ANSI/ITSDF B56.1-2009
(Revision of ANSI/ITSDF B56.1-2005)

Part II

​

For the User

​

4 GENERAL SAFETY PRACTICES

 

4.1 Introduction

 

4.1.1 Part II contains requirements for the users of powered industrial trucks. Included are requirements for operator qualifications and training, operating safety rules, and maintenance practices.

 

4.1.2 Unusual operating conditions may require additional safety precautions and special operating instructions.

 

4.1.3 Supervision is an essential element in the safe operation of powered industrial trucks.

 

4.2 Modifications, Nameplates, Markings, and Capacity

 

4.2.1 Except as provided in para. 4.2.2, no modifications or alterations to a powered industrial truck that may affect the capacity, stability, or safe operation of the truck shall be made without the prior written approval of the original truck manufacturer or its successor thereof. When the truck manufacturer or its successor approves a modification or alteration, appropriate changes shall be made to capacity plates, decals, tags, and operation and maintenance manuals.

 

4.2.2 If the truck manufacturer is no longer in business and there is no successor to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided however, the user (a) arranges for modification or alteration to be designed, tested, and implemented by an engineer(s) expert in industrial trucks and their safety (b) maintains a permanent record of the design test(s), and implementation of the modification or alteration (c) makes appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals (d) affixes a permanent and readily visible label on the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration, and the name of the organization that accomplished the tasks

 

4.2.3 If the truck is equipped with a front-end attachment(s), including fork extensions, the user shall see that the truck is marked to identify the attachment(s), show the weight of the truck and attachment combination, and show the capacity of the truck with attachment(s) at maximum elevation with the load laterally centered.

 

4.2.4 The user shall see that all nameplates and caution and instruction markings are in place and legible.

 

4.2.5 The user shall consider that changes in load dimension may affect truck capacity.

 

4.2.6 Fork extensions shall be designed for the application.

 

4.2.7 When modifications involve rebuild and repair of the basic unit, they shall be made in accordance with the manufacturer’s established criteria and procedures (see para. 6.2).

 

4.2.8 Where steering must be accomplished with one hand using a steering handwheel, a steering knob(s) or equivalent shall be used to promote safe and effective operation. The steering handwheel and knob configuration shall be of a design that will minimize the hazard from a spinning handwheel due to a road reaction feedback, or the steering mechanism shall be of a type that prevents road reactions from causing the steering handwheel to spin. The steering knob(s) shall be within the periphery of the steering handwheel.

 

4.2.9 Where steering can be accomplished with either hand, and the steering mechanism is of a type that prevents road reactions from causing the handwheel to spin (power steering or equivalent), steering knobs may be used. When used, steering knobs shall be of a type that can be engaged by the operator’s hand from the top, and shall be within the periphery of the steering handwheel.

 

4.2.10 Batteries used in electric trucks shall comply with the minimum/maximum battery weight range shown on the truck nameplate.

 

4.3 Stopping Distance (Descending Grades)

 

4.3.1 When descending a grade, stopping distance will be greater than on-level operation. Methods shall be provided to allow for this condition. Some methods are: reduce speed, limit loads, allow adequate clear space at the bottom of the grade, etc. (see para. 5.3.8).

 

Weight value to be accurate within + 5 %. ANSI/ITSDF B56.1-2009 SAFETY STANDARD FOR LOW LIFT AND HIGH LIFT TRUCKS 3

 

4.3.2 Approximate theoretical stopping distance for a dry clean asphalt, brushed concrete, or equivalent surface may be determined from the following formula: 0.394v 2 s = D-G or 3.34v 2 1 s1= D-G Where D = drawbar drag, as a percent, as determined from Fig. 2 (e.g. 25 for 25% G = percent grade (e.g., 5 for 5%) s = distance to stop, m s1 = distance to stop, ft v = velocity, km/h v1 = velocity, mph 4.4 Stability

 

4.4.1 Experience has shown that high lift trucks that comply with the stability requirements stated in para. 7.6 are stable when properly operated. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the Standard.

