4.

Fault State

In the fault state, a fault code from the list will be displayed on PCU, and ECU will
display fault code and description.
PCU ECU
Table 5: List of Fault Codes
Display Description Lift Reaction
System initialization Fault Disables All Motion
01
System communication Fault Disables All Motion
02
Invalid option setting Fault Disables All Motion
03
Calibration Fault Disables All Motion
04
GPS communication Fault Disables All Motion
09
GPS
Chassis Up or Down Switch ON Disable Chassis Control
12
Pothole Guard Fault Disable Lifting and Driving
18
BMS Comm. Fault Disable Lifting and Driving
20
BMS
Discharge Temperature Fault 1 Diagnostic Message Only
21
Discharge Current High Fault 1 Diagnostic Message Only
22
Total Voltage Low Fault 1 Disable Lifting, and Driving on
23 low speed

Cell Voltage Low Fault 1 Disable Lifting, and Driving on

24 low speed

Cell Voltage Low Fault 2 Disable Lifting and Driving

25
Sharp Difference in Voltage Disable Lifting and Driving
26
27 Sharp Difference in Temperature Disable Lifting and Driving
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 Discharge Current High Fault 2 Disable Lifting and Driving
28
Discharge Temperature Fault 2 Disable Lifting and Driving
29
Pressure Sensor 1 Fault Disables All Motion
31
1
Angle Sensor Fault Disables All Motion
32
Pressure Sensor 2 Fault Disables All Motion
35
2
Battery Drain Alarm Lift Slow to Drive Speed
36
Battery Drain Shutdown Disables All Motion
37
Platform Left Button ON Diagnostic Message Only
42
Platform Right Button ON Diagnostic Message Only
43
Platform Enable Button ON Disable Platform Control
46
Joystick Not In Neutral Lift Slow to Drive Speed
47
Forward Coil Fault Disable Lifting and Driving
52
Reverse Coil Fault Disable Lifting and Driving
53
Lift Up Coil Fault Disable Lifting and Driving
54
Lift Down Coil fault Disable Lifting and Driving
55
Right Turn Coil Fault Disable Lifting and Driving
56
Left Turn Coil Fault Disable Lifting and Driving
57
General Brake Coil Fault Disable Lifting and Driving
58
Parallel Coil Fault Disable Lifting and Driving
59
60 Motor Controller Fault Disable Lifting and Driving
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 Motor Controller Current Sensor Fault Disable Lifting and Driving
61
Motor Controller Hardware Failsafe Fault Disable Lifting and Driving
62
Motor Controller Motor Short Fault Disable All Motion
63
Motor Controller SRO Fault Disable Lifting and Driving
64
SRO
Motor Controller Throttle Fault Disable All Motion
65
Motor Controller Emergency Reverse Fault Disable All Motion
66
Motor Controller HPD Fault Disable All Motion
67
HPD
Total Voltage Low Fault 2 Disable All Motion
68
High Neutral Current Fault (Zapi Only) Disable Lifting and Driving
69
Zapi
Steer Input Out of Range (Zapi Only) Disable Lifting and Driving
70
Zapi
Motor Controller Main Contractor Fault Disable Lifting and Driving
71
Motor Controller Over Voltage Fault Disable Lifting and Driving
72
Motor Controller Thermal Cutback Fault Disable All Motion
73
Motor Controller Over Heat Fault Disable All Motion
74
Motor Controller Pump Motor Fault Disable All Motion
75
Motor Controller Left Drive Motor Fault Disable All Motion
76
Motor Controller Right Drive Motor Fault Disable Lifting and Driving
77
Pump Motor Short Fault Disable Lifting and Driving
78
Left Drive Motor Short Fault Disable All Motion
79
80 Over 82% Load Warning Warning Only
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 82%
Right Drive Motor Short Fault Disable All Motion
81
Left Brake Coil Fault Disable Lifting and Driving
82
Right Brake Coil Fault Disable Lifting and Driving
83
Motor Post Shorted Disable Lifting and Driving
84
Brake Release Switch On Diagnostic Message Only
85
Brake Release Switch On Diagnostic Message Only
86
Brake Release Not Showed Diagnostic Message Only
87
Motor Field Open Disable Lifting and Driving
89
Over 90% Load Warning Warning Only
90
90%
Left Motor Field Short Disable Lifting and Driving
91
Right Motor Field Short Disable Lifting and Driving
92
Over 99% Load Warning Warning Only
99
99%
Overloaded Platform Fault Disable All Motion
OL
Machine Tilted Disable Lifting and Driving
LL
Foot pedal no action Disable PCU Control
Ft
Anti-collision switch warning Disable Lifting and Driving
CL

Table 6: Troubleshooting Guide

Display
Description Reason & Solution
System Initialization Fault: ECU may be malfunctioning, replace it.
01
: ECU ECU
02 System Communication Fault: Check communications cable connections and
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 other wiring. If that does not resolve the problem, try replacing the PCU or
ECU.
PCU ECU.
Invalid Option setting Fault: Set appropriate option for this lift.
03
Calibration Fault: Re-calibration the system, or check the angle and pressure
04 sensor.

