Please read this User Manual before installation and operation of this product

General Series Overhead Crane

User Manual

Product Code: A133900066MS(HSM01)

DALIAN HUARUI HEAVY INDUSTRY GROUP CO.,LTD.

July. 2017
 Special Equipment Manufacture License No.: TS2410E60-2013

Please read this User Manual before installation and operation of this product

General Series Overhead Crane

User Manual

Product Code: A133900066MS(HSM01)

DALIAN HUARUI HEAVY INDUSTRY GROUP CO.,LTD.

DALIAN HUARUI HEAVY INDUSTRY CRANE CO.,LTD.

July. 2017
 Foreword

Distinguished clients:

Thanks for choosing our products!

To ensure correct assembly, safe and fault-free operation of the overhead crane, please
read carefully this User Manual and pay special attention to safety rules and warnings
herein.

Please put this “User Manual” at place of easy access for timely checkup in case of
any doubt.
This User Manual is delivered to the equipment user and the copyright belongs to
DHHI Co., Ltd. Without our authorization or approval, technical specification,
drawings or sketches can’t be duplicated, distributed, used for competition or
provided to the third party completely or partially.
Please keep carefully the User Manual within the equipment’s lifespan.
This “User Manual” is suitable for overhead cranes in general series.

If you can’t find answers about your query in this manual, please contact us and we
are pleased to offer any help.
Our Company’s Correspondence
Address: No.29, Shunda Road, Lushunkou Economic and Technological
Development Zone, Dalian, Liaoning
PC: 116052
Website: http://www.dhidcw.com
Hotline: 0411-86852642 E-mail:fanyl@dhidcw.com
Client Service Center: 0411-86202423 Fax: 0411-86202424
E-mail:qzjgs@dhidcw.com
 Use and operation(Mechanical Part)

Table of Content

4.1 Qualifications of driver (operator)

4.2 Attentions and safety inspection before operation

4.3 Attentions and safety inspection during operation

4.4 Attentions and safety inspection after operation

4.5 Operation procedure of crane and electrical part

4.6 Shutdown procedure, method and attentions

 Use and operation
4.1 Qualifications of driver (operator).
4.1.1 The driver must have received proper training and passed the exam.
4.1.2 Be familiar with the structural and technical performance of each
mechanism of the crane.
4.1.3 Be familiar with “Hoisting Machinery Safety Procedure” and relevant
regulation.
4.1.4 Be familiar with attentions before, during and after operation as well as
safety and inspection requirements.
4.1.5 Be familiar with the performance and position of safety device.
4.1.6 Be familiar with basic knowledge of motors and electric aspects.
4.1.7 Be familiar with knowledge of routine service and basic maintenance.
4..18 Important Note: I don’t hurt myself, I don’t hurt others and I am not hurt
by others.
4.2 Attentions and safety inspection before operation

