The following headings contain a description of the procedure for replacing each individual module in such a way that at the end of the operation the truck operates in exactly the same way as with the original modules.
Note: Ensure you perform this procedure without skipping any of the steps in the sequence. Incorrect operations could damage the new module.
Before replacing any of the modules check the table of settings relative to the module as shown in the manual and compare them with the parameters stored on the module in the PARAMETER CHANGE and SET OPTIONS submenus. The values could be different depending on the options enabled.
At the end of the replacement operation always check that the new module is programmed in exactly the same way as the original module.
8.1 REPLACING MODULES 2 OR 5 - TRACTION OR PUMP INVERTER AC2
Before starting the replacement procedure save the controller settings on the console by means of the
SAVE PARAMETERS submenu present in the MAIN MENU (for more details refer to the “AC MOTORS
MODULAR CONTROL SYSTEM” manual).
1) Switch off the keyswitch an press the emergency pushbutton. 2) Disconnect the battery.
3) Only when the battery is disconnected: connect a resistor of between 33 and 100 Ohm 50W across the inverter positive B+ and negative B-. Wait for approximately 8 seconds while for the controller internal capacitors to discharge and then disconnect the resistor.
Note: To avoid short-circuits ensure that the resistor is insulated.
If it is impractical to use an external resistor to discharge the capacitors you must wait at least 90 seconds before disconnecting any of the power cables.
1234 1234 1234 1234 1234 1234 1234 1234 60 Ohm 50W RESISTOR Fig. 26
ELECTRICAL SYSTEMELECTRICAL SYSTEM
4) Disconnect the power cables, ensuring that they are still marked in relation to the corresponding connectors; if the cables are not marked, mark them before disconnecting.
5) Disconnect auxiliary connectors C,D,F. In the case of the PUMP inverter, remember to disconnect the jumper on connector B to apply it to the new controller. Without this jumper the system is unable to operate. This jumper is not present on the TRACTION inverter.
B A TTER Y CABLES TRACTION MOTOR POWER CABLES A2 D2 F2 E2 B2 C2 Fig. 27 B A TTER Y CABLES PUMP MOTOR POWER CABLES A5 B5 D5 C5 F5 E5 Fig. 28
ELECTRICAL SYSTEM
6) Unscrew the screws that secure the controller to the truck and remove the inverter.
7) Install the new module fitting the screws, connectors and cables in accordance with a reverse sequence of operations with respect to the removal procedure. Remember that connector B of the PUMP inverter must be equipped with a jumper.
8) Connect the console to the inverter
9) After having checked the correct connection of the cables, connect the battery, reset the emergency switch and set the keyswitch to ON.
10) By means of the RESTORE PARAMETERS submenu in the MAIN MENU, download to the controller the module settings previously saved to the console by means of the SAVE PARAMETERS
procedure.
11) With the assistance of the table in the manual check that all the PARAMETER CHANGE and SET
OPTIONS submenu settings correspond.
12) Test all the truck functions.
8.2 REPLACING MODULE 1 - CAN I/O
Note: the CAN I/O module is identical in terms of size, shape, and connector positions, to the MHYRIO module. Therefore, when replacing this module pay special attention to the identification label on the outer case.
The truck duty hours are stored on the CAN I/O and SICOS (display) modules. If it should become necessary to renew the CAN I/O module you must first execute a procedure that makes it possible to transfer the duty hours value stored in the display to the new CAN I/O module.
1) With the keyswitch set to OFF connect the console to the SICOS module (display). Set the keyswitch to ON.
2) In the CONFIG MENU>SET OPTIONS submenu set the AUX FUNCTION 1>parameter to OFF.
This allows the CAN I/O module to set up to receive the truck duty hour data stored on the DISPLAY. Before starting the replacement procedure remember to save the controller settings to the console by means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to the “AC MOTORS MODULAR CONTROL SYSTEM” manual).
3) Switch off the keyswitch and press the emergency pushbutton. 4) Disconnect the battery.
5) Disconnect all the connectors after checking that their positions are clearly identified. 6) Unscrew the screws that secure the module to the truck and remove the module.
7) Install the new module, fitting the screws and connectors by following the removal steps in reverse order.
8) After having checked that the connectors are correctly inserted, connect the console to the CAN I/O module by means of the adapter that you removed from the faulty module and then inserted on the relative connector of the new CAN I/O module.
