La Farge Cement Services, Inc.

Norzagaray, Bulacan

HEAVY EQUIPMENT SAFETY TRAINING

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

PEOPLE360 CONSULTING CORPORATION

Report No. IR1506-11-00003

Deaths and heavy equipment

Deaths and heavy equipment

Over 60% of the deaths this year involve heavy equipment
So far this year, 26 construction workers in Ontario have died from injury. More information is on the chart on the next page. Falls account for nine of the deaths. And close analysis shows that 16 of the 26 deathsor 62%involved heavy vehicles or equipment such as dump trucks or backhoes. There are a variety of ways that heavy equipment can present hazards if you dont have the proper protection or controls. For example, you can be electrocuted if the equipment contacts an overhead powerline crushed if your equipment overturns struck by or crushed by material being moved by heavy equipment crushed if caught between the equipment and a wall or other object run over by a heavy vehicle. Over the next few pages, we identify some of the dangers of working with heavy vehicles or equipment, and we explain briefly how to protect yourself and your co-workers. We cant say everything in a few pages, but CSAO can give you more information if you want it. All you have to do is call or email: 1-800-781-2726, info@csao.org

Powerline contact
Three workers were killed this year after dump-truck boxes contacted overhead powerlines. Constructors must have written procedures to prevent contact when equipment could encroach on the minimum allowable distance to a powerline stated in section 188 of the Construction Regulation (Ontario Regulation 213/91 in the green book). The Regulation requires, among other things, that constructors K ensure that operators get written notification of the electrical hazards before they begin work K place warning devices (such as signs) near the powerlines so that the equipment operator can always see at least one of them K designate a competent worker as a signaller to warn the operator when any part of the equipment, load, or hoist line approaches the minimum allowable distance to a powerline. (See section 1 (1) of the Regulation for the legal definition of competent worker.) There are other requirements. The Summer 2006 edition of Construction Safety magazine contained a detailed article on the subject. Call CSAO for your copy or download it from www.csao.org.

CONSTRUCTION SAFETY MAGAZINE

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HEAVY EQUIPMENT
I. INTRODUCTION Improper procedures used by our employees can cause injury, disability, or death. By outlining and following safe operating procedures for use of heavy equipment, we learn to prevent injury and safeguard ourselves and our coworkers.

II. GOALS To ensure all employees know and understand the safe operating procedures for the safe operation and maintenance of Heavy Equipment. III. PURPOSE To reduce the risk of a work related injury or death by maximizing personal safety during Heavy Equipment 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. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can penetrate skin and cause serious bodily

Caution: harm.

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 Lock Out/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 MACHINE IN 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. 2

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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 operators 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 doesnt 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. 3

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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 as the 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. If necessary, 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 or hitch.

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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. 5

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Cross obstacles at an angle and at slow speed. Be alert for sudden movement of machine when going 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 pull equipment up onto the platform. Check for proper operation of all controls and protective devices while moving slowly in an open area. 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 the drawbar or hitch. Park on a level surface. If necessary to park on a grade, block the machine. Lower bowl to the ground 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 6

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parking brake, and placing the shift in park or neutral. Dismount the machine carefully. Do not jump 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 or on any type of truck. Our motor vehicle policy, as well as State and Federal regulations prohibit the operation of commercial motor vehicles by individuals who do not have the proper training and license. Do not 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 the truck into operation. This form is an excellent tool to help the operator remember to check all necessary 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 drivers 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 arent 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 trucks center of gravity goes up and the truck becomes less stable and more apt to tip over. If you must dump on a slope place the truck so that it faces straight up, or down the slope. Do not try to raise the box with the truck parked parallel with the slope. Remember that a dump truck is much more apt to tip over (or run into overhead obstructions) when spreading material then it is when dumping in a pile. NEVER work under a raised box (not even for just a little bit) unless the box is adequately supported by a prop rod or cribbing. Do not rely on the trucks hydraulic system to hold the box up while you work under it.

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

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

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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.

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These actions will have the following effects:

Action Tilting the load forward Raising the Load while tilted forward Driving on an incline with the load downhill Stopping forward travel or accelerating backward Tilting the load back Raising the load while tilted back Driving on an incline with the load uphill Accelerating forward or stopping backward travel Driving across an inclined surface Driving across a rough or uneven surface Turning

Center of Gravity Moves

Toward the front axle

Toward the rear axle

Toward the downhill side of the triangle Toward the low side of the triangle Toward the side now facing the original direction of travel.

