Cranes — Maintenance manual —
Contents
1. Annex informative Example of lubrication schedule Annex B informative Examples of warning safety signs Annex C informative Bibliography Table 1 Table 2 Table 3 N ND MIO A BIN NHN RRP eR RA j Copyright British Standards Institution I 05 1999 Provided by IHS under license with BSI Uncontrolled Copy No reproduction or networking permitted without license from IHS Licensee BP International 5928366101 Not for Resale 06 04 2010 21 26 19 MDT 2 blank Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy Licensee BP International 5928366101 No reproduction or networking permitted without license from IHS Not for Resale 06 04 2010 21 26 19 MDT BS ISO 12478 1997 INTERNATIONAL ISO STANDARD 12478 1 First edition 1997 07 15 Cranes Maintenance manual Part 1 General Appareils de levage a charge suspendue Manuel de maintenance Partie 1 G n ralit s NT Reference number ISO 12478 1 1997 E Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy No reproduction or networking permitted without license from IHS Licensee BP International 5928366101 Not for Resale 06 04 2010 21 26 19 MDT BS ISO 12478 1997 Foreword ISO the International Organization for Standardization is a worldwide federation of national standards bodies ISO member bodies The work of2. permitted without license from IHS Licensee BP International 5928366101 Not for Resale 06 04 2010 21 26 19 MDT BS ISO 12478 1997 Annex A informative Example of lubrication schedule Item Part Interval Type of lubricant H Con Hoisting machinery Trolley crab travelling mechanism Travelling mechanism Trolley wheel Travelling wheel Oil Oil Oil Grease Grease A Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy No reproduction or networking permitted without license from IHS Licensee BP International 5928366101 Not for Resale 06 04 2010 21 26 19 MDT BSI 05 1999 BS ISO 12478 1997 Annex B informative Examples of warning safety signs B 1 Example of safety sign with text DANGER Maintenance operation in progress Do not reconnect B 2 Example of safety sign without text For example to indicate Shut off engine and remove key before performing maintenance or repair work NOTE For further information regarding safety signs see ISO 13200 Annex C informative Bibliography 1 ISO 12480 1 Cranes Safe use Part 1 General 2 ISO 13200 1995 Cranes Safety signs and hazard pictorials General principles 1 To be published RCT 05 1999 oe os 5 Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy Lice
3. to work system see ISO 12480 BSI 05 1999 a Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy No reproduction or networking permitted without license from IHS Licensee BP International 5928366101 Not for Resale 06 04 2010 21 26 19 MDT BS ISO 12478 1997 use of warning signs examples are shown in Annex B disconnection and locking of power supply switch to prevent unauthorized reconnection discharge release or 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 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 appropriate specify authorized and qualified workers as required for applicable tasks appropriate handling and disposal of hazardous materials M RST 05 1999 D Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy No reproduction or networking
4. BRITISH STANDARD BS ISO 12478 1 1997 Cranes Maintenance manual Part 1 General ICS 53 020 20 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy Licensee BP International 5928366101 No reproduction or networking permitted without license from IHS Not for Resale 06 04 2010 21 26 19 MDT BS ISO 12478 1 1997 National foreword This British Standard reproduces verbatim ISO 12478 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 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 promulgate 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 the section entitled International Standards Correspondence Index or by using the Find facili
5. advice can be obtained from the Copyright Manager Tel 020 8996 7070 Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy No reproduction or networking permitted without license from IHS Licensee BP International 5928366101 Not for Resale 06 04 2010 21 26 19 MDT
6. er 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 driver s manual user s manual etc may be published in one or more 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 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 schematics charts e g switching sequences and check lists should be included RCI 05 1999 1 Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy Licensee BP International 5928366101 Not for Resale 06 04 2010 21 26 19 MDT No reproduction or networking permitted without license from IHS BS ISO 12478 1997 Table 1 Operation and Part name Estimated hours Interval 1 Interval 2 Etc location nomenclature labour Table 2 Designation Reference of Original s
7. ize Wear size limit Reference of the control gauges part number Table 3 Part Mechanism Capacity litres Ambient temperature C Recommended ISO classification Standard symbol or reference mark 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 which examples of typical column headings are shown in Table 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 may 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 with 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 for e g brakes clutches chains ropes etc d specification of necessary special tools and equipment e special requirements for the lifti
