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Yale ERP040VFN36TE082:
Error code 12576
This truck is actually a ERP040VTN36TE082; SER.# G807N02089H. I think this is an open motor or bad controller. I’m unsure how to isolate which motor or controller it might be. If that’s the problem at all. Any help is appreciated.
- Posted
9 Nov 2017 08:59 - Discussion started by
patiencedad - Massachusetts, United States
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First off, Check the truck wiring for short to frame. Both Positive and negative. The next thing is to check the CANbus loop for proper resistance and connectivity to each component. A lot of these codes are caused by faulty com wiring.
- Posted
10 Nov 2017 01:49 - Reply by
BREWSKI - Nebraska, United States
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These codes cover the three and four wheel electric trucks with the overhead display.
Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL):
DTC 12844 – Load Weigh Pressure
DTC 12836 – Service Brake Pressure
Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH):
DTC 12845 – Load Weigh Pressure
DTC 12837 – Service Brake Pressure
Accelerator Pedal Position A/B Out of Range Low (OORL):
DTC 12808 – Accelerator Pedal Position A
DTC 12810 – Accelerator Pedal Position B
Accelerator Pedal Position A/B Out of Range High (OORH):
DTC 12809 – Accelerator Pedal Position A
DTC 12811 – Accelerator Pedal Position B
Accelerator Pedal Position A/B Data Incorrect:
DTC 12812 – Accelerator Pedal Position A to B
DTC 29536 – Loss of Speed Sensor Channel A
DTC 65362 – Encoder Error
DTC 65512 – Wrong Encoder Set
DTC 65106 – FOC2 Traction Controller Encoder Error
DTC 29248 – Speed Sensor Feedback
Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL):
DTC 12820 – Steering Wheel Position
DTC 12824 – Steering Axle Position
Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH):
DTC 12821 – Steering Wheel Position
DTC 12825 – Steering Axle Position
Steer Axle Calibration Required:
DTC 4098 – Steer Axle Calibration
Hydraulic Temperature Sensor Out of Range Low (OORL) :
DTC 12852 – Hydraulic Temperature
Hydraulic Temperature Sensor Out of Range High (OORH) :
DTC 12853 – Hydraulic Temperature
Hydraulic Fluid Level Sensor Out Of Range Low (OORL):
DTC 12872 – Hydraulic Fluid Level
Hydraulic Fluid Level Sensor Out Of Range High (OORH):
DTC 12873 – Hydraulic Fluid Level
Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL):
DTC 12832 – Park Brake Position
DTC 12840 – Mast Tilt Position
Park Brake/Mast Tilt Position Sensor Out of Range High (OORH):
DTC 12831 – Park Brake Position
DTC 12841 – Mast Tilt Position
Travel Direction Select – Foot Pedal/Manual Hydraulic Out of Range Low (OORL):
DTC 12800 – Directional Select A
DTC 12804 – Directional Select B
Travel Direction Select – Foot Pedal/Manual Hydraulic Out of Range High (OORH):
DTC 12801 – Directional Select A
DTC 12805 – Directional Select B
Seat Sensor Out of Range Low (OORL):
DTC 12816 – Seat Sensor
Seat Sensor Out of Range High (OORH):
