POWERED INDUSTRIAL TRUCKS
1.0 INTRODUCTION
A powered industrial truck is a mobile, power propelled truck used to carry, push, pull, lift, or stack materials. Forklift trucks, pallet trucks, and motorized hand trucks are included. Vehicles that are used for earth moving and over-the-road hauling are excluded from this definition. Tens of thousands of injuries occur in U.S. workplaces each year from accidents involving powered industrial trucks. Ten percent of all serious industrial accidents are due to powered industrial trucks. Injuries usually involve employees being struck by lift trucks or falling while standing or working from elevated pallets and tines. Many employees are injured when lift trucks are driven off loading docks or when the lift falls between a dock and an unchocked trailer. Most incidents also involve property damage, including damage to overhead sprinklers, racking, pipes, walls, machinery, and other equipment.
2.0 TRAINING
1. Operators must be trained and authorized by the Safety Office before operating powered industrial trucks. Training programs shall include safe operating practices, OSHA regulations, and a driving test. All new operators, regardless of previous experience, will be trained.
2. Training in general safety practices and OSHA regulations will be provided by the Safety Manager. The Safety Manager will also maintain all training records. An experienced and knowledgeable operator will conduct the driving test and evaluate the competence of drivers. Departments using powered industrial trucks must provide a knowledgeable and experienced driver to conduct the driving test.
3. Training will include the following topics:
4. Appropriate retraining will be provided by the Safety Office or supervision when a:
5. Operators will be certified to drive a powered industrial truck. The certification will include the name of the operator, the date of testing, the date of the evaluation, and the name of the person(s) conducting the training and evaluation. Authorized drivers will be issued a license to operate powered industrial trucks and must have the license with them when operating the truck.
6. Retraining in safety procedures and OSHA regulations will be conducted every three years by the Safety Office.
7. An evaluation of driver performance will be conducted every three years by an experienced and knowledgeable driver.
3.0 INSPECTIONS
1. Lift trucks will be inspected daily by the driver before it is placed into operation. Items to be noted include:
2. Trucks will be thoroughly inspected by maintenance personnel on a regular schedule recommended by the manufacturer.
4.0 EQUIPMENT
1. Forklifts shall have horns or other warning devices that are loud enough to be heard above other noises in the area. Flashing lights shall be placed on the overhead guard if noise is excessive. Forklifts should have automatic backup alarms.
2. Auxiliary lighting shall be provided on the truck in areas where general lighting is less than two lumens per square foot.
3. A load backrest extension shall be used whenever necessary to minimize the possibility of the load falling backwards. The load should not exceed the top of the backrest. Placing extra weight on the rear of the lift truck to counterbalance the front load is not permitted.
4. Trucks capable of lifting loads higher than the operator's head or where there is a hazard from falling objects, must be equipped with an overhead guard. The guard is not designed to protect the operator from a full capacity load.
5. Hazardous moving parts such as gears, chains, and sprockets shall be guarded.
6. Seat belts are required to be worn, if installed on the vehicle.
5.0 BATTERY-OPERATED UNITS
1. Battery-charging installations shall be located in areas designated for that purpose. Equipment shall be present to flush and neutralize spilled electrolytes. Facilities must have adequate fire protection and ventilation for disposal of fumes from gassing batteries. An approved emergency shower and eyewash station must be readily available.
2. An overhead hoist, or equivalent equipment, must be used for handling batteries. Reinstalled batteries shall be properly positioned and secured in the truck.
3. A carboy or siphon shall be use for handling electrolytes. Acid must always be poured into water; water must never be poured into acid.
4. During charging operations, vent caps will be removed to avoid electrolyte spray. Care shall be taken to ensure that vent caps are operating properly. Battery or compartment cover or covers must be open to dissipate heat.
5. Precautions shall be taken to prevent open flames, sparks, or electric arcs in battery-charging areas. Tools and other metallic objects will be kept away from the tops of uncovered batteries. Smoking is prohibited in the charging area. "No Smoking" signs must be posted.
6. Employees charging and changing batteries shall be authorized to do the work, trained in the proper handling, and required to wear protective clothing, including eye protection, long sleeves, aprons, and gloves.
6.0 SERVICE & MAINTENANCE
1. Engines must be turned off before fuel tanks are filled. Refueling should be in open or in specifically designated areas, where ventilation is adequate to carry fuel vapors away. The storage and handling of fuel must be in compliance with NFPA 30 for gasoline and diesel fuel; and NFPA 58 for liquefied petroleum fuel. "No Smoking" signs must be posted in areas where fuel is stored or handled.
2. A truck in need of repair, or in any way unsafe, shall be taken out of service until it has been restored to a safe operating condition. Repairs shall be made by authorized personnel.
3. Modifications and additions which effect capacity and safe operation must not be performed without written approval from the manufacturer.
