1 Scope
This document specifies the minimum requirements for the design, calculation, inspection and installation of truck-mounted cranes on chassis or fixed chassis.
This document applies to all new truck-mounted cranes produced one year after its publication. No modifications to existing truck mounted cranes are required. This document does not apply to truck-mounted cranes mounted on the deck of a ship or on a floating structure, or to ammonium jib cranes specifically designed as an integral part of specialised equipment (travelling equipment with load).
This document covers all significant hazards, hazardous conditions or hazardous events associated with truck-mounted cranes other than manned hazards, but does not include hazards associated with irregularities and mishandling foreseeable by the manufacturer. The list of significant hazards is shown in Appendix A.
Note: Special national regulations may be applied when the truck-mounted crane is used to carry people.
2 Normative references
The contents of the following documents constitute essential provisions of this document through normative references in the text. Among them, note the date of the reference documents, only the date of the corresponding version applies to this document; not note the date of the reference documents, the latest version (including all the revision of the list) applies to this document.
GB/T 5226.32-2017 Electrical Safety of Machinery Electrical Equipment of Machinery Part 32: Technical Conditions of Hoisting Machinery (IEC 60204-32: 2008, IDT)
ISO3744 Acoustics - Determination of sound power levels and sound energy levels of noise sources using sound pressure - Engineering methods for an essentially free field over a reflecting plane
ISO 3864-1 Graphical Symbols - Safety Colors and Safety Signs - Part 1: Design Principles for Safety Signs and Safety Signs
(Graphical symbols - Safety colours and safety signs - Part 1: Design principles for safety signs and
safety markings )
ISO 4302 Crane - Wind load assessment
ISO 4306-1 Cranes - Vocabulary - Part 1: General
ISO 4310 Cranes - Test code and procedures
ISO 4413 Hydraulic fluid power - General rules relating to systems
ISO 5353 Earth moving machinery and tractors and machinery for agriculture and forestry - Seat index point
ISO 7752-1 Cranes Control Layout and Characteristics - Part 1: General principles
ISO 8566-1 Cranes Cabins and Control Stations - Part 1: General
ISO 8566-2 Crane Cab Part 2: Mobile Cranes
ISO 10245-1 Cranes - Limiting and indicating devices - Part 1: General
3 Terms and definitions
The terms defined in ISO 4306-1 and ISO 12100 and the following terms and definitions apply to this document.
3.1 Definitions
3.1.1
Truck-mounted crane loader crane
A crane, usually mounted on a chassis (including a trailer), which is powered by a turntable above the base and a boom system fixed to the top of the turntable, and which is used for the loading and unloading of goods.
Note 1: Commercial vehicles, as defined in ISO 3833;1999, are motor vehicles used primarily for the transport of goods and may also be used for towing trailers. An example of a truck-mounted crane mounted on a commercial vehicle is shown in ISO 4306-2:2012, Figure 9.
Note 2: Cranes mounted on other types of chassis or fixed bases are also considered to be truck-mounted cranes.
Note 3:Examples of construction forms and installation of truck-mounted cranes with different boom systems are shown in Appendix B.
[Source: ISO 4306-2:2012, 5.2, source definition does not include Note 3]
4 Safety and protective measures requirements
Truck-mounted cranes shall comply with the safety and protective measures requirements in this chapter. In addition, for relevant but non-significant hazards not covered by this document, the crane shall be designed in accordance with the relevant principles of ISO 12100.
4.1 Calculation of the rated lifting capacity
The rated lifting capacity shall be calculated in accordance with the following:
a) the working pressure of the hydraulic cylinder
b) the load area of the hydraulic cylinder;
c) kinematics;
d) self-weight;
e) load combination;
f) Lifting load.
For calculation purposes, the rated lifting capacity is equal to the total lifting capacity.
