ALL TRAINING MATERIALS CAN BE RE-USED & CUSTOMIZED TELESCOPIC HANDLER OPERATOR SAFETY TRAINING

Transcription

1 S This is a preview only. The number of pages displayed is limited. Shown: 83/207 slides. These slides are being provided to prove quality and help you with your decision. If further information is needed, contact us directly. ALL TRAINING MATERIALS CAN BE RE-USED & CUSTOMIZED Hard Hat Training. The content included herein is for review only. If you have purchased these samples or downloaded them for any purpose other than to review the product as presented by the creator and its authorized distributors, you are in violation of copyright laws. Please show respect and obey the law.

2 Accountability The material presented within this course is for educational and training purposes only. All parties involved in the development, distribution and maintenance of this course shall be held harmless from any incident resulting from misuse of the content beyond the guidelines and purposes herein stated. Before you begin you should understand that it is your responsibility to adhere to the laws and regulations presented within the following course and its corresponding materials. Likewise, it is your further responsibility to strictly follow any additional guidelines specific to your own workplace. Good Luck & Stay Safe! Note to Instructors: the first few slides in this presentation can be drawn upon as desired and used to initiate dialog as to the importance of safety training and operator responsibility. If you choose to skip these slides, the official presentation begins on slide 12.

3 S It s required everywhere you go. Why Safety Training?

4 S Why Safety Training? It s as easy as 1, 2, 3! 1. Training reduces the risk of accidents and injuries to you and those you work with 2. Training reduces operating costs (How?) 3. OSHA requires it no matter who you are or how long you ve been operating.

5 Powered Industrial Truck Safety Training Welcome to the Hard Hat Training series. Today you will learn about the safe operation of powered industrial trucks, also known as fork trucks, lift trucks or forklifts. We will strive to provide information that will increase your knowledge and help to make you a better operator.

6 Forklifts are a common sight Among material handling equipment, none are as common as the forklift. They are found in most industries that require transferring loads from delivery trucks to warehouses and worksites.

7 Equipment anatomy & inspection During this training we ll take a look at the different types of forklifts and their anatomy. We ll also show you why it s important to conduct a thorough pre-shift inspection each day before putting it into service.

8 Stability of forklifts We will look at forklift stability and the importance of knowing the machine s capacity.

9 6 most common hazards We will introduce the six most common hazards associated with forklift operation and show you how to recognize, avoid or minimize them.

10 Completion of training When you complete this training you should be familiar with the types of forklifts used by your company, have an increased knowledge of how to inspect them and safely operate them and be able to recognize and avoid the most common hazards associated with their use.

11 Telescopic handlers Telescopic Handler Telescopic handlers have extendable booms that can allow an operator to reach out and place loads in areas inaccessible to mast type forklifts. These are popular in the construction industry because of their versatility and the numerous attachments that they can be fitted with.

12 Evaluation every three years The standard also says that every three years each operator must be evaluated to see if they are still competent to operate the equipment.

13 Load tests Load tests of forklifts should be performed on a regular basis, especially if there have been any structural repairs. Load tests will determine whether the lift can handle its capacity through all of its functions. For boom-supported lifts, these will also test its stability and show the condition of the hydraulic components including the lift cylinders, extension cylinders and outriggers. For boom supported lifts, these will also test its stability and show the condition of the hydraulic components including the lift cylinders, extension cylinders, and outriggers.

14 Components & Anatomy These are the main components of a telescopic handler that an operator should be familiar with.

15 Operator s manual The operator s manual is required to be on the machine at all times and everyone who operates it should be familiar with the safe operations portion of it. This manual also has guides for inspection and maintenance. Usually it is found in a compartment behind the seat.

16 Operator s manual This manual is written by the manufacturer and includes information on how to use the machine properly and what practices are prohibited for each make and model. For example: Not all telescopic handlers are rated by the manufacturer to lift personnel in a manbasket.