GPS communication Fault: Check communications cable connections and

other wiring. If that does not resolve the problem, try replacing the GPS
09
module or ECU. GPS
GPS ECU.
Chassis Up or Down Fault: Check communications cable connections and
other wiring.If that does not resolve the problem, try replacing the ECU.
12
ECU
ECU
Pothole Guard Fault: Check that the pothole guards are extended, check the
pothole limit switches. Check wires to the switches, check the down limit
18
switch and connections.

BMS Comm. Fault: Check communications cable connections and other

20 wiring.
BMS
Discharge Temperature Fault 1: Tell BMS factory to check battery.
21
BMS
Discharge Current High Fault 1: Tell BMS factory to check battery.
22
BMS
Total Voltage Low Fault 1: Tell BMS factory to check battery.
23
BMS
Cell Voltage Low Fault 1: Tell BMS factory to check battery.
24
BMS
Cell Voltage Low Fault 2: Tell BMS factory to check battery.
25
BMS
Sharp Difference in Voltage: Tell BMS factory to check battery.
26
BMS
Sharp Difference in Temperature: Tell BMS factory to check battery.
27
BMS
Discharge Current High Fault 2: Tell BMS factory to check battery.
28
BMS
29 Discharge Temperature Fault 2: Tell BMS factory to check battery.
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 BMS
Pressure Sensor 1 Fault: Check the wiring to the sensor and then the sensor
itself. Also check to make sure that the correct option is properly selected (or
31
not) for load sensing. 1

Angle Sensor Fault: Check the wiring to the sensor and then the sensor itself.
Also check to make sure that the correct option is properly selected (or not) for
32
load sensing

Pressure Sensor 2 Fault: Check the wiring to the sensor and then the sensor
itself. Also check to make sure that the correct option is properly selected (or
35
not) for load sensing. 2

Battery Drain Alarm: Battery voltage is low, charge the battery.

36
Battery Drain Shutdown: Battery enters into sleep mode, and operate the
37 joystick or button on ECU controller to quit the mode.
ECU
Platform Left Turn Switch ON at power-up Message: Ensure that nothing is
holding the Joystick Toggle Switches down. If OK, consider replacing the
42
Joystick or PCU.
OK PCU
Platform Right Turn Switch ON at power-up Message: Ensure that nothing is
holding the Joystick Toggle Switches down. If OK, consider replacing the
43 Joystick or PCU.
OK PCU
Platform Joystick Enable Switch ON at power-up Fault: Ensure that nothing is
holding the Enable switch closed. Also check the neutral zone parameters. If
46 OK, consider replacing the Joystick or PCU.
OK
PCU
Platform Joystick not in neutral at power-up Message: Make sure that the Joystick
is in the neutral (upright) position. Check the neutral zone parameter setting in the
47 LabView Programmer. If it’s OK, consider replacing the Joystick or the PCU.

OK PCU
Forward Coil Fault: Check the connections to the Coil’s terminals and make sure
they are tight. If so, check the coil itself to see if it is open or shorted.
52

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 Reverse Coil Fault: Check the connections to the Coil’s terminals and make sure
they are tight. If so, check the coil itself to see if it is open or shorted.
53

Lift Up Coil Fault: Check the connections to the Coil’s terminals and make
sure they are tight. If so, check the coil itself to see if it is open or shorted.
54

Lift Down Coil Fault: Check the connections to the Coil’s terminals and make
sure they are tight. If so, check the coil itself to see if it is open or shorted.
55

Right Turn Coil Fault: Check the connections to the Coil’s terminals and make
sure they are tight. If so, check the coil itself to see if it is open or shorted.
56

Left Turn Coil Fault: Check the connections to the Coil’s terminals and make
sure they are tight. If so, check the coil itself to see if it is open or shorted.
57

General Brake Coil Fault: Check the connections to the Coil’s terminals and
make sure they are tight. If so, check the coil itself to see if it is open or
58
shorted.

Parallel Coil Fault: Check the connections to the Coil’s terminals and make
sure they are tight. If so, check the coil itself to see if it is open or shorted.
59

Motor Controller Fault Check the connections to motor and make sure they are tight.
60 If so, check there are other detail faults.

Motor Controller Current Sensor Fault: Drive or Lift Motor may be overheating. Let
the lift cool down. If that does not help, cycle power to reset the Motor controller. If
the problem persists, check the wiring and if OK, try replacing the Motor Controller.
61

OK
Motor Controller Hardware Failsafe Fault: Cycle power. If that does not resolve the
62 issue check for noise sources. If still needed, try replacing the Motor Controller.

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 Motor Controller Motor Short Fault: Check wiring first then cycle power. If needed
63 replace controller.

