12 Nov 2025

TROUBLESHOOTING COMMON ELECTRIC HOIST PROBLEMS: EXPERT GUIDE TO DIAGNOSIS & REPAIR

When your electric chain hoist stops working, productivity grinds to a halt. Whether it’s a hoist not lifting, a strange grinding noise, or a motor that overheats after a few minutes, the root cause can range from electrical faults to mechanical fatigue.

As specialists in lifting equipment, we’ve seen every kind of hoist failure - and the good news is, most issues can be diagnosed quickly with the right knowledge.

In this expert guide, we’ll break down the most common electric hoist problems, explain how to troubleshoot them step-by-step, and show you how to know when repair isn’t worth the cost.

1. COMMON ELECTRICAL ISSUES

Electrical faults are one of the top reasons for sudden hoist failure. If your hoist won’t lift or runs inconsistently, start by checking the following areas.

A. POWER SUPPLY & VOLTAGE

Many “dead” hoists simply aren’t getting proper power.

• Verify the power source: Is the hoist rated for single-phase or three-phase current?
• Check the circuit breaker or fuses for trips or blown elements.
• Inspect plugs, leads, and terminal connections - vibration often causes loosened wires.

⚙️ Tip: Always confirm your supply voltage matches the hoist’s rated voltage to prevent motor damage or sluggish lifting.

B. MOTOR PERFORMANCE PROBLEMS

If you hear a humming sound but the hoist doesn’t move, it’s likely a motor or brake issue.
Common symptoms include:

• Motor running hot even with light loads
• Intermittent operation or failure to start
• A distinct burning smell or tripped overload relay

POSSIBLE CAUSES:

• Worn motor bearings or brushes
• Shorted windings or open circuits
• Overheating from excessive duty cycles
• Faulty start/run capacitors (single-phase motors)

When motor performance deteriorates despite maintenance, it may be more cost-effective to upgrade to a new electric hoist for improved efficiency and reliability.

C. CONTROL & LIMIT SWITCH FAILURES

Modern hoists use pendant or wireless controls, which can fail from moisture, wear, or damaged wiring.

• Test each control button for continuity.
• Inspect the limit switch - if it’s stuck or misaligned, it may prevent the hoist from lifting even though the motor runs.
• Examine contactors for pitted or burned contacts.

2. LOAD SLIPPAGE, NOISE, OR OVERHEATING

When a hoist starts behaving differently - slipping, overheating, or making unusual noises - mechanical wear or lubrication issues are usually to blame.

A. LOAD SLIPPAGE

If the load rises and then slowly drops back, it’s likely a brake issue:

• Check for worn brake pads or oil contamination.
• Ensure the brake coil energises correctly when the lift command is pressed.
• Adjust brake spring tension per the manufacturer’s instructions.

Never operate a hoist with a slipping brake - it’s one of the most dangerous faults in lifting operations.

B. UNUSUAL NOISE OR VIBRATION

Grinding or rattling sounds are clear signs of mechanical wear:

• Inspect gearbox gears for wear or missing teeth.
• Check the load chain for kinks, corrosion, or stretching.
• Tighten any loose fasteners, and ensure the chain aligns properly on the sprocket.

Lack of lubrication can also cause vibration and accelerated wear - always use manufacturer-approved gear oil or chain lubricant.

C. OVERHEATING

Overheating shortens the life of the motor insulation and bearings.

• Confirm the hoist is operated within its duty cycle (e.g., 30% ED = 3 minutes on, 7 minutes off).
• Clean any dust buildup around cooling vents.
• Allow proper rest intervals between lifts.

3. PROFESSIONAL DIAGNOSTIC CHECKLIST

Here’s a concise diagnostic table to guide your troubleshooting process:

Keep a maintenance log — regular inspections and documentation not only prevent failures but also ensure compliance with ASME and OSHA safety standards.

4. PREVENTATIVE ACTIONS FOR LONG-TERM RELIABILITY

Proper care can extend the lifespan of your hoist by years. Implement these preventive steps:

• Inspect monthly: Check hooks, chains, limit switches, and wiring.
• Lubricate properly: Clean and oil the load chain regularly to minimise wear.
• Never overload: Respect the rated capacity and avoid shock loading.
• Store correctly: Keep hoists dry and covered when not in use.
• Annual load testing: Verify lifting performance under controlled conditions.

Preventive maintenance isn’t just about avoiding downtime - it’s about protecting people and property.

5. WHEN REPAIR ISN'T WORTH IT - TIME TO REPLACE

Even the most durable hoists reach a point where replacement is the smarter investment.

Replace your hoist when:

• You face repeated motor or brake failures within short intervals.
• Spare parts are discontinued or hard to source.
• The hoist struggles to lift within its rated capacity.
• Safety inspections consistently flag critical wear.

Upgrading to a modern hoist often delivers better energy efficiency, safety features, and precision control - reducing long-term operating costs.

👉 Explore our full range of electric chain hoists designed for industrial reliability and precision lifting.

Conclusion

A malfunctioning electric hoist doesn’t always mean the end of its service life - but understanding the root cause of electrical and mechanical issues is key to keeping operations safe and efficient.

By following this troubleshooting guide and maintaining a disciplined inspection schedule, you can minimise downtime, extend equipment life, and maintain compliance with safety regulations.

If your hoist continues to show symptoms like erratic movement, slipping loads, or overheating, it’s time to seek professional support or consider a new model built for modern performance standards.

Need expert help? Contact our highly trained team today for hoist diagnostics, parts replacement, or upgrade advice.