17 Load chart On the load chart will be information regarding how much weight it can lift safely at a certain radius. For example, loads that are near the maximum capacity of the machine can only be lifted a short distance out from the front wheels rather than the full length of the boom.

18 Attachments Any attachments that are added to the machine must be used with approval from the manufacturer. They will send you a new capacity plate with the capacity of the forklift when using that attachment.

19 Hydraulic fluid level The hydraulic fluid level should be checked each day. Check it with the boom lowered and fully retracted.

20 Propane characteristics Extremely flammable Propane is also extremely flammable. Never park a forklift in a confined space or near a high heat source. Turn off the service valve on the tank when parked for extended periods of time.

21 Checking for leaks Never use a match or a lighter! Examine hoses and fittings for cracks or leaks. Check for leaks using a spray bottle with a soapy solution. Never use a match or lighter.

22 Refueling gas or diesel forklifts Before refueling a gasoline or diesel forklift, turn off the engine. Use the correct type of fuel. Avoid topping off the tank, which could result in a spill. Clean up any spills and replace the gas cap before restarting engine. Always have a fire extinguisher nearby.

23 Overhead guard Check the overhead guard for bends and twists. Never tie cardboard on top of the overhead guard when it is raining, if it will obstruct your vision when lifting loads up high. If plexi glass is used, make sure it can be removed and cleaned from time to time.

24 Liquid-filled tires Some rough terrain forklifts have liquid filled tires (usually calcium chloride) to give the machine better traction, more counterweight and more capacity. Never replace a water or solid filled tire with an air filled one. The weight of the water in the tires is critical to accuracy of the load chart.

25 Outriggers Some telescopic handlers have outriggers to increase their capacity while picking or placing a load. Check for bent pads or floats, dents in the beam or lift cylinder, worn or damaged pins, hydraulic leaks, damaged hoses and cracks in the welds or loose bolts that attach the outriggers to the truck chassis.

26 Boom sections The boom sections should be completely extended and examined for dents, creases or twists.

27 Angle indicator Check the angle indicator. The arrow should swing freely and the grid should be legible and not worn.

28 Forks Before picking up a load, make sure that the forks are adjusted for width. Lubricate the bar so the forks slide across easily.

29 Tilt cylinder Check tilt cylinder and hydraulic hoses for leaks, cuts, and chaffing.

30 Attachments Inspect any attachments that will be used. Remember that front-end attachments will alter the forklift s capacity and stability and must be approved by the manufacturer and a new capacity plate issued.

31 Functional inspection With the emergency brake on and transmission in neutral, start the engine and test each function to make sure it does what it is supposed to do. Each control lever should be clearly labeled and tested to make sure they operate smoothly through all functions.

32 Emergency brake Check the emergency brake. It should hold on a slight incline. Adjust it if needed.

33 Conclusion of inspection At the conclusion of the inspection, report any damage or malfunction to your supervisor. Never use a machine in need of repair.

34 & CAPACITY Balancing point On a forklift, the front wheels are the fulcrum or balancing point and the combined weight of the load, and that part of the forklift in front of this point, is offset by the weight of the rest of the forklift in back.

35 & CAPACITY Offsetting weights The principle offsetting weight is the counterweight, which is basically a lot of thick, heavy steel in the back. The farther back the counterweight the more leverage it has.

36 & CAPACITY Stability pyramid The stability pyramid is formed by imaginary lines between the front and back wheels of the forklift and the highest point of the forklift. When the forks or a load is lifted the center of gravity of the forklift moves up and the forklift becomes more unstable.

37 & CAPACITY Working on inclines Always level the machine before raising the boom to place loads at heights. With the load low it may seem stable but as the load is lifted the machine s center of gravity will move closer to the tipping point making it more unstable.

38 & CAPACITY Braking Another dynamic force is braking. If an operator is moving forward with the load raised up high, braking abruptly could cause a tipover. The closer the load is to capacity the less braking action it takes. Hitting a pothole or small object can cause dynamic forces similar to braking.

