Forklift Safety
OR-OSHA 221Forklift SafetyA review of safe operations and work practices when operatingand working around powered industrial trucks.19242004Presented by the Public Education SectionDepartment of Business and Consumer BusinessOregon OSHA1005
OR-OSHA Mission StatementTo advance and improve workplace safety and health for all workers in Oregon.Consultative Services Offers no-cost on-site safety and health assistance to help Oregon employers recognize and correct safety and healthproblems in their workplaces. Provides consultations in the areas of safety, industrial hygiene, ergonomics, occupational safety and healthprograms, new-business assistance, the Safety and Health Achievement Recognition Program (SHARP), and theVoluntary Protection Program (VPP).Enforcement Offers pre-job conferences for mobile employers in industries such as logging and construction. Provides abatement assistance to employers who have received citations and provides compliance and technicalassistance by phone. Inspects places of employment for occupational safety and health rule violations and investigates workplace safetyand health complaints and accidents.Appeals, Informal Conferences Provides the opportunity for employers to hold informal meetings with OR-OSHA on workplace safety and healthconcerns. Discusses OR-OSHA’s requirements and clarifies workplace safety or health violations. Discusses abatement dates and negotiates settlement agreements to resolve disputed citations.Standards & Technical Resources Develops, interprets, and provides technical advice on safety and health standards. Provides copies of all OR-OSHA occupational safety and health standards. Publishes booklets, pamphlets, and other materials to assist in the implementation of safety and health standards andprograms. Operates a Resource Center containing books, topical files, technical periodicals, a video and film lending library,and more than 200 databases.Public Education & Conferences Conducts conferences, seminars, workshops, and rule forums. Presents many workshops that introduce managers, supervisors, safety committee members, and others tooccupational safety and health requirements, technical programs, and safety and health management concepts.Additional Public Education Services§ Safety for Small Business workshops§ Interactive Internet courses§ Professional Development Certificates§ On-site training requests§ Access workshop materials§ Spanish training aids§ Training and Education Grants§ Continuing Education Units/Credit HoursFor more information on Public Education services,please call (888) 292-5247 Option 2Portland Field OfficeSalem Field OfficeEugene Field OfficeMedford Field OfficeBend Field OfficePendleton Field Office(503) 229-5910(503) 378-3274(541) 686-7562(541) 776-6030(541) 388-6066(541) 276-9175Go online to check out ourProfessional Development Certificate Program!Salem Central Office: (800) 922-2689 or(503) 378-3272Web Site: www.orosha.org
This material is for training use onlyIntroductionWhether you call them jitneys, hi los, forklifts, or lift trucks, powered industrial trucks are as widelyused as your debit card. It seems everywhere you look these days, lift trucks are unloading trailers atdepartment stores, tiering product in a warehouse, or loading material at a construction site. Poweredindustrial trucks are also moving lumber in a sawmill and dropping stock in a grocery store aisle.With well over one million lift trucks in operation today, emphasis must be placed on both workerand pedestrian safety. This program will help you understand OR-OSHA safety and healthregulations governing these pieces of equipment in addition to providing you with assistance indeveloping training for your lift truck operators and other affected employees.Objectives:ã Review OR-OSHA Div 2/Sub N 29 CFR 1910.178 Powered Industrial Trucksã Discuss fundamental safe work practices for the operation of powered industrial trucksA special thank you to Norlift of Oregon, Inc., The Hyster Company, andThe Halton Company for the use of their materials and extensiveknowledge. Craig Hamelund, OR-OSHA Public EducationThe Powered Industrial TruckA powered industrial truck is defined as a mobile, power-driven vehicle