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People's Republic of China Construction Industry Standard JG5099-1998
Safety rules for aerial work machinery
Safety rules for aerial work machineryChina Construction Information Zone
1998-06-23 Issued
1998-12-01 Implementation
Ministry of Construction of the People's Republic of China
JG50981998
This standard refers to the structural safety factor, alarm device, design basis of the lifting mechanism, operation, manufacturer, seller, purchaser and operator's responsibility of the American standard ANSIA92551980 "Boom-type lifting work platform". This standard refers to the system protection, protection of workers, operation, control, etc. of the American standard ANSIA92.6-1979 "Self-propelled aerial work platform". Since 1978, aerial work machinery has developed rapidly and its application has spread across all walks of life, which has played a certain role in promoting social development. However, this equipment is a manned aerial work equipment, and there are many manufacturers. Due to the lack of corresponding standards and specifications, the safety awareness and production conditions of each manufacturer are not the same, and safety accidents occur from time to time. The purpose of this standard is to formulate unified regulations for design, production and use to ensure operational safety and prevent personal injury accidents. For this purpose, the "Safety Rules for Aerial Work Machinery" has been compiled to guide the design, manufacture and use of various products. This standard was proposed by the Standard and Quota Research Institute of the Ministry of Construction. This standard is under the jurisdiction of the Beijing Construction Machinery Comprehensive Research Institute, the technical unit responsible for mechanical equipment and vehicle standards of the Ministry of Construction. bzxz.net
The drafting units of this standard are: China Academy of Building Research Institute of Building Mechanization, Beijing Construction Machinery Factory, and Shanghai Baoshan Hydraulic Machinery Factory. The drafters of this standard are: Wang Zhenfeng, Liu Zijin, Bing Qizuo, Liu Qingbo, and Xu Yinhe. This standard is entrusted to the Institute of Building Mechanization of China Academy of Building Research for interpretation.
People's Republic of China Construction Industry Industry Standard Safety Rules for Aerial Work Machinery
Safety rules for aerial work machinery1Scope
JG5099—1998
This standard specifies the safety technical requirements for the design, manufacture, use, maintenance and management of aerial work machinery.
This standard applies to aerial work platforms and aerial work vehicles, and other aerial work machinery can also refer to it.
2Cited standards
The following clauses are included in the standard, which constitute the clauses of this standard through reference in this standard. When the standard is published, the versions shown are valid. All standards will be revised, and parties using this standard should explore the possibility of using the latest version of the following standards. GB3323-87 Radiography and quality classification of steel fusion welded butt joints GB3766-87 General technical conditions for hydraulic systems GB5972-86 Practical specification for inspection and scrapping of steel wire ropes for lifting machinery GB9465.2-88 Technical conditions for aerial work vehicles 3 Definitions
This standard adopts the following definitions.
3.1 Aerial work machinery aerial work machinery Approved by the Ministry of Construction of the People's Republic of China on June 23, 1998 and implemented on December 1, 1998
A general term for special engineering vehicles and equipment used to transport workers and equipment to a specified height for operation (including aerial work platforms and aerial work vehicles). 3.2 Leveling mechanism levelling mechanism A mechanism used to keep the platform in a horizontal state during the operation of the entire machine. 3.3 Stabilizer
A device used to keep the aerial work machinery stable does not have a leveling effect on the entire machine. 3.4 Limiting device limiting device
A device used to limit the working range of moving parts. 3.5 Auxiliary landing gear A spare device that can make the platform land to the starting position after the failure of the main power device, including spare moving gear, etc. 4 Structural design and manufacturing
4.1 Materials
Aerial work machinery shall be produced according to the materials specified in the drawings and shall have a material guarantee from the supplier. The materials used shall be subject to the factory inspection system. Materials that do not meet the requirements shall not be used in production. If substitute materials are used, their main technical performance shall not be lower than the original design requirements.
4.2 Connection
4.2.1 Welding
The welds of the main load-bearing components must be inspected for quality to ensure that the welds meet the design requirements.
