SERVICE ELECTRICAL

ELECTRICAL SYSTEMSYSTEM SERVICE

electrical system
WiriNG DiaGrams 4 models without initial lift 4 models with initial lift 6 electrical cOmPONeNts 8 identifiCation of
eleCtRiCal ComPonents 8 tilleR diaGRam10 cONtrOls 12 identifiCation of tilleR ContRols and main Panel 12
DisPlay (battery charGe level iNDicatOr) 14 BatteRY ChaRGe leVel indiCatoR 15 houR meteR 15 mDi
(OPtiONal) 16 BatteRY ChaRGe leVel indiCatoR 17 sPeed ReduCtion indiCatoR 17 houR meteR 17 waRninGs
indiCatoR 17 trUcK FUNctiONs 18 tRaCtion foRwaRd/ReVeRse 18 BReaKinG 21 steeriNG Wheel 24
liFtiNG/lOWeriNG 25 cONFiGUratiON Parameter access PrOceDUre 29 menu ReseaCh PRoCeduRe and
PaRameteR modifiCation 29 staNDarD cONFiGUratiON OF mODUle Parameters 32
"ComBi aC0" module 32 mODUle Parameter DescriPtiON 34 "ComBi aC0" module 34 cOmbi ac0 mODUle:
iNtrODUctiON 42 PositioninG of the "PC Console" ConneCtoR and Console43 rePlacemeNt mODUle:
iNstrUctiONs 44 RePlaCement of the ComBi aC0 module 44 electrical cOmPONeNt DismaNtliNG 46
RePlaCement of the GeneRal emeRGenCY switCh 46 disPlaY RePlaCement 48

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RePlaCement of the KeY switCh 49 RePlaCement of the waRninG BuZZeR 50 fuse RePlaCement 51 tiller
DiaGram: cONFiGUratiON aND calibratiON 52 tilleR CaRd RePlaCement 55 RePlaCement of tilleR Buttons 56
RePlaCement of the tilleR ContRol sPRinGs 57
RePlaCement of the tilleR assent sensoR 59
Renewal of 'foRKs aBoVe 1500 mm' sensoR (oPtional) foR initial lift VeRsion onlY 60
Renewal of 'foRKs aBoVe 500 mm' sensoR (oPtional) foR initial lift VeRsion onlY 61
Renewal of the 'foRKs loweRed' sensoR foR initial lift VeRsion onlY 62
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 ELECTRICAL SYSTEM SERVICE

WiriNG DiaGrams
mODels WithOUt iNitial liFt

ComPonents ConneCtoRs

ref Description ref Description

a1 Combi controller Xa1 35 pin male connector

a2 tiller controller X28 XCJ2 8 pin male connectors

X3 XaJ2
a3 Battery charge level indicator 6 pin male connectors
XJP1
B1 encoder
XJP2 XJP10
B2 heat sensor
4 pin male connectors
B4 tiller sensor
XJP12 X4
C1 Battery
X30 3 pin male connector
f1 Power fuse - 300 a X31 XJP11
f2 5a fuse for 24V power supply to keyswitch
10 a fuse for 24 V power supplyXJP13 XJP14
to solenoid
f3
coils XJP15 XJP16 2 pin male connectors
f4 3 a fuse for 24 V power supply to horn relay
XJP17 X6
3 a fuse for 24 V power supply to battery
f5
charge level indicator X7 X14
K1 horn relay Xff7 Xff20
K2 main remote control switch coil Xff8 Xff9
K3 Recycling diode Xff10 Xff11
m Complete traction motor Xff15 Xff16
m1 traction motor Xff18 Xff19
Xtf22 Xtf23 female terminals
m2 Pump motor
Xtf24 Xtf25
P1 horn
Xtf26 Xtf27
Q1 solenoid valve 1
Xtf28 Xtf29
R1 Varistor
Xff2 Xff3
R2 electromagnetic brake
Xff12 Xff13
R3 Resistor 120 Ω XtR1 XtR4
s Button not used ring terminals
s1 emergency button XtR14 XtR17
s2 Battery charger socket-plug microswitch
s3 Keyswitch
s5 Proportional lift button
s6 Proportional lowering button
s7 on-off lift button
s8 on-off lowering button
s9 horn button
s10 Belly switch
s11 snail button
s12 auxiliary function forward button
s13 auxiliary function reverse button
 t1 Battery charger

