Crane wire rope and pulley faults are usually caused by wear, poor alignment, inadequate lubrication, or mismatched dimensions. Below is a structured troubleshooting guide covering the most common faults, their inspection criteria, and corrective methods.
| Name | Failure and damage condition | Reason and Result | Trouble- shooting Method |
| Crane Wire rope | Breakage, knotting, abrasion | Cause to breakage of rope | Stop to use it when wire rope break and knot; replace according to standard wen thread break, and replace the wire rope according to standard when it have abrasion. |
| Hook Pulley | Uneven abrasion of block's groove | Material asymmetry, bad installation and bad connection of rope and wheel | Replace it when abrasion of groove's wall reaches / of previous thickness, and gauge ware reaches 1 /2 of wire rope diameter |
| Pulley can not rotate | Keeper of shaft loose or wire rope hop out of groove | Replace the shaft and bearing and then lubricate and maintain them | |
| Pulley incline or loose | Keeper of shaft loose or wire rope hop out of groove | Fasten the keeper and repair the wire rope's hopping | |
| Crack of pulley or break of wheel flange | Pulley damage | Replace |
🛠️ Key Maintenance & Prevention Tips
To prevent these faults, integrate the following into your routine:
Daily Checks: Visually inspect for broken wires, kinks, and obvious damage. Test the limit switches and brakes .
Monthly Maintenance: Measure rope diameter and check sheave groove wear. Confirm the lubrication status of both the rope and the sheave bearings .
Lubrication: Keep the wire rope clean and lubricated to prevent corrosion and internal friction . Ensure sheave bearings are packed with grease .
Alignment & Fit: Verify that the fleet angle is within the sheave design limits and that the rope diameter is compatible with the drum and sheave grooves to avoid abnormal wear .
