Crown ESR Fault Code List

Fault Codes

The ESR 5000 is fitted with an electronic control system for the key operating functions.

Malfunctions with event code display

Event codes are produced from tests carried out on the inputs and outputs of control signals. For most faults

the system generates an event code and stores it in the

log book. The last 16 events are displayed in the Log Events Menu.

Log book display

Malfunctions without event code display

The malfunctions that can occur without providing an event code can fall into one of three categories.

Malfunction during start-up

Malfunctions in the power-up circuit can keep the truckfrom powering up correctly (refer to the Power up circuit diagram).

Mechanical or hydraulic malfunctions

The malfunction occurs after the truck has started up, but without an event code display.

The fault is mechanical or hydraulic. The corresponding section in the maintenance section of this manualcan be used for troubleshooting purposes.

Malfunction in one of a group of unmonitored

inputs

One of the unmonitored inputs is causing the malfunction. They include:

• HNS (Horn switch)

• HGTS (Height switch)

• HGTRS (Height reset switch)

• BPS (Brake pressure switch)

• ORS (Override switch)

• PLS (Pressure load switch)

Locating malfunctions

Malfunctions occur primarily on external components such as fuses, solenoids, contactors, motors etc.

These components are necessarily subject to a certain degree of wear.

The next possible causes include connectors, wiring and input devices such as switches, potentiometers or

encoders. These are subject above all to ambient conditions.

The least likely to fail are the VCM (main module), TCM (traction module), HCM (hydraulic module) and SCM

(steer module) control modules.

The easiest way of locating a fault is to start troubleshooting on the component (the external component).

This is the quickest way of obtaining a result.

The following sections list the event code numbers in ascending order. In addition to each event code they

also list the possible causes, the effect on the truck and troubleshooting notes.

Codes 100 - 186

Event Code 100

Display: OVER CURRENT SDM

Explanation: Current in power part of steer module (SCM) > 40 A.

Effect: • Parking brake applied

• Traction module deactivated

• Main contactor ED1 de-energised

Possible Causes: • Error in internal power circuit of steer module

Remedy: Restart

1. Restart the truck.

 If the fault persists, proceed to step 2.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the steer module

Event Code 101

Display: HIGH CURRENT SDM

Explanation: Current in power part of steer module (SCM) > 27 A and < 40 A.

Effect: • Parking brake applied

• Traction module deactivated

• Main contactor ED1 de-energised

Possible Causes: • Error in internal power circuit of steer module

Remedy: Restart

1. Restart the truck.

 If the fault persists, proceed to step 2.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the steer module

Event Code 102

Display: ERROR STEER MOT.

Explanation: Open or shorted steer motor power circuit.

Effect: • Parking brake applied.

• Traction module deactivated

• Main contactor ED1 de-energised

Possible Causes: • Open circuit in or short circuit between phases R, S or T

Remedy: 1. Check power cables and connections.

2. Assess motor. Replace if faulty.

Event Code 110

Display: HIGH VOLTAGE SDM

Explanation: Overvoltage (> 63 V) in steer module power circuit.

Effect: • Parking brake applied

• Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

Possible Causes: • Emergency Disconnect pressed during plugging operation

• Error in steer module

Remedy: Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Event Code 111

Display: LOW VOLTAGE SDM

Explanation: Low voltage (< 24 V) in steer module power circuit.

Effect: • Parking brake applied

• Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

Possible Causes: • Emergency Disconnect pressed during plugging operation

• Error in steer module

Remedy: Check power cables

1. Check power cables.

 If there is no damage, proceed to step 2.

Check battery voltage with load

2. In the Analyzer menu select item A2.36.

3. Raise a heavy load and monitor the battery voltage during the lifting

operation.

 If the battery voltage drops significantly, proceed to step 4.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Repair the battery

4. Repair the battery in accordance with the manufacturers instructions or

replace it.

Event Code 112

Display: 15 VOLT SUPPLY SDM

Explanation: • 15 V supply in the steer module faulty

Effect: • Parking brake applied

• Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

Possible Causes: • Error in steer module

Remedy: 1. Replace the steer module.

Event Code 120

Display: OVER TEMP SDM

Explanation: Steer module overtemperature (t > 85 °C).

Effect: • Parking brake applied

• Traction module deactivated

• Main contactor ED1 de-energised

Possible Causes: • Steer module ventilation affected by:

– Excessive ambient temperature

– Overload

– Contamination

• Malfunction in power part of steer module

Remedy: Check application conditions and check for contamination

1. Check the application conditions with regard to ambient temperature and

load.

 If the application conditions are difficult, adapt the performance setting.

2. Check the steer module for contamination.

 Clean the steer module if contaminated.

Check the current consumption

3. Select item A2.32 in the Analyzer menu and check the steer motor con-

sumption when stationary and for slow steer operations.

 If the consumption is consistently > 18 A there may be a mechanical

problem with the gear unit of the steer motor or with the drive transmis-

sion.

4. Jack up the truck and check the steer motor consumption again.

 If the consumption is consistently > 6 A there may be a mechanical

problem with the gear unit of the steer motor or with the steering head

bearing.

Check for mechanical sluggishness

5. Check the steer motor gear unit and the steering head bearing for mechan-

ical sluggishness.

 If one of them is sluggish, replace or repair the corresponding compo-

nent.

Check the steer motor and steer module

6. Check the current consumption with the steer motor and steering bearing

head installed.

 If the consumption is still too high with the steer motor and steering

bearing head installed, the steer motor or steer module may be faulty.

Proceed to step 9.

Replace the steer module (SCM)

7. Replace the steer module (see page 259).

8. Check the current consumption with the steer motor and steering bearing

head installed.

Replace the steer motor

9. Replace the steer motor.

10. Check the current consumption with the steer motor installed.

 If the consumption is still too high with the steer motor installed, the

steer module may be faulty. Proceed to step 7.

 If the consumption is still too high, contact the Crown service department.

Event Code 121

Display: HIGH TEMP SDM

Explanation: Steer module internal temperature is > 75 °C.

Effect: • The display shows: HIGHTEMP STEERING MOTOR

Possible Causes: See event code 120, page 174.

Remedy: See event code 120, page 174.

Event Code 123

Display: OVER TEMP SMOT

Explanation: Steer motor coil temperature is > 150 °C.

Effect: • Parking brake applied

• Traction module deactivated

• Main contactor ED1 de-energised

Possible Causes: See event code 120, page 174.

Remedy: See event code 120, page 174.

Event Code 124

Display: OVER TEMP SMOT

Explanation: Steer motor overtemperature (t > 125 °C).

Effect: The display shows: HIGHTEMP STEERING MOTOR

Event Code 130

Display: ERROR CANBUS SDM

Explanation: Communication error on the CAN Bus between the main module (VCM) and

the steer module (SCM).

Effect: • Main contactor ED1 de-energised

Possible Causes: • Wiring error

• Error in main module (VCM)

• Error in steer module (SCM)

Remedy: Measure the load resistance of the CAN Bus wiring between the main

module and the steer module

1. Measure the resistance between PC416-1 and -2.

 If the resistance is 60 Ω, the main and steer modules are ok.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 173). If the event occurs frequently, contact the Crown

service department.

 If the resistance is 120 Ω, then either the main module or steer module

is faulty. Proceed to step 2.

Measure the load resistance in the main module (VCM)

2. Disconnect PC205 from the main module.

3. Measure the resistance on the main module between PC205-22 and -23.

 If the resistance is 120 Ω, the main module is ok. Proceed to step 5:

 If a different reading is obtained, the main module is faulty.

4. Replace the main module.

Measure the load resistance in the steer module (SCM)

5. Disconnect PC20 from the steer module.'

6. Measure the resistance on the steer module between PC205-10 and -11.

 If the resistance is 120 Ω, the steer module is ok.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

 If a different reading is obtained, the main module is faulty.

Replace the steer module (SCM)

Event Code 131

Display: ERROR EEPROM SDM

Explanation: Malfunction in memory module of steer module.

Effect: • No direct effect

Possible Causes: • Error in steer module

Remedy: Restart

1. Restart the truck.

 If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the

Crown service department.

 If the truck does not work, proceed to step 2.

Replace the steer module (SCM)

Event Code 160

Display: BRAKE COIL

Explanation: Open circuit or excessive current on steer module output to parking brake.

Effect: • Truck comes to rest through plugging.

• Traction module deactivated

• Main contactor ED1 de-energised

Possible Causes: • Fuse FU3 faulty

• Wiring or connector damaged

• Brake coil faulty

Remedy: Check fuse FU3

1. Check fuse FU3.

 Replace if faulty. If the fuse is ok, proceed to step 2.

Check wires and connections

2. Check wires and connections for discontinuity and short circuits.

 If there is no damage, proceed to step 3.

Measure the brake coil resistance

3. Using an ohmmeter measure the brake coil resistance.

 Rated resistance approx. 32 Ω (Crown motor) or 46.6 Ω (Danaher mo-

tor). If the reading differs significantly, the brake coil is faulty. Proceed

to step 4.

Replace the brake coil

4. Replace the brake coil

Event Code 180

Display: ECR3 HALL SENSOR

Explanation: Error in encoder ECR3 of steer motor.

ECR3 is a 2-channel Hall sensor fitted in the steer motor. This event code is

generated if a channel is not correctly identified or if 2 channels are shorted.

Effect: • Parking brake applied

• Traction module deactivated

• Main contactor ED1 de-energised

Possible Causes: • Wiring or connectors damaged

• No +5 V supply

Remedy: Check wires and connections

1. Check wires and connections for discontinuity and short circuits.

 If there is no damage, proceed to step 3.

Check +5 V supply

2. Disconnect PC414.

3. Using a voltmeter measure the voltage between PC414-5 and -6 and be-

tween PC414-7 and -8.

 If there is a +5 V supply, proceed to step 4.

 If there is no +5 V supply, proceed to step 6.

4. Reconnect PC414.

5. Using a voltmeter measure the voltage between PC436-1 and -2.

 If there is a +5 V supply, proceed to step 7.

 If there is no +5 V supply, this indicates that a wire has been discon-

nected. Proceed to step 8.

Replace steer module

6. Replace the steer module .

Replace steer motor

7. Replace the steer module .

Repair wiring

8. Repair the wiring.

Event Code 181

Display: ECR4 STEPPER MOTOR

Explanation: Error in steer encoder ECR4 (fitted on steering wheel).

ECR4 is a 4-channel Hall sensor fitted in the steer motor. This event code is

generated if a channel is not correctly identified or if 2 channels are shorted.

Effect: • Parking brake applied

• Traction module deactivated

• Main contactor ED1 de-energised

Possible Causes: • Wiring or connectors damaged

• No +5 V supply

Remedy: Check wiring

9. Check the wiring between PC414 and CA204 for discontinuity and short

circuits.

 If the wiring is faulty, proceed to step 12.

 If the wiring is ok, proceed to step 10.

Check +5 V supply

10. Disconnect PC414.

11. Using a voltmeter measure the voltage between PC414-5 and -6 and be-

tween PC414-7 and -8.

 If there is no 5 V supply, proceed to step 13.

 If there is a +5 V supply, proceed to step 16.

Repair wiring

12. Repair the wiring.

Check +5 V output on the steer module

13. Disconnect CA204 from the steer module.

14. Measure the voltage between CA204-3 and -4.

 If there is a +5 V supply, proceed to step 16.

 If there is no 5 V supply, proceed to step 15

Replace the steer module

15. Replace the steer module (see page 259).

Replace sensor bearing ECR4

16. Replace sensor bearing ECR4.

Event Code 182

Display: SW1 OR 2 SW ERROR

Explanation: Switch signal of sensor switch SFS1 SA or SFS2 not detected.

The expected signal change did not occur when the drive wheel was turned.

Effect: • An error routine is started (see page 303).

Possible Causes: • Wiring or connector damaged

• Incorrect screw depth of sensor SFS1 SA or SFS2

• Sensor SFS1 SA or SFS2 faulty

• 12 V supply in display faulty

Remedy: Check wires and connections

1. Check wires and connections for discontinuity and short circuits.

 If there is no damage, proceed to step 2.

