EP Equipment 508000003143 Operation Manual Download Page 32 | Manualshive

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4.Battery Maintenance & Charging

4.1 Safety regulations for handling acid batteries

Park the truck securely before carrying out any work on the batteries.

Maintenance personnel :

Batteries may only be charged, serviced or replaced by

trained personnel .The present operator manual and the manufacturer ’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.

Fire protection :

• Smoking and naked flames must be avoided when working with batteries.
• Wherever a truck is parked for charging there shall be no inflammable material or
operating fluids capable of creating sparks within 2 meters around the truck.
• The area must be well ventilated.
• Fire protection equipment must be provided.

Battery Disposal:

Batteries may only be disposed of in accordance with national

environmental protection regulations or disposal laws. The manufacturer’s disposal
instructions must be followed.

4.2 Battery type & dimension

The battery type & dimension is based on the local battery in the United States.

When replacing or installing batteries, ensure that the battery is correctly secured in

the battery compartment of the truck.

Warning!

The weight and dimensions of the battery have considerable affect on the
operational safety of the truck. Battery equipment may only be replaced
with the agreement of the manufacturer.

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Summary of Contents for 508000003143

Page 1: ...I Part No 508000003143 V1 10 2019 ...

Page 2: ... ordered Through our online after sales service system customers can process their warranty claims order spare parts and consult the operation manuals maintenance materials and spare parts catalogs With business all over the world EP has thousands of employees and hundreds of agents worldwide to provide our global customers with prompt local service Based on the concept of sharing economy EP also ...

Page 3: ... product and the description in this manual And the operator manual details will be different because of customer s special requirements If you have any questions please keep in touch with the sales department of Equipment or let the dealer know Notes 1 This manual is used for operation and maintenance the detail parameters size and specifications in context is only for reference the real paramete...

Page 4: ... position and remove the key 4 Before starting to operate truck Be in operating position Place directional control in neutral Before operating truck check functions of lift systems directional control speed control steering warning devices and brakes 5 Do not use open flame to check lever or for leakage of electrolyte and fluids or oil Do not use open pans of fuel or flammable cleaning fluids for ...

Page 5: ...on to minimize fire hazards facilitate detection of loose or detective parts 11 Modifications and additions which affect capacity and safe truck operation shall not be performed by the customer or user without manufacturers prior written approval Capacity operation and maintenance plates or decals shall be changed accordingly ...

Page 6: ...acing load units 22 3 5 Parking the truck securely 23 4 Battery Maintenance Charging 25 4 1 Safety regulations for handling acid batteries 25 4 2 Battery type dimension 25 4 3Charging the battery 26 4 4 Battery removal and installation 26 4 5 Battery maintenance 27 5 Maintenance 28 5 1 Operational safety and environmental protection 28 5 2 Maintenance Safety Regulations 28 5 3 Servicing and inspec...

Page 7: ...V 6 1 1 Traction Controller COMBIAC0 _MASTER uc 38 6 1 2 Traction Controller COMBIAC0_SLAVE uc 69 6 1 3 Steering Controller EPS AC0 75 ...

Page 8: ...ural or legal person who either uses the truck himself or on whose behalf it is used In special cases e g leasing or renting the proprietor is considered the person who in accordance with existing contractual agreements between the owner and user of the truck is charged with operational duties The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger...

Page 9: ... is an electric truck The J1HD is designed to transport and pick goods on level surfaces Loads can be stacked unstacked and transported over long distances The capacity can be obtained from the data plate Warning The truck can only be used indoors ...

Page 10: ...anel 11 Battery 2 Load handler 12 Dead man switch 3 Warning lamp 13 Height adjustable operator position 4 Cover 14 Load wheel 5 Controller 15 Gates 6 Balance wheel 16 Pallet 7 Frame 17 Mast 8 Drive wheel 18 Blue lamp 9 Hydraulic pump 19 White lamp 10 Battery baffle ...

