2001-08-30 ICS:53.020.20

EN 12644.01

HELLENIC STANDARD

- - 1:

Cranes - Information for use and testing - Part 2: Instructions

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EN 12644.01

EN 12644-1/2001

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National Foreword

This Endorsement Sheet ratifiesthe approval of EuropeanStandard

EN 12644-1/2001

as a Hellenic Standard.This standard is available inEnglish, French or German fromthe Hellenic Organization forStandardization S.A.

EUROPEAN STANDARDNORME EUROPENNEEUROPISCHE NORM

EN 12644-1

January 2001

ICS 53.020.20

English version

Cranes - Information for use and testing - Part 1: Instructions

Appareils de levage charge suspendue - Information pourl'utilisation et les essais - Partie 1: Instructions

Krane - Informationen fr die Nutzung und Prfung - Teil 1: Betriebsanleitungen

This European Standard was approved by CEN on 13 December 2000.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the Management Centre or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the officialversions.

CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATIONC O M I T E U R O P E N D E N O R M A LI S A T I O NEUR OP IS C HES KOM ITEE FR NOR M UNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

2001 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.

Ref. No. EN 12644-1:2001 E

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ContentsPage

Foreword 30 Introduction 31 Scope 32 Normative references 43 Terms and definitions 44 Hazards 55 Requirements for instructions 56 Verification of the requirements 9Annex ZA (informative) Relationship of this document with EC Directives 10Bibliography 11

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ForewordThis European Standard 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 publicationof an identical text or by endorsement, at the latest by July 2001, and conflicting nationalstandards shall be withdrawn at the latest by July 2001.This European Standard has been prepared under a mandate given to CEN by theEuropean Commission and the European Free Trade Association, and supports essentialrequirements of EU Directive(s).For relationship with EU Directive(s), see informative Annex ZA, which is an integral partof this standard.According to the CEN/CENELEC Internal Regulations, the national standards organizations ofthe following countries are bound to implement this European Standard: Austria, Belgium,Czech Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy,Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and the UnitedKingdom.

0 IntroductionThis European Standard is a type C-standard as defined in EN 414.This standard has been prepared to be a harmonized standard to provide one means ofconforming with the essential health and safety requirements of the Machinery Directive,as amended.This is part 1 of a series intended to give information for use to be supplied by themanufacturers of cranes.The other parts of this standard are:Part 2: MarkingPart 3: Fitness for purposeThis is the first edition of this part of EN 12644.The extent to which hazards are covered is indicated in the scope of this standard.

1 ScopeThis part of EN 12644 specifies requirements for the presentation and content ofinstruction handbook(s) supplied by the manufacturer for the use of cranes.This crane standard has been written to be used in conjunction with other cranestandards being prepared by CEN/TC 147.

NOTE Specific requirements for particular types of crane, are given in theappropriate European Standard for the particular crane type.

The hazards covered by this standard are identified in clause 4.This part of EN 12644 applies to cranes which are manufactured after the date ofapproval by CEN of this standard.This standard does not cover hazards related to the lifting of persons.

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2 Normative referencesThis European Standard incorporates, by dated or undated reference, provisions fromother publications. These normative references are cited at the appropriate places in thetext and publications are listed hereafter. For dated references, subsequent amendmentsto, or revisions of, any of these publications apply to this European Standard only whenincorporated in it by amendment or revision. For undated references the latest edition ofthe publication referred to applies (including amendments).

EN 292-2:1991 + A1:1995 Safety of machinery Basic concepts, generalprinciples for design Part 2: Technical principlesand specifications

EN 1070:1998 Safety of machinery - TerminologyprEN 13001-1:1997 Crane safety - General design - Part 1: General

principles and requirements

NOTE Informative annex ZA provides information regarding relevant EU directives,European and International Standards.

3 Terms and definitionsFor the purposes of this European Standard the terms and definitions given inEN 1070:1998 and the following apply.3.1checkvisual and functional assessment (not a test) of the condition of the crane withoutdismantling.

3.2crane driverperson operating the crane for the purpose of handling loads.

3.3examinationverification that the crane can safely continue in service including a functional test of allsafety devices i.e. limiting, indicating equipment, brakes, clutches etc to verify that theyoperate within the required tolerances. An examination is more thorough than aninspection.

3.4inspectionlooking at the crane for defects and checking the operation of the controls, limiting andindicating devices without loading the crane. This is much more than a check but doesnot normally require any part of the crane to be dismantled other than removal oropening of cover(s) or housing(s).3.5instruction handbookprincipal means by which the manufacturer provides information or instructions on howthe crane has to be used.

3.6rated capacityload(s) that the crane is designed to lift for a given operating condition (e.g.configuration, position of load).

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3.7service conditions

3.7.1in-servicecrane in use handling or preparing to handle loads up to the rated capacity inconditions as specified by the manufacturer.

3.7.2out-of-servicecrane out of use, without load and left in conditions as specified by the manufacturer.

3.8testspecific operation of the crane with or without a defined load in order to establishwhether the crane is fit for use.

3.9useany operation with or on the crane e.g. transportation, erection, dismantling,maintenance, movements of the load.

3.10user; user organisationperson or organisation which has direct control over the crane use.

4 HazardsCranes can present hazards to persons in the danger zone.Instructions regarding use, handling, maintenance etc. of cranes are necessary toreduce or eliminate the risks associated with the hazards.This standard specifies requirements for instructions in order to prevent or minimizehazards or hazardous situations.A list of hazards is given in the appropriate standards for each crane type.

5 Requirements for instructions5.1 GeneralAn instruction handbook with information for safe use of the crane shall be supplied.Presentation of this information shall comply with clause 5 of EN 292-2:1991. Theprovisions of language versions shall meet the requirements of A.1.7.4 revised inEN 292-2:1991.The instruction handbook may be published in one or more parts. Where appropriate,cross reference to other parts should be made to avoid unnecessary repetition. Allhandbook parts shall have clear identification as to which cranes they apply, includingas a minimum :a) title of handbook;b) title of other parts (if appropriate);c) model and serial number of the crane (if appropriate);d) list of contents, number of pages and/or index.The instruction handbook shall be written with internationally recognised terms,definitions, units and symbols with their key or signification.The text should be simple and adapted to the individuals who will use it with allinformation being explicit and comprehensive. Clear and simple illustrations, diagrams,

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graphs and tables should be used in preference to written text and be placed adjacent toany corresponding text.5.2 Crane specification5.2.1 GeneralThis section of the instruction handbook shall contain all the necessary information foridentification and technical data. The following items shall be included in the instructionhandbook if appropriate.5.2.2 Identificationa) name and address of the manufacturer;b) designation of series or type(s);c) serial number(s);The instruction handbook shall clearly indicate the crane, series, types, serial numbersand configurations to which it applies.5.2.3 Technical dataa) a drawing/sketch of the crane with overall dimensions and the number and

designation of main components;b) a description and explanation about classification (see prEN 13001-1:1997),

rated capacity and design standards;c) the design capability of the crane for overload test;d) a description and explanation about in-service and out-of-service conditions;e) those activities for which the crane is designed and those for which the crane

shall not be used;f) description of the limiting and indicating devices;g) description of the control system(s);h) where appropriate, a description of emergency escape(s);i) technical data of importance for the erection, dismantling and transportation (e.g.

dimensions and mass of components, reaction on supporting parts, powersupply and test conditions);

j) where appropriate, requirements for the tracks/rails and of the ground supportconditions;

k) where appropriate, the type and the means of installation of the ballast;l) information concerning airborne noise emission and, where appropriate, vibration

emission by the crane, with the method used to measure it and the operatingconditions of the crane during measurement, and an instruction that whenever anoise test code exists for the type of crane concerned, it shall be used;

m) where appropriate, a description of the technical requirements necessary tooperate in a potentially explosive atmoshpere;

n) information on materials and parts requiring specialised repair techniques.

5.3 Users instructionsThis section of the handbook shall include requirements on the user to ensure that thepurpose for which the crane is intended is compatible with the crane specificationincluding:a) the need to ascertain that ground or support conditions are adequate for the

maximum loadings imposed by the crane;

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b) checking that the specification for in-service conditions given in the instructionhandbook, is in accordance with the site conditions (e.g. effects of wind includingsite effects, snow, adverse temperature, visibility);

c) checking that the power supply is adequate;d) checking that there are no parts added to the crane which have not been verified

for fitness for purpose.NOTE Further guidance is given in ISO 12480-1.

5.4 Crane drivers instructions5.4.1 GeneralThis section of the instruction handbook shall contain any requirements relative to thecrane type.

NOTE The intention of this section is not to replicate the requirements whichare normally known by a competent crane driver.

5.4.2 InformationThis section is to help the user to inform the crane driver of the following:a) the technical data, rated capacity and safety devices which are necessary for thecrane driver to know before accessing and driving that crane;b) the controls and their layouts;c) the telephone, radio or closed circuit television communications (if provided);d) safety advice together with the appropriate safety signs and information;e) pictograms used on the crane;f) recommendation, when relevant, for the wearing of hearing protectors (this willapply in particular to cranes without an enclosed cabin).

5.4.3 Checks before starting any lifting operationThis section shall include :a) information given by all indicators of the crane (electrical power, fluid level and

pressure, wear limits, wind speed, etc.);b) correct operation of the controls;c) where practicable, the need for a clear and unrestricted view of the load and

operational area. If this is not practicable a check of the correct functioning ofcommunications equipment;

d) correct position (e.g. level of a mobile crane).

5.4.4 Specific safety aspects during operationThis section shall include (if appropriate) :a) slinging of the load;b) evaluating and monitoring of the load;c) loading and unloading;d) verticality of hoist line;e) starting and stopping motions;f) load control and balancing of the load;

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g) combined movements;h) correct use of emergency stop;i) minimum clearance between the load lifting attachment/load and the structure of

the crane.

5.4.5 Specific safety aspects before leaving the crane out-of-serviceThis section shall include (if appropriate) :a) out-of-service condition of the crane and lifting attachment;b) isolation of the power supply;c) security of the control equipment.

5.5 Maintenance instructions (preventative and corrective)This section shall include:a) drawings and parts lists as appropriate;b) preventative maintenance tasks and intervals;c) safety precautions during maintenance;d) maintenance parameters (pressure settings, torque values, rope discard criteria,

tolerances, etc.);e) checklists, test values and associated schematic diagrams;f) reference to specialist repair processes;g) reference to special tools;h) checks, inspections, examinations and tests, which are needed in accordance with

the design of the crane, including the safe conditions for carrying them out, withadvice for the recording of all defects and incidents;

NOTE Guidance for periodical checks, inspections, examinations andtests is given in ISO 12480-1.

i) criteria and, if appropriate, adequate records to enable determination of theapproach to the design constraints of the cranes components. If specific indicatingor recording devices are used to achieve this, instructions for use andmaintenance are to be given;

NOTE Guidance is given in ISO 12482-1.j) precautions required to maintain the crane for significant periods of non-use (on

site or dismantled);k) where appropriate, the examination and test programme after a significant period

of non-use, the necessary action before using the crane (such as lubricating,cleaning components, check of electric wiring etc.). The same, or a specificprogramme, shall apply following severe weather condition;

NOTE Further guidance is given in ISO 12480-1.l) repair conditions or reference to the manufacturer for advice. The instruction

handbook shall draw attention to and warn against servicing of the crane by non-specialised personnel, and to replacement parts which are not guaranteed inaccordance with the manufacturers specification;

NOTE Guidance for the content of spare parts manual is given inISO 10973.

m) conditions which are allowed to repair the elements of the crane instead ofreplacing them. In this situation the manufacturer needs to consider if the original

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fitness for purpose result can still be valid after certain repairs. Those componentswhich are needed for preventative maintenance shall be listed in the handbook.Any necessary reference and source of supply, together with replacementprocedures and tools that are needed shall also be given.

5.6 Transportation, erection and dismantlingInstructions shall be given regarding transportation, erection and dismantling procedures. Theinstructions shall describe all the necessary details to enable these processes to becompleted safely.If appropriate, the instruction handbook shall give a test programme to verify the new sitecondition after reassembly.

6 Verification of the requirementsBefore first use of any crane it shall be verified by a visual assessment that instructionhandbook(s) have been provided in accordance with this standard.

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Annex ZA (informative)Relationship of this document with EC DirectivesThis European Standard has been prepared under a mandate given to CEN by theEuropean Commission and the European Free Trade Association and supports essentialrequirements of EC Directive:Machinery Directive 98/37/EC, amended by Directive 98/79/EC.Compliance with this standard provides one means of conforming with the specificessential requirements of the Directive concerned.WARNING: Other requirements and other EC Directives may be applicable to theproducts falling within the scope of this standard.

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Bibliography

A.1 EU DirectivesEU Directive 98/37/EC dated 22.06.1998 for adjustment of the legal provisions of themember countries relating to machinery.EU Directive 89/655/EEC dated 30.11.1989, and its amendment 95/63/EEC on theminimum safety and health requirements for the use of work equipment by workers atwork.A.2 European StandardsEN 292-1:1991 Safety of machinery - Basic concepts; general principles for

design - Part 1: Basic terminology, methodologyCrane standards in preparation by CEN/TC 147.

A.3 International standardsISO 9926-1:1990 Cranes - Drivers training - Part 1: GeneralISO 9927-1:1994 Cranes - Inspections - Part 1: GeneralISO 9928-1:1990 Cranes - Crane driving manual - Part 1: GeneralISO 10973:1995 Cranes - Spare parts manualISO 12478-1:1997 Cranes - Maintenance manual - Part 1: GeneralISO 12480-1:1997 Cranes - Safe use - Part 1: GeneralISO 12482-1:1995 Cranes - Condition monitoring - Part 1: General