Electric hoists are important equipment that facilitate business processes in many areas from industrial production to logistics. However, due to intensive use or lack of regular maintenance, electric crane failures may occur from time to time. These failures can adversely affect the operational efficiency of businesses and cause production stoppages.
When the right steps are taken in electric crane failure solution, the problems that occur can be resolved quickly. Let’s take a detailed look at the most common crane malfunctions and the things to be considered in crane repair processes.
What are Electric Crane Faults?
Although electric cranes provide high performance and durability, some malfunctions may be encountered over time. The causes of such failures are usually caused by factors such as usage errors, inadequate maintenance, overloading of the equipment or wear due to environmental conditions. Failure to regularly check the moving parts, especially in cranes working at a busy pace, can lead to larger failures in the future.
For this reason, proper training of operators, regular maintenance of the equipment and use in accordance with the manufacturer’s instructions are among the things to be considered when using cranes. It is important to master the technical specifications of the equipment in order to provide effective solutions in case of failure. Common malfunctions and solutions for electric hoists can be listed as follows:
Failure 1: Crane not working
If the electric hoist does not operate completely, this may be due to power supply problems or faults in the control system. Check the fuse and make sure that the electrical connections are secure. It is also important to check that the emergency stop button is activated.
Any interruptions or loose connections in the control circuits must be rectified immediately. It is also recommended to inspect the electronic circuits and components inside the control cabinet at regular intervals.
- Possible Causes
Interruption in power supply connection
Blown fuse or damage to the power cord
Circuit interruption or malfunction in the control unit
- Solution Suggestions:
Check the electrical connections to make sure they are secure.
Replace the fuse and check the integrity of the cables.
Have the technical team inspect the control panel and control circuits.
Failure 2: Crane does not move (Forward, Backward, Right, Left)
If the crane does not move, which is among the electric hoist malfunctions, it is possible in cases where the circuits in the control controller are faulty or the motor is damaged. Make sure that the cables are uninterrupted and the control unit is working properly.
The solution to this problem usually requires a detailed examination of the motor or control system. Software problems in the drive unit can also cause movement problems. Ensure that the torque capacity of the motor is not exceeded and that the electrical flow is correct.
- Possible Causes:
Circuit malfunction in the control controller
Mechanical or electrical damage to the motor
Software problems in the drive unit
Interruptions or breaks in cables
- Solution Suggestions:
Inspect the control and connection cables.
Have the mechanical and electrical systems of the motor checked.
Get technical support by updating the software of the drive unit.
Diagnose the problem by testing the electrical flow and torque capacity.
Failure 3: Suspended Load
Suspension of the load on the crane may be caused by the wire rope in the lifting mechanism being jammed or the brake system not being activated. Check that the rope is properly wound on the rope winding drum and inspect the brake system. Since such a situation may cause safety risks, expert intervention is essential for a quick solution.
In electric hoists, such problems can also be caused by overloading or exceeding the lifting capacity. It is important that operators start using the crane by checking the load weights.
- Possible Causes:
Incorrect winding or jamming of the wire rope
Failure or non-engagement of the brake system
Overloading or exceeding the lifting capacity
- Solution Suggestions:
Make sure that the wire rope is properly wound and that there is no jamming.
Brake system should be mechanically and electronically examined in detail.
Operators should start using the crane by checking the load weights and capacity limits should be complied with.
Failure 4: Lifting and Lowering Function Not Working
Failure of the lifting and lowering mechanism to operate is usually caused by a low oil level in the hydraulic systems or engine failure. It is important to check the hydraulic oil level and ensure that the motor is operated without overloading.
Regular maintenance is critical for this type of malfunction. In addition, lifting chains or ropes should be inspected for tangling or loosening. It is recommended that users inspect mechanical parts before each operation of the hoist system.
- Possible Causes:
Low hydraulic oil level
Damage to the motor due to overload
Entanglement or loosening of lifting chains or ropes
- Solution Suggestions:
Check the hydraulic oil level regularly and top up when necessary.
Make sure that the engine is operated in accordance with its capacity and have technical maintenance performed.
Check that the chain and ropes are in good condition and correct any tangling or loosening.
Failure 5: Braking Problems (Excessive Slipping Distance)
If the crane cannot stop travelling when braking, it is possible that the brake pads are worn or the brake settings are out of adjustment. The brake system must be checked immediately and the brake pads must be replaced if necessary. Otherwise, serious accidents may occur, jeopardising work safety.
