learning process. 3. Explore the psychological characteristics

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