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Zapi Controller

The document provides service information for the XR09ac truck model, detailing modifications to the electronic and hydraulic systems compared to the previous LAC version. It includes software versions, system codes, and parameter settings for various operational aspects of the truck. Additionally, it outlines the differences between combined and uncombined movements in the hydraulic system and provides diagnostic software requirements.

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0% found this document useful (0 votes)

288 views91 pages

Zapi Controller

Uploaded by

iqbal.revival

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Service Information D11-05.

1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 1/91 020

Family Model Validity

4563 XR09ac

XR09ac (4563) preliminary information

- Bulletin D11-05.1 replaces bulletin D11-05 -
1. Introduction
The XR09ac truck has undergone important
modiﬁcations:
ELECTRONIC SYSTEM

Differences between the two systems.

The XR09ac"LAC version" The XR09ac "4563 series"
had: has:
2 COMBI ACE2s (one for traction
1 FPS
and one for the pump)
1 LAS 1 MHYRIO
2 LACs 1 ZAPI display
1 STILL display /

The following have also been added:

• a new electrical layout;
• new grommets;
• new fuses for traction and pump.
The ELK electrical steering system (motor re-
ducer, control and potentiometers) remain the
same as those on the LAC version.

Software Version System code

"TRACTION SYSTEM / "
PI 1.19 4563 360 50 06
ZAPI ACE2 350A
"LIFTING SYSTEM"
PI 1.19 4563 360 50 06
ZAPI ACE2 350A
"LIFTING SYSTEM"
PI 1.19 4563 360 50 07
ZAPI ACE2 450A
ZAPI SMART DISPLAY (STD 4563 020 56 02 (STD)
PI 1.14
+ PREMIUM) 4563 020 56 03 (PREMIUM)

HYDRAULIC SYSTEM
With regard to hydraulics, ZAPI systems have
introduced the possibility of versions with UN-
COMBINED movements.
For conﬁgurations without sideshift, only the
version with UNCOMBINED movements is avail-
able, while for conﬁgurations with auxiliary hy-
draulics, only the version with combined move-
ment is available.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to
third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 2/91 020

The main differences are:

• LAC combined movements: lift, mast, tilt
and sideshift movements can be combined
together in up to 4 simultaneous movements.
• ZAPI combined movements: lift and mast
movements and either tilt or sideshift move-
ments can be combined together in up to 3
simultaneous movements.

NOTE

The tilt and sideshift functions cannot be combi-

ned.
• ZAPI uncombined: lift, mast, tilt and sideshift
movements CANNOT be combined.

Software Version System code

"HYDRAULIC SYSTEM"
PI 1.03 4563 360 50 08
ZAPI MHYRIO FLASH
DIAGNOSTICS
The software required is contained in Navigator
(if missing, download and install the two patches
for this truck from the OM website).
The parameterisation and diagnostics software
for Converter, Display and Mhyrio is Canconsole
0.24; the software for "ELK" steering is ELK
Parameterisation.

The software for Flash programming is:

• Winﬂash for ELK steering;
• ZpCanﬂasher 0.38 for the other modules.
¾ For the Canconsole 0.24 diagnostics software,
the connection will only be activated if the
correct Baud rate is selected: 250 KB/s as
indicated in the illustration.

"CSV File" to load

• click on "Receive" and receive the parameters;
• click in the top left on "File" and select the
appropriate "CSV ﬁle", (see the "CSV ﬁle to

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to
third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 3/91 020

load" tables), and when the drop-down menu

appears, load it clicking on "Open";
• a window will open, click on "TxFile".
(from table code 45638089001 - Version 00 -
06/2011)

TRUCK WITH "COMBINED" MOVEMENTS

Lifting cylinders
Pump h1 column
CSV ﬁle to load Column type section
(cc) (mm)
(mm)
211 11 MN 37 < 2500
XR 12 212 11 MN 37 >/= 2500
214 11 GN 37 < 2900
211 11 MN 37 < 2500
>/= 2500
212 11 MN 37
XR 14-16 </= 2900
214 11 GN 37 </= 2900
224 17 GN 46 >/= 2950
XR 20 234 14 GN 46

Legend:
GN = ﬁxed column with tilt on forks
MN = tiltable column

TRUCK WITH "NON-COMBINED" MOVEMENTS

Lifting cylinders
Pump h1 column
CSV ﬁle to load Column type section
(cc) (mm)
(mm)
311 11 MN 37 < 2500
XR 12 312 11 MN 37 >/= 2500
314 11 GN 37 < 2900
311 11 MN 37 < 2500
>/= 2500
312 11 MN 37
XR 14-16 </=2900
314 11 GN 37 </= 2900
324 17 GN 46 >/= 2950
XR 20 334 14 GN 46

Legend:
GN = ﬁxed column with tilt on forks
MN = tiltable column

2. Parameters
The parameter menus for the ZAPI modules are
described in the following tables.

Table of parameters
(Updated 21/11/2011)

"DRIVE" Menu
Unit of mea-
surement
Name Description
Default
settings
Defines the acceleration of the drive motor. Maximum
ACCELERATION 0 T acceleration is at level 0. Increasing the parameter 1.7 sec.
value reduces acceleration.
Defines the acceleration of the drive motor after direc-
INV. ACCEL 0 T tion is reversed. Maximum acceleration is at level 0. 0.5 sec.
Increasing the parameter value reduces acceleration.
ACCELERATION 1 T 1.7 sec.
ACCELERATION 2 T 1.7 sec.
ACCELERATION 3 T 1.7 sec.
Defines the deceleration ramp when the drive request
RELEASE BRAKING 2.5 sec.
is released or the seat switch is released.
Defines the deceleration ramp when the direction is
INVERS. BRAKING 2.1 sec.
reversed while driving.
Defines the deceleration ramp applied to the motor
when the accelerator is partially released. Level 0
DECEL. BRAKING 3 sec.
gives maximum deceleration. Increasing the parame-
ter level reduces deceleration.
Defines the deceleration ramp when CURVE CUT-
CURVE BRAKING 2 sec.
BACK is activated.
Defines the deceleration ramp when the dead man’s
DEAD MAN BRAKING 1 sec.
pedal is released.
MAX SPEED FORW Defines the maximum speed with forks trailing. 120 Hz
MAX SPEED BACK Defines the maximum speed in fork-side drive 120 Hz
CUTBACK SPEED 1 Slow speed from dashboard switch. 30 %
CUTBACK SPEED 2 Slow speed with battery in incorrect position. 25 %
CUTBACK SPEED 3 Slow speed with forks lifted (UPA). 50 %
Slow speed with steering angle > STEER DEAD
CURVE CUTBACK 100 %
ANGLE.
Angle greater than that at which CURVE CUTBACK
STEER DEAD ANGLE 10 %
intervenes.
Establishes the dead zone on the drive accelerator
THROT 0 ZONE T 5%
curve.
Establishes a point on the drive accelerator curve (%
THROT X POINT T 40 %
VACC Max).
Establishes a point on the drive accelerator curve (Hz
THROT Y POINT T 25 %
SPEED Max).
Allows the temperature to be set, in 1°C steps, of the
SET TEMPERATURE 26 °C
drive system power module.
.

"TRAVEL" Menu
Unit of mea-
surement
Name Description
Default
settings
Defines the acceleration of the drive motor. Valid for
2- ACCELERATION 100 %
“travel profile” no. 2.
Defines the deceleration ramp when the drive request
2- REL BRAKING is released or the seat switch is released. Valid for 80 %
“travel profile” no. 2.
Defines the deceleration ramp when the direction is
2- INV BRAKING 80 %
reversed while driving. Valid for “travel profile” no. 2.
Defines the deceleration ramp, when the accelerator is
2- DECEL BRK lowered, but not completely released. Valid for “travel 100 %
profile” no. 2.
Defines the maximum speed with forks trailing. Valid
2- MAX SPEED FRW 120 Hz
for “travel profile” no. 2.
Defines the maximum speed in fork-side drive Valid for
2- MAX SPEED REV 120 Hz
“travel profile” no. 2.
Defines the acceleration of the drive motor. Valid for
3- ACCELERATION 90 %
“travel profile” no. 3.
Defines the deceleration ramp when the drive request
3- REL BRAKING is released or the seat switch is released. Valid for 80 %
“travel profile” no. 3.
Defines the deceleration ramp when the direction is
3- INV BRAKING 80 %
reversed while driving. Valid for “travel profile” no. 3.
Defines the deceleration ramp, when the accelerator is
3- DECEL BRK lowered, but not completely released. Valid for “travel 80 %
profile” no. 3.
Defines the maximum speed with forks trailing. Valid
3- MAX SPEED FRW 90 Hz
for “travel profile” no. 3.
Defines the maximum speed in fork-side drive Valid for
3- MAX SPEED REV 90 Hz
“travel profile” no. 3.
.

"SET" Menu
Unit of mea-
surement
Name Description
Default
settings
SLOW LIFT SPEED Slow lift speed 75 Hz
Deﬁnes the temperature above which system cooling
FAN TEMPERATURE 45 °C
fans are activated
SLOW LIFT TIME P Duration in sec. of timed slow lift 0.7 sec.
Effective only in the standard version (PREMIUM
DISPLAY OFF)
SHOW TRAC SPEED OFF
OFF: does not display the truck speed
ON: displays the truck speed
Effective only in the standard version (PREMIUM
DISPLAY OFF) and only if SHOW TRAC SPEED
SPEED UNIT OPTION # 1
OPTION #1: the speed is shown in km/h
OPTION #2: the speed is shown in mph

Performance Type value loaded by default on ignition.

Each level corresponds to the performance set on the
truck and shown on the display. Level 0: corresponds
to performance 0 and displayed with the tortoise.
LEVEL 0 (2.5 km/h + accel. 90%)
PERFORMANCE TYPE LEVEL 1 (12 km/h + accel. 90%) LEVEL 1
LEVEL 2 (12 km/h + accel. 80%)
LEVEL 3 (9 km/h + accel. 80%)
LEVEL 4 (6 km/h + accel. 90%)
NOTE: the tortoise is also shown with an active
cutback, for example: battery in incorrect position.
DISPLAY CONTRAST Indicates the contrast value for the LCD display. 50
.

"OPTIONS" Menu
Unit of mea-
surement
Name Description
Default
settings
NONE
OPTION #1 = Fork-side drive
LIGTH OPTION OPTION #2 = Operator-side drive NONE
OPTION #3= Dead man’s pedal pressed
OPTION #4 = Drive + lower.
ON = Calibration performed on traction control
CONFIG T ON
OFF= Perform calibration on traction control
NONE
OPTION #1 = Fork-side drive
BUZZER OPTION NONE
OPTION #2 = Operator-side drive
OPTION #3= Dead man’s pedal pressed
MULTIFUNCTION Multifunction ON = Contemporaneity active ON
Activates lowering and lift mast reach IN stop UPA
STOP 400MM FUN OFF
function
SLOW LIFT FUN Enables the timed lift function OFF
ON = Calibration performed on pump control system
CONFIG P ON
OFF= Perform calibration on pump control system
For input D1 of Display and A13 pump control system
OPTION #1 = speed reduction + lift stop
CTB LIFT/STOP TR OPTION # 1
OPTION #2 = speed reduction
OPTION #3 = lift stop
ON = OK for 3-lever version and for Joystick version
3 LEVERS OFF
OFF= OK for 4-lever version
ON = Calibration performed on Mhyrio control system
CONFIG MHYRIO ON
OFF= Perform calibration on Mhyrio control system
LEVEL 0 = Display base
LEVEL 1 = DIGICODE
DISPLAY TYPE LEVEL 0
LEVEL 2 = Preselector
LEVEL 3 = DIGICODE + preselector
.

