Some standard content:
Machinery Industry Standard of the People's Republic of China
Large Crawler Crane
Technical Conditions
Subject Content and Scope of Application
JB 5318—91
This standard recommends that Technical requirements, test methods, inspection rules and markings, packaging, transportation and storage of large crawler cranes. This standard applies to hydraulic crawler cranes (hereinafter referred to as cranes) with a maximum lifting capacity of 140 to 300t and powered by an internal combustion engine. The crane working levels are A1~~A3, and the mechanism working levels are: lifting and luffing mechanism M3; Rotary mechanism M2; running mechanism M1. Cranes with a maximum lifting capacity greater than 300t can also refer to the implementation. 2 Reference standards
GB1348 ductile iron castings
GB1497
Basic standards for low-voltage electrical appliances
GB2512
GB3766
GB3811
GB6067
Group, naming and code of hydraulic oil products General technical conditions for hydraulic systems
Crane design specifications
Safety regulations for lifting machinery
GB 6068. 3|| tt||GB8918
GB8923
GB 9286
GB10051
GB 10095
Determination of stability
Truck crane and tire crane test Standardize high-quality steel wire rope
Cross-hatch test of steel surface corrosion grade and rust removal grade paint and varnish film before painting
Lifting hook
Involute cinnamon gear accuracy
JB2299 Paint colors and safety signs for mining, engineering, lifting and transportation machinery products JB/ZQ4000.3 General technical requirements for welding parts JB/ZQ4286 General technical conditions for packaging
3 Technical requirements ||tt| |3.1 Basic requirements
3.1.1 The mechanical and electrical design of the crane should comply with the regulations of GB3811, and the design, manufacture and installation of the hydraulic system should comply with the regulations of GB3766.
3.1.2 Crane products should comply with the requirements of this standard and be manufactured according to drawings and technical documents approved through prescribed procedures. 3.2 Environmental conditions
3.2.1 The working environment temperature is -20~~+40C. The relative humidity is generally not greater than 85%, and is allowed to reach 100% in a short period of time. 3.2.2 The maximum working wind pressure is not greater than 60Pa (wind speed 9.8m/s). Maximum non-working wind pressure: not greater than 270Pa (wind speed 21m/s) when only the main arm is installed; not greater than 135Pa (wind speed 15m/s) when the auxiliary arm is installed.
Ministry of Mechanical and Electronics Industry of the People's Republic of China 1991- 07-01 Approval 902
1992-07-01 Implementation
JB 5318—91
When the wind pressure (wind speed) is greater than the above, the work should be stopped or the boom should be lowered. 3.2.3 The working ground should be solid and flat, and the ground inclination should not be greater than 5/1000. 3.3 Usage performance
3.3.1 Under the premise of meeting the environmental conditions, the crane should be able to operate at various arm lengths and different radius Lift the corresponding rated load at a certain temperature and rotate 360° with the load. When only the main boom is used, it should also be able to operate with rated load. At this time, the boom should be located directly in front of the vehicle. 3.3.2 The tension of the crawler tracks should be adjustable, and the spacing of the crawler racks should generally be wide or narrow. 3.3.3 The climbing ability of the basic crane when no-load is not less than 20%. 3.3.4 The crane should be able to pass the dynamic load test, static load test and stability test. 3.3.5 The crane should be equipped with a main arm and a auxiliary arm. The main and auxiliary arms should adopt a truss structure of seamless steel pipes and be manufactured in sections. Connect with pins. When working, the luffing range of the main arm is not less than 50°, and the luffing range of the luffing arm is not less than 55°. 3.3.6 Mechanisms such as lifting, luffing, rotation, and operation are all hydraulically driven and should be able to start from scratch without any problem. Level speed regulation. The relative error of the maximum speed of each mechanism is less than 5%.
