009 TroubleshootingDiagError RM 7570162-040

Repair manual: Troubleshooting Model(s): RRE120B,RRE140B,RRE160B
Publication Number: 7570162-040 Date: 2014-09-15 Applies from serial number: 6308581
8. Troubleshooting
8.1 Auxiliary functions
8.1.1 Error log menu
Description
The error log displays a list of the last 20 errors logged.
Five errors are listed directly on the menu. The log number, date and error
code are displayed for each error. The selected error is highlighted by means
of a box that can be moved up or down the list using the arrow keys. When
the selection approaches the top or bottom of the list, the menu rolls the list
on, to display more errors if there are any.
Access
i
The login screen may vary depending on the setting of parameter 503.
© TMHE 8– 1 T Code(s): 1006

8.1.2 Error information menu
Description
NOTE:
The error information menu is mainly intended for software development and
shows detailed information about the logged error.
The error code (3:143) is shown on the left of the window. Beneath it are the
log date (101109) and time (12:57) when the error occurred.
The window also shows logged information relating to the error.
Only five values are displayed at a time; to obtain more values, the arrow
keys must be used.
Access
8.1.3 Diagnostic screens
Description
The CID diagnostic screens are used to check the values of subsystems.
Some screens also show other information that may be of use to a service
technician.
NOTE:
Update of diagnostic screen data has lower priority than regular truck
functions. Thus, the screens are only updated once per second.
Access
1–19/
© TMHE 8– 2 T Code(s): 1006

Screen 1 – CID analogue inputs
Function Conn. Unit

~0.5 V / 4.5 V max
1 Lift/lowering lever X505:3
~2.5 V released
~0.5 V / 4.5 V max
2 Traversing lever X505:4
~2.5 V released
~0.5 V / 4.5 V max
3 Tilt lever X505:5
~2.5 V released
~0.5 V / 4.5 V max
4 Sideshift X505:6
~2.5 V released
5 - - -
~0.5 V left / 4.5 V
6 Travel direction selector X503:1 right ~2.5 V
released
7 - - -
8 – - -
9-10 - - -
© TMHE 8– 3 T Code(s): 1006

Screen 2 – CID digital inputs
Function Conn.
1 Steering pulse transducer 1 A X504:13
2 Steering pulse transducer 1 B X504:11
3 Steering pulse transducer 2 A X504:14
4 Steering pulse transducer 2 B X504:12
6 Horn X503:6
8 Height limitation bypass X503:4
9 Working lights X503:3
10 X503:9
11 X503:4
12
13
14
15
16
17
18
19 Emergency switch off X504:17
21-32 Not used
© TMHE 8– 4 T Code(s): 1006

Screen 3 – MCU analogue inputs
Function Conn. Unit

1 X130:2
2 X130:16
3 X130:30
4 X130:3
~0.5 V released
5 Accelerator X130:17
~4.5 V max.
~1.5 V released
6 Safety pedal X130:31
~3.5 V max.
~0.5 V released
7 Brake pedal, signal 1 X130:4
~4.5 V max.
~4.5 V released
8 Brake pedal, signal 2 X130:18
~0.5 V max.
9 X130:32
10 Battery voltage + X130:5 V
© TMHE 8– 5 T Code(s): 1006

Screen 4 – MCU digital inputs
Function Conn.
1 X130:10
2 X130:24
3 X130:38
4 X130:11
5 X130:25
6 X130:39
Height sensor in main lift
7 X130:12
zone, pulse A
Height sensor in main lift
8 X130:26
zone, pulse B
9 X130:40
10 X130:13
11 X130:27
12 Seat switch X130:41
13 Mast lowering mode A X131:2
14 X131:16
15 X131:30
16 X131:3
17 X131:17
18 X131:31
19 X131:4
20 X131:18
21 X131:32
22 Emergency switch off X131:5
23 X131:19
24 X131:33
25 Key relay X131:6
© TMHE 8– 6 T Code(s): 1006

Screen 5 – MCU digital outputs
Function Conn.
2 Chassis fan X131:34
3 Main contactor X131:7
4 Lifting valve X131:21
5 X131:35
6 Working lights X131:8
7 X131:22
8 Travel alarm 2 (Warning lamp) X131:36
9 Fan for frequency converter X131:9
10 Travel alarm 1 (Buzzer) X131:23
11 Extra hydraulic valve 1A X131:37
12 Reach carriage valve in X131:10
13 Reach carriage valve out X131:24
14 Routing valve. X131:38
15 Extra hydraulic valve 1B X131:11
16 Horn X131:25
17 X131:39
18 X131:12
© TMHE 8– 7 T Code(s): 1006

Screen 6 – Pulse-width modulated outputs
MCU signal Value

1 PWM1 X131:26 V
2 PWM2 X131:40 V
3 PWM3 X131:13 V
4 PWM4 X131:41 V
5 DO17 X131:39 V
6 PWM6 X131:12 V Parking brake
ACH signal
PWM1 T2:108 A Lowering valve
PWM2 T2:109 A
ACT signal
PWM1 T1:108 A
8 PWM2 T1:109 A
© TMHE 8– 8 T Code(s): 1006

Screen 11 – Temperatures
Unit °C
1 ACT motor temperature

2 ACT cooling flange temperature
3 ACH motor temperature
4 ACH cooling flange temperature
5 EPS motor temperature
Screen 12 – Voltages
A recently charged battery should

be ~ 51 V
1 Supply MCU
A battery under 48 V must be
charged
2 +15 V from MCU
3 +5 V from MCU
Should be the same value as for
4 Supply ACH
“Supply MCU”
5 Supply ACT
“Supply MCU”
6 Supply EPS
“Supply MCU”
All voltages are given in volt.
© TMHE 8– 9 T Code(s): 1006

Screen 13 – travel function
Function Unit
Left Travel speed, actual value m/s
Right Travel speed, target value m/s
~0.5 V: not depressed
A Accelerator
~4.5 V: Depressed all the way
B1 Brake pedal
~4.5 V: depressed all the way
B2 Brake pedal
~0.5 V: depressed all the way
1 Main contactor –
2 Power stage in ACT activated –
3 Safety switch –
4 Seat switch –
5 Parking brake –
Travel direction selector, drive
6 –
wheel direction
Travel direction selector, fork
7 –
direction
© TMHE 8 – 10 T Code(s): 1006

Screen 14 – Steering function
Function Unit
Steering response, actual
Left °
value
Steering response, target
Right °
value
0 RPM with stationary
steering wheel
Steering motor speed, actual
Left 2300 – 3000 RPM with
value
considerable steering wheel
movements
Steering motor speed, target Should be close to
Right
value corresponding actual value
S1 Steering command 0% with stationary steering
wheel
S2 Steering command 100% with considerable
steering wheel movements
1 – –
2 Steering reference sensor –
Drive wheel direction
3 –
requested
4 Fork direction requested –
5 Reverse steering –
6 –
7 –
8 –
© TMHE 8 – 11 T Code(s): 1006

Screen 15 – Displays information about lifting/lowering
Function Unit
H Height, total (displayed) mm
S Lifting/lowering speed mm/s
± 100%
0 when the
L Lift/lowering lever
lever is not
activated
Requested hydraulic pump
P Rpm
speed
1 Pulse A
2 Pulse B
3 Reference sensor
4 ACH Active
© TMHE 8 – 12 T Code(s): 1006

Screen 16 – Displays reach in and reach out information.
Function Unit
0% at maximum in
Actual reach movement
R 100% at maximum
length
out
*/- 100%
L Reach movement lever 0 when the lever is
not activated
P Rpm
speed
© TMHE 8 – 13 T Code(s): 1006

