Heavy Eqpt Safety Handouts

Report No. IR1506-‐11-‐00003

La Farge Cement Services, Inc. Norzagaray, Bulacan

HEAVY EQUIPMENT SAFETY TRAINING

(Payloader, Forklift, Crane & Dump Truck) June 25, 2011

PEOPLE360 CONSULTING CORPORATION

CONSTRUCTION SAFETY MAGAZINE4

Deaths and heavy equipment

Three workers were killed this yearafter dump-truck boxes contactedoverhead powerlines.

Constructors must have writtenprocedures to prevent contact whenequipment could encroach on theminimum allowable distance to apowerline stated in section 188 ofthe Construction Regulation(Ontario Regulation 213/91 in the“green book”).

The Regulation requires, amongother things, that constructors

q ensure that operators getwritten notification of theelectrical hazards before theybegin work

q place warning devices (such assigns) near the powerlines so

that the equipment operatorcan always see at least one ofthem

q designate a competent workeras a signaller to warn theoperator when any part of theequipment, load, or hoist lineapproaches the minimumallowable distance to apowerline. (See section 1 (1) ofthe Regulation for the legaldefinition of “competentworker.”)

There are other requirements. TheSummer 2006 edition ofConstruction Safety magazinecontained a detailed article on thesubject. Call CSAO for your copyor download it from www.csao.org.

So far this year, 26 constructionworkers in Ontario have died frominjury. More information is on thechart on the next page.

Falls account for nine of thedeaths. And close analysis showsthat 16 of the 26 deaths—or62%—involved heavy vehicles orequipment such as dump trucks orbackhoes.

There are a variety of ways thatheavy equipment can presenthazards if you don’t have theproper protection or controls. Forexample, you can be

ä electrocuted if the equipmentcontacts an overheadpowerline

ä crushed if your equipmentoverturns

ä struck by or crushed bymaterial being moved byheavy equipment

ä crushed if caught between theequipment and a wall or otherobject

ä run over by a heavy vehicle.

Over the next few pages, weidentify some of the dangers ofworking with heavy vehicles orequipment, and we explain brieflyhow to protect yourself and yourco-workers.

We can’t say everything in a fewpages, but CSAO can give youmore information if you want it.All you have to do is call or email:1-800-781-2726, [email protected]

Deaths and heavy equipment Over 60% of the deaths this year involve heavy equipment

Powerline contact

Workforce Safety & Insurancewww.WorkforceSafety.com

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June 2003 1

HEAVY EQUIPMENTI. INTRODUCTION

Improper procedures used by our employees can cause injury, disability, or death. By outlining andfollowing safe operating procedures for use of heavy equipment, we learn to prevent injury andsafeguard ourselves and our coworkers.

II. GOALSTo ensure all employees know and understand the safe operating procedures for the safeoperation and maintenance of Heavy Equipment.

III. PURPOSETo reduce the risk of a work related injury or death by maximizing personal safety during HeavyEquipment operation.

Safe Operating Procedures for the Following Heavy Equipment:

• Backhoe • Dozers • Loaders • Road Graders• Scrapers• Skidsteers• Trucks

General Safety for Heavy Equipment

Only trained and authorized operators shall be permitted to operate the designated equipment.

1. Personal protective equipment is mandatory and may include the following:- boots or safety shoes - eye/face protection- long pants - hard hat- hearing protection - gloves

2. Pre-start/Walk around inspection:• Check for loose or worn parts and repair or replace immediately.• Check all fluid/coolant levels.

Caution: Open the radiator cap only when the engine is cooled.

• Inspect hydraulic line connectors and hoses for leaks before applying pressure to the system. Usepaper or cardboard, not your hands, to search for leaks.

Caution: Hydraulic fluid escaping under pressure can penetrate skin and cause serious bodilyharm.

• Check tires for cuts, bulges, irregularities, abnormal wear and proper inflation.• A fire extinguisher and first aid kit shall be mounted in the cab.

3. Machine Maintenance:• When servicing equipment, fasten a Do Not Operate tag on the steering wheel. Review LockOut/Tag Out Procedures prior to servicing any equipment.


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• Ensure the cab area is clean and free of debris and tools.• Clean windshield, mirrors and lights.• Remove all oil, grease or mud and snow from grab irons, hand rails, steps, pedals, and

floor to prevent slips and falls.• Remove or secure any loose items such as tools, chains, or lunch boxes from the cab.

4. Work Site:• Check and mark the area for underground cables, gas lines, and water mains.• Know work area clearances - watch for overhead or underground objects, holes, drop-offs, and

partially hidden obstacles and wires.

5. Mount properly:

DO NOT GET ON OR OFF A MACHINE THAT IS IN MOTION

• Maintain a 3-point contact with the steps and hand rails while getting on/into the machine - do not use the controls or steering wheel as a handhold.

• Do not operate the machine with wet, greasy, or muddy hands or shoes.

6. Starting and Testing:

EXHAUST FUMES ARE DANGEROUS - ALWAYS HAVE A RUNNING MACHINEIN A WELL VENTILATED AREA.

• Fasten your seat belt and adjust the seat prior to starting.• Controls should be in neutral and the parking brake set before starting engine.• Start the engine only from the operator's seat.• Warn personnel in the area that you are starting the engine.• Check all gauges, light, instruments and warning devices to assure that they are functioning

properly and the readings are within normal range.• Test steering right and left.• Test brakes against ground speed to be certain there is no malfunction.• Ensure all implement controls are operating properly.

7. Machine Operation

SMOKING IS PROHIBITED AT ALL TIMES.

