The most common installation mistakes include incorrect air gap/shoe clearance, misalignment of the brake to the disc or brake wheel, and improper linkage geometry (rod length, lever angle, spring preload). These errors can cause dragging (overheating), delayed engagement, reduced torque, or uneven wear. Another frequent problem is incorrect wiring or power supply selection for electromagnetic brakes—undervoltage and wrong rectifiers lead to weak release and coil overheating.
Limit switches and interlocks are also critical: misadjusted brake-open switches can allow motion before full release, causing shock loads and lining damage; mis-set wear switches can fail to warn before torque drops below safe levels.
Finally, mixing non-OEM linings or springs can change friction coefficient and clamp force, producing unpredictable behavior. Commissioning should include clearance measurement, multiple apply/release cycles, controlled stop tests, and documentation. Treat crane brake installation like safety system commissioning—not routine assembly.