Views: 0 Author: Site Editor Publish Time: 2025-10-16 Origin: Site
During the operation of the crane, equipment failure and load out-of-control are two common and sudden situations that occur frequently. If not handled properly, they can lead to safety accidents. The following explains the emergency handling procedures for these two situations to ensure that the operators can respond quickly and scientifically.
When abnormal sounds, jamming, or abnormal instrument readings occur in the crane, the emergency procedure must be initiated immediately. First, the operators should press the emergency stop button at the first opportunity to cut off the power supply of the equipment, preventing the expansion of the fault; at the same time, through walkie-talkies or hand signals, inform the surrounding personnel to evacuate to a safe area (at least 5 meters away from the equipment), and prohibit irrelevant personnel from approaching. Subsequently, professional maintenance personnel should arrive with detection tools. They should first conduct a preliminary inspection of the faulty area: if it is a hydraulic system leakage, the hydraulic valves should be closed to prevent further loss of oil, and the leakage area should be cleaned to prevent people from slipping; if it is an electrical fault, the main power supply should be disconnected, and the line connectors should be checked for looseness and whether the fuses are blown. Non-professional personnel are strictly prohibited from disassembling the electrical components. During the inspection process, warning signs (such as warning tapes and warning signs) should be set up around the equipment to clearly prohibit the operation area. If the fault can be repaired quickly on-site (such as replacing small parts or tightening loose bolts), after the repair, a no-load test run should be conducted to test whether the lifting, slewing, rotation, etc. actions are normal. After confirming there are no abnormalities, the operation can be resumed; if the fault is complex (such as main beam deformation, motor damage), it should be immediately contacted with the equipment manufacturer or professional maintenance team, and the fault situation should be reported to the on-site supervisor. After thorough repair and passing the safety inspection, it can be reactivated.
Uncontrolled load (such as sudden descent of the lifted object or excessive swinging) is a high-risk situation in crane operations, which should be handled with the core principle of 'controlling risks and preventing falls'. When an abnormal load is detected, the operator must remain calm, strictly prohibit pulling the control lever violently or applying emergency braking, and instead slowly adjust the controller to attempt moving the load to an open area with no personnel or obstacles (such as the edge of the site or an open space). If movement is not possible, the load height should be reduced as much as possible to minimize impact force upon potential fall.
If the load continues to descend (e.g., due to brake failure), the operator must immediately activate the backup braking system (such as electromagnetic brakes or manual braking devices) while shouting for personnel below to evacuate urgently to avoid injury from falling objects. If the load swings violently, the large or small car running direction can be slowly adjusted to gradually counteract the swinging inertia; rapid reverse operation to exacerbate swinging is strictly prohibited.
Once the uncontrolled load situation is under control, operations must be immediately stopped, and a comprehensive inspection of critical components of the crane, such as the braking system, steel wire ropes, and hooks, must be conducted to check for issues like component wear, breakage, or looseness. If damaged components are found, they must be replaced or repaired promptly, and operations can only resume after passing tests. If the load has already fallen, first confirm if there are any casualties on-site; if there are casualties, immediately initiate first aid procedures and call for rescue services. Additionally, protect the accident scene and report to relevant departments for accident investigation.
Regardless of whether the fault is quickly repaired on-site or not, the performance of the equipment must be verified through a no-load test run. This is a core step for subsequent handling. Before the test run, it is necessary to confirm that the repaired part has been tightened, replaced, or debugged (such as sealing the leakage point of the hydraulic system, reconnecting the electrical circuit connections), and that there are no obstacles or irrelevant personnel remaining around and have been evacuated to a safe area. During the test run, each core action of the crane needs to be tested one by one: first start the equipment and observe whether the instrument readings are normal (such as voltage and oil pressure values); then operate the lifting mechanism, raise the hook to the maximum height and slowly lower it to check if the braking is smooth and there is no jamming; then test the luffing mechanism and rotation mechanism, respectively, run to the maximum range on both sides and rotate 360 degrees, confirm that the running trajectory is smooth and there are no abnormal noises. If any problems are found during the test run (such as delayed braking, flashing of the instrument), stop the operation immediately, re-examine the cause of the fault, and continue to solve the problem until it is completely resolved.
If the fault is of a complex type that cannot be repaired on-site (such as main beam deformation, motor burnout, reducer gear damage), two key actions must be completed immediately: First, submit a written fault report to the on-site supervisor, detailing the time of the fault occurrence, phenomena (such as sudden tilting of the crane during operation, smoke coming from the motor), and the initial investigation results to avoid information omission; Second, contact the equipment manufacturer or a qualified professional maintenance team, providing the equipment model, factory serial number, and details of the fault, to facilitate the arrival of maintenance personnel with the appropriate accessories and specialized tools.
Before the professional maintenance team arrives, it is necessary to carry out on-site protection work: continue to maintain the warning signs around the equipment (such as warning tapes, "Equipment Fault, Do Not Operate" signs), and prohibit any personnel from attempting to start or disassemble the equipment; if the fault involves hydraulic or electrical systems, ensure that the main power supply and hydraulic valves are in a closed state to prevent accidental startup and potential hazards. During the maintenance process, arrange dedicated personnel to fully cooperate (such as providing equipment drawings, assisting in transporting components), and supervise the maintenance quality (such as checking whether the replaced motor is an original factory product, and whether the main beam correction size meets the standard).
After the maintenance is completed, the maintenance team is required to provide a "Maintenance Qualification Certificate", and conduct no-load test runs and load tests (testing at 50%, 80%, and 100% of the equipment's rated load) to confirm that all performance meets the standards. At the same time, the maintenance records (including the information of the maintenance personnel, the list of replaced components, and test data) should be archived in the equipment safety file, providing a reference for subsequent regular inspections.
After all fault handling is completed and the equipment resumes normal operation, the operation personnel and maintenance personnel should organize a safety review meeting. During the meeting, the causes of the faults need to be deeply analyzed: if it is due to equipment aging (such as the steel wire rope breaking beyond its service life), a plan for equipment renewal needs to be formulated; if it is due to improper operation (such as violating regulations and overloading resulting in overload and leakage of the hydraulic system), targeted operation training should be carried out; if it is due to the lack of daily maintenance (such as not checking the electrical circuits according to the schedule leading to short circuits), the "Equipment Daily Maintenance Checklist" needs to be improved, specifying the inspection frequency (such as checking the brakes before each operation, checking the hydraulic oil level weekly) and the person responsible.
At the same time, based on the type of fault, supplementary emergency response plans should be added: if this fault exposes a shortage of backup equipment (such as the failure of the backup braking system when the braking system fails), a list of backup components (such as backup brakes, hydraulic valves) needs to be added; if it is found that the operators are not familiar with certain fault handling procedures, emergency drills (at least once a quarter) should be strengthened to simulate different fault scenarios (such as electrical faults, hydraulic leakage), improving the personnel's response capabilities. Through the review and prevention measures, similar faults can be reduced at the source.