DTC 12819 – Seat Sensor
Battery OORH/OORL:
DTC 12545 – Battery OORH
DTC 12546 – Battery OORL
VSM 5 Volt Supply (OORL) (OORH):
DTC 13056 – 5V OORL
DTC 13057 – 5V OORH
Manual Hydraulic Position Sensors Out Of Range Low (OORL):
DTC 12856 – Manual Hyd 1
DTC 12860 – Manual Hyd 2
DTC 12864 – Manual Hyd 3
DTC 12868 – Manual Hyd 4
Manual Hydraulic Position Sensor Out Of Range High (OORH):
DTC 12857 – Manual Hyd 1
DTC 12861 – Manual Hyd 2
DTC 12865 – Manual Hyd 3
DTC 12869 – Manual Hyd 4
E-Hydraulic Enable System Data Incorrect:
DTC 12332 – Data Incorrect
E-Hydraulic Coils Short To Battery Positive (STBP):
DTC 8960 – Lift
DTC 8964 – Lower
DTC 8968 – Tilt Forward
DTC 8972 – Tilt Back
DTC 8978 – Aux 1A
DTC 8980 – Aux 1B
DTC 8984 – Aux 2A
DTC 8988 – Aux 2B
E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC):
DTC 13312 – Lift
DTC 13316 – Lower
DTC 13320 – Tilt Forward
DTC 13324 – Tilt Back
DTC 13328 – Aux 1A
DTC 13332 – Aux 1B
DTC 13336 – Aux 2A
DTC 13340 – Aux 2B
A935 – K160 CAN Communication Failure:
DTC 33025 – VSM to Display
DTC 33026 – VSM to Traction 1 (Right)
DTC 33027 – VSM to Traction 2 (Left)
DTC 33029 – VSM to Pump
DTC 33034 – VSM to MLM (DCS)
DTC 33035 – VSM to Impact
DTC 33036 – VSM to CAN Reserved 1
DTC 33037 – VSM to CAN Reserved 2
DTC 33038 – VSM to CAN Reserved 3
DTC 33057 – Display to VSM
CBB 4 Wheel CAN Communication:
DTC 33025 – VSM to Display
DTC 33026 – VSM to Traction 1 (Right)
DTC 33027 – VSM to Traction 2 (Left)
DTC 33029 – VSM to Pump
DTC 33034 – VSM to MLM (DCS)
DTC 33035 – VSM to Impact
DTC 33036 – VSM to CAN Reserved 1
DTC 33037 – VSM to CAN Reserved 2
DTC 33038 – VSM to CAN Reserved 3
DTC 33057 – Display to VSM
DBB 4 Wheel CAN Communication:
DTC 33025 – VSM to Display
DTC 33026 – VSM to Traction 1 (Right)
DTC 33027 – VSM to Traction 2 (Left)
DTC 33029 – VSM to Pump
DTC 33034 – VSM to MLM (DCS)
DTC 33035 – VSM to Impact
DTC 33036 – VSM to CAN Reserved 1
DTC 33037 – VSM to CAN Reserved 2
DTC 33038 – VSM to CAN Reserved 3
DTC 33057 – Display to VSM
MLM Failure:
DTC 21830 – MLM EEPROM Write Error
DTC 21834 – MLM Sensor 1 Out of Range
DTC 21835 – MLM Sensor 2 Out of Range
DTC 21836 – MLM Sensor 3 Out of Range
DTC 21837 – MLM Sensor 4 Out of Range
DTC 25344 – MLM Checksum Error
MLM Incorrect Lever Installed:
DTC 4112 – Incorrect Lever 1 Installed
DTC 4113 – Incorrect Lever 2 Installed
DTC 4114 – Incorrect Lever 3 Installed
DTC 4115 – Incorrect Lever 4 Installed
DTC 4116 – Incorrect Lever 5 Installed
VSM 12 Volts Supply OORL/OORH:
DTC 13060 – VSM 12V OORL
DTC 13061 – VSM 12V OORH
Display Internal Failure:
DTC 22032 – Display EEPROM Checksum Error
DTC 22033 – Display Cell Write Error
DTC 33056 – Display Internal CAN Failure
DTC 33057 – Display Communications Error with VSM
DTC 8704 – Display Internal LCD Backlight
DTC 12934 – Display Internal LCD Backlight
DTC 12935 – Display Internal LCD Backlight
DTC 8705 – Display Internal LCD Heater
DTC 12936 – Display Internal LCD Heater
DTC 12937 – Display Internal LCD Heater
DTC 22528 – Display Button *
