Appendix B : Error Code List

EYE Error
Description Level Cause Troubleshooting
Code Code
1. Such an alarm can be caused also by the
presence of regeneration currents; when lift
truck is on release or reverse braking ramp,
motors work as generators, and battery voltage
can exceed overvoltage limit. In a case like
that, the battery condition should be verified ( if
the battery is new it is necessary to do some
Maximum Battery voltage, measured charge-discharge cycles before reaching the
1 F0 battery 1 by a circuit inside logic, rating declared by the constructor) or has a
voltage exceeds 34 V high internal resistance.
If the case is the second and it is not possible
to change the battery, the solution may be to
reduce the release and reverse braking ramp.
2. Incorrect wiring to battery positive or negative
terminals.
3. Verify if battery is still in good conditions.
4. Replace the logic.
1. Incorrect wiring to battery, or corroded positive
or negative terminals;
2. Verify battery conditions: if the electrolyte
inside is partially exhausted, an under voltage
Minimum Battery voltage, measured alarm can sometimes be detected from the
2 F1 battery 1 by an internal circuit, is controller; even in case of low battery charge
voltage lower than11.5 V (<10%), high current rates (i.e. both pump and
drive motors working in full load conditions)
could cause an under voltage alarm, in
particular in presence of an exhausted battery.
3. Replace the logic.
1. Verify if the accelerator initial set-up is correct;
if not, repeat calibration procedure.(You can
use both PC with serial communication
software and Instrument panel).
Voltage measured on
2. Verify if the following the 42pin main connector
accelerator circuit exceeds
terminals are correctly wired to their
the value calculated
Pedal correspondent inputs in accelerator circuit:
3 F2 2 averaging calibration and
trimmer fault - K2-1C(5 V)
reachable voltages;
- K1-6C (ground)
moreover, start switch
- K2-6A (pedal output-A)
seems to be open.
- K2-4A (pedal output-B)
3. In case of correct wiring, replace the
accelerator itself.
4. Replace the logic.
Eeprom does not work 1. Load default values for eeprom variables, both
Eeprom properly, or one of using PC with serial communication software
5 F 1
alarm memorized values is out of and Instrument panel.
correct limits. 2. Replace the logic.
Voltage level of pre -
charge capacitors is less
1. Verify if main breaker coil and power terminals
then 70 % of nominal
Pre -charge are in good conditions.
battery level.
capacitors 2. Verify if supply lines power fuse is damaged.
It could happen, in
low voltage 3. Verify if main breaker coils are correctly wired
example, if the power
6 A alarm 1 to their correspondent inputs :
module is working with
(Capacitors - K1-8B (positive terminal)
main breaker open.
not - K1-7C (negative terminal)
Capacitors voltage
charged) 4. Replace the main breaker.
decreases cause energy
5. Replace the logic.
spent to keep motors in
motion.

Micro Controller Control System 133 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
Drive motor 1. With such an alarm present when you turn on
8 F3 power 1 lift truck, disconnect the power cable between
module the malfunctioning power module and the
corresponding motor (first, turn off the system,
of course).
If turning lift truck on again, alarm is not active,
then:
Actual current exceeds
1. Replace the cable connecting logic and
Pump motor limits 1100 A
power module.
25 F5 power 1
2. Replace the power module.
module
3. Replace the logic.
If turning lift truck on again, alarm is active,
then :
1. Replace the power module.
2. Replace the motor.
1. Inspect whether the main connector is not
power loose.
Pre-charge capacitors
module 2. Inspect whether the drive connector is not
voltage increases too fast
9 A capacitors 1 loose.
when you turn the system
pre-charge 3. Replace the main breaker.
on.
too fast 4. Replace the drive power module.
5. Replace the logic.
1. Alarm could be caused by ineffective
temperature dissipation.
Verify thermal coupling between power module
block and aluminium plate, and between
aluminium plate and truck ballast.
The presence of a correct amount of thermal
The power module
grease in the coupling is essential to ensure an
Pump motor temperature
efficient heat exchange.
power (measured with a
2. Replace cable connecting the output pump of
10 E3 module 6 temperature connector),
the logic to the pump power module;
overtemper exceeds 100 , or is
3. If temperature readings seem too high in
ature inside [95 , 100 ] range
function of total time interval of lift truck using,
at least 30 s.
replace pump power module causing the
alarm.
You can read temperature measures using
Instrument panel or “EYE” communication
software.
4. Replace the logic.
1. Verify the correctness of wiring from pump
When you turn on the
motor and relative power module
system, capacitors are not
2. Replace wire connecting "pump" with the
completely discharged by
corresponding power module or if not possible
pump motor.
because the pump motor power module box
In fact, if you turn
integrates the outlet wire, substitute the power
Capacitors suddenly on the lift truck,
module box
11 A too charged 1 after a turning off,
3. Verify if main breaker has stuck closed
on start capacitors voltage level is
terminals: in such a case replace it
too high. You have to
4. Replace the wire connecting "drive" in logic to
discharge them before
right drive motor power module: a defective
checking the presence of
wire could give a wrong measure for capacitors
any fault (both of
voltage
capacitors and of logic)
5. Replace the logic.

