Forklift Inspections

 

Like any piece of construction equipment, forklifts need to be inspected and maintained. Although a regular maintenance schedule should be set up for lift trucks, you should always run down a safety checklist at the start of your shift.

This inspection includes checking fluid levels, hydraulics, wheels and tires, brakes and any potential mechanical problems with the vehicle. Make this examination at least daily.

Brakes

Brakes are the single most common cause of lift truck accidents due to mechanical failure. To check the brakes:

·            Push the brake pedal in. It should have free travel before meeting resistance.

·            Then, depress the pedal again and hold it for ten seconds. The pedal must hold solid and not be spongy or drift under pressure.

Steering

Steering is a vital maintenance concern. With the engine running, check if the steering wheel turns correctly both ways to its stops. The wheel should not feel loose and the pump should not squeal before reaching the stops.

 

Sample checklist

The following checklist should be strictly adhered to before operating the vehicle:

·            Check the fork pins and stops to make sure that they are in place.

·            Check all cowling and body parts.

·            Check the wheels and tires for excessive wear.

·            Look for any broken or loose parts.

·            Check the fuel level, crankcase oil level, and radiator water level.

·            Check the engine air cleaner, the fan belt, the hydraulic fluid level, and the battery water level.

·            Check the hour meter and record it. This is important for maintenance scheduling.

·            With the engine running, check operation of the hour meter, headlights, taillights, and warning lights.

·            Check the oil pressure gauge, the water temperature, ammeter, and sound the horn.

·            Note if the clutch is working properly, check incapability, the hydraulic controls, and any other controls on the lift system.

Report anything not up to par to your supervisor at once.

 

This information is provided by Assurance Agency https:www.assuranceagency.com

 

Handling Loads

 

One of the most common sights on a jobsite is the forklift. Whether it is a tow motor, a man lift, or a motorized cart, it is considered one of the most versatile pieces of material handling equipment available. These forklifts can be powered by propane gas, electric power, or diesel fuel.

General operating requirements
• When traveling behind another forklift, maintain a safe distance of about three truck lengths from the truck ahead.

• Slow down and sound the horn at cross aisles and other locations where vision is obstructed.

• Look in the direction of travel and keep a clear view of the path of travel.

• Operate the forklift at a speed that will permit it to be brought to a stop in a safe manner.

• Slow down for wet and slippery floors.

• Make sure dockboard or bridgeplates are properly secured; drive over them carefully and slowly and make sure their rated capacity is never exceeded.

• Operate forklifts equipped with attachments as partially loaded trucks when not handling a load.

Moving a load
• If the load being carried obstructs forward view, you must travel with the load trailing.

• Ascend and descend grades slowly. When ascending or descending grades in excess of 10 percent, drive the loaded forklift with the load upgrade.

• On all grades the load and load engaging means must be tilted back and raised only as far as necessary to clear the road surface.

• Only stable or safely arranged loads should be handled.

• Use caution when handling off-center loads which cannot be centered.

• Only handle loads that are within the rated capacity of the truck.

• Adjust long or high (including multiple-tiered) loads which could affect capacity.

• Place the load engaging means under the load as far as possible and tilt the mast backward to stabilize the load.

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

Remember, forklift operators need to be trained before they can use the forklift.

This information is provided by Assurance Agency https:www.assuranceagency.com

Forklifts- Training

 

All workers hired to operate a forklift must be trained—according to the operator training requirements in
29 CFR 1910.178(l)—BEFORE being allowed to use a forklift.

OSHA uses the term powered industrial truck to describe a mobile, power-driven vehicle used to carry, push, pull, lift, stack, or tier material. Included in this description would be: high lift, counterbalanced, cantilever, rider, forklift, high lift platform, and motorized hand/rider
trucks.

The following information highlights the requirements of the forklift training rule:

The OSHA forklift training standard is in the OSHA general industry regulations at 29 CFR 1910.178(l)–Powered industrial truck operator training.

If you are a forklift operator you must: (1) be competent to safely operate the particular forklift you will use, and (2) successfully complete the training required by the standard.

Your trainer must have the knowledge, training, and experience to train you and evaluate your competence. Trainees can only operate a forklift: (a) under the direct supervision of a knowledgeable trainer/evaluator, and (b) when it does not endanger you or others.

You must initially train in all topics listed in the regulations unless you and your employer can demonstrate that a topic is not applicable to safe forklift operations at your jobsite.

Topics are broken down into three broad categories: (1) truck-related, (2) worksite related, and (3) the forklift rule requirements.

Refresher training and evaluation must be done to ensure you have the knowledge and skills needed to operate the forklift safely. Refresher training is required when: (1) unsafe operation is observed, (2) an accident or near-miss has occurred, (3) an evaluation reveals unsafe operation, (4) you will operate a different truck, and (5) workplace conditions change that could affect safe operation.

