests described below:
TEST 1
- Operate the parking brake and switch off the machine
- Open the compartment and disconnect the battery
- Check the power cables on the motor are tight
- Check the power cables on the logic unit are tight
- Check the continuity values between the following points on the control unit using a tester:
Red Tip Black Tip
T1 - (+) = 6.3 Kohm
T2 - (+) = 6.3 Kohm
T3 - (+) = 6.3 Kohm
T1 - (-) = 6.3 Kohm If the measurements are very different to the
T2 - (-) = 6.3 Kohm reference ones described alongside,
T3 - (-) = 6.3 Kohm disconnect all the power cables from the logic
U - V = 0 ohm unit and check the values directly on the control
U - W = 0 ohm unit
V - W = 0 ohm
Values on the control unit:
U - (+) = 7.0 Kohm
V - (+) = 120 Kohm
W - (+) = 120 Kohm
U - (-) = 7.0 Kohm
V - (-) = 120 Kohm
W - (-) = 120 Kohm If an open circuit is detected, replace the control
U - V = 125 Kohm unit.
U - W = 125 Kohm
V - W = 260 Kohm
TEST 2
Connect the drive logic unit to the lifting motor and check whether the display shows the alarm code
"07".
YES: repace the logic unit
NO: check the traction motor insulation
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08 CONTACTOR OPEN

Fault with the contactor K1. The contactor is powered, but the contacts do not close.
- Check the main contactor coil and relevant cables.
09 STBY I HIGH

Failure on the current sensor.
- Replace the drive logic unit.
10 CAPACITOR CHARGE

When switching on, the logic unit charges the capacitors through a power resistor and checks whether
the capacitors charge in a set time. If they do not charge, an alarm is signalled and the main contactor
does not close.
- Check the negative connection.
- Check the voltage upstream from the key switch: there must always be battery voltage.
- Renew the key switch.
- Replace the logic unit.
Vb= battery
F1= key fuse PB1 KEY
+ Vb F1
PB1= emergency
button
KEY= key
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11 HIGH TEMPERAURE

The temperature of the logic unit has exceeded 75°C. The maximum current in the module is reduced
proportionally to the temperature increase.
At 85°C the current is reduced to 0 and the module stops.
Check:
- the fan filter must not be clogged
- the fan works correctly
- the air duct must be clear
Check the TEMPERATURE parameter with the console in the TESTER function. If higher than 85°C
wait for the control unit to cool gradually.
When the temperature falls under 75°C the alarm disappears automatically.
12 MOTOR TEMPERAURE

This alarm appears when the motor temperature sensor (digital signal) opens or the analog signal
exceeds the trip level. If this happens when the motor is cold, check:
Conditions of correct operation
The temperature sensor is digital and normally closed: R = 0 ohm
Connector J1 I/O card between pin 3 and 4 = 0 Volt. (For the card references, refer to the I/O Control
Card section).
Checkpoints:
- If the sensor is open with the motor cold: renew the sensor (see chapter 1000);
- if the sensor is closed, but there is 5V between pins J1-3 and J1-4: renew the I/O card;
- if the sensor is closed, there is 0V between pins J1-3 and J1-4, but there is the alarm on the
dashboard, renew the drive control unit.
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13 ENCODER ERROR

Encoder failure.
This alarm indicates that the encoder information is not correct or is not present.
The encoder transmits signals only when the motor is running. The logic unit recognizes an alarm only
if the motor exceeds 20Hz.
Therefore, if an error signal appears on the dashboard and the operator uses the reset key with the
machine stopped, the alarm disappears - however, it remains stored in the logic.
If the alarm signal starts before reaching 20Hz, the problem can be attributed to a possible wrong
insulation of a power cable on the frame. Without the correct encoder signals, the machine remains
stationary or moves very slowly. To determine whether the problem is to be attributed to the encoder or
to the logic, proceed as follows:
Set the SLIP CONTROL on OFF and speeding up slowly.
Note that if the motor speed increases it does not necessarily mean that the problem is connected to
the encoder. One of the following components may be defective:
- Logic internal circuit
- Wiring
- Sensorized bearing (encoder)
You may use a digital or analog multimeter to determine where the problem is located.
Encoder basic wiring diagram

The figure shows only one signal (A).
The encoders used generate two equal signals,
with a 90° difference (A-B).
1. Connect the tester positive point (red) to the
encoder positive terminal.
2. Connect the tester COM point (black) to the
encoder signal (A).
According to the engine position, the following
values will be displayed:
• low signal: 0.5 -- 1.5 Volt
• high signal: 10.5 -- 11.5 Volt
Intermediate values cannot be read as the motor
is stopped.
If the motor is running, the multimeter will
automatically read the Vm (average value)
Vm= 5.5 -- 6.5 Volt
Carrying out this test directly on the logic
connector, you can determine if signals are good
- see above-mentioned description - or if the
channels are open or in short circuit. If the
signals are good, the problem should be
attributed to the electronic control.
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14 THERMIC SENSOR KO

Thermic sensor of the logic unit out of range.
15 SAFETY

Stop in traction controlled by the lifting unit.
Pin 5 (negative input) of connector B in the drive unit is connected to pin 9 (negative output) of
connector B of the lifting unit. In case of trouble the lifting unit opens this connection eliminating
accordingly the negative signal. The drive unit stops and signals SAFETY (= safety stop). Check:
(1) If pin 5 of connector B (drive logic unit) is connected to the lifting unit
(2) If pin 9 of connector B (lifting logic unit) is a negative.
- If this is so, renew the drive logic unit (see the Necessary Adjustments paragraph after
renewing the drive logic unit)
- If it is not so, verify the presence of other alarms that could have inhibited the operation of the
lifting unit
- check there is connector D on the lifting logic unit
(3) Check there is the lifting logic unit power supply:
- connector B1 wire 102 = 80V
Connect the console on the lifting logic unit and see whether it switches on. On the contrary,
and with the power supply of 80V on B1, renew the lifting logic unit (see the Necessary
Adjustments paragraph after renewing the lifting logic unit)
Main
contact
TRACTION LIFTING
Key
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16 CAN BUS KO

Communication failure in the wires connecting the logic units (traction, lifting, Mhyrio) and all the other
cards. In this condition the rear brake and reversing lights are switched on and the lifting motor turns
on automatically to ensure the power steering function.
- Check there is connector D on the lifting logic unit.
The alarm appears in the case of:
• CAN H and/or CAN L signals disconnected.
• No comunication from a logic unity or card. In case the problem starts from one card the system
recognize in which one:
- CAN BUS KO 0A: I/O card.
- CAN BUS KO 05: lifting.
- CAN BUS KO 09: Mhyrio.
- CAN BUS KO 00: armrest card.
If the problem is genereated by the drive, the console will only show
- CAN BUS KO without any extension.
It is anyhow advised to make a preliminary check on all the CAN BUS connections before replacing
one or more components:
Try using the console to connect up with all the nodes through the connection number and with the
various cards, using the TESTER function to verify at least one of the signals, for example:
microswitches, potentiometers.
If it is not possible There is a line interruption.
17 WAITING FOR NODE

The logic unit has identified a delay in the data transmission of the I/O card or lifting logic.
WAITING FOR 0A: delay in transmission of the I/O card.
Checkpoints:
- If alarm 17(waiting for 0A) appears in combination with alarm 47 connect the console in the lifting
logic unit and check whether the WAITING FOR 0A alarm appears.
If this is so, renew the I/O card.
- If alarm 17(waiting for 0A) appears on its own, check:
general machine insulation;
renew the drive logic unit.
WAITING FOR 05: delay in transmission of the lifting logic.
Checkpoints:
- If alarm 17(waiting for 05) appears in combination with other alarms of the lifting logic unit:
If this is so, the alarm signals that the lifting logic has shut down.
Connect the console and check the alarms related to the lifting logic. After eliminating the causes of the
lifting logic shutdown, alarm 17 will automatically disappear.
If this is not so, check for false contacts in the CAN-BUS connection: connector C drive logic unit pin 1-
2-3-4, connector C lifting logic unit pin 1-2-3-4.
If there are no false contacts renew the drive logic unit.
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18 AUX OUTPUT KO

Failure on the contactor driver.
- Replace the traction logic unit.
19 DRIVER SHORTED

Failure on the driver of contactor K1.
- Check for any short circuiting between wires 125 and 129 supplying the coil. Check the state of the
coil (260 ohm).
- If the failure is not due to external causes, replace the traction logic unit.
20 CONTACTOR DRIVER

Failure on the traction contactor driver.
- Renew the drive unit.
21 COIL SHORTED

Failure on the drive contactor K1.
- If the failure is not due to external causes, replace the traction logic unit.
22 VACC NOT OK

Failure on the acceleration potentiometer signal at rest. The alarm points out that the voltage value
detected on the accelerator potentiometer is 1 Volt higher than the least value programmed with the
Vacc function. Check:
- The traction potentiometer (it could be damaged or not correctly calibrated: Vacc calibration)
- The traction potentiometer wiring (see potentiometer description)
- Carrry out the Vacc setting again (see dedicated section)
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23 INCORRECT START

- Seat switch open during traction.
24 PEDAL WIRE KO

Failure on the accelerator potentiometer. Check the wiring of the potentiometer (connector J32).
The positive wire (111) or the slider (109) can be disconnected.
25 WRONG SET BATT

When the key is turned ON, the controller checks the battery voltage and compares it with the “SET
BATTERY” parameter setting. If the actual value is 20% higher or lower than the nominal value, there
is a fault.
.- Check the status of the battery and if neccessary replace it with a correct one.
26 REMOTE INPUT

General incorrect starting procedure.
27 UNUSED
28 UNUSED
29 FORW + BACK

Incorrect starting sequence.
Check:
- Microswitch for forward/backward directions and relevant wires.
30 UNUSED
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1A I=0 EVER

Renew the drive logic unit.
1C BATTERY LOW

Battery discharged.
1E CONTACTOR CLOSED

Failure on the drive contactor. The contactor has remained closed.
Disconnect the battery, clean the contacts of the contactor. Renew if necessary.
2A CHOPPER NOT CONF

The drive module configuration is incorrect. Using the console it is possible to reprogram the module
correctly in conformity with the type of truck (see the TRACTION ACQUISITION section):
0) dual pedal system;
1) single pedal system + manual inverser;
2) single pedal system + armrest inverser;
2C GAIN ACQUISITION

