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SERVICE
DIAGNOSTICS AND MEASUREMENTS
ACe2 PUMP AND TRACTION MODULE DIAGNOSIS SYSTEM

ACE2 PUMP AND TRACTION MODULE ALARMS
programmer
message
WATCHDOG
EEPROM KO
LOGIC FAILURE #3
LOGIC FAILURE #2
message
sicos
CALL
SERVICE
description
effect
state of the truck
MC open, EB activated, Start up

The Watchdog signal is
traction/pump station- Stand-by
not in the correct state.
ary.
During traction
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Error
detected
in The control device
EEPROM or in EEPROM works using the default Continuous
management.
parameters.
Re-start procedure:
None.
CALL
SERVICE
Hardware protection cir- MC not closed, EB accuit failure due to high tivated, traction/pump Start up
current.
stationary.
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
MC open, EB activated, Switch-on (imMotor phase voltage feedtraction/pump station- mediately after the
back circuit failure.
ary.
MC closes)
Re-start procedure:
LOGIC FAILURE #1
Vmn low
Vmn HIGH
CONTACTOR
CLOSED
CALL
SERVICE
a condition of undervolt- MC not closed, EB ac- Start up

age/overvoltage has been tivated, traction/pump Stand-by
detected.
stationary.
During traction
Re-start procedure:
CALL
SERVICE
MC open, EB activated,
Motor output voltage low Start up
traction/pump stationer than expected.
During traction
ary.
Re-start procedure:
CALL
SERVICE
MC not closed, EB acMotor output voltage high Start up

tivated, traction/pump
er than expected.
Stand-by
stationary.
Re-start procedure:
CALL
SERVICE
The LC contact is locked
MC not closed (the

control has not been
activated), EB activat- Start up
ed, traction/pump stationary.
Re-start procedure:
13
programmer
message
CONTACTOR
OPEN
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
Switch-on (imThe MC coil has been ac- MC open, EB activated, mediately after the
tivated, but the MC fails to traction/pump station- MC closes)
close.
ary.
Stand-by
During traction
Re-start procedure:
STBY I HIGH
CALL
SERVICE
In stand-by conditions (no

current applied to the mo- MC not closed, EB actor), current feedback is tivated, traction/pump Start up
outside the permissible stationary.
stand-by limits.
Re-start procedure:
CAPACITOR
CHARGE
TH. PROTECTION
CALL
SERVICE
The voltage of the power MC not closed, EB accapacitors fails to in- tivated, traction/pump Start up
crease.
stationary.
Re-start procedure:
CALL
SERVICE
The control device has

reached the thermal reduction temperature of
85C when the current is
IMAX.
The traction control device reduces the maximum current linearly Continuous
from IMAX (85C) to 0A
(105C).
Re-start procedure:
None.
MOTOR
TEMPERAT.
CALL
SERVICE
The motor temperature

sensor is open (if dig- The maximum current
ital) or has exceeded the is halved and the speed Continuous
150C threshold (if ana- is reduced.
logue).
Re-start procedure:
None.
CALL
SERVICE
BATTERY LOW
DRIVER SHORTED
The battery is <= 10%

when
the
BATTERY
CHECK parameter is set
to >0
Re-start procedure:
Recharge the battery.
CALL
SERVICE
The MC driver has shorted and therefore is not

capable of opening the
contactor.
Re-start procedure:
14
The maximum current

Start up
is halved and the speed
Stand-by
is reduced (if CHECK
During traction
OPTION=1).
MC open (the control

Start up
has been released),
Stand-by
EB activated, traction/
During traction
pump stationary.
SERVICE
programmer
message
CONTACTOR
DRIVER
VACC NOT OK
message
sicos
CALL
SERVICE
description
effect
state of the truck
MC open (the control

The MC coil driver is dam- has been released), Stand-by
aged (it can't close).
EB activated, traction/ During traction
pump stationary.
Re-start procedure:
CALL
SERVICE
The
value
of
the
accelerator/lifting
potentiometer is greater
Start up
The traction/pump mothan
the
minimum
Stand-by
tor is stationary.
recorded
value
and
During traction
the
direction/activation
switches are off.
Re-start procedure:
INCORRECT
START
FORW + BACK
ENCODER ERROR
VDC OFF
SHORTED
WRONG SLAVE
VER.
VDC LINK OVERV.
CALL
SERVICE
Incorrect
quences.
starting
se- The traction/pump mo- Start up

tor is stationary.
Stand-by
Re-start procedure:
CALL
SERVICE
Drive requests active

in both directions at the Traction is stationary.
same time.
Start up
Stand-by
During traction
Re-start procedure:
Make a traction request.
CALL
SERVICE
Problem in reading the
traction/pump station- During traction
encoder.
ary.
Re-start procedure:
CALL
SERVICE
When switching on, the MC open, EB activated,