DTC 22529 – Display Button #
DTC 22530 – Display Arrow
DTC 22531 – Display ] Arrow
DTC 22532 – Display Button 1
DTC 22533 – Display Button 2
DTC 22534 – Display Button 3
DTC 22535 – Display Button 4
DTC 22536 – Display Button 5
DTC 22537 – Display Button 6
DTC 22538 – Display Button 7
DTC 22539 – Display Button 8
DTC 22540 – Display Button 9
DTC 22541 – Display Button 0
Display Failure – Keyswitch Relay Output:
DTC 9041 – Display Keyswitch Output
DTC 12940 – Display Keyswitch Output
DTC 12941 – Display Keyswitch Output
DTC 13070 – Keyswitch Data Incorrect
VSM Controller Check:
DTC 21760 – VSM BOOT_BLOCK Checksum failure
DTC 21761 – CDF_Checksum_failure
DTC 21762 – VSM APPLICATION_SOFTWARE Checksum failure/Error
DTC 21764 – VSM EEPROM Checksum failure/Error
DTC 21766 – VSM EEPROM Cell failure Write Error
DTC 21792 – VSM Serial Number Error
Controller Logic Failure:
DTC 65299 – Controller Logic Failure
Display Failure – Temperature/Buzzer:
DTC 12928 – Display Temperature Sensor (Freezer Option Only)
DTC 12929 – Display Temperature Sensor (Freezer Option Only)
DTC 9040 – Display Buzzer Output
DTC 12938 – Display Buzzer Output
DTC 12939 – Display Buzzer Output
Contactor/Relay/Valve Coil Short to Battery Positive (STBP):
DTC 9000 – Diverter Valve
DTC 9004 – E Hyd Enable
DTC 9008 – Clamp Solenoid (Optional)
DTC 9012 – Acc 2 Relay
DTC 9016 – Forward Relay
DTC 9020 – Reverse Relay
DTC 9026 – Spare 1 Relay
DTC 9028 – Spare 2 Relay
DTC 9032 – Main Contactor
DTC 9036 – 2nd Contactor
Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC):
DTC 13352 – Diverter Valve
DTC 13356 – Hyd Enable
DTC 13360 – Acc 1 Relay
DTC 13364 – Acc 2 Relay
DTC 13368 – Motion Relay
DTC 13372 – Reverse Relay
DTC 13376 – Spare 1 Relay
DTC 13380 – Brake Light Relay Short to B(-) or Open
DTC 13384 – Main Contactor
DTC 13388 – 2nd Contactor
Motor Controller Contactor Failure:
DTC 21569 – Contactor Open
DTC 21570 – Contactor Closed
DTC 65318 – Contactor Open
DTC 65317 – Contactor Closed
DTC 65354 – Driver Shorted High
DTC 65355 – Driver Shorted Low
A935 – K160 D203 Motor Controller Capacitor Failure:
DTC 12592 – Capacitor Charge
A935 – K160 D203 Motor Speed Sensor Failure:
DTC 29456 – Sensor Fault
CBB/DBB Motor Speed Sensor Failure:
DTC 25104 – Sensor Fault
DTC 29456 – Sensor Fault
A935 – K160 Motor Auto Brake Failure:
DTC 8786 – Brake Coil Shorted
DTC 12834 – Aux Driver Short to Bat (-) Brake Coil Open Circuit
DTC 12835 – Aux Driver Open Circuit Excess Current
A935 – K160 D203 Motor Controller Power Mosfet Failure :
DTC 65513 – Power MOS Shorted
A935 – K160 D203 Motor/Motor Controller Failure:
DTC 12576 – Motor Voltage Not OK
A935 – K160 D203 Motor Controller Failure:
DTC 65280 – Controller Failure
CBB/DBB Motor/Motor Controller Failure:
DTC 8976 – AC Current – Over Current
DTC 9024 – AC Current – Short Circuit
A935 – K160 D203 Motor Controller CAN Communication Failure:
DTC 65527 – No CAN Communication
CBB/DBB Motor Controller CAN Communication Failure:
DTC 33024 – CAN Communication Failure
