BYD P20PS, Operator'S Manual

MAINTENANCE

OPERATOR MANUAL

41

P20PS

42

OM-P20PS2019001-EN

02A86 POS. EB. SHORTED

H i g h   e n d   o f   d r i v e   o f 

electromagnetic brake 

provides output earlier than 

expected

High end of drive of electromagnetic brake outputs high voltage with the interlock not 

engaged.

1.Check whether another high voltage circuit is connected to the high end output connector of 

electromagnetic brake;

2.If the high end output connector of electromagnetic brake is not connected but high voltage 

still exists, the drive circuit in the controller has already been damaged;

02A80  EMERGENCY 

02A8

WATCHDOG#2 

Watchdog fault 2

Possible cause: During startup of the forklift, the watchdog circuit has been activated before 

the software is initiated. In the standby or operation state, the watchdog signal is invalid (alarm 

state).

Fault analysis: The watchdog hardware circuit or microcontroller output section is damaged. 

Neither of the two cases is associated with external components. Replace the controller.

02A75 CONT. DRV. EV  

EV drive of the controller is 

inoperable

EV drive of the controller is inoperable

02A89 POWER MOS SHORT 

Short circuit of the power 

MOS tube

Before the main contactor engages, the software can check the power bridge. Convert the 

low end power of the MOS tube. Lower the phase voltage to –BATT (lift to +BATT). If the 

phase voltage variation does not agree with the command, this fault can occur. Replace the 

controller. Replace the controller.

02A74 DRV. SHOR. EV

Short circuit of EV cable

Check whether the low end of EV1/EV2/EV3 is short circuited to B-. If not, it is required to 

replace the controller;

02A76  COIL SHOR. EV.

PEV coil fault

Fault with the PEV drive coil. Check whether the PEV drive coil connection or the coil itself 

are in good conditions;

02A92 CURRENT GAIN

Fault with current gain

Maximum current gain is the factory set value. It indicates that the maximum current 

adjustment procedure has not yet been initiated.

Solution: ZAPI technician correctly sets the current gain parameter.

02A96 ANALOG INPUT

Analogue signal input fault

This fault occurs when all analogue signals are converted into the same value by the A/

D converter, with delay exceeding 400ms. This function is used to detect fault with the A/D 

converter or conversion of analogue signal

Fault analysis: If this fault persists, replace the controller.

02A64 TILLER ERROR

Interlock mismatches H&S 

input

Replace the controller;

02A47 EVP2 NOT OK 

NAUX2 input voltage is 

outside the range

Check whether NAUX2 input voltage is within the range. If not, re-calibrate the maximum and 

minimum of NAUX2, and turn the key switch to “ON” again. This fault will disappear.

02A48 EVP1 NOT OK

NAUX1 input voltage is 

outside the range

Check whether NAUX2 input voltage is within the range. If not, re-calibrate the maximum and 

minimum of NAUX2, and turn the key switch to “ON” again. This fault will disappear.

02A49 LIFT + LOWER

Faults with lifting and 

lowering exist at the same 

time

1.Improper operation;

2.Fault with the “LIFT “and “LOWER” switches;

3.Replace the controller;

02A79 PUMP INC START 

Oil pump startup sequence 

fault

Incorrect oil pump startup sequence. Possible causes:

1.The “LIFT” or “TILT” switch has already at the “ON” position before the forklift is started.

2.Operation sequence error.

3.Incorrect wiring connection.

4.If the fault cannot be eliminated, replace the controller.

02A90 PUMP VACC RANGE

O i l   p u m p   l i f t   s p e e d 

regulation sensor signal is 

outside the range

1.Upper and lower voltage limits of the lift speed regulation sensor have not been correctly

taken. Move to the “PROGRAM VACC” menu and take them again;

2.Check whether the wiring of the lift speed regulation sensor is correct;

02A27 PHASE KO 

Open circuit of U/V/W phase Check whether U/V/W phase is correctly connected.

02A89 PUMP VACC NOT OK

O i l   p u m p   l i f t   s p e e d 

regulation sensor fault

Inspection time: idling state

The lift speed regulation sensor 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 voltage limits of the lift speed regulation sensor have not been taken.

Move to the “PROGRAM VACC” menu and take them again.

2.Lift speed regulation sensor error

3.Controller fault.

02A42  AUX DRIV.OPEN

Fault with drive of auxiliary 

output

Drive circuit of auxiliary coil is unable to drive the load. Device itself or drive coil.

02A0

DATA ACQUISITION

Data collection

Activation of this fault indicates data acquisition is under way. Wait data acquisition is 

completed.

02A67 NO CAN MSG.

No CAN signal

Fault with CAN communication between steering and towing. Check CAN connection, as well 

as version and configuration of software.

02A0

CHECK UP NEEDED 

Maintenance interval

Maintenance interval is expired. Maintenance is required.

02A61  THERMIC SENS. KO

Temperature sensor fault

Controller temperature sensor output signal is outside the range. This fault is not related to 

external components. Replace the controller.

02A41 WRONG BATTERY 

Fault with battery setting

While the forklift is being started, the controller checks whether battery voltage is within the 

nominal voltage range.

1.Check whether the “BATTERY VOLTAGE” setting in the “TESTER” agrees with the

indication of the voltmeter. In the case of disagreement, change battery voltage setting to be 

the same as the measured value, by using the “ADJUST BATTERY) function.

2.Replace the battery.

02A53 WRONG ZERO

Error of zero voltage

While the forklift is being started, feedback value of high end voltage of VMN is not in the 

order of 2.5V. Circuit of the controller is damaged.

Fault analysis: The following checks are recommended.

Check internal connection of the motor.

Check power cable connection of the motor.

Check for drain current between the motor and the forklift housing.

If the motor connection is in good condition, the fault is in the controller interior. Replace the 

controller.

02A99 SLIP_PROFILE

Slip fault

“SLIP PROFILE” selection error. Check hardware parameter settings.

02A40 

AUX DRIV.SHRT.     // all254 Short circuit of auxiliary drive

Short circuit of drive circuit of electromagnetic brake or auxiliary electric brake.

Check for short circuit or low-impedance push-pull output between A16 and –BATT.

Fault with drive circuit of logic card. Replace the controller.