ELECTRICAL SYSTEM

Event Codes

Event Codes Symbols

Use the symbols in the chart that follows as an aid for
Access 1 2 3® Modules Overview event code troubleshooting.
Access 1: Display Module
Access 2: Hydraulic Control Module Symbol Definition
Access 3™: Traction Control Module = is equal to
Access 4: Vehicle Control Module
Access 5: Steer Control Module
≠ is not equal to

Access 6: Guidance Control Module < less than

≤ is equal to or less than

2 4 5 1
> more than

≥ is equal to or more than

7
≈ is approximately

Static Return to Off (SRO) Messages

3 6 SRO messages usually occur when operating the lift
truck out of its correct sequence. After correcting the
Fig. 1 (28148)
condition that caused the message, the condition will
1 Access 1 be removed. A list of the messages as seen on
2 State of Charge (SOC) Access 1 with a description of the message function
3 Message display follows.
4 Performance level (P1, P2, P3) indicators
5 Navigation arrows - up, down, left, and right
6 ENTER
7 Steering and wire guidance indicator (optional)

SRO Messages

Display Description

CENTER THROTTLE The travel twist grip is not in the neutral position when turning on the lift truck. Move
the travel twist grip to the neutral position.
BRAKE PEDAL After turning on the lift truck, the brake pedal must be pushed before trying to
travel.
Access 1 does not show an The battery retainer switch (BRES1 or BRES2) is open. Make sure that the battery
SRO message, but the sta- retainer is installed correctly.
tus alarm (ALM1) operates
when trying to travel and the
BDI illuminates.
BRAKE PEDAL After turning on the lift truck, the brake pedal must be pushed before trying to lower
or raise the platform.
HANDS The pedestrian detection system option is only available on European lift trucks.
HANDS/FOOT The pedestrian detection system option is only available on European lift trucks.
GATE OPEN The side gate switch (GTS1 or GTS2) is open when trying to travel. Make sure that
the side gates are down.

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Event Codes

SRO Messages

Display Description

GATE OPEN GTS1 or GTS2 is open when trying to lower or raise the platform. Make sure that
the side gates are down.
BRAKE PEDAL The brake (BRK) has not released when trying to travel.
CENTER STEERING The steering wheel is turned too far (more than 10°) when trying to travel with the
WHEEL platform above the height limit. Move the steering wheel to the center position.
REDUCE LIFT HEIGHT The platform is above the height limit when trying to travel. Lower the platform.
STEER <^> (FLASHING) Make sure that the steer angle is no more than 10°.
RAISE SWITCH The variable raise potentiometer (POT2) is pushed when turning on the lift truck.
Release POT2.
LOWER SWITCH The variable lower potentiometer (POT3) is pushed when turning on the lift truck.
Release POT3.
CHAIN SLACK The chain has become slack. Make sure that the chain is tight.
CHAIN BROKEN The chain is broken. Repair or replace the chain.
OVERRIDE Use the override switch (ORS1) to raise or lower the platform through a height
cutout.
LIMIT The platform is at the height cutout. The platform cannot go higher than the height
cutout. Lower the platform below the height cutout.
STANDBY Wait for the lift truck software to complete the self test.
LIFT The lift truck is in lift lockout, or many hydraulic commands are selected at the
same time.
BATTERY The battery charge is low. The platform cannot raise until the battery is charged.
NO MESSAGE Only one wire guidance sensor (GS1, GS2) senses the floor signal for the guide
wire, or only one rail guide switch (RGSL, RGSR) senses an aisle with rail guid-
ance.
WIRE GS1 and GS2 sense the floor signal for the guide wire, or RGSL and RGSR sense
an aisle with rail guidance, but the lift truck has not traveled the distance set in the
F15.2 Distance menu.
WIRE • GS1 and GS2 sense the floor signal for the guide wire.
• RGSL and RGSR sense an aisle with rail guidance.
• The lift truck has traveled the distance set in the F15.2 Distance menu.
• The F15.1 Sense Mode menu is set to Sense Only.
WIRE • GS1 and GS2 sense the floor signal for the guide wire.
• RGSL and RGSR sense an aisle with rail guidance.
• The lift truck has traveled the distance set in the F15.2 Distance menu.
• The F15.1 Sense Mode menu is set to Sense&Slow.
WIRE • GS1 and GS2 sense the floor signal for the guide wire.
• RGSL and RGSR sense an aisle with rail guidance.
• The lift truck has traveled the distance set in the F15.2 Distance menu.
• The F15.1 Sense Mode menu is set to Sense&Stop.
STEER <^> (FLASHING) The lift truck steering is limited and the lift truck is free ranging for more than 5 s.

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Event Codes

SRO Messages

Display Description

STEER <^> (FLASHING) The lift truck steering is limited and the lift truck is free ranging for less than 5 s.
END OF AISLE ZONE The lift truck is at the end of an aisle.
GUIDED The lift truck uses the rail guidance system to travel.
SEARCH GS1 and GS2 are looking for a signal from the wire in the floor.
ACQUIRE GS1 and GS2 have found a signal from the wire in the floor.
GUIDED The lift truck uses the wire guidance system to travel.
NO MESSAGE The lift truck is far enough off the guide wire to decrease the travel speed.
SWITCH TO MANUAL The lift truck is far enough off the guide wire to stop. Set the guidance switch
(GUS1) to manual steering.
SIGNAL The signal strength from the wire in the floor is low.
RELEASE Release POT2 and POT3.
OVERRIDE The end aisle control (EAC) system requests that ORS1 is pushed and then re-
leased.
CHANGE DIRECTION During C5 Wire Guidance calibration, with the lift truck in the center of the guide
wire, travel in the opposite direction.
COME TO STOP During C5 Wire Guidance calibration, stop the lift truck.
DISTANCE REACHED During C5 Wire Guidance calibration, the lift truck is at the applicable distance.
COIL SATURATED During C5.1.2 Sensor Coil calibration, the signal strength from the wire in the floor
is low, or GS1 and GS2 are not 82–86 mm (3.23–3.38 in) from the floor.
PDS OVERRIDE The pedestrian detection system (PDS) option is only available on European lift
trucks.
PDS SLOWDOWN The pedestrian detection system option is only available on European lift trucks.
PDS ACTIVE The pedestrian detection system option is only available on European lift trucks.
PDS NOT ACTIVE The pedestrian detection system option is only available on European lift trucks.
PDS CYCLE TEST The pedestrian detection system option is only available on European lift trucks.
PDS BYPASSED The pedestrian detection system option is only available on European lift trucks.
PDS BRAKING The pedestrian detection system option is only available on European lift trucks.
PDS EMERGENCY STOP The pedestrian detection system option is only available on European lift trucks.
PDS ERROR The pedestrian detection system option is only available on European lift trucks.
PDS PEDESTRIAN STOP The pedestrian detection system option is only available on European lift trucks.
M1 TEMP The traction motor (M1) temperature is too high.
M3 TEMP The lift pump motor (M3) temperature is too high.

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Event Code 100

– Then continue to Step 4.

Step 4: Turn off the lift truck. Measure the resistance
Event Code 100 between CAN H and CAN L on platform distribution
panel TP13 and platform distribution panel TP14.
INVALID EVENT CODE FROM ACCESS 1 - NOT  The correct resistance = 60 Ω.
USED
• If:The resistance > 60 Ω.
The event code is not specified in the lift truck code.
Consult the factory. – Then the CAN circuit is open. Disconnect
Access 5 CA402 and measure the resistance be-
tween Access 5 CA402-4 and Access 5
CA402-5.
Event Code 101
• If:The resistance > 120 Ω.
ACCESS 1 CAN EVENT – Then replace Access 5.
Note: No battery negative to the Access 1 2 3® mod- • If:The resistance = 120 Ω.
ules on the CAN bus load the bus and stop CAN com- – Then check the CAN terminating resistor in
munications. Access 1. Disconnect Access 1 CA302 and mea-
Step 1: Turn off the lift truck. Check the condition of sure the resistance between Access 1 CA302-8
and Access 1 CA302-9.
the CAN wires, pins, and connectors.
• If: The resistance = 120 Ω.
CAN H: Check the wire continuity between Access 1 – Then check the condition of the applicable wires,
CA302-8 and platform distribution panel CA105-2. connectors, and fuses. Make the necessary re-
CAN L: Check the wire continuity between Access 1 pairs or replacements.
CA302-9 and platform distribution panel CA105-8. • If:The resistance > 120 Ω.
• If: The wires, pins, or connectors are damaged. – Then replace Access 1.
– Then make the necessary repairs or replace- Step 5: Keep the lift truck turned off. Measure the re-
ments. sistance at the power unit from CAN L to the battery
• If: The wires, pins, and connectors are correct and negative bus bar, CAN L to power unit distribution
Event Code 101 continues. panel TP3, and CAN L to the lift truck frame.
 The correct resistance > 10,000 Ω.
– Then continue to Step 2.
• If:The resistance < 10,000 Ω.
Step 2: Keep the lift truck turned off. Check the condi-
tion of the power wires, pins, and connectors. – Then make the necessary repairs or replace-
ments.
Check the wire continuity between Access 1
CA302-3 and platform distribution panel
CA103-10, and Access 1 CA302-4 and plat-
form distribution panel CA107-8.
• If: The wires, pins, or connectors are damaged.
– Then make the necessary repairs or replace-
ments.
• If: The wires, pins, and connectors are correct and
Event Code 101 continues.
– Then continue to Step 3.
Step 3: Turn on the lift truck. Check for battery nega-
tive to the other Access 1 2 3® modules on the
CAN bus by making sure that the power lamps
are on.
• If: The power lamps are on.
– Then continue to Step 5.
• If: The power lamps are off.

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Event Code 103

Step 2: Keep the lift truck turned on. Measure the

voltage between Access 3™ CA401-1 and the battery
ACCESS 1 POWER UNIT ACCESS 5 negative cable.
DISTRIBUTION PANEL
 The correct voltage = 36 V.
CA302 TP3
• If:The voltage = 36 V.
+BV 3
– Then replace Access 3™.
B- 4
• If:The voltage = 0 V.
CA402 – Then turn off the lift truck. Check Access 3™
CAN H CAN1 H
120 Ohm 8 4 120 Ohm CA401-1 to power unit distribution panel
Resistor
Resistor 9 5
CAN1 L
CA201-5 and the options fuse (FU3) on the
CAN L
power unit distribution panel. Make the neces-
sary repairs or replacements.
Step 3: Keep the lift truck turned off. Measure the re-
PLATFORM sistance between power unit distribution panel TP15
DISTRIBUTION PC301
(CAN H) and power unit distribution panel TP16
PANEL 1 (CAN L).
2
 The correct resistance = 60 Ω.
CA103 3
+BV FU1 1 4
• If:The resistance = 0 Ω.
+BV ED1 FU7 2 5 – Then there is a short circuit between CAN H and
CA105
6 CAN L. Check the condition of the applicable
CAN H 2
CAN wires, connectors, and fuses, and make the nec-
ACCESS essary repairs or replacements.
TP13 CAN H 3
• If:The resistance > 60 Ω.
CAN L 8
– Then continue to Step 4.
CAN L 9
TP14 Step 4: Keep the lift truck turned off. The CAN circuit
CA103
is open. Disconnect Access 5 CA402 and measure the
+BV_KYS 10
resistance between Access 5 CA402-4 and Access 5
CA107 CA402-5.
B- 1 • If:The resistance > 120 Ω.
B- 8
– Then replace Access 5.
• If:The resistance = 120 Ω.
Fig. 2 (28253)
– Then check the CAN terminating resistor in
Access 1. Disconnect Access 1 CA302 and mea-
Event Code 103 sure the resistance between Access 1 CA302-8
and Access 1 CA302-9.
ACCESS 1 CAN INITIALIZATION EVENT WITH • If:The resistance > 120 Ω.
Access 3™ – Then replace Access 1.
Note: Access 1 CAN bus communication with • If: The resistance = 120 Ω.
Access 3™ has stopped.
– Then check the condition of the applicable wires,
Step 1: Turn on the lift truck. Check the Access 3™ connectors, and fuses. Make the necessary re-
power lamps. pairs or replacements.
• If:The Access 3™ power lamps are on and Event Step 5: Keep the lift truck turned off. Measure the re-
Code 103 continues. sistance at the power unit from CAN L to the battery
– Then continue to Step 3. negative bus bar, CAN L to power unit distribution
• If:The Access 3™ power lamps are off. panel TP3, and CAN L to the lift truck frame.
– Then continue to Step 2.  The correct resistance > 10,000 Ω.
• If:The resistance < 10,000 Ω.
– Then make the necessary repairs or replace-
ments.

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Event Code 104

Step 2: Keep the lift truck turned on. Measure the

voltage between Access 4 CA304-1 and Access 4
ACCESS 1 CA304-3.
 The correct voltage = 36 V.
CA302
• If:The voltage = 36 V.
CAN H
8
– Then replace Access 4.
120 Ohm
Resistor 9 • If:The voltage = 0 V.
CAN L
– Then turn off the lift truck. Check Access 4
CA304-1 to platform distribution panel
CA103-12, Access 4 CA304-3 to platform distri-
POWER UNIT bution panel CA107-9, and the control circuit fuse
DISTRIBUTION
PANEL
(FU2) on the power unit distribution panel. Make
ACCESS 5 the necessary repairs or replacements.
CA201 Step 3: Keep the lift truck turned off. Measure the re-
+BV_K2 FU3 5 sistance between power unit distribution panel TP15
(CAN H) and power unit distribution panel TP16
(CAN L).
CA204
FU3  The correct resistance = 60 Ω.
CAN H 2
CA402 • If:The resistance = 0 Ω.
TP3 CAN1 H
4 120 Ohm – Then there is a short circuit between CAN H and
Resistor
TP15
CAN L 8 5
CAN1 L
CAN L. Check the condition of the applicable
wires, connectors, and fuses, and make the nec-
TP16 essary repairs or replacements.
• If:The resistance > 60 Ω.
– Then continue to Step 4.
ACCESS 3
Step 4: Keep the lift truck turned off. The CAN circuit
is open. Disconnect Access 5 CA402 and measure the
CA401
resistance between Access 5 CA402-4 and Access 5
CA402-5.
PWR 1
• If:The resistance > 120 Ω.
B- – Then replace Access 5.
• If:The resistance = 120 Ω.
Fig. 3 (28254)
– Then check the CAN terminating resistor in
Access 1. Disconnect Access 1 CA302 and mea-
sure the resistance between Access 1 CA302-8
and Access 1 CA302-9.
Event Code 104
• If:The resistance = 120 Ω.
ACCESS 1 CAN INITIALIZATION EVENT WITH – Then check the condition of the applicable wires,
ACCESS 4 connectors, and fuses. Make the necessary re-
Note: Access 1 CAN bus communication with pairs or replacements.
Access 4 has stopped. • If: The resistance > 120 Ω.
Step 1: Turn on the lift truck. Check the Access 4 – Then replace Access 1.
power lamps.
Step 5: Keep the lift truck turned off. Measure the re-
• If:The Access 4 power lamps are on and Event sistance at the power unit from CAN L to the battery
Code 104 continues. negative bus bar, CAN L to power unit distribution
– Then continue to Step 3. panel TP3, and CAN L to the lift truck frame.
• If:The Access 4 power lamps are off.  The correct resistance > 10,000 Ω.
– Then continue to Step 2. • If:The resistance < 10,000 Ω.

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Event Code 105

– Then make the necessary repairs or replace- – Then continue to Step 2.

ments. Step 2: Keep the lift truck turned on. Measure the
voltage between Access 5 CA403-10 and Access 5
CA403-26.
ACCESS 4 PLATFORM  The correct voltage = 36 V.
DISTRIBUTION
PANEL • If:The voltage = 36 V.
CA304 CA103 – Then replace Access 5.
PWR 1 12 +BV_KYS • If:The voltage = 0 V.
– Then turn off the lift truck. Check Access 5
B- 3 CA107
CA403-26 to Access 3™ CA401, Access 5
9 B-
CA403-10 to power unit distribution panel
CA201-6, and FU3 on the power unit distribution
panel. Make the necessary repairs or replace-
ACCESS 1
ments.
Step 3: Keep the lift truck turned off. Measure the re-
CA302 sistance between power unit distribution panel TP15
CAN H
120 Ohm 8 (CAN H) and power unit distribution panel TP16
Resistor 9 (CAN L).
CAN L
 The correct resistance = 60 Ω.
• If:The resistance = 0 Ω.
– Then there is a short circuit between CAN H and
POWER UNIT CAN L. Check the condition of the applicable
DISTRIBUTION
PANEL wires, connectors, and fuses, and make the nec-
ACCESS 5 essary repairs or replacements.
• If:The resistance > 60 Ω.
– Then continue to Step 4.
FU2
Step 4: Keep the lift truck turned off. The CAN circuit
CA204 is open. Disconnect Access 5 CA402 and measure the
CAN H 2 resistance between Access 5 CA402-4 and Access 5
CA402 CA402-5.
TP3 CAN1 H
4 120 Ohm
Resistor
• If:The resistance > 120 Ω.
CAN L 8 5
TP15 CAN1 L – Then replace Access 5.
• If:The resistance = 120 Ω.
TP16
– Then check the CAN terminating resistor in
Fig. 4 (28255) Access 1. Disconnect Access 1 CA302 and mea-
sure the resistance between Access 1 CA302-8
and Access 1 CA302-9.
Event Code 105 • If: The resistance = 120 Ω.
– Then check the condition of the applicable wires,
ACCESS 1 CAN INITIALIZATION EVENT WITH
connectors, and fuses. Make the necessary re-
ACCESS 5
pairs or replacements.
Note: Access 1 CAN bus communication with
• If:The resistance > 120 Ω.
Access 5 has stopped.
– Then replace Access 1.
Step 1: Turn on the lift truck. Check the Access 5
power lamps. Step 5: Keep the lift truck turned off. Measure the re-
sistance at the power unit from CAN L to the battery
• If:The Access 5 power lamps are on and Event
negative bus bar, CAN L to power unit distribution
Code 105 continues.
panel TP3, and CAN L to the lift truck frame.
– Then continue to Step 3.  The correct resistance > 10,000 Ω.
• If:The Access 5 power lamps are off. • If:The resistance < 10,000 Ω.

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Event Code 106

– Then make the necessary repairs or replace- Note: Access 1 CAN bus communication with
ments. Access 6 has stopped.
Step 1: Turn on the lift truck. Check the Access 6 pow-
er lamps.
ACCESS 4
PLATFORM • If:The Access 5 power lamps are on and Event
DISTRIBUTION Code 106 continues.
CA304 PANEL
– Then continue to Step 3.
PWR 1
CA107 • If:The Access 5 power lamps are off.
B- 3 9 B- – Then continue to Step 2.
CA103
Step 2: Keep the lift truck turned on. Measure the volt-
12 +BV_KYS
age between Access 6 CA601-1 and Access 6
ACCESS 1 CA601-2.
 The correct voltage = 36 V.
CA302 • If:The voltage = 36 V.
CAN H
120 Ohm 8 ACCESS 5 – Then replace Access 6.
Resistor
CAN L
9 • If:The voltage = 0 V.
– Then turn off the lift truck. Check Access 6
CA601-1 to power unit distribution panel
POWER UNIT CA201-6, Access 6 CA601-2 to the battery nega-
DISTRIBUTION
PANEL tive bus bar, and FU3 on the power unit distribu-
CA402 tion panel. Make the necessary repairs or
CAN1 H
4 120 Ohm replacements.
Resistor
5
CAN1 L
Step 3: Keep the lift truck turned off. Measure the re-
sistance between power unit distribution panel
CA403
TP15 (CAN H) and power unit distribution pan-
FU3 CA201 10 B+
+BV_K2
el TP16 (CAN L).
6
TP3 FU3  The correct resistance = 60 Ω.
CA204
CAN H 2
• If:The resistance = 0 Ω.
TP15
– Then there is a short circuit between CAN H and
CAN L 8 26 BDI SENSE CAN L. Check the condition of the applicable
TP16 NEG
wires, connectors, and fuses, and make the nec-
essary repairs or replacements.
ACCESS 3 • If:The resistance > 60 Ω.
ACCESS 6
– Then continue to Step 4.
Step 4: Keep the lift truck turned off. The CAN circuit
CA601 is open. Disconnect Access 5 CA402 and
BNEG 1 PWR measure the resistance between Access 5
B+ B-
CA402-4 and Access 5 CA402-5.
• If:The resistance > 120 Ω.
1
– Then replace Access 5.
• If:The resistance = 120 Ω.
Fig. 5 (28256) – Then check the CAN terminating resistor in
Access 1. Disconnect Access 1 CA302 and mea-
Event Code 106 sure the resistance between Access 1 CA302-8
and Access 1 CA302-9.
ACCESS 1 CAN INITIALIZATION EVENT WITH
ACCESS 6 • If: The resistance = 120 Ω.

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Event Code 111

– Then check the condition of the applicable wires,

connectors, and fuses. Make the necessary re-
pairs or replacements. ACCESS 1

• If:The resistance > 120 Ω.

– Then replace Access 1. CA302
CAN H
Step 5: Keep the lift truck turned off. Measure the re- 8
120 Ohm
sistance at the power unit from CAN L to the Resistor 9
CAN L
battery negative bus bar, CAN L to power unit
distribution panel TP3, and CAN L to the lift
truck frame.
POWER UNIT
 The correct resistance > 10,000 Ω. DISTRIBUTION
• If:The resistance < 10,000 Ω. PANEL
ACCESS 5
– Then make the necessary repairs or replace-
CA201
ments.
+BV_K2 FU3 5
+BV_K2 FU3 6

FU3 CA204
CAN H 2 CA402
TP3 CAN1 H
4 120 Ohm
CAN L 8 5 Resistor
TP15 CAN1 L

TP16

ACCESS 6
ACCESS 3

CA601
CA401
1 PWR
PWR 1
2 B-

BNEG
B+ B-

Fig. 6 (28257)

Event Code 111

ACCESS 1 SOFTWARE PARAMETER EVENT
Step 1: Download the newest software.
• If: Event Code 111 continues.
– Then replace Access 1.

Event Code 113

Access 3™ SOFTWARE IS INCOMPATIBLE
Step 1: Load Access 3™ with the compatible soft-

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Event Code 114

ware. • If:Event Code 131 continues.

– Then continue to Step 2.
Event Code 114 Step 2: Make sure that there is not a short circuit be-
ACCESS 4 SOFTWARE IS INCOMPATIBLE tween the wires from Access 1 to positive.
Step 1: Load Access 4 with the compatible software. • If:There is a short circuit.
– Then make the necessary repairs or replace-
Event Code 115 ments.
ACCESS 5 SOFTWARE IS INCOMPATIBLE • If:The wires are correct.
Step 1: Load Access 5 with the compatible software. – Then replace Access 1.

Event Code 116 ACCESS 1

ACCESS 6 SOFTWARE IS INCOMPATIBLE
Step 1: Load Access 6 with the compatible software.
CA302

GPD 2
Event Code 123
Access 3™ CAN EVENT
Note: Access 1 CAN bus communication with
Access 3™ was lost.
Step 1: See the procedures for Event Code 103.
PLATFORM
DISTRIBUTION
Event Code 124 PANEL

ACCESS 4 CAN EVENT

CA103
Note: Access 1 CAN bus communication with
ALARM 1 16
Access 4 was lost.
Step 1: See the procedures for Event Code 104. TP7

Event Code 125

TP8
ACCESS 5 CAN EVENT
Note: Access 1 CAN bus communication with
Access 5 was lost. Fig. 7 (28258)
Step 1: See the procedures for Event Code 105.
Event Code 133
Event Code 126 GUIDANCE STEER INDICATOR CAN EVENT
ACCESS 6 CAN EVENT Step 1: Turn on the lift truck. Check the guidance steer
Note: Access 1 CAN bus communication with indicator.
Access 6 was lost. • If:The power light for the guidance steer indicator is
Step 1: See the procedures for Event Code 106. on.
– Then continue to Step 4.
Event Code 131 • If:The power light for the guidance steer indicator is
off.
ALM1 DRIVER HAS A SHORT CIRCUIT
– Then continue to Step 2.
Step 1: Turn off the lift truck. Disconnect platform dis-
tribution panel CA103-16. Turn on the lift truck. Step 2: Turn on the lift truck. Measure the voltage be-
tween power unit distribution panel CA201-6
• If:The event code stops.
and power unit distribution panel CA206-5.
– Then replace the platform distribution panel.
 The correct voltage = 36 V.

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Event Code 134

• If:The voltage = 0 V.
– Then check FU3 on the power unit distribution
PLATFORM
panel and make the necessary repairs or re- DISTRIBUTION
CA323
placements. ACCESS 1
PANEL
1 CA105
• If:The voltage = 36 V.
2 4 CAN H
– Then continue to Step 3. 3
Step 3: Keep the lift truck turned on. Measure the volt- 4 10 CAN L
age between Access 5 CA403-10 and
GUIDANCE AND
Access 5 CA403-26. STEER INDICATOR
ACCESS 5
• If:The voltage = 0 V.
– Then make the necessary repairs or replace-
ments in the wires between Access 5 CA403-10
and Access 5 CA403-26. POWER UNIT
• If:The voltage = 36 V. DISTRIBUTION
PANEL
– Then replace the guidance steer indicator. CA402
CAN1 H
Step 4: Turn off the lift truck. Check the CAN connec- 4 120 Ohm
5 Resistor
tion to the guidance steer indicator. Turn on CAN1 L
CA201
the lift truck. +BV_K2 CA403
FU3 FU3
6
• If:The CAN connection is correct and Event Code CA204 10 B+
133 continues. TP15 CAN H 2
– Then turn off the lift truck. Measure the resistance
CAN L 8
between platform distribution panel CA105-4 and TP16
platform distribution panel CA105-10. CA206 BDI SENSE
 The correct resistance = 60 Ω. 26 NEG
B- BB 5
• If:The resistance = 0 Ω.
– Then there is a short circuit between platform dis- ACCESS 3 ACCESS 6
tribution panel CA105-4 and platform distribution
panel CA105-10. Make the necessary repairs or
replacements.
CA601
• If:The resistance > 60–65 Ω with all the connectors
1 PWR
connected. BNEG
B+ B-
– Then the CAN bus terminating resistor is missing
or damaged. The CAN bus contains two termi-
nating resistors: One is in Access 5 and the other 1
is in Access 1.
Step 5: Keep the lift truck turned off. Measure the re-
sistance at the power unit distribution panel Fig. 8 (28259)
between CAN L and CAN H and the battery
negative bus bar, CAN L and CAN H and pow- Event Code 134
er unit distribution panel TP15 and power unit ACCESS 4 CAN EVENT
distribution panel TP16, and CAN L and Step 1: Turn on the lift truck and check the Access 4
CAN H to the lift truck frame. power lamps.
 The correct resistance > 10,000 Ω. • If:Access 4 power lamps are on.
• If:The resistance < 10,000 Ω. – Then continue to Step 3.
– Then make the necessary repairs or replace- • If:The Access 4 power lamps are off.
ments. – Then continue to Step 2.

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Event Code 134

Step 2: Keep the lift truck turned on. Measure the volt- negative bus bar, between CAN L and CAN H
age between platform distribution panel and power unit distribution panel TP15 and
CA103-12 and platform distribution panel power unit distribution panel TP16, and CAN L
CA107-9. and CAN H to the lift truck frame.
 The correct voltage = 36 V.  The correct resistance > 10,000 Ω.
• If:The voltage = 36 V. • If:The resistance < 10,000 Ω.
– Then measure the voltage between Access 4 – Then make the necessary repairs or replace-
CA304-1 and Access 4 CA304-3. ments.
• If:The voltage = 36 V.
– Then replace Access 4.
• If:The voltage = 0 V.
– Then turn off the lift truck. Make the necessary re-
pairs or replacements in the wires between
Access 4 CA304-1 and Access 4 CA304-3.
Step 3: Keep the lift truck turned off. Measure the re-
sistance between CAN H and CAN L on plat-
form distribution panel TP13 and platform
distribution panel TP14.
 The correct resistance = 60 Ω.
• If:The resistance = 0 Ω.
– Then there is a short circuit between CAN H and
CAN L. Check the condition of the applicable
wires, connectors, and fuses, and make the nec-
essary repairs or replacements.
• If:The resistance > 60 Ω.
– Then continue to Step 4.
Step 4: Keep the lift truck turned off. The CAN circuit
is open. Disconnect Access 5 CA402 and
measure the resistance between Access 5
CA402-4 and Access 5 CA402-5.
• If:The resistance > 120 Ω.
– Then replace Access 5.
• If:The resistance = 120 Ω.
– Then check the CAN terminating resistor in
Access 1. Disconnect Access 1 CA302 and mea-
sure the resistance between Access 1 CA302-8
and Access 1 CA302-9.
• If: The resistance = 120 Ω.
– Then check the condition of the applicable wires,
connectors, and fuses. Make the necessary re-
pairs or replacements.
• If:The resistance > 120 Ω.
– Then replace Access 1.
Step 5: Keep the lift truck turned off. Measure the re-
sistance at the power unit distribution panel
between CAN L and CAN H and the battery

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Event Code 160

• If: The resistance = 60 Ω. If CA428 is opened, the

lift truck side resistance is 60 Ω and the battery side
ACCESS 4 is O/L.
PLATFORM
DISTRIBUTION – Then continue to step 2.
CA304 PANEL
• If: The resistance ≠ 60 Ω or O/L.
PWR 1
CA107 TP13 – Then follow the instructions in the V-Force® bat-
B- 3 9 B- tery manufacturer manual or Event Code 110.
TP14
CA103 Step 2: Check the wires between CA428-1 and
12 +BV_KYS CA428-2. Make sure that the wires are connected
ACCESS 1 properly.
• If: The wires are damaged or not connected prop-
erly.
CA302
CAN H – Then repair or replace the wires or connect
120 Ohm 8 CA428.
Resistor 9
CAN L • If: The wires and connections are good.
– Then continue to step 3.
ACCESS 5 Step 3: Turn off the battery then turn on the battery.
POWER UNIT
DISTRIBUTION Turn on the lift truck.
PANEL • If: The event code clears.
– Then return the lift truck to service.
• If: The event code does not clear.
FU2 – Then troubleshoot the battery by following the in-
CA204 structions in the V-Force® battery manufacturer
CAN H 2
manual.
TP15 CA402
CAN1 H

TP16
4 120 Ohm
Resistor
Event Code 161
CAN L 8 5
CAN1 L
Access 1 COMMUNICATION LOST FROM EPS
Step 1: Turn off the lift truck. Check the resistance
between CA428-1 and CA428-2.
ACCESS 3 • If: The resistance = 60 Ω. If CA428 is opened, the
lift truck side resistance is 60 Ω and the battery side
is O/L.
– Then continue to step 2.
• If: The resistance ≠ 60 Ω or O/L.
BNEG
B+ B- – Then follow the instructions in the V-Force® bat-
tery manufacturer manual or Event Code 110.
Step 2: Check the wires between CA428-1 and
CA428-2. Make sure that the wires are connected
properly.
Fig. 9 (28260) • If: The wires are damaged or not connected prop-
erly.
Event Code 160 – Then repair or replace the wires or connect
CA428.
Access 1 COMMUNICATION ERROR WITH EPS
• If: The wires and connections are good.
Step 1: Turn off the lift truck. Check the resistance
– Then continue to step 3.
between CA428-1 and CA428-2.
Step 3: Turn on the lift truck. Make sure that the Fea-
tures Menus are set correctly.

