Bsi bs en 01551 2000 scan

7 Information for use Annex A normative Single side loading fork lift trucks - Stability tests Annex B normative Rough terrain trucks with masts - Stability tests Annex C normative Bi-d

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Copyright European Committee for Standardization

Provided by IHS under license with CEN

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````,`-`-`,,`,,`,`,,` -S T D o B ````,`-`-`,,`,,`,`,,` -S I B ````,`-`-`,,`,,`,`,,` -S EN 155L-ENGL 2000 L b 2 4 6 6 7 O B b 2 2 7 0 580 W

BS EN 1551:2000

been prepared under the

direction of the Engineering

Sector Committee, was published

under the authority of the

Standards Committee and comes

into effect on 15 July 2000

Amd No

O BSI 07-2000

National foreword

This British Standard is the official English language version of EN 1551:2000

The UK participation in its prepasation was entrusted to Technical Committee

M H E l i , Industrial tnicks - Safety, which has the responsibility to:

- aid enquirers to understand the text,

- present to the responsible European committee any enquiries on the

- monitor related international and European developments and promulgate interpretation, or proposals for change, and keep the UK interests informed;

them in the UK

A list of organizations represented on this committee can be obtained on request to its secretary

Cross-references

The British Standards which implement international or European publications referred to in this document may be found in the BSI Standards Catalogue under the section entitled “International Standards Correspondence Index”, or by using the

“Find” facility of the BSI Standards Electronic Catalogue

A British Standard does not purport to include alI the necessary provisions of a

contract Users of British Standards are responsible for their correct application

from legal obligations

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This European Standard was approved by CEN on 16 April 1999

CEN members are bound to comply with the CENICENELEC Intemal Regulations which stipulate the conditions for giving this European

standards may be obtained on application to the Central Secretariat or to any CEN member

This European Standard exists in three official versions (English, French, German) A version in any other language made by traislation

worldwide for CEN national Members

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7 Information for use

Annex A (normative) Single side loading fork lift trucks - Stability tests

Annex B (normative) Rough terrain trucks with masts - Stability tests

Annex C (normative) Bi-directional and multi-directional trucks - Stability tests

Annex D (normative) Trucks operated with offset load (offset determined by utilization)

additional stability test Annex E (normative) Side loading trucks handling freight containers of 6 m length and above

additional stability tests Annex F (normative) Overhead guard - Impact drop test

Annex G (informative) Loading control

Annex ZA (informative) Clauses of this European Standard addressing essential requirements

Verification of safety requirements andlor measures

or other provisions of EU directives

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This European Standard has been prepared by Technical Committee CEN/TC 150, Industrial Trucks -

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 October 2000 conflicting national standards shall be withdrawn at the

latest by October 2000

This European Standard 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 standard

This European Standard is one of a series of European Standards for the safety of Industrial trucks The

complete series is as follows:

Part 1 : General requirements

Part 2 : Additional requirements for trucks with elevating operator position and trucks specifically designed to travel with elevated loads

Safety of Industrial trucks - Self propelled trucks over 1 O 000 kg capacity Safety of Industrial trucks - Self propelled variable reach trucks

Safety of Industrial trucks - Pedestrian propelled trucks

Part 1 : Stacker trucks Part 2 : Pallet trucks

Part 3 : Plaíform trucks

Part 4 : Scissors lift pallet trucks

Safety of Industrial trucks - Driverless trucks and their systems Safety of Industrial trucks - Additional requirements for automated functions on trucks Safety of Industrial trucks - Electrical requirements

Part 1: General requirements for battery powered trucks

Part 2: General requirements for IC engine powered trucks Part 3: Specific requirements for electrical power transmission systems of IC engine powered trucks

Safety of Industrial trucks - Operation in potentially explosive atmospheres; use in flammable gas, vapour, mist and dust

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S T D - B S I BS EN L552-ENGL 2 D O D 111 L b 2 4 b b î 0 8 b 2 2 9 4 L 2 b =

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EN 1551 :2000

EN 12053, Safety of Industrial trucks - Test methods for measuring noise emissions

EN IS0 13564, Safety of Industrial trucks - lest methods for measuring visibility from self propelled

trucks

EN 13059, Safety of Industrial trucks - Test methods for measuring vibration

EN 12895, Safety of Industrial trucks - Electromagnetic compatibility

According to the CENICENELEC Internal Regulations, the national standards organizations of the 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 United Kingdom

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This European Standard is a type C standard as stated in EN 292-1

This standard has been prepared to be a harmonized standard to provide one means of conforming with the

essential safety requirements of the Machinery Directive and associated EFTA regulations

The extent to which hazards are covered is indicated in the scope of this standard In addition, machinery

shall comply as appropriate with EN 292 for hazards which are not covered by this standard

1 Scope

1.1 This standard applies to self propelled lift trucks, the rated capacity of which exceeds 1 O O00 kg

This standard does not cover:

- Trucks powered by natural gas

- Trucks operated by remote control

- Trucks with elevating operator position

1.2 For the purposes of this standard, self propelled lift trucks (hereinafter referred to as "trucks") are

counterbalanced lift trucks, with masts, as defined in 3.1.3.1.1 of I S 0 5053:1987; side loading trucks are

defined in 3.1.3.1.7 of I S 0 5053:1987 or rough terrain trucks, with masts, as defined in 3.1.3.1.8 of

I S 0 5053:1987

1.3 This standard applies to industrial trucks equipped with load handling devices for normal industrial

duties, e.g fork arms or attachments for specified applications Fork arms and integrated attachments are

considered to be parts of the industrial truck

Attachments mounted on the load carrier or on the fork arms which are removable by the user are not

considered to be part of the industrial truck

For attachments the appropriate clauses of this standard are applicable

1.4 This European Standard contains the technical requirements to minimize the specific hazards listed in

clause 4 which may occur during normal operation and maintenance of the trucks in accordance with the

data given by the manufacturer or his authorized representatives

This European Standard does not cover those requirements to minimize hazards which may occur:

- during construction;

- when handling suspended loads which may swing freely;

- when using trucks on public roads;

- when using a work platform

This European Standard does not repeat the technical rules which are state of the art and which are

applicable to the material used to construct the truck Reference should be made to EN 292-2

1.5 Where industrial trucks are required to operate in severe conditions (e.g in extreme climates, in strong

magnetic fields, in potentially explosive atmospheres) special precautions may be necessary These are not

covered in this standard

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This European Standard incorporates by dated or undated reference, provisions from other publications

These normative references are cited at the appropriate places in the text and the publications are listed

hereafter For dated references, subsequent amendments to or revisions of any of these publications apply

to this European Standard only when incorporated in it by amendment or revision For undated references

the latest edition of the publication referred to applies

Safety of industrial trucks - Electrical requirements - Part 1: General requirements for battery powered trucks

Safety of industrial trucks - Electrical requirements - Part 2: General requirements for internal combustion engine powered trucks

Safety of industrial trucks - Electrical requirements - Part 3: Specific requirements for electrical power transmission systems of internal combustion engine powered trucks Safety of industrial trucks - Additional requirements for automated functions on trucks Safety of industrial trucks - Operation in potentially explosive atmospheres: Use in flammable gas, vapour mist and dust

Safety of industrial trucks - Test methods for measuring noise emissions Safety of industrial trucks - Test methods for measuring visibility from self propelled industrial trucks

Safety of industrial trucks - Test methods for measuring vibration

Counterbalanced fork lift trucks - Stability tests fork litl trucks - Fork arms - technical characteristics and testing

Earth moving machinery - Access systems Powered industrial trucks - Control symbols Road vehicles, and tractors and machinery for agriculture and forestry - Determination

of burning behaviour of interior materials

Series ? Freight containers - Handling and securing

Powered industrial trucks - Terminology Industrial trucks operating in special conditions of stacking with the mast tilted forward -

Additional stability test High lift rider trucks - Overhead guards - Specification and testing Powered industrial trucks - Brake performance and component strength

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IS0 10658:1996, Industrial trucks operating in special conditions of stacking wifh load laterally displaced by

powered devices - Additional stability test ISOIDIS 15870, Powered industrial trucks - Safety signs and hazard pictorials - General principles

3 Definitions

For the purposes of this standard, the definitions of the industrial trucks and their components given in

IS0 5053 apply, together with the following

3.1

rated capacity of truck

load in kilograms, given by the manufacturer, that the truck type is capable of transporting or lifting under the

following specific conditions

For the load Q the following conditions apply:

- Load centre of gravity G (see Figure 1) positioned at the standard load centre û (3.3)

- Load Q vertically stacked to the standard lift height (3.2)

- Truck equipped with a double mast where the maximum lift height is equal to the standard lift height

When the truck does not utilize a double mast it shall be given rated capacity on the standard lifl height

as if the mast were available

D = standard load centre distance

G = load centre of gravity, positioned in the longitudinal plane of symmetry between the mast uprights

H = standard lift height

Q = rated load

Figure I

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standard lift height

height H from the ground to the upper face of the fork arm blade, which is 5 O00 mm for all truck types

Standard load centre distance D, millimetres

3.3

standard load centre distance

distance D for the centre of gravity G of the load measured horizontally to the front face of the fork arm shank

and vertically to the upper face of the fork arm blade as specified in 3.3.1 for counterbalanced trucks and

3.3.2 for side loading trucks

From (included) To (excluded)

3.3.1 Values for distance D are defined in Table 1

3.3.2 The distance D for side loading trucks is specified by the manufacturer

3.4

actual capacity of the truck

the maximum load in kilograms permitted by the manufacturer, that the subject truck is capable of

transporting or lifting in normal use (the use for which the truck is designed according to the manufacturer or

his authorized representative)

Actual capacity will vary with the different types and heights of mast fitted, changes of fork arms or

attachments and different load centre distances used in rating

Additional actual capacity ratings with removable attachments may also be established where permitted by

the appropriate stability specifications

3.5

rated capacity of removable attachments

maximum load in kilograms, and load centre where applicable, that the attachment is capable of handling in

normal operating conditions; as specified by the attachment manufacturer

3.6

opera tor

any trained person who is responsible for the movement and load handling of the industrial truck

3.7

normal operating position

position in which the operator shall be able to control all functions for driving and load handling Additional

positions may be needed if it is not possible to control all functions of the truck from one position

3.8

forward driving direction and the front end of the truck

the front end of the truck and the forward direction is the end nearest the arrow in Figures 2 and 3

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automatically acting brakes

brakes which are applied in non-operated conditions by stored energy, e.g spring force, until released by sustained force under control of the operator

The brake system is automatically applied in the event of failure of energy supply to the brake system

3.1 O

normal operating conditions

are those described in the stability documents as shown in 5.8

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5.3

5.4

5.5.3 5.7 5.7.4 5.7.6

5.9.2 5.10.1 7.2.2 7.3.3.4

5.1.3 5.5.3 5.7.6

5.5.3

Brakes Controls Engine access Operator position Protection from road wheels Protection against crushing, shearing and trapping

Operators overhead guard Warning device

Visibility Cab Transport Operation of the truck Warning symbols

Brakes Controls Engine access Operator position Protection from road wheels Protection against crushing, shearing and trapping

Warning device Visibility Operation of the truck Warning symbols

Edges or angles Engine access Protection against crushing, shearing and trapping

Engine access

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5.6.2 5.6.3 5.6.5 5.6.6 5.6.7 5.9.1 5.9.3 5.1 1 I I

- from lifting or transporting a truck 5.1 1.5

Stabbing or puncture hazard 5.1.3

7.2.5 Friction or abrasion hazard

High pressure fluid ejection 5.1.4

5.6.4.1 5.6.4.2 5.6.7.3 5.6.7.4 7.2.2

Engine access Protection from road wheels Protection against crushing, shearing and trapping

Operators cablemergency exit Calculation

Lift chains and wire ropes Mechanical lifting system Hydraulic lifting and tilting system

Fork arms Structural verification Operation of the truck

Mechanical lifting system Hydraulic lifting and tilting system Fork arms

Fork carriers Load handling attachments Operators overhead guard Load backrest

Operators cab

Protection from road wheels Transport

Edges or angles Service and maintenance of the truck Not applicable

Stored energy components Hydraulic system

Pressure relief valves Attachment hydraulic system Combined hydraulic system Operation of the truck

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4.3.1 Burns and scalds

4.3.2 Severe climate conditions

4.4 Hazards generated by noise

- Not covered by this standard

5.1 1.2 Noise emission 7.2.1 Concerning the trucklattachment 7.2.2 Operation of the truck

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EN 1551 :2000

Hazard

4.5 Hazards generated by vibration

4.6 Hazards generated by radiation

4.7 Hazards generated by materials

4.7.1 Contact or inhalation

4.7.2 Fire or explosion

Corresponding requirement

5.1 1.3 Vibration 7.2.1 Concerning the trucklattachment

- Not covered by this standard

5.5.1 Exhaust system 5.1 1.1.3 Totally enclosed cab 7.2.4 Effect of exhaust emissions

5.1 I Electrical requirements 5.5.2 Fuel tanks

5.5.4 LPG requirements 5.1 1.1.2

7.2.1 Concerning the truckiattachment

Cab material fire resistance

4.7.3 Biological and microbiological hazards - Not applicable

4.8 Hazards due to neglect of ergonomics

4.8.1 Unhealthy postures or excess effort 5.7.1 Operator position dimensions

5.7.2 Operator access and egress 5.7.3 Seat

5.9.1 i Overhead guard headroom 5.1 1.1 l Cab headroom

7.2.2 Operation of truck

4.8.2 Inadequacy with human anatomy 5.5.1 Exhaust system

5.1 1.1.4 Cab heater 7.2.2 Operation of the truck

4.8.3 Neglected use of personal protection - Not applicable

equipment

4.8.4 Inadequate local lighting 5.10.2 Truck lighting

4.8.5 Mental overload and underload - Not applicable

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4.1 O Hazards due to functional disorders

4.10.1 Failure of energy supply

4.10.2 Ejection of parts

- Loss of load 4.1 0.3 Failure of control system

4.1 0.4 Errors of fitting

5.3.3 Automatically acting brakes 5.4.3.2 Steering power supply 5.6.4.3 Supply to hydraulic circuit

- Not applicable 7.2.2 Operation of truck

5.1 I Electrical requirements 5.2.2 Unintended movement 5.6.4 Hydraulic system 5.6.7.3 Attachment hydraulic system 5.6.7.4 Combined hydraulic system 7.2.5 Service and maintenance

5.1.4 Stored energy components 7.2.5 Service and maintenance 7.2.6 Transportation

4.10.5 Loss of machinery stability See 4.1 I 1

4.1 1 Hazards due to missing safety means - Not applicable

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EN 1551 :2000

Additional hazards due to mobility

4.12 Inadequate lighting of moving/working 5.10.2 Truck lighting

area

4.1 3 Hazards due to sudden movement, 5.2.1 Unintended starting

Instability etc, during handling 5.8 Stability

5.9.2 Warning device 5.1 1.5 Transport 6.3 Functional verification 7.2.2 Operation of the truck

4.14 Inadequate/inergonomic design of

driving position

4.14.1 Hazards due to dangerous 5.5.1 Exhaust system

Environments (contact with moving 5.5.3 Engine access parts, exhaust gases etc.)

5.7 Operator position 5.7.4 Protection from road wheels 5.1 1.4 Operation in potentially explosive

atmospheres

4.14.2 Inadequate visibility from drivers

Position 4.14.3 Inadequate seaheating

4.14.4 Inadequate/ergonornic design/

positioning of controls

- Distance between the levers

- Power for acting levers

- Strength of controls

- Strength of brake components

4.14.5 Startinglmoving of self propelled

machinery

- Layout of pedals

- Additional operator positions

5.10.1 Visibility 5.1 1 I .5 Windscreen wipers

5.4.2.1 Layout of pedals 5.4.1.2 Additional operator positions

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Movement of pedestrian controlled -

4.1 5.3 Hazards due to rollover

4.1 5.4 Hazards due to falling objects

4.1 5.5

4.1 5.6

4.15.7

5.9.1 5.9.3 5.1 1 I I Inadequate means of access 5.7.2

Hazards due to towing, coupling, connecting transmission etc

7.2.2

Hazards due to batteries, fire, 5.1.1

5.5.2 5.5.4 7.2.1 7.2.3 7.2.4

Layout of pedals Travel and braking controls Steering direction

Multifunction controls Lighting

Not applicable

Arrangement of controls Leakage in hydraulic lift system Leakage in hydraulic tilt system Not applicable

Not applicable

Overhead guard Load backrest Operators cab Operator access and egress

Operation of the truck

Electrical requirements

Ex haust system Fuel tanks LPG requirements Concerning the truck

- Fire extinguisher Battery powered trucks

- hydrogen accumulation Engine powered trucks

- exhaust emissions

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4.16.4 Hazards caused by uncontrolled

movement

5.4.2 5.4.4 5.4.5 5.6.3 5.4.6 5.6.2 5.6.4 5.6.7.2 5.6.7.3 5.6.7.4 5.6.7.5

Hazards caused by lightning

Hazards due to loading/overloading 5.6.4.2

Calculation Lift chains and wire ropes Mechanical lifting system Fork arms

Load handling attachments Verification, general Structural verification

Travel and braking controls Load handling controls Multifunction controls Hydraulic lifting and tilting system Controls for automated functions Mechanical lifting system Hydraulic system

Clamping devices Attachment hydraulic system Combined hydraulic system Spreader

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5.1.4 Stored energy components

Stored energy components which cannot be removed or disassembled without decompression, e.g hydraulic accumulator or spring applied brakes, shall have the capability of decompression

engine being started whilst the transmission is engaged

5.2.2.3 Travel controls on internal combustion engine powered trucks shall be so arranged that on level ground, the truck will not move from rest until the transmission has been engaged With the transmission engaged, the truck shall not move faster than 2,5 km/h as long as the controls for the driving speed are not activated

Internal combustion engine powered trucks shall be fitted with a device which prevents the

5.2.2.4 Means shall be provided to prevent powered travel when the operator dismounts from the truck

On internal combustion engine powered trucks, the parking brake and neutral travel control, applied by the

operator, may be used to satisfy this requirement

5.3 Brakes

5.3.1 Service and parking brakes shall comply with IS0 6292

5.3.2 For trucks with capacities greater than 50 O00 kg, brakes shall also comply with IS0 6292

5.3.3 Failure of the power supply for automatically acting brakes shall not result in loss of braking

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be confined within the plan view outline of the truck

Controls shall, where practicable, be consistent with the truck motions being operated and shall

5.4.1.2

from one operating position at a time, except the emergency switch off

If additional operating positions are fitted, the operation of the controls shall only be possible

A suitable safeguard shall be specified to ensure that the change over from one control position to another is done safely

5.4.2 Travel and braking controls

It shall be possible to unlock the differential when the truck is moving

5.4.2.3 Hand operated direction control lever

The movement of a direction control lever shall correspond to the required direction of travel

5.4.2.4 Hand operated accelerator control lever

The control lever shall be a hold to run control, on release of the control its action shall return to minimum speed The movement of an accelerator control lever shall be parallel to the longitudinal axis of the truck Movement towards the front of the truck shall increase speed

5.4.3 Steering controls

5.4.3.1 Steering direction

Clockwise rotation of the steering wheel shall steer the truck to the right when the truck is travelling in the forward direction If a reversible control unit or multiple controls are fitted, clockwise rotation of a steering wheel shall also steer the truck to the operators right when the truck is travelling in reverse with the operator facing in that direction

5.4.3.2 Power supply

In the event of an interruption of the power supplied to the steering system (including a dead motor or engine), it shall be possible to maintain the path being steered until the truck is brought to a controlled stop

5.4.3.3 The steering system shall be non reactive, full power or power assisted

5.4.4 Load handling controls

Controls shall return to neutral when released, even in the case of accidental operation, stopping all load movement

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EN 1551 :2000

Controls for lift and tilt shall preferably be located to be operable by the operators right hand and clearly separate from the driving controls

The control closest to the operator shall preferably be for lift

5.4.5 Multi function controls

Where a control is designed and constructed to perform more than one function each separate function shall

be clearly marked

The controls shall comply with EN 1526

5.4.7 Marking

For marking controls graphic symbols complying with 7.3.1.3 are sufficient

5.5 Power systems and accessories

5.5.2.2 Fuel spillage shall not be possible under normal operating conditions

5.5.3 Engine access

5.5.3.1 If when the engine cover is open there are unguarded moving parts within the engine compartment, access to the compartment shall be possible only by means of a key or tool or by a release handle within a lockable operator’s cab

Access from underneath is considered guarded if the access underclearance is less than 600 mm between the underside of the truck and level ground

5.5.3.2

means of preventing unintentional closure, where such unintentional closure could cause injury

Opening access covers, such as traction battery or engine covers, shall be provided with a

5.5.4 Additional requirements for internal combustion engine powered trucks using liquefied

petroleum gas (LPG)

5.5.4.1 Containers

a) Containers for LPG shall be either permanently fixed on the truck or removable

b) Removable containers shall be secured on the truck in such a way that only intentional release is possible

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The fuel take-off on the container shall be equipped with an easily and quickly accessible manually operated valve The position and method of operation of this valve shall be clearly marked on the outside of the truck on or near the valve

The fuel take-off shall be in a liquid form unless the container and engine are specially equipped for direct vapour withdrawal

Containers to be filled by the user shall have the following fitted:

1) A safety pressure relief valve shall be connected to the vapour space of the container Where such containers are fitted inside compartments of trucks the discharge side of the relief valve shall be piped to atmosphere The gas shall be led away safely See also 5.5.4.3d

2) A fixed maximum level indicating device shall be fitted Where containers are fitted inside compartments of trucks the discharge side of any maximum level indicating device which relies on bleeding gas to atmosphere shall at a readily visible position on the outside of the truck, as follows:

- Maximum level indicating devices which rely on bleeding to atmosphere shall be designed

so that the bleed hole is not larger than 1 3 mm diameter and also so that the parts of the device cannot be completely withdrawn in normal gauging operations

- All maximum liquid level devices shall be suitable for the LPG in use, indicate the maximum product level and shall not vent to atmosphere

If containers are installed in a compartment, this compartment shall have permanent openings at the bottom The total surface area of these ventilation openings shall be at least 200 c d allowing adequate ventilation to the outside atmosphere and without risk to the operator

When containers are removable, their fastenings shall permit easy handling and checking of the installation after the exchange of containers

Removable containers which incorporate a safety pressure relief valve shall be so positioned on the truck that the safety pressure relief valve is always in communication with the vapour space at the top of the container This may be accomplished by an indexing pin which positions the container when the container is properly installed

If a spare or an additional container is carried on the truck, it shall be secured in the same manner as the main container

Containers shall be positioned in such a way that they are not exposed to the damaging effects of heat, particularly heat from the engine and the exhaust system It shall be possible to fit a heat shield which shall not inhibit ventilation under any circumstances

Containers shall be fitted on the truck in such a way that they are not unduly exposed to abrasion or shock nor to the corrosive action of the products handled by the truck

Containers and their connections shall be installed in such a way that there are no projections outside the plan view outline of the truck

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- Piping shall be so arranged that damage or leaks are easily detectable

- Piping shall be installed in such a way that it cannot be damaged by the hot parts of the engine

- Fully rigid pipes shall not be used for connecting the container to equipment on the engine

Pressure hoses above 1 bar shall be supported at least every 500 mm Rigid pipes shall be supported

at least every 600 mm

Hoses, pipes and all connections operating at pressure above 1 bar shall be suitable for a working pressure of 25 bar and shall withstand without bursting a test pressure of 75 bar Hoses, pipes and all connections operating below 1 bar shall withstand without bursting a test pressure of five times the maximum pressure likely to be encountered in service

Excessive pressure shall be avoided in any section of pipework containing LPG in liquid form between two shut off valves which may be closed; e.g a pressure relief valve or other suitable means may be used if necessary

Aluminium piping shall not be used in LPG lines

Hose lengths shall be as short as practicable

High pressure unions and joints (above 1 bar) shall be made of metal except for any constrained sealing washers

Safety pressure relief valves and liquid level indicators shall be installed in such a way that they cannot discharge in the direction of the operator or onto truck components which may be a source of ignition

If corrosion of a part would interfere with its proper functioning, that part shall be provided with a corrosion resistant protective coating

All fuel system components shall be firmly secured to the truck

Pressure reducing valves shall be readily accessible for inspection and maintenance

5.6.1 Lift chains and wire ropes

Chains and wire ropes shall have a certificate on record, from the chain or wire rope manufacturer, showing the breaking load

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Qi = the rated capacity in tonnes

Pulley diameters shall be at least three times the pitch of the chains

Splicing of wire ropes except at the terminal ends is not allowed

5.6.2 Mechanical lifting system

5.6.2.1 The lifting system shall comply with the requirements of 5.6.3.3

5.6.2.2

lower the load using a friction brake

When mechanical lifting systems are used it shall not under normal operation be possible to

5.6.2.3 In the event of the failure of the lifting mechanism or its parts (e.g gearwheel, chainwheel, spindle or rope pulley) it shall not cause the elevated driver position and/or the load to fall This requirement also applies to rack and pinion lifting systems or with spindle drive

5.6.2.4 The lowering speed of the lifting mechanism with its rated load shall not exceed 0,6 m/s

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EN 1551:2000

5.6.3 Hydraulic lifting and tilting system

5.6.3.1 Hydraulic lifting system

The descent of the rated load caused by an

substantially vertical, shall not exceed 200 mm

normal operating temperature

5.6.3.2 Lowering speed limitation

internal leakage in the hydraulic system, with the mast

in the first 10 min, with the oil in the hydraulic system at

A control device shall be incorporated in the lift circuit which even in the event of failure of the hydraulic circuit, excluding the hydraulic lift cylinder(s), shall restrict the rate of descent of the lifting mechanism with its rated load to 0.6 m/s maximum

5.6.3.3 Limitation of stroke

The lift assembly shall be fitted with stops to prevent over travel In addition, means shall be provided to

prevent the fork carrier and moving elements of the mast structure from accidentally disengaging from the

upper end of the mast

5.6.3.4 Hydraulic tilting systems

The internal leakage rate of the complete hydraulic tilting system (¡.e cylinders, valve, etc.) with the oil at normal operating temperature shall allow an average tilting speed of the mast to the front of less than 5" in the first 10 minutes, from the vertical mast position when the rated load is at a height of 2 500 mm, or in the case of trucks with lift heights of less than 2 500 mm, at their maximum lift height The average tilting speed allowed by leakages shall not exceed O,S"/min for trucks with a maximum forward tilt of less than 5"

5.6.4 Hydraulic system

5.6.4.1 Hydraulic circuit

All hoses, piping and connections subject to internal pressure shall be capable of withstanding without bursting a pressure equal to at least three times the operating pressure to which the respective hydraulic circuit may be subjected

5.6.4.2 Pressure relief valves

All hydraulic systems shall include a device which prevents the pressure in the system from exceeding a preset level

The device shall be so designed and fitted that accidental loosening or adjustment is avoided and so that a

tool or key is required to alter the pressure setting

NOTE Loading control see informative Annex G

5.6.4.3 Failure of energy supply to hydraulic circuit

In the case of a fault or interruption of the supply of energy, the design of the hydraulic installation shall be such that the hydraulic pressure in the system does not unintentionally cause the pump to function as a hydraulic motor

5.6.4.4 Oil purification

The hydraulic systems shall be protected against the risk of contamination of the hydraulic oil e.g by means

of magnet(s), filter(s), etc

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the fork arms fitted to the truck shall not be less than the actual capacity of the truck

Fork arms shall be manufactured and tested in accordance with I S 0 2330 The total capacity of

Means shall be provided on the fork carrier to prevent lateral disengagement of the fork arms at

5.6.6.2 If a fork arm removal slot is provided at the bottom of the fork carrier it shall not be positioned opposite a slot at the top of the fork carrier unless means are provided to prevent the fork arm being inadvertently displaced

5.6.7 Load handling attachments

5.6.7.1 Attachments (e.g fork arm extensions, clamps, sideshifters, etc.) shall be designed and manufactured in such a way that unintentional lateral displacement or detachment from the truck is prevented Movement of the attachment and its parts shall be mechanically limited at the extreme positions

5.6.7.2 Clamping devices shall be so designed that the load is automatically retained for at least

10 minutes by means of non return valves, or any other effective system, when the trucks control mechanisms are in the neutral position or in the event of a malfunction in the power supply system for the attachment

5.6.7.3 If an attachment has its own separate hydraulic system, it shall comply with 5.6.4

5.6.7.4

two systems shall be compatible and the combined systems shall comply with 5.6.4

If an attachment has a hydraulic system which is connected to the truck hydraulic system, the

5.6.7.5 On spreaders for top lifting of freight containers a device shall be provided that prevents the containers being lifted unless all four twist locks are fully engaged and locked All attachments for the handling of freight containers shall be fitted with a device to prevent unlocking of the interface mechanism when the container is suspended

5.7 Operator position

5.7.1 Dimensions

The operators seat shall be so located that the operator whilst operating the truck has enough room to remain within the plan view outline of the truck The dimensions, in millimetres, shall not be less than those shown in Figure 4 Where there are facilities for additional personnel these minimum dimensions are also applicable

The operator positions shall be arranged and structured in such a way that, in the normal operating position, the operator is able to reach and operate all the controls whilst maintaining an ergonomic posture

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be provided, where necessary, to give three point contact at all heights (¡.e one hand and two feet or two

hands and one foot) Step and handhold dimensions shall comply with I S 0 2867

5.7.2.2 Steps may be of open construction but shall have slip resistant surfaces or covering (e.g expanded metal, abrasive coating) The first step shall be not more than 550 mm from the ground and succeeding steps shall preferably be at regular intervals of 250 mm to 350 mm Step width, instep clearance and toe clearance shall comply with Figure 1 of I S 0 2867

5.7.2.3 Any walkways, including appropriate parts of the operators compartment floor, shall have a slip resistant surface (e.g ribbed mats, abrasive coating, expanded metal, etc.) Walkways more than two metres from the ground shall have adequate guard rails 1 O00 mm to 1 100 mm high

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5.7.4 Protection from road wheels

The operator in the normal operating position shall be protected against contact with the truck road wheels and against objects thrown up by the wheels (e.g mud, gravel, stones, etc.) The protective device for the steered wheels need only cover the wheels in the straight line position

5.7.5 Protection from burning

All parts of the truck within the reach of the operator in the normal operating position, or when getting into or leaving the operating position, shall be insulated or shielded, if necessary, so that their surface temperature does not exceed 65 "C for bare metal parts and 83 "C for painted or plastic parts, where the heat is generated by the truck

The temperature of the air at the heater outlet, where fitted, shall not exceed 60 "C

5.7.6 Protection against crushing, shearing and trapping

5.7.6.1

normal operating position, shall be adequately, guarded or be separated by the following minimum distance:

Parts which move relative to one another, which are within the reach of the operator in the

- Places where the operators fingers can be trapped: 25 mm minimum

- Places where the operators hands or feet can be trapped: 50 mm minimum

- Places where the operators arms or legs can be trapped: 100 mm minimum

Relative moving parts that need to contact or move in close proximity to one another shall be guarded to prevent access when the distance between those parts is more than 8 mm

If residual hazards exist, those shall be identified on the truck in accordance with 7.3.3.4

5.7.6.2 Crushing and shearing hazards associated with attachments, except at the load supporting points, shall also meet the relevant requirements of 5.7.6.1 If residual hazards exist, those shall be identified

on the attachment in accordance with 7.3.3.4

5.7.7 Additional operator positions

Positions for additional operator(s) shall comply with the requirements as specified in 5.7.1 to 5.7.7

5.8 Verification of stability

5.8.1 In order to restrict the hazards of longitudinal and lateral tipover during normal operations, trucks shall comply with the requirements specified below without permanent deformation (see 7.2.2 and Annex G)

- Single side loading trucks: Annex A

- Bi-directional and multi-directional trucks: Annex C

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EN 1551:2000

5.8.2

shall apply where appropriate:

For the use of trucks other than in normal operating conditions, the following additional stability tests

- Counterbalanced trucks: I S 0 5767, I S 0 10525, I S 0 10658, Annex D

- Single side loading trucks: Annex E

- Rough terrain trucks: IS0 5767, I S 0 10658, Annex D

5.8.3

requirements specified in IS0 1074, IS0 5767, I S 0 10525 and I S 0 10658 as appropriate

For trucks with capacities greater than 50 O00 kg, stability shall also comply with the minimum

5.9 Protective devices

5.9.1 Operators overhead guard

5.9.1.1 Trucks shall be fitted with an overhead guard complying with I S 0 6055, to protect the operator

5.9.1.2 The overhead guard shall be constructed in such a manner that it can be provided with an additional fitting making it possible in special cases to increase the protection of the operator against small falling objects

5.9.1.3 Trucks shall be constructed in such a manner that they can be provided with an overhead guard complying with Annex F to provide increased protection for the operator when handling such items as paper reels or packaged timber

5.10.1 The operator shall have sufficient visibility so that all travel and manoeuvres can be carried out

safely If direct visibility is limited, aids shall be used to provide adequate visibility such as mirrors, cameras, monitors, audible and visual alarms, devices sensing persons and/or objects, raised or rotatable seat etc

Requirements for visibility shall be in accordance with prEN I S 0 13564

5.10.2 Trucks shall be so designed that it is possible for the manufacturer or any other qualified person referring to the manufacturers instructions to equip them with an electrical circuit whereby travel lights, working lights and signal lights can be installed

5.1 I Environmental conditions

5.1 1 I Operators cab

5.11.1.1 If a cab is fitted in lieu of an overhead guard on an industrial truck, it shall comply with 5.9.1

5.1 1 I 2

of 250 mm/min when the standard test piece is tested in accordance with I S 0 3795

The material of the cab and fixing devices shall be fire resistant, with a maximum burning speed

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possible to give precise technical requirements in this standard

Due to the fact that trucks are used in a wide range of temperature and environmental conditions it is not

5.11.1.4 If a totally enclosed cab is fitted with a heaterldemister the air intake shall be connected to a fresh air inlet, partial recycling of the air up to 50 % is permissible The heater shall be securely fixed The heater shall be so designed that the requirements of 5.7.5 can be met Demistldefrost capability shall be provided for the windscreen and rear window

5.11.1.5 The front and rear windows of the cab shall be fitted with wipers so that the operator has an adequate view of the road If glass is used in the window apertures it shall be toughened or laminated safety glass

5.11.1.6

emergency exit, which may be a window complying with I S 0 2867, allowing escape in another direction

The cab shall have at least one door complying with the requirements of IS0 2867, plus an

5.1 1.1.7

operators normal operation

Provision shall be made for the storage of the instruction handbook, which does not obstruct the

5.1 1.1.8 Positions for additional operator@) shall comply with 5.1 1 I i to 5.1 1.1.6

5.1 1.2 Noise emission

The value of noise emission shall be measured by the test method given in prEN 12053 The values shall be either the actual figure or a figure calculated from measurements performed on identical trucks The

A weighted emission sound pressure level and if necessary the sound power level emitted by the truck shall

be measured The results shall be recorded

5.11.3 Vibration

Whole body vibration shall be measured by the test method given in prEN 13059

The value of the vibration transmitted to the operator and the method of measurement shall be included in the instruction handbook The figures given shall be either the actual figure or a figure calculated from measurements on identical trucks

5.1 1.4 Operation in potentially explosive atmospheres

Trucks operating in potentially explosive atmospheres shall comply with prEN 1755

5.1 I 5 Transport

5.11.5.1

disassembling, locations for slinging points shall be provided

If the manufacturer specifies in the instruction handbook that a truck may be lifted without

5.1 1 S.2

shall be indicated on the assembly or in the operating instructions

Lifting points for the removal and transportation of individual assemblies of the truck, if required,

5.1 1 S 3

handbook

Locations for the slinging of removable attachments shall be provided as stated in the instruction

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The verifications shall be as follows:

- Visually e.g no permanent deformation after structural verification, verification of the marking of the truck

- By measures e.g tests of lowering speed, lift and tilt leakage

- By design e.g verification of drawings and documents

- Further tests e.g as described in 6.2 and 6.3

The loads may be applied at the corresponding height by means independent of the truck

The test shall not result in any visual permanent deformation or damage

6.3 Functional verification

6.3.1 General

The functional tests given in 6.3.3 and 6.3.4 shall be carried out on each truck to verify that it is able to perform the tasks for which it was designed

6.3.2 Inspection before tests

6.3.2.1 Each truck shall be inspected to make sure that the travelling, braking, steering, load handling controls and combined functions, if any, are appropriately identified and operate correctly The correct operation of warning devices, safety devices and lighting, if any, shall also be checked

6.3.2.2

shall be inspected to make sure that they contain the relevant information in accordance with 7.3

The information plates for the truck, battery (for battery powered trucks) and attachment, if any,

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Tests shall either be performed by operating the truck in the manner prescribed below or, where practicable,

be simulated by any method giving an equivalent effect and producing substantially the same result

This test shall be carried out with load QI as follows:

Pick up the test load into the travel position as recommended by the manufacturer e.g

- The load raised 300 mm from the ground and the mast fully tilted back

- The bottom of the freight container no higher than 1 O00 mm above the point of maximum depression of the seat cushion under the operator and the mast fully tilted back

- The load on a plaiform of a side loading truck

Drive the truck forward at low speed, change to reverse, and change to forward again to verify that the direction change mechanism operates effectively Reversal of direction changes shall be made at the speeds recommended by the manufacturer

Drive the truck forward and backward through all speed ranges to the maximum speed and check that range changing and service brakes operate in both directions

Make several turns in both forward and reverse directions at approximately one third maximum speed and approximately three times the minimum outside turning radius specified by the manufacturer Check the function and direction of the steering

Deposit the load on the ground

This test shall be carried out with load Q2

Pick up the test load from ground level and elevate it to maximum height Lower to ground level at maximum speed, making several stops during descent, and deposit the load on the ground

With the mast vertical, the maximum lowering speed shall be measured with load Q2 to verify that it does not exceed 0,6 m/s This may be determined by dividing the total lowering distance in metres by the number of seconds required for the total descent

The permissible lowering shall be tested in accordance with 5.6.3.1 and the permissible tilting in accordance with 5.6.3.4

Following the tests in 6.3.3 and 6.3.4 the truck shall be examined visually to ensure that there are no defects

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These manuals shall include, if applicable, at least the following information:

7.2.1 Concerning the trucklattachment

Name and address of the manufacturer or the authorized representative

Designation of type e.g counterbalanced, side loader

Description of the truck and its accessories

Attachments which are fitted to the truck and their assembly precautions

Details of use of the load backrest

Details for the installation of a fire extinguisher, if required by the application of the truck

Admissible wheel rims and tyres with inflation pressures for pneumatic tyres

Description of the safety devices and warning labels

Details of the noise and vibration generated by the truck (The noise and vibration declarations shall be made in accordance with prEN 12053 and prEN13059 respectively)

Overall dimensions, load capacity and performance details of the truck

7.2.2 Operation of the truck

- Intended and prohibited uses of the truck and attachments, including those relating to hazardous atmospheres and overhead guards when handling very small or large heavy objects

- Training required by the operator

- Function of operating controls and displays

- Daily checks before putting the truck into operation

- Instructions for adjustment of the operators seat

- Instructions for operation with/without a cab, with/without doors

- Instructions for access and egress

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EN 1551:2000

De-energizing of stored energy components

Instructions for safe handling by the operator e.g when changing attachment, moving fork arms

Influence of tyres and floor conditions on noise emission

Requirements of the floor where the truck is to be used

The use of additional aids when the operators direct visibility is limited

Instructions for starting, driving and stopping the truck

Instructions for handling loads, warning about the hazards due to the action of wind forces

Instructions when operating on a gradient

Instructions for towing the truck

Instructions for parking the truck

Warning of residual risks during the use of the truck and its attachments

Climatic conditions in which the truck is designed to operate

- Specification of approved batteries and battery chargers

- Service mass of battery including ballast when required

- Procedure for safe handling of batteries, including installation, removal and secure mounting on the truck

- Warning of risks of accumulation of hydrogen under covers

- Approved fuels

- Procedure for safe handling of fuels

- Procedure for refuelling

- Warning of the effect of exhaust emissions in confined spaces

- Warning of the effect of exhaust emissions for the operator

7.2.5 Service and maintenance of the truck

- Training and qualifications for service and maintenance staff

- Safe procedure for the identification, detection and correction of faults

- Type and frequency of inspections and maintenance operations with particular attention to the replacement and durability of wearing parts and to the users logbook

- Inspection for exhaust emission

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EN 1551:2000

- Instructions for verification of marking

- Instructions for decompression of stored energy components

- Access to maintenance at high levels

- Servicing operations for which no special skills are required

- Use of approved spare parts

- Drawing and diagrams necessary for truck servicing and maintenance

- Instructions for disposing of waste material e.g oils and batteries

7.2.6 Transportation, commissioning and storage

- Mass and overall dimensions of the truck and dismantled parts

- Procedures for transporting including loading and unloading

- Procedure for truck reassembly and mounting of attachments

- Functional tests on completion of commissioning

- Procedure for retrieval of defective trucks

- Procedure for prolonged shut down and storage of trucks

- Name and address of the manufacturer or authorized representative

- Designation of the series or type

- Serial number and the year of manufacture

- Unladen mass of the truck in working order without removable attachments and battery for battery powered trucks, but with fork arms or integral attachments The mass may vary from the figure shown by

up to I5 % or 1 O00 kg whichever is the lower

- Rated capacity

- Actual capacity at maximum lift height with load centre distance

- Actual capacities at other lift heights and load centre distances if applicable

- Actual capacity with each removable attachment fitted at the manufacturers authorized lift height@) and load centre(s)

- On battery powered trucks, the authorized maximum and minimum battery mass and the system voltage

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EN 1551:2000

- The nominal power in Kw

The actual capacities shall be easily readable by the operator in the normal operating position

Serial number and year of manufacture

Mass of attachment, which may vary from the figure shown by up to f5 % or 200 kg whichever is the lower

Distance of the centre of gravity of the attachment from its mounting face on the truck

Rated load capacity

In the case of hydraulically or pneumatically operated attachments, the maximum operating pressure recommended by the attachment manufacturer

The warning "The capacity of the truck and attachment combination shall be complied with"

7.3.1.3 Marking

Controls shall be legibly and indelibly marked (e.g weather proof, profiled letters) with graphic symbols indicating the function@) Each symbol shall be affixed on or in close proximity to the control to which it

applies Control symbols shall comply with IS0 3287 where available

7.3.2 Information plate for trucks operating in special conditions

If a truck is designed to operate in special conditions (see 1.5 and 5.8), it shall be legibly and indelibly marked (e.g weather proof, profiled letters) with the designation of the special conditions of use including capacity if different from the actual capacities

7.3.3 Other information

7.3.3.1 Marking for slinging of trucks

Locations for slinging shall be clearly indicated on the truck

7.3.3.2 Pneumatic tyre inflation pressure

The specified inflation pressures shall be clearly indicated on the truck

7.3.3.3 Filling points

Filling points for fuel and hydraulic oil shall be clearly indicated on the truck in accordance with I S 0 3287

O BSI 07-2000

Tiêu đề	Safety of Industrial Trucks - Self Propelled Trucks Over 10000 Kg Capacity
Trường học	British Standards Institution
Chuyên ngành	Safety of Industrial Trucks
Thể loại	British standard
Năm xuất bản	2000
Thành phố	London

Định dạng
Số trang	75
Dung lượng	3,13 MB