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    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 1

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    INTRODUCTION

    Handling Materials Safely

    50 tons per one ton shipped.Some is moved by machine and some by hand.When handling material, technique is everything.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 2

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    CAUSES OF INJURIES

    25% of all injuries are related to material handling.80% are to the lower back.Incorrect lifting causes most injuries.Incorrect use of equipment.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 3

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    CARELESSNESS

    Be aware of your environment.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 4

    Hey Charlie! Did you see that

    game last night?

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    AVOIDING WORKPLACE INJURIES

    Stay in shape.

    Consider where you will walk.Dont use your body if you dont have to.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 5

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    RULES FOR LIFTING

    Get close to the load.Keep feet apart.Keep back straight.Bend your knees.Tuck your chin.

    Grip the load with your palms.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 6

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    HAZARDS ASSOCIATED WITH MATERIALS

    HANDLINGCheck your environment for sufficient moving roomCheck for projecting objects, wear gloves.Are materials secure?Are chemicals to be moved?

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 7

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    TEAMWORK AND HANDLING VARIOUS SHAPES

    AND SIZES

    If an object seems to heavy to lift, it probably is.When working with others, communication is critical.Your back should be kept straight when you carry objects.Special lifting tools should be sought out and used for large objects.Protect yourself when handling things.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 8

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    EXAMPLES OF LIFTING EQUIPMENT

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 9

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    HAND TOOLS AND ACCESSORIES

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 10

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    POWER OPERATED HAND TRUCKS

    Examples of a walkie and a rider type powered hand trucks

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 11

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    POWERED INDUSTRIAL TRUCKS

    Trucks are usually classified by power source.Electric MotorsInternal Combustion Engine Gasoline Diesel LP Liquefied Petroleum

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 12

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    STANDARD POWERED INDUSTRIAL LIFT TRUCK

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 13

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    STRADDLE TRUCK

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 14

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    ORDER PICKER TRUCK

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 15

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    INDUSTRIAL TRUCK SAFETY

    POPULAR MISCONCEPTIONSAnyone can drive a lift truck.They handle just like a car.They are easier to drive than a car.You dont need any training to safely drive a fork lift.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 16

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    INDUSTRIAL TRUCK SAFETY

    FACTSThe center of gravity of a lift truck changes.Most trucks are rear steer.Most trucks have no suspension system.It is NOT safe to alter the lift trucks counterweight!

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 17

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    INDUSTRIAL TRUCK SAFETY

    What does OHSA say about powered industrial truck training?OSHA regulations state that only trained and authorized operators shall be permittedto operate a powered industrial truck.

    But why?

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 18

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    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 19

    Get the picture?

    Training helps to Prevent Accidents!

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    Data plate.I N D U S T R I A L S A F E T Y L E C T U R E F O U R

    20

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    POWERED INDUSTRIAL TRUCKS -OPERATOR TRAINING

    1 9 1 0 . 1 7 8 ( L )

    1 9 1 5 . 1 2 0 ( A )

    1 9 1 7. 1 ( A ) ( 2 ) ( X I V )

    1 9 1 8 . 1 ( B ) ( 1 0 )

    1 9 2 6 . 6 0 2 ( D )

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    DISCLAIMER

    This presentation is intended as a resource for providing training on OSHAs revisedpowered industrial truck operator standards. It is not a substitute for any of theprovisions of the Occupational Safety and Health Act of 1970, or for any standardsissued by the U.S. Department of Labors Occupational Safety and HealthAdministration (OSHA). It is also not a substitute for a powered industrial truckoperator training program.

    22

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    ACKNOWLEDGMENT

    OSHAs Office of Training and Education wishes toacknowledge the following for contributing someof the graphics used in this presentation:Caterpillar Lift TrucksMason Contractors Association of America

    Industrial Truck AssociationState of Utah Labor Commission - Occupational Safety &Health DivisionSteamship Trade Association of BaltimoreTaylor Machine Works, Inc.UAW - Ford National Joint Committee on Health and

    Safety

    Appearance of products does not imply endorsement by the U.S. Departmentof Labor.

