SIST EN 12999:2011
(Main)Cranes - Loader Cranes
Cranes - Loader Cranes
The standard now has two amendments. During the work with the second amendment, it became obvious that many areas outside the scope of that amendment need to be improved. Some provisions are unclear and some may not even be possible to fulfil. The state of the art has also developed and this should be reflected in the standard. The entire standard should be revised so that shortcomings are eliminated and the standard is brought up to date with respect to the development of other standards and the state of the art. Some
areas of particular interest are:
- 5.4 Mechanical arrangements
- 5.5 Hydraulic system
- 5.6 Limiting and indicating devices
- 6.2 Testing and test procedures
Krane - Ladekrane
Diese Europäische Norm legt die Mindestanforderungen für Gestaltung, Berechnung, Untersuchungen und Prüfungen von hydraulisch angetriebenen Ladekranen und ihre Montage auf Fahrzeuge oder ortsfeste Unterkonstruktion fest.
Diese Europäische Norm gilt nicht für Ladekrane auf Schiffen oder schwimmenden Konstruktionen sowie Krane mit Knickauslegersystem, die vollständig als integraler Bestandteil einer speziellen Ausrüstung, wie z. B. Rückfahrzeug (Forwarder), ausgelegt sind.
Die Gefährdungen, die von dieser Europäischen Norm behandelt sind, sind in Abschnitt 4 aufgeführt.
Diese Europäische Norm behandelt nicht die Gefährdungen, die beim Heben von Personen auftreten.
Diese Europäische Norm gilt nicht für Ladekrane, die vor dem Datum der Veröffentlichung dieser Norm als EN hergestellt wurden.
ANMERKUNG Die Verwendung von Kranen für das Heben von Personen kann besonderen nationalen Vorschriften unterliegen.
Appareils de levage a charge suspendue - Grues de chargement
La présente Norme européenne spécifie les prescriptions minimales relatives à la conception, au calcul, aux examens et aux essais des grues de chargement hydrauliques et à leur montage sur des véhicules ou massifs pour montage à poste fixe.
La présente Norme européenne ne s'applique pas aux grues de chargement utilisées à bord des navires ou structures flottantes et aux appareils de levage à charge suspendue à flèche articulée qui sont conçus comme faisant partie intégrante d’un équipement spécial tel que des débardeuses.
Les phénomènes dangereux couverts par la présente norme européenne sont identifiés à l'Article 4.
La présente Norme européenne ne couvre pas les phénomènes dangereux relatifs au levage de personnes.
La présente Norme s’applique aux grues de chargement fabriquées après la date d'approbation de cette norme par le CEN.
NOTE L’utilisation d’appareils de levage pour le levage de personnes peut être soumise à des réglementations nationales spécifiques.
Dvigala (žerjavi) - Nakladalni žerjavi
Standard ima zdaj dve dopolnili. Pri delu z drugim dopolnilom je postalo jasno, da je treba izboljšati številna področja, ki so zunaj njegovega področja uporabe. Nekatere določbe so nejasne in nekaterih niti ni mogoče izpolniti. Razvile so se sodobne tehnologije, kar bi moral standard odražati. Celoten standard je treba pregledati, tako da se izločijo pomanjkljivosti in se standard posodobi glede na razvoj drugih standardov in sodobno tehnologijo. Nekatera še zlasti zanimiva področja so:
- 5.4 mehanske postavitve;
- 5.5 hidravlični sistem;
- 5.6 omejevalne in kazalne naprave;
- 6.2 preskušanje in preskusni postopki.