Travel Direction Select Incorrect:
DTC 12802 – Direction Select Data Incorrect – Direction Signals Incorrect
Travel Direction Select Data Incorrect – 2 Sources:
DTC 12806 – Direction Select – Data Incorrect 2 + Direction Devices Installed
Direction Select Data Incorrect – No DCS Source:
DTC 12807 – Direction Select Data Incorrect – No DCS Source
CBB/DBB Motor/Motor Controller Temperature Sensor Failure:
DTC 16912 – Motor Temperature High
DTC 17168 – Controller/Heatsink Temperature High
DTC 25105 – Temperature Sensor Failure
CBB/DBB Motor Controller Current Sensor Failure :
DTC 21008 – Current Sensor Offset Calibration Error
Hydraulic Calibration Required:
DTC 4096 – Hydraulic Calibration Required
CBB/DBB Motor Controller 15 – 5 Volt Internal Failure:
DTC 20753 – 15 Volt Supply Low Voltage
DTC 20755 – 5 Volt Supply Low/High Voltage
CBB/DBB Motor Controller DC Bus Low/High:
DTC 12576 – DC Bus Charging Timeout
DTC 12817 – DC Bus Hi – Software Detected
DTC 12818 – DC Bus Hi – Hardware Detected
DTC 12833 – DC Bus Low – Hardware/Software
CBB/DBB Traction Controller Driver Current High:
DTC 21520 – Aux Driver Current High
DTC 25106 – Park Brake Solenoid and Fan Driver Current High
Synchronous Steering Coil Current:
DTC 8992 – Synchronous Steering Coil Current
DTC 13344 – Synch Steering Coil Open Circuit
DTC 9012 – ACC 2 Current OORH
DTC 65526 – Aux Driver Open
DTC 65534 – Aux Driver Short
DTC 65022 – FOC2 Traction Controller Aux Driver Short
DTC 65288 – Electric Steer Loss of Communication Between the Primary and Secondary
Controller
DTC 65293 – Electric Steer System Controller EEPROM Checksum Failure
DTC 95520 – Key Switch Voltage OORL
DTC 65296 – Motor U-W Phase Voltage Measurement Fault
DTC 65297 – Electric Steer Controller Motor U-V Phase Voltage Measurement Fault
DTC 65352 – Motor W-V Phase Voltage Measurement Fault
DTC 65312 – Motor Phase Voltage Out of Range
DTC 65333 – Electric Steer Controller Standby Current Too High
DTC 65340 – Electric Steer Controller DC Bus Capacitor Charge Timeout
DTC 65341 – Controller Temperature Above Limit
DTC 65345 – Electric Steer Motor Temperature Above Limit
DTC 65350 – Controller Internal Error
DTC 65487 – Electric Steer Initial Nominal Motor Voltage Low
DTC 65488 – Electric Steer Controller EEPROM KO
DTC 65490 – Electric Steer Primary and Secondary Controller Version Mismatch
DTC 65492 – Electric Steer Controller Internal Error
DTC 65493 – Electric Steer Default Parameter Restore
DTC 65495 – Controller Internal Error
DTC 65496 – Controller Internal Error
DTC 65501 – Controller Internal Error
DTC 65505 – Controller Internal Error
DTC 65517 – Electric Steer Controller Internal Error
DTC 65525 – Electric Steer Controller Internal Error
DTC 65530 – Electric Steer Controller Internal Error
DTC 65533 – Electric Steer Controller Internal Error
DTC 65498 – Electric Steer Controller Software Mismatch
DTC 65489 – Controller Internal Error
DTC 65350 – Motor Phase W Current OORL
DTC 65351 – Motor Phase V Current OORL
DTC 65353 – Motor Phase U Current OORL
