CAT forklift error codes
Clearing CAT forklift error codes on a Caterpillar lift truck can be daunting because most machines have steps that must be followed precisely. However, getting familiarized with the steps beforehand can make the process easier. This article outlines the steps to clear error codes on CAT forklifts.
For a list click here to see: CAT forklift error codes
What causes CAT forklift error codes?
Error codes on forklifts let the operator know something’s wrong with the machine. There can be many causes for error codes, but common problems include:
- Steering fluid levels. These codes indicate low steering fluid levels. Insufficient fluid levels can impact the steering mechanism, which poses an immediate safety risk to employees.
- Mast problems. These codes indicate an issue with the mast (e.g., raising or lowering as expected). It may be caused by low steering fluid levels, hydraulic problems, etc.
- Overheating. These codes show up when the machine’s temperature exceeds its limit. Overheating can be caused by a blockage that needs to be cleaned, problems with the radiator, etc.
- Bad battery. These codes can be caused by low voltage, incorrect calibration, faulty battery, etc. These issues must be fixed to run optimally.
- Trouble starting. Issues starting a truck could be caused by battery issues, low fuel, inadequate electricity, etc.
Each code has a unique meaning, allowing the forklift operator to diagnose and fix the problem adequately. In some instances, the problem may be simple (e.g., clearing a blockage), and the code will remove itself once fixed. However, this may not work and will need to be cleared manually.
What should you do when an error code on a Caterpillar lift truck appears?
The first thing CAT forklift operators should do when they see an error code is to document as much information as possible. This includes:
- The code (taking a picture of the code is advised)
- What is happening (e.g., the mast is not lifting)
- When the error happened
- What was the machine doing when the code popped up (e.g., moving pallets)
- If this error occurred before or occurs frequently
Once important information has been collected, the machine should be turned off. And the forklift should not be operated until the issue is resolved. Using a forklift without fixing an error can cause unnecessary accidents/injuries or irreparable damage to the machine.
Error codes can be found in forklift manuals or on a manufacturer’s website (examples of CAT forklift error codes here). These sources will describe the issue causing the error code. The problem may be a simple fix (e.g., topping up fluid levels) or indicate the need for more extensive maintenance.
How to clear CAT forklift error codes
Before manually clearing CAT error codes, it is vital to have a stopwatch handy. Specific steps are time-sensitive and may not work if not performed precisely. Below are the eight steps to clear error codes.
- Turn the forklift key switch on (without pressing the accelerator) and start the stopwatch at the same time. Wait three seconds.
- After three seconds, press the accelerator five times in succession (the pedal should be released at the end of the set). This step must be done within five seconds (or it may not successfully remove the code).
- Wait seven seconds after the previous step, then press and hold the accelerator for 10 seconds or more. Do this until the malfunction indicator light starts flashing.
- Release the accelerator pedal immediately after the malfunction light starts flashing. This step causes a self-diagnostic test to begin. The dashboard will show forklift DTC codes.
- Ensure the pedal is released for 10 seconds or more.
- Next, press and hold the accelerator for 10 seconds or more to erase the results from the self-diagnostic test and clear the codes.
- Release the accelerator pedal and turn the key switch off.
- Restart the forklift engine to ensure there are no more error codes and the forklift is functioning normally.
Preventing forklift error codes
The best way to prevent forklift error codes is to perform regular and proper maintenance on the machine. Other ways to avoid error codes include:
- Ensuring the battery does not show signs of damage (e.g., corrosion) and is correctly charged and connected when running.
- Check tire pressure and condition (e.g., ensure they are not deflated or damaged).
- Follow manufacturer guidelines (e.g., weight guidelines, oil change schedules, etc.)
- Check steering fluid and coolant levels before operating.