    23

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    POWERED INDUSTRIAL

    TRUCK - DEFINITION

    A mobile, power-propelled truck used to carry, push,pull, lift, stack or tier materials. [American Societyof Mechanical Engineers (ASME) definition]

    Excluded are vehicles used for earth moving and over-the-road hauling.

    Commonly known as forklifts, pallet trucks, ridertrucks, forktrucks, or lifttrucks.

    Can be powered through electric or combustionengines.

    24

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    SCOPE OF STANDARD

    The scope provisions of 1910.178(a), which arebased on ANSI B56.1 - 1969, remain in effectand cover: ... fork trucks, tractors, platform lift trucks, motorized hand trucks, and other

    specialized industrial trucks powered by electric motors or internal combustionengines.

    It does not apply to compressed air or nonflammable compressed gas-operatedindustrial trucks, farm vehicles, nor vehicles intended primarily for earth moving orover-the-road hauling.

    This scope covers general industry, constructionand shipyards.

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    SCOPE OF STANDARD (CONTINUED)

    For marine terminal and longshoring industries, all powered industrial trucks arecovered, no matter what specialized name they are given.This includes, but is not limited to, straddle carriers, hustlers, toploaders, container

    reach stackers, and other vehicles that carry, push, pull, lift, or tier loads.

    26

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    REASONS FOR NEW STANDARD

    Powered industrial truck accidents cause approximately 100 fatalities and 36,340serious 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.

    27

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    ADDITIONAL REASONS FOR NEW STANDARD

    Updated consensus standards have beenpublished.

    OSHA has been petitioned to improve therequirements for industrial truck training.

    Advisory Committee on Construction Safetyand Health has recommended improving thestandard.

    Resolutions have been introduced in theSenate and House urging OSHA to revise itsoutdated standard. 28

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    FORKLIFT FATALITIES, 1992-1996

    29

    Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts

    86 89

    120

    95

    114

    1992 1993 1994 1995 1996

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    FORKLIFT FATALITIES BY AGE

    GROUP

    1992 -1996

    3%

    10%

    22%

    21%

    12%

    5%

    27%

    Under 20

    20 - 24

    25 - 34

    35 - 44

    45 - 54

    56 - 64

    65 & over

    30Source: Bureau of Labor Statistics

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    INDUSTRIES WHERE POWEREDINDUSTRIAL TRUCK ACCIDENTS OCCURRED

    31Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic and

    Mechanical Engineering Safety Standards.

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    NONFATAL OCCUPATIONAL INJURIESAND ILLNESSES BY SOURCE, 1996

    32Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.

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    BACKGROUND

    The previous OSHA standards, while requiring operator training, did not define thetype of training or authorization required.March 15, 1988 - Industrial Truck Association (ITA) petitioned OSHA for specific

    training requirements.

    33

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    BACKGROUND (CONTINUED)

    American National Standards Institute (ANSI), in cooperation with ASME, has revisedits standard 4 times, including current lifttruck technology and specific trainingtopics.

    34

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    BACKGROUND (CONTINUED)

    OSHA published a proposed ruling on March14, 1995 for General Industry, Shipyard,Marine Terminals, and Longshoringregulations, adding specific trainingrequirements.

    On January 30, 1996, OSHA proposed arevision of the construction standards,mandating the development of an operatortraining program based on the priorknowledge and skills of the trainee andrequiring a periodic evaluation. 35

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    FINAL RULE

    OSHA published the final rule for Powered Industrial Truck Operator Training onDecember 1, 1998.

    The effective date is March 1, 1999. Start-up dates are included in paragraph (l)(7).It applies to all industries except agricultural operations.OSHA estimates that the new rule will prevent 11 deaths and 9,422 injuries per year.

    36

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    FATALITIES/INJURIES POTENTIALLY AVERTED

    ANNUALLY BY NEW STANDARD

    37Source: U.S. Department of Labor, OSHA, Office of Regulatory Analysis, 1997

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    PERFORMANCE-ORIENTED REQUIREMENTS

    The powered industrial truck operator training requirements are performance-oriented to permit employers to tailor a training program to the characteristics oftheir workplaces and the particular types of powered industrial trucks operated.

