Training Sign-In Sheet Client: Kintetsu World Express (KWE) - - PDF document

*Contact Hours: 50 minutes equals one contact hour. Therefore a 1 hour class equals 1.2 contact hours Fax class completed sign-in sheet to Du-All Safety at: (510) 651-8937 or email to safety@du-all.com

Training Sign-In Sheet Client: Kintetsu World Express (KWE) Location: ___________ Class/Regulatory Reference: Forklift Safety, 29 CFR 1910.178 Date: August 6, 2015 Certificates Yes / No Facilitator: Jose Mora________________ Wallet Cards Yes / No (Check the box for the class you attended) Contact Hours*: _2.4 ______ (English) Start Time (ET): 01:00 PM Finish Time: 03:00 PM Total: 2 hr (Spanish) Start Time (ET): 00:00 PM Finish Time: 00:00 PM Total: 0 hr Signature of Participant Print Name Very Clearly

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1 Powered Industrial Truck Operator Training - Initial

Presented by: Jose M Mora, Du-All Safety Date: 2015

Objectives

In this course, we will discuss the following:  Operator training and evaluation  Minimum OSHA general requirements for powered

industrial trucks (PITS) ( )  Safe operation of equipment  Hazard identification  Abatement methods and procedures

Operator Training

 Employer shall ensure each powered industrial

truck operator is competent to operate a powered industrial truck safely

 As demonstrated by successful completion of training and evaluation.

Operator Training

 Trainees may only operate the truck:

 Under direct supervision of trainer  Where such operation does not endanger the trainee or other employees

Operator Training

 Training program must consist of a combination of:  Formal instruction, for example

» Lecture » Discussion » Interactive computer learning » Video, written material

 Practical training exercises  Practical training exercises  Evaluation  Operator training and evaluation  Shall be conducted by a person who have the knowledge, training, and experience

Operator Training

 Training program content – initial training  Truck-related topics  Workplace-related topics Regulatory requirements

1910.178(l)(3)

 Regulatory requirements

2

Operator Training

 Truck-related topics  Differences from automobile  Operating instructions, warnings and precautions  Controls and instrumentation Co

• s a d

s u e a o  Engine or motor operation  Steering and maneuvering  Visibility

Operator Training

 Fork and attachment adaptation, operation, use  Vehicle capacity and stability  Vehicle inspection and maintenance that the

• perator will be required to perform

 Refueling/charging/recharging batteries  Operating limitations  Other instructions, etc.

Operator Training

 Workplace-related topics

 Surface conditions

 Composition and stability of loads L d i l ti t ki  Load manipulation, stacking, unstacking  Pedestrian traffic  Narrow aisles and restricted areas

Operator Training

 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

Operator Training

 Refresher training and evaluation  Operator observed operating vehicle in unsafe manner  Involved in accident or near-miss incident  Evaluation reveals not operating truck safely  Assigned to different type of truck  Conditions in workplace change

Operator Training

 Employer must certify that each operator has

been trained and evaluated

 Certification must include:  Name of operator Name of operator  Date of training  Date of evaluation  Identity of trainer

3

General Requirements

 This standard covers safety requirements

relating to fire protection, design, maintenance, and use of:

 Fork trucks  Tractors Tractors  Platform lift trucks  Motorized hand trucks  Other specialized industrial trucks

….powered by electric motors or internal combustion engines.

General Requirements

 Both Cal-OSHA and Fed-OSHA have

regulations regarding the operations of industrial trucks.

 Cal OSHA Title 8- General Safety Orders, Sections (Effective July 15 2000) (Effective July 15, 2000).

»3650 – Industrial Trucks. General. »3664 – Operating Rules. »3668 – Powered Industrial Truck Operator Training.

 Fed OSHA Title 29- Code of Federal Regulations, Section (Final)

»1910.178 - Powered Industrial Truck Operator Training.

Safe Operating Rules General Requirements

 Class I - Electric Motor Rider Trucks

Class I - Electric Motor Rider Trucks

 Counterbalanced rider

type, stand up.

 Three wheel electric

trucks, sit-down.

 Counterbalanced rider

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

 Counterbalanced rider,

pneumatic tire, sit-down (high and low platform.

 Risk - tip over

General Requirements

 Class II - Electric Motor Narrow Aisle Trucks

4 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 pickers

 Low lift pallet and platform (rider)  Designed to operate in narrow

passageways; have a narrow track that prevents their safe

• peration on rough surfaces.

