ELECTRICAL SYSTEM

Event Code Group 300 (all GPCs from 09/2012)

Event Code Group 300 (all GPCs from 09/2012)

If an event code keeps occurring without an obvious Now recalibrate the truck. If necessary adjust the
cause, do not replace the control module immediately. Parameters and Features.
First clear the EEPROM of the control module in ques- • Calibration, page 118
tion. The factory settings are then restored.
• Parameter settings from 09/2012, page 115

Event code 300

Display: EV 300
Service indicator: On
Operator error indicator: 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
Remedy: The first time the event code appears
1. Switch off the truck. Disconnect the battery. Wait for 6 seconds. Connect
the battery. Switch on the truck.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 86).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key 2 times.
 E1.1 LAST is displayed.
6. Use keys and to scroll through to the service hours and temperature
of the most recently logged event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is logged, proceed to step 7.
Replace Access 2/3
7. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 301

Display: EV 301
Service indicator: On
Operator error indicator: Off
Explanation: EEPROM memory error in Access 3
Possible causes: • Intermittent internal error in Access 3
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck. Disconnect the battery. Wait for 6 seconds. Connect
the battery. Switch on the truck.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Replace Access 2/3
2. Replace Access 2/3.

Event code 302

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

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Event Code Group 300 (all GPCs from 09/2012)

Event code 303

Display: EV 303
Service indicator: On
Operator error indicator: Off
Explanation: Phase voltage out of range
Possible causes: • B-POS and B-NEG connections on Access 3
• Access 3 faulty
Remedy: Check power cable connections
1. Check power cable connections, in particular on B-POS and B-NEG of
Access 3. Check terminals for corrosion and overheating.
 Repair any faulty connections.
 If the connections are ok, proceed to step 2.
Replace Access 2/3
2. Replace Access 2/3.

Event code 304

Display: EV 304
Service indicator: On
Operator error indicator: Off
Explanation: Low voltage or overvoltage detected.
If the voltage on pin PC200-13 drops below 9 V, this event code occurs. It also
occurs if the voltage at B-POS of Access 2/3 exceeds 35 V.
Possible causes: • Battery collapses under load
• Voltage drop via fuse FU2, relay K1 or key switch
• Contact resistance in connection of a power cable
• Access 3 faulty
• Battery with excessive voltage used
Remedy: Obtain the internally measured battery voltage
1. Select service level 2 (see page 86).
2. Press the key.
 A1 Status is displayed.
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.

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Compare internally measured battery voltage with actual battery voltage

8. Switch off the truck. Disconnect the battery.
9. Measure the battery voltage directly on the battery connector.
10. Compare this reading with the internally measured reading recorded pre-
viously.
 If there is a difference, proceed to step 11.
 If the voltage readings are the same, restart the truck and continue to mon-
itor the event display.
Check for battery voltage drop
11. Starting up the truck.
12. Select menu item A3.2 BATTERY VOLTAGE (see step 1).
13. Raise a load of approx. 1000 kg up to the lift lockout. 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 14.
Measure the voltage drop on the positive cable of Access 2/3
14. Measure the voltage between CA200-13 and B-NEG.
 If the voltage is approximately the same as the battery voltage (≈ 24 V),
the wire is ok. Proceed to step 19.
Note: The voltage at PC200-13 is always slightly 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 22 V, proceed to step 15.
Establish cause of the voltage drop
15. Measure the input and output voltage of the signal switch on the main
contactor.
 If there is no significant voltage drop, proceed to step 16.
 If the voltage drops extremely, replace main contactor ED.
16. Measure the input and output voltage of fuse FU2.
 If there is no significant voltage drop, proceed to step 17.
 If the voltage drops extremely, replace fuse FU2.
17. Measure the voltage at pin 30 (input) and pin 87 (output) of relay K1. If a
key switch is installed, measure the key switch input and output voltages.
 If there is no significant voltage drop, proceed to step 18.
 If the voltage drops extremely, replace relay K1 or the key switch.
18. Measure the voltage drop over the wires:
– Between the signal switch on the main contactor and fuse FU2
– Between FU2 and pin 30 on relay K1
– Pin 87 on relay K1 and pin CA200-13
 If there is no significant voltage drop, proceed to step 19.
 If the voltage drops extremely, repair the wire or connection.
Replace Access 2/3
19. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 305

