ISO 10896-1:2012

INTERNATIONAL ISO
STANDARD 10896-1
First edition
2012-07-01
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 2012
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Published in Switzerland
ii © ISO 2012 – All rights reserved

Contents Page
Foreword .iv
Introduction . v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 3
4 Requirements . 7
4.1 General . 7
4.2 Starting/moving . 7
4.3 Brakes . 8
4.4 Electrical and electronic systems . 8
4.5 Controls . 9
4.6 Power systems and accessories .12
4.7 Stabilizing devices .13
4.8 Design requirements for maintenance purposes .13
4.9 Systems for lifting, tilting and reaching .13
4.10 Operator’s station .15
4.11 Operator access .19
4.12 Protective measures and devices .20
4.13 Stability .21
4.14 Visibility .21
4.15 External lighting devices .21
4.16 Fire protection .22
4.17 Retrieval, transportation, lifting and towing .22
4.18 Noise .22
5 Verification of requirements and safety measures .23
5.1 General .23
5.2 Functional verification .23
5.3 Structural verification .23
5.4 Maximum load-lowering speed verification .24
6 Information for use .24
6.1 General .24
6.2 Operator’s and maintenance manuals .25
6.3 Marking .27
6.4 Load charts .27
Annex A (informative) List of significant hazards .29
Annex B (normative) Attachments and attachment brackets .34
Annex C (normative) Elevating/tiltable operator’s stations .37
Annex D (informative) Consistency of direction of motion for load-handling controls .39
Bibliography .40
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 10896-1 was prepared by Technical Committee ISO/TC 110, Industrial trucks, Subcommittee SC 4,
Rough-terrain trucks.
ISO 10896 consists of the following parts, under the general title Rough-terrain trucks — Safety requirements
and verification:
— Part 1: Variable-reach trucks
Slewing trucks, lorry-mounted trucks, freely swinging loads and straight-masted trucks are to form the subjects
of future parts 2, 3, 4 and 5.
iv © ISO 2012 – All rights reserved

Introduction
Variable-reach trucks are known by a variety of terms, including “telehandlers” and “multi-purpose handlers”.
The variable-reach rough-terrain trucks covered by this part of ISO 10896 are designed to transport loads to
and place them on elevated work areas and can be driven on unimproved or disturbed terrain.
They can also be equipped with a variety of attachments (e.g. fork arms, bale spikes) and interchangeable
equipment (e.g. mowers, sweepers).
INTERNATIONAL STANDARD ISO 10896-1:2012(E)
Rough-terrain trucks — Safety requirements and verification —
Part 1:
Variable-reach trucks
1 Scope
This part of ISO 10896 specifies general safety requirements for non-slewing, variable-reach rough-terrain
trucks (hereafter known as “trucks”), with an articulated or 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.
Other standards, in addition to the relevant provisions of this part of ISO 10896, can apply to the attachments.
This part of ISO 10896 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);
c) trucks designed primarily with variable-length load suspension elements (e.g. chain, ropes) from which the
1)
load may swing freely in all directions (mobile cranes) ;
d) trucks fitted with personnel/work platforms, designed to move persons to elevated working positions ;
e) trucks designed primarily for container handling.
The significant hazards covered by this part of ISO 10896 are listed in Annex A. This part of ISO 10896 does
not address hazards that can occur
— during manufacture,
— when handling suspended loads, which may swing freely,
— when using trucks on public roads,
— when operating in potentially explosive atmospheres, or
— with a battery, LPG or hybrid as the primary power source.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced document
(including any amendments) applies.
ISO 2330, Fork-lift trucks — Fork arms — Technical characteristics and testing
ISO 2867:2011, Earth-moving machinery — Access systems
ISO 3449, Earth-moving machinery — Falling-object protective structures — Laboratory tests and
performance requirements
1) Additional requirements for trucks intended for freely swinging load applications, their lifting devices and attachments,
and personnel/work platform applications on trucks, are being developed by ISO/TC 110/SC4.