Page 11: ...steering wheel is integrated in the control panel The position of the steered drive wheel is shown in the control panel display unit The maximum steer angle is 90 Controls and Displays The functions are activated via ergonomic thumb movement to ensure fatigue free operation without stressing the wrists sensitive application of travel and hydraulic movements to spare and position the goods precisel...

Page 12: ...riving side loading side kg 520 820 540 990 Types Chassis 3 1 Tyre type Driving wheels Loading wheels polyurethane polyurethane polyurethane polyurethane 3 2 Tyre size driving wheels Diameter Width mm Φ260 125 Φ260 125 3 3 Tyre size loading wheels Diameter Width mm Φ204 76 Φ204 76 3 4 Tyre size caster wheels diameter width mm Φ74 48 Φ74 48 3 5 Wheels number driving caster loading x drive wheels mm...

Page 13: ... 0 28 0 20 0 28 5 3 Lowering speed laden unladen m s 0 35 0 30 0 35 0 30 5 8 Max gradeability laden unladen 0 0 5 10 Service brake type Electromagnetic Electromagnetic Electric engine 6 1 Drive motor rating S2 60 min kW 4 4 6 2 Lift motor rating at S3 15 kW 4 4 6 3 The maximum allowed size battery mm 300x840x670 300x840x670 6 4 Battery voltage nominal capacity K20 V Ah 48V 360AH 48V 360AH 6 5 Batt...

Page 14: ...7 J1HD ...

Page 15: ...8 1 4 Identification points ...

Page 16: ...arning decal 4 Emergency Lowering label 5 AC Power Decal 6 Never put your hands in inner and outer mast warning 7 Nameplate 8 Operator danger decal 9 Key Switch decal 10 Lift Lower Horn decal 11 Forward Reverse travel 12 Power shut off 13 Foot pedal label 14 Operator caution decal ...

Page 17: ...s will flatten The flattening will disappear after a short period of operation 2 2 During brake in We recommended operating the machine under light load conditions for the first stage of operation to get the most from it Especially the requirements given below should be observed while the machine is in a stage of 100 hours of operation Must prevent the new battery from over discharging when early ...

Page 18: ...Damage and Faults The supervisor must be immediately informed of any damage or faults to the truck trucks not safe for operation e g wheel or brake problems must not be used until they have been rectified Repairs The driver must not carry out any repairs or alterations to the truck without the necessary training and authorization to do so The driver must never disable or adjust safety mechanisms o...

Page 19: ...12 3 2 Controls and Displays 3 2 1 Control panel controls and displays ...

Page 20: ... operator position 5 Horn button Activates the horn 6 Emergency stop switch Disconnects the supply current deactivates all electrical functions causing the truck to brake automatically 7 Travel switch Select the required driving direction 8 Key switch Switches control current on and off Removing the key prevents the truck from being switched on by unauthorized personnel 9 White lamp button Control...

Page 21: ...ation display area of LCD screen will display the warning and fault indication 3 Temperature alarm lamp When overuse makes the temperature of drive motor high the lamp will illuminate At the moment in order to preventing the motor from being burned out please don t use the truck temporarily And when the temperature drop continue to use 4 Drive pedal alarm lamp When you don t step on the drive peda...

Page 22: ...nd fault indication see 6 1 Error Message Page 35 Speed display area Displays possible travel speeds Unit Km h Steering display area Use the steering wheel to steer the truck outside narrow aisles The position of the drive wheel is shown here area 90 Driving mode display area 0h High speed Crawl speed Speed mode display area Four modes Mode 1 Mode 2 Mode 3 and Mode 4 Switch the mode Press the left...

Page 23: ...riplex mast Unit Km h Operator platform height in Speed mode Driving mode Mode 1 Mode 2 Mode 3 Mode 4 0 22 05 1 4 2 3 3 0 3 8 0h 2 1 3 2 4 4 5 5 22 05 74 80 1 4 2 2 3 0 3 8 74 80 102 36 1 1 1 6 2 1 2 5 102 36 MAX 0 4 0 6 0 8 1 0 ...

