Accident Prevention Manual

1

• Accident Prevention Manual
• for Business Industry
• Engineering Technology
• 13th edition
• National Safety Council

Compiled by Dr. S.D. Allen Iske, Associate
Professor University of Central Missouri
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CHAPTER 18

• POWERED INDUSTRIAL TRUCKS

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Introduction

• Factories, warehouses, docks, and transportation
  terminals use powered industrial trucks.
• They use these trucks to carry, push, pull, lift,
  stack, and tier material.
• All require the use of safeguards for the
  operators protection as well as other workers.
• Establishing safe practices for the operation,
  maintenance, and inspection of powered industrial
  trucks is essential.

4
Types of Trucks

• Powered industrial trucks may be classified by
  power sources, operator position, or means of
  engaging the load.
• Power sources include electric motors powered by
  storage batteries, engines using gasoline,
  liquefied petroleum gas, or diesel fuel, or a
  combination of gas or diesel and electricity.
• Provisions for safe operation, maintenance, and
  design should meet requirements of ANSI B 56.1.
• OSHAs standard is found at 29 CFR 1910.178.

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Rider-Controlled Trucks

• Lift trucks are rider-controlled trucks.
• They have a vertical mast, and elevating
  mechanism.
• High-lift trucks have an elevating mechanism that
  permits tiering of one load on another.
• Low-lift trucks have a mechanism that raises the
  load only enough to permit horizontal movement.

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Rider-Controlled Trucks

• Straddle carriers
• Carry long materials, such as pipe or lumber,
  under the trucks body, which rides on high legs
  above the wheels.

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Motorized Hand Truck

• These are trucks that are controlled by an
  operator who walks or rides behind it.
• They have a platform or lifting forks to engage
  the load and may be either a high-lift truck or a
  low-lift truck.

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General Safeguards

• Consider the worksite when purchasing or leasing
  industrial trucks.
• Working outdoors can call for long travel
  distances in less-than-perfect conditions.
• Operators have little control over their
  environment or situations.
• Some of the safeguards to reduce fatigue and
  strain include the following backup alarm lights
  or audible signals, headlights, turn signals,
  enhanced front and rear vision, noise reducing
  insulation, fail-safe breaks, safety belts, and
  comfortable wrap around seats.
• Offer operator-restraint systems on vehicles.

9
Requirements

• Powered industrial trucks capable of lifting
  loads higher than the operators head or when
  there is a hazard from falling objects must be
  equipped with an overhead guard.
• This guard should not interfere with visibility.
• Be sure that the openings in the guard are small
  enough to protect the operator from being struck
  by material falling from an overhead load or
  stack.
• Overhead guards extend beyond the operators
  position.
• Overhead guards should conform with ANSI/ASME
  B56.1.

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Requirements (Cont.)

• ANSI/ASME B56.1 is the standard which defines the
  safety requirements relating to the elements of
  design, operation, and maintenance of low lift
  and high lift powered industrial trucks
  controlled by a riding or walking operator, and
  intended for use on compacted, improved surfaces.
  

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Requirements (Cont.)

• Load backrest extension should be used when the
  load presents a hazard to the operator.
• The top of the load should not exceed the height
  of the backrest manufactured in accordance with
  the OSHA standard 29 CFR 1910.178.

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Requirements (Cont.)

• Guards need to be placed over the tires to
  prevent particles from being thrown at the
  operator.
• Guards need to be in place over hazardous moving
  parts such as chain-and-sprocket drives and
  exposed gears.
• Powered industrial trucks should have horns or
  other warning devices that make a distinctive
  sound that is loud enough to be heard above other
  noises.
• Backup alarms sound whenever the truck backs up.
• If noise can cause confusion, flashing lights
  mounted on overhead guards can warn employees of
  trucks.

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Requirements (Cont.)

