PMW20
123
PMW20
122
8.7 TABLE OF FAULT CODES
SM-PMW202020001-EN
SM-PMW202020001-EN
FAULT
CODE
FAULT REMEDY
02A00
WATCHDOG#2
FLASH CHECKSUM
WATCHDOG
02A17
LOGIC FAILURE#3
02A13
WRONG RAM
EPS RELE OPEN
WRONG CONFIG
BATTERY LOW
02A08
EEPROM KO
1.
Motor stalls.
2.
Fault appears in the encoder of the motor.
3.
Wiring harnesses is broken or fault is found in the wiring.
4.
The encoder is disabled in its power supply.
02A10
PARAM RESTORE
02A11 STALL ROTOR
If parameters of “BATTERY CHECK” are not set as “0”, the fault will be reported, and the lifting
function will be locked when the battery power is less than 15% and no bars are displayed on the
instrument. Please charge in time. If the battery is electric, check whether the value of
“ADJUST BATTERY” on the controller is consistent with that of battery voltage.
If the fault is activated to show that it is in a phase of data acquisition, please wait until data is
acquired completely.
DATA ACQUISITION
When the maintenance time is up, check it.
Revise CHECK UP DONE into ON. Shut down and restart.
Clear EEPROM
02A01
Watchdog circuit will be activated before software starts. Under working or standby states, the
signal of watchdog is ineffective (warning state).
Fault analysis: a broken state has been seen in the watchdog hardware circuit or the
microcontroller output part. If both of the above two are irrelevant with outer parts, replace the
controller.
After the key is turned on, the value of flash checksum on the program is positive. If it is negative,
the signal of fault will appear. Fault analysis: It is blamed for the flash memory of microcontroller.
The flash checksum may be broken, or the program stored suffered from damage. Try to reset the
pro-gram of the logic card. If the fault continues, it should be blamed for the microcontroller.
Replace the controller.
1.
Restart the electric lock. Please replace the controller if the fault still exists.
2.
Restart the electric lock. Please reset parameters if the fault disappears.
Perform CLEAR EEPROM. If the fault disappears, change the parameters as set values singly.
Instead, try to replace the controller.
Check whether the coil of electromagnetic brake is normal. If not, replace the controller.
02A16
AUXOUTPUT KO
The output circuit of coil suddenly disconnects during operation.
A fault is found in the current protection function of the logic card. Replace the controller.
02A18 LOGIC FAILURE#2
1. Check whether the circuit of motor power line is normal, including the safety device of the
controller.
2. Check the parameter list.
3. If it is bot blamed for the above two, replace the controller.
02A21 CHARGE SAFETY
When it is charging, any movement of forklifts will report the fault. It can protect forklifts from being
operated when charging.
02A27 PHASE KO
Check whether the connection among U/V/W is normal.
Cause: The Watchdog circuit will be activated before software starts. Under working or standby
states, the signal of watchdog is ineffective (warning state).
Fault analysis: A broken state has been seen in the watchdog hardware circuit or the
microcontroller output part. If both of the above two are irrelevant with outer parts, replace the
controller.
Find faults when performing tests for main ram: the registration address is “DIRTY”. The fault will
limit the operability of forklifts. Fault analysis: lose the key switch and open again. If the fault still
exists, replace the controller.
If CLEAR EEPROM has been performed, change the prompt parameters of fault as a default
value. If not, there is a fault inside the controller.
DATA ACQUISITION
02A42 AUX DRIV OPEN
02A41 WRONG BATTERY
02A28 PUMP VMN LOW
Cause: When the machine starts, the low-end voltage of MOS transistor
is 10% higher than that of normal battery or the phase voltage is 50% higher than battery voltage.
Possible causes：
1.The wiring of the motor is incorrect or a fault is found in the circuit of the motor; check whether
the three-phase connection is correct; check whether there is electric leakage in the motor
connecting to the ground; check whether the coil of the motor is broken.
2.Replace the controller.
02A31
02A38
02A40 AUX DRIV SHRT
When starting, check battery voltage with the controller and determine whether it reaches what is
allowed.
1.check whether the value of BATTERY VOLSIGNE on the TESTER menu is consistent
with that on the voltmeter. If not, use ADJUST BATTERY function and change the battery
voltage to match the measured value.
2.Replace the battery.
02A53
STBY I HIGH
WRONG ZERO
Cause: When the machine starts, the low-end voltage of MOS transistor is 10% higher than that of
normal battery or the phase voltage is 50% higher than battery voltage.
Possible causes:
1.The wiring of the motor is incorrect or a fault is found in the circuit of the motor; check whether
the three-phase connection is correct; check whether there is electric leakage in the motor
connecting to the ground; check whether the coil of the motor is broken.
2.Replace the controller.
02A29 PUMP VMN HIGH
02A37
Cause: When the machine starts, the low-end voltage of MOS transistor
is 10% higher than that of normal battery or the phase voltage is 50% higher than battery voltage.
Possible causes：
1.The wiring of the motor is incorrect or a fault is found in the circuit of the motor; check whether
the three-phase connection is correct; check whether there is electric leakage in the motor
connecting to the ground; check whether the coil of the motor is broken.
2.Replace the controller.
Check whether the master contactor adheres.
1.
The circuit of the master contactor coil disconnects.
2.
The main contactor is broken.
The driving circuit of the auxiliary coil can’t drive load. The device itself or driving coil is broken.
Replace the controller.
02A47 EVP2 NOT OK
Check whether the input voltage of NAUX2 is normal. If not, re-mark the maximum and minimum
values of NAUX2 and restart the key. Then the fault disappears.
02A48 EVP1 NOT OK
Check whether the input voltage of NAUX1 is normal. If not, re-mark the maximum and
minimum values of NAUX1 and restart the key. Then the fault disappears.
02A49
LIFT + LOWER
1.Operation is inappropriate.
2.It is blamed for faults of lifting and descending switches.
3.Replace the controller.
i=0 EVER
If the three-phase connection is correct, replace the controller.
02A50 EVP1COIL OPEN
Check whether the coil of NAUX1 is set as the open circuit or whether the type of EVPI is set
correctly.
02A51
EVP2COIL OPEN
Check whether the coil of NAUX1 is set as the open circuit or whether the type of EVPI2 is set
correctly.
TILLER OPEN
When the handle input switch disconnects, the master contactor will disconnect and report an
alarm after about 30 seconds. The alarm will not disappear until the master contactor runs again.
02A52 PUMP I=0 EEVER
Check whether it is correct in the connection among power lines of the oil-pump motor; if yes,
replace the controller.
The signal output from the current sensor, detected by the microcontroller, exceeds what is
allowed by the inactive current. Since the fault is irrelevant with peripheral components, just
replace the controller.
When it starts, the feedback value on the high-end voltage of VMN is not around 2.5V. The circuit
of the controller is broken. Fault analysis: recommend to check the following items.
Connection inside the motor.
Connection among motor power cables.
Drain current between the motor and the forklift housing.
If the connection of the motor is good, check the controller and replace it.
Check the three-phase02A30 VMN LOW
VMN HIGH
CONTACTOR CLOSED
CONTACTOR OPEN
The drive circuit for electromagnetic brake or auxiliary electrical brake is short-circuited.Check
whether the short circuit or low impedance push-pull output exists between A16 and –BATT. If a
circuit fault appears in the driver of the logic card, replace the controller.
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