C MAINTENANCE

EV100 LX TROUBLESHOOTING
RR, RS, RD Trucks with TC Traction Card
RC, RC 3000, SC Trucks with MT Traction Card

GENERAL HANDSET OPERATION

This section provides troubleshooting aids to facilitate analy- WARNING

sis of truck failures. Power components are easily accessible
and can be checked with a volt-ohmmeter (i.e. Simpson 260,
or equivalent). If power components are believed to be
faulty, or in need of replacement, refer to Power Component
Test and Replacement Section.
By using the appropriate troubleshooting aids (based on
status codes displayed through the use of the handset or
display module), truck wiring diagram, and information pro-
vided in this manual; most problems should be easily de-
tected and corrected.
Before connecting or disconnecting the handset,
lift the drive wheels clear of floor and place
hardwood blocks under truck frame. Turn key-
switch “OFF”, disconnect battery and discharge
capacitor 1C of the traction control.
UE
1C
09

CAUTION
Care must be taken when replacing the EV100
-1 00
EV
OL
control card. Installation of the wrong control card NTR
CO
may cause misoperation. Refer to subtitle and SCR
parts breakdown for card type and part number.

STATUS CODES 1 through 76 are for the traction SCR

control, STATUS CODES 90 through 95 are for the truck
management module (TMM).

1049
STATUS CODES
RR, RS, RD (Pre 3000 Series Trucks)
RC, RC 3000, SC ILLUSTRATION 1

The EV100 LX/LXT SCR control utilizes an on board micro-
processor to monitor the SCR control system. By monitoring
circuit voltages and system timing, the microprocessor can
isolate malfunctions in specific circuits. The malfunctions are
categorized by status codes, and on RR, RS, RD trucks will
be displayed on the display located in the overhead guard.
Faults which interrupt truck operation (PMT conditions which
can be reset by cycling the keyswitch) are stored in the
traction SCR control card microprocessor and are accessed
by use of a “plug in” handset (112209). The last fault to occur
is the status code in storage. Listed in this section are the
status codes which will be displayed and the possible causes
of the malfunction.
When the term “press key” or “depress key” is used, press
the appropriate key on the handset keypad for approximately
1 second.
The control card memory is accessed by disconnecting plug
in the “Y” receptacle of the traction control card and connect-
ing the handset. When the handset is plugged in, turn the
truck keyswitch to the “on” position. Do not depress any of
the handset buttons before, during or after power up.
When the handset is being used during troubleshooting,
there are three different types of information accessible;
Fault Codes, Battery State of Charge, and Hour Meters.

Trucks not equipped with a display panel can use the GE

handset as described in the following information. Use of the
truck display is described following handset operation.

920114 5216
Crown 1994 PF10467-1 Rev. 8/03 Printed in U.S.A.
03 REV. 8/03
M4.2–14.0–400 M4.2–14.0–400
 C MAINTENANCE

FAULT CODE ACCESS HOUR METER

Operate the truck until a failure occurs. When a failure occurs
the handset will display the appropriate fault code. Fault
codes always are preceded by a minus symbol (-)(illustration
2). Refer to the fault code descriptions in this section for
additional information and corrective procedures.
When the keyswitch is turned to the off position, a four digit
number is displayed. This number represents the number of
operation hours of the SCR system that the handset is
plugged into (illustration 4).

3412

3410 3411
HOUR METER EXAMPLE
FAULT CODE EXAMPLES ILLUSTRATION 4
ILLUSTRATION 2
The hour meter reading in this example indicates the SCR
Code numbers 1 through 6 and code number 8 are consid-
system that the handset is plugged into has been in
ered SRO codes (static return to off). SRO codes will be
operation 84 hours. To obtain the hours for the other SCR
displayed during improper sequencing of the operators
system (if applicable), the handset must be connected to
controls. For example, direction lever activated while brakes
the control card of that system.
are applied would display a code number -05.
Turn the truck keyswitch to the off position. The handset is
Code numbers 7 and 9 through 99 represent actual faults
now ready to be disconnected.
occurring on the traction panel. Refer to the fault code
descriptions in this section for additional information and WARNING
corrective procedures.
Before connecting or disconnecting the handset,
BATTERY STATE OF CHARGE lift the drive wheels clear of floor and place
hardwood blocks under truck frame. Turn key-
When the truck is being operated and faults are not occur- switch “OFF”, disconnect battery and discharge
ring, the display will show the Battery State of Charge. This capacitor 1C of the traction control.
is a 3 digit number without a minus symbol (illustration 3). In
When handset functions are complete, unplug handset and
this example the battery has 75% charge remaining.
connect plug removed for handset connection.

