ISO 10896-1:2020

INTERNATIONAL ISO
STANDARD 10896-1
Second edition
2020-04
Rough-terrain trucks — Safety
requirements and verification —
Part 1:
Variable-reach trucks
Chariots tout-terrain — Exigences de sécurité et vérification —
Partie 1: Chariots à portée variable
Reference number
©
ISO 2020
© ISO 2020
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ii © ISO 2020 – All rights reserved

Contents Page
Foreword .vi
Introduction .vii
1 Scope . 1
2 Normative references . 2
3 Terms and definitions . 3
4 Safety requirements and/or protective/risk reduction measures . 8
4.1 General . 8
4.1.1 General. 8
4.1.2 Sharp edges and acute angles . 8
4.1.3 Stored energy components . 8
4.2 Starting/moving and stopping . 8
4.2.1 Unauthorized starting . 8
4.2.2 Stopping system . 8
4.2.3 Unintended movement . 8
4.2.4 Uncontrolled motion . 9
4.2.5 Powered travel movement. 9
4.2.6 Non-activation of the parking brake . 9
4.2.7 Brakes . 9
4.3 Electrical and electronic systems . 9
4.3.1 General. 9
4.3.2 Degree of protection .10
4.3.3 Electrical connections .10
4.3.4 Batteries .11
4.4 Controls .11
4.4.1 General.11
4.4.2 Multiple operating positions .13
4.4.3 Controls of trucks accessible from ground level.13
4.4.4 Inadvertent activation .13
4.4.5 Travel controls .13
4.4.6 Differential locking . . .15
4.4.7 Steering controls .15
4.4.8 Load-handling controls .16
4.4.9 Multi-function controls .17
4.4.10 Stabilizing device control .17
4.4.11 Sway/levelling control .17
4.4.12 Axle oscillation locking-mechanism control .17
4.4.13 Hand throttle control .17
4.5 Power systems and accessories.17
4.5.1 Exhaust systems .17
4.5.2 Cooling systems .18
4.5.3 Tanks and pressure vessels .18
4.6 Stabilizing devices .18
4.7 Design requirements for maintenance purposes .19
4.7.1 General.19
4.7.2 Tiltable cab support device .19
4.8 Systems for lifting, tilting and reaching .19
4.8.1 Chains and wire ropes .19
4.8.2 Hydraulic system .20
4.8.3 Maximum load-lowering speed .21
4.8.4 Limitation of stroke .21
4.8.5 Fork arms, attachments and attachment brackets .21
4.9 Operator’s station .21
4.9.1 General requirements .21
4.9.2 Storage of operator’s manual .21
4.9.3 Hot parts .21
4.9.4 Pipes and hoses .22
4.9.5 Operator's station equipped with enclosed cab .22
4.9.6 Operator's seat.24
4.9.7 Control panels and symbols on displays .25
4.9.8 Other indicating devices .25
4.10 Operator access .25
4.10.1 General requirements .25
4.10.2 Enclosed cab openings . .25
4.11 Protective measures and devices .26
4.11.1 Hot parts .26
4.11.2 Protection against crushing, shearing and trapping .26
4.11.3 Guards .26
4.11.4 Engine compartment . .26
4.11.5 Fenders .27
4.11.6 Roll-over protective structures (ROPS) and falling object protective
structures (FOPS) .27
4.11.7 Elevating and/or tiltable operator's station .27
4.11.8 Audible warning devices .27
4.12 Stability .27
4.12.1 Stability tests on tilting platform .27
4.12.2 Longitudinal load moment control .27
4.13 Visibility .27
4.14 External lighting devices .27
4.15 Fire protection .28
4.15.1 Fire resistance .28
4.15.2 Fire extinguisher .28
4.16 Retrieval, transportation, lifting and towing .28
4.16.1 General.28
4.16.2 Retrieval .28
4.16.3 Tie-down .28
4.16.4 Lifting . .28
4.16.5 Towing .28
4.17 Noise .28
4.18 Electromagnetic compatibility .29
5 Verification of requirements and safety measures .29
5.1 General .29
5.2 Functional verification .29
5.3 Structural verification .29
5.3.1 Test loads .29
5.3.2 Static test .29
5.3.3 Dynamic testing .30
5.4 Load holding verification .30
5.5 Maximum load lowering speed .30
6 Information for use .31
6.1 Instruction handbook .31
6.1.1 General.31
6.1.2 Operating and maintenance instructions .31
6.1.3 Instructions regarding the truck .32
6.1.4 Instructions regarding the operational use of the truck .32
6.1.5 Instructions regarding internal combustion engine trucks .33
6.1.6 Instructions regarding transportation and storage of trucks .33
6.1.7 Instructions regarding inspection and routine maintenance .33
6.2 Graphical symbols and warnings .34
6.2.1 Safety signs and graphical symbols .34
6.2.2 Graphical symbols lift point .34
iv © ISO 2020 – All rights reserved

6.2.3 Graphical symbols tie-down point .34
6.2.4 Graphical symbols of retrieval point .34