4.2 Structural calculations
4.2.1 Information to be provided in the calculation
The following information shall be provided in the calculation:
a) type of crane and method of operation
b) The set values for all loads or working cycles;
c) information on the load carrying system, including the outline drawing and main dimensions, reflecting the actual working conditions;
d) Load setting conditions, including maximum crane inclination;
e) hoisting condition levels, hoisting mechanism operating levels and stress history levels or stress history parameters; and
f) component and connection materials;
g) shape, dimensions and static cross-sectional values of the load-bearing components;
h) analysis of the structural components and important connections separately.
4.3 Stress analysis
It is appropriate to assess the capacity of steel structures in accordance with ISO 20332, but other advanced and recognised standards consistent with similar principles may also be used. If the standard is based on the permissible stress calculation method, the sub-factors of safety (y ,) shown in Table 3 shall be used as an overall safety factor in the range 1 to 1.5. The fatigue working levels determined in accordance with ISO 20332 are shown in Appendix OO.
4.4 Arrangement of the truck-mounted crane
4.4.1 Outriggers
When the truck-mounted crane is mounted on a chassis, outriggers shall be provided if stability requirements are to be met (see 4.10.3).
4.4.1.1 Vertical outriggers
Vertical outriggers shall be provided with ground support (e.g. footplate). The footplate should be able to accommodate a ground inclination of at least 10°. For the main legs, the maximum ground pressure (P) should be calculated according to equation (5):
4.5 Hydraulic systems
4.5.1 General rules
The hydraulic system and its components shall conform to the provisions of ISO 4413.
Hydraulic components and piping shall be of such a diameter that the hydraulic system operates at the set operating pressure (including test pressure) without failures and excessive temperatures.
All hydraulic components in the hydraulic system should be matched to each other and to the hydraulic oil in the particular environment. The hydraulic system should have a filtering device to ensure that the hydraulic oil is not contaminated.
There should be a device for checking the pressure in each hydraulic circuit.
Pressure and flow control devices or their accessories should be equipped with anti-tampering devices to prevent possible hazards in the event of unauthorised modifications to pressure or flow. If modifications or adjustments are likely to be dangerous, appropriate means shall be used to lock the settings of the adjustable components or their accessories.
4.5.2 Pumps
The pump shall be capable of meeting the flow and pressure requirements specified for the truck mounted crane hydraulic system at the specified speed. The pump specification and rated speed should be matched to the power.
Note:See Appendix M for pump specification selection.The pump shall be adaptable to the hydraulic oil requirements.
4.6 Limiters and indicators
4.6.1 General rules
Limiters and indicators shall conform to the requirements of ISO 10245-1. The safety-related components of the limiting and indicating system shall comply with the requirements of ISO 13849-1.
4.6.2 Rated lifting capacity indicators
All truck-mounted cranes, other than log cranes and scrap recycling cranes, shall be equipped with a rated lifting capacity indicator.
The rated weight indicator shall be capable of giving the operator a visual or audible warning signal, or both, if the lifting capacity is greater than 90% of the rated capacity. If the rated lifting capacity is exceeded or when the rated lifting capacity limiter (if fitted) is in operation, there shall be a separate alarm signal to warn the operator and persons in the vicinity of the crane of the overload.
The alarm signal for approaching the rated lifting capacity and the overload alarm signal should be clearly distinguishable for the persons concerned. Both signals should be continuous.
An overload alarm signal is desirable when the working range is less than 12 m, except for wireless remote control.
4.6.3 Rated lifting capacity limiter
All cranes with a power-driven winch mechanism and all cranes with a rated lifting capacity of 1 000 kg or more, or with a maximum net lifting moment of 40 000 N-m or more, shall be equipped with a rated lifting capacity limiter. The rated lifting capacity shall be determined at each working range with the boom system horizontal.
5 Verification of safety and protective measures
5.1 General rules
Compliance of the design of the lorry crane with the safety requirements specified in chapter 4 shall be verified by means of calculations or tests. The manufacturer of the truck-mounted crane shall verify the safety of the mechanical strength on the first crane of the same type of batch. Each truck-mounted crane shall be tested and verified in accordance with the safety requirements in this document before it is used for the first time.
