forklift error codes – Page 8 – Forklift Error Codes

STATUS CODES 1 through 76 are for the traction Transistor control and STATUS CODES 90 through 95 are for the truck management module (TMM). STATUS CODES 200 through 299 are for the steering module. STATUS CODES 300 through 399 are for the display module and STATUS CODES 400 through 499 are for wire guidance. STATUS CODE BLANK DISPLAY This status code is displayed when input voltage to the control card and/or display unit is not present.Symptom: Blank display screen. Possible Cause: Positive or negative control volts missing.•Make certain keyswitch has been cycled from “off” to “test” to “on”. Battery volts should be present at CA402-1 and TB403-4 using power terminal N for negative.Open circuit between traction control card plug CA404 and display.•Check for open circuit or loose connections between each wire going between traction control card plug CA404 and display.Defective display.•Replace. STATUS CODE 01 This status code is displayed when TB403-3 is less than 50% of battery volts.Symptom: Forward or reverse contactor will not energize. Possible Cause: Operator left truck with direction control not in neutral.•Set direction control to neutral.Check input signal to TB403-3 on control card. STATUS CODE 02 or Neutral This status code is displayed when TB403-5 is greater than 60% battery volts atinitial power up.Symptom: Forward contactor will not energize. Static return to off (SRO) lock out. Possible Cause:-Direction control in forward at power up.•Set direction control to neutral. Input signal present at TB403-5 at power up.•Check for short circuit to TB403-5.Defective card.•Replace. STATUS CODE 03 or Neutral This status code is displayed when TB403-6 is greater than 60% battery volts atinitial power up.Symptom: Reverse contactor will not energize. Static return to off (SRO) lock out.Possible Cause-Direction control in reverse at power up.•Set direction control to neutral. Input signal present at TB403-6 at power up.•Check for short circuit to TB403-6.Defective card.•Replace. STATUS CODE 05 or Brake This status code is displayed when TB403-1 is less than 2.5 volts and TB403-2 is less than 60% of battery volts at the same time.Symptom: Forward or reverse contactor will not energize. Possible Cause Traction speed control signal present at TB403-1 before input signal to TB403-2 present.•Check input signal to TB403-2.•Check input signal to TB403-1. STATUS CODE 06 or Gate This status code is displayed when TB403-5 or TB403-6 are less than 60% of battery volts and TB403-1 is less than 2.5 volts.Symptom: Forward or reverse contactor will not energize. Also, when twistgrip rotated, no and/or intermittent traction (one or both directions), contactors do not pull in and "GATE" appears on display, no fault codes logged. Possible Cause Accelerator (potentiometer) input to card changes prior to switch closure.•Directional switch(es) out of adjustment. STATUS CODE 07 This status code is displayed when the accelerator input voltage at TB403-1 ishigher than 3.7 volts when a directional contactor is energized.NOTEThe code will only be displayed when attempting travel in one direction. When opposite direction is selected, codewill disappear.Symptom: Forward or reverse contactor energize but control does not operate when speed command is increased or statuscode is displayed until the truck starts to accelerate.Possible Cause Accelerator control associated wiring short or open circuited. Check signal path for TB403-1.Accelerator control defective.•Accelerator input at TB403-1 should be 3.7 volts with the key “on” and the accelerator released. As speed request is increased, voltage should decrease smoothly to .5 volts with top speed requested. Repair or replace accelerator control. STATUS CODE 08 or Neutral This status code is displayed when the accelerator input voltage at TB403-1 isless than 3.0 volts when any of the following inputs are interrupted; TB403-4,TB403-3 or TB403-2.Symptom: Forward or reverse contactor does not energize. Possible Cause With no speed command from the accelerator, voltage at TB403-1 should be greater than 3.0 volts.•Check adjustment of accelerator control and associated wiring.Input signal interruption to TB403-4, TB403-3 and/or TB403-2.•Check adjustment of switches in the above signal input lines and associated wiring. STATUS CODE 09 This status code will be displayed when TB403-5 and TB403-6 are greater than60% of battery volts at the same time.Symptom: Forward or reverse contactor will not energize. Possible Cause Forward and/or reverse switch contact welded or associated wiring short circuited.•With directional control in the neutral position, check forward and reverse switch contacts for short circuits. Check associated wiring for short circuits. STATUS CODE 15 or Battery This status code is displayed when the battery volts are less than 1.95 volts percell at initial start up.Symptom: Forward or reverse contactor will not energize. Possible Cause Insufficient battery charge.•Check battery state of charge and overall condition. Take corrective action if necessary.Incorrect control card setting.