1 Alarm codes

This chapter explains the meaning of the various alarms that the different
controllers may produce. Refer to Chapter 2 for information on using the console
and accessing the Alarms submenu.

1.1 Traction motor controller (Combi Ac1) Mode:2

Before you start to troubleshoot, make sure all power supplies, fuses and
connections are in order.

The fault diagnostic system of controller is divided into two main groups:

Alarms: These are the faults which open the power bridge and when
possible also the main contactor is opened and magnetic brake is
activated. Failures in the motor, controller or in the safety functions
cause alarms.

Warnings: These are faults which not stop the truck or stop the truck by using
regeneration braking. Controller is working well, but it has detected
conditions to reduce the performances or to stop the truck without
opening the power devices. Wrong operation sequences or
conditions which needs performance reduction, like high
temperatures etc. cause warnings.

“Stored” text means that alarm or warning is stored in the controller logbook.

Code: Console and display description:

0 NONE No alarms

1
8 WATCHDOG (Alarm) Stored

This is a safety related test. It is a self diagnosis test within the logic
between Master and Slave microcontrollers.

If fault persist replace the Combiac1 controller.

13 EEPROM KO (Warning) Stored

It’s due to a hardware or software defect of the non-volatile

embedded memory supporting the controller parameters. This
alarm does not inhibit the truck operations, but the truck will work
with the default values.

Try to execute a CLEAR EEPROM operation. Switch the key off

and on to check the result. If the alarm occurs permanently, it is
necessary to replace the Combiac1 controller. If the alarm
disappears, the previously stored parameters will have been
replaced by the default.

17 LOGIC FAILURE #3 (Alarm) Stored

It’s due to a hardware problem in the logic card circuit for high
current protection.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

18 LOGIC FAILURE #2 (Alarm) Stored

It’s due to a fault in the logic board which manages the phase’s
voltage feedback.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

19 LOGIC FAILURE #1 (Alarm) Stored

This fault is displayed when the controller detects an overvoltage or

undervoltage condition. Overvoltage threshold is 45V; undervoltage
threshold is 9V in the 24V controller.

If fault displayed at startup or in standby; in this case it is due to an

undervoltage, so it is important to check following:

2
 a) Key input signal down going pulses (below undervoltage
threshold) due external loads, like DC/DC converters starting up,
relays or contactors energizing/ denergizing.

b) If no voltage transient is detected on the supply line and the

alarm is present every time the key is switched ON, the fault is in
the Combiac1 controller.

If fault is displayed during motor driving; in this case due to an

undervoltage or an overvoltage condition.

a) If the alarm happens during traction acceleration or driving

hydraulic functions, the fault is an undervoltage condition; check
battery charge level and power cable connections.

b) If the alarm happens during release braking, the fault is an

overvoltage condition; check line contactor tips and battery power
cable connections.

30 VMN LOW (Alarm) Stored

Cause 1: startup test.

Before switching the main contactor on, the software checks the
power bridge; it turns on alternatingly the high side power mosfets
and expects the phase’s voltage to increase toward the rail
capacitor value. If the phase’s voltage does not increase, this alarm
occurs.

Cause 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, this alarm
occurs.
a) If the alarm happens during startup (the main contactor does not
close at all), check following:
- motor internal connections (ohmic continuity)
- motor power connections
- motor leakage to truck frame
- if the motor connections are OK, the fault is in the Combiac1
controller.

b) If the alarm happens during motor running, check following:

- motor connections
- if motor phases windings/cables have leakages towards truck
frame
- that the main contactor closes properly, with a good contact
- if no faults are found, the fault is in the Combiac1 controller.

3
31 VMN HIGH (Alarm) Stored

Cause 1:
Before switching the main contactor on, the software checks the
power bridge; it turns on alternatingly the low side and high side
power mosfets and expects the phases to be lower than 1/2 V batt.
If it is higher than this value, this alarm occurs.

Cause 2:
This alarm may occur also when the startup diagnosis is overcome
and the main contactor is closed. In this condition, the phases
voltages are expected to be lower than 1/2 V batt. If it is higher than
this value, this alarm occurs.

a) If the alarm happens during start up (the main contactor does not
close at all), check following:
- motor internal connections (ohmic continuity)
- motor power connections
- motor leakage to truck frame
- if the motor connections are OK, the fault is in the Combiac1
controller.

b) If the alarm occurs after closing the main contactor (the main
contactor closes and then opens again), check following:
- motor connections
- if motor phases windings/cables have leakages towards truck
frame
- that the main contactor closes properly, with a good contact
- if no faults are found, the fault is in the Combiac1 controller.

37 CONTACTOR CLOSED (Alarm) Stored

Cause:
Before driving the main contactor coil, the controller checks that
contactor not is stuck (closed). The controller drives the mosfets for
some milliseconds, trying to discharge the capacitor bank. If they
don’t discharge, this alarm occurs.