 

4.4.2 Some of the conditions that may affect stability are: ground and floor conditions, grade, speed, loading (trucks equipped with attachments behave as partially loaded trucks even when operated without a load on the attachment), battery weight, dynamic and static forces, and the judgment exercised by the operator.

 

4.4.3 On electric trucks, use only a battery or batteries having a total service weight within the minimum/maximum range specified on truck nameplate. See para. 7.5.8 for information on battery weight.

 

4.4.4 Users shall give consideration to special operating conditions. The amount of forward and rearward tilt to be used is governed by the application. The use of maximum rearward tilt is allowable under certain conditions such as traveling with the load lowered. The stability of a truck as determined by the tests outlined in para. 7.6 does not encompass consideration for excessive tilt at high elevations, or the operation of trucks with excessive off-center loads.

 

4.4.5 Some users may decide to establish, for their own use, stability requirements that will vary from those in para. 7.6. However, the requirements in para. 7.6 should serve as a guide for the user, working with the manufacturer, in establishing his own more stringent requirements. 4.5 Safety Guards 4.5.1 Overhead Guards

 

4.5.1.1 High lift rider trucks, including order picker trucks, shall be fitted with an overhead guard manufactured in accordance with para. 7.29.

 

4.5.1.2 An overhead guard is intended to offer protection to the operator from falling objects but cannot protect against every possible impact. Therefore, it should not be considered a substitute for good judgment and care in loading, handling, storage, etc.

 

4.5.1.3 Under certain unusual operating conditions, a stronger guard, or one having openings of smaller size, may be specified by the user working with the truck manufacturer.

 

4.5.1.4 Exceptions (a) Where overhead obstructions limit the overall lowered height of the truck, normal overhead guard height and the vertical clearance under the guard may be reduced to permit operation with a guard. (b) The user may operate the truck without the overhead guard, provided all of the following conditions are met: (1) vertical movement of the lifting mechanism is restricted to 1 825 mm (72 in.) or less from the ground (2) the truck will operate only in an area where (a) the bottom of the top tiered load is not higher than 1 825 mm (72 in.) and the top is not more than 3 050 mm (120 in.) from the ground when tiered (b) only stable (preferably interlocked, unitized, or containerized) loads are handled (c) there is protection against falling objects from adjacent high stack areas

 

4.5.2 Load Backrest Extension. If the type of load presents a hazard, the user shall equip forklift trucks with a vertical load backrest extension manufactured in accordance with para. 7.28.

 

4.5.3 Operator Compartment Guards. For stand up, end controlled, narrow aisle trucks, more or less guarding than specified by paras. 7.30 and 7.36 may be required to enhance safe operation. Changes shall be determined through cooperation between the user and manufacturer.

 

4.6 Fuel Handling and Storage

 

4.6.1 The storage and handling of liquid fuels (such as gasoline and diesel fuel) shall be in accordance with ANSI/NFPA 505 and ANSI/NFPA 30.

 

4.6.2 The storage and handling of liquefied petroleum gas fuel shall be in accordance with ANSI/NFPA 505 and ANSI/NFPA 58.

 

4.7 Changing and Charging Storage Batteries for Electric Trucks

 

4.7.1 Battery changing and charging facilities and procedures shall be in accordance with ANSI/NFPA 505.

 

4.7.2 The charger connector shall not be plugged into the truck connector under any circumstances.

 

4.7.3 To avoid damage to equipment or injury to personnel, consult manufacturer’s procedures when replacing contacts in any battery connector.

 

4.7.4 Failure to comply with specified nameplate battery weight range could result in truck instability.

 

4.8 Hazardous Locations

 

4.8.1 It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSI/NFPA 505.

 

4.8.2 Powered industrial trucks operated in and batteries used in hazardous areas shall be approved and of the type required by ANSI/NFPA 505. Dependent on the proposed type of truck and area, approved trucks shall be built in compliance with one of the following: (a) UL 558 (b) UL 583

 

4.8.3 Trucks and areas of use shall be marked in accordance with ANSI/NFPA 505.

 

4.9 Aisles and Obstructions

 

4.9.1 Permanent aisles, roadways or passageways, floors, and ramps shall be defined in some fashion or marked to conform with ANSI Z535.2.

