Electric overhead cranes are important lifting equipment widely used in industries such as industry and logistics. To ensure safe operation and extend their service life, strict precautions must be observed and regular maintenance performed. The following is a detailed guide:
I. Precautions
1. Pre-Operation Inspection
- Inspect the wire rope, hook, and pulley for wear, cracks, or deformation.
- Verify that the track is clear and that the limiters, brakes, and emergency stop buttons are functioning properly.
- Verify that the electrical system (such as cables and controllers) is free of exposed components or short-circuit risks.
2. Operating Specifications
- Overloading is strictly prohibited: The load must not exceed the rated lifting capacity (including the weight of the lifting equipment).
- Lift smoothly: Avoid sudden starts, sudden stops, or tilting the load to prevent swaying.
- Do not lift personnel or dangerous objects (such as flammable or explosive materials).
- Maintain full focus during operation and avoid distractions (such as making phone calls).
3. Environmental Requirements
- Avoid operating in inclement weather (such as strong winds, heavy rain, or lightning). - The operating environment temperature and humidity must meet the equipment's technical specifications (e.g., -20°C to 40°C).
4. Safety Distances
- Standing under the load is strictly prohibited, and the lifting path must be clear of personnel and equipment.
- When multiple cranes are working together, maintain a safe distance.
5. Abnormal Handling
- If any unusual noise, vibration, or control system malfunction occurs during operation, immediately shut down the machine and report it for repair.
- During a power outage, disconnect the power supply and manually release the brake with caution (for emergency purposes only).
II. Maintenance Items
1. Daily Maintenance
- Clean the equipment surface for oil and dust, and check fasteners (bolts and nuts) for looseness.
- Check the wire rope for lubrication and wear (number of broken wires ≤ standard value).
- Test the brake braking distance (no-load gliding distance ≤ rated value).
2. Monthly Maintenance
- Mechanical Section:
- Check wheel wear and the tightness of the track pressure plate bolts.
- Lubricate the pulleys, bearings, and gears (use specified grease, such as lithium-based grease).
- Electrical Section:
- Check the motor carbon brushes and contactor contacts for erosion.
- Test the sensitivity of the limit switches and overload protection devices.
3. Annual Overhaul
- Structural Inspection:
- Check the main beam deflection (≤ S/1000, where S is the span) and verify that the welds are free of cracks.
- Electrical System:
- Perform an insulation resistance test (≥ 1MΩ) and replace any aging cables.
- Functional Test:
- Tests at no load, rated load, dynamic load (1.1 times), and static load (1.25 times).
4. Key Component Replacement Cycles
Component: Replacement Standard/Cycle
Wire Rope: Wire breakage reaches 10% or diameter wear reaches 7%
Brake Friction Pad: Thickness <50% of original thickness
Gearbox Lubricant: Replace every 2000 hours or once a year
III. Records and Training
- Maintenance Records: Detailed records of all inspection results, troubleshooting, and component replacements.
- Personnel Training: Operators must be certified and regularly conduct safety drills (such as emergency shutdown procedures).
Proper use and scientific maintenance can significantly reduce equipment failure rates and ensure safe production. It is recommended to refer to the national standard "GB/T 14405-2011 General-Purpose Bridge Cranes" for specific operations.
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