Error Messages: Still GMBH Stand: 2/02 (Ersatz Für Stand:)

ERROR MESSAGES
ã STILL GmbH Stand: 2/02 ( Ersatz für Stand: )

Error Message 2008 - 14, 2018 - 24 08
Error message at console
The fault detection circuit of the electronic control
system detects, registers and memorizes faults that
have occurred during operation of the truck.
Some of the faults are displayed visually in the form
of a clear readout, i.e. indicated in words on the
display of the console.
To enable diagnoses to be made, the electronic
control system can be switched to the diagnostic
mode (password level 2). To this end the
SERVICE ADR. 150 – VALUE 01
must be set via the console.
After that a reset must first be initiated. PRG
Shut off the truck until the display goes off (or
disconnect the battery), then restart the truck. PRG NO
Thereupon, faults emanating from the software

diagnostics will be displayed additionally. The fault
indication will not disappear until YES (PRG ) is
pressed. The next fault (provided it exists) will then
be displayed. The standard display will appear once YES
all faults have been indicated.
By pressing F1 keypad in the diagnostic mode (the
associated LED will light), the ERROR LIST will be
displayed again. If the PRG keypad is pressed,
the next fault will be displayed. The LED integrated
into the F1 keypad will go out as soon as the end of
the ERROR LIST is reached, and the standard display
will appear again. The indication of the ERROR LIST ERRO R L I S T PRG
can be interrupted by pressing the PRG O keypad. RE S E T NO PRG
By pressing the F2 keypad in the diagnostic mode

(the associated LED will come on), all faults that have F2
occurred since the last erasing of the fault memory
will be displayed. Switching to the next fault is F1
possible as described above by pressing YES
(PRG ) keypad. The procedure can be interrupted
by pressing the NO (PRG O) keypad.
The error memory is cleared with the menu item at

password level 2 using the command:
ERROR LIST SE R V I C E AD DR 1 5 0 PRG
RESET YES
V AL UE 01 PRG
To switch off the diagnostic mode again, reset the

diagnostic mode (password level 2).
F2
SERVICE ADR. 150
VALUE 00
F1
ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: 04/00 ) 1

Error Massage 2008 - 14, 2018 - 24 08
Error message – Plain text messages, Calibration error
Plain text messages appearing in display, passw ord level 0
No Explanation Remarks
53 Controller (STG) overtemperature Emerg. operation, armature current limit = 72 A
> Poor heat dissipation
> check installation of controller in counterweight
195 Traction motor brush error 8 hr warning (followed by error 203)
196 Hydraulic motor brush error 8 hr warning (followed by error 204)
197 Traction motor overtemperature Emerg. operation, armature current limit = 72 A
198 Hydraulic motor overtemperature Emerg. operation, armature current limit = 72 A
203 Traction motor brush error Emerg. operation, armature current limit = 72 A
204 Hydraulic motor brush error Emerg. operation, armature current limit = 72 A
Calibration error (calibration only possible during diagnosis)
No. Explanation Remarks

Offset-Error
72 Brake transmitter offset too high Home position voltage over 0.85 Volt
73 Brake transmitter offset too low Home position voltage under 0.45 Volt
Collective error > new calibrate
211 Calibration offset error
> Addr 151 to value 03
212 Hoisting transmitter offset too high Home position voltage over 5.60 Volt
213 Hoisting transmitter offset too low Home position voltage under 4.40 Volt
214 Tilting transmitter offset too high Home position voltage over 5.60 Volt
215 Tilting transmitter offset too low Home position voltage under 4.40 Volt
216 Aux. hydr. 1 transmitter offset too high Home position voltage over 5.60 Volt
217 Aux. hydr. 1 transmitter offset too low Home position voltage under 4.40 Volt
218 Aux. hydr. 2 transmitter offset too high Home position voltage over 5.60 Volt
219 Aux. hydr. 2 transmitter offset too low Home position voltage under 4.40 Volt

Error Massage 2008 - 14, 2018 - 24 08
Diagnosis under Service Address 150, value 01

Accelerator pedal transmitter
0 Error in travel direction switch
1 Interruption GND 1st potentiometer
2 Interruption VCC 1st potentiometer Error also occurs after disconnecting connector
X16 from accelerator
3 Accel. pedal transmitter config. unknown Check parameter settings
4 Plausibility error (2 pedal) Potentiometers not set correctly or defective
5 Accelerator pedal switch not making
6 Accelerator pedal switch not breaking Error is irrelevant
7 Interruption GND 2nd potentiometer
8 Interruption VCC 2nd potentiometer
11 Drive transmitter calibration parameters
12 2-pedal calibration
Supply voltages
14 Internal power supply short External 10V power supply
> Short-circuit in sensor system (potentiometers)
> Change control panel
26 HSK link-circuit charging fault Link-circuit charging time exceeded

Contactor does not pick up
> Change controller
Truck
27 Invalid truck type Check parameter settings
28 Error in accel. pedal transm. parameters Check parameter settings
30 Angle of lock switch, left
31 Angle of lock switch, right
44 Calibration parameter error Channel 1 faulty Check parameter settings
45 Calibration parameter error Channel 0 faulty Check parameter settings

Error Massage 2008 - 14, 2018 - 24 08
Diagnosis under Service Address 150, Value 01

Temperature measurement of controller
51 Controller temperature sensor shorted Emerg. operation, armature current limit = 72 A
> Replace controller
52 Controller temperature sensor disconnected Emerg. operation, armature current limit = 72 A
53 Controller overtemperature Emerg. operation, armature current limit = 72 A
> poor heat dissipation towards counterweight
> Check installation
54 Controller temperature sensor failed Emerg. operation, armature current limit = 72 A
57 Overvoltage in controller Voltage over 75 Volt
> Check contactor, power cables, battery
Brake pedal transmitter
69 Error, brake pedal transmitter VCC pulled off
70 Error, brake pedal transmitter GND pulled off Transmitter voltage over 9.4 Volt
> Readjust brake
Transmitters for hydraulic functions
77 VCC hoisting transmitter pulled off
78 GND hoisting transmitter pulled off
79 VCC tilting transmitter pulled off
80 GND tilting transmitter disconnected
81 VCC on aux. hydr. 1 transmitter pulled off
82 GND on aux. hydr. 1 transmitter pulled off
83 VCC on aux. hydr. 2 transmitter pulled off
84 GND on aux. hydr. 2 transmitter pulled off
87
... Error Watchdog > Replace control card
96
Pressure sensor
97 VCC on pressure sensor pulled off
98 GND on pressure sensor pulled off
99 Load measurement configuration Only for FleetManager operation
> Check parameters

Error Massage 2008 - 14, 2018 - 24 08

Aux. electrical installation and relay box
100 Error in auxiliary electrical installation Outputs of an unlogged relay box in use or relay
box logged in and not used > check parameters
101 One of several inputs is "open" Input channel of a function block was not set
> check parameters
102 Error in relay boxes > Check parameters
> relay box defective
CAN bus
106
Undefined fault behaviour, console l does not
...
power up, but sticks on "Hello..."
... Hardware problems in CAN bus
> Check all CAN bus loads and replace if req'd:
...
CAN bus cable, console, relay boxes, control card
113
Console
117 Error in console Console keypads parametrisation incorrect
119 Angle of lock transmitter in console Fauly tranmission of transmitter pulses
Emergency operation, speed 6 km/h
> Check angle of lock transmitter
> Readjust console and timing wheel
> Increase error tolerance (parameterisation)
120 Console and controller communication Software versions do not match
121 Incorrect value from travel direction
transmitter
122 Hour meter REM memory damaged
> Replace control card
123 Fatal error in console controller Data mismatch between console and controller
> replace console and/or control card
124 Error in flash memory of console Text table in console and controller do not match
Download flash memory of console again
> Add 151 to Value 01
125 EEPROM in console or controller Incorrect data in console EEPROM or control card
126 Communication to console in console Incorrect data match between console and
controller controller
128 General diagnosis error Check diagnostic procedure
136
... Hardware error in control card Replace control card
143
153 Timeout communication with battery controller Replace control card
154
157

Error Massage 2008 - 14, 2018 - 24 08
Motor temperature measurement

159 Short in FM1 temperature sensor
161 Short in HM temperature sensor
162 FM1 temperature sensor disconnected
Emerg. operation, armature current limit = 72 A
164 HM temperature sensor disconnected
> Check temperature sensors
165 FM1 temperature sensor grounded > Replace control card
166 FM2 temperature sensor grounded
167 HM temperature sensor grounded
168 Reference point, temperature sensor
grounded
169 Motor temperature (MTT) collective error
Drives
173 Monitoring of FM1 armature regulator
Traction is cut out, armature regulator faulty
175 Monitoring of FM2 armature regulator
177 Monitoring of HM armature regulator
174 Monitoring of FM1 field regulator Traction is cut out, armature regulator faulty
176 Monitoring of FM2 field regulator > Replace field regulator or controller
178 Drive, right failed Check motor,

renew controller if necessary
179 Drive, left failed
180 Hydraulic drive failed Check hydraulic motor,
renew controller if necessary
193 Error in synchronised coupling to power Armature short, insulation measurement

electronics microprocessor > Replace control card
194
Motors
199 Failure of traction motor temperature sensor
200 Failure of hydr. motor temperature sensor
Emerg. operation, armature current limit = 72 A
201 Overtemperature at FM1

Error Massage 2008 - 14, 2018 - 24 08

205 Speed monitoring function for FM1 / FM2 Change speed of FM1 and/or FM2 RPM is too
high
206 FM1 speed sensor error Traction is cut out,
207 FM2 speed sensor error > Adjust, replace speed sensor
208 Error in calculated setting for FM1 Traction is cut out

Discrepancy between calculated and measured
speed is too high
> No signal from sensor
209 Error in calculated setting for FM2 > Incorrect measurement due to fault in field /
armature current, armature voltage, motor
temperature
> Replace sensor or control card / controller
210 HM speed sensor error Emerg. operation, armature current limit = 72 A
> Adjust, replace speed sensor
Traction is cut out The error can be cleared temporarily by

operating the accelerator
Hydraulics cablibration
211 Calibration offset error Recalibrate
> Addr. 151 to value 03
220 Fault in a switch unit Recalibrate > Addr. 151 to value 03
replace control board if necessary
Errors on trucks equipped w ith a joystick

224 Forward GND / VCC disconnected Transmitter voltage < 2 Volt or > 7.89 Volt
225 Reverse GND / VCC disconnected > Joystick Diagnosis
239 Check cable and connections
No voltage supply for potentiometer
renew hydraulic controller if necessary

Error Message 2015 08


The error memory is cleared with the menu item at

password level 2 using the command
ERROR LIST
RESET YES
SE R V I C E AD DR 1 5 0 PRG

V AL UE 01 PRG
SERVICE ADR. 150
VALUE 00 F2
F1
ã STILL GmbH Position as per: 05/01 ( Replaces version: ) 1

No. Meaning Remark

11 ADJUST
Drive transmitter calibration parameter error
12 ACCEL:SENSOR
2-pedal calibration error
24 VOLTAGE Check battery voltage
D.C. link undervoltage
68 VOLTAGE Overvoltage (> 105V) in converter
Overvoltage UC1-Max > Battery, contactor and power cabling, check
operating condition
71 SERVICE BRAKE
179 OVERHEATING
Fatal overtemperature converter drive 1
Emergency operation
180 OVERHEATING
> Poor heat dissipation to counterweight
Fatal overtemperature converter drive 2
181 OVERHEATING
Fatal overtemperture converter hydraulics
185 VOLTAGE
Overvoltage drive 1
Overvoltage (> 105V) in converter
186 VOLTAGE
> Battery, contactor and power cabling, check
Overvoltage drive 2
operating condition
187 VOLTAGE
Overvoltage hydraulic drive
197 OVERHEATING
Overtemperature motors
Emergency operation
198 OVERHEATING
Overtemperature hydraulic motor
ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: ) 2