• Acquaint yourself with the controls before operating the machine.• Only the operator is permitted to ride on the machine.• While backing up use extra care and sound the horn to clear the area.• If a malfunction is observed, "DO NOT OPERATE" until the proper repairs have been made.• Drive at speeds compatible with working conditions.• Do not coast downhill. Select a gear that will prevent excessive speed when going downhill. Do

not park on a steep incline.• Know the stopping distance at any given working speed.• Do not permit anyone to stand or pass under the bucket or lift arms.• Follow the manufacturer's load capacity limits. Identification plates are attached to all machines.• If the machine is stuck, back it out or stop engine and get help.• Do not make mechanical adjustments while the unit is in motion.• Always follow the manufacturer's recommendations for pulling or towing.• Lower all the hydraulic equipment before shutting down or getting off the machine.


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June 2003 3

• During snow removal, be alert for any obstructions covered by snow.

8. Ether - Cold Start Precautions• Diesel cold start systems contain ether which is explosive. Keep away from heat, sparks, and

open flames. Work in a well-ventilated area.• If swallowed, breathed or contacted on skin or eyes seek medical attention immediately. Follow

recommendations on the MSDS sheets.• Point the openings of the valve, tube or atomizer away from yourself and others while testing the

diesel cold start system.• Store replacement ether cylinders in a cool dry place away from direct sunlight. Do not keep them

in the operator’s compartment.

9. Operating a PTO• Shut off the engine and wait until the PTO stops completely before getting off, disconnecting or

servicing the PTO unit.• Wear snug fitting clothing when operating the power take-off, or when near rotating equipment.• When operating stationary PTO equipment, always apply the parking brake and block the rear

wheels front and back to prevent any unnecessary movement.• PTO shields are mandatory on all PTO-driven equipment.

10. Refueling• Shut off and cool the engine and any electrical equipment before fueling.• Ensure the fueling area is well ventilated.• Do not smoke while refueling. Keep open flames and sparks away from area.• Ground the funnel or fuel nozzle against the filler neck to avoid sparks when refueling.• Do not use gasoline or diesel fuel for cleaning parts.• Check the battery and electrolyte levels according to manufacturers instructions.• Know where the fire extinguishers are located.

11. Road Rules• When turning, use hand or turn signals.• Obey all traffic regulations. Know local traffic laws regarding lights, warning signs, load limits,

and slow moving equipment on highways/roadways.• When backing up traffic, pull over and allow the vehicles to pass.

12. Shut Down/Parking• Park on level ground.• When parking on a grade, block the wheels and set the parking brakes.• When parking, lower all loader, buckets, hydraulics to the ground.

BACKHOES

• KNOW THE WORKING RANGE OF THE MACHINE.• Be sure attachment or load doesn’t catch on obstructions when lifting or swinging.• When lifting a load, do not lift, swing or stop unnecessarily fast.• Be sure everyone is in the clear before swinging or moving in any direction. NEVER swing or

position attachment or load over personnel or vehicle cabs.• Never allow personnel to walk or work under any part of the machine or load while the machine

is operating.


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• Never allow anyone to ride the attachment or the load. This is an extremely dangerous practice.• Do not load a truck unless the driver is in a safe place. Then, load the truck from the rear or side.• Use a signal person. The signal person must be in direct communication with the operator, and

the operator must pay close attention to the signals.• Never exceed the lifting capacity of the machine. Stay within the lifting limits shown on the

Load Rating Chart. Remember - you may be able to lift the load in close, at ground level, but asthe load radius and elevation change, the lifting capacity of the excavator may decrease.

• Keep the machine well back from the edge of an excavation. Avoid undercutting the machine. Ifnecessary, provide adequate shoring to prevent the machine from falling into the excavation.

• Level off the work area if possible.• Avoid swinging or extending the bucket farther than necessary in a downhill direction. This will

reduce the stability of the machine.• When working with the bucket on the uphill side, the excavator may tip over if the slope is too

steep.• Avoid working with the tracks across the slope, as this reduces stability and increases the

tendency for the machine to slide.• Always be sure that slings or chains used to lift the load are of adequate strength and that they are

in good condition.• Watch your boom clearance at all times.• Turn off the engine and allow the machine to cool before working on the machine. Most fluids

on the excavator are hot enough to cause severe burns at normal operating temperatures.

DOZERS

• Operate the controls only with the engine running.• Do not allow riders on the machine unless additional seat, seat belt, and rollover protection are

provided.• The operator must satisfy himself that no one will be endangered before moving the machine.• Report any needed repairs noted during operation.• Carry implements close to the ground, approximately 40cm (15 in) above ground level.• Stay a safe distance from the edge of cliffs, overhangs, and slide areas.• If the machine begins to sideslip on a grade, immediately dispose of the load and turn the

machine downhill.• Be careful to avoid the condition which could lead to tipping when working on hills, banks, or

slopes, and when crossing ditches, ridges, or other obstructions.• Work up and down slopes, rather than sideways, whenever possible.• Keep the machine under control and do not work it over its capacity.• Be sure hitch points and the towing device are adequate.• Connect trailing equipment to a drawbar or hitch only.• Never straddle a cable, wire rope, or similar device nor allow others to do so.• Personnel are prohibited to be between the machine and trailing equipment when maneuvering to

connect them. Block the tongue or hitch of trailing equipment to align it with the drawbar orhitch.


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LOADERS

• This is a one-person machine, NO RIDERS ALLOWED.• Know the pinch points and wrap points on the loader.• Operate at a speed consistent with working conditions, visibility, and terrain.• Ensure loader has an adequate rear counterweight• When crossing exposed railroad tracks, ditches, ridges, or curbs reduce speed and cross at an

angle.• Carry loaded buckets as close to the ground as possible. The further a loaded bucket is from the

ground the more unstable the loader becomes.• Use extreme caution when operating a loader on a side slope. Slow down and carry the bucket,

loaded or empty, as close to the ground as possible.• Stay in gear when traveling downhill - this will help control speed.• Never move a load above the heads of other workers.• When back filling, use extreme caution. The weight of the material plus the weight of the

machine could cause the new construction to collapse.• Keep work area level; avoid developing ruts by occasionally back dragging the bucket to smooth

the surface.

