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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 78
02 EEPROM KO DRIVE LOGIC UNIT: Fault in the memory area 78
03 LOGIC FAILURE #3 DRIVE LOGIC UNIT: Logic defect 78
DRIVE LOGIC UNIT: Fault in the hardware section which
04 LOGIC FAILURE #2 79
manages the voltage of the 3 phases
DRIVE LOGIC UNIT: Protection from
05 LOGIC FAILURE #1 80
undervoltage/overvoltage
06 VMN LOW DRIVE LOGIC UNIT: Failure in the VMN test 81
07 VMN HIGH DRIVE LOGIC UNIT: Failure in the VMN test 82
DRIVE LOGIC UNIT: Failure on the contactor
08 CONTACTOR OPEN 83
driver
DRIVE LOGIC UNIT: Failure on the current
09 STBY I HIGH 83
sensor
CAPACITOR
10 DRIVE LOGIC UNIT: Capacitors not charged 83
CHARGE
HIGH DRIVE LOGIC UNIT: Logic unit’s temperature higher than
11 84
TEMPERATURE 75°C
MOTOR DRIVE LOGIC UNIT: Drive motor
12 84
TEMPERATURE sensor open
13 ENCODER ERROR DRIVE LOGIC UNIT: Fault of the encoder’s circuit 85
THERMIC DRIVE LOGIC UNIT: Logic unit’s internal sensor out of
14 86
SENSOR KO range
15 SAFETY DRIVE LOGIC UNIT: Protection activated 86
DRIVE LOGIC UNIT: It is detecting comunication of
16 CAN BUS KO 86
another card
WAITING FOR DRIVE LOGIC UNIT: It is detecting a delay in
17 87
NODE data transmission
DRIVE LOGIC UNIT: Failure on the contactor
18 AUX OUTPUT KO 87
driver
DRIVE LOGIC UNIT: Failure on the contactor
19 DRIVER SHORTED 87
driver
CONTACTOR DRIVE LOGIC UNIT: Failure on the contactor
20 88
DRIVER driver
DRIVE LOGIC UNIT: Failure on the contactor
21 COIL SHORTED 88
driver
DRIVE LOGIC UNIT: Failure on the acceleration potenti-
22 VACC NOT OK 88
ometer signal
23 INCORRECT START DRIVE LOGIC UNIT: Change the command 88
24 PEDAL WIRE KO DRIVE LOGIC UNIT: Change the command 88
WRONG SET
25 DRIVE LOGIC UNIT: Battery voltage out of range 89
BATTERY
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When an Error Code is Displayed


Displayed
Alarm specification Error mode Page
code
26 REMOTE INPUT DRIVE LOGIC UNIT: General incorrect starting procedure 89
27 UNUSED UNUSED 89
DRIVE LOGIC UNIT: Steering potentiometer value out of
28 STEER SENSOR KO 89
range
29 FORW + BACK DRIVE LOGIC UNIT: General incorrect starting procedure 90
30 UNUSED UNUSED 90
LIFTING LOGIC UNIT: Self-diagnostic
31 WATCHDOG 103
test
32 EEPROM KO LIFTING LOGIC UNIT: Fault in the memory area 103
33 LOGIC FAILURE #3 LIFTING LOGIC UNIT: Logic defect 103
LIFTING LOGIC UNIT: Fault in the
34 LOGIC FAILURE #2 104
hardware section
LIFTING LOGIC UNIT: Protection from
35 LOGIC FAILURE #1 105
undervoltage/overvoltage
36 VMN LOW LIFTING LOGIC UNIT: VMN test failure 106
37 VMN HIGH LIFTING LOGIC UNIT: VMN test failure 107
LIFTING LOGIC UNIT: Failure on the
38 CONTACTOR OPEN 108
main contactor
LIFTING LOGIC UNIT: Failure on the current
39 STBY I HIGH 108
sensor
CAPACITOR
40 LIFTING LOGIC UNIT: Capacitors not charged 108
CHARGE
HIGH LIFTING LOGIC UNIT: Logic unit’s temperature higher
41 109
TEMPERATURE than 75°C
MOTOR
42 LIFTING LOGIC UNIT: Sensor of lifting motor opened 109
TEMPERATURE
LIFTING LOGIC UNIT: Failure on the
43 ENCODER ERROR 110
encoder circuit
THERMIC LIFTING LOGIC UNIT: Logic unit’s internal sensor out of
44 111
SENSOR KO range
45 SAFETY LIFTING LOGIC UNIT: Protection activated 111
LIFTING LOGIC UNIT: It is detecting
46 CAN BUS KO 112
comunication of another card
WAITING FOR LIFTING LOGIC UNIT: it is detecting a delay in data
47 113
NODE transfer
LIFTING LOGIC UNIT: Failure on the contactor
48 AUX OUTPUT KO 114
driver
LIFTING LOGIC UNIT: Failure on the contactor
49 DRIVER SHORTED 114
driver
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When an Error Code is Displayed


