ELECTRICAL SYSTEM

Event Code Group 500 (GPC3020 up to 08/2012)

Event Code Group 500 (GPC3020 up to 08/2012)

Note: Valid only for GPC3020 up to 08/2012. Now recalibrate the truck. If necessary adjust the Pa-
If an event code keeps occurring without an obvious rameters and Features.
cause, do not replace the control module immediately. See also:
First clear the EEPROM of the control module in ques- • Calibration, page 118
tion. This restores the factory settings.
• Parameter Setting for GPC 3020 (up to 08/2012),
page 114

Event Tool Opera- Description Remedy

Code LED tor
error
LED

500 X - Control module internal error. - Replace control module.

501 X - Memory error. Parameter changes have - Re-load the default settings (attention
been cleared or are no longer stored. - this resets the default settings of all
The truck can operate, but uses the de- the control modules.): SERVICE
fault settings. MENU > PERFORMANCE > P20 >
LOAD FACTORY DEFAULTS
- If the error persists after switching the
truck off and on again, replace the con-
trol module.
502 X - Control module internal error. - Replace control module.
503 X - Control module internal error. - Replace control module.
504 X - Control module internal error. - Replace control module.
505 X - Control module internal error. - Replace control module.
506 X - Control module internal error. - Replace control module.
507 X - Open the main contactor. Access 3 has not closed the main con-
tactor in 1.5 seconds:
- In the SERVICE MENU > EVENTS >
E1 > CHRON HISTORY check events
triggered by Access 3.
- For troubleshooting see event code
306, page 127.
508 X - Control module internal error. - Replace control module.
Steer con- - X Access 5 heatsink temperature above - Test the fan: Service Level 3 > Ana-
trol mod- 75°C. lyzer Menu > A4.1 > FN1. Replace the
ule hot fan if faulty.
- Check the air duct and fan for contam-
ination and foreign bodies. Clean if
necessary.
- Check Access 5 temperature: If the
control module is not hot, the air duct
clean and free of foreign bodies and
the fan is working, the control module
is faulty. Replace control module.

134
 ELECTRICAL SYSTEM
Event Code Group 500 (GPC3020 up to 08/2012)

Event Tool Opera- Description Remedy

Code LED tor
error
LED

Steer mo- - X Motor temperature in the coils above - Check steer motor temperature sen-
tor hot 150°C. sor: R20 °C = 581 Ω and R120 °C =
1227 Ω. If the sensor is faulty, repair or
replace the motor.
- If the motor temperature is normal and
the sensor is not defective, then the
control module is faulty. Replace con-
trol module.
509 X - Control module internal error. - Replace control module.
510 X - Phase V does not conduct current. - Check fuse FU8.
- Check power cable connections on the
control module, voltage present be-
tween B+ and B- on control module?
If there is voltage present and the wiring
is ok, replace the control module.
511 X - Phase U does not conduct current. - Check fuse FU8.
- Check power cable connections on the
control module, voltage present be-
tween B+ and B- on control module?
If there is voltage present and the wiring
is ok, replace the control module.
512 X - Phase W does not conduct current. - Check fuse FU8.
- Check power cable connections on the
control module, voltage present be-
tween B+ and B- on control module?
If there is voltage present and the wiring
is ok, replace the control module.
513 X - Channels A & B swapped on encoder - Exchange CA202-7 and CA202-8.
ECR1.