General Information
Relations
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Dvigala (žerjavi) - Nakladalni žerjaviKrane - LadekraneAppareils de levage a charge suspendue - Grues de chargementCranes - Loader Cranes53.020.20DvigalaCranesICS:Ta slovenski standard je istoveten z:EN 12999:2011SIST EN 12999:2011en,fr,de01-junij-2011SIST EN 12999:2011SLOVENSKI
STANDARDSIST EN 12999:2003/A2:2006SIST EN 12999:2003/A1:2004SIST EN 12999:20031DGRPHãþD
SIST EN 12999:2011
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 12999
January 2011 ICS 53.020.20 Supersedes EN 12999:2002English Version
Cranes - Loader cranes
Appareils de levage à charge suspendue - Grues de chargement
Krane - Ladekrane This European Standard was approved by CEN on 10 December 2010.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,
B-1000 Brussels © 2011 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 12999:2011: ESIST EN 12999:2011
EN 12999:2011 (E) 2 Contents Page Foreword . 5Introduction . 61Scope . 72Normative references . 73Terms, definitions and terminology . 83.1Terms and definitions . 83.2Terminology . 124List of significant hazards . 145Safety requirements and/or safety measures . 175.1General . 175.2Structural calculation . 185.2.1Information to be given in the calculation . 185.2.2Dynamic factors . 185.2.3Loads and forces . 205.2.4Load combinations . 215.3Stress analysis . 235.4Mechanical arrangements . 235.4.1Stabilizers . 235.4.2Manual boom extensions . 245.4.3Securing for transport . 245.4.4Hoists . 245.4.5Load hooks . 255.5Hydraulic system . 255.5.1General . 255.5.2Pump . 255.5.3Hydraulic reservoir . 255.5.4Pressure limiting device . 255.5.5Hoses, tubes and fittings . 265.5.6Precautions against hydraulic line rupture. 265.5.7Sink rate for boom system. 275.5.8Slewing mechanism . 275.6Limiting and indicating devices . 275.6.1General . 275.6.2Rated capacity limiter . 285.6.3Lowering facility . 295.6.4Rated capacity indicators . 295.6.5Limiters . 295.6.6Operational warning . 295.6.7Acoustic warning . 295.6.8Stopping device . 305.7Controls . 305.7.1General . 305.7.2Symbols . 305.7.3Layout of bi-directional controls . 315.7.4Guidance for high seat controls . 315.8Control stations . 315.8.1General . 315.8.2Raised control stations . 325.9Electrical systems . 34SIST EN 12999:2011
EN 12999:2011 (E) 3 5.9.1General . 345.9.2Electromagnetic compatibility . 345.10Installation . 345.10.1General . 345.10.2Mounting . 345.10.3Stability . 355.10.4Noise . 355.10.5Vibrations . 355.10.6Electrical systems (installation) . 355.10.7Hydraulic components . 365.10.8Access . 366Verification of the safety requirements and/or measures . 366.1General . 366.2Testing and test procedures . 406.2.1General . 406.2.2Functional test . 406.2.3Static test . 406.2.4Dynamic test . 416.2.5Stability test . 416.2.6Test documentation . 426.3Noise emission measurement . 437Information for use . 437.1General . 437.2Manuals . 437.2.1Provision of manuals . 437.2.2Instructions for the installer . 437.2.3Operator's manual . 447.2.4Maintenance manual . 457.3Marking . 467.3.1General . 467.3.2Manufacturer's plate . 467.3.3Installer's plate . 467.3.4Load signs . 467.3.5Special signs on timber handling cranes . 507.3.6Marking of slewing centre . 50Annex A (informative)
Examples of configurations and mountings . 52A.1Boom systems . 52A.1.1Loader cranes with straight boom system . 52A.1.2Loader cranes with articulated boom system . 52A.2Examples of loader crane mountings . 53Annex B (informative)
Stress history parameter s and stress history classes S. 58Annex C (informative)
Explanatory notes . 60C.1Rated capacity limiters . 60C.2Timber handling cranes - Line rupture . 60C.3Control stations . 60Annex D (informative)
Examples of dangerous movements . 61Annex E (normative)
Symbols for working and setting-up functions . 62Annex F (informative)
Control system – Preferred vertical layout for controls operated from the ground . 64Annex G (informative)
Control system - Horizontal layout order . 66Annex H (informative)
Control levers for high seats and remote controls . 69H.1High seat controls . 69H.1.1Multidirectional (joy-stick) controls . 69H.1.2Bi-directional controls . 69SIST EN 12999:2011
EN 12999:2011 (E) 4 H.2Remote controls . 69Annex I (not used) . 72Annex J (normative)
Cabins fitted on vehicle mounted loader cranes up to a net lifting moment of 250 kNm . 73Annex K (informative)
Examples of raised control stations . 76Annex L (normative)
Raised control stations - Measures regarding hand rails and hand holds, ladders and steps . 78Annex M (informative)
Installation of a loader crane on a vehicle . 82M.1General . 82M.2Installation: minimum data . 82M.2.1Crane dimensions in transport position: data . 82M.2.2Crane data (see Figure M.2) . 83M.2.3Mounting data . 83M.2.4Power requirements . 83M.2.5Stability calculations: data . 83M.3Power take off (PTO) and pump displacement . 84M.4Calculation method for determination of sub-frame dimensions . 85M.4.1General considerations . 85M.4.2Stresses . 85M.4.3Material and limit states . 86M.4.4Symbols and equations . 86Annex N (informative)
Selection of a suitable set of crane standards for a given application . 88Annex ZA (informative)
Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC . 89Bibliography . 90 SIST EN 12999:2011
EN 12999:2011 (E) 5 Foreword This document (EN 12999:2011) has been prepared by Technical Committee CEN/TC 147 “Cranes - Safety”, the secretariat of which is held by BSI. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by July 2011, and conflicting national standards shall be withdrawn at the latest by July 2011. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights. This document supersedes EN 12999:2002. This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s). For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
SIST EN 12999:2011
EN 12999:2011 (E) 6 Introduction This European Standard is a harmonized standard to provide one means for loader cranes to conform to the essential health and safety requirements of the Machinery Directive 2006/42/EC. This European Standard is a type C standard as stated in EN ISO 12100. When provisions of this type C standard are different from those which are stated in type A or B standards, the provisions of this type C standard take precedence over the provisions of the other standards, for machines that have been designed and built according to the provisions of this type C standard. The machinery concerned and the extent to which hazards are covered are indicated in the scope of this European Standard. SIST EN 12999:2011
EN 12999:2011 (E) 7 1 Scope This European Standard specifies minimum requirements for design, calculation, examinations and tests of hydraulic powered loader cranes and their mountings on vehicles or static foundations. This European Standard does not apply to loader cranes used on board ships or floating structures or to articulated boom system cranes which are designed as total integral parts of special equipment such as forwarders.