6.2.5 Graphical symbols for pneumatic tyre inflation pressures .35
6.2.6 Graphical symbol for fuel filling points .35
6.2.7 Graphical symbol for hydraulic fluid filling points .35
6.2.8 Graphical symbol for stored energy components .36
6.2.9 Graphical symbol for brake fluid filling points .36
6.2.10 Graphical symbol for battery disconnection.36
6.2.11 Warnings .36
6.3 Marking .37
6.3.1 Manufacturer plate(s) .37
6.4 Load charts .37
6.4.1 Trucks with load-carrying attachments .37
6.4.2 Trucks with non-load-carrying attachments .38
Annex A (informative) List of significant hazards.39
Annex B (normative) Attachments and attachment brackets .43
Annex C (normative) Elevating operator's stations .46
Bibliography .48
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
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on the ISO list of patent declarations received (see www .iso .org/ patents).
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expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see www .iso .org/
iso/ foreword .html.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/ members .html.
This document was prepared by Technical Committee ISO/TC 110, Industrial trucks, Subcommittee
SC 4, Rough-terrain trucks.
This second edition cancels and replaces the first edition (ISO 10896-1:2012), which has been
technically revised.
The main changes compared to the previous edition are as follows:
— the document has been aligned with regional standards;
— a new steering test has been added;
— new requirements for the hydraulic circuit have been introduced.
A list of all parts in the ISO 10896 series can be found on the ISO website.
vi © ISO 2020 – All rights reserved

Introduction
This document is a type-C standard as stated in ISO 12100.
This document is of relevance, in particular, for the following stakeholder groups representing the
market players with regard to machinery safety:
— machine manufacturers (small, medium and large enterprises);
— health and safety bodies (regulators, accident prevention organisations, market surveillance etc.)
Others can be affected by the level of machinery safety achieved with the means of the document by the
above-mentioned stakeholder groups:
— machine users/employers (small, medium and large enterprises);
— machine users/employees (e.g. trade unions, organizations for people with special needs);
— service providers, e. g. for maintenance (small, medium and large enterprises);
— consumers (in case of machinery intended for use by consumers).
The above-mentioned stakeholder groups have been given the possibility to participate at the drafting
process of this document.
The machinery concerned and the extent to which hazards, hazardous situations or hazardous events
are covered are indicated in the Scope of this document.
When requirements of this type-C standard are different from those which are stated in type-A or
type-B standards, the requirements of this type-C standard take precedence over the requirements of
the other standards for machines that have been designed and built according to the requirements of
this type-C standard.
This document has been developed in order to align as far as possible its requirements to those of the
applicable regional standards in Australia, EU, USA.
INTERNATIONAL STANDARD ISO 10896-1:2020(E)
Rough-terrain trucks — Safety requirements and
verification —
Part 1:
Variable-reach trucks
1 Scope
This document specifies general safety requirements for non-slewing, rough-terrain variable-reach
trucks (referred to as trucks), with rigid chassis and equipped with a telescopic lifting means (pivoting
boom) on which a load-handling device such as a carriage with fork arms is typically fitted. Fork arms
and other integrated attachments are considered to be parts of the truck.
NOTE These trucks are also known as telehandlers, or telescopic handlers.
For the purpose of this document, trucks are designed to transport, lift and place loads and can be driven
on unimproved terrain. They can also be equipped with a variety of attachments or interchangeable
equipment (e.g. fork arms, bale spikes, mowers, sweepers) which can be both load-carrying and non-
load-carrying.
Other standards, in addition to the relevant provisions of this document, can apply to the attachments.
