Chapter 10 Forklifts

& Power Tools

Section 1 Presentation
Section 2 Narrative

1
FORKLIFT SAFETY

OSHA 29CFR 1910.178

2
REGULATORY STANDARD
POWERED INDUSTRIAL TRUCKS

29CFR - 1910 - 178

29CFR - SAFETY AND HEALTH STANDARDS

1910 - GENERAL INDUSTRY

178 - POWERED INDUSTRIAL TRUCKS

3
 ANSI STANDARD
POWERED INDUSTRIAL TRUCKS

ANSI - B56-1983

4
 FORKLIFT INJURY
STATISTICS
APPROXIMATELY 34,000 RELATED INJURIES A YEAR:
YEAR:
REAL
HEAVY
; INATTENTION PARTS
6500lbs
; DISTRACTION
; EXCESSIVE SPEED
; POOR DRIVING HABITS
; LACK OF TRAINING LOAD CAPACITY
6000 lbs
PROPANE ONLY

ACME FORKLIFTS

5
CIRCUMSTANCES OF INJURY

HOW MOST INJURIES OCCUR

; OVERLOADING CAUSING THE VEHICLE
TO TURNOVER
; LOAD INSTABILITY CAUSING TURNOVER
; OBSTRUCTIONS IN THE PATH OF TRAVEL
OR LIFT
; USING FORKLIFT OUTSIDE OF DESIGN
LIMITATIONS
; STRIKING A PEDESTRIAN

6
 Case Studies

Let’s look at three case studies involving forklift incidents. See if you can
determine what the violation is before you look at the citation.

7
 CASE STUDY #1
CRUSHED AGAINST A STEEL POLE
NARRATIVE: AN EMPLOYEE WAS SPOTTING A
FORKLIFT BACKING UP.
THE OPERATOR ATTEMPTED TO EASE THE
VEHICLE SLOWLY BACK.
THE GAS PEDAL STUCK CAUSING THE VEHICLE
TO LURCH, PINNING AND CRUSHING THE
SPOTTER.
RESULTING IN FATAL INJURIES.

CITATION: FAILURE TO MAINTAIN CLEARANCE

BETWEEN A FIXED OBJECT AND THE VEHICLE.

8
 CASE STUDY #2
KILLED BY TOPPLED FORKLIFT

NARRATIVE: AN EMPLOYEE WAS

TRANSFERRING MATERIAL FROM A
LOADING DOCK WHEN THE VEHICLE WAS
DRIVEN OFF OF THE SIDE OF THE DOCK.
RESULTING IN A LATERAL TIPOVER OF THE
VEHICLE AND FATAL OPERATOR INJURIES.

CITATION: FAILURE TO MAINTAIN CLEARANCE

BETWEEN THE EDGE OF THE DOCK AND THE
VEHICLE.

9
 CASE STUDY #3
KILLED BY TOPPLED FORKLIFT
NARRATIVE: AN EMPLOYEE WAS
TRANSFERRING MATERIAL FROM A STACKED
PALLET STORAGE.
THE OPERATOR BEGAN MOVING THE VEHICLE
WITH THE LOAD EXTENDED BEFORE LOWERING
THE LOAD, RESULTING IN A CENTRIFUGAL
OVERLOAD AND TOPPLING.
THE OPERATOR WAS CRUSHED BY THE
VEHICLE.
CITATION: FAILURE TO MAINTAIN VEHICULAR
CONTROL

10
 TRAINING REQUIREMENTS

OPERATORS MUST RECEIVE:

; CLASSROOM TRAINING COVERING SAFETY

RULES
; BASIC MATERIAL-HANDLING TECHNIQUES
; BASIC OPERATING TECHNIQUES
; DRIVER’S PERFORMANCE TEST

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

Training is performance-oriented. Your training will depend upon the

functions of your trucks and their operators. The amount of time the
training takes is determined by how long it takes to teach your operators
to perform their tasks safely.

11
RETRAINING REQUIREMENTS

REQUIRED WHEN THERE IS A:

; CHANGE IN VEHICLES AND HANDLING

EQUIPMENT
; CLOSE-CALL EVENT
; FAILURE IN THE SAFETY PROCEDURES
; REASON TO DOUBT EMPLOYEE
PROFICIENCY
LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

12
FORKLIFT SAFETY PROGRAM

THREE ELEMENTS TO THE PROGRAM:

1. WRITTEN COMPANY SAFETY

PROCEDURES

2. EMPLOYEE TRAINING

3. DRIVING PROFICIENCY
LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

13
FORKLIFT SAFETY PROGRAM

WRITTEN COMPANY SAFETY PROCEDURES

1. COMPANY FORKLIFT POLICY REVIEWED

ANNUALLY

2. DAILY OPERATOR INSPECTIONS

DOCUMENTED

3. DRIVING TRAINING AND LOAD CAPACITY

6000 lbs

PROFICIENCY DOCUMENTED PROPANE ONLY

ACME FORKLIFTS

14
 FORKLIFT TRAFFIC
PATTERNS
SETTING UP THE PATTERN:
; AISLES MUST BE WELL-LIGHTED AND
OBSTRUCTION FREE
; AISLES MUST BE CLEARLY MARKED AND OF
AMPLE WIDTH
; DRIVING SURFACES MUST IN GOOD REPAIR

15
 FORKLIFT TRAFFIC
PATTERNS
SETTING UP THE PATTERN:

; PEDESTRIANS MUST BE ACCOUNTED FOR IN

THE PATTERN
; REGULATORY SIGNS MUST BE PROMINENT AND
ENFORCED
; GUARDRAILS, DOOR WARNINGS, MIRRORS
AND OTHER STANDARD PRECAUTIONS MUST
BE CONSIDERED AND INSTALLED

16
 FORKLIFT TYPES AND
DESIGNATIONS
VARIOUS TYPES OF FORKLIFT CONFIGURATIONS:

; D DIESEL

; DS DIESEL- WITH ADDITIONAL

SAFEGUARDS TO EXHAUST, FUEL ETC.

; DY DIESEL- LIKE DS BUT HAVING NO

ELECTRICAL EQUIPMENT

17
 FORKLIFT TYPES AND
DESIGNATIONS
VARIOUS TYPES OF FORKLIFT CONFIGURATIONS:

; E ELECTRICALLY POWERED

; ES LIKE E BUT WITH ADDITIONAL SPARK

PRECAUTIONS INSTALLED

; EX LIKE E BUT WITH ADDITIONAL VAPOR

PRECAUTIONS INSTALLED

; G GASOLINE

18
 FORKLIFT TYPES AND
DESIGNATIONS
VARIOUS TYPES OF FORKLIFT CONFIGURATIONS:

; GS GASOLINE BUT WITH ADDITIONAL

SAFEGUARDS TO EXHAUST

; LP PROPANE
NOTE: YOU MUST ENSURE THAT THE TYPE OF
FORKLIFT YOU ARE USING IS COMPATIBLE
WITH THE TYPE OF ENVIRONMENTS AND
WORKING CONDITIONS THE VEHICLE WILL
BE EXPOSED TO.

