SERVICE

N-B-003 R01 (E)

Affected models

BULLETIN
see below

March 2005
Yale Europe

SUBJECT: COMBI CONTROLLER ALARM CODE UPDATE

Models affected: MP18 (B841); MP16-18-20 (C841); MP22 (C842); MP20L-MP22 (D842);
MP20-30 (C856); MP25-30HD (C856); MP20X (B843); MP20XD (A892);
MS10-12 (B846); MS14-16 (B852); MS12X-15X (B847); MO20 (C857);
MO20S (C858); MS12-15S (B855); MP20-30S (B853); MP20T (B854).

CONTENT:

Reason: Technical Recommendation

Technical Description:

Please find from pages 2-4 the updated COMBI CONTROLLER alarm code table.

COMBI Service Manual

English – 272486700
Italian – 272486600
German – 272486900
French – 272486800
Spanish - 272487000

INTERCHANGEABILITY:
PARTS STOCK:
EFFECTIVE SERIAL NUMBER:

Page 1 of 1

We reserve the right to make changes in design or add improvements without incurring the obligation to make such changes in equipment
previously manufactured.
The content of this publication is for information only and will not be considered for warranty reimbursement.
N-B-003R01(E) Pag.2/4

MDI Alarms Console Display

Alarms Description Possible Causes Solutions
Codes Alarms Description

a) No power on control circuit cables a) Check and, if necessary, renew the 10A fuse
b) Proportional valve open at rest b) Renew proportional valve
The alarm is generated by the failed operation of
AL01 EVP NOT OK c) Valve short-circuiting c) Renew proportional valve
the proportional lowering valve
d) Power cable connection incorrect d) Connect cables correctly
e) Controller driver faulty e) Renew controller
a) No power on control circuit cables a) Check and, if necessary, renew the 10A fuse
b) Electromagnetic brake driver on controller faulty b) Renew controller
This alarm occurs in the presence of problems on
AL02 BRAKE DRIVER KO c) Driver faulty, incapable of driving the electromagnetic brake c) Renew controller
the electromagnetic brake driver
d) No power on electromagnetic brake coil d) Check cable connections
e) Electromagnetic brake coil short circuiting e) Renew electromagnetic brake
a) Traction motor ground fault due to carbon powder from a) Clean and blow with compressed air to remove dust
b) Traction motor short circuit b) Renew motor
AL03 V FIELD NOT OK Alarm generated by traction fault
c) Incorrect cable connections from motor to controller c) Remake connections as per the electrical schematic
d) Field driver controller section fault d) Renew controller
a) Interrupted potentiometer connection cable a) Reconnect the interrupted cable
This alarm appears when the potentiometer b) Faulty potentiometer c) Renew potentiometer
AL04 PUMP VACC NOT OK button value is out of calibration or faulty c) Potentiometer incorrect programming d) Reprogram correctly
(the same fault also gives rise to alarm AL78) d) After turning on the truck with the ON/OFF buttons, pressing e) Release the button, the alarm will be cleared and all the
the fast lowering button truck functions will be restored
This alarm is caused by a communication error a) Main contactor control contacts not closing a) Renew the main contactor
AL06 SERIAL ERROR #1
between the MDI and the controller b) Bad contacts on the controller to MDI connector c) Renew connection cable
a) Controller/Tiller serial cable interrupted a) Renew the serial cable
b) The controller fails to respond to signals transmitted from the
b) Renew controller
This alarm is caused by a communication error tiller
AL07 SERIAL ERROR #2
between the controller and the tiller box
c) Tiller board faulty c) Renew tiller board

