VSB6 Section R - Vehicle Mounted Lifting Systems

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ContentsSection R — Overview1. Description2. Related Australian Design Rules3. Record keeping4. Types of VMLS5. Design requirements222222Modification Code R1 — Installation of vehicle mounted lifting systems 31. Scope32. Related standards33. Certification procedure34. Compliance requirements35. Design requirements46. Installation requirements57. Testing requirements8R1 Checklist — Installation of vehicle mounted lifting systems(example)9R1 Assessment report — Vehicle mounted lifting systems (example)11Modification Code R2 — Wheelchair loader installation1. Scope2. Related standards3. Certification procedure4. Compliance requirements5. Design requirements6. Installation requirementsR2 Checklist — Wheelchair loader installation (example)1313131313131416

Section R — Overview1. DescriptionThis section of Vehicle Standards Bulletin 6 (VSB6) relates to thefitting of vehicle mounted lifting systems (VMLS) and ofwheelchair loaders.VMLS covered by this section include but are not limited to: vehicle mounted cranes with a rated capacity between 1 mtand 150 mt, including slewing and non-slewing systems elevating platforms concrete pump assemblies hook lifts side lifts side or rear operated platform loaders wheelchair loaders.It does not cover the fitting of lifting systems designed to tow ortransport vehicles (except where a VMLS is intended for all-upoperation) which must be installed and certified in accordancewith VSB6 Section T — Tow trucks.This section consists of the following modification codes:R1 Installation of vehicle mounted lifting systems reinforcement of a vehicle chassis for the purpose offitting a VMLS installation of a VMLS certified as complying with therequirements of Australian Standard AS/NZS 1418 Cranes,hoists and winches installation of a type of VMLS where there is no AustralianStandard, but where the system and installation complieswith all relevant sections of this code.R2 Wheelchair loader installation installation of a wheelchair loader designed for automotiveuse.2. Related Australian Design RulesThe Australian Design Rules (ADRs) relevant to this sectioninclude:ADR no.13/.14/.TitleInstallation of Lighting and Light-SignallingDevices on Other than L-Group VehiclesRear Vision Mirrors42/.43/.58/.General Safety RequirementsVehicle Configuration & DimensionsRequirements for Omnibuses Designed for Hireand Reward62/.AS/NZS 1418AS/NZS1418.11Mechanical Connections Between VehiclesCranes, hoists and winches SetCranes, hoists and winches — Part 11: Vehicleloading cranesHoists and ramps for people with disabilities —Vehicle-mountedAS/NZS 38563. Record keepingThe person responsible for certifying the modification should: collate complete records, including drawings, calculations, testresults and copies of the appropriate issue of AustralianStandards and ADRs retain the records for a minimum of seven years after thecommissioning of the modified vehicle make the records available upon request for inspection byofficers of the relevant federal, state or territory authority orheavy vehicle regulator.Vehicle Standards Bulletin 6 — Version 3.1Section R — Vehicle mounted lifting systemsReports and checklistsThe person responsible for certifying the modification mustcomplete and record the following reports and checklists asapplicable:R1 ChecklistInstallation of vehicle mounted liftingsystemsR1 AssessmentReportR2 ChecklistVehicle mounted lifting systemsWheelchair loader installation4. Types of VMLSThere are two types of VMLS that may be fitted to a vehicle:VMLS for which there is an Australian Standard There are Australian Standards that apply to the design,construction and installation of many common types of VMLS.For example, vehicle mounted slewing cranes are providedfor by Australian Standard AS/NZS 1418 and can only be fittedif they comply with that standard.VMLS for which there is not an Australian Standard For some types of VMLS there is no Australian Standard thatapplies. For example, hook bin lift devices are a type of VMLS that arenot provided for by any Australian Standard. A hook bin liftsystem may be installed to a vehicle only if the system, and itsinstallation, complies with the requirements of this section ofVSB6.5. Design requirementsAdvanced braking systemsAdvanced braking systems are an important safety feature fittedto many new vehicles.Advanced braking systems are programmed by the vehiclemanufacturer and are specific to the vehicle to which they arefitted. Changes made to the vehicle, such as engine, tyre size,steering control, suspension characteristics, vehicle mass and itsdistribution, may impact the performance of the advancedbraking system.Exercise extra caution when modifying vehicles fitted withadvanced braking systems. Electric braking systems may beknown as: electronic stability control (ESC) electronic stability program (ESP) vehicle stability control (VSC) dynamic stability control (DSC) vehicle stability assist (VSA) roll stability control (RSC) roll control system (RCS) electronic braking system (EBS) trailer electronic braking system (TEBS). Advanced braking systems and their components may be easilydamaged by common modification, maintenance and servicingtechniques, such as the use of rattle guns within one metre of thesensors. When undertaking any work on a vehicle fitted with anadvanced braking system, ensure all modifiers are familiar withthese systems and the precautions that must be taken.Ensure that before undertaking any modification on a vehicle thatis fitted with an advanced braking system the modifier andapproved vehicle examiner (AVE) consult with the vehiclemanufacturer to determine the impact on the system.2 of 16