19
FORKLIFT TYPES

20
FORKLIFT TYPES

21
 BASIC FORKLIFT PRINCIPLES

FORKLIFT MANUFACTURER:

; DICTATES SPECIFIC OPERATION OF VEHICLE

; SPECIFIES MAINTENANCE REQUIREMENTS

; CONSULTED CONCERNING
“ADD-ON’s”

; FIRST CHOICE FOR SAFETY

QUESTIONS

It is very important to note that the forklift must be maintained and operated
within the guidelines published by the manufacturer.

22
BASIC FORKLIFT PRINCIPLES

; OVERHEAD GUARD

; MAST

; CARRIAGE
LOAD CAPACITY
6000 lbs

; BACKREST PROPANE ONLY

ACME FORKLIFTS
; LIFT CYLINDER

; TILT CYLINDERS

; FORKS

23
BASIC FORKLIFT PRINCIPLES

TYPES OF FORKS
; HALF-TAPERED FORKS

- USED WITH HEAVIER LOADS

; FULL-TAPERED FORKS

- USED WITH LIGHTER

LOADS
- USED WITH NARROW PALLETS

24
BASIC FORKLIFT PRINCIPLES
TYPES OF TIRES
AIR
; PNEUMATIC AIR FILLED TIRES

- USED WITH HEAVIER LOADS

- OUTDOORS OR UNEVEN
SURFACES SOLID
RUBBER
; PNEUMATIC SOLID TIRES

- PUNCTURE PROOF
- INTERCHANGED WITH AIR FILLED
CONSULT YOUR VEHICLE OWNERS MANUAL

25
BASIC FORKLIFT PRINCIPLES

TYPES OF TIRES
; CUSHION TIRES CUSHION

- INDOORS OR SMOOTH SURFACES

SOLID
; SOLID TIRES RUBBER

- PUNCTURE PROOF
- SMOOTH INDOOR SURFACES

CONSULT YOUR VEHICLE OWNERS MANUAL

26
BASIC FORKLIFT PRINCIPLES

THE RATED CAPACITY

THE RATED CAPACITY:

; THE MAXIMUM AMOUNT OF WEIGHT THAT CAN

BE SAFELY LIFTED
; HOW THE LOAD RESTS ON THE FORKS IS
CRITICAL
; THE CLOSER THE LOAD IS TO THE BACKREST
THE BETTER
; CAN BE FOUND ON THE NOMENCLATURE
PLATE OF THE VEHICLE

27
BASIC FORKLIFT PRINCIPLES

LIFTING PRINCIPLE

COUNTER PIVOT POINT

WEIGHT PIVOT POINT COUNTER WEIGHT

CONSULT YOUR VEHICLE OWNERS MANUAL

28
BASIC FORKLIFT PRINCIPLES
LIFTING PRINCIPLE

MOVING THE LOAD AWAY

REAL HEAVY
PARTS
FROM THE BACKREST CAN
LOWER THE RATED
LOAD CAPACITY
6000 lbs

6500lbs
PROPANE ONLY

ACME FORKLIFTS
CAPACITY OF THE
FORKLIFT BY HUNDREDS OF
POUNDS!
INCORRECT

CONSULT YOUR VEHICLE OWNERS MANUAL

29
BASIC FORKLIFT PRINCIPLES

LIFTING PRINCIPLE

REAL HEAVY PARTS REAL HEAVY PARTS

LOAD CAPACITY
6000 lbs LOAD CAPACITY
6000 lbs

6500lbs PROPANE ONLY 6500lbs

PROPANE ONLY

ACME FORKLIFTS
ACME FORKLIFTS

INCORRECT CORRECT

CONSULT YOUR VEHICLE OWNERS MANUAL

30
BASIC FORKLIFT PRINCIPLES

CENTRIFUGAL FORCES

REAL HEAVY PARTS

6500lbs
MOVING OR TURNING THE
VEHICLE WHEN THE LOAD
IS EXTENDED CAN RESULT
LOAD CAPACITY
IN TURNOVER BECAUSE OF
CENTRIFUGAL FORCES
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

APPLIED AT THE TOP OF

THE LOAD!

31
BASIC FORKLIFT PRINCIPLES

FORK ADJUSTMENT

FORKS SHOULD BE SPREAD AS

WIDE AS POSSIBLE TO ALLOW
FOR MAXIMUM STABILITY OF
THE LOAD!

32
FORKLIFT OPERATING
PRINCIPLES
PRE-USE INSPECTION
; MAST
; ROLLER TRACKS AND CHAINS
; FORKS AND ADJUSTMENT
; FLUID LEVELS
; HYDRAULIC LINES
; LIFT AND TILT CYLINDERS
; OVERHEAD GUARD MOUNTING
; FIRE EXTINGUISHER

33
 FORKLIFT OPERATING
PRINCIPLES
PRE-USE INSPECTION
; CYLINDER MOUNTING HARDWARE
; TIRES
; LIGHTS AND WARNING DEVICES
; HANDBRAKE
; STEERING AND BRAKES
; DRIVING CONTROLS
; LIFT CONTROLS
; SEAT ADJUSTMENT AND BELTS

Pre-use inspections should be done in writing on a form specifically

provided for that purpose. This form will help the operator remember what
to check and will serve as a record to show that the forklift was properly
checked.

34
FORKLIFT OPERATING
PRINCIPLES
TYPES OF POWER SOURCES

; BATTERY POWERED
; PROPANE POWERED
; DIESEL POWERED
; GASOLINE POWERED

CONSULT YOUR VEHICLE OWNERS MANUAL

35
 FORKLIFT OPERATING
PRINCIPLES
INSPECTION OF POWER SOURCES

; BATTERY POWERED
- REQUIRES CONSTANT CHARGING
- NO IGNITION SOURCES IN CHARGING AREA
- FOLLOW LOCAL CHARGING PROCEDURES

CONSULT YOUR VEHICLE OWNERS MANUAL

36
 FORKLIFT OPERATING
PRINCIPLES
INSPECTION OF POWER SOURCES

; PROPANE POWER
- INSPECT TANK FOR SERVICEABILITY
- INSPECT PROPANE TRANSFER SYSTEM
- INSPECT TANK RESTRAINT SYSTEM
- FOLLOW LOCAL REPLACEMENT PROCEDURES

CONSULT YOUR VEHICLE OWNERS MANUAL

37
 FORKLIFT OPERATING
PRINCIPLES
PROPANE SAFETY PRECAUTIONS
1. EXTINGUISH SMOKING MATERIALS AND REMOVE ANY SOURCES OF
IGNITION.
2. WEAR PROTECTIVE GLOVES AND EYE PROTECTION.
3. ENSURE VALVE IS CLOSED ANY TIME THE PROPANE TANK IS
DISCONNECTED.
4. FOLLOW MANUFACTURERS INSTRUCTIONS FOR REFUELING THE VEHICLE.
5. AFTER TANK IS REMOVED FROM THE VEHICLE, INSPECT IT FOR DAMAGE.
DAMAGE.