used to carry, push, pull,lift, stack, or tier material. Vehicles NOT covered by the Powered Industrial Truck standard arecompressed air or nonflammable compressed gas-operated industrial trucks, farm vehicles, andvehicles intended primarily for earth moving or over-the-road hauling.Norlift of Oregon, Inc.ManitouPlease Note: This material or any other material used to inform employers of safety and health issues or of compliancerequirements of Oregon OSHA standards through simplification of the regulations should not be considered a substitute for anyprovisions of the Oregon Safe Employment Act or for any standards issued by Oregon OSHA.Pictures on cover courtesy of Clark and Norlift of Oregon, Inc.OR-OSHA 221 Forklift Safety1
This material is for training use onlyGeneral RequirementsDesign and construction of powered industrial trucks must be in compliance with the current revisionof ANSI B56.1. ASME B56.1-1993, Safety Standard for Low Lift and High Lift Trucks, is the latestrevision.All nameplates and markings must be in place and .All modifications and additions which affect the safe operationand capacity must be approved by the manufacturer.––data labels must be changed accordinglythe approval must be in writingIf using front-end attachments (other than the manufacturers’), thetruck must be marked identifying the attachment and listing theapproximate combined weight of the truck and attachment atmaximum elevation with a centered load.A winch was welded on the boomof this telescoping truck withoutthe manufacturer’s approval.FOPSNorlift of Oregon, Inc.Most vertical mast forkliftsare equipped with FOPS(Falling Object ProtectiveStructure).What does FOPS protectyou from?What does FOPS notprotect you from?A load backrest (LBR) must be provided when handling small objectsor unbanded units. The LBR must be capable in size and strength toprevent the load, or any part of the load from falling toward theoperator.Norlift of Oregon, Inc.NOTE: Both the FOPS and LBR must not interfere with theoperator’s visibility and guard openings must not be larger than6 in. in one of the two dimensions. More specifications can befound in OR-OSHA Div 2/Sub N OAR 437-002-0227(1) & (2).OR-OSHA 221 Forklift Safety2
This material is for training use onlyStability1. Balancing Both EndsThe lift truck is based on the principle of two weights balanced on opposite sides of a pivot point( ). The forward wheels are the fulcrum. This is the same principle used fora teeter-totter. In order for this principle to work for a lift truck, the load of the forks must bebalanced by the weight of the lift truck.A properly loaded lift truck does not exceed the rated capacity of the truck (as listed on thetruck’s data plate).Norlift of Oregon, IncFulcrum2. Balancing In All DirectionsThe (CG) of any object is the single pointabout which the object is balanced in all directions. Every objecthas a CG.The lift truck has moving parts and therefore has aCG that moves. The CG moves forward and back asthe upright is tilted forward and back. The CG movesup and down as the upright moves up and down.Hyster Sales Co.OR-OSHA 221 Forklift Safety3
This material is for training use onlyStability3. Our Triangle on WheelsWhen the lift truck picks up a load, the truck and load have a new combined CG. The stabilityof the lift truck is determined by the location of its CG, or if the truck is loaded, the combinedCG.In order for the lift truck to bestable, the CG must stay within thearea represented by a triangledrawn between the drive wheelsand the pivot of the steering axle.This triangle is routinely called the.Hyster Sales Co.q Think of riding a tricycle around corners. If you lean forward you will overturn as youmoved your CG to the narrowest portion of the tricycle. If you lean back, applying yourCG over the two rear wheels, you are less likely to tip as you moved your CG to thewidest portion of the tricycle.If the CG moves forward of thedrive axle, the truck tends to tipforward (longitudinal). If the CGmoves outside of the stabilitytriangle, the truck tends to turn onits side (lateral).Hyster Sales Co.What factors have caused trucks to tipforward?OR-OSHA 221 Forklift Safety4What factors have caused trucks to tipover on their side?