This warning communicates that the logic is in phase of input acquisition. In this phase the logic
doesn't work. If the alarm persists replace the logic unit.
2E HANDBRAKE

Parking brake pulled or failure on the microswitch of the parking brake.
Check:
- release the parking brake
- the status of the parking brake microswitch SW2 and the relevant cables.
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2F RAM MEMORY NOT OK

Protection against electrostatic charges active.
Switch the machine off and back on again.
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LIFTING LOGIC UNIT

31 WATCHDOG

The test is made in both running and standby. It is a self-diagnosing test within the logic.
This alarm could also be caused by the can-bus malfunctioning.
Therefore, before replacing the controller check the can-bus.
32 EEPROM KO

Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibits truck
operation. If the defect persists when the truck is restarted, replace the module.
If the alarm disappears, the default parameters of the electronic control unit will automatically be
saved (see Settings table).
33 LOGIC FAILURE #3

Logic defect. Replace the logic unit.
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34 LOGIC FAILURE #2

Fault in the hardware section of the logic board which manages the phase voltage feedback. The
alarm appears even if the contactor K2 (lifting line) opens with the coil still powered.
Output voltage of the logic for coil power supply:
connector B: pin 2 wire 120 (+80V) - pin 8 wire 164 (-)
Check:
- connector present on the contactor unit: possible false contacts
(see Contactor Unit Assembly Drawing paragraph)
- coil resistance of contactor K2 = 260 ohm
- the status of the power cables connected to the motor
- replace the logic unit
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35 LOGIC FAILURE #1

This alarm signals that the low or high voltage protection cut-out has tripped.
- low voltage: the logic unit keeps the key input voltage under control (connector B1 wire 102). If the
voltage has a peak down the alarm trips.
- high voltage: the logic unit keeps the key input voltage under control (connector B1 wire 102). If the
voltage has a peak up the alarm trips.
The possible reasons are:
a. Battery voltage too low/too high or loss of voltage after key switch or after battery connector.
b. If the alarm is signalled when the vehicle is switched on and it appears in combination with alarm 15
of the lifting logic, check:
- the key switch connections (there must not be a drop in voltage between the input and output)
- the battery connector is well connected and the contacts are neither damaged nor oxidized
- the state of the battery. One of the elements could leaking or shorted
c. If the alarm appears when switching on and there is no loss of voltage on the key switch: fault in the
hardware section of the logic unit which controls this type of protection. Logic defect. Replace the
lifting module.
d. The alarm appears when driving is required, one or more phases of the motor do not have proper
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36 VMN LOW

stationary). The alarm appears if there is a leakage of current on one or more phases with respect to
battery negative; check the connections of the 3 power cables from the logic unit to the traction motor
and the cables condition. In order to point out if the fault is produced by an internal or external cause
proceed as follows:
- The alarm appears when driving is required, one or more phases of the motor do not have proper
- Switch off the machine and reverse the drive and lifting motor connections on the logic units.
- Check the state of the coil of contactor K2 (260 ohm).
- Switch on the machine and wait for the logic unit to run the test. Important: With the motors reversed
do not give any driving or lifting signals.
- If the alarm persists replace the lifting logic unit.
- If the alarm is detected by the drive logic unit, check and if necessary replace the lifting motor.
Two of the three phases are

controlled by a shunt. If the
logic unit detects a leakage of
current it keeps the truck
stopped.
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37 VMN HIGH

stationary). The alarm appears if the power circuit is open; check the connections of the 3 power
cables from the logic unit to the traction motor and the cables condition.
Check the state of the coil of contactor K2 (260 ohm).
Note: Two of the three phases are controlled by a shunt. If the logic unit detects a leakage of current it
keeps the truck stopped.
To determine the cause of the fault, proceed by running one of the tests described below:
TEST 1
- Operate the parking brake and switch off the machine
- Open the compartment and disconnect the battery
- Check the power cables on the motor are tight
- Check the power cables on the logic unit are tight
- Check the continuity values between the following points on the control unit using a tester:
Red Tip Black Tip
T1 - (+) = 6.3 Kohm
T2 - (+) = 6.3 Kohm
T3 - (+) = 6.3 Kohm
T1 - (-) = 6.3 Kohm If the measurements are very different to the
T2 - (-) = 6.3 Kohm reference ones described alongside,
T3 - (-) = 6.3 Kohm disconnect all the power cables from the logic
U - V = 0 ohm unit and check the values directly on the control
U - W = 0 ohm unit
V - W = 0 ohm
Values on the control unit:
U - (+) = 7.0 Kohm
V - (+) = 120 Kohm
W - (+) = 120 Kohm
U - (-) = 7.0 Kohm
V - (-) = 120 Kohm
W - (-) = 120 Kohm If an open circuit is detected, replace the control
U - V = 125 Kohm unit.
U - W = 125 Kohm
V - W = 260 Kohm
TEST 2
Connect the traction logic unit to the lifting motor and check if the alarm “07” appears on the display.
YES: repace the logic unit
NO: check the lifting motor insulation.
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38 CONTACTOR OPEN

Fault with the contactor K2. The contactor is powered, but the contacts do not close.
- Check the main contactor coil and relevant cables.
39 STBY I HIGH

Failure on the current sensor. Replace the lifting logic units.
40 CAPACITOR CHARGE

When switching on, the logic unit charges the capacitors through a power resistor and checks whether
the capacitors charge in a set time. If they do not charge, an alarm is signalled and the main contactor
does not close.
- Check the negative connection.
- Check the voltage upstream from the key switch: there must always be battery voltage.
- Renew the key switch.
Vb= battery
F1= key fuse PB1 KEY
PB1= emergency + Vb F1
button
KEY= key
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41 HIGH TEMPERATURE

The temperature of the logic unit has exceeded 75°C. The maximum current in the module is reduced
proportionally to the temperature increase.
At 85°C the current is reduced to 0 and the module stops.
Check:
- the fan filter must not be clogged
- the fan works correctly
- the air duct must be clear
Check the TEMPERATURE parameter with the console in the TESTER function. If higher than 85°C
wait for the control unit to cool gradually.
When the temperature falls under 75°C the alarm disappears automatically.
42 MOTOR TEMPERATURE

This alarm appears when the motor temperature sensor (digital signal) opens or the analog signal
exceeds the trip level. If this happens when the motor is cold, check:
Conditions of correct operation
The temperature sensor is digital and normally closed: R = 0 ohm
Connector J1 I/O card between pin 1 and 2 = 0 Volt. (For the card references, refer to the I/O Control
Card section).
Checkpoints:
- If the sensor is open with the motor cold: renew the sensor (see chapter 1000);
- if the sensor is closed, but there is 5V between pins J1-1 and J1-2: renew the I/O card;
- if the sensor is closed, there is 0V between pins J1-1 and J1-2, but there is the alarm on the
dashboard, renew the drive control unit.
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43 ENCODER ERROR

Encoder failure.
This alarm indicates that the encoder information is not correct or is not present.
The encoder transmits signals only when the motor is running. The logic unit recognizes an alarm only
if the motor exceeds 20Hz.
Therefore, if an error signal appears on the dashboard and the operator uses the reset key with the
machine stopped, the alarm disappears - however, it remains stored in the logic.
If the alarm signal starts before reaching 20Hz, the problem can be attributed to a possible wrong
insulation of a power cable on the frame. Without the correct encoder signals, the machine remains
stationary or moves very slowly. To determine whether the problem is to be attributed to the encoder or
to the logic, proceed as follows:
Set the SLIP CONTROL on OFF and speeding up slowly.
Note that if the motor speed increases it does not necessarily mean that the problem is connected to
the encoder. One of the following components may be defective:
- Logic internal circuit
- Wiring
- Sensorized bearing (encoder)
You may use a digital or analog multimeter to determine where the problem is located.
Encoder basic wiring diagram

The figure shows only one signal (A).
The encoders used generate two equal signals,
with a 90° difference (A-B).
1. Connect the tester positive point (red) to the
encoder positive terminal.
2. Connect the tester COM point (black) to the
encoder signal (A).
According to the engine position, the following
values will be displayed:
• low signal: 0.5 -- 1.5 Volt
• high signal: 10.5 -- 11.5 Volt
Intermediate values cannot be read as the motor
is stopped.
If the motor is running, the multimeter will
automatically read the Vm (average value)
Vm= 5.5 -- 6.5 Volt
Carrying out this test directly on the logic
connector, you can determine if signals are good
- see above-mentioned description - or if the
channels are open or in short circuit. If the
signals are good, the problem should be
attributed to the electronic control.
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44 THERMIC SENSOR KO

Thermic sensor of the logic unit out of range.
45 SAFETY

Stop of the lifting unit.
Pin 5 (negative input) of connector B in the lifting unit is connected to pin 11 (negative output); if this
jumper gets disconnected the logic stops and signals SAFETY (= safety stop). Check:
(1) If pin 5 of connector B is connected to pin 11
(2) Renew the lifting logic unit (see the Necessary Adjustments paragraph after renewing the lifting
logic unit)
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46 CAN BUS KO

Communication failure in the wires connecting the logic units (traction, lifting, Mhyrio) and all the other
cards. In this condition the rear brake and reversing lights are switched on and the lifting motor turns
on automatically to ensure the power steering function.
- Check there is connector D on the lifting logic unit.
The alarm appears in the case of:
• CAN H and/or CAN L signals disconnected.
• No comunication from a logic unity or card. In case the problem starts from one card the system
recognize in which one:
- CAN BUS KO 0A: I/O card.
- CAN BUS KO 02: drive.
- CAN BUS KO 09: Mhyrio.
- CAN BUS KO 00: armrest card.
If the problem is genereated by the drive, the console will only show
- CAN BUS KO without any extension.
It is anyhow advised to make a preliminary check on all the CAN BUS connections before replacing
one or more components:
Try using the console to connect up with all the nodes through the connection number and with the
various cards, using the TESTER function to verify at least one of the signals, for example:
microswitches, potentiometers.
If it is not possible There is a line interruption.
47 WAITING FOR NODE

