524162546

Part No.
524162546
Technical Information for

YALE Service Centers
This manual is addressed exclusively to the specialised

technicians of the Yale service network
MODULAR
CONTROL SYSTEM
FOR AC MOTORS
MR14
MR14 H
MR16
MR16 H
MR16 N C849
MR20
MR20 H
MR 20 W
MR25
MODULE DESCRIPTION
SERVICE
NOTE
NOTE:
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SERVICE
CONTENTS
Section: MODULE
DESCRIPTIONS
1.0
1.1
1.2
1.3
1.4
1.5
2.0
2.1
2.2
2.3
2.4
2.5
2.6
3.0
3.1
3.2
4.0
4.1
4.2
5.0
5.1
5.2
6.0
6.1
6.2
7.0
7.1
7.2
8.0
8.1
8.2
INTRODUCTION ...................................................................................................................................... 6
CAN-BUS - BRIEF DESCRIPTION .......................................................................................................... 7
INTRODUCTION TO THE AC2 INVERTER .............................................................................................. 7
THE THREE-PHASE AC INDUCTION MOTOR - BRIEF DESCRIPTION ................................................. 8
THE INVERTER - OPERATING PRINCIPLE ........................................................................................... 10
ENCODER .............................................................................................................................................12
COMPONENT DESCRIPTION ................................................................................................................12
ENCODER INPUTS/OUTPUTS .............................................................................................................. 13
CONNECTION TO THE CONTROL MODULES ......................................................................................13
INSTALLATION ON MOTOR ...................................................................................................................13
AC2 INVERTER ..................................................................................................................................... 14
INTRODUCTION ..................................................................................................................................... 14
OPERATING CHARACTERISTICS .........................................................................................................15
PROTECTION DEVICES ........................................................................................................................ 16
DIAGNOSTICS .......................................................................................................................................17
PRECAUTIONS ..................................................................................................................................... 17
POSSIBLE CONFIGURATIONS .............................................................................................................17
DRIVE MOTOR CONTROLLER CONFIGURATION ................................................................................. 18
DESCRIPTION OF CONNECTORS ........................................................................................................ 18
DRIVE CONFIGURATION CONNECTIONS .............................................................................................19
DESCRIPTION OF POWER CONNECTORS .........................................................................................19
PUMP MOTOR CONTROLLER CONFIGURATION ................................................................................. 20
PUMP CONFIGURATION CONNECTIONS .............................................................................................21
DESCRIPTION OF POWER CONNECTORS .........................................................................................21
MHYRIO ................................................................................................................................................22
INTRODUCTION ..................................................................................................................................... 22
SICOS ...................................................................................................................................................24
INTRODUCTION ..................................................................................................................................... 24
CAN I/O ................................................................................................................................................. 26
INTRODUCTION ..................................................................................................................................... 26
EPS - AC ............................................................................................................................................... 28
INTRODUCTION ..................................................................................................................................... 28
CONTENTS
Section: PROGRAMMING
9.0
9.1
9.2
9.2.1
9.2.2
PROGRAMMING THE MODULES .........................................................................................................32

INTRODUCTION ..................................................................................................................................... 32
PROGRAMMING TOOLS .......................................................................................................................32
PERSONAL COMPUTER ......................................................................................................................32
PROGRAMMING CONSOLE ................................................................................................................. 33
INTRODUCTION ..................................................................................................................................... 33
10.0 USING THE PROGRAMMING CONSOLE .............................................................................................. 34
CONNECTION TO THE CONTROLLER .................................................................................................. 34
10.1 CONSOLE FUNCTIONS MAP ................................................................................................................36
11.0 PROGRAMMING THE CONTROLLER ...................................................................................................37
11.1 CONFIG. MENU ..................................................................................................................................... 37
11.1.1 CONFIG MENU - SET MODEL .............................................................................................................. 38
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NOTE
11.1.2 CONFIG MENU - SET OPTIONS ........................................................................................................... 39

11.1.3 CONFIG MENU - ADJUSTMENT ............................................................................................................ 40
11.2 MAIN MENU ..........................................................................................................................................41
11.2.1 MAIN MENU - PARAMETER CHANGE .................................................................................................. 41
11.2.2 MAIN MENU - TESTER ..........................................................................................................................43
11.2.3 MAIN MENU - SAVE PARAMETER ....................................................................................................... 44
11.2.4 MAIN MENU - RESTORE PARAMETER ................................................................................................45
11.2.5 MAIN MENU - ALARMS ......................................................................................................................... 46
11.2.6 MAIN MENU - PROGRAM VACC ........................................................................................................... 47
12.0 POSITION OF THE PC/CONSOLE CONNECTORS ON THE MODULES ...............................................48
13.0 DRIVE CONTROL AC2 INVERTER - SUBMENUS ................................................................................. 49
13.1 MAIN MENU - PARAMETER CHANGE .................................................................................................. 49
MODULE
13.2 MAIN MENU - TESTER ..........................................................................................................................51
13.3 MAIN MENU - PROGRAM VACC ........................................................................................................... 52
13.4 CONFIG MENU - SET OPTIONS ........................................................................................................... 52
13.5 CONFIG MENU - ADJUSTMENTS .........................................................................................................53
14.0 PUMP CONTROL AC2 INVERTER - SUBMENUS ................................................................................. 54
14.1 MAIN MENU PARAMETER CHANGE .................................................................................................... 54
14.2 MAIN MENU - TESTER ......................................................................................................................... 54
15.0 CAN I/O - SUBMENUS ..........................................................................................................................56
15.2 MAIN MENU - TESTER ..........................................................................................................................59
16.0 MHYRIO - SUBMENUS ......................................................................................................................... 61
16.2 MAIN MENU - TESTER ..........................................................................................................................62
17.0 SICOS - SUBMENUS ............................................................................................................................ 64
17.2 MAIN MENU - TESTER ..........................................................................................................................64
CONTENTS
Section: DIAGNOSTICS
1.0
1.1
2.0
3.0
4.0
5.0
DIAGNOSTICS .......................................................................................................................................68
ALARMS ................................................................................................................................................68
DESCRIPTION OF AC2 INVERTER ALARMS - DRIVE CONTROL ........................................................ 68
DESCRIPTION OF AC2 INVERTER ALARMS - PUMP CONTROL .........................................................72
DESCRIPTION OF CAN I/O ALARMS .................................................................................................... 74
DESCRIPTION OF MHYRIO ALARMS ...................................................................................................76
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MODULE DESCRIPTION
Section: MODULE DESCRIPTIONS
MODULE
DESCRIPTIONS
UPDATE
INTRODUCTION ......................................................................... 6
CAN-BUS - BRIEF DESCRIPTION ............................................. 7
INTRODUCTION TO THE AC2 INVERTER ................................. 7
THE THREE-PHASE INDUCTION MOTOR BRIEF DESCRIPTION ................................................................ 8
THE INVERTER - OPERATING PRINCIPLE ............................. 10
ENCODER ............................................................................... 12
AC2 INVERTER ....................................................................... 14
DRIVE MOTOR CONTROLLER CONFIGURATION ................... 18
PUMP MOTOR CONTROLLER CONFIGURATION ................... 20
MHYRIO .................................................................................. 22
SICOS ..................................................................................... 24
CAN I/O ................................................................................... 26
EPS ......................................................................................... 28
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MODULE DESCRIPTION
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1.0 INTRODUCTION
The multi-module electronic control system described in this manual is system for the control of three AC
motors as well a range of control functions. It consists of 6 modules (or controllers) that communicate and
interact with each other through a CAN-BUS. The main functions of each of these 6 modules are as follows:
- AC2 DRIVE INVERTER (MODULE 2): module controlling the 3-phase induction drive motor.
- AC2 PUMP INVERTER (MODULE 5): module controlling the 3-phase induction pump motor.
- EPS-AC (Electric Power Steering-AC - MODULE 6): module controlling the 3-phase induction
steering motor.
- MHYRIO (Multifunctional Hydraulic Remote Input/Output - MODULE 9): module controlling the
hydraulic solenoid valves.
- SICOS: (Display - MODULE 16): module controlling the LCD functions.
- CAN I/O (MODULE 1): Input/Output manager. Manages the inputs common to different functions,
sending instructions to the other modules via the CAN-BUS.
Fig. 1
The modules are not numbered consecutively, but these numbers are of fundamental importance during
the programming stage (see the chapter programming).
As all of the modules interact with each other via the CAN-BUS to execute the various functions of the
truck, it makes sense to describe the system as a whole rather than dedicate a separate manual to each
individual module. However, the inputs and inputs of each module may vary according to the model of
truck on which the system is installed.
This manual must therefore be read in conjunction with the specific SERVICE MANUAL for the truck in
question.
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The CAN is a serial data bus particularly suitable for the interconnection of a network of intelligent devices
such as sensors and actuators.
The CAN has MULTIMASTER capability, i.e. all the nodes in the CAN can transmit data and two or more
nodes can request access to the bus simultaneously.
Unlike normal serial transmissions, data messages sent from CAN nodes do not contain addresses.
Instead the message is labelled with an identifier that determines its priority. The transmitting node sends
the message to all the other nodes in the CAN, and each receiving node decides whether or not to process
the message by performing an acceptance test on the identifier (see figure below).
Fig. 2
For example, in a multi-module system such as that described in this manual, when module 1 needs to
instruct module 2 to perform a certain function, it does not address the message just to module 2, but sends
it to all the modules. Module 2, on examination of the identifier, will recognise that the message is relevant
and thus process the content of the message and perform the required function. However all the other
modules will see that the message does not apply to them and thus will ignore it.
The identifier also determines the priority of the message; this is particularly important when there data
traffic between the various modules in the system is intense.
This system provides high-speed serial transmission capability at a relatively low cost. In fact, with the
CAN, the quantity of interconnection wiring required is significantly reduced.
1.2 INTRODUCTION TO THE AC2 INVERTER

The INVERTER AC2 controller is designed for the control of 3-phase alternating current induction motors.
The same controller can be configured for the control of either drive motors or pump motors. As will be
explained in more detail later on in this manual, all that is required in order to change the configuration from
drive to pump motor control is the positioning of a jumper across two pins of an external connector. Before
embarking on a detailed description of the INVERTER AC2, it is first necessary to understand the basic
principles of a 3-phase motor. The following section contains a brief outline of the subject.
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1.1 CAN-BUS (Controller Area Network Bus) - CENNI
MODULE DESCRIPTION
SERVICE
1.3
THE 3-PHASE AC INDUCTION MOTOR - BRIEF DESCRIPTION
Generally less is known about the control of AC motors than conventional DC systems, but the subject is really not so
complex once you have grasped a few basic
principles. In both types of motor, rotation is
caused by the magnetic flux created in the air
gap between the rotor and stator through the
interaction of the magnetic fields produced by
the currents passing through the rotor and stator
windings.
In an induction motor, the main components are
the stator (shown without its windings in figure 3) and the rotor, which is comprised of a
number of conducting bars connected by rings
at each end to form a squirrel cage.
The stator has number of slots into which the
three-phase winding is inserted. If this stator
winding is supplied with alternating current
through a system consisting of three conductors
with a phase difference of 120 (see fig. 4), a
rotating magnetic field is generated in the stator.
The speed at which the stator field rotates is
(fig. 3)
known as the synchronous speed and is
expressed in RPM.
No load operation - When the motor runs without
any load, the speed of the rotor is just slightly
less than the synchronous speed (the speed of
the rotating magnetic field) and practically no
voltage or current is induced in the conductor
rods of the squirrel cage.
Operation with load - When the motor is
connected to a load, the rotor speed falls (or
slips relative to the synchronous speed) to the
point where the voltage induced by the difference
between the speeds of the squirrel cage
conductor rods and the rotating magnetic field
produces additional current in the cage and
(fig. 4)
thus greater torque to overcome the resistance
of the load. This type of behaviour is similar to
that of a DC motor, the main difference being that the magnetic field is static in a DC motor whereas it rotates in an AC
induction motor.
The rotation speed of the magnetic field can be precisely regulated by means of an inverter; by slowly increasing the
rotation speed from zero, the rotor can be accelerated to provide precise and controlled torque without the large current
surges created by direct on-line starting of motors.
The synchronous speed is directly related to the frequency and can be calculated using the following expression:
Nsync = 120 f/P
where 120 is the angle between the phases, P denotes the number of pairs of poles and f is the phase-crossover
frequency.
Thus for a 4-pole motor (P=2) the synchronous speed is 3000 RPM at 50Hz. (3600 RPM at 60HZ).
The difference between the rotor speed and the synchronous speed is usually expressed in terms of slip s which is
given by:
s = (Nsync Nrotor)/Nsync
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Consequently the slip value varies between 0 and 1 according to the difference between the rotor speed and the
synchronous speed. The slip will be near to 0 when the motor is running without any load, while it will rise to 1 in the
extreme case of a locked rotor (short-circuited rotor). Normal slip values vary between 2 and 5%, although at maximum
torque the slip may rise to as much as 30%.
When the rotor is forced to rotate faster than the synchronous speed, the motor starts to function as a generator.
3-phase induction motors are controlled by varying in the voltage and frequency of the field. Torque and speed can be
reduced or increased by variations in these parameters in that they determine the magnetic flux at the air gap. Under
constant voltage and frequency conditions, torque will increase as the speed falls (as the speed slips) in the same
way as with a DC motor. This remains true up to the maximum torque value, after which the torque will start to decrease.
As with a DC motor, the power output of an AC motor is affected by losses. Total loss can be divided into losses due
to the Joule effect in the stator and rotor windings, core losses and losses due to friction and ventilation (although on
motors without fans the latter are negligible). As a result of the losses due to the Joule effect, the current is limited by
the thermal capacity of the insulation: the maximum permissible continuous temperature for normal insulation (thermal
class F) is 155 C. In an AC motor, the core losses occur mainly in the stator whereas in a DC motor they occur in the
rotor. Obviously there are no losses incurred at the commutator or brushes in an AC motor The power output of an
induction motor with a stator diameter of between 180 and 240 mm is thus between 80 and 90%.
Given that on an AC motor no space is required to house the commutator and brushes, it follows that an induction motor
is capable of delivering more power than an equivalent DC series motor of the same length and diameter.
CONCLUSIONS
From this brief description of 3-phase induction motors, we can conclude that these motors offer a number of advantages
when compared with standard DC motors:
The motor, when controlled by an Inverter providing fine regulation of the synchronous speed, can supply
elevated amounts of acceleration torque without excessive current surges.
The absence of brushes is certainly the most significant factor as it provides the following advantages:
- reduced maintenance costs (no need to change the brushes or re-grind the commutator after a certain
number of operating hours);
- increased output (80-90%) thanks to absence of losses incurred at the commutator and brushes;
- smaller dimensions compared with a DC motor of equal power.
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MODULE DESCRIPTION
MODULE DESCRIPTION
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1.4
THE INVERTER - OPERATING PRINCIPLE
The control of a 3-phase induction motor requires a particular type of electronic drive known as an INVERTER. Much more
than in DC system, the performance
characteristics of an AC system are
largely dependent on the controller
used.
A basic inverter consists of three
switches which receive a DC input
voltage. These switches convert the
DC voltage into AC.
The power can flow in both directions,
i.e. from DC to AC and vice versa, and
the DC source can be constant or
variable. In battery-powered vehicles,
the batteries provide the source for the
DC voltage.
The simplest form of 3-phase inverter
has just three switches (see fig. 5). For
example, by changing the position of
the switch S3 from positive to negative, the field is rotated 60 in a clockwise
direction. The switches may be
connected to a positive or negative,
but never in an intermediate position.
The faster the switching, the faster the
rotation speed. These switches in fact
consist of MOSFET transistors (see
Fig. 5
fig. 6). Connected to the terminals of
each transistor there is a diode that
allows the recirculation of the inductive
currents. When an inverter is used
with an induction motor, it must
constantly monitor the slip and regulate
both the frequency and the voltage of
the output.
Using the special technique of pulse
width modulation (PWM), both the
magnitude and the frequency of the
AC output voltage can be controlled
separately.
Speed inversion is achieved
electronically by inverting the switching
sequence: the transition from motor to
generator is instantaneous and free
Fig. 6
of current surges. As full braking torque
is available right from full speed down
to zero, there is much less need to use the mechanical brake.
CONCLUSIONS
In many non-vehicular applications, the inverter and the motor are designed to operate at constant speed with a fixed
slip value.
In a vehicle, however, the system must be able to produce torque efficiently over a wide range of slip values and speeds.
The driveability and performance characteristics of the vehicle are greatly dependent on the control algorithm. Unlike a
DC system in which torque can be varied by regulating the current applied to the rotor, an induction motor system is based
on induced currents. This leads us to the observation that torque control is difficult during during changes in the slip value
(s) or frequency.
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The terms slip control and vector control are often used to identify two different methods of controlling an induction
motor.
With slip control, the inverter regulates the amplitude and frequency of the air gap flux. This method entails rather a
slow torque response and a tendency for the system to hunt before finding equilibrium in a new position.
In contrast, vector control regulates the amplitude, the frequency and the instantaneous position of the air gap flux, but
requires the use of an encoder keyed to the motor shaft.
Since the induction motor represents a non-linear system with a number of variables, the ability to effect instantaneous
position changes requires a complex mathematic model.
The system used on the AC2 INVERTER is a hybrid system based on a sophisticated algorithm. The result is an inverter
that produces the response of a vector control drive in a package suited to lift truck applications.
As
compared to DC systems, the AC controller system offers the following advantages:

Precise speed control
abundant and progressive torque
progressive inversion of travel direction
improved output
improved dynamic regenerative braking
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MODULE DESCRIPTION
MODULE DESCRIPTION
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1.5 ENCODER
The encoder plays a fundamental role in the operation of electronic controllers for AC induction motors.
Its function is to provide the motor controller with information related to the instantaneous speed,
acceleration, braking and rotation direction of the motor (the latter being particularly important for steering
control). The encoder is therefore installed on the rotor shaft.
With the aid of this rotation signal, the electronic controller can maintain a constant motor speed even when
the truck is driven over changing inclines (e.g. when driving down a ramp). Likewise, if the controller knows
the direction of motor rotation, it can also control the direction of travel, this being particularly useful when
the 360 steering system is selected.
COMPONENT DESCRIPTION
The encoders we use are integrated in the bearings supporting the rotor shafts of each motor (drive, pump,
steering) and are known as encoder bearings (Ref. A Fig. 8).
Fig. 7
Fig. 8
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The inner ring of the bearing, which rotates with rotor shaft, has a series of magnetic poles alternating
north-south contained in a moulded plastic housing.
Inside the outer ring of the bearing there is a sensor that responds to the passage of alternating magnetic
poles caused by rotation of the inner ring (and hence the rotor shaft) by generating a sequence of on-off
signals (square wave signal).
The number of pulses per rotation is equal to the number of magnetic poles on the inner ring of the bearing.
The encoders we use on our motors provide 64 pulses per rotation.
Each encoder bearing has two outputs at a phase angle of 90 to each other. This allows the electronic
controller to determine the direction of motor rotation according to whether the pulse sequence is on-off
or off-on.
ENCODER INPUTS/OUTPUTS
RED WIRE
+12V or +5V power supply*
BLACK WIRE
0V negative power
BLUE WIRE
PHASE A OUTPUT
WHITE WIRE
PHASE B OUTPUT
*NOTE: 12V encoder bearings have a different code to 5V encoder bearings.

Before connection, check that the supply voltage is correct to avoid damaging the encoder.
CONNECTION TO THE CONTROL MODULES

See Electrical system section of the manual for models equipped with this device.
INSTALLATION ON MOTOR
See Mechanics section of the Service Manual for the models equipped with this device.
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MODULE DESCRIPTION
MODULE DESCRIPTION
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2.0 AC2 INVERTER
MODULE 2: DRIVE
MODULE 5: PUMP
2.1 INTRODUCTION
The AC2 INVERTER is an electronic drive for the control 3-phase induction motors using a DC power
supply. One of the fundamental characteristics of this system is that it be configured for the control of either
an AC drive motor or an AC pump motor. This is achieved simply by repositioning an external jumper. This
means that only one part need be stocked to cover both functions.
The schematic diagram below shows how the AC2 INVERTER is interfaced with the motor and the main
components of the system. It is important to remember that the components (sensors, microswitches,
potentiometers etc.) that send information to the inputs will not necessarily be connected directly to the AC2
INVERTER. In fact, on trucks equipped with a CAN BUS data transmission system, all input information
will collected by the CAN I/O module, which will interpret the data and then send the appropriate instructions
via serial line to the inverter.
Fig. 9
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MODULE DESCRIPTION
D2
A2
F2
B2 C2
E2
Fig. 10
2.2 OPERATING CHARACTERISTICS

- speed control
- excellent performance when driving on ramps thanks to speed feedback:
- The speed of the motor is determined by the position of the accelerator, so regenerative braking is
initiated whenever the speed exceeds the set point.
- The system can keep the truck stationary on a ramp for a programmable length of time.
- Speed stable in any accelerator position.
- Regenerative braking, based on deceleration ramps, on release of accelerator.
- Regenerative braking on partial release of the accelerator (deceleration).
- Regenerative braking based on deceleration ramp on reversal of travel direction.
- Regenerative braking and direction reversal without use of contactors: only main contactor present.
- The release braking ramp can be modulated by way of an analogue input to obtain the effect of
proportional braking.
- Excellent sensitivity at low speeds.
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- Voltage booster on start off and under overload condition to obtain increased torque (with current
control).
- The inverter pilots the electromechanical brake.
- High efficiency of motor and battery thanks to high switch frequency.
- Self-diagnosis with indication of fault type by means of a LED blink code.
- Parameter modification by means of the programming console.
- Internal hour meter with possibility to display values on console.
- Log of last 5 alarms with relative time and temperature displayed on the console.
- Console internal test function to check the main parameters.
2.3 PROTECTION DEVICES

- Battery polarity inversion:
A main contactor must be installed to protect the inverter against polarity inversion and for reasons of
safety
- Connection faults :
All inputs are protected against connection faults.
- Thermal protection device:
If the temperature of the inverter exceeds 75 C, the maximum current is automatically reduced in
proportion to the increase in temperature. The temperature can never exceed 100 C.
- External agents :
The inverter is protected against dust and splashes of liquids to an ingress protection rating of IP64.
- Protection against uncontrolled movements:
The main contactor will not close if:
-
The power unit fails to function.

The logic unit fails to operate correctly.
The accelerator output voltage is not less than the minimum voltage setting plus 1 V.
The start microswitch is closed.
The battery is discharged:
when the battery is low, the maximum current is reduced to half the maximum programmable
current.
- Protection against accidental starts:

a precise sequence of operations is required in order to start the truck If these operations are not
performed correctly, the truck will not start. Travel requests must be made after the keyswitch has been
closed.
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The microprocessor continuously monitors the inverter and implements diagnostic procedures for its
main functions.
Diagnostic tests are performed at 4 different points:
1) diagnostic tests performed on closure of the keyswitch, comprising: watchdog circuit test, current
sensor test, capacitor charge test, phase voltage test, contactor driver test, CAN bus interface test, and
tests to check that the operating sequence is correct and that the output of the accelerator unit is
correct.
2) Diagnostic tests performed in standby condition comprising: watchdog circuit test, phase voltages test,
contactor driver test, current sensors test and CAN bus interface test.
3) Diagnostic tests performed during operation of the inverter comprising: watchdog circuit test, contactor
driver test, current sensors test and CAN bus interface test.
4) Diagnostic tests performed continuously to check the inverter temperature and the motor temperature.
Diagnostic information is provided in two ways: the digital console can be used to obtain detailed
information on a fault; the fault code can also be transmitted via the CAN bus.
2.5 PRECAUTIONS
- Do not connect the inverter to a battery with a different nominal voltage to that indicated on the module
nameplate. If the battery voltage is greater, the MOS could be irreparably damaged: if it is less than the
nameplate value, the controller will not effect power up.
- During battery recharging, the inverter must be disconnected from the battery.
- Only power the inverter from the drive batteries; do not use a power supplier.
- When the inverter is first installed, perform tests with the truck wheels raised from the ground in order
to avoid the risk of incorrectly made connections giving rise to dangerous situations.
- After the inverter has been switched off (key off) , the filter capacitors remain charged for a few minutes;
if you need to work on the inverter, discharge the capacitors by connecting a 10-100 Ohm resistor
between +Batt and Batt.
2.6 POSSIBLE CONFIGURATIONS

DRIVE
(connector B
without jumper)
A2 B2 C2
F2
PUMP
(connector
on jumper B)
D2
A5 B5 C5
F5
E2
E5
Fig. 11
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D5
Fig. 12
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MODULE DESCRIPTION
2.4 DIAGNOSIS
MODULE DESCRIPTION
SERVICE
3.0 DRIVE MOTOR CONTROLLER CONFIGURATION

3.1 DESCRIPTION OF CONNECTORS
MOD. ALL MODELS
This chapter contains descriptions of the inputs/outputs of the AC2 INVERTER in the drive motor controller
configuration. Some of these inputs may be used for more than one function depending on how the relative
parameters are configured in the programming menu SET OPTIONS. Furthermore, if the controller is
interfaced with other modules via the CAN-BUS system, the connector E will not be utilised: no actuators
will be connected to it.
D2
A2
B2 C2
E2
F2
Fig. 13
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The following table describes the function of each input/output of the inverter when configured for drive
control on the truck model indicated in this chapter.
CONN.
FUNCTION
CONNECTOR
PIN
1
2
3
4
5
6
CONNECTION
PROGRAMM.
CONSOLE
O
O
-
DRIVE OR PUMP
CONFIG. MODE
CONNECTION CANBUS
CONNECTION MOTOR
ENCODER
(*)
(**)
NOT USED
INPUT FOR CONTROL

OUTPUTS
ACTUATORS
I = IN
8
1
2
1
2
3
4
1
2
3
4
O
I
I/O
I/O
I/O
I/O
O
O
I
5
6
1+14
1
2
3
4
I
O
O
I
6
7
8
9
10
O
O
O
O
O
11
12
FUNCTION
ACTIVE
DESCRIPTION
O = OUT
SERIAL REC EPTION POSITIVE
NEGLIGIBLE
SERIAL RECEPTION NEGATIVE

SERIAL TRANSMISION POSITIVE
SERIAL TRANSMISSION NEGATIVE
CONSOLE POWER NEGATIVE
0V
+12V
CONSOLE POWER POSITIVE

MUST BE CONNECTED BY JUMPER WITH A8 PROGRAMM. FLASH MEMORY (NOT
USED)
USED)
NOT CONNECTED
NON CONNECTED
CAN-BUS LOW LEVEL
CAN-BUS LOW LEVEL
CAN-BUS HIGH LEVEL
CAN-BUS HIGH LEVEL
POWER POSITIVE
POWER NEGATIVE
PHASE OUTPUT A (SQUARE WAVE PULSES)
NOT USED
PHASE OUTPUT B (ISQUARE WAVE PULSES AT PHASE ANGLE OF 90 RELATIVE TO
A)
NOT USED
+12V
0V
NOT USED
POWER POSITIVE
POWER POSITIVE TO LINE CONTACTOR COIL
POWER POSITIVE TO ELECTROMAGNETIC BRAKE COIL
OPERATOR PRESENT SENSOR
+VBATT (*)
+VBATT (**)
+VBATT (**)
+VBATT
INPUT: MUST ALWAYS BE CONNECTED TO NEGATIVE FOR INVERTER TO BE

OPERATIVE. RECEIVES NEGATIVE FROM 11/F VIA CONTACT ON EPS-AC
(CONNECTORS 7 AND 11/B). IN THE EVENT OF A FAULT IN THE ELECTRIC
STEERING, THE CONTACT OPENS, REMOVING THE NEGATIVE FROM 5/F. DRIVE
POWER POSITIVE TO MOTOR TEMP. SENSOR
+9V
NOT USED
CHOPPED POWER NEGATIVE FOR LINE CONTACTOR
CHOPPED POWER NEGATIVE FOR ELECTROMAGNETIC BRAKE
NOT USED
NEGATIVE CONNECTED TO SAFETY INPUT 5F VIA CONTACT OF RELAY ON
ELECTRIC STEERING MODULE EPS BETWEEN PINS 7 AND 1B
POWER NEGATIVE FOR MOTOR TEMP. SENSOR
PWR 50% (**)

PWR 50% (**)
0V
0V
Table 1
+VBATT = battery voltage
The outputs 2F and 3F, which respectively power the line contactor and the electromagnetic brake,
are at 48V if measured relative to the battery negative. If instead they are measured relative to the
negatives of their corresponding components (8F for the line contactor and 9F for the
electromagnetic brake), the readings will be 24V on power up, falling to a steady value of 19V.
LINE CONTACTOR
ELECTROMAGNETIC
BRAKE
VOLTMETER
DESCRIPTION OF POWER CONNECTORS

+B = battery positive after closing of the line contactor
-B = battery negative
W -V -U = the 3 phases of the motor field supply
UPDATE
6 Date: Mar. 2002
Part No.: 524162546
Page: 19
MODULE DESCRIPTION
3.2 DRIVE CONFIGURATION CONNECTIONS (MODULE 2)
SERVICE
MODULE DESCRIPTION
4.0
PUMP MOTOR CONTROLLER CONFIGURATION
4.1
DESCRIPTION OF CONNECTORS
MOD. ALL MODELS
This chapter contains descriptions of the inputs/outputs of the AC2 INVERTER in the pump motor
controller configuration. Some of these inputs may be used for more than one function depending on how
the relative parameters are configured in the programming menu SET OPTIONS. Furthermore, if the
controller is interfaced with other modules via the CAN-BUS system, the connector E will not be utilised:
no actuators will be connected to it.
D5
A5
B5 C5
E5
F5
Fig. 14
Page: 20
Part No.: 524162546
Date: Mar. 2002
5 6
UPDATE
SERVICE
The following table describes the function of each input/output of the inverter when configured for pump
controlon the truck model indicated in this chapter.
FUNCTION
CONNECTOR
PIN
PROGRAMMING
CONSOLE
CONNECTION
DRIVE OR PUMP
CONFIG. MODE
CAN-BUS
CONNECTION
MOTOR ENCODER
CONNECTION
NOT USED
INPUT FOR CONTROL

OUTPUTS
ACTUATORS
1
2
3
4
5
6
7
8
1
2
1
2
3
4
1
2
3
4
5
6
1+14
1
2
3
4
I = IN
O = OUT
O
O
O
I
I/O
I/O
I/O
I/O
O
O
I
I
I
O
O
-
6
7
8
9
10
11
12
O
O
O
O
O
FUNCTION
ACTIVE
DESCRIPTION
SERIAL RECEPTION POSITIVE

NEGLIGIBLE
SERIAL TRANSMISSION POSITIVE
0V
+12
MUST BE CONNECTED BY JUMPER WITH A8 PROGRAMM. FLASH MEMORY (NOT USED)
CONNECTED WITH 2B
CONNECTED WITH1B
-
+12V
CAN-BUS LOW LEVEL

CAN-BUS LOW LEVEL
CAN-BUS HIGH LEVEL
CAN-BUS HIGH LEVEL
POWER POSITIVE
POWER NEGATIVE
PHASE A OUTPUT (SQUARE WAVE PULSES)
NOT USED
PHASE B OUTPUT (SQUARE WAVE PULSES AT PHASE ANGLE OF 90 RELATIVE TO A )
NOT USED
NOT USED
POWER POSITIVE
FLASHING LIGHT POWER POSITIVE (OPTIONAL)
POWER POSITIVE FOR INVERTERS COOLING FAN
NOT USED
INPUT: MUST ALWAYS BE CONNECTED TO NEGATIVE FOR INVERTER TO BE
OPERATIVE. CONNECTED WITH PIN 11F.
+VBATT (*)
+VBATT (**)
+VBATT
-
MOTOR TEMP. SENSOR POWER POSITIVE
+9
NOT USED
CHOPPED POWER NEGATIVE FOR FLASHING LIGHT
CHOPPED POWER NEGATIVE INVERTERS COOLING FAN
NOT USED
NEGATIVR CONNECTED TO SAFETY INPUT 5F
PWR 50%
PWR 50%
0V
0V
MOTOR TEMP. SENSOR POWER NEGATIVE
Table 2
(*)
(**)