ROAD GRADER

• Do not permit riders in or on the grader. Grader is a one-person piece of equipment.• Do not dismount from the grader with the engine running - lower all attachments and stop engine

first.• Before backing up, use extra care to ensure persons and vehicles are clear of the grader.• Know and use hand signals required for particular jobs and know who has the responsibility for

signaling.• Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.• Note and avoid all hazards and obstructions such as overhangs, ledges, slide areas, electrical

lines, underground cables, water mains, or gas lines.• Watch for bystanders and never allow anyone to be under or to reach into the grader and its

attachments while operating.• Check the local traffic laws for correct traveling requirements. If necessary, pull over and allow

traffic to pass.• When working near traffic areas or at night, use extra care. Use precautions, such as flares or

reflectors, cones, red flags or red lights, barricades, flashing lights, and flagmen.• Do not operate the grader in areas where volatile gases, dust, and combustibles may be present.• Ensure the grader is properly equipped for grading in dry or forested areas.• Avoid lubrication or mechanical adjustments with the grader in motion or the engine operating.

Keep your head, body, limbs, feet, and hands away from all moving parts.• Use extreme care when working with hydraulic systems. Relieve the hydraulic system pressure

before performing any service.• Match speed of the vehicle to job conditions.• Be careful when operating with the wheels at right angle to a slope.• When hooking up trailing equipment, keep all personnel away.• Know your stopping distance at any given speed.• Use caution when crossing side hills, ridges, ditches, and other obstructions.• Keep close to inside bank when working on a side hill road or cut. Extend the blade to material

near outer edge.• Use extreme care to avoid tipping when working on hills, banks, or slopes.


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• Cross obstacles at an angle and at slow speed. Be alert for sudden movement of machine whengoing over center of obstacle.

• Operate the vehicle only on level surface when cutting high banks.

SCRAPERS

• Do not try to climb on or off the machine when carrying tools or supplies. Use a hand line to pullequipment up onto the platform.

• Check for proper operation of all controls and protective devices while moving slowly in an openarea.

• Operate the machine only while seated.• Operate the controls only with the engine running.• Do not allow riders on the machine unless additional seat, seat belt, and rollover protection are

provided.• Carry bowl close to the ground, approximately 40cm (15 in) above ground level.• Stay a safe distance from the edge of cliffs, overhangs, and slide areas.• If the machine begins to sideslip on a grade, lower the bowl and bring the machine to a safe stop.• Be careful to avoid the condition which could lead to tipping when working on hills, banks, or

slopes, and when crossing ditches, ridges, or other obstructions.• Work up and down slopes, rather than sideways, whenever possible.• Keep the machine under control and do not work it over its capacity.• Personnel are prohibited from being between the machine and trailing equipment when

maneuvering to connect them. Block the tongue or hitch of trailing equipment to align it with thedrawbar or hitch.

• Park on a level surface. If necessary to park on a grade, block the machine. Lower bowl to theground and apply slight down pressure. Stop the engine.

SKIDSTEERS

• Check to see that counterweights as recommended by the manufacturer are in place. NOTE: This is very important as improperly balanced skid-steer loaders are easily upset.

• Clean steps, pedals, and floor of any slippery substances.• Clear the driving compartment for loose items that might interfere with the controls.• Check the work area for hazards such as holes, soft spots, and obstructions. Check overhead for

utility lines, doorway clearances, or other obstructions.• Mount the machine wearing clean, dry shoes using the grab bars or handrails provided.• Adjust the seat, fasten the seat belt, set the brake, and place transmission in park or neutral before

cranking the engine.• Visually check for the presence of others in the area and warn them away. Be especially alert for

children.• If the machine is garaged, leave the door or some windows open for ventilating the exhaust.

CARBON MONOXIDE KILLS!• Start the engine and check all controls to see that they are functioning properly.• Check horn and backup alarm to see that they are working.• Operate with caution on uneven surfaces. Avoid steep slopes completely.• Carry the load as low as possible. Avoid sharp turns and slopes with a raised load.• Travel straight up or down, with the heavy end of the machine pointed uphill.• Operate with extreme caution near areas with sharp drop-offs.• Do not undercut banks or materials that are piled high, to avoid cave-ins or falling of material.• NEVER leave the machine without first lowering the bucket, stopping the engine, setting the


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parking brake, and placing the shift in park or neutral. Dismount the machine carefully. Do notjump out of the loader.

• If stopping for any length of time, lock the ignition and remove the key.

TRUCKS

• Truck drivers will be properly and thoroughly trained before attempting to do any work with oron any type of truck.

• Our motor vehicle policy, as well as State and Federal regulations prohibit the operation ofcommercial motor vehicles by individuals who do not have the proper training and license. Donot attempt to operate any dump truck unless you have the proper license and training.

• Thoroughly inspect the truck for any defects that may inhibit safe operation of the vehicle. DOT regulations require that the operator fill an inspection form each day before placing thetruck into operation. This form is an excellent tool to help the operator remember to check allnecessary items.

• Always use the steps and grab irons and face the vehicle when getting in or out of the truck.• Place the gearshift into neutral and set the parking brake before starting the engine.• Allow the engine to reach operating temperature and the air pressure to build to operating

pressure before placing the truck into motion.• Carefully check the area around the truck before placing it into motion. Objects or people that

are very close to the truck may not be visible from the driver’s seat.• Always make sure that your seatbelt is properly fastened before driving the truck.• Allow adequate stopping distance between the truck and the vehicles in front of it. • Check the area around the truck for obstructions (tree limbs, overhead wires, etc.) before raising

the dump box. Make sure that the spreader chains aren’t set if you intend to dump in a pile.• Always try to be on a level surface when you raise the dump box. As the box raises the truck’s

center of gravity goes up and the truck becomes less stable and more apt to tip over. If you mustdump on a slope place the truck so that it faces straight up, or down the slope. Do not try to raisethe box with the truck parked parallel with the slope. Remember that a dump truck is much moreapt to tip over (or run into overhead obstructions) when spreading material then it is whendumping in a pile.