The logic unit has identified a delay in the data transmission of the I/O card or drive logic or Mhyrio
unit.
WAITING FOR 0A: delay in transmission of the I/O card.
Checkpoints:
- If alarm 47(waiting for 0A) appears in combination with alarm 17 connect the console in the drive
logic unit and check whether the WAITING FOR 0A alarm appears. If this is so, renew the I/O card.
- If alarm 47(waiting for 0A) appears on its own, check:
general machine insulation;
renew the lifting logic unit.
WAITING FOR 02: delay in transmission of the drive logic.
Checkpoints:
- If alarm 47(waiting for 02) appears in combination with other alarms of the drive logic unit:
if this is so, the alarm signals that the drive logic has shut down.
Connect the console and check the alarms related to the drive logic. After eliminating the causes of the
drive logic shutdown, alarm 47 will automatically disappear.
If this is not so, check for false contacts in the CAN-BUS connection: connector C lifting logic unit pin 1-
2-3-4, connector C drive logic unit pin 1-2-3-4.
If there are no false contacts renew the lifting logic unit.
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48 AUX OUTPUT KO

Renew the lifting unit.
49 DRIVER SHORTED

Failure on the driver of contactor K2.
- Check for any short circuiting between wires 120 and 164 supplying the coil.
- Check the state of the coil (260 ohm)
50 CONTACTOR DRIVER

Renew the lifting unit.
51 COIL SHORTED

Failure on the lifting contactor K2.
- Check for any short circuiting between wires 120 and 164 supplying the coil.
- Check the state of the coil (260 ohm)
52 VACC NOT OK

Failure on the lifting acceleration potentiometer signal at rest. The alarm points out that the voltage
value detected on the accelerator potentiometer is 1Volt higher than the least value programmed with
the Vacc function. Check:
- The lifting potentiometer (it could be damaged or not correctly calibrated: Vacc calibration)
- The lifting potentiometer wiring (see potentiometer description)
- Carrry out the Vacc setting again (see dedicated section)
53 INCORRECT START

- Seat switch open when the pump is running.
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54 UNUSED
55 WRONG BATTERY

When the key is turned ON, the logic unit checks the battery voltage and compares it with the “SET
BATTERY” parameter setting. If the actual value is 20% higher or lower than the nominal value, there
is a fault.
.- Check the status of the battery and if neccessary replace it with a correct one.
56 REMOTE INPUT

General incorrect starting procedure.
57 WAITING MHYRIO

The logic unit has identified a delay in the data transmission of the Mhyrio logic unit.
WAITING FOR 09: delay in transmission of the Mhyrio logic unit.
Checkpoints:
- If alarm 57(waiting for 09) appears in combination with other alarms of the Mhyrio logic unit:
If this is so, the alarm signals that the Mhyrio logic has shut down. Connect the console and check the
alarms related to the Mhyrio logic unit. After eliminating the causes of the Mhyrio logic shutdown,
alarm 57 will automatically disappear.
If this is not so, check for false contacts in the CAN-BUS connection: connector JC pin 3-5.
If there are no false contacts renew the Mhyrio logic unit.
58 I = 0 EVER

- Replace the lifting logic unit.
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59 SEAT KO

The logic unit does not see the seat microswitch.
Check:
- the status of the seat microswitch
- pin B7 lifting logic = +Vb
- input B4 of the drive logic (wire 117) and input B4 of the lifting logic (wire 117).
If the inputs are correct, renew the logic unit.
60 UNUSED
4A UNUSED
4C BATTERY LOW

Battery discharged.
4E UNUSED
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5A CHOPPER NOT CONF

The lifting module configuration is incorrect.
Using the console it is possible to reprogram the module correctly in conformity with the type of truck
(see the Lifting Acquisition section):
- Joystick ON with electronic control valve
- Joystick OFF with mechanical control valve
5C GAIN ACQUISITION

This warning communicates that the logic is in phase of acquisition. In this phase the logic doesn't
work.
If the alarm persists replace the logic unit.
5E UNUSED
5F RAM MEMORY NOT OK

Protection against electrostatic charges active.
Switch the machine off and back on again.
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MHYRIO LOGIC UNIT

A1 EEPROM KO

Fault in the area of memory in which the adjustment parameters are saved;
this alarm inhibits the truck operation and the logic unit will use the initial parameters. If the defect
persists when the truck is restarted, replace the module. If the alarm disappears, remember that the
previously entered parameters will be replaced by the default parameters.
A2 DRIVER SHORTED
The transistor that controls the lifting and lowering valves supply positive is closed when it should be
open.
Check the status of the EVP and EV1 valves:
- EVP coil value = 19.5 ohm EV1= 24 ohm
If the coils are shorted, renew the Mhyrio module.
A3 CAN BUS KO

Failure in wires connecting the logic unit (traction, lifting, Mhyrio) and all the other cards.
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A4 FF VALVES

Problem with the circuit governing the short-circuiting protection of the valve drivers.
The cause can be external shorting on the coil of a valve, or interference inside the module.
Disconnect the wiring of the solenoid valves. If the alarm persists, renew the Mhyrio module.
A5 DRIVER OPENED

The transistor that controls the lifting and lowering valves supply positive is open when it should be
closed.
Replace the Mhyrio module.
A6 DRIVER EPV GR1

One or more MOS controlling the valves are in short-circuit.
A7 DRIVER EPV GR2

A8 DRIVER EPV GR3

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DASHBOARD
The alarm descriptions of the dashboard are not displayed on the console
b1 IO COMMUNIC KO

This alarm signals that the IO control board does not communicate.
- check the power supply; 24V must be present on the connector J8 pin 1 (wire 202)
- if the power supply is OK but it is not possible to operate the truck, replace the I/O card
b2 MHY COMMUNIC KO

This alarm signals that the Mhyrio logic unit is not communicating.
- check the power supply; 24V must be present on the connectorJC pin 4
- if the power supply is OK but it is not possible to operate the truck, replace the Mhyrio logic unit
b3 b1 + b2
b4 LIGHTS COMMUNIC KO

This alarm signals that the lights card is not communicating.
- check the power supply; 24V must be present on the connector J4 pin 1, 5 and 8
- if the power supply is OK but it is not possible to operate the truck, replace the lights card.
b5 b4 + b1
b6 b4 + b2
b7 b4 + b2 + b1
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d1 TRAC COMMUNIC KO

This alarm signals that the TRACTION logic unit does not communicate.
- check the power supply; 80V must be present on the connector B pin 1.
- if the power supply is OK but it is not possible to operate the truck, replace the DRIVE logic unit.
d2 PUMP COMMUNIC KO

This alarm signals that the LIFTING logic unit does not communicate.
- check the power supply; 80V must be present on the connector B pin 1.
- if the power supply is OK but it is not possible to operate the truck, replace the lifting logic unit.
d3 d1 + d2
d4 UNUSED
d5 UNUSED
d6 UNUSED
d7 UNUSED
d8 JOY KO

This alarm signals that the armrest board does not communicate.
- check the power supply; 24V must be present on the connector J8 pin5.
- if the power supply is OK but it is not possible to operate the truck, replace the armrest card
d9 d8 + d1
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dA d8 + d2
db d8 + d2 + d1
dC UNUSED
dd UNUSED
dE UNUSED
dF UNUSED
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I/O CONTROL BOARD

81 TRACTION INCORRECT START

Incorrect start sequence (mechanical control valve version) Check:
- The forward and reverse microswitches and their respective cables
- The parking brake microswitch and its respective cables
82 LOGIC FAILURE

Failure on the I/O card (mechanical control valve version). Renew the I/O card.
83 PEDAL WIRE KO

Failure on the acceleration potentiometer signal at rest. Check:
- traction potentiometer slider
- +V POT or GND POT could be interrupted
84 BAD MICRO SWITCH

Microswtich of the travel pedal or of the hand direction lever demaged.
85 UNUSED
86 UNUSED
87 UNUSED
88 PUMP INCORRECT START

Incorrect start sequence (mechanical control valve version) Check:
- the microswitches of the mechanical control valve and respective wirings.
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LIGHT CARD
C1 STOP OPEN

Failure on the stop lights. Check the bulbs of the brake lights and their respective cables.
The alarm appears if both brake lights are disconnected or the related light bulbs do not work
C2 UNUSED
C3 UNUSED
C4 RETRO-OPEN

Failure on the backup lights. Check the bulbs of the reversing lights and their respective cables.
The alarm appears if both reversing lights are disconnected or the related light bulbs do not work
C5 C1+C4
C6 UNUSED
C7 UNUSED
C8 UNUSED
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ARMREST BOARD
E1 UNUSED
E2 BAD LIFT POT

Failure on the lifting potentiometer in the fingertips / joysticks group.
- Switch off the machine, pull up the parking brake, connect the console in the lifting logic and switch
back on
- Select the TESTER menu
- Select the LIFTING SWITCH parameter
- Move the potentiometer and check whether the parameter changes from 0% to 100% progressively:
If there turns out to be potentiometer malfunctioning, proceed as follows:
JOYSTICK VERSION: reverse the lifting potentiometer with the sideshift potentiometer
FINGERTIP VERSION: reverse the lifting potentiometer with the tilting potentiometer
If the alarm persists replace the card.
If the alarm disappears, check the potentiometer wiring and then proceed with renewal.
If there is no potentiometer malfunctioning, renew the card.
E3 BAD TILT POT

Failure on the tilting potentiometer in the fingertips / joysticks group.
back on
- Select the 1ST LIFTING SWITCH parameter
JOYSTICK VERSION: reverse the tilting potentiometer with the 4th-way potentiometer
FINGERTIP VERSION: reverse the tilting potentiometer with the lifting potentiometer
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E4 BAD SIDESH POT

Failure on the sideshift potentiometer in the joysticks-fingertips group.
back on
- Select the 2ND SPEED SWITCH parameter
JOYSTICK VERSION: reverse the sideshift potentiometer with the lifting potentiometer
FINGERTIP VERSION: reverse the sideshift potentiometer with the tilting potentiometer
E5 BAD IV POT

Failure on the 4th-way potentiometer in the joysticks-fingertips group.
back on
- Select the 3RD SPEED SWITCH parameter
JOYSTICK VERSION: reverse the 4th-way potentiometer with the tilting potentiometer
FINGERTIP VERSION: reverse the 4th-way potentiometer with the sideshift potentiometer
E6 UNUSED

Unused.
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E7 PUMP INCORRECT START

Incorrect start sequence.
One of the potentiometers on the armrest is not in a neutral position when the machine is switched on.
Checkpoints:
- Switch off the machine, pull up the parking brake, connect the console and switch back on
- Check the state of the potentiometers:
LIFTING SWITCH = lifting potentiometer: must indicate 0%
1ST SPEED SWITCH = tilting potentiometer: must indicate 0%
2ND SPEED SWITCH = sideshift potentiometer: must indicate 0%
3RD SPEED SWITCH = 4th-way potentiometer: must indicate 0%
- After finding the potentiometer whose value is other than 0%:
(a) check the mechanical movement
(b) replace the potentiometer
(c) If the alarm persists replace the card
E8 BAD POTENTIOMETER