Check following:
- main contactor tips
- if needed replace the main contactor

4
38 CONTACTOR OPEN (Alarm) Stored

Cause:
The main contactor has been driven by the controller, but the
contactor does not close, check following:

a) the wires to the main contactor coil are interrupted or not

connected.

b) it can also be a fault in the main contactor itself, if needed

replace the contactor.

53 STBY I HIGH (Alarm) Stored

Cause:
The current transducer or the current feed back circuit is damaged
in the controller.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

60 CAPACITOR CHARGE (Alarm) Stored

Cause:
In working condition, a resistance connected between the key and
the rail capacitors, keeps the capacitors charged before the main
contactor closes. When the voltage on the rail capacitors,
measured on the motor phases are low and does not increase
when the main contactor is opened, this alarm occurs.

There are three possibilities:

- another device, connected in parallel with the rail capacitors, has
a failure.
- At least one motor phase is not connected to the controller or it is
broken.
- a power failure or a logic failure occurred in the controller. In this
case it is necessary to replace the Combiac1 controller.

62 TH. PROTECTION (Warning) Stored

Cause :
This alarm indicates that the controller temperature is over 85°C.
the maximum current is reduced proportionally to the temperature
increase. The controller stops when 105°C is reached.
If this alarm is signalled when the controller is cold:

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 - there is a fault in the thermal sensor wiring
- there is a failure in the thermal sensor
- there is a failure in the logic
If any of the above cases indicates faults, the Combiac1 controller
has to be replaced.

65 MOTOR TEMPERAT. (Warning) Stored

This warning occurs when the analog temperature sensor has

overtaken the threshold 150°C.

Check following:
- Check the thermal sensor inside the motor and the wiring outside.
the resistance of sensor is 580 ohm at 20°C.
- if the warning is present when the motor is cold and the thermal
Sensor is OK; improve the cooling of the motor, if that does not
help, the fault is in the Combiac1 controller.

66 BATTERY LOW (Warning) Stored

Cause:
It occurs when the battery charge is calculated being less or equal
to10% of full charge and the BATTERY CHECK setting is other
than 0 (refer to SET OPTION menu).

Charge the battery.

If it does not help, measure with a voltmeter the battery voltage and
compare it with the value in the BATTERY VOLTAGE parameter. If
they are different adjust the value of the ADJUST BATTERY
function.

74 DRIVER SHORTED (Alarm) Stored

Cause:
The driver of the main contactor coil is shorted.

a) Check if there is a short circuit between connector XA1 pin 17

and contactor K2 pin A2.

b) Check that contactor K2 get +24V supply from start button.

b) if there is no short circuit according previous point, the driver

circuit is damaged in the Combiac1 controller.

6
75 CONTACTOR DRIVER (Alarm) Stored

Cause:
The main contactor driver is not able to drive the load. The device
itself or its driving circuit is damaged.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

76 COIL SHORTED (Alarm) Stored

Cause:
This alarm occurs when there is a short circuit in the main contactor
coil.

a) the fault can be in harness or in the coil current load.

b) if no external fault found, the fault is in the Combiac1 controller.

78 VACC NOT OK (Alarm) Stored

Cause:
This alarm occurs when the accelerator output voltage differs more
than 1V from the acquired minimum during the PROGRAM VACC.

Check the output voltage programming and functionality of the

accelerator.

79 INCORRECT START (Warning)

Cause.
This warning occurs for an incorrect starting sequence.

Check possible reasons for this alarm, by using the console

TESTER menu. If no signal is active by key on, the fault is in the
Combiac1 controller.

80 FORW+BACK (Warning)

Cause:
This alarm occurs when both travel demands are active at the
same time.

Check possible reasons for this alarm, by using the console

TESTER menu, if both directions are active at the same time;
check the accelerator and its wiring.

7
 If not direction signals are active at the same time outside
controller, the fault is in the Combiac1 controller.

82 ENCODER ERROR (Alarm) Stored

Cause:
This error occurs in following conditions: the frequency supplied to
the motor is higher than 40Hz and the feedback signal from the
encoder has a jump higher than 40 Hz in few tens msec. This
condition is related to a malfunction of the encoder.

a) Check the encoder mechanical function and wirings connections.

b) Check the encoder mechanical installation; if the encoder slips

inside the housing, it is raising this alarm.

c) Also electromagnetic noise on the encoder can be a cause of the

alarm. In this case try to replace the encoder.

d) If the alarm is still present after replacing the encoder, the fault is
in the Combiac1 controller.

86 PEDAL WIRE KO (Alarm) Stored

Cause:
The software checks for the connection of the two supply ends of
the potentiometer in the accelerator. The test consists of reading
the voltage drop on a sense diode, connected between NPOT and
GND. If the accelerator gets disconnected on PPOT or NPOT, no
current flows in this sense diode and the voltage on NPOT
connection collapses down.
When the NPOT voltage is less than 0,3V this alarm occurs. This
alarm occurs also when the NPOT voltage is higher than 2V (to
detect also the condition of a broken sense diode).