The outputs 2Fand 3F, which respectively power the flashing light and the inverter cooling fan, are
at 48V if measured relative to the battery negative. If instead they are measured relative to the
negatives of their corresponding components (8F for the flashing light and 9F for the inverter cooling
fan), the readings will be 24V on hook up, falling to a steady value of 19V.
LINE CONTACTOR
ELECTROMAGNETIC
BRAKE
VOLTMETER
DESCRIPTION OF POWER CONNECTORS

+B = battery positive after closing of the line contactor
-B = battery negative
W -V -U = the 3 phases of the motor field supply
UPDATE
6 Date: Mar. 2002
Part No.: 524162546
Page: 21
MODULE DESCRIPTION
4.2 PUMP CONFIGURATION CONNECTIONS (MODULE 5)
MODULE DESCRIPTION
SERVICE

5.0 MHYRIO - Multifunctional Hydraulic Remote Input/output
MODULE 9
5.1 INTRODUCTION
Module 9, designated the MHYRIO, has the task of controlling the coils of all the solenoid valves, any
accessories such as the height indicator encoder, load cell and a series of actuators (inductive sensors)
related to the various hydraulic functions.
The MHYRIO interacts with the CAN-I/O module and the other modules via the CAN-BUS.
B9
G9
F9
E9
D9
A9
C9
Fig. 15
The table in the following paragraph contains descriptions of all the inputs and outputs of the MHYRIO.
Note that not all the inputs and outputs are always utilised. This will depend on the truck configuration. We
therefore recommend that you consult the connectors table in conjunction with the specific electrical
diagram for the truck in question, which can be found in the relative Service Manual.
The programming console can be directly connected to the MHYRIO.
Page: 22
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE

MOD. ALL MODELS
CONNECTOR
FUNCTION
CONN.
SENSORS
CONNECTION
CAN-BUS
CONNECTION
LOAD CELL
CONNECTION
(*)
PIN
HEIGHT ENCODER
CONNECTION
PROGRAMMING
CONSOLE
CONNECTION
SUPPLEMENTARY
SOLENOID VALVES
CONNECTION
SOLENOID VALVES
CONNECTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
I = IN
O = OUT
I
I
I
DESCRIPTION
INPUT FROM LIFTING SPEED REDUCTION SENSOR SW6
INPUT FROM CARRIAGE FORWARD REDUCTION SENSOR SW7
INPUT FROM CARRIAGE BACK REDUCTION SENSOR SW8
NOT USED
INPUT FROM LOWERING SPEED REDUCTION SENSOR SW6
POWER POSITIVE FOR SENSOR SW7-8
INPUT FROM FORK LOWERING LOCK SENSOR SW10
INPUT FROM LOAD PRESENCE SENSOR SW11
POWER NEGATIVE FOR SENSOR SW5
NOT USED
JUMPERED TO PIN 22
POWER POSITIVE FOR HEIGHT ENCODER RESET SENSOR SW5
NOT USED
POWER POSITIVE FOR SENSOR SW9
POWER POSITIVE FOR SENSOR SW10-11
POWER NEGATIVE FOR SENSOR SW7-8
POWER NEGATIVE FOR SENSOR SW10-11
JUMPERED TO PIN 11
CAN-BUS CONNECTION HIGH TO PIN 4C DRIVE AC2 TRAZIONE
INPUT FROM KEYSWITCH
48V POSITIVE TO PROPORTIONAL LOWERING VALVE EV1
CAN-BUS CONNECTION LOW TO PIN 2C DRIVE AC2
BATT. NEGATIVE
I
O
I
I
O
I
O
O
O
O
O
O
O
O
O
I
O
O
I
I
I
+48V
+VBATT (*)
+48V
+48V
+48V
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
48V BATT. POSITIVE

LOAD CELL INPUT SENSOR
NOT USED
NEGATIVE TO LOAD CELL

NOT USED
NOT USED
O
O
I
O
I
-
+5V
ENCODER SIGNAL A INPUT

MUST BE CONNECTED BY JUMPER WITH E8 PROGRAM. FLASH MEMORY (NOT USED)
O
O
MUST BE CONNECTED BY JUMPER WITH E7 PROGRAM. FLASH MEMORY (NOT USED)

NOT USED
CHOPPED POWER NEGATIVE FOR EV2 (OPTIONAL)
CHOPPED POWER NEGATIVE FOR EV1 (OPTIONAL)
CHOPPED NEGATIVE (NOT USED)
POWER POSITIVE FOR EV2 (OPTIONAL)
NOT USED
NOT USED
NOT USED
POSITIVE (NOT USED)
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
+12V
12V POSITIVE TO LOAD CELL

NEGATIVE TO HEIGHT ENCODER
ENCODER SIGNAL B INPUT
5V POSITIVE TO HEIGHT ENCODER
POWER POSITIVE FOR EV1 (OPTIONAL)

CHOPPED NEGATIVE FOR FORKS LEFT SHIFT EV8
CHOPPED NEGATIVE FOR FORKS RIGHT SHIFT EV7
CHOPPED NEGATIVE FOR FORKS TILT DOWN EV6
CHOPPED NEGATIVE FOR FORKS TILT UP EV5
CHOPPED NEGATIVE FOR CARRIAGE FORWARD EV4
CHOPPED NEGATIVE FOR CARRIAGE BACK EV3
CHOPPED NEGATIVE FOR FORKS LIFTING EV2
CHOPPED NEGATIVE FOR FORKS LOWERING EV1
POWER POSITIVE FOR FORKS TILT DOWN EV6
POWER POSITIVE FOR FORKS LIFTING EV2
POWER POSITIVE FOR CARRIAGE BACK EV3
POWER POSITIVE FOR FORKS LEFT SHIFT EV8
POWER POSITIVE FOR FORKS TILT UP EV5
NOT USED
POWER POSITIVE
POWER POSITIVE
UPDATE
ACTIVE
FUNCTION
+48V
+48V
+48V
+VBATT (*)
PWR 50%
PWR 50%
PWR 50%
+VBATT (*)
+VBATT (*)
+VBATT (*)
PWR 50%
PWR 50%
PWR 50%
PWR 50%
PWR 50%
PWR 50%
PWR 50%
PWR 50%
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
Table 3
5
Date: Mar. 2002
Part No.: 524162546
Page: 23
MODULE DESCRIPTION
MODULE DESCRIPTION
SERVICE

6.0 SICOS
MODULE 16
6.1 INTRODUCTION
The SICOS module controls the display of information related to the various functions, such as, for
example, the battery charge level, the operating hours of the truck and the individual modules, the position
of the steering wheel, the travel speed, and so on. The SICOS controller is integrated with the display unit
in a single module.
As the display functions vary according to the model of lift trucks, descriptions of the various screens and
messages can be found in the electrical system section of the Service Manual for the truck in question.
A1
B1
C1
D1
F1
E1
G1
Fig. 16
The table in the following paragraph contains descriptions of all the inputs and outputs of the SICOS
module.
Note that not all the inputs and outputs are always utilised. This will depend on the truck configuration. We
therefore recommend that you consult the connectors table in conjunction with the specific electrical
The programming console can be connected to the SICOS module via the adaptors code Yale 580026993
(supplied, available on connector E of the CAN I/O module) and Yale 580014574.
Page: 24
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE

MOD. ALL MODELS
CONN.
FUNCTION
CONNECTOR
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1-6
1-6
1-4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
1-16
PUSHBUTTONS
CONNECTION
B
C
D
I = IN
O = OUT
PROGRAMMING
CONSOLE
CONNECTION
CAN-BUS
CONNECTION
I
I
I
DESCRIPTION
INPUT FOR SLOW TRAVEL COMMAND WITH BATTERY OUT (SW 18)
INPUT FOR BRAKE COMMAND WITH TRUCK ON INCLINE (SW19)
INPUT FOR SOLENOID VALVE SWITCHING FOR OPTION FUNCTIONS (SW 22)
NOT USED
NOT USED
INPUT FOR SLOW TRAVEL COMMAND (SW 20)
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
INPUT FOR LOADED/UNLOADED COMMAND ON FORKS
NOT USED
NOT USED
NEGATIVE FROM BATTERY
NOT USED
NOT USED
NOT USED
NOT USED
FUNCTION
ACTIVE
48V
48V
48V
48V
48V
0V
NOT USED
NOT USED
NOT USED
PROGRAMMING CONSOLE
O
O
CAN-BUS LOW TO PIN 1F CAN I/O

CAN-BUS CONNECTION HIGH TO PIN 2F CAN I/O
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
POSITIVE FROM BATTERY
I
I
+VBATT (*)
0V
NOT USED
Table 4
(*)
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 25
MODULE DESCRIPTION
MODULE DESCRIPTION
SERVICE

7.0 CAN I/O
MODULE 1
7.1 INTRODUCTION
Module 1, designated CAN I/O, has the task of controlling the majority of the inputs that enable the various
functions of the truck. With its internal software and sophisticated microprocessor control, the CAN I/O
module, acting on the basis of the enabled inputs, sends information related to the requested functions to
the other modules in the system via the CAN-BUS. The other modules in turn process the information
received from the CAN I/O and send the appropriate output signals to the components under their control
(motors, solenoid valves etc.).
The table in the following paragraph contains descriptions of all the inputs and outputs of the CAN I/O
module.
Note that the function of many of the inputs will depend on the truck configuration and form the parameters
set in the SET OPTIONS programming menu of the CAN I/O module. We therefore recommend that
you consult the connectors table in conjunction with the specific electrical diagram for the truck in question,
which can be found in the relative Service Manual.
A1
B1
C1
D1
E4
F4
G4
Fig. 17
NOTES
- If the single JOYSTICK ITT is connected simultaneously with the other single function control levers,
priority will be given to the JOYSTICK as it is connected via the CAN-BUS.
- If only the single JOYSTICK is connected to the CAN I/O module, on disconnecting the joystick the alarm
CAN-BUS KO JOY will be displayed. This occurs also in the event of a malfunction of the JOYSTICK.
- The programming console can be connected to the CAN I/O module via the adaptors code Yale
580026993 (supplied, available on connector E of the CAN I/O module) and Yale 580014574.
Page: 26
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE

MOD. ALL MODELS
CONN.
FUNCTION
CONNECTOR
JOYSTICK
CONNECTION
JOYSTICK
CONNECTION
(*)
MULTIFUNCTION
JOYSTICK
CONNECTION
PROGRAMMING
CONSOLE
CONNECTION
CAN-BUS
CONNECTION
SERVICE SENSORS
CONNECTION
DESCRIPTION
I = IN
O = OUT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DRIVE
POTENTIOMETER
CONNECTION
PIN
NOT USED
NOT USED
NOT USED
O
I
DRIVE POTENTIOMETER POSITIVE

POTENTIOMETER INPUT SIGNAL
DRIVE POTENTIOMETER
+5V
NOT USED
I
I
I
O
O
O
O
O
O
I
I
O
I
I
O
I
I
O
I
I
O
O
I
I
O
O
O
O
O
I
I
I
I
I
I
I
I
O
NOT USED
INPUT OF BATTERY OUT SENSOR SW16
NOT USED
NOT USED
NOT USED
POSITIVE FROM HORN BUTTON SW21
POSITIVE FROM SEAT MICROSWITCH SW17
NOT USED
NOT USED
POSITIVE (NOT USED)
NEGATIVE (NOT USED)
POSITIVE (NOT USED)
POSITIVE (NOT USED)
NEGATIVE (NOT USED)
NEGATIVE (NOT USED)
INPUT FOR LIFT/LOWER COMMAND FROM JOYSTICK
CENTERING OF LIFT/LOWER JOYSTICK POTENTIOMETER
POWER POSITIVE TO JOYSTICK POTENTIOMETER
INPUT FOR CARRIAGE FORWARD/BACK COMMAND FROM JOYSTICK
CENTERING OF CARRIAGE FORWARD/BACK JOYSTICK POTENTIOMETER
POWER NEGATIVE TO JOYSTICK POTENTIOMETER
INPUT FOR TILT UP/DOWN COMMAND FROM JOYSTICK
CENTERING OF TILT UP/DOWN JOYSTICK POTENTIOMETER
POWER POSITIVE TO JOYSTICK POTENTIOMETER
INPUT FOR SHIT LEFT/RIGHT COMMAND FROM JOYSTICK
CENTERING OF FORKS SHFT LEFT/RIGHT JOYSTICK POTENTIOMETER
POWER NEGATIVE TO JOYSTICK POTENTIOMETER
POWER POSITIVE TO MULTIFUNCTION JOYSTICK
SERIAL INPUT FROM MULTIFUNCTION JOYSTICK
SERIAL INPUT FROM MULTIFUNCTION JOYSTICK
POWER NEGATIVE TO MULTIFUNCTION JOYSTICK
NOT USED
NOT USED
NOT USED
NOT USED
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+VBATT (*)
+0 - 5V
+2,5V
+5V
+0 - 5V
+2,5V
0V
+2,5V
+5V
+2,5V
0V
+12V
0V
0V
+12V
CAN-BUS LOW TO PIN 14A EPS AND 1F SICOS

CAN-BUS CONNECTION HIGH TO PIN 4A EPS AND 2F SICOS
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
POSITIVE FROM BATTERY
INPUT OFACCELERATOR SENSOR SW14
INPUT OF BRAKE SENSOR SW15
INPUT OF FORWARD TRAVEL SENSOR SW12
INPUT OF REVERSE TRAVEL SENSOR SW13
POSITIVE FROM MAN PRESENT PEDAL
POSITIVE FROM EMERGENCY CONTACTOR
CHOPPED POWER NEGATIVE TO ALARM BUZZER
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
POWER POSITIVE TO ALARM BUZZER
UPDATE
FUNCTION
ACTIVE
+VBATT (*)
0V
+48V
+48V
+48V
+48V
+VBATT (*)
+VBATT (*)
PWR 50%
+VBATT (*)
Table 5
4
Date: Mar. 2002
Part No.: 524162546
Page: 27
MODULE DESCRIPTION
MODULE DESCRIPTION
SERVICE

8.0 EPS-AC (Electric Power Steering AC)
MODULE 6
8.1 INTRODUCTION
Module 6, designated the EPS-AC, has the task of controlling the 3-phase induction steering motor.
Acting through a stepping motor that functions as a transducer, the EPS-AC module transforms
movements of the steering wheel into electrical current that turns the 3-phase motor and consequently the
steering road wheel in proportion to the movement of the steering wheel and the drive speed. The module
is connected to a number of essential components.
In addition to the stepping motor, there is an encoder bearing on the motor, which is necessary to determine
the direction of the steering action; a zero position sensor that provides the wheel centered reference
signal and a thermal sensor located inside the steering motor housing. There are therefore 4 CAN-BUS
connections to be interfaced with the other modules.
Inside the EPS-AC there is a relay the contact of which is connected to pins 7/b and 1/b. During normal
operation of the electrical steering, the relays coil is continuously energised and its contact is closed.
In the event of an anomaly in the electrical steering system, the coil is de-energised and contact opens.
This contact is normally connected to the drive control so that the drive function will be disabled if there is
a malfunction of the steering system.
More detailed information can be found in the specific manual for the EPS-AC.
Note that the function of many of the inputs/outputs will depend on the truck configuration and the module
settings.
We therefore recommend that you consult the connectors table in conjunction with the specific electrical
B6
A6
C6
Fig. 18
Page: 28
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE

MOD. ALL MODELS
CONN.
(*)
FUNCTION
CONNECTOR
I = IN
O = OUT
PIN
CAN-BUS ENCODER
CONNECTION
CAN-BUS
CONNECTION
PROGRAMMING
CONSOLE
CONNECTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
O
O
O
O
O
O
O
O
I
I
O
O
O
O
O
I
O
I
I
O
O
FUNCTION
ACTIVE
DESCRIPTION
NOT USED
NOT USED
CAN-BUS CONNECTION HIGH AT PIN 4C PUMP AC2
CAN-BUS CONNECTION HIGH AT PIN 2F CAN I/O
POWER POSITIVE FOR STEERING MOTOR ENCODER
POWER NEGATIVE FOR STEERING MOTOR THERMOSTAT
STEER MOTOR ENCODER NEGATIVE
NOT USED
NOT USED
POWER POSITIVE FOR STEERING MOTOR THERMOSTAT
NOT USED
CAN-BUS CONNECTION LOW AT PIN 2C PUMP AC2
CAN-BUS CONNECTION LOW AT PIN 1F CAN I/O
NOT USED
INPUT A OF STEERING MOTOR ENCODER
INPUT B OF STEERING MOTOR ENCODER
NOT USED
NOT USED
NOT USED
BATTERY NEGATIVE TO DRIVE AC2 PIN 11-F
POWER POSITIVE FOR STEERING CENTRED SENSOR SW4
POWER SUPPLY FOR STEERING WHEEL STEPPING MOTOR
POWER SUPPLY FOR STEERING WHEEL STEPPING MOTOR
POWER NEGATIVE FOR STEERING CENTERED SENSOR SW4
NOT USED
BATTERY NEGATIVE SAFETY FROM DRIVE AC2 PIN 5-F
NOT USED
POWER SUPPLY FOR STEERING MOTOR
NOT USED
POSITIVE FROM KEYSWITCH
POSITIVE INPUT FROM STEERING CENTERED SENSOR
USED)
USED)
+5V
0V
+16V
+5V
0V
0V
+VBATT (*)
+16V
NEGLIGIBLE
0V
+12V
Table 6
UPDATE
+5V
0V
0V
Date: Mar. 2002
Part No.: 524162546
Page: 29
MODULE DESCRIPTION
MODULE DESCRIPTION
SERVICE

NOTE:
Page: 30
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
UPDATE
PROGRAMMING THE MODULES ........................................... 32
USING THE PROGRAMMING CONSOLE ................................ 34
PROGRAMMING THE CONTROLLER ..................................... 37
POSITION OF THE PC/CONSOLE CONNECTORS

ON THE MODULES ................................................................. 48
DRIVE CONTROL AC2 INVERTER - SUBMENUS ................... 49
PUMP CONTROL AC2 INVERTER - SUBMENUS ................... 54
CAN I/O - SUBMENUS ............................................................ 56
MHYRIO - SUBMENUS ........................................................... 61
SICOS - SUBMENUS .............................................................. 65
Date: Mar. 2002
Part No.: 524162546
PROGRAMMING
PROGRAMMING
Page: 31
SERVICE
9.0 PROGRAMMING THE MODULES
9.1 INTRODUCTION
PROGRAMMING
After installation, each individual module must be programmed with the parameter settings recommended
by the manufacturer for the particular truck model.
A settings table is always provided in the electrical system section of the Service Manual.
Each module must be programmed using the special programming console or a PC equipped with specific
software and an interface cable.
With either of these tools, the user can perform a diagnostic analysis of any anomalies in the system using
the TESTER and ALARMS menus.
This chapter deals with the following topics:
-
Introduction to the programming console and software with PC interface cable.

Use of the programming console.
Information on how to access the individual programming menus on the console.
Description of the programming parameters for each module.
9.2 PROGRAMMING TOOLS

9.2.1 PERSONAL COMPUTER
With the aid of a PC, specific software and the connection cable shown in the figure you can access all
the available programming and diagnostic menus.
Instructions for installation of the software are included in the kit. As the software is very simple and intuitive,
we need not concern ourselves here with instructions on its use, but instead we can move on to a
description of the programming console.
Kit code:
Yale 272210700
Fig. 19
Page: 32
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
9.2.2 PROGRAMMING CONSOLE

INTRODUCTION
PROGRAMMING
The programming console is designed to facilitate the calibration and fault diagnosis of controllers.
Featuring the latest microprocessor technology, the console is connected to the controller via a cable that
serves for both data transmission (serial line) and power.
Messages are displayed in alphanumeric characters on an LCD with 2 rows of 16 characters.
DISPLAY
Console Code:
Yale 272210700
CONNECTOR
CONSOLE
CONNECTOR
KEYS
The console offers the following advantages:

- Quick and simple programming of operating parameters, obviating the need to access awkward
parts of the machine to make adjustments on the trimmers; in addition, parameters can be edited in real
time while the machine is running, thus allowing immediate verification.
- Rapid fault diagnosis.
The user can monitor the controller input signals in real time (potentiometer signal, currents, voltages,
etc).
Furthermore, in the event of a controller malfunction, the console can display the type of alarm in
progress.
For more in-depth diagnostics, the user can display the last 5 alarms to be activated.
- Standardized parameter settings:
Once the parameters have been optimized on one machine, they can be saved in the console memory,
from where they can be quickly and easily transferred to other machines.
.
- Special functions, such as acquisition of the potentiometer range.
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 33
SERVICE
10.0 USING THE PROGRAMMING CONSOLE
TAKE CARE TO OBSERVE THE CORRECT POLARITY WHEN PLUGGING THE CONSOLE
CONNECTOR INTO THE CONTROLLER.
FUNCTION KEYS
Description of the function keys:
Key 3 (ENTER)
PROGRAMMING
DISPLAY
Used to confirm the selected options.

Key 4 (OUT)
Used to exit the current function.
CONNECTOR
CONSOLE
Key 5 (SET UP)
CONNECTOR
Serves to increase parameter value

or to select the type of I/O connected.
KEYS
Key 6 (SET DOWN)

Serves to decrease parameter value
or to select the type of I/O connected.
Key 1 (ROLL UP)
Key 2 (ROLL DOWN)
Serves to select the next item or menu

option.
Serves to select the previous item or menu.
CONSOLE CONNECTOR
CONNECTION TO THE CONTROLLER

B
THE CONNECTION MUST BE MADE WHEN THE TRUCK IS

SWITCHED OFF as the controller and the console perform the
connection test only on power-up.
Plug the programming console connector into controller connector,
removing the protective cover, if present.
Take care to observe the correct polarity when connecting
the console connector.
Note: an adapter cable may required to connect the console to some modules/controllers.
Page: 34
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
On power up, the console attempts to establish a connection with the controller and displays the following
message:
CONNECTED: TO
NO COMMUNICATION
If this message appears, check that the physical connections have been made in accordance with the
enclosed diagrams. WARNING: it is possible that the correct polarity was not observed when the console
connector was connected to the controller. In the majority of cases this will have caused irreparable
damage to the console which will therefore have to be replaced.
If the display shows the message:
CONTROLLER NOT OK
this means that the controller is not compatible with the console to which it is connected.
If communication between the controller and console is established correctly, the following message will
appear:
AC2T 2B NA0.21
48V 350A 00000
The information displayed in this message is as follows:
AC2T 2B = Controller model.
NA 0.21 = version of program installed on the EPROM of the controller.
48V = nominal supply voltage.
350A = maximum current permitted by the system.
00000 = controller operating hours.
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 35
PROGRAMMING
If the connection attempt fails, the console displays the following message:
SERVICE
10.1 CONSOLE FUNCTIONS MAP
MAXIMUM
CURRENT
EPROM
VERSION
MODULE NAME
XXXX
XX XXX
XXXX
XXXX
MODULE DUTY
HOURS
PROGRAMMING
POWER SUPPLY
VOLTAGE
MAIN MENU
MAIN MENU
PARAMETER CHANGE
Serves to access the

programming function of the
various modules while
remaining connected to the
same module
CONFIG MENU
SET MODEL
Serves to analyze the input

and output signals
3
4
Serves to upload the Controller

program to the console. 32
memory locations available
Module configuration menu.

Serves to configure functions,
inputs and outputs
CONFIG MENU
SET OPTIONS
3
4
Serves to download a
previously saved program from
the console to the Controller
MAIN MENU
ALARMS
Contains the parameters that

serve to modify aspects of
truck performance
CONFIG. MENU
MAIN MENU
RESTORE PARAMETERS
+5
MAIN MENU
SAVE PARAMETERS
MAIN MENU
TESTER
Display the latest 5 alarms

stored in the memory
Allows fine adjustment of

accessories such as, for
example, potentiometers (if
present)
CONFIG MENU
ADJUSTMENTS
MAIN MENU
PROGRAM VACC
3
4
Procedure for fine adjustment

of accelerator potentiometer
via software
1
MAIN MENU
MOTOR DATA
3
4
Not Available
NOTE: the circled numbers between the menus indicate which key to press to move from one
menu to another (see figure above).
ACCESSING AND USING THE MENUS
The same procedure is used to access each menu on all modules. The only difference being that certain
menus are not available on some modules.
Page: 36
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
11.0 PROGRAMMING THE CONTROLLER

11.1 CONFIG. MENU
SET MODEL
ADJUSTMENTS
SET OPTION
CONFIG.MENU
As the CONFIG. MENU is a module configuration menu, once the parameters have been set on first
installation of the module, further modifications will not be required.
The procedures for programming the parameters of the CONFIG. MENU are described below.
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 37
PROGRAMMING
In order to operate correctly, the controller must be informed of the choices made with regard to the power
and control circuits and the power supply voltage utilized. The controller acquires this information by
means of the programming console.
Controller configuration is carried out by setting the parameters in the various submenus of the CONFIG.
MENU:
SERVICE
11.1.1
CONFIG. MENU / SET MODEL
PROGRAMMING
This submenu enables the user to access the programming functions for all the MODULES in the system
while remaining connected to the same module.
This is made possible by the CAN-BUS data transmission system.
All you need to do is connect the console to the most convenient module in order to display or program the
menus in any of the system modules. The procedure is described below.
Instructions for setting the parameters of the SET MODEL menu using the console:
DISPLAY
1)
Initial display
2)
Press ROLLUP+SETUP simultaneously
3)
The heading of the SET MODEL menu is displayed
4)
Press ENTER
5)
The number of the module to which you are connected

is displayed.
6)
Use SET UP or SET DOWN to select the module you

wish to connect to
7)
The new module is displayed
8)
Press OUT to quit the selection procedure
9)
A prompt asking you to confirm the change is displayed
CANIO
NA 0.15
48V
300 A 0000
KEYPAD
CONFIG MENU
SET MODEL
CONNECTED TO
1
CONNECTED TO
5
ARE YOU SURE?

YES = ENTER NO = OUT
10) Press ENTER to confirm or OUT to cancel the change

CONFIG MENU
SET MODEL
11) The heading of the SET MODEL menu is displayed

12) Press simultaneously ROLL DOWN, OUT, SET
DOWN
AC2P 2B NA 0.21
48V
350 A 0000
Page: 38
Part No.: 524162546
13) The display for the selected module will appear

from which you can proceed with the display or
programming all its menus
Date: Mar. 2002
UPDATE
SERVICE
11.1.2
CONFIG. MENU / SET OPTIONS
This submenu enables the user to set up controller operation according to the type of connection made
on the auxiliary control connectors and to select options, where available.
The procedure for accessing this submenu is described below.
DISPLAY
AC2T
48V
2B
NA 0.21
350 A
0000
KEYPAD
CONFIG MENU
SET MODEL
CONFIG MENU
SET OPTIONS
HOUR COUNTER
RUNNING
STOP ON RAMP
ON
1)
Initial display on power up
2)
Press ROLL UP + SET UP to access the SET

OPTIONS menu
3)
4)
Press ROLL UP to select the SET OPTIONS

submenu
5)
The heading of the SET OPTIONS menu is

displayed
6)
Press ENTER to access the menu
7)
The first menu option is displayed
8)
Press ROLL UP or ROLL DOWN to scroll through

the options until you find the one that interests you.
9)
A new option is displayed
10) Press SET UP or SET DOWN to change the

setting
11) The new setting is displayed
STOP ON RAMP
OFF
12) Press OUT to quit the menu

13) A prompt asking you to confirm the change is
displayed
ARE YOU SURE?

14) Press ENTER to confirm the change, or press

OUT to cancel the change
15) The heading of the SET OPTIONS menu is
displayed
CONFIG MENU
SET OPTIONS
16) Press OUT to return to the initial display
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 39
PROGRAMMING
Instructions for programming the SET OPTIONS parameters using the console:
SERVICE
11.1.3
CONFIG. MENU / ADJUSTMENT
Programming of the ADJUSTMENT submenu serves to inform the controller of the type of power supply
that it will receive and to carry out any adjustments, where present.
Instructions for setting the parameters of the ADJUSTMENT submenu using the programming console:
DISPLAY
AC2T 2B
NA 0.21
48V
350 A
0000
PROGRAMMING
KEYPAD
CONFIG MENU
SET MODEL
CONFIG MENU
ADJUSTMENTS
SET BATTERY TYPE

48V
ADJUST. BATTERY
48.2V
1)
2)
Press ROLL UP + SET UP to access the

ADJUSTMENTS menu
3)
4)
Press ROLL DOWN to select the ADJUSTMENTS menu
5)
The heading of the ADJUSTMENTS menu is displayed
6)
Press ENTER to access the menu
7)
The first menu item is displayed (to change the value,

press SET UP or SET DOWN)
8)
Press ROLL UP or ROLL DOWN to scroll through the

options.
9)
A new option is displayed
10) Press SET UP or SET DOWN to change the setting

ADJUST. BATTERY
48.7V
11) The new setting is displayed

12) Press OUT to quit the menu
ARE YOU SURE?

13) A prompt asking you to confirm the change is displayed

14) Press ENTER to confirm the change, or press OUT to
cancel the change
CONFIG MENU
ADJUSTMENTS
15) The heading of the ADJUSTMENTS menu is displayed

16) Press OUT to return to the initial display
Page: 40
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
11.2 MAIN MENU

The MAIN MENU is certainly the most important of all the menus. It contains the submenus that allow the
user to vary the performance characteristics of the truck to suit requirements, to display the status of the
various inputs and outputs via the TESTER submenu, to display the log of the last 5 alarms, etc. (for more
details, see the MENU MAP).
MAIN MENU
PROGRAMMING
PARAMETER CHANGE
TESTER
SAVE PARAMETERS
RESTORE PARAMETERS
ALARMS
PROGRAM VACC
MOTOR DATA
In the following pages we explain how to access the various menus using the console.
NOTES:
11.2.1
MAIN MENU / PARAMET. CHANGE
Truck operating characteristics, such as, for example, acceleration, release braking intensity, maximum
current, etc., can be easily adjusted to suit any specific operating requirements by using the console to
change the parameter settings in the PARAMETER CHANGE menu.
For each parameter there are 10 possible programming levels.
After changing each individual parameter, you can immediately check the effect on truck operation without
having to exit the programming menu.
On completion of programming, which must be done in accordance with the instructions given below,
it is essential to disconnect the power supply to the controller by setting the keyswitch to OFF
so that the new parameters are saved in the controllers non-volatile memory.
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 41
SERVICE
Instructions for programming the parameters of the PARAMETER CHANGE submenu using the console:
DISPLAY
AC2T 2B NA 0.21
48V 350 A
0000
KEYPAD
PROGRAMMING
MAIN MENU
PARAMETER CHANGE
ACCELER DELAY
LEVEL = 4
INVERS. BRAKING
LEV = 5
INVERS. BRAKING
LEV = 6
1)
Initial display
2)
Press ENTER to access the main menu
3)
The heading of the first item, PARAMETER

CHANGE, is displayed
4)
Press ENTER to access the PARAMETRI function
5)
The first parameter in the list is displayed
6)
Use ROLL UP and ROLL DOWN to scroll through

the list of parameters
7)
The various parameters are displayed
8)
Use SET UP and SET DOWN to change the

programmed level
9)
The new value is displayed
10) Press OUT to quit the programming procedure
ARE YOU SURE?

