Safety Regulations and Key Operational Guidelines for Crane Use

1. Operators must undergo training.

The operator must be familiar with the crane’s structure and performance, pass the required training and assessment, and obtain a “Special Equipment Operator Certificate” before being authorized to operate the crane independently, and must comply with all safety regulations.

II. Essential Operating Procedures for Operators

   1. Before each shift starts Must Perform the following inspections:

(1) Are there any defects on the hook head and pulleys?

(2) Is the wire rope in good condition? Is the rope end securely fastened on the drum, and are there any signs of the rope jumping out of the groove?

(3) Are the brakes of the trolley, hoist, and lifting mechanism safe and reliable?

(4) Are all transmission mechanisms functioning properly? Are all safety switches responsive and reliable? Are the hoisting limit switches and the trolley and gantry travel limit switches operating correctly?

(5) Are there any abnormal vibrations or noises during crane operation?

       2.  Before operating the vehicle, all control levers must be returned to the zero position, doors and windows must be securely closed, and a warning bell must be sounded before starting the engine.

      3.  The crane shall be started smoothly and accelerated step by step. The transition time for each gear of the hoisting mechanism may be… 1 ~2 2s ; The switching time for each gear of the drive mechanism shall be no less than 3s ; For bridge cranes with large lifting capacities, or depending on the lifting capacity, high‑speed starting is strictly prohibited.

      4.  The use of cranes beyond prescribed specifications is strictly prohibited; compliance with the “Ten Prohibitions on Lifting” outlined in the crane safety management regulations is mandatory.

(1) Do not lift when the load exceeds the rated capacity;

2) Do not lift when the command signal is unclear or lighting is insufficient.

(3) Do not lift if slings and attachments are not securely fastened or do not meet safety requirements.

(4) The crane shall not lift when the workpiece is directly clamped for machining.

(5) Do not lift with slanted or crooked rigging;

(6) Do not lift when personnel are standing on the workpiece or when loose, movable objects are resting on it.

(7) Do not lift flammable or explosive hazardous materials if no safety measures are in place.

(8) Do not lift objects with sharp edges or cutting edges that lack wire‑rope cut‑protection measures.

(9) Do not lift loads that are buried underground or have solidified on the ground without knowing their weight.

(10) The operator shall not lift when the commanding personnel issue an illegal order.

   5.  During the first lift of a load in each shift (or when the load is at the maximum rated lifting capacity), the load should be lifted approximately… above the ground or supporting surface. 0.3m Afterward, lower the load to verify that the brake is functioning properly; once confirmed to be reliable, resume lifting.

   6.  When operating the controller, movements must be made in accordance with the prescribed gear sequence. Ensure that the lifted load remains stable; do not raise the load while the hook is rotating to prevent the wire rope from jumping out of the groove.

    7.  When the crane or trolley is approaching its end point, it shall reduce speed. It is strictly prohibited to use the end‑limit switches as a means of stopping, and reversing the motor to achieve braking is also not permitted.

   8.  During operations, the operator shall sound the alarm bell as prescribed for the following tasks:

(1) When lifting or lowering heavy loads, or when operating the trolley and hoist travel;

(2) When the crane is passing through or traveling in areas with poor visibility;

(3) When the crane is operating and approaches another crane on the same span of track;

(4) When lifting and moving heavy loads near personnel.

   9.  It is strictly prohibited to leave suspended loads in the air for extended periods. While lifting a load, neither the operator nor the rigger shall leave their workstation without authorization.

   10.  During crane operation, personnel are prohibited from boarding or alighting, walking on the tracks or walkways, and performing maintenance work.

   11.  To Double hook (Primary and secondary hooks) Cranes shall not simultaneously use both hooks to lift two separate loads. The inactive hook must be raised to near its upper limit, and no load‑bearing slings shall be attached to it. When switching between the primary and secondary hooks, or when the heights of the two hooks are close, each hook must operate independently to prevent them from colliding.

