Group 19, Motor Controls

Section 4

Control Troubleshooting
This is the list of codes that the CLARK dash display may show

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 Group 19, Motor Controls

Fault Fault
Fault Name Control Fault Name Control
Code Code
1 SEAT SW OPEN Trac 82 ENCODER ERROR Trac/Pump
2 ANALOG INPUT Trac/Pump 83 OVERLOAD Pump
3 COIL SHORT HW KO Trac/Pump 84 LOAD SENS. ERROR Pump
4 SAFETY OUTPUT Trac/Pump 85 WAITING FOR NODE Trac/Pump
5 VACC OUT RANGE Trac/Pump 86 SEQUENCE FAULT Trac
7 SLIP_PROFILE Trac/Pump 90 ACQUIRE LIFT Pump
8 WATCHDOG#1 Trac/Pump 91 ACQUIRE TILT Pump
9 WATCHDOG# Trac/Pump 92 ACQUIRE AUX1 Pump
10 WAITING DISPLAY Trac 93 ACQUIRE AUX2 Pump
11 AUX DRIV.SHRT. Trac/Pump 94 MHYRIO IN ALARM Pump
12 SAFETY INPUT Trac/Pump 95 LIFT OUT OF RNG. Pump
13 EEPROM KO Trac/Pump 96 TILT OUT OF RNG. Pump
14 TH. PROTECTION Trac/Pump 97 AUX2 OUT OF RNG. Pump
15 AUX COIL SHORT Trac/Pump 98 AUX1 OUT OF RNG. Pump
16 AUX DRIV.OPEN Trac/Pump 99 ACQUIRE REACH Pump
17 LOGIC FAILURE #3 Trac/Pump 100 REACH OUT OF RNG Pump
18 LOGIC FAILURE #2 Trac/Pump 101 CAN BUS KO DISP. Trac/Pump
19 LOGIC FAILURE #1 Trac/Pump 113 NOT POSSIBLE Pump
30 VMN LOW Trac/Pump 114 ZERO POS. RESET Pump
31 VMN HIGH Trac/Pump 115 HEIGHT ENC. LOCK Pump
33 IDLE TIME Trac/Pump 241 DATA ACQUISITION Trac/Pump
37 CONTACTOR CLOSED Trac/Pump 243 NO CAN MSG. Trac/Pump
38 CONTACTOR OPEN Trac/Pump 245 WRONG SET BAT. Trac/Pump
39 KEY OFF SHORT Trac/Pump 249 THERMIC SENS. KO Trac/Pump
40 HARDWARE FAULT Trac/Pump
43 FLASH CHECKSUM Trac/Pump
44 WRONG RAM MEMORY Trac/Pump
45 SOFTWARE ERROR Trac/Pump
46 CURRENT GAIN Trac/Pump
47 WRONG 0 VOLTAGE Trac/Pump
48 PROG VACC NOT OK Trac/Pump
53 STBY I HIGH Trac/Pump
60 CAPACITOR CHARGE Trac/Pump
65 MOTOR TC START Trac/Pump
66 BATTERY LOW Trac/Pump
71 MOTOR SHUTDOWN Trac/Pump
72 MOTOR STALL Trac/Pump
74 DRIVER SHORTED Trac/Pump
75 CONTACTOR DRIVER Trac/Pump
76 MC COIL SHORT Trac/Pump
77 MAINTENANCE HOUR Trac
78 VACC NOT OK Trac/Pump
79 INCORRECT START Trac/Pump
80 FORW + BACK Trac
81 SENS MOT TEMP KO Trac/Pump