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    REVISED OPERATOR TRAINING REQUIREMENTS

    General Industry: 1910.178 is amended by revisingparagraph (l) and adding Appendix A.

    Shipyard Employment: New section 1915.120 andAppendix A are added.

    Marine Terminals: Section 1917.1 is amended byadding new paragraph (a)(2)(xiv) and Appendix A.

    Longshoring: Section 1918.1 is amended by addingnew paragraph (b)(10) and Appendix A.Construction: 1926.602 is amended by adding new

    paragraph (d) and Appendix A.39

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    OPERATOR TRAINING

    Safe operationsThe employer shall ensure that each poweredindustrial truck operator is competent to operate

    a powered industrial truck safely, as

    demonstrated by successful completion of thetraining and evaluation specified in the OSHAstandard.

    Prior to permitting an employee to operate a

    powered industrial truck (except for trainingpurposes), the employer shall ensure that eachoperator has successfully completed the

    required training (or previously receivedappropriate training). 40

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    TRAINING PROGRAM IMPLEMENTATION

    Trainees may operate a powered industrial truck only:Under direct supervision of a person who has

    the knowledge, training, and experience to

    train operators and evaluate their

    competence; and,

    Where such operation does not endanger the

    trainee or other employees.

    41

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    42

    Training Program Implementation(continued)

    Training shall consist of a combination of:

    Formal instruction (e.g., lecture, discussion,

    interactive computer learning, written material),Practical training (demonstrations and exercises

    performed by the trainee), and

    Evaluation of the operators performance in the

    workplace

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    TRAINING PROGRAM IMPLEMENTATION

    (CONTINUED)

    Training andevaluation shall beconducted by aperson with theknowledge, trainingand experience totrain poweredindustrial truckoperators andevaluate theircompetence. 43

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    TRAINING PROGRAM CONTENT

    Operators shall receive initial training in the following topics, except in topics which theemployer can demonstrate are not applicable to safe operation in the employersworkplace.

    Truck-related topics

    Workplace-related topics

    The requirements of the standard

    44

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    Operating instructions,warnings and precautions

    Differences from

    automobileControls and

    instrumentation

    Engine or motor operation

    Steering and

    maneuveringVisibility

    Fork and attachmentadaptation, operation, use

    Vehicle capacity and

    stabilityVehicle inspection and

    maintenance that theoperator will be required toperform

    Refueling/Charging/Recharging batteries

    Operating limitations

    Other instructions, etc.45

    TRAINING PROGRAM CONTENT (CONTINUED)

    Truck-related topics

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    Surface conditions

    Composition and stability

    of loads

    Load manipulation,

    stacking, unstacking

    Pedestrian traffic

    Narrow aisles and

    restricted areas

    Operating in hazardous

    (classified) locations

    Operating on ramps and

    sloped surfaces

    Potentially hazardous

    environmental conditions

    Operating in closed

    environments or other areas

    where poor ventilation or

    maintenance could causecarbon monoxide or diesel

    exhaust buildup

    46

    TRAINING PROGRAM CONTENT (CONTINUED)

    Workplace-related topics

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    TRAINING PROGRAM CONTENT (CONTINUED)

    The requirements of the OSHA standard on powered industrial trucks must also beincluded in the initial operator training program.

    47

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    REFRESHER TRAINING AND EVALUATION

    Refresher training, including an evaluation of the effectiveness of that training, shall beconducted to ensure that the operator has the knowledge and skills needed to operate thepowered industrial truck safely.

    Refresher training required when: Unsafe operation

    Accident or near-miss

    Evaluation indicates need Different type of equipment introduced

    Workplace condition changes

    48

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    REFRESHER TRAINING AND EVALUATION

    (CONTINUED)An evaluation of each powered industrial truck operators performance must be

    conducted: After initial training,

    After refresher training, and

    At least once every three years

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    AVOIDANCE OF DUPLICATIVE TRAINING

    If an operator has previously received training in a topic specified in this section, andthe training is appropriate to the truck and working conditions encountered,additional training in that topic is not required if the operator has been evaluatedand found competent to operate the truck safely.