VDC-off logic signal is traction/pump station- Start up
low.
ary.
Re-start procedure:
CALL
SERVICE
The software versions for MC open, EB activated,

the Slave and Master are traction/pump station- Start up
not the same.
ary.
Re-start procedure:
CALL
SERVICE
A condition of overvoltage
Stand-by
traction/pump stationhas been detected.
During traction
ary.
Re-start procedure:
Make a valve or traction or hydraulic request.
15
programmer
message
TILLER MISMATCH
message
sicos
CALL
SERVICE
description
effect
The Master C and Slave

C do not have the same
Traction is stationary.
value for the tiller input
from the VCM.
SERVICE
state of the truck
Start up
Stand-by
During traction
Re-start procedure:
BRAKE RUN OUT
STOP RQ. FROM

EPS
INIT VMN HIGH
CALL
SERVICE
The brakes potentiometer No effect. The warning

input is at the maximum is shown on the con- Continuous
value with no HB request. sole only.
Re-start procedure:
CALL
SERVICE
EPS sends a request to

Traction is stationary.
stop the motor.
Start up
Stand-by
During traction
Re-start procedure:
CALL
SERVICE
The motor phase voltage

is higher than expected,
traction/pump station- Start up
before activating the
ary.
bridge.
Re-start procedure:
INIT VMN LOW
CALL
SERVICE
The motor phase voltage

is lower than expected,
before activating the
ary.
bridge.
Re-start procedure:
EEPROM KO
PARAM RESTORE
CALL
SERVICE
it is impossible to
recover the data from the No effect.
memory.
Start up
Re-start procedure:
CALL
SERVICE
Partial/complete
parameter reset has been
No effect.
performed since the last
shutdown.
Start up
Re-start procedure:
WRONG RAM
MEM.
16
CALL
SERVICE
The program checks the

content of the main RAM
traction/pump station- Continuous
registers and finds a dirty
ary.
value.
Re-start procedure:
SERVICE
programmer
message
STALL ROTOR
message
sicos
CALL
SERVICE
description
The traction
blocked.
rotor
effect
state of the truck
Start up
is The traction/pump is
Stand-by
stationary.
During traction
Re-start procedure:
WAITING SLAVE
HARDWARE
FAULT
POT. ACCEL MISM
CALL
SERVICE
No activation message
from the Slave.
ary.
Re-start procedure:
CALL
SERVICE
The drivers fail to switch MC not closed, EB acoff with the Watchdog sig- tivated, traction/pump Start up
nal in an alarm state.
stationary.
Re-start procedure:
CALL
SERVICE
There is a discrepancy
Start up
between Master and The traction/pump is
Stand-by
Slave on the accelerator stationary.
During traction
signal.
Re-start procedure:
POT. BRAKE MISM
SENS MOT TEMP

KO
PEV NOT OK
CALL
SERVICE
There is a discrepancy be Start up

The traction/pump is
tween Master and Slave
Stand-by
stationary.
on the brake signal.
During traction
Re-start procedure:
CALL
SERVICE
The motor heat sensor The maximum current

output is outside the lim- is halved and the speed Continuous
its.
is reduced.
Re-start procedure:
None.
CALL
SERVICE
The PEV connector (A17)

MC closed, EB acti- Start up
is not connected to the
vated, traction/pump, Stand-by
battery or the voltage is
valves stationary.
During traction
different.
Re-start procedure:
Make a traction or hydraulic or valve request.
VKEY OFF
SHORTED
CALL
SERVICE
MC not closed, EB acWhen switching on, the

tivated, traction/pump Start up
Key-off logic signal is low.
stationary.
Re-start procedure:
17
programmer
message
FLASH
CHECKSUM
MC COIL SHOR.
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
MC not closed, EB acThe program check is not

OK.
stationary.
Re-start procedure:
CALL
SERVICE
Switch-on (imMC open, EB activated, mediately after the

Short-circuit on the MC
traction/pump station- MC closes)
coil.
Stand-by
ary.
During traction
Re-start procedure:
WAITING FOR
NODE
VACC OUT RANGE
CALL
SERVICE
No activation signals ar- MC open, EB activated, Start up

rive from the other system traction/pump station- Stand-by
units.
ary.
During traction
Re-start procedure:
CALL
SERVICE
The accelerator input is

outside the Vacc_min
Start up
to Vacc_max range that The traction/pump mo Stand-by
has been acquired with tor is stationary.
During traction
the PROGRAMM VACC
function.
Re-start procedure:
TILLER OPEN
OUTPUT
MISMATCH
WD SYNCRO
NO SLAVE
ENABLE
18
CALL
SERVICE
The truck is on stand-by

with the tiller switch off for LC opens.
longer than 30 seconds.
Stand-by
Re-start procedure:
CALL
SERVICE
There is a discrepancy be- MC not closed, EB ac Stand-by

tween Master and Slave tivated, traction/pump
During traction
on the motor control.
stationary.
Re-start procedure:
CALL
SERVICE
The Slave C has not re- MC open, EB activated, Start up

ceived the Watchdog sig- traction/pump station- Stand-by
nal from the Master C.
ary.
During traction
Re-start procedure:
CALL
SERVICE
No activation message
traction/pump station- During traction
from the Slave.
ary.
Re-start procedure:
SERVICE
programmer
message
DIR SEL OUT
RANG
POWER MOS
SHORT
COIL SHOR. EB
message
sicos
CALL
SERVICE
description
effect
state of the truck
Start up
The selected direction sig- Traction/pump station Stand-by
nal is outside the limits.
ary.
During traction
Re-start procedure:
CALL
SERVICE
MC not closed, EB acShort-circuit on the power

