DIAGNOSTICS AND MEASUREMENTS SERVICE

TROUBLESHOOTING: MODULE DIAGNOSIS SYSTEM

The modules are equipped with two LEDs (one red, one yellow) which, in the event of a fault, will flash the
corresponding error code. The red LED flashes once to indicate that the system is about to signal first digit
of the error code, then the yellow LED will emit the number of flashes corresponding to this first digit. The
red LED now flashes twice to indicate that the system is about to signal second digit of the error code, then
the yellow LED will emit the number of flashes corresponding to this second digit.
The two LEDs have four operating modes which are used to signal different type of information.

RED LED YELLOW LED STATUS

Off Off The control is off or damaged.
Off Flashing The controller is in operation.
On On The controller is in Flash Program mode.
Watchdog error or software not installed.
On Off Turn off and restart the truck or install the sof-
tware.
The controller has detected an error. The two
Flashing Flashing digit code is signalled by the flashing of the
two LEDs in a cyclical sequence.

"Traction" module ALARMS

ALARM troubleshooting
12 - “Controller Overcurrent”
Possible causes:
- External shortcircuit on connections of phases U, V or • Turn off and restart the truck.
W to the motor • Check the wiring and for a short-circuit or low impe-
- Motor parameters incorrect dance on the phases U, V and W.
- Controller fault • Check the motor parameters are correct.
• If no fault is found in the wiring or the parameters
Effects: but the alarm persists, then the problem lies in the
- Main contactor K2 open module.
- All truck functions disabled
- Electromagnetic brake activated

13 - “Current Sensor Fault”

Possible causes:
- Dispersion of current from phases U, V or W to the truck
chassis (short circuit of motor stator) • Turn off and restart the truck.
- Controller fault • Check motor insulation
• If no fault is found and the alarm persists, then the
Effects: problem lies in the module.
- Main contactor K2 open
- All truck functions disabled
- Electromagnetic brake activated

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SERVICE DIAGNOSTICS AND MEASUREMENTS

ALARM troubleshooting
14 - “Precharge failed”
Possible causes:
• Release all the tiller controls.
- External load on capacitor bank (connected to B+) pre-
venting capacitors from charging • Check the value of the parameter MAIN MENU
MONITOR / Battery / Capacitor Voltage
Effects: • If no fault is found and the alarm persists, then the
- Main contactor K2 open problem lies in the module.
- All truck functions disabled
- Electromagnetic brake activated

15 - “Controller Severe Undertemp”

Possible causes: • Check the value of the parameter MAIN MENU
MONITOR / Controller / Temperature
- The controller is operating in too low temperature condi-
tions (below -40°C) • Bring the temperature to above the lower limit of
-40°C, release all tiller controls, turn off and restart
Effects: the truck.
- Main contactor K2 open • If no fault is found and the alarm persists, then the
- All truck functions disabled problem lies in the module.
- Electromagnetic brake activated

16 - “Controller Severe Overtemp”

Possible causes: • Check the value of the parameter MAIN MENU
- The controller is operating in too high temperature con- MONITOR / Controller / Temperature
ditions (above 95°C) • Return the temperature to below the maximum limit
- Truck overloaded of 95°C, release all the tiller controls, remove all
- Controller incorrectly installed loads from the truck, turn off and restart the truck.
• Check that the module is installed correctly.
Effects:
• If no fault is found and the alarm persists, then the
- Main contactor K2 open
problem lies in the module.
- All truck functions disabled
- Electromagnetic brake activated

17 - “Severe Undervoltage”
Possible causes: • Check the value of the parameter MAIN MENU
MONITOR / Battery / Capacitor Voltage
- Incorrect battery parameters
• Return the capacitor voltage to above the minimum
- Battery resistance too high critical value.
- Battery disconnected during truck operation • Check the battery parameters.
- Loss of capacitor charge to below critical limit • Check the battery wiring.
- Fuse on positive feed to key switch disconnected or • Check the fuses
blown
• Check the status of the main contactor.
- The main contactor did not close
• If no fault is found and the alarm persists, then the
Effects: problem lies in the module.
- Drive reduced

