Troubleshooting

Troubleshooting using error code

T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

The first digit of the three-digit error code indicates the severity of the
error and how the truck is affected/responds when the error occurs.
.

Code Error category/action taken

number
n:0nn Caution. Generally an information code. No action to
be taken on the truck.
n:1nn Warning. Some functions may be disabled or
reduced. See the specific error code to see what
action has been taken.
n:2nn Error. All parts of the hydraulic system are disabled.
See the specific error code to see what action has
been taken.
n:3nn Error. The truck is braked by the motor and/or the
support arm brake and/or the parking brake until it
comes to a halt. It is not possible to drive. The steer-
ing may be disabled if there is a steering error. To
see what action has been taken, see the specific
error code.
n:4nn Error. The truck is braked by the motor brake until it
stops. Once the truck has stopped, or after 5 sec-
onds, the relays for the main power supply and key
are switched off.
n:5nn Critical error.
Main contactor and key relay opens.

The error codes are subdivided into smaller categories based on the
last two digits of the code (see below).

Error code, type of error

Code Description
number
n:n00–n09 Miscellaneous error codes.
n:n10–n19 CAN-related error codes.
n:n20–n39 Error codes related to specific units.
n:n40–n59 Error codes for short-circuited output data.
n:n60–n79 Error codes for output data from open electrical
circuits.
n:n80–n99 Faulty signals from sensors.

8 – 26 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

8.5.1 CID, warnings and errors

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1.003 Slight firmware version incompatibil- Update the truck software to the latest
ity. available version.
The firmware versions in the MCU and
CID do not match. The MCU does not
support some of the functions used by
the CID, or vice versa.
1.004 Incompatibility in the display Update the truck software to the latest
firmware. available version.
The firmware versions in the MCU and
CID do not match. The MCU does not
support some of the functions used by
the CID, or vice versa.
1.010 CAN 1 communication warning. 1. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
The CID CAN module has received too
contacts.
many error messages.
2. Disonnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect LID and
DHU.
1.120 LID sends an invalid status. Update the truck firmware to the latest
available version.
The LID is blocked.
1.121 No message received from the LID. 1. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
LID blocked.
contacts.
2. Disonnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect LID.
1:412 LID communication warning. 1. Verify that CAN 1 is complete with re-
gard to cabling, final resistor and ter-
The LID is blocked.
minals.
2. Disconnect the battery. Verify that the
resistor between [X41:3] and [X41:4]
provides 54 – 66 ohms.
3. Disable by changing parameter 1106
= 0 and disconnecting the LID

© BT Repair Manual RRE140/160/180/200/250 8 – 27

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
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1.431 External +5 V is outside the permit- 1. Disconnect the joysticks, buttons and
ted area. sensors connected to [X505:1] one at
a time and check if the error code dis-
appears.
2. Check the CID's internal wiring har-
ness.
3. Replace the CID.
1:500 Software error Update the truck's software to the latest
available version.
1.501 CID has detected an error in the Update the truck's software to the latest
MCU's program execution. available version.
1.503 Only one of the CID and the MCU is 1. Log off and make the truck without
in emergency driving mode. voltage for approx 1 minute.
2. Restart the truck and log in again.
1.504 The software for CID and MCU are 1. Update the software for CID, MCU and
not compatible. other units to the latest available ver-
Not possible to log in. sions.
2. Check that the software are compati-
ble.
1:507 CID and MCU firmware packages are Update the truck software to the latest
incompatible. available version.
The firmware versions in the MCU and
CID do not match. The MCU does not
support some of the functions used by
the CID, or vice versa.
1:508 LID and MCU firmware packages are Update the truck software to the latest
- incompatible. available version.
1:509
The firmware versions in the MCU and
LID do not match. The MCU does not
support some of the functions used by
the LID, or vice versa.
1.510 Communication error – CAN 1. 1. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
contacts.
2. Disonnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect LID, DHU
and collision sensor. Activate and then
connect them one by one to find out
which unit gives rise to the communi-
cation error.

8 – 28 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

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1.512 Communication disturbance – CAN 1. Check that CAN 1 is intact in terms of
1. wiring harness, final resistance and
contacts.
2. Disonnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect LID, DHU
and collision sensor. Activate and then
connect them one by one to find out
which unit gives rise to the communi-
cation error.
1.514 MCU or CID has not received a 1. Check that CAN 1 is intact in terms of
– response within 70 ms via CAN1. wiring harness, final resistance and
1.516 contacts.
2. Disonnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect LID, DHU
and collision sensor. Activate and then
connect them one by one to find out
which unit gives rise to the communi-
cation error.
1.520 Internal +5 V is outside the permitted Replace the CID.
area.
1.540 Key relay [K20] – Break in the control 1. Check that there is no break in the key
circuits relay's coil.
2. Check the contacts [X131] and [X504]
the relationship between [K20:A1] –
[X131:5] as well as [K20:A2] –
[X504:17].
3. Replace the CID [A1].
1.580 Key Relay [K20] – Contacts welded 1. Check the key relay's function and that
there is no relationship between
[K20:1] and [K20:2].
2. Check for the presence of a short cir-
cuit that may cause improper feeding
of [X504:7], e.g. from [X504:16],
[X504:17] and [X504:18].

© BT Repair Manual RRE140/160/180/200/250 8 – 29

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

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1.581 Key relay [K20] does not close Check if the CID's input [X504:7] switches
status when the key relay is used, CID's
diagnostic screen 2, pos 20:

If the input does not change status:

• Check that fuse [F74] is complete.
• Check the key relay's function and that
there is a relationship between [K20:1]
and [K20:2] when the relay is drawn.
• Check that conductor 26 from the key
relay to the fuse box and conductor 28
from the fuse box to the CID input
[X504: 7] are intact.
• Replace the CID.
If the input changes status:
• Update the CID's software.
• Replace the CID [A1].

8 – 30 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
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8.5.2 MCU and other warnings and errors

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2:002 The MCU is programmed using stand- Download or adjust the parameters to cor-
ard values for parameters. respond with the truck model and equip-
ment.
2:003 MCU memory error. 1. Backup the truck's parameters.
Backup data, hour meter and error log
2. Update to the latest software.
may be affected.
3. Check parameters and hour meter.
4. Copy the truck configuration from CID
to MCU.
2:004 Error in check sums of backup data. 1. If MCU or CID has been changed,
Normally shown after replacing MCU or copy the truck configuration from the
CID. MCU or CID unit which has not been
replaced to the new unit.
2. Backup the truck's parameters.
3. Update to the latest software.
4. Check parameters and hour meter.
2:005 Hour meter reading to service = 0. Carry out service reset the S counter
using TruckCom.
2:006 Full error log buffer. Shows that errors which would normally
No indication, logged only. be logged in the error log may have been
lost.
2:007 MCU internal memory full 1. Report the error to the manufacturer.
2. Restart the truck.
3. If the error remains, update the truck
firmware to the latest available ver-
sion.
2:008 Application time. Set when the application (20 ms) takes
No indication, logged only. longer than 17 ms.
1. Fix the error code generated in direct
relation with this error code.
2. Report the fault to the manufacturer.
2:009 Tick time. Set when tick time (1.25 ms) takes longer
No indication, logged only. than 1.10 ms.
1. Fix the error code generated in direct
relation with this error code.
2. Report the fault to the manufacturer.

© BT Repair Manual RRE140/160/180/200/250 8 – 31

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

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2:010 Communication disturbance – CAN 1. 1. If the CAN key is connected: Try using
MCU has received too many incorrect a CAN-key with a later production
telegrams. date.
2. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
contacts.
3. Disonnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
4. Deactivate and disconnect LID, DHU
and collision sensor. Activate and then
connect them one by one to find out
which unit gives rise to the communi-
cation error.
2:011 Communication disturbance – CAN2. 1. Check that CAN 2 is intact in terms of
MCU has received too many incorrect wiring harness, final resistance and
telegrams. contacts.
2. Disonnect the battery. Check that the
resistance between [X130:8] and
[X130:22] is 54 – 66 ohm.
3. Disconnect EPS, ACT and ACH. Then
connect them one by one to find out
which unit gives rise to the communi-
cation error.
2:101 Truck type incorrect. Use TruckCom to save the parameter val-
ues.
Factory parameters have not been
entered. If the MCU was replaced:
• Enter the truck's parameter list.
• Check parameter “1001 – Truck type”, if
it is incorrect all parameters must be
verified.
• Copy the Truck Configuration from the
CID to the MCU
2:102 Height pre-selection – Stop height 1. Lifting: Inspect/adjust parameters
error. 371, 373 and 375.
2. Lowering: Inspect the free-lowering
and main lowering valve calibration.
Inspect/adjust parameters 372, 374
and 376.
3. Adjust parameter 377

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 Troubleshooting
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2:103 Lifting height limiting. If the truck is equipped with height indica-
Lifting height limiting is activated and tion, activate this using factory parameter
height measurement is deactivated. 1009 = 1.
If the truck does not have height indica-
tion, deactivate the lifting height limiting
using parameter 1107 = 0.
2:104 Height pre-selection If the truck features height indication, ena-
ble this with factor parameter 1009 = 1
Height pre-selection is enabled and
height measurement is disabled If the truck does not feature height indica-
tion, disable height pre-selection with
parameter 1103 = 0
2:105 More than 80 % difference between Check parameter 113.
the MCU's measured power con- B-version: 280
sumption and the measure consump- E-version: 335
tion of the ACT/ACH (>2 sek @ >200
A).
No reduction/blocking of the truck's func-
tions.
2:106 Collision locking. If parameter 112 = 0: Use the special PIN
A collision value exceeding what has code to reset the collision sensor.
been input via parameters 110 and 111 If parameter 112 = 1: Restart the truck to
has been detected. teset the collision sensor.
The truck can only be driven at reduced
speed.
2:141 Digital output DO9 – short circuit. 1. Check that conductor X131:9, conduc-
tor 33, has not short circuited with con-
ductor 27.
2. Check that fan G3 has not short
circuited.
3. Check that cables and contacts are
undamaged.
4. Check output DO9 via the CID's diag-
nostic screen 5, pos 9:

© BT Repair Manual RRE140/160/180/200/250 8 – 33

 Troubleshooting
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T-code Valid from serial number Date Order number
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2:161 Digital output DO9 – break. 1. Check that there is no break in con-
ductor X131:9, conductor 33 and con-
ductor 27 leading to fan G3.
2. Check that cables and contacts are
undamaged.
3. Check output DO9 via the CID's diag-
nostic screen 5, pos 9:

2:180 No contact with the shock sensor. 1. If the truck is not equipped with a colli-
sion sensor, set parameter 110 = 0
and 111 = 0.
2. Check that cables and contacts are
undamaged.
3. Replace [B90]
2:401 Internal programme error 1. Report the error to the manufacturer.
2. Restart the truck.
3. If the error remains, update the truck
firmware to the latest available ver-
sion.
2:403 Permitted time for reading the ana- 1. Report the error to the manufacturer.
logue
2. Restart the truck.
signal exceeded.
3. If the error remains, update the truck
firmware to the latest available ver-
sion.
2:420 Battery voltage under 33.6 V. 1. Check the battery voltage.
2. Check that the battery cable is undam-
aged and free from oxidation.
3. Check that the voltage between
[X130:19] and [X130:32] corresponds
to the measured battery voltage.
4. Replace the MCU.

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 Troubleshooting
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2:421 Battery voltage over 72 V. 1. If the error code occurs in association
with strong motor braking directly after
charging: Log out/log in.
2. If the error code occurs during motor
braking during normal driving:
Check all power cabling between the
battery and transistor regulator for
breaks, poorly tightened screws/nuts
and oxidation.
2:431 +5 V for external sensors under +4.9 If the error code is shown at the same time
V. as error code 2:433, the troubleshooting
must begin with this.
1. Make sure that no short circuit or other
high load is present in the sensor [B4],
safety pedal or pedal unit for speed
and braking.
2. Check the wiring harness to the com-
ponents above.
3. Replace the MCU and check the func-
tion of the sensor [B4], safety pedal
and pedal unit for speed and braking.
2:432 +5 V for external sensors over +5.1 V. 1. Check that there is no short circuit
present in conductor 55 and any con-
ductor with higher voltage than 5 V,
e.g. battery voltage.
2. Check the function of
– Sensor [B4]
– Safety pedal
– Pedal unit for speed and brakes.
3. Replace the MCU.
2:433 +15 V for external sensors under +12 1. Check that there is no short circuit or
V. high load in sensors [B18] and [B19].
2. Check the wiring harness to the com-
ponents above.
3. replace the MCU and check the func-
tion of sensors [B18] and [B19].

© BT Repair Manual RRE140/160/180/200/250 8 – 35

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

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2:434 +15 V for external sensors over +16.5 1. Check that there is no short circuit
V. present in conductor 29 and any con-
ductor with higher voltage than 15 V,
e.g. battery voltage.
2. Check the function of sensors [B18]
and [B19].
3. Replace the MCU.
2:435 Internal +7.5 V under +7 V. Replace the MCU.
2:436 Internal +7.5 V over +8 V. Replace the MCU.
2:501 Check sum error, parameters 1. Restart the truck.
2. Replace the MCU.
2:502 Serious firmware error, MCU. 1. Report the error to the manufacturer.
2. Restart the truck.
3. If the error remains, update the truck
firmware to the latest available ver-
sion.
2:503 error in check sum, factory parame- 1. If MCU or CID has been changed,
ters. copy the truck configuration from the
Normally shown after replacing MCU or MCU or CID unit which has not been
CID. replaced to the new unit.
2. Backup the truck's parameters.
3. Update to the latest software.
4. Check factory parameters.
2:504 Only one of the CID and the MCU is in 1. Log off and make the truck without
emergency driving mode. voltage for approx 1 minute.
2. Restart the truck and log in again.
2:505 MCU has detected an error in the Update the truck's software to the latest
CID's program execution. available version.
2:507 Truck operation disabled. Contact the local representative of the
manufacturer, or the manufacturer
All functions are blocked.
directly, to reactivate the truck.

8 – 36 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
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2:510 Initialisation error – CAN 1. 1. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
contacts.
2. Disonnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
3. Deactivate, disconnect and reconnect
the units from CAN1 individually to find
the device giving rise to the initialisa-
tion error.
2:511 Initialisation error – CAN 2. 1. Check that CAN 2 is intact in terms of
wiring harness, final resistance and
contacts.
2. Disonnect the battery. Check that the
resistance between [X130:8] and
[X130:22] is 54 – 66 ohm.
3. Deactivate, disconnect and reconnect
the units from CAN2 individually to find
the device giving rise to the initialisa-
tion error.
2:512 Communication disturbance – CAN 1. 1. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
contacts.
2. Disonnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect LID, DHU
and collision sensor. Activate and then
connect them one by one to find out
which unit gives rise to the communi-
cation error.
2:513 Communication disturbance – CAN 2. 1. Check that CAN 2 is intact in terms of
wiring harness, final resistance and
contacts.
2. Disonnect the battery. Check that the
resistance between [X130:8] and
[X130:22] is 54 – 66 ohm.

© BT Repair Manual RRE140/160/180/200/250 8 – 37

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
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2:514 Login error – DHU. Check that parameter 503 corresponds to
the truck's equipment:
1. Check that it is possible to connect
TruckCom to the DHU.
If it is possible to connect them, check
the DHU's configuration.
2. Check that the DHU's green LED is lit.
If the LED is not lit: Check the DHU's
feed voltage: The battery voltage be-
tween [A82:1] and [A82:8].
If there is a battery voltage: Replace
the DHU.
3. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
contacts: Disonnect the battery. Check
that the resistance between [A82:2]
and [A82:3] is 54 – 66 ohm.
2:523 Discharge current over 800 A. Check parameter 113:
B-version: 280
E-version: 335

2:531 Internal +5 V under +4.9 V. Replace the MCU.

2:532 Internal +5 V over +5.5 V. Replace the MCU.
2:533 Internal +15 V under +14.25 V. Replace the MCU.
2:534 Internal +15 V over +15.75 V. Replace the MCU.
2:537 Internal feed supply for digital outputs Replace the MCU.
under 9.7 V.
2:538 Internal feed supply for digital outputs Replace the MCU.
over 12 V.
2:540 Short circuit in output for main con- 1. Check that the main contactor's coil
tactor [Q10]. has not short circuited.
2. Check that there is no short circuit in
connection [X131:7], cable 31.
3. Replace the MCU and check the main
contactor's function.
2:555 Valid time for startup exceeded. 1. Check that fuse [F73] is complete.
2. Check that the wiring harness and
contacts are intact and correctly at-
tached.

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 Troubleshooting
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2:556 Valid time for shut down exceeded. 1. Turn off the truck by disconnecting the
battery.
2. Restart the truck and log in.
2:560 Main contactor [Q10] output inter- 1. Verify that the main contactor coil is
rupted. not interrupted.
2. Verify that there is no interruption be-
tween terminal [Q10:A2] and [X131:7],
cable 31.
3. Verify that the battery voltage is
present between [Q10:A1] and B-.
If there is no battery voltage.
• Check that the emergency switch is
not depressed.
• Verify that the F60 fuse is not defec-
tive
4. Log in in the emergency travel mode
to reset the main contactor status.
5. Inspect the main contactor for correct
operation.
6. Replace the main contactor
7. Replace the MCU.
2:580 Main contactor [Q10] – Terminals 1. Inspect the main contactor for correct
welded operation and that there is no connec-
tion between [Q10:1] and [Q10:2].
2. Verify that there is no short-circuit that
could cause incorrect power supply to
[X131:5].
3. Log in in the emergency travel mode to
reset the main contactor status.
2:581 Main contactor [Q10] – Active, but not 1. Inspect the fuse [F71]
detected by MCU.
2. Inspect the main contactor for correct
operation and that there is connection
between [Q10:1] and [Q10:2].
3. Verify that there is no interruption in
conductor 8 between the main contac-
tor and the fuse panel as well as in
conductor 23 between the fuse panel
and [X131:15].
4. Log in in the emergency travel mode to
reset the main contactor status.

© BT Repair Manual RRE140/160/180/200/250 8 – 39

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2:582 Key relay input status is not the same 1. Inspect the fuse [F74]
between the MCU and CID 2. Verify that conductor 28 from the fuse
[F74] to the MCU input [X131:6] is in-
tact.
3. Verify that conductor 28 from the fuse
[F74] to the CID input [X504:7] is in-
tact.