Display: EV 305
Service indicator: On
Operator error indicator: 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
Remedy: Check power cable terminals
1. Check motor power cable terminals. Check terminals for corrosion and
overheating.
 Repair any faulty connections.
 If the connections are ok, proceed to step 2.
Check the insulation resistance
2. Check the motor housing insulation resistance to +BV/B-NEG.
 If there is a short to +BV or B-NEG, replace the motor.
 If the insulation resistance is ok, proceed to step 3.
Replace Access 2/3
3. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 306

Display: EV 306
Service indicator: On
Operator error indicator: 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
Remedy: Check power cable connections
1. Check connections and motor power cables for short circuits.
 If there is a short circuit, repair the wiring.
 If the cables are ok, proceed to step 2.
Check the insulation resistance
2. Check the motor housing insulation resistance to +BV/B-NEG.
 If there is a short to +BV/B-NEG, replace the motor.
 If the insulation resistance is ok, proceed to step 3.
Replace Access 2/3
3. Replace Access 2/3.

Event code 307

Display: EV 307
Service indicator: On
Operator error indicator: Off
Explanation: On power up a test is performed to check if the main contactor contacts are
open. If the circuit which the main contactor contacts close is closed, this event
code will be issued.
Possible causes: • Main contactor power contacts are welded
• Short circuit in the power routing on main contactor
• Access 3 faulty
Remedy: Check power cable connections
1. Check if power cable connections on the main contactor have shorted.
 If there is a short, repair the wiring.
 If the cables are ok, proceed to step 2.
Check main contactor contacts
2. Check the main contactor contacts (see page 263).
 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
3. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 308

Display: EV 308
Service indicator: On
Operator error indicator: Off
Explanation: Main contactor contacts do not close.
Possible causes: • Main contactor contacts jammed
• Fuse FU1 faulty
• Coil routing disconnected
• Main contactor coil faulty
• Access 3 faulty
Remedy: Check fuse FU1
1. Measure the voltage on B-POS of Access 2/3.
 If there is no voltage, replace fuse FU1.
 If the main contactor is ok, proceed to step 2.
Check the contactor coil power supply
2. Connect the positive lead of a voltmeter to the +connection of the coil
(white/red). Attach the negative lead of the voltmeter to B-NEG. Switch on
the truck.
 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.
3. Measure the positive power supply over the following components and
wires:
– From the signal switch input on the main contactor to fuse FU2
– From the output of fuse FU2 over pin 30 to pin 87 on relay K1
– From pin 87 on relay K1 to the +pin of the main contactor coil (LINE)
 If there is no significant voltage drop, proceed to step 4.
 If the voltage on one wire drops extremely or if there is no voltage, repair
the wire or connections.
Check the pilot line and coil connections
4. Check the negative lead (green/white) to the coil on the main contactor for
continuity to pin PC201-12.
 If there is a disconnection, repair the wiring.
 If the wiring is ok, proceed to step 5.
Check the main contactor coil
5. Remove both pilot lines from the coil.
6. Measure the coil resistance with an ohmmeter.
 If the coil resistance is significantly less or more than ≈ 30 Ω , replace
the main contactor or coil.
 If the wiring is ok, proceed to step 7.
Replace Access 2/3
7. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 309

Display: EV 309
Service indicator: On
Operator error indicator: Off
Explanation: Current flows to output stage when truck is idle
Possible causes: • Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck. Disconnect the battery. Wait for 6 seconds. Connect
the battery. Switch on the truck.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Replace Access 2/3
2. Replace Access 2/3.

Event code 310

Display: EV 310
Service indicator: On
Operator error indicator: Off
Explanation: Internal capacitor bank charge time exceeded.
Possible causes: • Additional unauthorised consumers installed
• Access 3 faulty
• Access 5 faulty
Note: If the event code occurs alternating with EV 224, first check Access 5.
Remedy: Check for additional consumers
1. Using the electrical diagram and Crown's list of options, check if non-ap-
proved consumers are connected along with the capacitor bank of B-POS
at Access 3 to B-NEG.
 Disconnect any non-approved consumers. Proceed to step 2.
 If no non-approved consumers are installed, proceed to step 3.
2. Switch the truck off and on again.
 If the event code occurs again, proceed to step 3.
Replace Access 2/3
3. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 314