ELECTRICAL SYSTEMELECTRICAL SYSTEM
10) With the console, via the RESTORE PARAMETERS submenu present in the MAIN MENU upload to the controller the settings of the module previously saved on the console by means of the SAVE
PARAMETERS procedure.
11) Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE and SET OPTIONS submenus correspond, including any option settings.
12) Test all the truck functions.
8.3 REPLACING SICOS MODULE 16 (display)
The truck duty hours are stored on the SICOS module and CAN I/O bus. If you need to replace the SICOS module you must perform a procedure that makes it possible to transfer the duty hours memorized on the CAN I/O to the SICOS.
1) With the keyswitch set to OFF connect the console to the SICOS module. Set the keyswitch to ON. 2) In CONFIG MENU>SET OPTIONS set the parameter AUX FUNCTION 1>to OFF. In this manner the SICOS module sets up to accept the truck operating hours stored on the CAN I/ O bus.
Before starting the replacement procedure remember to save the controller settings to the console by means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to the “AC MOTORS MODULAR CONTROL SYSTEM” manual).
3) Switch off the keyswitch and press the emergency pushbutton. 4) Disconnect the battery.
5) Disconnect all the connectors after checking that their positions are clearly identified. 6) Unscrew the screws that secure the module to the truck and remove the module.
7) Install the new module, fitting the screws and connectors by following the removal steps in reverse order.
8) After having checked that the connectors are correctly inserted, connect the console to the SICOS module by means of the adapter that you removed from the faulty module and then inserted on the relative connector of the new SICOS module.
9) Connect the battery, reset the emergency pushbutton and set the keyswitch to ON.
10) Using the console, by means of the RESTORE PARAMETERS submenu located in the MAIN MENU, download to the controller the settings of the original module saved on the console by means of the SAVE PARAMETERS procedure.
11) With the assistance of the table in the manual check that all the adjustments relative to the
PARAMETER CHANGE and SET OPTIONS submenus correspond, including possible changes
relative to the option settings. 12) Test all the truck functions.
Note: If the options “PASSWORD” or “PRE-HEIGHT SELECTOR” were enabled on the previous display, these functions must be completely reset by means of the new display (see relative heading).
ELECTRICAL SYSTEM
8.4 REPLACING MODULE 9 - MHYRIO
Before starting the replacement procedure remember to save the controller settings to the console by means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to the “AC MOTORS MODULAR CONTROL SYSTEM” manual).
1) Set the keyswitch to OFF and press the emergency pushbutton. 2) Disconnect the battery.
3) Disconnect all the connectors after checking that their positions are clearly identified. 4) Unscrew the screws that secure the controller to the truck and remove the module.
5) Install the new module, fitting the screws and connectors by following the removal steps in reverse order.
6) After having checked that the connectors are correctly inserted, connect the console to the MHYRIO module by means of the adapter that you removed from the faulty module and then inserted on the relative connector of the new MHYRIO module.
7) Connect the battery, activate the emergency switch and set the keyswitch to ON.
8) With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU, download to the controller the module settings previously saved to the console by means of the SAVE
PARAMETERS procedure.
9) Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE and SET OPTIONS submenus correspond, including any option settings.
10) Test all the truck functions.
8.5 REPLACING MODULE 6 - EPS-AC
Before starting the replacement procedure remember to save the controller settings to the console by means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to the “AC MOTORS MODULAR CONTROL SYSTEM” manual).
1) Set the keyswitch to OFF and press the emergency pushbutton. 2) Disconnect the battery.
3) Disconnect all the connectors after checking that their positions are clearly identified. 4) Unscrew the screws that secure the controller to the truck and remove the module.
5) Install the new module, fitting the screws and connectors by following the removal steps in reverse order.
6) After having checked that the connectors are correctly inserted, connect the console to the EPS-AC module by means of the adapter that you removed from the faulty module and then inserted on the
ELECTRICAL SYSTEMELECTRICAL SYSTEM
7) Connect the battery, activate the emergency switch and set the keyswitch to ON.
8) With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU, download to the controller the module settings previously saved to the console by means of theSAVE
PARAMETERS procedure.
9) Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE and SET OPTIONS submenus correspond, including any option settings.
10) Perform the most appropriate EPS-AC setup procedure depending whether or not the 360° steering or +90° -90° steering option is enabled (see “EPS-AC” manual).
11) Test all the truck functions.
