Top 5 Causes of Crane Breakdowns (And How to Avoid Them)

When a crane breaks down on-site, productivity comes to a screeching halt — and downtime isn’t just frustrating, it’s expensive. Whether you're running a warehouse, workshop, or construction site, knowing the most common causes of crane failures can help you keep your lifting operations running smoothly.

Here are the top five reasons cranes break down — and what you can do to prevent them.

1. Poor Maintenance

It’s easy to overlook routine maintenance when everything seems to be working fine. But over time, worn parts, old oil, and lack of inspections can lead to serious problems. Bearings can seize, gears can wear down, and electrical connections can fail — all of which can bring your crane to a stop.

How to avoid it:Stick to a regular maintenance schedule. Clean and lubricate moving parts, check wear on brakes and wheels, and inspect all electrical connections. Even small checks can prevent costly repairs later.

2. Overloading

Pushing a crane past its rated capacity puts enormous strain on every part of the system — from motors and chains to structural components. Overloading can cause permanent damage, and in worst cases, complete failure.

How to avoid it:Use load limiters or crane scales to make sure you're lifting within safe limits. We stock both at Hoist Factory for this exact reason — safety and longevity go hand in hand.

3. Faulty Controls or Remote Systems

Industrial remote controls and pendant stations are vital for safe and responsive crane operation. But when these systems are damaged, have faulty wiring, or suffer signal issues, operators are left flying blind — and breakdowns follow.

How to avoid it:Replace damaged remotes and ensure cables are intact. If you need replacements, Hoist Factory offers reliable pendant stations and wireless remotes designed for tough environments.

4. Worn or Stretched Chains and Slings

Chains, nylon slings, and lifting gear wear out over time, especially when they’re used daily. Stretched chains or damaged slings are dangerous — and they often go unnoticed until something fails.

How to avoid it:Inspect your lifting gear before each use. Replace any damaged or stretched chains and slings immediately. We offer high-quality, affordable replacements that ship fast.

5. Environmental Exposure

Cranes used outdoors or in dusty, wet, or corrosive environments face extra wear. Moisture can get into motors, dust can clog systems, and temperature extremes can affect performance.

How to avoid it:Use protective covers where possible, and choose equipment rated for your environment. For example, sealed industrial remotes or stainless-steel enclosures are ideal for harsh conditions.

Don’t Let a Breakdown Bring Your Business Down

At Hoist Factory, we stock a full range of industrial lifting products that are built to last — and designed to keep your operations moving. From electric chain hoists and pendant stations to load limiters, nylon slings, and remote controls, you can order everything you need online, with next-day shipping on standard items.

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