EN 12999:2002

SLOVENSKI STANDARD
01-maj-2003
Dvigala (žerjavi) – Nakladalna dvigala
Cranes - Loader cranes
Krane - Ladekrane
Appareils de levage a charge suspendue - Grues de chargement
Ta slovenski standard je istoveten z: EN 12999:2002
ICS:
53.020.20 Dvigala Cranes
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

EUROPEAN STANDARD
EN 12999
NORME EUROPÉENNE
EUROPÄISCHE NORM
September 2002
ICS 53.020.20
English version
Cranes - Loader cranes
Appareils de levage à charge suspendue - Grues de Krane - Ladekrane
chargement
This European Standard was approved by CEN on 8 March 2001.
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 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 Management Centre has the same status as the official
versions.
CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2002 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 12999:2002 E
worldwide for CEN national Members.

Contents
Foreword.3
Introduction .4
1 Scope .5
2 Normative references .5
3 Terms and definitions.6
4 List of significant hazards.11
5 Safety requirements and/or safety measures.14
6 Verification of the safety requirements and/or measures .29
7 Information for use .35
Annex A (informative) Examples of configurations and mountings.41
Annex B (informative) Structural calculations .46
Annex C (informativ) Explanatory notes .70
Annex D (informative) Examples of dangerous movements .71
Annex E (normative) Symbols for working and setting-up functions .72
Annex F (informative) Control system – Preferred vertical layout for controls operated from the
ground.74
Annex G (informative) Control system - Horizontal layout order .76
Annex H (informative) Control levers for high seats and remote controls.78
Annex I (Not used) .80
Annex J (normative) Minimum internal dimensions for cabins fitted on vehicle mounted loader
cranes up to a net lifting moment of 250 kNm.81
Annex K (informative) Examples of raised control stations .82
Annex L (normative) Raised control stations - Measures regarding hand rails and hand holds,
ladders and steps .84
Annex M (informative) Installation of a loader crane on a vehicle .87
Annex N (informative) Selection of a suitable set of crane standards for a given application .93
Annex ZA (informative) Relationship of this document with EC Directives.95
Bibliography .96
Foreword
This document (EN 12999:2002) 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 March 2003 and conflicting national standards shall be withdrawn at the
latest by March 2003.
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 document: Austria, Belgium, the Czech Republic, Denmark, Finland,
France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain,
Sweden, Switzerland and the United Kingdom.
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.
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.
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 1 Winches will be covered by a special standard being in preparation by CEN/TC 147.
NOTE 2 The use of cranes for the lifting of persons may be subject to specific national regulations.
2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications. These
normative references are cited at the appropriate places in the text and the publications are listed hereafter. For
dated references, subsequent amendments to, or revisions of, any of these publications apply to this European
Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the
publication referred to apply (including amendments).
EN 292-1:1991, Safety of machinery – Basic concepts – General principles for design – Part 1: Basic
terminology, methodology
EN 292-2:1991 + A1:1995, Safety of machinery – Basic concepts – General principles for design – Part 2:
Technical principles and specifications
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 954-1:1996, 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 1070:1998, Safety of machinery - Terminology
EN 12077-2:1998, Cranes safety – Requirements for health and safety – Part 2: Limiting and indicating devices
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
prEN 13557:1999, Cranes - Controls and control stations
prEN 13586:1999, Cranes - Access
EN 50081-2:1993, Electromagnetic compatibility – Generic emission standard – Part 2: Industrial environment
EN 50082-2:1995, Electromagnetic compatibility – Generic immunity standard – Part 2: Industrial environment
EN 60204-32:1998, Safety of machinery - Electrical equipment of machines - Part 32: Requirements for
hoisting machines.
EN 61000-6-2:1999, Electromagnetic compatability (EMC) - Part 6-2: Generic standards – Immunity for
industrial environments (IEC 61000-6-2:1999)
EN ISO 5353:1998, Earth-moving machinery and tractors and machinery for agriculture and forestry — Seat
index point (ISO 5353:1995)
ISO 4302:1981, Cranes — Wind load assessment
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 crane
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 vehicle (including trailer) and is designed for loading and
unloading the vehicle.
