If the intelligent instrument can not receive information from the CAN chain, the following can be done: ~~ I'the fault occurs with other faults, itis probably the freblem of the CAN interface of the display. That means the display ean not receive any information from CAN. It is suggested to check CAN Lines or other circuits to the display. sil it do not occur other faults, the problem may exists in the CAN interface of other modules, 7 “SEVICE REQUIRED’ ‘The routine maintenance falls due, it needs a thoroughly check and maintain. “COIL SHORTED” A short circuit occurs in a toad which connects to the power output (AT9 and, 20). So the relative drivers generate big current the following can be done: -~.check whether the load is broken or shot circuit or not. --- check the relative circuit IF the fault stilt exists when the load connective ire it is open, it is probably the broken of the big current protective circuit of the display. Change the instrument “HYDRAULIC O1 The input of the hydraulie oil lever is effective when starting. The following can be done #0 resolve the problem Check whether the relative digital input (A9) of the display is effective. (To TESER menu). And check the effective (ype of the electric lever of the input point B or GND) (a SET OPTIONS menut) f the input point is effective, check the condition of the relative switch, circuit and oil lever. ~if the input point is ineffective check the input circuit of the intelligent instrument... “PUMP MOTOR TEMPERATURE”9 LOGIC FAILURE#I 70 | HIGH CURRENT FORW VMN LOW 7 POWER FAILUREAS FORW VMN HIGH 2 POWER FATLTURER2 [ [ 73. | POWER FAILURE#I BACK VMN HIGH m4 ‘CURRENT SENS. KO LEFT VMN LOW 5 CONNECTER DRIVER 5 LEFT VMN HIGH 76 COIL SHORTED 26 RIGHT VMN LOW 7 COIL INTERRUPTED, 2 RIGHT VMN HIGH 78 VACC NOT OK 8 PUMP VMN LOW 1 INCORRECT START [29 PUMP VMN HIGH 80 FORW*BACK 30 VMNLOW 81 BAD STEER 0-SET (a VMN HIGH 2 ENCODER ERROR 2 VMN NOTOK 3 BAD ENCODER SIGN 3B NO FULL COND 7 STEER SENSOR KO M4 _RGTNO FULL COND 35 STEER HAZARO 35__|_LFTNO FULL COND 86 PEDAL WIRE KO 36 PUNO FULL COND 87 PEDAL FAILURE 37 CONNECTOR CLOSED 88 TRACYION BRUSHES 38 “CONNECTOR OPEN 89 PUMP BRUSHE ‘| 39 BRAKE CON. CLOSED _ 90 DRIVER | KO 40 BRAKE CONT. OPEN 31 DRIVER 2 KO a DIR CONT. OPEN 2 DRIVER 1 SIC. KO 42 | _DIRCONT. CLOSED 3 DRIVER2SIC. KO [Loa 4 INPUTERROR#6 a 95 INPUT ERRORS [as | _LeFreonr.cLoseD | 96 INVERTION | 46 | LEFT CONT. OPEN o7_ | POSITIONHANDLE a7 MAIN CONT. CLOSED | _ 98 INPUT ERROR#2 | 8 MAIN CONT. OPEN %9 INPUTERRORN | 49 __FOLEVER [- 50 LEFT I-0 EVER - Fault analysis, EEPROM KO” Itmeans a fault of parameter storing and adjustment in memory. “EEPROM KO” means the truck can work on under the set value before selling, If the fault still exists after restarting the electric lock, replace the instruments: If it disappears, the value set betiore will be replaced by the one set before selling, “CAUSE KO’ 60The error oceurs when 5 ous DATA adjusting the parameter of the | Turn the key switch ACQUISITION | current amplifier of obtaining again the motor impedance. - : 85 STEER ‘A warning of the exceeding oF HAZARD, steering angle ‘A waming that these ofthe warriyg | CAN BUS is PRESENT; The 2 | a7 data ofthe steering cooler | DATs is transferred through traction controller by CAN BUS. Steering controler works on ne condition that traction wari wairinG For |S : me 3 | 239 hone controler sends out the order of shutting off the safety switeh, ‘There isa disparity between the data from the processor's EPS NOT 4 iagnosis and the set one. Cut 238 | aignen | sismosis and the set one. Cu | the steering and traction ater 6 seconds | 4.6.3.4 Fault code on the intelligent instrument Code Fault name code | Fault name wo | NODE SI RIGHT I=0 EVER oO CHOPPER RUNNING 32 PUMP I=0 EVER 2 NO COMMUNICATION 3 STBY THIGH @ UNKONWN CHOPPER Sa LEFT STBY 1 HIGH o4 CONSOLE EEPROM 7 RCG STBY | HIGH _| 05 | SEARIAL ERROR? | PUMP STBY I HIGH 06 RIAL ERRORS HIGH FIELD CUR, 07 | __ CHOPPER NOT CONF 58 NO FIELD CUR, 08 WATCHDOG 39 HIGH BRAKING | 09 FIELD FF FAILURE oo CAPACITOR CHARGE 10 EEPROMDATAKO | 6l HIGH TEMPERATURE EEPROMPAR.KO | 62 HIGH TEMPERATURE 2 EEPROM CONF. KO 8 THERMIC LEVER 13 EEPROM KO ot PUMPTEMPEATURE | 4 EFPROM OFFLINE 65 MOTOR TEMPERAT. 