General alarm for one of the potentiometers malfunctioning.
The alarm appears in combination with one of the alarms dedicated to each function and indicates that
the armrest card has detected a defective potentiometer.
Checkpoints:
- Check the alarms dedicated to the other functions and repair or replace the defective potentiometer
- The general alarm must disappear
- If the indication remains, but the machine works correctly, replace the card
BF FW + BW

Double drive request signal.
The armrest card has detected a double request generated by the push-buttons PB1 and PB3 (see
wiring diagram).
Checkpoints:
- Check that the push-buttons are not pressed
- Check for short-circuiting in the wiring of the push-buttons
- If OK, replace the card
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CONSOLE
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CONSOLE FUNCTION GENERAL DESCRIPTION

HOUR METER:
The hour meter appears on the second line of the display when the chopper is connected; it has an
internal resolution of one minute and full scale 65,535 hours, where only the hours are displayed.
ALARMS:
The console can read the last 5 alarm messages saved in the chopper and show them on the display
together with the value of the hour meter where the alarm occured, the number of times the alarm
occured and the temperature at the time of the alarm.
PARAMETER PROGRAMMING:
The chopper parameters can be displayed and programmed via the keyboard, thereby making it
possible to set the chopper easily.
TESTER:
It makes it possible to display the state of the chopper analogue and digital values and thereby to have
a useful tool for the analysis of chopper operation and external cables.
SAVE:
It makes it possible to store all values relating to the parameters and the chopper hardware
configuration in the console with a program which can be selected from the keyboard.
RESTORE:
It makes it possible to program a chopper with the parameters contained in a program generated by a
SAVE.
ACCELERATOR TRAVEL PROGRAMMING:
Enables programming the travel of the accelerator.
CONSOLE DESCRIPTION
Button function:
ROLL 1 = Used to select the option or the next item in the
menu.
ROLL 2 = Used to select the option or the previous item in
the menu.
ENTER = Used to confirm the selected options.
OUT = Used to exit the function being performed.
PARAM = Used to increase the parameters or choose the
type of I/O connected.
SET = Used to decrease the parameters or choose the
type of I/O connected.
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PARAMETER CHANGE DESCRIPTION

DRIVE MODULE
PARAMETER CHANGE: Parameters shown in the adjusting table which can be modified in a fixed
range
1. ACCELERATION DELAY
Determines the acceleration ramp. Changing the parameter changes the acceleration time:
- minimum setting = maximum acceleration
- maximum setting = minimum acceleration
2. RELEASE BRAKING
Determines the deceleration ramp on releasing the pedal. Changing the parameter changes the
deceleration time:
- minimum setting = minimum deceleration
- maximum setting = maximum deceleration
3. INVERSION BRAKING
Determines the deceleration ramp on reversing:
4. PEDAL BRAKING
Determines the deceleration ramp when the pedal brake microswitch is pressed and the accelerator
pedal released:
5. SPEED LIMIT BRAKING
Determines the deceleration ramp by changing the position of the accelerator pedal without
releasing it completely:
6. BRAKE CUTBACK
Determines the deceleration ramp when a speed reduction request signal is activated.
Possible speed reductions:
a) cutback speed 1
b) cutback speed 2
c) cutback speed 3
7. MAX SPEED FORWARD
Determines the maximum forward speed:
- minimum setting = minimum speed
- maximum setting = maximum speed
8. MAX SPEED BACKWARD
Determines the maximum reverse speed:
9. CUTBACK SPEED
Determines the speed reduction with the “low speed selector“ push-button (turtle function) pressed:
- minimum setting = maximum cutback
- maximum setting = minimum cutback
10. CUTBACK SPEED 2
Determines the speed reduction when the accelerator pedal is pressed and the service brake pedal
microswitch activated:
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11. CUTBACK SPEED 3

Determines the speed reduction when it is enabled.
To enable this further cutback, refer to the Electric Circuit Connection paragraph
12. FREQUENCY CREEP
Determines the minimum speed with the driving microswitch activated and accelerator pedal on
minimum:
13. MAXIMUM CURRENT
Determines the maximum current the logic unit can deliver:
- minimum setting = minimum current
- maximum setting = maximum current
14. ACCELERATION SMOOTH
Determines the acceleration delay in the range between 0Hz and the frequency established by the
STOP SMOOTH parameter:
15. INVERSION SMOOTH
Determines the reverse acceleration delay in the range between 0Hz and the frequency established
by the STOP SMOOTH parameter:
16. STOP SMOOTH
Determines the end of the acceleration and inversion delays established by the ACCELERATION
SMOOTH and INVERSION SMOOTH parameters:
- minimum setting = minimum delays
- maximum setting = maximum delays
17. AUXILIARY TIME
Determines the time in which the truck is stationary on the ramp (with the “STOP ON RAMP”
function activated). For reasons of safety the parameter enables viewing only.
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PUMP MODULE
range
1. ACCELERATION DELAY
Determines the acceleration ramp. Changing the parameter changes the acceleration time:
2. DECELERATION DELAY
Determines the deceleration ramp. Changing the parameter changes the deceleration of the pump
motor on releasing the lifting lever:
- minimum setting = maximum deceleration
- maximum setting = minimum deceleration
3. MAX SPEED UP
Determines the maximum lifting speed:
4. MIN SPEED UP
Determines the minimum speed with the lifting microswitch with only the microswitch closed.
Changing the parameter changes the speed:
5. CUTBACK SPEED
Determines the speed reduction if enabled. To enable the cutback, connect a normally closed
microswitch between the outputs B7 and B10:
- microswitch open = reduction on
- microswitch closed = reduction off
6. CUTBACK SPEED 2
Not available
7. 1ST SPEED
Determines the tilting speed, Changing the parameter changes the speed::
8. 2ND SPEED
Determines the sideshift speed. Changing the parameter changes the speed:
9. 3RD SPEED
Determines the 4th-way speed. Changing the parameter changes the speed:
10. 4TH SPEED
Determines the 5th-way speed. Changing the parameter changes the speed:
11. AUXILIARY FUNCTION 1
Active only with fingertip/joystick configuration.
Determines the increase in the pump motor speed in relation to the percentage of the travel of the
lifting potentiometer:
- minimum setting = early acceleration of the lifting motor
- maximum setting = delayed acceleration of the lifting motor
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12. HYDRO SPEED

Determines the speed of the power steering. Changing the parameter changes the speed:
13. MAXIMUM CURRENT
Determines the maximum current the logic unit can deliver:
- minimum setting = minimum current
- maximum setting = maximum current
14. AUXILIARY TIME
Determines the delay time of the power steering when the request is switched off:
- minimum setting = minimum delay
- maximum setting = maximum delay
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MHYRIO UNIT
range
1. MIN LIFT
Determines the minimum voltage delivered to the lifting solenoid valve EV1
2. MIN LOWER
Determines the minimum voltage delivered to the lowering solenoid valve EVP
3. MIN DRAIN
Determines the minimum voltage delivered to the draining solenoid valve EV11
4. MIN REACH BWD
Not available
5. MIN TILT UP
Determines the minimum voltage delivered to the backward tilting solenoid valve EV4
6. MIN TILT DW
Determines the minimum voltage delivered to the forward tilting solenoid valve EV3
7. MIN SHIFT RGT
Determines the minimum voltage delivered to the right sideshift solenoid valve EV5
8. MIN SHIFT LFT
Determines the minimum voltage delivered to the left sideshift solenoid valve EV6
9. MAX LIFT
Determines the maximum voltage delivered to the lifting solenoid valve EV1
10. MAX LOWER
Determines the maximum voltage delivered to the lowering solenoid valve EVP. Changing the
parameter changes the lowering speed of the mast:
11. MAX DRAIN
Determines the maximum voltage delivered to the draining solenoid valve EV11
12. MAX REACH BWD
Not available
13. MAX TILT UP
Determines the maximum voltage delivered to the backward tilting solenoid valve EV4
14. MAX TILT DW
Determines the maximum voltage delivered to the forward tilting solenoid valve EV3
15. MAX SHIFT RGT
Determines the maximum voltage delivered to the right sideshift solenoid valve EV5
16. MAX SHIFT LFT
Determines the maximum voltage delivered to the left sideshift solenoid valve EV6
17. LIFT/LOW ACCELERATION DELAY
Determines a delay on opening the lifting/lowering solenoid valve
18. DRAIN ACCELERATION DELAY
Determines a delay on opening the draining solenoid valve
19. TI/SH ACCELERATION DELAY
Determines a delay on opening the tilting and sideshift solenoid valves
20. LIFT/LOW DECELERATION DELAY
Determines a delay on closing the lifting/lowering solenoid valve
21. DRAIN DECELERATION DELAY
Determines a delay on closing the draining solenoid valve
22. TI/SH DECELERATION DELAY
Determines a delay on closing the tilting and sideshift solenoid valve
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DASHBOARD
range
1. HOURS COUNTER
Determines the type of hour count:
- RUNNING: Display on the dashboard of the actual machine hours (std)
- KEY: Display on the dashboard of the machine key hours
2. DISPLAY SPEED
Used to view the truck speed:
- ON: Truck speed display enabled
- OFF: Truck speed display disabled (std)
3. SPEED RATIO
Determines the speed programming coefficient.
Setting the speed calculation coefficient: the value varies from 0 to 512 in steps of 2:
- GEAR RATIO = 142
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TESTER PARAMETER DESCRIPTION

DRIVE MODULE
TESTER: Display of the main input and output signals
1. MOTOR VOLTAGE
Voltage on the motor expressed as a percentage of the maximum voltage
2. FREQUENCY
Frequency of the voltage and current supplied to the motor by the inverter
3. ENCODER
Speed of the motor, expressed in Hz; this information is supplied to the module by the encoder
4. SLIP VALUE
Speed difference between the rotating magnetic field and the shaft of the motor: SLIP VALUE (Hz) =
FREQUENCY (Hz) – ENCODER (Hz)
5. CURRENT RMS
Root Mean Square value of the motor current
6. TEMPERATURE
Temperature of the module (inverter)
7. MOTOR TEMPERAURE
Temperature of the motor, current is reduced by 50%
8. ACCELERATOR
Voltage on the potentiometer
9. FORWARD SWITCH
Forward direction microswitch
OFF / GND = non-active input, open switch
ON / +Vb = active input, closed switch
10. BACKWARD SWITCH
Reverse direction microswitch
11. CUTBACK SWITCH
Speed reduction microswitch
OFF / +Vb = non-active input, closed switch
ON / GND = active input, open switch
12. CUTBACK SWITCH 3
Speed 3 reduction microswitch
13. BRAKE SWITCH
Brake pedal microswitch
14. SEAT SWITCH
Seat microswitch
15. EXCLUSIVE HYDRO
State of the power steering contactor (not present)
16. HAND BRAKE
Parking brake microswitch
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17. VOLTAGE BOOSTER