3.3.7 Any two of the lifting, luffing and slewing mechanisms should be able to work at the same time. 3.3.8 The hoisting, luffing and slewing mechanisms should be equipped with normally closed brakes. The slewing mechanism should also be equipped with a foot brake device and a mechanical brake release device to ensure free rotation of the crane during parking. 3.3.9 The fuel consumption rate of the diesel engine should not exceed 245g/(kWh), and a low-temperature starting device should be installed when working in low-temperature areas. 3.3.10 The hydraulic system should be able to safely stop the action of the corresponding mechanism when the hydraulic components or pipelines are damaged. The filtration precision of the main filter of the hydraulic system is 10~40μm, and the oil temperature in the tank does not exceed 80C. 3.4 Main components and materials
3.4.1 Rolling bearing-type slewing bearings should be used between the upper and lower vehicles, and high-strength bolts should be used for connection. 3.4.2 Lifting hooks should comply with the regulations of GB10051. 3.4.3 The lifting mechanism should use non-rotating wire ropes that comply with GB8918 or other wire ropes with equivalent performance. The method and strength of the fixed connection at the ends of the wire ropes should comply with the regulations of GB6067. 3.4.4 Except for the hook pulley, the remaining wire rope pulleys should be cast nylon pulleys. The main properties of cast nylon should comply with the provisions of Appendix A (Supplement).
3.4.5 Various DC low-voltage electrical appliances should comply with the regulations of GB1497, and the accuracy of various instruments should not be less than level 1.5. Outdoor electrical protection should comply with electrical protection grade IP55.
3.4.6 The viscosity of lubricating oil and hydraulic oil should be compatible with the working environment temperature, and the use of mixed oil is not allowed. The hydraulic oil should comply with the N32~~N68 anti-wear hydraulic oil specified in GB2512.
3.4.7 The purchased steel shall comply with the professional industry standards or national standards for materials, and shall have a formal inspection certificate. 3.4.8 The yield strength of the main arm chord material should not be less than 690MPa, and the impact energy of the ISO~-V-notch sample at -20C should not be less than 50J; the yield strength of the jib chord material should not be less than 460MPa. The impact energy of ISO-V-notch specimen at -20C should not be less than 39J.
3.4.9 The rotary sleeve of the rotary joint should be made of ductile iron with mechanical properties not lower than QT400--181 in GB1348. 3.4.10 The rollers are made of alloy steel. The fire hardness of the tread should reach 47~53HRC, and the hardness at a depth of 8mm should reach 40~50HRC.
3.4.11 The track shoes should be made of alloy steel. The service strength of the material should be no less than 637MPa, the elongation should not be less than 12% or the normal temperature impact value should not be less than 25J/cm2, and the elongation should not be less than 9%. 3.5 Assembly and manufacturing accuracy
3.5.1 All mechanisms should operate smoothly and flexibly, without overheating or abnormal noise. 3.5.2 The steel wire rope is wound in multiple layers on the drum, and the deflection angle to the transverse vertical plane of the drum is not greater than 2°, and the wire rope is wound neatly. 3.5.3 The rotary joint should be subjected to a 40MPa pressure test before assembly + there should be no leakage during the test; after the test, the rotary sleeve should be inspected and there should be no cracks.
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JB5318—91
3.5.4 After assembly, the local gap between the slewing bearing and the upper and lower joint surfaces should not be greater than 0.1mm. 3.5.5 The longitudinal symmetrical center lines of the track frame supporting wheels, driving wheels and driven wheels should be in the same vertical plane, and the deviation should not be greater than 2mm. 3.5.6 Each middle arm section of the boom should be interchangeable
3.5.7 The straightness tolerance of the main chord tube of the boom section should comply with the requirements in Table 1, and the straightness tolerance of the boom section web tube per meter should not exceed Greater than 1.5mm.