This document is not applicable to the following:
a) industrial variable-reach trucks covered by ISO 3691-2;
b) machines designed primarily for earth moving, such as loaders, even if their buckets are replaced
by fork arms (see ISO 20474-3);
c) trucks with articulated chassis;
d) machines designed primarily with variable-length load suspension elements (e.g. chain, ropes)
from which the load can swing freely in all directions (mobile cranes);
e) trucks fitted with personnel/work platforms, designed to move persons to elevated working
positions;
f) trucks designed primarily for container handling.
The significant hazards covered by this document are listed in Annex A. This document does not
address hazards that can occur:
— during manufacture;
— when handling suspended loads, which can swing freely (see ISO 10896-4);
— when using trucks on public roads;
— when operating in potentially explosive atmospheres;
— with a battery, LPG or hybrid as the primary power source.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements 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.
ISO 2330, Fork-lift trucks — Fork arms — Technical characteristics and testing
ISO 2860, Earth-moving machinery — Minimum access dimensions
ISO 2867:2011, Earth-moving machinery — Access systems
ISO 3449, Earth-moving machinery — Falling-object protective structures — Laboratory tests and
performance requirements
ISO 3457, Earth-moving machinery — Guards — Definitions and requirements
ISO 3471:2008, Earth-moving machinery — Roll-over protective structures — Laboratory tests and
performance requirements
ISO 3795, Road vehicles, and tractors and machinery for agriculture and forestry — Determination of
burning behaviour of interior materials
ISO 3864-1, Graphical symbols — Safety colours and safety signs — Part 1: Design principles for safety
signs and safety markings
ISO 3864-2, Graphical symbols — Safety colours and safety signs — Part 2: Design principles for product
safety labels
ISO 5053-1, Industrial trucks — Terminology and classification — Part 1: Types of industrial trucks
ISO 5353, Earth-moving machinery, and tractors and machinery for agriculture and forestry — Seat
index point
ISO 6016, Earth-moving machinery — Methods of measuring the masses of whole machines, their equipment
and components
ISO 6292:2020, Powered industrial trucks and tractors — Brake performance and component strength
ISO 6682, Earth-moving machinery — Zones of comfort and reach for controls
ISO 6683, Earth-moving machinery — Seat belts and seat belt anchorages — Performance requirements
and tests
ISO 7000, Graphical symbols for use on equipment — Registered symbol
ISO 7096, Earth-moving machinery — Laboratory evaluation of operator seat vibration
ISO 9533, Earth-moving machinery — Machine-mounted audible travel alarms and forward horns — Test
methods and performance criteria
ISO 10263-3, Earth-moving machinery — Operator enclosure environment — Part 3: Pressurization
test method
ISO 10263-4, Earth-moving machinery — Operator enclosure environment — Part 4: Heating, ventilating
and air conditioning (HVAC) test method and performance
ISO 10896-6, Rough-terrain trucks — Safety requirements and verification — Part 6: Tilting operator's cabs
ISO 10896-7, Rough-terrain trucks — Safety requirements and verification — Part 7: Longitudinal load
moment systems
ISO 11112, Earth-moving machinery — Operator's seat — Dimensions and requirements
2 © ISO 2020 – All rights reserved

ISO 12508, Earth-moving machinery — Operator station and maintenance areas — Bluntness of edges
ISO 13284, Fork-lift trucks — Fork-arm extensions and telescopic fork arms — Technical characteristics
and strength requirements
ISO 13732-1, Ergonomics of the thermal environment — Methods for the assessment of human responses to
contact with surfaces — Part 1: Hot surfaces
ISO 13766-1, Earth-moving and building construction machinery — Electromagnetic compatibility (EMC)
of machines with internal electrical power supply — Part 1: General EMC requirements under typical
electromagnetic environmental conditions
ISO 13849-1, Safety of machinery — Safety-related parts of control systems — Part 1: General principles
for design
ISO 13850, Safety of machinery — Emergency stop function — Principles for design
ISO 15817, Earth-moving machinery — Safety requirements for remote operator control systems
ISO 15818, Earth-moving machinery — Lifting and tying-down attachment points — Performance
requirements
ISO 18063-1, Rough-terrain trucks — Visibility test methods and their verification — Part 1: Variable-
reach trucks
ISO 21507, Earth-moving machinery — Performance requirements for non-metallic fuel tanks
