Powered Industrial Trucks

Today’s Journey

• Identification of lift truck hazards

• OSHA requirements
• #1 Hazard-Tip Overs
• Pre-use inspection
• Operating tips
• Propane fuel system/precautions
• Hands-on in-plant overview
What is a Lift Truck???

• What it’s not:

– Taxi
– Battering ram
– Door opener or closer
– Extension ladder
– Go Cart
– Weapon, or demolition derby entrant
Lift Truck Hazards
Lift Truck Hazards

• Heavy
• Poor braking
• Unstable
• Solid suspension
• Rear axle steering
• Top-heavy
• Restricted visibility
• Operate in heavy pedestrian traffic
Accident Causes by Ranking

1. Operator 8. Maintenance accidents

inattention 9. Obstructed view
2. Tip over 10.Improper equipment
3. Unstable load 11.Falling from platform
4. Operator struck by or curb
load 12.Co-worker struck by
5. Elevated employee load
6. Lack of training 13.Carrying passengers
7. Overload, improper 14.Vehicle left in gear
use 15.Trailer loading and
unloading
OSHA Requirements 1910.178
Powered Industrial Trucks
• Please read the information at
https://www.osha.gov/pls/oshaweb/owadisp.show_docume
nt?p_id=9828&p_table=standards
• Design
• Maintenance
• Use
• Electric or Internal Combustion Engines
• Fire protection
• In addition, training must be secured for the specific
equipment used at your location.This can be provided by the
client, the manufacturer, or other training service that trains
to OSHA requirements.
“Approved Trucks”

• Must meet ANSI B56.1-1969 standard

• Must have a label/plate attached stating such
Designations

• “D” = Diesel
• “G” = Gasoline
• “E” = Electric
• “LP” = LP gas (propane)
Hazardous Atmosphere Operation

• Trucks cannot operate in hazardous

atmospheres, unless protected/shielded
• NEVER drive into hazardous vapors, gas or spilled
hydrocarbons!
Other OSHA Requirements

• Trucks must have overhead guard

• Fuel must be stored/transferred in approved
containers and in designated areas
• Many requirements for changing and charging
battery-powered units
• Lights must be activated in low-light areas
• Trailers must be chocked prior to entry
 Operator Training

“Only trained and authorized operators

shall be permitted to operate a forklift”
29CFR 1910.178 (l)
Truck Operations

• Trucks shall not be driven in front of a person that

who can become trapped
• Personnel must not walk under elevated portion of
truck--loaded or empty
• Passengers are prohibited
• Arms, hands and feet must remain inside running
lines of a truck
Truck Operations (cont.)

• Parking requirements
– Park vehicle out of traffic flow
– Forks must be lowered & tilted forward
– Controls in neutral position
– Power shutoff
– Brakes set
– Wheels blocked, if parked on an incline
• Always maintain safe distance around docks,
platforms or changes in elevation
• Operate only with sufficient headroom
Traveling Tips

• Traffic regulations must be observed

• Maintain safe following distances--3 truck lengths
• Yield right-of-way to pedestrians
• Never pass another truck traveling in the same
direction if a blind spot exists
• Sound horn at cross aisles or when backing
• Cross railroad tracks perpendicular
• Maintain unobstructed view
• Grades--ascend or descend slowly
Traveling Tips (cont.)

• Loads shall be lowered as much as possible and tilted

backward
• Operate unit at safe speeds
• Stunt driving or horseplay is prohibited
• Slow down on wet/slippery surfaces
• Dock plates must be secured and within rated
capacities
• Avoid running over objects
• When turning, slow down and turn in a smooth, even
manner
• Loads on the uphill side of steep grades
Loading

• Lift only stable, well-arranged loads

• Lift only loads within the truck’s capacity
• Forks or clamps must be fully engaged
• Care should be taken when placing load
Operation of Truck

• Report defects to the maintenance department

ASAP
• Never change propane cylinders while truck is
running
• Fuel leaks must be immediately corrected
• Ignition sources must be removed during cylinder
changeout
Maintenance

• Remove from service any unit experiencing a

safety-related problem
• Only authorized personnel can perform
maintenance
• Repairs performed only in designated areas
• Battery disconnected during electrical repairs
• Use only approved parts
Maintenance (cont.)

• Trucks shall never be altered unless approved by

manufacturer
• Adding of additional counterweight is prohibited
• Trucks shall be examined for defects before use
• Trucks must be kept clean and in serviceable
condition
Tip Over #1 Killer

• 800,000 forklifts in U.S.

• 1.2 million operators
• 95,000 operators/pedestrians injured each year
• approximately 100 KILLED each year
• Tip Over accidents account for about 25% of
all forklift-related fatalities
Tip Over Facts

• Forklifts don’t handle like an automobile

• They have a short wheel base
• They have a narrow profile--wider is better!
• High center of gravity
• Forklift has only 3 points of stability-stability triangle
• Solid suspension
Tip Over Causes

• Sharp turns
• Turning on a ramp or incline
• Hitting a hole, even at slow speeds
• Soft shoulders
• Trailer not chocked
• Under-inflated/damaged tires
• Slippery surfaces
What to do in a Tip Over

• Stay within the confines of the protective

superstructure
• Brace yourself by gripping the steering wheel
and by planting your feet against firewall
• Leave the accident site immediately,
especially if fuel is leaking
Counterweight Issues

• Never over-lift
• Keep load close to lift mast
• Fully engage load into forks/clamps
• Remember, the higher the lift, the higher the
center of gravity--INSTABILITY!!!
• Even a light load can cause instability
• NEVER add additional counterweights
Lift Truck Brakes

• Even unloaded, forklifts weigh as much or more as a

car
• Big difference--most lift trucks have only two braking
wheels & much smaller brakes
• They can’t stop “on a dime”
• Many operators/pedestrians are hurt or killed each
year because of braking limitations
Inspection Points

• Tires/wheels
• Fluid leaks
• Fluid levels
• Condition of hoses/fittings
• Service and parking brakes
• Steering integrity
• Condition of forks/clamps
Inspection Points (cont.)

• Lifting cylinder/mast
• Counterweight attachment
• Unapproved attachments or questionable repairs
• Lights and horn
• Engine
• Fuel supply
Pre-Use Inspection-REQUIRED

• Reasons to do:
– For the sake of the equipment
– For the sake of you--the operator
– For the sake of the company
– For the sake of fellow workers
Propane Gas Properties

• Colorless, naturally odorless, stored as a liquid under

pressure
• Odorant added to detect its presence
• Flammable
• Propane Gas is heavier than air
• Liquid causes freeze burns
• Non-Toxic
• Simple asphyxiant
Propane Cylinders

• Filled to 80% of their capacity

• All have a safety relief valve
• Must be mounted properly
• Never expose to high temperatures or ignition
sources
• Handle with care-never abuse!!!
• Keep cylinders in their designated areas
Changing out Cylinders

• Turn off service valve on cylinder

• Run engine out of gas
• Disconnect quick disconnect connection
• Check for presence of o-rings in fitting, replace as
necessary
• Check for connection damage
• Tighten securely by hand, turn on service valve-
never use tools!
Parting Thoughts

• Enter and exit forklift with great caution

• Wear seat belt
• Never operate with obstructed view
• Be ever cautious for pedestrian traffic
• Pre-plan evasive maneuvers
• Be in control at all times
• One mistake can ruin your whole day
Parting Thoughts (cont.)

• Look out for low hanging obstacles

• Look out for electrical hazards
• Be extra cautious when changing out fuel
cylinders
• Never engage in horseplay
• Never use the lift truck for any purpose its not
intended to be used for
• Slow down, especially around corners