13 Alarm Codes: Traction Controller

NSP Service Manual
13 Alarm codes
This chapter explains the meaning of the various alarms that the different controllers
may produce. Refer to the chapter 11 for information on the TruckTool diagnostics
application.
13.1 Traction controller
NOTE: Before you start to troubleshoot the truck, make sure that all the power
supplies, fuses and connections are in order. Low voltage in the traction controller
can cause different sorts of alarms.
The fault diagnostic system of the traction controller is divided into two main groups:
• Alarms
These are faults, which open the power bridge and, when possible, also the main
contactor is opened and the magnetic brake activated. Failures in the motor, the
controller or the safety functions cause alarms.
• Warning
These are faults, which do not stop the truck or stop the truck by using regeneration
braking. The controller is working well, but it has detected some conditions that
reduce the performance or stop the truck without opening the power devices.
Incorrect operation sequences or conditions requiring performance reductions (for
example, high temperatures) cause warnings.
The text “Stored” means that the alarm or warning is stored in the traction controller
logbook.
Table 14. Traction controller alarm codes
CODE TRUCKTOOL AND DISPLAY DESCRIPTION
8 Self diagnosis test failed (Alarm) Stored

WATCHDOG
This is a safety-related self diagnosis test within the logic between the master (drive) and slave
(pump) microcontrollers. The alarm indicates that the master and slave watchdog message is
missing or late.
This alarm can be caused by a CAN bus malfunction, which blinds the master-slave
communication. Check all the CAN bus cables and measure the bus resistance between CAN
high and low. The bus resistance value should be 60 Ω. Measure also the CAN cables’
resistance between the truck chassis and the 0 cables. There should not be any significant
connection and the resistance value should be over 1 M Ω.
If CAN bus is OK, the problem is in the controller and it must be replaced.
Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 247 (322)
NSP Service Manual
13 Controller memory error (Warning) Stored

EEPROM KO
This warning is caused by a hardware or software defect of the non-volatile embedded memory
supporting the controller parameters. This alarm does not prevent truck operation, but the truck
will work with the default values.
In case of this warning, perform a CLEAR EEPROM operation. Switch the key off and on to
check the result. If the alarm occurs permanently, replace the traction controller. If the alarm
disappears, the previously stored parameter values will have been replaced by the default
values.
17 Hardware high current protection failure (Alarm) Stored

LOGIC FAILURE #3
This alarm is caused by a hardware problem in the logic card circuit for high current (overload)
protection.
This fault is not related to external components, so when it appears, replace the traction
controller.
18 Motor voltage feedback circuit damaged (Alarm) Stored

LOGIC FAILURE #2
This alarm is caused by a fault in the logic board managing the phase’s voltage feedback.
controller.
19 Over or under voltage detected (Alarm) Stored

LOGIC FAILURE #1
This alarm is displayed when the controller detects an overvoltage or undervoltage condition.
The overvoltage threshold is 35 V and the undervoltage threshold is 9.5 V in the 24V controller.
If the alarm is displayed at startup or in the standby mode, it is due to an undervoltage. In such
a case, check the following:
• The key input signal voltage drops below the undervoltage threshold due to external loads,
such as DC/DC converters starting up or relays or contactors energizing or de-energizing.
• If no voltage transient is detected on the supply line and the alarm is displayed every time
the key is switched ON, the problem is in the traction controller.
If fault is displayed during motor driving, it is due to an undervoltage or an overvoltage

condition.
• If the alarm occurs during traction acceleration or driving hydraulic functions, it is caused by
an undervoltage condition. In such a case, check the battery charge level and the power
cable connections.
• If the alarm occurs during release braking, it is caused by an overvoltage condition. In such
a case, check the line contactor tips and the battery power cable connections.
In some cases, this error can also happen during normal operation. Sharp hits may cause the
emergency stop switch contacts to open for a short period of time. This causes a short 0 V
pulse to the key line causing this error.
NSP Service Manual
28 Pump motor output voltage error (low) (Alarm) Stored