Display: EV 314
Service indicator: On
Operator error indicator: Off
Explanation: Main contactor driver shorted or wiring disconnected.
Possible causes: • Short circuit or disconnection in the wire from CA201-12 to the main con-
tactor coil.
• Access 3 faulty
Remedy: Check the wiring and main contactor coil for shorts
1. Disconnect the battery.
2. Measure the resistance between the negative connection (WHT/GRN) 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.
3. Disconnect CA200.
4. Measure the voltage between PC200-17 and B-NEG on Access 2/3.
 If there is a short (resistance < 10 Ω), there is a short either in the wiring
(between wire 5900 and B-NEG) or the coil of the main contactor. Pro-
ceed to step 6 or 7.
 If no short circuit is found, proceed to step 5.
Check the control module for shorts in the driver output
5. Disconnect CA200 and measure the resistance between JC200-17 and B-
NEG on Access 2/3.
 If the resistance < 10 Ω, proceed to step 8.
Repair the wiring
6. Short circuit in wire
Repair the main contactor
7. Replace the coil.
Replace Access 2/3
8. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 315

Display: EV 315
Service indicator: On
Operator error indicator: Off
Explanation: Driver cannot close the main contactor.
Possible causes: • Main contactor coil wiring disconnected
• Main contactor coil faulty
• Access 3 faulty
Remedy: Check the contactor coil power supply
1. Connect the positive lead of a voltmeter to the +connection of the coil
(white/red). Attach the negative lead of the voltmeter to B-NEG. Switch on
the truck.
 If there is no voltage applied, the wiring has been disconnected. Repair
wires 2900 and 2901 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 pilot line and coil connections
2. Check the negative wire (green/white) leading to the coil on the main con-
tactor for continuity to pin PC200-17.
 If there is a disconnection, repair the wiring.
 If the wiring is ok, proceed to step 3.
Check the main contactor coil
3. Remove both signal cables from the coil.
4. Measure the coil resistance with an ohmmeter.
 If the resistance is less than 30 Ω, replace the coil.
 If the coil is ok, proceed to step 5.
Replace Access 2/3
5. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 316

Display: EV 316
Service indicator: On
Operator error indicator: Off
Explanation: Excessive current through the driver for the main contactor or brake coil
Possible causes: • Short in brake coil circuit or brake coil itself
• Short in main contactor coil circuit or main contactor coil itself
• Access 3 faulty
Remedy: Check the wiring to the main contactor coil and the brake for short cir-
cuits
1. Check the wiring to the main contactor coil and the brake for short circuits.
2. Check if the connections on the main contactor have been shorted by a
foreign body.
 Rectify the short circuit if found.
 If there is no short circuit, proceed to step 3.
Check the coils of the main contactor coil and the brake for short circuits
Note: A short circuit is detected at a resistance of < 2 Ω.
3. Remove both signal cables from the main contactor coil.
4. Measure the coil resistance with an ohmmeter.
 If the resistance is less than ≈ 30 Ω, replace the main contactor or coil.
 If the coil is ok, proceed to step 5.
5. Remove the cable from the brake.
6. Measure the brake coil resistance with an ohmmeter.
 If the resistance is less than 10 Ω ±10%, replace the coil.
 If the coil is ok, proceed to step 7.
Replace Access 2/3
7. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 317

Display: EV 317
Service indicator: On
Operator error indicator: Off
Explanation: The zero point of the traction potentiometer deviates from the calibrated setting
by more than 1 V. The travel switch is open.
Possible causes: • Physical defect on the traction potentiometer
• Traction potentiometer replaced but not calibrated
Remedy: Check the traction potentiometer for physical damage
1. Select service level 2 (see page 86).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the A2 INPUTS menu.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Press the key 2 times.
 A2.3 ACCESS 3 INPUTS is displayed.
6. Press the key.
 A2.3.1 TEMP ACCESS 3 is displayed.
7. Press to scroll to the A2.3.5 > POT WPR 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
118).
 If the display does not revert to the same reading in neutral, the traction
potentiometer is faulty. Replace the traction potentiometer (see page
292). Now calibrate the traction potentiometer (see page 118).

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Event Code Group 300 (all GPCs from 09/2012)

Event code 319

Display: EV 319
Service indicator: On
Operator error indicator: Off
Explanation: Load sensor output voltage out of range
Possible causes: • Load sensor replaced but not re-calibrated
• Wiring damaged
• Load sensor faulty
• Access 3 faulty
Remedy: Check the load sensor wiring and output voltages
1. Select service level 2 (see page 86).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 A2 Inputs is displayed.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Press the key.
 A2.2 ACCESS 2 is displayed.
6. Press the key.
 A2.2.1 RAS SWITCH is displayed.
7. Press to scroll to A2.2.10.
 A2.2.10 PRESSURE TRANSDUCER is displayed.
8. Press the key.
 The current reading is displayed.
9. Fully lower the forks without load.
10. Check and record the reading.
11. Raise a 2,000 kg load. 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 reading is above or below the permissible range, proceed to step
13
Measure the load sensor power supply
13. Measure the voltage from CA223-1 to B-NEG. Measure the voltage from
CA223-2 to B-NEG.
 If the voltage at CA213-1 ≈ 0 V DC and at CA213-2 ≈ 12 V DC, the
power supply is ok. Proceed to step 15.
 If the power supply is faulty, proceed to step 14.

