Scales

Welch Allyn 5002: troubleshooting and error codes

The ServiceForge knowledge base holds 18 documented symptoms for the Welch Allyn 5002, with 34 ranked causes, 27 diagnostic checks with test points and expected values, and 22 error codes. Each symptom below shows its causes and the first check; the rest is one connection away. Connect ServiceForge to your AI

Symptoms

Scale beep codes and messages

Scale emits various audible signals and displays messages; user identifies meaning

Ranked causes

1. Print requested without valid weight displayed (common)
2. Printer in use or disabled (occasional)
3. Printer hardware problem (occasional)
4. Battery too weak to operate (occasional)
5. Scale general problem (rare)

First check

Identify beep pattern and count

Test point: Audio output from scale
Expected: One/two/three beeps (normal); four short/long or continuous beeps (error)

2 more checks with pass and fail actions, 5 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

No print, four long beeps

Four long beeps sound when printer has internal problem

Ranked causes

1. Jammed print head (occasional)
2. Out of paper (common)
3. Disconnected printer cable (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

No print, four short beeps

Four short beeps sound when print is requested but conditions are not met

Ranked causes

1. Weight display shows invalid value (e.g. '0.0') (common)
2. Printer in use (occasional)
3. Print function disabled in BMI calculation mode (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Reading does not change when weight applied

Scale shows no change in reading when object placed on platform

Ranked causes

1. Platform not plugged into readout (common)
2. Defective platform cable (occasional)
3. Defective load cell transducer (occasional)

First check

Verify platform cable plugged into readout

Test point: Platform cable connector at readout
Expected: Cable firmly connected

1 more check with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Scale displays CABLE or O-LOAd error

Console shows CABLE or O-LOAd message indicating signal issue

Ranked causes

1. Weight exceeds scale capacity (O-LOAd) (common)
2. Damaged transducer or defective instrument board (O-LOAd with valid reading) (occasional)
3. Damaged or disconnected transducer cable (CABLE) (common)

First check

Verify patient weight within capacity

Test point: Patient on scale
Expected: Weight reading within scale specifications (see inside front cover)

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Weight reading takes excessive time to display

Scale delays before showing stable weight value on display

Ranked causes

1. Platform in motion or excessive patient motion (common)
2. Platform rubbing against foreign object (occasional)
3. Loose cable connection (occasional)

First check

Verify platform and patient stability

Test point: Weighing platform
Expected: Platform stationary; patient not moving

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Four long beeps

Scale produces four long beeps indicating battery or mode issue

Ranked causes

1. Battery too weak to operate scale (common)
2. Scale in custom/factory/service/calibration mode (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Weight reading not accurate

Scale displays incorrect or unstable weight measurements on platform

Ranked causes

1. Mechanical obstruction preventing platform downward movement (common)
2. Loose or disconnected transducer cable (common)

First check

Inspect weighing platform for obstructions

Test point: Platform underside and surrounding area
Expected: No foreign objects visible; platform moves freely downward

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Battery replacement and storage

Annual battery replacement and proper storage procedures to prevent corrosion and maintain operation

Ranked causes

1. Routine battery maintenance (common)

First check

Replace batteries annually

Test point: Battery compartment
Expected: Fresh batteries installed, no corrosion

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Annual verification patient safety

Periodic service to confirm device functions within design specifications

Ranked causes

1. Routine maintenance requirement (common)

First check

Verify scale calibration

Test point: Scale output
Expected: Within design specifications

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Scale zero and span high voltage

Factory calibration drift or need to recalibrate zero point and measurement span using certified test weights

Ranked causes

1. Normal recalibration requirement or load cell/readout component damage (unknown)

First check

Verify scale is on flat hard surface with no physical interference

Test point: Scale platform
Expected: Flat, level, no obstructions

5 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Span only (default capacity) high voltage

Span calibration using default capacity and mV/V from scale type table without manual weight entry

Ranked causes

1. Need to recalibrate span using factory defaults (occasional)

First check

Verify scale is empty before default span calibration

Test point: Scale platform
Expected: Empty, no residual weight

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Zero only (default) high voltage

Quick zero calibration using default 0 kg = 0 mV/V without span adjustment

Ranked causes

1. Need to reset zero reference point only (occasional)

First check

Ensure scale is empty and on flat hard surface

Test point: Scale platform
Expected: No weight, flat level surface

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Continuous long beep

Scale produces continuous long beeping sound

Ranked causes

1. Scale malfunction (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Cradle inspection required patient safety

Visual inspection for physical damage that may affect scale stability or patient safety

Ranked causes

1. Preventive maintenance requirement (common)

First check

Inspect cradle for damage

Test point: Cradle assembly
Expected: No cracks, all hardware present and tight

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Enclosure inspection required patient safety

Visual inspection of scale housing for damage, cracks, or loose components

Ranked causes

1. Preventive maintenance requirement (common)

First check

Inspect enclosure for damage

Test point: Scale housing
Expected: No damage, all hardware present and tight

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Long/short beeps

Irregular beep pattern indicates scale problem

Ranked causes

1. Scale malfunction (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Power adapter cable inspection required high voltage

Visual check for signs of wear, abrasion, or damage to the power cable

Ranked causes

1. Preventive maintenance requirement (common)

First check

Inspect power adapter cable

Test point: Cable outer sheath and connectors
Expected: No abrasions, cracks, or visible wear

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Error codes

Code	Meaning	Trigger	Severity
`------`	Stationary display indicates a negative weight	Negative weight value displayed	warning
`bAttrY`	Battery power insufficient to operate scale	Battery voltage drops below minimum operating threshold	warning
`CABLE`	Measurement board connection lost or signal out of range	Signal from transducer outside a-d converter range; disconnected or damaged cable	error
`ER OL`	Span weight exceeds scale capacity		error
`ERR AD`	Measurement board cannot be read	Communication failure between scale processor and measurement board	error
`ERR AV`	Measurement board version incompatible	Measurement board firmware or hardware version not compatible with main scale firmware	error
`ERR CL`	Measurement board error; weight display blocked	Measurement board malfunction preventing weight calculation or display	error
`ERR DB`	Scale application database integrity compromised	Corruption or loss of application data in memory	critical
`ERR FD`	Scale factory database integrity compromised	Corruption or loss of factory configuration data in memory	critical
`ERRoR`	Scale flash memory integrity compromised	Flash memory corruption detected during self-test	critical
`ER SP1`	Span weight outside acceptable margin for mV/V reading		error
`ER SP2`	Calibration weight message failed to send		error
`ER SP4`	Calibration weight message failed to send		error
`ER SP5`	Error while waiting for scale to calibrate or measurement board internal error		error
`ER SP6`	Calibration did not save		error
`ER ZR0`	Reading is outside the scale type's acceptable mV/V range		error
`ER ZR1`	Calibration message failed to send		error
`ER ZR2`	Error while waiting for the scale to calibrate		error
`ER ZR3`	Calibration did not save		error
`LoBATT`	Battery power insufficient to print	Battery voltage too low for printer operation	warning
`OFF SCALE PLEASE`	Remove patient from weighing platform (wheelchair scales with ramps)	Patient on scale during power-up before ramp calibration completes	info
`O-LOAd`	Weight exceeds scale maximum capacity	Weight signal exceeds maximum design limit for scale model	warning

Likely causes and actions for each code are in ServiceForge. Connect ServiceForge to your AI

Community

0 fixes logged by technicians through their AI, with outcomes, for this model.

ServiceForge knowledge base record. Field-unverified unless technicians confirmed it. A teaching summary of the record, not a service manual. Export 2026-10-14.