Diagnostic mode, Passw ord level 2, Service Address 150, Value 01
No. Meaning Remark

Drive transmitter
1 Interruption GND, Poti 1
2 Interruption VCC, Poti 1 Fault also occurs after disconnection of connector
X16 at drive transmitter
3 Drive transmitter configuration unknown Check parameter values
4 Plausibility error (2-pedal) Potis incorrectly set or faulty
5 Drive pedal switch does not close
6 Drive pedal switch does not open Not relevant
7 Interruption GND, Poti 2
8 Interruption VCC, Poti 2
9 Invalid direction information from console CAN bus communication disturbed
> Console faulty
10 Evaluation error 2-pedal
11 Drive transmitter calibration parameter error 2-pedal values not in permissible range
> Recalibrate - Addr. 151 - Value 04
12 2-pedal calibration error
Supply voltage
14 Short-circuit in external supply 10V supply from central computer
> Short-circuit in sensor (potis)
> Replace central computer
15 Output short-circuit Relay switching outputs on fuse board
Relay switching outputs > Plug-in relay faulty
> Check cabling to fuse board
24 D.C. link undervoltage When battery connector is disconnected during
operation (S1=ON) or battery or contactor faulty
> Battery exhausted/faulty? Check voltage
> Contactor/connector contacts corroded/faulty
25 Main contactor sticks Converter does not discharge d.c. link
> Initiate manual discharge process
> Check main contactor
26 MFC (main fuse circuit) D.C. link charging time exceeded contactor does
D.C. link charging fault not pick up
> Check/replace battery computer
Truck
27 Invalid truck type Check parameter values
28 Drive program parameter error Check parameter values
30 Steer angle switch, left
31 Steer angle switch, right
41 Communication error converter FM1 Truck does not move:
42 Communication error converter FM2 > Check/replace battery computer
> Check converter indicator light:
44 Communication error converter HM on => ok, flashing => fault, off => dead
Together w ith error 24
> See error 24
> Ignore errors 41, 42, 43

No. Meaning Remark

43 Discharge indicator Hydraulic motor starts twice briefly
Starting measurement error > Check parameters
> Check shunt
> Replace battery computer
Temperature measurement controller

51 Open-circuit sensor converter hydraulics
> Replace converter
52 Short-circuit sensor converter hydraulics
53 Overtemperature converter hydraulics Power reduction
54 Open-circuit sensor converter drive 1
> Replace converter
55 Short-circuit sensor converter drive 1
56 Overtemperature converter drive 1 Power reduction
57 Open-circuit sensor converter drive 2
> Replace converter
58 Short-circuit sensor converter drive 2
59 Overtemperature converter drive 2 Power reduction
68 Overvoltage UC1-max Overvoltage (> 68V) in converter
> Check battery, contactor, power cabling
> Check operating condition for increased brake
operation, long operation on inclines...
Brake transmitter
69 Brake transmitter, interruption VCC
70 Brake transmitter, interruption GND Transmitter voltage above 9.4Volt
> Check brake, readjust if necessary
71
72 Offset brake transmitter too large
73 Offset brake transmitter too small
Hydraulic transmitter
77 Lift transmitter, interruption VCC
78 Lift transmitter, interruption GND
79 Tilt transmitter, interruption VCC
80 Tilt transmiter, interruption GND
81 Additional transmitter 1, interruption VCC
82 Additional transmitter 1, interruption GND
83 Additional transmitter 2, interruption VCC
84 Additional transmitter 2, interruption GND

No. Meaning Remark
87
... Watchdog error > Replace central computer
96
Pressure sensor
97 Pressure sensor, interruption VCC
98 Pressure sensor, interruption GND
Additional electrical installations and

relay box
100 Fault in additional electrical installation Relay box, outputs or connection faulty
> Check parameterisation
101 One input of several is OPEN Function blocks, inputs not set
102 Relay box fault > Check parameters
> Relay box faulty
CAN - Bus
106 Undefined fault behaviour, console sticks on
... "Guten Tag.."
... Hardware problems in CAN bus > Check all CAN bus users (CA bus cable,
... console, relay box, central computer) and renew if
113 necessary
Console
117 Fault in console Console buttons incorrectly parameterised >
check
119 Steer angle transmitter in console Faulty transmitter pulse transmission
emergency operation, speed at 6km/h
> Check steer angle
> Adjust console and transmitter wheel
> Increase error tolerance (parameterisation)
121 Incorrect value from direction transmitter
122 Hour meter fault Damage in RAM memory
> Renew central computer
123 Fatal fault in console control Incorrect data calibration between console and
central computer
> Check console and central computer and renew
if necessary
124 Error in console flash memory Text tables in console not identical with central
computer, console replacement error
> Reload text tables, Addr 151 to value 01
125 Console EEProm or controller Faulty data in EEProm, EEProm faulty
if necessary
126 Communication with console Faulty data calibration between console and
central computer
if necessary

Diagnostic mode, Passw ord level 2, Service- Address 150, Value 01
No. Meaning Remark
128 General diagnostic error > Check diagnostic sequence

136
...
143
Central computer hardware fault > Renew central computer
154
...
157
Drives
167 Calibration error current sensor hydraulics
Converter in fault status, LED flashes
168 Calibration error current sensor drive 1 Drive/hydraulic drive is off
169 Calibration error current sensor drive 2 > Renew converter
170 Error EEProm converter hydraulics Single error in memory

> Ignore error
171 Error EEProm converter drive 1
Multiple error in memory
172 Error EEProm converter drive 2 > Replace converter
173 Incorrect direction info at converter M1
Fault in battery computer
174 Incorrect direction info at converter FM2
> Replace battery computer
175 Incorrect direction info at converter HM
176 Sensor bearing fault motor 1
177 Sensor bearing fault motor 2 Sensor bearing faulty
178 Sensor bearing fault hydraulic motor
179 Fatal overtemperature converter FM 1 Truck without function, temperature at converter
>120°C
180 Fatal overtemperature converter FM 2
181 Fatal overtemperature converter HM > Check installation, application
182 Short-circuit or overcurrent drive 1
> Check motor and cable
183 Short-circuit or overcurrent drive 2
> Renew converter
184 Short-circuit or overcurrent hydraulic drive
185 Overcurrent converter FM 1 Overvoltage (> 68V) in converter
> Battery, contactor and power cabling
186 Overcurrent converter FM 2
> Check operating condition for increased brake
187 Overcurrent converter HM operation, long operation on inclines...
189 Speed monitoring error > Not relevant
191 CAN bus for converter FM 1 faulty
No operating data transfer, truck without function
192 CAN bus for converter FM 2 faulty > CAN bus cable
193 CAN bus for converter HM faulty > Battery computer faulty/renew

No. Meaning Remark
Motor
197 Motor overtemperature Power reduction from 120°C
198 Hydraulic motor overtemperature Plain text display
199 Motor temperature sensor failure
Not relevant
200 Hydraulic motor temperature sensor failure
201 Overtemperature motor 1 Power reduction from 120°C
> Check motor for fouling
202 Overtemperature motor 2 > Sluggish transmission/check brake
203 Short-circuit temperature sensor FM Power reduction to 95%
> Check cabling
204 Short-circuit temperature sensor HM
205 Speed sensor fault FM 1
206 Speed sensor fault FM 2
207 Hydraulic motor overtemperature Power reduction from 120°C
> Check motor for fouling
208 Undertemperature converter FM1+2 Temperature < -20°C in converter
209 Undertemperature converter HM Power reduction to 60%
210 Speed sensor fault HM
Calibration hydraulics
211 Calibration offset error Accumulative calibration error
Monitoring
220 Fault in a switch unit Currently inactive
221 Network watchdog CAN bus communication error
> Check CAN bus and battery computer
222 Too many AC faults on reconnection Converter attempts to reconnect in fault status.
After 7 unsuccessful attempts, the fault is set.
Hydraulic controller
224 Interruption forward
225 Interruption forward
239 No voltage for potentiometer Check cable and connections, renew hydraulic
controller if necessary

Error list 5051 - 55 08
Error messages
Error display
Distinction is made between customer mode and
diagnostic mode. The mode is defined by a parameter.
Address Value
DISPLAY 1 DISPLAY 2
0F1 00 Customer mode DISPLAY 2 DISPLAY 4
PGR
PGR
0F1 01 Diagnostic mode
In the customer mode, only plain text messages are
displayed.
In the diagnostic mode, various error lists can be
displayed.
Error list type Delete error list

ERROR LIST
The various error lists can be selected via specific
RESET NO
menu items on password level 2.
The devicve code is displayed in Field 2.
ERROR LIST All messages since deleting the
An error list reset can currently only be initiated in
error memory
the device code A (control computer) or X (pump
ERROR LIST 1 Errors occurred since switching controller). Confirm flashing display with the ENTER
on the electrical installation key.
ERROR LIST 2 Currrent errors (not yet activated) To initiate a reset, change indication in Field 4 from
NO to YES and confirm with the Enter key.
NOTE
Request error lists
The reset is only initiated by confirmation of the YES
ERROR LIST
in Field 4; it is therefore important to maintain the
The error list type is displayed In Field 1, the device
correct sequence!
code ( symbol stands for all devices) in Field 2.
Only the errors of all devices together can currently
be requested, i.e.set device code symbol (field Device codes and read-out options
flashes) and confirm with the Enter key.
All devices (collective
The following message is displayed for about 10 - co d e ) Read-out error lists A and X
seconds: SW versions
PLEASE WAIT Truck reset
A Control computer
Read-out error list A, reset
If the requested error list does not contain any errors, error codes
the following message is displayed:
SW versions
ERROR LIST E Converter
Error codes via error list A
If the requested error list does contain errors, the first H Hydraulic controller Option currently unavailable
error is displayed:
ERROR LIST I Joystick Option currently unavailable
ERROR A0303
Supervisory computer
The next error can be paged with the ENTER key. J (integral part of control SW versions
computer)
This mode cannot be cancelled until the whole error
list is displayed. When the final error has been K Mini console
SW versions
Error codes via error list A
displayed, the following message is displayed:
ERROR LIST L ADD-On p.c. board No data currently available
M Relay box No data currently available
P Acceleration sensor SW versions
SW versions
X Pump controller Read-out error list X, reset
error codes