d) Main contactor control contacts not closing d) Renew the main contactor
This alarm is generated because the watchdog a) Watchdog hardware circuit not OK a) Renew controller
AL08 WATCHDOG
circuit has tripped b) Software not OK b) Renew controller
Alarm appears in the presence of an EEPROM a) Switch the truck off and then on again; if the alarm persists
AL13 EEPROM KO a) Loss of saved parameters
memory error renew the controller
a) Incorrect wiring a) Wire correctly in accordance with the electrical schematic
Alarm appears when the forward and reverse
AL30 FORW + BACK b) Travel microswitch sticking b) Renew Tiller board
travel commands are active simultaneously
c) Incorrect operator manoeuvre c) Perform correct travel requires procedure
a) Traction motor ground fault due to carbon powder from
a) Clean and blow with compressed air to remove dust
brushes
Alarm appears when motor field voltage falls
AL32 VMN NOT OK b) Traction motor short circuit b) Renew motor
below battery value
c) Incorrect cable connections from motor to controller c) Remake connections as per the electrical schematic
d) Field driver controller section fault d) Renew controller
The alarm appears before closing of the main a) Contactor contact sticking a) Renew the main contactor
AL37 CONTACTOR CLOSED
contactor b) Power unit fault b) Renew controller
Alarm appears when traction current is always a) Faulty controller current sensor a) Renew controller
AL49 I = 0 EVER
lower than a given threshold value c) Logic feedback circuits fault c) Renew controller
Alarm appears during diagnosis in rest conditions a) Faulty controller sensor a) Renew controller
AL53 STBY I HIGH
if current is above a certain threshold c) Logic feedback circuits fault a) Renew controller
a) Motor field short circuit a) Renew motor
This alarm appears in the presence of a field
AL57 HIGH FIELD CURRENT c) Current transducer fault b) Renew controller
current anomaly
c) Power unit fault b) Renew controller
N-B-003R01(E) Pag.3/4
MDI Console Display
Alarms Description Possible Causes Solutions
Alarms Codes Alarms Description

This alarm appears in the presence of a field a) Controller current sensor fault a) Renew controller
AL58 NO FIELD CURRENT
current anomaly
b) Field power unit fault b) Renew controller

a) Main contactor fault

a) Renew the main contactor
The alarm is signalled if the capacitors have not
AL60 CAPACITOR CHARGE b) Brushes cable shorting against motor casing
started charging 500 ms after KEY-ON b) Change brushes and clean motor with compressed air

c) Logic unit fault b) Renew controller

This alarm appears when the battery is at 20%
with lift function inhibit; when the lift button is
AL66 BATTERY LOW
pressed the horn sounds three times signalling
that the battery power is low
a) If the alarm appears with a flat battery a) Charge the battery
b) If the alarm appears with a charged battery b) Perform the battery power configuration procedure on the
BATTERY ADJUSTMENT CALIBRATION: With the truck switched off connect the programming console to the controller on the
MDI connector. Switch on the truck and select "Config Menu ADJUSTMENT" followed by "ADJUST BATTERY". Lower the tiller
and close the main contactor. Using a multimeter check battery voltage directly on the controller across terminals B+ and B-.
Program the value read on the Multimeter on the console in the "ADJUST BATTERY" parameter. Switch the truck off and then
on again to save the data. WARNING: To check the voltage value you have just saved, select "Main Menu TESTER" on the
console, followed by the parameter "BATTERY VOLTAGE". If the value does not correspond, repeat the procedure described
above.

This alarm appears when the controller

AL67 THER. PROTECTION a) Controller thermal sensor driver fault a) Renew controller
temperature exceeds 80°C

a) Check that all the battery elements are in good condition; if

This alarm is generated at key-on: if the controller
you find damaged elements or if the battery is sulphated (i.e. as
AL68 CHARGING BATTERY detects a signal of 21,3V after closing the a) This fault must be sought on the battery
been standing for a long time without being charged or used), it
contactor, it inhibits operation of the truck
must be renewed
a) ON/OFF solenoid valve short-circuiting a) Renew solenoid valve
This alarm appears in the presence of short
AL73 POWER FAILURE #1 b) Main contactor coil short-circuiting b) Renew main contactor
circuits on components external to the controller
c) Electromagnetic brake coil short-circuiting c) Renew electromagnetic brake
This alarm appears with the main contactor open a) Controller driver short-circuited a) Renew controller
AL74 DRIVER SHORTED and it checks that the contactor driver is not short- b) Contactor coil wiring error b) Wire correctly in accordance with the electrical schematic
circuited. c) Fault in contactor coil voltage feedback circuit c) Renew controller
This alarm appears with the main contactor closed a) Contactor coil driver open a) Renew controller
AL75 CONTACTOR DRIVER
and it checks that the contactor driver is not open. b) Fault in contactor coil voltage feedback circuit b) Renew controller
Check that the resistance of the electromagnetic brake coil is
a) The electromagnetic brake coil is in short circuit
between about 12 Ohm and 30 Ohm, if not, replace the coil