   12.  When multiple cranes are operating within the same span, a clearance greater than … must be maintained between the two cranes. 1.5m the distance to prevent collisions. If work necessitates approaching, prior consent from the adjacent machine must be obtained; however, the minimum clearance shall be 0.3m That is all.

   13.  It is prohibited to use two cranes simultaneously to lift a single load. In special circumstances where dual‑crane lifting is required, appropriate safety measures must be implemented, each crane must remain within its rated capacity, and on‑site coordination must be overseen by a supervising engineer with specialized technical expertise.

   14.  When changing the direction of operation during normal work, the controller handle must be moved to the “zero position,” and the direction should be reversed only after the mechanism has come to a complete stop.

   15.  All protective devices of electrical equipment must be kept in good working order and shall not be adjusted or replaced without authorization.

   16.  Cranes operating outdoors, when wind speed exceeds 6 When operating at a certain level or during thunderstorms, work should be stopped immediately. When not in use, the crane should be moved to a parking position and securely anchored.

   17.  Upon completion of the lifting operation, move the crane to the designated location, position the trolley at the cab end, raise the hook (and lower the grab to the ground), return all controllers to the “zero” position, disconnect the power supply, and clean and wipe down the equipment to maintain cleanliness. Properly complete the shift‑operation log and ensure smooth handover procedures.

III. Safety Precautions

The safe operation of cranes requires attention to the following precautions:

1.  Operating a crane is prohibited without a valid operator’s license and when under the influence of alcohol.

   2.  During operation, one must remain fully focused and refrain from engaging in activities unrelated to the task at hand.

3.  During work, it is prohibited to use the hook to transport personnel.

4.  Keep the crane clean and free of debris; do not store equipment, tools, flammable materials, explosives, or hazardous substances in unauthorized locations.

5.  Under normal circumstances, cranes are not permitted to operate at overload conditions; in exceptional cases, operation at overload is allowed only after thorough review and approval by the relevant authorities and qualified technical personnel.

6.  Lifting is prohibited under any of the following conditions: insecure rigging; overloaded load; unclear signals; slantwise pulling; objects buried in or frozen to the ground; persons on the lifted object; flammable, explosive, or hazardous materials lacking adequate safety safeguards; wire ropes not meeting safety‑use requirements; or malfunctions in the hoisting mechanism.

7.  When the crane is operating on a clear, obstacle-free track, the hook or lifting attachment and the bottom surface of the suspended load must maintain a clearance from the ground. 2 More than one meter. When crossing an obstacle, it must be cleared. 0.5 Michael.

8.  Lifting loads are not permitted to travel over personnel.

9.  A bridge crane equipped with main and auxiliary hooks. Do not raise or lower the main and auxiliary hooks simultaneously (except in special cases).

10.  Welding or hammering on suspended loads, as well as working beneath them, is prohibited (unless the load is properly supported).

11.  Inspection or maintenance work may only be carried out after the power has been switched off and a “Power Off – Work in Progress” sign has been hung on the switchgear. If live‑working is unavoidable, appropriate safety measures must be in place, and a designated attendant must be assigned to supervise.

12.  It is prohibited to casually throw objects out of the vehicle.

13.  Limit switch Interlocking and protective devices must be inspected regularly.

14.  It is not permitted to use contact with limit switches as a means of stopping the machine.

15.  When the hook is at its lower limit position, at least two full turns of safety rope must remain on the drum.

16.  Cranes must not collide with one another, and it is strictly prohibited to use one crane to push another during operation.

17.  When lifting heavy objects, liquid metals, flammable, explosive, or hazardous materials, the load must first be slowly raised off the ground. 100 ~ 200mm , test the reliability of the brake, and only proceed with lifting after confirming that the brake is safe and reliable.

18.  The voltage of lighting lamps used for repair and inspection must be within 36V The following.

19.  Regular safety inspections shall be conducted, and preventive inspections and maintenance work shall be properly carried out.