• NEVER work under a raised box (not even “for just a little bit”) unless the box is adequatelysupported by a prop rod or cribbing. Do not rely on the truck’s hydraulic system to hold the boxup while you work under it.

Forklift Safety, 1

FORKLIFT SAFETY Percentage of Forklift Accidents

OSHA has identified key factors that have contributed to employees accidents from lift trucks. Based on Report of Serious Accident 1985-1990.

1. Tip over 25.3 % 2. Struck by powered industrial truck 18.8 % 3. Struck by falling load 14.4 % 4. Elevated employee on truck 12.2 % 5. Ran off Dock or other Surface 7.0 % 6. Improper Maintenance Procedures 6.1 % 7. Lost Control of Truck 4.4 % 8. Truck Struck material 4.4 % 9. Employees overcome by CO or propane fuel 4.4 % 10. Faulty powered Industrial Truck 3.1 % 11. Unloading Unchocked Trailer 3.1 % 12. Employee Fell from Vehicle 3.1 % 13. Improper Use of Vehicle 2.6 % 14. Electrocutions 1.0 %

Causes of Accidents

Cause Number of Reports

1. Operator Inattention 59 2. Overturn 53 3. Unstable load 45 4. Operator struck by load 37 5. Elevated employee 26 6. No Training 19 7. Overload, improper use 15 8. Accident during maintenance 14 9. Obstructed view 10 10. Improper Equipment 10 11. Falling from Platform or curb 9 12. Not powered industrial truck accident 9 13. Other employee struck by load 8 14. Carrying excess passenger 8 15. Vehicle left in gear 6 16. Falling from Trailer 6 17. Speeding 5

Forklift Safety, 2

STABILITY TRIANGLE

Forklift have a “stability triangle”. The sides of the triangle as shown in the illustration are formed by the center of each front wheel and the center of the rear wheel or at the center of the axle if there are two rear wheels. A vertical line extending from the center of gravity of the vehicle-load combination must be inside of the stability triangle to prevent the forklift from tipping forward, falling sideways or dropping its load.

Forklift Safety, 3

These actions will have the following effects:

Action Center of Gravity Moves

Tilting the load forward

Raising the Load while tilted forward

Driving on an incline with the load downhill

Stopping forward travel or accelerating backward

Toward the front axle

Tilting the load back

Raising the load while tilted back

Driving on an incline with the load uphill

Accelerating forward or stopping backward travel

Toward the rear axle

Driving across an inclined surface Toward the downhill side of the triangle

Driving across a rough or uneven surface

Toward the low side of the triangle

Turning Toward the side now facing the original direction of travel.

Forklift Safety, 4

PRE-USE INSPECTION

Check each items before the shift starts. Put a check in the box if the item is OK. Explain any unchecked items at the bottom and report them to a supervisor. Do not use an unsafe forklift. Your safety is at risk.

Steering and horn Brakes Lights and alarm Tilt Mast Scissors Reach Raising and lowering forks Side shifter Coolant level Fire extinguisher Brakes Tires Gauges Leaks Fuel Level Oil Level Propane Tank Overheard guard

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Forklift Safety, 5

GENERAL SAFETY GUIDELINES:

1. Operating surfaces should be smooth and free of holes, bumps or any other restriction to safe operation

2. Paths of travel should also be free of oil, grease, water or any other element that could affect turning, starting, traveling, or stopping. Never run over loose objects.

3. Pedestrians should have designated walking areas that do not create an exposure to moving equipment.

4. Overhead hazards should be relocated if possible. Items such as sprinkler pipes or gas pipes could be moved to prevent being struck by the lift truck load and mast. Other hazards that cannot be moved such as doorways, racking, beams and other obstacles- should be highlighted with black and yellow stripes. Proper lighting and added visual awareness signals will also assist in greater operator safety.

5. Flashing lights, convex or panoramic mirrors, stop signs, speed limit signs, painted walkways, intersections and machine and storage areas should be highlighted as much as possible to prevent collisions or damage to property.

6. Before lifting any load, properly adjust and lock the forks in place to prevent movement. Wear gloves to protect the hands.

7. Keep loads centered on the forks so that there is a balance of load weight. Keep the heavier part of the load towards or against the mast. If the heavier part of the load is facing away from the operator, turn the load around by approaching it from the opposite side. This may require lifting. Moving it to a spot that allows the lift truck to turn around and approaching it with the heavy side toward the forks.

8. Always allow for proper clearance when lifting, traveling or setting down a load. Pre-plan the route of travel before picking u an odd-shaped load. If a load is too long or wide, such as rolls of carpeting, make provisions with the supervisor ahead of time.

9. Always be on the alert for employees on foot, visitors, other pieces of power equipment, emergency equipment and tight quarters. Give other pieces of power equipment as much room as possible.

10. Do not tailgate other equipment. A good rule of thumb is to keep three to five lengths behind the lift truck in front of you. Keep alert to their stopping or turning. Brake lights on all vehicles improve operator safety. If following too close, a worker may stop his lift truck, get off and be in danger of being struck by the lift truck behind him.

11. Travel up or down any grade slowly. Any grade can be hazardous. 12. Never indulge in stunt driving or horseplay.

Forklift Safety, 6

13. When pulling into an elevator, approach and enter slowly with the forks first. The lift truck should keep centered on the elevator. Once in place, place the lift truck controls in neutral, lower the load to the floor, turn off the power, and set the brake.

14. When approaching a ramp, keep the load upgrade. This keeps it against the mast and backrest for stability.

15. When traveling down a ramp, keep the load upgrade for the same purpose – for greater stability. It is recommended that empty lift trucks be operated with the forks downgrade; even for those pieces of power equipment that contain attachments.

16. In the event of a chemical spill, know where the appropriate cleanup kit is stored. Handle all cleanup situations per safety guidelines. Wear the appropriate PPE. Properly dispose of waste.

