TL;DR
A rhythmic jerk during travel is almost always a flat spot on one travel wheel. Lock out and rotate each wheel by hand to find the flat spot, then replace the wheel.
What you might see
- crane jerks or bounces during travel
- rhythmic thump that repeats with wheel rotation
- load swing during travel motion
- unusual noise along a specific section of rail
Likely causes
Flat spot on a travel wheel from brake lock-up during an emergency stop
Rail debris or joint gap causing the wheel to impact as it passes
Travel drive acceleration ramp set too aggressively, causing wheel slip and jerk at start
Worn travel wheel flange allowing the wheel to oscillate laterally on the rail
Required tools
- Vernier calipers (flange width measurement)
- Crane drive controller access (ramp parameter)
- LOTO kit
- Replacement travel wheel per CXT specification
Safety first
- Lock out the crane at the main panel before accessing travel wheels.
- Do not stand on the bridge girder during testing without fall protection.
Procedure
- 1
Lock out the crane at the main disconnect.
- 2
Rotate each travel wheel by hand one full turn. A flat spot is felt as a hard stop in the rotation.[1]
- 3
Inspect the rail surface under the travel path. Look for debris, raised rail joints, or weld splatter.
- 4
Replace any travel wheel with a confirmed flat spot. Match the wheel diameter, flange profile, and material to the CXT specification.[1]
- 5
Check the travel drive acceleration ramp parameter. If the ramp is set below 2 seconds, increase it to reduce wheel slip at start.
- 6
Inspect wheel flanges for wear. A flange worn to below 60% of original thickness causes lateral oscillation. Replace worn-flanged wheels.
- 7
After repairs, run the crane at slow speed over the full travel range and confirm smooth motion before returning to service.
Sources
Konecranes CXT Wire Rope Hoist & Crane Maintenance Manual, Konecranes
Konecranes CXT Wire Rope Hoist Maintenance Manual, travel wheel inspection and drive ramp procedures (general)
View source
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Stop fixing the same fault twice.
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