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
18 - “Severe Overvoltage”
Possible causes:
- Incorrect battery parameters • Check the value of the parameter MAIN MENU
MONITOR / Battery / Capacitor Voltage
- Battery resistance too high to supply regenerative cur-
rent • Return the capacitor voltage to below the maximum
permitted value. Turn off and restart the truck.
- Battery disconnected during regenerative braking
• Check the battery parameters.
- Voltage at capacitors above critical limit
• Check the battery wiring.
Effects: • If no fault is found and the alarm persists, then the
- Main contactor K2 open problem lies in the module.
- All truck functions disabled
- Electromagnetic brake activated

21 - “Controller Undertemp Cutback” • Check the value of the parameter MAIN MENU
MONITOR / Controller / Temperature
Possible causes:
• Bring the temperature to above the lower limit of
- The controller is operating in low temperature conditions
value -30°C, release all tiller controls, turn off and
(below -30°C)
restart the truck.
Effects: • If no fault is found and the alarm persists, then the
- Reduced performance problem lies in the module.

22 - “Controller Overtemp Cutback”

• Check the value of the parameter MAIN MENU
Possible causes: MONITOR / Controller / Temperature
- The controller is operating in high temperature conditions • Return the temperature to below the maximum limit
(above 85°C) of 85°C, release all the tiller controls, remove all
- Truck overloaded loads from the truck, switch off the truck, wait a few
- Controller incorrectly installed minutes, then switch it on again.
• Check that the module is installed correctly.
Effects:
• If no fault is found and the alarm persists, then the
- Drive reduced
problem lies in the module.
- Braking effect reduced

23 - “Undervoltage Cutback”
Possible causes:
• Check the value of the parameter MAIN MENU
- The battery is discharged and the controller has reduced
MONITOR / Battery / Capacitor Voltage
truck performance.
• Return the capacitor voltage to above the minimum
- Incorrect battery parameters
permitted value.
- Battery resistance too high
• Check the battery parameters.
- Battery disconnected during truck operation
• Check the battery wiring.
- Fuse on positive feed to key switch disconnected or
• Check the fuses
blown
• Check the status of the main contactor.
- The main contactor did not close
• If no fault is found and the alarm persists, then the
- Excessive loss of capacitor charge
problem lies in the module.
Effects:
- Reduced drive

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SERVICE DIAGNOSTICS AND MEASUREMENTS

ALARM troubleshooting
24 - “Overvoltage Cutback”
Possible causes: • Check the value of the parameter MAIN MENU
- Voltage at battery too high during regenerative braking MONITOR / Battery / Capacitor Voltage
- Incorrect battery parameters • Return the capacitor voltage to below the maximum
- Battery resistance too high to supply regenerative cur- permitted limit. Turn off and restart the truck.
rent • Check the battery parameters.
- Battery disconnected during regenerative braking • Check the battery wiring.
- Voltage at capacitors above maximum limit • If no fault is found and the alarm persists, then the
problem lies in the module.
Effects:
- Braking action reduced

25 - “+5V Supply Failure”

Possible causes: • Return the voltage on pin 26 to within the permitted
- The external charge impedance on the +5V output (pin range. Turn off and restart the truck.
26) is too low (outside range ±10%) • If no fault is found and the alarm persists, then the
problem lies in the module.
Effects:
- None

26 - “Digital Out 6 Overcurrent”

Possible causes:
• Find the cause of the overcurrent.
- The external charge impedance on Digital Output 6 (pin
19) is too low (the current exceeds 15 mA) • If no fault is found and the alarm persists, then the
problem lies in the module.
Effects:
- The Digital Out 6 driver is not activated

27 - “Digital Out 7 Overcurrent”

Possible causes:
• Find the cause of the overcurrent.
-The external charge impedance on Digital Output 7 (pin
20) is too low (the current exceeds the limit by 15 mA) • If no fault is found and the alarm persists, then the
problem lies in the module.
Effects:
- The Digital Out 7 driver is not activated

28 - “Motor Temp Hot Cutback”