15 LOGIC FAILURE#S 66 BATTERY LOW 16 LOGIC FAILURE# 67 | _ BATTERY LEVER#2 | 17 | Loci FAILURE#3 | 68 BATTERY LEVER#] 18 LOGIC FAILURE? o | CURRENT SES. KOSENSOR KO. feedback potential( the truck did not apply to it) JERKING FB | The output voltage of the | Change feedback digital 7 23 por igital resistor is incorrect, resistor Check whether the feedback digital resistor lose or not; check whether the steering | Wheel seizures oF not. “The output voltage of the check whether the digital resistor is invariable. | feedback digital resistor LOCKED exceeds the limit ofthe electricity when the steering wheel moving; ‘check the rotation of the steering motor. A disparity between the 9 | a1 | STEPER jana compe of | Change hope va | exconen | Aap ten | ange sod - ERROR sencoder Irequeney andthe channel of the encoder, | order frequency t 13_| EEPROM KO | A failure of EPROM writing | Change the chopper. 7 T iis necessary to adjust eurrent 2a | GAIN | Iris necessary to aut Connect with ZAPI EEPROM KO | _ ofthe controler | | CURRENT eis necessary to aust current | a apy GAIN of the controle. HIGH The temperature ofthe | Change the way of heat 61 | TEMPERATUR | controller board is higher than | transferring or change E 155. the controller ‘Check the temperature TOR |The temperature sensor ofthe 2 os |, Moro he kemperatare sensor or change the TEMPERATE. | motors higher than 150° way of heat transferring ‘The current of the current ’ 53. STBYIHIGH ‘Change the chopper amplifier is high. ‘The voltage of the voltage ] 2 | 32 | VMNNoTOK < Change the chopper LY OK | amplifiers high, The voltage amplifier of ci Vu-Vw exceeds the range of 3 fav) toate es Change the chopper FAILURES | -0.25V-+0.25V under the | "|The voltage amplifier of — | - Locic | vw-Wv exceeds the range of hange the chopper 4 7 16 | eamrurees | -0.25V-+0.25V under the | hanes the chore alternate condition, 8controlier’s positive POWER ‘The current of the phase V is “ [7 | ramurees | ov when thematorwors. | Changethe shopper. | s | | tO | avvotncsenene' | chagetecmper | r Locie The voltae ofthe phases W ] + ag | MAINCONT, eens making the main OPEN - contactor open circuit in 8 | 2487 | CANBUSKO No communication "ne AN BUS 9 jaan | MOO na |i wtre oo ‘Check the connection of | | _ = - 3ohms more o ess) | | 5 op QLINE The voltage of A,B phases of | especially the resistance ~ SENSOR KO the walking motor is null. between the CAN#9 and | — 300hms more or less) 3 [zag | SPONTOF | therange ofthe digital resistor fre oie st 4 | nag | PR OUTOF | the range ofthe digital resistor ee Cheek whether the | POEITION The feedback digital resistor digital resistor input or 6 sa | STEER AA disparity between the order digital resistor and the | 3load. ‘No communication between 1 | aan | SECON. | Ae totendcboune | Change cprer 10 251 | KMOPEN hecho by saben Change the chopper The safe switch inside the - 11 | 254 | KSCLOSED | before receiving the order Choneechoper - "The safe switch inside the [an | ksorew | sities 00 | une tgp | The analogue signal sent by CLOCK PAL. rinciple processor is error, 28) “Norox | shih ischeckesty | Comet shonre - sabosinate processor | ‘Check whether the The current exceeds the motor and the controller wy | Mot | tscedcurme ae | Moore soot ‘motor starts or works. aster or change the | a — | cen fi chopper __ Check the fuse; check 5 POWER | The current of the phase W is cooler spose - Change the chopper. 