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Powered Industrial Truck Operator Training

Powered Industrial Truck Operator 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

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Powered Industrial Truck Operator Training

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  1. Powered Industrial Truck Operator Training

  2. 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 Signs

  3. 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

  4. An average of 94 workers are killed each year as a result of forklift accidents. Source: Bureau of Labor Statistics

  5. 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.

  6. 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)

  7. 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)

  8. 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

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

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

  11. Class VI - Electric & Internal Combustion Engine Tractors

  12. Class VII - Rough Terrain Forklift Trucks

  13. Rough Terrain Straight Mast Forklifts

  14. Rough Terrain Extended-Reach Forklifts

  15. Powered Industrial Trucks Used in Maritime

  16. 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:

  17. 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.

  18. Attachments and Modifications • Specific operator training • Weight of attachments • Increased load center 1910.178(a)(4)

  19. 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.

  20. 1910.178(a)(6) The user shall see that all nameplates and markings are in place and are maintained in a legible condition.

  21. RATED CAPACITIES 5000 4000 3000 2000 12 18 24 30 36 42 48 54 Load Center--Distance from front face of forks to center of gravity load--inches. 1910.178(a)(6) Based on Verticle Uprights with Max. Fork Heights Up to 153 1/2”

  22. NEC Hazardous Location Types 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. Divisions The division defines the probability of hazardous material being present in an ignitable concentration in the surrounding atmosphere. Classes The classes defines the general nature of hazardous material in the surrounding atmosphere.

  23. Fuel Handling and Storage1910.178(f) No ignition sources within 35’ Maintain contact between nozzle and unit Stay with refueling process while actively refueling Clean spills immediately

  24. 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

  25. 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

  26. Preoperation Inspection 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

  27. Preoperation Inspection In the seat • 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

  28. Preoperation Inspection • Forklifts are designed to be safe: • Seatbelts • Horns • Lights (if equipped) • Cage • Three point mount/dismount

  29. Operating a Lift Truck • 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

  30. 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

  31. Operating a Lift Truck • 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

  32. Operating a Lift Truck Be aware of blind spots where pedestrians can walk into your path of travel

  33. Operating a Lift Truck Compare an automobile to a forklift View is obscured by the masts

  34. Operating a Lift Truck Compare 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

  36. Operating a Lift Truck Compare an automobile to a forklift

  37. Operating a Lift Truck • Pedestrians • Ramps • Slippery floors • Weak trailer floors • Poor lighting • Congestion • Jack stands missing • While handling a load: • Large/bulky • Uneven weight • Broken pallet • Poorly stacked • Others?

  38. Operating a Lift Truck • Tipping Over • Do not jump • Hold onto the steering wheel • Brace your feet • Lean away from the fall • Stay in the cage!!!

  39. 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 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.

  40. Case Study April 11, 2008 Spokane Washington A 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.

  41. Case Study March 06, 2008 Mount Union A 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.

  42. Stability Triangle 3-point suspension • Forklift’s center of gravity • Combined center of gravity • Load center beyond 24”

  43. Center of Gravity 48” A Distance from the edge of the item to the item’s center of gravity 20” 40” B Balance point

  44. 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

  45. Center of Gravity

  46. 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)

  47. 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

  48. 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

  49. Docks 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. • Seat belts must always be worn

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

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