As a critical component of industrial lifting equipment, the reliability of a chain hoist‘s brake system directly impacts operational safety and production efficiency. The brake system serves as a key safety mechanism for chain hoists—once worn or malfunctioning, it may lead to serious accidents. This article provides a detailed guide on the brake replacement process for chain hoists, including precautions and maintenance recommendations, assisting equipment managers and technicians in ensuring safe and reliable lifting operations.
Pre-Replacement Preparations
1.Safety Assessment and Inspection
Before replacing the brake system, conduct a thorough inspection of the chain hoist.
Check the wear level of the existing brake pads (replacement is typically required when thickness is less than one-third of the original).
Inspect the brake drum or brake disc for cracks, deformation, or excessive wear.
Test brake performance and document the response time and braking force of the current system.
2.Tools and Materials Preparation
Specialized brake system repair toolkit
OEM or equivalent-quality replacement brake components
Cleaning solvent/degreaser
Personal protective equipment (PPE) (safety goggles, gloves, etc.)
Wrenches and measuring tools
3.Work Area Preparation
Ensure the work area is clean, dry, and well-illuminated
Install safety warning signs to prevent accidental activation
De-energize the chain hoist and implement lockout/tagout (LOTO) procedures
Detailed Brake System Replacement Procedure
Removal of Old Brake System
Follow the manufacturer’s step-by-step disassembly sequence
Document component orientation and positional relationships
Inspect and clean all contact surfaces thoroughly
Properly dispose of discarded brake materials (may contain hazardous substances like asbestos)
Installation of New Brake System
Verify specifications and model numbers of new components against technical manual
Perform precision installation using specialized tools
Tighten all bolts to specified torque values
Ensure all moving parts operate smoothly without binding
Adjustment and Testing
Perform initial adjustment of brake clearance to meet technical specifications
Conduct no-load test to verify braking response characteristics
Conduct progressive load testing (25%, 50%, 75%, 100% capacity)
Fine-tune until optimal performance is achieved
Post-Replacement Verification & Maintenance
Performance Verification Standards
Full-load braking slippage shall not exceed specified limits (typically ≤1% of lifting height)
Braking response time must comply with equipment specifications
No abnormal noise or vibration permitted
Routine Maintenance Essentials
Inspect brake pad wear regularly (recommended monthly)
Keep brake system clean and free from oil contamination
Conduct periodic brake performance tests with documentation
Monitor for abnormal braking phenomena (e.g., burning odor, unusual noises)
Operator Training
Introduction to New Brake System Characteristics
Abnormality Identification & Emergency Response
Daily Inspection Key Points Training
Common Issues & Solutions
Brake Overheating: Verify correct load rating compatibility and adjust braking frequency
Insufficient Braking Force: Check brake pressure and confirm proper brake pad contact area
Brake Noise: Clean contact surfaces; replace with material-matched pads if necessary
Incomplete Brake Release: Adjust return spring tension and inspect mechanical transmission components
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