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
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 mac hinery 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
hydraulic line rupture
failure of a hydraulic line which results in a loss of pressure in the line
3.1.19
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
3.1.20
main relief valve
valve which limits the pressure supplied to the hydraulic system of the crane
3.1.21
maximum working pressure
maximum pressure in pump circuit or individual working function
3.1.22
net lifting moment
rated capacity multiplied by outreach
3.1.23
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
3.1.24
outreach
the horizontal distance between the axis of rotation of the boom/boom system/jib in a vertical plane and point of
load attachment.
3.1.25
outreach, hydraulic
outreach which can be obtained with hydraulically actuated parts of the boom system
3.1.26
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)
3.1.27
port relief valve
valve which limits the pressure supplied to a hydraulic actuator
3.1.28
pressure relief valve
valve which automatically relieves the hydraulic oil to the tank when the pressure exceeds a specified value
3.1.29
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)
3.1.30
rated capacity
load that the crane is designed to lift for a given operating condition (e.g. configuration, position of the load)
3.1.31
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
3.1.32
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
3.1.33
setting-up function
crane function used to prepare the crane for lifting
3.1.34
sink rate
distance in a given time at which the load lowers due to internal leakage of hydraulic components
3.1.35
slewing
rotational movement of the column and boom system about a vertical axis
3.1.36
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
3.1.37
stabilizer extension
part of the stabilizer capable of extending the stabilizer leg laterally from the transport position to the operating
position
3.1.38
stabilizer leg
part of a stabilizer capable of contacting the ground to provide the required stability
3.1.39
static foundation
fixed support incorporating mounting points for a crane
3.1.40
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.
3.1.41
total lifting moment
sum of net lifting moment and the moment produced by dead loads.
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.
8 12
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
4 List of significant hazards
Table 1 shows a list 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 certain
Parts of EN 292, and 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 Annex A of Relevant clause(s) in this standard
EN 292-2:
1991/A1:1995
Hazards, hazardous situations and hazardous events
1 Mechanical hazards due to: 1.3, 1.4
- Inadequacy of mechanical strength of 4.1.2.3/4/5, 5.1, 5.2, 5.3, 5.5.1, 5.5.4, 5.5.5, 5.5.8, 5.5.9,
the crane and its parts 4.2.1.4 5.8.2.1, 5.8.2.2, 5.10.2.1, 5.10.2, 7.2.3.7.
1.1 Crushing hazard 1.3, 1.3.4, 1.3.7 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 ejection 1.3.2 5.5.1, 5.5.5, 5.10.7, 7.2.3.5, 7.2.4.2
hazard
1.10 Ejection of parts 1.3.3 5.4.1.1, 5.4.1.2, 5.4.1.3, 5.4.2, 5.4.3
1.11 Loss of stability 1.5.4 5.6.1, 5.6.2, 5.6.4, 5.6.5, 5.6.6.2, 5.10.3
1.12 Slip, trip, fall 1.6.2, 4.2.3 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 (direct 1.5.1, 1.6.3 5.6.1.3, 5.9, 5.10.6, 7.2.3.1d)
contact)
2.2 Contact of persons with parts which have 1.5.1
become live under faulty conditions
(indirect contact)
2.3 Approach to live parts under high voltage 1.5.1, 1.6.3
2.4 Electrostatic phenomena 1.5.2
Table 1 — List of significant hazards and associated requirements (continued)
No Hazards Annex A of Relevant clause(s) in this standard
. EN 292-2:
1991/A1:1995
2.5 Thermal radiation or other phenomena 1.5.1, 1.5.5
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 1.5.5, 1.5.6, 1.5.7 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 working 1.5.5 7.2.3.7
