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इंटरनेट मानक Disclosure to Promote the Right To Information Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public. “जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न’ 5 तरफ” Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru “The Right to Information, The Right to Live” “Step Out From the Old to the New” IS 4357 (2004): Methods for Stability Testing of Fork Lift Trucks [TED 22: Transport Tractors and Trailers] “!ान $ एक न’ भारत का +नम-ण” Satyanarayan Gangaram Pitroda ““IInnvveenntt aa NNeeww IInnddiiaa UUssiinngg KKnnoowwlleeddggee”” “!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता हहहहै””ै” Bhartṛhari—Nītiśatakam “Knowledge is such a treasure which cannot be stolen” IS4357:2004 Indian Standard METHODS FOR STABILITY TESTING OF FORK LIFT TRUCKS (Second Revision) ICS 53.060 @ BIS2004 BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002 oc(ober 2004 Price Group 3 Industrial Trucks Sectional Committee, TED 23 FOREWORD This Indian Standard (Second Revision) wasadopted bytheBureau ofIndian Standards, after the draft finalized bythe Industrial Trucks Sectional Committee hadbeenapproved bytheTransport Engineering Division Council. This standard was first published in 1967 and revised in 1974.This revision was undertaken to bring it in line withthe1S0 1074: 1991‘Counterbalanced fork lifttrucks—Stability tests’ issuedbyInternational Organization for Standardization. Inthis revision the following technical changes have been incorporated: a) Rated capacity of fork lift trucks enhanced from 10000 kgto 50000 kg. b) Table of tests for longitudinal stability and lateral stability had been modified for rated capacity up to 50000 kg (see Table 3). c) Table for test load dimensions had been made upto Q>10000 kg (seeTable 1). d) New table for height of blocks has been included (see Table 2). e) Three new diagrams are included for stability tests for trucks with attachments. This revision compiles the latest information and includes additional clause covering the current day practice in stability testing of fork lift trucks. With thetrend towards assistance toman-power inthehandling ofmaterials, the useofmechanical handling aids has greatly increased. Among the mechanical handling aids, the fork lift trucks intheir various forms play an important role. The safe use of such trucks under all conditions of operations depends to a large extent on the margins of stability that are designed intothe trucks inorder to meet various operational requirements. The composition of the Committee responsible for formulation ofthis standard isgiven inAnnex A. For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with 1S2 : 1960 ‘Rules for rounding off numerical values (revised)’. The number of significant places retained inthe rounded off value should be same asthat ofthe specified value inthis standard. IS 4357:2004 Indian Standard METHODS FOR STABILITY TESTING OF FORK LIFT TRUCKS (Second Revision) 1 SCOPE whenreasonably andappropriately used,undernormal operating conditions: 1.1 This standard specifies basic tests to verify the stability of counterbalanced fork lifttrucks. Itapplies a) Stackingwiththemastapproximately vertical tocounterbalanced fork lifttrucks withtiltable ornon- and the fork arms reasonably horizontal on tiltable masts, whether rider-controlled or with a substantially firm,smooth, levelandprepared separate operator, ofrated capacity uptoandincluding surfaces; 50000 kg. Italsoapplies totrucks operating under the b) Traveling with the mast or fork arms tilted same conditions when equipped with load-handling rearwards and the load in the lowered attachments. (traveling) position on substantially firm, 1.2 This standard does not apply to trucks with smooth and prepared surfaces; and retractable devices such as a mast or fork, or when c) Operating with the load centre of gravity on handling suspended loads which may swing freely. the longitudinal centre-plane of the truck. 2 REFERENCES 4.2 Operating Conditions Other than Normal The following standards contain provisions, which Whentheoperating conditions differ fromthose stated through reference inthis text, constitute provisions of in4.1, itisnecessary to use either: this standard. At the time of publication the editions a) A truck complying with other Standard(s) indicated were valid. All standards are subject to covering the different specific conditions in revision and parties to agreements based on this accordance with IS 7552; or standard are encouraged to investigate the possibility of applying the most recent editions of the standards b) Atruck, the stability ofwhich isagreed upon indicated below: betweenthepurchaserandmanufacturer. This agreed stability shall not be less than that 1SNo. Titl e required by the tests specified for normal 4660:1993 Powered industrial truck — operating conditions in4.1. Terminology (third revision) 5 STABILITY TESTS FOR FORK LIIT TRUCKS 7552:2003 Industrial trucks operating inspecial conditions