"HYDRAULICS" Menu
Description of "HYDRAULICS" parameters

Name Description
Determines the deceleration ramp when the pump motor acti-
RELEASE BRAKING
vation start is released
MAX SPEED LIFT Determines the maximum fork lifting speed
TILT SPEED UP Tilt up speed
TILT SPEED DW Tilt down speed
REACH SPEED IN Lift mast reach IN speed
REACH SPEED OUT Lift mast reach OUT speed
SHIFT SPEED RGT Right side-shift speed
SHIFT SPEED LFT Left side-shift speed
1ST SPEED UP 1st auxiliary hydraulics speed
1ST SPEED DW 1st auxiliary hydraulics speed
Deﬁnes the maximum speed for the 2nd auxiliary hydraulics
2ST SPEED UP
(UP)
Deﬁnes the maximum speed for the 2nd auxiliary hydraulics
2ST SPEED DOWN
(DOWN)
2ND SPEED UP 2nd auxiliary hydraulics speed
2ND SPEED DW 2nd auxiliary hydraulics speed
CUTBACK SPEED 1 Lift mast reach OUT cutback speed
CUTBACK SPEED 2 Lift mast reach IN cutback speed
THROT 0 ZONE P Establishes the dead zone on the pump activation curve
THROT X POINT P Establishes a point on the pump activation curve (% Vpot Max)
Establishes a point on the pump activation curve (Hz SPEED
THROT Y POINT P
Max)
Delay time between the end of lifting and the start of an addi-
AUX TIME #1
tional movement (for non-combined movements)
Allows the temperature to be set, in 1°C steps, of the pump
SET TEMPERATURE
system power module.
MIN EV LIFT Minimum current (lifting valve)
MIN EV LOW Minimum current (lowering proportional valve)
Sets the current value for the proportional valve that controls
MIN EV REACH OUT extension of the reach carriage. The current value determines
valve opening start.
Sets the current value for the proportional valve that controls
MIN EV REACH IN retraction of the reach carriage. The current value determines
valve opening start.
MIN EV CAR AV Minimum current (lift mast reach OUT valve)
MIN EV CAR IND Minimum current (lift mast reach IN valve)
MIN EV BR AVA Minimum current (tilt down valve)
MIN EV BR IND Minimum current (tilt up valve)
MIN EV TR DX Minimum current (right side-shift valve)
MIN EV TR SX Minimum current (left side-shift valve)
MAX EV LIFT Maximum current (lifting valve)
MAX EV LOW Maximum current (lowering proportional valve)
Sets the MAX current value for the proportional valve that
MAX EV REACH OUT
controls extension of the reach carriage.
Sets the MAX current value for the proportional valve that
MAX EV REACH IN
controls retraction of the reach carriage.
MAX EV CAR AV Maximum current (lift mast reach OUT valve)

MAX EV CAR IND Maximum current (lift mast reach IN valve)

MAX EV BR AVA Maximum current (tilt down valve)
MAX EV BR IND Maximum current (tilt up valve)
MAX EV TR DX Maximum current (right side-shift valve)
MAX EV TR SX Maximum current (left side-shift valve)

Values of "HYDRAULICS" parameters

The table shows the default values.
(*) = Value expressed in 1/255 where 255 corre-
sponds to 100% of the PWM.
(**) = Optional setting.

File to load
Name
211-a 212-a 214-a 224-a 234-a 311-a 312-a 314-a 324-a 334-a
RELEASE
0.3 sec.
BRAKING
MAX SPEED LIFT 130 Hz
TILT SPEED UP 13 Hz 10 Hz 11 Hz 9 Hz 10 Hz 13 Hz 10 Hz 11 Hz 9 Hz 10 Hz
TILT SPEED DW 11 Hz 8 Hz 7 Hz 8 Hz 11 Hz 8 Hz 7 Hz 8 Hz
REACH SPEED IN 24 Hz 17 Hz 20 Hz 24 Hz 17 Hz 20 Hz
REACH SPEED
35 Hz 24 Hz 27 Hz 35 Hz 24 Hz 27 Hz
OUT
SHIFT SPEED
10 Hz 11 Hz 10 Hz 11 Hz 10 Hz
RGT
SHIFT SPEED
10 Hz 11 Hz 10 Hz 11 Hz 10 Hz
LFT
1ST SPEED UP 11 Hz
1ST SPEED DW 11 Hz
2ND SPEED UP 11 Hz
2ND SPEED DW 11 Hz
CUTBACK
25 %
SPEED 1
CUTBACK
25 %
SPEED 2
THROT 0 ZONE P 5 %
THROT X POINT
40 %
P
THROT Y POINT
25 %
P
AUX TIME #1 0.3 sec.
SET
23° C
TEMPERATURE
MIN EV LIFT 155 (*) 170 (*)
MIN EV LOW 115 (*) - 88 (*) (Preselector**)
MIN EV CAR AV 145 (*) 130 (*)
MIN EV CAR IND 145 (*) 130 (*)
MIN EV BR AVA 145 (*) 92 (*)
MIN EV BR IND 145 (*) 92 (*)
MIN EV TR DX 145 (*) 92 (*)
MIN EV TR SX 145 (*) 92 (*)

MAX EV LIFT 230 () 246 ()

MAX EV LOW 190 (*) 230 (*) 190 (*) 230 (*)
MAX EV CAR AV 212 (*) 160 (*)
MAX EV CAR IND 230 (*) 160 (*)
MAX EV BR AVA 220 (*) 145 (*)
MAX EV BR IND 220 (*) 145 (*)
MAX EV TR DX 220 (*) 145 (*)
MAX EV TR SX 220 (*) 145 (*)
.

"PRESELECTOR" Menu
Unit of mea-
surement
Name Description
Default
settings
Speed reduction applied during lifting when the forks
CUTBACK LIFT MIN 9%
are at distance (d1) from the required height.
Speed reduction applied during lowering when the
CUTBACK LOW MIN 5%
forks are at distance (d1) from the required height.
H OFFSET CUTBACK This is value “d1” expressed in mm 50 mm
Tolerance in mm, which applies to programmed level,
LOW. STOP WINDOW when the forks are being lowered to reach the required 6 mm
height.
Tolerance in mm, which applies to programmed level,
LIFT STOP WINDOW when the forks are being lifted to reach the required 6 mm
height.
OFFSET PLACE A C 1 mm*
OFFSET PLACE A F 50 mm
OFFSET PLACE B C 1 mm*
OFFSET PLACE B F 50 mm
OFFSET PLACE C C 1 mm*
OFFSET PLACE C F 50 mm
OFFSET PLACE D C Parameters which deﬁne the offset to add to the 1 mm*
OFFSET PLACE D F programmed level, in aisle A, during the ﬁrst depositing 50 mm
OFFSET PLACE E C manoeuvre hD [mm] = OFFSET PLACE A C * 100 + 1 mm*
OFFSET PLACE E F OFFSET PLACE A F 50 mm
OFFSET PLACE F C 1 mm*
OFFSET PLACE F F 50 mm
OFFSET PLACE G C 1 mm*
OFFSET PLACE G F 50 mm
OFFSET PLACE H C 1 mm*
OFFSET PLACE H F 50 mm

mm* = to be multiplied by 100

"ADJUSTMENT" Menu
Unit of mea-
surement
Name Description
Default
settings
Allows the correct battery voltage value to be set for
ADJUST BATTERY T XX.XX V*
the traction system
VACC SETTING Accelerator calibration menu ---V
Allows the correct battery voltage value to be set for
ADJUST BATTERY P XX.XX V*
the traction system
Calibration of lift/lower lever potentiometer rest posi-
LIFT/LOW 0 POS 0.0 V*
tion
MAX LIFT Calibration of max. lift position 2.9 V*
MAX LOWER Calibration of max. lower position 2.9 V*
REACH 0 POS Calibration of lift mast reach OUT / IN pot. rest position 0.0 V*
MAX REACH OUT Calibration of max. lift mast reach OUT position 2.9 V*
MAX REACH IN Calibration of max. lift mast reach IN position 2.9 V*
TILT 0 POS Calibration of fork tilt lever pot. rest position 0.0 V*
MAX TILT UP Calibration of max. fork tilt up position 2.9 V*
MAX TILT DOWN Calibration of max. fork tilt down position 2.9 V*
SHIFT 0 POS Calibration of fork side-shift lever pot. rest position 0.0 V*
MAX SHIFT R Calibration of max right side-shift position 2.9 V*
MAX SHIFT L Calibration of max left side-shift position 2.9 V*
Setting dead angle for hydraulic control potentiome-
DEAD ANGLE HYD 0.7 V*
ters
V* = Voltage value set by manufacturer.

"HOUR COUNTER" Menu

Unit of mea-
surement
Name Description
Default
settings
Two minutes after ignition, if the traction and display
hour counters differ by more than 5 hours (HM MIS-
MATCH), how times are synchronised depends on
LOAD HM TYPE which of the following settings is selected: NONE
NONE = the greater value of the two is chosen
OPTION#1 = the display hour counter value is chosen
OPTION#2 = the traction hour counter value is chosen
Deﬁnes when the maintenance request alarm is
activated:
CHECK UP TYPE LEVEL 0: no maintenance. LEVEL 0
LEVEL 1: display times.
LEVEL 2: traction system times.
Hundreds of working hours between two mainte-
CHECK UP HOURS nance operations. Corresponding to the service hour 1000 hours
counter: traction + pump + lowering
When it is set to ON, the maintenance alarm is reset.
CHECK UP DONE It has to be switched off. The parameter returns OFF
automatically to OFF.
.

"HEIGHT DISPLAY" Menu

Unit of
measure-
Name Description ment
Default
settings
LEVEL 0: Standard altimeter
ENC TYPE LEVEL 1: Cold store altimeter LEVEL 0
LEVEL 2: Preselector
ENC COARSE OFFSET The ENC COARSE OFFSET and ENC FINE OFFSET 10 mm*
parameters define the height of the zero sensor, an
offset which is added to the values measured by the
ENC FINE OFFSET encoder to define the height of the forks H0sens [mm] 0 mm
= ENC COARSE * 100 + ENC FINE
MAX HEIGHT C Parameters which define the maximum height of the 200 mm*
forks HMAX [mm] = MAX HEIGHT C * 100 + MAX
HEIGHT F
NOTE: while programming the preselector levels, it is
not possible to save a height greater than HMAX. It can
MAX HEIGHT F happen that, after storing certain preselector levels, 0 mm
the maximum height of the forks is reduced. In this
case, every time the operator tries to pick up or deposit
with levels whose height is greater than the maximum
height, an error will be reported with the wording "ERR"

mm* = to be multiplied by 100

Description of the TESTER menu

"TRACTION TESTER" Menu
Unit of mea-
Name Description
surement
STATUS #1 Status of error frame counter on CAN BUS
Indication of the battery voltage value measured on
BATTERY VOLTAGE v
the key input
MOTOR VOLTAGE RMS voltage applied to the motor (% of V Max) %
VOLTAGE BOOSTER BOOSTER voltage applied to the motor (% of V Max) %
Frequency of the voltage and current applied to the
FREQUENCY Hz
motor
ENCODER Motor rotation frequency Hz
SLIP VALUE Slip value Hz
CURRENT RMS RMS current on the motor A
MOTOR POWER Motor power W
BATTERY CHARGE Battery charge %
TEMPERATURE Internal traction control system temperature °C
MOTOR TEMPERAT. Drive motor temperature °C
ACCELERATOR Accelerator potentiometer voltage v
DEADMAN SWITCH Dead man’s pedal signal status On/Off
HANDLE/SEAT SW. Seat micro switch signal status On/Off
FORWARD SWITCH Forward drive signal status On/Off
BACKWARD SWITCH Reverse drive signal status On/Off
ENABLE SWITCH Accelerator start micro switch signal status On/Off
CUTBACK SWITCH Slow speed micro switch signal status On/Off
CUTBACK SWITCH 2 Battery release micro switch signal status On/Off
HANDBRAKE Handbrake micro switch signal status On/Off
2ND HOURMETERS Not Used
STEER ANGLE Drive wheel angle of rotation °
.

