i.s.en12999-2011+a2-2018

IrishStandard I.S.EN 12999:2011+A2:2018 Cranes - Loadercranes © CEN 2018 Nocopying without NSAIpermissionexcept aspermittedby copyright law. This is a free 100 page sample. Access the full version online.

I.S. EN 12999:2011+A2:2018 Incorporating amendments/corrigenda/National Annexes issuedsince publication: The NationalStandards Authority of Ireland(NSAI)produces the following categories of formaldocuments: I.S.xxx: Irish Standard — nationalspecificationbasedontheconsensusof anexpertpanelandsubject topublicconsultation. S.R.xxx:Standard Recommendation — recommendationbasedontheconsensusof anexpertpanelandsubject topublicconsultation. SWiFTxxx: A rapidlydevelopedrecommendatorydocumentbasedontheconsensusof theparticipantsof an NSAI workshop. This document replaces/revises/consolidates the NSAIadoptionof the document(s) indicatedonthe CEN/CENELEC cover/Forewordandthe following Nationaldocument(s): NOTE:The date of any NSAIprevious adoption may not matchthe date of its original CEN/CENELEC document. This document is basedon: EN 12999:2011+A2:2018 Published: 2018-02-28 This document was published under the authority of the NSAI andcomes into effecton: 2018-03-18 ICS number: 53.020.20 NOTE: If blank see CEN/CENELEC coverpage NSAI 1 Swift Square, Northwood,Santry Dublin9 T +353 1 807 3800 F+353 1 807 3838 E [email protected] W NSAI.ie Sales: T +353 1 857 6730 F+353 1 857 6729 W standards.ie Údarás um Chaighdeáin Náisiúnta na hÉireann This is a free 100 page sample. Access the full version online.

National Foreword I.S.EN 12999:2011+A2:2018 is the adoptedIrishversionof the European Document EN 12999:2011+A2:2018, Cranes - Loader cranes This documentdoes notpurport to include all the necessary provisions of a contract. Users are responsible for its correct application. For relationships withotherpublications refer to the NSAI webstore. Compliance with this document does not of itself confer immunity from legal obligations. Inline withinternational standards practice the decimalpoint is shownas a comma (,) throughout this document.This is a free 100 page sample. Access the full version online.

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EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM EN 12999:2011+A2 February 2018 ICS 53.020.20 English Version Cranes - Loader cranes Appareils de levage à charge suspendue - Grues de chargement Krane - Ladekrane This European Standard was approved by CEN on 13 May 2012 and includes Amendment 2 approved by CEN on 10 March 2017. 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, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION C O M I T É E U R O P É E N D E N O R M A L I S A T I O N E U R O P Ä I S C H E S K O M I T E E F Ü R N O R M U N G CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels © 2018 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 12999:2011+A2:2018 E I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 2 Contents European foreword ...................................................................................................................................................... 5 Introduction.................................................................................................................................................................... 6 1 Scope.................................................................................................................................................................... 7 2 Normative references.................................................................................................................................... 7 3 Terms, definitions and terminology ........................................................................................................ 9 3.1 Terms and definitions................................................................................................................................... 9 3.2 Terminology ...................................................................................................................................................13 4 List of significant hazards ..........................................................................................................................15 5 Safety requirements and/or safety measures....................................................................................18 5.1 General..............................................................................................................................................................18 5.2 Structural calculation..................................................................................................................................19 5.2.1 Information to be given in the calculation...........................................................................................19 5.2.2 Dynamic factors.............................................................................................................................................19 5.2.3 Loads and forces............................................................................................................................................21 5.2.4 Load combinations .......................................................................................................................................23 5.3 Stress analysis................................................................................................................................................24 5.4 Mechanical arrangements .........................................................................................................................25 5.4.1 Stabilizers ........................................................................................................................................................25 5.4.2 Manual boom extensions ...........................................................................................................................26 5.4.3 Securing for transport.................................................................................................................................26 5.4.4 Hoists.................................................................................................................................................................26 5.4.5 Load hooks ......................................................................................................................................................26 5.5 Hydraulic system ..........................................................................................................................................27 5.5.1 General..............................................................................................................................................................27 5.5.2 Pump..................................................................................................................................................................27 5.5.3 Hydraulic reservoir......................................................................................................................................27 5.5.4 Pressure limiting device.............................................................................................................................27 5.5.5 Hoses, tubes and fittings.............................................................................................................................27 5.5.6 Precautions against hydraulic line rupture ........................................................................................28 5.5.7 Sink rate for boom system.........................................................................................................................28 5.5.8 Slewing mechanism......................................................................................................................................29 5.6 Limiting and indicating devices...............................................................................................................29 5.6.1 General..............................................................................................................................................................29 5.6.2 Rated capacity limiter .................................................................................................................................30 5.6.3 Lowering facility............................................................................................................................................31 5.6.4 Rated capacity indicators...........................................................................................................................31 5.6.5 Limiters ............................................................................................................................................................31 5.6.6 Operational warning....................................................................................................................................31 5.6.7 Acoustic warning...........................................................................................................................................32 5.6.8 Stopping device..............................................................................................................................................32 5.7 Controls ............................................................................................................................................................32 5.7.1 General..............................................................................................................................................................32 5.7.2 Symbols ............................................................................................................................................................32 5.7.3 Layout of bi-directional controls.............................................................................................................33 5.7.4 Guidance for high seat controls ...............................................................................................................33 5.8 Control stations .............................................................................................................................................33 5.8.1 General..............................................................................................................................................................33 5.8.2 Raised control stations ...............................................................................................................................35 5.9 Electrical systems .........................................................................................................................................36 I.S. 