My email is [email address removed] kindly send to me

so this morning had another look at the print and made an attempt to solder the resistors back. didn't make any difference but one got so brittle it broke off. Will get them replaced next week. Acc to my measurements they are both 17-18 ohms at 2Watt (the blueish one is 15 ohms at 2 Watts (its still visible on that one. on the white ones it has burned of... (if someone has other/more detailed info on these, please share)

I assume it's part of the problem. Wether it is a reason or consequence of something else is not yet clear.

My drive print has a sticker on the back saying " QA-tested 03-15-13"
considering it's a 2000 forklift, this one has already been replaced before...

I dug a bit deeper into the issue with my forklift and decided to look at the drive print. On the front side you can see 3 white/blueish resistors/transistors. I found the 2 white ones to be very loose on the board. Looking at the back you can see that there is somewhat of a burn mark where they are soldered to the print. I can wiggle them around by hand but I can't just pull them out.

I figured a bad contact could be the issue here so I turned the ignition on a few times and tried the pedal. Issue still remained. After that I tried to wiggle these resistors once more by hand and found the outher white one to be cold and the middle one to be extremely hot ( I burned my thumb on it).

Could this be an indication to something?

Any way to put some pictures on here?

Many thanks

I guess it's a shortcut issue as well considering that the line contactor is off when I touch the gas pedal.

Aside the regenarator contactor used to pull ON before, which it does not any more...

I sent you my list. These codes can be false. See them after a service when dirt is under contacts. You must check for short to frame, on any electric truck. ! 10K ohms or less minimum from neg or pos of battery plug to frame. If you see low resistance then stop, find the source by cleaning motors, then unhooking cables til you find short. Had a Cat last week with all those codes, short from lift motor brush holder to frame

orange and violet split together through a 3pin cross over into either blue (lower motor) or white (upper motor). It's pretty sure the connection here is less important.

just need to check the thermo wires but so far no numbers found and have removed the wiring protection for about 30-40cm.
cleaned all male-female connectors for improved contact...

i was afraid of that with the wire colors, over the years during model changes there were some differences in coloring and numbering.
In your case you would have to rely on the wire numbering and not the coloring so look on the wires for stamped or printed numbers.
you may have to cut back the loom a bit to expose the numbering, there may be a tag or even on the connector it might have the number printed on it.
if numbering still relates to schematic orientation then it shouldn't be difficult to verify their connections. As far as the order of the connection?
i wouldn't just assume you can connect them in any order, they are paired to each sensor so in effect they are paired in the connection like a pos/neg orientation. If you cross either component connection across each other then you will certainly get errors and could possibly damage the controller.

Checked the wiring and your info is correct. although I can't tell 100% sure if the wires are connected as should. the wiring coming out of the motor near were the brushes sit is 2X white. then there are 2 other ones coming out of the motor which are both black. does it matter how they are connected? I guess not, but could be wrong.

the error code is still there but I will try to switch the wires and run over their routing to see if the wiring is OK. so far it deems it does.

yes the larger cables are the power cables for armature and field, i wasn't refering to those. The small wires are a small harness like cables with smaller control wires in them, these should have 4 wires in each harness cable. These are sensor wires for motor temp and brush wear. if either get damaged and short out they can trigger several types of codes depending on how they get shorted.
the wire colors will be like green, brown, yellow, possibly white, there may be stripes on some of them. The schematic cat has is bad and not clear. There could be numbers on them as well such as Right motor 124, 125, 126, 127 and Left Motor would have 129, 130, 131, 132.
wires 124 (green) and 125 (Yellow) are for the thermostat in the motor and 126 (violet) and 127 (orange) are for brush wear indicator in right motor. Wires 129 (green) and 130 (yellow) are the thermostat in the motor and 131 (violet) and 132 (orange) are the brush wear indicator in Left motor. The connectors on the wires should keep you from plugging them in incorrectly. And if i remember correctly some of those wires might be unique with stripe colors or patterns on them so pay attention to that as well.

Just fyi, you will probably have to raise the forks up and chain or block the carriage and look through the front of the machine to see these sensor harnesses, they are almost impossible to see through the floor plate area.

thanks for your input. When replacing the motor brushes I encountered 4 cabels on each motor. fairly big ones so these must be power/ground cables. I did also find 2 smaller cables (+- 1.5mm² each) coming out of each motor of which I can't identify the function.

email signature should be ok now

one other thing, check the sensor harness at the drive motors. each motor has it's own, consists of 4 wires on each harness.
make sure they are not damaged, they can get exposed and things fly up off the floor and hit them and damage them which can trigger these codes.
verify those harness's are not damaged, if they are repair them and then if no other issues have occured because of that these codes should go away. if the errors do not go away then continue with further troubleshooting :o)

you must out email in profile, FA removes it in here
Re do your profile

thanks

mail : [email address removed]

I don't have complete manual on PDF, but do have code list. Put your email in profile. It's EP16-20

Hello do you know if this list is thesame for EP16KT?

Any chance you have a workshop manual on EP16KT ?

Many thanks