Transcript Features - E Light Safety, Training and Leadership Blog

Fork Lift Safety
E Light Electric
Services, Inc
2012
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Features
• Rough terrain forklift
– versatile material handler
– capable of moving thousands of pounds
over rugged surfaces
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Session Objectives
• Identify rough terrain forklift hazards
• Understand stability principles
• Follow basic safety rules
• Inspect forklifts and worksites for
safety
• Load, unload, and travel safely
• Prevent tip-overs
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Pre-quiz:
True or False?
How Much Do You Already Know?
Most rough terrain forklift accidents are caused
by operator error.
The weight of the load does not affect stability.
Anyone who has driven an all-terrain vehicle is
permitted to operate a rough terrain forklift.
You should check weight charts when loading
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Hazards
•
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•
Tip-overs/rollovers
Collisions
Slopes/edges
Confined areas
Obstructions
Terrain
– Dips, holes, trenches,
excavations
• Soft ground,
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Accidents
• Most
accidents
are
caused by
operator
error
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Forklifts
• The employer shall certify that each
operator has been trained and evaluated
as required by the standard.
• Certification shall include:
–
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–
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Name of operator
Date of training
Date of evaluation
Identity of person(s) performing the training or
evaluation
– Class of Fork lift
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Forklifts
• The Industrial Truck Association has placed
powered industrial trucks into 11 classes.
– These classifications are based on the type of
engine or motor and the atmosphere they to
operate in.
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Powered Industrial Trucks. 1910.178
• ..1910.178(l)
(l) Operator training.
(l)(1) Safe operation.
(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)(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).
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Powered Industrial Trucks. 1910.178
• (l)(2)
• Training program implementation.
• (l)(2)(i)
– Trainees may operate a powered industrial truck only:
• (l)(2)(i)(A)
– Under the direct supervision of persons who have the
knowledge, training, and experience to train operators and
evaluate their competence; and.
• (l)(2)(i)(B)
– Where such operation does not endanger the trainee or
other employees.
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Powered Industrial Trucks. 1910.178
• (l)(2)(ii)
– Training shall consist of a combination of formal instruction
(e.g., lecture, discussion, interactive computer learning,
video tape, written material), practical training
(demonstrations performed by the trainer and practical
exercises performed by the trainee), and evaluation of the
operator's performance in the workplace.
• (l)(2)(iii)
– All operator training and evaluation shall be conducted by
persons who have the knowledge, training, and experience
to train powered industrial truck operators and evaluate their
competence.
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Powered Industrial Trucks. 1910.178
• (l)(6)
– Certification. The employer shall certify that each operator
has been trained and evaluated as required by this
paragraph (l). The certification shall include the name of the
operator, the date of the training, the date of the evaluation,
and the identity of the person(s) performing the training or
evaluation.
– (l)(4)(iii)
– An evaluation of each powered industrial truck operator's
performance shall be conducted at least once every three
years.