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 Troubleshooting
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8.5.3 Drive system error

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3:080 Safety pedal actuated for more than Check input A6 via the CID diagnostic dis-
20 minutes. play 3, pos 6:

When the pedal is pressed down, the sig-

nal should be approx. 3.5 V and when
released the signal should be approx.
1.5 V.
If the signal does not change:
• Verify that the cabling and terminals are
intact.
• Replace the safety pedal [B31].
• Replace the MCU.
If the signal does change:
• Log out and disconnect the battery for
approx. 1 minute.
• Reconnect the battery, log in and check
whether the error indication has disap-
peared.
• Update the truck firmware to the latest
available version.
• Replace the MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 41

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3:081 Seat switch actuated for more than Check input DI12 via the CID diagnostic
20 minutes. display 4, pos 12:

When the seat is occupied, the signal

should be ‘1’ and when unoccupied it
should be ‘0’.
If the signal does not change:
• Verify that the cabling and terminals are
intact.
• Replace the seat switch [B49].
• Replace the MCU.
If the signal does change:
• Log out and disconnect the battery for
approx. 1 minute.
• Reconnect the battery, log in and check
whether the error indication has disap-
peared.
• Update the truck firmware to the latest
available version.
• Replace the MCU.
3:142 Short circuit in the left support arm 1. Check that the resistance of the brake
brake. coil [Q16] is between 44 and 52 ohm.
Max travel speed is limited to 9 km/h.
3:143 Short circuit in the right support arm 1. Check that the resistance of the brake
brake. coil [Q17] is between 44 and 52 ohm.
Max travel speed is limited to 9 km/h.
3:162 Break in the left support arm brake. 1. Check that the resistance of the brake
Max travel speed is limited to 9 km/h. coil [Q16] is between 44 and 52 ohm.
3:163 Break in the right support arm brake. 1. Check that the resistance of the brake
Max travel speed is limited to 9 km/h. coil [Q17] is between 44 and 52 ohm.

8 – 42 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
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Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
3:180 Safety pedal output voltage incorrect. Verify that the safety pedal output voltage
is within 1.5 V to 3.5 V. CID diagnostic dis-
play 3, pos 6:

If the output voltage is outside the lim-

its:
• Verify that the voltage is between 4.5 V
and 5.5 V between [B31:1] and [B31:3].
• Inspect [X130:31], conductor 84 for in-
terruptions, short-circuits or incorrect
power supply.
If the output voltage is within the limits,
but does not change when the pedal is
operated:
• Replace the pedal [B31].
• Update the truck firmware to the latest
available version.
• Replace the MCU.
3:300 Faulty reversing brake. 1. Check the battery charge status. If the
The truck is braked using the mechani- battery is fully charged when the motor
cal brake and driving is disabled. brakes strongly, this may be the cause
of the error.
2. Check the battery cables and their
connections.
3. Check the three phase connections
between the motor and the ACT.
4. Replace ACT.
3:305 Motor temperatur over 180 °C. 1. Check that the resistance in the drive
The truck is braked by the motor brake motor's temperature sensor is be-
until it stops. tween 550 ohms and 650 ohms. At
150 °C the resistance should be 600
ohm.
2. Check that the fan for the motor com-
partment works and that the ventilation
openings are not blocked.
3. Check that the drive motor is not dam-
aged.

© BT Repair Manual RRE140/160/180/200/250 8 – 43

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
3:314 The MCU or ACT have not responded 1. Check fuse [F73].
– via CAN2 within 70 ms.
2. Check that CAN 2 is intact in terms of
3:316 The truck is braked by the motor brake
wiring harness, final resistance and
until it stops.
contacts. Disonnect the battery. Check
that the resistance between [X130:8]
and [X130:22] is 54 – 66 ohm.
3. Check that the ACT's green LED is lit
constantly.
If the LED is not lit:
• Check that the ACT has a supply volt-
age of 48 V between [K1:9] and [B-].
• Replace ACT.
If the LED is lit:
• Replace ACT.
3:320 ACT – Voltage for motor supply out- Check
– side specified limits.
1. Fuse F71
3:322 The truck is braked by the motor brake
until it stops. 2. F1
3. That the main contactor [Q10] is
closed and that the contacts are not
burned.
4. That the wiring harness between the
battery and the ACT are complete and
not oxidised.
3:323 Overcurrent – ACT. Check
The truck is braked by the motor brake
1. That the battery voltage is correct
until it stops.
when connected to the ACT.
2. That the battery wiring harness is un-
damaged and there is no relationship
between B+ and B-.
3. That the motor cables are undamaged
and there is no relationship between
them or with B-.
4. The motor windings' resistance to the
motor yoke, there should be no rela-
tionship.
5. Test using a new motor controller. If
the error persists, the fault is probably
an internal motor problem. Replace
the motor and refit the old controller.

8 – 44 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
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Order number Date Valid from serial number T-code
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tor.
3:325 The ACT's cooling element is over Check that the cooling fan for the ACT
125 °C. and ACH is working normally. CID Service
The truck is braked by the motor brake function:
until it stops.

If the fan is working normally:

• Clean the ACT's cooling element and
associated ducts. If the error returns the
fault is probably an internal ACT prob-
lem.
If the fan does not work normally:
• If there is not 48 V between [G3:1] and
[G3:2]: Check the wiring harness and
the MCU.
• If there is not 48 V between [G3:1] and
[G3:2]: Check the fan
3:328 Short circuit in the ACT, the drive Check
motor or the motor cables.
1. That the motor cables are undamaged
The truck is braked by the motor brake
and there is no short circuit between
until it stops.
them or with B-.
2. The motor windings' resistance to the
motor yoke, there should be no rela-
tionship.
3. Test using a new motor controller. If
the error persists, the fault is probably
an internal motor problem. Replace
the motor and refit the old controller.
3:329 Measurement/Calibration error in the 1. Log off and make the truck without
ACT's current measurement. voltage for at least 1 minute.
The truck is braked by the motor brake
2. Restart the truck and log in again.
until it stops.
If the fault persists:
• Replace ACT.

© BT Repair Manual RRE140/160/180/200/250 8 – 45

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
3:331 The ACT's internal 5 volts is outside Check
the specified limits.
• Fuse F73
The truck is braked by the motor brake
until it stops. • The battery voltage [ACT K1:9] and B-.
If the voltage deviates from the battery
voltage:
• Check that cable 27, between the fuse
box and the ACT, is undamaged and
that the connections are not oxidised.
If the voltage is the same as the battery
voltage:
• Replace ACT.
3:333 The ACT's internal 15 volts is outside Check
the specified limits.
• Fuse F73
The truck is braked by the motor brake
until it stops. • The battery voltage [ACT K1:9] and B-.
If the voltage deviates from the battery
voltage:
• Check that cable 27, between the fuse
box and the ACT, is undamaged and
that the connections are not oxidised.
If the voltage is the same as the battery
voltage:
• Replace ACT.
3:380 Break or short circuit in the speed Loosen the sensor and remeasure [B11:1]
sensor [B11]. and [B11:4], ‘1’ = + and ‘4’ = -. The resist-
Max travel speed is reduced to 10.5km/ ance should be approx 160 kohm.
h. If the resistance measurement sug-
gests a break/short circuit in the sen-
sor:
• Replace the sensor.
If the resistance measurement
excludes a break/short circuit:
• Check conductors “10” and “11”,
[B11:1]/[K1:11] and [B11:4]/[K1:6], for
any break/short circuit.
If the conductors are undamaged:
• Replace ACT.

8 – 46 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
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Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
3:385 The voltage from the accelerator Check that the accelerator pedal's output
pedal [B32] is outside the specified voltage is between 0.25 V to 4.75 V. CID's
limits. diagnostic screen 3, pos 5:
Driving is blocked and the truck is
braked to a stop with the motor brake.

If the output voltage is outside these

limits:
• Check that the voltage is between 4.5 V
and 5.5 V between [B32:6] and [B32:1].
• Check that there is no break, short cir-
cuit or incorrect feed to [X130:17], con-
ductor 87/GY.
If the output voltage is within limits, but
that changes when the pedal is
affected:
• Replace the pedal [B32]
• Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.
• Replace MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 47

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
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Indica- Cause Tip

tor.
3:387 The voltage from the brake pedal Check that the brake pedal's signal 1 out-
[B32], signal 1, is outside the speci- put voltage is between 0.25 V to 4.75 V.
fied limits. CID's diagnostic screen 3, pos 7:
Driving is blocked and the truck is
braked to a stop with the motor brake.

If the output voltage is outside these

limits:
• Check that the voltage is between 4.5 V
and 5.5 V between [B32:6] and [B32:1].
• Check that there is no break, short cir-
cuit or incorrect feed to [X130:4], con-
ductor 85/WH.
If the output voltage is within limits, but
that changes when the pedal is
affected:
• Replace the pedal [B32]
• Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.
• Replace MCU.

8 – 48 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
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Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
3:388 The voltage from the brake pedal Check that the brake pedal's signal 2 out-
[B32], signal 2, is outside the speci- put voltage is between 0.25 V to 4.75 V.
fied limits. CID's diagnostic screen 3, pos 8:
Driving is blocked and the truck is
braked to a stop with the motor brake.

If the output voltage is outside these

limits:
• Check that the voltage is between 4.5 V
and 5.5 V between [B32:6] and [B32:1].
• Check that there is no break, short cir-
cuit or incorrect feed to [X130:18], con-
ductor 86/BK.
If the output voltage is within limits, but
that changes when the pedal is
affected:
• Replace the pedal [B32]
• Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.
• Replace MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 49

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
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Indica- Cause Tip

tor.
3:389 Too large discrepancy between both Check that both the brake pedal signals'
brake pedal signals. output voltages follow each other and that
Driving is blocked and the truck is one is inverse to the other.
braked to a stop with the motor brake.

V = brake pedal's output voltage,

Δpos = Brake pedal depression
The CID's diagnostic screen 3, pos 7 and
8:

If the output voltage does not change

normally:
• Check that the voltage is between 4.5 V
and 5.5 V between [B32:6] and [B32:1].
• Check that there is no poor relationship
or faulty supply of [X130:4], conductor
85/WH and [X130:18], conductor 86/
BK.
• Replace the pedal [B32].
If the output voltage changes normally:
• Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.
• Replace MCU.

8 – 50 Repair Manual RRE140/160/180/200/250 © BT

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Order number Date Valid from serial number T-code
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tor.
3:390 Voltage from the travel direction Verify that the travel direction selector out-
selector [B36] is outside the indicated put voltage is within 0.25 V to 4.75 V when
limits. the selector is moved between its end
positions. CID diagnostic display 1, pos 6:
Truck travel disabled and truck brakes to
standstill using the motor brake.

