Dangerous Action.Dangerous Action. Operating a powered indus-Operating a powered indus-
trial truck without inspecting, identifying, andtrial truck without inspecting, identifying, and
repairing fatigue cracks in the mast, carriage,repairing fatigue cracks in the mast, carriage,
attachment, steer axle, and frame weldments.attachment, steer axle, and frame weldments.
What Can Happen.What Can Happen. If the If the fatigue crack fatigue crack is allowedis allowed
to grow, catastrophic failure could occur in theto grow, catastrophic failure could occur in the
mast or other welded components causing seriousmast or other welded components causing serious
injury to personnel and / or property.injury to personnel and / or property.
How To Avoid The Danger.How To Avoid The Danger. Follow the OSHAFollow the OSHA
rules, 29 CFR, 1910.178 (q)(1), (5), & (7) whichrules, 29 CFR, 1910.178 (q)(1), (5), & (7) which
require inspecting industrial trucks daily beforerequire inspecting industrial trucks daily before
being placed in service, removing trucks from ser-being placed in service, removing trucks from ser-
vice if cracks are found, and making repairs onlyvice if cracks are found, and making repairs only
as authorized by the manufactureras authorized by the manufacturer. . If trucks If trucks areare
used on a round-the-clock basis, they shall beused on a round-the-clock basis, they shall be
examined after examined after each shift. each shift. OSHA 29 OSHA 29 CFRCFR
1910.178 (p)(1) requires that trucks in need of1910.178 (p)(1) requires that trucks in need of
repair be taken out of service.repair be taken out of service.
Structural Inspection and Reporting Proce-Structural Inspection and Reporting Proce-
dure.dure. The information The information enclosed in enclosed in this procedurethis procedure
is directed to the structural weldments of the truckis directed to the structural weldments of the truck
assembly. assembly. Areas that Areas that should be should be included forincluded for
inspection on the front end of the truck are theinspection on the front end of the truck are the
mast and mast and carriage. carriage. Areas to Areas to be inspected be inspected on theon the
truck chassis include mast hangers, drive axletruck chassis include mast hangers, drive axle
mounts, A-frame connections, and steer axlemounts, A-frame connections, and steer axle
mounts.mounts.
Inspection for Fatigue Cracks.Inspection for Fatigue Cracks. Welded steel Welded steel
structures always contain undetectable cracks,structures always contain undetectable cracks,
especially at especially at welded joints. welded joints. When these When these joints arejoints are
subject to fluctuating stresses of sufficient magni-subject to fluctuating stresses of sufficient magni-
tude these cracks will growtude these cracks will grow This is known asThis is known as
These symbols are in accordance with AWSThese symbols are in accordance with AWS
A2.4-76, “Symbols for A2.4-76, “Symbols for Non-Destructive TNon-Destructive Testing.”esting.”
Periodic inspection isPeriodic inspection is
required to detect fatigue cracks that haverequired to detect fatigue cracks that have
grown to a significant size in order to avoidgrown to a significant size in order to avoid
serious failure of the structural weldment.serious failure of the structural weldment.
When a crack is found, the truck must beWhen a crack is found, the truck must be
immediately taken out of service and repaired.immediately taken out of service and repaired.
Restoring the weld to its original condition by com-Restoring the weld to its original condition by com-
plete penetration welding is usually acceptable.plete penetration welding is usually acceptable.
Sometimes this is not practical and a change inSometimes this is not practical and a change in
geometry by means of cutting, grinding or addinggeometry by means of cutting, grinding or adding
additional material is additional material is more economical; more economical; howeverhowever,,
the user must be cautioned that OSHA 29 CFRthe user must be cautioned that OSHA 29 CFR
1910.178 (a)(4) requires manufacturer’s1910.178 (a)(4) requires manufacturer’s priorprior
written approvalwritten approvalfor modifications and additionsfor modifications and additions
which affect capacity and safe operation.which affect capacity and safe operation.
Cracking may occur due to overloading, roughCracking may occur due to overloading, rough
operation, poor yard conditions, severe dutyoperation, poor yard conditions, severe duty
cycles, failing to keep lift chains properly adjusted,cycles, failing to keep lift chains properly adjusted,
improper shimming of mast rails, carrying theimproper shimming of mast rails, carrying the
loads too high or not properly centered, usingloads too high or not properly centered, using
attachments that clamp the load to the forks, etc.attachments that clamp the load to the forks, etc.
If such cracking is found, a review of the operationIf such cracking is found, a review of the operation
should be made to see if any of the above listedshould be made to see if any of the above listed
problems are occurring and if so, a change in theproblems are occurring and if so, a change in the
operation should be made to avoid future prob-operation should be made to avoid future prob-
lems. lems. Some cracking Some cracking may be due may be due to geometryto geometry,,
modifications or due to the attachments welded tomodifications or due to the attachments welded to
the structure. the structure. If this If this is the case, is the case, the geometrythe geometry
may have to be changed, the modification cor-may have to be changed, the modification cor-
rected, or the attachment changed or relocated torected, or the attachment changed or relocated to
correct the correct the cracking problem. cracking problem. OSHA requires OSHA requires thatthat
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