39 & CAPACITY Load charts Load charts on telescopic handlers help to determine the capacity at a specific radius, height and angle. The main information you need to determine this is the weight of the load and the radius and height of the pick and placement spot.

40 & CAPACITY Lifting loads to heights If you are lifting a load onto a building or other structure, then the height and radius of the pick needs to be taken into consideration. The height of the building will prevent you from booming down very far to increase the radius.

41 & CAPACITY Know the weight of the load If you do not know the weight of the load then the load chart is not going to do you much good. If you are unsure of the weight and your best estimate is that it is half of the capacity of the forklift or more for the radius, then you should weigh the load or find out for sure how much it weighs.

42 & CAPACITY Weight tables Weight tables will also aid you in estimating the weights of many types of materials. For example, 1 inch steel plate is 40 lbs per square foot. So if you had a 8 foot by 12 foot by 1 inch steel plate you would multiply 8 times 12 to get the area which is 96 square feet and then multiply that number by 40 lbs to get the weight which will be 3,840 lbs.

43 & CAPACITY Load chart exercise We will use the following example: You need to place a load of 4 x 8 sheets of plywood on top of a 22 foot building. The closest the front wheels can get to the building is 6 feet so the closest the load can be placed is 8 feet. The height of the plywood is 4 feet and the unit weight is 36 lbs.

44 & CAPACITY Load chart exercise To plot this information on the load chart we will first draw an imaginary vertical line 8 feet from the front wheels which represents the radius of the pick.

45 & CAPACITY Critical lifts All lifts require some planning. But there are some lifts that because of a few factors or conditions need more planning than others. These are some times referred to as Critical Lifts.

46 & CAPACITY Critical lifts The load must pass over an area where pedestrians normally travel. The load is very valuable or the placement area is near very costly or sensitive equipment. Working in soft soils or near banks that are not shored or fortified. The exact weight of the load is not known and the best estimate puts the weight at over half of the capacity of the crane. Can you think of any other conditions that might make a lift a critical lift?

47 Struck by a forklift OSHA statistics have shown that there are certain inherent dangers associated with forklift operations even during normal working conditions. A forklift can be a very dangerous piece of equipment and most of the injuries and deaths are due to several basic hazards.

48 Pedestrian traffic Operators must continually be watchful for pedestrians, but it is everyone s responsibility including management's to keep them safe. Well placed mirrors on the telescopic handler can help to see the blind spots.

49 Accident profile #2 Employee #1 was using a telescoping boom forklift to move drill pipes around a storage yard. The pipes were 31 ft long and weighed 20 lb per ft. Employee #1 backed up with a load of 11 pipes and then dismounted to rearrange boards in front of the forklift in preparation for the next trip to the horizontal pipe rack. He left the load tilted back and elevated about 8 ft. While he was working in front of the forklift, the tilting mechanism bled down, causing the pipes to roll off the forks strike him on the back of the head. He was killed instantly. What went wrong?

50 Tipover They tipover frontwards when the capacity of the machine is exceeded while telescoping out or boom down. They tip over sideways when working on slopes or raising the boom on uneven ground. Other causes are turning with the forks or a load in the air; stopping abruptly with a load in the air. Consider the following accident:

51 What went wrong? There are many things that went wrong here which shows the lift was not planned properly and safeguards put into place. Number one, telescopic handlers should never be used to pick and carry a load with the boom fully extended and at that steep of an angle. Two, using an unauthorized attachment made the load chart obsolete. Three, the load was not properly rigged which allowed it to shift when the forklift hit the curb. And finally, the welders in the aerial lift should have waited until the load was safely in position before getting into position to weld it.

52 Soft soils Some tipovers are a result of or front wheels sinking into soft soil. When poor soil is encountered, or the outriggers have inadequate floats or pads, well-designed blocking or cribbing is needed under the outriggers. They also must be strong enough to prevent crushing and be of sufficient width and length to prevent shifting or sinking under load.