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 Group 19, Motor Controls

Fault Fault
Fault Name Control Fault Name Control
Code Code
20 EPS NOT ALIGNED EPS 166 CLOCK PAL NOT OK EPS
21 MICRO SLAVE #3 EPS 167 MICRO SLAVE #8 EPS
22 POSITION ERROR EPS 168 INPUT ERROR #1 EPS
23 SERIAL ERROR #1 EPS 169 CAN BUS KO SL EPS
24 MICRO SLAVE #4 EPS 170 SL EPS NOT ALL EPS
25 SLAVE COM. ERROR EPS
26 NO SYNC EPS
27 CURRENT GAIN EPS
28 FB SENS LOCKED EPS
29 STEER SENSOR KO EPS
120 HIGH CURRENT EPS Fault
Fault Name Control
121 POWER FAILURE #1 EPS Code
122 POWER FAILURE #2 EPS 8 WATCHDOG MhyrioCB
123 POWER FAILURE #3 EPS 13 EEPROM KO MhyrioCB
124 STBY I HIGH EPS 19 HI SIDEDRIVER KO MhyrioCB
125 D LINE SENSOR KO EPS 20 EVPG1 DRIVER KO MhyrioCB
126 Q LINE SENSOR KO EPS 21 EVPG2 DRIVER KO MhyrioCB
127 EEPROM KO EPS 22 EVPG3 DRIVER KO MhyrioCB
128 VMN NOT OK EPS 23 EVPG4 DRIVER KO MhyrioCB
129 HIGH TEMPERATURE EPS 24 EVP DRIVER KO MhyrioCB
130 DATA ACQUISITION EPS 30 EV DRIVER KO MhyrioCB
131 LOGIC FAILURE #1 EPS 31 EVPG1 DRIV SHORT MhyrioCB
132 LOGIC FAILURE #2 EPS 32 EVPG2 DRIV SHORT MhyrioCB
133 LOGIC FAILURE #3 EPS 33 EVPG3 DRIV SHORT MhyrioCB
134 LOGIC FAILURE #4 EPS 34 EVPG4 DRIV SHORT MhyrioCB
135 KS CLOSED EPS 35 EVP DRIVER SHORT MhyrioCB
136 KM CLOSED EPS 36 WAITING FOR PEV MhyrioCB
137 KS OPEN EPS 39 UNDER VOLTAGE MhyrioCB
138 KM OPEN EPS 40 FF VALVES MhyrioCB
139 MICRO SLAVE EPS 74 EV DRIVER SHORT MhyrioCB
140 JERKING FB EPS 76 COIL SHORTED MhyrioCB
141 F.B OUT OF RANGE EPS 243 CAN BUS KO MhyrioCB
142 MICRO SLAVE KO EPS 245 WRONG SET BAT. MhyrioCB
143 ENCODER ERROR EPS
144 BAD ENCODER SIGN EPS
145 GAIN EEPROM KO EPS
146 STEER HAZARD EPS
147 WAITING DATA EPS
148 CAN BUS KO EPS
149 WAITING FOR TRAC EPS
150 DIR. NOT CONIFIG EPS
162 SL CENTERING EPS
163 MOTOR TEMPERAT EPS
164 MOTOR LOCKED EPS
165 STEPPER MOT. MISM EPS

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 Group 19, Motor Controls

Fault Code Charts

1. Traction/ Pump Controller

Code Fault Name Fault Cause & Troubleshooting
1 SEAT SW OPEN Cause : When truck is moving, the seat sw opened.
Cause : This alarm occurs when the A/D conversion of the analog inputs gives
frozen value, on all of the converted signals, for more than 400msec. The goal
of this diagnosis is to detect a failure of the A/D converter or a problem in the
2 ANALOG INPUT code flow that omits the refreshing of the analog signal conversion.
Troubleshooting : If the problem occurs permanently it is necessary to substi-
tute ACE logic board.
Cause : The hardware circuits which manages short circuits protection of LC
and EB/AUX coils has a problem.
3 COIL SHORT HW KO
Troubleshooting : This type of fault is not related to external components :
replace the ACE logic board.
Cause : The safety out driver is shorted.

