1

DIAGNOSTICS AND MEASUREMENTS

Diagnostics anD measurements

DescriPtion moDuLe connectors 2

ace2 traction moDuLe 2

ACE2 PUMP MODULE 3

EPs ACw MODULE 4

MAsTER CONTROL CARD PREMIUM MODULE 5

tester menu 7

ACE2 TRACTION MODULE 7

ACE2 PUMP MODULE 7

EPs ACw MODULE 7

VCM MODULE 8

BreaKDoWn searcH 12

wARNING MEMORIZATION 12

ace2 PumP anD traction moDuLe Diagnosis sYstem 13

ACE2 PUMP AND TRACTION MODULE ALARMs 13

PUMP AND TRACTION ACE2 MODULE ALARM ANALYsIs AND TROUBLEsHOOTING 22

Diagnosis sYstem For Vcm moDuLe 33

Vcm - master moDuLe aLarm anaLYsis anD trouBLesHooting 33

Vcm - sLaVe moDuLe aLarm anaLYsis anD trouBLesHooting 38

ePs acW moDuLe Diagnosis sYstem 42

ePs acW moDuLe aLarm anaLYsis anD trouBLesHooting 42

SERVICE

2

DIAGNOSTICS AND MEASUREMENTS

DescriPtion moDuLe connectorsace2 traction moDuLe

A1 + 48V logic power supply A2 + 5V auxiliary power supply for Hall effect sensorsA3 Input of accelerator sensor output 1A4 Drive selector (analogue forward/reverse) (digital forward)A5 Reverse drive selectorA6 Input of service brake sensor output 2A7 Input CH A motor encoder A8 + 12V power supply for motor encoderA9 Horn negativeA10 Input of service brake sensor output 1A11 CAN communication line 2A12 CAN communication line 2A13 Input of accelerator sensor output 1A14 Input CH B motor encoder A15 - Batt auxiliary power supply for Hall effect sensors and encoderA16 Traction main contactor negativeA17 + 48V power supply for main contactor, electromagnetic brake, hornA18 Electromagnetic brake negativeA19 Man on board sensor output 1A20 CAN communication line 1A21 CAN communication line 1A22 Engine temperature sensor inputA23 - Batt engine temperature sensor

a

SERVICE

3

DIAGNOSTICS AND MEASUREMENTS

ace2 PumP moDuLe

A1 + 48V logic power supply A2 + 5V auxiliary power supply for Hall effect sensorsA3 Not used A4 Not usedA5 Not usedA6 Not used A7 Input CH A motor encoder A8 + 12V power supply for motor encoderA9 Flasher negativeA10 Not usedA11 CAN communication line 2A12 CAN communication line 2A13 Not usedA14 Input CH B motor encoder A15 - Batt auxiliary power supply for Hall effect sensors and encoderA16 Pump main contactor negativeA17 +48Vpowersupplyformaincontactor,flasher,fanA18 Fan negativeA19 Not usedA20 CAN communication line 1A21 CAN communication line 1A22 Engine temperature sensor inputA23 - Batt engine temperature sensor

a

SERVICE

4

DIAGNOSTICS AND MEASUREMENTS

ePs acW moDuLe

A1 CAN communication line 2A2 CAN communication line 2A3 Power supply positiveA4 Power supply positiveA5 Power supply positiveA6 Power supply negativeA7 Power supply negativeA8 Power supply negativeA9 Fan positive (+48V)A10 Fan negative A11 sensor with driving wheel at 90A12 sensor with driving wheel at 0 straight A13 Auxiliary power supply negativeA14 Not usedA15 + 48V logic power supply A16 stepper motor DL line power supply negativeA17 stepper motor QL line inputA18 Auxiliary power supply positive A19 stepper motor QL line power supply negativeA20 stepper motor DL line inputA21 Auxiliary power supply positive A22 CAN communication line 1A23 CAN communication line 1