MOSFETs.
stationary.
Re-start procedure:
CALL
SERVICE
Switch-on (imMC open, EB activated, mediately after the

Short-circuit on the EB
traction/pump station- MC closes)
coil.
Stand-by
ary.
During traction
Re-start procedure:
Current Gain
CALL
SERVICE
The maximum current

gain
parameters
are
the default values. This The control device
Start up
means that the maximum works, but with a low
Stand-by
current adjustment proce- maximum current.
dure has not yet been carried out.
Re-start procedure:
None.
Analog input
CALL
SERVICE
The analogue channel traction/pump station- Start up
reading is not up-to-date. ary.
During traction
Re-start procedure:
CALL
SERVICE
TILLER ERROR
Tiller failure.
The main remote-con Start up

trol switch, open power
Stand-by
bridge, electromagnetic
During traction
brake activated.
Re-start procedure:
Re-synchronisation of the system:
release all requests (traction and hydraulic)
make a traction or hydraulic request or both.
19
programmer
message
EVP DRIVER OPEN
M/S PAR CHK

MISM
INPUT MISMATCH
PARAM
TRANSFER
SP MISMATCH
Throttle prog.
Iq mismatched
Aux Driv. Open
20
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
The EVP coil driver is

MC closed, EB activatopen and is not able to
EVP on
ed, EVP stationary.
close.
Re-start procedure:
Make an EVP request.
CALL
SERVICE
The checksum test be- MC open, EB activated,

tween Master and Slave traction/pump station- Start up
has not been passed.
ary.
Re-start procedure:
CALL
SERVICE
The Slave C has differ- MC open, EB activated, Start up

ent values to the inputs traction/pump station- Stand-by
from the Master C.
ary.
During traction
Re-start procedure:
CALL
SERVICE
The Master cannot trans- MC open, EB activated,

fer the parameters to the traction/pump station- Start up
Slave.
ary.
Re-start procedure:
CALL
SERVICE
The Slave C has detect- MC open, EB activated, Start up

ed an incorrect set point traction/pump station- Stand-by
of the Master C.
ary.
During traction
Re-start procedure:
CALL
SERVICE
One of the potentiometers

Start up
Traction/pump stationhas not been programmed
Stand-by
ary.
correctly.
During traction
Re-start procedure:
CALL
SERVICE
The error between the lq

set point and the estimat- Traction stationary.
ed lq is outside the limits.
During traction
Re-start procedure:
CALL
SERVICE
The AUX coil driver has MC open, EB activated,

Stand-by
failed (it cannot operate traction/pump station During traction
the brake).
ary.
Re-start procedure:
SERVICE
programmer
message
DATA
ACQUISITION
message
sicos
CALL
SERVICE
description
effect
The maximum current

adjustment procedure is
in progress (NOTE: This
Traction stationary.
procedure must be performed by the Zapi testing
department only).
state of the truck
Stand-by
Re-start procedure:
NO CAN MSG.
CHECK UP
NEEDED
THERMIC SENS.
KO
Wrong set bat.
CALL
SERVICE

Communication error with
the supervisor.
ary.
During traction
Re-start procedure:
CALL
SERVICE
Start up
it is time to carry out Traction is reduced or
Stand-by
maintenance work.
stationary.
During traction
Re-start procedure:
Switch the key back on, after performing maintenance.
CALL
SERVICE
The control device heat The maximum current

sensor output is outside is halved and the speed Continuous
the limits.
is reduced.
Re-start procedure:
None.
CALL
SERVICE
The absolute difference

between the voltage of
MC not closed, EB acthe key and the nomitivated, traction/pump Start up
nal voltage of the battery
stationary.
is greater than 20% of
Vbatt nom.
Re-start procedure:
Wrong zero
Field orient. KO
aux driv.shrt.
CALL
SERVICE
The motor phase voltage MC not closed, EB acfeedback is outside the tivated, traction/pump Start up
permissible limits.
stationary.
Re-start procedure:
CALL
SERVICE
The error between the ld MC not closed, EB acset point and the estimat- tivated, traction/pump During traction
ed ld is outside the limits. stationary.
Re-start procedure:
CALL
SERVICE
The EB/AUX driver has

shorted and therefore is
not capable of opening
ary.
During traction
the contactor.
Re-start procedure:
21
SERVICE
PUMP AND TRACTION ACE2 MODULE ALARM ANALYSIS AND TROUBLESHOOTING

