Category: Potain MDT 219 J10

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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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Slewing Motor Encoder Failure (internal short)

If the motor encoder is internally shorted, the drive may not operate in partial open loop as it tries to protect itself.  If this is the case, unplug the 2 connectors from the slew drive and reprogram parameter 90.46 to Force Open Loop.

The drive will also need to be told not to look for the Encoder.

  • Parameter 75.12
  • Switch from 2 to 0
  • Save

In this specific case, operator experienced a separate fault showing “Transition 4” .  Here is the link to that fault.

https://service.rockymtncranes.com/2024/01/12/transition-4/

 

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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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MDT 219 loses functions – bad encoders

 Operator stated crane lost all functions. Found the LMI, and drives were all on with no codes. Looked in the CAN network of the LMI and saw the slew encoder wasn’t pairing,

this was confirmed by a blinking green and red light on the encoders.

Video of lights blinking

There was evidence of corrosion on the encoders,

and it was decided to replace the encoder assembly. Once it was replaced, we cleared the old encoder addresses and paired the new encoder and the crane regained functionality.

Moments later the crane stopped working again. The operator said all of his LMI information wasn’t present (hook position, weight on hook, and trolley location)

the drives were all operational but there were multiple faults codes being thrown. CAN Saturation, CAN Sense codes, and various codes relating to trolley, hoist and load.

The CCL plug was disconnected to test if the load pin, hoist or trolley were faulting the can network. When the crane was restarted the fault codes stopped happening, and the slew function was regained. We also put the crane into fitting mode, this allowed us to test functions without the use of the CAN network. We also saw that the encoders for the hoist, Tolley and load pin were being seen then shutting down then being seen on the CAN open network screen of the LMI.

It was decided to remove the CAN H and CAN L from the CAN Sense connection one at a time from each encoder by connecting the CAN H to CAN H and  CAN L to CAN L leads that come in and leave the encoder (taking the tested encoder out of the circuit) until functionality was regained and a loss of an encoder was recognized on the CAN Open Network.

The hoist encoder was the first tested, and when we removed the hoist encoder from the network, the CAN network connected to the trolley and load pin and showed the hoist was offline, the LMI regained load information, and trolley position, and the hoist encoder wasn’t being recognized.

The Hoist encoder was replaced, the new encoder was paired,

and the hoist min height was re-taught. The crane regained functions.  

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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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219 stuck on 99% moment

Crane won’t go to 100% moment and load.  Can’t change it from 99% to 100% on the display for your maximum moment and load.  Need to go to the CCT U246X and put in your tech code then go change the moment and load to 100% then you can go change it on the display in teach in and crane configuration. To access it on The CCT

5. CODE (put in your tech password) then

2. CONFIGURATION

2.4 MOUNTING

24.6 DERATING      246. Load 100%

246.Moment100%

24.7 POWER CONTROL     247. 100%