Check 12 V sensor supply

2. Using a voltmeter measure the voltage (rated +12 V DC) at the following

points:

– between CA203-14 and CA203-15 (with display connected)

– between PC439-A and PC439-B

– between PC438-1 and PC438-2

 If there is no voltage present at PC439, but there is at CA203, check the

wires for discontinuity.

 If there is a +12 V DC supply present on both connectors, proceed to

step 3.

Check sensor SFS1 SA

3. Set the drive wheel to the forward position.

4. Monitor the sensor LED while moving the drive wheel 20° to the left and to

the right. When moved to the left the LED should remain off and when

steered to the right it should be on.

 If there is no change, the sensor may be loose or require adjusting:

check the attachment and screw depth (see page 306).

5. If the attachment and screw depth are ok, remove the sensor and hold the

front against a metal surface.

 If the LED does not light up, replace the sensor (see page 306).

Replace the display

6. Replace the display

Event Code 183

Display: SFS2 SW EXPECTED

Explanation: Switch signal of sensor switch SFS2 not detected.

Quadrant recognition error.

Effect: • An error routine is started (see page 303)

Possible Causes: • Wiring or connector damaged

• Screw depth of sensor SFS2 incorrectly set

• Sensor SFS2 faulty

Remedy: Check wires and connections

1. Check wires and connections for discontinuity and short circuits.

 If there is no damage, proceed to step 2.

Check 12 V sensor supply

2. Using a voltmeter measure the voltage between CA203-14 and CA203-15

(on the display) and between PC438-1 and PC438-2: Rated

voltage +12 V DC.

 If there is no voltage at CA203, proceed to step 8.

 If there is no voltage present at PC438, but there is at CA203, proceed

to step 9.

 If there is a +12 V DC supply present on both connectors, proceed to

step 3.

Check sensor SFS2

3. Set the drive wheel to the forward position.

4. Monitor the sensor LED while moving the drive wheel more than 90° to the

right. When the wheel passes beyond 90° the LED should go out.

 If there is no change, the sensor may be loose or require adjusting.

Proceed to step 5.

 If the attachment and screw depth are ok, proceed to step 6.

Check the SFS2 attachment and screw depth

5. Check the attachment and screw depth (see page 306).

Test SFS2

6. Remove the sensor and connect it again.

7. Hold the front of the sensor against a metal surface.

 If the LED does not light up, replace the sensor (see page 306).

Replace the display

8. Replace the display (see page 259).

Check wiring

9. Check the wires for discontinuity.

Event Code 184

Display: START ERROR SDM

Explanation: Incorrect drive wheel position detected. The stored drive wheel position does

not match the current position.

Effect: • An error routine is started (see page 303)

Possible Causes: • Wiring or connector damaged

• Screw depth of sensor SFS1 SA incorrectly set

• Sensor SFS1 SA faulty

Remedy: Check wires and connections

1. Check wires and connections for discontinuity and short circuits.

 If there is no damage, proceed to step 2.

Check 12 V sensor supply

2. Using a voltmeter measure the voltage between CA203-14 and CA203-15

(on the display) and between PC439-A and PC439-B: Rated

voltage: +12 V DC.

 If there is no voltage supply at CA203, replace the display.

 If there is no voltage present at PC439, but there is at CA203, check the

wires for discontinuity.

 If there is a +12 V DC supply present on both connectors, proceed to

step 3.

Check sensor SFS1 SA

3. Set the drive wheel to the forward position.

4. Monitor the sensor LED while moving the drive wheel 20° to the left and to

the right. When moved to the left the LED should remain off and when

steered to the right it should be on.

 If there is no change, the sensor may be loose or require adjusting:

check the attachment and screw depth (see page 306).

5. If the attachment and screw depth are ok, remove the sensor and hold the

front against a metal surface.

 If the LED does not light up, replace the sensor

Event Code 186

Display: TEMP. SENSOR SMOT

Explanation: Short circuit or open circuit in control circuit of steer motor thermal sensor

THS3.

Effect: • Mast reach and lowering only

• Travel only at crawl speed

Possible Causes: • Wiring or connector damaged

• Thermal sensor faulty

Remedy: Check wires and connections

1. Check wires and connections (PC436) for discontinuity and short circuits.

 If there is no damage, proceed to step 2.

Measure the thermal sensor resistance

2. Disconnect PC436.

3. Using an ohmmeter measure the resistance between PC436-4 and

PC436-5. Rated resistance at t =20 °C: 570 Ω (PTC resistance, the resist-

ance increases as the temperature rises)

 If the resistance < 500 Ω or > 1 kΩ, replace the steer motor.

 If the resistance > 500 Ω and < 1 kΩ, proceed to step 4.

Replace the steer module (SCM)

4. Replace the steer module

Codes 200 - 286

Event Code 200

Display: HIGH CURRENT HM

Explanation: Current in power part of hydraulic module is too high (> 787 A).

Effect: • Parking brake applied

• Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

Possible Causes: • Short circuit in following components:

– Power cable to pump motor

– Pump motor coil

– Hydraulic module output stage

• Hydraulic pump blocked

Remedy: Check wires and connections

1. Check wires for short circuits.

 If there is no damage, proceed to step 2.

Measure the pump motor insulation resistance

2. Power down the truck.

3. Check motor coil insulation resistance.

 If a coil fails, proceed to step 4.

 If the coils are ok, proceed to step 5.

Replace the pump motor

4. Replace the pump motor (see page 307).

Check the hydraulic pump for blockage

5. Remove the pump motor and check the pump for freedom of movement.

 If the pump moves freely, proceed to step 6.

Replace the hydraulic module

6. Replace the hydraulic module

Event Code 200

Display: HIGH CURRENT HM

Explanation: Current in power part of hydraulic module is too high (> 787 A).

Effect: • Parking brake applied

• Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

Possible Causes: • Short circuit in following components:

– Power cable to pump motor

– Pump motor coil

– Hydraulic module output stage

• Hydraulic pump blocked

Remedy: Check wires and connections

1. Check wires for short circuits.

 If there is no damage, proceed to step 2.

Measure the pump motor insulation resistance

2. Power down the truck.

3. Check motor coil insulation resistance.

 If a coil fails, proceed to step 4.

 If the coils are ok, proceed to step 5.

Replace the pump motor

4. Replace the pump motor (see page 307).

Check the hydraulic pump for blockage

5. Remove the pump motor and check the pump for freedom of movement.

 If the pump moves freely, proceed to step 6.

Replace the hydraulic module

6. Replace the hydraulic module

Event Code 210

Display: HIGH VOLTAGE HM

Explanation: Overvoltage in hydraulic module power circuit (> 63 V).

Effect: • Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

• Parking brake applied

Possible Causes: • Emergency Disconnect pressed during plugging operation

• Hydraulic module error

Remedy: Rule out operator errors

1. Ask the operator if the Emergency Disconnect has been applied during a

plugging operation.

 If the Emergency Disconnect was not pressed during a plugging oper-

ation, proceed to step 2.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Replace the hydraulic module

2. Replace the hydraulic module

Event Code 211

Display: LOW VOLTAGE HM

Explanation: Overvoltage in hydraulic module power circuit (V < 18 V).

Effect: • Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

• Parking brake applied

Possible Causes: • Wiring error

• Faulty battery

• Hydraulic module error

Remedy: Check power cables

1. Check power cables.

 If there is no damage, proceed to step 2.

Check battery voltage with load

2. In the Analyzer menu select item A2.36.

3. Raise a heavy load and monitor the battery voltage during the lifting

operation.

 If the battery voltage drops significantly, proceed to step 4.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Repair the battery

4. Repair the battery in accordance with the manufacturer’s instructions or

replace

Event Code 212

Display: 15 VOLT SUPPLY HM

Explanation: Internal 15 V hydraulic module supply faulty.

Effect: • Parking brake applied

• Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

Possible Causes: • Hydraulic module error

Remedy: Replace the hydraulic module

1. Replace the hydraulic module

Event Code 213

Display: 5 VOLT SUPPLY HM

Explanation: Internal 5 V hydraulic module supply faulty.

Effect: • Hydraulic drive module is deactivated

• Travel at crawl speed enabled

Possible Causes: • Hydraulic module error

Remedy: Replace the hydraulic module

1. Replace the hydraulic module

Event Code 214

Display: CAP CHARGE HM

Explanation: Capacitor charge time exceeded.

Effect: • Main contactor ED1 does not close

Possible Causes: • Wiring error

• No B+ supply to hydraulic module

• Hydraulic module faulty

Remedy: Check fuse FU7

1. Check fuse FU7.

 Is FU7 has blown, proceed to step 6.

 Is FU7 is ok, proceed to step 2.

Check wires (B+, B–) and connections

2. Check wires for discontinuity and ensure connections are secure.

 If there is no damage, proceed to step 3.

 If there is damage, proceed to step 7.

Check B+ supply to hydraulic module

3. Power down the truck.

4. Connect voltmeter to B+ and B- of the hydraulic module.

5. Power up the truck.

 The voltage should rise from 0 V on B+ within 2 seconds. If not, proceed

to step 8.

Replace fuse FU7

6. Replace fuse FU7.

7. Repair wiring or connections.

Replace the hydraulic module

8. Replace the hydraulic module

Event Code 220

Display: OVER TEMP. HM

Explanation: Hydraulic module overtemperature (t > 115 °C)

Effect: • Hydraulic drive module is deactivated

• Travel at creep speed enabled

• The display shows: OVER TEMP. HM

Possible Causes: • Hydraulic module ventilation affected by:

– Excessive ambient temperature

– Overload

– Contamination

• Malfunction in power part of hydraulic module

Remedy: Test the fans

1. Test the fans (see U4 Check Fan 1 - 4, ).

 If a faulty fan is discovered, proceed to step 2.

 If the fans are working, proceed to step 3.

Replace the fans

2. Replace the fans.

Clean contaminated hydraulic module and air supplies

3. Clean the hydraulic module and air supplies if contaminated.

 If the hydraulic module and air supplies are clean, proceed to step 4.

Check the application conditions

4. Check the application conditions with regard to ambient temperature and

load.

 If the application conditions are difficult, adapt the performance setting.

See Performance Menu, .

 If the application conditions are not difficult and the error occurs fre-

quently, proceed to step 5.

Replace the hydraulic module

5. Replace the hydraulic module

Event Code 221

Display: OVER TEMP. HMOT

Explanation: Hydraulic motor coil overtemperature (t > 165 °C)

Effect: • Hydraulic module is deactivated

• Travel at crawl speed enabled

• The display shows: OVER TEMP. HMOT

Possible Causes: • Hydraulic module ventilation affected by:

– Excessive ambient temperature

– Overload

– Contamination

Remedy: Test the fans

1. Test the fans (see U4 Check Fan 1 - 4, ).

 If a faulty fan is discovered, proceed to step 2.

 If the fans are working, proceed to step 3.

Replace the fans

2. Replace the fans.

Clean contaminated hydraulic motor and air supplies

3. Clean the hydraulic motor and air supplies.

 If the hydraulic motor and air supplies are clean, proceed to step 4.

Check the application conditions

4. Check the application conditions with regard to ambient temperature and

load.

 If the application conditions are difficult, adapt the performance setting.

See Performance Menu, page 160.

 If the application conditions are not difficult and the error occurs fre-

quently, proceed to step 5.

Monitor the frequency of the event

5. Monitor the frequency of the event.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Event Code 222

Display: HIGH TEMP. HM

Explanation: Excessive temperature in hydraulic module (t > 85 °C)

Effect: • Between 85 °C and 115 °C the hydraulic module output current is reduced

in proportion to the rise in temperature down to 0 A.

• The display shows: HIGH TEMP. HM

Possible Causes: • Hydraulic module ventilation affected by:

– Excessive ambient temperature

– Overload

– Contamination

• Malfunction in power part of hydraulic module

Remedy: Test the fans

1. Test the fans (see U4 Check Fan 1 - 4, page 170).

 If a faulty fan is discovered, proceed to step 2.