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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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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 oddshaped 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.

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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. Its 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
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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 wont 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 trucks wheels are to be choked.

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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 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.

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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.

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Hoisting signals
Demonstrate

IHSAS SAFETY TALKS

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

3-point contact

CSAOS SAFETY TALKS

20

Vehicles and equipment

List vehicles & equipment used on site

Explain dangers
Getting on and off equipment is not as easy as it sounds. More than one-quarter of all injuries to equipment operators and truck drivers occur during mounting and dismounting.

Identify controls
To climb on and off construction equipment safely, always maintain three points of contact. That means two hands and one foot or two feet and one hand on the equipment at all times. Break 3-point contact only when you reach the ground, 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 for mounting and dismountingsteps, runningboards, traction strips, footholds, handgrips, etc. Keep these parts clear of mud, snow, grease, and other hazards that can cause slips, trips, or falls. Dont use wheel hubs, machine tracks, or door handles for mounting and dismounting.

Demonstrate
Demonstrate 3-point contact by mounting and dismounting from a truck, bulldozer, or other piece of heavy equipment on site. Ask your crew to try out 3-point contact as well.

Health Risks for Heavy Equipment Operators

6/24/11 9:02 PM

Health Risks FOR HEAVY EQUIPMENT OPERATORS

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

Unique risk factors

Heavy equipment operators are exposed to risk factors considerably different from those in other construction trades. Prolonged sitting, whole body vibration, and the repetitive operation of controls are major risk factors for work-related musculoskeletal disorders (WMDs) among operators.

Injuries Workplace Safety and Insurance Board (WSIB) injury reports show that the average number of lost-time injuries (LTIs) for operators in the period 1994-1996 was 102 per year. Based on total injuries reported, 29% were to the back, 12% to the shoulder or arm, and 9% to the ankle. Back injuries to equipment operators are higher than the industry average for construction (25%). The majority 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 operating equipment (26%) and dismounting (14%). Other research reveals that the most common work-related symptoms reported among operating engineers include shoulder problems, low back pain, stomach disorders, general fatigue, and irritability. These are caused by work position whole-body vibration (WBV) segmental vibration visual work
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environmental factors such as weather, diesel fuel exhaust, and noise psychological stress. Work Position Heavy equipment operators are required to sit for extended periods of time. Sitting exerts almost twice the pressure through the back that standing does. Sitting flattens out the small of the 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 position for any length of time. During extended sitting, ligaments in the back stretch and slacken. Even after you stand up, they remain stretched and slack for a while and cannot properly support the low back. For this reason, 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 neck muscles must work continuously to hold the head in position, especially in the presence of vibration. This exertion can lead to sore tired muscles and muscle strain. The repetitive operation of equipment controls also entails risks. Holding a foot pedal down over a long period of time may cause stiffness and spasm in the legs and low back. Operating hand controls may result in a repetitive strain disorder of the arm with shoulder or elbow tendinitis. Additionally, in colder weather operators may experience arthritic symptoms in the hands and/or Raynaud's syndrome. This syndrome is called "white finger disease" because constriction of the blood vessels causes whitening of the fingers as well as pain or numbness.

Posture
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is Important
Recommendations Maintaining proper posture is important to good back health. Backrests are designed to support 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 backrest for you will depend on your build and the size and shape of the equipment seat. If a back support 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 of alignment 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 and requires frequent changes of position. Try to get out of your vehicle for a couple of minutes every hour or two and gently stretch backwards. Ideally, the back of your seat should be tilted at 110 degrees from your legs to reduce disc pressure and relax back muscles. Avoid lifting immediately after driving. The first two to three minutes after you exit your vehicle is a high-risk time for injury. Your muscles are tired; your ligaments are stretched and unable to support your spine properly; your spinal discs are at risk of injury. Give yourself a couple of minutes to stretch and rest before trying to lift anything heavy. A standing 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 and shock on your spine. Over the years this can result in low back injury. Jumping down from vehicles may also cause knee and ankle injuries. Always face your vehicle when dismounting and maintain 3-point contact. Remember that 14% of back injuries to heavy equipment 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 still keep your low back in contact with the seat back. When driving for long periods, shift position occasionally to give your back a change of position. Before entering or exiting the cab, slide the seat back. This will give you more room and prevent the need to twist. Try to keep your back straight and avoid twisting when getting in 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 and grasping. Displays should be located so that they can be read accurately from a normal operating position. Armrests should be available to help reduce postural stress to the back and should fold up out 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 with individual weight adjustments is best.