3 n POWER ‘The current of the phase U is ‘Check the fuse; check “| FAILURE#2 | _ OV when the motor works. the input of the 56WARN controller will | and the alarm will ING send ater signal | disappear ifthe titing ro controller | checks the fault of iting chopper. PUMP Error starting | Exclude the fault) 243 | INC x |x) x corder of the | and the alarm will START lifting controller | disappear ~f The voltage of wn | eta 24 | Nor x |x | x higher than the | *™4 he alarm wit OK set min. voltage | “#PPOH WV. 4.6.3.3 The fault cade of EPS-ACO inverter | Glimmer ] Fault | Description in - description The condition | ing times | code_| the hand manual of excluding the faults MICRO SLAVE | disparity between the 1) 246 KO controller and the walking and | Change the chopper | steering motors A disparity of rotation direction MICRO | between the steering motor and 2 | 21 | sLaves | the watking motor checked by | Cranes te chopper controller The frozen of OXF field data 3 | 250 | MICRO SLAVE of the prineiple and Change the chopper subordinate miero processor «Jan | MER | tent penopcand | chert tmp: SLAVE#S subordinate processor | Before the turning off of the safe switch, the | voltage ofthe CAN#4 | ‘The vohage of the CAN#A | “lOSE (0 OV whether the : oo INPUT | higher than 12V before the safe soothes | ERROR# | switch ise the contotter | eee ech | | beingoth connected to the positive point, the CAN#4 will connect the negative point through aLOW disappear CPOT voltage higher than the vec set, number } Exclude the fut | 7s | Nor x 1 volt when | andthe alarm will OK switches of the disappear allowance point INCOR cir macign | EU the al 79 | Rect x an the alarm will START require order disappear FORW Both exe | ge an 80 ARD= x ofthe backwand and the alarm will BACK and forward disappear WARD input signal cnc The traction or ms ling controller | Exclude the fault ae | x temperature | andthe alarm will on sensor exceeds | disappear No Exclude the fault ast | FOR x Ale ted the alarm wil NODE Sepiyed in| dapper 4s contol want The traction NG prowess 0" | exclude theft 2st | FoR x tS andthe lar wll NODE lifting micro disappear 8 rooms ration No como 85 | gain a 247 CaN x the connection and the alarm will Mess withthe ‘en AGE#S iting controle, x contri | Bade he ut 247 CAN x the connection | and the alarm will MESS mss withthe iting | disappear contol PUMP x _The traction | Exclude the faultlifting ‘micro-processor or a disparity between the input order and the main order A disparity between the input state checked by INPUT lifting 5 Reclose the 250 | MISM x |x mmicro-processor ATCH input sae from | eee took traction nmiero-processor through CANBUS Exclude the Fault and the alarm will The short circuit | disappear ifin the AUX orbroken way | initializing tate; 253 | ouTP x | x of iFin other states, UTKO electromagnetic | exclude the Faults brake coil | and make the traction require in farce The fault oF the EEPRR Eprom as the | Exclude the fault | 13) OM x |x controller using | and the alarm wil Ko ating disappear _ parameter | Temperature of | HIGH | oe x | x retin mtr str ll ERATU orth met ee pew RE higher than 75°C - High temperature of | Exclude the fault 65 x x either traction or | and the alam will lifting motor or | disappear both 66 x lx Battery capacity | Exclude the fault lower than 20% and the alarm will‘main connector and electromagnetic brake; alert state or working state: short circuit of coils, connector and electromagnetic ‘and make the traction require in force brake - Exclude the faults CONT The when working; AcTO un-returning of a7 | touch point of | Tlose te electric lock CLOSE the main vin D contactor omerting Exclude the faults when working: coNr Poor connect of omnes ag | ACTO ‘oe reclose the | Blok a electric lock oven contactor he oft-working, ENco Abnormal ofthe DER . Reclose the 82 X | motor speed ERRO electric lock t sensor (encoder) PEDAL — Exclude the falls ac | wine | Thefault of the | and make the NPOT circuit | traction require in Ko " force WRON disparity | Exclude the faults ays | OSET between the and make the OS | Barre battery voltage | traction require in RY and battery set force ‘A fault of lifting mmiero-processor PUMP Reclose the 246 | ko. | checked By | tect lock traction _ mmicro-processor ‘A fault of action Reclose the nag | MAST x srnctio c ERKO miero-processor | electric lock checked by 2Taso eT foree “| ] Exclude the fault and the alarm will retuanor | tori the STBY! feedback circuit inisalizing