SRE-1000 System Faults:


forklift

    1) A contactor uses more than 2 amps (13) (14)

    The 2 Amp maximum contactor output current has been exceeded.

    1. Check the polarity of the contactor coil and/or suppressor.
    2. Measure contactor coil resistance using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 Volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.
    3. Using the ProBit adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum voltage of 31 Volts to stay under 2 Amps.
    2) A ctr. current of more than 2A was seen. Ctrs may be disabled.

    The 2 Amp maximum contactor output current has been exceeded.

    1. Check the polarity of the contactor coil and/or suppressor.
    2. Measure contactor coil resistance using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 Volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.
    3. Using the ProBit adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum voltage of 31 Volts to stay under 2 Amps.
    3) Accel must be mechanically adjusted, or replaced before use.

    The ProBit is reading no voltage sweep, or an insufficient sweep of the throttle.

    1. Physically adjust throttle mechanical linkage.
    2. Check the sweep with the ProBit or a multimeter.
    3. Re-calibrate throttle with the ProBit.
    4) Bad Accel Diff. from stop to full is to small

    The ProBit is reading an insufficient sweep of the throttle.

    1. Replace throttle for one with adequate travel.
    2. Physically adjust throttle mechanical linkage.
    3. Replace potentiometer with 5K single direction (20K double direction pot).
    4. Re-calibrate throttle.
    5) Bad Accel. Inconsistent polarity.

    The polarity of the accelerator is not consistent throughout the sweep.

    1. Adjust the pot mechanically so that the sweep is constant, up or down.
    2. Re-calibrate throttle with the ProBit.
    6) Battery current limit for drive exceeded (05)

    The controller's hardware current limit has been exceeded.

    1. There may be a short circuit in the main motor cables. Repair.
    2. The motor(s) may be drawing too much current from a shorted field or armature. Check the motor(s) and repair as necessary.
    7) Battery current limit for lift exceeded. (85)

    The controller's hardware current limit has been exceeded.

    1. There may be a short circuit in the main motor cables. Repair.
    2. The motor(s) may be drawing too much current from a shorted field or armature. Check the motor(s) and repair as necessary.
    8) Battery voltage too high for lift.(over 55V)(77)

    48 Volt battery recently charged. Surface charge has not dissipated.

    1. This fault can be self correcting. On a truck with power steering, the controller, if set to do so, will pull in the steering pump briefly to dissipate the surface charge. If the truck does not have a power steering, the surface charge will dissipate over a few minutes.
    2. Ensure that the high voltage response is properly set with the ProBit based on whether the truck has a power steering or not.
    3. Clear the fault(s) with the ProBit.
    9) Battery voltage too high on drive. (over 55V) (27)

    48 Volt battery recently charged. Surface charge has not dissipated.

    1. This fault can be self correcting. On a truck with power steering, the controller, if set to do so, will pull in the steering pump briefly to dissipate the surface charge. If the truck does not have a power steering, the surface charge will dissipate over a few minutes.
    2. Ensure that the high voltage response is properly set with the ProBit based on whether the truck has a power steering or not.
    3. Clear the fault(s) with the ProBit.
    10) Belly switch disabled since limit 1 used. (22)

    Limit 1 and Belly switch trying to be used at the same time.

    1. Only one of limit 1 and belly switch can be used at one time.
    11) Both direction switches on at same time (10)

    The Controller has seen both direction switches on at the same time.

    1. One or both switches are sticking. Replace
    2. Switches are miswired. Correct
    12) Bypass contactor not dropping out properly. (35)

    The Controller has determined that the Bypass (1-A) contactor did not drop out.

    1. SRE Controls strongly suggests removing the Bypass Contactor in all applications, as it serves no purpose and can only lead to problems. If for any reason the 1-A must be left in:
    2. The tips may be welded. Replace.
    3. There may be some conductive matter between the tips. Remove.
    4. The Bypass may be improperly wired. Correct.
    13) Bypass contactor not pulling in properly. (32)

    The Controller has determined that the Bypass (1-A) contactor did not pull in.