17. Ensure that the forks of the lift truck are long enough to safely handle the load. Forks should be at least 2/3 of the length of the load being moved.

18. Loads should be made as stable before moving bags, boxes and other individual items; they should be cross-stacked for greater stability. If possible, shrink-wrap pallets or add metal/plastic banding to allow for greater safety when transporting, handling, or storing.

19. Never turn on a ramp or slope; always travel straight up or down the incline. Once you are on level surface, turns become much safer.

20. Never make turns while a load is elevated because the lift truck can tip over. The higher the load is raised, the greater probability that the stability of the lift truck is effected.

21. When lifting a load, tilt it back for greater stability. Loads should always be against the backrest. Tilting the load allows the load to be cradled. Itʼs more difficult to spill a load after it has been properly tilted. Ensure that the backrest is in place.

22. Never drive up to anyone who is standing in front of a machine or other object. Should the operator make an error, the person would be easily be pinned by the lift truck. Alert everyone near the load that it is about to be spotted; have them stand clear.

23. Always keep your arms, hands, legs, feet, and head within the confines of the lift truck. It is not unusual for an operator to be moving a lift truck and have a foot, arm, or head make contact with another object.

24. Obey traffic rules as required by your employer and as identified by regulations. Be sure to yield the right of way to other vehicles where required.

25. Be sure your lift truck is properly rated for the areas in which it may be traveling.

26. When coming to a crosswalk, slow down and be prepared to stop. Using the horn to alert other operators and pedestrians adds to

Forklift Safety, 7

improved safety. Use caution when approaching or proceeding through any blind spot.

27. Always look in the direction of travel. There may be times when the operator wonʼt be able to look over the top of the load for safe trabvel; therefore travel in reverse.

28. When traveling, always operate at a speed that allows you to have full control of the equipment. Bring the lift truck to a safe stop in a safe manner. Stop without damaging or spilling the product being handled.

29. Slippery floors are invitations to incidents or injuries if the operator does not slow down.

30. If, while traveling through a facility, you see a block of wood or other obstacle or hazard in the path of travel, stop, get off, and remove the hazard. Just steering around a hazard allows it to remain a hazard for the next operator.

31. Reduce speed when making turns. Anticipate obstructions or personnel when making blind corners. Keep loads as low as possible when transporting.

32. Accept no riders on your power equipment. Never allow anyone to ride or be lifted on your forks.

32.Never use your lift truck to lift another lift truck. Never tow trailers, railroad cars, or other power equipment.

32.Powered equipment should be equipped with multi-purpose fire extinguisher if the equipment travels in an area where no fire extinguisher is readily available.

32.Great care must be exercised when lifting a load to deposit it on racking. Be sure the lift truck is not in motion when any load is being raised or lowered. Once the load has be made level up t the spot where it will be deposited, tilt forward, then lower the forks to deposit the load.

32.A lift truck can tip over when empty. Keep the mast low when traveling. Avoid ruts, holes or obstacles. Make turns at slow speeds. Never turn on a ramp.

32.If the unit has to operate on a roadway, be sure to add flashing lights, reflectors, and a slow-moving vehicle emblem to the powered equipment. The operator and any other employee on the roadway must wear a reflective vest. Someone to direct traffic may be necessary.

32.When a powered industrial truck is left unattended, the forks are to be lowered, controls neutralized, power shut off, brakes set, and key removed.

32.If stopped or parked on an incline, the lift truckʼs wheels are to be choked.

Forklift Safety, 8

32.OSHA considers a truck unattended when the operator is 25 or more feet form the vehicle or the vehicle is not within their vision.

32.No one is allowed to work or walk under elevated forks; this rules applies whether the forks are empty or loaded.

BATTERY CHARGING AREA:

1. All batteries are heavy. When pushing or pulling a battery in or out of a vehicle, it is best to use a mechanical device. When a manual method of handling is used, back injuries and pinched fingers are usually the result.

2. Battery acid and corrosion on the battery are harmful to the skin and eyes. Wear appropriate PPE.

3. Emergency spill units should be nearby and all employees should be trained in the use of these units.

4. Do not add water to the neck of the battery; keep water ¼” above the plates. If there is too much water, the acid and water may expand and cause a run-over of liquid. Workers should not “hot charge” a battery during lunch breaks. This process can cause malfunction of electrical components an shorten the life of the battery. Allow a battery to cool down for an entire shift.

5. A “No Smoking” rule must be enforced. Open flames, sparks, or any other ignition source must be avoided. Batteries contain hydrogen gas, which is explosive.

LPG POWERED VEHICLES:

1. LPG is heavier than air and will settle in low areas. The gas flammable and could be explosive. A “No Smoking” rule must be strictly enforced during refilling.

2. Place “No Smoking” signs where all LPG is stored and handled. 3. Have a CO2 fire extinguisher or multi-purpose extinguisher available at

all storage and filling areas. 4. Wearing PPE is essential when handling LPG. The gas can be very

cold and cause damage to the skin and eyes. Heavy duty gloves, face shields or goggles are needed.

5. Ensure LPG tanks are properly anchored to the lift truck. Have defective hold-down straps repaired as needed.

Forklift Safety, 9

GASOLINE AND DIESEL FUEL

1. Gasoline is highly flammable; it can cause fire or explosion if not handled properly. The “No Smoking” rule is paramount when pumping or handling gasoline.

2. Place proper “No Smoking” signs where gasoline is handled or stored.

3. If portable containers are used for refueling, be sure they are UL/FM approved. Ensure flame arrestors are intact within the container.

4. Properly identify all containers for content.

5. Diesel fuel has a higher flash point than gasoline and is more difficult to ignite. However, when heated or pressurized the liquid burns as readily as gasoline. Ensure that the proper storage of fuels is outside and as far away form any building as possible. Follow fire regulations.

IHSA’S SAFETY TALKSHoistingsignals

Demonstrate the hoisting signals below for your crew. Ask them to repeat after you and practicethem so that they become natural. Then, ask them to show you the signals for “Load Up,” “TurnRight,” and “Use Main Line.”