DTC 65531 – Controller Initialization Test Failed
DTC 65494 – Rapid Change in Steering Wheel Position
DTC 65528 – Electric Steer Wheel Sensor Output Mismatch
DTC 65378 – Steering Wheel Position Error
DTC 65491 – Electric Steer TFD Current within Range but Lower than Expected
DTC 65496 – TFD Resistance Out of Range
DTC 65515 – Electric Steer Controller TFD Short to battery Negative
DTC 65516 – Electric Steer Controller TFD Stand-by Current OORH
DTC 65500 – Electric Steer Steering Motor Locked
DTC 65521 – Electric Steer Controller Steer Axle Slow Response
DTC 65508 – Steer Axle Position Mismatch
DTC 65532 – Steer Axle Sensor Output Mismatch
DTC 65503 – Electric Steer Rapid Change in Steer Axle Position
DTC 65524 – Electric Steer Primary and Secondary Parameter Mismatch
DTC 33050 – E-Steer CAN Communications Failure Right
DTC 33051 – E-Steer CAN Communications Failure Left
DTC 13058 – 5V Internal Supply Out of Range
DTC 13104 – Sensor Ground Current OORH
DTC 16913 – Motor Temperature Sensor Open Circuit
DTC 16914 – Motor Temperature Sensor Short Circuit
DTC 16912 – Motor Temperature OORH
DTC 21521 – Fan Driver Current OORH
DTC 21776 – Internal Error – Hardware
DTC 29232 – Sensor Supply Reference voltage Out of Range
DTC 21522 – Automatic Park Brake Driver Current OORH
DTC 29216 – Speed Sensor High Current
DTC 29217 – Speed Sensor Not Connected
DTC 29233 – Sensor Supply Circuit Out of Range
DTC 29552 – Loss of Speed Sensor Channel B
DTC 65362 – Encoder Error
DTC 65512 – Wrong Encoder Set
DTC 65346 – Battery Low
DTC 65529 – Check Up Needed
DTC 95360 – Forw + Back
DTC 65481 – Wrong Slave Version
DTC 64969 – FOC2 Traction Controller Wrong Slave Version
DTC 65519 – Controller Mismatch
DTC 65007 – FOC2 Traction Controller Mismatch
DTC 65522 – Parameter Transfer
DTC 65010 – FOC2 Traction Controller Parameter Transfer
DTC 65511 – No Slave Enabled
DTC 64999 – FOC2 Traction Controller No Slave Enabled
DTC 65486 – Initial VMN High
DTC 65333 – Standby Current High
DTC 65310 – VMN Low
DTC 65311 – VMN High
DTC 65504 – Waiting for Node
DTC 12836 – Brake Pedal Sensor A OORL
DTC 12837 – Brake Pedal Sensor A OORH
DTC 12876 – Brake Pedal Sensor B OORL
DTC 12877 – Brake Pedal Sensor B OORH
DTC 12813 – Foot Brake Position Rationality
DTC 4117 – FOC Configuration Mismatch
DTC 33040 – Various CAN Errors
Observed Symptoms
No Display/No Truck Operation:
DTC None – No Display/No Truck Operation
A935 – K160 D203 Motor Controller Fan Failure:
DTC None – A935 – K160 Motor Controller Fan Failure
A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure:
DTC None – A935 – K160 Motor/Motor Controller Temperature Sensor Failure
DTC 64776 – Watchdog
DTC 64781 – FOC2 Traction Controller EEPROM Checksum Failure
DTC 65001 – FOC2 Power Transistor Shorted
DTC 65253 – FOC2 Output Mismatch
DTC 65003 – FOC2 coil_short_hw_ko
DTC 64785 – FOC2 Traction Controller Motor U-V Phase Voltage Measurement Fault
(Logic Failure #3)
DTC 64974 – FOC2 Traction Controller Initial Nominal Motor Voltage High.
