BYD P20PS, Operator'S Manual

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MAINTENANCE
OPERATOR MANUAL 39
P20PS
40 OM-P20PS2019001-EN
02A77
CONTACTOR OPEN
Contactor does not
engage
The coil of main contactor has been energized by the logic card, but the contactor does not
engage. Possible cause:
1.The contactor has mechanically become faulty, or its contacts get stuck.
2.The contacts of contactor cannot make securely.
3.If the contactor operates normally, replace the controller.
02A52 PUMP I=0 EVER Oil pump I=0 fault Check whether the power supply line of the oil pump motor is in good condition. If the line is
in good condition, replace the controller;
02A53 STBY I HIGH Standby current is high The micro controller system has detected that the signal of the current sensor is outside
the permissible range of current with the forklift in the idling state. This fault is irrelevant to
external components. Replace the controller.
02A60 CAPACITOR CHARGE
Capacitor charging
error
With the key switch turned to “ON”, the controller will charge the capacitor via the power
resistor. The controller will detect whether the capacitor is fully charged within the specified
time. If the capacitor is not fully charged within the specified time, and the capacitor voltage
is still less than 20% the battery voltage, the controller will display the warning and the main
contactor will not engage.
Possible causes:
1.The charge process of the controller is interfered by external devices (for example, DC-DC
converter and motor) or other devices. It is necessary to remove the interferences by these
devices.
2.The power resistor is disconnected. The charge circuit or power supply module becomes
faulty. In these cases, replace the controller.
02A62 TH. PROTECTION Controller over-temperature
protection
Lower the controller temperature to below 85oC. If the fault still exists, possibly the
temperature sensor or controller becomes faulty. Replace the controller.
02A65 MOTOR TEMPERAT MOTOR TEMPERAT Check whether U/V/W phase is correctly connected.
02A0 BATTERY LOW Battery level low
If the parameter “BATTERY CHECK” is not set to zero, no LED representing battery state-
of-charge will come on when battery state-of-charge is less than 15%. The warning will
be displayed and the lift function of the forklift will be disabled. In this case, it is imperative
to charge the battery. If the battery is operational, check whether the controller parameter
“ADJUST BATTERY” agrees with the battery voltage.
02A74 DRIVER SHORTED
Short circuit of drive
With the key switch turned to “ON”, the controller will check the drive of main contactor for
short circuit. In case of short circuit, the warning will be displayed. Check whether the positive
terminal of coil of main contractor is short circuited to A16 or negative terminal of power
supply. If externality is normal, replace the controller.
02A75 CONTACTOR DRIVER Short circuit of drive
With the key switch turned to “ON”, the microprocessor will check the drive of main contactor
for short circuit. In case of short circuit, the warning will be displayed. Check whether the
positive terminal of coil of main contractor is short circuited to A16 or negative terminal of
power supply. If externality is normal, replace the controller.
02A78 VACC NOT OK
Accelerator fault
Inspection time: With the forklift idling, the accelerator voltage is at least 1V higher than the
minimum set in the “PROGRAM VACC” menu for accelerator signal range.
Possible causes:
1.Upper and lower limits of accelerator voltage are not taken. Move to the PRPGRAM VACC
menu to take the limits again.
2.Accelerator error. Possible cause is that accelerator pedal failure to return to original
position, or internal error of accelerator.
3.Controller fault.
02A79 INCORRECT START
Startup sequence fault
Incorrect startup sequence. Possible causes:
1.The direction switch has already been turned on before the motor is turned on.
2.Operation sequence error.
3.Incorrect wiring connection.
4.If the fault cannot be eliminated, replace the controller.
02A80 FORW + BACK
F o r w a r d a n d r e v e r s e
signals exist at the same
time (direction switch gets
stuck)
The controller can keep checking for this fault. Having detected that request signals in the two
directions occur at the same time, the controller will issue a warning.
Possible causes:
1.Wire damaged.
2.Direction switch fault.
3.Improper operation.
4.If the fault cannot be eliminated, replace the controller.
02A82 ENCODER ERROR
Encoder fault
The controller detects that two successive speed readings of the encoder differs greatly from
each other. A normal encoder in the system cannot change speed readings greatly within a
very short time. Hence, a possible cause for the symptom is that the wires of one or more
encoders are worn or broken. Check the mechanical and electrical parts of the encoder.
Another possible for the symptom is electromagnetic interference from the sensor bearing
. If the symptom is not due to the two causes, replace the controller.
Note: Sometimes manual operations may also cause this fault indicating on the controller. In
these cases, it is required to turn off power supply and start the forklift again. For example:
1.The forklift suddenly collides with an obstacle so that it is incapable of travelling;
2.The driver applies the brake sharply while the forklift is travelling at a high speed.