3413

BATTERY STATE OF CHARGE EXAMPLE

ILLUSTRATION 3

Crown 1994 PF10467-2 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–401 M4.2–14.0–401
 C MAINTENANCE
STATUS CODES
RR, RS, RD (3000 Series Trucks)
The EV100 LX/LXT SCR control utilizes an on board micro-
processor to monitor the SCR control system. By monitoring
circuit voltages and system timing, the microprocessor can
isolate malfunctions in specific circuits. The malfunctions are
categorized by status codes which are communicated to the
service technician when using the display module. Listed in
this section are the status codes which will be displayed and
the possible causes of the malfunction.
The display module stores all fault codes except the codes
which are caused by the operator using the wrong control
sequence during operation (static return to off, SRO). These
codes are displayed as messages to the operator to indicate
the cause of the truck not operating. The display module
stores up to eight codes with any one code being stored only
once during a trucks powered up time.
3REC 4REC
10290
3REC 4REC
Crown 1994 PF10467-3 Rev. 8/03
03 REV. 8/03
M4.2–14.0–402
On General Electric EV100LX SCR systems, codes 52 and
53 are logged in the event of a PMT (Pulse Monitor Trip).
Troubleshooting procedures in the Service Manual for codes
52 and 53 lists, in part as possible causes, an open circuit or
loose connection in the 3REC or 4REC circuit. These codes
require the operator to re-key the truck in order to reset the
PMT function. This is notification to the operator and main-
tenance personnel that service is required and should not be
ignored. If a loose rectifier is not corrected, contactor tip
welding may result. Once contactor tip welding occurs,
status codes 23, 24 and 42, 46 may also be logged in status
code history.
Crown recommends following the status code maintenance
procedures described in the service manual and verifying
the condition of 3REC and 4REC(s) by removing and in-
specting per the following procedure:
Step 1: Inspect rectifiers and heat sink(s) per photo, includ-
ing thread condition. Replace if pitting and corrosion are
present.
Step 2: Apply lubricant 063002-043 to threads and mating
surfaces. Torque to 6.0 Nm (50 inch/lbs).
Step 3: Twist the braided pigtail in a clockwise direction to
tighten the braid and secure in place.
Step 4: Inspect the forward/reverse contactor tips for pitting.
Replace if necessary. See service manual section M4.4 for
inspection and replacement procedures.
Replace if signs
of pitting or corrosion
Inspect
are present
10291
Printed in U.S.A.
M4.2–14.0–402
 C MAINTENANCE

DISPLAY MODULE
RR, RS, RD (3000 Series Trucks)

The fault codes stored by the display module microproces- Messages which relate to SRO (static return to off) are
sor are displayed on the display module through the use of displayed to inform the operator why truck operation is not
the display switch. being permitted. SRO is control lockout due to switches
being operated in the wrong sequence i.e. direction selected
and traction requested before the truck is powered up.
FORKS
RR, RS, RD The message PWR is displayed when the power
ERS DPS
on pedal is not depressed and the truck is “powered up”. If the
power on pedal is depressed and this message is displayed,
check the adjustment and condition of DMS, wiring between
DMS and the traction control card, and the condition of the
traction control card.
PART OF
POWER UNIT RR, RS, RD The message BRAK is displayed when request-
ing traction and the power on pedal or brake pedal are not
RR, RS, RD depressed. If the power on pedal and brake pedal are
1856 ILLUSTRATION 4.2-2 depressed and this message is displayed, check the adjust-
ment and condition of DMS, adjustment and condition of
When the term “actuate” is used in this description, the BRS, wiring between DMS and the traction control card,
switch must be moved to the “on” position and held for at wiring between BRS and the traction control card, and the
least 1/4 of a second before it is released. This allows time condition of the traction control card.
for the system to “read” the switch closure. Likewise, the
switch must be released for at least 1/4 second before again
actuating.

With the keyswitch in the “off” position and the battery

connected, actuate the display switch. If no fault codes are
in memory, the message NONE will be displayed. If fault
codes are in memory, the code relating to the last fault that
occurred will be displayed. Each time the display switch is
actuated the next fault back from the last will be displayed
and so on until all codes in memory have been displayed.
After the last code is displayed, and the display switch is
again actuated, the message CLR? will be displayed. If it is
desired to erase the codes in memory, actuate the erase
switch next to the display switch. All codes in the display
memory will be erased.