Table 1
Arm section
Length
Local straightness tolerance
Full length straightness tolerance
3000| |tt||3
>3000~-6 000
Length per meter is 2
4
3.5.8 The middle part of the longest main arm and the longest jib The free deflection value should not be greater than 12/1000 of the boom length. >6000
6
mm
3.5.9 The straightness tolerance of the longest main arm and the longest jib, in the plane of the upper and lower trusses and side trusses, should not be greater than 1/1000 of the arm length. 3.5.10 For the pin hole of the main arm installed on the vehicle, the parallelism tolerance of its center line to the bottom plane of the upper frame should not be greater than 0.5mm, and the verticality tolerance to the longitudinal center line of the upper frame .0.4mm per meter of measured length. 3.5.11 The parallelism tolerance of the center line between the connecting holes between the top arm section of the main arm, the middle arm section (or transition section) of the main arm, and the base arm section of the jib should not be greater than 1.5mm. The verticality tolerance of the longitudinal centerline of the arm section should not be greater than 1.5mm. 3.5.12 The parallelism tolerance of the center line connecting the connection holes between the main arm base arm section, the upper frame and the middle arm section should not be greater than 1.5mm + The verticality tolerance of this center line to the longitudinal centerline of the main boom foundation boom section should not be greater than 1.5mm. 3.5.13 The parallelism tolerance of the center line between the connecting holes of the jib base arm section, the main arm top arm section and the jib middle arm section should not be greater than 1.5mm. The center line should be aligned with the longitudinal center of the jib base arm section. The verticality tolerance of the line should not be greater than 1.5mm. 3.5,14 The quality of the load-bearing welds of the upper frame, bottom frame, track frame, A-frame, upper and lower luffing brackets, booms and other main components should not be lower than BS and BK specified in JB/ZQ1000.3. The unnoted dimensional tolerances, angular differences and geometric tolerances of welded structural parts should comply with the requirements of precision grades B and F in JB/ZQ4000.3. 3.5.15 Before assembly, various hydraulic components must be tested on a bench (those with certificates are exempted from the test), and the safety valve should be pre-adjusted on the test bench.
3.5.16 The gear accuracy of the reducer should not be lower than level 7 specified in GB10095. 3.6 Safety and health
3.6.1 The crane should be equipped with a lifting height limiter and a jib luffing limiter. The upper limit of the jib luffing should be equipped with double limiters. All limiters should be accurate and have flexible and reliable movements. The angle limit error is ±1°. 3.6.2 The crane should be equipped with a lifting moment limiter, which should work reliably and be installed in a location convenient for observation and inspection. The comprehensive error of the lifting moment limiter should not be greater than 10%. The comprehensive error is calculated according to the following formula: Comprehensive error = measured lifting force short minus rated lifting force short × 100% rated lifting moment
When the actual lifting moment reaches 90% of the rated lifting moment, there should be an early warning indication , the setting moment of the overload limit point should be determined to ensure that the actual lifting moment of the crane is not less than the rated lifting moment, nor greater than 110% of the rated lifting moment. 3.6.3 The crane should be equipped with an anemometer on the top of the main boom, and an anemometer or wind speed alarm should be installed in the cab. 3.6.4 The main and auxiliary arms should be equipped with back-turning devices, which are used to reverse the arm before the boom reaches the maximum working elevation angle. The frame applies pre-thrust, and the item dies when it reaches the maximum working elevation angle
3.6.5 A level should be installed in the driver's room.
3.6.6 The driver's cab should have good vision and comfortable operating conditions. The illumination of the instrument panel, operating table or operating parts should not be less than 31x. There should be cold protection and cooling devices indoors, and the indoor temperature is generally 15 ~30C. 3.6.7 The doors and windows of the driver's cab should be made of tempered glass, the front window should be equipped with wipers and sun visors, and the interior should be equipped with a curve sign or performance table of the crane's lifting capacity.
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JB 5318—91
3.6.8 When the engine is running at rated speed, the noise in the cab should not be greater than 85dB (A), and the sound power level of the crane's radiated noise should be Comply with the requirements of Table 2.
Table 2
Engine power/kw
Sound power level/dB(A)
>160～200
120
3.6 .9 The crane should be equipped with lighting fixtures for night operations. 3.6.10 The spreader and counterweight should be painted with safety signs in accordance with the provisions of JB2299. 3.7 Appearance and painting
>200～250
122
>250~350
125
3.7.1 The crane should have beautiful appearance and neat edges , no obvious bulges, depressions and roughness. The paint should be smooth and even, with no paint leakage, peeling, peeling and different colors. There should be no flow marks or bubbles on the main large surfaces. The paint film should be tough. The thickness of each paint film should be 25~35μm, and the total paint film thickness should be 100~150μm. , the paint film adhesion should meet the first-level quality requirements in GB9286. 3.7.2 The surface pretreatment of the steel materials of the crawler frame, underframe, upper frame, A-frame, boom, and upper and lower luffing brackets should reach Sa21/2 level specified in GB8923, and the surface pretreatment of the other steel materials should reach St2 level 3.7 .3 The crane’s trademark and nameplate should be beautiful and eye-catching. 3.8 Complete sets
3.8.1
Complete supply scope:
a.
b.
c.
