Electrical systems — 5000 Diagnostic and troubleshooting T-kod Galler fran maskinnr. Datum Bestallningsnr. 789, 790, 791, 792, 817, 818 924454- 2006-10-02 230076-020 10.6.2 Fault code history Up to 50 of the most recently occurred fault codes will be stored in a log along with the hour meter reading when the fault occurred. When the fault code log is displayed, it shows the fault codes in chronological order with the newest code first. Carry out the following to display the fault code log: + Ensure the battery is connected. + Ensure the truckis switched off Press (on the keypad. + Press and hold horn button $18 for at least 1 second, enter a valid PIN-code and then press (J on the keypad, + Hold $18 depressed until “E” is displayed, then release $18. Fig. 11 1 afar Fault symbol lights, wat Piz The most recently occurred error will be displayed. The display will alternate between the fault code and the hour meter reading when the fault occurred. If the fault code log contains more than one faull code, these can be displayed by repeatedly operating the speed control L1 10.6.3 List of fault codes NOTE! The text “Restart the truck!” in the following tables always means switching the truck off completely by removing the battery connector [X1], reconnecting and then switching the truck on again. Table 31: List of fault codes Cod | Description Possible cause / Hint or Solution e c3 TLS: Shock sensor val- A shock sensor has reported values above limit. ues above limit Driving may be too tough Make sure that the shock sensor limits are correct. Make sure that the shock sensor is correct located./Brake acti- vates and stops the truck. A TLS reset command activates the truck. C4 TLS: Truck set out of use | Possibility to set the truck “out of use” with a TLS command. / Truck can’t be used before a TLS command sets the truck “in use” C49_| Default parameter value | "Certain parameter value(s) may be outside their normal max- warning min range. These parameter values will be reset to their default values. /" It may be necessary to check the settings of all parameters if this code is displayed 10-72 Servicemanual _ SPE125,1251, 1358, 160, 160L,200D, 200, 200. © BT Europe ABElectrical systems — 5000 Diagnostic’ and troubleshooting Bestallningsnr. Datum Giller fran maskinnr. T-kod 230076-020 2006-10-02 924d54- 789, 790, 791, 792, 817, 818 Table 31: List of fault codes Cod | Description Possible cause / Hint or Solution e C20_| Butterfly warming Problem with butterfly sensor [L1] Butterfly may have been activated during start up or faulty sen- sor(s).[A2] / Check action of butterfly C21 Lift/Lower control warn- Lift / Lower control for the forks may have been activated dur- ing ing start up or faulty sensor / Check action of Lift / Lower con- trol 28 | Emergency switch warn-| Emergency switch activated [S21] ing No voltage supply to Traction transistor regulator [A1]. Harness problem. / Check emergency switch is not depressed. ‘Check wiring. 29 Service time warning Next service is due / Check service counter. It may not be reset after latest service See *# 25 - Service interval” on page 53 for setting of parameter #26. ©30_| Maxfork load exceeded | The load on the forks has exceeded the truck's classified lift capacity. / Ensure the load to be lifted does not exceed the classified lift capacity Check that lifting is not performed against the mechanical stop. This applies to both fork lifting and support arm lifting. Ensure the mast sections and lifting chains move freely Check pressure sensor o/p [B1:INP.PRESSURE LIFT] voltage = 0,5V with no load & lowered forks / support arms Perform a Max. load calibration See * # 36 - Calibrate” on page 54 C35, Steer servo -Internal The internal temperature of the steer servo[AS] has exceeded temperature warming +68" C/ Steering may be too intensive C41_| Battery undervoliage _| Traction transistor regulator{A7] has detected battery voltage war-ning -traction tran- | < 17V. sistor re-gulator Battery parameter not correctly adjusted. See “# 21 - Battery size” on page 53 for setting of parameter #21 Battery due for charging C42 _| Battery overvoltage war- | Traction transistor regulator[A1] has detected battery ning -traction transistor voltage > 33V / regulator Can be caused by fully-charged battery and energy return feed to the battery during heavy reverse braking C43__| Traction transistor regu- | Driving may be too intensive lator thermal cutback —_| Defective Traction transistor regulator (A1] C47_| Baitery under voltage | Pump transistor regulator[Ad] has detected battery warning -pump transis- | voltage < 17V/ tor regulator Battery parameter not correctly adjusted. See “# 21 - Battery size” on page 53 for setting of parameter #21 Battery due for charging C48 ‘| Battery overvoltage - Pump transistor regulator[A3] has detected battery pump transistor regulator | voltage > 33V ©BT Europe AB ‘Servicemanual ‘SPE125,1251,135S, 160, 160L,200D, 200, 200L. 10-73Electrical systems — 5000 Diagnostic and troubleshooting T-kod Galler fran maskinnr. Datum Bestallningsnr. 