The hazards covered by this standard are identified in Clause 4. This European Standard does not cover hazards related to the lifting of persons. This European Standard is not applicable to loader cranes which are manufactured before the date of its publication as EN. NOTE The use of cranes for lifting of persons can be subject to specific national regulations. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 349:1993+A1:2008, Safety of machinery — Minimum gaps to avoid crushing of parts of the human body EN 12077-2:1998+A1:2008, Cranes safety — Requirements for health and safety — Part 2: Limiting and indicating devices EN 14492-2:2006+A1:2009, Cranes — Power driven winches and hoists — Part 2: Power driven hoists EN 12644-1:2001+A1:2008, Cranes – Information for use and testing — Part 1: Instructions EN 12644-2:2000+A1:2008, Cranes — Information for use and testing — Part 2: Marking EN 13001-1:2004+A1:2009, Cranes — General design — Part 1: General principles and requirements EN 13001-2:2004+A3:2009, Cranes safety — General design — Part 2: Load effects prEN 13001-3-1:2010, Cranes — General design — Part 3-1: Limit states and proof competence of steel structure EN 13557:2003+A2:2008, Cranes — Controls and control stations EN 13586:2004+A1:2008, Cranes — Access EN 61000-6-2:2005, Electromagnetic compatibility (EMC) — Part 6-2: Generic standards — Immunity for industrial environments (IEC 61000-6-2:2005) EN 61000-6-4:2007, Electromagnetic compatibility (EMC) — Part 6-4: Generic standards — Emission standard for industrial environments (IEC 61000-6-4:2006) EN 60204-32:2008, Safety of machinery — Electrical equipment of machines — Part 32: Requirements for hoisting machines (IEC 60204-32:2008) SIST EN 12999:2011
EN 12999:2011 (E) 8 EN 954-1:1996, Safety of machinery — Safety related parts of control systems — Part 1: General principles for design EN ISO 3744:2010, 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 3744:2010) EN ISO 4413:2010, Hydraulic fluid power — General rules and safety requirements for systems and their components (ISO 4413:2010) EN ISO 4871:2009, Acoustics — Declaration and verification of noise emission values of machinery and equipment (ISO 4871:1996) EN ISO 5353:1998, Earth-moving machinery and tractors and machinery for agriculture and forestry — Seat index point (ISO 5353:1995) EN ISO 11201:2010, Acoustics — Noise emitted by machinery and equipment — Determination of emission sound pressure levels at a work station and at other specified positions in an essentially free field over a reflecting plane with negligible environmental corrections (ISO 11201:2010) EN ISO 11688-1:2009, Acoustics — Recommended practice for the design of low-noise machinery and equipment — Part 1: Planning (ISO/TR 11688-1:1995) EN ISO 12100:2010, Safety of machinery — General principles for design — Risk assessment and risk reduction (ISO 12100:2010) EN ISO 13857:2008, Safety of machinery — Safety distances to prevent hazard zones being reached by upper and lower limbs (ISO 13857:2008) 3 Terms, definitions and terminology 3.1 Terms and definitions For the purposes of this document, the terms and definitions given in EN ISO 12100:2010 and the following apply. 1) 3.1.1 loader crane powered crane comprising a column, which slews about a base, and a boom system which is attached on to the top of the column, usually fitted on a commercial vehicle (including trailer) with a significant residual load carrying capability, and being designed for loading and unloading the vehicle as well as for other duties as specified by the manufacturer in the operator's manual NOTE 1 A loader crane, as defined above in 3.1.1, installed on a static foundation is still considered a loader crane. NOTE 2 Annex A gives examples of configuration and mountings. 3.1.2 articulated movement movement of boom members pivoting about a pin joint
1) For convenience of reference the definitions are - with the exception of 3.1.1 loader crane - grouped in alphabetical order in the English version. SIST EN 12999:2011
EN 12999:2011 (E) 9 3.1.3 base housing incorporating anchoring points and bearings for the slewing column 3.1.4 boom structural member in the boom system of the loader crane 3.1.5 boom extension, hydraulic part of the boom which is capable of hydraulic telescopic movement to vary its length 3.1.6 boom extension, manual part of the boom which can be manually extended or retracted 3.1.7 boom system complete system, consisting of booms, boom extensions and cylinders 3.1.8 column structural member which supports the boom system 3.1.9 control system interface between the operating levers and the actuating components which provide movements of the loader crane 3.1.10 control station position from which the loader crane may be