Bsi bs en 01459 2 2015

forward aligned position aligned position where the telescopic boom is oriented toward the front of the truck as defined by the manufacturer 3.23 rearward aligned position aligned posi

BSI Standards Publication

Rough-terrain trucks — Safety requirements and verification

Part 2: Slewing variable-reach trucks

This British Standard is the UK implementation of EN 1459-2:2015.The UK participation in its preparation was entrusted to Technical Committee MHE/7, Industrial trucks.

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

This publication does not purport to include all the necessary provisions of a contract Users are responsible for its correct application

© The British Standards Institution 2015

Published by BSI Standards Limited 2015

Amendments/corrigenda issued since publication

Date Text affected

Chariots tout-terrain - Prescriptions de sécurité et

vérification - Partie 2 : Chariots à portée variable

rotatifs

Geländegängige Stapler - Sicherheitstechnische Anforderungen und Verifizierung - Teil 2: Schwenkbare Stapler mit veränderlicher Reichweite This European Standard was approved by CEN on 17 July 2015

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

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

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

EUROPEAN COMMITTEE FOR STANDARDIZATION

C O M I T É E UR O P É E N DE N O R M A L I SA T I O N

E UR O P Ä I SC H E S KO M I T E E F ÜR N O R M UN G

CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2015 CEN All rights of exploitation in any form and by any means reserved

worldwide for CEN national Members Ref No EN 1459-2:2015 E

Contents Page

European foreword 4

Introduction 5

1 Scope 6

2 Normative references 7

3 Terms and definitions 9

4 Safety requirements and/or protective measures 14

4.1 General 14

4.2 Starting/moving 15

4.3 Brakes 16

4.4 Electrical and electronic systems 16

4.5 Controls 17

4.6 Power systems and accessories 23

4.7 Stabilizing devices 24

4.8 Design requirements for maintenance purposes 26

4.9 Systems for lifting, tilting, reaching and slewing 27

4.10 Operator’s station 29

4.11 Operator access 35

4.12 Protective measures and devices 36

4.13 Stability requirements 38

4.14 Visibility 38

4.15 Lighting 38

4.16 Fire protection 38

4.17 Retrieval, transportation and lifting 38

4.18 Noise 39

4.19 Electromagnetic compatibility 40

4.20 Elastic and rigid body stability / Structural and stability calculations 40

5 Verification of requirements and safety measures 43

5.1 General 43

5.2 Functional verification 43

5.3 Structural verification 44

5.4 Load holding verification 45

5.5 Maximum load lowering speed verification 45

6 Information for use 45

6.1 Signals and warning 45

6.2 Instruction handbook 47

6.3 Marking 51

6.4 Load chart 51

Annex A (informative) List of significant hazards 54

Annex B (informative) Consistency of motions 60

Annex C (normative) Rules for the construction and layout of pedals 61

C.1 Definitions 61

C.2 Requirements 61

C.3 Design and manufacture 62

Annex D (informative) Regular and occasional loads 64

D.1 General 64

D.2 Regular loads 64

D.3 Occasional loads 64

Annex ZA (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC 66

Bibliography 67

be withdrawn at the latest by March 2016

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 EU Directive(s)

For relationship with EU Directive, see informative Annex ZA, which is an integral part of this document

EN 1459, Rough-terrain trucks — Safety requirements and verification, consists of the following parts:

— Part 1: Variable-reach trucks

— Part 2: Slewing variable-reach trucks

— Part 3: Interface between the variable-reach truck and the work platform

— Part 4: Additional requirements for variable reach trucks handling suspended loads

— Part 5: Additional requirements for attachments and attachment interface

— Part 6: Risk assessment methodology and control system performance level determination (CEN/TR)

— Part 7: Test method and determination of noise emission (in development)

According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom

All quantities are in SI units, and this includes metric units

Acknowledging that, at the time of publication, the requirements included in this European Standard do not represent the state of the art, a transition period of 18 months is permitted after the date of publication, such that manufacturers can develop their products sufficiently to meet the requirements

of this European Standard

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

The machinery concerned and the extent to which hazards, hazardous situations and hazardous 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

1 Scope

This European Standard specifies the general safety requirements of slewing variable-reach terrain trucks (here-after referred to as trucks), consisting of a lower chassis with a slewing upper structure equipped with a telescopic lifting means (pivoted boom), on which a load handling device (e.g carriage and fork arms) is typically fitted

rough-Fork arms are covered by this European Standard and considered to be parts of the truck

This European Standard deals with all significant hazards, hazardous situations and events relevant to the trucks when they are used as intended and under conditions of misuse which are reasonably foreseeable by the manufacturer (see Annex A)

This European Standard does not apply to:

— variable-reach rough terrain trucks covered by prEN 1459-1 (non-slewing);

— industrial variable-reach trucks (covered by prEN ISO 3691-2);

— lorry-mounted variable-reach trucks;

— variable reach trucks fitted with tilting or elevating operator position;

— mobile cranes (covered by EN 13000);

— machines designed primarily for earth moving, such as loaders and dozers, even if their buckets and blades are replaced with forks (see EN 474 series);

— trucks designed primarily with variable length load suspension elements (e.g., chain, ropes) from which the load may swing freely in all directions;

— trucks designed primarily for container handling;

— trucks on tracks;

— attachments (prEN 1459-5)

This European Standard does not address hazards linked to:

— hybrid power systems;

— gas power system;

— trucks equipped with gasoline engine;

— battery power system;

— tractor specific devices (e.g PTO)

This European Standard does not address hazards which may occur when:

a) handling suspended loads which may swing freely (additional requirements are given in prEN 1459-4);

b) using trucks on public roads;

c) operating in potentially explosive atmospheres;

d) operating underground;

e) when towing trailers;

f) fitted with a personnel work platform (additional requirements are given in EN 1459-3)

2 Normative references

The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies

EN 842:1996+A1:2008, Safety of machinery ― Visual danger signals ― General requirements, design and

testing

EN 1175-2:1998+A1:2010, Safety of industrial trucks ― Electrical requirements ― Part 2: General

requirements of internal combustion engine powered trucks

EN 12053:2001+A1:2008, Safety of industrial trucks ― Test methods for measuring noise emissions

EN 12895:2015, Industrial trucks ― Electromagnetic compatibility

EN 13059:2001+A1:2008, Safety of industrial trucks ― Test methods for measuring vibration

EN 13309:2010, Construction machinery ― Electromagnetic compatibility of machines with internal

power supply

EN 60529:1991, Degrees of protection provided by enclosures (IP Code) (IEC 60529)

EN 62061:2005, Safety of machinery ― Functional safety of safety-related electrical, electronic and

programmable electronic control systems (IEC 62061:2003)

EN ISO 2860:2008, Earth-moving machinery ― Minimum access dimensions (ISO 2860:1992)

EN ISO 2867:2011, Earth-moving machinery ― Access systems (ISO 2867:2011)

EN ISO 3164:2013, Earth-moving machinery ― Laboratory evaluations of protective structures ―

Specifications for deflection-limiting volume (ISO 3164:2013)

EN ISO 3411:2007, Earth-moving machinery ― Physical dimensions of operators and minimum operator

space envelope (ISO 3411:2007)

EN ISO 3449:2008, Earth-moving machinery ― Falling-object protective structures ― Laboratory tests

and performance requirements (ISO 3449:2005)

EN ISO 3457:2008, Earth-moving machinery ― Guards ― Definitions and requirements (ISO 3457:2003)

EN ISO 3471:2008, Earth-moving machinery ― Roll-over protective structures ― Laboratory tests and

performance requirements (ISO 3471:2008)

EN ISO 4413:2010, Hydraulic fluid power ― General rules and safety requirements for systems and their

components (ISO 4413:2010)

EN ISO 4414:2010, Pneumatic fluid power ― General rules and safety requirements for systems and their

components (ISO 4414:2010)

EN ISO 5353:1998, Earth-moving machinery, and tractors and machinery for agriculture and forestry ―

Seat index point (ISO 5353:1995)

EN ISO 6682:2008, Earth-moving machinery ― Zones of comfort and reach for controls (ISO 6682:1986,

including Amd 1:1989)

EN ISO 6683:2008, Earth-moving machinery ― Seat belts and seat belt anchorages ― Performance

requirements and tests (ISO 6683:2005)

EN ISO 7096:2008, Earth-moving machinery ― Laboratory evaluation of operator seat vibration

(ISO 7096:2000)

EN ISO 12100:2010, Safety of machinery ― General principles for design ― Risk assessment and risk

reduction (ISO 12100:2010)

EN ISO 13732-1:2008, 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 13849-1:2008, Safety of machinery ― Safety-related parts of control systems ― Part 1: General

principles for design (ISO 13849-1:2006)

EN ISO 13850:2008, Safety of machinery ― Emergency stop ― Principles for design (ISO 13850:2006)

EN ISO 13857:2008, Safety of machinery ― Safety distances to prevent hazard zones being reached by

upper and lower limbs (ISO 13857:2008)

ISO 3795:1989, Road vehicles, and tractors and machinery for agriculture and forestry — Determination

of burning behaviour of interior materials

ISO 4305:2014, Mobile cranes — Determination of stability

ISO 5053-1:2014, Industrial trucks - Terminology and classification - Part 1: Types of industrial trucks ISO 6011:2003, Earth-moving machinery — Visual display of machine operation

ISO 6016:2008, Earth-moving machinery — Methods of measuring the masses of whole machines, their

equipment and components

ISO 6292:2008, Powered industrial trucks and tractors — Brake performance and component strength ISO 7000:2014, Graphical symbols for use on equipment — Registered symbols

ISO 9533:2010, Earth-moving machinery — Machine-mounted audible travel alarms and forward

horns — Test methods and performance criteria

ISO 10263-2:2009, Earth-moving machinery — Operator enclosure environment — Part 2: Air filter

element test method

ISO 10263-3:2009, Earth-moving machinery — Operator enclosure environment — Part 3: Pressurization

test method

ISO 10263-4:2009, Earth-moving machinery — Operator enclosure environment — Part 4: Heating,

ventilating and air conditioning (HVAC) test method and performance

ISO 10896-1:2012, Rough-terrain trucks — Safety requirements and verification — Part 1:

Variable-reach trucks

ISO 11112:1995, Earth-moving machinery — Operator's seat — Dimensions and requirements

ISO 11862:1993, Earth-moving machinery — Auxiliary starting aid electrical connector

ISO 12508:1994, Earth-moving machinery — Operator station and maintenance areas — Bluntness of

trucks operating in the special condition of stacking with load laterally displaced by powered devices

ISO 22915-20:2008, Industrial trucks — Verification of stability — Part 20: Additional stability test for

trucks operating in the special condition of offset load, offset by utilization

ISO 22915-24:2015, Industrial trucks ― Verification of stability ― Part 24: Slewing variable-reach

rough-terrain trucks

3 Terms and definitions

For the purposes of this document, the terms and definitions given in EN ISO 12100:2010 and ISO 5053-1:2014 and the following apply

3.1

slewing rough terrain variable reach truck

rough terrain variable reach truck with an upper structure which can rotate around a vertical axis of the chassis in a circular motion greater than 5° either side of the longitudinal axis of the truck

Note 1 to entry: The actual capacity depends on the configuration of the truck in terms of such variables as:

— lift height;

— reach of the boom (measured from the centre of slewing of the rotating upper structure);

— slewing position;

— standard load centre distance;

— load handling device (fork arms or attachment fitted);

— stabilizing devices

Note 2 to entry: This actual capacity defines the load handling ability of the particular truck as equipped Additional actual capacity ratings with removable attachments may also be established where permitted by the appropriate stability test or by calculation verified by empirical data

3.3

reach (d)

normal distance between the axis of rotation of the upper structure and the vertical plane including G perpendicular to the longitudinal axis of the upper structure

Note 1 to entry: The centre-of-gravity of the load (G) is defined in Table 1

Note 2 to entry: See Figure 1 for examples of reach

Note 3 to entry: For practical matters, d can be measured referring to point g, being g the vertical projection of the centre-of-gravity (G) of the load onto the plane of the top surface of the fork arms

Key

Figure 1 — Parameters for the designation of the actual capacity of the truck with fork

3.4

lift height (H)

vertical distance between the upper face of the fork arms and the ground

3.5

standard load centre distance (D)

distance from the centre of gravity (G) of the load measured horizontally back to the fronts of the fork

shanks and vertically down to the upper faces of the fork arms, as specified in Table 1

Note 1 to entry: See Figure 1 for example

Note 2 to entry: Typical standard load centre distances are given in Table 1

Table 1 — Typical standard load centre distance

rated capacity of attachments

maximum load that the attachment is permitted by its manufacturer to handle under specified conditions

Note 1 to entry: The rated capacity of the attachment can be associated with the load centre distance

3.8

axle oscillation lock

mechanism designed to prevent oscillation of an axle to improve truck stability

crab steering mode

steering mode where all wheels of the truck steer in the same direction

3.14

normal operator's position

position as specified by the manufacturer in which the operator is able to control the truck operations, including load handling functions

maximum working pressure

maximum pressure in the hydraulic circuit during normal operation

forward aligned position

aligned position where the telescopic boom is oriented toward the front of the truck as defined by the manufacturer

3.23

rearward aligned position

aligned position where the telescopic boom is oriented toward the back of the truck as defined by the manufacturer

3.24

level ground

ground with a gradient of (0 ± 2) %

3.25

load indicating device (LID)

device that warns the operator when truck overturning moment limits pre-determined by the manufacturer are reached as a consequence of a change to the load handling geometry, and/or warns when overloading

3.26

load limiting device (LLD)

device that prevents the operator changing the load handling geometry in direction(s) which would increase the load moment beyond the limits permitted by the manufacturer, and/or prevents overloading

3.27

load handling geometry

relationship of points, lines and angles, described by the position of the load centre of gravity (the position of the boom, carriage and attachment) and tipping line (on wheels or stabilizers)

4 Safety requirements and/or protective measures

4.1 General

4.1.1 Introduction

Trucks shall comply with the safety requirements and/or protective measures of this clause In addition, the truck shall be designed according to the principles of EN ISO 12100 for relevant but not significant hazards, which are not dealt with by this standard

4.1.2 Sharp edges and acute angles

Sharp edges and acute angles shall meet the requirements specified in ISO 12508:1994 in areas to which the operator can be exposed during operation, access, egress and maintenance

Verification by measurement

4.1.3 Stored energy components

Components that store energy and can cause a risk of injury during removal or disassembly, e.g hydraulic accumulators and spring-applied brakes, shall be provided with a means to release the energy before removal or disassembly and shall be marked according to 6.1.8

Verification by design check

This device shall comply with Table 3

Verification by functional test

4.2.3 Uncontrolled motion

Means shall be provided to prevent the truck from moving from rest on level ground until the drive system has been engaged These means shall comply with Table 3

Verification by functional test

4.2.4 Powered travel movement

Means shall be provided to prevent powered travel when the operator is not at the normal operator’s position

Powered travel shall not occur automatically when the operator returns to the normal operator’s position without an additional operation, e.g by requiring resetting the direction control Application of the parking brake shall apply neutral travel control, except on trucks with hydro-static transmission

Verification by functional test

Means to fulfil these requirements shall comply with Table 3

In the aligned positions, on starting a reverse movement respect to the position of the operator, an audible alarm complying with the requirements of ISO 9533:2010 shall be given for at least 1 s

Verification by measurement and functional test

4.2.5 Non-activation of the parking brake

A warning shall be activated when the operator is not at the normal operator’s position and the parking brake has not been applied

A clear warning (audible and/or visual) to the operator shall be activated when not at the normal operator's position and the parking brake has not been applied

Means to fulfil this requirement shall comply with Table 3

Verification by functional test

4.3 Brakes

4.3.1 General

Trucks shall be equipped with service brake(s) and parking brake system(s), complying with ISO 6292:2008

Verification by design-check and type-test

Where electromechanical parking brake system is fitted, the braking device shall be applied mechanically and released electrically

Verification by design check

4.3.2 Failure of energy supply

Failure of the energy supply for the brake release shall not result in loss of braking

The systems shall be able to bring the truck to a controlled stop and/or to hold the truck in a parking position

4.4.2 Safety related functions

Safety related parts of control systems shall comply with PLr (see EN ISO 13849-1) or SIL (see

EN 62061) according to Table 3

Verification by design check

Verification by design-check

4.4.4 Identification of wiring

The truck shall comply with EN 1175-2:1998+A1:2010, 5.4

Verification by visual examination and design-check

This requirement does not apply to electrical circuits of anti-theft systems, when fitted

4.4.5 Over-current protective devices

The truck shall comply with of EN 1175-2:1998+A1:2010, 5.5

Verification by design-check

4.4.6 Batteries

Batteries shall be restrained to prevent displacement which may give rise to danger in a ventilated location that provides access for maintenance

Verification by visual examination

Batteries and/or battery locations shall be designed and built or covered to minimize any hazard to the operator caused by battery acid or acid vapours in the event of overturning the truck

For marking, see 6.1.10

4.4.8 Electrical connector for auxiliary starting aids

If electrical connectors for an auxiliary starting aid or power supply are mounted on the truck, the connectors shall comply with ISO 11862:1993

Verification by design-check

b) The controls (hand levers, joysticks, pedals, switches, etc.) and indicators of the truck and attachment shall be clearly identified, except where obvious (e.g accelerator pedal), indelible and visible in the normal operator's position; if appropriate, graphical symbols in accordance with ISO 7000:2014 shall be used and shall be explained in the information for use (see 6.1.2)

Each symbol shall be affixed on or in close proximity to the control or indicator to which it applies

Verification by visual examination

c) indicators and movement of the control device shall correspond to the intended effect or common practice whenever possible;

NOTE 1 Annex B and ergonomic principals of EN 894-1 give guidance

Verification by type-test

d) pedal operated travel and braking controls shall comply with Annex C;

e) safety-related parts of control system shall comply with Table 3;

NOTE 2 CEN/TR 1459-6 describes the methodology followed to determine the values of PLr listed in Table 3

f) means shall be provided to prevent any possibility of powered movements actuated by controls if the operator is not at one operator’s position

g) remote operator controlled systems fitted to trucks shall comply with the relevant requirements of ISO 15817:2012

Verification by design-check

4.5.1.2 Multiple operator’s positions

Only if more than one operator’s position is fitted, an emergency stop at each operator's position shall

be fitted

Verification by visual examination and design-check

The use of the controls at one operator’s position shall preclude the use of the controls at other operator’s positions, except the emergency stop, which shall be operable from all operator’s positions Means to fulfil this requirement shall comply with Table 3

Verification by functional test

Emergency stop shall comply with EN ISO 13850

Verification by design check

Verification by visual examination

The following requirements shall be met when the truck is in the forward aligned position:

a) For trucks with a steering wheel control, clockwise rotation of a steering wheel shall steer the truck

to the right when the truck is travelling in the forward direction

b) On trucks with a crab-steering mode, clockwise rotation of the steering wheel shall move the truck

to the right when the truck is travelling in the forward direction and to the left when travelling in the reverse direction

c) On trucks in which the steering is controlled by means of a single lever control, moving the lever to the right shall cause the truck to be steered to the right when the truck is travelling in the forward direction

When the upper structure is slewed more than 90° to either side of the longitudinal axis of the chassis from the forward aligned position, a visual indicator shall warn the operator that steering controls are reversed compared to a) or b)

Verification by functional test

4.5.3.3 Failure of power supply

For trucks with a maximum speed of less than or equal to 20 km/h, in the event of an interruption of the power supplied to the steering system (including a dead engine), it shall be possible to maintain the path being steered until the truck is brought to a stop

— The steering effort on the steering control shall be measured until it reaches the position corresponding to the truck entering a turning circle of 12 m radius (considering the outermost part

of the steering wheels)

— The duration of the manoeuvre (time between the moment when the steering control is first operated and the moment when it reaches the position where the measurements are taken) shall not exceed 8 s

— One manoeuvre shall be made to the left and one to the right

— The emergency steering effort required to achieve a turning circle of 12 m radius, starting from the straight ahead position, shall not exceed 600 N

Verification by visual examination

4.5.4.2 Controls with detents or maintained engagement

4.5.4.2.1 General

By exception to 4.5.4.1, the boom float control and the auxiliary hydraulic control(s) (e.g for concrete mixers, brooms, augers) may be equipped with a control to maintain engagement of the function These controls shall comply with Table 3

Verification by design-check

A visual indication that this control is activated shall be provided to the operator

Verification by visual examination

The control mode shall:

— be automatically deactivated when the truck is switched off and not be automatically activated when the truck is switched on; or

— prevent the truck from being restarted until the control mode is deactivated

Verification by functional test

4.5.4.2.2 Boom float control

For trucks equipped with boom float control, protection shall be provided against unintended lowering

Verification by visual examination

Visual indication shall be provided to inform the operator of the selected mode(s) of operation

Means to fulfil this requirement shall comply with Table 3

Verification by visual examination

4.5.6 Stabilizing device control

For trucks equipped with stabilizing devices:

— stabilizing device control shall be separated from the main boom control;

— controls for deployment of the stabilizing devices shall be clearly marked (symbols 2074, 1291, 0750A, 0746A, 2078, 2080 of ISO 7000) See Table 2;

— controls for retraction of the stabilizing devices shall be clearly marked (symbols 2073, 1292, 0751A, 0747A, 2079, 2081 of ISO 7000) See Table 2

Table 2 — Symbols for stabilizing devices

2080 0750A 2081 0751A

Verification by visual examination

— each stabilizing device shall be controlled independently The left control shall operate the left stabilizing device, and the right control shall operate the right stabilizing device, in forward aligned position;

— a control may operate two or more stabilizing devices;

— means shall be provided to identify at all time (day and night) the stabilizing device operated by each control, regardless the truck slewing angle

Verification by functional test

4.5.7 Sway/levelling control

For trucks equipped with operator-controlled lateral levelling, operating the control to the left shall cause the truck to sway to the left, and operating the control to the right shall cause the truck to sway to the right, in the forward aligned position

Verification by functional test

Means shall be provided to identify at all time (day and night) the levelling direction operated by each levelling control, regardless the truck slewing angle

4.5.8 Axle oscillation locking

When operating on wheels, means shall be provided to automatically lock the oscillating axle when the slewing upper structure is not in forward aligned position and when the boom is lifted at height greater than the one corresponding to the travel position as defined by the manufacturer It can be possible to manually lock the axle oscillation locking This means shall comply with Table 3

For trucks equipped with manual axle locking, lock/unlock control(s) shall be clearly marked (symbols

2872 and 2873 of ISO 7000)

A visual indication that the axle locking has occurred shall be provided to the operator

Verification by visual examination

4.6 Power systems and accessories

4.6.1 Exhaust system

The exhaust system shall be designed to direct engine exhaust emissions away from the primary operator's position(s) and passenger position(s), if any Materials used in the vicinity of exhaust system shall be non-flammable and shall be chosen and/or protected so that they are not adversely affected by heat from the exhaust system

Verification by visual examination and design check

4.6.2 Cooling system

The cooling system shall be designed so as to prevent air flow through the system from being directed

at the operator and passenger position(s) if any, or so that the operator and passenger position(s) are shielded from air flow through the system The temperature of the shielding means shall not exceed 60

°C adjacent to the operator and passenger position(s)

Verification by design check

The temperature of the shielding means adjacent to the operator and passenger position(s) shall be in accordance with EN ISO 13732-1:2008 and shall not exceed 60 °C

4.6.3.2 Filler openings

Filler openings of tanks (except window washer and brake fluid reservoirs) shall:

— have provisions for lockable filler caps Filler caps located inside lockable compartments (e.g engine compartment), or caps that can only be opened with a special tool, do not need a lockable provision;

— be located outside the operator’s station

Verification by visual examination

4.6.3.3 Fuel tanks

The tank shall be securely fixed The installation arrangement and construction shall ensure that any fuel leaking from the tank, its filler or its connections shall not collect into pools without a passive means for drainage and shall not drain onto electrical or hot parts

Verification by visual examination

If the filler is located on the side of the truck, the filler cap shall not, when closed, project beyond the external envelope of the truck

Verification by visual examination

Fuel tanks shall withstand an internal pressure of 0,03 MPa (0,3 bar) without permanent deformation

or leakage

Stabilizing devices shall be fitted with means, in accordance with Table 3, which keep them in position

in case of hose failure or oil leakage

Verification by design check

Means in accordance with Table 3 shall be provided to the operator to indicate that the stabilizing devices are in the travelling position as defined by the manufacturer when moving the truck

Verification by visual examination

Each stabilizing device shall be equipped with a footplate that is self-aligning in at least one plane

Verification by visual examination

A visual indication shall be given to the operator (e.g light in the dash-board) when each stabilizing device is deployed to level and support the truck in conformity with the load chart(s)

Means to fulfil this requirement shall comply with Table 3

Verification by visual examination

Table 3 — Safety related parts of control systems

4.2.4 Powered travel movement

Means shall be provided to prevent powered travel

when the operator is not at the normal operator’s

position

Powered travel shall not occur automatically when the

operator returns to the normal operator’s position

without an additional operation, e.g., by requiring

resetting the direction control

Application of the parking brake shall apply neutral

travel control, except on trucks with hydro-static

Paragraph of this European Standard PLr

transmission

Means shall be provided to prevent any possibility of

powered movements actuated by controls if the

operator is not at one operator's position

The use of the controls at one operator’s position shall

preclude the use of the controls at other operator’s

positions

(only when the deactivation device is provided)

Visual indication shall be provided to inform the operator

of the selected mode(s) of operation

When operating on wheels, means shall be provided to

automatically lock the oscillating axle when the slewing

upper structure is not in forward aligned position and

when the boom is lifted at height greater than the one

corresponding to the travel position as defined by the

manufacturer

Stabilizing devices shall be fitted with means, in

accordance with Table 2, which keep them in position in

case of hose failure or oil leakage

Means in accordance with Table 3 shall be provided to the

operator to indicate that the stabilizing devices are in the

travelling position as defined by the manufacturer when

moving the truck

A visual indication shall be given to the operator (e.g light

in the dash-board) when each stabilizing device is

deployed to level and support the truck in conformity with

the load chart(s)

Paragraph of this European Standard PLr

Trucks shall be fitted with a load limiting device, in order

to prevent instability and/or overloading whichever is the

attachment fitted

The LLD shall operate automatically and without the need

for resetting when triggered The LLD, once triggered,

shall remain triggered until the overload condition has

been removed or the overturning moment has been

lessened within the limits permitted by the manufacturer

Where a truck can be operated in different configurations

of wheels, stabilizing devices, or slewing angle range, the

proper selection of correct LLD settings for the actual

configuration shall be automatic and their modification

by the operator shall not be possible This requirement

does not cover the interchange of attachment fitted on the

load carriage

When the truck is intended to be used with attachments

having different rated capacities, an attachment selector

may allow the operator to set the LLD with reference to

the attachment used

Verification of Table 3 by design check

4.8 Design requirements for maintenance purposes

be stored on a secure place on the truck

Verification by visual examination

4.8.2 Boom support device

Where maintenance procedures described in the information for maintenance can only be performed with the boom in a raised position, the boom shall be mechanically secured with a boom support device designed to withstand at least 1,5 times the mass of the boom and the carriage with forks

Verification by design-check

The boom support device, excluding the attaching parts, shall be red on all machines except where the machine colour is red, in which case the boom support device shall be yellow

This boom support device(s) shall be provided with the truck and permanently affixed to the truck or

be stored in a safe place on the truck

Verification by visual examination

4.8.3 Tiltable cab support device

If the operator's cab has an integral tilt system for maintenance, servicing or other non-operational purpose, the cab or system shall be equipped with a support device to hold the cab in the raised or tilted position that meet the requirements of ISO 13333:1994

Verification by design check

When a cab is designed to be tilted for maintenance, a means of locking the controls shall be provided If daily maintenance is required below a tilted cab, an automatically acting support device shall be provided

Verification by design-check

4.9 Systems for lifting, tilting, reaching and slewing

4.9.1 Chains and wire ropes

4.9.1.1 Chains

When the lifting or reaching mechanism includes one or more chains, the truck manufacturer shall use

only leaf or roller chains These chains shall provide a factor K1 whose minimum values are specified in Table 4

The calculation of K1 shall be related to the maximum static load, Q (Q is calculated assuming no friction

in the boom structure or lifting/reaching mechanism), that would exist in a single or more than one equally loaded chain when the truck and boom are stationary in the least favourable position

K1 is defined by the equation: K1 = (L c x n) / (Q+w)

where

Lc and Q shall be expressed with the same unit (e.g kg, t…)

Table 4 — K 1 factor

Pulley diameters shall follow chain manufacturer’s recommendations

Verification by design check

4.9.1.2 Wire ropes

When the lifting or reaching mechanism includes one or more wire ropes, the truck manufacturer shall

use only wire ropes able to provide a factor K2 of at least 6

The calculation of K2 shall be related to the maximum static load, Q (Q is calculated assuming no friction

in the boom structure or lifting/reaching mechanism), that would exist in a single or more than one equally loaded rope when the truck and boom are stationary in the least favourable position

K 2 is defined by the equation: K2 = (L wr x n) / (Q+w)

where

Lwr minimum breaking load for new wire rope;

L wr and Q shall be expressed with the same unit (e.g kg, t…)

Pulley diameters shall follow wire ropes manufacturer’s recommendations

Verification by design check

4.9.2 Hydraulic system

4.9.2.1 Hydraulic circuit

Hydraulic circuit shall comply with EN ISO 4413

Verification by design check

Hoses, piping and connections subject to internal pressure shall be capable of withstanding, without bursting or permanent deformation, a pressure equal to at least three times the maximum working pressure Pipes and hoses shall be so located and restrained to minimize deterioration, sharp edges, and other damage-causing sources The hydraulic system shall be designed and installed such that its performance and reliability are not reduced or its components damaged as a result of external stresses, vibration or movements of the truck or its components

Verification by type-test, design check, measurements and visual examination

4.9.2.2 Pressure control

Hydraulic systems shall include a device that prevents the pressure in the system from exceeding a preset level The device shall be designed and fitted so that unintentional loosening or adjustment is avoided and a tool or key is required to alter the pressure setting

Verification by design check

The test to verify this requirement is defined in 5.4

4.9.3 Maximum load lowering speed

The maximum permissible lowering speed shall be such that in the event of a sudden stop (e.g a hose burst, or trigger of LLD) of the lowering means, the rear wheels of the truck are only allowed to leave the ground momentarily, and shall return to the ground unassisted

The test to verify this requirement is defined in 5.5

4.9.4 Limitation of stroke

Any mechanism on the truck with movement requiring limits to prevent over-travel shall be provided with means for positive stops Hydraulic cylinders may fulfil this requirement if designed for that purpose

Verification by design check

4.9.5 Slewing brake

Slewing mechanisms shall be provided with an automatic holding brake or a locking mechanism to hold the slewing upper structure during operation with load and during out-of-service condition in a safe position The holding brake/locking mechanism shall withstand a torque moment at least 25 % above the torque required for holding the acting torque derived from wind loads combined with the inclination permitted by the manufacturer The slewing brake/ locking mechanism shall operate in all permissible slewing positions and on both stabilizers and wheels positions

4.9.6 Fork arms, attachments and attachment brackets

Fork arms, attachments and attachment brackets shall meet the requirements specified in prEN 1459-5 Mechanical stops shall be provided to prevent fork arms unintentional disengagement from the fork carrier

Verification by visual examination

4.10 Operator’s station

4.10.1 General requirements

The operator’s station shall be equipped with an enclosed cab

Normal operator’s position shall have space available for the operator to minimize potential for interior impact during normal operation

Verification by visual examination

4.10.2 Operator’s manual storage

An enclosure shall be provided inside the operator’s station to store and protect the operator’s manual and other instructions from climatic effects (e.g sunlight, rain, snow)

4.10.3 Pipes and hoses

Pipes and hoses located within 1 m of the DLV (see EN ISO 3164) with a pressure exceeding 5 MPa or a temperature of 60 °C shall be guarded in accordance with EN ISO 3457:2008

Guards (including flexible hose coverings) shall be sufficiently sturdy to stop, disperse or divert a fluid stream in case of hose, pipe or component failure

NOTE 1 Any part or component that diverts fluid stream can be regarded as a sufficient protection device NOTE 2 The enclosed cab may be considered as a guard when hoses are located outside the enclosed cab provided it meets the above requirement

NOTE 3 Enclosed cab doors or windows able to be opened during machine operations do not satisfy this requirement

When possible pipes and hoses should be placed outside the enclosed cab

4.10.4 Operator's cab

4.10.4.1 Climatic conditions

Provisions shall be made to accommodate a ventilation system, an adjustable heating system

4.10.4.2 Heating system

If a heating system is fitted it shall either:

a) comply with ISO 10263-4:2009; or

b) have the capability of increasing the temperature of the air inside the enclosed cab and maintain a temperature of 18 °C at minimum ambient temperature the truck is intended for The minimum

capacity of the heating system shall have a ΔT of 25 °C within 30 min;

c) The test shall be conducted with the engine running at working temperature as specified by the manufacturer Measurement of the system capacity shall be made at three points The three points shall be located in a vertical plane through the SIP and parallel to the longitudinal axis of the truck

as follows (see Figure 3):

1) at 660mm above the SIP and 20mm in front of it;

2) at the SIP as defined in EN ISO 5353;

3) 100 mm above floor plate and 600 mm in front of SIP

Figure 2 — Location of measuring points

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

Verification by test and measurement

Alternatively, the heating capacity can be determined by calculation

Verification by design check

4.10.4.4 Demisting and defrosting system(s)

Trucks shall provide facilities to demist and defrost the front, the boom-side and rear windows, for example by means of a heating system or a particular defrosting device