 Risk – tip over, fall, and crush

hazards

General Requirements

 Class III - Electric Motor Hand Trucks or

Hand/Rider Trucks

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

g

 Low lift walkie/rider pallet  Risk – Accidental damage

to property, crush/struck by injuries, load stability

General Requirements

 Class IV - Internal Combustion Engine

Trucks (Solid/Cushion Tires)

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

 Counterbalanced  Sit-down  Cushion (solid) tire  Cushion (solid) tire  Risk - tip over

General Requirements

 Class V - Internal Combustion Engine Trucks

(Pneumatic Tires)

5 Class V - Internal Combustion Engine Trucks (Pneumatic Tires)

 Counterbalanced  Sit-down  Pneumatic tire  Pneumatic tire  Risk - tip over

General Requirements

 Class VI - Electric and Internal Combustion

Engine Tractors Class VI - Electric & Internal Combustion Engine Tractors

Sit-down rider General Requirements

 Class VII - Rough Terrain Forklift Trucks

Rough Terrain Straight Mast Forklifts Rough Terrain Extended-Reach Forklifts

6

Common Misconceptions

• 1. Forklifts can’t go very fast and therefore are

not very dangerous. True or False?

• 2. Driving a forklift is basically no different from

driving a car. True or False?

• 3. All forklifts are basically the same. True or

y False?

Common Causes of Forklift Accidents

 Federal OSHA research has identified

the most common causes of forklift accidents.  Vehicle Tip-Over  Person Struck by Truck  Person Struck by Falling Load  Elevated Employee on the Truck  Running off a Loading Dock or Other Surfaces  Improper Maintenance  Lost Control of Truck  Material Struck by Truck  Review FACE Reports

General Requirements

 Does not apply to:  Compressed air or nonflammable compressed gas-operated industrial trucks  Farm vehicles  Vehicles intended primarily for earth moving or over-the-road hauling.  OSHA letter of interpretation dated 03/07/2000

General Requirements

 All new PITs acquired and used by an employer shall

meet the design requirements of:

 American National Standard for Powered Industrial Trucks, Part II, ANSI B56.1– 1969’’, which is incorporated by reference as specified in § 1910.6  Approved trucks shall bear a label or some other

identifying mark indicating approval by the testing laboratory.

General Requirements

 Modifications and additions which affect capacity and

safe operation must have prior written approval from manufacturer.

General Requirements

 Truck equipped with front-end attachments other than

factory installed:

 Marked to identify the attachments  Show approximate weight of truck and attachment

7

General Requirements

 All nameplates and markings must be in place and

maintained in a legible condition.

 The term, approved truck or approved industrial truck

means:

 A truck that is listed or approved for fire safety purposes for the intended fire safety purposes for the intended use by a national recognized testing laboratory. See PIT Hazard Classification and Acceptable PIT Designations Chart

Designations

 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. D, DS, DY Diesel E, ES, EE, EX Electric G, GS Gasoline LP, LPS Liquefied petroleum gas

Designated Locations

 Refer to Table N-1 in 1910.178 for the use of

industrial trucks in various locations.

 Power-operated industrial trucks shall not be

used in atmospheres containing hazardous p g concentrations:

 Gases or vapors  Dusts

Converted Industrial Trucks

 Industrial trucks approved for the use of gasoline may

be converted to liquefied petroleum gas and it may be used in those locations where G, GS or LP, and LPS designated trucks have been specified.

Fuel Handling and Storage

 Storage and handling of liquid fuels

must be in accordance with NFPA Flammable and Combustible Liquids Code [NFPA No. 30-1969].

 Incorporated by reference as specified in §1910.6.  The standards of agencies of the U S  The standards of agencies of the U.S. Government, and organizations which are not agencies of the U.S. Government which are incorporated by reference in this part, have the same force and effect as other standards in this

• part. Only the mandatory provisions (i.e.,

provisions containing the word "shall" or other mandatory language) of standards incorporated by reference are adopted as standards under the Occupational Safety and Health Act

Fuel Handling and Storage

 Storage and handling of liquefied petroleum

gas fuel must be in accordance with NFPA Storage and Handling of Liquefied Petroleum Gases [NFPA No. 58-1969].

 Incorporated by reference as specified in §1910 6 as specified in §1910.6

8

Changing/Charging Storage

 Battery charging installations must be located

in areas designated for that purpose.

Changing/Charging Storage

 Facilities must be provided

for flushing and neutralizing spilled electrolyte.

 Facilities must be provided

for protecting charging apparatus from damage by trucks.

Changing/Charging Storage

 Conveyor, overhead hoist, or equivalent material

handling equipment must be provided for handling batteries.