11) A prompt asking you to confirm the changes is

displayed
12) Press ENTER to confirm or OUT to cancel the
change
MAIN MENU
PARAMETER CHANGE
Page: 42
Part No.: 524162546
13) The heading PARAMETER CHANGE is displayed

14) Press ROLL UP or ROLL DOWN to scroll through
the other options, or press OUT to return to the initial
display
Date: Mar. 2002
UPDATE
SERVICE
11.2.2
MAIN MENU / TESTER
The TESTER function makes it possible to monitor in real time the status of the control sensors and drive
signal, the instantaneous current and voltage supplied to the drive motor and other important information,
all given in the table, that may be useful in troubleshooting.
Instructions for displaying the options of the TESTER submenu using the console:
AC2T 2B NA 0.21
48V 350 A
0000
KEYPAD
MAIN MENU
PARAMETER CHANGE
MAIN MENU
TESTER
MOTOR VOLTAGE
0.0 %
FORWARD SWITCH
OFF
GND
1)
Initial display
2)
3)
The first item in the list is displayed
4)
Scroll through the list using ROLL UP or ROLL DOWN

and select TESTER
5)
The selected item is displayed (TESTER)
6)
Press ENTER to access the TESTER function
7)
The first tested signal is displayed
8)
Scroll through the list of tested signals using ROLL UP or

ROLL DOWN
9)
The various signals are displayed
PROGRAMMING
DISPLAY
10) To return to the initial display press OUT

MAIN MENU
TESTER
UPDATE
11) The initial display appears
Date: Mar. 2002
Part No.: 524162546
Page: 43
SERVICE
PROGRAMMING
11.2.3
MAIN MENU / SAVE PARAMETER
The SAVE PARAM. function allows you to download to the console memory, the configuration data and
parameters relative to controller programming. The console can store up to 30 programs. Each program
stored in the console can be loaded on to another controller using the function RESTORE PARAM.
The SAVE PARAM. function allows you to upload the following data on the console:
- all the parameter settings (PARAMETER CHANGE);
- the options settings (SET OPTIONS);
- the model setting (SET MODEL).
Service technicians should ensure that programs for all the truck models used in the area for which they
are responsible are stored on their personal console. In this way, whenever a controller requires
replacement, once the new unit has been installed, it can be programmed with the same data as the old
unit using the RESTORE PARAM. function.
Controllers purchased as replacement parts are supplied with a standard program already loaded, but to
obtain the best performance from each truck the specific program for the relevant model must be
downloaded to the controller.
IMPORTANT: The parameters must be uploaded from the intersted module.
Instructions for using the SAVE PARAM. function from the console:
DISPLAY
AC2T 2B
NA 0.21
48V
350 A
0000
KEYPAD
MAIN MENU
PARAMETER CHANGE
MAIN MENU
SAVE PARAM.
1)
Initial display
2)
3)
4)

and select SAVE PARAM.
5)
The selected option is displayed (SAVE PARAM.)
6)
Press ENTER to access the SAVE function
7)
The top line displays the selected model code, while the
bottom line will either shows the message FREE, if the code
has not been assigned to a model,
or the name of the model associated with the code
8)
Use ROLL UP and ROLL DOWN to select the required

model code
9)
A new code is displayed along with the relative status (FREE

/ Model Name)
SELECT: Mod. 00
FREE
SELECT: Mod. 01
FREE
10) Press ENTER to confirm the read operation

READING ....
ACCELER. DELAY (ECC.)
MAIN MENU
SAVE PARAM.
Page: 44
Part No.: 524162546
11) The second line of the display will scroll through the list of
saved parameters
12) On completion of the operation, the message SAVE PARAM.
will reappear
Date: Mar. 2002
UPDATE
SERVICE
11.2.4
MAIN MENU / RESTORE PARAM.
The RESTORE PARAM function allows you to transfer any of the programs of the models stored in the
console memory using the SAVE PARAM. function, this making it possible to download to the controller
all the data relative to the truck model in a single operation.
Data loaded into the controller using the RESTORE PARAM. function are as follows:
- all the parameter values (PARAMETER CHANGE);
- the options settings (SET OPTIONS);
- the model setting (SET MODEL);
IMPORTANT: The parameter must be down loaded directly to the intersted module
DISPLAY
AC2T 2B
NA 0.21
48V
350 A
0000
KEYPAD
MAIN MENU
PARAMETER CHANGE
MAIN MENU
RESTORE PARAM.
SELECT: Mod. 00
H2 STANDARD
1)
Initial display
2)
3)
4)
Scroll through the list using ROLL UP or ROLL DOWN,

and select RESTORE PARAM.
5)
The selected item is displayed (RESTORE PARAM.)
6)
Press ENTER to access the RESTORE PARAM. function
7)
The top line shows the selected model code, while the
bottom line shows the type of controller in the memory (or
FREE if the memory is unoccupied)
8)
Use ROLL UP and ROLL DOWN to select the required

model code
9)
The selected model code will be shown together with the

relative type of controller in the memory
SELECT: Mod. 01
H2 REGENER.
10) Press ENTER to confirm the download procedure

11) A prompt asking you to confirm the operation is displayed
ENTER = YES, OUT = NO.
ARE YOU SURE?

12) Press ENTER to confirm the download operation

(OUT to abandon)
13) During the download operation, the display scrolls through
the list of parameters
STORING
ACCELER. DELAY ....
14) On completion of the operation, the submenu heading is

displayed.
MAIN MENU
RESTORE PARAM.
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 45
PROGRAMMING
WARNING: the RESTORE PARAM., operation overwrites data in the controller, consequently the data
previously stored in the memory will be lost.
Instructions for using the RESTORE PARAM. function with the console:
SERVICE
11.2.5
MAIN MENU / ALARMS
The controller stores the last 5 alarm events in its memory, recording the relative identification code, the
number of times that the same alarm has been activated and the temperature of the controller when the
alarm was tripped.
These alarms may be displayed on the console by interrogating the ALARMS submenu in the MAIN
MENU.
This function allows a more in-depth diagnosis of the electrical system, supplying historical data about the
controller
PROGRAMMING
Instructions for accessing the ALARMS function from the console:
DISPLAY
AC2T 2B
NA 0.21
48V
350 A
0000
KEYPAD
MAIN MENU
PARAMETER CHANGE
MAIN MENU
ALARMS
00007
00009
CODE
#02
CODE
#05
120
1)
2)
3)
4)
Scroll through the list with ROLL UP or ROLL DOWN and

select ALARMS.
5)
The selected item is displayed (ALARMS).
6)
Press ENTER to access the ALARMS function
7)
The display shows the code of the most recently

generated alarm, the hour counter value, the number of
times the alarm has been activated, and the program line
being scanned at the time the alarm was activated
8)
Use ROLL UP to scroll through the list of previous alarms

and DOWN to return to the more recent alarms
9)
Another alarm code is displayed. If there have been no

alarms the display shows ALARM NULL.
090
10) Press OUT to quit the ALARMS menu
CLEAR LOGBOOK?
Page: 46
Part No.: 524162546
11) A prompt is displayed asking you to confirm deletion of the

alarms memory
12) Press ENTER to delete. Press OUT to return to the main
menu
Date: Mar. 2002
UPDATE
SERVICE
11.2.6
MAIN MENU / PROGRAM VACC
Through this function, the controller acquires the minimum and maximum values of the potentiometer
signal, which are taken as the upper and lower speed control limits. This allows you to compensate for any
asymmetry in the potentiometer control mechanism or any errors in the fine mechanical adjustment.
Obviously this submenu is not available on all the controllers/modules.
DISPLAY
CANIO
NA 0.15
48V
300 A
0000
1)
Initial display
2)
3)
4)

and select PROGRAM VACC.
5)
The selected item is displayed (PROGRAM VACC).
6)
Press ENTER to access the PROGRAM VACC. function
7)
The minimum and maximum values currently assigned to

the potentiometer signal are displayed
8)
Press ENTER
9)
The controller is now ready to accept the new minimum

and maximum values of the potentiometer signal
KEYPAD
MAIN MENU
PARAMETER CHANGE
MAIN MENU
PROGRAM VACC
VACC SETTING
0.0
5.0
MIN
0.0
VACC
-
MAX
0.0
10) Press the accelerator pedal or turn the butterfly control

slowly until you reach the relative limit position
MIN
1.7
VACC
-
11) The display will show the new min. and max values.
The arrow indicates the selected travel direction
MAX
4.8
12) Press OUT

ARE YOU SURE?
13) A prompt is displayed asking you to confirm acquisition of

the new values
14) Press ENTER to confirm or OUT to cancel
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 47
PROGRAMMING
Instructions for using the PROGRAM VACC function from the console:
SERVICE
12.0 POSITION OF THE PC/CONSOLE CONNECTORS ON THE MODULES
(indicated by C)
PROGRAMMING
Fig. 20
No adaptor required
Fig. 21
No adaptor required
E9
C
C
E1
Fig. 22
Fig. 23
2 adaptors required
2 adaptors required
C
E4
Fig. 24
2 adaptors required
Codes of adaptors for Sicos - Mhyrio Can I/O:

C
-Yale 580026993 (supplied, available on the

connector of the CAN I/O module)
-Yale 580014574 (the same adaptor as that used
for the Combi controllers - available as spare part)
Page: 48
Part No.: 524162546
Date: Mar. 2002
Fig. 25
No adaptor required
0
UPDATE
SERVICE
13.0 DRIVE CONTROL AC2 INVERTER (Module 2) - SUBMENUS
ACCELER. DELAY:
The time the motor takes to accelerate from zero to the set maximum
speed with the accelerator fully depressed.
Possible settings range from 0 to 9:
0 = maximum acceleration
9 = minimum acceleration
RELEASE BRAKING:
Controls the deceleration ramp applied on release of accelerator.

0 = minimum deceleration
9 = maximum deceleration
INVERSION BRAKING:
Controls the braking ramp applied on inversion of the current supplied to

the motor (PLUGGING BRAKING) when the direction of travel is reversed.
0 = minimum braking intensity
9 = maximum braking intensity
PEDAL BRAKING:
Controls the electrical braking ramp applied when the switch enabled by
the brake pedal is closed on the battery positive.
0 = minimum braking intensity
9 = maximum braking intensity
MAX SPEED FORW:
Determines the maximum speed for forward travel.

Possible settings range from 33 Hz to 114 Hz:
33 Hz = minimum speed setting
114 Hz = maximum speed
MAX SPEED BACK:
Determines the maximum speed for reverse travel.

Possible settings range from 33 Hz 115 Hz:
33 Hz = minimum speed setting
114 Hz = maximum speed
CURVE CUTBACK:
Speed reduction applied when the steering angle is at the maximum value
(90). Expressed as a percentage of the maximum speed. The speed
reduction is proportional to the steering angle, rising to the maximum value
set here at a steering angle of 90.
STEER DEAD ANGLE:
Steering angle zone in which no speed reduction CURVE CUTBACK) is

applied. Expressed as a percentage of the maximum steering angle.
FREQUENCY CREEP:
Start speed on closure of the start sensor.

Expressed in Hz.
MAXIMUM CURRENT:
Maximum current applied to the motor, controlled by the inverter.
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 49
PROGRAMMING
13.1 MAIN MENU - PARAMETER CHANGE (AC2 drive control)
SERVICE
PROGRAMMING
AUXILIARY TIME:
Determines the length of time for which the truck is held in stall condition
on a ramp on releasing the accelerator.
This parameter is only activated if the STOP ON RAMP-ON function is
enabled in the SET OPTIONS submenu of the CONFIG MENU.
Possible settings range from 0 to 5
0 = minimum stall time
5 = maximum time
NOTE: We recommend that you maintain the factory settings as these have been calculated to
provide an optimum compromise between performance and component wear. However, performance characteristics may be customised to suit the particular needs of the user and the
application.
Do not alter the parameter settings relative to the maximum currents.
Do not alter any factory setting if doing so compromises the operational safety of the truck .
NOTE:
Page: 50
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
INPUT M ONITORED
STATUS
DESCRIPTION
MOTOR VOLTAGE
0%
Voltage supplied by the inverter to the m otor; expressed

as a percentage of the m axim um voltage (which
depends on the battery voltage)
FREQUENCY
0,00 Hz
Frequency of the voltages and currents supplied to the

m otor
ENCODER
0,00 Hz
Motor speed expressed in term s of the frequency of

pulses from the encoder
SLIP VALUE
0,00 Hz
Slip value expressed in term s of frequency: the

difference between the synchronous speed and the
speed of the m otor rotor
CURRENT RM S.
0A
TEMPERATURE
25 C
Tem perature of the inverter m easured at the alum inium

heatsink
MOTOR TEM PERATURE
18 C
Motor tem perature
ACCELERATOR
0%
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FORW ARD SW ITCH
BACKW ARD SW ITCH
ENABLE SW ITCH
DEAD M EN SW ITCH
CUTBACK SW ITCH
BRAKE SW ITCH
Effective m otor current
Accelerator pedal percentage level

OFF / GND
Level of forward travel input
ON / +VB
OFF / GND
Level of reverse travel input
ON / +VB
OFF / GND
Level of accelerator pedal start input
ON / +VB
OFF / GND
Level of dead m an input
ON / +VB
OFF / +VB
Level of speed reduction input (F10)
ON / GND
OFF / GND
Level of brake pedal input
ON / +VB
BRAKEPEDAL POT.
0%
Brake pedal pressed percentage
VOLTAGE BOOSTER
0%
Booster for voltage supplied to m otor; expressed as % of

m axim um voltage
BATTERY VOLTAGE
49,5V
COS.FI
0,99
BATTERY CURRENT
0A
BATTERY CHARGE
50%
Battery voltage level m easured at keyswitch input

Motor cos.fi value calculated in real tim e
Battery current
Level of battery charge
Table 7
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 51
PROGRAMMING
13.2 MAIN MENU - TESTER (AC2 drive control)
SERVICE
13.3 MAIN MENU - PROGRAM VACC (AC2 drive control)
NOT AVAILABLE
13.4 CONFIG. MENU - SET OPTIONS (AC2 drive control)

LEVEL
PARAMETER
DESCRIPTION
RUNNING
HOUR COUNTER
PROGRAMMING
KEY ON
OFF
Inhibits the "battery low" alarm
ON
The battery charge test is performed; when the charge

level falls to 20%, an alarm is signalled and the maximum
current is reduced to half the programmed value.
OFF
The "Stop on ramp" function is not enabled
ON
The "Stop on ramp" function is enabled (on releasing the

accelerator when on a ramp, the truck will remain in stall
condition for the time period set in the parameter
AUXILIARY TIME)
BRAKE
The F9 output pilots the coil of an electromagnetic brake
DIGITAL
The truck does not have a potentiometer on the

mechanical brake pedal, but only a microswitch/sensor.
When the accelerator pedal is released and the brake
pedal is depressed (brake switch closed), the inverter
applies electric braking
ANALOG
This setting is used when there is a potentiometer

installed on the brake pedal instead of a switch
BATTERY CHECK
STOP ON RAMP
AUX. OUTPUT # 1
The hour counter only records time while the truck is in

operation.
The hour counter records time when the keyswitch is
closed.
PEDAL BRAKING
Table 8
NOTE: to better understand the operation of the STOP ON RAMP function, see the following
table.
AUX OUTPUT
BRAKE
BRAKE
STOP ON RAMP
ON
OFF
OUTPUT F9
BEHAVIOUR ON RAMP
Pilots the coil of an

electromagnetic brake
The truck is held on the ramp electrically;

when the time period set in AUXILIARY
TIME parameter has elapsed, the brake
is applied and the 3-phase bridge is
released
Pilots the coil of an

electromagnetic brake
The truck is held on the ramp,

descending very slowly; when the time
period set in AUXILIARY TIME
parameter has elapsed, the brake is
applied and the 3-phase bridge is
released
Table 9
Page: 52
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
13.5 CONFIG. MENU - ADJUSTMENTS (AC2 drive control)

LEVEL
SET BATTERY TYPE
48V
+V Batt
50,6V
ADJUST BATTERY
ADJUSTMENTS # 4
120 c
ADJUSTMENTS # 2
Level 0 - 9
1
Level 0 - 9
3
ADJUSTMENTS # 1
DESCRIPTION
Selects the nominal battery voltage
Fine adjustment of battery voltage measured by the

controller. With the battery charged 20%, measure
with a voltmeter the -BATT and the positive on PIN 1 of
the F KEYSWITCH INPUT connector. The ADJUST
BATTERY parameter must be set to this value. This
setting
This parameter determines the motor temperature at

which the alarm "MOTOR TEMPERATURE" is
signalled. The range extends from 70 C to 160 C in
steps of 10 C. This parameter must be only be set if
the "SET TEMPERATURE" parameter ( "SET
OPTION" menu ) is
Sets the level between 30% and 20% at which the

battery charge status is considered to have changed.
Determines the threshold at which the charge status
changes from 30% to 20%. Level 0 corresponds to
45.8 Volts, level 9 to 48.5 Volts.
Sets the level between 90% and 100% at which the

battery charge status is considered to have changed.
To be increased if the display shows only 90% when
the battery is fully charged. The setting should be
decreased if the display shows 100% charge level.
Level 0 corrsponds to 49,1 Volts, level 9 to 51,8 Volts
Table 10
IMPORTANT:
UPDATE
the parameters contained in the submenus HARDWARE SETTINGS and

SPECIAL ADJUSTMENTS, which can be accessed via a PC, must not be altered
under any circumstances. Changing these parameter settings could give rise to
truck malfunction and component damage.
Date: Mar. 2002
Part No.: 524162546
Page: 53
PROGRAMMING
PARAMETER
SERVICE
14.0 PUMP CONTROL AC2 INVERTER (Module 5) - SUBMENUS
PROGRAMMING
14.1 MAIN MENU - PARAMETER CHANGE (AC2 pump control)

MAX SPEED UP*:
Determines the maximum speed of the pump during lifting operation.

