Are you looking for replacement overhead crane parts but don’t know where to start?


Let Hi-Speed walk you through the inspection and replacement process.


Overhead cranes are available in a broad range of configurations that include:


  • Single Girder
  • Double Girder
  • Box Girder
  • Truss Girder
  • I-Beam
  • Straddle
  • Tower
  • Stacker


If you operate or work around cranes, the first step is understanding the parts and assemblies that make up a “typical” crane. The chart below identifies the critical components of hoists and two popular crane options used in the manufacturing and material handling industries.

Crane Parts List

Overhead Cranes

Jib Cranes






Diagonal and pivots

Control Panel






Hoist Brakes


End Cap

Hoist Motors

Crane Wheels

Boom Pivot


Conductor Bars

Festooning Trolleys

Load Chain

End Trucks



Festoon Cable

End Stop


Festoon Track

Intermediate stop

Trolley Wheels


Rotary Brake

Wire Rope

Runway Rail

Control Panel


Please note this list includes only the essential operating components. Since most cranes are customized to meet specific load requirements and working conditions, your crane may have additional parts not listed above.



When Does a Crane Part Need Replacing?


Breakage and physical damage are the most obvious signs that it’s time to replace the crane part in question. Unfortunately, unanticipated breakage could render the crane inoperable, resulting in unforeseen production shutdowns and higher emergency repair costs.


Many crane parts have a “lifecycle,” typically expressed in operating hours. Since every crane’s location, work schedule, and materials handled are different, the stated lifecycle should be viewed more as a recommendation than an actual replacement schedule.



The Importance of Crane Inspections


OSHA requires that all cranes receive an annual inspection, but more frequent inspections can be scheduled based on the following:



Monthly (Frequent) inspections for normal usage

Weekly (Frequent) inspections for heavy usage

Daily (Frequent) inspections for severe usage



Yearly (Periodic) inspection for regular service

Semi-annual inspection for heavy service

Quarterly for severe service


Further, periodic inspections can be performed monthly or more often depending on the usage and environment of the crane.  It is normal industry speak, however, to call a frequent inspection a “monthly” and a periodic inspection an “annual.”  These terms simply refer to the depth/scope of the inspection.


A combination of daily inspections by the operator before each shift and inspection reports by a certified crane inspector provides the best insurance against breakdowns and component failures.


Additional signs that a part replacement is necessary can include.


Decreased reliability – the more often a crane fails to operate as expected, the more significant the impact on a company’s productivity and profits.


Physical damage – whenever physical damage becomes apparent, it’s time to inspect the affected part or assembly thoroughly. Depending on the damage, many crane parts can be repaired or refurbished to help keep repair costs and shutdowns to a minimum.


Noticeable wear and tear – applies to most moving parts, including the wire cable, brakes, bushings, drums/spools, slings, and operating controls. Left unchecked, normal wear and tear can quickly result in distortion, warpage, or other internal damage.


Obsolete parts – it’s no secret that many older cranes were severely over-engineered, resulting in frames, rails, and booms that outlast other crane parts such as the controls, trolley, or hoist components. If replacement crane parts cannot be easily found and acquired, it may be time to consider retrofitting the crane components with modern aftermarket assemblies.


Excessive repair/maintenance costs – typically result in increased downtime and lower productivity levels. These higher costs can indicate that a more modern or heavier-duty component or assembly may be required to maintain peak crane performance and safety while minimizing future downtime.


Expired warranties – many crane parts come with a manufacturer’s warranty that matches the expected lifespan. Should a part fail during this time, the manufacturer provides the necessary repairs or replacement, potentially saving the crane owner thousands of dollars.


Application changes – in most instances, changes to the process or handling application will require replacing some crane parts to meet revised load capacities, travel distances, or increased usage demands. Always consult a certified crane engineer before making any crane application changes to an existing crane assembly.


Let Hi-Speed help you with all your crane needs, including parts and replacement services, to ensure maximum uptime and worker safety. In addition to speedy response times, Hi-Speed can provide inspection contracts to identify potential problems before they require replacement parts or repairs. You can email the Hi-Speed Crane Experts to learn more or call us today at 800-713-0103.