An evaluation of each forklift operator must be conducted at least once every three years.

If you have previously trained in a required topic, the training is appropriate to the forklift and working conditions encountered, and you have been evaluated and found competent to operate the truck safely, that training does not have to be duplicated.

Your employer must certify that you have been trained and evaluated as required by the standard.

This information is provided by Assurance Agency https:www.assuranceagency.com

Drive Safely - Forklifts

 

Overview
Forklifts are one type of powered industrial truck. Others include platform lift trucks, motorized hand trucks, tractors, and other trucks that are powered by an electric motor or internal combustion engine. Improper handling or misuse of forklifts often causes injuries.

OSHA requires operators to be trained. Before operating a forklift, you should understand the basic operating and loading rules, basic rules for safe travel, truck-related and workplace-related information, and how to perform a safety check.

Basic Operating and Loading Rules
Accidents can be avoided if basic powered industrial truck operating and loading rules are followed. Some of these rules are:
• Do not allow anyone to stand or pass under raised forks, whether loaded or empty.
• Only stable or safely arranged loads can be handled.
• Only loads that are within the truck’s rated capacity can be handled. (When you are using an attachment to handle a load, keep the load within the attachment’s rated capacity.)
• When lifting a load, place the forks (or other load engaging means) under the load as far as possible. Then, carefully tilt the mast backwards slightly to stabilize the load.
• Never tilt the load forward unless you are depositing it.
• Trucks need to have an overhead guard to protect the operator from the impact of falling packages, boxes, etc. (the guard does not need to withstand the impact of a falling capacity load). A backrest extension is needed when the load could fall rearward.
• Only safety platforms can be used to lift people.
• If the forklift needs to be used in a hazardous (classified) location, it must be approved for the hazard.
• When you get off of the forklift temporarily, and remain within 25 feet of it (and the forklift remains in your view), lower the forks, put the controls in neutral, and set the brakes. Block the wheels if the truck is on an incline. If you will be leaving the forklift 25 or more feet away (or anytime it will be out of your view), shut it off.
• When you park the forklift, make sure access to fire aisles, stairways, and fire equipment is kept clear.

Basic Rules for Safe Travel
Most accidents happen while the truck is traveling. Follow these rules to travel safely:
• Watch where you are going. Drive in reverse with the load trailing if the load obstructs your view. Keep a clear view of your path, and look in the direction you are traveling.
• Never drive up to anyone standing in front of a bench or other fixed object.
• Allow no riders. (If riders are authorized, the truck must provide them with a safe place to ride.)
• Always keep your arms or legs within the truck. Placing them between the uprights of the mast or outside the running lines of the truck is not allowed.
• Keep the load close to the ground while you drive. Raise the forks only as much as you need to so that you clear the road surface. Tilt the load back slightly to stabilize it against the backrest.
• Keep to the right where there is two-way traffic.
• Obey speed limits. Slow down for wet and slippery floors. Slow down for turns. Keep the forklift under control so you can stop it safely.
• Slow down and sound the horn at cross aisles and other locations where vision is obstructed.
• Maintain a safe distance of about three truck lengths from a truck that you are following.
• Do not pass a truck that is traveling in your same direction at intersections, blind spots, or other dangerous locations.
• Do not allow stunt driving or horseplay. And, avoid running over loose objects.
• Make sure you always have enough clearance under overhead installations (lights, pipes, sprinkler system, doorways, etc.)
• Stay within the rated capacity of dockboards and bridgeplates. Make sure they are secure before you drive on them. Keep a safe distance from the edge of any elevated dock, ramp, or platform.
• While using the forklift to load and unload trucks, trailers, or railroad cars, always set the brakes and use wheel blocks to keep the truck/trailer/rail car from moving. Use fixed jacks to support a semitrailer that is not coupled to a tractor. Check the floor for breaks and weaknesses before you drive the forklift inside. Do not use the truck to open or close freight doors.
• Follow special precautions from your employer when the forklift will be driven on slopes, across railroad tracks, and into elevators.

Truck-related and Workplace-related Information
Your employer will make sure you know about the following topics:
• Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate.
• Differences between the truck and the automobile.
• Truck controls and instrumentation: where they are located, what they do, and how they work.
• Engine and motor operation.
• Steering and maneuvering.
• Visibility (including restrictions due to loading).
• Fork and attachment adaptation, operation, and use limitations.
• Vehicle capacity.
• Vehicle stability.
• Any vehicle inspection and maintenance that the operator will be required to perform.
• Refueling and/or charging and recharging of batteries.
• Operating limitations.
• Any other operating instructions, warnings, or precautions listed in the operator’s manual for the types of vehicle that the employee is being trained to operate.
• Surface conditions where the vehicle will be operated.
• Composition of loads to be carried and load stability.
• Load manipulation, stacking, and unstacking.
• Pedestrian traffic in areas where the vehicle will be operated.
• Narrow aisles and other restricted places where the vehicle will be operated.
• Hazardous (classified) locations where the vehicle will be operated.
• Ramps and other sloped surfaces that could affect the vehicle’s stability.
• 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 in the workplace that could affect safe operation.

