RT4000

ELECTRICAL SYSTEM
Event Codes
Event Codes Event code groups

This truck is fitted with an electronic control system for The first digit of an event code represents the group
the key operating functions. number. For example, if an event code starts with the
digit 2, then the event has occurred in the Access 2
Malfunctions with event code dis- module.
play
Event Code Groups
Event codes are produced from tests carried out on the
input and output of control signals. For most events the Group Module concerned
system generates an event code and stores it in the log
book. The last 15 events are displayed in the Events 100 Access 1 (Display control module)
menu. 200 Access 2 (Hydraulic control module)
Locating malfunctions 300 Access 3 (Traction control module)
Malfunctions occur primarily with external components. 400 Not used
Examples include:
500 Access 5 (Steering control module)
• Solenoid Valves
• Contactors 600 Not used
• Motors 700 Not used
These components are necessarily subject to a certain 800, 900 Access 8.x (CAN interfaces)
degree of wear.
1000 Access 10 (Battery control module)
Secondary level causes include:
• Fuses
• Plug connectors
• Electrical wiring
• Switches
• Potentiometers
• Encoders
These components are subject in particular to environ-
mental conditions.
Note: From experience, control modules rarely fail.
The easiest way of locating a fault is to start trouble-
shooting on the consumer (the external component).
The following sections list the event code numbers in
ascending order. In addition to each event code they
also list the possible causes, the effect on the truck and
troubleshooting notes.
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ELECTRICAL SYSTEM
Calibrate the load sensor
Calibrate the load sensor Save the calibration

13. Press the key.
Calibration is necessary after:
 The new settings are stored.
• The EEPROM has been cleared in Access 2/3  C3 LOAD SENSOR is displayed.
• Access 2/3 has been replaced 14. Wait for 5 seconds.
• A software update  After 5 seconds the new settings are stored.
• The load sensor has been replaced Activate the new setting
Requirements 15. Switch the truck off. Switch it on again.
• A test load with the maximum truck capacity is  The new settings are activated.
available. 16. Carry out a test run.
• The Calibration menu is selected (see Select the
Calibration menu, page 110).
Select load sensor calibration
1. Press the key.
 The C1 PF/FF ROCKER menu is selected.
2. Press the key twice.
 C3 LOAD SENSOR is displayed.
3. Press the key.
 The safety prompt SURE? N is displayed.
Confirm the security prompt
4. Press the key.
 The safety prompt SURE? Y appears.
5. Press the key.
 C3.1 AQUIRE MIN LOAD is displayed.
Calibrate the zero point
6. Lower the forks without load to the ground.
7. Press the key.
 The zero point is confirmed.
8. Press the key.
 C3.2 AQUIRE MAX LOAD is displayed.
Calibrate the maximum load
9. Raise the maximum permissible load (see data
plate).
10. Press the key.
 The maximum load is confirmed.
11. Press the key.
 The prompt for saving SAVE? N is displayed.
Note: To cancel the calibration, press the key.
Confirm the security prompt
12. Press the key.
 The prompt SAVE? Y appears.
112
ELECTRICAL SYSTEM
Event Code Group 100
Event Code Group 100 Now recalibrate the truck. If necessary adjust the pa-
rameter settings.
If an event code keeps occurring without an obvious
See also:
cause, do not replace the control module immediately.
First clear the EEPROM of the control module in ques- Parameter Settings, page 107.
tion. The factory settings are then restored.
Event code 100

Display: EV 100
Service display: On
Operator LED: Off
Explanation: Access 1 does not obtain a reply from Access 3.
Possible causes: • Wiring error
• Access 1 faulty
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch the truck off. Disconnect the battery. Wait for 6 seconds. Connect
the battery. Switch the truck on.
 If the event code no longer occurs, the fault has been rectified.
 If the event code occurs again, proceed to step 2.
Check status of Access 1
2. Select service level 2 (see page 81).
3. Press the key 3 times.
 A1.1 Access 1 ON or OFF is displayed.
 If the status is ON, proceed to step 14.
 If the status is OFF, proceed to step 4.
Check connectors CA201 and CA200 for damage
4. Disconnect CA201 from Access 2/3 and CA200 from Access 1.
5. Measure the resistance between PC200-8 and PC201-28.
 If the resistance of one or both wires > 2 Ω, repair the wiring.
 If the resistance < 2 Ω, , proceed to step 7.
Check the power supply
7. Connect PC200 and PC201.
8. Switch the truck on.
9. Measure the voltage between CA201-10 and B–.
 If the voltage is approx. 24 V, proceed to step 10.
 If there is no voltage or if the voltage is less than 24 V, proceed to step
19.
Check CAN-Bus wiring and termination
10. Switch the truck off.
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ELECTRICAL SYSTEM
11. Measure the resistance between CA220-1 and CA220-2.

 If the resistance is 60 Ω, the CAN-Bus termination is ok. Proceed to
step 14.
 If the resistance is not 60 Ω, proceed to step 12.
12. Disconnect CA200.
13. Measure the resistance between JC200-8 and JC200-9.
 If the resistance is 120 Ω, ι, the resistor in Access 1 is ok. Proceed to
step 14.
 If the resistance is not 120 Ω, ι, Access 1 is faulty. Proceed to step 20.
Check Access 1 software version
15. Using the key scroll through to the UTILITIES menu.
 The software version (PN) of Access 1 is displayed.
17. If the software version matches the other modules, proceed to step 20.
18. If the software version does not match the other modules, install the cor-
rect software version or proceed to step 20.
Repair wiring
19. Repair the wiring.
Replace Access 1
20. Replace Access 1.
114
ELECTRICAL SYSTEM

If an event code keeps occurring without an obvious Now recalibrate the truck. If necessary adjust the pa-
cause, do not replace the control module immediately. rameter settings.
First clear the EEPROM of the control module in ques- See also:
tion. The factory settings are then restored.
• Calibration, page 110
• Parameter Settings, page 107
Event code 202

Display: EV 202
Service display: On
Operator LED: Off
Explanation: Voltage at terminal -P of Access 2 is too low.
Possible causes: If the event is displayed during power up, but before the main contactor
applies:
• The power cables to pump motor M2 have a poor contact, are damaged or
connected incorrectly
• Access 2 output stage is faulty
If the event is displayed during power up, but after the main contactor
has applied:
• Check the power cable connections on pump motor M2
• Insulation resistances from the power cables or the winding of pump motor
M2 to the chassis are too low
If the event is displayed during lifting:
• The power cables to pump motor M2 have a poor contact, are damaged or
• Insulation resistances from the power cables or the winding of pump motor
M2 to the chassis are too low
• Main contactor tips are worn
Remedy: If the event is displayed during power up, but before the main contactor
applies:
Check the power cables and connections
1. Check the power cables to pump motor M2 and its connections are secure
and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 2.
Check the insulation resistance
2. Measure the insulation resistances of the motor coil and power cables
against the chassis.
 If the insulation resistance is ok, proceed to step 3.
 If there is a short to the chassis, locate and replace the faulty compo-
nents.
Check if the Access 2 output stage has shorted
3. Disconnect power cable from terminal -P on Access 2.
115
ELECTRICAL SYSTEM
4. Measure the resistance between terminal –P on Access 2 and B-NEG.

 If the resistance < 3 kΩ, the output stage is faulty. Replace Access 2/3.
 If the resistance > 100 kΩ, the output stage is faulty. The wiring from –
P to pump motor M2 or the wiring to the terminal on pump motor M2 is
faulty.
If the event is displayed after the main contactor has applied:
 If any cables are loose or damaged, rectify the cause.
nents.
7. Switch the truck off and on. Check if the error now occurs when the truck
is switched on.
 If the error now occurs when the truck is switched on, carry out steps3
to 4.
If the event is displayed during lifting:
 If any cables are loose or damaged, rectify the cause.
nents.
Checking the main contactor
10. Check the contacts of the main contactor for wear (see page 220).
 If the contacts are worn, repair the contactor.
 If all the above measures have been carried out and the event code per-
sists, replace Access 2/3.
116
ELECTRICAL SYSTEM
Event code 203

Display: EV 203
Service display: On
Operator LED: Off
Explanation: Voltage at terminal -P of Access 2 is higher than the battery voltage.
Possible causes: • The power cables to pump motor M2 have a poor contact, are damaged or
• Access 2 faulty
Remedy: Check the power cables and connections
1. Check power cables to pump motor M2 and their connections.
nents.
 If the insulation resistance is ok, replace Access 2/3.
Event code 204

Display: EV 204
Service display: On
Operator LED: Off
Explanation: As the pump motor starts up the current measured by Access 2 is either zero
or out of range.
• Access 2 faulty
1. Check power cables to pump motor M2 and their connections.
Test the current sensor in Access 2
3. Press the key.
 A1 Status is displayed.
4. Press the key.
 A2 Inputs is displayed.
5. Press the key.
 A2.1 ACCESS 1 is displayed.
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ELECTRICAL SYSTEM
6. Press the key.

7. Press the key.
 A2.2.1 RAS SWITCH is displayed.
8. Using the key scroll through to A2.2.4.
 A2.2.4 PUMP MOTOR CURRENT is displayed.
9. Press the key.
 The current reading is displayed in Amps.
10. Activate lifting. Check the reading.
 If the reading remains at 0 A as the motor is running, proceed to step 11.
 If a current > 0 A is displayed while the motor is running, there is no
error. Restart the truck. Check the event log.
Clear the EEPROM in Access 1
12. Press to scroll to the Features menu.
13. Press the key,
 F1 LANGUAGE is displayed.
14. Using the key scroll through to the F8 EEPROM CLEAR menu.
15. Press the key.
 NO is displayed.
16. Press the key.
 YES is displayed.
17. Press the key.
 ACCESS 1 is displayed.
18. Press the key.
Note: To cancel press the key.
19. Press the key.
20. Press the key.
 The EEPROM is cleared.
 CLEARED is displayed.
21. Switch the truck off and on.
22. Re-calibrate the truck.
 If the event code persists, proceed to step 23.
nents.
118
ELECTRICAL SYSTEM
Event code 205

Display: EV 205
Service display: On
Operator LED: Off
Explanation: While the pump motor is idle the current measured by Access 2 is > 0 A.
• Access 2 faulty
Test the current sensor in Access 2
3. Press the key.
 A1 STATUS is displayed.
4. Press the key.
 A2 INPUTS is displayed.
5. Press the key.
6. Press the key.
7. Press the key.
8. Using the key scroll through to A2.2.4.
 A2.2.4 PUMP MOTOR CURRENT is displayed.
9. Press the key.
 The current reading is displayed in Amps.
10. Activate lifting. Check the reading.
 If the reading remains at 0 A as the motor is running, proceed to step 11.
 If a current > 0 A is displayed while the motor is running, there is no
error. Restart the truck. Check the event log.
Clear EEPROM in Access 1 and Access 2/3
13. Press the key,
15. Press the key.
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ELECTRICAL SYSTEM
16. Press the key.

