What causes fault code PAL-HOIST1 (Palletizer Hoist / Elevator Overload)?

Pallet load exceeds the palletizer weight rating — too many layers or heavy product. Elevator mechanical friction increased — guide rails dry or misaligned. Elevator counterweight (if equipped) cable broken or out of adjustment. Hoist motor undersized for the application — motor is at its current limit. VFD current limit parameter set too low for the application

How do I fix fault code PAL-HOIST1?

Check pallet weight against palletizer nameplate capacity. Lubricate elevator guide rails and check for binding. If counterweight system, check cable integrity and counterweight position. Monitor hoist motor current during lift — compare to motor FLA and VFD current limit. If VFD current limit is too low, increase to motor FLA x 1.1 (but do not exceed motor rating). If motor is genuinely undersized, evaluate options: reduce pallet height (fewer layers) or upgrade motor

Palletizer Hoist / Elevator Overload

PAL-HOIST1

Palletizer hoist or main elevator overload protection tripped. Load on the elevator exceeds the rated capacity or the drive cannot lift the current load.

high palletizer

palletizer hoist elevator overload weight motor capacity

Probable Causes (ranked)

Pallet load exceeds the palletizer weight rating — too many layers or heavy product
Elevator mechanical friction increased — guide rails dry or misaligned
Elevator counterweight (if equipped) cable broken or out of adjustment
Hoist motor undersized for the application — motor is at its current limit
VFD current limit parameter set too low for the application

Fix Steps

1 Check pallet weight against palletizer nameplate capacity
2 Lubricate elevator guide rails and check for binding
3 If counterweight system, check cable integrity and counterweight position
4 Monitor hoist motor current during lift — compare to motor FLA and VFD current limit
5 If VFD current limit is too low, increase to motor FLA x 1.1 (but do not exceed motor rating)
6 If motor is genuinely undersized, evaluate options: reduce pallet height (fewer layers) or upgrade motor

Field Trick

Palletizer ratings assume a specific product weight per layer. When production switches to a heavier product, nobody recalculates the pallet weight. 8 layers of 12-oz cans is a lot different than 8 layers of 20-oz bottles. Know your per-layer weight and multiply by the number of layers before assuming the palletizer can handle it.

Suggested Replacement Parts

Parts matched to fault category: Motor

Baldor/ABB 1HP TEFC Motor P/N: EM3554T 1HP, 1765RPM, 143TC frame, 230/460V, TEFC, premium efficiency

AutomationDirect $285.00 Amazon $310.00 Grainger $345.00

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

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