What causes fault code PKG-004 (Packaging Line Servo Fault)?

Servo drive reported overcurrent — mechanical jam on axis. Encoder feedback lost — encoder cable or encoder failed. Following error exceeded — actual position too far from commanded position. Servo drive overtemperature — check cooling fan and ambient temp. Power supply to servo drive interrupted

How do I fix fault code PKG-004?

Check servo drive display for specific fault code. Clear fault and attempt reset — if jam was temporary, drive may restart. Check for mechanical binding on the faulted axis — rotate by hand if safe. Verify encoder cable connections at motor and drive. Check drive cooling fan and heatsink temperature. If following error, check mechanical coupling between motor and load. Review servo drive fault log for pattern — intermittent faults suggest loose connections

Packaging Line Servo Fault

PKG-004

Servo motor or servo drive on packaging machine has faulted. Motion control lost on one or more axes.

high packaging

packaging servo drive encoder motion control

Probable Causes (ranked)

Servo drive reported overcurrent — mechanical jam on axis
Encoder feedback lost — encoder cable or encoder failed
Following error exceeded — actual position too far from commanded position
Servo drive overtemperature — check cooling fan and ambient temp
Power supply to servo drive interrupted

Fix Steps

1 Check servo drive display for specific fault code
2 Clear fault and attempt reset — if jam was temporary, drive may restart
3 Check for mechanical binding on the faulted axis — rotate by hand if safe
4 Verify encoder cable connections at motor and drive
5 Check drive cooling fan and heatsink temperature
6 If following error, check mechanical coupling between motor and load
7 Review servo drive fault log for pattern — intermittent faults suggest loose connections

Field Trick

Most servo faults on packaging machines are mechanical — jammed product, worn bearings, or broken coupling. Clear the mechanism first before diagnosing the drive.

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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