Displayed
Alarm specification Error mode Page
code
CONTACTOR LIFTING LOGIC UNIT: Failure on the contactor
50 114
DRIVER driver
LIFTING LOGIC UNIT: Failure on the contactor
51 COIL SHORTED 114
driver
LIFTING LOGIC UNIT: Failure on the lifting potentiometer
52 VACC NOT OK 114
signal
53 INCORRECT START LIFTING LOGIC UNIT: Incorrect starting procedure 114
54 UNUSED UNUSED 115
55 WRONG BATTERY LIFTING LOGIC UNIT: Battery voltage out of range 115
56 REMOTE INPUT LIFTING LOGIC UNIT: Incorrect starting procedure 115
LIFTING LOGIC UNIT: It is detecting a delay in data
57 WAITING MHYRIO 115
transfer of Mhyrio logic unit
58 I=0 EVER LIFTING LOGIC UNIT: Failure on the current sensor 115
59 UNUSED UNUSED 115
61 WATCH-DOG DRIVE LOGIC UNIT: Self-diagnostic test SLAVE 92
62 EEPROM KO DRIVE LOGIC UNIT: Fault in the memory area SLAVE 92
63 LOGIC FAILURE #3 DRIVE LOGIC UNIT: Logic defect SLAVE 92
DRIVE LOGIC UNIT: Fault in the hardware section which
64 LOGIC FAILURE #2 93
manages the voltage of the 3 phases SLAVE
DRIVE LOGIC UNIT: Protection from
65 LOGIC FAILURE #1 94
undervoltage/overvoltage SLAVE
66 VMN LOW DRIVE LOGIC UNIT: Failure in the VMN test SLAVE 95
67 VMN HIGH DRIVE LOGIC UNIT: Failure in the VMN test SLAVE 96
DRIVE LOGIC UNIT: Failure on the contactor
68 CONTACTOR OPEN 97
driver SLAVE
DRIVE LOGIC UNIT: Failure on the current
69 STBY I HIGH 97
sensor SLAVE
CAPACITOR
70 DRIVE LOGIC UNIT: Capacitors not charged SLAVE 97
CHARGE
HIGH DRIVE LOGIC UNIT: Logic unit’s temperature higher than
71 98
TEMPERATURE 75°C SLAVE
MOTOR DRIVE LOGIC UNIT: Drive motor
72 98
TEMPERATURE sensor open SLAVE
73 ENCODER ERROR DRIVE LOGIC UNIT: Fault of the encoder’s circuit SLAVE 99
DRIVE LOGIC UNIT: Logic unit’s internal sensor out of
74 THERMIC SENS KO 100
range SLAVE
75 UNUSED UNUSED 100
DRIVE LOGIC UNIT: It is detecting comunication of
76 CAN BUS KO 100
another card SLAVE
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When an Error Code is Displayed


Displayed
Alarm specification Error mode Page
code
WAITING FOR DRIVE LOGIC UNIT: It is detecting a delay in
77 101
NODE data transmission SLAVE
78 UNUSED UNUSED 101
79 UNUSED UNUSED 101
CONTACTOR DRIVE LOGIC UNIT: Failure on the contactor
80 101
DRIVER driver SLAVE
81 INCORRECT START I/O CARD: Incorrect starting procedure 122
82 LOGIC FAILURE I/O CARD: Logic defect 122
I/O CARD: Failure on the acceleration potentiometer
83 PEDAL WIRE KO 122
signal at rest
84 BAD MICROSWITCH I/O CARD: General alarm of broken microswitch 122
85 UNUSED UNUSED 122
86 UNUSED UNUSED 122
87 UNUSED UNUSED 122
PUMP INCORRECT
88 I/O CARD: Incorrect starting procedure 122
START
DRIVE LOGIC UNIT: Communication fault form the
1A SLAVE KO 90
SLAVE unit
1C BATTERY LOW DRIVE LOGIC UNIT: Battery discharge 90
CONTACTOR DRIVE LOGIC UNIT: Failure on the contactor
1E 90
CLOSED driver
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 91
4A UNUSED UNUSED 115
4C BATTERY LOW LIFTING LOGIC UNIT: Battery discharge 116
4E UNUSED UNUSED 116
CHOPPER NOT
5A LIFTING LOGIC UNIT: Incorrect configuration 116
CONFIG.
LIFTING LOGIC UNIT: The logic unit is during the data
5C GAIN ACQUISITION 116
acquisition phase
5E UNUSED UNUSED 116
7A MASTER KO DRIVE LOGIC UNIT: Master logic unit communication folt 102
7C UNUSED UNUSED 102
8A UNUSED UNUSED 102
DRIVE LOGIC UNIT: The logic unit is during the data
8C GAIN ACQUISITION 102
acquisition phase
8E UNUSED UNUSED 102
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When an Error Code is Displayed


Displayed
Alarm specification Error mode Page
code
MHYRIO LOGIC UNIT: Fault in the area of memory in
A1 EEPROM KO 117
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 117
open
MHYRIO LOGIC UNIT: Failure of the can bus
A3 CAN BUS KO 117
comunication
A4 FF VALVES MHYRIO LOGIC UNIT: Problem in the hardware circuit 118
MHYRIO LOGIC UNIT: The transistor that controls the
A5 DRIVER OPENED lifting valves supply positive is open when it should be 118
closed
MHYRIO LOGIC UNIT: One or more MOS controlling the
A6 DRIVER EPV GR1 118
valves are in short-circuit
MHYRIO LOGIC UNIT: One or more MOS controlling the
A7 DRIVER EPV GR2 118
valves are in short-circuit
MHYRIO LOGIC UNIT: One or more MOS controlling the
A8 DRIVER EPV GR3 118
valves are in short-circuit
b1 IO COMMUNIC KO DASHBOARD: The dashboard doesn't detect the I/O card 119
MHY COMMUNIC DASHBOARD: The dashboard doesn't detect the Mhyrio
b2 119
KO logic
b3 b1 + b2 DASHBOARD: Alarm b1 + Alarm b2 119
LUCI COMMUNIC DASHBOARD: The dashboard doesn't detect the lights
b4 119
KO card
b5 b4 + b1 DASHBOARD: Alarm b1 + Alarm b4 119
b6 b4 + b2 DASHBOARD: Alarm b2 + Alarm b4 119
b7 b4 + b2 + b1 DASHBOARD: Alarm b1 + Alarm b2 + Alarm b4 119
C1 STOP OPEN LIGHT CARD: Failure on the stop lights 123
C2 UNUSED UNUSED 123
C3 UNUSED UNUSED 123
C4 RETRO OPEN LIGHT CARD: Failure on the reverse lights 123
C5 C1 + C4 LIGHT CARD: Alarm C1 + Alarm C4 123
C6 UNUSED UNUSED 123
C7 UNUSED UNUSED 123
C8 UNUSED UNUSED 123
TRAC COMMUNIC DASHBOARD: The dashboard doesn't detect the traction
d1 120
KO logic unit Master
PUMP COMMUNIC DASHBOARD: The dashboard doesn't detect the lifting
d2 120
KO logic unit
d3 d1 + d2 DASHBOARD: Alarm d1 + Alarm d2 120
TRAC COMMUNIC DASHBOARD: The dashboard doesn't detect the traction
d4 120
KO logic unit Slave
d5 d1 + d4 DASHBOARD: Alarm d1 + Alarm d4 120
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WHEN AN ERROR CODE IS DISPLAYED


TRACTION MASTER LOGIC UNIT
01 WATCHDOG

Condition for error detection


The test is performed both in running and in standby situation. It is a self-diagnosing test of the logic.
This alarm could also be caused by the canbus malfunctioning.
Checks to perform:
- verify the presence of the JBP connector on the logic of lifting
- verify the isolation of the truck
- verify the connections of can-bus
- replace the logic unir

02 EEPROM KO

Condition for error detection


Fault in the memory area where the adjustment parameters are stored; this alarm inhibists the truck
operation; the logic unit will restore the default parameters (stored in the factory).
If the defect persists after a general reset, switching OFF and ON again the key, replace the logic unit.
If the alarm disappears, the parameters previusly stored will be deleted and the the default parameters
(stored in the factory) will automatically be restored.