ISO 3450, Earth-moving machinery — Wheeled or high-speed rubber-tracked machines — Performance
requirements and test procedures for brake systems
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, Powered industrial trucks — Terminology
ISO 5353, Earth-moving machinery, and tractors and machinery for agriculture and forestry - Seat index point
ISO 6016:2008, Earth-moving machinery — Methods of measuring the masses of whole machines, their
equipment and components
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
2)
ISO 7000, Graphical symbols for use on equipment ― Registered symbols
ISO 7096:2000, Earth-moving machinery — Laboratory evaluation of operator seat vibration
ISO 9244, Earth-moving machinery — Machinery safety labels — General principles
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 10570, Earth-moving machinery — Articulated frame lock — Performance requirements
ISO 11112:1995, Earth-moving machinery — Operator’s seat — Dimensions and requirements. Amended by
ISO 11112:1995/Amd 1:2001
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 13849-1, Safety of machinery — Safety-related parts of control systems — Part 1: General principles for design
ISO 13850, Safety of machinery — Emergency stop — Principles for design
ISO 15817, Earth-moving machinery — Safety requirements for remote operator control
ISO 16528-1:2007, Boilers and pressure vessels — Part 1: Performance requirements
ISO 16528-2, Boilers and pressure vessels — Part 2: Procedures for fulfilling the requirements of ISO 16528-1
2) The database on Graphical Symbols for Use on Equipment contains the complete set of graphical symbols included in
IEC 60417 and ISO 7000: http://www.graphical-symbols.info/
2 © ISO 2012 – All rights reserved

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
IEC 60529, Degrees of protection provided by enclosures (IP Code)
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 5053 and the following apply.
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 of 2 150 mm, a maximum operating mass according to
ISO 6016 of 6 000 kg, and/or a maximum width in normal travel mode of 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 fully retracted
SEE: Figure 1.
3.4
rated capacity
maximum load that the attachment is permitted by its manufacturer to handle in normal operation
under specified conditions
Note to entry The rated capacity of the attachment 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 and reach (3.6), in
normal operation
SEE: Figure 1.
Note 1 to entry The actual capacity depends on the configuration of the truck in respect of variables including lift height,
the reach of the boom, the actual load centre, load-handling devices and stabilizing devices.
Note 2 to entry It defines the load-handling ability of the particular truck as equipped. Additional actual capacity with
removable attachments, 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
SEE: Figure 1.
NOTE 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.
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
4 © ISO 2012 – All rights reserved

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)
SEE: Figure 1.
Note 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 may be rated for special applications with load centres related to those applications.
a
600 mm is used in the USA.
b
600 mm is used in Asia, Australia and the USA.
c
500 mm is typically used in Europe.
3.9
lost load centre
LL
effective thickness
ET
horizontal shift in the standard load centre that may occur when removable attachments 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 devices
extendable and/or pivoting mechanical supports 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
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 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
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 to entry Other positions may be necessary if it is not possible to control all the functions of the truck from a
single position.
3.17
attachment
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 to connect and lock interchangeable attachments (3.17) without the use of
a tool to facilitate quick interchange of attachments
3.19
non-slewing
slewing movement not greater than 5° to either side of the longitudinal axis of the truck
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 to follow a contour
(e.g. the ground)
3.21
maximum working pressure
highest pressure at which a hydraulic circuit is intended to operate under normal operating conditions
3.22
articulated truck
truck in which steering is achieved by displacement of the front and rear frames around a central pivot
3.23
level ground
ground with a gradient of (0 ± 2) %
6 © ISO 2012 – All rights reserved

3.24
hybrid
truck powered using of two or more distinct power sources
4 Requirements
4.1 General
4.1.1 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.
4.1.2 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 clearly marked.
4.2 Starting/moving
4.2.1 Unauthorized starting
All trucks shall be provided with a device (e.g. key, key pad, magnetic card) that prevents starting without the
use of such device.