If the output voltage is outside the lim-

its:
• Verify that the voltage is between 4.5 V
and 5.5 V between [A61:1] and [A6:4].
• Inspect [X505:4], conductor 94/GY for
interruptions, short-circuits or incorrect
power supply.
If the output voltage is within the limits,
but does not change when the selector
is operated:
• Replace the A6 logic card including
the sensor.
• Update the truck firmware to the latest
available version.
• Replace the MCU.
3:500 Unknown ACT error. 1. Update the truck firmware to the latest
available version.
2. Replace the ACT.
3:520 ACT start up error. Check that the ACT's green LED is lit con-
stantly.
If the LED is not lit:
• Check fuse [F73].
• Check that the ACT has a supply volt-
age of 48 V between [K1:9] and [B-].
• Replace ACT.
If the LED is lit:
• Replace ACT.
• Check that CAN 2 is intact in terms of
wiring harness, final resistance and
contacts. Disonnect the battery. Check
that the resistance between [X130:8]
and [X130:22] is 54 – 66 ohm.

© BT Repair Manual RRE140/160/180/200/250 8 – 51

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tor.
3:540 Short circuit in parking brake circuit. 1. Check that the resistance in the park-
ing brake's coil is ~32 ohm.
2. Check that conductor 95, [X131:20],
does not receive a faulty 48 V supply.
3. Replace the MCU.
3:560 Break in the parking brake circuit. Make sure that the brake is released using
the Emergency release switch [S133].
If the brake is released in an emer-
gency:
• Check that the contact [X131] is com-
plete and that conductor 95 is undam-
aged.
• Replace MCU.
If the brake cannot be released:
• Check that the resistance in the parking
brake's coil is ~32 ohm.
• Check that there is 48 V at [Q1:1], to-
wards B- and that conductor 27 is un-
damaged.

8 – 52 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
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Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

8.5.4 Hydraulic system error

Indica- Reason Tip

tion
4:100 Side-shift bypass active, but auto- • If the automatic side-shift to centre op-
matic side-shifting to centre position tion has been installed, the function
is not available. should be activated using parameter
1110.
Side-shift bypass requires that the auto-
matic side-shift to centre option has • If the automatic side-shift to centre op-
been installed and has been activated. tion has not been installed, the func-
tion should be deactivated using
parameter 368.

© BT Repair Manual RRE140/160/180/200/250 8 – 53

 Troubleshooting
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T-code Valid from serial number Date Order number
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tor.
4:180 No pulses from the main lift height 1. Verify that hydraulic valve Q2 opens.
sensor during lifting/lowering.
Service function:
Lifting disabled.

+ +

2. Inspect the height sensor's mechani-

cal drive.
3. Verify that the status on inputs
[X130:12] and [X130:26] switches
when the sensor rotates. If the main lift
movement is disabled, the mechanical
drive of the sensor can be disconnect-
ed and the sensor can be turned by
hand.
CID diagnostic display 4, pos. 7 and 8:

If the status on the inputs changes:

• Update the truck firmware to the latest
available version.
• Replace the MCU.
If the status on the inputs does not
change:
• Verify that 15 V is available between
[B19:1] and [B19:4]. If 15 V is missing,
inspect conductors 29 [X130:37] and 30
[X130:20]. If these are intact: Replace
the MCU.
• Verify that conductors 75 [X130:12] and
76 [X130:26] are intact.
• Replace the height sensor [B19].
• Replace the MCU.
4. Replace the valve plate

8 – 54 Repair Manual RRE140/160/180/200/250 © BT

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tor.
4:181 Measured height deviates by more Check:
than ±30 mm when the main lift's ref-
• that inputs [X130:12] and [X130:26]
erence sensors are affected.
swap status when the height sensor ro-
Lifting blocked.
tates. If the main lift's movement is
blocked, the sensor's mechanical drive
is released and the sensor is turned by
hand.
• The reference sensors' inputs.
The CID's diagnostic screen 4:
[B19]: pos 7 and 8.
[B46]: pos 6, ‘1’ = Not in the main lift area.
[B57]: pos 11, ‘0’ = Not in the main lift
area.

See also CID diagnostic screen 15.

If the inputs [X130:12] and [X130:26] do
not change status:
• Check that there is 15 V between
[B19:1] and [B19:4]: If there is not 15 V,
conductors 29 [X130:37] and 30
[X130:20] must be checked. If these are
intact: Replace MCU.
• Check that conductors 75, [X130:12]
and 76 [X130:26] are intact.
• Replace the height sensor [B19].
• Replace MCU.
cont.

© BT Repair Manual RRE140/160/180/200/250 8 – 55

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tor.
(cont.) If the inputs [B46]/[X130:39] and [B57]/
4:181 [X130:27] do not change status:
• Check that the distance between the
sensors and the mast beam does not
exceed 6.5 mm.
• Check that there is a voltage between
[B46:1]/[B46:3] and [B57:1]/[B57:3].
• Check that conductors 73/[X130:39]
and 139/[X130:27] are intact.
If all the inputs change status normally:
• Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.
• Replace MCU.

8 – 56 Repair Manual RRE140/160/180/200/250 © BT

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tor.
4:182 No pulses from the free lift height 1. The load on the forks may exceed the
sensor on lift/lowering. lifting capacity.
Lifting blocked.
2. Check the height sensor's mechanical
driving.
3. Check that hydraulic valve Q3 is open.
Service function:

+ +

4. Check that inputs [X130:40] and

[X130:13] swap status when the sen-
sor rotates. If the free lift's movement
is blocked, the sensor's mechanical
drive is released and the sensor is
turned by hand.
The CID's diagnostic screen 4, pos 9
and 10:

If the inputs change status:

• Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.
• Replace MCU.
If the inputs do not change status:
• Check that there is 15 V between
[B18:1] and [B18:4]: If there is not 15 V,
conductors 29 [X130:37] and 30
[X130:20] must be checked. If these are
intact: Replace MCU.
• Check that conductors 130, [X130:40]
and 131 [X130:13] are intact.
• Replace the height sensor [B18].
• Replace MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 57

 Troubleshooting
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tor.
4:183 Measured height deviates by more Check:
than ±30 mm when the free lift's refer-
• that inputs for [B18], [X130:40] and
ence sensors is passed.
[X130:13] swap status when the height
Lifting blocked.
sensor rotates. If the free lift's move-
ment is blocked, the sensor's mechani-
cal drive is released and the sensor is
turned by hand.
• The reference sensors' inputs.
The CID's diagnostic screen 4:
[B18]: pos 9 and 10.
[B58]: pos 13, ‘1’ = Forks under 1 m.

See also CID diagnostic screen 15.

If the inputs [X130:40] and [X130:13] do
not change status:
• Check that there is 15 V between
[B18:1] and [B18:4]: If there is not 15 V,
conductors 29 [X130:37] and 30
[X130:20] must be checked. If these are
intact: Replace MCU.
• Check that conductors 130, [X130:40]
and 131 [X130:13] are intact.
• Replace the height sensor [B18].
• Replace MCU.
cont.

8 – 58 Repair Manual RRE140/160/180/200/250 © BT

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tor.
(cont'd) If [B58]/[X131:2] does not change sta-
4:183 tus when the sensor leaves the refer-
ence rail:
• Verify that the reference rail is not de-
formed and that the distance between
the sensor and rail does not exceed 6.5
mm.
• Verify that there is battery voltage be-
tween [B58:1] and [B58:3].
• Verify that conductor 141/[X131:2] is in-
tact.
• Verify that conductors 73/[X130:39] and
139/[X130:27] are intact.
If all affected inputs change status as
normal:
• Update the truck firmware to the latest
available version.
• Replace the MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 59

 Troubleshooting
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T-code Valid from serial number Date Order number
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tor.
4:184 Excessive lifting/lowering speed. Check the lifting/lowering speed
on the CID diagnostics screen 15, pos S
Lifting and lowering movement blocked.

The lifting/lowering speed should be max.

650 mm/s. If the speed is above 1000
mm/s, the fault code is generated.
If the speed is too high:
• Reduce the speed using parameter 341
for lifting or 342 for lowering.
If the speed is correct:
• Check the pulse sensor.
If the fault persists:
If an error indication arises when
lifting:
• Calibrate the free and main lifting valves
[Q3] and [Q2].

+ +1
and

+ +3

If an error indication is shown when

lowering
:
• Calibrate the free and main lowering
valves [Q5] and [Q4].

+ +2
and

+ +4
Calibrate the maximum opening points of
the free and main lowering valves [Q5]
and [Q4] .
(cont.)

8 – 60 Repair Manual RRE140/160/180/200/250 © BT

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tor.
(cont.) Excessive lifting/lowering speed. If the error indication persists after
calibration/adjustment:
4:184 Lifting and lowering movement blocked.
• Check that there is 15V between
[B18:1] and [B18:4] and between
[B19:1] and [B19:4]. If there is no 15V,
conductors 29 [X130:37] to [B18:1] and
30 [X130:20] to [B18:4], as well as 29
[X130:37] to [B19:1 and 30 [X130:20] to
[B19:4] must be checked.
• If the conductors are intact: Replace the
MCU.
• Check that conductors 130/[X130:40],
131/[X130:13], 75/[X130:12] and 76
[X130:26] are intact.
• Replace the height sensor [B18].
• Replace the height sensor [B19].
• Replace the MCU
4:185 Freelift reference sensor does not Verify that the status on input of [B58]
change status as expected. changes when the reference sensor
passes the upper edge of the reference
Reduced lifting/lowering speed.
rail, CID diagnostic display 4, pos 13, ‘1’ =
Forks under 1 m.