"PUMP TESTER" Menu

Unit of mea-
Name Description
surement
STATUS #1 Status of error frame counter on CAN BUS
Indication of the battery voltage value measured on
BATTERY VOLTAGE v
the key input
MOTOR VOLTAGE RMS voltage applied to the motor (% of V Max) %
VOLTAGE BOOSTER BOOSTER voltage applied to the motor (% of V Max) %
Frequency of the voltage and current applied to the
FREQUENCY Hz
motor
ENCODER Motor rotation frequency Hz
SLIP VALUE Slip value Hz
CURRENT RMS RMS current on the motor A
MOTOR POWER Motor power W
BATTERY CHARGE Battery charge %
TEMPERATURE Internal pump control system temperature °C

MOTOR TEMPERAT. Pump motor temperature °C

DEADMAN SWITCH Dead man’s pedal signal status v
HANDLE/SEAT SW. Seat micro switch signal status On / Off
LIFTING SWITCH Not Used On / Off
2ND SPEED SWITCH Not Used On / Off
HYDRO SPEED REQ. Not Used On / Off
CUTBACK SWITCH Lift mast reach OUT cutback On / Off
CUTBACK SWITCH 2 Lift mast reach IN cutback On / Off
SLOW LIFT SW Slow lift micro switch signal status (UPA) On / Off
Lift mast reach OUT limit micro switch signal status
END REACH SW On / Off
(UPA)
LIFT ENABLE Sensor 2S1 input status (UPA) On / Off
LIFT LIMIT SWITCH Sensor 2B5 input status (UPA) On / Off
1st auxiliary hydraulics micro switch signal status
1 VIA SW On / Off
(UPA)
2nd auxiliary hydraulics micro switch signal status
2 VIA SW On / Off
(UPA)
JOYSTICK SW Joystick activation signal status On / Off
BRAKE SWITCH Service brake pedal micro switch signal status On / Off
2 ND HOURMETERS Not Used
LIFT/LOWER POT. Lift/lower lever potentiometer voltage v
REACH POT. Lift mast reach lever potentiometer voltage v
TILT POT. Tilt lever potentiometer voltage v
SHIFT POT. Side-shift lever potentiometer voltage v
.

"MHYRIO TESTER" Menu

Unit of mea-
Name Description
surement
REACH OUT CTB SW Lift mast reach OUT sensor signal status On / Off
REACH IN CTB SW Lift mast reach IN sensor signal status On / Off
STOP LOW/RIN SWT Lift mast reach IN stop sensor signal status (UPA) On / Off
MIDDLE LFT LMT S Intermediate lift stop function status (UPA) On / Off
LIFT LIMIT SWITCH Lift limit switch sensor signal status (UPA) On / Off
FREE LIFT SWITCH Forks free lift sensor signal status On / Off
ZERO SENSOR Zero sensor signal status On / Off
Lift mast reach OUT limit switch sensor signal status
REACH OUT LIMIT On / Off
(UPA)
EV LOW Lowering valve activation status On / Off
EV LIFT Lifting valve activation status On / Off
EV REACH OUT Lift mast reach OUT valve activation status On / Off
EV REACH IN Lift mast reach IN valve activation status On / Off
EV TILT DOWN Tilt down valve activation status On / Off
EV TILT UP Tilt up valve activation status On / Off
EV SHIFT RIGHT Right side-shift valve activation status On / Off
EV SHIFT LEFT Left side-shift valve activation status On / Off

EV F4 ADDICT FUN Valve 2Y9/2Y11 valve activation status (UPA) On / Off

EV F3 ADDICT FUN Valve 2Y10/2Y12 valve activation status (UPA) On / Off
EV F2 ADDICT FUN Relay 2K1/2K2 activation status On / Off
.

"DISPLAY TESTER" Menu

Unit of mea-
Name Description
surement
KEY #1 Button (A) signal status, see illustration above. On / Off
KEY #2 Button (B) signal status, see illustration above. On / Off
KEY #3 Button (C) signal status, see illustration above. On / Off
KEY #4 Button (D) signal status, see illustration above. On / Off
KEY #5 Button (E) signal status, see illustration above. On / Off
KEY #6 Button (F) signal status, see illustration above. On / Off
NUM #0 Numeric keypad button “0” signal status On / Off
NUM #1 Numeric keypad button “1” signal status On / Off
NUM #2 Numeric keypad button “2” signal status On / Off
NUM #3 Numeric keypad button “3” signal status On / Off
NUM #4 Numeric keypad button “4” signal status On / Off
NUM #5 Numeric keypad button “5” signal status On / Off
NUM #6 Numeric keypad button “6” signal status On / Off
NUM #7 Numeric keypad button “7” signal status On / Off

NUM #8 Numeric keypad button “8” signal status On / Off

NUM #9 Numeric keypad button “9” signal status On / Off
STATUS PROG "PROG" button signal status On / Off
STATUS MAN "MAN" button signal status On / Off
ANALOG INPUT #1 Potentiometer 1 2R1 (Lift/lower) signal status On / Off
ANALOG INPUT #2 Potentiometer 2 2R1 (Lift/lower) signal status On / Off
ANALOG INPUT #3 Potentiometer 1 2R1 (Lift mast) signal status On / Off
ANALOG INPUT #4 Potentiometer 2 2R1 (Lift mast) signal status On / Off
ANALOG INPUT #5 Potentiometer 1 2R3 (Tilt) signal status On / Off
ANALOG INPUT #6 Potentiometer 2 2R3 (Tilt) signal status On / Off
ANALOG INPUT #7 Potentiometer 1 2R4 (Side-shift) signal status On / Off
ANALOG INPUT #8 Potentiometer 2 2R4 (Side-shift) signal status On / Off
ANALOG INPUT #9 2nd auxiliary hydraulics button signal status On / Off
ANALOG INPUT #10 Not Used On / Off
DIGITAL INPUT #1 Sensor 2B10 (UPA fork height) signal status On / Off
DIGITAL INPUT #2 1st auxiliary hydraulics button signal status On / Off
BATT. OUT SHAPE Battery release micro switch signal status On / Off
DIGITAL INPUT #7 Slow speed switch signal status On / Off
HANDBRAKE Parking brake switch signal status On / Off
REACH OUT Lift mast reach OUT sensor signal status On / Off
REACH IN Lift mast reach IN sensor signal status On / Off
ZERO SENSOR Zero sensor signal status On / Off
FREE LIFT ZONE Forks free lift sensor signal status On / Off
LIFT LIMIT SWITCH Lift limit switch sensor signal status (UPA) On / Off
STOP LOW/RIN SW Lower and lift mast reach IN stop function status (UPA) On / Off
Lift mast reach OUT limit switch sensor signal status
END SW REACH IN On / Off
(UPA)
Lower and lift mast reach IN release function status
UNLOCK LOW RIN On / Off
(UPA)
SLOW LIFT SW Sensor 2S3 (timed slow lift) signal status (UPA) On / Off
STOP LIFT INT. Intermediate lift stop function status (UPA) On / Off
UNLOCK LIFT SW Intermediate lift release function status On / Off
.

3. Alarms

Traction control system alarms

Alarm
Alarm Possible cause Corrective actions
codes
Enter serial number and Calibration with PC CAN
7 TR CHOPPER NOT CONF capacity. Console.

Try to run the CLEAR

EEPROM operation. If
the alarm disappears,
EEPROM KO the parameter default
13 TR Internal error.
EEPROM errors. values have been restored;
otherwise, if the problem
persists replace the
electronic control system.
LOGIC FAILURE #3
Fault due to high currents Problems inside the
17 TR Replace the control system.
in the hardware protection electronic control system.
circuit.
LOGIC FAILURE #2
Problems inside the
18 TR The motor voltage feedback Replace the control system.
electronic control system.
circuit is damaged.
If the alarm occurred on
ignition:
- check the key connection
- replace the electronic
LOGIC FAILURE #1 An abnormal under-voltage
control system.
Voltage surges (>65 V) or excess voltage condition
19 TR If the alarm occurred during
or for the system has been
traction:
Voltage drops (<11 V) detected.
- check the battery status
- check the wiring.
- check the contacts
- check the wiring
If the alarm occurs before
the main contactor closes,
check:
- Internal motor connections
- Motor wiring
- Insulation between motor
The software checks the and chassis
VMN LOW
electronic system; if the If the alarm occurs while the
30 TR Motor output voltage is lower
phase voltage does not rise, motor is running, check:
than expected.
this alarm occurs. - Motor connections
- Insulation between motor
and chassis
- Main contactor contact.
Otherwise, there are
problems inside the control
system.
If the alarm occurs before
the main contactor closes,
check:
- Internal motor connections
- Motor wiring
The software checks the If the alarm occurs after
VMN HIGH
electronic system; if the the main contactor closes,
31 TR Motor output voltage is
phase voltage does not check:
higher than expected.
decrease, this alarm occurs. - Motor connections.
- Insulation between motor
and chassis.
Otherwise, there are
problems inside the control
system.

CONTACTOR CLOSED Check the main contactor

37 TR The main contactor contact K1 contactor contacts stuck. contact and replace it if
is jammed close. required.
CONTACTOR OPEN
The connection with the
The main contactor coil Check wiring or replace the
38 TR coil has been broken or not
driver is powered but the main contactor.
executed.
contact did not close.
STBY I HIGH
In standby conditions, the Problems inside the Replace electronic control
53 TR
current feedback is outside electronic control system. system.
the permitted limits.
- Load in parallel to capacitor
battery. Check charge circuit of
CAPACITOR CHARGE - Load resistor is open. capacitor battery.
60 TR The input capacitor battery - Load circuit error in control If the error still occurs after
is not charging. system. turning the key on again,
- Power control system replace the control system.
problem.
Check correct operation of
TH PROTECTION
the temperature sensor.
Traction control system
The internal control system
62 TR Replace the electronic
overheating protection has
temperature is higher than
cut in. control system if the problem
85°C.
persists.
Check motor temperature
MOTOR TEMPERAT. (TESTER MENU).
65 TR High motor temperature External error. Replace the electronic
(>150°C). control system if the problem
persists.
Measure the battery voltage
and compare it with the
BATTERY LOW
"battery voltage" parameter
The battery charge is less
66 TR Battery charge problems. value (TESTER MENU); if
than 10% compared with the
they are different, modify
total charge
the value using the ADJUST
BATTERY function
Check that input X8:16 is
Fault in control circuit of
connected correctly.
74 TR DRIVER SHORTED driver that controls the main
Replace the drive inverter if
contactor coil.
the problem persists.
Main contactor driver control Replace electronic control
75 TR CONTACTOR DRIVER
circuit fault. system.
Repeat "VACC program"
The accelerator potentiome- Check the mechanical
78 TR VACC NOT OK
ter voltage value is incorrect. calibration and functionality
of the potentiometer.
Check the wiring and
operation of the micro
INCORRECT START
79 TR / switches; if the problem
Incorrect sequence
persists, replace the
electronic control system.