4.2.2 Unintended movement
Trucks shall be fitted with a device which prevents the engine being started while the drive system is engaged.
When the drive system direction control is in neutral, provisions shall be made to locate and maintain it in its
neutral position.
4.2.3 Uncontrolled motion
The truck shall not move from rest, on level ground, until the drive system has been engaged.
4.2.4 Powered travel movement
Means shall be provided to prevent powered travel when the operator is not in the normal operating position.
Powered travel shall not occur automatically when the operator returns to the normal operating position without
an additional operation, e.g. by reset of the direction control to neutral.
Application of the parking brake shall apply neutral travel control.
4.2.5 Non-activation of the parking brake
Means shall be provided to warn the operator, if he/she leaves the operating position when the parking brake
is not applied.
4.2.6 Inching pedal
If an inching pedal is fitted, it shall be depressed to modulate the transmission and may apply the service brake.
It shall be capable of being operated by the operator’s left foot. If there is no separate means of applying the
service brake, the inching pedal shall be a single pedal capable of being operated equally by either foot.
4.3 Brakes
4.3.1 General
Trucks shall be equipped with service brake(s), secondary brake(s) and parking brake systems, complying with
the following requirements for wheeled trucks, as specified in ISO 3450.
NOTE Local road regulations may apply when trucks are used on roads.
Where electromechanical brake systems are fitted, they shall be applied mechanically and released electrically.
Where hydromechanical parking brakes are fitted, they shall be applied mechanically and released hydraulically.
When the operator manually releases the parking brake from the normal operating position, it shall not disable
the service brakes.
4.3.2 Failure of energy supply
Failure of the energy supply shall not result in loss of braking for automatically applied brakes.
4.4 Electrical and electronic systems
4.4.1 General
Electrical components and conductors shall be installed in such a way as to minimize damage from exposure to
environmental conditions (corresponding to the use of the truck intended by the manufacturer) that can cause
deterioration.
Electrical component insulation shall have flame-retardant properties. Means to prevent abrasion of electrical
component insulation shall be provided, e.g. when routed through frames and bulkheads.
Electrical wires/cables not protected by over-current devices shall not be routed such that they are in contact
with pipes and hoses containing fuel.
For safety-related functions of control system(s), the principles outlined in ISO 13849-1 shall be followed, or
methods providing similar protection shall be applied.
4.4.2 Degree of protection
Depending on the location/installation of electrical and electronic components, the following degrees of
protection are required:
a) all components installed on the truck’s exterior or directly exposed to the environment shall have a minimum
degree of protection corresponding to IP55 (according to IEC 60529);
b) for all components installed in the operator’s enclosed cab or protected against the environment, the
protection shall be designed and executed so as to safeguard the intended function under expected and
intended conditions.
4.4.3 Electrical connections
Electric wires and cables used to connect components in electric circuits shall be marked and identified, using
ISO 9247 as guidance.
This requirement does not apply to electrical circuits used for anti-theft systems, when fitted.
4.4.4 Over-current protective devices
Electric equipment, except the starter motor, alternator and combustion pre-heater, shall be protected by an
over-current device (e.g. fuse) or other device giving the same protection.
8 © ISO 2012 – All rights reserved

4.4.5 Batteries
Batteries shall be securely mounted in a ventilated location that provides access for maintenance.
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.
Electrically energized wires and cables (not connected to the frame) and connectors shall be covered with
insulation material.
4.4.6 Battery disconnection
It shall be possible to disconnect batteries quickly, e.g. by a quick coupling or an accessible isolator switch.
Symbol 2063 of ISO 7000 may be used for identification.
4.5 Controls
4.5.1 General
The controls (hand levers, joysticks, pedals, switches, etc.) and indicators of the truck and attachment shall
be as follows:
a) easy to access from the operator’s position;
b) clearly identified, indelible and visible in the operator’s station; if appropriate, graphical symbols in
accordance with ISO 7000 may be used and shall be described in the operator’s manual (see 6.2);
c) designed such that movement of the controls to activate the functions and indicators corresponds to the
intended effect or common practice whenever possible.