Possible causes: • Check values of the parameters MAIN MENU MONI-
- The temperature of the motor has reached or exceeded TOR / Motor / Temperature and Inputs / Analog2
the limit value set in the parameter MAIN MENU PRO- • Check the motor parameters.
GRAM / Motor / Temperature Control / Temperature • Return the motor temperature to within the permitted
Hot limits.
- Motor temperature parameters incorrect • If no fault is found and the alarm persists, then the
Effects: problem lies in the module.
- Reduced drive

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
29 - “Motor Temp Sensor Fault”
Possible causes: • Check values of the parameters MAIN MENU MONI-
TOR / Motor / Temperature e Inputs / Analog2
- The motor thermistor is not connected correctly or is
faulty. • Check the status of the temperature sensor ther-
mistor.
- The analog input of the temperature sensor (pin 8) is
0V or 10V • Bring the thermistor voltage back to within the li-
mits.
Effects: • If no fault is found and the alarm persists, then the
- Reduced maximum speed problem lies in the module.
- Motor temperature cutback disabled

31 - “Coil 1 Driver Open/Short”

Possible causes: • Check wiring of the main contactor, clean the
- Driver of the main contactor coil open or short circuit connectors and check that the fastons are firmly
(pin 6) connected.
- Connector dirty • Turn off and restart the truck.
- Wiring damaged • If no fault is found and the alarm persists, then the
problem lies in the module.
Effects:
- Main contactor driver stopped

32 - “EM Brake Driver Open/Short”

Possible causes:
- Driver of the electromagnetic brake coil open or short
circuit (pin 5) • Check the brake wiring, clean the contacts.
- Connector dirty • Switch the truck off and then back on.
- Wiring damaged • If no fault is found and the alarm persists, then the
problem lies in the module.
Effects:
- Truck stops
- Electromagnetic brake activated

33 - “Coil 3 Driver Open/Short”

Possible causes:
• Check the wiring of the hydraulic pump contactor;
- Driver of the hydraulic pump coil open or short circuit
clean the contacts.
(pin 4)
• Switch the truck off and then back on.
- Connector dirty
• If no fault is found and the alarm persists, then the
- Wiring damaged
problem lies in the module.
Effects:
- Hydraulic pump contactor driver stopped

34 - “Coil 4 Driver Open/Short”

Possible causes: • Check the solenoid valve wiring, clean the connec-
- Driver of solenoid valve Q1 open or short circuit (pin 3) tors
- Connector dirty • Turn off and restart the truck.
- Wiring damaged • If no fault is found and the alarm persists, then the
problem lies in the module.
Effects:
- Solenoid valve driver stopped

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SERVICE DIAGNOSTICS AND MEASUREMENTS

ALARM troubleshooting
35 - “PD Open/Short”
Possible causes:
• Check the wiring, clean the connectors
- Auxiliary function driver open or short circuit (pin 2)
• Turn off and restart the truck.
- Connector dirty
• If no fault is found and the alarm persists, then the
- Wiring damaged
problem lies in the module.
Effects:
- Auxiliary function driver stopped

36 - “Encoder Fault”
• Check the value of the parameter MAIN MENU
Possible causes: MONITOR / Motor / Motor RPM
- Motor encoder phase error • Check the motor wiring, clean the connectors.
- Wiring damaged • Turn off and restart the truck.
Effects: • If no fault is found and the alarm persists, then the
problem lies in the module.
- Electromagnetic brake activated

37 - “Motor Open”
Possible causes:
• Check the wiring on phases U, V and W.
- One the motor phases is open
• Check continuity of the motor phases.
- Wiring damaged
• Switch the truck off and then back on.
Effects: • If no fault is found and the alarm persists, then the
- Main contactor K2 open problem lies in the module.
- All truck functions disabled
- Electromagnetic brake activated

38 - “Main Contactor Welded”

Possible causes:
- Main contactor contacts soldered • Check the wiring on phases U and V.
- Phase U or V disconnected or open • Check the power wiring of the main contactor, clean
- Just before closing the main contactor, the capacitor the connectors and check that the fastons are firmly
bank (connected to B+) is charged for a brief period but connected.
is not discharged • Switch the truck off and then back on.
Effects: • If no fault is found and the alarm persists, then the
problem lies in the module.
- Main contactor K2 open
- All truck functions disabled
- Electromagnetic brake activated

