Bulletin number:  SB 109

Category:            Safety

Date issued:        Nov. 19, 2005

Machine models: Alliance / TEI Pallet Handlers and Alliance / ASC Pallet Masters

Subject:              Acceptable Pallet Stack Heights

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Description of Problem

Discussion

Recommended Solution

To our valued customer:

This service bulletin is part of an ongoing effort to provide quality service and support for all Alliance Machine Systems International, LLC products. If you need assistance or more information, please call Gary Kneale, Field Service Manager, at (888) 768-2200 and select option two.

Alliance recently was advised of the following safety incident involving a PH3 Pallet Handler. While this incident involved a PH3, the same scenario is also applicable to PH1 / PH2 pallet handlers as well as the Alliance / ASC Style 1 and Style 3 Pallet Masters.

A forklift operator placed a stack of 22 pallets on a conveyor line to load the PH3 pallet handler. The operator backed the forklift away, then dismounted and proceeded to have a conversation with another employee. In the meantime, the stack of pallets advanced to the empty PH3 pallet handler, which cycled to raise the entire pallet stack. As the stack rose, the 3^rd or 4^th pallet from the bottom snagged on the pallet handler assembly backstop fairing. The stack then became unstable and fell, unexpectedly striking the forklift operator on the foot. The forklift operator was not injured by the falling pallets.

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Discussion

A review of our current pallet handler documentation indicates that the load capacity of the pallet handlers has been expressed in terms of stack weight, and not in terms of stack height. However, as stack heights become higher, at some point stack stability will become a limiting factor for safe operation. The pallet stack height limit may typically be reached before the pallet stack weight limit is reached.

Accordingly, Alliance has reviewed the design of the Pallet Handler series and the Pallet Master series and recommends that operators limit pallet stack heights to no more than 78” for safe operation of the standard machine. This height limit is measured from the top-of-roller conveyor upwards and assumes use of a standard 12” TOR floor conveyor.

This information will be included into the Pallet Handler Operator’s Manual and the Pallet Master Operator’s Manual for all new production pallet handlers.

In addition, Alliance has designed the safety decal shown below to be included on new production Pallet Handler series and Pallet Master series pallet handlers to advise operators of the safe height stack limits.

This change is effective for all Pallet Handler and Pallet Master machines delivered after October 2005.

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Alliance recommends that operators of Pallet Handler and Pallet Master machines accomplish the following tasks within 90 days of receiving this safety bulletin.

1. Advise their personnel of the new recommended stack height limit for all Pallet Handler and Pallet Master machines.

2. Order and install one of the new p/n 1034011 decals shown above on each affected pallet handler. The decal can be obtained at no charge by contacting the Alliance Parts Dept at (888) 768-2200 (US & Canada) or (509) 535-0356 (International) and selecting option 1. Please reference this safety bulletin when ordering.

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