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    CERTIFICATION

    The employer shall certify that each operator has been trained and evaluated asrequired by the standard.

    Certification shall include: Name of operator

    Date of training

    Date of evaluation

    Identity of person(s) performing the training or evaluation

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    DATES

    The employer shall ensure that operators ofpowered industrial trucks are trained, asappropriate, by the dates shown in the followingtable.

    52

    If the employee washired: The initial trainingand evaluation ofthat employee mustbe completed:

    Before December 1,

    1999

    By December 1, 1999

    After December 1, 1999Before the employee isassigned to operate apowered industrial truck.

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    APPENDIX A - STABILITY OF

    POWERED INDUSTRIAL TRUCKS

    Appendix A provides non-mandatory guidance to assist employers in implementing thestandard.

    This appendix does not add to, alter, or reduce the requirements of this section.

    53

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    APPENDIX A - STABILITY OF

    POWERED INDUSTRIAL TRUCKS

    DefinitionsGeneralBasic PrinciplesStability TriangleLongitudinal StabilityLateral StabilityDynamic Stability

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    55

    A

    B

    C

    Vehicle Center of

    Gravity (Unloaded)

    Center of Gravity

    of Vehicle and

    Maximum Load

    (Theoretical)

    Stability Triangle - Figure 1

    Notes:

    1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C.Theoretically the maximum load will result in the CG at the line B-C. In actual practice, thecombined CG should never be at line B-C.

    2. The addition of additional counterweight will cause the truck CG to shift toward point A andresult in a truck that is less stable laterally.

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    56

    Load CG

    VerticalStability

    Line

    (Line of Action)

    Combined CG

    Truck CG

    Load CG

    Combined CG

    Vertical

    Stability

    Line

    (Line of Action)

    Truck CG

    The vehicle is stable This vehicle is unstable and

    will continue to tip over

    Stability Triangle - Figure 2

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    EFFECTIVE POWERED INDUSTRIALTRUCK OPERATOR TRAINING

    PROGRAMour major areas of concern must be addressed: The general hazards that apply to the operation of all or most powered industrial

    trucks;

    The hazards associated with the operation of particular types of trucks;

    The hazards of workplaces generally; and,

    The hazards of the particular workplace where the vehicle operates.

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    TYPES OF POWERED INDUSTRIAL TRUCKS

    There are many different types of poweredindustrial trucks covered by the OSHAstandard.

    Commonly used types include:High lift trucks, counterbalanced trucks, cantilever trucks,

    rider trucks, forklift trucks, high lift trucks, high liftplatform trucks, low lift trucks, motorized hand trucks,pallet trucks, straddle trucks, reach rider trucks, high lift

    order picker trucks, motorized hand/rider trucks, andcounterbalanced front/side loader lift trucks.

    A single type of truck can only be described bycalling it by all of its characteristics, (e.g., ahigh lift, counterbalanced, sit down ridertruck .

    58

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    UNIQUE CHARACTERISTICS OFPOWERED INDUSTRIAL TRUCKSach type of powered industrial truck has its own unique characteristics and some

    inherent hazards.To be effective, training must address the unique characteristics of the type of vehicle

    the employee is being trained to operate.

    59

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    COMPONENTS OF A FORKLIFT TRUCK*

    60*One of the most common types of powered industrial trucks

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    CLASSES OF COMMONLY-USED POWERED

    INDUSTRIAL TRUCKS*

    The Industrial Truck Association has placed poweredindustrial trucks into 7 classes.Class I - Electric motor rider trucks

    Class II - Electric motor narrow aisle trucksClass III - Electric motor hand trucks or hand/rider trucksClass IV - Internal combustion engine trucks

    (solid/cushion tires)Class V - Internal combustion engine trucks (pneumatic

    tires)

    Class VI - Electric and internal combustion enginetractorsClass VII - Rough terrain forklift trucks

    61*Note that this classification refers to commonly-used vehicles and doesnot include all powered industrial trucks covered by the OSHA standard.