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EN 12999:2011+A2:2018 (E) 3 5.9.1 General .............................................................................................................................................................36 5.9.2 Electromagnetic compatibility ................................................................................................................36 5.10 Installation......................................................................................................................................................36 5.10.1 General .............................................................................................................................................................36 5.10.2 Mounting..........................................................................................................................................................36 5.10.3 Stability ............................................................................................................................................................37 5.10.4 Noise..................................................................................................................................................................37 5.10.5 Vibrations........................................................................................................................................................38 5.10.6 Electrical systems (installation) .............................................................................................................38 5.10.7 Hydraulic components................................................................................................................................38 5.10.8 Access................................................................................................................................................................38 6 Verification of the safety requirements and/or measures............................................................38 6.1 General .............................................................................................................................................................38 6.2 Testing and test procedures .....................................................................................................................42 6.2.1 General .............................................................................................................................................................42 6.2.2 Functional test...............................................................................................................................................42 6.2.3 Static test .........................................................................................................................................................42 6.2.4 Dynamic test...................................................................................................................................................43 6.2.5 Stability test....................................................................................................................................................43 6.2.6 Test documentation.....................................................................................................................................45 6.2.7 #Documentation for variable stabilizer deployment..................................................................45 6.3 Noise emission measurement..................................................................................................................45 7 Information for use......................................................................................................................................46 7.1 General .............................................................................................................................................................46 7.2 Manuals ............................................................................................................................................................46 7.2.1 Provision of manuals...................................................................................................................................46 7.2.2 Instructions for the installer ....................................................................................................................46 7.2.3 Operator's manual .......................................................................................................................................46 7.2.4 Maintenance manual...................................................................................................................................48 7.3 Marking ............................................................................................................................................................48 7.3.1 General .............................................................................................................................................................48 7.3.2 Manufacturer's plate ...................................................................................................................................48 7.3.3 Installer's plate..............................................................................................................................................49 7.3.4 Load signs........................................................................................................................................................49 7.3.5 Special signs on timber handling cranes..............................................................................................53 7.3.6 Marking of slewing centre.........................................................................................................................54 7.3.7 #Marking of maximum ground load ..................................................................................................54 7.3.8 Marking for high seat..................................................................................................................................54 Annex A (informative) Examples of configurations and mountings .......................................................55 A.1 Boom systems ................................................................................................................................................55 A.1.1 Loader cranes with straight boom system ..........................................................................................55 A.1.2 Loader cranes with articulated boom system....................................................................................55 A.2 Examples of loader crane mountings ....................................................................................................56 Annex B (informative) Stress history parameter s and stress history classes S.................................60 Annex C (informative) Explanatory notes.........................................................................................................64 C.1 Rated capacity limiters...............................................................................................................................64 C.2 Timber handling cranes - Line rupture ................................................................................................64 C.3 Control stations.............................................................................................................................................64 I.S. 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EN 12999:2011+A2:2018 (E) 4 Annex D (informative) Examples of dangerous movements......................................................................65 Annex E (normative) Symbols for working and setting-up functions.....................................................67 Annex F (informative) Control system – Preferred vertical layout for controls operated from the ground ............................................................................................................................................69 Annex G (informative) Control system - Horizontal layout order............................................................71 Annex H (informative) Control levers for high seats and remote controls...........................................74 H.1 High seat controls .........................................................................................................................................74 H.1.1 Multidirectional (joy-stick) controls .....................................................................................................74 H.1.2 Bi-directional controls................................................................................................................................74 H.2 Remote controls ............................................................................................................................................74 Annex I (not used).......................................................................................................................................................77 Annex J (normative) Cabins fitted on vehicle mounted loader cranes up to a net lifting moment of 250 kNm.....................................................................................................................................78 Annex K (informative) Examples of raised control stations .....................................................................81 Annex L (normative) Raised control stations - Measures regarding hand rails and hand holds, ladders and steps.............................................................................................................................83 Annex M (informative) Installation of a loader crane on a vehicle..........................................................86 M.1 General..............................................................................................................................................................86 M.2 Installation: minimum data ......................................................................................................................86 M.2.1 Crane dimensions in transport position: data ...................................................................................86 M.2.2 Crane data (see Figure M.2) ......................................................................................................................87 M.2.3 Mounting data ................................................................................................................................................87 M.2.4 Power requirements....................................................................................................................................87 M.2.5 Stability calculations: data ........................................................................................................................87 M.3 Power take off (PTO) and pump displacement..................................................................................88 M.4 Calculation method for determination of sub-frame dimensions...............................................88 M.4.1 General considerations...............................................................................................................................88 M.4.2 Stresses.............................................................................................................................................................89 M.4.3 Material and limit states ............................................................................................................................89 M.4.4 Symbols and equations...............................................................................................................................89 Annex N (informative) Selection of a suitable set of crane standards for a given application ......92 Annex ZA (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC ........................................................................................94 Bibliography .................................................................................................................................................................95 I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 5 European foreword This document (EN 12999:2011+A2:2018) 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 August 2018, and conflicting national standards shall be withdrawn at the latest by August 2018. 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 includes Amendment 1 approved by CEN on 13 May 2012. This document includes Amendment 2 approved by CEN on 10 March 2017. This document supersedes #EN 12999:2011+A1:2012$. The start and finish of text introduced or altered by amendment is indicated in the text by tags !". The start and finish of text introduced or altered by amendment is indicated in the text by tags #$. 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, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (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. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (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. #The amended provisions concerning stress calculations are not compulsory for cranes designed before the date of availability of EN 12999:2011+A2:2017.