03 LOGIC FAILURE #3

Condition for error detection


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

Condition for error detection


Fault in the hardware section of the logic board which manages the phase voltage feedback.
The alarm appears even if the contactor T2 (traction and lifting supply line) opens with the coil still
supplied
Checks to perform:
Output voltage of the logic for coil power supply:
- connector present on the contactor group: possible false contacts
(see Contactor Group Assembly Drawing paragraph)
- T2 contactor coil resistance = 140 ohm
- the power cables connected to the motor status
- replace the logic unit
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05 LOGIC FAILURE #1

Condition for error detection


This alarm signals that the under or over voltage protection cut-out has been triggered.
- under voltage: the logic unit keeps the key input voltage under control (connector JCT, pin 3, wire M).
If the voltage has a peak down the alarm is signalled.
- over voltage: the logic unit keeps the key input voltage under control (connector JCT, pin 3, wire M).
If the voltage has a peak up the alarm is signalled.
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 unit, 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 logic unit.
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, one at a time, so as to find the component that has lost its insulation.
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06 VMN LOW

Condition for error detection


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
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,one
at a time so as to find the component that has lost its insulation.
- Switch off the machine and reverse the right traction and lifting motor connections on the logic units.
- Check the state of the coil of contactor T2 (140 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 logic unit.
- If the alarm is detected by the lifting logic unit, check and if necessary replace the right 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

Condition for error detection


Failure in the VMN test.
This test starts when the ignition key is turned ON and there is no current consumption (still machine).
The alarm appears if the power circuit is open; check the connections of the 3 power cables from the
logic unit to the right traction motor and the cables condition.
Check the state of the coil of contactor T2 (140 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 multimeter:
Red Tip Black Tip
Um - (+) = 4,5 Kohm If the measurements are very different to the refer-
Vm - (+) = 4,5 Kohm ence ones described alongside, disconnect all the
Wm - (+) = 4,5 Kohm power cables from the logic unit and check the values
Um - (-) = 4,5 Kohm directly on the logic unit.
Vm - (-) = 4,5 Kohm
Wm - (-) = 4,5 Kohm
Um - Vm = 0 ohm
Um - Wm = 0 ohm
Vm - Wm = 0 ohm
Values on the logic unit with the motor disconnected:
Um - (+) = 5,0 Kohm
Vm - (+) = 125 Kohm
Wm - (+) = 100 Kohm
Um - (-) = 5,0 Kohm
Vm - (-) = 125 Kohm
Wm - (-) = 100 Kohm
Um - Vm = 135 Kohm If an open circuit is detected, replace the logic unit.
Um - Wm = 135 Kohm
Vm - Wm = 280 Kohm
TEST 2
Connect the traction master logic unit to the lifting motor and check if the display shows the alarm code
"07".
YES: repace the logic unit
NO: check the right traction motor insulation
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08 CONTACTOR OPEN

Condition for error detection


Fault with the contactor T2. The contactor is powered, but the contacts do not close.
- Check the main contactor coil (140 ) and relevant cables.

09 STBY I HIGH

Condition for error detection


Failure on the current sensor.
- Replace the logic unit.

10 CAPACITOR CHARGE

Condition for error detectione


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 between logic unity and battery
- Check the voltage upstream from the key switch: there always must be the battery voltage.
- Replace the key switch.
- Replace the logic unit.

Vb= battery PB1 KEY


D1= diode + Vb F1
F1= key fuse
D1
PB1= emergency button
KEY= key
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11 HIGH TEMPERATURE

Condition for error detection


The temperature of the logic unit has exceeded 75°C. The maximum current in the module is reduced
proportionally to the temperature increase.
At 100°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 100°C
wait for the control unit to cool gradually.
When the temperature falls under 75°C the alarm disappears automatically.

12 MOTOR TEMPERATURE

Condition for error detection


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).
Checks to perform:
- If the sensor is open with the motor cold: replace the sensor (see chapter 1000);
- if the sensor is closed, but there is 5V between pins J1-3 and J1-4: replace 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, replace the logic unit.
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13 ENCODER ERROR

Condition for error detection


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
stopped 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 unit 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 picture shows only one signal (A).
The used encoders generate two equal signals,
with a a phase displacement of 90° (A-B).
1. Connect the multimeter positive tip (red) to
the encoder positive terminal
2. Connect the multimeter COM tip (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 logic unit
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14 THERMIC SENSOR KO

Condition for error detection


The logic unit thermic sensor is out of range.
- Replace the logic unit

15 SAFETY

Condition for error detection


Stop in the logic unit
- Replace the logic unit.

16 CAN BUS KO

Condition for error detection


Communication failure in the wires connecting the logic units (traction, lifting, Mhyrio) and all the other
cards. In this condition the stop lights and reversing lights are switched on and the lifting motor turns
on automatically to ensure the power steering function.
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. logic unit
- CAN BUS KO 09: Mhyrio logic unit.
- CAN BUS KO 00: armrest card.
If the problem is genereated by the traction logic unit, 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.
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17 WAITING FOR NODE

Condition for error detection


The logic unit has identified a delay in the data transmission from the I/O card or lifting logic unit.
WAITING FOR 0A: delay in transmission of the I/O card.
Checks to perform:
- If alarm 17(waiting for 0A) appears in combination with alarm 47 connect the console in the lifting
logic unit and check if the WAITING FOR 0A alarm appears.
If this is so, replace the I/O card.
- If alarm 17(waiting for 0A) appears on its own, check:
general machine insulation;
replace the logic unit.
WAITING FOR 05: delay in transmission from the lifting logic unit.
Checks to perform:
- 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 unit 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 JAT traction logic unit
pin 1-4-6-7, connector JCP lifting logic unit pin 1-3.
If there are no false contacts replace the logic unit.
WAITING FOR 04: delay in transmission from the slave traction logic unit
Checks to perform:
- If alarm 17(waiting for 04) appears in combination with other alarms of the master traction logic unit:
If this is so, the alarm signals that the master traction logic unit has shut down.
After eliminating the causes of the lifting logic shutdown, alarm 17 will automatically disappear
If the bridge on the JBP connector of the lifting logic unit is present.
If no, restore the connection.