6. IF TANK IS SERVICEABLE, HAVE IT MOVED TO EMPTY TANK STORAGE.

7. IF YOU HAVE ANY DOUBTS ABOUT THE SERVICEABILITY CONTACT SAFETY.
SAFETY.

CONSULT YOUR VEHICLE OWNERS MANUAL

38
 FORKLIFT OPERATING
PRINCIPLES
INSPECTION OF POWER SOURCES

; DIESEL AND GASOLINE POWERED

- INSPECT FOR LEAKS
- ENSURE ADEQUATE VENTILATION EXISTS
- FOLLOW LOCAL REFUELING PROCEDURES

CONSULT YOUR VEHICLE OWNERS MANUAL

39
 FORKLIFT OPERATING
PRINCIPLES
STARTING THE FORKLIFT
; APPLY THE FOOT BRAKE

; SHIFT GEARS TO NEUTRAL

; ENSURE LOAD IS LOWERED AND CONTROLS NEUTRALIZED
; START FORKLIFT AND CHECK GAUGES
; DISENGAGE HAND BRAKE
; CHECK CONTROLS, STEERING AND BRAKES

CONSULT YOUR VEHICLE OWNERS MANUAL

40
 FORKLIFT OPERATING
PRINCIPLES
SHUTTING DOWN THE FORKLIFT
; APPLY THE HAND BRAKE
; LOWER THE LOAD
; TURN OFF THE ENGINE
; NEUTRALIZE THE CONTROLS (DISSIPATE LINE PRESSURES)

; FOLLOW ADDITIONAL REQUIREMENTS FOR PROPANE OR

BATTERY POWERED VEHICLES

CONSULT YOUR VEHICLE OWNERS MANUAL

41
 FORKLIFT OPERATING
PRINCIPLES
DEFINITION - ATTENDED VEHICLE

IF OPERATOR IS DISMOUNTED:

; OPERATOR IS WITHIN 25 FEET OF THE VEHICLE

; OPERATOR HAS LINE-
LINE-OF-
OF-SITE OF THE VEHICLE
; OPERATOR HAS NO OBSTRUCTION OF ACCESS TO VEHICLE
; LOAD ENGAGING MEANS IS FULLY LOWERED
; CONTROLS NEUTRALIZED AND HANDBRAKES SET

CONSULT YOUR VEHICLE OWNERS MANUAL

42
 FORKLIFT OPERATING
PRINCIPLES
DEFINITION - UNATTENDED VEHICLE
IF OPERATOR IS DISMOUNTED:
; OPERATOR IS MORE THAN 25 FEET FROM THE VEHICLE
; OPERATOR HAS NO LINE OF SITE OF THE VEHICLE
; OPERATOR IS OBSTRUCTED FROM ACCESS TO VEHICLE
; LOAD ENGAGING MEANS IS NOT FULLY LOWERED
; HANDBRAKES NOT SET

CONSULT YOUR VEHICLE OWNERS MANUAL

43
 HANDLING AND MOVING
LOADS
TO PICK UP A LOAD
; APPROACH THE LOAD SLOWLY AND STRAIGHT ON (LOAD
CENTERED)
; STOP WHEN THE TIP OF THE FORKS ARE ABOUT A FOOT AWAY
; LEVEL FORKS AND ADJUST FORK HEIGHT
; MOVE FORWARD SLOWLY UNTIL LOAD IS FULLY AGAINST
BACKREST
; LIFT THE LOAD HIGH ENOUGH TO CLEAR FLOOR OBSTRUCTIONS
; BACK THE LOAD OUT SLIGHTLY FROM THE STORAGE LOCATION
; CAREFULLY TILT MASK BACK TO STABILIZE THE LOAD
; ENSURE REAR IS CLEAR, BACK OUT

44
 HANDLING AND MOVING
LOADS
TO PUT DOWN A LOAD

; APPROACH THE DELIVERY LOCATION STRAIGHT ON

; STOP WHEN THE TIP OF THE FORKS ARE ABOUT A FOOT AWAY
; LOWER LOAD, CAREFULLY LEVEL FORKS
; MOVE FORWARD SLOWLY UNTIL LOAD IS IN DESIRED LOCATION
; LOWER THE LOAD TO FLOOR OR STORAGE LOCATION
; ENSURE FORKS ARE CLEAR OF PALLET
; ENSURE REAR IS CLEAR, BACK OUT
LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

45
 HANDLING AND MOVING
LOADS
UNSTACKING LOADS
; APPROACH THE LOAD SLOWLY AND STRAIGHT ON (LOAD
CENTERED)
; STOP ABOUT A FOOT AWAY AND RAISE FORKS TO DESIRED
HEIGHT
; LEVEL FORKS AND DRIVE FORWARD
; MOVE FORWARD SLOWLY UNTIL LOAD IS FULLY AGAINST
BACKREST
; LIFT THE LOAD HIGH ENOUGH TO CLEAR OBSTRUCTIONS
; ENSURE REAR IS CLEAR, BACK OUT
; ONCE THE STACK IS CLEARED - LOWER TO DESIRED HEIGHT
; CAREFULLY TILT MASK BACK TO STABILIZE THE LOAD

46
 HANDLING AND MOVING
LOADS
STACKING LOADS
; APPROACH THE LOCATION SLOWLY AND STRAIGHT ON
; STOP ABOUT A FOOT AWAY AND RAISE LOAD TO DESIRED HEIGHT
; DRIVE FORWARD UNTIL LOAD IS SQUARE OVER STACK
; LEVEL FORKS AND LOWER LOAD UNTIL LOAD IS SUPPORTED
; ENSURE FORKS ARE CLEAR OF PALLET
; ENSURE REAR IS CLEAR, BACK OUT

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

47
 HANDLING AND MOVING
LOADS
DRIVING WITH A LOAD
; TRAVEL WITH THE LOAD TILTED SLIGHTLY BACK FOR STABILITY
; IF YOU CAN’
CAN’T SEE OVER THE LOAD DRIVE IN REVERSE
; DRIVE WITH LOAD APPROXIMATELY SIX INCHES ABOVE SURFACE
; NEVER PASS PEDESTRIANS - THEY MUST ALWAYS YIELD WAY!
; REMEMBER THAT THE DRIVING WHEELS ARE YOUR PIVOT POINT
; OBEY TRAFFIC RULES AND LOCAL POLICIES
; ALWAYS SLOWDOWN TO ATTEMPT A TURN
LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

