Forklift Error Codes – Forklift Troubleshooting

I found these error codes and procedures to work on the Clark forklift with the Hyundai engine. Displaying Fault Codes from ECM Memory To enter code display mode, you must turn OFF the ignition key. Now turn ON the key but do not start the engine. As soon as you turn the key to the ON position you must cycle the foot pedal by depressing it to the floor and then fully releasing the pedal (pedal maneuver). You must fully cycle the foot pedal three (3) times within five (5) seconds to enable the display codes feature of the SECM. Simply turn the key OFF to exit display mode. The code list will continue to repeat until the key is turned OFF. An automatic code display feature is activated if a foot pedal fault condition exists. This feature enables the service technician to view the fault codes by turning the key to the ON position, if a foot pedal malfunction is preventing the retrieval of the stored fault codes from the SECM. Reading Diagnostic Fault Codes All MI-4 fault codes are two digit codes. When the fault codes are retrieved (displayed) the MIL will flash for each digit with a short pause (.5 seconds) between digits and a long pause (1.2 seconds) between fault codes. A code 12 is displayed at the beginning of the code list.EXAMPLE: A code 26 has been detected (ETC Sticking) and the engine has shut down and the MIL has remained ON. When the codes are displayed the MIL will flash one time (1), pause, then flash two times (2). This identifies a twelve (12), which is the beginning of the fault list. It will then pause for 1.2 seconds (long pause) and flash two times (2), pause, then flash six times (6). This identifies a twenty-six (26), which is the ETC Sticking fault. If any additional faults were stored the SECM would again have a long pause, then display the next fault by flashing each digit. Since no other faults were stored, there will be a long pause then one flash (1), pause, then two flashes (2). This identifies a twelve meaning the fault list will begin again. Diagnostic Fault Codes (Flash Codes) DFCProbable FaultActionCorrective Action, First Check12NONESignifies the end of one passthrough the fault listNONENone, used as a beginning and end of the fault listidentification14ECTSensorInputLowCoolant sensor failure or shortedto GNDStored Fault Code(MIL Only)Check ECT sensor connector and wiring for a shortto GNDSECM(SIGNAL) PIN 16 to ECT PIN ASECM(GND) PIN 1 to ECT PIN B15ECTSensorInputHighCoolant sensor disconnected oropen circuitStored Fault Code(MIL Only)Check if ECT sensor connector is disconnected orfor an open ECT circuitSECM(SIGNAL) PIN 16 to ECT PIN ASECM(GND) PIN 1 to ECT PIN B16ECTRangeHighEngine OverheatingDelayed EngineShutdownCheck coolant system for radiator blockage, propercoolant level and for leaks in the system.Possible ECT short to GND, check ECT signal wiringSECM(SIGNAL) PIN 16 to ECT PIN ASECM(GND) PIN 1 to ECT PIN B22ThrottleSensorInputLoTPS1 signal disconnected oropen circuit(Expected faults when ETCconnector is unpluggedCODES: 22 & 24)Disable ThrottleCheck throttle connector connection and TPS1sensor for an open circuitETC PIN 6 to SECM PIN 17(SIGNAL)ETC PIN 2 to SECM PIN 1(GND)23ThrottleSensorInputHiTPS1 sensor failure or shortedcircuitDisable ThrottleCheck throttle connector and TPS1 sensor wiring fora shorted circuitETC PIN 6 to SECM PIN 17(SIGNAL)ETC PIN 2 to SECM PIN 1(GND)24ThrottleSensorRangeLoTPS1 potentiometer malfunction.Improper TPS reading may bedue to dirt or oxidation on thesensor traces.Stored Fault Code(MIL Only)Check the throttle connector and pins for corrosion.