If [B58]/[X131:2] does not change sta-

tus when the sensor leaves the refer-
ence rail:
• Verify that the reference rail is not de-
formed and that the distance between
the sensor and rail does not exceed 6.5
mm.
• Verify that there is battery voltage be-
tween [B58:1] and [B58:3].
• Verify that conductor 141/[X131:2] is in-
tact.
• Verify that conductors 73/[X130:39] and
139/[X130:27] are intact.
If all affected inputs change status as
normal:
• Update the truck firmware to the latest
available version.
• Replace the MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 61

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tor.
4:186 Main lift reference sensor does not Verify that the status on the input of [B46]
change status as expected. and [B57] changes when the main lift
leaves/reaches its lowest position, CID
Reduced lifting/lowering speed.
diagnostic display 4:
[B46]: pos 6, ‘1’ = Not in main lift range.
[B57]: pos 11, ‘0’ = Not in main lift range.

If the status on inputs [B46]/[X130:39]

and [B57]/[X130:27] does not change:
• Verify that the distance between the
sensors and the mast girder does not
exceed 6.5 mm.
• Verify that there is battery voltage be-
tween [B46:1]/[B46:3] and [B57:1]/
[B57:3].
• Verify that conductors 73/[X130:39] and
139/[X130:27] are intact.
If all affected inputs change status as
normal:
• Update the truck firmware to the latest
available version.
• Replace the MCU.
4:187 Invalid lifting height. Check that parameter 1274, which defines
The forks estimated height is lower than the mast's lift height, is correctly set.
the lowest possible level - including tol-
erance of 150 mm - or 50 mm above the
maximum lifting height according to
parameter 1274.
Lift/lowering speed reduced.

8 – 62 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
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tor.
4:188 Invalid signal combination from the Verify the status of the cab tilt sensors
cab tilt sensor. [B29] and [B28], CID diagnostic display 4,
pos 1 and 2:
Cab tilting disabled.

Valid combinations:

[B29] [B28]
Cab completely tilted down: ‘1’ ‘1’
Cab in tilt range: ‘1’ ‘0’
Cab completely tilted up: ‘0’ ‘0’

If combinations [B29] = ‘0’ and [B28] =

‘1’ are detected:
• Sensors were mixed up in connection
with repairs.
• Verify that there is battery voltage be-
tween [B28:1]/[B28:3] and [B29:1]/
[B29:3].
• Verify that the conductors 80/[X130:24]
and 81/[X130:10] are intact.
• Download new firmware to the MCU. If
this involves an update, then the CID
firmware should also be replaced.
• Replace the MCU.
If the diagnostic display only shows
valid combinations:
• Update the truck firmware to the latest
available version.
• Replace the MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 63

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:189 Pressure sensor error – Load sen- 1. Check that parameter 1010 has been
sors. set correctly.
The truck assumes maximum load. P = 2. Verify that the output voltage is mini-
25 MPa (250 bar) mum 0.3 V without any load and max-
imum 4.7 V with full load from
pressure sensor [B4], CID diagnostic
display 3, pos 4:

If the voltage at any time is outside the

indicated limits:
• Verify that 5 V is available between
[B4:3] and [B4:1].
• Verify that conductor 69/[X130:3] is in-
tact.
• Replace the pressure sensor [B4].
• Update the truck firmware to the latest
available version.
• Replace the MCU.
If the voltage is within the indicated
limits:
• Update the truck firmware to the latest
available version.
• Replace the MCU.
(Continued)

8 – 64 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
(Contin- Pressure sensor error – Load sen- 3. Verify that the output voltage is mini-
ued) sors. mum 0.3 V without any load and max-
imum 4.7 V with full load from
4:189 The truck assumes maximum load. P =
pressure sensor [B6], CID diagnostic
25 MPa (250 bar)
display 3, pos 3.

If the voltage at any time is outside the

indicated limits:
• Inspect voltage of 5 V between [B6:3]
and [B6:1].
• Verify that conductor 89/[X130:30] is in-
tact.
• Replace the pressure sensor [B6].
• Update the truck firmware to the latest
available version.
• Replace the MCU.
If the voltage is within the indicated
limits:
• Update the truck firmware to the latest
available version.
• Replace the MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 65

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:190 Incorrect signal change from free-lift Verify that the status on input of [B58]
reference sensor changes when the reference sensor
passes the upper edge of the reference
Reduced lifting/lowering speed.
rail, CID diagnostic display 4, pos 13, ‘1’ =
Applies to height measurement Forks under 1 m.

If [B58]/[X131:2] does not change sta-

tus when the sensor leaves the refer-
ence rail:
• Verify that the reference rail is not de-
formed and that the distance between
the sensor and rail does not exceed 5
mm.
• Verify that there is battery voltage be-
tween [B58:1] and [B58:3].
• Verify that conductor 141/[X131:2] is in-
tact.
• Verify that conductors 73/[X130:39] and
139/[X130:27] are intact.
If all affected inputs change status as
normal:
• Update the truck firmware to the latest
available version.
• Replace the MCU.

8 – 66 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:192 Incorrect signal combination from the Verify the status of the main lift sensors
main lift sensor at the lowest height. [B46 and [B57], CID diagnostic display 4,
pos 6 and 11:
Reduced lifting/lowering speed.

Valid combinations:
[B46] [B57]
Main lift at bottom position: ‘1’ ‘0’
Main lift engaged: ‘0’ ‘1’
If one of the signals does not change
status as expected:
• Verify that the distance between the
sensors and the mast girder does not
exceed 6.5 mm.
• Verify that each sensor has supply volt-
age: Battery voltage between [Bxx:1]
and [Bxx:3]
• Inspect conductor 73/[X130:39] of [B46]
and 139/[X130:27] of [B57].
• Replace the sensor that does not
change status.
• Download new firmware to the MCU. If
this involves an update, then the CID
firmware should also be replaced.
• Replace the MCU.
If the signal combinations are valid:
• Update the truck firmware to the latest
available version.
• Replace the MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 67

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:193 Signal missing from reach carriage If the reach carriage moves:
sensor. • Verify the status of the reach carriage
Reduced extension movement. sensor, CID diagnostic display 4:
• [B26]/[X130:38] and [B27]/[X130:11]:
pos 3 and 4.

If the status on one of the inputs does

not change:
• Inspect the distance between the sen-
sor and rule, max. 6 mm.
• Verify that there is battery voltage be-
tween [B2x:1] and [B2x:3].
• Inspect the conductors 78/[X130:38]
and 79/[X130:11].
• Replace the sensor that does not
change status.
• Download new firmware to the MCU. If
this involves an update, then the CID
firmware should also be replaced.
• Replace the MCU.
If the reach carriage does not move:
• Check that the reach carriage is not me-
chanically blocked.
• Calibrate the valves [Q6] and [Q7].
• Replace the main valve block if calibra-
tion is not possible.
• Update the truck firmware to the latest
available version.
• Replace the MCU.

8 – 68 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:194 Missing signal from the main lift sen- No signal even though the main lift sensor
sor at the lowest height. indicates the mast is at the bottom posi-
tion.
Reduced lifting/lowering speed.
1. Verify that the status on the input of
Does not apply to height measurement [B46] and [B57] changes when the
main lift leaves/reaches its lowest po-
sition, CID diagnostic display 4:
[B46]: pos 6, ‘1’ = Not in main lift range.
[B57]: pos 11, ‘0’ = Not in main lift range.

If the status on inputs [B46]/[X130:39]

and [B57]/[X130:27] does not change:
• Verify that the sensors have not been
mixed up.
• Verify that the distance between the
sensors and the mast girder does not
exceed 5 mm.
• Verify that there is battery voltage be-
tween [B46:1]/[B46:3] and [B57:1]/
[B57:3].
• Verify that conductors 73/[X130:39]
and 139/[X130:27] are intact.
2. Verify that the input of [B33]/[X130:12]
changes status when the mast reach-
es the bottom position. CID diagnostic
display 4, pos 7, ‘1’ = Mast in bottom
position.

(Continued)

© BT Repair Manual RRE140/160/180/200/250 8 – 69

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
(Contin- Missing signal from the main lift sen- If input [B33]/[X131:12] does not
ued) sor at the lowest height. change status:
4:194 Reduced lifting/lowering speed. • Verify that the reference rail is not de-
formed and that the distance between
Does not apply to height measurement the sensor and rail does not exceed 5
mm.
• Verify that there is battery voltage be-
tween [B33:1] and [B33:3].
• Verify that conductor 75/[X130:12] is
intact.
If all affected inputs change status as
normal:
• Update the truck firmware to the latest
available version.
• Replace the MCU.

8 – 70 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:195 Mast separation error The mast remains separated when the
forks are 1.5 metres below the max. free lift
height or 0.6 metres from the ground..
1. Calibrate the main lowering valve.
2. Calibrate mast separation
3. Inspect the shims used for the mast
4. Verify that the status on the input of
[B46] and [B57] changes when the
main lift leaves/reaches its lowest po-
sition, CID diagnostic display 4:
[B46]: pos 6, ‘1’ = Not in main lift range.
[B57]: pos 11, ‘0’ = Not in main lift range.

If the status on inputs [B46]/[X130:39]

and [B57]/[X130:27] does not change:
• Verify that the sensors have not been
mixed up.
• Verify that the distance between the
sensors and the mast girder does not
exceed 5 mm.
• Verify that there is battery voltage be-
tween [B46:1]/[B46:3] and [B57:1]/
[B57:3].
• Verify that conductors 73/[X130:39]
and 139/[X130:27] are intact.
5. Verify that the input of [B33]/[X130:12]
changes status when the mast reach-
es the bottom position. CID diagnostic
display 4, pos 7, ‘1’ = Mast in bottom
position.

