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

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.

Brake Failures and Repair

Reducer Failures and Repair

Wire Rope Pulley System Failures and Repair

Forged Lifting Hook Failures and Repair

Laminated Lifting Hook Failures and Repair

Wire Rope Failures and Repair

Drum Failures and Repair

Gear Failures and Repair

Shaft Failures and Repair

Crane Wheel Failures and Repair

1. Failures: Wheel tread and wheel flange have fatigue crack

• Causes and Result: Damage of wheel
• Repair: Replace

2. Failures: Uneven abrasion of drive wheel tread

• Causes and Result: Leads to rail gnawing and tilt of crane
• Repair: Replace in pairs

3. Failures: Abrasion of tread reaches 15% of wheel flange thickness

• Causes and Result: Vibration when traveling, damage to wheel
• Repair: Replace

4. Failures: Wheel flange abrasion reaches 50% of the original thickness

• Causes and Result: Caused by the crane tilt and rail gnawing, increases the risk of derailment
• Repair: Replace

Brake Parts Failures and Repair

1. Failures: Fatigue crack on lever

• Causes and Result: Brake fails to work
• Repair: Replace

2. Failures: Fatigue crack on spring

• Causes and Result: Brake fails to work
• Repair: Replace

3. Failures: The abrasion of minor shaft and mandrel reaches 3%-5% of the nominal diameter

• Causes and Result: Fails to brake
• Repair: Replace

4. Failures: The abrasion of brake wheel reaches 40% – 50% of the original wheel flange thickness

• Causes and Result: Load fall off or crane slide
• Repair: Replace

5. Failures: Brake shoe friction shim wear 2mm, or to 50% of original thickness

• Causes and Result: Bad break
• Repair: Replace friction shim

Coupling Failures and Repair

1. Failures: Crack on coupling

• Causes and Result: Damage of coupling
• Repair: Replace

2. Failures: Loose in connection bolts

• Causes and Result: Impact and vibration during braking/starting will cause bolt leakage and falling of load
• Repair: Tightened

3. Failures: The gear teeth of the gear coupling are worn or broken

• Causes and Result: Lack of lubrication, heavy workload, start oppositely will lead to damage to the coupling
• Repair: 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

4. Failures: Press or deformation of the key groove

• Causes and Result: Cannot transmit the moment of torsion key falls off
• Repair: For lifting mechanism, replace them, for other mechanisms, repair them

5. Failures: Abrasion in shaft, pin and rubber ring etc

• Causes and Result: Strong impact and vibration occur during starting and braking
• Repair: Replace worn parts

Rolling Bearing Failures and Repair

1. Failures: Temperature is too high

• Causes and Result: Lubricating oil dirt
• Repair: Clean dirt, replace bearing

• Causes and Result: Completely lack of oil
• Repair: Add lubrication oil as required

2. Failures: Abnormal noise

• Causes and Result: Too much oil
• Repair: Check the quantity of lubrication

• Causes and Result: Dirty bearing
• Repair: Clean dirty

3. Failures: Metal grinding noise

• Causes and Result: Lack of oil
• Repair: Add oil

4. Failures: Topping or impact sound

• Causes and Result: Damage of coupling support, rolling body
• Repair: Replace bearing

Sliding Bearing Failures and Repair

Failures: Overheating

• Causes and Result: Incline of bearing and press too tight
• Repair: Eliminate misalignment and ensure proper fastening

• Causes and Result: Improper clearance
• Repair: Adjust clearance

• Causes and Result: Lack of lubrication
• Repair: Add lubrication

• Causes and Result: The lubricant quality is substandard
• Repair: Replace with a qualified lubricant

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Overhead Crane Hoisting Mechanism Failure and Repair

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