operated 3.1.11 crane inclination angle between the slewing axis and a vertical line, due to working on slanted or uneven ground 3.1.12 danger zone any space within and/or around machinery in which a person can be exposed to a hazard [EN ISO 12100:2010] 3.1.13 dead load force due to masses of fixed and movable crane parts which act permanently on the structure while the crane is being used 3.1.14 dynamic pressure pressure in a hydraulic system component or part of hydraulic system caused by dynamic forces on actuators when handling the load 3.1.15 fixed load lifting attachment equipment from which the net load may be suspended and which is fitted directly to the boom head as an integral part of the crane NOTE This comprises for example hooks or grapples. SIST EN 12999:2011
EN 12999:2011 (E) 10 3.1.16 flow sensitive check valve valve which stops the flow when a pre-set pressure drop level is exceeded 3.1.17 gross load sum of payload, lifting attachments and if applicable a
...
SLOVENSKI STANDARD
oSIST prEN 12999:2007
01-september-2007
Dvigala (žerjavi) - Nakladalna dvigala
Cranes - Loader Cranes
Krane - Ladekrane
Appareils de levage a charge suspendue - Grues de chargement
Ta slovenski standard je istoveten z: prEN 12999
ICS:
53.020.20 Dvigala Cranes
oSIST prEN 12999:2007 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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EUROPEAN STANDARD
DRAFT
prEN 12999
NORME EUROPÉENNE
EUROPÄISCHE NORM
July 2007
ICS Will supersede EN 12999:2002
English Version
Cranes - Loader Cranes
Appareils de levage à charge suspendue - Grues de Krane - Ladekrane
chargement
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 147.
If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which
stipulate the conditions for giving this European Standard the status of a national standard without any alteration.
This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language
made by translation under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the
same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to
provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36 B-1050 Brussels
© 2007 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 12999:2007: E
worldwide for CEN national Members.
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prEN 12999:2007 (E)
Contents Page
Introduction .4
1 Scope .6
2 Normative references .6
3 Terms and definitions .7
3.1 Definitions .7
3.2 Terminology .11
4 List of significant hazards .12
5 Safety requirements and/or safety measures.15
5.1 General.15
5.2 Structural calculation .16
5.3 Stress analysis.20
5.4 Mechanical arrangements.20
5.5 Hydraulic system .22
5.6 Limiting and indicating devices .24
5.7 Controls .26
5.8 Control stations .28
5.9 Electrical systems and related phenomena.30
5.10 Installation .30
6 Verification of the safety requirements and/or measures .32
6.1 General.32
6.2 Testing and test procedures.37
7 Information for use .39
7.1 General.39
7.2 Manuals.39
7.3 Marking .41
Annex A (informative) Examples of configurations and mountings .46
Annex B (informative) Stress history parameter s and stress history classes S .51
Annex C (informative) Explanatory notes .53
Annex D (informative) Examples of dangerous movements.54
Annex E (normative) Symbols for working and setting-up functions.55
Annex F (informative) Control system – Preferred vertical layout for controls operated from the
ground.57
Annex G (informative) Control system - Horizontal layout order .59
Annex H (informative) Control levers for high seats and remote controls.61
Annex I (not used).63
Annex J (normative) Minimum internal dimensions for cabins fitted on vehicle mounted loader
cranes up to a net lifting moment of 250 kNm.64
Annex K (informative) Examples of raised control stations .65
Annex L (normative) Raised control stations - Measures regarding hand rails and hand holds,
ladders and steps .67
Annex M (informative) Installation of a loader crane on a vehicle .70
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prEN 12999:2007 (E)
Annex N (informative) Selection of a suitable set of crane standards for a given application.76
Annex ZA (informative) Relationship of this document with EC Directives .77
Annex ZB (informative) Relationship of this document with EC Directives .78
Bibliography.79
3
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prEN 12999:2007 (E)
Foreword
This document (prEN 12999:2007) has been prepared by Technical Committee CEN/TC 147 “Cranes -
Safety”, the secretariat of which is held by BSI.
This document is currently submitted to the CEN Enquiry.
This document will supersede EN 12999:2002.
This document has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association, and supports essential requirements of EU Directive(s).
