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Common Electric Chain Hoist Issues & Solutions

Short Answer

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.

Initial Thoughts

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.

User Error 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.

1. Purchasing the Wrong Voltage Hoist

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.

Solution:

  • Verify Your Electrical Supply: Consult an electrician or review your facility’s electrical documentation to confirm voltage and phase requirements.
  • Match Specifications: Cross-check the hoist’s power needs with your site’s capabilities before purchasing.
  • Consider Future Growth: If you plan to upgrade your electrical system later, factor that into your hoist selection to avoid unnecessary replacements.

2. Buying the Wrong Lift Height or Reach

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.

Solution:

  • Clarify Your Requirements: Measure the distance between the hoist’s mounting point and the lowest point the hook must reach.
  • Account for Extra Clearance: Include additional length if you need to clear obstacles or position loads precisely.
  • Consult Technical Resources: Manufacturer documentation often provides calculations and recommendations for lift height and reach.

3. Choosing a Trolley That Doesn’t Fit the Beam Size

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.

Solution:

  • Accurate Beam Measurements: Use calipers or a tape measure to determine the exact beam width and flange thickness.
  • Check Manufacturer Guidelines: Ensure the trolley’s adjustment range matches your beam dimensions.
  • Test Fit If Possible: Some suppliers allow you to test fit or provide specific documentation to confirm compatibility.

4. Selecting the Wrong Speed Control (Single vs. Multi-Speed)

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.

Solution:

  • Assess Load Placement Needs: If you need precise load positioning, consider a multi-speed or variable frequency drive (VFD) hoist.
  • Avoid Severe Plugging: Use the correct type of hoist motor control for your application to prevent excessive wear.
  • Train Operators: Ensure employees understand how to operate single-speed vs. multi-speed hoists effectively.

5. Failing to Set Limit Switches

Limit switches prevent the hoist from over-traveling, commonly referred to as “two-blocking,” which can severely damage or destroy the hoist.

Solution:

  • Follow Manufacturer’s Instructions: Properly set both upper and lower limit switches according to the hoist manual.
  • Regular Testing and Calibration: Inspect and test limit switches routinely to ensure they remain accurate.
  • Lockout/Tagout for Adjustments: Always use lockout/tagout procedures when making adjustments to avoid accidental operation.

6. Inadequate Operator Training

Untrained or undertrained operators may overload a hoist, attempt side picks, or misuse the equipment, leading to unsafe conditions and potential damage.

Solution:

  • Comprehensive Training Programs: Provide formal instruction on hoist operation, load limits, and safe handling practices.
  • Frequent Refresher Courses: Maintain skills and knowledge through regular refresher training, especially when new equipment is introduced.
  • Clear Signage and Manuals: Make manuals readily accessible and post warning signs outlining weight limits and safe usage guidelines.

7. Pulling Heavy Loads by the Pendant or Push Button

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.

Solution:

  • Use Proper Handling Tools: If you need to move loads horizontally, use a trolley, forklift, or appropriate rigging, not the pendant.
  • Reinforce Safe Practices: Train operators to never apply lateral force on the hoist’s pendant cables.
  • Inspect Cords Regularly: Check for signs of cord damage or strain, and replace at the first sign of wear.

8. Side-Pulling Instead of Using the Proper Equipment

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.

Solution:

  • Use the Correct Machinery: For lateral movement, use equipment designed for that purpose (forklifts, dollies, or overhead cranes with proper rigging).
  • Position Loads Correctly: Ensure the hoist is vertically aligned with the load before lifting.
  • Implement Clear Procedures: Have clear, enforced work procedures that prohibit side-pulling or diagonal lifting.

9. Plugging Errors

“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.

Solution:

  • Use Appropriate Controls: If you need precise control, select a multi-speed hoist or a VFD hoist that can manage speed adjustments smoothly.
  • Operator Training: Emphasize the importance of smooth starts and stops, and discourage rapid on/off motions.
  • Regular Motor Inspections: Check for signs of overheating or excessive wear if plugging is common in your operations.

10. Lifting Over People or Attempting to Lift People

Industrial hoists are not designed or rated for lifting people. Doing so is extremely dangerous and can lead to catastrophic failures.

