Overhead Crane Hoisting Mechanisms Failures and Repair: Common Component Issues and Solutions

студзень 23, 2025

Змест

Overhead cranes are essential in industrial production, and the reliability of their hoisting mechanisms is key to safety and efficiency. Understanding overhead crane hoisting mechanisms failures and repair methods helps extend equipment life and improve productivity. This article explores common failures in hoisting mechanism components, analyzes their causes, and provides practical repair solutions.

Overhead Crane Hoisting Mechanisms Failures and Repair

Brake Failures and Repair

Няўдачы	Прычыны	Рамонт
Failure to lock the brake wheel (load fall down)	The hinge of the lever is jammed	Eliminate the jamming fault and apply lubrication
	Oil on the brake wheel and friction shim	Clean off the oil dirt
	Lack of travel distance of magnet iron core	Adjust brake
	The brake wheel and friction shim have heavy abrasive wear	Replace friction shim
	Main spring loose or damage	Replace the main spring and nut
	Lock nut and lever loose	Fasten lock nut
	The hydraulic thruster impeller does not work	Check the electrical part of the thruster
The brake fails to release	Magnetic wire burns down	Замяніць
	Disconnection of wire to magnetic conductor	Connect the wire
	Shoe block on braking wheel	Clean with kerosene
	Gemel stuck	Eliminate the lock and lubricate it
	The main spring force is too large or configuration is too heavy	Adjust the main spring
	Push bar inflected, can not move the magnetic iron (hydraulic push bar break)	Straighten the mandril or change the mandril
	Improper oil application	Change oil according to working condition
	Impeller is locked	Adjust the push rod and check electrical part
	85% lower than the rated load, magnetic force is not enough	Find out the reason for voltage reduction to eliminate the trouble
The brake is overheating, the friction pads emit a burnt smell, and they are wearing out quickly	The shoe can’t fully disengage the braking wheel when breaks loose, so causes friction	Adjust clearance
	Asymmetrical distance from shoes to braking wheel	Adjust clearance for two brake
	Supporting spring damage or bending	Replace or repair the spring
	The rough surface of the brake wheel	Turning the surface of the brake according to the requirements
The brake is easy to deviate from the adjusted position, and the breaking torque is not steady	The fastening nut is loose. Screw thread damage.	Fasten nut. Replace it.
Magnetic overheat or abnormal noise	Main spring is over pressed	Adjust to proper extent
	Push bar is blocked	Eliminate the block and make lubrication
	Wrong position of iron core and mandrel	Leveling fitting surfaces

Overhead Crane Brake Failures and Repairs

Reducer Failures and Repair

Няўдачы	Прычыны	Рамонт
Periodic gear chatter phenomenon, particularly noticeable in the driven gear	Section distance error, gear side clearance beyond tolerance	Repair, re-install
Severe metal friction sound, reducer shake, shell tinkers.	Gear backlash that is too small, gear axes are not parallel, gear has sharp edges	Adjust, re-install
During gear meshing, there is an uneven knocking sound, and the housing vibrates	Teeth surface is not flat, teeth with flaws, gear contact surface is not completely clenched, but contact on one angle	Replace gear
Shell heating especially the place where the bearing installation	Bearing damage	Замяніць падшыпнік
	Bearing neck is stunk	Замяніць падшыпнік
	Gear teeth wear	Replace gear
	Lack of lubrication oil	Replace lubrication oil
Oil leakage of subdivision surfaces	Seal failure	Replace sealing parts
	Shell deformation	Check subdivision surfaces, and replace them when heavily damaged
	The subdivision surfaces are not flat	Subdivision surface levelled
	Connection bolt loose	Clear the return chute and tighten the nuts
Reducer shake on base	The anchor bolt is loose	Adjust anchor bolt
	Shaft centerlines do not align	Adjust the diagonal alignment
	Base rigidity is not enough	Reinforce base and increase rigidity
Heating of reducer	Too much oil	Adjust oil level