Page 24: ...ear and damage Test the warning device Make sure the load chains are evenly tensioned Check whether the normal function of all safety devices To prepare the truck for operation Close the safety gates Insert the key in the key switch and turn it to the ON position Pull up the emergency stop switch Test horn Check the operation of the brake Warning Before the truck can be commissioned operated or a ...

Page 25: ...tted It is forbidden to lean out of or reach beyond the working and operating area Negotiating lifts and docks Lifts and docks must only be used if they have sufficient capacity are suitable for driving on and authorized for truck traffic by the owner The driver must satisfy himself of the above before entering these areas The truck must enter lifts with the load in front and must take up a positi...

Page 26: ...ON position Pull up the emergency stop switch 3 Apply the drive pedal 2 Use the travel switch 4 to select the required driving direction Forward V Backward R The travel speed is governed by the speed mode Use steering wheel 1 to steer the truck in the required direction Warning When the circuit is switched on the vehicle will have a self test process Make sure the lamps on the display unit stop fl...

Page 27: ...oasting brake Not apply the drive pedal 2 Travel inhibited truck decelerates With the emergency brake Press the emergency brake switch 3 The truck brakes until it comes to a halt 3 4 3 Lifting Lowering Ensure there are no other people standing underneath the raised load and driver s cab Instruct other people to move out of the hazardous area Lifting Press the Lifting button 1 until you reach the d...

Page 28: ...n Warning Do not climb out of the lift cage while the operator position is elevated The lift mast cannot be climbed safely An elevated operator position has a high center of gravity and can be tipped easily Standing on or leaning out from the outside of a cage rail may cause the lift vehicle to tip over Tipping the lift vehicle over can cause severe injury or death and equipment damage ...

Page 29: ...s shelves Pull the Lowering button 2 until load handler completely lowered WARNING When the operator position lifted please try to avoid steering and emergency stop operation Transporting loads Always transport loads with the mast completely lowered Always transport loads with load handler or pallet CAUTION Before a load can be placed the driver must ensure that the storage location is suitable fo...

Page 30: ... 1 to the vertical and horizontal plane Put the pallet 1 into the shroud 2 Opening the pallet is in the reverse order of operations 3 5 Parking the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time Lower the load completely and position it horizontally Retract the mast support fully Set the emergency brake switch 2 OFF Turn off ...

Page 31: ...24 ...

Page 32: ...or operating fluids capable of creating sparks within 2 meters around the truck The area must be well ventilated Fire protection equipment must be provided Battery Disposal Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws The manufacturer s disposal instructions must be followed 4 2 Battery type dimension The battery type dimension...

Page 33: ...ve the plug 1 Connect the plug 1 with the charger 2 Connect the battery plug 3 with the charging lead of the stationary charger and turn on the charger 4 4 Battery removal and installation Park the truck securely See 3 5 Parking the truck securely Page 21 Place the battery plug or the battery cable in such a way that they will not get caught on the truck when the battery 1 is removed Remove batter...

Page 34: ... appears need for charge please charge it quickly Battery maintenance The battery cell covers must be kept dry and clean The terminals and cable shoes must be clean secure and have a light coating of dielectric grease Batteries with non insulated terminals must be covered with a non slip insulation mat Battery storage If batteries are taken out of service for a lengthy period they should be stored...

Page 35: ...vice department has field technicians specially trained for these tasks We therefore recommend a maintenance contract with the manufacturer s local service center Lifting and jacking up When a truck is to be lifted the lifting gear must only be secured to the points specially provided for this purpose When jacking up the truck take appropriate measures to prevent it from slipping or tipping over e...

Page 36: ...placed every six years When replacing hydraulic components also replace the hoses in the hydraulic system 5 3 Servicing and inspection Thorough and expert servicing is one of the most important requirements for the safe operation of the truck Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment The service intervals stated are based...

Page 37: ...ease terminals if necessary Travel Check transmission for noise and leakage Check travel mechanism adjust and lubricate if necessary Check wheels for wear and damage Check wheel suspension and attachments Check drive support plate Truck frame Check chassis for damage Check labels Check mast attachment Check screw connections Check gates and panels are secure and free of damage Hydraulic operations...