 If the fans are working, proceed to step 3.

Replace the fans

2. Replace the fans.

Clean contaminated hydraulic module and air supplies

3. Clean the hydraulic module and air supplies if contaminated.

 If the hydraulic module and air supplies are clean, proceed to step 4.

Check the application conditions

4. Check the application conditions with regard to ambient temperature and

load.

 If the application conditions are difficult, adapt the performance setting.

See Performance Menu, page 160.

 If the application conditions are not difficult and the error occurs fre-

quently, proceed to step 5.

Replace the hydraulic module

5. Replace the hydraulic module

Event Code 223

Display: LOW TEMP. HM

Explanation: Too low temperature in hydraulic module (t < -20 °C)

Effect: • The display shows: LOW TEMP. HM

Possible Causes: • Truck has been parked for too long in a cold environment

Remedy: Check the application conditions

1. Check the application conditions.

 If the truck has been parked in temperatures below -20 °C, proceed to

step 2

 If the truck has been parked in temperatures above 0 °C, proceed to

step 3

Instruct the operator

2. Inform the operator that the truck must never be parked in temperatures

below 0 °C.

Monitor the frequency of the event

3. Monitor the frequency of the event.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Event Code 223

Display: LOW TEMP. HM

Explanation: Too low temperature in hydraulic module (t < -20 °C)

Effect: • The display shows: LOW TEMP. HM

Possible Causes: • Truck has been parked for too long in a cold environment

Remedy: Check the application conditions

1. Check the application conditions.

 If the truck has been parked in temperatures below -20 °C, proceed to

step 2

 If the truck has been parked in temperatures above 0 °C, proceed to

step 3

Instruct the operator

2. Inform the operator that the truck must never be parked in temperatures

below 0 °C.

Monitor the frequency of the event

3. Monitor the frequency of the event.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Event Code 225

Display: LOW TEMP. HMOT

Explanation: Too low temperature in hydraulic motor (t < -30 °C)

Effect: • The display shows: LOW TEMP. HMOT

Possible Causes: • Truck has been parked for too long in a cold environment.

Remedy: Check the application conditions

1. Check the application conditions.

 If the truck has been parked in temperatures below -30 °C, proceed to

step 2

 If the truck has been parked in temperatures above 0 °C, proceed to

step 3

Instruct the operator

2. Inform the operator that the truck must never be parked in temperatures

below 0 °C.

Monitor the frequency of the event

3. Monitor the frequency of the event.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Event Code 225

Display: LOW TEMP. HMOT

Explanation: Too low temperature in hydraulic motor (t < -30 °C)

Effect: • The display shows: LOW TEMP. HMOT

Possible Causes: • Truck has been parked for too long in a cold environment.

Remedy: Check the application conditions

1. Check the application conditions.

 If the truck has been parked in temperatures below -30 °C, proceed to

step 2

 If the truck has been parked in temperatures above 0 °C, proceed to

step 3

Instruct the operator

2. Inform the operator that the truck must never be parked in temperatures

below 0 °C.

Monitor the frequency of the event

3. Monitor the frequency of the event.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Event Code 241

Display: POT2 UNDER LIMIT

Explanation: The voltage on the slider of potentiometer POT2 is permanently monitored

during power-up and operation. The reading has dropped below the lower limit

of 0.6 volts.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Short circuit or discontinuity in wiring

• Potentiometer faulty

• Faulty contact in connector or potentiometer

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.4 (see page 119).

2. Apply “Lift/Lower".

 If approx. 0 V are displayed, there is either an open circuit between

CA407-2, CA407-1 and the main module (VCM) or a short circuit be-

tween CA407-2 and CA407-3. proceed to step 3.

Check the potentiometer wiring

3. Check the wiring to connectors PC407 and PC205 for discontinuity and

short circuits.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Leave the control handle in neutral and using a multimeter measure the

voltage between CA407-2 and CA407-1.

 It should be 4.3 – 5.3 V.

5. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA407-2 and CA407-1.

 It should be 7.8 – 9.5 V.

6. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA407-2 and CA407-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 0 V are displayed

in the Analyzer menu, this indicates a transient event.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

7. Replace the potentiometer POT2

Event Code 243

Display: POT3 ABOVE LIMIT

Explanation: The voltage on the slider of potentiometer POT3 is permanently monitored

during power-up and operation. The upper limit of 10.8 volts has been ex-

ceeded.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Wiring short circuit

• Potentiometer faulty

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.5 (see page 119).

2. Apply “Lift/Lower".

 If approx. 12 V is displayed, either there is a short circuit or an input on

the VCM is faulty. Proceed to step 3.

Check the potentiometer wiring

3. Check the potentiometer wiring for a short circuit.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Using a multimeter measure the voltage between CA408-2 and CA408-1.

 If approx. 12 V are displayed, this indicates the potentiometer is faulty.

Proceed to step 8.

5. Leave the control handle in neutral and using a multimeter measure the

voltage between CA408-2 and CA408-1.

 It should be 4.3 – 5.3 V.

6. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 7.8 – 9.5 V.

7. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed

in the Analyzer menu, this indicates that the VCM input is faulty. Proceed

to step 9.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

8. Replace the potentiometer POT3 (see page 268).

Replace the main module (VCM)

9. Replace the VCM

Event Code 243

Display: POT3 ABOVE LIMIT

Explanation: The voltage on the slider of potentiometer POT3 is permanently monitored

during power-up and operation. The upper limit of 10.8 volts has been ex-

ceeded.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Wiring short circuit

• Potentiometer faulty

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.5 (see page 119).

2. Apply “Lift/Lower".

 If approx. 12 V is displayed, either there is a short circuit or an input on

the VCM is faulty. Proceed to step 3.

Check the potentiometer wiring

3. Check the potentiometer wiring for a short circuit.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Using a multimeter measure the voltage between CA408-2 and CA408-1.

 If approx. 12 V are displayed, this indicates the potentiometer is faulty.

Proceed to step 8.

5. Leave the control handle in neutral and using a multimeter measure the

voltage between CA408-2 and CA408-1.

 It should be 4.3 – 5.3 V.

6. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 7.8 – 9.5 V.

7. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed

in the Analyzer menu, this indicates that the VCM input is faulty. Proceed

to step 9.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

8. Replace the potentiometer POT3 (see page 268).

Replace the main module (VCM)

9. Replace the VCM

Event Code 243

Display: POT3 ABOVE LIMIT

Explanation: The voltage on the slider of potentiometer POT3 is permanently monitored

during power-up and operation. The upper limit of 10.8 volts has been ex-

ceeded.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Wiring short circuit

• Potentiometer faulty

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.5 (see page 119).

2. Apply “Lift/Lower".

 If approx. 12 V is displayed, either there is a short circuit or an input on

the VCM is faulty. Proceed to step 3.

Check the potentiometer wiring

3. Check the potentiometer wiring for a short circuit.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Using a multimeter measure the voltage between CA408-2 and CA408-1.

 If approx. 12 V are displayed, this indicates the potentiometer is faulty.

Proceed to step 8.

5. Leave the control handle in neutral and using a multimeter measure the

voltage between CA408-2 and CA408-1.

 It should be 4.3 – 5.3 V.

6. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 7.8 – 9.5 V.

7. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed

in the Analyzer menu, this indicates that the VCM input is faulty. Proceed

to step 9.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

8. Replace the potentiometer POT3 (see page 268).

Replace the main module (VCM)

9. Replace the VCM

Event Code 243

Display: POT3 ABOVE LIMIT

Explanation: The voltage on the slider of potentiometer POT3 is permanently monitored

during power-up and operation. The upper limit of 10.8 volts has been ex-

ceeded.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Wiring short circuit

• Potentiometer faulty

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.5 (see page 119).

2. Apply “Lift/Lower".

 If approx. 12 V is displayed, either there is a short circuit or an input on

the VCM is faulty. Proceed to step 3.

Check the potentiometer wiring

3. Check the potentiometer wiring for a short circuit.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Using a multimeter measure the voltage between CA408-2 and CA408-1.

 If approx. 12 V are displayed, this indicates the potentiometer is faulty.

Proceed to step 8.

5. Leave the control handle in neutral and using a multimeter measure the

voltage between CA408-2 and CA408-1.

 It should be 4.3 – 5.3 V.

6. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 7.8 – 9.5 V.

7. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed

in the Analyzer menu, this indicates that the VCM input is faulty. Proceed

to step 9.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

8. Replace the potentiometer POT3 (see page 268).

Replace the main module (VCM)

9. Replace the VCM

Event Code 243

Display: POT3 ABOVE LIMIT

Explanation: The voltage on the slider of potentiometer POT3 is permanently monitored

during power-up and operation. The upper limit of 10.8 volts has been ex-

ceeded.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Wiring short circuit

• Potentiometer faulty

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.5 (see page 119).

2. Apply “Lift/Lower".

 If approx. 12 V is displayed, either there is a short circuit or an input on

the VCM is faulty. Proceed to step 3.

Check the potentiometer wiring

3. Check the potentiometer wiring for a short circuit.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Using a multimeter measure the voltage between CA408-2 and CA408-1.

 If approx. 12 V are displayed, this indicates the potentiometer is faulty.

Proceed to step 8.

5. Leave the control handle in neutral and using a multimeter measure the

voltage between CA408-2 and CA408-1.

 It should be 4.3 – 5.3 V.

6. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 7.8 – 9.5 V.

7. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA408-2 and CA408-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed

in the Analyzer menu, this indicates that the VCM input is faulty. Proceed

to step 9.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

8. Replace the potentiometer POT3 (see page 268).

Replace the main module (VCM)

9. Replace the VCM

Event Code 250

Display: POT5 UNDER LIMIT

Explanation: The voltage on the slider of potentiometer POT5 is permanently monitored

during power-up and operation. The reading has dropped below the lower limit

of 0.6 volts.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Short circuit or discontinuity in wiring

• Potentiometer faulty

• Faulty contact in connector or potentiometer

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.7 (see page 119).

2. Apply “Lift/Lower".

 If approx. 0 V are displayed, there is either an open circuit between

CA410-2, CA410-1 and the main module (VCM) or a short circuit be-

tween CA410-2 and CA410-3. proceed to step 3.

Check the potentiometer wiring

3. Check the wiring to connectors PC410 and PC205 for discontinuity and

short circuits.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Leave the control handle in neutral and using a multimeter measure the

voltage between CA41008-2 and CA410-1.

 It should be 4.3 – 5.3 V.

5. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA410-2 and CA410-1.

 It should be 7.8 – 9.5 V.

6. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA410-2 and CA410-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 0 V are displayed

in the Analyzer menu, this indicates a transient event.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

7. Replace the potentiometer

Event Code 250

Display: POT5 UNDER LIMIT

Explanation: The voltage on the slider of potentiometer POT5 is permanently monitored

during power-up and operation. The reading has dropped below the lower limit

of 0.6 volts.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Short circuit or discontinuity in wiring

• Potentiometer faulty

• Faulty contact in connector or potentiometer

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.7 (see page 119).

2. Apply “Lift/Lower".

 If approx. 0 V are displayed, there is either an open circuit between

CA410-2, CA410-1 and the main module (VCM) or a short circuit be-

tween CA410-2 and CA410-3. proceed to step 3.

Check the potentiometer wiring

3. Check the wiring to connectors PC410 and PC205 for discontinuity and

short circuits.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Leave the control handle in neutral and using a multimeter measure the

voltage between CA41008-2 and CA410-1.

 It should be 4.3 – 5.3 V.

5. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA410-2 and CA410-1.

 It should be 7.8 – 9.5 V.

6. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA410-2 and CA410-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 0 V are displayed

in the Analyzer menu, this indicates a transient event.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

7. Replace the potentiometer

Event Code 250

Display: POT5 UNDER LIMIT

Explanation: The voltage on the slider of potentiometer POT5 is permanently monitored

during power-up and operation. The reading has dropped below the lower limit

of 0.6 volts.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Short circuit or discontinuity in wiring

• Potentiometer faulty

• Faulty contact in connector or potentiometer

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.7 (see page 119).