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Locate the fault in the load sensor power supply

14. Check the respective wire and plug connector of CA213-1 and CA213-2
leading to CA200-26 and CA200-41 for damage.
 If there is no damage, proceed to step 24.
Calibrate the load sensor
15. Calibrate the load sensor (see page 119).
Measure the load sensor output signal directly
16. Connect the voltmeter at CA213-3 to battery negative.
17. Fully lower the forks without load.
18. Check and record the reading on the voltmeter.
19. Raise a 2,000 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 and re-calibrate the load sensor (see page 119).
Check the pilot line
22. Check the pilot line from CA213-3 to CA200-23 for damage.
 If the wire or a connector contact is damaged, proceed to step 23.
 If there is no damage, proceed to step 24.
Repair the wiring
23. Repair the wiring.
Replace Access 2/3
24. Replace Access 2/3.

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Event Code Group 300 (all GPCs from 09/2012)

Event code 320

Display: EV 320
Service indicator: On
Operator error indicator: Off
Explanation: CAN Bus communication failure between Access 3 and Access 1
Possible causes: • Wiring damaged
• Terminating resistor faulty
Remedy: The first time the event code appears
1. Switch off the truck. Disconnect the battery. Wait for 6 seconds. Connect
the battery. Switch on the truck.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 86).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key 2 times.
 E1.1 LAST is displayed.
6. Use keys and to scroll through to the service hours and temperature
of the most recently logged event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok. Proceed to step 7.
 If no event is logged, proceed to step 16.
Check CAN Bus wiring and terminations between Access 3 and Access 1
7. Switch off the truck.
8. Measure the resistance between CA210-1 and CA210-2.
 If the resistance is 60 Ω (a) the CAN-Bus termination is ok. Proceed to
step 15.
 If the resistance is not 60 Ω, proceed to step 9.
9. Disconnect PC400 from Access 1.
10. Disconnect PC201 from Access 5.
11. Measure the resistance between CA210-1 and CA210-2.
 If the resistance is 0 Ω , the CAN-Bus termination is ok. Proceed to step
12.
 If the resistance is not 0 Ω , proceed to step 12.
12. Measure the termination resistance between JC400-8 and JC400-9
(socket on Access 1).
 If the resistance is 120 Ω , proceed to step 13.
 If the resistance is not 120 Ω , proceed to step 16.

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13. Measure the resistance between PC200-27 and PC200-42 on Access 2/3.
 If the resistance is 120 Ω , Access 2/3 is ok. Restart the truck. Check
the event log.
 If the resistance is not 120 Ω , proceed to step 15.
Repair the wiring
14. Repair the wiring.
Replace Access 2/3
15. Replace Access 2/3.
Replace Access 1
16. Replace Access 1.
a. A small number of trucks have a CAN-Handle printed circuit board with a 40 Ω terminating resistor. On these trucks the overall re-
sistance on the CAN-Bus is just 40 Ω.

Event code 321

Display: EV 321
Service indicator: On
Operator error indicator: Off
Explanation: Incorrect truck model selected.
Possible causes: • Control module replaced and not set
Remedy: Set the truck model
1. Select service level 2 (see page 86).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the Features menu.
4. Press the key,
 F1 LANGUAGE is displayed.
5. Press to scroll to the F4 TRUCK TYPE menu.
6. Press the key.
 3020 is displayed.
7. Press the key to select the right model. (See truck data plate).
8. Press the key.
 SAVE N is displayed.
9. Press or to change the display to SAVE Y.
10. Press the key.
 The selected model is stored.
11. Restart the truck.
12. Set parameters if required.
13. Calibrate the truck (see page 118).
14. Restart the truck.

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Event code 322

Display: EV 322
Service indicator: On
Operator error indicator: Off
Explanation: Short circuit in the brake positive wire
Possible causes: • Wiring short circuit
Remedy: Check wiring
1. Measure the voltage between CA200-30 and B-NEG.
 If the reading ≈ +BV, proceed to step 2.
 If the reading is not ≈ +BV, remove the short circuit between the positive
cable (red/white) on the brake and PC200-30.
2. Remove the negative brake connection (green/white) from CA201-4.
 If the event code persists, proceed to step 3.
Replace Access 2/3
3. Replace Access 2/3.

