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范围
本文件规定了随车起重机的设计、计算、检验以及安装在底盘或固定机座上的最低要求。
本文件适用于其发布一年后生产的所有新的随车起重机。不要求对现存随车起重机进行改造。本文件不适用于安装在船甲板上或浮动结构上的随车起重机﹐以及专门设计作为专用设备(带载行走设备)的整体部分的铵接臂式起重机。
本文件涉及与随车起重机相关的,载人危险之外的所有重大危险﹑危险状态或危险事件,但不包括制造商可预见的违规操作和误操作造成的相关危险。重大危险清单见附录A。
注:随车起重机用于载人时可执行专用的国家法规。
2规范性引用文件
下列文件中的内容通过文中的规范性引用而构成本文件必不可少的条款。其中,注日期的引用文件,仅该日期对应的版本适用于本文件;不注日期的引用文件,其最新版本(包括所有的修改单)适用于本文件。
GB/T 5226.32-2017 机械电气安全机械电气设备第32部分:起重机械技术条件(IEC 60204-32 :2008 ,IDT)
ISO3744声学声压法测定噪声源声功率级和声能量级反射面上方近似自由场的工程法(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图形 符号安全色和安全标志第1部分:安全标志和安全标记的设计原则
(Graphical symbols - Safety colours and safety signs - Part 1: Design principles for safety signs and
safety markings )
ISO 4302起重机风载 荷评估(Cranes - Wind load assessment)
ISO 4306-1起重机术语第1部分:通用术语(Cranes - Vocabulary - Part 1:General)
ISO 4310起重机试验 规范和程序(Cranes - Test code and procedures)
ISO 4413液压传动系 统通用原则(Hydraulic fluid power - General rules relating to systems)
ISO 5353 土方机械农业林业用拖拉机和机械司 机座椅标定点( Earth-moving machinery and tractors and machinery for agriculture and forestry- Seat index point)
ISO 7752-1起重机控制装置 布置形式和特性第 1部分:总则(Cranes-Control layout and characteristics- Part 1 :General principles)
ISO 8566-1起重机司机室和控制站第1部分:总则(Cranes- -Cabins and control stations - Part 1:General )
ISO 8566-2起重机司机室第2部分:流动式起重机(Cranes - Cabins - Part 2: Mobile cranes)
ISO 10245-1起重机限制器和指示器第1部分:总则(Cranes - Limiting and indicating devices - Part 1 :General)
3术语和定义
ISO 4306-1和ISO 12100界定的以及下列术语和定义适用于本文件。
3.1定义
3.1.1
随车起重机loader crane
通常安装在底盘上(包括拖车),由基座上方的转台和固定到转台顶端的臂架系统组成的动力驱动，用于货物装卸的起重机。
注1:ISO 3833;1999定义的商用车辆,主要用于运输货物,也可用于牵引拖车的机动车辆。安装在商用车辆上的随车起重机示例见ISO 4306-2:2012图9。
注2:安装在其他类型的底盘或固定基座上的起重机也认为是随车起重机。
注3:不同臂架系统的随车起重机的结构形式和安装示例见附录B。
[来源:ISO 4306-2:2012,5.2,来源定义不包含注3]
4安全及防护措施要求
随车起重机应符合本章中的安全及防护措施要求。此外,对于本文件未涉及的相关但非重大危险应按照ISO 12100的有关原则设计起重机。
4.1额定起重量计算
额定起重量应按下列内容计算:
a)液压油缸的工作压力﹔
b)液压油缸的承载面积;
c)运动学;
d)自重;
e)载荷组合;
f）起升载荷。
为了便于计算,额定起重量等于总起重量。