Modification Code R1 — Installation of vehicle mounted lifting systemsThis modification code covers installation of VMLS such ascranes, elevating platforms, concrete pump assemblies, hooklifts, skip bin loaders, side lifts, hoists and winches to a vehicle.Modifications covered under this code:Covered reinforcement of a vehicle chassis for the purpose of fitting aVMLS installation of a VMLS certified as complying with therequirements of AS/NZS 1418 Cranes, hoists and winches installation of a type of VMLS where there is no AustralianStandard, but where the system and installation complieswith all relevant sections of this code.Not covered cutting of the chassis to facilitate the installation of a VMLS(see VSB6 Section H — Chassis) installation of a type of VMLS for which there is an AustralianStandard, but the system and installation does not complywith the standard installation of a type of VMLS for which there is not anAustralian Standard, and where the system and installationdoes not comply with this code fitting equipment that is not suitable for automotive use installation of a body (see VSB6 Section J — Body) conversion of a motor vehicle into a dedicated self-propelledmobile crane (specific modification application to the relevantheavy vehicle regulator required).2. Related standardsModified vehicles must comply with all ADRs, AustralianStandards, acts and regulations. Below are some but not all ofthe areas that may be affected by the modifications in this codeand require certification testing or evidence to demonstratecompliance.The certifier must ensure that the modified vehicle continues tocomply with all related Australian Design Rules.This Chassis alterationsPower take-off fittingRemounting of bodyPerform inspection, complete R1 checklist anddetermine if compliance has been achieved: If yes, proceed to step 6. If no, do not proceed, advise modifier rework isrequired to ensure compliance. Return to step 2.Issue modification certificate, affix modification6. R1 AVEplate, and submit paperwork as required by therelevant AVE registration scheme.AVEs must be satisfied that the vehicle modificationrequirements are being met. It is advised that beforemodifications are carried out they are discussed with thecertifying AVE.5. R1 AVE1. ScopeMust comply with VSB6 Modification Code H4VSB6 Modification Code G6VSB6 Modification Code J13. Certification procedureThe certification procedure for this modification code is asfollows:1. Modifier Determine if the modification is withinmanufacturer specifications. If yes, the modification will need to be done inaccordance with manufacturer specifications. If no, the modification will need to be done inaccordance with this modification code.2. Modifier Consult with an accredited R1 AVE for guidanceon how to perform the modification.3. Modifier Perform modification in accordance with AVEadvice and this code.4. Modifier Organise approval inspection by an accreditedR1 AVE.Vehicle Standards Bulletin 6 — Version 3.1Section R — Vehicle mounted lifting systems4. Compliance requirementsRequired: Where an Australian Standard exists, ensure all systems ofthat type comply with the relevant Australian Standard as wellas VSB6 Section R requirements. Where an Australian Standard does not exist, therequirements of VSB6 Section R apply and the VMLS is to befully tested, evaluated and certified as appropriate for theapplication. If the requirements of the Australian Standard and this sectionare inconsistent, the requirements of the Australian Standardtake precedence. Ensure all vehicles having a VMLS with a capacity of between1 mt and 150 mt installed, are modified and certified inaccordance with this modification code. Ensure all vehicles being modified with a VMLS are modifiedand certified in accordance with this modification code. Ensure a VMLS is certified to the relevant Australian standard(if applicable), by a professional engineer registered with aprofessional engineer registration body, or by a certificateissued by the VMLS manufacturer. AS/NZS 1418.11 – 2014 is a modified version of EuropeanStandard EN 12999:2011. As such, VMLS certified to theEuropean Standard are likely to be equivalent to an AS/NZS1418.11 crane but may require modifications.If a type of VMLS is not coved by AS/NZS 1418, for example binhook lifts, install the VMLS in accordance with thismodification code, including stability requirements, vehicleloading, attachment to the chassis and testing. Do not modify the VMLS platform, linkages or structurewithout written approval of the lifting system manufacturer. Additional requirements applicable to the modificationscertifiable under this code may be found within the relevantparts of AS/NZS 1418, including Part 11. Obtaining a copy ofthe relevant parts of these Australian Standards is stronglyrecommended. Ensure all modifications made to the vehicle are performedand certified in accordance with the relevant modificationcode/s of VSB6.Recommended: Before starting modifications consult with the vehicle, bodyand VMLS manufacturers or suppliers to establish suitability ofthe vehicle for the selected loader type, capacity and size. For VMLS manufactured outside of Australia and not built inaccordance with AS/NZS 1418, ensure that it providesequivalent or superior results to AS/NZS 1418 if it is coveredby AS/NZS 1418. Note that VMLS may be required to comply with additionalrequirements outside of VSB6 such as registration withworkplace health and safety regulators.3 of 16

