Esr 5000

ELECTRICAL SYSTEM
EVENT CODES 100 - 186
Event Codes 100 - 186

Event Code 100
Display: OVER CURRENT SCM
Explanation: Current in power part of steer module (SCM) > 40 A.
Effect: • Parking brake applied
• Traction module deactivated
• Main contactor ED1 de-energised
Possible Causes: • Error in internal power circuit of steer module
Remedy: Restart
1. Restart the truck.
If the fault persists, proceed to step 2.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu (Software V1.0),
page 240). If the event occurs frequently, contact the Crown service depart-
ment.
Replacing the steer module
2. Replace the steer module (see page 326).
Event Code 101

Display: HIGH CURRENT SCM
Explanation: Current in power part of steer module (SCM) > 27 A and < 40 A.
Possible Causes: • Error in internal power circuit of steer module
Remedy: Restart
If the fault persists, proceed to step 2.
ment.
Replacing the steer module
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ELECTRICAL SYSTEM
Event Code 102

Display: ERROR STEER MOT.
Explanation: Open or shorted steer motor power circuit.
Effect: • Parking brake applied.
Possible Causes: • Open circuit in or short circuit between phases R, S or T
Remedy: 1. Check power cables and connections.
2. Assess motor. Replace if faulty.
Event Code 110

Display: HIGH VOLTAGE SCM
Explanation: Overvoltage (> 63 V) in steer module power circuit.
• Traction and hydraulic modules deactivated
Possible Causes: • Emergency Disconnect pressed during plugging operation
• Error in steer module
Remedy: Note: If no cause can be found and the truck works correctly after restarting,
ment.
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242
ELECTRICAL SYSTEM
Event Code 111

Display: LOW VOLTAGE SCM
Explanation: Low voltage (< 24 V) in steer module power circuit.
Possible Causes: • Emergency Disconnect pressed during plugging operation
• Error in steer module
Remedy: Check power cables
1. Check power cables.
If there is no damage, proceed to step 2.
Check battery voltage with load
2. In the Analyzer menu select item A2.36.
3. Raise a heavy load and monitor the battery voltage during the lifting
operation.
If the battery voltage drops significantly, proceed to step 4.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu (Software V1.0), page 157). If the event occurs frequently,
contact the Crown service department.
Repair the battery
4. Repair the battery in accordance with the manufacturer's instructions or
replace it.
Event Code 112

Display: 15 VOLT SUPPLY SCM
Explanation: • 15 V supply in the steer module faulty
Possible Causes: • Error in steer module
Remedy: 1. Replace the steer module.
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243
ELECTRICAL SYSTEM
Event Code 120

Display: OVER TEMP SCM
Explanation: Steer module overtemperature (t > 85 °C).
Possible Causes: • Steer module ventilation affected by:
– Excessive ambient temperature
– Overload
– Contamination
• Malfunction in power part of steer module
Remedy: Check application conditions and check for contamination
1. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
2. Check the steer module for contamination.
Clean the steer module if contaminated.
Check the current consumption
3. Select item A2.32 in the Analyzer menu and check the steer motor con-
sumption when stationary and for slow steer operations.
If the consumption is consistently > 18 A there may be a mechanical
problem with the gear unit of the steer motor or with the drive transmis-
sion.
4. Jack up the truck and check the steer motor consumption again.
If the consumption is consistently > 6 A there may be a mechanical
problem with the gear unit of the steer motor or with the steering head
bearing.
Check for mechanical sluggishness
5. Check the steer motor transmission and steering head bearing for me-
chanical sluggishness.
If one of these is sluggish, replace or repair the respective part.
Check the steer motor and steer module
6. Check the current consumption with the steer motor and steering bearing
head installed.
If the consumption is still too high with the steer motor and steering
bearing head installed, the steer motor or steer module may be faulty.
Proceed to step 9.
Replace the steer module (SCM)
8. Check the current consumption with the steer motor and steering bearing
head installed.
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ELECTRICAL SYSTEM
Replace the steer motor

9. Replace the steer motor.
10. Check the current consumption with the steer motor installed.
If the consumption is still too high with the steer motor installed, the
steer module may be faulty. Proceed to step 7.
If the consumption is still too high, contact the Crown service department.
Event Code 121

Display: HIGH TEMP SCM
Explanation: Steer module internal temperature is > 75 °C.
Effect: • The display shows: HIGHTEMP STEERING MOTOR
Possible Causes: See event code 120, page 241.
Remedy: See event code 120, page 241.
Event Code 123

Display: OVER TEMP SMOT
Explanation: Steer motor coil temperature is > 150 °C.
Event Code 124

Display: OVER TEMP SMOT
Explanation: Steer motor overtemperature (t > 125 °C).
Effect: The display shows: HIGHTEMP STEERING MOTOR
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ELECTRICAL SYSTEM
Event Code 130

Display: ERROR CANBUS SCM
Explanation: Communication error on the CAN Bus between the main module (VCM) and
the steer module (SCM).
Effect: • Main contactor ED1 de-energised
Possible Causes: • Wiring error
• Error in main module (VCM)
• Error in steer module (SCM)
Remedy: Measure the load resistance of the CAN Bus wiring between the main
module and the steer module
1. Measure the resistance between PC416-1 and -2.
If the resistance is 60 , the main and steer modules are ok.
If the resistance is 120 , then either the main module or steer module
is faulty. Proceed to step 2.
Measure the load resistance in the main module (VCM)
2. Disconnect PC205 from the main module.
3. Measure the resistance on the main module between PC205-22 and -23.
If the resistance is 120 , the main module is ok. Proceed to step 5:
If a different reading is obtained, the main module is faulty.
4. Replace the main module.
Measure the load resistance in the steer module (SCM)
5. Disconnect PC204 from the steer module.
6. Measure the resistance on the steer module between PC205-10 and -11.
If the resistance is 120 , the steer module is ok.
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ELECTRICAL SYSTEM
Event Code 131

Display: ERROR EEPROM SCM
Explanation: Malfunction in memory module of steer module.
Effect: • No direct effect
Possible Causes: • Error in steer module
Remedy: Restart
If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu (Software V1.0), page 240). If the event occurs fre-
quently, contact the Crown service department.
If the truck does not work, proceed to step 2.
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ELECTRICAL SYSTEM
Event Code 160

Display: BRAKE COIL
Explanation: Open circuit or excessive current on steer module output to parking brake.
Effect: • Truck comes to rest through plugging.
Possible Causes: • Fuse FU3 faulty
• Wiring or connector damaged
• Brake coil faulty
Remedy: Check fuse FU3
1. Check fuse FU3.
Replace if faulty. If the fuse is ok, proceed to step 2.
Check wires and connections
2. Check wires and connections for discontinuity and short circuits.
Measure the brake coil resistance
3. Using an ohmmeter measure the brake coil resistance.
Rated resistance approx. 32 (Crown motor) or 46.6 (Danaher mo-
tor). If the reading differs significantly, the brake coil is faulty. Proceed
to step 4.
Replace the brake coil
4. Replace the brake coil (see page 384).
Note: A truck with a faulty parking brake can be driven out of the aisle at creep
speed (see U3 Brake Override, page 170).
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ELECTRICAL SYSTEM
Event Code 180