ALARM
breakdown search
Watchdog
This alarm could be caused by a malfunctioning of the
Cause:
canbus shutting off Master-Slave communication.
This is a safety test. it is a self-diagnosis test within the
logic between the Master and Slave micro-controllers.
Eeprom ko
Try to carry out a CLEAR EEPROM operation (see the

console manual). Turn off then on again with the key to
Cause:
verify the result. If the alarm persists, the control device
This alarm is due to a HW or SW defect in the integrated
needs replacing. If the alarm disappears, the paramnon-volatile memory that supports the parameters of the
eters previously reset will be replaced by the default
control device. This alarm does not inhibit machine operaparameters.
tion, but the truck will work with the default values.
Logic failure #3
This type of failure is not connected to external compoCause:

nents, so when it manifests itself the ACE logic board
A hardware problem pertaining to the logic card as a pro- needs replacing.
tection against high current values (overload).
Logic failure #2

nents, so when it manifests itself the ACE2 logic board
The fault pertains to the hardware section of the logic card needs replacing.
that manages the retroaction of the phase voltage.
Logic failure #1
Cause:
This alarm appears when the control device detects over
or under voltage conditions. The overvoltage threshold is
45V, the undervoltage threshold is 9V on the 24V control
device. On the 48V control device, the overvoltage threshold is 65V and the undervoltage threshold is 11V.
22
Finding the trouble appearing on start up or in standby,

it is very likely in these cases that the fault is due to undervoltage, so it is advisable to check:
Diminishing pulsations of the key input signal (beneath the undervoltage threshold) due to external
loads, such as switching on DC/DC converters,
switching on relays or contactors, energizing/deenergizing solenoids.
Check the connection of the electrical cables to the
battery terminal, positive and negative, to MC and to
the control device +Batt and Batt, which must be
tightened to a torque of between 13Nm and 15Nm.
If no voltage transient is detected on the power supply line and the alarm is present every time the key
is switched on, then the fault probably lies with the
hardware of the control device and so the logic board
needs replacing.
Finding the trouble appearing during motor operation, in
this case there could be undervoltage or overvoltage.
If the alarm appears during acceleration while in traction or operation of the hydraulic functions, it is most
likely due to undervoltage; check the battery charge
and the connection of the electrical cables.
If the alarm appears during brake release, it is most
likely due to overvoltage; check the contact of the line
contactor and the connection of the electrical cables
of the battery.
SERVICE
ALARM
breakdown search
Vmn low
If the problem appears on start up (LC doesn't close at

all), check:
The internal motor connections (ohm continuity)
Cause 1:
The motor power cable connections
Test on start-up. Before switching on the LC, the software Motor loss to the truck frame
checks the power bridge: it turns on the top side power If the motor connections are OK, the problem lies
MOSFETs alternately and waits until the phase voltage
within the control device, so replace it.
rises up to the value of the capacitor in parallel. If the
voltage of the phases is under 66% of the voltage of the If the alarm takes place while the motor is operating,
check:
capacitor in parallel, this alarm appears.
The motor connections
Cause 2:
If the coil-winding/cables of the motor phases show
losses towards the truck's bodywork
Motor operating test. When the motor is operating, the

That the LC power contact closes correctly, with a
power bridge is ON and the motor voltage feedback is
good contact
tested; if it is below the controlled value (considering a

If no trouble is found with the motors, the problem
range of values), an error status appears.
lies within the control device, so replace it.
Vmn high
Cause 1:
Before switching on the LC, the software checks the power
bridge: it turns on the bottom side power MOSFETs alternately and waits until the phase voltage decreases down
to -BATT. If the voltage of the phases is under 10% of the
nominal voltage of the battery, this alarm appears.
Cause 2:
This alarm may appear even once the start-up diagnosis
has been passed and therefore the LC has closed. In
this situation, the phase voltage should be less than 1/2
Vbatt. Should it exceed this value, an error status would
appear.
If the problem appears on start up (LC doesn't close at

all), check:
If the motor connections are OK, the problem lies
If the problem appears after having closed the LC (LC
closes and then opens again), check:
The motor connections
If the coil-winding/cables of the motor phases show
losses towards the truck's bodywork
If no trouble is found with the motors, the problem
lies within the control device, so replace it.
Contactor closed
Cause:
Before activating the MC coil, the control device verifies
Please check the LC power contacts and replace it if
whether the contactor is blocked. The control device acnecessary.
tivates the bridge for a few tens of milliseconds, trying to
discharge the bank of capacitors If the capacitor voltage
fails to decrease by 20% of the key voltage, an alarm is
generated.
Contactor open
It could be a problem with the contacts in the MC not