Screen 17 – Displays tilt and sideshift information.
Function Unit
± 100%
0 when the
L1 Tilt lever
lever is not
activated
± 100%
0 when the
L2 Sideshift lever
lever is not
activated
P Rpm
speed
© TMHE 8 – 14 T Code(s): 1006

8.2 Initial troubleshooting
Begin troubleshooting
CID lit? No Troubleshooting without

indications
Yes
Blocking Yes Troubleshooting using

symbol blocking symbol
displayed?
No
Yes Troubleshooting using

Error code
error code
displayed?
No
Troubleshooting
without indications
© TMHE 8 – 15 T Code(s): 1006

8.3 Troubleshooting using blocking symbol
Symbol Cause Hints

Software failure • Create a truck report and save it.
• Reinstall truck software. Use the latest software, even if this
involves an update.
• Check the truck parameters against the saved truck report.
Reactivation of requested function The activation sequence for a requested function is not
required correct.
The latest function used must be redone from the start.
The MCU does not know if the seat If the indication is intermittent, this may be due to gaps in the
switch [B49] is affected. cable connections or the sensor's mechanical mounting.
If the indication is shown constantly, check that MCU digital

input X130:41 changes status when the seat is loaded; CID
diagnostic screen 4/pos 12.
1: If the input remains low, the sensor's function and the

wiring harness must be checked for any break in
conductors 27, 40 and 83.
2: If the input is constantly high, the sensor's function and the
wiring harness must be checked for short-circuiting
between conductors 27 and 83.
3: If there is a voltage at input X130:41 when the seat is not
loaded, but the input status shows this, the MCU must be
replaced.
© TMHE 8 – 16 T Code(s): 1006

Symbol Cause Hints

The control sequence performed in Perform the control sequence in the right order.
the wrong order. If the indication is intermittent, this may be due to gaps in the
or cable connections or mechanical fault in the sensor.
The MCU does not know if the If the indication is shown constantly, check that the signal from
safety pedal [B31] is affected. the safety pedal switches status when the chair is loaded, CID
diagnosis screen 3/pos 6.
Normal values are:

approx 1.5 V when the pedal is free
approx 3.5 V when the pedal is depressed fully.
If the value on the diagnostic screen does not change:

• Replace the pedal
• Update the truck's software to the latest available
version.
• Replace the MCU.
If the value on the diagnostic screen changes:

• Update the truck's software to the latest available
version
© TMHE 8 – 17 T Code(s): 1006

Symbol Cause Hints

ACT or ACH signal that the The truck has been used more intensively than its maximum
temperature exceeds 85 °C. specification. Let the truck cool down.
Fan [G3] and/or [G6] not working:
– Fan testing can be done using the CID service functions
– Fan control, MCU output X131:9, can be checked via CID

diagnostic screen 5, pos 9.
The motor control heatsinks are dirty and must be cleaned.
If there is not 48 V between [G3:1] and [G3:2]: Check the

wiring harness and the MCU.
If there is 48 V between [G3:1] and [G3:2]: Check the fan.
If there is not 48 V between [G6:1] and [G6:2]: Check the

wiring harness and the MCU.
If there is 48 V between [G6:1] and [G6:2]: Check the fan.
The MCU detects that the Check that the emergency switch off is not depressed.
emergency switch off [S21], ESO, is Check that fuse F60 is complete.
depressed. Check that MCU digital input X131:5 changes status when the
emergency switch off buttons are operated, CID diagnostic
screen 4/pos 22.
If the input does not change status, the function of the

emergency switch off button and the wiring harness must be
checked for any break in conductors 20, 21 and 22.
Replace the MCU if there is a voltage at input X131:5,
conductor 21, when the emergency switch off button is not
pressed, but the input status shows it is so.
The hour meter reading to the next Carry out service and reset parameter 101 to the agreed
service has reached 0. service interval.
© TMHE 8 – 18 T Code(s): 1006

Symbol Cause Hints

The reference sensor has not been If the forks are raised, lower them fully so that [B] is affected by
activated the reference rail.
If main lift is not activated, the mechanical drive to the pulse
transducer [B19] must be checked.
The CID's diagnostic screen 4, pos 7 and 8.
.
Main lift not in bottom position Speed reduction is due to the truck being driven with the
main lift above the bottom position.
Check that the sensor [B58] is correctly connected. The
CID's diagnostic screen 4, pos 13 [B58]
Applicable combinations are:

[B58]
Main lift in bottom position: ‘1’
Main lift raised: ‘0’
If the signals do not correspond with the mast's position,
the switches may be confused.
Brake activated at start-up The brake pedal was active during login.
Start the truck without touching the pedals.
The brake does not release.

CID diagnostic screen 3, pos 7: ~0.5 V,
pos 8: ~4.5 V when the brake pedal is completely released:
The brake pedal must be completely released in order to start

driving.
If the diagnostic screen shows that the brake is not completely
released, 7: > ~1 V and 8: < ~4 V, the brake pedal may have
mechanically seized in the partly or completely pressed down
position.
© TMHE 8 – 19 T Code(s): 1006

8.4 Troubleshooting using error codes

The first digit of the error code identifies the subsystem where the error code
has arisen.
Troubleshooting using
error codes
Error Yes
CID, warnings and
code
No
Error Yes MCU and

code miscellaneous
No
Error Yes
Drive system error
code
No
Error Yes
Hydraulic system error
code
No
Error Yes Steering system,

code warnings and errors
No
Troubleshooting
without
© TMHE 8 – 20 T Code(s): 1006

The first digit of the three-digit error code indicates the severity of the error
and how the truck is affected/responds when the error occurs.
.
Code Error category/action taken

number
n:0nn Caution. Generally an information code. No change
in truck behaviour.
n:1nn Warning. Some functions may be disabled or
reduced. See the specific error code to see what
action has been taken.
n:2nn Error. Selected parts of the hydraulic system are
disabled. See the specific error code to see what
action has been taken.
n:3nn Error. The truck is braked by the plug braking and/or
the parking brake until it comes to a halt. It is not
possible to drive. The steering may be disabled if
there is a steering error. To see what action has been
taken, see the specific error code.
n:4nn Error. The truck is braked by the plug brake until it
stops. Once the truck has stopped, or after 5
seconds, the relays for the main power supply and
key are switched off.
n:5nn Critical error.
Main contactor and key relay opens.
The error codes are subdivided into smaller categories based on the last two
digits of the code (see below).
Error code, type of error

Code Description
number
n:n00–n09 Miscellaneous error codes.
n:n10–n19 CAN-related error codes
n:n20–n39 Error codes related to specific units.
n:n40–n59 Error codes for short-circuited output data.
n:n60–n79 Error codes for output data from open electrical
circuits
n:n80–n99 Faulty signals from sensors.
© TMHE 8 – 21 T Code(s): 1006