environment
4 Hazards generated by noise 1.5.8, 1.7.4 f) “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 1.5.9 5.10.5
7 Hazards generated by materials and 5.10.2.3
substances (and their constituent
elements) processed or used by the
machinery
7.1 Hazards from contact with or inhalation of 1.1.3, 1.5.13, 7.2.4.1
harmful fluids, gases, mists, fumes and 1.6.5
dusts
8 Hazards generated by neglecting
ergonomic principles in machinery
design, as e.g. hazards from:
8.1 Unhealthy postures or excessive effort 1.1.2 d), 1.1.5, 5.4.1.3, 5.4.2, 5.4.3, 5.7, 5.8, 5.10.8
1.6.2, 1.6.4
8.2 Inadequate consideration of hand-arm or 1.1.2d), 2.2 5.7, 5.8
foot-leg anatomy
8.3 Neglected use of personal protection 1.1.2e) 7.2.4.1
equipment
8.4 Inadequate local lighting 1.1.4 5.8.1, 7.2.4.1, 7.2.3.6d)
8.6 Human error, human behaviour 1.1.2 d), 1.2.2, 5.6, 5.7.1, 5.7.2, 7.2.3, 7.2.4
1.2.5, 1.2.8,
1.5.4, 1.7
Table 1 — List of significant hazards and associated requirements (continued)
No Hazards Annex A of Relevant clause(s) in this standard
EN 292-2:
1991/A1:1995
8.7 Inadequate design, location or 1.2.2 5.4.1.3, 5.4.3, 5.7, 5.8
identification of manual controls
8.8 Inadequate design or location of 1.7.1
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 system 1,2,6, 1,6,3 5.5.6.1, 5.5.6.2, 5.5.7, 5.6.6, 5.6.8,5.7.1
11 Hazards caused by missing and/or
incorrectly positioned safety
related measures/ means
11.1 Guards 1.2.5, 1.4.2.2, 5.5.5, 5.7.1, 5.8.2.2, 5.8.2.3, 5.10.2.3
1.4.3
11.2 Safety related (protection) devices 1.2.5, 1.4.2.2, 5.4.1, 5.4.3, 5.6.3, 5.6.6, 5.6.7
1.4.3
11.4 Safety signs, signals, symbols 1.7.1, 1.7.2 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 1.7.0, 1.7.1 5.6.1, 5.6.2, 5.6.4, 5.6.7, 7.1, 7.2, 7.3
11.6 Visibility 3.2.1, 4.1.2.7 5.4.3, 5.8.1, 7.3.4.1
11.7 Emergency devices 1.2.4 5.6.3, 5.6.8
15 Assembly errors 1.5.4 7.2.2, 7.2.4
18 Loss of stability/overturning of 1.3.1 5.4.1, 5.6.1, 5.6.2, 5.6.4, 5.6.5, 5.6.6, 5.10.3
machine
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 4.1.2.1 5.10.3, 6.2.5
27.1.2 Uncontrolled loading – overloading – 4.2.1.4, 4.3.3, 5.5.4, 5.6.1, 5.6.2, 5.6.3, 5.6.4, 5.6.5
overturning moments exceeded 4.4.2a)
Table 1 — List of significant hazards and associated requirements (continued)
No Hazards Annex A of Relevant clause(s) in this standard
EN 292-2:
1991/A1:1995
27.1.3 Uncontrolled amplitude of movements 4.1.2.6a), 4.2.1.3 5.6.6
27.1.4 Unexpected/unintended movement of 4.1.2.6c) 5.5.6, 5.5.7, 5.5.8
loads
27.1.5 Inadequate holding devices/ 4.1.2.6e), 4.4.1 5.4.2, 7.2.3.6
accessories
27.2 From access of persons to load support 4.3.3 1, 7.2.3.1 e)
27.4 From insufficient mechanical strength of 4.1.2.3 5.1, 5.2, 5.3, 5.5.8, 5.5.9, 5.10.2
parts
27.8 From abnormal conditions of 4.4.1, 4.4.2.d) 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 4.1.2.7, 4.4.2c) 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 292 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;
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 classes and loading groups;
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 F = 1,1 on the masses of the crane. It shall be used for the design of the crane
structure itself and its supports.
5.2.2.2 Hoisting and gravity effects of the gross load
The dynamic effects due to hoisting the gross load shall be taken into account by applying the factor F on the
gross load.
According to their dynamic characteristics cranes are assigned to hoisting classes as a basis for the
determination of the factor F . The hoisting classes of loader cranes are given in table 2:
Table 2 — Hoist load factor FF
Hoisting class Hoist load factor Hoist load factor
v £ 1.5 m/s v > 1.5 m/s
h h
H 1
F = 1,1 + 0,132 · v F = 1,3
h
2 2
H 2
F = 1,2 + 0,264 · v F = 1,6
h
2 2
v …. Raising/ lowering speed of the load in m/s
h
For loader cranes the following hoisting classes shall be applied:
H 1 for crane mounted on a vehicle or foundation of equivalent flexibility.