$ NOTE The use of cranes for lifting of persons can be subject to specific national regulations. 2 Normative references !The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies." #NOTE In the event of conflicting statements between referenced documents and this document, the statements in this document apply.$ 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 #EN 13001-3-1$, Cranes — General design — Part 3-1: Limit states and proof competence of steel structure #EN 13001-3-2, Cranes - General design - Part 3-2: Limit states and proof of competence of wire ropes in reeving systems$ EN 13557:2003+A2:2008, Cranes - Controls and control stations EN 13586:2004+A1:2008, Cranes - Access #EN 14033-2, Railway applications – Track – Railbound construction and maintenance machines – Part 2: Technical requirements for working$ I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 8 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) 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) I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 9 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 #power driven crane, designed for being attached to a chassis, comprising a column, which slews about a base, and a boom system which is attached on to the top of the column, designed to be 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 to entry: A loader crane, as defined above in 3.1.1, installed on another type of vehicle (e.g. rail vehicle) or on a static foundation is still considered a loader crane. Note 2 to entry: Annex A gives examples of configuration and mountings.$ 3.1.2 articulated movement 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 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. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 10 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 !deleted text" 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 portion of the hoist rope 3.1.18 high seat control station connected to the column, consequently rotating with the crane 3.1.19 hoist machines for lifting and lowering suspended loads over predetermined distances, using ropes, chains or belts I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 11 3.1.20 hydraulic line rupture failure of a hydraulic line which results in a loss of pressure in the line #3.1.21 lifting movement raising or lowering of the boom system and/or the load which causes a change in its vertical position$ 3.1.22 load holding valve valve which is normally closed and is opened by an external force to enable flow of fluid out of a hydraulic actuator 3.1.23 main relief valve valve which limits the pressure supplied to the hydraulic system of the crane 3.1.24 maximum working load the maximum load that may be lifted NOTE The largest load appearing in the load plate. 3.1.25 maximum working pressure maximum pressure in pump circuit or individual working function 3.1.26 net lifting moment rated capacity multiplied by outreach 3.1.27 non-fixed load lifting attachment lifting accessory 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 3.1.28 outreach horizontal distance between the axis of rotation of the column and point of load attachment 3.1.29 outreach, hydraulic outreach which can be obtained with hydraulically actuated parts of the boom system 3.1.30 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) 3.1.31 port relief valve valve which limits the pressure supplied to a hydraulic actuator I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 12 3.1.32 pressure relief valve valve which automatically relieves the hydraulic oil to the tank when the pressure exceeds a specified value 3.1.33 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) 3.1.34 rated capacity load that the crane is designed to lift for a given operating condition (e.g. configuration, position of the load) 3.1.35 rated capacity indicator device which gives, within tolerance limits specified in 5.6.2.1, 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 3.1.36 rated capacity limiter system that automatically prevents the crane from handling loads in excess of its rated capacity, see also C.1 3.1.37 setting-up function crane function used to prepare the crane for lifting 3.1.38 sink rate distance in a given time at which the load lowers due to internal leakage of hydraulic components 3.1.39 slewing rotational movement of the column and boom system about the axis of the column 3.1.40 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 3.1.41 stabilizer extension part of the stabilizer capable of extending the stabilizer leg laterally from the transport position to the operating position 3.1.42 stabilizer leg part of a stabilizer capable of contacting the ground to provide the required stability 3.1.43 static foundation fixed support incorporating mounting points for a crane I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 13 3.1.44 timber handling crane loader crane specifically designed, manufactured and equipped with a grapple for loading/unloading of unprepared timber (e.g. tree trunks, branches) NOTE The operator controls the crane from a high seat or from a cabin. 3.1.45 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 European Standard for the main parts of a loader crane are indicated in Figure 1. Boom system consists of items 6 to 12 plus items 16 to 22, if applicable. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 14 Key 1 base 7 1st boom cylinder 13 hook 19 boom extension, hydraulic 2 stabilizer extension 8 2nd boom 14 controls 20 extension cylinders 3 stabilizer leg 9 2nd boom cylinder 15 stabilizer foot 21 hook 4 slewing mechanism #e.g. rack and pinion, 10 boom extension, hydraulic 16 3rd boom adapter 22 boom extension, manual I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 15 slewing ring$ 5 column 11 extension cylinders 17 3rd boom 6 1st boom 12 boom extension, manual 18 3rd boom cylinder Figure 1 — Main parts of a loader crane 4 List of significant hazards Table 1 shows a list !deleted text" of significant hazardous situations and hazardous events that could result in risks to persons during intended use and foreseeable misuse. It also contains corresponding cross-references to the relevant clauses in this European Standard that are necessary to reduce or eliminate the risks associated with those hazards. Before using this European Standard it is important to carry out a risk assessment of the crane. As a minimum the hazards covered by Table 1 should be included in the risk assessment. Table 1 — List of significant hazards and associated requirements No. Hazards Relevant clause(s) in this European Standard 1 Mechanical hazards due to: - Inadequacy of mechanical strength of the crane and its parts 5.1, 5.2, 5.3, 5.4, 5.5.1, 5.5.4, 5.5.5, 5.5.8, 5.8.2.1, 5.8.2.2, 5.10.2 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 ejection hazard 5.5.1, 5.5.5, 5.10.7, 7.2.3.6, 7.2.4.2 1.10 Ejection of parts 5.4.1.2, 5.4.1.3, 5.4.2, 5.4.3 1.11 Loss of stability 5.4.1, 5.6.1.1, 5.6.1.2, 5.6.1.8, 5.6.3, 5.10.2.1, 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 (direct contact) 5.9, 5.10.6, 7.2.3.1 d) 2.2 Contact of persons with parts which have become live under faulty conditions (indirect contact) I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 16 No. Hazards Relevant clause(s) in this European Standard 2.3 Approach to live parts under high voltage 5.6.1.3 2.4 Electrostatic phenomena Not applicable. 2.5 Thermal radiation or other phenomena such as the projection of molten particles and chemical effects from short circuits, overloads, etc. Not applicable. 3 Thermal hazards, resulting in: 3.1 Burns, scalds and other injuries by possible contact of persons with objects or materials with an extreme high or low temperature, by flames or explosions and also by radiation of heat sources 5.5.5, 5.10.2.3 3.2 Damage to health by hot or cold working environment 7.2.3.8 4 Hazards generated by noise 5.10.4, 7.2.3.9 5 Hazards generated by vibration 5.10.5 7 Hazards generated by materials and substances (and their constituent elements) processed or used by the machinery 5.10.2.3 7.1 Hazards from contact with or inhalation of harmful fluids, gases, mists, fumes and dusts 7.2.4.1 8 Hazards generated by neglecting ergonomic principles in machinery design, as e.g. hazards from: 8.1 Unhealthy postures or excessive effort 5.4.1.3, 5.4.2, 5.7, 5.8, 5.10.8 8.2 Inadequate consideration of hand-arm or foot-leg anatomy 5.7, 5.8 8.3 Neglected use of personal protective equipment 8.4 Inadequate local lighting 7.2.3.7 f) 8.6 Human error, human behaviour 5.6, 5.7.1, 5.7.2, 7.2.3, 7.2.4 I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 17 No. Hazards Relevant clause(s) in this European Standard 8.7 Inadequate design, location or identification of manual controls 5.4.1.3, 5.4.3, 5.7, 5.8 8.8 Inadequate design or location of visual display units 5.6.1.1 9 Combination of hazards 10 Unexpected start-up, unexpected overrun/overspeed (or any similar malfunction) from: 10.1 Failure/disorder of the control system 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 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, 7.3.4, 7.3.5 11.5 Information or warning devices 5.6.1, 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 machine 5.4.1, 5.6.1, 5.6.2, 5.6.4, 5.6.5, 5.6.6, 5.10.3 I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 18 No. Hazards Relevant clause(s) in this European 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 – stabilizing moment exceeded 5.5.4, 5.6.1, 5.6.2, 5.6.3, 5.6.4, 5.6.5 27.1.3 Uncontrolled amplitude of movements 5.6.6 27.1.4 Unexpected/unintended movement of loads 5.5.6, 5.5.7, 5.5.8 27.1.5 Inadequate holding devices/ accessories 5.4.2, 7.2.3.7 27.2 From access of persons to load support 7.2.3.1 e) 27.4 From insufficient mechanical strength of parts 5.1, 5.2, 5.3, 5.5.8, 5.10.2 27.8 From abnormal conditions of assembly/testing/use/maintenance 5.10, 7.1, 7.2. 7.3 29 Hazards generated by neglecting ergonomic principles 29.1 Insufficient visibility from the driving position 5.8.1 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 in accordance with the principles of EN ISO 12100 for hazards relevant but not significant which are not dealt with by this European 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. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 19 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 maximum crane inclination; e) the governing hoisting class, hoist drive class and stress history classes or stress history parameters; 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 included in the loading by applying the factor ϕ 1 on the gravitational forces due to the masses of the crane. It shall be used for the design of the crane structure itself and its supports. For load combinations A1, B1 and C1, the value of ϕ 1 shall be the lowest of the two values 1,1 and ϕ 2, or expressed as an equation: ϕ 1 = min (1,1 ; ϕ 2) NOTE In general ϕ 1 = 1,1. However, it shall not exceed the value of ϕ 2 in case ϕ 2 is less than 1,1. #For load combinations A2 and B2, the value of ϕ1 shall be 0,95.$ 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 vibrational effects shall be included in the loading by multiplying the gravitational force due to the mass of the hoist load by a factor ϕ 2. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 20 # Figure 2 — Dynamic effect when hoisting a load $ The factor ϕ 2 shall be taken as follows: ϕ 2 = ϕ 2,min + β2 × vh ϕ 2,min and β2 are given in Table 2a for the appropriate hoisting class. Loader cranes are assigned to hoisting classes HC1 and HC2 in accordance with their dynamic and elastic characteristics: HC1 for crane mounted on a vehicle or structures of equivalent flexibility; HC2 for rigidly mounted cranes. 