Micro Controller Control System 134 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
Battery voltage level is
lower than minimum 1. Measure battery voltage with a tester and, if
Low battery charge value expected, different from the value reported on Instrument
12 EL 3
alarm referred to table 3 in panel, replace the logic;
Instrument panel technical 2. Otherwise recharge battery.
documentation.
Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
operating mode) you have to measure a
resistance of about 10 kohm between the two
wires of the temperature connector ( execute
the measure at ambient temperature of 25°C) .
If the measure is not correct it is necessary to
replace the temperature connector;
Drive motor The measure of drive 2. Disconnect the temperature connector and
13 E4 over 5 motor temperature check the wiring insulation between signal wire
temperature exceeds 155 . an ground wire (towards logic);
3. Replace the logic.

Presence of alarm with hot motors :

1. If temperature value (you can read it from
Instrument panel or via PC) seems correct,
verify if fans (if present) work properly; fault is
caused by an inefficient motor refreshing, or by
operating out of nominal maximum ranges.
Presence of alarm with cold motors:
1. With a handheld multimeter in resistance
operating mode, you have to measure about
10kohm at ambient temperature of 25°C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor The measure of pump 2. Disconnect the temperature connector and
14 E6 over 6 motor temperature check the wiring insulation between signal wire
temperature exceeds 155 . and ground wire (towards logic);
3. Replace the logic.

Presence of alarm with hot motors:

1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
1. Replace the wire connecting power module to
Drive motor
Non-zero phase currents logic.
15 F6 current 1
when you turn lift truck on. 2. Replace the power module.
offset alarm
3. Replace the logic.
Main Overcurrent on main 1. Replace the main breaker.
17 17 1
breaker fault breaker coil. 2. If alarm is still present, replace the logic.
Improper communication
1. Using EYE program interface, try to program
Watchdog between DSPs present on
18 F 1 logic flash memory. (default setting)
timer alarm logic, or/and defective
2. Replace the logic .
logic.

Micro Controller Control System 135 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
1. Alarm could be caused by ineffective
temperature dissipation; verify thermal coupling
between power module block and aluminium
plate and between aluminium plate and truck
ballast. The presence of the correct amount of
thermal grease in the coupling are essential to
Drive motor power module ensure a correct heat exchange;
power temperature, measured 2. Check cable connecting the communication
20 E1 module 5 with a connector, exceed output connector of the logic to the
overtemper 100 , or is inside corresponding power module;
ature [100 ] range at least 30 s. 3. If temperature readings seem too high in
function of total time interval of lift truck using,
replace power module unit causing the alarm.
You can read temperature measures using
“Instrument panel” or “EYE” communication
software.
4. Replace the logic.
Error in serial 1. Switch on the system and the turn it on again.
communication between 2. Program pump and drive DSP again; maybe
Serial the two DSP; DSP present software present in flash memory was
21 F communicat 1 on logic make a mutual corrupted. (REFLASH)
ion alarm software control, to insure 3. Try to the default setting (LOAD EEPRON
fast diagnosis of such a DEFAULT-TOTAL LOAD EEPROM)
fault. 4. Replace the logic.
1. Replace the wire connecting power module to
Pump motor
Non-zero phase currents logic.
36 F8 current 1
when you turn lift truck on. 2. Replace the power module.
offset alarm
3. Replace the logic.
1. Verify if 5 V output is grounded, cause an
incorrect encoder wiring.
Alarm on 5 logic K2-1C terminal
2. Verify if 5 V output is grounded, cause any
37 FH V encoder 1 (5 V output) voltage is
encoder malfunction. In that case, replace the
voltage lower than 4.3 V.
defective one.
3. Replace the logic.
1. Verify if 12 V output is grounded, cause an
incorrect wiring to:
Alarm on 12 logic K1-3C terminal - Steering sensor
38 FA V output 1 (12 V output) voltage is - Buzzer
voltage lower than 10.5 V. - Display
2. Replace defective device;
3. Replace the logic.
1. Before starting to operate, turn off any active
Pump motor
You find a pump motor command (both levers and switches);
commands
50 FL 1 command active when you 2. Be sure that lift, tilt and auxiliary command
active on
turn your system on. switches, are not active;
start
3. Replace the valve board.
Battery miss Battery is not suitable
60 60 1 Check battery voltage at the system.
matching voltage to controller.