Percentage of additional voltage supplied to the motor under conditions of load
18. BATTERY VOLTAGE
Battery voltage measured with the key inserted
19. COS FI
Phase displacement angle, displayed in real time, between motor voltage and current
20. BATTERY CURRENT
Battery current (calculated)
21. BATTERY CHARGE
Percentage of battery charge
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PUMP MODULE
1. MOTOR VOLTAGE
Voltage on the motor expressed as a percentage of the maximum voltage
2. FREQUENCY
Frequency of the voltage and current supplied to the motor by the inverter
3. ENCODER
Speed of the motor, expressed in Hz; this information is supplied to the module by the encoder
4. SLIP VALUE
Speed difference between the rotating magnetic field and the shaft of the motor: SLIP VALUE (Hz) =
FREQUENCY (Hz) – ENCODER (Hz)
5. CURRENT RMS
Root Mean Square value of the motor current
6. TEMPERATURE
Temperature of the module (inverter)
7. MOTOR TEMPERAURE
Temperature of the motor (not used)
8. ACCELERATOR
Voltage on the potentiometer
9. LIFTING SWITCH
Lifting microswitch
10. 1ST SPEED
Tilt microswitch
11. 2ND SPEED
Sideshift microswitch
12. 3RD SPEED
4th-way microswitch
13. 4TH SPEED
5th-way microswitch
14. HYDRO SPEED REQ
State of the hydro speed request of the pump
15. CUTBACK SWITCH
Speed reduction microswitch
16. CUTBACK SWITCH 3
Speed 3 reduction microswitch
17. VOLTAGE BOOSTER
Percentage of additional voltage supplied to the motor under conditions of load
18. BATTERY VOLTAGE
Battery voltage
19. COS FI
Phase displacement angle, displayed in real time, between motor voltage and current
20. BATTERY CURRENT
Battery current (calculated)
21. BATTERY CHARGE
Percentage of battery charge
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MODULO MHYRIO
1. BATTERY VOLTAGE
Level of battery voltage measured with the key switch ON
2. VALVES SUPPLY
Level of voltage at the positive power supply (0-Vb)
3. CAN POT EVP
Level of current of the single proportional valves, received by the Can-bus (x of the current supplied
to the valve)
4. CAN POT GROUP1
Group 1 proportional valves current setpoint, received by canbus (0-100% of the current supplied to
lifting, proportional % for the lowering valve)
5. CAN POT GROUP2
lifting, proportional % for the tilting unit valve)
6. CAN POT GROUP3
lifting, proportional % for the sideshift unit valve)
7. CAN POT GROUP4
Group 4 proportional valves current setpoint, received by can-bus (0-100% of the current supplied
to lifting, proportional % for the command 4th unit valve)
8. INPUT 0
Level of the DIGITAL INPUT 0
ON / +Vb: active input, closed switch
OFF / COND : non-active input, open switch
9. INPUT 1
ON / +Vb: active input, closed switch *:
OFF / COND : non-active input, open switch ON = active when the microswitch is closed
10. INPUT 2 (+BATT)
ON / +Vb: active input, closed switch
OFF / COND : non-active input, open switch
11. ANALOG INPUT 1
Voltage of the analog input
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MAPS FOR USING THE CONSOLE
TRACTION
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NECESSARY SETTING AFTER REPLACING THE TRACTION LOGIC UNIT
1. TRACTION ACQUISITION
2. ADJUST BATTERY
3. PROGRAM Vacc
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DRIVE UNIT CONSOLE MENU STANDARD DESCRIPTION

The console can be connected to the traction logic unit in two different ways:
1. Directly, by means of an interface cable on the logic unit
2. Connecting the console in another logic unit (pump or Mhyrio) and selecting the relevant connection
number as directed in the box below
AC3P2CIM CE X.XX In case the console is connected to the lifting logic unit
80V 450A 00000
Press ROLL and PARAM together
* CONFIG. MENU *
SET MODEL
Press ENTER
CONNECTED TO It is the connection number of the lifting logic unit

5
Pressing SET selects the number of connections of the

drive logic unit
CONNECTED TO It is the connection number of the traction logic unit

2
CONNECTION NUMBER
Press OUT
2 DRIVE
5 PUMP
9 MHYRIO
ARE YOU SURE?
11 DASHBOARD
YES=ENTER NO=OUT
Press ENTER to confirm
* CONFIG. MENU *
SET MODEL
Press ROLL, OUT and SET together
AC3T2JIB CE X.XX Connected to the traction logic unit

80V 450A 00000
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BLOCK DIAGRAM
HEADING
MAIN MENU
ACCELERATION DELAY 0-9

RELEASE BRAKING 0-9
INVERS. BRAKING 0-9
PEDAL BRAKING 0-9
PARAMETER SPEED LIMIT BRAK. 0-9
SET MODEL CONNECTED TO ...
CHANGE BRAKE CUTBACK 0-9 TRAC. CONFIG.
MAX SPEED FORW Hz
MAX SPEED BACK Hz
CUTBACK SPEED %
CUTBACK SPEED 3 %
CUTBACK SPEED 2 %
FREQUENCY CREEP Hz
MAXIMUM CURRENT 0-9
ACC. SMOOTH 1-3.0Hz HOUR COUNTER RUNNING / KEY ON
INV. SMOOTH 1-3.5Hz BATTERY CHECK ON / OFF
STOP SMOOTH 5-27Hz HYDRO KEY ON ON / OFF
AUXILIARY TIME Sec STOP ON RAMP ON / OFF
SET OPTIONS PEDAL BRAKING ANALOG / DIGITAL
SET TEMPERATURE ANALOG / DIGITAL /
NONE
MOTOR VOLTAGE % HYDROSTAT BRAKE ON / OFF
FREQUENCY Hz CUTBACK MODE PRESENT / ABSENT
ENCODER Hz
SLIP VALUE Hz
CURRENT RMS A
TEMPERATURE °C
MOTOR TEMPERAURE °C
TESTER V
ACCELERATOR SET POT BRK MIN. ...V
FORWARD SWITCH OFF-GND ADJUSTMENTS SET POT BRK MAX. ...V
BACKWARD SWITCH OFF-GND
SET BATTERY TYPE 48/72/80/96
ENABLE SWITCH OFF-GND
ADJUST BATTERY ...V
SEAT SWITCH OFF-GND
THROTTLE 0 ZONE ...%
CUTBACK SWITCH ON-GND
THROTTLE X POINT ...%
CUTBACK SWITCH 3 ON-GND
THROTTLE Y POINT ...%
BRAKE SWITCH OFF-GND
ADJUSTMENT #04 ...°C
EXCLUSIVE HYDRO OFF-GND
BRAKE PEDAL POT. %
ADJUSTMENT #02 1-9
HAND BRAKE ON-OFF
ADJUSTMENT #01 1-9
VOLTAGE BOOSTER V
BATTERY VOLTAGE V
COS FI
BATTERY CURRENT A
BATTERY CHARGE %
SAVE
PARAMETER
RESTORE
PARAMETER
CODE
ALARMS
h, N°, C°
PROGRAM
VACC VACC SETTING MIN/MAX
STEER
TABLE NOT AVAIBLE
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MAIN MENU: PARAMETER CHANGE (traction: nr. connection 2)

PARAMETER CHANGE; Parameters shown in the adjusting table which can be modified in a fixed
range
AC3T2JIB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ENTER
ACCELERATION DELAY: Determines the acceleration ramp

RELEASE BRAKING: controls the deceleration ramp when the pedal is released
INVERS. BRAKING: controls the deceleration ramp when the direction switch is inverted
during travel
PEDAL BRAKING: determines the deceleration ramp when the travel pedal is released and
the brake pedal microswitch is pressed
SPEED LIMIT BRAKING: determines the deceleration ramp by changing the position of the
accelerator pedal without releasing it completely
BRAKE CUTBACK: determines the deceleration ramp when the speed reduction input is
activated
MAX SPEED FORW: determines the maximum forward speed
MAX SPEED BACK: determines the maximum reverse speed
CUTBACK SPEED: speed reduction when the cutback switch is active (turtle function)
CUTBACK SPEED 2: speed reduction with brake pedal pressed
CUTBACK SPEED 3: optional speed reduction (JBT pin10)
FREQUENCY CREEP: minimum speed with the driving microswitch activated and accelerator
pedal on minimum
MAXIMUM CURRENT: regulates the maximum current to the module
ACC. SMOOTH: this delays the acceleration ramp from 0 hz to “STOP SMOOTH”
INV. SMOOTH: this delays the deceleration ramp of the inversion from “STOP SMOOTH”
to 0 hz.
STOP. SMOOTH: reference speed for the parameters “ACC SMOOTH” and
“INV.SMOOTH”.
AUXILIARY TIME: time in which the truck is stationary on the ramp (if STOP ON RAMP is
activated)
Scroll the parameters using ROLL and save the new values pressing OUT and then ENTER.
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MAIN MENU: TESTER (traction: nr. connection 2)
AC3T2JIB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ENTER
MOTOR VOLTAGE %
FREQUENCY Hz
ENCODER Hz
SLIP VALUE Hz
CURRENT RMS A
TEMPERATURE °C
MOTOR TEMPERATURE °C
ACCELERATOR V Scroll the parameters using ROLL.
FORWARD SWITCH OFF-GND
BACKWARD SWITCH OFF-GND Press OUT to exit.
ENABLE SWITCH OFF-GND
SEAT SWITCH OFF-GND
CUTBACK SWITCH 3 ON-GND
BRAKE SWITCH OFF-GND
EXCLUSIVE HYDRO OFF-GND
BRAKE PEDAL POT. %
HAND BRAKE ON-OFF
VOLTAGE BOOSTER V
BATTERY VOLTAGE V
COS FI
BATTERY CURRENT A
BATTERY CHARGE %
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MAIN MENU: SAVE PARAMETER (traction: nr. connection 2)
AC3T2JIB CE X.XX
80V 450A 00000
Be careful:
not all the parameters Press ENTER
will be saved
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ENTER
Select the box (0-31) where you want to save the program:
SELECT Mod 00 = Program number
FREE/AC4T2C M = Program version stored
SELECT Mod 00 SELECT Mod 00

