What causes fault code PAL-003 (Palletizer Height Overtravel)?

Layer count exceeded — more layers than recipe allows. Height sensor/encoder missed counts — thinks it's lower than actual. Layer sheet or slip sheet jammed adding extra height. Product is taller than spec — different SKU loaded. Lift table overrun — drive decel too slow to stop at limit

How do I fix fault code PAL-003?

Verify layer count matches recipe on HMI. Check product height against recipe specification. Inspect for jammed slip sheets adding extra height. Verify height encoder is reading correctly — compare to physical measurement. Check high limit switch — must stop lift reliably. Adjust lift deceleration if overrunning the stop point

Palletizer Height Overtravel

PAL-003

Elevator/lift table exceeded maximum height limit. Safety switch or encoder detected position beyond normal range.

high palletizer

palletizer height overtravel elevator limit

Probable Causes (ranked)

Layer count exceeded — more layers than recipe allows
Height sensor/encoder missed counts — thinks it's lower than actual
Layer sheet or slip sheet jammed adding extra height
Product is taller than spec — different SKU loaded
Lift table overrun — drive decel too slow to stop at limit

Fix Steps

1 Verify layer count matches recipe on HMI
2 Check product height against recipe specification
3 Inspect for jammed slip sheets adding extra height
4 Verify height encoder is reading correctly — compare to physical measurement
5 Check high limit switch — must stop lift reliably
6 Adjust lift deceleration if overrunning the stop point

Field Trick

Count the layers on the pallet. If there's one extra layer, the layer counter in the PLC is off by one — probably a missed or double-counted photoeye pulse.

Suggested Replacement Parts

Parts matched to fault category: Limit Switch

Allen-Bradley 802T-AP Limit Switch P/N: 802T-AP NEMA Type 4, lever type, 1 N.O. + 1 N.C., plug-in

AutomationDirect $65.00 Amazon $55.00 Grainger $82.00

Omron D4N-4132 Safety Limit Switch P/N: D4N-4132 Top plunger, 1 N.C. + 1 N.O., M20 conduit entry

AutomationDirect $28.00 Amazon $22.00

Prices are estimates. Verify part numbers match your equipment before ordering.

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