- Replace brakes of damage or softness
List of CAT forklift error fault codes
| Error Code | Code Meaning | Advice |
|---|---|---|
| E03 | VCM communication error | To fix the E-03 VCM Communication Error: Check fuses. Next disconnect the battery. Hold the positive and negative cable ends together for a moment, then reconnect to see if code clears. Could be a poor connection in the wire harness or at the VCM. Damage to a wire in the harness is possible. |
| E04 | ECM communication error | Start with the fuses: ensure they're intact. Next, assess the battery's charge; ideally, it should register over 14 volts at idle. Investigate the alternator and related wiring for anomalies. Check connections for debris or corrosion. If encountering error codes, attempt a reset by briefly disconnecting and reconnecting battery cables. |
| E05 | DCM communication error | Problem with the Data Communication Module, which facilitates communication between the forklift's electronic components. Causes can include faulty wiring, a malfunctioning DCM, or external interruptions |
| E06 | HST communication error | Indicates an error with Hydrostatic Transmission system. run a diagnostic test to pinpoint the problem. Ensure the wiring and connections are intact and undamaged. Inspect and possibly replace the HST module. Update the software and reset the system by toggling the battery connection. |
| E07 | MP communication error | Signifies a disruption with the Main Processor. To address this, use diagnostic tools to identify the cause. Inspect and repair any compromised wiring or connections, and assess the Main Processor for potential replacement or updates |
| E08 | TMS communication error | Points to communication issues within the Transmission Management System (TMS). Use diagnostic tools to identify the underlying cause. Then inspect all wiring and connections linked to the TMS for any damages or loose connections. If the hardware appears intact, consider checking the software aspects of the TMS for updates or inconsistencies. |
| E21 | Air flow meter error signal | Possible faulty airflow meter. Issues may also stem from wiring at the connector, which is replaceable. |
| E22 | Water temperature sensor error signal | Check the wiring and connection to engine temperature sensor. Also ensure sensor is working. |
| E23 | Throttle sensor error signal | Obstruction between the connection and the motor, so it is crucial to check cables to ensure they are undamaged and clean. |
| E24 | Accelerator sensor error signal | Issues within the throttle sensor circuit. Might be malfunctioning throttle sensor, compromised wiring, or poor connections in the throttle's electrical system. |
| E25 | O2 sensor error signal | Signifies problems related to the lift truck's system voltage. Triggered by an overvoltage or undervoltage condition. May be malfunctioning alternator, a failing battery, or issues within the electrical system. |
| E26 | O2 sensor heater error signal | Disconnect the battery cables and touch them together for a minute. Reconnect them and check if the code persists. |
| E27 | POS sensor error signal | Check the spark plug and replace. If code persists check/replace the lift truck's coil packs. |
| E28 | PHASE sensor error signal | indicates malfunction or disruption related to the phase sensor, which monitors the forklift's rotational aspects. Use diagnostic tools to gain understanding of the sensor's condition. Examine the phase sensor for damage. Also look at associated wiring and connections for breaks or disconnections. In cases where the hardware appears functional, it might be beneficial to check for potential software glitches or calibration errors related to the sensor. |
| E29 | Self shutdown system diagnostic result error signal | Points to issues with the forklift's automated shutdown system, a crucial feature for ensuring operational safety. Use diagnostic tools for understanding of the exact cause. Inspect the system's components, wiring, and connections, ensuring they're intact and free from damage. Software glitches or misconfigurations can also trigger this error. Verify the system's software is up-to-date and correctly calibrated. |
| E30 | ECCS C/U error signal | Issue with the Electronic Concentrated Control System's Central Unit. To troubleshoot, use specialized diagnostic tools to identify the problem. Examine the system's wiring and connections for damages and ensure the software is updated. |
| E31 | Electronic control throttle control error signal | Evaluate the throttle's sensors, actuators, and associated wiring for visible signs of wear or damage. Check the electronic control unit's software, ensuring it's up-to-date and functioning well. A system reset or recalibration might be needed. |