Event code 324

Display: EV 324
Service indicator: On
Operator error indicator: Off
Explanation: Driver short circuit fuse for the main contactor coil and brakes has tripped.
Possible causes: • Wiring short circuit
• Short circuit in the brake coil or the main contactor coil
• Access 3 faulty
Remedy: Check main contactor coil for shorts
1. Disconnect wires 2900 and 5900 from the main contactor.
2. Measure the coil resistance.
 If the resistance ≈ 30 Ω , the main contactor coil is ok. Proceed to step 3.
 If the resistance ≤ 25 Ω , the main contactor coil is faulty. Proceed to
step 7.
Check the brake coil for shorts
3. Remove wires 203 and 5907 from the brake.
4. Measure the coil resistance.
 If the resistance ≈ 10 Ω , the brake coil is ok. Proceed to step 5.
 If the resistance ≤ 8 Ω , the brake coil is faulty. Proceed to step 8.
Check the wiring for short circuits
5. Check the wires from Access 3 leading to the brake and the main contactor
for shorts.
 If there is no short, proceed to step 9.
 If there is a short, proceed to step 6.

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Repair the wiring

6. Repair the wiring.
Repair the main contactor
7. Replace the entire main contactor or coil.
Repair the brake
8. Replace the entire brake or the magnetic body of the brake.
Replace Access 2/3
9. Replace Access 2/3.

Event code 325

Display: EV 325
Service indicator: On
Operator error indicator: Off
Explanation: Processor communication error
Possible causes: • Communication error
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch on the truck again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 86).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key 2 times.
 E1.1 LAST is displayed.
6. Use keys and to scroll through to the service hours and temperature
of the most recently logged event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is logged, proceed to step 7.
Replace Access 2/3
7. Replace Access 2/3

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Event code 326

Display: EV 326
Service indicator: On
Operator error indicator: Off
Explanation: Power output stage short circuit
Possible causes: • Short circuit in the power cables
• Control module faulty
Remedy: Check the power cables and connections
1. Switch off the truck and disconnect the battery.
2. Check the power cable to the traction motor M1 and its terminals for short
circuits.
3. Check the power cable connections on the control module for shorts with
B-POS and B-NEG connections.
 If any cables or terminals are shorted, rectify the cause.
 If the power cables and the connections are ok, proceed to step 4.
Check the insulation resistance
4. Measure the insulation resistance from the motor coil and power cables to
the truck chassis.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
 If the insulation resistance is ok, proceed to step 5.
Check control module
5. On the control module unscrew the wires from connections U, V and W.
6. Using an ohmmeter measure the resistance from connection U on the con-
trol module to B-POS 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
8. Replace Access 2/3.

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Event code 328

Display: EV 328
Service indicator: On
Operator error indicator: Off
Explanation: Control module faulty
Possible causes: • Control module faulty
Remedy: Replace Access 2/3
1. Replace Access 2/3.

Event code 329

Display: EV 329
Service indicator: On
Operator error indicator: Off
Explanation: Control module faulty
Possible causes: • Communication error on the CAN bus
• Access 1 faulty
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch on the truck again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 86).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key twice.
 E1.1 LAST is displayed.
6. Use keys and to scroll through to the service hours and temperature
of the most recently logged event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is logged, proceed to step 7.
Replace Access 2/3
7. Replace Access 2/3.

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Event code 330

Display: EV 330
Service indicator: On
Operator error indicator: Off
Explanation: ON signal of more than one PPCS applied.
Possible causes: • Wiring error
• PPCS faulty
• Access 3 faulty
Remedy: Check the status of switches PPCS1 to PPCS2
1. Select service level 2 (see page 86).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the A3 INPUTS menu.
4. Press the key.
 A2.3.1 TEMP ACCESS 3 is displayed.
5. Press to scroll to A2.3.11.
 A2.3.11 PPCS1 SWITCH is displayed.
6. Press the key.
 The status of PPCS1 (ON or OFF) is displayed.
7. Scroll back to A2.3.11 PPCS1 SWITCH.
8. Press to scroll to A2.3.12.
 A2.3.12 PPCS1 SWITCH is displayed.
9. Press the key.
 The status of PPCS2 (ON or OFF) is displayed.
Note: Switches PPCS3 and PPCS4 are only available with special trucks.
They must also be checked if applicable.
 When all the switches are OFF, restart the truck and check the event
log.
 If at least one of the switches is ON despite not being pressed, replace
the respective switch.