The brake shall be tested firstly before lifting load, whatever the weight is.
Lift firstly the load to about 0.5m above the ground, conduct the brake test
(ascending and descending). Lower down and brake to prove that the brake
works reliably and then ascend formally. Don’t operate the crane before proving
that the lifting mechanism’s brake is reliable.
After the initial static load test and change of the steel wire rope, check
immediately fixed rope clamp and wedge joint at the end of steel wire rope, start
immediately from the end of shrink ring, then tighten the rope clamp’s nut in
sequence.
4.2.1 Confirm firstly that the power supply and voltage is normal. Close the door
to each passage, check whether the limit switch is at the correct position,
determine whether the switch of electric device and control lever are at the
normal position.
4.2.2 Check whether the brake works normally.
4.2.4 Check whether two ends of steel wire rope are fixed normally.
4.2.4 Check whether fastening bolts of drum coupler is loose, whether the
clamping plate fixed at end of the steel wire rope on the drum is reliable.
4.2.5 When the hook is at the lowest working position, steel wire rope wound on
the drum shall be at least two turns except for turns fixing the rope end.
4.2.6 Fill grease into each lubrication point as specified.
4.2.7 Check if there is any loose object on the crane.
4.2.8 Check if there is any object that hinders the traveling on or near the track.
4.2.9 Start the crane, let it run once without a load at low speed, operate the
crane only after having confirmed that safety device works normally.
Refer to Table 4.1 for inspection methods
 Table 4.1 Safety inspection before operation
No. Inspection items Inspection method
1 Any obstacle within the working scope of the crane Visual inspection
2 Condition of the crane’s power supply system Visual inspection
3 Condition of the trolley’s power supply system Visual inspection
4 Position of steel wire rope of drum and pulley inside Visual inspection
the groove
5 Fixation and lubrication at end of steel wire rope Visual inspection
6 Brake disc and brake wheel Visual inspection, light knocking
7 Action of each brake Start
8 Instrument panels and indicators Start
9 Action of safety switch Start
10 Action of control lever and buttons Start
11 Recovery of last faulty position Action
4.3 Attentions and safety inspection during operation
Start and brake steadily, stop at the required position precisely, coordinate
the mechanism’s action, shorten the working cycle, no personal or equipment
accident
In case of any fault during the operation, notify the commander immediately
Stop the crane, shut down the power and inspect if any abnormal sound is heard
during operation, lower down the load slowly, notify the commander
In case of sudden power-off or abrupt drop of line voltage during operation,
reset every controller quickly, cut off the main switch, notify the commander,
don’t leave the position, give warnings of not passing through the dangerous area
Refuse to operate when it exceeds the rated load, refuse to operate when the
load isn’t clear
Refuse to work in dark workplace where the site, load and signals can’t be
seen clearly
Never adjust the lifting mechanism’s brake when there is load
4.3.1 Concentrated, don’t talk with other persons in the driver’s cab, don’t
smoke or eat.
4.3.2 Before startup, ring the bell or alarm. When approaching any person
during the operation, ring the bell or alarm.
4.3.3 Confirm whether each mechanism works normally before starting each
mechanism.
4.3.4 If there is people standing on the traveling route when each mechanism is
started, a warning signal must be issued.
4.3.5 Abide by instructions and signals, don’t start the crane when the situation
isn’t clear, stop the crane immediately when there is any stopping signal.
4.3.6 Never operate three or more mechanisms at the same time.
4.3.7 When lifting a load, the trolley and truck shall start and brake steadily.
4.3.8 As to the crane with double trolleys, when one trolley is used, the other
trolley must be moved to approaching the limit position.
4.3.9 When the main hook works independently, the auxiliary hook shall rise to
the position approaching the upper limit, but not touching the limit switch.
4.3.10 Don’t use the limit switch as the means of normal stopping, but the limit
switch shall be always kept at the correct and normal state.
4.3.11 Never stop the normal traveling by working on the emergency stop device.
4.3.12 Don’t open the switch cabinet and junction box before the power is cut off.
4.3.13 The mechanism can’t be kept at the low speed level for quite a long period.
It can be engaged to low speed level only under three working conditions: start,
brake and alignment. It shall work at high speed level under normal situations
other than above three conditions.

Never exceed the crane’s working capacity (rated lifting capacity)

Never use the emergency stop switch, limit switch of lifting and
traveling mechanism as the switch for normal stopping. The switch
on the console shall be operated for normal stopping.

Refer to Table 4.2 for the inspection method.

Table 4.2 Safety inspection during operation
No. Inspection items Inspection method
1 Abnormal odor, abnormal sound, abnormal heat or Smell, listen and touch
abnormal vibration (including winding, iron core,
collector ring)
2 Abnormal voltage or current Visual inspection
3 Abnormal changes of external environment Visual inspection
4.4 Attentions and safety inspection after operation
Clean and inspect each mechanism
Fill the operation record, carry out the shift formalities
4.4.1 Park the crane at the designated position.
4.4.2 Park the trolley at the cab’s end, approaching the limit position, lift the
empty hook to approaching the limit position.
4.4.3 Reset each control lever and each switch inside the control room to the
designated position.
4.4.4 To make sure that next start is implemented at the optimum state, confirm
sufficient power supply to each safety device.
Refer to Table 4.3 for the inspection method
Table 4.3 Safety inspection after operation
No. Inspection items Inspection method
1 The crane parks at the correct position Visual inspection
2 Oil leakage at each part, especially the speed Visual inspection
reducer and brake
3 Abnormal temperature rise of the shell of motor Touch
and speed reducer
 4 Whether the control lever and button are rese Visual inspection
5 Whether the power switch is open Action
6 Working record Reading
7 The driver’s cab is locked Observation
8 Cleanness of the crane (motor’s collector ring and Visual inspection
etc)
4.5 Refer to the Electrical Part for the crane’s operation procedure.
4.6 Shutdown procedure, method and attentions.
If the crane stops due to some reasons, follow steps as below:
4.6.1 Move the crane to the position that will not affect other cranes. If it can’t
meet above requirements due to certain constraints, reliable protective measures
shall be adopted or supervisors are designated.
4.6.2 Reset all control levers.
4.6.3 Cut off the main power supply, lock or hang signs. The signs shall be put at
places that could be easily seen.
If the mechanical or electrical equipment are changed without
permission, the changing party shall shoulder all responsibilities
arising hereof.
 Use and operation(Electric Part)