For relationship with EU Directive(s), see informative Annex ZA & ZB which is an integral part of this
document.
4
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prEN 12999:2007 (E)
Introduction
This European Standard is a harmonised standard to provide one means for loader cranes to conform to the
essential health and safety requirements of the Machinery Directive 98/37/EEC and the Machinery Directive
2006/42/EC.
This European Standard is a type C standard as stated in EN 1070.
The machinery concerned and the extent to which hazards are covered are indicated in the scope of this standard.
5
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prEN 12999:2007 (E)
1 Scope
This European Standard specifies minimum requirements for design, calculation, examinations and tests of
hydraulic powered loader cranes and their mountings onto vehicles or static foundations.
This standard does not apply to loader cranes used on board ships or floating structures and to articulated
boom system cranes which are designed as total integral parts of special equipment such as forwarders.
The hazards covered by this standard are identified in clause 4.
This standard does not cover hazards related to the lifting of persons.
This standard applies to loader cranes (including timber handling cranes) which are manufactured after the
date of approval by CEN of this standard.
NOTE The use of cranes for the lifting of persons may be subject to specific national regulations.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
EN 294:1992, Safety of machinery - Safety distances to prevent danger zones being reached by the upper
limbs.
EN 349:1993, Safety of machinery – Minimum distances to avoid crushing of parts of the human body.
EN 811:1996, Safety of machinery – Safety distances to prevent danger zones being reached by the lower
limbs.
EN ISO 13849-1:2006, Safety of machinery - Safety-related parts of control systems - Part 1: General
principles for design
EN 982:1996, Safety requirements for fluid power systems and components – Hydraulics
EN 1050:1996, Safety of machinery – Principles for risk assessment
EN 1070:1998, Safety of machinery - Terminology
EN 12077-2:1998, Cranes safety – Requirements for health and safety – Part 2: Limiting and indicating
devices
EN 14492-2: 2006 Cranes - Power driven winches and hoists - Par 2: Power driven hoists
EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1: Basic
terminology, methodology (EN ISO 12100-1:2003)
EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2:
Technical principles (EN ISO 12100-2:2003)
EN 12644-1:2001, Cranes – Information for use and testing – Part 1: Instructions
EN 12644-2:2000, Cranes – Information for use and testing – Part 2: Marking
EN 13001-1:2004, Cranes — General design — Part 1: General principles and requirements
6
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prEN 12999:2007 (E)
EN 13001-2:2004, Cranes — General design — Part 2: Load actions
EN 13001-3-1, Cranes — General design — Part 3-1: Limit states and proof of competence of steel structures
EN 13557:2003, Cranes - Controls and control stations
EN 13586:2004, Cranes - Access
EN 61000-6-2:2005, Electromagnetic compatibility (EMC) — Part 6-2: Generic standards — Immunity for
industrial environments (IEC 61000-6-2:1999, modified)
EN 61000-6-4:2001, Electromagnetic compatibility (EMC) — Part 6-4: Generic standards — Emission
standard for industrial environments (IEC 61000-6-4:1997, modified)
EN 60204-32:1998, Safety of machinery - Electrical equipment of machines - Part 32: Requirements for
hoisting machines.
EN ISO 5353:1998, Earth-moving machinery and tractors and machinery for agriculture and forestry — Seat
index point (ISO 5353:1995)
3 Terms and definitions
3.1 Definitions
For convenience of reference the definitions are - with the exception of 3.1.1 loader crane - grouped in
alphabetical order in the English version.
For the purposes of this standard, the definitions given in EN 1070:1998 apply, together with the following:
3.1.1
loader cranes
powered crane comprising of a column, which slews about a base, and a boom system which is attached on
to the top of the column. The crane is usually fitted on a commercial vehicle (including trailer) with a residual
load carrying capability. Loader cranes are designed for loading and unloading the vehicle as well for as for
other duties as specified by the manufacturer in the operator's manual.
NOTE 1 A crane, as defined above, installed on a static foundation is still considered a loader crane.
NOTE 2 Annex A give examples of configuration and mountings.
