for Loader Owners / Operators
(1) Owners / operators of skid-steer loaders should not disable or modify factory installed or retrofitted safety features.
Safety interlocks are designed to prevent unintentional lowering of the bucket by movement of the pedals or hydraulic linkages. All safety devices should be maintained and kept in working order, regardless of the possible inconvenience they may cause. If they are altered for the sake of convenience, operators pay a steep price in terms of safety. The ROPS is an essential safety feature of a skid-steer loader. Due to close proximity to the loader bucket and lift arms, the operator is in great danger if the ROPS is removed or modified. Also, factory-installed ROPS may have other safety features built in to their design, such as lift arm safety stops and the ignition safety interlocks. It is important that seatbelts or other restraint systems are worn to provide two protective functions: (1.) restraining the operator in the protective zone of the ROPS, and (2.) providing protection from unexpected movement of the loader bucket or liftarms. Operators who modify these safety systems are gambling with their life, for one absent minded action can lead to their death.
(2) Tractor front-end loader / skid-steer loader operators should be made aware of overturn hazard and methods to reduce this hazard while they work.
Front end loaders are typically capable of lifting a heavy load, thus raising the center of gravity of the machine and shifting the weight off the rear wheels to the front wheels. This can greatly reduce the stability of the tractor and increase the risk of overturn and also cause brake failure if brakes are only on rear wheels. Operators must be aware of these hazards and drive with the loader bucket down, avoiding unstable ground, driving straight up and down hills with the loader on the uphill side, turning around on level ground, using counterweights whenever appropriate, and especially avoiding the use of tricycle-type tractors with loaders.
Increased attention is needed to address overturn hazards in operating skid-steer loaders. Their compact size and narrow wheelbase contribute to their instability, and they can easily roll if on rough terrain. Because of their smaller size, safety can easily be ignored by many operators. These machines are often used in tight places with workers in close proximity and have great potential to cause serious injury or death. Operators must be taught about overturn hazard, seatbelt use, modifications of the safety devices, and the potential to be crushed between the bucket and the frame. Loading areas should be designed to minimize the risk of tractor and loader overturns. Ideally these areas should be on level ground with ample space to turn around safely. This should be a consideration when designing buildings, roads, and fences. If it is impractical to repair sloping work areas, barriers may be installed to prevent machines entering dangerous areas.
(3) Tractors used with front-end loaders should be equipped with ROPS, and tricycle type narrow-front tractors should not be equipped with front-end loaders.
Front end loaders significantly raise the center of gravity and make all tractors less stable. Rollovers to the side are therefore more likely and the need for ROPS is evident. Older tricycle type tractors are very common on row crop production farms and many have been fitted with front-end loaders. Few farmers have experienced problems working on level ground, but operating the tractor on hilly terrain is very dangerous due to the unstable front end, and many farmers die from rollovers every year. Rear counterweights or liquid-filled tires would improve stability, but the operator must still be constantly aware of changing slopes, holes, bumps, and ruts which can dangerously shift the center of gravity with the bucket raised. Tricycle type tractors are significantly more prone to rollovers than wide front tractors and should therefore not be equipped with front-end loaders. Using a wide-front tractor with an installed ROPS would certainly prevent many fatal farm accidents. Tractors may still tip over, but the ROPS will usually stop the roll and prevent a complete rollover. The operator may be injured, but not crushed to death under the rear tires or fenders.
(4) Owners / operators of loading equipment should provide sufficient space for safe maintenance and cleaning of their equipment. Employers should plan routine procedures that minimize hazards to workers, providing mechanical supports for loading attachments that must be repaired or dismantled.
Proper storage space for loading equipment is often considered a low priority on farms and construction sites. However, adequate storage is needed for proper maintenance and cleaning, especially in winter conditions. Using a skid steer loader on the farm in winter requires frequent cleaning as mud and manure will freeze to the machine floor, especially if the machine is stored outside. Also, if proper space is not provided, then important maintenance may be delayed or forgotten. Machine operators must keep their equipment in proper working order to ensure its dependability and safety. Older equipment must be carefully examined for signs of wear, neglect, and abuse. Those who dismantle cars or other machines on a routine basis should provide a level area with solid racks, braces, or other means to support the machine while working under it. They should never rely solely on the integrity of the hydraulic systems.
(5) Operators of front-end loaders or forklifts should use safety chains or other means to secure their load during transport of the load.. Operators should also secure their loader by mechanical means whenever working under the raised attachment.
Forklifts are ideally suited for work on level surfaces. On rough terrain their loads can easily shift and slide on the forks and additional safety measures are needed. A safety chain or other means of securing the load to the forklift should be considered, for an operator can make a mistake at any time and endanger workers who are in close proximity. According to CFR 1910.178(m)(2), workers should always stand clear of elevated loads when they are being adjusted or transported.