Crown 1994 PF10467-4 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–403 M4.2–14.0–403
 C MAINTENANCE

PCZ-9 PCZ-8

WHT/BLUE
BLUE
TB TERMINALS 1-6
CONTROL CARD

JCA JCB JCY JCZ

WHT/VIO
PCZ-12
PCZ-13
VIOLET
BLACK
PCZ-1 5 REC
PCZ-5
GRAY
TP 23 FIL 24 FIL WHITE
PCZ-7
25 WHT/RED PCZ-10
REC 22 REC
CAPACITOR (1C) PCZ-11
RED

W
HT
CATHODE 2 REC

/
BL
ANODE

K
T2 1 REC T5
T4
N
OW

ET
HEAT SINK VIOL T3
BR

3 REC
ORANGE
PCZ-14
WHT/GRN

REACTOR/CHOKE (1X)

A2 4 REC

BATTERY
NEGATIVE
CURRENT SENSOR

BATTERY
YELLOW

BROWN
GREEN

A1
POSITIVE TWISTED PAIR

PCZ-4 PCZ-2
PCZ-3
TWISTED PAIR WITH THIRD
WIRE WRAPPED AROUND

0305S-01
PICTORIAL WIRING DIAGRAM

Crown 1994 PF10467-5 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–404 M4.2–14.0–404
 C MAINTENANCE

Monitoring Circuitry

The EV100 traction control system monitors various switches of a truck, which relate operator action, and accepts a speed
control signal. These truck monitors are inputs to the control card at screw terminals which are designated as TB11. The
following charts and schematics list the signal name for each input and provides a schematic to show the switches between
the battery and input point. Use this information when the Probable Cause under a status code directs to check the input
signal.
BATTERY BATTERY
NEGATIVE POSITIVE

KYS
(Key)
RC, RC 3000 CIRCUIT MONITOR

Input Signal RES23 TB11-4

Terminal Description STS
TB11-3 (Steer ing)
TB11-1 Accelerator TB11-1
FREE LIFT
TB11-2 Brake LIMIT
ACCELERATOR
TB11-3 Seat or Floorboard SWITCH EV100 LX
LMS1 CONTR OL
TB11-4 Keyswitch CARD
BRS-3
(Park)
TB11-5 Forward
TB11-2
TB11-6 Reverse
RC 3000 TRUCKS FS
(Forward)
WITH ENTRY BAR TB11-5
(MANUFACTURED RS
AFTER 2/1/98) (Reverse)
ONLY TB11-6

6272

BATTERY BATTERY
NEGATIVE POSITIVE

KYS
SES (Key)
(Seat)
SC CIRCUIT MONITOR K2

Input Signal TB11-4

Terminal Description
K2-B
TB11-3
TB11-1 Accelerator TB11-1 BRS ORS
TB11-2 Brake ACCELERATOR (Park) (Override)
TB11-3 Seat or Floorboard EV100 LX
TB11-4 Keyswitch CONTROL ACS
CARD (Accel.)
TB11-5 Forward
TB11-2
TB11-6 Reverse
FS
(Forward)
TB11-5
RS
(Reverse)
TB11-6

1316

Crown 1994 PF10467-6 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–405 M4.2–14.0–405
 C MAINTENANCE

BATTERY BATTERY
NEGATIVE POSITIVE

KYS
(Key)
RR, RS, RD CIRCUIT MONITOR
(Pre 3000 Series Trucks)
TB11-4
Input Signal STS
Terminal Description TB11-3 (Steering)

TB11-1 BRS-2
TB11-1 Accelerator ACCELERATOR (Park)
TB11-2 Brake EV100 LX
TB11-3 Seat or Floorboard CONTROL
CARD BRS-1
TB11-4 Keyswitch (Linkage)
TB11-2
TB11-5 Forward
TB11-6 Reverse FS
(Forward)
TB11-5
RS
(Reverse)
TB11-6
1317

BATTERY BATTERY
NEGATIVE POSITIVE

KYS
RR, RS, RD CIRCUIT MONITOR (Key)
(3000 Series Trucks)

Input Signal TB11-4

Terminal Description
TB11-3 DMS
(Floorboard)
TB11-1 Accelerator TB11-1
TB11-2 Brake ACCELERATOR BMS
TB11-3 Seat or Floorboard EV100 LX (Linkage)
CONTROL
TB11-4 Keyswitch CARD BRS
TB11-5 Forward (Pedal)
TB11-2
TB11-6 Reverse
FS
(Forward)
TB11-5
RS
(Reverse)
TB11-6
1897

Crown 1994 PF10467-7 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–406 M4.2–14.0–406
 C MAINTENANCE

This status code is displayed when input voltage to the control card and/or display STATUS CODE
unit is not present. BLANK DISPLAY
Symptom: Blank display screen.

Possible Cause:

- Positive or negative control volts missing.

• Make certain keyswitch has been cycled from “off” to “start” to “on”. Battery volts should be present at TB11-4 and
PCZ-7 using PCZ-3 for negative.

- Open circuit between traction control card plug PCY and display.

• Check for open circuit or loose connections between each wire going between traction control card plug PCY and
display.

- Defective display.

• Replace

STATUS CODE
This status code is displayed when TB11-3 is less than 50% of battery volts.
SEAT or
Symptom: Forward or reverse contactor will not energize.
PWR or
Possible Cause:
01
- Operator left truck with direction control not in neutral.

• Set direction control to neutral.

- Check input signal to TB11-3 on control card.