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Event Code 162

• If: The menu settings are not correct. – Then troubleshoot the battery by following the in-
– Then change the menus to the correct settings. structions in the V-Force® battery manufacturer
manual.
• If: The menu settings are correct.
– Then continue to step 4.
Step 4: Turn off the battery then turn on the battery.
Event Code 163
Turn on the lift truck. Access 1 COMMUNICATION ERROR WITH EPS
• If: The event code clears. Step 1: Turn off the lift truck. Check the resistance
– Then return the lift truck to service. between the CA428-1 and CA428-2.
• If: The event code does not clear. • If: The resistance = 60 Ω. If CA428 is opened, the
– Then troubleshoot the battery by following the in- lift truck side resistance is 60 Ω and the battery side
structions in the V-Force® battery manufacturer is O/L.
manual. – Then continue to step 2.
• If: The resistance ≠ 60 Ω or O/L.
Event Code 162 – Then follow the instructions in the V-Force® bat-
tery manufacturer manual or Event Code 110.
Access 1 COMMUNICATION LOST FROM EPS
Step 2: Check the wires between CA428-1 and
Step 1: Turn off the lift truck. Check the resistance CA428-2. Make sure that the wires are connected
between the CA428-1 and CA428-2. properly.
• If: The resistance = 60 Ω. If CA428 is opened, the • If: The wires are damaged or not connected prop-
lift truck side resistance is 60 Ω and the battery side erly.
is O/L.
– Then repair or replace the wires or connect
– Then continue to step 2. CA428.
• If: The resistance ≠ 60 Ω or O/L. • If: The wires and connections are good.
– Then follow the instructions in the V-Force® bat- – Then continue to step 3.
tery manufacturer manual or Event Code 110.
Step 3: Turn on the lift truck. Make sure that the Fea-
Step 2: Check the wires between CA428-1 and tures Menus are set correctly.
CA428-2. Make sure that the wires are connected
• If: The menu settings are not correct.
properly.
– Then change the menus to the correct settings.
• If: The wires are damaged or not connected prop-
erly. • If: The menu settings are correct.
– Then repair or replace the wires or connect – Then continue to step 4.
CA428. Step 4: Turn off the battery then turn on the battery.
• If: The wires and connections are good. Turn on the lift truck.
– Then continue to step 3. • If: The event code clears.
Step 3: Turn on the lift truck. Make sure that the Fea- – Then return the lift truck to service.
tures Menus are set correctly. • If: The event code does not clear.
• If: The menu settings are not correct. – Then troubleshoot the battery by following the in-
– Then change the menus to the correct settings. structions in the V-Force® battery manufacturer
manual.
• If: The menu settings are correct.
– Then continue to step 4.
Step 4: Turn off the battery then turn on the battery.
Event Code 164
Turn on the lift truck. EPS Software is Incompatible
• If: The event code clears. The lift truck software is not compatible with the
– Then return the lift truck to service. V-Force® lithium-ion battery software.
• If: The event code does not clear. Step 1: Download the latest software into the lift truck
and correctly set up the Features Menu.
• If: The event code is cleared.

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Event Code 165

– Then return the lift truck to service. – Then unplug the charger from the battery. Cycle
• If: The event code is not cleared. the key to operate the lift truck or plug the charger
back in to continue charging.
– Then continue to step 3.
• If: The charger is not plugged into the battery.
Step 2: Download the latest software into the
V-Force® lithium-ion battery. – Then the battery has a software issue. Check and
update the battery protocol level and Consult the
• If: The event code is cleared.
Crown Customer Service.
– Then return the lift truck to service.
• If: The event code is not cleared. Event Code 167
– Then contact the Crown Service Department.
EPS ERROR STATE LOGGED
Note: Troubleshoot the battery by following the instruc-
Event Code 165 tions in the V-Force® battery manufacturer manual.
Access 1 COMMUNICATION ERROR WITH EPS
Step 1: Turn off the lift truck. Check the resistance Event Code 168
between CA428-1 and CA428-2.
EWS EVENT
• If: The resistance = 60 Ω. If CA428 is opened, the
lift truck side resistance is 60 Ω and the battery side The lift truck does not have power.
is O/L. Step 1: View the external display unit on the
– Then continue to step 2. V-Force® lithium-ion battery.
• If: The resistance ≠ 60 Ω or O/L. • If: The V-Force® lithium-ion battery is on.
– Then follow the instructions in the V-Force® bat- – Then continue to step 2.
tery manufacturer manual or Event Code 110. • If: The V-Force® lithium-ion battery is not on.
Step 2: Check the wires between CA428-1 and – Then turn on the lithium-ion battery. If the lithium-
CA428-2. Make sure that the wires are connected ion battery turns on, continue to step 2. If the lith-
properly. ium-ion battery does not turn on, then trouble-
• If: The wires are damaged or not connected prop- shoot the battery by following the instructions in
erly. the V-Force® battery manufacturer manual.
– Then repair or replace the wires or connect Step 2: View the fault indicator LED on the V-Force®
CA428. lithium-ion battery.
• If: The wires and connections are good. • If: The fault indicator LED is flashing.
– Then continue to step 3. – Then troubleshoot the battery by following the in-
structions in the V-Force® battery manufacturer
Step 3: Turn off the battery then turn on the battery. manual.
Turn on the lift truck.
• If: The fault indicator LED is not flashing.
• If: The event code clears.
– Then continue to step 3.
– Then return the lift truck to service.
Step 3: View the battery state of charge LEDs on the
• If: The event code does not clear. V-Force® lithium-ion battery.
– Then troubleshoot the battery by following the in- • If: The battery state of charge is greater than 0%.
structions in the V-Force® battery manufacturer
manual. – Then continue to step 4.
• If: The battery state of charge is 0%.
Event Code 166 – Then charge the battery.
Step 4: Confirm that the battery and the EPS harness
Load Shed Zero are properly connected.
The EPS has requested immobilization of the lift truck. • If: The battery and harness are properly connected.
Step 1: Check to see if the charger is plugged into – Then continue to step 5.
the battery.
• If: The battery and harness are not properly con-
• If: The charger is plugged into the battery. nected.

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Event Code 169

– Then connect the battery and the EPS harness to – Then repair or replace the wire between FU25
the lift truck and continue to step 5. and K20-4.
Step 5: Measure the voltage on CA428. Measure the Step 11: Measure the voltage on the relay connector.
voltage between CA428-4 (+) and the battery connec- Measure the voltage between K20-4 (+) and K20-B (-).
tor (-). • If: The voltage is 34–39 V or 46–51 V.
• If: The voltage is 34–39 V or 46–51 V. – Then continue to step 12.
– Then continue to step 6. • If: The voltage is not 34–39 V or 46–51 V.
• If: The voltage is not 34–39 V or 46–51 V. – Then repair or replace the wire between K20-B
– Then troubleshoot the battery by following the in- and PC203-8.
structions in the V-Force® battery manufacturer Step 12: Measure the voltage on the relay connector.
manual. Measure the voltage between K20-4 (+) and K20-7 (-).
Step 6: Measure the voltage on CA428. Measure the • If: The voltage is 34–39 V or 46–51 V.
voltage between CA428-5 (+) and the battery connec-
– Then continue to step 13.
tor (-).
• If: The voltage is not 34–39 V or 46–51 V.
• If: The voltage is 34–39 V or 46–51 V.
– Then replace K20.
– Then continue to step 7.
Step 13: Measure the voltage on the relay connector.
• If: The voltage is not 34–39 V or 46–51 V.
Measure the voltage between K20-4 (+) and CA411-20
– Then replace FU25 in the EPS harness. (-) on Access 3™.
Step 7: Disconnect the battery connector from the lift • If: The voltage is 34–39 V or 46–51 V.
truck. Measure the voltage on the (+) and (-) terminals
– Then replace Access 3™.
of the battery connector.
• If: The voltage is not 34–39 V or 46–51 V.
• If: The voltage is 34–39 V or 46–51 V.
– Then repair or replace the wire between CA411-
– Then continue to step 8.
20 and K20-7.
• If: The voltage is not 34–39 V or 46–51 V.
– Then troubleshoot the battery by following the in-
structions in the V-Force® battery manufacturer
Event Code 169
manual. EPS/BRES Configuration Mismatch
Step 8: Connect the battery connector to the lift truck. The lift truck Features are not configured correctly for
Turn on the lift truck. the EPS type and the level installed in the lift truck. The
• If: The lift truck has power. lift truck software is not compatible with the V-Force®
– Then continue to step 9. lithium-ion battery software.
• If: The lift truck does not have power. Step 1: Use the Features > F15 Electrical Power
Source > F15.1 Type and F15.2 Level menus to config-
– Then see the schematic diagram to troubleshoot ure the EPS type and level.
the FU4, KYS, and K1 relay startup circuit.
• If: The Features are configured correctly.
Step 9: Check the event code history, is event code
168 logged? – Then continue to step 2.
• If: Event Code 168 is logged. • If: The Features are not configured correctly.
– Then continue to step 10. – Then configure the EPS type and level to match
the EPS installed in the lift truck. Turn off the lift
• If: Event Code 168 is not logged. truck then turn on the lift truck. If the event code
– Then return the lift truck to service. is cleared, return the lift truck to service. If the
Step 10: Measure the voltage on the relay connector. event code is not cleared, continue to step 2.
Measure the voltage between K20-4 (+) and the bat- Step 2: Download the latest software into the lift truck
tery connector (-). and correctly set up the Features Menu.
• If: The voltage is 34–39 V or 46–51 V. • If: The event code is cleared.
– Then continue to step 11. – Then return the lift truck to service.
• If: The voltage is not 34–39 V or 46–51 V. • If: The event code is not cleared.

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 ELECTRICAL SYSTEM
Event Code 200

– Then continue to step 3. • If:The resistance > 60 Ω.

Step 3: Download the latest software into the – Then continue to Step 3.
V-Force® lithium-ion battery. Step 3: Keep the lift truck turned off. The CAN circuit
• If: The event code is cleared. is open. Disconnect Access 5 CA402 and
– Then return the lift truck to service. measure the resistance between Access 5
• If: The event code is not cleared. CA402-4 and Access 5 CA402-5.
– Then contact the Crown Service Department. • If:The resistance > 120 Ω.
– Then replace Access 5.
Event Code 200 • If:The resistance = 120 V.
INVALID EVENT CODE FROM ACCESS 2 - NOT – Then check the CAN terminating resistor in
USED Access 1. Disconnect Access 1 CA302 and mea-
The event code is not specified in the lift truck code. sure the resistance between Access 1 CA302-8
Consult the factory. and Access 1 CA302-9.
• If: The resistance = 120 Ω.
Event Code 201 – Then check the condition of the applicable wires,
ACCESS 1 CAN EVENT WITH ACCESS 2 connectors, and fuses. Make the necessary re-
pairs or replacements.
Step 1: Turn off the lift truck. Check the condition of
• If:The resistance > 120 Ω.
the CAN wires, pins, and connectors.
– Then replace Access 1.
CAN H: Check the wire continuity between Access 2
CA404-23 and power unit distribution panel CA204-4.
Then check the wire continuity between power unit dis-
tribution panel CA203-2 and platform distribution panel
CA104-2. Then check the wire continuity between
Access 1 CA302-8 and platform distribution panel
CA105-2.
CAN L: Check the wire continuity between Access 2
CA404-15 and power unit distribution panel CA204-10.
Then check the wire continuity between power unit dis-
tribution panel CA203-3 and platform distribution panel
CA104-3. Then check the wire continuity between
Access 1 CA302-9 and platform distribution panel
CA105-8.
• If:The wires, pins, or connectors are damaged.
– Then make the necessary repairs or replace-
ments.
• If:The wires, pins, and connectors are correct.
– Then continue to Step 2.
Step 2: Keep the lift truck turned off. Measure the re-
sistance between CAN H and CAN L on plat-
form distribution panel TP13 and platform
distribution panel TP14.
 The correct resistance = 60 Ω.
• If:The resistance = 0 Ω.
– Then there is a short circuit between CAN H and
CAN L. Check the condition of the applicable
wires, connectors, and fuses, and make the nec-
essary repairs or replacements.

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Event Code 205

– Then make the necessary repairs or replace-

ments.
• If:The wires, pins, and connectors are correct.
PLATFORM
– Then continue to Step 2.
ACCESS 1
DISTRIBUTION Step 2: Keep the lift truck turned off. Measure the re-
PANEL
sistance between CAN H and CAN L on plat-
CA105
CA302
CAN H
form distribution panel TP13 and platform
CAN H 2
120 Ohm 8 distribution panel TP14.
Resistor 9 CAN L 8
CAN L CA104  The correct resistance = 60 Ω.
2 CAN H TP13 • If:The resistance = 0 Ω.
3 CAN L
– Then there is a short circuit between CAN H and
POWER UNIT TP14
CAN L. Check the condition of the applicable
DISTRIBUTION
PANEL wires, connectors, and fuses, and make the nec-
ACCESS 5 essary repairs or replacements.
CA203 • If:The resistance > 60 Ω.
CAN H 2
– Then continue to Step 3.
CAN L 3
Step 3: Keep the lift truck turned off. The CAN circuit
is open. Disconnect Access 5 CA402 and
CA204 CA402
CAN1 H measure the resistance between Access 5
CAN H 2 4 120 Ohm
Resistor CA402-4 and Access 5 CA402-5.
5
CAN H 4 CAN1 L
• If:The resistance > 120 Ω.
CAN L 8 – Then replace Access 5.
CAN L 10 • If:The resistance = 120 Ω.
– Then check the CAN terminating resistor in
ACCESS 2 Access 1. Disconnect Access 1 CA302 and mea-
sure the resistance between Access 1 CA302-8
and Access 1 CA302-9.
CA404
• If:The resistance > 120 Ω.
CAN L 15
– Then replace Access 1.
CAN H 23
• If: The resistance = 120 Ω.
– Then check the condition of the applicable wires,
Fig. 10 (28261) connectors, and fuses. Make the necessary re-
pairs or replacements.
Event Code 205
ACCESS 5 CAN EVENT WITH ACCESS 2
Step 1: Turn off the lift truck. Check the condition of
the CAN wires, pins, and connectors.

CAN H: Check the wire continuity between Access 2

CA404-23 and power unit distribution panel CA204-4.
Then check the wire continuity between Access 5
CA402-4 and power unit distribution panel CA204-2.
CAN L: Check the wire continuity between Access 2
CA404-15 and power unit distribution panel CA204-10.
Then check the wire continuity between Access 5
CA402-5 and power unit distribution panel CA204-8.
• If:The wires, pins, or connectors are damaged.

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Event Code 221

– Then check to make sure that the battery has the

correct specifications for the lift truck and the duty
cycle. Make the necessary repairs or replace-
ments.
ACCESS 1 PLATFORM
DISTRIBUTION
• If:The battery is correct.
PANEL – Then continue to Step 2.
CA105 Step 2: Turn off the lift truck. Check for the correct bat-
CA302
CAN H CAN H 2
120 Ohm 8 tery, power cable connections, Access 2 fuse
Resistor
CAN L
9 CAN L 8 (FU13), and steer and traction contactor
(ED2).
TP13
• If:The battery, power cable connections, FU13, or
POWER UNIT TP14 ED2 are incorrect.
DISTRIBUTION
PANEL – Then make the necessary repairs or replace-
ACCESS 5 ments.
• If:The battery, power cable connections, FU13, and
ED2 are correct.
– Then continue to Step 3.
Step 3: Check the battery charge level.
CA204 CA402
CAN1 H • If:The battery charge level is incorrect.
CAN H 2 4 120 Ohm
5 Resistor – Then charge the battery.
CAN H 4 CAN1 L
• If:The battery charge level is correct.
CAN L 8 – Then replace Access 2.
CAN L 10

ACCESS 2 ACCESS 2

CA404
CAN L 15

CAN H 23 BNEG
B+ + B-

Fig. 11 (28262)

FU13
Event Code 221
CURRENT SENSOR EVENT ED2
Step 1: Replace Access 2. Fig. 12 (28263)

Event Code 222 Event Code 223

ACCESS 2 VOLTAGE IS TOO LOW ACCESS 2 VOLTAGE IS TOO HIGH
Note: If Event Code 222 occurs with Event Code 541, Note: If Event Code 223 occurs with Event Code 541,
then see the procedures for Event Code 541 first. then see the procedures for Event Code 541 first.
Step 1: Turn on the lift truck. Measure the voltage be- Step 1: Turn on the lift truck. Measure the voltage be-
tween the positive terminal and the battery tween the positive terminal and the battery
negative terminal on Access 2. negative terminal on Access 2.
 The correct voltage = 36 V.  The correct voltage = 36 V.
• If:The voltage < 36 V.

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Event Code 224

• If:The voltage < 36 V.

– Then check to make sure that the battery has the Event Code 226
correct specifications for the lift truck and the duty ACCESS 2 INTERNAL TEMPERATURE IS MORE
cycle. Make the necessary repairs or replace- THAN 85 °C (185 °F)
ments.
Step 1: Turn off the lift truck. Check the condition of
• If:The battery is correct.
Access 2.
– Then replace Access 2.
• If:The Access 2 heatsink is dirty.
– Then use air to clean the heatsink.
ACCESS 2 • If:The Access 2 heatsink is clean.
– Then continue to Step 2.
Step 2: Turn on the lift truck. Check the operation of
the power unit fan (FAN2/3). Use Analyzer
Menu/A4.2.2 FAN3 to test FAN2/3.
BNEG
B+ + B- • If:FAN2/3 does not operate correctly.
– Then correct the FAN2/3 operation problem.
• If:FAN2/3 does operate correctly and Access 2 is
hot.
– Then continue to Step 3.
Fig. 13 (28264) Step 3: Turn off the lift truck. Check the power cable
connections.
Event Code 224 • If:The power cable connections are incorrect.
ACCESS 2 INTERNAL TEMPERATURE IS LESS – Then make the necessary repairs or replace-
THAN -25 °C (-13 °F) ments.
Step 1: Check the air temperature of the environment. • If:The power cable connections are correct.
• If:The air temperature is less than -25 °C (-13 °F) – Then continue to Step 4.
and the lift truck has been idle for an extended time. Step 4: Check the temperature of Access 2.
– Then warm the Access 2 heatsink to operate with
 The correct temperature ≥ 85 °C (185 °F).
full traction.
• If:The air temperature is more than -25 °C (-13 °F) • If:The temperature ≥ 85 °C (185 °F).
and Event Code 224 continues. – Then let Access 2 cool.
– Then replace Access 2. • If:The temperature < 85 °C (185 °F).
– Then replace Access 2.
Event Code 225
ACCESS 2 INTERNAL TEMPERATURE IS LESS Event Code 227
THAN -40 °C (-40 °F) ACCESS 2 INTERNAL TEMPERATURE IS MORE
Step 1: Check the air temperature of the environment. THAN 105 °C (221 °F).
• If:The air temperature is less than -40 °C (-40 °F) Step 1: See the procedures for Event Code 226.
and the lift truck has been idle for an extended time.
– Then warm the Access 2 heatsink to operate with Event Code 228
full traction. M3 TEMPERATURE SENSOR (TS2) TEMPERA-
• If:The air temperature is more than -40 °C (-40 °F) TURE IS MORE THAN 165 °C (329 °F).
and Event Code 225 continues. Note: A heavy duty cycle or high temperatures in the
– Then replace Access 2. operation environment could cause Event Code 228 to
occur.
Step 1: Check the M3 performance settings.

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 ELECTRICAL SYSTEM
Event Code 229

• If:The settings are incorrect. the lift truck frame. Then check the wire from TS2
– Then make corrections to the M3 settings. CA408-1 to Access 2 CA404-16.
 The correct resistance < 10,000 Ω.
• If:The settings are correct.
• If:There is a short circuit.
– Then continue to Step 2.
– Then make the necessary repairs or replace-
Step 2: Turn off the lift truck. Check the wires to TS2
ments.
and the M3 power cable connections.
• If:The resistance is correct.
• If:The wires or connections are incorrect.
– Then continue to Step 2.
– Then make the necessary repairs or replace-
Step 2: Keep the lift truck turned off. Check the wires
ments.
to TS2 for an open circuit.
• If:The wires and connections are correct, but Event
Code 228 continues. Check the continuity of TS2 CA408-1 to Access 2
– Then continue to Step 3. CA404-16 and from TS2 CA408-2 to Access 2
CA404-4.
Step 3: Check the battery condition.
• If:The resistance > 0 Ω.
• If:The battery condition is incorrect.
– Then make the necessary repairs or replace-
– Then make the necessary repairs or replace-
ments.
ments.
• If:The resistance = 0 Ω.
• If:The battery condition is correct, but Event Code
228 continues. – Then replace M3.
– Then continue to Step 4.
Step 4: Check the temperature of M3.
ACCESS 2
 The correct temperature ≥ 165 °C (329 °F).
• If:The temperature < 165 °C (329 °F).
– Then replace M3.
CA404
• If:The temperature ≥ 165 °C (329 °F).
3 +12 V
– Then replace Access 2. CA408
4 LOGIC NEG
BRN TS2
1
BRN/BLK T+
2
16 TEMP(+)
M3
ACCESS 2 LIFT PUMP MOTOR

UM U CA409 ECR7
VM V M3 1 +12 V RED
WM W
2 NEG BLACK
CH A WHITE
3
CH B BLUE
4
CA404
Fig. 15 (28266)
4 LOGIC NEG CA408 TS2
BRN
1
BRN/BLK T+

16 TEMP(+)
2
M3
Event Code 230
LIFT PUMP MOTOR HYDRAULIC FEEDBACK ENCODER (ECR7)
COUNT EVENT
Note: One or both channels are not found at Access 2
Fig. 14 (28265)
during lift truck travel.
Step 1: Turn on the lift truck. Check for Event Codes
Event Code 229 266, 267, 276, and 277.
TS2 TEMPERATURE IS TOO LOW OR TOO HIGH
• If:Event Codes 266, 267, 276, or 277 occur.
Step 1: Turn off the lift truck. Check the wires to TS2
– Then see the procedures for Event Codes 266,
for a short circuit to the lift truck frame.
267, 276, or 277.
Measure the resistance from CA409-1 and CA409-2 to

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Event Code 231

• If:Event Codes 266, 267, 276, and 277 do not oc-

cur.
ACCESS 2
– Then continue to Step 2.
Step 2: Turn off the lift truck. Then turn the lift truck on
CA404
again.
3 +12 V
• If:Event Code 230 occurs. 4 LOGIC NEG

– Then continue to Step 3. 5 ECR7 A

6 ECR7 B CA408 TS2
Step 3: Turn off the lift truck. Check the condition of 1
BRN
BRN/BLK T+
2
the wires between ECR7 channel A and
16 TEMP(+)
CA409-3, ECR7 channel B and CA409-4, M3
LIFT PUMP MOTOR
CA409-3 and Access 2 CA404-5, and
CA409 ECR7
CA409-4 and Access 2 CA404-6. 1 +12 V RED
2 NEG BLACK
• If:The wires are damaged. 3
CH A WHITE
CH B BLUE
4
– Then make the necessary repairs or replace-
ments. Fig. 16 (28267)
• If:The wires are correct and Event Code 230 con-
tinues. Event Code 231
– Then continue to Step 4. ACCESS 2 STALL IS DETECTED
Step 4: Turn on the lift truck. Measure the voltage be- Step 1: Make sure that unusual operation did not
tween ECR7 12 V and CA409-1, and ECR7 cause the event (for example, unwanted mate-
negative and CA409-2. rial in the tire, etc.).
 The correct voltage = 12 V. Step 2: Turn on the lift truck. Use Analyzer Menu/
• If:The voltage ≠ 12 V. A2.2.1.1 SPEED to check the M3 speed
– Then replace the wires or the connections to against the M3 target speed.
ECR7. If Event Code 230 continues, then replace • If:The speed is incorrect.
ECR7.
– Then replace M3.
• If:The voltage = 12 V.
• If:The speed is correct.
– Then continue to Step 5.
– Then replace Access 2.
Step 5: Keep the lift truck turned on. Measure the volt-
age between CA409-1 and Access 2
CA404-3, and CA409-2 and Access 2
Event Code 232
M3 ROTATION IS MORE THAN 4000 rpm
CA404-4.
Step 1: Turn off the lift truck. Check the condition of
• If:The voltage ≠ 12 V. the wires between ECR7 channel A and
– Then replace the wires or the connections to CA409-3, ECR7 channel B and CA409-4,
Access 2. CA409-3 and Access 2 CA404-5, and
CA409-4 and Access 2 CA404-6.
• If:The wires are damaged.
– Then make the necessary repairs or replace-
ments.
• If:The wires are correct and Event Code 232 con-
tinues.
– Then continue to Step 2.

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Event Code 233

Step 2: Turn on the lift truck. Measure the voltage be-

tween ECR7 12 V and CA409-1, and ECR7 Event Code 235
negative and CA409-2. ACCESS 2 VOLTAGE IS TOO HIGH
 The correct voltage = 12 V. Note: If Event Code 235 occurs with Event Code 541,
• If:The voltage ≠ 12 V. then see the procedures for Event Code 541 first.
– Then replace the wires or the connections to Step 1: See the procedures for Event Code 223.
ECR7. If Event Code 232 continues, then replace
ECR7. Event Code 236
• If:The voltage = 12 V. ACCESS 2 VOLTAGE IS VERY HIGH
– Then continue to Step 3. Note: If Event Code 236 occurs with Event Code 541,
Step 3: Keep the lift truck turned on. Measure the volt- then see the procedures for Event Code 541 first.
age between CA409-1 and Access 2 Step 1: See the procedures for Event Code 223.
CA404-3, and CA409-2 and Access 2
CA404-4. Event Code 237
• If:The voltage ≠ 12 V. ACCESS 2 VOLTAGE IS FLUCTUATING
– Then replace the wires or the connections to Note: The battery voltage decreases too much when it
Access 2. is under load.
Step 1: Turn on the lift truck. Measure the voltage be-
tween the positive terminal and the battery
ACCESS 2 negative terminal on Access 2.
 The correct voltage = 36 V.
CA404
• If:The voltage < 36 V.
3 +12 V
– Then continue to Step 2.
4 LOGIC NEG
5 ECR7 A Step 2: Turn off the lift truck. Check the power cables
6 ECR7 B CA408
BRN TS2 and the power cable connections.
1
BRN/BLK T+
2 • If:The power cables or the power cable connec-
16 TEMP(+) tions are incorrect.
M3
LIFT PUMP MOTOR
– Then make the necessary repairs or replace-
CA409 ECR7 ments.
1 +12 V RED
2 NEG BLACK • If:The power cables and the power cable connec-
CH A WHITE
3 tions are correct.
CH B BLUE
4
– Then continue to Step 3.
Fig. 17 (28267)
Step 3: Check the battery charge and the individual
cell conditions.
Event Code 233
• If:The battery condition is not satisfactory.
ACCESS 2 VOLTAGE IS TOO LOW
– Then make the necessary repairs or replace-
Note: If Event Code 233 occurs with Event Code 541,
ments.
then see the procedures for Event Code 541 first.
• If:The battery is correctly charged and has the cor-
Step 1: See the procedures for Event Code 222.
rect specifications.
– Then continue to Step 4.
Event Code 234 Step 4: Install a good battery.
ACCESS 2 VOLTAGE IS VERY LOW
• If:Event Code 237 continues.
Note: If Event Code 234 occurs with Event Code 541,
then see the procedures for Event Code 541 first. – Then replace Access 2.
Step 1: See the procedures for Event Code 222.

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Event Code 238

– Then check power cable condition and the con-

nection. Make the necessary repairs or replace-
ACCESS 2 ments.

ACCESS 2 PLATFORM
DISTRIBUTION
PANEL
BNEG
B+ + B- CA404 CA201
PWR 1 9 +BV_K2 FU3

BNEG
B+ + B-

Fig. 18 (28264)

Event Code 238

Fig. 19 (28268)
KEY SWITCH (KYS) VOLTAGE IS TOO LOW
Step 1: Check the battery charge and the individual
cell conditions.
Event Code 239
KYS VOLTAGE IS TOO HIGH
• If:The battery condition is not satisfactory.
Step 1: See the procedures for Event Code 238.
– Then make the necessary repairs or replace-
ments.
• If:The battery is correctly charged and has the cor-
Event Code 240
rect specifications. MAIN CONTACTOR (ED1) COIL DRIVER HAS TOO
MUCH CURRENT
– Then continue to Step 2.
Step 1: Turn on the lift truck to energize ED1.
Step 2: Turn on the lift truck. Measure the voltage be-
tween Access 2 CA404-1 and the battery neg- • If:ED1 does not energize.
ative terminal on Access 2. – Then continue to Step 4.
 The correct voltage = 36 V. • If:ED1 energizes.
• If:The voltage = 36 V. – Then continue to Step 2.
– Then check the wires between power unit distri- Step 2: Keep the lift truck turned on. Measure the
bution panel CA201-9 and Access 2 CA404-1. voltage between the battery positive terminal and the
Make the necessary repairs or replacements. battery negative terminal on Access 2.
• If:The voltage > 0 V, but much < 36 V.  The correct voltage = 36 V.
– Then continue to Step 3. • If:The voltage < 36 V.
Step 3: Keep the lift truck turned on. Measure the volt- – Then measure the battery voltage.
age between power unit distribution panel • If:The voltage = 36 V.
CA201-9 and the battery negative terminal on – Then continue to Step 3.
Access 2. Step 3: Turn off the lift truck. Then turn on the lift truck
again.
• If:The voltage > 0 V, but much < 36 V.
• If:Event Code 240 continues.
– Then check the condition of power unit distribu-
tion panel. Make the necessary repairs or re- – Then replace Access 5.
placements. Step 4: Turn off the lift truck. Check the condition of
Step 4: Keep the lift truck turned on. Measure the volt- all the fuses on the power unit distribution panel (FU1–
FU9).
age between the positive terminal and the bat-
tery negative terminal on Access 2. • If:FU1–FU9 are open or damaged.