PUMP VMN LOW
Cause 1: Startup test

Before switching the main contactor on, the software checks the power bridge. It turns on the
high side power MOSFETs one by one and expects the phase voltage to increase toward the
bus capacitor value. If the phase voltage does not increase, this alarm occurs.
In such a case (the main contactor does not close at all), check the following:
• Motor internal connections (ohmic continuity)
• Motor power connections
• Motor leakage current to the truck frame
If the motor connections are OK, the problem is in the traction controller.
Cause 2: Motor run-up test
When the motor is running and the power bridge is on, the motor voltage feedback is tested. If
the motor voltage feedback is lower than the commanded value, this alarm occurs.
In such a case, check the following:
• Motor connections
• Whether the motor’s phase windings or cables have leakage currents towards the truck
frame
• That the main contactor closes properly, with a good contact
If no faults are found, the problem is in the traction controller.
29 Pump motor output voltage error (high) (Alarm) Stored

PUMP VMN HIGH
This test is carried out when the pump motor is running. The alarm indicates that the pump
motor output is higher than expected.
• If the motor windings or cables have leakage currents towards the truck frame
If no problems are found on the motor, the problem is in the traction controller.
NSP Service Manual
30 Traction motor output voltage error (Alarm) Stored

(low)
VMN LOW
Cause 1: Startup test

Before switching the main contactor on, the software checks the power bridge. It turns the high
side power MOSFETs on one by one and expects the phase voltage to increase toward the
bus capacitor value. If the phase voltage does not increase, this alarm occurs.
Cause 2: Motor run-up test
When the motor is running and the power bridge is on, the motor voltage feedback is tested. If
the motor voltage feedback is lower than commanded value, this alarm occurs.
frame
• That the main contactor closes properly, with a good contact.
31 Traction motor output voltage error (Alarm) Stored

(high)
VMN HIGH
Cause 1:
Before switching the main contactor on, the software checks the power bridge. It turns the low
side and high side power MOSFETs on one by one and expects the phase voltage to decrease
down to –Batt. If the phase voltage does not decrease, this alarm occurs.
Cause 2:
This alarm may also occur when the startup diagnosis has been completed and the main
contactor is closed. In this case, the phase voltage is expected to be lower than 50% of the
battery voltage. If it is higher than this value, this alarm occurs.
In such a case (the main contactor closes and then opens again), check the following:
frame
• That the main contactor closes properly, with a good contact
NSP Service Manual
37 Contactor is stuck closed (Alarm) Stored

CONTACTOR CLOSED
Before driving the main contactor coil, the controller checks that the contactor is not stuck
(closed). The controller drives the MOSFETs for some milliseconds, trying to discharge the
capacitor bank. If the contactor is stuck, this alarm occurs.
In such a case, check the main contactor tips. If needed, replace the main contactor.
38 Contactor does not close circuit (Alarm) Stored

CONTACTOR OPEN
This alarm occurs if the main contactor has been driven by the controller, but the contactor
does not close.
In such a case, check that the wires to the main contactor coil are not interrupted or
disconnected.
The alarm can also be caused by a fault in the main contactor itself. If needed, replace the
contactor.
52 Pump current 0A while pump running (Warning) Stored

PUMP I=0 EVER
This test is carried out when the pump motor is running, and it verifies that the current feedback
sensor is not constantly stuck to 0.
If this warning is displayed, check that the motor connection has continuity. If the motor
connection is opened, the current cannot flow, so the test fails and the warning is displayed.
If the motor circuit is OK, the problem can be in the current sensor. In this case, replace the
traction controller.
53 Controller current sensor failure (Alarm) Stored

STBY I HIGH
This alarm is displayed if the current transducer or the current feedback circuit is damaged in
the controller.
controller.
60 Power capacitor charging error (Alarm) Stored

CAPACITOR CHARGE
When the main contactor is open, the bus capacitors are charged from the key line through a
charging resistor. If the voltage on the bus capacitors is low and does not increase, this alarm
is displayed.
In such a case, there are four possibilities:
• Another device connected in parallel with the bus capacitors has failed.
• Something is draining the current between the main contactor and the controller when the
main contactor is open.
• There is a problem in the charging section (for example, a bad contact in the key line).
• A power failure or a logic failure occurred in the controller. In this case, replace the traction
controller.
NSP Service Manual
62 Controller has overheated (Warning) Stored

TH. PROTECTION
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 occurs when the controller is cold, there are three possibilities:
• There is a fault in the thermal sensor wiring.
• There is a failure in the thermal sensor.
• There is a failure in the logic.
In all of the above cases, replace the traction controller.
65 Traction motor has overheated (Warning) Stored

