Powered Industrial Truck OSHE 112, Spring 2016 Instructor: Mr. Chris Kuiper, CSP Email: august.kuiper@selu.edu Phone: 985-549-3751 1

Review: Crane, Conveyor, and Rigging Crane hazards and control Typical conveyor hazards and safety rules Fiber rope types and strengths Wire rope problems Rigging equipment sling requirements

Definition A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials (ASME) Excludes vehicles used for earth moving and over-the-road hauling Commonly known as forklifts, pallet trucks, rider trucks, fork-trucks, or lift-trucks Can be powered through electric or combustion engines

Injury and Death Annually around 100 workers are killed and another 36,300 seriously injured in forklift-related incidents. (OSHA Data 2015) Forklift overturns (22%) Worker on foot struck by forklift (20%) Victim crushed by forklift (16%) Fall from forklift (9%)

Forklift Training Formal training program required by OSHA standard 1910.178 OSHA specified topics: Stability, operation, etc. Initial training before use Refresher training (based on observations) Employer must certify proper training

Standards OSHA 29 CFR 1910.178: Powered industrial trucks OSHA 29 CFR 1926.600 and 1926.602 ASME/ANSI B56.1-1993 http://www.osha.gov/SLTC/poweredindustrialtrucks/index.html

TYPES OF FORKLIFTS 3 types generally used in construction Industrial counter balanced lift truck Rough terrain counter balanced lift truck Telescopic material handler

INDUSTRIAL COUNTER BALANCED PIT Counter weight to balance Mast Only raise or lower Operate on smooth solid surfaces Poor ground clearance Usually solid tires Fueled by battery/electric, gas, diesel Counter weight for ballast, similar to crane. Mast which holds forks can only be tilted through 15o Loads can only be raised or lowered. A smooth surface such as concrete or tarmac is needed for safe operations. Will get stuck if driven on rough or soft surfaces. Solid tyres give stability but poor traction. Very low center of gravity.

Counter Balanced PIT ANSI Approved: Identifying label Owner modification: Only with mfg. approval and new label required Front-end attachments: Should have new label

ROUGH TERRAIN COUNTER BALANCED Similar to industrial type Larger pneumatic tires Rough terrain capabilities Good ground clearance Usually diesel engine First 3 conditions the same as industrial counter balance. Large pneumatic tyres give it greater ground clearance. It has greater ability to operate on uneven and soft ground and it is used in the construction and agri businesses. Rough terrain forks usually hual crab steer and 4 wheel drive.

ROUGH TERRAIN COUNTER BALANCED

ROUGH TERRAIN AND COUNTER BALANCED SAFETY Tires Slippery slopes 4 wheel drive Bounce Parking brake Forks position Check route Operator skill Steep gradients Site signage The terrain travelled is usually varied sloping, soft, steep, slippy and muddy, so a greater skill is required to operator a rough terrain LT. Travel routes should be chosen carefully and the condition of tyres is important. LT’s are harder to steer and control due to 4 wheel drive and loss of traction due to bounce. Some inclines can be so steep the parking brake will not hold.

TELESCOPIC PIT Crane type boom Hydraulic power Telescopic 4 wheel drive 4 wheel steer Stabilizers Other useful attachments Similar to a mobile crane, this fork is fitted with a boom that is usually pivoted at the rear of the machine. The boom is raised and lowered by hydraulic rams. In addition, the boom can be extended or retracted to give extra height and reach. These machines come in 2 or 4 wheel drive and can hual 2 or 4 wheel steering. Heavy duty machines have stabilizers, various attachments can be used such as concrete skips and loading shovels. They are widely used in construction.

Telescopic PIT

TELESCOPIC MATERIAL HANDLERS 4 wheel drive Crab steer Greater reach for stacking More likely to over turn Stabilizers Telescopic boom Load indicators Keep door shut Safety belt Limited visibility The same principles apply to telescopic booms as to rough terrain c/b. The ability to achieve greater reach with loads increase the hazards of operation particularly over turning to counter act this. Some machines haul stabilizes. The telescopic boom presents the hazard of tipping forward. Therefore, the boom must be fully retracted when travelling. Operator skills are a major factor in the safe operating of telescopic machines as the SWL decreases with the extension of the boom and its degree of elevation. Manufactures specifications must be adhered to. Automatic load indicators must be fitting and operated.

Qualification to Operate Training Basic Job Specific Testing Written, Practical Certification required

ROUTE PLANNING Laydown areas Pedestrian routes / crossings Other traffic Excavations Other obstructions Gradients Unstable surfaces All drivers and operators should be made aware of Fab 14’s traffic plan / laydown areas. Before operating, drivers must be fully familiar with pedestrian routes, vendor traffic, excavation gradients and speed limits.

Pedestrian Safety

PEDESTRIANS / PERSONNEL Segregation of pedestrians – marked walking lanes Audible warning devices - horns Flashing beacon – while unit in operation High visibility clothing – bright orange vests Head and foot protection – hard hat/steel toe footwear Reversing beeper – must be functional and may flash Side mirrors – clean and not cracked Warning signs – pedestrian crossings and fork traffic Always plan lifts using SPA. Don’t encroach on pedestrian routes. If necessary obtain permission and post signage / barriers. Use the horn when approaching blind corners or entering and leaving buildings. Make sure the LT has a flashing beacon and reversing beeper. Drivers must use the minimum PPE required on site. When reversing always check the route with your mirrors as well as turning around.