2. Apply “Lift/Lower".

 If approx. 0 V are displayed, there is either an open circuit between

CA410-2, CA410-1 and the main module (VCM) or a short circuit be-

tween CA410-2 and CA410-3. proceed to step 3.

Check the potentiometer wiring

3. Check the wiring to connectors PC410 and PC205 for discontinuity and

short circuits.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Leave the control handle in neutral and using a multimeter measure the

voltage between CA41008-2 and CA410-1.

 It should be 4.3 – 5.3 V.

5. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA410-2 and CA410-1.

 It should be 7.8 – 9.5 V.

6. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA410-2 and CA410-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 0 V are displayed

in the Analyzer menu, this indicates a transient event.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

7. Replace the potentiometer

Event Code 250

Display: POT5 UNDER LIMIT

Explanation: The voltage on the slider of potentiometer POT5 is permanently monitored

during power-up and operation. The reading has dropped below the lower limit

of 0.6 volts.

Effect: • Hydraulic functions are deactivated

Possible Causes: • Short circuit or discontinuity in wiring

• Potentiometer faulty

• Faulty contact in connector or potentiometer

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.7 (see page 119).

2. Apply “Lift/Lower".

 If approx. 0 V are displayed, there is either an open circuit between

CA410-2, CA410-1 and the main module (VCM) or a short circuit be-

tween CA410-2 and CA410-3. proceed to step 3.

Check the potentiometer wiring

3. Check the wiring to connectors PC410 and PC205 for discontinuity and

short circuits.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Leave the control handle in neutral and using a multimeter measure the

voltage between CA41008-2 and CA410-1.

 It should be 4.3 – 5.3 V.

5. Move the control handle as far as the stop in the "Lift" position and using

a multimeter measure the voltage between CA410-2 and CA410-1.

 It should be 7.8 – 9.5 V.

6. Move the control handle as far as the stop in the "Lower" position and

using a multimeter measure the voltage between CA410-2 and CA410-1.

 It should be 0.7 – 1.9 V.

 If normal readings are taken in steps 5 to 7, this indicates the potentiome-

ter is ok.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 5 to 7 but approx. 0 V are displayed

in the Analyzer menu, this indicates a transient event.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

7. Replace the potentiometer

Event Code 263

Display: PVRE REACH VALVE

Explanation: Overcurrent detected on PVRE valve coil during mast reach carriage extend

operation. Output to PVRE cut out by VCM.

Effect: • All outputs to the hydraulic valve coils are cut out.

Possible Causes: • Faulty coil

• Wiring short circuit

• Main module VCM faulty

Remedy: Measure the coil resistance

1. Disconnect PC808 from valve.

2. Measure resistance between pin 1 and pin 2 on the coil.

 If the resistance is 25 Ω, proceed to step 4.

 If the resistance is not 25 Ω, proceed to step 3.

Replace the coil

3. Replace the coil.

Check the wiring for short circuits

4. Connect PC808.

5. Start up the truck.

6. Leave the "Reach" control handle in neutral and measure the voltage be-

tween PC422-10 and B–.

 If B+ is present, proceed to step 7. If not, proceed to step 10.

7. Disconnect PC808 from the valve and measure the voltage again between

PC422-10 and B–.

 If B+ is still present, this indicates a short circuit to B+ between PC808-

2 and PC205-15. Proceed to step 12.

 If B+ is not present, proceed to step 8.

8. Power down the truck.

9. Re-connect PC808. Proceed to step 13.

Locate and repair disconnected wires

10. Check for disconnected wires.

 Is a wire is disconnected, proceed to step 11.

 If not, proceed to step 7.

11. Repair the wire.

Locate and clear short circuits

12. Clear the short circuit to B+ in the wire from PC808-2 to PC205-15.

Check the driver output from the main module (VCM)

13. Start up the truck.

14. Connect the voltmeter between PC422-10 and B–.

15. Activate "Extend reach carriage" as far as the stop and record the voltage.

 The reading should drop to approx. 31 V. If not, proceed to step 16.

Event Code 263

Display: PVRE REACH VALVE

Explanation: Overcurrent detected on PVRE valve coil during mast reach carriage extend

operation. Output to PVRE cut out by VCM.

Effect: • All outputs to the hydraulic valve coils are cut out.

Possible Causes: • Faulty coil

• Wiring short circuit

• Main module VCM faulty

Remedy: Measure the coil resistance

1. Disconnect PC808 from valve.

2. Measure resistance between pin 1 and pin 2 on the coil.

 If the resistance is 25 Ω, proceed to step 4.

 If the resistance is not 25 Ω, proceed to step 3.

Replace the coil

3. Replace the coil.

Check the wiring for short circuits

4. Connect PC808.

5. Start up the truck.

6. Leave the "Reach" control handle in neutral and measure the voltage be-

tween PC422-10 and B–.

 If B+ is present, proceed to step 7. If not, proceed to step 10.

7. Disconnect PC808 from the valve and measure the voltage again between

PC422-10 and B–.

 If B+ is still present, this indicates a short circuit to B+ between PC808-

2 and PC205-15. Proceed to step 12.

 If B+ is not present, proceed to step 8.

8. Power down the truck.

9. Re-connect PC808. Proceed to step 13.

Locate and repair disconnected wires

10. Check for disconnected wires.

 Is a wire is disconnected, proceed to step 11.

 If not, proceed to step 7.

11. Repair the wire.

Locate and clear short circuits

12. Clear the short circuit to B+ in the wire from PC808-2 to PC205-15.

Check the driver output from the main module (VCM)

13. Start up the truck.

14. Connect the voltmeter between PC422-10 and B–.

15. Activate "Extend reach carriage" as far as the stop and record the voltage.

 The reading should drop to approx. 31 V. If not, proceed to step 16.

Event Code 263

Display: PVRE REACH VALVE

Explanation: Overcurrent detected on PVRE valve coil during mast reach carriage extend

operation. Output to PVRE cut out by VCM.

Effect: • All outputs to the hydraulic valve coils are cut out.

Possible Causes: • Faulty coil

• Wiring short circuit

• Main module VCM faulty

Remedy: Measure the coil resistance

1. Disconnect PC808 from valve.

2. Measure resistance between pin 1 and pin 2 on the coil.

 If the resistance is 25 Ω, proceed to step 4.

 If the resistance is not 25 Ω, proceed to step 3.

Replace the coil

3. Replace the coil.

Check the wiring for short circuits

4. Connect PC808.

5. Start up the truck.

6. Leave the "Reach" control handle in neutral and measure the voltage be-

tween PC422-10 and B–.

 If B+ is present, proceed to step 7. If not, proceed to step 10.

7. Disconnect PC808 from the valve and measure the voltage again between

PC422-10 and B–.

 If B+ is still present, this indicates a short circuit to B+ between PC808-

2 and PC205-15. Proceed to step 12.

 If B+ is not present, proceed to step 8.

8. Power down the truck.

9. Re-connect PC808. Proceed to step 13.

Locate and repair disconnected wires

10. Check for disconnected wires.

 Is a wire is disconnected, proceed to step 11.

 If not, proceed to step 7.

11. Repair the wire.

Locate and clear short circuits

12. Clear the short circuit to B+ in the wire from PC808-2 to PC205-15.

Check the driver output from the main module (VCM)

13. Start up the truck.

14. Connect the voltmeter between PC422-10 and B–.

15. Activate "Extend reach carriage" as far as the stop and record the voltage.

 The reading should drop to approx. 31 V. If not, proceed to step 16.

Event Code 265

Display: PVAR ACCESSORY R

Explanation: Overcurrent detected on PVAR valve coil as “5th function right” is performed.

Output to PVAR cut out by VCM.

Effect: • All outputs to the hydraulic valve coils are cut out.

Possible Causes: • Faulty coil

• Wiring short circuit

• Main module VCM faulty

Remedy: Measure the coil resistance

1. Disconnect PC811 from valve.

2. Measure resistance between pin 1 and pin 2 on the coil.

 If the resistance is 25 Ω, proceed to step 4.

 If the resistance is not 25 Ω, proceed to step 3.

Replace the coil

3. Replace the coil.

Check the wiring for short circuits

4. Attach connector PC811.

5. Start up the truck.

6. Leave the "5th function" control handle in neutral and measure the voltage

between PC422-11 and B–.

 If B+ is present, proceed to step 7. If not, proceed to step 10.

7. Disconnect PC811 from the valve and measure the voltage again between

PC422-11 and B–.

 If B+ is still present, this indicates a short circuit to B+ between PC811-

2 and PC205-27. Proceed to step 12.

 If B+ is not present, proceed to step 8.

8. Power down the truck.

9. Re-connect PC811. Proceed to step 13.

Locate and repair disconnected wires

10. Check for disconnected wires.

 Is a wire is disconnected, proceed to step 11.

 If not, proceed to step 7.

11. Repair the wire.

Locate and clear short circuits

12. Clear the short circuit to B+ in the wire from PC811-2 to PC205-27.

Check the driver output from the main module (VCM)

13. Start up the truck.

14. Connect the voltmeter between PC422-11 and B–.

15. Change to the 5th function.

16. Apply 5th function right as far as the stop and record the voltage.

 The reading should drop to approx. 29 V. If not, proceed to step 17.

Replace the main module (VCM)

17. Replace the VCM

Event Code 266

Display: SVT TILT VALVE

Explanation: Overcurrent detected on SVT valve coil as tilting is performed. Output to SVT

cut out by VCM.

Effect: • All outputs to the hydraulic valve coils are cut out.

Possible Causes: • Faulty coil

• Wiring short circuit

• Main module VCM faulty

Remedy: Measure the coil resistance

1. Disconnect PC801 from valve.

2. Measure resistance between pin 1 and pin 2 on the coil.

 If the resistance is 39 Ω, proceed to step 4.

 If the resistance is not 39 Ω, proceed to step 3.

Replace the coil

3. Replace the coil.

Check the wiring for short circuits

4. Connect PC801.

5. Start up the truck.

6. Leave the "fork tilt" control handle in neutral and measure the voltage be-

tween PC422-1 and B–.

 If B+ is present, proceed to step 7. If not, proceed to step 10.

7. Disconnect PC801 from the valve and measure the voltage again between

PC422-1 and B–.

 If B+ is still present, this indicates a short circuit to B+ between PC801-

2 and PC205-41. Proceed to step 12.

 If B+ is not present, proceed to step 8.

8. Power down the truck.

9. Re-connect PC801. Proceed to step 13.

Locate and repair disconnected wires

10. Check for disconnected wires.

 Is a wire is disconnected, proceed to step 11.

 If not, proceed to step 7.

11. Repair the wire.

Locate and clear short circuits

12. Clear the short circuit to B+ in the wire from PC801-2 to PC205-41.

Check the driver output from the main module (VCM)

13. Start up the truck.

14. Connect the voltmeter between PC422-1 and B–.

15. Activate "fork tilt" as far as the stop and record the voltage.

 The reading should drop to approx. 15 V. If not, proceed to step 16.

Replace the main module (VCM)

16. Replace the VCM

Event Code 267

Display: SVS SIDE SHIFT V

Explanation: Overcurrent detected on SVS valve coil as sideshift is performed. Output to

SVS cut out by VCM.

Effect: • All outputs to the hydraulic valve coils are cut out.

Possible Causes: • Faulty coil

• Wiring short circuit

• Main module VCM faulty

Remedy: Measure the coil resistance

1. Disconnect PC801 from valve.

2. Measure resistance between pin 5 and pin 6 on the coil.

 If the resistance is 39 Ω, proceed to step 4.

 If the resistance is not 39 Ω, proceed to step 3.

Replace the coil

3. Replace the coil.

Check the wiring for short circuits

4. Connect PC801.

5. Start up the truck.

6. Leave the "sideshift" control handle in neutral and measure the voltage

between PC422-5 and B–.

 If B+ is present, proceed to step 7. If not, proceed to step 10.

