other applicable pit standards n ansi/itsdf ( b56.1-2009 n ansi/itsdf (industrial truck standards...

The Safety Institute of America©

Powered Industrial TruckOperator Training


Other Applicable PIT Standards ANSI/ITSDF (INDUSTRIAL TRUCK STANDARDS DEVELOPMENT

FOUNDATION) B56.1-2009 2/2/2004 ANSI/UL 583-1991 Standard for Safety for Electric-Battery-

Powered Industrial Trucks 3/2/2005 ANSI/NFPA 58-1995 Storage and Handling of Liquefied

Petroleum Gases 3/21/2005 ANSI/UL 558-1991 Standard for Safety for Internal

Combustion-Engine-Powered Industrial Trucks 4/13/2005 ANSI/NFPA 30-1996 Flammable and Combustible Liquids

Code 4/21/2005 ANSI/NFPA505-1996 Fire Safety Standard for Powered

Industrial Trucks Including Type Designations, Areas of Use, Maintenance, and Operation

7/23/2005 ANSI/IES RP7-1990 Practice for Industrial Lighting (not a safety standard)

7/23/2005 ANSI Z535.2-1991 Environmental and Facility Safety Signs2


Reasons for Training Powered industrial truck accidents cause

approximately 36,340 serious injuries in general industry and construction annually.

It is estimated that 20 - 25% of the accidents are, at least in part, caused by inadequate training.

Review changes to policy and procedure Required by OSHA 1910.178


Source: Bureau of Labor Statistics

89

120

95

114

7867

2003 2004 2005 2006 2007 2008

An average of 94 workers are killed each year as a result of forklift accidents.


Defining ‘PIT’

A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials.

Excluded are 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.


Class I - Electric Motor Rider Trucks

Counterbalanced rider type, stand up

Three wheel electric trucks, sit-down

Counterbalanced rider type, cushion tires, sit-down (high and low platform)

Counterbalanced rider, pneumatic tire, sit-down (high and low platform)


Class II - Electric Motor Narrow Aisle Trucks

High lift straddle Order picker Reach type outrigger Side loaders, turret trucks,

swing mast and convertible turret/stock pickers

Low lift pallet and platform (rider)


Class III - Electric Motor Hand or Hand/Rider Trucks

Low lift platform Low lift walkie pallet Reach type outrigger High lift straddle High lift counterbalanced Low lift walkie/rider pallet


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


Class V - Internal Combustion Engine Trucks (Pneumatic Tires)


Class VI - Electric & Internal Combustion Engine Tractors


Class VII - Rough Terrain Forklift Trucks


Rough Terrain Straight Mast Forklifts


Rough Terrain Extended-Reach Forklifts


Powered Industrial Trucks Used in Maritime


Yard Trucks not used OTR

Based on this section of the standard, a yard tractor that operates off-road would fall under the scope of the standard due to the fact that it can be classified as a tractor or other specialized industrial truck powered by an electric motor or internal combustion engine. Additionally, yard tractors fall into Class VI – Electric and Internal Combustion Engine Tractors of the forklift classification system.

According to OSHA:


OSHA 1910.178

Contains safety requirements relating to fire protection, design, maintenance, and use of fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines.


Attachments and Modifications

Specific operator training

Weight of attachments

Increased load center

1910.178(a)(4)


1910.178(a)(5)

If the truck is equipped with front-end attachments other than factory installed attachments, the user

shall request that the truck be marked to identify the attachments and show the approximate weight of the

truck and attachment combination at maximum elevation with load laterally centered.


1910.178(a)(6)

The user shall see that all nameplates and markings are in place and are maintained

in a legible condition.


1910.178(a)(6)

Based on Verticle Uprights with Max. Fork Heights Up to 153 1/2”

5000

3000

4000

2000

12 18 24 30 36 42 48 54

RATED CAPACITIES

Load Center--Distance from front face of forks to center of gravity load--inches.


NEC Hazardous Location Types

ClassHazardous Material in Surrounding Atmosphere

Class I

Hazardous because flammable gases or vapors are present in the air in quantities sufficient to produce explosive or ignitable mixtures.

Class IIHazardous because combustible or conductive dusts are present.

Class III

Hazardous because ignitable fibers or flying's are present, but not likely to be in suspension in sufficient quantities to produce ignitable mixtures. (Group classifications are not applied to this class.)

DivisionPresence of Hazardous Material

Division 1

The substance referred to by class is present during normal conditions.

Division 2

The substance referred to by class is present only in abnormal conditions, such as a container failure or system breakdown.

ClassesThe classes defines the general nature of hazardous

material in the surrounding atmosphere.

DivisionsThe division defines the probability of hazardous

material being present in an ignitable concentration in the surrounding atmosphere.