Crown 1994 PF10467-8 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–407 M4.2–14.0–407
 C MAINTENANCE

This status code is displayed when TB11-5 is greater than 60% battery volts at STATUS CODE
initial power up.
DIR or 02
Symptom: Forward contactor will not energize. Static return to off (SRO) lock out.

Possible Cause

- Direction control in forward at power up.

• Set direction control to neutral.

- Input signal present at TB11-5 at power up.

• Check for short circuit to TB11-5.

- Defective card.

• Replace.

This status code is displayed when TB11-6 is greater than 60% battery volts at STATUS CODE
initial power up. DIR or 03
Symptom: Reverse contactor will not energize. Static return to off (SRO) lock out.

Possible Cause

- Direction control in reverse at power up.

• Set direction control to neutral.

- Input signal present at TB11-6 at power up.

• Check for short circuit to TB11-6.

- Defective card.

• Replace.

Crown 1994 PF10467-9 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–408 M4.2–14.0–408
 C MAINTENANCE

This status code is displayed when voltage at TB11-2 is less than 60% of battery STATUS CODE
volts at initial start-up. DIR or 04
Symptom: Forward or reverse contactor will not pick-up.

Possible Cause

- Direction control not in neutral at power up. Request traction. Status code display should change to 02 if forward travel
selected and 03 if reverse travel selected.

• Use proper sequence for operating controls.

• Input signal to TB11-2 present at power up.

This status code is displayed when TB11-1 is less than 2.5 volts and TB11-2 is STATUS CODE
less than 60% of battery volts at the same time. BRAK or 05
Symptom: Forward or reverse contactor will not energize.

Possible Cause

- Traction speed control signal present at TB11-1 before input signal to TB11-2 present.

• Check input signal to TB11-2.

• Check input signal to TB11-1.

Crown 1994 PF10467-10 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–409 M4.2–14.0–409
 C MAINTENANCE

This status code is displayed when TB11-5 or TB11-6 are less than 60% of STATUS CODE
battery volts and TB11-1 is less than 2.5 volts. DIR or 06
Symptom: Forward or reverse contactor will not energize.

Possible Cause

- Traction speed control signal present at TB11-1 before input signal present at TB11-5 (forward) or TB11-6 (reverse).

• Select direction before requesting traction.

• Check input signals to TB11-5 and TB11-6.

• Check input signal to TB11-1.

This status code is displayed when the accelerator input voltage at TB11-1 is STATUS CODE
higher than 3.7 volts when a directional contactor is energized. 07
NOTE The code will only be displayed when attempting travel in one direction. When opposite direction is selected, code
will disappear.

Symptom: Forward or reverse contactor energize but control does not operate when speed command is increased or status
code is displayed until the truck starts to accelerate.

Possible Cause

- Accelerator control associated wiring short or open circuited. Check signal path for TB11-1.

- Accelerator control defective.

• Accelerator input at TB11-1 should be 3.7 volts with the key “on” and the accelerator released. As speed request is
increased, voltage should decrease smoothly to .5 volts with top speed requested. Repair or replace accelerator
control.

Crown 1994 PF10467-11 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–410 M4.2–14.0–410
 C MAINTENANCE

This status code is displayed when the accelerator input voltage at TB11-1 is STATUS CODE
less than 3.0 volts when any of the following inputs are interrupted; TB11-4,
TB11-3 or TB11-2.
ACCEL or 08
Symptom: Forward or reverse contactor does not energize.

Possible Cause

- With no speed command from the accelerator, voltage at TB11-1 should be greater than 3.0 volts.

• Check adjustment of accelerator control and associated wiring.

- Input signal interruption to TB11-4, TB11-3 and/or TB11-2.

• Check adjustment of switches in the above signal input lines and associated wiring.

Crown 1994 PF10467-12 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–411 M4.2–14.0–411
 C MAINTENANCE

This status code will be displayed when TB11-5 and TB11-6 are greater than STATUS CODE
60% of battery volts at the same time.
09
Symptom: Forward or reverse contactor will not energize.

Possible Cause

- Forward and/or reverse switch contact welded or associated wiring short circuited.

• With directional control in the neutral position, check forward and reverse switch contacts for short circuits. Check
associated wiring for short circuits.

This status code is displayed when the battery volts are less than 1.95 volts per STATUS CODE
cell at initial start up. 15
Symptom: Forward or reverse contactor will not energize.

Possible Cause

- Insufficient battery charge.

• Check battery state of charge and overall condition. Take corrective action if necessary.

- Incorrect control card setting.

• If control card was just installed, make certain Function 15 of control card tune up is set correctly. Refer to tune up
section (M4.2) for correct value.

Crown 1994 PF10467-13 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–412 M4.2–14.0–412
 C MAINTENANCE

This status code is displayed when the battery volts are greater than 2.40 volts STATUS CODE
per cell at initial start up. 16
Symptom: Forward or reverse contactor will not energize.