FREE AC3T2C M
Press ENTER Press ENTER
OVERWRITE DATA?
READING........
YES=ENTER NO=OUT
MAIN MENU
SAVE PARAM
Press ENTER to Press OUT to exit
confirm
READING........ MAIN MENU

SAVE PARAM
MAIN MENU
SAVE PARAM
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MAIN MENU: RESTORE PARAMETER (traction: nr. connection 2)
AC3T2JIB CE X.XX
80V 450A 00000
Press ENTER
Be careful:
MAIN MENU not all the parameters
PARAM. CHANGE will be saved
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ROLL
MAIN MENU
RESTORE PARAM
Press ENTER

SELECT Mod 00
FREE/AC3T2CIC = Program version stored
AC3T2CIC
Press ROLL to select the box (0-31) where you

want to save the program
OVERWRITE DATA?
YES=ENTER NO=OUT
Press ENTER to Press OUT to

confirm exit
STORING........ MAIN MENU

RESTORE PARAM
MAIN MENU
RESTORE PARAM
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MAIN MENU: ALARM (tester: nr. connection 2)
AC3T2JIB CE X.XX
80V 450A 00000
Press ENTER
MAIN. MENU
PARAM. CHANGE
Press ROLL until reaching MAIN

MENU ALARM
MAIN. MENU
ALARM
Press ENTER
no alarms stored max 5 alarms stored
NONE ALARM CODE

00000h #000°C 23h 2 25°C
hours counter nr. temperature alarms
Press OUT Press ENTER
CLEAR LOGBOOK
YES=ENTER NO=OUT

confirm
ARE YOU SURE?

YES=ENTER NO=OUT

confirm
LOGBOOK CLEARED
(PRESS OUT)
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MAIN MENU: PROGRAM VACC. (traction: nr. connection 2)

This setting must be made with the parking brake released.
AC3T2JIB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL until reaching the program VACC
MAIN MENU
PROGRAM VACC
Press ENTER
VACC SETTING These are the old parameters stored

0.6 1.6
Press ENTER
VACC SETTING Reset of the parameters

0.0 0.0
Select the forward direction.

Press the accelerator pedal slowly until the maximum stroke
VACC SETTING
0.6 1.6
Press OUT keeping the acc. pedal pressed
ARE YOU SURE?

YES=ENTER NO=OUT
Press ENTER to confirm and release the pedal
Repeat the same operation selecting the backward direction

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STOP ON RAMP (traction: nr. connection 2)
AC3T2JIB CE X.XX
80V 450A 00000
* CONFIG. MENU *
SET MODEL
Press ROLL
* CONFIG. MENU * Scroll the parameters using ROLL

SET OPTIONS
Press ENTER
HOUR COUNTER RUNNING/ KEY ON

BATTERY CHECK ON/OFF
HYDRO KEY ON/OFF
STOP ON RAMP ON/OFF Scroll the parameters using ROLL
PEDAL BRAKING ANALOG/DIGITAL
SET TEMPERATURE ANALOG/DIGITAL/NONE
SOFT BRAKING ON/OFF
HYDROSTAT BRAKE ON/OFF
CUT BACK MODE PRESENT/ABSENT
Select STOP ON RAMP and change the status using PARAM or SET
ONACTIVATED
OFFDEACTIVATED
and store the parameter pressing OUT and then ENTER to confirm.
After releasing the pedals the truck can stay still on a ramp for about 1 second.
This parameter activates/deactivates this function.
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SLIP CONTROL (traction: nr. connections 2)

This function is useful to understand if a traction problem is due to the encoder or not.
In case of stop or low speed of the machine with consequently high consumption of current (and
relevant alarm code shown on the dashboard) it is possible to disable the encoder for some seconds,
no longer, given that the logic unit cannot control the motor any longer.
Do not work with this configuration
AC3T2JIB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL until reaching ALARM menu
MAIN MENU
ALARM
With the SLIP CONTROL OFF
push the accelerator pedal
Press ENTER slowly otherwise the motor
stands still.
DESCRIPTION OF THE
ALARM CODE
Press PARAM and SET together
* MENU *
SPECIAL ADJUST
Press ROLL
* MENU *
HARDWARE SETTING
Press ENTER
Select SLIP CONTROL ON or OFF and store the
parameter pressing OUT and then ENTER to confirm.
COMPENSATION
After that switch the truck OFF and ON.
SLIP CONTROL ON/OFF
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BATTERY INDICATOR
The control of the battery LED indication on the dashboard and the relevant reduction of the speed are
managed by the traction logic unit.
The dashboard reads only the information coming from the logic unit and shows, using the LED battery
indicator, the status of the battery.
In order to have a precise reading of the logic unit it is necessary to set the parameter ADJUST
BATTERY everytime the traction logic unit is replaced or you received a new truck without
battery.
ADJUST BATTERY SETTING

• Connect the analyzer
• Switch the truck on
In order to have a pricise measure of the battery voltage you have to set the parameter ADJUST
BATTERY with the same value read directly on the battery by a multimeter.
Note that the logic uses as refernce voltage the key input which is not at the same potential of the
positive pole of the battery due to the fact that between them a diode is located. (The diode creates a
potential drop of aproximately 0.9 Volt).
100 146 139 101 102
D1 F1 PB S1
BATTERY LOGIC UNIT
After measuring the voltage, set the "ADJUST BATTERY" parameter following the instructions
in the “BATTERY SETTING MAP“.
Advice
Set the voltmeter on volts and join the two terminals. The display must show zero. If you read another
value you need to take it into consideration when measuring the battery voltage.
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RESETTING BATTERY INDICATOR
20 % The battery indicator is only reset under 70% of the

100 % total charge.
With highter values there is no indicator reset. It means
that it does not come back to 100%.
The battery indicator is reset according to the following
formula:
RESET = ADJ#1 + 0,45 V
The battery indicator can be adjusted with the console and it is possible to change in sequence:
• Restore value ADJUSTMENT #01
• Flat battery value ADJUSTMENT #02
V
ADJUSTMENT #1
DISCHARGE CURVE
ADJUSTMENT #2
To modify the above parameters see “ADJUST BATTERY“

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BATTERY (traction: nr. connection 2)

The control of the battery LED indication on the dashboard and the relevant reduction of speed are
performed by the traction unit.
Scroll the parameters using ROLL and
AC3T2JIB CE X.XX
save the new values by pressing OUT and
80V 450A 00000
then press ENTER
* CONFIG. MENU *
SET MODEL
Press ROLL
HOUR COUNTER RUNNING/KEY ON
* CONFIG. MENU * BATTERY CHECK ON

SET OPTIONS
HYDRO KEY ON ON/OFF
STOP ON RAMP ON/OFF
PEDAL BREAKING ANALOG/DIGITAL
Press ENTER SET TEMPERATURE ANALOG/DIG/NONE
HYDROSTATE BRAKE ON/OFF

CUTBACK MODE PRESENT/ABSENT
ARE YOU SURE?

YES=ENTER NO=OUT Press OUT
Press ENTER
* CONFIG. MANU *
SET OPTIONS
Press ROLL
SET POT BRK MIN ...V

* CONFIG. MANU * SET POT BRK MAX ...V
SET BATTERY TYPE 80
ADJUSTMENTS ADJUST BATTERY ...V
THROTTLE X ZONE ...%
Press ENTER THROTTLE Y ZONE ...%
ADJUSTMENT #02 1-9
ADJUSTMENT #01 1-9
ARE YOU SURE?
YES=ENTER NO=OUT
Press OUT
Press ENTER
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SET BATTERY TYPE: Select the nominal value of the battery

ADJUST BATTERY: Set the value written on the console with the actual battery value
measured with a tester
ADJUSTMENT #02 Minimum charge
ADJUSTMENT #01 Reset value of the charge indicator on the dashboard
ADJUSTMENT #01
RESETTING of the
CONSOLE VALUE
battery indicator
0 81.80
1 82.25
2 82.70
3 83.15
4 83.60
5 84.04
6 84.49
7 84.94
8 85.39
9 86.29
ADJUSTMENT #02
CONSOLE VALUE VOLT
0 76.85
1 77.30
2 77.75
3 78.20
4 78.65
5 79.10
6 79.55
7 80.00
8 80.45
9 81.35
The values refer to battery functions with the machine at rest (only with key ON)
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TRACTION ACQUISITION (traction: nr. connection 2)

Connect the console on the TRACTION logic unit
AC3T2JIB CE X.XX
80V 450A 00000
* CONFIG. MENU *
SET MODEL
Press ENTER
CONNECTED TO 2
Press ROLL
0 with double pedal version

LEVEL 0
1 with hand direction lever

LEVEL 1
2 with inversor on the arm

LEVEL 2
Press OUT
ARE YOU SURE?