The safety requirements listed in Chapter 4 shall be verified by the method described in Table 4 and the test procedure described in 5.2. Limiters and indicators shall be calibrated using the manufacturer's specified lifting capacity, crane configuration and method.
The crane shall be provided with the information required in chapter 6 before it is put into service.
6 Information for use
6.1 General rules
All information for use shall be in accordance with ISO 12100.
6.2 Instruction manuals
6.2.1 Provisions for instruction manuals
The manufacturer of the truck-mounted crane shall provide instructions which shall comply with the relevant requirements specified in this clause.
Appendix A (informative) list of significant hazards
Appendix B (informative) Examples of crane construction forms and installation
Appendix C (informative) Instructions
Appendix D (informative) Examples of movements to be prevented in case of overload
Appendix E (normative) Additional requirements for wireless remote controls and control systems
Appendix F (normative) Symbols for operating and setting functions
Appendix G (informative) Ground handling systems for vertical arrangements
Appendix H (Informative) Horizontally arranged ground handling system
Appendix I (Informative) Manoeuvring system for high seats and remote control
Appendix J (normative) Crane operating room with lifting moment of 250 kN-m and below mounted on the chassis
Appendix K (informative) Example of a high level console
Appendix L (prescriptive) Handrails and handles, climbing ladders and steps for high level consoles
Appendix M (Informative) Truck-mounted crane installation
Appendix N (normative) Noise related user information
Appendix О (informative) Stress history parameters (s) and stress history levels (S)
Appendix NA (informative) National documents with consistent correspondence to normatively referenced international documents
Bibliography
1 Scope
2 Normative references
3 Terms and definitions
4 Safety and protective measures requirements
5 Verification of safety and protective measures
6 Information for use
Appendix A (informative) list of significant hazards
Appendix B (informative) Examples of crane construction forms and installation
Appendix C (informative) Instructions
Appendix D (informative) Examples of movements to be prevented in case of overload
Appendix E (normative) Additional requirements for wireless remote controls and control systems