Error message - Control Computer R5051-55 - SW.V. 0.32 Stand 11.08.03
Device Group No. Name Cause Remark Reaction Quit Remedy from SW- Fehler
Version sichtbar
für
A 12 01 Hardware error I2C-Bus Parameter block cannot be read System operates with default from Service
out (error message from parameters 0.01
EEPROM driver)
A 12 05 Checksum parameter range Incorrect checksum after System operates with default Delete parmeter block and from Service
reading EEPROM data parameters reload 0.01
A 12 06 Default parameter activated No consistent (valid) EEPROM For safety reasons, the main Delete parameter block and from Service
data record available contactor cannot be energised reload 0.27
A 12 10 Checksum adjustment values Incorrect checksum after System operates with default Replace printed circuit board from Service
reading EEPROM data adjustment values (can only be adjusted in 0.01
production)
A 12 11 Default adjustment values No consistent (valid) EEPROM System operates with default Replace printed circuit board from Service
activated data record available parameters (can only be adjusted in 0.01
production)
A 12 16 EEPROM backup copy read Error in EEPROM parameter Controlled via "Default Check CAN-BUS cabling if from Service
error transfer from pump controller parameter activated" error necessary 0.27
to control computer
A 12 17 Checksum EEPROM backup Incorrect backup copy Write backup copy with control from Service
copy checksum after reading computer parameter block 0.27
EEPROM data
A 12 18 EEPROM backup copy write Error in EEPROM parameter Controlled via "Default Check CAN-BUS cabling if from Service
error transfer from control computer parameter activated" error necessary 0.27
to pump controller
A 15 01 Synchronous serial interface init Synchronous serial interface No communication between Change hardware from Service
error could not be initialised control computer and 0.21
supervisory computer
A 15 02 Synchronous serial interface Watchdog error during No communication between Change hardware from Service
watchdog error initialisation of synchronous control computer and 0.21
serial interface supervisory computer
A 15 02 Synchronous serial interface Synchronous serial interface Fault possibly due to EMC from Service
checksum error checksum error during transfer problems (radio) 0.21
A 21 11 Invalid HW version Incorrect HW version No main contactor control Correct parameters or replace from Driver
parameterised or faulty printed Plain text error message: control computer 024
circuit board INVALID HW VERSION
A 22 37 Short-circuit 10V sensor Short-circuit in sensor supply Reduction of drive to zero Via repair from Driver
speed and brief activation of 0.20
steering speed for pump drive.
Remark: VCC open-circuit fault
for hydraulic sensor and travel
sender is also indicated.
Plain text error message:
SHORT-CIRCUIT 10V EXT
A 23 02 Error buffer for Slave errors Error management overtaxed, Error cannot occur Does not exist from Service
not all errors were indicated. 0.01
Too many errors sent to control
computer.
A 23 03 Error buffer for all errors Error management overtaxed, Doers not exist, 128 erros can from Service
not all errors were indicated. be temporarily stored as long 0.01
Too many errors sent to control as no new values are displayed
computer. (driver does not confirm)
A 25 03 Overvoltage multiple fault Short-circuit on power Hydraulic drive blocks Release travel sender Locate cause of overcurrent from Service
terminals of pump controller or 0.01
pump motor
FehlerSR_gb
12.12.03 1 von 6 AS2 Richter
Version sichtbar
für
A 26 10 Diagnostic group error Diagnostic communication error None from Service
0.30
A 28 01 Process monitor Proc 1 Travel sender signal 1 Truck not ready, contactor Replace control computer from Service
Voltage difference control open or remains open V024
computer <--> supervisory
computer outside limit.
A 28 02 Process monitor Proc 2 Travel sender signal 1 Truck not ready, contactor Replace control computer from Service
Voltage difference control open or remains open V024
computer <--> supervisory
computer outside limit.
A 28 03 Process monitor Proc 3 - 5 Process monitor detected lift Truck not ready, contactor Replace control computer from Service
lever fault (FR-forward, FR- open or remains open V027
back, FR-actuation)
A 28 06 Process monitor Proc 6 Mini console CAN message Truck not ready, contactor Check CAN-BUS, replace from Service
travel direction information open or remains open control computer, replace mini V027
(misinterpretation) console
A 28 09 Process monitor Proc 9 Limit of Vsetpoint exceeded --> Truck not ready, contactor Replace control computer from Service
Vmax forward, reverse open or remains open V027
A 28 10 Process monitor Proc 10 Vsetpoint does not correspond Truck not ready, contactor Replace control computer from Service
to FR open or remains open V027
A 28 11 Process monitor Proc 11 Manipulated variable of Truck not ready, contactor Replace control computer, from Service
coverter outside permissible open or remains open replace converter V027
range
A 28 14 Process monitor Proc 14 Measured motor speed Currently none Check speed sensor and check ab V024 Service
incorrect cabling, replace converter or
control computer if necessary
A 28 15 Process monitor Proc 15 CAN manipulated variable does Truck not ready, contactor Replace control computer from Service
not correspond to control open or remains open V027
computer manipulated variable
converter
A 28 18 Process monitor Proc 8 No response to ramp-function Truck not ready, contactor Replace control computer V027 Service
generator reset command open or remains open
A 30 02 GND open-circuit travel sender Potentiometer voltage outside Travel sender value is zero Check travel sender from Service
potentiometer 1 permissible range 0.01
A 30 03 VCC open-circuit travel sender Potentiometer voltage outside Travel sender value is zero Check travel sender from Service
A 30 04 GND open-circuit travel sender Potentiometer voltage outside Travel sender value is zero Check travel sender from Service
A 30 05 VCC open-circuit travel sender Potentiometer voltage outside Travel sender value is zero Check travel sender from Service
A 30 06 Travel sender switch does not Excessive travel sender voltage Travel sender value is zero Check travel sender from Service
switch on causes switch to operate 0.01
A 30 07 Travel sender switch does not Insufficient travel sender Travel sender value is zero Check travel sender from Service
switch off voltage causes switch to 0.01
operate
A 30 08 Plausibilty limit violated Travel sender voltages do not Travel sender value is zero Check 2-pedal plate from Service
match 0.01
A 30 16 GND open-circuit brake sender Potentiometer voltage outside none Check brake sender from Service
permissible range 0.01
A 30 17 VCC open-circuit brake sender Potentiometer voltage outside none Check brake sender from Service
FehlerSR_gb
Version sichtbar
für
A 30 20 Direction selection error Switch fault detected on lift Travel drive blocks Switch on keyswitch Repair cabling or replace lift from Service
lever again lever 0.27
A 30 27 Seat switch permanently closed Seat switch overridden Reduction of drive to zero Seat switch must open from Driver
speed and setting of steering once after a specific time 0.20
speed for pump drive.
SEAT SWITCH
A 30 35 Brake fluid Brake fluid level too low or Reduction of max. speed none Top up fluid or repair switch from Driver
switch faulty Plain text error message: 0.09
SERVICE BRAKE
A 31 02 GND open-circuit lift sensor Potentiometer voltage outside none check lift sensor from Service
A 31 03 VCC open-circuit lift sensor Potentiometer voltage outside none check lift sensor from Service
A 31 07 GND open-circuit tilt sensor Potentiometer voltage outside none Check tilt sensor from Service
A 31 08 VCC open-circuit tilt sensor Potentiometer voltage outside none Check tilt sensor from Service
A 31 12 GND open-circuit additional 1 Potentiometer voltage outside none Check additional 1 sensor from Service
A 31 13 VCC open-circuit additional 1 Potentiometer voltage outside none Check additional 1 sensor from Service
A 31 17 GND open-circuit additional 2 Potentiometer voltage outside none Check additional 2 sensor from Service
A 31 18 VCC open-circuit additional 2 Potentiometer voltage outside none Check additional 2 sensor from Service
A 31 27 Open-circuit GND pressure GND short-circuit Check faulty sensor from Service
sensor 0.01
A 31 28 Open-circuit VCC pressure VCC open-circuit Check faulty sensor from Service
sensor 0.01
A 31 48 Plausibility safety package hoist Model calculation for hoist Only with variant: Hoist height Driver is requested to carry out Reference operation possible from Service
height detection (SHE) height error detected detection safety package a new reference operation Causes: -> sensor or cabling 0.32
faulty -> incorrect cylinder
cross-section parameterised
A 32 02 Plausibility steer angle sensor Steer angle sensor detects Limitation of max speed to Reset check sensor adjustment, from Fahrer
implausible condition 5.5km/h parameter, union 0.32
plain text error message: sprocket/steer motor
STEER
A 35 00 Calibration failed Evaluation with default values Check faulty sensor from Service
for zero position 0.01
A 35 02 Upper calibration limit Potentiometer voltage outside Zero position defined in Evaluation with default value Check zero position voltage of from Service
exceeded permissible range drawing number 376984 for zero position travel sender 0.31
A 35 03 Lower calibration limit not Potentiometer voltage outside Zero position defined in Evaluation for default value for Check zero position voltage of from Service
reached permissible range drawing number 376984 zero position travel sender 0.31
A 35 04 Calibration parameter (2-pedal Potentiometer voltage outside See also documentation for 2- Truck operates with default Check 2-pelal plate, from Driver
plate) limit violated permissible range pedal floor plate values plain text error parameterise travel sender 0.20
message: ADJUST
A 35 05 Calibration parameter (2-pedal Potentiometer voltage outside See also documentation for 2- Calibration is interrupted plain Check 2-pelal plate, from Driver
plate), error in measurement permissible range pedal floor plate text error message: TRAVEL parameterise travel sender, 0.20
for calculation of adjustment SENDER check configuration
values
A 35 06 Travel sender limit violated Calibration value outside Evaluation with default for zero Calibrate zero position from Service
permissible range position 0.31
A 35 11 Calibration upper limit brake Potentiometer voltage outside Evaluation with default value Check brake sender from Service
sender permissible range for zero position 0.20
FehlerSR_gb
Version sichtbar
für
A 35 12 Calibration lower limit brake Potentiometer voltage outside Evaluation with default value Check brake sender from Service
sender permissible range for zero position 0.20
A 35 16 Calibration upper limit lift Potentiometer voltage outside Evaluation with default value Check lift sensor from Service
sensorr permissible range for zero position 0.20
A 35 17 Calibration lower limit lift Potentiometer voltage outside Evaluation with default value Check lift sensor from Service
sensor permissible range for zero position 0.20
A 35 21 Calibration upper limit tilt Potentiometer voltage outside Evaluation with default value Check tilt sensor from Service
A 35 22 Calibration lower limit tilt Potentiometer voltage outside Evaluation with default value Check tilt sensor from Service
A 35 26 Calibration upper limit Potentiometer voltage outside Evaluation with default value Check additional 1 sensor from Service
additional 1 sensor permissible range for zero position 0.20
A 35 27 Calibration lower limit Potentiometer voltage outside Evaluation with default value Check additional 1 sensor from Service
Additional 1 sensor permissible range for zero position 0.20
A 35 31 Calibration upper limit Zusatz2- Potentiometer voltage outside Evaluation with default value Check additional 2 sensor from Service
Geber permissible range for zero position 0.20
A 35 32 Calibration lower limit Potentiometer voltage outside Evaluation with default value Check additional 2 sensor from Service
Additional 2 sensor permissible range for zero position 0.20
A 35 90 Fault 10V sensor 10V power source for sensor Evaluation with default values Check power supply from Service
failed for zero position 0.20
A 37 02 Hour meter No valid data block for hour Fatal error, all counters Hour meter reinitialises itself to Replace printed circuit board from Service
meter available damaged 0 (EEPROM is faulty) 0.20
A 37 07 Checksum mileage meter RAM backup has invalid Can occur when battery back- Odometer and trip counter are No battery 0.08 Service
checksum up for RAM missing set to zero
A 38 01 Invalid truck type EEprom data for truck type No main contactor control Change parameters or check 0.01 Driver
does not correspond with Plain text error message: software version
associated SW
A 38 11 Unknown travel sender Travel sender value is zero Change parameters for travel from Service
configuration selected sender configuration 0.01
A 38 12 Invalid truck program Truck program parameters Parameters are internally Change parameters 0.01 Service
parameter outside permissible range limited
A 38 22 Incorrect converter Incorrect converter version No main contactor energisation Replace converter 0.01 Service
number detected by control
computer
A 38 31 Group fault additional electrical Only the channels of Check parameterisation of ZEL from Service
installation configurated/available additional functions 0.20
components functions
A 38 32 ZEL function: insufficient Insufficient arguments for Relevant ZEL function does not Check parameterisation of ZEL 0.01 Service
arguments processing a parameterisable operate additional functions
ZEL function
A 38 40 Group fault relay box Configuration error Applies to R50: - Relay control No function of channels for Check parameterisation of ZEL from Service
(parameter), invalid relay box of distributor p.c. board - ADD- components with errors additional functions 0.20
channel or output multiple ON p.c. board - front relay box
configured
A 38 60 Parameterisation safety Parameter limits exceeded Only for variant: Hoist height Parameter aendern from Service
package hoist height detection detection safety package 0.32
(SHE)
A 39 02 CANopen signal TN1 (pump No communication with pump Main contactor and drive off Schaltschloss erneut Check CAN-BUS cabling from Service
controller) controller einschalten 0.01
A 39 03 PDO Watchdog Control Control computer cannot send Watchdog operates, travel and Release travel sender Check CAN-BUS cabling if from Service
computer->Pump controller messages in time pump drives are disabled necessary 0.01
(TX) (CANop)
A 39 04 PDO Watchdog Control Control computer cannot Watchdog operates, travel and Release travel sender Check CAN-BUS cabling if from Service
computer<-Pump controller receive messages in time pump drives are disabled necessary 0.01
(RX) (CANop)
FehlerSR_gb
Version sichtbar
für
A 39 05 SDO runtime for pump Communication is interrupted Can occur during parameter Check CAN-BUS cabling from Service
controller too long download 0.01
A 39 07 CANopen signal TN2 No communication with drive Main contactor and drive off Switch on keyswitch Check CAN-BUS cabling from Service
(converter) converter again 0.01
A 39 08 PDO Watchdog Control Control computer cannot send Watchdog operates, travel drive Release travel sender Check CAN-BUS cabling if from Service
computer->Converter (TX) messages in time is disabled necessary 0.01
(CANop)
A 39 09 PDO Watchdog Control Control computer cannot Watchdog operates, travel drive Release travel sender Check CAN-BUS cabling if from Service
computer<-Converter (RX) receive messages in time is disabled necessary 0.01
(CANop)
A 39 10 SDO runtime for converter too Communication is interrupted Can occur during parameter Check CAN-BUS cabling+I84 from Service
long download 0.01
A 39 12 CANopen signal TN3 (Mini No communication with mini Travel drive disabled Switch on keyswitch Check CAN-BUS cabling from Service
console) console again 0.20
A 39 13 PDO Watchdog Control Control computer cannot send Watchdog operates, travel drive Release travel sender Check CAN-BUS cabling if from Service
computer->Mini console (TX) PDO's in time is disabled necessary 0.20
(CANop)
A 39 14 PDO Watchdog Control Control computer cannot Watchdog operates, travel drive Release travel sender Check CAN-BUS cabling if from Service
computer<-Mini console (RX) receive PDO's in time is disabled necessary 0.20
(CANop)
A 39 15 SDO runtime for mini console SDO communication interrupted Can occur during parameter Check CAN-BUS cabling from Service
too long download) 0.20
A 50 02 Warning pump motor brushes Brushes worn Only indication of service Error is automatically Replace brushes, can also be a from Driver
required. Truck can be cancelled when NC cabling error 0.01
operated for max. 10 hours contact circuit recloses
before switching to emergency
operation.
CARBON BRUSHES
A 50 04 Brushes - pump motor Brushes worn Emergency operation for Error is automatically Replace brushes, can also be a from Driver
emergency operation hydraulic drive. Full current is cancelled when NC cabling error 0.01
only available briefly. contact circuit recloses
CARBON BRUSHES
A 50 31 Motor temperature sensor Implausible measured Detailed info: By reading out none Check temperature sensor 0.01 Service
group fault pump motor temperature error on pump controller
A 50 34 Pump motor overtemperature Motor too hot Reduction of current or output. Error is automatically Check sensor or external fan 0.01 Driver
Plain text error message: cancelled when
OVERTEMPERATURE temperature falls below
the limit
A 50 44 Motor overtemperature Motor too hot Reduction of current or output. Error is automatically Check sensor 0.01 Driver
Plain text error message: cancelled when
OVERTEMPERATURE temperature falls below
the limit
E 12 05 Converter parameter Checksum monitor detects Warning converter Converter operates with default Replace converter 0.01 Service
error parameter block
E 20 02 Converter temperature sensor Warning converter Replace converter 0.01 Service
short-circuit
E 20 03 Converter temperature sensor Warning converter Replace converter 0.01 Service
open-circuit
E 20 04 Conveter overtemperature Error converter Current reduction for travel Check converter 0.01 Service
drive
E 20 05 Converter undertemperature Warning converter 0.01 Service
E 20 06 Converter overtemperature Warning converter 0.01 Service
FehlerSR_gb
Version sichtbar
für
E 22 29 VCC-CAN converter Error converter Check converter and CAN 0.01 Service
undervoltage cabling
E 22 30 VCC-CAN converter overvoltage Error converter Check converter 0.01 Service
E 22 93 Converter overvoltage Error converter Check battery and power 0.01 Service
cabling
E 22 94 Converter capacitor precharge Error converter Check battery and power 0.01 Service
cabling
E 25 01 Converter overcurrent Error converter Check converter and cabling 0.01 Service
E 26 00 Converter communication Messages from control Error converter Check CAN cabling 0.01 Service
computer were not received in
time
E 35 00 Converter calibration Warning converter 0.01 Service
E 50 42 Motor temperature sensor GND Warning converter none 0.01 Service
converter
E 50 43 Motor temperature sensor open- Warning converter none 0.01 Service
circuit converter
E 50 72 Converter speed measurement Error pulse detected Error converter Check sensor bearing/ 0.01 Service
converter
E 50 74 Converter speed outside range Speed outside permissible Warning converter 0.01 Service
range
K 15 00 Mini console internal Supervisory computer of mini Travel drive blocks none Replace mini console from Service
communication fault console detected internal 0.30
communication fault
K 24 13 Mini console hardware fault Supervisory computer detects Travel drive blocks none Replace mini console from Service
hardware fault 0.30
K 24 18 Mini console switch hardware Supervisory computer detects Travel drive blocks none Replace direction blinker switch from Service
fault deviating switch status for module or mini console 0.30
direction blinker switch module
K 26 00 Mini console CAN- Supervisory computer of mini Travel drive blocks none Check communication from Service
communication error console detected CAN error parameters for PDO's, replace 0.30
mini console or control
computer
FehlerSR_gb
Error messages - Pump Controller R5051-55 - SW-V 0.24 Stand 11.08.03
Device Group No. Name Cause Remark Reaction Quit Remedy from Level
SW-V.
X 12 01 Hardware error I2C-Bus Parameter block cannot be System operates with default from Service
read out (error message from parameters 0.01
EEPROM driver)
X 12 05 Checksum parameter range Incorrect checksum after System operates with default Delete parmeter block and from Service
reading EEPROM data parameters reload 0.01
X 12 06 Default parameter activated kein konsistenter (gueltiger) System operates with default Delete parmeter block and from Service
EEPROM-Datensatz vorhanden parameters reload 0.01
X 12 10 Checksum adjustment values Incorrect checksum after System operates with default Replace printed circuit board from Service
reading EEPROM data adjustment values (can only be adjusted in 0.01
production)
X 12 11 Default adjustment values kein konsistenter (gueltiger) System operates with default Replace printed circuit board from Service
activated EEPROM-Datensatz vorhanden parameters (can only be adjusted in 0.01
production)
X 12 16 EEPROM read error backup Parameter block cannot be Parameter block of control None (only status message to from Service
copy read out (error message from computer cannot be read out control computer) 0.01
EEPROM driver)
X 12 17 EEPROM checksum backup Incorrect checksum after No consistent parameter block None (only status messge to Delete parmeter block and from Service
copy reading EEPROM data available for backup copy control computer) reload 0.01
X 20 02 Controller temperature short- Temperatursensor(Steuerung) - none from Service