• Powered industrial trucks must carry a name plate
  showing the weight of the truck and its rated
  capacity as specified by ANSI/ASME B56.1.
• Specifications of steering, braking, and other
  controls should conform to ANSI B56.1.
• Trucks should also be constructed and equipped to
  comply with Underwriters Laboratories Standard
  for Safety, No. 558 and 583.

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Industrial Trucks in Hazardous Locations

• Trucks, electric-or gasoline-powered, should not
  be used in hazardous locations (those with a
  flammable atmosphere) unless they comply with
  NFPA requirements or are specifically approved by
  the inspection authority for the location
  involved.
• Lift trucks should be fitted with an appropriate
  fire extinguisher, and the operator must be
  properly trained to use the extinguisher.

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Straddle Trucks

• Straddle trucks should be fitted with horns,
  warning devices, headlights, tail lamps,
  safe-access ladders, wheel guards, and
  chain-drive guards. Some require a rigid overhead
  guard to protect the operator.
• A special problem for operators is due to their
  height off the ground, which reduces their angle
  of sight and obscures the view of objects
  immediately to the front or rear.
• Use precaution toward pedestrians and attach red
  flags to the end of loads or use signal person(s)
  in congested areas.

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Crane Trucks

• Model types include those where the operator sits
  behind a small pillar-type jib crane mounted on a
  chassis, or stands on a platform and operates a
  fully or partly rotating crane, or fixed boom so
  the entire rig must be moved to make side
  motions.
• Operators should drive a crane carrying a load at
  the lowest possible speed and the load as low as
  possible.
• Use a helper who can hook on the load and give
  signals. Tag lines may be needed for long loads.
• When traveling without a load, secure the boom to
  prevent swinging.

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Motorized Hand Trucks

• Principal hazards a) the operator may be pinned
  between the truck and a fixed object and b) the
  truck may run up the operators heels.
• When a truck is driven close to a wall or other
  obstruction, down an incline, or onto an
  elevator, operators should put the truck in
  reverse and walk behind it facing the direction
  of travel.
• Guards are required for steering handles to
  prevent operators hand or the controls from
  contacting obstacles.
• Apply brakes when the handle is in the fully
  raised or lowered position.

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Automated Guided Vehicles (AGV)

• AGVs do not require an operator so they must be
  provided with some means to stop completely
  should someone step in front of unit.
• Equipped with a sensor. If triggered, the truck
  applies the brake and shuts off the power.
• Using AGV, aisles must be clearly marked and
  clear of materials.
• Forbid employees from riding on these units.
• Do not load or unload when the unit is in motion.
• Protect employees from pinch points while in use.

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General Operating Principles

• Operators of powered industrial trucks can
  prevent traffic accidents by using the same safe
  practices that apply to highway traffic.
• Operators should observe rules regarding speed,
  maneuvering, and loading and unloading other
  vehicles.
• Operators should consider their own safety and
  the safety of other workers and equipment when
  using a powered industrial truck.

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Speed

• Excessive speed can lead to accidents both in the
  facility and on the road.
• Safe speed is the rate of travel that will permit
  the truck to stop well within the clear distance
  ahead or to make a turn without overturning.
• Post speed limits in the facility or have
  governors installed to control vehicle speed.
• Operators should avoid making quick starts, jerky
  stops, or quick turns. Never use reverse control
  for braking.
• Operators should keep trucks at a safe distance
  apart during operations some specify three truck
  lengths.

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Elevators, Bridge Plates, and Railroad Tracks

• Drivers should not drive trucks onto elevators
  unless they have been authorized to do so.
• Powered industrial trucks should be driven
  carefully and slowly over bridge plates that are
  properly secured.
• Trucks should cross railroad tracks diagonally
  whenever possible and park at least 8 ft from the
  centerline of the tracks.

22
Loading and Unloading

• Highway trucks, trailers, and railroad cars
  should have their brakes set and their wheels
  securely blocked while they are being loaded and
  unloaded by a powered industrial trucks.
• Before entering a trailer, operators should make
  sure that the wheel chocks are squarely placed in
  front of the rearmost tires.
• The loads should be stacked properly and ensure
  that they are stable.
• Place heavy loads low to the ground if possible.

