1、BRITISH STANDARD BS ISO 12478-1:1997 Cranes Maintenance manual Part 1: General ICS 53.020.20BSISO12478-1:1997 This British Standard, having been prepared under the directionof the Engineering SectorBoard, was published underthe authority of the Standards Board and comes intoeffect on 15 July 1998 BS
2、I 05-1999 ISBN 0 580 30122 2 National foreword This British Standard reproduces verbatim ISO12478-1:1997 and implements it as the UK national standard. The UK participation in its preparation was entrusted by Technical Committee MHE/3, Cranes and derricks, to Subcommittee MHE/3/11, Crane safety and
3、testing, which has the responsibility to: aid enquirers to understand the text; present to the responsible international/European committee any enquiries on the interpretation, or proposals for change, and keep the UK interests informed; monitor related international and European developments and pr
4、omulgate them in the UK. A list of organizations represented on this subcommittee can be obtained on request to its secretary. Cross-references The British Standards which implement international or European publications referred to in this document may be found in the BSI Standards Catalogue under
5、the section entitled “International Standards Correspondence Index”, or by using the “Find” facility of the BSI Standards Electronic Catalogue. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct appl
6、ication. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, theISO title page, page ii, pages 1 to 5 and a back cover. This standard has been updated (see copyrig
7、ht date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Amendments issued since publication Amd. No. Date CommentsBSISO12478-1:1997 BSI 05-1999 i Contents Page National foreword Inside front cover Foreword ii 1 Scope 1 2 Normative r
8、eferences 1 3 Presentation of the manual 1 4 Maintenance 1 5 Lubrication and fluids 2 6 Safety during maintenance operations 2 Annex A (informative) Example of lubrication schedule 4 Annex B (informative) Examples of warning/safety signs 5 Annex C (informative) Bibliography 5 Table 1 2 Table 2 2 Tab
9、le 3 2ii blankBSISO12478:1997 ii BSI 05-1999 Foreword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each memb
10、er body interested in a subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Ele
11、ctrotechnical Commission (IEC) on all matters of electrotechnical standardization. Draft International Standards adopted by the technical committees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75% of the member bodies casting
12、 a vote. International Standard ISO12478-1 was prepared by Technical Committee ISO/TC96, Cranes, Subcommittee SC5, Use, operation and maintenance. ISO 12478 consists of the following parts under the general title Cranes Maintenance manual: Part 1: General; Part 2: Mobile cranes; Part 3: Tower cranes
13、; Part 4: Jib cranes; Part 5: Overhead travelling and portal bridge cranes. Annex A, Annex B andAnnex C of this part of ISO12478 are for information only. Descriptors: Handling equipment, lifting equipment, cranes (hoists), maintenance, handbooks, preparation, presentation, generalities.BSISO12478:1
14、997 BSI 05-1999 1 1 Scope This part of ISO12478 establishes guidelines on the general requirements necessary for the preparation and presentation of maintenance manuals for cranes. 2 Normative references The following standards contain provisions which, through reference in this text, constitute pro
15、visions of this part of ISO12478. At the time of publication, the editions indicated were valid. All standards are subject to revision, and parties to agreements based on this part of ISO12478 are encouraged to investigate the possibility of applying the most recent editions of the standards indicat
16、ed below. Members of IEC and ISO maintain registers of currently valid International Standards. ISO 31-0:1992, Quantities and units Part 0: General principles. ISO 4306-1:1990, Cranes Vocabulary Part 1: General. ISO 4306-2:1985, Lifting applicances Vocabulary Part 2: Mobile cranes. ISO 4306-3:1991,
17、Cranes Vocabulary Part 3: Tower cranes. ISO 9927-1:1994, Cranes Inspections Part 1: General. 3 Presentation of the manual 3.1 General A maintenance manual shall be provided by the crane manufacturer. This manual a) should be simple to understand and have adequate explanatory notes; b) shall incorpor
18、ate the use of internationally recognized symbols, if established; c) should be easy to use, compact and made of durable hardwearing material; d) shall be compiled in the language normally used by the manufacturer, unless a specific language has been agreed on between the parties to the contract. Th
19、e manual is a working tool which should be both convenient and complete. The text should be simple and adapted to the individuals who will use it, with all information being explicit and comprehensive. Illustrations, diagrams, graphs and tables should be used in preference to written text to avoid t
20、he risk of misunderstanding. They should be clear and simple, and be placed adjacent to any corresponding text. The terms (see ISO4306), definitions, units (see ISO31) and symbols shall comply with the relevant International Standards. When the units specified differ from those in common use, this s
21、hould be noted in the manual in brackets or by means of a footnote. Only those items relative to the particular crane and its application shall be included. 3.2 Preliminary information The following information shall be given on the front or back cover, or on the first pages of the manual: a) title
22、of the manual; b) reference number of the manual (if any); c) identification (designation, type, series, model, etc.) of the crane with which the manual is intended to be used; d) serial number or numbers of crane or, where appropriate, range of serial numbers covered; e) name and full address of th