This material is for training use onlyStabilityThe center of gravity, and therefore the stability, of the loaded truck is affected by a number offactors including size, weight, shape, and position of the load. Also, the height to which theload is elevated, the amount of forward or backward tilt, tire pressure, and the dynamic forcescreated when the truck is moving. These dynamic forces are caused by things like acceleration,braking, operating on uneven surfaces or on an incline, and turning. These factors must beconsidered when traveling with an unloaded truck, as well, because an unloaded truck will tipover to the side easier than a loaded truck with its load in the lowered position.A recent test was done at a lift truck manufacturer’s technical center involving a 5000 poundcapacity, unloaded lift truck. The three-stage mast was fully extended and tilted back. Oneman was able to tip the truck over by simply grabbing and pulling on the overhead guard.4. Load Center48”24”24”24”When the load is carried at a greater distance than the loadcenter, the maximum capacity of the truck is .The use of special attachments instead of forks will alsothe nominal capacity of the lift truck.Let’stake alook atthis7000 lb.load.48”24”The distance from the front face of the forks (or the load face ofan attachment) to the center of the load is called the. The load center is determined by the location of theCG of the load. Most lift trucks are rated at a load center of 24inches.40”40”40”40”Centered on48” Pallet40”Load Center?Capacity 8050 lbs.Load Center?Capacity 7350 lbs.40”Centered on60” PalletLoad Center?Capacity 6550 lbs.The capacity is the maximum load the lift truck can handle. The capacity of the lifttruck, at load center, is shown on the data plate. The capacity is listed in terms ofweight and load center at a specified load height.Load CenterReverse itOR-OSHA 221 Forklift Safety5Center of the Load
This material is for training use onlyOperator Seat RestraintsOSHA’s Powered Industrial Truck safety standard does not specifically require the use of seat belts;however, employers are required to protect workers from serious and recognized hazards as well asrequire all employees to make full use of safety devices. The current version of ASME B56.1-1993does contain provisions for operator restraint use.Furthermore, employers are expected to strictly adhere to equipment manufacturer recommendations.Most (if not all) industrial truck manufacturers recommend the use of operator restraints and installoperator restraint systems on new sit down trucks. Depending on the manufacturer, operatorrestraints normally include seat belts and side seat retention devices. Most (if not all) manufacturersoffer approved conversion kits for older models.If your truck comes equipped with seat restraints, employees must use them when exposed to anoverturn hazard or traveling in areas where an operator can be thrown from the operator’scompartment. If your existing trucks are not equipped with seat restraints and your employeesoperate the trucks in areas where overturning or being thrown from the truck is possible (i.e. thedynamic forces associated with an unloaded truck, unguarded docks & ramps, unstable loads, uneventerrain, other vehicle traffic, etc.), it is recommended to contact your manufacturer representative foran approved conversion kit.OR-OSHA can cite employers for not requiring/enforcing seatrestraint use when operators are exposed to hazardous areas whereoverturning or being thrown from the truck can occur. In additionto evaluating other contributing factors, the Compliance Officerwill evaluate training and supervision to substantiate a citation.OR-OSHA can also cite employers for not taking advantage of theapproved retrofit kit if any of those hazards exist.Norlift of Oregon, Inc.Bottom Line - Effective Training & Supervision. Competent operators should be able to recognizethose hazardous areas or exposures where overturning or being thrown from the truck can exist.Evaluating the potential hazards:4 Speed4 Speed bumps4 Loading docks4 Debris in roadway4 Ramps/Inclines4 Tire pressure4 Other vehicle traffic4 Railroad tracks4 Defined traffic lanes4 Potholes4 Driving surface (rough or uneven)4 Slick surfaces4 Tight areas4 CG outside of stability triangle4 An unloaded truck is less stable than a properly loaded truck! Is my trainer(s) qualified? How have my operators been determined competent?Are we evaluating our operators and training program in regards to seat belt use?OR-OSHA 221 Forklift Safety6Hyster Sales Co.