Troubleshooting :
4 SAFETY OUTPUT - Check if there is a short or a low impedance pull-down between SAFETY
OUT (CAN#19) and –BATT.
- The driver circuit is damaged in the logic board, which has to be replaced.
Cause : The CPOT input red by the microcontroller is not comprised in the
range Vacc_min ÷ Vacc_max, programmed through the “PROGRAMM
VACC” function.
5 VACC OUT RANGE Troubleshooting : Acquire the maximum and minimum potentiometer value
through the PROGRAM VACC function. If the alarm is still present, check the
mechanical calibration and the functionality of the potentiometer. If the alarm
is not disappeared the failure is in the ACE logic board, replace it.
Cause : SLIP_PROFILE parameters are not correct setup.
There is an error on the choice of the parameters of the slip profile.
7 SLIP_PROFILE
Troubleshooting :
Check in the hardware setting menu the value of those parameter.
Cause : At start-up the watch dog signal is already active before the software
has generated it. At stby or running condition the watch dog signal is not
active. (in alarm status)
8 WATCHDOG#1
Troubleshooting :
The WD hardware circuit or microcontroller output port are damaged. In both
cases no external component are involved. Replace the logic board.
Cause : At start-up the watch dog signal is already active before the software
has generated it. At stby or running condition the watch dog signal is not
active. (in alarm status)
9 WATCHDOG#
Troubleshooting :
The WD hardware circuit or microcontroller output port are damaged. In both
cases no external component are involved. Replace the logic board.

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 Group 19, Motor Controls

Code Fault Name Fault Cause & Troubleshooting

10 WAITING DISPLAY Cause : The traction is waiting for the display enable.
Cause :
The driver of the electro mechanic brake/ auxiliary electro valve coil is
shorted.

11 AUX DRIVER SHORTED Troubleshooting :

- Check if there is a short or a low impedance pull-down between NEB/NAUX
(CNA#18) and –BATT.
- The driver circuit is damaged in the logic board, which has to be replaced.
Cause :
The safety input is opened and accordingly the MC is opened an EB/AUX
OUT coil is driven.
12 SAFETY INPUT
Troubleshooting : Check the CAN#11 input, if it is connected to –Batt and
the alarm is generated then there is a fault in the SAFETY IN hardware circuit.
Replace the logic board.
Cause :
It’s due to a HW or SW defect of the non-volatile embedded memory support-
ing the controller parameters. This alarm does not inhibit the machine opera-
tions, but the truck will work with the default values.
13 EEPROM KO Troubleshooting :
Try to execute a CLEAR EEPROM operation (refer to Console manual).
Switch the key off and on to check the result. If the alarm occurs permanently,
it is necessary to replace the controller. If the alarm disappears, the previously
stored parameters will have been replaced by the default parameters.
Cause :
The EB/AUX coil driver is not able to drive the load. The device itself or its
driving circuit is damaged.
16 AUX DRIVER OPEN
Troubleshooting :
This type of fault is not related to external components; replace the ACE2
logic board.
Cause :
Hardware problem in the logic card circuit for high current (overload) protec-
tion.
17 LOGIC FAILURE #3
Troubleshooting :
This type of fault is not related to external components, so, when it is present it
is necessary to replace the ACE logic board.
Cause :
Fault is in the hardware section of the logic board which manages the phase’s
voltage feedback.
18 LOGIC FAILURE #2
Troubleshooting :
This type of fault is not related to external components, so when it happens it is
necessary to replace the ACE2 logic board.