On the other hand, the brake system should be checked for air accumulation or lack of hydraulic fluid. Such problems usually occur due to intensive use of the crane system. If regular maintenance is not carried out, it can lead to more serious mechanical failures and operational disruptions over time.
- Possible Causes:
Wear or exhaustion of the brake pads
Disturbance of brake settings
Air build-up or lack of hydraulic fluid in the brake system
- Solution Suggestions:
Check the brake pads regularly and replace them if worn.
Calibrate and optimise the brake settings.
Check and top up the hydraulic fluid and ventilate the system if there is air in the brake system.
Failure 6: Engine Overheating
Overheating of the crane motor usually occurs due to prolonged use or carrying loads over the capacity of the motor. In this case, which is frequently among the electric hoist malfunctions, the cooling system of the motor should be checked and the maximum capacity specified during use should not be exceeded. If the heating problem recurs continuously, the engine may need to be renewed or repaired.
In addition, it should be ensured that the ventilation channels on the motor are not blocked. Since overheating can cause burns in the electrical windings of the motor or mechanical failures, the problem must be taken seriously. Without regular maintenance, this can seriously reduce the performance of the crane system and increase operating costs.
- Possible Causes:
Carrying load over the capacity of the engine
Cooling system malfunction or blockage of ventilation ducts
Engine fatigue due to prolonged intensive use
- Solution Suggestions:
Regularly check and clean the cooling system and the ventilation ducts.
Ensure that the engine is operated within the specified capacity limits.
If you notice that the motor is operating under overload, optimise the operation times and seek technical support if necessary.
Failure 7: Gearbox Oil Leakage
If oil is leaking from the gear unit, this may indicate seal failures or wear of gear unit parts. It is important to check the oil level regularly and have the gearbox serviced when necessary. If oil leakage is not eliminated, mechanical parts may be damaged and crane performance may be seriously affected.
In addition, it is necessary to check whether the oil used has the correct viscosity. If the gearbox shows symptoms such as jamming or overheating, professional technical service support should be obtained. Oil leakage problem may cause serious damage to the gears in the long term and may cause operations to stop.
- Possible Causes:
Damage to seals or sealing elements
Wear or deformation of gearbox parts
Use of oil with the wrong viscosity
- Solution Suggestions:
Regularly check the gaskets and elements ensuring oil tightness, replace them if necessary.
Inspect the internal mechanical parts of the gearbox and replace if there is wear or deformation.
Optimise the system by using oil with the correct viscosity recommended by the manufacturer.
Failure 8: Wire Rope Wear
Wire rope wear is a common problem with frequently used cranes. This may be caused by incorrect winding of the rope or continuous overload operation. In order to prevent this situation, which is frequently seen among electric hoist malfunctions, it is necessary to check the rope regularly and replace it if necessary to prevent possible accidents. Symptoms such as broken wires, deformations or rusting on the rope must be taken into consideration.
Using a corroded rope can lead to falling loads and serious occupational safety problems. It is also essential that the wire rope is used in accordance with the manufacturer’s specified carrying capacity. Ensuring that the rope is properly wound during use is one of the effective ways to extend its life.
- Possible Causes:
Use of wire rope under excessive load
Incorrect winding or misalignment of the rope
Using the rope in unsuitable environmental conditions (corrosion and humidity)
- Solution Suggestions:
Check the carrying capacity of the wire rope and avoid overloading.
Make sure that the wire rope is properly wound and correctly aligned on the pulleys.
Check the rope regularly and replace it immediately if there are signs of wear or corrosion.
Electric hoists are critical equipment that increase the efficiency of businesses and streamline work processes. However, failures may occur from time to time as a result of intensive use, inadequate maintenance or incorrect applications. Effective elimination of these malfunctions is extremely important to ensure the long-lasting use of cranes and to protect occupational safety. The solution of each malfunction is possible by correctly identifying the source of the problem and performing appropriate maintenance operations.
Offering engineering-oriented solutions in the crane industry, Arnikon Crane is a reliable business partner in the lifting and transport processes of enterprises with its long years of experience and innovative approach. You can get expert support by contacting Arnikon Crane to ensure the smooth operation of your electric crane systems and prevent possible malfunctions!