    1. SRE Controls strongly suggests removing the Bypass Contactor in all applications, as it serves no purpose and can only lead to problems. If for any reason the 1-A must be left in:
    2. The tips may be welded. Replace.
    3. There may be some conductive matter between the tips. Remove.
    4. The Bypass may be improperly wired. Correct.
    13) Bypass contactor not pulling in properly. (32)

    The Controller has determined that the Bypass (1-A) contactor did not pull in.

    1. SRE Controls strongly suggests removing the Bypass Contactor in all applications, as it serves no purpose and can only lead to problems. If for any reason the 1-A must be left in:
    2. The tips may be bad. Replace.
    3. There may be some obstructive matter between the tips. Remove.
    4. The Bypass may be improperly wired. Correct.
    14) Cannot use new SE325/175 features. Dealer can update.

    The Controller has features that your ProBit cannot access.

    1. a) The ProBit that you are using is too old to access all of the features of your controller. It can still be used to access most of the functions. Send back to SRE Controls for an update to the latest version.
    15) Cannot use new PC325/175 features. Dealer can update.

    The Controller has features that your ProBit cannot access.

    1. The ProBit that you are using is too old to access all of the features of your controller. It can still be used to access most of the functions. Send back to SRE Controls for an update to the latest version.
    16) Check for a sticky forward contactor. (30)

    The controller has determined that the forward contactor has not dropped out properly or has not pulled in fast enough.

    1. If this message appears on a truck that has the ability to coast in neutral, i.e. stand-up reach trucks and power pallet trucks, it is likely due to a problem called residual magnetism. This issue has been fixed on the later SE175/325. On older units, please contact SRE for further information.
    2. On all trucks not included above, the switching time of the contactor exceeds the maximum allowable value. Check the plungers for free movement, the coils for shorts and anything that could physically restrict the speed of the contactor.
    17) Check for a sticky reverse contactor. (31)

    The controller has determined that the reverse contactor has not dropped out properly or has not pulled in fast enough.

    1. If this message appears on a truck that has the ability to coast in neutral, i.e. stand-up reach trucks and power pallet trucks, it is likely due to a problem called residual magnetism. This issue has been fixed on the later SE175/325. On older units, please contact SRE for further information.
    2. On all trucks not included above, the switching time of the contactor exceeds the maximum allowable value. Check the plungers for free movement, the coils for shorts and anything that could physically restrict the speed of the contactor.
    18) Check for welded direction contactor (20)

    The directional contactor has failed to open, or is shorted.

    1. Tips may be welded. Replace.
    2. Something is shorting the contactor posts or tips.
    19) Check forward reverse and lift coils (if lift in) more than 2A was seen. Ctrs may be disabled.

    The 2 Amp maximum contactor output current has been exceeded.

    1. Check the polarity of the contactor coil and/or suppressor.
    2. Measure contactor coil resistance using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 Volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.
    3. Using the ProBit adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum voltage of 31 Volts to stay under 2 Amps.
    20) Check if field (F) bar shorting to B- bar. (21B)

    The controller is reading a short between the motor field and B-.

    1. The most common cause of this fault is a ground fault on the truck. As a rule of thumb, the maximum allowable voltage between the battery and the chassis is 50% of battery voltage. The resistance measured between the chassis and motor terminals or controller bars should be in excess of 30K Ohms. Clean up any existing ground fault and try again.
    2. With all cables disconnected and the capacitors fully discharged, read the resistance between the "B-" bar on the controller and the "F" bar. The reading should exceed 10K Ohms. If the resistance is substantially lower ( 0 to 100 Ohms ) the controller will need to be replaced.
    21) Check if the contactor change time too short.

    The controller has determined that the contactor are switching slower than the set value.

    1. This will only apply to very old controllers, as the contactor switching time is now set automatically by the controller. Adjust the time to a higher value, or replace the contactors with faster ones.
    22) Check the bypass wiring and the contactor (21)

    This message can only appear if the Bypass is enabled.