3.8.2| |tt||a.
b.
c.
d.
e.
f.
As specified in the order contract product part;
random spare parts;
random tools and accessories.
Random documents:
Product inspection certificate;
Installation drawings;
Operating instructions:
Maintenance instructions;
Spare parts catalog;
packing list.
4 Test Methods
4.1
General Requirements
4.1.1 Testing instruments and measuring tools should be calibrated before they can be used. The accuracy of the instruments and measuring tools should be the same as that of the ones being tested. Parts are suitable. 4.1.2 For testing items not specified in this chapter, general testing instruments should be used and tested according to general testing methods. 4.2 Inspection and testing of components
4.2.1 The position tolerances of the longitudinal symmetrical center lines of the track frame supporting wheels, driving wheels and driven wheels are shown in Figure 1, passing through the center points of the treads of the driving wheels and driven wheels. A and B pull a 0.49-0.52mm steel wire as the baseline, and the pulling force is 147V. Measure the offset of the longitudinal symmetrical center line of each supporting wheel to the steel wire, and its value should comply with the requirements of Article 3.5.5. Cong Dongyan
Zhongzhongyan
Picture 1
LA
Driving wheel
Steel wire
905
4.2. 2 boom section chord straightness
JB5318-91
From all the boom sections of each crane, randomly select 2 sections for inspection. a. Local straightness of the chord
As shown in Figure 2, use a 1m ruler close to the arm section chord in two directions that are 90° to each other. The maximum gap and the minimum gap between the ruler and the tube wall are The difference should be no more than 2 mm.
String
Ruler
Full length straightness of the string
b.
Figure 2
Ruler||tt| |As shown in Figure 3, pull a 0.49~0.52mm steel wire along the length of the string tube 30mm away from the end of the string tube, with a pulling force of 147N. Measure the horizontal distance from the steel wire to the chord, and the difference between the maximum value and the minimum value shall comply with the requirements of Article 3.5.7. Turn the boom 90° and repeat the above inspection on the same chord. $?
4.2.3 Interchangeability of intermediate boom sections
Figure 3
After the welding of the boom is completed, the interchange connection inspection is carried out. All intermediate boom sections should be interchangeable. . 4.2.4 Straightness and free deflection of the boom
a.
Chord
Steel wire
Assemble the longest main and auxiliary arms respectively, and lay them flat on the On a flat ground, find the center of each arm joint connection point on the upper plane truss of the boom + 200mm away from the center points of both ends of the boom, and pull a 90.8~1.2mm steel wire against the flat truss along the entire length of the boom. As a baseline, the pulling force is 295 to 490N. Measure the horizontal distance from each center point to the steel wire, and record the difference between the maximum value and the minimum value. The measurement method is shown in Figure 4.
Turn the arm 90° and repeat the above measurement. The two differences obtained by the above measurements are the straightness of the boom along the entire length, both of which should meet the requirements of Article 3.5.9 b. According to the actual installation position, support the two ends of the main arm and the auxiliary arm with brackets. Make the two ends of the arm on the same horizontal line, and use a level to measure the degree of the middle part of the arm in the free state. The value should meet the requirements of Article 3.5.8. Midpoint of the center line of the connection
Figure 4
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4.2.5 Paint film thickness and adhesion
JB 5318—91
on the arm Select any 10 places on the frame, and select a total of 10 places on the upper car, bottom frame, and track frame, and measure the paint film thickness with a paint film thickness measuring instrument. The average thickness of each 10 places should be 100 to 150m, and the thickness of each place The value should be no less than 70μm. The adhesion of the paint film in the above-mentioned places shall be tested according to the provisions of GB9286. Use the cross-cutting method to test. When crossing, the force should be even. After crossing, use a soft brush to brush gently in the diagonal direction, 3 times in forward and reverse directions. Then check the peeling area of ??the paint layer. More than 8 out of every 10 areas should meet the intermediate quality requirements of GB9286.