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Three Sources of Vibration

Whole Body Vibration Whole body vibration (WBV) is a form of mechanical vibration transmitted through a supporting surface to the body. Heavy equipment vibration is transmitted through the seat of the vehicle to the operator's spine. Operators are subjected to various sources of vibration: low-frequency vibration caused by tires and terrain high-frequency vibration from engine and transmission shock from running into potholes or obstacles. Long-term exposure to whole body vibration may cause low back disorders such as disc herniations, may accelerate degenerative changes in the spine, and may lead to problems with the urogenital and gastrointestinal systems (abdominal pain and nausea). WBV has also been shown to affect the cardiovascular system (increased heart rate and blood pressure). Because of these health concerns, the International Standards Organization (ISO) has developed a standard providing numerical limits for exposure to WBV. But even when vibration levels are within ISO standards, other factors may influence operator exposure, such as how well the machine is maintained, the type of terrain travelled, seat design, and vibration from other equipment. Additionally, operators are often required to drive backwards or look from one side of their vehicle, forcing them to adopt a twisted posture. This is considered a risk factor for the development 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 back injuries. In fact, 12% of back injuries to operators are due to shocks or jolts sustained while driving. Poor ergonomic design of cabs, seats, and controls can also affect the operator's musculoskeletal health. Recommendations Maintain equipment in sound working order. A good suspension system and correct tire pressure 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 of vibration 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
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a break from vibration. Segmental Vibration Segmental vibration is transmitted through the hands and arms and is known to cause specific health effects such as Raynaud's syndrome (white finger disease). Construction workers are exposed to segmental vibration when using equipment such as grinders, jackhammers, and power tools. Heavy equipment operators are exposed to segmental vibration when they operate controls. 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, eye strain and fatigue can become an occupational hazard. In addition, poor visibility from the cab, reduced visibility in rainy or winter conditions, and glaring 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're located 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 Cabs Reduce Risks

ENVIRONMENTAL FACTORS
Weather
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Equipment operators must work in all kinds of weather. In summer they may have to contend with heat in cabs that aren't air-conditioned. In winter, ice and snow can make mounting or dismounting from equipment hazardous and lead to slips and falls. Controls and grips may also be 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 3point contact and face the vehicle to avoid slips and falls. Noise Operators are exposed daily to high levels of noise from heavy equipment. Research has demonstrated that excessive exposure to noise in the workplace may induce hearing loss. Noise exposures on Ontario construction sites are not regulated. But the industrial regulations stipulate a maximum of 90 dBA exposure for eight hours. A CSAO study concluded that operators in equipment with no cabs or with open doors may be exposed to levels exceeding 90 dBA for an 8-hour period. Bulldozer operators in the study had the highest average exposure at 102.4 dBA. Recommendations Cabs of heavy equipment should be enclosed to reduce noise and air-conditioned to allow operators to keep doors closed. Periodic maintenance should be carried out to reduce noise caused by equipment that is not 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 lung cancer. 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. Pay particular attention to the exhaust pipe and check for any leaks in the system. Further research should be conducted to determine levels of diesel exhaust exposure among equipment operators.

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Psychological Stress Heavy equipment operators are exposed to psychological stress from the physical conditions already described: the size and power of the equipment they operate, changing site conditions that require constant monitoring, exposure to hazards such as vibration and noise, prolonged sitting, and the repetitive operation of hand and foot controls. Additionally, they may work for 4 or 5 hour stretches in virtual isolation, responding only to signals from co-workers. Operators may work 10 or 12 hour shifts during the construction season. 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 stress under which equipment operators must often work and 2) understand the controls and practices that can help to reduce stress. Ergonomic improvements in cab design can help to reduce musculoskeletal hazards and some of the psychological stress that goes along with them. Operators should be encouraged to do a pre-work warm-up and take enough stretch breaks to reduce their exposure to vibration and prolonged sitting. Exercise programs and active forms of recreation to keep fit can improve mental attitude and reduce the risk of musculoskeletal injury.

Conclusions Strategies to reduce work-related health problems among heavy equipment operators should include the following: in-depth evaluations of vehicle designs to determine possible improvements in-depth evaluation of work practices to identify safer, healthier approaches implementing sound ergonomic procedures training workers in how to prevent musculoskeletal injury focusing attention on the psychological aspects of operating heavy equipment in the
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unique construction environment. Through their coordinated efforts, contractors, equipment manufacturers, suppliers, unions and workers can help to reduce and control the occupational hazards affecting heavy equipment operators.