    1. SRE Controls strongly suggests removing the Bypass Contactor in all applications, as it serves no purpose and can only lead to problems. If for any reason the 1-A must be left in:
    2. The most common cause of this fault is a ground fault on the truck. As a rule of thumb, the maximum allowable voltage between the battery and the chassis is 50% of battery voltage. The resistance measured between the chassis and motor terminals or controller bars should be in excess of 30K Ohms. Clean up any existing ground fault and try again.
    3. With all cables disconnected, read the resistance between the "B-" bar on the controller and the "F" bar. The reading should exceed 10K Ohms. If the resistance is substantially lower ( 0 to 100 Ohms ) the controller will need to be replaced.
    4. The Bypass may be improperly wired. Correct.
    23) Check the forward contactor. (25)

    This error occurs during start-up. The controller is reading an open circuit across the motor when the contactor is pulled in.

    1. The most likely cause of this fault is a poor contact across the contactor tips, specially on the normally closed side of the directional contactor assembly. Check and correct.
    2. Check cable connections to the motor terminals and contactors. There should be continuity between the "A" bar and the "F" bar when either the forward or reverse contactor is pulled in.
    24) Check the reverse contactor. (24)

    This error occurs during start-up. The controller is reading an open circuit across the motor when the contactor is pulled in.

    1. The most likely cause of this fault is a poor contact across the contactor tips, specially on the normally closed side of the directional contactor assembly. Check and correct.
    2. Check cable connections to the motor terminals and contactors. There should be continuity between the "A" bar and the "F" bar when either the forward or reverse contactor is pulled in.
    25) Contactor current draw more than 2 A.

    The 2 Amp maximum contactor output current has been exceeded.

    1. Check the polarity of the contactor coil and/or suppressor.
    2. Measure contactor coil resistance using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 Volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.
    3. Using the ProBit adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum voltage of 31 Volts to stay under 2 Amps.
    26) Contactor current draw more than 2A. Ctrs disabled.

    The 2 Amp maximum contactor output current has been exceeded.

    1. Check the polarity of the contactor coil and/or suppressor.
    2. Measure contactor coil resistance using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 Volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.
    3. Using the ProBit adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum voltage of 31 Volts to stay under 2 Amps.
    27) Contactor current draw too high.

    The 2 Amp maximum contactor output current has been exceeded.

    1. Check the polarity of the contactor coil and/or suppressor.
    2. Measure contactor coil resistance using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 Volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.
    3. Using the ProBit adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum voltage of 31 Volts to stay under 2 Amps.
    28) Contactor current draw too high. Ctrs disabled.

    The 2 Amp maximum contactor output current has been exceeded.

    1. Check the polarity of the contactor coil and/or suppressor.
    2. Measure contactor coil resistance using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 Volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.
    3. Using the ProBit adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum voltage of 31 Volts to stay under 2 Amps.
    29) Direction contactor failed to drop out. (33)

    The controller has the detected that the contactor tips were still closed after the contactor coil was dropped.

    1. Most likely the contactor tips are welded, or mechanically held closed. Correct.
    2. On older controllers, the change time may be set too low. Correct with the ProBit.
    30) Fault detected. Truck will not run.

    This message indicates that the controller has been disabled, and leads to another message.

    1. Press "OK" to continue to the next message. This will be the actual fault.
    2. Correct the fault and clear the faults with the ProBit before resetting the truck.
    31) Fault detected. Truck will not lift.

    This message indicates that the controller has been disabled, and leads to another message.

    1. Press "OK" to continue to the next message. This will be the actual fault.
    2. Correct the fault and clear the faults with the ProBit before resetting the truck.
    32) Lift contactor controlled by SRO. SRO is off.

    The SRO switch is open and the Lift Lock is turned on.

    1. The controller gives you the option of having the SRO Lift Lock on or off. In the "ON" position the hydraulics can only be used with someone in the operator position (SRO switch is closed).
    2. In the "OFF" position the hydraulics can be used at all times when the key is on, as long as the battery is above the minimum operating level (see "BDI" settings).
    33) Lift contactor draws more than 2A

    The 2 Amp maximum contactor output current has been exceeded.

    1. Check the polarity of the contactor coil and/or suppressor.
    2. Measure contactor coil resistance using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 Volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.
    3. Using the ProBit adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum voltage of 31 Volts to stay under 2 Amps.
    34) Lift contactor may draw more than 2A

    The 2 Amp maximum contactor output current has been exceeded.

    1. Check the polarity of the contactor coil and/or suppressor.
    2. Measure contactor coil resistance using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 Volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.
    3. Using the ProBit adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum voltage of 31 Volts to stay under 2 Amps.
    35) Low Battery. Lift locked out.

    The BDI ( Battery Discharge Interlock) has been activated.

    1. By default the controller is set to lift interrupt when the battery reaches 1.85 Volts per cell.
    2. A bad cell in the battery will reduce total battery voltage and prematurely set off the BDI. This can be compensated for by adjusting the battery voltage in "Customize" with the ProBit.
    3. The cut out level can also be changed with the ProBit under "Customize" and "Protection"
    36) No cct path from A thru armature, fld & FWD ctr (23)

    This error occurs during start-up. The controller is reading an open circuit across the motor when the contactor is pulled in.

    1. The most likely cause of this fault is a poor contact across the contactor tips, specially on the normally closed side of the directional contactor assembly. Check and correct.
    2. Check cable connections to the motor terminals and contactors. There should be continuity between the "A" bar and the "F" bar when either the forward or reverse contactor is pulled in.
    37) No power circuit through lift motor. Check wiring.

    This error occurs during start-up. The controller is reading an open circuit across the motor.

    1. Check for loose or broken motor cables.
    38) Open circuit. Check wiring to lift motor. (70)

    This error occurs during start-up. The controller is reading an open circuit across the motor when the contactor is pulled in.

    1. Check for loose or broken motor cables.
    39) PARAMETER fault: Lift disabled! Phone SRE

    The Programming has been corrupted. Fatal error.

    1. Contact SRE Controls for assistance.
    40) PARAMETER fault: Truck disabled! Phone SRE

    The Programming has been corrupted. Fatal error.

    1. Contact SRE Controls for assistance.
    41) PC325/175 TOO NEW! Call Dealer/SRE

    The software version of your ProBit is too old to access all of the features of the controller.

    1. Contact SRE Controls or your dealer for an upgrade.
    42) Recommend lift controller be replaced. #74

    The Lift controller has lost all its parameter settings.

    1. This problem can happen in the event of someone connecting the battery charger to the truck instead of the battery. The key on the truck would have had to be left on, or turned on while the charger was connected.
    2. The BDI and the temperature limits calibration may be lost. Current limits may not work correctly.
    3. Running the "Auto Install" procedure with the ProBit may restore the controller to service, but the calibrations will not be restored.
    4. Contact your dealer or SRE for assistance.
    43) Recommend drive controller be replaced. #4

    The Drive controller has lost all its parameter settings.

    1. This problem can happen in the event of someone connecting the battery charger to the truck instead of the battery. The key on the truck would have had to be left on, or turned on while the charger was connected.
    2. The BDI and the temperature limits calibration may be lost. Current limits may not work correctly.
    3. Running the "Auto Install" procedure with the ProBit will restore the controller to service, but the calibrations will not be restored.
    4. Contact your dealer or SRE for assistance.
    44) Runtime Error

    Error 0 Missing Module
    Error 1 Stack Overflow
    Error 2 Unknown Module
    Error 3 Stack Underflow
    Error 4 Corrupt call/ret
    ??????? Unknown Error

    1. Internal error.
    2. Communication problem between ProBit and controller. Turn the key off and try again.
    3. If the problem persists contact your dealer or SRE for assistance.
    45) Runtime error missing modules

    "startup & run error" System halted (00)

    1. Internal error.
    2. Communication problem between ProBit and controller. Turn the key off and try again.
    3. If the problem persists contact your dealer or SRE for assistance.
    46) SE325/175 TOO NEW! Call Dealer /SRE

    The software version of your ProBit is too old to access all of the features of the controller.

    1. Contact SRE Controls or your dealer for an upgrade.
    47) There is a path from B+ to the F bar. Pls check wiring.

    The controller has seen continuity between the B+ bar and the F bar.

    1. If this is the initial installation, check for improper wiring. Correct.
    2. Check to see if a directional contactor is stuck on. Correct.
    3. If the truck uses a Bypass (1-A) contactor, the tips may be welded. Correct. It is strongly recommended that the Bypass contactor NOT be used, as it is not needed with the SRE System.
    4. With the "A" "AF" and "F" bars disconnected, measuring with a voltmeter, you should get approximately 50% of battery voltage between these two points. If you get full battery voltage, replace the controller.
    5. With the "A" "AF" and "F" bars disconnected and the capacitors fully discharged, measuring with the Ohmmeter you should get in excess of 10K Ohms. If the resistance is very low (0 to 100 Ohms) replace the controller.
    48) There is a path from B- to the F bar. Pls check wiring.