working (not inserted), try replacing the MC.
Cause:
If the MC contactors work properly, the problem lies
The main contactor coil has been activated by the control
device, but the contactor fails to close.
Stby I high
This type of error is not connected to external comCause:

ponents, so when it manifests itself the control device
The current transducer or the current feedback circuit has needs replacing.
a fault in the control device.
23
ALARM
SERVICE
breakdown search
Capacitor charge
The charging capacitor diagram is shown below:
Cause:
When the key is turned on, the inverter tries to charge
the power capacitors through a series of PTC and the
power resistance and it checks whether the capacitors
have charged within a short time frame. If the measured
capacitor voltage is less than 20% of the nominal voltage
of the battery, an alarm is signalled; the main contactor is
not closed.
There is an external load in parallel with the bank

of capacitors that disperses the current from the
pre-charging circuit of the capacitors of the control
device, thereby preventing the central contacts from
charging. Check if a lamp bulb or a dc/dc converter
or an auxiliary load is positioned in parallel with the
bank of capacitors.
The charge resistance or PTC is open; add a power
resistance over the electrical terminals of the line
contactor; if the alarm disappears, it means that the
internal charge resistance of the control device is
damaged.
The charging circuit is faulty inside the control device.
There is a problem in the electrical section of the
control device.
Th. protection
it is necessary to increase the cooling of the control

device. In the case of a finned heat dissipation device,
to achieve adequate cooling, these factors are important:
the flow [m3/h] and temperature [C] of the cooling air. In
Cause:
the case of a heat dissipation device with the base plate
This alarm appears when the base plate temperature is of the control device installed on the truck's bodywork, the
above 85C. Afterwards, the maximum current decreases thickness of the bodywork and the flatness and roughin proportion to the increase in temperature from 85C to ness of its surface are important. If, when the alarm is
105C. At 105 the current is limited to 0 Amps.
signalled, the control device is cold, the possible causes
could be failure of the thermal sensor or of the logic card.
In this case the control device needs to be replaced.
Motor temperat.
Check the heat sensor inside the motor (look for MOTOR TEMPERATURE in the TESTER menu); check the
Cause:
value in ohms of the sensor and the sensor cabling. If
This warning appears when the temperature sensor is the sensor is OK, boost the motor cooling. If the warning
open (if digital) or it has exceeded the 150C threshold is present when the motor is cold, then the problem is
(if analog).
located inside the control device.
Battery low
Take the charged battery. If it doesn't work, measure the

Cause:
battery voltage with a voltmeter and compare it to the value
It appears when the battery charge is less than or equal to in the BATTERY VOLTAGE parameter. If they are differ10% of the total charge and the BATTERY CHECK adjust- ent, adjust the value of the ADJUST BATTERY function.
ment is not 0 (refer to SET OPTION menu).
Driver shorted
Cause:
The driver of the main contactor coil has shorted.
24
Check if there is a short circuit or a low pull-down

impedance between NMC (CNA#16) and BATT.
The driver circuit is damaged in the logic board, which
must be replaced.
SERVICE
ALARM
troubleshooting
Contactor driver
This kind of failure is not connected to external compoCause:
nents; replace the ACE2 logic board.
The MC coil driver is not capable of carrying the load. The
device or its pilot circuit is damaged.
Vacc not ok
Cause:
The test has been performed with the key activated and
immediately after both drive requests have been deactivated. This alarm appears if the ACCELERATOR reading
in the TESTER menu is 1.0V over the min. PROGRAM
VACC acquisition when the throttle is released.
Incorrect start
Cause:
It is a warning for an incorrect start sequence.
Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the
alarm persists, check the mechanical calibration and
the operation of the potentiometer. If the alarm is not
deactivated, the fault is in the ACE logic board, therefore
proceed with replacement.
The possible causes of this alarm are (see the TESTER
items to make troubleshooting easier):
Active drive request with key activated
Active man on board sensor with key activated.
Check the wiring. Check the microswitches. It could also
be an issue of an incorrect error sequence performed by
the operator. a fault in the logic board is another possibility; therefore, after checking all the above conditions and
finding nothing, replace the ACE logic board.
Forw+back
Check the wiring of the inputs of the Fwd and Rev drive
requests (see the TESTER items to make troubleshooting easier). Check for any faults with the microswitches.
Cause:
a fault in the logic board is another possibility. Therefore,
This alarm appears when both the (Fwd and Bwd) motion after checking that the drive request switches work
requests are active at the same time.
properly and the wiring is correct, the ACE-2 logic board
needs replacing.
Encoder error
Cause:
This fault is signalled under the following conditions: the
frequency supplied to the motor is greater than 40 Hz and
the encoder's feedback signal shows leaps of more than
40 Hz in just a few tens of mSec. This behaviour is linked
to an encoder malfunction.
Check both the electrical and mechanical operation