Check the voltage on NPOT and the accelerator connections.

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217 ENC CAN KO (Alarm) Stored

Used only in SST/SSI models!

Cause:
Can Encoder card (Model 10) does not respond via CAN-bus.

a) Check that connectors and cables are in order.

b) Change new Can Encoder card.

218 EPS REDUCTION (Warning)

Cause:
Warning in the steering controller (EPS) what causes reduction of
the steering functionality.

Connect handset to steering controller and check steering controller

functionality.

219 ANGLE NOT VALID (Warning)

Cause:
Steering system has not yet found the inductive sensors which
calibrates the steering angle. Truck travel speed is reduced as long
as this warning is active.

Connect handset to steering controller and check steering controller

functionality.

220 MOT TH SENSOR KO (Alarm) Stored

Cause:
Motor thermal sensor knockout. Motor thermal sensor either short
or open circuited.

Check connector contacts and that cables are in order. Measure

resistance of thermal sensor (580 ohm at 20°C)

221 LOAD SENS NOT OK (Warning) Stored

Cause:
Load sensing pressure sensor out of range. Truck travel speed is
limited to max load speed.
a) Check that pressure sensor is calibrated correctly.

9
 b) Check connector XB42 and that cables are in order.

c) Malfunction in the pressure sensor (Contamination can cause

this problem) Change new pressure sensor.

222 EPS RELE OPEN (Warning)

Cause:
Fault in EPS, which causes that the safety output is open.

Connect handset to the steering controller (EPS) and check the real
fault.

223 SAFETY FEEDBACK (Alarm) Stored

Cause:
This is a safety related test. The microprocessor has detected a
problem on the feedback of electro valve driver.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

224 WAITING FOR NODE (Warning)

Cause:
The controller receives from the CAN the message that another
controller in the network is in fault condition; as a consequence the
traction controller itself cannot enter an operative status, but has to
wait for the other controller coming out from the fault status.
The problem is inside the logic of the other controller; replace the
Combiac1 controller.

225 CAN ENC KO DISP (Warning)

Cause:
Display does not respond to the controller via CAN-bus.

a) Check that connectors and cables are in order.

b) Replace display

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226 ACC OUT OF RANGE (Alarm) Stored

Used only in Stand on / Sit on Stackers! (Analog sensor)

Cause:
Throttle minilever voltage out of range.

a) Teach minilever values again.

b) Check that connectors and cables are in order.

c) Change new minilever and teach new values.

228 TILLER OPEN (Warning) Not showed on Display

Cause:
This is a warning, when the safety mat is not activated, after a fixed
time in standby the main contactor open (30s).

After next travel request the warning disappear.

229 POS AUX SHORT (Alarm) Stored

Cause:
The output of the built in smart driver, which supplies the positive to
the electromechanical brake coil is high when the Tiller and H&S
switch are open.

a) Check the wiring in order to verify that no extra positive supply is

connected to the electromechanical brake when the Tiller H&S
switch are open, at connector XA1 pin 30.

b) The driver circuit is damaged inside the Combiac1 controller,

which has to be replaced.

231 COIL SHORT HW KO (Alarm) Stored

Cause:
The hardware circuit which manages short circuit protections for the
main contactor and the electromagnetic brake coils has a problem.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

11
232 WRONG SET POINT (Alarm) Stored

Cause:
This is a safety related test. The microprocessor has detected a
wrong traction function set point.

This is a internal fault of the Combiac1 controller, so it must be

replaced.

233 POWER MOS SHORT (Alarm) Stored

Cause:
Before switching the main contactor on, the software checks the
power bridge: it turns on alternatingly the low and high side power
mosfets and expects the phase’s voltage to decrease down to –
BATT. If the phase’s voltage does not follow the commands, this
alarm occurs.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

236 CURRENT GAIN (Alarm) Stored

Cause:
The maximum current gain parameters are at default values, which
mean the maximum current procedure has not been carried out.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

237 ANALOG INPUT (Alarm) Stored

Cause:
This alarm occurs when the conversion of the analog inputs gives
frozen values.

If the alarm occurs permanently, it is necessary to replace the

Combiac1 controller.

239 PUMP WARNING (Warning)

Cause:
This is a warning from the pump controller.

Connect the console to the pump controller and check the warning.

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240 HARDWARE FAULT (Alarm) Stored

Cause:
The microprocessor has detected that the pump controller is not
able to stop the traction.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

246 AUX DRIV. OPEN (Alarm) Stored

Cause:
The driver of the electromagnetic brake coil is not able to drive the
load.

The driver is damaged inside the Combiac1 controller, which has to

be replaced.

247 DATA ACQUISITION (Warning)

Cause:
Acquisition of the current gains.