| E32 | Overheat signal (STEP 1) | Signals elevated temperatures beyond safe limits. Power down the forklift, allowing it to cool. Conduct inspection of the cooling system to identify potential blockages or malfunctions. Equally vital is ensuring the forklift operates in a well-ventilated environment. Checking the thermostat and temperature sensor to rule out false alarms or pinpoint further issues. |
| E33 | Overheat signal (STEP 2) | Signals advanced overheating. Immediately halt operations and let the machine cool. Inspect the cooling system, ensuring the radiator is clear, and assess the coolant's quality. Check the thermostat and temperature sensors for accurate function. Review the operating environment for adequate ventilation and inspect other key components like the transmission |
| E34 | Spark system error signal | Indicates a malfunction in the spark ignition system. Examine the spark plugs for wear, damage, or carbon build-up, replacing them if necessary. The ignition coils and spark plug wires should also be inspected for any visible damage or wear; faulty components can disrupt the electrical current, leading to ignition failures. Ensure that the ignition module, responsible for timing and distribution of the spark, functions optimally. Using diagnostic tools can offer a precise fault identification. Moreover, ensure the forklift's software is up-to-date, as outdated firmware can sometimes contribute to such errors. |
| P03 | VCM communication error | Pertains to potential malfunctions in the engine control module (ECM) or related systems. To address this issue, start by using a reliable diagnostic tool, which can offer a more specific fault code or insight into the problem's nature. Ensure the ECM's wiring and connectors are secure, free from damage, corrosion, or loose connections. If the error persists, it might be worthwhile to check the forklift's software and consider an update if available, as software glitches can sometimes trigger such errors. Inspect associated sensors and actuators for defects, as they can often be the culprits behind ECM-related issues. |
| P04 | ECM communication error | Initiate diagnostics using a specialized tool to identify the communication glitch's root cause. Scrutinize the wiring and connectors linked to the ECM for potential damage, loose connections, or corrosion. The forklift's software should be up-to-date, as outdated firmware can lead to these communication barriers. If doubts arise about the ECM's functionality, ponder over a module reset or possible replacement |
| P05 | DCM communication error | Thoroughly inspect the wiring and connectors related to the DCM for damages, disconnections, or corrosion. It's essential to ensure that the forklift's firmware is up-to-date, as older versions might trigger such communication hiccups. If you suspect the DCM itself to be problematic, consider a module reset or replacement. |
| P06 | HST communication error | Diagnostic tool to hone in on the specific communication breakdown. Check the wiring and connectors tied to the HST, looking out for damages or loose connections. The forklift's firmware should be current; outdated versions can lead to communication anomalies. In situations where the HST system itself might be the culprit, contemplate a system reset or even replacement. |
| P07 | MP communication error | Use a diagnostic tool to narrow down the specific communication fault. Inspect wiring and connectors associated with the MP for any damages, loose connections, or corrosion. Ensure the forklift's software is up-to-date, as outdated firmware can cause communication issues. If the MP itself seems compromised, consider a reset or, in some cases, replacement |
| P08 | TMS communication error | Check the engine sensors, wiring, and connections for damage or disconnections. Ensure that the engine control module (ECM) is functioning correctly and consider updating its firmware if outdated versions are present |
| P22 | Shift lever error signal | start by examining the physical condition of the shift lever and its immediate surroundings. Use a diagnostic tool to capture specific discrepancies or signaling issues. Inspect the wiring and connectors related to the shift lever for damage, disconnections, or signs of wear. A calibration or adjustment of the shift lever might be required in certain cases. If these interventions don't rectify the situation, consider replacing the affected components. |