MOTOR TEMPERAT.
This alarm occurs when the analogue temperature sensor has exceeded the threshold 150°C.
• The thermal sensor inside the motor and the outside wiring. The resistance of the sensor
(type KTY83) is 960 Ω at 20°C.
• If the warning occurs when the motor is cold and the thermal sensor is OK, the problem is
in the traction controller.
• If the motor is overheating, check that air ventilates freely in the motor compartment.
66 Battery charge lower than 10% (Warning) Stored

BATTERY LOW
This warning occurs when the battery charge is calculated as being less or equal to 10% of a
full charge and the BATTERY CHECK parameter is set to a value other than 0 (located in the
SET OPTION menu).
In such a case, charge the battery. If it does not help, measure the battery voltage with a
voltmeter and compare it with the value of the BATTERY VOLTAGE parameter. If they are
different, adjust the value of the ADJUST BATTERY parameter.
When adjusting the battery voltage, voltage should be measured from the key line, after the
reverse polarity protection diode. A good measuring point is, for example, the emergency stop
button terminal. If the battery voltage is measured anywhere else, it will cause invalid operation
of the battery discharge indicator.
74 Contactor driver circuit error (Alarm) Stored

DRIVER SHORTED
This alarm occurs if the driver of the main contactor coil is shorted or the coil is disconnected.
• If there is a short circuit between the connector XA1 C pin 6 and –Batt.
• Condition of the wiring of the main contactor related harness.
If there is no short circuit and the wiring is OK, the driver circuit in the traction controller is
damaged.
NSP Service Manual
75 Contactor driver damaged (Alarm) Stored

CONTACTOR DRIVER
This alarm indicates that the main contactor driver is not able to drive the load. The device itself
or its driving circuit is damaged.
controller.
78 Accelerator voltage not OK (Alarm) Stored

VACC NOT OK
This alarm occurs when the accelerator output voltage differs more than 1 V from the acquired
minimum during PROGRAM VACC.
In such a case, check the functionality of the accelerator. Perform the accelerator calibration
wizard function.
79 Invalid starting sequence (Warning)

INCORRECT START
This warning occurs because of an incorrect starting sequence.

Use a tester to check for possible reasons for this alarm. The most likely reasons are:
• Incorrect sequence made by the operator.
• Accelerator was active at startup.
• Tiller sensor was active at startup.
• Brake release was active at startup.
• Safety button was active at startup.
If no signal was active at startup, the problem is in the traction controller.
80 Direction switches active (Warning)

simultaneously
FORW+BACK
This warning occurs when both travel demands are active at the same time.
Use a tester to check for possible reasons for this warning. If both directions are active at the
same time, check the accelerator and its wiring.
If no direction signals are active at the same time outside the controller, the problem is in the
traction controller.
82 Encoder error (Alarm) Stored

ENCODER ERROR
This alarm occurs if the frequency supplied to the motor is higher than 40 Hz and the feedback
signal from the encoder has a jump higher than 40 Hz within 20-40 milliseconds. This condition
is related to a malfunction of the encoder. In such a case, check the encoder’s mechanical
functioning and its wirings’ connections. Also check the encoder’s mechanical installation; if the
encoder slips inside the housing, it causes this alarm.
Also electromagnetic noise on the encoder can cause this alarm. In such a case, replace the
encoder. If the alarm persists after replacing the encoder, the problem is in the traction
controller.
NSP Service Manual
86 PEDAL WIRE KO (Alarm) Stored

PEDAL WIRE KO
The software checks for the connection of the two supply ends of the accelerator’s
potentiometer. 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 the NPOT connection drops down.
This alarm occurs if the NPOT voltage is less than 0.3 V and also when the NPOT voltage is
higher than 2 V (to detect also the condition of a broken sense diode).
In such a case, check the voltage on the NPOT and the accelerator connections.
185 Height sensor mismatch (Alarm) Stored