 Reinstalled batteries shall be properly secured.

Changing/Charging Storage

 Trucks must be properly positioned and brake

applied before attempting to change or charge batteries.

Changing/Charging Storage

 When charging batteries, vent caps must be checked

for proper functioning.

 The battery cover must be opened to dissipate heat.

Changing/Charging Storage

 Facilities must be provided for adequate

ventilation for dispersal of fumes from gassing batteries.

9 Changing/Charging Storage

 Smoking must be prohibited

in the charging area.

 Precautions must be

taken to prevent open flames, sparks or electric arcs in charging area.

Changing/Charging Storage

 Tools and other metallic objects must be kept

away from the top of uncovered batteries.

Lighting for Operating Areas

 Where general lighting is less than 2 lumens

per square foot, auxiliary directional lighting shall be provided on the truck.

Noxious Gases and Fumes

 Concentration levels of carbon monoxide gas

created by powered industrial truck operations must not exceed the levels specified in 1910.1000.

 Air contaminants/Carbon monoxide “CO”  Symptoms of Carbon Monoxide Poisoning

» Low levels poisoning can be confused with flu symptoms food » Low levels poisoning can be confused with flu symptoms, food poisoning or other illnesses and carry a long-term health risk if left

• unattended. Some of the symptoms are:

» Shortness of breath, mild nausea, mild headaches » Moderate levels of CO exposure can cause death if the following symptoms persist for a long measure of time. » Headaches, dizziness, nausea, light-headedness » High levels of CO can be fatal causing death within minutes.

Forklift Types & Fundamentals Vehicles vs Industrial Trucks

 Rear wheel steering- causes the rear end of

the industrial truck to swing.

 Forklifts can weigh as much as 5 x more than a

vehicle.

 Additional weight can cause slowed braking

g g response and handling.

 Some have features like vehicles others use

completely different controls.

10

Makes and Models

 Controls and operation may vary from one

manufacturer to the next.

 Individuals should be trained on the equipment

they will be using.

 Familiarity with your equipment is critical to safe  Familiarity with your equipment is critical to safe

• peration.

 Review operator manual before use.  Different Types of Forklifts = Different Hazards

Equipment Major Parts

Other:

• Attachments
• Nameplate
• Danger , Warning and

Caution Decals

• Controls
• Instruments
• Battery
• Tires
• Safety & Warning

Devices

Danger, Warning, & Caution Decals

Safety labels should be clearly visible to the

• perator and must be replaced if missing,

damaged, or illegible. Under one classification system, there are three types of warning labels or decals: DANGER means if the danger is not avoided, it will cause death or serious injury. WARNING means if the warning is not heeded, it can cause death or serious injury. CAUTION means if the precaution is not taken, it may cause minor or moderate injury.

Controls



Forward/Reverse Directional Controls The directional control allows the operator to move the forklift forwards or backwards.



Hydraulic Lift Controls Forklifts have hydraulic lift controls to raise and lower the forks and to tilt the forks.



Pedals Forklifts have accelerator and brake pedals that operate Forklifts have accelerator and brake pedals that operate similarly to these pedals in other vehicles. Some forklifts also have a clutch, which allows shifting into higher forward gears.  The inching pedal gives the operator more control of the forklift in tight places.



Parking Brake Forklifts are equipped with a parking brake. Be sure to set the parking brake when leaving a forklift and block the wheels if the forklift is parked on an incline.

Instrumentation

Never operate a forklift if a warning light or gauge signals an unsafe condition.

– Instrument Panel – Oil Pressure Gauge – Temperature Gauge/Light Temperature Gauge/Light – Transmission Temperature – Fuel Gauge – Hour Meter – Battery Discharge Indicator

Parts – Attachments

Powered industrial trucks often use various attachments in place of traditional forks. These attachments increase the versatility of the truck, but can present important safety considerations, including stability, capacity, and visibility.

Carton Clamp Slipsheet Clamp Data Plate for Attachment

11

Safety Guards

 High lift rider trucks must be

fitted with an overhead guard.

 Overhead guard required unless operating conditions do not permit.  An overhead guard is designed to protect the

• perator from falling objects.

 Check for broken welds, missing bolts, or damaged areas

Safety Guards

 If the type of load presents a hazard, then the

user must equip fork truck with a vertical backrest extension manufactured in accordance with the standard.

Tires

Common types of forklift tires include pneumatic, solid, and polyurethane.

• As part of the daily

inspection of the forklift inspection of the forklift, check tire condition, including cuts and gouges, and check pressure for air- filled tires – level.