Page 38: ...t for wear and damage Perform sight check of rollers sliding elements and stops Steering system Test electric steering Check steering toothing for wear and lubricate Lubrication Grease the vehicle in accordance with the lubrication schedule Gearbox After the initial operation of 150 500 hours change the gear oil every 800 1000 hours ...

Page 39: ...32 5 3 2 Lubrication Schedule ...

Page 40: ... disposed of in accordance with regulations Code Type Specification Amount A Anti wear hydraulic oil L HM32 See the table below Low temperature anti wear hydraulic oil cold storage L HV32 B Multi purpose grease Polylub GA352P Appropriate amount C Heavy duty gear oil 80W 90GL 5 1 8L Align with oiling port Application Amount of Hydraulic Oil Mast Series Lifting height mm Amount L 3 stage Mast 4200 8...

Page 41: ...ication Schedule P29 Add hydraulic oil till you cant hear explosion sound during lifting Installation is the reverse order Checking electrical fuses Prepare the stacker for maintenance and repairs See 5 3 3 Maintenance Instructions Page30 Open the cover Check rating of all fuses in accordance with table replace if necessary Item To protect Rating 1 Traction Lift Steer motor Fuse 200A 2 Controller ...

Page 42: ...e truck Check the brakes Check the hydraulic oil level and replenish as necessary See 5 3 3 Maintenance Instructions Page30 Apply a thin layer of oil or grease to any non painted mechanical components Lubricate the truck in accordance with the maintenance schedule See 5 3 2 Lubrication Schedule P29 Charge the battery See 4 4Charging the battery P23 Disconnect the battery clean it and apply grease ...

Page 43: ... truck from purely a safety viewpoint without regard to operational or economic circumstances The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of trucks A thorough test of the truck must be undertaken with regard to ...

Page 44: ...ressed Foot switch not pressed Battery charge too low Faulty fuse truck in charge mode Check the battery connector and connect if necessary Set key switch to ON Close the safety gates Unlatch EMERGENCY DISCONNECT switch Press foot switch Check battery charge charge battery if Necessary Test fuses Interrupt charging Load can not be lifted Hydraulic oil level too low Excessive load Fuse blown Check ...

Page 45: ...used by a CAN bus malfunctioning which blinds master supervisor communication 17 LOGIC FAILURE 3 A hardware problem in the logic board due to high currents overload An overcurrent condition is triggered even if the power bridge is not driven The failure lies in the controller hardware Replace the controller 18 LOGIC FAILURE 2 Fault in the hardware section of the logic board which deals with voltag...

Page 46: ... starting up relays or contactors during switching periods solenoids energizing or de energizing Consider to remove such loads 2 If no voltage transient is detected on the supply line and the alarm is present every time the key switches on the failure probably lies in the controller hardware Replace the logic board 3 If the alarm occurs during motor acceleration or when there is a hydraulic relate...

Page 47: ...oller C If the alarm occurs during motor running check Motor internal connections If motor 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 it is necessary to replace the logic board 29 PUMP VMN HIGH This test is carried out when the pump motor is turning PWM ap...

Page 48: ... voltages decrease down to B If the phase voltages are higher than a certain percentage of the nominal battery voltage this alarm occurs This alarm may also occur when the start up diagnosis has succeeded and so the LC has been closed In this condition the phase voltages are expected to be lower than half the battery voltage If one of them is higher than that value this alarm occurs A If the probl...

Page 49: ...r the current feedback circuit is damaged Replace the controller 60 CAPACITO R CHARGE When the key is switched on the inverter tries to charge the power capacitors through the series of a PTC and a power resistance checking if the capacitors are charged within a certain timeout If the capacitor voltage results less than a certain percentage of the nominal battery voltage the alarm is raised and th...