17. Press the key.
18. Press the key.
19. Press the key.
20. Press the key.
 The EEPROM in Access 1 is cleared.
21. Press the key.
22. Press the key.
 ACCESS 2 & 3 is displayed.
23. Press the key.
24. Press the key.
25. Press the key.
 The EEPROM in Access 2/3 is cleared.
27. Re-calibrate the truck.
nents.
120
ELECTRICAL SYSTEM
Event code 208

Display: EV 208
Service display: On
Operator LED: Off
Explanation: As the truck is powered up the voltage on the power part of Access 2 is greater
than 0 V.
are shorted with respect to each other
• Access 2/3 is faulty
nents.
Check power cables for short circuits with respect to each other
3. Unscrew both power cables from the motor (+ and -) and Access 2/3 (+Batt
and
–P).
4. Measure the resistance of the cables with respect to each other.
 If there is a short replace the power cables.
 If the resistance is ∞, there is no short circuit. Proceed to step 5.
Replace Access 2/3
5. Replace Access 2/3.
121
ELECTRICAL SYSTEM
Event code 228

Display: EV 228
Service display On
Operator LED: Off
Explanation: One or more drivers for FAN, HN, ALM or FLS are faulty.
Possible causes: • One of the connected components is faulty
• Access 2/3 is faulty
Remedy: Check the connected components for physical damage
1. Check FAN, HN, ALM and FLS for physical damage.
 Replace any faulty components.
 If the components are ok, proceed to step 2.
Locate the affected driver
2. Switch the truck off. Switch it on again.
3. Activate the connected components HN, ALM and FLS in turn and individ-
ually. In the process check if event 228 is displayed for one of these com-
ponents.
 If the event is displayed on one of the components, replace the compo-
nent or repair its wiring.
 If no short is found in HN, ALM or FLS, proceed to step 4.
Check fan (FAN) driver
5. Press the key.
6. Using the key scroll through to the A4 TEST OUTPUTS menu.
7. Press the key.
 A4.1 FAN is displayed.
8. Press the key.
 ENTER TO CANCEL is displayed. The fan starts up for 5 seconds.
Note: Press to cancel the test prematurely.
 If event code 228 is displayed, repair the wiring to the fan or replace the
fan.
 If no short is found in HN, ALM or FLS, proceed to step 9.
Replace Access 2/3
122
ELECTRICAL SYSTEM
Event code 229

Display: EV 229
Service display On
Operator LED: Off
Explanation: One or more drivers for FAN, HN, ALM or FLS have a short.
Possible causes: • Physical damage to one of the attached components
• Short circuit in the feed wire to one of the attached components
• Access 2 faulty
Remedy: Check the connected components for physical damage
1. Check FAN, HN, ALM and FLS for physical damage.
 If one component is damaged, replace the faulty component.
 If the components are ok, proceed to step 2.
Check terminals for short circuits or open connections
2. Check connections and wiring for FAN, HN, ALM and FLS for shorts or
open connections.
 If there is a short or an open connection, repair the wiring.
 If the wiring is ok, proceed to step 3.
Activate the travel alarm driver output
Note: All drivers are monitored even if some options are not installed. All driv-
ers must therefore be activated in order to test.
4. Press the key.
6. Press the key.
7. Using the key scroll through to the F2 TRAVEL ALARM ALM menu.
 The current setting OFF, BOTH, FF or PF is displayed.
8. If BOTH is not set, press .
 OFF is displayed.
9. Using the key, select BOTH.
10. Press the key.
 The travel alarm is activated for both travel directions.
Activate the beacon driver output
11. Press the key.
 F2 TRAVEL ALARM ALM is displayed.
12. Using the key scroll through to the F3 BEACON FLS menu.
 The current setting OFF, BOTH, FF or PF is displayed.
13. If BOTH is not set, press .
 OFF is displayed.
123
ELECTRICAL SYSTEM
14. Using the key, select BOTH.

15. Press the key.
 The beacon driver is activated for both travel directions.
16. Disconnect the +wires (red/white) from all the components connected to
the drivers. Make wires to the unused driver outputs accessible.
17. Using an ohmmeter measure each driver output in turn between the neg-
ative wires (green/white) and +Batt.
 If the resistance is at least 10 k, the respective 10 kΩ, driver output is
ok.
 If less than 10 kΩ is measured on a driver output, proceed to step 18.
Replace Access 2/3
124
ELECTRICAL SYSTEM
Event code 230

Display: EV 230
Service display On
Operator LED: Off
Explanation: One or more of the following components have an internal short circuit: FAN,
HN, ALM or FLS.
Possible causes: • Short circuit in one of the attached components
• Access 2 faulty
Remedy: Rule out the main contactor circuit
 If the error occurs when the truck is switched on, the main contactor
circuit is affected. Proceed to step 8.
 If the truck starts normally, proceed to step 2.
Restrict error in the power circuits
2. Activate the connected components BR, HN, ALM and FS in turn and in-
dividually. In the process check for which component event EV 230 is dis-
played.
Note: If both options ALM and FS are installed, adjust these options before the
test so that they do not switch simultaneously. In the Features menu set the
options F2 TRAVEL ALARM ALM to FF and F3 BEACON FLS to PF.
 If event 230 is displayed for one of these components, proceed to step
9.
 If event 230 is not displayed, proceed to step 3.
Switch on the fan
4. Press the key.
5. Using the key scroll through to the A4 TEST OUTPUTS menu.
6. Press the key.
 A4.1 FAN is displayed.
7. Press the key.
 ENTER TO CANCEL is displayed. The fan starts up for 5 seconds.
Note: Press to cancel the test prematurely.
 If event 230 is displayed, repair the wiring to the fan or replace the fan.
 If event 230 is not displayed, proceed to step 10.
Measure the affected component
8. Disconnect the positive wire (red/white) and the negative wire (green/
white) from the respective component.
Note: If ALM or FLS are affected, disconnect the positive wire (red/white) and
the negative wire (green/white) from both components.
125
ELECTRICAL SYSTEM
9. Using an ohmmeter measure the resistance of the actuating components:

– EDS = 18 Ω
– BRK = 13 Ω
– FAN > 100 kΩ
– PV = 31 Ω
– HN > 100 kΩ
– ALM > 100 kΩ
– FLS > 100 kΩ
 If the resistance at ALM and FLS is at least 6 MΩ these components are
ok. Proceed to step 10.
 If the resistance at FLS or ALM is still only approx. 10 Ω, replace the
component.
 If the resistance on all other components is ok, proceed to step 10.
 If the resistance of one component (apart from ALM and FLS) does not
match the above readings, replace the component.
Replace Access 2/3
Event code 231

Display: EV 231
Service display On
Operator LED: Off
Explanation: The control module detects an open circuit on the lowering valve SV
Possible causes: • Faulty coil in lowering valve
• Disconnected circuit to lowering valve
• Access 2 faulty
Remedy: Test the lowering command
2. Press the key.
3. Press the key.
4. Press the key.
5. Press the key.
6. Press the key.
 A2.2.1 RAS ENC is displayed.
7. Press the key.
 A2.2.1 LOS ENC is displayed.
126
ELECTRICAL SYSTEM
8. Press the key.

 The current reading (0 if not applied) is displayed.
9. Apply the fork lift switch (RAS ENC). Check the display.
 If the reading is 1, there is no fault. Restart the truck. Check the event
log.
 If the reading remains at 0, proceed to step 10.
Check the wiring and lowering valve for physical damage
10. Check wiring and lowering valve SV for physical damage.
 If there is no physical damage, proceed to step 11.
 If there is physical damage, repair the damaged parts.
Check the coil of the lowering valve SV
11. Open both lines on SV. Measure the coil resistance.
 If the resistance > 100 Ω, replace the valve coil.
 If the resistance < 100 Ω, proceed to step 12.
Check the lowering valve power supply
12. Using an voltmeter measure between the positive wire (red/white) on SV
and B-NEG.
 If the voltage is ≠ +Batt, check fuse FU3 and the wiring to the lowering
valve.
 If the voltage is the same as +Batt, proceed to step 13.
Replace Access 2/3
13. Replace Access 2/3
127
ELECTRICAL SYSTEM
Event code 234

Display: EV 234
Service display On
Operator LED: Off
Explanation: The control module detects a short to B-NEG on the coil of lowering valve SV
Possible causes: • Faulty coil in lowering valve
• Access 2 faulty
Remedy: Test the lowering command
2. Press the key.
3. Press the key.
4. Press the key.
5. Press the key.
6. Press the key.
 A2.2.1 RAS ENC is displayed.
7. Press the key.
 A2.2.1 LOS ENC is displayed.
8. Press the key.
 The current reading (0 if not applied) is displayed.
9. Apply the fork lower switch (LOS ENC). Check the display.
 If the reading is 1 is displayed, proceed to step 11.
 If the reading remains at 0, proceed to step 10.
Check the wiring and lowering valve for physical damage
10. Check LOS ENC, wiring and lowering valve for physical damage.
 If there is no physical damage, proceed to step 12.
 If there is physical damage, repair the damaged parts.
Check the lowering valve coil resistance
11. Remove the connector from the lowering valve.
12. Measure the valve coil resistance.
 If the resistance is ≈30 Ω, the coil is ok. Proceed to step 13.
 If the resistance is not ≈30 Ω, replace the coil.
Replace Access 2/3
128
ELECTRICAL SYSTEM
Event Code - Group 300
Event Code - Group 300 Now recalibrate the truck. If necessary adjust the pa-
rameter settings.
If an event code keeps occurring without an obvious See also:
First clear the EEPROM of the control module in ques-
tion. The factory settings are then restored. • Parameter Settings, page 107
Event code 300

Display: EV 300
Service display: On
Operator LED: Off
Explanation: Watchdog error
Effect: • The traction current is cut out and the main contactor drops.
Possible causes: • Communication error on the CAN bus
• Access 3 faulty
Replace Access 2/3
Event code 301