YES=ENTER NO=OUT

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LIFTING
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NECESSARY SETTING AFTER REPLACING THE LIFTING LOGIC UNIT

1. LIFTING ACQUISITION
2. Vacc PROGRAM (with mechanical control valve only)
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LIFTING UNIT CONSOLE MENU

STANDARD DESCRIPTION
The console can be connected to the lifting logic unit in two different ways:
1. Directly, by means of an interface cable on the logic unit
2. Connecting the console with another logic unit (traction or Mhyrio) and selecting the relevant
connection number as directed in the box below
AC3T2BIB CE X.XX In this case the console is connected to the drive logic unit
80V 450A 00000
* CONFIG. MENU *
SET MODEL
Press ENTER

2
Press SET and select the connection number of the lifting

logic unit
CONNECTED TO It is the connection number of the lifting logic unit

5
Press OUT CONNECTION NUMBER

2 DRIVE
5 PUMP
ARE YOU SURE? 9 MHYRIO
YES=ENTER NO=OUT 11 DASHBOARD
* CONFIG. MENU *
SET MODEL
AC3P2CIM CE X.XX Connected to the lifting logic unit

80V 450A 00000
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BLOCK DIAGRAM
HEADING
MAIN MENU
PARAMETER ACCELER. DELAY 0-9

CHANGE DECELER. DELAY 0-9 SET MODEL CONNECTED TO ....
MAX SPEED UP Hz JOYSTICK ON-OFF
MIN SPEED UP Hz
CUTBACK SPEED %
CUTBACK SPEED 2 %
1ST SPEED FINE Hz
2ND SPEED FINE Hz
3RD SPEED FINE Hz
4TH SPEED FINE Hz
AUX FUNCTION %
1HYDSPEEDFINE Hz
MAXIMUM CURRENT 0-
AUXLIARY TIME 0-5 HOUR COUNTER RUNNING/KEY ON
SET OPTIONS BATTERY CHECK ON/OFF
SET TEMPERATURE DIGITAL/ANALOGIC/
NONE
MOTOR VOLTAGE %
FREQUENCY Hz
ENCODER Hz
SLIP VALUE Hz
CURRENT RMS A
TESTER TEMPERATURE °C SET BATTERY TYPE 48/72/80/96
MOTOR TEMPERAURE °C ADJUST BATTERY ...V
SEAT SWITCH OFF-GND ADJUSTMENTS
ACCELERATOR V THROTTLE X POINT ...%
LIFTING SWITCH % THROTTLE Y POINT ...%
1ST SPEED SWITCH % ADJUSTMENT #04 ...°C
2ND SPEED SWITCH % ADJUSTMENT #03 ...°C
3RD SPEED SWITCH % ADJUSTMENT #029 0-9
4TH SPEED SWITCH % ADJUSTMENT #01 0-9
HYDRO SPEED REQ OFF-GND
CUTBACK SWITCH2 OFF-GND
VOLTAGE BOOSTER %
BATTERY VOLTAGE V
COS FI
BATTERY CURRENT A
SAVE BATTERY CHARGE %
PARAMETER
RESTORE
PARAMETER
ALARMS CODE
h, N°, C°
PROGRAM
VACC SETTING MIN/MAX
VACC
STEER
TABLE NOT AVAILABLE
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MAIN MENU: PARAMETER CHANGE (pump: nr. connection 5)
AC3P2CIM CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ENTER
ACCELERATION DELAY: Determines the acceleration ramp.

DECELER. DELAY: Determines the deceleration ramp.
MAX SPEED UP: determines the maximum lifting speed controlled by its potentiometer.
MIN SPEED UP: determines the minimum lifting speed controlled by its potentiometer and
is enabled by its switch when it is closed.
CUTBACK SPEED: speed reduction when the cutback switch is active.
(+V =E4; input E13: if E13 is open the Cutback speed is on. E13 closed =
speed reduction off).
CUTBACK SPEED 2: speed reduction when the cutback switch is active.
(+V =E4; input E14. E14 open = speed reduction off. if E14 is closed the
Cutbackspeed is on.
1ST SPEED FINE: tilt speed, fine regulation.
2ND SPEED FINE: sideshift speed, fine regulation.
3RD SPEED FINE: 4th-way speed, fine regulation.
4TH SPEED FINE: 5th-way speed, fine regulation.
AUX FUNCTION 1: pot. value increasing the motor RPM.
HYDRO SPEED FINE: power steering speed, fine regulation.
MAXIMUM CURRENT: maximum current of the logic unit.
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MAIN MENU: TESTER (pump: nr. connection 5)
AC3P2CIM CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ENTER
MOTOR VOLTAGE %
FREQUENCY Hz
ENCODER Hz
SLIP VALUE Hz
CURRENT RMS A
TEMPERATURE °C
MOTOR TEMPERATURE °C
ACCELERATOR V
SEAT SWITCH OFF-GND Scroll the parameters using ROLL.
LIFTING SWITCH % Press OUT to exit.
1ST SPEED SWITCH %
2ND SPEED SWITCH %
3RD SPEED SWITCH %
4TH SPEED SWITCH %
HYDRO SPEED REQ. OFF-GND
VOLTAGE BOOSTER %
BATTERY VOLTAGE V
COS FI
BATTERY CURRENT A
BATTERY CHARGE %
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MAIN MENU: SAVE PARAMETER (pump: nr. connection 5)
AC3P2CIM CE X.XX
80V 450A 00000
Be careful:
not all the parameters Press ENTER
will be saved
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ENTER
FREE/AC3P2CIM= Program version stored

FREE AC3P2CIM
READING........ OVERWRITE DATA?

RUN ALL PARAMETERS YES=ENTER NO=OUT
MAIN MENU
SAVE PARAM

confirm

RUN ALL PARAMETERS SAVE PARAM
MAIN MENU
SAVE PARAM
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MAIN MENU: RESTORE PARAMETER (pump: nr. connection 5)
AC3P2BIB CE X.XX
80V 450A 00000
Press ENTER
Be careful:
MAIN MENU not all the parameters
PARAM. CHANGE
will be saved
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ROLL
MAIN MENU
RESTORE PARAM
Press ENTER
SELECT Mod 00 SELECT Mod 00 = Program number

AC3P2CIM FREE/AC3P2CIM = Program version stored
Press ROLL to select the box (0-31) where you want to

save the program
OVERWRITE DATA?
YES=ENTER NO=OUT

confirm

RUN ALL PARAMETERS RESTORE PARAM
MAIN MENU
RESTORE PARAM
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MAIN MENU: ALARM (pump: nr. connection 5)
AC3P2BIB CE X.XX
80V 450A 00000
Press ENTER
MAIN. MENU
PARAM. CHANGE

MENU ALARM
MAIN. MENU
ALARM
Press ENTER
NONE ALARM CODE

00000h #00 0°C 23h 2 25°C

Press
Press ENTER
OUT
CLEAR LOGBOOK
YES=ENTER NO=OUT

confirm
ARE YOU SURE?

YES=ENTER NO=OUT

confirm exit
LOGBOOK CLEARED
(PRESS OUT)
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MAIN MENU: PROGRAM VACC. (pump: nr. connection 5)

This setting must be made with the parking brake released
AC3P2BIB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL until reaching the program VACC
MAIN MENU
PROGRAM VACC
Press ENTER
VACC SETTING These are the old parameters stored

0.2 4.8
Press ENTER
VACC SETTING Reset of the parameters

0.0 0.0
Pull the lifting lever slowly until the maximun stroke
VACC SETTING
0.2 4.8
Press OUT keeping the lever pulled
ARE YOU SURE?

YES=ENTER NO=OUT
Press ENTER to confirm and release the lever

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CHAPTER 5000
page 156
SLIP CONTROL (pump: connection with nr. 5)

This functions is useful to understand if a lifting problem is due to the encoder or not.
In case of stop or low speed of the machine with consequently high consumption of current (and
relevant alarm code displayed on the dashboard) it is possible to disable the encoder for some
seconds, no longer, given that the logic unit cannot control the motor any longer.
Do not work with this configuration
AC3P2BIB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL until reaching ALARM menu
MAIN MENU
ALARM
Press ENTER
DESCRIPTION OF THE
ALARM CODE
Press PARAM and SET together
* MENU *
SPECIAL ADJUST
Press ROLL
* MENU *
HARDWARE SETTING
Press ENTER
Select SLIP CONTROL ON or OFF and store the

COMPENSATION parameter pressing OUT and then ENTER to confirm.
SLIP CONTROL ON/OFF After that switch the truck OFF and ON.
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BATTERY (pump: connection with nr. 5)

The control of the battery LED indication on the dashboard and the relevant reduction of speed are
performed by the main
traction logic unit.
Scroll the parameters using ROLL and
AC3P2CIM CE X.XX
save the new values pressing OUT and
80V 450A 00000
then ENTER
* CONFIG. MENU *
SET MODEL
Press ROLL HOUR COUNTER RUNNING KEY ON
BATTERY CHECK OFF
* CONFIG. MENU * HYDRO KEY ON ON/OFF

SET OPTIONS STOP ON RAMP ON/OFF
AUX INPUT #1 EXCLUSIVE HYDRO
OPTION#1
CUTBACK SPEED
Press ENTER PEDAL BREAKING ANALOG/DIGITAL
SET TEMPERATURE ANALOG/DIG./NONE
STEER TABLE OPTION#1
OPTION#2
ARE YOU SURE?

YES=ENTER NO=OUT Press OUT
Press ENTER
* CONFIG. MENU *
SET OPTIONS
Press ROLL
* CONFIG. MENU *
SET BATTERY TYPE 80
ADJUSTMENTS ADJUST BATTERY ...V
THROTTLE X ZONE ...%
THROTTLE Y ZONE ...%
Press ENTER
ADJUSTMENT #02 1-9
ADJUSTMENT #01 1-9
ARE YOU SURE?
YES=ENTER NO=OUT
Press OUT
Press ENTER
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CHAPTER 5000
page 158
PUMP DATA ACQUISITION (pump: connection with nr. 5)

Connect the console on the LIFTING logic unit
AC3P2CIM CE X.XX
80V 450A 00000
* CONFIG. MENU *
SET MODEL
Press ENTER
CONNECTED TO 5
Press ROLL
Solenoid valve control valve

JOYSTICK ON
JOYSTICK OFF
Mechanical control valve
Press OUT
ARE YOU SURE?