H 2 for crane mounted on a static foundation.
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 as a normal working procedure, such as when grabs or
magnets are used, the peak dynamic effect on the crane can be simulated by multiplying the gross load by the
factor F .
The value is given by: F = 1 - D m x (1 + b ) /m where:
m . the mass of the gross load;
D m . the released or dropped part of the gross load;
b = 0,5 for cranes equipped with grabs or similar slow-release devices;
b = 1,0 for cranes equipped with magnets or similar rapid-release devices.
5.2.2.4 Effects caused by acceleration/deceleration of all crane drives including hoist drives
These effects shall be taken into account by various factors F .
The factor F = F shall apply on the masses of the boom system and the gross load in order to take into
5v 2
account the effects caused by raising or lowering the boom system with the gross load.
The factor F shall apply on the horizontal forces caused by slewing the crane with the gross load. The values
5h
of F shall be chosen according to 5.2.3.2.3:
5h
For superposing the loads resulting from the factors F and F load combination A, the max. vertical speed for
5v 5h,
F , F may be reduced to 0,5 x v for cranes with a stepless variable speed control. The value v is
5v 2 hmax hmax
calculated as the maximum speed at the load position resulting from the actuation of any one of the boom lift
cylinders.
5.2.3 Loads and forces
5.2.3.1 General
The following loads and forces shall be taken into account:
a) Regular loads:
1) dead loads;
2) gross load;
3) dynamic forces;
4) centrifugal forces;
b) Occasional loads:
1) in-service wind loads;
2) other climatic and environmental effects such as temperature, snow and ice;
3) loads on stairways, platforms and hand rails;
c) Exceptional loads:
1) test loads;
2) loads caused by movements suddenly stopped by a mechanical device, e.g. end stroke of slewing cylinder
or a safety device, e.g. emergency stop, hydraulic line rupture valve;
3) sudden release of the load, e.g. rope failure, sling failure.
5.2.3.2 Regular loads
5.2.3.2.1 Dead loads
See 3.1.12.
5.2.3.2.2 Gross load
See 3.1.16.
5.2.3.2.3 Forces due to acceleration/deceleration of the slewing drive
The horizontal force F shall be calculated according to the following:
h
M
F  F
h = x 5h
R
where:
F = 1,05 for hook duty and 1,3 for bucket or grapple duty;
h
F = horizontal load in [N];
h
M  = gross slewing moment [Nm] - (theoretical slewing moment with 100% efficiency);
R = outreach at calculated position [m]. If R < R /2 the value R = R /2 is used in the equation for
max max
calculating F ;
h
R = maximum hydraulic outreach [m].
max
As an alternative the value of F may be based on practical tests.
h
5.2.3.2.4 Centrifugal forces (see table 3)
The centrifugal forces acting on slewing cranes shall only be calculated from the dead load of the boom system
components, the counterweight, if applicable, and the gross load without applying the factors mentioned in
5.2.2.2 or 5.2.2.3.
5.2.3.3 Occasional loads
5.2.3.3.1 Wind loads
Wind loads shall be calculated according to ISO 4302:1981. Only in-service wind loads need to be applied.
5.2.3.3.2 Loads on stairways, platforms and hand rails
See 5.8.2.
5.2.3.3.3 Exceptional loads
Such loads may act in exceptional situations (e.g. testing, hydraulic line rupture).
5.2.4 Load combinations
5.2.4.1 Basic load combinations
Loads shall be combined to determine the stresses the crane will experience during normal operation. Basic
load combinations are given in table 3.
NOTE In general, load combinations A cover regular loads, load combinations B cover regular loads combined with
wind loads, and load combinations C cover regular loads combined with occasional and exceptional loads.
5.2.4.2 Load combinations to be covered (see table 3)
A1 and B1 Normal service conditions, raising/lowering loads with winch: A1 without wind effects, B1 with
wind effects. No other movements take place.