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. vh is the steady vertical hook speed, in metres per second, related to the lifting attachment. Values of vh are given in Table 2b. Table 2a — Value of β2 and ϕ 2,min # Hoisting class of appliance β2 ϕ2,min for HD1 and HD4 ϕ2,min for HD5 HC 1 0,17 1,05 1,05 HC 2 0,34 1,10 1,05 $ Table 2b — Values of vh Load combination Type of #control system$and its operation method HD1 HD4 HD5 A1, B1 vh,max 0,5 × vh,max vh = 0 C1 vh,max vh,max 0,5 × vh,max where HD1 #is when the lifting movement can only be operated at a fixed speed, e.g. simple on-off control;$ I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 21 HD4 #is when the start of the lifting movement is performed with continuously increasing speed, e.g. proportional spool valve;$ HD5 #is when the step-less control automatically ensures that the dynamic factor ϕ2 does not exceed ϕ2,min, e.g. electronically controlled proportional pressure compensated spool valve;$ vh,max is the maximum vertical hook speed. In load combinations A1 and B1, vh,max is the maximum vertical hook speed that is given by any single hydraulic drive action. In load combination C1, vh,max is the maximum vertical hook speed from all articulation hydraulic drives acting simultaneously. NOTE In load combinations A and B it is assumed that the dynamic peaks from simultaneous movements do not coincide. The unlikely event that the dynamic peaks coincide and are superimposed is covered by load combination C1. 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 working procedure during intended use, 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 Φ3 . The value is given by: Φ3 = 1 - Δm × (1 + β) /m where m is the mass of the gross load; Δm is the released or dropped part of the gross load; β = 0,5 for cranes equipped with grabs or similar slow-release devices; β = 1,0 for cranes equipped with magnets or similar rapid-release devices. 5.2.2.4 Effects caused by acceleration/deceleration of the slewing drive The dynamic factor Φ5h shall have the value 1,05 for hook duty and 1,3 for bucket or grapple duty. 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; I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 22 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; 4) forces due to simultaneous dynamic peaks caused by raising or lowering a load at the maximum sum of the vertical speeds from all articulation drives. 5.2.3.2 Regular loads 5.2.3.2.1Dead loads See 3.1.13. 5.2.3.2.2Gross load See 3.1.17. 5.2.3.2.3Forces due to acceleration/deceleration of the slewing drive The horizontal loads from the masses of the crane and of the payload shall be calculated as follows: Fhi = mi ⋅ g ⋅ tan α, α ≥ 3° where Fhi is the horizontal load i acting on the payload or a mass point of the boom; mi is the payload or mass point of boom; g is the gravity constant; α is the maximum inclination for the crane in accordance with the manufacturer’s specification. However, the minimum value that may be used is α = 3°. 5.2.3.2.4Centrifugal 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. 5.2.3.2.5Forces on stabilizer legs The stabilizer legs shall be loaded by simultaneously acting vertical and horizontal forces. The horizontal force shall act at the stabilizer foot with the leg at its maximum length and in the most unfavourable direction. The magnitude of the horizontal force shall be at least 5 % of the vertical force. 5.2.3.3 Occasional loads 5.2.3.3.1Wind loads Wind loads shall be calculated according to EN 13001-2. Only in-service wind needs to be applied. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 23 5.2.3.3.2Loads on stairways, platforms and hand rails See 5.8.2. 5.2.3.4 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 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 Intended service conditions, raising/lowering loads with dynamic peak from any single hydraulic function while slewing: A1 without wind effects, B1 with wind effects. A2 and B2 Intended service conditions, with grapple, magnet or similar accessory allowing sudden release of a part of the gross load while slewing: A2 without wind effects, B2 with wind effects. C1 Simultaneous dynamic peaks caused by raising or lowering a load at the maximum sum of the vertical speeds from all articulation drives, taking into account the available oil flow. C3 Crane under test condition. 5.2.4.3 Application of Table 3 Basic load combinations for the calculation to prove that mechanical hazards from yielding and elastic instability from extreme values do not occur are given in Table 3. For the proof of fatigue strength, load combinations A1 and A2, with all partial safety factors γp set to 1,00, shall be applied. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 24 Table 3 — Load combinations to be covered Categorie s of load Loads Load comb. A Load comb. B Load comb. C Ro γp A1 A2 γp B1 B2 γp C1 C3 w Regular Gravity, Acceler ation of lifting drives Moved masses of the crane 1,22 ϕ1 ϕ1 1,16 ϕ1 ϕ1 1,1 ϕ1 1 1 Mass of the gross load 1,34 ϕ2 ϕ3 1,22 ϕ2 ϕ3 1,1 - - 2 Acceler ation of slewing drive Moved masses of the crane 1,22 ϕ5h ϕ5h 1,16 ϕ5h ϕ5h - - - 3 Mass of the gross load 1,34 ϕ5h ϕ5h 1,22 ϕ5h ϕ5h - - - 4 Centrif ugal loads a Masses of the crane 1,22 1 1 1,16 1 1 - - - 5 Mass of the gross load 1,34 1 1 1,22 1 1 - - - 6 Occasional Climate effects In service wind b - - - 1,22 1 1 - - - 7 Exception al Forces due to one exceptional event - - - - - - 1,1 ϕ2 1 8 a Only centrifugal loads that increase the load effects shall be included. b Forces acting simultaneously with wind forces shall only be applied to such an extent that the drive force in row 3 and row 4 is not exceeded. 5.2.4.4 Loads from foreseeable misuse When calculating the effects of foreseeable misuse, all partial safety factors γp shall be set to 1,1. 5.3 Stress analysis #The strength of the steel structure shall be assessed in accordance with EN 13001-1, EN 13001-2 and EN 13001-3-1.$. The limit states given in #EN 13001-3-1$should be used in conjunction with a static analysis that is made for all boom positions and for all crane configurations. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 25 5.4 Mechanical arrangements 5.4.1 Stabilizers 5.4.1.1 General Stabilizers shall be provided when necessary 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 a foot for ground support. Stabilizer feet shall be designed to adjust to a ground unevenness of at least 10°. !Timber handling cranes may however have fixed stabilizer feet, in which case the leg shall be designed for the additional bending moment." The area of each foot shall be such that the resultant maximum ground pressure is less than 4 MPa. For the main stabilizers, the maximum ground pressure shall be calculated as: L A M P dyn ⋅ = where Mdyn is the maximum moment at slewing centre including dynamic factors; L is the distance from slewing centre to stabilizer leg #at maximum spread$; A is the area of stabilizer foot. In case of auxiliary stabilizers, their feet shall have the same size as for the main stabilizers. Alternatively a detailed calculation of the entire installation shall be carried out or stabilizers forces shall be measured. #NOTE The actual ground pressure during operation can be higher than 4 MPa due to reduced stabilizer spread or partly lifted vehicle.$ When the stabilizer leg has a tilting device, locking means which can withstand operational forces from intended use (e.g. pins) shall be provided to secure the leg in both the working and transport position (see 5.4.3). If stabilizer legs have to be tilted (rotated) up or down manually, the maximum force to activate one of them shall not exceed 250 N, measured at the stabilizer foot. 5.4.1.3 Stabilizer extension #There shall be an indication showing that the stabilizer extensions are fully extended.$ Manually operated extensions shall be fitted with: a) handles for the manual operation; b) devices for locking extensions in the working and transport positions (see 5.4.3); c) pull out stops. Locking means in the working position shall be fitted if the hydraulic cylinders are not able to resist the forces during load handling. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 26 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 5.4.3.1 General !A system (e.g. angle sensor) detecting that the first boom is not stowed below permissible transport height shall be provided to all vehicle mounted loader cranes, see 5.6.1.3." Locking means shall be provided to prevent uncontrolled movements of the crane and stabilizers installed on vehicles when travelling. Each of the stabilizer extension locking devices shall be designed to withstand, with no permanent deformation, the forces resulting from an acceleration of 2 g, applied in the direction of the movement. 5.4.3.2 Manually operated extensions Manually operated stabilizer extensions 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 shall be protected against unintentional removal, e.g. by locking pins with spring clips. It shall be clearly visible to the operator when the manual locking devices are in the locked and unlocked position. In addition, it shall be indicated when the stabilizers are not locked in the transport position, see 5.6.1.5. 5.4.3.3 Hydraulically operated extensions Hydraulically operated stabilizer extensions shall be fitted with an automatic hydraulic or automatic mechanical locking device for the transport position, in addition to a control valve that is closed in its neutral position. Any valve used for automatic hydraulic locking shall be in accordance with 5.5.6.1. A mechanical locking device shall be designed to withstand, without permanent deformation, the force due to the foreseeable misuse of attempting to extend the stabilizers with the locking devices engaged. 5.4.4 Hoists Power driven hoists shall be in accordance with EN 14492-2. #deleted sentence$. #Rope reeving systems shall be designed in accordance with EN 13001-3-2.$ 5.4.5 Load hooks Hooks shall be designed in accordance with the state of the art. NOTE More information can be found in DIN 15400 and DIN 15401–2. Hooks shall be such that the unintentional detachment of the load is prevented. This can be achieved by: — a safety device or — the shape of the hook. Hooks equipped with a safety-latch fulfil these requirements. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 27 5.5 Hydraulic system 5.5.1 General The hydraulic system and components shall conform to the requirements specified in EN ISO 4413. The hydraulic components and lines shall be sized such that the hydraulic system can be operated at the intended working pressure and flow (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 with each other and with 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. Pressure and flow control devices or their enclosures shall be fitted with tamper-evident devices where an unauthorized alteration to pressure or flow can cause a hazard. Means shall be supplied for locking the setting of adjustable components or of locking their enclosures, if changes or adjustment can cause a hazard. 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. There shall be a device that limits the pressure supplied by the pump to the loader crane. NOTE See Annex M for guidance on selecting the correct pump size. The pump shall be suitable for the fluid used in the hydraulic system. 5.5.3 Hydraulic reservoir The hydraulic reservoir shall have sufficient fluid capacity for the pump to operate correctly when all the hydraulic cylinders are fully extended, including any auxiliary equipment. 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 limiting device If a load carrying circuit cannot withstand the maximum pressure that can occur, means shall be provided to limit the maximum pressure to the design value. Such pressure limiting devices shall, except for — loader cranes with a rated capacity of less than 1 000 kg and a maximum net lifting moment of less than 40 000 Nm; — timber handling cranes, #be set so that no uncontrolled movement can occur at a pressure lower than 1,1 times the pressure corresponding to the tolerance limit of the rated capacity limiter as specified in 5.6.2.1.$ 5.5.5 Hoses, tubes and fittings #Burst pressure for hoses shall in general be at least four times the maximum working pressure of the hose. However, for HD5 drives, hoses may have a burst pressure that is minimum 3,5 times the maximum working pressure. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 28 NOTE The reduced pressure peaks in an HD5 drive allows the use of the factor 3,5.$ Burst pressure for fittings and raw material for tubes 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 protection device. Hoses intended to withstand a pressure of more than 15 MPa shall not be fitted with reusable end fittings. Hydraulic hoses that are used for the connection of interchangeable equipment shall be designed or identified or located to avoid any incorrect connection causing a hazard, e.g. to reverse the direction of movement of a hydraulic cylinder. 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. This does not apply to rotators attached to the boom tip. 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 close to the cylinder and connected to it by means of short rigid pipes having welded, flanged or threaded connections.$ #However, for boom extension cylinders or for parallel boom articulation cylinders, one load holding valve may be used for several cylinders that are connected by rigid pipes having welded, flanged or threaded connections.$ Burst pressure of the raw material for tubes between lock valve and actuator shall be minimum 3 times the maximum working pressure. 5.5.6.2 Timber handling cranes In the event of hydraulic line rupture the lowering speed of the boom shall not exceed the maximum lowering speed at rated capacity by more than 30 % (see explanatory Note in C.2). Stabilizer leg and extension 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 cranes with more than 12 m outreach, the sink rate shall not exceed 0,2 % of outreach per minute. For timber handling cranes, however, the sink rate may be 2 % of outreach per minute for all outreaches. Sink rate shall be tested at rated capacity at maximum hydraulic outreach (i.e. without manual extensions). I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 29 5.5.8 Slewing mechanism The slewing mechanism shall be able to withstand the maximum slewing forces (see 5.2.3.3.1), to bring it to a stop and sustain the load under the most adverse operating conditions. 5.6 Limiting and indicating devices 5.6.1 General 5.6.1.1 Rated capacity limiters 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 indicators shall be provided on all cranes. Limiting and indicating devices shall conform to EN 12077-2. 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. In case a recognized fault in the rated capacity limiter causes it not to remain effective, all crane movements shall stop. In the event the crane has been stopped due to the rated capacity being reached or due to a fault in the rated capacity limiter, all movements that increase the load moment of the crane shall be blocked, while other movements may remain available. Blocked movements may only be allowed after that a lowering facility in accordance with 5.6.3 has been activated. NOTE Regarding rated capacity limiters on loader cranes see also explanatory note given in C.1. 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 and a maximum net lifting moment of less than 40 000 Nm the relief valves in accordance with 5.6.2.2 and 5.6.2.3 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 operator’s 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 A warning visible and audible from the transport driving position !shall indicate that the first boom is not correctly stowed (as described in 5.4.3.1 and 7.2.3.4). The audible warning" may be silenced by an acknowledgement button or by a signal that the parking brake of the vehicle is engaged. !NOTE The same warning device may be used to fulfil the requirements of both 5.6.1.3 and 5.6.1.5." 5.6.1.4 Cranes, equipped with stabilizers, shall be provided with a level indicator in clear view of the operator at each fixed stabilizer control station. 5.6.1.5 Cranes, with manually operated stabilizer extensions, shall have a warning visible and audible from the transport driving position that indicates when the stabilizers are not locked in the transport position. Cranes, with hydraulically operated stabilizer extensions, shall have a warning visible and audible from the transport driving position that indicates when the stabilizers are not in the transport position. The audible warning may be silenced by an acknowledgement button or by a signal that the parking brake of the vehicle is engaged. !NOTE The same warning device may be used to fulfil the requirements of both 5.6.1.3 and 5.6.1.5." I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 30 5.6.1.6 For cranes with a rated capacity of 1 000 kg or above, or a maximum net lifting moment of 40 000 Nm or above, the hoist shall be included in the system of the rated capacity limiter. Hoists that are able to lift loads in excess of 1 000 kg shall always be included in the system of the rated capacity limiter. The upper hoisting limiter may be activated by the maximum line pull of the rope, providing the contact between the hook and the boom is designed to withstand the corresponding force. NOTE More information about the calculation of ropes can be found in #EN 13001–3-2$. 5.6.1.7 For cranes with a rated capacity of 1 000 kg or above, or a maximum net lifting moment of 40 000 Nm or above, equipped with manual extensions, these extensions shall be included in the system of the rated capacity limiter. A mode selector may be provided to select the boom system configuration on the limiting and indicating device when manual extensions are fitted. 5.6.1.8 For cranes with a rated capacity of 1 000 kg or above, or a maximum net lifting moment of 40 000 Nm or above, the stability of the vehicle shall be included in the safety function of the rated capacity limiter. #NOTE Stability in this case means: Deployment of every stabilizer is monitored by the rated capacity limiter and the rated capacity can be reduced or the crane can be stopped, if not sufficiently deployed. It is essential that the rated capacity limiter reacts quickly enough in all working boom positions, in particular at high boom angles, where the lifting radius could increase very rapidly, or slewing into potentially unstable areas (see also 5.6.1.2).$ This requirement does not apply to timber handling cranes. 5.6.2 Rated capacity limiter 5.6.2.1 The tolerance of the rated capacity limiter shall be such that it is activated between 100 % and (100 + Δ %) of the rated capacity. The value of Δ depends on hydraulic outreach in accordance with the following equation: Δ ≤ 8 + 0,5 R ≤ 20 where R #is the hydraulic outreach in meters$. For timber handling cranes and for loader cranes with a rated capacity of less than 1 000 kg and a maximum net lifting moment of less than 40 000 Nm, the tolerance Δ = 20 % may be used independently of the hydraulic outreach. For hoists, the tolerance Δ = 25 % of the rated capacity may be used independent of the outreach. However, the tolerance as above still applies to the crane. NOTE It is generally accepted that a rated 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 rated capacity limiter as stated above have been set considering the ratio of load moment to dead weight moment. 5.6.2.2 For loader cranes with a rated capacity of less than 1 000 kg and a maximum net lifting moment of less than 40 000 Nm or timber handling cranes, overload protection may be provided by a main relief valve or port relief valves for the boom cylinders. These pressure relief functions shall have tolerances in accordance with 5.6.2.1. 5.6.2.3 For loader cranes with a rated capacity of less than 1 000 kg and a maximum net lifting moment of less than 40 000 Nm, other than timber handling cranes, overload protection may be I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 31 provided by a pressure relief function in the load holding valves for the boom cylinders. These pressure relief functions shall have tolerances in accordance with 5.6.2.1. 5.6.2.4 Any device capable of inhibiting the rated capacity limiter shall be fitted with a tamperevident device. 5.6.3 Lowering facility To avoid locking in of the loader crane, a lowering facility may be provided. This facility shall not allow any movement which may lead to a component failure or a loss of stability. If this 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 s at intervals not shorter than 30 s. 5.6.4 Rated capacity indicators The rated capacity indicator shall give a warning to the operator and persons in the vicinity of the crane 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. 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 required for a loader crane with an outreach less than 12 m. 5.6.5 Limiters 5.6.5.1 Motion limiters Slewing, raising/lowering and telescoping motion limits shall be determined by the stroke of the cylinder or by appropriate stops. Unless the geometry of the crane ensures that the boom system remains stable in all working positions (e.g. booms approaching or passing the vertical), the crane shall be equipped with motion limiters for that purpose. This requirement does not apply to movements for coming in to or out of transport position. 5.6.5.2 Speed limiters Speed limiters shall be incorporated into the slewing, raising/lowering and telescoping motion to ensure that any forces resulting from these motions are restricted to the design criteria of the loader crane. 5.6.5.3#Inclination limiter for timber handling cranes Timber handling cranes may be equipped with a device which measures inclination of the crane base due to load moment and when the inclination reaches a predetermined maximum causes all crane movements which need pump pressure to be stopped. This device should not be confused with an inclination sensing device which may be incorporated into the rated capacity limiter required by 5.6.1.1.$ 5.6.6 Operational warning Cranes with a remote control system shall have a device to warn persons in the vicinity that the crane is in operation. The warning device shall be either acoustic or by flashing lights that are visible from all directions. The warning shall be continuously given when the crane is in operation. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 32 5.6.7 Acoustic warning When a crane has a remote control system or a boom system having an outreach greater than 12 m, an audible warning device, e.g. horn, shall be provided. The audible warning device shall be capable of being actuated by the operator from each control station, unless the control station is not intended for normal operation or it is solely used for operating the stabilizer functions. 5.6.8 Stopping device A control device to bring the loader crane safely to a complete stop shall be fitted at every control station unless the control station is solely used for operating the stabilizer functions. The device shall be designed, fitted and shall function as follows: a) it shall be easily visible by red coloured actuators, where practicable in front of an yellow background; b) activating the device shall not require any decision by the operator about the resultant function and effects, e.g. mushroom-type push button; c) the actuator shall be arranged for easy access and for non-hazardous operation by the operator; d) after stopping the crane no further dangerous movements of the boom system shall appear; e) the actuator shall lock-in where operated. 