of the encoder and check for any constriction of the
cables.
Verify the encoder's mechanical installation, checking whether the encoder slides inside its housing,
producing an alarm condition.
E ven an electromagnetic sound on the sensor
bearing could cause this alarm. In these cases, try
replacing the encoder.
If the problem persists even after replacing the encoder, the fault lies with the control device.
25
ALARM
SERVICE
troubleshooting
Vdc off shorted
it is very likely that the fault is due to overvoltage, therefore you should check:
The connection of the electrical cables to the battery
terminal, positive and negative, to MC and to the control device +Batt and Batt, which must be tightened
Cause:
to a torque of between 13Nm and 15Nm.
This fault is displayed when the control device detects
If no voltage transient is detected on the line +B and
a low logic level of the VDC-off signal during start-up
the alarm is present every time the key is switched
diagnosis.
on, then the fault probably lies with the hardware
of the control device and so the logic board needs
replacing.
Wrong slave ver.

Cause:
Check the two software versions.
The software versions for the Slave and Master are not
the same.
Vdc link overv.
Finding the trouble appearing on start up or in standby:

Check the connection of the electrical cables to the
battery terminal, positive and negative, to LC and to
the control device +Batt and Batt, which must be
Cause:
This fault is displayed when the control device detects a If no voltage transient is detected on the power
line and the alarm is present every time the key is
condition of overvoltage. The overvoltage threshold is 65V
switched on, then the fault probably lies with the
on the 48V control device. On the 116V control device, the
undervoltage threshold is 30V.
needs replacing.
Finding the trouble appearing during motor operation:
If the alarm appears during brake release, check the
contact of the line contactor and the connection of the
electrical cables of the battery.
Tiller mismatch
Check the wiring of the Tiller input (use the TESTER

items to make troubleshooting easier). a fault in the logic
Cause:
is another possibility. Therefore, after checking that the
The Master and Slave have a different value to the Tiller Tiller switch works properly and the wiring is correct, the
signal from the VCM unit.
ACE-2 logic board needs replacing.
Brake run out
Check the mechanical calibration and the operation of

the brake potentiometer. If the alarm remains, the fault
Cause:
lies with the ACE logic board, proceed with replaceThe CPOTBRAKE input read by the microcontroller is at
ment.
the maximum value with no handbrake request.
Stop rq. from eps

Cause:
The EPS sends a signal causing the motor to stop.
26
Check the EPS.
SERVICE
ALARM
Init vmn high
Cause:
Before switching on the LC, the software checks the voltage of the power bridge without activating it. The software
expects the voltage to have a stationary state value. If
this value is too high, this alarm appears.
troubleshooting
Check:
The internal motor connections
Motor loss to the truck frame
within the control device.
Init vmn low
Check:
Cause:
Before switching on the LC, the software checks the volt Motor loss to the truck frame
age of the power bridge without activating it. The software
expects the voltage to have a stationary state value. If
within the control device.
this value is too low, this alarm appears.
Eeprom ko
Cause:
The control device cannot access the memory.
This kind of failure is not connected to external components; replace the ACE2 logic board.
Param restore
If CLEAR EEPROM has been run before last switching

on the key, this warning only means that the EEPROM
has been completely reset. A drive request or a hydraulic
Cause:
request cancels the alarm. If this alarm appears when
This warning appears when the control device has reset the key is activated without CLEAR EEPROM being
to its default values.
requested by the operator, then the problem could be
located inside the control device.
Wrong ram mem

Cause:
Try switching the key off and back on again. If the alarm
The algorithm implemented to check the main RAM reg- still remains, replace the ACE2 logic board.
isters finds incorrect content: the register is dirty. This
alarm inhibits machine operations.
Stall rotor
Check that the indications of FREQUENCY and ENCause:

CODER in the tester menu are the same and are not
The traction rotor is blocked or the encoder signal is not zero during a traction request.
received correctly by the control device.
Waiting slave
Cause:
still remains, replace the ACE2 logic board.
When switching on, there is no activation message from
Slave C to Master C.
Hardware fault

nents, so when it manifests itself the ACE logic board
The software versions for the Slave and Master are dif- needs replacing.
ferent.
27
ALARM
SERVICE
troubleshooting
Pot accel mism
Check the potentiometers. a fault in the logic board is

another possibility. Therefore, after checking that the
Cause:
potentiometer works properly and the wiring is correct,
The Master and Slave do not have the same value on the
the ACE-2 logic board needs replacing.
accelerator signal from one of the two potentiometers.
Pot brake mism
Check the potentiometers. a fault in the logic board is

another possibility. Therefore, after checking that the
Cause:
potentiometer works properly and the wiring is correct,
The Master and Slave do not have the same value on the
the ACE-2 logic board needs replacing.
brake signal from one of the two potentiometers.
Sens mot temp ko

Cause:
The motor heat sensor output is outside the limits.
Check the ohm value of the sensor and the wire harness assembly of the sensor. If the sensor is OK, then
the problem is in the ACE logic board, proceed with
replacement.
Pev not ok
Cause:
The PEV connector (CNA#17) is not connected to the Check the connector A17.
battery or the voltage is different. The traction is stationary if AUXOUT is used for electrical braking and PEV is
indispensable (AUX OUT FUNCTION = PRESENT).
Vkey off shorted
it is very likely that the fault is due to undervoltage,

therefore you should check:
Diminishing pulsations of the key input signal (beneath the undervoltage threshold) due to external
loads, such as switching on DC/DC converters,
switching on relays or contactors, energizing / deenergizing solenoids.