7.0 HAZARDOUS ATMOSPHERES
1. When fuel powered trucks are used in enclosed areas, concentrations of carbon monoxide and other hazardous gases shall not exceed OSHA permissible exposure limits. Operators should not allow fuel powered trucks to idle for long periods in enclosed areas.
2. Only approved trucks shall be used in locations containing hazardous atmospheres such as flammable vapors, dusts, and easily ignitable fibers.
8.0 LOADING
1. Only stable or safely arranged loads shall be handled and caution must be exercised when handling off-center loads. Objects should be neatly piled. Irregularly shaped objects should be loaded so they cannot roll or fall off. Heavy objects should be placed with the weight as low as possible. Round objects should be blocked or tied so they cannot roll. Loading should not be done to a height that blocks the view ahead or makes it likely the load may fall.
2. Forks must be placed under the load as far as possible and the mast shall be carefully tilted backward to stabilize the load. Operators must never operate a truck with an overload. The rated capacity should be marked on the truck. Loads should not be lowered or raised en route.
3. Extreme care must be used when tilting the load forward or backward, particularly when high tiering. Tilting forward with forks elevated is not permitted except to pick up a load. Elevated loads must not be tilted forward unless the load is in a deposit position over a rack or stack. When stacking or tiering, only enough backward tilt to stabilize the load shall be used.
4. Forklifts shall not be driven up to anyone standing in front of a fixed object. No person shall stand or pass under the elevated portion of a truck, whether loaded or empty.
5. When standard forks are used to pick up round objects, such as drums, care must be used to ensure that the tips do not puncture the object or push it into other workers.
6. While loading or unloading trucks and trailers, brakes shall be set and wheel blocks shall be in place to prevent movement. Fixed jacks will be used when necessary to support an uncoupled trailer.
7. Powered industrial trucks should only be used for the purpose for which it is designed. Trucks should not be used to bump skids, push piles, move other trucks, or used as a hoist.
9.0 TRAVELING
1. Operating powered industrial trucks carries considerable responsibility. Reckless or careless driving will not be tolerated. All traffic regulations must be observed, including facility speed limits. Trucks must be kept under control at all times. Operators shall always look in the direction of travel.
2. Safe distances must be maintained. Approximately three truck lengths from the truck ahead must be maintained. Other trucks traveling in the same direction must not be passed at intersections, blind spots, or other dangerous locations.
3. Drivers are required to slow down and sound horns at cross aisles and other locations where vision is obstructed. Large convex mirrors should be installed at blind corners. The operator should lightly tap the horn to warn pedestrians when approaching from behind. If the load obstructs the driver's forward view, the driver shall travel with the load trailing.
4. Grades must be ascended or descended slowly. Loaded trucks must be driven with the load upgrade when ascending or descending grades in excess of 10%. On all grades, forks shall be tilted back and raised only as far as necessary to clear the road surface. Low gear or the slowest speed should be used when descending a grade.
5. Under all travel conditions, forklifts must be operated at a speed that will permit it to be brought to a stop in a safe manner. The driver shall slow down for wet or slippery floors. Never run over loose objects on the roadway surface.
6. Dockboards or bridgeplates are to be driven over carefully and slowly and only after they have been properly secured. Never exceed their rated weight capacity.
7. Elevators should be approached slowly. Check to make sure the weight of the truck, load, and driver do not exceed the capacity of the elevator. Once on the elevator, the controls should be put in neutral, the brakes set, and the engine shut off.
8. While negotiating turns, speed must be reduced to a safe level by turning the steering wheel in a smooth, sweeping motion. Except when maneuvering at a very low speed, the steering wheel shall be turned at a moderate, even rate.
9. Operators should not make quick starts, jerky stops, or turns at excessive speeds. Extreme caution should be used on turns, ramps, grades, or inclines. A safe distance shall be maintained from the edges of elevated ramps or platforms.
10. The operator should be particularly careful to avoid striking overhead objects such as lights, conduits, and sprinkler heads. Loads should not be raised or lowered while traveling. Forks should be carried as low as possible whether loaded or empty.
11. Unauthorized personnel shall not ride on trucks. It is the responsibility of the operator to keep unauthorized individuals off the truck. A safe place to ride must be provided for authorized passengers.
12. When operating in close quarters, hands must be placed where they cannot be pinched between steering controls and projecting stationary objects. Legs and feet must be kept inside the guard or the operating stations of the truck.
10.0 PARKING
1. Trucks shall only be parked in designated areas- never in an aisle or doorway, or obstructing equipment or material. When a truck is left unattended, forks shall be fully lowered, controls put in neutral, power shut off, key removed, and the brakes set. Unattended means the operator is greater than 25 feet from the vehicle, or the vehicle is not in view, regardless of the distance. Wheels shall be blocked if the truck is parked on an incline.
2. When the operator is dismounted and within 25 feet of the truck still in his view, the forks shall be fully lowered, controls neutralized, and the brakes set.
3. Fire aisles, access to stairways, doorways, and fire equipment shall be kept clear.