Overhead Crane Reducer Failures and Repairs

Wire Rope Pulley System Failures and Repair

Няўдачы	Прычыны	Рамонт
The wire rope wears out quickly or frequently gets damaged	The diameter of the pulley and drum is too small	Replace the wire rope with one of better flexibility, and increase the diameter of the pulley and drum
	The wire rope dimensions do not match the groove of the drum; it is too small.	Replace the wire rope with one of equal lifting capacity but smaller diameter, or replace the pulley and drum
	Dirty and lacking oil	Clean and lubricate
	Incorrect installation of the lifting baffle, causing frequent rope abrasion	Adjust
	The pulley groove and wheel edge are not smooth and have defects	Grind the defective areas manually
Some pulleys cannotrotate	Bearing lacks oil, dirt and corrosion in bearing	Lubricate, clean

Overhead Crane Wire Rope Pulley System Failures and Repairs

Forged Lifting Hook Failures and Repair

Няўдачы	Causes and Result	Рамонт
Fatigue cracks on the hook surface	Overload, prolonged use, or material defects	Replace it if any cracks are found
Wear of the opening and dangerous sections	Lessen the rigidity, or it is easy to cause hook break and accident	Replace hook when the abrasion over 5% of the dangerous section
Permanent deformation occurs at the open areas and bend points	Caused by long time overload and fatigue	Replace immediately

Overhead Crane Forged Lifting Hook Failures and Repairs

Laminated Lifting Hook Failures and Repair

Няўдачы	Causes and Result	Рамонт
Distortion of hook	Long time overload, and it is easy to cause hook break	Замяніць
Surface has fatigue crack	Overtime, overload and hook damage	Замяніць
The abrasion of pin shaft is more than 3%-5% of nominal diameter	Hook fall off	Замяніць
Eye has crack or burr	Eye breakage	Замяніць
The abrasion of eye’s lining reaches 5% of original thickness	Bad forced condition	Замяніць

Overhead Crane Laminated Lifting Hook Failures and Repair

Wire Rope Failures and Repair

Няўдачы	Causes and Result	Рамонт
Breakage, knotting, abrasion	Cause of breakage of rope	Stop using it when wire rope break and knot, replace according to standard when thread break, and replace the wire rope according to standard when it has abrasion
Uneven wear of pulley rope grooves	Material asymmetry, bad installation and bad connection of rope and wheel	Replace it when abrasion of groove’s wall reaches 1/5 of previous thickness, and gauge ware reaches 1/2 of wire rope diameter
Pulley can not rotate	Shaft damage or bearing damage	Replace the shaft and bearing and then lubricate and maintain them
Pulley incline or loose	Keeper of shaft loose or wire rope hop out of groove	Fasten the keeper and repair the wire rope’s hopping
Crack of pulley or break of wheel flange	Pulley damage	Замяніць

Overhead Crane Wire Rope Failures and Repair

Drum Failures and Repair

Няўдачы	Causes and Result	Рамонт
Drum has fatigue crack	Break of drum	Replace drum
Abrasion of drum’s shaft and key	Break of shaft and cause the load fall off	Stop using and inspect the shaft key immediately
Groove abrasion and rope hopping. The abrasion reaches 15%-20% of the original thickness	The rigidity of drum becomes weaker and easy to break. And wire rope is twisted	Replace the drum

Overhead Crane Drum Failures and Repair

Gear Failures and Repair

Няўдачы	Causes and Result	Рамонт
Gear teeth break	Abnormal noise during operation, if continued to use, will damage the transmission mechanism	Replace the new gear
Abrasion of gear reaches 15%-20% of the original teeth thickness	Impact and vibration occured during working and then damage the transmission mechanism	Replace the new gear
Gear crack, gear key groove damaged by rolling of key	Vibration and noise caused by overtime use and improper installation, which make load fall off	For lifting mechanism, replace them, for traveling mechanism, repair or renew the key
The spalling area of the tooth surface reaches 30% of the total working surface, and the spalling depth reaches 10% of the tooth thickness, carburized layer abrasion reaches 80% of the tooth thickness	Overtime use	Replacement: For reducers with a circumferential speed > 8 m/s, the high-speed gears should be replaced in pairs when worn