48
 DANGEROUS DRIVING
CONDITIONS
UNSTABLE FLOOR SURFACES

; TRACTION PROBLEMS, SKIDDING AND SLIDING CAN OCCUR

; DRIVE CAUTIOUSLY AND AT SLOW SPEEDS
; BE AWARE OF DEBRIS AND SPILLS
; CONSIDER AREAS WHERE CONTRACTORS MAY BE WORKING
; AVOID MAKING TIGHT TURNS
; ENSURE BRAKES ARE APPLIED CAREFULLY

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

49
 DANGEROUS DRIVING
CONDITIONS
OVERHEAD CLEARANCES

; PLAN YOUR ROUTE IN ADVANCE

; DRIVE CAUTIOUSLY AND AT SLOW SPEEDS
; KNOW THE MAST HEIGHT AND FACILITY OVERHEAD CLEARANCES
; BE CAREFUL AROUND ELECTRICAL LINES

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

50
 DANGEROUS DRIVING
CONDITIONS
SPATIALLY RESTRICTED AREAS

; CONSIDER GETTING OUT BEFORE YOU GET IN

; TRY MOVING EMPTY FORKS TO ONE SIDE OF THE CARRIAGE
; USE MAXIMUM TURNING ANGLES
; BE CAREFUL WHEN MAKING TIGHT TURNS

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

51
 DANGEROUS DRIVING
CONDITIONS
HIGH TRAFFIC AREAS

PEDESTRIAN CONSIDERATIONS
; NEVER ALLOW A PEDESTRIAN BETWEEN YOU AND A FIXED OBJECT
; NEVER PASS A PEDESTRIAN THEY MUST YIELD RIGHT OF WAY
; MAINTAIN A SAFE DISTANCE WHEN LOADING AND UNLOADING
; BE CAREFUL WHEN MAKING TIGHT TURNS
; NEVER ASSUME PEDESTRIANS KNOW YOU’
YOU’RE
THERE
LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

52
 DANGEROUS DRIVING
CONDITIONS
HIGH TRAFFIC AREAS

MULTIPLE FORKLIFT CONSIDERATIONS

; OBEY ALL LOCAL TRAFFIC RULES AND SIGNS
; KNOW WHERE ALL MIRRORS ARE POSITIONED
; USE HORNS WHEN APPROACHING CORNERS, DOORWAYS AND AISLES
; NEVER EXCEED THE SAFE WORKING SPEED OF FIVE MPH

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

53
 DANGEROUS DRIVING
CONDITIONS
HIGH TRAFFIC AREAS

MULTIPLE FORKLIFT CONSIDERATIONS (CONT.)

; KEEP A SAFE DISTANCE FROM OTHER FORKLIFTS (3 LENGTHS)
; KNOW WHERE ALL MIRRORS ARE POSITIONED
; PASS ONLY IN AUTHORIZED AREAS

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

54
 DANGEROUS DRIVING
CONDITIONS
UNEVEN DRIVING SURFACES

; UNDERSTAND THE TYPE TIRES ON THE VEHICLE AND

LIMITATIONS
; APPROACH RAILROAD TRACKS AT A 45-
45-DEGREE ANGLE
; FIND ANOTHER ROUTE RATHER THAN TAKE AN
UNNECESSARY RISK
; CONSIDER USING A DIFFERENT TYPE
OF VEHICLE IF ONE IS AVAILABLE
LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

55
 DANGEROUS DRIVING
CONDITIONS
LOADING DOCK OPERATIONS

; ENSURE BRIDGE OR DOCK PLATES ARE SECURE

; ENSURE BRIDGE OR DOCK PLATES ARE RATED FOR THE VEHICLE
; ENSURE TRAILER, TRUCK, OR RAILCAR WHEELS ARE SECURED
; NEVER ACCELERATE ON BRIDGE OR DOCK PLATES
; ALWAYS DRIVE STRAIGHT ON TO BRIDGE OR DOCK PLATES
; ALWAYS MAINTAIN A SAFE DISTANCE FROM EDGES
; NEVER COMPETE WITH PEDESTRIANS
LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

56
 DANGEROUS DRIVING
CONDITIONS
TRAILER OPERATIONS
; ENSURE THE TRAILER FLOOR IS RATED FOR THE VEHICLE WEIGHT
; VERIFY THAT THE TRAILER FLOOR IS IN SERVICEABLE CONDITION
; ENSURE THE FORKLIFT WILL NOT UNBALANCE THE TRAILER
; USE ADDITIONAL TRAILER SUPPORTS IF UNBALANCING IS A RISK
; CONSIDER THE INTERIOR TRAILER HEIGHT
; ENSURE THE TRAILER CANNOT ROLL
AWAY FROM THE DOCK
; CONSIDER LIGHTING AND INCLEMENT LOAD CAPACITY
6000 lbs

WEATHER PROPANE ONLY

ACME FORKLIFTS

57
 DANGEROUS DRIVING
CONDITIONS
LOADED FORKLIFT RAMP OPERATIONS
ALWAYS APPROACH RAMP LOAD FIRST!

REAL HEAVY PARTS

LOAD CAPACITY
6000 lbs

6500lbs PROPANE ONLY

ACME FORKLIFTS

58
 DANGEROUS DRIVING
CONDITIONS
LOADED FORKLIFT RAMP OPERATIONS
ALWAYS LEAVE RAMP LOAD LAST!

REAL HEAVY PARTS

LOAD CAPACITY
6000 lbs

6500lbs PROPANE ONLY

ACME FORKLIFTS

59
 DANGEROUS DRIVING
CONDITIONS
UNLOADED FORKLIFT RAMP OPERATIONS
ALWAYS APPROACH A RAMP FORKS LAST!

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

60
 DANGEROUS DRIVING
CONDITIONS
UNLOADED FORKLIFT RAMP OPERATIONS
ALWAYS LEAVE A RAMP FORKS FIRST!

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

61
DANGEROUS DRIVING
CONDITIONS
TURNOVERS
LONGITUDINAL TURNOVER

62
DANGEROUS DRIVING
CONDITIONS
TURNOVERS
LATERAL TURNOVER

63
 DANGEROUS DRIVING
CONDITIONS
LONGITUDINAL TURNOVER
; USUALLY BEST TO LEAVE THE VEHICLE
; NO GUARANTEE OF SAFETY DURING A LONGITUDINAL TURNOVER

64
 DANGEROUS DRIVING
CONDITIONS
LATERAL TURNOVER
; USUALLY BEST TO STAY WITH THE VEHICLE
; HOLD ON TO THE STEERING WHEEL AND PUSH INTO THE SEAT
; NO GUARANTEE OF SAFETY DURING A LATERAL TURNOVER

65
 DANGEROUS DRIVING
CONDITIONS
SPOTTERS

NEVER UNDERESTIMATE THE VALUE

OF A SPOTTER!