For safety-related functions of the control system(s), the principles outlined in ISO 13849-1 shall be followed,
or methods providing similar protection shall be applied. See also 4.4.1.
Remote-operator-controlled systems fitted to the truck shall comply with the relevant provisions of ISO 15817,
using ISO 6682 and ISO 10968 as guidance.
4.5.1.1 Multiple operating positions
If more than one operating position is fitted, the use of the controls at one operating position shall preclude the use
of the controls at others, except for the emergency stop, which shall be operable from all active operating positions.
The emergency stop shall comply with ISO 13850.
4.5.1.2 Controls of trucks accessible from ground level
Where controls are accessible from the ground, means shall be provided to minimize the possibility of actuating
them from the ground (e.g. protection by door, guard or by interlocking devices).
4.5.1.3 Inadvertent activation
Controls that can cause a hazard due to inadvertent activation when the operator gets into or out of the normal
operator position shall be so arranged, deactivated or guarded as to minimize the risk. A deactivation device
shall either be self-acting or acting by compulsory activation of the relevant device.
4.5.2 Differential locking
If the truck is equipped with a pedal-operated differential lock, depressing the pedal shall lock the differential.
If the truck is equipped with a differential lock that is engaged by other means (e.g. switch or hand lever), the
engaged and disengaged positions shall be clearly marked.
4.5.3 Steering controls
4.5.3.1 Steering direction
4.5.3.1.1 On 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.
4.5.3.1.2 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 it is travelling in the reverse direction.
4.5.3.1.3 On trucks on 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.
4.5.3.1.4 On trucks with reversible control unit or dual controls, the requirements of 4.5.3.1.1 and 4.5.3.1.2
shall be met when the operator is facing in the intended direction of forward travel.
4.5.3.2 Failure of power supply
For trucks with a maximum speed of ≤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.
Trucks with a maximum speed greater than 20 km/h shall meet the following requirements.
a) 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.
b) In order to verify compliance with the requirement in a), the truck shall describe a spiral movement at
a speed of 10 km/h, starting from the straight ahead position, on a dry, flat road surface offering good
tyre adhesion. The steering effort on the steering control shall be noted until it reaches the position
corresponding to the truck entering a turning circle of 12 m radius. 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 truck shall be tested at its operating mass according to ISO 6016:2008, 3.2.1,
with the attachment approved by the manufacturer that produces the greatest load on the steered axle(s).
4.5.3.3 Strength of components
The steering control and its support members shall be capable of withstanding a force of 900 N in any direction
at the actuating means (e.g. steering wheel) without any functional damage or permanent deformation.
4.5.3.4 Steering knobs
Steering knobs (if installed) shall be capable of being reached by the operator’s hand from the top, and shall be
within the periphery of the steering wheel.
Steering knobs shall meet the requirements of 4.5.3.3.
10 © ISO 2012 – All rights reserved

4.5.4 Load-handling controls
4.5.4.1 General
Controls shall return to neutral when released and shall stop load movements, except where otherwise specified
in this part of ISO 10896.
The controls for the load-handling functions shall be separate from the driving controls, except the travel
direction control, which may or may not be separate.
4.5.4.2 Controls with detents or maintained engagement
4.5.4.2.1 General
The boom float control and the auxiliary hydraulic control(s) (e.g. for concrete mixers, brooms, augers) may be
equipped with detents or other devices to maintain engagement of the function.
A visual indication that the detent is activated shall be provided to the operator.
The detent mode shall either
a) be automatically deactivated when the truck is switched off and not be automatically activated when the
truck is switched on, or
b) prevent the truck from being restarted until the detent mode is deactivated.
4.5.4.2.2 Boom float control
On trucks equipped with boom float control, unintended lowering of the boom shall be protected against.
In addition to the provisions of 4.5.4.2.1, the boom float control mode shall be automatically deactivated when
the boom-raising/-lowering control is operated.
