Author: Chad

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Crane will not hoist

Crane will not hoist up or down.  No fault on CCS, but drive shows “E OC” which means motor overcurrent.

Manually release brake, and fault changes to “E 68″ brake switch malfunction.  This indicates that the drive is seeing an over current fault, and the brake is typically not the culprit.  Verify brake is being released by drive, and verify brake disk adjustment.  With brake manually released, the drum spins freely.

Found contactor K466M (motor heating) was stuck in the activated position.  Could not release the contactor coil (contacts may be welded)  Switched off Q407F, and crane hoists normally.

As drive would send voltage to motor to work, but motor was requiring more voltage than the drive was sending to rotate because it was heating the motor additionally.  Drive would stop due to this ‘over current” sitauation.

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Igo T85 keeps shutting off when the hook is near upper limit

Looking in the fault stack, 1-400-711 showing in the fault stack and BrF on the hoist drive this was the first fault.  The second fault was 1-230-007 load sensor wiring problem.

It would always have the 400 code then the 230 code.  Need to always look past the first fault code

Checked and all drives were shutting off, not just the hoist drive.  Tomas says if all drives shut off, its not the brake but rather the brake fault is a result of another failure.

Near the upper limit, the 0 load was showing 230 pions.  In the manual, the crane wants between 1150-1350 pions.  As a result, the crane would fault and shut off all drives and the fault 1-400-711 was a result of shutting off the brake contactor and the 230 code from the processor shutting down the drives.

The teach-in portion of the manual tells the tech to lower the block all the way to the ground raise until the hoist cable is in the middle of the drum.  This load cell was only reading 364 pions.

Replaced the load cell and redid the teach-in.  The crane was only reading 936 pions at 0 load.  Although lower than what the manual specified, it is within the operating range of the crane.

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Crane load indication accuracy

1917.46(a)(1)(ii)

The accuracy of the load indicating device, weight-moment device, or overload protection device shall be such that any indicated load (or limit), including the sum of actual weight hoisted and additional equipment or “add ons” such as slings, sensors, blocks, etc., is within the range between 95 percent (5 percent underload) and 110 percent (10 percent overload) of the actual true total load. Such accuracy shall be required over the range of daily operating variables reasonably anticipated under the conditions of use.

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Hoist Drive Update

Hoist drive failed.  Instructions for drive replacement are in the folder, however it is required to add +24 vdc to DQ+.  This applies power to the hoist brake control relay.

See attached schematic.  Typically, the dotted lines are optional, but this is required.

ATV320 Hoist Drive MA21

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FM Gru 1589 Relay Explanation

Rundown of relay to contactor logic

Contactor 34K1 controls valve bank coils.

Y1 Mast down

Y2 Mast up

Y3 Jib up

Y4 Jib down

Relay bank

36K1-5 relays

36K1 Mast down (34K1-Y1)

36K2 Mast up (34K1-Y2)

36K3 Jib up (34K1-Y3)

36K4 Jib down (34K1-Y4)

36K5 Control relay (supply)

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FM Gru 1589 will not raise the jib in erection mode

Tried to erect 1589 and the jib would not raise.  Checked hydraulic pump, and it was building pressure, but the coil to open the valve bank was not being activated.

Contactor was switching to open, but the control relay for the valve was bad.

Light would turn on the face of the relay, but would not actually switch.  The orange screw could be turned to manually make the switch and the jib would go up.  Replace relay.

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Crane shuts off, but immediately restarts

Crane would shut off intermittently.  Red circle would display in the bottom right, but turn back to green circle right away.  There were no active faults, but fault history showed  Emergency stop chain : Incoherent state.

The emergency stop switch has NO and NC contacts.  The fault means 1 set of contacts are acted on, but the other contacts are in “normal” state.  (For example NC contacts are closed, but NO contacts are also closed).

The only e-stop that will register this fault would be the one on the armrest (per JP).  Could be the e-stop or the joystick itself.  The joysticks are the same, so swap to test.