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Proper Care of Trucks

• Operators should not use a powered industrial
  truck for any purpose other than the one for
  which it is designed.
• Common misuses include bumping skids, pushing
  piles of material out of the way, using makeshift
  connections to move heavy objects, using the
  forks as a hoist, and moving other trucks.
• Disabled trucks should not be pushed or carried
  by another lift truck.
• Do not tow or push freight cars or operate
  freight-car doors with the trucks.

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Proper Care of Trucks (Cont.)

• Operators should leave a truck unattended only
  after the controls have been put in neutral, the
  power shut off, the brakes set, the key removed,
  the connector plug pulled and the load-engaging
  mechanism placed in a lowered and inoperative
  position.
• Never park a truck in an aisle or doorway or
  obstruct material or equipment to which another
  worker may need access.
• Do not allow the unit to operate for long periods
  of time in idle because exhaust vapors and gases
  accumulate.

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Operator and Pedestrian Safety

• Operators should keep their feet and legs inside
  the guard or inside the operating station of the
  truck.
• Operators should keep their hands from being
  pinched between steering or control levers and
  projecting object.
• Passengers must never be permitted to ride on a
  powered industrial truck coupling or trailer.
• Looking for pedestrians is also the operators
  responsibility.
• Operators should sound the horn when approaching
  pedestrians or intersections.
• Pedestrians also have a responsibility to watch
  out for trucks and to move out of the way.

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Maneuvering

• Operators should learn to judge the correct aisle
  width for the truck size and load.
• Observe the general operating safety rules
• Observe the specific rules for the lift trucks.
• All starts and stops should be easy and gradual
  to prevent the load from shifting.
• Operators should avoid striking overhead
  structures and nearby objects.
• Operators should raise or lower loads only when
  the truck is stopped

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Driving on Grades

• Trucks should ascend or descend grades slowly.
• If grades are in excess of 10, loaded trucks
  should be driven with the load toward the
  upgrade. Unloaded trucks should be operated
  toward downgrade.
• On all grades, the load and load-engaging
  mechanism should be tilted back and raised only
  enough to clear the roads surface. Low gear or
  the slowest speed should be used when truck is
  descending grade.
• Keep clear of the edge of loading docks and
  ramps. No sharp turns.

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Load Capacity

• Lift trucks are rated by capacity in pounds and
  load center in inches.
• Every operator should be familiar with the
  maximum load limits of the truck being operated
  and observe them.
• ANSI B56.1 provides more information on the
  stability of lift trucks.
• Operators should never operate an overloaded
  truck.
• Never stand on a truck or add counter weights to
  compensate for an overloaded truck.
• Never exceed floor-load limits. The force on a
  floor varies with speed, load and total weight
  distribution.

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Loading and Unloading

• When picking up a palletized load, keep the forks
  fully and squarely seated in the pallet, an equal
  distance from the center stringers and well out
  toward sides.
• When raising or lowering loads while standing
  still, never leave the truck in gear with clutch
  depressed.
• Return to neutral and disengage the clutch.
• Operators should refuse improperly loaded skids
  or pallets, broken pallets, or loads too heavy
  for the truck.
• Ensure proper identification for all chemicals
  moved.
• When truck is parked, forks should be flat on the
  floor.
• Allow no one to stand or walk under elevated
  forks.
• Employees can only be lifted with the truck if an
  approved safety work platform with guardrails and
  toeboards is secured to the forks and mast.
• Overhead guard installed.

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Inspection and Maintenance

• Maintenance personnel should thoroughly inspect
  powered industrial trucks on a regular basis and
  give them a complete overhaul after regular
  periods of operation.
• Operators should make daily inspections of
  controls, brakes, tires, and other moving parts.
• Operators must do this at the start of every
  shift.
• Operators should use a checklist to record
  conditions requiring corrections.
• Repair any defective items before trucks are
  allowed back in service.
• Prohibit operators from making repairs on trucks.