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Event code 332

Display: EV 332
Service indicator: On
Operator error indicator: Off
Explanation: Control module faulty
Possible causes: • Communication error on the CAN bus
• Access 1 faulty
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch on the truck again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 86).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key 2 times.
 E1.1 LAST is displayed.
6. Use keys and to scroll through to the service hours and temperature
of the most recently logged event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is logged, proceed to step 7.
Replace Access 2/3
7. Replace Access 2/3.

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Event code 333

Display: EV 333
Service indicator: On
Operator error indicator: Off
Explanation: The driver cannot activate the brake
Possible causes: • Wiring disconnected
• Open brake coil
• Control module faulty
Remedy: Check wiring
1. Measure the voltage between CA200-30 and B-NEG.
 If the reading ≈ +BV, proceed to step 2.
 If the voltage is not ≈ +BV, repair the wire (red/white) between the brake
and PC200-30.
Check the brake coil
2. Remove the cable from the brake.
3. Measure the brake coil resistance with an ohmmeter.
 If the resistance is not 10 Ω ±10%, replace the brake.
 If the coil is ok, proceed to step 4.
Replace Access 2/3
4. Replace Access 2/3.

Event code 334

Display: EV 334
Service indicator: On
Operator error indicator: Off
Explanation: Occurs only in connection with EV 328
Possible causes: • None
Remedy: 1. No action required, the alarm goes out automatically.

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Event code 335

Display: EV 335
Service indicator: On
Operator error indicator: Off
Explanation: Breakdown in CAN-Bus communication between Access 1 (display) and Ac-
cess 5.
Possible causes: • Wiring error
• Display faulty
• Access 5 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch on the truck again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 86).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key 2 times.
 E1.1 LAST is displayed.
6. Use keys and to scroll through to the service hours and temperature
of the most recently logged event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok. Proceed to step 15.
 If no event is logged, proceed to step 16.
Check CAN-Bus wiring and termination
7. Switch off the truck.
8. Measure the resistance between CA210-1 and CA210-2.
 If the resistance is 60 Ω (a), the CAN-Bus termination is ok. Proceed to
step 15.
 If the resistance is not 60 Ω, proceed to step 9.
9. Disconnect PC201 from Access 5 and PC400 from the display.
10. Measure the resistance between CA210-1 and CA210-2.
 If the resistance is >1 MΩ the CAN-Bus wiring is ok. Proceed to step 12.
 If the resistance <1 MΩ, proceed to step 13.
11. Measure the termination resistance between JC400-8 and JC400-9
(socket on Access 1).
 If the resistance is 120 Ω, proceed to step 13.
 If the resistance is not 120 Ω, proceed to step 14.

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12. Measure the resistance between JC201-14 and JC201-6 on Access 5.

 If the resistance is 120 Ω, Access 5 is ok. Restart the truck and monitor
the event log.
 If the resistance is not 120 Ω, proceed to step 15.
Repair the wiring
13. Repair the wiring.
Replace Access 1
14. Replace Access 1.
Replace Access 5
15. Replace Access 2/3.
a. A small number of trucks have a CAN-Handle printed circuit board with a 40 Ω terminating resistor. On these trucks the overall re-
sistance on the CAN-Bus is just 40 Ω.

Event code 337

Display: EV 337
Service indicator: On
Operator error indicator: Off
Explanation: Temperature sensor in the control module returns values beyond the measur-
ing range of -80°C to +120°C.
Possible causes: • Display faulty
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch on the truck again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
1. Select service level 2 (see page 86).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the EVENTS menu.
4. Press the key 2 times.
 E1.1 LAST is displayed.
5. Use keys and to scroll through to the service hours and temperature
of the most recently logged event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok. Proceed to step 6.
 If no event is logged, replace Access 1.
Replace Access 2/3
6. Replace Access 2/3.

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Event code 338

Display: EV 338
Service indicator: On
Operator error indicator: Off
Explanation: Battery voltage out of range.
Possible causes: • Display 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.
Compare internally measured battery voltage with actual battery voltage
5. Select service level 2 (see page 86).
6. Press the key.
 A1 Status is displayed.
7. Using the key scroll through to the A3 OUTPUTS menu.
8. Press the key.
 A3.1 BATTERY% is displayed.
9. Press the key.
 A3.2 BATTERY VOLTAGE is displayed.
10. Using a voltmeter measure the battery voltage and compare it with the
reading from the Analyzer menu.
 If the readings are identical, the error has been resolved.
 If the readings differ, connect the console and set the reading measured
for the battery voltage.