    The controller is reading a short between the motor field and B-.

    1. The most common cause of this fault is a ground fault on the truck. As a rule of thumb, the maximum allowable voltage between the battery and the chassis is 50% of battery voltage. The resistance measured between the chassis and motor terminals or controller bars should be in excess of 30K Ohms. Clean up any existing ground fault and try again.
    2. With all cables disconnected and the capacitors fully discharged, read the resistance between the "B-" bar on the controller and the "F" bar. The reading should exceed 10K Ohms. If the resistance is substantially lower ( 0 to 100 Ohms ) the controller will need to be replaced.
    49) Truck not in Neutral. Cause Unclear.

    The controller has determined that the truck is not in "neutral".

    1. The operating neutral for the SRE system means that both directional switches are open, the throttle is at rest and that the SRO switch is closed.
    2. Use the ProBit under "Troubleshoot" and "Find Problems" to determine which switch is out of sequence. Correct as necessary.
    50) Truck not in Neutral. Forward switch stuck on.

    The controller has determined that the Forward switch is closed.

    1. The switch may be stuck. Correct.
    2. The switch may be miswired (normally closed used instead of normally open). Correct.
    3. The wiring may be faulty. Correct.
    4. The controller may be in an "Install Interlock". Run through "Find Problems" in the "Troubleshoot" section of the ProBit to correct the problem.
    51) Truck not in Neutral. Reverse switch stuck on.

    The controller has determined that the Forward switch is closed.

    1. The switch may be stuck. Correct.
    2. The switch may be miswired (normally closed used instead of normally open). Correct.
    3. The wiring may be faulty. Correct.
    4. The controller may be in an "Install Interlock". Run through "Find Problems" in the "Troubleshoot" section of the ProBit to correct the problem.
    52) Truck not in Neutral. SRO Switch open.

    The controller has determined that the SRO (seat or dead-man switch) is open.

    1. The switch may be stuck. Correct.
    2. The switch may be miswired (normally closed used instead of normally open). Correct.
    3. The wiring may be faulty. Correct.
    53) Truck not in Neutral. Throttle not at rest.

    The controller has determined that the accelerator is not at rest.

    1. Check that the accelerator is moving freely.
    2. Check to wiring to the accelerator.
    3. With the ProBit check that the accelerator is giving a reasonable sweep (2 to 5 volts). Replace if necessary.
    4. With the ProBit, check the minimum and maximum settings of the throttle. Reset if necessary.
    54) Unsafe sequence. Probably Bad throttle Setup

    The controller has determined that there was an attempt to operate the truck out of sequence.

    1. For the controller to operate SRO and brake switches must be closed and throttle must be at rest before a direction is selected.
    2. Check that the accelerator is moving freely.
    3. Check to wiring to the accelerator.
    4. With the ProBit check that the accelerator is giving a reasonable sweep (2 to 5 volts). Replace if necessary.
    5. With the ProBit, check the minimum and maximum settings of the throttle. Reset if necessary.
    55) Warning: Battery over 55V. Pump will not lift!

    48 Volt battery recently charged. Surface charge has not dissipated.

    1. This fault may be self correcting. On a truck with power steering, the controller, if set to do so, will pull in the steering pump briefly to dissipate the surface charge. If the truck does not have a power steering, the surface charge will dissipate over a few minutes.
    2. Ensure that the high voltage response is properly set with the ProBit based on whether the truck has a power steering or not.
    3. Clear the fault(s) with the ProBit.
    56) Warning: Battery over 55V. Truck will not run!

    48 Volt battery recently charged. Surface charge has not dissipated.

    1. This fault may be self correcting. On a truck with power steering, the controller, if set to do so, will pull in the steering pump briefly to dissipate the surface charge. If the truck does not have a power steering, the surface charge will dissipate over a few minutes.
    2. Make sure that the high voltage response is properly set with the ProBit based on whether the truck has a power steering or not.
    3. Clear the fault(s) with the ProBit.