Demonstrate

CSAO’S SAFETY TALKS3-pointcontact 20

Getting on and off equipment is not as easy as itsounds. More than one-quarter of all injuries toequipment operators and truck drivers occur duringmounting and dismounting.

Explain dangers

Identify controls

Demonstrate

To climb on and off construction equipment safely,always maintain three points of contact. Thatmeans two hands and one foot or two feet and onehand on the equipment at all times.

• Break 3-point contact only when you reach theground, the cab, or a stable platform.

• Mount and dismount facing the equipment.

• Climb on and off only when the equipment is stationary.

• Use the parts designed by the manufacturer formounting and dismounting—steps, runningboards, traction strips, footholds,handgrips, etc.

• Keep these parts clear of mud, snow, grease,and other hazards that can cause slips, trips, orfalls.

• Don’t use wheel hubs, machine tracks, or doorhandles for mounting and dismounting. Demonstrate 3-point contact by mounting and

dismounting from a truck, bulldozer, or other pieceof heavy equipment on site. Ask your crew to tryout 3-point contact as well.

List vehicles & equipment used on site

Vehicles and equipment

6/24/11 9:02 PMHealth Risks for Heavy Equipment Operators

Page 1 of 8http://www.csao.org/UploadFiles/Magazine/Vol9No3/93health.htm

Health RisksFOR HEAVY EQUIPMENT OPERATORS

by Nadine Marks, B.Sc. (P.T.) Project Coordinator, CSAO

Unique risk factorsHeavy equipment operators are exposed to risk factors considerably different from those inother construction trades. Prolonged sitting, whole body vibration, and the repetitive operationof controls are major risk factors for work-related musculoskeletal disorders (WMDs) amongoperators.

Injuries

Workplace Safety and Insurance Board (WSIB) injury reports show that the average number oflost-time injuries (LTIs) for operators in the period 1994-1996 was 102 per year. Based on totalinjuries reported, 29% were to the back, 12% to the shoulder or arm, and 9% to the ankle. Backinjuries to equipment operators are higher than the industry average for construction (25%). Themajority of the back injuries (43%) were caused by overexertion, followed by slips and falls(22.5%). Most of the back injuries occurred while lifting (42%), followed by operatingequipment (26%) and dismounting (14%).

Other research reveals that the most common work-related symptoms reported among operatingengineers include shoulder problems, low back pain, stomach disorders, general fatigue, andirritability. These are caused by

work positionwhole-body vibration (WBV)segmental vibrationvisual work



environmental factors such as weather, diesel fuel exhaust, and noisepsychological stress.

Work Position

Heavy equipment operators are required to sit for extended periods of time. Sitting exertsalmost twice the pressure through the back that standing does. Sitting flattens out the small ofthe back. This increases pressure on the spinal discs and limits their ability to absorb vibration.In addition, back muscles tire, become stiff, and start to hurt when the back is in one positionfor any length of time.

During extended sitting, ligaments in the back stretch and slacken. Even after you stand up, theyremain stretched and slack for a while and cannot properly support the low back. For thisreason, lifting immediately after prolonged sitting increases the risk of back injury.

Other causes can also contribute to injury in the heavy equipment operator. Back and neckmuscles must work continuously to hold the head in position, especially in the presence ofvibration. This exertion can lead to sore tired muscles and muscle strain.

The repetitive operation of equipment controls also entails risks. Holding a foot pedal downover a long period of time may cause stiffness and spasm in the legs and low back. Operatinghand controls may result in a repetitive strain disorder of the arm with shoulder or elbowtendinitis. Additionally, in colder weather operators may experience arthritic symptoms in thehands and/or Raynaud's syndrome. This syndrome is called "white finger disease" becauseconstriction of the blood vessels causes whitening of the fingers as well as pain or numbness.

Posture



is Important

Recommendations

Maintaining proper posture is important to good back health. Backrests are designed tosupport the natural curves in your spine, especially the low back lumbar curve. A backrest(lumbar support) will improve the seat's shape and your own posture. The right backrestfor you will depend on your build and the size and shape of the equipment seat. If a backsupport is not available, a rolled-up towel placed in the small of your back can help.Don't drive with your wallet in your back pocket. The wallet may put your spine out ofalignment and exert pressure on your sciatic nerve, which can lead to back and leg pain.Maintaining good sitting posture is important. But sitting is still hard on your back andrequires frequent changes of position. Try to get out of your vehicle for a couple ofminutes every hour or two and gently stretch backwards. Ideally, the back of your seatshould be tilted at 110 degrees from your legs to reduce disc pressure and relax backmuscles.Avoid lifting immediately after driving. The first two to three minutes after you exit yourvehicle is a high-risk time for injury. Your muscles are tired; your ligaments are stretchedand unable to support your spine properly; your spinal discs are at risk of injury. Giveyourself a couple of minutes to stretch and rest before trying to lift anything heavy. Astanding back bend, slow and easy, will help reduce the stress on your spine from sitting.Avoid jumping down from your vehicle. The impact of jumping puts additional stress andshock on your spine. Over the years this can result in low back injury. Jumping downfrom vehicles may also cause knee and ankle injuries. Always face your vehicle whendismounting and maintain 3-point contact. Remember that 14% of back injuries to heavyequipment operators are caused by improper dismounting from the vehicle.If possible, adjust your seat and steering wheel so that you can use the pedals and stillkeep your low back in contact with the seat back.When driving for long periods, shift position occasionally to give your back a change ofposition.Before entering or exiting the cab, slide the seat back. This will give you more room andprevent the need to twist. Try to keep your back straight and avoid twisting when gettingin and out. Bend at your hips and knees rather than at your back.