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Event code 340

Display: EV340
Service indicator: On
Operator error indicator: Off
Explanation: Parameters for traction motor M1 are faulty.
Possible causes: • EEPROM error
• Access 3 faulty
Remedy: Clear the EEPROM in Access 3
11. Select service level 3 (see page 86).
12. Using the key scroll through to the UTILITIES menu.
13. Press the key,
 U1 PART NUMBERS is displayed.
14. Using the key scroll through to the U2 EEPROM CLEAR menu.
15. Press the key.
 U2.1 ACCESS 2 is displayed.
16. Press to scroll to U2.2 ACCESS 3.
17. Press the key.
 CONFIRM is displayed.
18. Press the key.
 The EEPROM in Access 3 is cleared.
19. Switch the truck off and on again.
 If the event code persists, proceed to step 21.
20. Re-calibrate the truck completely.
Replace Access 2/3
21. Replace Access 2/3

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Event code 341

Display: EV 341
Service indicator: On
Operator error indicator: Off
Explanation: Short circuit on the negative side of the brake driver
Possible causes: • Open connection in the brake positive wire
• Short circuit between positive wire leading to brake and B-NEG.
• Short circuit on the negative side of the driver in Access 3
Remedy: Check wiring and power supply
1. Disconnect PC200 from Access 3 and the negative wire 5907 (green/
white) from the brake.
2. Check wire 5907 (pin PC200-31) for continuity.
 If the wire is ok, proceed to step 3.
 If the wire is disconnected, repair the wire.
3. Reconnect PC200.
4. Disconnect wire 5907 (green/white) from the brake. Measure voltage be-
tween both brake terminals and B-NEG.
 If the reading ≈ 24 V, proceed to step 5.
 If there is no 24 volt supply, replace the brake.
5. Measure the resistance between PC200-31 and B-NEG.
 If the resistance < 1 kΩ, proceed to step 6.
 If the resistance is > 1 kΩ, repair the wiring.
Replace Access 2/3
6. Replace Access 2/3.

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Event code 342

Display: EV 342
Service indicator: On
Operator error indicator: 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
1. Select service level 2 (see page 86).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 A2 Inputs is displayed.
4. Press the key.
 A2.1 ACCESS 1 INPUTS is displayed.
5. Press the key 2 times.
 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
control module 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
control module is faulty. Proceed to step 12.
Check wiring
12. Check plug connector CA411 in the steer 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 printed circuit board
13. Replace the potentiometer and printed circuit board in the steer handle.
Replace Access 2/3
14. Replace Access 2/3.

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Event code 343

Display: EV 343
Service indicator: On
Operator error indicator: 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: Calibrate traction potentiometer
1. Calibrate the traction potentiometer (see page 118).
 If the event code occurs again after re-starting, proceed to step 2.
Check encoder pulses in Analyzer menu
2. Select service level 2 (see page 86).
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.
6. Press the key 2 times.
 A2.3 ACCESS 3 is displayed.
7. Press the key.
 A2.2.3 TEMP ACCESS 3 is displayed.
8. Press to scroll to A2.3.16 ECR1 ENCODER 64P.
9. Press the key.
 The encoder pulses are displayed (0 pulses when system idle).
10. Accelerate the truck and monitor the display.
 If 0 pulses are shown when truck is idle and ±13680 pulses are shown
at full speed, the encoder is ok. Restart the truck and check the event
log.
 If 0 pulses are not shown when truck is idle and ±13680 pulses are
shown at full speed, proceed to step 11.

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Check wiring
11. Check the wiring of the encoder including that of connector CA221 for:
– Corrosion
– Loose connections
– Faulty butt splice connections on the pins
– Trapped wires
 Repair the wiring if faulty.
 If there is no damage, proceed to step 12
Check 12 volt supply
12. Measure voltage between CA221-1 (on ECR1) and B-NEG. It must be
≈ +12 V.
13. Measure the voltage (GND) from CA221-4 to B-NEG. It must be ≈ 0 V.
 If the voltages measured in steps12 and 13 are correct, the 12 V supply
is ok. Proceed to step 14.
 If there is no +12 V supply, repair the disconnection in the wiring be-
tween CA221-1 and CA200-9.
 If a higher reading than ≈ +12 V is measured at CA202-1, the control
module is faulty. Proceed to step 15.
 If a reading higher than 1 V is measured at CA221-4, the control module
is faulty. Proceed to step 15.
Check the sensor bearing for physical damage
14. Monitor the running noise of the traction motor.
 If the motor rattles, the encoder (sensor bearing) is probably damaged.
Repair or replace the motor (see page 250).
 If no physical damage is found, restart the truck and check the event
log.
Replace Access 2/3
15. Replace Access 2/3.