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OSHA Requirements
• Operating instructions, warnings,
and precautions
• Differences between the truck and
the automobile;
• Controls and instrumentation
• Engine or motor operation
• Steering and maneuvering
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OSHA Requirements
• Visibility
• Fork and attachment adaptation,
operation, and use limitations
• Vehicle capacity
• Vehicle stability;
• Vehicle inspection and maintenance
• Operating limitations
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Workplace-related
topics:
• Hazardous (classified) locations
• Ramps and other sloped surfaces
• Closed environments and other areas
where insufficient ventilation or poor
vehicle maintenance could cause a
buildup of carbon monoxide or diesel
exhaust
• Other unique or potentially hazardous
environmental conditions
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Rough Terrain Forklifts
• Transportable, vertical
mast, reach type
• The vertical Mast type
• Variable reach
(telescoping boom)
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Protect Yourself
• Avoid Pinch points
• Avoid entanglements
• Avoid rotating Parts
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Vehicle inspection and
maintenance
• Refer to the operators manual
– Each manufacture is different
– Check the interval and method for air
filters
– Some manufactures require this be
done only by an authorized technician
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Pre-Operating Checks
•
•
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•
•
All instruments and gauges
Horns and backup alarm
Steering
All controls for proper operation
Brakes for proper operation
Fluid levels
Hydraulic leaks
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Pre-Operating Checks
•
•
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•
•
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Lights
Safety belt
Fork tilt mechanism
Battery cables and connections
General wiring
Boom
– Slide pads (extendable)
• Mast
– lift assemble / chains
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Pre-operations
• Check Forks
– Cracks
– Welds
• Fork
• Mount
• Check tires
– Tire inflation effects stability
• Engine pre- operation
checks
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Engine or Motor
Operation
• Rough Terrain with diesel engine
– The majority of rentals in the field
– Cold start problems
– Lack cold cranking batteries
– Lack glow plug system
• Solutions
– If equipped plug in engine heater
– Check operators manual for stating
procedure
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Engine or Motor
Operation
• Warehouse type with propane engine
• Fueling / tank change out
• Follow instruction in operators
manual
• Requires adequate ventilation
– Propane still produces carbon
monoxide
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Differences between the
truck and the automobile
• A car steers only from the front axle
• Forklifts generally steer from the back axle
• Rough Terrain extended boom fork lifts can
steer (depending on model)
–
–
–
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Rear steer
Front Steer
Four wheel steer
Crab Steer
• Check the operators manual to understand how to set
or change and how to correct
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Difference Between an
Automobile and a Forklift
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Difference Between
Front and Rear Steering
• Rear steering provides
a much shorter turning
radius
• Rear steering also has
the tail swing effect
that can strike objects
or personnel
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Rear Steering
• Rough Terrain Fork lift with rear
steering only
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Front Wheel Steer
• Drives like a car
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4 Wheel Steer Tuning
• Rough Terrain
Fork lift with all
wheel steering
• Caution
Tail swing
Fork Swing
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Crab Steer
• All four wheels angle the same way
• Allows for a sideways movement
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The Problem
• In shifting form front steer to rear to crab to
four wheel
• If not reset can have the wheel miss aliened
for any of the steering modes
• Return front or rear to inline with machine
• Then set the other wheels to in line with the
machine.
• Check operators manual
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Controls and
instrumentation
• Refer to the operators manual
– Every manufacture is different
– Take the time to know and understand
the controls and the instrumentation
– Take time to do a dry run or mock run
• Be familiar with the specific controls
• Better to practice before moving expensive
materials with lead time to have shipped
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The Work Site
• Avoid :
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Holes
Drop-offs
Obstacles
Rough Spots
Soft Soil
Deep Mud
Standing Water
Oil Spills
Wet Spots
Slippery Surfaces
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Know your Work Area
• Watch for conditions
that could cause
– Loss of control
– A collision
– Tip over
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Know your Work Area
• Overhead Electrical
– De-energize line if needed
• Hazardous weather
• Confined Spaces
• Maintain a SAFE SPEED
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Plan Your Work
• Avoid Ruts and Ditches
• Curbs
• Exposed Railroad
Tracks
• Know the Weight of the
Load
• Use Signal person to
land loads at a distance
or obstructed view
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Plan Your Work
• Watch for Tail and
Fork swing
• Lower load / forks
• Set the parking
Brake before
dismounting
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Visibility
• Rough terrain Forklift have large
blind spots
– To the rear
– To the side
• Visibility can be blocked by the load
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Visibility
• Blind spots
– To the rear
– To the side
• Know what
is all the
way around
your forklift
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Visibility
• Visibility can be blocked by the load
– Operate in reverse if vision is blocked
– Get a spotter to when visibility is
blocked
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Vehicle Stability
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Stability
Vehicle Center of Gravity
(unloaded)
Stability Triangle
Center of Gravity of Vehicle
and Maximum Load
(Theoretical)
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Out Side the Stability
Triangle
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Stability Triangle
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Combined Center of
Gravity
• When the
combined center
of gravity is with in
the triangle the
forklift is stable
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Combined Center of
Gravity
• When the combined
center of gravity is
with in the triangle the
forklift is stable
• When the combined
center of gravity is
outside the triangle
instability / tip over
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Conditions that
Affect Stability
–
–
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Ground conditions
Speed
Grade
Load
Tire inflation
Operator skill,
knowledge,
judgment
Vehicle Capacity
• Know and understand
load charts
• Posted on the
machine
• In operators manual
– With outriggers
– Without outriggers
– With attachments
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Operating Limitations
• Center of gravity
out side the
stability triangle
• Load extended
beyond load
capacity
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Stability Review:
Make the Right Choice
• To prevent tip-overs,
where should the center
of gravity be in relation
to the stability triangle?