3.1.2
articulated
movement of boom members pivoting about a pin joint
3.1.3
base
housing incorporating anchoring points and bearings for the slewing column
3.1.4
boom
structural member in the boom system of the loader crane
3.1.5
boom extension, hydraulic
part of the boom which is capable of hydraulic telescopic movement to vary its length
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prEN 12999:2007 (E)
3.1.6
boom extension, manual
part of the boom which can be manually extended or retracted
3.1.7
boom system
complete system, consisting of booms, boom extensions and cylinders
3.1.8
column
structural member which supports the boom system
3.1.9
control system
interface between the operating levers and the actuating components which provide movements of the loader
crane
3.1.10
control station
position from which the loader crane may be operated
3.1.11
danger zone
any zone within and/or around the machinery in which a person is exposed to risk of injury or damage to
health. (EN 1070:1998)
3.1.12
dead loads
forces due to the masses of the fixed and movable crane parts which act permanently on the structure while
the crane is being used
3.1.13
dynamic pressure
pressure in a hydraulic system component or part of hydraulic system caused by dynamic forces on actuators
when handling the load
3.1.14
fixed load lifting attachment
equipment from which the net load may be suspended and which is fitted directly to the boom head as an
integral part of the crane. This comprises e.g. hooks, grabs,
3.1.15
flow sensitive check valve
valve which stops the flow when a pre-set pressure drop level is exceeded
3.1.16
gross load
sum of payload, lifting attachments and if applicable a portion of the hoist rope
3.1.17
high seat
control station connected to the column, consequently rotating with the crane
3.1.18
hoist
machines for lifting and lowering suspended loads over predetermined distances, using ropes or chains
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3.1.19
hydraulic line rupture
failure of a hydraulic line which results in a loss of pressure in the line
3.1.20
load holding valve
valve which is normally closed and is opened by an external force to allow the flow of fluid out of a hydraulic
actuator
3.1.21
main relief valve
valve which limits the pressure supplied to the hydraulic system of the crane
3.1.22
maximum working pressure
maximum pressure in pump circuit or individual working function
3.1.23
net lifting moment
rated capacity multiplied by outreach
3.1.24
non-fixed load lifting attachment
interchangeable equipment which can be fitted directly or indirectly to the hook or any other coupling device of
a crane by the user without affecting its integrity
3.1.25
outreach
the horizontal distance between the axis of rotation of the boom/boom system/jib in a vertical plane and point
of load attachment.
3.1.26
outreach, hydraulic
outreach which can be obtained with hydraulically actuated parts of the boom system
3.1.27
payload
load, which is lifted by the crane and suspended from the non-fixed load-lifting attachment(s) or, if such an
attachment is not used, directly from the fixed load-lifting attachment(s)
3.1.28
port relief valve
valve which limits the pressure supplied to a hydraulic actuator
3.1.29
pressure relief valve
valve which automatically relieves the hydraulic oil to the tank when the pressure exceeds a specified value
3.1.30
raised control station
control station at a height above the ground level, i.e. a high seat attached to the column of the loader crane
or a platform positioned above the base of the loader crane (see annex K)
3.1.31
rated capacity
load that the crane is designed to lift for a given operating condition (e.g. configuration, position of the load)
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3.1.32
rated capacity indicator
device which gives, within specified tolerance limits, at least a continuous indication that the rated capacity is
exceeded, and another continuous indication (on certain crane types) of the approach to the rated capacity
3.1.33
rated capacity limiter
device that automatically prevents the crane from handling loads in excess of its rated capacity, taking into
account the dynamic effects during normal operations use
3.1.34
setting-up function
crane function used to prepare the crane for lifting
3.1.35
sink rate
distance in a given time at which the load lowers due to internal leakage of hydraulic components
3.1.36
slewing
rotational movement of the column and boom system about a vertical axis
3.1.37
stabilizer
aid to the supporting structure connected to the base of the crane or to the vehicle to provide stability, without
lifting the vehicle from the ground
3.1.38
stabilizer extension
part of the stabilizer capable of extending the stabilizer leg laterally from the transport position to the operating
position
3.1.39
stabilizer leg
part of a stabilizer capable of contacting the ground to provide the required stability
3.1.40
static foundation
fixed support incorporating mounting points for a crane
3.1.41
timber handling crane
loader crane specifically designed, manufactured and equipped with a grapple for loading/unloading of
unprepared timber (e.g. tree trunks, branches). The operator controls the crane from a high seat or from a
cabin.
3.1.42
total lifting moment
sum of net lifting moment and the moment produced by dead loads.
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3.2 Terminology
The terms which are used in this standard for the main parts of a loader crane are indicated in figure 1.
Boom system consists of items 6-12.
11
6
10
8
12
13
9
7
5
2
1
3
4
14
4
14
Key
1. Base 2. Stabilizer extension 3. Stabilizer leg 4. Slewing mechanism
5. Column 6. 1st boom 7. 1st boom cylinder 8. 2nd boom
9. 2nd boom cylinder 10. Boom extension, 11. Extension cylinders 12. Boom extension,
hydraulic manual
13. Hook 14. Controls
Figure 1 — Main parts of a loader crane
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4 List of significant hazards
Table 1 shows a list, arranged according to EN 1050, of significant hazardous situations and hazardous
events that could result in risks to persons during normal use and foreseeable misuse. It also contains
corresponding cross-references to the relevant clauses in this standard that are necessary to reduce or
eliminate the risks associated with those hazards.
