Section: ELECTRICAL SYSTEM SERVICE

8.0 MODULES REPLACEMENT PROCEDURE

ELECTRICAL SYSTEM

The following headings contain a description of the procedure for replacing each individual module in such
a way that at the end of the operation the truck operates in exactly the same way as with the original
modules.

Note: Ensure you perform this procedure without skipping any of the steps in the sequence.
Incorrect operations could damage the new module.

Before replacing any of the modules check the table of settings relative to the module as shown in the
manual and compare them with the parameters stored on the module in the PARAMETER CHANGE and
SET OPTIONS submenus. The values could be different depending on the options enabled.
At the end of the replacement operation always check that the new module is programmed in exactly the
same way as the original module.

8.1 REPLACING MODULES 2 OR 5 - TRACTION OR PUMP INVERTER AC2

Before starting the replacement procedure save the controller settings on the console by means of the
SAVE PARAMETERS submenu present in the MAIN MENU (for more details refer to the “AC MOTORS
MODULAR CONTROL SYSTEM” manual).

1) Switch off the keyswitch an press the emergency pushbutton.

2) Disconnect the battery.

3) Only when the battery is disconnected: connect a resistor of between 33 and 100 Ohm 50W across
the inverter positive B+ and negative B-. Wait for approximately 8 seconds while for the controller
internal capacitors to discharge and then disconnect the resistor.

Note: To avoid short-circuits ensure that the resistor is insulated.

If it is impractical to use an external resistor to discharge the capacitors you must wait at least 90
seconds before disconnecting any of the power cables.

1234
1234
60 Ohm 50W

1234
1234
RESISTOR

1234
1234
1234
1234

Fig. 26

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SERVICE Section: ELECTRICAL SYSTEM

4) Disconnect the power cables, ensuring that they are still marked in relation to the corresponding
connectors; if the cables are not marked, mark them before disconnecting.

ELECTRICAL SYSTEM
5) Disconnect auxiliary connectors C,D,F. In the case of the PUMP inverter, remember to disconnect the
jumper on connector B to apply it to the new controller. Without this jumper the system is unable to
operate. This jumper is not present on the TRACTION inverter.

TRACTION MOTOR
POWER CABLES
BATTERY CABLES

D2
A2 B2 C2

F2 E2

Fig. 27

PUMP MOTOR
POWER CABLES
BATTERY CABLES

D5
A5 B5 C5

F5 E5

Fig. 28

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6) Unscrew the screws that secure the controller to the truck and remove the inverter.
ELECTRICAL SYSTEM

7) Install the new module fitting the screws, connectors and cables in accordance with a reverse
sequence of operations with respect to the removal procedure. Remember that connector B of the
PUMP inverter must be equipped with a jumper.

8) Connect the console to the inverter

9) After having checked the correct connection of the cables, connect the battery, reset the emergency
switch and set the keyswitch to ON.

10) By means of the RESTORE PARAMETERS submenu in the MAIN MENU, download to the controller
the module settings previously saved to the console by means of the SAVE PARAMETERS
procedure.

11) With the assistance of the table in the manual check that all the PARAMETER CHANGE and SET
OPTIONS submenu settings correspond.

12) Test all the truck functions.

8.2 REPLACING MODULE 1 - CAN I/O

Note: the CAN I/O module is identical in terms of size, shape, and connector positions, to the MHYRIO
module. Therefore, when replacing this module pay special attention to the identification label on the
outer case.
The truck duty hours are stored on the CAN I/O and SICOS (display) modules. If it should become
necessary to renew the CAN I/O module you must first execute a procedure that makes it possible to
transfer the duty hours value stored in the display to the new CAN I/O module.

1) With the keyswitch set to OFF connect the console to the SICOS module (display). Set the keyswitch
to ON.

2) In the CONFIG MENU>SET OPTIONS submenu set the AUX FUNCTION 1>parameter to OFF.
This allows the CAN I/O module to set up to receive the truck duty hour data stored on the DISPLAY.

Before starting the replacement procedure remember to save the controller settings to the console by
means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to
the “AC MOTORS MODULAR CONTROL SYSTEM” manual).

3) Switch off the keyswitch and press the emergency pushbutton.

4) Disconnect the battery.

5) Disconnect all the connectors after checking that their positions are clearly identified.

6) Unscrew the screws that secure the module to the truck and remove the module.

7) Install the new module, fitting the screws and connectors by following the removal steps in reverse
order.

8) After having checked that the connectors are correctly inserted, connect the console to the CAN I/O
module by means of the adapter that you removed from the faulty module and then inserted on the
relative connector of the new CAN I/O module.

