ISO 11525-4:2016

DRAFT INTERNATIONAL STANDARD
ISO/DIS 11525-4
ISO/TC 110/SC 4 Secretariat: AFNOR
Voting begins on: Voting terminates on:
2013-11-06 2014-02-06
Rough-terrain trucks — User requirements —
Part 4:
Additional requirements for variable-reach trucks
handling freely suspended loads
Chariots tout-terrain — Exigences pour l’utilisateur
ICS: 53.060
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
THEREFORE SUBJECT TO CHANGE AND MAY
NOT BE REFERRED TO AS AN INTERNATIONAL
STANDARD UNTIL PUBLISHED AS SUCH.
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STANDARDS MAY ON OCCASION HAVE TO
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WHICH REFERENCE MAY BE MADE IN
Reference number
NATIONAL REGULATIONS.
ISO/DIS 11525-4:2013(E)
RECIPIENTS OF THIS DRAFT ARE INVITED
TO SUBMIT, WITH THEIR COMMENTS,
NOTIFICATION OF ANY RELEVANT PATENT
RIGHTS OF WHICH THEY ARE AWARE AND TO
©
PROVIDE SUPPORTING DOCUMENTATION. ISO 2013

ISO/DIS 11525-4:2013(E)
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ii © ISO 2013 – All rights reserved

ISO/DIS 11525-4
Contents Page
Foreword . iv
Introduction . v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 General safety requirements . 2
4.1 Principles. 2
4.2 Operator's manual . 2
4.3 Modifications or alterations. 2
4.4 Manufacturer's bulletins . 2
4.5 Operator qualifications . 3
4.6 Operator's responsibility for training . 3
4.7 Operator training . 3
4.7.1 Operator training programme . 3
4.7.2 Testing, retraining and enforcement . 5
4.8 Inspection and maintenance . 6
4.8.1 General . 6
4.8.2 Preparation for inspection or repair . 6
4.8.3 Performance checks . 7
4.8.4 Inspection and maintenance precautions . 7
4.8.5 Inspection and maintenance requirements . 8
4.9 Hazardous environments. 8
5 Operating safety rules and precautions . 9
5.1 Operator's responsibility for safety . 9
5.2 Visual inspection and functional tests . 9
5.3 General operating instructions . 10
5.4 Travelling . 12
5.5 Picking and placing suspended loads . 13
5.6 Using attachments . 15
5.7 Slinger/Rigger Requirements . 15
Bibliography . 17

ISO/DIS 11525-4
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.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.
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.
ISO 11525-4 was prepared by Technical Committee ISO/TC 110, Industrial trucks, Subcommittee SC 4,
Rough-terrain trucks.
ISO 11525 consists of the following parts, under the general title Rough-terrain trucks — User requirements:
 Part 1: General requirements
 Part 2: Slewing variable-reach trucks
 Part 3: Lorry-mounted trucks
 Part 4: Additional requirements for variable-reach trucks handling freely suspended loads
 Part 5: Interface between rough-terrain truck and integrated personnel work platform
 Part 6: Agricultural applications
iv © ISO 2013 – All rights reserved

ISO/DIS 11525-4
Introduction
This International Standard is one of a set of standards produced by ISO/TC 110/SC 4 as part of its
programme of work regarding standardization of terminology, general safety, performance and user
requirements for rough-terrain trucks (hereafter also referred to as trucks) operating with freely suspended
loads.
DRAFT INTERNATIONAL STANDARD ISO/DIS 11525-4

Rough-terrain trucks — User requirements — Part 4: Additional
requirements for variable-reach trucks handling freely
suspended loads
1 Scope
This part of ISO 11525 defines user requirements relating to the use of non-slewing and slewing trucks
operating with freely suspended loads.
It is intended to achieve the following:
a) the prevention of personal injuries, property damage and accidents;
b) the establishment of criteria for inspection, maintenance, operation and training.
NOTE National or local requirements can apply, which could be more stringent.
General user requirements for trucks are given in ISO 11525-1.
User requirements for slewing trucks are given in ISO 11525-2.
This part of ISO 11525 is not applicable to flexible intermediate bulk containers as defined in ISO 21898.
2 Normative references
The following reference 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.
ISO 5057, Industrial trucks – Inspection and repair of fork arms in service on fork-lift trucks
ISO 10896-1, Rough-terrain trucks – Safety requirements and verification – Part 1: Variable-reach trucks
ISO 10896-4, Rough-terrain trucks – Safety requirements and verification – Part 4: Additional requirements for
variable-reach trucks handling freely suspended loads ISO 11525-1, Rough-terrain trucks – User
Requirements – Part 1: General requirements
ISO XXXXX, referred to in 5.4 u)3) and 5.5 b)1)
ISO 21898, Packaging - Flexible intermediate bulk containers (FIBCs) for non-dangerous goods
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 10896-4 and ISO 11525-1, and the
following apply:
3.1
fall zone
area below an elevated, or suspended, load, the attachment and the supporting boom structure