7. Disconnect PC801 from the valve and measure the voltage again between

PC422-5 and B–.

 If B+ is still present, this indicates a short circuit to B+ between PC801-

5 and PC205-12. Proceed to step 12.

 If B+ is not present, proceed to step 8.

8. Power down the truck.

9. Re-connect PC801. Proceed to step 13.

Locate and repair disconnected wires

10. Check for disconnected wires.

 Is a wire is disconnected, proceed to step 11.

 If not, proceed to step 7.

11. Repair the wire.

Locate and clear short circuits

12. Clear the short circuit to B+ in the wire from PC801-5 to PC205-12.

Check the driver output from the main module (VCM)

13. Start up the truck.

14. Connect the voltmeter between PC422-5 and B–.

15. Activate "sideshift" as far as the stop and record the voltage.

 The reading should drop to approx. 15 V. If not, proceed to step 16.

Replace the main module (VCM)

16. Replace the VCM

Event Code 268

Display: SV5 5TH FUNC. AV

Explanation: Overcurrent detected on SV5 valve coil as the 5th function is performed. Out-

put to SV5 cut out by VCM.

Effect: • All outputs to the hydraulic valve coils are cut out.

Possible Causes: • Faulty coil

• Wiring short circuit

• Main module VCM faulty

Remedy: Measure the coil resistance

1. Disconnect PC801 from valve.

2. Measure resistance between pin 7 and pin 8 on the coil.

 If the resistance is 39 Ω, proceed to step 4.

 If the resistance is not 39 Ω, proceed to step 3.

Event Code 268

Display: SV5 5TH FUNC. AV

Explanation: Overcurrent detected on SV5 valve coil as the 5th function is performed. Out-

put to SV5 cut out by VCM.

Effect: • All outputs to the hydraulic valve coils are cut out.

Possible Causes: • Faulty coil

• Wiring short circuit

• Main module VCM faulty

Remedy: Measure the coil resistance

1. Disconnect PC801 from valve.

2. Measure resistance between pin 7 and pin 8 on the coil.

 If the resistance is 39 Ω, proceed to step 4.

 If the resistance is not 39 Ω, proceed to step 3.

Event Code 280

Display: CURR SENSOR HM

Explanation: Offset error detected in current sensors to monitor the hydraulic module power

circuit during power-up.

Effect: • Hydraulic module is deactivated

• Travel at crawl speed enabled

Possible Causes: • Hydraulic module faulty

Remedy: Replace the hydraulic module

1. Replace the hydraulic module (see page 259).

Event Code 281

Display: TEMP. SENSOR HM

Explanation: Open circuit or short circuit detected in hydraulic module thermal sensors.

Effect: • Reach and fork lower are still enabled

• Travel at crawl speed enabled

Possible Causes: • Hydraulic module faulty

Remedy: Replace the hydraulic module

1. Replace the hydraulic module (see page 259).

Event Code 282

Display: ECR2 SHORT CIRC.

Explanation: Short circuit between channels A and B of encoder ECR2.

Effect: • Reach and fork lower are still enabled

• Travel at crawl speed enabled

Possible Causes: • Encoder ECR2 faulty

• Encoder wiring short circuit

• Main module or hydraulic module faulty

Remedy: Check the module and encoder

1. Select Analyzer menu A2.29 (see page 120).

2. Extend and retract the reach carriage.

 If SET SPEED = 1000 (for reach carriage extend) and

SET SPEED = 530 (for reach carriage retract) are displayed, proceed

to step 5.

 If SET SPEED = 0 is displayed, proceed to step 3.

Check the wiring between VCM and HCM

3. Check the wiring between PC429 and CA 201 for short circuits.

 If no error is found, proceed to step 4.

Replace encoder ECR2

4. Replace sensor bearing (ECR2).

 If the event code persists, proceed to step 5.

Replace the hydraulic module

5. Replace the hydraulic module

Event Code 283

Display: ECR2 OPEN CIRC.

Explanation: Open circuit or no power supply to encoder ECR2.

Effect: • Reach and fork lower are still enabled

• Travel at crawl speed enabled

Possible Causes: • Encoder ECR2 faulty

• Encoder wiring disconnected

• Main module or hydraulic module faulty

Remedy: Check the encoder power supply

1. Disconnect PC429.

For Danaher motors:

2. Measure the voltage between PC429-1 and PC429-4.

 It should be 12 V. If not, proceed to step 6.

 If there is a 12 V supply, proceed to step 4.

For Crown motors:

3. Measure the voltage between PC429-1 and PC429-2.

 It should be 12 V. If not, proceed to step 6.

 If there is a 12 V supply, proceed to step 4.

Check the module and encoder

4. Select Analyzer menu A2.29 (see page 120).

5. Extend and retract the reach carriage.

 If SET SPEED = 1000 (for reach carriage extend) and

SET SPEED = 530 (for reach carriage retract) are displayed, proceed

to step 5.

 If SET SPEED = 0 is displayed, proceed to step 7.

Check the wiring between VCM and HCM

6. Check the wiring between PC429 and CA 201.

 If no error is found, proceed to step 7.

Replace encoder ECR2

7. Replace sensor bearing (ECR2).

Replace the hydraulic module

8. Replace the hydraulic module

Event Code 284

Display: ECR2 LOST CHANN.

Explanation: No channel A or B on encoder ECR2.

Effect: • Reach and fork lower are still enabled

• Travel at crawl speed enabled

Possible Causes: • Encoder ECR2 faulty

• Encoder wiring disconnected

• Main module or hydraulic module faulty

Remedy: Check the module and encoder

1. Select Analyzer menu A2.29 (see page 120).

2. Extend and retract the reach carriage.

 If SET SPEED = 1000 (for reach carriage extend) and

SET SPEED = 530 (for reach carriage retract) are displayed, proceed

to step 4.

 If SET SPEED = 0 is displayed, proceed to step 3.

Check the wiring between VCM and HCM

3. Check for disconnect wires between PC429 and CA 201.

 If no error is found, proceed to step 4.

Replace encoder ECR2

4. Replace sensor bearing (ECR2).

 If the event code persists, proceed to step 5.

Replace the hydraulic module

5. Replace the hydraulic module (see page 259).

Event Code 285

Display: TEMP. SENSOR HMOT

Explanation: Open circuit or short circuit detected in pump motor thermal sensor.

Effect: • Reach and fork lower are still enabled

• Travel at crawl speed enabled

Possible Causes: • Faulty wiring

• THS2 faulty

Remedy: Check the wiring

1. Check for short circuits or wire disconnections between CA201-17,

CA201-16 and CA430-1 and CA430-2.

 If the wiring is faulty, proceed to step 2. If not, proceed to step 3.

Repair wiring

2. Repair the wiring.

Measure THS2 resistance

3. Disconnect PC430.

4. Measure THS2 resistance between CA430-1 and -2.

 If the resistance < 500 Ω or > 1 kΩ, proceed to step 5.

 If the resistance is approx. 600 Ω (rated resistance for t =20 °C is

600 Ω), monitor the error frequency.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the pump motor

5. Replace the pump motor

Codes 300 - 385

Event Code 300

Display: HIGH CURRENT TM

Explanation: Current in power part of traction module is too high (> 525 A).

Effect: • Parking brake applied

• Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

Possible Causes: • Short circuit in following components:

– Power cable to traction motor

– Traction motor coil

– Traction module output stage

• Blocked drive

Remedy: Check wires and connections

1. Check wires for short circuits.

 If there is no damage, proceed to step 2.

Measure the traction motor insulation resistance

2. Power down the truck.

3. Check the motor coil insulation resistance.

 If a coil fails, proceed to step 4.

 If the coils are ok, proceed to step 5.

Replace the traction motor

4. Replace the traction motor ).

Check the drive for blockage

5. Check the drive for freedom of movement.

 If the drive moves freely, proceed to step 6.

Replace the traction module

6. Replace the traction module ).

Event Code 301

Display: SHORT CIRCUIT TM

Explanation: Short circuit in power circuit of traction module.

Effect: • Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

• Parking brake applied

Possible Causes: • Short circuit in following components:

– Power cable to traction motor

– Traction motor coil

– Traction module output stage.Remedy: Measure the traction motor insulation resistance

1. Power down the truck.

2. Check the motor coil insulation resistance.

 If a coil fails, proceed to step 3.

 If the motor coils are ok, proceed to step 4.

Replace the traction motor

3. Replace the traction motor ( ).

Replace the traction module

4. Replace the traction module

Event Code 311

Display: LOW VOLTAGE TM

Explanation: Low voltage in traction module power circuit (V < 18 V).

Effect: • Traction and hydraulic modules deactivated

• Main contactor ED1 de-energised

• Parking brake applied

Possible Causes: • Wiring error

• Faulty battery

• Error in traction drive module

Remedy: 1. Check power cables.

 If there is no damage, proceed to step 2.

2. Check battery voltage with load:

In the Analyzer menu select item A2.36.

Raise a heavy load and monitor the battery voltage during the lifting

operation.

 If the battery voltage drops significantly, repair the battery.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Event Code 312

Display: 15 VOLT SUPPLY TM

Explanation: 15 V traction module supply faulty.

Effect: • Truck stops through plugging

• Traction module deactivated

• Mast reach and lowering only

Possible Causes: • Error in traction module

Remedy: Replace traction module

1. Replace the traction module (see page 258)

Event Code 313

Display: 5 VOLT SUPPLY TM

Explanation: 5 V traction module supply faulty.

Effect: • Truck stops through plugging

• Traction module deactivated

• Mast reach and lowering only

Possible Causes: • Error in traction module

Remedy: Replace traction module

1. Replace the traction module (see page 258)

Event Code 314

Display: CAP CHARGE TM

Explanation: Capacitor charge time exceeded.

Effect: • Main contactor ED1 does not close

Possible Causes: • Wiring error

• No B+ supply to traction module

• Traction module faulty

Remedy: Check wires (B+, B–) and connections

1. Check for disconnected wires and make sure connections are secure.

 If there is no damage, proceed to step 2.

Check B+ supply to traction module

2. Power down the truck.

3. Connect voltmeter to B+ and B- of the traction module.

4. Power up the truck.

 The voltage should rise from 0 V on B+ within 2 seconds. If not, proceed to step 5.

Replace traction module

5. Replace the traction module

Event Code 320

Display: OVER TEMP. TM

Explanation: Traction module overtemperature (t > 115 °C)

Effect: • Traction module deactivated

• Mast reach and lowering only

• The display shows: OVER TEMP. TM

Possible Causes: • Traction module ventilation affected by:

– Excessive ambient temperature

– Overload

– Contamination

• Malfunction in power part of traction module

Remedy: Test the fans

1. Test the fans (see U4 Check Fan 1 - 4, page 170).

 If a faulty fan is discovered, proceed to step 2.

 If the fans are working, proceed to step 3.

Replace the fans

2. Replace the fans.

Clean contaminated traction module and air supplies

3. Clean contaminated traction module and air supplies.

 If the traction module and air supplies are clean, proceed to step 4.

Check the application conditions

4. Check the application conditions with regard to ambient temperature and

load.

 If the application conditions are difficult, adapt the performance setting.

See Performance Menu, page 160.

 If the application conditions are not difficult and the error occurs fre-

quently, proceed to step 5.

Replace hydraulic module

5. Replace the hydraulic module

Event Code 320

Display: OVER TEMP. TM

Explanation: Traction module overtemperature (t > 115 °C)

Effect: • Traction module deactivated

• Mast reach and lowering only

• The display shows: OVER TEMP. TM

Possible Causes: • Traction module ventilation affected by:

– Excessive ambient temperature

– Overload

– Contamination

• Malfunction in power part of traction module

Remedy: Test the fans

1. Test the fans (see U4 Check Fan 1 - 4, page 170).

 If a faulty fan is discovered, proceed to step 2.

 If the fans are working, proceed to step 3.

Replace the fans

2. Replace the fans.

Clean contaminated traction module and air supplies

3. Clean contaminated traction module and air supplies.

 If the traction module and air supplies are clean, proceed to step 4.