Possible Cause

- Battery overcharged or incorrect battery installed.

• Check battery state-of-charge and take corrective action if necessary.

- Incorrect control card setting.

• If control card was just installed, make certain Function 15 of control card tune up is set correctly. Refer to tune up
section (M4.2) for correct value.

- Open circuit in regenerative braking sensor circuit.

• Check for broken yellow wire between regenerative braking sensor and control card plug PCA.

• Check condition of contact in position 4 of plug PCA.

• Check wire connections to regenerative braking sensor.

This status code is displayed when the control card type selection value is set to STATUS CODE
an invalid number. 17
Symptom: Forward or reverse contactors will not energize.

Possible Cause

- Invalid card type selection made during new control card tune up.

• Make certain Function 17 of control card tune up is set correctly. Refer to tune up section (M4.2) for correct value.

Crown 1994 PF10467-14 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–413 M4.2–14.0–413
 C MAINTENANCE

This status code is displayed when the current draw in the forward or reverse STATUS CODE
contactor coil circuit is less than 100 ma. 23
Symptom: Forward or reverse contactor will not energize. Status code may alternate between status code 23 and status
code 24. Complete check for status code 23 and if the problem is not found, perform checks for status code 24.

Possible Cause

- Open circuit in forward or reverse contactor coil circuit.

• Check wiring and connections between control card plug PCB position 4 and positive side of forward contactor coil.
Resistance of this circuit should be between 10 and 14 ohms.

• Check wiring and connections between control card plug PCB position 5 and positive side of reverse contactor coil.
Resistance of this circuit should be between 10 and 14 ohms.

- Open circuit in 1A,RB, SP, or FW contactor coil circuit.

• Disconnect plug PCB from control card and check resistance between positive side of contactor coils and plug PCB.
Resistance should be between 10 and 14 ohms. Plug PCB position 6 for the 1A contactor, position 2 for the
regenerative braking contactor, position 3 for the steering pump contactor and position 1 for the field weakening
contactor.

Refer to status codes, page M4.2-14.0-402 for additional information.

This status code is displayed when T2 volts is greater than 12% of battery volts STATUS CODE
and the forward and reverse driver is enabled. 24
Symptom: SCR control does not operate. Status code display may alternate between status code 23 and status code 24.
Complete check for status code 24 and if the problem is not found, perform checks for status code 23.

Possible Cause

- Forward or reverse contactor normally open tips do not close.

• Check for welded contactor normally closed contacts.

• Check for binding in contactor assembly.

• Make status code 23 checks.

- RB contactor failure.

• Check contactor for binding parts.

• Disconnect plug PCB from control card and check resistance between positive side of contactor coil and plug PCB
position 2. Resistance should be between 10 and 14 ohms.

- Open motor circuit.

• Check for loose connection or open circuit in motor circuit between terminals A1 and A2 on SCR panel.

Refer to status codes, page M4.2-14.0-402 for additional information.

Crown 1994 PF10467-15 Rev. 8/03 Printed in U.S.A.
03 REV. 8/03
M4.2–14.0–414 M4.2–14.0–414
 C MAINTENANCE

STATUS CODE
This status code is displayed when 1A contactor drop out time exceeds .060
seconds.
25
Symptom: Short tip life on forward and reverse or 1A contactor. Status code 46 displayed and no fault found.

Possible Cause

NOTE: This status code is a troubleshooting aid for status code 46.

- 1A contactor not functioning properly.

• Check 1A contactor for binding. Contactor must operate freely.

• Check 1A contactor return spring condition.

STATUS CODE
This status code is displayed when a shorted RB, SP or FW coil driver is present 26
in the control card.

Symptom: RB, SP or FW contactor energizes immediately when keyswitch is closed.

Possible Cause

- Defective coil driver internal to control card.

• Replace control card.

Crown 1994 PF10467-16 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–415 M4.2–14.0–415
 C MAINTENANCE

STATUS CODE
This status code is displayed when voltage between PCZ-1 and PCZ-5 is greater
than 1.8 volts.
41
Symptom: Reduced or no power to traction control in SCR range.

Possible Cause

- Open circuit in thermal protector circuit.

• Check for loose connection or broken black wire between the thermal protector and control card plug PCZ-1.

• Check for loose connection or broken gray wire between the thermal protector and control card plug PCZ-5.

- Thermal protector defective.

• Disconnect plug PCZ from control card. With thermal protector at room temperature (75° F / 25° C), check resistance
between plug positions 1 and 5. Replace thermal protector if resistance value is greater than 300 ohms.

- SCR control operating is thermal cutback.

• Allow control to cool.

STATUS CODE
This status code is displayed when voltage between plug PCZ-4 and battery 42
negative is greater than 1.6 volts with no current flowing in the motor circuit.