Display: ECR3 HALL SENSOR
Explanation: Error in encoder ECR3 of steer motor.
ECR3 is a 2-channel Hall sensor fitted in the steer motor. This event code is
generated if a channel is not correctly identified or if 2 channels are shorted.
Possible Causes: • Wiring or connectors damaged
• +5 V supply
Remedy: Check wires and connections
+5 V supply
2. Disconnect PC414.
3. Using a voltmeter measure the voltage between PC414-5 and -6 and be-
tween PC414-7 and -8.
If there is a +5 V supply, proceed to step 4.
If there is no +5 V supply, proceed to step 6.
4. Reconnect PC414.
5. Using a voltmeter measure the voltage between PC436-1 and -2.
If there is no +5 V supply, this indicates that a wire has been discon-
nected. Proceed to step 8.
Replace steer module
Replace steer motor
Repair wiring
8. Repair the wiring.
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ELECTRICAL SYSTEM
Event Code 181

Display: ECR4 STEPPER MOTOR
Explanation: Error in steer encoder ECR4 (fitted on steering wheel).
ECR4 is a 4-channel Hall sensor fitted in the steer motor. This event code is
generated if a channel is not correctly identified or if 2 channels are shorted.
Possible Causes: • Wiring or connectors damaged
• +5 V supply
Remedy: Check wiring
9. Check the wiring between PC414 and CA204 for discontinuity and short
circuits.
If the wiring is faulty, proceed to step .12.
If the wiring is ok, proceed to step 10.
+5 V supply
11. Using a voltmeter measure the voltage between PC414-5 and -6 and be-
tween PC414-7 and -8.
If there is no 5 V supply, proceed to step 13.
Repair wiring
+5 V output on the steer module
13. Disconnect CA204 from the steer module.
14. Measure the voltage between CA204-3 and -4.
If there is no 5 V supply, proceed to step 15
Replace the steer module
Replace sensor bearing ECR4
16. Replace sensor bearing ECR4.
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ELECTRICAL SYSTEM
Event Code 182

Display: SW1 OR 2 SW ERROR
Explanation: Switch signal of sensor switch SFS1 SA or SFS2 not detected.
The expected signal change did not occur when the drive wheel was turned.
Effect: • An error routine is started (see page 397).
Possible Causes: • Wiring or connector damaged
• Incorrect screw depth of sensor SFS1 SA or SFS2
• Sensor SFS1 SA or SFS2 faulty
• 12 V supply in display faulty
12 V sensor supply
2. Using a voltmeter measure the voltage (rated +12 V DC) at the following
points:
– between CA203-14 and CA203-15 (with display connected)
– between PC439-A and PC439-B
– between PC438-1 and PC438-2
If there is no voltage present at PC439, but there is at CA203, check the
wires for discontinuity.
If there is a +12 V DC supply present on both connectors, proceed to
step 3.
Check sensor SFS1 SA
3. Set the drive wheel to the forward position.
4. Monitor the sensor LED while moving the drive wheel 20° to the left and to
the right. When moved to the left the LED should remain off and when
steered to the right it should be on.
If there is no change, the sensor may be loose or require adjusting:
check the attachment and screw depth (see page 400).
5. If the attachment and screw depth are ok, remove the sensor and hold the
front against a metal surface.
If the LED does not light up, replace the sensor (see page 400).
Replace the display
6. Replace the display (see page 326).
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ELECTRICAL SYSTEM
Event Code 183

Display: SFS2 SW EXPECTED
Explanation: Switch signal of sensor switch SFS2 not detected.
Quadrant recognition error.
Effect: • An error routine is started (see page 397)
• Screw depth of sensor SFS2 incorrectly set
• Sensor SFS2 faulty
12 V sensor supply
2. Using a voltmeter measure the voltage between CA203-14 and CA203-15
(on the display) and between PC438-1 and PC438-2: Rated
voltage +12 V DC.
If there is no voltage at CA203, proceed to step 8.
If there is no voltage present at PC438, but there is at CA203, proceed
to step 9.
step 3.
Check sensor SFS2
4. Monitor the sensor LED while moving the drive wheel more than 90° to the
right. When the wheel passes beyond 90° the LED should go out.
If there is no change, the sensor may be loose or require adjusting.
Proceed to step 5.
If the attachment and screw depth are ok, proceed to step 6.
Check the SFS2 attachment and screw depth
5. Check the attachment and screw depth (see page 400).
Test SFS2
6. Remove the sensor and connect it again.
7. Hold the front of the sensor against a metal surface.
Replace the display
Check wiring
9. . Check the wires for discontinuity.
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ELECTRICAL SYSTEM
Event Code 184

Display: START ERROR SCM
Explanation: Incorrect drive wheel position detected. The stored drive wheel position does
not match the current position.
Effect: • An error routine is started (see page 397)
• Screw depth of sensor SFS1 SA incorrectly set
• Sensor SFS1 SA faulty
12 V sensor supply
2. Using a voltmeter measure the voltage between CA203-14 and CA203-15
(on the display) and between PC439-A and PC439-B: Rated
voltage: +12 V DC.
If there is no voltage supply at CA203, replace the display.
If there is no voltage present at PC439, but there is at CA203, check the
wires for discontinuity.
step 3.
Check sensor SFS1 SA
4. Monitor the sensor LED while moving the drive wheel 20° to the left and to
the right. When moved to the left the LED should remain off and when
steered to the right it should be on.
If there is no change, the sensor may be loose or require adjusting:
check the attachment and screw depth (see page 400).
5. If the attachment and screw depth are ok, remove the sensor and hold the
front against a metal surface.
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ELECTRICAL SYSTEM
Event Code 186

Display: TEMP. SENSOR SMOT
Explanation: Short circuit or open circuit in control circuit of steer motor thermal sensor
THS3.
Effect: • Mast reach and lowering only
• Travel only at creep speed
• Thermal sensor faulty
1. Check wires and connections (PC436) for discontinuity and short circuits.
Measure the thermal sensor resistance
3. Using an ohmmeter measure the resistance between PC436-4 and
PC436-5. Rated resistance at t =20 °C: 570 (PTC resistance, the resist-
ance increases as the temperature rises)
If the resistance < 500 or > 1 k , replace the steer motor.
If the resistance > 500 and < 1 k , proceed to step 4.
Replace the steer module (SCM).
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ELECTRICAL SYSTEM
Event Code 200

Display: HIGH CURRENT HM
Explanation: Current in power part of hydraulic module is too high (> 787 A).
Possible causes: • Short circuit in following components:
– Power cable to pump motor
– Pump motor coil
– Hydraulic module output stage
• Hydraulic pump blocked
1. Check wires for short circuits.
Measure the pump motor insulation resistance
2. Power down the truck.
3. Check the motor coil insulation resistance.
If a coil fails, proceed to step 4.
If the coils are ok, proceed to step 5.
Replace the pump motor
4. Replace the pump motor (see page 402).
Check the hydraulic pump for blockage
5. Remove the pump motor and check the pump for freedom of movement.
If the pump moves freely, proceed to step 6.
Replace the hydraulic module
6. Replace the hydraulic module (see page 326).
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ELECTRICAL SYSTEM
Event Code 201

Display: SHORT CIRCUIT HM
Explanation: Short circuit in power circuit of hydraulic module.
Effect: • Traction and hydraulic modules deactivated
• Parking brake applied
Possible causes: • Short circuit in following components:
– Power cable to pump motor
– Pump motor coil
– Hydraulic module output stage
Remedy: Measure the pump motor insulation resistance
If the motor coils are ok, proceed to step 4.
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ELECTRICAL SYSTEM
Event Code 210

Display: HIGH VOLTAGE HM
Explanation: Overvoltage in hydraulic module power circuit(> 63 V).
Possible causes: • Emergency Disconnect pressed during plugging operation
• Hydraulic module error
Remedy: Rule out operator errors
1. Ask the operator if the Emergency Disconnect has been applied during a
plugging operation.
If the Emergency Disconnect was not pressed during a plugging oper-
ation, proceed to step 2.
Event Code 211

Display: LOW VOLTAGE HM
Explanation: Overvoltage in hydraulic module power circuit (V < 18 V).
Possible causes: • Wiring error
• Faulty battery
• Hydraulic module error
Remedy: Check power cables
1. Check power cables.
Check battery voltage with load
2. In the Analyzer menu select item A2.36.
3. Raise a heavy load and monitor the battery voltage during the lifting
operation.
If the battery voltage drops significantly, proceed to step 4.
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ELECTRICAL SYSTEM
Repair the battery

4. Repair the battery in accordance with the manufacturer's instructions or
replace it.
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ELECTRICAL SYSTEM
Event Code 212

Display: 15 VOLT SUPPLY HM
Explanation: Internal 15 V hydraulic module supply faulty.
Possible causes: • Hydraulic module error
Remedy: Replace the hydraulic module
1. Replace the hydraulic module (see page 326)
Event Code 213

Display: 5 VOLT SUPPLY HM
Explanation: Internal 5 V hydraulic module supply faulty.
Effect: • Hydraulic module is deactivated
• Travel at creep speed enabled
Possible causes: • Hydraulic module error
1. Replace the hydraulic module (see page 326)
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ELECTRICAL SYSTEM
Event Code 214

Display: CAP CHARGE HM
Explanation: Capacitor charge time exceeded.
Effect: • Main contactor ED1 does not close
Possible causes: • Wiring error
• No B+ supply to hydraulic module
• Hydraulic module faulty
Remedy: Check fuse FU7
1. Check fuse FU7.
Is FU7 has blown, proceed to step 6.
Is FU7 is ok, proceed to step 2.
Check wires (B+, B–) and connections
2. Check wires for discontinuity and ensure connections are secure.
If there is damage, proceed to step 7.
Check B+ supply to hydraulic module
4. Connect voltmeter to B+ and B- of the hydraulic module.
5. Power up the truck.
The voltage should rise from 0 V on B+ within 2 seconds. If not, proceed
to step 8.
Replace fuse FU7
6. Replace fuse FU7.
7. Repair wiring or connections.
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ELECTRICAL SYSTEM
Event Code 220

Display: OVER TEMP. HM
Explanation: Hydraulic module overtemperature (t > 115 °C)
• The display shows: HIGH TEMP. HM
Possible causes: • Hydraulic module ventilation affected by:
– Overload
– Contamination
• Malfunction in power part of hydraulic module
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 169).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replacing the fan
2. Replace the fans.
Clean contaminated hydraulic module and air supplies
3. Clean the hydraulic module and air supplies if contaminated.
If the hydraulic module and air supplies are clean, proceed to step 4.
Check the application conditions
load.
See Performance Menu (Software V1.0), page 159.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
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ELECTRICAL SYSTEM
Event Code 221

Display: OVER TEMP. HMOT
Explanation: Hydraulic motor coil overtemperature (t > 165 °C)
– Overload
– Contamination
Replacing the fan
Clean contaminated hydraulic motor and air supplies
3. Clean the hydraulic motor and air supplies.
If the hydraulic motor and air supplies are clean, proceed to step 4.
load.
Monitor the frequency of the event
5. Monitor the frequency of the event.
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ELECTRICAL SYSTEM
Event Code 222

Display: HIGH TEMP. HM
Explanation: Excessive temperature in hydraulic module (t > 85 °C)
Effect: • Between 85 °C and 115 °C the hydraulic module output current is reduced
in proportion to the rise in temperature down to 0 A.
– Overload
– Contamination
• Malfunction in power part of hydraulic module
Replacing the fan
Clean contaminated hydraulic module and air supplies
3. Clean the hydraulic module and air supplies if contaminated.
If the hydraulic module and air supplies are clean, proceed to step 4.
load.
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ELECTRICAL SYSTEM
Event Code 223

Display: LOW TEMP. HM
Explanation: Too low temperature in hydraulic module (t < -20 °C)
Effect: • The display shows: LOW TEMP. HM.
Possible causes: • Truck has been parked for too long in a cold environment
Remedy: Check the application conditions
1. Check the application conditions.
If the truck has been parked in temperatures below -20 °C, proceed to
step 2
If the truck has been parked in temperatures above 0 °C, proceed to
step 3
Instruct the operator
2. Inform the operator that the truck must never be parked in temperatures
below 0 °C.
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ELECTRICAL SYSTEM
Event Code 224

Display: HIGH TEMP. HMOT
Explanation: Excessive temperature in hydraulic motor coil (t > 145 °C)
Effect: • Between 145 °C and 165 °C the hydraulic module output current is re-
duced in proportion to the rise in temperature down to 0 A.
• The display shows: HIGH TEMP. HMOT
– Overload
– Contamination
Replacing the fan
Clean contaminated hydraulic motor and air supplies
3. Clean the hydraulic motor and air supplies.
If the hydraulic motor and air supplies are clean, proceed to step 4.
load.
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ELECTRICAL SYSTEM
Event Code 225

Display: LOW TEMP. HMOT
Explanation: Too low temperature in hydraulic motor (t < -30 °C)
Effect: • The display shows: HYDRAULIC MOTOR COLD
Possible causes: • Truck has been parked for too long in a cold environment.
step 2
step 3
below 0 °C.
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ELECTRICAL SYSTEM
Event Code 240

Display: POT2 ABOVE LIMIT
Explanation: The voltage on the slider of potentiometer POT2 is permanently monitored
during power-up and operation. The upper limit of 10.8 volts has been ex-
ceeded.
Effect: • Hydraulic functions are deactivated
Possible causes: • Wiring short circuit
• Potentiometer faulty
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.4 (see page 118).
2. Apply “Lift/Lower".
If approx. 12 V is displayed, either there is a short circuit or an input on
the VCM is faulty. Proceed to step 3.
Check the potentiometer wiring
3. Check the potentiometer wiring for a short circuit.
Measure the voltage levels on the potentiometer with a multimeter
4. Using a multimeter measure the voltage between CA407-2 and CA407-1.
If approx. 12 V are displayed, this indicates the potentiometer is faulty.
Proceed to step 8.
5. Leave the control lever in neutral and using a multimeter measure the volt-
age between CA407-2 and CA407-1.
It should be 4,3 – 5,3 V.
6. Move the control handle as far as the stop in the "Lift" position and using
a multimeter measure the voltage between CA407-2 and CA407-1.
7. Move the control handle as far as the stop in the "Lower" position and
using a multimeter measure the voltage between CA407-2 and CA407-1.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed
in the Analyzer menu, this indicates that the VCM input is faulty. Proceed
to step 9.
Replace the potentiometer
8. Replace the potentiometer POT2 (see page 335).
Replace the main module (VCM)
9. Replace the VCM (see page 325).
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ELECTRICAL SYSTEM
Event Code 241

Display: POT2 UNDER LIMIT
during power-up and operation. The reading has dropped below the lower limit
of 0.6 volts.
Possible causes: • Short circuit or discontinuity in wiring
• Faulty contact in connector or potentiometer
If approx. 0 V are displayed, there is either an open circuit between
CA407-2, CA407-1 and the main module (VCM) or a short circuit be-
tween CA407-2 and CA407-3. Proceed to step 3.
3. Check the wiring to connectors PC407 and PC205 for discontinuity and
short circuits.
4. Leave the control lever in neutral and using a multimeter measure the volt-
age between CA407-2 and CA407-1.
ter is ok.
lyzer menu display.
in the Analyzer menu, this indicates a transient event.
ment.
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ELECTRICAL SYSTEM
Event Code 243

ceeded.
Proceed to step 8.
5. Leave the control handle in neutral and using a multimeter measure the
voltage between CA408-2 and CA408-1.
7. Move the control lever as far as the stop in the "Lower" position and using
ter is ok.
lyzer menu display.
to step 9.
ment.
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Event Code 244

of 0.6 volts.
short circuits.
6. Move the control lever as far as the stop in the "Lower" position and using
ter is ok.
lyzer menu display.
ment.
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ELECTRICAL SYSTEM
Event Code 246

ceeded.
Note: For trucks with the multi-task control handle (MTC) this event code indi-
cates an incorrect setting in the F26 Right Handle menu, page 151.
Proceed to step 8.
ter is ok.
lyzer menu display.
to step 9.
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Event Code 247

of 0.6 volts.
Note: For trucks with the multi-task control handle (MTC) this event code indi-
cates an incorrect setting in the F26 Right Handle menu, page 151.
short circuits.
ter is ok.
lyzer menu display.
ment.
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Event Code 249

ceeded.
Proceed to step 8.
ter is ok.
lyzer menu display.
to step 9.
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ELECTRICAL SYSTEM
Event Code 250

of 0.6 volts.
short circuits.
ter is ok.
lyzer menu display.
ment.
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ELECTRICAL SYSTEM
Event Code 260

Display: SVH LIFT VALVE
Explanation: Overcurrent detected on SVH valve coil during lifting operation. Output to SVH
cut out by VCM.
Effect: • All outputs to the hydraulic valve coils are cut out.
Possible causes: • Faulty coil
• Wiring short circuit
• Main module VCM faulty
Remedy: Measuring the coil resistance
1. Disconnect PC807 from valve.
2. Measure resistance between pin 2 and pin 3 on the coil.
If the resistance is 75 , proceed to step 4.
If the resistance is not 75 , proceed to step 3.
Replace the coil
3. Replace the coil.
Check the wiring for short circuits
4. Attach connector PC807.
5. Start up the truck.
6. Leave the "Lift/Lower" control lever in neutral and measure the voltage
between PC422-9 and B–.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC807 from the valve and measure the voltage again between
PC422-9 and B–.
If B+ is still present, this indicates a short circuit to B+ between PC807-
3 and PC205-1. Proceed to step 12.
If B+ is not present, proceed to step 8.
9. Re-connect PC807. Proceed to step 13.
Locate and repair disconnected wires
10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC807-3 to PC205-1.
Check the driver output from the main module (VCM)
14. Connect the voltmeter between PC422-9 and B–.
15. Activate "Lift" as far as the stop and record the voltage.
The reading should drop to approx. 15 V. If not, proceed to step 16.
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ELECTRICAL SYSTEM
Event Code 261

Display: PVL LOWER VALVE
Explanation: Overcurrent detected on PVL valve coil during lowering operation. Output to
PVL cut out by VCM.
Replace the coil
6. Leave the "Lift/Lower" control lever in neutral and measure the voltage
PC422-42 and B–.
15. Activate "Lift" as far as the stop and record the voltage.
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ELECTRICAL SYSTEM
Event Code 262

Display: PVRT RETRACT VA.
Explanation: Overcurrent detected on PVRT valve coil during mast reach carriage retract
operation. Output to PVRT cut out by VCM.
Replace the coil
4. Connect PC810.
6. Leave the "Reach" control lever in neutral and measure the voltage be-
tween PC422-16 and B–.
PC422-16 and B–.
15. Activate "Retract reach carriage" as far as the stop and record the voltage.
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ELECTRICAL SYSTEM
Event Code 263

Display: PVRE REACH VALVE
Explanation: Overcurrent detected on PVRE valve coil during mast reach carriage extend
operation. Output to PVRE cut out by VCM.
Replace the coil
4. Connect PC808.
6. Leave the "Reach" control lever in neutral and measure the voltage be-
PC422-10 and B–.
15. Activate "Extend reach carriage" as far as the stop and record the voltage.
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278
ELECTRICAL SYSTEM

Event Code 264

Display: PVAL ACCESSORY L
Explanation: Overcurrent detected on PVAL valve coil as “5th function left” is performed.
Output to PVAL cut out by VCM.
Replace the coil
4. Connect PC809.
6. Leave the "5th function" control lever in neutral and measure the voltage
PC422-12 and B–.
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ELECTRICAL SYSTEM

15. Change to the 5th function.
16. “5th function left" as far as the stop and record the voltage.
Event Code 265

Display: PVAR ACCESSORY R
Explanation: Overcurrent detected on PVAR valve coil as “5th function right” is performed.
Output to PVAR cut out by VCM.
Replace the coil
PC422-11 and B–.
If B+ is still present, this indicates a short circuit to PC811-2 and PC205-
27. Proceed to step 12.
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ELECTRICAL SYSTEM

15. Change to the 5th function.
16. Apply “5th function right” as far as the stop and record the voltage.
Event Code 266

Display: SVT TILT VALVE
Explanation: Overcurrent detected on SVT valve coil as tilting is performed. Output to SVT
cut out by VCM.
Replace the coil
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281
ELECTRICAL SYSTEM

4. Connect PC801.
6. Leave the "fork tilt" control lever in neutral and measure the voltage be-
PC422-1 and B–.
15. Activate "fork tilt" as far as the stop and record the voltage.
Event Code 267

Display: SVS SIDE SHIFT V
Explanation: Overcurrent detected on SVS valve coil as sideshift is performed. Output to
SVS cut out by VCM.
Replace the coil
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282
ELECTRICAL SYSTEM

4. Connect PC801.
6. Leave the "sideshift" control lever in neutral and measure the voltage be-
PC422-5 and B–.
15. Activate "sideshift" as far as the stop and record the voltage.
Event Code 268

Display: SV5 5TH FUNC. AV
Explanation: Overcurrent detected on SV5 valve coil as the 5th function is performed. Out-
put to SV5 cut out by VCM.
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ELECTRICAL SYSTEM
Replace the coil

4. Connect PC801.
PC422-18 and B–.
15. Apply the 5th function as far as the stop and record the voltage.
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284
ELECTRICAL SYSTEM
Event Code 280

Display: CURR SENSOR HM
Explanation: Offset error detected in current sensors to monitor the hydraulic module power
circuit during power-up.
Possible causes: • Hydraulic module faulty
Event Code 281

Display: TEMP. SENSOR HM
Explanation: Open circuit or short circuit detected in hydraulic module thermal sensors.
Effect: • Reach and fork lower are still enabled
Possible causes: • Hydraulic module faulty
Event Code 282

Display: ECR2 SHORT CIRC.
Explanation: Short circuit between channels A and B of encoder ECR2.
Possible causes: • Encoder ECR2 faulty
• Encoder wiring short circuit
• Main module or hydraulic module faulty
Remedy: Check the module and encoder
1. Select Analyzer menu A2.29 (see page 119).
2. Extend and retract the reach carriage.
If SET SPEED = 1000 (for reach carriage extend) and
SET SPEED = 530 (for reach carriage retract) are displayed, proceed
to step 5.
If SET SPEED = 0 is displayed, proceed to step 3.
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285
ELECTRICAL SYSTEM
Check the wiring between VCM and HCM

3. Check the wiring between PC429 and CA 201 for short circuits.
If no error is found, proceed to step 4.
Replace encoder ECR2
4. Replace sensor bearing (ECR2).
If the event code persists, proceed to step 5.
Event Code 283

Display: ECR2 OPEN CIRC.
Explanation: Open circuit or no power supply to encoder ECR2.
• Encoder wiring disconnected
Remedy: Check the encoder power supply
For Danaher motors:
2. Measure the voltage between PC429-1 and PC429-4.
It should be 12 V. If not, proceed to step 6.
If there is a 12 V supply, proceed to step 4.
For Crown motors:
Check the module and encoder
to step 5.
6. Check the wiring between PC429 and CA 201.
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286
ELECTRICAL SYSTEM
Event Code 284

Display: ECR2 LOST CHANN.
Explanation: No channel A or B on encoder ECR2.
to step 4.
3. Check for disconnect wires between PC429 and CA 201.
Event Code 285

Display: TEMP. SENSOR HMOT
Explanation: Open circuit or short circuit detected in pump motor thermal sensor.
Possible causes: • Faulty wiring
• THS2 faulty
Remedy: Check the wiring
1. Check for short circuits or wire disconnections between CA201-17,
CA201-16 and CA430-1 and CA430-2.
If the wiring is faulty, proceed to step 2. If not, proceed to step 3.
Repair wiring
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ELECTRICAL SYSTEM
Measure THS2 resistance

4. Measure THS2 resistance between CA430-1 and -2.
If the resistance < 500 or > 1 k , proceed to step 5.
If the resistance is approx. 600 (rated resistance for t =20 °C is
600 ), monitor the error frequency.
ment.
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288
ELECTRICAL SYSTEM
Event Code 300

Display: HIGH CURRENT TM
Explanation: Current in power part of traction module is too high (> 525 A).
Possible Causes: • Short circuit in following components:
– Power cable to traction motor
– Traction motor coil
– Traction module output stage
• Blocked drive
1. Check wires for short circuits.
Measure the traction motor insulation resistance
If the coils are ok, proceed to step 5.
Replace the traction motor
4. Replace the traction motor (see page 352).
Check the drive for blockage
5. Check the drive for freedom of movement.
If the drive moves freely, proceed to step 6.
Replace the traction module
6. Replace the traction module (see page 325).
Event Code 301

Display: SHORT CIRCUIT TM
Explanation: Short circuit in power circuit of traction module.
Possible Causes: • Short circuit in following components:
– Power cable to traction motor
– Traction motor coil
– Traction module output stage
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ELECTRICAL SYSTEM
Remedy: Measure the traction motor insulation resistance

If the motor coils are ok, proceed to step 4.
Replace the traction motor
3. Replace the traction motor (see page 352).
Event Code 311

Display: LOW VOLTAGE TM
Explanation: Low voltage in traction module power circuit (V < 18 V).
• Faulty battery
• Error in traction drive module
Remedy: 1. Check power cables.
2. Check battery voltage with load:
In the Analyzer menu select item A2.36.
Raise a heavy load and monitor the battery voltage during the lifting
operation.
If the battery voltage drops significantly, repair the battery.
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290
ELECTRICAL SYSTEM
Event Code 312

Display: 15 VOLT SUPPLY TM
Explanation: 15 V traction module supply faulty.
Effect: • Truck stops through plugging
• Mast reach and lowering only
Possible Causes: • Error in traction module
Remedy: Replace traction module
1. Replace the traction module (see page 325)
Event Code 313

Display: 5 VOLT SUPPLY TM
Explanation: 5 V traction module supply faulty.
Effect: • Truck stops through plugging
Possible Causes: • Error in traction module
Remedy: Replace traction module
Event Code 314

Display: CAP CHARGE TM
Explanation: Capacitor charge time exceeded.
Effect: • Main contactor ED1 does not close
• No B+ supply to traction module
• Traction module faulty
Remedy: Check wires (B+, B–) and connections
1. Check for disconnected wires and make sure connections are secure.
Check B+ supply to traction module
3. Connect voltmeter to B+ and B- of the traction module.
The voltage should rise from 0 V on B+ within 2 seconds. If not, proceed
to step 5.
Replace traction module
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291
ELECTRICAL SYSTEM
Event Code 320

Display: OVER TEMP. TM
Explanation: Traction module overtemperature (t > 115 °C)
Effect: • Traction module deactivated
• The display shows: OVER TEMP. TM
Possible Causes: • Traction module ventilation affected by:
– Overload
– Contamination
• Malfunction in power part of traction module
Replace the fans
Clean contaminated traction module and air supplies
3. Clean contaminated traction module and air supplies.
If the traction module and air supplies are clean, proceed to step 4.
load.
Replace hydraulic module
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292
ELECTRICAL SYSTEM
Event Code 321

Display: OVER TEMP. TMOT
Explanation: Traction motor coil overtemperature (t > 165 °C)
• Travel at inching speed enabled
• The display shows: OVER TEMP. TMOT
Possible Causes: • Traction motor ventilation affected by:
– Overload
– Contamination
Replace the fans
Clean contaminated traction motor and air supplies
3. Clean traction motor and air supplies.
If the traction motor and air supplies are clean, proceed to step 4.
load.
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293
ELECTRICAL SYSTEM
Event Code 322

Display: HIGH TEMP. TM
Explanation: Excessive temperature in traction module (t > 85 °C)
Effect: • Between 85 °C and 115 °C the traction module output current is reduced in
proportion to the rise in temperature down to 0 A.
• The display shows: HIGH TEMP. TM
– Overload
– Contamination
• Malfunction in power part of traction module
Replace the fans
Clean contaminated traction module and air supplies
3. Clean contaminated traction module and air supplies.
If the traction module and air supplies are clean, proceed to step 4.
load.
Replace traction module
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294
ELECTRICAL SYSTEM
Event Code 323

Display: LOW TEMP. TM
Explanation: Too low temperature in traction module (t < -20 °C)
Effect: • The display shows: LOW TEMP. TM
Possible Causes: • Truck has been parked for too long in a cold environment
step 2
step 3
below 0 °C.
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295
ELECTRICAL SYSTEM
Event Code 324

Display: HIGH TEMP. TMOT
Explanation: Excessive temperature in traction motor coil (t > 145 °C)
Effect: • Between 145 °C and 165 °C the traction module output current is reduced
in proportion to the rise in temperature down to 0 A.
• The display shows: HIGH TEMP. TMOT
– Overload
– Contamination
Replace the fans
Clean contaminated traction motor and air supplies
3. Clean traction motor and air supplies.
If the traction motor and air supplies are clean, proceed to step 4.
load.
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296
ELECTRICAL SYSTEM
Event Code 325

Display: LOW TEMP. TMOT
Explanation: Too low temperature in traction motor (t < -30 °C)
Effect: • The display shows: LOW TEMP. TMOT
Possible Causes: • Truck has been parked for too long in a cold environment.
step 2
step 3
below 0 °C.
Event Code 330

Display: ERROR CANBUS TM
Explanation: Communication error on the CAN Bus between the main module (VCM) and
the traction module (TCM).
module and the traction module
If the resistance is 60 , the main and traction modules are ok.
If the resistance is 120 , then either the main or traction module is
faulty. Proceed to step 2.
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Measure the load resistance in the traction module (TCM)
5. Disconnect PC204 from the traction module.
6. Measure the resistance on the traction module between PC205-22 and -
23.
If the resistance is 120 , the traction module is ok.
If a different reading is obtained, the traction module is faulty. Proceed
to step 7.
Replace the traction module (TCM)
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ELECTRICAL SYSTEM
Event Code 340

ceeded.
Effect: • Travel functions are deactivated
Possible Causes: • Wiring short circuit
2. Depress accelerator.
If 0 V is displayed, there is either an open circuit between CA407-2,
CA407-1 and the main module (VCM) or a short circuit between CA407-
2 and CA407-3. Proceed with step 3.
short circuits.
4. Leave the accelerator pedal in neutral and using a multimeter measure the
5. Depress the accelerator pedal as far as the stop and using a multimeter
measure the voltage between CA407-2 and CA407-1.
ter is ok. If not, proceed to step 300.
lyzer menu display.
ment.
6. Replace potentiometer POT1 (see page 334).
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ELECTRICAL SYSTEM
Event Code 341

of 0.6 volts.
Possible Causes: • Short circuit or discontinuity in wiring
short circuits.
ter is ok. If not, proceed to step 300.
lyzer menu display.
ment.
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300
ELECTRICAL SYSTEM
Event Code 343

Display: POT1/ACS STATUS
Explanation: The voltage reading supplied from POT1 does not match the value expected
by the current switch position of the ACS.
Possible Causes: • Short circuit or discontinuity in wiring
• ACS switch faulty
• Potentiometer POT1 faulty
• Calibration faulty
Remedy: Test potentiometer POT1
short circuits.
Record the voltage readings on the potentiometer with a multimeter and
compare them with the display in the Analyzer menu
6. In the Analyzer menu, item A2.3 (see page 118) compare the recordings
with the display reading.
If normal readings are taken in steps 4 to 5 but approx. 0 V is displayed
in the Analyzer menu, this indicates a transient event. Proceed to
step 7.
Restart the truck
7. Restart the truck
If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu (Software V1.0), page 157). If the event occurs fre-
If the error message persists after restarting, proceed to step 8.
Test the ACS switch
9. Press the ACS switch and check its operation.
If ACS does not switch, proceed to step 10.
If the switch is ok, proceed to step 11.
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ELECTRICAL SYSTEM
Check the ACS switch wiring

10. Check the wiring between CA417 and CA205 for discontinuity and short
circuits.
If the wiring is ok, replace the ACS switch
If the wiring is faulty, repair the wiring.
Calibrate the travel function
11. Calibrate the travel function (see page 126).
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302
ELECTRICAL SYSTEM
Event Code 380

Display: CURR SENSOR TM
Explanation: Offset error detected in current sensors to monitor the traction module power
circuit during power-up.
Effect: • Traction module remains deactivated.
Possible Causes: • Hydraulic module faulty
Remedy: Replace the traction module
Event Code 381

Display: TEMP. SENSOR TM
Explanation: Open circuit or short circuit detected in traction module thermal sensors.
Possible Causes: • Traction module faulty
Remedy: Replace the traction module
Event Code 382

Display: ECR1 SHORT CIRC.
Explanation: Short circuit between channels A and B of encoder ECR1.
Possible Causes: • Encoder ECR1 faulty
• Main module or traction module faulty
2. Apply travel function.
If SET SPEED = 685 is displayed (when accelerator pedal applied), the
traction and main modules are ok.
ment.5
If ACTUAL SPEED = 0 is displayed, proceed to step 3.
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ELECTRICAL SYSTEM
Check the wiring between VCM and TCM

3. Check the wiring between PC425 and CA 201 for short circuits.
4. Replace encoder (ECR1).
Event Code 383

Display: ECR1 OPEN CIRC.
Explanation: Open circuit or no power supply to encoder ECR1.
Remedy: Check the encoder power supply
For Danaher motors:
For Crown motors:
Check the module and encoder
ment.
6. Check the wiring between PC425 and CA 201.
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304
ELECTRICAL SYSTEM

Event Code 384

Display: ECR1 LOST CHANN.
Explanation: No channel A or B on encoder ECR1.
• Main module or traction module faulty
2. Apply travel.
ment.5
Check the wiring between VCM and TCM
3. Check for disconnected wiring between PC425 and CA 201.
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305
ELECTRICAL SYSTEM
Event Code 430

Display: ERROR CANBUS VM
Explanation: Communication error on CAN Bus of main module (VCM).
Event Code 431

Display: ERROR CANBUS DSPLAY
Explanation: Communication error on CAN Bus of main module (VCM) and display.
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306
ELECTRICAL SYSTEM
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ELECTRICAL SYSTEM
Event Code 460

Display: MAINC NOT CLOSED
Explanation: During power-up VCM detects an overcurrent in the coil of contactor ED1 and
switches off the driver output to ED1.
Effect: • Main contactor ED1 not energised
Possible Causes: • Short circuit in contactor coil
2. Remove PC402 from the start up card.
3. Remove control cable from contactor.
4. Check control cable to contactor (PC402-10 and -9) for short circuit.
If there is a short circuit, proceed to step 5.
If there is no short circuit in the wiring, proceed to step 6.
Repair wiring
5. Repair wiring.
Check contactor coil
6. With the control cables still removed, measure the contactor coil resist-
ance with an ohmmeter.
If the resistance is approx. 1.5 k , the contactor coil is ok.
If the resistance is approx. 0 , proceed to step 7.
Repair contactor
7. Repair contactor ED1 (see page 350).
Event Code 461

Display: MAINC WELDED
Explanation: Battery voltage applied to CA205-14 although truck has not been powered up.
Effect: • Main contactor ED1 not energised
Possible Causes: • Contactor welded.
Remedy: 1. Repair or replace contactor (see page 350).
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308
ELECTRICAL SYSTEM
Event Code 462

Display: FAN OUTPUT
Explanation: Overcurrent detected on HCM output to fans during power-up. Output to fans
switched off by the HCM.
Effect: • Travel at inching speed enabled
Possible Causes: • Faulty fan
• Short circuit
Replace the fans
2. Replace any faulty fans.
Trace short circuit
3. Trace for a short circuit between PC415 or PC435 to CA201-2 on HCM.
Repair faulty wiring.
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309
ELECTRICAL SYSTEM
Event Code 463

Display: BEACON OUTPUT
Explanation: Overcurrent detected on output of VCM to strobe. Output to strobe switched
off by VCM.
Effect: • SVH, PVL, PVRE, PVRT, PVAL and PVAR deactivated.
Possible Causes: • Faulty strobe
• Coil (on relay bracket under the floorboard) is faulty
• Wire harness error
• Main module error
Remedy: Check strobe
2. Disconnect PC435 from the strobe .
3. Switch on the truck and strobe .
If the event code no longer occurs, proceed to step 5.
If the event code is still displayed, proceed to step 6.
4.
Replace strobe
5. Replace the strobe.
Check strobe and coil wiring
7. Disconnect JC433.
8. Switch on the truck and strobe.
9. Check wiring between JC433-1 and - 2 to PC435-1 and -2 for short cir-
cuits.
Check main harness for short circuits
11. Disconnect PC205 and PC206.
12. Check the wiring between PC433-1 and -2 for short circuits.
If no short circuit is found, proceed to step 13.
13. Check contacts are securely connected to PC205 and PC206.
If the contacts are damaged, proceed to step 16.
If the contacts are ok, proceed to step 17.
Repair wiring
Replace the coil
15. Replace the coil (fitted on the relay bracket underneath the floorboard).
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ELECTRICAL SYSTEM
Repair contacts on PC205 and PC206

16. Repair contacts.
Replace the main module
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ELECTRICAL SYSTEM
Event Code 464

Display: ALARM2 OUTPUT
Explanation: Overcurrent detected on output of VCM to travel alarm (CA205-11). Output to
travel alarm switched off by VCM.
Possible Causes: • Travel alarm faulty
• Coil (fitted between travel and pump motors) is faulty
• Wire harness error
Remedy: Check travel alarm
2. Disconnect PC437 (fitted between the travel and pump motors).
3. Power up the truck and activate the travel alarm.
Check wiring to travel alarm and coil
5. Disconnect JC421.
6. Power up the truck and activate the travel alarm.
7. Check wiring between JC421-1 and - 2 to PC437-1 and -2 for short cir-
cuits.
Check main harness for short circuits
9. Disconnect PC205 and PC206.
10. Check the wiring between PC421-1 and -2 for short circuits.
11. Check contacts are securely connected to PC205 and PC206.
If the contacts are damaged, proceed to step 14.
Repair wiring
Replace the coil
13. Replace the coil (fitted between travel and pump motors).
Repair contacts on PC205 and PC206
14. Repair contacts.
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ELECTRICAL SYSTEM
Event Code 465

Display: VMC OUTPUTS
Explanation: Overcurrent detected on VCM outputs. The overcurrent could not be assigned
directly to an output. All outputs are switched off by the VCM.
Effect: • Either SVH, PVL, PVRE, PVRT, PVAL ,PVAR or SVT, SVS, SV5 are deac-
tivated or main contactor ED1 is de-energised.
Possible Causes: • Wire harness error
• Error in mast reach wire harness (see page 563)
• Error in reach carriage wire harness (see page 567)
• Error in mast cable (see page 578 or 579)
• Error in fork carriage wire harness (see page 570 ff.)
• Valve modulation error
• Horn modulation error
Remedy: Trace short circuit
1. Troubleshoot as described in event codes 463 and 464.
2. Check the valve modulation and horn wiring for short circuits.
3. Check the valve modulation and horn wiring for short circuits:
– SVH (PC807 on main valve block)
– PVRE (PC808 on main valve block)
– PVRT (PC810 on main valve block)
– PVAL (PC809 on main valve block)
– PVAR (PC811 on main valve block)
– SVT, SVS (PC801 on “accessory functions” valve block)
– Horn (PC402-3 and -12 on the start up card)
Check contacts
4. Check contact pins are properly connected to the following:
– PC205, PC206, CA422 (on mast)
– CA601, CA604 (in reach carriage)
If a contact error is found, proceed to step 9.
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ELECTRICAL SYSTEM
Test components individually

Note: Each of the components named in step 3 must be tested individually.
The following shows for example how to test the SVH valve. The other compo-
nents are tested in the same way.
6. Remove PC807 from the SVH valve.
8. Check the event code displayed.
If the event code is shown again, the problem lies with one of the other
components. Repeat steps 5 to 8 for the next component.
Note: Re-fit the connector before powering up the truck again.
If the event code is no longer displayed, that component is the cause of
the error. Proceed to step 11.
If the error is shown for all components, the main module is the cause.
Proceed to step 12.
Repair connector
9. Repair the connector.
Repair wiring
10. Eradicate the short circuit.
Replace faulty component
11. Replace the faulty component.
12. Replace the main module (VCM).
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ELECTRICAL SYSTEM
Event Code 840

Display: FS&RS CLOSED
Explanation: Forward and reverse switches detected simultaneously on the VCM inputs.
• Faulty switch
Remedy: Check direction switches
2. Disconnect CA411 (in armrest).
If the event code disappears, monitor the error frequency (see Log
Events Menu (Software V1.0), page 157). If the event occurs fre-
Check interface
5. Reconnect CA411.
6. Disconnect CA406.
If the event code disappears, the interface PCB is faulty. Proceed to
step 9.
Check wiring and switches
8. Check wiring from CA406-2 to CA470-2 and on to CA205-4.
If the wiring is faulty, proceed to step 10.
Replace interface
9. Replace the interface PCB.
Repair wiring
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315
ELECTRICAL SYSTEM
Event Code 841

Display: LOW BRAKE FLUID
Explanation: Brake fluid level too low.
Effect: • Brake fluid level indicator lights up
Possible Causes: • Brake fluid level too low
• Faulty wiring
• Faulty switch
Remedy: Check brake fluid level
1. Check brake fluid container level.
If the level is ok, proceed to step 2.
If there is insufficient brake fluid, rectify the cause (worn brake linings in
the load wheels, leaks etc.) (see page 386). Then add brake fluid
(DOT4) (see page 389).
Check BFS switch
Note: The lid must be screwed onto the container and the brake fluid filled to
the max. marking.
2. Remove the wiring from the BFS switch.
3. Using an ohmmeter check the switch.
If the switch has continuity, the switch is faulty and must be replaced.
If the switch does not have continuity, proceed to step 4.
Check wiring
4. Measure the voltage between CA204-31 and B–.
If the voltage is approx. B+, there is a short circuit to B+. Proceed to
step 5.
If the reading is 0 V, the main module (VCM) is faulty. Proceed to
step 6.
Repair wiring
5. Clear short circuit in wire no. 007 between BFS and CA205-31.
Event Code 880

Display: SHORT CIRCUIT ECR5
Explanation: Short circuit between channels A and B of the height encoder
Effect: • Lift speed reduced to 50 %
• Graphic height display switched off
• The display shows: height measurement switched off
Possible Causes: • Wiring short circuit
• Encoder faulty
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ELECTRICAL SYSTEM

2. Disconnect CA205 from the VCM and PC803 from height encoder ECR5.
3. Using an ohmmeter check the wires between CA205-9 and -38 for short
circuits.
Repair wiring
4. Repair wiring.
Check height encoder ECR5
5. In the Analyzer menu open item A2.19.
6. Continue raising the fork carriage above free lift height while monitoring
the display.
If the number of encoder pulses does not continually rise, ECR5 is
faulty. Proceed to step 7.
If the number of encoder pulses rises continually, ECR5 is ok. Proceed
to step 8.
Replace height encoder ECR5
7. Replace ECR5 (see page 332).
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317
ELECTRICAL SYSTEM
Event Code 881