•Perform Throttle test with the Service Tool sev-eral times to clean sensorTo check the TPS disconnect the throttle connectorand measure the resistance(1.25KΩ +/-30%) fromTPS PIN 2 (GND) to PIN 6 (TPS1 SIGNAL)TPS PIN 3 (PWR) to PIN 6 (TPS1 SIGNAL)25ThrottleSensorRangeHiTPS1 potentiometer malfunction.Improper TPS reading may bedue to dirt or oxidation on thesensor traces.Stored Fault Code(MIL Only)Check the throttle connector and pins for corrosion.•Perform Throttle test with the Service Tool several times to clean sensorTo check the TPS disconnect the throttle connectorand measure the resistance (1.25KΩ +/-30%) fromTPS PIN 2 (GND) to PIN 6 (TPS1 SIGNAL)TPS PIN 3 (PWR) to PIN 6 (TPS1 SIGNAL)26ETCStickingThrottle plate sticking inside thethrottle body or the ETC driversignal is openEngine ShutdownCheck for debris or obstructions inside the throttlebody•Perform Throttle test using the Service Tooland re-check for fault•Check throttle-plate shaft for bearing wearCheck the ETC driver wiring for an open circuitETC+ PIN 1to SECM PIN 22ETC- PIN 4 to SECM PIN 24Check the ETC internal motor drive bydisconnecting the throttle connector and measuring the motor drive resistance at the throttleTPS PIN 1 (+DRIVER) to PIN 4 (-DRIVER) ~3.0Ω+/-30%27PredictedTPSDifferenceMeasured TPS1 is different thanSECM Calculated throttle positionEngine ShutdownCheck for manifold leaks between the throttle andthe engine28ETCSpringTestFailedUpon initial key-up the internalthrottle return spring has becomeweakPower LimitPerform throttle spring test by cycling the ignition key and re-check for fault29ETCDriverFaultThrottle driver over-current ordriver signals shortedDisable ThrottleCheck ETC driver wiring for a shorted circuitETC+ PIN 1 to SECM PIN 22ETC- PIN 4 to SECM PIN 24•Perform Throttle test and with the Service Tool and re-check for faultCheck the ETC internal motor drive bydisconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS PIN 1 (+DRIVER) to PIN 4 (-DRIVER) ~3.0Ω +/-30%33MapSensorInputLowMAP signal disconnected, opencircuit or sensor malfunction(Expected faults when TMAPconnector is unpluggedCODES: 33 & 38)Disable ThrottleCheck TMAP connector and MAP signal wiring foran open circuitTMAP PIN 4 to SECM PIN 5 (SIGNAL)TMAP PIN 1 to SECM PIN 1 (GND)TMAP PIN 3 to SECM PIN 18 (XDCR +5VDC)Check the MAP sensor by disconnecting the TMAPconnector and measuring at the sensorTMAP PIN 1(GND) to PIN 4 (PRESSURE SIGNALKPA) (2.4kΩ -8.2kΩ)TMAP PIN 3(PWR) to PIN 4 (PRESSURE SIGNALKPA) (3.4kΩ -8.2kΩ)34MapSensorInputHighTMAP sensor failure or shortedcircuitDisable ThrottleCheck TMAP connector and MAP signal wiring for ashorted circuitTMAP PIN 4 to SECM PIN 5 (SIGNAL)TMAP PIN 1 to SECM PIN 1 (GND)TMAP PIN 3 to SECM PIN 18 (XDCR +5VDC)Check the MAP sensor by disconnecting the TMAPconnector and measuring at the sensorTMAP PIN 1(GND) to PIN 4 (PRESSURE SIGNALKPA) (2.4kΩ -8.2kΩ)TMAP PIN 1(PWR) to PIN 4 (PRESSURE SIGNALKPA) (3.4kΩ -8.2kΩ)37IATSensorInputLowTMAP sensor failure or shortedcircuitStored Fault Code(MIL Only)Check TMAP connector and IAT signal wiring for ashorted circuitTMAP PIN 2 to SECM PIN 4 (SIGNAL)TMAP PIN 1 to SECM PIN 1 (GND)TMAP PIN 3 to SECM PIN 18 (XDCR +5VDC)To check the IAT sensor of the TMAP disconnect theTMAP connector and measure the IAT resistance38IATSensorInputHighIAT signal disconnected, opencircuit or sensor malfunctionStored Fault Code(MIL Only)Check TMAP connector and IAT signal wiring for anopen circuitTMAP PIN 2 to SECM PIN 4 (SIGNAL)TMAP PIN 1 to SECM PIN 1 (GND)TMAP PIN 3 to SECM PIN 18 (XDCR +5VDC)To check the IAT sensor of the TMAP disconnect theTMAP connector and measure the IAT resistance42EST1LowCoil driver signal low or under-currentStored Fault Code(MIL Only)Check coil