1. 1 Powered Industrial Trucks SafetyWorks! 623-7900

2. 2 Contents Background & Purpose Training requirements Common operations Job hazard analysis Workplace & Equipment Safe operation Center of gravity Inspection Hands-on exercise

3. 3 Background The Industrial Truck Association (ITA) petitioned OSHA Accidents could be avoided if operators were better trained Studies found If operators received better training operator error rates could be reduced by 70%

4. 4 Injuries – Maine relating to forklifts by persons age 3 – under 19 7 – 19-24 8 – 25-29 9 – 30-34 8 – 35-39 7 – 40-44 10 – 45-49 6 – 50-54 4 – 55-59 2 – over 60

5. 5 7 Classes of Powered Ind. Trucks Electric motor rider Electric motor narrow isle Hand and hand/rider Internal combustion-solid tire Internal combustion-pneumatic tire Elec. & Internal combustion tractors Rough terrain (straight and ext. boom)

6. 6 Class I - Electric Motor Rider Trucks

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8. 8 Class II - Narrow Aisle Trucks

9. 9 Class III - Hand & Hand/Rider Trucks

10. 10 Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires

11. 11 Class V - Internal Combustion Engine Trucks (Pneumatic Tires)

12. 12 Class VI - Electric & Internal Combustion Engine Tractors Sit-down riders

13. 13 Class VII - Rough Terrain Forklift Trucks Straight-mast forklift Extended-reach forklift All rough terrain forklift trucks

14. 14 Rough Terrain Straight Mast Forklifts

15. 15 Rough Terrain Extended-Reach Forklifts

16. 16 Powered Industrial Trucks Used in Maritime Straddle Carriers

17. 17 Powered Industrial Trucks Used in Maritime Container Reach Stacker

18. 18 Powered Industrial Trucks Used in Maritime Empty-Container Handler

19. 19 Powered Industrial Trucks Used in Maritime Container Handlers

20. 20 Common Elements Forks that pick up loads, hold it during transit, put it in place at new location Forks tilt forwards / backwards Space between forks is adjustable Forks can be replaced with attachments

21. 21 Training Requirements Performance oriented standard Allows employer the flexibility in teaching / content and to exclude topics that are not relevant to safe operations at their workplace

22. 22 1910.178(l)(2)(ii) Training shall consist of: Formal instruction Demonstrations by trainer and exercises by trainee Evaluation of operator’s performance in the workplace

23. 23 1910.178 (l)(5) Avoidance of duplicative training If operator has demonstrated competency in training topics further training is not required.

24. 24 1910.178(l)(4)(ii)(D)-(E) Additional training needed if: The truck is modified Assigned to a different truck Conditions in the workplace change

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27. 27 1910.178(l)(4)(ii)(A)-(C) Refresher training needed if : Operating in an unsafe manner Accident Near miss Unfavorable evaluation

28. 28 1910.178 (l)(2)(iii) Training and evaluation shall be conducted by persons who have: Knowledge Training Experience

29. 29 1910.178(l)(6) Certification of training: Name of operator Date of training Date of evaluation Person performing the evaluation Training/certification is the responsibility of the employer

30. 30 1910.178(l)(4)(iii) Evaluation of operator’s performance shall be conducted at least every three years

31. 31 1910.178(l)(1)(i) Employer shall assure the operator is competent Employee shall demonstrate competency

32. 32 1910.178(l)(2)(i) Trainee may only operate under the supervision of competent person with skills to train and evaluate

33. 33 Maine Public Sector only Skid steer If used 50% or more of the time as a forklift -- forklift training required Training in safe operation is required for all equipment

34. 34 Forktruck Operators Operators must be at least 18 years of age.

35. 35 Unique Characteristics Each type has its own unique characteristics and some inherent hazards. Training must address the unique characteristics of the type of vehicle the employee is being trained to operate AND the hazards of the workplace

36. 36 Job Hazard Analysis Before starting training an assessment of the workplace should be done. A JHA is one approach to search for hazards

37. 37 JHA Unusual situations Unstable loads Rough terrain inside / outside Movement / traffic control

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39. 39 Modification to trucks are not authorized unless approved by manufacturer

40. 40 JHA List the safe practices in the operation of each type of truck at that location Each type of trucks has its own controls, attachments, and lifting capacities

41. 41 1910.178(l)(3)(ii)(H) Hazardous conditions: Closed environment Insufficient ventilation Carbon monoxide (CO) Flammable materials Some hazard classes may require selection of a different type of truck..see 1910.178(c)(2)(iv) Table N-1