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    CLASS I - ELECTRIC MOTOR RIDER TRUCKS

    Counterbalanced rider type, stand upThree wheel electric trucks, sit-downCounterbalanced rider type, cushion tires, sit-down (high and low platform)Counterbalanced rider, pneumatic tire, sit-down (high and low platform)

    62

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    CLASS I - ELECTRIC MOTOR RIDER TRUCKS

    63

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    CLASS I - ELECTRIC MOTOR RIDER TRUCKS

    Counterbalanced RiderType, Stand-Up

    64

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    CLASS II - ELECTRIC MOTORNARROW AISLE TRUCKSigh lift straddleOrder pickerReach type outriggerSide loaders, turret trucks, swing mast and convertible turret/stock pickersLow lift pallet and platform (rider)

    65

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    CLASS II - ELECTRIC MOTOR NARROW

    AISLE TRUCKS

    66

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    CLASS II - NARROW AISLE TRUCKS

    67

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    CLASS III - ELECTRIC MOTOR

    HAND OR HAND/RIDER TRUCKSow lift platform

    Low lift walkie palletReach type outriggerHigh lift straddleHigh lift counterbalancedLow lift walkie/rider pallet

    68

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    CLASS III - ELECTRIC MOTOR HAND OR

    HAND/RIDER TRUCKS

    69

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    CLASS III - HAND & HAND/RIDER TRUCKS

    70

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    CLASS IV - INTERNAL COMBUSTIONENGINE TRUCKS - CUSHION (SOLID)

    TIRES

    71Fork, counterbalanced (cushion/solid tires)

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    CLASS IV - INTERNALCOMBUSTION ENGINE TRUCKS -

    CUSHION (SOLID) TIRES

    72

    CLASS V INTERNAL COMBUSTION

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    CLASS V - INTERNAL COMBUSTIONENGINE TRUCKS - PNEUMATIC

    TIRES

    73Fork, counterbalanced (pneumatic tires)

    CLASS V INTERNAL COMBUSTION

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    CLASS V - INTERNAL COMBUSTION

    ENGINE TRUCKS (PNEUMATIC

    TIRES)

    74

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    CLASS VI - ELECTRIC & INTERNAL

    COMBUSTION ENGINE TRACTORS

    75

    Sit-down rider

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    Straight-mast forklift Extended-reach forklift

    76

    CLASS VII - ROUGH TERRAIN

    FORKLIFT TRUCKS

    All rough terrain forklift trucks

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    ROUGH TERRAIN STRAIGHT MAST

    FORKLIFTS

    77

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    ROUGH TERRAIN EXTENDED-

    REACH FORKLIFTS

    78

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    Container top handlers

    Container reach stackers

    Straddle carriers

    Semi-tractors/ Utilityvehicles

    Sidehandlers

    Combination vacuum lifts

    Yard tractors

    79

    SOME TYPES OF POWEREDINDUSTRIAL TRUCKS USED IN

    MARITIME

    The following types of vehicles are

    covered by the OSHA standard if the

    vehicles carry, push, pull, lift, or tierloads.

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    POWERED INDUSTRIAL TRUCKSUSED IN MARITIME

    80

    Container Handlers

    POWERED INDUSTRIAL TRUCKS

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    POWERED INDUSTRIAL TRUCKS

    USED IN MARITIME

    81Empty-Container Handler

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    POWERED INDUSTRIAL TRUCKS

    USED IN MARITIME

    82

    Container Reach Stacker

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    POWERED INDUSTRIAL TRUCKSUSED IN MARITIME

    83

    Straddle Carriers

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    POWERED INDUSTRIAL TRUCKS

    USED IN MARITIME

    84Yard Tractor

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    DOCK SAFETYPainting of area.Trailer brakes and securing.People in the area.Perform daily check of truck.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 8

    5

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    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 8

    6

    DOCK SAFETY

    Portable Docking Plate

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    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 8

    7

    DOCK SAFETY

    Dock Restraint Mechanism

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    CONVEYORS

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 8

    8

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    CONVEYORS

    Powered type is most dangerous.Most people get hurt while working on them.Most injuries involve fingers, hands, and arms.Accidents can be prevented if workers are careful to turn off the power and lock it out.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 8

    9

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    HOISTS AND CRANES

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R 9

    0

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    HOISTS AND

    CRANES

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    HOISTS AND CRANES

    Hoists and Cranes should be inspected before use, every time.When cranes fail, it usually happens fast.Tension on a sling is relative to total weight be lifted and angle of sling.Never stand under a suspended load.