4.5.5 Multi-function controls
If a control is designed to perform more than one function, each separate function shall be clearly identified in
accordance with ISO 7000 in the operator’s station and explained in the operator’s manual (see 6.2).
Visual indication shall be provided to inform the operator of the selected mode(s) of operation.
4.5.6 Stabilizing device control
On trucks equipped with stabilizing devices, controls for deployment and retraction of such devices shall be
clearly marked in accordance with ISO 7000.
Where independent or selectable controls for stabilizing devices are provided, the left control shall operate the
left stabilizing device, and the right control shall operate the right stabilizing device.
If selectable controls are provided, a middle position may operate both stabilizing devices.
4.5.7 Sway/levelling control
On 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.
4.5.8 Axle oscillation lock control
On trucks equipped with a manual axle oscillation lock, the lock/unlock control(s) shall be clearly marked in
accordance with ISO 7000.
4.5.9 Auxiliary hydraulic control
On trucks equipped with auxiliary hydraulic control, this control shall be clearly marked in accordance with ISO 7000.
The control may be equipped with a detent or other device to maintain engagement of the function. See 4.5.4.2.
4.6 Power systems and accessories
4.6.1 Exhaust systems
Exhaust systems shall be designed to direct engine exhaust emissions away from the normal operating position(s)
and any passenger position(s). Materials used in the vicinity of an exhaust system shall be non-flammable and
shall be chosen and protected so that they are not adversely affected by heat from the exhaust system.
4.6.2 Cooling systems
Cooling systems shall be designed to prevent air flow through the system from being directed at the operator
and any passenger position(s), or so that the operator and passenger(s) are shielded from airflow through
the system. The surface temperature of any shielding shall not exceed 60 °C adjacent to the operator and
passenger position(s).
4.6.3 Tanks and pressure vessels
4.6.3.1 General
Fuel and hydraulic tanks shall be provided with fluid level indicators. Pressure in the tanks exceeding the
pressure specified by the manufacturer shall be automatically compensated by a suitable device (vent, safety
valve, etc.).
4.6.3.2 Filler openings
Filler openings of tanks (except window washer and brake fluid reservoirs) shall
a) have provisions for lockable filler caps (filler caps located inside lockable compartments, e.g. the engine
compartment, or those caps that can only be opened with a special tool, do not require a lockable
provision), and
b) be located outside the operator’s station.
4.6.3.3 Fuel tanks
Fuel tanks shall be securely mounted. The installation arrangement and construction shall ensure that any fuel
leaking from the tank, its filler or its connections shall not collect in pools without a passive means for drainage
and shall not drain onto unprotected electrical or hot parts.
If the tank is to contain gasoline, the tank installation shall be designed and installed in the truck such that any
ignition hazard due to static electricity is avoided.
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.
3)
Fuel tanks shall withstand an internal pressure of 0,03 MPa (0,3 bar)
without permanent deformation or leakage.
Fuel spillage shall not be possible during normal operating conditions, as specified by the manufacturer,
excluding refuelling and fuel filter replacement.
If constructed with non-metallic materials, the fuel tank shall comply with ISO 21507.
2 2
3) 1 bar = 0,1 MPa = 0,1 N/mm = 105 N/m .
12 © ISO 2012 – All rights reserved

4.6.3.4 Air pressure vessels
Simple air pressure vessels shall be designed and tested in accordance with ISO 16528-1 and ISO 16528-2.
4.7 Stabilizing devices
When stabilizing devices are provided,
a) they shall be fitted with interlocking devices, e.g. load holding valves, to keep them in position in case of
hose failure or oil leakage,
b) means shall be provided to the operator to ensure that the stabilizing devices are positioned in a safe
travelling position when moving the truck,
c) each stabilizing device shall be equipped with a footplate that is self-aligning in at least one plane, and
d) an indication shall be given to the operator (sensors, painted marks, etc.) when each horizontally extendable
stabilizing device is extended to level and/or supports the truck in conformity with the load chart(s).