 

4.9.2 Permanent or temporary protrusions of loads, equipment, material, and construction facilities into the usual operating area shall be guarded, clearly and distinctively marked, or clearly visible.

 

4.10 Lighting for Operating Areas

 

4.10.1 Controlled lighting of adequate intensity should be provided in operating areas in conformance with ANSI/IES RP7. 4.10.2 Where operating conditions indicate, the user shall be responsible for having the truck equipped with lights.

 

4.11 Control of Noxious Gases and Fumes

 

4.11.1 Carbon monoxide is a colorless, odorless, tasteless, poisonous gas. This gas is the product of incomplete burning of any material containing carbon, such as gasoline, LP and natural gas, and diesel fuel. Internal combustion engines that use these fuels are sources of exposure in the workplace. Control of carbon monoxide levels in the workplace is dependent on ventilation and proper maintenance of carbon monoxide producers including internal combustion-powered equipment. Properly running internal combustion engines will still produce carbon monoxide emissions and deplete the oxygen supply sufficiently, affecting the ambient air of the work environment if the ambient air exchange is not adequate. Always use ventilation as the primary means of control by providing necessary air exchange capability.

 

4.11.2 Ventilation shall be provided in enclosed areas where internal combustion powered equipment is used to maintain an atmosphere that shall not exceed the contamination levels specified by the American Conference of Governmental Industrial Hygienists, “Threshold Limit Values of Airborne Contaminants.” (See 29 CFR 1910.1000 Table Z-1). This includes the atmosphere within the truck cab when a cab is provided.

 

4.11.3 Common symptoms of carbon monoxide exposure may include headaches, dizziness, and nausea. If employees exhibit these symptoms, move them into fresh air, seek medical attention as required, and determine the source of carbon monoxide by monitoring “threshold limit values” in areas of exposure.

 

4.11.4 Questions concerning degree of concentration and methods of sampling to ascertain the conditions present should be referred to a qualified professional. Users must follow applicable local, state, and federal regulations that apply to their workplace.

 

4.12 Sound Powered industrial trucks can contribute to the ambient sound in the work area. Consideration should be given to the sound exposure of personnel in the work area. ANSI/ITSDF B56.1-2009 SAFETY STANDARD FOR LOW LIFT AND HIGH LIFT TRUCKS 5 4.13 Dockboards (Bridge Plates)

 

4.13.1 Portable and powered dockboards shall be marked conspicuously with their carrying capacity. The carrying capacity indicated shall not be exceeded.

 

4.13.2 Portable dockboards shall be secured in position, either by being anchored or by being equipped with devices that will prevent their slipping.

 

4.13.3 Handholds or other effective means shall be provided on portable dockboards to permit safe handling. When possible, fork loops or lugs shall be provided for handling by fork trucks.

 

4.13.4 All types of dockboards shall have a high friction surface designed to reduce the possibility of employees or trucks slipping.

 

4.13.5 All types of dockboards shall be designed and maintained so that one end will have a substantial contact with the dock (or loading platform) and the other end with the transport vehicle to prevent the dockboard from rocking or sliding.

 

4.14 Trucks and Railroad Cars

 

4.14.1 When powered industrial trucks are driven on and off highway trucks or trailers, the brakes on the highway trucks or trailers shall be applied, and wheel chocks or other positive mechanical means shall be used to prevent unintentional movement of highway trucks and trailers.

 

4.14.2 Provision shall be made to prevent railroad cars from being moved during loading and unloading. Wheel stops, hand brakes, or other recognized positive means shall be used to prevent movement during loading and unloading.

 

4.14.3 Whenever powered industrial trucks are driven on and off semitrailers not coupled to a tractor, supports may be needed to prevent upending or corner dipping.

 

4.14.4 Maintain a safe distance from the edge of ramps, platforms, or other similar working surfaces.

 

4.14.5 Do not move railroad cars or trailers with a powered industrial truck unless the truck is properly designed and equipped for that operation. 4.15 Warning Device

 

4.15.1 Every truck shall be equipped with an operator-controlled horn, whistle, gong, or other sound-producing device(s). ________ 2 Dockboard recommendations also apply to bridge plates.