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

66
 CONTRACTOR SAFETY
REQUIREMENTS
OUTSIDE CONTRACTORS MUST:
MUST:

; FOLLOW YOUR RULES AND HAVE ADEQUATE TRAINING

MUST:
FACILITY OR COMPANY REPRESENTATIVES MUST:

; INFORM THE CONTRACTOR OF INTERNAL POLICIES

AND PROCEDURES

; ENSURE THAT THE CONTRACTOR(S) ARE FOLLOWING

YOUR PROCEDURES

67
 TIPS FOR USING
CONTRACTORS
; REMEMBER, YOU CONTROL YOUR FACILITY!

; REVIEW THEIR PROCEDURES WITH THEM BEFORE STARTING THE

JOB!

; DETERMINE THEIR SAFETY PERFORMANCE RECORD!

; DETERMINE WHO IS IN CHARGE OF THEIR PEOPLE!

; DETERMINE HOW THEY WILL AFFECT YOUR EMPLOYEES!

LOAD CAPACITY
6000 lbs

PROPANE ONLY

ACME FORKLIFTS

68
 KEY ELEMENTS TO AN
EFFECTIVE PROGRAM
1. DEVELOP AND STRICTLY ADHERE TO SAFETY
PROCEDURES.

2. ESTABLISH AND ENFORCE SAFE WORK PRACTICES.

3. ENSURE PROPER TRAINING AND SUPERVISION.

4. STRENGTHEN AND MODIFY PRESENT POLICIES.

5. UNDERSTAND THE RELATIONSHIP BETWEEN 29 CFR

1910.178 AND THE BUSINESS OR INDUSTRY INVOLVED.

69
 OSHA'S PERCEPTION
OF A SUCCESSFUL PROGRAM

1. DETAILED FORKLIFT SAFETY PROCEDURES

2. EXTENSIVE EMPLOYEE TRAINING PROGRAMS

3. PERIODIC REINFORCEMENT OF TRAINING

4. SUFFICIENT DISCIPLINE REGARDING

IMPLEMENTATION

70
Chapter 10 Powered Industrial Trucks and
Power Tools
TABLE OF CONTENTS

TOPIC PAGE

General Requirements ................................................................................................... 1

Operator Training ........................................................................................................... 3

Truck Operations ........................................................................................................... 5

Hand and Portable Powered Tools ................................................................................ 7

Reduction of Air Pressure ............................................................................................ 15

 P OWERED INDUSTRIAL T RUCKS - 1910.178

General Requirements
This section contains safety
requirements relating to fire protection,
design, maintenance, and use of fork
trucks, tractors, platform lift trucks,
motorized hand trucks, and other
specialized industrial trucks powered by
electric motors or internal combustion
engines. This section does not apply to
compressed air or nonflammable
compressed gas-operated industrial
trucks, nor to farm vehicles, nor to
vehicles intended primarily for earth
moving or over-the-road hauling.

Approved powered industrial trucks shall bear a label or some other identifying mark
indicating approval by the testing laboratory.

Modifications and additions which affect capacity and safe operation of trucks shall not
be performed by the user without manufacturers' prior written approval.

As used in this section, the term "approved truck" or "approved industrial truck" means a
truck that is listed or approved for fire safety purposes for the intended use by a
nationally recognized testing laboratory, using nationally recognized testing standards.

Designations

For the purpose of this standard, there are eleven different designations of industrial
trucks or tractors as follows:

D, DS, DY, E, ES, EE, EX, G, GS, LP, LPS

1. The "D" designated units are diesel engine powered units having minimum
acceptable safeguards against inherent fire hazards.
2. The "DS" designated units are diesel powered units that are provided with additional
safeguards to the exhaust, fuel, and electrical systems.
3. The "DY" designated units are diesel powered units that have all the safeguards of
the "DS" units and in addition do not have any electrical equipment including the
ignition and are equipped with temperature limitation features.
4. The "E" designated units are electrically powered units that have minimum
acceptable safeguards against inherent fire hazards.
5. The "ES" designated units are electrically powered units that, in addition to all the
requirements for the "E" units, are provided with additional safeguards to the
electrical system to prevent emission of hazardous sparks and to limit surface
 temperatures.
6. The "EE" designated units are electrically powered units that have, in addition to all
of the requirements for the "E" and "ES" units, the electric motors and all other
electrical equipment completely enclosed.
7. The "EX" designated units are electrically powered units that differ from the E",
"ES", or "EE" units in that the electrical fittings and equipment are so designed,
constructed and assembled so that the units may be used in certain atmospheres
containing flammable vapors or dusts.
8. The "G" designated units are gasoline powered units having minimum acceptable
safeguards against inherent fire hazards.
9. The "GS" designated units are gasoline powered units that are provided with
additional safeguards to the exhaust, fuel, and electrical systems.
10. The "LP" designated unit is similar to the "G" unit except that liquefied petroleum
gas is used for fuel instead of gasoline.
11. The "LPS" designated units are liquefied petroleum gas powered units that are
provided with additional safeguards to the exhaust, fuel, and electrical systems.

Atmospheres or locations throughout the plant must be classified hazardous or non-

hazardous prior to the consideration of industrial trucks being used therein. Refer to
Table N-1 of §1910.178(c)(2) which is a summary table on use of industrial trucks in
various locations.

Safety Guards
All high lift rider trucks shall be fitted with overhead guards where overhead lifting is
performed unless operating conditions do not permit. In those cases where high lift
rider trucks must enter, for example, truck trailers and the overhead guard will not
permit this entry, the guard may be removed or a powered industrial truck without a
guard may be used.

If a powered industrial fork truck carries a load that presents a hazard of falling back
onto the operator, it shall be equipped with a vertical load back rest extension.

Changing and Charging Storage Batteries

Workplaces using electrically powered industrial trucks will have battery-charging areas
somewhere in the plant. In many cases, depending on the number of electrically
powered industrial trucks, there will be more than one changing and charging area.
This section only applies to storage battery changing and charging areas associated
with powered industrial trucks. It does not apply to areas where other batteries, such as
those used in motor vehicles (cars or trucks), are charged, although some of the same
hazardous conditions may exist. Some of the requirements specified in the regulation
include:

! Battery charging installations shall be located in areas designated for that

purpose.
! Facilities shall be provided for flushing and neutralizing spilled electrolyte, for

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 fire protection, for protecting charging apparatus from damage by trucks, and
for adequate ventilation for dispersal of air contaminants from gassing batteries.
! A conveyor, overhead hoist, or equivalent material handling equipment shall be
provided for handling batteries.
! Smoking shall be prohibited in the charging area.
! Precautions shall be taken to prevent open flames, sparks, or electric arcs in
battery charging areas.