MAINTENANCE Mast Hydraulics Chains Brakes Tires Battery Operator’s cab Lights Steering Mast Chains Tires Operator’s cab 6 months or 1,000 hour maintenance periods are recommended by the manufacture. All chains and lifting tackle must be thoroughly examined every 6 months. Each machine must be examined and certified annually. Every 50 hours or weekly, the LT should be checked by a competent person other than the operator.

DAILY CHECKS Tire pressure Water Brakes / hand break Oil Horn Battery Lights / beacon Fuel Water Oil Battery Hydraulics The LT driver is obliged to check hit LT prior to use. He is responsible for reporting defects and keeping an inspection log. A check sheet is available. https://www.osha.gov/dte/library/pit/pit_checklist.html

LIFTING AND TRANSPORTING Load weight Load security Pallets Lifting capacity Check route Over head hazards Other traffic Travelling load position Speed limit Loading bays Defective equipment Emergency exits Operators must have a copy of the test certificates. He/she must know the capabilities of the machine. Operator must lift and secure the load so it will safely reach its destination. Must keep the set routes obeying speed limits and signage. Operator must not use a defective or uncertified LT.

REFUELING Diesel Gas Electric

BATTERY CHARGING Charge in well ventilated area Use eye protection when making connections Have eye wash facilities available Acid neutralizing agent available Don’t over fill the batteries with water

Battery Charging

PROPANE FUEL Use refueling area Set parking brake Turn off fuel valve at cylinder Let engine die to purge all LPP from lines Disconnect cylinder and remove Replace with full cylinder Reconnect and turn on valve Check for leaks

Propane Refueling

DIESEL FUEL Use refueling area Turn off engine and use parking brake Avoid overfilling the fuel tank

Diesel Refueling

Classes of Commonly-Used Powered Industrial Trucks The Industrial Truck Association has placed powered industrial trucks into 7 classes: Class I - Electric motor rider trucks Class II - Electric motor narrow aisle trucks Class III - Electric motor hand trucks or hand/rider trucks Class IV - Internal combustion engine trucks (solid/cushion tires) Class V - Internal combustion engine trucks (pneumatic tires) Class VI - Electric and internal combustion engine tractors Class VII - Rough terrain forklift trucks

Class I - Electric Motor Rider Trucks

Class II - Electric Motor Narrow Aisle Trucks

Class II - Narrow Aisle Trucks

Class III - Electric Motor Hand or Hand/Rider Trucks

Class III - Hand & Hand/Rider Trucks

Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires Counterbalanced Forklift (cushion/solid tires)

Class V - Internal Combustion Engine Trucks - Pneumatic Tires Counterbalanced Forklift (pneumatic tires)

Class VI - Electric & Internal Combustion Engine Tractors

Class VII - Rough Terrain Forklift Trucks Straight-Mast Extended-Reach

Trucks for Hazardous Locations “Explosion proof” forklifts are used to control ignition Example: DS (Diesel), EE (completely enclosed electrical), or EX (explosion proof) trucks where flammable gases or liquids are handled, but contained

Battery charging station Hazards and Control Fuel, liquid or gas Handled in accord with NFPA standards Batteries Hazards Lifting and handling Acid (electrolyte) Hydrogen produced during charging Precautions Designated battery charging area Spill control, fire protection, ventilation, etc. Mechanical handling equipment No smoking Forklift battery Battery charging station

Hazards and Control Trucks and Railroad cars Many deaths occur when a truck moves as it is loaded Forklift travel and braking action cause the truck to move away from the dock The forklift falls into the gap and the driver is crushed Precautions Brakes set, wheel chocks (trucks) Wheel stops (railroad cars) Trailer restraints secure the truck to the loading dock Wheel chock Trailer restraint

Safe Forklift Operation Never drive toward a person standing in front of a fixed object Travel with forks at about 4 inches No person under any elevated portion Do not place arms or legs in the mast or outside the truck Unattended trucks must be shut off with lowered load

Safe Forklift Operation (cont.) Set brakes and wheel blocks when loading vehicles (trucks, rail cars, etc.) Maintain headroom under lights, sprinkler systems, etc. Use overhead guard to protect from falling objects Use load backrest when necessary

Safe Forklift Operation (cont.) Cross railroad tracks on the diagonal Sound horn at blind intersections Back down ramps, drive forward up ramps Operate at safe speed, avoid quick turns Personnel on loading platform must have an emergency shut-off for truck power

Safe Forklift Operation (cont.) Secure dockboards and bridge plates Loads must be stable and safely arranged Disconnect battery before repairing electrical system Replacement parts must be equivalent to original A dockboard is used to bridge the gap between loading dock and truck/trailer.

Stability Triangle Vehicle Center of Gravity (Unloaded) of Vehicle and Maximum Load (Theoretical) C Notes: 1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C. Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the combined CG should never be at line B-C. 2. The addition of additional counterweight will cause the truck CG to shift toward point A and result in a truck that is less stable laterally.

Stability Triangle The vehicle is stable This vehicle is unstable and Load CG Load CG Vertical Stability Line (Line of Action) Combined CG Combined CG Vertical Stability Line (Line of Action) Truck CG Truck CG The vehicle is stable This vehicle is unstable and will continue to tip over

Mental Stability …?

Operation of Heavy Equipment Common hazards and general precautions Driving qualifications and training Operating vehicles near workers Backing: signal with three horn blasts (Crunch Zone) Moving forward: blow two blasts Grounding for Powered equipment: ground rods or electrodes should be driven at least 8 ft into the ground Hand signaling

“Classic” Forklift Accidents Trailer moves while being loaded or unloaded, causing the forklift to fall Forklift overturns when traveling or lifting a load