18 AUX OUTPUT KO

Condition for error detection


Failure on the contactor driver.
- Replace the logic unit

19 DRIVER SHORTED

Condition for error detection


Failure on the driver of contactor T2.
- Check for any short circuiting between wires BG and BC supplying the coil. Check the state of the coil
(140 ohm).
- If the failure is not due to external causes, replace the logic unit
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20 CONTACTOR DRIVER

Condition for error detection


Failure on the traction contactor driver.
- Replace the logic unit

21 COIL SHORTED

Condition for error detection


Failure on the drive contactor T2.
Check the contactor coil state (140 ohm) and the relevant wiring loom.
- If the failure is not due to external causes, replace the logic unit.

22 VACC NOT OK

Condition for error detection


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)

23 INCORRECT START

Condition for error detection


Unused
- if it appears replace the logic unit

24 PEDAL WIRE KO

Condition for error detection


Failure on the accelerator potentiometer. Check the potentiometer wiring (connector J32).
The positive wire (G3) or the wiper (v1) can be disconnected.
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25 WRONG SET BATTERY

Condition for error detection


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 if the "SET BATTERY" parameter is setted to 48V
- check the status of the battery and if neccessary replace it with a correct one

26 REMOTE INPUT

Condition for error detection


General incorrect starting procedure.

27 UNUSED

28 STEER SENSOR KO

Condition for error detection


This alarm signals that the steering potentiometer is out of range.
There is a fault in the following conditions:
1 The “SET STEER 0 pos” (straight wheels programmation) parameter is wrong (lower than “SET
STEER MIN” or higher than “SET STEER MAX”).
Check:
- repeat the direction potentiometer acquisition (see section "STEERING POTENTIOMETER
ADJUSTMENT")
2 Supply absence (+12 V). In this condition the wheel directions indicator, on the dashboard, stays
fixed to the center
Check:
- the connection of the potentiometer positive wire:
connector J14 pin 3 colour G (yellow)
connector JCT drive logic unit 16 colour G (yellow)
3 Wiper signal absence (min. aprox. 4 V; max. aprox. 9 V measured with multimeter). In this
condition the wheel direction indicator, on the dashboard, stay fixed to the center
Check:
- the connection of the potentiometer wiper wire:
connector J14 pin 2 colour V (green)
connector JCT drive logic unit pin 17 colour V (green)
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29 FORW + BACK

Condition for error detection


Incorrect starting sequence.
The alarm appears in case of contemporaneous requests of foreward and backward march.
Check:
- Microswitch for forward/backward directions and relevant wires

30 UNUSED

1A SLAVE KO

Condition for error detection


Communication fault from SLAVE logic unit. The alarm can be originated by:
1. Interferences on the CAN-BUS: in this condition the alarm appears in combination with other
alarms
Checks to perform:
- truck insulation
- presence of the antistatic discharger if the truck is equipped with no marking tyres
- verify drive logic unit connectors JCT and JAT; all the pins must be in line and not lifted
- verify light board connector J130; all pin must be correctly connected
2. Defective logic unit
Checks to perform:
- communication between MASTER and SLAVE logic units by the console
YES: see point 1
NO: replace the logic unit

1C BATTERY LOW

Condition for error detection


Battery discharged

1E CONTACTOR CLOSED

Condition for error detection


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

Condition for error detection


The logic unit 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 + drive direction lever;
2) single pedal system + drive direction push buttons on the armrest
3) single pedal system + drive direction lever + drive direction push buttons on the armrest.

2C GAIN ACQUISITION

Condition for error detection


This warning alarm 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

Condition for error detection


Parking brake lever pulled or failure on the parking brake micro.
Checks to perform:
- release the parking brake lever
- verify the status of the parking brake micro S13 and the relevant cables.
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TRACTION SLAVE LOGIC UNIT


61 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.

62 EEPROM KO

Condition for error detection


Fault in the memory area where the adjustment parameters are stored; this alarm inhibists the truck
operation; the logic unit will restore the default parameters (stored in the factory).
If the defect persists after a general reset, switching OFF and ON again the key, replace the logic unit.
If the alarm disappears, the parameters previusly stored will be deleted and the the default parameters
(stored in the factory) will automatically be restored.

63 LOGIC FAILURE #3

Condition for error detection


Logic defect.
- Replace the logic unit.
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64 LOGIC FAILURE #2

Condition for error detection


Fault in the hardware section of the logic board which manages the phase voltage feedback.
The alarm appears even if the contactor T2 (traction and lifting supply line) opens with the coil still
powered.
Output voltage of the logic for coil power supply:
connettore JCT: pin 27 cable BC (+48V) - pin 26 cable BG (-)
Checks to perform:
- connector present on the contactor group: possible false contacts
(see Contactor Unit Assembly Drawing paragraph)
-T2 contactor coil resistance = 140 ohm
- the power cables connected to the motor status
- replace the logic unit
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65 LOGIC FAILURE #1

Condition for error detection


This alarm signals that the under or over voltage protection cut-out has been triggered.
- under voltage: the logic unit keeps the key input voltage under control (connector JCT, pin 3, wire M).
If the voltage has a peak down the alarm is signalled.
- over voltage: the logic unit keeps the key input voltage under control (connector JCT, pin 3, wire M).
If the voltage has a peak up the alarm is signalled.
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 unit, 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 logic unit.
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, one at a time, so as to find the component that has lost its insulation.
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66 VMN LOW

Condition for error detection


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
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,one
at a time so as to find the component that has lost its insulation.
- Switch off the machine and reverse the left drive and lifting motor connections on the logic units.
- Check the state of the coil of contactor T2 (140 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 logic unit.
- If the alarm is detected by the lifting logic unit, check and if necessary replace the left 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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67 VMN HIGH