Appendix F (normative) Symbols for operating and setting functions
Appendix G (informative) Ground handling systems for vertical arrangements
Appendix H (Informative) Horizontally arranged ground handling system
Appendix I (Informative) Manoeuvring system for high seats and remote control
Appendix J (normative) Crane operating room with lifting moment of 250 kN-m and below mounted on the chassis
Appendix K (informative) Example of a high level console
Appendix L (prescriptive) Handrails and handles, climbing ladders and steps for high level consoles
Appendix M (Informative) Truck-mounted crane installation
Appendix N (normative) Noise related user information
Appendix O (informative) Stress history parameters (s) and stress history levels (S)
Appendix NA (informative) National documents with consistent correspondence to normatively referenced international documents
Bibliography
1范圍
本文件規定了隨車起重機的設計、計算、檢驗以及安裝在底盤或固定機座上的最低要求。
本文件適用于其發布一年后生產的所有新的隨車起重機。不要求對現存隨車起重機進行改造。本文件不適用于安裝在船甲板上或浮動結構上的隨車起重機﹐以及專門設計作為專用設備(帶載行走設備)的整體部分的銨接臂式起重機。
本文件涉及與隨車起重機相關的,載人危險之外的所有重大危險﹑危險狀態或危險事件,但不包括制造商可預見的違規操作和誤操作造成的相關危險。重大危險清單見附錄A。
注:隨車起重機用于載人時可執行專用的國家法規。
2規范性引用文件
下列文件中的內容通過文中的規范性引用而構成本文件必不可少的條款。其中,注日期的引用文件,僅該日期對應的版本適用于本文件;不注日期的引用文件,其最新版本(包括所有的修改單)適用于本文件。
GB/T 5226.32-2017 機械電氣安全機械電氣設備第32部分:起重機械技術條件(IEC 60204-32 :2008 ,IDT)
ISO3744聲學聲壓法測定噪聲源聲功率級和聲能量級反射面上方近似自由場的工程法(A-Coustics - Determination of sound powellevels and sound energy levels of noise sources using sound pressur- Engineering methods for an essentially free field over a reflecting plane)
ISO 3864-1圖形 符號安全色和安全標志第1部分:安全標志和安全標記的設計原則
(Graphical symbols - Safety colours and safety signs - Part 1: Design principles for safety signs and
safety markings )
ISO 4302起重機風載 荷評估(Cranes - Wind load assessment)
ISO 4306-1起重機術語第1部分:通用術語(Cranes - Vocabulary - Part 1:General)
ISO 4310起重機試驗 規范和程序(Cranes - Test code and procedures)
ISO 4413液壓傳動系 統通用原則(Hydraulic fluid power - General rules relating to systems)
ISO 5353 土方機械農業林業用拖拉機和機械司 機座椅標定點( Earth-moving machinery and tractors and machinery for agriculture and forestry- Seat index point)
ISO 7752-1起重機控制裝置 布置形式和特性第 1部分:總則(Cranes-Control layout and characteristics- Part 1 :General principles)
ISO 8566-1起重機司機室和控制站第1部分:總則(Cranes- -Cabins and control stations - Part 1:General )
ISO 8566-2起重機司機室第2部分:流動式起重機(Cranes - Cabins - Part 2: Mobile cranes)
ISO 10245-1起重機限制器和指示器第1部分:總則(Cranes - Limiting and indicating devices - Part 1 :General)
