What causes fault code PAL-GRIP1 (Palletizer Gripper / Vacuum Head — Pickup Failure)?

Vacuum level insufficient — vacuum pump worn, filter clogged, or leak in the manifold. Vacuum cups worn or damaged — not forming seal on product surface. Product surface too porous or textured for vacuum pickup — air leaks through product surface. Gripper clamp fingers not closing fully — cylinder pressure low or mechanical obstruction. Layer not formed correctly — gaps between products prevent full vacuum seal

How do I fix fault code PAL-GRIP1?

Check vacuum level at the gripper head — should be at least 18 inches Hg for most applications. Inspect all vacuum cups — replace any that are cracked, torn, or permanently deformed. Check vacuum pump oil level and filter — replace filter, add oil if low. For mechanical grippers, check clamp cylinder pressure and travel — verify full clamp force. Verify layer is fully formed with no gaps before pickup — gaps cause vacuum leaks between products. If product surface is textured, try foam-padded vacuum cups that conform to the surface

Palletizer Gripper / Vacuum Head — Pickup Failure

PAL-GRIP1

Palletizer layer pickup gripper or vacuum head failed to grip and lift a complete layer. Layer dropped, shifted, or was not picked at all.

high palletizer

palletizer gripper vacuum head pickup layer cup

Probable Causes (ranked)

Vacuum level insufficient — vacuum pump worn, filter clogged, or leak in the manifold
Vacuum cups worn or damaged — not forming seal on product surface
Product surface too porous or textured for vacuum pickup — air leaks through product surface
Gripper clamp fingers not closing fully — cylinder pressure low or mechanical obstruction
Layer not formed correctly — gaps between products prevent full vacuum seal

Fix Steps

1 Check vacuum level at the gripper head — should be at least 18 inches Hg for most applications
2 Inspect all vacuum cups — replace any that are cracked, torn, or permanently deformed
3 Check vacuum pump oil level and filter — replace filter, add oil if low
4 For mechanical grippers, check clamp cylinder pressure and travel — verify full clamp force
5 Verify layer is fully formed with no gaps before pickup — gaps cause vacuum leaks between products
6 If product surface is textured, try foam-padded vacuum cups that conform to the surface

Field Trick

Vacuum heads on palletizers have dozens of cups, and if even 3-4 cups are bad, the head can still pick up most of the time. But those bad cups cause intermittent drops. Run your hand over every cup with the vacuum on — you'll feel the dead ones instantly. Replace all the bad cups at once, don't chase one drop at a time.

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