The alarm ends when the acquisition is done.

248 NO CAN MSG. N. (Alarm) Stored

Cause:
No can message from the pump microprocessor.

This alarm can be caused by a canbus malfunction, which blinds

traction-pump communication. If not, it is an internal fault in
Combiac1 controller.

249 CHECK UP NEEDED (Warning)

Cause:
This is just a warning to call for programmed maintenance.

It is just enough to turn the CHECK UP DONE option level to ON

after the maintenance is carried out.

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250 THERMIC SENS KO (Warning) Stored

Cause:
The output of the controller thermal sensor is out of range.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

251 WRONG SET BAT. (Alarm) Stored

At startup the controller check the battery voltage and verify that it
is within a window around the nominal value.

a) Check that the controller SET BATTERY parameter value

matches the battery nominal voltage.

b) Check that the TESTER MENU/ BATTERY VOLTAGE

parameter shows same value as the battery voltage measured wit a
voltmeter. If it does not match; then do a “ADJUST BATTERY”
function.

c) Replace the battery.

253 SLIP PROFILE (Alarm) Stored

Cause:
There is an error on the choice of the parameters of the slip profile.

Check in the HARDWARE SETTING menu the value of those

parameters.

254 AUX DRIV. SHRT. (Alarm) Stored

The driver of the electromechanical brake is shorted.

a) Check if there is a short between XA1 pin 31 and XA1 pin 30.

b) The driver is damaged in the Combiac1 controller, which has to

be replaced.

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1.2 Pump motor controller (Combi Ac1) (Mode:5)
Before you start to troubleshoot, make sure all power supplies, fuses and
connections are in order.

The fault diagnostic system of controller is divided into two main groups:

Alarms: These are the faults which open the power bridge and when
possible also the main contactor is opened and magnetic brake is
activated. Failures in the motor, controller or in the safety functions
cause alarms.

Warnings: These are faults which not stop the truck or stop the truck by using
regeneration braking. Controller is working well, but it has detected
conditions to reduce the performances or to stop the truck without
opening the power devices. Wrong operation sequences or
conditions which needs performance reduction, like high
temperatures etc. cause warnings.

“Stored” text means that alarm or warning is stored in the controller logbook.

Code: Console description:

0 NONE No alarms

1 CHOPPER RUNNING (Warning)

2 NO COMMUNICATION (Warning)

Cause:
CombiAC1 does not respond to the handset.

Check wiring, check handset by connecting it to some other

controller. If handset is functional with another controller,
CombiAC1 is faulty.

8 WATCHDOG (Alarm) Stored

This is a safety related test. It is a self diagnosis test within the logic
between Master and Slave microcontrollers.

If fault persist replace the Combiac1 controller.

15
13 EEPROM KO (Warning) Stored

It’s due to a hardware or software defect of the non-volatile

embedded memory supporting the controller parameters. This
alarm does not inhibit the truck operations, but the truck will work
with the default values.

Try to execute a CLEAR EEPROM operation. Switch the key off

and on to check the result. If the alarm occurs permanently, it is
necessary to replace the Combiac1 controller. If the alarm
disappears, the previously stored parameters will have been
replaced by the default.

19 LOGIC FAILURE #1 (Alarm) Stored

This fault is displayed when the controller detects an overvoltage or

undervoltage condition. Overvoltage threshold is 45V; undervoltage
threshold is 9V in the 24V controller.

If fault displayed at startup or in standby; in this case it is due to an

undervoltage, so it is important to check following:

a) Key input signal down going pulses (below undervoltage

threshold) due external loads, like DC/DC converters starting up,
relays or contactors energizing/ denergizing.

b) If no voltage transient is detected on the supply line and the

alarm is present every time the key is switched ON, the fault is in
the Combiac1 controller.

If fault is displayed during motor driving; in this case due to an

undervoltage or an overvoltage condition.

a) If the alarm happens during traction acceleration or driving

hydraulic functions, the fault is an undervoltage condition; check
battery charge level and power cable connections.

b) If the alarm happens during release braking, the fault is an

overvoltage condition; check line contactor tips and battery power
cable connections.

28 PUMP VMN LOW (Alarm) Stored

Cause:
The pump motor output is lower than expected, considering the
pulswidthmodulation applied.

16
 a) If the alarm occurs at startup (the main contactor does not close
at all), check:
- motor internal connections (ohmic continuity)
- motor power cable connections
- motor leakage to truck frame
- if the motor connections are OK, the fault is in the Combiac1
controller.

b) If the alarm occurs after closing the main contactor (closing and
open again), check:
- motor connections
- if motor phases windings/cables have leakages towards truck
frame
- if no faults are found, the fault is in the Combiac1 controller.

c) If the alarm occurs during motor running, check following:

- motor connections
- if motor phases windings/cables have leakages towards truck
frame
- that the main contactor closes properly, with a good contact
- if no faults are found, the fault is in the Combiac1 controller.