• If:The voltage < 36 V.

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Event Code 243

– Then make the necessary repairs or replace- • If:The voltage ≠ 36 V.

ments.
– Then replace Access 2.
• If:FU1–FU9 are correct.
– Then continue to Step 6.
Step 5: Turn on the lift truck. Measure the voltage be- POWER UNIT
tween the positive terminal on the ED1 coil and the bat- DISTRIBUTION
PANEL
tery negative terminal on Access 2.
• If:The voltage = 3 V.
ACCESS 5
– Then replace ED1. FU4
• If:The voltage = 30 V.
FU1
– Then replace Access 2. CA403
FU2 B+ BRAKE
• If:The voltage = 36 V. 7 FEED INNER

– Then continue to Step 7. FU7 B+ BRAKE

9 FEED OUTER
• If:The voltage = 0 V. FU8 FU5
– Then continue to Step 6.
FU9 FU6 B+
Step 6: Turn off the lift truck. Disconnect the wire
from Access 5 CA403-18. Turn on the lift truck. Mea- CA202 B-
sure the voltage between the disconnected wire and ED DRIVER
FEED 8
18 ED_+BV
the battery negative terminal on Access 5.
• If:The voltage = 36 V.
FU3
– Then replace Access 5.
• If:The voltage = 0 V.
– Then turn off the lift truck. Check the condition of ACCESS 2
the wires between Access 5 CA403-18 and the
battery positive terminal on Access 5. Make the
necessary repairs or replacements. B+
CA404
Step 7: Keep the lift truck turned off. Disconnect the
negative wire from the ED1 coil. Measure the resis- B- GPD 1 2 ED1

tance of the ED1 coil.

 The correct resistance = 28–30 Ω. Fig. 20 (28179)
• If:The resistance ≠ 28–30 Ω.
– Then replace ED1. Event Code 243
• If:The resistance = 28–30 Ω. SOLENOID VALVE LOWER (SVL2) HAS TOO
MUCH CURRENT
– Then connect the negative wire to the ED1 coil.
Continue to Step 8. Step 1: Turn off the lift truck. Disconnect the negative
Step 8: Turn on the lift truck. Use Analyzer Menu/ wire from SVL2. Turn on the lift truck.
A4.2.3 ED1 to test ED1. Measure the voltage between • If:The event code changes to open circuit (Event
the negative terminal on the ED1 coil and the battery Code 248).
negative terminal on Access 2 without using Analyzer – Then there is a short circuit in SVL2 or the posi-
Menu/A4.2.3 ED1. tive circuit. Continue to Step 2.
• If:The voltage = 0 V. • If:Event Code 243 continues.
– Then turn off the lift truck. Disconnect the wire – Then there is a short circuit internal to Access 2
from Access 2 CA404-2. Turn on the lift truck. or in the negative circuit. Continue to Step 3.
Measure the voltage at Access 2 CA404-2 and
the battery negative terminal on Access 2. Step 2: Turn off the lift truck. Measure the resistance
across SVL2 from the positive terminal to the
• If:The voltage = 36 V.
– Then replace Access 3™.

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Event Code 244

negative terminal. – Then there is a short circuit in FAN2/3 or the pos-

 The correct resistance = 29 Ω. itive circuit. Continue to Step 2.
• If:The resistance is not = 29 Ω. • If:Event Code 244 continues.
– Then there is a short circuit in the SVL2 coil. Re- – Then there is a short circuit internal to Access 2
place SVL2. or in the negative circuit. Continue to Step 3.
• If:The resistance = 29 Ω. Step 2: Turn off the lift truck. Measure the resistance
– Then there is a short circuit in the positive circuit. across FAN2/3 from the positive terminal to
Repair or replace the wire from power unit distri- the negative terminal.
bution panel CA201-9 to SVL2.  The correct resistance = 29 Ω.
Step 3: Keep the lift truck turned off. Disconnect the • If:The resistance is not = 29 Ω.
negative wire from Access 2 CA404-22. Turn – Then there is a short circuit in the FAN2/3 coil.
on the lift truck. Replace FAN2/3.
• If:The event code changes to open circuit (Event • If:The resistance = 29 Ω.
Code 248). – Then there is a short circuit in the positive circuit.
– Then there is a short circuit in the negative circuit. Repair or replace the wire from power unit distri-
Repair or replace the wire from Access 2 bution panel CA201-8 to FAN2/3.
CA404-22 to SVL2. Step 3: Keep the lift truck turned off. Disconnect the
• If:Event Code 243 continues. negative wire from Access 2 CA404-8. Turn
– Then replace Access 2. on the lift truck.
• If:The event code changes to open circuit (Event
Code 249).
POWER UNIT – Then there is a short circuit in the negative circuit.
DISTRIBUTION
PANEL Repair or replace the wire from Access 2
CA404-8 to FAN2/3.
CA201
• If:Event Code 244 continues.
+BV_K2 FU3 9
– Then replace Access 2.

+
POWER UNIT
SVL2 DISTRIBUTION
PANEL

ACCESS 2 CA201
8

CA404
GPD 4 22

FAN2/3

Fig. 21 (28269)
ACCESS 2

Event Code 244

FAN2/3 DRIVER HAS TOO MUCH CURRENT CA404

Step 1: Turn off the lift truck. Disconnect the negative GPD 5 8
wire from FAN2/3. Turn on the lift truck.
• If:The event code changes to open circuit (Event
Code 249). Fig. 22 (28270)

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Event Code 245

Event Code 245 POWER UNIT

ED1 DRIVER HAS AN OPEN CIRCUIT DISTRIBUTION
PANEL
Step 1: See the procedures for Event Code 240. CA201
+BV_K2 FU3 9
Event Code 248 TP3
SVL2 DRIVER HAS AN OPEN CIRCUIT
TP4
Step 1: Turn off the lift truck. Disconnect the wires
from SVL2. Measure the resistance across +
SVL2
SVL2 from the positive terminal to the negative
terminal.
 The correct resistance = 29 Ω. ACCESS 2
• If:The resistance is not = 29 Ω.
– Then replace SVL2.
CA404
• If:The resistance = 29 Ω. GPD 4 22
– Then continue to Step 2.
Step 2: Turn on the lift truck. While pushing and hold-
ing POT3, measure the voltage between pow-
Fig. 23 (28271)
er unit distribution panel CA201-9 and
Access 2 CA404-22.
Event Code 249
• If:The voltage = 0 V. FAN2/3 DRIVER HAS AN OPEN CIRCUIT
– Then disconnect the wire from Access 2 Step 1: Turn off the lift truck. Disconnect the wires
CA404-22. While pushing and holding POT3,
from FAN2/3. Measure the resistance across
measure the voltage between Access 2
CA404-22 and power unit distribution panel TP4. FAN2/3 from the positive terminal to the nega-
• If:The voltage = 0 V. tive terminal.
 The correct resistance = 29 Ω.
– Then replace Access 2.
• If:The resistance is not = 29 Ω.
• If:The voltage = 36 V.
– Then replace FAN2/3.
– Then continue to Step 3.
• If:The resistance = 29 Ω.
Step 3: Turn off the lift truck. Check the wires to SVL2.
– Then continue to Step 2.
• If:The wires are correct.
Step 2: Connect FAN2/3. Turn on the lift truck. Mea-
– Then continue to Step 4.
sure the voltage from power unit distribution
Step 4: Turn on the lift truck. While pushing and hold-
panel CA201-8 to FAN2/3.
ing POT3, measure the voltage from power
 The correct voltage = 36 V.
unit distribution panel TP3 to power unit distri-
• If: The voltage = 0 V.
bution panel CA201-9.
– Then continue to Step 3.
• If:The voltage = 0 V.
Step 3: Disconnect the wire from Access 2 CA404-8.
– Then check the power unit distribution panel and Measure the voltage on the distribution panel
the related wires for the positive circuit. Make the
at Access 2 CA404-8 and power unit distribu-
necessary repairs or replacements.
tion panel TP4.
• If:The voltage = 36 V.
– Then check the power unit distribution panel and
the related wires for the positive circuit. Make the
necessary repairs or replacements.

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Event Code 250

• If:The voltage = 0 V.
– Then replace Access 2.
Event Code 255
ACCESS 2 PWM DRIVER HAS TOO MUCH VOLT-
POWER UNIT AGE
DISTRIBUTION
PANEL Step 1: Turn on the lift truck. Measure the battery
negative voltage at power unit distribution panel
CA201 CA201-9 and power unit distribution panel TP3.
8  The correct voltage = 36 V.
TP4 • If:The voltage = 0 V.
– Then turn off the lift truck. Check FU3 on the
power unit distribution panel for an open circuit.
• If:The voltage = 80 V.
FAN2/3 – Then continue to Step 2.
ACCESS 2
Step 2: Turn on the lift truck. Measure the voltage be-
tween Access 2 CA404-1 and power unit distribution
panel TP3.
CA404 • If:The voltage = 0 V.
GPD 5 8 – Then repair or replace the wire between
Access 2 CA404-1 and power unit distribution
panel CA201-9.
• If:The voltage = 80 V.
Fig. 24 (28272)
– Then replace Access 2.

Event Code 250

POWER UNIT
ED1 DRIVER HAS A SHORT CIRCUIT DISTRIBUTION
PANEL
Step 1: See the procedures for Event Code 240.
CA201

Event Code 253 +BV_K2 FU3 9

SVL2 DRIVER HAS A SHORT CIRCUIT

Step 1: See the procedures for Event Code 243. FU3

TP3

Event Code 254

ACCESS 2
FAN2/3 DRIVER HAS A SHORT CIRCUIT
Step 1: See the procedures for Event Code 244.
CA404
PWR 1

Fig. 25 (28273)

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Event Code 258

Event Code 258 POWER UNIT

DISTRIBUTION
PANEL
ACCESS 2 PRE-CHARGE POWER LIMIT IS TOO
LOW OR TOO HIGH
CA201
Note: The power limit of the pre-charge resistor in +BV_K2 FU3 9
Access 2 has been exceeded.
Step 1: Check the battery condition.
• If:The battery does not have the correct voltage or
is incorrectly charged.
– Then correct the battery problem.
ACCESS 2
• If:The battery is correctly charged and has the cor-
rect specifications.
– Then continue to Step 2. CA404

Step 2: Turn on the lift truck. Operate the brake PWR 1

pedal. Measure the voltage between the positive termi-
nal and the battery negative terminal on Access 2. BNEG
B+ + B-
 The correct voltage = 36 V.
• If:The voltage > 0 V, but much < 36 V.
– Then check the cables to Access 2. Make the
necessary repairs or replacements.
• If:The voltage = 36 V.
Fig. 26 (28274)
– Then continue to Step 3.
Step 3: Keep the lift truck turned on. Measure the
voltage between Access 2 CA404-1 and the battery Event Code 259
negative terminal on Access 2.
ACCESS 2 PRE-CHARGE TIME LIMIT HAS BEEN
• If:The voltage > 0 V, but much < 36 V.
EXCEEDED
– Then continue to Step 4.
Step 1: Check the battery condition.
Step 4: Keep the lift truck turned on. Measure the
• If:The battery does not have the correct voltage or
voltage between power unit distribution panel CA201-9
is incorrectly charged.
and the battery negative terminal on Access 2.
– Then correct the battery problem.
• If:The voltage = 36 V.
• If:The battery is correctly charged and has the cor-
– Then measure the voltage between power unit
rect specifications.
distribution panel CA201-9 and Access 2
CA404-1. – Then continue to Step 2.
• If:The voltage > 0 V, but much < 36 V. Step 2: Turn on the lift truck. Measure the voltage on
both sides of FU13.
– Then check the condition of the power unit distri-
bution panel and related wires. Make the neces- • If:The voltage drop across FU13 > 0.5 V.
sary repairs or replacements. – Then replace FU13.
Step 5: Replace Access 2. Step 3: Keep the lift truck turned on. Operate the
brake pedal. Measure the voltage between the positive
terminal and the battery negative terminal on Access 2.
 The correct voltage = 36 V.
• If:The voltage > 0 V, but much < 36 V.
– Then check the cables to Access 2. Make the
necessary repairs or replacements.

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Event Code 260

• If:The voltage = 36 V. Step 1: Check to make sure that the battery has the
– Then continue to Step 4. correct specifications for the lift truck and the duty cy-
cle.
Step 4: Keep the lift truck turned on. Measure the
voltage between Access 2 CA404-1 and the battery • If:The battery is incorrect.
negative terminal on Access 2. – Then replace the battery as necessary.
• If:The voltage > 0 V, but much < 36 V. • If:The battery is correct.
– Then continue to Step 5. – Then continue to Step 2.
Step 5: Keep the lift truck turned on. Measure the Step 2: Check the battery charge and the individual
voltage between power unit distribution panel CA201-9 cell conditions.
and the battery negative terminal on Access 2. • If:The battery condition is not satisfactory.
• If:The voltage = 36 V. – Then make the necessary repairs or replace-
– Then measure the voltage between power unit ments.
distribution panel CA201-9 and Access 2 • If:The battery is correctly charged and has the cor-
CA404-1. rect specifications.
• If:The voltage > 0 V, but much < 36 V. – Then continue to Step 3.
– Then replace Access 2. Step 3: Turn on the lift truck. Use Features Menu/F5
Truck Model to check for the correct lift truck configura-
tion and lift truck model.
POWER UNIT • If:The configuration is incorrect.
DISTRIBUTION
PANEL – Then correct the lift truck configuration.
• If:The configuration is correct.
CA201
– Then continue to Step 4.
+BV_K2 FU3 9
Step 4: Keep the lift truck turned on. Measure the
voltage between Access 2 CA404-1 and the battery
negative terminal on Access 2.
 The correct voltage = 36 V.
• If:The voltage > 0 V, but much < 36 V.
ACCESS 2 – Then check the condition of the power unit distri-
bution panel and related wires. Make the neces-
sary repairs or replacements.
CA404
• If:The voltage = 36 V.
PWR 1
– Then continue to Step 5.
BNEG Step 5: Turn off the lift truck. Check the wires from
B+ + B-
power unit distribution panel CA201-9 to Access 2
CA404-1. Make the necessary repairs or replace-
ments.
FU13 Step 6: Turn on the lift truck. Check for other event
codes to occur with Event Code 260.
Fig. 27 (28275) • If:No other event codes occur.
– Then replace Access 2.

Event Code 260

ACCESS 2 PRE-CHARGE ELECTRICAL EVENT
Note: There is a resistive load on the ED1 bus during
pre-charge.

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Event Code 261

POWER UNIT
DISTRIBUTION
Event Code 266
PANEL
12 V SUPPLY VOLTAGE FOR ECR7 IS TOO LOW
OR TOO HIGH
CA201
+BV_K2 FU3
Event Code 266 and 267
9
Event Code 266: 12 V SUPPLY VOLTAGE FOR ECR7
IS TOO HIGH
Event Code 267: 12 V SUPPLY VOLTAGE FOR ECR7
IS TOO LOW
ACCESS 2 Step 1: Turn on the lift truck. Measure the voltage be-
tween Access 2 CA404-3 and power unit distribution
panel TP3.
CA404
• If:The voltage = 0 V.
PWR 1
– Then replace Access 2.
BNEG • If:The voltage = 12 V and Event Code 266 or Event
B+ + B- Code 267 continues.
– Then continue to Step 2.
Step 2: Turn off the lift truck. Disconnect the wire
from Access 2 CA404-3. Turn on the lift truck. Measure
the voltage between Access 2 CA404-3 and power unit
Fig. 28 (28274) distribution panel TP3.
• If:The voltage = 12 V.
– Then replace ECR7.
Event Code 261 • If:The voltage ≠ 12 V and Event Code 266 or Event
ACCESS 2 EVENT Code 267 continues.
Step 1: Replace Access 2. – Then replace Access 2.

Event Code 264 ACCESS 2 POWER UNIT

DISTRIBUTION
INTERNAL 5 V SUPPLY FOR ACCESS 2 IS TOO PANEL
LOW OR TOO HIGH CA404
Event Code 264 and 265 +12 V 3
TP3
Event Code 264: INTERNAL 5 V SUPPLY FOR
Access 2 IS TOO HIGH
Event Code 265: INTERNAL 5 V SUPPLY FOR
M3
Access 2 IS TOO LOW LIFT PUMP MOTOR
Step 1: Turn off the lift truck. Then turn the lift truck on
CA409 ECR7
again. 1 +12 V RED
2 NEG BLACK
• If:Event Code 264 or Event Code 265 continues. 3
CH A WHITE
CH B BLUE
4
– Then replace Access 2.
Fig. 29 (28276)

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Event Code 268

Event Code 268 Event Code 274

15 V POWER SUPPLY FOR ACCESS 2 IS TOO LOW INTERNAL 2.5 V REFERENCE VOLTAGE FOR
OR TOO HIGH ACCESS 2 IS TOO LOW OR TOO HIGH
Event Code 268 and 269 Event Code 274 and 275
Event Code 268: 15 V POWER SUPPLY FOR Event Code 274: INTERNAL 2.5 V REFERENCE
Access 2 IS TOO HIGH VOLTAGE FOR Access 2 IS TOO HIGH
Event Code 269: 15 V POWER SUPPLY FOR Event Code 275: INTERNAL 2.5 V REFERENCE
Access 2 IS TOO LOW VOLTAGE FOR Access 2 IS TOO LOW
Step 1: There is an internal failure in Access 2. Step 1: There is an internal failure in Access 2.
• If:Event Code 268 or Event Code 269 continues. • If:Event Code 274 or Event Code 275 continues.
– Then replace Access 2. – Then replace Access 2.

Event Code 270 Event Code 276

5 V POWER SUPPLY FOR ACCESS 2 IS TOO LOW INTERNAL ANALOG GROUND VOLTAGE FOR
OR TOO HIGH ACCESS 2 IS TOO LOW OR TOO HIGH
Event Code 270 and 271 Event Code 276 and 277
Event Code 270: 5 V POWER SUPPLY FOR Access 2 Event Code 276: INTERNAL ANALOG GROUND
IS TOO HIGH VOLTAGE FOR Access 2 IS TOO HIGH
Event Code 271: 5 V POWER SUPPLY FOR Access 2 Event Code 277: INTERNAL ANALOG GROUND
IS TOO LOW VOLTAGE FOR Access 2 IS TOO LOW
Step 1: There is an internal failure in Access 2. Step 1: Turn off the lift truck. Then turn the lift truck on
• If:Event Code 270 or Event Code 271 continues. again.
– Then replace Access 2. • If:Event Code 276 or Event Code 277 continues.
– Then replace Access 2.

Event Code 272

Event Code 278
INTERNAL 227 mV REFERENCE VOLTAGE FOR
ACCESS 2 IS TOO LOW OR TOO HIGH ACCESS 2 CURRENT IS TOO HIGH
Event Code 272 and 273 Step 1: Turn off the lift truck. Disconnect the M3
power cables from Access 2. Turn on the lift truck.
Event Code 272: INTERNAL 227 mV REFERENCE
VOLTAGE FOR Access 2 IS TOO HIGH • If:Event Code 278 continues.
– Then replace Access 2.
Event Code 273: INTERNAL 227 mV REFERENCE
VOLTAGE FOR Access 2 IS TOO LOW • If:Event Code 278 does not continue.
Step 1: There is an internal failure in Access 2. – Then continue to Step 2.
• If:Event Code 272 or Event Code 273 continues. Step 2: Turn off the lift truck. Check the M3 power ca-
bles for phase to phase or phase to lift truck frame short
– Then replace Access 2.
circuits.
• If:There is a short circuit between the U, V, or W
power cables or to the lift truck frame (with the
power cables connected to M3).
– Then continue to Step 3.

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Event Code 279

Step 3: Keep the lift truck turned off. Disconnect the • If:The M3 power cables are correct.
power cables from M3. Check for a short circuit from – Then continue to Step 2.
the M3 windings to the lift truck frame.
Step 2: Keep the lift truck turned off. Disconnect the
• If:There is a short circuit in the windings. M3 power cables from Access 2. Turn on the lift truck.
– Then replace M3. • If:Event Code 281 or Event Code 282 does not con-
• If:The windings are correct. tinue.
– Then repair or replace the applicable M3 power – Then replace M3.
cable. • If:Event Code 281 or Event Code 282 continues.
– Then replace Access 2.

ACCESS 2

ACCESS 2
UM U

VM V M3
WM W
UM U

VM V M3
WM W

BNEG
B+ + B-
BNEG
B+ + B-

Fig. 30 (28277)

Fig. 31 (28277)

Event Code 279

ACCESS 2 HAS AN INTERNAL SHORT CIRCUIT Event Code 283
Event Code 279 and 280 M3 HAS A SHORT CIRCUIT
Step 1: Turn off the lift truck. Then turn the lift truck on Event Code 283 and 284
again.
Event Code 283: THERE IS A SHORT CIRCUIT BE-
• If:Event Code 279 or Event Code 280 continues.
TWEEN BATTERY POSITIVE AND THE V TERMINAL
– Then replace Access 2.
Event Code 284: THERE IS A SHORT CIRCUIT BE-
TWEEN BATTERY NEGATIVE AND THE V TERMI-
Event Code 281 NAL
Step 1: See the procedures for Event Code 281 and
M3 HAS A SHORT CIRCUIT 282.
Event Code 281 and 282
Event Code 281: THERE IS A SHORT CIRCUIT BE-
TWEEN BATTERY POSITIVE AND THE U TERMI- Event Code 285
NAL
M3 HAS A SHORT CIRCUIT
Event Code 282: THERE IS A SHORT CIRCUIT BE- Event Code 285 and 286
TWEEN BATTERY NEGATIVE AND THE U TERMI-
NAL Event Code 285: THERE IS A SHORT CIRCUIT BE-
TWEEN BATTERY POSITIVE AND THE W TERMI-
Step 1: Turn off the lift truck. Check the condition of
NAL
the M3 power cables.
• If:There is a short circuit in the M3 power cables. Event Code 286: THERE IS A SHORT CIRCUIT BE-
TWEEN BATTERY NEGATIVE AND THE W TERMI-
– Then make the necessary repairs or replace-
NAL
ments.

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Event Code 287

Step 1: See the procedures for Event Code 281 and TWEEN THE WH TERMINAL AND THE UL TERMI-
282. NAL
Step 1: See the procedures for Event Code 281 and
282.
Event Code 287
M3 HAS A SHORT CIRCUIT BETWEEN THE U TER-
MINAL AND THE V TERMINAL
Event Code 300
Event Code 287 through 289 INVALID EVENT CODE FROM Access 3™ - NOT
USED
Event Code 287: THERE IS A SHORT CIRCUIT BE-
TWEEN THE U TERMINAL AND THE V TERMINAL The event code is not specified in the lift truck code.
Consult the factory.
Event Code 288: THERE IS A SHORT CIRCUIT BE-
TWEEN THE UL TERMINAL AND THE VH TERMINAL
Event Code 289: THERE IS A SHORT CIRCUIT BE- Event Code 301
TWEEN THE UH TERMINAL AND THE VL TERMINAL
ACCESS 1 CAN EVENT WITH Access 3™
Step 1: See the procedures for Event Code 281 and
Step 1: Turn off the lift truck. Check the condition of
282.
the CAN wires, pins, and connectors.
CAN H: Check the wire continuity between Access 3™
Event Code 290 CA401-23 and power unit distribution panel CA204-1.
Then check the wire continuity between power unit dis-
M3 HAS A SHORT CIRCUIT BETWEEN THE V TER- tribution panel CA203-2 and platform distribution panel
MINAL AND THE W TERMINAL CA104-2. Then check the wire continuity between plat-
Event Code 290 through 292 form distribution panel CA105-2 and Access 1
CA302-8.
Event Code 290: THERE IS A SHORT CIRCUIT BE-
TWEEN THE V TERMINAL AND THE W TERMINAL CAN L: Check the wire continuity between Access 3™
CA401-15 and power unit distribution panel CA204-7.
Event Code 291: THERE IS A SHORT CIRCUIT BE- Then check the wire continuity between power unit dis-
TWEEN THE VL TERMINAL AND THE WH TERMI- tribution panel CA203-3 and platform distribution panel
NAL CA104-3. Then check the wire continuity between plat-
Event Code 292: THERE IS A SHORT CIRCUIT BE- form distribution panel CA105-8 and Access 1
TWEEN THE VH TERMINAL AND THE WL TERMI- CA302-9.
NAL • If:The wires, pins, or connectors are damaged.
Step 1: See the procedures for Event Code 281 and – Then make the necessary repairs or replace-
282. ments.
• If:The wires, pins, and connectors are correct.
– Then continue to Step 2.
Event Code 293 Step 2: Keep the lift truck turned off. Measure the re-
sistance between CAN H and CAN L on platform distri-
M3 HAS A SHORT CIRCUIT BETWEEN THE W TER-
bution panel TP13 and platform distribution panel
MINAL AND THE U TERMINAL
TP14.
Event Code 293 through 295  The correct resistance = 60 Ω.
Event Code 293: THERE IS A SHORT CIRCUIT BE- • If:The resistance = 0 Ω.
TWEEN THE W TERMINAL AND THE U TERMINAL – Then there is a short circuit between CAN H and
Event Code 294: THERE IS A SHORT CIRCUIT BE- CAN L. Check the condition of the applicable
TWEEN THE WL TERMINAL AND THE UH TERMI- wires, connectors, and fuses, and make the nec-
NAL essary repairs or replacements.
• If:The resistance > 60 Ω.
Event Code 295: THERE IS A SHORT CIRCUIT BE-
– Then continue to Step 3.

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Event Code 303

Step 3: Keep the lift truck turned off. The CAN circuit
is open. Disconnect Access 5 CA402 and measure the
resistance between Access 5 CA402-4 and Access 5
CA402-5.
ACCESS 1 PLATFORM
• If:The resistance > 120 Ω. DISTRIBUTION
– Then replace Access 5. PANEL

• If:The resistance = 120 Ω. CA105

CA302
CAN H CAN H 2
– Then check the CAN terminating resistor in 120 Ohm 8
Access 1. Disconnect Access 1 CA302 and mea- Resistor 9 CAN L 8
CAN L CA104
sure the resistance between Access 1 CA302-8
2 CAN H TP13
and Access 1 CA302-9.
3 CAN L
• If:The resistance = 120 Ω. POWER UNIT TP14
– Then check the condition of the applicable wires, DISTRIBUTION
PANEL
connectors, and fuses. Make the necessary re- ACCESS 5
pairs or replacements.
CA203
• If:The resistance > 120 Ω. CAN H 2
– Then replace Access 1. CAN L 3

CA204
CAN H 1 CA402
CAN1 H
CAN H 2 4 120 Ohm
5 Resistor
CAN1 L
CAN L 7
CAN L 8

ACCESS 3

CA401
CAN L 15

CAN H 23

Fig. 32 (28278)

Event Code 303

Access 3™ CAN EVENT
Step 1: Turn off the lift truck. Then turn the lift truck on
again.
• If:Event Code 303 continues.
– Then replace Access 3™.

Event Code 304

ACCESS 4 CAN EVENT WITH Access 3™
Step 1: Turn off the lift truck. Check the condition of
the CAN wires, pins, and connectors.

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Event Code 304

CAN H: Check the wire continuity between Access 3™ • If:The resistance = 120 Ω.
CA401-23 and power unit distribution panel CA204-1. – Then check the CAN terminating resistor in
Then check the wire continuity between platform distri- Access 1. Disconnect Access 1 CA302 and mea-
bution panel CA105-1 and Access 4 CA303-7. sure the resistance between Access 1 CA302-8
CAN L: Check the wire continuity between Access 3™ and Access 1 CA302-9.
CA401-15 and power unit distribution panel CA204-7. • If:The resistance = 120 Ω.
Then check the wire continuity between platform distri- – Then check the condition of the applicable wires,
bution panel CA105-7 and Access 4 CA303-8. connectors, and fuses. Make the necessary re-
• If:The wires, pins, or connectors are damaged. pairs or replacements.
– Then make the necessary repairs or replace- • If:The resistance > 120 Ω.
ments. – Then replace Access 1.
• If:The wires, pins, and connectors are correct.
– Then continue to Step 2.
Step 2: Keep the lift truck turned off. Measure the re-
sistance between CAN H and CAN L on platform distri-
bution panel TP13 and platform distribution panel ACCESS 4 PLATFORM
TP14. DISTRIBUTION
PANEL
 The correct resistance = 60 Ω.
CA105
CA303
• If:The resistance = 0 Ω. CAN H 1
CAN H 7
– Then there is a short circuit between CAN H and
CAN L 8 CAN L 7
CAN L. Check the condition of the applicable
wires, connectors, and fuses, and make the nec- TP13
essary repairs or replacements.
• If:The resistance > 60 Ω. TP14

– Then continue to Step 3.

POWER UNIT ACCESS 5
Step 3: Keep the lift truck turned off. The CAN circuit DISTRIBUTION
is open. Disconnect Access 5 CA402 and measure the PANEL
resistance between Access 5 CA402-4 and Access 5
CA402-5.
• If:The resistance > 120 Ω. CA204
CA402
– Then replace Access 5. CAN H 1
CAN1 H
CAN H 2 4 120 Ohm
5 Resistor
CAN1 L
CAN L 7
CAN L 8

ACCESS 3

CA401
CAN L 15

CAN H 23

Fig. 33 (28279)

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Event Code 305

– Then replace Access 1.