Display: EV 301
Service display: On
Operator LED: Off
Explanation: EEPROM memory error in Access 3
Possible causes: • Intermittent internal error in Access 3
• Access 3 faulty
Replace Access 2/3
129
ELECTRICAL SYSTEM
Event code 302

Display: EV 302
Service display: On
Operator LED: Off
Explanation: As the truck is switched on, before the main contactor closes, a current > 0 A
is detected in the output stage.
Possible causes: • +Batt and B-NEG terminals on Access 3
• Access 3 faulty
Remedy: Check power cable terminals
1. Check power cable terminals on Access 3, in particular +Batt and B-NEG.
 Repair any faulty terminals.
 If the connections are ok, proceed to step 2.
Replace Access 2/3
Event code 303

Display: EV 303
Service display: On
Operator LED: Off
Explanation: Phase voltage out of range
Possible causes: • +Batt and B-NEG terminals on Access 3
• Access 3 faulty
1. Check power cable connections on Access 2/3. In particular check the
+Batt and B-NEG terminals for corrosion and overheating.
Replace Access 2/3
130
ELECTRICAL SYSTEM
Event code 304

Display: EV 304
Service display: On
Operator LED: Off
Explanation: Low voltage or overvoltage detected. The event occurs if the voltage at pin
CA201-10 drops below 9 V or the voltage at the battery positive terminal of
Access 2/3 exceeds 35 V.
Possible causes: • Battery collapses under load
• Voltage drop via fuse FU2, relay K1 or key switch
• Transitional resistance in terminal of a power cable
• Access 3 faulty
• Battery used with excessive voltagea)
Remedy: Establish the internally measured battery voltage
2. Press the key.
3. Press to scroll to A3 OUTPUTS.
4. Press the key.
 A3.1 Battery % is displayed.
5. Press to scroll to A3.2 BATTERY VOLTAGE.
6. Press the key.
 The internally measured battery voltage is displayed.
7. Note the battery voltage.
Compare internally measured battery voltage with actual battery voltage
8. Measure the battery voltage directly on the battery connector.
9. Compare this reading with the internally measured reading recorded be-
fore.
 If there is a difference, proceed to step 10.
 If the voltage readings are the same, restart the truck and continue to mon-
itor the event display.
Check for battery voltage drop
10. Starting up the truck.
11. Select menu item A3.2 BATTERY VOLTAGE (see step1)
12. Raise a load of approx. 1000 kg up to the lift limit cutout. At the same time
observe the battery voltage display.
 If the battery voltage drops below 22 V, repair the battery or replace it
with a new one.
 If the battery voltage remains above 22 V during the lift test, the battery
is ok. Proceed to step 13.
131
ELECTRICAL SYSTEM
Measure the voltage drop on the positive cable of Access 2/3

13. Measure the voltage from CA201-10 to B-NEG.
 If the voltage ≈ 24 V, the wiring is ok. Proceed to step 18.
Note: The voltage at CA201-10 is always less than the battery voltage. This is
due to the voltage drop via the main contactor, fuse FU2, relay K1 or the key
switch. However, this is only a few tenths of a volt.
 If the voltage is less than 22V, proceed to step 14.
Establish cause of the voltage drop
14. Measure the input and output voltage of the signal switch on the main
contactor.
 If there is no significant voltage drop, proceed to step 15.
 If the voltage drops extremely, replace main contactor.
15. Measure the input and output voltage of fuse FU2.
 If the voltage drops extremely, replace FU2.
16. Measure the voltage at pin 30 (input) and pin 87 (output) of relay K1. If the
truck has a key switch, measure the key switch input and output voltages.
 If the voltage drops significantly, replace relay K1 or the key switch.
17. Measure the voltage drop over the wires:
– Between the main contactor and fuse FU2
– Between FU2 and pin 30 on relay K1
– Pin 87 on relay K1 and pin CA201-10
 If the voltage drops significantly on one wire, repair the wire or connec-
tions.
Replace Access 2/3
a). Theoretically this event code may be displayed in the event of overvoltage. However, this would only occur if a 48 volt battery
connector and a 48 volt battery were installed.
132
ELECTRICAL SYSTEM
Event code 305

Display: EV 305
Service display: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W too low
Possible causes: • The power cables to traction motor M1 have a poor contact or transition
resistances on the terminals.
• Access 3 faulty
1. Check motor power cable terminals. Check terminals for corrosion and
overheating.
2. Check the motor housing insulation resistance to +BV and B-NEG.
 If there is a short to +BV or B–NEG, replace the motor.
Replace Access 2/3
Event code 306

Display: EV 306
Service display: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W too high
Possible causes: • Power cables to traction motor M1 have a short or the motor itself has a
short.
• Access 3 faulty
1. Check terminals and motor power cables for short circuits.
 If there is a short, repair the power cables.
 If the power cables are ok, proceed to step 2.
2. Check the motor housing insulation resistance to +BV and B-NEG.
 If there is a short to +BV or B–NEG, replace the motor.
Replace Access 2/3
133
ELECTRICAL SYSTEM
Event code 307

Display: EV 307
Service display: On
Operator LED: Off
Explanation: On power up a test is performed to check if the main contactor contacts are
open. This event code is issued if the main contactor contacts are already
closed.
Possible causes: • Main contactor power contacts are welded
• Short circuit in the power routing on main contactor
• Access 3 faulty
Remedy: Check power cables
1. Check power cables on the main contactor for shorts.
 If there is a short, repair the power cables.
 If the power cables are ok, proceed to step 2.
Check main contactor contacts
2. Check the contacts of the main contactor (see page 220).
 If the contacts are welded, replace the contacts or the main contactor.
 If the main contactor is ok, proceed to step 3.
Replace Access 2/3
Event code 308

Display: EV 308
Service display: On
Operator LED: Off
Explanation: Main contactor contacts do not close.
Possible causes: • Main contactor contacts jammed
• Fuse FU1 faulty
• A wire to the coil is disconnected
• Main contactor coil faulty
• Access 3 faulty
Remedy: Check fuse FU1
1. Measure the voltage on +Batt of Access 2/3.
 If there is no voltage, replace fuse FU1.
 If FU1 is ok, proceed to step 2.
Check the contactor coil power supply
2. Connect the positive lead of a voltmeter to the +terminal of the coil (2911).
Attach the negative lead of the voltmeter to B-NEG. Switch the truck on.
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ELECTRICAL SYSTEM
 If there is no voltage, proceed to step 3.

 If the reading ≈ 24 V, the positive power supply to the coil is ok. Proceed
to step 4.
Check the control line and coil connections
3. Check wire 5902 between the main contactor coil and pin CA201-12 for
continuity.
 If there is a disconnection, repair the wire.
 If the wire is ok, proceed to step 6.
Check the main contactor coil
4. Remove both wires from the coil.
5. Measure the coil resistance.
 If the coil resistance is significantly less or more than ≈ 18 Ω, replace the
main contactor or main contactor coil.
 If the main contactor coil is ok, proceed to step 6.
Replace Access 2/3
Event code 309

Display: EV 309
Service display: On
Operator LED: Off
Explanation: Current flows to output stage when truck is idle
Possible causes: • Access 3 faulty
Replace Access 2/3
135
ELECTRICAL SYSTEM
Event code 310

Display: EV 310
Service display: On
Operator LED: Off
Explanation: Internal capacitor bank charge time exceeded
Possible causes: • Additional non-approved consumers installed
• Access 3 faulty
Remedy: Check for non-approved consumers
1. Using the circuit diagram and Crown's list of options, check if non-ap-
proved consumers are connected to +BF and B-NEG on Access 2/3.
 Disconnect any non-approved consumers. Proceed to step 2.
 If no non-approved consumers are installed, proceed to step 3.
Replace Access 2/3
Event code 314

Display: EV 314
Service display: On
Operator LED: Off
Explanation: Short circuit in the driver for the main contactor or a disconnection in the exter-
nal circuit exists
Possible causes: • Disconnection in the wires from CA201-10 or -12 to the main contactor coil
• Main contactor coil disconnected
• Access 3 faulty
Remedy: Check the wiring and main contactor coil for shorts
1. Disconnect the battery.
2. Measure the resistance between the negative terminal (wire 5902) on the
main contactor and B-NEG on Access 2/3.
 If the resistance < 10 Ω, proceed to step 3.
 If the resistance > 10 Ω, proceed to step 7.
4. Measure the resistance between PC201-12 and B-NEG on Access 2/3.
 If the resistance < 10 Ω, there is a short in wire 5902 and B-NEG or the
main contactor coil.
 If no short circuit is found, proceed to step 5.
 If there is a short in wire 5902, proceed to step 6.
 If there is a short in the coil, proceed to step 7.
136
ELECTRICAL SYSTEM
Check the control module for shorts in the driver output

5. Disconnect CA201 and measure the resistance between JC201-12 and
B-NEG on Access 2/3.
 If the resistance < 10 Ω, proceed to step 8.
Repair wiring
6. Replace wire
Repair the main contactor
7. Replace the coil.
Replace Access 2/3
Event code 315

Display: EV 315
Service display: On
Operator LED: Off
Explanation: Driver cannot close the main contactor.
Possible causes: • A wire to the main contactor coil is disconnected
• Main contactor coil faulty
• Access 3 faulty
Remedy: Check positive power supply
1. Connect the positive lead of a voltmeter to the +terminal of the coil (2911).
Attach the negative lead of the voltmeter to B-NEG. Switch the truck on.
 If there is no voltage applied, a wire has been disconnected. Repair wire
2911 leading to the contactor coil.
 If the reading ≈ 24 V, the positive power supply to the coil is ok. Proceed
to step 2.
Check the wires and coil connections
2. Check wire 5902 to the main contactor coil for continuity to pin PC201-12.
 If there is a disconnection, repair the wire.
Check the main contactor coil
3. Remove both wires from the coil.
 If the resistance is less than ≈ 18 Ω, replace the main contactor or main
contactor coil.
 If the main contactor coil is ok, proceed to step 5.
Replace Access 2/3
137
ELECTRICAL SYSTEM
Event code 316

Display: EV 316
Service display: On
Operator LED: Off
Explanation: Excessive current through the driver for the main contactor coil or brake coil
Possible causes: • Short circuit in the power circuit of the brake or brake coil
• Short circuit in the power circuit of the main contactor or main contactor coil
• Access 3 faulty
Remedy: Check the wiring to the main contactor coil and the brake for short cir-
cuits
1. Check the wires to the main contactor coil and the brake for short circuits.
2. Check if the terminals on the main contactor have been shorted by a for-
eign body.
 Remove any short circuits found.
 If there is no short, proceed to step 3.
Check the coils of the main contactor coil and the brake for shorts
Note: A short is detected at a resistance of < 2 Ω.
3. Remove both wires from the main contactor coil.
 If the coil resistance is less than ≈ 18 Ω, replace the main contactor or
coil.
 If the coil is ok, proceed to step 5.
5. Remove the wires from the brake.
6. Measure the brake coil resistance.
 If the resistance is not ≈ 13 Ω, replace the brake coil.
 If the brake coil is ok, proceed to step 7.
Replace Access 2/3
138
ELECTRICAL SYSTEM
Event code 317