29 PUMP VMN HIGH (Alarm) Stored

Cause:
This test is carried out when the pump motor is turning
(pulswidthmodulation applied). Check following:
- motor connections
- if motor phases windings/cables have leakages towards truck
frame
- if no faults are found, the fault is in the Combiac1 controller.

52 PUMP I=0 EVER (Alarm) Stored

Cause:
This test is carried out when the pump motor is running and it
verifies that current feedback is not constantly stuck to 0.

a) Check the motor connection, that there is continuity. If the motor

connection is open, the current cannot, so the test fails and the
alarm is displayed.

b) If everything is OK, concerning the motor, the fault is inside the

Combiac1 controller.

17
56 PUMP STBY I HIGH (Alarm) Stored

Cause:
In standby condition (pump motor not driven) the feedback coming
from the current sensor in the controller gives a value too high.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

64 PUMP TEMPERATURE (Warning) Stored

Cause:
This warning occurs when the analog temperature sensor has
overtaken the threshold 150°C.

Check following:
- Check the thermal sensor inside the motor and the wiring outside.
the resistance of sensor is 580 ohm at 20°C.
- if the warning is present when the motor is cold and the thermal
Sensor is OK; improve the cooling of the motor, if that does not
help, the fault is in the Combiac1 controller.

227 ENC CAN KO (Warning)

Only in models which have lifting height measurement option!

Cause:
Can Encoder card (Model 10) does not respond via CAN-bus.

b) Check that connectors and cables are in order.

b) Change new Can Encoder card

228 ACC OUT OF RANGE (Warning)

Used only in Stand on / Sit on Stackers! (Analog sensor)

Cause:
Lift/lower minilever voltage out of range.

a) Teach minilever values again.

b) Check that connectors and cables are in order.

c) Change new minilever and teach new values.

18
229 WRONG ZERO (Alarm) Stored

Cause:
This alarm occurs when the outputs of the amplifier to measure the
motor current are too low.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the Combiac1 controller.

230 OUT. MISMATCH (Alarm) Stored

Cause:
This is a safety related test. The microprocessor has detected that
the traction motor is driving in a wrong way.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

231 SAFETY FEED (Alarm) Stored

Cause:
This is a safety related test. The microprocessor has detected a
problem on the main contactor feedback.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

232 WRONG SET POINT (Alarm) Stored

Cause:
This is a safety related test. The micro processor has detected a
wrong pump function set point.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

233 RESET ENCODER (Warning)

Only in models which have lifting height measurement option!

Cause:
Can encoder card read pulses from the mast height measurement
before the free-lift sensor is activated, Lifting / lowering speeds are
reduced.

19
 Mast must be lowered to free-lift area, and truck switched Off/On. If
fault continues, check the functionality of the free-lift sensor.

234 INPUT MISMATCH (Alarm) Stored

Cause:
This is a safety related test. The micro processor has detected a
mismatch between analogy and digital information.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

235 HW FAULT VALVE (Alarm) Stored

Cause:
The micro processor has detected that the controller is not able to
stop hydraulic valve functions.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

236 HARDWARE FAULT (Alarm) Stored

Cause:
The microprocessor has detected that the controller is not able to
stop the traction.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

237 MASTER REDUCTION (Warning)

Cause:
This is information from traction controller side. There is some
reduction active at the traction controller. Warning disappears when
reduction is not active.

Connect handset to traction controller and check traction controller

functionality.

20
238 LIFT+LOWER (Warning)

Cause:
This alarm occurs when both requests lift and lower are active at
the same time.

Check the wirings of the lift and lower inputs (use the readings in
the TESTER menu) check the accelerator for failure.
If no failure found, the fault is in the logic of the Combiac1
controller, which must be replaced.

239 PUMP INC START (Warning)

Cause:
This warning occurs for an incorrect starting sequence.

Check possible reasons for this alarm, by using the console

TESTER menu. If no signal is active by key on, the fault is in the
Combiac1 controller.

240 PUMP VACC NOT OK (Warning)

Cause:
The test is made at key on and after 20 sec to make sure that the
hydraulic accelerator lift/lower is back in neutral position.
This alarm occurs if the lift/lower accelerator reading in the
TESTER menu is 1,0V higher than the minimum programmed
value, when the accelerator is released.

Check the mechanical calibration and the function of the lift lower
accelerator.

241 NO ENC PULSES (Alarm) Stored

Only in models which have lifting height measurement option!

Cause:
No encoder pulses from the mast height measurement after the
free-lift sensor has activated.

Check the sensor bearing wiring. If there is no fault, replace sensor

bearing or can-encoder card.

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242 CURR. SENS. LOW (Alarm) Stored

Cause:
Pump chopper current sensor feedback is too low.

Either whole pump motor is disconnected from the pump controller,

or CombiAC1 controller is faulty and should be replaced.

