What are the daily fault handling procedures for overhead crane maintenance electricians?
4 Answers
There are many small details to pay attention to in the daily fault handling for overhead crane maintenance electricians. Below is an introduction to the daily fault handling procedures for overhead crane maintenance electricians: 1. Brake failure or inability to stop: inspect the electrical components; replace the brake lining; replace the fatigued main spring and adjust the brake according to technical requirements. 2. Brake not releasing: remove obstructions; adjust the main spring to meet standards; adjust or replace the brake screw; replace the coil. 3. Hook assembly falling: immediately repair the upper limit switch; strictly prohibit overloading; replace the rope. 4. Brake lining emitting a burnt smell, smoking, or wearing out quickly: adjust the brake to ensure even clearance and that the lining can separate from the brake wheel during operation; replace the auxiliary spring; repair the working surface of the brake wheel.
The most common issue we encounter when repairing overhead cranes is the motor failing to start. In such cases, we need to troubleshoot step by step. First, check if the operation switch is stuck—sometimes buttons get jammed by dust and become unresponsive. Then, test whether the power supply voltage is normal; if the voltage is unstable, inspect the main contactor for any signs of burning. Lack of lubrication in the motor bearings can also cause abnormal noise and jamming—I've encountered this several times, and adding some grease usually solves the problem. Malfunctioning limit switches are another headache, as misaligned limit blocks on the track can cause the crane to overshoot. After each repair, it's also a good practice to clean out metal shavings from the electrical control box—those tiny particles can cause serious issues if they get into the contactors. Safety is particularly crucial; locking out and tagging out the power is mandatory. Just last week, a colleague got their hand burned by an electric spark while working on a live circuit.
I mainly categorize overhead crane troubleshooting into three types. For electrical issues, such as contactor contacts sticking together, which is common in old equipment, I use sandpaper to polish the contacts or simply replace them with new parts. If the remote control signal fails, changing the batteries might fix it, but if the receiver module is faulty, I have to open the control box for inspection. Mechanical faults, like wire rope derailment, require adjusting the pulley position. Worn brake pads can cause the hook to slip, so when replacing them, it's essential to adjust the braking clearance properly. Hydraulic pusher oil leaks are more troublesome, but replacing the seal ring usually solves the problem. Regular maintenance is crucial. Every weekend, I routinely check all wiring connections to prevent oxidation and looseness. I remember last time the crane deviated from the track, and it took me two hours to adjust the track level. With enough experience, you can spot the problem at a glance—experience is more useful than the manual.
When dealing with overhead crane faults, I prefer troubleshooting from simple to complex. First, check if the fuse is blown—it saves the most time. Then see if the contactor is engaged; a burnt coil will have a charred smell. If the trolley won't move, inspect the gearbox first—broken gears make clicking noises. Worn collector carbon brushes can cause power interruptions, which is easily overlooked. For cranes with sliding line power supply, pay special attention to poor contact at the sliders. I always test-run the equipment three times before handing it over—after all, aerial equipment must be absolutely safe. Last month, I fixed a main hook that wouldn't lift—turned out to be poor contact at the auxiliary contacts of the lifting contactor.