Page 50: ...e temperature sensor is open if digital or if it has overtaken the MAX MOTOR TEMP threshold if analog see paragraph 8 2 3 1 Check the temperature read by the thermal sensor inside the motor through the MOTOR TEMPERATURE reading in the TESTER function 2 Check the sensor ohmic value and the sensor wiring 3 If the sensor is OK improve the cooling of the motor 4 If the warning is present when the moto...

Page 51: ... potentiometer 3 Acquire the maximum and minimum potentiometer value through the PROGRAM VACC function 4 If the problem is not solved replace the logic board 79 INCORRECT START Incorrect starting sequence Possible reasons for this alarm are 1 A travel demand active at key on 2 Man presence sensor active at key on 1 Check wirings 2 Check microswitches for failures 3 Through the TESTER function chec...

Page 52: ...C E STOP PLC device has opened the Main Contactor and the Electric Brake coils and the A19 DI5 input is closed to key This problem is due to PLC device MIR 106 AGV WAIT BOOT XX Zapi controller is waiting the right behaviour of the A19 DI5 input drived by the PLC to close the Main Contactor XX 1 From the key on event to BOOT TIME A19 LO the controller checks if the A19 DI5 input is open to key XX 2...

Page 53: ...VEL 1 Mismatch of CAN and wired A31 DI4 AGV mode requests With AGV CHECK LEVEL 2 Mismatch of CAN and wired A31 DI4 AGV mode requests or mismatch of CAN AGV mode requests on messages ID 0x208 traction and 0x218 EPS This problem is due to AGV master device MIR 110 AUX OUT OF RNG Aux pot out of the normal range 111 VACC AUX NOTOK The output of aux pot is present but the enable switch is not active 11...

Page 54: ...ng the state machine sequence SHELF WR INP xx Bit 2 of xx HEIGHT OFFS A MM higher than HEIGHT OFFS B MM SHELF WR INP xx Bit 3 of xx HEIGHT OFFS A MM out of range SHELF WR INP xx Bit 4 of xx HEIGHT OFFS B MM out of range SHELF WR INP xx Bit 5 of xx SHELF CUTBACK MM out of range SHELF WR INP xx Bit 6 of xx SHELF CUTBACK SP out of range SHELF WR INP xx Bit 7 of xx HEIGHT TOLER MM out of range or high...

Page 55: ... Zero switch vs encoder speed diagnosis Checks if the zero switch edges matches with encoder speed Activates the bit 2 of xx of the HEIGHT ZERO xx alarm in case of zero switch positive edge and negative encoder speed Activates the bit 3 of xx of the HEIGHT ZERO xx alarm in case of zero switch negative edge and positive encoder speed This diagnosis is made on height regions 4 5 120 HEIGHT ENC LOCK ...

Page 56: ...f a wrong patters is detected filtered the alarms is set Check encoder signal wiring change the encoder 125 WRONG INV MODEL Model TYPE and Inverter Type do not match with the HW Check the coherence between the HW and the parameter settings 129 WRONG CONFIG wrong set of controller type and model type 1 check the parameter controller type in sepcial adjustment menu 2 check the parameter model type i...

Page 57: ... check the wiring of the sideshift pot 136 VACC SHFT NOT OK the output of sideshift pot is present but the enable switch is not active 1 check the sideshift pot 2 check the wiring 137 ALL ACQU TILT do the wrong way of tilt pot teaching do the teaching in correct way 138 ALL ACQU SHIFT do the wrong way of sideshift pot teaching do the teaching in correct way 139 NO CAN TILL EP the controller lost t...

Page 58: ...1 enter the correct password 2 disable the password function 144 NO CAN DISP EP When the truck is running if the DISPLAY TYPE 5 but the controller lose the communication with EP DISPLAY this alarm occurs 1 check the communication wiring between EP DISPLAY and controller 2 check if the EP DISPLAY is broken 145 WAIT DISP EP if the DISPLAY TYPE 5 but the controller can t get message from EP DISPLAY w...

