Common Overhead Crane Issues
Common Overhead Crane Issues
Overhead cranes are complex machines that integrate several systems to lift and move heavy equipment. Ensuring these systems operate correctly requires ongoing monitoring and regular maintenance. Failure to address common crane issues can lead to costly downtime, safety hazards, and reduced efficiency.
In this blog, we’ll discuss the most common overhead crane problems, their impact on operations, and why partnering with Atlantic Crane & Material Handling is the best way to ensure your lifting equipment remains reliable and safe.
Common Overhead Crane Issues
1. Electrical Component Failures
Overhead cranes rely on intricate electrical systems that include wiring, sensors, switches, relays, fuses, and contacts. These components are subjected to constant strain from lifting heavy loads and operator input.
Common electrical failures include:
Blown fuses or faulty radio controls
Corrosion or loose connections
Loss of wire insulation
Malfunctioning switches
Solution: Regular inspections can help detect and repair damaged electrical components before they cause operational failure.
2. Crane Alignment and Skew
Misalignment of an overhead crane can result in excessive stress on runway beams, rail systems, and supporting structures, leading to premature wear and system failure.
Signs of misalignment:
Loud scraping sounds
Cracked or broken wheel flanges
Increased power consumption for movement
Uneven rail wear
Premature motor and brake wear
According to the Crane Manufacturers Association of America (CMAA), cranes must adhere to strict alignment tolerances:
Crane Span Tolerances: ±3/16” for spans under 50 feet, ±1/4” for spans 51-100 feet, and ±3/8” for spans greater than 100 feet.
Rail-to-Rail Tolerances: Same as above.
Straightness & Elevation Tolerance: ±3/8”.
Solution: Regular alignment checks prevent excess stress on structural components and ensure safe, efficient operations.
3. End Truck Wear
End trucks enable the crane bridge and hoist to move along the runway. Frequent use leads to wheel wear, which can impact performance.
Common issues include:
Premature wheel wear
Improper tracking causing damage to rails
Skewed movement increasing stress on components
Solution: Matching wheel hardness to rail hardness and performing regular maintenance can extend end truck lifespan and maintain operational efficiency.
4. Wire Rope Damage
Wire ropes endure significant stress and can deteriorate due to environmental exposure, shock loads, and improper handling.
Common wire rope problems:
Corrosion at connection points
Jumping the reeving system
Worn or broken strands
Reduction below nominal size
Solution: Daily inspections help identify damage early, reducing the risk of failure and improving safety.
5. Overhead Crane Hooks and Below-the-Hook Devices
Hooks and lifting devices experience wear and tear, which can lead to dropped loads and accidents if not monitored properly.
Signs of hook failure:
Bending or stretching
Cracking under heavy loads
Visible deformities
Solution: Daily pre-shift inspections help detect damage before an accident occurs.
Overhead cranes are essential to many industries, but their complex systems require vigilant monitoring and maintenance. By understanding common issues—like electrical failures, alignment problems, end truck wear, wire rope damage, and hook degradation—you can take proactive steps to improve safety and efficiency.
Let us help you with your overhead crane requirements
Hercules Crane & Lifting Supplies has crane divisions across the country and Atlantic Crane & Material Handling is a division of the Hercules Group of Companies.
The Advantages of Partnering with Atlantic Crane
Routine maintenance and inspections are critical to keeping your overhead crane in peak condition. Atlantic Crane & Material Handling, a division of the Hercules Group of Companies, offers expert service, high-quality parts, and ongoing support to help you maximize crane performance and safety.
Why choose Atlantic Crane?
Expert Inspections & Preventive Maintenance: Our team conducts thorough assessments to catch issues early, reducing costly downtime.
High-Quality Parts & Repairs: We supply top-grade replacement components to ensure optimal crane operation.
Alignment & Calibration Services: Our specialists help maintain proper crane alignment, preventing excessive wear and tear.
Customized Maintenance Plans: We tailor service schedules to your facility’s needs, ensuring long-term reliability.
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The Hercules Group of Companies encompasses a wide portfolio of products and services across multiple, diverse companies.