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 Group 19, Motor Controls

Code Fault Name Fault Cause & Troubleshooting

Cause : This fault is displayed when the controller detects an over voltage or
under voltage condition. Over voltage threshold is 45V, under voltage thresh-
old is 9V in the 24V controller. In 48V controller over voltage threshold is
65V, under voltage threshold is 11V.
Troubleshooting :
Troubleshooting of fault displayed at start-up or in standb:
in these cases it is very likely the fault is due to an under voltage, so it is sug-
gested to check:
- Key input signal down-going pulses (below under voltage threshold) due to
external loads, like DC/DC converters starting-up, relays or contactor
switching, solenoids energizing / de-energizing.
- Check the connection of power cables to the battery terminal, positive and
19 LOGIC FAILURE #1 negative, to MC and to controller +Batt and –Batt, which must be screwed
with a torque comprised in the range 13Nm÷15Nm.
- If no voltage transient is detected on the supply line and the alarm is present
every time the key is switched ON, the failure is probably in the controller
hardware, so it is necessary to replace the logic board.
Troubleshooting of fault displayed during motor driving:
in this case it can be an under voltage or an over voltage condition.
- If the alarm happens during traction acceleration or driving hydraulic func-
tions, it is very likely it is an under voltage condition; check battery charge
condition, power cable connection.
- If the alarm happens during release braking, it is very likely it is due to over
voltage condition; check line contactor contact, battery power cable connec-
tion.
Cause :
1. Start-up test.
Before switching the LC on, the software checks the power bridge: it turns on
alternatingly the High side Power Mosfets and expects the phases voltage to
increase toward the rail capacitor value. If the phases voltage is less than 66%
of the rail capacitor voltage, this alarm occurs.
2. Motor running test.
When the motor is running, power bridge is ON, the motor voltage feedback is
tested; if it is lower than commanded value (a window of values are consid-
ered) fault status is entered.

Troubleshooting :
30 VMN LOW If the problem occurs at start up (the LC does not close at all), check.
- Motor internal connections. (ohmic continuity)
- Motor power cables connections.
- Motor leakage to truck frame.
- If the motor connections are OK, the problem is inside the controller, replace it.
If the alarm occurs during motor running, check.
- Motor connections.
- If motor phases windings/cables have leakages towards truck frame.
- That the LC power contact closer properly, with a good contact.
- If no problem are found on the motors, the problem is inside the controller,
replace it.

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 Group 19, Motor Controls

Code Fault Name Fault Cause & Troubleshooting

Cause :
1. Before switching the LC on, the software checks the power bridge: it turns
on alternatingly the Low side Power Mosfets and expects the phases voltage
to decrease down to -BATT. If the phases voltage is higher than 10% of
nominal battery voltage, this alarm occurs.
2. This alarm may occur also when the start up diagnosis is overcome, and so
the LC is closed. In this condition, the phases’ voltages are expected to be
lower than 1/2 Vbatt. If it is higher than that value, fault status is entered.

Troubleshooting :
31 VMN HIGH If the problem occurs at start up (the LC does not close at all), check.
- Motor internal connections. (ohmic continuity)
- Motor power cables connections.
- If the motor connection are OK, the problem is inside the controller, replace it.
If the problem occurs after closing the LC (the LC closed and then opens back
again), check.
- Motor connections.
- If motor phases windings/cables have leakages towards truck frame.
- If no problem are found on the motors, the problem is inside the controller,
replace it.
33 IDLE TIME Cause : When truck is idle more than " IDLE TIME SEAT " parameter.
Cause :
Before driving the MC coil, the controller checks if the contactor is stuck.
The controller drives the bridge for some tens milliseconds, trying to discharge
the capacitors bank. If the capacitor voltage does decrease by 20% of the key
37 CONTACTOR CLOSED voltage the alarm is generated.
Troubleshooting :
It is suggested to verify the power contacts of LC :
to replace the LC is necessary.
Cause :
The main contactor coil has been driven by the controller, but the contactor
does not close.

38 CONTACTOR OPEN Troubleshooting :

- It could be a problem of the contacts in the MC that are not working (does not
pull-in), try replacing the MC.
- If the contactors of MC are working correctly than the problem is in the con-
troller, replace it.

SM 931 Control Troubleshooting • 19-4-7

 Group 19, Motor Controls

Code Fault Name Fault Cause & Troubleshooting

Cause : This fault is displayed when the controller detects a low logic level of
Key-Off signal during Start-Up diagnosis.

