Powered Industrial Trucks: Safety and Operation Guidelines

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

2. CHAPTER 18 POWERED INDUSTRIAL TRUCKS

3. 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 operator’s 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. • OSHA’s standard is found at 29 CFR 1910.178.

5. 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.

6. Rider-Controlled Trucks • Straddle carriers • Carry long materials, such as pipe or lumber, under the truck’s body, which rides on high legs above the wheels.

7. 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.

8. 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 operator’s 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 operator’s position. • Overhead guards should conform with ANSI/ASME B56.1.

10. 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.

11. 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.

12. 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.

13. 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.

14. 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.

15. 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.

16. 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.

17. 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 operator’s 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 operator’s hand or the controls from contacting obstacles. • Apply brakes when the handle is in the fully raised or lowered position.

18. 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.

19. 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.

20. 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.

21. 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.

23. 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.

24. 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.

25. 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 operator’s 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.

26. 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

27. 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 road’s 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.

28. 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.

29. 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.

30. 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.

31. 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.

32. 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

33. 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 tank’s cap and allow spilled fuel to vaporize.

34. 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.

35. Operators • Trainees should have valid driver’s 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 operator’s 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.

36. Selection • Trainees should meet certain physical standards and should be examined by a qualified physician familiar with the job’s 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.

37. 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 company’s policies, operating conditions and type of trucks used. • As with any program, management’s support is essential if the truck operator’s training is to be effective and lasting.

38. 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