1. Powered Industrial Truck OSHE 112, Spring 2016
Instructor: Mr. Chris Kuiper, CSP
Phone: 1

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
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 and
ASME/ANSI B

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
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.

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
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.

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
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.

13. 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.

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
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.

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
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.

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
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.

20. 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.

21. 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.

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
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.

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-Mast
Extended-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. 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

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. 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.

47. 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.

48. 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

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