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Electric Trucks

• Battery changing and charging operations for
  electric truck must be performed only by trained
  and authorized personnel.
• Handling and charging storage batteries
  introduces several hazards.
• When charging batteries, wear goggles, rubber
  gloves, aprons, and rubber boots to protect the
  worker against acid burns.
• Use proper mats or floorboards to prevent slips
  and falls.
• Prevent open flames, sparks, or electric arcs in
  battery-charging areas.
• Protect employees with eye protection and
  adequate wash facilities if exposed to toxic
  liquids or fumes.
• Use proper handling equipment to prevent strain
  injuries to employees.

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Electric Trucks (Cont.)

• Charge batteries in areas designated for that
  purpose.
• Also provide facilities for
• flushing and neutralizing spilled electrolyte
• fire protection and extinguishment
• protecting charging apparatus from damage by
  trucks
• adequate ventilation to disperse flammable
  hydrogen gases, vapors, and fumes from batteries

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Gasoline-Operated Trucks

• Handle and store gasoline for trucks according to
  the provisions of NFPA 30, Flammable and
  Combustible Liquids Code.
• Safety cans should contain a flame-resistant,
  self-closing lid.
• Engines must be stopped and operators off trucks
  before trucks can be refueled.
• Fill tanks in open air, with the filling hose and
  equipment properly grounded and bonded.
• Before attempting to start the engine, replace
  the gas tanks cap and allow spilled fuel to
  vaporize.

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Liquefied Petroleum Gas Trucks

• Use of LP-gas as fuel for powered industrial
  trucks is increasing.
• Engines burning LPG produce lower concentrations
  of CO.
• Fittings used for refueling should be fitted
  correctly and properly tightened.
• Only listed fuel containers, designed in
  accordance with DOT or ASME standards, should be
  used.
• A special building or outside storage area is
  recommended for the storage of fuel containers.
• The person filling the containers must be trained
  to handle LP-gas safely.
• Follow a rigid and thorough inspection and
  maintenance procedure for LPG-fueled trucks.

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Operators

• Trainees should have valid drivers licenses,
  good driving records, and few, if any, traffic
  violation tickets.
• They should have good attitudes toward the
  responsibility of operating expensive, heavy,
  industrial equipment in new and difficult
  situations.
• Verify the operators previous experience, both
  off and on the job, whenever possible. Driving a
  car is not equivalent to driving a forklift.
• Fair Labor Standard Act prohibits minors under
  the age of 18 from working in occupations deemed
  hazardous.

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Selection

• Trainees should meet certain physical standards
  and should be examined by a qualified physician
  familiar with the jobs requirements.
• Minimum requirements would be 20/40 vision,
  corrected if necessary good reaction time depth
  perception of no less than 90 of normal and
  good hearing, preferably without use of hearing
  aids.
• Check their driving records off the job and on
  the job.
• Give drivers a physical examination every 2
  years.
• Operators must respect importance of training and
  safety policies and procedures.

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Training

• Persons with necessary knowledge, training, and
  experience to train powered industrial truck
  operators and evaluate their competence must
  conduct training and evaluations.
• Federal OSHA regulations state that only trained
  and authorized operators shall be permitted to
  operate a powered industrial truck.
• Operators must receive some form of powered
  industrial truck training as well as pedestrian
  safety training.
• To be effective, a training program should center
  around the companys policies, operating
  conditions and type of trucks used.
• As with any program, managements support is
  essential if the truck operators training is to
  be effective and lasting.

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Training (Cont.)

• Maintenance personnel should be involved in the
  program also.
• Other factors to consider when setting up
  training are
• who will be in charge
• the qualifications for both instructors and
  trainees
• the number and length of the sessions for both
  classroom and hands-on instruction
• the number of trainees in a class
• whether experienced operators who are taking a
  refresher course should be in the same class with
  the trainees
• how to establish and maintain a record system
  that stays current and can be used by regulatory
  officers reviewing program