Warning & Safety Devices

Powered industrial trucks may be equipped by the manufacturer with the following safety devices: Seat belts and similar restraints Horns Backup alarms that sound when forklift reverses Fire extinguisher Warning lights that flash Directional signals and brake lights Mirrors Mirrors Requirements and Recommended Practices: Equip every power-propelled truck with an operator-controlled horn, whistle, gong, or other sound-producing device. ANSI B56.1-1969 Equip every truck with an operator-controlled horn, whistle, gong, or

• ther sound-producing device. ANSI/ITSDF B56.1-2005.

Where appropriate to the worksite, equip trucks with additional sound-producing or visual (such as lights or blinkers) devices. ANSI/ITSDF B56.1-2005.

Truck Operations

 Trucks shall not be driven up to anyone

standing in front of a bench or other fixed

• bject.

 No person shall be allowed to stand or pass

d th l t d ti f t k under the elevated portion of any truck, whether loaded or empty.

12

Truck Operations

 Unauthorized personnel shall not be permitted to ride.  A safe place to ride shall be provided where riding of trucks is authorized.  The employer shall prohibit arms

• r legs from being placed between

the uprights of the mast or outside the running lines of the truck.

Review: Cal OSHA Reported Case

Truck Operations

 When a powered industrial truck is left

unattended:

 Load engaging means shall be fully lowered.  Controls shall be neutralized.  Power shall be shut off and brakes set. Power shall be shut off and brakes set.  Wheels shall be blocked, if the truck is parked on an incline.

Truck Operations

 Follow the previous requirements if the

• perator leaves the vehicle:

 Unattended, or  Operator is 25 feet or more away from the vehicle,

• r
• r

 Whenever it’s not in his view

Truck Operations

 When the operator of an industrial truck is

dismounted and within 25 feet of the truck still in his view, the load engaging means shall be:

Fully lowered  Fully lowered  Controls neutralized  Brakes set to prevent movement  Wheels blocked if truck parked on incline

Truck Operations

 A safe distance shall be

maintained from the edge of ramps or platforms while on any elevated dock, or platform or freight car.

 The width of one tire on the PIT shall be the minimum distance maintained from the edge by the truck.

 Forklifts are not to be used

to open or close freight doors.

Truck Operations

 Brakes shall be set and wheel blocks shall be

in place to prevent movement of trucks, trailers, or railroad cars while loading or unloading.

13

Truck Operations

 Fixed jacks may be necessary to support

semi-trailer during loading or unloading when the trailer is not coupled to a tractor.

Railroad Cars

 Wheel stops or other positive protection must

be provided to prevent railroad cars from moving during loading or unloading

• perations.

Railroad Cars

 Setting the hand brake would be positive

protection to prevent railroad car movement.

Truck Operations

 There shall be sufficient headroom.  Lights, pipes, sprinkler system, etc.

Elevating Employees

 A safe work platform must be used

14

Elevating Employees

 A safe work platform must be used with Fall

Protection System.

Work Platforms

 Must be securely attached to the mast of the

forklift

 42” High guardrail, mid-rail and toeboard  Employees may not be transported to the work

location in the platform p

 Employees must wear approved fall arrest

system

Traveling

 All traffic regulations shall be observed,

including authorized facility speed limits.

 A safe distance shall be maintained.  Approximately three truck lengths  Right of way  Ambulances, fire trucks, etc. …  Fire aisles, access to stairways, and fire

equipment shall be kept clear.

Traveling

 Watch for intersections, blind spots or other dangerous

locations.

 All drivers must slow down, sound horn at cross aisles

and other locations where vision is obstructed.

 If load obstructs forward view, then travel with load trailing.

15

Traveling

 Railroad tracks shall be crossed diagonally

wherever possible.

 Operators shall keep a clear view

• f the path of travel.

p

Traveling

 When ascending or descending grades in

excess of 10 percent, loaded trucks must be driven with the load upgrade.

 Never turn a forklift on a grade.

Traveling Empty (Forks Downgrade)

 When traveling without a load, the forks should

point downgrade, regardless of direction of travel..

 Never turn a forklift on a grade.

g

16

Traveling

 Dockboards or bridgeplates must be properly

secured before being driven over.

 Potential hazards  While entering and leaving truck trailers or railroad cars: cars:

» Falling off loading dock » Moving trucks or railroad cars during loading and unloading » Slipping or inadequate dockboards

Traveling

 Elevators shall be approached slowly and

squarely.