circuit Kurzschluss 0.01
X 20 03 Controller temperature open- Temperatursensor(Steuerung) - none from Service
circuit Abriss 0.01
X 20 04 Pump controller Thermal overload Reduzierung des Stromes from Driver
overtemperature Klartextfehlermeldung: 0.01
UEBERTEMPERATUR
X 21 11 Invalid HW version Incorrect HW version keine Correct parameter or replace from Driver
parameterised or faulty printed Hauptschuetzansteuerung control card V016
circuit board Klartextfeklermeldung:
X 22 44 Undervoltage VCC 12Vext. Short-circuit, switched-mode none Locate external short-circuit, from Service
power supply voltage regulator replace pump controller 0.01
faulty
X 22 45 Overvoltage VCC 12Vext. Switched-mode power supply none Replace pump controller from Service
voltage regulator faulty 0.01
X 22 92 Battery undervoltage fault Voltage fallen below limit Currently none Replace sensor if necessary from Service
0.01
X 22 93 Overvoltage fault Battery voltage exceeded max. Pump controller switches on to ueber Schaltschloss, wenn from Service
Permissible value reduce overvoltge, main Spannung weit genug 0.01
contactor is opened abgebaut ist
X 22 94 Precharging fault d.c. link Fault in power unit pump Pumpensteller versucht nicht Power Down from Service
controller or converter (short- erneut einzuschalten, sondern 0.01
circuit) verhindert das Vorladen für
min. 20 sec. Und erwartet
Quittierung
X 22 95 Main contactor sticking fault Contactor does not separate Errors can occur in download Travel and hydraulic drive Error release only by renewed Check main contactor from Service
correctly (contactor contact control computer software blocked power-up of electrical 0.01
sticks) installation possible
X 26 10 Group fault diagnostics Diagnostic communication none from Service
error 0.30
X 27 10 Entladeanzeiger (ELA) Adjustment values outside ELA operates with default Replace printed circuit board from Service
Abgleichwerte permissible range values (discharge indicator 0.01
inaccurate)
FehlerPS_gb
Error messages - Pump Controller R5051-55 - SW-V 0.24 Stand 11.08.03
Device Group No. Name Cause Remark Reaction Quit Remedy from Level
SW-V.
X 27 16 Actual current adjustment Adjustment values outside Stromregler (IIH) arbeitet mit Replace printed circuit board from Service
value permissible range Defaultwerten. Strommesssung 0.01
arbeitet ungenau
X 27 17 Actual current offset correction Offset outside permissible Hydraulic drive blocks none Replace printed circuit board from Service
range 0.01
X 27 18 Actual current measured-value Current sensor measures Currently none from Service
error implausible value 0.01
X 39 03 PDO-Watchdog Pump Pumpensteller empfaengt Can occur during program Watchdog operates, travel and Via control computer Check CAN-BUS cabling if from Service
controller<-Control computer Nachrichten nicht rechtzeitig download for control computer pump drive are disabled (keyswitch ON->OFF) necessary 0.01
(RX) (CANop)
X 39 04 PDO-Watchdog Pump controller Pumpensteller kann Watchdog operates, travel and Via control computer Check CAN-BUS cabling if from Service
->Control computer (TX) Nachrichten nicht rechtzeitig pump drive are disabled (keyswitch ON->OFF) necessary 0.01
(CANop) senden
X 50 32 Temperature HM short-circuit Hydraulikmotor none from Service
Kurzschluss Temperatursensor 0.01
X 50 33 Temperature HM open-circuit Hydraulikmotor none from Service