5.7 Controls 5.7.1 General The following specify arrangement and direction of movements of controls assigned to working functions, such as slewing column, raising/lowering boom. Stabilizer functions are also included. The requirements cover bi-directional and multidirectional (joy-stick) control levers. The layout order of bi-directional controls shall follow the sequence of working functions from the base of the loader crane to the load handling device. Control levers for setting-up functions shall be separated by space or clearly distinguished (other than by using symbols) from other control levers. All controls shall return automatically to the control position when they are released. They shall be marked permanently with clearly visible symbols as given in 5.7.2. All controls shall be in accordance with the safety and ergonomic principles as specified in EN 13557 with the exception of lever force and lever spacing for remote controls. For remote controls the lever force shall be between 2 N and 20 N and the minimum free space between lever tops shall be 8 mm. The minimum centre-centre distance between levers on remote controls shall be 30 mm. 5.7.2 Symbols Symbols for the working and setting up functions of loader cranes having boom systems with two articulated booms shall be in accordance with Annex E. For loader cranes having other boom systems, any additional symbols that are necessary shall be derivatives of Annex E. The symbols shall be used as follows for bi-directional control levers: a) On the control lever knobs: Inside arrows indicate the movement of the corresponding lever. Only one symbol for a crane function and one arrow for the lever movement shall be combined. See #Figure 3$; I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 33 b) When placed on a separate plate adjacent to the control levers, the symbols can be used without lever movement arrows. Two symbols for each lever can be used. See Figure G.3; c) The minimum size of a symbol shall be such that it is circumscribed by a 15 mm circle. For remote controls the minimum symbol size shall be 12 mm. In the case of multi-symbols the minimum size shall relate to the smallest, e.g. in accordance with #Figure 3$. Dimensions in millimetres Knob of control lever Meaning of symbol/arrow combination for one symbol/arrow combination Move control lever to the left to raise second boom and Move control lever to the right to lower second boom #Figure 3$— Symbols for working function 5.7.3 Layout of bi-directional controls 5.7.3.1 General The principles described in 5.7.1 apply to both vertical and horizontal control lever arrangements. 5.7.3.2 Vertical layout order Information is given in Annex F regarding the layout order for vertical control lever arrangements operated from ground level. 5.7.3.3 Horizontal layout order Information is given in Annex G regarding the layout order for horizontal control lever arrangements operated from ground level. 5.7.4 Guidance for high seat controls Information is given in Annex H. 5.8 Control stations 5.8.1 General Control stations can be of the following types: a) ground control; I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 34 b) raised control from fixed platform, slewing platform or high seat; c) remote control; d) cabin. Vehicle mounted cranes with a rated capacity of 1 000 kg or above, or a maximum net lifting moment of 40 000 Nm or above, with ground control stations and that do not have remote control shall have at least two fixed control stations. NOTE This requirement is intended to provide the operator with an alternative operating position outside a potential danger zone, e.g. folding/unfolding. When more than one control station is provided there shall be means preventing simultaneous operation from two stations unless the controls are mechanically linked to each other (see explanatory Note to 5.8 in informative Annex C). A control station for each stabilizer function shall be positioned so that the operator has an unobstructed view of the movements being controlled. If the stabilizers can be operated with a suspended load, a two-stage control action shall be required for the operation. The control station for stabilizer extension deployment shall only operate movements in full view of the operator. These requirements also apply to stabilizer extensions that are remote controlled, in which case a device shall be provided that detects that the operator can have a clear view of a stabilizer extension before it may start to extend. Raised control stations shall be provided in such a way that the operator cannot be crushed or struck, or the clothing of the operator become trapped due to moving parts of the crane. For control stations, with the exceptions listed below in this clause, the safety distances of EN ISO 13857 shall apply. Where any guards are provided these shall not (unless specifically designed for the purpose) be able to be used to support the operators weight or be used as hand holds. Where it is not practicable to install guards, gaps between moving parts shall conform to the dimensions given in appropriate standards for the prevention of finger, hand and foot trapping (see EN 349). For areas such as: — stabilizers moving into transport position; — resting points for boom system moving into transport position; — control platform and moving column; — high seat and moving first boom where neither minimum gaps in accordance with EN 349 nor safety distances in accordance with EN ISO 13857 is possible, warning notices shall be fitted. However, control stations shall be placed so that the use of the controls does not require the operator to reach into danger zones, where risk of shearing and trapping exists. All control stations except cabins shall be in accordance with EN 13557. Vehicle mounted loader cranes are generally operated for short periods and therefore a cabin is usually not installed. For applications when a cabin is preferred, due to e.g. environmental conditions, the specification shall conform to EN 13557 with the exceptions as specified in Annex J. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 35 5.8.2 Raised control stations 5.8.2.1 Strength of components Handrails shall withstand a horizontal force of 300 N distributed over 100 mm. Platforms shall withstand a force of 1 500 N applied on a circular area diameter 125 mm at any location on the surface. Steps and rungs shall withstand a force of 1 500 N applied over 100 mm. The components shall resist these applied forces without any permanent deformation and without any elastic deformation greater than 2 % of the span between supports or 10 mm whichever is the lesser. 5.8.2.2 High seat (see informative Annex K) The construction and mounting of a high seat shall be in accordance with the following requirements: a) #accessibility to the seat shall not be inhibited by the controls. There shall be full accessibility to the high seat in accordance with Annex L when the crane is in all transport positions;$ b) #the minimum capacity of the seat with supporting members shall be 150 kg and it shall withstand a load of 1,5 times the capacity acting centrally on the horizontal area of the seat without permanent deformation;$ c) horizontal positions shall be adjustable and lockable without the use of tools; d) the seat shall be provided with means to reduce the risk of falling when the operator is in working position; this shall not impair accessibility to the seat. If side-guards are fitted these shall be at a height of minimum 100 mm from the seat index point as defined in EN ISO 5353; e) guards shall be provided to prevent moving parts of the loader crane trapping the operator or his clothing; f) a platform shall be provided for the operator's feet. Minimum dimension 160 mm × 300 mm for each foot. 5.8.2.3 Platform (see informative Annex K) The construction of a platform shall conform to the following requirements: a) #during operation from the platform the operator shall be protected against moving parts of the crane; guards and/or limitation of the crane movements shall be provided;$ b) the floor shall be horizontal with minimum dimensions 400 mm × 500 mm; c) the floor shall be manufactured from slip-resistant material; the design shall provide means to eliminate the retention of liquid and debris; d) precautions shall be taken to prevent the operator from falling from the platform; this shall be in accordance with EN 13586. 5.8.2.4 Access and egress to raised control stations The means of access to raised control stations shall fulfil the following requirements: a) provision shall be made for a simultaneous three-point support (two hands and one foot or two feet and one hand); b) safe exit for all service configurations of the crane shall be provided; I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 36 c) hand rails and hand holds shall not have sharp edges and should preferably be of circular section; d) steps and all surfaces shall be slip resistant at the foot contact area. Round steps shall not be used; NOTE Annex L gives examples of acceptable profiles. e) ladders steps shall be of minimum width 300 mm (see Table L.2); a footstep of 150 mm width is only acceptable where space restrictions do not permit 300 mm width; f) the angle of ladders shall be 75° to 90° above the horizontal. For dimensional data see normative Annex L and EN 13586. 5.9 Electrical systems 5.9.1 General The electrical equipment of loader cranes shall, where appropriate, conform to EN 60204-32. 5.9.2 Electromagnetic compatibility For immunity the electrical system shall conform to EN 61000-6-2. For emission the electrical system shall conform to EN 61000-6-4. 5.10 Installation 5.10.1 General Loader cranes can be installed on various types of mountings. 5.10.2 Mounting 5.10.2.1 Vehicle mounting The installer of a loader crane shall adhere to any specific requirements issued by the crane manufacturer, the vehicle manufacturer, local regulations which may apply, and any site conditions (for static installations). The mounting frame shall be constructed and secured to the vehicle frame so that it can withstand the imposed loads and conform to the requirements of chassis strength specified by the vehicle manufacturer. NOTE 1 Annex M shows the method for calculating mounting frame size. The loader crane shall be positioned on the chassis to ensure that the completed installation conforms to the stability requirements of 5.10.3. NOTE 2 Road regulation should be considered as they may apply to axle capacities, vehicle widths and vehicle heights. #When the vehicle engine can be started by the crane control, means shall be provided to ensure that the vehicle will not move as a result of the engine being started.$ 5.10.2.2 Static mounting The foundation shall be constructed so that it can withstand the imposed loads and provide positive securement for the crane fastenings at the mounting points; the size of the foundation shall not inhibitintended crane movements. The dimensions of the foundation in the ground shall be designed to withstand the total imposed loads under relevant ground conditions. NOTE More information of the design of static foundations can be found in EN 1993–1-1. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 37 5.10.2.3 Location When determining the position of the crane and the location of the ground control stations and any additional control stations, the following shall be considered: a) to ensure that operators are not exposed to inhalation of exhaust gases; b) to ensure that operators cannot touch hot surfaces during crane operations. Any surfaces with temperatures exceeding 55 °C shall be protected; c) to minimize the risk of crushing, striking or trapping the operator by movements of any of the loader crane or stabilizer functions; for raised control stations, guards shall be fitted as necessary to protect/prevent the operator from being crushed or trapped in any confined areas between the crane and the vehicle. Danger zones caused by moving parts of the stabilizers and its drives shall be protected by guards/safety measures. Examples of stabilizer danger zones are: — entanglement zones at pulleys/bogie wheels; — shearing zones at openings in the moving part of the stabilizer extension; — entanglement zones at chains/cables of the stabilizer extension. The safety distances of EN 349 and EN ISO 13857 shall apply with the following exceptions: For the areas of chassis, stabilizers and moving counterweight, where neither minimum gaps in accordance with EN 349 nor safety distances in accordance with EN ISO 13857 is possible, warning notices shall be fitted. However, control stations shall be placed so that the use of the controls does not require the operator to reach into danger zones, where risk of shearing and trapping exists. 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. 5.10.3 Stability The stability for a loader crane installed on a vehicle shall be such that the working unit does not overturn under foreseen operating conditions. Verification of the stability shall be made by test loading in accordance with 6.2.5. 