What causes fault code ASRS-LOAD1 (AS/RS Load Presence Detection — Load Overhang)?

Load shifted during retrieval — not centered on fork/platform. Wrong pallet size for the storage location — pallet oversize for the rack. Pallet damaged — broken stringer causing pallet to sag and overhang. Fork pickup point was off-center — crane X or Y position was slightly off during pickup. Overhang sensor misaligned — detecting overhang when load is actually centered

How do I fix fault code ASRS-LOAD1?

Visually inspect the load on the crane — confirm if there is actual overhang. If load is shifted, manually re-center it (follow LOTO procedure for working on crane). Check overhang sensors — clean and verify alignment. If load overhang is genuine, do not travel — return load to origin location and investigate. Check crane positioning accuracy — a position error causes off-center pickups. Verify pallet dimensions match the AS/RS system configuration — length, width, and weight

AS/RS Load Presence Detection — Load Overhang

ASRS-LOAD1

Load overhang sensor detected that a pallet or tote is not properly positioned on the crane platform or fork. Load extends beyond the safe travel envelope.

high asrs

asrs load overhang pallet safety sensor

Probable Causes (ranked)

Load shifted during retrieval — not centered on fork/platform
Wrong pallet size for the storage location — pallet oversize for the rack
Pallet damaged — broken stringer causing pallet to sag and overhang
Fork pickup point was off-center — crane X or Y position was slightly off during pickup
Overhang sensor misaligned — detecting overhang when load is actually centered

Fix Steps

1 Visually inspect the load on the crane — confirm if there is actual overhang
2 If load is shifted, manually re-center it (follow LOTO procedure for working on crane)
3 Check overhang sensors — clean and verify alignment
4 If load overhang is genuine, do not travel — return load to origin location and investigate
5 Check crane positioning accuracy — a position error causes off-center pickups
6 Verify pallet dimensions match the AS/RS system configuration — length, width, and weight

Field Trick

When load overhang faults start happening on loads that used to be fine, check if the supplier changed pallet sizes. A pallet that's 1 inch wider than spec causes intermittent overhang trips. Measure 10 random pallets from the latest delivery — you'll often find the issue is the pallet, not the crane.

Suggested Replacement Parts

Parts matched to fault category: Photoelectric Sensor

Banner QS18VP6D Photoelectric Sensor P/N: QS18VP6D Diffuse mode, 18mm barrel, 100mm range, PNP

AutomationDirect $65.00 Amazon $72.00 Grainger $85.00

IFM Efector O5D100 Photoelectric Sensor P/N: O5D100 Diffuse reflection, M18, 50-1000mm range, IO-Link

AutomationDirect $85.00 Amazon $95.00 Digikey $90.00

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

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