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
39 - “Main Contactor Did Not Close”
Possible causes:
- The main contactor did not close • Check the power wiring of the main contactor, clean
- The contacts of the main contactor are oxidised or burned the connectors and check that the fastons are firmly
or disconnected connected.
- External load on the capacitor bank (connected to B+) • Check value of the parameter MAIN MENU MONI-
preventing capacitors from charging TOR / Battery / Capacitor Voltage
- Fuse on positive feed to keyswitch disconnected or • Check the fuses
blown • Turn off and restart the truck.
Effects: • If no fault is found and the alarm persists, then the
problem lies in the module.
- Main contactor K2 open
- All truck functions disabled
- Electromagnetic brake activated

41 - “Throttle Wiper High”

Possible causes: • This kind of failure is not connected to external com-
- Voltage on pin 16 (not used) too high ponents. When it appears persistently the module
must be replaced.
Effects:
- Butterfly drive control deactivated

42 - “Throttle Wiper Low”

Possible causes: • This kind of failure is not connected to external com-
- Voltage on pin 16 (not used) too low ponents. When it appears persistently the module
must be replaced.
Effects:
- Butterfly drive control deactivated

43 - “Brake Wiper High”

Possible causes: • This kind of failure is not connected to external com-
- Voltage on pin 17 (not used) too high ponents. When it appears persistently the module
must be replaced.
Effects:
- Electromagnetic brake activated

44 - “Brake Wiper Low”

Possible causes: • This kind of failure is not connected to external com-
- Voltage on pin 17 (not used) too low ponents. When it appears persistently the module
must be replaced.
Effects:
- Electromagnetic brake activated

45 - “Pot Low Overcurrent”

Possible causes:
- Voltage on pin 18 (not used) too high • This kind of failure is not connected to external com-
ponents. When it appears persistently the module
Effects: must be replaced.
- Butterfly drive deactivated
- Electromagnetic brake activated

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SERVICE DIAGNOSTICS AND MEASUREMENTS

ALARM troubleshooting
46 - “EEPROM Failure”
Possible causes: • If this error occurs after editing parameters or instal-
ling new software, restore conditions existing prior
- Error writing to the Eeprom caused by programming lan- to the error.
guage or the Can Bus or by incorrect parameter editing
with the console or installation of new software. • Download and install the correct software; use the
standard parameter configuration.
Effects: • Turn off and restart the truck.
- Main contactor K2 open • If no fault is found and the alarm persists, then the
- All truck functions disabled problem lies in the module.
- Electromagnetic brake activated

47 - “HPD/Sequencing Fault” • Follow the correct start up sequence

Possible causes: • Check the tiller wiring and the electrical panel wi-
ring
Incorrect start up sequence
• Check condition of pushbutton connectors, clean if
- Wiring or connectors or pushbuttons damaged
necessary.
Effects: • If no fault is found and the alarm persists, then the
- Butterfly drive control deactivated problem lies in the module.

47 - “Emer Rev HPD”

Possible causes: • Release all the tiller controls.
- After an emergency reversing manoeuvre, some of the • Check that the belly button is released.
inputs may not have returned to neutral position. • Switch the truck off and then back on.
Effects: • If no fault is found and the alarm persists, then the
- Butterfly drive deactivated problem lies in the module.
- Electromagnetic brake activated

49 - “Parameter Change Fault”

Possible causes:
- The truck was not turned off and restarted after editing
one or more parameters • Turn off and restart the truck.
• If no fault is found and the alarm persists, then the
Effects: problem lies in the module.
- Main contactor K2 open
- All truck functions disabled
- Electromagnetic brake activated

51 - “CAN Startup Failure”

Possible causes:
- Communication with tiller failed • Check that there no faults on the line.
- Short or open circuit on pins 35-23 • Check the wiring.
Effects: • Check that the connectors are clean.
- Main contactor K2 open
- All truck functions disabled
- Electromagnetic brake activated