9) Connect the battery, reset the emergency pushbutton and set the keyswitch to ON.

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SERVICE Section: ELECTRICAL SYSTEM

10) With the console, via the RESTORE PARAMETERS submenu present in the MAIN MENU upload
to the controller the settings of the module previously saved on the console by means of the SAVE

ELECTRICAL SYSTEM
PARAMETERS procedure.

11) Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE
and SET OPTIONS submenus correspond, including any option settings.

12) Test all the truck functions.

8.3 REPLACING SICOS MODULE 16 (display)

The truck duty hours are stored on the SICOS module and CAN I/O bus. If you need to replace the
SICOS module you must perform a procedure that makes it possible to transfer the duty hours memorized
on the CAN I/O to the SICOS.

1) With the keyswitch set to OFF connect the console to the SICOS module. Set the keyswitch to ON.

2) In CONFIG MENU>SET OPTIONS set the parameter AUX FUNCTION 1>to OFF.
In this manner the SICOS module sets up to accept the truck operating hours stored on the CAN I/
O bus.

Before starting the replacement procedure remember to save the controller settings to the console by
means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to
the “AC MOTORS MODULAR CONTROL SYSTEM” manual).

3) Switch off the keyswitch and press the emergency pushbutton.

4) Disconnect the battery.

5) Disconnect all the connectors after checking that their positions are clearly identified.

6) Unscrew the screws that secure the module to the truck and remove the module.

7) Install the new module, fitting the screws and connectors by following the removal steps in reverse
order.

8) After having checked that the connectors are correctly inserted, connect the console to the SICOS
module by means of the adapter that you removed from the faulty module and then inserted on the
relative connector of the new SICOS module.

9) Connect the battery, reset the emergency pushbutton and set the keyswitch to ON.

10) Using the console, by means of the RESTORE PARAMETERS submenu located in the MAIN
MENU, download to the controller the settings of the original module saved on the console by means
of the SAVE PARAMETERS procedure.

11) With the assistance of the table in the manual check that all the adjustments relative to the
PARAMETER CHANGE and SET OPTIONS submenus correspond, including possible changes
relative to the option settings.

12) Test all the truck functions.

Note: If the options “PASSWORD” or “PRE-HEIGHT SELECTOR” were enabled on the previous
display, these functions must be completely reset by means of the new display (see relative
heading).

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8.4 REPLACING MODULE 9 - MHYRIO

ELECTRICAL SYSTEM

Before starting the replacement procedure remember to save the controller settings to the console by
means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to
the “AC MOTORS MODULAR CONTROL SYSTEM” manual).

1) Set the keyswitch to OFF and press the emergency pushbutton.

2) Disconnect the battery.

3) Disconnect all the connectors after checking that their positions are clearly identified.

4) Unscrew the screws that secure the controller to the truck and remove the module.

5) Install the new module, fitting the screws and connectors by following the removal steps in reverse
order.

6) After having checked that the connectors are correctly inserted, connect the console to the MHYRIO
module by means of the adapter that you removed from the faulty module and then inserted on the
relative connector of the new MHYRIO module.

7) Connect the battery, activate the emergency switch and set the keyswitch to ON.

8) With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU,
download to the controller the module settings previously saved to the console by means of the SAVE
PARAMETERS procedure.

9) Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE
and SET OPTIONS submenus correspond, including any option settings.

10) Test all the truck functions.

8.5 REPLACING MODULE 6 - EPS-AC

Before starting the replacement procedure remember to save the controller settings to the console by
means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to
the “AC MOTORS MODULAR CONTROL SYSTEM” manual).

1) Set the keyswitch to OFF and press the emergency pushbutton.

2) Disconnect the battery.

3) Disconnect all the connectors after checking that their positions are clearly identified.

4) Unscrew the screws that secure the controller to the truck and remove the module.

5) Install the new module, fitting the screws and connectors by following the removal steps in reverse
order.

6) After having checked that the connectors are correctly inserted, connect the console to the EPS-AC
module by means of the adapter that you removed from the faulty module and then inserted on the
relative connector of the new EPS-AC module.

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7) Connect the battery, activate the emergency switch and set the keyswitch to ON.

ELECTRICAL SYSTEM
8) With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU,
download to the controller the module settings previously saved to the console by means of theSAVE
PARAMETERS procedure.

9) Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE
and SET OPTIONS submenus correspond, including any option settings.

10) Perform the most appropriate EPS-AC setup procedure depending whether or not the 360° steering
or +90° -90° steering option is enabled (see “EPS-AC” manual).

11) Test all the truck functions.

NOTES:

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