Display: EV 317
Service display: On
Operator LED: Off
Explanation: When the travel switch is open the zero point of the traction potentiometer
deviates from the calibrated value by more than 1 V.
Possible causes: • Physical defect on the traction potentiometer
• Traction potentiometer replaced but not calibrated
Remedy: Check the traction potentiometer for physical damage
2. Press the key.
3. Press to scroll to the A2 INPUTS menu.
4. Press the key.
6. Press the key.
 A2.3.1 TEMP Access 2/3 is displayed.
7. Using the key scroll through to the A2.3.5 > DRIVE POT menu.
8. Press the key.
 The current reading is displayed.
9. Apply the travel switch in both directions. Then return it to the neutral po-
sition. Monitor the display in the process.
 If the display always reverts to the same reading in neutral, the traction
potentiometer is ok. Calibrate the traction potentiometer (see page
110).
 If the display does not revert to the same reading in neutral, the traction
potentiometer is faulty. Replace the traction potentiometer. Now cali-
brate the traction potentiometer (see page 110).
139
ELECTRICAL SYSTEM
Event code 319

Display: EV 319
Service display: On
Operator LED: Off
Explanation: Load sensor output voltage out of range
Possible causes: • Load sensor not calibrated
• Wiring damaged
• Load sensor faulty
• Access 3 faulty
Remedy: Check the load sensor wiring and output voltages
2. Press the key.
3. Press the key.
4. Press the key.
5. Press the key.
6. Press the key.
7. Press to scroll to A2.2.10.
 A2.2.3 PRESSURE TRANSDUCER is displayed.
8. Press the key.
 The current reading is displayed.
9. Lower the forks without load.
10. Check and record the reading.
11. Raise a load of 2000 kg. Raise the forks.
12. Check and record the reading.
 If the reading without load is 1 ± 0.5 V DC and with load at least 8 ±
0.5 V DC the wiring and load sensor are ok. Proceed to step 15.
 If the voltage is out of range, proceed to step 13
Measure the load sensor power supply
13. Measure the voltage between CA217-1 and B-NEG and between CA217-
2 and B-NEG.
 If the voltage at CA217-1 ≈ 0 VDC and at CA213-2 ≈ 13 VDC, the power
supply is ok. Proceed to step 15.
 If the supply is faulty, proceed to step 14.
140
ELECTRICAL SYSTEM
Locating the fault in the load sensor power supply

14. Check the respective wires and plug connectors of CA217-1 and CA217-
2 leading to CA200-5 and CA201-25 for damage.
 If there is no damage, proceed to step 24.
Calibrate the load sensor
15. Calibrate the load sensor (see page 112).
Measure the load sensor output signal
16. Connect the voltmeter at CA217-3 to B-NEG.
17. Lower the forks without load.
18. Check and record the reading on the voltmeter.
19. Raise a 200 kg load. Raise the forks.
20. Check and record the reading on the voltmeter.
 If the reading without load is 1 ±0,5 V DC and with load is 8 ±0,5 V DC
the load sensor is ok. Proceed to step 15.
 If the reading is above or below the permissible range, proceed to step
21
Replace the load sensor
21. Replace the load sensor. Calibrate the load sensor (see page 112).
Check the signal wire
22. Check the wire between CA217-3 and CA201-30 for damage.
 If the wire or a connector contact is damaged, proceed to step 23.
Repair wiring
Replace Access 2/3
141
ELECTRICAL SYSTEM
Event code 320

Display: EV 320
Service display: On
Operator LED: Off
Explanation: CAN Bus communication failure between Access 3 and Access 1
Possible causes: • Wiring damaged
• Load resistor faulty
 If the resistance is 60 Ω the CAN-Bus termination is ok. Proceed to step
10.
4. Disconnect CA200 from Access 1.
 If the resistance is >1 MΩ the CAN-Bus wiring is ok. Proceed to step 7.
 If the resistance <1 MΩ, proceed to step 9.
7. Measure the load resistance between JC200-8 and JC200-9 (socket on
Access 1).
 If the resistance is 120 Ω, proceed to step 8.
8. Measure the resistance between JC209-14 and JC209-6 on Access 5.
 If the resistance is 120 Ω, Access 5 is ok. Restart the truck. Check the
event log.
 If the resistance is not 120 Ω proceed to step 10.
Repair wiring
Replace Access 5
Replace Access 1
142
ELECTRICAL SYSTEM
Event code 321

Display: EV 321
Service display: On
Operator LED: Off
Explanation: Incorrect truck model selected.
Possible causes: • Control module replaced and truck model not set
Remedy: Set the truck model
2. Press the key.
4. Press the key,
5. Press to scroll to the F4 TRUCK TYPE menu.
6. Press the key.
 RT4020 RH STEER, RT4020 LH STEER or RT4040 is displayed.
7. Press the key to select the right model. (See truck data plate).
8. Press the key.
 The selected model is stored.
9. Wait for 5 seconds.
10. Restart the truck.
11. Set the parameters if necessary (see page 107).
12. Calibrate the truck (see page 110).
143
ELECTRICAL SYSTEM
Event code 322

Display: EV 322
Service display: On
Operator LED: Off
Explanation: Short circuit in the brake positive wire
Possible causes: • Wiring short circuit
Remedy: Check wiring
 If the reading ≈ +BV, proceed to step 2.
 If the voltage is not ≈ +BV, remove the short circuit between the positive
cable (red/white) on the brake and PC200-4.
2. Remove the brake negative terminal (green/white) from the brake.
Replace Access 2/3
Event code 326

Display: EV 326
Service display: On
Operator LED: Off
Explanation: Power output stage short circuit
Possible causes: • Short circuit in the power cables
• Control module faulty
1. Switch the truck off. Disconnect the battery.
2. Check the power cable to the traction motor M1 and its terminals for short
circuits.
3. Check the power cable terminals on the controller for shorts with +Batt and
B-NEG terminals.
 If any power cables or terminals are shorted, rectify the cause.
nents.
144
ELECTRICAL SYSTEM
Check control module

5. On the control module unscrew the power cables from terminals U, V and
W.
6. Using an ohmmeter measure the resistance from terminal U on the control
module to +Batt and then to B-NEG.
7. Repeat step 6 with phase V and phase W.
 If the resistance at one of the phases is ≤ 100 Ω, the output stage is
faulty. Proceed to step 8.
 If no error is found, restart the truck. Check the event log.
Replace Access 2/3
Event code 328

Display: EV 328
Service display: On
Operator LED: Off
Explanation: Control module faulty
Possible causes: • Control module faulty
Remedy: Replace Access 2/3
Event code 329

Display: EV 329
Service display: On
Operator LED: Off
Explanation: Control module faulty
1. Switch the truck off. Disconnect the battery. Wait for 6 seconds, then con-
nect the battery. Switch the truck on.
Replace Access 2/3
145
ELECTRICAL SYSTEM
Event code 333

Display: EV 333
Service display: On
Operator LED: Off
Explanation: The driver cannot activate the brake
Possible causes: • Wiring disconnected
• Open brake coil
• Control module faulty
 If the reading ≈ +BV, proceed to step 2.
 If the voltage is not ≈ +BV, repair the wire (red/white) between the brake
and CA201-2.
Check the brake coil
2. Remove the wires from the brake.
 If the resistance is not ≈ 13 Ω, replace the brake.
Replace Access 2/3
Event code 334

Display: EV 334
Service display: On
Operator LED: Off
Explanation: Occurs only in connection with EV 328
Possible causes: • None
Remedy: 1. No action required, the alarm goes out automatically.
146
ELECTRICAL SYSTEM
Event code 335

Display: EV 335
Service display: On
Operator LED: Off
Explanation: Breakdown in CAN-Bus communication between Access 1 and Access 5.
• Display faulty
• Access 5 faulty
 If the resistance is 60 Ω, the CAN-Bus termination is ok. Proceed to step
10.
4. Disconnect PC209 from Access 5. Disconnect PC201 from the display.
 If the resistance is >1 MΩ the CAN-Bus wiring is ok. Proceed to step 7.
 If the resistance <1 MΩ, proceed to step 8.
6. Measure the load resistance between JC201-8 and JC201-9 (socket on
Access 1).
 If the resistance is 120 Ω, proceed to step 8.
7. Measure the resistance between JC209-14 and JC201-6 on Access 5.
 If the resistance is 120 Ω, Access 5 is ok. Restart the truck. Check the
event log.
 If the resistance is not 120 Ω proceed to step 10.
Repair wiring
Replace Access 1
Replace Access 5
147
ELECTRICAL SYSTEM
Event code 337

Display: EV 337
Service display: On
Operator LED: Off
Explanation: Thermal sensor in the control module returns values beyond the measuring
range of -80°C to +120°C.
Replace Access 2/3
Event code 338

Display: EV 338
Service display: On
Operator LED: Off
Explanation: Battery voltage out of range
Possible causes: • Battery faulty
• Access 3 faulty
Remedy: Check the battery condition
1. Check the battery for physical damage.
2. Check the battery terminals for corrosion.
3. Ensure the battery cable is attached securely.
 If the items in steps 1 to 3 are ok, proceed to step 4.
Check the condition of the battery cells
4. Measure the individual voltages of the battery cells.
 Replace any faulty cells.
 If all the cells are ok and the sum of the cell voltages is ≈ 24 V, proceed
to step 5.
6. Press the key.
7. Using the key scroll through to the A3 OUTPUTS menu.
8. Press the key.
 A3.1 BATTERY % is displayed.
148
ELECTRICAL SYSTEM
9. Press the key.