Also found in OSHA 1910.178 TABLE N-1. -- SUMMARY TABLE ON USE OF INDUSTRIAL TRUCKS IN VARIOUS LOCATIONS

1910.178(b)(12) The atmosphere or location shall have been classified as to whether it is hazardous or nonhazardous prior to the consideration of industrial trucks being used therein and the type of

industrial truck required shall be as provided in paragraph (d) of this section for such location.


No ignition sources within 35’

Maintain contact between nozzle and unit

Fuel Handling and Storage1910.178(f)

Stay with refueling process while actively refueling

Clean spills immediately


Battery Charging

Inspect battery connectors for damage

No smoking in battery-charging area

Immediately clean up electrolyte spills

PPE includes face mask, acid-resistant gloves, and an apron


Preoperation Inspection

As an authorized operator, it is your responsibility to make sure your forklift functions properly

OSHA requires preoperation inspections

Your goal is to provide a hazard free workplace which includes maintaining equipment in the safest manner possible


Walk Around Forklift properly disengaged

Forks down, key off, neutral gear, parking brake on Left/right side

Tire condition, tight lug nuts, no debris around axle, overhead guard is solid, no debris behind the mast

Front Forks in good shape, fork pins in place, backrest solid, mast

& chains greased, hoses in good shape Rear

Counterbalance bolt is tight, radiator clear of debris Look for fluids on floor under vehicle



Nonmoving checks Gauges, lights, horn, back-up

alarm, blinking warning light, operate the tilt & lift mechanism, check the parking brake

Moving checks Put on the seat belt, check the

running brakes, check the steering

In the seat



Forklifts are designed to be safe: Seatbelts Horns Lights (if equipped) Cage

Three point mount/dismount



Avoid loose objects or holes If load blocks view, travel in reverse Never carry passengers Pedestrians always have the right-of-way Safe distance from edge of ramps or docks Never eat or drink No stunt driving or horseplay

Operating a Lift Truck


Only trained, authorized operators Immediately report forklift-related incidents No person should stand under elevated

portion of lift truck Forklift controls operated only from

driver’s seat Never block exits or emergency equipment Smoking is not permitted Keep forks as low as safely possible



Always look in the direction of travel Keep body inside the cage When moving, the mast must not be

raised Sound the horn Operate at safe speeds When turning, watch rear end swing Clearance under overhead

installations



View is obscured by the masts


Compare an automobile to a forklift


Operating a Lift TruckCompare a tugger (AKA Tow Tractor, Tow Motor, etc.) to a

Forklift

•A typical configuration for a tugger includes one tugger and two to three carts. Each cart can carry the same dunnage as a forklift. Thus, a three cart system carries three times the dunnage of a forklift.

•A forklift can travel in reverse while carrying a load.


35

Powered Pallet Jacks

• Gradually start and stop the jack to prevent the load from slipping

• Ensure that your pathway is clear and that you will not trip backwards or run into obstacles.

• Keep your body and your coworkers clear of the pallet jack to avoid being crushed by the machine

• Never ride on a pallet jack and avoid horseplay when you are using one.

• Watch for coworkers and obstacles at all times when you are using an electric pallet jack



Compare an automobile to a forklift


Pedestrians Ramps Slippery floors Weak trailer floors

While handling a load: • Large/bulky• Uneven weight• Broken pallet• Poorly stacked• Others?

Poor lighting Congestion Jack stands missing



Tipping Over Do not jump Hold onto the steering wheel Brace your feet Lean away from the fall Stay in the cage!!!



town, along Highway 44. Although the details were limited Tuesday night, the Jim Wells County Sheriff ’s Department tells us that the man was operating a forklift in the back of the store, when he lost control, fell off and was somehow pinned underneath it. He died at around 4:30 PM, about an hour after the incident at Christus Spohn Alice medical center.

Case Study April 25, 2008 Corpus Christi

A 19-year-old man was killed Tuesday in a forklift accident at the Tractor Supply Company in Alice. Sources have identified the victim as Michael Gomez of the Benbolt area. The Tractor Supply Company just opened a few weeks ago. It’s located on the east end of


April 11, 2008 Spokane WashingtonA Spokane man suffered fatal injuries in a forklift accident in Kendrick Friday morning. Officials said at about 9:30 the Latah County Sheriff ’s office responded to a report of an industrial accident at Brocke and Son’s warehouse in Kendrick. Authorities said 26-year-old Darrell Noakes was negotiating the forklift in an outdoor area near the warehouse when it rolled onto its side, landing on top of Noakes. According to reports, the forklift wasn’t carrying anything at the time. No other injuries were reported in the accident.