8.4.1 CID, warnings and errors
Indicator. Cause Hints

1.003 Minor incompatibility in program Update the truck's software to the latest
version. available version.
The software versions in the MCU and
CID do not match each other.
The MCU does not support some of the
functions used by the CID, or vice versa.
1.010 CAN 1 communication warning. 1. Check that CAN 1 is intact in terms of
The CID CAN module received too many wiring harness, final resistance and
erroneous messages. contacts.
2. Disconnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect the DHU
and collision sensor. Then reconnect
them one by one to find out which unit
causes the communication error.
1.431 External +5 V is outside the permitted 1. Disconnect the joysticks, buttons and
range. sensors connected to [X505:1] one at
a time and check if the error code
disappears.
2. Check the CID's internal wiring
harness.
3. Replace the CID.
1:500 Software failure Update the truck's software to the latest
available version.
1.501 CID has detected an error in the Update the truck's software to the latest
MCU's program execution. available version.
1.503 Only one of the CID and the MCU is in 1. Log off and make the truck without
emergency driving mode. voltage for approx 1 minute.
2. Restart the truck and log in again.
1.504 The software for CID and MCU are not 1. Update the software for CID, MCU and
compatible. other units to the latest available
Not possible to log in. versions.
2. Check that the software
are compatible.
1:505 CID configuration error 1. Wrong CID log-in ID
Not available
© TMHE 8 – 22 T Code(s): 1006


1:506 CID position error 1. CID position is wrong.
Not available
1:507 The software for CID and MCU are not Update the truck's software to the latest
compatible. available version.
The software versions in the MCU and
CID do not match each other.
The MCU does not support some of the
functions used by the CID, or vice versa
1.510 Communication error – CAN 1. 1. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
contacts.
[X41:4] is 54 – 66 ohm.
and collision sensor. Then connect
gives rise to the communication error.
1.512 Communication disturbance – CAN 1. 1. Check that CAN 1 is intact in terms of
contacts.
[X41:4] is 54 – 66 ohm.
1.514 MCU or CID has not received a 1. Check that CAN 1 is intact in terms of
– response within 70 ms via CAN1. wiring harness, final resistance and
1.516 contacts.
[X41:4] is 54 – 66 ohm.
1.520 Internal +5 V is outside the permitted Replace the CID
range.
© TMHE 8 – 23 T Code(s): 1006


1.540 Key relay [K20] – Break in the control 1. Check that there is no break in the
circuits coil of the control circuit.
2. Check the contacts [X131] and [X504]
the relationship between [K20:A1] –
[X131:5] as well as [K20:A2] –
[X504:17].
3. Replace the CID [A1].
1.580 Key Relay [K20] – Contacts welded 1. Check the key relay's function and that
there is no connection between
[K20:1] and [K20:2].
2. Check for the presence of a short
circuit that may cause improper
feeding of [X504:7], e.g. from
[X504:16], [X504:17] and [X504:18].
3. Replace the CID [A1]
1.581 Key relay [K20] does not close Check if the MCU input [X131:6] switches
status when the key relay is activated,
diagnostic screen 4, pos 25:
If the input does not change status:

• Check that fuse [F73] is intact.
• Check the key relay's function and that
there is a relationship between [K20:1]
and [K20:2] when the relay is drawn.
• Check that wire 27 from the key relay to
fuse box is intact.
• Replace the CID.
If the input changes status:
• Update the CID's software.
• Replace the CID [A1].
© TMHE 8 – 24 T Code(s): 1006

8.4.2 MCU and other warnings and errors

2:001 Error in the error log 1. Delete the error log
2. Update to the latest software
2:002 The MCU is programmed using Download or adjust the parameters to
standard values for parameters. correspond with the truck model and
equipment.
2:003 MCU memory error. 1. Backup the truck's parameters.
Backup data, hour meter and error log
2. Update to the latest software.
may be affected.
3. Check parameters and hour meter.
4. Copy the truck configuration from CID to
MCU.
2:004 Error in check sums of backup data. 1. If MCU or CID has been changed, copy
Normally shown after replacing MCU or the truck configuration from the MCU or
CID. CID unit which has not been replaced to
the new unit.
2. Backup the truck's parameters.
4. Check parameters and hour meter.
2:005 Hour counter reading to service = 0. Carry out servicing and reset the S counter
using TruckCom.
2:006 Full error log buffer. Shows that errors which would normally be
No indication, logged only. logged in the error log may have been lost.
2:007 MCU's internal memory full 1: Restart the truck.
2: If the error persists, update the truck's
software to the latest available version.
3: Report the fault to the manufacturer.
2:008 Application time. Set when the application (20ms) takes
No indication, logged only. longer than 18ms.
1. Rectify the error code that occurred in
direct conjunction with this error code.
2. Report the fault to the manufacturer.
2:009 Tick time. Set when tick time (1 ms) takes longer than
No indication, logged only. 0.7 ms.
1. Rectify the error code that occurred in
direct conjunction with this error code
© TMHE 8 – 25 T Code(s): 1006


2:010 Communication disturbance – CAN 1. 1. If the CAN key is connected: Try using a
MCU has received too many incorrect CAN-key with a later production date.
telegrams.
2. Check that CAN 1 is intact in terms of
contacts.
resistance between [X41:3] and [X41:4]
is 54 – 66 ohm.
4. Deactivate and disconnect the DHU and
collision sensor. Activate and then
connect them one by one to find out
which unit gives rise to the
communication error.
2:011 Communication disturbance – CAN2. 1. Check that CAN 2 is intact in terms of
MCU has received too many incorrect wiring harness, final resistance and
telegrams. contacts.
[X130:22] is 54 – 66 ohm.
3. Disconnect EPS, ACT and ACH. Then
2:021 Not correctly logged out by the truck The truck was not switched off correctly. The
battery was disconnected before the truck
was logged out.
2:022 The MCU does not have the same The code is not displayed, only added to the
software it had when last started up. error log to show that the software has been
Shown when the software has been updated.
updated.
2:101 Incorrect type of truck. Use TruckCom to save the parameter
Factory parameters not loaded. values.
If the MCU has been replaced:
• Run a Change MCU in TruckCom.
• Enter the truck's parameter list.
• Check parameter “1001 – Truck type”. If it
is not correct, all parameters must be
checked.
• Copy the truck configuration from CID to
MCU
© TMHE 8 – 26 T Code(s): 1006


2:102 Lift height limitation - Stop height error. 1. Lifting: check/adjust parameters 371,
373 and 375.
2. Adjust parameter 377
2:103 Lifting height limiting. If the truck is equipped with height
Lifting height limiting is activated and indication, activate this using factory
height measurement is deactivated. parameter 1009 = 1.
If the truck does not have height indication,
deactivate the lifting height limiting using
parameter 1103 = 0.
2:106 Collision locking. If parameter 112 = 0: Use the special PIN
A collision value exceeding what has code to reset the collision sensor.
been input via parameters 110 and 111 If parameter 112 = 1: Restart the truck to
has been detected. reset the collision sensor.
The truck can only be driven at reduced
speed.
2:107 Truck at standstill
The truck can only be driven at reduced
speed.
2:141 Wrong digital output in fan 4: Check that the wiring and connectors
are intact and correctly connected.
The fan output is short-circuited to the
motor controller 5: Check the functionality of the fan
2:161 Wrong digital output in fan 1. Check that there is no break in
conductor X131:9, conductor 33 and
Fan output has an open circuit.
conductor 27 leading to fan G3.
2. Check that cables and contacts are
undamaged.
3. Check output DO9 via the CID's
diagnostic screen 5, pos 9:
2:180 No contact with the shock sensor. 1. If the truck is not equipped with a
collision sensor, set parameter 110 = 0
and 111 = 0.
2. Check that cables and contacts are
undamaged.
3. Replace [B90]
© TMHE 8 – 27 T Code(s): 1006