Abriss Temperatursensor 0.01
X 50 61 DNH speed sensor fault Hydraulikmotor Hydraulic drive blocks none Motor, Ankerkabel pruefen, from Service
Defekt des Sensors oder Abriss ggf. Sensor tauschen 0.01
FehlerPS_gb
Error Message 6022-32 08


The error memory is cleared with the menu item

ERROR LIST
at password level 2 using the command
RESET YES

V AL UE 01 PRG
F2
F1
 STILL GmbH Stand: 2/2000 ( Ersatz für Stand: ) (1)

R eadouts appearing in the display
No Explanati on Remarks
53 C ontroller (STG) overtempertaure Emerg. operati on, armature current li mi t = 130A
> Poor heat di ssi pati on
> check i nstallati on of controller i n counterwei ght
195 Tracti on motor brush error 8 hr warni ng (followed by error 203)
196 Hydrauli c motor brush error 8 hr warni ng (followed by error 204)
197 Tracti on motor overtemperature Emerg. operati on, armature current li mi t = 130A
198 Hydrauli c motor overtemperature Emerg. operati on, armature current li mi t = 130A
203 Tracti on motor brush error Emerg. operati on, armature current li mi t = 130A
204 Hydrauli c motor brush error Emerg. operati on, armature current li mi t = 130A
D iagnosis under Service Address 150, value 01
No. Explanati on Remarks

Accelerator pedal transmitter
0 Error i n travel di recti on swi tch
1 Interrupti on GND 1st potenti ometer
2 Interrupti on VC C 1st potenti ometer Error also occurs after di sconnecti ng connector
X16 from accelerator
3 Accel. pedal transmi tter confi g. unknown C heck parameter setti ngs
4 Plausi bi li ty error (2 pedal) Potenti ometers not set correctly or defecti ve
5 Accelerator pedal swi tch not maki ng
6 Accelerator pedal swi tch not breaki ng Error i s i rrelevant
7 Interrupti on GND 2nd potenti ometer
8 Interrupti on VC C 2nd potenti ometer
9 Invali d travel di recti on from console C heck console
11 Travel sender cali brati on parameter error C heck travel sender parameter s
12 2-pedal cali brati on error C heck 2-pedal travel sender setti ngen
Supply voltages
14 Internal power supply short External 10V power supply
> Short-ci rcui t i n sensor system ( potenti ometers)
> C hange control panel
24 Undervoltage UC 1 Battery di scharged, bad connecti ons
25
25 Mai n contactor sti cki ng C heck contactor and contacts
26 HSK li nk-ci rcui t chargi ng fault Li nk-ci rcui t chargi ng ti me exceeded, contactor
does not pi ck up
> C hange controller
Truck
27 Invali d truck type C heck parameter setti ngs
28 Error i n accel. pedal transm. parameters C heck parameter setti ngs
44 Error i n cali brati on parameter channel 11 C heck parameter values
(48V/72V)
45 Error i n cali brati on parameter channel 10 C heck parameter values
(80V)

D iagnosis under Service Address 150, Value 01

Temperature measurement of controller
51 C ontroller temperature sensor shorted Emerg. operati on, armature current li mi t = 130A
52 C ontroller temperature sensor di sconnected Emerg. operati on, armature current li mi t = 130A
53 C ontroller overtemperature Emerg. operati on, armature current li mi t = 130A
> Poor heat di ssi pati on towards counterwei ght
> C heck i nstallati on
54 C ontroller temperature sensor fai led Emerg. operati on, armature current li mi t = 130A
57 Overvoltage UC 1max i n controller Overvoltage (> 105V), > i s also i nduced by
openi ng Emergency swi tch or keyswi tch, check
addi ti onal battery, contactor and power cabli ng
58 Overvoltage UC 1max i n controller As No. 57, wi thout Emergency swi tch or keyswi tch
bei ng actuated.
B rake pedal transmitter
69 Error, brake pedal transmi tter VC C pulled off
70 Error, brake pedal transmi tter GND pulled off Transmi tter voltage over 9.4 Volt
> Readjust brake
71 Brake flui d swi tch
72 Excessi ve brake sender offset C heck brake sender
73 Insuffi ci ent brake sender offset C heck brake sender
Transmitters for hydraulic functions
77 Li ft sensor, open-ci rcui t VC C C heck power supply li ft sensor
78 Li ft sensor, open-ci rcui t GND C heck negati ve cable li ft sensor
79 Ti lt sensor, open-ci rcui t VC C C heck power supply ti lt sensor
80 Ti lt sensor, open-ci rcui t GND C heck negati ve cable ti lt sensor
81 Addi ti onal sensor 1, open-ci rcui t VC C C heck power supply addi ti onal sensor 2
82 Addi ti onal sensor 1, open-ci rcui t GND C heck negati ve cable addi ti onal sensor 1
83 Addi ti onal sensor 2, open-ci rcui t VC C C heck power supply addi i tonal sensor 2
84 Addi ti onal sensor 2, open-ci rcui t GND C heck negati ve cable addi ti onal sensor 2
89
... Error Watchdog > Replace control card
95
Pressure sensor
97 VC C on pressure sensor pulled off
98 GND on pressure sensor pulled off
99 C onfi gurati on of load measurement C heck parameters
Aux. electrical installation and relay box
100 Error i n auxi li ary electri cal i nstallati on Outputs of an unlogged relay box i n use or relay
box logged i n and not used > check parameters
101 One of several i nputs i s "open" Input channel of a functi on block was not set
> check parameters
102 Error i n relay boxes > C heck parameters
> relay box defecti ve


CAN bus
106
Undefined fault behaviour, console does not power
...
up, but sticks on "Guten Tag.."
... Hardware problems in CAN bus
> Check all CAN bus loads and replace if req'd:
...
CAN bus cable, console, relay boxes, control card
113
Console
117 Error in console Console keypads parametrisation incorrect
120 Console and controller communication Software versions do not match
121 Incorrect value from travel direction
transmitter
122 Hour meter REM memory damaged
> Replace control card
123 Fatal error in console controller Data mismatch between console and controller
124 Error in flash memory of console Text table in console and controller do not match
Download flash memory of console again
> Add 151 to Value 01
125 EEPROM in console or controller Incorrect data in console EEPROM or control card
126 Communication to console in console Incorrect data match between console and
controller controller
128 General diagnosis error Check diagnostic procedure
136
143
153 Timeout communication with battery
Check central computer battery controller
controller
154
155 Hardware error in control card Replace control card
156
157 Control-specific calibration values of battery Replace battery controller
controller incorrect

Motor temperature measurement

161 Short in HM temperature sensor
164 HM temperature sensor disconnected Emerg. operation,
armature current limit = 130A / 100A
165 FM1 temperature sensor grounded > Temperatursensoren prüfen
167 HM temperature sensor grounded > Replace control card
168 Reference point, temperature sensor
grounded
169 Motor temperature (MTT) collective error
Drives
170 Offset-Überwachung Stromsensor Traction is cut out, armature regulator faulty
173 Monitoring of FM1 armature regulator > Replace controller
177 Monitoring of HM armature regulator Hydraulic is cut out, armature regulator faulty
174 Monitoring of FM1 field regulator Traction is cut out, armature regulator faulty
> Replace field regulator or controller
178 Drive failed Check FM, otherwise renew controller
180 Hydraulic drive failed Check HM, otherwise renew controller
181 V2 ( IGBT ) faulty Check battery charge,
otherwise renew controller
182 Offset error current sensor field regulator Renew field regulator
191 Monitoring V2 on When vehicle moves: Ignore, if not, replace
192 Monitoring V2 off controller, see also fault 181
191 Main contactor control absent Check contactor connections,
otherwise renew controller
193 Error in synchronised coupling to power Armature short, isolation measurement
electronics microprocessor > Replace control card
194 Fault in synchronising interface to L-computer Renew control board
Motors
197 Motor overtemperature
198 Hydraulic motor overtemperature
199 Failure of traction motor temperature sensor
200 Failure of hydr. motor temperature sensor Emerg. operation,
201 Overtemperature at FM1 armature current limit = 130A / 100A

D iagnosis under Service Address 150, Value 01

203 Motor brush fault Emergency operati on
204 Hydrauli c motor brush fault Emergency operati on
205 Speed moni tori ng functi on for FM1 / FM2 C hange speed of FM1 and/or FM2 RPM i s too
hi gh
206 FM1 speed sensor error Tracti on i s cut out,
208 Error i n calculated setti ng for FM1 Tracti on i s cut out

D i screpancy between calculated and measured
speed i s too hi gh
> No si gnal from sensor
> Incorrect measurement due to fault i n fi eld /
armature current, armature voltage, motor
temperature
> Replace sensor or control card / controller
210 HM speed sensor error Emerg. operati on, armature current li mi t = 72 A
Traction is cut out The error can be cleared temporarily by

operating the accelerator
Errors on trucks equipped w ith a joystick

224 Forward GND / VC C di sconnected Transmi tter voltage < 2 Volt or > 7.89 Volt
225 Reverse GND / VC C di sconnected > Joysti ck D i agnosi s
239 No voltage supply for poti C heck cable, change hydrauli c controller
Calibration error (calibration only possible during diagnosis)
Offset-Fehler
72 Brake sender out of range (to high) Voltage above 0,85Volt
73 Brake sender out of range (to low) Voltage below 0,45Volt
211 Calibration offset error Recalibrate
> Addr. 151 to value 03
212 Lift sender out of range (to high) Voltage above 5,60Volt
213 Lift sender out of range (to low) Voltage below 4,40Volt
214 Tilt sender out of range (to high) Voltage above 5,60Volt
215 Tilt sender out of range (to low) Voltage below 4,40Volt
216 Aux. hydr.1 sender out of range Voltage above 5,60Volt
217 Aux. hydr.1 sender out of range Voltage below 4,40Volt
218 Aux. hydr.2 sender out of range Voltage above 5,60Volt
219 Aux. hydr.2 sender out of range Voltage below 4,40Volt
220 Fault in a switch unit Recalibrate > Addr. 151 to value 03
replace control board if necessary
226 Model calculation error at speed 0 Check/replace controller
227 Model calculation error at speed unequal to 0 Check speed sensor and controller

Error messages R6022 - 29 08
R60S60 – Error messages
Fault 1 – Brake fluid switch
Effect: None
Cause: Brake fluid too low; switch sticks, fault feed line.
Remedy: Clear fault, replace controller
Fault 2 – Brake sender open-circuit

Effect: No operation
Cause: Brake sender faulty or feed line broken off.
Remedy: Clear fault
Fault 3: – Hydraulic motor speed sensor faulty

Effect: Motor runs at maximum speed
Cause 1: Sensor faulty or incorrect distance to sender wheel; faulty cable; external fault (e.g.
welding machines); possibly fault in control (S and T board)
Remedy 1: Adjust or replace sensor
Cause 2: 24V supply faulty in controller
Remedy 2: Replace controller
Fault 4, 6, 8 – Control sensor adjustment faulty

Effect: No defined switch off, power reduction
Cause:
Remedy: Replace controller
Fault 7 – Internal 15V power supply

Effect: Drive and hydraulics without function or drive stops intermittently
Cause: Short-circuit or loose contact with 5V ext. or 10V ext; S board or power supply faulty in
controller
Remedy: Clear short-circuit or replace controller
Fault 9 – Power supply external consumers