This material is for training use onlySafe OperationsEarthworks Training andAssessment ServicesPicking up a load Ensure the load does not exceed the forklift’s capacityEnsure forks are positioned properlyEnsure the load is balanced and secureEnsure bottom of the load is to the propertraveling heightDrive as far into the load as possibleSlightly tilt and liftBack, stop, and lower load 2-6 inches from thefloorBefore backing up, checkand on both sides for pedestrians orother trafficTraveling with a load The operator and pedestrians mustNo riders/passengersTravel at walking speedAll traffic regulations must be met, includingplant speed limits (if established)Maintain at least truck lengthsBe aware of the traveling surfaceKeep the load slightly off gradeAvoid sudden brakingTurn in a sweeping motionKeep the load slightly tilted backSound when approaching corners andblind areasWhen traveling with a load, drive up andLift and lower the load only when stoppedback down inclines and rampsPlacing and stacking a load Completely stop before raising a load Never walk, stand, or allow anyone to passa raised load Move slowly after raising the load Tilt forward, level only when over a stack or rack Make sure forks have cleared the pallet whenbacking out & before turning or changing height Before backing up, check and on bothsides for pedestrians or other traffic Caution must be exercised when handlingunusually shaped and off center loadsOR-OSHA 221 Forklift Safety7Alwaysstackthe loadsquareandstraightHyster Sales Co.
This material is for training use onlySafe Operations Only loads within the rated capacity must be handled Trucks equipped with must be operated as partially loaded trucks even whenunloaded Avoid running over loose objects Under all travel conditions, the truck must be operated at a speed that will permit it to be brought to a stop in a safe mannerNo horseplay or stuntsCross railroad tracksNever park closer than eight feet from tracksRight of way must be given to emergency vehiclesKeep arms and legs from the mast and within the running lines of the truckNever drive up to someone standing next to a fixed objectPowered hand trucks must enter enclosed areas load end forwardNever pass another truck traveling in the same direction at blind corners, intersections, orother dangerous areasLower forks, neutralize controls, shut off, and set brakes (block if on an incline) if truck willbe unattendedIf the load is high obstructing forward view,it is usually recommended to drive inreverse.Can there be a concern if this is a constantpractice?Norlift of Oregon, Inc.Lifting PeoplennNorlift of Oregon, Inc.nSome trucks aredesigned to liftworkers.nnnA work platform equipped with a standard railing firmlysecured to the carriage or forks must be usedFalling object protection must be provided if a hazardexistsAn operator must attend the forklift while workers are onthe platformThe operator must be in the normal operating positionwhile raising/lowering the platformA guard must be provided between the worker(s) and themast if exposure to the chains and/or shear points existMaintain stability of the truck and ensure the loadcapacity is not exceeded (account for platform, workers,materials, etc.)OR-OSHA 221 Forklift Safety8Cotterman Co.
This material is for training use onlyTrainingFederal OSHA proposed the revised training rule in the Federal Register on 12/1/98. OregonOSHA adopted this rule by reference effective 5/26/99. The date by which employers wererequired to be in compliance with this revised rule was 12/1/99. OR-OSHA’s revised operator trainingrequirements {Div 2/Sub N 29 CFR 1910.178(l)} apply to general industry, construction, and maritime activities.OSHA estimates compliance with this revised training rule will prevent fatalities and injuries tothe nearly 1.5 million employees who operate forklifts. Furthermore, complying with this revisionwill reduce the significant risk of death and injury to others caused by the unsafe operation ofpowered industrial trucks driven by untrained or inadequately trained operators.Based on the number of forklifts (1 million), approx. 2/3 are involved in a mishap during theirnormal 8 year work life.Studies showed a 70% reduction in operator errors following training.OSHA estimates this revised rule will prevent 11 deaths and 9,422 injuries per year in generalindustry workplaces and 3 to 4 deaths and 463 to 601 serious disabling injuries each year in theconstruction industry.The rule before the 1999 revision:Wow.That was it.“Only trained and authorized operators shall be permitted tooperate a powered industrial truck. Methods shall be devised totrain operators in the safe operation of powered industrial trucks.”The rule after the 1999 revision: Clarifies training methods and content Requires evaluation and retraining Requires “certification” Provides an avoidance of duplicative training Includes info on stability!Wow!Much better.The first change occurs early in the revised rule. It basically replaces the word “trained” with“competent”.Each powered industrial truck operator must be competent to operate a poweredindustrial truck safely.The employer should determine that each potential operator of a powered industrial truck iscapable of performing the duties that are required of the job.What is your definition of competent?What abilities should be considered?OR-OSHA 221 Forklift Safety9