HT SENS.MISM
If the truck is not equipped with side stabilizers, check that the parameter INITIAL LIFT is not
set to 2.
If the truck is equipped with side stabilizers:
• Check the wiring of the height sensor.
• Disconnect the height sensor and test the redundant switches. If the states are not equal,
test if the switch works by moving a magnet in front of it.
• Check that the magnet counterpart (attached to the lifting carriage) is intact.
• Check the wiring of the encoder card (extra I/O).
If the problem persists, replace the height sensor.
186 Motor temperature notification (Warning)

WARN. MOT.TEMP
This is only a notification. To limit further heat generation, the parameter cutback starts when
the motor temperature reaches 120 ˚C. The truck can be used normally.
187 Controller temperature notification (Warning)

WARN. TH.PROTECT
This is only a notification. To limit further heat generation, the parameter cutback starts when
the controller temperature reaches 75 ˚C. The truck can be used normally.
188 Load sensor value is out of range (Warning) Stored

LOAD.SEN.OUT RNG
This warning indicates a pressure sensor problem. Either the pressure sensor’s voltage is not
within the calibrated value range or it exceeds the calibrated values too much.
NSP Service Manual
189 Battery lock not closed (Alarm)

BATTERY LOCK
This alarm indicates that the battery lock is not closed.

In such a case, check the battery lock state from the tester menu. If the lock is stated to be
open while the battery is mechanically locked, check the battery lock sensor operation and
wiring.
190 Motor braking error (Alarm) Stored

BRK TIMEOUT
One possible cause for this alarm is too steep braking ramp (parameter). Try to lower the
braking ramps from the parameters. Also braking at a slope when the truck is loaded can
cause this error.
192 Waiting for EPS (Alarm) Stored

EPS RELAY OPEN
This alarm indicates that there is some problem in the steering and the steering has frozen.
193 Sideguard inputs illegal state (Alarm)

SIDEGUARD INPUTS
This alarm is caused by an invalid combination of side guard inputs.

If both the side guards are in the correct position (both open or both closed), check from the
tester menu if the logic inputs are the same. Check the correct positioning and operation of the
side guard sensors. Also check the wiring of the sensors.
194 Platform inputs illegal state (Alarm) Stored

PLATFORM INPUTS
This alarm is caused by an invalid combination of operator’s platform inputs.

When the operator’s platform is either down with a driver standing on it or up, check from the
tester menu that the logic inputs are correct. Check the correct positioning and operation of the
platform sensors. Also check the sensor wiring.
195 Platform inputs inactive (Warning)

WAITING DRIVER
This is a general warning indicating only that the truck is waiting for an operator.
196 Invalid motor resistance (Alarm) Stored

MISMATCHED RM
This alarm occurs if the motor resistance is different than the value of the parameter MOTOR
RESIST.
In such a case, teach the new motor resistance value by setting the parameter MOTOR
RESIST to 0 and saving the value while holding the tiller arm in the drive position. Restart the
truck after the main contactor is opened. The new settings are active after the restart.
NSP Service Manual
197 Motor resistance acquiring failed (Alarm) Stored

WRONG ACQ
This warning occurs if the controller did not acquire the motor resistance value correctly.
In most cases, this alarm signals that the controller cannot inject current in the motor coils for
some reason. Check the motor connections. Also make sure that the main contactor is closed.
198 Sensorless feedback hardware error (Alarm) Stored

ERROR FEEDBACK
This alarm indicates damage to the controller’s hardware which provides feedback for the
sensorless motor control.
If the problem occurs permanently, replace the controller.
199 PIN teach mode (Warning)

TEACHING PIN
This warning is displayed when the PIN code teaching procedure is active. It disappears when
the teaching is finished.
This warning should occur only if the truck is equipped with a PIN code lock.
200 Waiting for valid PIN code (Warning)

WAITING FOR PIN
This warning indicates that the controller is waiting for a valid PIN code. If it occurs in a truck
that does not use PIN code lock, check that the PIN CODE LOCK parameter is set to ABSENT.
This warning should occur only if the truck is equipped with a PIN code lock.
201 Accelerator teach mode (Alarm)

LEVER TEACH IN
This alarm indicates that the controller entered the throttle lever teaching mode. It disappears
as soon as the teaching of the throttle lever is finished.
202 Lift cutout timer active (Warning)