Trucks and Railroad Cars

In plant receiving and shipping areas, powered industrial trucks are often utilized to load
and unload materials from trucks and railroad cars. The brakes of highway trucks shall
be set and wheelchocks placed under the rear wheels to prevent trucks from rolling
while they are boarded with powered industrial trucks.

Wheel stops or other positive protection shall be provided to prevent railroad cars from
moving during loading or unloading operations.

Fixed jacks may be necessary to support a semitrailer and prevent unending during the
loading or unloading when the trailer is not coupled to a tractor.

Operator Training
Safe Operation -
The employer must ensure that each powered industrial truck operator is competent to
operate a powered industrial truck safely, as demonstrated by the successful
completion of the required training and evaluation. Prior to permitting an employee to
operate a powered industrial truck (except for training purposes), the employer must
ensure that each operator has successfully completed the training required.

Training program implementation -

Trainees may operate a powered industrial truck only under the direct supervision of
persons who have the knowledge, training, and experience to train operators and
evaluate their competence; and where such operation does not endanger the trainee or
other employees.

Training must consist of a combination of formal instruction (e.g., lecture, discussion,

interactive computer learning, video tape, written material), practical training
(demonstrations performed by the trainer and practical exercises performed by the
trainee), and evaluation of the operator's performance in the workplace.

All operator training and evaluation must be conducted by persons who have the
knowledge, training, and experience to train powered industrial truck operators and
evaluate their competence.

Training program content -

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Powered industrial truck operators must receive initial training in the following topics,
except in topics which the employer can demonstrate are not applicable to safe
operation of the truck in the employer's workplace.
Truck-related 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 or 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.
! The requirements of the standard

Refresher training, including an evaluation of the effectiveness of that training, must

be conducted to ensure that the operator has the knowledge and skills needed to
operate the powered industrial truck safely. Refresher training in relevant topics
must be provided to the operator when:

! The operator has been observed to operate the vehicle in an unsafe manner;
! The operator has been involved in an accident or near-miss incident;
! The operator has received an evaluation that reveals that the operator is not
operating the truck safely;

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 ! The operator is assigned to drive a different type of truck; or
! A condition in the workplace changes in a manner that could affect safe
operation of the truck.
! An evaluation of each powered industrial truck operator's performance must be
conducted at least once every three years.
! Avoidance of duplicative training. If an operator has previously received training
in a required topic and such training is appropriate to the truck and working
conditions encountered, additional training in that topic is not required if the
operator has been evaluated and found competent to operate the truck safely.

Certification -
The employer must certify that each operator has been trained and evaluated as
required. The certification must include the name of the operator, the date of the
training, the date of the evaluation, and the identity of the person(s) performing
the training or evaluation.

Guidelines -
Appendix A to 1910.178 provides non-mandatory guidance to assist employers in
implementing these requirements.

Truck Operations
Some of the requirements regarding industrial truck operations include:

! No person shall be allowed to stand or pass under the elevated portion of any
truck, whether loaded or empty.
! Unauthorized personnel shall not be permitted to ride on powered industrial
trucks. A safe place to ride shall be provided where riding of trucks is
authorized.
! When a powered industrial truck is left unattended, load engaging means shall
be fully lowered, controls shall be neutralized, power shall be shut off, and
brakes set. Wheels shall be blocked if the truck is parked on an incline. A
powered industrial truck is "unattended" when the operator is 25 ft. or more
away from the vehicle which remains in his view, or whenever the operator
leaves the vehicle and it is not in his view.

Traveling
This section contains requirements for traveling in powered industrial trucks. Some of
these requirements include:

! All traffic regulations shall be observed, including authorized plant speed limits.
! The driver shall be required to slow down and sound the horn at cross aisles
and other locations where vision is obstructed. If the load being carried
obstructs forward view, the driver shall be required to travel with the load
trailing.

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 ! Railroad tracks shall be crossed diagonally whenever possible. Parking closer
than 8 feet from the center of railroad tracks is prohibited.
! When ascending or descending grades in excess of 10 percent, loaded trucks
shall be driven with the load upgrade.
! Dockboards or bridgeplates shall be properly secured before they are driven
over. Dockboards or bridgeplates shall be driven over carefully and slowly and
their rated capacity never exceeded.

Loading
Only stable or safely arranged loads shall be handled. Caution shall be exercised when
handling off-center loads which cannot be centered.

Only loads within the rated capacity of the truck shall be handled.

Operation of the Truck

If at any time a powered industrial truck is found to be in need of repair, defective, or in
any way unsafe, the truck shall be taken out of service until it has been restored to safe
operating condition.

Fuel tanks shall not be filled while the engine is running. Spillage shall be avoided. Any
spillage of oil or fuel shall be carefully washed away or completely evaporated and the
fuel tank cap replaced before restarting the engine.

Open flames shall not be used for checking electrolyte level in storage batteries or
gasoline level in fuel tanks.

Maintenance of Industrial Trucks

Any power-operated industrial truck not in safe operating condition shall be removed
from service. All repairs shall be made by authorized personnel.
No repairs shall be made in Class I, II, or III locations. Those repairs to the fuel and
ignition systems which involve fire hazards shall be conducted only in locations
designated for such repairs.

Industrial trucks shall be examined before being placed in service, and shall not be
placed in service if the examination shows any condition adversely affecting the safety
of the vehicle. Examinations shall be made at least daily. Where trucks are used on a
round-the-clock basis, they shall be examined after each shift.

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 H AND AND P ORTABLE P OWERED T OOLS
S UBPART P

Hazard Recognition
Tools are such a common part of our lives that it is difficult to remember that they may
pose hazards. All tools are manufactured with safety in mind but, tragically, a serious
accident often occurs before steps are taken to search out and avoid or eliminate tool-
related hazards.

In the process of removing or avoiding the hazards, workers must learn to recognize the
hazards associated with the different types of tools and the safety precautions
necessary to prevent those hazards.

Hand Tools
Hand tools are non-powered. They include anything
from axes to wrenches. The greatest hazards posed
by hand tools result from misuse and improper
maintenance.

Some examples:

! Using a screwdriver as a chisel may cause the tip of the screwdriver to break
and fly, hitting the user or other employees.

! If a wooden handle on a tool such as a hammer or an axe is loose, splintered,

or cracked, the head of the tool may fly off and strike the user or another
worker.

