Handset

CONTROLLER TROUBLESHOOTING
The System Controller runs diagnostic tests on the integrity HANDSET TROUBLESHOOTING AIDS
of its internal controls and may recognize when a problem
with external circuitry exists. When diagnosing a problem, • Plug handset into connector CA402 on controller.
the controller sounds appropriate alarms, inhibits proper
vehicle functions and displays a service code number. When Bus Bar Connections
the service code number is located in the following pages, for Power Circuitry
the possible causes direct the service technician to the
suspected problem area.
• Service Code Numbers can be retrieved through a BDI
CA401 CA402 ML- B- MR-
light code on the display panel or with the use of a 20 11 4 3 ML+ B+ MR+
handset. Both methods are explained later.
• 31 fault service history recorded and stored by the 10 1 21
controller chronologically from last to first. Retrieved
through use of handset only. Vehicle is not disabled Control Wiring Service Terminal
during access to service history. 6094 Connects to CA401 Connects to CA402
• Handset provides the ability to check inputs to the
controller from sensing switches and operator input
controls. TEST
• Handset provides the ability to check outputs from the
controller to vehicle mounted devices.
DISPLAY TROUBLESHOOTING INDICATORS DIAGNOSTICS

• Wrench light blinks when a service required condition
exists on the vehicle.
• BDI display changes from indicating battery state of
charge to service code indicator whenever improper PROGRAM TEST DIAGNOSTICS
sequence of operator controls is realized and when

service required condition exists.
• Translating BDI indication to a service code number SCROLL
DISPLAY
CHANGE
VALUE
involves adding the place value of each illuminated

segment.
Example: MORE INFO
CURTIS PMC
Segment Place Value A DIVISION OF CURTIS INSTRUMENTS INC
128 64 32 16 8 4 2 1
2620-01
• Press the diagnostics key on keypad.

• Service code occuring most recently is displayed.
• Scroll display keys can be used to view service codes
previous to current code in chronological order. Could
assist in evaluating cause of current code.
• Use test key to monitor switch inputs to controller and
outputs from controller if suspected as cause.
Wrench Light
Display is showing service code (16+4=20) 20

6109
M4.2–2350–400
® 971126 L2
Crown 1997 PF11202-1 Rev. 3/01 04 REV. 3/01
SERVICE CODES
The service codes listed in the following pages, are arranged

for ease of locating information needed.
• Display information provides what is present on the
display of the vehicle.
• Handset information provides what is viewed on the
handset.
• Vehicle information provides alarm status and vehicle
status.
• Code information provides the explanation of the code
and a list of possible causes.
When troubleshooting a problem remember the ability of the

handset to look at the inputs and outputs of the controller by
using the test mode on the handset. May greatly decrease
downtime by isolating a problem to input or output circuitry.
• Without proper inputs, specific outputs are not possible.
• An output present but no action would indicate a
problem with wiring or component.
M4.2–2350–401
®
Crown 1997 PF11202-2 Rev. 3/01 04 REV. 3/01
Service Code 1
DISPLAY INFORMATION: BDI Light Code:
BDI Display: Always blinking
Wrench Light: Off HANDSET INFORMATION
Message: CODE INPUT
VEHICLE INFORMATION: Alarm: One quick beep

Effect on Vehicle: Disabled
CODE INFORMATION
Explanation: Drive code enabled
Possible Cause
- No drive code input
- Wrong drive code input
Service Code 2

BDI Display: Blinking three seconds
Message: THERMAL WARNING
VEHICLE INFORMATION: Alarm: Two quick beeps

Effect on Vehicle: –
CODE INFORMATION
Explanation: Overtemperature controller, heatsink temperature @ 70°C during operation
Possible Cause
- Controller dirty
- Poor controller to chassis thermal conduction
- Current limit set too high
M4.2–2350–402
®
Crown 1997 PF11202-3 Rev. 3/01 04 REV. 3/01
Service Code 3
Message: MOTOR COVER WARNING
VEHICLE INFORMATION: Alarm: Repeatedly one beep