• a. Inside triangle
• b. Outside triangle
• The stability triangle is
formed by the two front
wheels and the:
• a. Operator’s seat
• b. Center of rear axle
• How does adding a load
affect the center of
gravity?
• a. Shifts it
• b. Doesn’t affect
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Basic Safety Rules
• Authorization
• Controls
• Alarm/horn
• Visibility
• Seat belt
Basic Safety Rules
– Don’t stand under
forks
– No riders
– Don’t park on an
incline
– Don’t leave trucks
unattended
– Use proper
shutdown
(cont.)
Rules of Operation
• Know the Load Capacity
• Buckle the Seat belt
• Lower forks flat on the
ground before dismounting
• Never Lift personnel
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Review
•Do you understand:
• Rough terrain forklift
features?
• Hazards?
• Stability principles?
• Inspection
procedures?
• Basic safety rules?
Operate Safely
• Know the weight
of the Load
• Know the Load
capacities
• Avoid Double
stacking
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Operate Safely
• Travel Slowly
over rough
terrain
• Avoid Jerks
and Sudden
Stops
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Unloading from Trucks
• Center forks on load
– Center of gravity of load
• Tilt load back
– Lifting load by tilting
• Raise load for adequate clearance
• Retract boom or back slowly
• Depending on situation and type of forklift
• Lower load before traveling
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Operate Safely
• Load positioned
correctly an balanced
on forks
• Know clearances
• Look for workers on
the ground
• 360o view
• Slow careful turns
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Transporting the load
• Keep Forks
tilted back
• Secure Loose
loads
• Look Where You
are Traveling
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Safe Operations
• Start Slowly for stable
lifts
• Avoid Unstable loads
• Place load gently and
retract forks smoothly
• Check cracking noises
that may indicate
overloading
• Do not extend load
beyond capacity
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Operate Safely
• Have Adequate
Clearance for fork
and tail swing
• Keep loads low
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Transporting the load
• DO NOT travel with the boom
UP across a slope
• Traveling with no load / forks
pointed down (counter
weight / most weight UP)
• Traveling with a load / forks
pointed uphill (The most
weight Up )
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Surface Loading
• Know Landing Weight
limits
• DRIVE as close as
possible to landing
• Set parking brake
before lifting load
• KEEP loads level
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Forklift Damage
• Never load the fork lift with a twist
force on the boom
• This can damage the machine
• Leaving dangerous hidden damage
– In the boom structure
– In the boom guides and slides
– In the pins and bushing of the machine
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Loading
• Check weight charts
• Set forks
• Slide forks
• Center load
• Tilt mast
• Lift load
Causes of
Tip-overs
•
•
•
•
•
•
Weight
Collisions
Speed
Edges
Load too high
Sudden turning
or braking
• Load tilted too far
forward
Preventing Tip-overs
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–
–
–
Load capacity
Turns
Inclines
Load position
Ground conditions
Braking
Exercise
• Which are possible causes of a
tip-over?
– Exceeding load capacity
– Center of gravity inside stability triangle
– Excessive speed when turning
– Traveling with load raised too high
– Tilting load back while traveling
– Braking suddenly with load raised
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In the Event of a Tip-over
•
•
•
•
Never Jump
Stay seated
Keep seat belt on
Keep arms and legs inside
the ROPS
– (roll over protection structure)
• Brace your self in a tip over
• Lean Away from the Impact
• Shut the engine off
Immediately
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Review
•Do you understand:
– Safety procedures for
loading and
unloading?
– Traveling safely?
– Causes of tip-overs?
– Preventing tip-overs?
– What to do in the
event of a tip-over?
Key Points to Remember
Know the hazards
Know how to be safe
Understand stability principles
Never operate unless you are authorized
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