Event Code 305

ACCESS 1
ACCESS 5 CAN EVENT WITH Access 3™
Step 1: Turn off the lift truck. Check the condition of
the CAN wires, pins, and connectors.
CA302
CAN H PLATFORM
CAN H: Check the wire continuity between Access 3™ 120 Ohm 8 DISTRIBUTION
CA401-23 and power unit distribution panel CA204-1. Resistor 9 PANEL
CAN L
Then check the wire continuity between power unit dis-
tribution panel CA204-2 and Access 5 CA402-4. TP13

CAN L: Check the wire continuity between Access 3™ POWER UNIT TP14
CA401-15 and power unit distribution panel CA204-7. DISTRIBUTION
PANEL
Then check the wire continuity between power unit dis- ACCESS 5
tribution panel CA204-8 and Access 5 CA402-5.
• If:The wires, pins, or connectors are damaged.
– Then make the necessary repairs or replace-
ments.
CA204
• If:The wires, pins, and connectors are correct.
CAN H 1 CA402
– Then continue to Step 2. 4
CAN1 H
CAN H 2 120 Ohm
Step 2: Keep the lift truck turned off. Measure the re- 5 Resistor
CAN1 L
sistance between CAN H and CAN L on platform distri- CAN L 7
bution panel TP13 and platform distribution panel CAN L 8
TP14.
 The correct resistance = 60 Ω.
• If:The resistance = 0 Ω.
ACCESS 3
– Then there is a short circuit between CAN H and
CAN L. Check the condition of the applicable
wires, connectors, and fuses, and make the nec- CA401
essary repairs or replacements.
CAN L 15
• If:The resistance > 60 Ω.
CAN H 23
– Then continue to Step 3.
Step 3: Keep the lift truck turned off. The CAN circuit
is open. Disconnect Access 5 CA402 and measure the Fig. 34 (28280)
resistance between Access 5 CA402-4 and Access 5
CA402-5.
• If:The resistance > 120 Ω. Event Code 306
– Then replace Access 5.
ACCESS 6 CAN EVENT WITH Access 3™
• If:The resistance = 120 Ω.
Step 1: Turn off the lift truck. Check the condition of
– Then check the CAN terminating resistor in the CAN wires, pins, and connectors.
Access 1. Disconnect Access 1 CA302 and mea-
sure the resistance between Access 1 CA302-8 CAN H: Check the wire continuity between Access 3™
and Access 1 CA302-9. CA401-23 and power unit distribution panel CA204-1.
Then check the wire continuity between power unit dis-
• If:The resistance = 120 Ω.
tribution panel CA204-3 and Access 6 CA601-4.
– Then check the condition of the applicable wires,
connectors, and fuses. Make the necessary re- CAN L: Check the wire continuity between Access 3™
pairs or replacements. CA401-15 and power unit distribution panel CA204-7.
Then check the wire continuity between power unit dis-
• If:The resistance > 120 Ω.
tribution panel CA204-9 and Access 6 CA601-5.

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Event Code 310

• If:The wires, pins, or connectors are damaged.

– Then make the necessary repairs or replace-
ACCESS 1
ments.
PLATFORM
• If:The wires, pins, and connectors are correct. DISTRIBUTION
PANEL
– Then continue to Step 2. CA302
CAN H
Step 2: Keep the lift truck turned off. Measure the re- 120 Ohm 8 TP13
sistance between CAN H and CAN L on platform distri- Resistor
9
CAN L TP14
bution panel TP13 and platform distribution panel
TP14.
 The correct resistance = 60 Ω. ACCESS 5
POWER UNIT
• If:The resistance = 0 Ω. DISTRIBUTION
PANEL
– Then there is a short circuit between CAN H and
CAN L. Check the condition of the applicable
wires, connectors, and fuses, and make the nec-
CA204
essary repairs or replacements.
CAN H 1 CA402
• If:The resistance > 60 Ω. CAN H 2 4
CAN1 H
120 Ohm
– Then continue to Step 3. CAN H 3 5 Resistor
CAN1 L
Step 3: Keep the lift truck turned off. The CAN circuit CAN L 7
is open. Disconnect Access 5 CA402 and measure the CAN L 8
resistance between Access 5 CA402-4 and Access 5 CAN L 9
CA402-5.
• If:The resistance > 120 Ω. ACCESS 6

– Then replace Access 5. ACCESS 3

• If:The resistance = 120 Ω. CA601

– Then check the CAN terminating resistor in CA401 4 CAN H
Access 1. Disconnect Access 1 CA302 and mea- CAN L 15 5 CAN L
sure the resistance between Access 1 CA302-8
CAN H 23
and Access 1 CA302-9.
• If:The resistance = 120 Ω.
– Then check the condition of the applicable wires, Fig. 35 (28281)
connectors, and fuses. Make the necessary re-
pairs or replacements.
• If:The resistance > 120 Ω. Event Code 310
– Then replace Access 1. HEIGHT ENCODER (ECR4) AND HEIGHT FEED-
BACK ENCODER (ECR6) SOFTWARE INCOMPATI-
BILITY
Step 1: Load the compatible software for ECR4 and
ECR6.
• If:Event Code 310 continues.
– Then replace Access 3™.

Event Code 321

CURRENT SENSOR EVENT
Step 1: Replace Access 3™.

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Event Code 322

Event Code 322 Event Code 323

Access 3™ VOLTAGE IS TOO LOW Access 3™ VOLTAGE IS TOO HIGH (MORE THAN
Note: If Event Code 322 occurs with Event Code 541, 63 V)
then see the procedures for Event Code 541 first. Note: If Event Code 323 occurs with Event Code 541,
Step 1: Turn on the lift truck. Measure the voltage be- then see the procedures for Event Code 541 first.
tween the positive terminal and the battery negative Step 1: Turn on the lift truck. Measure the voltage be-
terminal on Access 3™. tween the positive terminal and the battery negative
 The correct voltage = 36 V. terminal on Access 3™.
• If:The voltage < 36 V.  The correct voltage = 36 V.
– Then check to make sure that the battery has the • If:The voltage < 36 V.
correct specifications for the lift truck and the duty – Then check to make sure that the battery has the
cycle. Make the necessary repairs or replace- correct specifications for the lift truck and the duty
ments. cycle. Make the necessary repairs or replace-
• If:The battery is correct. ments.
– Then continue to Step 2. • If:The battery is correct.
Step 2: Turn off the lift truck. Check for the correct – Then replace Access 3™.
battery, power cable connections, Access 3™ fuse
(FU15), and ED2.
• If:The battery, power cable connections, FU15, or ACCESS 3
ED2 are incorrect.
– Then make the necessary repairs or replace-
ments.
• If:The battery, power cable connections, FU15, and
ED2 are correct. BNEG
B+ + B-
– Then continue to Step 3.
Step 3: Check the battery charge level.
• If:The battery charge level is incorrect.
– Then charge the battery.
• If:The battery charge level is correct. Fig. 37 (28283)
– Then replace Access 3™.

Event Code 324

ACCESS 3
Access 3™ INTERNAL TEMPERATURE IS LESS
THAN -25 °C (-13 °F)
Step 1: Check the air temperature of the environ-
ment.
• If:The air temperature is less than -25 °C (-13 °F)
BNEG and the lift truck has been idle for an extended time.
B+ + B-
– Then warm the Access 3™ heatsink to operate
with full traction.
FU15
• If:The air temperature is more than -25 °C (-13 °F)
and Event Code 324 continues.
ED2 – Then replace Access 3™.
Fig. 36 (28282)

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Event Code 325

• If:The temperature < 85 °C (185 °F).

– Then replace Access 3™.
Event Code 325
Access 3™ INTERNAL TEMPERATURE IS LESS
THAN -40 °C (-40 °F)
Event Code 327
Step 1: Check the air temperature of the environ- Access 3™ INTERNAL TEMPERATURE IS MORE
ment. THAN 105 °C (221 °F).
• If:The air temperature is less than -40 °C (-40 °F) Step 1: See the procedures for Event Code 326.
and the lift truck has been idle for an extended time.
– Then warm the Access 3™ heatsink to operate
with full traction. Event Code 328
• If:The air temperature is more than -40 °C (-40 °F) M1 TEMPERATURE SENSOR (TS1) TEMPERA-
and Event Code 325 continues. TURE IS MORE THAN 165 °C (329 °F).
– Then replace Access 3™. Note: A heavy duty cycle or high temperatures in the
operation environment could cause Event Code 328 to
occur.
Event Code 326 Step 1: Check the M1 performance settings.
Access 3™ INTERNAL TEMPERATURE IS MORE • If:The settings are incorrect.
THAN 85 °C (185 °F) – Then make corrections to the M1 settings.
Step 1: Turn off the lift truck. Check the condition of • If:The settings are correct.
Access 3™.
– Then continue to Step 2.
• If:The Access 3™ heatsink is dirty.
Step 2: Turn off the lift truck. Check the wires to TS1
– Then use air to clean the heatsink. and the M1 power cable connections.
• If:The Access 3™ heatsink is clean. • If:The wires or connections are incorrect.
– Then continue to Step 2. – Then make the necessary repairs or replace-
Step 2: Turn on the lift truck. Check the operation of ments.
FAN2/3. Use Analyzer Menu/A4.3.2 FAN2 to • If:The wires and connections are correct, but Event
test FAN2/3. Code 328 continues.
• If:FAN2/3 does not operate correctly. – Then continue to Step 3.
– Then correct the FAN2/3 operation problem. Step 3: Check the battery condition.
• If:FAN2/3 does operate correctly and Access 3™ is • If:The battery condition is incorrect.
hot. – Then make the necessary repairs or replace-
– Then continue to Step 3. ments.
Step 3: Turn off the lift truck. Check the power cable • If:The battery condition is correct, but Event Code
connections. 328 continues.
• If:The power cable connections are incorrect. – Then continue to Step 4.
– Then make the necessary repairs or replace- Step 4: Check the temperature of M1.
ments.  The correct temperature ≥ 165 °C (329 °F).
• If:The power cable connections are correct. • If:The temperature < 165 °C (329 °F).
– Then continue to Step 4. – Then replace M1.
Step 4: Check the temperature of Access 3™.
• If:The temperature ≥ 165 °C (329 °F).
 The correct temperature ≥ 85 °C (185 °F).
– Then replace Access 3™.
• If:The temperature ≥ 85 °C (185 °F).
– Then let Access 3™ cool.

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Event Code 329

ACCESS 3 ACCESS 3

UM U

VM V M1
WM W

CA401

CA401 3 +12 V

CA412 4 LOGIC NEG CA412 TS1

4 LOGIC NEG
BRN TS1 BRN
1 1
BRN/BLK T+ BRN/BLK T+
2 2

16 TEMP(+) 16 TEMP(+)
M1 M1
TRACTION MOTOR TRACTION MOTOR

CA411 ECR3
1 +12 V RED
2 NEG BLACK
Fig. 38 (28284) CH A WHITE
3
CH B BLUE
4

Event Code 329 Fig. 39 (28285)

TS1 TEMPERATURE IS TOO LOW OR TOO HIGH

Step 1: Turn off the lift truck. Check the wires to TS1 Event Code 330
for a short circuit to the lift truck frame. TRAVEL SPEED ENCODER (ECR3) COUNT EVENT
Measure the resistance from CA411-1 and CA411-2 to Note: One or both channels are not found at
the lift truck frame. Then check the wire from TS1 Access 3™ during lift truck travel.
CA412-1 to Access 3™ CA401-16. Step 1: Turn on the lift truck. Check for Event Codes
 The correct resistance < 10,000 Ω. 366, 367, 376, and 377.
• If:There is a short circuit. • If:Event Codes 366, 367, 376, or 377 occur.
– Then make the necessary repairs or replace- – Then see the procedures for Event Codes 366,
ments. 367, 376, or 377.
• If:The resistance is correct. • If:Event Codes 366, 367, 376, and 377 do not oc-
– Then continue to Step 2. cur.
Step 2: Keep the lift truck turned off. Check the wires – Then continue to Step 2.
to TS1 for an open circuit. Step 2: Turn off the lift truck. Then turn the lift truck on
Check the continuity of TS1 CA412-1 to Access 3™ again.
CA401-16 and from TS1 CA412-2 to Access 3™ • If:Event Code 330 occurs.
CA401-4. – Then continue to Step 3.
• If:The resistance > 0 Ω. Step 3: Turn off the lift truck. Check the condition of
– Then make the necessary repairs or replace- the wires between ECR3 channel A and CA411-3,
ments. ECR3 channel B and CA411-4, CA411-3 and
• If:The resistance = 0 Ω. Access 3™ CA401-5, and CA411-4 and Access 3™
– Then replace M1. CA401-6.
• If:The wires are damaged.
– Then make the necessary repairs or replace-
ments.
• If:The wires are correct and Event Code 330 con-
tinues.
– Then continue to Step 4.

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Event Code 331

Step 4: Turn on the lift truck. Measure the voltage be- Step 3: Make sure that M1 and the drive unit are
tween ECR3 12 V and CA411-1, and ECR3 negative aligned. Operate the lift truck and monitor the drive unit
and CA411-2. for lateral movement.
 The correct voltage = 12 V. • If:The operation is correct and Event Code 331
• If:The voltage ≠ 12 V. continues.
– Then replace the wires or the connections to – Then replace Access 3™.
ECR3. If Event Code 330 continues, then replace
ECR3.
• If:The voltage = 12 V. Event Code 332
– Then continue to Step 5. M1 ROTATION IS MORE THAN 4000 rpm
Step 5: Keep the lift truck turned on. Measure the Step 1: Turn off the lift truck. Check the condition of
voltage between CA411-1 and Access 3™ CA401-3, the wires between ECR3 channel A and CA411-3,
and CA411-2 and Access 3™ CA401-4. ECR3 channel B and CA411-4, CA411-3 and
• If:The voltage ≠ 12 V. Access 3™ CA401-5, and CA411-4 and Access 3™
CA401-6.
– Then replace the wires or the connections to
Access 3™. • If:The wires are damaged.
– Then make the necessary repairs or replace-
ments.
ACCESS 3 • If:The wires are correct and Event Code 332 con-
tinues.
CA401 – Then continue to Step 2.
3 +12 V Step 2: Turn on the lift truck. Measure the voltage be-
4 LOGIC NEG tween ECR3 12 V and CA411-1, and ECR3 negative
5 ECR3 A and CA411-2.
6 ECR3 B CA412 TS1  The correct voltage = 12 V.
BRN
1
BRN/BLK T+
2
• If:The voltage ≠ 12 V.
16 TEMP(+)
M1 – Then replace the wires or the connections to
TRACTION MOTOR
ECR3. If Event Code 332 continues, then replace
CA411 ECR3 ECR3.
1 +12 V RED
NEG BLACK
2
CH A WHITE • If:The voltage = 12 V.
3
CH B BLUE
4 – Then continue to Step 3.
Fig. 40 (28286) Step 3: Keep the lift truck turned on. Measure the
voltage between CA411-1 and Access 3™ CA401-3,
and CA411-2 and Access 3™ CA401-4.
Event Code 331 • If:The voltage ≠ 12 V.
Access 3™ STALL IS DETECTED – Then replace the wires or the connections to
Access 3™.
Step 1: Make sure that unusual operation did not
cause the event (for example, unwanted material in the
tire, etc.).
Step 2: Turn on the lift truck. Use Analyzer Menu/
A2.3.1.1 Speed to check the M1 travel speed against
the M1 target speed.
• If:The speed is correct.
– Then continue to Step 3.
• If:The speed is incorrect.
– Then replace M1.

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Event Code 333

Event Code 337

ACCESS 3 Access 3™ VOLTAGE IS FLUCTUATING
Note: The battery voltage decreases too much when it
CA401
is under load.
3 +12 V
Step 1: Turn on the lift truck. Measure the voltage be-
4 LOGIC NEG
tween the positive terminal and the battery negative
5 ECR3 A
CA412
terminal on Access 3™.
6 ECR3 B
BRN TS1
1
BRN/BLK T+
 The correct voltage = 36 V.
2
16 TEMP(+)
• If:The voltage < 36 V.
M1
TRACTION MOTOR – Then continue to Step 2.
CA411 ECR3
Step 2: Turn off the lift truck. Check the power cables
1 +12 V RED
NEG BLACK
and the power cable connections.
2
CH A WHITE
3
CH B BLUE
• If:The power cables or the power cable connec-
4
tions are incorrect.
Fig. 41 (28286) – Then make the necessary repairs or replace-
ments.
• If:The power cables and the power cable connec-
Event Code 333 tions are correct.
Access 3™ VOLTAGE IS TOO LOW – Then continue to Step 3.
Note: If Event Code 333 occurs with Event Code 541, Step 3: Check the battery charge and the individual
then see the procedures for Event Code 541 first. cell conditions.
Step 1: See the procedures for Event Code 322. • If:The battery condition is not satisfactory.
– Then make the necessary repairs or replace-
ments.
Event Code 334 • If:The battery is correctly charged and has the cor-
rect specifications.
Access 3™ VOLTAGE IS VERY LOW
– Then continue to Step 4.
Note: If Event Code 334 occurs with Event Code 541,
then see the procedures for Event Code 541 first. Step 4: Install a good battery.

Step 1: See the procedures for Event Code 322. • If:Event Code 337 continues.
– Then replace Access 3™.

Event Code 335

ACCESS 3
Access 3™ VOLTAGE IS TOO HIGH
Note: If Event Code 335 occurs with Event Code 541,
then see the procedures for Event Code 541 first.
Step 1: See the procedures for Event Code 323.
BNEG
B+ + B-
Event Code 336
Access 3™ VOLTAGE IS VERY HIGH
Note: If Event Code 336 occurs with Event Code 541,
then see the procedures for Event Code 541 first.
Fig. 42 (28283)
Step 1: See the procedures for Event Code 323.

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Event Code 338

Event Code 338 ACCESS 3 POWER UNIT

DISTRIBUTION
PANEL
KYS VOLTAGE IS TOO LOW (LESS THAN 7 V)
CA401 CA201
Step 1: Check the battery charge and the individual
cell conditions. PWR 1 5 +BV_K2 FU3

• If:The battery condition is not satisfactory. BNEG

B+ + B-
– Then make the necessary repairs or replace-
ments.
• If:The battery is correctly charged and has the cor-
rect specifications.
– Then continue to Step 2. Fig. 43 (28287)
Step 2: Turn on the lift truck. Measure the voltage be-
tween Access 3™ CA401-1 and the battery negative
terminal on Access 3™. Event Code 339
 The correct voltage = 36 V.
• If:The voltage = 36 V. KYS VOLTAGE IS TOO HIGH
– Then check the wires between power unit distri- Step 1: See the procedures for Event Code 338.
bution panel CA201-5 and Access 3™ CA401-1.
Make the necessary repairs or replacements.
• If:The voltage > 0 V, but much < 36 V.
Event Code 340
– Then continue to Step 3. ED2 COIL DRIVER HAS TOO MUCH CURRENT
Step 3: Keep the lift truck turned on. Measure the Step 1: See the procedures for Event Code 541.
voltage between power unit distribution panel CA201-5
and the battery negative terminal on Access 3™.
• If:The voltage > 0 V, but much < 36 V. Event Code 343
– Then check the condition of power unit distribu-
tion panel. Make the necessary repairs or re- SOLENOID VALVE LOWER (SVL1) HAS TOO MUCH
placements. CURRENT
Step 4: Keep the lift truck turned on. Measure the Step 1: Turn off the lift truck. Disconnect the negative
voltage between the positive terminal and the battery wire from SVL1. Turn on the lift truck.
negative terminal on Access 3™. • If:The event code changes to open circuit (Event
• If:The voltage < 36 V. Code 348).
– Then check power cable condition and the con- – Then there is a short circuit in SVL1 or the posi-
nection. Make the necessary repairs or replace- tive circuit. Continue to Step 2.
ments. • If:Event Code 343 continues.
– Then there is a short circuit internal to
Access 3™ or in the negative circuit. Continue to
Step 3.
Step 2: Turn off the lift truck. Measure the resistance
across SVL1 from the positive terminal to the negative
terminal.
 The correct resistance = 29 Ω.
• If:The resistance is not = 29 Ω.
– Then there is a short circuit in the SVL1 coil. Re-
place SVL1.
• If:The resistance = 29 Ω.

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Event Code 344

– Then there is a short circuit in the positive circuit. Step 2: Turn off the lift truck. Measure the resistance
Repair or replace the wire from power unit distri- across FAN2/3 from the positive terminal to the nega-
bution panel CA201-10 to SVL1. tive terminal.
Step 3: Keep the lift truck turned off. Disconnect the  The correct resistance = 29 Ω.
negative wire from Access 3™ CA401-22. Turn on the • If:The resistance is not = 29 Ω.
lift truck. – Then there is a short circuit in the FAN2/3 coil.
• If:The event code changes to open circuit (Event Replace FAN2/3.
Code 348). • If:The resistance = 29 Ω.
– Then there is a short circuit in the negative circuit. – Then there is a short circuit in the positive circuit.
Repair or replace the wire from Access 3™ Repair or replace the wire from power unit distri-
CA401-22 to SVL1. bution panel CA201-8 to FAN2/3.
• If:Event Code 343 continues. Step 3: Keep the lift truck turned off. Disconnect the
– Then replace Access 3™. negative wire from Access 3™ CA401-8. Turn on the
lift truck.
• If:The event code changes to open circuit (Event
POWER UNIT Code 349).
DISTRIBUTION
PANEL – Then there is a short circuit in the negative circuit.
Repair or replace the wire from Access 3™
CA201 CA401-8 to FAN2/3.
+BV_K2 FU3 10
• If:Event Code 344 continues.
– Then replace Access 3™.

+
SVL1
POWER UNIT
DISTRIBUTION
PANEL
ACCESS 3
CA201
8
CA401
GPD 4 22

Fig. 44 (28288) FAN2/3

ACCESS 3

Event Code 344

CA401
FAN2/3 DRIVER HAS TOO MUCH CURRENT
GPD 5 8
Step 1: Turn off the lift truck. Disconnect the negative
wire from FAN2/3. Turn on the lift truck.
• If:The event code changes to open circuit (Event
Code 349). Fig. 45 (28289)
– Then there is a short circuit in FAN2/3 or the pos-
itive circuit. Continue to Step 2.
• If:Event Code 344 continues. Event Code 345
– Then there is a short circuit internal to ED2 DRIVER HAS AN OPEN CIRCUIT
Access 3™ or in the negative circuit. Continue to
Step 1: See the procedures for Event Code 541.
Step 3.

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Event Code 348

Event Code 348 POWER UNIT

DISTRIBUTION
PANEL
SVL1 DRIVER HAS AN OPEN CIRCUIT CA201
Step 1: Turn off the lift truck. Disconnect the wires +BV_K2 FU3 10
from SVL1. Measure the resistance across SVL1 from
TP3
the positive terminal to the negative terminal.
 The correct resistance = 29 Ω. TP4
• If:The resistance is not = 29 Ω.
+
– Then replace SVL1. SVL1

• If:The resistance = 29 Ω.
– Then continue to Step 2. ACCESS 3
Step 2: Turn on the lift truck. While pushing and hold-
ing POT3, Measure the voltage between power unit
distribution panel CA201-10 and Access 3™ CA401
CA401-22. GPD 4 22
• If:The voltage = 0 V.
– Then disconnect the wire from Access 3™
CA401-22. While pushing and holding POT3,
Fig. 46 (28290)
measure the voltage between Access 3™
CA401-22 and power unit distribution panel TP4.
• If:The voltage = 0 V.
Event Code 349
– Then replace Access 3™.
• If:The voltage = 36 V. FAN2/3 DRIVER HAS AN OPEN CIRCUIT
– Then continue to Step 3. Step 1: Turn off the lift truck. Disconnect the wires
from FAN2/3. Measure the resistance across FAN2/3
Step 3: Turn off the lift truck. Check the wires to
from the positive terminal to the negative terminal.
SVL1.
 The correct resistance = 29 Ω.
• If:The wires are correct.
• If:The resistance is not = 29 Ω.
– Then continue to Step 4.
– Then replace FAN2/3.
Step 4: Turn on the lift truck. While pushing and hold-
• If:The resistance = 29 Ω.
ing POT3, measure the voltage from power unit distri-
bution panel TP3 to power unit distribution panel – Then continue to Step 2.
CA201-10. Step 2: Connect FAN2/3. Turn on the lift truck. Mea-
• If:The voltage = 0 V. sure the voltage from power unit distribution panel
CA201-8 to FAN2/3.
– Then check the power unit distribution panel and
 The correct voltage = 36 V.
the related wires for the positive circuit. Make the
necessary repairs or replacements. • If:The voltage = 0 V.
– Then continue to Step 3.
Step 3: Disconnect the wire from Access 3™
CA401-8. Measure the voltage on the distribution panel
at Access 3™ CA401-8 and power unit distribution
panel TP4.
• If:The voltage = 36 V.
– Then check the power unit distribution panel and
the related wires for the positive circuit. Make the
necessary repairs or replacements.
• If:The voltage = 0 V.

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Event Code 350

– Then replace Access 3™. • If:The voltage = 0 V.

– Then turn off the lift truck. Check FU3 on the
power unit distribution panel for an open circuit.
POWER UNIT • If:The voltage = 80 V.
DISTRIBUTION
PANEL – Then continue to Step 2.
Step 2: Turn on the lift truck. Measure the voltage be-
CA201
tween Access 3™ CA401-1 and power unit distribution
8 panel TP3.
TP4 • If:The voltage = 0 V.
– Then repair or replace the wire between
Access 3™ CA401-1 and power unit distribution
panel CA201-5.
FAN2/3 • If:The voltage = 80 V.
– Then replace Access 3™.
ACCESS 3

CA401 POWER UNIT

DISTRIBUTION
GPD 5 8 PANEL

CA201
+BV_K2 FU3 5
Fig. 47 (28291)

Event Code 350 FU3

TP3
ED2 DRIVER HAS A SHORT CIRCUIT
Step 1: See the procedures for Event Code 541.
ACCESS 3

Event Code 353

CA401
SVL1 DRIVER HAS A SHORT CIRCUIT PWR 1
Step 1: See the procedures for Event Code 343.

Fig. 48 (28292)
Event Code 354
FAN2/3 DRIVER HAS A SHORT CIRCUIT
Step 1: See the procedures for Event Code 344.
Event Code 356
ED2 WIRING HAS AN OPEN CIRCUIT
Step 1: See the procedures for Event Code 541.
Event Code 355
Access 3™ PWM DRIVER HAS TOO MUCH VOLT-
AGE Event Code 357
Step 1: Turn on the lift truck. Measure the battery ED2 CONTACTOR TIPS ARE WELDED
negative voltage at power unit distribution panel
Step 1: Turn off the lift truck. Check the ED2 contac-
CA201-5 and power unit distribution panel TP3.
tor tips for a short circuit.
 The correct voltage = 36 V.
• If:The ED2 contactor tips have a short circuit.

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Event Code 358

– Then make the necessary repairs or replace- • If:The voltage = 36 V.

ments. – Then continue to Step 3.
• If:The ED2 contactor tips are correct. Step 3: Keep the lift truck turned on. Measure the
– Then continue to Step 2. voltage between Access 3™ CA401-1 and the battery
Step 2: Keep the lift truck turned off. Check the ED2 negative terminal on Access 3™.
load bus connections for a short circuit. • If:The voltage > 0 V, but much < 36 V.
• If:The ED2 load bus connections have a short cir- – Then continue to Step 4.
cuit. Step 4: Keep the lift truck turned on. Measure the
– Then make the necessary repairs or replace- voltage between power unit distribution panel CA201-5
ments. and the battery negative terminal on Access 3™.
• If:The ED2 load bus connections are correct. • If:The voltage = 36 V.
– Then see the procedures for Event Code 541. – Then measure the voltage between power unit
distribution panel CA201-5 and Access 3™
CA401-1.
ACCESS 3 • If:The voltage > 0 V, but much < 36 V.
– Then check the condition of the power unit distri-
bution panel and related wires. Make the neces-
sary repairs or replacements.
Step 5: Replace Access 3™.
BNEG
B+ + B-

POWER UNIT
DISTRIBUTION
PANEL

ED2 CA201
+BV_K2 FU3 5
Fig. 49 (28293)

Event Code 358

Access 3™ PRE-CHARGE POWER LIMIT EVENT
ACCESS 3
Note: The power limit of the pre-charge resistor in
Access 3™ has been exceeded.
Step 1: Check the battery condition. CA401

• If:The battery does not have the correct voltage or PWR 1

is incorrectly charged.
BNEG
– Then correct the battery problem. B+ + B-
• If:The battery is correctly charged and has the cor-
rect specifications.
– Then continue to Step 2.
Step 2: Turn on the lift truck. Operate the brake
pedal. Measure the voltage between the positive termi- Fig. 50 (28294)
nal and the battery negative terminal on Access 3™.
 The correct voltage = 36 V.
• If:The voltage > 0 V, but much < 36 V.
– Then check the cables to Access 3™. Make the
necessary repairs or replacements.

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Event Code 359

Event Code 359 POWER UNIT

DISTRIBUTION
PANEL
Access 3™ PRE-CHARGE TIME LIMIT HAS BEEN
EXCEEDED
CA201
Step 1: Check the battery condition. +BV_K2 FU3 5
• If:The battery does not have the correct voltage or
is incorrectly charged.
– Then correct the battery problem.
• If:The battery is correctly charged and has the cor-
rect specifications.
ACCESS 3
– Then continue to Step 2.
Step 2: Turn on the lift truck. Measure the voltage on
both sides of FU15. CA401

• If:The voltage drop across FU15 > 0.5 V. PWR 1

– Then replace FU15.