DTC 64798 – FOC2 Traction Controller Operating Nominal Motor Voltage Low
DTC 64799 – FOC2 Traction Controller Operating Nominal Motor Voltage High
DTC 64975 – FOC2 Traction Initial Nominal Motor Voltage Low
DTC 64821 – FOC2 Traction Controller Standby Current Too High
DTC 64828 – FOC2 Traction Controller DC Bus Capacitor Charge Timeout
DTC 64833 – FOC2 Traction Motor Temperature Above Limit
DTC 64976 – EEPROM KO
DTC 64781 – EEPROM KO
DTC 64978 – FOC2 Controller Wrong RAM Memory
DTC 64980 – FOC2 Traction Controller Waiting for Slave Node Response
DTC 65009 – FOC2 Traction Controller Master To Slave Parameter Check Mismatch
DTC 64981 – FOC2 Traction Controller Hardware Fault
DTC 64986 – FOC2 Traction Motor Temperature Sensor KO
DTC 64992 – FOC2 Traction Controller Waiting for Node
DTC 65016 – FOC2 Traction Controller No CAN Message
DTC 65004 – FOC2 Current Gain
DTC 64991 – FOC2 Contactor Coil Shorted
DTC 64806 – FOC2 Traction Controller Contactor Open
DTC 64805 – FOC2 Traction Controller Contactor Closed
DTC 64842 – FOC2 Traction Controller Contactor Driver Shorted High
DTC 64843 – FOC2 Traction Controller Contactor Driver Shorted Low
DTC 65005 – Analog Input
DTC 65013 – FOC2 Traction Controller IQ Mismatch
DTC 65015 – FOC2 Traction Controller Data Acquisition
DTC 65018 – FOC2 Traction Controller Thermic Sensor KO
DTC 65021 – FOC2 Traction Controller Field Oriented Control KO
DTC 64979 – FOC2 Traction Controller Rotor Stall
DTC 64988 – FOC2 Traction Controller Vkey OFF Shorted
DTC 64787 – FOC2 Traction Controller DC Bus High and Key Voltage Low
DTC 65032 – Watchdog (Slave)
DTC 65043 – FOC2 DC Bus High / Key Voltage Low
DTC 65077 – FOC2 Traction Controller Standby Current Too High
DTC 65086 – FOC2 Thermal Protection
DTC 65106 – FOC2 Encoder Error
DTC 64850 – FOC2 Encoder Error
DTC 65232 – EEPROM KO (Slave)
DTC 65234 – FOC2 Controller Wrong RAM Memory (Slave)
DTC 65236 – FOC2 Waiting Master
DTC 65254 – FOC2 W.D. SYNCRO
DTC 65259 – FOC2 Coil_Short_HW_KO
DTC 65261 – FOC2 Analog Input
DTC 65263 – FOC2 Controller Mismatch
DTC 65266 – FOC2 SP Mismatch
DTC 65270 – FOC2 Aux Drive Open
DTC 65278 – FOC2 Aux Driver Short
DTC 65528 – FOC2 No CAN Message
DTC 65272 – FOC2 No CAN Message
DTC 65341 – Controller Internal Temperature OORL
DTC 17232 – Controller Internal Temperature OORL
DTC 65341 – Controller Internal Temperature OORH
DTC 65342 – Thermal Protection / Motor Temperature High
DTC 64830 – FOC2 Traction Controller Motor Temperature High
DTC 17184 – Controller Internal Temperature OORH
YALE Pallet Lift Truck Fault Codes DTC
Error: no LEDs or LCDs on
What the issue is: Inoperative
Cause of Problem: B+ and / or B- missing at controller, defective battery charger, or defective battery charger
What to do: Ensure the battery is connected, the key switch is on, and the brake override circuit is in the run position; also test your battery charger and motor controller and replace any
nonworking parts
Error: no LEDs or LCDs on
What the issue is: Forklift functions as normal
Cause of Problem: open connection between display and controller, defective display, or defective LEDs
What to do: make sure harnesses are connected at MDI and connector B on controller; test the dash display by connecting a handset to it and testing for communication; test LEDs by disconnecting
them, connecting the handset, and testing the handset; replace any non-working parts
Error: no LEDs or LCDs on
What the issue is: Forklift functions as normal
Cause of Problem: Because this condition is similar to the last, it will take a handset to determine its cause. If the handset displays “NO COMMUNICATION,” the controller is defective.