Expressed in Hz.
MAXIMUM CURRENT:
Maximum current applied to the motor, controlled by the inverter.

We recommend that you do not alter these parameter settings for any
reason.
* NOTE: MAX SPEED UP determines the maximum speed range of the pump, within which the
speed may be varied (if necessary) by changing the setting of the 1ST SPEED CORSE parameter
in the PARAMETER CHANGE menu of module 1 (CANI/O).
14.2 MAIN MENU - TESTER (AC2 pump control)

INPUT MONITORED
STATUS
MOTOR VOLTAGE
0%
Voltage supplied by the inverter to the motor;

expressed as a percentage of the maximum voltage
(which depends on the battery voltage)
FREQUENCY
0,00 Hz
Frequency of the voltage and current supplied to the

motor
ENCODER
0,00 Hz
Motor speed expressed in terms of the frequency of

pulses from the encoder
SLIP VALUE
0,00 Hz
Slip value expressed in terms of frequency; is the

difference between the synchronous speed and the
motor rotor speed
CURRENT RMS.
0A
TEMPERATURE
22 C
Inverter temperature measured on the aluminium

heatsink
MOTOR TEMPERATURE
23 C
Motor temperature measured by the sensor
ACCELERATOR
0%
Travel of potentiometric lever expressed as a

percentage value
VOLTAGE BOOSTER
0%
Booster for voltage supplied to the motor; expressed as

% of maximum voltage
BATTERY VOLTAGE
48V
Battery voltage level measured at keyswitch input
COS.FI
0.99
The cos.fi of the motor calculated in real time
BATTERY CURRENT
0A
BATTERY CHARGE
100%
DESCRIPTION
Effective motor current
Battery current (calculated not measured)

Battery charge level percentage
Table 11
Page: 54
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
14.3 MAIN MENU - PROGRAM VACC (AC2 pump control)

NOT AVAILABLE
PARAMETER
LEVEL
DESCRIPTION
RUNNING
The hour counter only records the time while the truck is
in operation
KEY ON
The hour counter only records when keyswitch is closed
HOUR COUNTER
OFF
Inhibits the battery low alarm
ON
The battery charge level test is performed; when the

battery charge level falls to 20%, an alarm is signalled
and lifting is inhibited. On turning the keyswitch off and
on again, lifting will enabled for two minutes, after which
it will be inhibited again.
BATTERY CHECK
Table 12
14.5 CONFIG MENU - ADJUSTMENTS (AC2 pump control)
PARAMETER
LEVEL
SET BATTERY TYPE
48V
ADJUST BATTERY
50,6V
DESCRIPTION
Selects nominal battery voltage
Fine adjustment of battery voltage measured by
controller (NOT UTILISED)
Table 13
IMPORTANT:
UPDATE

Date: Mar. 2002
Part No.: 524162546
Page: 55
PROGRAMMING
14.4 CONFIG. MENU - SET OPTIONS (AC2 pump control)
SERVICE
15.0 CAN I/O (Module 1) - SUBMENUS
15.1 MAIN MENU - PARAMETER CHANGE (Can I/O)
Reduction in drive speed enabled by way of the pushbutton connected

directly to the SICOS (SW20).
0 = minimum speed
9 = maximum speed
CUTBACK SPEED 2:
Reduction in drive speed enabled after free lift in presence of the sensor
SW5 connected to input 12/A of the MHYRIO.
With 12/A at +VBATT = no speed reduction. The speed reduction is enabled
by removing the positive or by setting this input to negative.
0 = minimum speed
9 = maximum speed
1ST SPEED COURSE:
Pump speed setting for lifting function.

0 = minimum speed
9 = maximum speed
2ND SPEED COURSE:
Pump speed setting for carriage retraction function.

0 = minimum speed
9 = maximum speed
3RD SPEED COURSE:
Pump speed setting for retractable carriage forward function.

0 = minimum speed
9 = maximum speed
4TH SPEED COURSE:
Pump speed setting for forks tilt.

0 = minimum speed
9 = maximum speed
5TH SPEED COURSE:
Pump speed setting for forks translation function.

0 = minimum speed
9 = maximum speed
PROGRAMMING
CUTBACK SPEED 1:
Page: 56
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
PUMP CREEP # 1:
Minimum voltage applied to motor at start of lift function
PUMP CREEP # 2-3:
Minimum voltage applied to motor at start of truck movement function
PUMP CREEP # 4:
Minimum voltage applied to motor at start of forks tilt function
PUMP CREEP # 5:
Minimum voltage applied to motor at start of fork translation
LIFT SPEED CUTBACK:
Reduction in lift speed. Enabled by input 1/A of the MHYRIO module.

Enabled when the input changes to +VBATT (normally not used)
LOW SPEED CUTBACK:
Reduction in lowering speed. Enabled by the 5/A input of the MHYRIO

module.
Enabled when the input changes to +VBATT (normally not used)
SPEED 2 CUTBACK:
Reduction in retractable carriage forward/back speed. Enabled when the

+VBATT is cut from the 2/A input (forward) and 3/A input (back) of the
MHYRIO module.
PUMP ACC. # 1:
Lifting acceleration ramp. Level 0 corresponds to maximum acceleration
PUMP ACC. # 2-3:
Retractable carriage acceleration ramp. Level 0 corresponds to maximum

acceleration
PUMP ACC. # 4-5:
Fork translation-tilt acceleration ramp. Level 0 corresponds to maximum

acceleration
PUMP DEC DELAY:
Lifting deceleration ramp. Level 0 corresponds to maximum acceleration
PUMP DEC DELAY # 2-3: Retractable carriage deceleration ramp. Level 0 corresponds to maximum
acceleration
ADJUST # 2:
UPDATE
Maximum aperture of proportional solenoid valves for the retractable

carriage. Used to balance hydraulic oil flow during two simultaneous
operations (e.g. movement of retractable carriage + lifting).
This parameter has been set to the optimum value in the factory. We
recommend that you not alter the value.
Date: Mar. 2002
Part No.: 524162546
Page: 57
PROGRAMMING
SERVICE
PROGRAMMING
PRE-H. LIFT CTB:
Lifting speed reduction applied only when the option PRE-HEIGHT

SELECT) is set to ON. The speed reduction intervenes automatically a
few centimetres before reaching the selected height by way of the lifting
function. The point at which the speed reduction intervenes can be adjusted
by way of the parameter OPTION 03.
PRE-H. LOW CTB:
Lowering speed reduction applied only when the option PRE-HEIGHT

SELECT) is set to ON. The speed reduction intervenes automatically a
few centimetres before reaching the selected height by way of the lowering
function. The point at which the speed reduction intervenes can be adjusted
by way of the parameter OPTION 04.
OPTION 03:
The distance from the set height at which the lifting speed reduction
intervenes (PRE-H LIFT CTB). This function is only enabled if the PREHEIGHT SELECT function is set to ON.
OPTION 04:
The distance from the set height at which the lowering speed reduction
intervenes (PRE-H LOW CTB). This function is only enabled if the PREHEIGHT SELECT function is set to ON.
OPTION 05:
Set down offset. Distance to be added to the pickup distance so as to be

able to deposit the load without hitting the rack. This function is only enabled
if the PRE-HEIGHT SELECT function is set to ON.
OPTION 06:
Pickup offset. Distance required to separate the pallet from the rack and
withdraw it during pickup stage. This function is only enabled if the PREHEIGHT SELECT function is set to ON.
NOTE: for more information on the operating logic of the pre-height select function, see the
the explanation given in the section OPTIONALS of the Service manual for the truck
in question.
Page: 58
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
15.2 MAIN MENU - TESTER (Can I/O)

STATUS
DESCRIPTION
ACCELERATOR
1.6V
Voltage at accelerator potentiometer
ANALOG INPUT # 1
2.45V
Voltage at lift/lower potentiometer
ANALOG INPUT # 2
2.52V
Voltage at carriage forward/back potentiometer
ANALOG INPUT # 3
2.47V
Voltage at tilt up/down potentiometer
ANALOG INPUT # 4
2.52V
Voltage at forks left/right potentiometer
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FORW ARD SW ITCH
BACKW ARD SW ITCH
ENABLE SW ITCH
SEAT SW ITCH
DEAD SW ITCH
BRAKE SW ITCH
CUTBACK SW ITCH 1
1 ST SPEED SW ITCH
2 ND SPEED SW ITCH
3 RD SPEED SW ITCH
4 TH SPEED SW ITCH
OFF/GND
Level of the forward travel input
ON/+VBATT
OFF/GND
PROGRAMMING
INPUT MONITORED
Level of the reverse travel input

ON/+VBATT
OFF/GND
Level of the start microswitch input of the accelerator
ON/+VBATT
OFF/GND
Level of the seat switch input (when present)
ON/+VBATT
OFF/GND
Level of the operator presence switch input
ON/+VBATT
OFF/GND
Level of the brake pedal switch input
ON/+VBATT
OFF/GND
Level of the speed reduction input
ON/+VBATT
OFF/GND
ON/+VBATT
OFF/GND
ON/+VBATT
OFF/GND
ON/+VBATT
OFF/GND
ON/+VBATT
DIGITAL INPUT # 1
OFF
GND
DIGITAL INPUT # 2
OFF
GND
DIGITAL INPUT # 3
OFF
GND
DIGITAL INPUT # 4
OFF
GND
DIGITAL INPUT # 5
OFF
GND
Level of the start microswitch input of the lift/lower

joystick
Level of the start microswitch input of the carriage

forward/back joystick
Level of the start microswitch input of the tilt up/down

joystick
Level of the start microswitch input of the forks shift

left/right joystick
Table 14
15.3 MAIN MENU - PROGRAM VACC (Can I/O)

Carry out the PROGRAM VACC procedure described in the chapter Accessing and using the menus.
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 59
SERVICE
15.4 CONFIG MENU - SET OPTIONS (Can I/O)
LEVEL
PARAMETER
RUNNING
DESCRIPTION
Hour counter setting. Running = time recorded only
while using the drive and hydraulic functions
HOUR COUNTER
KEY ON
Hour counter setting. Key on = the hour counter

records time when the keyswitch is closed
ON/OFF
W hen enabled (ON), inhibits lifting when the battery

charge level falls to 20 % . Not used as the battery
check function is normally performed by the drive
controller
CHECK UP DONE
ON/OFF
If CHECK UP TYPE is set to 1 and the message

CHECK NEEDED is displayed, after servicing the
truck, this parameter must be set to ON and the
keyswitch turned off. On turning the keyswitch back
on, another 350 operating hours will elapse before the
servicing alarm reappears
SEAT SW ITCH
ON/OFF
Seat microswitch setting

ON = switch present
OFF = switch absent (default)
SINGLE FUNCTION
ON/OFF
If this parameter is set to ON, the use of two

simultaneous hydraulic functions will be inhibited (e.g.
lifting and carriage back). By default it is set to OFF
ON/OFF
Optional function used when the loads on the forks are

wider than the "legs" of the truck and there is a risk of
the load coming to rest on the "legs" when lowered to
the ground. If this function is enabled by setting this
parameter to ON it will not be possible to lower the
forks beyond the limit established by a sensor when
the retractable carriage is fully back
AUX FUNCTION 2
ON/OFF
Setting associated with the "height preselection"

function. W ith this parameter set to ON, the fork
carriage forward/back movement will be included in the
automatic pickup/deposit sequence of movements
AUX FUNCTION 3
ON/OFF
Truck in motion warning horn.

OFF = active forward
ON = active in reverse
PROGRAMMING
BATTERY CHECK
AUX FUNCTION 1
CHECK UP TYPE
0/1
W hen this parameter is set to 1, it is possible to

enable the "CHECK NEEDED" service interval warning
function. Every 350 hours, the message CHECK
NEEDED will be displayed. By default the function is
disabled and therefore this parameter is set to 0.
Table 15
Page: 60
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
15.4.1 CONFIG MENU - SET OPTIONS (Can I/O)
PARAMETER
LEVEL
0
CHECK UP TYPE
OFF
DESCRIPTIONS
Disables the maintenance warning function
Enables the function "MAINTENANCE WARNING". Every 350
working hours, "CHECK NEEDED" appears on the display
Counts the working hours only when the driving and lifting
functions are performed
Counts the working hours when the key switch is enabled
When the battery discharge level reaches 20%, an alarm is
signalled and the lifting is stopped. Only the slow movement
remains enabled
Disabled the discharged battery alarm.
After performing the maintenance, set to ON and disable the
key. When the truck is started again, the maintenance hours will
begin from "0". A new maintenance will be required when the
maintenance hours reaches 350 hours.
Disables the function
Seat microswitch on
Seat microswitch off
Cuts out the double hydraulic functions (ex. Contemporaneous
lifting and movement of the carriage)
Enables the double hydraulic functions
Enables the fork lowering stop, when the loads on the forks are
larger than the side truck structure. This control is enabled when
the sensor signalling the fork lowering limit is signalled
Enables the forward and backward movement of the carriage
next to the height preselector during the picking and depositing
movement
ON
Enables the horn signalling the backward running of the carriage
1
RUNNING
HOUR COUNTER
KEY ON
ON
BATTERY CHECK
OFF
ON
CHECK UP DONE
OFF
ON
OFF
SEAT SWITCH
ON
SINGLE FUNCTION
OFF
ON
AUX FUNCTION 1
OFF
ON
AUX FUNCTION 2
AUX FUNCTION 3
OFF
Enables the horn signalling the forward running of the carriage

Enables the speed reduction function with the carriage
completely extended
Disables the speed reduction with the carriage completely
extended
ON
SPEED LIMIT
OFF
"AC
MODULE "CAN I/O" TABLE UPDATES TO BE INSERTED IN THE SERVICE MANUAL
MOTOR CONTROL MODULAR SYSTEM"
SECTION
"PROGRAMMING"
Release
Update description
1
15.4.1 New Config Menu "SET OPTIONS" parameter table
UPDATE
0 1
2 3
Page
60
5 6 Date: March 2004 Comp. No: 524162546 Page: 60a
PROGRAMMING
This table does not substitute the previous one, but it is an integral part of it.
The update refers to the possibility to disable the the speed reduction function with carriage completely
extended. Connect the console to Module 1 CAN I/O, enter Set Options and act on parameter SPEED
LIMIT
The update begins from the serial number of Module 1 CAN I/O P/N 300208628
SERVICE
PROGRAMMING
Page: 60b Comp.No.: 524162546 Date: March 2004 0
3 4
5 6
UPDATE
SERVICE
15.5 CONFIG MENU - ADJUSTMENTS (Can I/O)

PARAMETER
LEVEL
MIN. ACC. LIFT
2.6V
Minimum voltage setting joystick lift forks
MAX. ACC. LIFT
4.5V
Maximum voltage setting joystick lift forks
MIN. ACC. LOW
2.4V
Minimum voltage setting joystick lower forks
MAX. ACC. LOW
0.5V
Maximum voltage setting joystick lower forks
MIN REACH BACK
2.6V
Minimum voltage setting joystick fork carriage forward
MAX REACH BACK
4.5V
Maximum voltage setting joystick fork carriage forward
MIN REACH FORWARD
2.4V
Minimum voltage setting joystick fork carriage back
MAX REACH FORWARD
0.5V
Maximum voltage setting joystick fork carriage back
MIN. TILT UP
2.6V
Minimum voltage setting joystick tilt forks up
MAX. TILT UP
4.5V
Maximum voltage setting joystick tilt forks up
MIN. TILT DOWN
2.4V
Minimum voltage setting joystick tilt forks down
MAX. TILT DOWN
0.5V
Maximum voltage setting joystick tilt forks down
MIN SHIFT RIGHT
2.6V
Minimum voltage setting joystick shift forks right
MAX SHIFT RIGHT
4.5V
Maximum voltage setting joystick shift forks right
MIN SHIFT LEFT
2.4V
Minimum voltage setting joystick shift forks left
MAX SHIFT LEFT
0.5V
Maximum voltage setting joystick shift forks left
PROGRAMMING
DESCRIPTION
Table 16
IMPORTANT:
the settings of the parameters in the ADJUSTMENTS menu must not be altered.
The parameters have been set so that they work with all the types of
potentiometric control levers envisaged for use on the trucks.
16.0 MHYRIO (Module 9) - SUBMENUS (Multifunctional Hydraulic remote Input/Output)