Troubleshooting :
It is very likely the fault is due to an under voltage, so it is suggested to check:
- Key input signal down-going pulses (below under voltage threshold) due to
external loads, like DC/DC converters starting-up, relays or contactor
39 KEY OFF SHORT switching, solenoids energizing / de-energizing.
- Check the connection of power cables to the battery terminal, positive and
negative, to MC and to controller +Batt and –Batt, which must be screwed
with a torque comprised in the range 13Nm÷15Nm.
- If no voltage transient is detected on the supply line and the alarm is present
every time the key is switched ON, the failure is probably in the controller
hardware, so it is necessary to replace the logic board.
HARDWARE FAULT 20
Cause : Before driving the MC coil, the controller checks if the Mosfets driv-
ers are turned of by a not active (alarm status) Watch-dog signal. If they are
not turned of then the alarm is generated.
Troubleshooting : The problem is inside the controller, no external compo-
nent are involved, replace the logic board.

HARDWARE FAULT 21
Cause : Before driving the MC coil, the controller checks if the EB/AUX
driver is turned of by a not active (alarm status) Watch-dog signal.
40 HARDWARE FAULT
If it is not turned of then the alarm is generated.
Troubleshooting : The problem is inside the controller, no external compo-
nent are involved, replace the logic board.

HARDWARE FAULT A1
Cause : Before driving the MC coil, the controller checks if the MC/AUX
driver is turned of by a not active (alarm status) Watch-dog signal.
If it is not turned of then the alarm is generated.
Troubleshooting : The problem is inside the controller, no external compo-
nent are involved, replace the logic board.
Cause : After Key-on the software verifies the integrity of program stored in
the flash memory, if the verify has a negative result this alarm is generated.

43 FLASH CHECKSUM Troubleshooting : The problem is in the microcontroller flash memory, which
could be damaged, or in the program stored inside, which could be corrupted.
Try to program the logic again, if the alarms is still signalled the problem is in
the microcontroller. Replace the ACE logic board.
Cause :
The algorithm implemented to check the main RAM registers finds a wrong
44 WRONG RAM MEMORY contents: the register is “dirty”. This alarm inhibit the machine operations.
Troubleshooting : Try to switch the key off and then on, if the alarm is still
present replace the ACE2 logic board.

SM 931 Control Troubleshooting • 19-4-8

 Group 19, Motor Controls

Code Fault Name Fault Cause & Troubleshooting

45 SOFTWARE ERROR Cause : Only when “DEBUG MODE” parameter is ON.
Cause : Current gain parameters are out of range.
The Maximum current gain parameters are at the default values, which means
46 CURRENT GAIN the maximum current adjustment procedure has not been carried out yet.
Troubleshooting : Ask the assistance of a Zapi technician to do the correct
adjustment procedure of the current gain parameters.
Cause :
At start-up the high resolution VMN feedback is not comprised in a permitted
window of values centred around 2,5V. The circuit is damaged in the controller.

Troubleshooting :
47 WRONG 0 VOLTAGE It is suggested to check.
- Motor internal connections. (ohmic continuity)
- Motor power cables connections.
- Motor leakage to truck frame.
- If the motor connections are OK, the problem is inside the controller, replace
the logic board.
48 PROG VACC NOT OK Not used.
Cause : The current transducer or the current feedback circuit is damaged in
the controller.
53 STBY I HIGH
Troubleshooting : This type of fault is not related to external components so,
when it is present, it is necessary to replace the controller.
Follows the charging capacitor system :

Cause : When the key is switched ON, the inverter tries to charge the power
capacitors through a series of a PTC and a power resistance, and check if the
60 CAPACITOR CHARGE capacitor are charged within a timeout. If the capacitor voltage measured is
less than 20% of the nominal battery voltage, an alarm is signalled; the main
contactor is not closed.