Symptom: No power to traction motor in SCR range.

Possible Cause

- SCR motor current sensor input missing.

• Check for broken green wire between current sensor and control card plug PCZ-4.

• Check condition of contact in plug PCZ position 4.

Refer to status codes, page M4.2-14.0-402 for additional information.

Crown 1994 PF10467-17 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–416 M4.2–14.0–416
 C MAINTENANCE

This status code is displayed when voltage between PCZ-4 and battery negative STATUS CODE
is less than .84 volts with no current flowing in motor circuit. 43
Possible Cause

- SCR motor current sensor input missing.

• Check for broken yellow wire between current sensor and control card plug PCZ-3.

• Check condition of contact in plug PCZ position 3.

This status code is displayed when, during SCR operation, 1 REC fails to turn off. STATUS CODE
44
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- Defective 5 REC circuit.

• Check for shorted 5 REC.

• Check for shorted 5 REC snubber (25 REC).

- Defective 2 REC circuit.

• Check for shorted 2 REC.

• Check for shorted 2 REC snubber (22 REC).

-1X choke open circuit.

• Check for open circuit between terminals T5 and T3 of reactor/choke. Resistance reading should be near zero ohms.

- Defective 1 REC.

• Turn off time for 1 REC out of specification. No field test is reliable. Replace 1 REC after above checks show no
problem found.
Crown 1994 PF10467-18 Rev. 8/03 Printed in U.S.A.
03 REV. 8/03
M4.2–14.0–417 M4.2–14.0–417
 C MAINTENANCE

This status code is displayed when 1 REC fails to gate on. STATUS CODE
45
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

- Defective 2 REC circuit.

• Check for shorted 2 REC.

• Check for shorted 2 REC snubber (22 REC).

- Defective 1 REC circuit.

• Check for open circuit or loose connections of white stripe/blue wire between 1 REC and control card plug PCZ
position 8.

• Check condition of contact in plug PCZ position 8.

• Check for open circuit or loose connection of blue wire between 1 REC and control card plug PCZ position 9.

• Check condition of contact in plug PCZ position 9.

- Defective 1 REC.

• Intermittent or open 1 REC gate. Field test may not show defect. Replace 1 REC after above checks show no problem
found.

This status code is displayed when the voltage at T2 is greater than 85% of STATUS CODE
battery volts during the look ahead test. 46
Symptom: Forward or reverse contactor will not energize.

Possible Cause

- Defective 1 REC

• Check for shorted 1 REC.

• Check for defective 1 REC insulator that may allow short circuit between 1 REC heat sink and base plate.

- Defective 1A contactor.

• Check for welded 1A contactor tips.

• Check for shorted 1A contactor tips.

- Use handset and access function 1. If status code 25 or 125 is displayed, proceed that status code and perform checks
listed.

Refer to status codes, page M4.2-14.0-402 for additional information.

Crown 1994 PF10467-19 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–418 M4.2–14.0–418
 C MAINTENANCE

This status code is displayed when the 2 REC fails to turn on. STATUS CODE
47
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- Defective 2 REC circuit.

• Check that 2 REC will gate on.

• Check for open circuit or loose connection in white stripe/red wire between 2 REC gate and control card plug PCZ
position 10

• Check for open circuit or loose connection between 1 REC and 1C in the 2 REC circuit.

- Forward or reverse contactor tips bouncing open.

• Check condition of forward and reverse contactors.

This status code is displayed when the voltage at T2 is less than 12% of battery STATUS CODE
volts during the look ahead test. 48
Symptom: Forward or reverse contactor will not energize.

Possible Cause

- Defective forward or reverse contactor.

• Check for welded forward or reverse contact tips.

• Check condition of forward and reverse contactors. Sluggish operation will cause this status code.

- Defective 3 REC circuit.

• Check for shorted 3 REC.

• Check for shorted 3 REC snubber (23 REC).

Crown 1994 PF10467-20 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–419 M4.2–14.0–419
 C MAINTENANCE

This status code is displayed when the 5 REC fails to turn on. STATUS CODE
49
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- Defective 5 REC circuit.

• Check that 5 REC will gate on.

• Check for shorted 5 REC.

• Check for shorted 5 REC snubber (25 REC).

• Check for open circuit or loose connection of white stripe/ violet wire between 5 REC gate and control card plug PCZ
position 12.

- Shorted 2 REC circuit.

• Check for shorted 2 REC.

• Check for shorted 2 REC snubber (22 REC).

- Defective capacitor 1C circuit.

• Check for loose connections at capacitor terminals.

• Check capacitor 1C for open circuit.With meter an the R x 10,000 ohm scale, Measure resistance through the
capacitor. Meter should indicate zero ohms, then swing slowly to above 100,000 ohms. Replace capacitor if this
action is not obtained.