42. 42 It’s not just how you run the truck

43. 43 It’s the Truck in the Workplace

44. 44 1910.178(i) Carbon Monoxide Maine Data 7 disabling cases  2 – ages 25-29  1- ages 35-39  1- ages 40-44  1 – ages 45-49  2 – ages 50-54

45. 45 Carbon Monoxide (CO) Gas, diesel and propane forklifts Generators Heaters Stoves Lanterns Created by burning fuel

46. 46 CO Symptoms Headaches Fatigue Shortness of breath Nausea Dizziness Many people with CO poisoning mistake their symptoms for the flu (but no fever) or are misdiagnosed by physicians

47. 47 1910.178 (a) Forklifts cannot be modified without prior approval from the manufacturer Machines must be used for their “intended purpose”

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49. 49 1910.178.(l)(3)(i)(B) Differences between powered industrial truck and cars

50. 50 1910.178(l)(3)(i)(C)-(F) Controls and instruments Engine / motor operations Steering / maneuvering Visibility Weight

51. 51 1910.178(l)(3)(i)(K)-(M) Fuel / battery Operating limitations Manual for instructions / warnings / precautions

52. 52 1910.178(l)(3)(i)(G)-(J) Attachments and limitations Capacity Stability Inspection / maintenance by operator

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56. 56 1910.178(l)(3)(i)(G) (Res.) Cage must be secured to the mast Operator must be in the forklift No one in the cage when forklift is being moved All pinch points must be guarded. Standard railings MAY BE PROHIBITED! Consult your dealer or manufacturer Must have load rating

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59. 59 Not Good !

60. 60 Even Worse!

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62. 62 1910.178(l)(3)(ii)(B) Vehicle Center of Gravity Loaded Unloaded Attachments Uneven surface Turning

63. 63 Appendix A - Stability Definitions General Basic Principles Stability Triangle Longitudinal Stability Lateral Stability Dynamic Stability

64. 64 Stability Triangle - Figure 1 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.

65. 65 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 - Figure 2

66. 66 Pedestrian traffic must be controlled

67. 67 1910.178(l)(3)(ii)(E) Aisles and restricted places make operations difficult Speed control is important

68. 68 1910.178(l)(3)(I)(M) Seat belts are necessary to protect the operator and must be worn.

69. 69 1910.178(l)(3)(ii)(F) Hazardous locations must be identified during training

70. 70 1910.178(m)(3) Unauthorized riding shall not be permitted When authorized a safe place to ride shall be provided

71. 71 Unattended truck: Forks lowered Power off/In neutral Brakes set If parked on an incline, chock wheels Not blocking passageways/exits Long term ? Shut off fuel/unplug battery 25 feet defined by OSHA 1910.178(m)(5)

72. 72 Unattended lift

73. 73 1910.178 (m)(7) Trailers or rail cars Brakes set to prevent movement Wheels chocked or dock lock engaged Jacks may be needed for semi-trailers if tractor disconnected. Floors capable of supporting the weight of the forklift and load. Inspect first. Bridge plate inspected & secured

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75. 75 Inspect trailers, floors elevators…etc.1910.178(m)(7)

76. 76 Common Precautions Respond to surface conditions Wrap or secure loads Keep forks low Look in direction of travel Watch for pedestrians Drive straight up & down ramps Use for intended purpose

77. 77 Common Precautions (2) Allow for counterweight swing Inspect each shift/ before using Stop & sound horn at blind intersections Park & secure properly when unattended. Cross RR tracks at slight diagonal Watch for overhead obstructions

78. 78 Overhead Obstructions??

79. 79 1910.178 (g) Battery charging No smoking/sparks Adequate ventilation Eyewash Proper reinstallation of batteries Goggles, faceshield, apron, gloves

80. 80 Propane Tank Change Select safe location/control traffic Shut off tank & run engine to drain Wear safety glasses/goggles & gloves Use Good body mechanics Align new tank properly Hand tighten Open tank slowly and check for leaks

81. 81 1910.178 (f) Liquid fuels storage National Fire Protective Association Flammable and Combustible Liquid Liquids Code (NFPA #30-1969)

82. 82 1910.178 (q)(7) Pre shift inspection Daily record Parts of truck Controls / instruments

83. 83 Pre shift Pre/use Inspection If you find a defect…….. Park & secure the truck safely Take the keys Tag the truck “Do Not Use” or as required by company procedures Report the problem to your supervisor

84. 84 Components of a Forklift Truck* *One of the most common types of powered industrial trucks

85. 85 Let’s Talk About These ………

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