How to inspect the Cable Trolleys in your crane system?

  • The cable trolley is one of the most essential components of a crane system.

    Regular inspection of cable trolleys and influencing factors in the workstation’s surroundings is important in order to optimise the performance of the crane system

    We recommend the following procedure to check the status and performance of cable trolleys.

    1. Listen and feel
    Carefully listen for faint noises, squeaking or scraping. Cable Trolleys should run without any sound and their passage should feel flat and smooth along the full length of the rail system.

    2. Compare theoretical performance with actual outcome
    Calculate the theoretical starting force for the system. Normally, for manually moving loads, crane system needs a starting force equal to between 1 and 1.5% of the total weight of the load recalculated to traction & pressure, together with the weight of rail components, lifting equipment and any tool. The moving force required to keep the load in the state of motion is less than 1%.

    Once the theoretical value is obtained, the actual outcome can be measured for comparison and initial diagnosis.

    3. Inspect the wheel contact surfaces in the profiles
    Examine the profile surfaces on which the trolley runs and clean if needed. The surface should be dry & clean. Sooner or later, dirty and greasy running surfaces will always have a bad impact of the crane system’s overall performance. Use a dry & clean piece of cloth.

    4. Inspect the wheels
    Dismantle the cable trolley from the profile for inspection. Check for damage, debris or wear to bearings. If any of these are visible, the trolley will need to be replaced. The wheel should not wobble by more than 0.1 mm. It should rotate evenly & freely without problem.


    Though, examining the status of trolleys is a vital part of planned maintenance for a crane system, it is not adequate in itself. How well a system functions is also influenced by factors such as the accuracy of installation, track’s condition, joints & profiles, the status of accessories and additional components etc