This material is for training use onlyTrainingPrior to permitting an employee to operate a powered industrial truck (except for trainingpurposes), the employer must ensure that each operator has successfully completed the trainingrequired by this rule, except as permitted under Duplicative Training (p. 11 ).The TrainerThe person(s) training your powered industrial truck operators must have the knowledge,training, and experience to train operators and evaluate their competence.What do you look for when determining your trainer?Training MethodsOperator training must consist of a combination of:1. Formal training2. Practical training3. Evaluation of their performance in the workplaceRetrainingWhen must retraining be conducted?–––––When the operator has been observed to operate the vehicle in an mannerWhen the operator has received an that reveals unsafe operationWhen the operator has been involved in an orWhen the operator is assigned to operate a type of truckWhen a in the workplace changes in a manner that could affect safeoperation of the truckOR-OSHA 221 Forklift Safety10
This material is for training use onlyTraining ContentThe following topics must be covered unless they’re not applicable to the particular workplace:Truck-Related Topics:All o
the upright is tilted forward and back. The CG moves up and down as the upright moves up and down. Hyster Sales Co. OR-OSHA 221 Forklift Safety 4 . The use of special attachments instead of forks will also _ the nomi
When installing a forklift scale on an electric forklift, static discharge protection must be installed on the forklift When installing a forklift scale, OSHA requires the end user to de-rate the lift capacity of the forklift Compatible with most Class II and Class III forklift attachments, consult factory
FORKLIFT SITE-2014/15 INTRODUCTION In general the forklift can be defined as a tool capable of lifting hundreds of kilograms. A forklift is a vehicle similar to a small truck that has two metal forks on the front used to lift cargo. The forklift operator drives the forklift forward until the forks push under the cargo, and can then lift the cargo
Forklift overturned 279 16 Forklift struck something, or ran off dock 293 17 Worker pinned between objects 139 8 Worker struck by material 152 9 Worker struck by forklift 237 14 Worker fell from forklift 176 10 Worker died during forklift repair 147 9 Other accident 297 17 Total 1720 100
forklift’s lifting and balance characteristics and lead to a forklift overturning. Whenever an attachment is used that could affect the capacity or safe operation of a forklift, its use must be approved by the forklift manufacturer. The employer must mark the forklift to show the new weight with attachment. The maximum capacity at
Forklift Battery Charging Methods The Discovery Process Before you buy consider The age of your forklift, is the forklift operating correctly? Why did the battery Fail: Age, Poor Quality, Lack of Maintenance? Does your forklift still meet your needs or have they changed? The Battery
require a forklift scale system for a Class III cleat type forklift truck. This robust system allows operators to easily and quickly capture weight data. › ITA Class III Cleat Type carriages: 2,500kg x 2kg - 5,000kg x 10kg FLSC The FLSC digital forklift scale is a market leading system which turns an ordinary class II forklift truck into a mobile
Optimizes the forklift for maximum speed. Eco mode extends the forklift's battery time by 15% compared to Kalmar's previous electric forklift, the ECF50-90. Using a Kalmar Electric Forklift truck pays off in the long run. In just 2 years time Kalmar's new Electric forklift truck will break even compared to the equivalent Diesel truck.
Types of Forklift Cameras Carriage Views "Carriage" views from a forklift move up and down with the forks of the forklift, allowing the cameras to remain useful at any fork level. Fork insertion, also known as load engagement, at high elevation, or deep racking, is the task that will most benefit from a forklift camera. Uses:
