It is starting to make sense now. I thought it was odd to have the direction buttons latching which was the impression I got at first. So there is one contactor that is the main ON / OFF control that should latch on. I think the fault is in this part of the controls.
So we are back to my first theory about the stop button or the maintainer contact. Again guessing I guess that when the ON button is pressed only one of all the contactors in the system is actuated. This will be the one that should latch on. The fault could also be in the cable between the main controls and the pendant. (This cable will have to survive a lot of flexing.)

Les.

 

It is starting to make sense now. I thought it was odd to have the direction buttons latching which was the impression I got at first. So there is one contactor that is the main ON / OFF control that should latch on. I think the fault is in this part of the controls.
So we are back to my first theory about the stop button or the maintainer contact. Again guessing I guess that when the ON button is pressed only one of all the contactors in the system is actuated. This will be the one that should latch on. The fault could also be in the cable between the main controls and the pendant. (This cable will have to survive a lot of flexing.)

Les.

I understand what you are saying. What baffles me is when I install the brand new one it will not do anything. I feel like it has been wired to bypass something in the overload

 

I agree with @LesJones. I think you should be looking at your control circuit. You already know that the motors are working. If the OFF switch is faulty it could cause this kind of symptom. I like your cable tie and nut solution. That's ingenuity!

 

Lol this crane is our life line haha. Had to make it work. Ill do some testing on the stop wiring but it still doesn't explain the 2 new relays stop the crane from working no matter what

 

Ok so there is a place on the relay that has nc on it. One side has 2 wires the other side doesn't have any connection

 

 

The installed old one has another wire attached to the pre-wired side. Is that wire bypassingsomething on the old one and needs to be on the otherside of new one?

 

 

I know this is very simplistic, but this is what should be happening on your system. The ON button switches the relay on, the relay keeps itself on until the OFF button allows it to drop out. I know your system is much more complex but this is all I can offer right now.

 

@Kevin79 please be careful with what you do on your hoist. You have high voltages and low control voltages if you mix them up you could hurt yourself or damage the system. Achtung!

 

Normally Open contacts on a relay that is NOT energized means that no power can go thru those contacts until the relay is energized. Normally Closed contacts on a relay that is NOT energized means that power will go thru those contacts and will stop when the relay is energized. On diagrams and circuit schematics relay contacts are drawn(usually) in their NON energized positions.

 

I'm always cautious lol. I even test for power with the breaker off. Thank you still. My issue with trying to fix this myself is there isn't anyone close by that actually works on these things and local electricians are near impossible to get. Im fairly knowledgeable with this place and wired my new office and passed inspection

 

What type of O/L's are the old Westinghouse contactors using, the old style used replicable element style, rather than the latest electronic versions.
Being thermal style, they had a habit of going open circuit after years of use.

 

I posted a picture of the tag on the westing house.