4.2.1.2 The welds of the main load-bearing components shall meet the requirements of the intermediate provisions of GB3323. The outside of the welds is not allowed to have burn-through, glue edges, slag inclusions, weld nodules, etc. No cracks are allowed in the longitudinal and transverse directions of the weld and on the parent metal. The continuous weld cannot be interrupted. The corrugation should be uniform and the maximum height difference should not be greater than 2m. 4.21.3 Different connection methods shall not be used at the same connection point of the main load-bearing parts. 4.2.2 Rivet connection and bolt connection
4.2.2.1 Rivet connection and bolt connection shall comply with the requirements of the drawings. 4.2.2.2 Structures connected by high-strength bolts. The connection surface shall be cleaned of dust, paint, oil stains and rust. The connection bolts must be tightened according to the design technical requirements using a torque wrench or special tools.
4.3 Structural safety factor
4.3.1 The plastic material used for the load-bearing parts shall be calculated according to the yield strength of the material, and the structural safety factor shall not be less than 2.
4.3.2 The non-plastic material used for the load-bearing parts shall be calculated according to the tensile strength of the material, and the structural safety factor shall not be less than 5.
4.3.3 The design stress for determining the structural safety factor refers to the maximum stress value generated in the structural parts when the aerial work machinery is under rated load and in compliance with the operating procedures. The design stress should also take into account the influence of stress concentration and dynamic load. The structural safety factor is calculated according to formula (1):
n=（+）
Where: n total structural coefficient
—yield strength described in 4.3.1 or material tensile strength described in 4.3.2, MPa
stress generated by the structural mass, Ma:
stress generated by rated load, MPa;
stress concentration coefficient;
—dynamic load coefficient. The values of
and L can be determined by experimental stress analysis of the prototype, or taken as >1.10, f≥1.25.
4.4 Structural scrapping
4.4.1 The main structural parts shall be scrapped when the stress increases by more than 10% due to corrosion, wear and other reasons.
4.4.2 The main load-bearing components shall be scrapped when they are permanently deformed and cannot be repaired. 4.4.3 The main load-bearing components such as booms and legs shall not be repaired after the overall instability and must be scrapped.
4.4.4 If cracks occur in the structural parts and their welds, the causes shall be analyzed, and measures such as strengthening or re-welding may be taken to prevent the cracks from developing. They can only be used when they meet the original design requirements, otherwise they shall be scrapped.
5 Leveling mechanism
5.1 During the leveling process, it must be stable and reliable, and no vibration, impact, slipping, or jamming shall occur.
5.2 It must be ensured that the platform is in a horizontal state at any working position, and the angle between the platform surface and the horizontal plane shall not exceed 1.5°. 6 Chains and wire ropes
6.1 When a wire rope or chain bears a rated load, the safety factor of the wire rope or chain shall not be less than 8 according to the tensile strength.
6.2 The inspection and scrapping of wire ropes shall comply with the provisions of GB5972. 7 Platforms
7.1 The position of the safety belt must be set on the platform, and the work surface should be non-slip. 7.2 The insulation voltage and its detection cycle must be indicated on the platform for each insulation part. 7.3 For boom-type aerial work machinery with a height of more than 20m, anti-collision alarm and automatic stop devices should be installed in the front, lower and direction of the platform. 8 Hydraulic system
8.1 The hydraulic system shall comply with the relevant provisions of GB3766. 8.2 The hydraulic system shall be equipped with a device to prevent overload and impact. The set pressure of the safety relief valve shall not be greater than 110% of the rated working pressure of the system, and the rated working pressure of the system shall not be greater than the rated pressure of the hydraulic pump.
8.3 The hydraulic system should be equipped with a device to prevent the hydraulic cylinder and working mechanism from sliding down due to their own weight or from overspeeding and crashing due to pipeline rupture or leakage. 8.4 Hydraulically driven outriggers or stabilizers should be equipped with a device to prevent them from retracting when a hydraulic circuit fails.
8.5 The minimum rupture strength of all hydraulic system components (such as hoses, hard pipes, etc.) determined by rupture strength should not be less than 3 times the system design pressure. 8.6 For any aerial work machinery operated by hydraulic transmission, the system should be equipped with corresponding protection measures to prevent the aerial work machinery from losing control when the hydraulic system fails.