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 ELECTRICAL SYSTEM SERVICE

mODels With iNitial liFt

ComPonents

ref Description

a1 Combi controller
a2 tiller controller
a3 Battery charge level indicator
B1 encoder
B2 heat sensor
B4 tiller sensor
B5 'forks above 500mm' position sensor
B6 'forks above 1500mm' position sensor
B7 lift lock sensor
B8 'straddle legs down' sensor ref Description
C1 Battery ref Description
s8 on-off lowering button
f1 Power fuse - 300 a
s9 Xa1
horn button 35 pin male connector
f2 5a fuse for 24V power supply to keyswitch
X28 Belly
s10 XCJ2
switch8 pin male connectors
10 a fuse for 24 V power supply to solenoid
f3 X19 snail X3
s11 button
coils
6 pin male connectors
f4 3 a fuse for 24 V power supply to horn relay s12 auxiliary function forward button
XaJ2 XJP1
3 a fuse for 24 V power supply to battery s13
X4 auxiliary
X18 function reverse button
f5
charge level indicator s14
X24 lifting release
XJP2 button
4 pin male connectors
K1 horn relay XJP10
s15 mode XJP12
selector button
K2 main contactor coil t1 X33
Battery charger
K3 Recycling diode X18a X18B
m Complete traction motor 3-way male connectors
X19a X24a
m1 traction motor
X23 X30
m2 Pump motor
X7 X8
P1 horn X9 X10
Q1 solenoid valve 1 X11 X12
Q2 solenoid valve 2 X14 X6
Q3 solenoid valve 3 2 pin male connectors
Q4 solenoid valve 4 X31 XJP11
XJP13 XJP14
Q5 solenoid valve 5
XJP15 XJP16
Q6 solenoid valve 6
XJP17
R1 Varistor
X19B 6-way female connector
R2 electromagnetic brake
X18C X24C 4-way female connector
R3 Resistor 120 Ω X33B X23a 3-way female connector
s Button not used X24B 2-way female connector
s1 emergency button
ConneCtoRs
s2 Battery charger socket-plug microswitch
s3 Keyswitch
s5 Proportional lift button
6 s6 Proportional lowering button
s7 on-off lift button
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 ELECTRICAL SYSTEM SERVICE

electrical cOmPONeNts
iDeNtiFicatiON OF electrical cOmPONeNts

ref Description ref wiring diagram

1 traction motor m1
2 Pump motor m2
3 electromagnetic break R2
4 tiller control sensor B4
5 Battery C1
6 tiller diagram a2
7 acoustic buzzer P1
8 horn relay K1
9 Key fuse switch - 5 a f2
10 solenoid valve coil fuse - 10 a f3
11 horn relay fuse - 3 a f4
12 Battery charge level indicator fuse - 3 a f5
13 Power fuse - 300 a f1
14 ComBi aC0 module a1
15 Battery charger t1
16 General remote control switch - emergency button s1
17 General remote control coil contacts K2
18 auxiliary general remote control connector contacts
19 Battery charge level indicator a3
20 3 way connector for control panel connection X30
21 2 wayconnector for control panel connection X31
22 'straddle legs down' sensor (initial lift only) B8
23 'forks above 500 mm' position sensor ( initial lift only) B5
24 'forks above 1500 mm' position sensor ( initial lift only) B6

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SERVICE ELECTRICAL SYSTEM

tiller DiaGram

ref wiring
ref Description
diagram
1 led display for traction throttle calibration
2 micro quick reverse mode s10
3 micro slow progress enabling with vertical tiller s11
4 tiller control cable connection connector XJP1
5 tiller enabling sensor connection connector XJP2
6 unused connector XaJ2
7 Configuration selector bridge
8 Proportional fork lifting button connection connector XJP10
9 Can Bus Connection connector XCJ2
10 Proportional fork lowering button connection connector XJP12
on/off slow lifting button connection connector
11 XJP14
straddle leg lifting on/off button wiring connector (initial lift only)
on/off slow lowering button connection connector
12 XJP15
straddle leg lowering on/off button wiring connector (initial lift only)
13 on/off button connection connector for auxiliary functions XJP16
14 on/off button connection connector for auxiliary functions XJP17
15 unused connector XJP11
16 unused connector XJP13
17 micro enabling acoustic buzzer s9