! A wrench must not be used if its jaws are sprung, because it might slip.

! Impact tools such as chisels, wedges, or drift pins are unsafe if they have
mushroomed heads. The heads might shatter on impact, sending sharp
fragments flying.

The employer is responsible for the safe condition of tools and equipment used by
employees but the employees have the responsibility for properly using and maintaining
tools.

Employers should caution employees that saw blades, knives, or other tools be directed
away from aisle areas and other employees working in close proximity. Knives and
scissors must be sharp. Dull tools can be more hazardous than sharp ones.

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Appropriate personal protective equipment, e.g., safety goggles, gloves, etc., should be
worn due to hazards that may be encountered while using portable power tools and
hand tools.

Safety requires that floors be kept as clean and dry as possible to prevent accidental
slips with or around dangerous hand tools.

Around flammable substances, sparks produced by iron and steel hand tools can be a
dangerous ignition source. Where this hazard exists, spark-resistant tools made from
brass, plastic, aluminum, or wood will provide for safety.

Power Tool Precautions

Power tools can be hazardous when improperly used. There are several types of power
tools, based on the power source they use: electric, pneumatic, liquid fuel, hydraulic,
and powder-actuated.

Employees should be trained in the use of all tools - not just power tools. They should
understand the potential hazards as well as the safety precautions to prevent those
hazards from occurring.

The following general precautions should be observed by power tool users:

! Never carry a tool by the cord or hose.

! Never yank the cord or the hose to disconnect it from the receptacle.

! Keep cords and hoses away from heat, oil, and sharp edges.

! Disconnect tools when not in use, before servicing, and when changing
accessories such as blades, bits and cutters.

! All observers should be kept at a safe distance away from the work area.

! Secure work with clamps or a vise, freeing both hands to operate the tool.

! Avoid accidental starting. The worker should not hold a finger on the switch
button while carrying a plugged-in tool.

! Tools should be maintained with care. They should be kept sharp and clean for
the best performance. Follow instructions in the user's manual for lubricating
and changing accessories.

! Be sure to keep good footing and maintain good balance.

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 ! The proper apparel should be worn. Loose clothing, ties, or jewelry can
become caught in moving parts.

! All portable electric tools that are damaged shall be removed from use and
tagged "Do Not Use."

Guards
Hazardous moving parts of a power tool need to be
safeguarded. For example, belts, gears, shafts, pulleys,
sprockets, spindles, drums, fly wheels, chains, or other
reciprocating, rotating, or moving parts of equipment must be
guarded if such parts are exposed to contact by employees.

Guards, as necessary, should be provided to protect the

operator and others from the following:

! point of operation,

! in-running nip points,

! rotating parts, and

! flying chips and sparks.

Safety guards must never be removed when a tool is being used. For example,
portable circular saws must be equipped with guards. An upper guard must cover the
entire blade of the saw. A retractable lower guard must cover the teeth of the saw,
except when it makes contact with the work material. The lower guard must
automatically return to the covering position when the tool is withdrawn from the work.

Safety Switches
The following hand-held powered tools must be equipped with a momentary contact
"on-off" control switch: drills, tappers, fastener drivers, horizontal, vertical and angle
grinders with wheels larger than 2 inches in diameter, disc and belt sanders,
reciprocating saws, saber saws, and other similar tools. These tools also may be
equipped with a lock-on control provided that turnoff can be accomplished by a single
motion of the same finger or fingers that turn it on.

The following hand-held powered tools may be equipped with only a positive "on-off"
control switch: platen sanders, disc sanders with discs 2 inches or less in diameter;
grinders with wheels 2 inches or less in diameter; routers, planers, laminate trimmers,
nibblers, shears, scroll saws and jigsaws with blade shanks ¼-inch wide or less.

Other hand-held powered tools such as circular saws having a blade diameter greater
than 2 inches, chain saws, and percussion tools without positive accessory holding

9
means must be equipped with a constant pressure switch that will shut off the power
when the pressure is released.

Electric Tools
Employees using electric tools must be aware of several
dangers; the most serious is the possibility of electrocution.

Among the chief hazards of electric-powered tools are burns

and slight shocks which can lead to injuries or even heart
failure. Under certain conditions, even a small amount of
current can result in fibrillation of the heart and eventual death.
A shock also can cause the user to fall off a ladder or other
elevated work surface.

To protect the user from shock, tools must either have a three-wire cord with ground
and be grounded, be double insulated, or be powered by a low-voltage isolation
transformer. Three-wire cords contain two current-carrying conductors and a grounding
conductor. One end of the grounding conductor connects to the tool's metal housing.
The other end is grounded through a prong on the plug. Anytime an adapter is used to
accommodate a two-hole receptacle, the adapter wire must be attached to a known
ground. The third prong should never be removed from the plug.

Double insulation is more convenient. The user and the tools are protected in two
ways: by normal insulation on the wires inside, and by a housing that cannot conduct
electricity to the operator in the event of a malfunction.

These general practices should be followed when using electric tools:

! Electric tools should be operated within their design limitations.

! Gloves and safety footwear are recommended during use of electric tools.

! When not in use, tools should be stored in a dry place.

! Electric tools should not be used in damp or wet locations.

! Work areas should be well lighted.

Powered Abrasive Wheel Tools

Powered abrasive grinding, cutting, polishing, and wire buffing wheels create special
safety problems because they may throw off flying fragments.

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Before an abrasive wheel is mounted, it should be inspected closely and sound- or ring-
tested to be sure that it is free from cracks or defects. To test, wheels should be tapped
gently with a light non-metallic instrument. If they sound cracked or dead, they could fly
apart in operation and so must not be used. A sound and undamaged wheel will give a
clear metallic tone or "ring."

To prevent the wheel from cracking, the user should be sure it fits freely on the spindle.
The spindle nut must be tightened enough to hold the wheel in place, without distorting
the flange. Follow the manufacturer's recommendations. Care must be taken to assure
that the spindle wheel will not exceed the abrasive wheel specifications.

Due to the possibility of a wheel disintegrating (exploding) during start-up, the employee
should never stand directly in front of the wheel as it accelerates to full operating speed.

Portable grinding tools need to be equipped with safety guards to protect workers not
only from the moving wheel surface, but also from flying fragments in case of breakage.

In addition, when using a powered grinder:

! Always use eye protection.

! Turn off the power when not in use.

! Never clamp a hand-held grinder in a vise.

Pneumatic Tools
Pneumatic tools are powered by compressed air and include chippers, drills, hammers,
and sanders.

There are several dangers encountered in the use of pneumatic tools. The main one is
the danger of getting hit by one of the tool's attachments or by some kind of fastener the
worker is using with the tool.

Eye protection is required and face protection is recommended for employees working
with pneumatic tools.