Consider these ergonomic points:

Frequently used controls should be in the most favourable position for reaching andgrasping. Displays should be located so that they can be read accurately from a normaloperating position.Armrests should be available to help reduce postural stress to the back and should fold upout of the way at the operator's discretion.Cabs should be equipped with adjustable seating that provides good lumbar support.Seating material should be suitable to vehicle type. Ideally, an air suspension system withindividual weight adjustments is best.



Three Sourcesof Vibration

Whole Body Vibration

Whole body vibration (WBV) is a form of mechanical vibration transmitted through asupporting surface to the body. Heavy equipment vibration is transmitted through the seat of thevehicle to the operator's spine.

Operators are subjected to various sources of vibration:

low-frequency vibration caused by tires and terrainhigh-frequency vibration from engine and transmissionshock from running into potholes or obstacles.

Long-term exposure to whole body vibration may cause low back disorders such as discherniations, may accelerate degenerative changes in the spine, and may lead to problems withthe urogenital and gastrointestinal systems (abdominal pain and nausea). WBV has also beenshown to affect the cardiovascular system (increased heart rate and blood pressure).

Because of these health concerns, the International Standards Organization (ISO) has developeda standard providing numerical limits for exposure to WBV. But even when vibration levels arewithin ISO standards, other factors may influence operator exposure, such as how well themachine is maintained, the type of terrain travelled, seat design, and vibration from otherequipment.

Additionally, operators are often required to drive backwards or look from one side of theirvehicle, forcing them to adopt a twisted posture. This is considered a risk factor for thedevelopment of back and neck disorders. When a vehicle hits an unexpected pothole or bump,the operator's muscles may not have time to contract properly to protect against neck and backinjuries. In fact, 12% of back injuries to operators are due to shocks or jolts sustained whiledriving.

Poor ergonomic design of cabs, seats, and controls can also affect the operator'smusculoskeletal health.

Recommendations

Maintain equipment in sound working order. A good suspension system and correct tirepressure will help to reduce vibration.Use specially designed cushions with vibration-reducing material.Take extra care and reduce travel speed over rough terrain (shale or rock).If possible, tilt your seat a notch or two every 30 minutes. This alters the direction ofvibration through your body and helps reduce its effects.Try to get out of your vehicle every one to two hours for a few minutes to give your body



a break from vibration.

Segmental Vibration

Segmental vibration is transmitted through the hands and arms and is known to cause specifichealth effects such as Raynaud's syndrome (white finger disease). Construction workers areexposed to segmental vibration when using equipment such as grinders, jackhammers, andpower tools. Heavy equipment operators are exposed to segmental vibration when they operatecontrols.

Equipment operators may report symptoms of Raynaud's syndrome or arthritis in their hands,especially in colder weather.

Recommendations

Wear gloves to keep your hands warm in cold weather.Take breaks when possible and stretch your fingers and hands.Equipment controls should have vibration-reducing material built into the grips.

Visual Work

Operators must not only operate equipment but also keep an eye on site activity at all times.They have to monitor their changing environment and watch for overhead powerlines,underground utilities, obstacles, site traffic, signallers, and workers on foot. As a result, eyestrain and fatigue can become an occupational hazard.

In addition, poor visibility from the cab, reduced visibility in rainy or winter conditions, andglaring sunlight on bright days can contribute to eye strain.

Recommendations

When possible, take breaks and give your eyes a rest.Ensure that there's an adequate number of defogging vents in the cab and that they'relocated in the correct position to prevent side and back windows from fogging up.Keep windshield wiper blades in good working condition.If reflection or glare makes displays difficult to read, use shields or filters.

Improved CabsReduce Risks

ENVIRONMENTAL FACTORS

Weather



Equipment operators must work in all kinds of weather. In summer they may have to contendwith heat in cabs that aren't air-conditioned. In winter, ice and snow can make mounting ordismounting from equipment hazardous and lead to slips and falls. Controls and grips may alsobe cold and contribute to Raynaud's syndrome or arthritic conditions of the hand.

Recommendations

Cabs should be equipped with adequate air-conditioning in summer and heat in winter.Allow extra time in winter to clean ice and snow from equipment.Take it slow and easy when getting in or out of equipment in winter. Always maintain 3-point contact and face the vehicle to avoid slips and falls.

Noise

Operators are exposed daily to high levels of noise from heavy equipment. Research hasdemonstrated that excessive exposure to noise in the workplace may induce hearing loss. Noiseexposures on Ontario construction sites are not regulated. But the industrial regulations stipulatea maximum of 90 dBA exposure for eight hours.

A CSAO study concluded that operators in equipment with no cabs or with open doors may beexposed to levels exceeding 90 dBA for an 8-hour period. Bulldozer operators in the study hadthe highest average exposure at 102.4 dBA.

Recommendations

Cabs of heavy equipment should be enclosed to reduce noise and air-conditioned to allowoperators to keep doors closed.Periodic maintenance should be carried out to reduce noise caused by equipment that isnot well tuned or working properly.Hearing protection programs, including training in the proper use of plugs and muffs,should be implemented.

Diesel Exhaust

The chronic effects of diesel exhaust exposure can include lung function disorders and lungcancer. Studies have reported an excess risk of lung cancer in heavy equipment operators,attributed in part to soot particles and constituents such as benzene in diesel fuel exhaust.

Recommendations

Ensure that the equipment is in good working condition and properly maintained. Payparticular attention to the exhaust pipe and check for any leaks in the system.Further research should be conducted to determine levels of diesel exhaust exposureamong equipment operators.



Psychological Stress

Heavy equipment operators are exposed to psychological stress from the physical conditionsalready described: the size and power of the equipment they operate, changing site conditionsthat require constant monitoring, exposure to hazards such as vibration and noise, prolongedsitting, and the repetitive operation of hand and foot controls.

Additionally, they may work for 4 or 5 hour stretches in virtual isolation, responding only tosignals from co-workers. Operators may work 10 or 12 hour shifts during the constructionseason. Fatigue can be a significant factor in their overall psychological well-being.