Modification Code R15. Design requirementsRecommended: Fit all other types of VMLS that are not platform type to theleft or the rear of the vehicle. For operator safety, install external vehicle mounted controlson the left or rear of the vehicle.Recommended: Consult the vehicle manufacturer’s manual or VMLSinstructions as the first source of information for modifyingthe vehicle. If possible, use the standard manufacturer’smountings and method of attachment. If these are unavailable then, prior to installation, usecalculations to ensure that the vehicle has sufficient chassisreinforcement within the chassis design limits to withstand theload moment induced by all dynamic forces imposed duringoperation.Load distribution requirementsFor most vehicles, guidelines for the installation of VMLS will beavailable from the VMLS or vehicle manufacturer. Wheremanufacturers guidelines have been produced, ensure that theinstallation complies with these guidelines rather than VSB6.Mass and dimensions requirementsRequired: Ensure that all equipment, when not deployed, does notprotrude from the vehicle and thereby increase risk of injury. If an object protrudes from the vehicle but is technicallyessential, ensure it is designed, positioned and constructed soas to minimise risk of injury. When not in operation, ensure that no part of the VMLS andassociated components protrudes more than 150 mm past thevehicle’s outer extremity on either side and the maximumoverall width does not exceed regulatory limits. If a VMLS or associated component protrudes more than150 mm either side of the vehicle, and is less than 500 mmthick from top to bottom, ensure the vehicle has: a warning light attached to the vehicle a delineator attached to the front and rear of the projectionon each side of the vehicle so that its reflective surface isfacing forward for the front delineator and rearwards forthe rear delineator. A delineator is a yellow, rigid piece of material that is atleast 300 mm long and at least 300 mm wide; andcomplies with Class 400 or 2 of Australian Standard AS1906 Retro-reflective Materials and Devices for RoadTraffic. Ensure all regulations concerning mass and dimension arecomplied with. If an installation results in a vehicle’s dimensions exceedingregulatory limits, do not perform or certify the installationusing this section of VSB6. For modifications where mass or dimension limits areexceeded, seek modification approval from the relevant heavyvehicle regulator before starting work. The regulator will likelyrequire the installation to comply with this section.Recommended: Ensure the rear departure angle of the vehicle with the liftingsystem fitted is not less than 11 degrees.Before any VMLS is mounted on to a vehicle, a weightdistribution calculation is required to: Ensure that axles will not be overloaded by the fitting. Establish the available payload at which both stability andloading limitations are met.Required: Perform load distribution as outlined in VSB6 Section H —Overview ‘calculations’ to verify that, with the vehicle in anyload condition and with the loader in its non-operating (travel)position, the minimum front axle load is suitable to alloweffective steering and braking. Ensure that adequate front axle loads are maintained toprovide effective steering and braking. If this information isnot available from the vehicle manufacturer, consult with aqualified engineer or refer to the performance based standard(PBS) standard for steer tyre friction demand. Ensure that the location of the VMLS on the vehicle does notresult in a load on the vehicle that makes the vehicle unstableor unsafe. Ensure that when the tailgate loader is extended and atmaximum load it does not cause the chassis stress limit to beexceeded.Lights and markers requirementsRequired: Ensure all lamps and marker plates on the vehicle meetvisibility requirements of all applicable ADRs and relevantheavy vehicle standards while the vehicle is in travel mode. If the VMLS or associated components diminish the visibility ofany lamp or marker plate, restore compliance, possiblythrough fitting supplementary lamps or plates.Vehicle rating requirementsRequired: When selecting a VMLS, ensure the vehicle it will be fitted todoes not exceed any of its ratings for gross vehicle mass(GVM), axle and suspension capacity. If fitting the intended VMLS is likely to cause the vehicle toexceed any of its ratings, select a more suitable vehicle orupgrade it in accordance with VSB6 Section S — Vehicle ratingbefore installing and certifying the VMLS. When assessing if the vehicle is likely to exceed any of itsratings, take into consideration capacity to carry goods.VMLS locationRequired: Install all non-slewing platform type VMLS (for example,tailgate loaders) at either the rear or the left side of thevehicle. Locate the VMLS to ensure adequate clearance from thevehicle's moving parts, such as axles, brakes and suspension. Ensure in-cab controls, where fitted, do not interfere with thedriver’s control of the vehicle. Ensure safety devices incorporated in the design of the liftingsystem are operational.Vehicle Standards Bulletin 6 — Version 3.1Section R — Vehicle mounted lifting systems4 of 16