2:401 Internal program error 1: Restart the truck.
2:403 The permitted time for reading 1: Restart the truck.
analogue
signals has been exceeded.
2:415 Problem in CAN 1. Software error, report error to manufacturer
2:420 Battery voltage under 33.6 V. 1. Check the battery voltage.
2. Check that the battery cable (X1) is
undamaged and free from oxidation.
3. Check that the voltage between
[X130:19] and [X130:32] corresponds to
the measured battery voltage.
4. Replace the MCU
2:421 Battery voltage over 59.5 V. 1. If the error code occurs in association
with strong motor braking directly after
charging: Log out/log in.
2. If the error code occurs during motor
braking during normal driving:
Check all power cabling between the
battery and transistor regulator for
breaks, poorly tightened screws/nuts
and oxidation.
2:431 +5 V for external sensors under +4.9 V. 1. Make sure that no short circuit or other
high load is present in the sensor, safety
pedal or pedal unit for speed and
braking.
2. Check the wiring harness to the
components above.
3. Replace the MCU and check the
function of the sensor, safety pedal and
accelerator and brake pedal unit.
© TMHE 8 – 28 T Code(s): 1006


2:432 +5 V for external sensors over +5.1 V. 1. Check that there is no short circuit
between conductor 55 and any
conductor with voltage higher than
5 V, e.g. battery voltage.
2. Check the function of
– Sensor
– Safety pedal
– Pedal unit for accelerator and brakes.
3. Replace the MCU
2:433 +15 V for external sensors under +12 V. 1. Check that there is no short circuit or
high load in sensor [B19].
2. Check the wiring harness to the
components above.
3. replace the MCU and check the function
of sensors [B18] and [B19].
2:434 +15 V for external sensors over +16.5 1. Check that there is no short circuit
V. between conductor 29 and any
conductor with voltage higher than
15 V, e.g. battery voltage.
2. Check the function of sensor [B19].
3. Replace the MCU.
2:435 Internal +7.5 V under +7 V. Replace the MCU
2:436 Erroneous external signal +5 Replace the MCU
Internal +7.5 V over +8 V.
2:501 Check sum error, parameters 1. Restart the truck.
Check for uninitiated parameters that
2. Change one parameter in each
have values such as -32768
category (operator, service,
manufacturer, calibration) to create a
new check-sum. Start the truck. Then
switch off and reset all values.
3. Replace the MCU
2:502 Serious software error, MCU. 1: Restart the truck.
2: If the error persists: update the truck's
3: Report the fault to the manufacturer
© TMHE 8 – 29 T Code(s): 1006


2:503 error in check sum, factory 1. If MCU or CID has been changed, copy
parameters. the truck configuration from the MCU or
Normally shown after replacing MCU or CID unit which has not been replaced to
CID. the new unit.
2. Backup the truck's parameters.
4. Check factory parameters.
2:504 Only one of the CID and the MCU is in 1. Log off and make the truck without
emergency driving mode. voltage for approx 1 minute.
2. Restart the truck and log in again.
2:505 MCU has detected an error in the CID's 1: Update the truck's software to the latest
program execution. available version.
2: Report the fault to the manufacturer
2:510 Initialisation error – CAN 1. 1. Check that CAN 1 is intact in terms of
contacts.
is 54 – 66 ohm.
3. Deactivate, disconnect and reconnect
the units from CAN1 individually to find
the device giving rise to the initialisation
error.
2:511 Initialisation error – CAN 2. 1. Check that CAN 2 is intact in terms of
contacts.
[X130:22] is 54 – 66 ohm.
error.
© TMHE 8 – 30 T Code(s): 1006


2:512 Communication disturbance – CAN 1. 1. Check that CAN 1 is intact in terms of
The MCU has problems sending wiring harness, final resistance and
messages via CAN 1. contacts.
is 54 – 66 ohm.
3. Deactivate and disconnect the DHU and
collision sensor. Activate and then
2:513 Communication disturbance – CAN 2. 1. Check that CAN 2 is intact in terms of
The MCU has problems sending wiring harness, final resistance and
messages via CAN 2. contacts.
[X130:22] is 54 – 66 ohm.
error.
2:514 Login error – DHU. Check that parameter 503 corresponds to
No log-in answer from DHU the truck's equipment:
1. Check that it is possible to connect
TruckCom to the DHU.
If it is possible to connect them, check
the DHU's configuration.
2. Check that the DHU's green LED is lit.
If the LED is not lit: Check the DHU's
supply voltage: The battery voltage
between [A82:1] and [A82:8].
If there is a battery voltage: Replace
the DHU.
contacts: Disconnect the battery. Check
that the resistance between [A82:2] and
[A82:3] is 54 – 66 ohm.
2:515 CAN 2 sends buffer
2:531 Internal +5 V under +4.9 V. Replace the MCU
© TMHE 8 – 31 T Code(s): 1006


2:532 Internal +5 V over +5.5 V. Replace the MCU
2:533 Internal +15 V under +14.25 V. Replace the MCU
2:534 Internal +15 V over +15.75 V. Replace the MCU
2:537 Internal supply for digital outputs under Replace the MCU
9.7 V.
2:538 Internal supply for digital outputs over Replace the MCU
12 V.
2:540 Short circuit in output for main 1. Check that the main contactor coil is not
contactor [Q10]. short circuited.
2. Check that there is no short circuit in
connection [X131:7], wire 31.
3. Replace the MCU and check the main
contactor's function.
2:555 Valid time for startup exceeded. 1. Check that fuse [F73] is intact.
2. Check that the wiring harness and
contacts are intact and correctly
attached.
2:556 Valid time for shutdown exceeded. 1. Turn off the truck by disconnecting the
battery.
2. Restart the truck and log in.
2:560 Error on digital output 3 1. Check that there is no break in the main
Break in output for main contactor contactor coil.
[Q10].
2. Check that there is no break between
connection [Q10:A2] and [X131:7],
wire 31.
3. Check that there is a battery voltage
between [Q10:A1] and B-.
If there is not battery voltage.
• Check that the emergency switches are
not pressed.
• Check that fuse F60 is intact
4. Log in to emergency travel mode to
reset the status of the main contactor.
5. Check the function of the main
contactor.
6. Replace the main contactor.
7. Replace the MCU.
© TMHE 8 – 32 T Code(s): 1006


2:580 Main contactor [Q10] – Contacts 1. Check the main contactor's function and
welded that there is no relationship between
[Q10:1] and [Q10:2].
2. Check that there is no short circuit that
can cause improper supply to [X131:5].
2:581 Main contactor [Q10] – Activated but 1. Check fuse [F71]
the MCU is unaware of this.
2. Check the main contactor's function and
that there is a relationship between
[Q10:1] and [Q10:2].
3. Check that there are no breaks in
conductor 8 between the main contactor
and the fuse panel, as well as conductor
23 between the fuse panel and
[X131:15].
2:598 The selected truck model is not 1: Check that the correct software is
permitted installed in the truck
2: Check that the latest version of
TruckCom is used.
2:599 The license key used to set parameter 1: Check that parameter 499 has the
499 is wrong correct value
Note: only for trucks in field testing
2: Perform a truck report and send it to the
factory to obtain the correct value.
© TMHE 8 – 33 T Code(s): 1006