789, 790, 791, 792, 817, 818 924454- 2006-10-02 230076-020 Table 31: List of fault codes Cod | Description Possible cause / Hint or Solution e ‘C49__| Pump transistorregulator | Lifting may be too intensive -thermal cutback Defective pump transistor regulator [A3] ‘C60 | Pressure sensor error, | Voltage at ip [B4:INP.PRESSURE LIFT] outside range Lift system +0,3V to +7,7V 1. Check pressure sensor [64] wiring and function Defective pressure sensor [B4] C61_| Pressure sensor error-_| Voltage at ip [BS1INPPRESSURE PT] outside range powertrak +0,3V to +7,7V 1’ Check pressure sensor [B5] wiring and function Defective pressure sensor [B5] 62 | Powertrak error Unexpected pressure level in Powertrak system / Check wiring & connections to Powertrak related components [Y58}, [Y59], [B4] & [85] Mechanical failure in powertrak valves C63__| Powertrak valve output _| Valve defective [Y59] or fault in o/p from traction transistor re- error gulator [A1:OUT.POWERTRAK FILL UP VALVE] ‘64 | Powertrak valve output _| Valve defective [Y58] or fault in o/p from traction transistor re- error gulator [A1:OUT.POWERTRAK DRAIN VALVE] 70 | Pump motorfield circuit | Shunt field open [M3], harness broken, pump transistor regula. open tor defective [A3]./ Check wiring and connections to shunt field [M3] 71 | Mminus error- Pump | Problem with switch transistor in armature circuit inside Pump transistor regulator [A3] _| transistor regulator [A3] Defective Pump transistor regulator (A3]. ©72_| Current sensor error- _| Armature current sensor fault in pump transistor regulator [A3] Pump transistor regulator | Defective pump transistor regulator [A3] (A3] C73__| CAN timeout error - Pump transistor regulator (A3] reports unexpected loss of data Pump transistorregulator | flow from tiller head [A2]./ Check CAN bus signal cables and [A3] connections.[A3, A2] Restart the truck C74_| Data not received - Data from [A3] not received by [A2] Pump transistor regulator | Broken CAN wire (A3] J. Check CAN bus signal cables and connections.(A3, A2] Restart the truck C75 | Transmission to Pump —_| Data from [A2] not received by [A3] transistor controller{A3] _ | Broken CAN wire failed Defective Pump transistor regulator (A3] Check CAN bus signal cables and connections.[A3, A2] Restart the truck 10-74 Servicemanual _ SPE125,1261,135S, 160, 1601,200D, 200, 200. © BT Europe ABElectrical systems — 5000 Diagnostic’ and troubleshooting Bestallningsnr. Datum Giller fran maskinnr. T-kod 230076-020 2006-10-02 924d54- 789, 790, 791, 792, 817, 818 Table 31: List of fault codes Cod | Description Possible cause / Hint or Solution e C76 | Pumptransistor regulator | Incorrect type of pump transistor regulator is fitted / Check cor- [A3] incompatible with | rect transistor regulator type is fitted the type of truck c77 Lift potentiometer [R14] Analogue potentiometer control not detected. connection error | Check wiring & connections between potentiometer [R14] & Az] CB0_| Steer servo- Reference | Steer servo reference current <0,1A sensor current error Supply fault to home reference sensor [S65] Defective home reference sensor [S65] / Check wiring to sen- sor C81__| Steer servo - Reference | Sensor supply from sensor supply error Defective home reference sensor [S65] / Check supply voltage is 12V between wires 95-97 / Check Wi- ring to sensor Check condition of [F50] C82 ‘Steer servo - drive cur- Steer servo drive current is exceeding 80% of maximum. rent warning Steering activity may be too intensive See also code E132 C90 | Communication problem | Verify the voltage supplied to the SEU 1 unit (A36 POWER. with the SEU 1 unit, SUPPLY 24 VDC) and check that the CAN cabling is OK If no configurable option is fitted, ensure that service parame- ter #16-#19 are set to cot ‘Communication problem | Verify the voltage supplied to the second SEU and check that with the SEU 2 unit the CAN cabling is OK If no configurable option is fitted, ensure that service parame- ter #16-#19 are set to “0” 92 | Programming waming | Incorrect programming of the SEU 1 unit 1 [A36]. The truck ‘SEU 1 unit (A36) travels at creep speed. / May have been caused by incorrect allocation of an output during adjustment of the option parame- ters (16 to 19). Verify all settings of any option parameters./ If no configurable option is fitted, ensure that service parameter #16-H19 are set to “0” €93__| Programming waming __| Incorrect programming of the SEU 2 unit. The truck travels at ‘SEU 2 unit creep speed. / May have been caused by incorrect allocation of an output during adjustment of the option parameters (16 to 18). Verify all settings of any option parameters. If no config- urable option is ffitted, ensure that service parameter #16-#19 are set to “0” E100 | Steer servo - configura- | Presence of steer servo and parameter #38 setting do not tion error match/ Ensure parameter #38 is set correctly E101 | Traction transistor regu- | Incorrect type of traction transistor regulator is fitted / Check lator [A1] incompatible —_| correct transistor regulator type is fitted with the type of truck ©BT Europe AB ‘Servicemanual ‘SPE125,1251,135S, 160, 160L,200D, 200, 200L. 10-75Electrical systems — 5000 Diagnostic and troubleshooting T-kod Galler fran maskinnr. Datum Bestallningsnr. 