driver wiring and connector for shortsSECM PIN 7(EST1) to COIL PIN AVerify GND on COIL PIN BVerify GND on COIL PIN CVerify GND on COIL PIN DVerify +12vdc on COIL PIN ETo check the Smart Coil internal circuit disconnectthe coil connector and measure the resistance frompin to pin43EST1HighCoil driver signal high or over-currentStored Fault Code(MIL Only)Check coil driver wiring for an open circuit ordisconnected connectorSECM PIN 7(EST1) to COIL PIN AVerify GND on COIL PIN BVerify GND on COIL PIN CVerify GND on COIL PIN DVerify +12vdc on COIL PIN ETo check the Smart Coil internal circuit disconnectthe coil connector and measure the resistance frompin to pin52LowOilPressureLow Engine Oil PressureDelayed EngineShutdownCheck engine oil levelCheck electrical connection to the oil pressureswitchSECM PIN 23 to Oil Pressure Switch53BatterySensorInputLowBattery voltage measured below+8.5 VDCStored Fault Code(MIL Only)Check battery voltage•Perform maintenance check on electrical con-nections to the battery and chassis ground•Check battery voltage during starting and withthe engine running to verify charging systemand alternator functionMeasure battery power at the SECM with amultimeterSECM PIN 13 (BATT +) toSECM PIN 14(BATT -)54DFCProbable FaultBatterySensorInputHighBattery voltage measured above+15.9 VDCStored Fault Code(MIL Only)Check battery and charging system voltage•Check battery voltage during starting and withthe engine running•Check voltage regulator, alternator and charg-ing system•Check battery and wiring for overheating anddamage•Measure battery power at the SECM with amultimeterSECM PIN 13 (BATT +) toSECM PIN 14 (BATT -)55XDRPSensorInputLow+5VDC Transducer powersupplied by the SECM to thesensors is below +4.60VDC(Expected faults whenTransducer power is lostCODES: 22, 24, 33, 62, 64, 66,68 & 69)Engine ShutdownMeasrue transducer power at the TMAP connectorwith a multimeterTMAP PIN 3 +5VDC to TMAP PIN 1 XDCR GNDVerify transducer power at the SECM with amultimeterSECM PIN 18 +5VDC to SECM PIN 1 XDCR GNDVerify transducer power at ECT with a multimeterETC PIN 3 XDCR PWR to ETC PIN 2 XDCR GNDVerify transducer power to the foot pedal with amultimeter56XDRPSensorInputHigh+5VDC Transducer powersupplied by the SECM to thesensors is above +5.20VDCEngine ShutdownMeasrue transducer power at the TMAP connectorwith a multimeterTMAP PIN 3 +5VDC to TMAP PIN 1 XDCR GNDVerify transducer power at the SECM with amultimeterSECM PIN 18 +5VDC to SECM PIN 1 XDCR GNDVerify transducer power at ECT with a multimeterETC PIN 3 XDCR PWR to ETC PIN 2 XDCR GNDVerify transducer power to the foot pedal with amultimeter57Engine OverSpeedEngine RPM increased beyondmaximum RPM set pointEngine ShutdownUsually associated with additional ETC faults•Check for ETC Sticking or other ETC faults•Verify if the lift truck was motored down a steepgrade61Pedal1SensorInputLoAPP1 signal disconnected, opencircuit or sensor malfunction(Expected faults when APPconnector is unpluggedCODES: 61 & 66)MIN Power LimitCheck foot pedal connector•Check APP1 signal at SECM PIN 1562Pedal1SensorInputHiAPP1 sensor failure or shortedcircuitMIN Power limitCheck foot pedal connector•Check APP1 signal at SECM PIN 1563Pedal1SensorRangeLoAPP1 potentiometer malfunction.Improper APP1 reading may bedue to dirt or oxidation on thesensor traces.Stored Fault Code(MIL Only)Check foot pedal connector•Cycle the pedal several times and check APP1signal at SECM PIN 1564Pedal1SensorRangeHiAPP1 potentiometer malfunction.Improper APP1 reading may bedue to dirt or oxidation on thesensor tracesStored Fault Code(MIL Only)Check foot pedal connector•Cycle the pedal several times and check APP1signal at SECM