8.4.3 Drive system error

3:001 Plug brake error 1. Check the battery.
The motor cannot use the plug brake 2. May occur when braking with a fully
adequately according to the braking charged battery.
norm. The ACT cannot supply
sufficient power to the motor with the 3. Inspect the battery cables.
result that this cannot maintain the
speed required. May occur when
driving downhill.
3:081 Seat switch active for more than Check input DI12 via the CID's diagnostic
20 minutes. screen 4, pos 12:
When the seat is loaded the signal should

read '1' and when unloaded '0'.
If the signal does not change:
• Check that the wiring harness and
contacts are undamaged.
• Replace the seat switch Comfort [B49]
and Basic [S89]
If the signal changes:
• Log off and disconnect the battery for
approx 1 minute.
• Connect the battery, log on and check
that the error indication has
disappeared.
• Update the truck's software to the latest
available version.
© TMHE 8 – 34 T Code(s): 1006


3:180 Safety pedal output voltage Check that safety pedal output voltage is
incorrect. within the interval 1.5 V to 3.5 V. The
CID's diagnostic screen 3, pos 6:
If the output voltage is outside these

limits:
• Check that the voltage is between 4.5 V
and 5.5 V between [B31:1] and [B31:3].
• Check that there is no break, short
circuit or incorrect feed to [X130:31],
conductor 84.
If the output voltage is within limits, but
that changes when the pedal is
operated:
• Replace the pedal [B31].
available version.
3:305 Motor temperature over 180 °C. 1. Check that the resistance in the drive
The truck is braked by the plug brake motor's temperature sensor is
until it stops. between 550 ohms and 650 ohms. At
150 °C the resistance should be 600
ohm.
2. Check that the fan for the motor
compartment works and that the
ventilation openings are not blocked.
3. Check that the drive motor is not
damaged.
© TMHE 8 – 35 T Code(s): 1006


3:314 The MCU or ACT has not responded 1. Check fuse [F73].
– via CAN2 within 70 ms.
3:316 The truck is braked until it stops.
contacts. Disconnect the battery.
Check that the resistance between
[X130:8] and [X130:22] is 54 – 66
ohm.
3. Check that the ACT's green LED is lit
constantly.
If the LED is not lit:
• Check that the ACT has a supply
voltage of 48 V between [K1:9] and [B-].
• Replace ACT.
If the LED is lit:
• Replace ACT.
3:320 ACT – Voltage for motor power supply Check
– outside specified limits.
1. Fuse F71
3:322 The truck is braked until it stops.
2. Fuse F1
3. That the main contactor [Q10] is
closed and that the contacts are not
burned.
4. That the wiring harness between the
battery and the ACT is intact and not
oxidised.
© TMHE 8 – 36 T Code(s): 1006


3:323 Overcurrent – ACT. Check
The truck is braked until it stops.
1. That the battery voltage is correct at
the connection to the ACT.
2. That the battery harness is
undamaged and there is no
connection between B+ and
B-.
3. That the motor cables are undamaged
and there is no connection between
them or with B-.
4. The motor windings' resistance to the
motor yoke, there should be no
relationship.
5. Test using a new motor controller. If
the error persists, the fault is probably
an internal motor problem. Replace
the motor and refit the old controller.
3:325 Temperature error Check that the cooling fan for the ACT
The ACT's cooling element is over and ACH is working normally. CID Service
125 °C. function:
If the fan is working normally:

• Clean the ACT's cooling element and
associated ducts. If the error returns the
fault is probably an internal ACT
problem.
If the fan does not work normally:
• If there is not 48 V between [G3:1] and
[G3:2]: Check the wiring harness and
the MCU.
• If there is 48 V between [G3:1] and
[G3:2]: Check the fan.
© TMHE 8 – 37 T Code(s): 1006


3:328 Short circuit in the ACT, the drive Check
motor or the motor cables.
1. That the motor cables are undamaged
and there is no short circuit between
them or with B-.
2. The motor windings' resistance to the
relationship.
3. Test using a new motor controller. If
the error persists, the fault is probably
an internal motor problem. Replace
the motor and refit the old controller.
3:329 Measurement/Calibration error in the 1. Log off and cut off voltage to the truck
ACT's current measurement. for at least one minute.
The shift in the current measurement
2. Restart the truck and log in again
is too large
The truck is braked until it stops. 3. Check the wiring harness between the
motor and the ACT.
If the fault persists:
• Replace ACT.
3:333 The ACT's internal 15 volts is outside Check
the specified limits.
• Fuse F73
• The battery voltage [ACT K1:9] and B-.
If the voltage differs from the battery
voltage:
• Check that wire 27 between the fuse
box and the ACT, is undamaged and
that the connections are not oxidised.
If the voltage is the same as the battery
voltage:
• Replace ACT.
© TMHE 8 – 38 T Code(s): 1006


3:380 Break or short circuit in the speed Loosen the sensor and remeasure [B11:1]
sensor [B11]. and [B11:4], ‘1’ = + and ‘4’ = -. The
resistance should be approx 160 kOhm.
If the resistance measurement
suggests a break/short circuit in the
sensor:
• Replace the sensor.
excludes a break/short circuit:
• Check conductors “10” and “11”,
[B11:1]/[K1:11] and [B11:4]/[K1:6], for
any break/short circuit.
If the conductors are undamaged:
• Replace ACT.
3:381 Loss of one channel in the speed Loosen the sensor and remeasure [B11:1]
sensor and [B11:4], ‘1’ = + and ‘4’ = -. The
sensor:
[B11:1]/[K1:11] and [B11:4]/[K1:6], for
• Replace ACT.
© TMHE 8 – 39 T Code(s): 1006


3:382 No current or earth to speed sensor. Loosen the sensor and remeasure [B11:1]
The truck is braked until it stops. and [B11:4], ‘1’ = + and ‘4’ = -. The
sensor:
[B11:1]/[K1:11] and [B11:4]/[K1:6], for
• Replace ACT.
3:385 The voltage from the accelerator Check that accelerator output voltage is
pedal [B32] is outside the specified within the interval 0.25 V to 4.75 V. The
limits. CID's diagnostic screen 3, pos 5:
Driving is blocked and the truck is
brought to a stop with the plug brake.

limits:
circuit or incorrect power supply to
[X130:17], conductor 87/GY.
operated:
• Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.
© TMHE 8 – 40 T Code(s): 1006


3:387 The voltage from the brake pedal Check that brake pedal, signal 1, output
[B32], signal 1, is outside the voltage is within the interval 0.25 V to
specified limits. 4.75 V. The CID's diagnostic screen 3,
Driving is blocked and the truck is pos 7:

limits:
circuit or incorrect power supply to
[X130:4], conductor 85/WH.
operated:
© TMHE 8 – 41 T Code(s): 1006


3:388 The voltage from the brake pedal Check that brake pedal, signal 2, output
[B32], signal 2, is outside the voltage is within the interval 0.25 V to
specified limits. 4.75 V. The CID's diagnostic screen 3,
Driving is blocked and the truck is pos 8:

limits:
conductor 86/BK.
operated:
© TMHE 8 – 42 T Code(s): 1006


3:389 Too large discrepancy between both Check that both the brake pedal signals'
brake pedal signals. output voltages follow each other and that
Driving is blocked and the truck is one is inverse to the other.
V = brake pedal's output voltage,

pos = Brake pedal depression
The CID's diagnostic screen 3, pos 7 and
8:
If the output voltage does not change

normally:
• Check that there is no poor relationship
or faulty supply of [X130:4], conductor
85/WH and [X130:18], conductor 86/
BK.
If the output voltage changes normally:
© TMHE 8 – 43 T Code(s): 1006