Check
the connection of the electrical cables to the
Cause:
battery
terminal, positive and negative, to MC and
This fault is displayed when the control device detects a low
to
the
control
device +Batt and Batt, which must be
logic level of the Key-off signal during start-up diagnosis.
If no voltage transient is detected on the power supply line and the alarm is present every time the key
is switched on, then the fault probably lies with the
needs replacing.
"Flash checksum"
The problem is in the flash memory of the microcontroller that could be damaged or in the program saved in
Cause:
it that could be corrupted. Try reprogramming the logic,
After switching on the key, the software checks the integrity
if the alarm is still signalled, then the problem is in the
of the program saved in the flash memory. If the outcome
microcontroller. Replace the ACE logic board.
of the test is negative, this alarm is generated.
MC coil shor.
The most likely cause of this error code is in the wire

harness assembly or in the load coil. Therefore, the
Cause:
first step is to check the connections between the
This alarm occurs when there is a short circuit in the MC
outputs of the control device and the loads.
coils connected to the output CNA#16. Once the overload If no faults/problems are found on the outside, the
has been removed the alarm automatically disappears,
trouble lies in the control device that must therefore
releasing and therefore re-enabling a drive request.
be replaced.
28
SERVICE
ALARM
troubleshooting
Waiting for node

Cause:
Check the communication channel.
The control device is waiting for the activation signal from
one of the system's units but this signal fails to arrive.
Vacc out range

Cause:
The CPOT input read by the microcontroller is not within
the Vacc_min to Vacc_max range, programmed via the
PROGRAMM VACC function.
Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the alarm
persists, check the mechanical calibration and the operation of the potentiometer. If the alarm remains, the fault
is in the ACE logic board, proceed with replacement.
Tiller open
Cause:
The warning disappears with the next drive request.
This warning appears when the tiller is released, after a set
stand-by time (30 seconds) the main contactor opens.
Output mismatch
Cause:
This is a fault inside the control device, it is necessary
This is a safety test. The Slave C checks the command to proceed with replacement.
output data of the motor of the Master C and finds a
discrepancy.
Wd syncro
This is a fault inside the control device, it is necessary
Cause:
to proceed with replacement.
The Watchdog signal is not received by the Slave's microcontroller.
No slave enable
Cause:
still remains, replace the ACE2 logic board.
There is no activation message from the Slave C to the
Master C while the control device is in operation.
Dir sel out rang

Check the connections of the switch and measure the
Cause:
signal with a tester.
The signal from the drive request switch is outside the
limits.
Power mos short

Cause:
Before switching on the MC, the software checks the power This kind of failure is not connected to external compobridge: it turns on the bottom and top side power MOSFETs nents; replace the control device.
alternately and waits until the phase voltage decreases
toward -BATT (increase up to +Batt). If the phase voltage
does not follow the commands, this alarm appears.
29
ALARM
SERVICE
troubleshooting
Coil shor. eb.
The most likely cause of this error code is in the wire

harness assembly or in the load coil. Therefore, the
Cause:
first step is to check the connections between the
This alarm appears when there is a short circuit in the
outputs of the control device and the loads.
EB/AUX coils connected to the output CNA#18. Once the If no faults/problems are found on the outside, the
overload has been removed the alarm automatically disaptrouble lies in the control device that must therefore
pears, releasing and then re-enabling a drive request.
be replaced.
Current gain
Request the assistance of a Zapi technician to carry out
Cause:
the correct adjustment procedure for the current gain
The maximum current gain parameters contain default
parameters.
values, which means that the maximum current adjustment
procedure has not yet been performed.
Analog input
Cause:
This alarm appears when the A/D conversion of the analog
If the problem persists, the ACE logic board needs
inputs gives a frozen value, on all the converted signals,
replacing.
for longer than 400msec. The aim of this diagnosis is to
find a fault in the A//D converter or a problem in the stream
of codes that omits resetting the conversion of the analog
signal.
Tiller error
Using a voltmeter check the voltage between the two

PIN's If the state of one of the inputs is correct, it could
Cause:
be a problem internal to the module. Replace the modIncongruence between PIN signals (XA2-1) and (XA2ule.
15).
Evp driver open