Effect: Power supply attempts to switch on after 1 second
Cause: 24V supply is short-circuited or has a loose contact; also faulty T or S board
Remedy: Clear short-circuit
Fault 10 – Motor speed sensor faulty or sender wheel wobble

Effect: With brief intermittent operation:None
With total failure: Vehicle moves briefly, drive is subsequently without power
Cause: Sensor faulty or distance to sender wheel incorrect; loose contact and fault due to
interference; 5V supply faulty; incorrect parameter in address 28/29 (see faults 42, 44)
Remedy: Adjust FM speed sensor or replace, check parameter
With missing 5V supply: Replace controller
Fault 11, 13, 15 – No significance
Fault 12, 14 – Overcurrent in motor/hydraulic motor

Effect:
Cause: Loose contact in power section; motor short circuit to frame; hardware fault in controller;
short-circuit in power section
Remedy: Check wiring, measure motor insulation, replace controller
Fault 16 – Motor emergency operation

Effect: Vehicle assumes emergency operating mode
Cause: Motor temperature above 160°C; temperature sensor open-circuit; brush wear and/or
discharge cut-off function parameterised; also together with fault 18 and 84
Remedy: Clear fault
ã STILL GmbH Position as per: 02/00 (Replaces vers.: 10/98 ) 2

Fault 18, 20 – Motor and hydraulic motor brush wear
Effect: Under 10 hours only warning or parameterised limit.
Cause: Carbon brushes worn; loose contact in brush yoke/cable; open-circuit or short-circuit.
Only hydraulic motor: Incorrect parameterisation of address 4B, fuse F7
Remedy: Clear fault, subsequently set address 13 to the value 01 (reset)
Test: Insert jumpers on mother board to check whether fault lies in measuring circuit or
controller
Fault 22 – Overvoltage C1
Effect: Contactor drops out
Cause: Battery discharge; RCD circuitry faulty; loose contact in wiring; main fuse or contactor
coil connecting cable faulty; battery plug disconnected during regenerative braking or
main contactor dropped out.
Remedy: Clear fault beseitigen, replace controller
Fault 26: – Backup capacitor precharge faulty

Effect: Contactor does not pick-up
Cause: Discharge battery; RCD circuitry faulty; C1 leaky; precharge in controller failed;
discharge thyristor faulty
Remedy: Check RCD circuitry, discharge thyristor or C1, replace controller
Fault 36 – Driver board power supply faulty

Otherwise no drive and hydraulic function
Cause: Driver board, MOSFET, power supply faulty
Fault 38 – L board power supply faulty

Effect: Power section of controller without function
Cause: L board, power supply faulty
Fault 40 – Hydraulic motor emergency operation

Effect: Vehicle assumes emergency operating mode
Cause: Motor temperature above 160°C; temperature sensor open-circuit; brush wear and/or
discharge cut-off function parameterised; also together with Fault 20 and 84
Remedy: Clear fault
Fault 42 – Model calculation

Cause: From software version1.09, this fault is indicated together with fault 10 as additional
information. Fault in sensor or cabling, fault in field rheostat
Remedy: Check sensor and cabling. If no fault can be found, replace controller
Fault 44 – Speed sensor monitoring

Cause: From software version 1.09, this fault is indicated together with fault 10 as additional
information. Speed sensor faulty
Remedy: Adjust or replace speed sensor

Fault 80 – Travel sender fault
Effect: With brief intermittent operation:Drive cuts out
With total failure: Vehicle stationary
Cause 1: Travel sender or cable faulty
Cause 2: External 10V suppl failed, S board or mother board in controller faulty
Remedy 1: Clear fault
Fault 81, 83, 85, 87 – Hydraulic sensor fault

Effect 1: Intermittent operation in hydraulic drive
Cause 1: Loose contact in sender cable
Effect 2: No hydraulic function
Cause 2: S board, power supply or mother board faulty
Fault 84 – Motor temperature sensor fault

Effect: With brief intermittent operation:Motor cuts out
With total failure: Emergency operation
Cause 1: Loose contact in brush yoke, short circuit to frame, open-circuit or sensor short-circuit,
high external interference, overtemperature > 160°C at HM or FM, often together with
faults 90 and 160
Cause 2: 15V power supply of S board absent
Fault 86 – Controller temperature sensor fault

Effect: Vehicle power is restricted, emergency operation is not indicated
Cause: L board has short-circuit with union, sensor in controller has loose contact or is faulty.
Remedy: Loosen mother board. Remove L and S board and cover below. A single two-pole
connector is located on the now visible driver board next to the circular current sensor.
Disconnect the connecting cable and solder a 2kOhm/0.3W resistor to the connector
and insulate.
Fault 90 – Temperature sensor motor fault

Cause: Overtemperature of > 160°C at motor
see fault 84
Fault 91 – Oil filter switch

Effect: None
Cause: Oil filter clogged, switch sticks, open-circuit, loose contact or short in cable. T or S
board faulty
Remedy: Clear fault
Fault 92, 94 – L board memory fault

Effect: Various phenomena
Cause: Faulty L board
Remedy: Replace L board, replace controller
Fault 93 – No function of relay boxes

Effect: Consumer/additional electrics faulty or without function
Cause: Relay boxes faulty, without function
Remedy: Check parameters in address 9A to E3
Replace relay boxes
ã STILL GmbH Position as per: 02/00 (Replaces vers: 10/98 ) 4

Fault 96, 98, 100, 107, 109 – S board memory fault
Effect: Various faults
Cause: S board faulty
Remedy: Replace S board, replace controller
Fault 160 – Hydraulic motor temperature sensor

Cause: Overtemperature of > 160°C at hydraulic motor
See fault 84
Fault 173 – Service interval expired

Effect: None
Remedy: Reset service interval
Note:
Since the introduction of the new R60S20 controller and ET-controller R60S20 adapter solution, no more
individual circuit boards are available as a spare part.
If the case should arise, the controller must always be replace completely. In this connection, the console
must also be replaced by a series console.
See installation description in the Workshop Manual, Group 08,
as wellas Schnell-Info 17/2000.

Error Message 6033 - 35 08


The error memory is cleared with the menu item

ERROR LIST
at password level 2 using the command
RESET YES

V AL UE 01 PRG
F2
F1

No. Meaning Remark

53 Overtemperature converter hydraulics Emergency operation
56 Hydraulics > Poor heat dissipation towards counterweight
Overtemperature converter travel > Check installation
197 Overtemperature drive motor Emergency operation
207 Overtemperature hydraulic motor Emergency operation
Diagnosis mode, passw ord level 2, service address 150, value 01
No. Meaning Remark

Travel sender
0 Fault in direction indicator switch
1 Interruption GND, Potentiometer 1
2 Interruption VCC, Potentiometer 1 Fault also occurs when connector X16 at the
travel sender is disconnected
3 Travel sender configuration unknown Check parameter values
4 Plausibility error (2-pedal) Potiometers incorrectly set or faulty
5 Pedal switch does not close
6 Pedal switch does not open Fault is unrelevant
7 Interruption GND, Pot 2
8 Interruption GND, Pot 2
10 Evaluation error 2-pedal
Supply voltage
14 Short-circuit in external supply 10V supply from central computer-
> Short-circuit in sensor system (potentiometers)
> Change central computer
15 Short-circuit in output Profet SK1-SK3
24 Link-circuit under voltage Check battery voltage
25 Main contactor sticks
26 HSK link-circuit charging fault Link-circuit charging time exceeded, contactor
does not pick up
> Check/change battery computer
Vehicle
27 Invalid vehicle type Check parameter values
28 Travel program parameter error Check parameter valuese
41 Comm. error converter travel Vehicle does not move:
42 Comm. error converter hydraulics Check/change battery computer
Converter indicator lamp - flashes?
Check/change converter
F24+41+42: occurs with low battery voltager -
check battery when vehicle is moving, otherwise
ignore.
43 ELA error in start measurement
ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand: ) (2)

Diagnosis mode, passw ord level 2, service- address 150, value 01
No. Meaning Remark

51 Interruption sensor converter hydraulics Emergency operation
> Change converter
52 Short-circuit sensor converter hydraulics Emergency operation
> Change converter
53 Overtemperature converter hydraulics Emergency operation
> Poor heat dissipation towards counterweight
54 Interruption sensor converter travel Emergency operation
> Change controller
55 Short-circuit sensor converter travel Emergency operation
> Change controller
56 Overtemperature converter travel Emergency operation
> Poor heat dissipation towards counterweight
68 Overvoltage in converter Overvoltage (> 105V) at UC1
> Check battery, contactor and power cabling
Check operating conditions
Brake sender
69 Brake sender, interruption VCC
70 Brake sender, interruption GND Sender voltage above 9.4V
> Check brake, readjust if necessary
71 Brake fluid switch
72 Brake sender offset too large
73 Brake sender offset too small
Hydraulic sender
77 Lift sender, interruption VCC
78 Lift sender, interruption GND
79 Tilt sender, interruption VCC
80 Tilt sender, interruption GND
81 Additional sender 1, interruption VCC
82 Additional sender 1, interruption GND
83 Additional sender 2, interruption VCC
84 Additional sender 2, interruption GND
87
... Watchdog fault > Change central computer
96
Pressure sensor
97 Pressure sensor, interruption VCC
98 Pressuresensor, interruption GND

Diagnosis mode, passw ord level 2, service- address 150, value 01
No. Meaning Remark
Supplementary electrics and relay box
100 Supplementary electrics fault Relay box, outputs or signalling faulty

101 One input of several is OPEN Function blocks, inputs not set
102 Relay box fault > Check parameters

> Relay box faulty
CAN Bus
106 Undefined fault behaviour, console does not power
... up, but sticks on "Guten Tag.."
... Hardware problems in CAN bus > Check all CAN bus users (CAN bus cable,
... console, relays box, central computer) and renew
113 if necessary
Console
117 Fault in console Console buttons incorrectly parameterised >
check
9 Invalid information from console Wrong direction sender
121 Incorrect value from direction sender
122 Hour meter fault Damage in RAM memory
> Renew central computer
123 Fatal fault in console control Data adjustment between console and central
computer faulty
> Check console and central computer, renew if
necessary
124 Fault in flash memory of console Taxt tables in console different to central computer,
fault when changing console
> Reload text tables, address 151 to value 01
125 EEProm of console of controller Data in EEProm faulty, EEProm faulty
necessary
126 Communication with console Data adjustment between console and central
computer faulty
necessary
128 General diagnosis error Check diagnosis sequence
136
... Central computer hardware fault Renew central computer
143
154 EEProm write error
155 Hardware fault 12C bus, access problems
Renew central computer
156 Parameter checksum not o.k.
157 BCC control-specific adjustment values

Diagnosis mode, passw ord level 2, service address 150, value 01
No. Meaning Remark
Temperature sensors/drives
51 Interruption T-sensor converter HM
52 Short-circuiut T-sensor converter HM Emergency operation
54 Interruption T-sensor converter FM Change converter
55 Short-circuit T-sensor converter FM
68 Overvoltage UC1 max Check battery, battery connector, contactor and
power cabling
167 Cal. error current sensor hydraulics
168 Cal. error current sensor travel Drive is switched off
170 Fault E-Prom converter hydraulics > Renew converter
171 Fault E-Prom converter travel
173 Converter travel failed
Fault in battery computer
175 Converter hydraulics failed
176 Fault sensor bearing drive motor
178 Fault sensor bearing hydraulic motor
179 Fatal overtemperature converter FM
Check heat transfer compound, check operation
181 Fatal overtemperature converter HM
182 Short-circuit or over-current drive Check FM and cable
Renew converter
184 Short-circuiut of over-current hydraulic drive Check HM and cable
Renew converter
185 Overvoltage converter travel
Voltage on link-circuit >105V
187 Overvoltage converter hydraulics
189 Speed monitoring fault Check speed sensor
191 CAN bus for converter travel faulty Check CAN bus cable, battery computer faulty
193 CAN bus for converter hydraulics faulty