3:390 The voltage from the travel direction Check that the travel direction selector
selector [B36] is outside the specified output voltage is between 0.25 V and
limits. 4.75 V when the selector is moved to the
Driving is blocked and the truck is respective end positions. The CID's
brought to a stop with the plug brake. diagnostic screen 1, pos 6:

limits:
and 5.5 V between [X503:7] and
[503:8].
conductor 94/GY.
that changes when the selector is
affected:
• Replace PCB A6 with sensor.
available version.
3:440 Error in PWM 6 output 1. Check that solenoid [Q1] has the
Output to parking brake is short- correct voltage, 48 V
circuited
2. Check output [X131:12]
3:460 Error in PWM 6 output 1. Check that solenoid [Q1] has the
Break in output to parking brake correct voltage, 48 V
2. Check output [X131:12]
3:461 Error in parking brake 1: Check that solenoid [Q1] has the
Broken output to parking brake. correct voltage, 48 V
The parking brake does not brake when 2: Check that the parking brake is
required. activated when you are stationary and
Driving is blocked and the truck is pressing down on the pedal
3: Replace the MCU
3:462 Unexpected movement in a stationary 1: Check the sensor B11 and its wiring.
truck There may be a short-circuit.
Examples: If the truck gets hit. 2: This error code may be generated if
pushing a load with the truck
© TMHE 8 – 44 T Code(s): 1006


3:500 Unexpected error 1: Update to the latest software version
Unknown error, maybe version
2: Software error, report to manufacturer.
mismatch in ACT and MCU
3:520 Error at upstart 1. Check fuse
ACT was started wrongly, it did not
respond or set the log-in message
within 10 seconds
© TMHE 8 – 45 T Code(s): 1006

8.4.4 Hydraulic system error

4:180 No pulses from the main lift height sensor 1: Check the height sensor, battery voltage
on lift/lowering. or wiring harness as well as the wire for
the height indicator
2: Recalibrate the valve (Q4)
3: The fork load may be too heavy on
lifting.
4:181 Measured height deviates by more than 1: Check the signal from the height sensor
±30 mm when the main lift's reference in diagnostic screen 15
sensors are affected.
2: Check that the wire for the height
indicator, the wiring and connectors are
intact and correctly connected
4:184 Excessive lifting/lowering speed. Check the lifting and lowering speeds
Lifting and lowering movement blocked. CID diagnostic screen 15, pos S
The lifting and lowering speeds should be

maximum
450 mm/s when lifting and 550mm/s when
lowering. If the speed is above 1000 mm/s,
the error code is generated.
If the speed is correct:
• Check the pulse sensor.
If an error indication arises when
lowering:
• Calibrate [Q4].
Adjust [Q4], maximum opening point.

(cont.)
© TMHE 8 – 46 T Code(s): 1006


(cont.) Excessive lifting/lowering speed. If the error indication persists
4:184 Lifting and lowering movement blocked. after calibration/adjustment:
• Check that there is 15 V between [B19:1]
and [B19:4]. If there is not 15 V,
conductors 29 [X130:37] for [B19:1] and
30 [X130:20] for [B19:4] must be checked.
• If the conductors are intact: Replace the
MCU.
• Check that conductors 75/[X130:12] and
76 [X130:26] are intact.
• Replace the height indicator wire
• Replace the height sensor [B19].
• Replace the MCU
4:186 The main lift's reference sensor does not • Check the height indicator wire
switch status as expected.
• Check the sensors B19/B58
Lift/lowering speed reduced.
• Check that the height on the display tallies
with the actual fork height.
4:187 Invalid lifting height. 1: Activate the reference sensors by lifting
The forks estimated height is lower than the and lowering the forks
lowest possible level - including tolerance of
2: Check all parameters relating to height.
150 mm - or 50 mm above the maximum
Recalibrate if they are wrong.
lifting height according to parameter 1252.
Lift/lowering speed reduced.
4:200 Unknown error 1. Download new software to the ACH. If
Unknown hydraulic error, maybe version this involves an update, the software for
mismatch in ACH and MCU the MCU, the CID and other units may
Hydraulic movements blocked also need to be changed.
2. Report the fault to the manufacturer
4:201 Levers for hydraulic functions not 1. Calibrate the hydraulic levers.
calibrated
2. Check the activation of the hydraulic
Hydraulic movements blocked
levers with parameter 1007.
© TMHE 8 – 47 T Code(s): 1006


4:205 Temperature error 1: An overload in the hydraulic system may
Motor temperature over 180 °C. generate this error code.
2: Check that the resistance in the pump
motor's temperature sensor is between
550 ohms and 650 ohms. At 150 °C the
resistance should be 600 ohm.
3. Check that the fan for the motor
compartment works and that the
ventilation openings are not blocked.
4. Check that the pump motor is not
damaged.
4:214 The MCU or ACH has not responded via 1. Check fuse [F73].
– CAN2 within 70 ms.
4:216 Hydraulic movements blocked
contacts. Disconnect the battery. Check
that the resistance between [X130:8] and
[X130:22] is 54 – 66 ohm.
3. Check whether the ACH's green LED is
lit constantly.
• Check that the ACH has a supply voltage
of 48 V between [K1:9] and [B-].
• Replace ACH.
If the LED is lit:
• Replace ACH.
4:217 Communication error to service tool
See 4:205.
4:220 ACH – Voltage for motor supply outside Check
– specified limits.
• – Fuse F71
4:222 Hydraulic movements blocked
See 4:205. • Check that the wiring harness and
connectors are intact and correctly
connected.
© TMHE 8 – 48 T Code(s): 1006


4:223 Overcurrent – ACH. Check
• – That the battery voltage is correct when
connected to the ACH.
• – That the battery wiring harness is
undamaged and there is no relationship
between B+ and B-.
• – That the motor cables are undamaged
and there is no relationship between them
or with B-.
• – The motor windings' resistance to the
relationship.
• – Test using a new motor controller. If the
error persists, the fault is probably an
internal motor problem. Replace the
motor and refit the old controller.
4:225 The ACH's cooling element is over 125 °C. Check that the cooling fan for the ACT and
Hydraulic movements blocked ACH is working normally. CID Service
function:
If the fan is working normally:

– Clean the ACH heat sink and associated
duct. If the error returns the fault is probably
an internal ACH problem.
If the fan does not work normally:
• There is a voltage to the fan, replace the
fan.
• There is no power to the fan, check the
fan's wiring harness. If the wiring harness
is intact: replace the MCU.
© TMHE 8 – 49 T Code(s): 1006


4:228 Short circuit in the ACH, the pump motor Check
or the motor cables.
• That the motor cables are undamaged
and there is no short circuit between them
or with B-.
• The motor windings' resistance to the
relationship.
• Test using a new motor controller. If the
error persists, the fault is probably an
internal motor problem. Replace the
motor and refit the old controller.
4:229 Measurement/Calibration error in the • Log off and cut off voltage to the truck for
ACH's current measurement. at least one minute.
• Restart the truck and log in again.
• Replace ACH.
4:233 The ACH's internal 15 volts is outside the Check
specified limits.
• Fuse F73
• The battery voltage [ACH K1:9] and B-.
If the voltage differs from the battery
voltage:
• Check that cable 27, between the fuse
box and the ACH, is undamaged and that
the connections are not oxidised.
If the voltage is the same as the battery
voltage:
• Replace ACH.
4:240 Error in the lifting valve 1. Check the solenoids, power supply,
Short circuit in the circuit for raising the connectors and wiring harness.
lift [Q2].
2. With power to the truck cut off and fuse
Lifting blocked.
F73 removed: Check that the resistance
in the coil to valve [Q2] is approx. 48
ohms, [X131:21]
3. Replace ACH.
© TMHE 8 – 50 T Code(s): 1006