Check the application conditions

4. Check the application conditions with regard to ambient temperature and

load.

 If the application conditions are difficult, adapt the performance setting.

See Performance Menu, page 160.

 If the application conditions are not difficult and the error occurs fre-

quently, proceed to step 5.

Replace hydraulic module

5. Replace the hydraulic module

Event Code 322

Display: HIGH TEMP. TM

Explanation: Excessive temperature in traction module (t > 85 °C)

Effect: • Between 85 °C and 115 °C the traction module output current is reduced in

proportion to the rise in temperature down to 0 A.

• The display shows: HIGH TEMP. TM

Possible Causes: • Traction module ventilation affected by:

– Excessive ambient temperature

– Overload

– Contamination

• Malfunction in power part of traction module

Remedy: Test the fans

1. Test the fans (see U4 Check Fan 1 - 4, page 170).

 If a faulty fan is discovered, proceed to step 2.

 If the fans are working, proceed to step 3.

Replace the fans

2. Replace the fans.

Clean contaminated traction module and air supplies

3. Clean contaminated traction module and air supplies.

 If the traction module and air supplies are clean, proceed to step 4.

Check the application conditions

4. Check the application conditions with regard to ambient temperature and

load.

 If the application conditions are difficult, adapt the performance setting.

See Performance Menu, page 160.

 If the application conditions are not difficult and the error occurs fre-

quently, proceed to step 5.

Replace traction module

5. Replace the traction module

Event Code 323

Display: LOW TEMP. TM

Explanation: Too low temperature in traction module (t < -20 °C)

Effect: • The display shows: LOW TEMP. TM

Possible Causes: • Truck has been parked for too long in a cold environment

Remedy: Check the application conditions

1. Check the application conditions.

 If the truck has been parked in temperatures below -20 °C, proceed to

step 2

 If the truck has been parked in temperatures above 0 °C, proceed to

step 3

Instruct the operator

2. Inform the operator that the truck must never be parked in temperatures

below 0 °C.

Monitor the frequency of the event

3. Monitor the frequency of the event.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Event Code 323

Display: LOW TEMP. TM

Explanation: Too low temperature in traction module (t < -20 °C)

Effect: • The display shows: LOW TEMP. TM

Possible Causes: • Truck has been parked for too long in a cold environment

Remedy: Check the application conditions

1. Check the application conditions.

 If the truck has been parked in temperatures below -20 °C, proceed to

step 2

 If the truck has been parked in temperatures above 0 °C, proceed to

step 3

Instruct the operator

2. Inform the operator that the truck must never be parked in temperatures

below 0 °C.

Monitor the frequency of the event

3. Monitor the frequency of the event.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Event Code 325

Display: LOW TEMP. TMOT

Explanation: Too low temperature in traction motor (t < -30 °C)

Effect: • The display shows: LOW TEMP. TMOT

Possible Causes: • Truck has been parked for too long in a cold environment.

Remedy: Check the application conditions

1. Check the application conditions.

 If the truck has been parked in temperatures below -30 °C, proceed to

step 2

 If the truck has been parked in temperatures above 0 °C, proceed to

step 3

Instruct the operator

2. Inform the operator that the truck must never be parked in temperatures

below 0 °C.

Monitor the frequency of the event

3. Monitor the frequency of the event.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

Event Code 330

Display: ERROR CANBUS TM

Explanation: Communication error on the CAN Bus between the main module (VCM) and

the traction module (TCM).

Effect: • Main contactor ED1 de-energised

Possible Causes: • Wiring error

• Error in main module (VCM)

• Error in steer module (SCM)

Remedy: Measure the load resistance of the CAN Bus wiring between the main

module and the traction module

1. Measure the resistance between PC416-1 and -2.

 If the resistance is 60 Ω, the main and traction modules are ok.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

 If the resistance is 120 Ω, then either the main module or traction mod-

ule is faulty. Proceed to step 2.

Measure the load resistance in the main module (VCM)

2. Disconnect PC205 from the main module.

3. Measure the resistance on the main module between PC205-22 and -23.

 If the resistance is 120 Ω, the main module is ok. Proceed to step 5:

 If a different reading is obtained, the main module is faulty.

4. Replace the main module.

Measure the load resistance in the traction module (TCM)

5. Disconnect PC204 from the traction module.

6. Measure the resistance on the traction module between PC205-22 and -

23.

 If the resistance is 120 Ω, the traction module is ok.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

 If a different reading is obtained, the traction module is faulty. Proceed

to step 7.

Replace the traction module (TCM)

7. Replace the traction module

Event Code 340

Display: POT1 ABOVE LIMIT

Explanation: The voltage on the slider of potentiometer POT1 is permanently monitored

during power-up and operation. The upper limit of 10.8 volts has been ex-

ceeded.

Effect: • Travel functions are deactivated

Possible Causes: • Wiring short circuit

• Potentiometer faulty

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.3 (see page 119).

2. Depress accelerator.

 If 0 V is displayed, there is either an open circuit between CA407-2,

CA407-1 and the main module (VCM) or a short circuit between CA407-

2 and CA407-3. Proceed with step 3.

Check the potentiometer wiring

3. Check the wiring to connectors PC407 and PC205 for discontinuity and

short circuits.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Leave the accelerator pedal in neutral and using a multimeter measure the

voltage between CA407-2 and CA407-1.

 It should be 0.7 – 1.5 V.

5. Depress the accelerator pedal as far as the stop and using a multimeter

measure the voltage between CA407-2 and CA407-1.

 It should be 9.5 – 10.5 V.

 If normal readings are taken in steps 4 to 5, this indicates the potentiome-

ter is ok. If not, proceed to step 233.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 4 to 5 but approx. 0 V are displayed

in the Analyzer menu, this indicates a transient event.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

6. Replace potentiometer POT1

Event Code 341

Display: POT1 UNDER LIMIT

Explanation: The voltage on the slider of potentiometer POT1 is permanently monitored

during power-up and operation. The reading has dropped below the lower limit

of 0.6 volts.

Effect: • Travel functions are deactivated

Possible Causes: • Short circuit or discontinuity in wiring

• Potentiometer faulty

• Faulty contact in connector or potentiometer

Remedy: Check the voltage readings

1. In the Analyzer menu select item A2.3 (see page 119).

2. Depress accelerator.

 If 0 V is displayed, there is either an open circuit between CA407-2,

CA407-1 and the main module (VCM) or a short circuit between CA407-

2 and CA407-3. Proceed with step 3.

Check the potentiometer wiring

3. Check the wiring to connectors PC407 and PC205 for discontinuity and

short circuits.

 If the wiring is ok, proceed to step 4.

Measure the voltage levels on the potentiometer with a multimeter

4. Leave the accelerator pedal in neutral and using a multimeter measure the

voltage between CA407-2 and CA407-1.

 It should be 0.7 – 1.5 V.

5. Depress the accelerator pedal as far as the stop and using a multimeter

measure the voltage between CA407-2 and CA407-1.

 It should be 9.5 – 10.5 V.

 If normal readings are taken in steps 4 to 5, this indicates the potentiome-

ter is ok. If not, proceed to step 233.

Compare the readings taken with the multimeter with those in the Ana-

lyzer menu display.

 If normal readings are taken in steps 4 to 5 but approx. 0 V are displayed

in the Analyzer menu, this indicates a transient event.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Replace the potentiometer

6. Replace potentiometer POT1

Event Code 343

Display: POT1/ACS STATUS

Explanation: The voltage reading supplied from POT1 does not match the value expected

by the current switch position of the ACS.

Effect: • Travel functions are deactivated

Possible Causes: • Short circuit or discontinuity in wiring

• ACS switch faulty

• Potentiometer POT1 faulty

• Calibration faulty

Remedy: Test potentiometer POT1

1. In the Analyzer menu select item A2.3 (see page 119).

2. Depress accelerator.

 If 0 V is displayed, there is either an open circuit between CA418-2,

CA418-1 and the main module (VCM) or a short circuit between CA418-

2 und CA418-3. Proceed with step 3.

Check the potentiometer wiring

3. Check the wiring to connectors PC418 and PC205 for discontinuity and

short circuits.

 If the wiring is ok, proceed to step 4.

Record the voltage readings on the potentiometer with a multimeter and

compare them with the display in the Analyzer menu

4. Leave the accelerator pedal in neutral and using a multimeter measure the

voltage between CA418-2 and CA418-1.

 It should be 0.7 – 1.5 V.

5. Depress the accelerator pedal as far as the stop and using a multimeter

measure the voltage between CA418-2 and CA418-1.

 It should be 9.5 – 10.5 V.

6. In the Analyzer menu, item A2.3 (see page 119) compare the recordings

with the display reading.

 If normal readings are taken in steps 4 to 5 but approx. 0 V is displayed

in the Analyzer menu, this indicates a transient event. Proceed to

step 7.

Restart the truck

7. Restart the truck

 If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the

Crown service department.

 If the error message persists after restarting, proceed to step 8.

Test the ACS switch

8. In the Analyzer menu select item A2.9 (see page 119).

9. Press the ACS switch and check its operation.

 If ACS does not switch, proceed to step 10.

 If the switch is ok, proceed to step 11.

Check the ACS switch wiring

10. Check the wiring between CA417 and CA205 for discontinuity and short

circuits.

 If the wiring is ok, replace the ACS switch

 If the wiring is faulty, repair the wiring.

Calibrate the travel function

11. Calibrate the travel function (see page 127).

Replace the potentiometer

12. Replace potentiometer POT1

Event Code 380

Display: CURR SENSOR TM

Explanation: Offset error detected in current sensors to monitor the traction module power

circuit during power-up.

Effect: • Traction module remains deactivated.

• Mast reach and lowering only

Possible Causes: • Hydraulic module faulty

Remedy: Replace the traction module

1. Replace the traction module (see page 259).

Event Code 381

Display: TEMP. SENSOR TM

Explanation: Open circuit or short circuit detected in traction module thermal sensors.

Effect: • Reach and fork lower are still enabled

• Travel at crawl speed enabled

Possible Causes: • Traction module faulty

Remedy: Replace the traction module

1. Replace the traction module (see page 259).

Event Code 382

Display: ECR1 SHORT CIRC.

Explanation: Short circuit between channels A and B of encoder ECR1.

Effect: • Reach and fork lower are still enabled

• Travel at crawl speed enabled

Possible Causes: • Encoder ECR1 faulty

• Encoder wiring short circuit

• Main module or traction module faulty

Remedy: Check the module and encoder

1. Select Analyzer menu A2.26 (see page 120).

2. Apply travel function.

 If SET SPEED = 685 is displayed (when accelerator pedal applied), the

traction and main modules are ok.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.5

 If ACTUAL SPEED = 0 is displayed, proceed to step 3.

Check the wiring between VCM and TCM

3. Check the wiring between PC425 and CA 201 for short circuits.

 If no error is found, proceed to step 4.

Replace encoder ECR1

4. Replace encoder (ECR1).

 If the event code persists, proceed to step 5.

Replace the traction module

5. Replace the traction module

Event Code 383

Display: ECR1 OPEN CIRC.

Explanation: Open circuit or no power supply to encoder ECR1.

Effect: • Reach and fork lower are still enabled

• Travel at crawl speed enabled

Possible Causes: • Encoder ECR1 faulty

• Encoder wiring disconnected

• Main module or hydraulic module faulty

Remedy: Check the encoder power supply

1. Disconnect PC425.

For Danaher motors:

2. Measure the voltage between PC425-1 and PC425-4.

 It should be 12 V. If not, proceed to step 6.

 If there is a 12 V supply, proceed to step 4.

For Crown motors:

3. Measure the voltage between PC425-1 and PC425-2.

 It should be 12 V. If not, proceed to step 6.

 If there is a 12 V supply, proceed to step 4.

Check the module and encoder

4. Select Analyzer menu A2.29 (see page 120).

5. Extend and retract the reach carriage.

 If SET SPEED = 685 is displayed (when accelerator pedal applied), the

traction and main modules are ok.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

 If ACTUAL SPEED = 0 is displayed, proceed to step 6.