5.10.4 Noise When designing loader cranes that have the power source as an integral part, the information and technical measures to reduce noise at source given in EN ISO 11688-1 shall be taken into account. Also the information given in EN ISO 11688-2 may be taken into account. The most relevant noise sources are: — power source (e.g. auxiliary engine) used for the crane functions; — pumps, valves and hydraulic components; — cylinders and other mechanical components; — hoist drives and slewing gears. NOTE In most cases, the power source is not an integral part of the loader crane and all significant noise is emitted by the vehicle. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 38 5.10.5 Vibrations A loader crane is generally only used for short periods of time and the effect of vibrations on the operator is not significant. 5.10.6 Electrical systems (installation) 5.10.6.1 General The electrical installation for the loader cranes on a vehicle, or similar, shall, where appropriate, comply with EN 60204-32. For lorry loader cranes any electrical connection to the existing vehicle electrical system shall only be made at the manufacturer’s designated connection points. 5.10.6.2 Electromagnetic compatibility Immunity – For electromagnetic compatibility the electrical system shall conform to EN 61000-6-2. Emission – For electromagnetic compatibility the electrical system shall conform to EN 61000-6-4. When the installer of the crane uses certified components (for any additional items in the electrical system) which fulfil the requirements of the above mentioned standards and install these components in accordance with the recommendations of the supplier, testing of the electromagnetic compatibility of the modified system is not necessary. 5.10.7 Hydraulic components Hydraulic components which may be added to a loader crane by the installer to modify the existing hydraulic system for additional crane applications/ extra accessories shall conform to 5.5. New hydraulic components shall be compatible with existing components and be sized such that the functioning of the modified hydraulic system conforms to all the original design specifications for flow, pressure and temperature. 5.10.8 Access The installation of the loader crane on to a vehicle shall provide suitable access to any raised control station on the crane from ground level. The access system shall conform to the requirements as specified in 5.8.2.4. 6 Verification of the safety requirements and/or measures 6.1 General The design of a loader crane shall be checked for conformity of each safety requirement and/or measures (given in Clause 5) by means of calculation and/or test. A conceptual verification to show adequate safety for any hazard due to loss of mechanical strength shall be done on the first crane of a series of cranes of the same type. Conformity of each safety requirement and/or measures (given in Clause 5) shall be verified by the methods specified in the Table 4 and by the testing and test procedures detailed in 6.2. For the calibration of limiting and indicating devices the appropriate loads and crane configurations and methods as recommended by the manufacturer shall be used. All information for use detailed in Clause 7 shall be available with the crane before putting it into service. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 39 Table 4 — Methods to be used to verify conformity with the safety requirements and/or measures Clause number Method of verification 5.1, 5.2 and 5.3 Calculations, tests in accordance with 6.2.1 to 6.2.4 and analysis of the results. 5.4.1 Inspection and test to confirm that devices are functioning correctly. 5.4.2 Inspection and test to confirm that devices are functioning correctly. 5.4.3.1, 5.4.3.2 Inspection and test to confirm that the locking devices are functioning correctly. Test the effectiveness of the stabilizer locking devices, by engaging them at least three times at an adverse inclination of 5°. Both locking devices (cam locks and automatic latches) shall engage correctly on every occasion, irrespective of speed of operation. Test the locking device for the stabilizer extensions with forces resulting from an acceleration of 2 g, applied in the direction of the movement. The test to be performed as a type test by the crane manufacturer. Test that the warning light works properly. 5.4.3.1, 5.4.3.3 Check the specification of the hydraulic circuit and ensure that check valves are correctly mounted. Pressure required to open check valve shall at least correspond to the force of 2 g acting on the stabilizer mass. Test a mechanical locking device for the stabilizer extension with forces resulting from the extension cylinder or an acceleration of 2 g, whichever is higher, applied in the direction of the movement. The test to be performed as a type test by the crane manufacturer. 5.5.1 Check specification of components and test to confirm that devices are functioning correctly. Check of hydraulic diagram being in accordance with EN ISO 4413. 5.5.2 Check specification of components and test to confirm that devices are functioning correctly. 5.5.3 Check specification of components and test to confirm that devices are functioning correctly. 5.5.4 Review of hydraulic circuit diagram to confirm that devices are fitted in accordance with the standard. Check setting of pressure relief valves. 5.5.5 Burst pressure: Examination of supplier’s specifications. Chafing, trapping and guards inspection. 5.5.6.1 Test, by simulating line rupture and inspection of mounting. 5.5.6.2 Inspection, to confirm that devices are fitted on cranes where required. Test of lowering speed. 5.5.7 Test in accordance with 5.5.7. Test performed with most unfavourable combination of fluid and fluid temperature in accordance with manufacturers recommendation. 5.5.8 Calculation, test and analysis of the results. 5.6.1.1 Review of crane specification to ensure that appropriate devices are fitted in accordance with EN 12077–2. 5.6.1.2 Stability test in accordance with 6.2.5 to determine if slew limiters are required. – When fitted, test functionality to ensure correct operation. 5.6.1.3 Check if height warning is required in accordance with 5.6.1.3. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 40 – When fitted, test functionality to ensure correct operation. 5.6.1.4 Inspection and test to confirm that devices are functioning correctly. 5.6.1.5 For manual stabilizer extensions, test functionality of warning for transport lockings unlocked. 5.6.1.6 If hoist is fitted, check for correct functionality. 5.6.1.7 Functional check. 5.6.1.8 Functional check. 5.6.2.1 Determination of accuracy of rated capacity indicator/limiter: a) Plot a graph of rated capacity against outreach (see #Figure 4$) for the horizontal configuration of the boom assemblies. Key 1 rated capacity w 2 outreach r #Figure 4$— Graph of rated capacity against outreach b) Attach a load, approximately equal to the crane’s rated capacity of the at 80 % outreach (w1), to the crane at an outreach well within the rated capacity (r1). c) Raise the load so that the boom system is in accordance with the position on the load plate as described in 7.3.4.1. For cranes with telescopic booms the booms should be fully retracted. d) Slowly extend the outreach of the crane keeping the boom tip at the horizontal position. For cranes with telescopic booms this movement should be by extending the telescopic sections. e) At the point that the rated capacity indicator gives the first warning measure the outreach (r2). From the graph measure the rated capacity (w2) of the crane at r2. Determine the percentage of the rated capacity i.e. w1/w2 multiplied by 100. f) Subtract 90 from the percentage found in e) and this is the value of the prewarning. g) Continue to slowly extend the outreach of the crane in the manner described in d) above until the rated capacity limiter stops the motion. h) Measure the outreach (r3). From the graph measure the rated capacity (w3) of the I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 41 crane at r3. Determine the percentage i.e. w1/w3 multiplied by 100. i) Subtract 100 from the percentage found and this is the value of the rated capacity limiter. This value does not exceed the preconditions. j) The greatest value found in f) or i) shall be taken as the tolerance of the rated capacity indicator or limiter. Repeat the test for different loads spanning the range of rated capacities of the crane (see #Figure 4$) and using different crane motions. The resulting tolerances shall all be less than the tolerance of the rated capacity limiter. Check that the rated capacity limiter operates to prevent dangerous movements, as specified by the crane manufacturer, and enables movements to a safe condition. #This also means that the response time should be short enough with respect to movements that decrease the stability margin and thus compromise the stability of the vehicle.$ 5.6.2.2, 5.6.2.3 Ensure that the crane conforms with requirements that waive the need of a rated capacity limiter. Check the specifications of the hydraulic circuit for correct port relief valves. Test to ensure that the relief valves are functioning correctly and prevent dangerous movements. 5.6.2.4 Visual inspection. 5.6.3 Functionality check. 5.6.4 Functionality check. 5.6.5.1 Check that appropriate devices if necessary are fitted and function correctly. Check that the boom system remains stable in all working positions. 5.6.5.2 Check the hydraulic schematic and measure the speed. 5.6.6 Visual inspection and functionality check. 5.6.7 Functional check. 5.6.8 Inspection to ensure every control station has a stopping control device. Test to ensure to correct functionality. 5.7.1 Inspection of crane that controls are correctly fitted and marked. Check that all controls automatically return to neutral position – See also EN 13557 for conformance. 5.7.2 Check to ensure correct marking. 5.7.3 Visual inspection and functionality check. 5.7.4 Visual inspection and functionality check. 5.8.1 Visual inspection and functional check. If cabin is fitted, verify the dimensions. – See also EN 349, EN ISO 13857 and EN 13557 for conformance. 5.8.2.1, 5.8.2.2, 5.8.2.3, 5.8.2.4 Calculations. Visual check, measurement. – See also EN 13586 and EN ISO 5353 for conformance. 5.9.1 Inspection of installation to ensure conformance to requirements – See EN 60204–32. 5.9.2 Tests in accordance with EN 61000–6-2. 5.10.1, a) check instructions of the vehicle and crane manufacturer, or verify with a static analysis in accordance with section 5.1 I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 42 5.10.2 b) inspection of the installation to ensure conformance to requirements. See also EN 349 and EN ISO 13857 for conformance. 5.10.3 Check the stability in accordance with the procedure described in 6.2.5. 5.10.4 Check noise emission in accordance with the procedure in 6.3. Check that the operator’s manual provides information on noise in accordance with 7.2.3.9. 5.10.5 No check necessary under normal circumstances. 5.10.6.1 Inspection of installation to ensure that the requirements are fulfilled. – See EN 60204–32 for conformance. 5.10.6.2 Tests in accordance EN 61000–6-2. 5.10.7 Inspection and test to conform that devices are functioning correctly. See 5.5.1 to 5.5.5 above. 5.10.8 Check to ensure suitability and that the requirements in accordance with 5.8.2.4 are fulfilled. 6.2 Testing and test procedures 6.2.1 General The loader crane and the installation shall be tested to verify they conform to the operational requirements stipulated by the manufacturer’s specification and to verify the integrity of the structure and all the components. All tests shall be under the worst conditions foreseeable by the manufacturer when the crane is used as intended. At the time of testing the wind speed shall not exceed 8,3 m/s (30 km/h) and the vehicle tyres shall be inflated to the pressure recommended by the vehicle manufacturer. During the tests the crane shall be set up and controlled in accordance with the manufacturer's instructions as detailed in the crane manuals. For some tests it may be necessary to adjust, override or disable any safety and limiting devices which are installed on the crane. Care shall be taken to ensure that any such devices are reconnected, recalibrated and re-tested after the tests are completed. For the calibration of the limiting and indicating devices the appropriate loads and crane configurations and methods as recommended by the manufacturer shall be used. 6.2.2 Functional test The crane functions shall be operated throughout the range of all movements up to the maximum speeds and up to the rated capacity, to demonstrate the satisfactory operation of the control system and any performance limiting devices fitted. 