states 33 HIGH x voltage of the if'in other states, essa he ate cients] ue icon ee | force Newest thovalngs of tepowsr cape thee CAP being off; the | Exclude the fault 60 | CHAR faults ofthe | and the alarm will GE power disappear Ph pnt oft logic er orth diving PCB | Beckie fa andthe sa Soper te DRIVE ‘The short circuit | initializing state: Pan x Sicmsn | noha wor cometor cot | exclu ts and make the wan ee force cont Te akan of hem | acto thedvng | Excite as |r x crete one Be tiie ore R connector’s coil - “I Initializing | Exclude the fault con se: he woken | and ie al wi 16. | sHoRT x ofthe driving | disappear if in the ros postion | ian ste L cle he4.6.3.2 Fault code of the COMBIA AC2 inverter The states ofthe controller coa | eau | = = The condition aul Traci © | the | TM | description | of excluding the e | name | on ina work alert faults S| sate | "8 state state | Exclude the ful andthe alarm wil disappear iin the ware | intalizing sate are The failure of| we ses 8 | HDOG | x Xx fx | Tee | tin other sates, we watch JOB | sctude the faults and make the traction require in forve elude the faults Fait Oren atc iy | TAU x protection ofthe | Smt meke the RERS tration requie in hardware ciruit | force The fault ofthe | Exclude the faults ws lout | x x feedback circuit | and make the oF U.V,W phase | tration require in UREW voltage force | Loaie wer voltage or | Reclose the 19 | FAW | x x |x |x oe vole ; el ‘ bac short of voltge | electric loc Exclude the fault ‘The fault ofthe | and the alarm will output of motor | disappear iin the | | wer the fault | inializing stat: vMN | powes © 30 x X | x | xX | ofpower | ifinotherstates. Low assessment, oF | exclude the faults MOS driving | and make the cireuit or motor | traction require in | force The fault ofthe | Exelude the fault output of motor | andthe alarm will power; the faut | disappear iin the | vn power the fut | sppea iin ihe | a x x | x of power | initializing state: HIGH : assessment, ot | ifn other stats, MOS driving | exclude the faults LL circuit or motor |_and make the2) Use notice: © Auto liquid replenishment shall be carried out at the end of charging, and it is strictly prohibited to be done before charging, @The auto liquid replenishment device shall ensure the correct liquid pressure. @ Liquid storage devices and pipelines shall be kept clean and there shall be no dirt. @ only special liquid for batteries shall be used. its strictly forbidden to flush the injection plug with tap water, @ Pay attention to the temperature to prevent the auto liquid replenishment system from freezing 4.6.2.6 Panel switch Switches on the panel can be on or off according to the customer's choose. If the button is pressed, the speed of the whole truck will slow down. ©) © = irihe two buttons are pressed at the same time, the steering wheel will center automatically. 4.6.3 Diagnosis 4.6.3.| General instruction The traction control system, loading control system, steering control system and clligent instrument system assembled in the truck are continually monitoring micro-processor controller. They all have a diagnosis program to a main function, The program includes the following point: (1) diagnosis when the eleetrie lock being off: the circuit of the watching dog, current censor, charging of the capacity, phase voltage, driving of the connector, can-bus connector, the order of the switch operation, the output of the acceleration, the synchronism of the two micro-processor, the input of the hardware that having something to do with the safety. (2) The alternate check; The circuit of the watch dog, phase voltage, current censor, driving of the connector, can-bus connector (3) Check when working: the circuit of the watch dog, the driving of the connector, the current sensor, can-bus connector (4) Continuously check: inverter temperature, motor temperature Ways of diagnosis: the digital hand manual which can supply detailed diagnosis information; the can-bus which will send fault code and the code and module node will display in the meter ”