4:241 Short circuit in the circuit for lowering the 1. Check the solenoids, power supply,
lift [Q4]. connectors and wiring harness.
Lifting and lowering are blocked.
ohms, [T2:108] in ACH .
3. Replace ACH.
4:246 Short circuit in the circuit for function 1: Check the solenoids, power supply,
AUX1 [Q9]. connectors and wiring harness.
AUX functions are blocked.
2: With power to the truck cut off and fuse
ohms, [X131:38]
3: Replace the MCU.
4:248 Short circuit in the circuit for function 1. Check the solenoids, power supply,
AUX, direction A [Q18]. connectors and wiring harness.
ohms, [X131:37]
3. Replace the MCU.
AUX, direction B [Q19]. connectors and wiring harness.
AUX blocked.
ohms, [X131:11]
3. Replace the MCU.
4:252 Short circuit in the circuit for the fork 1. Check the solenoids, power supply,
carriage's “Out” movement [Q7]. connectors and wiring harness.
Reach carriage's movement blocked.
ohms, [X131:24]
3. Replace the MCU.
© TMHE 8 – 51 T Code(s): 1006


4:253 Short circuit in the circuit for the fork 1. Check the solenoids, power supply,
carriage's “In” movement [Q6]. connectors and wiring harness.
ohms, [X131:10]
3. Replace the MCU.
4:260 Break in output for lifting valve 1. Check the solenoids, power supply,
[Q2]. connectors and wiring harness.
Lifting blocked.
ohms, [*X131:21]
3. Replace ACH.
AUX [Q9]. connectors and wiring harness.
AUX functions are blocked
ohms, [*X131:38]
3. Replace ACH.
4:268 Break in the circuit for function AUX 1: Check the solenoids, power supply,
direction A [Q18]. connectors and wiring harness.
2: With power to the truck cut off and fuse
ohms, [X131:37]
3: Replace the MCU.
4:269 Break in the circuit for function AUX, 1. Check the solenoids, power supply,
direction B [Q19]. connectors and wiring harness.
ohms, [X131:11]
3. Replace the MCU.
© TMHE 8 – 52 T Code(s): 1006


4:272 Break in the circuit for the fork carriage's 1. Check the solenoids, power supply,
“Out” movement [Q7]. connectors and wiring harness.
Reach carriage's movement blocked
ohms, [X131:24]
3. Replace the MCU.
4:273 Break in the circuit for the fork carriage's 1. Check the solenoids, power supply,
“In” movement [Q6]. connectors and wiring harness.
ohms, [X131:10]
3. Replace the MCU.
4:280 The voltage for the lifting/lowering lever is Check that the output voltage is min 0.3 V
outside the permitted range. and max 4.7 V in each position, from joystick
[B20], CID's diagnostic screen 1, pos 1:
Lifting and lowering are blocked
If the voltage at any time is outside the

specified limits:
• Check 5 V between [B20:1] and [B20:2].
• Check that cable 50/BK is intact, [B20:3]
to [X505:2].
• Replace the joystick [B20].
If the voltage is within the specified
limits:
available version.
© TMHE 8 – 53 T Code(s): 1006


4:281 Input signal from joystick reach outside Check that the output voltage is min. 0.3 V
specified limits. and max. 4.7 V in each end position, from
Reach movement blocked. joystick [B21], CID diagnostic screen 1, pos
2:

specified limits:
and [B21:2].
• Check that cable 51/BN is intact, [B21:3]
to [X505:11].
limits:
available version.
© TMHE 8 – 54 T Code(s): 1006


4:282 Input signal from joystick tilt outside Check that the output voltage is min. 0.3 V
specified limits. and max. 4.7 V at each end position, from
Tilt movement blocked. joystick [B22], CID diagnostic screen 1, pos
3:

specified limits:
and [B22:2].
• Check that cable 52/OG is intact, [B22:3]
to [X505:17].
limits:
available version.
© TMHE 8 – 55 T Code(s): 1006


4:283 Input signal from joystick AUX2/sideshift Check that the output voltage is min. 0.3 V
outside specified limits. and max. 4.7 V in each end position, from
AUX1/sideshift blocked. joystick [B23], CID diagnostic screen 1, pos
4:

specified limits:
and [B23:2].
• Check that cable 53/YE is intact, [B23:3]
to [X505:3].
limits:
available version.
4:285 Break or short circuit in the speed sensor Loosen the sensor and remeasure [B12:1]
[B12]. and [B12:4], ‘1’ = + and ‘4’ = -. The
All hydraulic functions blocked. resistance should be approx 160 kOhm.
If the resistance measurement suggests
a break/short circuit in the sensor:
If the resistance measurement excludes a
break/short circuit:
[B12:1]/[K1:11] and [B12:4]/[K1:6], for any
break/short circuit.
• Replace ACH.
4:288 The speed sensor has lost the signal Check
All hydraulic functions blocked.
• That the wiring harness is intact and
correctly fitted.
• Replace the sensor [B12]
© TMHE 8 – 56 T Code(s): 1006


4:292 Bad pulse signal or no pulse signal from 1: Check the main lift sensor and its
main lift sensor when lifting or lowering connectors. There may be a short
mast. circuit.
4:520 ACH start up error. Check whether the ACH's green LED is lit
constantly.
• Check fuse [F73].
• Check that the ACH has a supply voltage
of 48 V between [K1:9] and [B-].
• Replace ACH.
If the LED is lit:
• Replace ACH
• Check that CAN 2 is intact in terms of
contacts. Disconnect the battery. Check
that the resistance between [X130:8] and
[X130:22] is 54 – 66 ohm.
4:561 Short circuit in the circuit for lowering the 1. With power to the truck cut off and fuse
lift [Q4]. F73 removed: Check that the resistance
ohms, [*T2:108] in ACH
2. Replace ACH.
© TMHE 8 – 57 T Code(s): 1006

8.4.5 Steering system, warnings and errors

5:010 The EPS CAN module has received or 1. Check that CAN 2 is intact in terms of
– sent too many faulty messages. wiring harness, final resistance and
5:011 contacts. Disconnect the battery.
Check that the resistance between
[X130:8] and [X130:22] is 54 – 66 ohm.
2. Update the truck's software to the latest
available version.
3. Replace the steering motor.
4. Replace the MCU.
5:080 EPS han no connection with the Check
reference sensor [B17]
• That the wiring harness and connector
are intact and correctly fitted.
• Replace the steering angle sensor [B17]
5:081 Reference sensor [B17] has no Check
connection
• That the wiring harness and connector
are intact and correctly fitted.
• Replace the steering angle sensor [B17]
5:135 Risk of thermal overload in the 1. Check that there are no objects
steering servo. blocking the steering movement.
The indication is shown from 80 % up to
2. Check that the steering gear is not
100 %. At 100 % the indication switches
jammed or blocked by dust, thread or
over to error code 5:325.
contaminants.
Travel speed limited to
maximum 4 km/h. 3. Replace the steering servo.
© TMHE 8 – 58 T Code(s): 1006


5:182 Signal from the steering angle sensor 1. Check the mechanical fastening of
- incorrect by 180°. steering angle sensor [B17].
5:184 Travel speed limited to
2. Compare with the direction arrows
maximum 4 km/h.
and check that the signal from the steering

angle sensor changes status twice for
every complete turn of the steering wheel,
CID diagnostic screen 14, pos 2:
If the signal does not change status:

• Check that there is battery voltage
between [B17:1] and [B17:3].
• Check that conductor 57/[B17:2] to
[X901:11] is intact and does not receive
an incorrect 48 V supply.
• Replace steering angle sensor.
available version.
If the signal changes status:
5:185 EPS reports an error during reference 1: Check the wiring harness (*X901:11)
- run or reference run not completed 2: Check the reference sensor (B17)
5:186 within 15 seconds.
© TMHE 8 – 59 T Code(s): 1006


5:300 The servo steering does not react as 1. Restart the truck.
& expected.
2. In the error log/list: Check other
5:304 Driving is disabled and the truck is
simultaneous error codes.
braked to a stop with plug braking.
If there are other error codes, correct
these before continuing with
troubleshooting.
3. Check the steering servo's wiring
harness.
4. Replace the steering servo.
5:301 Steering servo power stage fault. 1. Check fuse [F72].
Driving is disabled and the truck is
2. Check that there is a battery voltage
between conductors 250/[X901:8] +
[X901:16] and 40/[X901:7] + [X901:15].
5:302 The MCU cannot transfer the Update the truck's software to the latest
parameters to the steering servo. available version.
5:303 The steering servo does not respond 1. Check fuse [F72].
on start up.
1. Check that the wiring harness and
connected.
2. Replace the steering servo (A2).
5:320 The steering servo voltage is below 1. Check the battery voltage.
24V.
2. Check fuse [F72].
braked to a stop with plug braking. 3. Check that the wiring harness and
connected
5:325 EPS has been using too much power 1. Check that there are no objects
in too little time. blocking the steering movement (Drive
See 5:300. wheel)
5:326 The steering servo power stage is
below -40°C or above +85°C.
See 5:300.
© TMHE 8 – 60 T Code(s): 1006


5:335 Internal error in the steering servo. 1: Download software to EPS, even if the
– See 5:300. truck already has the latest version.
5:336 Restart the truck (the first startup after
installing new firmware takes a longer
time than a normal startup), do not cut
the power.
2: Replace the steering servo if the error
code returns once the truck has
started.
5:380 Error in steering sensor 1: Check that the wiring harness and
Supply error – Steering sensor 1. connectors are intact and correctly
Driving is disabled and the truck is connected.
2: Replace the steering sensor (B13)
Supply error – Steering sensor 2. connectors are intact and correctly
Driving is disabled and the truck is connected.
Abnormal pulse frequency from the connectors are intact and correctly
steering sensor. connected
2: Replace the steering sensor (B13).
5:383 Error in steering sensor 1. Check that the wiring harness and
Steering sensors 1 and 2 different connectors are intact and correctly
signals. connected.
2. Replace the steering sensor (B13)
Power supply error – Steering sensors connectors are intact and correctly
1 and 2. connected.
5:385 Error in reference sensor 1: Turn the steering wheel so that the
The signal from the reference sensor sensor (B17) starts to detect the
does not match the EPS steering correct steering angle.
angle.
This is a warning that the green
directional arrow may be pointing in
the wrong direction.
Truck travel disabled
© TMHE 8 – 61 T Code(s): 1006


5:414 CAN 2 communication error 1. Check fuse [F64] & [72].
– The MCU or steering servo have not
5:416 responded via CAN2 within 70 ms.
The truck is brought to a stop by the plug
contacts. Disconnect the battery.
brake.
Check that the resistance between the
points 2 and 10 is 54 – 66 ohms.
4. Replace the MCU
5:421 The steering servo's direct voltage is 1. Check the wiring harness and fuse
above 78 V. (F64).
brake.
5:422 Short circuit in the steering servo
brake.
See 5:414.
5:435 Internal error in the steering servo.
– The truck is brought to a stop by the plug
5:438 brake.
See 5:414.
5:439 Anomaly in steering angle
brake.
See 5:414.
5:500 Unknown steering servo error. 1. Update the truck's software to the latest
All functions are stopped available version.
5:501 Error in the MCU Update software
The steering servo has detected an
error in the MCU.
8.5 Troubleshooting without indications
8.5.1 Mechanical brake (3000)
Error Cause Hints

Brake does not release Voltage too low. Check the truck battery. Charge if
necessary.
Break in voltage supply. Check wiring harness to the brake.
Restart the truck.
© TMHE 8 – 62 T Code(s): 1006

Error Cause Hints

Too much play. Adjust the play.
Worn friction disc. Replace the friction disc.
Coil defective. Replace the brake.
Too little play. Adjust the play.
Brake does not brake Voltage remains when truck Check the truck battery and its
is switched off. connections.
Grease on friction surfaces. Replace the friction disc and
readjust the play.
Uneven braking effect Voltage too low. Check the truck battery. Charge if
necessary.
8.5.2 Steering (4000)
Error Cause Hints

No steering manoeuvre Error in steering sensor 1. Replace the steering sensor
when the steering wheel is [B13]. [B13].
turned.
2. Check that all the CID inputs
from the steering pulse sensors
change status when the steering
wheel is turned, CID diagnostic
screen 2, pos 1 – 4:
— End of section —
© TMHE 8 – 63 T Code(s): 1006

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Repair manual: Troubleshooting Model(s): RRE120B,RRE140B,RRE160B

8.1.1 Error log menu

© TMHE 8– 1 T Code(s): 1006

8.1.2 Error information menu

8.1.3 Diagnostic screens

© TMHE 8– 2 T Code(s): 1006

Screen 1 – CID analogue inputs

Function Conn. Unit

© TMHE 8– 3 T Code(s): 1006

Screen 2 – CID digital inputs

© TMHE 8– 4 T Code(s): 1006

Screen 3 – MCU analogue inputs

Function Conn. Unit

© TMHE 8– 5 T Code(s): 1006

Screen 4 – MCU digital inputs

© TMHE 8– 6 T Code(s): 1006

Screen 5 – MCU digital outputs

© TMHE 8– 7 T Code(s): 1006

Screen 6 – Pulse-width modulated outputs

MCU signal Value

© TMHE 8– 8 T Code(s): 1006

1 ACT motor temperature

A recently charged battery should

All voltages are given in volt.

© TMHE 8– 9 T Code(s): 1006

Screen 13 – travel function

© TMHE 8 – 10 T Code(s): 1006

Screen 14 – Steering function

© TMHE 8 – 11 T Code(s): 1006

Screen 15 – Displays information about lifting/lowering

© TMHE 8 – 12 T Code(s): 1006

Screen 16 – Displays reach in and reach out information.

© TMHE 8 – 13 T Code(s): 1006

Screen 17 – Displays tilt and sideshift information.

© TMHE 8 – 14 T Code(s): 1006

8.2 Initial troubleshooting

CID lit? No Troubleshooting without

Blocking Yes Troubleshooting using

Yes Troubleshooting using

© TMHE 8 – 15 T Code(s): 1006

8.3 Troubleshooting using blocking symbol

Symbol Cause Hints

If the indication is shown constantly, check that MCU digital

1: If the input remains low, the sensor's function and the

© TMHE 8 – 16 T Code(s): 1006

Symbol Cause Hints

Normal values are:

If the value on the diagnostic screen does not change:

If the value on the diagnostic screen changes:

© TMHE 8 – 17 T Code(s): 1006

Symbol Cause Hints

– Fan control, MCU output X131:9, can be checked via CID

The motor control heatsinks are dirty and must be cleaned.

If there is not 48 V between [G3:1] and [G3:2]: Check the

If there is not 48 V between [G6:1] and [G6:2]: Check the

If the input does not change status, the function of the

© TMHE 8 – 18 T Code(s): 1006

Symbol Cause Hints

Applicable combinations are: