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Error LPE200-250 - 7572514-040

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Repair manual 7572514-040

LPE200, LPE220, LPE250.

www.toyota-forklifts.eu stronger together


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

8.4 Error code system


See the tables below for an explanation of the error code system.
Structure Description
X.YZZ Example: 3.510
X (3) Group. Indicates which truck system is affected by the
error.
YZZ (510) Sequential number

Group. Description
1 Not used.
2 Main Control Unit (A5)
3 Drive system
4 Hydraulic system
5 Steering system:
6 Not used.
7 Not used.
8 Option/auxiliary system
9 Not used.

© TMHE 8– 5 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

8.5 Error codes


Please note that some error codes are saved in the log and disappear from
the display, while other error codes remain on the display and require that the
truck be switched off and then on again for the error code to disappear.

Truck
Code Description Error cause(s) Procedure
behaviour
Parameters set 1: New software 1: Check parameters
to default has been
• Check that factory parameters
values. loaded in the
are set according to the truck
At start-up, it was truck, adding a
configuration.
detected that one new
or more parameter, or • Check that other parameters
2:002 parameters were Not influenced it has changed are set correctly.
not within the parameter 2: Replace A5:
acceptable limit values
intervals; they • See section "13.1.6 Replacing
2: Corrupt the logic card".
have therefore
memory A5
been reset to
default values
1: Copy the truck configuration
using TruckCom
1: Hardware (T1
• See the separate manual for
or A5) has
TruckCom.
been
Backup copies replaced. 2: Copy the truck configuration
do not match. using TruckCom
2: Software has
Backup copy in been updated • See the separate manual for
2:004 secondary unit Not influenced to an older TruckCom.
(T1) does not version
match data in 3: Replace T1
primary unit (A5) 3: Corrupt
• See section "14.7.2 Replacing
memory T1
the motor control".
4: Corrupt
4: Replace A5
memory A5
• See section "13.1.6 Replacing
the logic card".
Everything is
stopped at • Create a truck report. Send a
once, the report to the manufacturer.
Internal Internal program
2:005 parking brake is
program error error A5 • Update the truck software to the
activated, and
the main latest version.
contactor opens

© TMHE 8– 6 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Connect the battery connector.
1: Battery 2: Check battery voltage
connector • Check the voltage using the
disconnected built-in test procedure and
from truck that comparing with value from
Saving to is started
memory failed. external volt meter
Saving to 2: Voltage loss • Check connectors, joints and
memory failed on supply to splices for damage or corrosion.
2:006 because low Not influenced A5
• Check fuses F1 and F50
battery voltage. 3: The battery is
Battery voltage defective 3: Inspect the battery.
below 15 V at the
4: Battery 4: Check parameters
time of saving
parameter • Check that factory parameters
#107 has an are set according to the truck
erroneous configuration.
value
• Check that other parameters
are set correctly.
• Create a truck report. Send a
Internal report to the manufacturer.
Internal program
2:007 program error Not influenced
error • Update the truck software to the
A5
latest version.
• Create a truck report. Send a
Internal report to the manufacturer.
Internal program
2:008 program error Not influenced
error • Update the truck software to the
A5
latest version.
• Create a truck report. Send a
Internal report to the manufacturer.
Internal program
2:009 program error Not influenced
error • Update the truck software to the
A5
latest version.

© TMHE 8– 7 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
that the resistance between
(X41:3) and (X41:4) is 54 - 66
ohms.
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
1: Error on CAN the chassis and CAN contact.
bus wiring or Limit value >24 kOhm
CAN connections 2: Check for loose connections
communication 2: Loose • Switch on the truck, and pull
warning. connections
2:010 Not influenced carefully in the branches of the
A5 has received
3: Defective CAN wiring harness to find any loose
too may
node connections, and note when/if
erroneous signals
the error code appears.
4: Software
failure 3: Check the CAN node
• Deactivate and disconnect the
option unit connected to the
CAN wiring (e.g. K110,B90,T14
and A36/A37). Activate and
then connect them one by one
to identify which unit produces
the communication error.
4: Update the truck software
• Update the truck software
package to the latest available
version.
New software.
New software
installed. In order
to look in the New software Logged in the error log to see
2:011 Not influenced
error code log to installed when the software was updated
see when new
software was
installed.

© TMHE 8– 8 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Create a truck report. Send a
report to the manufacturer.
Creep speed, 1: Internal
• Update the truck software to the
Internal blocked lifting/ program error
2:080 latest version.
program error lowering 2: Manufacturing
movement 2: Replace A5:
defect in A5
• See section "13.1.6 Replacing
the logic card".
1: Check parameters
Configuration
error. Creep speed, • Check that factory parameters
Truck blocked lifting/ Incorrect value for are set according to the truck
2:102
configuration lowering parameter 1102 configuration.
does not match movement
• Check that other parameters
parameter 1102
are set correctly.
Creep speed, • Create a truck report. Send a
Internal blocked lifting/ Internal program report to the manufacturer.
2:180
program error lowering error • Update the truck software to the
movement latest version.
1: Check the sensor signal
• Check that the distance
between the sensor and the
opposite part is correct.
• Check that there is no dirt or
foreign objects on the sensor
• Inspect cabling.
1: High signal
from both • Measure the signals from the
B119 and sensor with a volt meter and
Incorrect signal B120 verify using TruckCom or the
combination from built-in test that the signal is
2:281 Creep speed 2: Constantly
platform position correct
sensor. high signal at
inputs 2: Check the signal to the unit
(T1:101) and • Compare the signals from the
(T1:97) sensor with the input signal (use
a volt meter and verify using
TruckCom or the built-in test
that the signals are the same)
• Check the pins on the unit and in
the connector
• Replace the unit if you cannot
get it to work properly

© TMHE 8– 9 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Handling error - no action
2: Check the sensor signal
• Check that the distance
between the sensor and the
opposite part is correct.
• Check that there is no dirt or
foreign objects on the sensor

1: Platform • Inspect cabling.


loaded • Measure the signals from the
The platform
sensor has been 2: Constantly sensor with a volt meter and
activated for more high signal verify using TruckCom or the
2:282 Creep speed built-in test that the signal is
than 5 minutes from B119
without any truck correct
activity. 3: Constantly
high signal at 3: Check the signal to the unit
inputs T1:101 • Compare the signals from the
sensor with the input signal (use
a volt meter and verify using
TruckCom or the built-in test
that the signals are the same)
• Check the pins on the unit and in
the connector
• Replace the unit if you cannot
get it to work properly

© TMHE 8 – 10 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the sensor signal
• Check that the distance
between the sensor and the
opposite part is correct.
• Check that there is no dirt or
foreign objects on the sensor
• Inspect cabling.
1: High signal • Measure the signals from the
from both sensor with a volt meter and
Incorrect signal B121 and verify using TruckCom or the
combination from B122 built-in test that the signal is
2:284 Creep speed
the gate position 2: Constantly correct
sensor high signal at 2: Check the signal to the unit
inputs (T1:88)
and (T1:96) • Compare the signals from the
sensor with the input signal (use
a volt meter and verify using
TruckCom or the built-in test
that the signals are the same)
• Check the pins on the unit and in
the connector
• Replace the unit if you cannot
get it to work properly
1: Charge the battery.
2: Check battery voltage

1: The battery is • Check the voltage using the


discharged built-in test procedure and
comparing with value from
2: Voltage loss external volt meter
Everything is
on supply to
A5 • Check connectors, joints and
Low battery voltage stopped at once,
splices for damage or corrosion.
below 16.8 Volts for the parking brake 3: The battery is
2:501
more than 2 is activated, and defective • Check fuses F1 and F50
seconds the main
contactor opens 4: Battery 3: Inspect the battery.
parameter 4: Check parameters
#107 has an
erroneous • Check that factory parameters
value are set according to the truck
configuration.
• Check that other parameters
are set correctly.

© TMHE 8 – 11 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Copy the truck configuration
1: A5 is replaced using TruckCom
and/or • See the separate manual for
Everything is erroneous TruckCom.
stopped at once, value for
Truck type not set
the parking brake factory 2: Check parameters.
2:502 Parameter 1001 is
is activated, and parameters
incorrectly set
the main
• Check that factory parameters
contactor opens 2: Incorrect value are set according to the truck
for parameter configuration.
1001 • Check that other parameters
are set correctly.
1: Copy the truck configuration
1: A5 is replaced using TruckCom
and/or
erroneous • See the separate manual for
Wrong truck model Everything is TruckCom.
set. stopped at once, value for
Parameter 1108 is the parking brake factory 2: Check parameters.
2:503 parameters
wrongly set in is activated, and
combination with the main
• Check that factory parameters
2: Wrong value are set according to the truck
1001 contactor opens
for parameter configuration.
1108 and/or
1001 • Check that other parameters
are set correctly.

© TMHE 8 – 12 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Charge the battery
2: Check the voltages in T1
• Check fuses F50 and F1
• Check the voltage using a volt
meter (Measuring point F50 - B-
) and compare with the
TruckCom value “Battery
Voltage” (Node:ACT, Analogue
I/O) (Limit values?) (TBD)
• Check the voltage using a volt
1: The battery is meter (Measuring point F1 - B-)
discharged and compare with the
2: Voltage loss TruckCom value “Battery
on pre-supply Voltage” (Node:ACT, Analogue
The battery voltage Everything is I/O) (Limit values?) If the
to the capacitors in stopped at once, to T1
contactor is open, there is
T1 is below 16.0 the parking brake 3: The battery is
2:504
Volt when the main is activated, and
several volts of difference --
defective normal. If the contactor is
contactor must be the main
closed contactor opens 4: Battery closed, voltage should match
parameter the point over +XX
#107 has an • Check the connectors, joints
erroneous and splices
value
• Check that any extra equipment
is connected in accordance with
our recommendation.
3: Inspect the battery.
4: Check parameters
• Check that factory parameters
are set according to the truck
configuration.
• Check that other parameters
are set correctly.

© TMHE 8 – 13 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
that the resistance between
(X41:3) and (X41:4) is 54 - 66
ohms.
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
1: Error on CAN the chassis and CAN contact.
bus wiring or Limit value >24 kOhm
Everything is connection
2: Check for loose connections
A5 has received stopped at once, 2: Loose
the parking brake connections • Switch on the truck, and pull
2:511 too may
is activated, and carefully in the branches of the
erroneous signals the main 3: Defective CAN wiring harness to find any loose
contactor opens node connections, and note when/if
4: Software the error code appears.
failure 3: Check the CAN node
• Deactivate and disconnect the
option unit connected to the
CAN wiring (e.g. K110,B90,T14
and A36/A37). Activate and
then connect them one by one
to identify which unit produces
the communication error.
4: Update the truck software
• Update the truck software to the
latest version.

© TMHE 8 – 14 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
that the resistance between
(X41:3) and (X41:4) is 54 - 66
ohms.
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
2: Check parameters.
• Check that factory parameters
1: Error on CAN
are set according to the truck
bus wiring or
configuration.
connection
• Check that other parameters
2: Wrong setting
are set correctly.
Everything is for parameter
No return signal 3: Check K110 (DHU/TWIS)
stopped at once, 102
from K110 (DHU/
the parking brake
2:515 TWIS) within 0.6
is activated, and
3: No connection • Check that the DHU's green
seconds after
the main with K110 LED is lit. If the LED is not lit:
logging on Check the DHU's feed voltage =
contactor opens 4: Loose
battery voltage
connections
• Check that it is possible to
5: Software
connect TruckCom to the DHU.
failure
If it is possible to connect them,
check the DHU's configuration.
If there is a power supply but no
communication, check the CAN
bus. If it still not possible to
communicate with the DHU,
replace the unit.
4: Check for loose connections
• Switch on the truck, and pull
carefully in the branches of the
wiring harness to find any loose
connections, and note when/if
the error code appears.
5: Update the truck software
• Update the truck software to the
latest version.

© TMHE 8 – 15 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
A5 has an incorrect 1: Check whether contact X203
box address. Everything is is short circuited. If a jumper is
There is a jumper/ stopped at once,
fitted, remove it.
short circuit in the parking brake Box address error on
2:516
contact X203 is activated, and A5 2: Replace A5
between pin 1 and the main
0 V internally on contactor opens • See section "13.1.6 Replacing
the A5 card. the logic card".
1: Check parameters
• Check that factory parameters
are set according to the truck
configuration.
• Check that other parameters
are set correctly.
2: Replace A5
• See section "13.1.6 Replacing
1: New software the logic card".
has been
loaded in the 3: Set new checksum
truck, adding a • If the problem with the check
Everything is new sum occurs directly in
The checksum of
stopped at once, parameter, or connection with the software
the parameter
the parking brake it has changed update, proceed as follows:
2:520 values does not
is activated, and the parameter
match the • Change the value of one
the main limit values
parameter values. parameter in each category,
contactor opens
2: Corrupt operator parameters, service
memory circuit parameters and calibration
3: Checksum parameters.
error • Save the changes and restart
the truck.
• Reset the values you changed
in the previous step back to their
original values.
• Restart the truck.
• The program will have
performed a new checksum
calculation.

© TMHE 8 – 16 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the Hall sensors
• Check with TruckCom or the
built-in test that the Hall sensors
Incorrect power
Plug braking to work the way they should.
supply to the Hall
stop, then the
sensors. Incorrect power • A Hall sensor that is being
parking brake is
2:522 High (or low) signal supply to the Hall influenced should give a low
activated and the
from all Hall sensors. signal.
main contactor
sensors A5:S300-
opens
S318 • Replace A5 if the Hall sensors
have an error function. See
section "13.1.6 Replacing the
logic card".
Everything is
Internal memory
stopped at once, 1: Replace A5
(FRAM or RAM) is
the parking brake • Corrupt
2:523 faulty Reading from • See section "13.1.6 Replacing
or writing to
is activated, and memory circuit
the main the logic card".
memory failed
contactor opens
1: Update the truck software.
A5 does not have The truck cannot Software download • Update the truck entire software
2:525
any truck software be started interrupted package to the latest available
version.
1: Check contactor
• Check the function of the main
contactor and that there is no
Contactor points in connection between the points.
the main contactor
fused • Check that there is no short-
Everything is circuit that can cause improper
High voltage over
stopped at once, Contactor points in
the capacitor bank power supply.
the parking brake the main contactor
2:540 internally in the
is activated, and are fused. Q10:3, • If this voltage does not increase
motor control unit
the main Q10:4 when the main contactor pulls
on the secondary
contactor opens and the voltage is close to
side of the
connector when it battery voltage (measured via
is open precharge in), it is a sign that the
contactor points in the main
contactor are fused.
• Replace the contactor.

© TMHE 8 – 17 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check contactor
• Check the function of the main
contactor and that there is no
connection between the points.

Contactor points for • Check that there is no short-


steering servo and circuit that can cause improper
Everything is power supply.
pump etc. in the
stopped at once, Contactor points in
main contactor are
the parking brake the main contactor • On this side of the main
2:541 fused.
is activated, and are fused. Q10:1, contactor, there is no PTC
Voltage on this
the main Q10:2 resistor that can precharge any
side is measured
contactor opens capacitor bank. So, this voltage
through the
steering servo. drops towards zero when the
main contactor is open. Check
that the voltage drops at least 1
V over 5 seconds before trying
to pull the main contactor again.
• Replace the contactor.
1: Check fuses
• Check if there is any contact on
the fuse. Replace the fuse if it is
defective.
2: Check contactor
• Check the contactor's function
1: Fuse F1 and that there is a connection
Main contactor defective between the points [Q10:3] and
Everything is
ordered to close [Q10:4].
stopped at once,
but stays open. 2: Poor or no
the parking brake • Check that there is no short-
2:560 Low voltage on the connection
is activated, and circuit that can cause improper
secondary side of between the
the main
the contactor when points. power supply.
contactor opens
it is closed
3: Broken wiring • Replace the contactor.
3: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.
• Measure and check the voltage
with the functions activated

© TMHE 8 – 18 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check fuses
• Check if there is any contact on
the fuse. Replace the fuse if it is
defective.
2: Check contactor
• Check the contactor's function
1: Fuse F53 and that there is a connection
Main contactor defective between the points [Q10:1] and
Everything is
ordered to close [Q10:2].
stopped at once,
but stays open. 2: Poor or no
the parking brake • Check that there is no short-
2:561 Low voltage on the connection
is activated, and circuit that can cause improper
secondary side of between the
the main
the contactor when points. power supply.
contactor opens
it is closed
3: Broken wiring • Replace the contactor.
3: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.
• Measure and check the voltage
with the functions activated
1: Check the Hall sensors
• Check with TruckCom or the
built-in test for the Hall sensors
Plug braking to that they work the way they
The Hall element
stop, then the
for the speed should. A Hall sensor that is
main contactor
2:580 control gives a A5 defective being influenced should give a
opens and the
signal (active low) low signal.
parking brake is
when it should not
activated • Replace A5 if the Hall sensors
have an error function. See
section "13.1.6 Replacing the
logic card".

© TMHE 8 – 19 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Let go of the control, and wait
for four seconds
2: Check the speed control
• Check the spring function
• Check that the speed control is
not seized
The speed control 1: Control
manipulated. • Check that the plastic cover
was not in the
neutral position at
where the spring is attached is
2: The speed intact.
start-up The truck cannot
control does
3:001 One or more Hall be driven, other 3: Check the Hall sensors
elements for the functions OK
not spring
speed control give back to neutral • Check with TruckCom or the
an active signal at position. built-in test for the Hall sensors
start 3: A5 defective that they work the way they
should. A Hall sensor that is
being influenced should give a
low signal.
• Replace A5 if the Hall sensors
have an error function. See
section "13.1.6 Replacing the
logic card".

© TMHE 8 – 20 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
2: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
steering motor as well as the
battery charger and fans and
filters for accumulations of dirt
and dust. Too much dust and dirt
cause the cooling not to work
properly.
• Check that the fans work when
The temperature the speed control is activated
1: Cooling is
sensor in the motor (fans behind T1 and motor fan)
The motor control reduced or the
control power stage
3:080 is limiting the temperature • Check that the fan on charger
is outside the limit
values. Above
voltage. sensor is T14 works when the charging
130°C defective. begins, i.e. when the mains
cable is connected
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.

© TMHE 8 – 21 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
steering motor as well as the
battery charger and fans and
filters for accumulations of dirt
and dust. Too much dust and dirt
cause the cooling not to work
properly.
• Check that the fans work when
the speed control is activated
The motor 1: Cooling is
(fans behind T1 and motor fan)
temperature sensor Creep speed and reduced or the
3:081 is outside of limit motor control temperature • Check that the fan on charger
values. Above limits the voltage. sensor is T14 works when the charging
210°C. defective. begins, i.e. when the mains
cable is connected
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.
Creep speed, 1: Internal 1: Create a truck report. Send a
Motor control program error report to the manufacturer.
blocked lifting/
3:100 warning. Unknown
lowering 2: Software 2: Update the truck software to
warning
movement failure the latest version.
Creep speed, • Replace T1
Incorrect checksum
blocked lifting/
3:120 for the motor Motor control corrupt • See section "14.7.2 Replacing
lowering
control parameters the motor control".
movement
The strength of the
current through the • Replace T1
horn is more than Defective transistor
3:127 Not influenced • See section "14.7.2 Replacing
200mA even on the output
though the output the motor control".
is deactivated

© TMHE 8 – 22 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
The strength of the
current through the
output to the fans is • Replace T1
Defective transistor
3:128 more than 200mA Not influenced • See section "14.7.2 Replacing
on the output
even though the the motor control".
output is
deactivated
1: Check for overcurrent or short
circuit:
• Check the ohms and the
Hardware amperes of the component,
protection in T1 compare them to the setpoint
detects a short values if they outside the
circuit in the output
accepted range.
for the horn. The High power
3:140 current through the Not influenced consumption or • Check the connections and
horn is above the short circuit wiring harness for short-circuit.
valid limit value.
Maximum value = • Check that the component does
500mA, continuous not seize or is jammed.
value = 300mA • If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component
1: Check for overcurrent or short
circuit:
• Check the ohms and the
Hardware amperes of the component,
protection in T1 compare them to the setpoint
detects a short values if they outside the
circuit in the output
accepted range.
for the fans. The High power
3:141 current through the Not influenced consumption or • Check the connections and
fan is above the short circuit wiring harness for short-circuit.
valid limit value.
Maximum value = • Check that the component does
2.5A, continuous not seize or is jammed.
value = 1.5A • If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component

© TMHE 8 – 23 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the rotational speed
sensor
T1 detects to high • Disconnect the B11. Check that
speed for the • Defective there are no metal fragments on
3:225 Creep speed
motor, more than component B11 sensor points.
5000 rpm
• Check that the toothed wheel on
the motor axle is clean, intact
and properly mounted.
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
that the resistance between
(X41:3) and (X41:4) is 54 - 66
ohms.
• Check that the CAN wiring
harness is not pinched.
1: Error on CAN Measure resistance between
bus wiring or the chassis and CAN contact.
connection Limit value >24 kOhm
2: Incorrect value 2: Check parameters.
Motor control start- The truck cannot for parameter
3:303 • Check that factory parameters
up failed be started 1001
are set according to the truck
3: No power configuration.
supply
• Check that other parameters
4: Wrong kind of are set correctly.
motor control
3: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.
• Measure and check the voltage
for the activated functions
4: Replace T1
• See section "14.7.2 Replacing
the motor control".

© TMHE 8 – 24 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
Everything is
stopped at once, 1: Replace T1
the parking brake Defective motor
3:500 Internal error in T1 • See section "14.7.2 Replacing
is activated, and control
the main the motor control".
contactor opens
Everything is
stopped at once, 1: Replace T1
Error in T1 when the parking brake Defective motor
3:502 • See section "14.7.2 Replacing
saving parameters is activated, and control
the main the motor control".
contactor opens
Everything is
stopped at once, 1: Update the truck software
Unknown error in the parking brake No software • Update the truck entire software
3:505
T1 is activated, and compatibility package to the latest available
the main version.
contactor opens
1: Charge the battery
Motor control 2: Check battery voltage
detects excessively 1: Battery • Check the voltage using the
low battery voltage discharged built-in test procedure and
at start-up. The truck cannot
3:506 2: Voltage loss comparing with value from
Battery voltage be started
below 15.3V after on supply to external volt meter
10 seconds from T1 • Check connectors, joints and
power-on splices for damage or corrosion.
• Check fuses F1 and F50
Everything is
stopped at once, 1: Replace T1
the parking brake Defective motor
3:507 Internal error in T1 • See section "14.7.2 Replacing
is activated, and control
the main the motor control".
contactor opens

© TMHE 8 – 25 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
that the resistance between
Everything is 1: Error on CAN (X41:3) and (X41:4) is 54 - 66
CAN
stopped at once, bus wiring or
communication ohms.
the parking brake connection
3:511 problem between
T1 and A5, A5 gets
is activated, and • Check that the CAN wiring
the main 2: CAN module harness is not pinched.
no signals from T1
contactor opens in A5 defective Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
2: Replace A5
• See section "13.1.6 Replacing
the logic card".
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Everything is Disconnect the battery. Check
CAN
stopped at once,
communication 1: Error on CAN that the resistance between
the parking brake
3:512 problem between bus wiring or (X41:3) and (X41:4) is 54 - 66
is activated, and
A5 and T1, T1 gets connection ohms.
the main
no signals from A5
contactor opens • Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm

© TMHE 8 – 26 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
that the resistance between
Everything is 1: Error on CAN (X41:3) and (X41:4) is 54 - 66
CAN stopped at once, bus wiring or ohms.
communication the parking brake connection
3:514
problem, A5 cannot is activated, and • Check that the CAN wiring
send to T1 the main 2: CAN module harness is not pinched.
contactor opens in A5 defective Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
2: Replace A5
• See section "13.1.6 Replacing
the logic card".
Everything is The ground for
stopped at once, speed sensor and
Signal ground in T1
the parking brake temperature sensor
3:520 out of valid range
is activated, and is connected to
??V (TBD)
the main chassis, battery- or
contactor opens battery+
The amperage
Everything is
through the output
stopped at once, 1: Replace T1
to the brake (Q1) is
the parking brake Defective transistor
3:523 more than 200mA • See section "14.7.2 Replacing
is activated, and on the output
even though the the motor control".
the main
output is
contactor opens
deactivated
The amperage
through the output Everything is
to the main stopped at once, 1: Replace T1
contactor (Q10) is the parking brake Defective transistor
3:524 • See section "14.7.2 Replacing
more than 200mA is activated, and on the output
even though the the main the motor control".
output is contactor opens
deactivated
1: Check the rotational speed
sensor
T1 detects to high The drive is • Disconnect the B11. Check that
speed for the stopped • Defective there are no metal fragments on
3:525
motor, more than immediately with component B11 sensor points.
6000 rpm the parking brake
• Check that the toothed wheel on
the motor axle is clean, intact
and properly mounted.

© TMHE 8 – 27 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the motor
• Disconnect motor wiring
including sensor wires.
• Insulation test. Check that the
coils are not electrically
connected to the chassis.
Replace M1 if the motor is not
isolated
2: Check the motor wiring
1: Short circuit in harness
Hardware in T1 motor
detects a short
Everything is • Visual check of the motor wiring
stopped at once, harness. Check that there is no
circuit in the power 2: Short circuit in
the parking brake contact between the pole
3:540 stage and a phase- motor wiring
is activated, and connections on the motor/motor
to-phase short harness
the main control. Search for contact and
circuit, phase B-
contactor opens 3: Short circuit in
and phase B+ damaged insulation on the
power stage wiring harness.
• Disconnect the motor wiring
harness at the motor control and
the motor and measure the
ohms of the wiring harness
between the phases and verify
that there is no contact.
3: Replace T1
• See section "14.7.2 Replacing
the motor control".
1: Check for overcurrent or short
circuit:
• Check the ohms and the
amperes of the component,
compare them to the setpoint
values if they outside the
Too many amperes The drive is accepted range.
High power
to the speed stopped
3:542 consumption or • Check the connections and
sensor, limit value immediately with
short circuit wiring harness for short-circuit.
68 mA the parking brake
• Check that the component does
not seize or is jammed.
• If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component

© TMHE 8 – 28 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check for overcurrent or short
circuit:
Hardware • Check the ohms and the
protection in T1 amperes of the component,
detects a short compare them to the setpoint
circuit in the output values if they outside the
Everything is
to the brake (Q1)
stopped at once, accepted range.
The current High power
the parking brake
3:545 through the brake consumption or • Check the connections and
is activated, and
exceeds the limit short circuit wiring harness for short-circuit.
the main
values. Maximum
contactor opens • Check that the component does
value = 5.95A,
continuous value = not seize or is jammed.
3A • If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component
1: Check for overcurrent or short
circuit:
• Check the ohms and the
Hardware amperes of the component,
protection in T1 compare them to the setpoint
detects a short values if they outside the
Everything is
circuit or current
stopped at once, accepted range.
through the main High power
the parking brake
3:546 contactor (Q10) consumption or • Check the connections and
is activated, and
exceeds valid limit short circuit wiring harness for short-circuit.
the main
values. Maximum
contactor opens • Check that the component does
value = 2.5A,
continuous value = not seize or is jammed.
1.5A • If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component
Everything is
Hardware
stopped at once, Components are
protection in T1
the parking brake using too much
3:547 detects a short •
is activated, and power or wiring is
circuit in the output
the main short circuited.
“High Side driver”
contactor opens

© TMHE 8 – 29 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.
• Measure and check the voltage
The amperage to The drive is 1: Broken wiring for the activated functions
speed sensor (B11) stopped
3:560 2: Check the rotational speed
is below the 6mA immediately with 2: Defective
limit value the parking brake component sensor
• Disconnect the B11. Check that
there are no metal fragments on
B11 sensor points.
• Check that the toothed wheel on
the motor axle is clean, intact
and properly mounted.
1: Check wiring and component
after the break
• Disconnect the battery
• Visually inspect the wiring
harness
Everything is
The amperage is • Using instruments, check that
stopped at once,
below the limit 1: Low power there is no break in any wire
the parking brake
3:563 value 100mA on consumption
is activated, and • Check the ohms and the
the output to brake or break
the main amperes of the component,
(Q1)
contactor opens
compare them to the setpoint
values and replace if they are
outside the accepted range.
• Reconnect the battery. Measure
and check the voltage for the
activated functions.

© TMHE 8 – 30 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check wiring and component
after the break
• Disconnect the battery
• Visually inspect the wiring
harness
Everything is
The amperage is • Using instruments, check that
stopped at once,
below the limit 1: Low power there is no break in any wire
the parking brake
3:564 value 100mA on consumption
is activated, and • Check the ohms and the
the output to brake or break
the main amperes of the component,
(Q10)
contactor opens
compare them to the setpoint
values and replace if they are
outside the accepted range.
• Reconnect the battery. Measure
and check the voltage for the
activated functions.
1: Check for overcurrent or short
circuit:
• Check the ohms and the
amperes of the component,
compare them to the setpoint
values if they outside the
accepted range.
Power supply to 1: High power • Check the connections and
The drive is consumption
B11 out of valid wiring harness for short-circuit.
stopped or short circuit.
3:584 range. External
12V outside of valid
immediately with • Check that the component does
the parking brake 2: Defective not seize or is jammed.
range: 10V - 14V
motor control.
• If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component
2: Replace T1
• See section "14.7.2 Replacing
the motor control".

© TMHE 8 – 31 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the motor
• Disconnect motor wiring
including sensor wires.
• Insulation test. Check that the
coils are not electrically
connected to the chassis.
Replace M1 if the motor is not
isolated
2: Check the motor wiring
Software in T1
1: Short circuit in harness
detects too high a
current in the motor • Visual check of the motor wiring
power stage and The drive is harness. Check that there is no
2: Short circuit in
also high current stopped contact between the pole
3:586 motor wiring
phase-phase, immediately with connections on the motor/motor
phase B- and the parking brake harness
control. Search for contact and
phase B+. The 3: Short circuit in damaged insulation on the
current is 150% of power stage
maximum current.
wiring harness.
• Disconnect the motor wiring
harness at the motor control and
the motor and measure the
ohms of the wiring harness
between the phases and verify
that there is no contact.
3: Replace T1
• See section "14.7.2 Replacing
the motor control".
1: Check battery voltage
• Check the voltage using the
Everything is 1: Voltage loss built-in test procedure and
stopped at once, on supply to comparing with value from
Battery voltage the parking brake T1 external volt meter
3:587
exceeds 33 V is activated, and
the main 2: Battery • Check connectors, joints and
contactor opens defective splices for damage or corrosion.
• Check fuses F1 and F50
2: Inspect the battery.

© TMHE 8 – 32 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Charge the battery.
2: Check the voltages in T1
• Check fuses F50 and F1
• Check the voltage using a volt
meter (Measuring point F50 - B-
) and compare with the
TruckCom value “Battery
Voltage” (Node:ACT, Analogue
I/O) (Limit values?) (TBD)
• Check the voltage using a volt
1: The battery is meter (Measuring point F1 - B-)
discharged and compare with the
2: Voltage loss TruckCom value “Battery
on power Voltage” (Node:ACT, Analogue
Everything is I/O) (Limit values?) If the
stopped at once, supply to T1
contactor is open, there is
Battery voltage is the parking brake 3: The battery is
3:589
below 12 V is activated, and
several volts of difference --
defective normal. If the contactor is
the main
contactor opens 4: Battery closed, voltage should match
parameter # the point over +XX
107 has an • Check the connectors, joints
erroneous and splices
value
• Check that any extra equipment
is connected in accordance with
our recommendation.
3: Inspect the battery.
4: Check parameters
• Check that factory parameters
are set according to the truck
configuration.
• Check that other parameters
are set correctly.

© TMHE 8 – 33 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.

1: Broken wiring • Measure and check the voltage


with the functions activated
2: Defective
The drive is 2: Check the rotational speed
The change component
stopped sensor
3:590 exceeds 1000 rpm
immediately with 3: Change in
in 20 ms
the parking brake surface friction • Disconnect the B11. Check that
combined with there are no metal fragments on
slippage B11 sensor points.
• Check that the toothed wheel on
the motor axle is clean, intact
and properly mounted.
3: Drive carefully if there is a risk
of slipping
1: Check the rotational speed
sensor
Improbable motor The drive is • Disconnect the B11. Check that
rpm stopped 1: Defective there are no metal fragments on
3:591
Rpm over 15000 immediately with component B11 sensor points.
rpm the parking brake
• Check that the toothed wheel on
the motor axle is clean, intact
and properly mounted.
Internal electrical The drive is 1: Replace T1
fault. stopped 1: Defective
3:592 • See section "14.7.2 Replacing
Sensor offset is too immediately with motor control
high the parking brake the motor control".

© TMHE 8 – 34 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.
• Measure and check the voltage
Signal error B11. with the functions activated
The drive is 1: Broken wiring
Loss of channel A
stopped
3:593 in the rotational 2: Check the rotational speed
immediately with 2: Defective
speed sensor
the parking brake component sensor
detected
• Disconnect the B11. Check that
there are no metal fragments on
B11 sensor points.
• Check that the toothed wheel on
the motor axle is clean, intact
and properly mounted.
1: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.
• Measure and check the voltage
Signal error B11. with the functions activated
The drive is 1: Broken wiring
Loss of channel B
stopped
3:594 in the rotational 2: Check the rotational speed
immediately with 2: Defective
speed sensor
the parking brake component sensor
detected
• Disconnect the B11. Check that
there are no metal fragments on
B11 sensor points.
• Check that the toothed wheel on
the motor axle is clean, intact
and properly mounted.

© TMHE 8 – 35 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Intensive use of the truck. Let
the truck cool down.
2: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
steering motor as well as the
battery charger and fans and
filters for accumulations of dirt
and dust. Too much dust and dirt
cause the cooling not to work
properly.
1: Intensive use
of the truck • Check that the fans work when
The drive is the speed control is activated
The motor control 2: Cooling is
stopped (fans behind T1 and motor fan)
3:596 unit temperature reduced or the
immediately with
exceeds +110°C. temperature • Check that the fan on charger
the parking brake
sensor is T14 works when the charging
defective. begins, i.e. when the mains
cable is connected
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.

© TMHE 8 – 36 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Intensive use of the truck. Let
the truck cool down.
2: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
steering motor as well as the
battery charger and fans and
filters for accumulations of dirt
and dust. Too much dust and dirt
cause the cooling not to work
properly.
1: Intensive use
of the truck • Check that the fans work when
The drive is the speed control is activated
The motor 2: Cooling is
stopped (fans behind T1 and motor fan)
3:597 temperature reduced or the
immediately with
exceeds +180°C. temperature • Check that the fan on charger
the parking brake
sensor is T14 works when the charging
defective. begins, i.e. when the mains
cable is connected
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.
Internal 5V outside
Everything is
of valid range:
stopped at once, 1: Replace T1
4.12V - 5.88V or
the parking brake 1: Defective
3:598 internal 15V • See section "14.7.2 Replacing
voltage outside
is activated, and motor control
the main the motor control".
valid range: 10.56V
contactor opens
- 19V

© TMHE 8 – 37 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check for overcurrent or short
circuit:
• Check the ohms and the
amperes of the component,
compare them to the setpoint
values if they outside the
Voltage regulator Creep speed, accepted range.
1: High power
for analogue blocked lifting/
3:599 consumption • Check the connections and
sensors out of valid lowering
range: 4V - 6V movement or short circuit wiring harness for short-circuit.
• Check that the component does
not seize or is jammed.
• If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component.
Lifting/lowering
control is not in
neutral position at
Blocked lifting/
start-up. Lifting is 1: Control 1: Let go of the control, and wait
4:001 lowering
prevented until the
movement
manipulated for four seconds
lifting/lowering
controller is back in
the neutral position.
1: Check parameters
• Check that factory parameters
Signal from the 1: Incorrect value
sensilift are set according to the truck
for parameter
potentiometer Blocked lifting/ configuration.
1102
4:102 detected even lowering • Check that other parameters
though parameter movement 2: Error in
are set correctly.
1102 does not have hydraulic
the value 4. controls 2: Replacement of the hydraulic
control. See section
"13.1 Steering arm C4110".

© TMHE 8 – 38 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the analogue sensors
• Check that the sensor has a 5V
or 24V power supply
(depending on the component)
• Compare the measured output
from the sensor with the
corresponding value in
The signal from the 1: Defective TruckCom or built-in test. If the
pressure sensor B4 Creep speed,
component, values are the same and are out
4:180 is out of valid blocked lifting
range: 0.3 V - 4.86 movement
short circuit or of the valid range, it indicates an
V wire cut off error in the sensor or the wiring
harness. Repair or replace the
component.
• If the values are not the same, it
points to an error in T1. Replace
T1
• See section "14.7.2 Replacing
the motor control".
Current through the
Everything is
output to the
stopped at once, 1: Replace T1
PowerTrak valve 1: Defective
the parking brake
4:231 (Q58) is more than transistor on • See section "14.7.2 Replacing
is activated, and
200 mA even the output. the motor control".
the main
though the output
contactor opens
is deactivated.
The current Everything is
through output stopped at once, 1: Replace T1
1: Defective
exceeds 200mA to the parking brake
4:232 transistor on • See section "14.7.2 Replacing
the pump contactor is activated, and
(Q25) when it is not the main the output. the motor control".
active. contactor opens
Everything is
Current through the
stopped at once, 1: Replace T1
Q70 output is more 1: Defective
the parking brake
4:233 than 200 mA even transistor on • See section "14.7.2 Replacing
is activated, and
though the output the output. the motor control".
the main
is inactive.
contactor opens
Everything is
Current through the
stopped at once, 1: Replace T1
Q4/Q40 output is 1: Defective
the parking brake
4:234 more than 200 mA transistor on • See section "14.7.2 Replacing
is activated, and
even though the the output. the motor control".
the main
output is inactive.
contactor opens

© TMHE 8 – 39 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
Everything is
Current through the
stopped at once, 1: Replace T1
Q41/Q23 output is 1: Defective
the parking brake
4:235 more than 200 mA transistor on • See section "14.7.2 Replacing
is activated, and
even though the the output. the motor control".
the main
output is inactive.
contactor opens
Plug braking to
Too high a current
stop, then the
measured in the
parking brake is
4:236 Q59 output when it 1: 1:
activated and the
is not active
main contactor
(exceeds 200 mA)
opens
1: Check for overcurrent or short
circuit:
• Check the ohms and the
amperes of the component,
Lowering valve compare them to the setpoint
(Q4/Q40) output is values if they outside the
short circuited or
accepted range.
too high a current Blocked lifting/ 1: High power
4:243 through the output. lowering consumption • Check the connections and
Valid limit values - movement or short circuit. wiring harness for short-circuit.
maximum value =
2.5 A, continuous • Check that the component does
value = 1.5 A not seize or is jammed.
• If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component
1: Check for overcurrent or short
circuit:
• Check the ohms and the
amperes of the component,
Valve coil (Q41/ compare them to the setpoint
Q23) output is values if they outside the
short circuited or
accepted range.
too high a current Blocked lifting/ 1: High power
4:244 through the output. lowering consumption • Check the connections and
Valid limit values - movement or short circuit. wiring harness for short-circuit.
maximum value =
2.5 A, continuous • Check that the component does
value = 1.5 A not seize or is jammed.
• If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component

© TMHE 8 – 40 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check for overcurrent or short
circuit:
• Check the ohms and the
PowerTrak drain amperes of the component,
valve (Q58) output compare them to the setpoint
is short circuited or values if they outside the
too high a current accepted range.
Creep speed, 1: High power
through the valve
4:245 blocked lifting consumption • Check the connections and
output Valid limit
movement or short circuit. wiring harness for short-circuit.
values - maximum
value = 2.5 A, • Check that the component does
continuous value = not seize or is jammed.
1.5 A
• If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component
1: Check for overcurrent or short
circuit:
Hardware • Check the ohms and the
protection in T1 amperes of the component,
detects a short compare them to the setpoint
circuit in the output values if they outside the
Q25 (pump
accepted range.
contactor). The Blocked lifting/ 1: High power
4:246 current through the lowering consumption • Check the connections and
contactor (Q25) is movement or short circuit wiring harness for short-circuit.
above the valid
limit value. • Check that the component does
Maximum value = not seize or is jammed.
2.5 A, continuous • If points 1-3 are OK, it indicates
value = 1.5 A
that the output stage is short
circuited - Replace the power-
supplying component

© TMHE 8 – 41 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check for overcurrent or short
circuit:
Hardware
protection in T1 • Check the ohms and the
detects a short amperes of the component,
circuit in output compare them to the setpoint
Q70 values if they outside the
(decompression accepted range.
Creep speed, 1: High power
locking valve) or
4:247 blocked lifting consumption • Check the connections and
current through the
movement or short circuit wiring harness for short-circuit.
valve output
exceeds the limit • Check that the component does
values. Maximum not seize or is jammed.
value = 2.5 A,
continuous value = • If points 1-3 are OK, it indicates
1.5 A that the output stage is short
circuited - Replace the power-
supplying component
Filler valve
(PowerTrak Q59)
Creep speed,
output is short
4:248 blocked lifting 1: 1:
circuited or too high
movement
a current through
the output
1: Check wiring and component
after the break
• Disconnect the battery
• Visually inspect the wiring
harness
Too low a current
on the PowerTrak • Using instruments, check that
Creep speed, 1: Low power there is no break in any wire
valve output (Q58).
4:561 blocked lifting consumption
Current exceeds • Check the ohms and the
movement or break
the limit value 100 amperes of the component,
mA.
compare them to the setpoint
values and replace if they are
outside the accepted range.
• Reconnect the battery. Measure
and check the voltage for the
activated functions.

© TMHE 8 – 42 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check wiring and component
after the break
• Disconnect the battery
• Visually inspect the wiring
harness
Current too low on • Using instruments, check that
pump contactor Blocked lifting/ 1: Low power there is no break in any wire
4:562 output (Q22,Q25, lowering consumption
Q52) - limit value movement or break • Check the ohms and the
100 mA amperes of the component,
compare them to the setpoint
values and replace if they are
outside the accepted range.
• Reconnect the battery. Measure
and check the voltage for the
activated functions.
1: Check wiring and component
after the break
• Disconnect the battery
• Visually inspect the wiring
harness
Too low a current • Using instruments, check that
on decompression Creep speed, 1: Low power there is no break in any wire
4:563 locking valve blocked lifting consumption
output (Q70) - limit movement or break • Check the ohms and the
value 100 mA amperes of the component,
compare them to the setpoint
values and replace if they are
outside the accepted range.
• Reconnect the battery. Measure
and check the voltage for the
activated functions.

© TMHE 8 – 43 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check wiring and component
after the break
• Disconnect the battery
• Visually inspect the wiring
harness

Too low a current • Using instruments, check that


Blocked lifting/ 1: Low power there is no break in any wire
on valve output
4:565 lowering consumption
(Q23 - Q41) - limit • Check the ohms and the
movement or break
value 100 mA amperes of the component,
compare them to the setpoint
values and replace if they are
outside the accepted range.
• Reconnect the battery. Measure
and check the voltage for the
activated functions.
Current on filler Creep speed,
4:566 valve (Powertrak) blocked lifting 1: 1:
output is too low movement

© TMHE 8 – 44 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Intensive use of the truck. Let
the truck cool down.
2: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
steering motor as well as the
battery charger and fans and
filters for accumulations of dirt
and dust. Too much dust and dirt
cause the cooling not to work
properly.
1: Intensive use
of the truck • Check that the fans work when
The temperature in the speed control is activated
the steering motor 2: Cooling is
5:035 Not influenced (fans behind T1 and motor fan)
power stage reduced or the
exceeds 68°C. temperature • Check that the fan on charger
sensor is T14 works when the charging
defective. begins, i.e. when the mains
cable is connected
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.

© TMHE 8 – 45 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.
• Measure and check the voltage
for the activated functions
2: Check the reference sensor
• Steer slightly to the right so that
the gear ring is correctly
positioned in relation to the
reference sensor.
• Cut off power to the truck.
• Check the clearance between
the sensor and the gear ring
Reference sensor 1: Broken wiring
error, amperes
elevation using a feeler gauge.
5:080 Not influenced 2: Defective Nominal measurement: 1.5 mm
below limit value
500µA component Note: Risk of personal injury if
power is restored to the truck
while work is performed on the
gear ring.
• Restore power to the truck.
• Check if there is any power
supply to B17, 9.8 - 13.5V
between wires 95 and 97.
• If there is a power supply,
replace B17.
• Check if there is a short circuit
between wires 95 and 97, but
also between wire 95 and the
rest of the electrical system.
• If there is no power supply or
short circuit, replace the T13

© TMHE 8 – 46 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the reference sensor
• Steer slightly to the right so that
the gear ring is correctly
positioned in relation to the
reference sensor.
• Cut off power to the truck.
• Check the clearance between
the sensor and the gear ring
elevation using a feeler gauge.
Nominal measurement: 1.5 mm
Power supply to Note: Risk of personal injury if
reference sensor power is restored to the truck
outside of valid while work is performed on the
1: Defective gear ring.
5:081 range. It should be Not influenced
9.8 - 13.5V
component
• Restore power to the truck.
between the wires
95-97. • Check if there is any power
supply to B17, 9.8 - 13.5V
between wires 95 and 97.
• If there is a power supply,
replace B17.
• Check if there is a short circuit
between wires 95 and 97, but
also between wire 95 and the
rest of the electrical system.
• If there is no power supply or
short circuit, replace the T13

© TMHE 8 – 47 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Avoid steering the truck when
stationary
2: Checking the steerability of the
drive unit.
1: Intensive • Check why the drive wheel
steering with cannot be turned with the help of
stationary the steering motor in the
Overloaded
truck following places.
steering motor to
5:135 Creep speed
80% of maximum 2: Turning of • Steering motor
capacity. drive wheel • Gears of the steering motor
was
prevented. • Gears
• Steering bearings
• Crown wheel/ steering motor
gear
• Drive wheel/surface

© TMHE 8 – 48 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check for overcurrent or short
circuit:
• Check the ohms and the
amperes of the component,
compare them to the setpoint
values if they outside the
accepted range.
• Check the connections and
wiring harness for short-circuit.
• Check that the component does
not seize or is jammed.
• If points 1-3 are OK, it indicates
Error in power that the output stage is short
supply to brake coil
1: High power
consumption circuited - Replace the power-
in (A83). Current
or short circuit supplying component.
differs from
5:136 Creep speed
requested current 2: Low power 2: Check wiring and component
by 100 mA and consumption after the break
current exceeds 2
or break • Disconnect the battery
A.
• Visually inspect the wiring
harness
• Using instruments, check that
there is no break in any wire
• Check the ohms and the
amperes of the component,
compare them to the setpoint
values and replace if they are
outside the accepted range.
• Reconnect the battery. Measure
and check the voltage for the
activated functions.

© TMHE 8 – 49 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the analogue sensor
• Check that the sensor has a 5V
or 24V power supply
(depending on the component)
The signal for the • Compare the measured output
steering angle from the sensor with the
sensor is out of corresponding value in
permitted range 1: Defective TruckCom or built-in test. If the
(only for component, values are the same and are out
5:180 Creep speed
mechanical short circuit or of the valid range, it indicates an
steering, not power wire cut off error in the sensor or the wiring.
steering) Permitted
Repair or replace the
range: 0.18V -
4.86V
component.
• If the values are not the same, it
points to an error in T1. Replace
the T1. See section
"14.7.2 Replacing the motor
control".

© TMHE 8 – 50 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the reference sensor
• Steer slightly to the right so that
the gear ring is correctly
positioned in relation to the
reference sensor.
• Cut off power to the truck.
• Check the clearance between
the sensor and the gear ring
elevation using a feeler gauge.
Nominal measurement: 1.5 mm
Note: Risk of personal injury if
power is restored to the truck
while work is performed on the
gear ring.
• Restore power to the truck.
• Check if there is any power
supply to B17, 9.8 - 13.5V
1: The clearance between wires 95 and 97.
between • If there is a power supply,
reference replace B17.
sensor and
When B17 • Check if there is a short circuit
crown wheel is
indicates 0 between wires 95 and 97, but
wrong
5:182 degrees, A83 must Creep speed also between wire 95 and the
lie in the interval +/- 2: Defective rest of the electrical system.
7 degrees component
• If there is no power supply or
3: Erroneous short circuit, replace the T13
steering angle
2: See above
signal
3: Check the steering angle
sensor
• Check the wiring between T13
and A83 for short circuit or
disruption - repair or replace the
wiring.
• Digital PWM signal from A83
cannot be measured, use an
A83 that works as a reference.
• Compare the steering angle
with the steering angle that is
indicated by the system via
Service Information Mode 13 or
TruckCom - If it does not seem
to be the same, check the
mechanical fastening of the
steering arm and make a new
steering angle calibration.
© TMHE 8 – 51 T Code(s): 1010
Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
Everything is
stopped at once,
Steering motor
the parking brake
5:301 control power stage 1: TBD 1: TBD
is activated, and
defective
the main
contactor opens
1: Check the voltages in T13
• Check the voltage using a volt
meter (Measuring points wires
40 and 23 at T13), and compare
with the value from TruckCom
“DC Bus Voltage” Compare with
battery voltage.
• Check the connectors, joints
and splices.
• Check fuse F53
1: Voltage loss
on supply to 2: Check the CAN bus
Everything is T13
stopped at once, • Check that CAN is intact in
the parking brake 2: Error on CAN terms of wiring harness,
5:303 Start of T13 failed
is activated, and bus wiring or resistance and connectors.
the main connections Disconnect the battery. Check
contactor opens that the resistance between
3: No software
(X41:3) and (X41:4) is 54 - 66
compatibility
ohms.
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
3: Update the truck software
• Update the truck entire software
package to the latest available
version.

© TMHE 8 – 52 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the voltages in T13
• Check the voltage using a volt
meter (Measuring points wires
40 and 23 at T13), and compare
1: Voltage loss with the value from TruckCom
on supply to “DC Bus Voltage” Compare with
T13 battery voltage.
Everything is
stopped at once, 2: The battery is • Check the connectors, joints
Voltage below valid the parking brake defective and splices.
5:320
level: 12V is activated, and • Check fuse F53
the main
3: Battery
contactor opens parameter # 2: Inspect the battery.
107 has an
erroneous 3: Check parameters
value • Check that factory parameters
are set according to the truck
configuration.
• Check that other parameters
are set correctly.
1: Checking the steerability of the
drive unit.
• Check why the drive wheel
cannot be turned with the help of
the steering motor in the
1: Turning of following places.
Everything is
drive wheel
was • Steering motor
stopped at once,
Overloaded the parking brake prevented. • Gears of the steering motor
5:325
steering motor is activated, and 2: Intensive
the main • Gears
steering with
contactor opens • Steering bearings
stationary
truck • Crown wheel/ steering motor
gear
• Drive wheel/surface
2: Avoid steering the truck when
stationary

© TMHE 8 – 53 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Intensive use of the truck. Let
the truck cool down.
2: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
steering motor as well as the
battery charger and fans and
filters for accumulations of dirt
and dust. Too much dust and dirt
cause the cooling not to work
properly.
1: Intensive use
Everything is of the truck • Check that the fans work when
The temperature in stopped at once, the speed control is activated
the steering motor the parking brake 2: Cooling is
5:326 (fans behind T1 and motor fan)
power stage is activated, and reduced or the
exceeds 85°C. the main temperature • Check that the fan on charger
contactor opens sensor is T14 works when the charging
defective. begins, i.e. when the mains
cable is connected
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.
1: No software 1: Update the truck software
compatibility
• Update the truck software to the
Everything is 2: Wrong latest version.
The internal stopped at once, electronic unit
2: Check the P/N of the electronic
parameters in the the parking brake in the motor
5:335 unit.
steering motor are is activated, and servo in
erroneous the main connection 3: Replace T13
contactor opens with change • See section "10.2.2 Replacing
3: Defective the steering motor".
electronic unit

© TMHE 8 – 54 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: No software 1: Update the truck software
compatibility
• Update the truck software to the
Everything is 2: Wrong latest version.
The internal stopped at once, electronic unit
2: Check the P/N of the electronic
parameters in the the parking brake in the motor
5:336 unit.
steering motor are is activated, and servo in
erroneous the main connection 3: Replace T13
contactor opens with change • See section "10.2.2 Replacing
3: Defective the steering motor".
electronic unit

© TMHE 8 – 55 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the reference sensor
• Steer slightly to the right so that
the gear ring is correctly
positioned in relation to the
reference sensor.
• Cut off power to the truck.
• Check the clearance between
the sensor and the gear ring
elevation using a feeler gauge.
Nominal measurement: 1.5 mm
Note: Risk of personal injury if
power is restored to the truck
while work is performed on the
gear ring.
• Restore power to the truck.
• Check if there is any power
supply to B17, 9.8 - 13.5V
between wires 95 and 97.

1: Defective • If there is a power supply,


Everything is replace B17.
stopped at once, component
T13 reports an • Check if there is a short circuit
the parking brake 2: Turning of
5:337 error during
is activated, and drive wheel between wires 95 and 97, but
reference run
the main was also between wire 95 and the
contactor opens rest of the electrical system.
prevented.
• If there is no power supply or
short circuit, replace the T13.
See section "10.2.2 Replacing
the steering motor".
2: Checking the steerability of the
drive unit.
• Check why the drive wheel
cannot be turned with the help of
the steering motor in the
following places.
• Steering motor
• Gears of the steering motor
• Gears
• Steering bearings
• Crown wheel/ steering motor
gear
• Drive wheel/surface

© TMHE 8 – 56 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
Everything is
Temperature in stopped at once,
steering motor the parking brake
5:380 1: TBD 1: TBD
exceeds high is activated, and
temperature the main
contactor opens
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
CAN Everything is Disconnect the battery. Check
communication stopped at once,
1: Error on CAN that the resistance between
problems between the parking brake
5:414 bus wiring or (X41:3) and (X41:4) is 54 - 66
A5 and T13. T13 is activated, and
does not get any the main connections ohms.
commands from A5 contactor opens • Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
CAN resistance and connectors.
communication Everything is Disconnect the battery. Check
problems between stopped at once,
1: Error on CAN that the resistance between
A5 and T13. A5 the parking brake
5:415 bus wiring or (X41:3) and (X41:4) is 54 - 66
gets no responses is activated, and
from T13 or the main connections ohms.
answers are contactor opens • Check that the CAN wiring
corrupted harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm

© TMHE 8 – 57 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
CAN Everything is Disconnect the battery. Check
communication stopped at once,
1: Error on CAN that the resistance between
problems between the parking brake
5:416 bus wiring or (X41:3) and (X41:4) is 54 - 66
A5 and T13. A5 is activated, and
gets no response the main connections ohms.
from T13. contactor opens • Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Everything is Disconnect the battery. Check
CAN stopped at once,
1: Error on CAN that the resistance between
communication the parking brake
5:417 bus wiring or (X41:3) and (X41:4) is 54 - 66
problems between is activated, and
A5 and T13 the main connections ohms.
contactor opens • Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm

© TMHE 8 – 58 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check battery voltage
• Check the voltage using the
built-in test procedure and
comparing with value from
external volt meter
• Check connectors, joints and
1: Voltage loss splices for damage or corrosion.
on supply to
Everything is • Check fuses F1 and F50
T1
stopped at once,
2: Check the voltages in T13
Voltage above limit the parking brake 2: Voltage
5:421
of 39V is activated, and measurement • Check the voltage using a volt
the main error in T13 meter (Measuring points wires
contactor opens 40 and 23 at T13), and compare
3: The battery is
with the value from TruckCom
defective
“DC Bus Voltage” Compare with
battery voltage.
• Check the connectors, joints
and splices.
• Check fuse F53
3: Inspect the battery.
Everything is 1: Replace M6
Current exceeds 1: Short circuit in
stopped at once, • See RM for instructions (TBD)
limit value 95 A. steering motor
the parking brake
5:422 Short circuit in 2: Replace T13
is activated, and 2: Short circuit in
steering motor
the main power stage • See section "10.2.2 Replacing
power stage.
contactor opens
the steering motor".
Everything is
stopped at once,
Internal program the parking brake 1: Software 1: Update the truck software to
5:435
error is activated, and failure the latest version.
the main
contactor opens
Everything is 1: Replace M6
stopped at once, 1: Interruption in
Interruptions in one servo motor • See RM for instructions (TBD)
the parking brake
5:436 or more phases in
is activated, and 2: Interruption in 2: Replace T13
T13/M6
the main power stage
contactor opens • See RM for instructions (TBD)

© TMHE 8 – 59 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour

Everything is
1: Defective
1: Replace M6
stopped at once, components
T13 detects an internally in • See RM for instructions (TBD)
the parking brake
5:437 erroneous signal M6
is activated, and 2: Replace T13
from Hall sensor
the main 2: Erroneous in-
contactor opens • See RM for instructions (TBD)
signal
Everything is
T13 detects a stopped at once,
problem with the parking brake 1: Internal error 1: Replace the T13 or the
5:438
voltage is activated, and in electronics complete unit (TBD)
measurement the main
contactor opens
Everything is 1: Update the truck software
stopped at once,
Unknown steering the parking brake 1: No software • Update the truck software to the
5:500 latest version.
motor error is activated, and compatibility
the main
contactor opens
Everything is 1: Create a truck report.
stopped at once,
Internal program the parking brake 1: Internal • Send a report to the
5:501 manufacturer.
error is activated, and program error
the main
contactor opens
1: Check parameters
Everything is
A5 detects T13 • Check that factory parameters
stopped at once,
even though 1: Incorrect value
the parking brake are set according to the truck
5:502 parameter 1107 is for parameter
set for mechanical
is activated, and configuration.
the main 1107
steering 1: Check that other parameters
contactor opens
are set correctly.

© TMHE 8 – 60 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the power supply to the
steering angle sensor
• Check the wiring between T13
and A83 for short circuit or
disruption - repair or replace the
wiring.
Everything is 1: Defective
stopped at once, • Measure the voltage between
Power supply to component,
the parking brake wires 91 and 94. Set point: 4.5V
5:520 A83 outside of valid short circuit or
range: 4.5V-5.5V
is activated, and - 5.5V
the main internal error
contactor opens in T13 • If the voltage is too high -
replace T13
• If the voltage is too low - open
splice A83 and measure output
4 on T13. If the voltage is too
low - replace T13, otherwise
replace A83
1: Check the steering angle
sensor
• Check the wiring between T13
and A83 for short circuit or
disruption - repair or replace the
wiring.

T13 detects a short


Everything is 1: Defective • Digital PWM signal from A83
stopped at once, cannot be measured, use an
circuit between component,
the parking brake A83 that works as a reference.
5:540 steering angle short circuit or
is activated, and
sensor signals 1 internal error • Compare the steering angle
the main
and 2 in T13 with the steering angle that is
contactor opens
indicated by the system via
Service Information Mode 13 or
TruckCom - If it does not seem
to be the same, check the
mechanical fastening of the
steering arm and make a new
steering angle calibration.

© TMHE 8 – 61 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the reference sensor
• Steer slightly to the right so that
the gear ring is correctly
positioned in relation to the
reference sensor.
• Cut off power to the truck.
• Check the clearance between
the sensor and the gear ring
elevation using a feeler gauge.
Nominal measurement: 1.5 mm
Note: Risk of personal injury if
power is restored to the truck
while work is performed on the
gear ring.
• Restore power to the truck.
• Check if there is any power
supply to B17, 9.8 - 13.5V
between wires 95 and 97.
Everything is 1: Defective • If there is a power supply,
stopped at once, component replace B17.
Reference run not
the parking brake
5:580 terminated within 2: Turning of
is activated, and • Check if there is a short circuit
15 seconds drive wheel
the main between wires 95 and 97, but
contactor opens was prevented also between wire 95 and the
rest of the electrical system.
• If there is no power supply or
short circuit, replace the T13
2: Checking the steerability of the
drive unit.
• Check why the drive wheel
cannot be turned with the help of
the steering motor in the
following places.
• Steering motor
• Gears of the steering motor
• Gears
• Steering bearings
• Crown wheel/ steering motor
gear
• Drive wheel/surface

© TMHE 8 – 62 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the steering angle
sensor
• Check the wiring between T13
and A83 for short circuit or
disruption - repair or replace the
wiring.
Everything is 1: Defective • Digital PWM signal from A83
stopped at once, cannot be measured, use an
Steering angle component,
the parking brake A83 that works as a reference.
5:582 signal 1 and 2 out short circuit or
is activated, and
of valid range internal error • Compare the steering angle
the main
contactor opens in T13 with the steering angle that is
indicated by the system via
Service Information Mode 13 or
TruckCom - If it does not seem
to be the same, check the
mechanical fastening of the
steering arm and make a new
steering angle calibration.
1: Check the steering angle
sensor
• Check steering angle signal 1
between pin 3 (contact A83) and
pin 5 (contact T13)
• Check the wiring between T13
and A83 for short circuit or
disruption - repair or replace the
Everything is 1: Defective wiring.
stopped at once,
Steering angle component,
the parking brake • Digital PWM signal from A83
5:583 signal 1 out of valid short circuit or
is activated, and cannot be measured, use an
range internal error
the main A83 that works as a reference.
contactor opens in T13
• Compare the steering angle
with the steering angle that is
indicated by the system via
Service Information Mode 13 or
TruckCom - If it does not seem
to be the same, check the
mechanical fastening of the
steering arm and make a new
steering angle calibration.

© TMHE 8 – 63 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the steering angle
sensor
• Check steering angle signal 2
between pin 4 (contact A83) and
pin 13 (contact T13)
• Check the wiring between T13
and A83 for short circuit or
disruption - repair or replace the
Everything is 1: Defective wiring.
stopped at once,
Steering angle component,
the parking brake • Digital PWM signal from A83
5:584 signal 2 out of valid short circuit or
is activated, and cannot be measured, use an
range internal error
the main A83 that works as a reference.
contactor opens in T13
• Compare the steering angle
with the steering angle that is
indicated by the system via
Service Information Mode 13 or
TruckCom - If it does not seem
to be the same, check the
mechanical fastening of the
steering arm and make a new
steering angle calibration.
Everything is 1: Update the truck software
stopped at once,
Incorrect • Update the truck software to the
the parking brake 1: No software
5:585 configuration of latest version.
steering motor
is activated, and compatibility
the main
contactor opens

© TMHE 8 – 64 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the steering angle
sensor
• Check the wiring between T13
and A83 for short circuit or
disruption - repair or replace the
wiring.
Everything is 1: Defective • Digital PWM signal from A83
stopped at once, cannot be measured, use an
Sums of steering component,
the parking brake A83 that works as a reference.
5:586 angle signals 1 and short circuit or
is activated, and
2 out of valid range internal error • Compare the steering angle
the main
contactor opens in T13 with the steering angle that is
indicated by the system via
Service Information Mode 13 or
TruckCom - If it does not seem
to be the same, check the
mechanical fastening of the
steering arm and make a new
steering angle calibration.
1: Resetting truck after collision
Collision sensor
has registered 2: Check parameters
1: Collision
collision levels • Check that factory parameters
8:001 outside set limit Creep speed 2: Parameters
are set according to the truck
values as defined 105 and 106
configuration.
by parameters 105 set too low.
and 106. • Check that other parameters
are set correctly.
The truck was
intentionally taken
8:002 Creep speed 1: TBD 1: Not implemented in I-site
out of service via
I_site
1: Check parameters
1: Option
Argument error in Not influenced. • Check that factory parameters
argument
option. Invalid The alarming are set according to the truck
8:003 error,
configuration in one option does not configuration.
or more options. work. parameters
1003 - 1042 • Check that other parameters
are set correctly.

© TMHE 8 – 65 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check your option buttons

Not influenced. • Check the function of the option


All option buttons buttons via the built-in test
One or more option are non- mode, Service Information
1: Option button
buttons on A5 is functional until mode 9 or TruckCom.
8:004 pressed
activated at start- the option button
up. that is influenced during start-up • If there is still a signal from a
is not influenced seemingly uninfluenced button,
any more. the button must be checked for
jamming or unwanted
connection.
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
CAN Disconnect the battery. Check
communication 1: Error on CAN that the resistance between
8:010 problem with the Not influenced bus wiring or (X41:3) and (X41:4) is 54 - 66
built-in charger T14 connections ohms.
at start-up
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
CAN Disconnect the battery. Check
communication 1: Error on CAN that the resistance between
8:011 problem with the Not influenced bus wiring or (X41:3) and (X41:4) is 54 - 66
built-in charger connections ohms.
T14.
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm

© TMHE 8 – 66 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the battery charger
cables.
• Disconnect the battery by
T14 detects no disconnecting the connector
1: Battery not
battery, voltage and power cable from the
8:020 Not influenced connected to
below valid level: charger.
6V charger
• Measure the ohms on red and
black cable from T14 to X1.
Replace the cables in case of
breakage.
T14 detects
excessively low
battery voltage 1: The battery is
8:021 Not influenced 1: Inspect the battery.
when charging. defective
Voltage below valid
level: 19.8V
T14 detects
excessively high
battery voltage 1: The battery is
8:022 Not influenced 1: Inspect the battery.
when charging. defective
Voltage above valid
level: 34.8V
1: Inform the client that the truck
T14 detects should be stored in normal
1: Truck used in
excessively low ambient temperatures to avoid
8:023 Not influenced cold
temperature when unnecessary wear and tear of
charging. environments.
the battery and other
components.

© TMHE 8 – 67 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
steering motor as well as the
battery charger and fans and
filters for accumulations of dirt
and dust. Too much dust and dirt
cause the cooling not to work
properly.
• Check that the fans work when
the speed control is activated
T14 has reduced 1: Cooling is
(fans behind T1 and motor fan)
the charging reduced or the
8:024 current to 0A Not influenced temperature • Check that the fan on charger
because of high sensor is T14 works when the charging
temperature. defective. begins, i.e. when the mains
cable is connected
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.
1: Update the truck software
1: No software • Update the truck software to the
Internal error in compatibility latest version.
8:027 Not influenced
T14 2: Defective 2: Replace the T14
component
• See section "18.6 Integrated
battery charger C5170".
1: Check parameters
1: Battery
The main charging • Check that factory parameters
parameters
time is exceeded are set according to the truck
109 and 110
8:028 by 5-11 hours Not influenced configuration.
incorrectly set.
depending of • Check that other parameters
battery capacity. 2: The battery is
are set correctly.
defective
2: Inspect the battery.

© TMHE 8 – 68 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check parameters
1: Battery
• Check that factory parameters
parameters
Charged capacity are set according to the truck
109 and 110
8:029 exceeds battery Not influenced configuration.
incorrectly set.
capacity. • Check that other parameters
2: The battery is
are set correctly.
defective
2: Inspect the battery.
1: Check parameters
Communication • Check that factory parameters
with charger T14 1: Incorrect value
are set according to the truck
8:030 exists, but factory Not influenced for parameter
parameter 1101 is
configuration.
1101
not activated. • Check that other parameters
are set correctly.
1: Update the truck software
Saving parameter 1: No software
8:031 Not influenced • Update the truck software to the
in T14 failed. compatibility
latest version.
1: Check parameters
Wrong battery type 1: Battery • Check that factory parameters
selected via parameters are set according to the truck
8:032 Not influenced
parameters 109 109 and 110 configuration.
and 110. incorrectly set.
• Check that other parameters
are set correctly.
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
CAN Creep speed,
1: Error on CAN that the resistance between
communication blocked lifting/
8:110 bus wiring or (X41:3) and (X41:4) is 54 - 66
problems between lowering
A5 and A36/A37 movement connections ohms.
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm

© TMHE 8 – 69 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
CAN Creep speed,
1: Error on CAN that the resistance between
communication blocked lifting/
8:111 bus wiring or (X41:3) and (X41:4) is 54 - 66
problems between lowering
A5 and A36/A37 movement connections ohms.
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
CAN
1: Error on CAN that the resistance between
communication
8:112 Not influenced bus wiring or (X41:3) and (X41:4) is 54 - 66
problems between
A5 and B90 connections ohms.
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
1: Check parameters
Argument error in Creep speed, • Check that factory parameters
option. Invalid blocked lifting/ 1: Argument are set according to the truck
8:123
configuration in one lowering error option configuration.
or more options. movement
• Check that other parameters
are set correctly.

© TMHE 8 – 70 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Creep speed, Disconnect the battery. Check
CAN blocked lifting
1: Error on CAN that the resistance between
communication movement If
8:130 bus wiring or (X41:3) and (X41:4) is 54 - 66
error with li-ion CAN key
battery connected - connections ohms.
creep speed • Check that the CAN wiring
harness is not pinched.
Measure resistance between
the chassis and CAN contact.
Limit value >24 kOhm
Temperature in the Creep speed, 1: Let the battery cool down
8:131 li-ion battery is too blocked lifting 1:
high movement
1: No action.
2: Check battery voltage
1: Regenerative • Check the voltage using the
Creep speed, braking with built-in test procedure and
Current in the li-ion fully-charged
8:132 blocked lifting comparing with value from
battery is too high battery.
movement external volt meter
2: • Check connectors, joints and
splices for damage or corrosion.
• Check fuses F1 and F50
Li-ion battery Creep speed, 1: Move the truck to a warmer
8:133 temperature below blocked lifting 1: area
permitted level movement
Creep speed, 1: Defective 1: Contact the battery
Defective hardware
8:134 blocked lifting sensor in the manufacturer.
in the li-ion battery
movement module.
1: Communication 1: Contact the battery
Internal CAN Creep speed, problem manufacturer.
8:135 problem in the li-ion blocked lifting between
battery movement modules in the
battery.
1: A module in 1: Restart the battery.
the battery has
Creep speed,
Overvoltage in the been switched
8:136 blocked lifting
li-ion battery
movement
off because its
voltage is too
high.

© TMHE 8 – 71 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Overvoltage, undervoltage,
Battery cells Creep speed, 1: Some battery temperature too high,
8:137 deactivated by blocked lifting functions are temperature too low. Let the
internal monitoring movement not working. battery rest and then restart
the battery.
1: Charge the battery
2: Check battery voltage
• Check the voltage using the
Creep speed, 1: Battery built-in test procedure and
Low battery voltage discharged
8:138 blocked lifting comparing with value from
in the li-ion battery
movement 2: Voltage drop. external volt meter
• Check connectors, joints and
splices for damage or corrosion.
• Check fuses F1 and F50
1: Check parameters
1: Battery
• Check that factory parameters
Wrong battery type Creep speed, parameter
are set according to the truck
8:139 selected via blocked lifting 1045 has
parameter 1045 movement
configuration.
incorrect
setting. • Check that other parameters
are set correctly.
1: Update the truck software
Start-up problem
Creep speed, • Create a truck report. Send a
between truck and 1: Internal
8:140 blocked lifting report to the manufacturer.
li-ion battery during
movement
program error
start. • Update the truck software to the
latest version.

© TMHE 8 – 72 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Lower the platform or lower the
gate.
2: Move the gate to a defined
position
3: Lower the gate for stacking
above 1.8 meters in order to
1: The gate is not have three escape routes
lowered when
the platform is 1: Check the sensor signal
The position of the raised.
gate in combination • Check that the distance
with the platform 2: Gate in an between the sensor and the
Driving or lifting opposite part is correct
gATE position and height undefined
stopped
sensor (SPE, position • Check that there is no dirt or
SWE) is not
3: Gate raised foreign objects on the sensor
permitted
when stacking • Inspect cabling.
above height
limit 1.8 m • Measure the signals from the
sensor with a volt meter and
verify using TruckCom or the
built-in test that the signal is
correct.
2: See above
3: See above
1: Move the platform to a defined
position
1: Check the sensor signal and/
or adjust the platform
• Check that the distance
between the sensor and the
The platform is 1: Platform in opposite part is correct
StOP lowered but not Driving stopped undefined • Check that there is no dirt or
loaded position foreign objects on the sensor
• Inspect cabling.
• Measure the signals from the
sensor with a volt meter and
verify using TruckCom or the
built-in test that the signal is
correct.