9 Electrical system
9.1 A main switch to cut off the source should be provided in the electrical system. 9.2 For any aerial work machinery controlled by electric transmission, corresponding protection measures should be provided in the system design to prevent the equipment from losing control when the power circuit fails. 10 Stability
10.1 Stability on the horizontal plane
The aerial work machinery is placed on a solid horizontal ground, and its stability should meet the following conditions:
a) The platform should be stable when the maximum specified lateral force is applied to any part of its periphery after the platform is lifted to the maximum height under the action of the rated load. b) The platform bears 1.5 times the rated load, and its center of gravity can be placed at any point within the periphery of the platform 300mm away from the periphery, and it should be stable at all positions within the working range. ) If the platform can be extended, it must be able to extend the platform to the limit position. When the extended part is subjected to 1.5 times the maximum load allowed by the part, its center of gravity can be placed at any point within 300mm of the periphery of the extended platform, and it should be stable at all positions within the working range. 10.2 Stability on inclined surfaces
10.2.1 Except for special requirements, aerial work machinery using outriggers is not allowed to be used on inclined surfaces. Special aerial work machinery used on inclined surfaces must also comply with the provisions of 10.2.3.
10.2.2 Aerial work platforms that do not use outriggers must comply with the provisions of 10.2.3. 10.2.3
When the aerial work platform is placed on an inclined surface at an angle of 3 to the horizontal plane, the whole machine is in the most prone to tipping state, and the platform should be stable when subjected to 1.33 times the rated load. 10.2.4 The use of outriggers or other stabilizing devices during work should be explained. 10.2.5 The stability requirements of aerial work vehicles on inclined surfaces should comply with the provisions of 4.4.2 in GB9465.2-88.
11 Insulation
11.1 For aerial work machinery with insulation, the insulation range and rated voltage of the insulator shall be clearly indicated in the manual and on the label, and the insulation test voltage and test cycle shall be indicated in the manual.
11.2 For aerial work machinery with insulation performance, each unit shall be tested for insulation performance before leaving the factory.
11.3 For boom-type aerial work machinery with a rated voltage of 63kV or above, a test electrode shall be provided and fixedly installed on the inner and outer surfaces of the upper arm insulation part, located 50 to 150mm from the lower metal part of the upper arm insulator. All hydraulic and pneumatic pipes connected to the upper arm insulation part shall be connected to each hose with a metal connector and located near the test electrode of the insulation arm.
The test electrode on the outer surface of the insulation of the telescopic boom aerial work machinery may be detachable. The position of the test electrode shall be fixedly marked for use during retesting. 11.4 For aerial work machinery with a rated voltage not exceeding 63kV, permanent electrodes are not required. In order to make the detection consistent for data comparison, the electrode position on the arm should remain the same for each test of the same aerial work machinery. The test voltage is 90kV, 50Hz, and the test is 3min. The current should not exceed 1mA. The detection voltage of aerial work machinery with a rated voltage below 35kV should be 50kV50H. It is required to test for 5min without breakdown, overheating or other insulation damage. 11.5 For boom-type aerial work machinery with a voltage exceeding 63kV, the detection voltage is twice the rated voltage, and it is required to be instantaneous without breakdown.
1.6 If the aerial work machinery is equipped with a lower insulator, its detection method is basically the same as the method for detecting the upper insulator. The effective value of its AC test voltage is 50kV, 50H, and it is required to test for 5min without breakdown, overheating or other insulation damage. 11.7 When the platform uses an insulating lining, the insulating lining should be placed in a conductive solution for inspection. The distance from the liquid level inside and outside the lining to the top of the lining should not be greater than 150mm. The effective value of the detection voltage is 50kV50Hz. It is required that there is no electric spark or lining wall breakdown within 1 minute.
11.8 Aerial work machinery with insulation performance requirements should be coated with insulating paint, and the hydraulic oil used should ensure insulation.
11.9 Aerial work machinery with insulation performance should be subject to periodic insulation performance testing.
12 Safety protection device
12.1 All moving parts that are unsafe for the human body should be equipped with protective devices. 12.2 A horizontal indicator device must be installed. The aerial work machinery can only work when the chassis is adjusted to a horizontal level.