a

SERVICE

5

DIAGNOSTICS AND MEASUREMENTS

master controL carD Premium moDuLe

A1 + 48V output power supply A2 Negative of proportional valve for carriage forward (PwM) Current controlledA3 Negative of proportional valve for carriage backward (PwM) Current controlledA4 Negative of diverter valve for Tilt or side shift (PwM) Current controlledA5 Negative of diverter valve for 5th way (PwM) Current controlledA6 Negative of electromagnet for battery block release (PwM) Current controlledA7 Negative of reverse drive buzzer (PwM) Current controlledA8 seat microswitchA9 Man on board sensor output 2A10 Traction speed reduction buttonA11 CAN communication line 1A12 CAN communication line 1A13 + 48V auxiliary power supplyA14 + 48V auxiliary power supplyA15 + 48V auxiliary power supplyA16 + 48V auxiliary power supplyA17 + 48V auxiliary power supplyA18 sensor 1 battery out Normally openA19 sensor 2 battery out Normally closedA20 seat belt microswitch A21 steering mode selection button 180- 360A22 - Batt auxiliary power supply A23 Carriage position potentiometer inputA24 Negative of lowering proportional valve (PwM) Current controlledA25 Negative of lifting proportional valve (PwM) Current controlledA26 Negative of proportional valve right hydraulic function (PwM) Current controlledA27 Negative of proportional valve left hydraulic function (PwM) Current controlled

aB

SERVICE

6

DIAGNOSTICS AND MEASUREMENTS

A28 + 48V logic power supply A29 - Batt logic power supplyA30 CAN communication line 2A31 CAN communication line 2A32 Not usedA33 + 12V auxiliary power supply A34 + 5V auxiliary power supply A35 Not used

B1 side shift position sensorB2 Not usedB3 Tilt position inclinometer inputB4 Encoder reset sensor input B5 Not usedB6 Pressure transducer sensor inputB7 + 48V output power supply B8 + 48V auxiliary power supplyB9 Main lifting cylinder position potentiometer transducer inputB10 Main lifting cylinder position potentiometer transducer inputB11 Load cell inputB12 Not usedB13 weighing buttonB14 Lifting by-pass button B15 Negative of pallet recognition laser (PwM) Current controlledB16 + 5V auxiliary power supply B17 Free lifting cylinder position potentiometer transducer inputB18 Free lifting cylinder position potentiometer transducer inputB19 - Batt auxiliary power supply B20 - Batt auxiliary power supply B21 Pallet presence sensorB22 Not usedB23 Negative of load wheel brakes (PwM 4A) Current controlled

SERVICE

7

DIAGNOSTICS AND MEASUREMENTS

ace2 traction moDuLe

tester menuThe main input and output signals can be measured in real time using the TEsTER function of the pro-grammer The programmer acts as a multimeter capable of reading voltage, current and temperature Certain of these menu parameters refer to functions whose status is received via Can bus, others refer to functions directly connected to the analog/digital inputs of the module The following list shows the relative measurements:

MAIN TEsTER MENU

Parameter measurement unit

BatterY VoLtage Volt

Battery voltage measured on the key input

ace2 PumP moDuLe

MAIN TEsTER MENU

Parameter measurement unit

BatterY VoLtage Volt

Battery voltage measured on the key input

ePs acW moDuLe

MAIN TEsTER MENU

Parameter measurement unit

BatterY VoLtage Volt

Battery voltage measured on the key input

SERVICE

8

DIAGNOSTICS AND MEASUREMENTS

Vcm moDuLe

MAIN TEsTER MENU

Parameter measurement unit

WorKing Hours Hours

Indicates the truck's working hours according to the setting of the HOUR COUNTER option

ForK HeigHt mm

Indicates the fork height off the ground in real time if the HEIGHT INDICATOR option is activated

BatterY VoLtage V

Value of the voltage to 1 decimal place Level of battery voltage measured at key-switch on

BatterY cHarge %

Percentage value Provides the battery's residual charge as a percentage of the level of the complete charge