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
52 - “CAN PDO Timeout”
Possible causes:
- Failure to receive message via CAN within 50 ms
• Check that there no faults on the line.
- Short or open circuit on pins 35-23
• Check the wiring.
Effects: • Check that the connectors are clean.
- Main contactor K2 open
- All truck functions disabled
- Electromagnetic brake activated

61 - “BB Sequence Fault”

Possible causes: • Release all the tiller controls.
- Belly button activation request with tiller at rest • Check that the belly button is released.
- Short or open circuit on pin 22 • Switch the truck off and then back on.
Effects: • If no fault is found and the alarm persists, then the
problem lies in the module.
- All truck functions disabled
- Electromagnetic brake activated

62 - “Interlock SRO”
Possible causes:
- Startup with tiller in operating position
- Short to power on pin 9 • Release all the tiller controls.
Effects: • Follow the correct startup sequence.
- Main contactor K2 open
- All truck functions disabled
- Electromagnetic brake activated

68 - “VCL Runtime Error” • Check values of the parameters MAIN MENU MONI-
Possible causes: TOR / Controller / VCL Error Module e VCL Error.
This error can be compared with “VCL module ID”
- Error in the programming language code
and the definition of the error code that can be found
Effects: in the “information file” of the operating system.
- Main contactor K2 open • Turn off and restart the truck.
- All truck functions disabled • If no fault is found and the alarm persists, then the
- Electromagnetic brake activated problem lies in the module.

69 - “External Supply Out Of Range”

• Check value of the parameter MAIN MENU MONI-
Possible causes: TOR / Outputs / External Supply Current
- External supply current on 5V (pin 26) and 12V (pin 25) • Bring the external supply current to within the li-
outputs too high or too low mits.
Effects: • If no fault is found and the alarm persists, then the
problem lies in the module.
- None

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SERVICE DIAGNOSTICS AND MEASUREMENTS

ALARM troubleshooting
71 - “OS General”
Possible causes:
- Controller internal fault
• Turn off and restart the truck.
Effects: • If the alarm persists, replace the module.
- Main contactor K2 open
- All truck functions disabled
- Electromagnetic brake activated

72 - “PDO Timeout”
Possible causes: • Turn off and restart the truck.
- Delay in reception of CAN PDO message • If no fault is found and the alarm persists, then the
problem lies in the module.
Effects:
- Tiller deactivated

73 - “Stall Detected” • Identify valid signals at the encoder and check that
the parameters MAIN MENU MONITOR / Motor /
Possible causes: Motor RPM and Inputs / Throttle Command return
- Motor stalled to 0.
- Motor encoder fault • Check the general mechanical condition.
- Wiring damaged • Check that the electromagnetic brake is released
- Problems with the power supply to the motor encoder when energised.
• Turn off and restart the truck.
Effects:
• If no fault is found and the alarm persists, then the
- Electromagnetic brake activated problem lies in the module.

87 - “Motor Characterization Fault”

• Identify fault from the parameter MAIN MENU MONI-
Possible causes: TOR / Controller / Motor Characterization Error
- Motor characterization process failed • Switch the truck off and then back on.
Effects: • Check the condition of the motor.
- Main contactor K2 open • Check that the motor is in good condition.
- All truck functions disabled • If no fault is found and the alarm persists, then the
problem lies in the module.
- Electromagnetic brake activated

89 - “Motor Type Fault”

Possible causes:
- The Motor_type parameter is out of range • Turn off and restart the truck.
Effects: • If no fault is found and the alarm persists, the pro-
blem lies in the motor.
- Main contactor K2 open
- All truck functions disabled
- Electromagnetic brake activated

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

ALARM troubleshooting
92 - “EM Brake Failed To Set”
Possible causes: • This alarm is displayed for few seconds then disap-
pears. If it is present in the Fault History, check the
- The electromagnetic brake is unable to block rotation of efficiency of the brake.
the motor so the truck continues to move
• Turn the butterfly drive control a few times to restore
Effects: brake operation.
- Butterfly drive deactivated

93 - “Encoder LOS (Limited Operating Strategy)

Possible causes:
- The LOS has been activated due to an error (code 36
or 73) • Turn off and restart the truck.
- Vehicle stalled • Follow the troubleshooting guide for the faults Stall
- Motor encoder fault Detected or Encoder Fault
- Wiring damaged
Effects:
- LOS mode activated

