EOT Crane Repair, Inspection and Servicing
EOT crane faults, brakes, ropes, electrical controls and service planning. Find the right fitter, electrician and inspection scope for your site.
EOT crane repair starts by identifying the failed motion: hoist, cross travel or long travel. A hoist that does not lift can have a brake, motor, supply or control fault; replacing the motor without checking the circuit can repeat the failure. Inspection and servicing cover both mechanical lifting components and electrical controls. A crane fitter and a qualified electrician often handle different parts of the same job. Record the crane and hoist nameplates, fault indication and working height before planning access, tools and replacement parts.
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Hoist, CT and LT faults: checks and repair resources
| Symptom | Checks to Make | Site vs Workshop Assessment | Likely Replacement Parts |
|---|---|---|---|
| Hoist will not lift | Supply, contactor/VFD, limit circuit, motor or brake release | Electrical and mechanical diagnosis at site | Contactor, coil, brake parts, limit switch or motor after testing |
| Load creeps after stopping | Brake lining/gap, brake mechanism or holding-system defect | Crane specialist assessment; controlled verification after repair | Brake lining/disc, spring, coil or assembly-specific parts |
| Rope has broken wires or poor winding | Rope deterioration, drum/sheave wear, guide or reeving problem | Inspect and replace at height using safe access and the specified rope | Correct wire rope, rope guide or sheave components |
| Hook latch damaged or throat distorted | Latch wear or load-related hook deformation | Measure and assess; damaged load-bearing hook needs proper replacement | Rated hook/latch assembly as identified |
| VFD trips or motor overheats | Supply imbalance, motor/cable condition, brake drag or duty/load | Electrical testing at site; motor repair usually off-machine | Drive components, cable, brake or motor parts after diagnosis |
| Cross/long travel noisy or skewed | Wheel wear, drive mismatch or runway/trolley alignment | Measure alignment and drives before changing wheels | Wheels, bearings, drive parts; rail correction separately scoped |
| Gearbox leaks or runs noisily | Seal, bearing, gear or lubrication problem | Accessible seals at site; internal rebuilding needs suitable facilities | Specified oil, seals, bearings or gear set |
| Intermittent power along the runway | Conductor/DSL collector wear, alignment or cable fault | Qualified electrical work with safe access and isolation | Collector shoes, spring assemblies, conductor joints or cable |
| Festoon cable or pendant damaged | Cable fatigue, snagging, strain-relief or switch failure | Site replacement with suitable cable/control parts | Festoon cable/trolley, pendant switches or strain relief |
| Radio or limit control unreliable | Control supply, receiver/transmitter, wiring or switch alignment | Diagnose the control chain at site | Remote-control parts, limit switch or wiring |
Machine type and use
An electric overhead travelling (EOT) crane moves loads within a workshop, factory or maintenance bay. The bridge travels along runway rails; the trolley moves across the bridge; the hoist raises and lowers the load. Single-girder and double-girder designs have different access, hoist and structural arrangements.
Before the first technical call
Report HOIST, CT or LT rather than saying only 'crane stopped'. CT is trolley movement across the bridge; LT is bridge movement along the runway. Say whether the problem occurs at one runway position or everywhere. That distinction helps separate a conductor-rail or cable problem from a drive or motor problem.
Access, shutdown and workshop planning
Most diagnosis happens on the crane, but access is part of the repair plan. The site needs a safe platform, isolation and a shutdown window. Brake, switch, collector and cable work is usually accessible once those arrangements are in place. A gearbox or motor rebuild often happens off the crane. Wheel-flange damage needs a runway and drive review; fitting new wheels without dealing with misalignment can recreate the problem.
Servicing and condition inspection
Plan servicing around the crane manual, duty and operating environment. Include lubrication, brake and rope condition, travel drives, electrical connections and safety devices. A heavily used foundry crane and an occasional-use workshop crane should not automatically follow the same maintenance plan.
Inspection areas to include
- Hoist: rope or chain as fitted, hook assembly, drum, sheaves, gearbox, brake and visible fastening condition.
- Cross travel (CT): trolley wheels, drive, CT gearbox, brake and rail condition. Long travel (LT): bridge end-carriage wheels, drives and runway-related symptoms.
- Electrical system: supply, pendant or radio control, contactors or variable-frequency drives, cables and motor condition.