Hydraulic systems alone do not provide adequate safety when working under a loader bucket or forklift. A worn hose, a poor connection, or other part of the system can fail causing sudden movement of machine components. The load may easily shift and fall on workers underneath. Workers should not be permitted to work under hydraulically-supported machine components or loads. Due to the possibility of mechanical / hydraulic failure or operator error, a mechanical support, blocking, or heavy bracing is needed to prevent worker injury and death. Many newer hydraulic systems have built-in mechanical stops on the hydraulic cylinders. These should always be used if present.
(6) Employers / operators should establish safe loading / unloading procedures with powered industrial forklifts or other machines with front-end loaders.
Workers should not be allowed to stand or work in the narrow space between a forklift, tractor, or skid-steer loader and another stationary object or vehicle. Operators must be keenly aware of the position of co-workers when using a front-end loader. It is difficult to safely control vehicles in narrow spaces given the natural limitations of drive trains, drivers, and controls. A driver error or mechanical malfunction can easily set the machine in motion and crush the worker in a narrow space. During operation adequate distance must be kept to allow the worker time to escape in case of mechanical malfunction or operator error. It is also hazardous to keep the transmission in a forward gear, when people are working in front of the bucket. If the tractor is on an incline, it would be better to have the transmission in park or in a reverse gear, so that in case of malfunction or error, the tractor will stay in place or move backwards, away from the workers. If workers must work in these narrow spaces, then attachments must be fully lowered, controls neutralized, and brakes set to prevent any unintentional movements. This also applies to working under hydraulically-supported machine attachments (mechanically supported by blocking or bracing).
If a loading vehicle is on an incline (see diagram), upward movement of the bucket can seriously injure workers. Operators must be aware of loader geometry, knowing that the loader bucket will move forward considerably while being raised from ground level, especially on an incline. When working in close quarters, this forward movement of the bucket is potentially dangerous. Also, when raised quickly, a loader with a heavy load momentarily reduces weight on the rear wheels and may cause slipping, especially if weight is already increased on the front wheels due to forward sloping terrain. This can be very significant, since most tractors have brakes only on the rear wheels.
Forklift operators should lift and balance a load only with the parking brake set, releasing this brake only when the service brake is applied and forward or reverse movement of the forklift is desired. The parking brake should always be set when someone is in front of the machine, and released only when the worker is clear of danger. Employers should demonstrate safe distances to park or idle loading machines adjacent to stationary objects, allowing sufficient time and room for workers to escape.
Operators should consider safer procedures for loading / unloading tasks, not allowing workers to enter a hazardous space between two vehicles, or between a load vehicle and dock. This may include parking parallel to a stationary object or load vehicle during the loading procedures. Then unintentional movements will not be directed towards the narrow space where a worker may be present. Under no circumstances should an operator of a loading vehicle put himself in jeopardy by walking, stepping, or leaning under the raised load or bucket--at any time. Years of safe operation must never be used to justify unsafe practices or alteration of safety devices on any equipment.
(7) Manufacturers should design reliable safety mechanisms to prevent the loader bucket from falling unintentionally.
Several safety mechanisms should be provided in all skid-steer loaders to protect the operators from the danger of being crushed under the bucket. These mechanisms could include a safety belt-operated interlock, an ignition-operated interlock which locks the hydraulics when the machine is not running, an operator presence sensor in the seat shutting off the engine or attached to a hydraulic interlock, a front door interlocking the hydraulics, a safety bar requiring the operator to be present in the seat when using hydraulics, and a mechanical lift arm stop. These mechanical lift arm stops should be operable in all loader positions where there is adequate space for the operator to safely step in and out of the machine.
(8) Manufacturers should design equipment and controls to function in wet, muddy, or cold conditions when those conditions are frequently encountered in normal operation.
Build-up of mud, snow, manure, grain, etc. under floor pedals of skid-steer loaders is a common occurrence and becomes especially hazardous in winter when the accumulation can quickly freeze and limit the pedals’ movement. Manufacturers should ensure that controls do not malfunction because of normal buildup of debris on the floor of their machines. Since this is so common with skid-steer loaders, the design should be improved by providing adequate room under the pedals and linkages, installing a perforated floor to allow debris to fall through, or replacing foot controls by hand controls away from the floor.
| Wayne Johnson, M.D. | Risto Rautiainen, M.Sc.Agr. |
| Trauma Investigator (FACE) | Coordinator |
| Institute for Rural & Environmental Health | Great Plains Center for Agricultural Health |
| University of Iowa -- Iowa City, Iowa | Institute for Rural & Environmental Health |
| University of Iowa -- Iowa City, Iowa |