Check:
- the electrical and mechan-
ical functionality of the en-
coder
- the mechanical installation
Encoder signal reading
82 TR ENCODER ERROR of the encoder
problems.
- the electromagnetic
interference which the
sensor is subject to
Replace the encoder if the
problem persists.
A conflict is found between
Check wiring and repair if
203 TR SAFETY MISMATCH the Safety IN input and CAN
necessary.
signals.
A conflict had been found
Check wiring and repair if
204 TR A13 INPUT MISM. between the A13 pump and
necessary.
D1 Display inputs (UPA).
Activate diagnostics for the
Electrical steering locked
217 TR ELK EMERGENCY electrical steering and then
due to fault.
look for fault.
Alarm on MHYRIO control
system (generic alarm).
This alarm usually appears
219 TR WARNING MHYRIO with specific alarms for the See specific alarm.
MHYRIO control system
(those with the number +
HY).
Check that inputs X8:6
and X12:6 are connected
Conflict detected between
correctly.
the status of input X8:6 (dead
Check that the dead man’s
221 TR DEADMAN MISMATCH man N.C.) and the status
pedal is working properly.
of input X12:6 (dead man
Replace the drive inverter
N.O.).
or the pump inverter if the
problem persists.
WAITING FOR NODE
No message received from Replace the control system if
222 TR CAN communication
the pump control system. the problem persists.
expected.
WATCHDOG #1 Problems inside the Replace electronic control
223 TR Watchdog #1 signal electronic control system. system.
incorrect.
Check wiring and repair if
necessary.
Short-circuit of the AUX
224 TR AUX COIL SHORT Replace the brake and the
output coil.
contactor if the problem
persists.
Check wiring and repair if
Accelerator potentiometer necessary.
226 TR AUX VACC OUT RANGE . out of range. Replace the accelerator if
the problem persists.
WATCHDOG #2
Problems inside the Replace electronic control
227 TR Watchdog #1 signal
electronic control system. system.
incorrect.

At the next drive request, the

TILLER OPEN
alarm will disappear.
The truck is in standby with Dead man’s pedal switch
228 TR If it doesn’t disappear, check
the dead man’s pedal switch open too long.
the wiring of the dead man’s
open for more than 40 sec.
pedal
Electrical steering locked
due to fault or Safety input Check wiring and repair if
229 TR SAFETY INPUT not connected (steering necessary.
working).
Check wiring and repair if
necessary.
Short circuit of main
230 TR MC COIL SHORT Replace the brake and the
contactor coil.
contactor if the problem
persists.
Problems with hardware
Replace electronic control
231 TR COIL SHORT HW KO circuit which controls MC or
system.
EB/AUX outputs.
Check wiring and repair if
necessary.
232 TR KEY OFF SHORT Found Key off input too low. Replace the electronic
control system if the problem
persists.
POWER MOS SHORT
Problems inside the Replace electronic control
233 TR Short circuit of the power
electronic control system. system.
MOS.
CURRENT GAIN
The current maximum gain
parameters have the default Replace electronic control
236 TR Internal error.
value; this means that the system.
calibration procedure is still
in progress.
ANALOG INPUT
Problems inside the Replace electronic control
237 TR Conversion problems in A/D
electronic control system. system.
converters.
WRONG 0 VOLTAGE
The output from the
feedback stages on the Internal hardware error
238 TR Internal error.
motor (used to measure found.
the motor voltage) is close to
zero.
Output A19 driver open or Check wiring and repair if
239 TR SAFETY OUTPUT .
short-circuited. necessary.
Internal hardware error Replace electronic control
240 TR HARDWARE FAULT
found. system.
Replace electronic control
241 TR FLASH CHECKSUM Check sum error.
system.
Encoder connector discon- Check wiring and repair if
242 TR ENCODER LOCKED
nected. necessary
SENS MOT TEMP KO
243 TR Motor thermal sensor output Motor thermal sensor faulty. Check if the sensor is faulty
incorrect
Replace electronic control
244 TR SOFTWARE ERROR Internal error.
system.

WRONG RAM MEM-

ORYThe initial diagnostic Replace electronic control
245 TR Internal error.
cycle found errors on the system.
main RAM
Check wiring and repair if
The EB/AUX output coil necessary.
246 TR AUX DRIV. OPEN
drivers are open. Replace the electromagnetic
brake if the problem persists.
NO CAN MSG. Replace electronic control
248 TR Poor communication errors Internal error.
system.
via CANBUS
Pedal brake micro switch still
When the brake micro switch
active (open) without seat
249 TR PEDAL BRK STUCK contact is closed, the alarm
micro switch and dead man’s
disappears.
pedal micro switch.
THERMIC SENS. KO
Replace electronic control
250 TR Traction control thermal Internal error.
system.
sensor output incorrect
Please check:
- the "SET BATTERY"
parameter has the value of
the battery nominal voltage.
- the "BATTERY VOLTAGE
WRONG SET BAT. Problems with electronic
251 TR (TESTER MENU)" param-
Battery voltage too low control system parameters.
eter has the same value as
the battery nominal voltage
measured with the voltmeter.
Replace the battery if the
problem persists.
Dead man’s pedal micro
Check wiring and repair if
switch active for more
necessary.
252 TR TIMEOUT LOCKOUT than 5 minutes without
Replace the dead man’s
request for drive or hydraulic
pedal if the problem persists.
movements.
Errors in parameters Check the parameter which
253 TR SLIP PROFILE
concerning SLIP. deﬁnes the SLIP proﬁle.
Check wiring and repair if
The EB/AUX output coil necessary.
254 TR AUX DRIV. SHRT.
drivers have short-circuited. Replace the electromagnetic
brake if the problem persists.
.

Pump control alarms

Alarm
Alarm Possible cause Corrective actions
codes
Enter serial number and Calibration with PC CAN
7 PU CHOPPER NOT CONF capacity. Console.

Try to run the CLEAR

EEPROM operation. If
the alarm disappears,
EEPROM KO the parameter default
13 PU Internal error.
EEPROM errors. values have been restored;
otherwise, if the problem
persists replace the
electronic control system.
LOGIC FAILURE #3
Fault due to high currents Problems inside the
17 PU Replace the control system.
in the hardware protection electronic control system.
circuit.
LOGIC FAILURE #2
Problems inside the
18 PU The motor voltage feedback Replace the control system.
electronic control system.
circuit is damaged.
If the alarm occurred on
ignition:
- check the key connection
- replace the electronic
LOGIC FAILURE #1 An abnormal under-voltage
control system.
Voltage surges (>65 V) or excess voltage condition
19 PU If the alarm occurred during
or for the system has been
traction:
Voltage drops (<11 V) detected.
- check the battery status
- check the wiring.
- check the contacts
- check the wiring
If the alarm occurs before
the main contactor closes,
check:
- Internal motor connections
- Motor wiring
- Insulation between motor
The software checks the and chassis
VMN LOW
electronic system; if the If the alarm occurs while the
30 PU Motor output voltage is lower
phase voltage does not rise, motor is running, check:
than expected.
this alarm occurs. - Motor connections
- Insulation between motor
and chassis
- Main contactor contact.
Otherwise, there are
problems inside the control
system.
If the alarm occurs before
the main contactor closes,
check:
- Internal motor connections
- Motor wiring
The software checks the If the alarm occurs after
VMN HIGH
electronic system; if the the main contactor closes,
31 PU Motor output voltage is
phase voltage does not check:
higher than expected.
decrease, this alarm occurs. - Motor connections.
- Insulation between motor
and chassis.
Otherwise, there are
problems inside the control
system.

CONTACTOR CLOSED Check the main contactor

37 PU The main contactor contact K1 contactor contacts stuck. contact and replace it if
is jammed close. required.
Check that the main
contactor is working
The main contactor coil properly.
38 PU CONTACTOR OPEN driver is powered but the Check that the coil connec-
contact did not close. tion is correct.
Replace the drive inverter if
the problem persists.
STBY I HIGH
In standby conditions, the Problems inside the Replace electronic control
53 PU
current feedback is outside electronic control system. system.
the permitted limits.
- Load in parallel to capacitor
battery. Check charge circuit of
CAPACITOR CHARGE - Load resistor is open. capacitor battery.
60 PU The input capacitor battery - Load circuit error in control If the error still occurs after
is not charging. system. turning the key on again,
- Power control system replace the control system.
problem.
Check correct operation of
TH PROTECTION
Traction control system the temperature sensor.
The internal control system
62 PU overheating protection has Replace the electronic
temperature is higher than
cut in. control system if the problem
85°C.
persists.
Check motor temperature
MOTOR TEMPERAT. (TESTER MENU).
65 PU High motor temperature External error. Replace the electronic
(>150°C). control system if the problem
persists.
Check that the connections
on connector 9X2 are
Fault in the control circuit
correct.
of the driver that controls
Check the status of fuse 9F1.
74 PU DRIVER SHORTED the power supply negative
Check that input X12:16 is
for fans 9M1/1-4 (drive and
connected correctly.
pump inverter cooling).
Replace the pump inverter if
the problem persists.
Check that the alarm
disappears with the correct
sequence.
Check that input X12:6 is
Incorrect sequence detected
connected correctly.
for hydraulic controls. (Seat
79 PU INCORRECT START Use the diagnostics software
switch, dead man’s pedal
to check that the voltage
and potentiometric lever).
values for the potentiometric
levers are correct.
Replace the display if the
problem persists.

Check:
- the electrical and mechan-
ical functionality of the en-
coder
- the mechanical installation
Encoder signal reading
82 PU ENCODER ERROR of the encoder
problems.
- the electromagnetic
interference which the
sensor is subject to
Replace the encoder if the
problem persists.
A conﬂict has been found
Check wiring and repair if
202 PU CTB STOP MISM. between the A13 pump and
necessary.
D1 Display inputs (UPA)
A conﬂict had been found
Check wiring and repair if
204 PU A13 INPUT MISM. between the A13 pump and
necessary.
D1 Display inputs (UPA).
Inconsistency between the Check wiring and repair if
pot.1 and pot.2 signals necessary.
205 PU POT. 4 FAILURE
of the side-shift lever Replace the lever if the
potentiometer. problem persists.
Check wiring and repair if
Inconsistency between the
necessary.
206 PU POT. 3 FAILURE pot.1 and pot.2 signals of the
Replace the lever if the
tilt lever potentiometer.
problem persists.
Inconsistency between the Check wiring and repair if
pot.1 and pot.2 signals of necessary.
207 PU POT. 2 FAILURE
the lift mast reach lever Replace the lever if the
potentiometer. problem persists.
Inconsistency between the Check wiring and repair if
pot.1 and pot.2 signals necessary.
208 PU POT. 1 FAILURE
of the lift/lower lever Replace the lever if the
potentiometer. problem persists.
Recalibrate the max. and
Side-shift lever potentiome-
min. lever values.
209 PU VACC NOT OK S ter already active on ignition
Replace the lever if the
or before dead man’s switch.
problem persists.
Recalibrate the max. and
"Side-shift lever" poten-
min. lever values.
210 PU VACC OUT RNG S tiometer voltage value out
Replace the lever if the
of range.
problem persists.
Recalibrate the max. and
"Tilt lever" potentiometer
min. lever values. Replace
211 PU VACC NOT OK T already active on ignition or
the lever if the problem
before dead man’s switch.
persists.
Recalibrate the max. and
"Tilt lever" potentiometer min. lever values. Replace
212 PU VACC OUT RNG T voltage value out of range. the lever if the problem
persists
Recalibrate the max. and
"Reach lever" potentiometer min. lever values. Replace
213 PU VACC OUT RNG R
voltage value out of range. the lever if the problem
persists.