(Continued)

© BT Repair Manual RRE140/160/180/200/250 8 – 71

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
(Contin- Mast separation error If input [B33]/[X131:12] does not
ued) change status:
4:195 • Verify that the reference rail is not de-
formed and that the distance between
the sensor and rail does not exceed 5
mm.
• Verify that there is battery voltage be-
tween [B33:1] and [B33:3].
• Verify that conductor 75/[X130:12] is
intact.
If all affected inputs change status as
normal:
• Update the truck firmware to the latest
available version.
• Replace the MCU.
4:200 Unknown ACH error. 1. Download new software to the ACH. If
this involves an update, the software
for the MCU, CID and other units must
also be changed.
2. Replace ACH.
4:201 Levers for hydraulic functions not 1. Calibrate the hydraulic levers.
calibrated 2. Check activation of the hydraulic le-
Hydraulic movements blocked vers with parameter 1007.

4:205 Motor temperatur over 180 °C. 1. Check that the resistance in the pump
Hydraulic movement blocked motor's temperature sensor is be-
tween 550 ohms and 650 ohms. At
150 °C the resistance should be 600
ohm.
2. Check that the fan for the motor com-
partment works and that the ventilation
openings are not blocked.
3. Check that the pump motor is not dam-
aged.

8 – 72 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:214 The MCU or ACH have not responded 1. Check fuse [F73].
– via CAN2 within 70 ms.
2. Check that CAN 2 is intact in terms of
4:216 Hydraulic movement blocked
wiring harness, final resistance and
contacts. Disonnect the battery. Check
that the resistance between [X130:8]
and [X130:22] is 54 – 66 ohm.
3. Check that the ACH's green LED is lit
constantly.
If the LED is not lit:
• Check that the ACH has a supply volt-
age of 48 V between [K1:9] and [B-].
• Replace ACH.
If the LED is lit:
• Replace ACH.
4:220 ACH – Voltage for motor supply out- Check
– side specified limits.
• – Fuse F71
4:222 Hydraulic movement blocked
• – F3
• – That the main contactor [Q10] is
closed and that the contacts are not
burned.
• – That the wiring harness between the
battery and the ACH are complete and
not oxidised.
4:223 Overcurrent – ACH. Check
Hydraulic movement blocked
• – That the battery voltage is correct
when connected to the ACH.
• – That the battery wiring harness is un-
damaged and there is no relationship
between B+ and B-.
• – That the motor cables are undam-
aged and there is no relationship be-
tween them or with B-.
• – The motor windings' resistance to the
motor yoke, there should be no relation-
ship.
• – Test using a new motor controller. If
the error persists, the fault is probably
an internal motor problem. Replace the
motor and refit the old controller.

© BT Repair Manual RRE140/160/180/200/250 8 – 73

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:225 The ACH's cooling element is over Check that the cooling fan for the ACT
125 °C. and ACH is working normally. CID Service
Hydraulic movement blocked function:

If the fan is working normally:

– Clean the ACH's cooling element and
associated ducts. If the error returns the
fault is probably an internal ACH problem.
If the fan does not work normally:
• There is a voltage to the fan, replace the
fan.
• There is no voltage to the fan, check the
fan's wiring harness. If the wiring har-
ness is intact: Replace MCU.
4:228 Short circuit in the ACH, the pump Check
motor or the motor cables.
• That the motor cables are undamaged
Hydraulic movement blocked
and there is no short circuit between
them or with B-.
• The motor windings' resistance to the
motor yoke, there should be no relation-
ship.
• Test using a new motor controller. If the
error persists, the fault is probably an in-
ternal motor problem. Replace the mo-
tor and refit the old controller.
4:229 Measurement/Calibration error in the • Log off and make the truck without volt-
ACH's current measurement. age for at least 1 minute.
Hydraulic movement blocked
• Restart the truck and log in again.
If the fault persists:
• Replace ACH.

8 – 74 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:231 The ACH's internal 5 volts is outside Check
the specified limits.
• Fuse F73
Hydraulic movement blocked
• The battery voltage [ACH K1:9] and B-.
If the voltage deviates from the battery
voltage:
• Check that cable 27, between the fuse
box and the ACH, is undamaged and
that the connections are not oxidised.
If the voltage is the same as the battery
voltage:
• Replace ACH.
4:233 The ACH's internal 15 volts is outside Check
the specified limits.
• Fuse F73
Hydraulic movement blocked
• The battery voltage [ACH K1:9] and B-.
If the voltage deviates from the battery
voltage:
• Check that cable 27, between the fuse
box and the ACH, is undamaged and
that the connections are not oxidised.
If the voltage is the same as the battery
voltage:
• Replace ACH.
4:240 Short circuit in the circuit for raising 1. Check that conductor 36,
the free lift [Q3]. [ACH:K1:10], does not receive a faulty
Lifting blocked. 48 V supply.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q3] is approx
24 ohm, [ACH:K1:10] towards fuse
holder [F73].
3. Replace ACH.
4:241 Short circuit in the circuit for lowering 1. Check that conductor 35, [ACH:K1:2],
the free lift [Q5]. does not receive a faulty 48 V supply.
Lowering of forks in the free lift area is
2. With the truck disconnected and fuse
blocked.
F73 removed: Check that the resist-
ance in the coil to valve [Q5] is approx
24 ohm, [ACH:K1:2] towards fuse
holder [F73].
3. Replace ACH.

© BT Repair Manual RRE140/160/180/200/250 8 – 75

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:242 Short circuit in the circuit for tilting 1. Check that conductor 64, [ACT:K1:10],
the cabin upwards [Q11]. does not receive a faulty 48 V supply.
Upward tilting of cabin blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q11] is approx
24 ohm, [ACT:K1:10] towards fuse
holder [F73].
3. Replace ACT.
4:243 Short circuit in the circuit for function 1. Check that conductor 65, [X131:21],
AUX2 [Q12]. does not receive a faulty 48 V supply.
AUX functions are blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q12] is ap-
prox 64 ohm, [X131:21] towards fuse
holder [F73].
3. Replace MCU.
4:244 Short circuit in the circuit for function 1. Check that conductor 67, [X131:10],
AUX3 [Q14]. does not receive a faulty 48 V supply.
AUX functions are blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q14] is ap-
prox 64 ohm, [X131:10] towards fuse
holder [F73].
3. Replace MCU.
4:245 Short circuit in the circuit for function 1. Check that conductor 68, [X131:24],
AUX4 [Q15]. does not receive a faulty 48 V supply.
AUX functions are blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q15] is ap-
prox 64 ohm, [X131:24] towards fuse
holder [F73].
3. Replace MCU.
4:246 Short circuit in the circuit for function 1. Check that conductor 66, [X131:38],
AUX1 [Q18]. does not receive a faulty 48 V supply.
AUX functions are blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q18] is ap-
prox 64 ohm, [X131:38] towards fuse
holder [F73].
3. Replace MCU.

8 – 76 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:247 Short circuit in the circuit for tilting 1. Check that conductor 41, [ACT:K1:2],
the cabin downwards [Q21]. does not receive a faulty 48 V supply.
Tilting of cabin blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q21] is ap-
prox 64 ohm, [ACT:K1:2] towards fuse
holder [F73].
3. Replace MCU.
4:248 Short circuit in the circuit for function 1. Check that conductor 62, [X131:37],
AUX, direction A [Q8]. does not receive a faulty 48 V supply.
AUX functions are blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q8] is approx
64 ohm, [X131:37] towards fuse holder
[F73].
3. Replace MCU.
4:249 Short circuit in the circuit for function 1. Check that conductor 63, [X131:11],
AUX, direction B [Q9]. does not receive a faulty 48 V supply.
AUX blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q9] is approx
64 ohm, [X131:11] towards fuse holder
[F73].
3. Replace MCU.
4:250 Short circuit in the circuit for raising 1. Check that conductor 59, [X131:26],
the main lift [Q2]. does not receive a faulty 48 V supply.
All hydraulic functions blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q2] is approx
24 ohm, [X131:26] towards fuse holder
[F73].
3. Replace MCU.
4:251 Short circuit in the circuit for lowering 1. Check that conductor 58, [X131:40],
the main lift [Q4]. does not receive a faulty 48 V supply.
All hydraulic functions blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q4] is approx
24 ohm, [X131:40] towards fuse holder
[F73].
3. Replace MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 77

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:252 Short circuit in the circuit for the 1. Check that conductor 61, [X131:41],
reach carriage's “Out” movement does not receive a faulty 48 V supply.
[Q7].
2. With the truck disconnected and fuse
Reach carriages movement blocked.
F73 removed: Check that the resist-
ance in the coil to valve [Q7] is approx
24 ohm, [X131:41] towards fuse holder
[F73].
3. Replace MCU.
4:253 Short circuit in the circuit for the 1. Check that conductor 60, [X131:13],
reach carriage's “In” movement [Q6]. does not receive a faulty 48 V supply.
Reach carriages movement blocked.
2. With the truck disconnected and fuse
F73 removed: Check that the resist-
ance in the coil to valve [Q6] is approx
24 ohm, [X131:13] towards fuse holder
[F73].
3. Replace MCU.
4:260 Break in the circuit for raising the free 1. With the truck disconnected and fuse
lift [Q3]. F73 removed: Check that the resist-
Lifting blocked. ance in the coil to valve [Q3] is approx
24 ohm, [ACH:K1:10] towards fuse
holder [F73].
2. Replace ACH.
4:262 Break in the circuit for tilting the 1. With the truck disconnected and fuse
cabin upwards [Q11]. F73 removed: Check that the resist-
Upward tilting of cabin blocked. ance in the coil to valve [Q11] is approx
24 ohm, [ACT:K1:10] towards fuse
holder [F73].
2. Replace ACT.
4:263 Break in the circuit for function AUX2 1. With the truck disconnected and fuse
[Q12]. F73 removed: Check that the resist-
ance in the coil to valve [Q12] is ap-
prox 64 ohm, [X131:21] towards fuse
holder [F73].
2. Replace MCU.
4:264 Break in the circuit for function AUX3 1. With the truck disconnected and fuse
[Q14]. F73 removed: Check that the resist-
ance in the coil to valve [Q14] is ap-
prox 64 ohm, [X131:10] towards fuse
holder [F73].
2. Replace MCU.

