504 Codes

MCFA Document: 000025-20J

Issue Date: 09/15/2020

Model(s) and Serial Number(s):

All Jungheinrich® truck models.

The information provided herein is considered to be confidential information and is intended to assist you in resolving product issues. In addition, the information herein is not to be an authorization for
any financial claim against MCFA. Always follow all Safety, Warning, Caution and Precaution information that is provided in the appropriate Service Manual and Operation and Maintenance Manual(s).
 504 CODES

• Refer to Service Manual and Operating Instructions Manual (OMM) for safety
guidelines prior to working on equipment.

• Make all repairs with the industrial truck parked on a level, hard surface. Block the
industrial truck to prevent rolling while working on, or under, the industrial truck.
Use a tire cage if tires are to be replaced or worked on.

• Ensure enforcement of company policy for proper lockout/tagout (LOTO)

procedure.

• Do not operate this industrial truck until you read and understand the instructions in
the Service Handbook and Operating Instructions. Improper industrial truck
operation is dangerous and could result in injury or death.

• Disconnect battery prior to working on any electrical components or welding.

• Obey all safety guidelines when welding on or near flammable fluids. Always have
an approved fire extinguisher on hand.
 504 CODES

Event
Messages:
 504 CODES
Cause:
Event code list is not available in the JETI SH:

• 504 codes are caused when an output circuit is in a state, other then its defined state in the
controller software. Example; if the controller identifies a truck light that is faulty, a 504 code
will appear. The output circuits are being monitored for resistance and current draw, so a
deviation from predefined values will initiate a 504code.
• OEM Jungheinrich parts have an added diode. So if incorrect parts are fitted, the controller
may code 504.
• If fitting options after delivery, they will need to be switched ON in the software to prevent
coding.
• In the event of faulty components on circuits such as lighting, etc., some options can be
turned OFF in the software to allow the truck to operate while waiting on new parts.
 504 CODES

Resolution:

The following slides show three sets of 504 codes. It is important to note
that the architecture of each truck’s codes are unique, so the dedicated
codes to each truck is generated and shown differently.

• The EFG list shows the codes and the pin from the Kombi controller from
which they originate.

• The ETV list shows the codes and the control from which they originate.

• The ETR list shows the codes as on Input on the VMC30.

 504 CODES

EFG specific
504 codes:
504 CODES
 504 CODES
ETV specific 504 codes:

Output driver identifier (subindex of event 504)

MASTER 504 1 Main Contactor
5 BRAKELIGHT
6 ENGINE COMPARTMENT FAN
8 WORKING LIGHTS LOAD DIRECTION
9 WORKING LIGHTS LOAD DIRECTION

SLACE IO 8 WORKING LIGHT FORKS 1

9 WORKING LIGHT FORKS 2

SLAVE AC 3 FLASHING BEACON

15 FRONT SPOT
20 LIGHT DRIVE DIRECTION
30 MAIN CONTROLLER FAN
 504 CODES
ETR specific 504 codes:
- check cable connection; Channel 1 (Pin2 on controller)
0
- check connected loads (brake magnet, valves, ...), replace if necessary; Set w hen HW Short Circuit signal is detected. Disabling of output required to clear event.
1 504 1
- check outputs via JUDIT; Set w hen measured current is below the NotConnectedLevel.
2 - replace control; Set w hen Peak Overcurrent or Overload is detected.

Error that is possible to disable via SW configuration. If error is enabled via SW configuration, this bit is set if the current is above the error limit. The Open Drain Outputs are then disabled and the drive is tripped. '-
Current error. The difference betw een reference and measured current into the current regulator shall not exceed the limit. If it is exceeded a counter increases, if not the counter is decreased. When counter value
Open Drain Chanel 1 Problem is above a counter limit, there is an error.
- check cable connection; - When an OD channel is active(ON) and measured OD current is below a certain min value during 60 ms or w hen an OD channel is NOT active(OFF) and measured OD current is above the certain min level.
"Digital output driver circuit" has reported a fault - check connected loads (brake magnet, valves, ...), replace if necessary; - When OD current is above a trip level. Trip level is defined by either a hw related level or set by the application engineer.
- check outputs via JUDIT; - When hardw are open drain trip signal connected to PDPINTB on CPU gets active.
3
- replace control;
Channel 1 (Pin2 on controller)
Set w hen HW Short Circuit signal is detected. Disabling of output required to clear event.
Set w hen measured current is below the NotConnectedLevel.
Set w hen Peak Overcurrent or Overload is detected.
Set w hen more than 200 mA current is measured w hen the output should be off.

0 Channel 2 (Pin10 on controller)

Open Drain Chanel 2 Problem '- Check cable connection;
1 Set w hen HW Short Circuit signal is detected. Disabling of output required to clear event.
- Check connected loads (brake solenoid, valves, ...), replace if
2 504 2 Set w hen measured current is below the NotConnectedLevel.
"Drive circuit digital output" has reported a fault necessary;
Set w hen Peak Overcurrent or Overload is detected.
3 - Check outputs via JUDIT;
Set w hen more than 200 mA current is measured w hen the output should be off.
- Replace control;

- check cable connection;

Channel 2 (Pin10 on controller)
Open Drain Chanel 3 Problem - check connected loads (brake magnet, valves, ...), replace if necessary;
Set w hen HW Short Circuit signal is detected. Disabling of output required to clear event.
- check outputs via JUDIT;
3 504 3 Set w hen measured current is below the NotConnectedLevel.
"Digital output driver circuit" has reported a fault - replace control;
Set w hen Peak Overcurrent or Overload is detected.
Set w hen more than 200 mA current is measured w hen the output should be off.

Set w hen HW Short Circuit signal is detected. Disabling of output required to clear event.
When High Side output is enabled. Checked at 50Hz. Signal is reset once and if signal becomes active again w ithin 100ms the event is set and output is latched in tripped state.

"Open Drain Chanel 4 Problem

Detected that nothing has been connected to High side out.
- check cable connection;
Checked during high side start-up check (state 2).
Digital output driver circuit" has reported a fault - check connected loads (brake magnet, valves, ...), replace if necessary;
3 504 4
- check outputs via JUDIT;
Channel 2 (Pin10 on controller)
- replace control;
Set w hen HW Short Circuit signal is detected. Disabling of output required to clear event.
Set w hen measured current is below the NotConnectedLevel.
Set w hen Peak Overcurrent or Overload is detected.
Set w hen more than 200 mA current is measured w hen the output should be off.

'- check cable connection;

The high side input has been detected to be low .
3 504 28 - check connected loads (brake magnet, valves, ...), replace if necessary;
Checked during high side start-up check (state 1) and continuous.
"Digital output driver circuit" has reported a fault - check outputs via JUDIT;
- replace control;
 504 CODES

The high side output has been detected to be low .

This indicate that the high side output is shorted to B-.
- check cable connection; Checked during high side start-up check (state 1) and continuous.
- check connected loads (brake magnet, valves, ...), replace if necessary;
"Digital output driver circuit" has reported a fault
3 504 29 - check outputs via JUDIT; Internal High side failure detected.
- replace control; Checked during high side start-up check (state 5).

High current on High side out.

Alw ays

0
'- Check cable connection;
1 Digital output not Connected or Open Circuit at Startup.
- Check connected loads (brake solenoid, valves, ...), replace if
2 504 1…n
"Drive circuit digital output" has reported a fault necessary;
3
 504 CODES

Please Note:

90% of the tickets opened for 504 codes

result from loose wiring, or damage to
the truck lighting system.

Questions? If you have any questions regarding this HPK, please open a Service Support Ticket.