© TMHE 8 – 73 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Return the emergency stop
switch to the normal position
and restart the truck
Everything is 1: Emergency 2: Check the circuit of the
stopped at once, stop activated
Emergency stop emergency stop
the parking brake
ESO circuit open, low 2: Open
voltage on T1:114
is activated, and • Check that the emergency stop
the main electrical is in the normal position
contactor opens circuit
• Check fuse F51
• Check wiring and S21 after the
break
Travel speed
reduced because of
Reduced travel Reduced speed activated Click-2-
SLO 1:
speed and acceleration Creep, turtle or
emergency drive
mode.
1: After service is complete, enter
S-0h Time for service Not influenced Time for service a new or the same value in
parameter 101
1: Keep the feet inside the truck
profile.
2: Check the foot protection
1: A foot is sensor
A foot is indicated
outside of the truck breaking the • Check whether the light source
Foot Driving stopped light barrier
profile (sensor is misdirected
B124/B125) 2: Signal error • Check the wiring harness for a
break
• Check whether dirt or another
object is blocking the light
1: The tiller arm
The tiller arm comes down
Fold UP comes down too Driving stopped before the 1: Raise the arm.
quickly after start. motor control
unit is running.

© TMHE 8 – 74 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Intensive use of the truck. Let
the truck cool down.
2: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
steering motor as well as the
battery charger and fans and
filters for accumulations of dirt
The power stage in and dust. Too much dust and dirt
T1 shows a high cause the cooling not to work
temperature.
properly.
The temperature 1: Intensive use
exceeds 85°C.
The motor control of the truck • Check that the fans work when
reduces the the speed control is activated
The motor 2: Cooling is
Hot maximum (fans behind T1 and motor fan)
temperature sensor reduced or the
accelerating temperature • Check that the fan on charger
shows a high
voltage linearly T14 works when the charging
temperature. sensor is
The motor defective. begins, i.e. when the mains
temperature cable is connected
exceeds +150°C
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.

© TMHE 8 – 75 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Truck
Code Description Error cause(s) Procedure
behaviour
1: Inform the client that the truck
should be stored in normal
ambient temperatures to avoid
unnecessary wear and tear of
the battery and other
components.
2: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
The power stage of steering motor as well as the
the motor control is battery charger and fans and
very cold. filters for accumulations of dirt
The motor control
1: Truck used in and dust. Too much dust and dirt
unit temperature is
below -20°C
cold cause the cooling not to work
The motor control environments properly.
reduces the
The motor 2: Cooling is • Check that the fans work when
Cold maximum
temperature sensor reduced or the the speed control is activated
accelerating
shows a low temperature (fans behind T1 and motor fan)
voltage linearly
temperature
sensor is
The motor • Check that the fan on charger
defective.
temperature is T14 works when the charging
below begins, i.e. when the mains
-35°C cable is connected
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.

© TMHE 8 – 76 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

8.6 Service information


The truck has a service information mode that is a useful aid for
troubleshooting. To activate:
1. Connect the CAN service key to [X41] and log in.
2. The battery status symbol lights up.
3. Press the horn button [S18] repeatedly to select the desired mode in the
8 4 2 1 service information mode.
Note!
All truck functions work as normal when the service information mode is
active. Care should be taken when operating the truck and reading the
display at the same time.

Data Flashing symbol Description Resolution Unit Standard value


- BDI 10 % 0-100
Depending on
battery type.
1 Battery voltage 0.1 V
Compare with the
real battery voltage
Battery voltage, the value
indicated in an
2 approximate value of 1 A 0-450A
motor and pump
voltages.
Set speed sent to [T1]
from A5. Positive value in -12.5 - 12.5 km/h
3 the drive wheel direction. 0.1 km/h (depending on truck
Negative value in the fork type)
direction.
Speed value from the
speed sensor. Positive -12.5 - 12.5 km/h
4 value in the drive wheel 0.1 km/h (depending on truck
direction. Negative value type)
in the fork direction.
Forks or support arms,
lifting or lowering
5 1 % 0-100%
command. 100% shown
for on/off checked signals
Pressure sensor 1
(hydraulic pressure).
6 0.001 V 0.5-4.5V
“nonE” is shown if no
pressure sensor exists.
Pressure sensor 2
(hydraulic pressure).
7 0.001 V 0.5-4.5V
“nonE” is shown if no
pressure sensor exists.

© TMHE 8 – 77 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

Data Flashing symbol Description Resolution Unit Standard value


± 1,5 ° A higher
Sensor leaning angle.
value will activate
8 “nonE” is shown if no 0.1 °
the decompression
sensor exists.
locking
Digital I/0 for A5 and [T1].
9 See description in “Test - - -
mode “9” –” on page 79

10 TBD - - -

Maximum value for


collision sensor X and Y.
11 0.1 G 0 G - 10 G
“nonE” is shown if no
sensor exists.
SEU digital I/0. See
description in “Test mode
“12” – Expansion unit
12 - - -
SEU (option).” on
page 80 “nonE” is shown
if no SEU exists.

13 Steering angle 1 ° 0-90°

14 Drive motor temperature 1 °C ?

15 [T1] temperature 1 °C ?

© TMHE 8 – 78 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

8.7 Digital input/output status

8.7.1 Test mode “9” –

In this mode, the digital inputs and outputs are tested by checking specific
segments on the display according to the following tables.
1
6 7 2

5 3
8
1 2 3 4 4
Position:
1. Digital input of A5 [A5]
2. Digital input/output of A5 [A5]
3. Transistor regulator inputs
4. Transistor regulator inputs
1 – 8: Reference to segment
Digit 1, A5 digital in Digit 2, A5 digital in/out
Segment Description Segment Description
1 1 Option button 6
1 1 Rear button up
2 Option button 5 2 Rear button down
6 7 2 3 Option button 4 6 7 2 3 Front button up
4 Option button 1 4 Front button down
5 Option button 2 5 Main contactor
5 3 6 Option button 3
5 3 6 Horn input
8 7 A5 address (node ID) 8 7 Brake output
4 8 - 4 8 Pump

Digit 3, [T1] digital in Digit 4, [T1] digital in


Segment Description Segment Description
Top position sensor not
1 1
active (B61)
1 1 Input 9

2 Steering arm active (B60) 2 Input 10


6 7 2 3
Operator on platform 6 7 2 3 Input 11
[B119]
4 Input 4 4 Input 12
5 3 5 Input 5 5 3 5 Input 13
8 6 Platform up (B120) 8 6 Input 14
4 7 Gate up (121) 4 7 Motor encode, channel A
8 Gate down (B122) 8 Motor encode, channel B

© TMHE 8 – 79 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

8.7.2 Test mode “12” – Expansion unit SEU (option).

In this mode, the digital inputs and outputs are tested by checking specific
segments on the display according to the following tables.
1
6 7 2

5 3
8
1 2 3 4 4
Position:
1. SEU 0 inputs
2. SEU 0 outputs
3. SEU 1 inputs
4. SEU 1 outputs
1 – 8: Reference to segment

Digit 1, SEU 0 digital in Digit 2, SEU 0 digital out


Segment Description Segment Description
1 1 In 1
1 1 Out 1
2 In 2 2 Out 2
6 7 2 3 In 3 6 7 2 3 Out 3
4 In 4 4 Out 4
5 In 5 5
5 3 6 In 6
5 3 6
8 7 In 7 8 7
4 8 In 8 4 8

Digit 3, SEU 1 digital in Digit 4, SEU 1 digital out


Segment Description Segment Description
1 1 In 1
1 1 Out 1
2 In 2 2 Out 2
6 7 2 3 In 3 6 7 2 3 Out 3
4 In 4 4 Out 4
5 In 5 5
5 3 6 In 6
5 3 6
8 7 In 7 8 7
4 8 In 8 4 8

© TMHE 8 – 80 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

8.8 Built-in test function for the tiller arm


1: Make sure the battery is connected.
2: Check that the truck is switched off. Press the OFF button.
3: Connect the CAN key or enter the PIN code. Note: Do not press the ON
button.
4: Press and then release the horn button. “Info“ is shown on the display.
5: Press and release the horn button to select the "Info" menu.
6: Turn the speed control several times until “tESt” is shown on the display.
7: Press the horn button and release it to enter the test mode.
8: The first one you arrive at is the display test. Press on the button/function
you want to test to proceed. In this mode, the 2 LEDs on the keypad
flash.

8.8.1 Display test


The digital display [A6] can be tested to verify all the segments of the display
function correctly. A moving 8 tests all the segments of the display.

8.8.2 Speed control


The Hall elements are tested by moving the speed control all the way back
and forth. Follow these steps to test the Hall elements:
Move the rocker from the neutral position to begin the test. This is visualised
as number X Y when the rocker is moved in the fork direction and X-Y when
the rocker is moved in the drive wheel direction. X is the total number of Hall
elements that are affected by the magnet and Y is the number of existing Hall
elements. At full movement in both directions 9-9 or 9 9 is shown when all Hall
elements are OK.

8.8.3 Safety reversing


Press the button for safety reversing “Er 1” is shown in the display

8.8.4 Controls for lifting/lowering


Press a button for lifting / lowering in order to start the test. “L1”, “L2”, “L3” or
“L4” is shown in the display depending on which button has been pressed.

© TMHE 8 – 81 T Code(s): 1010


Repair manual: Troubleshooting Model(s): LPE200, LPE220, LPE250
Publication number:7572514-040 Date: 2015-10-01 Applies from serial number: 6304531-

8.8.5 Sensilift
Move the sensilift rocker from the neutral position to begin the test. The
analogue value from the sensilift potentiometer is shown in mV.

8.8.6 Keypad
Press a number to start testing the keypad. “b1” up to “b11” is shown in the
display depending on which button is pressed. The numbers 0-9 are shown
as “b0” to “b9”. The red button “b10” and the green button “b11”
9: Switch off the truck by pressing the OFF button or return to the previous
menu by pressing the horn button.

© TMHE 8 – 82 T Code(s): 1010

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