135
ELECTRICAL SYSTEM
Event Code Group 500 (GPC3020 up to 08/2012)

Event Tool Opera- Description Remedy

Code LED tor
error
LED

514 X - Steer sensor signal interrupted. - This error can occur temporarily due to
a major impact on the truck. Restart
the truck.
- If the error persists after restarting the
truck, check the wiring:
Measure the voltage between CA220-
4 and CA220-2 while moving the steer-
ing to the left. The voltage must drop
from 2.5 V to 0.5 V. If it does not, then
either the wiring or the steer sensor is
faulty. Replace the steer sensor.
If ok, then measure the voltage be-
tween CA220-3 and CA220-2 while
moving the steering to the right. The
voltage must drop from 4.5 V to 2.5 V.
If it does not, then either the wiring or
the steer sensor is faulty. Replace the
steer sensor.
515 - X Steering hazard. - The message is reset as soon as the
The steering has applied and intercepted steering reverts to neutral.
a steering angle which was too great for
the current speed.
516 X - Safety relays in the control module have - Check wiring between CA201-4 and
not closed. CA200-7.
- Disconnect CA201 and measure the
voltage on pin 4 of the connector. If the
voltage > 12 V and there is no short
circuit in the wire, the problem lies with
Access 3.
- Check Access 3 event codes.

136
 ELECTRICAL SYSTEM
Event Code Group 500 (GPC3020 up to 08/2012)

Event Tool Opera- Description Remedy

Code LED tor
error
LED

517 X - In idle and with the steering in neutral the - Check encoder ECR1. To do this, in
SAHS (Straight Ahead Sensor) continu- the service menu select Analyzer
ally switches On/Off. Menu > Access 5 Inputs > A2.5.6 &
A2.5.7 > ECR1:
Steer left and right. The number of
pulses must change without interrup-
tion. If not, replace ESR1.
- Jack up the truck and check the steer-
ing bearing for slack. (If there is any
slack in the bearing the transmission
will tip and the cam will be removed
from the sensor).
- Check SAHS:
Turn the steering to the right, the sen-
sor LED must be permanently off.
Turn the steering to the left, the sensor
LED must be permanently on. If the
LED is not permanently on or off re-
spectively, check the edge of the cam
on the transmission for possible build-
up of conductive contamination. Clean
if necessary.
- Check the screw-in depth of SAHS.
See page 296.
- If none of the above problems is the
cause, replace the control module.
518 X - Control module internal error. - Replace control module.
519 X - Control module internal error. - Replace control module.
520 X - Control module internal error. - Replace control module.
522 X - Control module internal error. - Replace control module.
523 X - Steer motor blocked. (The maximum cur- - Check if the drive tyre is blocked (for
rent is drawn for more than 1 second). example, if it is stuck in a hole).
- Check if motor wiring has shorted.
- Check motor insulation resistance.
524 X - Control module internal error. - Replace control module.
525 X - Feedback sensors (ECR1 & ECR2) do - Check if the drive tyre is blocked (for
not change value when the steer sensor example, if it is stuck in a hole).
output level changes. - Check if the steer sensor is physically
jammed.
- If the steer motor was replaced before,
check the motor direction of turn. If it is
turning the wrong direction, the power
cable connections have been
swapped.

137
ELECTRICAL SYSTEM
Event Code Group 500 (GPC3020 up to 08/2012)

Event Tool Opera- Description Remedy

Code LED tor
error
LED

526 X - The steer sensor has an unstable output - Check if the steer sensor is physically
voltage (fluctuations >0.3 V in less than jammed.
16 ms). - Replace steer sensor.
527 X - Control module internal error. - Replace control module.
528 X - Control module internal error. - Replace control module.
529 X - Control module internal error. - Replace control module.
530 X - Position error. Steer sensor and feed- - Check if the steer sensor is physically
back encoder (ECR1) give different posi- jammed. Check wiring for a short cir-
tions. cuit. Check if the connector is correctly
positioned.
- If the steer sensor is ok: Check if the
drive tyre is blocked (for example, if it
is stuck in a hole). If this is also not the
case, replace encoder ECR1 (or the
entire steer motor).
531 X - Access 3 parameter list cannot be read. - Check CAN Bus between Access 3
Steering not operational. and Access 5:
Switch off the truck and measure the
resistance between CA210-1 and
CA210-2. It must be = 60 Ω.
- Leave the truck switched off and dis-
connect CA201. Measure the resist-
ance between CA201-A14 and
CA201-A6. It must be = 120 Ω. If not,
then replace the control module.
532 X - Steering control module cannot align the - Check wiring of the SAHS and the con-
drive tyre when the truck is switched on. nector for damage.
- In the Service Menu > Analyzer Menu
> Access 5 inputs > A2.5.8 Straight
Ahead Sensor check the connection
status of the SAHS. The connection
status must change for a +/- 10° steer-
ing request (this can be observed di-
rectly on the LED of the SAHS).
- Check the edge of the cam on the
transmission (by removing the SAHS)
for possible build-up of conductive
contamination. Clean if necessary.
- Jack up the truck and check the steer-
ing bearing for slack. (If there is any
slack in the bearing the transmission
will tip and the cam will be removed
from the sensor).
- If the error persists, replace the SAHS.
See page 296.