Modification Code R16. Installation requirementsChassis installation requirementsRequired: Assure chassis strength for static loads, loads during liftingoperations and loads during travel by performing assessmentcalculations in accordance with VSB6 Section H — Chassis. If the chassis requires reinforcing to accommodate liftingsystem mounts, carry out the reinforcing in accordance withthe vehicle manufacturer's recommendations or VSB6 SectionH — Chassis. Do not allow the vehicle manufacturer’s maximum allowablechassis stress level to be exceeded by operation of the loaderat its nominated rated capacity. If there is no vehiclemanufacturer’s maximum allowable stress level ensure thefactor of safety (FoS) is not less than three, and is appropriatefor the installation. Install the VMLS such that it is held securely in place on thechassis or body against forces resulting from accelerationsgenerated by the motion of the vehicle of at least: 0.8 g longitudinal 0.5 g lateral 0.2 g vertical (in excess of the acceleration generated bygravity). Apply an appropriate FoS to the stresses calculated for theseforces and ensure the factored stresses do not exceed theyield strength of the materials being used. Drill chassis members to attach mounting brackets inaccordance with VSB6 Section H — Chassis.Fittings requirementsRequired: Apply an insulating compound, or other approved means toprevent corrosion due to electrolysis when components ofdissimilar metal are bolted together. Ensure additional or substitute hydraulic hoses, fittings andcomponents meet the hydraulic standard and flow/pressureratings of the existing equipment. Locate hydraulic parts and fittings away from the brakes andexhaust. Ensure all electrical and hydraulic service lines are securedadequately to prevent chafing, kinking or other mechanicaldamage under normal motion of the parts to which they areattached. Ensure all hydraulic VMLS contain burst protection that willprevent movement of any loadbearing hydraulic cylinders asrequired by AS/NZS 1418.11 in the event of hose rupture orpipe fracture. Ensure that all bolts are tightened to the manufacturer’srecommended torque, or if this is not available, the relevantAustralian Standard. Attach brackets to the chassis in front of the rearmostsuspension bracket by bolting and not by welding. Ensure the loader and all associated components canwithstand rated capacity without causing permanentdeformation or excessive deflection. Perform all chassis modifications in accordance with VSB6Section H — Chassis.Recommended: Brackets attached to the chassis forward of the last 30% of therear overhang are attached by bolting not welding. Brackets within 30% of the rear overhang are attached to thechassis with bolts at least ISO Grade 8.8 (SAE Class 5) andvibration proof self-locking nuts or by welding (see VSB6Section H — Chassis). Do not allow fastener tensile stress, induced by the VMLS loadmoment, to exceed 20% of the material yield stress.Sub-frame to chassis attachmentsIf a sub-frame is to be fitted between the VMLS and chassis tospread the load moment of the VMLS along the chassis sidemembers, the following applies:Required: Ensure that sub-frames have full continuous contact with thevehicle chassis, where the chassis fastening method inhibitsthis, ensure suitable alternative methods are used (e.g. installadditional strips of material either side of the rivets to allowfor contact with the sub-frame).Recommended: Fit th

Vehicle Standards Bulletin 6 —Version 3.1 Section R — Vehicle mounted lifting systems 2 of 16 . Section R — Overview 1. Description This section of Vehicle Standards Bulletin 6 (VSB6) relates to the fitting of vehicle mounted lifting systems (VMLS) and of wheelchair loaders. VMLS

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