BNEG
Step 3: Keep the lift truck turned on. Operate the B+ + B-
brake pedal. Measure the voltage between the positive
terminal and the battery negative terminal on
Access 3™. FU15
 The correct voltage = 36 V.
• If:The voltage > 0 V, but much < 36 V.
Fig. 51 (28295)
– Then check the cables to Access 3™. Make the
necessary repairs or replacements.
• If:The voltage = 36 V. Event Code 360
– Then continue to Step 4.
Access 3™ PRE-CHARGE ELECTRICAL EVENT
Step 4: Keep the lift truck turned on. Measure the
Note: There is a resistive load on the ED1 bus during
voltage between Access 3™ CA401-1 and the battery
pre-charge.
negative terminal on Access 3™.
Step 1: Check to make sure that the battery has the
• If:The voltage > 0 V, but much < 36 V.
correct specifications for the lift truck and the duty cy-
– Then continue to Step 5. cle.
Step 5: Keep the lift truck turned on. Measure the • If:The battery is incorrect.
voltage between power unit distribution panel CA201-5
– Then replace the battery as necessary.
and the battery negative terminal on Access 3™.
• If:The battery is correct.
• If:The voltage = 36 V.
– Then continue to Step 2.
– Then measure the voltage between power unit
distribution panel CA201-5 and Access 3™ Step 2: Check the battery charge and the individual
CA401-1. cell conditions.
• If:The voltage > 0 V, but much < 36 V. • If:The battery condition is not satisfactory.
– Then replace Access 3™. – Then make the necessary repairs or replace-
ments.
• If:The battery is correctly charged and has the cor-
rect specifications.
– Then continue to Step 3.
Step 3: Turn on the lift truck. Use Features Menu/F5
Truck Model to check for the correct lift truck configura-
tion and lift truck model.

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Event Code 361

• If:The configuration is incorrect.

– Then correct the lift truck configuration.
• If:The configuration is correct. Event Code 361
– Then continue to Step 4. Access 3™ EVENT
Step 4: Keep the lift truck turned on. Measure the Step 1: Replace Access 3™.
voltage between Access 3™ CA401-1 and the battery
negative terminal on Access 3™.
 The correct voltage = 36 V. Event Code 362
• If:The voltage > 0 V, but much < 36 V.
Access 3™ INTERNAL EVENT
– Then check the condition of the power unit distri-
bution panel and related wires. Make the neces- Event Code 362 and 363
sary repairs or replacements. Step 1: Turn off the lift truck. Then turn the lift truck on
• If:The voltage = 36 V. again.
– Then continue to Step 5. • If:Event Code 362 or Event Code 363 continues.
Step 5: Turn off the lift truck. Check the wires from – Then replace Access 3™.
power unit distribution panel CA201-5 to Access 3™
CA401-1. Make the necessary repairs or replace-
ments. Event Code 364
Step 6: Turn on the lift truck. Check for other event INTERNAL 5 V SUPPLY FOR Access 3™ IS TOO
codes to occur with Event Code 360. LOW OR TOO HIGH
• If:No other event codes occur. Event Code 364 and 365
– Then replace Access 3™.
Event Code 364: INTERNAL 5 V SUPPLY FOR
Access 3™ IS TOO HIGH

POWER UNIT Event Code 365: INTERNAL 5 V SUPPLY FOR

DISTRIBUTION Access 3™ IS TOO LOW
PANEL
Step 1: Turn off the lift truck. Then turn the lift truck on
again.
CA201
+BV_K2 FU3
• If:Event Code 364 or Event Code 365 continues.
5
– Then replace Access 3™.

Event Code 366

ACCESS 3 12 V SUPPLY VOLTAGE FOR ECR3 IS TOO LOW
OR TOO HIGH
Event Code 366 and 367
CA401
Event Code 366: 12 V SUPPLY VOLTAGE FOR ECR3
PWR 1
IS TOO HIGH
BNEG Event Code 367: 12 V SUPPLY VOLTAGE FOR ECR3
B+ + B-
IS TOO LOW
Step 1: Turn on the lift truck. Measure the voltage be-
tween Access 3™ CA401-3 and power unit distribution
panel TP3.
• If:The voltage = 0 V.
Fig. 52 (28294)
– Then replace Access 3™.
• If:The voltage = 12 V and Event Code 366 or Event
Code 367 continues.

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Event Code 368

– Then continue to Step 2. Event Code 370: 5 V POWER SUPPLY FOR

Step 2: Turn off the lift truck. Disconnect the wire Access 3™ IS TOO HIGH
from Access 3™ CA401-3. Turn on the lift truck. Mea- Event Code 371: 5 V POWER SUPPLY FOR
sure the voltage between Access 3™ CA401-3 and Access 3™ IS TOO LOW
power unit distribution panel TP3.
Step 1: There is an internal failure in Access 3™.
• If:The voltage = 12 V.
• If:Event Code 370 or Event Code 371 continues.
– Then replace ECR3.
– Then replace Access 3™.
• If:The voltage ≠ 12 V and Event Code 366 or Event
Code 367 continues.
– Then replace Access 3™. Event Code 372
INTERNAL 227 mV REFERENCE VOLTAGE FOR
Access 3™ IS TOO LOW OR TOO HIGH
ACCESS 3 POWER UNIT
DISTRIBUTION Event Code 372 and 373
PANEL
Event Code 372: INTERNAL 227 mV REFERENCE
CA401 VOLTAGE FOR Access 3™ IS TOO HIGH
+12 V 3
TP3 Event Code 373: INTERNAL 227 mV REFERENCE
VOLTAGE FOR Access 3™ IS TOO LOW
Step 1: There is an internal failure in Access 3™.
• If:Event Code 372 or Event Code 373 continues.
M1
TRACTION MOTOR – Then replace Access 3™.
CA411 ECR3
1 +12 V RED
2
3
NEG BLACK
CH A WHITE
CH B BLUE
Event Code 374
4
INTERNAL 2.5 V REFERENCE VOLTAGE FOR
Fig. 53 (28296) Access 3™ IS TOO LOW OR TOO HIGH
Event Code 374 and 375
Event Code 368 Event Code 374: INTERNAL 2.5 V REFERENCE
VOLTAGE FOR Access 3™ IS TOO HIGH
15 V POWER SUPPLY FOR Access 3™ IS TOO
LOW OR TOO HIGH Event Code 375: INTERNAL 2.5 V REFERENCE
VOLTAGE FOR Access 3™ IS TOO LOW
Event Code 368 and 369
Step 1: There is an internal failure in Access 3™.
Event Code 368: 15 V POWER SUPPLY FOR • If:Event Code 374 or Event Code 375 continues.
Access 3™ IS TOO HIGH
– Then replace Access 3™.
Event Code 369: 15 V POWER SUPPLY FOR
Access 3™ IS TOO LOW
Step 1: There is an internal failure in Access 3™. Event Code 376
• If:Event Code 368 or Event Code 369 continues.
INTERNAL ANALOG GROUND VOLTAGE FOR
– Then replace Access 3™. Access 3™ IS TOO LOW OR TOO HIGH
Event Code 376 and 377
Event Code 370 Event Code 376: INTERNAL ANALOG GROUND
VOLTAGE FOR Access 3™ IS TOO HIGH
5 V POWER SUPPLY FOR Access 3™ IS TOO LOW
OR TOO HIGH Event Code 377: INTERNAL ANALOG GROUND
VOLTAGE FOR Access 3™ IS TOO LOW
Event Code 370 and 371

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Event Code 378

Step 1: Turn off the lift truck. Then turn the lift truck on
again.
• If:Event Code 376 or Event Code 377 continues. Event Code 379
– Then replace Access 3™. Access 3™ HAS AN INTERNAL SHORT CIRCUIT
Event Code 379 and 380
Event Code 378 Step 1: Turn off the lift truck. Then turn the lift truck on
again.
Access 3™ CURRENT IS TOO HIGH • If:Event Code 379 or Event Code 380 continues.
Step 1: Turn off the lift truck. Disconnect the M1 – Then replace Access 3™.
power cables from Access 3™. Turn on the lift truck.
• If:Event Code 378 continues.
– Then replace Access 3™. Event Code 381
• If:Event Code 378 does not continue. M1 HAS A SHORT CIRCUIT
– Then continue to Step 2. Event Code 381 and 382
Step 2: Turn off the lift truck. Check the M1 power ca-
bles for phase to phase or phase to lift truck frame short Event Code 381: THERE IS A SHORT CIRCUIT BE-
circuits. TWEEN BATTERY POSITIVE AND THE U TERMI-
NAL
• If:There is a short circuit between the U, V, or W
power cables or to the lift truck frame (with the Event Code 382: THERE IS A SHORT CIRCUIT BE-
power cables connected to M1). TWEEN BATTERY NEGATIVE AND THE U TERMI-
– Then continue to Step 3. NAL
Step 3: Keep the lift truck turned off. Disconnect the Step 1: Turn off the lift truck. Check the condition of
power cables from M1. Check for a short circuit from the M1 power cables.
the M1 windings to the lift truck frame. • If:There is a short circuit in the M1 power cables.
• If:There is a short circuit in the windings. – Then make the necessary repairs or replace-
– Then replace M1. ments.
• If:The windings are correct. • If:The M1 power cables are correct.
– Then repair or replace the applicable M1 power – Then continue to Step 2.
cable. Step 2: Keep the lift truck turned off. Disconnect the
M1 power cables from Access 3™. Turn on the lift
truck.
ACCESS 3 • If:Event Code 381 or Event Code 382 does not con-
tinue.
UM U – Then replace M1.
VM V M1
WM W • If:Event Code 381 or Event Code 382 continues.
– Then replace Access 3™.
BNEG
B+ + B-

Fig. 54 (28297)

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Event Code 383

Event Code 388: THERE IS A SHORT CIRCUIT BE-

TWEEN THE UL TERMINAL AND THE VH TERMINAL
ACCESS 3
Event Code 389: THERE IS A SHORT CIRCUIT BE-
UM U
TWEEN THE UH TERMINAL AND THE VL TERMINAL
VM V M1 Step 1: See the procedures for Event Code 381 and
WM W

382.

BNEG
B+ + B-
Event Code 390
M1 HAS A SHORT CIRCUIT BETWEEN THE V TER-
MINAL AND THE W TERMINAL
Event Code 390 through 392
Fig. 55 (28297)
Event Code 390: THERE IS A SHORT CIRCUIT BE-
TWEEN THE V TERMINAL AND THE W TERMINAL
Event Code 383 Event Code 391: THERE IS A SHORT CIRCUIT BE-
TWEEN THE VL TERMINAL AND THE WH TERMI-
M1 HAS A SHORT CIRCUIT NAL
Event Code 383 and 384 Event Code 392: THERE IS A SHORT CIRCUIT BE-
Event Code 383: THERE IS A SHORT CIRCUIT BE- TWEEN THE VH TERMINAL AND THE WL TERMI-
TWEEN BATTERY POSITIVE AND THE V TERMINAL NAL
Event Code 384: THERE IS A SHORT CIRCUIT BE- Step 1: See the procedures for Event Code 381 and
TWEEN BATTERY NEGATIVE AND THE V TERMI- 382.
NAL
Step 1: See the procedures for Event Code 381 and
382.
Event Code 393
M1 HAS A SHORT CIRCUIT BETWEEN THE W TER-
MINAL AND THE U TERMINAL
Event Code 385 Event Code 393 through 395
M1 HAS A SHORT CIRCUIT Event Code 393: THERE IS A SHORT CIRCUIT BE-
Event Code 385 and 386 TWEEN THE W TERMINAL AND THE U TERMINAL
Event Code 385: THERE IS A SHORT CIRCUIT BE- Event Code 394: THERE IS A SHORT CIRCUIT BE-
TWEEN BATTERY POSITIVE AND THE W TERMI- TWEEN THE WL TERMINAL AND THE UH TERMI-
NAL NAL

Event Code 386: THERE IS A SHORT CIRCUIT BE- Event Code 395: THERE IS A SHORT CIRCUIT BE-
TWEEN BATTERY NEGATIVE AND THE W TERMI- TWEEN THE WH TERMINAL AND THE UL TERMI-
NAL NAL
Step 1: See the procedures for Event Code 381 and Step 1: See the procedures for Event Code 381 and
382. 382.

Event Code 387 Event Code 396

M1 HAS A SHORT CIRCUIT BETWEEN THE U TER- M3 TEMPERATURE IS TOO HIGH
MINAL AND THE V TERMINAL Step 1: Turn off the lift truck. Check for loose connec-
Event Code 387 through 389 tions and corroded terminals.
Event Code 387: THERE IS A SHORT CIRCUIT BE- • If:There are loose connections or corroded termi-
TWEEN THE U TERMINAL AND THE V TERMINAL nals.

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Event Code 400

– Then make the necessary repairs or replace- • If:The resistance = 0 Ω.

ments. – Then there is a short circuit between CAN H and
• If:The connections and terminals are correct. CAN L. Check the condition of the applicable
– Then continue to Step 2. wires, connectors, and fuses, and make the nec-
essary repairs or replacements.
Step 2: Turn on the lift truck. Check to make sure that
the lift pump (P1) turns freely. • If:The resistance > 60 Ω.
• If:P1 does not turn freely. – Then continue to Step 3.
– Then make the necessary repairs or replace- Step 3: Keep the lift truck turned off. The CAN circuit
ments. is open. Disconnect Access 5 CA402 and measure the
resistance between Access 5 CA402-4 and Access 5
• If:P1 turns freely.
CA402-5.
– Then replace M3.
• If:The resistance > 120 Ω.
– Then replace Access 5.
Event Code 400 • If:The resistance = 120 Ω.
– Then check the CAN terminating resistor in
INVALID EVENT CODE FROM ACCESS 4 - NOT Access 1. Disconnect Access 1 CA302 and mea-
USED sure the resistance between Access 1 CA302-8
The event code is not specified in the lift truck code. and Access 1 CA302-9.
Consult the factory. • If:The resistance = 120 Ω.
– Then check the condition of the applicable wires,
connectors, and fuses. Make the necessary re-
Event Code 401 pairs or replacements.
ACCESS 1 CAN EVENT WITH ACCESS 4 • If:The resistance > 120 Ω.
Step 1: Turn off the lift truck. Check the condition of – Then replace Access 1.
the CAN wires, pins, and connectors.
CAN H: Check the wire continuity between Access 4
ACCESS 1 ACCESS 5
CA303-7 and platform distribution panel CA105-1.
Then check the wire continuity between power unit dis-
tribution panel CA203-2 and platform distribution panel CA302 CA402
CAN H CAN1 H
CA104-2. Then check the wire continuity between plat- 120 Ohm 8 4 120 Ohm
form distribution panel CA105-2 and Access 1 Resistor 5 Resistor
9 CAN1 L
CAN L
CA302-8.
CAN L: Check the wire continuity between Access 4
CA303-8 and platform distribution panel CA105-7. POWER UNIT
Then check the wire continuity between power unit dis- PLATFORM DISTRIBUTION
DISTRIBUTION PANEL
tribution panel CA203-3 and platform distribution panel PANEL
CA104-3. Then check the wire continuity between plat- CA203

form distribution panel CA105-8 and Access 1 2 CAN H

CA302-9. CA104 3 CAN L
• If:The wires, pins, or connectors are damaged. CAN H 2
– Then make the necessary repairs or replace- CAN L 3 ACCESS 4
ments. CA105 CA303
• If:The wires, pins, and connectors are correct. CAN H 1 7 CAN H
– Then continue to Step 2. TP13 CAN H 2 8 CAN L

Step 2: Keep the lift truck turned off. Measure the re- CAN L 7
sistance between CAN H and CAN L on platform distri- CAN L 8
bution panel TP13 and platform distribution panel TP14
TP14.
 The correct resistance = 60 Ω. Fig. 56 (28298)

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Event Code 405

– Then replace Access 1.

Event Code 405

ACCESS 1 ACCESS 5
ACCESS 5 CAN EVENT WITH ACCESS 4
Step 1: Turn off the lift truck. Check the condition of CA302 CA402
the CAN wires, pins, and connectors. CAN H CAN1 H
120 Ohm 8 4 120 Ohm
Resistor
CAN H: Check the wire continuity between Access 4 Resistor 9 5
CAN1 L
CAN L
CA303-7 and platform distribution panel CA105-1.
Then check the wire continuity between power unit dis-
tribution panel CA204-2 and Access 5 CA402-4.
POWER UNIT
CAN L: Check the wire continuity between Access 4 PLATFORM DISTRIBUTION
DISTRIBUTION PANEL
CA303-8 and platform distribution panel CA105-7. PANEL
Then check the wire continuity between power unit dis- CA204

tribution panel CA204-8 and Access 5 CA402-5. 2 CAN H

• If:The wires are damaged.
8 CAN L
– Then make the necessary repairs or replace-
ments. ACCESS 4

• If:The wires are correct. CA105 CA303

– Then continue to Step 2. CAN H 1 7 CAN H

TP13 8 CAN L
Step 2: Keep the lift truck turned off. Measure the re-
sistance between CAN H and CAN L on platform distri- CAN L 7
bution panel TP13 and platform distribution panel
TP14. TP14
 The correct resistance = 60 Ω.
Fig. 57 (28299)
• If:The resistance = 0 Ω.
– Then there is a short circuit between CAN H and
CAN L. Check the condition of the applicable
wires, connectors, and fuses, and make the nec-
Event Code 411
essary repairs or replacements. ACCESS 1 EVENT WITH ACCESS 4
• If:The resistance > 60 Ω. Step 1: See the procedures for Event Code 101.
– Then continue to Step 3.
Step 3: Keep the lift truck turned off. The CAN circuit
is open. Disconnect Access 5 CA402 and measure the Event Code 413
resistance between Access 5 CA402-4 and Access 5
CA402-5. Access 3™ EVENT WITH ACCESS 4
• If:The resistance > 120 Ω. Step 1: See the procedures for Event Code 103.
– Then replace Access 5.
• If:The resistance = 120 Ω. Event Code 415
– Then check the CAN terminating resistor in
Access 1. Disconnect Access 1 CA302 and mea- ACCESS 5 EVENT WITH ACCESS 4
sure the resistance between Access 1 CA302-8 Step 1: See the procedures for Event Code 105.
and Access 1 CA302-9.
• If:The resistance = 120 Ω.
– Then check the condition of the applicable wires, Event Code 416
connectors, and fuses. Make the necessary re- ACCESS 6 EVENT WITH ACCESS 4
pairs or replacements.
Step 1: See the procedures for Event Code 106.
• If:The resistance > 120 Ω.

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Event Code 421

Event Code 421 POWER UNIT

DISTRIBUTION
ACCESS 4

PANEL
ACCESS 4 INTERNAL EVENT
Step 1: Replace Access 4. TP16

CA303

Event Code 422 4 +5 V

5 V POWER SUPPLY FOR TRACTION ACCELERA-

TOR POTENTIOMETER (POT1) IS TOO LOW OR
TOO HIGH
Step 1: Turn on the lift truck. Measure the voltage be-
tween Access 4 CA303-4 and platform distribution CA309
panel TP16. 1
GREEN
POT1
 The correct voltage = 5 V. 2
ORANGE

• If:The voltage = 5 V and Event Code 422 contin- VIOLET

3
ues.
Fig. 58 (28300)
– Then continue to Step 2.
Step 2: Keep the lift truck turned on. Measure the
voltage between POT1 CA309-2 and platform distribu- Event Code 423
tion panel TP16.
POT1 ELECTRICAL RANGE IS TOO LOW OR TOO
• If:The voltage = 0 V.
HIGH
– Then replace Access 5.
Step 1: Turn on the lift truck. Use Analyzer Menu/
• If:The voltage < 5 V and the Event Code 422 con- A2.4.3.1 Raw to show the POT1 voltage.
tinues.
• If:The voltage ≥ 5 V.
– Then continue to Step 3.
– Then POT1 is incorrectly wired, the wire between
Step 3: Turn off the lift truck. Disconnect the wire
POT1 and Access 4 has a short circuit to the lift
from Access 4 CA303-4. Turn on the lift truck. Measure
truck frame, or a wire has an open circuit. Turn off
the voltage between Access 4 CA303-4 and platform
the lift truck. Check the condition and make sure
distribution panel TP16.
that the wires and the connector terminals be-
• If:The voltage = 5 V. tween Access 4 CA303-1, Access 4 CA303-4,
– Then the wires have a short circuit. Make the Access 4 CA303-19, and POT1 are correct.
necessary repairs or replacements. • If:The wires and the connector terminals are cor-
• If:The voltage < 5 V. rect.
– Then replace Access 4. – Then use Calibration Menu/C1.1 Traction to cali-
brate POT1.
Step 2: Turn on the lift truck. Use Analyzer Menu/
A2.4.3.1 Raw to show the POT1 voltage.
When the travel twist grip is in the maximum forks first
(reverse) direction, the voltage must be 0.7–1.5 V.
When the travel twist grip is in the neutral position, the
voltage must be 2.1–2.9 V.
When the travel twist grip is in the maximum power unit
first (forward) direction, the voltage must be 3.4–4.3 V.
• If: The voltages are correct.

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Event Code 424

– Then turn off the lift truck. Check the condition of power unit first (forward) direction. Then use Analyzer
POT1 and make sure that the wires and the con- Menu/A2.4.3.1 Raw to show 2.1–2.9 V when the travel
nector terminals between Access 4 CA303-1, twist grip is in the neutral position and 3.4–4.3 V when
Access 4 CA303-4, Access 4 CA303-19, and the travel twist grip is in the power unit first (forward)
POT1 are correct. direction.
• If:The wires and the connector terminals are cor- • If:The voltages are incorrect.
rect. – Then turn off the lift truck. Check the condition of
– Then replace POT1. FS and the wires to FS and the reverse switch
Step 3: Turn on the lift truck. Use Analyzer Menu/ (RS).
A2.4.3.1 Raw to show the POT1 voltage. • If:FS or the wires are damaged.
• If:The voltage < 0.7 V. – Then make the necessary repairs or replace-
– Then POT1 is incorrectly wired, the wire between ments.
POT1 and Access 4 has a short circuit to the lift Step 2: Turn on the lift truck. Use Calibration Menu/
truck frame, or a wire has an open circuit. Turn off C1.1 Traction to calibrate POT1. Then use Analyzer
the lift truck. Check the condition and make sure Menu/A2.4.3.1 Raw to show 2.1–2.9 V when the travel
that the wires and the connector terminals be- twist grip is in the neutral position and 3.4–4.3 V when
tween Access 4 CA303-1, Access 4 CA303-4, the travel twist grip is in the power unit first (forward)
Access 4 CA303-19, and POT1 are correct. direction.
• If:The wires and the connector terminals are cor- • If:The voltages are incorrect.
rect. – Then use Calibration Menu/C1.1 Traction to cali-
– Then replace POT1. brate POT1 again.

POWER UNIT ACCESS 4 ACCESS 4

DISTRIBUTION
PANEL

TP16
CA303 CA304

1 AN1 8 SW12
9 SW11
4 +5 V

19 RS-232 COM PLATFORM

DISTRIBUTION
PANEL

CA309 CA103 CA308

GREEN
1 POT1 +BV_KYS 11 4
ORANGE
2 5
VIOLET FS
3 6 1
RS
Fig. 59 (28301) 1

Fig. 60 (28302)

Event Code 424

POT1 DOES NOT MATCH THE FORWARD SWITCH
(FS)
Step 1: Turn on the lift truck. Use Analyzer Menu/
A2.4.7 FS to show 0 (the switch is open) when the
travel twist grip is in the neutral position and 1 (the
switch is closed) when the travel twist grip is in the

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Event Code 425

Event Code 425 Event Code 426

POT1 DOES NOT MATCH RS FS AND RS ARE CLOSED AT THE SAME TIME
Step 1: Turn on the lift truck. Use Analyzer Menu/ Step 1: Turn off the lift truck. Check the condition of
A2.4.6 RS to show 0 (the switch is open) when the FS and RS.
travel twist grip is in the neutral position and 1 (the • If:FS or RS is damaged.
switch is closed) when the travel twist grip is in the forks
– Then replace FS or RS. Turn on the lift truck. Do
first (reverse) direction. Then use Analyzer Menu/
the Calibration Menu/C1.1 Traction calibration.
A2.4.3.1 Raw to show 2.1–2.9 V when the travel twist
grip is in the forks first (reverse) direction. • If:FS and RS are correct.
• If:The voltages are incorrect. – Then continue to Step 2.
– Then turn off the lift truck. Check the condition of Step 2: Keep the lift truck turned on. Use Analyzer
RS and the wires to FS and RS. Menu/A2.4.6 RS to show 0 (the switch is open) when
the travel twist grip is in the neutral position and 1 (the
• If:RS or the wires are damaged.
switch is closed) when the travel twist grip is in the forks
– Then make the necessary repairs or replace- first (reverse) direction. Then use Analyzer Menu/
ments. A2.4.7 FS to show 0 (the switch is open) when the
Step 2: Turn on the lift truck. Use Calibration Menu/ travel twist grip is in the neutral position and 1 (the
C1.1 Traction to calibrate POT1. Then use Analyzer switch is closed) when the travel twist grip is in the
Menu/A2.4.3.1 Raw to show 2.1–2.9 V when the travel power unit first (forward) direction.
twist grip is in the neutral position and 0.8 V when the • If:FS or RS shows 1.
travel twist grip is in the forks first (reverse) direction.
– Then select the switch that shows 1 to use in
• If:The voltages are incorrect. Step 3.
– Then use Calibration Menu/C1.1 Traction to cali- • If:FS and RS show 1.
brate POT1 again.
– Then select FS or RS to use in Step 3.
Step 3: Turn off the lift truck. Disconnect the output
ACCESS 4 wire of FS or RS.
• If:FS or RS changes to 0 when the output wire is
disconnected.
– Then replace FS or RS. Turn on the lift truck. Do
CA304
the Calibration Menu/C1.1 Traction calibration.
8 SW12
• If:FS or RS shows 1 when the travel twist grip is in
9 SW11
the neutral position.
– Then replace Access 4.
PLATFORM
DISTRIBUTION
PANEL

CA103 CA308
+BV_KYS 11 4
5
FS
6 1
RS
1

Fig. 61 (28302)

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Event Code 427

ACCESS 4 POWER UNIT ACCESS 4

DISTRIBUTION
PANEL

TP16
CA304

8 SW12
9 SW11
CA303

PLATFORM 19 RS-232 COM

DISTRIBUTION
PANEL

CA103 CA308 CA309

GREEN
+BV_KYS 11 4 1 POT1
ORANGE
5 2
FS VIOLET
6 1 3
RS
1 Fig. 63 (28303)
Fig. 62 (28302)

Event Code 429

Event Code 427 STEERING COMMAND ENCODERS (ECR1 AND
POT1 VOLTAGE IS TOO LOW OR TOO HIGH ECR5) COUNT EVENT
Step 1: Turn on the lift truck. Measure the voltage be- Note: Event Code 429 occurs if the count between
tween Access 4 CA303-19 and power unit distribution ECR1 and ECR5 is not equal. This event code could
panel TP16. occur if the power decreases or if there is no channel A
or channel B of ECR1 or ECR5.
• If:The voltage > 5 V.
Step 1: Turn on the lift truck. Use Analyzer Menu/
– Then check the wires between Access 4
A2.4.2 ECR1/ECR5 to show the ECR1 counts.
CA303-19 and POT1 CA309-3 to battery positive
or the lift truck frame. Make the necessary repairs • If:ECR1 operates.
or replacements. – Then continue to Step 2.
• If:The voltage = 0 V. • If:ECR1 does not operate.
– Then replace Access 4. – Then continue to Step 3.
Step 2: Keep the lift truck turned on. Use Analyzer
Menu/A2.4.2 ECR1/ECR5 to show the ECR5 counts.
• If:ECR5 operates.
– Then continue to Step 3.
• If:ECR5 does not operate.
– Then continue to Step 4.
Step 3: Turn off the lift truck. Check the tiller knob to
make sure that ECR1 and ECR5 are in the correct po-
sition. Then check the condition of the wires between
ECR1 and ECR5 to CA318.
• If:ECR1 or ECR5 is not in the correct position or the
wires are damaged.
– Then make the necessary repairs or replace-
ments.