Check that the resistance of the Main Line Contactor coil is

b) The Main Line Contactor coil is in short circuit
This alarm appears in the presence of a coil in between about 20 Ohm and 45 Ohm, if not, replace the coil
AL76 COIL SHORTED
short circuit
Check that the horn has a resistance between about 6 Ohm
c) The horn coil is in short circuit
and 18 Ohm, if not, replace it.
Check that the motor cables are correctly connected, that they
d) The pump and/or traction motor cables are not connected
are not shorting between themselves and that the connections
correctly
are properly tightened.
a) Potentiometer incorrect connection b) Restore connection as per electrical schematic
b) Faulty potentiometer c) Renew potentiometer
c) Potentiometer incorrect programming d) Reprogram correctly
PROGRAMMING: With the truck switched off, shift the jumper from "A" to "B". Switch on
This alarm appears in the presence of a fault on the truck and slowly turn the butterfly control in the forward travel direction as far as it will
AL78 VACC NOT OK
the accelerator inductive potentiometer. go then release it gradually so that it returns to its rest position; perform the same
operation for the reverse travel direction. Perform the signal acquisition procedure for the
potentiometric pushbuttons, if present. Slowly press the lifting pushbutton fully down and
release it gradually; repeat the same operation for the lowering pushbutton. Move the jumper B
A
from "B" to "A". Switch off the truck and then switch it on again after 30 seconds.
a) When the truck is switched on the controller detects a
a) Renew the tiller board
This alarm is generated by an incorrect traction command on the tiller board
AL79 ICORRECT START
start sequence. b) Release the butterfly control; the alarm disappears; perform
b) Incorrect start sequence
the start sequence correctly
N-B-003R01(E) Pag.4/4
MDI Alarms Console Display
Alarms Description Possible Causes Solutions
Codes Alarms Description
AL80 FORWARD + BACK See AL30

This alarm is generated when the Display (MDI)
or Combi controller are renewed. It signals
AL94 incongruence between the hours memorised on
the display and the hours stored in the Combi
controller.
After replacing the controller the duty hours in the memory of the MDI and COMBI are in conflict; when the truck is switched on the MDI will
display AL 94 for sixty seconds (with traction inhibit); this alarm message warns the operator of the imminent erasure of the hour meter
memory. To prevent this from happening the data transfer procedure must be executed.
PROCEDURE: with the truck switched off, before connecting the MDI to the Combi controller, connect the console; now switch on the truck
and enter the "CONFIG MENU SET OPTIONS" menu, select the option " AUX FUNCTION 1" and select ON (default is OFF), confirm the
new setting and then switch off the truck. Remove the console connector, connect the MDI, and then switch on again; at this point the hour
meter count of the previous system will be saved on the newly installed controller.

This alarm is generated when the rapid inversion a) Rapid inversion input not present on controller a) Renew controller
AL98 IMPUT ERROR 2
function (belly switch) is not functioning. b) If the problem persists b) Check connection of the serial cable

This alarm is generated when the rapid inversion

AL99 IMPUT ERROR 1 a) Rapid inversion input not present on tiller board a) Renew the tiller board
function (belly switch) is not functioning.

This alarm is generated when 250 operating
hours have been reached; it informs the user that
ORE 250 CHECK UP ENABLE
a "maintenance service" (when programmed) is
needed.
PROCEDURE: with the truck switched off disconnect the MDI connector from the controller and connect the console in its
place. Switch on the truck, enter "CONFIG MENU SET OPTIONS", select the option "CHECK UP ENABLE" and set "ON"
(default is "OFF"). In this condition the display of the maintenance request occurs automatically by flashing of the wrench
symbol every 250 hours of duty (the 250 maintenance time interval is fixed and cannot be altered). After performing the service
work the maintenance hour meter must be reset. Again in Config Menu "Set Options" select the option "CHECK UP DONE"
and set to "ON". When you switch the truck off and then on again the function will have automatically reset to " OFF" (consult
Service Manual P/N 2795674).

Display situation when the truck is switched on.

Also the EEPROM version installed on the truck
is displayed for a few seconds..

This symbol indicates activation of the travel

speed cut-back function.

A flashing hourglass means that the hour meter is

running.