Insufficient thruster stroke means the brake may not fully release, partially release, or fail to achieve the intended clearance. The most immediate risk is brake dragging, which generates continuous heat, accelerates lining wear, and can damage the brake wheel/disc. Over time, dragging can lead to brake fade and loss of holding torque, undermining safety during emergency events.
In crane travel mechanisms, partial release reduces efficiency and can cause unstable motion, overheating of motors, and VFD alarms. In hoisting, incomplete release can cause poor lifting performance and can create harsh engagement as the brake “fights” the drive torque.
Causes include incorrect thruster selection (stroke too short), misadjusted linkage, mechanical binding, low fluid level, internal thruster wear, or incorrect power supply. The solution is not just “adjust tighter”—verify required stroke from the brake design, ensure full mechanical travel, and confirm correct installation geometry. After correction, measure clearance and run a controlled thermal check to ensure the brake is not dragging.