4.8 Design requirements for maintenance purposes
4.8.1 General
Trucks shall be designed such that routine lubrication and maintenance operations can be performed safely,
using ISO 11525 as guidance on the safe maintenance of trucks and ISO 2860 for openings intended for
maintenance purposes.
Where the maintenance procedures described in the operator’s manual can only be performed with a component
(e.g. boom, tiltable cab) in a position that could cause injury, the component shall be mechanically secured
with a device(s) provided with, and permanently affixed to, the truck, or stored in a secure place on the truck.
4.8.2 Tiltable cab support device
When a cab is designed to be tilted for maintenance, servicing or other non-operational purpose, 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.
4.9 Systems for lifting, tilting and reaching
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, K , with the minimum values specified in Table 2. The
calculation of K shall be related to the maximum static load, Q, 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, assuming no
friction in the boom structure or lifting/reaching mechanism.
Ln×
c
K =
Qw+
where
L is the minimum breaking load for new chain;
c
n is the number of chains;
Q is the maximum static load in chains;
w is the friction load in lifting/telescoping mechanism carried by the chains.
and where L , Q and w are expressed using the same unit.
c
Pulley diameters shall follow the chain manufacturer’s recommendations.
Table 2 — Factor K
Trucks < 10 000 kg rated capacity K ≥ 5
Trucks > 10 000 kg rated capacity K ≥ 5 − 0,2 (Q − 10)
1 1
K shall never be less than 4.
Q is expressed in tonnes (t).
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 with a factor, K , of at least 6. The calculation of K shall be related to the maximum static load, Q,
2 2
that would exist in a single or in equally loaded wire ropes when the truck and boom are stationary in the least
favourable position, assuming no friction in the boom structure and in the lifting/reaching mechanism.
Ln×
wr
K =
Qw+
where
L is the minimum breaking load for new wire rope;
wr
n is the number of wire ropes;
Q is the maximum static load in wire ropes;
w is the friction load in lifting/telescoping mechanism carried by the wire ropes.
and where L , Q and w are expressed using the same unit.
wr
Pulley diameters shall follow the wire rope manufacturer’s recommendations.
4.9.2 Hydraulic system
4.9.2.1 Hydraulic circuit
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 as to minimize deterioration, sharp edges and other damage-causing
14 © ISO 2012 – All rights reserved

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.
4.9.2.2 Pressure control
Hydraulic systems shall include devices that prevent the pressures in the systems from exceeding pre-set
levels. The devices 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.
4.9.2.3 Oil purification
The hydraulic system(s) shall be continuously protected against the risk of contamination of the hydraulic oil,
e.g. by means of magnet(s), filter(s), etc.
4.9.2.4 Load holding
Means shall be provided to maintain the load in the event of leakage, a fault or interruption of the power supply,
failure in the hydraulic circuit of the load lifting, tilting, reaching, stabilizing or lateral levelling systems.
The descent of the rated load in its least favourable position shall not exceed 150 mm in 10 min with the oil in
the hydraulic system at normal working temperature.
The average forward tilting of fork carriage speed with the rated load shall not exceed 0,5° per min.
4.9.3 Maximum load-lowering speed
The maximum permissible lowering speed shall be such that in the event of a sudden stop of the lowering
means, at the maximum reach for any load zone with the specified load, the rear wheels of the truck are only
able to leave the ground momentarily and will return to the ground unassisted.
The test to be used for verifying this requirement is given in 5.4.
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 can fulfil this requirement if designed for that purpose.
4.9.5 Fork arms, attachments and attachment brackets
Fork arms, attachments and attachment brackets shall be in accordance with Annex B.
4.10 Operator’s station
4.10.1 General requirements
The normal operating position shall have space available for the operator to minimize the potential for interior
impact during normal operation, using ISO 3411 as guidance.
4.10.2 Storage of operator’s manual
A m
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