When to Repair vs Replace a Damaged Manitowoc Crane Component Deciding whether to repair or replace a damaged crane part isn’t always obvious. You want safety, uptime, and reasonable cost. You also want to avoid guesswork. This guide walks through practical factors you can use on the job to make that call — whether y ou’re a technician, supervisor, or procurement lead. Start with safety first If a component’s failure could endanger people, replace it. No exceptions. Temporary fixes and jury - rigged parts aren’t acceptable for load - bearing pins, critical linkages, or structural elements. Safety - driven replacement is cheaper than a serious inciden t. Assess the damage objectively Look beyond the surface. Check for cracks, deformation, wear beyond spec, corrosion, and internal damage. Use nondestructive testing if you can: dye penetrant, magnetic particle, ultrasound. If the damage is surface - only and within repair limits, fixing mi ght make sense. If the integrity is compromised, replace. Consider the part’s role and risk Ask: how critical is this component to safe lifting? • Critical structural or load - path parts typically lean toward replacement. • Non - structural covers, guards, or cosmetic parts are easier to repair. • Moving parts with tight tolerances (bearings, pins, gears) often require replacement because even small deviations change performance. Match your decision to the part’s function. The worse the consequence of failure, the lower the tolerance for compromise. Check manufacturer guidance OEM manuals give repair limits, wear tolerances, and inspection intervals. Manitowoc parts come with specs for a reason. If the manual says replace when wear passes X, follow it. OEM guidance also protects you with traceability and supports warranty or tec hnical claims later. Factor in age and history Older components near the end of their service life are poor candidates for repair. If the part has been repaired before or shows cyclical failures, replacement is often the smarter long - term choice. Consider the entire lifecycle, not just the immediate co st. Do a cost - versus - risk calculation Compare repair cost (parts, labour, testing) against replacement cost plus downtime. Include hidden costs: inspection time, future failures, loss of productivity, and increased inspection frequency. A cheap repair that requires repeated fixes can cost more than a new genuine part over a year. Use this simple rule of thumb: if repair cost is more than 50 – 60% of replacement, replace. Adjust that threshold based on risk and criticality. Lead time and availability matter If a genuine replacement is available quickly from a trusted crane parts supplier, replacement may beat a temporary repair that forces repeated downtime. Conversely, when long lead times would halt critical operations, a certified repair can be a pragmatic interim step — but only if safe and documented. Always verify authenticity and provenance when sourcing parts. Counterfeits or off - spec parts increase risk. Think about traceability and documentation Replacement with genuine Manitowoc parts gives you serial numbers, batch records, and manufacturing data. That matters for audits and root - cause investigations. Repairs should be documented with details: technician, method, parts used, and test results. If you can’t document a repair to the same standard as a replacement, favour replacing. Warranty and manufacturer support Replacing with OEM parts often restores or maintains warranty coverage and gives you access to technical support. Repairs — especially by third parties — can void warranties. If the manufacturer’s technical team can diagnose and support, replacement may resolv e the issue faster and with less uncertainty. Who’s doing the work? Qualified technicians make repairs safer and more reliable. If you lack certified personnel or proper tooling, replacement is the safer option. A proper repair requires the right equipment, jigs, welding procedures, and testing. Improper repairs introduce new failure modes. If you use a repair shop, check certifications and past work on Manitowoc equipment. A reputable crane parts supplier can often recommend approved service providers. Long - term fleet strategy Think beyond the single part. If one component fails, what’s likely next? For older cranes, selectively replacing a set of components can reduce future downtime. For newer cranes, targeted repairs might keep costs down while meeting performance needs. Alig n decisions with your maintenance strategy: run - to - failure, preventive, or predictive. Practical examples • A bent boom pin with minor surface scoring but intact cross - section: if within tolerances and restorable by machining followed by NDT, repair may be acceptable. Document and monitor closely. • A cracked master link or hoist hook: replace immediately with a genuine part. These are high - risk, load - bearing parts. • Worn hydraulic seals causing leaks: replace seals and inspect mating surfaces. If cylinders show scored bores beyond repair, replace the cylinder. • Gearbox with minor bearing wear: replacing bearings and re - grinding shafts might work if alignment and hardness remain within spec. If root causes (contamination, misalignment) persist, consider replacement. How a trusted crane parts supplier helps A good supplier does more than sell parts. They verify authenticity, advise on lead times, and help you plan spare inventories. They can also point you toward approved repair shops and OEM service bulletins. Using a vetted supplier reduces the chance of co unterfeits and speeds up safe replacements. When in doubt, ask the supplier for documentation and fitment verification. Genuine Manitowoc parts will have traceable data you can rely on. Document the decision Whatever you decide, write it down. Record the inspection findings, the rationale, cost estimates, approvals, and follow - up actions. This record helps future choices and supports safety reviews. It also protects your team if questions arise later. Final checklist before you sign off • Does the damaged part affect load paths or personnel safety? If yes, replace. • Have you followed OEM limits and guidance? If no, err on the side of replacement. • Is the repair cost close to replacement cost? If yes, replace. • Are genuine Manitowoc parts available within an acceptable lead time from a trusted crane parts supplier? If yes, prefer replacement. • Can certified technicians perform a documented repair with testing? If yes and risk is low, repair may be acceptable. Repair or replace is a judgment call. Make it methodical. Prioritize safety, consider lifecycle costs, and use OEM guidance and trusted suppliers as your compass. When you do, you’ll balance uptime and safety without guessing.