Troubleshooting :
- There is an external load in parallel to capacitor bank, which sinks current
from the controller capacitors pre-charging circuit, thus preventing the caps
from charging. Check if a lamp or a dc/dc converter or an auxiliary load is
placed in parallel to capacitor bank.
- The charging resistance or PTC is opened; insert a power resistance across
line contactor power terminals; if the alarm disappears, it means the control-
ler internal charging resistance is damaged.
- The charging circuit has a failure, inside the controller.
- There is a problem in the controller power section.

SM 931 Control Troubleshooting • 19-4-9

 Group 19, Motor Controls

Code Fault Name Fault Cause & Troubleshooting

65 MOTOR TC START Cause : When motor temperature is over than " MOTOR TC START " parameter.
66 BATTERY LOW Cause : When voltage battery is under minimun voltage.
71 MOTOR SHUTDOWN Cause : The traction stopped because of a too high temperature on the motor.
Cause : The controller is trying to move the motor but the motor seems stuck.
72 MOTOR STALL
There could be also a problem with the encoder.
Cause :
The driver of the main contactor coil is shorted.

74 DRIVER SHORTED Troubleshooting :

- Check if there is a short or a low impedance pull-down between NMC
(CNA#16) and –BATT.
- The driver circuit is damaged in the logic board, which has to be replaced.
Cause : The MC coil driver is not able to drive the load.
The device itself or its driving circuit is damaged.
75 CONTACTOR DRIVER Troubleshooting :
This type of fault is not related to external components:
replace the ACE2 logic board.
COIL SHORTED MC
Cause :
This alarm occurs when there is a short circuit of the MC coils connected to
CNA#16 output. After the overload condition has been removed, the alarm
exits automatically by releasing and then enabling a travel demand.
Troubleshooting :
- The typical root cause for this error code to be displayed is in the harness or
in the load coil. So the very first check to carry out concerns connections
between controller outputs and loads.
- In case no failures/problems have been found externally, the problem is in the
controller, which has to be replaced.
76 MC COIL SHORT
COIL SHORTED EF
Cause :
This alarm occurs when there is a short circuit of the EB/AUX coils connected
to CNA#18 output. After the overload condition has been removed, the alarm
exits automatically by releasing and then enabling a travel demand.
Troubleshooting :
- The typical root cause for this error code to be displayed is in the harness or
in the load coil. So the very first check to carry out concerns connections
between controller outputs and loads.
- In case no failures/problems have been found externally, the problem is in the
controller, which has to be replaced.
77 MAINTENANCE HOUR Cause : The truck reached the maintenance working hours.

SM 931 Control Troubleshooting • 19-4-10

 Group 19, Motor Controls

Code Fault Name Fault Cause & Troubleshooting

Cause : The test is made at key-on and immediately after that both the travel
demands have been turned off. This alarm occurs if the ACCELERATOR
reading in the TESTER menu’ is 1,0V higher than PROGRAM VACC min
acquisition when the accelerator is released.
78 VACC NOT OK
Troubleshooting : Acquire the maximum and minimum potentiometer value
through the PROGRAM VACC function. If the alarm is still present, check the
mechanical calibration and the functionality of the potentiometer. If the alarm
is not disappeared the failure is in the ACE logic board, replace it.
Cause : This is a warning for an incorrect starting sequence.