12.3 Aerial work machinery should be equipped with an anti-rollover alarm device. When the angle between the chassis and the horizontal plane in any direction is greater than 3, the device will automatically alarm. 12.4 Except for manual aerial work platforms, aerial work machinery with outriggers, stabilizers and telescopic shafts shall have interlocking or locking devices for getting off and getting on. 12.5 The end positions of each action of aerial work machinery getting on shall be provided with limit devices. 12.6 Aerial work machinery shall be provided with emergency stop devices and placed in a position that is easily accessible to the operator. In the event of misoperation, the device can effectively cut off all power systems. 127 Auxiliary lowering devices shall be provided when the main power of aerial work machinery fails. 12.8 For platforms that are raised and lowered solely by lifting wire ropes or chain drives, the system shall have rope and chain breaking protection devices. 12.9 The maximum total weight of aerial work machinery shall not exceed the maximum total weight required by the selected chassis, and the maximum axle load shall comply with the maximum axle load specified for the chassis. 12.10 Aerial work machinery with an operating height of more than 20m shall be provided with overload protection devices.
13 Control system
13.1 Aerial work machinery with an operating height of more than 20m should be equipped with intercom equipment. 13.2 The control device of the aerial work machinery should be easy to operate, flexible, accurate and reliable, and should have signs or markings.
13.33 The operating direction of the control handle should be consistent with the functional movement direction of the control. When the control handle is released, it should automatically return to the "stop" position or the "interval" position, and cannot leave the position due to vibration or other reasons.
13.4 Except for the manual working platform, the aerial work platform with an operating height greater than 8m and the aerial work vehicle with an operating height greater than 16m should be equipped with an upper and lower set of control devices. The upper control device should be located on the platform to make it easy for the operator to operate and should prevent correct or erroneous operation. The lower control device should have the function of the upper control device and be able to override the upper control device so that it can be controlled on the ground in time when a fault occurs. 13.5 The operating force and stroke of the operating handle should meet the following requirements: a) The manual operating force is greater than 100N and the operating stroke is not greater than 400 mmb) The pedal operating force shall not exceed 200N, and the operating stroke shall not exceed 200mm. 14 Driver and operator
14.1 Before operation
14.1 Before using aerial work machinery, the operator must: a) undergo training and read the instruction manual and safety rules; b) be familiar with all diagrams and warnings marked on the aerial work machinery; ?) Check whether the hydraulic oil, fuel and electrical systems meet the requirements. 14.1.2 Before each shift change, the aerial work machinery should be checked for defects that may affect its use and operation. The inspection contents are as follows: a) Observe for cracked welds or other structural defects, leakage in the hydraulic system, damage to the control cable, looseness of the wire rope joints and damage to the tires; b) Operate each control system to Inspections should be carried out to ensure that various actions can be completed. All items should be carefully checked and a conclusion should be made as to whether they endanger safety. All factors endangering safety should be eliminated before use. 14.1.3 Before using aerial work machinery, check whether the workplace is dangerous. For example: trenches, steep slopes, caves, gravel, overhead obstacles, high-voltage wires, and other places that may cause danger.
14.2 During operation
14.2.1 Aerial work machinery can only be used in compliance with the manufacturer's instruction manual and safety rules.
14.2.2 During each work, the operator should a) check the overhead obstacles and high-voltage wires. According to current regulations and standards, the platform should always maintain a safe distance from live high-voltage wires. a) Work must be done on a solid and flat surface; b) The load and distribution on the platform must comply with the manufacturer's regulations; d) Use outriggers or stabilizers according to the manufacturer's instructions; e) All personnel on the platform must wear safety belts correctly. 14.2.3 For aerial work machinery that is allowed to operate in a waiting state, before and during driving, the operator should do the following: a) Keep an eye on the route and maintain a good field of vision, and ensure that the road surface is solid and flat. b) Keep a certain distance from obstacles.
14.2/4 Stunt driving or other fancy driving is not allowed. 14/2.5
During the work process, the personnel on the platform must always have a stable foothold.
14.2.6 During the operation, any fault or malfunction should be eliminated immediately before continued use.
14.2.7 It is prohibited to change, modify or abandon the safety device. 14.2.8 When the platform is rising, falling or moving, pay attention to prevent the wire rope, electric wire, hose, etc. from being entangled.
14.3 Other requirements
14.3.1 Fuel tank
a) It is not allowed to add fuel when the engine is running, and no measurement is allowed when adding fuel. b) It is not allowed to add hydraulic oil in the working state. 14.3.2 Battery charging
Battery charging can only be carried out in a turned on, well-ventilated environment without smoke or open flames.
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