Micro Controller Control System 136 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
operating mode) you have to measure a
resistance of about 10 kohm between the two
wires of the temperature connector (execute
the measure at ambient temperature of 25°C) .
If the measure is not correct it is necessary to
replace the temperature connector;
Drive motor The measure of right drive 2. Disconnect the temperature connector and
61 61 shutdown 1 motor temperature check the wiring insulation between signal
temperature exceeds 165 . wire an ground wire ( towards logic);
3. Replace the logic.

Presence of alarm with hot motors :

1. If temperature value (you can read it from
Instrument panel or via PC) seems correct,
verify if fans (if present) work properly; fault is
caused by an inefficient motor refreshing, or by
operating out of nominal maximum ranges.
When you start working,
you find seat switch open,
Seat switch
EE or, after the main breaker 1. Verify if seat switch is defective;
63 open on 1
(flash) is closed, the seat switch 2. Replace the logic.
start
remains opened for at least
“ seat switch delay” s.
1. verify if a switch was active or the pedal
pressed, when you turn on the lift truck;
When you start working,
2. verify if start, forward or reverse switches are
you find accelerator pedal
64 EE Wrong start 1 stuck close;
pressed or a forward/
3. verify if pedal circuit voltage exceeds 1/3 its
reverse switch active.
maximum range (measured in Volt);
4. Replace the logic.
Presence of alarm with cold motors:
1. With a handheld multimeter in resistance
operating mode, you have to measure about
10kohm at ambient temperature of 25°C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor The measure of pump 2. Disconnect the temperature connector and
65 65 shutdown 1 motor temperature check the wiring insulation between signal wire
temperature exceeds 165 . and ground wire ( towards logic);
3. Replace the logic.

Presence of alarm with hot motors:

1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K2-1B terminal
Drive motor An encoder channel is
- + 5 V: K2-1C terminal
74 Fc Encoder 1 disconnected, and motor
- A channel: K2-5C terminal
alarm is working.
- B channel: K2-4C terminal
2. If correctly wired, replace the encoder;
3. Replace the logic.

Micro Controller Control System 137 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K2-1B terminal
Pump motor An encoder channel is
- + 5 V: K2–1C terminal
76 76 encoder 1 disconnected, and motor
- A channel: K2–3C terminal
alarm is working.
- B channel: K2–2C terminal
2. If correctly wired, replace the encoder;
3. Replace the logic.
Alarm of
drive motor
77 77
thermal
Temperature difference 1. Verify if the wiring is correct;
connector
7 between both motors 2. Replace the connector;
Alarm of
results greater than 70 . 3. Replace the logic.
pump motor
79 79
thermal
connector
Alarm of
drive motor
80 80 7
module Temperature difference 1. Check the wiring connecting control unit and
connector between both power power module;
Alarm of modules results greater 2. Replace the power module;
pump motor than 70 . 3. If alarm is still present, replace the logic.
82 82 7
module
connector
1. restore eeprom with EYE application software,
using the “RESTORE” item present in main
Faulty eeprom or page
CRC fault
83 83 1 mismatching software 2. Try to the default setting (LOAD EEPROM
alarm
release. DEFAULT-TOTAL LOAD EEPROM)
3. if alarm is still present, replace the logic.
CRC : Cyclic Redundancy Checking error.
There was an eeprom 1. Switch on the system and the turn it on again
Bank CRC
84 84 1 restore, caused by a CRC 2. Try to the default setting (LOAD EEPROM
restored
alarm. DEFAULT-TOTAL LOAD EEPROM)
1. verify correctness of wiring with :
- K1-3C (12 V),
Steering
Steer circuit voltage is out - K1-6C (ground)
91 F9 sensor 5
of nominal range. - K2-1A (steering sensor input);
alarm
2. if correctly wired, replace the steering sensor;
3. Replace the logic.
1. Check assembly of the main connector.
Pre-charge capacitor
Capacitors 2. Check cable connecting the Drive/Pump
voltage grows too slowly,
98 A pre -charge 1 output of the logic with the corresponding
when you turn on the
too slow power module.
system.
3. Replace the logic;
Pre-charge capacitors 1. Check assembly of the main connector.
Capacitors voltage does not reach the 2. Check cable connecting the Drive/Pump
99 A pre-charge 1 rated battery voltage output of the logic with the corresponding
too slow within a limit time, when power module.
you turn on the system. 3. Replace the logic;

Micro Controller Control System 138 Appendix