 

4.15.2 The user shall determine if operating conditions require the truck to be equipped with additional sound-producing or visual (such as lights or blinkers) devices, and be responsible for providing and maintaining such devices.

 

4.16 Relocating Powered Industrial Trucks When utilizing lifting equipment such as elevators, cranes, ship hoisting gear, etc., to relocate a powered industrial truck, the user shall ensure that the capacity of the hoisting equipment being used is not exceeded.

 

4.17 Elevating Personnel

 

4.17.1 Only operator-up high lift trucks have been designed to lift personnel. If a work platform is used on trucks designed and intended for handling materials, the requirements of paras.

 

4.17.2 and 4.17.3 shall be met for protection of personnel.

 

4.17.2 Whenever a truck is used to elevate personnel, the following precautions for the protection of personnel shall be taken: (a) Comply with the design requirements in para. 7.367of this Standard. (b) Provide protection for personnel in their normal working position on the platform from moving parts of the truck that represent a hazard. (c) Be certain that required restraining means such as railings, chains, cable, body belt(s) with lanyard(s), or deceleration devices, etc., are in place and properly used. (d) Be certain that the lifting mechanism is operating smoothly throughout its entire lift height, both empty and loaded, and that all lift limiting devices and latches, if provided, are functional. (e) Provide overhead protection as indicated to be necessary by the operating conditions. (f) Replace any body belt, lanyard, or deceleration device that has sustained permanent deformation or is otherwise damaged.

 

4.17.3 Whenever a truck is equipped with a work platform (does not include operator-up high lift trucks), precautions specified in para.

 

4.17.2 shall be taken and the following additional precautions shall be taken for the protection of personnel: (a) Provide a platform that complies with the design requirements in para. 7.37.3. (b) The platform attachment means are applied and the platform is securely attached to the lifting carriage or forks. (c) When the lifting carriage and/or forks are supporting the platform used to elevate personnel, the lifting carriage and/or forks are secured to prevent them from pivoting upward.

 

ANSI/ITSDF B56.1-2009 SAFETY STANDARD FOR LOW LIFT AND HIGH LIFT TRUCKS 6 (d) The mast is vertical – do not operate on a side slope. (e) The platform is horizontal and centered and not tilted forward or rearward when elevated. (f) The truck has a firm and level footing. (g) Place all travel controls in neutral and set parking brake. (h) Before elevating personnel, mark area with cones or other devices to warn of work by elevated personnel. (i) Lift and lower personnel smoothly, with caution, and only at their request. (j) Avoid overhead obstructions and electric wires. (k) Keep hands and feet clear of controls other than those in use. (l) Move truck and/or platform slowly, only for minor adjustments in horizontal positioning when personnel are on the platform, and only at their request. (m) On trucks equipped with rotators, mechanically secure the rotator to prevent movement. (n) Have a trained operator in position to control the truck, or available to operate controls. When the operator is not in the operating position, engage the parking brake and block the wheels. (o) The combined weight of the platform, load, and personnel is not to exceed one-half of the capacity as indicated on the nameplate of the truck on which the platform is used. (p) Personnel are to remain on the platform floor. Use of railings, planks, ladders, etc., on the platform for purpose of achieving additional reach or height is prohibited. (q) Personnel and equipment on the platform are not to exceed the available space. (r) Lower platform to floor level for personnel to enter and exit. Do not climb on any part of the truck in attempting to enter and exit.

 

4.18 Operator Qualifications Only trained and authorized persons shall be permitted to operate a powered industrial truck. Operators of powered industrial trucks shall be qualified as to visual, auditory, physical, and mental ability to operate the equipment safely according to para. 4.19 and all other applicable parts of para.

 

4. 4.19 Operator Training

 

4.19.1 Personnel who have not been trained to operate powered industrial trucks may operate a truck for the purposes of training only, and only under the direct supervision of the trainer. This training should be conducted in an area away from other trucks, obstacles, and pedestrians.