94 - “Emer Rev Timeout”

Possible causes:
- Emergency reverse time has elapsed and the emergency
reverse input remains ser to ON • Check the condition of the belly button and the in-
ternal microswitch.
Effects:
- Butterfly drive deactivated
- Electromagnetic brake activated

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SERVICE DIAGNOSTICS AND MEASUREMENTS

"EPS" module ALARMS

LED CODE DISPLAY CODE ALARM

129 GENERIC HARDWARE FAULT
133 MOTOR TRAP
11 150 CURRENT U
151 CURRENT V
181 INCOMPATIBLE DEVICE
12 160 CONTROLLER OVERCURRENT
13 161 CURRENT SENSOR
147 PRECHARGE
14
148 PREDRIVE
15 162 CONTROLLER SEVERE UNDERTEMP
16 163 CONTROLLER SEVERE OVERTEMP
17 164 SEVERE UNDERVOLTAGE
18 165 SEVERE OVERVOLTAGE
21 166 CONTROLLER UNDERTEMP CUTBACK
22 167 CONTROLLER OVERTEMP CUTBACK
23 168 UNDERVOLTAGE CUTBACK
24 169 OVERVOLTAGE CUTBACK
28 170 MOTOR TEMP HOT CUTBACK
29 171 MOTOR TEMP SENSOR
31 136 MAIN CONTACTOR CLOSED
183 FAULT OUTPUT SHORTED
32 184 FAULT OUTPUT LOW
185 SAFETY RELAY NOT OPEN
36 140 MOTOR ENCODER
37 172 MOTOR OPEN
38 137 MAIN CONTACTOR TIME-OUT OPENING
138 MAIN CONTACTOR TIME-OUT CLOSING
39
139 MAIN CONTACTOR OPEN
141 ANALOG INPUT 1 HIGH
41
143 POSITION FEEDBACK HIGH
142 ANALOG INPUT 1 LOW
42
144 POSITION FEEDBACK LOW
182 HOME REFERENCE DISPLACED
43 182 HOME POSITION NOT FOUND
182 HOME REFERENCE LOST
46 173 EEPROM

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

LED CODE DISPLAY CODE ALARM

145 ENCODER INPUT
48
146 STEPPER MOTOR
134 FEEDBACK CONFIG INVALID
49 135 INPUT CONFIG INVALID
149 PARAMETER CONFLICT
69 157 COMMAND SUPPLY OUT OF RANGE
128 GENERIC SOFTWARE FAULT
130 INVALID OBJECT
71 131 UNEXPECTED VALUE
132 OUT OF RANGE
159 UNRESOLVED SUP EVENT NOTIFICATION
152 CAN PDO1 TIMEOUT
153 CAN PDO2 TIMEOUT
72 154 CAN PDO3 TIMEOUT
155 CAN PDO4 TIMEOUT
156 PDO INTERNAL TIMEOUT
73 158 MOTOR STALLED
174 FEEDBACK OUT OF RANGE
81
175 FEEDBACK REDUNDANCY
176 INPUT ENCODER REDUNDANCY
82
177 STEPPER MOTOR INPUT FAULT
83 178 MOTOR ENCODER REDUNDANCY
84 179 STEERING SUPERVISION
95 180 MOTOR ENCODER SUPERVISION

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SERVICE DIAGNOSTICS AND MEASUREMENTS

ELECTRICAL COMPONENT MEASUREMENTS

SOLENOID VALVE COIL

Q1

ELECTROMAGNETIC BRAKE COIL

Drive wheel electroma-

gnetic brake

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 DIAGNOSTICS AND MEASUREMENTS SERVICE

MOTORS
To measure the motor insulation resistance, disconnect the phase wires (U, V, W). Connect one of the
tester probes to the U phase and the other probe to the bodywork. The resistance reading (Ω) on the tester
should be infinity ( ). If not. the motor is not insulated and the module connected to the motor in question
will diagnose the alarm "capacitor charge".
Repeat the operation with the other two phases (V, W).

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