YES=ENTER NO=OUT

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MHYRIO UNIT
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page 160
MHYRIO CONSOLE MENU STANDARD DESCRIPTION

The console can be connected to the MHYRIO logic unit in two different ways:
1. Directly by means of an interface cable on the Mhyrio unit
2. Connecting the console with another logic unit (pump or traction) and selecting the relevant
connection number as directed in the box below
AC3P2CIM CE X.XX In this case the console is connected to the lifting logic
80V 450A 00000 unit
* CONFIG. MENU *
SET MODEL
Press ENTER
CONNECTED TO It is the connection number of the logic unit

5
Press SET and select the connection number of the

Mhyrio logic unit
CONNECTED TO It is the connection number of the Mhyrio logic unit

9
CONNECTION NUMBER
Press OUT
2 DRIVE
5 PUMP
* CONFIG. MENU *
SET MODEL
MHY CB CE X.XX Connected to the MHYRIO logic unit

80V 450A 00000
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BLOCK DIAGRAM
HEADING
MAIN MENU
MIN EVP EVP OPEN DELAY

MAX EVP EVP CLOSE DELAY
MIN EVP1 EVP1 OPEN DELAY
PARAMETER MAX EVP1 EVP1 CLOSE DELAY
CHANGE MIN EVP2 EVP2 OPEN DELAY SET MODEL CONNECTED TO 9
MAX EVP2 EVP2 CLOSE DELAY
MIN EVP6 EVP6 OPEN DELAY SET BATTERY TYPE 12/24/36/48/72/80V
MAX EVP6 EVP6 CLOSE DELAY V VALVES COIL 12/24/36/48/72/80V
MIN EVP7 EVP7 OPEN DELAY VALVES SUPPLAY 12/24/36/48/72/80V
MAX EVP7 EVP7 CLOSE DELAY EVP TYPE ANALOGIC/DIGITAL
MIN EVP8 EVP8 OPEN DELAY EVP1 TYPE ANALOGIC/DIGITAL
MAX EVP8 EVP8 CLOSE DELAY SET OPTIONS EVP2 TYPE ANALOGIC/DIGITAL
EVP3 TYPE ANALOGIC/DIGITAL
BATTERY VOLTAGE V EVP8 TYPE ANALOGIC/DIGITAL
VALVES SUPPLY V
CAN POT EVP %
CAN POT GROUP 1 %
CAN POT GROUP 2 %
TESTER CAN POT GROUP 3 % ADJUST BATTERY ...V
ADJUSTMENTS
CAN POT GROUP 4 %
INPUT 0 ON/OFF
INPUT 1 ON/OFF
INPUT 2 ON/OFF
INPUT AN ON/OFF
SAVE
PARAMETER
RESTORE
PARAMETER
ALARMS CODE
h, N°, C°
PROGRAM
VACC VACC SETTING MIN/MAX
STEER
TABLE NOT AVAILABLE
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CHAPTER 5000
page 162
MAIN MENU: PARAMETER CHANGE (mhyrio: nr. connection 9)
MHY CB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ENTER
MIN EVP Minimum voltage on the draining solenoid valve

MAX EVP Maximum voltage on the draining solenoid valve
MIN EVP1 Min. voltage on the lowering solenoid valve
MAX EVP1 Max. voltage on the lowering solenoid valve
MIN EV2 Min. voltage on the lifting solenoid valve
MAX EV2 Max. voltage on the lifting solenoid valve
MIN EV3 Min. voltage on the forward tilt solenoid valve
MAX EV3 Max. voltage on the forward tilt solenoid valve
MIN EV4 Min. voltage on the backward tilt solenoid valve
MAX EV4 Max. voltage on the backward tilt solenoid valve
MIN EV5 Min. voltage on the left sideshift solenoid valve
MAX EV5 Max. voltage on the left sideshift solenoid valve
MIN EV6 Min. voltage on the right sideshift solenoid valve
MAX EV6 Max. voltage on the right sideshift solenoid valve
MIN EV7 Min. voltage on the 4th-way (forward) solenoid valve
MAX EV7 Max. voltage on the 4th-way (backward) solenoid valve
MIN EV8 Min. voltage on the 5th-way (forward) solenoid valve
MAX EV8 Max. voltage on the 5th-way (backward) solenoid valve
EVP OPEN DELAY Delay of the EVP in opening
EVP CLOSE DELAY Delay of the EVP in closing
EVP1 OPEN DELAY Delay of the EVP1 in opening
EVP1 CLOSE DELAY Delay of the EVP1 in closing
EV2 OPEN DELAY Delay of the EVP2 in opening
EV2 CLOSE DELAY Delay of the EVP2 in closing
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ELECTRIC
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MAIN MENU: TESTER (mhyrio: nr. connection 9)
MHY CB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ENTER
BATTERY VOLTAGE V
VALVES SUPPLY V
CAN POT EVP %
CAN POT GROUP 1 % Scroll the parameters using ROLL.
CAN POT GROUP 2 %
CAN POT GROUP 3 % Press OUT to exit.
CAN POT GROUP 4 %
INPUT 0 ON/OFF
INPUT 1 ON/OFF
INPUT 2 ON/OFF
ANALOG INPUT 1 %
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MAIN MENU: SAVE PARAMETER (mhyrio: nr. connection 9)
MHY CB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ENTER
FREE/MHY CB = Program version stored

FREE MHY CB
READING........ OVERWRITE DATA?

RUN ALL PARAMETERS YES=ENTER NO=OUT
MAIN MENU
SAVE PARAM

confirm

RUN ALL PARAMETERS SAVE PARAM
MAIN MENU
SAVE PARAM
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MAIN MENU: RESTORE PARAMETER (mhyrio: nr. connection 9)
MHY CB CE X.XX
80V 450A 00000
Press ENTER
MAIN MENU
PARAM. CHANGE
Press ROLL
MAIN MENU
TESTER
Press ROLL
MAIN MENU
SAVE PARAM
Press ROLL
MAIN MENU
RESTORE PARAM
Press ENTER
SELECT Mod 00
FREE/MHY CB = Program version stored
MHY CB
Press ROLL to select the box (0-31) where you

want to save the program
OVERWRITE DATA?
YES=ENTER NO=OUT

confirm
RUN ALL PARAMETERS RESTORE PARAM
MAIN MENU
RESTORE PARAM
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MAIN MENU: ALARM (mhyrio: nr. connection 9)
MHY CB CE X.XX
80V 450A 00000
Press ENTER
MAIN. MENU
PARAM. CHANGE

MENU ALARM
MAIN. MENU
ALARM
Press ENTER
NONE ALARM CODE

00000h #00 0°C 23h 2 25°C
Press OUT Press ENTER
CLEAR LOGBOOK
YES=ENTER NO=OUT

confirm escape
ARE YOU SURE?

YES=ENTER NO=OUT

confirm escape
LOGBOOK CLEARED
(PRESS OUT)
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MAIN MENU: PROGRAM VACC. (mhyrio: nr. connection 9)

Not available
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DASHBOARD
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MAIN MENU: PARAMETER CHANGE (dashboard: nr. connection 11)

The console can be connected to the dashboard in the following way:
• connect the console to the drive logic or to the lifting logic and select connection nr. 11 as indicated in
the box below
If the console is connected to the drive logic unit
AC3T2JIB CE X.XX
80V 450A 00000
I
* CONFIG. MENU *
SET MODEL
Press ENTER

2
Press PARAM and select the connection number of the

dashboard unit
Dashboard
CONNECTED TO
11
CONNECTION NUMBER
Press OUT
2 DRIVE
5 LIFTING
* CONFIG. MENU *
SET MODEL
Connected to the dashboard unit

DASH CE X.XX
24 0A 00000
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Press ENTER
MAIN MENU
PARAM. CHANGE
Press ENTER
HOURS COUNTER RUNNING/KEY:key on / lifting unit working hours counter switch

DISPLAY ON/OFF: Displayed speed setting
SPEED RATIO 0-512: speed calculation factor
Scroll the parameters using ROLL and save the new values pressing OUT and after ENTER
Reset by ignition key whenever a modification is carried out
• If the parameter HOURS COUNTER is switched to KEY ON option the hourglass will start to blink
whenever the ignition key is turned on (key workhours count)
• If the parameter DISPLAY SPEED is switched ON on the display used to point off the alarm codes,
there will appear two zeros (truck speed displayed)
0. 0.
In case of fault the speed indication disappears and the alarm code appears.
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WIRING DIAGRAMS
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CHAPTER 5000
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PAGINA INTENZIONALMENTE BIANCA
INTENTIONALLY LEFT BLANK
PAGE INTENTIONNELLEMENT BLANCHE
WEIß SEITE
PÀGINA INTENCIONALMENTE BLANCA

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2,5-3,0-3,0L-3,5 t

BATTERY COMPARTMENT AND REQUIRED WEIGHT ................................... 7

ELECTRIC CIRCUIT CONNECTION.................................................................... 39

LIFTING LOGIC UNIT........................................................................................... 93

BATTERY SETTING ............................................................................................. 141

PAGINA INTENZIONALMENTE BIANCA

INTENTIONALLY LEFT BLANK

PAGE INTENTIONNELLEMENT BLANCHE

PÀGINA INTENCIONALMENTE BLANCA

BATTERY COMPARTMENT AND REQUIRED WEIGHT

Batteries to DIN standards (DIN 43531 / 35 / 36 A, B, C, No)

* Value of battery on standby (only with key ON and no power consumption)

Low Remaining Battery Charge Warning

TROUBLESHOOTING ON THE BATTERY

Plate corrosion Sulfation Plate warpage and active substance freeing

Deposition of free Fouled terminal or

Short circuit Electrolyte leakage end reduction Loosened or corroded connection

2. Battery electrolyte specific gravity inspection.

The specific gravity of the electrolyte at 20 °C (68 °F)

How to use the hydrometer

3. Insulation resistance inspection

* Battery control table

Time and date Specific gravity Temperature Capacity

I/O CARD LOGIC UNIT

2.5 - 3.0 - 3.0L - 3.5 t

LIFTING LOGIC UNIT

MHYRIO LOGIC UNIT (optional)

ARMREST BOARD (optional)

BATTERY PLUG UNIT

1. Insulation resistance measurement

Measurement terminals Controller side of battery plug-body

(2) Measurement method and standard list

JDT (1-BS) J15 (1-BS) Positive output 12V

Colour Value of the

COLORI COLOURS FARBEN COULEURS COLORES

DRIVE LOGIC UNIT

CN (wire pin) ⇔ CN (wire pin)

LIFTING LOGIC UNIT

I/O CONTROL BOARD

MHYRIO LOGIC UNIT

ELECTRIC CIRCUIT CONNECTION

DISCONNECT IN THE HYDRAULIC

CUTBACK SPEED 3 (enabling for further speed reduction)

CHECK TRACTION MOTOR PHASES BALANCING

Measuring method Procedure using a Measuring method Procedure using a

CHECK LIFTING MOTOR PHASES BALANCING

DRIVE LOGIC UNIT LIFTING LOGIC UNIT

ARMREST BOARD ADJUSTMENT

FINGERTIP = switch 2 ON JOYSTICK = All the switches are OFF

VOLTAGES ON ARMREST POTENTIOMETERS

MHYRIO LOGIC UNIT

In the front it has three connectors:

Voltage supplied to the ON-OFF valve coil: battery voltage

I/O CONTROL BOARD

1. Connector J1 for temperature sensors of traction and lifting motors

COLORI COLOURS FARBEN COULEURS COLORES

LIGHT CARD UNIT

The light card is located at the back of the truck in a

1. Connector for lights (J2D)

See wiring diagram.

MATERIALS HANDLING AC DRIVER, CONTACTOR PANEL

Contactor unit assembly drawing

Drive logic Contactor Description Standard