 A3.2 BATTERY VOLTAGE is displayed.
10. Measure the battery voltages with a calibrated voltmeter. Round the read-
ing to a decimal point. Compare the rounded value with the display in the
Analyzer menu.
 If the value in the Analyzer menu is 0.2 V DC higher, the error has been
rectified.
 If the value in the Analyzer menu is not 0.2 V DC higher, adjust the BDI.
See Checking and Adjusting the BDI Setting, page 205.
Event code 340

Display: EV340
Service display: On
Operator LED: Off
Explanation: Parameters for drive motor M1 are faulty.
Possible causes: • EEPROM error
• Access 3 faulty
Remedy: Clear the EEPROM in Access 3

3. Press the key,
 U1 PART NUMBERS is displayed.
5. Press the key.
6. Press to scroll to FEATURES.
7. Press the key.
8. Press to scroll to ACCESS 2&3.
9. Press the key.
10. Press the key once.
11. Press the key.
 CLEARED is displayed. The EEPROM in Access 2/3 is cleared.
13. Re-calibrate the truck (see page 110).
149
ELECTRICAL SYSTEM
Replace Access 2/3

14. Replace Access 2 & 3
Event code 341

Display: EV 341
Service display: On
Operator LED: Off
Explanation: • Internal short circuit on the negative side of the brake driver
• External short circuit from CA201-4 to B-NEG or GND
• Disconnection from CA201-4 to brake
There is a pull-down resistor on CA201-4 l(see circuit diagram). If there is a
disconnection between CA201-4 and CA201-2, this pull-down resistor pulls
the commutator voltage of the driver to 0 volts. The microprocessor detects the
commutator voltage of 0 V as a short circuit.
Possible causes: • Open connection in the brake positive wire
• Short circuit between positive wire leading to the brake and B-NEG
• Short circuit on the negative side of the driver in Access 3
Remedy: Check wiring and power supply
1. Disconnect PC201 from Access 3 and the negative wire 5901 (green/
white) from the brake.
2. Check wire 5901 (pin PC201-4) for continuity.
 If the wire is disconnected, repair the wire.
3. Connect PC201.
4. Connect wire 5901 to the brake. Measure the voltage from both brake ter-
minals to B-NEG.
 If the reading ≈ 24 V, proceed to step 5.
 If there is no voltage supply, replace the brake.
5. Measure the resistance between PC201-2 and B-NEG.
 If the resistance < 1 kΩ, proceed to step 6.
 If the resistance > 1 kΩ, repair the wire.
Replace Access 2/3
150
ELECTRICAL SYSTEM
Event code 342

Display: EV 342
Service display: On
Operator LED: Off
Explanation: Forward and reverse travel commands applied simultaneously.
Possible causes: • Open connection, corrosion or short circuit
• Access 3 faulty
Remedy: Check travel switch zero position
2. Press the key.
3. Press the key.
4. Press the key.
 A2.1 ACCESS 1 INPUTS is displayed.
 A2.3 ACCESS 3 INPUTS is displayed.
6. Press the key.
 A2.3.1 TEMP ACCESS 3 is displayed.
7. Press to scroll to A2.3.3 FWD SWITCH.
8. Press the key.
 If OFF is displayed, the switch is ok. Proceed to step 9.
 If ON is displayed, the fault lies either in plug connector CA411 or the
controller is faulty. Proceed to step 12.
9. Press to scroll back to A2.2.3 TEMP ACCESS 3.
10. Press the key.
 A2.3.4 REV SWITCH is displayed.
11. Press the key.
 If OFF is displayed, the switch is ok. Proceed to step 14.
 If ON is displayed, the fault lies either in plug connector CA411 or the
controller is faulty. Proceed to step 12.
Check wiring
12. Check plug connector CA411 in the tiller handle for corrosion and shorts.
 If the plug connector is ok, proceed to step 14.
 If the plug connector is not ok, proceed to step 13.
Replace potentiometer and PC board
13. Replace potentiometer and PC board in tiller handle.
Replace Access 2/3
151
ELECTRICAL SYSTEM
Event code 343

Display: EV 343
Service display: On
Operator LED: Off
Explanation: Encoder ECR1 in the traction motor has a fault. The event code is issued if the
encoder detects a change of more than 40 Hz in less than 16 ms.
Possible causes: • Slip in encoder drive
• Wiring error
• Access 3 faulty
• Traction potentiometer calibration out of range
Remedy: Check encoder pulses in Analyzer menu
2. Press the key.
3. Press the key.
4. Press the key.
6. Press the key.
 A2.2.3 TEMP ACCESS 2 & 3 is displayed.
7. Using the key scroll through to A2.3.15 ECR1.
8. Press the key.
 The encoder pulses are displayed (0 pulses when system idle).
9. Accelerate. Check the display.
 If 0 pulses are shown when truck is idle and ±12000 to ± 15000 pulses
are shown at full speed, the encoder is ok. Restart the truck. Check the
event log.
 If 0 pulses are not shown when truck is idle and ±12000 to ± 15000
pulses are shown at full speed, proceed to step 10.
Check wiring
10. Check the encoder wiring, including connector CA202, for:
– Corrosion
– Loose connections
– Faulty crimp connections on the pins
– Trapped wires
 Repair the wiring if faulty.
 If there is no damage, proceed to step 11
152
ELECTRICAL SYSTEM
Check 12 volt supply

11. Measure the voltage from CA202-1 (on ECR1) to B-NEG. It should be
≈ +12 V.
12. Measure the voltage (GND) from CA202-2 to B-NEG. It should be ≈ +0 V.

 If there is no +12 V supply, repair the disconnection in the wiring be-
tween CA202-1 and CA201-25.
 If the voltages measured in steps11 and 12 are correct, the 12 V supply
Replace Access 2/3
Event code 348

Display: EV 348
Service display: On
Operator LED: Off
Explanation: Parking brake does not hold.
When the truck is idle, the control module checks if the traction motor is turn-
ing. The event code is displayed if a rotary movement with at least 0.25 Hz is
detected for more than 2 s.
Possible causes: • Brake faulty
Remedy: Check the parking brake
1. Check the parking brake for damage (see page 230).
Event code 351

Display: EV 351
Service LED: On
Operator LED: Off
Explanation: RAM copy error.
Possible causes: • Static charge
• Insulation resistance too low
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
Check for static charge
2. Operate the truck for a while, then leave the truck and touch the panel.
 If you feel an electrostic charge, proceed to step 3.
 If you do not feel an electrostic charge, proceed to step 6.
153
ELECTRICAL SYSTEM
Fit the anti-static strap

3. Fit a commercial anti-static strap to the bottom of the truck.
Note: The connection point on the truck must be bare metal prior to assembly.
4. Protect the connection point on the truck against corrosion.
5. Operate the truck again for a while.
 If the event code no longer occurs, the cause has been rectified.
Test the truck's insulation resistance
6. Test the truck's insulation resistance.
 If the insulation resistance is too low, locate and replace the faulty com-
ponents.
Event code 353

Display: EV 353
Service LED: On
Operator LED: Off
Explanation: Thermal sensor TS1 in the drive motor returns values beyond the measuring
range of -40 °C to +200 °C.
• Thermal sensor faulty
• Access 2/3 faulty.
Remedy: Check display
2. Press the key.
4. Press the key.
6. Press the key.
 A2.3.1 TEMP Access 2/3 is displayed.
7. Check temperature reading.
8. Measure the temperature on the motor housing.
 If the temperature on the motor housing is approx. 10°C lower, thermal
sensor TS1 is ok. Proceed to step 13.
 If the temperature difference is greater than approx. 10°C, proceed to
step 9.
154
ELECTRICAL SYSTEM
Check thermal sensor

Note: For the following test the internal motor temperature should be approx.
20°C.
9. Disconnect CA203 and measure the resistance of thermal sensor TS1 be-
tween pins JC203-1 and JC203-2.
 If the resistance ≈ 600 Ω (at 20 °C internal motor temperature), proceed
to step 10.
 If the resistance differs significantly from this value, the thermal sensor
is faulty. Replace traction motor M1.
Check wiring
10. Check lines from PC203-2 to PC201-5 and PC203-1 to PC201-22 using
an ohmmeter.
 If the resistance in a line ≈ 0 Ω, the wiring is ok. Proceed to step 11.
 If the resistance differs significantly from this value, repair the wiring.
Check the thermal sensor voltage readings
11. Connect PC201 and switch on the truck.
12. Measure the voltage between CA201-5 and CA201-22. It should be: ≈ 3 V
for tM1 ≈ 150 °C and > 0.7 V for tM1 ≈ -25 °C
 If the voltage is ok, proceed to step 13.
 If the voltage is incorrect, replace traction motor M1 (see page 214).
Replace Access 2/3
Event code 354

Display: EV 354
Service LED: On
Operator LED: Off
Explanation: No positive power supply for the SMART driver within Access 2/3.
Possible causes: • FU3 faulty
• Faulty wiring
Remedy: Check fuse
1. Check fuse FU3.
 If FU3 has blown, replace fuse 4 A / 32 V.
 If the fuse is ok, proceed to step 2.
Check wiring
2. Measure the voltage from CA201-3 to battery negative.
 If there is no ≈ 24 V supply, repair the wire between FU3 and CA201-3.
 If there is a ≈ 24 V supply, the wiring is ok. Proceed to step 3.
Replace Access 2/3
155
ELECTRICAL SYSTEM
Event code 355

Display: EV 355
Service LED: On
Operator LED: Off
Explanation: Overvoltage or low voltage when the truck is switched on
Possible causes: • See event code 304.
Remedy: See event code 304.
Event code 356

Display: EV 356
Service LED: On
Operator LED: Off
Explanation: Error in FLASH memory of Access 2/3
Possible causes: • Static charge
 If the event code no longer occurs, the problem is resolved.
Fit the anti-static strap
2. Fit a commercial anti-static strap to the bottom of the truck.
Note: The connection point on the truck must be bare metal prior to assembly.
3. Protect the connection point on the truck against corrosion.
4. Switch the truck on and then off again.
5. Disconnect the battery, wait for 6 seconds, then connect the battery.
6. Switch the truck on.
Importing the software
7. If possible and applicable, download software for Access 3.
8. Clear the EEPROM and reset and calibrate the truck.
Note: If you cannot re-install the software, replace Access 2&3.
Replace Access 2/3
Event code 357
156
ELECTRICAL SYSTEM
Display: EV 357
Service LED: On
Operator LED: Off
Explanation: Brake driver (SMART driver) does not supply an output signal
Possible causes: • Faulty wiring
• Brake coil faulty
Remedy: Check the wiring
1. Check the wiring between CA201-2, the brake and CA201-4 for disconti-
nuity and short circuits.
 Repair the wiring if damaged.
Check the parking brake
2. Check the parking brake for signs of overheating and physical damage.
 Repair the brake if damaged or overheated.
 If the brake is ok, proceed to step 3.
3. Disconnect lines 2917 and 5901 from the brake (BRK).
Note: Measure the resistance when the brake is cold (approx. room tempera-
ture), otherwise the reading will be falsified.
 If the resistance is less than 13 Ω ±10%, replace the coil.
5. Measure the voltage from CA201-3 to battery negative.
 If there is no ≈ 24 V supply, repair the wire between FU3 and CA201-3.
 If there is a ≈ 24 V supply, the wiring is ok. Proceed to step 6.
Replace Access 2/3
157
ELECTRICAL SYSTEM
Event code 358