8. l 5928366101 No reproduction or networking permitted without license from IHS Not for Resale 06 04 2010 21 26 19 MDT BS ISO 12478 1997 1 Scope This part of ISO 12478 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 provisions of this part of ISO 12478 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 ISO 12478 are encouraged to investigate the possibility of applying the most recent editions of the standards indicated 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 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 incorporate the use of internationally recognized symbols if established c shou
9. ld 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 The 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 the risk of misunderstanding They should be clear and simple and be placed adjacent to any corresponding text The terms see ISO 4306 definitions units see ISO 31 and symbols shall comply with the relevant International Standards When the units specified differ from those in common use this should 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 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 the crane manufactur
10. ng and handling of crane components 4 5 Test and inspection procedures The requirements given in ISO 9927 1 shall apply 5 Lubrication and fluids 5 1 Data concerning 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 in litres c list of manufacturer s recommended lubricant types and or brands where appropriate An example of a typical table for lubricant specification is given in Table 3 5 2 Lubrication schedule This schedule shall cover the crane lubrication requirements indicating time intervals at which these are to be carried out It shall include a diagram showing which parts require lubrication a typical example is shown in Annex A 6 Safety during maintenance operations The following are typical examples of items which should be included for observation of safety precautions by the maintenance 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 prevention of energizing movement use of a clearly defined permit
11. nsee BP International 5928366101 No reproduction or networking permitted without license from IHS Not for Resale 06 04 2010 21 26 19 MDT BS ISO 12478 1 1997 BSI 389 Chiswick High Road London W4 4AL BSI British Standards Institution BSI is the independent national body responsible for preparing British Standards It presents the UK view on standards in Europe and at the international level It is incorporated by Royal Charter Revisions British Standards are updated by amendment or revision Users of British Standards should make sure that they possess the latest amendments or editions It is the constant aim of BSI to improve the quality of our products and services We would be grateful if anyone finding an inaccuracy or ambiguity while using this British Standard would inform the Secretary of the technical committee responsible the identity of which can be found on the inside front cover Tel 020 8996 9000 Fax 020 8996 7400 BSI offers members an individual updating service called PLUS which ensures that subscribers automatically receive the latest editions of standards Buying standards Orders for all BSI international and foreign standards publications should be addressed to Customer Services Tel 020 8996 9001 Fax 020 8996 7001 In response to orders for international standards it is BSI policy to supply the BSI implementation of those that have been published as British Standards unless otherwise req
12. preparing International Standards is normally carried out through ISO technical committees Each member 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 Electrotechnical 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 a vote International Standard ISO 12478 1 was prepared by Technical Committee ISO TC 96 Cranes Subcommittee SC 5 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 8 Tower cranes Part 4 Jib cranes Part 5 Overhead travelling and portal bridge cranes Annex A Annex B and Annex C of this part of ISO 12478 are for information only Descriptors Handling equipment lifting equipment cranes hoists maintenance handbooks preparation presentation generalities 11 BSI 05 1999 Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy Licensee BP Internationa
13. ty 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 application 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 the ISO title page page 11 pages 1 to 5 and a back cover This standard has been updated see copyright date and may have had amendments incorporated This will be indicated in the amendment table on the inside front cover This British Standard having Amendments issued since publication been prepared under the direction of the Engineering Sector Board was published Amd No Date Comments under the authority of the Standards Board and comes into effect on 15 July 1998 BSI 05 1999 ISBN 0 580 30122 2 Copyright British Standards Institution Provided by IHS under license with BSI Uncontrolled Copy Licensee BP International 5928366101 No reproduction or networking permitted without license from IHS Not for Resale 06 04 2010 21 26 19 MDT BS ISO 12478 1 1997 Contents National foreword Foreword Page Inside front cover il Scope Normative references Presentation of the manual Maintenance Lubrication and fluids Safety during maintenance operations D ND re
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