Condition for error detection


Failure in the VMN test.
This test starts when the ignition key is turned ON and there is no current consumption (still machine).
The alarm appears if the power circuit is open; check the connections of the 3 power cables from the
logic unit to the left traction motor and the cables condition.
Check the state of the coil of contactor T2 (140 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 multimeter:
Red Tip Black Tip
Us - (+) = 4,5 Kohm
Vs - (+) = 4,5 Kohm
Ws - (+) = 4,5 Kohm
Us - (-) = 4,5 Kohm If the measurements are very different to the
Vs - (-) = 4,5 Kohm reference ones described alongside, discon-
Ws - (-) = 4,5 Kohm nect all the power cables from the logic unit and
Us - Vs = 0 ohm check the values directly on the logic unit.
Us - Ws = 0 ohm
Vs - Ws = 0 ohm
Values on the logic unit with the motor disconnected:
Us - (+) = 5,0 Kohm
Vs - (+) = 125 Kohm
Ws - (+) = 100 Kohm
Us - (-) = 5,0 Kohm
Vs - (-) = 125 Kohm
Ws - (-) = 100 Kohm If an open circuit is detected, replace the logic unit.
Us - Vs = 135 Kohm
Us - Ws = 135 Kohm
Vs - Ws = 280 Kohm
TEST 2
Connect the tractio slave logic unit to the lifting motor and check if the display shows the alarm code
"67".
YES: repace the logic unit
NO: check the left traction motor insulation
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68 CONTACTOR OPEN

Condition for error detection


Fault with the contactor T2. The contactor is powered, but the contacts do not close.
- Check the main contactor coil (140 ) and relevant cables.

69 STBY I HIGH

Condition for error detection


Failure on the current sensor.
- Replace the logic unit.

70 CAPACITOR CHARGE

Condition for error detection


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 between logic unity and battery
- Check the voltage upstream from the key switch: there always must be the battery voltage.
- Replace the key switch.
- Replace the logic unit.

Vb= battery PB1 KEY


D1= diode + Vb F1
F1= key fuse
D1
PB1= emergency button
KEY= key
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71 HIGH TEMPERATURE

Condition for error detection


The temperature of the logic unit has exceeded 75°C. The maximum current in the module is reduced
proportionally to the temperature increase.
At 100°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 100°C
wait for the control unit to cool gradually.
When the temperature falls under 75°C the alarm disappears automatically.

72 MOTOR TEMPERATURE

Condition for error detection


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).
Checks to perform:
- If the sensor is open with the motor cold: replace the sensor (see chapter 1000);
- if the sensor is closed, but there is 5V between pins J1-3 and J1-4: replace 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, replace the logic unit.
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73 ENCODER ERROR

Condition for error detection


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
stopped 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 unit 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 picture shows only one signal (A).
The used encoders generate two equal signals,
with a a phase displacement of 90° (A-B).
1. Connect the multimeter positive tip (red) to
the encoder positive terminal
2. Connect the multimeter COM tip (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 logic unit
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74 THERMIC SENSOR KO

Condition for error detection


The logic unit thermic sensor is out of range.
- Replace the logic unit

75 UNUSED

76 CAN BUS KO

Condition for error detection


Communication failure in the wires connecting the logic units (traction, lifting, Mhyrio) and all the other
cards. In this condition the stop lights and reversing lights are switched on and the lifting motor turns
on automatically to ensure the power steering function.
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. logic unit
- CAN BUS KO 09: Mhyrio logic unit.
- CAN BUS KO 00: armrest card.
If the problem is genereated by the traction logic unit, 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.
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77 WAITING FOR NODE

Condition for error detection


The logic unit has identified a delay in the data transmission from the I/O card or lifting logic unit.
WAITING FOR 0A: delay in transmission of the I/O card.
Checks to perform:
- If alarm 77(waiting for 0A) appears in combination with alarm 47 connect the console in the lifting
logic unit and check if the WAITING FOR 0A alarm appears.
If this is so, replace the I/O card.
- If alarm 77(waiting for 0A) appears on its own, check:
general machine insulation;
replace the logic unit.
WAITING FOR 05: delay in transmission from the lifting logic unit.
Checks to perform:
- If alarm 77(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 unit 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 77 will automatically disappear.
If this is not so, check for false contacts in the CAN-BUS connection: connector JAT traction logic unit
pin 1-4-6-7, connector JCP lifting logic unit pin 1-3.
If there are no false contacts replace the logic unit.
WAITING FOR 04: delay in transmission from the slave traction logic unit
Checks to perform:
- If alarm 77(waiting for 04) appears in combination with other alarms of the slave traction logic unit:
If this is so, the alarm signals that the slave traction logic unit has shut down.
After eliminating the causes of the lifting logic shutdown, alarm 77 will automatically disappear
If the bridge on the JBP connector of the lifting logic unit is present.
If no, restore the connection.

78 UNUSED

79 UNUSED

80 CONTACTOR DRIVER

Condition for error detection


Failure on the traction contactor driver.
- Replace the drive logic unit.
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7A MASTER KO

Condition for error detection


Communication fault from traction master logic unit. The alarm can be originated by:
1. Interferences on the CAN-BUS: in this condition the alarm appears in combination with other
alarms
Checks to perform:
- truck insulation
- presence of the antistatic discharger if the truck is equipped with no marking tyres
- verify drive logic unit connectors JCT and JAT; all the pins must be in line and not lifted
- verify light board connector J130; all pin must be correctly connected
2. Defective logic unit
Checks to perform:
- communication between traction slave logic unit and traction master logic unit by the console
: see point 1
NO: replace the logic unit

7C UNUSED

8A UNUSED

8C GAIN ACQUISITION

Condition for error detection


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

8E UNUSED
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LIFTING LOGIC UNIT


31 WATCHDOG

Condition for error detection


The test is performed both in running and in standby situation. It is a self-diagnosing test of the logic.
This alarm could also be caused by the canbus malfunctioning
Therefore, before replace the lifting logic unit, controll the can-bus

32 EEPROM KO

Condition for error detection


Fault in the memory area where the adjustment parameters are stored; this alarm inhibists the truck
operation; the logic unit will restore the default parameters (stored in the factory).
If the defect persists after a general reset, switching OFF and ON again the key, replace the logic unit.
If the alarm disappears, the parameters previusly stored will be deleted and the the default parameters
(stored in the factory) will automatically be restored.