Recommendations

Employers and supervisors should 1) be aware of the physical and psychological stressunder which equipment operators must often work and 2) understand the controls andpractices that can help to reduce stress.Ergonomic improvements in cab design can help to reduce musculoskeletal hazards andsome of the psychological stress that goes along with them.Operators should be encouraged to do a pre-work warm-up and take enough stretchbreaks to reduce their exposure to vibration and prolonged sitting.Exercise programs and active forms of recreation to keep fit can improve mental attitudeand reduce the risk of musculoskeletal injury.

Conclusions

Strategies to reduce work-related health problems among heavy equipment operators shouldinclude the following:

in-depth evaluations of vehicle designs to determine possible improvementsin-depth evaluation of work practices to identify safer, healthier approachesimplementing sound ergonomic procedurestraining workers in how to prevent musculoskeletal injuryfocusing attention on the psychological aspects of operating heavy equipment in the



unique construction environment.

Through their coordinated efforts, contractors, equipment manufacturers, suppliers, unions andworkers can help to reduce and control the occupational hazards affecting heavy equipmentoperators.

Back to Contents

http://www.csao.org/UploadFiles/Magazine/Vol9No3/VOL9NO3.HTM

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. © 2009 Caterpillar All Rights Reserved

V0810.1

Operator/Inspector______________________________ Date__________________ Time_______________ Serial Number_________________________ Machine Hours_________________________

What are you inspecting? What are you looking for? Evaluator Comments

For more information, please refer to the Operation and Maintenance Manual or any other applicable manuals and instructions for this product. If you have questions, please contact your local Caterpillar dealer.

FROM THE GROUND Tires, Wheels, Lug Nuts, Stem Caps Inflation, Leaks, Damage, Wear Bucket Cutting Edge, Moldboard Excessive wear, Damage Bucket Lift and Tilt Cylinders, Lines, Hoses Excessive wear, Damage, Leaks Loader Frame, Arms Excessive wear, Damage Underneath Machine Leaks, Damage Transmission, Transfer Case Leaks Steps and Handholds Condition, Cleanliness Fuel Tank Fuel Level, Damage, Leaks Differential and Final Drive Oil Fluid Level Air Tank (if equipped w/ air brakes) Drain Moisture Axles – Final Drives, Differentials, Brakes, Duo-cone Seals

Leaks, Damage, Wear

Hydraulic Tank Fluid Level, Damage, Leaks Transmission Oil Fluid Level

Lights, Front and Rear Function, Damage to Lens, Housing,

or Wiring

Battery Compartment Cleanliness, Loose Nuts & Bolts ENGINE COMPARTMENT Engine Oil Fluid Level Engine Coolant Fluid Level Radiator Fin Blockage, Leaks All Hoses Cracks, Wear Spots, Leaks Fuel Filters / Water Separator Leaks / Drain Water (if equipped) All Belts Tension, Wear, Cracks Air Filter Restriction Indicator Overall Engine Compartment Trash or Dirt Buildup, Leaks ON THE MACHINE, OUTSIDE THE CAB Handholds Condition and Cleanliness ROPS Damage, Loose Mounting Bolts Fire Extinguisher/System Charge, Damage Windshield, Windows Broken Glass, Cleanliness Windshield Wipers / Washers Wear, Damage / Fluid Level Doors Open properly, broken glass INSIDE THE CAB

Seat Adjustment-Height, Weight, Able to

Reach Pedals

Seat Belt & Mounting Damage, Wear, Adjustment, Age Horn, Backup Alarm, Lights Proper Function Mirrors Damage, Adjust for Best Visibility Cab Air Filter Dirt, Dust Gauges, Indicators, Switches, Controls Damage, function Overall Cab Interior Cleanliness

Safety & Maintenance Inspection: Wheel Loaders

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. © 2010 Caterpillar All Rights Reserved

V0810.1

Operator/Inspector_____________________ Date________________ Time__________________ Serial Number_________________ Machine Hours_____________________

What are you inspecting? What are you looking for? Evaluator Comments For more information, please refer to the Operation and Maintenance Manual or any other applicable manuals and instructions for this product. If you have questions, please contact your local Caterpillar dealer

With Engine OFF Pass/Fail Action Needed Fuel Leaks, Level Hydraulic Oil Leaks, Level Engine Oil Leaks, Level Radiator Coolant Leaks, Level Transmission Fluid Leaks, Level Tires Condition and Pressure Forks, Top Clip Retaining Pin and Heel Check Condition Hydraulic Hoses, Mast Chains, Cables and Stops Visual Check, Leaks, Damage Overhead Guard Attached, Damage

Safety Warnings Attached, Visible, Legible (Refer to Parts Manual for Location)

Battery Check Water/Electrolyte Level and Charge All Engine Belts Cracked, Damage, Rips, Visual Check

Engine Air Cleaner Squeeze Rubber Dirt Trap or Check the Restriction Alarm (if equipped)

Fuel Sedimentor (Diesel) Condition Operator's Manual In Cab

Nameplate Attached and Information Matches Model, Serial Number and Attachments

Seat Belt, Buckle, Retractor Condition, Torn, Ripped, Damage to housing

Hood Latch Adjusted and Securely Fastened Brake Fluid Leaks, Level

With Engine ON

Accelerator or Direction Control Pedal Functioning Smoothly and Properly Service Brake Functioning Smoothly and Properly

Parking Brake Functioning Smoothly and Properly

Steering Operation Functioning Smoothly and Properly

Drive Control – Forward/Reverse Functioning Smoothly and Properly Tilt Control – Forward and Back Functioning Smoothly and Properly Hoist and Lowering Control Functioning Smoothly and Properly Attachment Control Operation Horn and Lights Functioning Properly Cab (if equipped) – Heater, Defroster, Wipers Functioning Properly Gauges: Ammeter, Engine Oil Pressure, Hour Meter, Fuel Level, Temperature, Instrument Monitors

Functioning Properly

Safety & Maintenance Inspection – Fork Lifts

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