, The operator shall know Item

1.  Operators must strictly adhere to safety operating procedures and possess a thorough understanding of the crane’s performance, structure, operating principles, and operating methods. They must also conduct regular inspections and perform timely maintenance, promptly addressing any issues that arise. If a problem cannot be resolved immediately, it should be reported to the maintenance department without delay.

2.  Operators must have a thorough understanding of the workshop, the work area, and the characteristics of the production process. Only in this way can they coordinate effectively with ground‑level supervisors, fully exploit the crane’s capabilities, enhance operational efficiency, and minimize accidents. In general, operators should strictly follow the hand signals issued by the signalman. Operators also have the right to refuse to lift or move any load that violates safety regulations.

3.  Be familiar with the rigging operator’s signals, hand gestures, and whistle commands. Do not proceed if the signal is unclear. Continuously monitor the signals given by ground personnel to prevent accidents caused by sudden changes in signaling.

4.  When the signal given by the rigger differs from the operator’s intention, an inquiry signal shall be issued to confirm that there are no issues before proceeding with the operation. However, even if the rigger has already issued a work signal but is not keeping the load in view, the operation must not be initiated; a second signal should be given and repeated until the rigger is observing the load, at which point the operation may proceed.

5.  When a signaler is positioned between two objects to give commands, they must issue a signal to ensure the objects are moved away. However, if the nature of the work requires the signaler to remain in this position, operations must be carried out with extreme caution to prevent the objects from swinging and injuring the signaler.

6.  When multiple personnel are involved in rigging operations, the operator shall follow only the signals of the designated signalman; however, any stop signal issued by anyone must be obeyed immediately.

7.  Before commencing operations, first verify whether there are any personnel on the vehicle, whether there are obstacles on or near the track, whether a collision with an adjacent vehicle is possible, and whether anyone on the neighboring vehicle is performing maintenance. In addition, carefully assess the size, weight, and shape of the load to anticipate potential issues that may arise during operation. This way, even if problems occur during travel, you will be mentally prepared and avoid being caught off guard. When approaching an adjacent vehicle or detecting personnel on the operating route, always sound the appropriate signal.

8.  When there are differing opinions regarding the working conditions on the ground, do not proceed with operations. Wait until a signal has been given and the supervisor has inspected the situation, then issue another signal before lifting, lowering, or starting the equipment. If you determine that a problem is imminent, even if the operation signal has already been issued, refrain from proceeding until the potential hazard has been eliminated.

9.  Signals must be given in the following situations: when starting or stopping the trolley and hoist; when approaching an adjacent crane or a crane on an upper or lower level; when commencing lifting or lowering operations; and when a load or hook is approaching personnel.

10.  The controller handle shall be operated in accordance with the prescribed procedure. Before the mechanism comes to a complete stop, do not abruptly move the controller handle to the opposite direction. When lifting or lowering loads, avoid abrupt changes in the hoisting or lowering speed to prevent vehicle vibration. If the controller handwheel becomes jammed, immediately activate the emergency switch or press the main stop button.

11.  When using two cranes to lift an object simultaneously, first determine whether its weight exceeds the rated lifting capacity of a single crane. If it does, ensure that the load on each crane remains within its respective rated capacity, and pay close attention to the signaler’s hand signals, the other personnel involved, the coordination between the two cranes, and the surrounding environment.

12.  When lifting an object, the hook must be positioned directly above it. Only in this way can the object be lifted smoothly and accurately, while preventing the wire rope from slipping out of the pulley groove or damaging the pulley flange.