4.3 Complete machine test
4.3.1—General requirements
The test should comply with the relevant provisions of the product manual. Adjust the track frame distance to the maximum. Dynamic load test, static load test and lifting moment limiter test should be carried out before leaving the factory. If there are objective difficulties in manufacturing the arm, retesting at the user's construction site is allowed, but at least two arm length tests (main arm, main arm and ten auxiliary arms) should be conducted at the manufacturer. The test of climbing ability should generally be conducted at the manufacturer. If the manufacturer does not have the conditions, it can also be verified during use by the user. 4.3.2 Test conditions
The whole machine test should be conducted on a solid, flat ground with an inclination of no more than 5/1000, and the working environment temperature is -20 to +40C. The mass error of the test weight is ±1%.
4.3.3 Test arm length
a. The longest main boom at maximum lifting capacity;
b. The longest main arm;
c. The combination of the longest main boom and the shortest jib at maximum lifting capacity; d. The longest main and jib combination that can be moved by itself; e. Any of the above boom lengths, but under this boom length, it should be satisfied that the boom amplitude is larger, smaller and intermediate. The corresponding rated lifting capacity is determined by the overall stability of the crane. 4.3.4 General inspection
Inspect the appearance, paint surface quality, completeness and correctness of assembly of the complete machine, which should comply with the requirements of this standard and product manufacturing drawings.
4.3.5 No-load test
4.3.5.1 The no-load test can be conducted crosswise with the dynamic load test and static load test. The performance of the limit switch should be checked before raising the arm. The wind speed during the test shall not be greater than the maximum operating wind speed allowed by the product. 4.3.5.2 According to the operating procedures, start the engine and run idling for 20 minutes, and then carry out the entire lifting and lowering of the main and auxiliary hooks (braking once in the air), and the luffing of the main and auxiliary arms throughout the entire process (braking once in the middle). , get in the car and brake once each for a 360° left turn and right turn), move forward, backward, turn left, turn right and turn on the spot, each action should be performed no less than 3 times. The test results should meet the following requirements: a. The engine runs smoothly, the test instruments are normal, the instruments and signals are normal, and the speed adjustment range meets the requirements; b. The hydraulic system works normally and there should be no dripping; the operating system is flexible and easy to use, and the instrument signals display normal; c
d. Each mechanism operates smoothly and flexibly, and can adjust the speed steplessly from zero; e. All limiters can limit the position at the specified position, the action is flexible and reliable, and the angle limit error is 1°; f. The swivel joint operates normally.
4.3.5.3 When the main boom reaches the maximum elevation angle, the anti-rollover device should be able to push the main boom to death. 4.3.5.4 Short-circuit the maximum elevation limit switch of the jib installed on the top of the main boom. When the jib is enlarged to the maximum elevation angle, the limit switch on the anti-backturning device should be able to limit the position accurately.
4.3.6 Test of lifting moment limiter
The test shall be carried out when there is no wind or light wind.
According to the four arm lengths a, bc, and d specified in Article 4.3.3, the selection range of each arm length is large, small, and medium, respectively 907
JB 5318 —91
When lifting the corresponding rated load, the working condition of the lifting moment limiter and the comprehensive accuracy of the system shall comply with the provisions of Article 3.6.2. 4.3.7 Static load test
The wind speed during the test shall not be greater than 8.3m/s. The test load is 1.25G (G is the rated load under the test range). According to the four arm lengths a, bc, and d specified in Article 4.3.3, at the minimum amplitude, slowly lift the test load to about 200mm above the ground and hover for 10 minutes.
After the test, the crane shall not have cracks, permanent deformation, paint peeling, loose connections, or damage that may affect the performance and safety of the crane. 4.3.8 Dynamic load test
During the test, the wind speed is not greater than 8.3m/s, and the test load is 1.1G. a. According to the four arm lengths a, b, c, and d specified in Article 4.3.3, lift the test load with a larger amplitude, and carry out the lifting and lowering of the main hook or the auxiliary hook (braking once in the middle) , the main arm or jib luffs (braking once in the middle), turning left and right 360° (braking once in the middle), each action is no less than 3 times. | |tt | Run 20m. Operation is not allowed when the jib is loaded.