Verification by design check

4.10.4.5 Air conditioning

If air conditioning is fitted, it shall comply with ISO 10263-4:2009

Verification by test and design check

4.10.4.6 Wipers and washers

The front and rear window(s) shall be fitted with motorized windscreen wiper(s) and washer(s)

Wiper(s) and washer(s) shall be provided for the roof window if it is necessary for the operator to view the attachment or load through the roof window

Wiper(s) shall clear a sufficient area to allow the operator to view the attachment or load through the entire lift zone

The tank of the window washer(s) shall be easily accessible

Verification by visual examination

4.10.4.7 Pressurization system

Where an enclosed cab is provided with a pressurization system, it shall be tested according to ISO 10263-3 and shall provide an interior relative pressure of at least 50 Pa

Verification by test and measurement

4.10.4.8 Doors and windows

Doors, windows and flaps shall be securely held in their functional positions; measures shall be taken for preventing inadvertent opening Doors shall be retained in their intended operator's position(s) by a positive engagement device The locking device of the open door for the primary opening shall be releasable from the operator's station

Verification by visual examination

Windows shall be made of safety glass or other material that provides similar safety performance (see e.g ECE R43)

Verification by design check

It shall not be possible to open the boom side window

Verification by visual examination

Means shall be provided to ensure that, in the event of a missing or broken boom-side window, the driver is not at risk of being trapped between the descending boom and the controls These means shall exclude the driver from the area under the boom or prevent continuing actuation of the controls by the driver's body

Such protection may be provided by other safety devices in addition to their originally intended purposes (see e.g Driver-in-seat device, Dead-man control)

If such protection relies solely upon the glass of the boom-side window, then the glass shall be of the safety laminated type The laminated glass shall be made of a minimum of two layers of glass with an interlayer of plastic material The glazing material should be approved and marked to ECE R43

Verification by design check and visual examination

4.10.4.9 Interior lighting system

The enclosed cab shall be fitted with a fixed inner lighting system It shall be able to function with the engine is switched off, to make it possible to illuminate the operator's station and to read the operator’s manual in darkness

Verification by visual examination

4.10.5 Operator's seat

4.10.5.1 General requirements

Trucks shall be fitted with an adjustable seat that supports the operator in a position that allows the operator to control the truck under intended operating conditions All the adjustments of the seat shall

be possible without the use of tools They shall be clearly described in the operator’s manual

Verification by visual examination

The seat dimensions and adjustments shall comply with ISO 11112:1995

Operator’s seat shall be fitted with suspension

Verification by visual examination

The seat shall meet the following requirements:

a) If a weight adjustable seat is fitted, the adjustment shall accommodate a minimum range of operator weights from 55 kg to 110 kg

b) Swivelling seats shall be provided with a mechanism, e.g a spring or latch, to lock the seat in position The swivel shall be possible in all positions of adjustment

c) The seat mounting shall withstand the forces that may occur during operation, e.g braking

The requirements from a) to c) shall apply to operator's and optional seats

Verification by design check and visual examination

4.10.5.2 Vibration

Vibration transmitted by the truck to the whole body shall be measured according to EN 13059

In addition, if stabilizing devices are fitted, vibration transmitted by the truck to the whole body in stationary operating mode shall be measured according to the principles given in ISO 2631-1 in the following conditions:

— unladen;

— on stabilizing devices,

— slewing angle of 90°;

— the boom fully lowered and retracted;

— engine speed at 3/4 of maximum speed specified by the manufacturer

Operator's seat shall meet the requirements of the following input spectral class with regard to its ability to reduce the vibration transmitted to the operator:

4.10.6 Control panels, and symbols on displays

Control displays for operation of the truck shall comply with ISO 6011:2003, 6.1, 7.1 and 7.2

Visual displays for the truck operation functional information shall comply with the requirements of ISO 6011:2003 and the requirements for backhoe loaders in ISO 6011:2003, Table 1

Verification by visual design check

4.10.6.3 Symbols on displays

Symbols for use on displays shall follow ISO 7000

Verification by visual examination and/or design check

4.10.7 Limiting and indicating devices

4.10.7.1 Load limiting device (LLD)

1) the calculation made according to 4.20; and

2) the stability verification (see 4.13);

or

b) exceed the structural limits determined:

1) according to 4.20 by the manufacturer; and

2) according to structural tests (see 5.3)

Arresting the movement shall not in itself give rise to instability

The LLD shall operate automatically and without the need for resetting when triggered The LLD, once triggered, shall remain triggered until the overload condition has been removed or the overturning moment has been lessened within the limits permitted by the manufacturer The means shall comply with Table 3

Where a truck can be operated in different configurations of wheels, stabilizing devices, or slewing angle range, the proper selection of correct LLD settings for the actual configuration shall be automatic and their modification by the operator shall not be possible This requirement does not cover the interchange of attachment fitted on the load carriage The means shall comply with Table 3