Case Study


March 06, 2008 Mount UnionA 38-year-old man is dead following an accident involving a forklift at a Snyder County construction site. State police identify the victim as 38-year-old Ronald Collins, of Mount Union. The accident happened Wednesday at the Monroe Marketplace construction site in Hummels Wharf. Police say Collins was walking alongside the forklift and was run over by the back wheel. A Snyder County deputy coroner says he died at the scene of a traumatic head injury.

Case Study


Stability Triangle

3-point suspension Forklift’s center of gravity

Combined center of gravity

Load center beyond 24”


Center of Gravity

Balance point48”

A

B

20” 40”

Distance from the edge of the item to the item’s center of gravity


Distance from vertical face of the forks to the load’s center of gravity

Typical Load center = 24"

80”

B

1 inch = 100 lbs Important reason for keeping the load

resting against the vertical face of forks

Center of Gravity


Center of Gravity


Loading/Unloading

Before raising a load, understand: Approximate weight of the load Location of the load’s center of gravity

Inspect load for stability, projections, damaged pallets before lifting

Restack unstable loads Never place weight on the back of

a lift truck to increase its capacity Towing always done from rear towing pin Tilt the load back for better load stability Keep forks low when traveling with a load

(ideal 4” above driving surface)


Ramps and Railroads Never turn on a ramp On ramps the load should

be upgrade Ascend or descend ramps

slowly Railroad tracks are crossed

diagonally Never park within 8 feet of

the center of railroad tracks


Dock Safety

Inspect the dock plate Check the trailer floor condition Trailer wheels are chocked, and/or

docks are locked. Nose of the trailer is supported

by the tractor or a fixed jack


Docks Seat belts must always be worn

Date: September 2, 2003 Early DepartureA service crew employee was unloading a trailer

containing roll banding materials. The employee had made a trip into the trailer and was beginning to enter

the trailer again when the truck driver pulled away from the dock. The front wheels of the forklift were practically off of the dock and the employee had his foot firmly on the brake. When the forklift operator

released his foot from the brake the forklift fell forward off of the dock landing on the mast as shown in this photo. The forklift operator was wearing his seat belt keeping him from being injured by being thrown into the mast or other support structure.


Parking

Lower the forks Set gear to neutral Set the parking brake Turn off the key

When is a PIT considered unattended?

1. When the operator is 25’ or more away from vehicle

2. When the operator leaves the vehicle and the vehicle is no longer in his/her view

3. Neither 1 nor 2

4. Both 1 and 2


1910.178(l)(1)(i) The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l).

1910.178(l)(1)(ii) Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the training required by this paragraph (l), except as permitted by paragraph (l)(5).

Training Program1910.178(l)


Trainees may operate a powered industrial truck only:

Under direct supervision of a person who has the knowledge, training, and experience to train operators and evaluate their competence; and,

Where such operation does not endanger the trainee or other employees.



Training shall consist of a combination of: Formal instruction (e.g., lecture,

discussion, interactive computer learning, written material),

Practical training (demonstrations and exercises performed by the trainee), and

Evaluation of the operator’s performance in the workplace



Operating instructions, warnings and precautions

Differences from automobile

Controls and instrumentation

Engine or motor operation

Steering and maneuvering

Visibility Operating

Limitations

Truck-related topics Fork and attachment

adaptation, operation, use

Vehicle capacity and stability

Vehicle inspection and maintenance that the operator will be required to perform

Refueling/Charging/ Recharging batteries

Other instructions, etc.



Surface conditions Composition and

stability of loads Load manipulation,

stacking, unstacking Pedestrian traffic Narrow aisles and

restricted areas Operating in

hazardous (classified) locations

Operating on ramps and sloped surfaces

Potentially hazardous environmental conditions

Operating in closed environments or other areas where poor ventilation or maintenance could cause carbon monoxide or diesel exhaust buildup

Workplace-related topics



The requirements of the OSHA standard on powered industrial trucks must also be included in the initial operator training

program.



An evaluation of each powered industrial truck operator’s performance must be

conducted:After initial training,

After refresher training, andAt least once every three years

Refresher and Remedial Training


Unsafe operation Accident or near-miss Evaluation indicates

need Different type of

equipment introduced

Workplace condition changes

Refresher and Remedial Training


An authorized operator…

is trained and authorized to operate a powered industrial truck

should keep unauthorized employees off of forklifts

should keep pedestrians away from the operating zone of a forklift

will lock out unsafe lifts as determined in a preoperation inspection


Summary

BE SAFE!!!

other applicable pit standards n ansi/itsdf ( b56.1-2009 n ansi/itsdf (industrial truck standards...

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industrial trucks n

procedure n

operation n

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powered industrial trucks

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