6.2.3 Static test 6.2.3.1 Conceptual (type) test The test load shall be at least 1,25 times the rated capacity. The loader crane shall be tested in positions and configurations that impose the maximum loads or maximum stresses in the crane components and structures. The results shall be recorded and retained by the manufacturer. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 43 6.2.3.2 Installed test The loader crane shall be tested after it has been installed in its final working position ready to be put into service. The tests as detailed below shall be carried out with a test load of at least 1.25 times the rated capacity at or close to the following radii: a) maximum radius with any manual extensions; b) maximum radius attainable with hydraulic outreach; c) #radius corresponding to maximum working load or the shortest practical radius achievable after installation using the corresponding rated capacity. These values shall be recorded in the test documentation.$ At each radius the load shall be positioned 100 mm approximately from the ground and slewed slowly through the full in service slewing arc of the crane. The installation test may be part of the stability test described in 6.2.5. If the maximum test load used is less than the one corresponding to the maximum working load of the crane as specified by its manufacturer, the maximum working load and corresponding radius for the installed crane shall be reduced accordingly. 6.2.3.3 Static test approval criteria The test shall be considered to be successful if no crack, permanent deformation, paint flaking or damage which affects the function and safety of the crane and its installation is visible and no connection has loosened or been damaged. 6.2.4 Dynamic test 6.2.4.1 Test load The loader crane shall be tested after it has been installed in its final working position ready to be put into service. The test load shall be at least 1,1 times the rated capacity. Dynamic tests shall be performed separately for each crane motion and with simultaneous crane motions using positions and configurations that will impose the maximum loading or maximum stresses in the crane components (i.e. least favourable conditions). The crane shall be tested at speeds appropriate to intended use and the test shall include repeated starting and stopping of each motion throughout the range of the motion. The setting of the rated capacity limiter may temporarily be increased by up to 15 % for the purpose of this test. 6.2.4.2 Dynamic test approval criteria The test shall be considered to be successful if all the components concerned have been found to perform their functions correct to the design specification and an examination after the test reveals no damage to the mechanisms or structural components. The temperature of the hydraulic oil shall be within the limits recommended for the oil specification. 6.2.5 Stability test 6.2.5.1 General The stability for a vehicle carrying a loader crane deduced by calculation is to be used for guidance only. Stability shall be verified by test loading. #Loader cranes mounted on rail vehicles shall be tested in accordance with EN 14033-2.$ I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 44 The purpose of the test is to verify the stability of the loader crane mounted on the unloaded vehicle. The test loading shall be #conducted$with the unloaded vehicle without the driver. 6.2.5.2 Test load Stability test loads shall be determined in accordance with the following: TL = Ks × P + (Ks – 1) × G´b where Ks is the stability factor, Ks = 1,2; TL is the test load; P is the rated capacity; G´b is the point mass at boom tip, giving the same dead load moment around the slewing centre as the real boom does. For timber handling cranes, the stability factor Ks may be assigned the value of the actual tolerance of the rated capacity limiter (Ks = 1 + Δ% / 100) according to 5.6.2.1. However, Ks shall at least have the value of 1,1. For cranes other than timber handling cranes, the test load TL shall always be at least 1,25 × P. The value of TL shall be verified by the manufacturer. NOTE The application of the test load TL constitutes load combination C3, see 5.2.4.2. Alternatively, the test load may be divided into two parts, one at the boom tip and one closer to the column. The two parts of the test load shall produce the same tipping moment with respect to the tipping line under consideration as the test load TL above. The part of the test load at the boom tip shall be at least 1,25 × P. The maximum test load at the boom tip shall be as recommended by the crane manufacturer. 6.2.5.3 Test conditions Stability shall be tested in accordance with the least favourable boom configuration including maximum manual boom extension within the whole slewing range. If the rated capacity is lower in part of the slewing range, the test load in those parts shall be determined accordingly. Limiting and indicating devices may be temporarily disconnected during the test. Stability shall be tested with the crane placed on a firm surface under the least favourable conditions, with the respect of the tipping line, in accordance with the manufacturer's specification. The crane inclination shall be within the maximum inclination in accordance with the manufacturer's specification. The appropriate test method depends on whether the crane has a fixed load moment or not: — the stability calculations of a vehicle/loader crane combination with a fixed load moment shall be verified by deploying the stabilizers correctly, attaching the test load, and slewing the crane throughout its full slewing arc; — some vehicle/loader crane combinations will incorporate a load moment setting that varies with the slew angle, (e.g. loader crane over the rear of the vehicle, or over the cab), or varies with the amount of stabilizer extension, (e.g. stabilizers fully extended, or fully retracted), or both. The stability calculations for these types of installation shall be verified by the requisite overloads being applied at the positions with maximum and minimum load moment settings, as identified by the calculations. #The test load as defined in 6.2.5.2 applies to all stabilizer configurations.$ It will not be necessary to verify, (by overload testing), the stability calculations for all the intermediate positions, (between a maximum and minimum load moment setting). It will suffice to attach a load equal to the maximum working load at maximum radius, and slew this load through the full slewing I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 45 arc, reducing the radius of the load as demanded by the loader crane, to confirm that the available load moment at every position, conforms to the predictions of the stability calculations. For stability verification, the required overturning moment with respect to the actual tipping line may be obtained at a reduced outreach. NOTE Stability calculations may be necessary to establish the least favourable position. #Timber handling cranes may incorporate an inclination limiter in accordance with 5.6.5.3. For such installations, the rated capacity P has to be measured for the least favourable position, when the inclination limiter is activated. The measured P shall be used for calculation of TL, described in 6.2.5.2.$ 6.2.5.4 Stability test approval criteria The test shall be considered to be successful if the test load is held static. During the test loading, one or more stabilizer legs or wheels may lift from the ground. However, at least one wheel braked by the parking brake shall remain in contact with the ground. 6.2.6 Test documentation #A test report detailing static, dynamic and stability tests carried out during installation shall be provided by the installer. If the stability at intermediate positions is demonstrated solely by calculations, these calculations shall also be provided. The test report shall be appended to the operating manual and shall accompany the crane.$ 6.2.7 #Documentation for variable stabilizer deployment If the installation allows for operation of the crane with various predetermined stabilizer positions, then the rated capacities at all positions shall be given. If the installation allows for steplessly variable stabilizer deployments, the rated capacities in the maximum and minimum and at least three intermediate positions shall be given for the unloaded vehicle. If the crane can be used in more than one boom configuration, e.g. with and without a 3rd boom, the rated capacities shall be given for all configurations. The documentation shall be appended to the operating manual and shall accompany the crane. NOTE In the case where the rated capacity additionally is vehicle load dependant, the actual rated capacity can exceed these documented minimum values.$ 6.3 Noise emission measurement Maximum emission sound pressure levels at all fixed control stations, excluding control stations used solely to operate the stabilizers, shall be measured in accordance with EN ISO 11201. The sound power level shall be measured in accordance with EN ISO 3744. For crane fitted with remote controls measurements shall be taken at a distance of 1 m from the principal noise source and at a height of 1,6 m from the floor. Operating conditions during noise measurement: — the crane shall perform all working movements over the full operating range (e.g. slewing, boom articulation, boom extension, hoisting) at approximately 50 % of the maximum rated capacity; — the power source shall be set at the speed required to perform the test at normal crane speeds. NOTE #Noise is mainly caused by the truck engine or by the hydraulic supply system. For this reason,$ the level of noise emission may be assessed with reference to comparative emission data for similar loader cranes installations. I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.

EN 12999:2011+A2:2018 (E) 46 7 Information for use 7.1 General All information for use shall be in accordance with EN ISO 12100:2010, Clause 6. 7.2 Manuals 7.2.1 Provision of manuals Manuals (instructions) shall be provided with each crane. The manuals shall be in accordance with EN 12644-1. 7.2.2 Instructions for the installer 7.2.2.1 Mounting instructions shall include: a) Description of the chassis on which the crane may be mounted; b) requirements on bolts and fastenings for mounting the loader crane onto a vehicle or a static foundation; c) masses, centres of gravity and all information required for calculation of axle loadings and stability; d) the values of TL, G´b and, if applicable, Δ for the stability test in accordance with 6.2.5.2; e) hydraulic system specifications which shall include: — pressure and flow requirements; — system oil capacity; — system oil specification; — minimum reservoir capacity recommendations; — recommended filtration; f) electrical system requirements; g) requirements for access and egress to control stations, see Annex L; h) an instruction to carry out the tests in accordance with Clause 6. 7.2.2.2 Equipment added to the loader crane during installations shall have appropriate instructions added to the crane manuals. 7.2.3 Operator's manual 7.2.3.1 The manual shall give technical data and information about the following: a) a description of the control system, including diagrams and descriptions of the symbols used with the control levers; b) a description of the limiting and indicating devices; I.S. EN 12999:2011+A2:2018 This is a free 100 page sample. Access the full version online.