04/12/2025
Field Service Report
Sriperumbudur
India
04/12/2025
Equipment: Demag DMR (Demag Modular Rope) Hoist
Nature of Call: Breakdown Service / Error Codes Clearing
1. Problem Reported
The customer reported a total crane breakdown. Initially, the crane stopped working due to a brake issue, but subsequent attempts to troubleshoot by the customer led to further communication errors and a complete standstill.
2. Diagnosis & Observation
Upon site arrival and inspection, the following sequence of events was identified:
* Initial Fault: The crane initially experienced a Brake Slip (Error 6). This was caused by the customer lifting a load exceeding the limit (Overload), causing the brake to slip and the system to lock out for safety.
* Blind Troubleshooting: The Pendant Display was non-functional (damaged). Because the customer could not read the error code on the screen, they attempted to troubleshoot the issue blindly.
* Secondary Faults (Induced): During the customer's manual inspection of the cables:
* The CAN-Bus cable was disturbed, resulting in a communication error.
* The Hoist-2 plug/connection to the contactor was loosened, triggering a Contactor Error (Error 7).
3. Action Taken
* Connected the IDAPSY Diagnostic Software to the crane control system to read the internal fault history.
* Identified Error 6 (Brake Slip) and Error 7 (Contactor Error).
* Physically inspected the panel and hoist connections.
* Rectification:
* Tightened and secured the loose CAN-Bus communication wires.
* Reconnected and secured the loose plug for Hoist-2.
* Performed a Service Reset using the software to clear the "Brake Slip" and "Contactor" errors.
* Calibrated the system and conducted a trial run.
4. Recommendations
* Urgent: The Pendant Display must be repaired or replaced immediately. Without a working display, operators cannot see safety warnings or load weight, leading to overload situations.
* Safety: Operators should be advised not to open panels or disturb wiring during a breakdown. All electrical troubleshooting should be handled by a qualified technician to avoid creating secondary faults (like the CAN-bus and contactor errors observed today).
5. Final Status
The crane has been restored to full working condition. All error codes have been cleared, and the hoist is operating smoothly.