Troubleshooting :
The possible reasons for this alarm are (use the readings in the TESTER to
facilitate the troubleshooting):
79 INCORRECT START - A travel demand active at key on
- Presence man sensor active at key on
Check the wirings. Check the micro switches. It could be also an error
sequence made by the operator. A failure in the logic is possible too; so when
all of the above conditions were checked and nothing was found, replace the
ACE logic board.
Cause : This alarm occurs when both the travel demands (Fwd and Bwd) are
active at the same time.
Troubleshooting :
Check the wiring of the Fwd and Rev travel demand inputs (use the readings in
80 FORW + BACK the TESTER to facilitate the troubleshooting).
Check the microswitches for failures.
A failure in the logic is possible too. So, when you have verified the travel
demand switches are fine working and the wiring is right, it is necessary to
replace the ACE-2 logic board.
Cause : The output of the motor thermal sensor is out of range.
81 SENS MOT TEMP KO Troubleshooting : Check the sensor ohmic value and the sensor wiring.
If the sensor is OK, then the problem is inside the ACE logic board, replace it.
Cause : This fault is signalled in following conditions: the frequency supplied
to the motor is higher than 40 Hz and the signal feedback from the encoder has
a jump higher than 40 Hz in few tens mSec. This condition is related to a mal-
functioning of the encoder.
Troubleshooting :
- Check both the electric and the mechanical encoder functionality, the wires
82 ENCODER ERROR crimping.
- Check the encoder mechanical installation, if the encoder slips inside its com-
partment raising this alarm condition.
- Also the electromagnetic noise on the sensor bearing can be a cause for the
alarm. In these cases try to replace the encoder.
- If the problem is still present after replacing the encoder, the failure is in the
controller.
83 OVERLOAD Request in your specs.

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 Group 19, Motor Controls

Code Fault Name Fault Cause & Troubleshooting

84 LOAD SENS. ERROR Request in your specs.
85 WAITING FOR NODE Cause : Truck waiting pump or viceversa.
86 SEQUENCE FAULT Not used.
90 ACQUIRE LIFT Cause : MAX/MIN LIFT parameters are not correct.
91 ACQUIRE TILT Cause : MAX/MIN TILT parameters are not correct.
92 ACQUIRE AUX1 Cause : MAX/MIN AUX1 parameters are not correct.
93 ACQUIRE AUX2 Cause : MAX/MIN AUX2 parameters are not correct.
94 MHYRIO IN ALARM Cause : Error that Mhyrio send via can when it is in alarm.
Cause :
The voltage on A3 (PAUX) is too low, compared to the battery voltage.
95 LIFT OUT OF RNG.
Troubleshooting : Please check the wiring.
On A3 there should be a positive voltage.
96 TILT OUT OF RNG. Cause : TILT out of range.
97 AUX2 OUT OF RNG. Cause : AUX2 out of range.
98 AUX1 OUT OF RNG. Cause : AUX1 out of range.
99 ACQUIRE REACH Cause : MAX/MIN REACH parameters are not correct.
100 REACH OUT OF RNG Cause : REACH out of range.
101 CAN BUS KO DISP. Cause : The traction controller does not receive the display CAN messages.
113 NOT POSSIBLE Cause : The selected hydraulic function is not possible.
114 ZERO POS. RESET Cause : When height encoder need to get zero position.
115 HEIGHT ENC. LOCK Cause : When height encoder is lock.
241 DATA ACQUISITION Cause : Need current data acquisition.
Cause : The traction controller is not receiving the CAN messages from one of
the other nodes. (node number is displayed)
243 NO CAN MSG.
Troubleshooting :
Please check the can bus wiring and the status of the missing node.
Cause : The set battery selected is not correct.
At start-up, the controller checks the battery voltage and verify it is within a
window around the nominal value.
Troubleshooting :
245 WRONG SET BATTERY - Check that the controller SET BATTERY parameter value matches the bat-
tery nominal voltage.
- Check that TESTER MENU / BATTERY VOLTAGE parameter shows same
value as the battery voltage measured with a voltmeter.
If it does not match, then do an “ADJUST BATTERY” function.
- Replace the battery.
Cause : The value of thermic sensor are out of range.
The output of the controller thermal sensor is out of range.
249 THERMIC SENS. KO
Troubleshooting :
This type of fault is not related to external components; replace the controller.

