AGV fault codes are critical notifications that appear during the operation of Automated Guided Vehicles (AGVs). Understanding these fault codes enables operators to respond promptly, ensuring that the equipment operates safely and efficiently.
Below is a summary table of common fault codes and warnings for the AGV iDonkey along with corresponding troubleshooting methods to help operators act quickly and minimize disruptions in operation.
| Fault Code | Fault Name | Description | Troubleshooting |
| 00 | AGV READY! | AGV is ready. | |
| 01 | BUMPER TRIGGERED | Bumper impact sensor activated. | Remove obstruction from bumper operation area. Press reset. |
| 02 | EMERGENCY STOP! | Emergency stop activated. | Release the Emergency button. Press Reset. |
| 03 | LEFT DRIVER ERROR! | Left motor driver error. | Press Reset. AGV to reset the driver error.* |
| 04 | RIGHT DRIVER ERROR! | Right motor driver error | Press Reset. AGV to reset the driver error.* |
| 05 | DRIVER MOTOR ERROR! | Both motor driver error. | Press Reset. AGV to reset the driver error.* |
| 06 | DANGEROUS AREA TRIGGERED! | Stopped due to obstacle in the danger zone. | Press Reset. Move the obstacle out of AGV’s working area. |
| 07 | AGV OUT OF LINE! | AGV is running outside the line. | Press Reset. Move AGV back onto the line and let it run again. |
| 08 | AGV NOT IN LINE! | The top sensor of AGV is not positioned on the line when START. | Press Reset. Move AGV into line, let it run again. |
| 09 | PID PARAMETER ERROR! | PID parameters not set. | Contact a qualified technician or supplier for setup. |
| 10 | LOW BATTERY! | Battery voltage low (vehicle is operational). | Vehicle operates normally. Upon reaching the charging station, it will stop and beep to alert the operator to replace the battery. |
| 11 | VERY LOW BATTERY! | Battery voltage very low (vehicle cannot continue operating). | Power off, replace battery. |
| 12 | OVER CURRENT! | Overcurrent (exceeding allowable load or obstruction preventing vehicle operation). | Press Reset. Check load and obstruction in front and at the wheel. |
| 13 | NO ROUTE CHOSEN! | Route not selected. | Set the route on HMI. |
| 14 | OVERTIME PINTLE! | Timeout when lifting or lowering the pintle. | Press Reset. Check for obstructions on the pintle?* |
| 15 | OVERLOAD FOR UPPER PINTLE! | Overload when lifting the pintle. | Press Reset. Check for obstructions on the pintle?* |
| 16 | ERROR FOR STATION TROLLEY! | IO error at the running station. | Check the status and position of trolley at stations. |
| 17 | TROLLEY MISSING IN ALL ROUTES! | IO not available at all routes. | Check status and position of trolleys at stations |
| 18 | AGV DISCONNECTED FROM SERVER! | AGV not connected to server. | Check software on the PC server, router, repeater wifi… |
| 19 | USB ERROR! | USB error: Incorrect USB format, map file not in correct format… | Verify USB format, naming of files in USB… |
| 20 | CHARGE STATION! | Battery voltage low, stopped to charge battery. | Power off, charge and replace with a new battery. |
| 21 | NOT RECEIVING DATA FROM REMOTE IO! | Data cannot be retrieved from remote IO. | Check the status of remote IO, server, repeater wifi… |
| 22 | EEPROM INITIALIZATION ERROR! | Failed to initialize EEPROM read. | Power off, restart after 5 seconds. |
| 102-104 | MODBUS COMMUNICATION ERROR! | Communication errors within AGV’s PCBs. | Power off, restart after 5 seconds.* |
| 200-254 | ERROR FOR STATION X TROLLEY! | Status errors for the station, X is the sequence of the previously configured stations. | Press Reset. Check and adjust trolleys suitably. |
*If resetting and checking does not resolve the issue, please contact the maintenance department or the manufacturer.
Note:
- Always check safety factors before operating the vehicle.
- Perform regular maintenance to ensure stable and durable vehicle operation.
- Advanced settings and troubleshooting should only be performed when expertise is available or support from the technical team is provided.
Understanding the AGV fault codes and their corresponding troubleshooting methods is crucial for operators to maintain proactive, safe, and efficient control over the equipment. Especially with AGV models like the iDonkey, fault codes are intentionally designed to alert operators and prevent issues before they affect the entire system. When operators correctly understand and respond appropriately, sudden machine stops, collisions, or production interruptions can be minimized.
Not only does effective fault management ensure continuity in operations, but it also extends equipment lifespan, reduces maintenance costs, and creates a safe working environment for all personnel in a factory or logistics setting.
However, with a complex automated system like AGV, it isn’t always possible to manually or locally resolve faults. When fault codes cannot be remedied through basic actions, operators need to promptly reach out to their technical team or manufacturer for in-depth support to avoid broader impacts on other devices and processes.
At IDEA, we not only provide advanced AGV models such as iDonkey, but we also accompany our customers throughout the usage process – from technical consulting and operation training to post-sales support. Whenever you encounter difficulties with your equipment, rest assured that our technical team is always ready to assist you promptly and effectively.