Table of Content

4.1 Preparation and inspection before use

4.2 Safety and safety protection during use, safety signs and instructions

4.3 Operation method and attentions

4.4 Monitoring and recording during operation

4.5 Shut-down procedure, method and attentions

 Use and operation

4.1 Preparation and inspection before use

4.1.1 General requirements

 The driver shall observe rigorously applicable rules in the Hoisting Machinery
Safety Procedure GB6067.1-2010.
 The driver shall understand the structure and performance of crane used, be
familiar with the working principle and maneuvering device and master the
function of safety device and correct operation method to ensure elaborate
maintenance and timely repair.
 If someone violates the crane’s safety procedure, the driver has the right to refuse
the lifting operation.
 The driver shall be familiar with commanding signals of the commanding worker
(gesture, whistle, clock sound) and work closely with the commanding worker.

4.1.2 Preparation and inspection before use.

 Check whether the worksite has temporary shutdown for maintenance
 Check whether each safety switch, each transmission mechanism and each
mechanism’s brake are intact and reliable.
 Check whether fastening bolts at each part are loose or not, whether there are
loose objects on the crane.
 Fill lubricant to each lubrication point as specified.
 Before power on, all handles must be turned to zero position and the door to each
passage shall be closed.

4.2 Safety and safety protection during use, safety signs and instructions
 The crane must be operated in strict observance to “Crane Safety Procedure”.
 Ring the bell for alarming before startup.
 Have trial run on each mechanism firstly under zero load and judge whether each
mechanism works normally. If the brake on the crane malfunctions or isn’t
adjusted properly, don’t operate the crane.
 When lifting the load for the first time at each shift or lifting a large load at other
times, it shall be lifted 0.2m above the ground and then lowered down. Check the
braking effect and put it into normal work after it meets the requirements.
 When the crane comes close to the crane at the same span or at a higher layer, a
distance more than 1.5m must be kept. When two cranes lift the same object, the
minimum distance between two cranes shall be kept above 0.3m, and the load on
each crane shall not exceed 80% of the rated load.
 The driver must observe strictly commanding signals of the crane. When signals
are not clear or the crane hasn’t left the dangerous area, don’t operate the crane.
 If the lifting method is inappropriate or there is possibly danger during lifting, the
driver shall refuse to carry out the lifting operation and put forward improvement
advice.
 As to the crane with main and auxiliary hooks, don’t use two hooks to lift two
loads at the same time. The non-working hook shall be lifted to the limit position
and the hook shall not be hung with auxiliary sling.
 When lifting a load, it must be lifted along the vertical direction. Don’t drag or
lift the load obliquely. Don’t ascend when the hook rotates.
 When it approaches the end of rail, the crane’s truck ad trolley shall be
decelerated and approach at a slow speed to avoid collision with the retainer
occasionally.
 The crane can’t collide with another crane.
 The load being lifted can’t stay in air for a long period. In case of sudden outage
or remarkable drop of line voltage, the controller’s handle shall be reset as
quickly as possible, cut off the main switch (or main contact) in the protective
cabinet and notify the crane. If the load is suspended in air for emergent reasons,
the driver and crane operator can’t leave their positions. Other site staff shall be
warned not to pass the dangerous area.
 When the lifting mechanism’s brake malfunctions suddenly, the operator shall
stay calm and put the controller to low-speed gear for slow-speed repeated
ascending and descending. Operate the truck and trolley at the same time and
lower down the load in a safe area.
 If the crane works continuously, each shift shall have 15~20min cleaning and
inspection period.
 Never have the sling (lifting electromagnet) and worker to handle materials in the
same coach or cargo hold at the same time.
 When the crane works, nobody shall stay on the crane, trolley or crane’s rail.
 The load being lifted shall move in the safe passage.
When traveling in unobstructed passage, the bottom of sling or load must be
more than 2m above the working plane.
When it needs to pass an obstacle on the traveling route, the bottom of sling or
load shall rise more than 0.5m above the obstacle.
 When the crane travel without a load, the hook must rise to the height higher than
one person.
 Never store inflammable and explosive substances (like kerosene, gasoline and
etc) on the crane
 Under normal conditions, don’t use the limit switch for parking purpose.
 Don’t open the switch and junction box before the power supply is cut off. Never
 use the emergency stop device to stop the normal operation.