16.1 MAIN MENU - PARAMETER CHANGE (Mhyrio)
NOT AVAILABLE
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 61
SERVICE
16.2 MAIN MENU - TESTER (Mhyrio)

STATUS
INPUT MONITORED
DIGITAL INPUT # 1
DIGITAL INPUT # 2
DIGITAL INPUT # 3
PROGRAMMING
DIGITAL INPUT # 4
DIGITAL INPUT # 5
DIGITAL INPUT # 6
DIGITAL INPUT # 7
DIGITAL INPUT # 8
EV # 1
EV # 2
EV # 3
EV # 4
EV # 5
EV # 6
EV # 7
EV # 8
STATUS # 1
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
DESCRIPTION
OFF / GND
Encoder reset sensor + drive speed reduction
ON / +VB
OFF / GND
Lifting speed reduction sensor
ON / +VB
OFF / GND
ON / +VB
OFF / GND
ON / +VB
Carriage back stop and carriage forward deceleration

sensor
Carriage forward stop and carriage back deceleration

sensor
OFF / GND
Input not utilised
ON / +VB
OFF / GND
Lowering speed reduction sensor
ON / +VB
OFF / GND
Fork interlock sensor
ON / +VB
OFF / GND
Load presence sensor
ON / +VB
OFF / GND
Proportional valve n 1 output
ON / +VB
OFF / GND
ON / +VB
OFF / GND
ON / +VB
OFF / GND
ON / +VB
OFF / GND
Valve n 5 output
ON / +VB
OFF / +VB
Valve n 6 output
ON / GND
OFF / GND
Valve n 7 output
ON / +VB
OFF / GND
Valve n 8 output
ON / +VB
ON / +VB
Digital output n 1 valve option 1 (5th hydraulic

function)a)
Table 18
Page: 62
Part No.: 524162546
Date: Mar. 2002
continued
UPDATE
SERVICE
STATUS
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
STATUS # 2
STATUS # 3
OFF /
GND
ON / +VB
OFF /
GND
DESCRIPTION
Digital output n 2 valve option 2 (5th hydraulic
function)
Digital output n 3 valve option 3
ON / +VB
ENCODER
Encoder for height indicator and pre-selector
ANALOG INPUT # 1
Load cell input
ANALOG INPUT # 2
Analog input - not utilised
ANALOG INPUT # 3
255
Analog input for program selection (not available)
ANALOG INPUT # 4
255
Analog input for program selection (not available)
PROGRAMMING
INPUT MONITORED
Table 18
16.3 MAIN MENU - PROGRAM VACC (Mhyrio)

NOT AVAILABLE
16.4 CONFIG MENU - SET OPTIONS (Mhyrio)

LEVEL
PARAMETER
DESCRIPTION
OPTION # 1
Setting for ON-OFF type valve
OPTION # 2
Setting for PROPORTIONAL type valve
OPTION # 1
OPTION # 2
OPTION # 1
OPTION # 2
OPTION # 1
OPTION # 2
OPTION # 1
OPTION # 2
OPTION # 1
OPTION # 2
OPTION # 1
OPTION # 2
OPTION # 1
OPTION # 2
EV2 TYPE
EV1 TYPE
EV3 TYPE
EV4 TYPE
EV5 TYPE
EV6 TYPE
EV7 TYPE
EV8 TYPE
SET BATTERY TYPE
48V
Nominal battery voltage selection It is

important to set the correct voltage to
ensure that the system functions properly
16.5 CONFIG MENU - ADJUSTMENTS (Mhyrio)
Table 19
NOT AVAILABLE
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 63
SERVICE
IMPORTANT:

17.0 SICOS (DISPLAY) (Module 16) - SUBMENUS

17.1 MAIN MENU - PARAMETER CHANGE (Sicos)
PROGRAMMING
NOT AVAILABLE
17.2 MAIN MENU - TESTER (Sicos)

STATUS
INPUT MONITORED
CUTBACK SWITCH 1
HANDBRAKE
DIGITAL INPUT # 1
DIGITAL INPUT # 2
DIGITAL INPUT # 3
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
FUNCTION
DISABLED
FUNCTION
ENABLED
OFF /
GND
ON / +VB
OFF /
GND
ON / +VB
OFF /
GND
DESCRIPTION
Level of the slow travel enabling button input
(input 6/A SICOS)
Level of the handbrake enabling button input

(input 2/A SICOS)
Deactivation of slow travel
ON / +VB Selection of slow travel with battery out

OFF /
GND
Deactivation of 5th hydraulic way
ON / +VB Selection of 5th hydraulic way

OFF /
GND
Deactivation of weighing function
ON / +VB Selection of weighing function
Table 20
17.3 MAIN MENU - PROGRAM VACC (Sicos)

NOT AVAILABLE
Page: 64
NOTE:
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
17.4 CONFIG MENU - SET OPTIONS (Sicos)

LEV EL
0
1
3
4
P E RFO RM A NCE TY P E
=
=
=
=
DES CRIP TIO N
S low
S oft
S tandard
Hard
RUNNING
HO UR COUNTE R
K E Y ON
P erform anc e ty pe s etting: s oft-s td-hard This

c an als o be s et without the us e of the c ons ole
by way of a pus hbutton on the truc k das hboard
Hour c ounter s etting. Running = tim e rec orded
Hour c ounter s etting. K ey on = the hour
Height indic ator enc oder not pres ent
Height indic ator enc oder pres ent and alway s

us ed when "P RE -HIGH S E LE CT" param eter is
s et to O N
E NCODE R TY P E
ON
S ens or for pres enc e of load on fork s ins talled

(with height pre-s elec tor)
LO A D S E NS O R
O FF
S ens or for pres enc e of load on fork s not

ins talled
ON
Height pre-s elec tor enabled
O FF
Height pre-s elec tor dis abled
P RE -HIGH S E LE CT
ON
P A S S W O RD
O FF
ON
A UX FUNCTION 1
O FF
ON
OP TIO NA L 1-2 IDRA UL

V A LV E
O FF
ON
A UTO M A TIC W E IG HT
O FF
E nables pas s word func tion to protec t ac c es s

to truc k operation via the dis play
Dis ables the func tion
The CA N I/O m odule to s et up to rec eive the
truc k duty hour data s tored on the S ICO S
(Dis play )
The S ICO S (Dis play ) m odule s et up to ac c ept
the truc k operating hours s tored on the CA N
I/O
E nables the input 3/A S ICO S . W hen + V B A TT
is c onnec ted to this input by operating a
pus hbutton, the 5th hy draulic func tion c an be
enabled by way of the fork trans lation c ontrol
lever
E nables the input 15/A S ICO S . W hen + V B A TT

is c onnec ted to this input by operating a
pus hbutton, the autom atic weighing s y s tem is
ac tivated. This s y s tem enables the lifting
func tion for approx . 4 s ec onds . This allows the
s y s tem to read the approx im ate weig
Table 21
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 65
PROGRAMMING
P ARAM ETER
SERVICE
17.4.1
CONFIG MENU - SET OPTIONS (Sicos)
This table does not substitute the previous one, but it is an integral part of it.
The update concerns the enabling of the weighing by varying the parameter AUX INPUT 1 in the config
menu Set Options and the storing of the weights by means of the config menu Adjustment
The update begins from the serial number Modul 16 SICOS P/N 300206213
PARAMETER
PROGRAMMING
PERFORMANCE TYPE
0
1
2
3
=
=
=
=
LEVEL
Slow
Soft
Standard
Hard
RUNNING
HOUR COUNTER
KEY ON
0
ENCODER TYPE
AUX INPUT 1
PRE-HEIGHT SELECTOR
PASSW ORD
1
0
1
2
OFF
ON
OFF
ON
OFF
AUX FUNCTION
ON
OFF
OPTIONAL 1-2 HYD
ON
OFF
AUTOMATIC W EIGHT
17.4.1
ON
DESCRIPTIONS
Selection of the drive mode (soft-std-hard)
It can be set also without the console, by performing the
selection by means of a push button located on the instrument
panel
Hour counter setting, it counts only if drive or lifting functions
are performed
Hour counter setting, the hour counter detects that the key
switch is disabled
No height encoder on the machine
Height encoder present on the working machine when the
parameter "PRE-HEIGHT SELECT" is set to "ON"
Not configured
Configuration with pallet presence sensor
Configuration with lifting lock sensor
Height preselector disabled
Height preselector enabled
Disables the password using programme
Enables the password using programme, the password for the
machine operation by means of the DISPLAY
Allows reading the working hours detected by Module 16
SICOS on the display
Allows reading on the display the the working hours detected
by Module 1 CAN / I O
Disables the 5. Hydraulic function
Enables input 3/A SICOS by sending +Vbatt. by means of a
key on the display and enable the 5. Hydraulic function by
means of the lever "Fork movement"
Disables the weighing function
Enables input 15/A SICOS by sending +Vbatt. by means of a
key corresponding to this input and enable the automatic
weighing system.
CONFIG MENU - ADJUSTMENT (Sicos)
PARAMETER
ENCODER ADJUSTMENT
ADJ 2000 KG POINT
ADJ 1500 KG POINT
ADJ 1000 KG POINT
ADJ 0 KG POINT
LEVEL
127
DESCRIPTION
It is used to reduce the possible encoder clearance (Min. 1 - Max 225
Value to be stored with a sample weight of 2000 Kg
Value to be stored when the forks are empty
MODULE "SICOS" TABLE UPDATE TO BE INSERTED IN THE SERVICE MANUAL "AC

MOTOR CONTROL MODULAR SYSTEM"
SECTION
"PROGRAMMING"
Release
Update Description
1
17.4.1 New Config Menu "SET OPTIONS" parameter table
2
17.4.2 New Config Menu "ADJUSTMENT" parameter table
Page: 65a Comp.No.: 524162546 Date: March 2004 0
Page
65
65
3 4
5 6
UPDATE
SERVICE
PROGRAMMING
UPDATE
0 1
2 3
5 6 Date: March 2004 Comp. No: 524162546 Page: 65b
SERVICE
17.5 CONFIG MENU - ADJUSTMENTS (Sicos)
NOT AVAILABLE
PROGRAMMING
IMPORTANT: the parameters contained in the submenus HARDWARE SETTINGS and

SPECIAL ADJUSTMENTS, which can be accessed via a PC, must not be altered under any
circumstances. Changing these parameter settings could give rise to truck malfunction and
component damage. IMPORTANT: the parameters contained in the submenus HARDWARE
SETTINGS and SPECIAL ADJUSTMENTS, which can be accessed via a PC, must not be
altered under any circumstances. Changing these parameter settings could give rise to truck
malfunction and component damage.
NOTES:
Page: 66
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
Section: DIAGNOSTIC
DIAGNOSTICS
UPDATE
DIAGNOSTICS ......................................................................... 68
DESCRIPTION OF AC2 INVERTER ALARMS DRIVE CONTROL .................................................................... 68
DESCRIPTION OF AC2 INVERTER ALARMS PUMP CONTROL .................................................................... 72
DESCRIPTION OF CAN I/O ALARMS ...................................... 74
DESCRIPTION OF MHYRIO ALARMS ..................................... 76
Date: Mar. 2002
Part No.: 524162546
Page: 67
SERVICE
Section: DIAGNOSTIC
1.0 DIAGNOSTICS
This section contains descriptions of all the possible alarm for each of the modules.
Note that, with the CAN-BUS system, whenever an alarm condition occurs on one module all the other
modules will lock up.
Those modules not affected by the alarm condition will lock up and display the alarm WAITING......
indicating the name of the controller on which the alarm was generated.
The user can access the faulty controller and display the alarm through any of the controllers using the
procedure SET MODEL (see Programming).
1.1 ALARMS
The controllers store the last 5 alarm events in their memory, recording the relative identification code, the
number of times that the same alarm has been activated and the temperature of the controller at the time
the alarm was tripped.
These alarms are displayed on the display unit (SICOS controller) along with the name of the module on
which the alarm was generated.
Connect the console to the module thus identified and interrogate the ALARMS submenu contained in the
MAIN MENU.
DIAGNOSTIC
2.0 DESCRIPTION OF AC2 INVERTER ALARMS - DRIVE CONTROL
WATCH DOG:
The test is performed in both running and standby conditions. It is an

internal self-diagnostic test of the logic.
If the alarm persists - replace the controller.
EEPROM KO:
Fault in memory area where the configured parameters are stored; this
alarm inhibits truck operation.
Switch the keyswitch off and then on again: if the alarm condition does not
reappear, remember that the previously stored parameter settings will have
been cancelled and replaced by the default values.
LOGIC FAILURE #1:
This alarm signals the intervention of an undervoltage/overvoltage protection. There are two possible causes:
a) A real undervoltage/overvoltage event has occurred; in which case turn
the keyswitch off and then on again.
b) Fault in the hardware section of the logic board that controls overvoltage
protection - replace the controller.
LOGIC FAILURE #2:
Page: 68
Fault in the hardware section of the logic board that controls the feedback
of the phase voltages.
Replace the controller
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
Section: DIAGNOSTIC
LOGIC FAILURE #3:
Fault in the hardware section of the logic board that controls the hardware
current protection.
Replace the controller.
CHECK UP NEEDED:
This message warns the operator that the programmed maintenance

interval has expired. The alarm appears when the parameter CHECK UP
DONE of the CAN I/O module is set to ON and then the keyswitch is reset.
By default it is set to OFF
INCORRECT START:
This alarm appears when the starting sequence is not correct. Possible
causes:
a) Fault in the operator presence sensor or the start sensor - Replace the
sensor
b) Operator error in carrying out the starting sequence - Carry out the
correct starting sequence.
c) Incorrect wiring - make sure wiring is connected correctly
d) If the fault persists - replace the controller
FORW + BACK:
The test performed continuously. An alarm is signalled whenever a two drive

requests are made simultaneously. Possible causes:
a) Faulty wiring - make sure wiring is connected correctly
b) Check the travel direction sensors - if faulty, replace the sensor
c) Drive request operation incorrect - Repeat the drive request operations
in the correct sequence
e) If the fault persists - replace the controller
HANDBRAKE:
The truck fails to start because the contact of the parking brake pushbutton
is open. Possible causes:
a) The parking brake is on - release it
b) Parking brake pushbutton short circuited - replace the pushbutton
c) Operator error - Release the parking brake in correct manner
CAPACITOR CHARGE:
When the keyswitch is closed, the inverter attempts to charge the capacitors
through a power resistor Rc, and checks that the capacitors have been
charged within a certain time period: if not, an alarm is generated and the
main contactor will not be closed.
Possible reasons:
a) The charging resistor contact is open - replace the controller
b) There is a fault in the charging circuit - replace the controller
c) There is a problem in the power module - replace the controller
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 69
SERVICE
Section: DIAGNOSTIC
VMN LOW (24V):
VMN HIGH (48V)
This test is performed during the initial diagnostic procedure and in standby.
In these conditions, due to the two grid-bias resistors and that all the Mosfets
of the bridge are open, the voltage at point A should be equal to VB/2
(24V). If this is not the case, the alarm is generated; this alarm is also
generated on closing the power Mosfets one at a time alternatively towards
ground and towards +VBat (48V) and verifying that the voltage is 0 or +VBat.
If not, the alarm is generated.
Possible causes :
a) There is a problem in the motor connections or in the motor power
circuits; check that the three phase are connected correctly; heck for
any dispersion of motor current to earth;
b) Fault in the inverter - replace the controller
STBY I HIGH:
Test performed in standby condition. It checks that the current is 0. If the

current is 0, the Hall effect sensor will produce a voltage of 2.5V. If this
does not happen, the resulting alarm will inhibit truck operations.
Possible causes:
a) Fault in the current sensor - Replace the controller
b) Fault in the logic unit - replace the controller
MAIN CONTACTOR ALARMS