Check the wiring between VCM and HCM

6. Check the wiring between PC425 and CA 201.

 If no error is found, proceed to step 8.

Replace encoder ECR1

7. Replace encoder (ECR1).

Replace the traction module

8. Replace the traction module

Event Code 384

Display: ECR1 LOST CHANN.

Explanation: No channel A or B on encoder ECR1.

Effect: • Reach and fork lower are still enabled

• Travel at crawl speed enabled

Possible Causes: • Encoder ECR1 faulty

• Encoder wiring short circuit

• Main module or traction module faulty

Remedy: Check the module and encoder

1. Select Analyzer menu A2.26 (see page 120).

2. Apply travel.

 If SET SPEED = 685 is displayed (when accelerator pedal applied), the

traction and main modules are ok.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.5

 If ACTUAL SPEED = 0 is displayed, proceed to step 3.

Check the wiring between VCM and TCM

3. Check for disconnected wiring between PC425 and CA 201.

 If no error is found, proceed to step 4.

Replace encoder ECR1

4. Replace encoder (ECR1).

 If the event code persists, proceed to step 5.

Replace the traction module

5. Replace the traction module

Codes 430 - 465

Event Code 430

Display: ERROR CANBUS VM

Explanation: Communication error on CAN Bus of main module (VCM).

Effect: • Main contactor ED1 de-energised

Possible Causes: • Wiring error

• Error in main module (VCM)

• Error in steer module (SCM)

Remedy: Measure the load resistance of the CAN Bus wiring between the main

module and the steer module

1. Measure the resistance between PC416-1 and -2.

 If the resistance is 60 Ω, the main and steer modules are ok.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

 If the resistance is 120 Ω, then either the main module or steer module

is faulty. Proceed to step 2.

Measure the load resistance in the main module (VCM)

2. Disconnect PC205 from the main module.

3. Measure the resistance on the main module between PC205-22 and -23.

 If the resistance is 120 Ω, the main module is ok. Proceed to step 5:

 If a different reading is obtained, the main module is faulty.

4. Replace the main module.

Measure the load resistance in the steer module (SCM)

5. Disconnect PC204 from the steer module.

6. Measure the resistance on the steer module between PC205-10 and -11.

 If the resistance is 120 Ω, the steer module is ok.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

 If a different reading is obtained, the main module is faulty.

Replace the steer module (SCM)

7. Replace the steer module (see page 259).

Event Code 431

Display: ERROR CANBUS DSPLAY

Explanation: Communication error on CAN Bus of main module (VCM) and display.

Effect: • Main contactor ED1 de-energised

Possible Causes: • Wiring error

• Error in main module (VCM)

• Error in steer module (SCM)

Measure the load resistance of the CAN Bus wiring between the main

module and the steer module

1. Measure the resistance between PC416-1 and -2.

 If the resistance is 60 Ω, the main and steer modules are ok.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

 If the resistance is 120 Ω, then either the main module or steer module

is faulty. Proceed to step 2.

Measure the load resistance in the main module (VCM)

2. Disconnect PC205 from the main module.

3. Measure the resistance on the main module between PC205-22 and -23.

 If the resistance is 120 Ω, the main module is ok. Proceed to step 5:

 If a different reading is obtained, the main module is faulty.

4. Replace the main module.

Measure the load resistance in the steer module (SCM)

5. Disconnect PC204 from the steer module.

6. Measure the resistance on the steer module between PC205-10 and -11.

 If the resistance is 120 Ω, the steer module is ok.

Note: If the truck works after restarting, monitor the frequency of the fault (see

Log Events Menu, page 158). If the event occurs frequently, contact the Crown

service department.

 If a different reading is obtained, the main module is faulty.

Replace the steer module (SCM)

7. Replace the steer module

Event Code 460

Display: MAINC NOT CLOSED

Explanation: During power-up VCM detects an overcurrent in the coil of contactor ED1 and

switches off the driver output to ED1.

Effect: • Main contactor ED1 not energised

Possible Causes: • Short circuit in contactor coil

• Wiring short circuit

Remedy: Check wiring

1. Power down the truck.

2. Remove PC402 from the start up card.

3. Remove control cable from contactor.

4. Check control cable to contactor (PC402-10 and -9) for short circuit.

 If there is a short circuit, proceed to step 5.

 If there is no short circuit in the wiring, proceed to step 6.

Repair wiring

5. Repair wiring.

Check contactor coil

6. With the control cables still removed, measure the contactor coil resist-

ance with an ohmmeter.

 If the resistance is approx. 1.5 kΩ, the contactor coil is ok.

 If the resistance is approx. 0 Ω, proceed to step 7.

Repair contactor

7. Repair contactor ED1

Event Code 461

Display: MAINC WELDED

Explanation: Battery voltage applied to CA205-14 although truck has not been powered up.

Effect: • Main contactor ED1 not energised

Possible Causes: • Contactor welded.

Remedy: 1. Repair or replace contactor

Event Code 460

Display: MAINC NOT CLOSED

Explanation: During power-up VCM detects an overcurrent in the coil of contactor ED1 and

switches off the driver output to ED1.

Effect: • Main contactor ED1 not energised

Possible Causes: • Short circuit in contactor coil

• Wiring short circuit

Remedy: Check wiring

1. Power down the truck.

2. Remove PC402 from the start up card.

3. Remove control cable from contactor.

4. Check control cable to contactor (PC402-10 and -9) for short circuit.

 If there is a short circuit, proceed to step 5.

 If there is no short circuit in the wiring, proceed to step 6.

Repair wiring

5. Repair wiring.

Check contactor coil

6. With the control cables still removed, measure the contactor coil resist-

ance with an ohmmeter.

 If the resistance is approx. 1.5 kΩ, the contactor coil is ok.

 If the resistance is approx. 0 Ω, proceed to step 7.

Repair contactor

7. Repair contactor ED1 (see page 271).

Event Code 461

Display: MAINC WELDED

Explanation: Battery voltage applied to CA205-14 although truck has not been powered up.

Effect: • Main contactor ED1 not energised

Possible Causes: • Contactor welded.

Remedy: 1. Repair or replace contactor .

Event Code 463

Display: BEACON OUTPUT

Explanation: Overcurrent detected on output of VCM to strobe. Output to strobe switched

off by VCM.

Effect: • SVH, PVL, PVRE, PVRT, PVAL and PVAR deactivated.

Possible Causes: • Faulty strobe

• Coil (on relay bracket under the floorboard) is faulty

• Wire harness error

• Main module error

Remedy: Check strobe

1. Power down the truck.

2. Disconnect PC435 from the strobe .

3. Switch on the truck and strobe .

 If the event code no longer occurs, proceed to step 5.

 If the event code is still displayed, proceed to step 6.

4.

Replace strobe

5. Replace the strobe.

Check strobe and coil wiring

6. Power down the truck.

7. Disconnect JC433.

8. Switch on the truck and strobe.

 If the event code no longer occurs, proceed to step 9.

 If the event code is still displayed, proceed to step 10.

9. Check wiring between JC433-1 and - 2 to PC435-1 and -2 for short cir-

cuits.

 If there is a short circuit, proceed to step 14.

 If the wiring is ok, proceed to step 15.

Check main wire harness for short circuits

10. Power down the truck.

11. Disconnect PC205 and PC206.

12. Check the wiring between PC433-1 and -2 for short circuits.

 If there is a short circuit, proceed to step 14.

 If no short circuit is found, proceed to step 13.

13. Check contacts are securely connected to PC205 and PC206.

 If the contacts are damaged, proceed to step 16.

 If the contacts are ok, proceed to step 17.

Repair wiring

14. Repair the wiring.

Replace the coil

15. Replace the coil (fitted on the relay bracket underneath the floorboard).

Repair contacts on PC205 and PC206

16. Repair contacts.

Replace the main module

17. Replace the main module.

Event Code 464

Display: ALARM2 OUTPUT

Explanation: Overcurrent detected on output of VCM to travel alarm (CA205-11). Output to

travel alarm switched off by VCM.

Effect: • Main contactor ED1 de-energised

Possible Causes: • Travel alarm faulty

• Coil (fitted between travel and pump motors) is faulty

• Wire harness error

• Main module error

Remedy: Check travel alarm

1. Power down the truck.

2. Disconnect PC437 (fitted between the travel and pump motors).

3. Power up the truck and activate the travel alarm.

 If the event code no longer occurs, proceed to step 4.

 If the event code is still displayed, proceed to step 6.

Check wiring to travel alarm and coil

4. Power down the truck.

5. Disconnect JC421.

6. Power up the truck and activate the travel alarm.

 If the event code no longer occurs, proceed to step 7.

 If the event code is still displayed, proceed to step 8.

7. Check wiring between JC421-1 and - 2 to PC437-1 and -2 for short cir-

cuits.

 If there is a short circuit, proceed to step 12.

 If the wiring is ok, proceed to step 13.

Check main wire harness for short circuits

8. Power down the truck.

9. Disconnect PC205 and PC206.

10. Check the wiring between PC421-1 and -2 for short circuits.

 If there is a short circuit, proceed to step 12.

 If no short circuit is found, proceed to step 11.

11. Check contacts are securely connected to PC205 and PC206.

 If the contacts are damaged, proceed to step 14.

 If the contacts are ok, proceed to step 15.

Repair wiring

12. Repair the wiring.

Replace the coil

13. Replace the coil (fitted between travel and pump motors).

Repair contacts on PC205 and PC206

14. Repair contacts.

Replace the main module

15. Replace the main module.

Event Code 465

Display: VMC OUTPUTS

Explanation: Overcurrent detected on VCM outputs. The overcurrent could not be assigned

directly to an output. All outputs are switched off by the VCM.

Effect: • Either SVH, PVL, PVRE, PVRT, PVAL, PVAR or SVT, SVS, SV5 are deac-

tivated or main contactor ED1 is de-energised.

Possible Causes: • Wire harness error

• Error in mast reach wire harness (see page 443)

• Error in reach carriage wire harness (see page 447)

• Error in mast cable (see page 458 or 459)

• Error in fork carriage wire harness (see page 450 ff.)

• Valve modulation error

• Main module error

• Horn modulation error

Remedy: Trace short circuit

1. Troubleshoot as described in event codes 463 and 464.

 If no error is found, proceed to step 2.

2. Check the valve modulation and horn wiring for short circuits.

3. Check the valve modulation and horn wiring for short circuits:

– SVH (PC807 on main valve block)

– PVRE (PC808 on main valve block)

– PVRT (PC810 on main valve block)

– PVAL (PC809 on main valve block)

– PVAR (PC811 on main valve block)

– SVT, SVS (PC801 on “Auxiliary functions” valve block)

– Horn (PC402-3 and -12 on the start up card)

 If there is a short circuit, proceed to step 10.

 If no short circuit is found, proceed to step 4.

Check contacts

4. Check contact pins are properly connected to the following:

– PC205, PC206, CA422 (on mast)

– CA601, CA604 (in reach carriage)

 If the contacts are ok, proceed to step 5.

 If a contact error is found, proceed to step 9.

Test components individually

Note: Each of the components named in step 3 must be tested individually.

The following shows for example how to test the SVH valve. The other compo-

nents are tested in the same way.

5. Power down the truck.

6. Remove PC807 from the SVH valve.

7. Power up the truck.

8. Check the event code displayed.

 If the event code is shown again, the problem lies with one of the other

components. Repeat steps 5 to 8 for the next component.

Note: Re-fit the connector before powering up the truck again.

 If the event code is no longer displayed, that component is the cause of

the error. Proceed to step 11.

 If the error is shown for all components, the main module is the cause.

Proceed to step 12.

Repair connector

9. Repair the connector.

Repair wiring

10. Eradicate the short circuit.

Replace faulty component

11. Replace the faulty component.

Replace the main module

12. Replace the main module (VCM).

Codes 840 - 886

Event Code 840

Display: FS&RS CLOSED

Explanation: Forward and reverse switches detected simultaneously on the VCM inputs.