Table 1 — List of significant hazards and associated requirements
No. Hazards Relevant clause(s) in this standard
Hazards, hazardous situations and hazardous events
1 Mechanical hazards due to:
- Inadequacy of mechanical strength 5.1, 5.2, 5.3, 5.5.1, 5.5.4, 5.5.5, 5.5.8,
of the crane and its parts 5.8.2.1, 5.8.2.2, 5.10.2.1, 5.10.2, 7.2.3.7.
1.1 Crushing hazard 5.8.1, 5.8.2.2, 5.8.2.3, 5.10.2.3
1.2 Shearing hazard
1.3 Cutting or severing hazard
1.4 Entanglement hazard
1.5 Drawing-in or trapping hazard
1.6 Impact hazard
1.7 Stabbing or puncture hazard
1.8 Friction or abrasion hazard
1.9 High pressure fluid injection or 5.5.1, 5.5.5, 5.10.7, 7.2.3.5, 7.2.4.2
ejection hazard
1.10 Ejection of parts 5.4.1.1, 5.4.1.2, 5.4.1.3, 5.4.2, 5.4.3
1.11 Loss of stability 5.6.1, 5.6.2, 5.6.4, 5.6.5, 5.6.6.2, 5.10.3
1.12 Slip, trip, fall 5.8.2.2, 5.8.2.3, 5.8.2.4, 5.10.8
2 Electrical hazards due to:
2.1 Contact of persons with live parts 5.6.1.3, 5.9, 5.10.6, 7.2.3.1d)
(direct contact)
2.2 Contact of persons with parts which
have become live under faulty
conditions (indirect contact)
2.3 Approach to live parts under high
voltage
2.4
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No. Hazards Relevant clause(s) in this standard
2.5 Thermal radiation or other
phenomena such as the projection
of molten particles and chemical
effects from short circuits,
overloads, etc
3 Thermal hazards, resulting in:
3.1 Burns, scalds and other injuries by a 5.5.5, 5.10.2.3, 7.2.4.1
possible contact of persons with
objects or materials with an extreme
high or low temperature, by flames
or explosions and also by the
radiation of heat sources
3.2 Damage to health by hot or cold 7.2.3.7
working environment
4 Hazards generated by noise “Not significant for cranes that do not
include the power source. See 7.2.3.8
regarding information on noise”.
5 Hazards generated by vibration 5.10.5
7 Hazards generated by materials 5.10.2.3
and substances (and their
constituent elements) processed
or used by the machinery
7.1 Hazards from contact with or 7.2.4.1
inhalation of harmful fluids, gases,
mists, fumes and dusts
8 Hazards generated by neglecting
ergonomic principles in
machinery design, as e.g.
hazards from:
8.1 Unhealthy postures or excessive 5.4.1.3, 5.4.2, 5.4.3, 5.7, 5.8, 5.10.8
effort
8.2 Inadequate consideration of hand- 5.7, 5.8
arm or foot-leg anatomy
8.3 Neglected use of personal 7.2.4.1
protection equipment
8.4 Inadequate local lighting 5.8.1, 7.2.4.1, 7.2.3.6d)
8.6 Human error, human behaviour 5.6, 5.7.1, 5.7.2, 7.2.3, 7.2.4
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No. Hazards Relevant clause(s) in this standard
8.7 Inadequate design, location or 5.4.1.3, 5.4.3, 5.7, 5.8
identification of manual controls
8.8 Inadequate design or location of
visual display units
9 Combination of hazards 5.2.3, 5.2.4
10 Unexpected start-up, unexpected
overrun/overspeed (or any similar
malfunction) from:
10.1 Failure/disorder of the control 5.5.6.1, 5.5.6.2, 5.5.7, 5.6.6, 5.6.8,5.7.1
system
11 Hazards caused by missing
and/or incorrectly positioned
safety related measures/ means
11.1 Guards 5.5.5, 5.7.1, 5.8.2.2, 5.8.2.3, 5.10.2.3
11.2 Safety related (protection) devices 5.4.1, 5.4.3, 5.6.3, 5.6.6, 5.6.7
11.4 Safety signs, signals, symbols 5.4.1.3, 5.6.7, 5.7.2, 7.2.3.5, 7.3.4, 7.3.5
11.5 Information or warning devices 5.6.1, 5.6.2, 5.6.4, 5.6.7, 7.1, 7.2, 7.3
11.6 Visibility 5.4.3, 5.8.1, 7.3.4.1
11.7 Emergency devices 5.6.3, 5.6.8
15 Assembly errors 7.2.2, 7.2.4
18 Loss of stability/overturning of 5.4.1, 5.6.1, 5.6.2, 5.6.4, 5.6.5, 5.6.6,
machine 5.10.3
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No. Hazards Relevant clause(s) in this standard
Additional hazards, hazardous situations and hazardous events due to lifting
27 Mechanical hazards and
hazardous events
27.1 From load falls, collisions, machine
tipping caused by:
27.1.1 Lack of stability 5.10.3, 6.2.5
27.1.2 Uncontrolled loading – overloading 5.5.4, 5.6.1, 5.6.2, 5.6.3, 5.6.4, 5.6.5
– overturning moments exceeded
27.1.3 Uncontrolled amplitude of 5.6.6
movements
27.1.4 Unexpected/unintended movement 5.5.6, 5.5.7, 5.5.8
of loads
27.1.5 Inadequate holding devices/ 5.4.2, 7.2.3.6
accessories
27.2 From access of persons to load 1, 7.2.3.1 e)
support
27.4 From insufficient mechanical 5.1, 5.2, 5.3, 5.5.8, 5.10.2
strength of parts
27.8 From abnormal conditions of 5.10, 7.1, 7.2. 7.3
assembly/testing/use/maintenance
29 Hazards generated by neglecting
ergonomic principles
29.1 Insufficient visibility from the driving 5.8.1
position
5 Safety requirements and/or safety measures
5.1 General
Machinery shall conform to the safety requirements and/or measures of this clause. In addition, the machine
shall be designed according to the principles of EN 12100 for hazards relevant but not significant which are
not dealt with by this standard.