33 LOGIC FAILURE #3

Condition for error detection


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

Condition for error detection


Fault in the hardware section of the logic board which manages the phase voltage feedback.
The alarm appears even if the contactor T2 (traction and lifting supply line) opens with the coil still
supplied
Logic unit output voltage to supply the contactor coil
connector JCT: pin 27 wire BC (+48V) - pin 26 wire BG (-)
Checks to perform:
- connector present on the contactor group: possible false contacts
(see Contactor Group Assembly Drawing paragraph)
- T2 contactor coil resistance = 140 ohm
- the power cables connected to the motor status
- replace the logic unit
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35 LOGIC FAILURE #1

Condition for error detection


This alarm signals that the under or over voltage protection cut-out has been triggered.
- under voltage: the logic unit keeps the key input voltage under control (connector JFP, pin 3, wire
M). If the voltage has a peak down the alarm is signalled.
- over voltage: the logic unit keeps the key input voltage under control (connector JFP, pin 3, wire M).
If the voltage has a peak up the alarm is signalled.
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
05 or 65 of the traction logic unit, 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 logic unit.
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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36 VMN LOW

Condition for error detection


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 lifting 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 lifting 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,one
at a time so as to find the component that has lost its insulation.
- Switch off the machine and reverse the lifting and one of the traction motor connections on the logic
units.
- Check the state of the coil of contactor T2 (140 ohm).
- Switch on the machine and wait for the logic unit to run the test. Important: with the motors reversed
do not give any traction or lifting signals.
- If the alarm persists replace the logic unit.
- If the alarm is detected by the traction 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

Condition for error detection


Failure in the VMN test.
This test starts when the ignition key is turned ON and there is no current consumption (still machine).
The alarm appears if the power circuit is open; check the connections of the 3 power cables from the
logic unit to the lifting motor and the cables condition.
Check the state of the coil of contactor T2 (140 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 multimeter:
Red Tip Black Tip
V - (+) = 4,5 Kohm
U - (+) = 4,5 Kohm
W - (+) = 4,5 Kohm
V - (-) = 4,5 Kohm If the measurements are very different to the
U - (-) = 4,5 Kohm reference ones described alongside, discon-
W - (-) = 4,5 Kohm nect all the power cables from the logic unit and
U - V = 0 ohm check the values directly on the logic unit.
U - W = 0 ohm
V - W = 0 ohm
Values on the logic unit with the motor disconnected:
U - (+) = 5,0 Kohm
V - (+) = 130 Kohm
W - (+) = 90 Kohm
U - (-) = 5,0 Kohm
V - (-) = 130 Kohm
W - (-) = 90 Kohm If an open circut is detected, replace the logic unit
U - V = 125 Kohm
U - W = 125 Kohm
V - W = 260 Kohm
TEST 2
Connect the lifting logic unit to the one of the traction motor and check if the display shows the alarm
code "37".
YES: repace the logic unit
NO: check the lifting motor insulation.
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38 CONTACTOR OPEN

Condition for error detection


Fault with the contactor T2. The contactor is powered, but the contacts do not close.
- Check the main contactor coil (140 ) and relevant cables.

39 STBY I HIGH

Condition for error detection


Failure on the current sensor. Replace the lifting logic unit.

40 CAPACITOR CHARGE

Condition for error detection


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 between logic unity and battery
- Check the voltage upstream from the key switch: there always must be the battery voltage.
- Replace the key switch.
- Replace the logic unit.

Vb= battery PB1 KEY


D1= diode + Vb F1
F1= key fuse
D1
PB1= emergency button
KEY= key
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41 HIGH TEMPERAURE

Condition for error detection


The temperature of the logic unit has exceeded 75°C. The maximum current in the module is reduced
proportionally to the temperature increase.
At 100°C the current is reduced to 0 and the logic unit stops.
Checks to perform:
- the fan works correctly
- the air duct must be clear
Check the TEMPERATURE parameter with the console in the TESTER function. If higher than 100°C
wait for the control unit to cool gradually.
When the temperature falls under 75°C the alarm disappears automatically.

42 MOTOR TEMPERAURE

Condition for error detection


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 J13 between pin 5 and 6 = 0 Volt.
Checks to perform:
- If the sensor is open with the motor cold: replace the sensor (see chapter 1000);
- if the sensor is closed, but there is 10V between pins J13-5 and J13-6: replace the lifting logic unit.
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43 ENCODER ERROR

Condition for error detection


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
stopped 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 picture shows only one signal (A).
The used encoders generate two equal signals,
with a a phase displacement of 90° (A-B).
1. Connect the multimeter positive tip (red) to
the encoder positive terminal.
2. Connect the tester COM tip (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 logic unit.
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44 THERMIC SENSOR KO

Condition for error detection


The logic unit thermic sensor is out of range.
- Replace the logic unit.

45 SAFETY

Condition for error detection


Lifting logic uni stop
In the logic unit, on JFP connector, the pin 5 (negative input) is connected to the pin 11 (negative
output); if this bridge is disconnected the logic stops, signalling SAFETY (= safety arrest). Check:
(1) If, in the JFP connector, the pin 5 is connected to the pin 11 by the B wire
(2) Replace the logic unit (see paragraph “Necessary adjustments after have replaced the lifting
logical unity”)

LIFTING
LOGIC UNIT
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46 CAN BUS KO

Condition for error detection


Communication failure in the wires connecting the logic units (drive, lifting, Mhyrio) and all the other
cards. In this condition the stop lights and reversing lights are switched on and the lifting motor turns
on automatically to ensure the power steering function.
- verify the presence of the JFP connector 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 this case the system recognize in which one:
- CAN BUS KO 0A: I/O board.
- CAN BUS KO 03: Master.
- CAN BUS KO 04: Slave.
- CAN BUS KO 09: Mhyrio.
- CAN BUS KO 00: Armrest card.
If the problem is genereated by the lifting logic unit, 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 here is a line interruption.
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47 WAITING FOR NODE