138
 ELECTRICAL SYSTEM
Event Code Group 500 (GPC3020 up to 08/2012)

Event Tool Opera- Description Remedy

Code LED tor
error
LED

533 X - An error in Access 3 prevents the two - Check Access 3 event codes:
safety relays in Access 5 from closing. Service Menu > Events > E1 >
The steer control module remains CHRON HISTORY
switched off.
534 X - Frequency of feedback encoder ECR1 is - Software version error. In the SER-
out of range. VICE MENU > UTILITIES > U1 > U1.4
> ACCESS 5 > U1.4.2 >
SOFTWARE PN check the version
number.
- Check wiring of ECR1 and ECR2.
- If the software version is correct and
the wiring is ok, replace encoder ECR1
(or the entire steer motor).
535 X - Control module internal error. - Replace control module.
536 X - Data request takes too long. - Switch the truck off and on again.
537 X - Control module internal error. - Replace control module.
538 X - CAN Bus communication between - Check CAN Bus between Access 3
Access 5 and Access 3 failed for more and Access 5. To do this, switch off the
than one second. truck:
Measure the resistance between
CA210-1 and CA210-2. It must be =
60 Ω.
Disconnect CA201 and measure the
resistance between CA201-A14 and
CA201-A6. It must be = 120 Ω.
Disconnect CA400 and measure the
resistance between CA400-8 and
CA400-9. It must be = 120 Ω.
Disconnect CA200 and measure the
resistance between CA200-27 and
CA200-42. It must be = ∞.
- Disconnect CA205 and CA207. Meas-
ure the resistance on both interface
cards between pins B1 & B4. It must
be = ∞.

139
ELECTRICAL SYSTEM
Event Code Group 500 (GPC3020 up to 08/2012)

Event Tool Opera- Description Remedy

Code LED tor
error
LED

540 X - Position error between encoder ECR1 - Check ECR1 wiring and connector.
and SAHS. - In the service menu select Analyzer >
A2 > Access 5 Inputs > A2.5.6 and
turn the steering to the right. This must
increase the reading. If not, replace
encoder ECR1 (or the entire steer mo-
tor).
- In the Service Menu > Analyzer Menu
> Access 5 inputs > A2.5.8 Straight
Ahead Sensor check the connection
status of the SAHS. The connection
status must change for a +/- 10° steer-
ing request (this can be observed di-
rectly on the LED of the SAHS).
- Check the edge of the cam on the
transmission (by removing the SAHS)
for possible build-up of conductive
contamination. Clean if necessary.
See page 296.
- If the error persists, replace the SAHS.
See page 296.
- If the error still persists, replace
Access 5.
541 X - Control module internal error. - Replace control module.
542 X - Control module internal error. - Replace control module.
543 X - Control module internal error. - Replace control module.
544 X - Safety relay KM (internal) closed but - Check wiring from CA201-4 and
should be open. CA201-5 to CA200-7 for a short circuit.
- Switch off the truck and disconnect
CA201. Measure the resistance be-
tween CA201-4 and CA201-5. It must
be = ∞. If not, replace Access 5.
545 X - Safety relay KS (internal) closed but - Check wiring from CA201-4 and
should be open. CA201-5 to CA200-7 for a short circuit.
- Switch off the truck and disconnect
CA201. Measure the resistance be-
tween CA201-4 and CA201-5. It must
be = ∞. If not, replace Access 5.

140