789, 790, 791, 792, 817, 818 924454- 2006-10-02 230076-020 Table 31: List of fault codes Cod | Description Possible cause / Hint or Solution e £104 | Brake switch transistor Defective Traction transistor regulator [A1] / Check cables and output in Traction transis- | magnetic coil to the brake [Y1] tor regulator [A1] shorted E106 | Digital output fault or field | Attempting to drive more current than specified from outputs. current limit OR problem regulating field current. Internal Traction transistor regulator fault. [A1] £107 | Main contactor not acti-_ | Problem with main contactor tips or cabling (open circuit). vated [K10] Contactor control wire not connected Contactor drive output in controller faulty (off) / Check main contactor tips. Check control wires to main contactor. Check contactor drive output goes low. [A1] £108 | Main contactor tips Main contactor tips welded. welded or open circuit in | Contactor drive output in controller faulty (on) / Check main coil. [K10] contactor tips Check contactor drive output goes high. [A1] £110 | Fault in armature current | Possible defect in the transistor regulator [A1]. reading Can be caused by excessive moisture inside regulator. / Restart the truck E112 | Steer servo- wheel pos Error when comparing actual wheel position (reference sensor tion error signal) with steer servo's calculated position, I Check reference sensor{S65] functions correctly Check steer servo pinion is not loose and in contact with drive unit's gear ring Restart the truck E113 | Unspecified steer servo Control system has detected a fault condition but is unable to fault ascertain the exact cause. / Restart the truck £114 | Steer servo phase error Loss of motor phase to steer servo motor. / Check internal (AS, M6] motor cable connections in steer servo[AS, M6] E115 | Steer servo initialisation | Faulty Servo [A5] error [A5] Internal logical fault Wrong parameters / Restart the truck E116 | Steer servo checksum Can occur after new firmware has been loaded into truck / error [A5] Restart the truck E117 | Steer servo communica- | Shall not occur under normal conditions./ Contact support tion error organisation E118 | Command mode error | Shall not occur under normal conditions./ Contact support organisation E119 | Steer servo error during | Home position (steering straight) not achieved within preset homing operation (Time | time. out) Home reference sensor [S65] not adjusted correctly Faulty reference sensor / Check reference sensor gap is adjusted correctly, check wiring to sensor 10-76 Servicemanual _ SPE125,1251, 1358, 160, 160L,200D, 200, 200. © BT Europe ABElectrical systems — 5000 Diagnostic’ and troubleshooting Bestallningsnr. Datum Giller fran maskinnr. T-kod 230076-020 2006-10-02 924d54- 789, 790, 791, 792, 817, 818 Table 31: List of fault codes Cod | Description Possible cause / Hint or Solution e £120 | Steer servo- potentiome- | Comparison of voltages between IN_0 & IN_1 is out of range. / ter error Check potentiometer inputs E121 | Steer servo error-steer- | Restart the truck ing angle value check Check that sum of voltages between wire nos. 92-94 and 93-94 = 5V Re calibrate steering (See “# 36 - Calibrate” on page 54) E722 | Steer servo -reference steer servo [AS] Check voltage between wire nos. supply out of range 4,510 5,5V. £123 | Steer servo - Hall sensor | Intermittent contacts inside steer servo fault Defective steer servo [AS] | Check internal connections from Hall sensors to main circuit board in steer servo [A5] E124 | Steer servo - overvolt- May occur when performing heavy reverse braking on newly age [A5] charged battery (Voltage exceeded 39V) / Restart the truck £125 | Steer servo - internal Defective steer servo [A5,M6] / short circuit [A5, M6) Check wiring for short-circuit Restart the truck £126 | Steer servo - current off- | Defective steer servo [A5,M6] / Restart the truck set error [A5, M6] £127 | Steer servo - tempera- Steer servo internal temperature outside range -40 to +85° C ture error[A5, M6] Steering activity may be too intensive Defective steer servo [A5,M6] / Restart the truck (See also code C35) E128 | Notapplicable