Bsi bs en 01501 3 2008

BS EN 1501 3 2008 ICS 43 160 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW BRITISH STANDARD Refuse collection vehicles and their associated lifting devices — General requireme[.]

This British Standard

was published under the

authority of the Standards

Policy and Strategy

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

This publication does not purport to include all the necessary provisions

of a contract Users are responsible for its correct application

Compliance with a British Standard cannot confer immunity from legal obligations.

NORME EUROPÉENNE

ICS 43.160

English Version

Refuse collection vehicles and their associated lifting devices

-General requirements and safety requirements - Part 3: Front

loaded refuse collection vehicles

Bennes de collecte des déchets et leurs lève-conteneurs

associés Exigences générales et exigences de sécurité

-Partie 3: Bennes à chargement frontal

Abfallsammelfahrzeuge und die dazugehörigen Schüttungen - Allgemeine Anforderungen und Sicherheitsanforderungen - Teil 3: Frontlader

This European Standard was approved by CEN on 12 January 2008.

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 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 Management Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

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

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

Contents Page

Foreword 4

Introduction 5

1 Scope 6

2 Normative references 6

3 Terms and definitions 8

4 Modes and controls of front loaded RCV 12

5 List of significant hazards 14

6 Safety requirements 20

7 Verification 37

8 Information for use 41

Annex A (normative) Definition of working and functional spaces 46

Annex B (normative) Examples of data sheet 48

Annex C (informative) Types of systems for front loaded RCVs: lifting devices, compaction and discharge systems and types of waste containers 54

Annex D (normative) Warning signals 60

Annex ZA (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 98/37/EC, amended by 98/79/EC 61

Annex ZB (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC 62

Bibliography 63

Figures Figure A.1 — Side view of a front loaded RCV 46

Figure A.2 — Top view of a front loaded RCV 47

Figure B.1 — Example of data sheet Dimensions, volumes and centres of gravity 48

Figure B.2.1 — Example of data sheet - Axle load calculation 49

Figure B.2.2.1 — Lateral tipping edge at outer tire 50

Figure B.2.2.2 — Rear tipping edge at centre line of the most rear axle 50

Figure B.2.2 — Example of data sheet - Calculation of side and rear stability on fully tipped body / bodywork 51

Figure B.2.3.1 — Longitudinal stability 52

Figure B.2.3.2 — Lateral stability 52

Figure B.2.3 — Example of data sheet - Stability calculation in container lifting mode 53

Figure C.1 — Types of lifting devices for front loaded RCV 54

Figure C.2 — Types of compaction systems 55

Figure C.3 — Types of discharge systems 56

Figure C.4 — Recommended types of waste containers 57

Figure C.5 — Description of forks 58

Figure C.6 — Types of top doors 59

Figure D.1 — Warning signal for extending lifting devices 60

Tables Table 1 — List of significant hazards 14

Table 2 — Graphical symbols 26

Table 3 — Verification 37

Foreword

This document (EN 1501-3:2008) has been prepared by Technical Committee CEN/TC 183 “Waste management”, the secretariat of which is held by DIN

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 September 2008, and conflicting national standards shall be withdrawn at the latest by September 2009

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 has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EC Directive(s)

For relationship with EC Directive(s), see informative Annexes ZA and ZB, which are an integral part of this document

The minimum essential criteria are considered to be of primary importance in providing safe, serviceable, economical, and practical front loaded refuse collection vehicles

This European Standard is one part of the series of coordinated standards EN 1501 about “Refuse collection vehicles and their associated lifting devices - General requirements and safety requirements” comprising the following parts:

 Part 1: Rear-end loaded refuse collection vehicles, as amended by A1: Footboards (under revision)

 Part 2: Side loaded refuse collection vehicles

 Part 3: Front loaded refuse collection vehicles

 Part 4: Noise test code for refuse collection vehicles

 Part 5: Lifting devices for refuse collection vehicles (under preparation)

This European Standard is the third one of a series of standards dealing with specification, design, safety and testing of refuse collection vehicles (RCVs) and their associated lifting devices

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, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom

Introduction

This document is a type C standard as stated in EN ISO 12100-1

The machinery concerned and the extent to which hazards, hazardous situations and events are covered are indicated in the scope of this document

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 series of standards should be read in conjunction with the documents developed by CEN/TC 183/WG 1 for mobile waste containers (according to the series of standards EN 840), for stationary waste containers (according

to the series of standards EN 12574) and for selective collection containers emptied by the top (Type B of

EN 13071) that are compatible with some of the lifting devices specified in this standard (see Figure C.4)

While producing this standard it was assumed that:

 only persons who have been appropriately trained will operate the front loaded RCV;

 the guidelines issued by the chassis manufacturer have been taken into account;

 components without specific requirements are designed in accordance with the usual engineering practice and calculation codes, including all failure modes, of sound mechanical and electrical construction and made of materials with adequate strength and of suitable quality;

 harmful materials, such as asbestos, are not used as part of the machine;

 components are kept in good repair and working order, so that the characteristics, within the specified limits as stated in the maintenance manual, remain despite wear;

 by design of the load bearing elements, a safe operation of the machine is assured for loading ranging from zero to 100 % of the rated capacities;

 the equipment has been designed for operation with an ambient temperature between –25 °C and 40 °C;

 specific uses and operating conditions of the machinery are taken into account by negotiation between the manufacturer and the user (for example: type of waste, extended temperature range, type of driving conditions)

The standard is designed for careful consideration by designers, manufacturers, suppliers and users of the front loaded RCV

This standard part 3 describes and gives the requirements of the front loaded RCV and the associated lifting device(s) and refers to part 4 of this series of standards for the noise test code

Examples for standard types of front loaded refuse collection vehicles are given in Annex C

This European Standard is not applicable to:

 operation in severe conditions (e.g extreme environmental conditions such as: temperatures below –25 °C and above 40 °C, corrosive environment, tropical environment, lightning, wind velocity in excess of 75 km/h);

 operation subject to special rules (e.g potentially explosive atmospheres, contaminating environments);

 transportation of passengers, lifting of persons;

 loading by crane;

 loading by satellite vehicle;

 containers other than defined in EN 840-1 to -4, EN 12574-1 to -3 and type B of EN 13071;

 handling of loads the nature of which could lead to dangerous situations such as hot wastes, acids and bases, radioactive materials, especially fragile loads, explosives

This document is not applicable to machinery which is manufactured before the date of its publication by CEN

2 Normative references

The following referenced documents are indispensable for the application of this document For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies

EN 294, Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs

EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body

EN 574, Safety of machinery - Two-hand control devices - Functional aspects - Principles for design

EN 811, Safety of machinery - Safety distances to prevent danger zones being reached by the lower limbs

EN 840-1, Mobile waste containers - Part 1: Containers with 2 wheels with a capacity up to 400 l for comb lifting

devices, dimensions and design

EN 840-2, Mobile waste containers - Part 2: Containers with 4 wheels with a capacity up to 1 300 l with flat lid(s),

for trunnion and/or comb lifting devices - Dimensions and design

EN 840-4, Mobile waste containers - Part 4: Containers with 4 wheels with a capacity up to 1 700 l with flat lid(s),

for wide trunnion or BG- and/or wide comb lifting devices - Dimensions and design

EN 842, Safety of machinery - Visual danger signals - General requirements, design and testing

EN 894-1, Safety of machinery - Ergonomics requirements for the design of displays and control actuators - Part 1:

General principles for human interactions with displays and control actuators

EN 894-2, Safety of machinery - Ergonomics requirements for the design of displays and control actuators - Part 2:

EN 982, Safety of machinery - Safety requirements for fluid power systems and their components - Hydraulics

EN 983, Safety of machinery - Safety requirements for fluid power systems and their components - Pneumatics

EN 1032, Mechanical vibration - Testing of mobile machinery in order to determine the vibration emission value

EN 1037, Safety of machinery - Prevention of unexpected start-up

EN 1050:1996, Safety of machinery - Principles for risk assessment

EN 1088:1995, Safety of machinery - Interlocking devices associated with guards - Principles for design and

selection

EN 1501-4, Refuse collection vehicles and their associated lifting devices - General requirements and safety

requirements - Part 4: Noise test code for refuse collection vehicles

EN 1837, Safety of machinery - Integral lighting of machines

EN 12574-1, Stationary waste containers - Part 1: Containers with a capacity up to 10 000 l with flat or dome lid(s),

for trunnion, double trunnion or pocket lifting device - Dimensions and design

EN 12574-2, Stationary waste containers - Part 2: Performance requirements and test methods

EN 12574-3, Stationary waste containers - Part 3: Safety and health requirements

EN 13071, Selective waste collection containers - Above-ground mechanically-lifted containers with capacities from

80 l to 5000 l for selective collection of waste

EN 13309, Construction machinery - Electromagnetic compatibility of machines with internal electrical power supply

EN 13478, Safety of machinery - Fire prevention and protection

EN 60204-1:2006, Safety of machinery - Electrical equipment of machines - Part 1: General requirements (IEC

60204-1:2005, modified)

EN 60529, Degrees of protection provided by enclosures (IP code) (IEC 60529:1989)

EN 61310-1, Safety of machinery - Indication, marking and actuation - Part 1: Requirements for visual, auditory and

tactile signals (IEC 61310-1:1995)

EN ISO 7731, Ergonomics - Danger signals for public and work areas - Auditory danger signals (ISO 7731:2003)

EN ISO 11688-1, Acoustics - Recommended practice for the design of low-noise machinery and equipment - Part

1: Planning (ISO/TR 11688-1:1995)

EN ISO 12100-1:2003, Safety of machinery - Basic concepts, general principles for design - Part 1: Basic

terminology, methodology (ISO 12100-1:2003)

EN ISO 12100-2 Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles

(ISO 12100-2:2003)

EN ISO 13732-1, Ergonomics of the thermal environment - Methods for the assessment of human responses to

contact with surfaces - Part 1: Hot surfaces (ISO 13732-1:2006)

EN ISO 13849-1, Safety of machinery - Safety-related parts of control systems - Part 1: General principles for

design (ISO 13849-1:2006)

EN ISO 13850, Safety of machinery - Emergency stop - Principles for design (ISO 13850:2006)

EN ISO 14122-2, Safety of machinery - Permanent means of access to machinery - Part 2: Working platforms and

walkways (ISO 14122-2:2001)

IEC 60417, Graphical symbols for use on equipment

ISO 7000, Graphical symbols for use on equipment - Index and synopsis

3 Terms and definitions

For the purposes of this document, the terms and definitions given in EN ISO 12100-1:2003 and the following apply

3.1

refuse collection vehicle (RCV)

vehicle intended to be used for the collection and transportation of refuse based on loading via waste containers or

RCV, as defined in 3.1, where refuse is loaded from the front via waste containers into the hopper/body

NOTE The trajectory of the waste container is over the top of the cab or the front axle, regardless where the waste container is picked up

3.3

combination with other types of RCVs

a combination of a front loaded RCV with a rear and/or side loaded RCV

3.6

capacity of the front loaded RCV

internal volume of the body and discharge door available for the refuse, measured in cubic metres rounded off to one decimal (V3 and V4 in Figure B.1)

capacity of the hopper

volume of non-compacted refuse the hopper contains, measured in cubic metres rounded off to one decimal When

a compaction mechanism leaves a volume it is included in the capacity of the hopper (V1 + V2 in Figure B.1)

mechanism used to compact and transfer the refuse from the hopper into the body

NOTE Several types are shown in Figure C.2

3.13

discharge system

system to empty the body

NOTE Several types are shown in Figure C.3

3.13.1

ejection plate system

system to empty the body by moving the ejection plate to the rear, after opening the discharge door

3.13.2

discharge by tipping

system to empty the body by tilting the body after opening the discharge door

3.13.3

rotation drum system

system to empty the body by rotation of the drum after opening the discharge door

3.13.4

walking floor

system to empty the body by moving floor segments after opening the discharge door

3.13.5

interchangeable body

when the whole body is demounted and then discharged independently

3.14

designated waste container

range or types of receptacles for storing refuse prior to the collection by the front loaded RCV and which are compatible with the lifting device of the front loaded RCV

NOTE Some of these waste containers are standardized following EN 840-1, to -4 and EN 12574-1 to -3 (see: Operation manual) Main types of designated waste containers are described in Figure C.4

functional space of lifting device

space covered by the movements of the lifting device (including the waste container) as specified by the manufacturer

NOTE See Figures A.1 and A.2

3.15.4.4

trunnion holding system

part of the lifting device attached to the lift arm or the extending arm consisting of a pair of arms with a locking mechanism to hold and pick up the designated waste container(s) fitted with trunnion

3.16

travelling position of the lifting device

location of the lifting device and/or extending arm and/or fork within the designed dimensions of the front loaded RCV (according to road traffic regulations) for the purpose of travel movement of the RCV

3.17

waste container emptying cycle

number of sequences to hold, pick-up, lift and tip the waste container and put it back on the ground

3.18

top door

cover for the hopper

NOTE Several types are described in Figure C.6

mono-operative front loaded RCV

when the whole sequence of movements of the waste container emptying cycle can be achieved only through the actuation of the controls located in the cab

3.27

functional space

volume covered by the movements of the designated waste container(s) when lifted by the lifting device as specified by the manufacturer (see Figures A.1 and A.2)

4 Modes and controls of front loaded RCV

NOTE Travel and positioning movements are not included

4.1 Operating modes

Movements of the mechanically moved parts of the front loaded RCV:

4.1.1 Manual: the mechanism achieves each movement within the waste container emptying cycle or the

compaction cycle by a specific, separate command

4.1.2 Semi-automatic: the mechanism achieves each sequence of movements (two or more movements in one

sequence) within the waste container emptying cycle or the compaction cycle by a specific command

4.1.3 Automatic: the mechanism achieves all sequences of the waste container emptying cycle or the

compaction cycle by one command without any other action

4.2 Compaction operating modes and controls

4.2.1 General

Each front loaded RCV may be fitted with one or more of the following compaction operating modes

4.2.2 Automatic compaction

Automatic compaction mechanisms are activated by an impulse command, e.g by a start control device or

emptying a container into the hopper:

 continuous cycle is one that cycles by a start impulse and that continually cycles until stopped by an independent action;

 single cycle is one that cycles once with a start impulse or the emptying and then stops without any further

operating action;

 multi cycle is one that cycles by a start impulse for a given number of times and then stops without any other action The number of cycles is pre-determined

For single and multi cycles the start impulse may be generated by means of the start command of the lifting device

It can also be stopped by activation of a stop control

4.2.3 Semi-automatic compaction

The controlled cycle is activated by one single hold-to-run control, e.g button or lever, from the start until all shear

traps have been passed Thereafter, the cycle will be completed as a single cycle as described in 4.2.2, even if the control is released

4.2.4 Manual compaction

The compaction mechanism is commanded and controlled by the operative by means of a hold-to-run control, e.g

4.3.2 Automatic discharge mode

The automatic discharge door opening and closing modes are not allowed

4.3.3 Semi-automatic discharge mode

The semi-automatic mode of the discharge door achieving each sequence of the discharge cycle shall be activated

by a hold-to-run control device except for the final closure The final closure shall only be possible by the external control with a two-hand hold-to-run control device (see 6.3.1.3)

4.3.4 Manual discharge mode

The discharge door achieves each movement within the discharge cycle by a separate command of a hold-to-run control device The final closure shall only be possible by the external two-hand hold-to-run control (see 6.3.1.3)

4.4.2 Automatic lifting mode

The lifting device achieves all sequences of the emptying cycle by one command

4.4.3 Semi-automatic lifting mode

The lifting device achieves each sequence of movements (two or more movements in the sequence) of the emptying cycle by a command using a hold-to-run control device

4.4.4 Manual lifting mode

The lifting device achieves each movement within the emptying cycle by a specific separate command of the to-run control device

hold-4.4.5 Selection of mode/lifting device

A selection of mode is when a lifting operating mode can be changed to or from any of the modes mentioned under 4.4.2 to 4.4.4

5 List of significant hazards

This clause contains all the significant hazards, risk areas and hazardous situations and events as far as they are dealt with in the standard, identified by risk assessment as significant according to EN 1050 for this type of machinery and which require action to eliminate or reduce the risk

Table 1 — List of significant hazards Corresponding

clause in

Annex A of

EN 1050:1996

Hazard Risk Area Hazardous situation this standard Reference in

1 Mechanical from mass

and velocity

Lifting device

Too high a speed of the lifting device 6.5.1.2

2

Inadequacy

of mechanical strength

Discharge system

Lock between interchangeable body and compaction mechanism

Unexpected demounting of the interchangeable body 6.8.2

4

Inadequacy

of mechanical strength

Lifting device Break up of arms or forks 6.5.1.2

5 Crushing, hitting Lifting device Hitting and / or crushing between lifting device or waste container and ground during

lowering operation

6.5.1.1, 6.5.1.3

6

Crushing, trapping, hitting

Lifting device Clamping of a pedestrian 6.5.2.3, 6.5.2.4,

6.5.2.5, 6.5.2.6

7 Crushing, trapping Lifting device Trapping between lifting arms and the bodywork and/or cab, when lowering and

lifting the lifting device

6.5.1.1, 6.5.1.2, 6.5.1.3

8 Crushing Lifting device Crushing or trapping between parts of the lifting device 6.5.1.3, 6.5.2.5,

6.5.2.6

Lifting device Crushing or trapping between waste

container and lifting device

6.5.1.2, 6.5.2.5, 6.5.2.6

10 Crushing, shearing,

hitting

Discharge system Crushing between discharge door and body when laterally hinged door is being

opened

6.3.1.3, 6.3.1.4

11

Crushing, shearing, hitting

Discharge system Crushing between open lateral hinged discharge door and body when the

discharge door is unintentionally closed (by wind)

6.3.1.3, 6.3.1.4

12 Crushing, shearing,

hitting

Discharge system Crushing between discharge door and body when discharge door is being

lowered

6.3.1

13

Hitting, crushing, shearing, trapping

Space between body and

compaction system

Trapping between body and other parts of the machine 6.3.3, 6.8.6,

6.8.7

14

Crushing, shearing, hitting

Space between body and chassis and rear of the body

Trapping between body and chassis or hitting third party at rear

6.8.4, 6.8.7, 6.8.8

15 Crushing shearing Compaction mechanism Crushing or shearing between compaction mechanism and its housing when the

body is removed

6.2.2.4

16 Crushing, shearing,

trapping

Inside body Crushing or shearing by compaction

mechanism or ejection plate during maintenance

19 Crushing, shearing

trapping

Rotation drum body Crushing, shearing, trapping between body and rollers 6.2.2.5

20 Crushing, Top door Operative trapped and injured by top door closing during maintenance 6.11.3.4, 8.3

21

Projection

of hydraulic fluid under high pressure

Lifting device bodywork Ejection of high pressure oil jet caused by loose or burst oil hoses 6.7

Hazard Risk Area Hazardous situation this standard Reference in

22 Electrocution General Contact with overhead energy transmission cables, e.g by top door, lift

arms, container…

6.3.3, 6.4.2, 6.6

23 Contact with hot surfaces Exhaust pipe Burns 6.18.1

24

Hazard generated by noise resulting

in hearing damage or interference in communication

Any working area Incorrect operation because of inaudible information 6.14.4, 6.18,

8.1, 8.2

25

Lack of information RCV Risky reactions of the operative(s) 6.3.3, 6.4.2,

6.8.5, 6.11.2.3, 8.1.3.2, 8.1.3.4

26

Modifications

by operatives Areas covered

previously for risks due

to mechanisms

Unauthorised modification of controls/control circuits

6.11.3.1, 6.12.1.2

27 Explosion Body Refuse insufficiently ventilated 6.18.2

28 Fire Body Fire in the body 6.19.3, 6.19.4

29 Contamination Body Operative contaminated 6.19.5

30

Insufficient illumination Functional area of

waste container lifting device

Various hazards e.g by unsafe handling

of waste containers and controls 6.12.11

31 Human error, behaviour RCV Various hazards resulting from human error during operation, maintenance and

repair

8.1, 8.2

32

Inadequate design, location or identification of manual

controls

All moving parts

Unexpected movement by activation of the wrong control command

6.11.3

All moving parts

Unexpected movement by activation of the wrong control command

6.9, 6.11.3.1

34

Failure of hydraulic and control system

Closing edge

of discharge door

Failure of system that controls raising or lowering the discharge door when the discharge door is being raised

6.3.1.1, 6.3.1.2, 6.3.2, 6.7

35

Failure of hydraulic and control system

Lifting device Descent of forks and/or lift arms 6.5.1.1,

6.5.1.2, 6.7

36 Restoring of energy All moving parts Unintentional machine movement caused by recovered energy e g after unexpected

engine stop

6.11.1.2, 6.11.1.3

37

External influences

on electronic equipment

RCV Poor immunity to electromagnetic

radiation 6.13

38 External influences RCV Lack of stability under influence of the wind 6.17

39

Failure of control circuit

All moving parts Unintentional machine movement 6.11.1.2, 6.11.1.3,

6.11.3.3, 6.12.1.1

40

Failure of control circuit

All moving parts Unintentional starting or failure on stop functions due to poor design of

controls/control circuit

6.11.1, 6.11.2.1, 6.11.3, 6.11.3.2, 6.12.2, 6.12.3, 6.12.4, 6.12.5, 6.12.7, 6.12.8, 6.12.9, 6.12.10, 6.12.11

41

Fitting Errors

RCV Incorrect hydraulic and/or electric

connections

6.7, 6.12.1, 6.12.3, 6.12.10, 6.12.11

42

Rupture of hoses

Area underneath top hinged discharge door

Free fall of the raised discharge door due

to rupture of the oil pressure hoses when

it is not secured during maintenance

6.3.1.1, 6.3.1.3

43 Rupture of hoses Lifting device Free fall of arms 6.5.1.1

44 Failure during operation Interchange-able body Loss of interchangeable body during compaction by failure of locks 6.8.2

45 Falling of container Lifting device Waste container falls off due to collision with compaction mechanism 6.5.1.1

46

Falling of container

Lifting device Waste container falls off caused by

human error while controlling the lifting device

6.5.1.2, 6.5.1, 6.5.2.4

47

Falling of container

Lifting device Container falls because it is incorrectly

positioned on forks or/and because damaged

6.5.1.2, 6.5.2.5

48

Falling of refuse Lifting device Refuse falls off the waste container beside the RCV due to improper design

either of the hopper or of the kinematics

of the lifting device and/or incorrect operation

6.5.1.1, 6.5.1.2, 6.5.1.3

49 Falling of container or

refuse

RCV Refuse and/or waste container falls on

the roof and then on the ground because

of unintentional closing of top door

6.4.1

50

Falling off due

to inadequate closure of the body

able body Refuse falls out off the body 6.8.1

Interchange-51 Tipping over RCV Tipping over of RCV due to lack of stability when tipping the body or lifting

too heavy waste container

6.8.4

53 Slip, fall of person Roof of the body Person falling from the roof when cleaning 6.15.4

54

Movement without driver

at the driving position

RCV Movement of RCV when driver activates

the remote control 6.8.8

55

Movement without all Lifting device Hitting other vehicles or pedestrians when driving with lifting device extended 6.5.2.1, 6.5.1.3,

56

Movement without all parts in rest position

Top door Hitting overhead object when driving with

top door opened

6.4.2

57

Movement without all parts in rest position

Body Hitting overhead objects when driving with

tipped body

6.3.3

58

Insufficient ability to be slowed down and stopped

RCV Steering ability reduced, overload 6.16

59 Penetration by objects Cab seats Hard and sharp wastes pushed into the cab by the compaction mechanism 6.2.2.2

60

Insufficient visibility

Lifting device Injuries to pedestrians and cyclists by

operation of the lifting device without observing the functional area by the operator

6.5.2.5, 6.12.11

61 Insufficient visibility Cab working station (seat) When filtering into the flowing traffic if driver’s seat is located on kerb side 6.14.3

62 Insufficient visibility Discharge door Injury to other person when opening or closing of the discharge door 6.3.1.2

63 Vibration Working positions Disability of operative 6.19.6, 8.2

64 Unexpected movement of

lifting device

Lifting device Hitting other vehicles or pedestrians by

accidental extension of the extending arm 6.5.2.1

65

Lack or inadequacy

of visual or acoustic warning means

RCV Incorrect activation by the driver 8.1.3.2,

8.1.3.4

66 Insufficient instructions

for driver

RCV Incorrect activation by the driver 7

67 From access of persons to

testing/use/

maintenance

Lifting device (RCV) Incorrect movements, operation and maintenance 6.7, 6.11,

6.12

6 Safety requirements

6.1 General

The front loaded RCV shall comply with the safety requirements and/or measures of this clause Furthermore, the front loaded RCV shall be designed in accordance with EN ISO 12100-1 and EN ISO 12100-2 for hazards relevant but not significant which are not dealt with in this standard All systems and components shall be specified and installed in accordance with their manufacturer’s instructions

For the application of EN 294, EN 349, EN 982, EN 60204-1, the manufacturer shall carry out a risk assessment for any additional requirement not dealt with in this standard

6.2 Compaction mechanism

6.2.1 Controls for the compaction mechanism

The automatic cycle of the compaction mechanism shall only be operable with closed systems

6.2.2 Interaction between the compaction mechanism and other parts of the bodywork

6.2.2.1 Compaction plate against the lifting device

The design of the compaction mechanism and the lifting device shall prevent waste from being loaded behind the compaction plate Contact between the compaction mechanism and the waste container shall not be possible It shall be ensured that the waste container cannot be pushed away from its receiver by the waste moved by the compaction mechanism

6.2.2.2 Compaction against the discharge door

The design shall take into account the dynamic forces on the discharge door, the connections between the discharge door and the body, and the connections between the compaction mechanism and the body all of which need to withstand the forces generated by the compaction mechanism

6.2.2.3 Rear of the cab protection

The design of the compaction mechanism and its mounting inside the bodywork shall take into account the compaction type, the dynamic forces with special regard to the protection of the cab The design shall be such that

no hard and sharp waste can be pushed out of the body by the compaction mechanism, e.g retracting compaction plate, and penetrate the cab through its rear wall, for example by deflection of the waste, reinforced rear wall, or shield with sensor

6.2.2.4 RCV with tilting or interchangeable body

When the body is not locked to the compaction mechanism, the compaction mechanism shall be impossible to operate in automatic mode and semi automatic mode

6.2.2.5 RCV with rotation drum body

Where the rotation drum body creates a potential shearing or crushing trap, fixed guards according to EN 953 shall

be fitted

6.3.1.3 The control device for locking and un-locking of the discharge door shall be situated outside the discharge door trajectory at a safety distance according to EN 294 to prevent hitting or trapping of the operative

A single hold-to-run control device shall be used for opening the discharge door

A two-hand hold-to-run control device shall be used for closing the discharge door The control shall comply with type III A of EN 574 and shall be located in such a way that the operative has a permanent direct view of the closing edges

An additional set of hold-to-run controls for closing the discharge door may be installed in the cab These controls shall be designed to avoid actuation other than intentionally (see also 6.11.3) The cab controls shall not be capable of completely closing the discharge door and a minimum gap of 1 000 mm shall be left between the bottom edge of the discharge door and the body The final closure shall only be possible by the external control

When more than one control station can be used, interlocked controls according to EN 60204-1 shall be used The total closure time of the discharge door shall not be less than 20 s

If the closing operation of the discharge door is achieved by an equivalent positively hand operated mechanism (e.g a hand powered pump), a two-hand operated control is not required

6.3.1.4 When the discharge door is laterally hinged, mechanical restraint devices shall be provided in the open position to avoid unintentional closure or further opening

6.3.2 Emptying the bodywork

Emptying the bodywork shall be by means of a hold-to-run control

6.3.3 Emptying the compaction mechanism

For emptying the compaction mechanism and hopper (V2 and V1 in Figure B.1), the compaction mechanism shall

be activated from the discharge door operating station by a hold-to-run control device only when the bodywork is fully tilted or the ejection plate is totally extended

6.3.4 Raised body and discharge door warning

As a minimum, a visual warning shall be activated in the cab to warn the driver that the body is not in travel position

or the powered discharge door is not in the closed position required for travelling It shall not be possible to de-activate this warning The warning device shall meet the provisions of EN 842

6.4 Top door

6.4.1 Opening of the top door

The emptying of the designated waste container shall only be possible when the top door is sufficiently opened for

The lifting device shall be interlocked to stop the dumping part of the emptying cycle if the top door is not sufficiently opened to accept the designated waste container

6.4.2 Top door warning

As a minimum, a visual warning shall be activated in the cab whenever the front loaded RCV is in motion to warn the driver that the top door is not in a closed position required for travelling

6.5 Lifting device

6.5.1 General requirements

6.5.1.1 General requirements for the design

With regard to crushing and shearing hazards, the design shall meet the requirements of EN 349 or appropriate shielding according to EN 953, considering the safety distances according to EN 294 and EN 811

To prevent foot injuries, the distance between the lower edge of the lifting device and the level on which the front loaded RCV is standing shall be at least 120 mm If movement of the lifting device down to the ground level is necessary, the distance between 120 mm and the horizontal ground shall be controlled by a hold-to-run control situated in a position where the lifting device is in full view

The volume of the hopper and the performances of the compaction mechanism and the lifting device shall be designed taking into consideration the volume of the largest designated waste container in order to avoid refuse falling out of the hopper

When the hopper is emptied by the compaction mechanism at the same time as the lifting device is being operated, the design shall be such that the designated waste container and the compaction mechanism shall not collide and

no damage to the container shall result

In case of hydraulically operated cylinders, they shall be at least pilot operated check valves mounted directly on the lifting cylinders In case of devices other than hydraulic, they shall be mounted directly on the lifting arms and the lifting carriage which allow only positively powered lowering and provide equivalent safety

6.5.1.2 Other requirements

The lifting device shall meet the following requirements:

 be designed for the designated waste containers as noted in the operation manual;

 be designed for the maximum permissible load of the designated waste containers The dynamic test load shall be 1,1 times the maximum permissible load The maximum permissible load is calculated by:

 for mobile waste containers, the maximum permissible mass applied at the centre of gravity of an uniformly distributed load in the largest standardized designated waste container;

 for designated stationary waste containers, the maximum permissible mass applied at a distance of

1 500 mm from the rotation axis of the holding system;

 be provided with a device preventing a lift in excess of the maximum permissible mass, as calculated according to Figure B.2.3; e g by setting lifting pressure limits;

 with the exception of clamps and pocket receivers for stationary waste containers, be provided with a device to securely position the designated waste container on the lifting carriage;

container reaches 30 degrees from vertical or before the height of the holding point reaches 2 000 mm from the horizontal level where the front loaded RCV is standing for safety requirements of the device(s) see 6.7;

 If fitted with forks, be provided at the tip of the prongs with a step which prevents the slipping of the designated waste container out of the fork The minimum height of the step shall be 30 mm (see Figure C.5)

The designated waste container once locked shall remain locked in position even if electrical, hydraulic or pneumatic energy fails, see 6.11.1.2

The maximum peripheral speed of any reachable part of the lifting device with designated waste container(s) in the area up to 2,5 m above the ground shall not exceed 1,5 m/s to enable a person leaving the danger zone underneath the lifting device before being hit

NOTE The speed of the lifting device may be limited due to the maximum allowable inertia forces not to damage the structure of the lifting device or the designated waste container

Provisions shall be made to ensure that no refuse is spilt by designing the relative position of the waste container to the hopper during emptying

6.5.1.3 Operation of lifting devices

Control devices for lifting devices shall be designed to avoid any activation other than intentional manual action The movement of control devices shall be consistent with their effect and user-friendly, for example:

For button operated lifting devices:

 upper button = lift arm / lift carriage;

 lower button = lower arm / lower carriage

For lever operated lifting devices, the operating direction of the lever shall correspond to the stated movement:

 pull = lift arm / carriage;

 push = lower arm / carriage

For joystick operated lifting devices, the operation direction shall correspond to the stated movement:

 pull = lift arm  right = lift carriage;

 push = lower arm  left = lower carriage The direction of movement achieved by a button, lever, joystick or mode selector shall be clearly identified by an arrow highlighting the direction

If applicable, operating controls shall be switched over to manual mode with a selective switch for maintenance, repair, resetting or restoring following degraded working conditions The change-over operation shall not initiate any lifting or tilting operation In any case, operations that could release lifted containers shall only be possible in the lowest lift position The selected mode shall be indicated and unauthorized changes shall be avoided

Stopping the lifting device, in the semi-automatic mode, will require a new command to restart

When the front loaded RCV is equipped with more than one lifting device, it shall not be possible for the same operative to simultaneously operate more than one lifting device

If the lifting device is in a position where some parts of it and/or waste container protrude beyond the dimensions of the front loaded RCV, according to road traffic regulations, any possibility of travel movement shall be prevented

If the lifting device can be activated from both inside the cab and outside, a selector switch is provided in the cab to ensure that only one is operable at the same time

6.5.2 Additional requirements for extending and/or clamping lifting devices

6.5.2.1 When the front loaded RCV is travelling, the lifting device shall not be capable of being operated and shall be positively secured in its travelling position against any unintentional movement except for positioning purposes (see 8.2)

6.5.2.2 If the lifting device is in a position where some parts of it protrude beyond the dimensions of the front loaded RCV only positioning movement is possible The speed of the positioning movement is limited to 6 km/h

6.5.2.3 Clamps and/or extending arms shall be locked in their travelling position by a mechanical locking actuated positively by gravity, pneumatically, hydraulically, electrically or by a check valve mounted directly on the hydraulic cylinders when the front loaded RCV is travelling

6.5.2.4 The clamping mechanism shall be compatible with the designated waste container and its intended use as described in the information for use manual

6.5.2.5 The clamp itself shall only be controlled by a specific hold-to-run control In case of loss of power the clamp shall not open and release the waste container and its load

6.5.2.6 The closing forces of the clamp shall be calculated to hold the designated waste container and the

nominal load safely during the whole cycle The dynamic test load shall be according to 6.5.1.2 (second dash)

6.5.2.7 If a container is not present, the closing clamps shall leave a gap of more than 180 mm (see EN 349) when the clamps are below 2,5 m above the ground level

6.5.2.8 Opening of the clamp(s) shall only be possible when the clamp has been returned to the same or a lower level as when closing the clamps

6.6 Cab shield

The front loaded RCV shall be fitted with a cab shield The cab shield shall prevent the penetration of the cab roof

in the area above the operative(s) Tests shall be made by an object, with a shape of a cube with a 150 mm edge and a minimum mass of 15 kg, falling from a height of 1 m and impacting on a corner

The cab shield, if fitted, can be hydraulically actuated Then the control shall be of a hold-to-run type

6.7 Hydraulic, pneumatic and electric power system

6.7.1 Hydraulic power system

The hydraulic power system shall comply with the requirements of EN 982

All hydraulic hoses, tubes and fittings shall be designed for a burst pressure of at least 2 times the working pressure Where hoses are located on the sides of the front loaded RCV and within 500 mm of persons standing or passing by, they shall be shielded against oil jets resulting from sudden hose failure (oil jet coming out) The protection shall be sufficiently sturdy to divert fluids away from persons

6.7.2 Pneumatic power system

The pneumatic power system shall comply with the requirements of EN 983

All pneumatic hoses, tubes and fittings shall be designed for a burst pressure of at least 2 times the working pressure

6.7.3 Electric power system

The electric power system shall comply with the requirements of EN 60204-1

6.8 Interchangeable body system

6.8.1 The refuse shall be securely contained inside the body during separation of the body and subsequent

handling

6.8.2 The locking system between the compaction mechanism and the body and / or between the body and the

chassis, shall be designed to withstand the compaction forces taking into account the maximum dynamic stress Unlocking shall only be possible by an intentional action

6.8.3 If reachable, mounting/demounting mechanisms shall be guarded according to EN 953 and considering

EN 294 and EN 811

6.8.4 The body shall be compatible with the designated handling system and stable under all handling and

storage conditions These conditions shall be stated in the operation manual

6.8.5 The control for the mounting / demounting of the body shall be hold-to-run and be positioned to provide a

complete view of the operation The locking procedure for on the chassis and/or with the compaction system shall

be stated in the information for use manual

6.8.6 If a direct view on the closing gap is not possible from inside the cab, the control inside the cab shall not be

capable of completely mounting the body and a minimum gap of 1 000 mm shall be left between the edge of the interchangeable body and the compaction mechanism In this case, the final mounting shall only be achieved by an outside two-hand hold-to-run control located in such a way that the operative has a clear direct view of the entire shear/crushing gap

6.8.7 A camera giving a clear view of the chassis and the storage area is mandatory for all mounting and

demounting operations controlled from inside the cab During these operations the camera / monitor shall be automatically activated with no possibility to switch it off