Under preparation.
ISO/DIS 11525-4
4 General safety requirements
4.1 Principles
This part of ISO 11525 shall be supplemented by good management practices, safety controls and application
of sound principles of safety, training, inspection, maintenance, application selection and operation. All data
available regarding the parameters of intended use and expected environment shall be considered. Those
with direct control over the application and operation of the truck shall be responsible for ensuring good safety
practices.
NOTE Different operating conditions can require additional safety precautions, training, and special safe operating
procedures.
The operation of any truck is subject to certain hazards that can be protected against only by the exercise of
care and common sense. It is essential to have competent persons trained in the intended use, safe operation,
maintenance and service of this equipment.
The user shall ensure that the operator understands that safe operation of the truck is also the operator’s
responsibility.
The user shall ensure that the operator's mental or physical condition will not impair his/her ability to operate
the truck.
4.2 Operator's manual
The user shall ensure that the operator's manual and any additional safety manuals provided by the
manufacturer with the truck are always available to the operator and maintenance personnel.
The user and/or the operator shall refer to the responsible entity should doubts on either the use of the truck
or the interpretation of the operator's manual arise.
4.3 Modifications or alterations
Except as provided below, no modifications or alterations to a truck that may affect its capacity, stability or
safe operation shall be made without the prior written approval of the original truck manufacturer or its
successor. When the truck manufacturer or its successor approves a modification or alteration, the user shall
be responsible, prior to operation, for ensuring that appropriate changes are made to information plate(s),
documents, certificates, labels, tags, and operator's manual(s).
If the truck manufacturer is no longer in business and there is no successor, modifications or alterations to the
truck shall be carried out under the following conditions:
a) the design, testing and implementation of the modification or alteration is made in accordance with the
appropriate part of ISO 10896 by a competent person;
b) a permanent record is kept of the design, test(s) and implementation of the modification or alteration;
c) appropriate changes are made to the information plate(s), documents, certificates, labels, tags, and
operator's manual(s);
d) a permanent and readily visible label is affixed to the truck stating the manner in which the truck has been
modified or altered, together with the date of the modification or alteration, and the name of the person or
organization responsible for the design, testing and implementation of the modifications.
4.4 Manufacturer's bulletins
The user shall comply with the applicable bulletins as directed by the responsible entity.
2 © ISO 2013 – All rights reserved

ISO/DIS 11525-4
4.5 Operator qualifications
Users shall only allow competent and authorized persons to operate a truck. Truck operators shall be
competent to operate the equipment safely, in addition to being trained in accordance with this part of
ISO 11525.
The operator may be required, in some local, regional, national markets, to undergo additional training beyond
the scope of this part of ISO 11525. Users shall ensure that operators receive the necessary level of training
as required.
4.6 Operator's responsibility for training
Before operating any truck, the operator shall be trained in accordance with 4.7 and shall have read and be
familiar with the operator's manual(s) and any other safety information provided by the manufacturer and user
on the particular truck being operated, the application and the environment in which the truck is to be used
and any attachments used.
4.7 Operator training
4.7.1 Operator training programme
Personnel who are not considered competent to operate a truck shall operate the truck only as part of the
operator training programme. This training shall be conducted under the direct supervision of a trainer.
The operator training programme shall be based on user policies, industry standards, local regulations and
policies, operating conditions and manufacturer's instructions.
NOTE Information on operator training is available from such sources as: users, truck manufacturers, government
agencies dealing with employee safety, trade organizations of trucks users, public and private organizations and safety
consultants.
The training programme shall emphasize safe and proper operation that avoids injury to the operator and
others and prevents property damage. The training program shall include the following items:
a) information about the truck(s) the trainee will operate:
1) characteristics of the truck(s), including possible variations between the truck and others in the
workplace;
2) similarities to, and differences from, other mobile equipment;
3) significance of information plate(s), the load chart(s), warnings and instructions affixed to the truck;
4) operating and safety instructions in the truck's operator's manual;
5) instructions for inspection and maintenance to be performed by the operator;
6) engine operation;
7) type of drive system and its characteristics;
8) methods of steering and manoeuvring;
9) braking methods and characteristics, with and without loads;
10) visibility, with and without loads;
11) load charts, how to read and comprehend them and the limitations of the load chart due to the mass
and load centres;
ISO/DIS 11525-4
12) explanation of the stability triangle and other stability characteristics affected by speed, acceleration,
braking, raising or lowering loads while travelling, operation/manoeuvring without loads, sharp
cornering, height, attachments, grade/ramps, centre of gravity of the load and truck, combined load
centre of gravity, counterbalance principle, machine level, and any features that can affect stability
(i.e. rear axle locking system etc.);
13) controls and instrumentation, including their location, identification, function, method of operation and
identification of symbols;
14) load-handling capabilities and proper use of forks and other attachments;
15) refuelling and battery charging;
16) guards and protective devices for the specific type of truck;
17) how to use stabilizing devices, chassis levelling and other stability-related functions, and examples of
improper operation and the risks associated with them;
18) how to correctly use the operator restraint(s), e.g. seat belt, and other safety devices;
19) basic steps to take in the event of a tip-over, e.g. bracing for impact;
20) wheel loadings when loaded and unloaded;
21) when entering and exiting the operator's station, the need to always maintain three points of contact,
i.e. one hand and two feet or two hands and one foot;
22) types of attachments and their applications/limitations, and;
23) other characteristics, if any, of the specific truck.
b) operation and worksite-related topics:
1) surface conditions on which the truck is to be operated, loaded and unloaded, e.g. floor and ground
conditions, ground pressure, ramps and inclines, trailers;
2) load handling at height and at ground level while picking and placing loads;
3) levelling of the truck prior to picking and placing loads;
4) pedestrian traffic in areas in which the truck is to be used;
5) narrow-aisle and other confined-area operations;
6) potentially hazardous locations where the truck will be operated;
7) ramps and gradients and how the stability of the truck could be affected by them;
8) enclosed environments and other areas where insufficient ventilation could result in a concentration
of carbon monoxide gas from the engine exhaust;
9) other unique or potentially hazardous environmental conditions at the worksite that could affect other
workers and the safe operation of the truck.
c) handling free-suspended loads:
1) how handling, and traveling with, a suspended load affects the trucks stability, i.e. operation on
slopes, fast and sudden movements;
4 © ISO 2013 – All rights reserved