4.3 Operation method and attentions

4.3.1 Operation method

 When each mechanism of the crane starts and approaches the crane at the same
span or other layers (above or below), and there is people in the traveling route of
the load, a warning signal (bell or other alarms) must be sent out.
 Must concentrate, don’t talk with others, don’t drink alcohol, don’t smoke
cigarette or eat food.
 Start each mechanism under idle load and judge whether each mechanism works
normally
 If the smelt steel tank is lifted for pouring out smelt steel, the tank must be lifted
about 0.5m above the ground. Move it up and down and test the brake. The
casting work is carried out only after having confirmed that the brake works
reliably.
 When pouring or blending smelt steel and after the tank hangs steadily on the
auxiliary hook, listen to instructions and tip over the tank steadily. Never operate
more than three mechanisms at the same time.
 When handling a tank full of smelt steel, the truck and trolley shall travel, start
and brake steadily.

4.3.2 Attentions
 When only an auxiliary trolley is used, the main trolley must approach the limit
position. When the main trolley works independently, the auxiliary hook needs to
approach the upper limit position. But don’t touch the limit switch.
 Never use the main and auxiliary hook to bring along the coach and smelt steel’s
tank truck.
 When lifting the steel ladle, the main lifting mechanism has two motors and one
motor malfunctions, it is only allowed to work for one cycle with a single motor
after the accident is properly handled when the maintenance staff gives
instructions to lower down the steel ladle.
 Every mechanism can’t work for a long period under low-speed gear. It is only
allowed to work under three working conditions: startup, braking and alignment.
At normal conditions beyond above three conditions, it shall operate at
high-speed gear.
 The crane’s controller shall be started by stages. Never put the control handle
from the positive direction to reverse direction directly, or from the reverse
direction to the positive direction directly to achieve stopping.
 It is allowed to set to the first reverse gear to achieve emergency stop only under
special conditions to prevent occurrence of accident.
 Must abide by commanding signals. Don’t operate the crane when signals are not
 clear or the commanding worker doesn’t leave the dangerous area. Don’t operate
the crane when the commanding worker doesn’t stare at the load being lifted.
 The driver observes only startup signals given by the commanding worker
appointed in advance, but must stop the crane when any one gives the stop signal.
 Due to influence of environment and other factors, when the stop signal issued by
anyone is different from the signal expected by the driver, the driver shall send
out an inquiry signal and operate the crane only after having confirmed that the
instruction signals agree with the instruction intentions.
 If you hear abnormal sound during operation, you shall stop the crane, switch off
the power and then inspect, the load being lifted shall be lowered down to the
ground steadily.
 When two workers operate one crane, the non-working driver could only enter or
leave the crane at the stop station.

4.4 Monitoring and recording during operation

Record and monitor problems and faulty state occurring and identified during the
operation; record and monitor abnormal sound; record abnormal operation

4.5 Shut-down procedure, method and attentions

4.5.1 Shut-down operation procedure

 Before the work is ended, move the crane to the parking spot specified, park the
trolley at the other side of the driver’s cab, lift the empty hook to the upper limit,
put each controller’s handle to zero position, the electromagnet or other slings are
lowered down to the ground or piles of materials. Tighten the lifting rope.
 After the crane’s work is ended, push the power-off button, the main contact is
released, the power supply indicator is off, pull out the key switch.
 Turn off the lighting or power supply of other auxiliary equipment in the driver’s
cab.
 Main cut-off breaker and light switch inside the electric room.

4.5.2 Attentions
 Sweep and wipe the lifting equipment, check the condition of each mechanism,
make necessary preparation for the next shift
 As to crane that works continuously, each shift shall have 15~20min cleaning and
inspection period.
 When cleaning the equipment, don’t stand on the main beam (except for that the
main beam and walkway are shared) and never walk from one main beam to
another main beam.
 Grease on the crane shall be removed timely to prevent slip and fall.
 Pass the handover record to the next shift’s driver, record problems occurring and
identified during operation and report to the next shift’s driver or relevant leader.
 As to crane working outdoors, the rail clamping device shall be put down or other
parking or anchorage methods are adopted to fasten the crane.