02A86 PEDAL WIRE KO
Fault with connection of
positive and negative
terminals of accelerator
Check whether the positive and negative terminals of the accelerator have been connected to
the controller;
02A84 CAN BUS KO BMS CAN BUS KO BMS Check whether the BMS communication line operates normally.
02A21 CHARGE SAFETY
Charge safety This fault can be reported if the forklift is operated while the battery is being charged. This
prevents anyone from operating the forklift while the battery is being charged.
02A22 HEIGHT SENS LOCK
02A20 HEIGHT SENS OPEN
02A11 STALL ROTOR Motor stalling
1.Motor stops running.
2.Motor encoder fault
3.Damaged harness or incorrect wiring connection.
4.Problem with power supply to the encoder.
02A71 HANDBRAKE
02A78 BACKING INPUT
02A10 WRONG RAM Fault with the dynamic
memory
The fault is detected when the main memory is tested. Registered address is “DIRTY”. This
fault can limit the operability of the forklift.
Fault analysis: Turn the key switch to “OFF”, then to “ON”. If the fault still exists, replace the
controller.
02A74 AUX BATT. SHORT. Fault with auxiliary drive
voltage
Check whether BI is correctly connected to B5. If so, replace the controller;
02A50 EVP1 COIL OPEN Open circuit of NAUX1 coil Check NAUX1 coil for open circuit, and whether EVP1 type setting is correct.
02A51 EVP2 COIL OPEN Open circuit of NAUX2 coil Check NAUX2 coil for open circuit, and whether EVP2 type setting is correct.
02A79 WRONG STEER PAR.
02A56 PUMP I NO ZERO
Current exceeds limit while
pump motor does not run
Replace the controller;
02A67 SENS MOT TEMP KO
Temperature sensor fault
Symptom: Output signal of motor temperature sensor is outside the permissible range.
Solution: Check the signal value and connection of the sensor. If they are normal, the fault
occurred in the controller.
02A98 DEAD MAN ABSENT
02A76 KEY OFF SHORTED Short circuit of the key
switch
In the startup phase, if the controller detects a low logic level when the key switch is turned to
“OFF”, this fault will be displayed.
Fault analysis: A highly possible cause is voltage being too low. Perform the following checks.
-Key switch based external load (for example, turning on the DC-DC converter. Relay or
contactor switch input signal lower than startup voltage).
-Check the connections of the power supply cables to the positive and negative terminals
of the battery, and to the terminals -BATT and + BATT terminals of the main contactor and
controller. The screws shall be tightened to torque 13Nm to 15Nm.
-If no voltage drop in the power supply circuit is detected, this fault will be reported each
time the key switch is turned to “ON”. The hardware of controller could become faulty. It is
necessary to replace the controller.
02A8 FLASH CHECKSUM Flash memory fault
With the key switch turned to “ON”, the value stored in the flash memory by the program
should be a positive value. This fault will be reported in the case of a negative value.
Fault analysis: The flash memory of the microcontroller could become faulty. The flash
memory, or the program stored could be damaged. Attempt to configure the program of the
logic card again. If the fault is still there, it exists in the microcontroller. Replace the controller.
02A68 SMARTDRIVER KO
Drive of electromagnetic
brake fault
Check whether the high end (CNB#1) of the drive of electromagnetic brake is short circuited
to the terminal B-. If not, the internal drive module could be damaged.
02A76 COIL SHOR. MC-EB
M a i n c o n t a c t o r o r
electromagnetic brake is
heavily loaded
1.Check whether the output and load of the controller are excessive;
2.Replace the controller;
02A68 WAITING FOR NODE Waiting for signal from a
node
In the CAN communication network, a certain controller has received the signal that another
controller cannot communicate normally. The said certain controller hence remains waiting
until the whole CAN communication network reverts to normality. Check the controller that
cannot communicate normally for failed connection. Check whether the software version or
parameter settings are correct.
02A26 CURRENT SENS. KO
02A85 VACC OUT RANGE Accelerator input is outside
the permissible range.
1.Upper and lower limits of accelerator voltage are not correctly taken. Move to the
PRPGRAM VACC menu to take the limits again;
2.Check whether the accelerator connection is correct;
02A0 EPS RELE OPEN
02A51 TILLER OPEN
Ti l l e r i n p u t s w i t c h i s
disconnected
With the tiller input switch disconnected, after a period approximately 30s has elapsed, the
main contactor will disengage and the warning will occur. The warning will not occur next time
the forklift is operated.