13.  When aligning the hook with the load’s center of gravity, operating the main trolley is relatively straightforward, as the hook is positioned directly in front of the operator. By contrast, maneuvering the auxiliary trolley requires simultaneous attention: you must both lift the hook and monitor the tension on both sides of the sling. If the sling bears load evenly, it indicates that the hook is aligned above the object’s center of gravity. If one side of the sling becomes loaded before the other, this suggests a misalignment between the hook and the load’s center of gravity; in such cases, move the auxiliary trolley toward the end of the sling that is bearing the initial load. Once the entire sling is under uniform tension, proceed with gentle, incremental movements. Only after the load has completely cleared the ground may you increase the travel speed—sudden lifting is strictly prohibited. As the load approaches the ground, lower it slowly; ideally, bring it to a complete stop just above the surface. This careful handling prevents damage or deformation to the workpiece while also minimizing vibration and deformation of the bridge structure.

14.  Sometimes, during operations, continuous jogging of the equipment is required to complete the work process. In such cases, the operator must have a thorough understanding of the overall job requirements and maintain close coordination with the supervisor. The speed of jogging should be determined according to the supervisor’s hand signals and must not be based on subjective assumptions.

15.  When the suspended load is being moved toward its destination and both the trolley and the hoist must be operated simultaneously, start slowly, maintain a rapid speed during the middle phase, and control both mechanisms at the same time. As the load approaches its target, decelerate well in advance; do not allow it to reach the destination quickly and then stop abruptly. Otherwise, the load will swing violently, causing rapid wear on the wheels and rails, subjecting the drive mechanism to impact, shortening the crane’s service life, and increasing the risk of accidents.

16.  When lifting or lowering heavy loads, deceleration must begin well before reaching the designated speed. A rapid, abrupt stop can cause significant vibration and deformation of the vehicle body, shorten the service life of the wire rope, and even lead to deformation or damage of the workpiece—posing safety risks and increasing the likelihood of accidents.

17.  For bridge cranes equipped with main and auxiliary hooks, when switching between the two hooks, it is prohibited to use the hoisting limit switch as a means of stopping the hook; it is also forbidden to operate both hooks simultaneously once they have reached the same height; furthermore, it is strictly forbidden to move the trolley or carriage while the main and auxiliary hooks are lifting or lowering a load. Failure to comply with these precautions may result in the hook head striking the ground or the load becoming detached from the hook.

18.  The idle hook must be raised to its upper limit, and it is not permitted to carry any load.

With respect to external noises, remain vigilant in listening and conducting a thorough analysis and assessment. If the noise is attributable to mechanical or electrical components, evaluate its severity and, in conjunction with the equipment’s current operating condition, determine whether to stop the machine immediately or defer shutdown. After stopping, it is imperative to identify the root cause and address it promptly.

19.  When multiple workers are jointly rigging or hoisting an object, they must first confirm that each person has completed their task before responding to the signal from the rigger. If the rigging or hoisting method is deemed inadequate or potentially hazardous during operation, do not proceed with the lift and instead propose corrective measures. Furthermore, if ground personnel lack proficiency and repeated attempts to secure the load fail, patiently and proactively suggest improvements—never become impatient or frustrated—and under no circumstances raise or lower the load or start the equipment without receiving a clear signal.

20.  During operation, it is essential to ensure stability, precision, speed, and safety. By “stability,” we mean smooth starts and stops without jerks, with the hook remaining steady and free from swaying. “Precision” refers to the ability to lift loads smoothly, move them accurately, and position them precisely at the designated location. “Speed” means enabling multiple mechanisms to operate simultaneously. And “safety” entails operating the equipment responsibly, preventing any personal injury or equipment damage.

21.  It is prohibited to use a rapidly descending heavy object to strike other objects or to collide the vehicle body with adjacent vehicles.

22.  The distance between cranes on the same track shall be maintained at 1m That is all.

23.  Upon completion of the shift, raise the empty hook to its upper limit, move the trolley to the side of the operator’s cab, position the gantry crane at the ladder entrance, return the controller handle to the zero position, and disconnect the power supply. Then, clean and wipe down the equipment, inspect the external condition of all mechanisms, and finally complete the handover procedures.