Recalibrate the max. and

"Reach lever" potentiometer
min. lever values. Replace
214 PU VACC NOT OK R already active on ignition or
the lever if the problem
before dead man’s switch.
persists.
"Lift/Lower lever" poten- Recalibrate the max. and
tiometer already active on min. lever values. Replace
215 PU VACC NOT OK P
ignition or before dead man’s the lever if the problem
switch. persists.
Recalibrate the max. and
"Lift/Lower lever" poten-
min. lever values. Replace
216 PU VACC OUT RNG P tiometer voltage value out of
the lever if the problem
range.
persists.
No CAN message from node
218 PU NO CAN MSG. 9 Check Mhyrio connections.
no. 9 (Mhyrio).
Check Mhyrio connections.
WARNING MHYRIO Fault on Mhyrio control
219 PU Replace the Mhyrio if the
Alarm on Mhyrio system.
problem persists.
Conﬂict between the Check wiring and repair if
signals sent via dead man’s necessary. Replace the
221 PU DEADMAN MISMATCH
hardware and those sent by control system if the problem
CAN. persists.
WAITING FOR NODE
No message received from Replace the control system if
222 PU CAN communication
the pump control system. the problem persists.
expected.
WATCHDOG #1
Problems inside the Replace electronic control
223 PU Watchdog #1 signal
electronic control system. system.
incorrect.
WATCHDOG #2 Problems inside the Replace electronic control
227 PU Watchdog #1 signal
electronic control system. system.
incorrect.
Check that input X12:11 is
connected correctly.
Opening of input X12:11 Check that the electrical
229 PU SAFETY INPUT
detected (SAFETY INPUT). steering is working properly.
Replace the pump inverter if
the problem persists.
Check wiring and repair if
Found "Key off" input too necessary. Replace the
232 PU KEY OFF SHORT
low. electronic control system if
the problem persists.
POWER MOS SHORT Problems inside the Replace electronic control
233 PU Short circuit of the power electronic control system. system.
MOS.
CURRENT GAIN
The current maximum gain
parameters have the default Replace electronic control
236 PU Internal error.
value; this means that the system.
calibration procedure is still
in progress.
ANALOG INPUT Problems inside the Replace electronic control
237 PU Conversion problems in A/D electronic control system. system.
converters.

WRONG 0 VOLTAGE
The output from the
feedback stages on the Internal hardware error
238 PU Internal error.
motor (used to measure found.
the motor voltage) is close to
zero.
Output A19 driver open or Check wiring and repair if
239 PU SAFETY OUTPUT
short-circuited. necessary.
Internal hardware error Replace electronic control
240 PU HARDWARE FAULT
found. system.
FLASH CHECKSUM Replace electronic control
241 PU Check sum error.
Check sum error system.
Encoder connector discon- Check wiring and repair if
242 PU ENCODER LOCKED
nected. necessary
SENS MOT TEMP KO
243 PU Motor thermal sensor output Motor thermal sensor faulty. Check if the sensor is faulty
incorrect
Replace electronic control
244 PU SOFTWARE ERROR Internal error.
system.
WRONG RAM MEM-
ORYThe initial diagnostic Replace electronic control
245 PU Internal error.
cycle found errors on the system.
main RAM
NO CAN MSG. Replace electronic control
248 PU Poor communication errors Internal error.
system.
via CANBUS
Pedal brake micro switch still
When the brake micro switch
active (open) without seat
249 PU PEDAL BRK STUCK contact is closed, the alarm
micro switch and dead man’s
disappears.
pedal micro switch.
THERMIC SENS. KO
Replace electronic control
250 PU Traction control thermal Internal error.
system.
sensor output incorrect
Please check:
- the "SET BATTERY"
parameter has the value of
the battery nominal voltage.
- the "BATTERY VOLTAGE
WRONG SET BAT. Problems with electronic
251 PU (TESTER MENU)" param-
Battery voltage too low control system parameters.
eter has the same value as
the battery nominal voltage
measured with the voltmeter.
Replace the battery if the
problem persists.
Errors in parameters Check the parameter which
253 PU SLIP PROFILE concerning SLIP. deﬁnes the SLIP proﬁle.
.

Mhyrio control alarms

Alarm
Alarm Possible cause Corrective actions
codes
Enter serial number and Calibration with PC CAN
07 HY CHOPPER NOT CONF
capacity. Console.

Try to run the CLEAR

EEPROM operation. If
the alarm disappears,
EEPROM KO the parameter default
13 HY Internal error.
EEPROM errors. values have been restored;
otherwise, if the problem
persists replace the
electronic control system.
The driver driving the (safety) Check connections.
74 HY DRIVER SHORTED valve positive is closed when If correct, replace the control
it should be open. system.
Check connections.
Problem linked to the CAN
241 HY CAN BUS KO If correct, replace the control
BUS line.
system.
Check connections.
There is a short-circuit on a
242 HY SHUNT VALVES If correct, replace the control
valve coil.
system.
The driver driving the (safety) Check connections.
243 HY DRIVER OPENED valve positive is open when it If correct, replace the control
should be closed. system.
One or more MOS driving Check connections.
244 HY DRIVER EVP GR1 valves 1 and 2 have If correct, replace the control
short-circuited. system.
One or more MOS driving Check connections.
245 HY DRIVER EVP GR2 valves 3 and 4 have If correct, replace the control
short-circuited. system.
One or more MOS driving Check connections.
246 HY DRIVER EVP GR3 valves 5, 6, 7 and 8 have If correct, replace the control
short-circuited. system.
Check connections.
One or more outputs driving
247 HY EVP GROUP 1 OPEN If correct, replace the control
valves 1 and 2 are open.
system.
Check connections.
One or more outputs driving
248 HY EVP GROUP 2 OPEN If correct, replace the control
valves 3 and 4 are open.
system.
Check connections.
One or more outputs driving
249 HY EVP GROUP 3 OPEN If correct, replace the control
valves 5, 6, 7 and 8 are open.
system.
Check connections.
Driver of output F2 or F3 or
250 HY ON/OFF DRV SHORT If correct, replace the control
F4 has short-circuited
system.
.

Display control alarms

Alarm
Alarm Possible cause Corrective actions
codes
Enter serial number and Calibration with PC CAN
7 DI CHOPPER NOT CONF capacity. Console.
WATCHDOG Problems inside the Replace electronic control
8 DI electronic control system. system.
Watchdog signal incorrect.

Try to run the CLEAR

EEPROM operation. If
the alarm disappears,
EEPROM KO the parameter default
13 DI Internal error.
EEPROM errors. values have been restored;
otherwise, if the problem
persists replace the
electronic control system.
Check connections.
76 DI COIL SHORTED Output B1 short-circuited. If correct, replace the
display.
Check connections and
mechanical operation of the
Encoder won’t read even if
82 DI ENCODER ERROR encoder.
the pump is controlled.
If correct, replace the
encoder or the display.
Input D5 (fork lowering Check that the buttons
release button 2S4) are released and working
pin X16:5 or input D6 properly.
(intermediate lift release Check that the wires on
241 DI D5 D6 INP. STUCK
button 2S5) pin X16:6 connectors X16 and X17
already closed at +10 Vdc are connected correctly.
on start up (on UPA version) Replace the display if the
detected. problem persists.
Check sensor assembly and
wiring.
Error in reading of "forks free Check that the sensor is
242 DI FREE LFT SENS KO
lift" sensor. working correctly.
If the alarm persists, replace
the display.
Check sensor assembly and
wiring.
Error in reading of "zero" Check that the sensor is
243 DI SENSOR 0 KO
sensor. working correctly.
If the alarm persists, replace
the display.
The display does not receive Check connections.
244 DI CAN BUS KO PUMP CAN messages from the If correct, replace the display
pump module. or the pump control system.
Check connections.
The driver of output B1
245 DI AUX DRIV. OPEN If correct, replace the
cannot drive the charge.
display.
Check connections.
The driver of output B1 has
246 DI AUX DRIV. SHRT If correct, replace the
short-circuited.
display.
The display does not receive Check connections. If
247 DI CAN BUS KO
any CAN messages correct, replace the display
Internal hardware error
248 DI HARDWARE FAULT Replace the display
found
The number of working hours
set after which servicing by
249 DI SERVICE REQUIRED No fault
a technician is required has
been reached.

ANALOG INPUT Replace display control

250 DI Conversion problems in A/D Problems inside the display system.
converters.
On ignition, Display requests
a copy of the hour counter Check connections.
from traction. If correct, replace the
251 DI HM SYNC. FAILED
If there is no traction display or the traction control
communication, the alarm system.
signal is generated.
HM MISMATCH
This alarm is displayed for a
period of two minutes when
the value of the hour counter
copy in traction differs by
more than ﬁve hours from
252 DI No fault
that in the display.
After two minutes the
hour counter is updated in
accordance with the "LOAD
HM TYPE" parameter
setting.
Check sensor assembly and
"Zero" sensor and "forks free
wiring.
253 DI LIFT SENS MISM. lift" sensor active at the same
Check that the sensors are
time.
working correctly.
"Lift mast reach IN cutback" Check sensor assembly and
sensor and "reach OUT wiring.
254 DI REACH SENS MISM.
cutback" sensors active at Check that the sensors are
the same time. working correctly.
.

Electrical steering control alarms

Alarm codes Possible cause Corrective actions

Check that the voltage value for inputs
3X1:10 and 3X1:11 is correct.
Electrical steering alarm in battery over / Check that the connections on connector
80 ST / 180 ST
under-voltage conditions. 3X1 are correct.
Replace the electrical steering control if
the problem persists.
Check that the steering turntable rotates
Electrical steering alarm in over-current
81 ST / 181 ST correctly without excessive effort.
conditions.
Replace the electrical steering control.
Check that the steering turntable rotates
Electrical steering alarm in overheating
82 ST / 182 ST correctly without excessive effort.
conditions.
Replace the electrical steering control.
Check that connectors 3X3 and 3X3a are
correctly connected.
Electrical steering alarm caused by
Check that potentiometer 3R2 works
83 ST / 183 ST steering wheel potentiometer: loose wire
properly.
or short-circuit.
Replace the electrical steering control if
the problem persists.