What to do: replace controller
Error: no alarm
What the issue is: Traction and hydraulic functions not working
Cause of Problem: improper startup sequence by jack operator
What to do: check brake switch, accelerator, steer handle, and hydraulic inputs
Error: AL66
What the issue is: Hydraulic function not working
Cause of Problem: battery voltage is low or controller voltage calibration is incorrect
What to do: Charge or replace battery; otherwise, use handset to determine the voltage read by the controller and compare it to an actual voltmeter reading; replace controller if the two readings
differ by more than 1.5 volts
Error: AL99
What the issue is: Traction and hydraulic functions not working
Cause of Problem: incorrect battery selected, damaged battery, or damaged connection to batter
What to do: check that you have the right voltage for your truck, manually check the voltage of your battery, inspect it for any damage, and check its connecting crimps and cables for damage as
well
Error: AL01
What the issue is: Traction and hoist functions not working
Cause of Problem: control card throttle or lift/lower calibration is out of range; control card is damaged or defective
What to do: Use the tester function on a handset to see if either calibration is greater than 1 volt at neutral; replace control card if damaged or defective, which can be checked by seeing if
both “forward switch” and “backward switch” are on at the same time when testing
Error: AL01
What the issue is: Traction and hoist functions not working
Cause of Problem: incomplete connection between control card and controller; traction reversing switch not connected; damaged or defective tiller card
What to do: Check connections between control card and controller; use a handset to test for operation of traction reversing switch; replace control card if tiller card is damaged
Error: AL02
What the issue is: Traction and hydraulic functions not working
Cause of Problem: main contactor tips are welded closed or motor field circuit is broken
What to do: disconnect power leads at contactor and test for an open circuit; check connections between motor field and controller
Error: AL04
What the issue is: traction and hydraulic functions not working
Cause of Problem: damaged connection to lowering valve; damaged lowering coil or lowering valve cartridge
What to do: check electrical connection between valve coil and controller; check lowering valve coil for resistance, replace if not approximately 17.7 ohms; replace lowering valve cartridge if
necessary
Error: AL05
What the issue is: traction and hydraulic functions not working
Cause: damaged connection to brake or brake coil damaged
What to do: check connection between electric brake and controller; check brake coil for resistance in both directions and replace if not between 27.36 and 30.24 ohms
Error: AL06
What the issue is: Traction and hydraulic functions not working
Cause of Problem: Damaged connection to traction motor; traction motor armature resistance is too low; field wires are loose or damaged; motor field winding is shorted or too low.
What to Do: Check electrical connection between traction motor, field wires, and controller; check traction motor armature for shorts; check motor field resistance and correct if not between 0.5
and 1.5 ohms; check contactor coil for resistance of 52 ohms
Error: AL07
What the issue is: traction functions reduced below 14°F or above 167°F and not working above 194°F
Cause of Problem: controller temperature is too hot or cold; controller temperature is not calibrated correctly; controller sensor or controller itself is damaged
What to do: move truck to a warmer or cooler location; use a handset to check that controller temperature matches room temperature (if not, replace controller)
Error: AL8
What the issue is: traction and hydraulic functions not working
Cause of Problem: over current in driven component
What to do: check main harness for damaged connections to main contactor, brake, and electric valve coils; check contactor, brake, and electric valve coils for correct resistance (52 ohms for
contactor, between 27.36 and 30.24 ohms for brake coil, and 17.7 ohms for electric valve coils)
Error: AL10
What the issue is: Traction and hydraulic functions not working
Cause of Problem: controller is damaged; damaged wire connection; short circuit in harness; ground between motor windings and chassis; motor field winding is shorted to chassis; field current
driver circuit has failed; watchdog hardware circuit is damaged
What to do: Cycle key switch off and on and replace controller if problem not solved; check wire connections at contactor, pump motor, and traction motor; check main harness for shorts; check for
grounds or shorts between motor windings and chassis; check motor field resistance (should be about 1.5 ohms); measure voltage between F1 and B- and F2 and B- on field current driver (should be
half the voltage between B+ and B-)
Error: AL94
What the issue is: Traction and hydraulic functions not working for one minute.
Cause of Problem: No fault is occurring. The controller is installing hour meter memory from MDI display if controller has been replaced.
What to do: No solution necessary. Fork truck will operate as soon as data transfer is complete.