Display: EV 358
Service LED: On
Operator LED: Off
Explanation: Current sensor measuring range limits in Access 3 exceeded.
Possible causes: • Access 2/3 faulty.
Replace Access 2/3
Event code 359

Display: EV 359
Service LED: On
Operator LED: Off
Explanation: Traction potentiometer voltage exceeds the limits set during calibration by
more than 0.4V.
Possible causes: • Potentiometer drift
• Travel direction switch drift
• Faulty calibration
• Sluggish or jerky moving parts
• Wiring error
Remedy: Check the mechanical system
1. Check the mechanical system of the travel switch for excessive friction
and freedom of movement.
 Repair the mechanical system if faulty.
 If the mechanical system is ok, proceed to step 2.
Check travel direction switch
2. Press the key.
3. Press the key.
4. Press the key.
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ELECTRICAL SYSTEM

6. Press the key.
 A2.2.3 TEMP ACCESS 2&3 is displayed.
7. Using the key scroll through to A2.3.3 PF SWITCH.
8. Press the key.
 The current status is displayed.
9. Apply the travel switch in the opposite direction of the forks (FF) and mon-
itor the display.
 If the travel switch changes from OFF to ON, proceed to step 10.
 If the switch does not work correctly replace the traction potentiometer.
10. Press the key.
 A2.3.4 FF SWITCH is displayed.
11. Press the key.
12. Apply the travel switch in the forks direction (FF) and monitor the display.
Check the traction potentiometer for interruptions.
13. Using the key scroll through to A2.3.5 DRIVE POT.
14. Press the key.
 The current voltage is displayed.
15. Apply the travel switch slowly in both directions while monitoring the dis-
play.
 If the reading increases without leaps from 0 to approx. 11.8 V and re-
turns to 0 in the same way, the traction potentiometer is ok. Restart the
truck and check the event log.
 If there are interruptions or leaps in the signal, replace the traction po-
tentiometer.
159
ELECTRICAL SYSTEM
Event code 361

Display: EV 361
Service LED: On
Operator LED: Off
Explanation: Voltage reference for ACCESS 2/3 differs from the voltage +BV(AK)
Possible causes: • FU3 faulty
• Main contactor faulty
• Faulty wiring
Remedy: Check fuse FU3
1. Check fuse FU3.
 Replace the fuse if faulty.
Check wiring
2. Check the wiring between FU3 and CA201-3 for discontinuity and short to
-Batt.
Check main contactor contacts
3. Check the condition of the contacts of the main contactor for wear (see
page 220).
 If the contacts are damaged, repair the contactor.
 If the contacts are ok, proceed to step 4.
Check the main contactor power cable connections
4. Check the main contactor power cable connections for loose cables, cor-
rosion and burning.
 If there is any damage, repair the affected parts.
Replace Access 2/3
160
ELECTRICAL SYSTEM
Event code 362

Display: EV 362
Service LED: On
Operator LED: Off
Explanation: Watchdog error
Effect: • The traction current is cut out and the main contactor ED drops.
Possible causes: • Communication error on the CAN bus
• Access 1 faulty
• Access 3 faulty
Replace Access 2/3
Event code 365

Display: EV 365
Service LED: On
Operator LED: Off
Explanation: Short in one of the phases U, V or W.
Possible causes: • Short circuit in the power cables
• Traction motor M1 faulty
1. Check the power cables of Access 2/3 to traction motor M1 for damage.
 Replace any cables that are physically damaged.
 If the cables are ok, proceed to step 2.
2. Unscrew the power cables from the traction motor and Access 2/3.
3. Using an ohmmeter check the power cables for shorts with respect to each
other.
 If there are short circuits, replace the power cables in question.
 If there are no short circuits, replace traction motor M1.
161
ELECTRICAL SYSTEM
Event code 368

Display: EV 368
Service LED: On
Operator LED: Off
Explanation:
Possible causes: • Intermittent error due to high vertical acceleration
• Steer sensor or TFD module faulty
Replace steer sensor or TFD module
2. Replace steer sensor or TFD module.
Event code 371

Display: EV 371
Service LED: On
Operator LED: Off
Explanation: Access 3 receives a travel signal although the travel direction switches are
open.
Possible causes: • Traction potentiometer not calibrated
• Traction potentiometer faulty
• Travel switch faulty
• Faulty wiring
Remedy: Calibrate traction potentiometer
1. Calibrate the traction potentiometer (see page 110).
Check travel direction switch
3. Press the key.
4. Press the key.
5. Press the key.
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ELECTRICAL SYSTEM
7. Press the key.

 A2.2.3 TEMP ACCESS 2&3 is displayed.
8. Using the key scroll through to A2.3.3 PF SWITCH.
9. Press the key.
10. Apply the travel switch in the opposite direction of the forks (FF) and mon-
itor the display.
11. Press the key.
 A2.3.4 FF SWITCH is displayed.
12. Press the key.
13. Apply the travel switch in the forks direction (FF) and monitor the display.
Check traction potentiometer
14. Using the key scroll through to A2.3.5 DRIVE POT.
15. Press the key.
 The current voltage is displayed.
16. Apply the travel switch slowly in both directions while monitoring the dis-
play.
 If the reading increases constantly from 0 to approx. 11.8 V and returns
to 0 in the same way, the traction potentiometer is ok. Restart the truck
and check the event log.
 If there are interruptions or leaps in the signal, replace the traction po-
tentiometer.
163
ELECTRICAL SYSTEM
rameter settings.
If an event code keeps occurring without an obvious See also:
First clear the EEPROM of the control module in ques-
Event codes 500–505

Display: EV500
Service display: On
Operator LED: Off
Explanation: Access 5 faulty
Possible causes: • Internal errors
Replace Access 5
Event code 506

Display: EV506
Service display: On
Operator LED: Off
Explanation: When the truck is switched on there is an incorrect voltage on the outputs of
the amplifiers in Access 5.
Possible causes: • The power cables to steer motor M3 have a poor contact, are damaged or
• Access 5 faulty
1. Check the power cable leading to steer motor M3 and its terminals to en-
sure they are securely attached and not damaged.
2. Check the motor housing insulation resistance to battery positive/negative.
 If there is a short, locate and replace the faulty components.
 If the insulation resistance is ok, replace Access 5.
164
ELECTRICAL SYSTEM
Event code 508

Display: EV508
Service display: On
Operator LED: Off
Explanation: When the steer motor M3 is idle the current on the steer motor measured by
Access 5 is > 0A.
Possible causes: • Error in output stage of Access 5
• Error in current sensor of Access 5
Replace Access 5
Event code 509

Display: EV509
Service display: On
Operator LED: Off
Explanation: The current at steer motor M3 measured by Access 5 is too high.
• Access 5 faulty
Check current sensor
4. Press the key.
5. Press to scroll to the A2.5 ACCESS 5 menu.
6. Press the key.
7. Using the key scroll through to the A2.5.3 STEER MOTOR CURRENT
menu.
165
ELECTRICAL SYSTEM
8. Press the key.

 The steer motor current consumption is displayed in real time.
 If the reading is 0A, restart the truck. Check the event log.
 If the reading with the steer motor idle > 15 A, proceed to step 9.
Clear the EEPROM of Access 5
11. Press the key,
13. Press the key.
15. Press the key.
16. Press to scroll to ACCESS 5.
17. Press the key.
19. Press the key.
 CLEARED is displayed. The EEPROM in Access 5 is cleared.
22. Check the insulation resistance of the motor coil and the power cables.
166
ELECTRICAL SYSTEM
Event code 510

Display: EV510
Service display: On
Operator LED: Off
Explanation: No current at phase V
Possible causes: • Fuse FU5 faulty
• Wiring voltage drop
• Battery voltage drop
• Access 5 faulty
Remedy: Check power fuse FU5
1. Check power fuse FU5 (30A) on Access 5.
 Replace the fuse if faulty.
3. Press the key.
5. Press the key.
6. Press the key.
7. Press the key.
 The current battery voltage reading is displayed.
8. Make a note of the reading (it should be ≈24 V).
9. Using a voltmeter measure the battery voltage on the battery connector.
Compare this reading with the value in the Analyzer menu.
 If the value displayed in the Analyzer menu is 0.2 V higher, proceed to
step 10.
 If the value displayed is less than the voltage on the battery connector,
proceed to step 18.
Check for battery voltage drop
10. Press to scroll back to the Performance menu.
11. Press to scroll to the Analyzer menu.
12. Press the key.
14. Press the key.
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ELECTRICAL SYSTEM
15. Press the key.

