Just got this at an auction for cheap. Wrench flash I assume indicates there's a fault, but default code(s) don't work to access DTC. 55555, 12345, 54321, and about 10 other random attempts.
Everything works except travel. Travel is.001 MPH but it sometimes surges if you floor it.
I assume I'll have to get a tech to reset the Service Password, but until then I'm looking for an easy fix. Has 54 hours on it. 2007. I think this got parked for a decade+ not working.
While I was trying to "work out" some unknown corrosion? I was driving it around in what feels like limp mode, and it would blast away at full speed, then quit, then go again randomly. the 3 main leads from the controller were getting very hot, so I stopped.
Without accessing the service DTC with password, it does flash "1" and sometimes "3" and sometimes "11".
I decoded the model number and seems like it should be 36v system, but all the controllers say 48v. I though that was weird, but I'm new to this.
Thanks,
Kevin
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I called my old buddy Red about the forklift and he said he had a similar problem with a model like this. He said to check the brushes in the motor...
I dug down to the motor, took it apart, and what do you know? This motor is brushless. :) Everything in the motor looks right.
I also rechecked the "go" pedal potentiometer with some better knowledge, and it's working as it should.
I also hooked the battery pack from our Toyota up to this truck and there was zero change. Just to eliminate a battery problem.
So I have a new theory now: No codes thrown.... I know on our Toyota forklift we can set the max speed, max lift rate, etc. Maybe somebody set this forklift to a max speed of.01 mph? If I could figure out the password to it, maybe I could check that setting (if it has it). That would be a super simple fix.
-Kevin
I did call a Yale dealership and it's about $500 for them just to show up, so I'm going to keep dinking around with this. Yale said it's very weird symptoms. He also didn't have an answer for me about a 36v system/battery having 48v controllers, but the motors say 36 or 48v.
I'm having a really hard time finding any troubleshooting online for this model, so I'm going to keep posting my progress here in hopes that someone has some insight into it.
The batteries seem fine according to my charger. Everything works crisp and like new with the pump motor. Power steering, lift, tilt, etc. There are no codes thrown. I was mistaken on the codes, it was just simple stuff: E-brake warning, not in seat, pressing accelerator when not in fwd/rev.
The main issue is travel/traction motor speed. It only will creep along. Barely moving. There was one moment when it took off intermittently, but I haven't been able to get it to repeat that.
The cables from the black box controller to the motor get warm/hot when I try to travel. I lifted the battery box out and inspected the motor connections hoping for massive corrosion, but there was none. I pulled the wires off the motor, cleaned the connections with a wire brush and reassembled with no improvement.
I also checked the accelerator pedal potentiometer (if that's the right name) and it changed resistance as I moved the pedal. Not sure the right way to test, but it seems to work.
I'll just keep researching and trying stuff until I fix it or take it in.
Thanks,
Kevin
Test. I've made two follow up posts, but they don't show up.
Testing.
-Kevin
From Admin...glad to see you are seeing your post now. There does not appear to be anything wrong with the system.
Cheers and good luck,,,Admin
>Thanks. Not sure what I was doing wrong... -Kevin
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