Check that connectors 3X2 and 3X2a are

connected correctly.
Electrical steering alarm caused by wheel Check that potentiometer 3R1 works
84 ST / 184 ST
potentiometer: loose wire or short-circuit. properly.
Replace the electrical steering control if
the problem persists.
Check that the transmission ratio is
Electrical steering alarm caused by model calibrated correctly.
85 ST / 185 ST
error. Replace the electrical steering control if
the problem persists.
Check that the potentiometers are
Electrical steering alarm caused by error calibrated correctly.
86 ST / 186 ST
in the motor encoder. Replace the electrical steering control if
the problem persists.

Internal error detected in the electrical

87 ST / 187 ST Replace the electrical steering control.
steering control logic.

Check that connector 6X3 is connected

CAN BUS error detected in the electrical correctly.
88 ST / 188 ST
steering control. Replace the electrical steering control if
the problem persists.
EEPROM error detected in the electrical
89 ST / 189 ST Replace the electrical steering control.
steering control.
.

4. Tightening torques

Tightening torque
Description Thread locks
(Nm)
Fitting the pump suction ﬂange 9,5
Fitting the pump supply elbow
9,5
ﬂange
Tightening the mast cylinder
9,5
mounting screws
Tightening the cable and
fuse mounting screws on the 14
electronic controllers
Fitting the load wheel mounting
23 Loctite no. 222 (weak)
cover
Fitting the leaf spring 23
Fitting the battery stop 23
Fitting the 6-tube harness
23
support bracket
Fitting the valve holder unit in the
23
frame
Fitting the traction motor 23
Fitting the load wheel brakes 46 Loctite no. 243 (medium)
Tightening the cylinder retainer
46
mounting screws
Tightening the steering motor
46
mounting screws
Tightening the load guard screws 46
Fitting the pump 70
Fitting the reduction gear,
tightening the screw of the 100
reduction gear
Fitting the drive wheel on the
150
reduction gear
Tightening the adjustment of the
200
reach carriage
Tightening the lower mast
coupling screws to the reach 200
carriage
Tightening the lower column
385
coupling screws
Fitting the battery holder trolley
Loctite no. 243 (medium)
slide guides
Fitting load wheel protection Loctite no. 222 (weak)
.

Electrical connection diagram

Sheet 1 of 18

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CODE DESCRIPTION LOCATION

350 A traction
A1 2-4
inverter
350 A lifting
A2 5-7
inverter
Electrical steering
A3 10-12
control
1F1 Safety fuse (200A) 2
2F1 Safety fuse (300A) 5
Electrical steering
3F1 10
safety fuse (30 A)
9F1 Fan safety fuse 8
G1 Battery 1
K1 General contactor 2
1M1 Traction motor 3
2M1 Lift motor 6
Electrical steering
3M1 11
motor
Motor
9M1 compartment 8
cooling fan
Battery negative
X0 10
centre
Battery socket /
X1 1
plug connector
MTA 8-way fuse
X2 8-10
holder
Black 16-pin SAAB
3X1 10-12
connector
4-way AMP TIMER
9X1 8/9
connector
.

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Electrical connection diagram

Sheet 2 of 18

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CODE DESCRIPTION LOCATION Intermediate lift Lift mast stroke-end MOLEX MINIFIT
2X2 17-29
MHYRIO FLASH 2B4 stroke-end inductive 26 2B8 inductive sensor 30 18-way connector
A4 14-30 sensor (OPT) (OPT) MOLEX MINIFIT
controller
2X3 26-27
Lift mast retraction Lift stroke-end Auxiliary safety fuse 4-way connector
F1 15
2B1 retardation inductive 18 2B5 inductive sensor 27 (10 A) 4-way SAAB
(OPT) 2X4 28
sensor MOLEX MINIFIT connector
Lift mast extension X3 14-16 MOLEX MINIFIT
Forks in free lift 6-way connector
2B2 retardation inductive 21 2X5 29
2B6 inductive sensor 28 MOLEX MINIFIT 6-way connector
sensor (OPT) X4 17-18/20-28 4-way SAAB
22-way connector
Lowering / 400 mm 2x6 29
Height detection MOLEX MINIFIT connector
lift mast retraction 2B7 inductive sensor 29 X7 19/29-30 4-way AMP TIMER
2B3 24 6-way connector 2X6/1 29
block inductive (OPT) connector
MOLEX MINIFIT
sensor (OPT) 2x1 17-30
18-way connector
.

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21/11/2011 OM Service 36/91 020

Electrical connection diagram

Sheet 3 of 18

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CODE DESCRIPTION LOCATION 2Y6 Tilt up solenoid valve 41 MOLEX MINIFIT 2X10 2-way JPT connector 34
X3 32
MHYRIO FLASH Right side shift 6-way connector 2X11 2-way JPT connector 37
A4 31-52 MOLEX MINIFIT
controller 2Y7 solenoid valve 43 2X12 2-way JPT connector 39
X4 35-36
...... ...... ...... (OPTIONAL) 22-way connector
2X13 2-way JPT connector 41
2Y1 Lifting solenoid valve 31 Left side shift MOLEX MINIFIT
X5 31/33-45 2X14 2-way JPT connector 43
2Y8 solenoid valve 45 16-way connector
Lowering
2Y2 proportional solenoid 33 (OPTIONAL) MOLEX MINIFIT 2X15 2-way JPT connector 45
X6 46-52
valve 1st auxiliary 10-way connector 2X16 2-way JPT connector 48
Lift mast reach IN 2Y9 hydraulics solenoid 48 2X7 3-way JPT connector 31-33 2-way JPT connector
2Y3 34 2X17 52
solenoid valve valve 1 (OPTIONAL) MOLEX MINIFIT
2X8 38-52
.

Lift mast reach OUT 1st auxiliary 16-way connector

2Y4 37
solenoid valve 2Y10 hydraulics solenoid 52 MOLEX MINIFIT
Tilt down solenoid valve 2 (OPTIONAL) 2X9 38-52
2Y5 39 16-way connector
valve

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Electrical connection diagram

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CODE DESCRIPTION LOCATION Tilt down solenoid 1st auxiliary MOLEX MINIFIT
2Y5 39 2X9 38-52
MHYRIO FLASH valve 2Y11 hydraulics solenoid 51 16-way connector
A4 31-52 2Y6 Tilt up solenoid valve 41 valve 2 (OPTIONAL)
controller 2X10 2-way JPT connector 34
6th hydraulics Right side shift 2nd auxiliary 2X11 2-way JPT connector 37
2K1 activation relay 48 2Y7 solenoid valve 43 2Y12 hydraulics solenoid 53
2X12 2-way JPT connector 39
contact (UPA) (OPTIONAL) valve " (OPTIONAL)
6th hydraulics Left side shift MOLEX MINIFIT 2X13 2-way JPT connector 41
X3 32 2-way JPT connector
2K2 activation relay 52 2Y8 solenoid valve 45 6-way connector 2X14 43
contact (UPA) (OPTIONAL) MOLEX MINIFIT 2X15 2-way JPT connector 45
X4 35-36
2Y1 Lifting solenoid valve 31 1st auxiliary 22-way connector 2-way JPT connector
2X16 47
Lowering 2Y9 hydraulics solenoid 47 MOLEX MINIFIT
X5 31/33-45 2X17 2-way JPT connector 51
2Y2 proportional solenoid 33 valve 1 (OPTIONAL) 16-way connector
1st auxiliary MOLEX MINIFIT 2X18 2-way JPT connector 49
valve
hydraulics solenoid X6 46-52 2X19 2-way JPT connector 53
Lift mast reach IN 2Y10 49 10-way connector
2Y3 34
solenoid valve valve 2 (OPTIONAL) 2X7 3-way JPT connector 31-33
.

Lift mast reach OUT MOLEX MINIFIT

2Y4 37
solenoid valve 2X8 38-52
16-way connector

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Electrical connection diagram

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CODE DESCRIPTION LOCATION Altimeter MOLEX MINIFIT MOLEX MINIFIT

8P1/1 60-64 X7 74-75 2X9 67-69
MHYRIO FLASH (OPTIONAL) 6-way connector 14-way connector
A4 54-77 MOLEX MINIFIT MOLEX MINIFIT
controller 6S1 Programming switch 65
2x1 54-57 6X1 59-66
1st/2nd auxiliary 2V1 Diode 73 18-way connector 8-way connector
2K1 hydraulic line relay 68 MOLEX MINIFIT 6-way SAAB
2V2 Diode 74 2X2 54-57 8X1 54-57
coil 18-way connector connector
1st/2nd auxiliary 2V3 Diode 75 MATE-N-LOCK
6-way SAAB 8X1/1 60-64
2K2 hydraulic line relay 70 MOLEX MINIFIT 2X5 54-57 4-way connector
X4 72-73 connector
coil 22-way connector 4-way SAAB MOLEX MINIFIT
MOLEX MINIFIT 2x6 58 8X2 54-57
6P1 MHYRIO console 59-64 connector 4-way connector
X5 76-77
Pre-selector 16-way connector MOLEX MINIFIT
8P1 54-57 2X8 67-69
.

(OPTIONAL) MOLEX MINIFIT 16-way connector

X6 67-71
10-way connector

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Electrical connection diagram

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CODE DESCRIPTION LOCATION 16-way SAAB FCI SICMA

3X1 78-79/88-90 3X3 84-87
Electrical steering connector connector
A3 78-90 6-way FCI SICMA 8-way ESCHA
control 3X2 80-83 3X3a 84-87
Drive wheel connector connector
3R1 80-83 8-way ESCHA
potentiometer
.

3X2a 80-83
Steering potentiome- connector
3R2 84-87
ter

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Electrical connection diagram

Sheet 7 of 18

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CODE DESCRIPTION LOCATION 9R1 10 Ohm NTC 101 MOLEX MINIFIT 3-way AMP
X9 94-97/101
350 A traction Direction-of-travel 12-way connector 1X3 ECONOSEAL 115
A1 91-122 1S1 104 MOLEX MINIFIT connector
inverter button
X10 104 3-way AMP
Traction motor 6S2 Programming switch 97 20-way connector
1B1 110 1x4 ECONOSEAL 116-117
temperature sensor 103 10-way AMP TIMER
7S1 Seat micro X11 115-122 connector
1B2 Gear selector 115-117 connector
Dead man’s micro 6X2 8-way connector 91-98
Flashing (OPTIO- 7S2 122 MOLEX MINIFIT
switch X17 104
4H1 96 / 101 14-way connector 4-way AMP
NAL) V1 Diode 112
MOLEX MINIFIT 7x1 SUPERSEAL 103
Flashing (OPTIO- 1V1 Diode 113 X21 94 / 96
4H1/1 100 10-way connector connector
NAL) 4-way AMP JPT
4V1 Diode 102 3-way AMP 8X3 106-109
K1 Main switch coil 112 connector
Electromagnetic 1X1 ECONOSEAL 110
6P2 Console 91-96 Y1 114
brake connector
.

8P2 Traction encoder 106-109 23-way AMP SEAL 4-way AMP TIMER
X8 99-122 1X2 114
470 Ohm 4 watt connector connector
1R1 ......
resistor

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Electrical connection diagram

Sheet 8 of 18

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CODE DESCRIPTION LOCATION 6P3 Console 123-128 MOLEX MINIFIT AMP ECONOSEAL
X9 134-148 2X20 140
8P3 Pump motor encoder 136-139 12-way connector 3-way connector
A2 350 A lifting inverter 123-149 23-way AMP SEAL
Brake pedal micro 6X3 8-way connector 123-130
Pump motor thermal 1S2 142 X12 131-149
2B9 140 switch connector 4-way AMP JPT
sensor MOLEX MINIFIT 8X4 136-139
2S1 Lift stop (UPA) 134 2X8 134 connector
9M2/1 Logic cooling fan 144 16-way connector MOLEX MINIFIT
6S3 Programming switch 129 9X2 144-146
9M2/2 Logic cooling fan 145 MOLEX MINIFIT 4-way connector
9V1 Diode 143 2X9 134
9M2/3 Logic cooling fan 146 16-way connector .

