Common Electric Chain Hoist Failures and How to Avoid Them

Electric chain hoists stand as indispensable tools in various industries, playing a vital role in streamlining material handling processes. However, despite their reliability, electric chain hoists are not immune to issues, often stemming from improper operation. In this article, we explore the common failures that can compromise their functionality.

Operators and industry professionals must be aware of these potential pitfalls and, more importantly, understand preventive measures. By gaining insights into the workings of electric chain hoists and implementing best practices, one can effectively sidestep these failures, ensuring a seamless and safe lifting experience in manufacturing, construction, and logistics sectors alike.

7 Common Failures in Electric Chain Hoists: Causes and Solutions

In this comprehensive guide, we address both electrical and mechanical issues that commonly afflict electric chain hoists, providing insights into their causes and outlining effective solutions.

  1. Power Failure

Power failures can happen due to a burned-out power fuse or an automatic switch-off without the fuse burning, disrupting the continuous operation of the hoist. To address this issue, it is crucial to check the current within the rated scope. If it exceeds the acceptable range, identify and resolve the underlying cause. Additionally, replacing the burnt fuse or restarting the breaker is necessary to restore the power supply to the hoist.

  1. Motor Failure

Motor failures in electric chain hoists, such as overheating due to overloading or poor heat dissipation, demand a thorough load examination and cooling measures. For failures to start, inspecting power supply normalcy and conducting meticulous motor examinations and repairs are essential for restoration to optimal working conditions.

  1. Voltage Failure

Insufficient power supply voltage risks hoist performance. Measure the voltage value to identify if it falls below 10% of the rated power voltage. Timely identification and resolution of power supply issues maintain the required voltage for optimal electric chain hoist operation.

  1. Chain Breakage

Chain breakage, a common problem in electric chain hoists, requires prompt attention to prevent additional damage. Addressing root causes like overloading or poor operating conditions is crucial before replacing the damaged chain with a new one, ensuring proper installation for optimal hoist performance.

  1. Control Failure

Control failures in electric chain hoists, hindering intended movements, may result from issues in the control circuit or controller damage. Solutions include checking the circuit integrity, ensuring proper connections, and conducting inspections and repairs for restored control functionality.

  1. Brake Failure

Brake failures, including insensitivity and non-functionality, pose safety risks in electric chain hoists. Prompt identification of root causes, such as faulty mechanisms or worn pads, is critical. Remedial actions involve comprehensive checks and the replacement of worn brake pads to restore effective braking.

  1. Circuit Failure

A contactor coil short circuit disrupting the hoist’s electrical circuit requires prompt action. Replace the faulty contactor promptly to ensure the electric chain hoist’s circuit operates smoothly without interruptions.

Safety Implications of Failures in Electric Chain Hoists

The consequences of electric chain hoist failures extend beyond equipment damage. Workplace accidents can result in injuries or even fatalities, leading to legal and financial repercussions for the company. Moreover, downtime caused by hoist failures affects productivity and overall business operations. Some of the common preventive maintenance strategies to mitigate the risks associated with hoist failures are.

Regular Inspections

Frequent inspections of the hoist’s components can identify potential issues before they escalate. Inspections should cover the chain, electrical wiring, brakes, and control systems.


Proper lubrication is essential for the smooth operation of the hoist. Regularly applying the recommended lubricants helps prevent friction-related failures.

Electrical Checks

Scheduled electrical checks, including testing the wiring and control panel, can detect and address potential electrical failures.

Training for Operators

Ensuring that operators are well-trained in hoist operation and safety protocols is a key preventive measure. Knowledgeable operators are more likely to identify and address issues promptly.

In addition to the identified common failures, several crucial elements contribute to the overall safety of electric chain hoists. Firstly, selecting a hoist with the appropriate weight capacity for the intended workload is fundamental. This preventative measure significantly mitigates the risk of overloading, a primary cause of hoist failures. 

Secondly, investing in a high-quality electric chain hoist is paramount. Such hoists, designed and manufactured to stringent standards, exhibit enhanced reliability and durability, reducing the likelihood of failures. Finally, ensuring that chosen hoists comply with industry standards and hold relevant certifications is essential. 

Adherence to these standards not only guarantees the hoist’s safety and performance but also assures meeting regulatory requirements, contributing to a safer working environment. These additional considerations underscore the importance of proactive measures in preventing failures and enhancing the overall safety of electric chain hoists.

Need details on electric chain hoist maintenance or want to explore the types available? Just get in touch with us! Further, for any lingering problems or doubts about electric chain hoists, shoot us an email at [], call us at [+91 (22) 489-33303] or message us on WhatsApp at [8006238006]. Count on Bajaj Indef to respond promptly—within 24 working hours—to assist with your electric chain hoist concerns.