Electric Chain Hoists
Hoists
There are a number of problems that can occur with your electric chain hoist. Most of them are user-related issues but some are manufacturer-related. Keep in mind, for every problem, there is a solution and Hoists.com is here to help.
When your equipment stops working or doesn’t work as expected, it can hinder production and become a potential safety hazard. At Hoists.com, we want to help you avoid these situations if at all possible and help you resolve them quickly if unavoidable. Let’s take a deep dive into the two main sources of these issues: user error and manufacturer issues.
Although manufacturers can make mistakes, the majority of electric hoist issues we see are user related. The best way to avoid user-related issues with your hoist is to become a certified hoist operator and by reading the user manual for the specific hoist you’re using. With that said, let’s look at some of the most common user-related hoist issues and their solutions.
Many buyers fail to check the electrical requirements before purchasing, resulting in a hoist that doesn’t match their available power supply. Common mismatches include 230V vs. 460V, or single-phase vs. three-phase configurations.
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Some users confuse “feet of lift” with “total reach” and end up with a hoist that either cannot lift high enough or has too much unused cable. This misunderstanding can result in operational inefficiency or even unsafe conditions if operators try to compensate improperly.
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Failing to measure the flange width and beam size can result in purchasing a trolley that’s either too large or too small. This improper fit can cause instability and uneven load distribution.
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Not all hoisting applications require the same level of speed control. A single-speed hoist used for precise positioning can lead to “plugging” (jogging the motor on and off rapidly) that may wear out components or damage the hoist prematurely.
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Limit switches prevent the hoist from over-traveling, commonly referred to as “two-blocking,” which can severely damage or destroy the hoist.
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Untrained or undertrained operators may overload a hoist, attempt side picks, or misuse the equipment, leading to unsafe conditions and potential damage.
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Using the pendant control to drag loads (side-pulling) can yank the cord out of the hoist or damage the push button station. It also risks misalignment and hoist damage.
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Operators sometimes use a hoist in place of a forklift or other machinery, attempting to pull loads from the side. This not only strains the hoist components but also poses significant safety risks.
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“Plugging” is when the hoist motor is repeatedly turned on and off or reversed rapidly to control movement. This practice can be extremely hard on motors not designed for such use.
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Industrial hoists are not designed or rated for lifting people. Doing so is extremely dangerous and can lead to catastrophic failures.
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A hoist holding a load for an extended time puts excessive pressure on the brake system, increasing wear and the risk of brake failure.
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Manufacturer-related are rare, but they do happen on occasion. The best way to handle these issues are to inspect your electric chain hoist upon delivery, identify any issues immediately, register your hoist with your manufacturer for warranty purposes, and submit a warranty claim. Here are some of the issues to look out for.
Manufacturers sometimes ship hoists set for the wrong voltage (e.g., 460 V instead of 230 V), or incorrectly wired for single-phase vs. three-phase.
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A hoist might arrive with a chain that’s too short (inadequate lift) or excessively long (risking chain entanglement or wasted space).
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Occasionally, hoists arrive labeled for load ratings or duty cycles that do not match their actual performance capabilities.
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Documentation such as user manuals, wiring diagrams, or maintenance guides may be poorly translated, incomplete, or contradictory.
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Components like gears, motors, and braking systems might be assembled with inconsistent materials or tolerances, leading to premature wear or equipment failure.
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Hoists may be shipped with minimal protective packaging, risking damage to motors, chains, or external parts in transit.
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