 Once on the elevator:

»Controls shall be neutralized »Power shut off »Brakes set

 Motorized hand trucks

must enter elevator or

• ther confined areas

with load end forward.

 Verify elevator load capacity.

Traveling

 Running over loose objects on

roadway surfaces must be avoided.

 Look out for smalls amount od

water and oil on smooth floor water and oil on smooth floor surfaces.

 Watching your speed and how

you should negotiate turns.

 Watch for pedestrians.

Loading

 Only stable or safely arranged loads shall be

handled.

 Exercise caution when handling off-center loads.

Loading

 Only loads within the rated capacity of the

truck must be handled.

Stability

 Forward wheels are the fulcrum

Fulcrum Fulcrum

17

Stability Stability Triangle

 Counterbalanced powered industrial trucks

 Vehicle is supported at three points

Stability Triangle

 Counterbalanced powered industrial trucks

 Vehicle is supported at three points

Incident Review Loading

 Long or high (including

multiple-tiered) loads which may affect capacity must be adjusted. O ll d th l d d

 On all grades the load and

load engaging means shall be tilted back if applicable, and raised only as far as necessary to clear the road surface.

Loading

 Use extreme care when

tilting the load forward or backward, particularly when high tiering.

 Tilting forward with load  Tilting forward with load

engaging means elevated shall be prohibited except to pick up a load.

18

Truck Operation

 Operation of trucks  Repairs, defectives or unsafe conditions  Fuel tanks must not be filled while the engine is running  Clean up any spillage before starting truck  Do not operate if fuel is leaking from vehicle  No open flames

Fuel cap (note spilled gas

• n the outside of the truck.)

Trucks Maintenance

 Trucks not in safe operating condition must be

removed from service.

 Repairs must be made by authorized personnel.  Any repairs to the fuel and ignition systems shall be

conducted only in locations designated for such repairs.

Trucks Maintenance

 Mufflers shall be inspected as required.  Vehicle shall be removed from service when

temperature of parts indicates overheating.

 Industrial trucks must be kept in a clean condition. Free of lint excess oil and grease  Free of lint, excess oil and grease

Trucks Maintenance

 Prior to repairs to electrical system, the battery shall be

disconnected.

 Parts replaced shall be replaced only by the equivalent

type of part from the manufacturer.

 Trucks shall not be altered so that the relative positions  Trucks shall not be altered so that the relative positions

• f the various parts are different from what they were

when originally received from the manufacturer.

Pre – Operation Inspection

OSHA requires that all forklifts be examined at least daily before being placed in service. Forklifts used on a round- the-clock basis must be examined after each shift. The operator should conduct a pre-start visual check with the key off and then perform an operational check with the engine running. The forklift should not be placed in service if the examinations show that the vehicle may not be safe to operate. Any problems should be recorded on the appropriate documents and reported to a supervisor.

Pre – Operation Inspection

• Internal Combustion Forklifts
• Engine oil
• Brake reservoir
• Engine coolant
• Air filter

Properly mounted tank Pressure relief valve pointing up Hose and connectors Air filter

• Belts and hoses
• Radiator
• Hood latch
• Liquid Propane Forklifts
• .

Tank restraint brackets Tank for dents and cracks Tank fits within profile of truck Leaks

19

Operational Inspection

After completing the pre-

• peration inspection,
• perators should conduct an
• perational inspection with the

engine running. This inspection includes: Accelerator linkage Tilt control: forward and back Hoist and lowering control Attachment control Horn g Inch control (if equipped) Brakes Steering Drive control: forward and reverse Lights Back-up alarm (if equipped) Hour meter

NOTE: Unusual noises or vibrations should be reported immediately.

Tipovers or Rollovers

 There are two basic type of tipovers in a forklift:  A forward tip or longitudinal tip  A lateral or side tip  The procedure to follow in the event of tipover varies

depending on the type of tipover and the class of depending on the type of tipover and the class of forklifts that you may use in your facility.

Accident Investigation Summary

We covered the following requirements for the

• peration and maintenance of power industrial

equipment:  Operator training and evaluation

Minimum OSHA general requirements for

 Minimum OSHA general requirements for

powered industrial trucks  Safe operation of equipment  Hazard identification  Abatement methods and procedures

Thank You For Attending!

Final Questions? Final Questions?

20

Thank You For Attending!

Written Test Written Test

Thank You For Attending!

Practical Practical Evaluation

Questions

 Class: Forklift Training  Instructor: Jose Mora, Safety Specialist  Contact: 510 – 651-8289; du-all.com  Fax Sign In sheets to (510) 651-8937 or

email to safety @du-all.com y @