LIFT TIMEOUT
This warning is displayed when the lifting cut off timer has expired (the default value is seven
seconds).
In case of this warning, release the lift button. If the lift buttons are released and the warning
persists: check the following:
• The lift inputs are correct in the tester menu.
• Operation of the tiller and the lift buttons is correct.
• There are no short circuits in the lift button wirings.
NSP Service Manual
203 Pump voltage error (Alarm) Stored

PUMP VMN NOT OK
Cause 1: At startup
The software checks the voltage on the –P terminal and expects it to remain at a steady value.
This alarm occurs if the value does not remain steady.
Cause 2: During operation
If this alarm is displayed during operation, it indicates that the voltage on the –P terminal is too
low when the main contactor is closed.
The software waits for 30 seconds before displaying this alarm, because there are situations
where the pump motor can rotate while the –P output is not activated (pump deceleration).
During this time, it shows the WAIT MOT P STILL warning.
In case of this alarm, check the following:
• Pump motor internal connections
• Pump motor power cable connections
• Pump motor leakage current to the truck frame
If the pump motor connections are OK, the problem is in the traction controller.
204 Pump voltage warning (Warning)

WAIT MOT.P STILL
See the description of the alarm 203 PUMP VMN NOT OK.
206 High motor voltage during startup (Alarm) Stored

INIT VMN HIGH
Before switching the main contactor on, the software checks the power bridge voltage without
driving it. The software expects the voltage to be at a steady state value. If the voltage is too
high, this alarm occurs.
• Motor internal connections
• Motor power cable connections
207 Low motor voltage during startup (Alarm) Stored

INIT VMN LOW
Before switching the LC on, the software checks the power bridge voltage without driving it.
The software expects the voltage to be at a steady state value. If the voltage is too low, this
alarm occurs.
• Motor power cable connections
NSP Service Manual
208 Controller memory error (EEPROM) (Alarm) Stored

EEPROM KO
This alarm is caused by a hardware or software defect in the non-volatile embedded memory
supporting the controller parameters. This alarm does not prevent the truck from operating, but
the truck will work with the default values.
In the case of this alarm, perform the CLEAR EEPROM operation. Switch the key off and on to
check the result. If the alarm persists, replace the traction controller. If the alarm disappears,
the previously stored parameter values will have been replaced by the default parameter
values.
210 Controller memory error (RAM) (Alarm) Stored

WRONG RAM MEM.
This alarm is caused by a hardware or software defect in the volatile embedded memory.
The controller could be damaged and it should be replaced.
211 Traction motor jammed (Alarm) Stored

STALL ROTOR
This alarm indicates that the traction rotor is stuck or the encoder signal is not correctly
received by the controller.
In the case of this alarm, check if the sign of FREQUENCY and ENCODER on the tester menu
are the same. Also check that it is not zero during a traction request.
212 Controller memory error (RAM wrong) (Alarm)

WRONG RAM
This alarm indicates that the used program, etc. is incorrect.
213 Auxiliary output driver error (Alarm) Stored

AUX BATT. SHORT.
If this alarm occurs, the POSITIVE EB parameter is probably not set correctly. Set the
parameter to LEVEL=0.
214 Lowering valve circuit open (Alarm) Stored

EVP COIL OPEN
This alarm is displayed if the solenoid valve circuit is open.

• Wiring, verify that the solenoid valve coil circuit is in order between XA1_B/3 and fuse 3F1.
• Solenoid valve coil
If the wiring and the solenoid valve coil are OK, the problem is in the traction controller.
NSP Service Manual
215 Lowering valve coil, or driver shorted (Alarm) Stored

EVP DRIV. SHORT.
This alarm is displayed if the microcontroller detects a mismatch between the valve set-point
and the voltage measured on the solenoid valve output. This can be caused by the following:
• The solenoid valve coil circuit is shorted.
• The traction solenoid valve driver is shorted.
If there is low impedance between the negative of the solenoid valve coil and –Batt, the driver
circuit is damaged and the traction controller must be replaced.
217 Pump current feedback sensor (Alarm) Stored

damaged
PUMP I NO ZERO
This alarm indicates that the pump motor’s current feedback sensor has detected current
flowing in the circuit while the pump motor is not running.
controller.
218 Motor thermal sensor error (Warning) Stored