Cause:
The EVP driver is not capable of carrying the load.
The driver circuit is damaged in the logic board, which

must be replaced.
M/S par chk mism

Cause:
Try resetting and saving the list of parameters.
When switching on, there is a discrepancy between Master
and Slave in the checksum parameter.
Input mismatch
This is a fault inside the control device, proceed with
Cause:
replacement.
The Slave C has different values to the inputs from the
Master C.
Param transfer
Cause:
replacement.
The Master cannot transfer the list of parameters to the
Slave.
30
SERVICE
ALARM
troubleshooting
Sp mismatch
Cause:
replacement.
This is a safety test. The Master C has detected an incorrect set point of the Slave C.
Throttle prog.
Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the
alarm persists, check the mechanical calibration and
Cause:
the operation of the potentiometer. If the alarm is not
One of the potentiometers has not been programmed
deactivated, the fault is in the ACE logic board, therefore
correctly.
proceed with replacement.
Iq mismatched
Cause:
the correct adjustment of the motor parameters.
The error between the lq set point and the estimated lq is
outside the limits.
Aux driv.open
nents; replace the ACE2 logic board.
The EB/AUX coil driver is not capable of carrying the load.
The device or its pilot circuit is damaged.
Data acquisition
Cause:
Acquisition of current gains.
The alarm ends when the acquisition is completed.
No can msg.
nents, so when it persists the ACE logic board needs
This fault is signalled when there is no communication with
replacing.
the supervisor uC.
Check up needed
Cause:
it is sufficient to take the CHECK UP DONE option onto
It is only a warning reminding you to call scheduled main- level ON after maintenance has been performed.
tenance.
Thermic sensor ko
nents; replace the control device.
The control device heat sensor output is outside the limits.
Wrong set bat.
Check that the value of the SET-BATTERY parameter

of the control device corresponds to the nominal voltage of the battery.
Cause:
Verify that the TESTER MENU / BATTERY VOLTAGE
On start up, the control device checks the battery voltparameter has the same value as the battery voltage
age and ensures that it is within a specific range of the
measured using a voltmeter. If it does not match, run
nominal value.
the ADJUST BATTERY function.
Replace the battery.
31
ALARM
SERVICE
troubleshooting
Wrong zero
It is recommended to check:
Cause:
On start up, the high resolution VMN feedback does not Motor loss to the truck frame
come within the range of permissible values around 2.5V. If the motor connections are OK, the problem lies
The circuit is damaged in the control device.
Field orient ko
Cause:
the correct adjustment of the motor parameters.
The error between the ld set point and the estimated ld is
outside the limits.
Aux driv. shrt.
Check if there is a short circuit or a low pull-down

impedance between NEB/NAUX (CNA#18) and
Cause:
BATT.
The driver of the coil of the electromechanical brake / The driver circuit is damaged in the logic board, which
auxiliary solenoid valve has shorted.
must be replaced.
32

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SERVICE

DIAGNOSTICS AND MEASUREMENTS

ACe2 PUMP AND TRACTION MODULE DIAGNOSIS SYSTEM

state of the truck

MC open, EB activated, Start up

a condition of undervolt- MC not closed, EB ac- Start up

MC not closed, EB acMotor output voltage high Start up

The LC contact is locked

MC not closed (the

DIAGNOSTICS AND MEASUREMENTS

In stand-by conditions (no

The control device has

The motor temperature

The battery is <= 10%

The MC driver has shorted and therefore is not

The maximum current

MC open (the control

DIAGNOSTICS AND MEASUREMENTS

state of the truck

MC open (the control

VDC LINK OVERV.

se- The traction/pump mo- Start up

Drive requests active

When switching on, the MC open, EB activated,

The software versions for MC open, EB activated,

DIAGNOSTICS AND MEASUREMENTS

The Master C and Slave

BRAKE RUN OUT

STOP RQ. FROM

INIT VMN HIGH

The brakes potentiometer No effect. The warning

EPS sends a request to

The motor phase voltage

INIT VMN LOW

The motor phase voltage

The program checks the

DIAGNOSTICS AND MEASUREMENTS

state of the truck

POT. ACCEL MISM

POT. BRAKE MISM

SENS MOT TEMP

There is a discrepancy be Start up

The motor heat sensor The maximum current

The PEV connector (A17)

MC not closed, EB acWhen switching on, the

DIAGNOSTICS AND MEASUREMENTS

MC not closed, EB acThe program check is not

Switch-on (imMC open, EB activated, mediately after the

VACC OUT RANGE

No activation signals ar- MC open, EB activated, Start up

The accelerator input is

The truck is on stand-by

There is a discrepancy be- MC not closed, EB ac Stand-by

The Slave C has not re- MC open, EB activated, Start up

DIAGNOSTICS AND MEASUREMENTS

state of the truck

MC not closed, EB acShort-circuit on the power

Switch-on (imMC open, EB activated, mediately after the

The maximum current

The main remote-con Start up

DIAGNOSTICS AND MEASUREMENTS

EVP DRIVER OPEN