4.2结构计算
4.2.1计算中应提供的信息
计算中应提供以下信息:
a）起重机的类型和操作方法﹔
b)所有载荷或工作循环的设定值;
c）反应实际工作状态的承载系统信息﹐包括外形图和主要尺寸;
d)载荷设定条件,包括起重机最大倾角;
e)起升状态级别,起升机构工作级别和应力历程级别或应力历程参数﹔
f)部件与连接材料;
g)承载部件的形状、尺寸和静态横截面值;
h)分别对各结构部件和重要连接处进行分析。
4.3应力分析
宜按照ISO 20332评估钢结构的能力,也可采用与类似原则一致的其他先进、公认的标准。如标准中采用基于许用应力计算方法,则表3所示的分项安全系数(y ,)应作为整体安全系数使用,范围应在1～1.5。根据ISO 20332确定的疲劳工作级别,见附录О。
4.4随车起重机的布置
4.4.1支腿
当随车起重机安装在底盘上,需要满足稳定性要求时应提供支腿(见4.10.3)。
4.4.1.1垂直支腿
垂直支腿应有地面支撑装置(如:支脚盘)。支脚盘应可适应至少10°的地面倾斜度。应确保每个支脚盘产生的最大地面压力小于4 MPa。对于主支腿,应按式(5)计算最大地面压力(P):
4.5液压系统
4.5.1通则
液压系统及其元件应符合ISO 4413的规定。
液压元件和管路的通径应保证液压系统在设定的工作压力(包括试验压力)下操作时,不产生故障和过高温度。
液压系统中的所有液压元件应相互匹配,并与特殊环境下液压油相互匹配。液压系统应有过滤装置,确保液压油不受污染。
应有检查各液压回路压力的装置。
压力和流量控制装置或其附件应配备防篡改装置,防止未经授权修改压力或流量时可能造成危险。如果修改或调整可能产生危险﹐则应采取适当的方法锁定可调节部件或其附件的设置。
4.5.2泵
泵在规定的转速时应能满足随车起重机液压系统规定的流量和压力的要求。泵的规格和额定转速应与动力相匹配。
注:泵的规格选择见附录M。泵应能适应液压油要求。
4.6限制器和指示器
4.6.1通则
限制器和指示器应符合ISO 10245-1的要求。限制和指示系统中与安全有关的元件应符合ISO 13849-1的要求。
4.6.2额定起重量指示器
除原木起重机及废料回收起重机以外的所有随车起重机都应配备额定起重量指示器。
额定起重量指示器应能在起重量大于额定起重量的90%时,向操作员发出一种视觉或听觉报警信号,或同时发出这两种报警信号。如果超过额定起重量或者当额定起重量限制器(如配备)运行时,还应有单独的报警信号,向操作员和随车起重机周围人员发出过载警报。
接近额定起重量的报警信号和过载报警信号应有明显区别,能使相关人员辨别。两种信号都应是持续的。
工作幅度小于12 m时宜有过载报警信号,无线遥控除外。
4.6.3额定起重量限制器
配备动力驱动卷扬机构的所有起重机,以及额定起重量达到或超过1 000 kg,或起重量产生的最大净起重力矩达到或超过40 000 N·m的所有起重机都应配备额定起重量限制器。额定起重量应在臂架系统水平时的各个工作幅度下测定。
5安全及防护措施验证
5.1通则
应通过计算或试验的方法验证随车起重机的设计是否符合第4章中规定的安全要求。随车起重机制造商应在同型号批量产品的第一台起重机上进行机械强度的安全性验证。每台随车起重机在第一次使用前应按本文件的安全要求进行试验验证。
第4章中列出的安全要求应通过表4所述的方法和5.2中所述的试验程序进行验证。应采用制造商规定的起重量、起重机配置和方法校准限制器和指示器。
随车起重机在投入使用前应按第6章中的要求提供资料。
6使用信息
6.1通则
所有使用信息应符合ISO 12100的规定。
6.2说明书
6.2.1说明书的规定
随车起重机制造商应提供说明书,说明书应符合本条款规定的相关要求。
附录A（资料性)重大危险一览表
附录B(资料性）起重机的结构形式和安装示例
附录C(资料性)说明
附录D(资料性）超载时应防止的运动示例
附录E(规范性)无线遥控器和控制系统的附加要求
附录F(规范性)作业和设置功能的符号
附录G(资料性)垂直布置的地面操纵系统
附录H(资料性）水平布置的地面操纵系统
附录Ⅰ(资料性)高位座椅和遥控的操纵系统
附录J(规范性)起重力矩为250 kN·m及以下安装在底盘上的起重机操作室
附录K(资料性)高位操纵台示例
附录L(规范性)高位控制台扶手和把手、爬梯和台阶
附录M(资料性)随车起重机安装
附录N(规范性)噪声相关用户信息
附录О(资料性)应力历程参数(s)和应力历程级别(S)
附录NA(资料性)与规范性引用的国际文件有一致性对应关系的我国文件
参考文献