steer angLe degrees

Value in degrees Indicates the current steering angle

rtc Hour hours

Hour of the Real Time Clock

rtc minutes minutes

Minutes of the Real Time Clock

LiFt/LoW Pot %

Percentage value Level of the LIFT/LOwER control

reacH Pot %

Percentage value Level of the REACH control

tiLt Pot %

Percentage value Level of the TILT control

siDe sHiFt Pot %

Percentage value Level of the sHIFT control

autocssHiFt sW %

ON/OFF Level of the self-centring side shift button

autoctiLt sW %

ON/OFF Level of the self-centring side shift button

5 WaY sWitcH

ON/OFF Level of the hydraulic 5th way button

JoY Horn sW

ON/OFF Level of the horn button

SERVICE

9

DIAGNOSTICS AND MEASUREMENTS

Parameter measurement unit

PaLLet sWitcH

ON/OFF Level of the Pallet button

seatBeLt sWitcH

ON/OFF Level of the seat belt button

seat sWitcH

ON/OFF Level of the seat button

BatterY out sW1

ON/OFF Level of the Battery 1 disconnected sensor

BatterY out sW2

ON/OFF Level of the Battery 2 disconnected sensor

ssHiFt Pos sW %

ON/OFF Level of the side shift position sensor

tiLt Pos sW %

ON/OFF Level of the tilt position sensor

reacH an i sensor mV

Value in volts Level of the analog input A23 (truck potentiometer position)

outPut grouP #1 %

Value % Percentage of the maximum current applied on output unit #1 (EVP1 and EVP2 lifting/lowering)

outPut grouP #2 %

Value % Percentage of the maximum current applied on output unit #2 (EVP3 and EVP4 retractable carriage backward / forward)

outPut grouP #3 %

Value % Percentage of the maximum current applied on output unit #3 (EVP5 and EVP6 tilt down/left side shift - tilt up/right side shift)

outPut grouP #4 %

Value % Percentage of the maximum current applied on output unit #4 (EVP7 and EVP8 tilt / side shift valve sen-sor - 5th way valve sensor)

neVP9 outPut %

Value % Percentage of the maximum current applied on EVP9 (wheel brakes charge)

neV3 outPut %

Value % Percentage of battery voltage applied on EV3 (Laser)

neV2 outPut %

Value % Percentage of battery voltage applied on EV2 (Back-up alarm)

SERVICE

10

DIAGNOSTICS AND MEASUREMENTS

Parameter measurement unit

neV1 outPut %

Value % Percentage of battery voltage applied on EV1 (not used)

reset encoDer #1

ON/OFF Encoder reset sensor level

encoDer #1 pulses

Number of pulses ready by encoder 1

encoDer #2 pulses

Number of pulses ready by encoder 2

rPm PumP Hz

Value in Hz Pump motor speed

DigitaL inPut #1

ON/OFF A8 digital input level

DigitaL inPut #2

ON/OFF A9 digital input level

DigitaL inPut #3

ON/OFF A10 digital input level

DigitaL inPut #4

ON/OFF A18 digital input level

DigitaL inPut #5

ON/OFF A19 digital input level

DigitaL inPut #6

ON/OFF A20 digital input level

DigitaL inPut #7

ON/OFF A21 digital input level

DigitaL inPut #8

ON/OFF B13 digital input level

DigitaL inPut #9

ON/OFF B14 digital input level

Dig inPut #10

ON/OFF B21 digital input level

Dig inPut #11

ON/OFF B22 digital input level

SERVICE

11

DIAGNOSTICS AND MEASUREMENTS

Parameter measurement unit

anaLog inPut #1 mV

Value in volts Level of the analog input A23 (truck potentiometer position)

anaLog inPut #2 mV

Value in volts Level of the analog input A35 (not used)

anaLog inPut #3 mV

Value in volts Level of the analog input B1 (side shift position)

anaLog inPut #4 mV

Value in volts Level of the analog input B2 (not used)

anaLog inPut #5 mV

Value in volts Level of the analog input B3 (tilt position)

anaLog inPut #6 mV

Value in volts Level of the analog input B4 (encoder reset)

anaLog inPut #7 mV

Value in volts Level of the analog input B5 (not used)

anaLog inPut #8 mV

Value in volts Level of the analog input B6 (transducer pressure)

anaLog inPut #9 mV

Value in volts Level of the analog input B11 (load cell)

anaLog inPut #10 mV

Value in volts Level of the analog input B12 (not used)

SERVICE

12

DIAGNOSTICS AND MEASUREMENTS

BreaKDoWn searcHWarning memoriZation

Enter the main menu 1 /alarms on the display to visualize the last 20 warnings memorized and the infor-mation relative to the total number of hours worked by the module, the number of times the warning has beenactivatedandthenumberthatidentifiesthemodule.

MODULE 2: ACE2 Traction MODULE 6: EPs ACwMODULE 5: ACE2 Pump MODULE 1: VCM

SERVICE