In the above two tests a and b, each mechanism of the crane should work normally and the braking should be reliable. 4.3.9 Stability test
During the test, the wind speed is not greater than 8.3m/s, and the test load is 1.25Gn+0.1F: (F: is the weight of the arm converted to the head of the main arm or jib, its value Calculated according to GB6068.3)
Select an arm length according to the provisions of Article 4.3.3e, and slowly lift the test load to about 100mm above the ground when the amplitude is large, small and medium, and hang it Stop for 10 minutes and the crane should be in a stable state. 4.3.10 Measurement of noise
4.3.10.1—General requirements
a.
Use A sound level meter with an instrument accuracy of 0.5dB(A); b. The ambient noise should be The measured noise must be lower than 6dB(A), otherwise it will be invalid; the engine is running at rated speed, the total noise is measured when lifting or descending without load, and the background noise is measured after turning off the engine. c.
4.3.10.2 Cab noise
a.
b.
Close the cab door and measure the background noise and total noise at the driver's ears. ; Cabin noise = total noise - background noise shadow value (see Table 3). Measure 3 times and take the maximum value as the cab noise value. c.
Table 3
Difference between total noise and background noise
Background noise impact value
6
1
4.3. 10.3 Crane radiated noise sound power level 1
8
1
9
0.5
10
0. 5||tt| |dB(A)
>10
0
As shown in Figure 5, the distance from the crane rotation center is measured to be 16m and the height of A and B is 1.5m from the ground. , background noise and total noise at four points C and D, measure each point for 20~~25s, and take the maximum value of the fluctuation range of the meter pointer (excluding instantaneous interference); b., each point Sound level value - total noise value - background noise impact value; the sum of the four sound level values ??+ 32.
c.
908
Sound power level one
4
5 Inspection rules
5.1 Factory inspection
fs '
AB
JB5318
N
91
15
EWww.bzxZ.net
ft
Figure 5
16m
Each product must undergo factory inspection in accordance with the provisions of Articles 4.3.4~4.3.8 of this standard. 5.2 Type inspection
Type inspection should be carried out when one of the following situations occurs: a.
b.
c.
d.
New product or old product Trial prototype identification of products transferred to factory production; after formal production, if there are major changes in structure, materials, and processes, which may affect product performance; when there are major abnormalities in the outgoing inspection results;
National Quality Supervision Agency When requesting type inspection. Type inspection includes inspection of all items in Chapter 4 of this standard. 5.3 The quality inspection department of the manufacturer should conduct inspections of all specified items in accordance with the requirements of this standard and product drawings. Only after passing the inspection will the product be accepted for shipment and a product inspection certificate will be issued to the user. 909
6 Marking, Packaging, Transportation and Storage
6.1 Mark
JB5318-91
6.1.1 Each crane is set on both sides of the main boom ladder section A sign indicating the name of the manufacturer. 6. 1.2
b.
c.
6.1.3
a.
b.
c.||tt| |d.
6.1.4
a.
b.
Spray eye-catching logos on the large flat surfaces on both sides of the truck with the content: Crane model :
Manufacturer name;
Safety warning.
Set product signage at appropriate parts of the cab, including: product model and name;
manufacturer name;
maximum lifting weight;
factory date.
On the upper middle part of the chassis in front of the vehicle, stamp the following with a steel stamp: product manufacturing number;
date of manufacture.
6.2 Packaging
Product packaging should comply with the provisions of JB/ZQ4286. Packaging anti-rust validity period: half a year from the date of shipment from the manufacturer. 6.3 Transportation
Product transportation should comply with the regulations of the relevant national or regional railway, highway and shipping departments. The product packaging must not be damaged during transportation, nor should the product be damaged due to other reasons. 6.4 Storage
Product storage should be protected from frequent sun and rain as much as possible, and necessary maintenance should be carried out. Products that have not yet been installed should be packaged in good condition.
Quality Assurance
7
On the premise that the user complies with the crane operation and maintenance rules, within 12 months from the date of use, but not more than 18 months from the date of shipment, if the product is damaged or cannot be used normally due to poor manufacturing and assembly or quality problems of purchased accessories, the manufacturer should promptly repair the product free of charge.
910
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