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 Group 19, Motor Controls

2. EPS (Steering) Controller

Code Fault Name Fault Cause & Troubleshooting
Cause : Current gain parameters are out of range.
The Maximum current gain parameters are at the default values, which means
27 CURRENT GAIN the maximum current adjustment procedure has not been carried out yet.
Troubleshooting : Ask the assistance of a Zapi technician to do the correct
adjustment procedure of the current gain parameters.
28 FB SENS LOCKED Cause : Alarm fb pot locked.
Cause :
This alarm occurs when the temperature of the base plate is higher than 85°.
Then the maximum current decreases proportionally with the temperature
increases from 85° up to 105°. At 105° the Current is limited to 0 Amps.
Troubleshooting :
129 HIGH TEMPERATURE It is necessary to improve the controller cooling. For realise an adequately
cooling in case of finned heat sink are important factor the flux [m3/h] and
temperature [°C] of cooling air. In case of thermal dissipation realised with the
controller base plate installed on truck frame it is important the thickness of
frame and the planarity and roughness of its surface. If the alarm is signalled
when the controller is cold, the possible reasons are a thermal sensor failure or
a failure in the logic card. In this case, it is necessary to replace the controller.
Cause : This fault is displayed when the controller detects an over voltage or
under voltage condition. Over voltage threshold is 45V, under voltage thresh-
old is 9V in the 24V controller. In 48V controller over voltage threshold is
65V, under voltage threshold is 11V.

Troubleshooting :
Troubleshooting of fault displayed at start-up or in standb:
in these cases it is very likely the fault is due to an under voltage, so it is sug-
gested to check:
- Key input signal down-going pulses (below under voltage threshold) due to
external loads, like DC/DC converters starting-up, relays or contactor
switching, solenoids energizing / de-energizing.
- Check the connection of power cables to the battery terminal, positive and
131 LOGIC FAILURE #1 negative, to MC and to controller +Batt and –Batt, which must be screwed
with a torque comprised in the range 13Nm÷15Nm.
- If no voltage transient is detected on the supply line and the alarm is present
every time the key is switched ON, the failure is probably in the controller
hardware, so it is necessary to replace the logic board.

Troubleshooting of fault displayed during motor driving:

in this case it can be an under voltage or an over voltage condition.
- If the alarm happens during traction acceleration or driving hydraulic func-
tions, it is very likely it is an under voltage condition; check battery charge
condition, power cable connection.
- If the alarm happens during release braking, it is very likely it is due to over
voltage condition; check line contactor contact, battery power cable connec-
tion.

SM 931 Control Troubleshooting • 19-4-13

 Group 19, Motor Controls

Code Fault Name Fault Cause & Troubleshooting

Cause :
Fault is in the hardware section of the logic board which manages the phase’s
voltage feedback.
132 LOGIC FAILURE #2
Troubleshooting :
This type of fault is not related to external components, so when it happens it is
necessary to replace the ACE2 logic board.
Cause :
Hardware problem in the logic card circuit for high current (overload) protec-
tion.
133 LOGIC FAILURE #3
Troubleshooting :
This type of fault is not related to external components, so, when it is present it
is necessary to replace the ACE logic board.
144 BAD ENCODER SIGN Cause : Encoder wire is reversed.
150 DIR. NOT CONIFIG Cause : STEER TIRE DIR.1 and STEER TIRE DIR.2 mismatch.
Cause :
This warning occurs when the temperature sensor is opened (if digital) or has
overtaken the threshold of 150° (if analogue).
Troubleshooting :
163 MOTOR TEMPERAT Check the thermal sensor inside the motor (use the MOTOR TEMPERATURE
reading in the TESTER menu:
Check the sensor ohmic value and the sensor wiring. If the sensor is OK,
improve the cooling of the motor. If the warning is present when the motor is
cool, then the problem is inside the controller.
169 CAN BUS KO SL Cause : Alarm can bus slave.
170 SL EPS NOT ALL Cause : Slave not aligned.

SM 931 Control Troubleshooting • 19-4-14