•If control card was just installed, make certain Function 15 of control card tune up is set correctly. Refer to tune up section (M4.2 of truck Service Manual) for correct value. STATUS CODE 16 This status code is displayed when the battery volts are greater than 2.40 voltsper cell at initial startup.Symptom: Forward or reverse contactor will not energize. Possible Cause Battery overcharged or incorrect battery installed.•Check battery state-of-charge and take corrective action if necessary.Incorrect control card setting.•If control card was just installed, make certain Function 15 of control card tune up is set correctly. Refer to tune up section (M4.2 in truck Service Manual) for correct value. STATUS CODE 17 This status code is displayed when the control card type selection value is set to aninvalid number.Symptom: Forward or reverse contactor will not energize. Possible Cause Invalid card type selection made during new control card tune up.•Make certain Function 17 of control card tune up is set correctly. Refer to tune up section (M4.2 in truck Service Manual) for correct value. STATUS CODE 23 This status code is displayed when the current draw in the forward or reversecontactor coil circuit is less than 100 ma.Symptom: Forward or reverse contactor will not energize. Status code may alternate between status code 23 and status code 24. Complete check for status code 23 and if the problem is not found, perform checks for status code 24. Possible Cause Open circuit in forward or reverse contactor coil circuit.•Check wiring and connections between control card plug CA402 position 4 and positive side of forward contactor coil.Resistance of this circuit should be between 10 and 14 ohms.•Check wiring and connections between control card plug CA402 position 5 and positive side of reverse contactor coil.Resistance of this circuit should be between 10 and 14 ohms.Open circuit in 1A, RB, SP, or FW contactor coil circuit.•Disconnect plug CA402 from control card and check resistance between positive side of contactor coils and plug CA402. Resistance should be between 10 and 14 ohms. Plug CA402 position 6 for the 1A contactor, position 2 for the regenerative braking contactor, position 3 for the steering pump contactor and position 1 for the field weakening contactor. STATUS CODE 24 This status code is displayed when T2 volts is greater than 88% of battery voltsand the forward and reverse driver is enabled. Symptom: Transistor control does not operate. Status code display may alternate between status code 23 and status code 24. Complete check for status code 24 and if the problem is not found, perform checks for status code 23. Possible Cause Forward or reverse contactor normally open tips do not close.•Check for welded contactor normally closed contacts.•Check for binding in contactor assembly.•Make status code 23 checks.RB contactor failure.•Check contactor for binding parts.•Disconnect plug CA402 from control card and check resistance between positive side of contactor coil and plug CA402 position 2. Resistance should be between 10 and 14 ohms.Open motor circuit.•Check for loose connection or open circuit in motor circuit between terminals A1 and A2 on SCR panel. STATUS CODE 26 This status code is displayed when a shorted RB, SP or FW coil driver is presentin the control card.Symptom: RB, SP or FW contactor energizes immediately when keyswitch is closed. Possible Cause Defective coil driver internal to control card.•Replace control card. STATUS CODE 27 This status code is displayed when the control card supply voltage is less than 10volts.Symptom: Forward or reverse contactors open momentarily, close and open again (PMT trip). Possible Cause Insufficient battery charge.•Check battery state of charge and overall condition. Take corrective action if necessary.Loose connection at CA402-1•Make certain contact is making good electrical connection. STATUS CODE 41 This status code is displayed when voltage between PCZ-2 and PCZ-5 is greater than 0.8 volts.Symptom: Reduced or no power to traction control in Transistor range. Possible Cause Open circuit in thermal protector circuit.•Check for loose connection or broken violet wire between the thermal protector and control card plug PCZ-2.•Check for loose connection or broken violet stripe/white wire between the thermal protector and control card plug PCZ-5.Thermal protector defective.•Disconnect plug PCZ from control card. With thermal protector at room temperature (75° F / 25° C), check resistance between plug positions 2 and 5. Replace thermal protector if resistance value is greater than 900 ohms.Transistor control operating is thermal cutback.•Allow control to cool. STATUS CODE 42 This status code is displayed when voltage between plug PCZ-12 and PCZ-13 isgreater than 0.1 volt with no current flowing in the motor circuit.Symptom: No power to traction motor in Transistor range. Possible Cause Transistor motor current sensor input missing.•Check for broken green wire between current sensor and control card plug PCZ-12.•Check condition of contact in plug PCZ position 12. STATUS CODE 43 This status code is displayed when voltage between PCZ-12 and PCZ-13 is lessthan 0.1 volts with no current flowing in motor circuit. Possible Cause SCR motor current sensor input missing.•Check for broken yellow wire between current sensor and control card plug PCZ-13.•Check condition of contact in plug PCZ position 13.