Effect: • Traction module deactivated

Possible Causes: • Wiring error

• Faulty switch

• Error in main module (VCM)

Remedy: Check direction switches

1. Power down the truck.

2. Disconnect CA411 (in armrest).

3. Start up the truck.

 If the event code persists, proceed to step 4.

 If the event code disappears, monitor the error frequency (see Log

Events Menu, page 158). If the event occurs frequently, contact the

Crown service department.

Check interface

4. Power down the truck.

5. Reconnect CA411.

6. Disconnect CA406.

7. Power up the truck.

 If the event code persists, proceed to step 8.

 If the event code disappears, the interface PCB is faulty. Proceed to

step 9.

Check wiring and switches

8. Check wiring from CA406-2 to CA470-2 and on to CA205-4.

 If the wiring is faulty, proceed to step 10.

 If the wiring is ok, proceed to step 11.

Replace interface

9. Replace the interface PCB.

Repair wiring

10. Repair the wiring.

Replace the main module (VCM)

11. Replace the main module.

Event Code 841

Display: LOW BRAKE FLUID

Explanation: Brake fluid level too low.

Effect: • Brake fluid level indicator lights up

Possible Causes: • Brake fluid level too low

• Faulty wiring

• Faulty switch

Remedy: Check brake fluid level

1. Check brake fluid container level.

 If the level is ok, proceed to step 2.

 If there is insufficient brake fluid, rectify the cause (worn brake linings in

the load wheels, leaks etc.) (see page 292). Then add brake fluid

(DOT4) (see page 295).

Check BFS switch

Note: The lid must be screwed onto the container and the brake fluid filled to

the max. marking.

2. Remove the wiring from the BFS switch.

3. Using an ohmmeter check the switch.

 If the switch has continuity, the switch is faulty and must be replaced.

 If the switch does not have continuity, proceed to step 4.

Check wiring

4. Measure the voltage between CA204-31 and B–.

 If the voltage is approx. B+, there is a short circuit to B+. Proceed to

step 5.

 If the reading is 0 V, the main module (VCM) is faulty. Proceed to

step 6.

Repair wiring

5. Clear short circuit in wire no. 007 between BFS and CA205-31.

Replace the main module (VCM)

6. Replace the VCM

Event Code 880

Display: SHORT CIRCUIT ECR5

Explanation: Short circuit between channels A and B of the height encoder

Effect: • Lift speed reduced to 50 %

• Graphic height display switched off

• The display shows: height measurement switched off

Possible Causes: • Wiring short circuit

• Encoder faulty

Check wiring

1. Power down the truck.

2. Disconnect CA205 from the VCM and PC803 from height encoder ECR5.

3. Using an ohmmeter check the wires between CA205-9 and -38 for short

circuits.

 If there is a short circuit, proceed to step 4.

 If the wiring is ok, proceed to step 5.

Repair wiring

4. Repair wiring.

Check height encoder ECR5

5. In the Analyzer menu open item A2.19.

6. Continue raising the fork carriage above free lift height while monitoring

the display.

 If the number of encoder pulses does not continually rise, ECR5 is

faulty. Proceed to step 7.

 If the number of encoder pulses rises continually, ECR5 is ok. Proceed

to step 8.

Replace height encoder ECR5

7. Replace ECR5 (see page 265).

Replace the main module (VCM)

8. Replace the VCM

Event Code 881

Display: NO COUNTS LIFT

Explanation: No pulses from height encoder ECR5 detected during lifting.

Effect: • Lift speed reduced to 50%

• Graphic height display switched off

• The display shows: height measurement switched off

Possible Causes: • Faulty wiring

• Height reset switch (HGTRS) does not connect

• Height encoder ECR5 faulty

• 12 V supply faulty

• Main module VCM faulty

Remedy: Test HGTRS

1. In the Analyzer menu open item A2.18.

2. Raise the fork carriage above free lift height.

 If the HGTRS switch changes from ON to OFF when the fork carriage

exceeds free lift height, it is ok. Proceed to step 4.

 If it does not change, the HGTRS switch is not working. Proceed to

step 3.

Replace HGTRS

3. Replace the HGTRS switch (see page 266).

Test height encoder ECR5

4. In the Analyzer menu open item A2.19.

5. Raise the fork carriage slowly above free lift height while monitoring if the

number of encoder pulses rises continually up to maximum lift height.

 If the number of pulses does not rise, either the wiring, the power supply

(display), the encoder or the VCM are faulty. Proceed to step 7.

 If the number of pulses does rise, proceed to step 17.

Check 12 V supply of height encoder ECR5

6. Using a voltmeter measure the voltage between CA203-14 and B- on the

display.

 If there is a 12 V supply present, proceed to step 7.

 If there is no supply, proceed to step 13.

7. Using a voltmeter measure the voltage between PC803-1 (GND) and -

3 (+12 V) on height encoder ECR5.

 If there is a 12 V supply present, proceed to step 9.

 If there is no supply, proceed to step 18.

Check wiring and operation of channel A on height encoder ECR5

8. Connect the voltmeter between PC205-9 and B–.

9. Raise the fork carriage above free lift height and then continue raising it

very slowly.

 If the voltage jumps between 0 V and 5 V, channel A is ok. Proceed to

step 10.

 If 0 V is constantly displayed, proceed to step 13.

Check wiring and operation of channel B on height encoder ECR5

10. Connect the voltmeter between PC205-38 and B–.

11. Raise the fork carriage above free lift height and then continue raising it

very slowly.

 If the voltage jumps between 0 V and 5 V, channel B is ok. Proceed to

step 17.

 If 0 V is constantly displayed, proceed to step 14.

Check 12 V supply wiring

12. Check for disconnected wiring from CA203-14 (on display) to CA803-3

and from CA203-20 to CA803-1.

 If there is a disconnection, proceed to step 15.

 If there is no disconnection, proceed to step 18.

Check channel A wiring on ECR5

13. Check for disconnected wiring from CA205-9 via CA422-31, CA600-2 to

CA803-2.

 If there is a disconnection, proceed to step 15.

 If there is no disconnection, proceed to step 16.

Check channel A wiring on ECR5

14. Check for disconnected wiring from CA205-38 via CA422-32, CA600-4 to

CA803-4.

 If there is a disconnection, proceed to step 15.

 If there is no disconnection, proceed to step 16.

Repair wiring

15. Repair wiring.

Replace encoder ECR5

16. Replace ECR5 (see page 265).

Replace the main module (VCM)

17. Replace the VCM (see page 258).

Replace the display

18. Replace the display

Event Code 883

Display: EXEED MAX HEIGHT

Explanation: Height encoder ECR5 records a value above maximum lift height.

Effect: • Lift speed reduced to 50%

• Graphic height display switched off

• The display shows: height measurement switched off

Possible Causes: • Slip in height encoder drive

• Height encoder calibration faulty

Remedy: Check drive of height encoder ECR5 for slip

1. Check drive of ECR5 for slip.

 If slip is discovered in the drive, proceed to step 2.

 If the drive is ok, proceed to step 3.

Repair the drive of height encoder ECR5

2. Replace faulty drive components.

Calibrate height encoder ECR5

3. Calibrate ECR5

Event Code 884

Display: NO COUNTS LOWER

Explanation: No pulses from height encoder ECR5 detected during lowering.

Effect: • Lift speed reduced to 50%

• Graphic height display switched off

• The display shows: height measurement switched off

Possible Causes: • Faulty wiring

• Height reset switch (HGTRS) does not connect

• Height encoder ECR5 faulty

• 12 V supply faulty

• Main module VCM faulty

Remedy: Test HGTRS

1. In the Analyzer menu open item A2.18.

2. Raise the fork carriage above free lift height.

 If the HGTRS switch changes from ON to OFF when the fork carriage

exceeds free lift height, it is ok. Proceed to step 4.

 If it does not change, the HGTRS switch is not working. Proceed to

step 3.

Replace HGTRS

3. Replace the HGTRS switch (see page 266).

Test height encoder ECR5

4. In the Analyzer menu open item A2.19.

5. Raise the fork carriage far beyond the free lift height. Then lower it and

monitor if the number of encoder pulses falls continuously.

 If the number of pulses does not fall, either the wiring, the power supply

(display), the encoder or the VCM are faulty. Proceed to step 7.

 If the number of pulses does rise, proceed to step 17.

Check 12 V supply of height encoder ECR5

6. Using a voltmeter measure the voltage between CA203-14 and B- on the

display.

 If there is a 12 V supply, proceed to step 7.

 If there is no supply, proceed to step 13.

7. Using a voltmeter measure the voltage between PC803-1 (GND) and -

3 (+12 V) on height encoder ECR5.

 If there is a 12 V supply, proceed to step 9.

 If there is no supply, proceed to step 18.

Check wiring and operation of channel A on height encoder ECR5

8. Connect the voltmeter between PC205-9 and B–.

9. Raise the fork carriage above free lift height and then continue raising it

very slowly.

 If the voltage jumps between 0 V and 5 V, channel A is ok. Proceed to

step 10.

 If 0 V is constantly displayed, proceed to step 13.

Check wiring and operation of channel B on height encoder ECR5

10. Connect the voltmeter between PC205-38 and B–.

11. Raise the fork carriage above free lift height and then continue raising it

very slowly.

 If the voltage jumps between 0 V and 5 V, channel B is ok. Proceed to

step 17.

 If 0 V is constantly displayed, proceed to step 14.

Check 12 V supply wiring

12. Check for disconnected wiring from CA203-14 (on display) to CA803-3

and from CA203-20 to CA803-1.

 If there is a disconnection, proceed to step 15.

 If there is no disconnection, proceed to step 18.

Check channel A wiring on ECR5

13. Check for disconnected wiring from CA205-9 via CA422-31, CA600-2 to

CA803-2.

 If there is a disconnection, proceed to step 15.

 If there is no disconnection, proceed to step 16.

Check channel A wiring on ECR5

14. Check for disconnected wiring from CA205-38 via CA422-32, CA600-4 to

CA803-4.

 If there is a disconnection, proceed to step 15.

 If there is no disconnection, proceed to step 16.

Repair wiring

15. Then repair wiring.

Replace encoder ECR5

16. Replace ECR5 (see page 265).

Replace the main module (VCM)

17. Replace the VCM (see page 258).

Replace the display

18. Replace the display

Event Code 885

Display: ERROR HGTRS

Explanation: Height reset switch HGTRS malfunction

Effect: • Lift speed reduced to 50%

• Graphic height display switched off

• The display shows: height measurement switched off

Possible Causes: • Faulty wiring

• Height reset switch (HGTRS) does not connect

Remedy: Test HGTRS

1. In the Analyzer menu open item A2.18.

2. Raise the fork carriage above free lift height.

 If it does not change, the HGTRS switch is not working. Proceed to

step 3.

 If the HGTRS switch changes from ON to OFF when the fork carriage

exceeds free lift height, it is ok.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.

Check wiring

3. Disconnect PC802 and raise the fork carriage above free lift height.

 If ON is still displayed, there is a short circuit to B+. Proceed to step 4.

 If OFF is displayed, HGTRS is faulty. Proceed to step 5.

Repair wiring

4. Repair wiring.

Replace HGTRS

5. Replace the HGTRS switch

Event Code 886

Display: ERROR ECR5 - HGTRS

Explanation: This test compares the number of count pulses of a lifting operation with those

of a lowering operation. The event code is generated if a permissible difference

is exceeded.

Effect: • Lift speed reduced to 50%

• Graphic height display switched off

• The display shows: height measurement switched off

Possible Causes: • Height reset switch (HGTRS) does not connect reliably

• Slip in height encoder drive

Remedy: Check drive of height encoder ECR5 for slip

1. See Event Code 883, page 253.

 If the height encoder drive is ok, proceed to step 2.

Check height reset switch HGTRS

2. See Event Code 885, page 256.

Note: If no cause can be found and the truck works correctly after restarting,

monitor the frequency of the fault (see Log Events Menu, page 158). If the

event occurs frequently, contact the Crown service department.