8 – 78 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:265 Break in the circuit for function AUX4 1. With the truck disconnected and fuse
[Q15]. F73 removed: Check that the resist-
ance in the coil to valve [Q15] is ap-
prox 64 ohm, [X131:24] towards fuse
holder [F73].
2. Replace MCU.
4:266 Break in the circuit for function AUX1 1. With the truck disconnected and fuse
[Q18]. F73 removed: Check that the resist-
ance in the coil to valve [Q18] is ap-
prox 64 ohm, [X131:38] towards fuse
holder [F73].
2. Replace MCU.
4:267 Break in the circuit for tilting the 1. With the truck disconnected and fuse
cabin downwards [Q21]. F73 removed: Check that the resist-
Tilting of cabin blocked. ance in the coil to valve [Q21] is ap-
prox 64 ohm, [ACT:K1:2] towards fuse
holder [F73].
2. Replace MCU.
4:268 Break in the circuit for function AUX, 1. With the truck disconnected and fuse
direction A [Q8]. F73 removed: Check that the resist-
AUX blocked. ance in the coil to valve [Q8] is approx
64 ohm, [X131:37] towards fuse holder
[F73].
2. Replace MCU.
4:269 Break in the circuit for function AUX, 1. With the truck disconnected and fuse
direction B [Q9]. F73 removed: Check that the resist-
AUX blocked. ance in the coil to valve [Q9] is approx
64 ohm, [X131:11] towards fuse holder
[F73].
2. Replace MCU.
4:270 Break in the circuit for raising the 1. With the truck disconnected and fuse
main lift [Q2]. F73 removed: Check that the resist-
All hydraulic functions blocked. ance in the coil to valve [Q2] is approx
24 ohm, [X131:26] towards fuse holder
[F73].
2. Replace MCU.
4:272 Break in the circuit for the reach car- 1. With the truck disconnected and fuse
riage's “Out” movement [Q7]. F73 removed: Check that the resist-
Reach carriages movement blocked. ance in the coil to valve [Q7] is approx
24 ohm, [X131:41] towards fuse holder
[F73].
2. Replace MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 79

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:273 Break in the circuit for the reach car- 1. With the truck disconnected and fuse
riage's “In” movement [Q6]. F73 removed: Check that the resist-
Reach carriages movement blocked. ance in the coil to valve [Q6] is approx
24 ohm, [X131:13] towards fuse holder
[F73].
2. Replace MCU.
4:280 Input signal from joystick lift/lower Check that the output voltage is min 0.3 V
outside specified limits. and max 4.7 V in each position, from joy-
Lifting/lowering blocked. stick [B20], CID's diagnostic screen 1, pos
1:

If the voltage at any time is outside the

specified limits:
• Check 5 V between [B20:1] and
[B20:2].
• Check that cable 50/BK is intact,
[B20:3] to [X505:2].
• Replace the joystick [B20].
• Replace the CID.
If the voltage is within the specified
limits:
• Update the truck firmware to the latest
available version
• Replace the CID.

8 – 80 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:281 Input signal from joystick reach out- Check that the output voltage is min 0.3 V
side specified limits. and max 4.7 V in each position, from joy-
Reach movement blocked. stick [B21], CID's diagnostic screen 1, pos
2:

If the voltage at any time is outside the

specified limits:
• Check 5 V between [B21:1] and
[B21:2].
• Check that cable 51/BN is intact,
[B21:3] to [X505:11].
• Replace the joystick [B21].
• Replace the CID.
If the voltage is within the specified
limits:
• Update the truck firmware to the latest
available version
• Replace the CID.

© BT Repair Manual RRE140/160/180/200/250 8 – 81

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:282 Input signal from joystick tilt outside Check that the output voltage is min 0.3 V
specified limits. and max 4.7 V in each position, from joy-
Tilt movement blocked. stick [B22], CID's diagnostic screen 1, pos
3:

If the voltage at any time is outside the

specified limits:
• Check 5 V between [B22:1] and
[B22:2].
• Check that cable 52/OG is intact,
[B22:3] to [X505:17].
• Replace the joystick [B22].
• Replace the CID.
If the voltage is within the specified
limits:
• Update the truck firmware to the latest
available version
• Replace the CID.

8 – 82 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:283 Input signal from joystick AUX1/side- Check that the output voltage is min 0.3 V
shift outside specified limits. and max 4.7 V in each position, from joy-
AUX1/sideshift blocked. stick [B23], CID's diagnostic screen 1, pos
4:

If the voltage at any time is outside the

specified limits:
• Check 5 V between [B23:1] and
[B23:2].
• Check that cable 53/YEis intact, [B23:3]
to [X505:3].
• Replace the joystick [B23].
• Replace the CID.
If the voltage is within the specified
limits:
• Update the truck firmware to the latest
available version
• Replace the CID.

© BT Repair Manual RRE140/160/180/200/250 8 – 83

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:284 Input signal from joystick AUX2/fork Check that the output voltage is min 0.3 V
spreading outside specified limits. and max 4.7 V in each position, from joy-
AUX2/fork spreading blocked. stick [B24], CID's diagnostic screen 1, pos
5:

If the voltage at any time is outside the

specified limits:
• Check 5 V between [B24:1] and
[B24:2].
• Check that cable 54/GN is intact,
[B24:3] to [X505:12].
• Replace the joystick [B24].
• Replace the CID.
If the voltage is within the specified
limits:
• Update the truck firmware to the latest
available version.
• Replace the CID.
4:285 Break or short circuit in the Loosen the sensor and remeasure [B12:1]
revolution sensor [B12]. and [B12:4], ‘1’ = + and ‘4’ = -. The resist-
All hydraulic functions blocked. ance should be approx 160 kohm.
If the resistance measurement sug-
gests a break/short circuit in the sen-
sor:
• Replace the sensor.
If the resistance measurement
excludes a break/short circuit:
• Check conductors “15” and “16”,
[B12:1]/[K1:11] and [B12:4]/[K1:6], for
any break/short circuit.
If the conductors are undamaged:
• Replace ACH.

8 – 84 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
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7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:286 Input signal from the fork incline If the truck is not equipped with a fork
angle sensor [B5] outside the speci- incline angle sensor:
fied limits.
Check that parameter 1111 = ‘0’.
All hydraulic functions blocked.
If the truck is equipped with a fork incline
angle sensor:
Check that the output voltage is min 0.3 V
and max 4.7 V for angle sensor [B5], CID's
diagnostic screen 3, pos 2:

If the voltage at any time is outside the

specified limits:
• Check the voltage is 48 V between
[B5:1] and [B5:3].
• Check that conductor 74/[B5:2] to
[X130:16] is intact.
• Replace angle sensor [B5].
• Update the truck firmware to the latest
available version
• Replace MCU.
If the voltage is within the specified
limits:
• Update the truck firmware to the latest
available version
• Replace MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 85

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
4:287 Invalid combination of input signals If the truck is not equipped with centre
from sideshift position sensors [B47]. positioning of the forks sideshift:
All hydraulic functions blocked.
• Check that parameter 1110 = ‘0’.
If the truck is equipped with centre
positioning of the forks sideshift:
• Check the status of both signals from
the sideshift sensor, CID's diagnostic
screen 4, pos 20 & 21:

If both signals = ‘0’ (invalid combina-

tion):
• Check 48 V between [B47:1] and
[B47:4].
• Check that conductor 111/[B47:2] to
[X131:18] and conductor 112/[B47:3] to
[X131:32] are intact.
• Replace sideshift position sensor.
• Update the truck firmware to the latest
available version
• Replace MCU.
If both signals display “01”, “10” or
“11” (valid combinations):
• Update the truck firmware to the latest
available version.
• Replace MCU.

8 – 86 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
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7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
4:520 ACH start up error. Check that the ACH's green LED is lit con-
stantly.
If the LED is not lit:
• Check fuse [F73].
• Check that the ACH has a supply volt-
age of 48 V between [K1:9] and [B-].
• Replace ACH.
If the LED is lit:
• Replace ACH
• Check that CAN 2 is intact in terms of
wiring harness, final resistance and
contacts. Disonnect the battery. Check
that the resistance between [X130:8]
and [X130:22] is 54 – 66 ohm.
4:561 Short circuit in the circuit for lowering 1. With the truck disconnected and fuse
the free lift [Q5]. F73 removed: Check that the resist-
ance in the coil to valve [Q5] is approx
24 ohm, [ACH:K1:2] towards fuse
holder [F73].
2. Replace ACH.
4:571 Break in the circuit for lowering the 1. With the truck disconnected and fuse
main lift [Q4]. F73 removed: Check that the resist-
ance in the coil to valve [Q4] is approx
24 ohm, [X131:40] towards fuse holder
[F73].
2. Replace MCU.

© BT Repair Manual RRE140/160/180/200/250 8 – 87

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

8.5.5 Steering system, warnings and errors

Indica- Cause Tip

tor.
5:010 The steering servo's CAN module has 1. Check that CAN 2 is intact in terms of
– received or sent too many faulty tele- wiring harness, final resistance and
5:011 grams. contacts. Disonnect the battery. Check
that the resistance between [X130:8]
and [X130:22] is 54 – 66 ohm.
2. Update the truck firmware to the latest
available version
3. Replace the steering motor.
4. Replace MCU.
5:035 The temperature of the steering servo Check that the chassi's cooling fan is
exceeds 68 °C. working normally. CID Service function:

If the fan is working normally:

– Clean the steering servo's cooling ele-
ment and the fan. If the error returns the
fault is probably an internal steering servo
problem.
If the fan does not work normally:
• There is a voltage to the fan, replace the
fan.
• There is no voltage to the fan, check the
fan's wiring harness. If the wiring har-
ness is intact: Replace MCU.
5:135 Risk of thermal overload in the steer- 1. Check that there are no objects block-
ing servo. ing the steering movement.
The indication is shown from 80 % up to
2. Check that the steering gear is not
100 %. At 100 % the indication switches
jammed or blocked by dust, thread or
over to error code 5:325.
contaminants.
Travel speed is limited to max 8 km/h.
3. Replace the steering servo.

