Overhead crane maintenance involves systematic inspection, lubrication, repair, and testing of the crane’s mechanical, structural, electrical, and safety components to ensure safe and reliable operation. Overhead crane systems include bridge, trolley, hoist, hooks, limit switches, motors, wheels, rails, and more.
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Overhead Crane Maintenance
Regular Maintenance
Prevents failures that could lead to load drops, structural failure, or accidents. Identifying wear early reduces unplanned downtime.
Overhead Hoist & Crane Specialist Lubrication, component replacement, and structural care extend the crane’s life. Regular inspections help meet regulatory / standards requirements (OSHA, ISO, etc.).
Key Maintenance Activities / Checklist
Here are the major maintenance tasks, organized by frequency and component:
1. Daily / Shift Inspections
Check hook for cracks, deformation; verify hook rotates freely.
Test control buttons, limit switches, and emergency stops.
Listen for abnormal noises during operation (motors, gears)
2. Weekly / Monthly Inspections
Inspect brakes, check brake pad wear, and adjust braking torque.
Inspect and lubricate bearings, pulleys, and transmission components.
Check all bolts, structural connections (bridge, trolley, end beams) for tightness.
Review and test electrical connections, wiring, and control circuits.
3. Semi-Annual / Biannual Maintenance
According to Weihuaglobal:
Change gearbox / transmission oil completely.
Inspect and repair brake assemblies: brake pads, surfaces, clearances.
Perform load test: static (e.g. 1.25× rated) and dynamic tests to verify strength and performance.
Check wire rope / chain condition thoroughly; replace if worn or damaged.
Repaint or perform corrosion protection on structural parts if needed.
4. Annual Inspection
Detailed structural inspection: bridge girders, end beams, welds, bolts.
Test all safety devices: limit switches, overload protection, emergency
Load testing under controlled conditions.
Detailed inspection of the steel structure for fatigue, cracks, or corrosion.
Maintenance Safety Procedures
Lockout / Tagout (LOTO): Before maintenance, isolate power, land any load, and lock out controls.
Use Barriers / Warning Signs: Set up barriers under cranes during maintenance to prevent accidents.