Condition for error detection


The logic unit has identified a delay in the data transmission from the I/O board, armrest board, traction
logic unit or Mhyrio logic unit.
WAITING FOR 0A: delay in transmission of the I/O bo rd.
Checks to perform:
- If alarm 47(waiting for 0A) appears in combination with alarm 17 connect the console in the traction
logic unit and check whether the WAITING FOR 0A alarm appears. If this is so, replace the I/O card.
- If alarm 47(waiting for 0A) appears on its own, check:
• general machine insulation;
• alarm presence in the tractio slave logic unit: if alarms are present, once eliminated the causes of
the drive logic unit block the alarm 47 will disappear automatically;
• replace the lifting logic unit.
WAITING FOR 03 or 04: delay in transmission from the traction logic unit.
Checks to perform:
- If alarm 47 (waiting for 03 Master o 04 Slave) appears in combination with other alarms of the traction
logic unit:
• If this is so, the alarm signals that the lifting logic unit has shut down.
• verify the presence of the bridge in the JBP connector on the lifting logic unit
• Connect the console and check the alarms related to the Master & Slave drive logic unit. After
eliminating the causes of the drive logic unit 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
• connect the console and verify the alarms relative to the Slave traction logic unit
• If there are no false contacts replace the lifting logic unit.
WAITING FOR 09: delay in transmission from the Mhyrio logic unit.
Checks to perform:
- If alarm 47 (waiting for 09) appears in combination with other alarms of the Mhyrio logic unit:
• If this is so, the alarm signals that the lifting logic unit has shut down.
• once eliminated the causes of the lifting logic unit block the alarm 47 will disappear automatically;
• If this is not so check for false contacts in the CAN-BUS connection: connector J140 Mhyrio logic
unit pin 4-13;
• if there are no false contacts replace the lifting logic unit
WAITING FOR 00: delay in transmission from the Armrest board
Checks to perform:
- If alarm 47 (waiting for 00) appears in combination with other alarms
• If this is so, connect the console and check the alarms related to the Master, Slave and Mhyrio (if
Mhyrio is present)
• after eliminating the causes of the logic units shutdown, alarm 47 will automatically disappear.
• If this is not so check for false contacts in the CAN-BUS connection: connector J138 Armrest board
1-2, connector J131 Light board pin 1-2
• if there are no false contacts replace the lifting logic unit
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48 AUX OUTPUT KO

Condition for error detection


Failure on the T2 contactor driver.
- Replace the lifting logic unit.

49 DRIVER SHORTED

Condition for error detection


Failure on the T2 contactor driver.
- Replace the lifting logic unit.

50 CONTACTOR DRIVER

Condition for error detection


Failure on the T2 contactor driver.
- Replace the lifting logic unit.

51 COIL SHORTED

Condition for error detection


Failure on the drive contactor T2.
Check the contactor coil state (140 ohm) and the relevant wiring loom.
- If the failure is not due to external causes, replace the lifting logic unit

52 VACC NOT OK

Condition for error detection


Failure on the lifting potentiometer signal at rest. The alarm points out that the voltage value detected
on the accelerator potentiometer is 1 Volt higher than the least programmed Vacc function.
Checks to perform:
- 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

Condition for error detection


- Seat interrupter opened in case of operating pump
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54 UNUSED

55 WRONG BATTERY

Condition for error detection


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

Condition for error detection


General incorrect starting procedure.

57 WAITING MHYRIO

Condition for error detection


The logic unit has identified a delay in the data transmission from Mhyrio logic unit.
WAITING FOR 09: delay in transmission of Mhyrio logic unit.
Checks to perform:
- check if alarm 57(waiting for 09) appears in combination with others alarms of Mhyrio logic unit
- If this is so, the alarm signals that the Mhyrio logic unit has shut down. Connect the console in the
Mhyrio logic unit and check the Mhyrio logic unit alarms. 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 J139 pin 1-2
- If there are no false contacts replace the Mhyrio logic unit.

58 I = 0 EVER

Condition for error detection


Failure on the current sensor.
- Replace the logic unit.

59 UNUSED

4A UNUSED
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4C BATTERY LOW

Condition for error detection


Battery discharged

4E UNUSED

5A CHOPPER NOT CONF

Condition for error detection


The lifting logic unit configuration is incorrect.
Using the console it is possible to reprogram the logic unit correctly in conformity with the type of truck
(see the LIFTING ACQUISITION section):
- joystick ON with electic control valve
- joystick OFF with mechanical control valve

5C GAIN ACQUISITION

Condition for error detection


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

5E UNUSED
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MHYRIO LOGIC UNIT


A1 EEPROM KO

Condition for error detection


Fault in the memory area where the adjustment parameters are stored; this alarm inhibists the truck
operation; the logic unit will restore the default parameters (stored in the factory).
If the defect persists after a general reset, switching OFF and ON again the key, replace the logic unit.
If the alarm disappears, the parameters previusly stored will be deleted and the the default parameters
(stored in the factory) will automatically be restored.

A2 DRIVER SHORTED

Condition for error detection


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 coils:
- EVP coil value = 19.5 ohm EV1= 90 ohm
If the coils are shorted, replace the Mhyrio logic unit
.

A3 CAN BUS KO

Condition for error detection


Failure in wires connecting the logic units (traction, lifting, Mhyrio) and all the other boards
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A4 FF VALVES

Condition for error detection


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 logic unit.
Disconnect the solenoid valves wiring. If the alarm persists, replace the Mhyrio logic unit

A5 DRIVER OPENED

Condition for error detection


The transistor that controls the lifting and lowering valves supply positive is open when it should be
closed.
Replace the Mhyrio logic unit.

A6 DRIVER EPV GR1

Condition for error detection


One or more MOS controlling the valves are in short-circuit.
Replace the Mhyrio logic unit

A7 DRIVER EPV GR2

Condition for error detection


One or more MOS controlling the valves are in short-circuit.
Replace the Mhyrio logic unit

A8 DRIVER EPV GR3

Condition for error detection


One or more MOS controlling the valves are in short-circuit.
Replace the Mhyrio logic unit
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DASHBOARD
The alarm descriptions of the dashboard are not displayed on the console
b1 IO COMMUNIC KO

Condition for error detection


This alarm signals that the I/O board does not communicate.
- check the power supply; 24V must be present on the connector J135 pin 5 (wire B)
- connect the console to the drive logic unit and verify the communication using the tester function.
If to verify the status of the micros and the potentiometer of accelerator pedal is not possible, replace
the I/O board
- if the power supply is OK but it is not possible to operate the truck, replace the I/O board

b2 MHY COMMUNIC KO

Condition for error detection


This alarm signals that the Mhyrio logic unit is not communicating.
- check the power supply; 24V must be present on the connector JC 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 LUCI COMMUNIC KO