Overhead Crane Gear Failures and Repair

Shaft Failures and Repair

Няўдачы	Causes and Result	Рамонт
Crack	Poor material quality and improper heat treatment lead to shaft damage	Замяніць
The shaft bend exceeds 0.5mm/m	Cause damage to shaft neck and influence the transmission and cause vibration	Change or rectify
Damage of key groove	Unable to transmit torsion	For the lifting mechanism, replace them, for the traveling mechanism, repair them

Overhead Crane Shaft Failures and Repair

Crane Wheel Failures and Repair

Няўдачы	Causes and Result	Рамонт
Wheel tread and wheel flange have fatigue crack	Damage of wheel	Замяніць
Uneven abrasion of drive wheel tread	Leads to rail gnawing and tilt of crane	Replace in pairs
Abrasion of tread reaches 15% of wheel flange thickness	Vibration when traveling, damage to wheel	Замяніць
Wheel flange abrasion reaches 50% of the original thickness	Caused by the crane tilt and rail gnawing, increases the risk of derailment	Замяніць

Overhead Crane Wheel Failures and Repair

Brake Parts Failures and Repair

Няўдачы	Causes and Result	Рамонт
Fatigue crack on lever	Brake fails to work	Замяніць
Fatigue crack on spring	Brake fails to work	Замяніць
The abrasion of minor shaft and mandrel reaches 3%-5% of the nominal diameter	Fails to brake	Замяніць
The abrasion of brake wheel reaches 40%～50% of the original wheel flange thickness	Load fall off or crane slide	Замяніць
Brake shoe friction shim wear 2mm, or to 50% of original thickness	Bad break	Replace friction shim

Overhead Crane Brake Parts Failures and Repair

Coupling Failures and Repair

Няўдачы	Causes and Result	Рамонт
Crack on coupling	Damage of coupling	Замяніць
Loose in connection bolts	Impact and vibration during braking/starting will cause bolt reakage and falling of load	Tightened
The gear teeth of the gear coupling are worn or broken	Lack of lubrication, heavy workload, start oppositely will lead to damage to the coupling	For the lifting mechanism, when the abrasion of gear teeth reaches 15% of the original thickness, replace it, and for the traveling mechanism, when the abrasion of gear teeth reaches 30% of the original thickness, replace it
Press or deformation of the key groove	Cannot transmit the moment of torsion key falls off	For lifting mechanism, replace them, for other mechanisms, repair them
Abrasion in shaft, pin and rubber ring etc	Strong impact and vibration occur during starting and braking	Replace worn parts

Overhead Crane Coupling Failures and Repair

Rolling Bearing Failures and Repair

Няўдачы	Causes and Result	Рамонт
Temperature is too high	Lubricating oil dirt	Clean dirt, replace bearing
Temperature is too high	Completely lack of oil	Add lubrication oil as required
Abnormal noise	Too much oil	Check the quantity of labricantion
Abnormal noise	Dirty bearing	Clean dirty
Metal grinding noise	Lack of oil	Add oil
Topping or impact sound	Damage of coupling support, rolling body	Замяніць падшыпнік

Overhead Crane Rolling Bearing Failures and Repair

Sliding Bearing Failures and Repair

Няўдачы	Causes and Result	Рамонт
Overheating	Incline of bearing and press to tight	Eliminate misalignment and ensure proper fastening
	Improper clearance	Adjust clearance
	Lack of lubrication	Add lubrication
	The lubricant quality is substandard	Replace with a qualified lubricant

Overhead Crane Sliding Bearing Failures and Repair

Спампаваць PDF

Overhead Crane Hoisting Mechanism Failure and Repair Спампаваць PDF

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