8 – 88 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
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Order number Date Valid from serial number T-code
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Indica- Cause Tip

tor.
5:181 Signal from the steering angle 1. Check the mechanical fastening of
- transducer 180° incorrect. steering angle sensor [B17].
5:184
Travel speed is limited to 2. Check the routing of the wiring at the
max 8 km/h. steering angle sensor [B17]. The
wiring must be routed as shown in Fig
1. The wiring must not be routed as
shown in Fig 2, as there is a risk of the
terminal coming loose.

Fig 1. Fig 2.
3. Compare with the travel direction
arrows

and check that the signal from the steering

angle sensor changes status twice per
steering turn, CID's diagnostic screen 4,
pos 5:

If the signal does not change status:

• Check that there is battery voltage
between [B17:1] and [B17:3].
• Check that conductor 57/[B17:2] to
[X130:25] is intact and does not receive
an incorrect 48 V supply.
• Replace the steering angle transducer.
• Update the truck's software to the latest
available version.
• Replace the MCU.
If the signal changes status:
• Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.
• Replace the MCU.
© BT Repair Manual RRE140/160/180/200/250 8 – 89
 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
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Indica- Cause Tip

tor.
5:185 Reference seeking. 1. Verify that parameter 1115 has been
- set to correspond to the optional
Option only
5:186 equipment mounted on the truck.
2. Inspect the reference sensor, [B59],
for correct operation, CID diagnostic
display 14, pos 2:

3. Verify whether 12 V is available be-

tween [B59:1] and [B59:3].
Voltage of 12 V is available:
Check the distance between the sensor
and the reference plate.
Verify that conductor 211 between [B59:2]
and [X901:11] is intact.
Replace the reference sensor [B59].
Voltage of 12 V is not available:
• Verify that conductors 203/[X901:3] to
[B59:1] and 212/[X901:12] to [B59:3]
are intact.
• Replace the power steering unit.
5:300 The servo steering does not react as 1. Restart the truck.
& expected.
2. In the error log/list: Check other simul-
5:304 Driving is blocked and the truck is
taneous error codes.
braked to a stop with the motor brake.
If there are other error codes, correct
these before continuing with trouble-
shooting.
3. Check the steering servo's wiring har-
ness.
4. Replace the steering servo.
5:301 Steering servo power stage fault. 1. Check fuse [F72].
Driving is blocked and the truck is
2. Check that there is a battery voltage
braked to a stop with the motor brake.
between conductors 250/[X901:8] +
[X901:16] och 40/[X901:7] +
[X901:15].
3. Replace the steering servo.

8 – 90 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
Troubleshooting using error code
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

Indica- Cause Tip

tor.
5:302 The MCU cannot transfer the parame- Update the truck firmware to the latest
ters to the steering servo. available version
Driving is blocked and the truck is
braked to a stop with the motor brake.
5:303 The steering servo does not respond 1. Check fuse [F64] and [F72].
on start up.
2. Check that there is a battery voltage
Driving is blocked and the truck is
between conductors 250/[X901:8] +
braked to a stop with the motor brake.
[X901:16] och 40/[X901:7] + [X901:15]
as well as between conductors 9/
[X901:6] och 40/[X901:7] + [X901:15].
3. Check there is approx 60 ohm in the
wiring harness for CAN2 at [X901:2]
[X901:10].
4. Replace the steering servo.
5:320 The steering servo's supply is less 1. Check the battery voltage.
than 24 VDC.
2. Check fuse [F64] and [F72].
Driving is blocked and the truck is
braked to a stop with the motor brake. 3. Check that there is a battery voltage
between conductors 250/[X901:8] +
[X901:16] och 40/[X901:7] + [X901:15]
as well as between conductors 9/
[X901:6] och 40/[X901:7] + [X901:15].
5:325 Thermal overcurrent in the steering 1. Check that there are no objects block-
servo, 100 % of permitted value. ing the steering movement.
Driving is blocked and the truck is
2. Check that the steering gear is not
braked to a stop with the motor brake.
jammed or blocked by dust, thread or
contaminants.
3. Replace the steering servo.
5:326 The steering servo's power stage is If the truck is used where the ambient
under -40 °C or over +85 °C. temperature is within specified
Driving is blocked and the truck is temperature limits:
braked to a stop with the motor brake. Check that the motor compartment fan is
working normally. CID Service function:

5:335 Internal error in the steering servo. Replace the steering servo.
– Driving is blocked and the truck is
5:336 braked to a stop with the motor brake.

© BT Repair Manual RRE140/160/180/200/250 8 – 91

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
5:380 Supply error – Steering sensor 1. Check that there is 5 V between [B13:1]
Driving is blocked and the truck is and [B13:4]:
braked to a stop with the motor brake. If there is 5 V:
Replace the CID.
If there is not 5 V:
• Check that conductors 42/[504:14] to
[B13:1] and 45/[X504:5] to [B13:4] are
intact.
• Check 5 V between [X504:14] and
[X504:5].
• Replace the CID.
5:381 Supply error – Steering sensor 2. Check that there is 5 V between [B13:5]
Driving is blocked and the truck is and [B13:8]:
braked to a stop with the motor brake. If there is 5 V:
Replace the CID.
If there is not 5 V:
• Check that conductors 46/[504:12] to
[B13:5] and 45/[X504:5] to [B13:8] are
intact.
• Check 5 V between [X504:12] and
[X504:5].
• Replace the CID.
5:382 Abnormal pulse frequency from the 1. Check that the CID's inputs from the
steering sensor. steering pulse sensors are stable,
Driving is blocked and the truck is CID's diagnostic screen 2, pos 1 – 4:
braked to a stop with the motor brake.

2. Check that conductors

43/[X504:13] to [B13:3],
44/[X504:4] to [B13:2],
47/[X504:11] to [B14:7],
48/[X504:2] to [B14:6] are intact.
3. Replace the steering sensor.
4. Replace the CID.

8 – 92 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
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Indica- Cause Tip

tor.
5:383 Interruption in pulse series from 1. Check that all the CID's inputs from the
steering sensors 1 and 2. steering pulse sensors switch status
Driving is blocked and the truck is when the steering wheel is turned,
braked to a stop with the motor brake. CID's diagnostic screen 2, pos 1 – 4:

2. Check that conductors

43/[X504:13] to [B13:3],
44/[X504:4] to [B13:2],
47/[X504:11] to [B14:7],
48/[X504:2] to [B14:6] are intact.
3. Replace the steering sensor.
4. Replace the CID.
5:384 Power supply error - Steering sensor • Check whether 5 V is available be-
1 and 2. tween [B13:1] and [B13:4] as well as
between [B13:5] and [B13:8].
Truck travel disabled and truck brakes to
standstill using the motor brake. Voltage of 5 V is available:
• Replace the CID.
Voltage of 5 V is not available:
• Verify that conductors 42/[504:14] to
[B13:1] and 45/[X504:5] to [B13:4] are
intact.
• Inspect 5 V between [X504:14] and
[X504:5].
• Verify that conductors 46/[504:12] to
[B13:5] and 45/[X504:5] to [B13:8] are
intact.
• Inspect 5 V between [X504:12] and
[X504:5].
• Replace the CID.

© BT Repair Manual RRE140/160/180/200/250 8 – 93

 Troubleshooting
Troubleshooting using error code
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040

Indica- Cause Tip

tor.
5:414 The MCU or steering servo have not 1. Check fuse [F64] & [72].
– responded via CAN2 within 70 ms.
2. Check that CAN 2 is intact in terms of
5:416 The truck is braked by the motor brake
wiring harness, final resistance and
until it stops.
contacts. Disonnect the battery. Check
that the resistance between [X130:8]
and [X130:22] is 54 – 66 ohm.
3. Check that there is a battery voltage
between conductors 250/[X901:8] +
[X901:16] och 40/[X901:7] + [X901:15]
as well as between conductors 9/
[X901:6] och 40/[X901:7] + [X901:15].
4. Replace the steering servo.
5:421 The steering servo's direct voltage is 1. Check whether there are other, simul-
above 72 V. taneous error codes being stored. If
The truck is braked by the motor brake this is the case: fix these before contin-
until it stops. uing the troubleshooting.
2. Replace the steering servo.
5:422 Short circuit in the steering servo Replace the steering servo.
The truck is braked by the motor brake
until it stops.
5:435 Internal error in the steering servo. Replace the steering servo.
– The truck is braked by the motor brake
5:438 until it stops.
5:500 Unknown steering servo error. 1. Update the truck firmware to the latest
available version
2. Replace the steering servo.
5:501 The steering servo has detected an Make a back up copy of the truck's param-
error in the MCU. eter settings and update all software.
5:509 Steering manoeuvre without request. Replace the steering servo.

8 – 94 Repair Manual RRE140/160/180/200/250 © BT

 Troubleshooting
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Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816

8.5.6 GFU, warnings and errors

Indica- Cause Tip

tor.
7:411 The MCU or GFU have not responded 1. Check fuse [F65].
– via CAN1 within 70 ms.
2. Disonnect the battery. Check that the
7:412 The truck is braked by the motor brake
resistance between [X41:3] and
until it stops.
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect GFU.
4. Replace the GFU.

© BT Repair Manual RRE140/160/180/200/250 8 – 95