Page 59: ...charge level is to low the BMS require the controller to stop the lift function this alarm occurs 1 check the battery charge level 2 check if the battery is ok 3 replace the BMS 151 EP BMS TRAC STOP if the battery charge level is to low the BMS require the controller to stop the traction function this alarm occurs 1 check the battery charge level 2 check if the battery is ok 3 replace the BMS 153 ...

Page 60: ...roblem is not solved replace the logic board 177 COIL SHOR EB This alarm occurs when an overload of the EB driver occurs 1 Check the connections between the controller outputs and the loads 2 Collect information about characteristics of the coil connected to the driver and ask for assistance to a EP technician in order to verify that the maximum current that can be supplied by the hardware is not ...

Page 61: ...e steering potentiometer through the STEER ACQUIRING function If the alarm is still present check the mechanical calibration and the functionality of the potentiometer 2 If the problem is not solved replace the logic board 180 OVERLOAD The motor current has overcome the limit fixed by hardware If the alarm condition occurs again ask for assistance to a EP technician The fault condition could be af...

Page 62: ...o drive the EVP2 coil The device itself or its driving circuit is damaged This fault is not related to external components Replace the logic board 186 WAIT MOT P STILL If DC Pump option is set to ON the software expects the voltage on P output to be at a steady state value before switching the LC on If the voltage is different it could be due to the fact that the motor connected to P is not still ...

Page 63: ...ace the logic board 190 PUMP VMN NOT OK Switching the LC on the software checks the output voltage on P connector and expects that it is at a steady state value if DC PUMP option is set to ON see HYDRO SETTINGS If the voltage is too low this alarm occurs 1 The motor connected to P must be completely still before this alarm occurs The software waits 30 seconds before showing this alarm During this ...

Page 64: ...sions where the smart driver is not installed 36 48V and 80V it is possible to decide where the positive supply for pin A2 comes from by choosing a dedicated hardware configuration The parameter POSITIVE E B has to be set in accordance with the hardware configuration because the software makes a proper diagnosis depending on the parameter a wrong setting could generate a false fault The available ...

Page 65: ... the alarm does not disappear the problem is in the motor Replace it 197 WRONG SLAVE VER Wrong software version on supervisor uC Upload the correct software version 198 M S PAR CHK MISM At start up there is a mismatch in the parameter checksum between the master and the supervisor microcontrollers Restore and save again the parameters list 199 PARAM TRANSFER Master uC is transferring parameters to...

Page 66: ...oltage Undervoltage condition If the alarm happens during the brake release check the line contactor contact and the battery power cable connection 203 HW FAULT MC the Mcu and the Scu check the status of the main contactor is different from each other This type of fault is related to internal components Replace the logic board 204 BRAKE RUN OUT The CPOT BRAKE input read by the microcontroller is o...

Page 67: ...dentifies the faulty phase 01 phase U 02 phase V 03 phase W 1 Check the motor power cables 2 Check the impedance between U V and W terminals and B terminal of the controller 3 Check the motor leakage to truck frame 4 If the motor connections are OK and there are no external low impedance paths the problem is inside the controller Replace it 208 EEPROM KO the connection of the EEPROM is not ok This...

Page 68: ...cian about the correct adjustment of the motor parameters 213 POSITIVE LC OPEN The positive voltage of LC is different from expected 1 Verify LC coil is properly connected 2 Verify CONF POSITIVE LC parameter is set in accordance with the actual coil positive supply see paragraph 8 2 5 Software depending on the parameter value makes a proper diagnosis a mismatch between the hardware and the paramet...

Page 69: ...blem is not solved replace the logic board 217 PEV NOT OK Terminal PCOM is not connected to the battery or the voltage is different from that defined by parameter SET POSITIVE PEB see the ADJUSTMENTS list paragraph 8 2 3 This alarm can occur if output NAUX1 is present and the related setting is active or the AUX OUT function is active 1 Check PCOM terminal it must be connected to the battery volta...

Page 70: ...ultimotor one There is an input mismatch between the traction controller and the pump controller relatively to the TILLER SEAT input A1 the two values recorded by the two controllers are different 1 Check if there are wrong connections in the external wiring 2 Using the TESTER function verify that the seat inputs are in accordance with the actual state of the external switch 3 In case no failures ...