23、e crane manufacturer and/or his agent; f) table of contents and/or index; g) basic characteristics of the crane. 3.3 Number of volumes The maintenance manual, with the other manuals particular to the crane in question, (for example drivers manual, users manual, etc.) may be published in one or more
24、volumes. The choice of the volume and grouping of the parts should be suitable for the type of product, its normal application and personnel requirements. Where appropriate, cross-reference to other volumes should be made so that the same information is not repeated unnecessarily. 4 Maintenance 4.1
25、General According to the level of maintenance dealt with in the manual, it may be necessary for a clear understanding of maintenance operations that such points as: description of the working principles of units working sequences of units test values to measure should be explained and that necessary
26、 schematics, charts (e.g.switching sequences) and check lists should be included.BSISO12478:1997 2 BSI 05-1999 Table 1 Table 2 Table 3 4.2 Preventive maintenance The maintenance operations and their frequency, together with an indication of the labour requirement, shall be grouped in a table, for wh
27、ich examples of typical column headings are shown inTable 1. The frequencies shall be established so that several operations can be performed at the same time, to facilitate maximum utilization of the crane and manpower. 4.3 Wear limit The wear limit of parts which are considered to be items which m
28、ay need replacing during maintenance shall be given in a table, with examples of column headings as suggested in Table 2. 4.4 Corrective maintenance The maintenance instructions shall be organized by sections with constituent illustrations relating to major assemblies and systems, and shall deal wit
29、h the following: a) troubleshooting procedures; b) sequential disassembly and assembly, including specification of relevant torques, preloads and other assembly hints; c) specification of parts and assemblies which require checking of wear, elongation and cracking, together with any discard criteria
30、 for e.g.brakes, clutches, chains, ropes, etc.; d) specification of necessary special tools and equipment; e) special requirements for the lifting and handling of crane components. 4.5 Test and inspection procedures The requirements given in ISO9927-1 shall apply. 5 Lubrication and fluids 5.1 Data c
31、oncerning lubricants and fluids The following information shall be included and should normally be located in an annex: a) specification of the lubricants, fluids etc. to be used. Their designation should be made in accordance with the relevant International Standard; b) tank and circuit capacities
32、(in litres); c) list of manufacturers recommended lubricant types and/or brands (where appropriate). An example of a typical table for lubricant specification is given inTable 3: 5.2 Lubrication schedule This schedule shall cover the crane lubrication requirements, indicating time intervals at which
33、 these are to be carried out. It shall include a diagram showing which parts require lubrication (a typical example is shown inAnnex A). 6 Safety during maintenance operations The following are typical examples of items which should be included for observation of safety precautions by the maintenanc
34、e, inspection and lubrication personnel: a) Regarding the site (provision of a safe work place): removal of the crane to a maintenance position area; fencing off the maintenance area; anticollision measures when several cranes are operating on the same tracks or site. b) Regarding the crane (prevent
35、ion of energizing/movement): use of a clearly defined permit-to-work system (see ISO 12480); Operation and location Part name/ nomenclature Estimated hours labour Interval 1 Interval 2 (Etc.) Designation Reference of part number Original size Wear size limit Reference of the control gauges Part (Mec
36、hanism) Capacity litres Ambient temperature C Recommended ISO classification Standard symbol or reference markBSISO12478:1997 BSI 05-1999 3 use of warning signs (examples are shown inAnnex B); disconnection and locking of power supply switch to prevent unauthorized reconnection; discharge, release o
37、r vent of stored energy (hydraulic, pneumatic or electric) prior to maintenance; checking of functions after disconnect to confirm all energy is removed; request assistance from the manufacturer for situations or conditions not included in the manual. c) Regarding the operation being performed: use
38、of safety ropes; use of working platforms where appropriate; observation of appropriate precautions when welding in area close to bearings and electronic circuits. d) Regarding the personnel: wear safety equipment (safety belt, helmet, eye protection, etc.); use support bracing or blocking where app
39、ropriate; specify authorized and qualified workers as required for applicable tasks; appropriate handling and disposal of hazardous materials.BSISO12478:1997 4 BSI 05-1999 Annex A (informative) Example of lubrication schedule Item Part Interval Type of lubricant A Hoisting machinery Oil B Trolley (c
40、rab) travelling mechanism Oil C Travelling mechanism . Oil D Trolley wheel . Grease E Travelling wheel . GreaseBSISO12478:1997 BSI 05-1999 5 Annex B (informative) Examples of warning/safety signs B.1 Example of safety sign with text B.2 Example of safety sign without text For example, to indicate “S
41、hut off engine and remove key before performing maintenance or repair work”. NOTEFor further information regarding safety signs, see ISO13200. Annex C (informative) Bibliography 1 ISO 12480-1, Cranes Safe use Part 1: General 1) . 2 ISO 13200:1995, Cranes Safety signs and hazard pictorials General pr
42、inciples. 1) To be published.BS ISO 12478-1:1997 BSI 389 Chiswick High Road London W4 4AL BSIBritishStandardsInstitution BSI is the independent national body responsible for preparing BritishStandards. It presents the UK view on standards in Europe and at the international level. It is incorporated
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