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Event Code 429

• If:ECR1 and ECR5 are in the correct position and • If:The voltage is not 11.5–12.5 V.
the wires are correct. – Then replace ECR5.
– Then continue to Step 4. • If:The voltage is 11.5–12.5 V.
Step 4: Keep the lift truck turned off. Check the con- – Then continue to Step 11.
dition of the wires and the terminals where ECR1 con-
• If:The voltage is 11.5–12.5 V with CA318 discon-
nects to Access 4 CA304-16 and ECR5 connects to
nected and ECR5 replaced.
Access 4 CA304-23.
– Then continue to Step 10.
• If:The wires or the terminals are damaged.
Step 10: Keep the lift truck turned on. Measure the
– Then make the necessary repairs or replace-
voltage between Access 4 CA304-20 and Access 4
ments.
CA304-21.
• If:The wires and the terminals are correct.
• If:The voltage is not 11.5–12.5 V.
– Then continue to Step 5.
– Then replace Access 4.
Step 5: Disconnect CA318. Turn on the lift truck.
• If:The voltage is between 11.5–12.5 V.
Measure the voltage between CA318-3 and CA318-4.
 The correct voltage = 12 V. – Then turn off the lift truck. Check the continuity of
the wiring harness between CA318-7 and
• If:The voltage is 11.5–12.5 V.
Access 4 CA304-21, and CA318-8 and Access 4
– Then continue to Step 6. CA304-20. Make the necessary repairs or re-
Step 6: Turn off the lift truck. Connect CA318. Turn placements.
on the lift truck. Measure the voltage between CA318-3 Step 11: Connect CA318. Turn on the lift truck. While
and CA318-4. turning the tiller knob, measure the voltage between
• If:The voltage is not 11.5–12.5 V. Access 4 CA304-17 and Access 4 CA304-19.
– Then replace ECR1. • If:The voltage slowly changes from 0.5–11.5 V.
• If:The voltage is 11.5–12.5 V. – Then continue to Step 13.
– Then continue to Step 8. • If:The voltage does not change from 0.5V–11.5 V.
• If:The voltage is 11.5–12.5 V with CA318 discon- – Then continue to Step 12.
nected and ECR1 replaced. Step 12: Keep the lift truck turned on. Measure the
– Then continue to Step 7. voltage between CA318-1 and CA318-4.
Step 7: Keep the lift truck turned on. Measure the • If:The voltage slowly changes from 0.5–11.5 V.
voltage between Access 4 CA304-18 and Access 4 – Then turn off the lift truck. Check the condition of
CA304-19. the wiring harness between Access 4 CA304 and
• If:The voltage is not 11.5–12.5 V. CA318. Make the necessary repairs or replace-
– Then replace Access 4. ments.
• If:The voltage is between 11.5–12.5 V. • If:The voltage does not change from 0.5–11.5 V.
– Then turn off the lift truck. Check the continuity of – Then replace ECR1.
the wiring harness between CA318-3 and Step 13: Turn on the lift truck. Make sure that
Access 4 CA304-18, and CA318-4 and Access 4 Access 4 CA304 and CA318 are connected. While
CA304-19. Make the necessary repairs or re- turning the tiller knob, measure the voltage between
placements. Access 4 CA304-16 and Access 4 CA304-19.
Step 8: Disconnect CA318. Turn on the lift truck. • If:The voltage slowly changes from 0.5–11.5 V.
Measure the voltage between CA318-7 and CA318-8. – Then continue to Step 15.
 The correct voltage = 12 V.
• If:The voltage does not change from 0.5–11.5 V.
• If:The voltage is 11.5–12.5 V.
– Then continue to Step 14.
– Then continue to Step 9.
Step 14: Keep the lift truck turned on. Measure the
Step 9: Turn off the lift truck. Connect CA318. Turn voltage between CA318-2 and CA318-4.
on the lift truck. Measure the voltage between CA318-7
• If:The voltage slowly changes from 0.5–11.5 V.
and CA318-8.
– Then turn off the lift truck. Check the condition of
the wiring harness between Access 4 CA304 and

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Event Code 430

CA318. Make the necessary repairs or replace-

ments.
ACCESS 4
• If:The voltage does not change from 0.5–11.5 V.
CA304
– Then replace ECR1.
16 ECR2 B
Step 15: Turn on the lift truck. Make sure that
17 ECR2 A
Access 4 CA304 and CA318 are connected. While
18 +12 V
turning the tiller knob, measure the voltage between
19 LOGIC NEG
Access 4 CA304-23 and Access 4 CA304-20.
20 LOGIC NEG
• If:The voltage slowly changes from 0.5–11.5 V.
21 +12 V
– Then continue to Step 17. 22 ECR3 B
• If:The voltage does not change from 0.5–11.5 V. 23 ECR3 A
– Then continue to Step 16.
Step 16: Keep the lift truck turned on. Measure the
voltage between CA318-5 and CA318-8.
• If:The voltage slowly changes from 0.5–11.5 V. CA318
WHITE
– Then turn off the lift truck. Check the condition of 1 CH A
BLUE
the wiring harness between Access 4 CA304 and 2 CH B
CA318. Make the necessary repairs or replace- RED ECR1
3 +12 V
ments. 4
BLACK
NEG
• If:The voltage does not change from 0.5–11.5 V.
– Then replace ECR5. WHITE
5 CH A
Step 17: Turn on the lift truck. Make sure that 6
BLUE
CH B
Access 4 CA304 and CA318 are connected. While RED ECR5
7 +12 V
turning the tiller knob, measure the voltage between BLACK
8 NEG
Access 4 CA304-22 and Access 4 CA304-20.
• If:The voltage slowly changes from 0.5–11.5 V and
Fig. 64 (28304)
Event Code 429 continues.
– Then replace Access 4.
• If:The voltage does not change from 0.5–11.5 V. Event Code 430
– Then continue to Step 18.
ECR1 AND ECR5 TURN RATE EVENT
Step 18: Keep the lift truck turned on. Measure the
voltage between CA318-6 and CA318-8. Note: Event Code 430 occurs if there is a turn rate dif-
ference between ECR1 and ECR5. ECR1 and ECR5
• If:The voltage slowly changes from 0.5–11.5 V. turn at the same rate through the tiller knob. Other
– Then turn off the lift truck. Check the condition of causes for Event Code 430 include:
the wiring harness between Access 4 CA304 and • ECR1 or ECR5 is not in the correct position.
CA318. Make the necessary repairs or replace-
ments. • It is necessary to repair or replace ECR1 or ECR5.
• If:The voltage does not change from 0.5–11.5 V. • The wires between ECR1, ECR5, and Access 4 are
damaged.
– Then replace ECR5.
Step 1: See the procedures for Event Code 429.

Event Code 431

ECR1 AND ECR5 DIRECTION EVENT
Note: Event Code 431 occurs if there is a turn direction
difference between ECR1 and ECR5. ECR1 and ECR5
turn at the same rate through the tiller knob. Other
causes for Event Code 431 include:

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Event Code 432

• ECR1 or ECR5 is not in the correct position.

• It is necessary to repair or replace ECR1 or ECR5.
ACCESS 4
• The wires between ECR1, ECR5, and Access 4 are
damaged.
Step 1: See the procedures for Event Code 429.
CA303

12 +5 V
Event Code 432 15 LOGIC NEG

5 V POWER SUPPLY FOR HEIGHT ENCODER

(ECR4) IS TOO LOW OR TOO HIGH
Step 1: Turn on the lift truck. Measure the voltage be- CA317
tween Access 4 CA303-12 and Access 4 CA303-15. WHITE
1 CH A
• If:The voltage is not 4.75–5.5 V. 2
BLUE
CH B
– Then turn off the lift truck. Disconnect the wire RED ECR4
3 +5 V
from Access 4 CA303-12. Turn on the lift truck. 4
BLACK
NEG
Measure the voltage at Access 4 CA303-12.
• If:The voltage is 4.75–5.5 V with the wire discon- Fig. 65 (28305)
nected.
– Then continue to Step 2.
Step 2: Turn off the lift truck. There is a short circuit in Event Code 433
the wires or ECR4. Check the condition of the wires
between CA317-3 and Access 4 CA303-15, and 5 V POWER SUPPLY RUNTIME EVENT
CA317-4 and Access 4 CA303-12. Step 1: Turn off the lift truck. Then turn the lift truck on
• If:The wires are damaged. again.
– Then make the necessary repairs or replace- • If:Event Code 433 continues.
ments. – Then replace Access 4.
• If:The wires are correct and Event Code 432 con-
tinues.
– Then replace ECR4.
Event Code 435
• If:The voltage is not 4.75–5.5 V with the wire dis- THE HEIGHT SWITCH (HGTRS) DOES NOT CLOSE
connected. AT THE CORRECT TIME
– Then replace Access 4. Step 1: Turn on the lift truck. Fully lower the platform.
Raise the platform approximately 0.9 m (3 ft), then
lower the platform.
• If:Event Code 435 does not continue.
– Then continue to operate the lift truck. Check for
Event Code 435.
• If:Event Code 435 continues.
– Then continue to Step 2.
Step 2: Keep the lift truck turned on. With the plat-
form fully lowered, raise the platform. Use Analyzer
Menu/A2.4.1.1 HEIGHT to show the height.
• If:The height changes.
– Then continue to Step 3.
• If:The height does not change.
– Then continue to Step 4.

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Event Code 435

Step 3: Keep the lift truck turned on. Use Analyzer • If:The wires are correct and Event Code 435 con-
Menu/A2.4.10 HGTRS to show the input. tinues.
 When the platform is at 381 mm (15 in), the HG- – Then continue to Step 8.
TRS input must change from 1 (the switch is
Step 8: Keep the lift truck turned off. Disconnect
closed) to 0 (the switch is open).
CA317. Disconnect the white wire from JC317-1 and
• If:The HGTRS input does not change from 1 to 0. the blue wire from JC317-2. Turn on the lift truck. Mea-
– Then check the condition of HGTRS and the ap- sure the voltage between the white wire and Access 4
plicable wires. Make the necessary repairs or re- CA303-15, and the blue wire and Access 4 CA303-15.
placements.  The correct voltage = 0 V or 5 V (because of the
• If:The HGTRS input changes from 1 to 0. position of ECR4).
– Then continue to Step 4. • If:The voltage ≠ 0 V or 5 V.
Step 4: Turn off the lift truck. Disconnect CA317 and – Then replace ECR4.
check the condition of the ECR4 wire crimps. If it is nec- • If:The voltage = 0 V or 5 V.
essary, disconnect the wires from CA317 for inspec-
– Then connect the white wire to JC317-1 and the
tion.
blue wire to JC317-2.
• If:The wire crimps are damaged.
• If:The voltage = 0 V or 5 V and Event Code 435
– Then make the necessary repairs or replace- continues.
ments.
– Then replace Access 4.
• If:The wire crimps are correct.
– Then continue to Step 5.
Step 5: Turn on the lift truck. With CA317 discon- PLATFORM
nected, measure the voltage to ECR4 between DISTRIBUTION
PANEL
CA317-3 and CA317-4. CA320
HGTRS
 The correct voltage = 5 V. CA107 1
• If:The voltage = 5 V. HGTRS 4 2

– Then turn off the lift truck. Connect CA317. Con- ACCESS 4
tinue to Step 7.
CA303
• If:The voltage ≠ 5 V.
6 SW7
– Then continue to Step 6.
Step 6: Turn off the lift truck. Disconnect the wires 12 +5 V
from Access 4 CA303-12 and Access 4 CA303-15. 13 ECR1 A
Turn on the lift truck. Measure the voltage between 14 ECR1 B
Access 4 CA303-12 and Access 4 CA303-15. 15 LOGIC NEG
• If:The voltage = 5 V.
– Then turn off the lift truck. Check the condition of
the wires between CA317-3 and Access 4
CA303-12, and CA317-4 and Access 4
CA303-15. Make the necessary repairs or re-
placements.
CA317
• If:The voltage ≠ 5 V. WHITE
1 CH A
– Then replace Access 4. 2
BLUE
CH B
RED ECR4
Step 7: Keep the lift truck turned off. Check the con- 3 +5V
BLACK
dition of the wires between CA317-1 and Access 4 4 NEG
CA303-13, and CA317-2 and Access 4 CA303-14.
• If:The wires are damaged. Fig. 66 (28306)
– Then make the necessary repairs or replace-
ments.

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Event Code 440

Event Code 440 ACCESS 4

ZONE SELECT SWITCH (ZSS) WIRES HAVE AN

CA304
OPEN CIRCUIT
13 SW15
Note: If the F25 Zone Switch Menu is set to YES, one
of the three outputs from ZSS (ZSSA, ZSSB, or ZSSC) 14 SW14
CA303
must be closed. Event Code 440 occurs if none of the
three outputs are closed or if the wire to ZSS has an 23 SW6
open circuit.
Step 1: Turn off the lift truck. Check the condition of
CA332
ZSS. ZSS
1
• If:ZSS or the wires is damaged. CA333
– Then make the necessary repairs or replace- 1
ments. CA334

• If:ZSS and the wires are correct. 1

– Then continue to Step 2. Fig. 67 (28307)

Step 2: Turn on the lift truck. Use Features Menu/F25
Zone Switch to make sure that the menu is not set to
YES if the lift truck does not have the zone select op- Event Code 441
tion. ZSS WIRES HAVE A SHORT CIRCUIT
• If:The menu is set to YES and the lift truck does not Note: If the F25 Zone Switch Menu is set to YES, one
have the zone select option. of the three outputs from ZSS (ZSSA, ZSSB, or ZSSC)
– Then set the menu to NO. must be closed. Event Code 441 occurs if more than
• If:The menu is set to YES and the lift truck has the one outputs are closed at the same time.
zone select option. Step 1: Turn off the lift truck. Check the condition of
– Then continue to Step 3. the wires between ZSS and Access 4 CA303-23,
Step 3: Turn off the lift truck. Check the condition of Access 4 CA304-13, and Access 4 CA304-14.
the wires between ZSS and Access 4 CA303-23, • If:The wires are damaged.
Access 4 CA304-13, and Access 4 CA304-14. – Then make the necessary repairs or replace-
• If:The wires are damaged. ments.
– Then make the necessary repairs or replace- • If:The wires are correct.
ments. – Then continue to Step 2.
• If:The wires are correct and Event Code 440 con- Step 2: Keep the lift truck turned off. Check ZSS for
tinues. internal short circuits.
– Then replace Access 4. Note: Each individual internal switch must be isolated
from the other.
• If:ZSS has a short circuit.
– Then replace ZSS.
• If:ZSS is correct and Event Code 441 continues.
– Then replace Access 4.

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Event Code 442

ACCESS 4 PLATFORM ACCESS 4

DISTRIBUTION
PANEL

CA304 TP7 CA304

13 SW15 13 SW15
14 SW14 14 SW14
CA303 CA303

23 SW6 23 SW6

CA332 CA332
1 ZSS 1 ZSS
CA333 CA333
1 1
CA334 CA334
1 1

Fig. 68 (28307) Fig. 69 (28308)

Event Code 442 Event Code 448

ZSS IS DETECTED BUT THE FEATURE IS NOT EN- TRAVEL ALARM (ALM2) DRIVER HAS A SHORT
ABLED CIRCUIT
Note: If the lift truck has the zone select option, con- Step 1: Turn off the lift truck. Disconnect the wire
tinue to Step 1. If the lift truck does not have the zone from Access 4 CA304-7. Measure the voltage between
select option, continue to Step 2. platform distribution panel TP7 and Access 4 PC304-7.
Step 1: Turn on the lift truck. Use Features Menu/F25  The correct voltage = 36 V.
Zone Switch to set the menu to YES. • If:The voltage = 36 V.
• If:Event Code 442 continues. – Then the wire has a short circuit. Make the nec-
– Then replace Access 4. essary repairs or replacements.
Step 2: Turn on the lift truck. Use Features Menu/F25 • If:The voltage = 0 V.
Zone Switch to show the setting. – Then replace Access 4.
• If:The menu is set to YES.
– Then set the menu to NO.
ACCESS 4 PLATFORM
• If:The menu it set to NO. DISTRIBUTION
– Then continue to Step 3. PANEL

Step 3: Keep the lift truck turned on. Measure the TP7
CA304 CA336
voltage between platform distribution panel TP7 and
Access 4 CA303-23, Access 4 CA304-13, and PWM4 7 1
Access 4 CA304-14.
 The correct voltage = 36 V.
• If:The voltage = 36 V.
– Then the wires or the terminals to platform distri-
bution panel TP7 have a short circuit. Make the
Fig. 70 (28309)
necessary repairs or replacements.
• If:The voltage ≠ 36 V.
– Then replace Access 4.

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Event Code 452

Event Code 452 Event Code 466

ACCESS 4 INTERNAL DRIVER HAS A SHORT CIR- ACCESS 1 CAN EVENT
CUIT Event Code 466 through 469
Step 1: Replace Access 4.
Event Code 466: Access 1 RECEIVES PACKETS
TOO FAST

Event Code 460 Event Code 467: Access 1 RECEIVES SHORT PACK-
ETS
ACCESS 5 CAN EVENT
Event Code 468: Access 1 RECEIVES LONG PACK-
Event Code 460 through 462 ETS
Event Code 460: Access 5 RECEIVES PACKETS Event Code 469: Access 1 RECEIVES A DUPLICATE
TOO FAST ID
Event Code 461: Access 5 RECEIVES SHORT PACK- Step 1: Turn off the lift truck. Then turn on the lift
ETS truck.
Event Code 462: Access 5 RECEIVES LONG PACK- • If: Event Code 466, 467, 468, or 469 continues.
ETS – Then replace Access 5.
Step 1: Turn off the lift truck. Then turn on the lift
truck.
• If:Event Code 460, 461, or 462 continues. Event Code 470
– Then replace Access 5. ACCESS 2 CAN EVENT
Event Code 470 through 473

Event Code 463 Event Code 470: Access 2 RECEIVES PACKETS

TOO FAST
ACCESS 6 CAN EVENT
Event Code 471: Access 2 RECEIVES SHORT PACK-
Event Code 463 through 465 ETS
Event Code 463: Access 6 RECEIVES PACKETS Event Code 472: Access 2 RECEIVES LONG PACK-
TOO FAST ETS
Event Code 464: Access 6 RECEIVES SHORT PACK- Event Code 473: Access 2 RECEIVES A DUPLICATE
ETS ID
Event Code 465: Access 6 RECEIVES LONG PACK- Step 1: Turn off the lift truck. Then turn on the lift
ETS truck.
Step 1: Turn off the lift truck. Then turn on the lift truck. • If: Event Code 470, 471, 472, or 473 continues.
• If: Event Code 463, 464, or 465 continues. – Then replace Access 5.
– Then replace Access 5.

Event Code 474

Access 3™ CAN EVENT
Event Code 474 through 477
Event Code 474: Access 3™ RECEIVES PACKETS
TOO FAST
Event Code 475: Access 3™ RECEIVES SHORT
PACKETS

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Event Code 478

Event Code 476: Access 3™ RECEIVES LONG

PACKETS
Event Code 477: Access 3™ RECEIVES A DUPLI- Event Code 488
CATE ID Access 3™ CAN EVENT
Step 1: Turn off the lift truck. Then turn on the lift Event Code 488 through 490
truck. Step 1: Turn off the lift truck. Then turn on the lift
• If: Event Code 474, 475, 476, or 477 continues. truck.
– Then replace Access 5. • If:Event Code 488, 489, or 490 continues.
– Then replace Access 5.

Event Code 478

ACCESS 5 CAN EVENT Event Code 500
Event Code 478 and 479 INVALID EVENT CODE FROM ACCESS 5 - NOT
Step 1: Turn off the lift truck. Then turn on the lift USED
truck. The event code is not specified in the lift truck code.
• If:Event Code 478 or Event Code 479 continues. Consult the factory.
– Then replace Access 5.

Event Code 501

Event Code 480
ACCESS 1 CAN EVENT WITH ACCESS 5
ACCESS 6 CAN EVENT Note: Intermittent CAN communication between
Event Code 480 and 481 Access 1 and Access 5 can cause Event Code 501 to
Step 1: Turn off the lift truck. Then turn on the lift occur. Access 5 shows Event Code 501. Access 1
truck. must receive Event Code 501 from Access 5 to illumi-
• If:Event Code 480 or Event Code 481 continues. nate the service required indicator (the service indica-
tor). If the service required indicator illuminates, the
– Then replace Access 5.
CAN communication between Access 1 and Access 5
is intermittent.

Event Code 482 Note: No CAN communication between Access 1 and

Access 5 after turning on the lift truck can cause Event
ACCESS 1 CAN EVENT Code 501 to occur. Access 5 shows Event Code 501.
Event Code 482 through 484 If there is no CAN communication between Access 1
and Access 5, Access 1 does not show Event Code
Step 1: Turn off the lift truck. Then turn on the lift
501, and the service required indicator (the service in-
truck.
dicator) does not illuminate.
• If:Event Code 482, 483, or 484 continues.
Step 1: Turn on the lift truck. Find which
– Then replace Access 5. Access 1 2 3® module shows Event Code 501.
• If:Access 1 shows the service required indicator
and Event Code 501.
Event Code 485
– Then continue to Step 2.
ACCESS 2 CAN EVENT • If:Access 1 does not show the service required in-
Event Code 485 through 487 dicator, traction, hydraulics, and steering do not op-
Step 1: Turn off the lift truck. Then turn on the lift erate, and Access 5 shows Event Code 501.
truck. – Then continue to Step 4.
• If:Event Code 485, 486, or 487 continues. Step 2: Keep the lift truck turned on. There is inter-
– Then replace Access 5. mittent CAN communication between Access 1 and
Access 5. Check for more event codes.
• If:Event Code 301 or Event Code 401 occurs.

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Event Code 503

– Then turn off the lift truck. Disconnect Access 1

CA302. Turn on the lift truck. Measure the volt-
age between Access 1 CA302-4 and Access 1 ACCESS 1
CA302-3.
 The correct voltage = 36 V. CA302
• If:The voltage = 36 V +BV 3
– Then continue to Step 3. B- 4
Step 3: Turn off the lift truck. Check the condition of
the wires between platform distribution panel CA105-2 CAN H
and Access 1 CA302-8, and platform distribution panel 120 Ohm 8
CA105-8 and Access 1 CA302-9. Make the necessary Resistor 9
CAN L
repairs or replacements.
• If:Event Code 305 or Event Code 405 occurs.
– Then check the condition of the wires between
power unit distribution panel CA204-2 and PLATFORM
DISTRIBUTION
Access 5 CA402-4, and power unit distribution PANEL
panel CA204-8 and Access 5 CA402-5. Make the
necessary repairs or replacements.
CA105
Step 4: Turn on the lift truck. There is no CAN com-
CAN H 2
munication between Access 1 and Access 5. Access 5
shows Event Code 501. Turn off the lift truck. Then turn
CAN L 8
on the lift truck.
CA103
• If:Access 1 does not turn on.
+BV_KYS 10
– Then measure the voltage between platform dis-
tribution panel CA103-10 and platform distribu- CA107

tion panel CA107-8. B- 8

 The correct voltage = 36 V. ACCESS 5
• If:The voltage = 0 V.
– Then continue to Step 5. POWER UNIT
DISTRIBUTION
Step 5: Keep the lift truck turned on. Measure the PANEL
voltage between platform distribution panel CA103-10
and Access 1 CA302-3, and platform distribution panel CA204 CA402
CAN1 H
CA107-8 and Access 1 CA302-4. CAN H 2 4 120 Ohm
• If:The voltage = 36 V and Access 1 does not turn 5 Resistor
CAN1 L
on.
– Then replace Access 1. CAN L 8

• If:Access 1 turns on, the service required indicator

illuminates, and Event Code 305 and Event Code
Fig. 71 (28311)
405 occur.
– Then turn off the lift truck. Check the condition of
the wires between power unit distribution panel
CA204-2 and Access 5 CA402-4, and power unit
Event Code 503
distribution panel CA204-8 and Access 5 Access 3™ CAN EVENT WITH ACCESS 5
CA402-5. Make the necessary repairs or replace-
Step 1: See the procedures for Event Code 305.
ments.

Event Code 504

ACCESS 4 CAN EVENT WITH ACCESS 5
Step 1: See the procedures for Event Code 405.

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Event Code 505

• If:The voltage = 0 V.
– Then turn off the lift truck. Check the condition of
Event Code 505 the wires between power unit distribution panel
CA201-6 and Access 6 CA601-1, and Access 6
ACCESS 5 CAN EVENT CA601-2 and the battery negative terminal on
Step 1: Turn off the lift truck. Check the condition of Access 3™. Make the necessary repairs or re-
the connections and the wires between power unit dis- placements.
tribution panel CA204-2 and Access 5 CA402-4, and • If:The voltage = 36 V.
power unit distribution panel CA204-8 and Access 5
– Then replace Access 6.
CA402-5.
• If:The connections or the wires are damaged.
– Then make the necessary repairs or replace- POWER UNIT
ments. DISTRIBUTION
PANEL
• If:The connections and the wires are correct.
– Then clean the connections.
CA201
B- BB 6
POWER UNIT ACCESS 5
DISTRIBUTION CA204
PANEL CAN H 3

CAN L 9

CA204
CAN H 2 ACCESS 6
CA402 ACCESS 3
CAN1 H
4 120 Ohm
CAN L 8 5 Resistor
CAN1 L CA601
1 PWR
2 -BV

BNEG CAN1 H
Fig. 72 (28312) B+ + B- 4 120 Ohm
5 Resistor
CAN1 L

Event Code 506 2

ACCESS 6 CAN EVENT WITH ACCESS 5

Fig. 73 (28313)
Step 1: Turn on the lift truck. Check the Access 6
power lamps.
• If:The Access 6 power lamps are on. Event Code 511
– Then turn off the lift truck. Check the condition of
the wires between power unit distribution panel ACCESS 5 INTERNAL EVENT
CA204-3 and Access 6 CA601-4, and power unit Event Code 511 and 512
distribution panel CA204-9 and Access 6 Step 1: Replace Access 5.
CA601-5. Make the necessary repairs or replace-
ments.
• If:The Access 6 power lamps are off. Event Code 513
– Then continue to Step 2.
ACCESS 5 INTERNAL EVENT
Step 2: Turn on the lift truck. Measure the voltage be-
tween Access 6 CA601-1 and Access 6 CA601-2. Event Code 513 and 514
 The correct voltage = 36 V. Step 1: Replace Access 5.

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Event Code 515

Event Code 515 ACCESS 5

ACCESS 5 INTERNAL EVENT

Event Code 515 through 521 B+
Step 1: Replace Access 5.
CA403

20 +5 V B-
Event Code 522 21 +5 V

5 V POWER SUPPLY FOR ACCESS 5 IS TOO LOW

OR TOO HIGH
Event Code 522 and 523 CA410 ECR2
Event Code 522: 5 V POWER SUPPLY FOR Access 5 4
RED
+5 V
IS TOO HIGH
Event Code 523: 5 V POWER SUPPLY FOR Access 5
IS TOO LOW Fig. 74 (28314)
Step 1: Turn on the lift truck. Measure the voltage be-
tween Access 5 CA403-20 and Access 5
CA403-21. Event Code 524
 The correct voltage = 5 V. STEER MOTOR (M2) VOLTAGE IS TOO HIGH
• If:The voltage = 5 V and Event Code 522 or Event Step 1: See the procedures for Event Code 528.
Code 523 continues.
– Then replace Access 5.
• If:The voltage < 5 V. Event Code 525
– Then continue to Step 2.
M2 VOLTAGE IS TOO LOW
Step 2: Turn off the lift truck. Disconnect the wire
from Access 5 CA403-20. Turn on the lift truck. Mea- Step 1: See the procedures for Event Code 529.
sure the voltage between Access 5 CA403-20 and the
battery negative terminal on Access 5.
• If:The voltage = 5 V. Event Code 526
– Then turn off the lift truck. Connect the wire to BRK VOLTAGE IS TOO HIGH OR TOO LOW
Access 5 CA403-20. Continue to Step 3.
Event Code 526 and 527
• If:The voltage < 5 V.
Event Code 526: BRK VOLTAGE IS TOO HIGH
– Then continue to Step 3.
Step 3: Keep the lift truck turned off. Disconnect Event Code 527: BRK VOLTAGE IS TOO LOW
CA410. Turn on the lift truck. Measure the voltage be- Step 1: Turn on the lift truck. Check for Event Codes
tween Access 5 CA403-20 and the battery negative 528, 529, 530, 531, or 540.
terminal on Access 5. • If:Event Codes 528, 529, 530, 531, or 540 occur.
• If:The voltage = 5 V. – Then see the procedures for Event Codes 528,
– Then replace the steering feedback encoder 529, 530, 531, or 540.
(ECR2). • If:Only Event Code 526 or Event Code 527 occurs.
• If:The voltage < 5 V. – Then replace Access 5.
– Then turn off the lift truck. Check the condition of
the wires between CA410-4 and Access 5
CA403-20. Make the necessary repairs or re-
placements.

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Event Code 528

• If:Event Code 540 does not occur.

– Then continue to Step 2.
Event Code 528 Step 2: Turn off the lift truck. Check the condition of
BRK INNER COIL VOLTAGE IS TOO HIGH the inner brake coil fuse (FU6) on the power unit distri-
bution panel.
Step 1: Turn on the lift truck. Check for Event Code
540. • If:FU6 is damaged.
• If:Event Code 540 occurs. – Then make the necessary repairs or replace-
ments.
– Then see the procedures for Event Code 540.
• If:FU6 is correct.
• If:Event Code 540 does not occur.
– Then continue to Step 3.
– Then continue to Step 2.
Step 3: Keep the lift truck turned off. Check the con-
Step 2: Turn off the lift truck. Check the condition of dition of the ED2 contactor tips.
the ED2 contactor tips.
• If:The contactor tips are damaged.
• If:The contactor tips are damaged.
– Then make the necessary repairs or replace-
– Then make the necessary repairs or replace- ments.
ments.
• If:The contactor tips are correct.
• If:The contactor tips are correct.
– Then continue to Step 4.
– Then continue to Step 3.
Step 4: Turn on the lift truck. Measure the voltage be-
Step 3: Turn on the lift truck. Measure the battery tween Access 5 CA403-7 and the battery negative ter-
voltage. minal on Access 5.
 The correct voltage = 36 V.  The correct voltage = 36 V.
• If:The battery voltage is 24 V. • If:The voltage is 36 V and Event Code 529 contin-
– Then install a 36 V battery. ues.
– Then replace Access 5.

ACCESS 3

BNEG
B+ + B-

FU15

ED2
Fig. 75 (28282)

Event Code 529

BRK INNER COIL VOLTAGE IS TOO LOW
Step 1: Turn on the lift truck. Check for Event Code
540.
• If:Event Code 540 occurs.
– Then see the procedures for Event Code 540.

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Event Code 530

• If:FU5 is correct.
– Then continue to Step 3.
POWER UNIT ACCESS 5
DISTRIBUTION Step 3: Keep the lift truck turned off. Check the con-
PANEL dition of the ED2 contactor tips.
• If:The contactor tips are damaged.
B+
– Then make the necessary repairs or replace-
FU6 ments.
CA202 CA403
B- • If:The contactor tips are correct.
BRAKE COIL 2 7 B+ BRAKE
INNER FEED INNER – Then continue to Step 4.
Step 4: Turn on the lift truck. Measure the voltage be-
tween Access 5 CA403-9 and the battery negative ter-
minal on Access 5.
ACCESS 3
CA407  The correct voltage = 36 V.
1 • If:The voltage is 36 V and Event Code 529 contin-
BLU I+
2 ues.
BRK
3
YEL I- – Then replace Access 5.
4
BNEG
B+ + B-
POWER UNIT ACCESS 5
DISTRIBUTION
PANEL

B+
ED2
Fig. 76 (28315) FU5
CA202 CA403
B-
BRAKE COIL 1 9 B+ BRAKE
OUTER FEED OUTER
Event Code 530
BRK OUTER COIL VOLTAGE IS TOO HIGH
CA407
Step 1: See the procedures for Event Code 528. ACCESS 3 WHT 0+
1
2
BRK
Event Code 531 3
4
ORG 0-
BRK OUTER COIL VOLTAGE IS TOO LOW
BNEG
Step 1: Turn on the lift truck. Check for Event Code B+ + B-
540.
• If:Event Code 540 occurs.
– Then see the procedures for Event Code 540.
• If:Event Code 540 does not occur.
ED2
– Then continue to Step 2.
Fig. 77 (28316)
Step 2: Turn off the lift truck. Check the condition of
the outer brake coil fuse (FU5) on the power unit distri-
bution panel.
• If:FU5 is damaged.
– Then make the necessary repairs or replace-
ments.