53 How to survive a tipover Tipover is also the number one cause of death of the operator. For some reason, a high percentage of operators when the forklift begins to tipover sideways, attempt to leave the forklift in the same direction that it is tipping. This may be due in part because during the initial stages of a tipover the rate of tipping is comparatively slow and it may seem possible to escape before it pins you.

54 What went wrong? Standing on an elevated platform 22 feet above the ground with no fall protection is extremely dangerous. He should have used a OSHA/ASME approve manbasket that was securely attached to the carriage or backrest. Using rough terrain forklifts that are not specifically designed to elevate personnel can be hazardous unless precautions are taken to ensure the safety of the person being elevated and those in the area. Here are some guidelines from the ANSI standard:

55 Obstruction of vision Obstruction of the vision of the operator constitutes a serious hazard with telescopic handlers. There are many blind spots that prevent the operator from seeing everything around him. Consider the following accident:

56 What went wrong? This was an unfortunate accident that shows the importance of being able to see exactly where you are extending the boom and forks. In this case the use of a spotter would have prevented this fatality. Here are some common causes of blind spots while operating this type of forklift:

57 Behind the forklift It is also very difficult to completely see everything behind you, especially down low and to the right because of where the boom is mounted. Well-placed mirrors can assist you in seeing these areas. Just because mirrors don t come with the machine does not mean you cannot add them later.

58 Accident profile #6 Four employees were assigned to dismantle a scaffold and move it to another side of a building. The scaffold was five sections high. Because they were left without any direct supervision, the employees decided, after they removed the top two sections, to use a telescopic boom forklift to move the scaffold. The employees attached a wire rope to the top of the scaffold and used the forklift to lift the scaffold off the ground. Two of the employees held the scaffold, with one employee on each side of the scaffold to keep it balanced while it was moving. The forklift operator was moving forward when the load backrest extension contacted a 7200-volt, single-phase overhead power line located 9.4 meters above the ground. The ground was wet and muddy. The two employees guiding the scaffold received electric shocks. They were transported to a hospital, where they were pronounced dead of electrocution. What went wrong?

59 What to do if power line contact occurs If you contact power lines with any part of the boom or hoist line you must not panic. Stay where you are and alert others of the situation and warn them to keep away. Only when you are certain that the lines have been de-energized by the electric company should you leave the crane or let anyone approach.

60 KNOW YOUR FORKLIFT Know your forklift In this portion of the training we will go over some safe operation guidelines. Forklift safety begins with being completely familiar with the machine you are using and what it can and cannot do.

61 KNOW YOUR FORKLIFT Pre-shift inspection Conduct a thorough pre-shift inspection of the forklift at the beginning of the day or work shift. If this inspection was performed by someone else you still need to insure that there is adequate fuel.

62 KNOW YOUR FORKLIFT Unintended purposes Using forklifts to push loads can put undue stresses on the transmission or clutch. Pulling trailers or boats with a trailer ball on the end of one fork could damage the forks or carriage through side loading.

63 KNOW YOUR WORKSITE Know your workplace It is important to be familiar with the worksite where you will be operating the forklift. As stated earlier, OSHA requires refresher training if a condition in the workplace changes in a manner that could affect safe operation of the machine.

64 KNOW YOUR WORKSITE Elevated docks or edges Maintain a safe distance from the edge of ramps, platforms, docks, slopes or inclines.

65 KNOW YOUR WORKSITE Overhead obstructions Make sure that there is sufficient headroom under overhead installations such as lights, pipes, sprinkler system, air conditioning units, and powerlines.

66 PARKING THE FORKLILFT Parking the forklift Park you forklift in appropriate locations. Never park in an area that would block fire lanes, emergency equipment, or access to stairways, entrances or exits.

67 PARKING THE FORKLIFT Attended parking OSHA states: When the operator of an industrial truck is dismounted and within 25 ft. of the truck still in his view, the load engaging means shall be fully lowered, controls neutralized, and the brakes set to prevent movement. This is called attended parking.