How to Perform a Safety Check
Proper maintenance helps keep forklifts operating safely. Inspect the forklift for damage, defects, and unusual conditions. A safety check must be performed before operating the forklift each day (and, check it after each shift when it is used round-the-clock). Consider these items:
• The fork pins and stops must be in place.
• All cowling and body parts must not be broken, loose, or missing.
• Check the fuel level, crankcase oil level, radiator fluid level, hydraulic fluid level, and the battery electrolyte level. Look for any leaks (check under the truck). Never use an open flame to help you see fluid levels.
• Check all belts, hoses, tires, etc. for damage or excessive wear.
• Check the operation of the brakes, steering, lift and tilt controls, hour meter, lights, and horn.
• If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck is to be taken out of service until it is restored to a safe condition.
• Truck repairs must be made by an authorized person. Before repairs are made to the electrical system, the truck’s battery must be disconnected.
• Any vehicle that emits hazardous sparks or flames from the exhaust system must be immediately removed from service.
• Forklifts that have a leak in the fuel system may not be operated until the leak is repaired.
• When a part of a forklift is found to be in excess of its normal operating temperature (creating a hazardous condition), the forklift must be removed from service until the cause for the overheating has been eliminated.
• Water mufflers on industrial trucks must be checked daily or often enough to keep them adequately filled.
• Flames, sparks, or electric arcs are to be prevented in battery charging areas. Smoking is not allowed. Tools and other metallic objects are to be kept away from the top of uncovered batteries.

This information is provided by Assurance Agency https:www.assuranceagency.com

Flammable Liquids

 

They’re called flammable liquids, but it’s not the liquid that you need to worry about—it’s the vapor that begins to form as soon as the container is opened. This vapor can explode at the first spark from a tool, a match, simple friction, static electricity or even high temperatures. Most flammable liquids are volatile, that is, they evaporate quickly and reach a concentration in the air that could lead to an explosion. Flammable vapors are especially dangerous because you can’t see them, and often you can’t smell them. Solvents, cleaning fluids, acetone, alcohol and fuels are some of the flammable liquids you may use on the job.

Working Safely With Flammable Liquids
• Control the three potential hazards: temperature, concentration of vapor and ignition sources.

• Read the safety data sheet (SDS) for each liquid you use so you’ll know its flash point as well as its upper and lower explosive limits—the range in which vapors are at the right concentration to explode if they’re ignited.

• Follow your employer’s flammable liquids safety policy.

• Always wear the correct, properly fitted personal protective equipment.

• Ventilate the area to keep vapor concentration down.

• Know which chemicals, such as oxidizers, increase the fire dangers of flammables.

• Know the location of the correct fire extinguisher to use in a flammables fire.

• Never smoke in areas with flammable liquids.

• Avoid mixing flammables; even small amounts of highly volatile liquids can lower the flash point of the mixture to dangerous levels.

• Check with your supervisor for instruction on how to dispose of flammable liquids.

• Store flammable-soaked rags and other waste materials in tightly covered, specially designated containers.

• Never pour flammable liquids down drains.

• Keep flammables away from welding, cutting and grinding operations.

• Be cautious with empty drums that have contained flammable liquids.

• Never do repair work or welding on an empty flammables drum without getting clearance first.

• Make sure that areas below where you’re working are ventilated or sealed off to prevent the vapors from flowing down into them.

• Special spark-proof switches and fixtures should be installed in areas where flammable liquids are used.

Storing Flammable Liquids
• Keep flammable-liquid containers tightly covered, and store away from other chemicals and ignition sources in well-ventilated, temperature-controlled areas.

• Storage areas for flammables should be equipped with non-sparking electrical systems and heat sources.

• Store flammables separately from other chemicals, especially reactives such as oxidizers, in well-ventilated, temperature controlled areas.

• Make sure flammables are stored in authorized containers and are correctly and clearly labeled for flammability. Liquids with a flash point of 80° F or less must be marked with a red label.

• Make certain containers are fireproof and have vapor screens and vapor-tight caps.

• Attach grounding wires to flammable storage containers to prevent static electricity buildup.

• Before transferring flammable liquids from a drum to a container, be sure to connect the container to the drum with a bonding wire before pouring the liquid, since the friction of pouring can ignite the vapors.

This information is provided by Assurance Agency https:www.assuranceagency.com