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

2. 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

3. 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

4. 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%)

5. 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

6. 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/poweredindustr ialtrucks/index.htmlhttp://www.osha.gov/SLTC/poweredindustr ialtrucks/index.html

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

8. 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

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

10. ROUGH TERRAIN COUNTER BALANCED Similar to industrial type Larger pneumatic tires Rough terrain capabilities Good ground clearance Usually diesel engine

11. ROUGH TERRAIN COUNTER BALANCED

12. 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

13. TELESCOPIC PIT Crane type boom Hydraulic power Telescopic 4 wheel drive 4 wheel steer Stabilizers Other useful attachments

14. Telescopic PIT

15. 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

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

17. ROUTE PLANNING Laydown areas Pedestrian routes / crossings Other traffic Excavations Other obstructions Gradients Unstable surfaces

18. Pedestrian Safety

19. 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

20. MAINTENANCE Hydraulics Brakes Battery Lights Steering Mast Chains Tires Operator’s cab

21. DAILY CHECKS Tire pressure Brakes / hand break Horn Lights / beacon Fuel Water Oil Battery Hydraulics https://www.osha.gov/dte/library/pit/pit_checklist.html

22. 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

23. REFUELING Diesel Gas Electric

24. 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

25. Battery Charging

26. 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

27. Propane Refueling

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

29. Diesel Refueling

30. 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

31. Class I - Electric Motor Rider Trucks

32. Class II - Electric Motor Narrow Aisle Trucks

33. Class II - Narrow Aisle Trucks

34. Class III - Electric Motor Hand or Hand/Rider Trucks

35. Class III - Hand & Hand/Rider Trucks

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

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

38. Class VI - Electric & Internal Combustion Engine Tractors

39. Class VII - Rough Terrain Forklift Trucks Straight-MastExtended-Reach

40. 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

41. 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 Battery charging station Forklift battery

42. 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

43. 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

44. 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

45. 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

46. 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 Safe Forklift Operation (cont.) A dockboard is used to bridge the gap between loading dock and truck/trailer.

47. A B C Vehicle Center of Gravity (Unloaded) Center of Gravity of Vehicle and Maximum Load (Theoretical) 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

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

49. Mental Stability …?

50. 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

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