A2 and B2 Normal service conditions, with grapple, magnet or similar accessory allowing sudden release of
a part of the gross load:A2 without wind effects, B2 with wind effects.
A3 and B3 Normal service conditions, slewing while lifting or lowering the load: A3 without wind effects, B3
with wind effects.
C Gross load in combination with one exceptional load.
5.2.4.3 Application of table 3
The masses in column 2, lines 1 and 2, shall be multiplied by gravitational acceleration g, and masses in column
2, lines 3 and 4, by the appropriate accelerations. The resulting or given loads shall be multiplied by the
corresponding factors or by 1.
Table 3 — Load combinations to be covered
12 3 4 56
Categories Loads Load combinations Load Load Line
of loads A combinations B combina No
-tion. C
A1 A2 A3 B1 B2 B3 C
Regular Moved masses of 1 11 1
f f f f
1 1 1 1
the crane
Gravity,
Acceleration Mass of the gross 1 11 2
f f f f
2 3 2 3
load
Acceleration Moved masses of
from drives the crane and the
f f
5 5
gross load
Centrifugal forces 1 1 4
Occasional In service wind 111 5
x)
load
Effects of
climate Other climatic or 111 6
environmental.
effects
Exceptional Forces due to one exceptional 17
effects
)


Acceleration and retarding forces acting simultaneously with wind loads shall only be applied to such an extent
that the drive forces in line 3 are not exceeded
5.3 Stress analysis
Information about calculations and stress analysis is given in annex B.
5.4 Mechanical arrangements
5.4.1 Stabilizers
5.4.1.1 General
Stabilizers shall be provided when needed to fulfil the stability requirements (see 5.10.3) when loader cranes
are fitted on vehicles.
5.4.1.2 Stabilizer leg
The stabilizer leg shall have means (e.g. feet) for ground support.
Stabilizer ground support shall be constructed to accommodate ground unevenness of at least 10 .
When the stabilizer leg has a tilting device, locking means which can withstand normal operational forces (e.g.
pins) shall be provided to secure the leg in both the working and transport position (see 5.4.3).
5.4.1.3 Stabilizer extension
Stabilizers extensions shall be marked to show when they are correctly deployed.
Manually operated extensions shall be fitted with:
a) handles for the manual operation;
b) devices for locking in the working and transport positions (see 5.4.3);
c) pull out stops.
Hydraulically operated stabilizer extensions shall be fitted with locking means for the transport position. Locking
means in the working position shall be fitted if the hydraulic cylinders are not able to resist the forces during the
load handling.
5.4.2 Manual boom extensions
Manual boom extensions shall have pull out stops and mechanical locking means for their retracted and
extended positions.
5.4.3 Securing for transport
Mechanical means shall be provided to prevent uncontrolled movements of the crane and stabilizers installed
on vehicles when travelling. The stabilizers shall be locked in the transport position by two separate locking
devices for each stabilizer, at least one of these shall be automatically operated, e.g. a spring operated cam
lock and an automatic spring latch. These shall be attached to the crane and/or stabilizers and be protected
against unintentional removal, e.g. by locking pins with spring clips.
It shall be clearly visible to the operator when the locking device is in the locked and unlocked position. In
addition it shall be possible for the operator, when in the transport driving position, to check that the stabilizers
are in the transport position e.g. mirrors, warning light/buzzer interlocked to the stabilizer position.
5.5 Hydraulic system
5.5.1 General
The hydraulic system and components shall conform to the requirements as specified in EN 982:1996.
The hydraulic components and lines shall be sized such that the hydraulic system can be operated at the
intended working pressure (including any pressure required during test procedures) without any failures and
excessive temperatures being created.
Hydraulic systems shall be designed such that all components are compatible to each other and to the fluid
being used in the system at specified environmental conditions. The hydraulic system shall have adequate
filters to ensure that the fluid does not become contaminated.
Each hydraulic circuit shall be provided with means for checking the pressure.
5.5.2 Pump
A pump shall have the capacity to deliver the correct flow and pressure specified by the crane manufacturer for
the hydraulic system when being driven at the specified speed. The pump size and its specified driven speed
shall be chosen to ensure that the capacity of the power supplier is utilized efficiently.
