Category: Potain MDT 109

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Crane shuts down during operation

Crane is shutting down during operation, however no fault is displayed and the operation symbol on the LMI bottom right goes from a red circle to flashing green almost immediately.  After searching for the fault history (no active faults), found a list of Can Bus faults.

2032.33057 CAN bus CMD: CAN error bus off

2032.33058 CAN bus CMD: CAN alarm bus error

2032.33040 CAN bus CMD: CAN saturation

2032.33058 CAN bus CMD: CAN alarm bus error

2032.33057 CAN bus CMD: CAN error bus off

2032.33040 CAN bus CMD: CAN saturation

Located on the Can Bus CMD (Command) ‘channel’ is the crane’s modem.  Disconnect the top 3 and the bottom large connector.  Crane will restart and work

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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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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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Windshield washer check valves

While filling the washer bottle, all the fluid would leak out.

On the output side of each washer pump is a check valve. 

to access the valves the A/C unit must be removed.
found that the check valves were broken and cracked, presumably from freezing. Replaced the valves ( toyota part # 85321-26020) and washer bottle stays filled.

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Crane Topsite Shunt Code

Shunt code for Topsite shunt when activated is 8528
This code can be any code you choose, in an attempt to standardize the shunt code please make it 8528 at the time of setup.

Currently the shunt code for the MDT389 SN: 627012 is 1025

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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.

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E68 Error on CCS and KEB Drive

Hoist suddenly stops, and often will not restart until several attempts later.  E68 code is displayed on CCS messages.  It means that the KEB hoist drive releases the brake, and looks for the microswitch contact within 600ms (.6 seconds).  If it does not, it will fault.  Follow the steps below.

E68

Hoist Brake Microswitch Adjustment

Also with this situation, the operator claimed the load would drop slightly.  Was able to verify during startup, K405A (validated drive contactor) would close and K409M would energize allowing the brake to release, then the drive would shut down.  Could recreate and U400X #29 was supplying +24VDC at startup to energize K409M.  This comes directly from the drive, replace hoist frequency drive

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Crane Starts but will not Swing

Crane starts, but will not swing.  the Green Square is flashing on bottom right of LMI.  Swing drive has 3 fault codes, AFE1 AFE2 and FBA A Missing.

For AFE! and AFE2 see link.

https://service.rockymtncranes.com/2022/09/07/afe1-and-or-afeb-faults-on-start-up/

Replace the memory stick, and had to force the K600M to stay active for complete download of the memory stick to the drive, and then restart crane.  Crane swings and weathervanes properly.

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AC not working in cab

Here is the condensed version of the expanded troubleshooting tree.

Issue

AC/Heat unit not working

Cause

The AC unit not working can be caused by multiple problems, follow the procedures in the resolution notes to find out what is wrong with the unit, or if it need replaced

Resolution

  1. Check the circuit breakers that control the AC and heat units
    2. Check phase detector inside AC unit to be sure it has 2 lights
    3. Replace AC controller to the left of seat
    4. Check to see if the Condenser fan on the back of the cab runs when AC is selected, if not, check the fuses
    5. Try using the “Defrost” setting and see if the AC turns on
    6. Access AC unit and check to see if all the sensors are connected and working properly
    7. If you cannot figure out why the AC unit is not running, order a new unit and replace it

TA23-450-C – Troubleshooting flow chart for the ultraview cab air conditioning system_EN