243 EEP CHECKSUM (Alarm) Stored

Cause:
Fault in the internal EEPROM memory.

Try first to clear EEPROM. If this operation does not help and the
fault persists, it is an internal fault of the CombiAC1 controller, so it
must be replaced.

244 RAM WARNING (Alarm) Stored

Cause:
Checksum of the ram failed.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

245 WAITING FOR TRAC (Warning) Not showed on Display

Cause:
The pump controller receives from the CAN a message the traction
controller is in fault condition and has to wait.

Check with help of the CONSOLE, what is the fault in the traction
controller.

246 EVP DRIVER KO (Alarm) Stored

The EVP (electro valve driver) is not able to drive the load.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

247 EVP DRIV SHORTED (Alarm) Stored

Cause:
The EVP (electro valve driver) is shorted.

22
 Check there is no short between the connectors XA1 pin 3 or XA1
pin 28 or XA1 pin 39 and +BATT. Otherwise there is an internal
fault of the Combiac1 controller, so it must be replaced.

248 ANALOG INPUT (Alarm) Stored

Cause:
This alarm occurs when the conversion of the analog inputs gives
frozen value on all converted signals.

If the fault occurs permanently it is necessary to replace the

Combiac1 controller.

249 NO CAN MSG. 02 (Alarm) Stored

Cause:
No can message from the traction microprocessor.

This alarm can be caused by a canbus malfunction, which blinds

traction-pump communication. If not, it is an internal fault in
Combiac1 controller.

250 CAN BUS KO DISP (Alarm) Stored

Cause:
Display does not respond to the controller via CAN-bus.

a) Check that connectors and cables are in order.

b) Replace display

251 PUMP MOTOR TEMPERAT (Warning) Stored

Cause:
This warning occurs when the analog temperature sensor has
overtaken the threshold 150°C.

Check following:
- Check the thermal sensor inside the motor and the wiring outside.
the resistance of sensor is 580 ohm at 20°C.
- if the warning is present when the motor is cold and the thermal
Sensor is OK; improve the cooling of the motor, if that does not
help, the fault is in the Combiac1 controller.

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252 VALVE CONT DRV (Alarm) Stored

Cause:
This alarm occurs when one or more valve drivers are not able to
drive the load.

This is an internal fault of the Combiac1 controller, so it must be

replaced.

253 VALVE DRV SHORT (Alarm) Stored

Cause:
This alarm occurs when one or more valve drivers are shorted.

Check that there is no short between the negative of the coils and
-BATT. Otherwise there is an internal fault of the Combiac1
controller, so it must be replaced.

254 VALVE COIL SHOR. (Alarm) Stored

Cause:
This alarm occurs when there is a short circuit in a valve coil.
a) If the fault is present at start up, it is the hardware overcurrent
protection circuit which is damaged; the Combiac1 controller must
be replaced.

b) If the fault is present only when the controller activates the

outputs, the problem is in the harness or in the coils.

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1.3 Electric power steering controller (EPS) Mode:6
Before you start to troubleshoot, make sure all power supplies, fuses and
connections are in order.

The fault diagnostic system of controller is divided into two main groups:

Alarms: These are the faults which open the power bridge and when
possible also the main contactor is opened and magnetic brake is
activated. Failures in the motor, controller or in the safety functions
cause alarms.

Warnings: These are faults which not stop the truck or stop the truck by using
regeneration braking. Controller is working well, but it has detected
conditions to reduce the performances or to stop the truck without
opening the power devices. Wrong operation sequences or
conditions which needs performance reduction, like high
temperatures etc. cause warnings.

“Stored” text means that alarm or warning is stored in the controller logbook.

Code: Console description:

0 NONE No alarms

1 CHOPPER RUNNING (Warning)

2 NO COMMUNICATION (Warning)

Cause:
Combiac1 does not respond to the handset.

Check wiring, check handset by connecting it to some other

controller. If handset is functional with another controller, Combiac1
is faulty.

13 EEPROM KO (Warning)

Cause:
It’s due to a hardware or software defect of the non-volatile
embedded memory supporting the controller parameters. This
alarm does not inhibit the truck operations, but the truck will work
with the default values.

Try to execute a CLEAR EEPROM operation. Switch the key off

and on to check the result. If the alarm occurs permanently, it is

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 necessary to replace the combi ac controller. If the alarm
disappears, the previously stored parameters will have been
replaced by the default.

16 LOGIC FAILURE #4 (Alarm) Stored

Cause:
This alarm occurs in rest state if the output of the voltage amplifier
Wv-Vv have a drift larger than ±0,25V.

In this case it is necessary to replace the EPS steering controller.

17 LOGIC FAILURE #3 (Alarm) Stored

Cause:
It’s due to a hardware problem in the logic card circuit for high
current protection.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the EPS steering controller.