Solution:

  • Never Lift People with an Industrial Hoist: Only use equipment explicitly designed and certified for personnel lifting.
  • Strict Safety Policies: Establish policies that forbid loads from traveling over personnel.
  • Use Barricades and Warnings: Set up designated safety zones to keep people clear of overhead loads.

11. Leaving a Load Suspended for Extended Periods

A hoist holding a load for an extended time puts excessive pressure on the brake system, increasing wear and the risk of brake failure.

Solution:

  • Unload Promptly: Whenever possible, lower the load to the ground or a stable support.
  • Use Proper Storage or Support: If a load must remain suspended temporarily, consider using additional rigging or support stands designed for holding loads.
  • Brake Inspections: Regularly check the brake mechanism for signs of wear, especially if loads are often left hanging.

Final Tips

  • Always Read the Manual: Manufacturer guidelines are critical. They provide explicit instructions for safe operation, maintenance intervals, and specific hoist capabilities.
  • Regular Maintenance: A routine inspection and preventive maintenance plan can catch issues like worn brakes, misaligned trolleys, or faulty limit switches before they lead to costly downtime.
  • Engage Professionals: For more complex or specialized applications, consult with professional engineers or experienced hoist technicians to ensure you choose the right equipment for the job.

Manufacturer Issues

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.

1. Incorrect Voltage Configuration

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.

Solution:

  • Verify Prior to Installation: Always check the nameplate and wiring diagram against your facility’s power supply.
  • Request Correct Setup: Specify exact voltage and phase requirements when ordering, and confirm it in writing with the manufacturer.
  • Professional Inspection: Have a qualified electrician verify the wiring and voltage settings before first use.

2. Wrong Chain Length or Lift Height

A hoist might arrive with a chain that’s too short (inadequate lift) or excessively long (risking chain entanglement or wasted space).

Solution:

  • Confirm Lift Requirements: Clearly communicate your required lifting height and any extra clearance before placing an order.
  • Inspect on Delivery: Measure the chain length right out of the box to ensure it matches specifications.
  • Contact Manufacturer for Adjustments: If chain length is incorrect, coordinate promptly for a replacement or proper adjustment.

3. Mislabeling of Load Capacities or Duty Cycles

Occasionally, hoists arrive labeled for load ratings or duty cycles that do not match their actual performance capabilities.

Solution:

  • Request Test Certificates: Ask the manufacturer for proof of load testing or third-party certifications (e.g., CE, UL, ASME).
  • Conduct In-House Load Test: Perform a controlled test to confirm the hoist can handle the stated capacity.
  • Return or Replace if Necessary: If actual performance doesn’t meet labeled ratings, contact the manufacturer to resolve the discrepancy.

4. Incomplete or Conflicting Documentation

Documentation such as user manuals, wiring diagrams, or maintenance guides may be poorly translated, incomplete, or contradictory.

Solution:

  • Ask for Updated Manuals: Request the latest documentation directly from the manufacturer.
  • Consult Technical Support: If instructions are unclear, contact the manufacturer’s support line or a qualified distributor.
  • Document Your Findings: Keep notes on any inconsistencies and share them with the manufacturer to help them improve future releases.

5. Inadequate Quality Control

Components like gears, motors, and braking systems might be assembled with inconsistent materials or tolerances, leading to premature wear or equipment failure.

Solution:

  • Reputable Brands/Reviews: Purchase from manufacturers known for robust QC and positive user feedback.
  • Incoming Inspection: Inspect critical components (chain, hook, motor housing) immediately upon delivery.
  • Request Replacements/Repairs: Document any defects with photos and notify the manufacturer for warranty service.

6. Insufficient Shipping Protection

Hoists may be shipped with minimal protective packaging, risking damage to motors, chains, or external parts in transit.

Solution:

  • Specify Packaging Requirements: Ask for reinforced crates or foam inserts if your shipping environment is prone to rough handling.
  • Inspect Immediately: Check for dents, scratches, or other damage upon receipt.
  • File Claims Promptly: If damage is found, file a claim with the carrier and contact the manufacturer to arrange repairs or replacement parts.