Diagnosemodus, Passw ortebene 2, Service- Adresse 150, Wert 01
Nr. Bedeutung Bemerkung
Motor
197 Overtemperature drive motor
198 Overtemperature hydraulic motor
199 Failure tem p. sensor m otor Ignore fault
200 Failure tem p. sensor hydraulic m otor Ignore fault
201 Drive overtemperature Activate emergency converter
203 Short-circuiut temp.sensor drive motor Emergency operation
204 Short-circuiut temp.sensor hydraulic motor Emergency operation
205 Motor speed change too fast
206 Fault speed sensor drive motor Drive motor is switched off,
> check speed sensor and renew if necessary
207 Overtemperature pump Emergency operation hydraulic converter
208 Undertemperature motor Limitation
209 Under temperature hydraulic motor Limitation
210 Fault speed sensor hydraulic motor Emergency operation,
> check speed sensor and renew if necessary
Motor is switched off This function can be released at short notice
by actuating the travel sender
Calibration hydraulics
211 Offset error calibration Collective fault
Monitoring
220 Fault in a switch-construct Currently inactive
221 Network watchdog for battery computer Communication error Can- bus
Check Can bus and battery computer
222 Too many errors when switching on converter Converters are switched off, switch lock switch off
and on again
224 Interruption forward direction Joystick fault
225 Interruption reverse direction Joystick fault
239 No voltage supply for poti Check cable, change battery computer
ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand: ) (6 )

Error Message R70 digital 08
DISPLAY 1 (5) DISPLAY 2 (6) PRG
DISPLAY 3 (7) DISPLAY 4 (8) PRG
F2
F1
Console R 7052 / 56, 7054 / 58; R 7062 - 70; R 7084 - 86; R 7087 - 89
Console R 7201-03 / 05 - 07
 STILL GmbH Stand: 4/2002 ( Ersatz für Stand: ) 1

Diagnose F1 under Service Address 150 , Value 01 Diagnose F1 under Service Address 150 , Value 01
No Signification No Signification
Information displayed in clear on the DISPLAY Drive pedal
1 Interruption GND potentiometer 1
12 Coolant temperature too high 2 Interruption VCC potentiometer 1
18 „ALTERNATOR“ D+ at 9G2 interrupted 3 FGB configuration unknown
19 „ALTERNATOR“ 9G2 no voltage 4 Plausibility error (2-Pedal)
71 Brake fluid level is low 5 Pedal switch does not close
148 Engine oil pressure 6 Pedal switch does not open
(engine running) is low 7 Interruption GND potentiometer 2
149 Coolant level is low 8 Interruption VCC potentiometer 2
150 Switch, air cleaner 9 2-Pedal; calibration error
151 Switch, exhaust gas purifier 10 2-Pedal; parameter/values outside tolerance
165 Temperature drive motor too high (truck does not drive)
167 Temperature generator too high
199 Generator brush wear Coolant temperature
200 LH drive motor brush wear 11 Interruption of sensor resistor
201 RH drive motor brush wear 12 Coolant temperature too high
202 Drive motor/generator Supply voltages
temperature too high 13 Short-circuit current sensor
255 „ADJUST“: Truck is not calibrated 14 Short-circuit external supply
15 Overvoltage for switched 24V detected
Calibration faults
9 2-Pedal; Calibration error 16 10Vi supply transistor
44 Absence of engine rev signal 17 10Vx supply transistor
45 time out when accelerating in idle 18 D+ at generator 9G2 interrupted,
(rate of accel. out of time limit) or no V-engine speed signal
46 time out when accelerating to 19 Generator 9G2; no voltage
max. speed (rate of accel. Out of time limit) 20 Switching high/low level
47 Low idle <==> (clearance Shut-off valve and relay
between mech. stop & oper. lever too small) 22 Program sequence error ABS
50 Max. engine speed <==> Glow
(clearance betw. mech. stop & 24 Program sequence error GLR
operating lever too small)
53 Resolution too small Truck
72 Offset, tolerance brake sender too big 26 Unknown V-engine
73 Offset, tolerance brake sender too small 27 Set value for EMR missing
212 Offset, tolerance hoist sender too big 28 EMR faulty (=SERDIA/constant light)
213 Offset, tolerance hoist sender too small 29 EMR faulty (=SERDIA/flashing light)
214 Offset, tolerance tilt sender too big
215 Offset, tolerance tilt sender too small Hardware
216 Offset, tolerance 3rd hyd. function sender too big
217 Offset, tolerance 3rd hyd. function sender too small 30 Driver start repeat block overcurrent
218 Offset, tolerance 4th hyd. function sender too big 31 Emergency switch 7S14 set to ON
219 Offset, tolerance 4th hyd. Function sender too small (7062-64,7068-70)
227 Supply voltage VCC servomotor 32 Driver start repeat block polarity reversal
pos. pot. —open circuit fault 33 Driver shut-off valve overcurrent
228 Servomotor position potentiometer 34 Driver shut-off relay overcurrent
ground fault (—open circuit) 35 Driver shut-off relay interruption
229 Position potentiometer —pilot/test lead 36 Shut-off relay V-engine incorrectly connected
236/237 Interruption tacho 37 NOTBETRIEB Fehler 37 erscheint blinkend
238 Parking brake released im Display - Abriss Retardersteuerung-
239 Absence of 10 V supply voltage Fahrzeuggeschwindigkeit wird reduziert
for external sender - ab SW 3.12 gültig
240 Display tachogenerator offset fault
 STILL GmbH Stand:
255 „“ADJUST““: Truck
4/2002 ( Ersatz fürisStand:
not calibrated
) 2
Regulation of servomotor position Pressure sensor

41 Position potentiometer servomotor VCC 97 Pressure sensor interruption VCC
interruption 98 Pressure sensor interruption GND
42 Position potentiometer servomotor GND
interruption Auxiliary electrics and relay boxes
43 Position potentiometer measuring circuit 100 Auxiliary electrics fault
44 No signal VBM speed 101 One input of several set to „open“
45 Bottom idling speed not reached 102 Relay box fault
46 Top idling speed not reached ASM control; fault classification only
47 Distance stop <==> UL too small possible with diagnostic program
50 Distance stop <==> NVBM -MAX too small 103 Communication converter<=>control
104 Converter fault
Servomotor current regulator 105 Control fault
48 Hardware signals overcurrent
49 Controller cannot adjust set value
51 Short-circuit temperature sensor controller CAN bus
52 Interruption temperature sensor controller 106 Error byte of CAN controller
53 Resolution too small 107 Error in CAN layer 0
Charge compensating circuit 108 Error in CAN layer 1
55 Error program sequence LAS 109 Error in CAN layer 2
56 Error GND measuring circuit 110 General error in CAN
57 Error 12V measuring circuit 113 Transfer EEPROM-STG -> console interrupted
58 Error 24V measuring circuit 118 CAN bus error
59 Error overvoltage
60 Errorr 12-Volt-Relais Console
61 Error controller IC not active 117 Fault in console
62 Error controller IC failed or no 24V supply 120
63 Charge 12V capacitors 121 Incorrect value from direction sensor
64 R12V too high 122 Work hour meter
65 12V relay LAS does not open 123 Fatal console starting error
124 Flash memory console faulty
125 EEPROM daten configuration error
126 Console starting communication error
Brake sender
69 Error brake sender interruption VCC
70 Error brake sender interruption GND Diagnostic
71 Brake fluid level too low 127 Diagnostic CAN connection error
72 Brake sender offset too large 128 General diagnostic error
73 Brake sender offset too small 129 Diagnostic language transfer error
Digital drive motor speed measurement
74 Too many disturbing pulses Combustion engine
75 Faulty speed signal 148 Oil return switch function
Sender for hydraulic functions 149 Coolant switch function
77 Lifting interruption VCC 150 Air filter switch function
78 Lifting interruption GND 151 Exhaust cleaner filter switch
79 Inclination interruption VCC 152
80 Inclination interruption GND 153
81 Additional sender 1 interruption VCC 154 EEPROM write error
82 Additional sender 1 interruption GND 155 J2C bus hardware fault
83 Additional sender 2 interruption VCC 156 EDA checksum not OK
84 Additional sender 2 interruption GND 157 BCC control-specific calibration value
Hydraulic controller (Joystick) 158
85 Max. idling too high; Set value control
86 Min. idling too low; set value control
87 Interruption driving direction V
88 Interruption driving direction R
Motor temperature measurement Brush monitoring/temperature

159 Short-circuit generator temp. sensor measurement FM/Gen
160 Interruption generator temp. sensor 199 Brush fault generator
161 Short-cirtuit drive motor temp. sensor 200 Brush fault drive motor left
162 Interruption drive motor temp. sensor 201 Brush fault drive motor right
163 Short-circuit drive motor temp. sensor 202 Motor/generator temperature too high
164 Interruption drive motor temp. sensor
165 LH Drive motor temperature too high Connection to supervisory computer
166 LH Drive motor temperature too high 203 Incorrect address MBX2 model error
167 Generator overtemperature 205 Model error: Speed sensor/
168 Incorrect temperature motor setting measured value/motor field
current/aramture voltage/
Armature voltage adjustment
Drive motor field current controller 207 Error offset aramture
169 Controller cannot adjust set value voltage pseudo error to
170 Interruption VCC at current sensor display error message on console
171 Interruption GND at current sensor 208 for object 1 for error display
172 excessive current -> no operation 209 for object 2 for error display
210 for object 3 for error display
Generator field current controller 211 für Objekt 4 for error display
175 Controller cannot adjust set value 212 Offset lift sensor too large
176 Controller cannot adjust set value 213 Offset lift sensor too small
177 Interruption VCC at current sensor 214 Offset inclination sensor too large
178 Interruption GND at current sensor 215 Offset inclination sensor too small
179 Excessive current -> no operation 216 Offset auxiliary sensor 1 too large
180 Sensor monitor : no plausible values 217 Offset auxiliary sensor 1 too small
218 Offset auxiliary sensor 2 too large
Armature current control 219 Offset auxiliary sensor 2 too small
182 Interruption VCC at current sensor 1
183 Interruption GND at current sensor 1 Current sensor calibration
184 Excessive current -> no operation 220 Offset error IA sensor 1
185 Offset error at current sensor 2 221 Offset error motor field sensor
186 Interruption VCC at current sensor 2 222 Offset error generator field sensor
187 Interruption GND at current sensor 2 223 Display no calibration possible
188 Drive motor plausibility error
189 Plausibility error 1 current sensors Fan
190 Plausibility error 2 current sensors 224 Short-circuit fan switch
225 Transistor failed or cabling faulty
Field rheostat 226 Sustained short-circuit
193 Relay on field rheostat does not pick up
194 Short-circuit on field rheostat Calibration error
195 Sammelfehler H-Brücke Gen.Feld 227 Position potentiometer servomotor
196 Abgleichwerte für Stromsensoren außerhalb VCC interruption
des zulässigen Bereiches 228 Position potentiometer servomotor
GND interruption
ASM control; fault classification 229 Position potentiometer measuring circuit
only possible with diagnostics program 230
231
195 Fault ASM converter 232
196 Fault ASM controller
197 Fault ASM communication Tachogenerator calibration
198 Fault ASM parameter set 233 Offset too small
234 Offset too large
235 Offset too small
236/237 Interruption tacho
 STILL GmbH Stand: 12/2003 ( Ersatz für Stand: 4/2002 ) 4