inthis | - truck E129 | Steer servo - supply und- | Battery charge too low ervoltage Intermittent connection in servo supply circuit [AS] Steer servo fuse [F52] faulty or blown. / Check condition of Fuse [F52] Charge battery £730 | Steer servo- analogue _ | Faully steer angle potentiometer [R2] steer signal input fault Intermittent connection in potentiometer circuit [R2,A5] / Check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist. E131 | Steer servo - analogue _| Faulty steer angle potentiometer [R2] steer signal input 0 fault | Intermittent connection in potentiometer circuit [R2,A5:INP.A_INO] / Check 0,4 to 4.8V between wires 94-93, check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist. ©BT Europe AB ‘Servicemanual ‘SPE125,1251,135S, 160, 160L,200D, 200, 200L. 10-77Electrical systems — 5000 Diagnostic and troubleshooting T-kod Galler fran maskinnr. Datum Bestallningsnr. 789, 790, 791, 792, 817, 818 924454- 2006-10-02 230076-020 Table 31: List of fault codes Cod | Description Possible cause / Hint or Solution e £132 | Steer servo - current limit | Output current to steer motor exceeding 80% of maximum for reached longer than 5 seconds. Steered portion of drive unit not moving freely./ Check for free movement of drive wheel on floor. Check steering drive train is free of dirt or other foreign objects.(See also code C82) £133 | Steer servo - analogue _| Faulty steer angle potentiometer [R2] steer signal input 1 fault | Intermittent connection in potentiometer circuit [R2,A5:INP.A_IN1] / Check 0,4 to 4.8V between wires 94-92 , check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist. £134 | Steer servo - analogue _| Faulty steer angle potentiometer [R2] or wiring short circuit steer signal input short | between [A5:INP.A_IN1 and INP.A_INO] / Check wiring to circuit potentiometer [R2], Move tiller handle in all directions to ensure no wiring problems exist. E135 | Steer servo - offset value | Vollage difference between [AS:INP.A_IN1 and INP.A_INO]is error too great Requires re calibration / Re calibrate steering (parameter #36) ‘See “ # 36 - Calibrate” on page 54 E136 | Steer servo- steer angle | Calibrated neutral position value is out of range. potentiometer error Defective potentiometer [R2] / Ensure potentiometer is fitted correctly. Re calibrate steering (parameter #36). See “## 36 - Calibrate” ‘on page 54 E137 | Steer servo - checksum Faulty wiring / Check CAN bus signal cables and connec- error on received data tions.[A5, A2] Restart the truck £138 | CAN data not received _ | Data from traction transistor regulator not received by [A2] Faulty wiring / Check CAN bus signal cables and connec- tions.[A1, A2] Restart the truck £139 | Steer servo - data trans- | Faulty wiring / Check CAN bus signal cables and connec- mission to servo failed | tions.(A5, A2] Restart the truck £140 | Checksum error Faulty internal micro controller [A2], faulty software £141 | Software problem Faulty internal micro controller [A2], faulty software / New soft- ware may need loading via CAN £150 | Data not received - Trac- | Traction transistor regulator [A1] does not answer, bad connec- tion transistor controller _| tions or faulty Traction transistor regulator [A1] E151 | Transmission to traction | Broken CAN-wire, transistor regulator failed | Traction transistor regulator [A1] defective 10-78 Servicemanual _ SPE125,1251, 1358, 160, 160L,200D, 200, 200. © BT Europe ABElectrical systems — 5000 Diagnostic’ and troubleshooting Bestallningsnr. Datum Giller fran maskinnr. T-kod 230076-020 2006-10-02 924d54- 789, 790, 791, 792, 817, 818 Table 31: List of fault codes Cod | Description Possible cause / Hint or Solution e E157 | Bus off error ‘CAN-bus problem, wiring hamess or hardware problem [A2]/ Check CAN wiring £759 | Over-run error CAN-bus problem, wiring hamess or hardware problem [A2]/ Check CAN wiring E160 | Error -safety switch Error in Hall sensor for safety switch against collision "belly against collision button’/ Check switch is not activated. £200 | Drive motor field circuit Shunt field open [M1], harness broken, Traction transistor reg- ‘open ulator defective [A1]. / Check wiring and connections to shunt field [M1] £201 | M minus error Problem with switch transistor in armature circuit inside Trac- tion transistor regulator [A1] Defective Traction transistor regulator [A1]. £202 | Current sensor error- | Armature current sensor fault in Traction transistor regulator traction transistor regula- | [A1]. tor [A1] Defective Traction transistor regulator [A1] £214 | CAN-timeout error - trac- | Traction transistor regulator reports unexpected loss of data tion transistor regulator flow from tiller head [A2]./ Check CAN bus signal cables and [At] connections ©BT Europe AB ‘Servicemanual ‘SPE125,1251,135S, 160, 160L,200D, 200, 200L. 10-79