Back to Contents

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Safety & Maintenance Inspection: Wheel Loaders

Operator/Inspector______________________________ Date__________________ Time_______________ Serial Number_________________________ Machine Hours_________________________ What are you looking for? Evaluator Comments What are you inspecting?
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 Bucket Cutting Edge, Moldboard Bucket Lift and Tilt Cylinders, Lines, Hoses Loader Frame, Arms Underneath Machine Transmission, Transfer Case Steps and Handholds Fuel Tank Differential and Final Drive Oil Air Tank (if equipped w/ air brakes) Axles Final Drives, Differentials, Brakes, Duo-cone Seals Hydraulic Tank Transmission Oil Lights, Front and Rear Battery Compartment Inflation, Leaks, Damage, Wear Excessive wear, Damage Excessive wear, Damage, Leaks Excessive wear, Damage Leaks, Damage Leaks Condition, Cleanliness Fuel Level, Damage, Leaks Fluid Level Drain Moisture Leaks, Damage, Wear Fluid Level, Damage, Leaks Fluid Level Function, Damage to Lens, Housing, or Wiring Cleanliness, Loose Nuts & Bolts Fluid Level Fluid Level Fin Blockage, Leaks Cracks, Wear Spots, Leaks Leaks / Drain Water (if equipped) Tension, Wear, Cracks Restriction Indicator Trash or Dirt Buildup, Leaks Condition and Cleanliness Damage, Loose Mounting Bolts Charge, Damage Broken Glass, Cleanliness Wear, Damage / Fluid Level Open properly, broken glass Adjustment-Height, Weight, Able to Reach Pedals Damage, Wear, Adjustment, Age Proper Function Damage, Adjust for Best Visibility Dirt, Dust Damage, function Cleanliness

ENGINE COMPARTMENT
Engine Oil Engine Coolant Radiator All Hoses Fuel Filters / Water Separator All Belts Air Filter Overall Engine Compartment

ON THE MACHINE, OUTSIDE THE CAB

Handholds ROPS Fire Extinguisher/System Windshield, Windows Windshield Wipers / Washers Doors

INSIDE THE CAB

Seat Seat Belt & Mounting Horn, Backup Alarm, Lights Mirrors Cab Air Filter Gauges, Indicators, Switches, Controls Overall Cab Interior

V0810.1
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

Safety & Maintenance Inspection Fork Lifts

Operator/Inspector_____________________ Date________________ Time__________________ Serial Number_________________ Machine Hours_____________________ What are you looking for? What are you inspecting? 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 Fuel Hydraulic Oil Engine Oil Radiator Coolant Transmission Fluid Tires Forks, Top Clip Retaining Pin and Heel Hydraulic Hoses, Mast Chains, Cables and Stops Overhead Guard Safety Warnings Battery All Engine Belts Engine Air Cleaner Fuel Sedimentor (Diesel) Operator's Manual Nameplate Seat Belt, Buckle, Retractor Hood Latch Brake Fluid With Engine ON Accelerator or Direction Control Pedal Service Brake Parking Brake Steering Operation Drive Control Forward/Reverse Tilt Control Forward and Back Hoist and Lowering Control Attachment Control Horn and Lights Cab (if equipped) Heater, Defroster, Wipers Gauges: Ammeter, Engine Oil Pressure, Hour Meter, Fuel Level, Temperature, Instrument Monitors Pass/Fail Leaks, Level Leaks, Level Leaks, Level Leaks, Level Leaks, Level Condition and Pressure Check Condition Visual Check, Leaks, Damage Attached, Damage Attached, Visible, Legible (Refer to Parts Manual for Location) Check Water/Electrolyte Level and Charge Cracked, Damage, Rips, Visual Check Squeeze Rubber Dirt Trap or Check the Restriction Alarm (if equipped) Condition In Cab Attached and Information Matches Model, Serial Number and Attachments Condition, Torn, Ripped, Damage to housing Adjusted and Securely Fastened Leaks, Level Functioning Smoothly and Properly Functioning Smoothly and Properly Functioning Smoothly and Properly Functioning Smoothly and Properly Functioning Smoothly and Properly Functioning Smoothly and Properly Functioning Smoothly and Properly Operation Functioning Properly Functioning Properly Functioning Properly Action Needed

V0810.1
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