Motor Controller SRO Fault: Look at motor enable delay with the Scissor
Programmer, it may be too short. Make sure other Motor Controller
64
parameters are properly selected. SRO
enable delay
Motor Controller Throttle Fault: Check wiring. Make sure the correct throttle
65 type is selected in the Motor Controller. :

Motor Controller Emergency Reverse Fault: Ensure that the Emergency

66 Reverse Check parameter is off in the Motor Controller.
off
Motor Controller HPD Fault: Look at motor enable delay with the Scissor
Programmer, it may be too short. Make sure other Motor Controller
67 parameters are properly selected. HPD
motor enable delay

Total Voltage Low Fault 2: Check battery voltage and charge if necessary. Check
the battery connections and tight or clean. Check the voltage to the ECU and
68 PCU.

ECU PCU
High Neutral Current: The MC is sensing current in the motors when there
should not be. This could occur anytime the MC thinks the brakes are on and
the motors are still turning. This message sometimes comes just before other
69 faults but should be ignored in those cases. MC
MC

Steering Input Out of Range: There is an inappropriate voltage at the steering

input of the ZAPI motor controller. The ZAPI may need to be “trained” for the
three steering voltages (on Differential Steered machines). Or the steering
voltage from the ECU was at some point outside of the range that was
70 recorded during the “training” session. Re- train the ZAPI and/or check for
fluctuating voltages due to lose wires, etc. ZAPI
ZAPI “ ”
ZAPI /
71 Motor Controller Main Contactor Fault: Check the connections to the main
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 contactor. Replace the contactor if necessary. Replace the Motor Controller if
necessary.

Motor Controller Over Voltage Fault. Check battery voltage and make sure the
battery charger is not on. Then cycle power to the lift. If that does not resolve
72 the issue, try replacing the Motor Controller.

Motor Controller Thermal Cutback Fault: Drive or Lift Motor may be

overheating. Let the lift cool down. If that does not help cycle power to reset
the Motor controller. If that doesn’t resolve the issue, replace the Motor
73 Controller.

Motor Controller Motor Fault: Check connections to the motors. Cycle power
to the lift and if that does not resolve the issue, replace the Motor Controller.
74

Motor Controller Pump Motor Fault: Check connections to the Pump Motor.
Cycle power to the lift and if that does not resolve the issue, replace the Motor
75
Controller.

Motor Controller Left Drive Motor Fault: Check connections to the motors.
Cycle power to the lift and if that does not resolve the issue, replace the
76
Motor Controller.

Motor Controller Right Drive Motor Fault: Check connections to the motors.
Cycle power to the lift and if that does not resolve the issue, replace the Motor
77
Controller.

Pump Motor Short Fault: Check connections to the pump motor. Cycle power
to the lift and if that does not resolve the issue, replace the Motor Controller.
78

Left Drive Motor Short Fault: Check the Motor connections and make sure
79 they are tight. Check the Motor for a short.

Over 80% Load Warning: Platform is getting close to its limit of weight.
80 Consider not adding more load. 80%

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 Right Drive Motor Short Fault: Check the Motor connections and make sure
81 they are tight. Check the Motor for a short.

Left Brake Coil Fault: Check the connections to the Coil’s terminals and make
sure they are tight. If so, check the coil itself to see if it is open or shorted.
82

Right Brake Coil Fault: Check the connections to the Coil’s terminals and
make sure they are tight. If so, check the coil itself to see if it is open or
83
shorted.

Motor Post shorted: Check the connections of the controller and motor. Make
84 sure the wiring is not shorted.

Brake Release Switch On: Check the wires to brake release switch or look for
85 a stuck switch.

Brake Release Not Stowed: Check if the platform is below down limit height.
86 Check the down limit switch and connections.

Brake Release Need Switch On: Check the wires to brake release switch or
look for a stuck switch. Check the wires to the Toggle Switch or look for a
87 stuck Toggle Switch.

Motor Field Open: The field voltage is different from 1/2 Vbatt. Check
connections of the field wires or leakage to the vehicle frame.
89
1/2

Over 90% Load Warning: Platform is getting close to its limit of weight.
90 Consider not adding more load. 90%

Left Motor Field Short: Check connections of the field wires or leakage to the
91 vehicle frame.

Right Motor Field Short: Check connections of the field wires or leakage to the
92 vehicle frame.

99 Over 99% Load Warning: Platform has reached its limit of weight. Do not add
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 more load. 99%

Overloaded Platform Fault: Remove the excess load immediately.

OL
Machine Tilted Beyond Safe Limits Fault: If the machine is tilted, find a way to
make it level. If the machine is level, check the wiring to the tilt sensor and
LL
then the sensor itself.

Foot pedal no action: when operate the joystick to drive and lift, there is no
action on foot pedal, so please check the switch of foot pedal.
Ft

Anti-collision switch warning: When lifting up and close to the obstacle,

CL warning and check the anti-collision switch.

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