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Event Code 532

Event Code 532 ACCESS 5

CURRENT SENSOR (CS1) VOLTAGE IS TOO HIGH

Step 1: Turn on the lift truck. Measure the voltage be-
tween Access 5 CA403-27 and the battery negative B-
CA403
terminal on Access 5. BDI CURRENT
 The correct voltage = 5 V. 24 SENSE

• If:The voltage = 5 V. 27 +5 V
– Then check for Event Code 540 or Event Code 28 LOGIC NEG
541.
• If:The voltage ≠ 5 V.
– Then continue to Step 2. CA406
VIOLET
Step 2: Turn off the lift truck. Disconnect the wire A +
BROWN
from Access 5 CA403-27. Turn on the lift truck. Mea- B 0 CS1
GREEN
sure the voltage between Access 5 CA403-27 and the C -
battery negative terminal on Access 5.
Fig. 78 (28317)
• If:The voltage = 5 V.
– Then turn off the lift truck. Connect the wire to
Access 5 CA403-27. Continue to Step 3. Event Code 533
• If:The voltage ≠ 5 V.
CS1 VOLTAGE IS TOO LOW
– Then replace Access 5.
Step 1: See the procedures for Event Code 532.
Step 3: Keep the lift truck turned off. Disconnect
CS1. Turn on the lift truck. Measure the voltage be-
tween CA406-A and CA406-B.
Event Code 534
• If:The voltage = 5 V.
– Then replace CS1. BATTERY CURRENT IS TOO HIGH OR TOO LOW
Event Code 534 and 535
• If:The voltage ≠ 5 V.
Step 1: Turn on the lift truck. Check for Event Codes
– Then turn off the lift truck. Check the condition of
532, 533, 536, or 537.
the wires between CA406-A and Access 5
CA403-27, CA406-B and Access 5 CA403-24, • If:Event Codes 532, 533, 536, or 537 occur.
and CA406-C and Access 5 CA403-28. Make the – Then see the procedures for Event Codes 532,
necessary repairs or replacements. 533, 536, or 537.
• If:Event Codes 532, 533, 536 and 537 do not occur.
– Then continue to Step 2.
Step 2: Turn off the lift truck. Check the condition of
the wires between CA406-A and Access 5 CA403-27,
CA406-B and Access 5 CA403-24, and CA406-C and
Access 5 CA403-28.
• If:The wires are damaged.
– Then make the necessary repairs or replace-
ments.
• If:The wires are correct.
– Then replace CS1.

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Event Code 536

• If:The CS1 installation is correct and Event Code

536 continues.
ACCESS 5
– Then replace CS1.

ACCESS 5
B-
CA403
BDI CURRENT
24 SENSE

27 +5 V
B-
28 LOGIC NEG CA403
BDI CURRENT
24 SENSE

27 +5 V
CA406 28 LOGIC NEG
VIOLET
A +
BROWN
B 0 CS1
GREEN
C -
CA406
VIOLET
Fig. 79 (28317) A +
BROWN
B 0 CS1
GREEN
C -
Event Code 536 Fig. 80 (28317)
CS1 IS NOT INSTALLED CORRECTLY
Step 1: Turn on the lift truck. Check for Event Code
537. Event Code 537
• If:Event Code 537 occurs. ZERO CURRENT IS TOO HIGH OR TOO LOW
– Then see the procedures for Event Code 537. Step 1: Turn on the lift truck. Check for Event Code
• If:Event Code 537 does not occur. 532 or Event Code 533.
– Then continue to Step 2. • If:Event Code 532 or Event Code 533 occurs.
Step 2: Keep the lift truck turned on. Enter Service – Then see the procedures for Event Code 532 or
Mode 2 and view CS1 sensor input. During full traction Event Code 533.
and plugging, use Analyzer Menu/A2.5.7 CS1 to show • If:Event Code 532 and Event Code 533 do not oc-
the values. cur.
• If:The values are negative during full traction. – Then continue to Step 2.
– Then turn off the lift truck. Check the installation Step 2: Keep the lift truck turned on. Step off the lift
of CS1 to the bus bar. Then check the condition truck to let the ED2 contactor tips open. Wait 2 min for
of the wires between CA406-A and Access 5 the ED2 bus to discharge. Measure the voltage be-
CA403-27, CA406-B and Access 5 CA403-24, tween Access 5 CA403-24 and the battery negative
and CA406-C and Access 5 CA403-28. Make the terminal on Access 5.
necessary repairs or replacements.  The correct voltage is 2.5 V.
• If:The values are positive during full traction. • If:The voltage is 2.4–2.6 V and Event Code 537
– Then continue to Step 3. continues.
Step 3: Keep the lift truck turned off. Check the instal- – Then replace Access 5.
lation of CS1. • If:The voltage > or < 2.4–2.6 V.
• If:The CS1 installation is incorrect. – Then continue to Step 3.
– Then correct the installation. Step 3: Turn off the lift truck. Disconnect the wire
from Access 5 CA403-24. Turn on the lift truck. Mea-

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Event Code 538

sure the voltage between the disconnected wire and Step 3: Turn on the lift truck. Measure the voltage be-
the battery negative terminal on Access 5. tween power unit distribution panel CA202-3 and
• If:The voltage is 2.4–2.6 V and Event Code 537 power unit distribution panel CA206-5.
continues.  The correct voltage = 36 V.
– Then replace Access 5. • If:The voltage = 36 V and Event Code 538 or Event
Code 539 continues.
• If:The voltage > or < 2.4–2.6 V.
– Then measure the voltage between power unit
– Then replace CS1.
distribution panel CA202-3 and Access 5
CA403-25.
• If:The voltage = 0 V.
ACCESS 5
– Then turn off the lift truck. Check the condition of
the wires between power unit distribution panel
CA202-3 and Access 5 CA403-25. Make the
necessary repairs or replacements.
B-

CA403
POWER UNIT ACCESS 5
24 BDI CURRENT
SENSE
DISTRIBUTION
PANEL

CA202 CA403
BATTERY BDI SENSE
SENSE 3 25 POSITIVE
CA406
VIOLET
A +
BROWN
FU2
B 0 CS1 CA206
GREEN
C - 5

Fig. 81 (28318)
Fig. 82 (28319)

Event Code 538 Event Code 540

BATTERY VOLTAGE IS TOO HIGH OR TOO LOW INCORRECT BATTERY IS INSTALLED
Event Code 538 and 539 Step 1: Turn on the lift truck. Measure the battery
Event Code 538: BATTERY VOLTAGE IS TOO HIGH voltage.
 The correct voltage = 36 V.
Event Code 539: BATTERY VOLTAGE IS TOO LOW
• If:The battery voltage is 24 V.
Step 1: Turn on the lift truck. Check for Event Code
540. – Then install a 36 V battery.
• If:Event Code 540 occurs.
– Then see the procedures for Event Code 540. Event Code 541
• If:Event Code 540 does not occur.
ED2 IS NOT CLOSED
– Then continue to Step 2.
Step 1: Turn on the lift truck. Push the brake pedal to
Step 2: Turn off the lift truck. Check the condition of
energize ED2.
FU2 on the power unit distribution panel.
• If:ED2 does not energize.
• If:FU2 is damaged.
– Then continue to Step 5.
– Then make the necessary repairs or replace-
ments. • If:ED2 energizes.
• If:FU2 is correct. – Then continue to Step 2.
– Then continue to Step 3. Step 2: Keep the lift truck turned on. Measure the
voltage between the battery positive terminal and the

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Event Code 541

battery negative terminal on Access 5. Then measure • If:The voltage = 30 V.

the voltage between the battery negative terminal on – Then replace Access 3™.
Access 5, Access 5 CA403-7, and Access 5 CA403-9.
• If:The voltage = 36 V.
 The correct voltage = 36 V.
– Then continue to Step 8.
• If:The voltage < 36 V.
• If:The voltage = 0 V.
– Then measure the battery voltage.
– Then continue to Step 7.
• If:The voltage = 36 V.
Step 7: Turn off the lift truck. Disconnect the wire
– Then continue to Step 3.
from Access 5 CA403-18. Turn on the lift truck. Mea-
Step 3: Turn off the lift truck. Then turn on the lift sure the voltage between the disconnected wire and
truck. the battery negative terminal on Access 5.
• If:Event Code 541 continues. • If:The voltage = 36 V.
– Then replace Access 5. – Then replace Access 5.
Step 4: Keep the lift truck turned on. Measure the • If:The voltage = 0 V.
voltage between the battery negative terminal on
– Then turn off the lift truck. Check the condition of
Access 5, Access 5 CA403-7, and Access 5 CA403-9.
the wires between Access 5 CA403-18 and the
• If:The voltage < 36 V. battery positive terminal on Access 5. Make the
– Then turn off the lift truck. Disconnect Access 5 necessary repairs or replacements.
CA403 and the battery positive cable from Step 8: Keep the lift truck turned off. Disconnect the
Access 5. Measure the resistance between negative wire from the ED2 coil. Measure the resis-
Access 5 CA403-7 and the battery negative ter- tance of the ED2 coil.
minal on Access 5, Access 5 CA403-9 and the  The correct resistance = 28–30 Ω.
battery negative terminal on Access 5, and the
battery positive terminal and the battery negative • If:The resistance ≠ 28–30 Ω.
terminal on Access 5. – Then replace ED2.
 The correct resistance = 10,000 Ω for Access 5 • If:The resistance = 28–30 Ω.
CA403-7 and the battery negative terminal on
– Then connect the negative wire to the ED2 coil.
Access 5, and Access 5 CA403-9 and the bat-
Continue to Step 9.
tery negative terminal on Access 5.
 The correct resistance = 40,000 Ω for the bat- Step 9: Keep the lift truck turned off. Measure the re-
tery positive terminal and the battery negative sistance between Access 5 CA403-19 and the positive
terminal on Access 5. terminal on the ED2 coil.
• If:The resistance < 10,000 Ω or 40,000 Ω. • If:The resistance ≠ 0 Ω.
– Then replace Access 5. – Then make the necessary repairs or replace-
• If:The resistance = 10,000 Ω or 40,000 Ω. ments to the wire between Access 5 CA403-19
and the positive terminal on the ED2 coil.
– Then continue to Step 5.
• If:The resistance = 0 Ω.
Step 5: Keep the lift truck turned off. Check the con-
dition of all the fuses on the power unit distribution – Then continue to Step 10.
panel (FU1–FU9). Step 10: Turn on the lift truck. Use Analyzer Menu/
• If:FU1–FU9 are open or damaged. A4.5.1.1 HIGH SIDE to test the battery positive that
Access 5 supplies. Then use Analyzer Menu/A4.5.1.2
– Then make the necessary repairs or replace-
BOTH to test the battery negative that Access 3™ sup-
ments.
plies and the battery positive that Access 5 supplies.
• If:FU1–FU9 are correct. Measure the voltage between the negative terminal on
– Then continue to Step 6. the ED2 coil and the battery negative terminal on
Step 6: Turn on the lift truck. Measure the voltage be- Access 5 without using Analyzer Menu/A4.5.1.1 HIGH
tween the positive terminal on the ED2 coil and the bat- SIDE or Analyzer Menu/A4.5.1.2 BOTH.
tery negative terminal on Access 5. • If:The voltage = 0 V.
• If:The voltage = 3 V. – Then turn off the lift truck. Disconnect the wire
– Then replace ED2. from Access 3™ CA401-2. Turn on the lift truck.

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Event Code 542

Measure the voltage at Access 3™ CA401-2 and

the battery negative terminal on Access 3™.
POWER UNIT
• If:The voltage = 36 V. DISTRIBUTION
– Then replace Access 3™. PANEL

• If:The voltage ≠ 36 V.
ACCESS 5
– Then replace Access 5. FU4
• If:The voltage = 30 V.
FU1
– Then continue to Step 11. CA403
FU2 B+ BRAKE
Step 11: Keep the lift truck turned on. While pushing 7 FEED INNER
ENTER, use Analyzer Menu/A4.5.1.1 HIGH SIDE to FU7 B+ BRAKE
9
test the battery positive that Access 5 supplies. FEED OUTER
FU8 FU5
• If:The voltage = 30 V.
FU9 FU6
– Then replace Access 5. B+

• If:The voltage = 36 V.
CA202 B-
– Then continue to Step 12. ED DRIVER
FEED 8
18 ED_+BV
Step 12: Keep the lift truck turned on. While pushing ED SOURCING
19 DRIVER
ENTER, use Analyzer Menu/A4.5.1.2 BOTH to test the
FU3
battery negative that Access 3™ supplies and the bat-
tery positive that Access 5 supplies.
• If:The voltage = 36 V. ACCESS 3
– Then replace Access 3™.
• If:The voltage < 10 V.
– Then replace Access 5.
CA401
GPD 1 2

+
ED2

Fig. 83 (28310)

Event Code 542

FUSE EVENT
Step 1: Turn off the lift truck. Check the condition of
FU5, FU6, and the Access 5 fuse (FU10).
• If:FU5, FU6, or FU10 are damaged.
– Then make the necessary repairs or replace-
ments.
• If:FU5, FU6, and FU10 are correct.
– Then continue to Step 2.
Step 2: Keep the lift truck turned off. Check the con-
dition of the power supply wires from power unit distri-
bution panel TP5 to Access 5 CA403-7, Access 5
CA403-9, and the battery positive terminal on
Access 3™.

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Event Code 543

• If:The wires are damaged.

– Then make the necessary repairs or replace-
ments. Event Code 546
Access 3™ ED2 PRE-CHARGE EVENT
POWER UNIT Event Code 546 through 548
DISTRIBUTION Event Code 546: GENERAL ED2 PRE-CHARGE
PANEL
ACCESS 5
EVENT
Event Code 547: Access 3™ ED2 PRE-CHARGE
POWER LIMIT IS TOO HIGH OR TOO LOW
BNEG Event Code 548: Access 3™ ED2 PRE-CHARGE
EVENT
CA202 CA403
B+ BRAKE
B- Step 1: Turn off the lift truck. Measure the resistance
1 7 FEED INNER
FU5 from the ED2 bus (the output contact) to the
2
FU6 B+ BRAKE battery negative terminal on Access 5.
9 FEED OUTER
CA206

4
 The correct resistance = 1,000 Ω.
B+
TP5 • If:The resistance < 25 Ω.
– Then disconnect bus load fuses one at a time un-
til the resistance increases to normal value of
1000 ohm.
FU10
• If:ED bus resistance returns to normal.
– Then note last fuse disconnected and replace all
Fig. 84 (28320)
others to verify that bus resistance remains the
same.
Event Code 543
ED2 CONTACTOR TIPS ARE WELDED Event Code 549
Step 1: See the procedures for Event Code 357. Access 3™ CHAIN SLACK
Step 1: Turn on the lift truck. Use Analyzer Menu/
A2.3.3 CHS3/CHS4 to show 0 (the switch is open) or 1
Event Code 544 (the switch is closed).
ED2 LOAD HAS AN OPEN CIRCUIT OR ED2 • If:The switch is closed.
DRIVER HAS A SHORT CIRCUIT – Then the lift truck status is correct. Event Code
Step 1: See the procedures for Event Code 541. 549 could have occurred because of chain ad-
justments.
• If:The switch is open.
Event Code 545 – Then continue to Step 2.
ED2 DRIVER DROPOUT EVENT Step 2: Turn off the lift truck. Check the chain adjust-
Step 1: See the procedures for Event Code 541. ment. See LIFTING MECHANISM/Planned Mainte-
nance for Lift Chains.
• If:The chain adjustment is correct and Event Code
549 continues.
– Then check the chain slack switch (CHS3 and
CHS4) adjustment.
• If:The CHS3 and CHS4 adjustment is correct.
– Then continue to Step 3.

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Event Code 551

Step 3: Keep the lift truck turned off. Measure the re- Step 1: Turn off the lift truck. Then turn on the lift
sistance of CHS3 and CHS4. truck.
 The correct resistance = 0 Ω. • If:Event Code 551 does not continue.
• If:The resistance = 0 Ω and Event Code 549 contin- – Then the lift truck status is correct.
ues.
• If:Event Code 551 continues.
– Then check the condition of the wires between
– Then replace Access 5.
Access 3™ CA401-17 and PC414-1, and power
unit distribution panel CA201-7 and PC415-1.
Make the necessary repairs or replacements.
• If:The voltage is correct at Access 3™ CA401-17.
Event Code 552
– Then replace Access 3™. ACCESS 5 PARAMETER EVENT
Event Code 552 and 553
Step 1: Load the default parameters and change the
POWER UNIT
DISTRIBUTION
settings as it is necessary.
PANEL

Event Code 554

CA201
+BV_K2 FU3
ACCESS 5 EAC PARAMETER EVENT
7
Step 1: Turn on the lift truck. Operate the lift truck
above the magnets for end aisle control to reset the
data.
• If:Event Code 554 does not continue.
ACCESS 3
– Then the lift truck status is correct.
• If:Event Code 554 continues.
– Then replace Access 5.
CA401

DI4 / ID0 17
Event Code 555
ECR2 FEEDBACK COUNTS ARE INCORRECT
Event Code 555 and 556
Note: If Event Code 522 or Event Code 523 occurs,
CA414
CHS3 BLK then see the procedures for Event Code 522 and Event
1
Code 523 first.
CA415
BLK
Step 1: Turn on the lift truck. Measure the voltage be-
1 tween CA410-2 and CA410-4.
CHS4  The correct voltage = 5 V.
• If:The voltage < 4.75 V or > 5.25 V.
– Then see the procedures for Event Code 522 and
Fig. 85 (28321) Event Code 523.
• If:The voltage = 5 V.
– Then continue to Step 2.
Event Code 551 Step 2: Keep the lift truck turned on. Use Analyzer
ACCESS 5 PARAMETER EVENT Menu/A2.5.1 ECR2 to show the counts when turning
Note: Event Code 551 could occur when turning on the the steering wheel clockwise and counterclockwise.
lift truck for the first time after downloading new soft- The counts change smoothly and continuously as turn-
ware. This is normal. ing the steering wheel. Record the counts when the
steering wheel is in the neutral position.

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Event Code 557

• If:The ECR2 counts change smoothly, but the • If:The voltage < 4.75 V or > 5.25 V.
counts do not align with the steering wheel position. – Then see the procedures for Event Code 522 and
– Then use Calibration Menu/C4 Steer Encoder to Event Code 523.
calibrate and align ECR2. • If:The voltage = 5 V.
• If:There is no change in the ECR2 counts, or the – Then continue to Step 2.
change is not consistent.
Step 2: Turn off the lift truck. Check the condition of
– Then continue to Step 3. the wires between CA410-5 and Access 5 CA403-23.
Step 3: Turn off the lift truck. Check the condition of • If:The wires are damaged.
the wires between CA410-1 and Access 5 CA403-13,
– Then make the necessary repairs or replace-
and CA410-3 and Access 5 CA403-14. Then check the
ments.
condition of the blue wire between CA410 and ECR2,
and the orange wire between CA410 and ECR2. • If:The wires are correct.
• If:The wires are correct and Event Code 555 or – Then continue to Step 3.
Event Code 556 continues. Step 3: Turn on the lift truck. Use Analyzer Menu/
– Then replace ECR2. A2.5.1 ECR2 to show the counts when turning the
steering wheel clockwise and counterclockwise. The
• If:ECR2 is correct and Event Code 555 or Event
counts change smoothly and continuously as turning
Code 556 continues.
the steering wheel. Record the counts when the steer-
– Then replace Access 5. ing wheel is in the neutral position.
• If:The ECR2 counts change smoothly, but the
counts do not align with the steering wheel position.
ACCESS 5
– Then use Calibration Menu/C4 Steer Encoder to
calibrate and align ECR2.
CA403
• If:There is no change in the ECR2 counts, or the
change is not consistent.
13 ECR2 A
14 ECR2 B – Then continue to Step 4.
Step 4: Turn off the lift truck and check the condition
of the wires between CA410-1 and Access 5
CA403-13, and CA410-3 and Access 5 CA403-14.
CA410 Then check the condition of the blue wire between
BLUE CA410 and ECR2, and the orange wire between
1 CH A
2 ECR2 CA410 and ECR2.
ORANGE
3 CH B • If:The wires are correct and Event Code 557 con-
4 tinues.
Fig. 86 (28322) – Then replace ECR2.
• If:ECR2 is correct and Event Code 557 continues.
– Then replace Access 5.
Event Code 557
ECR2 INDEX EVENT
Note: The ECR2 count shows that the steering wheel
goes through zero position, but the index signal does
not.
Note: If Event Code 522 or Event Code 523 occurs,
then see the procedures for Event Code 522 and Event
Code 523 first.
Step 1: Turn on the lift truck. Measure the voltage be-
tween CA410-2 and CA410-4.
 The correct voltage = 5 V.

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Event Code 558

Step 3: Turn on the lift truck. Use Analyzer Menu/

A2.5.1 ECR2 to show the counts when turning the
ACCESS 5 steering wheel clockwise and counterclockwise. The
counts change smoothly and continuously as turning
the steering wheel. Record the counts when the steer-
CA403 ing wheel is in the neutral position.
13 ECR2 A • If:The ECR2 counts change smoothly, but the
14 ECR2 B counts do not align with the steering wheel position.
– Then use Calibration Menu/C4 Steer Encoder to
23 ECR2 INDEX calibrate and align ECR2.
• If:There is no change in the ECR2 counts, or the
change is not consistent.
– Then continue to Step 4.
CA410
BLUE
Step 4: Turn off the lift truck and check the condition
1 CH A of the wires between CA410-1 and Access 5
2 CA403-13, and CA410-3 and Access 5 CA403-14.
ORANGE
3 CH B ECR2 Then check the condition of the blue wire between
4 CA410 and ECR2, and the orange wire between
YELLOW
5 INDEX CA410 and ECR2.
• If:The wires are correct and Event Code 557 con-
Fig. 87 (28323) tinues.
– Then replace ECR2.
Event Code 558 • If:ECR2 is correct and Event Code 557 continues.
– Then replace Access 5.
ECR2 EVENT
Event Code 558 through 561
Note: If there is no steering wheel movement on com- ACCESS 5
mand, Event Codes 558, 559, 560, and 561 occurs.
Note: If Event Code 522 or Event Code 523 occurs, A1
then see the procedures for Event Code 522 and Event
M2
Code 523 first. B+
Step 1: Turn on the lift truck. Measure the voltage be- CA403
tween CA410-2 and CA410-4. 13 ECR2 A A2
 The correct voltage = 5 V. 14 ECR2 B
• If:The voltage < 4.75 V or > 5.25 V. B-

– Then see the procedures for Event Code 522 and

Event Code 523.
CA410
• If:The voltage = 5 V. BLUE
1 CH A
– Then continue to Step 3. ECR2
2
Step 2: Turn off the lift truck. Check the condition of ORANGE
3 CH B
the wire connections between the A1 terminal on 4
Access 5, the A2 terminal on Access 5, and M2.
Fig. 88 (28324)
• If:The wire connections are damaged.
– Then make the necessary repairs or replace-
ments.
• If:The wire connections are correct.
– Then continue to Step 3.

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Event Code 562

Event Code 562 ACCESS 5

STEERING EVENT
A1
Note: If Event Codes 524, 525, or 540 occur, then see
M2
the procedures for Event Codes 524, 525, and 540
B+
first.
Step 1: Turn off the lift truck, disconnect the battery, A2
and remove the battery positive cable and the battery
negative cable from Access 5. Install a jumper between B-
the battery positive terminal and the battery negative
terminal on Access 5. Measure the resistance between Fig. 89 (28325)
these components:
• The A1 terminal on Access 5 to the battery positive
terminal on Access 5.
Event Code 563
 The correct resistance = 15,000 Ω. ACCESS 5 AND ACCESS 6 COMMUNICATION
• The A1 terminal on Access 5 to the battery negative EVENT
terminal on Access 5. Note: Access 5 receives a wire guidance command
 The correct resistance = 15,000 Ω. from GUS1, but does not receive communication from
• The A2 terminal on Access 5 to the battery positive Access 6.
terminal on Access 5. Step 1: Turn on the lift truck. Use Features Menu/F14
 The correct resistance = 15,000 Ω. Wire Guidance to make sure that the menu is not set to
• The A2 terminal on Access 5 to the battery negative Enable if the lift truck does not have the wire guidance
terminal on Access 5. option.
 The correct resistance = 15,000 Ω. • If:The menu is set to Enable and the lift truck does
• The A1 terminal on Access 5 to the A2 terminal on not have the wire guidance option.
Access 5. – Then set the menu to DISABLE.
 The correct resistance = 30,000 Ω.
• If:The menu is set to Enable and the lift truck has
• If: The resistance measurements are more than the wire guidance option.
5,000 Ω less than the correct resistance.
– Then continue to Step 2.
– Then replace Access 5.
Step 2: Turn off the lift truck. Then turn on the lift
• If:The resistance measurements are correct. truck.
– Then continue to Step 2. • If:Event Code 563 continues.
Step 2: Keep the lift truck turned off. Connect the bat- – Then see the procedures for Event Code 506.
tery positive cable and the battery negative cable to
Access 5. Check the Access 5 A1 cable and the
Access 5 A2 cable for a short circuit. Event Code 564
• If:The cables have a short circuit.
– Then make the necessary repairs or replace- WIRE GUIDANCE ENABLE EVENT
ments. Note: Access 5 receives a wire guidance command
• If:The cables are correct and Event Code 562 con- from GUS1, but the F14 Wire Guidance menu is not set
tinues. to Enable.
– Then replace Access 5. Step 1: Turn on the lift truck. Use Features Menu/F14
Wire Guidance to set the menu to Enable.

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Event Code 565

– Then measure the voltage between Access 6

CA602-3 and the battery negative terminal on
Event Code 565 Access 6.
• If:The voltage > 1 V.
ECR3 EVENT
– Then replace Access 6.
Step 1: See the procedures for Event Code 330.
• If:The voltage = 0 V.
– Then continue to Step 2.
Event Code 566 Step 2: Turn off the lift truck. Disconnect the wire
from EAC distribution panel CA607-3. Turn on the lift
EAC ENABLE EVENT truck. Measure the voltage between the disconnected
Note: The F16 End Aisle Control menu is set to North wire and the battery negative terminal on Access 6.
Sensing or South Sensing, but the lift truck cannot find • If:The voltage = 5 V.
the EAC hardware. – Then replace the EAC distribution panel.
Step 1: Make sure that the lift truck has the EAC op- • If:The voltage = 0 V.
tion.
– Then continue to Step 3.
• If:the lift truck does not have the EAC option.
Step 3: Turn off the lift truck. Disconnect the wire
– Then turn on the lift truck. Use Features Menu/ from Access 6 CA602-5. Turn on the lift truck. Measure
F16 End Aisle Control to set the menu to NO the voltage between Access 6 CA602-5 and the battery
EAC. negative terminal on Access 6.
• If:the lift truck has the EAC option. • If:The voltage = 5 V.
– Then continue to Step 2. – Then turn off the lift truck. Check the condition of
Step 2: Keep the lift truck turned on. Check for Event the wires between EAC distribution panel
Code 105. CA607-3 and Access 6 CA602-5. Make the nec-
• If:Event Code 105 occurs. essary repairs or replacements.
– Then turn off the lift truck. Check the condition of • If:The voltage = 0 V.
the connections to Access 6. Make the neces- – Then replace Access 6.
sary repairs or replacements.
• If:The connections are correct.
– Then continue to Step 3. ACCESS 6

Step 3: Turn on the lift truck. Check for Event Code EAC
506.
• If:Event Code 506 occurs. CA607 CA602

– Then see the procedures for Event Code 506. 1 3 EAC A1 TEST

3 5 EAC A1 DIGITAL
B-
Event Code 567
END AISLE CONTROL SENSOR (EACA1) Fig. 90 (28326)
LATCHED ON EVENT
Note: If Event Code 625 or Event Code 626 occurs,
then see the procedures for Event Code 625 and Event Event Code 568
Code 626 first. END AISLE CONTROL SENSOR (EACB1)
Step 1: Turn on the lift truck. Measure the voltage be- LATCHED ON EVENT
tween Access 6 CA602-5 and the battery negative ter- Note: If Event Code 625 or Event Code 626 occurs,
minal on Access 6. then see the procedures for Event Code 625 and Event
 The correct voltage = 5 V. Code 626 first.
• If:The voltage = 0 V.

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Event Code 569

Step 1: Turn on the lift truck. Measure the voltage be-

tween Access 6 CA602-11 and the battery negative
terminal on Access 6. Event Code 569
 The correct voltage = 5 V.
• If:The voltage = 0 V. END AISLE CONTROL SENSOR (EACA2)
LATCHED ON EVENT
– Then measure the voltage between Access 6
CA602-9 and the battery negative terminal on Note: If Event Code 625 or Event Code 626 occurs,
Access 6. then see the procedures for Event Code 625 and Event
Code 626 first.
• If:The voltage > 1 V.
Step 1: Turn on the lift truck. Measure the voltage be-
– Then replace Access 6. tween Access 6 CA602-8 and the battery negative ter-
• If:The voltage = 0 V. minal on Access 6.
– Then continue to Step 2.  The correct voltage = 5 V.
Step 2: Turn off the lift truck. Disconnect the wire • If:The voltage = 0 V.
from EAC distribution panel CA607-9. Turn on the lift – Then measure the voltage between Access 6
truck. Measure the voltage between the disconnected CA602-6 and the battery negative terminal on
wire and the battery negative terminal on Access 6. Access 6.
• If:The voltage = 5 V. • If:The voltage > 1 V.
– Then replace the EAC distribution panel. – Then replace Access 6.
• If:The voltage = 0 V. • If:The voltage = 0 V.
– Then continue to Step 3. – Then continue to Step 2.
Step 3: Turn off the lift truck. Disconnect the wire Step 2: Turn off the lift truck. Disconnect the wire
from Access 6 CA602-11. Turn on the lift truck. Mea- from EAC distribution panel CA607-6. Turn on the lift
sure the voltage between Access 6 CA602-11 and the truck. Measure the voltage between the disconnected
battery negative terminal on Access 6. wire and the battery negative terminal on Access 6.
• If:The voltage = 5 V. • If:The voltage = 5 V.
– Then turn off the lift truck. Check the condition of – Then replace the EAC distribution panel.
the wires between EAC distribution panel • If:The voltage = 0 V.
CA607-9 and Access 6 CA602-11. Make the
necessary repairs or replacements. – Then continue to Step 3.
• If:The voltage = 0 V. Step 3: Turn off the lift truck. Disconnect the wire
from Access 6 CA602-8. Turn on the lift truck. Measure
– Then replace Access 6. the voltage between Access 6 CA602-8 and the battery
negative terminal on Access 6.
• If:The voltage = 5 V.
ACCESS 6
– Then turn off the lift truck. Check the condition of
EAC the wires between EAC distribution panel
CA607-6 and Access 6 CA602-8. Make the nec-
CA607 CA602 essary repairs or replacements.
7 9 EAC B1 TEST • If:The voltage = 0 V.
9 11 EAC B1 DIGITAL – Then replace Access 6.
B-

Fig. 91 (28327)

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Event Code 570

• If:The voltage = 0 V.
– Then replace Access 6.
ACCESS 6

EAC
ACCESS 6
CA607 CA602
EAC
4 6 EAC A2 TEST

6 8 EAC A2 DIGITAL CA607 CA602

B-
10 12 EAC B2 TEST

12 14 EAC B2 DIGITAL
Fig. 92 (28328) B-

Event Code 570 Fig. 93 (28329)

END AISLE CONTROL SENSOR (EACB2)

LATCHED ON EVENT Event Code 571
Note: If Event Code 625 or Event Code 626 occurs,
EAC MAGNET EVENT
then see the procedures for Event Code 625 and Event
Code 626 first. Event Code 571 and 572
Step 1: Turn on the lift truck. Measure the voltage be- Event Code 571: INNER MAGNET EVENT
tween Access 6 CA602-14 and the battery negative Event Code 572: OUTER MAGNET EVENT
terminal on Access 6. Step 1: Turn on the lift truck. Operate the lift truck out
 The correct voltage = 5 V.
of the end of an aisle, then into the aisle again.
• If:The voltage = 0 V.
• If:Event Code 571 and Event Code 572 does not
– Then measure the voltage between Access 6 occur.
CA602-12 and the battery negative terminal on
– Then the lift truck status is correct.
Access 6.
• If:Event Code 571 or Event Code 572 occurs.
• If:The voltage > 1 V.
– Then continue to Step 2.
– Then replace Access 6.
Step 2: Keep the lift truck turned on. While operating
• If:The voltage = 0 V.
the lift truck slowly over the magnets, use Analyzer
– Then continue to Step 2. Menu/A2.6.3 EACA1, Analyzer Menu/A2.6.4 EACA2,
Step 2: Turn off the lift truck. Disconnect the wire Analyzer Menu/A2.6.5 EACB1, and Analyzer Menu/
from EAC distribution panel CA607-12. Turn on the lift A2.6.6 EACB2 to show 0 (if the EAC system senses
truck. Measure the voltage between the disconnected the magnets) or 1 (if the EAC system does not sense
wire and the battery negative terminal on Access 6. the magnets).
• If:The voltage = 5 V. • If:The EAC system does not sense a magnet or
– Then replace the EAC distribution panel. magnets.
• If:The voltage = 0 V. – Then turn off the lift truck. Check the condition of
– Then continue to Step 3. the wires of EACA1, EACA2, EACB1, or EACB2.

Step 3: Turn off the lift truck. Disconnect the wire • If:The wires are correct.
from Access 6 CA602-14. Turn on the lift truck. Mea- – Then continue to Step 3.
sure the voltage between Access 6 CA602-14 and the Step 3: Do Step 2 again.
battery negative terminal on Access 6. • If:The EAC system senses the magnets.
• If:The voltage = 5 V. – Then check the condition of the magnets in the
– Then turn off the lift truck. Check the condition of floor. Put a piece of metal above a magnet. The
the wires between EAC distribution panel magnetic signal must be strong. Compare it to a
CA607-12 and Access 6 CA602-14. Make the different magnet. If there is a large difference in
necessary repairs or replacements. the magnetic signal, replace the magnet.

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Event Code 573

• If:The magnets are correct. • If:The voltage = 5 V.

– Then continue to Step 4. – Then turn off the lift truck. Connect CA317 and
Step 4: Turn off the lift truck. Then turn on the lift continue to Step 3.
truck. When the lift truck has the EAC signal, operate • If:The voltage < 5 V.
the lift truck out of the end of an aisle. Stay there while – Then continue to Step 3.
pushing the brake pedal. Wait 20 s for the lift truck di-
Step 3: Turn off the lift truck. Disconnect the wires
agnostics to occur.
from Access 4 CA303-12 and Access 4 CA303-15.
• If:EACA1, EACA2, EACB1, or EACB2 fail. Turn on the lift truck. Measure the voltage between
– Then check for a 500 or a 600 event code. See Access 4 CA303-12 and Access 4 CA303-15.
the procedures for those event codes. • If:The voltage = 5 V.
• If:No event code occurs. – Then turn off the lift truck. Check the condition of
– Then the EAC system is correct. the wires between CA317-3 and Access 4
CA303-12, and CA317-4 and Access 4
CA303-15. Make the necessary repairs or re-
EAC SENSOR B1 A1 EAC SENSOR placements.
5 5
CA605 CA606 • If:The voltage < 5 V.
– Then replace Access 4.
Step 4: Turn off the lift truck. Disconnect CA317. Dis-
connect the white wire from JC317-1 and the blue wire
EAC from JC317-2. Turn on the lift truck. Measure the volt-
age between the white wire and Access 4 CA303-15,
and the blue wire and Access 4 CA303-15.
 The correct voltage = 0 or 5 V (because of the
position of ECR4).
CA610 CA609
5 5 • If:The voltage ≠ 0 or 5 V.
EAC SENSOR B2 A2 EAC SENSOR
– Then replace ECR4.
Fig. 94 (28330)
• If:The voltage = 0 or 5 V.
– Then connect the white wire to JC317-1 and the
Event Code 573 blue wire to JC317-2.
• If:The voltage = 0 or 5 V and Event Code 573 or
ECR4 COUNT EVENT Event Code 574 continues.
Event Code 573 and 574 – Then replace Access 4.
Event Code 573: ECR4 DOES NOT COUNT DURING
RAISE
Event Code 574: ECR4 DOES NOT COUNT DURING
LOWER
Step 1: Turn off the lift truck. Disconnect CA317.
Check the condition of the wires between
CA317 and ECR4.
• If:The wires are damaged.
– Then make the necessary repairs or replace-
ments.
• If:The wires are correct.
– Then continue to Step 2.
Step 2: Turn on the lift truck. Keep CA317 discon-
nected. Measure the voltage between CA317-3 and
CA317-4.
 The correct voltage = 5 V.

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Event Code 576

Step 3: Keep the lift truck turned off. With the coils at
room temperature, measure the resistance of the coils.
ACCESS 4  The correct resistance of the BRK inner coil =
3.5 Ω.
 The correct resistance of the BRK outer coil =
1.5 Ω.
CA303
• If:The BRK inner coil > 3.5 Ω or the BRK outer coil
12 +5 V
> 1.5 Ω.
15 LOGIC NEG – Then replace the BRK inner coil or the BRK outer
coil.

CA317
WHITE
Event Code 582
1 CH A
2
BLUE
CH B BRK CURRENT IS TOO LOW OR TOO HIGH
RED ECR4
3 +5 V Event Code 582 through 585
BLACK
4 NEG Event Code 582: BRK INNER COIL HAS TOO MUCH
CURRENT
Fig. 95 (28305) Event Code 583: BRK INNER COIL RESISTANCE IS
TOO LOW
Event Code 584: BRK OUTER COIL HAS TOO MUCH
Event Code 576 CURRENT
BRK CURRENT OR RESISTANCE EVENT Event Code 585: BRK OUTER COIL RESISTANCE IS
TOO LOW
Event Code 576 through 581
Step 1: Turn off the lift truck. Disconnect CA407. With
Event Code 576: BRK INNER COIL HAS LOW
the coils at room temperature, measure the re-
CURRENT
sistance between CA407-2 and CA407-3 on
Event Code 577: BRK INNER COIL IS HOT
the BRK inner coil side.
Event Code 578: BRK INNER COIL RESISTANCE IS
 The correct resistance of the BRK inner coil =
HIGH
3.5 Ω.
Event Code 579: BRK OUTER COIL HAS LOW
• If:The resistance < 3.5 Ω.
CURRENT
– Then replace the BRK inner coil.
Event Code 580: BRK OUTER COIL IS HOT
• If:The resistance = 3.5 Ω and Event Codes 582,
Event Code 581: BRK OUTER COIL RESISTANCE IS
583, 584, or 585 continue.
HIGH
– Then replace Access 5.
Step 1: Turn off the lift truck. Let BRK cool. Remove
BRK from M1. Disassemble BRK to inspect
the coils. CA407

Step 2: Inspect the coils for heat damage. 1

BLU I+
2
• If:The coils are damaged. BRK
3
YEL I-
– Then make the necessary repairs or replace- 4
ments.
• If:The coils are correct. Fig. 96 (28331)

– Then continue to Step 3.

Event Code 586
BRK INNER COIL HAS A SHORT CIRCUIT
Step 1: Turn off the lift truck. Disconnect CA407. With
the coils at room temperature, measure the resistance

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Event Code 587

between CA407-2 and CA407-3 on the BRK inner coil • If:FU6 is correct.
side. – Then continue to Step 2.
 The correct resistance of the BRK inner coil =
Step 2: Turn on the lift truck. Measure the voltage be-
3.5 Ω.
tween Access 5 CA403-7 and the battery negative ter-
• If:The resistance < 3.5 Ω. minal on Access 5.
– Then replace the BRK inner coil.  The correct voltage = 36 V.
• If:The resistance = 3.5 Ω and Event Code 586 con- • If:The voltage < 36 V.
tinues. – Then turn off the lift truck. Check the condition of
– Then replace Access 5. the wires between power unit distribution panel
CA206-4 and ED2, and power unit distribution
panel CA202-2 and Access 5 CA403-7. Make the
CA407 necessary repairs or replacements.
1
BLU I+
2
BRK
3 POWER UNIT
YEL I- ACCESS 5
4 DISTRIBUTION
PANEL
Fig. 97 (28331)

FU6
CA202 CA403
Event Code 587 +BV_ED2 2
B+ BRAKE
7 FEED INNER
B-

BRK OUTER COIL HAS A SHORT CIRCUIT

CA206
Step 1: Turn off the lift truck. Disconnect CA407. With +BV_ED2 4
the coils at room temperature, measure the resistance
between CA407-1 and CA407-4 on the BRK outer coil
side.
ACCESS 3
 The correct resistance of the BRK outer coil =
1.5 Ω.
• If:The resistance < 1.5 Ω.
– Then replace the BRK outer coil.
• If:The resistance = 1.5 Ω and Event Code 587 con- BNEG
B+ + B-
tinues.
– Then replace Access 5.

CA407
WHT 0+ ED2
1
2
BRK
3 Fig. 99 (28333)
4
ORG 0-

Fig. 98 (28332) Event Code 589

BRK OUTER COIL HAS AN OPEN CIRCUIT
Event Code 588 Step 1: Turn off the lift truck. Check FU5 on the
power unit distribution panel for an open circuit.
BRK INNER COIL HAS AN OPEN CIRCUIT
• If:FU5 has an open circuit.
Step 1: Turn off the lift truck. Check FU6 on the
power unit distribution panel for an open circuit. – Then replace FU5.
• If:FU6 has an open circuit. • If:FU5 is correct.
– Then replace FU6. – Then continue to Step 2.

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Event Code 590

Step 2: Turn on the lift truck. Measure the voltage be- • If:The results of Step 1 and Step 2 are not a short
tween Access 5 CA403-9 and the battery negative ter- circuit or an open circuit.
minal on Access 5. – Then replace Access 5.
 The correct voltage = 36 V.
• If:The voltage < 36 V.
– Then turn off the lift truck. Check the condition of Event Code 592
the wires between power unit distribution panel
CA206-4 and ED2, and power unit distribution BRK DRIVER HAS A SHORT CIRCUIT
panel CA202-1 and Access 5 CA403-9. Make the Event Code 592 and 593
necessary repairs or replacements. Event Code 592: BRK INNER COIL HIGH SIDE
DRIVER HAS A SHORT CIRCUIT
Event Code 593: BRK OUTER COIL HIGH SIDE
POWER UNIT ACCESS 5 DRIVER HAS A SHORT CIRCUIT
DISTRIBUTION
PANEL Step 1: See the procedures for Event Code 583 or
Event Code 585.
FU5 • If:The result of Step 1 is not low BRK inner coil or
CA202 CA403 BRK outer coil resistance.
B-
B+ BRAKE
+BV_ED2 1 9 FEED OUTER
– Then replace Access 5.
CA206
+BV_ED2 4
Event Code 600
INVALID EVENT CODE FROM ACCESS 6 - NOT
ACCESS 3
USED
The event code is not specified in the lift truck code.
Consult the factory.

BNEG
B+ + B- Event Code 601
ACCESS 1 CAN EVENT WITH ACCESS 6
Step 1: See the procedures for Event Code 106.

ED2
Event Code 603
Fig. 100 (28334) Access 3™ CAN EVENT WITH ACCESS 6
Step 1: See the procedures for Event Code 306.

Event Code 590

BRK DRIVER EVENT Event Code 604
Event Code 590 and 591 ACCESS 4 CAN EVENT WITH ACCESS 6
Event Code 590: BRK INNER COIL DRIVER EVENT Step 1: Turn on the lift truck. Check the source of
Event Code 591: BRK OUTER COIL DRIVER EVENT Event Code 604.
Step 1: See the procedures for Event Code 588 or • If:Access 6 shows Event Code 604, but Access 1
Event Code 589. does not.
Step 2: See the procedures for Event Code 586 or – Then turn off the lift truck. Check the condition of
Event Code 587. the connections and the wires between power
unit distribution panel CA204-3 and Access 6

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Event Code 605

CA601-4, and power unit distribution panel

CA204-9 and Access 6 CA601-5. Make the nec-
essary repairs or replacements. Event Code 606
• If:Access 1 shows Event Code 604.
ACCESS 6 CAN EVENT
– Then continue to Step 2.
Step 1: Turn off the lift truck. Then turn the lift truck on
Step 2: Turn on the lift truck. Check the Access 4 again.
power lamps.
• If:Event Code 606 continues.
• If:The Access 4 power lamps are on.
– Then replace Access 6.
– Then turn off the lift truck. Check the condition of
the connections and the wires between platform
distribution panel CA105-7 and Access 4
CA303-8, and platform distribution panel
Event Code 611
CA105-1 and Access 4 CA303-7. Make the nec- ACCESS 6 INTERNAL EVENT
essary repairs or replacements.
Event Code 611 and 612
• If:The Access 4 power lamps are off.
Step 1: Replace Access 6.
– Then check the condition of the connections and
the wires between platform distribution panel
CA103-12 and Access 4 CA304-1. Make the
necessary repairs or replacements.
Event Code 621
ACCESS 6 INTERNAL EVENT
Event Code 621 through 628
ACCESS 4 PLATFORM
DISTRIBUTION
Step 1: Replace Access 6.
PANEL

CA303
CAN H 7
CA105
1 CAN H
Event Code 631
CAN L 8 7 CAN L WIRE GUIDANCE SENSOR (GS1 OR GS2) AMPLI-
FIER SELF TEST
CA304 CA103
Step 1: Replace Access 6.
PWR 1 12 +BV KYS

POWER UNIT
Event Code 632
ACCESS 6
DISTRIBUTION
PANEL GS2 EVENT
Note: Event Code 632 could occur if the F14 Wire
Guidance menu is set to Enable and GS2 is not on the
CA204
lift truck.
CAN H 3 CA601
Step 1: Turn on the lift truck. Measure the voltage be-
tween Access 6 CA602-22 and the battery negative
4 CAN H
terminal on Access 6.
5 CAN L
 The correct voltage = 5 V.
CAN L 9
• If:The voltage = 5 V.
– Then GS2 is correct. Continue to Step 4.
Fig. 101 (28335) • If:The voltage = 0 V.
– Then continue to Step 2.
Step 2: Turn off the lift truck. Disconnect the wire
Event Code 605 from Access 6 CA602-15. Turn on the lift truck. Mea-
sure the voltage between Access 6 CA602-22 and the
ACCESS 5 CAN EVENT WITH ACCESS 6
battery negative terminal on Access 6.
Step 1: See the procedures for Event Code 506.

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Event Code 633

• If:The voltage = 5 V.
– Then make the necessary repairs or replace- GS1
ments to the wires between GS1 and Access 6.
• If:The voltage = 0 V. CA603

– Then continue to Step 3. +5 V 5

Step 3: Turn off the lift truck. Disconnect the wire

from Access 6 CA602-22. Turn on the lift truck. Mea-
sure the voltage between Access 6 CA602-22 and the
ACCESS 6
battery negative terminal on Access 6.
• If:The voltage = 5 V.
– Then make the necessary repairs or replace- CA602
ments to the wires between GS2 and Access 6. 15 +5 V
• If:The voltage = 0 V.
GS2
– Then replace Access 6.
Step 4: Keep the lift truck turned on. When operating CA604
22 +5 V
the lift truck slowly over the guide wire, use Analyzer +5 V 5
Menu/A2.6.2.1 Raw to show the values. B-
 The values must increase and decrease as the
lift truck goes above the guide wire.
• If:The four coils in GS2 do not sense the guide wire.
– Then turn off the lift truck. Check the condition of
the wires to the applicable coil. Make the neces-
sary repairs or replacements.
• If:The wires are correct. Fig. 102 (28336)
– Then replace GS2.
• If:Event Code 632 continues.
Event Code 633
– Then replace Access 6.
GS1 EVENT
Note: Event Code 633 could occur if the F14 Wire
Guidance menu is set to Enable and GS1 is not on the
lift truck.
Step 1: Turn on the lift truck. Measure the voltage be-
tween Access 6 CA602-15 and the battery negative
terminal on Access 6.
 The correct voltage = 5 V.
• If:The voltage = 5 V.
– Then GS1 is correct. Continue to Step 4.
• If:The voltage = 0 V.
– Then continue to Step 2.
Step 2: Turn off the lift truck. Disconnect the wire
from Access 6 CA602-15. Turn on the lift truck. Mea-
sure the voltage between Access 6 CA602-22 and the
battery negative terminal on Access 6.
• If:The voltage = 5 V.
– Then make the necessary repairs or replace-
ments to the wires between GS1 and Access 6.
• If:The voltage = 0 V.

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Event Code 636

– Then continue to Step 3.

Step 3: Turn off the lift truck. Disconnect the wire
from Access 6 CA602-22. Turn on the lift truck. Mea- Event Code 636
sure the voltage between Access 6 CA602-22 and the
battery negative terminal on Access 6. LOSS OF WIRE GUIDANCE SIGNAL WHILE
TRACKING
• If:The voltage = 5 V.
Note: Event Code 636 could occur if the lift truck goes
– Then make the necessary repairs or replace- off the guide wire during automatic steering.
ments to the wires between GS2 and Access 6.
Step 1: Turn on the lift truck. If Event Code 636 oc-
• If:The voltage = 0 V. curs when the lift truck goes off the guide wire during
– Then replace Access 6. automatic steering, the lift truck status is correct.
Step 4: Keep the lift truck turned on. When operating • If:Event Code 632 or Event Code 633 occurs.
the lift truck slowly over the guide wire, use Analyzer – Then see the procedures for Event Code 632 or
Menu/A2.6.1.1 Raw to show the values. Event Code 633.
 The values must increase and decrease as the
lift truck goes above the guide wire. • If:Event Code 636 occurs when the lift truck is on
the guide wire during automatic steering.
• If:The four coils in GS1 do not sense the guide wire.
– Then continue to Step 2.
– Then turn off the lift truck. Check the condition of
the wires to the applicable coil. Make the neces- Step 2: Turn off the lift truck. Check the condition of
sary repairs or replacements. GS1 and GS2.
• If:The wires are correct. • If:GS1 or GS2 is damaged.
– Then replace GS1. – Then make the necessary repairs or replace-
ments.
• If:Event Code 633 continues.
• If:GS1 and GS2 are correct.
– Then replace Access 6.
– Then continue to Step 3.
Step 3: Turn on the lift truck. Do the C4 Steer En-
GS1 coder and the C5 Wire Guidance calibrations.
• If:Event Code 636 does not occur because of align-
CA603 ment or calibration.
+5 V 5
– Then use the Crown Field Strength Meter to
check the field strength of the guide wire.
 The correct field strength for 5.2 kHz and 7 kHz
= 100–118 mA.
ACCESS 6  The correct field strength for 6.25 kHz and
10 kHz = 168–190 mA.
• If:The field strength is correct and Event Code 636
CA602
continues.
15 +5 V
– Then check the floor surface. Make any neces-
GS2 sary repairs or replacements.
Note: These could effect the wire guidance perfor-
CA604 mance:
22 +5 V
+5 V 5
• Floor surface defects
B-
• A bad signal
• Metal pipes
• Electrical wires below the floor surface in a metal or
a plastic pipe

Fig. 103 (28336)

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Event Code 637

• If:Event Code 638 occurs.

– Then turn off the lift truck. Check the condition of
Event Code 637 the wires between GS2 CA604-1 and Access 6
CA602-27, GS2 CA604-2 and Access 6 CA602-
LOSS OF WIRE GUIDANCE SIGNAL AT GS1 AND 26, GS2 CA604-7 and Access 6 CA602-25, and
GS2 GS2 CA604-8 and Access 6 CA602-24. Make
Step 1: Turn on the lift truck. Check for Event Code the necessary repairs or replacements.
632 or Event Code 633. • If:Event Code 638 does not occur.
• If:Event Code 632 or Event Code 633 occurs. – Then continue to Step 3.
– Then see the procedures for Event Code 632 or Step 3: Turn on the lift truck. Check for Event Code
Event Code 633. 639.
• If:Event Code 632 and Event Code 633 do not oc- • If:Event Code 639 occurs.
cur.
– Then turn off the lift truck. Check the condition of
– Then continue to Step 2. the wires between GS1 CA603-1 and Access 6
Step 2: Use the Crown Field Strength Meter to check CA602-20, GS1 CA603-2 and Access 6
the line driver output. CA602-19, GS1 CA603-7 and Access 6
• If:The line driver output is incorrect. CA602-18, and GS1 CA603-8 and Access 6
– Then adjust the line driver output. See ELECTRI- CA602-17. Make the necessary repairs or re-
CAL SYSTEM / Wire Guidance / Adjust the line placements.
driver output. • If:Event Code 639 does not occur.
• If:The line driver output is correct. – Then continue to Step 4.
– Then check the condition of the guide wire. Make Step 4: Turn on the lift truck. Check for Event Code
the necessary repairs or replacements. 638 or Event Code 639.
• If:Event Code 638 or Event Code 639 occurs.
– Then replace GS1 or GS2.
Event Code 638 • If:Event Code 638 or Event Code 639 occurs after
LOSS OF WIRE GUIDANCE SIGNAL AT GS1 AND replacing GS1 or GS2.
GS2 COILS WHILE TRACKING – Then replace Access 6.
Event Code 638 and 639
Event Code 638: LOSS OF WIRE GUIDANCE
SIGNAL AT GS2 COIL WHILE TRACKING
Event Code 639: LOSS OF WIRE GUIDANCE
SIGNAL AT GS1 COIL WHILE TRACKING
Step 1: Turn on the lift truck. Check for Event Code
632 or Event Code 633.
• If:Event Code 632 or Event Code 633 occurs.
– Then see the procedures for Event Code 632 or
Event Code 633.
• If:Event Code 632 and Event Code 633 do not oc-
cur.
– Then continue to Step 2.
Step 2: Keep the lift truck turned on. Check for Event
Code 638.

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Event Code 652

• If:The input = 0.
CA603
– Then check the EACA1, EACA2, EACB1, and
EACB2 wires and connections. Make the neces-
COIL 4 1
sary repairs or replacements.
COIL 3 2
ACCESS 6 • If:The input = 1.
– Then replace the end aisle control sensor that
GS1 matches the event code.
CA602
• If:Event Code 652, 653, 654, 655, 656, 657, 658, or
17 COIL 4
659 continues.
COIL 2 7 18 COIL 3
– Then replace Access 6.
COIL 1 8 19 COIL 2
20 COIL 1
EAC SENSOR B1 A1 EAC SENSOR
5 5
CA605 CA606
ACCESS 6
CA604 CA608
24 COIL 4
COIL 1 1 1 CA602
25 COIL 3
COIL 2 2 2 1 EAC SENSORS +12 V
26 COIL 2
CA607 2 EAC SENSORS B-
27 COIL 1
GS2 1 3 EACA1 TEST
2 4 EACA1 ANALOG
3 5 EACA1 DIGITAL
4 6 EACA2 TEST
COIL 3 7
EAC 5 7 EACA2 ANALOG
COIL 4 8
6 8 EACA2 DIGITAL
7 9 EACB1 TEST
Fig. 104 (28337)
8 10 EACB1 ANALOG
9 11 EACB1 DIGITAL

Event Code 652 10

11
12 EACB2 TEST
13 EACB2 ANALOG
END AISLE CONTROL SENSOR SIGNAL IS TOO 12 14 EACB2 DIGITAL
HIGH OR TOO LOW
CA610 CA609
Event Code 652 through 659 5 5
EAC SENSOR B2 A2 EAC SENSOR
Event Code 652: EACA1 SIGNAL IS TOO HIGH
Fig. 105 (28180)
Event Code 653: EACA1 SIGNAL IS TOO LOW
Event Code 654: EACB1 SIGNAL IS TOO HIGH
Event Code 655: EACB1 SIGNAL IS TOO LOW Event Code 660
Event Code 656: EACA2 SIGNAL IS TOO HIGH
END AISLE CONTROL SENSOR DIGITAL SIGNAL
Event Code 657: EACA2 SIGNAL IS TOO LOW EVENT
Event Code 658: EACB2 SIGNAL IS TOO HIGH Event Code 660 through 663
Event Code 659: EACB2 SIGNAL IS TOO LOW Event Code 660: EACA1 DIGITAL SIGNAL EVENT
Step 1: Turn on the lift truck. Use Analyzer Menu/ Event Code 661: EACB1 DIGITAL SIGNAL EVENT
A2.6.3 EACA1, A2.6.4 EACA2, A2.6.5
Event Code 662: EACA2 DIGITAL SIGNAL EVENT
EACB1, and A2.6.6 EACB2 to check the end
Event Code 663: EACB2 DIGITAL SIGNAL EVENT
aisle control sensor inputs when the lift truck
Step 1: See the procedures for Event Code 652
travels over the magnets.
through 659.
 The inputs change from 0 to 1.

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Event Code 664

EAC SENSOR B1 A1 EAC SENSOR

Event Code 664 5 5
CA605 CA606
EAC MAGNET FIELD STRENGTH IS TOO LOW
Event Code 664 through 667
Step 1: Check the magnet locations for the incorrect
installation or damage (for example, the incor- EAC

rect pole, the position alignment, and a floor

crack through the magnet). Make the neces-
sary repairs or replacements.
CA610 CA609
5 5
EAC SENSOR B2 A2 EAC SENSOR
Event Code 668 Fig. 106 (28330)
END AISLE CONTROL SENSOR SELF TEST EVENT
Event Code 668 through 671
Event Code 668: EACA1 SELF TEST EVENT
Event Code 669: EACB1 SELF TEST EVENT
Event Code 670: EACA2 SELF TEST EVENT
Event Code 671: EACB2 SELF TEST EVENT
Step 1: Turn off the lift truck. Check the condition of
the connections and the wires to EACA1,
EACB1, EACA2, and EACB2.
• If:The connections or the wires are damaged.
– Then make the necessary repairs or replace-
ments.
• If:The connections and the wires are correct and
Event Codes 668, 669, 670, or 671 continue.
– Then continue to Step 2.
Step 2: Keep the lift truck turned off. Replace the end
aisle control sensor in relation to the event code.
• If:Event Codes 668, 669, 670, or 671 continue.
– Then replace Access 6.

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Event Code 672

EAC SENSOR B1 A1 EAC SENSOR

Event Code 672 5 5
CA605 CA606
ACCESS 6
MANY END AISLE CONTROL SENSORS ARE AC-
TIVE
Step 1: Turn off the lift truck. Check the condition of CA607 CA602
EACA1, EACB1, EACA2, and EACB2. 3 5 A1 DIGITAL
• If:EACA1, EACB1, EACA2, or EACB2 are dam-
aged. EAC 6 8 A2 DIGITAL

– Then make the necessary repairs or replace-

ments. 9 11 B1 DIGITAL
• If:EACA1, EACB1, EACA2, and EACB2 are cor-
rect. 12 14 B2 DIGITAL

– Then continue to Step 2. CA610 CA609

5 5
Step 2: Turn on the lift truck. Operate the lift truck out EAC SENSOR B2 A2 EAC SENSOR
of the end of an aisle. Measure the voltage between
Fig. 107 (28338)
Access 6 CA602-5, Access 6 CA602-8, Access 6
CA602-11, and Access 6 CA602-14 and the battery
negative terminal on Access 6.
 The correct voltage = 5 V.
• If:The voltage < 1 V.
– Then turn off the lift truck. Disconnect the wire
from Access 6 CA602-5, Access 6 CA602-8,
Access 6 CA602-11, or Access 6 CA602-14.
Turn on the lift truck. Measure the voltage at the
pin on Access 6 CA602 from which the wire was
disconnected.
• If:The voltage < 1 V.
– Then replace Access 6.
• If:The voltage > 3.5 V.
– Then continue to Step 3.
Step 3: Keep the lift truck turned on. Measure the
voltage at EAC distribution panel CA607-3, EAC distri-
bution panel CA607-6, EAC distribution panel CA607-
9, or EAC distribution panel CA607-12.
• If:The voltage = 0 V.
– Then replace EACA1, EACB1, EACA2, or
EACB2.
• If:The voltage > 5 V.
– Then replace Access 6.

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