16. Press the key.
 The current battery voltage reading is displayed.
17. Raise a load of approx. 1000 kg to the maximum height. At the same time
observe the battery voltage display.
 If the battery voltage drops below 22 V, repair the battery or replace it
with a new one.
 If the battery voltage remains above 22 V during the lift test, the battery
Check Access 5 for possible input voltage drop
18. Measure the resistance between CA209-A7 and B-NEG.
 If the voltage is considerably less than Batt POS, locate and remove the
transitional resistance in the wiring.
 If the voltage ≈ 24 V, the wiring is ok. Proceed to step 19.
19. Check the power cables to steer motor M3 and its connections are secure
Check for voltage drop over fuse FU5
20. Measure the input voltage from FU5 to B-NEG.
21. Measure the output voltage from FU5 to B-NEG.
 If the input and output voltages are different, replace FU5. Check the
contacts for corrosion.
 If the input and output voltages are identical, proceed to step 22.
Check signal switch AxEDS in the main contactor
22. Measure voltage at input and output of signal switch in main contactor to
B-NEG.
 If the input and output voltages are different, replace the main contactor.
 If the input and output voltages are identical, proceed to step 23.
Check the power part of the main contactor
23. Check the power cables on the main contactor and its connections are
secure and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause. If the
main contactor is overheated (recognisable from blue colouring), re-
place the main contactor.
 If the power cables, connections and main contactor are ok, proceed to
step 24.
Replace Access 5
168
ELECTRICAL SYSTEM
Event code 511

Display: EV511
Service display: On
Operator LED: Off
Explanation: No current at phase U
• Access 5 faulty
Event code 512

Display: EV512
Service display: On
Operator LED: Off
Explanation: No current at phase W
• Access 5 faulty
Event code 513

Display: EV513
Service display: On
Operator LED: Off
Explanation: Channels A and B of encoder ECR2 were swapped when connected.
1. Check wiring for damage.
 If the wiring is not damaged, proceed to step 2.
Check wiring of ECR2 is correct
2. Using the circuit diagram and the cable numbers indicated, check if wires to
CA211 or CA209 have been connected incorrectly.
 If CA209 has been wired incorrectly, replace PC209-7 with PC209-8.
 If CA211 has been wired incorrectly, replace PC211-2 with PC211-3.
169
ELECTRICAL SYSTEM
Event code 514

Display: EV514
Service display: On
Operator LED: Off
Explanation: A short has occurred in wire DL or QL to GND.
• Excessive impact on truck
• Access 8.2 faulty
Remedy: Establish triggering event
1. Ask operators when the error occurred. For example, after travelling over
a pothole.
 If so, restart the truck. Check the event log.
 If not, proceed to step 2.
Check encoder ECR4
2. Set the steering to the centre position.
4. Press the key.
6. Press the key.
7. Using the key scroll through to the A2 5 ACCESS 5 menu.
8. Press the key.
9. Using the key scroll through to the A2.5.4 STEER ECR4-A menu.
10. Press the key.
 The output voltages is displayed.
11. Turn the steering wheel. Check the display.
 If the voltage continually rises and falls between 0 V and 1.5 V, channel
A is ok.
12. Press the key twice.
13. Press the key.
 A2.5.5 STEER ECR4-B is displayed.
14. Press the key.
B is ok.
170
ELECTRICAL SYSTEM

 If the event occurs again, proceed to step 17.
Check wiring
17. Check the wiring from CA205 to CA218. Repair the wiring if damaged.
 If the wiring is ok, replace Access 8.2.
19. If the event code occurs again, replace ECR4.
Event code 515

Display: EV515
Service display: Off
Operator LED: On
Explanation: Maximum angle reached on steered wheel
Possible causes: • LIMIT DEVICE is set to ON
Remedy: When the steering is set to neutral the event automatically clears itself.
Event code 516

Display: EV516
Service display: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 does not close.
Remedy: Check for shorts
1. Check wiring from Access 5 for shorts.
 If there is a short, repair the wiring.
3. Remove wire and pin from PC209-4.
4. Insert PC209.
5. Measure the voltage between wire 2917 and B-NEG.
 If the reading is 0 V DC, proceed to step 6.
 If the voltage ≈ 24 V, proceed to step 8.
Check wire 2912 for a short
6. Measure the resistance between wire 2917 and B-NEG.
 If there is a short to B-NEG, proceed to step 7.
 If the resistance ∞(> MΩ), proceed to step 9.
7. Rectify the short to B-NEG in the wire from PC209-4 to CA201-6.
8. Rectify the short to +Batt in wire 2917.
171
ELECTRICAL SYSTEM

 If the event occurs again, proceed to step 10.
Replace Access 5
Event code 519

Display: EV519
Service display: On
Operator LED: Off
Explanation: The processors in Access 5 detect different direction messages from the steer-
ing potentiometer.
Replace Access 5
Event code 520

Display: EV520
Service display: On
Operator LED: Off
Explanation: The processors in Access 5 detect different signals from channel A or B, or
from A and B of steering encoder ECR3.
Replace Access 5
172
ELECTRICAL SYSTEM
Event code 522

Display: EV522
Service display: On
Operator LED: Off
Explanation: Internal error in Access 5.
Remedy: Replace Access 5
Event code 523

Display: EV523
Service display: On
Operator LED: Off
Explanation: The steer motor draws the maximum current for more than 1 second.
• Access 5 faulty
Check current sensor
4. Press the key.
6. Press the key.
7. Using the key scroll through to the A2.5.3 STEER MOTOR CURRENT
menu.
8. Press the key.
 The current flowing through the output stage is displayed.
 If the reading is 0A, restart the truck. Check the event log.
 If the reading with the steer motor idle > 15 A, proceed to step 9.
Clear the EEPROM in Access 5
173
ELECTRICAL SYSTEM

11. Press the key,
13. Press the key.
15. Press the key.
16. Press to scroll to ACCESS 5.
17. Press the key.
19. Press the key.
 CLEARED is displayed. The EEPROM in Access 5 is cleared.
21. Re-calibrate the truck (see page 110).
22. Check the insulation resistance on the motor coils and the power cables.
Event code 524

Display: EV524
Service display: On
Operator LED: Off
Replace Access 5
174
ELECTRICAL SYSTEM
Event code 525

Display: EV525
Service display: On
Operator LED: Off
Explanation: Access 5 has tried to drive the steer motor but encoder ECR2 does not provide
an output signal.
Note: This event can also occur if the steering is applied very rapidly.
Possible causes: • Encoder ECR2 faulty
• Insulation resistance too low
• Access 5 faulty
Remedy: Check encoder ECR2
2. Press the key.
4. Press the key.
6. Press the key.
7. Using the key scroll through to the A2.5.6 ECR2 menu.
8. Press the key.
 The output pulses for ECR2 are displayed.
9. Leave the steering in neutral. Note the reading.
10. Turn the steering to the left stop. Check the display for fluctuations. Note
the final reading.
11. Turn the steering to the right stop. Check the display for fluctuations. Note
the final reading.
12. Repeat steps 10 to 11. Compare the readings with the previously recorded
readings.
 If the display jumps significantly as you steer, or if there are large devi-
ations in the number of pulses counted at the end stops, replace steer
motor M3.
 If encoder ECR2 is ok, proceed to step 13.
14. If the power cables and the connections are ok, proceed to step 15.
175
ELECTRICAL SYSTEM

15. Check the insulation resistance of the motor coil and the power cables.
Replace Access 5
Event code 527

Display: EV527
Service display: On
Operator LED: Off
Event code 528

Display: EV528
Service display: On
Operator LED: Off
Event code 529

Display: EV529
Service display: On
Operator LED: Off
Replace Access 5
176
ELECTRICAL SYSTEM
Event code 530

Display: EV530
Service display: On
Operator LED: Off
Explanation: Output signals of encoders ECR2 and ECR3 do not match.
• ECR3 or ECR2 in steer motor M3 faulty
1. Check wiring on encoders ECR2 and ECR3 from CA218 and CA219 to
CA222 and CA221 for shorts and damage.
Check encoder ECR2
3. Press the key.
5. Press the key.
6. Press to scroll to the A2.5 ACCESS 5 menu.
7. Press the key.
8. Using the key scroll through to the A2.5.6 ECR2 menu.
9. Press the key.
11. Turn the steering slowly to the left stop. Check the display for fluctuations.
Note the final reading.
12. Turn the steering slowly to the right stop. Check the display for fluctua-
tions. Note the final reading.
Check encoder ECR3
13. Press the key.
 A2.5.6 ECR2 is displayed.
14. Press the key.
 A2.5.7 ECR3 is displayed.
15. Press the key.
177
ELECTRICAL SYSTEM
17. Turn the steering slowly to the left stop. Check the display for fluctuations.
Note the final reading.
18. Turn the steering slowly to the right stop. Check the display for fluctua-
tions. Note the final reading.
 If there are no fluctuations in the displays, re-start the truck and monitor
the event.
 If there are significant fluctuations, replace steer motor M3.
Note: With the steering in the centre position, 120 ±10 pulses should be shown
for ECR3. In the end stops minimum 15±10, maximum 220±10. ECR2 and
ECR3 rotate in opposite directions: if the number of pulses on ECR2 increase,
they decrease on ECR3.
Event code 532

Display: EV532
Service display: On
Operator LED: Off
Explanation: On power up SAHS cannot find the cam within a 270° rotation.
Possible causes: • Steering bearing faulty
• Wiring damaged
• Contamination
• Faulty sensor adjustment
• Sensor faulty
• Access 1 faulty
• Access 5 faulty
Remedy: Check steering bearing for slack
1. Jack up the truck. Check steering bearing for slack.
Note: The transmission will tilt if there is slack in the bearing. The cam will be
removed from the sensor.
 If there is any slack in the bearing, replace the bearing.
 If there is no slack, proceed to step 2.
Check communication of SAHS with Access 5
2. Check wiring of sensor SAHS and connector CA221 for shorts and dam-
age.
Check if SAHS switches
4. Press the key.
178
ELECTRICAL SYSTEM
6. Press the key.

8. Press the key.
9. Press to scroll to the A2.5.8 SAHS SENSOR menu.
10. Press the key.
 The switch status of sensor SAHS is displayed (0 = OFF, 1 = ON).
11. Turn the steering to the left and right while checking if the switch status in
the display and on the LED of the SAHS change at the same time.
 If the switch conditions change at the same time, SAHS and communi-
cation with Access 5 are ok. Restart the truck. Check the event log.
 If the switch status does not change, or not at the same time, proceed
to step 12.
Check the cam for contamination
12. Check the gap between SAHS and the cam for foreign bodies and accu-
mulation of dirt.
 Remove any foreign bodies or accumulation of dirt.
 If there are no foreign bodies or accumulation of dirt, proceed to step 13.
Check the screw-in depth of SAHS
13. Check the distance between the SAHS sensor and the cam.
 Adjust the distance if incorrectly set (page 237).
 If the distance is within range and the sensor does not switch, proceed
to step 14.
Replace the SAHS sensor
14. Replace the SAHS sensor (page 237).
15. Repeat step 11.
16. If the event still persists, replace Access 5.
Event code 535

Display: EV535
Service display: On
Operator LED: Off
Replace Access 5
179
ELECTRICAL SYSTEM
Event code 536

Display: EV536
Service display: On
Operator LED: Off
Explanation: Access 5 needs time to calculate the motor resistance and adapt the current
gain accordingly.
Possible causes: • Transient error
Remedy: Restart the truck
Event code 537

Display: EV537
Service display: On
Operator LED: Off
Replace Access 5
Event code 538

Display: EV538
Service display: On
Operator LED: Off
Explanation: CAN-Bus error
• Access 1 faulty
• Access 5 faulty
Remedy: Check module status
2. Press the key.
180
ELECTRICAL SYSTEM
3. Press the key.