9M2/4 Logic cooling fan 147

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Electrical connection diagram

Sheet 9 of 18

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CODE DESCRIPTION LOCATION Timed slow lifting MOLEX MINIFIT MOLEX MINIFIT
X13 168 2X9 156-157
2S3 activation photo eye 160 6-way connector 16-way connector
A5 Display ZAPI 150-169 (UPA) MOLEX MINIFIT MOLEX MINIFIT
Fork height over xxx X15 166-167 6X4 150-157
Fork lowering 12-way connector 8-way connector
2B10 mm magnetic sensor 156-157 2S4 162
release button (OPT) MOLEX MINIFIT .

(UPA) Intermediate fork X16 158-165

8-way connector
6P4 Console 150-155 2S5 lowering release 163 MOLEX MINIFIT
Contoured battery button (OPT) X17 162/163/164
14-way connector
1S3 161
micro switch 2nd auxiliary MOLEX MINIFIT
Slow speed 2S6 hydraulics button 166 2x1 160
1S4 164 18-way connector
activation switch (UPT) MOLEX MINIFIT
1S5 Parking brake switch 165 Programming switch 2X2 160
6S4 156 18-way connector
1st auxiliary MOLEX MINIFIT 158/160/161/168- MOLEX MINIFIT
2S2 hydraulics button 159 X10 2X8 156-157
20-way connector 169 16-way connector
(OPT)

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Electrical connection diagram

Sheet 10 of 18

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CODE DESCRIPTION LOCATION Tilt up / down MOLEX MINIFIT MOLEX MINIFIT

2R3 175-176 X14 180-182 2X23 173-174
potentiometer 4-way connector 4-way connector
A5 Display ZAPI 170-184 Right / left side MOLEX MINIFIT MOLEX MINIFIT
Keypad relay coil shift potentiometer X15 170-179 2X24 175-176
K2 180 2R4 177-179 12-way connector 4-way connector
(UPA) (OPTIONAL) MOLEX MINIFIT MOLEX MINIFIT
Lifting / lowering MOLEX MINIFIT X22 180 2X25 177-179
2R1 170-172 4-way connector 4-way connector
potentiometer X10 182-184
20-way connector MOLEX MINIFIT MOLEX MINIFIT
Lift mast forwards MOLEX MINIFIT 2X22 170-172
4-way connector 2X26 12-way / 16-way 170-176/170-179
2R2 / backwards 173-174 X13 183-184
6-way connector connector
potentiometer .

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Electrical connection diagram

Sheet 11 of 18

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CODE DESCRIPTION LOCATION 48/12V converter Emergency stop MOLEX MINIFIT

G4 198-200 7S3 187-188 X17 186/187-188/191
(OPTIONAL) button 14-way connector
F2 10 A safety fuse 186 3V1 Diode 189 MOLEX MINIFIT
4H3 Horn 190 192-194/195-
10A safety fuse X18
F3 194 K2 Keypad relay contact 185 4V2 Diode 190 14-way connector 196/198-199
(OPTIONAL) MOLEX MINIFIT
Electrical steering 4V3 Diode 191 X22 185
10A safety fuse 3K1 189 4-way connector
F4 196 contactor coil 8-way MTA
(OPTIONAL) X2 186/194/196 2-way FASTIN
4K1 Horn relay 190/191 connector X26 185
48/24 V converter FASTON connector
G2 192-194 S1 Key 186 MOLEX MINIFIT
(OPTIONAL) X10 186/187-188/191
20-way connector
.

48/24 V converter 4S1 Horn button 191

G3 195-197
(OPTIONAL)

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Electrical connection diagram

Sheet 12 of 18

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CODE DESCRIPTION LOCATION 10A safety fuse Seat + cabin heater MOLEX MINIFIT
F6 202 9S1 205 X18 206/207/208/209
(OPTIONAL) switch (OPT) 14-way connector
Left work light
5E1 213 9K4 48 V relay 207-208 Thermal switch MOLEX MINIFIT
(OPTIONAL) 9S2 208 X19 203-205
Step plate heater (OPTIONAL) 6-way connector
Right work light 9R1 207
5E2 215 (OPTIONAL) 9V2 Diode 207 4-way ITT CANNON
(OPTIONAL) X20 206/207/208
9R2 Seat heater (UPA) 209 9V3 Diode 208 connector
Left position light
5E3 211
.

(UPA) Work light switch 8-way MTA

5S1 203 X2 201/202
Right position light (OPTIONAL) connector
5E4 212 Position light switch MOLEX MINIFIT
(UPA) 5S2 204 X9 211/214
(UPA) 12-way connector
2A safety fuse
F5 201
(OPTIONAL)

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Electrical connection diagram

Sheet 13 of 18

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CODE DESCRIPTION LOCATION A5 Display 216-218 MOLEX MINIFIT 4-way AMP CPC
X13 216-217 6X6 225-226
MOLEX MINIFIT 6-way connector connector
350 A traction X3 225-226 BINDER 4-way
A1 219-220 6-way connector MOLEX MINIFIT 6X7 227-228
inverter X14 218 connector
23-way AMP SEAL 6-way connector
A2 350 A lifting inverter 221-222 X8 219-220
connector MOLEX MINIFIT
.

Electrical steering 6X5 216-217

A3 227-228 23-way AMP SEAL 4-way connector
control X12 221-222
connector
Controller MHYRIO
A4 225-226
FLASH

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Electrical connection diagram

Sheet 14 of 18

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CODE DESCRIPTION LOCATION Side shift / tilt Emergency stop MOLEX MINIFIT
7S3 247 2X26 230-241
2R3 /1st hydraulics 238-241 button 16-way connector
A5 Disply 230-243 potentiometer MOLEX MINIFIT 16-way AMP
X15 230-242
A6 Joystick 230-246 Direction-of-travel 12-way connector 2X27 MULTILOC 230-237
1S1 245
Lifting / lowering button MOLEX MINIFIT connector
2R1 230-233 X16 243
potentiometer Side shift activation 8-way connector .

2S2/1 243
Lift mast forwards button MOLEX MINIFIT
1st auxiliary X17 242-245
2R2 / backwards 234-237 14-way connector
2S6/1 hydraulics activation 242 12-way AMP
potentiometer
button X24 MULTILOC 238-246
4S1 Horn button 244 connector

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Electrical connection diagram

Sheet 15 of 18

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CODE DESCRIPTION LOCATION MOLEX MINIFIT BINDER 4-way

X18 248-250 9X5 257-260
14-way connector connector
MOTEC monitor BINDER 4-way
9E1 251-260 MOLEX MINIFIT 9X6 261-264
(OPTIONAL) X25 249-250 connector
2-way connector
MOTEC camera BINDER 5-way
9E2 261-265 MOLEX MINIFIT 9X7 261-265
(OPTIONAL) 9X3 251-256 connector
6-way connector
G2 48 V/24 V converter 248-250
.

BKL connector -
9X4 257-260
4-way electronic

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Electrical connection diagram

Sheet 16 of 18

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CODE DESCRIPTION LOCATION MATE-N-LOCK

9X8 267-269/274-276
3-way connector
G3 48 V/24 V converter 266-268 BINDER 3-way
9X9 270-272/277-279
G4 48 V/12V converter 273-275 connector
MOLEX MINIFIT
.

X18 266-267/273-274
14-way connector

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Electrical connection diagram

Sheet 17 of 18

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CODE DESCRIPTION LOCATION 20A safety fuse Front window resi- 5°- 30° temperature
9F4 294 9R3 291 9S3 299
(OPTIONAL) stor (OPTIONAL) switch (OPTIONAL)
Hot air conveyor
A7 300-304 35A safety fuse Left window resistor 9S4 Switch (OPTIONAL) 298
(OPTIONAL) 9F5 303 9R4 291
(OPTIONAL) (OPTIONAL) 9S5 Switch (OPTIONAL) 299
Cab light
5E5 284 15A safety fuse Rear window resistor
(OPTIONAL) 9F6 304 9R5 293 9S6 Switch (OPTIONAL) 302
(OPTIONAL) (OPTIONAL)
Socket for radio or MOLEX MINIFIT
9E3 289 48 V/24 V converter Right window resi- X18 280-286
CB (OPTIONAL) G2 280-282 9R6 293 14-way connector
(OPTIONAL) stor (OPTIONAL)
80 A safety fuse MOLEX MINIFIT 283-284/286/300-
F7 287 Cab general Upper window resi- X21
(OPTIONAL) 9R7 293 10-way connector 302
K3 contactor 286/287 stor (OPTIONAL)
5A safety fuse (OPTIONAL) MOLEX MINIFIT
F8 298 1200 W conveyor
(OPTIONAL) X25 2-way connector 281-282
Window resistors 9R8 resistors 303
Safety fuse (OPTIONAL)
F9 297 9K1 contactor 292/295 (OPTIONAL)
(OPTIONAL) (OPTIONAL) FASTIN FASTON
500 W conveyor
5A safety fuse 9X10 3-way connector 300-302
5F1 284 Conveyor resistors 9R9 resistors 304
(OPTIONAL) 9K2 298/303 (OPTIONAL)
contactor (OPT) (OPTIONAL)
3A safety fuse Connector
9F2 289 Conveyor resistors Interior light switch 9X11 290/292/294
(OPTIONAL) 9K3 299/304 5S3 283 (OPTIONAL)
contactor (OPT) (OPTIONAL)
20A safety fuse Connector
9F3 290 Fan conveyor Door position light 9X12 295/296/297
(OPTIONAL) 9M3 300 5S4 285 (OPTIONAL)
(OPTIONAL) switch (OPTIONAL) .

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 66/91 020

Electrical connection diagram

Sheet 18 of 18

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 67/91 020

CODE DESCRIPTION LOCATION MOLEX MINIFIT MOLEX MINIFIT

X10 281/282-286 X17 281/284-285
20-way connector 14-way connector
K2 Digicode option relay 282-283 MOLEX MINIFIT MOLEX MINIFIT
X13 280 X22 282/283
Emergency stop 6-way connector 4-way connector
7S3 281/284-285
button MOLEX MINIFIT .

X14 282
4-way connector

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 68/91 020

Electrical connection diagram

Sheet 19

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 69/91 020

CODE DESCRIPTION LOCATION

Relay for optional
4K2 287-288
BUZZER
4H2 BUZZER (UPA) 290-291
4V4 Diode 291
MOLEX
X9 MINIFIT 12-way 287
connector
.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 70/91 020

Hydraulic connection diagram - sheet 1/10

Functional diagram
2Y2 2Y1 2Y3 2Y4 2Y5 2Y6 2Y8 2Y7 2Y9 2Y10
n
M1 (2X7 (2X7 (2X10 (2X11 (2X12 (2X13 (2X15 (2X14 (2X16 (2X17
(1/min)
connector) connector) connector) connector) connector) connector) connector) connector) connector) connector)
Lifting X XH X
Lift mast
Lowering X
Side shift lift Extension X XH X
mast Retraction X XH X
High (+) X XH X
Tilt
Low (-) X XH X
Right (steering
X XH X
Side shift wheel side)
Left (seat side) X XH X
1 auxiliary a X XH X
hydraulics b X XH X

XH: speed control from 0 to the maximum set Ø (B1) 2.4 2.6 2.7 2.8
speed Default
X: powered .