SENS MOT TEMP KO
This warning indicates a motor thermal sensor knockout, meaning that the motor thermal
sensor has either short or open circuited.
In such a case, check that the connector contacts and the cables are in order. Measure the
resistance of the thermal sensor (960 Ω at 20°C).
219 Proportional valve error (Alarm) Stored

PEV NOT OK
This alarm indicates that the voltage on the positive line of the EV outputs (B2) is too high or
too low.
In such a case, check if the voltage dropped down because of a faulty load connected to B2. If
not, replace the traction controller.
220 Startup diagnosis for key-line failed (Alarm)

KEY OFF SHORTED
This is a startup diagnostic for the key line. This alarm occurs if the key line (XA1 C/1) voltage
drops below the threshold level of 9.5 V.
In such a case, check if the key input signal voltage drops below the undervoltage threshold
due to external loads, such as DC/DC converters starting up or relays or contactors energizing
or de-energizing.
If no voltage transient is detected on the supply line and the alarm occurs every time the key is
switched ON, the problem is in the traction controller.
NSP Service Manual
222 Magnetic brake driver error (Alarm)

SMARTDRIVER KO
This alarm indicates that the built-in smart driver is open and not able to provide the magnetic
brake positive.
In such a case, check the harness to see if the smart driver output XA1 B/1 is shorted to –Batt.
If the output stays at a low level even when disconnecting the wire from the connector pin, the
problem is in the traction controller.
223 Short circuit main cont. or magn. brake (Alarm)

coil
COIL SHOR. MC-EB
This alarm occurs when there is a short circuit in the main contactor or magnetic brake coil.
The typical root cause for this alarm is a problem in the harness or in the coil. Check the
connections and wiring between the controller and coils.
If there are no external failures or problems, the problem is in the controller and it needs to be
replaced.
224 Another device is inhibiting controller (Warning)

WAITING FOR NODE
This warning indicates that the controller has received a message from the CAN bus that
another controller or device in the network has experienced a failure. As a consequence, the
traction controller itself cannot operate, but has to wait for the other controller or device to
recover from the failure.
In case of this warning, check the additional CAN bus devices for faults.
226 Accelerator voltage out of range (Alarm) Stored

VACC OUT RANGE
This alarm is displayed if accelerator voltage is out of range.

In such a case:
• Teach the accelerator values again.
• Check that the connectors and cables are in order.
• Replace the accelerator and teach the accelerator new values.
228 Tiller switch is open (Warning) Not shown in the display

TILLER OPEN
This warning occurs when the tiller is released after a fixed time in the standby mode with the
main contactor open (30 seconds).
After the next travel request, the warning disappears.
NSP Service Manual
229 Magnetic brake driver output error (Alarm) Stored

POS. EB. SHORTED
This alarm is displayed when the output of the built-in smart driver, which supplies the positive
to the electromechanical brake coil, is high when the tiller and the brake release switch are
open.
In such a case, check the wiring to see that there is no extra positive supply connected to the
electromechanical brake at the connector XA1 B/1 when the tiller and the brake release switch
are open.
If the output stays at a low value even when disconnecting the wire from the connector pin, the
problem is in the traction controller.
230 Failure in motor control (Alarm) Stored

LOW TORQUE
This alarm indicates a failure in the motor control.

If this alarm occurs often, some of the hardware settings are probably not correct. Also check
the motor connections.
231 WATCHDOG#2 (Alarm)

WATCHDOG#2
This is a safety related, self-diagnosis test within the logic. The watchdog circuit is composed of
two monostable multivibrators, so there is a double-check of the software execution.
This alarm can be caused by a hardware failure in one or both of the multivibrators or it can be
due to a software execution problem. In both cases, the problem is in the traction controller,
which must be replaced.
232 Auxiliary output load too high (Alarm)

CONT. DRV. EV
This alarm is displayed if the hydraulic valve coil load is too high for the controller valve driver
circuit.
• Hydraulic valve coil condition
• Wiring
If the device or its driving circuit is damaged, replace the controller.
233 Power MOSFET error in controller (Alarm) Stored

POWER MOS SHORT
Before switching the main contactor on, the software checks the power bridge. It turns the low
and high side power MOSFETs on one by one and expects the phase voltage to decrease
down to –Batt. If the phase voltage does not decrease, this alarm occurs.
controller.
234 Electrovalve driver is shorted (Alarm) Stored