 

4.19.2 The operator training program should include the user’s policies for the site where the trainee will operate the truck, the operating conditions for that location, and the specific truck the trainee will operate. The training program shall be presented to all new operators regardless of previous experience.

 

4.19.3 The training program shall inform the trainee of the following: (a) The primary responsibility of the operator is to use the powered industrial truck safely following the instructions given in the training program. (b) Unsafe or improper operation of a powered industrial truck can result in (1) death or serious injury to the operator or others (2) damage to the powered industrial truck or other property

 

4.19.4 The training program shall emphasize safe and proper operation to avoid injury to the operator and others and prevent property damage, and shall cover the following areas: (a) fundamentals of the powered industrial truck(s) the trainee will operate, including (1) characteristics of the powered industrial truck(s), including variations between trucks in the workplace (2) similarities to and differences from automobiles (3) significance of nameplate data, including rated capacity, warnings, and the instructions affixed to the truck (4) operating instructions and warnings in the operating manual for the truck, and instructions for inspection and maintenance to be performed by the operator (5) type of motive power and its characteristics (6) method of steering (7) braking method and characteristics, with and without load (8) visibility, with and without load, forward and reverse (9) load handling capacity, weight and load center (10) stability characteristics with and without load, with and without attachments (11) controls-location, function, method of operation, identification of symbols (12) load handling capabilities, forks, attachments (13) hazards due to production of carbon monoxide by internal combustion engines and common initial symptoms of exposure (14) fueling and battery charging (15) guards and protective devices for the specific type of truck (16) other characteristics of the specific industrial truck (b) operating environment and its effect on truck operation including ANSI/ITSDF B56.1-2009 SAFETY STANDARD FOR LOW LIFT AND HIGH LIFT TRUCKS 7 (1) floor or ground conditions including temporary conditions (2) ramps and inclines, with and without load (3) trailers, railcars, and dockboards (including the use of wheel chocks, jacks, and other securing devices) (4) fueling and battery charging facilities (5) the use of “classified” trucks in areas classified as hazardous due to risk of fire or explosion, as defined in ANSI/NFPA 505 (6) narrow aisles, doorways, overhead wires and piping, and other areas of limited clearance (7) areas where the truck may be operated near other powered industrial trucks, other vehicles, or pedestrians (8) use and capacity of elevators (9) operation near edge of dock or edge of improved surface (10) other special operating conditions and hazards that may be encountered (c) operation of the powered industrial truck, including: (1) proper preshift inspection and approved method for removing from service a truck that is in need of repair (2) load handling techniques: lifting, lowering, picking up, placing, tilting (3) traveling, with and without loads; turning corners (4) parking and shutdown procedures (5) other special operating conditions for the specific application (d) operating safety rules and practices including: (1) provisions of this Standard in para. 5.1 to 5.4 address operating safety rules and practices (2) provisions of this Standard in para. 5.5 address care of the truck (3) other rules, regulations, or practices specified by the employer at the location where the powered industrial truck will be used (e) Operational training practice, including: (1) if feasible, practice in the operation of powered industrial trucks shall be conducted in an area separate from other workplace activities and personnel (2) training practice shall be conducted under the supervision of the trainer (3) training practice shall include the actual operation or simulated performance of all operating tasks such as load handling, maneuvering, traveling, stopping, starting, and other activities under the conditions that will be encountered in the use of the truck

 

4.19.5 Testing Restraining, and Enforcement (a) During training, performance and oral and/or written tests shall be given by the employer to measure the skill and knowledge of the operator in meeting the requirements of the Standard. Employers may delegate such testing to others but shall remain responsible for the testing. Appropriate records shall be kept. (b) Operators shall be retrained when new equipment is introduced, existing equipment is modified, operating conditions are changed, or an operator’s performance is unsatisfactory. (c) The user shall be responsible for enforcing the safe use of the powered industrial truck according to the provisions of this Standard NOTE: Information on operator training is available from such sources as powered industrial truck manufacturers, government agencies dealing with employee safety, trade organizations of users of powered industrial trucks, public private organizations, and safety consultants.