Settings
Maximum pressure setting: working pressure
with load +10%
Maximum lowering speed setting: max.
0.6 m/s with load
Overcenter valve opening pressure: 17 -
34 bar

Tilt diaphragm = 3S
2600
BH < h1 < GN +
≤H≤
2600 3600 SS
3600
De-
Ø (A1) 1.9 1.9 1.9 1.9
fault
De-
Ø (B1) 1.8 1.8 1.8 1.8
fault
.

Diaphragms for limiting side shift lift mast

speed
Vmax
Side 10.5 11.5 10.5
12 cm/s
shift lift cm/s cm/s cm/s
mast
Ø (A1) 3 3.2 3.5 3.7

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 71/91 020

Hydraulic connection diagram - sheet 2/10

Main block - uncombined movements

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 72/91 020

Legend
Lato operatore Operator side
rientro Retraction
uscita Extension
Lato forche Fork arm side
Diametri Diameters
Bilanciamento di
Pressure balancing
pressione
Nachsaugung Cavitation
Discesa manuale Manual lowering
Regolazione max. vel. Maximum adjustment.
discesa Lowering speed
discesa Lowering
sollevamento Lifting
regolazione pressione Maximum pressure
di max. setting
Valvola Proporzionale Proportional valve
Attacco misurazione
MP measurement port
Mp
Attacchi Connections
.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 73/91 020

Hydraulic connection diagram - sheet 3/10

Main block - combined movements

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 74/91 020

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 75/91 020

Hydraulic connection diagram - sheet 4/10

MN column tilt - uncombined

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 76/91 020

Legend
Basso Low
Alto High
Lato forche Fork arm side
Lato operatore Operator side
Brandeggio Tilt
Corsa Travel
.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 77/91 020

Hydraulic connection diagram - sheet 5/10

Column tilt + side shift MN + SS - uncombined movements

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 78/91 020

Legend
Basso Low
Alto High
Lato forche Fork arm side
Lato operatore Operator side
Brandeggio Tilt
Corsa Travel
Destra Right
Sinistra Left
Right steering wheel
DX (lato volante)
side
SX (lato sedile) Left seat side
Attacchi .... come vista Connections... as
su foglio ... seen on sheet...
.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 79/91 020

Hydraulic connection diagram - sheet 6/10

Column tilt + side shift MN + SS - combined movements

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 80/91 020

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 81/91 020

Hydraulic connection diagram - sheet 7/10

Fork tilt, side shift GN + SS - uncombined movements

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 82/91 020

Legend
Basso Low
Alto High
Lato forche Fork arm side
Lato operatore Operator side
Destra Right
Sinistra Left
Right steering wheel
DX (lato volante)
side
SX (lato sedile) Left seat side
Attacchi .... come vista Connections... as
su foglio successivo seen on next sheet
.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 83/91 020

Hydraulic connection diagram - sheet 8/10

Fork tilt, side shift GN + SS - combined movements

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 84/91 020

Legend
Basso Low
Alto High
Destra Right
Sinistra Left
Right steering wheel
DX (lato volante)
side
SX (lato sedile) Left seat side
Diaframma ... vedi tab. Diaphragm ... see
foglio 1 table on sheet 1
Lato forche Fork arm side
Lato operatore Operator side
.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 85/91 020

Fork tilt + side shift + 1 aux. hydr. GN + SS + 1 ZH - combined movements

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 86/91 020

Legend
montata su piastra
Fitted on baseplate
base
Lato forche Fork arm side
Lato operatore Operator side
Diaframma ... vedi tab. Diaphragm ... see
foglio 1 table on sheet 1
Quick-release
Attacchi rapidi
couplings
.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 87/91 020

Hydraulic connection diagram - sheet 9/10

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 88/91 020

Legend
per to
da from
sempre per always to
.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 89/91 020

Hydraulic connection diagram - sheet 10/10

De- Manu- AV
Appli-
Pos. scrip- factu- Code Qty MN 5335
cation
tion rer + SS hy- Buch-
B12 8423576 1
XR com- drau- holz
12-14-16 AV bined lic
h1≤ 6267 block
2900 hy- Buch- AV
B11 0009440419
1 GN
UN- drau- holz 6279
+ SS
COM- lic hy- Buch-
B12 un- 0009440425
1
BI- block drau- holz
com-
NED lic
bined
XR block
14-16 AV
AV
h1> GN 5532
6268
2900 + SS hy- Buch-
hy- Buch- B12 0009442260
1
B11 UN- 0009440420
1 com- drau- holz
drau- holz
COM- bined lic
lic
BI- block
block
NED AV
GN +
XR 20 5545
SS +
AV hy- Buch-
XR B12 1ZH 0009442261
1
5767 drau- holz
12-14-16 com-
hy- lic
h1≤ Buch- bined
B11 drau- 0009442686
1 block
2900 holz
lic B16 + 1ZH Valve Hytos 8424581 1
com-
block 11.5
bined
(white) M1 kW July
XR AV motor
14-16 5333 XR
h1> hy- 12-14-16
Buch- 11.9
B11 2900 drau- 8425931 1 h1≤
Ca-
holz cc
com- lic P1 2900 8426480 1
sappa
bined block un- pump
XR 20 (red) com-
AV bined
MN 6162 XR
un- hy- Buch- 14-16
B12 0009440414
1 h1
com- drau- holz 17.9
bined lic h1> Ca-
P1 cc 8426482 1
block 2900 sappa
pump
AV un-
MN
6161 com-
+ SS
hy- Buch- bined
B12 un- 0009440413
1 15.4
drau- holz Ca-
com- cc
lic P1 XR 20 8426481 1
bined sappa
block pump

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
D11-05.1 Service Information
Date by Page Group Register no. Valid until
21/11/2011 OM Service 90/91 020

Safety Safety
valve valve
with with
525556 523514
S2 8417847 1
LB3C0,5-52 LB3C2X1,2-70
still S8 (or 8417898 1
dia- 1,7-
phragm 70)
Safety still
valve dia-
with phragm
S3 524500LB4C1,5-90
8414779 1 Safety
still valve
dia- with
phragm 525555
S9 8417845 1
Safety LB3C1,0-48
valve still
with dia-
S4 522100LB3C1,2-63
8415310 1 phragm
still See
S10 8417847 1
dia- S2
phragm
Safety T1 Tank 8427806 1
valve Argo
W1 Filter 8429976 1
with
S5 LB3C0,8-80 8417844 1
still De-
dia- pen-
phragm ding
on Ø 50/30
Still side
527089 bat-
tery shift
S Va-
Z1 lift 1
B31c- com- rious
part- mast
S6 43/200 8421546 1
ﬂow ment cylin-
and der
cont-
rol capa-
valve city
Safety MN
h1< Ø 55
valve
2500 tilt
with Z2 0388422 2
(-1st / cylin-
525557
S7
LB3C0,5-35
8417848 1 3rd) der....44
still MN
h1≥ Ø 55
dia-
2500 tilt
phragm Z2 0618526 2
(-1st / cylin-
2nd) der....26.5

Ø 46
right
Z7 side Still 1
cylin-
der

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.
Service Information D11-05.1
Date by Page Group Register no. Valid until
21/11/2011 OM Service 91/91 020

Ø 46
left
Z8 side Still 1
cylin-
der
Ø 68
centre
Z9 Still 1
cylin-
der
Ø 63
See
centre
Z9 sheet Still 1
cylin-
8
der
Ø37
DV
See side
Z10 sheet cylin- Still 1
8 der
(feed-
through)
Ø 37
left
Z11 side Still 1
cylin-
der
Ø 55
centre
Z12 Still 1
cylin-
der

Kaup
Cylin-
Z13 GN / Cas- 2
der
cade
Kaup
Cylin-
Z14 SS / Cas- 2
der
cade
.

This service document is provided for use only and remains the exclusive property of OM Carrelli Elevatori S.p.A. Distribution to third party is strictly prohibited.

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Zapi Controller

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Zapi Controller

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Service Information D11-05.

Family Model Validity

XR09ac (4563) preliminary information

Differences between the two systems.

The following have also been added:

Software Version System code

The main differences are:

The tilt and sideshift functions cannot be combi-

Software Version System code

The software for Flash programming is:

"CSV File" to load

load" tables), and when the drop-down menu

TRUCK WITH "COMBINED" MOVEMENTS

TRUCK WITH "NON-COMBINED" MOVEMENTS

Performance Type value loaded by default on ignition.

MAX EV CAR IND Maximum current (lift mast reach IN valve)

Values of "HYDRAULICS" parameters

MAX EV LIFT 230 (*) 246 (*)

mm* = to be multiplied by 100

"HOUR COUNTER" Menu

"HEIGHT DISPLAY" Menu

mm* = to be multiplied by 100

Description of the TESTER menu

"PUMP TESTER" Menu

MOTOR TEMPERAT. Pump motor temperature °C

"MHYRIO TESTER" Menu

EV F4 ADDICT FUN Valve 2Y9/2Y11 valve activation status (UPA) On / Off

"DISPLAY TESTER" Menu

NUM #8 Numeric keypad button “8” signal status On / Off

Traction control system alarms

Try to run the CLEAR

CONTACTOR CLOSED Check the main contactor

At the next drive request, the

WRONG RAM MEM-

Pump control alarms

Try to run the CLEAR

CONTACTOR CLOSED Check the main contactor

Recalibrate the max. and

Mhyrio control alarms

Try to run the CLEAR

Display control alarms

Try to run the CLEAR

ANALOG INPUT Replace display control

Electrical steering control alarms

Alarm codes Possible cause Corrective actions

Check that connectors 3X2 and 3X2a are

Internal error detected in the electrical

Check that connector 6X3 is connected

Electrical connection diagram

CODE DESCRIPTION LOCATION

Electrical connection diagram

Electrical connection diagram

Lift mast reach OUT 1st auxiliary 16-way connector

Electrical connection diagram

Lift mast reach OUT MOLEX MINIFIT

Electrical connection diagram

CODE DESCRIPTION LOCATION Altimeter MOLEX MINIFIT MOLEX MINIFIT

(OPTIONAL) MOLEX MINIFIT 16-way connector

Electrical connection diagram

CODE DESCRIPTION LOCATION 16-way SAAB FCI SICMA

Electrical connection diagram

Electrical connection diagram

9M2/4 Logic cooling fan 147

Electrical connection diagram

(UPA) Intermediate fork X16 158-165

Electrical connection diagram

CODE DESCRIPTION LOCATION Tilt up / down MOLEX MINIFIT MOLEX MINIFIT

Electrical connection diagram

CODE DESCRIPTION LOCATION 48/12V converter Emergency stop MOLEX MINIFIT

48/24 V converter 4S1 Horn button 191

Electrical connection diagram

(UPA) Work light switch 8-way MTA

Electrical connection diagram

Electrical steering 6X5 216-217

Electrical connection diagram

Electrical connection diagram

MAX EV LIFT 230 () 246 ()