DRV. SHOR. EV
This alarm is displayed if the solenoid valve EVXX (XX = 01, 02 or 03) driver is shorted.
Check if there is a short or low impedance between the negative of one of the coils and –Batt.
If not, the driver circuit is damaged and the controller must be replaced.
NSP Service Manual
235 Electrovalve coil is shorted (Warning) Stored

COIL SHOR. EV.
This warning is displayed if one of the solenoid valve’s EV (XY1 or XY2) coils is shorted.
Check if there is a short or low impedance between the negative of the EV coil and +Batt. If
not, the controller is damaged and must be replaced.
236 Error in controller initialization at (Alarm) Stored

manufacturer
CURRENT GAIN
This alarm indicates that the maximum current gain parameters are at their default values,
meaning that the maximum current procedure has not been carried out.
controller.
237 Error in analog input values (Alarm) Stored

ANALOG INPUT
This alarm occurs when the conversion of the analogue inputs provides frozen values.
If the alarm occurs permanently, replace the traction controller.
238 TILLER ERROR (Alarm)

TILLER ERROR
This alarm indicates that there is a mismatch between the H&S input and the tiller input.
In such a case, check the harness related to CAN#1 and CAN#29 with a voltmeter. If the state
of these inputs is OK, the problem is in the traction controller, which must be replaced.
239 Software not compatible with controller (Alarm) Stored

CONTROLLER MISM.
This alarm indicates that the software is not compatible with the controller.
In case of this alarm, flash new software to the controller. If the alarm occurs permanently
replace the traction controller.
240 Error in lowering valve coil or driver (Alarm) Stored

EVP DRIVER OPEN
This alarm is displayed if the solenoid valve driver is damaged or the solenoid valve coil
impedance is too low.
• Solenoid valve coil impedance
• Wiring
If the solenoid valve driver circuit is damaged, replace the controller.
NSP Service Manual
241 Lift and lower demands active (Warning)

simultaneously
LIFT + LOWER
This alarm occurs when lifting and lowering demands are active at the same time.
Use a tester to check the possible reasons for this alarm. If both demands are active at the
same time, check the switches and wiring.
If no lifting and lowering signals are active at the same time outside the controller, the problem
is in the traction controller.
242 Incorrect pump starting sequence (Warning)

PUMP INC START
This warning indicates an incorrect pump starting sequence.

The possible reasons for this alarm are the following:
• Pump request is active at startup.
• Pump request is active but the tiller arm is not in the driving position.
In the case of this alarm, check the following:
• Wirings
• Microswitches
• The alarm may also be caused by an error sequence made by the operator.
If the wiring and microswitches are OK and the alarm was not caused by an operator error,
replace the traction controller.
243 Error in pump command value range (Alarm)

PUMP VACC RANGE
This alarm indicates that the lift lever voltage is out of range.
• Teach the lift lever values again.
• Check that the connectors and cables are in order.
• Replace the lift lever and teach the new values.
245 Error in the pump command value (Alarm)

PUMP VACC NOT OK
This alarm occurs when the lift lever output voltage differs from the values acquired at
calibration.
In such a case, check the functionality of the lift lever. Perform the lift lever calibration wizard
function.
246 Error in magnetic brake driver error (Alarm) Stored

AUX DRIV. OPEN
This alarm indicates that the driver of the electromagnetic brake coil is not able to drive the
load.
The driver inside the traction controller is damaged, so the controller has to be replaced.
NSP Service Manual
247 Acquisition of gain values (Warning)

DATA ACQUISITION
This warning indicates acquisition of the current gains.

The warning disappears when the acquisition is done. This alarm is a part of normal operation
of the controller.
248 Curtis display not present (Alarm) Stored

NO CAN MSG.
This alarm is displayed where there is no CAN message from the Curtis display.
This alarm can be caused by a CAN bus malfunction, which blinds the traction-display
communication. If not, it is an internal problem in the traction controller or in the Curtis display.
249 Call for programmed maintenance (Warning)

CHECK UP NEEDED
This is a warning calling for programmed maintenance.