NOTE See annex M for guidance on selecting the correct pump size.
The pump shall be suitable for the fluid specification used in the hydraulic system.
5.5.3 Hydraulic reservoir
The hydraulic reservoir shall be specified by the crane manufacturer and shall have sufficient fluid capacity for
the pump to operate correctly when all the hydraulic cylinders are fully extended. There shall also be sufficient
capacity for the fluid in the system when all the cylinders are retracted. Devices shall be incorporated to enable
monitoring the maximum and minimum fluid level. An access opening and a drain valve with plug shall be
provided for cleaning purposes.
5.5.4 Pressure relief valves
Each load carrying circuit shall be equipped with automatic means (e.g. port relief valves) which limit the
pressure to a maximum of 25 % above the maximum working pressure or shall be designed to withstand the
maximum pressure which can occur under the foreseen operating conditions.
The minimum setting of the pressure relief valves, except for timber handling cranes (see 5.6.2.1 and 5.6.2.2),
shall be such that no uncontrolled movement can take place with loads up to 1,3 x the rated capacity.
5.5.5 Hoses, tubes and fittings
Burst pressure for hoses shall be minimum four times the maximum working pressure for hoses without end
fittings. Burst pressure for tubes and fittings shall be minimum 2,5 times the maximum working pressure.
Hoses, tubes and fittings shall be so located, installed and, where appropriate, protected so that they do not get
damaged by chafing, trapping etc.
°
Hydraulic hoses containing fluid with a pressure of more than 5 MPa and/or having a temperature over 50 C
and which are located within 1,0 m of the operator, shall be guarded.
Any part or component which may divert a possible jet of fluid can be considered as a sufficient protection
device.
Hoses intended to withstand a pressure of more than 15 MPa shall not be fitted with reusable end fittings.
5.5.6 Precautions against hydraulic line rupture
5.5.6.1 Loader cranes other than timber handling cranes
All load carrying circuits shall be equipped with automatic means, e.g. load holding valves, to prevent
uncontrolled movement of the crane in the case of hydraulic line rupture. Flow sensitive check valves shall only
be used for equalizing and pressure sensing lines. The maximum flow through these lines shall not exceed 3
l/min.
Valves used for this means shall be close coupled to the cylinder. They shall be either:
a) integral with the cylinder, or
b) directly and rigidly flange mounted, or
c) placed closed to the cylinder or connected to it by means of short rigid pipes having welded, flanged or
threaded connections.
For tubes and fitting between lock valve and actuator the safety factor shall be 2,5 calculated against the
maximum dynamic pressure.
5.5.6.2 Timber handling cranes
In the event of hydraulic line rupture the lowering speed of the load shall not exceed the maximum lowering
speed at rated capacity by more than 30%. (see explanatory note to 5.5.6.2 in informative annex C).
Stabilizer leg cylinders shall be equipped as specified in 5.5.6.1.
5.5.7 Sink rate for boom system
The sink rate measured at the boom system tip caused by leakage in hydraulic components shall not exceed
0,5 % of outreach per minute. For timber handling cranes, however, the sink rate may be 2 % of outreach per
minute.
Sink rate shall be tested at maximum rated capacity and at maximum hydraulic outreach. (i e without manual
extensions).
5.5.8 Slewing mechanism
The slewing mechanism shall be able to withstand the maximum slewing forces (see 5.2.3.3.3) to bring it to a
stop and sustain the load under the most adverse operating conditions.
5.5.9 Calculation of hydraulic cylinders
Hydraulic cylinders shall be calculated for dynamic working pressure with a safety factor against the yield stress
of minimum 1,5.
5.6 Limiting and indicating devices
5.6.1 General
5.6.1.1 Rated capacity limiters and indicators shall be provided on all cranes having a rated capacity of 1 000
kg or above, or a maximum net lifting moment of 40 000 Nm or above due to the load. The rated capacity shall
be determined at all outreaches corresponding to the boom system being horizontal.
Rated capacity limiters/indicators shall conform to EN 12077-2:1998. Safety related parts of limiting and
indicating systems shall conform to EN 954-1:1996 category 1 except for electronic parts of the system for
limiting devices which shall conform to EN 954-1:1996 category 2.