Page 71: ...e functionality of the accelerator potentiometer 2 If the problem is not solved replace the logic board 227 HW FAULT At start up some hardware circuit intended to enable and disable the power bridge or the LC driver output A12 is found to be faulty The hexadecimal value XX facilitates EP technicians debugging the problem This type of fault is related to internal components Replace the logic board ...

Page 72: ...s turned on 1 Check that motor phases are correctly connected 2 Check that there is no dispersion to ground for every motor phases 3 In case the problem is not solved replace the controller 234 DRV SHOR EV AUX valve driver is shorted 1 Check if there is a short circuit or a low impedance path between the negative terminal of the coils and B 2 If the problem is not solved replace the logic board 23...

Page 73: ...o be faulty The hexadecimal value XX facilitates EP technicians debugging the problem This type of fault is not related to external components Replace the logic board 239 CONTROL LER MISM The software is not compatible with the hardware Each controller produced is signed at the end of line test with a specific code mark saved in EEPROM according to the customized part number According with this si...

Page 74: ...lt appears when no load is connected between one or more EV outputs and the positive terminal PEV pin A3 For the meaning of code XX refer to paragraph 10 5 EVP1 BIT 0 EV1 BIT 1 EV2 BIT 2 EV3 BIT 3 EVP2 BIT 4 EV4 BIT 5 EV5 BIT 7 HORN BIT 6 1 Check the coils 2 Check the wiring 3 If the problem is not solved replace the logic board 243 THROTTLE PROG A wrong profile has been set in the throttle profil...

Page 75: ...ot work properly The hexadecimal value XX identifies the faulty node 1 Verify the CANbus network external issue 2 Replace the logic board internal issue 249 CHECK UP NEEDED This is a warning to point out that it is time for the programmed maintenance Turn on the CHECK UP DONE option after that the maintenance service Error Message Possible cause Fault elimination Error Error text 250 THERMIC SENS ...

Page 76: ...oltmeter on pin A10 If it does not match then modify the ADJUST BATTERY parameter according to the value read by the voltmeter 4 Replace the battery 253 FIELD ORIENT KO The error between the Id d axis current setpoint and the estimated Id is out of range Ask for assistance to a EP technician in order to do the correct adjustment of the motor parameters 254 EB DRIV SHRT 1 The EB driver is shorted 2...

Page 77: ...ler hardware Replace the logic board 3 If the alarm occurs during motor acceleration or when there is a hydraulic related request check the battery charge the battery health and power cable connections 194 AGV CAN BUS KO Missed or wrong at least one of the AGV messages with ID 0x208 0x218 from AGV master device MIR This problem is due to AGV master device MIR 195 WRONG CONFIG wrong set of controll...

Page 78: ...VERV This fault is displayed when the controller detects an overvoltage condition Overvoltage threshold depends on the nominal voltage of the controller Nominal voltage 24V 36 48V 72 80V 96V Overvoltage threshold 35V 65V 115V 130V As soon as the fault occurs power bridge and MC are opened The condition is triggered using the same HW interrupt used for undervoltage detection uC discerns between the...

Page 79: ...behaviour of the A19 DI5 input drived by the PLC to close the Main Contactor XX 1 From the key on event to BOOT TIME A19 LO the controller checks if the A19 DI5 input is open to key XX 2 From the end of the above check the controller wait BOOT TIME TOL LO the closing to key of the A19 DI5 input XX 3 From the end of the above check the controller check if the A19 DI5 input is closed to key for at l...

Page 80: ...d internal issue 230 SOFTWARE ERROR it means the software of the slave controller is wrong This type of fault is related to internal components Replace the logic board 237 ANALOG INPUT This alarm occurs when the A D conversion of the analog inputs returns frozen values on all the converted signals for more than 400 ms The goal of this diagnosis is to detect a failure in the A D converter or a prob...

