Applicable Systems
Street Crane Overhead Crane
Symptoms
The crane overload protection has activated. The hoist motor stops and an alarm sounds. The load indicator shows the load exceeding 100% of the rated capacity.
Possible Causes
- Actual load exceeding the rated Safe Working Load (SWL)
- Load cell or load sensor giving a false high reading due to calibration drift
- Tilt or side-pull on the load causing asymmetric loading and a false high reading
- Load moment indicator (LMI) incorrectly configured for the current boom/derricking position
Troubleshooting Steps
- Step 1: Verify the actual load weight against the crane's rated load chart for the current configuration
If the actual load exceeds the rated SWL, reduce the load immediately - Step 2: If the load is within the rated capacity, check the load sensor calibration
Use a certified test weight to verify the sensor reading - Step 3: Inspect the load for tilt or side-pull that could affect the sensor
Re-rig the load to ensure vertical lifting - Step 4: Verify the LMI configuration matches the crane setup (boom length, radius, attachments)
Reconfigure the LMI if the setup has changed
How to Reset
Reset: After the load is reduced or the sensor is verified correct, reset the overload relay from the crane control panel.
Common Replacement Parts
- Load cell: Compression or tension type (Match to crane capacity and rigging)
- LMI display: OEM-specific, touchscreen (Verify configuration matches crane setup)
- Test weight: Certified, traceable to national standard (For annual calibration verification)
Frequently Asked Questions
- Q: What is SWL?
Safe Working Load is the maximum load the crane is rated to lift under specific conditions. Always check the load chart for the current boom length and radius.
- Q: How often should the load cell be calibrated?
Annually, or after any overload event. Use certified test weights traceable to a national standard.
- Q: What is side-pull?
Lifting a load that is not directly below the hook. Side-pull causes sideways force on the boom and can lead to structural failure. Always position the crane directly above the load.
Source: OEM Operation Manual
Category: Crane