18 LOGIC FAILURE #2 (Alarm) Stored

Cause:
It’s due to a fault in the logic board which manages the phase’s
voltage feedback.

This type of fault is not related to external components; so, when it

is present it is necessary to replace the EPS steering controller.

19 LOGIC FAILURE #1 (Alarm) Stored

Cause:
This fault is displayed when the controller detects an overvoltage or
undervoltage condition. Overvoltage threshold is 45V; undervoltage
threshold is 9V in the 24V controller.

If fault displayed at startup or in standby; in this case it is due to an

undervoltage, so it is important to check following:

a) Key input signal down going pulses (below undervoltage

threshold) due external loads, like DC/DC converters starting up,
relays or contactors energizing/ denergizing.
b) If no voltage transient is detected on the supply line and the
alarm is present every time the key is switched ON, the fault is in
the EPS steering controller.

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 If fault is displayed during motor steering; in this case due to an
undervoltage or an overvoltage condition.

b) If the alarm happens during traction acceleration or driving

hydraulic functions, the fault is an undervoltage condition; check
battery charge level and power cable connections.

32 VMN NOT OK (Alarm) Stored

Cause:
This alarm occurs in the initial rest state after key on if the outputs
of the motor voltage amplifiers are not in the window from 2,2V to
2,8V.
It is necessary to replace the EPS controller.

48 MAIN CONT: OPEN (Warning)

Cause:
This alarm occurs only when the setting CAN BUS is PRESENT.
Then the EPS controller must receive the event messages from the
traction controller.

Find in the traction controller ALARMS the reason for keeping the
main contactor open.

61 HIGH TEMPERATURE (Alarm) Stored

Cause:
This alarm occurs if the controller base plate overtakes 75°C.

Improve the cooling of the controller; otherwise it is necessary to

replace the EPS controller.

65 MOTOR TEMPERAT. (Alarm) Stored

This warning occurs when the analog temperature sensor has

overtaken the threshold 150°C.

Check following:
- Check the thermal sensor inside the motor and the wiring outside.
the resistance of sensor is 580 ohm at 20°C.
- if the warning is present when the motor is cold and the thermal
Sensor is OK; improve the cooling of the motor, if that does not
help, the fault is in the combi ac controller.

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70 HIGH CURRENT (Alarm) Stored

Cause:
This alarm indicates that the output current amplifier has been over
the I max current level (not adjustable) too long.

If the alarm occurs permanently, it is necessary to replace the EPS

controller.

71 POWER FAILURE #3 (Alarm) Stored

Cause:
This alarm occurs when the current in phase V of the motor is zero
and the motor is commanded for turning.

Check following:
- that main fuse 3F1 is OK
- there is positive supply to the controller
- continuity of the phase cable from controller to motor
- if above points are OK, it is necessary to replace the EPS
controller.

72 POWER FAILURE #2 (Alarm) Stored

Cause:
This alarm occurs when the current in phase U of the motor is zero
and the motor is commanded for turning.

Check following:
- that main fuse 3F1 is OK
- there is positive supply to the controller
- continuity of the phase cable from controller to motor
- if above points are OK, it is necessary to replace the EPS
controller.

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73 POWER FAILURE #1 (Alarm) Stored

Cause:
This alarm occurs when the current in phase W of the motor is zero
and the motor is commanded for turning.

Check following:
- that main fuse 3F1 is OK
- there is positive supply to the controller
- continuity of the phase cable from controller to motor
- if above points are OK, it is necessary to replace the EPS
controller.

83 BAD ENCODER SIGN (Alarm) Stored

Cause:
It occurs in this application with toggle switches applied (straight
and 90° position switches) when FREQUENCY and the ENC
SPEED have opposite polarity.

Swap the encoder channels.

85 STEER HAZARD (Warning) Not showed on Display

Cause:
This is just a warning to inform that the steering controller is limiting
the angle in steering direction. No speed reduction occurs on the
traction.

216 MICRO SLAVE #8 (Alarm) Stored

It occurs when the encoder counting of the main microprocessor is

not matching to the encoder counting.

It is necessary to replace the EPS controller.

218 CLOCK PAL NOT OK (Alarm) Stored

Cause:
This alarm occurs if one of the internal analogue signals is not
correct.

It is necessary to replace the EPS controller.

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219 STEPPER MOTOR MISM (Alarm) Stored

Cause:
This alarm occurs if the frequency and the amplitude of the
voltages from the stepper motor lines are mismatched in between
the D and Q line of the stepper motor.

It is necessary to replace the EPS controller.

220 MOTOR LOCKED (Alarm) Stored

Cause:
This alarm occurs if the current in the steering motor stays close to
the maximum current longer than 1 sec.

Search for a mechanical problem locking the steering motor.