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1

17

16

15

14

13

12

11

10
9

7 6

5 4

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SERVICE ELECTRICAL SYSTEM

cONtrOls
iDeNtiFicatiON OF tiller cONtrOls aND maiN PaNel

4 5 6 7

3
1

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ref wiring
ref Description
diagram
1 Quick reverse button s10
2 acoustic buzzer button s9
3 forward reverse traction throttle
slow fork lowering button
4 s8
straddle leg lowering button (initial lift only)
slow fork lifting button
5 s7
straddle leg lifting button (initial lift only)
6 Proportional* fork lifting button s5
7 Proportional* fork lowering button s6
8 slow progress enabling button with tiller in rest position s11
9 emergency button s1
10 Key switch s3
* the buttons are of the on/off variety for trucks with nominal load capacity of 1000/1200 kg

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 SERVICE ELECTRICAL SYSTEM

DisPlay (battery charGe level iNDicatOr)

ref Description

1 Battery charge level indicator

2 total work hour indicator

battery charGe level iNDicatOr

the battery charge level is indicated by the display with ten notches, each of which corresponds to 10%
When the charge reaches 30% the third notch starts to flash. When the charge reaches 20% the first
two notches start to flash and the fork lift system is immediately inhibited
to reset the low battery charge indicator recharge the battery when the recharge reaches 100% the low
battery charge indicator is reset, and the fork lift system is restored

if a battery is installed in the truck that is not provided by

the factory, in order for the battery charge indicator to
work correctly the "battery vOltaGe settiNG" procedure
performed on installation must be performed (see
“iNstallatiON aND settiNGs” section)

hOUr meter
when any function is active (lowered tiller, traction, lift/lowering) the
hour meter flashes, indicating that the battery level indicator is
recording the hours of work

When the battery charge level display is replaced the

truck working hours will be lost

mDi (OPtiONal)

Description
ref

1 total work hour indicator and warnings

2 Battery charge level indicator
3 light emitting diode - led in warning state

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 ELECTRICAL SYSTEM
1 2
SERVICE

4 hour meter
4
5 speed reduction status indicator
6 Programmed maintenance and warning status indicator
5 6
battery charGe level iNDicatOr
the battery charge level is indicated by the display
3 with ten notches,
each of which corresponds to 10%
when the battery charge state reaches 30% the battery symbol
placed beneath the notches starts to flash.
when the battery charge state reaches 20% the fork lifting is inhibited
1
to reset the low battery charge indicator recharge the battery when
the recharge reaches 100%% the low battery charge indicator is
reset, and the fork lift system is restored

if a battery is installed in the truck that is not provided

by the factory, in order for the battery charge indicator to work correctly the "battery
vOltaGe settiNG" procedure performed on installation must
be performed (see “iNstallatiON aND settiNGs” section)
2

sPeeD reDUctiON iNDicatOr

the symbol indicates that the speed reduction function is active
(for speed reduction see “tRuCK funCtions”)

hOUr meter
when any function is active (lowered tiller, traction, lift/lowering) the hour
meter flashes, indicating that the MDI is recording the hours of work

When the mDi or cOmbi modules are replaced, one can maintain the truck operating
hours and memorize them on the new modules (see "rePlacemeNt mODUle:
iNstrUctiONs")

WarNiNGs iNDicatOr
the mdi provides an indication of the truck's warning status when a
warning in generated, the light emitting diode - LED starts to flash
and the spanner symbol appears
the error code that has generated the warning appears on the display
(XXAYY), comprised of a number that identifies the module (XX) and
one (YY) that identifies the kind of error (see “DIAGNOSTICS"
section)

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the error code 16a06 corresponds to the NO cOmmUNicatiON warning

indicates that there is a communication problem between the mDi
and the cOmbi verify the cable connections

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