Display: NO COUNTS LIFT
Explanation: No pulses from height encoder ECR5 detected during lifting.
Possible Causes: • Faulty wiring
• Height reset switch (HGTRS) does not connect
• Height encoder ECR5 faulty
• 12 V supply faulty
Remedy: Test HGTRS
2. Raise the fork carriage above free lift height.
If the HGTRS switch changes from ON to OFF when the fork carriage
exceeds free lift height, it is ok. Proceed to step 4.
If it does not change, the HGTRS switch is not working. Proceed to
step 3.
Replace HGTRS
3. Replace the HGTRS switch (see page 333).
Test height encoder ECR5
5. Raise the fork carriage slowly above free lift height while monitoring if the
number of encoder pulses rises continually up to maximum lift height.
If the number of pulses does not rise, either the wiring, the power supply
(display), the encoder or the VCM are faulty. Proceed to step 7.
If the number of pulses does rise, proceed to step 17.
Check 12 V supply of height encoder ECR5
6. Using a voltmeter measure the voltage between CA203-14 and B- on the
display.
If there is no supply, proceed to step 13.
7. Using a voltmeter measure the voltage between PC803-1 (GND) and -
3 (+12 V) on height encoder ECR5.
Check wiring and operation of channel A on height encoder ECR5
9. Raise the fork carriage above free lift height and then continue raising it
very slowly.
If the voltage jumps between 0 V and 5 V, channel A is ok. Proceed to
step 10.
If 0 V is constantly displayed, proceed to step 13.
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ELECTRICAL SYSTEM
Check wiring and operation of channel B on height encoder ECR5

very slowly.
If the voltage jumps between 0 V and 5 V, channel B is ok. Proceed to
step 17.
Check 12 V supply wiring
12. Check for disconnected wiring from CA203-14 (on display) to CA803-3
and from CA203-20 to CA803-1.
If there is a disconnection, proceed to step 15.
If there is no disconnection, proceed to step 18.
Check channel A wiring on ECR5
13. Check for disconnected wiring from CA205-9 via CA422-31, CA600-2 to
CA803-2.
CA803-4.
Repair wiring
15. Repair wiring.
Replace the display
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319
ELECTRICAL SYSTEM
Event Code 883

Display: EXEED MAX HEIGHT
Explanation: Height encoder ECR5 records a value above maximum lift height.
Possible Causes: • Slip in height encoder drive
• Height encoder calibration faulty
Remedy: Check drive of height encoder ECR5 for slip
1. Check drive of ECR5 for slip.
If slip is discovered in the drive, proceed to step 2.
If the drive is ok, proceed to step 3.
Repair the drive of height encoder ECR5
2. Replace faulty drive components.
Calibrate height encoder ECR5
3. Calibrate ECR5 (see page 131).
ESR 5000 Series
320
ELECTRICAL SYSTEM
Event Code 884

Display: NO COUNTS LOWER
Explanation: No pulses from height encoder ECR5 detected during lowering.
Effect: • Lift speed reduced to 50%
• Height encoder ECR5 faulty
• 12 V supply faulty
Remedy: Test HGTRS
exceeds free lift height, it is ok. Proceed to step 4.
step 3.
Replace HGTRS
Test height encoder ECR5
5. Raise the fork carriage far beyond the free lift height. Then lower it and
monitor if the number of encoder pulses falls continuously.
If the number of pulses does not fall, either the wiring, the power supply
(display), the encoder or the VCM are faulty. Proceed to step 7.
If the number of pulses does rise, proceed to step 17.
Check 12 V supply of height encoder ECR5
6. Using a voltmeter measure the voltage between CA203-14 and B- on the
display.
7. Using a voltmeter measure the voltage between PC803-1 (GND) and -
3 (+12 V) on height encoder ECR5.
Check wiring and operation of channel A on height encoder ECR5
very slowly.
If the voltage jumps between 0 V and 5 V, channel A is ok. Proceed to
step 10.
ESR 5000 Series
321
ELECTRICAL SYSTEM
Check wiring and operation of channel B on height encoder ECR5

very slowly.
If the voltage jumps between 0 V and 5 V, channel B is ok. Proceed to
step 17.
Check 12 V supply wiring
12. Check for disconnected wiring from CA203-14 (on display) to CA803-3
and from CA203-20 to CA803-1.
CA803-2.
CA803-4.
Repair wiring
15. Then repair wiring.
Replace the display
ESR 5000 Series
322
ELECTRICAL SYSTEM
Event Code 885

Display: ERROR HGTRS
Explanation: Height reset switch HGTRS malfunction
Effect: • Lift speed reduced to 50%
Remedy: Test HGTRS
step 3.
exceeds free lift height, it is ok.
ment.
Check wiring
3. Disconnect PC802 and raise the fork carriage above free lift height.
If ON is still displayed, there is a short circuit to B+. Proceed to step 4.
If OFF is displayed, HGTRS is faulty. Proceed to step 5.
Repair wiring
4. Repair wiring.
Replace HGTRS
ESR 5000 Series
323
ELECTRICAL SYSTEM
Event Code 886

Display: ERROR ECR5 - HGTRS
Explanation: This test compares the number of count pulses of a lifting operation with those
of a lowering operation. The event code is generated if a permissible difference
is exceeded.
Possible Causes: • Height reset switch (HGTRS) does not connect reliably
• Slip in height encoder drive
Remedy: Check drive of height encoder ECR5 for slip
1. See Event Code 883, page 320.
If the height encoder drive is ok, proceed to step 2.
Check height reset switch HGTRS
2. See Event Code 885, page 323.
ment.
ESR 5000 Series
324

Esr 5000

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ELECTRICAL SYSTEM

EVENT CODES 100 - 186

Event Codes 100 - 186

Event Code 101

ESR 5000 Series

Event Code 102

Event Code 110

ESR 5000 Series

Event Code 111

Event Code 112

ESR 5000 Series

Event Code 120

ESR 5000 Series

Replace the steer motor

Event Code 121

Event Code 123

Event Code 124

ESR 5000 Series

Event Code 130

ESR 5000 Series

Event Code 131

ESR 5000 Series

Event Code 160

ESR 5000 Series

Event Code 180

ESR 5000 Series

Event Code 181

ESR 5000 Series

Event Code 182

ESR 5000 Series

Event Code 183

ESR 5000 Series

Event Code 184

ESR 5000 Series

Event Code 186

ESR 5000 Series

Event Codes 200 - 286

Event Code 200

ESR 5000 Series

Event Code 201

ESR 5000 Series

Event Code 210

Event Code 211

ESR 5000 Series

Repair the battery

ESR 5000 Series

Event Code 212

Event Code 213

ESR 5000 Series

Event Code 214

ESR 5000 Series

Event Code 220

ESR 5000 Series

Event Code 221

ESR 5000 Series

Event Code 222

ESR 5000 Series

Event Code 223

ESR 5000 Series

Event Code 224

ESR 5000 Series

Event Code 225

ESR 5000 Series