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    WHEN STORING MATERIALS

    Place large, heavy packages on the bottom andlighter ones on top.Never place materials where they can be trippedover or where someone could get hurtattempting to retrieve them.When materials are moved to where you areworking, they should be secured so they cantfall on anyone.Never block a traffic path or prop materials upagainst a wall where they might slide over and

    cause an accident.

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    CORROSIVE AND FLAMMABLE LIQUIDS

    Understand what it is that you are about to move.Examine the containers to make sure they are sealed and properly labeled.Make sure you are wearing all required PPE.

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    SAFETY GUARDS

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    SAFETY GUARDS

    Are required to prevent accidents.Protect people, not the machine.Hazardous parts include point of operation components, control mechanisms, parts

    that transmit power, and parts that retain stored energy

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    MOVING PARTS

    MAKE GUARDSNECESSARY

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    MOVING PARTS MAKE

    GUARDS NECESSARY

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    POINT OF OPERATION GUARD

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    POINT OF OPERATION GUARD

    OSHA 29 CFR 1910.217I N D U S T R I A L S A F E T Y L E C T U R E F O U R

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    INTERLOCKING GUARDS

    Used when a fixed guard cannot be used.Connected to machine controls or power source.Can be mechanical, electrical, or pneumatic.

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    AUTOMATIC GUARDS

    Push, pull, or sweep the operators hands out of the danger zone.Example: Automatic Pull Backs

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    POWER TRANSMISSION GUARDS

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    POWER TRANSMISSION GUARDS

    Prevent pieces from flying out.Should be kept in place at all times while the

    machine is running.Should only be removed for repair work.

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    OTHER SAFETY DEVICES

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    OTHER SAFETY DEVICES

    Machine controls.Feeding and extracting tools.Ejectors.

    I N D U S T R I A L S A F E T Y L E C T U R E F O U R

    1

    0

    OSHA LOCK OUT/TAG OUT PROCEDURES 29 CFR

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    OSHA LOCK OUT/TAG OUT PROCEDURES 29 CFR

    1910.147

    Locking out has to do with the removal orprevention of hazardous energy.Tag out is a communication technique that warnsothers of the machines repair work.

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    CONTROL OF HAZARDOUS

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    ENERGY

    29 CFR 1910.147The standard covers the servicing and maintenance of machines and equipment in

    which the unexpected energization or start up of the machines or equipment , orrelease of stored energy could cause injury to employees.

    10

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    PROVISIONS OF THE STANDARD

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    PROVISIONS OF THE STANDARD

    Requires employers to establish procedures for isolating machines or equipmentfrom their source of energy and affixing appropriate locks or tags to energyisolating devices

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    EMPLOYER RESPONSIBILITIES

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    EMPLOYER RESPONSIBILITIESEstablish energy control programEstablish energy control procedures for machines and equipmentProvide employee trainingConduct periodic inspections of the energy control program

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    APPLICATION OF THE STANDARD

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    APPLICATION OF THE STANDARD

    An employee is required to remove orbypass a guard or other safety deviceAn employee is required to place any partof their body in contact with the point ofoperation of the operational machine orpiece of equipmentAn employee is required to place any part

    of their body into a danger zoneassociated with a machine operatingcycle11

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    EXCEPTIONS TO THE STANDARD

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    EXCEPTIONS TO THE STANDARDHot tap operations involving transmission and distribution systems for substances

    such as gas, steam, water, or petroleum products

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    MINOR SERVICING TASKSEmployees performing minor tool changes and adjustments that are routine,

    repetitive, and integral to the use of the equipment and that occur during normaloperations are not covered by the lockout/tagout standard, provided the work isperformed using alternative measures that provide effective protection.

