As an indispensable lifting device in industrial production, the safe operation of overhead cranes is of utmost importance. To ensure safety and efficiency during operation, operators must not only comply with all regulations but also adhere to the following four key principles:

1. Maintain Stability During Operation:

During start and stop phases, the operator must ensure that the hook, sling, and load do not swing, thereby guaranteeing smooth operation.

2. Ensure Accurate Positioning:

Based on stable operation, the hook, sling, and load must be precisely lowered above the designated location to ensure accurate placement.

3. Prioritize Safety:

Operators must confirm that the crane is in good working condition and strictly follow safety operation procedures to prevent any personal injury or equipment damage.

4. Operate Rationally:

Operators should have a thorough understanding of the crane’s performance and motor mechanical characteristics, and operate the controller reasonably based on the load characteristics to achieve proper control.

Key Safety Inspection Points Before Operating an Overhead Crane:

  • Conduct a comprehensive and detailed safety check, covering crucial components such as brakes, control buttons, emergency stop buttons, and upper and lower limit switches.
  • Confirm that there are no abnormal noises or vibrations from the hoisting and traveling mechanisms, the hoisting wire rope is undamaged, and the hook pulley group is functioning normally.
  • For cranes that have been out of service for a long time, a full inspection and trial operation must be carried out before use to ensure everything functions properly.
  • Remove any foreign objects or obstacles from the crane rails and operating area, and ensure no personnel are working or performing maintenance at height to guarantee safe passage.

Key Safety Operation Points During Crane Operation:

  • Strictly follow the “Ten Do-Not-Lift” rules. Ensure the load does not exceed the rated capacity — for example, a 3 ton overhead crane must not lift a 5-ton load. Clear signal communication, known load weight, and adequate lighting must be ensured before operation.
  • It is strictly forbidden for loads to pass over or stop above people. The load must move steadily along a safe transportation path.
  • During hoisting, the load should be lifted at least 5 meters above the highest equipment to avoid collisions. Once in the passage area, the load should be lowered to about 5 meters above the ground for transport.
  • Always pay attention to the upper and lower limit positions of the load to ensure adequate clearance before triggering the upper limit switch or hitting ground equipment.
  • For cranes without a lower limit switch, at least two safe turns of wire rope must remain on the drum when the sling is at the lowest position.
  • Do not use the lifting limit switch, buffers, or stoppers as stopping mechanisms to ensure safe control.
  • When lifting a load close to or at the rated capacity, conduct a trial lift with a small height and short travel distance first. Proceed with the full lift only after confirming safety.
  • Always ensure the hook is directly above the load when lifting, and monitor the surroundings to avoid collisions with nearby personnel.
  • It is strictly forbidden to alter or remove any safety devices on the crane, such as brakes or limit switches. The hoisting wire rope must be within serviceable condition to operate the crane safely.
  • Maintenance and repairs must not be performed during lifting operations. In case of any malfunction, the operator must immediately contact maintenance personnel and address the issue before resuming work. Operations must be stopped immediately, and power should be disconnected if a fault is found.
  • Operators should follow the “Three Stability” principle: stable start, stable operation, and stable stop, to ensure the crane runs smoothly and safely.

Safety Precautions After Crane Operation:

  • After completing the task, raise the hook close to the upper limit position and make sure no slings or loads are hanging.
  • Electromagnetic lifting devices must be lowered to the ground and must not be suspended in the air to avoid accidents.
  • Reset all buttons on the remote control to zero, cut off the power to the remote control, and pull down the main power switch to ensure the crane is safely shut down.
  • Record the crane’s operating conditions for future analysis and maintenance.

In real-world applications—whether small-sized cranes or large-duty workstations—safety is always the top priority. Additionally, when purchasing overhead crane equipment, it is recommended to refer to the Top 10 Global Overhead Crane Suppliers to gain insights into industry leaders’ performance in safety features, service response speed, and core technical strengths, aiding in making a more comprehensive and reliable procurement decision.