Mechanical and electrical failures never happen at the convenience of the business owner. That makes it very important for crane and hoist owners and supervisors to recognize and deal with potential problems before they happen. At Protek Crane Solutions, we break this process into Common Malfunctions, Preventative Maintenance, and Basic Troubleshooting Tips. 

Common Malfunctions

• Brake Failures – These malfunctions include abnormal brake noise, overheating during operation, reduced torque, and sudden failure while lifting or lowering workloads. 

The causes are usually prolonged use over the recommended time, improper adjustment by someone other than a trained maintenance technician, or wear of the brake pads and the bolts holding the pads in place. 

Protek recommends stopping operations immediately, inspecting the brake pads for contamination and wear, and replacing the hydraulic oil. 

• Load Brake Failures – Examples include dragging, locked-up, and slipping brakes. These result in erratic operations, which means refusing to lift or drop workloads during operation.

The causes are often corroded internal parts, damaged load gears, scored brake friction surfaces, and dirt that has worked its way inside the housing. 

Solutions recommended by Protek include inspecting and cleaning brake parts. If it has slipped, adjust and re-install the load chain.

• Electrical System Failures—Examples include the crane and hoist not responding, sluggish or stuttering movement, movement in the wrong direction, and motor overheating.

The causes are often corroded or damaged contacts, faulty wiring, and improper installation.

Solutions recommended by Protek include checking for clean contacts, ensuring an uninterrupted power supply, and testing voltage.

Preventative Maintenance – Daily and Weekly Inspection Checks

• Daily checks: At the start of each shift, the operator needs to inspect the control pendant, chain, trolley (if there is one), bridge, runway, and any visible parts and examine power cords for fraying. 

• Weekly checks: A supervisor or inspector who knows the machine needs to look for signs of damage to the crane or hoist structure, cables, chains, and hooks. It is also a good opportunity to ensure the crane or hoist is adequately lubricated.

Basic Troubleshooting Steps

• If a problem occurs, use visual inspections to check for noticeable signs of damage. Then, an operational test should be performed unless there is concern that it might cause further damage.

• Next, use the operating manual to identify specific steps to reset the machine and eliminate the problem.

• Call Protek Crane Solutions. If the malfunction continues or the machine locks up, call our Maintenance Team immediately. Although it may be simple to replace some parts, doing so could void your Manufacturer's Warranty.

For additional information on troubleshooting and malfunctions specific to your cranes or hoists, call Protek Crane Solutions at (855) 776-8354. You can follow us on Facebook and X for our recent product updates.