The rated capacity shall be calculated from the following:
a) the working pressure in the cylinders;
b) the area of the load carrying cylinders;
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prEN 12999:2007 (E)
c) the geometry;
d) dead loads;
e) load combinations.
For the purpose of the calculations rated capacity is equal to gross load.
5.2 Structural calculation
5.2.1 Information to be given in the calculation
The following information shall be given in the calculation:
a) type of crane and method of operation;
b) the assumed number of all load or working cycles;
c) details of the load-carrying system reflecting actual service conditions including outline drawings and
principal dimensions;
d) the assumed loading conditions including ground slope;
e) the governing hoisting class, hoist drive class and stress history classes;
f) the material for the individual components and joints;
g) the shapes, dimensions and static cross-section values of all load-carrying members;
h) the analyses separately for the individual structural components and essential connections.
5.2.2 Dynamic factors
5.2.2.1 Hoisting and gravity effects of the mass of the crane
The dynamic effects due to vibrations of the structure when raising or lowering a load shall be taken into
account by applying the factor φ on the gravitational forces due to the masses of the crane. It shall be used
1
for the design of the crane structure itself and its supports. The value of φ shall be the lowest of the two
1
values 1,1 and φ , or expressed as an equation:
2
φ = min(1,1 ; φ )
1 2
5.2.2.2 Hoisting and gravity effects of the gross load
In the case of hoisting or grounding a load as well as starting or stopping a vertical motion, the hereby
included vibrational effects shall be taken into account by multiplying the gravitational force due to the mass of
the hoist load by a factor φ .
2
The factor φ shall be taken as follows:
2
φ = φ + β × v
2 2,min 2 h
φ and β are given in Table 2a for the appropriate hoisting class. Loader cranes are assigned to hoisting
2,min 2
classes HC1 and HC2 according to their dynamic and elastic characteristics:
HC1 for crane mounted on a vehicle or structures of equivalent flexibility;
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HC2 for rigidly mounted cranes, e.g. static foundation or rail car.
Rigidly mounted cranes, equipped with a device that limits the peak pressure (e.g. an accumulator) in the first
boom cylinder, may be assigned to HC1.
v is the steady vertical hook speed, in metres per second, related to the lifting attachment. Values of v are
h h
given in Table 2b.
Table 2a — Value of ββ and φφ
ββ φφ
2 2,min
Hoisting class of appliance
β φ
2 2,min
HC 1 0,17 1,05
HC 2 0,34 1,10
Table 2b — Values of v
h
Type of hoist drive and its operation method
Load combination
HD1 HD4 HD5
A1, B1 v 0,5 × v v = 0
h,max h,max h
C1 - v
h,max 0,5 × v
h,max
where
HD1: hoist drive can only be operated at a fixed speed;
HD4: a step-less variable speed control can be operated by the crane driver;
HD5: after pre-stressing the hoist medium, the hoist drive control provides the reaching of a selected
speed with an acceleration independent of the crane driver;
v is the maximum vertical hook speed.
h,max
In load combinations A1 and B1, v is the maximum vertical hook speed that is given by any single
h,max
hydraulic drive action.
In load combination C1, v is the maximum vertical hook speed from all articulation hydraulic drives acting
h,max
simultaneously.
5.2.2.3 Effect of sudden release of a part of the gross load
For cranes that release or drop a part of the gross load
...
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