| F02 | Battery voltage error | First ensure all battery connections are secure and free of corrosion. Use a multimeter to measure the battery's voltage to confirm it aligns with the manufacturer's specs. Examine the battery's age, its cells (if applicable), and the condition of its wiring. Check the functionality of the battery charger and consider any software or sensor issues. |
| F57 | Tilt backward solenoid error | Inspect the solenoid's wiring for damage or disconnections. Test the solenoid with a multimeter to verify its functionality. Examine the hydraulic system for leaks or blockages that may impact the tilting mechanism. Ensure all connections are secure, and consider replacing the solenoid if it's malfunctioning |
| F03 | VCM communication error | |
| F59 | Tilt solenoid leak | Points to a malfunction associated with the solenoid that governs the tilt mechanism of the forklift's mast. Addressing this issue involves a series of targeted steps: Firstly, visually inspect the tilt solenoid for any apparent damages or disconnections. Electrical connections leading to the solenoid should be examined for signs of wear, corrosion, or breaks in the wiring. Use a multimeter to test the solenoid's resistance and ensure it's within the recommended range. If the solenoid is deemed faulty, replacement might be necessary. Additionally, check the hydraulic system, ensuring that there's no fluid leakage or pressure issues that might be impacting the tilt function. |
| F04 | ECM communication error | |
| F60 | Attack-1A solenoid error | Start by inspecting the solenoid for visible damage or wear. Examine its electrical connections to ensure they are securely attached and free from corrosion. Utilize a diagnostic tool to assess the solenoid's proper operation. If identified as defective, the solenoid might need replacement. Additionally, assess the hydraulic fluid's level and quality, as this can influence solenoid performance. |
| F05 | DCM communication error | |
| F62 | Attach-1B solenoid error | |
| F06 | HST communication error | |
| F64 | Attach-1 solenoid leak | Begin by visually inspecting the solenoid for any obvious signs of leakage or damage. Check the hydraulic lines and connectors associated with the solenoid to ensure they're intact and securely connected. Using a diagnostic tool can provide further insights into the leak's origin. If the solenoid is confirmed to be leaking, replacement is often the best course of action |
| F07 | MP communication error | Inspect MP-related wiring and connectors for damage, corrosion, or loose connections. Ensure the forklift's software is current, as outdated versions might contribute to communication glitches. If potential hardware malfunctions in the MP are suspected, consider resetting or replacing it |
| F65 | Attach-2A solenoid error | Issue with the Attach-2A solenoid, a component regulating hydraulic functions. To resolve, inspect the solenoid for visible damage or wear. Check electrical connections to ensure they're secure and free from corrosion. Utilize a diagnostic tool to confirm solenoid functionality. If faulty, consider replacing the solenoid. Lastly, monitor the hydraulic fluid level and quality, as issues here can impact solenoid operation. |
| F08 | TMS communication error | Inspect the TMS-related wiring and connectors for damage or disconnection, and ensure the forklift's software is updated. If the TMS module itself is suspected, it may need a reset or replacement |
| F67 | Attach-2B solenoid error | |
| F10 | Lift lever neutral error | |
| F69 | Attach-2 solenoid leak | |
| F11 | Tilt lever neutral error | |
| F70 | Attach-3A solenoid error | |
| F12 | Attach-1 lever neutral error | |
| F72 | Attach-3B solenoid error | |
| F13 | Attach-2 lever neutral error | |
| F74 | Attach-3 solenoid leak | |
| F14 | Attach-3 lever neutral error | |
| F75 | Unload solenoid error | |
| F16 | Shift lever error | |
| F77 | Lift lock solenoid error | |
| F17 | Speed error | |
| F79 | Unload solenoid leak | |
| E29 | Self shutdown system diagnostic result error signal | |
| F20 | Lift lever error | |
| F80 | Knob position solenoid error | |
| F22 | Tilt lever error | |
| F82 | Tilt lock solenoid error | |
| F24 | Attach-1 lever error | |
| F84 | Knob position solenoid leak | |
| F26 | Attach-2 lever error | |
| F85 | T/M forward solenoid error | |
| F28 | Attach-3 lever error | |
| F87 | T/M backward solenoid error | |
| F30 | Main oil pressure sensor error | |
| F89 | T/M solenoid leak | |
| F32 | Lift oil pressure sensor error | |
| F34 | Speed sensor error | |
| F36 | Tire angle sensor error | |
| F38 | Tilt angle sensor error | |
| F40 | Steering error | |
| F50 | Lift up solenoid error | |
| F52 | Lift down solenoid error | |
| F54 | Lift solenoid leak | |
| F01 | Memory check error | |
| F55 | Tilt forward solenoid error |