237 Tachogenerator interruption Insignificant errors when truck function o.k.

238 Parking brake released
239 10V supply for external sensor missing 6 Pedal switch does not open
240 Display tachogenerator offset error 35 Driver shutdown relay interruption
49 Controller cannot adjust set value
CONSOLE (errors are generated from console) 60 Error 12V relay
61 Error controller IC not active
241 Write/read error EEPROM console 62 Error control IC failed or no 24V supply
242 Data error EEPROM console
243 Write/read error flash console 63 Charge 12V capacitators
244 Data error flash console 64 R12V voltage too high
245 Error display console 65 12V relay LAS does not open
246 Error ROM console 94 10ms grid
247 Error RAM console 107 Error in CAN layer 0
248 Error external RAM console 169 Controller cannot adjust set value
172 Excessive current-> no operation
Parameter backup 175 Controller cannot adjust set value
249 No memory block for parameter backup free 176 Controller cannot adjust set value
250 No valid parameter block available 179 Excessive current-> no operation
184 Excessive current-> no operation
ASM control; fault classification 188 Plausibility error drive motor
only possible with diagnostic program 203 Incorrect address MBX2
250 Converter signal 0-7 223 Display, no adjustment possible
251 Converter signal 0-7
Further errors from control
252 Parameter backup in flash
253 Parameter loading from flash
254 Unknown truck number: no parameters possible
256 Total number of errors
Other error messages (without plain text)
251 Unknown truck number and truck variant
Drive motor speed monitoring

253 Drive motor speed too high
Calibration
255 Display truck not calibrated

Supplementary descriptions to specific ASM
drive faults
Definition of terms used in the descriptions of the Description of error messages:

individual error messages:
195 Fault in ASM drive.
CAN bus cable problem: ERR_ASM_Umrichter
Mechanical damage of the cable, plug-in contacts of This fault can affect the converter, braking resistor,
the cable or the connector at the control unit or CAN bus connection to the converter, drive motor or
converter. generator. Exact fault diagnosis is possible with the
group error messages.
Fault on starting: This fault results in stoppage of the drive.
A drop in the battery voltage during starting can give
rise to the generation of error messages. These error 196 Fault in controller.
messages can be ignored if the truck resumes nor- ERR_ASM_Steuergerät
mal operation after starting. Typical error messages This fault can affect the software, hardware of the
in this case are ‘ERR_ASM_UMRICHTER’ and computer/interface card or the unit for generating the
‘ERR_ASM_CANBus’. CAN bus supply. Exact fault diagnosis is possible
with the group error messages.
Group error messages: This fault results in stoppage of the drive.
Group error messages can contain up to eight diffe-
rent error messages, which are each displayed 197 Data exchange between controller and
bitcoded. converter disturbed.
Group errors can only be evaluated via the diagnostic ERR_ASM_CANBus
program. This fault can affect the CAN bus connection,
Evaluation via the truck instrument panel is not controller or converter. Exact fault diagnosis is
possible. possible with the group error messages.
The entry in the error memory only provides the This fault results in stoppage of the drive.
information that a single error has occurred. The group
error messages can however support evaluation of 198 Controller and converter parameters not
“normal” error messages in providing more accurate o.k.
location of the fault occurred in the truck. ERR_ASM_Parameter
Only emergency operation is possible (reduced
speed).
This fault can be cleared by parameterisation of the
controller

Description of group error messages:
167 Has no significance for fault diagnosis 251 (Group error message)
ERR_asm_Umri_UeL: ERR_asm_Umri_FeH:
168 Has no significance for fault diagnosis Bit 0: Excessive drive motor speed
ERR_asm_Umri_UeH: ASM_UEBER_DREHZAHL
165 (group error message) Converter too h Bit 1: Converter or braking resistor can be faulty
ERR_asm_Umri_WaL: ASM_BALLAST_ERR
The converter reduces its power to protect itself. If
this measure does not suffice, the converter shuts Bit 2: No significance
down following the generation of an appropriate error
message (see ERR_asm_Umri_FeL). Bit 3: Converter faulty
ASM_END_MODUL_ERR
166 Has no significance for fault diagnosis
ERR_asm_Umri_WaH: Bit 4: No significance
Bit 5: No significance
250 (Group error message)
ERR_asm_Umri_FeL: Bit 6: CAN bus communication failure
ASM_UMR_BUSS_OFF
Bit 0: Converter too hot and shutdown This fault can occur during starting, in connection
ASM_TEMP_ENDSTUFE with a CAN bus cable problem or a faulty controller.
Bit 1: Converter or braking resistor can be faulty
ASM_UZK_UEBERSPANNUNG
Bit 6: Converter faulty (reset converter controller)

ASM_RECHNERFEHLER
This fault can also occur during starting or in
connection with a CAN bus cable problem or the CAN
bus supply generated by the truck controller.
Bit 7: CAN bus communication failure

ASM_UMR_WADO
This fault can occur during starting, in connection
with a CAN bus cable problem, the CAN bus supply
generated by the truck controller or a fault controller.

103 (Group error message) 104 (Group error message)

ERR_asm_Kommu: ERR_asm_Umri:
Bit 0: Converter does not accept received data. Bit 0: Converter is not connected to CAN net-
ASM_DST_ANFO work
This fault can occur during starting, in connection ASM_NWS_TIOUT
with a faulty converter or converter or controller This fault indicates a defective CAN bus connection
software problem. or a faulty converter.
If this fault occurs several times in succession, it This fault results in the generation of an error mes-
results in the generation of an error message sage ERR_ASM_CANBus
ERR_ASM_CANBus and stoppage of the drive.
Bit 1: Controller software fault. Bit 1: Converter version incompatible with con-
ASM_CAN_QUEUE troller
This fault results in the generation of an error message ASM_KENNUNG
ERR_ASM_Steuergeraet and stoppage of the drive. This fault results in the generation of an error mes-
sage ERR_ASM_Umrichter
Bit 2: Converter does not acknowledge received
data. Bit 2: Parameters stored in converter not o.k.
ASM_NO_QUIT ASM_U_PAR_ERR
This fault can occur during starting, in connection The converter takes over the controller parameters
with a faulty converter or a CAN bus cable problem.
If this fault occurs several times in succession, it Bit 3: Converter does not release drive
results in the generation of an error message ASM_HWRE_FREI
ERR_ASM_CANBus and stoppage of the drive. This fault indicates a faulty converter.
Bit 3: Converter incorrectly acknowledges This fault results in the generation of an error mes-
received data. sage ERR_ASM_Umrichter
ASM_FAL_QUIT
This fault can occur during starting, in connection Bit 4: This fault indicates a faulty CAN bus con-
with a faulty converter or a converter or controller nection or a faulty converter.
software problem. ASM_SOLIST_WD
If this fault occurs several times in succession, it This fault results in the generation of an error mes-
results in the generation of an error message sage ERR_ASM_CANBus
ERR_ASM_CANBus and stoppage of the drive.
Bit 4: Controller detects faults on CAN bus cable Bit 5: Converter software fault
This fault can start during starting. ASM_SPO_DIEN
ASM_NWS_STOER This fault results in the generation of an error mes-
If this fault occurs several times in succession, it sage ERR_ASM_Umrichter
results in the generation of an error message
ERR_ASM_CANBus and stoppage of the drive. Bit 6: Converter does not release drive
Bit 5: No significance ASM_BER_TIOUT
Bit 6: No significance This fault indicates a faulty converter, a faulty brak-
Bit 7: No significance ing resistor or a faulty drive motor.
This fault results in the generation of an error mes-
Bit 7: Converter has blocked drive during opera-

tion
ASM_NOBEREIT
This fault indicates a faulty converter, a faulty brak-
ing resistor or a faulty drive motor.

105 (Group error message)

ERR_ASM_Steuer:
Bit 0: The unit in the controller responsible for

generation of the CAN bus supply is faulty
sage ERR_ASM_Steuer
Bit 1: Uncritical fault in the controller software

ASM_SPOBUF_OV
Bit 2: The parameters stored in the controller

are not o.k.
ASM_S_PAR_ERR
The controller takes over the converter parameters
Bit 4: Controller software fault

ASM_INIT_TIO
sage ERR_ASM_Steuer

Error Messages: Still GMBH Stand: 2/02 (Ersatz Für Stand:)

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Error Messages: Still GMBH Stand: 2/02 (Ersatz Für Stand:)

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ERROR MESSAGES

ã STILL GmbH Stand: 2/02 ( Ersatz für Stand: )

Thereupon, faults emanating from the software

can be interrupted by pressing the PRG O keypad. RE S E T NO PRG

By pressing the F2 keypad in the diagnostic mode

The error memory is cleared with the menu item at

To switch off the diagnostic mode again, reset the

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: 04/00 ) 1

Calibration error (calibration only possible during diagnosis)

No. Explanation Remarks

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: 04/00 ) 2

No. Explanation Remarks

26 HSK link-circuit charging fault Link-circuit charging time exceeded

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: 04/00 ) 3

No. Explanation Remarks

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: 04/00 ) 4

No. Explanation Remarks

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: 04/00 ) 5

No. Explanation Remarks

Motor temperature measurement

178 Drive, right failed Check motor,

193 Error in synchronised coupling to power Armature short, insulation measurement

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: 04/00 ) 6

No. Explanation Remarks

208 Error in calculated setting for FM1 Traction is cut out

Traction is cut out The error can be cleared temporarily by

Errors on trucks equipped w ith a joystick

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: 04/00 ) 7

Thereupon, faults emanating from the software

can be interrupted by pressing the PRG O keypad. RE S E T NO PRG

By pressing the F2 keypad in the diagnostic mode

The error memory is cleared with the menu item at

To switch off the diagnostic mode again, reset the

ã STILL GmbH Position as per: 05/01 ( Replaces version: ) 1

No. Meaning Remark

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: ) 2

No. Meaning Remark

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: ) 3

No. Meaning Remark

Temperature measurement controller

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: ) 4

No. Meaning Remark

Additional electrical installations and

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: ) 5

No. Meaning Remark

128 General diagnostic error > Check diagnostic sequence

170 Error EEProm converter hydraulics Single error in memory

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: ) 6

ã STILL GmbH Stand: 08/02 ( Ersatz für Stand: ) 7

Error list type Delete error list

M Relay box No data currently available

P Acceleration sensor SW versions

ã STILL GmbH Stand: 07/2003 ( Ersatz für Stand: 01/03 ) 1

X 20 02 Controller temperature short- Temperatursensor(Steuerung) - none from Service

X 50 33 Temperature HM open-circuit Hydraulikmotor none from Service

Thereupon, faults emanating from the software

can be interrupted by pressing the PRG O keypad. RE S E T NO PRG

By pressing the F2 keypad in the diagnostic mode

The error memory is cleared with the menu item

To switch off the diagnostic mode again, reset the

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand: ) (1)

D iagnosis under Service Address 150, value 01