of stacking with mast 5.1 Test Requirements tilted forward—Additional stability The stability ofthesetrucks shallbeverified bymeans test (firsretvision) of one of the procedures described below. For trucks 11113:1999 Earth-moving machine~ andtractors with a rated capacity up to and including 10000 kg, and machinery for agriculture and thetilting platform testshallbeusedtoverify stability forestry — Seat index point (second inthe event of adispute. revision) 5.2 Verification Procedure 3 TERMINOLOGY 5.2.1 Tilting Platform For the purpose of this standard the terms and Atestplatform which canbetilted about onesideshall definitions given inIS 4660 shall apply. beused. Atruck being tested for stability isplaced on 4 CONDITIONS OF VALIDITY the initially horizontal testplatform, inthe conditions specified in 5.3 and successively, in each of the 4.1 Normal Operating Conditions positions described in Table 3. In each of these tests, The basic tests specified in this standard ensure that the test platform shall be tilted slowly to the slope such a lift truck demonstrates satisfactory stability indicated inTable 3.The truck isconsidered stable if 1 IS 4357:2004 itpasses alltestswithout overturning. Forthepurpose b) FortestsNo.3and4,thetruck shallbeplaced of these tests, overturning is defined as the test onthetestplatform inaturning position with platform slope value which, ifincreased, would cause line A4Nparallel to the tilt axis, XYof the overturningofthetruck. Itispermissible inlateraltests test platform. In Fig. 8, 9 and 10, the steer for oneofthe loadwheels to losecontact with the test wheel nearest tothetilt axis shall beparallel platform and it isacceptable for parts ofthe structure with it. or other designed features to make contact with the c) Lateral stability tests shall be conducted to test platform. the side ofthe truck which is less stable. d) Point N is the centre point of the area of 5.2.2 Fixed Slope contact between thetestplatform surface and Fixed slopes, with inclinations equivalent to the the front wheel nearest the tilting axis prescribed test slope, shall beused. The slope surface (see Fig. 8,9 and 10). shall be smooth and capable of supporting the truck e) Point Misdefined asfollows: mass with no deformation likely to affect the test 1) For trucks having an articulated steering results. The truck under test shall be driven onto the axle: The projection onthe test platform fixed slopes with mast lowered and positioned of the intersection of the longitudinal according to Table 3. For each of the laden truck centre-plane AB ofthetruck with theaxis positions, the load shall be elevated slowly and ofthis axle (see Fig. 8); smoothly to the height indicated inTable 3. 2) For trucks steered by a single swiveling 5.2.3 Calculation wheel: The centre point of the tread contact areabetween the steerwheel and Compliance with the specified values may be the test platform surface (see Fig. 9); determined by calculation. Such calculated capacities shalItake into account manufacturing variations and 3) For trucks steered by twin swiveling deflections ofmast, tyres, etc. wheels: The centre point of the tread contact area between the steer wheel 5.3 Test Conditions nearer to the axis of tiltXY,and the test platform surface (see Fig. 10);and 5.3.1 Condition of Truck 4) For trucks having steer wheels not The tests shall be carried out on an operational truck. connected by acommon axle, but which The operator on rider-controlled trucks shall be are arranged to articulate about the simulated by an object having a mass of 90 kg, ifthe longitudinal center-plane ofthetruck, the stability during atest isthereby decreased. Foratruck projection on the test platform of the designed for operation with a standing operator, an intersection of the longitudinal center- object having amass of90kgshal lbesecured with its plane of the truck, AB, with a line CD centre of gravity 1000 mm above the floor of the (see Fig. 8) connecting the vertical operator’s platform at the centre of the position turning axes ofthe steer wheels. normally occupied by the operator. For a truck 5.3.3 Test Load designed for operation with a seated operator, the centre of gravity of the object shall be secured 150 The test load shall have a mass equivalent to the mm above the seat index point (SIP) asdetermined in maximum load, Q, which the truck can elevate to its accordance with IS 11113,withtheseatatthemidpoint maximum lift height acting through the centre of of the adjustments provided. Fuel tanks of internal gravity, G, nominally positioned at the standard load combustion engine trucks shall be full, if stability is centredistance,D, asindicatedontheinformation plate thereby decreased. All other tanks shall be tilled to of the truck both horizontally from the front face of their correct operating levels,asapplicable. Tyresshall the fork arm shank and vertically from the upper face be inflated to the pressure specified by the truck of the fork arm blade. When additional lift heights, manufacturer. loads and load centre distances areto be indicated on the information plate, the truck shall meet the 5.3.2 Position of Truck on Platform requirements established bythe tests specified inthis a) For tests No. 1and 2(see Table 3),the truck standard for these additional ratings. The centre of shall be placed on the test platform so that gravity, G,ofthetest load (seeFig. 