The rated capacity limiter for a loader crane generally has three different tasks to fulfil:
1) prevent the structure from being overloaded;
2) prevent the risk of overturning of the vehicle;
3) prevent dangerous movements of the load.
All movements that will reduce the loading on the crane shall always be available.
NOTE Regarding rated capacity limiters on loader cranes see also explanatory note to 5.6 given in informative annex
C. For examples of dangerous movement for different crane types see informative annex D.
For loader cranes with a rated capacity of less than 1 000 kg or a maximum net lifting moment of less than
40 000 Nm the relief valves according to 5.5.4 and 5.6.5 shall provide overload protection when a rated capacity
limiter is not provided. The provision of a clearly marked pressure gauge showing the approach to the rated
capacity, visible from the operators station, will fulfil the function of a rated capacity indicator for these cranes.
5.6.1.2 If the rated capacity is lower in sectors of the slewing range the crane shall be provided with slew
limiters. These shall operate to override the controls of the crane when attempting to slew into this sector with a
load higher than the rated capacity or lift loads above the rated capacities within the sector. The rated capacity
indicator/limiter shall operate in all sectors of the slewing range.
5.6.1.3 When the boom system of a vehicle mounted loader crane is to be parked on the load platform or on
top of the load during transport, an indicator (e.g. angle sensor) shall be provided. This indicator shall inform the
operator when the crane height exceeds a predetermined maximum (as described in 7.2.3.3).
5.6.1.4 Cranes equipped with stabilizers shall be provided with a level indicator in clear view of the operator at
the stabilizer control station.
5.6.1.5 For cranes, equipped with a winch, the winch shall be included in the system of the rated capacity
limiter.
5.6.1.6 For cranes equipped with manual extensions, these extensions shall be included in the system of the
rated capacity limiter. A mode selector may be provided to select the boom system configuration on the limiting
and indicating device when manual extensions are fitted.
5.6.2 Rated capacity limiter
5.6.2.1 The rated capacity limiter shall operate within the designed operating accelerations of the crane
between 100% and (100 + D %) of the rated capacity. The value of D depends on hydraulic outreach according
to the following formula:
D £ 8 + 0,5 R £ 20
where:
R = hydraulic outreach in metres
For timber handling cranes, the tolerance 20% may be used independent of the hydraulic outreach.
NOTE It is generally accepted that a capacity limiter for loader cranes limits the load moment. At long outreach the
main part of the total lifting moment comes from the dead loads and only a small part from the payload. Tolerances for the
capacity limiter as stated above have been set taking this into account.
5.6.2.2 For timber handling cranes port relief valves with tolerances according to 5.6.2.1 shall provide overload
protection when a rated capacity limiter is not provided.
5.6.3 Emergency lowering facility
In order to avoid locking-in of the loader crane after an actuation of the rated capacity limiter an emergency
overriding facility may be provided. This facility shall not allow any boom extension.
If this emergency facility is fitted it shall be clearly identified. This facility shall only function whilst the control is
held by the operator and for a period of maximum 5 seconds at intervals not shorter than 30 seconds.
5.6.4 Rated capacity indicators
The rated capacity indicator shall give a warning to the operator when the load exceeds 90% of the rated
capacity. If the rated capacity is being exceeded there shall be a separate warning for overload to the operator
and persons in the vicinity of the crane.
There shall be a clear difference between the warning for approach to rated capacity and the warning for
overload. Both warnings shall be continuous and shall be distinguishable as a warning to the persons
concerned whilst the crane is being operated.
The warning of persons in the danger zone is not appropriate for a loader crane with an outreach less than
12 m.
5.6.5 Main relief valve
All loader cranes shall be fitted with one or more main relief valves.
The main relief valve shall operate within the designed operating accelerations of the crane between 100 % and
110 % of the rated capacity.
5.6.6 Performance limiters
5.6.6.1 Motion limiters
Slewing, raising/lowering and telescoping motion limits shall be determined by the stroke of the cylinder or by
appropriate stops.
5.6.6.2 Speed limiters
Speed limiters shall be incorporated into the slewing, raising/lowering and telescoping motion to ensure that any
forces resul
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