Condition for error detection


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

Condition for error detection


This alarm signals that the Traction Master logic unit does not communicate.
- check the power supply; 48 V must be present on the connector JCT pin 3.
- if the power supply is OK but it is not possible to operate the truck, replace the Traction logic unit

d2 PUMP COMMUNIC KO

Condition for error detection


This alarm signals that the Lifting logic unit does not communicate.
- check the power supply; 48 V must be present on the connector JFP 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 TRAC COMMUNIC KO

Condition for error detection


This alarm signals that the Traction Slave logic unit does not communicate.
- check the power supply; 48V must be present on the connector JCT pin 3.
- if the power supply is OK but it is not possible to operate the truck, replace the Traction logic unit

d5 d1 + d4

d6 d2 + d4

d7 d1 + d2 + d4

d8 JOY KO

Condition for error detection


This alarm signals that the Armrest board does not communicate.
- check the power supply; 24V must be present on the connector J8 pin 5.
- if the power supply is OK but it is not possible to operate the truck, replace the Armrest board.
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d9 d1 + d8

dA d2 + d8

db d1 + d2 + d8

dC d4 + d8

dd d1 + d4 + d8

dE d2 + d4 + d8

dF d1 + d2 + d4 + d8
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I/O BOARD
81 TRACTION INCORRECT START

Condition for error detection


Incorrect start sequence (mechanical control valve version). Checks to perform:
- The forward and reverse micros and their relevant cables
- The parking brake micro and its relevant cables

82 LOGIC FAILURE

Condition for error detection


Failure on the I/O board (mechanical control valve version). Renew the I/O board

83 PEDAL WIRE KO

Condition for error detection


Failure on the acceleration potentiometer signal at rest. Checks to perform:
- traction potentiometer wiper
- +V POT or GND POT could be interrupted

84 BAD MICRO SWITCH

Condition for error detection


The micro of the travel pedal or of the hand direction lever is demaged.

85 UNUSED

86 UNUSED

87 UNUSED

88 PUMP INCORRECT START

Condition for error detection


Incorrect start sequence (mechanical control valve version) Checks to perform:
- the mechanical control valve micros and relevant wirings.
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LIGHT BOARD
C1 STOP OPEN

Condition for error detection


Failure on the stop lights. Check the bulbs of the brake lights and their relevant cables.
The alarm appears if both stop lights are disconnected or the related light bulbs do not work

C2 UNUSED

C3 UNUSED

C4 RETRO-OPEN

Condition for error detection


Failure on the reverse lights. Check the reverse lights bulbs and their respective cables.
The alarm appears if both reverse lights are disconnected or the r levant 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

Condition for error detection


Failure on the lifting potentiometer in the fingertips / joysticks group.
- switch off the machine, pull the parking brake lever, connect the console in the lifting logic unit 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 is a potentiometer malfunctioning, proceed as follows:
JOYSTICK VERSION: exchange the lifting potentiometer with the sideshift potentiometer
FINGERTIP VERSION: reverse the lifting potentiometer with the tilting potentiometer
If the alarm persists replace the board.
If the alarm disappears, check the potentiometer wiring and then proceed with replacement.
If there is no potentiometer malfunctioning, replace the board.

E3 BAD TILT POT

Condition for error detection


Failure on the tilting potentiometer in the fingertips / joysticks group.
- switch off the machine, pull the parking brake lever, connect the console in the lifting logic unit and
switch back on
- select the TESTER menu
- select the 1ST LIFTING SWITCH parameter
- Move the potentiometer and check whether the parameter changes from 0% to 100% progressively:
If there is a potentiometer malfunctioning, proceed as follows:
JOYSTICK VERSION: exchange the tilting potentiometer with the IV way potentiometer
FINGERTIP VERSION: reverse the tilting potentiometer with the lifting potentiometer
If the alarm persists replace the board.
If the alarm disappears, check the potentiometer wiring and then proceed with replacement.
If there is no potentiometer malfunctioning, replace the board.
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E4 BAD SIDESH POT

Condition for error detection


Failure on the sideshift potentiometer in the fingertips / joysticks group.
- Switch off the machine, pull the parking brake lever, connect the console in the lifting logic unit and
switch back on
- Select the TESTER menu
- Select the 2ST LIFTING SWITCH parameter
- Move the potentiometer and check whether the parameter changes from 0% to 100% progressively:
If there is a potentiometer malfunctioning, proceed as follows:
JOYSTICK VERSION: exchange the sideshift potentiometer with the lifting potentiometer
FINGERTIP VERSION: reverse the sideshift potentiometer with the tilting potentiometer
If the alarm persists replace the board.
If the alarm disappears, check the potentiometer wiring and then proceed with replacement.
If there is no potentiometer malfunctioning, replace the board.

E5 BAD IV POT

Condition for error detection


Failure on the IV way potentiometer in the fingertips / joysticks group.
- Switch off the machine, pull the parking brake lever, connect the console in the lifting logic unit and
switch back on
- Select the TESTER menu
- Select the 3ST LIFTING SWITCH parameter
- Move the potentiometer and check whether the parameter changes from 0% to 100% progressively:
If there is a potentiometer malfunctioning, proceed as follows:
JOYSTICK VERSION: exchange the IV way potentiometer with the tilting potentiometer
FINGERTIP VERSION: reverse the IV way potentiometer with the sideshift potentiometer
If the alarm persists replace the board.
If the alarm disappears, check the potentiometer wiring and then proceed with replacement.
If there is no potentiometer malfunctioning, replace the board

E6 BAD V POT

Condition for error detection


Unused.
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E7 INCORRECT START

Condition for error detection


Incorrect start sequence.
One of the potentiometers on the armrest is not in a neutral position when the machine is switched on.
Checks to perform:
- switch off the machine, pull the parking brake lever, connect the console and switch back on
- select the TESTER menu
- 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 board

E8 BAD POTENTIOMETER

Condition for error detection


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.
Checks to perform:
- 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 board

EF FW + BW

Condition for error detection


Double direction request activated.
The armrest board has detected a double direction request from the buttons PB1 and PB3 (see
electric wiring)
Checks to perform:
- check that the buttons are not pressed
- check a possible short circuit in the buttons wirings
- if everything is OK, replace the board

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