Page 81: ...master μC 1 Check the matching of the parameters between master and supervisor 2 Ask for assistance to a EP technician 3 If the problem is not solved replace the logic board 242 SP MISMATCH XX This is a safety related test The supervisor μC has detected a mismatch in the speed setpoint with respect to the master μC The hexadecimal value XX facilitates EP technicians debugging the problem 1 Check t...

Page 82: ... the controller 17 LOGIC FAILURE 3 This alarm occurs in the rest state if the output of the voltage amplifier of the phase Vu Vw have a drift larger than 0 25 V It is necessary to replace the controller 18 LOGIC FAILURE 2 This alarm occurs when the real voltage between phases W and V of the motor is different from the desired It is necessary to replace the controller 19 LOGIC FAILURE 1 This alarm ...

Page 83: ... degree still with DIAG MOTOR TEMP to ON Check the thermal sensor in the motor is right working If it is improve the cooling of the motor 70 HIGH CURRENT This alarm occurs if the circuit to limit via hardware the current in the motor is either always active at key on or repeatedly active when the motor is turning Check the motor is suited to work with the eps ac0 not oversized Otherwise it is nece...

Page 84: ...EER HAZARD This is just a warning to inform that the steering controller is limiting the angle in the steering direction No speed reduction occurs on the traction 218 CLOCK PAL NOT OK The main uC sends an analog signal towards the slave uC to reset the slave uC on demand When the slave uC detects this analog signal external to a window from 2 2 to 2 8 and not in the range to generate the reset on ...

Page 85: ...t occurs when the encoder counting of the main uC is not matched with the encoder counting of the slave uC It is necessary to replace the controller 217 MICRO SLAVE 3 218 CLOCK PAL NOT OK The main uC sends an analog signal towards the slave uC to reset the slave uC on demand When the slave uC detects this analog signal external to a window from 2 2 to 2 8 and not in the range to generate the reset...

Page 86: ...e stepper motor speed this alarm occurs Closed loop application only If the slave uC detects the stator voltage phasor rotates in the opposite direction respect to the commanded position this alarm occurs It is necessary to replace the controller 222 FB POT LOCKED In application with a feedback potentiometer this alarm occurs if the feedback potentiometer CPOT on CNB 6 does not change or changes i...

Page 87: ...is just a watch dog function when the main uC does not execute the code cycle it does not update the SYNC signal and the slave uC cuts off the steer and traction It is necessary to replace the controller 227 SLAVE COM ERROR Main uC and Slave uC communicate via a local serial interface This alarm occurs when the main uC does not receive the communication from the slave uC through this serial interf...

Page 88: ...roller to send a list of parameters via CAN Bus From the request until the parameters are correctly relieved this warning occurs The steer is not activated yet and the safety relays remain open when this warning is present 238 EPS NOT ALIGNED This is a real alarm that cut off the traction It occurs at the initial alignment if the straight ahead condition is not matched within 6sec Throughout this ...

Page 89: ...s when the mean voltage on the Quadrature line of the stepper motor connection CNA 8 is not null the voltage on every stepper motor line is a sine wave with null mean voltage Check the continuity of the stepper motor connections In particular the resistance between CNA 8 and the minus battery with the stepper motor at rest is expected being very low close to 30 ohms 243 D LINE SENSOR KO This alarm...

Page 90: ... slave uC is detecting Furthermore this alarm occurs also if the main uC is detecting no steering limitation meanwhile the slave uC is detecting e steering limitation It is necessary to replace the controller 247 CAN BUS KO This alarm occurs only when the setting CAN BUS is PRESENT Then the eps ac0 must receive the event messages from the traction controller If these messages lack more than about ...

Page 91: ...troller 252 KS OPEN This alarm occurs if the main uC detects the safety contact of the slave uC open when expected being closed It is necessary to replace the controller 253 KM CLOSED This alarm occurs at key on if the slave uC detects the safety contact of the main uC closed prior to be commanded This alarm occurs if the connection CNA 5 K1 is around a voltage of 12 Vdc when switching on the key ...

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