3術語和定義
ISO 4306-1和ISO 12100界定的以及下列術語和定義適用于本文件。
3.1定義
3.1.1
隨車起重機loader crane
通常安裝在底盤上(包括拖車),由基座上方的轉臺和固定到轉臺頂端的臂架系統組成的動力驅動，用于貨物裝卸的起重機。
注1:ISO 3833;1999定義的商用車輛,主要用于運輸貨物,也可用于牽引拖車的機動車輛。安裝在商用車輛上的隨車起重機示例見ISO 4306-2:2012圖9。
注2:安裝在其他類型的底盤或固定基座上的起重機也認為是隨車起重機。
注3:不同臂架系統的隨車起重機的結構形式和安裝示例見附錄B。
[來源:ISO 4306-2:2012,5.2,來源定義不包含注3]
4安全及防護措施要求
隨車起重機應符合本章中的安全及防護措施要求。此外,對于本文件未涉及的相關但非重大危險應按照ISO 12100的有關原則設計起重機。
4.1額定起重量計算
額定起重量應按下列內容計算:
a)液壓油缸的工作壓力﹔
b)液壓油缸的承載面積;
c)運動學;
d)自重;
e)載荷組合;
f）起升載荷。
為了便于計算,額定起重量等于總起重量。
4.2結構計算
4.2.1計算中應提供的信息
計算中應提供以下信息:
a）起重機的類型和操作方法﹔
b)所有載荷或工作循環的設定值;
c）反應實際工作狀態的承載系統信息﹐包括外形圖和主要尺寸;
d)載荷設定條件,包括起重機最大傾角;
e)起升狀態級別,起升機構工作級別和應力歷程級別或應力歷程參數﹔
f)部件與連接材料;
g)承載部件的形狀、尺寸和靜態橫截面值;
h)分別對各結構部件和重要連接處進行分析。
4.3應力分析
宜按照ISO 20332評估鋼結構的能力,也可采用與類似原則一致的其他先進、公認的標準。如標準中采用基于許用應力計算方法,則表3所示的分項安全系數(y ,)應作為整體安全系數使用,范圍應在1～1.5。根據ISO 20332確定的疲勞工作級別,見附錄О。
4.4隨車起重機的布置
4.4.1支腿
當隨車起重機安裝在底盤上,需要滿足穩定性要求時應提供支腿(見4.10.3)。
4.4.1.1垂直支腿
垂直支腿應有地面支撐裝置(如:支腳盤)。支腳盤應可適應至少10°的地面傾斜度。應確保每個支腳盤產生的最大地面壓力小于4 MPa。對于主支腿,應按式(5)計算最大地面壓力(P):
4.5液壓系統
4.5.1通則
液壓系統及其元件應符合ISO 4413的規定。
液壓元件和管路的通徑應保證液壓系統在設定的工作壓力(包括試驗壓力)下操作時,不產生故障和過高溫度。
液壓系統中的所有液壓元件應相互匹配,并與特殊環境下液壓油相互匹配。液壓系統應有過濾裝置,確保液壓油不受污染。
應有檢查各液壓回路壓力的裝置。
壓力和流量控制裝置或其附件應配備防篡改裝置,防止未經授權修改壓力或流量時可能造成危險。如果修改或調整可能產生危險﹐則應采取適當的方法鎖定可調節部件或其附件的設置。
4.5.2泵
泵在規定的轉速時應能滿足隨車起重機液壓系統規定的流量和壓力的要求。泵的規格和額定轉速應與動力相匹配。
注:泵的規格選擇見附錄M。泵應能適應液壓油要求。
4.6限制器和指示器
4.6.1通則
限制器和指示器應符合ISO 10245-1的要求。限制和指示系統中與安全有關的元件應符合ISO 13849-1的要求。
4.6.2額定起重量指示器
除原木起重機及廢料回收起重機以外的所有隨車起重機都應配備額定起重量指示器。
額定起重量指示器應能在起重量大于額定起重量的90%時,向操作員發出一種視覺或聽覺報警信號,或同時發出這兩種報警信號。如果超過額定起重量或者當額定起重量限制器(如配備)運行時,還應有單獨的報警信號,向操作員和隨車起重機周圍人員發出過載警報。
接近額定起重量的報警信號和過載報警信號應有明顯區別,能使相關人員辨別。兩種信號都應是持續的。
工作幅度小于12 m時宜有過載報警信號,無線遙控除外。
4.6.3額定起重量限制器
配備動力驅動卷揚機構的所有起重機,以及額定起重量達到或超過1 000 kg,或起重量產生的最大凈起重力矩達到或超過40 000 N·m的所有起重機都應配備額定起重量限制器。額定起重量應在臂架系統水平時的各個工作幅度下測定。
5安全及防護措施驗證
5.1通則
應通過計算或試驗的方法驗證隨車起重機的設計是否符合第4章中規定的安全要求。隨車起重機制造商應在同型號批量產品的第一臺起重機上進行機械強度的安全性驗證。每臺隨車起重機在第一次使用前應按本文件的安全要求進行試驗驗證。
第4章中列出的安全要求應通過表4所述的方法和5.2中所述的試驗程序進行驗證。應采用制造商規定的起重量、起重機配置和方法校準限制器和指示器。
隨車起重機在投入使用前應按第6章中的要求提供資料。
6使用信息
6.1通則
所有使用信息應符合ISO 12100的規定。
6.2說明書
6.2.1說明書的規定
隨車起重機制造商應提供說明書,說明書應符合本條款規定的相關要求。
附錄A（資料性)重大危險一覽表
附錄B(資料性）起重機的結構形式和安裝示例
附錄C(資料性)說明
附錄D(資料性）超載時應防止的運動示例
附錄E(規范性)無線遙控器和控制系統的附加要求
附錄F(規范性)作業和設置功能的符號
附錄G(資料性)垂直布置的地面操縱系統
附錄H(資料性）水平布置的地面操縱系統
附錄Ⅰ(資料性)高位座椅和遙控的操縱系統
附錄J(規范性)起重力矩為250 kN·m及以下安裝在底盤上的起重機操作室
附錄K(資料性)高位操縱臺示例
附錄L(規范性)高位控制臺扶手和把手、爬梯和臺階
附錄M(資料性)隨車起重機安裝
附錄N(規范性)噪聲相關用戶信息
附錄О(資料性)應力歷程參數(s)和應力歷程級別(S)
附錄NA(資料性)與規范性引用的國際文件有一致性對應關系的我國文件
參考文獻