ISO 22915-10, Industrial trucks — Verification of stability — Part 10: Additional stability test for trucks
operating in the special condition of stacking with load laterally displaced by powered devices
ISO 22915-14, Industrial trucks — Verification of stability — Part 14: Rough-terrain variable-reach trucks
ISO 22915-20, Industrial trucks — Verification of stability — Part 20: Additional stability test for trucks
operating in the special condition of offset load, offset by utilization
ISO 19014-1, Earth-moving machinery — Functional safety — Part 1: Methodology to determine safety-
related parts of the control system and performance requirements
ISO 4413:2010, Hydraulic fluid power — General rules and safety requirements for systems and their
components
ISO 13857, Safety of machinery — Safety distances to prevent hazard zones being reached by upper and
lower limbs
ISO 12100, Safety of machinery — General principles for design — Risk assessment and risk reduction
IEC 60529, Degrees of protection provided by enclosures (IP Code)
EN 12053, Safety of industrial trucks — Test methods for measuring noise emissions
EN 12895, Industrial trucks — Electromagnetic compatibility
ANSI B56.11.5, Measurement of Sound Emitted by Low Lift, High Lift, and Rough Terrain Powered
Industrial Trucks
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 5053-1 and the following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— IEC Electropedia: available at http:// www .electropedia .org
— ISO Online browsing platform: available at http:// www .iso .org/ obp
3.1
rough-terrain truck
truck designed for operation on unimproved natural terrain as well as the disturbed terrain of work sites
3.2
compact truck
truck having a maximum height in normal travel mode not exceeding 2 150 mm, a maximum operating
mass according to ISO 6016 not exceeding 6 000 kg, and a maximum width in normal travel mode not
exceeding 1 850 mm
3.3
rated capacity
Q
maximum load permitted by the manufacturer at the standard load centre distance that the
truck is capable of lifting and transporting on fork arms (3.13) in normal conditions with the boom
(3.14) fully retracted
Note 1 to entry: See Figure 1.
3.4
rated capacity
maximum load that the attachment (3.17) is permitted by its manufacturer to handle in
normal operation under specified conditions
Note 1 to entry: The rated capacity of the attachment (3.17) can be associated with the load centre distance. See
Table 1.
3.5
actual capacity
maximum load at a specified load centre distance, established by the manufacturer based on component
strength and truck stability, that the truck can carry, lift and stack to a specified lift height (3.7) and
reach (3.6), in normal operation
Note 1 to entry: See Figure 1.
Note 2 to entry: The actual capacity depends on the configuration of the truck in respect of variables including
lift height, the reach of the boom (3.14), the actual load centre, load-handling devices and stabilizing devices (3.11).
Note 3 to entry: It defines the load-handling ability of the particular truck as equipped. Different actual capacity
with removable attachments (3.17), where permitted, may also be established by the appropriate stability test or
by calculation verified by empirical data.
3.6
reach
d
distance between two vertical parallel planes, one plane being tangent to the front of the outside
diameter of the front tyres or tracks, the other plane being tangent to the curve described by the centre
of gravity of the load moving from its highest position to its lowest position
Note 1 to entry: See Figure 1.
Note 2 to entry: In practice, the reach can be measured by referring to a point, g, corresponding to the vertical
projection of the centre of gravity, G, of the load onto the plane of the top surface of the fork arms (3.13), as shown
in Figure 1.
4 © ISO 2020 – All rights reserved

Key
d reach
D standard load centre distance
G centre of gravity of the load
g point corresponding to vertical projection of G
Q rated capacity
Q actual capacity at maximum lift height
Q actual capacity at maximum reach
Figure 1 — Parameters for determining actual capacity of a truck with fork arms
3.7
lift height
height from the ground to the upper face of the fork arms or underside of the load, whichever is the lower
3.8
standard load centre distance
D
distance from the centre of gravity of the load, horizontally rearwards to the front of the fork shanks
and vertically downwards to the upper faces of the fork arms (3.13)
Note 1 to entry: See Figure 1.
Note 2 to entry: Table 1 gives standard load centre distances in relation to their rated capacities.