4. Press the key.
 The status of the module (ON or OFF) is displayed.
 If one module is OFF, proceed to step 6.
5. Scroll through to A1.2 to A1.7 in turn and check the status of the modules
(see menu structure).
 If one of the modules is OFF, proceed to step 6.
 If all modules are ON, restart the truck. Check the event log.
Note: To view the next module, press the key twice. Now press the key,
followed by the key twice.
Check the CAN Bus wiring
6. Check CAN Bus wiring between Access 3 and Access 5 for shorts and
damage.
 If the resistance is 60 Ω,, the CAN-Bus is ok. Restart the truck. Check
the event log.
Test terminal resistance in Access 5
 If the resistance is 120 Ω, the terminal resistance in Access 5 is ok,
proceed to step 11.
 If the resistance is not 120 Ω, replace Access 5.
Test terminal resistance in Access 1
11. Disconnect CA200 from Access 1
 If the resistance is 120 Ω, the terminal resistance is ok. Restart the
truck. Check the event log.
 If the resistance is not 120 Ω, replace Access 1.
181
ELECTRICAL SYSTEM
Event code 540

Display: EV540
Service display: On
Operator LED: Off
Explanation: Switch status of SAHS does not match the output signal of ECR2.
• Access 5 faulty
Remedy: See Event code 525, page 175 and Event code 532, page 178.
Event code 541

Display: EV541
Service display: On
Operator LED: Off
Replace Access 5
Event code 542

Display: EV542
Service display: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is open.
• Access 5 faulty
Remedy: Check status of Access 5
2. Press the key.
3. Press the key.
4. Press to scroll to A1.2 ACCESS 5.
182
ELECTRICAL SYSTEM

 The status (ON or OFF) of Access 5 is displayed.
 If the status is OFF, re-start the truck. Check the event log.
6. Disconnect the wire from PC209-4. Measure the voltage from JC209-4 to
B-NEG.
 If the reading is not ≈ 24 V DC, there is an error in the positive wire.
Repair the wiring.
 If the reading is ≈24 V DC, proceed to step 7.
Check entries in event log
7. Press to scroll back to A1 STATUS.
8. Using the key scroll through to the EVENTS menu.
9. Press the key.
 E1 CHRON HISTORY is displayed.
 If, in addition to event code 542 another event with identical time and
temperature is logged, rectify this other error first.
 If no further event is logged with an identical time and temperature, pro-
ceed to step 10.
Replace Access 5
Event code 543

Display: EV543
Service display: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is open.
• Access 5 faulty
Remedy: See Event code 542, page 182
183
ELECTRICAL SYSTEM
Event code 544

Display: EV544
Service display: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is closed.
Remedy: Check status of Access 5
2. Press the key.
3. Press the key.
4. Press to scroll to A1.2 ACCESS 5.
 The status (ON or OFF) of Access 5 is displayed.
 If the status is OFF, re-start the truck. Check the event log.
6. Disconnect the wire from PC209-4. Measure the voltage from JC209-4 to
B-NEG.
 If the reading is not ≈ 24 V DC, there is an error in the positive wire.
Repair the wiring.
 If the reading is ≈24 V DC, proceed to step 7.
Check wires for short circuits
7. Remove PC201. Measure the resistance between JC201-4 and JC201-5.
 If the resistance ∞ (> MΩ), proceed to step 8.
 If the resistance is less, proceed to step 11.
Check entries in event log
8. Press to scroll back to A1 STATUS.
9. Using the key scroll through to the EVENTS menu.
10. Press the key.
 E1 CHRON HISTORY is displayed.
 If, in addition to event code 542 another event with identical time and
temperature is logged, rectify this other error first.
 If no further event is logged with an identical time and temperature, pro-
ceed to step 11.
Replace Access 5
184
ELECTRICAL SYSTEM
Event code 545

Display: EV545
Service display: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is closed.
• Access 5 faulty
Remedy: See Event code 544, page 184
Event code 547

Display: EV 547
Service LED: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W of Access 5 is higher than the refer-
ence voltage setting.
• Access 5 faulty
1. Check the power cables to steer motor M3 and the power supply cables to
Access 5 for loose attachment and damage.
against the truck frame.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
185
ELECTRICAL SYSTEM
Event code 550

Display: EV550
Service display: On
Operator LED: Off
Explanation: The drive wheel is outside of the centre position on start-up (±20°).
Replace Access 5
Event code 551

Display: EV551
Service display: On
Operator LED: Off
Explanation: Auto-centring not working.
Replace Access 5
186
ELECTRICAL SYSTEM
Event code 552

Display: EV552
Service display: On
Operator LED: Off
Explanation: Internal error
Replace Access 5
Event code 553

Display: EV553
Service display: On
Operator LED: Off
Explanation: Wire DL to ECR4 is disconnected
• ECR4 faulty
Check encoder ECR4
4. Press the key.
6. Press the key.
8. Press the key.
9. Using the key scroll through to the A2.5.4 STEER ECR4-A menu.
187
ELECTRICAL SYSTEM
10. Press the key.

DL is ok.
Check wiring
12. Check the wiring from CA205 to CA218. If there is a wiring error, repair the
wiring.
Event code 554

Display: EV555
Service display: On
Operator LED: Off
Explanation: Wire QL to ECR4 is disconnected
• ECR4 faulty
Check encoder ECR4
4. Press the key.
6. Press the key.
8. Press the key.
9. Using the key scroll through to the A2.5.4 STEER ECR4-B menu.
10. Press the key.
188
ELECTRICAL SYSTEM

QL is ok.
Check wiring
12. Check the wiring from CA205 to CA218. If there is a wiring error, repair the
wiring.
Event code 555

Display: EV555
Service display: On
Operator LED: Off
Effect: All functions are deactivated
Replace Access 5
Event code 556

Display: EV556
Service display: On
Operator LED: Off
Possible causes: • Access 8.2 faulty
Effect: All functions active, but with factory settings
 If the event code no longer occurs, set the parameters as required.
Note: The control module clears the stored parameters and replaces them
with the factory settings.
189
ELECTRICAL SYSTEM
Replace Access 8.2

2. Replace Access 8.2.
Event code 557

Display: EV557
Service display: On
Operator LED: Off
Explanation: Low voltage detected
Possible causes: • Voltage drop caused by faulty battery
• Wiring transition resistances
• Access 5 faulty
Effect: All functions are deactivated
Establish cause of voltage drop
2. See Event code 304, page 131 and Event code 523, page 173.
 If there is no cause for the voltage drop, proceed to step 3.
Replace Access 5
Event code 558

Display: EV558
Service display: On
Operator LED: Off
Replace Access 5
190
ELECTRICAL SYSTEM
Event code 559

Display: EV559
Service display: On
Operator LED: Off
Effect: All functions active, but with factory settings
 If the event code no longer occurs, set the parameters as required.
Note: The control module clears the stored parameters and replaces them
with the factory settings.
Replace Access 8.2
Event code 560

Display: EV560
Service display: On
Operator LED: Off
Explanation: ECR4 error
2. See Event code 514, page 170
191
ELECTRICAL SYSTEM
Event code 561

Display: EV561
Service display: On
Operator LED: Off
Possible causes: • Error in CAN-Bus wiring
• Faulty control module on CAN-Bus
Check wiring
2. Check connectors CA218 and CA217 for damage.
3. Check pins CA218-16 and CA218-17 for corrosion and loose contacts.
 Repair existing damage.
Check CAN Bus
 If the CAN-Bus is ok, proceed to step 5.
Update software
5. Upgrade to the latest software version.
7. Adjust the parameters if necessary (see page 107).
 If the event code occurs again, replace Access 8.2.
Event code 562

Display: EV562
Service display: On
Operator LED: Off
192
ELECTRICAL SYSTEM
rameter settings.
See also:
First clear the EEPROM of the control module in ques- • Calibration, page 110
Event code 800

Display: EV800
Service display: On
Operator LED: Off
Explanation: Traction potentiometer voltage out of range
• Traction potentiometer faulty
Check wiring
2. Check wiring to CA410 for damage and short circuits.
3. Check the wiring between CA411 and CA414 for damage and shorts.
Replace Access 8.1
 If the event code no longer occurs, calibrate the traction potentiometer.
 If the event code occurs again, replace the traction potentiometer.
193
ELECTRICAL SYSTEM
Event code 801

Display: EV801
Service display: On
Operator LED: Off
Replace Access 8.1
194
ELECTRICAL SYSTEM
Event Code - Group 1000 Now recalibrate the truck. If necessary adjust the pa-
rameter settings and features.
See also:
First clear the EEPROM of the control module in ques- • Calibration, page 110
Event code 1000

Display: EV1000
Service LED: On
Operator LED: Off
• Access 10 faulty
Check battery type setting
3. Press the key.
5. Press the key.
6. Press to scroll to F22 ENERGY SYSTEM.
7. Press the key.
 If LITHIUM ION is displayed, Access 10 is faulty. Replace the battery.
 If LEAD ACID or FUEL CELL is displayed, proceed to step 8.
8. Set LITHIUM ION battery type.
9. Save the setting.
195
ELECTRICAL SYSTEM
Event code 1001 or 1002

Display: EV1001
Service LED: On
Operator LED: Off
Explanation: Non-specific error
Possible causes: • Unspecified error
 If the event code occurs again, contact the battery manufacturer.
196

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ELECTRICAL SYSTEM

Event Codes Event code groups

Calibrate the load sensor Save the calibration

Event code 100

11. Measure the resistance between CA220-1 and CA220-2.

Event Code Group 200

Event code 202

4. Measure the resistance between terminal –P on Access 2 and B-NEG.

Event code 203

Event code 204

6. Press the key.

Event code 205

16. Press the key.

Event code 208

Event code 228

Event code 229

14. Using the key, select BOTH.

Event code 230

9. Using an ohmmeter measure the resistance of the actuating components:

Event code 231

8. Press the key.

Event code 234

Event code 300

Event code 301

Event code 302

Event code 303

Event code 304

Measure the voltage drop on the positive cable of Access 2/3

Event code 305

Event code 306

Event code 307

Event code 308

 If there is no voltage, proceed to step 3.

Event code 309

Event code 310

Event code 314

Check the control module for shorts in the driver output

Event code 315

Event code 316

Event code 317

Event code 319

Locating the fault in the load sensor power supply

Event code 320

Event code 321

Event code 322

Event code 326

Check control module

Event code 328

Event code 329

Event code 333

Event code 334

Event code 335

Event code 337

Event code 338

9. Press the key.

Event code 340

2. Press to scroll to the Features menu.

Replace Access 2/3

Event code 341

Event code 342