Crown 1994 PF10467-21 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–420 M4.2–14.0–420
 C MAINTENANCE

This status code is displayed when 2 REC circuit fails to turn on at initial start up. STATUS CODE
Capacitor 1C volts too low. 50
Symptom: Forward or reverse contactor energizes. Control does not operate.

Possible Cause

- Defective 2 REC circuit.

• Check for open circuit or loose connection on bus bar between spider assembly and 5 REC.

• Check for open circuit or loose connection on bus bar between 5 REC and 2 REC.

• Check for open circuit or loose connection on red wire between 2 REC and control card plug PCZ position 11.

• Check for open circuit or loose connection on white stripe/red wire between 2 REC and control card plug PCZ position
10.

• Check 2 REC ability to gate on.

This status code is displayed when capacitor volts exceed 225 volts and motor STATUS CODE
current is greater than 300 amps. 51
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- Excessive source inductance.

• Electronic equipment added to truck electrical system without proper filtering being used.

• If battery cables were replaced, length of cables may be excessive.

- High peak current in motor.

• Check motor for shorted field winding.

• Check motor for shorted armature winding.

Crown 1994 PF10467-22 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–421 M4.2–14.0–421
 C MAINTENANCE

This status code is displayed when capacitor volts exceed 225 volts and motor STATUS CODE
current is less than 200 amps. 52
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- Excessive source inductance.

• Electronic equipment added to truck electrical system without proper filtering being used.

• If battery cables were replaced, length of cables may be excessive.

- Defective 4 REC circuit.

• Check for shorted 4 REC.

• Check for open circuit or loose connection in 4 REC circuit.

- Defective 3 REC circuit.

• Check for open circuit or loose connection in 3 REC circuit.

Refer to status codes, page M4.2-14.0-402 for additional information.

Crown 1994 PF10467-23 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–422 M4.2–14.0–422
 C MAINTENANCE

This status code is displayed when 1 REC fails to turn off during plug cycle. STATUS CODE
53
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- 1 REC turn off failure not related to plugging.

• Stall vehicle in both directions for no more than 3 seconds at a time and allow motor to cool between stalls. Note any
status codes displayed that may more closely define the failure. Troubleshoot for the new status code.

- Defective plugging circuit.

• Check 4 REC for open circuit.

• Check 4 REC circuit for loose or open bus bar and cable connections.

• Check current sensor power circuit for loose or open connections.

• Check yellow wire between current sensor and control card plug PCZ position 3 for open circuit and loose
connections.

• Check green wire between current sensor and control card plug position 4 for open circuit and loose connections.

- Defective motor circuit.

• Check motor circuit for open or loose connections.

• Check motor brushes for proper seating.

- Forward or reverse contactor tips bouncing open.

• Check condition of forward and reverse contactors.

Refer to status codes, page M4.2-14.0-402 for additional information.

Crown 1994 PF10467-24 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–423 M4.2–14.0–423
 C MAINTENANCE

This status code is displayed when the forward, reverse or 1A contactor coil STATUS CODE
driver is short circuited internal to the control card. 54
Symptom: Control will not operate.

Possible Cause

- Defective control card.

• Replace.

This status code is displayed when the voltage input to control card plug PCZ STATUS CODE
positions 3 and 4 are wrong polarity. 57
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- Current sensor wires reversed in plug PCZ.

• Check that green wire from current sensor is in position 4 of control card plug PCZ.

• Check that yellow wire from current sensor is in position 3 of control card plug PCZ.

- Power cables reversed.

• Make certain battery negative cable connects to SCR NEG terminal of SCR panel.

• Make certain motor A2 cable connects to the SCR A2 terminal of SCR panel.

Crown 1994 PF10467-25 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–424 M4.2–14.0–424
 C MAINTENANCE

This status code is displayed when regenerative braking current sensor input STATUS CODE
signal at PCA-4 (yellow wire) is missing. 70
Symptom: Control does not operate.

Possible Cause

- Defective regenerative braking sensor input circuit.

• Check yellow wire between current sensor and control card connector PCA position 4 for loose connections and open
circuit.

• Check condition of contact in connector PCA position 4.

This status code is displayed when regenerative braking current sensor input STATUS CODE
signal at PCA-5 (green wire) is missing. 71
Symptom: Control does not operate.

Possible Cause

- Defective regenerative braking sensor input circuit.

• Check green wire between current sensor and control card connector PCA position 5 for loose connections and open
circuit.

• Check condition of contact in connector PCA position 5.

Crown 1994 PF10467-26 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–425 M4.2–14.0–425
 C MAINTENANCE

This status code is displayed when traction control card is in the normal opera- STATUS CODE
tion mode and 2.5 volts or greater is present at control card connector PCA-6.
72
Symptom: Regenerative braking contactor (RB) does not energize.

Possible Cause

- Loss of input to traction control card plug PCA-6.