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Event code 344

Display: EV 344
Service indicator: On
Operator error indicator: Off
Explanation: The status of the brake switch (BRS) is monitored via the CAN bus and addi-
tionally via a hard wired line. The hard wired line acts as a backup for the signal
via the CAN bus. This event code is displayed if the input at Pin CA200-33 =
OFF and the CAN signal = ON.
Possible causes: • Wiring error
• Access 3 faulty
Remedy: Test the brake switch status
1. Select service level 2 (see page 86).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 A2 Inputs is displayed.
4. Press the key.
 A2.1 ACCESS 1 INPUTS is displayed.
5. Press the key 2 times.
 A2.3 ACCESS 3 INPUTS is displayed.
6. Press the key.
 A2.3.1 TEMP ACCESS 3 is displayed.
7. Press to scroll to A2.3.8 BRS SWITCH.
8. Press the key.
Note: Do not press the switch.
 If OFF is displayed, the switch is ok. Proceed to step 9.
 If ON is displayed, proceed to step 13.
Check the signal wire to CA200-33
9. Remove wire and pin from CA200-33.
10. Measure the voltage between the cable and B-NEG.
 If the voltage corresponds to B-POS, the wire is ok.
 If the voltage does not correspond to B-POS, proceed to step 11.
11. .Remove wire and pin from CA205-6.
12. Measure the voltage between the cable and B-NEG.
 If the voltage corresponds to B-POS, the CAN interface card is faulty.
Replace the card.
 If the voltage does not correspond to B-POS, proceed to step 13.
13. Insert wires and pins back in the connector.
14. Back to step 1 and scroll back to A2.3.8 BRS SWITCH.
15. Apply the brake switch.

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 If OFF is now displayed, the control wire is ok and the CAN interface
card is faulty. Replace the card.
 If the switch status does not change when BRS is pressed, replace
BRS.

Event code 347

Display: EV347
Service indicator: On
Operator error indicator: Off
Explanation: The travel command frequency for more than 15 s > 20 kHz and the frequency
of encoder ECR1 in the traction motor is < 0.6 Hz.
Possible causes: • Intermittent internal error in Access 3
• Motor blocked
• Faulty wiring
• ECR1 faulty
• Access 3 faulty
Remedy: Note: This event also occurs when the traction motor is blocked. For example,
if the drive tyre is stuck in a hole or pallets have been pushed in an unauthor-
ised manner. Check this first!
The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch on the truck again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
1. Select service level 2 (see page 86).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the EVENTS menu.
4. Press the key 2 times.
 E1.1 LAST is displayed.
5. Use keys and to scroll through to the service hours and temperature
of the most recently logged event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is logged, proceed to step 6.
Check the consumption of the traction motor and test encoder ECR1
6. Select service level 2 (see page 86).
7. Press the key.
 A1 Status is displayed.
8. Press the key.
 A2 Inputs is displayed.

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9. Press the key.

 A2.1 ACCESS 1 INPUTS is displayed.
10. Press the key 2 times.
 A2.3 ACCESS 3 INPUTS is displayed.
11. Press the key.
 A2.3.1 TEMP ACCESS 3 is displayed.
12. Press to scroll to A2.3.15 TRACTION MOTOR CURRENT.
13. Press the key.
14. Accelerate the unladen truck up to maximum speed and check the current.
 If the current is approx. 35A, the wiring and encoder are ok. Proceed to
step 16.
 If the current is considerably greater than 35 A and the truck still only
travels at creep speed, the wiring or the encoder in M1 are faulty. Pro-
ceed to step 15.
15. Check wiring of encoder ECR1 for damage.
 Repair the wiring if faulty.
 If the wiring is ok, repair or replace the motor.
 If neither the encoder nor the wiring is faulty, proceed to step 17.
Check ECR1 (sensor bearing) for physical damage
16. Monitor the running noise of the traction motor.
 If the motor “rattles”, the encoder (sensor bearing) is probably dam-
aged. Repair or replace the motor.
 If no physical damage is found, proceed to step 17
Replace Access 2/3
17. Replace Access 2/3

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Event code 348

Display: EV 348
Service indicator: On
Operator error indicator: 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 0.75 Hz is
detected for more than 2 seconds.
Possible causes: • Brake faulty
• EEPROM contains incorrect content in memory
Remedy: Check the parking brake
1. Check the parking brake for damage (see page 269).
2. In service level 3 perform Clear EEPROM and re-calibrate the truck.

200