ELECTRICAL SYSTEM
9.0 SICOS (DISPLAY)
9.1 GENERAL DESCRIPTION OF CONTROL COMPONENTS AND INSTRUMENTS
The following section contains a description of the controls indicated on the display, the position of the controls, and their method of use.
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100 50 20 1 2 3 4 5 6 7 8 9P
11 12 10 13 14 15 17 169.2 TABLE OF DISPLAY SYMBOLS WITH DESCRIPTIONS
Fig. 29
Ref. Description
1 Auxiliary hydraulic function (5th function) selector button
2 Traction permissive selection button with battery out
3 Parking brake function selector button
4 Traction mode selector button
5 LCD screen
6 Numerical keypad for altimeter / pre-height selector settings (when installed)
7 ENTER' key to use during reading of the various display menus
8 UP and DOWN keys to use during reading of the display menus
9 Out key to use during reading of the display menus
10 Indicator for truck speed, hour meter, forks height, alarms on module
11 Travel direction and drive wheel rotation indicator
12 Hour meter running indicator
13 Parking brake indicator
14 Battery charge status indicator
15 Selected hydraulic function indicator
ELECTRICAL SYSTEMELECTRICAL SYSTEM 9.3 BATTERY CHARGE STATUS INDICATOR
Provides a proportional reading of battery charge status. The AC2 traction inverter reads the battery voltage and transmits the information to the display. Battery charge status is shown on the display by means of ten lines, each of which corresponds to 10%. When the battery charge falls to 30%, the corresponding three lines start flashing. At this point it is advisable to charge the battery. When battery charge reaches 20%, Traction inverter AC2 transmits a message to the display to give a 20% charge reading, and another message to the AC2 pump controller instructing it to inhibit the lift function, leaving only the reach carriage operational. Furthermore, the available traction current is reduced by 50% (this precaution serves to allow the truck to proceed to the charging station) (Fig. 30).
NOTE: The battery charge indicator can operate correctly only if the ADJUST BATTERY procedure has been performed correctly prior to delivery of the truck (see the section of the manual regarding the electrical system). + -
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100 50 20 Battery charge indicator Fig. 309.4 SPEED CUTBACK INDICATOR
This indicator is activated when ‘SLOW’ traction mode is selected (Fig. 31) pressing the button with the symbol , (the display presents the same symbol). Or when the following speed reduction speed states are tripped:
- Reach carriage extended (50% current supplied to traction motor, not adjustable).
- Forks height above free lift height (SW5 mast sensor connected to MHYRIO unit; speed cutback intensity is adjustable by means of CUTBACK SPEED 2 in CAN I/O).
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100 50 20 Speed cutback selector button Fig. 31P
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9.5 TRAVEL DIRECTION AND DRIVE WHEEL ROTATION INDICATOR
This indicator performs the following three functions: indication of truck forward travel direction, reverse travel direction and drive wheel rotation (in 45° steps).
The drive wheel angular position and truck travel direction are shown by the arrow positioned inside the truck logo.
When the truck is in use the arrow illuminates in accordance with the forward/reverse travel selector when the operator presses the accelerator pedal. The arrow shows the travel direction of the truck with respect to the seated operator; the right hand arrow illuminates when the truck proceeds in reverse, while the left hand arrow indicates that the truck is travelling forward (Fig. 32)
Travel direction and drive wheel rotation indicator + -
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100 50 209.6 SELECTED HYDRAULIC FUNCTION INDICATOR
An arrow on the display indicates the type of hydraulic movement being performed: reach carriage extend/ retract, lift/lower, tilt back/forward (Fig. 33).
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Fig. 32 Fig. 33ELECTRICAL SYSTEMELECTRICAL SYSTEM 9.7 SELECTED TRACTION OPERATING MODE INDICATOR
SLOW / STND / SOFT / HARD
SLOW - Maximum speed settable by means of the console connected to the CAN I/O module, edit the CUTBACK SPEED 1 parameter.
STND - The acceleration, release braking, and top speed parameters programmed in the AC2 Traction Inverter module are applied.
SOFT - The acceleration, release braking, and top speed functions are executed at a level below the levels programmed in the AC2 Traction Inverter module 2.
HARD - The acceleration, braking, release braking, and top speed functions are executed at a level above the levels programmed in AC2 Traction Inverter module 2 (Fig. 34).
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100 50 20 Selected traction mode indicator9.8 HOUR METER RUNNING INDICATOR
Flashes during execution of any of the truck functions, thereby indicating that the hour meter is running (Fig. 35). + -
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100 50 20 Hour meter running indicatorIndicates the traction mode selected by means of the relevant pushbutton ; this function allows the operator to personalize truck traction functions without requiring the intervention of a skilled technician.