222 FB POT LOCKED (Alarm) Stored

Cause:
This alarm occurs if the feedback hall sensor or potentiometer does
not change (or changes to opposite direction) value even if it is
commanded to change.

a) Check that feedback sensor is not mechanically loosened.

b) Check that connectors and cables of feedback sensor are in

order.

b) Verify that motor phases are not wrong way, cables are installed
in correct places.

223 JERKING FB POT (Alarm) Stored

Cause:
This alarm occurs if the feedback hall sensor or potentiometer
voltage switching more than 0,3V in 16msec. This alarm is used to
catch potentiometer discontinuities.

Replace the feedback sensor.

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225 CURRENT GAIN (Warning)

Cause:
This warning occurs when the parameters to compensate for the
gain if the current amplifiers have the default values (the maximum
current was not regulated.

It is necessary to replace the EPS controller.

226 NO SYNC (Alarm) Stored

Cause:
This alarm occurs when the inside checking cycle does not update
the information, the controller cuts of the steering and traction.

It is necessary to replace the EPS controller.

227 SLAVE COM. ERROR (Alarm) Stored

Cause:
This alarm occurs when there is a fault in the internal
communication.

It is necessary to replace the EPS controller.

237 WAITING DATA (Warning) Not showed on Display

Cause:
This is a warning, while the EPS controller receives information
from the combi ac controller. The safety relays remain open when
this warning is present and the steering is not activated.

238 EPS NOT ALIGNED (Warning) Not showed on Display

Cause:
This is a real alarm which cut off the traction function. It occurs at
the initial alignment if straight ahead condition is not matched within
6 sec. Throughout this time, the steering is not activated, the safety
relays are open and the traction is stopped.

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239 WAITIN FOR TRAC (Warning) Not showed on Display

Cause:
At key-on the EPS controller needs information from the traction
controller to close the internal safety contacts and to turn onto
operational mode. Until this information, this warning occurs. The
steering is not activated and the safety relays remain open while
this warning is present.

241 ENCODER ERROR (Alarm) Stored

NOT VALID FOR THIS APPLICATION!

This alarm occurs in application, when ENCODER CONTROL is
set ON.

242 Q LINE SENSOR (Alarm) Stored

Cause:
This alarm can occur when the stepper motor channel on XA3A pin
12 is open.

Check the stepper motor wires and measure the D line resistance
(must be close to 30 ohm between XA3A pin 8 and 12).
If the problem is not due to wiring, the stepper motor must be
replaced.

243 D LINE SENSOR (Alarm) Stored

Cause:
This alarm can occur when the stepper motor channel on XA3A pin
10 is open.

Check the stepper motor wires and measure the Q line resistance
(must be close to 30 ohm between XA3A pin 9 and 10).
If the problem is not due to wiring, the stepper motor must be
replaced.

244 GAIN EEPROM KO (Warning)

Cause:
The parameters to compensate values for the gain of the current
are not in the memory any more.

It is necessary to replace the EPS controller.

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245 DATA ACQUISITION (Warning)

Cause:
Acquisition of the current gains.

The alarm ends when the acquisition is done.

246 MICRO SLAVE KO (Alarm) Stored

Cause:
This alarm occurs if the microprocessor detects a mismatch in
commanded and active steering directions.

It is necessary to replace the EPS controller.

247 CAN BUS KO (Warning)

Cause:
This alarm occurs if the EPS controller does not receive a message
from the traction controller within 1 sec.

Check the can bus wiring from the Combiac1 controller to EPS
controller.

248 S.P. OUT OF RANGE (Alarm) Stored

Cause:
This alarm occurs if command hall sensor (or potentiometer) signal
voltage is out of the range (0,8Vdc to 4,2Vdc).

Check that connectors and cables are in order and measure that
command sensor signal voltage is in tolerance.

249 F.FB: OUT OF RANGE (Alarm) Stored

Cause:
This alarm occurs if feedback hall sensor (or potentiometer) signal
voltage is out of the range (0,3Vdc to 4,7Vdc).

Check that connectors and cables are in order and measure that
feedback sensor signal voltage is in tolerance.

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250 MICRO SLAVE (Alarm) Stored

Cause:
This alarm occurs when the internal microprocessor information
does not match.

It is necessary to replace the EPS controller.

251 KM OPEN (Alarm) Stored

Cause:
This alarm occurs when the microprocessor detects that the
internal safety contact is open, when expected to be closed.

It is necessary to replace the EPS controller.

252 KS OPEN (Alarm) Stored

Cause:
This alarm occurs when the microprocessor detects that the second
internal safety contact is open, when expected to be closed.

It is necessary to replace the EPS controller.

253 KM CLOSED (Alarm) Stored

Cause:
This alarm occurs when the microprocessor detects that the
internal safety contact is closed, when expected to be open.

It is necessary to replace the EPS controller.

254 KS CLOSED (Alarm) Stored

Cause:
This alarm occurs when the microprocessor detects that the second
internal safety contact is closed, when expected to be open.

It is necessary to replace the EPS controller.

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