ISO/DIS 11525-4
2) how to minimize the hazards associated with the movement of the suspended load during handling
and traveling, i.e. tethering, boom position, slow gradual boom movements, slow travel speed;
3) potential hazards around a free-suspended load, i.e. collisions, crushing, falling objects;
4) unapproved applications for free-suspended loads, i.e. lifting of personnel;
5) any additional training requirements outlined by the truck manufacturer or local, state, federal,
national standards and regulations, i.e. signalling, rigging/slinging.
4.7.2 Testing, retraining and enforcement
4.7.2.1 Testing
During training, performance and oral and/or written tests shall be given by the examiner to measure the skill
and knowledge of the trainee in meeting the requirements of the operator training programme based on this
part of ISO 11525. Examiners shall establish a pass/fail requirement for such tests. The user shall verify that
the testing has been satisfactorily performed.
Following the completion of instruction and practice, all trainees shall be evaluated.
The evaluation shall be conducted on the specific work tasks and shall include the following items:
a) preoperational inspection;
b) function test;
c) start-up;
d) travelling, with and without a load (including pedestrian safety);
e) use of the approved load handling attachment;
f) load selection and securement;
g) handling the suspended load including load pickup and placement;
h) engagement of the load handling means;
i) handling specific to docks, trucks, and rail cars;
j) driving on ramps and grades;
k) proper use of the truck's safety features;
l) shutdown;
m) refuelling/recharging;
n) operational maintenance.
Records shall be retained in accordance with 4.7.2.4.
4.7.2.2 Retraining
Operators shall be retrained when new equipment is introduced, existing equipment modified, operating
conditions change, current training expires or an operator's performance is deemed unsatisfactory by the user.
ISO/DIS 11525-4
The user shall determine the extent of operator retraining, as well as the need for retraining, taking into
consideration regional or local requirements.
4.7.2.3 Enforcement
The user shall be responsible for enforcing the safe use of the truck according to the provisions of this part of
ISO 11525.
4.7.2.4 Record keeping
Records of the person or persons trained in the operation of the truck shall be retained for at least the period
of time for which the training is valid. In addition:
 the successful trainee shall be furnished with proof of training, verifying compliance with the operator
training program based on this part of ISO 11525;
 the records shall reflect the period of time when the training has not expired;
 the records shall include the name of the entity providing training or retraining, the name of trainer(s) and
examiner(s), clear identification of the truck(s) and attachment(s) covered by training, and the date of
training.
 when requested, records regarding proof of training shall be readily available.
4.8 Inspection and maintenance
4.8.1 General
The inspection and maintenance of trucks shall be performed in accordance with the manufacturer’s and
user’s recommendations, national regulations and the following practices:
a) a planned syste
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