Noise is another hazard. Working with noisy tools such as jackhammers requires
proper, effective use of hearing protection.

When using pneumatic tools, employees must check to see that they are fastened
securely to the hose to prevent them from becoming disconnected. A short wire or
positive locking device attaching the air hose to the tool will serve as an added
safeguard.

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A safety clip or retainer must be installed to prevent attachments, such as chisels on a
chipping hammer, from being unintentionally shot from the barrel.

Screens must be set up to protect nearby workers from being struck by flying fragments
around chippers, riveting guns, staplers, or air drills.

Compressed air guns should never be pointed toward anyone. Users should never
"dead-end" it against themselves or anyone else.

Powder-Actuated Tools
Powder-actuated tools operate like a loaded gun and should be treated with the same
respect and precautions. In fact, they are so dangerous that they must be operated
only by specially trained employees.

Safety precautions to remember include the following:

! These tools should not be used in an explosive or flammable atmosphere.

! Before using the tool, the worker should inspect it to determine that it is clean,
that all moving parts operate freely, and that the barrel is free from obstructions.

! The tool should never be pointed at anybody.

! The tool should not be loaded unless it is to be used immediately. A loaded tool
should not be left unattended, especially where it would be available to
unauthorized persons.

! Hands should be kept clear of the barrel end. To prevent the tool from firing
accidentally, two separate motions are required for firing: one to bring the tool
into position, and another to pull the trigger. The tools must not be able to
operate until they are pressed against the work surface with a force of at least 5
pounds greater than the total weight of the tool.

If a powder-actuated tool misfires, the employee should wait at least 30 seconds, then
try firing it again. If it still will not fire, the user should wait another 30 seconds so that
the faulty cartridge is less likely to explode, than carefully remove the load. The bad
cartridge should be put in water.

Suitable eye and face protection are essential when using a powder-actuated tool.

The muzzle end of the tool must have a protective shield or guard centered
perpendicularly on the barrel to confine any flying fragments or particles that might
otherwise create a hazard when the tool is fired. The tool must be designed so that it
will not fire unless it has this kind of safety device.

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All powder-actuated tools must be designed for varying powder charges so that the user
can select a powder level necessary to do the work without excessive force.

If the tool develops a defect during use it should be tagged and taken out of service
immediately until it is properly repaired.

Fasteners
When using powder-actuated tools to apply fasteners, there are some precautions to
consider. Fasteners must not be fired into material that would let them pass through to
the other side. The fastener must not be driven into materials like brick or concrete any
closer than 3 inches to an edge or corner. In steel, the fastener must not come any
closer than one-half inch from a corner or edge. Fasteners must not be driven into very
hard or brittle materials which might chip or splatter, or make the fastener ricochet.

An alignment guide must be used when shooting a fastener into an existing hole. A
fastener must not be driven into a spalled area caused by an unsatisfactory fastening.

Hydraulic Power Tools

The fluid used in hydraulic power tools must be an approved fire-resistant fluid and must
retain its operating characteristics at the most extreme temperatures to which it will be
exposed.

The manufacturer's recommended safe operating pressure for hoses, valves, pipes,
filters, and other fittings must not be exceeded.

Jacks
All jacks - lever and rachet jacks, screw jacks, and hydraulic jacks - must have a device
that stops them from jacking up too high. Also, the manufacturer's load limit must be
permanently marked in a prominent place on the jack and should not be exceeded.

A jack should never be used to support a lifted load. Once the load has been lifted, it
must immediately be blocked up.

Use wooden blocking under the base if necessary to make the jack level and secure. If
the lift surface is metal, place a 1-inch-thick hardwood block or equivalent between it
and the metal jack head to reduce the danger of slippage.

To set up a jack, make certain of the following:

! the base rests on a firm level surface,

! the jack is correctly centered,

! the jack head bears against a level surface, and

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 ! the lift force is applied evenly.

Proper maintenance of jacks is essential for safety. All jacks must be inspected before
each use and lubricated regularly. If a jack is subjected to an abnormal load or shock, it
should be thoroughly examined to make sure it has not been damaged.

Hydraulic jacks exposed to freezing temperatures must be filled with an adequate

antifreeze liquid.

General Safety Precautions

Employees who use hand and power tools and who are exposed to the hazards of
falling, flying, abrasive and splashing objects, or exposed to harmful dusts, fumes,
mists, vapors, or gases must be provided with the particular personal equipment
necessary to protect them from the hazard.

All hazards involved in the use of power tools can be prevented by following five basic
safety rules:

! Keep all tools in good condition with regular maintenance.

! Use the right tool for the job.

! Examine each tool for damage before use.

! Operate according to the manufacturer's instructions.

! Provide and use the proper protective equipment.

Employees and employers have a responsibility to work together to establish safe

working procedures. If a hazardous situation is encountered, it should be brought to the
attention of the proper individual immediately.

OSHA PROGRAM DIRECTIVE: Reduction of Air Pressure Below 30 psi for

Cleaning Purposes

TO: National and Field Offices

SUBJECT: Reduction of Air Pressure Below 30 psi for Cleaning Purposes
ATTACHMENT: Acceptable Methods for Complying with 41 CFR 50-204.8 and 29
CFR 1910.242(b)

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1. Purpose. To provide guidance and examples of what alternate systems will meet
the requirements of this section, and to clarify its intent.

2. Background. A number of inquiries have been received requesting a clarification

of the meaning of 1910.242(b) also known as 41 CFR 50-2048 under the
Walsh-Healey Act.

3. Interpretation. The phrase "reduce to less than 30 psi" means that the
downstream pressure of the air at the nozzle (nozzle pressure) or opening of a
gun, pipe, cleaning lance, etc., used for cleaning purposes will remain at a
pressure level below 30 psi for all static conditions. The requirements for
dynamic flow are such that in the case when dead ending occurs a static
pressure at the main orifice shall not exceed 30 psi. This requirement is
necessary in order to prevent a back pressure buildup in case the nozzle is
obstructed or dead ended.See enclosure (1) for two acceptable methods of
meeting this requirement.Also, there is no intent to restrict the diameter of the
nozzle orifice or the volume (CFM) flowing from it.

"Effective chip guarding" means any method or equipment which will prevent a
chip or particle (of whatever size) from being blown into the eyes or unbroken
skin of the operator or other workers. Effective chip guarding may be separate
from the air nozzle as in the case where screens or barriers are used. The use of
protective cone air nozzles are acceptable in general for protection of the
operator but barriers, baffles or screens may be required to protect other workers
if they are exposed to flying chips or particles.

4. Action. Inquiries about subject section should be handled in accordance with this
instruction.

5. Effective Date. This instruction is effective immediately, and will remain in effect
until canceled or superseded.

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