PIN 1565Pedal2SensorInputLoAPP2 sensor failure or shortedcircuitMIN power LimitCheck foot pedal connector•Cycle the pedal several times and check APP2signal at SECM PIN 266Pedal2SensorInputHiAPP2 signal disconnected, opencircuit or sensor malfunction(Expected faults when APPconnector is unpluggedCODES: 61 & 66)MIN power LimitCheck foot pedal connector•Check APP2 signal at SECM PIN 267Pedal2SensorRangeLoAPP2 potentiometer malfunction.Improper APP2 reading may bedue to dirt or oxidation on thesensor traces.Stored Fault Code(MIL Only)Check foot pedal connector•Cycle the pedal several times and check APP2signal at SECM PIN 268edal2SensorRangeHiAPP2 potentiometer malfunction.Improper APP2 reading may bedue to dirt or oxidation on thesensor traces.Stored Fault Code(MIL Only)Check foot pedal connector•Cycle the pedal several times and check APP2signal at SECM PIN 269Pedal1ToPedal2DifferenceMeasured APP2 pedal positionsignal is different than APP1signalMIN power LimitCheck foot pedal connector•Cycle the pedal several times and check APP1signal at SECM PIN 15•Check APP2 signal at SECM PIN 271AFRTrimValveOutputFTV modulation driver signal faultStored Fault Code(MIL, Disable Adaptivelearns)Check FTV for an open wire or FTV connector beingdisconnectedFTV PIN A (SIGNAL) to PIN B (PWR)Check FTV for an open coil by disconnecting theFTV connector and measuring the resistance(~26Ω +/-2Ω)FTV PIN A (SIGNAL) to PIN B (PWR)72AFRTrimValveLowerDCFTV duty cycle at lower (lean)limitStored Fault Code(MIL, Disable Adaptivelearns)Engine measured Air/Fuel ratio at the O2 sensor isexcessively lean•Check for intake manifold leaks•Check balance line(vacuum hose) connectionat the regulator•Check N-CA55-500-TR mixer for heavy endbuild-up and operation (see mixer section)•Check N2001 secondary for operation or lowprimary pressure73AFRTrimValveUpperDCFTV duty cycle at high (rich) limit(Expected fault when FTVconnector is unplugged)Stored Fault Code(MIL, Disable Adaptivelearns)Engine measured Air/Fuel ratio at the O2 sensor isexcessively richCheck FTV connector wiring for an open circuitFTV PIN 4 (SIGNAL) to PIN B (PWR)Check FTV for an open coil by disconnecting theFTV connector and measuring the resistance(~26Ω +/-2Ω)FTV PIN A (SIGNAL) to PIN B (PWR)•Check N-CA55-500-TR mixer for heavy endbuild-up and operation (see mixer section)•Check N2001 secondary for operation (seeN2001 Regulator section)74O2SensorSwitchingO2 sensor is not switching acrossthe reference AFR voltageStored Fault Code(MIL, Disable Adaptivelearns)Check the FTV for proper operation•Check FTV Hose ConnectionsCheck FTV for an open coil by disconnecting theFTV connector and measuring the resistance(~26Ω +/-2Ω)FTV PIN A (SIGNAL) to PIN B (PWR)77OxygenSensorInputHighO2 sensor SECM driver signal isshorted to powerStored Fault Code(MIL, Disable Adapts)Check if O2 sensor is shorted to +5VDC or BatteryO2 (SIGNAL) PIN B to SECM PIN 3(AFR Trim Valve Lower DC fault should also occur)Verify O2 sensor heater circuit is operating bymeasuring circuit resistance (~2.1Ω +/-0.4Ω)O2 PIN C (HEATER GND) to PIN D (HEATER PWR) Error CodeError MessageDescription014DRI. FWD S/CDIRECTION FORWARD LINE S/C011DRI. REV S/CDIRECTION REVERSE LINE S/C018FUEL SENDRE S/CFUEL SENSER S/C025HORN RELAY S/CHORN RELAY COIL S/C027BACKUPO ALARM S/CBACKUP ALARM LINE S/C033ST. RELAY S/CSTART RELAY COIL LINE S/C021GLOWPLUG S/CPREHEATER RELAY COIL LINE S/C006HEADLAMP S/CHEAD LAMP S/C028DIR. FWD SOLENOID S/CDIRECTION FORWARD SOL OUT S/C007DIR. REV SOL S/CDIRECTION REVERSE SOL OUT S/C900DOUBLE ERRORERROR OF THE CAUSING PIN NUMBERCAN'T BE DETERMINED404INTERNAL SHORTINTERNAL SHORT

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