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    DEFINITIONSTagout: The placement of a tagout device on an energy isolating device to indicate

    the equipment being controlled may not be operated until the tagout device isremoved

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    STORED ENERGY

    If there is a possibility of reaccumulation of stored energy to a hazardous level,verification of isolation shall be continued until the possibility of suchaccumulation no longer exists

    12

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    RE-ENERGIZING EQUIPMENT

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    RE-ENERGIZING EQUIPMENT

    Ensure that machine or equipmentcomponents are operationally intact

    Ensure that all employees are safelypositioned or removed from equipmentEnsure that lockout or tagout devices are

    removed from each energy isolationdevice by the employee who applied thedevice

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    LOCKOUT REQUIREMENTSAfter January 1990, whenever replacement, major repair, or modification of a

    machine is performed, or whenever new machines or equipment are installed,they must be designed to accept a lockout device

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    DEVICE REQUIREMENTSDurable: Lockout and tagout devices must

    withstand the environment to which they areexposed for the maximum durationStandardized: Both lockout and tagout devicesmust be standardized according to eithercolor, shape, or size

    Tagout devices must also be standardizedaccording to print and format12

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    PERIODIC INSPECTIONS

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    PERIODIC INSPECTIONS

    The employer shall conduct a periodic inspection of the energy control procedureat least annually

    Shall be performed by an authorized employee other than the person(s) utilizingthe energy control procedure being inspected

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    PERIODIC INSPECTIONS

    Shall be conducted to correct any deviations or inadequacies identifiedWhere lockout is used, the inspection shall include a review between the inspector

    and each authorized employee

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    PERIODIC INSPECTIONS

    Where tagout is used, the inspection shall include a review between the inspectorand each authorized and affected employees

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    PERIODIC INSPECTIONS

    The employer shall:Certify that the periodic inspections have been

    performed

    Identify the machine or equipment on whichenergy control procedures were used

    The employer shall also note:The date of the inspection

    The employees included in the inspectionThe person performing the inspection

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    TRAINING AND COMMUNICATION

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    TRAINING AND COMMUNICATION

    Each authorized employee shall receive training in: Recognition of applicable hazardous energy sources

    Type and magnitude of the energy available in the workplace

    Methods and means necessary for energy isolation and control

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    TRAINING AND COMMUNICATIONach affected employee shall be instructed in the purpose and use of the energycontrol procedureAll other employees shall be instructed about the prohibition relating to attempts torestart or reenergize machines or equipment which are locked out or tagged out

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    TRAINING AND COMMUNICATION

    The employer shall certify that employee training has been accomplished and isbeing kept up to date

    Certification shall contain employee names and dates of training

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    OUTSIDE PERSONNEL

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    Whenever outside servicing personnel are engaged in activities covered bylockout/tagout, the on-site employer and the outside employer shall inform eachother of their respective lockout or tagout procedures

    13

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    TAGOUT TAGS

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    13

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    GROUP LOCKOUT

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    TAGOUT TAG

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    LOCKOUT SIGNAGE

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    14

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    REVIEW

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    1. What is the best way to avoid hurting yourself when moving material?2. What is most dangerous when wearing gloves around rotating equipment?3. Describe the best method for lifting.4. What is the best way to carry a small box or carton?5. What equipment can you use to move a barrel alone?6. Describe how to handle moving a loaded hand truck down a ramp.7. When is it permissible to ride on the platform of a moving truck?8. What must be checked before entering a trailer on a shipping dock?9. What is the best way to prevent accidents while working on conveyors?10. What does the angle of a lifting sling have to do with the stress placed on it?11. What is a pinch point?12. What is meant by the term point of operation?13. What word is used to mean a back and forth motion?14. What is the correct spacing for a grinder wheel from the work rest?15. What type of machine guard limits the operators access to the danger zone?16. Which type of machine guard prevents access to the danger zone altogether?17. What type of guard cannot be moved while the machine is running?18. What type of guard, when removed, prevents the machine from running?