This driver can take1.5A continuously and is protected against short circuit.
When the keyswitch is closed, the microprocessor checks the driver of
the main contactor and the protection circuit comprised of the flip flop FF.
If it does not respond correctly to the stimulus from the microprocessor,
the alarm is signalled. Replace the controller.
The flip flop FF provides hardware control of the current in the coil of the
main contactor. If the current is too high, the FF opens the main contactor
and the alarm is signalled.
Check for external short-circuits and that the ohms value of the main contactor coil is correct. If not, replace the controller.
DRIVER SHORTED:
When the keyswitch is closed, the microprocessor checks that the coil of
main contactor is not shorted. If the coil is shorted, this alarm is generated
- replace the controller
CONTACTOR DRIVER:
When the initial diagnostics procedure has been completed, the drive logic
closes the main contactor and checks the voltage on the driver drain. If
the driver has been programmed to drive the coil of the contactor with
PWM at 50%, then the analogue input read by the microprocessor should
be approx. 2.5V.
The alarm is signalled if the voltage differs from this value - replace the
controller.
CONTACTOR OPEN:
The main contactor is driven by the logic unit, but the contactor is not
closed. There are two possible reasons:
a) The coil connections are interrupted or poorly connected Make the connections correctly
b) The contacts of the contactor do not work correctly
Check the contactor contacts and, if necessary, replace them.
DIAGNOSTIC
COIL SHORTED:
Page: 70
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
Section: DIAGNOSTIC
AUX OUTPUT KO:
The microprocessor controls the driver of the electromagnetic brake. If the

driver output does not match the signal from the microprocessor, this alarm
is signalled.
HIGH TEMPERATURE:
The temperature of the inverter exceeds 75C. The maximum current is

reduced proportionally to the temperature increase. The inverter locks up
at 100C.
If this alarm is signalled when the inverter is cold:
a) Fault in temperature sensor - replace the controller
MOTOR TEMPERATURE: This warning is displayed if the analogue signal exceeds the trip threshold.
If this happens when the motor is cold, check the wiring.
If the wiring is OK - replace the controller.
The temperature sensor used is a PTC with 10mV/C. It provides an output of 2.73V at 0C and 3.73V at 100C; if this output falls to 0 or rises to
+5V, this means that the sensor is broken or the circuit is interrupted replace the sensor
THERMIC SENSOR KO:
The inverter temperature sensor is monitored continuously and a warning

signal (Inverter) is generated if the temperature is outside the permitted
range.
When this alarm is signalled, check the sensor connection.
WAITING .............:
This alarm can appear in systems comprised of a number of modules

connected by a Can Bus. A module has detected a fault, and the drive
cannot close the main contactor due to the alarm condition on this module
(which the drive can identify by way of the CAN-BUS). The alarm indicates
the module on which the fault has been detected (e.g. Waiting Pump)
CAN BUS KO:
This alarm is signalled if the inverter fails to receive any messages via the
CAN-BUS. First check the wiring.
If the wiring is OK - replace the controller
BATTERY LOW:
If the battery check option is set to ON, a battery discharge algorithm is

applied. When the charge level falls to 20%, this alarm is signalled and the
current is reduced to half the programmed level. Lifting is inhibited, but the
retractable carriage and slow drive functions remain operational so that
the truck can be driven back to the charging station.
ENCODER ERROR:
This alarm is generated if the encoder input is subjected to a large surge

(more than 20Hz in 32mSec); this means that the encoder is faulty - replace the encoder
SAFETY:
This alarm is generated if the safety input is open (this input opens the line
of the main contactor driver)
Look for the alarm on the EPS controller.
WRONG SET BATTERY:
This alarm is generated if the battery voltage differs significantly from the
nominal value (48V) on start up. Normally it is due to an incorrect adjust
battery setting.
Set the correct battery value in the Adjust Battery parameter of the Config
Menu ADJUSTMENT.
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 71
SERVICE
Section: DIAGNOSTIC
3.0 DESCRIPTION OF AC2 INVERTER ALARMS - PUMP CONTROL
The test is performed in both running and standby condition. It is an internal self-diagnostic test of the logic.
EEPROM KO:
Fault in memory area where the configured parameters are stored; this
alarm inhibits operation of the truck.
Switch the keyswitch off and then on again: if the alarm condition does not
reappear, remember that the previously stored parameter settings will have
been cancelled and replaced by the default values.
LOGIC FAILURE #1:
This alarm signals the intervention of an undervoltage/overvoltage protection. There are two possible causes:
a) A real undervoltage/overvoltage event has occurred; turn the keyswitch
off and then on again.
b) Fault in the hardware section of the logic board that controls overvoltage
protection - replace the controller
LOGIC FAILURE #2:
Fault in the hardware section of the logic board that controls the feedback
of the phase voltages - replace the controller.
LOGIC FAILURE #3:
Fault in the hardware section of the logic board that controls the hardware
current protection - replace the controller.
INCORRECT START
This alarm appears when the starting sequence is not correct. Possible
causes:
a) Fault in the pump start microswitch - identify the faulty joystick and
replace it.
b) Operator error in carrying out the starting sequence - Carry out the
correct starting sequence.
c) Incorrect wiring - make sure wiring is connected correctly
d) If the fault persists - replace the controller
CAPACITOR CHARGE:
When the keyswitch is closed, the inverter attempts to charge the capacitors through a power resistor Rc, and checks that the capacitors have
been charged within a certain time period. If not, an alarm is generated
and the main contactor will not be closed.
Possible reasons:
a) The charging resistor contact is open - replace the controller
b) There is a fault in the charging circuit - replace the controller
c) There is a problem in the power module - replace the controller
VMN LOW (24V):

VMN HIGH (48V)
This test is performed during the initial diagnostic procedure and in standby.
Possible causes :
a) There is a problem in the motor connections or in the motor power
circuits; check that the 3 phases are connected correctly;
check if there is loss to earth from the motor;
b) Fault in the inverter - replace the controller
STBY I HIGH:
Test performed in standby. Checks that the current is 0. If not, the resulting
alarm inhibits operation of the truck.
Possible causes:
a) fault in the current sensor- replace the controller
DIAGNOSTIC
WATCH DOG:
Page: 72
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
Section: DIAGNOSTIC
COIL SHORTED:
When the keyswitch is closed, the microprocessor checks the driver of

the flasher FF SR. If it does not respond to the stimulus from the microprocessor, this alarm is signalled - replace the controller.
DRIVER SHORTED:
When the keyswitch is closed, the microprocessor checks that the driver
of the flasher is not short-circuited; If this alarm is signalled - replace the
controller
CONTACTOR DRIVER:
When the initial diagnostics procedure has been completed, the logic checks
the voltage of the driver drain. If the voltage is not low, the alarm is signalled - Replace the controller
HIGH TEMPERATURE:
The temperature of the inverter exceeds 75 C. The maximum current is

reduced proportionally to the temperature increase. The inverter locks up
at 100 C.
If this alarm is signalled when the inverter is cold:
a) Fault in temperature sensor - replace the controller
MOTOR TEMPERATURE: This warning is displayed if the analogue signal exceeds the trip threshold.
If this happens when the motor is cold, check the wiring.
If the wiring is OK - replace the controller
The temperature sensor used is a PTC with 10mV/C. It provides an output of 2.73V at 0C and 3.73V at 100C; if this output falls to 0 or rises to
+5V, this means that the sensor is broken or the circuit is interrupted replace the sensor
THERMIC SENSOR KO:
The inverter temperature sensor is monitored continuously and a

warning signal (Inverter) is generated if the temperature is outside the permitted range..
When this alarm is signalled, and the controller temperature does not correspond - replace the sensor
AUX OUTPUT KO:
The microprocessor controls the driver of the controllers cooling fan. If the
driver output does not match the signal from the microprocessor, this alarm
is signalled.
WAITING ..............:
This alarm can appear in systems comprised of a number of modules

connected by a Can Bus. One of the modules has detected a fault and
informed the pump control inverter via the Can Bus. The pump controller
is waiting for the ok signal. Look for the fault on the module indicated in the
alarm.
CAN BUS KO:
Diagnostics of the CAN-BUS line is only available when the inverter uses
this connection (depends on the software version): This alarm is signalled
if the inverter fails to receive any messages via the CAN-BUS. First check
the wiring. If the wiring is OK - replace the controller
BATTERY LOW:
If the battery check option is set to ON, a battery discharge algorithm is

applied. When the charge level falls to 20%, this alarm is signalled and the
current is reduced to half the programmed level. Lifting is inhibited, but the
retractable carriage and slow drive functions remain operational so that
the truck can be driven back to the charging station.
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 73
SERVICE
Section: DIAGNOSTIC
DIAGNOSTIC
4.0 DESCRIPTION OF CAN I/O ALARMS

VACC NOT OK:
Throttle high in standby without enabling signal from start microswitch or

accelerator incorrectly programmed
a) Program the potentiometer from the Program Vacc option of the Main
Menu.
b) Replace the potentiometer if circuit is interrupted
PEDAL WIRE KO:
Drive potentiometer above maximum programmed value.

Check the wiring connections; if OK, replace the potentiometer.
POT #1 NOT OK:
Lifting potentiometer high in standby without enabling signal or

incorrectly programmed
a) Program the potentiometer
b) Replace the joystick
POT #2 NOT OK:
Carriage potentiometer high in standby without enabling signal or incorrectly programmed

POT #4 NOT OK:
Translation potentiometer high in standby without enabling signal or incorrectly programmed

CAN BUS KO TR:
The periodic messages from the drive control have not arrived before
timeout
a) Look for the alarm on the drive control inverter
b) Check the CAN BUS connections
CAN BUS KO PU:
The periodic messages from the pump control have not arrived before
timeout
a) Look for the alarm on the pump control inverter
b) Check the CAN BUS connections
CAN BUS KO VALVE:
The periodic messages from the Mhyrio have not been received before
timeout
a) Look for the alarm on the Mhyrio module
b) Check the CAN BUS connections of the Mhyrio module
CAN BUS KO JOY:
The multifunction joystick does not send its periodic messages before
timeout
a) Check the joystick connections and re-make correctly if necessary
b) If the fault persists - replace the joystick
CAN BUS KO EPS:
The periodic messages from the EPS have not been received before
timeout -> drive is forced to slow
a) Check the EPS connections and re-make them if necessary
b) Check for alarms on the EPS module
CHECK UP NEEDED:
Programmed maintenance request. The parameter is set to OFF

so the alarm does not occur.
If the parameter is set to ON, a warning is displayed advising the operator
to have the truck serviced.
To reset the alarm, set the CHECK UP DONE parameter in Set Model to
ON and reset the keyswitch.
Page: 74
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
Section: DIAGNOSTIC
EEPROM KO:
Error in parameter management in the EEPROM

BATTERY OUT:
CANIO input. The alarm is signalled when the battery is not correctly inserted. Lifting is inhibited, but the retractable carriage and slow drive functions remain operational so that the truck can be driven back to the charging station.
Alternatively the battery position sensor may be incorrectly adjusted or faulty
- adjust or replace the sensor.
FORW+BACK:
Forward and reverse travel controls pressed simultaneously. This alarm

is signalled when the forward and reverse travel requests are made simultaneously.
INCORRECT START:
Active drive and/or pump request on power up.i.e. request made before
activation of the operator present button. Repeat the correct power up sequence main switch, keyswitch, operator present pushbutton, drive request)
POWER FAILURE #1:
Short on one of the digital outputs of the CAN I/O. The

CANIO provides two digital outputs:
a) Reverse travel or truck in motion buzzer - replace the controller
b) Horn - replace the controller
EMERGENCY:
Emergency pushbutton pressed (an input of the CANIO)

when the keyswitch was turned on. Reset the emergency pushbutton
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 75
SERVICE
Section: DIAGNOSTIC
DIAGNOSTIC
5.0 DESCRIPTION OF MHYRIO ALARMS

EEPROM KO:
Fault in memory area where the parameter settings are stored. This alarm
inhibits operation of the machine.
Turn the keyswitch of and then on again; if the alarm disappears, remember that all the previously programmed parameter settings will have been
deleted and replaced with the default values.
If the fault persists after turning the keyswitch back on - replace the controller.
CAN BUS KO:
There is a problem with the CAN BUS. This alarm is signalled if the MHYRIO
does not receive any message from the SICOS via the CAN. First check
the wiring. If the wiring is OK, then the problem is in the logic board - replace the controller
FF VALVES:
Flip flop circuit that signals that the driver of the ON/OFF valves is disabled. This alarm refers to the inputs of the auxiliary valves (referred to CNF
pin 4/9F - 3/10F - 2/5F)
The cause could be a high current at the shunt - replace the control
DRIVER OPEN:
The MOS that pilots the positive of the forks down solenoid valve EV1 (pin
3 CNB) is open when it should be closed. Replace the controller
DRIVER EPV GR1:
The MOS that pilots the positive of the forks up solenoid valve EV2 (pin 10
CNG) is open when it should be closed. Replace the controller.
DRIVER EPV GR2:
The MOS that pilots the positive of the carriage translation solenoid valves
EV3-4 (pins 11-16 CNG) is open when it should be closed. Replace the
controller.
DRIVER EPV GR3:
The MOS that pilots the positive of the forks up/down tilting solenoid valves
EV5-6 (pin 9-13 CNG), right/left fork translation solenoids EV 7-8 (pins 1215 CNG) is open when it should be closed.
DRIVER SHORTED:
The MOS that pilots the positive to the solenoid valves is closed when it
should be open.
Page: 76
Part No.: 524162546
Date: Mar. 2002
UPDATE
SERVICE
Section: DIAGNOSTIC
NOTES:
UPDATE
Date: Mar. 2002
Part No.: 524162546
Page: 77
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Part No.

Technical Information for

This manual is addressed exclusively to the specialised

Part No.: 524162546

Date: Mar. 2002

PROGRAMMING THE MODULES .........................................................................................................32

Date: Mar. 2002

Part No.: 524162546

11.1.2 CONFIG MENU - SET OPTIONS ........................................................................................................... 39

Part No.: 524162546

Date: Mar. 2002

Section: MODULE DESCRIPTIONS

CAN-BUS - BRIEF DESCRIPTION ............................................. 7

INTRODUCTION TO THE AC2 INVERTER ................................. 7

THE THREE-PHASE INDUCTION MOTOR BRIEF DESCRIPTION ................................................................ 8

THE INVERTER - OPERATING PRINCIPLE ............................. 10

AC2 INVERTER ....................................................................... 14

DRIVE MOTOR CONTROLLER CONFIGURATION ................... 18

PUMP MOTOR CONTROLLER CONFIGURATION ................... 20

CAN I/O ................................................................................... 26

Date: Mar. 2002

Part No.: 524162546

Section: MODULE DESCRIPTIONS

Part No.: 524162546

Date: Mar. 2002

Section: MODULE DESCRIPTIONS

1.2 INTRODUCTION TO THE AC2 INVERTER

Date: Mar. 2002

Part No.: 524162546

1.1 CAN-BUS (Controller Area Network Bus) - CENNI

Section: MODULE DESCRIPTIONS

THE 3-PHASE AC INDUCTION MOTOR - BRIEF DESCRIPTION

Part No.: 524162546

Date: Mar. 2002

Date: Mar. 2002

Part No.: 524162546

Section: MODULE DESCRIPTIONS

Section: MODULE DESCRIPTIONS

THE INVERTER - OPERATING PRINCIPLE

Part No.: 524162546

Date: Mar. 2002

compared to DC systems, the AC controller system offers the following advantages:

Date: Mar. 2002

Part No.: 524162546

Section: MODULE DESCRIPTIONS

Section: MODULE DESCRIPTIONS

Part No.: 524162546

Date: Mar. 2002

+12V or +5V power supply*

*NOTE: 12V encoder bearings have a different code to 5V encoder bearings.

CONNECTION TO THE CONTROL MODULES

Date: Mar. 2002

Part No.: 524162546

Section: MODULE DESCRIPTIONS

Section: MODULE DESCRIPTIONS

Part No.: 524162546

Date: Mar. 2002

Section: MODULE DESCRIPTIONS

2.2 OPERATING CHARACTERISTICS

Date: Mar. 2002

Part No.: 524162546

Section: MODULE DESCRIPTIONS

2.3 PROTECTION DEVICES

The power unit fails to function.