Set the CHECK UP DONE parameter to the ON value after the maintenance is carried out.
250 Controller thermal sensor failure (Warning) Stored

THERMIC SENS. KO
This warning indicates that the output of the controller thermal sensor is out of range.
controller.
251 Incorrect battery voltage (Alarm) Stored

WRONG BATTERY
At startup, the controller checks the battery voltage and verifies that it is within a certain
window around the nominal value. If this is not the case, this alarm is displayed.
In such a case, do the following:
• Check that the controller’s SET BATTERY parameter value matches the battery nominal
voltage.
• Check from the tester menu that the BATTERY VOLTAGE parameter shows the same
value as the battery voltage measured with a voltmeter. If it does not match, perform the
ADJUST BATTERY function.
• Replace the battery.
When adjusting the battery voltage, voltage should be measured from the key line, after the
reverse polarity protection diode. A good measuring point is, for example, the emergency stop
button terminal. If the battery voltage is measured anywhere else, it will cause invalid operation
of the battery discharge indicator.
NSP Service Manual
252 Traction motor feedback amplifier (Alarm) Stored

failure
WRONG ZERO
The outputs of the amplifiers (used to measure the traction motor voltage) are checked to be
within a certain range. This alarm occurs when the voltage signals exceed 3 V or fall below 2 V
at the startup.
controller.
253 Error in motor control parameters (Alarm) Stored

SLIP_PROFILE
This alarm indicates that there is an error in the chosen slip profile parameters.
Check the value of those parameters in the HARDWARE SETTING menu.
254 Magnetic brake driver is shorted (Alarm) Stored

AUX DRIV.SHRT.
This alarm indicates that the driver of the magnetic brake is shorted.
Check if there is a shortcut between XA1 A/4 and –Batt. Otherwise, the driver in the traction
controller is damaged and the controller has to be replaced.

13 Alarm Codes: Traction Controller

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13 Alarm Codes: Traction Controller

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NSP Service Manual

13.1 Traction controller

Table 14. Traction controller alarm codes

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

8 Self diagnosis test failed (Alarm) Stored

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

13 Controller memory error (Warning) Stored

17 Hardware high current protection failure (Alarm) Stored

18 Motor voltage feedback circuit damaged (Alarm) Stored

19 Over or under voltage detected (Alarm) Stored

If fault is displayed during motor driving, it is due to an undervoltage or an overvoltage

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

28 Pump motor output voltage error (low) (Alarm) Stored

Cause 1: Startup test

29 Pump motor output voltage error (high) (Alarm) Stored

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

30 Traction motor output voltage error (Alarm) Stored

Cause 1: Startup test

31 Traction motor output voltage error (Alarm) Stored

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

37 Contactor is stuck closed (Alarm) Stored

38 Contactor does not close circuit (Alarm) Stored

52 Pump current 0A while pump running (Warning) Stored

53 Controller current sensor failure (Alarm) Stored

60 Power capacitor charging error (Alarm) Stored

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

62 Controller has overheated (Warning) Stored

65 Traction motor has overheated (Warning) Stored

66 Battery charge lower than 10% (Warning) Stored

74 Contactor driver circuit error (Alarm) Stored

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

75 Contactor driver damaged (Alarm) Stored

78 Accelerator voltage not OK (Alarm) Stored

79 Invalid starting sequence (Warning)

This warning occurs because of an incorrect starting sequence.

80 Direction switches active (Warning)

82 Encoder error (Alarm) Stored

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

86 PEDAL WIRE KO (Alarm) Stored

185 Height sensor mismatch (Alarm) Stored

186 Motor temperature notification (Warning)

187 Controller temperature notification (Warning)

188 Load sensor value is out of range (Warning) Stored

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

189 Battery lock not closed (Alarm)

This alarm indicates that the battery lock is not closed.

190 Motor braking error (Alarm) Stored

192 Waiting for EPS (Alarm) Stored

193 Sideguard inputs illegal state (Alarm)

This alarm is caused by an invalid combination of side guard inputs.

194 Platform inputs illegal state (Alarm) Stored

This alarm is caused by an invalid combination of operator’s platform inputs.

195 Platform inputs inactive (Warning)

196 Invalid motor resistance (Alarm) Stored

CODE TRUCKTOOL AND DISPLAY DESCRIPTION

197 Motor resistance acquiring failed (Alarm) Stored

198 Sensorless feedback hardware error (Alarm) Stored

199 PIN teach mode (Warning)

200 Waiting for valid PIN code (Warning)