• Check for open circuit or loose connection between traction control card plug PCA position 6 and the A2 connection
of the RB contactor.

• Check for open circuit or loose connection between 7 REC and the A2 connection of the RB contactor.

This status code is displayed when the RB contactor tips do no open after 100 STATUS CODE
milliseconds after power is removed from the RB contactor coil. 73
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- Defective RB contactor.

• Check RB contactor for binding and excessive wear .

- Intermittent input at traction control card plug PCA position 6.

• Check for loose connections in the circuit between the traction control card plug PCA-6 and the A2 connection of the
RB contactor.

• Check condition of contact in plug PCA position 6.

Crown 1994 PF10467-27 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–426 M4.2–14.0–426
 C MAINTENANCE

This status code is displayed when the regenerative braking (RB) contactor tips STATUS CODE
do not close within 100 milliseconds after power is applied to the RB contactor
coil.
74
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- Defective RB contactor.

• Check RB contactor for binding and excessive wear .

- Intermittent input at traction control card plug PCA position 6.

• Check for loose connections in the circuit between the traction control card plug PCA-6 and the A2 connection of the
RB contactor.

• Check condition of contact in plug PCA position 6.

- Defective RB contactor coil circuit.

• Check resistance of RB contactor coil (10 - 14 ohms).

• Check wiring between coil negative terminal and traction control card plug PCB position 2 for open circuits and loose
connections.

• Check wiring between coil positive terminal and battery positive for open circuits and loose connections.

Crown 1994 PF10467-28 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–427 M4.2–14.0–427
 C MAINTENANCE

This status code is displayed when 1 REC does not turn off during the regenera- STATUS CODE
tive braking cycle. 75
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- 1 REC not turning off unrelated to regenerative braking.

• Stall vehicle in both directions for no more than 3 seconds at a time and allow motor to cool between stalls. Note any
status codes displayed that may more closely define the failure. Troubleshoot for the new status code.

- 1 REC turn off related to regenerative braking.

• Check for loose connections on regenerative braking power circuits from battery positive to the RB contactor A2
connection.

• Check yellow wire between RB current sensor and control card plug PCA position 4 for open circuit and loose
connections.

• Check green wire between RB current sensor and control card plug PCA position 5 for open circuit and loose
connections.

• Check control wire between RB contactor coil positive terminal and control card plug PCA position 6.

- Defective motor circuit.

• Check motor circuit for open or loose connections.

• Check motor brushes for proper seating.

- Forward or reverse contactor tips bouncing open.

• Check condition of forward and reverse contactors.

Crown 1994 PF10467-29 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–428 M4.2–14.0–428
 C MAINTENANCE

This status code is displayed when capacitor voltage is greater than 225 volts STATUS CODE
during the regenerative braking cycle. 76
Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip).

Possible Cause

- Intermittent connection in battery circuit.

• Check for loose connections in battery circuit between the battery and the SCR panel.

- Excessive source inductance.

• Electronic equipment added to truck electrical system without proper filtering being used.

• If battery cables were replaced, length of cables may be excessive.

Not Used. Reserved for pump motor temperature sensor. STATUS CODE
90

Crown 1994 PF10467-30 Rev. 8/803 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–429 M4.2–14.0–429
 C MAINTENANCE

Not Used. Reserved for power steering pump motor temperature sensor. STATUS CODE
91

This status code is displayed when voltage at terminal 4 of Truck Management STATUS CODE
Module (TMM) is zero volts. 92
Symptom: Status code flashes on and off.

Possible Cause

- Traction motor temperature high.

• Any condition which will cause the motor to draw excessive current will increase the operating temperature. Check
mechanical condition of motor, drive unit, brakes etc. Check motor armature and field windings for short circuits.

- Traction motor temperature normal.

• Terminal 4 of TMM short circuited to battery negative.

• Thermostat on traction motor shorted.

• Defective TMM control card.

Crown 1994 PF10467-31 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–430 M4.2–14.0–430
 C MAINTENANCE

Not Used. Reserved for pump motor brush wear indicator. STATUS CODE
93

Not Used. Reserved for power steering pump motor brush wear indicator. STATUS CODE
94

Crown 1994 PF10467-32 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–431 M4.2–14.0–431
 C MAINTENANCE

This status code is displayed when voltage at terminal 11 or 12 of Truck Manage- STATUS CODE
ment Module (TMM) is zero volts. 95
Symptom: Status code flashes on and off.

Possible Cause

- Brushes of traction motor worn to sensors.

• Replace brushes.

- Brushes of traction motor are not worn to sensors.

• Terminal 11 or 12 of TMM short circuited to battery negative.

• Sensor wire in brush short circuited to battery negative.

• Defective TMM control card.

Crown 1994 PF10467-33 Rev. 8/03 Printed in U.S.A.

03 REV. 8/03
M4.2–14.0–432 M4.2–14.0–432