Table 1 — Standard load centre distances and rated capacities
Rated capacity Standard load centre distance
Q D
kg mm
400 500 600 900 1 200
a
0 <1 000 X X
c b
≥1 000 <5 000 X X
≥5 000 <10 000 X
≥10 000 <20 000 X X X
≥20 000 <25 000 X X
≥25 000 X
NOTE  Trucks can be rated for special applications with load centres related to those applications.
a
600 mm is typically used in the USA.
b
600 mm is typically used in Asia, Australia and the USA.
c
500 mm is typically used in Europe.
3.9
lost load distance
l
L
effective thickness
d
E
horizontal shift in the standard load centre that can occur when removable attachments (3.17) are
added to a truck
3.10
axle oscillation locking-mechanism
mechanism designed to lock oscillation of an axle to improve truck stability
3.11
stabilizing device
extendable or pivoting mechanical support used to improve the stability of a truck when stationary
3.12
lateral levelling
change in the lateral inclination angle between the chassis and the ground made to ensure that the
boom (3.14) operates in a vertical plane even when the truck is positioned on a side slope
3.13
fork arms
device comprising two or more solid fork arms, each consisting of a shank (vertical portion) and a blade,
which is hook- or shaft-mounted, fitted on the carriage and usually adjusted manually
3.14
boom
pivoting support member that permits horizontal and vertical placement of the load or attachment (3.17)
3.15
crab steering mode
steering mode where all wheels of the truck steer in the same direction
6 © ISO 2020 – All rights reserved

3.16
normal operating position
position specified by the manufacturer in which the operator is able to control the truck operations,
including load-handling functions
Note 1 to entry: Other positions can be necessary if it is not possible to control all the functions of the truck from
a single position.
3.17
attachment
interchangeable equipment
component or assembly of components which can be mounted on the attachment bracket (3.18) for a
specific use
3.18
attachment bracket
device fitted at the end of the boom (3.14) to connect and lock interchangeable attachment(s) (3.17)
without the use of a tool to facilitate quick interchange of attachment(s) (3.17)
3.19
non-slewing
slewing movement not greater than 5° to either side of the longitudinal axis of the truck
Note 1 to entry: See Figure 2.
Figure 2 — Non-slewing movement
3.20
boom float
control mode that uses gravity to allow an attachment (3.17) at the end of the boom (3.14) to follow a
contour (e.g. the ground)
3.21
maximum working pressure
highest pressure at which a hydraulic circuit is intended to operate in steady-state operating conditions
[SOURCE: ISO 5598:2020, 3.2.429, modified — In the definition, “system or sub-system” has been
replaced by “hydraulic circuit”.]
3.22
level ground
ground with a gradient of (0 ± 2) %
3.23
hybrid
truck powered using two or more distinct power sources
3.24
rough-terrain variable-reach truck
rough-terrain truck fitted with one or more articulated arms, telescopic or not, non-slewing or having
a slewing movement of not more than 5° either side of the longitudinal axis of the truck used for
stacking loads
3.25
technically permissible maximum operating mass
operating mass without the forks and including the heaviest attachment approved by the truck
manufacturer without load
4 Safety requirements and/or protective/risk reduction measures
4.1 General
4.1.1 General
Rough-terrain variable-reach trucks, as defined in 3.24, shall comply with the safety requirements and/
or protective measures/risk reduction of this clause. In addition, the truck shall be designed according
to the principles of ISO 12100 for relevant but not significant hazards, which are not dealt with by this
document.
4.1.2 Sharp edges and acute angles
Sharp edges and acute angles shall meet the requirements specified in ISO 12508 in areas to which the
operator can be exposed during operation, access, egress and daily maintenance.
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 visibly marked according to 6.2.8.
4.2 Starting/moving and stopping
4.2.1 Unauthorized starting
All trucks shall be provided with a device (e.g. key, key pad, magnetic card) within the zone of reach of
the operator at their normal operating position as defined in ISO 6682 that prevents starting without
the use of such device.
4.2.2 Stopping system
The truck shall be provided with a stopping device (e.g. a key) within the zone of reach of the operator
at their normal operating position as defined in ISO 6682.
The normal stop control device shall be clearly identifiable, and clearly visible.
4.2.3 Unintended movement
Trucks shall be designed such that the engine cannot be started while the drive system is engaged.
When the drive system direction control is in neutral position, a means shall be provided to main
...