There are four different preset levels that are shown on the display:
Fig. 34
ELECTRICAL SYSTEM
9.9 INDICATOR FOR TRUCK SPEED, TRUCK HOUR METER, FORKS HEIGHT, MODULE ALARM
HOUR METER / SPEEDOMETER
For two seconds after the truck is switched on this meter indicates the total truck duty hours, reading the value stored on the CAN I/O module; the indication is subsequently replaced by a display of the truck speed. To display the truck duty hours without turning off the keyswitch press the ENTER key to access the main menu and then the OUT key to exit. This action will generate a two-second display of truck duty hours. NOTE:When the SICOS or CAN I/O module is replaced the truck duty hours can be retained (see below).
PROCEDURE FOR RETAINING DUTY HOURS WHEN RENEWING THE CAN I/O MODULE Before renewing the CAN I/O module use the console to check that AUX FUNCTION 1 in SICOS is set to OFF, and then change the CAN I/O module by following the directions on page 30. When the truck is switched on the RESET HOUR METER alarm is displayed. After 1 minute the alarm message will be cleared and the duty hours memorized in SICOS will be transferred to the CAN I/O module and shown on the display.
PROCEDURE FOR RETAINING DUTY HOURS WHEN RENEWING THE SICOS MODULE
Change the SICOS module in accordance with the directions on page 31. When the truck is switched on the RESET HOUR METER alarm will be displayed; at this point you have one minute to connect the console to the SICOS module and change AUX FUNCTION 1 from OFF to ON. This done, the RESET HOUR METER alarm will be cleared and the duty hours memorized on the CAN I/O module will be shown on the display. We recommend resetting AUX FUNCTION 1 in SICOS from ON to OFF (default value) when the operation is terminated.
SPEED/MODULE ALARM
If an alarm is generated, the relevant name and the module on which the alarm is present will be shown in place of the truck speed display. To perform additional diagnostics the programming console must be connected to the faulty module.
SPEED/FORKS HEIGHT INDICATION
When a forks height indicator is installed with the relative correctly calibrated encoder, the height of the forks is displayed in place of the truck speed (Fig. 36).
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100 50 20Indicator of truck speed, hour meter, module alarm forks height
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9.11 AUXILIARY HYDRAULIC FUNCTION SELECTION BUTTON (5th FUNCTION)
Enables an auxiliary hydraulic function (5th function). The function must be set initially with the programming console connected to the SICOS module, selecting “CONFIG MENU’ - SET OPTIONS”, and subsequently selecting the parameter “OPTIONAL 1-2 HYDRAUL VALVE ON/OFF”.
When level OFF is selected the pushbutton has no effect.
When level ON is selected the function is shown in place of the forks down indicator by means of an icon representing a hydraulic gripper (Fig. 38).
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100 50 20 Auxiliary hydraulic function selection button (5th function)ATTENTION The parking brake selector can be activated only when the keyswitch is set to 1 (ON). Do not use the parking brake as a service brake during normal operation of the truck. The parking brake must be applied by pressing the relevant button with the “P” symbol; at this point the display will shown the letter “P” and all drive functions are inhibited, although the truck’s hydraulic functions remain active. When the button is pressed again the parking brake is released and truck drive functions are re-enabled (Fig. 37).
Parking brake indicator
9.10 PARKING BRAKE SELECTOR BUTTON PARKING BRAKE INDICATOR
Fig. 38
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100 50 20 Fig. 37P
Parking brake selector buttonThe fork logo changes and is replaced with a hydraulic gripper icon
ELECTRICAL SYSTEM
9.12 TRACTION PERMISSIVE WITH BATTERY OUT FUNCTION SELECTOR BUTTON
This button serves to allow limited truck traction mobility in order to facilitate a battery change.
When, during loading and unloading of a battery to and from the battery change rollerway, it becomes necessary to move the truck slightly backwards or forwards, the truck safety systems prevent the normal travel controls from being used. In these circumstances, to move the truck the operator, seated at the controls, must press the relevant permissive button and then press the accelerator pedal.
The resulting travel speed corresponds to 50% of the current available at Vmax. This value cannot be adjusted by means of the console (Fig. 39).
ATTENTION This control must not be used during normal working procedures. Pressing this button at any speed would result in intensive deceleration.
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