Top 10 Most Common Overhead Crane Faults — And How to Prevent Them

Keeping overhead cranes running safely and reliably is essential for productivity, compliance and workplace safety. Across every industry we service — manufacturing, logistics, defence, steel, mining and more — the same faults appear again and again.

Most of these issues are avoidable with correct servicing, operator awareness and early intervention.

Here are the top 10 most common overhead crane faults our technicians see, what causes them, and how you can prevent costly downtime.

1. Hoist Wire Rope Wear or Damage

The fault:
Flattening, broken wires, birdcaging, kinks or crushing.

Why it happens:
High duty cycles, poor reeving, lack of lubrication, overloads or side pulling.

Prevention:

  • Regular inspections (AS2550)

  • Correct lubrication

  • Immediate replacement when wear limits are reached

  • Operator training to avoid side pulls

2. Worn or Faulty Brakes

The fault:
Hoist or travel brakes slipping, grabbing, or failing to hold load.

Why it happens:
Normal wear, dust contamination, overheating, poor adjustment.

Prevention:

  • Brake wear measurements at every service

  • Proper torque adjustment

  • Timely pad/lining replacement

3. Limit Switch Failures

The fault:
Upper/lower hoist limits not functioning, travel limits overrun.

Why it happens:
Mechanical impact damage, lack of testing, wiring issues, operator misuse.

Prevention:

  • Test limits every service

  • Replace damaged cams, actuators or wiring

  • Never bypass or “block out” limits

4. Load Cell or Overload Protection Issues

The fault:
Incorrect readings, nuisance trips, or operators bypassing overload protection.

Why it happens:
Wiring faults, calibration drift, outdated equipment, or intentional bypassing.

Prevention:

  • Routine calibration

  • Replacing old or faulty load monitoring devices

  • Strong operator training on why bypassing is dangerous

5. Wheel Wear & Alignment Problems

The fault:
Wheel flanges wearing, wheels chipping, crane drifting or “crabbing.”

Why it happens:
Poor runway alignment, uneven loads, worn guide rollers or excessive skew.

Prevention:

  • Annual runway survey

  • Correct wheel alignment

  • Monitoring travel resistances

6. Electrical Contact Issues

The fault:
Intermittent operation, jerky travel, tripping breakers, or dead radio signals.

Why it happens:
Loose terminals, worn contactors, dust/grease contamination, vibration.

Prevention:

  • Tightening electrical connections

  • Cleaning and replacing contactors

  • Inspecting pendant and radio systems

7. Travel Drive Problems

The fault:
Noisy travel, slow acceleration, motor overheating, or uneven travel.

Why it happens:
Worn gearboxes, misaligned drives, faulty VFDs, or lack of lubrication.

Prevention:

  • Gearbox oil checks

  • Drive alignment during servicing

  • Monitoring motor temperature and load

8. Hoist Drum & Sheave Wear

The fault:
Rope not winding correctly, rope jumping grooves, or grooving wear.

Why it happens:
Excessive rope wear, misalignment, lack of lubrication, or worn bearings.

Prevention:

  • Inspect drum grooves

  • Replace worn sheaves

  • Correct reeving of wire rope

9. Pendant or Remote-Control Failures

The fault:
Buttons sticking, lost signal, cracked housings, intermittent commands.

Why it happens:
Drops, dust, water ingress, old wiring, or outdated controllers.

Prevention:

  • Regular pendant inspection

  • Upgrading to radio remotes

  • Replacing broken housings or cables

10. Overheating Motors

The fault:
Motors running hot, thermal trips, loss of lifting power.

Why it happens:
High-duty operation, brake drag, poor ventilation, or worn bearings.

Prevention:

  • Brake adjustment

  • Inspection of cooling fans

  • Replacing worn bearings

  • Assessing duty cycle suitability

Preventing Crane Faults Starts With Routine Servicing

Most faults above are avoidable with correct maintenance, operator awareness and routine inspections in line with AS2550.1. Early detection prevents:
✔ costly downtime
✔ emergency repairs
✔ unsafe conditions
✔ equipment damage
✔ compliance issues

West Crane Services provides full-service inspections, maintenance, repairs and upgrades across all makes and models — backed by the largest service and installation team in Victoria.

Need Help Reducing Crane Faults?

Talk to our service team about preventative maintenance or book your next inspection.

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