- Safety functions and visible structural defects, checked under a defined inspection scope. An ordinary service inspection does not establish a new lifting capacity.
What the inspection or repair report should record
A condition report should distinguish visual observations, functional checks and measurements. For example, 'brake inspected' is less useful than the actual lining condition, action taken and post-repair result. Ask for identification of hoist, CT and LT defects, with photographs and outstanding items. A load test needs its own method, load, competent personnel and records; test weights are not required for every ordinary service visit.
Condition inspection and formal examination
For factory EOT cranes, the statutory basis changed when the OSH Code came into force on 21 November 2025. Section 143 repealed the Factories Act 1948 and preserves qualifying earlier rules and actions until superseded. Establish the applicable state or central provisions and the competent-person examination schedule for the factory. Historically, Factories Act 1948, Section 29 required lifting machines, chains, ropes and lifting tackles to be thoroughly examined by a competent person at least every twelve months, or at intervals specified in writing by the Chief Inspector. IS 3177:2020 is the EOT and gantry-crane code of practice; IS 807:2006 covers design, erection and testing of structural portions of cranes and hoists. Check the applicable editions and specifications for the actual crane. Mine installations also require the applicable DGMS framework. A service inspection is a condition report; it is not the competent-person examination or certificate.
Manufacturer examples and machine identification
Crane-builder examples include ElectroMech, Konecranes, Demag, Safex, Anupam and Brady & Morris; installed equipment may also carry WMI or Mukand nameplates. Hoist examples include INDEF and STAHL. Demag industrial cranes are part of the Konecranes Group. Identify the bridge builder, hoist and electrical drives separately: the bridge name alone may not identify a replacement hoist brake or drive. Manufacturer names identify equipment; no OEM affiliation is implied.
Planning service for an Indian project
An EOT crane in a workshop, steel plant or production bay sees a different combination of dust, temperature and operating duty. Record the shift pattern, load cycle and surrounding process, including heat or corrosive exposure. An overhead crane is primarily an electrical and mechanical service job; it should not be dispatched as a diesel-engine breakdown. Identify the hoist and electrical drive separately from the bridge builder when mixed makes are installed.
Fitter, electrician or controls specialist?
The normal skill mix is a crane fitter for lifting/travel mechanics and a qualified electrician for power and controls. PLC or VFD faults need controls experience. Rail alignment, structural assessment and formal examination are separate specialist tasks.
Equipment to arrange for the work
- Suitable access platform and isolation equipment for overhead work.
- Electrical meters and, where appropriate, insulation-testing equipment used by a qualified electrician with sensitive circuits protected.
- Brake and rope measuring tools, torque tools and gearbox inspection equipment.
- Specialist rail survey, non-destructive testing or controlled load-test equipment only when separately required and arranged.
Before maintenance starts
Keep the crane out of lifting service for a defective brake, damaged load-bearing component or failed essential limit device.
Frequently asked questions
Does an EOT crane inspection include load testing or certification?
A service inspection records the agreed machine condition. Statutory examination and any required testing need a separately defined scope and the appropriate competent party.
What should I report when only cross travel stops?
State that CT is affected, whether the hoist and long travel still work, and any control-panel fault indication. Do not repeatedly reset a trip or bypass a limit device.
Does a motor trip always mean the motor has burned out?
A trip does not establish motor failure. Supply imbalance, cable faults, brake drag, overload and drive settings are part of the investigation.
Why do new crane wheels wear quickly?
Repeated flange wear is a reason to check alignment and drive behaviour. Wheel replacement alone does not correct the cause of skewing.
What equipment is needed for EOT work at height?
Provide safe access suitable for the repair location and an isolation arrangement. Component lifting, test weights and specialist inspection tools are additional items for the jobs that require them.
Information to prepare for a repair or inspection enquiry
- Crane capacity, bridge nameplate and separate hoist/drive identification where fitted.
- Affected motion (hoist, CT or LT), symptoms, exact fault codes and existing photographs or safely recorded video.
- Operating hours or shift/duty pattern, service history and recent repairs or alterations.
- Site location, working height, current crane position and safe access constraints.
- Required shutdown window and available isolation, component-lifting, power and workshop arrangements.
Need a mechanic or an inspection?
Send the machine make and model, site location and symptoms through the Mech On Site contact page. Include the service or inspection you need and any fault codes or existing photographs.
Technical References
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