1)shall be located the load axle isparallel tothetilt axis,XY,of in the longitudinal centre-plane, AB, of the truck the test platform (see Fig. 7). (see Fig. 7,8,9, 10 and Table 1). 2 -..— IS 4357:2004 D be increased, ifnecessary by an appropriate friction- t-- -+ increasing material. 5.3.5 Position of Front Face ofFork Arm Shank Test No. 1 shall be conducted with the horizontal A:G A position of load datum point (for example, point E) unchanged when elevated from its lowered position Q 3 [see Fig. 2(c)]. By means of a plumb-line or other ) suitable equipment, set the mast vertical. Elevate the fork andtheprescribed test loadto 300 mm above the testplatform. Withthefront faceofthe fork arm shank vertical, establish apoi’nt,E [see Fig.2(a)] onthe fork t orfork carrier having afixed relationship to the centre (2 ofgravity ofthetestload,G(seeFig. 1).Thispoint, E, shall be used to provide a reference datum, F, on the FIG. 1TEST LOAD testplatform [seeFig.2(a)]. when themastiselevated, Table 1 Standard Load Centre Distance a new point, F,, on the test platform may occur [seeFig. 2(b)], by the following adjustments this new (Foreword and Clause 5.3.3) point, F] canbe returned to the original location of F N Load Load Centre Distance [see Fig.’2(c)]. No. Q D 5.3.5.1 Fortrucks with tiltable masts, changes inthe kg mm location ofFI shall be corrected by varying the tilt of (1) (2) (3) the mast within the limits provided by the design of i) Q< IOOO 400 the truck. ii) 1000< Qs4999 500 iii) 5OOO<QS1OOOO 600 5.3.5.2 Fortrucks with fixed masts, adjustments inthe iv) Q> 10000 600or fork arms orfork carrier tilt (where provided) maybe 900 or usedtocorrectforchangesinlocationofpointF1within 1200 or the limits oftilt provided by the design ofthe truck. 1500 5.3.5.3 Fortruckshavingnon-tiltable masts,fork arms, 5.3.4 Location of Truck on Test Platform or fork carrier, adjustments cannot be made. The initial position of the truck on the test platform 5.3.6 Lij Height for Tests Simulating Trmel shall be maintained during each test. This may be achieved by application of park i ng or service brakes, For tests simulating travel, that is,tests No. 2 and 4, which can be secured in the ‘on ’ position, or by the upper face of the fork arms, measured at the heel ofthe fork arm, shall be positioned 300 mm from the wedging the wheels against the truck frame, ensuring test platform. however that articulation is not affected. Blocks (chocks) having amaximum height not exceeding the 5.3.7 Safety Precautions value indicated in Table 2may be used, if necessary, Precautions shall be taken to prevent the overturning to maintain the initial position of the truck onthe test ofthetruck ordisplacement ofthetest load during the platform. Blocks (chocks), ifused, shallnotartificially course ofthetest. Ifthe means forpreventing thetotal improve stability (see Table 2). overturing ofthetruck consist ofrope lashing orchain, thisshallbesufficiently slacktoimposenoappreciable Table 2 Height of Blocks restriction on the truck until the overturning point is (Foreword and Clause 5.3.4) reached. Alldimensions inmillimetres, Displacement of the test load shall be prevented by SI Tyre Outside Height ofBlocks means such as: No. Diameter, d (Chocks) Max a) Firmlysecuringthetestloadtotheloadcarrier (1) (2) (3) orequivalent structure; and i) d s 25o 25 b) Suspending thetestloadneartheground from ii) d <250 0.1d anappropriate support placed on the fork so thatthesuspension point isatthe point where Thecoefficient offriction oftheplatform surfacemay thecentre ofgravity, G,ofthetestloadwould 3 IS 4357:2004 be, ifthetest load were to beplaced on the fork. 6 STABILITY TESTS FOR TRUCKS WITH ATTACHMENTS 6.1Trucks fitted withattachments otherthanforkarms shall be subjected tothe same stability tests, except in cases where the attachment can bring the centre of gravity ofthe loadoutofthe longitudinal centre-pkme, (a) All, of the truck [see4.1(c)]. 6.2Forverification ofthevertical position ofthemast, a reference point having a fixed relationship to the centre of gravity of the test load, G (see Fig. 1)shall be chosen. 6.3 The test load shall be the specified load, at the specified load centre distance indicated for the attachment when used on the truck being tested. 6.4 The fork litl height specified for the tests shall be measured between the test platform surface and the underside of the load or the attachment, whichever is the lower. (b) F (c) FIG. 2 POSITIONOFLOAD DATUM POINTINRELATION TOTEST LOAD Table 3 Summary of Tests (Foreword &d Clauses 5.2.1,5.2.2 and 5.3.2) ., ,.. U ‘)v=maximumspeedofunladentruck,inkm/ii. No0 * .A-