68 PARKING THE FORKLIFT Unattended parking When the forklift is left unattended, the forks should be fully lowered, controls put in neutral, power shut off, and brakes set. If the machine is on an incline the wheels should be blocked.

69 OPERATING THE FORKLIFT Operate only from the operator s cab Operate only from the operator s compartment. Keep all body parts inside. Don t lean out to see around a wide load. Travel in reverse if forward vision is blocked.

70 OPERATING THE FORKLIFT Three vehicle length Always maintain at least three vehicle lengths when following another forklift.

71 OPERATING THE FORKLIFT Keep load or forks low On all grades, the load and load-engaging means should be tilted back if applicable, and raised only as far as necessary to clear the road surface. Never drive with empty forks more than a few inches off the ground.

72 PEDESTRIANS Slow down! Pedestrians have the right of way but that does not mean that they are always right. It is your responsibility to be aware of all people on foot.

73 PEDESTRIANS Working in tight quarters Especially be aware of pedestrians when working in tight quarters. Never drive a forklift up to or turn your forklift near a pedestrian who is next to a fixed object. Watch rear end swing of the forklift so as not to clip someone or something.

74 PEDESTRIANS Establish eye contact Establish eye contact with pedestrians and operators of other vehicles. Make sure they are aware of your intent.

75 PEDESTRIANS Never allow anyone under the load for forks No person should ever be allowed to stand or pass under the elevated portion of any forklift, whether it is loaded or empty.

76 PEDESTRIANS No riders! Never allow someone to ride beside you unless there is a designated seat for passengers. Never allow someone to ride on the forks or hang on the side while you are driving.

77 SAFE LOAD HANDLING Near capacity loads Never lower a maximum capacity load without retracting the boom. Lowering the boom will extend the radius of the load possibly overloading the machine.

78 SAFE LOAD HANDLING Secure the load Only stable or safely arranged loads should be transported. Some loads may need to be shrink-wrapped or secured before moving. Make sure there are no parts of the load sticking out that could catch on something.

79 SAFE LOAD HANDLING Center the load on the forks Loads should be centered on the forks with the heavy side up against the backrest rather than on the end of the forks. This will give the forklift better stability. Always exercise caution when handling off-center loads which cannot be centered.

80 SAFE LOAD HANDLING Hazardous loads If you are handling hazardous materials you must be trained in what they are, how to handle them and how to clean them up in case of a spill. Refer to the appropriate MSDS sheet for more information.

81 TRAVELING WITH THE LOAD Traveling with the load Maintain control of your forklift at all times. Start, turn, and brake smoothly. Watch rear end swing when executing turns and stay close to the inside corner.

82 TRAVELING WITH THE LOAD Keep clear view of travel Keep a clear view of travel. If the load blocks your forward vision then you should travel in reverse or use a spotter.

83 ELEVATING PERSONNEL Approved platform Capacity plate Manufacturer Weight of platform Max. occupants Safe working load A platform that is built to OSHA/ASME standards is required to elevate personnel with a forklift. Their should be a manufacturer s plate that shows the weight of the platform, the maximum number of occupants, and the safe working capacity.

84 ELEVATING PERSONNEL Elevating personnel procedures The operator should remain with the forklift at all times and only elevate or lower the basket at the request of the occupant. Raise and lower the platform in as smooth a manner as possible. Never move the forklift with the platform raised at heights.

85 ELEVATING PERSONNEL Never elevate someone on the forks! Under no circumstances should anyone be raised on just the forks, even if they are on a pallet.

86 CONCLUSION Forklifts can inflict serious injury or death Forklifts, like all equipment, can inflict serious injury or death when misused or abused. Improper training, poor operation, failure to perform preventive maintenance, and failure to inspect can have serious consequences. Safety is the responsibility of everyone involved in forklift operations, from operators to supervisors. You can help ensure safe operation by knowing and following all safe work practices and safety regulations that are applicable to forklifts in your workplace.