Effect on Vehicle: – Traction and lower inhibited
CODE INFORMATION
Explanation: Motor cover is depressed. After fault is cleared, traciton control must be returned to netural before traction
can be resumed and lower is enabled 4 seconds after fault is cleared.
Possible Cause
- Weight on motor cover
- Broken wire
- Switch open circuit
Service Code 5
BDI Display: Always blinking
Message: – No Known Faults
VEHICLE INFORMATION: Alarm: Three quick beeps repeating

Effect on Vehicle: – No lift possible
CODE INFORMATION
Explanation: Tilt fault has been received
Possible Cause
- Vehicle on too high a grade and Lift Height is greater than 20" with gates closed
M4.2–2350–403
®
Crown 1997 PF11202-4 Rev. 3/01 04 REV. 3/01
Service Code 6

Message: – No Known Faults
VEHICLE INFORMATION: Alarm: Three quick beeps

Effect on Vehicle: – Toggles Drive mode from "Out of Rail" to "In Rail"
CODE INFORMATION
Explanation: Guided rail aisle has been entered or exited
Possible Cause
- Rail guidance switches actuated or deactuated
Service Code 7
Message: SRO
VEHICLE INFORMATION: Alarm: One quick beep

Effect on Vehicle: – No travel allowed
CODE INFORMATION
Explanation: Static return to off (SRO) during operation
Possible Cause
- Attempted to move vehicle with out hands and feet in place
- Open ED-B contact or related circuit wiring
M4.2–2350–404
®
Crown 1997 PF11202-5 Rev. 3/01 04 REV. 3/01
Service Code 8

BDI Display:
Message: FRAM WARNING
VEHICLE INFORMATION: Alarm: Two quick beeps

Effect on Vehicle: – None
CODE INFORMATION
Explanation: Noncritical F-RAM read/write failure in controller

F-Ram warning is stored, but not displayed
Possible Cause
- Software failure
Service Code 16
BDI Display: Blinking
Wrench Light: Blinking HANDSET INFORMATION
Message: OVERVOLTAGE
VEHICLE INFORMATION: Alarm: Repeatedly two quick beeps

Effect on Vehicle: Fast stop with shutdown, or no startup
CODE INFORMATION
Explanation: Overvoltage on battery
Possible Cause
- Overvoltage during operation or at startup > 32.4 volt
- Battery condition is bad and charger connected
- Incorrect Batteries or Battery configuration
M4.2–2350–405
®
Crown 1997 PF11202-6 Rev. 3/01 04 REV. 3/01
Service Code 17

Message: THERMAL HIGH

Effect on Vehicle: Normal stop with shutdown
CODE INFORMATION
Explanation: Temperature limit on heatsink exceeded
Possible Cause
- Overtemperature > 80°C during operation - Excessive load on vehicle
- Overtemperature > 70°C at startup - Improper mounting of controller
Service Code 18
Message: INHIBIT

CODE INFORMATION
Explanation: Function inhibited when chager connected
Possible Cause
- Charger connected
- Wire to INHIBIT pin of controller is open
- Charger unit defective
M4.2–2350–406
®
Crown 1997 PF11202-7 Rev. 3/01 04 REV. 3/01
Service Code 19

Message: SRO

Effect on Vehicle: – Shall not power up
CODE INFORMATION
Explanation: Static return to off
Possible Cause
- Pots are not in neutral position at startup - Pots are out of deadband; recalibrate pots
- Presence of right or left hand is sensed at startup - Defective or miswired presence sensors
Service Code 20
Message: BRAKE DRIVER OC

Effect on Vehicle: Fast stop with shut down
CODE INFORMATION
Explanation: Brake driver overcurrent during operation while brakes energized.
Possible Cause
- Too much load connected to the brake output; 2A limit is exceeded
- Brake output shorted to battery negative
M4.2–2350–407
®
Crown 1997 PF11202-8 Rev. 3/01 04 REV. 3/01
Service Code 21

Message: GATE

Effect on Vehicle: Fast stop with shutdown
CODE INFORMATION
Explanation: Gate position fault
Possible Cause
- Switches on the gate are not working properly
- GATES OPEN or GATES CLOSED input shorted to battery negative
Service Code 23
Message: LOW BATTERY VOLTAGE

CODE INFORMATION
Explanation: Low battery voltage. When Code 23 is logged, BDI automatically resets to 19%. If this causes the BDI
indication to drop, check setting of Battery Rate in the Controller Settings section of manual.
Possible Cause
- Battery voltage is below 18V at startup
- Battery voltage is below 15.5V during operation
- Battery charge available has reached 5%
M4.2–2350–408
®
Crown 1997 PF11202-9 Rev. 3/01 04 REV. 3/01
Service Code 24

Message: LEFT MOTOR OPEN

Effect on Vehicle: Shall not Power Up
CODE INFORMATION
Explanation: Left motor open circuit at Power Up
Possible Cause
- Wiring to the left motor is open
- Left motor is defective
Service Code 25
Message: RIGHT MOTOR OPEN

Effect on Vehicle: Shall not Power Up
CODE INFORMATION
Explanation: Right motor open circuit at Power Up
Possible Cause
- Wiring to the right motor is open
- Right motor is defective
M4.2–2350–409
®
Crown 1997 PF11202-10 Rev. 3/01 04 REV. 3/01
Service Code 26

Message: C/L

CODE INFORMATION
Explanation: Motor current limiting fault
Possible Cause
- Excessive load on vehicle
- Motor shorted
- Controller failure (if it occurs frequently)
Service Code 27
Message: HARDWARE FAILSAFE 1

CODE INFORMATION
Explanation: Controller hardware failure
Possible Cause
- Controller failure
M4.2–2350–410
®
Crown 1997 PF11202-11 Rev. 3/01 04 REV. 3/01
Service Code 28

Message: CONFIG LOST

CODE INFORMATION
Explanation: Configuration parameters are corrupted
Possible Cause
- Controller failure (if not cleared after executing FACTORY VALUES)
Service Code 29
Message: MAIN CONT FAULT

Effect on Vehicle: – Shall not Power Up
CODE INFORMATION
Explanation: Main contactor fault (ED contactor fault)
Possible Cause
- Battery positive wire is open on controller busbar X4 - Fu2 Blown
- Main contactor (ED contactor) is not closing
- Main contactor (ED contactor) is welded
- ED COIL output of controller open or shorted to battery negative or battery positive
M4.2–2350–411
®
Crown 1997 PF11202-12 Rev. 3/01 04 REV. 3/01
Service Code 30

Message: CURRENT MEASURE

Effect on Vehicle: – Shut Down
CODE INFORMATION
Explanation: Current measurement circuit is out of range
Possible Cause
- Controller Failure
Service Code 31
Message: HARDWARE FAILSAFE 2

Effect on Vehicle: Normal stop with Shutdown
CODE INFORMATION
Explanation: Hardware failure
Possible Cause
- Communications or controller board failure
- Poor correction at CA401
M4.2–2350–412
®
Crown 1997 PF11202-13 Rev. 3/01 04 REV. 3/01
Service Code 32
BDI Display:
Message: MOTOR STALL

Effect on Vehicle: Shutdown
CODE INFORMATION
Explanation: Both motors stalled for 15 seconds
Possible Cause
- Obstruction
Service Code 34

Message: FRAM FAULT

CODE INFORMATION
Explanation: Data in the nonvolatile parameter store is corrupted
Possible Cause
M4.2–2350–413
®
Crown 1997 PF11202-14 Rev. 3/01 04 REV. 3/01
Service Code 35
Message: SFW

CODE INFORMATION
Explanation: Controller software failure
Possible Cause
- Controller (software) failure. Try to restart (power up) again
Service Code 36

Message: MAIN CONT DRVR

Effect on Vehicle: – Shall not Power-up
CODE INFORMATION
Explanation: Main contactor driver
Possible Cause
- Miswiring in ED Circuit
- Failed ED Contactor
M4.2–2350–414
®
Crown 1997 PF11202-15 Rev. 3/01 04 REV. 3/01
Service Code 37
Message: DRIVE THROTTLE

CODE INFORMATION
Explanation: Drive throttle fault
Possible Cause
- Traction pot is misadjusted; recalibration needed
- Open or shorted wire(s) on traction potentiometer
Service Code 38

Message: STEER THROTTLE

CODE INFORMATION
Explanation: Steer Throttle Fault
Possible Cause
- Steering potentiometer is misadjusted; recalibration needed
- Open or shorted wire(s) on steering potentiometer
M4.2–2350–415
®
Crown 1997 PF11202-16 Rev. 3/01 04 REV. 3/01
Service Code 39
Message: MOTOR SHORT

Effect on Vehicle: – Shutdown
CODE INFORMATION
Explanation: Motor short fault
Possible Cause
- Motor is shorted
- Busbar connections battery negative and battery positive on controller are wired backwards
- Open ED Contacts
- Shorted Lift Solenoid Contacts
Service Code 40

Message: LEFT POWER FAULT

Effect on Vehicle: – Shall not Power Up
CODE INFORMATION
Explanation: Left power fault at Power Up
Possible Cause
- One motor lead of left motor is shorted to battery positive
M4.2–2350–416
®
Crown 1997 PF11202-17 Rev. 3/01 04 REV. 3/01
Service Code 41
Message: RIGHT POWER FAULT

Effect on Vehicle: – Shall not Power up
CODE INFORMATION
Explanation: Right power fault at Power up
Possible Cause
- One motor lead of right motor is shorted to battery positive
Service Code 42

Message: PRESENCE SENSOR

CODE INFORMATION
Explanation: Left power fault
Possible Cause
- Too much daylight on the receiver of the left or right - Short circuit in receiver of the left or right presence
presence sensor sensor
- Open circuit in the wiring of the left or right LED's - Short circuit to battery positive on the receiver input
(emitter) of the left or right presence sensor
M4.2–2350–417
®
Crown 1997 PF11202-18 Rev. 3/01 04 REV. 3/01
Service Code 43, 44

or
BDI Display: Blinking HANDSET INFORMATION
Wrench Light: Blinking
Message: CAN
VEHICLE INFORMATION: Alarm: Repeatedly two quick beeps or repeatedly cracking

CODE INFORMATION
Explanation: communication fault
Possible Cause
- Open or short circuit on communication lines
- Short circuit to battery positive on communication lines
- Faulty Display or Controller
Service Code 45
Message: MOTOR SHORT

CODE INFORMATION
Explanation: Motor short fault
Possible Cause
- Short circuit from motor lead to motor lead
- Short circuit from motor lead to battery positive or battery negative
M4.2–2350–418
®
Crown 1997 PF11202-19 Rev. 3/01 04 REV. 3/01
Service Code 49
Message: THERMAL LOW

CODE INFORMATION
Explanation: Heatsink less than 10°F (-12°C) during operation or at power up
Possible Cause
- Trying to operate vehicle at a temperature below the cold temperature limit 10°F (-12°C)
Service Code 50

BDI Display: Blinking or static
Wrench Light: Blinking or static HANDSET INFORMATION
Message: BRAKE FAULT
VEHICLE INFORMATION: Alarm: Repeatedly two quick beeps or nothing

CODE INFORMATION
Explanation: Brake fault
Possible Cause
- Wiring of brake is open or shorted to battery positive
M4.2–2350–419
®
Crown 1997 PF11202-20 Rev. 3/01 04 REV. 3/01
Service Code 128

Message: – CAN
VEHICLE INFORMATION: Alarm: Repeatedly cracking

Effect on Vehicle: Fast stop with shutdown, or shall not Power up
CODE INFORMATION
Explanation: – No Watchdog Trigger Signal
Possible Cause
- Controller or Display Failure
Service Code 136

Message: – CAN

Effect on Vehicle: Fast stop with shutdown, or no Power up
CODE INFORMATION
Explanation: – No messages received
Possible Cause
- Unexpected failure of controller software. Try to restart (power up) again
- Display or controller Failure
M4.2–2350–420
®
Crown 1997 PF11202-21 Rev. 3/01 04 REV. 3/01
Service Code 160

Message: – CAN

CODE INFORMATION
Explanation: – Unexpected SFW interrupt
Possible Cause
- Unexpected failure of communication board software. Try to restart (power up) again
- Display or Controller Failure
Service Code 192

Message: – CAN

CODE INFORMATION
Explanation: –
Possible Cause
- Unexpected failure of controller software. Try to restart (power up) again
M4.2–2350–421
®
Crown 1997 PF11202-22 Rev. 3/01 04 REV. 3/01

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CONTROLLER TROUBLESHOOTING

DISPLAY TROUBLESHOOTING INDICATORS DIAGNOSTICS

sequence of operator controls is realized and when

involves adding the place value of each illuminated

Example: MORE INFO

• Press the diagnostics key on keypad.

Display is showing service code (16+4=20) 20

The service codes listed in the following pages, are arranged

When troubleshooting a problem remember the ability of the

Message: CODE INPUT

VEHICLE INFORMATION: Alarm: One quick beep

Explanation: Drive code enabled

- No drive code input

- Wrong drive code input

DISPLAY INFORMATION: BDI Light Code:

Message: THERMAL WARNING

VEHICLE INFORMATION: Alarm: Two quick beeps

Explanation: Overtemperature controller, heatsink temperature @ 70°C during operation

- Poor controller to chassis thermal conduction

- Current limit set too high

Message: MOTOR COVER WARNING

VEHICLE INFORMATION: Alarm: Repeatedly one beep

- Weight on motor cover

- Switch open circuit

Message: – No Known Faults

VEHICLE INFORMATION: Alarm: Three quick beeps repeating

Explanation: Tilt fault has been received

DISPLAY INFORMATION: BDI Light Code:

Message: – No Known Faults

VEHICLE INFORMATION: Alarm: Three quick beeps

Explanation: Guided rail aisle has been entered or exited

- Rail guidance switches actuated or deactuated

VEHICLE INFORMATION: Alarm: One quick beep

Explanation: Static return to off (SRO) during operation

- Attempted to move vehicle with out hands and feet in place

- Open ED-B contact or related circuit wiring

DISPLAY INFORMATION: BDI Light Code:

Message: FRAM WARNING

VEHICLE INFORMATION: Alarm: Two quick beeps

Explanation: Noncritical F-RAM read/write failure in controller

VEHICLE INFORMATION: Alarm: Repeatedly two quick beeps

Explanation: Overvoltage on battery

- Overvoltage during operation or at startup > 32.4 volt

- Battery condition is bad and charger connected

- Incorrect Batteries or Battery configuration

DISPLAY INFORMATION: BDI Light Code:

Message: THERMAL HIGH

VEHICLE INFORMATION: Alarm: Repeatedly two quick beeps

Explanation: Temperature limit on heatsink exceeded

- Overtemperature > 80°C during operation - Excessive load on vehicle

- Overtemperature > 70°C at startup - Improper mounting of controller

VEHICLE INFORMATION: Alarm: Repeatedly two quick beeps

Explanation: Function inhibited when chager connected

- Wire to INHIBIT pin of controller is open

- Charger unit defective

DISPLAY INFORMATION: BDI Light Code:

VEHICLE INFORMATION: Alarm: Repeatedly two quick beeps

Explanation: Static return to off

Message: BRAKE DRIVER OC