6.8.8 When using a remote control, it shall not be possible to operate the remote control from inside the cab It

shall not be possible to operate the in-cab control and the remote control at the same time The switch-over to remote control shall only be possible by key-locked control device If it is a wireless remote control according to 6.12.2, it shall not be operable from a location with no direct view on the closing gap If it is a wired remote control, the cable shall be of sufficient length to allow the operative control from a safe area The final closing of the

1 000 mm gap shall only be achieved by a two-hand hold-to-run control as defined in 6.8.6

6.9 Operating symbols

6.9.1 The following operating elements shall be provided with pictograms (graphical symbols) according to their

function and direction of movement Examples are shown in Table 2 All the other operating elements shall be provided with a pictogram and/or a proper description

6.9.2 Pictograms / descriptions may be engraved, or fixed via stickers at the control stations Both designs shall

be durable and durably fixed at the control station

6.9.3 Colours for pictograms: black or white, on a contrasting background

6.9.4 The following colours are exclusive to control devices (see 10.2 of EN 60204-1:2006)

red: stop (see 10.7.3 of EN 60204-1:2006)

red on yellow background: emergency stop (red mushroom-head, see 10.7.3 of EN 60204-1:2006 and EN ISO 13850)

green: start

yellow: rescue

Colours shall be permanent

Table 2 — Graphical symbols

No Symbol Meaning No of symbol according to ISO 7000/IEC 60417 a

Multi cycle

11

Mounting of the interchangeable body

12

Tipping the body

a The numbers below 5 000 are according to the pictograms of ISO 7000 and the numbers above

5 000 to the pictograms of IEC 60417

6.10 Riding on front loaded RCV by operatives

6.10.1 Cab

The front loaded RCV shall be provided with a cab and operative(s) shall only ride inside the cab

The lift arms shall not interfere with the cab doors Free access to and/or from the cab shall be guaranteed in any case

If fitted, automatic cab doors will remain closed when the front loaded RCV is travelling Travel movement shall only

be possible when the automatic doors are closed

6.10.2 Bodywork

There shall be no recesses or projections, except the means of access to the roof as described in 6.15.4, that could serve as a foot or hand hold on any side of the bodywork

6.11 Control systems

6.11.1 General requirements for safety circuits

6.11.1.1 Safety related parts of controls shall be determined from the categories derived from the risk analysis

as defined by EN ISO 13849-1, e g.:

 at least category 3: for hazardous movements of the automatic lifting device(s) or the compaction mechanism with a tilting or an interchangeable body, or for the components monitoring the access to the compaction mechanism and its interlocks ;

 at least category 1: for hold-to-run controls;

 category B: for all other controls

For each risk area the safety categories shall be verified every time

6.11.1.2 In case of electrical or hydraulic energy loss, hazardous movements shall be stopped and shall not restart automatically when energy is restored (see 7.5 and 9.4.3.2 of EN 60204-1:2006)

6.11.1.3 If for any reason, the compaction mechanism and/or the lifting device(s) stop(s),except during its (their) intended cycles, it (they) shall not restart automatically

6.11.2 Emergency stop devices

6.11.2.1 Emergency stop devices shall have a stop function of category 0 according to 9.2.2 of

EN 60204-1:2006 and EN ISO 13850

6.11.2.2 Emergency stop devices shall:

 be provided in the cab and at any working station except for two-hand controls;

 stop any movement of the bodywork;

 be located within easy reach of the operative;

 overrule all other operating controls - except the yellow rescue switches;

 be designed according to 10.7 of EN 60204-1:2006;

 not be connected to the 0 volt ground potential of the chassis

6.11.2.3 An unmistakable auditory signal according to EN ISO 7731 shall sound in the cab when an emergency switch is activated

6.11.3 Control circuits and devices

6.11.3.1 General

All control devices shall be:

 adapted to the ergonomic requirements of the operatives according to EN 894-1 to EN 894-3;

 located, positioned and marked such that they can be clearly and permanently identified;

 located in a position with a clear view for the operative to the functional space;

 fitted in a position with a clear view from the appropriate operating station;

 so designed, that unintentional activation is avoided or minimized (this applies only to controls which initiate any movement and does not apply to rescue controls);

 operable when wearing working gloves (for out-of-the-cab controls only), e.g a minimum diameter of 20 mm for push buttons

Marking shall be done by graphic symbols according to Table 2 (see also 10.2.2 of EN 60204-1:2006)

6.11.3.2 Main switch

A main switch for the bodywork shall be provided and shall be so designed and located that unintentional activation

is avoided When placed outside the cab, it shall be protected (see 6.12.1.1) This main switch shall cut the power supply to the bodywork Warning signals and signals related to safety shall not be switched off No function shall start automatically when the main switch is switched on (see also 7.5 of EN 60204-1:2006)

The main switch shall meet the requirements of 5.3.3 of EN 60204-1:2006

6.11.3.3 Operation mode selection

A manual operating control for selection of operation modes, if provided, shall be fitted in a position with a clear view from the appropriate operating stations

Indication of the selected mode shall be given to the driver and operative at all working positions affected by this mode

Choosing another operation mode by the mode selector shall not initiate any movement or cycle of any part of the bodywork without an additional command

Mode selection shall fulfil the requirements of 9.2.3 of EN 60204-1:2006

6.11.3.4 Control of the top door(s)

Unintended movements of the top door(s) shall be avoided